FORM-1: Proposed of Specialty Chemicals Manufacturing Unit

FORM-1
For
PROPOSED OF SPECIALTY CHEMICALS MANUFACTURING

UNIT
of
M/s. UMIYA DYES & INTERMEDIATES

PLOT NO. D2/CH/90, GIDC, DAHEJ-II,
TAL: VAGRA, DIST: BHARUCH-392130 (GUJ.)
Prepared By:
NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
1
APPENDIX I
(See paragraph - 6)
FORM 1
(I) Basic Information
Sr. Item Details

No.
1. Name of the project/s M/s. Umiya Dyes & Intermediates
2. S. No. in the schedule 5(f)
3. Proposed capacity/area/length/tonnage to For detail Please refer Annexure – I
be handled/command area/lease
area/number of wells to be drilled
4. New/Expansion/Modernization New
5. Existing Capacity/Area etc. Proposed Capacity: 1250 MT/Month
6. Category of Project i.e. ‘A’ or ‘B’ ‘B’
7. Does it attract the general condition? If No
yes, please specify.
8. Does it attract the specific condition? If No
yes, please specify.
9. Location
Plot/Survey/Khasra No. Plot No: D2/CH/90
Village Dahej-II
Tehsil Vagra
District Bharuch
State Gujarat
10. Nearest railway station/airport along with
Nearest Railway Station: Bharuch = 35 kms
distance in kms. Nearest Airport: Surat = 80 kms
11. Nearest Town, city, District Headquarters
Nearest town: Bharuch = 35 kms,
along with distance in kms. Nearest District Head quarter: Bharuch =
35 km
12. Village Panchayats, Zilla Parishad, Vill: Dahej, Tal: Vagra, Dist: Bharuch,
Municipal Corporation, local body Gujarat.
(complete postal address with telephone
nos. to be given)
13. Name of the applicant M/s. Umiya Dyes & Intermediates
14. Registered Address Plot No: D2/CH/90, GIDC, Dahej-II, Tal: Vagra,
Dist: Bharuch-392130 (Guj.).
15. Address for correspondence: M/s. Umiya Dyes & Intermediates
Plot No: D2/CH/90, GIDC, Dahej-II, Tal:
Vagra, Dist: Bharuch-392130 (Guj.).
Name Mr. Pratik V Patel
Designation (Owner/Partner/Director) Partner
2
Address 408/12, Sardar Patel Society, GIDC,
Ankleshwar
Pin Code 393001
e-mail Umiyadyes_dahej@yahoo.com
Telephone No. +919824579926
Fax No. -
16. Details of Alternative Sites examined, if NA
any.
Location of these sites should be shown
on a topo sheet.
17. Interlinked Projects NA
18. Whether separate application of NA
interlinked project has been submitted?
19. If yes, date of submission NA
20. If no, reason NA
21. Whether the proposal involves No
approval/clearance under: if yes, details of
the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z. Notification, 1991?
22. Whether there is any Government No
Order/Policy relevant/relating to the site?
23. Forest land involved (hectares) NA
24. Whether there is any litigation pending NA
against the project and/or land in which
the project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

mining lease area and production capacity for mineral production, area for mineral
exploration, length for linear transport infrastructure, generation capacity for power
generation etc.).
3
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will
cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr. Information/Checklist confirmation Yes/ Details thereof with approximate

No. No quantities frates, wherever possible)
with source of information data
1.1 Permanent or temporary change in No --
land use, land cover or topography
including increase intensity of land use
(with respect to local land use plan)
1.2 Clearance of existing land, vegetation Yes Minor site clearance activities shall be
and Buildings? carried out to clear shrubs and weed.
1.3 Creation of new land uses? No --
1.4 Pre-construction investigations e.g. No
bore Houses, soil testing?
1.5 Construction works? Yes For detail Please refer Annexure – II
1.6 Demolition works? No There will not any demolition work at
the site.
1.7 Temporary sites used for construction No --
works or housing of construction
workers?
1.8 Above ground buildings, structures or Yes For detail Please refer Annexure – II
earthworks including linear structures,
cut and fill or excavations
1.9 Underground works mining or No --
tunneling?
1.10 Reclamation works? No --
1.11 Dredging? No --
1.12 Off shore structures? No --
1.13 Production and manufacturing Yes For detail Please refer Annexure -III
processes?
1.14 Facilities for storage of goods or Yes Dedicated storage area for storage of
materials? Raw Materials, finished products and
solvents, etc. shall be provided.
1.15 Facilities for treatment or disposal of Yes Facilities for treatment or disposal of
solid waste or liquid effluents? liquid effluents are given as
Annexure – V & Facilities for
treatment or disposal of solid waste
is given as Annexure –VI.
1.16 Facilities for long term housing of No The unit shall be running round the
operational workers? clock. The operational staff will be
recruited locally and working in shift,
hence no housing for the operational
workers.
1.17 New road, rail or sea traffic during No There will not be any new road/rail
Construction or Operation? or sea traffic during construction or
operational phase.
1.18 New road, rail, air waterborne or other No --
4
transport infrastructure including new
or altered routes and stations, ports,
airports etc?
1.19 Closure or diversion of existing No --
transport routes or infrastructure
leading to changes in traffic
movements?
1.20 New or diverted transmission lines or No --
Pipelines?
1.21 Impoundment, damming, culverting, No --
realignment or other changes to the
hydrology of watercourses or aquifers?
1.22 Stream crossings? No --
1.23 Abstraction or transfers of water form Yes Water Source: GIDC Water Supply
ground or surface waters?
1.24 Changes in water bodies or the land No --
surface
Affecting drainage or run-off?
1.25 Transport of personnel or materials for Yes By road only.
construction, operation or
decommissioning?
1.26 Long-term dismantling or No --
decommissioning or restoration works?
1.27 Ongoing activity during No --
decommissioning which could have an
impact on the environment?
1.28 Influx of people to an area either No --
temporarily or permanently?
1.29 Introduction of alien species? No --
1.30 Loss of native species or genetic No --

diversity?
1.31 Any other actions? No --
2. Use of Natural resources for construction or operation of the Project (such as land, water,
materials or energy, especially any resources which are non-renewable or in short supply):
Sr. Information/checklist confirmation Yes/ Details there of (with approximate

No. No quantities frates, wherever possible) with
source of information data
2.1 Land especially undeveloped or No The land is for Industrial Use
agricultural land (ha)
2.2 Water (expected source & competing Yes Water Source = GIDC Water Supply
users) unit: KLD Water balance is given as Annexure – IV
5
2.3 Minerals (MT) No --
2.4 Construction material - stone, Yes Construction materials like steel, cement,
aggregates, crushed stones, sand, rubble, etc.
and / soil (expected source - MT) required for the project shall be procured
from the local market of the region.
2.5 Forests and timber (source - MT) No. --
2.6 Energy including electricity and fuels Yes Power required from DGVCL is
(source, competing users) Unit: fuel Proposed = 200 KW
(MT), energy (MW) D. G. Set : Proposed = 250 KVA
Fuel
Proposed
Bio-Coal/ Agro waste : 7.5 MT/day
Natural Gas: 1300 Nm3/Day
HSD: 1.4 MT/Day
2.7 Any other natural resources (use No --
appropriate standard units)
3. Use, storage, transport, handling or production of substances or materials, which could

be harmful to human health or the environment or raise concerns about actual or
perceived risks to human health.
Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

No. No quantities/rates, wherever possible) with
3.1 Use of substances or materials, which Yes For details please refer Annexure – VIII
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
3.2 Changes in occurrence of disease or No --
affect disease vectors (e.g. insect or
water borne diseases)
3.3 Affect the welfare of people e.g. by No --
changing living conditions?
3.4 Vulnerable groups of people who could No --
be affected by the project e.g. hospital
patients, children, the elderly etc.
3.5 Any other causes No --
6
4. Production of solid wastes during construction or operation or decommissioning

4.1 Spoil, overburden or mine wastes No --
4.2 Municipal waste (domestic and or No --

commercial wastes)
4.3 Hazardous wastes (as per Hazardous Yes Please refer Annexure –VI
Waste Management Rules)
4.4 Other industrial process wastes No --
4.5 Surplus product No --
4.6 Sewage sludge or other sludge from Yes
Please refer Annexure – VI
effluent treatment
4.7 Construction or demolition wastes No Construction waste shall be utilized for
leveling & land filling in the premises.
4.8 Redundant machinery or equipment No --
4.9 Contaminated soils or other materials No --
4.10 Agricultural wastes No --
4.11 Other solid wastes Yes Please refer Annexure –VI
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

