form - i unit ii 17.11.14 -...

[Vide Notification dated 14th September, 2006

Amendment on 1st December, 2009]

FORM ‐ I

For Proposed

“PROPOSED EXPANSION & ADDITION OF AROMA

CHEMICAL MANUFACTURING CAPACITY IN UNIT-II” Unit‐II Prepared For

PRIVI ORGANICS LIMITED Plot no. - C-3,4,5,6,7, 6/1, 8, 9, C-33/1 & X-9, 10, 11,

MIDC Industrial Estate, Mahad, Dist. Raigad - 402309, Maharashtra, India

Conducted & Prepared By

Integrated HSEQR Consulting Engineers, Scientists & Trainers (MoEF Recognized Environment Laboratory)

(An ISO: 9001, 14001, OHSAS: 18001 Certified Organization & GPCB approved Environment Auditor – Schedule II) Gujarat High court stay order for QCI NABET No. C/SCA/10311/2012 dated 04.02.2014

Corp. Office & Environmental Research Laboratory

Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India |Tel: 0265-2371269

www.greencircleinc.com E: [email protected]

ALSO AT

BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA OVERSEAS

AUSTRALIA OMAN KUWAIT AFRICA VIETNAM

Project: Environmental Clearance for the Proposed Expansion & Addition Of Aroma Chemical Manufacturing Capacity in Unit-II. Project Proponent: M/s. Privi Organics Ltd.

Form – I

Prepared By: Green Circle, Inc. 1

FORM – I (I) BASIC INFORMATION

Sr. No. Item Details

1 Name of the project Environmental Clearance for the

“Proposed Expansion & Addition of

Aroma Chemical Manufacturing in

Unit-II”of Privi Organics Ltd, MIDC Area,

Mahad, Dist. Raigad

2 S. No. in the schedule 5(f) of the Schedule of EIA

notification 2006

3 Proposed capacity/ area/ length/ tonnage

to handled/ command area/ lease area /

number wells to be drilled

Existing Capacity: 1820.65 MT/M

Proposed Capacity: 4961.34 MT/M

Total Capacity: 6781.99 MT/M

4 New/Expansion/Modernization Expansion

5 Existing Capacity/Area etc. Existing Capacity: 1820.65 MT/M

Existing Area: 55756 M2 (46625 M2 +

4050 M2 + 5081 M2)

6 Category of Project i.e. 'A' or 'B' ‘A’

7 Does it attract the general condition? If yes,

please specify.

No, doesn’t attract general condition

8 Does it attract the specific condition If’ yes,

please specify.

No, doesn’t attract specific condition.

9 Location:

Plot/Survey/Khasra No. Plot No.C-3,4,5,6,6/1,7,8,9 & C-33/1, X-

9,10,11

Village Mahad Industrial Area,

Tehsil Mahad

District Raigad

State Maharashtra

10 Nearest railway station/airport along with

distance in km

Veer Railway Station: 18 KM

Pune Airport: 130 KM

11 Nearest Town, City, District Headquarters

along with distance (km)

Nearest Town: Mahad at 7.5 KM.

12 Village Panchayat, Zilla Parishad, Municipal

Corporation, Local body (complete postal

addresses with telephone nos. to be given)

Mr. Lakshman Powar

Village Panchayat: Birwadi.

Taluka: Mahad


Form – I


District: Raigad

Phone: +919271438399

13 Name of the applicant Mr D.B. Rao

14 Registered Address Privi House, A-71,TTC, Thane Belapur

Road, Near Kopar Khairane Railway

station, Navi Mumbai-400709

15 Address for correspondence : Privi Organics Limited.

Name Mr D.B. Rao

Designation (Owner/Partner/CEO) Executive Director

Address Privi House, A-71,TTC, Thane Belapur

Road,Near Kopar Khairane Railway

station, Navi Mumbai-400709

Pin Code 402309

E-mail [email protected]

Telephone No. 022- 27783040-48

Fax No. 022- 27783049

16 Details of Alternative Sites examined, if any.

Location of these sites should be shown on a

toposheet.

No

17 Interlinked Projects No

18 Whether separate application of interlinked

project has been submitted?

N/A no interlinked project

19 If yes, date of submission --

20 If no, reason --

21 Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

(a) The forest (conservation) Act, 1980

(b) The wildlife (protection) Act, 1972

(c) C.R.Z Notification, 1991

No, the proposed project does not

require any of this approval/clearance

as the site is located in MIDC area.

22 Whether there is any government order /

policy relevant/ relating to the site?

No

23 Forest land involved (hectares) No, there is no involvement of forest

land for this project.

24 Whether there is any litigation pending

against the project and/or land in which the

No, Court litigation


Form – I


project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any and

its relevance with the proposed project. (II) ACTIVITY

1. Construction, operation or decommissioning of the project involving actions, which will

cause physical changes in the locality (topography, land use, changes in water bodies, etc.).

Sr.

No. Information/Checklist confirmation

Yes

/No

Details thereof (with approximate

quantities /rates, wherever possible) with

source of information data

1.1 Permanent or temporary change in

land use, land cover or topography

including increase in intensity of

land use (with respect to local land

use plan)

No The zoning of the land is Industrial Area as

of now as per the Regional Plan. There

will be no significant change in the

existing land use pattern by proposed

project as it shall be set up in Notified

Industrial Area, MIDC-Mahad.

Construction shall be done in an area of

5416.54 M2 (Plot No.C-3,4,5,6, 6/1, 7, 8, 9)

+ 648.0 M2 (Plot No. C-33/1, X-9,10,11)

1.2 Clearance of existing land,

vegetation and buildings?

No The proposed project site area is an

existing manufacturing industry. No

existing structures have to demolish Site

area will be leveled and graded and site

preparation shall involve clearing of

shrubs and vegetation.

1.3 Creation of new land uses? No The existing land use pattern is Industrial

land. This land is use for manufacturing

and marketing plant of aroma organics.

1.4 Pre-construction investigations e.g.

bore houses, soil testing?

Yes Analysis of river water, air samples and

soil samples of site will be taken. Further

Soil testing and geo- technical

investigations shall be carried out prior to

construction.


Form – I


Sr.


Yes

/No




1.5 Construction works? Yes The construction work proposed includes

Expansion of plant buildings to house

equipments, machinery and auxiliaries.

1.6 Demolition works? No Site is an existing plant. So no demolition

involved.

1.7 Temporary sites used for

construction works or housing of

construction workers?

No Majority of the labor will be hired from

nearby villages so no housing or shelter

facilities required for construction

workers. However, temporary campsites

shall be provided with minimum drinking

and sanitation facilities for workers during

working hours.

1.8 Above ground buildings, structures

or Earthworks including linear

structures, cut and fill or

excavations.

Yes Estimated Excavation quantity would be

around 4000 kg/day of soil. The

excavated soil would be used within the

premises for filling, leveling etc. and

excavated rocks would be used of

construction of boundary wall and

internal roads. The premises do not

contain any sort of rocks or old building

and hence no debris expected.

Above ground building shall be

constructed for Plant area and

manufacturing of products.

1.9 Underground works including mining

or tunneling?

