Detail Project Report (DPR)

DETAIL PROJECT REPORT (DPR)

M/s. Shimmer Chemicals Pvt. Ltd. (SCPL) is located at Survey No. 313, Padra-Borsad State
Highway, Vill: Mujpur-391440 Tal:Padra, Dist: Vadodara, Gujarat, INDIA, and it involved
in production of organic chemicals production capacity of 210.0 MTM. The company
proposes to increase its production capacity from 210.0 MTM to 1000.0 MTM with inclusion
of 9 more new products [Ortho/Para Chloro Benzyl Alcohol (2-chloro Benzyl Alcohol), Para
Chloro Benzyl Chloride (4-Chloro Benzyl Chloride), 2-Methyl Benzyl Chloride (2-chloro
Ortho xylene), Dichloro Ortho Xylene (2,2-Dichloro Ortho Xylene), 2,4-Dichloro Benzyl
Chloride, Meta-Chloro Benzyl Chloride, 2,4-Dichloro Benzaldehyde, N-Hexyl Chloride] and
increase in the capacity of existing products as well.

The estimated approx. capital cost of the proposed project shall be approx. Rs.7.30 Cr. Out of
which Rs. 42 Lakhs will be used for Environmental Management System and Rs. 8.4 Lakhs
as recurring cost per annum. Rs. 18.25 Lakhs will be used for Enterprise Social Commitment
(i.e. equivalent to 2.5 % of project cost).

M/s. Shimmer Chemicals Pvt. Ltd. is an operational manufacturing unit located at

Survey No. 313, Padra-Borsad State Highway, Vill: Mujpur-391440 Tal:Padra, Dist:
Vadodara, Gujarat, INDIA. Proposed expansion is to be carried out at the existing premises
only.

 The unit has total 16200.0 sq. m plot area.

 Proposed green belt development 5347.49 sq. m. (approx. 33% of total plot area)
 No eco sensitive zone.
 The project is not covered under CRZ.
 The site is located about 19.46 km from Vadodara Railway Station and about 23.77
km from Vadodara Airport. Mujpur village is the nearest densely populated village,
located about 1.01 km from the project site. M/s. Shimmer Chemicals Pvt. Ltd.
 The estate is located at sufficient distance from reserved forests and sanctuaries,
archeological sites and historical sites to ensure that there is no impact of industrial
activities.
 No alternative site study is carried out as this is an expansion project at existing
premises itself.

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EC applied
Total after
CTO for additional
Name of EC
Sr. No. CAS No. available / new End Use
Products expansion
(MTM) production
(MTM)
(MTM)
1. Benzyl Pharmaceutical
100-51-6 6 19 25
(Existing) Alcohol & Perfumery
Ortho/Para
Chloro Benzyl
2. 17849-38-6 Pharmaceutical
Alcohol (2- -- 25 25
(New) & Drugs
chloro Benzyl
Alcohol)
Pharmaceuticals
3. Benzylidine
1896-62-4 20 30 50 & Electro
(Existing) Acetone
Plating
Ortho Chloro
4.
Benzyl 611-19-8 40 235 (Max)
(Existing)
Chloride
5. Benzyl
100-44-7 15 260 (Max)
(Existing) Chloride
Para Chloro
Benzyl
6. Chloride
104-83-6 --
(New) (4-Chloro
Benzyl
Chloride)
2-Methyl
Benzyl 275 (Either
7. Pesticide,
Chloride 552-45-4 -- individual
(New) Perfumery, Dyes
(2-chloro or total of 7
& Drugs
Ortho xylene) products)
275 (Max)
Dichloro Ortho
8. Xylene
612-12-4 --
(New) (2,2-Dichloro
Ortho Xylene)
2,4-Dichloro
9.
Benzyl 94-99-5 --
(New)
Chloride

10. Meta-Chloro
(New) Benzyl
-- --
Chloride

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 Detail Project Report (DPR)

EC applied
Total after
CTO for additional
Name of EC
Sr. No. CAS No. available / new End Use
Products expansion
(MTM) production
(MTM)
(MTM)
11. Ortho Chloro
89-98-5 4 296 (Max)
(Existing) Benzaldehyde
12. Para Chloro
89-98-5 -- 300 (Max) 300 (Either Drugs,
(New) Benzaldehyde
individual Pesticides,
13. or total of 4 pharmaceutical
(Existing) Benzaldehyde 100-52-7 88 212 (Max) products) & Perfumery