No. No quantities/rates, wherever possible)
5.1 Emissions from combustion of fossil Yes For details Please refer Annexure – VII.
fuels from stationary or mobile
sources
5.2 Emissions from production processes Yes Stack emission will remain within the
norms prescribed by CPCB. Please refer
Annexure – VII.
5.3 Emissions from materials handling Yes The construction materials such as stones,
storage or transport cements, bricks & coal may pollute the air by
dust particles. But it will be controlled by
covering the trucks & trailers by clothes during
transportation.
5.4 Emissions from construction activities Yes During construction work, the Nearby
including plant and equipment buildings area will be covered by sheets or
clothes to avoid dust Contamination in air.
7
5.5 Dust or odors from handling of No --
materials including construction
materials, sewage and waste
5.6 Emissions from incineration of waste No --
5.7 Emissions from burning of waste in No --
open air (e.g. slash materials,
construction debris)
5.8 Emissions from any other sources No --
6. Generation of Noise and Vibration, and Emissions of Light and Heat:

with source of information data with
6.1 From operation of equipment e.g. Yes The Noise level will be within the
engines, ventilation plant, crushers prescribed limit. Adequate preventive &
control measures will be taken at noisy
area. No significant noise, vibration or
emission of light & heat from the unit.
6.2 From industrial or similar processes No All machinery / equipment shall be well
maintained, shall have proper
foundation with anti-vibrating pads
wherever applicable to keep noise levels
within permissible limits. Acoustic
enclosures shall be provided for DG set.
6.3 From construction or demolition No --
6.4 From blasting or piling No --
6.5 From construction or operational No --
traffic
6.6 From lighting or cooling systems No --
6.7 From any other sources No --
7. Risks of contamination of land or water from releases of pollutants into the ground or into
sewers, surface waters, groundwater, coastal waters or the sea:

7.1 From handling, storage, use or spillage Yes For detail please refer Annexure – VIII
of hazardous materials
7.2 From discharge of sewage or other No --
effluents to water or the land
(expected mode and place of
8
discharge)
7.3 By deposition of pollutants emitted to No --

air into and or into water
7.4 From any other sources No --
7.5 Is there a risk of long term build up of No --
pollutants in the environment from
these sources?
8. Risk of accidents during construction or operation of the Project, which could affect
human health or the environment

8.1 From explosions, spillages, fires etc. Yes For detail please refer Annexure – VIII
from storage, handling, use or
production of hazardous substances
8.2 From any other causes No --
8.3 Could the project be affected by No --

natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
9. Factors which should be considered (such as consequential development) which could lead
to environmental effects or the potential for cumulative impacts with other existing or
planned activities in the locality

9.1 Lead to development of supporting. Yes For detail please refer Annexure – IX
lities, ancillary development or
development stimulated by the
project which could have impact on
the environment e.g.
• Supporting infrastructure (roads,

power supply, waste or waste water
treatment, etc.)
• housing development
• extractive industry
• supply industry
• other
9
9.2 Lead to after-use of the site, which No --
could have an impact on the
environment
9.3 Set a precedent for later No --
developments
9.4 Have cumulative effects due to No --
proximity to other existing or
planned projects with similar effects
(II) Environmental Sensitivity
Sr. Areas Name/ Aerial distance (within 15km.)

No. Identity Proposed project location boundary
1 Areas protected under international Yes Site is located in Dahej-II Industrial

conventions, national or local legislation for Area, Tal. Vagra, Dist. Bharuch, Gujarat.
their ecological, landscape, cultural or other
related value
2 Areas which important for are or sensitive Yes Site is located in Dahej-II Industrial
Ecol logical reasons - Wetlands, Area, Tal. Vagra, Dist. Bharuch, Gujarat.
watercourses or other water bodies, coastal Forest area of Rajpipla is 100 kms
zone, biospheres, mountains, forests away.
3 Area used by protected, important or Yes Site is located in Dahej-II Industrial
sensitive Area, Tal. Vagra, Dist. Bharuch, Gujarat.
Species of flora or fauna for breeding,
nesting, foraging, resting, over wintering,
migration
4 Inland, coastal, marine or underground Yes Narmada River: 10 km (approx.) away
waters from Project Site
5 State, National boundaries No N.A.
6 Routes or facilities used by the public for No Public transportation
access to recreation or other tourist, pilgrim
areas
7 Defense installations No N.A.
8 Densely populated or built-up area No Bharuch City: 5 lakh population.
9 Area occupied by sensitive man-made land No N.A.

uses Hospitals, schools, places of worship,
community facilities)
10 Areas containing important, high quality or No The project being in industrial area
scarce resources (ground water resources, does not affect agricultural land.
surface resources, forestry, agriculture,
fisheries, tourism, minerals)
10
11 Areas already subjected to pollution No Site is located in Dahej-II Industrial
environmental damage. (those where Area, Tal. Vagra, Dist. Bharuch,
existing legal environmental standards are Gujarat.
exceeded)
12 Are as susceptible to natural hazard which No N.A.
could cause the project to present
environmental problems (earthquake,
subsidence, landslides, flooding erosion, or
extreme or adverse climatic conditions)
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – X.
I hereby give undertaking that, the data and information given in the application and enclosures
are true to the best of my knowledge and belief and I am aware that if any part of the data and
information submitted is found to be false or misleading at any stage the project will be rejected
and clearance given, if any, to the project will be revoked at our risk and cost.
Date: 26/4/2019
Place: Ankleshwar
Stamp and Signature of the Applicant
11
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE Page No.

I List of Products with their Production Capacity 13
II List of Raw materials 14
II Layout Map of the Plant 17
III Brief Manufacturing Process Description 18
IV Details of Water Consumption & Waste water Generation 55
V Details of Treatment Scheme and Disposal 57
VI Details of Hazardous /Solid Waste Generation, Handling and Disposal 61
VII Details of Stack and Vent 63
VIII Details of Hazardous Chemical Storage & Handling 64
IX Socio-Economic Impacts 65
X Proposed Terms of Reference for EIA studies 66
XI Toposheet 68
XII GIDC Plot Allotment Letter 69
XIII GIDC Water Supply Letter 70
12
ANNEXURE-I
LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY
SR. NAME OF PRODUCTS CAS NO. TOTAL PRODUCT