No No underground works including mining

or tunneling involved only foundation for

various structures shall be provided as

sub-structure based on load requirement.

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No No Dredging shall be required as no

offshore area is involved.

1.12 Offshore structures? No No offshore structures involve

1.13 Production and manufacturing Yes The proposed project is manufacturing of


Form – I


Sr.


Yes

/No




processes? Aroma Chemicals.

Details of manufacturing process are

given in Pre-feasibility Report (PFR).

1.14 Facilities for storage of goods or

materials.

Yes Raw materials required for construction

shall be stored at the campsites during

construction phase.

Adequate storage facilities for raw

material and finished goods will be

provided.

Details given in the Pre-Feasibility report

and location marked in Plot plan.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes Construction phase:

Solid waste shall be segregated into

biodegradable and non biodegradable

shall be handed over to authorized

vendors.

Sewage from temporary camp site shall

be disposed off through septic tank and

soak pit.

Operation phase:

Solid waste shall be segregated and

handed over to authorized vendors.

Effluents shall be treated in ETP (primary &

secondary treatment & STP) of Capacity

160 m3/day. The total effluent generation

is 140.0 m3/day, from which 98.0 m3/day

will be transferred to CETP after aerobic

treatment and rest of the treated effluent

(42.0 m3/day) sent to RO (Capacity-300

m3/day) and MEE (Capacity-72 m3/day)

for further treatment.

Details are given in Pre-Feasibility report

(PFR).


Form – I


Sr.


Yes

/No




1.16 Facilities for long term housing of

operational workers?

No The unit shall run in three shifts round the

clock. The operation staff will be hired

from nearby villages, while higher level

staff is provided by housing facilities in

MIDC residential area.

1.17 New road, rail or sea traffic during

construction or operation?

No There shall be slight increase in road

traffic during construction and operation

phase of the project.

The site has good road connectivity.

1.18 New road, rail, air waterborne or

other transport infrastructure

including new or altered routes and

stations, ports, airports etc?

No It is intended to make maximum use of

existing road network for mobilization of

men and materials. Hence no new road

is proposed.

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No There will not be any closure or diversion

of existing transportation routes.

1.20 New or diverted transmission lines or

pipelines?

No There is no need of any diverted

transmission lines of pipelines.

1.21 Impoundment, damming,

culverting, realignment or other

changes to the hydrology of

watercourses or aquifers?

No There will be no significant changes in the

hydrology of watercourses / aquifers for

proposed project.

1.22 Stream crossing? No The study area does not involve any

stream crossings.

1.23 Abstraction or transfers of water

from ground or surface waters?

No Water requirement will be met from MIDC

Water supply.

1.24 Changes in water bodies or the land

surface affecting drainage or run-

off?

No The site shall be restored back to normal

after construction and surface run off

from site shall be channelized through

storm water drains.

1.25 Transport of personnel or materials

for construction, operation or

decommissioning?

Yes Road transport will be used for

transportation of man and materials for

construction phase.


Form – I


Sr.


Yes

/No




During operation phase, the road

transport shall be utilized for

transportation of raw materials, finished

products and by the employees of the

industries.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No Proposed project does not involve any

long-term dismantling or

decommissioning or restoration works.

1.27 Ongoing activity during

decommissioning which could have

an impact on the environment?

No No impact on environment, since project

does not involve any decommissioning.

1.28 Influx of people to an area in either

temporarily or permanently?

No No influx of people during construction

phase since local labors will be

employed.

During operation phase permanent influx

of people shall be around 63 nos.

1.29 Introduction of alien species? No The green belt as per the requirements of

MoEF/CPCB will be developed. Only

native species will be planted so no

introduction of alien species is

anticipated.

1.30 Loss of native species or genetic

diversity?

No Deforestation is not involved, only site

clearance shall be taken up to clear

thorny bushes or surrounding vegetation

and care shall be taken to avoid loss of

any native species or genetic diversity.

1.31 Any other actions? No No other actions/activities envisaged

2. Use of Natural resources for construction or operation of the Project (such as land, water,

materials or energy, especially any resources which are non-renewable or in short supply).

Sr.

No. Information/checklist confirmation

Yes

/No


quantities / rates, wherever possible)

with source of information data


Form – I


Sr.


Yes

/No




2.1 Land especially undeveloped or

agricultural land (ha)

No The zoning of the land as of now as per

the Regional Plan is Industrial Area and

comes under MIDC. There will be no

significant change in the existing land

use pattern by proposed project.

2.2 Water (expected source &

competing users) unit: KLD

Yes Construction Phase:

Source: MIDC/Tanker water

Total Demand = 65.5 m3/day

Domestic = 5.5 m3/day

Construction = 60 m3/day

Operation Phase:

Source: MIDC

The total water requirement during the

operation phase is about 927.2 M3 /day

(Dry Season) and 899.2 M3 /day (Wet

Season).

Details of water requirement are given

in PFR.

2.3 Minerals (MT) No No minerals were used.

2.4 Construction material – stone,

aggregates, sand/soil (expected

source – MT)

Yes Locally available construction materials

shall be utilized.

2.5 Forests Timber (source – MT) No There will be no use of timber in the

Project.

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes Construction Phase:

Source: Maharashtra State Electricity

Distribution Co. Ltd. (MSEDCL)

Quantity: 30 KVA

Operation Phase:

Source: Maharashtra State Electricity

Distribution Co. Ltd.

Requirement: 3295 KVA

(Existing: 1700 KVA & Proposed: 1595

KVA)


Form – I


Sr.


Yes

/No




DG set (for Backup)

Quantity: 1000 KVA, 750 KVA & 380 KVA

(Existing)

2.7 Any other natural resources (use

appropriate standard units)

Yes Coal & FO for Boiler and diesel for DG

sets.

Fuel Details:

Coal : 90 TPD (Existing)

120 TPD (Proposed)

3.624 TPD(Propose for Thermo

pack)

FO/Biofuel : 4.1 KLPD (Existing)

4.1 KLPD/5.9KLPD (Proposed)

Diesel: 250 lit/hrs (Existing)

Details of fuel requirement are given in

PFR.

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

harmful to human health or the environment or raise concerns about actual or perceived

risks to human health.

Sr.


Yes

/No


quantities/rates, wherever possible) with


3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna and water supplies)

Yes Hazardous raw materials will be handled

as per MSIHC rules, 1989 and

amendment rules, 2000.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No There will be no occurrence of disease

or disease vector by the project.

3.3 Affect the welfare of people e.g. by

changing living conditions?

Yes Employment opportunity during

construction and operation of the

project will improve the socio-economic


Form – I


Sr.


Yes

/No




condition of the local population.

Ancillary development near the project

site will additionally improve the

economic status of nearby Village.

3.4 Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.,

No No, since the proposed site within

notified industrial area.

3.5 Any other causes No Not Applicable.

4. Production of solid wastes during construction or operation or decommissioning

(MT/month).

Sr.


Yes

/No




4.1 Spoil, overburden or mine wastes No Not Applicable.

4.2 Municipal waste (domestic and or

commercial wastes)

Yes During construction phase:

Small quantity of Solid wastes

generated from the temporary camp-

sites and other wastes like plastics,

paper, cardboard etc. shall be

properly collected, segregated and

disposed off suitably as per norms.

