Pre-Feasibility Report: UPL LTD

PRE-FEASIBILITY REPORT
FOR
Proposed Expansion in Existing

Production Capacity & Addition of New
Products of Pesticides & Intermediates
within existing premises
OF
UPL Ltd.
AT
Plot No. 3–11, A–2/1, A–2/2, A–2/6 & A–1/2,

Phase – I, Notified GIDC Industrial Estate,
Vapi – 396195, Dist: Valsad, Gujarat.
Prepared By
Eco Chem Sales & Services
Surat
(NABET Accredited consultant)
Proposed Expansion in Existing Production Capacity &
Addition of New Products of Pesticides & Intermediates
within Existing Premises
Contents
LIST OF TABLES ...............................................................................................................................3
LIST OF ANNEXURE ........................................................................................................................4
1. EXECUTIVE SUMMARY ..........................................................................................................5
2. INTRODUCTION OF THE PROJECT .......................................................................................8
2.1 Identification of project and project proponent.....................................................................8
2.2 Brief description of nature of the project ..............................................................................9
2.3 Need of Proposed Project ......................................................................................................9
2.4 Demand Supply Gap .............................................................................................................9
2.5 Employment Generation .....................................................................................................10
3. PROPOSED PROJECT & APPLICABILITY OF EIA .............................................................11
4. PROJECT DESCRIPTION ........................................................................................................12
4.1 Project Location ..................................................................................................................12
4.2 Alternative Sites ..................................................................................................................12
4.3 Resource Requirement ........................................................................................................12
4.3.1 Raw Material ...............................................................................................................12
4.3.2 Land Requirement ........................................................................................................22
4.3.4 Power & Fuel ..............................................................................................................23
4.3.5 Water Requirement ......................................................................................................24
4.3.3 Man Power...................................................................................................................24
4.4 Product & By-Product .........................................................................................................25
5. MANUFACTURING PROCESS...............................................................................................28
5.1 Cypermethrin ......................................................................................................................28
5.2 Permethrin ...........................................................................................................................29
5.3 Propanil ...............................................................................................................................31
5.4 UPH 203 S – Safeners (Cloquinocnt Mexyl) ......................................................................32
5.5 Sulfosulfuron (SF-10) .........................................................................................................34
5.6 Alpha Cypermethrin ............................................................................................................37
5.7 Beta Cypermethrin ..............................................................................................................39
5.8 Imidacloprid ........................................................................................................................40
5.9 Bifenthrin ............................................................................................................................42
5.10 Lambda Cyhalothrin ...........................................................................................................44
5.11 Clodinifop ...........................................................................................................................48
5.12 Thiomethoxam (STAR) ......................................................................................................51
5.13 Desmedipham (DMP) .........................................................................................................53
5.14 Phenmedipham (PMP) ........................................................................................................55
5.15 Metribuzin ...........................................................................................................................57
5.16 Metamitron ..........................................................................................................................59
5.17 Aluminium Phosphide.........................................................................................................60
5.18 Magnesium Phosphide ........................................................................................................62
5.19 Zinc Phosphide ....................................................................................................................64
5.20 Red Phosphorus...................................................................................................................65
Pre-Feasibility Report Page 1

5.21 Denatonium Benzoate (DB) ................................................................................................66

5.22 Di Vinyl Acid Chloride (DVACl) .......................................................................................68
5.23 Metaphenoxy Benzaldehyde ...............................................................................................73
5.24 Azoxystrobin .......................................................................................................................77
5.25 Kresoxim Methyl ................................................................................................................80
5.26 Trifloxystrobin ....................................................................................................................84
5.27 Meta Phenoxy Benzyl Alcohol (MPBAL) ..........................................................................89
5.28 Triphenyle Phosphate (TPPA) ............................................................................................90
5.29 L-2 Chloro Propionic Acid .................................................................................................92
5.30 2-Chloro Propionic Acid Chloride ......................................................................................93
5.31 Amino Aceto Nitrile Sulphate (AANS) ..............................................................................94
5.32 ASAM .................................................................................................................................96
5.33 Hydrazide ............................................................................................................................99
5.34 Ammonium Carbamate .....................................................................................................101
6. WATER ENVIRONMENT .....................................................................................................103
6.1 Water Consumption ..........................................................................................................103
6.2 Wastewater Generation .....................................................................................................103
6.3 Water Balance Diagram ....................................................................................................104
6.4 Method of Treatment of sewage/wastewater ....................................................................105
6.4.1 Sewage .......................................................................................................................105
6.4.2 Effluent .......................................................................................................................105
7. AIR ENVIRONMENT .............................................................................................................117
7.1 Flue gas emission ..........................................................................................................117
7.2 Process Emission ...........................................................................................................120
8. SOLID/HAZARDOUS WASTE ..............................................................................................122
9. NOISE ENVIRONMENT ........................................................................................................128
10. SOLVENT MANAGEMENT PLAN ...................................................................................129
11. OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT .......................................132
12. SITE ANALYSIS .................................................................................................................133
12.1 Connectivity.......................................................................................................................133
12.2 Topography........................................................................................................................133
12.3 Existing Infrastructure........................................................................................................134
12.4 Soil Classification ..............................................................................................................134
12.5 Climate data from the secondary source .............................................................................134
13. PROPOSED INFRASTRUCTURE......................................................................................135
14. PROJECT SCHEDULE & COST ESTIMATES .................................................................136
14.1 Project Schedule ................................................................................................................136
14.2 Project Cost Estimation ......................................................................................................136
14.3 Financial & Social Benefits................................................................................................137
15. CONCLUSION.....................................................................................................................138

LIST OF TABLES
Table No. 1 – Raw Material Details 12
Table No. 2 – Land area details 22
Table No. 3 – Fuel details 23
Table No. 4 –Water Consumption 24
Table No. 5 – Product Details 25
Table No. 6 – By-Product Details 26
Table No. 7 – Wastewater generation with segregation of effluent streams 103
Table No. 8 – Details of Existing ETP 109
Table No. 9 – Description of proposed STP Unit & their size 113
Table No. 10 – Detail of existing Agitated Thin Film Dryer 116
Table No. 11 – Details of flue gas emission 117
Table No. 12 – Details of ESP 118
Table No. 13 – Details of Process Emission 120
Table No. 14 – Details of Hazardous/Solid Waste Generation and Management 122
Table No. 15 – Details of Hazardous chemical storage 124
Table No. 16 – Solvent Recovery 130

LIST OF ANNEXURE
Annexure No. Description

Annexure – 1 Copy of Existing EC
Annexure – 2 Copy of Existing CC&A
Annexure – 3 Location of the project site on Google map
Annexure – 4 Layout plan showing existing & proposed area
Annexure – 5 Additional Water permission letter to GIDC
Annexure – 6 Schematic flow diagram of existing ETP
Annexure – 7 P&ID for existing MEE &ATFD
Annexure – 8 P&ID for proposed MEE
Annexure – 9 CETP membership certificate
Annexure – 10 Permission from the PESO department
Annexure – 11 Membership certificate for TSDF and Incinerator

1. EXECUTIVE SUMMARY
UPL Limited (formerly known as United phosphorous Limited), popularly known as „UPL‟, is an
International company started its operation in the year 1969. It`s almost 45 years ago, they had
started as a small scale unit to manufacture Red Phosphorus. Since then it has established well-
equipped manufacturing units with corporate office at Mumbai. Through backward and forward
integrations respectively, today they are a leading global producer of crop protection products,
intermediates, speciality chemicals and other industrial chemicals. Being the largest manufacture of
agrochemicals in India, they offer a wide range of products that includes Insecticides, Fungicides,
Herbicides, Fumigants and Rodenticides. UPL of late has made a significant entry in Seed business
as well. In Gujarat, UPL Limited, is engaged in manufacturing of wide range of pesticides
(technical), intermediates of pesticides and other inorganic chemicals.
The Unit has implemented Environmental Management System Standard i.e. ISO 14001,
Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management
System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible
Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo
by Indian Chemical Council (ICC).
The pre-feasibility report includes a brief introduction of the company, need and justification of the
project, manufacturing process description, required and available resources, proposed
Environment Management Systems, existing land-use and proposed infrastructure, project schedule
and cost estimate.
The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultant to
conduct the Environmental Impact Assessment (EIA) studies for obtaining Environmental
Clearance (EC) for the proposed project. ECSS is a National Accreditation Board for Education &
Training (NABET) accredited Environmental Consultant.

PROJECT BRIEF
No. Description Proposed Project Details
Name of project & UPL Limited
1. Address Plot No. 3–11, A–2/1, A–2/2, A–2/6 & A–1/2, Phase – I, GIDC
Notified Industrial Estate, Vapi – 396195, Dist: Valsad, Gujarat.
2. Project Category 5 (b) – A of EIA notification – 2006.
3. Project capital cost Rs. 28,563.13 Lacs
4. Products Mention in 4.4 of section – 4.
5. By-products Mention in 4.4 of section – 4.
6. Resource Requirement
Land Land area is 69,639 m2. No additional land will be required for
a.
proposed expansion.
Water Source: GIDC water supply
Existing: 3,815.24 KL/day
b.
Proposed: 1,424.00 KL/day
Total after proposed expansion: 5,239.21 KL/day
Electricity Source: DGVCL
Existing: 9,082.34 KW
Proposed: 10,703.93 KW
c. Total: 19,786.27 KW
D. G. Set (used in case of power failure and/or emergency)
Existing: 2 x 500 KVA and 1 x 1250 KVA
Proposed: 2 x 500 KVA
Man power For the proposed expansion:
e. During Construction phase – 200 nos.
During Operation phase – 276 nos.
7. Source of Pollution
Waste Water Existing:
Generation Normal Effluent to ETP Plant: 2,312.40 KL/day
High COD effluent to Incineration: 16.00 KL/day
High TDS effluent to Evaporation system: 135.87 KL/day
Sewage to Proposed STP: 93.40 KL/day
Proposed:
Normal Effluent to ETP Plant: 996.30 KL/day
a.
Sewage to proposed STP: 20.00 KL/day
Total after proposed expansion:

Normal Effluent to ETP Plant: 3308.7 KL/day

PROJECT BRIEF
No. Description Proposed Project Details
Sewage to proposed STP: 113.40 KL/day
Air Emission Flue gas emmission: PM, SO2 & NOx
b. Process gas emission: Cl2, HCl, PM, HBr, P2O5as H3PO4, PCl3,
SO2, SPM, Zn, Br2, Methyl Bromide.
Hazardous Waste ETP waste, used oil, Discarded Containers/ Bags, Oil/ Grease from
Generation ETP, Spent Filter Material, Evaporation Salt, Sludge of wet
Scrubber, Used Batteries, Process Inorganics waste, Al, Mg, Zn
c. Hydroxide (Dust collection), Distillation residue, Spent Solvent,
Waste/Residue Containing Pesticide, Date expired/ off
specification products
Solid Waste Generation Fly ash & STP Sludge
8. Mode of Treatment
Waste water As per the existing practice, generated effluent shall be segregated
stream wise. Additional high COD & toxic effluent will be treated
in incinerator. High TDS effluent shall be treated in new MEE.
a. Normal effluent shall be treated in existing ETP with spare
capacity and after treatment effluent shall be discharged in to
CETP for further treatment. Sewage will be treated in proposed
STP.
Air Air pollution control devices – Adequate scrubber with stack of
sufficient height is being/ shall be provided for process gas
b. emission to achieve GPCB norms.
The details of Air pollution control measures for process gas
emission and flue gas emission are mentioned in section 7.
Solid/Hazardous Waste Collection, storage and disposal of solid/hazardous waste shall be
c.
as per Hazardous Waste Management Rules 2016.

2. INTRODUCTION OF THE PROJECT
2.1 Identification of project and project proponent
UPL Limited (formerly known as United phosphorous Limited), popularly known as „UPL‟, is an
International company started its operation in the year 1969. It`s almost 45 years ago, they had
started as a small scale unit to manufacture Red Phosphorus. Since then it has established well-
equipped manufacturing units with corporate office at Mumbai. Through backward and forward
integrations respectively, today they are a leading global producer of crop protection products,
intermediates, speciality chemicals and other industrial chemicals. Being the largest manufacture of
agrochemicals in India, they offer a wide range of products that includes Insecticides, Fungicides,
Herbicides, Fumigants and Rodenticides. UPL of late has made a significant entry in Seed business
as well. In Gujarat, UPL Limited, is engaged in manufacturing of wide range of pesticides
(technical), intermediates of pesticides and other inorganic chemicals.
UPL have 23 manufacturing sites and customer base in 123 countries all over the world. The
company has marketing network in 25 countries including America, Europe, Africa, besides in all
states of India. They rank amongst the top 5 post patent agrochemical industries in the world.
The Unit has implemented Environmental Management System Standard i.e. ISO 14001,
Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management
System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible
Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo
by Indian Chemical Council (ICC).
The existing unit at Vapi is having various infrastructure facilities, which includes Effluent
Treatment Plant (ETP), Evaporation system for High TDS effluent, Air pollution control
equipment, etc. The Company had obtained Environmental Clearance (EC) for their existing unit
vide No.: J-11011/32/2007-IA-II(I) dated 23rd July, 2007. Copy of EC is attached as Annexure – 1.
The Unit holds Consolidated Consent and Authorization (CC&A) having order no. AWH – 60886
dated 03/03/2014, which is valid up to 05/02/2019. Copy of CC&A is attached as Annexure – 2.
The Company is now planning to expand their existing production capacity and addition of new
products within existing premises.

2.2 Brief description of nature of the project
The company is located at Plot No. 3–11, A–2/1, A–2/2, A–2/6 & A–1/2, Phase – I, GIDC Notified
Industrial Estate, Vapi – 396195, Dist: Valsad, Gujarat. The existing project site is located within 5
km from the boundary of UT of Daman & Dadra Nagar Haveli and Gujarat state. The company is
situated in Gujarat Industrial Development Corporation (GIDC), a Notified Industrial Estate in the
state of Gujarat, at Vapi in Valsad district. It is an industrialized chemical belt, a notified chemical
zone, and one of the main hubs for agrochemical manufacturing of the country. The unit is involved
in manufacturing of Pesticide, Pesticide Intermediate, Pesticide Formulation Product, etc. The Unit
holds valid EC & CC&A. The unit is now planning to expand their existing production capacity
and addition of new products within existing premises.
2.3 Need of Proposed Project
The company is already engaged in the business of manufacturing of Pesticide, Pesticide

Intermediate, Pesticide Formulation Product, etc. The proposed expansion project provides a
potential growth opportunity for the already running business of the company. With the advent of
new technology and in-house research and development, many new products have been developed.
In order to increase the market share not only in India but also in abroad and to generate more
employment in line with “Make in India” initiative of Government of India.
Due to the ever-increasing demand of these products in order to reduce the gap between demand-
supply, the company proposes to expand its current manufacturing capacity. The demands of such
products are tremendous in our country, the products market is growing at a fast pace, and there are
many opportunities in indigenous as well as export market. With already available infrastructure
facilities (i.e. electricity, water, steam, roads, communication, rail network etc.) and skilled
manpower, UPL will be able to accomplish this goal.
2.4 Demand Supply Gap
Company is always focusing on manufacturing all products locally with backward integration so
that country will get benefits like growth, employment, infrastructure etc. UPL‟s R&D team is
constantly engaged in identifying & evaluating new molecules. After a very careful scrutiny of the
developments of R&D, UPL is ready to launch new intermediates as well as several new pesticides

products. Company is importing only such products for which, either the technology is not
available in India or the manufacturing cost is higher than the cost of import.
The export accounts 100 billion that is out of the present business of 180 Billion and is steadily
growing at a rate of 6.7%. This is 2.5 times more than the world market. With the introduction of
genetically modified crops in India, the consumption of Insecticides decreased marginally but the
other sectors such as Herbicides, Fungicides etc. are rapidly growing and UPL is focuses on the
sectors of Fungicides and Herbicides and also strong in export of these group.
The global marketing network of UPL is mainly, America, Europe & Africa, Indian subcontinent &
Asia Pacific which sales are 37%, 28%, 35 % respectively.
2.5 Employment Generation
There are possibilities to generate employment during the construction and operation phase of the
proposed expansion project. Local skilled and semi-skilled workers will be hired during
construction phase, thus no need to provide housing facility to workers. Approx. 200 nos. of people
will get direct employment during construction phase.
During operation phase, technical staff for plant, general staff for administrative work and other
ancillary services i.e. Security, O&M contractor and maintenance services will be required. For
proposed expansion, total 276 nos. of individuals will get direct employment during operation
phase.

3. PROPOSED PROJECT & APPLICABILITY OF EIA
Industrial Estate, Vapi – 396195, Dist: Valsad, Gujarat. The unit is now planning to expand their
existing production capacity and addition of new products within existing premises.
The expansion in the existing production capacity and addition of new products falls under the item
no. 5 (b) i. e. Pesticides industry and pesticide specific intermediates (excluding formulations) and
under Category as per the EIA notification – 2006 (as amended timely). Also, the project site is
located within 5 km from the inter-state boundary (UT of Daman & Dadra Nagar Haveli) and Vapi
GIDC. Hence it is required to apply for approval of Terms of Reference (TOR) along with Form-I
and Pre-Feasibility Report (PFR) to the Ministry of Environment Forest & Climate Change
(MoEF&CC). The EIA study is required to comply with all the approved TORs from MoEF&CC.
Public hearing is not applicable as per the O. M. No. J–11013/36/2014–IA–I, dated 10/12/2014.

4. PROJECT DESCRIPTION
4.1 Project Location
Industrial Estate, Vapi – 396195, Dist: Valsad, Gujarat. The project site falls in GIDC Notified
Industrial Vapi of Valsad district of Gujarat. Project site is surrounded by Valwada Village in the
South, Vapi in the North, Chanod village in the East and Chandor village in the West. The project
location is well connected with road and rail for transportation activities. The location of the project
site on Google map is attached as Annexure – 3. Layout plan is attached as Annexure – 4.
4.2 Alternative Sites
Alternative site has not been considered, as the proposed project is an expansion project within
existing premises. Moreover, all the utilities and infrastructure facilities are available in the present
set up. Hence the existing premises is the best option available for the proposed expansion.
4.3 Resource Requirement
To carry out proposed expansion various resources like raw materials, power, fuel, water,
manpower, etc., will be utilized. Details of the same are mentioned below:
4.3.1 Raw Material
Estimated requirements of various raw materials for expansion in existing production capacity and
addition of new products are given below:
Table No. 1 – Raw Material Details
Consumption (MT/M)
Sr. No. Raw Material Name
Exiting Proposed Total
I. Cypermethrin (Insecticide)
1. Di Vinyl Acid chloride 192.39 99.11 291.50
2. Meta Phoxy Benzaldehyde 157.41 81.09 238.50
3. N-hexane 11.22 5.78 17.00
4. Caustic Soda Lye (32%) 10.23 5.27 15.50
5. Sodium Cyanide 40.59 20.91 61.50
6. Triethyl Benzyl Ammonium Chloride 2.97 1.53 4.50

Consumption (MT/M)
(TEBACL)
7. Sodium Hypochloride (8%) 371.25 191.25 562.50
II. Alpha Cypermethrin (Insecticide)
2. Cypermethric acid chloride (CMAC) 17.20 28.67 45.87
3. Sodium Cyanide 4.03 6.72 10.75
4. N-hexane 2.67 4.44 7.11
5. catalyst-1 0.29 0.48 0.77
6. Soda Ash(5%) 28.94 48.23 77.17
7. IPA 2.34 3.90 6.24
8. catalyst-2 2.58 4.30 6.88
9. 10% Sodium Hypochloride 64.50 107.50 172.00
III. Beta Cypermethrin
2. Cypermethric acid chloride (CMAC) 17.20 28.67 45.87
3. Sodium Cyanide 4.03 6.72 10.75
4. N-hexane 2.64 4.40 7.04
5. catalyst-1 0.29 0.48 0.77
6. Soda Ash(5%) 28.94 48.23 77.17
7. IPA 2.34 3.90 6.24
8. catalyst-2 2.58 4.30 6.88
9. 10% Sodium Hypochloride 64.50 107.50 172.00
IV. Imidacloprid Tech.
2-Chloro5-Chloromethyl Pyridine
1. 21.00 35.00 56.00
(CCMP)
2. 2-Nitroiminoimidazoline (NII) 18.09 30.15 48.24
3. Potassium Carbonate 19.50 32.50 52.00
4. Di Methyl Fornamide(DMF) 2.25 3.75 6.00
5. Catalyst 0.18 0.30 0.48
6. Acetic Acid 0.75 1.25 2.00
V. Permethrin
1. Di Vinyl Acid chloride 61.40 30.70 92.10
2. Meta Phoxy benzyl Alcohol 52.20 26.10 78.30
3. Caustic Soda Lye (32%) 21.80 10.90 32.70
VI. Propanil (STAM)

Consumption (MT/M)
1. 3,4 Dichloro Aniline 80.57 367.03 447.60
2. 100% Propanic Acid 38.34 174.66 213.00
VII. Safener (UPH 203s)
1. Haptenol Alcohol (HOL) 1.94 17.46 19.40
2. Mono Chloro Acetic Acid (MCAA) 1.67 15.03 16.70
3. Para Toluene Sulphonic Acid 0.04 0.31 0.35
4. Toluene 0.13 1.17 1.30
5. Hydrochloric Acid 0.02 0.18 0.20
6. 8 Hydroxy 5 chloroquinoline (QCH) 2.93 26.32 29.25
7. Potassium Chloride 2.33 20.97 23.30
Tetra Butyl Ammonium Bromide
8. 0.085 0.765 0.85
(TBAB)
9. Sodium Bisulfite 0.085 0.765 0.85
10. Di Methyl Fornamide (DMF) 0.25 2.25 2.50
11. Acetic Acid 0.03 0.27 0.30
12. Sodium Carbonate 0.12 1.03 1.15
13. N-hexane 0.04 0.36 0.40
VIII. Bifenthrin (BF 20) (Insecticide)
1. 2-Methyl 3-Bipheyl Methanol 16.26 59.97 76.23
3. Hexane 1.54 5.66 7.20
4. Triethyl Benzyl Ammonium Chloride 0.35 1.27 1.62
5. Tetra Butyl Ammonium Bromide 0.81 2.00 3.81
6. Cyhylothric Acid (98%) 20.06 73.99 94.05
8. Sodium Carbonate 4.88 17.98 22.86
IX. Lambda Cyhalothrin
1. Cyhylothric Acid (98%) (MTH-Acid) 22.72 83.78 106.50
2. Hexane 3.37 12.43 15.80
3. Catalyst-1 0.10 0.35 0.45
4. SOCl2 13.63 50.27 63.90
5. Sodium Cynide 4.45 16.40 20.85
6. Meta Phoxybenzaldehyde 17.25 63.59 80.84
7. Catalyst-2 0.35 1.30 1.65
8. Caustic Soda Lye (32%) 0.74 2.74 3.48

Consumption (MT/M)
9. 2% NaOCl wash 13.44 49.56 63.00
10. Catalyst-20212 0.12 0.44 0.56
11. Catalyst-3 0.19 0.71 0.90
12. TSO-11 (Trade Secret) 0.38 1.42 1.80
13. Lambda Cylothrin tech (seed) 0.38 1.42 1.80
14. Sulfuric Acid (H2SO4) 0.38 1.42 1.80
X. ClodinafopPropargyl (UPH – 203)
1. Hydroquinone 25.48 93.97 119.45
2. Caustic Soda Lye (32%) 50.50 186.23 236.73
3. Sodium Bisulfite (SBS) 1.11 4.08 5.19
4. 2-Chloro Propionic Acid (2-CPA) 16.62 61.28 77.90
5. Propargyl Chloride (PCI-306.2) 9.80 36.13 45.93
7. MP302 2.35 8.68 11.03
8. Sodium Hydrosulfite (SHS) 1.11 4.08 5.19
10. Di Methyl Formamide(DMF) 2.17 8.00 10.17
11. 5-Chloro-2,3-Difluro Pyridine (CDF) 17.53 64.66 82.19
Tetra Phenyl Phosphonium
12. 0.26 0.96 1.22
bromide(Cat 203)
13. Toluene 1.47 5.43 6.90
14. IPA 1.86 6.84 8.70
XI. Thiomethoxam (STAR)
1. Formic Acid 4.93 18.17 23.10
2. N-Methyl-Nitro Guinadine (NMG) 18.98 69.97 88.95
3. Para Formaldehyde (PFA) 12.93 47.67 60.60
4. Methane Sulphonic Acid (MSA) 0.96 3.54 4.50
5. Caustic Soda Lye (48%) 3.97 14.63 18.60
6. Caustic Soda Flakes 5.73 21.12 26.85
7. Di Methyl Fornamide(DMF) 1.76 6.49 8.25
2 chloro 5 chloro Methyl Thiozole
8. 22.85 84.25 107.10
(MAX)
9. Potassium iodide (Cat 203s/1) 0.29 1.06 1.35
10. Methanol (IP-4 Solvent) 2.06 7.58 9.64