NO CAPACITY END – USE
(MT/MONTH)
1. META PHENYLENE DIAMINE-4-
88-63-1 DYES INTER.
SULPHONIC ACID
2. Acetyl M.P.D.S.A 88-64-2 DYES INTER.
3. CARBAMOYL PYRIDONE 34562-97-5 DYES INTER.
4. SULPHOMETHYL PYRIDONE 40306-70-5 DYES INTER.
5. META URIDO ANILINE 59690-88-9 DYES INTER.
6. 8 – HYDROXY QUINOLINE 148-24-3 PHARMA INTER.
7. 5-NITRO AMINO PHENOL & 4-NITRO
121-88-0 DYES INTER.
AMINO PHENOL 250
8. 4-CHLORO AMINO PHENOL 95-85-2 DYES/ PHARMA INTER.
9. 2-CHLORO AMINO RHENOL 3964-52-1 DYES/ PHARMA INTER
10. 5-CHLORO AMINO PHENOL 28443-50-7 DYES/ PHARMA INTER.
11. 5-CHLORO 8-HYDROXY QUINOLINE 130-16-5 PHARMA INTER.
12. 4-CHLORO NITRO PHENOL 89-64-5 DYE/PHARMA INTER.
13. 2-CHLORO NITRO PHENOL 619-08-9 DYE / PHARMA INTER.
14. 2,6-DICHLORO PARA NITRO ANILINE 90-30-9 DYES INTER.
15. 2-CHLORO-5-CHLOROMETHYL PYRIDIN 70258-18-3 SRECIALITY PRODUCT
16. 2,4-DINITRO CHLORO BENZENE 97-00-7 DYES INTER.
17. 2,4- DINITRO ANILINE 97-02-9 DYES INTER.
18. 2,6-DIBROMO PARA NITRO ANILINE 827-94-1 DYES INTER.
19. 2,5-DICHLORO NITRO BENZENE 89-61-2 DYES INTER.
20. 3,4-DICHLORO NITRO BENZENE 99-54-7 DYES INTER.
21. 2,5-DICHLORO ANILINE 95-82-9 1000 DYES INTER.
22. 2,3-DICHLORO ANILINE 608-27-5 DYES INTER.
25. 6-BROMO-2,4-DINITRO ANILINE 1817-73-8 DYES INTER.
26. 6-CHLORO-2,4-DINITRO ANILINE 3531-19-9 DYES INTER.
TOTAL 1250
13
LIST OF RAW MATERIALS
Sr. Name of the CAS / CI no. of Quantity
Name of the Raw Materials
no. Products raw materials. MT/Month
Sodium Bi sulfite 7631-90-5 345
2,4-Di Nitro Chloro Benzene 97-00-7 413.75
META PHENYLENE Magnesium Oxide 1309-48-4 86.25
1 DIAMINE-4- Iron Powder 7439-89-6 325
SULPHONIC ACID Hydrochloric acid 7647-01-0 189.75
Soda ash 497-19-8 25.75
Sodium chloride 7647-14-5 379.25
Sodium Bi sulfite 7631-90-5 345
Di Nitro Chloro Benzene 97-00-7 413.75
Magnesium Oxide 1309-48-4 86.25
Iron 7439-89-6 325
2 Acetyl M.P.D.S.A
Hydrochloric acid 7647-01-0 17.25
Soda ash 497-19-8 25.75
Sodium chloride 7647-14-5 379.25
Acetic Anhydride 108-24-7 172.5
Mono ethyl Amine 75-04-7 111
Methyl Cyanoacetate 105-34-0 145.75
CARBAMOYL
3 Sosa Ash 497-19-8 94.5
PYRIDONE
Methyl acetoacetate Easter 105-45-3 183.25
Sulfuric Acid (98%) 7664-93-9 1000
2-Carbamoyl Pyridone 29097-12-9 187.5
SULPHOMETHYL Sodium Bi Sulfite 7631-90-5 120
4
PYRIDONE Sulfuric Acid (45-55%) 7664-93-9 250
Formaldehyde 50-00-0 93.75
Meta Phenyline Diamine 108-45-2 166.5
META URIDO
5 Sodium Cynate 917-61-3 116.5
ANILINE
Hydrochloric Acid (30%) 7647-01-0 333.25
2-Aminophenol 95-55-6 289.5
Glycerin 56-81-5 206.25
8 – HYDROXY
6 Sulfuric Acid(45-55%) 7664-93-9 326.25
QUINOLINE
Acetic Acid 64-19-7 24
Caustic Lye 1310-73-2 459
Ortho Amino Phenol 95-55-6 190.5
Acetic acid 64-19-7 110.25
5-NITRO AMINO
Solvent Toluene 108-88-3 174.75
PHENOL & 4-
7 Solvent EDC 107-06-2 174.75
NITRO AMINO
Sulfuric Acid(45-55%) 7664-93-9 353.25
PHENOL
Nitric Acid 7697-37-2 157.25
Caustic Soda Lye 1310-73-2 17.5
2,5-DCNB 89-61-2 480.75
4-CHLORO AMINO
8 Caustic Soda Lye 1310-73-2 1071.25
PHENOL
HCL 7647-01-0 425
14
Iron Powder 7439-89-6 250
Activated Carbon 7440-44-0 12.5
3,4-DCNB 99-54-7 480.75
2-CHLORO AMINO
9 HCL 7647-01-0 425
RHENOL
2,4-DCNB 97-00-7 480.75
5-CHLORO AMINO
10 HCL 7647-01-0 425
PHENOL
4-Chloro 2-Aminophenol 95-85-2 156.25
4-Chloro 2-Nitrophenol 89-64-5 131.25
5-CHLORO 8- Glycerin 56-81-5 206.25
11 HYDROXY Sulfuric acid (45-55%) 7664-93-9 165
QUINOLINE Acetic Acid 64-19-7 25
NaOH (50%) 7647-14-5 275
Soda Ash 497-19-8 200
2,5 DCNB 89-61-2 312.5
4-CHLORO NITRO
12 Caustic Lye 1310-73-2 332
PHENOL
HCL 7647-01-0 390.75
3,4 DCNB 99-54-7 312.5
2-CHLORO NITRO
13 Caustic Lye 1310-73-2 332
PHENOL
HCL 7647-01-0 390.75
2,6-DICHLORO HCL( FRESH) 7647-01-0 225
14 PARA NITRO Para Nitro Aniline 100-01-6 173.75
ANILINE Chlorine Gas 7782-50-5 188.5
3-PICOLINE 108-99-6 231.75
Sodium Tangstate 10213-10-2 2.5
Hydrogen Peroxide 7722-84-1 203
Sulphuric Acid 7664-93-9 23.25
2-CHLORO-5- MDC 75-09-2 184.75
15 CHLOROMETHYL Triethylamine 121-44-8 247.25
PYRIDIN HCl 7647-01-0 3.25
Benzoyl Chloride 98-88-4 103
Sodium Hydroxide 1310-73-2 7.75
Chlorine Gas 7782-50-5 101.75
Azo Isobutro Nitrile 78-67-1 8.5
Para Nitro Chloro Benzene 100-00-5 778
2,4-DINITRO
16 Nitric Acid (98%) 7697-37-2 340
CHLORO BENZENE
Sulfuric Acid (98%) 7664-93-9 296
2,4- DINITRO 2,4-DiNitro Chloro benzene 97-00-7 1140
17
ANILINE Liquid Ammonia 7664-41-7 1500
2,6-DIBROMO Para Nitro Aniline 100-01-6 475
18
PARA NITRO HCL (fresh) 7647-01-0 300
15
ANILINE Liquid Bromine 7726-95-6 575
Chlorine Gas 7782-50-5 275
2,5 – DCB 20103-09-7 918
2,5-DICHLORO
19 Nitric Acid (fresh) 7697-37-2 406
NITRO BENZENE
Sulfuric Acid 7664-93-9 340
3,4 – DCB 5858-17-3 918
3,4-DICHLORO
20 Nitric Acid (fresh) 7697-37-2 406
NITRO BENZENE
Sulfuric Acid 7664-93-9 340
2,5-DCNB 89-61-2 1282
2,5-DICHLORO Iron Powder 7439-89-6 350
21
ANILINE HCL 7647-01-0 77
Caustic Soda Lye 1310-73-2 64
2,3-DCNB 3209-22-1 1282
22
3,4-DCNB 99-54-7 1282
23
3,5-DCNB 618-62-2 1282
24
2,4-DNA 97-02-9 715
6-BROMO-2,4- Chlorine Gas 7782-50-5 145
25
DINITRO ANILINE Liq. Bromine 7726-95-6 325
HCL 7647-01-0 505
2,4-DNA 97-02-9 705
6-CHLORO-2,4-
26 HCL 7647-01-0 885
DINITRO ANILINE
Chlorine Gas 7782-50-5 280
16
ANNEXURE-II
LAYOUT MAP OF THE PLANT
17
ANNEXURE-III
BRIEF PROCESS DESCRIPTION
1. META PHENYLENE DIAMINE-4-SULPHONIC ACID:
MANUFACTURING PROCESS:
Charge 2400 KG DNCB, 6500 Liter water, 500 Kg Magnesium oxide in S.S vessel. Then add
sodium bisulfite 2000 Kg. Free starring for 2 hours then filtrate it. Filtrate liquid charged in
another S.S. vessel. Then add 2200 Kg sodium chloride. Then do isolation. After 2 hour filtrate it.
Filtrate mass charged in reduction vessel than add water of previous batch than add 3000 Kg
iron, 100 Kg hydrochloric acid and 150 Kg soda ash. After 2 hour filter than charge all liquid
material in tie line vessel and charge 1000 Kg HCL. Then isolate the material, than after 3 hours
do centrifuge.
CHEMICAL REACTION
MATERIAL BALANCE
INPUT KG OUTPUT KG
SBS 1380 REACTION MASS 7863
DNCB 1655 SULPHONATION
CONDENSET WATER (FROM MEE)
REUSE 4483
MGO 345
TOTAL 7863 TOTAL 7863
INPUT KG OUTPUT KG
REACTION MASS 7863 FILTER FILTRATE REACTION MASS 7483
WASTE MGO 380
INPUT KG OUTPUT KG
FILTRATE MASS 7483 ISOLATION MASS 9000
NACL 1517
18
INPUT KG OUTPUT KG
MASS 9000 FILTER WET CAKE 2517
EFFLUENT TO MEE 6483
INPUT KG OUTPUT KG
WET CAKE 2517 MASS 6592
CONDENSET WATER FROM MEE 103
FRESH WATER 2500 REDUCTION
IRON POWDER 1300
HCL 69
SODA ASH 103
INPUT KG OUTPUT KG
MASS 6592 FILTER IRON SLUDGE 2145
MASS 4447
INPUT KG OUTPUT KG
MASS 4447 ISOLATION MASS 5137
HCL 690
INPUT KG OUTPUT KG
MASS 5137 CENTRIFUGE PRODUCT 1103
INPUT KG OUTPUT KG
MASS 1103 DRYING PRODUCT 1000
LOSS 103
19
2. ACETYL MPDSA:
MANUFACTURING PROCESS
Charge 2400 KG DNCB, 6500 Liter water, 500 Kg Magnesium oxide in S.S vessel. Then add
sodium bisulfite 2000 Kg. Free starring for 2 hours then filtrate it. Filtrate liquid charged in
another S.S. vessel. Then add 2200 Kg sodium chloride. Then do isolation. After 2 hour filtrate it.
Filtrate mass charged in reduction vessel than add water of previous batch than add 3000 Kg
iron, 100 Kg hydrochloric acid and 150 Kg soda ash. After 2 hour filter than charge all liquid
material in tie line vessel and charge 1000 Kg ACETIC ANHYDRIDE. Then isolate the material,than
after 3 hours do centrifuge
CHEMICAL REACTION
MATERIAL BALANCE
INPUT KG OUTPUT KG
SBS 1380 REACTION MASS 7863
DNCB 1655 SULPHONATION
CONDENSET WATER (FROM MEE)
REUSE 4483
MGO 345
INPUT KG OUTPUT KG
REACTION MASS 7863 FILTER FILTRATE REACTION MASS 7483
WASTE MGO 380
INPUT KG OUTPUT KG
FILTRATE MASS 7483 ISOLATION MASS 9000
NACL 1517
INPUT KG OUTPUT KG
MASS 9000 FILTER WET CAKE 2517
20
INPUT KG OUTPUT KG
WET CAKE 2517 MASS 6592
CONDENSET WATER FROM MEE 103
FRESH WATER 2500 REDUCTION
IRON POWDER 1300
HCL 69
SODA ASH 103
INPUT KG OUTPUT KG
MASS 6592 FILTER IRON SLUDGE 2145
MASS 4447
INPUT KG OUTPUT KG
MASS 4447 ISOLATION MASS 5137
ACETIC ANHYDRIDE 690
INPUT KG OUTPUT KG
MASS 5137 CENTRIFUGE PRODUCT 1103
INPUT KG OUTPUT KG
LOSS 103
21
3. Carbamoyl Pyridone:
Process Description:
Manufacturing Process:
Mono ethyl amine, Cyanoethyl acetate and methyl acetoacetate ester are reacted together in a
reactor. When the reaction is completed, the mass is isolated by addition of sulphuric acid.
Spent sulphuric acid is collected and utilized for the manufacture of Magnesium sulphate. The
product is then filtered and washed with water. Wash water is collected and recycled. The wet
cake is dried in dryer and packed.
Chemical Reaction:
22
Mass Balance:
INPUT KG OUTPUT KG
MONO METHYL AMINE 444 CYNO AMIDE 1405
METHYL CYNO ACETATE 583 CONDENSATION
SODA ASH 378
INPUT KG OUTPUT KG
CYNO AMIDE 1405 CONDENSATION CYNO PYRIDONE 2138
METHYL ACETO ACETATE ESTER 733
INPUT KG OUTPUT KG
CYNO PYRIDONE 2138 HYDROLYSIS MASS 6138
H2SO4(98%) 4000
INPUT KG OUTPUT KG
WASH WATER FROM PRIVIUS BATCH 3852 DROWNING 2-PYRIDONE(75%) 1139
MASS 6138 SPENT (H2SO4)(45-55%) 8851
INPUT KG WASHING,FILTER OUTPUT KG