The construction debris shall be used

for leveling and base course

preparation.

During operation phase:

The total solid waste generated shall

be around 65.1 Kg/day, which shall be

segregated as organic and inorganic

and handed over authorized vendor

for disposal.

4.3 Hazardous wastes (as per Hazardous Yes The expected hazardous wastes


Form – I


Sr.


Yes

/No




Waste Management Rules) including spent oil, containers, ETP

sludge etc. shall be generated from

site which shall be handed over to

authorized vendors.

Details are given in Pre-Feasibility report

(PFR).

4.4 Other industrial process wastes No There will be no other industrial process

waste.

4.5 Surplus product No Not Applicable.

4.6 Sewage sludge or other sludge from

effluent treatment

Yes Sludge generated from ETP (40 MT/M)

will be handed to authorized agency

for further disposal.

4.7 Construction or demolition wastes Yes The major construction wastes are

packing material or containers which

will be disposed off to authorized

vendors. Construction debris about 4.0

MT/day shall be generated during

construction phase, which shall be

used for leveling of low-lying areas or

base course preparation of approach

roads.

No demolition involved.

4.8 Redundant machinery or equipment No No redundant machinery shall be

available, as the construction and

other equipments involved shall be

transported out of the project area

once the construction work is over.

4.9 Contaminated soils or other

materials

No There will be no contaminated soil.

4.10 Agricultural wastes No There will be no agricultural wastes.

4.11 Other solid wastes No No


Form – I


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

Sr.


Yes

/No


quantities/ rates, wherever possible) with


5.1 Emissions from combustion of fossil

fuels from stationary or mobile sources

Yes During Construction phase, emissions

shall be from combustion of Fossil fuels

used in Construction machineries,

vehicles, and DG Sets.

Gaseous emissions like SO2, NOx, CO and

particulate matter will be generated

from Boiler and Incinerator. DG sets used

during only power break down.

Adequate stack height of boiler (46 m)

and Incinerator (30 m) already installed

for effective dispersion of pollutants.

5.2 Emissions from production processes Yes Gaseous emission will be within the

prescribed limits & stack with adequate

height will be provided for the effective

dispersion of pollutants.

5.3 Emissions from materials handling

including storage or transport

Yes During raw material handling and

transportation, negligible dust emission

may occur. However, suitable mitigation

measures like sprinkling of water etc.

may be carried out to control dust.

5.4 Emissions from construction activities

including plant and equipment.

Yes Fugitive dust and emissions from

vehicular movement and construction

equipments. Water spraying on

temporary roads inside the Project Site

will be carried out to control the dust

and monitoring shall be carried out

periodically.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Dusting will occur during transportation

and handling of construction or raw

materials and products. However,

suitable mitigation measures like

sprinkling of water etc. may be carried


Form – I


Sr.


Yes

/No


quantities/ rates, wherever possible) with


out to control dusting.

No odor problem will occur from effluent

or solid waste since proper segregation

and treatment is proposed for the

project.

5.6 Emissions from incineration of waste Yes Gaseous emissions like SO2, NOx, CO

and particulate matter will be

generated from Incinerator. Adequate

stack height of Incinerator (30 m) has

already installed for effective dispersion

of pollutants.

5.7 Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No There will be no burning of waste in open

air.

5.8 Emissions from any other sources No Not envisaged

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

Sr.


Yes

/No

Details thereof (with approximate quantities

/rates, wherever possible) with source of

information data with source of information

data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes The noise generation sources from the

proposed activities include:

Construction phase – There shall be

temporary increase in noise due to

Construction and transport equipment. The

expected noise levels will be in the range of

70-85 dB (A).

Operation phase– Noise expected during

operation shall be from Process pumps and

motors.

The design of the equipment and

machinery will be such that the sound


Form – I


Sr.


Yes

/No




data

pressure level in the work area will not

exceed 75 dB(A)during day time and 70 dB

(A) in night hours. Further proper acoustic

measures & vibration isolators shall be

provided along with DG sets & process

pumps & motors to reduce the noise and

vibrations. Noise levels will be reduced by

the use of adequate mufflers on all

motorized equipment. Personnel protective

equipment will be provided and their

proper usage will be ensured for ear- plug

protection of the workers.

There shall be no emission of light and heat.

6.2 From industrial or similar processes No No significant noise, vibrations, or emission

of light or heat, which can create problem

to surrounding environment or people living

near by, will be generated since the unit

shall be located within the notified industrial

area (MIDC) and adequate green belt

around the unit shall further act as noise

barrier.

6.3 From construction or demolition Yes There will be marginal increase in noise up

to 80 dB (A) during construction work and it

shall be localized to work site. The activities

will be restricted to the daytime. Personnel

protective equipment will be provided and

their proper usage will be ensured for ear

plug protection of the workers.

6.4 From blasting or piling No Not Applicable.

6.5 From construction or operational

traffic.

Yes There will be marginal noise generation from

vehicle movement especially due to

movement of trucks for transportation of

raw materials and finished products.


Form – I


Sr.


Yes

/No




data

However, the noise levels will be less than 75

dB (A). Further suitable mitigation measures

including green belt shall be proposed to

reduce the noise generated from

construction or operation traffic.

6.6 From lighting or cooling systems Yes There will some amount of noise increased

due to use of utilities.

6.7 From any other sources No Not applicable.

7. Risks of contamination of land or water from releases of pollutants into the ground or into

sewers, surface waters, groundwater, coastal waters or the sea.

Sr.

No.

Information/Checklist confirmation Yes

/No




7.1 From handling, storage, use or

spillage of hazardous materials

Yes Proper measures will be taken for risk of

contamination of land and water from

hazardous materials. Storage of

hazardous raw materials shall be as per

MSIHC rules, 1989. Collection, treatment

and disposal of hazardous waste will be as

per hazardous waste (Management &

Handling) rule 2008 and hence no

adverse impact on land environment is

envisaged.

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

Yes During construction phase, generated

sewage shall be disposed off through

septic tank and soak pit.

During operation phase, the total effluent

generation is 140.0 m3/day, from which

98.0 m3/day will be transferred to CETP

after aerobic treatment and rest of the

treated effluent (42.0 m3/day) sent to RO


Form – I


(Capacity-300 m3/day) and MEE

(Capacity-72 m3/day) for further

treatment.

7.3 By deposition of pollutants emitted

to air into the land or into water.

No Proper mitigation measures will be taken

to reduce the emission. Air Pollution

Control System shall be provided. All the

gaseous emission discharge will be well

within the prescribed limit.

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term build up

of pollutants in the environment

from these sources?

No Proper maintenance of machineries and

equipments shall be carried out

periodically for emission control.

Monitoring of air, soil and water including

inlet and outlet waste water shall be

analyzed and mitigation measures shall

be taken. Adequate pollution control

measures for air, water and noise shall be

provided. Hence there is no risk of long

term build up of pollutants.

8. Risk of accidents during construction or operation of the Project, which could affect human

health or the environment.

Sr.

No.

Information/Checklist confirmation Yes

/No



source of information data.

8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous

substances.