Consumption (MT/M)
XII. Desmedipham
1. Meta Amino Phenol 40.50 67.50 108.00
2. Ethyl Chloro Formate 41.76 69.60 111.36
3. Di sodium Hydrogen Phosphate 15.84 26.40 42.24
4. Butyl Acetate (Solvent-2) 9.00 15.00 24.00
5. Caustic Soda Lye (32%) 14.76 24.60 39.36
6. Phenyl Isocynate 44.01 73.35 117.36
7. Triethyl amine 0.99 1.65 2.64
XIII. Phenmedipham
1. Meta Amino Phenol 36.63 61.05 97.68
2. Methyl Chloro Formate 33.84 56.40 90.24
3. Di sodium Hydrogen Phosphate 14.40 24.00 38.40
4. Butyl Acetate (Solvent-1) 9.00 15.00 24.00
5. Caustic Soda Lye (32%) 14.04 23.40 37.44
6. Meta totylisocynate 44.19 73.65 117.84
7. Triethyl amine 0.63 1.05 1.68
XIV. Metribuzin
1. Sulfur 3.24 5.40 8.64
2. Bromine 19.71 32.85 52.56
3. Methanol 1.26 2.10 3.36
4. Sodium Bisulfite 1.35 2.25 3.60
5. Triazinone 97.20 162.00 259.20
6. Caustic Soda Lye (32%) 30.69 51.15 81.84
7. 2 Ethyl Hexanol 0.63 1.05 1.68
8. Caustic Soda Lye 30.69 51.15 81.84
9. Chlorine 3.06 5.10 8.16
10. Caustic solution (10%) 27.27 45.45 72.72
XV. Metamitron
1. Hyrazide 124.02 82.68 206.70
2. DMAC 0.72 0.48 1.20
3. Toluene 2.16 1.44 3.60
XVI. ASAM
1. 2-Amino pyridine 2.586 2.586
2. Mono Chloro Acetic Acid (MCAA) 3.078 Nil 3.078
3. Soda Ash 2.514 2.514

Consumption (MT/M)
4. Toluene 0.272 0.272
5. Phosphorous Oxychloride 12.636 12.636
6. Ethylene Di Chloride (EDC) 0.452 0.452
7. Liquor ammonia 7.276 7.276
8. Hyflow 0.012 0.012
9. Hexane 0.18 0.18
10. Methylene Dichloride (MDC) 1.364 1.364
11. CSA 3.14 3.14
12. Triethyl amine 4.06 4.06
13. Acrelonitrile 9 9
14. Liquor Ammonia 11.476 11.476
XVII. Aluminium Phosphide (Fumigant)
1. Aluminium Powder 70.00 210.00 280.00
2. White Phosphorous 77.80 233.40 311.20
3. Groundnut Oil 1.00 3.00 4.00
4. Paraffin Wax 5.80 17.40 23.20
5. Urea 8.40 25.20 33.60
6. Ammonium Carbamate (MR-17) 39.00 117.00 156.00
7. Zinc Stearate 9.00 27.00 36.00
8. Graphite Powder 11.60 34.80 46.40
XVIII. Magnesium Phosphide
1. Magnasium Powder 3.88 20.37 24.25
2. Red Phosphorous 3.52 18.48 22.00
3. Paraffin Wax 0.37 1.93 2.30
4. Ammonium Carbamate (MR-17) 1.08 5.67 6.75
5. Magnasium Oxide 0.06 0.34 0.40
6. Zinc Stearate 0.42 2.18 2.60
7. Graphite Powder 0.42 2.23 2.65
XIX. Zinc Phosphide (Rodenticide)
1. Zinc Dust 31.68 63.36 95.04
2. White Phosphorous 9.08 18.16 27.24
XX. Di Vinyl Acid Chloride (DVACL)
1. Carbon Tetra Chloride 417.30 69.55 486.85
2. Acrylonitrile 146.70 24.45 171.15
3. Acetonitrile 4.80 0.8 5.60

Consumption (MT/M)
5. Catalyst-1 3.90 0.65 4.55
6. Catalyst-2 2.70 0.45 3.15
8. Caustic Soda Lye (32%) 2105.70 350.95 2456.65
9. Phosphorous Trichloride 348.00 58.00 406.00
10. Chlorine 180.00 30.00 210.00
11. Trimethyl Amine 15.00 2.50 17.50
12. Isobutylene 135.60 22.60 158.20
13. Sodium bi carbonate 44.40 7.40 51.80
14. Boron Trifluroride Etharate 3.90 0.65 4.55
15. Thionyl Chloride 186.00 31.00 217.00
16. Dimethyl Formamide 2.10 0.35 2.45
17. Toluene 3.90 0.65 4.55
18. N-hexane 116.70 19.45 136.15
XXI. Metaphenoxy Benzaldehyde (MPBAD)
1. Benzaldehyde 190.58 51.97 242.55
2. Ethylene Di Chloride (EDC) 25.30 6.90 32.20
3. Formic Acid 4.13 1.12 5.25
4. Mono Ethylene Glycol(MEG) 6.05 1.65 7.70
5. Para Toluene Sulphonic Acid (PTSA) 0.83 0.22 1.05
6. Phenol 193.33 52.72 246.05
7. Toluene 18.98 5.17 24.15
8. Turkey Red Oil 0.28 0.07 0.35
9. Anhydrous Aluminium Chloride 316.25 86.25 402.50
10. Caustic Potash 121.00 33.00 154.00
11. Hyflow 0.28 0.07 0.35
12. Liquid Bromine 152.63 41.62 194.25
13. Sodium Sulphate 6.33 1.72 8.05
14. Sodium Thio 9.63 2.62 12.25
15. Sulphuric Acid 21.45 5.85 27.30
16. Caustic Soda Lye (32%) 41.25 11.25 52.50
17. Chlorine 140.25 38.25 178.50
XXII. Hydrazide

Consumption (MT/M)
1. Sulfuric Acid (H2SO4) 44.04 44.04
2. Hydrochloric Acid 23.5 23.5
3. Methanol 3.16 3.16
4. Ethylene Di Chloride (EDC) 2.14 2.14
5. Liq Ammonia 2.72 Nil 2.72
6. Mandelonitrile 18.46 18.46
7. Sodium Hypo Chloride 108.06 108.06
8. Ethyl acetate 12.94 12.94
9. Hydrazine Hydrate 16.4 16.4
XXIII. Red Phosphorus
1. White Phosphorous 82.08 82.08
2. Caustic Soda Lye (48%) 6.96 Nil 6.96
XXIV. Denatonium Benzoate
1. Lidocaine 0.66 2.64 3.30
2. Benzyl Chloride 0.36 1.42 1.78
3. Methanol (solvent) 0.004 0.016 0.02
4. Caustic soda Lye (48%) 0.32 1.30 1.62
5. Ethyl Acetate 0.12 0.46 0.58
6. Benzoic Acid 0.33 1.30 1.63
XXV. Azoxystrobin
1. 2-Coumaranone 60.00 60.00
2. Trimethyl Orthoformate 255.95 255.95
3. Acetic Anhydride 130.00 130.00
4. Methanol 8.40 8.40
5. 4, 6 DCP 64.98 64.98
6. Sodium methoxide (30%) 80.00 80.00
7. Potassium Hydroxide Flakes Nil 4.50 4.50
8. Methane Sulphonic Acid (MSA) 3.30 3.30
9. Toluene 6.60 6.60
10. Ethyl Acetate 54.98 54.98
11. Di Methyl Fornamide(DMF) 9.89 9.89
12. Potassium Carbonate 54.67 54.67
13. 2-Cyno Phenol 35.19 35.19
XXVI. Trifloxystrobin

Consumption (MT/M)
Methyl O-methylpheylglyoxylate
1. 127.00 127.00
(methyl-MPG)
2. O-Methoxy Hydroxy Amine HCl 62.50 62.50
3. Methanol 36.60 36.60
5. Hexane 27.60 27.60
Nil
6. N-Bromosuccinamide (NBS) 127.70 127.70
3- Trifluro methyl aceto phenone (TF-
7. 92.00 92.00
Acetophenone)
8. Hydroxyl amine hydrochloride 28.00 28.00
9. Sodium Hydride (NaH) 20.00 20.00
10. Di Methyl Fornamide (DMF) 9.00 9.00
XXVII. Kresoxim Methyl
1. O-Cresol 67.20 67.20
2. Sodium methoxide 114.60 114.60
3. Phthalide 80.00 80.00
4. Toluene 31.30 31.30
6. Di Methyl Fornamide (DMF) 3.50 3.50
7. SOCl2 71.50 71.50
Nil
8. Sodium Cynide 29.50 29.50
9. Dilute HCl 9.50 9.50
10. Catalyst 0.35 0.35
11. Methanol 24.70 24.70
13. Caustic Soda Flakes 45.00 45.00
14. O-Methoxy Hydroxy Amine HCl 41.20 41.20
XXVIII. Sulfosulfuron
1. Di Methyl Formamide (DMF) 0.87 0.87
2. Ethyl Merceptane 6.83 6.83
3. Sodium Hydride (NaH) 4.42 4.42
4. ASAM Nil 9.03 9.03
5. Hexane 0.51 0.51
7. Cat-7000 30.58 30.58

Consumption (MT/M)
8. Sulfuric Acid (H2SO4) 23.33 23.33
9. ADP 98% 4.98 4.98
10. DX-1 14.00 14.00
11. DX-2 6.82 6.82
12. P-1 8.62 8.62
13. Sol-1 2.02 2.02
14. CAN 99% 28.50 28.50
15. DBU 99% 3.77 3.77
XXIX. MPBAL
1. Meta Phoxybenzaldehyde 156.30 156.30
2. Hydrogen 1.65 1.65
NIl
3. Catalyst 1.50 1.50
4. Triethyl amine 0.30 0..30
XXX. TPPA
1. POCl3 21.88 21.88
2. Phenol 38.60 38.60
3. Catalyst Nil 0.08 0.08
4. 1.5% NaoH solution 87.76 87.76
5. Hyflow 0.40 0.40
XXXI. 2,4 Hydroxy Phenyl Propionic Acid or L-2 Chloro Propionic Acid
1. L-Alamine 40.00 40.00
2. Sodium Nitrile 61.40 61.40
3. Hydrochloric Acid Nil 214.36 214.36
5. Catalyst 0.20 0.20
XXXII. 2- Chloro Propionic Acid Chloride
1. Alpha-CPC 14.68 14.68
2. Toluene 1.16 1.16
3. 46% Caustic Nil 11.84 11.84
4. Di ethyl amine 9.64 9.64
5. 50% EDTA 0.05 0.05
XXXIII. AMINO ACETO NITRILE SULPHATE (AANS)
1. Methanol 5.18 5.18
2. Sulfuric Acid (H2SO4) Nil 38.64 38.64
3. MAAN 45.46 45.46

Consumption (MT/M)
4. Caustic Soda Lye (32%) 15.05 15.05
XXXIV. Ammonium Carbamate (MR 17)
1. Ammonia 88.00 88.00
Nil
2. Carbon dioxide 112.00 112.00
4.3.2 Land Requirement
The proposed expansion shall be developed within existing premises. No additional land will be
purchased/procured for proposed expansion. New equipments and utilities required for proposed
expansion will be set up in the existing process plant area. Hence, no additional spare land will be
required for proposed expansion. Land area break up is mentioned in the following table:
Table No. 2 – Land area details
Sr. Area (m2)

Description
No. Existing Proposed Total
1. Process Plant & Tankfarm 22,092 0 22,092
2. Fabrication Shed 1,010 0 1,010
3. ETP 1,631 0 1,631
4. Security 626 0 626
5. Work Shop 806 0 806
6. Canteen & Toilet Block 677 0 677
7. Safety 495 0 495
8. Office and Bungalow 642 0 642
9. Green space 2,691 0 2,691
10. Ware House 1,848 0 1,848
11. Utility 7,014 0 7,014
12. Loading unloading 156 0 156
13. Roads 12,000 0 12,000
14. Margins near boundary wall 9,040 0 9,040
15. Open space / working space around plant 3,200 0 3,200
16. Open space / working space around utility 1,700 0 1,700
17. Other area 1,511 0 1,511
18. Open area 2,500 0 2,500
Total (A) 69,639 0 69,639

Sr. Area (m2)

Description
B. Green belt at Vikram Farm 14,163 6,145 20,308
Total (A +B) 83,802 6,145 89,947
4.3.4 Power & Fuel
a. Power
Source: DGVCL for existing as well as proposed expansion
Existing: 9,082.34 KW
Proposed: 10,703.93 KW
Total: 19,786.27 KW
D. G. Set (used in case of power failure and/or emergency)
Existing: 2 x 500 KVA and 1 x 1250 KVA
Proposed: 2 x 500 KVA
b. Fuel
Details of fuel are mentioned in the below table:
Table No. 3 – Fuel details
Sr. Consumption
Type of fuel
3 3
1. Natural Gas 1200 sm /hr 600 sm /hr 1800 sm3/hr
2. FO 909 lit/hr 450 lit/hr 1359 lit/hr
3. Coal
a. Imported Coal 5 MT/hr 2 MT/hr 7 MT/hr
OR
b. Indian Coal 7 MT/hr 3 MT/hr 10 MT/hr
4. LDO 43 kg/hr 20 kg/hr 63 kg/hr
5. HSD 340 lit/hr 340 lit/hr 680 lit/hr

4.3.5 Water Requirement
The additional water requirement for proposed expansion will be fulfilled by existing source i.e.
GIDC during the construction as well as operation phase. Ground water is not being extracted for
the existing operation nor it will be extracted for proposed expansion. The unit has already obtained
permission from GIDC for their existing water requirement and for proposed expansion,
application is already submitted to the GIDC. Copy of the letter is attached as Annexure – 5. Water
consumption during operation phase for existing and proposed expansion project is mentioned in
the below table:
Table No. 4 –Water Consumption
Sr. Existing Proposed Total

Particular
No. (KL/Day)
A. Domestic 154.00 25.00 179.00
B. Gardening 5.00 5.00 10.00
C. Industrial
1. Process & RD 1,770.14 355.50 2,125.61
2. Boiler 673.60 609.00 1,282.60
3. Cooling 1,207.00 424.00 1,631.00
4. Washing 5.50 5.50 11.00
Total (C) 3,656.24 1,394.00 5,050.21
Total (A+B+C) 3,815.24 1,424.00 5,239.21
4.3.3 Man Power
The company employs around 80% of the existing manpower from the nearby areas. Same policy
of local employment will be followed for the proposed expansion project requirement.
The existing unit has total manpower of 403 nos. Additional Manpower shall be employed during
the construction & operation phase directly and indirectly through contracts for Civil Construction,
Mechanical erection, Electrification, Piping Works and Associated Amenities for proposed
expansion project.
During construction phase, it is expected to generate direct & indirect employment of about 200
people of various skills. This will also increase local business of the area.
In order to operate and maintain the proposed expansion approximately 276 man power will be
required during the operation phase.

4.4 Product & By-Product
The product details are given in following table no. 5. Total production after proposed expansion
will be 1,921 MT/Month to 5,177 MT/Month.
Table No. 5 – Product Details
Sr. Quantity (MT/Month)

Products Name
No. Exiting Proposed Total
Pesticide
1. Cypermethrin 330 170 500
2. Permethrin (Insecticide) 100 50 150
3. Propanil (Herbicide) 108 492 600
4. Safener (UPH-203 S) (Herbicide) 5 45 50
Alpha Cypermethrin (Insecticide)
OR
5. Beta Cypermethrin 30 50 80
OR
Imidacloprid (Tech)
Bifenthrin
OR
Lambda Cyhalothrin
6. OR 32 118 150
Clodinafop Propargyl (UPH – 203)
OR
Thiomethoxam (STAR)
Desmedipham (DMP) (Herbicide) or
Phenmedipham (PMP)
OR
7. 90 150 240
Metribuzin
OR
Metamitron
8. ASAM 2 Nil 2
9. Aluminum Phosphide 200 600 800
10. Magnesium Phosphide (fumigant) 8 42 50
11. Zinc Phosphide 40 80 120
Pesticide Formulation
12. Liquids and/or Solids 300 700 1000

Sr. Quantity (MT/Month)

Products Name
No. Exiting Proposed Total
Pesticide Intermediates
13. Dichloro Vinyl Acid Chloride (DVACL) 300 50 350
14. Metaphenoxy Benzaldehyde (MPBAD) 275 75 350
15. Hydrazide 20 Nil 20
16. Red Phosphorus 80 Nil 80
17. Denatonium Benzoate 1 4 5
New Products
Pesticides
Azoxystrobin or Trifloxystrobinor
18. Nil 100 100
Kresoxim Methyl
19. Sulfosulfuron Nil 10 10
Pesticide Intermediates
20. MPBAL Nil 150 150
21. TPPA Nil 40 40
2,4 Hydroxy Phenyl Propionic Acid or
22. Nil 40 40
L-2 Chloro Propionic Acid
23. 2- Chloro Propionic Acid Chloride Nil 40 40
24. AANS Nil 50 50
25. Ammonium Carbamate (MR 17) Nil 200 200
Total 1,921 3,256 5,177
Table No. 6 – By-Product Details
Sr. Exiting Proposed Total

By Products
No. MT/Month
Existing
1. Phosphoric Acid (100% basis) 40 98.40 138.40
2. Hydrochloric Acid 30% 2048 239.90 2287.90
Spent Sulfuric Acid (46%) 1025 140.15 1165.15
3. OR
Ammonium Sulfate 600 86.38 686.38
4. Phosphorous Oxychloride 640 58.55 698.55
5. Ammonium Chloride 34.80 Nil 34.80
6. Sodium Bromide solution 720 570.19 1290.19
Sodium Sulfite Solution 930 218.66 1148.70
7.
OR

Sr. Exiting Proposed Total

By Products
No. MT/Month
Sodium Sulfite salt 190 41.92 231.92
OR
Sodium Bi sulfite Solution 930 240.69 1170.69
OR
Sodium Bi Sulfite (solid) 190 48.14 238.14
KCl salt 160 28.00 188.00
8. OR
KCl Sol 900 158.00 1058.00
9. Cu(OH)2/CuSO4 10 1.66 11.66
10. Sodium Sulfate 160 23.00 183.00
11. MPBAD distillation Cut 20 2.25 22.25
12. AlCl3 20%/ Poly AlCl3 1130 319.27 1449.27
New
13. Mono Chloro Benzene Nil 29.85 29.85
14. Methyl Benzate Nil 15.00 15.00
15. Formic Acid Nil 108.68 108.68
16. Dimethoxy methane Nil 36.11 36.11
17. Methoxy Propanol Nil 15.16 15.16
Total 9,727.80 2,479.90 12,208.00

5. MANUFACTURING PROCESS
5.1 Cypermethrin
Process Description
Di vinyl Acid Chloride (DVACl) is condensed with Meta Phenoxy Benzaldehyde (MPBAD) along
with Sodium Cyanide in presence of solvent n-Hexane. After it is washed with water, Sodium
Hypochlorite and organic mass containing solvent is taken for solvent distillation. Cypermethrin
thus obtained is packed in drums. The aqueous layer, containing excess Cyanide is treated with
Sodium Hypochlorite and sent to Effluent Treatment Plant.
Process Chemistry
Formula C8H9OCl3 NaCN C13H10O2 C.S. Lye + C22H19O3Cl2N NaCl

TEBACl
Sodium Sodium
Name DVACl + + MPBAD Cypermethrin +
Cyanide Chloride
Mol. Wt. 227.5 49 198 416 58.5
Process Flow Diagram Basis: All quantities are in Kg

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Di vinyl Acid Chloride (DVACl) 583 Product
Meta Phenoxy Benzaldehyde (MPBAD) 477 Cypermethrin Tech 1000
n - Hexane 1146 Recycled Streams
Caustic Soda Lye 32% 31 Rec Hexane 1112
Cypermethrin
Sodium Cyanide 123 (1000 KG) Vapor Loss
Triethyl Benzyl Ammonium Chloride
9 Hexane Vapor 14
(TEBACL)
8% Sodium Hypochlorite 1125 To ETP
Water for Cyanide Sol. 574 Aqueous Layer 2558
Water For Washing 616
TOTAL 4684 TOTAL 4684
5.2 Permethrin
Process Description
Di Vinyl Acid Chloride (DVACl) is reacted with Meta Phenoxy Benzyl Alcohol (MPBAL). HCl
gas generated is scrubbed to water to form 25-30% HCl Solution. After it is washed with water &
soda ash, Organic mass containing solvent is taken for solvent distillation. Permethrin thus obtained
is packed in drums.
Reaction Chemistry
Formula C8H9OCl3 C13H10O2 C21H18O3Cl2 HCl

Hydrochlori
Name DVACl + MPBAL Permethrin +
c acid
Mol. Wt. 227.5 198 389 36.5

Process Flow Diagram
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
DVACl 614 Product
MPBAL 522 Permethrin Tech 1000
PERMETHRIN
Caustic Soda Lye 32% 218 By-product
(1000 KG)
Water 2250 30% HCL 316
To ETP
Aqueous Layer 2288

5.3 Propanil
Process Description
3,4 DCA (3,4 Dichloroaniline) is reacted with propionic acid in the reaction kettle. During Reaction
excess propionic acid (diluted) is recovered back and recycled. The Propanil so formed is subjected
to flaking via flaker machine & Packed in Bulk Bag.
Process Chemistry
Formula C6H5Cl2N CH3CH2COOH C9H9Cl2NO H2O

3,4
Name + Propionic Acid Propanil + Water
Dichloroaniline
Mol. Wt. 162 74 218 18
Material Balance
Quantity Quantity
Input Output
KG KG
3,4 Dichloro Aniline 746 Product
100% Propionic Acid 355 Propanil 1000
Recovered 25 to 30 %
125 Recovery
Propionic Acid PROPANIL
Recovered 70 to 75 % (1000 Kg)
394 25 To 30 % Propionic Acid 125
Propionic Acid
70 To 75 % Propionic Acid 394
To ETP
8% Propionic Acid 90
Loses To Atmosphere

Pa + Water 11
5.4 UPH 203 S – Safeners (Cloquinocnt Mexyl)
Process Description
HES Stage
Esterification between HOL (alcohol) and Mono Chloro acetic acid forms HES. Water is removed
forming azeotrop with Toluene. Organic layer containing HES in toluene is washed with sodium bi
carbonate to remove acidity. Toluene is distilled out to get HES.
UPH203 S Stage
Condensation of QCH with HES to form UPH203 S. Potassium salt is generated during this process
which is filtered and the organic containing UPH203 S in SOLVENT undergoes SOLVENT
recovery. Hexane is used for the crystallization of UPH203 S. Slurry is filtered to get wet cake of
UPH203 S, which is dried.
Process Chemistry
HES Stage
O O CH 3
║ PTSA
CH3(CH2)4CHCH3 + Cl-CH2-C-OH Cl-CH2-C-OCH(CH2)4CH3 + H2O
Toluene
2-HOL MCA HES Water

[116] [94.5] [192.5] [18]
UPH203 S(Clo-quinocent mexyl) Stage - Add reaction for 2nd stage

HOL 388
MCA 334
Toluene 869 esterification
PTSA 7
Total 1598
azo distillation water 60
Total 1538
toluene rec 843
Toluene distillation toluen loss 25
Total 670
water 5000 Incinerator 497

sodium bicarbo 23 Aq. layer 4612
QCH 585
water washing &
DMF 1655
condensation
Cat 17
K2CO3 466
Total 3307
salt 713
filteration
Total 2594
acetic acid 6 DMF recover 1605

sodium
bicarbonate 23 DMF recovery DMF loss 16
Total 1002
Hexane 958 Hexane vapor 950

Hexane loss 8
Crystallization
safener 1000

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
HOL 388 Product
Mono Chloro Acetic Acid 334 Safener 1000
Para Toluene Sulphonic Acid - PTSA 7 Residue
Toluene 869 To Incineration 497
HCl 4 Landfilling
8 Hydroxy 5 chloroquinoline (QCH) 585 K - Salt 713
Potassium Carbonate 466 To ETP
Tetra Butyl Ammonium Bromide Safener
17 Aq. Layer 4672
(TBAB) (1000 KG)
Sodium Bisulphite 17 Recovered Streams
DMF 1655 Toluene 843
Acetic acid 6 DMF 1605
n Hexane 950
Sodium carbonate 23 Solvent Loss
Water 5000 Toluene 25
N Hexane 958 DMF 16
N Hexane 8
5.5 Sulfosulfuron (SF-10)
Process Description
STEP 1: ASAM (2-Chloroimidazo[1,2-a]pyridine-3-sulfamide) to ESPA (2-Ethylthioimidazo

[1,2-a]pyridine-3-sulfamide)
Ethyl Mercaptan (EM) is reacted with Sodium Hydride under suitable conditions to give Na-EM
and Hydrogen gas. Na-EA and ASAM are reacted to give corresponding ESPA (2-
Ethylthioimidazo [1,2-a]pyridine-3-sulfamide) and Sodium Chloride.
STEP 2: ESPA (2-Ethylthioimidazo [1,2-a]pyridine-3-sulfamide) to ESPO (2-

EthylSulfonylimidazo [1,2-a]pyridine-3-sulfamide)
ESPA reacts with Hydrogen Peroxide in presence of catalyst, solvent & other reaction conditions to
give ESPO.
STEP 3: ADP to ADCP (4,6-Dimethoxy-2-(Phenoxy Carbonyl)amino)Pyrimidine)