FRESH WATER 3852 & MASS 1139
MASS 1139 CENTRIFUGE REUSE IN NEXT BATCH 3852
INPUT KG OUTPUT KG
MASS 1139 DRYING LOSS 139
PRODUCT 1000
23
4. SULPHOMETHYL PYRIDONE :
In reactor take 1000 lit water charge 480 kg sodium bisulfite then add 375 kg formaldehyde
under cooling then add 751 kg 2-carbamoyl c stirrpyridone heat to 75 then check sample if ok
cool to Rt add slowly dil. sulfuric acid 55-60% under cooling then filter centrifuge it.
Chemical Reaction:
24
Mass Balance:
INPUT KG OUTPUT KG
2-CARBAMOYL PYRIDONE 750 MASS 3605
MEE CONDENSET WATER 1000 SULPHONATION
SODIUM BI SULPHITE 480
SPENT H2SO4 (45-60%) 1000
FORMALDEHYDE 375
INPUT KG OUTPUT KG
MASS 3605 CENTRIFUGE WETCAKE 1250
EFFLUENT 2355
INPUT KG OUTPUT KG
WET CAKE 1250 DRYING PRODUCT 1000
LOSS 250
25
5. Meta Urido Aniline:
Meta Phenyline Diamine is treated with sodium cynate and Hydrochloric acid to produce Meta
uriedo aniline and then filtered.
Mother Liquor generated from process is sent to ETP and wet cake is centrifuged and packed as
final product.
Chemical reaction:
Stage-1
Material Balance:
INPUT KG OUTPUT KG
META PHENYLENE
DIAMINE 666 MASS 4131
SODIUM CYNATE 466 REACTION
HCL (30%) 1333
MEE CONDENSET WATER 1666
INPUT KG OUTPUT KG
MASS 4131 CENTRIFUGE WETCAKE 1133
INPUT KG OUTPUT KG
LOSS 133
26
6. 8 – Hydroxy Quinoline:
2-Amino Phenol is reacted with Glycerine leading to cyclization in presence of Sulfuric Acid. The
reaction leads to form 8-Hydroxyquinoline; the excess of 2-Amino Phenol is removed by
distillation.
The residual mass diluted with water and pH adjusted with C S Lye followed by filtration and
washing. The wet cake dried to obtain product 8-Hydroxyquinoline [8-HQ]
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
ORTHO AMINO PHENOL 1158 MASS 3689
GLYCERINE 825 HYDROLYSIS RECOVERED- OAP 260
H2SO4 1305
ACETIC ACID 96
FRESH WATER 565
INPUT KG OUTPUT KG
PH
MASS 3689 ADJUSTMENT MASS 10525
CS LYE 1836
CONDENSET WATER FROM
MEE 5000
INPUT KG OUTPUT KG
MASS 10525 FILTER MASS 1418
FRESH WATER FOR WASHING 1500 EFFLUENT 10607
INPUT KG OUTPUT KG
LOSS 418
27
7. 5-Nitro Amino Phenol & 4-Nitro Amino Phenol :
Ortho amino phenol is acetylated using acetic acid for producing the amine group. Acetylated
intermediate is then subjected to nitration using mix acid of nitric and sulphuric Acid. The
nitrated mass after waste up is hydrolyzed yielding desired product.
Chemical reaction:
28
Material Balance
INPUT KG OUTPUT KG
ORTHO AMINO PHENOL 762 MASS 1063
SOLVENT TOLUENE 699 ACETYLATION EFFLUENT TO MEE 490
ACETIC ACID 441 TOLUENE RECOVERED 685
MEE CONDENSET WATER 350 DISTILLATION LOSS 14
INPUT KG OUTPUT KG
MASS 1063 MASS 2021
SOLVENT EDC 699 SPENT ACID 1713
H2SO4 1413 NITRATION EFFLUENT TO MEE 490
NITRIC ACID 629
CS LYE 70
MEE CONDENSETWATER FOR
WASH 350
INPUT KG OUTPUT KG
MASS 2021 FILTER PRODUCT 1000
WATER FOR WASHING 699 & DISTILLATION LOSS 30
CONDENSET WATER FROM MEE 2448 DRYING RECOVERED EDC 686
CS LYE 583 EFFLUENT TO MEE 4035
29
8. 4-Chloro Amino Phenol
2,5Dichloronitrobenzene [2,5 DCNB] is hydrolysed with Sodium Hydroxide at a
controlledreaction parameter. After the hydrolysis is completed, ML from the reaction mass is
decantedand the residual mass is acidified.
The Acidified mass is then subjected to conventional reduction using Iron Powder. After
completion of reduction Iron Sludge separated out. The residual filtrate is treated with activated
charcoal, followed by Charcoal removal and adding other additives along with pH adjustment is
then filtered, washed and dried.
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
2,5 DCNB 1923 REACTION MASS 5000
CS LYE 2043 HYDROLYSIS EFFLUENT TO MEE 466
MEE CONDUNSET WATER 1500
INPUT KG OUTPUT KG
REACTION MASS 5000 REACTION MASS 8942
HCL 1000
IRON POWDER 1000 REDUCTION
CS LYE 1442
INPUT KG OUTPUT KG
MASS 8942 FILTERATION MASS 6686
MEE CONDUNSETWATE FOR
WASHING 500 IRON SLUDGE 2756
INPUT KG OUTPUT KG
MASS 6686 CARBON MASS 7336
ACTIVATED CARBON 50 TREATMENT CARBON SLUDGE 100
HCL 700
30
INPUT KG OUTPUT KG
MASS 7336 MASS 9636
CS LYE 800
FRESH WATER 1500 PH ADJUSTMENT
INPUT KG OUTPUT KG
MASS 12450 FILTER EFFLUENT TO MEE 8736
WASH 1000 MASS 1900
INPUT KG OUTPUT KG
LOSS 900
31
9. 2-Chloro Amino Rhenol
3,4Dichloronitrobenzene [3,4 DCNB] is hydrolysed with Sodium Hydroxide at a controlled
reaction parameter. After the hydrolysis is completed, ML from the reaction mass is decanted and
the residual mass is acidified.
 The Acidified mass is then subjected to conventional reduction using Iron Powder. After
then filtered, washed and dried.
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
HCL 1000
CS LYE 1442
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
32
HCL 700
INPUT KG OUTPUT KG
MASS 7336 MASS 9636
CS LYE 800
FRESH WATER 1500 PH ADJUSTMENT
INPUT KG OUTPUT KG
WASH 1000 MASS 1900
INPUT KG OUTPUT KG
LOSS 900
33
10. 5-Chloro Amino Phenol
reaction parameter. After the hydrolysis is completed, ML from the reaction mass is decanted and
the residual mass is acidified.
The Acidified mass is then subjected to conventional reduction using Iron Powder. After
then filtered, washed and dried
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
HCL 1000
CS LYE 1442
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
34
HCL 700
INPUT KG OUTPUT KG
MASS 7336 MASS 9636
CS LYE 800
PH
FRESH WATER 1500 ADJUSTMENT
INPUT KG OUTPUT KG
WASH 1000 MASS 1900
INPUT KG OUTPUT KG
LOSS 900
35
11. 5-Chloro 8-Hydroxy Quinoline:
4-Chloro-2-Amino Phenol is reacted with Glycerine leading to cyclization in presence of Sulphuric
Acid. The reaction leads to form 5-Chloro-8-Hydroxyquinoline; the excess of 4-CAP is removed by
distillation.
The residual mass diluted with water and pH adjusted with C S Lye followed by filtration and
washing. The wet cake dried to obtain product 5-Chloro-8-Hydroxyquinoline [5-CHQ]
Chemical Reaction:
Mass Balance:
INPUT KG OUTPUT KG
4 CAP 625 MASS 2735
GLYCERINE 825 REACTION
4 CNP 525
H2SO4(45-60%) 660
ACETIC ACID 100
INPUT KG OUTPUT KG
MASS 2735 PH ADJUSTMENT MASS 6995
NAOH 1100 & FILTER SLUDGE 340
INPUT KG OUTPUT KG
MASS 6995 ISOLATION & WET CAKE 1100
SODA ASH 800 CENTRIFUGE EFFLUENT TO MEE 6695
INPUT KG OUTPUT KG
LOSS 100
36
12. 4-Chloro Nitro Phenol :
reaction parameter. After the hydrolysis is completed, ML from the reaction mass is decanted
and the residual mass is acidified.
The Acidification results into falling out of 4-Chloro-2-Nitro Phenol [4-CNP], which is filtered,
washed and dried.
Chemical Reaction:
Mass Balance:
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
HCL 1563 ACIDIFICATION
INPUT KG OUTPUT KG
MEE CONDUNSET WATER FOR
WASH 1200 MASS 1400
INPUT KG OUTPUT KG
LOSS 400
37
13. 2-Chloro Nitro Phenol :
Take 3,4Dichloronitrobenzene [3, 4 DCNB] is hydrolysed with Sodium Hydroxide at a controlled
reaction parameter. After the hydrolysis is completed, ML from the reaction mass is decanted
and the residual mass is acidified.
The Acidification results into falling out of 2-Chloro-4-Nitro Phenol [2-CNP], which is filtered,
washed and dried.
Chemical Reaction:
Material Balance:
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
HCL 1563 ACIDIFICATION
INPUT KG OUTPUT KG
MEE CONDENSET WATER FOR WASH 1200 MASS 1400
INPUT KG OUTPUT KG
LOSS 400
38
14. 2,6-Dichloro Para Nitro Aniline :
In reactor charge hydrochloric acid. Add Para nitro aniline then pass chlorine gas. Scrubber is on
throughout process. Then filter, wash, wet cake sent for drying. Filtrate reuse in next batch.
Chemical Reaction:
Mass Balance:
INPUT KG OUTPUT KG
PARA NITRO ANILINE 695 MASS 4349
HCL(FRESH) 900 REACTION
CHLORIN GAS 754
INPUT KG OUTPUT KG
MASS 4349 WET CAKE 1250
MEE CONDENSET WATER 2000 FILTERATION EFFLUENT TO MEE 5099
INPUT KG OUTPUT KG
LOSS 250
39
15. 2-Chloro-5-Chloromethyl Pyridin :
Manufacturing Process
Step-1 3-Picoline when reacted with H2O2 and H2SO4 in a reaction vessel forms 3- Picoline –
N-Oxide Solution.
Step–2 This 3-Picoline-N-Oxide Solution is further treated with triethyl amine, benzoyl
chloride and MDC to form CMP Isomers.
Step–3 Chlorine gas along with CMP and AIBN gives 2-Chloro 5- Chloro Methyl Pyridine
(CCMP)
Chemical Reaction
40
Material Balance
INPUT KG OUTPUT KG
SULPHURIC ACID 93 MASS 1863
3-PICOLINE 927 REACTION EFFLUENT TO MEE 1007
SODIUM TUNGSTATE 10
HYDROGEN PEROXIDE 812
INPUT KG OUTPUT KG
MASS 1863 WET CAKE 1083
MDC 739 REACTION EFFLUENT TO MEE 629
TRIETHYL AMINE 989 MDC RECYCLED 724
HCL 13 TRIETHYL AMINE RECYCLED 959
BENZOYL CHLORIDE 412 BENZOIC ACID RECYCLED 652
SODIUM HYDROXIDE 31
INPUT KG OUTPUT KG
WET CAKE 1083 REACTION PRODUCT 1000
MEE CONDENSET WATER 50 EFFLUENT TO MEE 487
CHLORINE GAS 407 LOSS 87
AZO ISOBUTYRO NITRILE 34
41
16. 2,4-Dinitro Chloro Benzene :
Mixed acid containing concentrated nitric acid and concentrated sulphuric acid is reacted with
Para Nitro Chloro Benzene to produce 2, 4 Di Nitro Chloro Benzene. The reaction gets completed
in series of Nitrators with cooling coils and jackets. Reaction is followed by spent acid separation,
washing by water, drying to get a 2, 4 Di Nitro Chloro Benzene.
CHEMICAL REACTION:
MATERIAL BALANCE:
INPUT KG OUTPUT KG
PARA NITRO CHLORO BENZENE 1945 MASS 4092
CON.NITRIC ACID 850 NITRATION
CON.SULPHURIC ACID 740
RECOVERED SPENT ACID 557
INPUT KG OUTPUT KG
MASS 4092 MIXED ACID 1285
WATER 250 SEPARATION SPENT ACID REUSE 557
DNCB 2500
INPUT KG OUTPUT KG
CRUDE DNCB 2500 WASHING MASS 2750
WATER WASH 250
INPUT KG OUTPUT KG
MASS 2750 SEPARATION PRODUCT 2500
EFFLUENT 250
42
17. 2,4- Dinitro Aniline :
In reactor take liq. Ammonia, then add 2,4: DNCB, then close all opening heat to 120○C, Pressure
3.5 Kg/cm2. Maintain for 4 hrs. Start ammonia recovery. R/NH3=100 Kgs (Real). Then cool to
room temperature. Filter & filtrate goes to ETP.
CHEMICAL REACTION:
MATERIAL BALANCE
INPUT KG OUTPUT KG
2,4 DNCB 1140 MASS 2640
AMMONIA 1500 REACTION AMMONIA RECOVERED
RECOVERED AMMONIA 100 FOR NEXT BATCH 100
INPUT KG OUTPUT KG
MASS 2640 FILTER & EFFLUENT 1300