No During Construction phase: Adequate

safety measures shall be undertaken by

construction contractor. PPE like Safety

helmet, safety belts, safety shoes, safety

goggles, etc. shall be provided to workers.

Fire alarm and extinguishers shall put in

place.

Operation phase:

The hazards will be thoroughly identified

through Risk Assessment and would be

adequately addressed at the design


Form – I


stage itself by incorporating a Detailed

Disaster Management Plan to bring down

risk involved/ hazards/ accidents as low as

reasonably practicable.

Adequate Fire Extinguishers along with

closed loop fire hydrant system shall be

installed at all strategic locations within the

plant.

MSDS of each raw material and finished

product shall be displayed at suitable

location in plant.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g.

floods, earthquakes, landslides,

cloudburst etc)?

Yes The project falls under seismic zone – IV

and the building will be designed as per

seismic zone - IV norms.

9. Factors which should be considered (such as consequential development) which could

lead to environmental effects or the potential for cumulative impacts with other existing or

planned activities in the locality.

Sr.


Yes

/No


quantities/rates, wherever possible)


9.1 Lead to development of supporting,

facilities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.:

• Supporting infrastructure (roads, power

supply, waste or waste water treatment,

etc.)

• housing development

• extractive industries

• supply industries

Yes The internal approach roads would

be developed by proponent. The

peripheral infrastructure facility shall

be provided and maintained by

MIDC.


Form – I


Sr.


Yes

/No


quantities/rates, wherever possible)


• other

9.2 Lead to after-use of the site, which could

have an impact on the environment

No The proposed project will have

marginal & negligible impact on

the environment.

9.3 Set a precedent for later developments No There will not be any future

development

9.4 Have cumulative effects due to proximity

to other existing or planned projects with

similar effects

No As the environmental impact from

the project is marginal, no

cumulative effects are envisaged.

(III) ENVIRONMENTAL SENSITIVITY

Sr.

No. Areas

Name/

Identity

Aerial distance (within 15 km.)

Proposed project location

boundary

1 Areas protected under international

conventions, national or local legislation

for their ecological, landscape, cultural

or other related value.

No This area is not protected under

any International Conventions,

National or Local Legislation. No

eco- sensitive zone around 15 km

periphery. The area fall within

MIDC Industrial Area.

2 Areas which are important or sensitive for

ecological reasons - Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests.

Yes Savitri River- 2.6 Km & Kal River-

1.5 Km

The above project falls within 5

Km radius from the boundary of

Eco-Sensitive Area as per

Direction under section 5 of the

Environmental (protection )

Act,1986 by MoEF (F. No. 1-

4/2012-RE(Pt.) dated 13.11.2013

and EIA Notification dated

25.06.2014


Form – I


Sr.

No. Areas

Name/

Identity

Aerial distance (within 15 km.)

Proposed project location

boundary

3 Areas used by protected, important or

sensitive species of flora or fauna for

breeding, nesting, foraging, resting, over

wintering, migration.

No Not Present within 15 km.

4 Inland, coastal, marine or underground

waters.

No There is no coast line or marine

Ecosystem in the zone.

5 State, National boundaries. No There is no National and State

Boundary within 15 Km from the

project site.

6 Routes or facilities used by the public for

access to recreation or other tourist,

pilgrim areas.

Yes NH 66 - 03 KM

7 Defense installations No Not present within 15 km radius.

8 Densely populated or built-up area Yes Mahad: 07.5 KM

9 Areas occupied by sensitive man-made

land uses (hospitals, schools, places of

worship, community facilities)

Yes MMA Hospital: 03 Km

10 Areas containing important, high quality

or scarce resources (ground water

resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

Yes Pandav Leni (10 km, NW) for

tourism

11 Areas already subjected to pollution or

environmental damage. (those where

existing legal environmental standards

are exceeded)

No Not present within 15 km.

12 Areas susceptible to natural hazard

which could cause the project to

present environmental problems.

(earthquakes, subsidence, landslides,

erosion, flooding or extreme or adverse

climatic conditions)

No The proposed project site falls

under seismic zone IV.


Form – I


(IV) Proposed Terms of Reference

Project: The proposed project “Environmental Clearance for the proposed expansion &

addition of aroma chemical manufacturing capacity in Unit-II of Privi Organics Ltd, MIDC

area, Mahad, Dist. Raigad” is located at Plot No.C-3/4/5/6, 6/1,7,8,9 & C-33/1, X-9,10,11

Mahad Industrial Area, Mahad, Raigad, Maharashtra.

Consultant: Green Circle, Inc., Vadodara.

Proposed Terms of Reference (TOR) for Environmental Impact Assessment study for

“Environmental Clearance for the proposed expansion & addition of aroma chemical

manufacturing capacity in Unit-II of Privi Organics Ltd, MIDC area, Mahad, Dist. Raigad”

1. Executive summary of the project – giving a prima facie idea of the objectives of the

proposal, use of resources, justification, etc. In addition, it should provide a compilation of

EIA report, including EMP and the post-project monitoring plan in brief.

Project description:

2. Justification for selecting the proposed product and unit size.

3. Land requirement for the project including its break up for various purposes, its

availability and optimization.

4. Details of proposed layout clearly demarcating various units within the plant.

5. Product spectrum (Proposed products along with production Capacity) and processes.

6. Complete process flow diagram describing each unit, its processes and operations, along

with material (material balance).

7. Details on raw materials, source and storage within the premises.

8. Details on solvent balance, measures for solvent recovery

9. Details on requirement of energy and water along with its source and authorization from

the concerned department.

10. Details on water balance including quantity of effluent generated, recycled & reused.

Efforts to minimize effluent discharge and to maintain quality of receiving water body.

11. Segregation of waste stream, characterization and quality with specific treatment

12. Details of end of the pipe effluent treatment plant, inlet and treated water quality with

specific efficiency of each treatment unit in reduction in respect of all concerned / regulated

environmental parameters.


Form – I


13. Details on volatile organic compounds from the plant operations and occupational safety

and health protection measures

14. Details on channelized emissions and control equipment for each of the source.

15. Control technologies for combustion emissions

16. Details on composition, generation and utilization of waste from the plant.

17. Management plan for solid/hazardous waste including storage, utilization and safe

disposal. CPCB guidelines in respect of specific treatment, such as solar evaporation,

incineration, etc., need to be followed.

18. Details of proposed source-specific pollution control schemes and equipments to meet

the national standards.

19. Details regarding infrastructure facilities such as sanitation, fuel storage, restroom, etc., to

the workers during construction and operation phase.

20. In case of expansion of existing industries, remediation measures adopted to restore the

environmental quality if the groundwater, soil, crop, air, etc., are affected and a detailed

compliance to the prior environmental clearance/consent conditions.

21. Any litigation pending against the project and /or any direction /order passed by any

Court of Law against the project, if so, details thereof.

Description of the environment:

22. The study area shall be up to a distance of 10 km from the boundary of the proposed

project site.

23. Location of the project site and nearest habitats with distances from the project site to be

demarcated on a toposheet (1: 50000 scale).

24. Landuse based on satellite imagery including location specific sensitivities such as national

parks / wildlife sanctuary, villages, industries, etc., for the study area.