ADP (2 Amino 4,6- Dimethoxy Pyrimidine) and PCF (Phenyl Chloro Format) are reacted in
presence of catalyst, solvent & other reaction conditions to give corresponding ADCP (phenyl 2
Amino 4,6- Dimethoxy Pyrimidine carbamate) and Hydrochloric Acid. Wet cake is dried and
solvent is recycled.
STEP 4: ESPO (2-EthylSulfonylimidazo [1,2-a]pyridine-3-sulfamide) to SF-10
ESPO and ADCP are reacted to form Safener as a product. The product mixture is the filtered and
wet cake is washed with water. The aqueous ML and wash ML are further treated. The wet cake
obtained is dried to get desired product SF-10.
Process Chemistry
Formula C2H6S NaH C2H5SNa H2

Sodium
Name EM + EM-Na + Hydrogen
Hydride
Mol. Wt. 62 24 84 2
STEP 1: ASAM to ESPA
Formula C7H6ClN3O2S C2H5SNa C9H11N3O2S2 NaCl

Sodium
Name ASAM + EM-Na ESPA +
Chloride
Mol. Wt. 231.5 84 257 58.5
STEP 2: ESPA to ESPO
Formula C9H11N3O2S2 H2O2 C9H11N3O4S2 H2

Hydrogen
Name ESPA + ESPO + Hydrogen
Peroxide
Mol. Wt. 257 34 289 2
STEP 3: ADP to ADCP
Formula C6H9N3O2 C7H5ClO2 C13H13N3O4 HCl

Hydrochloric
Name ADP + PCF ADCP +
Acid
Mol. Wt. 155 156.5 275 36.5

STEP 4: ESPO to SF-10
Formula C9H11N3O4S2 C13H13N3O4 C16H18N6O7S2 C6H6O

Name ESPO + ADCP SF-10 + PH-1
Mol. Wt. 289 275 470 94

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
DMF 2933 Product
EM 683 SF-10 1000
NaH (60%) 442 To Evaporation
ASAM 903 ML 74875
Hexane 1725 Wash ML 9610
HCl 1458 Recycled Streams
Water 77546 Hexane Rec. 1674
Cat-700 3058 Sulfosulfuron DMF Rec. 2846
SF-10
H2SO4 2333 (1000 KG) To Incineration
ADP 98% 498 ML 7088
DX-1 1400 WML 720
DX-2 682 Loss
P-1 862 Hexane Loss 51

Sol-1 202 DMF Loss 88
CAN 99% 2850
DBU 99% 377
5.6 Alpha Cypermethrin
Process Description
In first stage condensation Reaction is carried out between Di vinyl Acid chloride (DVACL) and
Meta phenoxy benzaldehyde (MPBAD) in presence of Sodium Cyanide (NaCN) solution &
catalyst. This oil is taken forward and then epimerized with Hexane and Iso propyl Alcohol (IPA).
The aqueous phase subject to cyanide detoxification using sodium hypochlorite. The powder is
subjected to purification in presence of IPA.
Reaction Chemistry
Formula C8H9Cl3O NaCN C13H10O2 Epimerisation C22H19Cl2O3N NaCl
Sodium IPA Catalyst Alpha Sodium
Name DVACl + + MPBAD +
Cyanide Cypermethrin Chloride
Mol. Wt. 227.5 49 198 416 58.5


Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Meta Phenoxy Benzaldehyde (MPBAD) 491.9 Product
Di Vinyl acid chlioride (DVACl) 575.3 Alpha Cypermethrin 1000
Sodium Cyanide (NaCN) 134.3 Recycled Streams
Water 983.9 n-Hexane 2874.11
n-Hexane 2963 ML of Epimerisation (Rec. IPA) 1490
Catalyst-1 9.646 Alpha ML after Purification (Rec. IPA) 1022
Cypermethrin
Soda Ash (5%) 964.6 (1000 KG) To ETP
Water for Wash 964.6 Aq. Eff. Soda Ash Wash 877
Iso Propyl Alcohol (IPA) 2590 Aq. Eff. Water Wash 854.27
Catalyst-2 86 Detoxified Eff. 3367
10% Sodium Hypochlorite 2150 Vapour Loss
Water 264.03
Solvent 165.59
5.7 Beta Cypermethrin
Process Description
Meta phenoxy Benzaldehyde (MPBAD) is reacted with sodium cyanide to form Meta phenoxy
Benzaldehyde cyanohydrin as intermediate. This on reaction with Di Vinyl Acid Chloride
(DVACL) of high cis > 96% form the product Beta-Cypermethrin oil. In this process n-Hexane is
used as solvent along with phase transfer catalyst.
The reaction is washed by Soda-ash solution and plain water.
The n-Hexane is then stripped off to get pure Beta-Cypermethrin oil in Racemic form which is
epimerised by catalyst in presence of IPA-solvent to form the final product Beta Cypermethrin of
>95% Purity
Aqueous layers of reaction as well as washings which contains traces of sodium cyanide is treated
by sodium hypochlorite solution to kill cyanide up to 0.2 PPM level, which is then given to ETP
for further treatment.

Reaction Chemistry
C8H9Cl3O NaCN C13H10O2 Epimerisation C22H19Cl2O3N NaCl

Formula
IPA Catalyst
Sodium Beta Sodium
Name DVACl + + MPBAD +
Cyanide Cypermethrin Chloride
Mol.
227.5 49 198 416 58.5
Wt.
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
MPBAD 491.9 Product
DVACl 575.3 Beta Cypermethrin 1000
NaCN 134.3 Recycled Streams
Water 983.9 n-Hexane 2875
n-Hexane 2963 ML of Epimerisation (IPA) 1490
Catalyst-1 9.646 Beta ML after Purification (IPA) 1022
Cypermethrin
Soda Ash (5%) 964.6 (1000 KG) To ETP
Water for Wash 964.6 Aq. Eff. Soda Ash Wash 877
IPA 2590 Aq. Eff. Water Wash 854.27
Catalyst-2 86 Detoxified Eff. 3367
10% Sodium Hypochlorite 2150 Vapour Loss
Water 262.73
Solvent 166
5.8 Imidacloprid
Process Description
Charge all ingredient in a reactor and filter out the K salt formed. Do DMF recovering of the
mother liquor from K salt filtration .Give acetic acid and water wash . Filter to set final washout
after drying.
Reaction Chemistry
Formula C6H5Cl2N C3H6N4O2 K2CO3 C9H10ClN5O2 KCl KHCO3
Potassium Potassium Potassium
Name CCMP + NII + IMIDA + +
Carbonate Chloride Bicarbonate
Mol. Wt. 162 130 138 255.5 74.5 100

Material Balance
Quantity Quantity
INPUT OUTPUT
Kg Kg
CCMP 700 Product
Imidacloprid
NII 603 Imidacloprid 1000
(1000 Kg)
K2CO3 650 Recovery
DMF 2500 DMF 2425

Acetic Acid 25 Stream:1 to ETP

Wash water 1742
Wash water 2068 DMF 12.50
Acetic Acid 25
Un. CCMP 0.66
Un. NII 0.94
Hazardous Waste (To Incinerator)
K-Salts waste 792.86
Residue 227.04
Loss
DMF 62.5
Water(Drying) 257.5
5.9 Bifenthrin
Process Description
STEP-1: Manufacture of 2Biphenyl Methyl Chloride (BPC)
2 - Methyl -3 Biphenyl - Methanol is chlorinated with HCl solution to give BPC (Biphenyl Methyl
Chloride) using Hexane as a solvent. The conversion takes place. BPC (Biphenyl Methyl
Chloride) in Hexane is then washed with water.
STEP-2: Manufacture of Bifenthrin
K-salt of Cyhalothric Acid is prepared with K2CO3 (Potassium Carbonate).It undergoes
condensation reaction with BPC to give BF20 (Bifenthrin) using Hexane as a solvent. BF20
(Bifenthrin) in Hexane is given Sodium Carbonate wash to remove traces of Cyhalothric acid
followed by the plain water wash. Hexane is recovered and BF 20 (Bifenthrin) is crystallized.
Process Chemistry
Stage 1: BPC Reaction
Formula C14H14O HCl C14H13Cl H2O
2-Methyl
+ Hydrochloric 2-Biphenyl Methyl +
Name 3-Biphenyl Water
Acid Chloride (BPC)
Methanol
Mol. Wt. 198 36.5 216.5 18

Stage 2: Bifenthrin Reaction
Formula C14H13Cl C9H10F3O2Cl K2CO3 C23H22F3O2Cl KHCO3 KCl

Potassium
Cyhalothric Carbonate Bifenthrin Potassium Potassium
Name BPC + + + Bicarbonate + Chloride
Acid (BF-20)
Mol.
216.5 242.5 198 422.5 130 104.5
Wt.
PROCESS FLOW DIAGRAM Basis: All quantities are in Kg

MATERIAL BALANCE
MASS MASS
INPUT OUTPUT
KG KG
2-Methyl 3-Biphenyl Methanol 508.1 Product
Hydrochloric Acid (30%) 976.83 Bifenthrin (BF-20) 1000
Water of HCL 2279.27 Recovery
Hexane 1626 Hexane 1578
Triethyl Benzyl Ammonium
10.8 To Batch Evaporation Then Landfilling
Chloride
Tetra Butyl Ammonium
25.4 Stream-1
Bromide BIFENTHRIN
Water 6405.5 (1000 KG) Aq. Stream From BPC Wash-1 3213.5
Cyhylothric Acid (98%) 627 Stream-2
Potassium Carbonate 448.2 Aq. Stream From BPC Wash-2 3135.2
Sodium Carbonate 152.4 Stream-3
Aq. Stream From Bf-20 Washing 4055.1
Hazardous Waste
Residue 48.8
Loss
Hexane Vapour Loss 28.9
TOTAL 13059.5 TOTAL 13059.5
5.10 Lambda Cyhalothrin
Process Description
STAGE 1: CHLORINATION - MTH ACID TO ACID CHLORIDE

Charge Hexane, MTH-Acid & DMF under stirring. Start addition of SOCl2. After addition
maintain the same temp. Slowly heat the reaction mass Maintain the reaction mass same temp.
Send the sample for analysis (Free acid should be less than 0.5%) Recover Hexane at atm. pressure.
Slowly apply the vacuum. Send the sample for analysis.During the reaction SO2 and HCl gas
liberated which is scrubbed by water and Caustic solution. Therefore dilute HCl and Sodium
sulphate generate as by-product.
STAGE 2: CONDENSATION - ACID CHLORIDE TO CIC-CYHALOTHRIN

Charge Hexane & MPBAD under stirring. Add MTH Acid chloride. Start addition of NaCN
solution (NaCN + water + C.lye + TEBA-Cl solution) after addition increase the temp. Send the
sample for analysis. Heat the rean. Separate out bottom aq. NaCN layer (CN : 9000 ppm) & give
fowling wash to organic layer. 1st wash - water wash, 2nd wash - 2% NaOCl wash, 3rd wash -
water wash . Recover Hexane from organic layer under vacuum. Send the sample for analysis.
STAGE 3: EPIMERISATION - CIS-CYHALOTHRIN TO LAMBDA-CYHALOTHRIN

Charge Cyhalothrin, Hexane, water & Catalyst - 20212 under stirring. Send the sample for analysis.
Add HCl + Water solution. Slowly heat the reaction mass. Stir the mass. Filter the organic layer &
remove water by azeotropic distillation at atm. pressure. Then cool the rean mass. Again cool the
rean mass. Further cool the rean mass. Transfer for filtration. Filter the rean mass & wash the wet
cake with chilled Hexane. Suck dry the wet cake & finally dry the wet cake. Send the sample for
analysis. Recover Hexane from M.L+W.L (as per plant sop) to get Cis-Cyhalothrin oil.
Chemical Reaction
STAGE 1: CHLORINATION - MTH ACID TO ACID CHLORIDE
Formula C9H10ClF3O2 SOCl2 C9H9Cl2F3O SO2 HCl
+ Thionyl Acid + Sulfur + Hydrochloric

Name MTH Acid
Chloride Chloride Dioxide Acid
Mol. Wt. 242.5 119 261 64 36.5
STAGE 2: CONDENSATION - ACID CHLORIDE TO CIC-CYHALOTHRIN
NaCN
Formula C9H9Cl2F3O C13H10O2 C23H19ClF3NO3 NaCl
Solvent
+ 3-phenoxy + Sodium,
Name Acid Chloride Cis - Cyhalothrin
benzaldehyde Chloride
Mol. Wt. 261 198 449.5 58.5
STAGE 3: EPIMERISATION - CIS-CYHALOTHRIN TO LAMBDA-CYHALOTHRIN
Catalyst
Formula C23H19ClF3NO3 C23H19ClF3NO3
Solvent
Name Cis - Cyhalothrin Lambda - Cyhalothrin
Mol. Wt. 449.5 449.5


Material Balance
MASS MASS
INPUT OUTPUT
KG KG
MTH-Acid 710 Product
Hexane 2177.3 Lambda Cyhalothrin 1000
Catalyst-1 3 Recovery
SOCl2 426 Hexane 2110
NaCN 139 Recycled Streams
Water 2346.05 Cis Cyhalothrin Oil 181.33
MPBAD 538.9 SOCl2 92
Catalyst-2 11 Detoxification
Caustic Lye 23.17 Lambda Aq. Layer-1 after Washing 363.23
Cyhalothrin
Water for Washing 1247.48 (1000 KG) Aq. Layer-2 after Washing 423.77
2% NaOCl Wash 420 Aq. Layer-3 after Washing 349
Aq. Layer-4 616.9
Catalyst-20212 3.74 Aq. NaCN Layer 553
Catalyst-3 5.98 Loss
TSU-11 11.96 Loss after stage 1 56
Seed 11.96 Loss after stage 2 174.59
H2SO4 11.96
To ETP
Aq. Layer 1835.42
To Incineration

Residue 70.25
Oily layer 44.1
To Scrubber (by product)
HCL 107
Na2SO3 187
5.11 Clodinifop
Process Description
4HPA (2-4-(hydroxyphenoxy)-propionic acid) Stage:
Condensation of Hydroquinone with 2-Chloro Propionic Acid (2-CPA) to give 4HPA in the form
of Na-salt. Hydroquinone is used in excess which is extracted in Methyl Isobutyl ketone (MP302),
recovered from it and recycled. 4HPA is crystallized by adding 30% HCl solution. This slurry is
filtered and wet cake of 4HPA is obtained, which is dried.
UPH203 Stage (Prop-2-ynyl-2-(4-5-chloro-3-flouro-2-pyrydyloxy)-phenoxy) propionate:
Condensation of 4HPA and 5-Chloro-2,3-Difluro Pyridine (CDF) forms UPH acid which further on
condensation with PCL gives UPH203 using DMF as a solvent. Potassium salts are generated
during this process which is filtered and the organic containing UPH203 in DMF undergoes DMF
recovery. IPA is used for the crystallizations of UPH203. Slurry is filtered to get wet cake of
UPH203, which is dried.
Process Chemistry
Stage: 4HPA (2-4-(hydroxyphenoxy)-propionic acid) s Preparation
Formula C6H6O2 2 NaOH C6H4Na2O2 2 H2O

Hydroquinone Sodium
Name + Di-Na HQ + Water
(HQ) Hydroxide
Mol. Wt. 110 40 154 18
Form. C6H4Na2O2 C3H5ClO2 NaOH 2 HCl C9H10O4 3 NaCl H2O

Hydrochloric 2-4-
Acid (hydroxyp
+ + Sodium + + Sodium +
Name Di-Na HQ L-CPA henoxy)- Water
Hydroxide Chloride
propionic
acid
Mol.Wt. 154 108.5 40 36.5 182 58.5 18

Stage: 4HPA to CLODINOFOP
Formula C9H10O4 2 K2CO3 C5H2ClF2N C14H10ClFKNO4 2 KHCO3 KF

2-4- CDF
(hydroxyp
Potassium + Potassium Potassium
Name henoxy)- + + UPH Acid K-Salt +
Carbonate Bicarbonate Fluoride
propionic
acid
Mol. Wt. 182.8 138 149.5 349.7 100 58
K2CO3
Formula C14H10ClFNO4 C3H3Cl C17H13ClFNO4 + HCl
UPH Acid K- Propogyl

Name + UPH Acid K-Salt Hydrochloric Acid
Salt Chloride
Mol.
311.7 74.5 349.75 36.5
Wt.

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Hydroquinone (HQ) 796.3 Product
Water 6167.9 Clodinafop Propargyl (UPH-203) 1000
Caustic 1578.2 Recovery
Sodium Bisulfite (SBS) 34.6 MP302 2379
2-Chloro Propionic Acid (2-CPA) 519.3 HQ 283.9
HCl 2354.2 DMF 2192.29
Methyl isobutyl ketone (MP302) 2452.5 Toluene 1489
Sodium Hydrosulfite (SHS) 34.6 IPA 1875.78
Potassium Carbonate 906.5 Clodinafop To Batch Evaporation Then Landfilling
Propargyl
Di Methyl Formamide(DMF) 2260.1 Stream:1
(1000 KG)
5-Chloro-2,3-Difluro Pyridine Aqueous Layer From 4HPA
547.9 7360.6
(CDF) Filtration
Tetra Phenyl Phosphonium
8.1 Stream:2
bromide(Cat 203)
Salt Solution From UPH K Salt
Propogyl Chloride 306.2 3813.1
Solution
Toluene 1535.0 Hazardous Waste
IPA 1933.8 Residue 770.4
Vapour Losses
DMF 67.71
IPA 58

CO2 99.42
Toluene 46
TOTAL 21435.2 TOTAL 21435.2
5.12 Thiomethoxam (STAR)
Step I
N-Methyl -Nitro Guanidine (NMG) is cyclized with Para Formaldehyde (PFA) in presence of
solvent Formic Acid to form OXID. Organic mass contain Formic Acid is taken for distillation.
After it is diluted with water, neutralized with Caustic Soda Lye, cool it to form crystal & filtered it
to get OXID. The diluted 16% formic acid solution used as by-product and recycled 99% formic
acid reuse in process.
Step II
OXID is condensed with 2-Chloro-5-Chloro Methyl Thiozole (MAX) in presence of solvent Di

Methyl Formamide to form STAR. Organic mass contain Di Methyl Formamide is taken for
distillation. After it is diluted with water, neutralized with Hydrochloric Acid, cool it to form
crystal & filtered it to get STAR. Again reslurry it in Spent Solvent-MH, cooled & filtered.
Reaction Chemistry
Step-1: N-methyl N-nitro guanidine (NMG) to 3 – Methyl - N-nitro –4H-4-imino- 1,3,5-

oxadiazine ( OXID )
N NO 2 O
1) Formic acid
H2N 2)MSA
NH
+ 2 (HCHO) n HN N CH3 + H2O
H3C
N
O 2N
Water
Methyl ni tro guani dine Paraformal dehyde OXID
18
118 30 160
Step-2:
Formula C4H3Cl2NS C4H7N4O3Na C8H10ClN5O3S NaCl

Sodium
Name OXID + MAX STAR + Chloride
Mol. Wt. 168 182 291.5 58.5

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Formic Acid (99%) 1077 Product
N-Methyl- Nitro Guinadine (NMG) 593 STAR 1000
Para Formaldehyde (PFA) 404 Residue
Methane Sulphonic Acid (MSA) 30 Residue 107
Caustic Soda Lye 48% 124 By-product
Caustic Soda Flakes 179 Formic Acid (16.5%) 921
Di Methyl Formamide (DMF) 1833 Recycled Streams
2-Chloro-5-chloro Methyl Thiozole Thiomethoxam
714 (1000 KG) Formic Acid (99%) 923
(MAX)
STAR Mother Liquor
Potassium iodide (CAT 203 S / 1) 9 2078.71
(IP-4)
Sulphuric Acid 10 DMF 1778.01
Methanol (IP-4 Solvent) 2143 To ETP
Water 4786 Oxid Mother Liquor 2244
Aq. Mother Liquor 2731
Vapour Loss
IP-4 +Solvent 119.28

5.13 Desmedipham (DMP)
Process Description
Butyl acetate and water is taken in the reactor and cooled. 2-Amino Phenol (MAP) and Di-Sodium
Hydrogen Phosphate (DSHP) in it. Ethyl chloro formate is added maintaining reaction temperature.
Reaction mass is cooked so that %MAP is less than 0.1 % by GC. Aqueous layer is separated and
water wash is given to organic layer.
Reaction mass is checked for Tri Ethyl Amine (TEA) requirement and if the Tri Ethyl Amine
(TEA) requirement is more than 0.4 ml/100 ml hydroxy compound then water wash is repeated.
Reaction mass is vacuum distilled (azeotropic distillation) to remove water. Further butyl acetate
recovery is carried out till moisture content is less than 0.1%. (L.T. 75 C max) Calculated quantity
of TEA is added to adjust the pH.
Phenyl Isocyanate is added under vacuum and reaction mass is cooked till PI Content is less than
0.1%. Reaction mass is cooled. Desmedipham (DMP) slurry is filtered get wet DMP. It is further
dried under vacuum till LOD is less than 1%
Note: Previous M.L is recycled in the next batches as a makeup with recovered butyl acetate.
Process Chemistry
STEP 1
Formula C6H7N0 C3H5ClO2 C9H11O3N HCl
+ + Hydrochloric
Name 2 -Amino Phenol Ethyl Chloroformate Hydroxy Compound
Acid
Mol. Wt. 109 109 181 37
STEP 2
Formula C9H11O3N C7H5NO C16H16O4N2

Phenyl Iso
Name Hydroxy Compound + Desmedipham
Cyanate
Mol. Wt. 181 119 300

Process Flow Diagram Basis : All quantities are in Kg
Butyl acetate 3341

water 1592 Mixing
2 MAP 450
DSHP 176
first reaction
Ethyl chloro formate 464
Caustic for reaction pH maintain 164
Hcl 410
seperation Aq. layer 2403
water 796
Washing
residue 329
solvent removal butyl acetate recovered 3241
loss 100
second reaction
phenyl isocyanate 489 DMP ( final product ) 1000
TEA 11
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Meta Amino Phenol 450 Product
Ethyl Chloro Formate 464 Desmedipham 1000
Di Sodium Hydrogen Phosphate 176 By-product
Butyl Acetate (Solvent 2) 3341 HCL 410
Caustic Lye 164 Desmedipham Recycled Streams
Phenyl Isocyanate 489 (1000 KG) Butyl Acetate (Solvent 2) 3241
Tri Ethyl Amine 11 To ETP
Water in Reaction 1592 Aqueous Layer 2403
Water for Washing 796 Incineration
Residue 329
Solvent 2 Loss 100

5.14 Phenmedipham (PMP)
Process Description
Butyl acetate and water is taken in the reactor and cooled. Meta AminoPhenol (MAP) and Di-
Sodium Hydrogen Phosphate (DSHP) in it. Methyl Chloroformate and NaOH 10% is added
maintaining reaction temperature and p H. Reaction mass is cooked so that %MAP is less than
0.1% by GC.
Aqueous layer is separated and water wash is given to organic layer. Reaction mass is checked for
Triethyl Amine (TEA) requirement and if the TEA requirement is more than 0.4 ml/100 ml
hydroxy compound then water wash is repeated. Reaction mass is vacuum distilled (azeotropic
distillation) to remove water. Further butyl acetate recovery is carried out till moisture content is
less than 0.1%. (LT. 75oC max) Calculated quantity of TEA is added to adjust the pH range. Meta
tolylisocyanate (MTI) is added under vacuum and reaction mass is cooked till MTI Content is less
than 0.1%. Reaction mass is cooled to 0OC. Phenmedipham (PMP) slurry is filtered get wet PMP. It
is further dried under vacuum till LOD is less than 1%. Note: Previous M.L is recycled in the next
batches as a makeup with recovered butyl acetate.
Process Chemistry
STEP 1
Formula C6H7N0 C3H3ClO2 C8H9O3N HCl
Methyl Hydrochloric
Name 2 -Amino Phenol + Hydroxy Compound +
Chloroformate Acid
Mol. Wt. 109 94 167 36
STEP 2
Formula C8H9O3N C8H7NO C16H16O4N2
Name Hydroxy Compound + Metatolyl Iso Cyanate Phenmedipham
Mol. Wt. 167 133 300

Butyl acetate 3360

water 1601 Mixing
2 MAP 407
DSHP 160
first reaction
Methyl chloro formate 376
Caustic for reaction pH maintain 156
Hcl 650
seperation Aq. layer 2213
water 800
Washing
residue 135
solvent removal solvent recovered 3260
loss 100
methyl tolyl isocyanate 491 second reaction PMP (final product ) 1000
TEA 7
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Meta Amino Phenol 407 Product
Methyl Chloro Formate 376 Phenmedipham 1000
Di Sodium Hydrogen Phosphate 160 By-product
Butyl Acetate (Solvent 1) 3360 HCl 650
Caustic Lye 156 Phenmedipham Recycled Streams
Meta Tolyl Isocyanate 491 (1000 KG) Butyl Acetate (Solvent 1) 3260
Tri Ethyl Amine 7 To ETP
Water in Reaction 1601 Aqueous Layer 2213
Water for Washing 800 Incineration
Residue 135
Solvent 1 Loss 100