CENTRIFUGE WET CAKE 1340
INPUT KG OUTPUT KG
LOSS 340
43
18. 2,6-Dibromo Para Nitro Aniline :
In the reaction vessel first Para nitro aniline and Hydrochloric acid is charged. Stirring is carried
out for 1 hour. Chilled liquid bromine is charged gradually with the help of dip pipe. Chlorination
is then carried out under cooling conditions with the help of chlorine gas for 6 to 7 hours.
Reacted material is checked and if found as per desired quality it is filtered in filter nutch. Filtrate
is reused in next batch. Chlorine, HCL, Bromine gases generated during reaction are sent to
Alkali scrubber. The process involves chlorination and bromination.
Finally washing is given to the cake with water. The wastewater goes to ETP. Cake is dried and
packed.
Chemical Reaction:
Mass Balance:
INPUT KG OUTPUT KG
PARA NITRO ANILINE 475 MASS 1825
HCL(FRESH) 300 REACTION
FRESH WATER 1050
INPUT KG OUTPUT KG
MASS 1825 MASS 2675
LIQ BROMINE 575 BROMINATION
CHLORINE GAS 275
INPUT KG OUTPUT KG
MASS 2675 FILTERATION WET CAKE 1345
EFFLUENT 1330
INPUT KG OUTPUT KG
DRYIN LOSS 345
44
19. 2,5-Dichloro Nitro Benzene
Mixed acid containing concentrated nitric acid and concentrated sulphuric acid is reacted with 2,
5 Di Chloro benzene to produce 2,5 Di Chloro nitro benzene . The reaction gets completed in
series of Nitrators with cooling coils and jackets. Reaction is followed by spent acid separation,
washing by water, drying to get a 2,5 Di Chloro nitro benzene.
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
2,5 DICHLORO BENZENE 918 MASS 3164
INPUT KG OUTPUT KG
SEPARATION SPENT ACID REUSE 1500
CRUDE DCNB 1115
INPUT KG OUTPUT KG
WATER WASH 110
INPUT KG OUTPUT KG
EFFLUENT 175
INPUT KG OUTPUT KG
DCNB 1050 CRYSTALIZER MASS 210
PRODUCT 840
45
INPUT KG OUTPUT KG
MASS 210 DISTILATION SLUDGE 50
PRODUCT 160
TOTAL 210 TOTAL 210
46
20. 3,4-Dichloro Nitro Benzene
Mixed acid containing concentrated nitric acid and concentrated sulphuric acid is reacted with 3,
4 Di Chloro benzene to produce 3,4 Di Chloro nitro benzene . The reaction gets completed in
series of Nitrators with cooling coils and jackets. Reaction is followed by spent acid separation,
washing by water, drying to get a 3,4 Di Chloro nitro benzene.
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
3,4 DICHLORO BENZENE 918 MASS 3164
INPUT KG OUTPUT KG
SEPARATION SPENT ACID REUSE 1500
CRUDE DCNB 1115
INPUT KG OUTPUT KG
WATER WASH 110
INPUT KG OUTPUT KG
EFFLUENT 175
47
INPUT KG OUTPUT KG
DCNB 1050 CRYSTALIZER MASS 210
PRODUCT 840
INPUT KG OUTPUT KG
MASS 210 DISTILATION SLUDGE 50
PRODUCT 160
TOTAL 210 TOTAL 210
48
21. 2,5-Dichloro Aniline
2, 5 Dichloro Nitro Benzene [2, 5 DCNB] is subjected to reduction using Iron Powder under acidic
condition to form 2, 5 Dichloro Aniline. 2, 5 DCA thus formed is then suitably isolated from the
reaction mixture by means of filtration and distillation.
Chemical Reaction:
Material Balance
INPUT KG OUTPUT KG
2,5 DCNB 1282 MASS 2542
HCL 77
WATER 833
INPUT KG OUTPUT KG
MASS 2542 FILTER PRESS IRON SLUDGE 424