14. 2,4-Dichloro
-- -- 300 (Max)
(New) Benzaldehyde
15. N-Chloro 37
543-59-9
(Existing) Pentane (Either
16. N-Butyl individual Perfumery,
109-69-3 or total of 288 (Max) 325 (Either
(Existing) Chloride pharmaceutical,
individual
3 drugs, Oxidizing
17. 1,6-Dichloro or total of 4
2163-00-0 products) agent, Dyes
(Existing) Hexane products)
intermediates
18. N-Hexyl
544-10-5 -- 325 (Max)
(New) Chloride
Total Products 210 790 (Max) 1000

LAND REQUIREMENT
The unit has total 16200 sq. m plot area. The proposed expansion is to be carried out in the
existing premises itself, but the construction will slightly increased inside the plant premises.
The area allocated for green belt development 5347.49 sq. m. is marked in the layout and
forms 33% of the total land area.

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 Detail Project Report (DPR)

POWER REQUIREMENT
The total power requirement will increase from 250 kVA to 500 kVA upon the proposed
expansion. Unit fulfils its power requirement through Madhya Gujarat Vij Company Ltd.
(MGVCL). There are two D.G. Sets of 175 KVA and 75 KVA is already being utilized during
power failures, so there will be no additional D.G. Set required as a part of the expansion.

FUEL REQUIREMENT
Existing fuel consumption: Briquette/Agro-waste: 5.0 MT/day, LDO: 42.0 Litres/hr. Total fuel
consumption after proposed expansion: Briquette/Agro-waste or Sawmill waste/Coal - 10.0
MT/day, LDO- 42.0 Litres/hr. *saw mill waste/coal will only be used on unavailability of
Briquette/Agro-waste.

MAN POWER REQUIREMENT

Manpower is one of the important resources for efficient and better working of the plant. The unit
is currently employing total 50 nos. of people. Proposed additional Man Power will be Permanent:
50 Nos. + Contract Labor: 50 Nos. = Total: 100 Nos.

RAW MATERIALS REQUIREMENT

Total
Proposed
Sr. Existing Proposed Total
Product Name Production Raw Materials
No (MTM) (MTM) (MTM)
Capacity
(MTM)
Toluene 5.40 17.10 22.50
1 Benzyl Alcohol 25 Chlorine 4.20 13.30 17.50
Calcium Hydroxide 2.06 6.52 8.58
TOTAL 11.66 36.92 48.58
Ortho Chloro Benzyl
Ortho/Para Chloro NIL 30.00 30.00
2 25 Chloride
Benzyl Alcohol
Calcium Hydroxide Soln. NIL 37.50 37.50
TOTAL NIL 67.50 67.50
Benzylidine Benzaldehyde 15.00 22.50 37.50
3 50
Acetone Acetone 10.00 15.00 25.00
TOTAL 25.00 37.50 62.50
Ortho Chloro Ortho Chloro Toluene 35.56 208.92 244.48
4 275 (Max)
Benzyl Chloride Chlorine 23.04 135.36 158.40
TOTAL 58.60 344.28 402.88
Toluene 12.00 208.00 220.00
5 Benzyl Chloride 275 (Max)
Chlorine 9.75 169.00 178.75
TOTAL 21.75 377.00 398.75
Para Chloro Para Chloro Toluene NIL 228.25 228.25
6 275 (Max)
Benzyl Chloride Chlorine NIL 151.25 151.25
TOTAL NIL 379.50 379.50
2-Methyl Benzyl O-Xylene NIL 220.00 220.00
7 275 (Max)
Chloride Chlorine NIL 154.00 154.00
TOTAL NIL 374.00 374.00