5.15 Metribuzin
Process Description
Charge water and Triazinone in reaction kettle with stirring and cool. Charge 48% C.S. Lye & stir.
Charge Sodium bisulphite and 2-Ethyl hexanol. pH of mass is reduced adding 10% C.S. Lye.
Methyl Bromide Generation:
Charge methanol and Sulfur powder and apply heating start addition of Bromine Purge the
generated Methyl bromide gas continuously & adding 10% C.S. Lye. Complete the addition of
bromine. Filter the slurry. Wash & dry the wet cake
Bromine recovery:
Mix sodium bromide, saw dust and acid, then filter saw dust and organic, send NaBr in acidic
medium to evaporation for recovery.
Reaction Chemistry
STEP 1: Preparation of Methyl Bromide
Formula 6 CH3OH S 3 Br2 6 CH3Br H2SO4 2 H2O
Sulfuric
Name Methanol + Sulphur + Bromine Methyl Bromide + + Water
Acid
Mol.
192 32 480 570 98 36
Wt.
STEP 2 : Triazinone to Metribuzin
Formula C8H12ON3S NaOH C8H11ON3S-Na H2O

+ Sodium +
Name Triazinone Na-Salt of Triazinone Water
Hydroxide
Mol. Wt. 198 40 220 18
Formula C8H11ON3S-Na CH3Br C9H14ON3S NaBr

Na-Salt of + Methyl + Sodium
Name Metribuzin
Triazinone Bromide Bromide
Mol. Wt. 220 95 212 103

Material Balance
INPUT MASS OUTPUT MASS
Kg Kg
Methanol 279 Product
Sulfur 36 Metribuzin 1000
Bromine 219 To Evaporation
Triazinone 1080 NaCl solution 4926
Water 4966 To Incineration
Sodium Bisulfite 15 Solid waste 291
Metribuzin
2 Ethyl Hexanol 7 To ETP
(1000kg)
10% Caustic solution 303 Effluent 1007
Chlorine 34 Recovery
Caustic Lye 341 Methanol 270
Saw Dust 36 Bromine 208
Steam 65 Losses
32% Caustic 341 Methanol 9
Bromine 11
Total 7722 Total 7722

5.16 Metamitron
Brief Manufacturing Process:-

Hydrazide solids are dissolved in the mixture of solvents and cyclized by dehydration to
Metamitron. The water generated in the reaction due to dehydration is removed from the system in
the form of binary azeotrope with the solvent at about 100 deg C (Which after condensation,
separates into two layers,water layer is drained out the organic Layer recycled back). After
completion of this dehydration reaction, the solution of Metamitron in organic solvents is cooled
from 100 deg to 0 deg C progressively by using first cooling tower followed by chilled brine.
Here we get slurry of Metamitron solids in the organic solvents. The slurry is centrifuged. The
centrifuged mother liquor is recycled for few batches and then distilled, the distilled residue is
incinerated. The metamitron solid cake from centrifuge is dried under vacuum in steam heated
rotary dryer, weighed and packed.
Chemical Equation:-

Material Balance
KG KG
Hydrazide 1378 Product
DMAC 272 Metamitron 1000
Toluene 806 Solvent Recovery
DMAC 264
Toluene 782
Metamitron
To ETP
1000 Kg
Aq. Layer 201
To incineration
Residue 176
Losses
DMAC 8
Toluene 25
5.17 Aluminium Phosphide
Process Description
Aluminium Powder is mixed with White (Yellow) Phosphorus in presence of Groundnut oil to give
Technical Aluminium Phosphide (87%), P2O5 generated during the reaction, is scrubbed with
water to give H3PO4 acid as a byproduct. Technical aluminum phosphide is then diluted with
ingredients like Paraffin Wax, Ammonium Carbamate (MR-17), T.G.Urea, Zinc Stearate, Graphite
to give required Aluminium Phosphide with 56% to 60% and 15%.
This Aluminium Phosphide is then sent for either tableting or directly for Pouch Packing.
In tableting, basically there are three types of tablets: Flat (3gm wt), Round (3gm wt) and Pellet
(0.6 gm wt). Tablets are packed either in aluminium flasks & then in boxes Or in tubes-tins & then
CFB boxes. In pouch packing, aluminium phosphide powder is packed in pouches, single or
interlinked with each other called as chains or blanket. Such single or interlinked pouches are then
packed in secondary packing of aluminium foil, which is vacuumed to remove air. This vacuumed
aluminium foil is then packed in tins & then in CFB boxes. After CFB packing of pouches &
tablets, boxes are strapped individually or on wooden pallets for dispatch.
Reaction Chemistry
Formula 4 Al P4 4 AlP
Name Aluminium + Phosphorus Aluminium Phosphide
Atomic / Mol. Wt. 27 31 58
Formula P2O5 3 H2O 2 H3PO4
Name Phosphorus Pentaoxide + Water Phosphoric Acid

Mol. Wt. 142 18 98

Formula AlP 3 H2O PH3 Al(OH)3

Aluminium + +
Name Water Phosphine Aluminium Hydroxide
Phosphide
Mol. Wt. 58 18 34 78
Aluminium
350 By-Product
Powder
White
389 Phosphoric Acid (60%) 150
Phosphorus
Groundnut Oil 5 To Landfill

Reaction and
scrubber Al(OH)3 (Aluminium Hydroxide)
Water 2824 13
Waste
To ETP
Effluent 2774
631
Paraffin Wax 29 Product
Urea 42 Aluminium Phosphide 1000
Ammonium
195 Formulation
Carbamate
Zinc Stearate 45
Graphite Powder 58

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Aluminium Powder 350 Product
White Phosphorus 389 Aluminium Phosphide 1000
Groundnut Oil 5 By-Product
Paraffin Wax 29 Aluminium Phosphoric Acid (60%) 150
Urea 42 Phosphide To Landfill
(1000 KG) Al(OH)3 (Aluminium
Ammonium Carbamate 195 13
Hydroxide) Waste
Zinc Stearate 45 To ETP
Graphite Powder 58 Effluent 2774
Water 2824
5.18 Magnesium Phosphide
Process Description
Magnesium powder is mixed with Red Phosphorus in presence of Ground nut oil to give Technical
Magnesium Phosphide (86%). P2O5 generated during the reaction, is scrubbed with water to give
H3PO4 acid as a byproduct. Technical Magnesium phosphide is then diluted with ingredients like
Paraffin Wax, Ammonium Carbamate (MR 17), T.G.Urea, Zinc Stearate, and Graphite to give
required Magnesium Phosphide with 66%. This Magnesium Phosphide is then sent for either
tableting or Directly for Pouch Packing. In tableting, basically there are two types of tablets:
Round (3gm wt) and Pellet (0.6 gm wt). Tablets are packed in aluminium flasks & then in CFB
boxes. In pouch packing, magnesium phosphide powder is packed in pouches, single or interlinked
with each other called as chains or blanket. Such single or interlinked pouches are then packed in
secondary packing of aluminium foil which is vacuumed to remove air. This vacuumed aluminium
foil is then packed in tins & then in CFB boxes. After CFB packing of pouches & tablets, boxes are
strapped individually or on wooden pallets for dispatch.
Reaction Chemistry
Formula 6 Mg P4 4 MgP
Magnesium
Name Magnesium + Phosphorus
Phosphide
Atomic / Mol.
24 31 55
Wt.

Formula P2O5 3 H2O 2 H3PO4
Name Phosphorus Pentaoxide + Water Phosphoric Acid

Mol. Wt. 142 18 98
Formula MgP 3 H2O PH3 Mg(OH)3
Name Magnesium Phosphide + Water Phosphine + Magnesium Hydroxide
Mol. Wt. 55 18 34 75

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Magnesium Powder 485 Product
Red Phosphorus 440 Magnesium Phosphide 1000
Paraffin Wax 46 Magnesium By-Product
Ammonium Carbamate 135 Phosphide Phosphoric Acid (60%) 200
Magnesium Oxide 8 (1000 KG) To Landfill
Zinc Stearate 52 Solid waste 45
Graphite Powder 53 To ETP
Water 2800 Effluent 2774
5.19 Zinc Phosphide
Process Description
Zinc Dust coarse and fine grade both are mixed with White (Yellow) Phosphorus to give Technical
Zinc Phosphide (84%). This zinc Phosphide powder is then packed into drums / tin / Pouches.
Reaction Chemistry
Formula 6 Zn P4 2 Zn3P2
Name Zinc + Phosphorus Zinc Phosphide

Atomic / Mol. Wt. 65.34 31 258

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Zinc Dust 792 Zinc Phosphide Product
White Phosphorus 227 (1000 KG) ZnP 1000
To Landfill
Solid Waste 19
5.20 Red Phosphorus
Process Description
White Phosphorus is charged to pots, which are heated in electric furnaces. Temperature is
maintained for prescribed period, and the pots are taken out and cooled. Solid Red Phosphorus
(RP) is crushed and grounded under water. This slurry is neutralized with alkali followed by acid
and washed with water. This slurry is filtered after adding stabilizer. The filtered cake is dried,
powdered and packed in to required size of containers.
All the floor washings, water sprays, and filtrate are decanted in settling tanks. This is further
passed through a leaf filter and recycled.
Reaction Chemistry
Formula P4 P4
Name White Phosphorus Red Phosphorus
Atomic / Mol. Wt. 31 31

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
White Phosphorus 1026 Product
Caustic Soda Lye (48%) 87 Red Red Phosphorus 1000
Hydrochloric Acid (30%) 424 Phosphorus Recycle to Fresh Batch
Fresh Water 62000 (1000 KG)
Water Wash 62000
To ETP
Aqueous Layer 537
5.21 Denatonium Benzoate (DB)
Manufacturing Process
Benzyl chloride reacts with lidocaine in presence of methanol solvent acting as media. The solvent
media is recovered. The reaction mass is subjected to washing and filtration the ML is taken to ETP
for treatment. The solid is reacted with benzoic acid in presence of EA. EA is recovered back. The
bottom mass goes for incineration. The product DB is derived.

Chemical Reaction
Step I:
C14H22N2O + C6H5CH2Cl C21H29ClN2O
Lidocaine Benzyl Chloride Bitrex chloride
234 126.5 360.5
Step II:
C21H29ClN2O + NaOH C21H30N2O2 + NaCl
Sodium Bitrex Hydroxide Sodium Chloride

Bitrex chloride Hydroxide
360.5 40 342 58.5
Step III:
C21H30N2O2 + C7H6O2 C28H34N2O3 + H2O
Bitrex Hydroxide Benzoic Acid DB Water
342 122 446 18
Process Flow Diagram:
MASS MASS
INPUT OUTPUT
KG KG
Lidocaine 659 Reaction 1
Benzyl Chloride 356
Solvent (Methnol) 158
1173
MeOH recovery Recovered Methanol 154
1019
Caustic (48%) 323 washing and filtration ML
Water for Caustic Sol. 1000 To ETP 5009
Water 4000
1333
Recovered Ethyl
3742
reaction 2 Acetate
Ethyl Acetate 3857 and Residue
Benzoic Acid 326 EA recovery For Incineration 329
Loss 445
1000 DB

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Lidocaine 659 Product
Benzyl Chloride 356 Denatonium Benzoate 1000
Solvent (Methnol) 158 Recovery
Caustic (48%) 323 Denatonium Recovered Ethyl Acetate 3742
Benzoate Recovered Methanol 154
Water for Caustic Sol. 1000 (1000 KG) Residue
Water 4000 For Incineration 329
Ethyl Acetate 3857 Loss 445
Benzoic Acid 326 ML
To ETP 5009
5.22 Di Vinyl Acid Chloride (DVACl)
Process Description
Acrylonitrile and Carbon tetrachloride in presence of Acetonitrile as solvent are reacted at elevated
temperature and pressure in presence of catalyst to give Tetrachloro Butyronitrile (TCBN). Crude
TCBN is separated as organic layer. This organic layer is distilled under vacuum to remove mixture
of Carbon tetrachloride and Acetonitrile as first cut and Distilled TCBN as main cut. The mixture is
completely recycled back at Crude TCBN Reaction stage.
Purified TCBN is hydrolyzed by water at elevated temperature in presence of Sulfuric acid and
converted to Tetrachloro Butyric Acid (TCBA). TCBA is further extracted in toluene. Toluene is
further stripped off and recycled at reaction stage, using vacuum distillation.
TCBA is chlorinated by Phosphorus Trichloride & Chlorine to make TCB Acid Chloride
(TCBACL). The liberated HCL gas is scrubbed with water & caustic solution. By product
Phosphorus oxychloride is removed by distillation from crude TCBACL, which is sent for further
purification to get commercial grade. On the other hand crude TCBACL is distilled under high
vacuum and elevated temperature to remove the traces of the impurities.
Distilled TCBACl is reacted with Isobutylene at high temperature in presence of Tri Ethyl Amine
(TEA) & hexane as solvent and is converted to 2-Chloro Cyclobutanone (2CB). TEA is recovered
for reuse from aqueous layer of TEA+HCl by Caustic wash, distillation and demoisturization.

2CB in hexane is further concentrated by hexane recovery. This recovered hexane is recycled at
2CB and 4CB stage. Concentrated 2CB is isomerized in presence of catalyst and TEA to 4-Chloro
Cyclobutanone (4CB).
4CB is reacted with caustic soda solution at slight elevated temperature to form Sodium salt of
DVA (DVA Na). DVA Na is separated as aqueous layer from the reaction mass & hexane is
recovered for reuse by distillation of the organic layer.
DVA Na is acidified with HCL solution using hexane as solvent to give DVAcid, which is
separated as organic layer along with hexane from the reaction mass. Giving caustic wash to
organic layer to remove the traces of the impurities further purifies this DV Acid. Hexane is
recovered from this organic layer by distillation, which gives concentrated DVAcid.
DVAcid is chlorinated by Thionyl chloride at slight elevated temperature using DMF as catalyst to
obtain DVA Chloride (DVACl). HCL and SO2 liberated during this chlorination are scrubbed in to
the water & caustic solution scrubbers.
Crude DVACl is sent for hexane recovery followed by vacuum distillation at elevated temperature
to get purified DVACl.
Process Chemistry
1) TCBN Cl Cl
Catalyst
CH2=CHCN + CCl4 Cl-C-CH2-CH-CN
Acrylonitrile Carbon Tetra
M.W. 53 Chloride TCBN
M.W.: 154 Cl M.W.: 207
2) TCBA
Cl Cl Cl Cl
Cl-C-CH2-CH-COOH+ (NH4)2SO4
Cl-C-CH2-CH-CN
+ H2O + H2SO4
Cl TCBA
TCBN
M.W. 226
Cl M.W.: 207
3) TCBACl
Cl Cl Cl Cl
Cl-C-CH2-CH-COOH + PCl3 + Cl2 Cl-C-CH2-CH-COCl + POCl3 + HCl
Cl Cl
TCBA TCBACl POCl3
M.W. 226 M.W. 244.5 M.W. 153
4) 2 CB Cl O
Cl3C-CH2
Cl3C-CH2-CHCl-COCl + (CH3)2C=CH2 + (C2H5)3N
2CB
TCBACl TEA CH3 M.W.

264.0
M.W. 244.5 M.W. 101 CH3 H
5) 4 CB
Cl O H O
Isomerisation
Cl3C-CH2 Cl3C-CH2
CH3 CH3
H Cl
CH3 CH3
2CB M.W. 264 4CB M.W. 264

6) Na-DVA Salt
H O CH3 CH3
Cl3C-CH2 Cl2C=CH –CH – CH – COONa + NaCl
+ 3 NaOH
Na Salt of Dichlorovinyl Acid
M.W. 231.0
H3C Cl Na Salt of
H3C
CH3 CH3 CH3 CH3
Cl2C=CH –CH – CH – COONa + HCl Cl2C=CH –CH – CH – COOH + NaCl
Na Salt of Sat. Dichlorovinyl Acid Dichlorovinyl Acid
M.W. 231.0 M.W. 209.0

CH3 CH3
CH3 CH3
Cl2C=CH –CH – CH – COOH + SOCl2

Cl2C=CH –CH – CH – COCl + SO2 + HCL
Dichlorovinyl Acid
Dichlorovinyl Acid Chloride
M.W. 209.0
M.W. 227.5


Carbon Tetra Chloride 1391
Acrylonitrile 489 TCBN Aq 530 evaporation
Acetonitrile 16
TCBN
30% HCl (LR) 0.09
Catalyst 1 13
Catalyst 2 9
1388.09
Spent
Sulphuric Acid 1477 Sulphuric 2803
TCBA Acid
recycl
Toluene (Total) 414 Toluene 401
e
Toluene 5 vapor loss
70.09
Caustic Lye 7019 By-product
Phosphorus Trichloride 1160 TCBACL & 30% HCl 613
scrubbing 20% Na2SO3
Chlorine 600 2516
(18% to 22 %)
POCl3 1171
4549.09
Tri Ethyl Amine 50 2CB
Isobutylene 452 To ETP
Sodium Bicarbonate 148 Effluent 9750
Boron Trifluoride
13
Etherate
Water 13805
4CB Recycled Streams
n Hexane (Total) 13385
n-hexane 12996
Vapour Loss
n-hexane 127
9529.09
nadva
9529.09
DVA To Evaporation
DVA Aq 8507
1022.09
DVAC
Thionyl Chloride 620
L
Dimethyl Formamide 7 To Incineration
Organic Residue 649
1000.09

Material Balance
MASS MASS
INPUT OUTPUT
Kg MT
Carbon Tetra Chloride 1391 Product
Acrylonitrile 489 DVACl (96%) 1000
Acetonitrile 16 To Incineration
30% HCl (LR) 0.09 Organic Residue 649
Catalyst 1 13 To Evaporation
Catalyst 2 9 TCBN Aq 530
Sulphuric Acid 1477 DVA Aq 8507
Caustic Lye 7019 By-product
Phosphorus Trichloride 1160 DVACl 30% HCl 613
Chlorine 600 (1000 KG) 20% Na2SO3 (18% to 22 %) 2516
Tri Ethyl Amine 50 Spent Sulphuric Acid 2803
Isobutylene 452 POCl3 1171
Sodium Bicarbonate 148 Recycled Streams
Boron Trifluoride Etherate 13 Toluene 401
Thionyl Chloride 620 n-hexane 12996
Dimethyl Formamide 7 Vapour Loss
Toluene (Total) 414 n-hexane 127
n Hexane (Total) 13385 Toluene 5
Water 13805 To ETP
Effluent 9750
5.23 Metaphenoxy Benzaldehyde
Process Description
Step I :
Bromination of Benzaldehyde (BzH) is done with Bromo-chloride method to form Meta
Bromobenzaldehyde (MBB) with the help of aluminium Chloride (AlCl3) in presence of solvent
Ethylene dichloride (EDC). Organic mass is quenched in 3-4 % HCl solution and washed with
sodium thio sulphate. HCl generated during reaction and quenching is scrubbed with water to form
3-4% HCl solution which is recycled to quenching stage. Aluminium Chloride Solution generated
as by-product.
Step II :
MBB formed is converted into Meta Bromo Benzylacetal (MBBA) in presence of Monoethylene
Glycol (MEG).
Step III :

Potassium phenate (K-phenate) is formed by the reaction of phenol and potassium hydroxide
(KOH). K-phenate in turns reacts with MBBA to form meta-phenoxy benzyl acetate (MPBA). KBr
liberated from the reaction is used for bromine recovery; which is recycled in MBB stage.
Step IV :
MPBA is converted into Meta Phenoxy Benzaldehyde (MPBAD) by hydrolysis with H2SO4.
Aqueous MEG liberated is distilled and recycled in MBBA stage.
Process Chemistry
STAGE 1:
Formula 2 C7H6O Br2 Cl2 2 C7H5OBr 2 HCl

Meta Bromo Hydrochloric
Name Benzaldehyde Bromine Chlorine
+ + Benzaldehyde + Acid
Mol.
106 160 71 185 36.5
Wt.
STAGE 2 :
Formula C7H5OBr C2H6O2 C9H9O2Br H2O

Mono
Meta Bromo + Meta Bromo +
Name Ethylene Water
Benzaldehyde Benzyl-Acetal
Glycol
Mol. Wt. 185 62 229 18
STAGE 3 :
Formula C9H9O2Br C6H6O KOH C15H14O3 KBr H2O
Meta Bromo Potassium Meta Phenoxy Potassium

Name + Phenol + + Water
Benzyl-Acetal Hydroxide Benzyl Acetate Bromide +
Mol.
229 94 56 242 119 18
Wt.
STAGE 4 :
Formula C15H14O3 H2O C13H10O2 C2H6O2
Meta Phenoxy + Meta Phenoxy + Mono Ethylene

Name Water
Benzyl Acetate Benzaldehyde Glycol
Mol. Wt. 242 18 198 62

Benzaldehyde 693
Liq. Bromine 555
Anhydrous AlCl3 1150
EDC 3055
Chlorine 510
Water for scrubber 4377 MBB reaction
AlCl3
HCl Virgin (30%) 1600 4254
Solution byproduct
Formic Acid 15 MBB drawning
7701
Sodium Thio 35 To ETP
Caustic Soda Lye 150 MBB washing Effluent 9584
Water 8910
7212
Rec.
2963
EDC recovery EDC
4249
MCB 398 byproduct

Rec. Benzaldehyde
434 recovered
MBB distillation
3417
Rec.
MEG 718 696
MEG
MEG
PTSA 3 77
Residue
MBBA reaction
3365

Phenol 703
Toluene 2306
Turkey Red Oil 1
Cuprous Chloride 12
Caustic Potash 440
MPBA reaction
6827
Rec.
2237
Toluene
Rec.
Sulphuric Acid 78 538
Bromine
Bromine
40
Residue
KCl
Salt/Soluti 2100
on
Toluene
Distillatio 130
n Residue
KBR treatment, bromine
recovery & toluene recovery
1860
HyFlow 1 Residue
MPBAD
120
Residue
MPBAD
Sodium Sulphate 23 Emulsion 53
Residue
By-product
MPBAD
Distillatio 30
n Cut
Dist.
681
MPBAD final distllation Phenol recovery
1000

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Benzaldehyde 693 Product
EDC 3055 MPBAD 1000
Formic Acid 15 Residue
MEG 718 MPBAD Residue 120
PTSA 3 MEG Residue 77
Phenol 703 Toluene Distillation Residue 130
Toluene 2306 MPBAD Emulsion Residue 53
Turkey Red Oil 1 Bromine Residue 40
Anhydrous AlCl3 1150 By-product
Caustic Potash 440 AlCl3 Solution 4254
Cuprous Chloride 12 MPBAD Distillation Cut 30
MPBAD
HyFlow 1 MCB 398
(1000 KG)
Liq. Bromine 555 KCl Salt/Solution 2100
Sodium Sulphate 23 Recycled Streams
Sodium Thio 35
Sulphuric Acid 78 Rec. EDC 2963
Caustic Soda Lye 150 Rec. MEG 696
Chlorine 510 Rec. Toluene 2237
Process Water 13287 Rec. Bromine 538
HCl Virgin (30%) 1600 Rec. Benzaldehyde 434
Dist. Phenol 681
To ETP
Effluent 9584
5.24 Azoxystrobin
Process Description
Step-1 (MMBF)
Mix the 2-Coumaranone, acetic anhydride & trimethyl orthoformate with stirring heat the reaction
mass with simultaneous distillation of low boilers & high boilers with stirring. Crystallize the crude
product from methanol. Then Recover methanol from ML & remaining residue sent for
Incineration.
Step-2 (MDCPP)
1) Mix the solid MMBF, 4, 6-DCP, trimethyl orthoformate & Catalyst. Then added of 30%
NaOCH3 solution at ambient temp., continue stirring after reaction is over distilled out
trimethyl orthoformate & methanol which is recycled for next batch.
2) To the Concentrated reaction mass, add water & toluene. Separate organic layer & again
washed with KOH solution & separated. Then add methane Sulphonic acid & heat & then wash

with water & organic layer is concentrate & residue is crystallized & solvent is recovered &
residue sent for Incineration.
Step-3 (Azoxystrobin)
Mix the MDCPP & Cyanophenol, DMF, catalyst & K2CO3 with nitrogen atmosphere heat reaction
mass. After completion of reaction filter the salts& distilled out the solvent the crude product is
crystallized from methanol & residue after recovery of solvent sent for Incineration.
Process Chemistry
OCH3
Acetic Anhydride N N
O
TMOF
O +
O O Cl Cl
2 Coumaranone MMBF
M.W. 176 4,6 DCP
M.W. 134 M.W. 149
TMOF
30%NaOCH3
N N
Cl O N N
Methane sulphonic acid
OCH3
MeOOC Toluene Cl O
MDCPP OCH3
M.W. 320 MeOOC
MCPPA OCH3
M.W. 352
DMF
K2CO 3
OH
CN
2 Cyanophenol
M.W. 119
N N
O O
CN OCH3
MeOOC
Azoxystrobin
M.W. 403


2 - Coumaranone 600
total Trimethyl Orthoformate 2559.9
Mixture of Methyl
MMBF reaction,fitration , Formate, MeOH,
Acetic Anhydride 1300 crystallisation and Methyl Acetate, 1749.45
distillation Acetic Acid And
Acetic Anhydride
Total Methanol 2800 Methanol (71.7%) 3788
4,6 - DCP 649.82 Methanol Loss 84

Trimethyl
30% NaOCH3 800 50.9
Orthoformate Loss
MDCPP reaction , mixing
Toluene Loss 65.98
,distillation
Trimethyl
1767
Orthoformate
Toluene Cut 2133.66
Water 5839.7 Inorganic Salts 630

KOH Flakes 45 Residue to BEIL 484
Methane Sulfonic Acid 33 DMF 1900
Toluene 2199.65 Azoxystrobin reaction , DMF Loss 59.9
Ethyl Acetate 549.82 DMF recovery Ethyl Acetate 522
DMF 1959.9 Ethyl Acetate Loss 11
K2CO3 546.68 final Aq. Effluent 5989.45
2 - Cyno Phenol 351.9 Azoxystrobin 1000
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
2 - Coumaranone 600 Product
Trimethyl Orthoformate 2559.9 Azoxystrobin 1000
Acetic Anhydride 1300 Recycle
Mixture of Methyl Formate,
Methanol 2800 MeOH, Methyl Acetate, Acetic 1749.45
Acid And Acetic Anhydride
4,6 - DCP 649.82 Methanol (71.7%) 3788
30% NaOCH3 800 Trimethyl Orthoformate 1767
Water 5839.7 Toluene Cut 2133.66
KOH Flakes 45 DMF 1900
Azoxystrobin
Methane Sulfonic Acid 33 Ethyl Acetate 522
(1000 KG)
Toluene 2199.65 Incineration
Ethyl Acetate 549.82 Inorganic Salts 630
DMF 1959.9 Residue to BEIL 484
K2CO3 546.68 To ETP
2 - Cyno Phenol 351.9 Aqueous Effluent 5989.45
Solvent Loss
Methanol Loss 84
Trimethyl Orthoformate Loss 50.9
Toluene Loss 65.98
DMF Loss 59.9
Ethyl Acetate Loss 11
TOTAL 20235.37 TOTAL 20235.37

5.25 Kresoxim Methyl
Process Description
Stage 1: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoic Acid.
Charge O-Cresol and mixed with sodium Methoxide solution. Then add Phthalide and heat the
mass. Distill methanol. Cool to ambient temperature and add water. Extract the aqueous mass with
toluene and acidify the aqueous layer with H2SO4 Solution to obtain solid. Filter solid and wash
with water.
Stage 2: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoyl Chloride.
Charge Stage-1 product and DMF under stirring. Add Thionyl Chloride, heat the reaction mass for
4 hrs. Then distill toluene and use above chloride solution for next stage immediately,
Stage 3: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoyl Cyanide
Charge sodium cyanide solution and add dilute HCl. Add stage-2 solution and heat for 1 hr. after
completion of reaction, separate aqueous and organic layer and wash the organic layer with water.
Then distill 95% toluene and use this concentrated solution for next stage.
Stage 4: Preparation of Methyl-2-(2-methylphenoxymethyl)phenyl glyoxylate.
Charge MDC, Methanol and water and cool reaction mass, To this add stage-3 solution under
stirring. Purge dry HCl gas reaction mass for 4 to 5 hrs and after completion of purging stirring
continue for 12 to 15 hrs at ambient temperature. Then distill out MDC and Add Methanol and
H2SO4 in to residue. Heat the mass for 4 to 5 hrs. Then distill methanol and add water with MDC.
Separate organic and aqueous layer. Distill out MDC and use residue for next batch.
Stage 5: Preparation of Kresoxim-Methyl.
Charge above Residue of Stage-4 with methanol and add O-methoxyhydroxylamine HCl Salt under
stirring. Heat the reaction mass for 7 to 8 hrs and distilled out methanol under vacuum. And
Residue is dissolve in MDC and Purge dry HCl gas for 4 to 5 hrs and maintain for 24 hrs. Then
wash with water, separate MDC layer and distill MDC. Then purified residue by using methanol
and filter, wash with methanol and dry the solid.