MASS 2118
INPUT KG OUTPUT KG
MASS 2118 ISOLATION & MASS 1010
CS LYE 64 FILTER EFFLUENT 1172
INPUT KG OUTPUT KG
MASS 1010 DISTILLATION PRODUCT 1000
IRON SLUDGE 10
49
2,3Dichloro Nitro Benzene [2,3 DCNB] is subjected to reduction using Iron Powder under acidic
condition to form 2,3 Dichloro Aniline. 2, 3 DCA thus formed is then suitably isolated from the
Chemical reaction:
Material Balance
INPUT KG OUTPUT KG
2,3 DCNB 1282 MASS 2542
HCL 77
WATER 833
INPUT KG OUTPUT KG

MASS 2118
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
IRON SLUDGE 10
50
Chemical reaction:
Material Balance
INPUT KG OUTPUT KG
3,4 DCNB 1282 MASS 2542
HCL 77
WATER 833
INPUT KG OUTPUT KG

MASS 2118
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
IRON SLUDGE 10
51
Chemical reaction:
Material Balance
INPUT KG OUTPUT KG
3,5 DCNB 1282 MASS 2892
HCL 77
WATER 833
INPUT KG OUTPUT KG

MASS 2118
INPUT KG OUTPUT KG
INPUT KG OUTPUT KG
SLUDGE 10
52
25. 6-Bromo-2,4-Dinitro Aniline
In the reaction vessel first Para nitro aniline and Hydrochloric acid is charged. Stirring is carried
out for 1 hour. Chilled liquid bromine is charged gradually with the help of dip pipe.
Chlorination is then carried out under cooling conditions with the help of chlorine gas for 6 to 7
hours. Reacted material is checked and if found as per desired quality it is filtered in filter nutch.
Filtrate is reused in next batch. Chlorine, HCL, Bromine gases generated during reaction are sent
to Alkali scrubber. The process involves chlorination and bromination.
Finally washing is given to the cake with water. The wastewater goes to ETP. Cake is dried and
packed.
Chemical reaction:
Material Balance
INPUT KG OUTPUT KG
2,4 DNA 715 MASS 1680
LIQ BROMINE 325 REACTION UNREAACTED CL2 & BR2
CHLORINE GAS 145 TO SCRUBBER 10
HCL 505
INPUT KG OUTPUT KG

WASH WATER 400 CENTRIFUGE WET CAKE 1100
INPUT KG OUTPUT KG
LOSS 100
53
25. 6-Chloro-2,4-Dinitro Aniline
In the glass lined reaction vessel first hydrochloric acid is charged. Dinitro aniline is then added.
Chlorination is then carried out under cooling conditions with the help of chlorine gas for 12 to 24
hours. Reacted material is checked and if found as per desired quality it is filtered in filter nutch.
Filtrate is reused in next batch. Chlorine, HCL gases generated during reaction are sent to Alkali
scrubber. The process involves mainly chlorination. Finally washing is given to the cake with
water upto congo negative. The wastewater goes to ETP. Cake is dried and packed.
Chemical reaction:
Material Balance
INPUT KG OUTPUT KG
2,4 DNA 705 MASS 1860
HCL 885 REACTION UNREAACTED CL2 & BR2
CHLORINE GAS 280 TO SCRUBBER 10
INPUT KG OUTPUT KG

WASH WATER 500 CENTRIFUGE WET CAKE 1115
INPUT KG OUTPUT KG
LOSS 115
54
ANNEXURE - IV
WATER CONSUMPTION & WASTEWATER GENERATION
Proposed
Proposed Scenario (m3/day)
Sr. No. Category
Water Consumption Waste Water Generation
1 Industrial
Process 75.0 131.0
Boiler 20.0 1.0
Cooling 15.0 1.0
Washing 4.0 4.0
Scrubber 1.0 1.4
2 Gardening 3.0 --
3 Domestic 2.0 1.6
Total (Industrial) 115.0 138.4
Total 120.0 140.0
Note:
- Total water requirement will be 74 KLD.
- Total wastewater generation will be 140 KLD.
- Low COD & TDS effluent (43 KLD) will be treated in primary ETP and then sent to CETP,
Dahej.
- High COD & TDS effluent (88 KLD) will be treated in primary ETP with solvent stripper and
then sent to M/s. BEIL (35 KLD) and (50 KLD) effluent will be treated in-house MEE.
- 46 KLD from MEE condensate will be reused in Process.
- 1.6 KLD domestic waste water will be sent to Septic Tank & Soak Pit.
55
WATER BALANCE DIAGRAM
Total 120 KLD (Reuse: 80 KLD + Fresh: 40 KLD)
Process: 75 Boiler:
KLD (Reuse: 60 Washing: Cooling Gardeni Scrubber:
Domestic: 2.0 (Reuse:
+ Fresh: 15) 4 KLD Tower: 15 ng: 3 1 KLD
KLD 20 KLD)
KLD KLD
1.4 KLD
131 KLD 4 KLD
Soak Pit/ 1 KLD 1 KLD Scrubber: 0.71 KLD of
Septic Tank: Dil. HCl (reuse in Mfg.
1.6 KLD process)
ETP: 92 Scrubber: 0.29 KLD of
KLD Sodium sulphite (sold
under rule-9
ETP: 45 KLD permission)
Stripper Scrubber: 0.42 KLD of
Solvent Stripper:
Loss: 3 KLD Dil. HBr (sold under
92 KLD
rule-9 permission)
CETP, Dahej
MEE Salt:
MEE: 89 KLD 5 KLD
80 KLD MEE Loss: 4