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Total
Proposed
Sr. Existing Proposed Total
Product Name Production Raw Materials
No (MTM) (MTM) (MTM)
Capacity
(MTM)
Dichloro Ortho O-Xylene NIL 178.75 178.75
8 275 (Max)
Xylene Chlorine NIL 236.50 236.50
TOTAL NIL 415.25 415.25
2,4-Dichloro 2,4-Dichloro Toluene NIL 233.75 233.75
9 275 (Max)
Benzyl Chloride Chlorine NIL 110.00 110.00
TOTAL NIL 343.75 343.75
Meta. Chloro Meta. Chloro Toluene NIL 233.75 233.75
10 275 (Max)
Benzyl Chloride Chlorine NIL 151.25 151.25
TOTAL NIL 385.00 385.00
Ortho Chloro Ortho Chloro benzal chloride 5.58 412.62 418.20
11 300 (Max)
Benzaldehyde Water 0.64 47.36 48.00
TOTAL 6.22 459.98 466.20
Para Chloro Para Chloro Benzal Chloride NIL 418.20 418.20
12 300 (Max)
Benzaldehyde Water NIL 48.00 48.00
TOTAL NIL 466.20 466.20
Toluene 42.24 101.76 144.00
Chlorine 31.68 76.32 108.00
13 Benzaldehyde 300 (Max)
Water 16.72 40.28 57.00
Benzal Chloride 44.09 106.21 150.30
TOTAL 134.73 324.57 459.30
2,4-Dichloro Toluene NIL 246.00 246.00
2,4-Dichloro
14 300 (Max) Chlorine NIL 417.00 417.00
Benzaldehyde
Water NIL 30.00 30.00
TOTAL NIL 693.00 693.00
n-Pentanol 30.60 238.18 268.78
15 n-Chloro Pentane 325 (Max)
Hydrochloric acid 15.28 118.94 134.23
TOTAL 45.88 357.12 403.00
n-Butanol 29.60 230.40 260.00
16 n-Butyl Chloride 325 (Max)
Hydrochloric Acid 17.58 136.80 154.38
TOTAL 47.18 367.20 414.38
1,6-Di Chloro 1,6-Hexandiol 28.31 220.32 248.63
17 325 (Max)
Hexane Hydrochloric Acid 20.17 156.96 177.13
TOTAL 48.47 377.28 425.75
N-Hexanol NIL 273.98 273.98
18 n-Hexyl Chloride 325 (Max)
HCl gas NIL 121.88 121.88
TOTAL NIL 395.85 395.85

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WATER REQUIREMENT:

Source of water supply is ground water i.e. bore-well. Existing bore-well is efficient enough
to abstract water after proposed expansion. At present, domestic water consumption is 12.4
KLD and industrial water consumption is 27.6 KLD as per current CTO. After proposed
expansion, domestic water consumption will be NIL as existing water is sufficient for
proposed expansion. Industrial water consumption will be 50.3 KLD. Total water
consumption after proposed expansion will be 79.1 KLD, from which 16.4 KLD water will
be recycled from sewage treatment plant and industrial waste-water. Hence, total fresh water
requirement after proposed expansion will be 62.7 KLD.

Details of Water Consumption

Quantity of Fresh Water Consumption (in KL / day)

Total fresh
Existing Additional Total after Available water
as per for proposed from requirement
CTO expansion expansion Recycle after Proposed
Expansion
Domestic 12.4 NIL**** 12.4 - 12.4
1. RO Water 5.4 7.3 12.7 - 12.7
a. Process 1.6 0.5 2.1 - 2.1
b. Boiler -
(R.O. 2.0 2.93 4.93 5.0
Water)
Industrial c. Cooling -
(R.O. 1.2 1.8 3.0 3.0
Water)
2. APCM 14.4 29.6 44.0* -6.4** 37.6
7.8 -
3. Green Belt 2.2 10.0 NIL
10.0***
A DOMESTIC 12.4 NIL 12.4 - 12.4
INDUSTRIA
B 27.6 39.1 66.7 -16.4 50.3
L (1+2+3)
TOTAL (A+B) 40.0 39.1 79.1 -16.4 62.7

*For 30% HCl Solution preparation and for 10% NaOCl Solution preparation total 44.0 KLD
water will be used respectively.
**Boiler Blow down, RO Reject, Cooling & process water (2.5 + 2.67 + 1 + 0.23 = 6.4
KLD) is being used in HCl scrubbing to form 30% HCl solution and Cl2 scrubbing to form
10% NaOCl solution, hence total fresh water requirement for APCM will be 37.6 KLD.

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 Detail Project Report (DPR)

***The domestic 10 KLD Waste-water generated is treated in Sewage Treatment Plant and
used for green belt development, hence total fresh water requirement for green belt will be
NIL.
****Existing Domestic water consumption will be sufficient after proposed expansion (for
total manpower of 100 people).

Details of Wastewater Generation

Quantity of Waste-water Generation (in KL / Day)

Existing Additional Total after
as per for proposed Treatment and disposal
CTO expansion expansion

10.0 KLD sewage shall be

treated in Sewage Treatment
Domestic 2.0 8.0 10.0 Plant & treated water will be
used for Green belt
development

(a) Process NIL 0.23 0.23 Boiler Blow down, RO Reject,

Cooling water & process water
(b) Boiler 0.2 2.3 2.5 (2.5+2.67+1+0.23 = 6.4 KLD)
will be used in HCl scrubbing
Industrial (c) Cooling 0.6 0.4 1.0 to form 30% HCl solution and
Cl2 scrubbing to form 10%
(d) RO Reject 0.6 2.07 2.67^ NaOCl solution
DOMESTIC 2.0 8.0 10.0

INDUSTRIAL 1.4 5.0 6.4

^RO plant capacity- 2.0 KL/hr., 14hrs working.