Process Chemistry
Stage 1: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoic Acid.

O CH3
CH3 COOH
NaOCH3
+ O
O
OH
O-Cresol Phthalide 2-[(2-methylphenoxy)methyl]benzoic acid

M.W. 108 M.W. 134
M.W. 242
Stage 2: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoyl Chloride.
COOH SOCl2 COCl

DMF
O O
CH3 Toluene CH3
2-[(2-methylphenoxy)methyl]benzoic acid 2-[(2-methylphenoxy)methyl]benzoyl chloride

M.W. 242
M.W. 260.5
Stage 3: Preparation of 2-[(2-Methylphenoxy) methyl)] Benzoyl Cyanide
COCl COCN
Aq. NaCN
O Solvent O
CH3 Catalyst CH3
Benzoyl Chloride
M.W. 260.5 Benzoyl Cyanide
M.W. 251
Stage 4: Preparation of Methyl-2-(2-methylphenoxymethyl)phenyl glyoxylate.
CH3
COCN O
MeOH, Solvent
O Conc. HCl O
O
CH3
OCH3
Benzoyl Cyanide Phenyl Glyoxylate
M.W. 251 M.W. 284

Stage 5: Preparation of Kresoxim-Methyl.
CH3 CH3
O H3CONH 2.HCl M.W. 83.5 O
O Methanol OCH3
O H3CO
N
OCH3
O
Phenyl Glyoxylate
M.W. 284 Kresoxim Methyl ( E-Isomer)
M.W. 313
Isomerisation Z- to E- Isomer
CH3
HCl Gas O
MDC H3CO OCH3

N
O
Kresoxim Methyl ( E-Isomer)

Process Flow Diagram:
O-Cresol 672 Re cove ry

NaOMe 30% 1146 2-[(2-Methylphenoxy) Methanol 7993
Phthalide 800 methyl)] Benzoic Acid Toluene 10117.1
Total Water 22535 reaction , extraction Losse s
Total Toluene 10430 filtration drying Methanol 247
Total H2SO4 1632 Toluene 312.9
By product
DMF 35 Preparation of 2-[(2- HCl 833
SOCl2 715 Na2SO3 708
Methylphenoxy) methyl)]
Caustic flakes 450 Benzoyl Chloride reaction By-Product
and scrubber
Water for HCl scrubber 583 Methyl Benzoate 150
NaCN 295 Preparation of 2-[(2-

Dilute HCl 95 Methylphenoxy) methyl)]
Catalyst 3.5 Benzoyl Cyanide
To Incine rator
Total MDC 11430 Preparation of Methyl-2-(2- Residue 35
methylphenoxymethyl) To ETP
phenyl glyoxylate Aqueous Layers 26612.5
to stage 5
from stage 4
O-MethoxyhydroxylamineHCl 412
Recovery
Methanol 8240 MDC 11087.1
Preparation of Kresoxim-
DMF -
Methyl Loss
MDC 342.9
DMF 35
Kre soxim Me thyl

Te chnical
(1000 Kg)

Material Balance
Quantity Quantity
Input Output
(Kg) (Kg)
O-Cresol 672 Product
NaOMe 30% 1146 Kresoxim Methyl 1000
Phthalide 800 By-Product
Water 22535 Methyl Benzoate 150
Toluene 10430 Recovery
H2SO4 1632 Methanol 7993
DMF 35 MDC 11087.1
SOCl2 715 DMF -
NaCN 295 Toluene 10117.1
Kresoxim
Dilute HCl 95 To ETP
Methyl
Catalyst 3.5 Aqueous Layers 26612.5
Technical
Methanol 8240 By product
(1000 Kg)
MDC 11430 HCl 833
O-
412 Na2SO3 708
MethoxyhydroxylamineHCl
Caustic flakes 450 Losses
Water for HCl scrubber 583 Methanol 247
MDC 342.9
DMF 35
Toluene 312.9
To Incinerator
Residue 35
TOTAL 59473.5 TOTAL 59473.5
5.26 Trifloxystrobin
Process Description
Stage-1: Preparation of Oxime Form Phenyl Glyoxylate.
Phenyl glyoxylate and O-Methoxyhydroxylamine Hydrochloride is mixed in methanol and heated

to reflux. Methanol is distilled off and extracted with MDC, Organic layer is distilled after water
wash and crude product is purified from hexane. Solvents are recovered and recycled in the
subsequent batches.
Stage-2: Preparation of 2-(Bromomethyl) Phenyl Glyoxylate O-Methyl Oxime.
Oxime, NBS and MDC mixed and heat to reflux and after completion of reaction, filter the solid
and distilled MDC to get crude product which is purified from hexane. Solvents are recovered and
recycled in the subsequent batches.

Stage-3: Preparation of 3-Trifluromethyl Acetophenone Oxime.
Acetophenone and hydroxylamine hydrochloride is mixed in methanol and heat to reflux. Distilled
Methanol and crude purified from hexane. Solvents are recovered and recycled in the subsequent
batches.
Stage-4: Preparation of Trifloxystrobin Technical.
Acetophenone oxime and Sodium hydride is mixed in DMF. Add Bromo derivative under stirring.
After completion the reaction filter solid and solvent is distilled. Crude product is purified from
methanol. Solvents are recovered and recycled in the subsequent batches.
Process Chemistry
Stage-1: Preparation of Oxime Form Phenyl Glyoxylate
OCH3
O N
OCH3 OCH3
O-methoxyhydroxylamine.HCl
O + O
CH3 Methanol
CH3
M.W. 178
+ H2O
M.W. 207
Stage-2: Preparation of 2-(Bromomethyl) Phenyl Glyoxylate O-Methyl Oxime
OCH3 OCH3
N N
OCH3 MDC OCH3 H

N
O
+ O O
O Bromination
CH3
M.W. 207 Br M.W. 99
M.W. 285
Stage-3: Preparation of 3-Trifluromethyl Acetophenone Oxime
OH
O N
F 3C F 3C
CH3 Hydroxylamine.HCl CH3
Methanol
+ H2O
M.W. 188 M.W. 203

Stage-4: Preparation of Trifloxystrobin Technical
OCH3
N OH CH3
N
OCH3
O CF 3
F 3C DMF N
O
+ CH3
H3CO OCH3
N
Br
O + NaBr
M.W. 285 M.W. 203 M.W. 408
Process Flow Chart
stage 1 : preparation of Oxime form Phenyl glyoxylate:
Phenyl
Glyoxylate 1270
o-
charging and reaction mass
methoxyhy 625
methanol 6100
7995
MeOH recycle 5917

MeOH loss 183
methanol distillation
1895
MDC 3000
Aq. Layer 6793
Water 5300
Extraction and layer separation
3402
MDC loss 90
MDC distillation
MDC recycle 2910
Crystallisation and drying

Hexane 3066 Dry soild 3468

stage 2 : preparation of 2- (bromomethyl ) Phenyl glyoxylate o-methyl oxime:
Stage 1
oxime 3468
Charging, addition reaction
MDC 3000
NBS 1277
7745
MDC removal MDC 3000
4745
Crystallization , filtration and

Hexane 3066
drying
Dry solid 7811
stage 3 : preparation of 3- trifluromethyl acetophenone oxime:
3-trifluro methyl
acetophenone 920
Hydroxylamine charging and heating
hydrochloride.Hcl 280
MeOH 6100
7300
MeOH 6100
Methanol distillation
Distilled
1200
crystallisation & drying

Hexane 3066
product 4266

stage 4 : preparation of triflurostrobin technical :
Stage 3
product 4266
stage 2 charging, adddition and
product 7811 maintainig
NaH 200
DMF 3000
15277
Filtration , crude
NaBr 1650
purification,DMF
Residue 421
distillation
DMF 3000
10206
Hexane 9206
filltation and drying
Trifloxystrobin technical 1000
Material Balance
Quantity Quantity
Input Output
(Kg) (Kg)
Methyl-MPG 1270 Product
O-Methoxyhydroxylamine. HCl 625 Trifloxystrobin 1000
Methanol 12200 By-Product
MDC 6000 NaBr 1650
Water 5300 Recovery
Hexane 9200 Methanol 11834
NBS 1277 MDC 5820
TF_Acetophenone 920 Hexane 8924
Hydroxylaminehydrochloride.HCl 280 Trifloxystrobin DMF 2910
NaH 200 Technical To ETP
DMF 3000 (1000 Kg) Aqueous layers 6793
To Air
H2 8
Losses
Methanol 366
MDC 180
Hexane 276
DMF 90
To Incinerator
Residue 421

5.27 Meta Phenoxy Benzyl Alcohol (MPBAL)
Process Description
Hydrogenation of m-Phenoxy Benzaldehyde in presence of Tri Ethyl Amine and catalyst at

appropriate temperature and controlled condition in autoclave produces the m-Phenoxy Benzyl
Alcohol (MPBAL). After the completion of reaction decant the organic layer, stripped the organic
layer to remove Tri ethyl amine/other impurities under vacuum. Catalyst is Left in The Bottom of
the Reactor While Decanting the organic mass. The product is filled in drum as a final product. The
aqueous waste will be sent BEIL for liquid incineration.
Process Chemistry
Catalyst
Formula C13H10O2 H2 C13H12O2
Name MPBAD + Hydrogen MPBAL
Mol. Wt. 198 2 200

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Meta Phenoxy Benzaldehyde 1042 Product
Hydrogen 11 MPBAL 1000
Catalyst 10 MPBAL Recovery
Tri Ethyl Amine 2 (1000 KG) Catalyst 10
Incinerator
Liquid Waste 54
To Flare / Scrubber
Hydrogen 1
5.28 Triphenyle Phosphate (TPPA)
Process Description
Take Phosphorus oxy-chloride and Phenol in a reactor. Cook the material at about 180oC in the
reactor. Then take the crude into distillation column and from column take two cuts. After this take
washing for removing impurities, then send it to flakers unit.
Process Chemistry
Formula POCl3 3 C6H5OH C18H15O4P 3 HCl

Hydrochloric Acid
Phosphorous + +
Name Phenol TPPA
Oxychloride
Mol. Wt. 153.5 282 326 109.5

MB and PFD for TPPA :
POCL3 547
Phenol 965
catalyst 2 Reaction
Hcl 328
Hcl scrubbing
Water 772 Hcl solution 1100
to incinerator
input is Hcl from 1st step
1186
1.5 % NaOH 2194 phenol cut 139

methoxy having mixed with
hyflow 10 propaonl solution 379 701 water 1080
organic layer 1080 Stripping and washing water 1243
water 1561
aq. ml 1080 incinerator
TPPA 1000
Material Balance
MASS MASS
INPUT OUTPUT
KG KG
POCl3 547 Product
Phenol 965 TPPA 1000
Catalyst 2 To Scrubber
1.5% NaOH Solution 2194 Methoxy Propanol solution 379
Hyflow Powder 10 Recycled Streams
Organic Layer (Methoxy TPPA
1080 Water 1243
Propanol) (1000 KG)
Water 2333 Phenol Cut 139
To Incineration
Aq. ML 1 1080
Aq. ML 2 1100
Aq. ML 3 1080
Aq. ML 4 1110

5.29 L-2 Chloro Propionic Acid
Process Description
Alanine is reacted with Sodium Nitrite in presence of Hydrochloric Acid under reaction conditions
to give L-2 Chloro Propionic Acid as a product. Water, Sodium Chloride & Nitrogen are generated
as byproduct.
Process Chemistry
Formula C3H7NO2 NaNO2 2 HCl C3H5O2Cl 2 H2O NaCl N2

(S)-(-) 2
(S)- + Sodium + Hydrochloric Chloro + + Sodium +
Name Water Nitrogen
Alanine Nitrite Acid Propionic Chloride
Acid
Mol. Wt. 89 69 36.5 108.5 18 58.5 28
MB and PFD of LCPA
NaNO2 1535
Water 1535
L alanine 1000 Diazotination reaction and nitrogen gas 308
Hcl 5359 sandmayer reaction
Catalyst 5
9126
Nacl solution 406

Filteration
8720
MDC 12091 Aq. layer 7235

Extraction
organic layer 13576
Solvent recovery
Rec. solvent 11729
other losses 847
Product 1000

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
L-Alanine 1000 Product
Sodium Nitrite 1535 LCPA 1000
HCl (35%) 5359 Recycle
Water 1535 MDC 11729
MDC 12091 LCPA To Incineration
Catalyst 5 (1000 KG) Salt 406
To ETP
Aq. Layer 7235
Losses
N2 308
Other 847
5.30 2-Chloro Propionic Acid Chloride
Process Description
DEA and Alpha CPA are reacted in Caustic solution to give Alpha CPAM. Reaction mixture is
washed with water. Aqueous layer is separated. Excess unreacted DEA is stripped off from organic.
The recovered DEA is re-cycled to next batch.
Process Chemistry
Formula C3H4Cl2O C4H11N C7H14ClNO HCl

Name 2 – CPC + DEA CPAM + Hydrochloric Acid
Mol. Wt. 126.9 73 163.5 36.5
Formula NaOH HCl NaCl H2O

Sodium Hydrochloric
Name + Sodium Chloride + Water
Hydroxide Acid
Mol. Wt. 40 36.5 58.5 18

Material Balance
MASS MASS
INPUT OUTPUT
KG KG
Alpha-CPC 367 Product
Toluene 981 2CPAC 1000
46% Caustic 296 2CPAC Recovery
(1000 KG)
DEA 241 Toluene 952
Water 545 To ETP
50% EDTA 1.11 Aqueous Layer 479.11
TOTAL 2431.11 TOTAL 2431.11
5.31 Amino Aceto Nitrile Sulphate (AANS)
Process Description
H2SO4 is added with agitation to aq. solution of methanol at Room temperature. The solid MAAN
powder added with agitation at Room Temperature. The reaction is mild exothermic, cooling being
employed for temperature control.
Process Chemistry
2 0.5 ((C2H4N2 )
Formula C3H4N2 0.5 H2SO4 C3H8O2
CH3OH H2SO4)
Methyelene
Sulfuric Amino Aceto Dimethoxy
Name Amino + + Methanol +
Acid Nitrile Sulphate Methane
Aceto Nitrile
Mol. Wt. 68 49 64 105 76

MB and PFD AANS
Methanol 3000
Sulfuric acid 772.7 Dimethoxy methane 722
MAAN 909.1 Reaction and layer seperation
3959.8
MeOH wash 454.5 Salt residue 860

Water 600
Filteration
4154.3
NaOH 300 MeOH ® 3351
Recycle MeOH 103
MeOH recovery
6036 5036
Product 1000
Material Balance
INPUT Qty, kg OUTPUT Qty, kg

Methanol 3000.0 Product
Water 600.0 AANS dry 1000
H2SO4 772.7 By Product
Methyelene Amino Aceto Dimethoxy
909.1 722.1
Nitrile (MAAN) methane
AANS
MeOH (wash) 454.5 Loss
1000 Kg
NaOH 300.9 Methanol 103.5
Recycle
Methanol 3351
To Incineration
Salt Residue 860.7
TOTAL 6037.3 TOTAL 6037.3

5.32 ASAM
A) Brief Manufacturing Process and Reactions: -
STEP-1: Manufacture of ADN
Amino Pyridine under condensation with Mono Chloro Acetic acid gives ADN
NH2 O NH
O
+ Cl
OH
N N
OH
Amino Pyridine Monochloro Acetic Acid ADN

M.W. 94 M.W. 94.5 M.W. 152
STEP-2: Manufacture of ADCl
ADN with excess of POCl3 is first cyclized and chlorinated to get ADCl. ADCl is further extracted
in EDC and cyclised in Hexane
NH
O N + H 3PO4
+ 2 POCl 3
Cl
N
OH
+2H2O N
HCl
+ ADN
ADCl
M.W 152 M.W. 153.5
STEP-3: Manufacture of ASAM
ADCl reacts with Chlorosulfonic acid gives ADSA that on reaction with excess of POCl3 gives
ADSCl. ADSCl further undergoes amidation to give ASAM.
N N
C
C + ClS 3H
O N l
N l
S
O
O
OH
ADCl ADSA

N N
Cl Cl
N
+ P
O
C
l 3 N + H3P
O 4 + HCl
+ 2H2O
S S
O O
O O
OH Cl
M.W 153.5 M.W. 233.5
ADSA ADSCl
N N
Cl
N
Cl + N
H 4C
l
N + 2N
H 3
S S
O O
O O
Cl NH2
M.W. 252 M.W. 232.5
ADSCl ASAM

Process Flow Diagram: -
MB and PFD of ASAM
Soda Ash 1257

2- Amino Pyridine 1293
Mono Chloro Acetic A D N reaction
1539
Acid
Phosphorous
3171.5 Phosphoric Acid 2903
oxychloride
Ethylene Di chloride 7531 Hexane 2923
ADCL reaction
Hyflow Supercell 6 Ethylene Di Chloride 7305
Hexane 3013 Hexane 90
Ethylene Di Chloride 226
Chlorosulfuric acid
1570
(CSA)
ADSA reaction
Methylene Dichloride 22720
Phosphorous
3171.5 Toluene 4398
oxychloride Recover
Toluene 4534 ADSCL reaction Toluene 136 loss
Triethyl Amine (TEA) 2030
To ETP
water 18514 Quenching Effluent 31912
Methylene Di
ACTN 4500 22038
chloride recover
ASAM reaction and crystallization
Methylene Di
Liquor Ammonia 5738 682
chloride loss
ACTN 135 loss
ACTN 4365 recover
Incineration
ASAM 1000 Residue 2475
Material Balance

KG KG
Product
ASAM
2- Amino Pyridine 1293 ASAM 1000
1000 KG
Mono Chloro Acetic Acid 1539 Incineration
Soda Ash 1257 Residue 2475
water 18514 Byproduct

Toluene 4534 Phosphoric Acid 2903

Phosphorous oxychloride 6343 Recycle stream
Ethylene Di chloride 7531 Hexane 2923
Liquor Ammonia 5738 Toluene 4398
Hyflow Supercell 6 Ethylene Di 7305
Chloride
Hexane 3013 Methylene Di 22038
chloride
Methylene Dichloride 22720 ACTN 4365
Chlorosulfuric acid (CSA) 1570 Losses
Triethyl Amine (TEA) 2030 Hexane 90
ACTN 4500 Toluene 136
Ethylene Di 226
Chloride
Methylene Di 682
chloride
ACTN 135
To ETP
Effluent 31912
5.33 Hydrazide
Brief Manufacturing Process:
By contacting HCl with H2SO4(98%), dry HCl gas and spent acid are generated. HCl gas is
absorbed in Methanol & EDC mixture. This mixture is reacted with Mandelonitrile to form
MethylMandelate and NH4Cl. After addition of water the mass is neutralized with liquor ammonia.
NH4Cl is separated from organic reaction mass. This NH4Cl is disposed off by sale. Methyl
mandelate in EDC is reacted with sodium hypochlorite solution to form Methyl Ester. Organic
mass is washed and aqueous layer is sent to ETP. From the organic mass, EDC is recovered and
reused and methyl ester is distilled. Residue generated during distillation is sent for incineration.
Ethyl acetate is reacted with hydrazine hydrate to produce Acetyl hydrazide and Ethanol solution
(60%). Acetyl hydrazide is further reacted with Methyl ester and hydrazine hydrate to produce
Phenyl Glyoxylic acid Hydrazide 2- Acetyl Hydrazone (HYDRAZIDE). This mass is centrifuged
and dried to get HYDRAZIDE powder. The mother liquor is distilled and reused. Residue will go
for incineration.