Condensate reused KLD
in Process & Boiler
56
ANNEXURE - V
EFFLUENT TREATMET PLANT DETAILS:
M/s. Umiya Dyes and Intermediates shall have an Effluent treatment plant consisting of primary
and advance treatment units. The details of up gradation ETP are as follows.
DETAILS OF EFFLUENT TREATMENT PLANT (Stream 1 ETP: 45 KLD)
All raw effluent streams of (low COD) of wastewater shall be collected in Collection cum
Neutralization Tank-01 (CNT-01) where the continuous addition and stirring of Alkaline solution
is done to maintain neutral pH of wastewater from Alkaline Dosing Tank (ALDT-01) as per
requirement by gravity. Mixer is provided in the CNT-01 to keep all suspended solids in
suspension and for proper mixing.
Then after, equalized wastewater shall be pumped to Flash Mixer-01 (FM-01) where Alum and
Poly shall be dosed from Alum Dosing Tank (ADT-01) and Poly Dosing Tank (PDT-01) respectively
by gravity. Then after, coagulated wastewater shall be settled in Primary Settling tank (PST-01).
Clear supernatant from PST-01 shall be passed in Aeration Tank (AT-01). Here, biodegradation of
organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the AT-
01 and for that oxygen shall be supplied by 2 nos. of air blowers (B-01-A/B) through diffusers. Air
blowers also keep MLSS in suspension.
Then after, wastewater shall go to Secondary Settling Tank (SST-01). Here, the suspended solids
shall be settled. Sludge shall be removed from bottom of SST-01 and pumped to AT-01 to
maintain MLSS and excess activated sludge shall be sent to Filter Press (FP-01). Nutrients will be
added from Nutrient Dosing Tanks (NDTs-01) to Aeration Tank for growth of Bacteria. Clear
effluent from SST-01 is the collected in Treated Effluent Sump (TES-01) by gravity before sent to
common effluent treatment plant of Dahej for further treatment and disposal.
Sludge settled in PST-01&PST-02, and excess sludge from SST-01 shall be collected in the sludge
shall be pumped to Filter Press (FP-01).Then, dewatered sludge shall be stored in HWSA and
then ultimate disposal shall be sent back to CNT-01 for further treatment.
DETAILS OF EFFLUENT TREATMENT PLANT (Stream 2 ETP: 92 KLD)

All raw effluent streams of high COD shall be collected inCollection cum Neutralization Tank-02
(CNT-02) where the continuous addition and stirring of Alkaline solution is done to maintain
neutral pH of wastewater from Alkaline Dosing Tank (ALDT-01) as per requirement by gravity.
Mixer is provided in the CNT-01 to keep all suspended solids in suspension and for proper
mixing.
Then effluent shall be Flash Mixer-02 (FM-02) where Alum and Poly shall be dosed from Alum
Dosing Tank (ADT-01) and Poly Dosing Tank (PDT-01) respectively by gravity. Then after,
coagulated wastewater shall be settled in Primary Settling Tank-02 (PST-02). Clear effluent from
PST-02 shall be collected in Holding Tank (HT-01). Then it will be pumped to Stripper (S-01)to
remove solvent from waste water and effluent from Stripper shall be then collected in MEE Feed
Tank (MFT-01). Then effluent from MFT-01 shall be sent to Multiple Effect Evaporator (MEE-01)
57
for further treatment followed by Agitated Thin Film Dryer (ATFD-01) for solids dewatering.
Condensate from MEE shall be collected in Condensate Storage Tank before reuse in Process &
Boiler and salts from ATFD-01 shall be collected and stored in HWSA for disposal in TSDF.
Details of ETP Units:

S.N. Name of unit Size No. MOC
L x B x (LD + FB) in m
Stream I (Low COD Stream)– 45 KLD
1 Collection cum Neutralization 4.0 x 3.0 x (2.5+0.5) 1 RCC M25 with
Tank-1 (CNT-01) A/A Lining
2 Flash Mixer-01 (FM-01) 1.5 x 1.5 (2.5+0.3) 1 RCC M25
3 Primary Settling Tank-01 (PST-01) 3.0 x 2.0 (2.0+1.0+0.5) 1 RCC M25
4 Aeration Tank (AT-01) 8.0 x 4.0 x (4.0+0.5) 1 RCC M25

5 Secondary Settling Tank-01 (SST- 4.0 x 2.0 (2.0+1.0+0.5) 1 RCC M25
01)
6 Treated Effluent Sump (TES-01) 6.0 x 3.0 x (2.5+0.5) 1 RCC M25
7 Alkaline Dosing Tank (ALDT-01) 2000 lit 1 HDPE
8 Alum Dosing Tank (ADT-01) 1500 lit 1 HDPE
9 Poly Dosing Tank (PDT-01) 1000 lit 1 HDPE
10 Sludge Sump 1 SSM25
11 Filter Press (FP-01) 4m3/D 1 MS+PP
Stream II (High COD Stream) 92 KLD
1 Collection cum Neutralization 6.0 x 4.0 x (2.5+0.5) 1 RCC M25 with
Tank-01 (CNT-01) A/A Lining
2 Flash Mixer-02 (FM-02) 2.0 x 1.5 (2.5+0.3) 1 RCC M25
3 Primary Settling Tank-01 (PST-02) 4.0 x 2.0 (2.5+1.0+0.5) 1 RCC M25
4 Holding Tank (HT-01) 6.0 x 4.0 x (2.5+0.3) 1 RCC M25
5 Strippers (ST-01) 100 m3/D 1 SS316l
6 MEE Feed Tank (MFT-01) 6.0 x 4.0 x (2.5+0.5) 1 RCC M25
7 Multiple Effect Evaporator 100 m3/D 1 SS316L
(MEE-01)
8 Agitated Thin Film Dryer (ATFD-01) 20 m3/D 1 SS316L
9 Condensate Storage tank (CST-01) 4.0 x 2.0 (2.0+1.0+0.5) 1 RCC M25
58
CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT (LOW COD& TDS)
Sr. Characteristics (mg/L)
Parameter CETP Inlet Norms
No. Untreated Final Treated
1. pH 6.0-8.0 7.0-7.5 6.5-7.5
2. TDS 5000 < 5000 8000
3. COD 4500 < 1000 5000
4. BOD3 2500 < 200 3500
5. Ammonical Nitrogen 150 < 50 200
CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT (High COD & TDS)
Sr. Characteristics (mg/L)
Parameter
No. Untreated Final Treated
1. pH 6.0-8.0 7.0-7.5
2. TDS 50,000 < 500
3. COD 25,000 < 500
4. Ammonical Nitrogen 150 < 50
59
BLOCK DIAGRAM FOR EFFLUENT TREATMENT PLANT
60
ANNEXURE-VI
DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL
Sr. Type Of Source Of Quantity Mode Of Treatment And