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FLUE GAS STACKS

 There will be 1 no. of stack attached to IRB Boiler and 2 Nos. of stacks for DG set (to be
used during power failure only).
 After proposed expansion the 02 TPH IBR Boiler will be replaced by 03 TPH
 Existing DG Sets: 2 Nos.: 175 KVA and 75 KVA (Both Stand-by), remains same for
proposed expansion; the stack height will 3.0 meter.
 There is no requirement of additional stack as existing stack is sufficient to control
flue gas emissions after proposed expansion.
 Briquette/Agro-waste or Saw mill waste/Coal & LDO will be used as fuel, Multi cyclone
separator and bag filter will be provided as Air Pollution Control Measure.

DETAILS OF EXISTING FLUE GAS STACKS & EMISSION DETAILS (AS PER CTO)

Air Pollution
Stack
Sr. Stack Control Permissible
Capacity Height Parameters
No. Attached to Measure Limit
(m)
(APCM)
1 IBR Boiler 02 TPH PM 150 mg/Nm3
30.0 Multi Cyclone
IBR Boiler SO2 100 ppm
2 02 TPH Separator
(Standby) NOX 50 ppm

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Air Pollution
Stack
Sr. Stack Control Permissible
Capacity Height Parameters
No. Attached to Measure Limit
(m)
(APCM)
3 D.G. set 175 KVA 3.0
To be used during power failure
4 D.G. set 75 KVA 3.0

DETAILS OF PRAPOSED FLUE GAS EMISSION AND THEIR CONTROL MEASURES

Air Pollution
Stack
Stack Control Permissible
Sr. No. Capacity Height Parameters
Attached to Measure Limit
(m)
(APCM)
1 Bag Filter &
IBR Boiler 03 TPH
(New) Multi Cyclone PM 150mg/Nm3
30.0 Separator SO2 100 ppm
2 IBR Boiler NOX 50 ppm
02 TPH
(Existing) (Standby)
3
D.G. set 175 KVA 3.0
(Existing)
To be used during power failure
4
D.G. set 75 KVA 3.0
(Existing)

PROCESS GAS STACK

 The existing process gas emission is within the permissible limit as per the norms of
CPCB & there will be no requirement of new additional process gas stack after proposed
expansion.
 Company has installed an online monitoring system for HCl and Cl2 gas.
 The Capacity of Benzyl Chloride reactor and Benzaldehyde reactor will increase to 10
Nos. respectively.
 Two stage water scrubber and single stage Alkali scrubber will be added after proposed
expansion as the reactor of Benzyl Chloride increased by 5 Nos.
Final solutions obtained from scrubbers and their disposal:
 Presently, 30% HCl solution is being generated from scrubbing of HCl gas, which is being
sold to actual user, same practice will be followed after proposed expansion.
 Presently, 10% NaOCl solution is being generated from scrubbing of Cl 2, which is being
sold to actual user, same practice will be followed after proposed expansion.

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DETAILS OF EXISTING PROCESS GAS EMISSION & THEIR CONTROL MEASURE

Air Pollution Stack Parameter &

Sr. Stack Name of
Control Measure Height Permissible
No. Attached to process/ Plant
(APCM) (m) Limit
Benzyl
Two stage water HCl - 20
Chloride 15
1. Benzyl Chloride scrubber & Single mg/Nm3
Reactors - 5
stage Alkali Scrubber Cl2 - 09 mg/Nm3
Nos.
Benzaldehyde Three stage water HCl - 20
2. Reactors - 2 Benzaldehyde scrubber & Single 17 mg/Nm3
Nos. stage Alkali Scrubber Cl2 - 09 mg/Nm3

DETAILS OF PRAPOSSED PROCESS GAS EMISSION & THEIR CONTROL MEASURE

Air Pollution Stack Parameter &

Sr. Stack Name of
Control Measure Heigh Permissible
No. Attached to process/ Plant
(APCM) t (m) Limit
Benzyl Two stage water HCl - 20
1. Chloride Benzyl scrubber & Single 15 mg/Nm3
(New) Reactors Chloride stage Alkali Cl2 - 09
(10 Nos.) Scrubber (2 Nos.) mg/Nm3
Three stage water HCl - 20
Benzaldehyde
2. scrubber & Single mg/Nm3
Reactors Benzaldehyde 17
(New) stage Alkali Cl2 - 09
(10 Nos.)
Scrubber mg/Nm3