Chemical Equation:-
MMZ
a) ESTERIFICATION:
i) Methanolic HCl
ii) Water
OH Methanolic HCl COOCH3
CH-CN CH-OH +NH4Cl
Water
M.W. 133 M.W 166
b) OXIDATION:
COOCH3 NaOCl COOCH3
CH-OH C=O +H2O + NaCl
M.W. 166 M.W. 164
c) HYDRAZONE PREPARATION:
COOCH3 CH3CONHNH2 COOCH3
C=O C=N-NH-COCH3
(CH3COOrt + NH2NH2)
M.W 164 M.W. 220
d) HYDRAZIDE PREPARATION:
COOCH3 NH2NH2 H2O CONHNH2
C=N-NH-COCH3 C=NNHCOCH3
M.W. 220 M.W. 220

Material Balance
KG KG
Sulphuric Acid 2202 Product
HCl 30% 1175 Hydrazide 1000
Methanol 5267 By Product
Ethylene Di chloride 3537 Ammonium Chloride 1740
Liquor Ammonia 136 Spent Sulphuric Acid 3024
Mandelonitrile 923 Recycle stream
Water 2125 Hydrazide Methanol 5109
Sodium Hypochoride sol 5403 (1000 kg) Ethylene Di chloride 3430
Ethyl Acetate 647 Loss
Hydrazide hydrate 820 Methanol 158
Ethylene Di Chloride 107
To ETP
Effluent 7092
Incineration
Residue 575
5.34 Ammonium Carbamate
Process Description
For Production of Ammonium Carbamate ammonia gas and Carbon dioxide Gas are purge into
PVC balloon. The product Ammonium Carbamate produces in the foam of solid flakes on the inner
surface of balloon. When the reaction has completed then it take out from balloon then send for
crushing and packing into drums.
2NH3 + CO2 CO2(NH4)2
Ammonia (17 MW) Carbon Di Oxide (44 MW) Ammonium Carbamate (78 MW)
NH3 440kg
PVC Balloon
CO2 560kg
CO2(NH4)2 1000kg
440kg

Material Balance

KG KG
Ammonia Gas 440 Ammonium Product
Carbon dioxide 560 Carbamate (MR-17) Ammonium Carbamate 1000
(MR-17)

6. WATER ENVIRONMENT
6.1 Water Consumption
Water consumption detail is mentioned in table no. 4.
6.2 Wastewater Generation
Wastewater generation with segregation of effluent streams details are mentioned in below table:
Table No. 7 – Wastewater generation with segregation of effluent streams

Particular
No. (KL/Day)
A. Domestic 93.40 20.00 113.40
B. Gardening --- --- ---
C. Industrial
1 Process (ETP+Incinerator+MEE) 1,354.12 443.30 1,797.42
2 Boiler 553.40 500.00 1,053.40
3 Cooling 150.50 84.80 235.30
4 Washing 5.50 5.50 11.00
5 MEE Condensate 400.75 119.00 519.75
Total (C) 2,464.27 1,152.60 3,616.87
Total (A+B+C) 2,557.67 1,172.60 3,730.27
Total effluent to ETP
I Normal process effluent 1,202.25 287.00 1,489.25
II Boiler 553.40 500.00 1,053.40
III Cooling 150.50 84.80 235.30
IV Washing 5.50 5.50 11.00
V MEE Condensate 400.75 119.00 519.75
Total effluent to ETP (I+II+III+IV+V) 2,312.40 996.30 3,308.70
Segregation of Conc. effluent
I High COD effluent to Incinerator 16.00 27.30 43.30
II High TDS effluent to MEE 135.87 129.00 264.87
III Normal effluent stream to ETP 2,312.40 996.30 3,308.70
Total (I+II+III) 2,464.27 1,152.60 3,616.87
Company is manufacturing their products as per the market demand and wastewater generation
quantity of last three year is maximum 1,171.00 KLD. Wastewater generation due to proposed
expansion will be 996.30 KLD. Hence total wastewater generation after proposed expansion will be

2167.30 KLD. Existing ETP is having sufficient capacity of 2500 KLD to take the additional load
of proposed expansion. Unit will be provided STP for the treatment of sewage having capacity of
150 KLD.
6.3 Water Balance Diagram
Water Balance Diagram for Existing (KL/Day)
Water Balance Diagram after Expansion (KL/Day)

6.4 Method of Treatment of sewage/wastewater
6.4.1 Sewage
Sewage will be expected to generate due to domestic activities of workmen and staff personnel
during construction phase as well as operation phase. Existing sewage quantity is 93.40 KLD and
after proposed expansion additional 20.00 KLD of sewage will be generated during operation
phase. Total sewage generation after proposed expansion i. e. 113.40 will be treated in proposed
Sewage Treatment Plant (STP) having capacity of 150 KLD.
6.4.2 Effluent
Effluent from the plant is being/shall be properly segregated and treated individually as under:
High COD and toxic concentrated effluent is being/shall be treated in to Incinerator of BEIL,
Ankleshwar. High TDS effluent is being treated in existing Multiple Effect Evaporation (MEE)
System. Industry will be installed new MEE for additional high TDS effluent generated after
proposed expansion.
Normal effluent is being treated in existing Effluent Treatment Plant (ETP). The existing
wastewater generated from the plant is treated in existing ETP of 2500 KLD capacity. The ETP
consists of primary and secondary stage treatment units. The schematic flow diagram of existing
ETP is mentioned in Annexure – 6. Company is manufacturing their products as per the market
demand and wastewater generation quantity of last three year is maximum 1,171.00 KLD.
Wastewater generation due to proposed expansion will be 996.30 KLD. Hence total wastewater
generation after proposed expansion will be 2167.30 KLD. Existing ETP is having sufficient
capacity of 2500 KLD to take the additional load of proposed expansion.
The final treated effluent from the ETP confirming the CETP norms is being/shall be discharged in
to GIDC underground drainage system and treated in CETP and discharged in to Arabian sea.
CETP membership certificate is attached as Annexure – 9.
Details of Existing ETP
Collection tank:
Two collection tanks are provided to receive raw acidic effluent having FRP/MSEP roof to trap the
acid fume & provide the Acid fume scrubbing system.

Oil & Grease trap (T-01):
One Oil & grease trap is provided to separate floating oil & grease (if any) from effluent. Required
underflow baffle wall at inlet to kill the pumping velocity & overflow weir are provided at outlet.
RCC launder is provided near outlet to collect floating oil & grease. De-oiled effluent will then
overflow into inlet chamber.
Slope is given at tank floor towards one end/outlet to drain out settled heavy oil/scum (if any).
Necessary drain pipe with valve is provided at lowest point outside of oil & grease trap. Small pit is
provided near the drain nozzle to put drum for collection of floating oil (from overflow launder) &
heavy oil (from drain nozzle located at bottom).
Inlet chamber to Equalization tank (T-02):
This chamber receives effluent from oil & grease trap as well as other recirculation flow from
process drains. This combined flow is being taken in to Equalization tank-I or II. For isolation, two
sluice gate are provided, one at inlet of each Equalization tank.
Equalization tank (T-03-A/B):
These equalization tanks will serve the purpose of equalizing the effluent in terms of flow &
strength, hence improving efficiency of downstream treatment units & holding capacity in case of
any downtime / necessary maintenance in plant.
The tank has two compartments, each having 6 hr holding capacity for a flow of 2500 m3/day i.e.
wet volume of each compartment is 650 m3. The tank/compartment will be operated on fill & draw
basis i.e. when one compartment receives raw effluent, second compartment will be under
withdrawal mode.
For equalized the effluent, coarse air mixing is provided. For this, 3 (2 working + 1 standby) Air
blowers (twin lobe type) each having capacity of 650 Nm3/hr & 1.0 kg/cm2 are provided to supply
air. HDPE Pipe grid with perforation at tank floor level is being provided for uniform air
distribution.
Horizontal Centrifugal type equalized flow pumps 2 (1 working + 1 standby) are provided to pump
the equalized effluent to neutralization tank-I. Diaphragm seal pressure gauges are provided on
discharge header of each pump and to measure pump discharge pressure.
Level Transmitter (LIT-01 & LIT-02) is provided at each tank to indicate the liquid level, to give
alarm at high & low level & also trip the associated equalized flow pump at low level.
Tank MOC is RCCM30 with acid/alkali proof lining inside the tank. Tank is provided with RCC
staircase with FRP railing & one cage ladder to access tank top. CI rungs with FRP coating are
provided inside tank to access bottom floor of tank.
Neutralization tank-I&II (T-04-A/B):
Equalized effluent will be pumped to Neutralization tank-I. Here, acidic effluent gets neutralized by
addition of lime slurry solution. Effective mixing period for lime slurry solution is 20-30 min.
Hence, two Neutralization tanks (tank-I & II) working in series having total retention time of 30
min for flow of 2500 m3/day are provided. Necessary baffle wall at inlet & outlet are provided to
avoid the short circuiting of effluent/chemical solution and to have efficient blending.
Tank MOC is RCC M25 with acid/alkali proof lining inside the tank. Tank is provided with RCC
platform to mount the agitator & have CI rungs to access tank bottom while cleaning /
maintenance. Both tanks are provided with drain for ease of cleaning. Neutralized effluent will then
be lead to Primary clarifier through channel.
Primary Clarifier (T-05):
pH raised effluent from above neutralization tank-II outlet will be lead to Primary clarifier thru‟
FRP/MSEP channel. Here, polyelectrolyte solution will be dosed to aid in big settable flocs
formation. These flocs will travel downwards towards hopper bottom whereas clear water will
travel upward & then overflow into the outlet launder. Clarified effluent will be lead to clarified
effluent collection tank which also serve as PSF feed & backwash water feed tank.
Centrally driven clarifier mechanism is provided to scrap the settled sludge to central bottom cone
from where sludge will be withdrawn periodically to sludge sump & then from here it will be
pumped to filter press for dewatering. MOC of clarifier mechanism is MSEP. Torque transmitter is
also provided to measure & transmit operating torque to PLC.
Sludge withdrawal will be periodically at regular intervals, depend on sludge generation rate &
filter press cycle, so that operating torque in the Clarifier mechanism does not increase beyond the
designed value.
Clarifier mechanism is with provided lifting arrangement which is interlocked with torque
transmitter. Incase torque value crosses the set point, it will lift the mechanism & will give
annunciation so that operator can take necessary action. As a second measure of safety,

annunciation system followed by finally tripping of Clarifier mechanism is also provided at high-
high torque value.
Clarified Effluent collection tank (T-06):
This tank receives clarified effluent from overflow launder of Primary clarifier. Here, effluent will
be pumped to Pressure sand filter for filtration & reduce the suspended solid prior to leading it to
the Aeration tank. It is also designed to hold enough quantity of effluent to use as backwash water
for PSF media. Tanks MOC is RCC M25 and is provided with CI rungs to access tank floor for
maintenance.
Pressure Sand Filter (PSF-01-A/B/C):
Pressure sand filter are provided to filter the clarified effluent prior to leading it to downstream
unit. Total 3 (2 working + 1 standby) Pressure sand filter (PSF) are provided. Each PSF is designed
for 50% capacity & operating for 22-23 hr (considering 1-1.5 hr for back washing any two filter
unit). Size of each PSF is 2.8 m dia x 2 m L.
PSF is down-flow type & during course of traveling, suspended solids get trapped on/around media
surface. Hence, as time elapse, slowly media gets chocked which ultimately reduces filtration rate.
Hence, it is required to agitate filter media with pressurized water to improve the filtration rate.
For backwashing, same feed pump & clarified effluent will be used to backwash filter media.
Hence, there are total 3 PSF feed/backwash pumps (Horizontal Centrifugal type), out of which, one
will be working during filtration mode and 2nd will be working during backwash mode. At a time
only one PSF will be under backwash & during backwash cycle, no filtration will be take place in
either of PSF. Dirty backwash water coming out from PSF will be transferred to equalization tank.
Sludge sump (T-13):
Settled primary sludge will be collected at sludge sump & from there it will be pumped to filter
press for dewatering. Tank is provided with agitator to keep the content in suspension & feed
consistent sludge slurry to filter press.
Tanks MOC is RCC M25 & is provided with CI rungs to access tank floor for maintenance.
Filter Press (FP-01-A/B):
From Sludge sump, lime sludge will be pumped to Filter-press at regular interval for dewatering.
There are Semi Auto type two filter presses. Dewatered sludge from press will be collected directly

into truck & will be suitably disposed off. Filtrate will be recycled back to inlet chamber of
equalization tank by gravity.
Lime Dosing system:
Two Lime dosing tanks (T-07-A/B) are provided with slow speed agitator to prepare 10% lime
solution. There are 2 (1 working + 1 standby) Lime dosing pumps (Horizontal Centrifugal type) to
pump lime slurry to Neutralization tank.
Tanks MOC is RCC M30 & are underground to have an ease of unloading the lime bags into tank
directly from floor level of building. Pumps are located with flooded condition & for same
necessary pump house (below ground) is constructed within the building.
To avoid the dusty atmosphere, while unloading the lime bags, De-dusting system with exhaust
blower is provided for Lime dosing tank.
PE Dosing system:
Two PE dosing tanks (MOC-HDPE) (T-12-A/B) are provided to prepare & dose 0.05% PE solution
at outlet of neutralization tank. Both tanks are provided with agitator of MOC SS304. To dose PE
solution, 2 nos. (1 working + 1 standby) PE dosing pumps (of metering type) are provided.
Secondary Treatment:
The primary treated effluent is given secondary treatment in the aeration tanks. This treatment
works on principle of activated sludge system. Suitable bacterial mass is developed & maintained
in the aeration tanks. In these aeration tanks, the organic material present is decomposed by
bacteria taking oxygen supplied by Fine Bubble air diffusers. The overflow goes to secondary
clarifier. In secondary clarifier, the Biomass is separated and recycled back to bio reactor.
Generated excess Biomass is taken to Solid Bowl Centrifuge of Capacity 500 kg/hr (dry Basis).
The clear treated water overflows out through Magnetic flow meter to GIDC underground drainage
system which joins CETP.
Table No. 8 – Details of Existing ETP
Sr. Tag
Description Dimensions MOC Qty.
No. no.
ET-01- 5.5 m x 4.5 m x 3.6 m RCC M30 + Acid/alkali
1. Collection tanks 1
A/B LD + 0.5 m FB proof lining

Sr. Tag
No. no.
6.25 m long x 1.8 m RCC M30 with Acid-
2. Oil & grease trap T-01 wide x 2.7m LD + 0.5 alkali proof lining 1
mFB (HDPE/PPGL lining)
RCC M30 with Acid-
1.8 m x 1.7 m x 2.0 m
3. Inlet chamber T-02 alkali proof lining 1
LD + 0.7 m FB
(HDPE/PPGL lining)
RCC M30 with Acid-
T-03- 16 m x 7.15 m x 5.5 m
4. Equalization tank alkali proof lining 2
A/B LD +0.5 m FB
(HDPE/PPGL lining)
Tank-I : 3 m x 3 m x
Neutralization T-04- 3.3 m LD +0.5 m FB RCC M25 with Acid
5. 2
tank-I &II A/B Tank- II: 3 m x 3 m x 3 alkali proof brick lining
m LD +0.8 m FB
Primary Clarifier 13 m dia x 3 m LD +
6. T-05 RCC M30 2
(cum thickener) 0.5 m FB
Clarified effluent T-06 3.3 m x 3.3 m x 5 m
7. RCC M30 1
collection tank LD + 0.5mFB
Lime dosing tanks T-07- 2.5 m x 2.5 m x 2.3 m
8. RCC M30 2
(underground) A/B LD +0.5 m FB
5.31 m x 5.885 m x
9. PLC room (FF) - - 1
4.65 m ht
3 m x 3 m x 3 m LD +
10. Sludge sump T-11 RCC M25 1
0.5 m FB
Bio-Reactor 22.40 x 11.2 x 5.0
11. RCC 2
(Aeration Tanks) LD+0.5 FB
Secondary 16.5 Dia x 3.5
12. RCC 1
Clarifier SWD+0.5 FB
13. Final Outlet tank 3.0 x 3.0 x 1 RCC 1
Raw Effluent P-01- Approx. 105 m3/hr & 3

14. PP/PVDF 1+1
transfer pumps A/B kg/cm2
P-03-
15. Scrubber pumps 6 m3/h PP 1
A/B
Equalized flow P-04- 130 m3/hr & 1.5
16. PP/ PVDF 1+1
pumps A/B kg/cm2
PSF feed/ P-05- 115 m3/hr & 3.0
17. CI with SS304 impeller 3
backwash pumps A/B/C kg/cm2
Filter press feed P-06-
18. 35 m3/hr & 6-8 kg/cm2 CI with SS316 rotor 2+1
pump A/B/C

Sr. Tag
No. no.
Lime dosing P-07-
19. 5 m3/hr & 1.5 kg/cm2 Ci/ Ni Hard 1+1
pumps A/B
P-08- 0-600 LPH & 2.0
20. PE dosing pumps PP 1+1
A/B kg/cm2
21. Lime drain pump P-09 2 m3/hr & 1.0 kg/cm2 Ci/ Ni Hard 1
Process drain
22. P-10 2 m3/hr & 1.2 kg/cm2 PP/PVDF 1
pump-I
Process drain
23. P-11 2 m3/hr & 1.2 kg/cm2 CI with SS316 wetted part 1
pump-II
Service water P-12-
24. 10 m3/hr & 2.5 kg/cm2 CI with SS304 impeller 1+1
pumps A/B
25. Service water tank T-11 15 m3 HDPE 1
T-12-
26. PE dosing tanks 4000 lit HDPE 2
AB
Blowers for AB-01- 150 Nm3/hr & 0.45
27. CI 1+1
collection tank A/B kg/cm2
Aeration grid (at
28. - as per detail engg HDPE/ CFRP/ MSHDPE Lot
collection tank
Scrubbing system
with Exhaust
As per detail
29. blower AB-02 As per mfr‟sstd 1
engineering
(for existing
equalization tank)
Blowers for Eq. AB-03- 650 Nm3/hr& 1.0
30. CI 2+1
tank A/B/C kg/cm2
Aeration grid (at
31. - as per detail engg HDPE/ CFRP/ MSHDPE -
equalization tank)
Primary clarifier CLF- For 13 m dia x 3 m
32. MSEP 1
mechanism 01 SWD + 0.5 m FB
PSF-
Pressure sand 2.8 m dia x 2 m TL to 2W
33. 01- MSEP
filters (PSF) TL +1S
A/B/C
FP-01-
34. Filter press As per detail engg CI frame with PP plates 2W
A/B
35. De-dusting system AB-04 500 CFM MS 1
Air compressor for 40 CFM capacity with

36. AC-02 CI 1 no.
Filter press system 2 m3 air receiver

Sr. Tag
No. no.
Single Exhaust
37. - As per detail engg As per manf standard 1
Blower
Boi Sludge
38. Recirculation 50 m3/hr CI with SS 316 impeller 2
Pump
Feed Pumps for
39. 10 m3/hr CI with SS 316 Rotor 2
Bio Sludge SBC
Air Blowers for 1650 m3/hr, 0.64
40. CI 4+1
Aeration Tank kg/cm2
Fine Bubble air 144 x
41. 2 m long Silicone rubber based
diffusers 2
PE Dosing Pump
42. for Bio sludge 0-300 LPH & 4 kg/cm2 pp 2
SBC
Secondary
16.5 m dia x 3.5 m LD
43. Clarifier Scraper MS FRP 1
+ 0.5 FB
Mechanism
Solid Bowl
44. Centrifuge for Bio 500 kg/hr SS 1
Sludge
Details of Proposed STP
Treatment is based on activated sludge principle, where the organic matter present in sewage is
decomposed by biomass present in suspension inside the tank. The external oxygen source is
provided to satisfy the process requirement.
Primary Treatment: The sewage generated from the source shall be first passed through oil and
grease chamber in order to remove free oil present in it. As the density of oil is less than that of
water it will start floating on the surface of water. The chamber arrangement is so provided that the
floating oil is restricted to get into the outlet zone of chamber. Oil floating on the surface of water
will be collected by the controlled openings provided in the chamber. Then the sewage will enter in
to equalization tank which serves the purpose of both flow equalization and characteristic
equalization. Air is provided in the equalization tank for better mixing and to avoid solids
accumulation inside the equalization tank.
After equalization, sewage is transferred to the aeration tank. In aeration tank, aerobic bacteria
present in suspension shall decompose the organic matter present in sewage. The desired level of

biomass required about 3500 mg/l will be maintained to achieve the best possible performance. The
oxygen requirements of suspended biomass will be satisfied by diffused aeration, which is cost
effective method over conventional aeration methods. The biomass generated inside the tank will
be allowed to settle in the clarifier by gravity. The part of settled biomass is recycled back to
maintain MLSS level inside the aeration tank. Rest of the settled sludge is transferred to the sludge
drying bed for moisture removal and drying. The treated sewage from clarifier will be collected in
supernatant sump. NaOCl dosing shall be done in the sump for the purpose of disinfection.
Further the collected treated sewage will be passed through pressure sand filter and activated
carbon filter for polishing. The quality of treated sewage achieved is well below the GPCB/CPCB
discharge standards. The treated sewage will be utilized for greenbelt development and flushing in
the project premises.
Table No. 9 – Description of proposed STP Unit & their size
Sr. No. NAME SIZE

1. Screen Chamber 3mX1mX1m
2. Oil & Grease Tank 2mX1mX1m
3. Equalization Tank 3 m X 3 m X 3.5 m
4. Aeration Tank 8 m X 8 m X 3.5 m
5. Flocculation Channel 1mX1mX1m
6. Clarifier 4 m X 4 m X 3.5 m
7. Chlorination tank (NaOCl) 4 m X 2 m X 3.5 m
8. Pressure Sand Filter 400 dia. X 1800 mm
9. Activated Carbon Filter 600 dia. X 1800 mm
9. Sludge Drying Beds 8 m X 8 m X 1.5 m

Flow diagram of STP @150KLD

Details of Existing MEE
The evaporator plant is a forward feed triple effect system having capacity of 100 KLD.
The effluent solution is fed to series of pre-heater where in the heat from the exit condensate of
each effect is extracted and the effluent is heated to certain temperature. Prior to feeding the
solution to first rising film calandria-1 the effluent solution feed is thus preheated in plate feed pre-
heaters. The condensate from respective calandria is used as hearing media in this PHs.
Heated effluent solution is fed to the calandria-1 and enters in VLS-01. This is a rising film
calandria having 38.1 mm OD tubes and 4 m in length. The vapours from thermo compressor shall
heat the calandria. The liquid travel bottom to top of the tubes and are separated in a specially
designed vapour liquid separator with tangential entry. Separator is designed to ensure effective
separation of entrained liquid droplets from the vapours. The liquid is transferred to next effect and
vapours are used for heating next effect as well as a part vapours are pulled by thermo compressor.
The partially concentrated effluent solution is then fed to second forced circulation calandria. The
liquid velocities inside the tubes are maintained by a specially designed axial flow pump. This
pump is capable of handling the slurries and saturated liquid at higher flow rates alwaus
recirculates from bottom towards top. A vapour liquid separator mounted at the top ensures
effective separation. Slurry is transferred to the next and last effect which is similar to effect-2 and
operates on same principle. Concentrated slurry is extracted of by means of the product pump and
transferred to the incinerator.
The vapours from this effect are passed through surface condenser. This is connected to a steam jet
ejector system which generated and maintains vaccum inside the system. Condensate I withdrawn
by means of pumps.
A set of inter connecting piping, fittings and valves is provided.
A temperature control loop is provided on the steam inlet line. Flow of the incoming steam is
controlled by the temperature of the first effect shell temperature. A control panel with the on/off
switches and suitable temperature indications provided.
Detail of existing Agitated Thin Film Dryer is mentioned below:

Table No. 10 – Detail of existing Agitated Thin Film Dryer
Sr. No. Particulars Details

1. Capacity 1100 kg/hr water evaporation
2. Feed rate 2300 kg/hr
3. Initial solids 50 %
4. Final moisture in dry product Less than 10 %
5. Water evaporation 1100 kg/hr
6. Dry solid output 1200 kg/hr
7. Dry saturated steam requirement
a. at 8 kg/cm2-g pressure 1320 kg/h
b. Electrical load 38 KW
8. Cooling water circulation
a. Inlet rate at 30-32OC 60 m3/h
b. Cooling water outlet temperature 38OC
9. Jacket temperature 250OC
10. Jacket pressure 10 kg/cm2-g
11. Surface area 20 m2 (2 Nos.)
12. Rotor design High performance hinged blades
13. Rotor speed 270-300 rpm
P & ID schematic flow diagram for MEE & ATFD is attached as Annexure – 7.
PROPOSED MEE:
Company has mechanical evaporators to take care of high TDS effluent. P & ID schematic flow
diagram for proposed MEE having capacity of 150 KLD is attached as Annexure – 8.