Category
No. Waste Generation (MT/Annum) Disposal
Collection, Storage and
reuse in Mfg Process of (2,5
Process
Spent H2SO4 Schedule- DCNB) + (5-Chloro 8-
1 Carbamoyl 26550
(50%) (I)-(26.3) Hydroxy Quinoline) = Reqd.
Pyridine
Qty. (25500) + (1980)
MT/Annum
Collection, Storage,
Process acetyl Schedule-
2 MGO Sludge 1120 Transportation and Disposal
MPDSA (I)-(26.1)
to TSDF site.
Process 2,5 Transportation and sent for
Process Schedule-
3 Dichloro Nitro 576 co-processing in cement
Waste (I)-(26.1)
Benzene industries or Disposal at
common incineration site.
Schedule-
4 ETP Sludge ETP Treatment 576 Transportation and Disposal
(I)-(35.3)
to TSDF site.
Discarded
Raw Material Schedule- Decontamination, Reuse,
5 Drums/Cont 2
and Storage (I)-(33.1) Transportation and sale to
ainers/Bags
authorized vendor.
From Moving Schedule-
6 Used Oil 6 Transportation, Reuse and
Machineries (I)-(5.1)
sale to authorized recycles.
5 Chloro Schedule-
7 Spent carbon 298.8 Transportation and Disposal
Amino Phenol (I)-(26.1)
to TSDF site.
Spent Manufacturing Schedule- Collection, Storage and sent
8 1300
Solvent Process (I)-(26.4) for Job Work.
Sodium
Schedule -
9 Sulphite Scrubber 102.9
(II)-B36 Collection, Storage,
(28%)
Transportation and Sell to
Dil.
end users Having
Hydrogen Schedule -
10 Scrubber 150 permission Rule-9
Bromide (II)-B36
(28%)
Salt from Schedule -
11 MEE Process 1800 Transportation and Disposal
MEE (I)-(35.3)
to TSDF site.
Solvent Solvent Schedule- Collection, Storage,
12 1080
Stripper Stripper (I)-(35.3) Transportation and sent for
61
Residue co-processing in cement
Off industries or Disposal at
Failure of Schedule-
13 Specification 12 common incineration site.
Batch (I)-(28.4)
Products
Process (4 Collection, Storage,
Chloro Amino Transportation and Disposal
Schedule-
14 Iron Sludge Phenol) + (2,5 13471.2 to co-processing in cement
(I)-(26.1)
Dichloro industries or to TSDF site.
Aniline)
Process 2,6 Collection, Storage and
Schedule-
15 Dichloro Para 18.33 reuse in manufacturing
Dilute HCl (I)-(26.3)
Nitro Aniline process of 2,6 Dichloro Para
(30%)
Schedule- Nitro Aniline (2700
16 Scrubber 257.1
(II)-(B15) MT/Annum)
62
ANNEXURE-VII
DETAILS OF STACK AND VENTS
Proposed Flue Gas Emission

Stack Stack attached Fuel used & rate of Stack Pollutnat APCM
no. to consumption height
(m)
Briquettes of Bio PM < 150mg/NM3 Multi-cyclone
1 Boiler (2 TPH) Coal/Coal (2.5 30 SO2 < 100 ppm separator
MT/Day) NOX < 50 ppm with bag filter
PM < 150mg/NM3
Natural Gas (1300 Adequate
2 Boiler (1 TPH) 30 SO2 < 100 ppm
Nm3/Day) Stack Height
NOX < 50 ppm
Thermic Fluid Briquettes of Bio PM < 150mg/NM3 Multi-cyclone
3 Heater (5 lakhs Coal/Coal (5 30 SO2 < 100 ppm separator
kcal/hr) MT/Day) NOX < 50 ppm with bag filter
PM < 150mg/NM3
D. G Set (250 Adequate
4 HSD (1.4 MT/Day) 11 SO2 < 100 ppm
KVA) Stack Height
NOX < 50 ppm
Proposed Process gas Emission

Sr. Vent (m) Type of Emission
Source of Emission APCM
No. Height Diameter
Process Vent
HCl < 20 mg/Nm3 Two stage Water
1 (2,6 Dibromo Para Nitro 11 0.1
Cl2 < 9 mg/Nm3 scrubber
Aniline)
Process Vent Two stage Water +
2 11 0.1 SO2 < 40 mg/Nm3
(5 Nitro Amino Phenol) Alkali scrubber
Process Vent
Two stage water
3 (6-Bromo-2,4-Dinitro 11 0.1 Br2 < 5 mg/Nm3
Scrubber
Aniline)
63
ANNEXURE-VIII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
SR. NAME OF THE MATERIAL TYPE OF NUMBER OF MAXIMUMA

NO HAZARD TANKS/CYLINDERS QTY TO STORE
1 HCL CORROSIVE 20 KL * 2 TANKS 40 KL
2 SULFURIC ACID CORROSIVE 30 KL TANK 30 KL
3 ACETIC ACID FLAMABLE 200 LITER DRUMS 5 KL
4 TOLUENE FLAMMABLE 200 LITER DRUMS 10 KL
5 EDC TOXIC 200 LITER DRUMS 10 KL
6 CHLORINE GAS TOXIC 900 KG TONNER 3 MT
7 MDC TOXIC 200 LITER DRUMS 10 KL
8 LIQUID AMMONIA CORROSIVE 200 LITER DRUMS 15 KL
9 LIQUID BROMINE CORROSIVE 3 KG BOTTLE * 8 10 KL
nos./CARBA
64
ANNEXURE-IX
___________________________________________________________________________
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
The manpower requirement for the proposed project is being expected to generate some
permanent jobs and secondary jobs for the operation and maintenance of plant. This will
increase direct / indirect employment opportunities and ancillary business development to some
extent for the local population.
This phase is expected to create a beneficial impact on the local socio-economic environment.
2) INDUSTRIES
Required raw materials and skilled and unskilled laborers will be utilized maximum from the
local area. The increasing industrial activity will boost the commercial and economical status of
the locality, to some extent.
3) PUBLIC HEALTH
The company regularly examines, inspects and tests its emission from sources to make sure that
the emission is below the permissible limit. Hence, there will not be any significant change in the
status of sanitation and the community health of the area, as sufficient measures have been
taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION

Since the existing factory is having proper linkage for the transport and communication, the
development of this project will not cause any additional impact.
In brief, as a result of the proposed project there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be taken
under the EMP. The proposed project is not expected to make any significant change in the
existing status of the socio - economic environment of this region.
65
ANNEXURE-X
___________________________________________________________________
PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Project location and Plant layout.
• Existing infrastructure facilities
• Water source and utilization including proposed water balance.
• List of Products and their capacity
• List of hazardous chemicals with their toxicity levels.
• Mass balance of each product along with the batch size
• Storage and Transportation of raw materials and products.
2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5
km area.
• Study of Data from secondary sources.
• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.
For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in the
study area were surveyed.
4. Impacts Identification and Mitigatory Measures.

• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan

• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
66
6. Risk Assessment
• Details on storage facilities
• Identification of hazards
• Consequence analysis
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Occupational Health and Safety Program for the Project.
67
ANNEXURE-XI
TOPOSHEET
68
ANNEXURE-XII
GIDC PLOT ALLOTMENT LETTER
69
70
ANNEXURE-XIII
GIDC WATER SUPPLY LETTER
71

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FORM-1

PROPOSED OF SPECIALTY CHEMICALS MANUFACTURING

M/s. UMIYA DYES & INTERMEDIATES

NABL Accredited Testing Laboratory

Sr. Item Details

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

Sr. Information/Checklist confirmation Yes/ Details thereof with approximate

1.30 Loss of native species or genetic No --

1.31 Any other actions? No --

Sr. Information/checklist confirmation Yes/ Details there of (with approximate

3. Use, storage, transport, handling or production of substances or materials, which could

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

3.5 Any other causes No --

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

4.1 Spoil, overburden or mine wastes No --

4.2 Municipal waste (domestic and or No --

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

7.3 By deposition of pollutants emitted to No --

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

8.3 Could the project be affected by No --

Sr. Information/Checklist confirmation Yes/ Details there of (with approximate

• Supporting infrastructure (roads,

(II) Environmental Sensitivity

Sr. Areas Name/ Aerial distance (within 15km.)

1 Areas protected under international Yes Site is located in Dahej-II Industrial

9 Area occupied by sensitive man-made land No N.A.

Stamp and Signature of the Applicant

SR. NO. NAME OF ANNEXURE Page No.

SR. NAME OF PRODUCTS CAS NO. TOTAL PRODUCT

1. META PHENYLENE DIAMINE-4-SULPHONIC ACID:

TOTAL 1405 TOTAL 1405

INPUT KG WASHING,FILTER OUTPUT KG

TOTAL 7795 TOTAL 7795

TOTAL 4341 TOTAL 4341

TOTAL 4341 TOTAL 4341

TOTAL 6349 TOTAL 2795

TOTAL 4047 TOTAL 4047

TOTAL 2740 TOTAL 2740

MASS 2640 FILTER & EFFLUENT 1300

TOTAL 1825 TOTAL 1825

TOTAL 2542 TOTAL 2542

MASS 2542 FILTER PRESS IRON SLUDGE 424

TOTAL 2542 TOTAL 2542

MASS 2542 FILTER PRESS IRON SLUDGE 424

TOTAL 2542 TOTAL 2542

MASS 2542 FILTER PRESS IRON SLUDGE 424

TOTAL 2892 TOTAL 2892

MASS 2892 FILTER PRESS IRON SLUDGE 774

MASS 1680 FILTER & EFFLUENT 980

MASS 1860 FILTER & EFFLUENT 1245

Total 120 KLD (Reuse: 80 KLD + Fresh: 40 KLD)

80 KLD MEE Loss: 4

DETAILS OF EFFLUENT TREATMENT PLANT (Stream 2 ETP: 92 KLD)