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DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL

Quantity Per Annum

Sr. Name of
Source of Mode of Disposal &
Hazardous Schedule Category EC applied Facility
No. Existing as Total after EC Generation Remarks
Waste for additional
per CTO expansion
quantity
Distillation Collection, Storage, Sent for incineration at M/s.
1. I 20.3 6.48 MT 67.52 MT 74.0 MT From Process
residue Transportation NECL, Nandesari
Disposal by reuse in plant &
Collection, Disposal,
Used or Spent machinery as lubricant or
2. I 5.1 0.1 KL 0.9 KL 1.0 KL From Machinery reuse, Storage,
oil sell it to authorized re-
Transportation.
refiners/ recycler
1000 Nos. From raw Collection, Storage,
Discarded Empty barrels/ Containers/
bags, NIL 1000 Nos. bags materials/ Transportation,
3. containers/ I 33.1 Liners/ Drums/ Bags - Sent
1500 Nos. 1500 Nos. drums container/bags/ Disposal, Reuse &
Barrels/Liners to GPCB authorized dealer.
drums drums Decontamination.
Distillation is done of the
From Process waste and the
Collection, Storage,
4. Process waste I 36.1 6.0 MT 138.0 MT 144.0 MT manufacturing recovered materials are used
Transportation
process as Raw materials in
products.
From
Collection, Storage, Sent for incineration at M/s.
5. Spent catalyst I 29.5 1.0 MT NIL 1.0 MT manufacturing
Transportation NECL, Nandesari
process

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Quantity Per Annum

Sr. Name of
Source of Mode of Disposal &
Hazardous Schedule Category EC applied Facility
No. Existing as Total after EC Generation Remarks
Waste for additional
per CTO expansion
quantity
Collection, Storage,
Treatment, Transportation
and Disposal and selling to
Spent HCl (30% Collection, Storage actual re-users having valid
6. II B-15 3444.0 MT 13116.0 MT 16560.0 MT From process
Solution) and Transportation. authorization from GPCB &
permission of Central
Pollution Control Board,
New Delhi.
Sodium Collection, Storage,
Collection, Storage
7. Hypochlorite II B-7 762.0 MT 4800.0 MT 5562.0 MT From process Transportation and selling to
and Transportation.
(10% Solution) actual re-users
Sodium Collection, Storage,
Collection, Storage
8. Benzoate (10% -- -- NIL 1800.0 MT 1800.0 MT From Process Transportation and selling to
and Transportation.
Solution) actual re-users
Collection, Storage
9. Fly Ash -- -- 60.0 MT 60.0 MT 120.0 MT From fuel usage Sale to brick manufacturers
and Transportation
Calcium Collection, Storage,
Collection, Storage
10. Chloride III B 2040 154.2 MT 493.56 MT 647.76 MT From Process Transportation and selling to
and Transportation.
Solution actual re-users

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Existing Additional
Sr. No. Name of Equipment
Nos. Capacity Nos. Capacity
Reactors O.C Bcl + O Bcl +
1 7 1 KL/day 10 1 KL /day
Bcl2
2 Separation Units 10 1 KL/day 15 1 KL/day
3 Distillation Units 8 1 KL/day 15 1 KL/day
4 Glass Line Reactors(BHY) 4 1.6 KL 4 1.6 KL
5 S.S. Vessel 2 3.5 KL 3 3.5 KL
6 N. Chloro Pantane 5 1.6 KL 4 1.6 KL
7 N. Chloro Butane 4 1.6 KL 4 1.6 KL
8 P.C.B, O.C.B Distillation 2 1 KL/day 6 1 KL/day
9 BDA Rectors 2 2 KL/day - NA
10 BDA Distilation 2 0.8 KL 2 0.8 KL
11 BHY Distilation 3 1.5 KL/day 2 1.5 KL/day
12 Sepration Bcl2 8 1 KL/day 12 1 KL/day
13 Boiler 2 2MT 1 3 MT
14 Ref. Unit/ (gas) F22 1 20 TR 1 40 TR
2 100 TR
15 Cooling Tower 5 100 TR
3 40 TR
16 Vacuum System 2 - 2 -
17 R.O Plant 1 1 KL/hr 1 1 KL/hr
18 HCl Scrubber 16 20 KL 16 20 KL
19 Caustic Scrubber 2 1 KL/day 3 1 KL/day

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