7. AIR ENVIRONMENT
7.1 Flue gas emission
The flue gas emission and its control measures are mentioned in below table:
Table No. 11 – Details of flue gas emission
Air Pollution
Sr. Capacity Type of Stack Stack Conc. of
Stack attached to Control
No. (TPH) fuel height (m) dia (m) pollutants
system
Existing
30.5 or 11
Adequate
with
1. Boiler No. 1 10 FO/NG 0.9 Stack height
condensing
with SMF
economizer
Adequate
2. Boiler No. 2 8 FO/NG 30.5 0.7 Stack height
with SMF
Adequate
3. Boiler No. 3 5 FO/NG 30.5 0.7 Stack height
with SMF
Imported PM < 150 Electrostatic
4. Boiler No. 4 23 55 1.2 mg/NM3
Coal precipitator
SO2 < 100
Thermic Fluid Adequate
4 lakh ppm
5. Heater (MPBAD- LDO 30.5 0.35 Stack height
Kcal/hr NOx < 50
Plant) with SMF
ppm
4.5 lakh
6. Heater (Pesticides LDO 30.5 0.35 Stack height
Kcal/hr
Plant) with SMF
4.5 lakh
7. Heater (STAM LDO 30.5 0.35 Stack height
Kcal/hr
Plant) with SMF
1 x 1250 Adequate
8. D. G. Set HSD 15.5 0.15
KVA Stack height
(In case of
emergency) 2 x 500 Adequate
9. HSD 15.5 0.15
KVA Stack height
Proposed
Thermic Fluid PM < 150 Adequate
4 lakh
10. Heater (MPBAD-
Kcal/hr
LDO 30.5 0.35 mg/NM3 Stack height
Plant) SO2 < 100 with SMF
Thermic Fluid 5 lakh ppm Adequate
11. LDO 30.5 0.35 NOx < 50
Heater Kcal/hr Stack height

Air Pollution
Sr. Capacity Type of Stack Stack Conc. of
Stack attached to Control
No. (TPH) fuel height (m) dia (m) pollutants
system
(Multipurpose ppm with SMF
Plant)
4.5 lakh
12. Heater (Pesticides LDO 30.5 0.35 Stack height
Kcal/hr
Plant) with SMF
D. G. Set
2 x 500 Adequate
13. (In case of HSD 15.5 0.15
KVA Stack height
emergency)
Electrostatic Precipitators (ESP) for existing Coal-Fired Boiler
Table No. 12 – Details of ESP
Sr.
Description Unit Details
No.
O
1. Design Temperature C 250
2. Design Pressure mmwc + 400
Pressure drop through ESP
3. mmwc 25
(Flange to Flange)
4. Fuel used --- Indian Coal
5. Inlet Dust Concentration gm/Nm3 55
O
6. Flue gas Temperature C 150
7. No. of Working field --- 3
8. Collecting Electrode
a. Material --- IS513 CRCA Grade D
b. Width x Height mm 480 x 6950
c. Thickness mm 1.2
d. Clear gap between twoelectrodes mm 400
e. Total no. of gas passages Nos. 10
Specific collecting area with All
f. m2/m3/sec 127.37
fields in service
g. Total collecting area m2 1401
h. Flue Gas velocity m/s 0.40
i. Treatment Time s 25.47
j. Aspect ratio --- 1.55
9. Emitting Electrode

Sr.
Description Unit Details
No.
a. Type --- Variodyn 15
Carbon Steel With Copper
b. Material of Electrode ---
coated Pins
c. Material of frame --- MS
Effective distance between 200 (Between Collecting & Emitting
d. mm
twoElectrodes between across gas flow)
15 mm strip with Copper
e. Electrode size mm
Coated Pins
10. Gas distribution system
a. No. of screen Nos. 2@ Inlet and 1@ Outlet
Perforated and flap type at inlet & U
b. Type ---
beam type at outlet
c. Location --- Inlet and Outlet Funnel
11. Dust Hoppers
a. Type --- Pyramidal
b. Material --- IS2062
c. Thickness mm 4
d. Hopper valley angle Deg 55
e. No of Hoppers --- 1 / Field
f. Outlet size mm x mm 400 x 400
g. Heating --- Provided
h. Baffling Arrangement --- Provided

7.2 Process Emission
Detail of process emission is mentioned in below table:
Table No. 13 – Details of Process Emission
Stack Stack
Sr. Air Pollution Control Parameter &
Stack attached to height Dia.
No. system Permissible limit
(m) (mm)
EXISTING
HCl < 20 mg/Nm3
Pesticide plant – 1 Water scrubber followed
1. 12 100 Cl2 < 5 mg/Nm3
reactor by Caustic scrubber
PM < 20 mg/Nm3
Pesticide plant – 2 Water scrubber followed
2. 12 100
reactor by Caustic scrubber
HCl < 20 mg/Nm3
Pesticide plant – 2 & Cl2 < 5 mg/Nm3
3. Permerthrin (Stand by 12 --- Water/Alkali Scrubber
scrubber)
PM < 20 mg/Nm3
ALP plant firing Mist Eliminator & Water
4. 30 --- P2O5 as H3PO4 < 5
chamber scrubber
mg/Nm3
MPBAD plant reaction Sodium Thiosulphate HCl < 20 mg/Nm3
5. vessel & Bromine 22 150 absorber for Br2 recovery Cl2 < 5 mg/Nm3
recovery system and Caustic scrubber HBr < 5 mg/Nm3
DVACL PLANT HCl < 20 mg/Nm3
6. 22 150 Alkali Scrubber
(TCBACl reactor) PCl3< 9 mg/Nm3
DVACL plant (DVACl Water scrubber followed
7.
reactor)
22 100
by Alkali Scrubber HCl < 20 mg/Nm3
PCl3 < 9 mg/Nm3
DVACl plant (Storage SO2 < 40 mg/Nm3
and Recovery System)
HCl < 20 mg/Nm3
DVACl plant (Fugitive
9. 22 100 Alkali Scrubber Cl2 < 5 mg/Nm3
emission)
SO2 < 40 mg/Nm3
Water scrubber followed HCl < 20 mg/Nm3
10. ASAM 12 100
by Alkali Scrubber Cl2 < 5 mg/Nm3
Mist Eliminator with PM < 20 mg/Nm3
11. ZnP plant reactor 12 200
Koch Filter P2O5 < 5 mg/Nm3
HCl < 20 mg/Nm3
12. Lambda Cyhalothrin 12 100 Alkali Scrubber
SO2 < 40 mg/Nm3
Water/Alkali scrubber
(Sodium Thiosulphate
13. Metribuzin 12 100 HBr < 5 mg/Nm3
absorber)

Stack Stack
Sr. Air Pollution Control Parameter &
Stack attached to height Dia.
No. system Permissible limit
(m) (mm)
PROPOSED
ALP plant firing Vet Scrubber with Mist PM < 20 mg/Nm3
1. 30 ---
chamber Eliminator P2O5 < 5 mg/Nm3
DVACL PLANT HCl < 20 mg/Nm3
(TCBACL reactor) PCl3 < 9 mg/Nm3
DVACL plant (DVACL Water/Alkali Two stage
3.
reactor)
30 80
Scrubber HCl < 20 mg/Nm3
PCl3 < 9 mg/Nm3
DVACL plant (storage SO2 < 40 mg/Nm3
and Recovery System)
Mist Eliminator with PM < 20 mg/Nm3
5. ZnP plant reactor 30 200
Koch filter P2O5 < 5 mg/Nm3
HCl < 20 mg/Nm3
Pesticides Plant-1 Water /Alkali Two stage
6. 30 100 SO2 < 40 mg/Nm3
reactor Scrubber
Cl2 < 9 mg/Nm3
HCl < 20 mg/Nm3
MPBAD plant Bromine Cl2 < 9 mg/Nm3
7. 30 150 Water /alkali Scrubber
recovery & plant reactor HBr < 5 mg/Nm3
Br2 < 9 mg/Nm3
HCl < 20 mg/Nm3
8. ETP scrubber 30 150 Caustic Scrubber
Cl2 < 9 mg/Nm3
MPBAL flare and
9. 30 100 Caustic Scrubber HCl < 20 mg/Nm3
scrubber
Methyl bromide as
10. Metribuzin 30 100 Caustic Scrubber
Br < 5 mg/Nm3
HCl < 20 mg/Nm3
11. Kresoxim Methyl 30 100 Caustic Scrubber
SO2 < 40 mg/Nm3
12. Multiproduct plant stack 30 100 Caustic Scrubber HCl < 20 mg/Nm3

8. SOLID/HAZARDOUS WASTE
The details of solid/hazardous waste to be generated from proposed activities are mentioned in the
below table:
Table No. 14 – Details of Hazardous/Solid Waste Generation and Management

Description Category Mode of Disposal
No. MT/Month
Collection, storage,
transportation, disposal
1. ETP waste 35.3 544.417 144 688.417
at TSDF-VWEMCL-
Vapi/ BEIL-Ankleshwar
4.197 6.356 10.553 transportation, disposal
2. Used oil 5.1
KL/Month KL/Month KL/Month by selling to registered
reprocessors
Discarded
42,052 63,724 1,05,776 decontamination &
3. Containers/ 33.1
Nos./Month Nos./Month Nos./Month recycle or sold to scrap
Bags
operators
Oil/ Grease
4. 35.4 0.468 0.709 1.177 by incineration at TSDF-
from ETP
VWEMCL-Vapi/ BEIL-
Ankleshwar
Spent Filter
5. 36.2 3 4.546 7.546 by incineration at TSDF-
Material
VWEMCL-Vapi/ BEIL-
Ankleshwar
6. MEE Salt 37.3 760 714 1,474
at TSDF-VWEMCL-
Sludge of 4.197 6.36 10.557
7. 37.1 by incineration at TSDF-
wet Scrubber KL/Month KL/Month KL/Month
VWEMCL-Vapi/ BEIL-
Ankleshwar
Used B1 3 5 8 transportation, disposal
8.
Batteries (B1020) Nos./Month Nos./Month Nos./Month by selling to registered
reprocessors.


Description Category Mode of Disposal
No. MT/Month
Process
9. Inorganics 29.1 30.80 30.00 60.80
at TSDF-VWEMCL-
waste
Al, Mg, Zn Collection, storage,
Hydroxide transportation, disposal
10. Sch-II 2.608 9.000 11.608
(Dust at TSDF-VWEMCL-
collection) Vapi/ BEIL-Ankleshwar.
Distillation
11. 29.1 681.343 710.54 1,391.88 by incineration at TSDF-
residue
VWEMCL-Vapi/ BEIL-
Ankleshwar
Spent
Solvent
VWEMCL-Vapi/ BEIL-
Ankleshwar
Waste/
Residue
Containing
VWEMCL-Vapi/ BEIL-
Pesticide
Ankleshwar
Date
expired/ off
specification
VWEMCL-Vapi/ BEIL-
products
Ankleshwar
Non Hazardous waste
15. Fly ash --- 550 2000 2550 Send to End User
Will be used as manure
16. STP Sludge --- --- 10.00 10.00
within the premises.
Membership certificate for TSDF and Incinerator are attached as Annexure – 11.

The details of hazardous chemical storage are mentioned in the below table and Permission from
the PESO department is attached as Annexure – 10.
Table No. 15 – Details of Hazardous chemical storage
Storage Mode Maximum Storage

Sr.
Name of Raw Material State (Tank/ Bag/ Capacity (MT or
No.
Drums) KL)
1. Acetic Acid liquid Drums 0.226
2. Acetic Anhydrate liquid Tank 20
3. Acetonitrile liquid Drum 1.219
4. Acrylonitrile liquid Tank 30
5. Aluminium Powder Solid Bag 22.5
6. Aluminium Chloride (Anhydrous) liquid Bag 43.1
7. Ammonia Gas Tonner 5.7
8. Ammonia (liquor) liquid Cylinder 0.276
9. Benzaldehyde liquid Tank 30
10. Benzoic Acid liquid Drum 0.2
11. Benzyl Chloride liquid Drum 1.78
12. Boron Triflurotide etharate liquid Drum 4.55
13. Bromine liquid Tanker 2
14. Carbon dioxide Gas Tanker 22.5
15. Carbon tetra chloride liquid Tanker (ISO) 486.85
16. Caustic Potash Solid Bag 16.5
17. Caustic Soda Lye (48%) liquid Tank 100
18. Chlorine Gas Gas Tonner 29.5
19. Cyhylothric Acid liquid Drum 307
20. Di Ethyl Amine liquid Drum 9.64
21. Di methyl Formamide (DMF) liquid Tank 30
22. Di Sodium Hydrogen Phosphate Solid Bag 8.6
23. Di Vinyl Acid Chloride (DVACl) liquid Drum 41.1
24. Ethyl Acetate liquid Drums 2.304
25. Ethyl chloro Formate liquid Drum 111.36
26. Ethylene Di chloride liquid Tank 10
Ethylene Diamine Tetra Acetic Acid
27. solid Bags 0.044
(EDTA) 50%
28. Ethyl Mercaptan liquid Tanker 6.83
29. Formic Acid liquid Tanker 28.35


Sr.
No.
Drums) KL)
30. Graphite Powder Solid Bag 7.1
31. Groundnut Oil liquid Drum 3
32. Hexane liquid Tank 30
33. Hydrazine Hydrate liquid Tanker 16.4
34. Hydrochloric Acid liquid Tank 50
35. Hydrogen Gas Cylinder 0.1
36. Hydroqunone (HQ) liquid Drum 76.84
37. Hydroxylamine hydrochloride Solid Bag 3
38. Hyflow Solid Bag 0.1
39. Isobutylene Gas Bullets 17
40. L- Alanine Solid Drum 4.3
41. Lidocaine liquid Drum 0.4
42. Magnesium Oxide Solid Bag 0.5
43. Magnesium Powder Solid Bag 31.2
44. Methylene di chloride (MDC) liquid Tank 50
45. Mono Ethylene Glycol(MEG) liquid Drum 28
46. Meta Amino Phenol liquid Drum 206
47. Methane Sulphonic Acid (MSP) liquid Drum 7.8
48. Methanol liquid Tank 30
49. Methyl Chloro Formate liquid Tanker 90.24
50. Methyl Chloro Acetic Acid liquid Tanker 15
51. Methyl Propylene Glycol liquid Tanker 15
52. Methyl Iso Butyl Ketonene liquid Tanker 30
53. N- Bromosuccinamide (NBS) Solid Bag 13.7
54. 2- Nitroiminoimidazoline (NII) Solid Bag 5.2
55. N-Methyl nitro Guinadine (NMG) Solid Bag 9.5
56. O-Cresol Solid Bag 7.2
57. O-Methoxy hydroxy Amine HCl Solid Bag 11.2
58. Propargyl chloride (PCl-306.2) Bag 46
59. Para Formaldehyde (PFA) Solid Bag 6.5
60. Para Toluene Sulphonic Acid (PTSA) liquid Tanker 1.05
61. Paraffin Wax Solid Bag 4.8
62. Phenol liquid Tanker 252
63. Phenyl Isocynide liquid Tanker 118


Sr.
No.
Drums) KL)
64. Phosphorus Trichloride (POCl3) liquid Drum 13
65. Phthalide Solid Bag 8.6
66. Potassium Carbonate Solid Bag 33.2
67. Potassium Chloride Solid Bag 1.7
68. Potassium Hydroxide flakes Solid Bag 0.5
69. Propanic Acid liquid Tank 60
70. 8 Hydroxy 5 chloroquinoline Solid Bag 2.2
71. Soda Ash( 5%) Solid Bag 16.8
72. Sodium Bi sulfite (SBS) Liquid Drum 5.19
73. Sodium Hydro Sulphite (SHS) Liquid Drum 5.19
74. Sodium Bicarbonate Solid Bag 5.6
75. Sodium cynide Solid Bag 14.3
76. Sodium hydride Solid Bag 2.7
77. Sodium Hypochloride liquid Tank 40
78. Sodium Methoxide (NaOCH3) Solid Bag 12.3
79. Sodium Nitrile Solid Bag 6.6
80. Sodium Sulphate Solid Bag 0.9
81. Sodium thio Solid Bag 1.3
82. Sulfur Solid Bag 0.9
83. Sulfuric Acid liquid Tank 40
84. Triethyl Benzyl Ammonium Chloride Solid Bag 0.7
3- Trifluromethyl acetophenone (TF-
85. Solid Bag 9.9
Acetophenone)
86. Tetra Butyl Ammonium Bromide (TBAB) Solid Bag 2.7
87. Thionyl Chloride liquid Tank 25
88. Toluene liquid Tank 40
89. Triazinole Liquid Drum 272
90. Triethyl Amine liquid Drum 9
91. Triethyl Benzyl Ammonium Chloride Solid Bag 0.7
92. Trimethyl Orthoformate liquid Tanker 80
93. Turkey Red Oil liquid Drum 0.35
94. Urea Solid Bag 2.7
95. White Phosphorous Solid Drum 48.4
96. Zinc Dust Solid Bag 50.9


Sr.
No.
Drums) KL)
97. Zinc Stearate Solid Bag 6.2
98. ADP 98% Solid Bag 0.5
99. Alpha-CPC Solid Bag 1
Tetra phenyl Phosphonium bromide (cat
100. Solid Bag 0.1
203)
101. Potassium Iodide (KI) (cat 203s/1) Solid Bag 0.1
102. 2- Chloro 5-chloromethyl pyridine (CCMP) Solid Bag 25
103. 5-Chloro-2,3-Difluro Pyridine (CDF) solid Bag 50
104. Cypermethric Acid Chloride (CMAC) liquid Drum 200
105. 2-Chloro,5-Chloro methyl Thiozole liquid Drum 100
106. 2-Coumaranone Solid Bag 6.4
107. 2-Cyno Phenol Solid Bag 3.8
108. 2-Chloro Propionic Acid liquid Drum 20
109. 2-Ethyl Hexanone liquid Drum 0.216
110. Iso Propyl Alcohol liquid Tank 15
111. 2- Methyl 3-Biphenyl Methanol Solid Bag 8.2
112. 3,4 Dichloro Aniline Solid Bag 48

9. NOISE ENVIRONMENT
The company has already developed green belt around the periphery of the premises, which shall
act as a barrier to the propagation of noise from the factory premises. This shall further reduce the
noise levels appreciably. Following measures shall be adopted for abatement of noise during the
operation phase:
 Noise generating equipments like pumps, motors, compressors, blowers, turbine/engines,

power generator sets/ engines etc. are/shall be mounted on sturdy concrete foundations with
proper & suitable rubber padding to reduce vibrations & thereby noise generation.
 Acoustic laggings, enclosures and silencers are/shall be provided wherever necessary for
high noise generating equipment.
 Acoustic enclosure for D. G. Set and similar provision like noise attenuator wherever
suitable/possible.
 Safety blow off valves, discharge pipes, relief valves, etc. is/will be equipped with silencers.
 Silencers for Boilers are provided and/or attached with various noise generating parts of
boiler.
 Regular lubrication & preventive maintenance is being/shall be done to reduce vibration &
noise generation.
 Use of PPEs like ear plugs and ear muffs are/will be made compulsory near the high noise
generating machines.
 Moreover, the personnel are provided breaks in their working hours, with the continuous
exposure not increasing three (3) hours.
 All vehicles shall maintain speed limit inside the premises and unusual acceleration of
engine & loud horns is being/shall be prohibited.
 Periodic monitoring of noise levels as per post-project monitoring plan is/shall be done on
regular basis.

10. SOLVENT MANAGEMENT PLAN
 The solvent distillation system is/will be designed so as to achieve minimum 97% recovery
of solvent.
 Company is having dedicated multipurpose solvent distillation and recovery plant.
 Pure solvent, crude solvent and distilled (recovered) solvent are/shall be stored only in
storage tanks and are not/shall not be used drums at any stage in the Solvent Management
System.
 Wherever required, the solvents are/shall be directly pumped into day tanks from the
storage tanks and are/shall be charged into the reactors without involving any manual
handling.
 All the pumps are/will mechanical seal type to avoid any leakage of solvent.
 All necessary firefighting systems are/will be provided with alarm system. Flame proof
wiring and flame proof electrical accessories are/will be provided to avoid any mishap.
 All the storage tank and day tank are/shall be connected to a vent system through chilled
water/chilled Brine condensers to prevent loss of solvents in the atmosphere.
 Also, all the distillation column vents are/shall be connected to chilled water/chilled Brine
condensers for maximum possible recovery of the solvents.
 Pipelines connected with reactors and scrubbers are/will be installed with minimum number of
flanges, joints and valves.
 Operators are/will be available round the clock at operation floor and maintain the parameters as per
procedure.
 Periodic monitoring of work area is being/will be carried out to check the secondary fugitive
emission.
The detail of solvent recovery is mentioned in the below table:

Table No. 16 – Solvent Recovery
Production Capacity
Sr. (MTPM) Name of Consumption Recovery Difference %
Product
No. After Solvent Recovery
Existing
expansion Kg/MT
1. Cypermethrin 330 500 Hexane 1146 1112 34 97.03
Sulfosulfuron 0 10 Hexane 1725 1674 51 97.04
2. (SF-10) DMF 2933 2846 87 97.03
Safener 5 50 Toluene 869 843 26 97.01
3. DMF 1655 1605 50 96.98
N-Hexane 958 950 8 99.16
Alpha- 30 80 Hexane 2963 2874.11 88.89 97.00
4. cypermethrin IPA 2590 2512 78 96.99
Bita- 30 80 Hexane 2963 2875 88 97.03
5. Cypermethrin IPA 2590 2512 78 96.99
6. Imidaclopid 30 80 DMF 2500 2425 75 97.00
7. Bifenthrin 32 150 Hexane 1626 1578 48 97.05
Lambda 32 150 Hexane 2177.3 2110 67.3 97.00
8.
Cyhalothrin
Clodinofop 32 150 MP302 2452.5 2379 73.5 97.00
propargyl Toluene 1535 1489 46 97.00
9.
IPA 1933.8 1875.78 58.02 97.00
DMF 2260.1 2192.29 67.81 97.00
Thiomethoxan 32 150 Methanol 2143 2078.71 64.29 97.00
(STAR) DMF 1833 1778.01 54.99 97.00
10.
Formic 1077 1074 3 99.72
acid
Desmedipham 90 240 Butyl 3341 3241 100 97.01
11.
Acetate
Phenmedipham 90 240 Butyl 3360 3260 100 97.02
12.
Acetate
Metamitron 90 240 DMAC 272 264 8 97.06
13.
Toluene 806 782 24 97.02
Di Vinyl Acid 300 350 Toluene 414 401 13 96.86
14. Chloride Hexane 13385 12996 389 97.09
(DVACl)
Meta Phenoxy 275 350 Ethylene 3055 2963 92 96.99
Benzaldehyde Dichloride
(MPBAD) MEG 718 696 22 96.94
15.
Toluene 2306 2237 69 97.01
Bromine 555 538 17 96.94
Denatonium 1 5 Ethyl 3857 3742 115 97.02
16.
Benzoate Acetate

Production Capacity
Sr. (MTPM) Name of Consumption Recovery Difference %
Product
No. After Solvent Recovery
Existing
expansion Kg/MT
Methanol 158 154 4 97.47
Azoxystrobin 0 100 Toluene 2199.65 2133.66 65.99 97.00
17. Methanol 2800 2716 84 97.00
DMF 1959.9 1900 59.9 96.94
Kresoxim 0 100 MDC 11430 11087.1 342.9 97.00
18. Methyl Methanol 8240 7993 247 97.00
Toluene 10430 10117.1 312.9 97.00
Trifloxystrobin 0 100 Methanol 12200 11834 366 97.00
MDC 6000 5820 180 97.00
19.
DMF 3000 2910 90 97.00
Hexane 9200 8924 276 97.00
L-2 Chloro 0 40 MDC 12091 11729 362 97.01
20.
Propionic Acid
2-Chloro 0 40 Toluene 981 952 29 97.04
21. Propionic Acid
Chloride
Amino Aceto 0 50 Methanol 3454.5 3351 103.5 97.00
22. Nitrile Sulphate
(AANS)
Hydrazide 20 20 Methanol 5267 5109 158 97.00
23. Ethylene 3537 3430 107 96.97
Dichloride
ASAM 2 2 Hexane 3013 2923 90 97.01
Toluene 4534 4398 136 97.00
24. Ethylene 7531 7305 226 97.00
Dichloride
MDC 22720 22038 682 97.00

11. OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT
The company is very much concerned in terms of health, safety and environment protection. UPL
commitment towards safety can be reflected from its „Health, Safety & Environment Policy‟
prepared for the existing project.
From the previous performance, same dedication is to be continued for the proposed expansion. To
maintain high standard in Health, Safety and Environment, various activities are undertaken at the
site. Similar practice will be followed for the proposed activities.
The following key safety measures are implemented in the existing plant and the same shall be a
part of proposed activities:
1. Safety Training is provided to the employees.
2. Safety Sirens with Alarm System in case of emergency are provided.
3. Emergency Control Room is established.
4. Assembly point is provided.
5. Sprinkler Systems is/will be provided as needed
6. Fire Hydrant System is installed.
7. Fire Extinguishers are provided.
8. Mock drills are periodically conducted and factors like response time are evaluated.
9. Fire squad team is formed for handling any emergency situation.
10. First Aid Facility and training are provided.
11. Personal protective gears and equipments are provided to employees.
12. Health check ups are organized at regular intervals.
13. Safety / Health records and MSDS are maintained.
14. On line stack analyzer installed.

12. SITE ANALYSIS
12.1 Connectivity
The project location is well connected with road and rail route to transport raw materials,
machineries etc. and hence, it exhibits good potential for industrial growth. The salient features
mentioned below indicate favorable condition for industrial development at the project location.
Detail of connectivity is as shown in table:
Particulars Details
Approx. Geographical Co-ordinates 20°21'04.58"N Latitude
72°54'35.36"E Longitude
Village Chanod
Nearest Town Vapi
River/Streams Daman Ganga River
Nearest Highway NH- 08
Nearest Railway Station Vapi
Nearest Airport Daman
Tourist places Daman & Silvassa
Protected areas (National parks/sanctuaries) None within 10 km radial periphery
Nearest state boundary Daman & Dadra
Defense installations No defense Installation.
Sites of Historical/ Archaeological Importance None within 10 km radial periphery
Densely Populated or built – up Area Vapi
12.2 Topography
The location is at 20°21'04.58"N Latitude and 72°54'35.36"E Longitude having elevation of 27 m

above sea level. The overall project site is located on plain barren land devoid of any permanent
and economically useful vegetation. The topography of the proposed site for project is plain terrain.
No other forests, national park or wild life sanctuary is located within 10 km periphery of the
proposed project site. No change in land use/Topography will be observed as the proposed project
is expansion project and located in GIDC Notified Industrial Estate.

12.3 Existing Infrastructure
Key infrastructures available around the:
Sr. No. Description Available within 10 km around the project

1 Railway station Yes (Vapi)
2 Bus Station Yes
3 National Highways National highway No-8
4 School/College Vapi has primary, secondary and higher secondary schools.
Valsad city has also primary, secondary, higher and CBSC
schools as well as Engineering, Arts, Commerce & Science
colleges.
5 Hospital In the study area villages have either primary health centers or
sub centers. Some villages have medical facilities within
distance of 3-5 Km. Civil Hospital and private experts of every
medicine are available in the area.
6 Religious place Yes
12.4 Soil Classification
The project site is located within GIDC and the soil quality of the area is not considered fertile for
agricultural activities. No evidence of any influence of contaminant has been noticed. In overall
area the agricultural productivity is very less due to absence of fertilization practices & poor
fertility of soil.
12.5 Climate data from the secondary source
Climate Semi Arid

Seismic Zone II
Maximum temperature, 0C 42°C
Minimum temperature, °C 8.5°C
Relative Humidity Max.:- 89%; Min.:- 56%
Max Rain Period June to September

13. PROPOSED INFRASTRUCTURE
Sr.
Infrastructure Description
No.
Industrial area (processing Existing
1.
area)
Non-Processing area Ware house & storage area will be constructed as per
2.
the requirement of proposed product storage.
Green belt Necessary green belt will be developed in & around
3.
the proposed plot and also at Nahuli UPL plot
4. Connectivity (transportation) As mention in 12
5. Drinking water management GIDC VAPI
6. Sewage system Sewage will be treated in proposed STP.
Industrial waste management Adequate size of ETP has been provided & treated
7. water is being sent to Vapi CETP for further
treatment & disposal.
Solid/ Hazardous waste Proper treatment and disposal at TSDF Facility of
8.
management BEIL Ankleshwar or TSDF-VWEMCL, Vapi.