25. Demography details of all the villages falling within the study area.

26. Topography details of the project area.

27. The baseline data to be collected from the study area w.r.t. different components of

environment viz. air, noise, water, land, and biology and socio-economic.

28. Geological features and geo-hydrological status of the study area.

29. Details of groundwater and surface water quality of nearby water sources and other

surface drains. Water quality parameters may include pH*, BOD* (3 days at 27 oC), COD*,

toxicity factor*, Nitrate* (as N), Arsenic*, Chromium*, Hexavalent*, Total Lead*, Cyanide as

CN*, Zinc*, Mercury*, Copper*, Nickel*, Phenolics* as C6H5OH, Sulphide, etc. (* - as

applicable)

30. Details on existing ambient air quality and expected, stack and fugitive emissions for

PM10*, PM2.5*, SO2*, NOx*, VOC*, mercaptans*, solvents*, NH3*, chlorine*, HCl*, HBr*, H2S*,


Form – I


HF*, other process-specific pollutants*, etc., and evaluation of the adequacy of the proposed

pollution control devices to meet standards for point sources and to meet AAQ standards. (* -

as applicable)

31. The air quality contours may be plotted on a location map showing the location of project

site, habitation nearby, sensitive receptors, if any and wind roses.

32. Details on noise levels at sensitive/commercial receptors.

33. Site-specific micro-meteorological data including mixing height.

34. One season site-specific data excluding monsoon season.

35. Proposed baseline monitoring network for the consideration and approval of the

Competent Authority.

36. Ecological status (terrestrial and aquatic) of the study area such as habitat type and

quality, species, diversity, rarity, fragmentation, ecological linkage, age, abundance, etc.

37. If any incompatible landuse attributes fall within the study area, proponent shall describe

the sensitivity (distance, area and significance) and propose the additional points based on

significance for review and acceptance by the SEAC. Incompatible land use attributes

include:

a. Public water supply areas from rivers/surface water bodies, from ground water

b. Scenic areas/tourism areas/hill resorts

c. Religious places, pilgrim centers that attract over 10 lakh pilgrims a year

d. Protected tribal settlements (notified tribal areas where industrial activity is not permitted)

e. Monuments of national significance, World Heritage Sites

f. Cyclone, Tsunami prone areas (based on last 25 years);

g. Airport areas

h. Any other feature as specified by the State or local government and other features as

locally applicable, including prime agricultural lands, pastures, migratory corridors, etc.

38. If ecologically sensitive attributes fall within the study area, proponent shall describe the

sensitivity

(distance, area and significance) and propose additional points based on significance for

review and acceptance by the SEAC. Ecological sensitive attributes include:

a. National parks

b. Wild life sanctuaries Game reserve

c. Tiger reserve/elephant reserve/turtle nesting ground

d. Mangrove area

e. Wetlands

f. Reserved and protected forests

g. Any other closed/protected area under the Wild Life (Protection) Act, 1972, any other area

locally applicable


Form – I


h. Any other eco-sensitive areas

39. If the location falls in Valley, specific issues connected to the natural resources

management shall be studied and presented.

40. If the location falls in CRZ area: A CRZ map duly authenticated by one of the authorized

agencies demarcating LTL, HTL, CRZ area, location of the project and associate facilities w.r.t.

CRZ, coastal features such as mangroves, if any.

Provide the CRZ map in 1:10000 scale in general cases and in 1:5000 scales for specific

observations. Proposed site for disposal of dredged material and environmental quality at the

point of disposal/impact areas.

Fisheries study should be done w.r.t. Benthos and Marine organic material and coastal

fisheries. Anticipated environmental impacts and mitigation measures.

41. Anticipated generic environmental impacts due to this project.

42. Impact prediction tools used for the appropriate assessment of environmental impacts .

43. While identifying the likely impacts, also include the following for analysis of significance

and required mitigation measures:

a. impacts due to transportation of raw materials and end products on the surrounding

environment

b. impacts on surface water, soil and groundwater

c. impacts due to air pollution

d. impacts due to odour pollution

e. impacts due to noise

f. impacts due to fugitive emissions including VOCs / HAPs

g. impact on health of workers due to proposed project activities

44. Proposed odour control measures

45. Action plan for the greenbelt development – species, width of plantations, planning

schedule, etc., in accordance to CPCB published guidelines.

46. In case of likely impact from the proposed project on the surrounding reserve forests, Plan

for the conservation of wild fauna in consultation with the State Forest Department.

47. Mitigation measures – for source control and treatment.

48. Comparison of alternate sites considered and the reasons for selecting the proposed site.

Conformity of the site with prescribed guidelines in terms of CRZ, river, highways, railways, etc.

49. Details on improved technologies.

50. Details on proposed recovery options.

Environmental monitoring program:

51. Monitoring programme for pollution control at source.


Form – I


52. Monitoring pollutants at receiving environment for the appropriate notified parameters –

air quality, groundwater, surface water, gas quality, etc. during operational phase of the

project.

53. Specific programme to monitor safety and health protection of workers

54. Proposed plan to estimate and monitor fugitive emissions including VOCs from all the

sources and appropriated control measures.

55. Stack and fugitive emissions may be monitored for SPM, PM10, PM2.5, SO2, NOx, HC, CO,

VOC and evaluation of the adequacy of the proposed pollution control devices to meet

gaseous emissions.

56. Monitoring of carbon foot print

57. Appropriate monitoring network has to be designed and proposed, to assess the possible

residual impacts on VECs.

58. Details of in-house monitoring capabilities and the recognized agencies if proposed for

conducting monitoring.

Additional studies:

59. Details on risk assessment and damage control during different phases of the project and

proposed safeguard measures.

60. Details on socio-economic development activities such as commercial property values,

generation of jobs, education, social conflicts, cultural status, accidents, etc.

61. Proposed plan to handle the socio-economic influence on the local community. The plan

should include quantitative dimension as far as possible.

62. Details on compensation package for the people affected by the project, considering

the socioeconomic status of the area, homestead oustees, land oustees, and landless

labourers.

63. Points identified in the public hearing and commitment of the project proponent to the

same. Detailed action plan addressing the issues raised, and the details of necessary

allocation of funds.

64. Details on plan for corporate social responsibility including the villages, population spread,

SC/ST/backward communities, upgradation of existing schools, establishing new schools with

facilities (such as laboratories, toilets, etc.), link roads, community halls, primary health

facilities, health camps, etc.

65. Administrative and technical organizational structure to ensure proposed post-project

monitoring programme for approved mitigation measures.

66. EMP devised to mitigate the adverse impacts of the project should be provided along

with item-wise cost of its implementation (capital and recurring costs).

67. Allocation of resources and responsibilities for plan implementation.


Form – I


68. Details of the emergency preparedness plan and on-site and off-site disaster

management plan. Above points shall be adequately addressed in the EIA report at

corresponding chapters, in addition to the contents given in the reporting structure as below:

.

EIA Structure Contents:

1. Introduction a. Purpose of the report:

a. Identification of project & project proponent

b. Brief description of nature, size, location of the project and its

importance to the country, region

c. Scope of the study – details of regulatory scoping carried out (As per

Terms of Reference)

2 .Project Description:

Condensed description of those aspects of the project (based on project

feasibility study), likely to cause environmental effects. Details should be

provided to give clear picture of the following:

a. Type of project

b. Need for the project

c. Location (maps showing general location, specific location, project

boundary & project site layout)

d. Size or magnitude of operation (incl. Associated activities required by or for the project)

e. Proposed schedule for approval and implementation

f. Technology and process description

g. Project description including drawings showing project layout,

components of project etc. Schematic representations of the feasibility

drawings which give information important for EIA purpose

h. Description of mitigation measures incorporated into the project to

meet environmental standards, environmental operating conditions, or

other EIA requirements (as required by the scope).

i. Assessment of new & untested technology for the risk of technological failure

3 Description of the Environment:

a. Study area, period, components & methodology

b. Establishment of baseline for VECs, as identified in the scope

c. Base maps of all environmental components


Form – I


4. Anticipated Environmental Impacts & Mitigation Measures:

a. Details of Investigated Environmental impacts due to project location, possible accidents,

project design, project construction, regular operations, final decommissioning or

rehabilitation of a completed project.

b. Measures for minimizing and / or offsetting adverse impacts identified.

c. Irreversible and irretrievable commitments of environmental components.

d. Assessment of significance of impacts (Criteria for determining significance, Assigning

significance)

e. Mitigation measures

5 Analysis of Alternatives (Technology & Site):

a. In case, the scoping exercise results in need for alternatives:

b. Description of each alternative

c. Summary of adverse impacts of each alternative

d. Mitigation measures proposed for each alternative and selection of alternative

6 Environmental Monitoring Program:

Technical aspects of monitoring the effectiveness of mitigation measures (incl.

measurement methodologies, frequency, location, data analysis, reporting

schedules, emergency procedures, detailed budget & procurement schedules)

7 Additional Studies:

a. Public consultation

b. Risk assessment

c. Social impact assessment, R&R action plans

8 Project Benefits a. Improvements in physical infrastructure:

a. Improvements in social infrastructure

b. Employment potential –skilled; semi-skilled and unskilled

c. Other tangible benefits

9 Environmental Cost Benefit Analysis If recommended at the scoping stage

10 EMP Description of the administrative aspects that ensures proper implementation

of mitigative measures and their effectiveness monitored, after approval of the EIA

11 Summary & Conclusion (This will constitute the summary of the


Form – I


a. Overall justification for implementation of the project

b. Explanation of how, adverse effects have been mitigated EIA Report)

12 Disclosure of Consultants engaged

Names of the Consultants engaged with their brief resume and nature of

Consultancy rendered

PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT

For

“PROPOSED EXPANSION & ADDITION OF AROMA CHEMICAL MANUFACTURING

CAPACITY IN UNIT-II”

By

M/s. PRIVI ORGANICS LIMITED

Unit-II

Plot no. - C-3, 4, 5, 6, 7, 6/1, 8, 9, C-33/1 & X-9, 10, 11, MIDC Industrial Estate, Mahad,

Dist. Raigad - 402309, Maharashtra, India

Conducted & Prepared By

GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers

(MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, NABL/17025:2005, OHSAS: 18001 Certified Organization & GPCB approved

Environment Auditor – Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 04.02.2014

Corp. Office & Environmental Research Laboratory:

Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India

Mumbai office

Flat No 6, Ground Floor, Shakuntala Niwas, M G Road, Borivali (E),Mumbai- 400066 Tel: 022-28943090 /60

www.greencircleinc.com E: [email protected] ALSO AT

BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA

OVERSEAS

AUSTRALIA OMAN KUWAIT AFRICA VIETNAM

Project: Proposed Expansion & Addition of Aroma Chemical Manufacturing Capacity in Unit II Developer: M/s. Privi Organics Ltd.

Green Circle, Inc. Pre Feasibility Report 2

TABLE OF CONTENTS

LIST OF TABLES

Sl. No. Particulars Page No.

1 Introduction 4

2 Market Analysis 5

3 Benefits of Project 6

4 Project Location 6

5 Cost of Project 7

6 Proposed Product and By-Product Details and Capacity 7

7 Raw Material Required and Storage 17

8 Process Description 28

9 Recovery of Concentrated Sulfuric Acid 91

10 Installation of 4 MW Thermal Power Plant 93

11 Land requirement Details 95

12 Utility and Requirements 100

13 Solid Waste Management 108

14 Hazardous Waste Details 108

15 Green Belt Development 109

16 Rain Water Harvesting 109

17 Storm Water-Collection and Disposal 110

18 Air Pollution Control Measures 110

Table.

No. Particulars Page No.

1 Environment setting of the proposed project 6

2 Proposed Product details 8

3 Proposed BY- Product details 10

4 Existing By-product details 16



LIST OF FIGURES

5 Action Plan for Consumption, Storage & Transportation

of proposed Raw Materials 17

6 Details and Quantity of Sulfuric acid 91

7 Process Standard for Sulfuric acid Plant 91

8 Area Statement of Plots 95

9 Area Statement of Plots 96

10 Water Consumption and Waste water generation

details for Dry Season 100

11 Water Consumption and Waste water generation

details for Wet Season 101

12 Waste Water Characteristics 103

13 Details of Power Consumption 105

14 Fuel requirement details 105

15 Details of Stack 106

16 Fly ash generation and disposal facility 107

17 Employment Details 107

18 Hazardous Waste Handling and Disposal Details 108

19 Annual Runoff 110

Fig. No. Particulars Page No.

1 Google image of Project Site 8

2 Layout of Sulfuric acid concentration and polishing unit

92

3 Block diagram of 4 MW thermal power plant 95

4 Plant Layout of proposed expansion project 98

5 Layout Plan of proposed expansion project 99

6 Schematic Diagram of ETP 102

7 Flow Diagram for STP 103

8 Flow Diagram for MEE 104



1.0 INTRODUCTION

1.1 COMPANY PROFILE

M/s Privi Organics Limited was promoted by Mr. D.B. Rao (Executive Director) and Mr.

Mahesh.P.Babani (Managing Director) as a Private Limited Company. It was commissioned in

1999 and commercial production commenced in same year. Currently Privi Organics is

manufacturing 18 Aroma products, and planned to manufacture 24 additional products and

expanding 5 existing products. Ever since the beginning, Privi has been gradually increasing its

manufacturing capacity and the range of products. Privi has entered in the Global market in

1998 and today manufacturing site has grown to Global Standards. M/s Privi Organics Ltd. have

the bouquet of products consists of around 18 aroma chemicals such as Rose Oxide, Prionyl,

Rosaxanol, Alpha Pinene, etc. The present capacity of plant is 1820.65 MT per month. The

company which was once engaged in manufacturing of commodity products has graduated

to manufacturing specialty and value added products like Isobornyl Cyclohexanol, D-Limonene,

Orange oil, Myrcene, L-Carvone,etc.

M/s. Privi Organics Ltd. has proposed to increase its manufacturing capacity of aroma

chemicals products at plot No. C-3, 4, 5, 6, 6/1, 7, 8, 9 and C-33/1, X-9, 10, 11 will be used as utility

service at MIDC, Mahad, Taluka: Mahad, District: Raigad, Maharashtra.