14. PROJECT SCHEDULE & COST ESTIMATES
14.1 Project Schedule
Proposed project activities will be started after getting statutory clearance from MoEF&CC and
SPCB.
14.2 Project Cost Estimation
Sr. Estimate cost

Project
No. (Rs. in Lacs)
For expansion in existing capacity and addition of
1. 20,660.35
new products
2. HAZOP cost 619.81
3. Services cost 2,685.85
4. Out of Pocket expenses 413.21
5. Utility cost 2,066.03
6. ETP 759.76
7. Hazardous Waste Area 67.67
8. MEE + ATFD 590.45
9. STP 200.00
10. Solid Waste Handling System 150.00
11. Greenbelt Development 200.00
12. Other Misc. 150.00
TOTAL 28,563.13
ROI of proposed project:
Sr. No. Description Estimate cost (Rs. in Lacs)

1. Grand Capital Investment 28,563.12
2. Profit per Annum (Contribution) 15,000.00
3. ROI in Years 1.90

14.3 Financial & Social Benefits
 More employment opportunities.
 The proposed activities will be carried out in the existing unit itself. Hence, no additional
land is to be purchased.
 The company has allocated some budget for CSR activities, which can lead to improved
social infrastructure, if planned properly.
 UPL Management have taken up various CSR activities and major activities are in the field
of education, health protection and improvement of infrastructure facilities. The important
organizations under the umbrella of UPL are Sanskardeep Vidyalaya (Ankleshwar), Gyan
Dham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical
Technology (Ankleshwar).

15. CONCLUSION
Existing site located inside Notified GIDC Industrial estate. As summarized in above sections, it
has been noticed that the proposed expansion in existing production capacity (Pesticides &
Intermediates products) and addition of new products (Pesticides & Intermediates products) will
not have any major impacts, which can lead to serious issue of environmental pollution or any other
hazards.
Considering the probability of impacts, proponent has planned adequate mitigation measures and
EMP. Further, it has also been planned by proponent to organize CSR programs, energy
conservation, which will have considerable beneficial impacts. Looking to the employment
potentials and other allied developmental potentials, it has been noticed that the proposed project
will significantly help in improving social status of the region.

1-
GUJARAT POLLUTION CONTROL BOARD
PARYAVARAN BHAVAN
Sector 10-A. Gandhinagar 382 010
Phone (079) 23226295
Fax . (079) 23232156
Website WI'\YIItI1l,llob.govin
In exercise ufthe power conferred under section-25 of the Water (Prevention and Control of Polhltiun)
Act-\974, under SCCtiOD-21ufthe Air (Prevention and Control ofPol1ution)·1981 and Authorization under rule
5(4) urthe Hazardous Waste (Management, Handling & Transboundary Movement) Rules-ZOOS, framed under
the Environmental (Protection) Act-1986,
And whereas Board has received CC& A application dated 20/112014 tor the Consolidated Consent
and Authorization (CC & A) of this Board under the provisions/rules of the aforesaid Acts. Consents &
Authorization are hereby granted as under:
CONSENTS AND AUTHORISATION:

(Under the provisions !rules of the aforesaid environmental acts)
~UNITED PHOSPHOROUS LTD,

Plot No. 3-11, A-2/1, A-2/Z, A-2/6 & A-Ill, PHASE-I,
GIDC Estate, Vapi~396195,
Dist.Valsad.
I. Consent Order No.: AWH-60886, Date of issue: 3/312014.

2. The consents shall be valid up to 51l12019 for usc of outlet for the discharge of trade cenuent &
emission due lo ooeration of industrial lant for manufacture of the following items/products:
Sr.No. Prodnct Quantity (MTlMontb)
1. Aluminum Phosphide (Fumi ant) 200
2. Zinc Phosphide (Rodenticide) 40
3. Cypermethrin (Insecticide) 330
4. Alpha Cypermethrin (Insecticide) OR 30
Beta Cypermethrin OR
Imidacloprid Tech.
5. Pennethrln (Insecticide) 100
--
6. Desmedipham (DMP) (Herbicide) OR 90
Phenmooipham (PMP) Either OR
Metamitron OR
Metribuzin
7. Bifenthrin (BF 20) (Insecticide) OR 32
Clodinofop Propargyl(UPII-20J) OR
Thiomethaxam (STAR) OR
Lambda Cyhalothrin
8. Safner (UPH-203 S) (Herbicide) 5.0
--
9. Magnesium Phosphide (Fumi ant) 8.0
10. ASAM 2.0
11. Pronanil (Herbicide) 108.00
12. Pesticide Formulation Product JOO
13. Dichloro Vinvl Acid Chloride (DVACL) JOO
14. Meta henoxy 8""Dzaldehvde (MPBAD) 275
15. Hydrazide 20
16. Red Phosphorus (Non Pesticide) 80
17. Denatonium Benzoate 1
By-Product
1. Phosnhoric Acid (100 %basis 40
2. Hydrochloric Add (30 % 2048
3. SpentSulfuricAcj,d(46-68%) OR --lO25~
Ammonium Sulnhatc 600
4. Phosnhorous OXYchloride 640
Ammonium Chloride (Solid) 34.8
. • Tljo
m, ., '. _"';lOA.' OA."
:..ff ~
ISO - 9001 - 2008 & ISO - 14001 ,2004 Certified Organisation
/,
7. Sodium Bromide solution 720
8. Sodium Sultite (20 %) 930
9. KC1Salt oc 160 oc
KCI Solution 91~O__
10. Copner HydroxiddCoDpcr Sui hate
11. Sodium Sulohate (20%) 160
12. MPBAD Distillation Cut 20
13. Aluminium Chloride (20 %) QB. 1130
Poly Aluminium Chloride (PAC)
r-~ ~7dcapacitv)
• Sodium Sulphite Solution and! OR
Solid Sodium Sulphite
QR Sodium Bi Sulphite Solution
Sodium Hi Sulphite Solids --l
and I OR
1130
930/
190
930
1JI
~binedcapacity) 190
-- --------
SPECIFIC CONDITION:
As Board has granted merger of two units, uDit-llocated at plot no. 3-11 & Unit-2 located at A-
211, A·212, A-2/6 & A-If2 Applicant shall surrender CC&A No: WH 56192 dated 09108/2013 to
the board along with GPCB ID No.: 24356 issued by GPCB.
3 CONDITIONS UNDER THE WATER ACT:

3.\ The quantity of trade emuent from the industry shall not exceed 2,312.542 MJIDA Y.
3.2 The quantity of Sewage etlluent from the industry shaH not eXI.'eed93.4 MJIDA Y.
3.3 TRADE EFFLUENT:

3.3.1 fbt: effluent from the industrial unit shall conform to the CEll' inlet norms mentioned in column No.1
helow (in ca:;e of CETP mt:mbt:r). The final discharge from CETP shall adhere to tht: prt:seribed
standards tor CUT?
3.3.2 In the evt:nt. if the effluent from indUstrial unit not routed through CETP. the applicant shall prm ide
adequate efnuent treatment system in order to achieve the quality of the treated efflucnl as per GPCB
norms mentioned in column No 3
PARAMETERS CETP INLET NORMS GPCBNORMS
pH 6.51D8.5 6.5 TO g.5
femnerature 40 C 40C
Color (ot.co.scale) in units 100 units
f--.--.--.
Suspended Solids 300m /1 lOO~
Oil and Urease 10m 11 10 mel
Phenolic Compounds Imgll Img.1
C 'anidcs D.2m 1 O.2m 1
~.~es 2mgll 2mgl,'
~hides 2mQ/1 2m¥-1
I\mmonicalNitrogcn 5Dm0\ 5Om.l
Arsenic O.2mgll 0211Ul-I
Total Chromium 2mgll 2 ••• 1
Hexavelent Chromium O.lmg/l O.11D2.1
3mgll :; DJ21
~-~--_._-
O·l~ O.11J121
~- O.Olmgll o.Ol1D2.1
Nickel
Zinc 5m,
3mll 3iM-l
5m2.~
Cadmium 2m ' ••• 1
Iron 3m 1 :; mg.l
400m 30111£1
Yob(5da~~ __ f--
lOOOrn "'50mgl
Chlorides 600m£!l 600 mg/l
Sulphates 100Omg/l 1000mg/l
Total dissolved Solids 2100m II 2100mg/1
Insecticides/Pesticides Absent Absent
Sodium absor tion ratio 26
-~
Sodium Percent 60 60
Bio·assaytest ---_..- 90% Survj,,'al offish after 96
hour in 100% effluent.
All efforts shall be made to remove color & unpleasant odor as far as practicable.
3.3.3 The final treated effluent confirming to the above standards shan be discharged into GlDe
underground drainage system & shall ultimately be conveyed into tidal zone of river Damanganga
through CETP.
3.3.4 High TDS & low COD effluent shall be segregated & sent to Multiple Effect Evaporator. High COD &
low TDS effluent shall be sent to Incinerator of BElL, Ankleshwar-following manifest system.
3.3.5 Cyanide bearing effluent shall be detoxified by adequate system & then sent to ETP after cheddng
cyanide & p<..-'Sticidelevels. Only treated effluent shan be sent to ETP for further treatment to achieve
norms.
3.3.6 Unit to provide magnetic tlow meter & online TOCITN at final outlet of ETP with provisiun of
recording.
3.3.7 Domestic effluent shall be disposed off through septic tankJsoak pit system or it shall be treated along
with indUstrial effluent or it shall be treated separately to conform to the following standards and shall
discharge into GIOC under ground drainage system.
BOD (5 days at 20 IC) Less than 20 mgll
Suspended solids Less than 30 mgll
Residual Chlorine Minimum 0.5 mgll
4 CONDITIONS UNDER THE AIR ACT:

4.1 The following shall be used as fuel in boiler, furnace, and heater res ectivc1y.
Sr.No. Fuel uanti
l. Natura} Gas 1,200 sm3/hr
2. HSD 340litfhr
3. FO 909litlhr
4. LDO I Other 43 k
4.2 fhe applicant shall install & operate air pollution control system in order to achieve norms prescribed
below:
4.3 The flue gas emission throu h stack shall conform to the followin standards:
Stack
"
l.
.. Stack attached to
Boiler#l(lO
Stack height in
Meter
11 with
Air Pollution
Control System
NA
Parameter
Particulate matter
Permissible
Limit
150 mgfNM
TPH) condensing SOl 100 ppm
economizer or NO, 50 ppm
30.5 meter when
usim!F.O.
2. Boiler #2 (8 TPH) II with NA
condensing
economizer or
30.5 meter when
I
using F.O.
3. Boiler #3 (5 TPH) 30.5 NA
4. Thennic Fluid 30.5 NA
Heater
(MPBAD Plant)
5. Thermic Fluid 30.5 NA
Heater
(Pesticide Plant)
6. Thermic Fluid 30.5 NA
Heater (Propanil
Plant)
7. DO Set -} (1250 15.5 NA
KVA)
(Stand by fad lit )
R. DO Set Il 15.5 NA
( 500 KVA)
(Stand by facility)
9. DO Set III 15.5 NA
(500KVA)
(Stand bvtilcility)
4.4 Thc Process emission through various stacks/vent of reactors, proccss, vessel shall conform to the
followinl!: standar d s:
Stack Stack attached to Stack height Air Pollution Parameter Permissible
No. in Meter Control svstem Limit
!I Pesticide Plant (Permethrin

Reactor)
12 Water scrubber
followed by
Hel
CI,
20mg/NM
5 mgfNl\..l'
Caustic Scrubber PM 20mgiNM.1
2. Alp Plant Firing Chamber 30 Misteliminator & PM 20 mgiNM
Water Scrubber p]OS a~ HJP04 5mgINM1
3. MPBAD Plant Reaction 22 Sodium Hel 20 mgINM
Vessel & Bromine Thiosulphate CI, 5 mgINM3
recovery system absorber for Br2 HB, 5mgINM'
reooveryand
Caustic Scrubber
4. DVACI plant (TCBACI 22 Alkali Scrubber HCI 20 mg,fNM
Reactor) PCI] 9mg/NMJ
5. DVACI Plant (DVACI 22 Alkali Scrubber HCI 20 mgINM
Reactor) PCI) 9mg/NM1
6. DVACI Plant 22 Alkali Scrubber S02 40mg/NM)
(PCl3 storage
tankiPOCL2& PCL3
recovery system/distillation
svstem)
7. DVACI Plant 22 Alkali Scrubber HCI 20mgiNM
(Fugitive Emission) el, 5 mg/NM3
SO, 40 mgINM\
8. ASAM 22 Alkali Scrubber ~CI 20mgINM
Cb 5m~M)
9. 7npPlantReactor 12 Mistcliminator PM 20mgiNM
I P205 asHJPO. 5m~M.1
10. Lambda CYHALOTHRIN 12 Alkali Scrubber IICI 20 mgINM
S02 40mgmMJ
II. Metribuzine 12 Water and Alkali IIBr 5 mg/NM
scrubber (Sodium
Thiosulphate
absorber)
4.7 The concentration of the following substances in the ambient air within the premises of the industry and
at a distance of 10 meters from the source (other than the stack/vent with height of more than 9 meters
from the ground level) shall not exceed the following levels:
====+~08~0~M~:~~oRMi!J,[~~S
P.~~~~i~~"~~~~S~~E~,pR~h'=' p~s:Iii~~i:i;~biLi:i, ~~,:~::q,
Oxides of Nitro en 080 Microgram Per cubic meter
PMIO 100 Microgram Per cubic meter
PM 2.5 60 Micro ram P(.,"fcubic meter
C[, 100 MicrOi!ram Per cubic meter
HC[ 200 Micro ram Per cubic meter
PCh 100 Microgram Per cubic meter
Phos horous Pentoxide 30 Micro ram Pcr cubic meter
Bromine 20 Micro ram Per cubic metcr
11 droR,en Bromide 300 Microgram Per cubic m(.,1.er
4.& The applicant shall provide portholes, ladder, platform etc at chimney(s) for monitoring the air
emissions and the same shall be open for inspection to/and for usc of Board's statf. The chimney(s)
vents attached to various sources of emission shall be designed by numbers such as S- L S-2, etc. and
thesc shall be painted! displayed to facilitate identification.
4.9 The industry shall take adequate measures for control of noise levels from its own sources within the
premises so as to maintain ambient air quality standards in respect of noise to less than 75 d13 (a)
during day time and 70 dB (A) during night time. Daytime is reckoned in between 6 a.m. and 10 p.m.
and nighttime is reckoned between 10 p.m. and 6 a.m.
5 GENERAL CONDITlONS:-
5.1. Any change in personnel, equipment or working conditions as mcntioned in the consents torm/order
should immediately be intimated to this Board.
5.2 Applicant shall also comply with the general conditions given in annexure I
6. AUTHORISATION FOR THE MANAGEMENT & HANDLING OF HAZARDOUS WASTES

Form·2 (5 (4))
6.1 Number of authorization: A WH-60886, Date of issue: 3/3/2014.
MIs. UNITED PHOSPHOROUS LTD is hereby granted an authorization to operate facility for
tollO\ving hazardous wastes on the premises situated at Plot No. 3-11, A·211, A-2f2, A-216 & A-tl2,
PHASE-I GlDC Estate, Yaoi- 396195, Dist.Valsad.
S,. Waste Quantity Schedule-l Facility
No Process No,
[ ETPwaste 544.417 34.3 Collection, storage, transportation, disposal at
MT/Month TSDF· VWEMCLlREIL-Ankleshwar.
2 Used Oil 4.197 5.[ Collection, Storage, Transportation,
KLiMonth Disposal by selling to regislercd re roccssors.
3 Discarded 42052 33.3 Collection, Storage, Decontamination &
ContainerlBall.s Nos/Month recycle or sold to scrap operators. ~,_
4 Oil/Grease from 0.468 34.4 Collection, storage, transportation, disposal by
ETP MT/Month incineration ,t rSDF-VWEMCLlBEIL-
Ankleshwar.
5 Spent filter 3.00 35.1 Collection, storage, transportation, disposal by
material MTlMonth incineration TSDF-VWEMCLlBElI.-
Ankleshwar. " . _-;----
6 Salt from 760 34.4 Collection, stor •.ge, transportation, disposal at
evaporation MT/Month TSDF- VWEMCLIBEIL-Ankleshwar.
system
7 Sludge f'Om wet 4.197 36.1 Collection, storage, transportation, disposal by
scrubber KLlMonth incineration at TSDF-VWEMCLiBEIL-
Ankleshwar.
Collection, Storage. Transportation,
--
8 Used batteries 3 "4
NosIMonth Disposal by selling to re!!;istered reprocessors.
9 Process Inorganic 30.8 34.3 Collection, storage, transportation, disposal at
Waste MTlMonth TSDF- VWEMCLlBEIL-Ankleshwar.
10 AI, M, Zoo 2.608 Sch-II Collection, storage, trans ortation, dis osal at
Hydroxide (Dust MTiMonth TSDF- V\oVEMCI ./BELL-Ankleshwar.
collection)
II Distillation 681.343 28.1 Collection, storage, transportation. disposal b)
TSDF-VWEMCLiBEIL-
Residue MTrM:onth incineration
Ankleshwar. "
12 Spent Solvent 22.917 20.2 Collection, storage. transportation, disposal by
incineration TSDF-VWEMCLiBEIL-
MT/Month
Ankleshwar. "
13 Waste/Residue 0.795 29.1 Collection, storage. transportation, disposal b)'
incineration TSDF-VWEMCLiBEIL-
containing
esticide
MTlMonth
Ankleshwar. "
14 Date expired/off 2.4 29.3 Collection, storage, transportation, disposal hy
specification MT/Month incineration TSDF-VWEMCLiBEIL-
I nroducts Ankleshwar. "
6.2 The authorization is granted to operate a facility for collection, storage within factory premisl."S
transportation and ultimate disposal of Hazardous wastes at TSDF developed hy the Vapi Waste &
Effiucnt Management Co. Ltd -Vapi.
6.3 The authorization shall be valid up to 5/212019.
6.4 The authorization is subject to the conditions stated below and such other conditions as rna" be
specified in the ruJcs fro~ time to time under the Environment (Protection) Aet-1986. -
6.5 TERMS AND CONDITIONS OF AUTHORISATION:
a) The applicant shall comply with the provisions of the Environment (Protection) Act - 1986 and the
rules made there under.
b) The authorizJltion shall be produced tOr inspection at the request of an officer authorized b)' the
Gujarat Pollution Control Board.
c) The persons authorized shaH not rl.'1lt, land, sell, and transfer of otherwise transport the ha7.ardous
wastes without obtaining prior pennission ofthe Gujarat Pollution Control Board.
d) Any unauthorized change in personnel. equipment or working conditions as mentioned in the
authorization order by the persons authorized shall constitute a breach of thb authorization.
e) It is the duty of the authorized person to take prior permission of the Gujarat Pollution Control
Board to close down the facility.
f) An application for the renewal of an authorization shall be made as laid dO\V11in rule-7.
6.6 In addition to above terms and conditions Industry shall also comply following dire",ives issued by the
Supreme Court of India dated.l4.l0.2003.
a) Industry shan have to display the relevant information with regard to hazardous waste as indicated
in the Court's order in W,P. No.657 of 1995 dated 14th October 2003.
b) lndustry sball have to display on-line data outside the main factory gate with regard to quantity and
nature of hazardous chemicals being bandied in the plant, including wastewater and air em issions
and solid hazardous wastes generated within the factory premises.
For and on behalf of
Gujarat Pollution Control Board
_ ..
NO: GPCBlCCA-VSD-218(2)/1D:
MIs. UNITED PHOSPHOROUS

24711{ f2..D '6"
LTD,
'2b
~~}~
(T. B.SHAH)
End;hme~~o~Dle~r4
-.V_
•••• fIifa 3-11. PHASE-I,
e-:••.••.
Vapi- 396195,
_ '-4
GUJARAT POLLUTION CONTROL BOARb
PARYAVARAN BHAVAN
Sector 10-A, Gandhinagaf38tO'&
Phone : (079) ~295
Fax: (079) 23232156
Website : www.gpcb.gov.in
BYR.P.A.D.
NO: GPCB/CCA-VSD-218(2) /10: 24711/
~. UNITED PHOSPHOROUS LTO,

Plot No. 3-11, PHASE-I,
GIDC ESTATE, VAPI-396 195,
Dist: Valsad.
SUB: Amendment to CC&A No (AWH-77786) Consolidated Consent & Authorization (CC & A) under
various Environmental Acts/ Rules.
REF: 1) Your Application inward no 103048 dated: 08/0212016.

2) CTE issued vide this office letter dated: 20/11/2014.
Sir,
This has reference to the CCA order nO.AWH-60886 dated: 03/03/2014 issued vide letter No.
GPCB/CCA-VSD-218(2)/ID:24711/208120 the dated:25103/2014 having validity up to 5/0212019
provisions of the various Environmental AcU Rules, which stands amended as under, for the conditions
under rule act
CONDITIONS UNDER AIR ACT 1981:
1. The following shall be used as fuel in the Boiler. _

~ Fuel I Quantity
CI:J Coal 5000 Kg/Hr
1.1 The applicant shall install & operate air pollution control system in order to achieve norms
prescribed below
16
1.2 The flue Qas emission throuqh stack shall conform to the followinq standards:
20
Stack Stack attached Stack Air Pollution Parameter PermIsSible

No. to height in Control Limit
4/
Meter svstem
/0
1. Coal fired Boiler 55 ESP PM 100mgINM'

(23 TPH) SO, 100 ppm
•
18
NO, 50 ppm
9,
Note: After installation of new 23 TPH Boiler, unit shall use other boilers as stand by.
69
• All other conditions of CCA order nO.AWH-60886 dated:03/03/2014 issued vide letter No.
52
GPCB/CCA-VSD-218(2)/ID: 24711/208120 the dated:25/03/2014 shall remain unchanged.

:3
For and on behalf of

No
Gujarat Pollution control Board
DP~
d
ar
(Smt.~.P.StWt)
Environmental Engineer
tw
Ou
Clean Gujarat Green Gujarat

150-9001-2008 & 150-14001 - 2004 Certified Organisation
FLOW DIAGARMA OF ETP PLANT

Pre-Feasibility Report: UPL LTD

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PRE-FEASIBILITY REPORT

Proposed Expansion in Existing

Plot No. 3–11, A–2/1, A–2/2, A–2/6 & A–1/2,

Pre-Feasibility Report Page 1

5.21 Denatonium Benzoate (DB) ................................................................................................66

Pre-Feasibility Report Page 2

Pre-Feasibility Report Page 3

Annexure No. Description

Pre-Feasibility Report Page 4

Pre-Feasibility Report Page 5

Total after proposed expansion:

Pre-Feasibility Report Page 6

Pre-Feasibility Report Page 7

2. INTRODUCTION OF THE PROJECT

2.1 Identification of project and project proponent

Pre-Feasibility Report Page 8

2.2 Brief description of nature of the project

2.3 Need of Proposed Project

The company is already engaged in the business of manufacturing of Pesticide, Pesticide

2.4 Demand Supply Gap

Pre-Feasibility Report Page 9

2.5 Employment Generation

Pre-Feasibility Report Page 10

3. PROPOSED PROJECT & APPLICABILITY OF EIA

Pre-Feasibility Report Page 11

4.1 Project Location

4.2 Alternative Sites

4.3 Resource Requirement

4.3.1 Raw Material

Table No. 1 – Raw Material Details

Pre-Feasibility Report Page 12

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Pre-Feasibility Report Page 14

Pre-Feasibility Report Page 15

Pre-Feasibility Report Page 16

Pre-Feasibility Report Page 17

Pre-Feasibility Report Page 18

Pre-Feasibility Report Page 19

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Pre-Feasibility Report Page 21

4.3.2 Land Requirement

Table No. 2 – Land area details

Sr. Area (m2)

Pre-Feasibility Report Page 22

Sr. Area (m2)

4.3.4 Power & Fuel

Source: DGVCL for existing as well as proposed expansion

D. G. Set (used in case of power failure and/or emergency)

Existing: 2 x 500 KVA and 1 x 1250 KVA

Proposed: 2 x 500 KVA

Details of fuel are mentioned in the below table:

Table No. 3 – Fuel details

Pre-Feasibility Report Page 23

4.3.5 Water Requirement

Table No. 4 –Water Consumption

Sr. Existing Proposed Total

4.3.3 Man Power

Pre-Feasibility Report Page 24

4.4 Product & By-Product

Table No. 5 – Product Details

Sr. Quantity (MT/Month)

Pre-Feasibility Report Page 25

Sr. Quantity (MT/Month)