Privi conferred with various awards / certificates like;

“Lalit Doshi Memorial Award” (Year 2000) for its outstanding performance in year

2000- (This prestigious award was instituted by Lalit Doshi Memorial Foundation

and SICOM Limited is annually presented to a SICOM assisted unit having

outstanding performance.)

“Export House Certification Status ( Year 2002)

Unit-II became an Export oriented Unit

ISO 9001 certification

ISO 14001 certification

OHSAS 18001 certification

Certificate of Merit – Meritorious Performance in Industrial Safety in CHEMICALS

AND FERTILIZERS industry group from National Safety Council.

KOSHER Certification for Flavour Ingredients

Halal Certification for Flavour Ingredients

Privi supplies its aroma ingredients to Top ten fragrance houses in the world and known for its

consistent quality and competitive pricing. Over the past 12 years, Privi has maintained an

impressive average annual growth of more than 30%. This has been possible due to relentless



drive to deliver exceptional value Privi has provided to its customer in terms of product, pricing

and service.

1.2 OUR VISION

To enable M/s. Privi Organics Ltd. to emerge as a leading Global manufacturer of Aroma

Chemicals.

Privi Organics intends to become the leading aroma chemicals brand across the globe with its

wide range of innovative products, reliable quality along with exemplary services, to fulfil the

ever growing demands of our rising customers.

1.3 OUR MISSION

To be the best by giving only the best!

At any given moment, we are self-assured and prepared to provide quality products by

adopting safe and healthy practices in procuring, preparing and presenting our products.

M/s. Privi Organics Ltd. shall continue to be a leader in the local aroma chemicals industry and

keep on thriving and innovating for the international market, thereby portraying India’s potential

as a market leader in Aroma Chemicals. Our mission shall always be to fulfil customer's needs

first.

2.0 MARKET ANALYSIS

Flavor and fragrance demand—including demand for flavor and fragrance blends, essential oils

and natural extracts, and aroma chemicals—is expected to rise 4.4% a year to reach $26.5

billion in 2016. In 2011, total world aroma chemicals consumption was worth $ 3.37 billion.

M/s Privi Organics limited supplies its aroma ingredients to Top ten fragrance houses in the world,

which accounts 66% of world total flavour and fragrance market share and known for its

consistent quality and competitive pricing. It is estimated that International houses (foreign

players) account for about 70% of the organised Indian market while domestic companies cater

to the rest. The Asia/Pacific region is expected to surpass Western Europe to become the

second largest regional consumer of flavors and fragrances, behind North America in next few

years.

The Indian Fragrances and Flavours industry has been growing rapidly following liberalisation. The

global economic slowdown did not have any impact on the industry; instead, it clocked a

growth rate of 12 -15 per cent. With globalisation, there have been improvements in technology,

competition and brand images. The global industry is looking at India as a future hub for

fragrances and flavours.



3.0 BENEFITS OF PROJECT

The products e.g., Isobornyl Cyclohexanol, D-Limonene & Orange oil, Myrcene, L-Carvone &

Alpha-Campholenic aldehyde etc which Privi Organics intend to manufacture are used as

fragrance agents and/or flavoring agents. Apart from use in flavorings/fragrances, the

products have other important and valuable applications.

For example, D-Limonene & Orange oil is also used as adhesive and stain removers. Oils

containing carvones are used in aromatherapy and alternative medicine.

The Project will create direct & indirect employment opportunities within the surrounding region.

The Unit will use good faith efforts to employ local people from the nearby villages depending

upon the availability of skilled & un-skilled man-power surrounding the project site. In operation

phase, the proposed project would require significant workforce of non-technical and technical

persons. Migration of highly education and skilled experience will result in increase of literacy in

the surrounding villages.

The revenue generated will also promote CSR activities.

Privi Organics Ltd aims to become the largest global supplier of competitive and quality aroma

chemicals. This project will enhance India’s potential of supplying aroma chemicals/products to

worldwide leading to step-up of India’s position in global market sector and strengthening of

Indian economy. This will also enable to meet rising demands of such products in domestic

market.

4.0 PROJECT LOCATION

The proposed project is located at Plot No. C-3, 4, 5, 6, 6/1, 7, 8, 9 and C33/1, X-9, 10, 11, MIDC,

Taluka: Mahad, District: Raigad, Maharashtra. The environmental setting around the proposed

site is given in Table-1. The location plan of project site is given in figure 1.

Table 1: Environment setting of the proposed project

S. No. Particulars Details

1 Latitude 18°06.397’N

2 Longitude 73°29.321’E

3 Elevation above MSL 56 ft above Mean Sea Level

4 Climatic Conditions

(As per IMD)

Annual Mean Maximum Temperature :32° C

Annual Mean Minimum Temperature :

22.7° C

Annual average Rainfall : 3413 mm**

5 Present land use of the project site Land specified for industrial development

6 Nearest village Jite (2 km, S)



S. No. Particulars Details

7 Nearest Town/City Birwadi (3 km)

8 Nearest Railway Station Veer Railway Station (18 Km)

9 Nearest Highway NH – 66 (2.5 Km., East)

10 Nearest Airport Pune Airport (130 Km)

11 Nearest Water Body Kal River (1.5 km)

12 Ecologically sensitive Areas (ESA) Village Jite

13 Historical/ Archaeological places Pandav Leni(10 km, NW)

14 National Parks/Wild Life Sanctuary No national parks/wild life sanctuary is present

within 10 Km radius.

15 Major Industry (within 10 km) Hikal Chemical Plant & Sudarshan chemical (SW

side of the project site)

16 Seismic Zone Zone –IV

Figure 1: Google image of Project Site



5.0 PROJECT COST

The expected cost of the proposed project will be around Rs. 67.92 crores. Rs 7.72 crores shall be

earmarked for development of EMS (Environment Management Systems).

6.0 PROPOSED PRODUCT AND BY-PRODUCT DETAILS AND CAPACITY

The details of products with capacity, category and action plan for transportation of products

and by- products are summarized in Table 2.4, Table 2.5 and Table 2.6 respectively.

Table 2: Summary of Products

No Product Category Existing

Qty MTPM

Proposed

Qty MTPM

Total

Qty MTPM

01 Isobornyl cyclohexanol (IBCH) Aroma chemical 1.0 50.0 51.0

02 L-Carvone Aroma chemical - 50.0 50.0

03 Orange oil folds Aroma chemical - 12.0 12.0

04 D-Limonene Aroma chemical - 125.0 125.0

05 Myrcene Aroma chemical - 400.0 400.0

06 Alpha-Campholenic aldehyde Aroma chemical - 50.0 50.0

07 Floreol Aroma chemical - 80.0 80.0

08 D-Carvone Aroma chemical - 5.0 5.0

09 Dihydrocarvone Aroma chemical - 5.0 5.0

10 Carvomenthone Aroma chemical - 5.0 5.0

11 Nimberol Aroma chemical - 1.0 1.0

12 Dihydromyrcene Aroma chemical - 150.0 150.0

13 Sandal fleur & derivatives Aroma chemical - 20.0 20.0

14 Sandal touch Aroma chemical - 5.0 5.0

15 Citral extra pure Aroma chemical - 30.0 30.0

16 Citronellal Aroma chemical - 20.0 20.0

17 Cyclocitral (Alpha & Beta

mixture) Aroma chemical - 2.0 2.0

18 Isocitronellene & Isomer Aroma chemical - 30.0 30.0

19 Citronellyl nitrile Aroma chemical - 30.0 30.0

20 A-Pinene from CST Aroma chemical 666.66 945.0 1611.66

21 B-Pinene from CST Aroma chemical 216.66 288.2 504.86

22 Limonene from CST Aroma chemical 83.33 -42.01 41.32

23

Mixed Terpenes/Terpene biofuel

from CST or Aroma chemical - 744.0 744.0

DDTO/Carene varities 60,90,98/

Terpene bio fuel Aroma chemical - 679.15 679.15



24 A-Pinene from GTO Aroma chemical - 537.0 537.0

25 B-Pinene from GTO Aroma chemical - 334.0 334.0

26 Amberfleur Aroma chemical - 400.0 400.0

27 MI for soap Aroma chemical - 1.0 1.0

28 Violetone Coeur Aroma chemical - 2.0 2.0

29 Timber Touch/Timber forte Aroma chemical 2.0 3.0 5.0

Esters

30 Para Tertiary Butyl Cyclo Hexyl

Acetate Aroma chemical

297.0 - 297.0

31 Ortho Tertiary Butyl Cyclo Hexyl

Acetate Aroma chemical

32 Styrallyl Acetate ( SA) Aroma chemical

33 Terpinyl Acetate (TA) Aroma chemical

34 Citronellyl Acetate (COLA) Aroma chemical

35 Geranyl Acetate(GOLA) Aroma chemical

36 Dimethyl Octonol A Aroma chemical

37 Nerol A Aroma chemical

38 ISO Boronyl Acetate Aroma chemical

39 Longifolene Acetate Aroma chemical

Alcohols

40 Citronellol (Col) Aroma chemical

445.0 - 445.0

41 Geraniol (Gol) Aroma chemical

42 Damascone (DMO) Aroma chemical

43 Nerol Aroma chemical

44 Terpineol Aroma chemical

45 Dihydromyrcenol Aroma chemical

46 Rose Oxide Aroma chemical 3.0 - 3.0

47 Nitriles – Geranyl /Citronellyl Nitrile Aroma chemical 10.0 - 10.0

48 Ionones - GMI,NMI,AI,BI-

Gammanolene Aroma chemical 50.0 - 50.0

49 Geraniol Formate Aroma chemical 05.0 - 05.0

50 Citronellol Formate Aroma chemical 05.0 - 05.0

51 Camphene Aroma chemical 01.0 - 01.0

52 ISO Longifoline Ketone Aroma chemical 01.0 - 01.0

53 Prionyl Aroma chemical 1.0 - 1.0

54 Rosaxanol Aroma chemical 10.0 - 10.0

55 Muganol Aroma chemical 6.0 - 6.0



Note: Mixed Terpenes/Terpene biofuel from CST is taken in addition while DDTO/Carene varities 60,90,98/ Terpene bio fuel is not included in addition because the same is the product of Mixed Terpenes/Terpene biofuel after distillation.

Table 3: Proposed BY- Product details

Sl.No. Products By-Products

Proposed

Quantity

(MT/M)

Utilization

1.

Isobornyl

Cyclohexanol

Aqueous fluoroboric acid

(Fluoboric acid) 43.34

Sale to PCB registered

party

2. Recovered Toluene 128.3 Reuse or Sale to PCB

registered party

3. Recovered catalyst 3.9 Reuse or Sale to PCB

registered party

4. Recovered IPA 22.1 Reuse or Sale to PCB

registered

5. Recovered Methanol 5.0 Reuse or Sale to PCB

registered

6. Column tops 34.9 Sale to PCB registered

party

7. Column bottom mass 41.9 Sale to PCB registered

party

8.

L-Carvone

Recovered cyclohexane 30.0 Reuse or Sale to PCB

registered party

9. Recovered D-Limonene 20.6 Reuse or Sale to PCB

10.

Spent Aq Layer

(Aluminium Sulphate

+IPA)

94.6 Reuse or Sale to PCB

registered party

11. MEK+Butanol recovered 133.0

Separate mixture and

Reuse or Sale to PCB

registered party

12. Column tops 20.1 Sale to PCB registered

party

13. Column bottom mass 22.8 Sale to PCB registered

56 Polysantol (Super Sandal Core) Aroma chemical 2.0 - 2.0

57 Hydrogen 15.0 - 15.0

Total 1820.65 4961.34 6781.99



party

14

2-Butanol (Separated

from MEK + Butanol

mixture)


registered party

15

Floreol

Recovered EDC 22.73 Reuse or Sale to PCB

registered Party

16 DHP 28.05 Reuse or Sale to PCB

registered Party

17 Column Tops 8.64 Reuse or Sale to PCB

registered Party

18 Column Bottom mass 7.45 Reuse or Sale to PCB

registered Party

19

A-Campholenic

Aldehyde

Recovered Toluene 110.3 Reuse or Sale to PCB

registered party

20 Column tops 4.2 Sale to PCB registered

party

21 Column bottom mass 19.7 Sale to PCB registered

party

22 Zinc bromide solution

(16-20%) 8.2


party

23 Sodium Sulphate

decahydrate 25.5


party

24

D-Carvone


registered party

25 Recovered L-Limonene 2.1 Reuse or Sale to PCB

registered party

26

Spent Aq.layer

(Aluminium sulphate

+IPA)


registered party

27 MEK+Butanol rec 13.3



registered party


party




party

30

2-Butanol (recovered

from MEK+Butanol

mixture)


registered party

31

Dihydrocarvone


registered party

32 Recovered EDC 17.4 Reuse or Sale to PCB

registered party


registered party

34 Column Bottom mass 2.9



registered party

35

Carvomenthone

Catalyst recovered 0.05 Reuse or Sale to PCB

registered party

36 IPA recovered 5.19 Reuse or Sale to PCB

registered party

37 Recovered cyclohexane 13.88 Reuse or Sale to PCB

registered party


registered party

39 Column Bottom mass 2.69 Reuse or Sale to PCB

registered party

40 Myrcene Column Bottom mass 1.80 Reuse or Sale to PCB

registered party

41

Nimberol

Spent Aq.Layer (27%

Acid) 3.85


party

42 Recovered Toluene 3.44 Reuse / Sale to PCB

registered party

43 Spent acid layer solution 0.48 Reuse or Sale to PCB

registered party

44 Acetic acid solution (50-

60%) 3.79


party

45 Recovered MPK 2.51 Reuse or Sale to PCB

registered party

46 recovered catalyst 0.01 Sale to PCB registered



party

47 Column Tops 0.61 Sale to PCB registered

party


party

49

Dihydromyrcene

Column Tops 19.5 Reuse / Sale to PCB

registered party

50 Column Bottom mass 32.3 Reuse / Sale to PCB

registered party

51

Sandal fleur &

derivatives

Recovered Cyclohexane 28.8 Reuse / Sale to PCB

registered party

52 Recovered methanol 43.0 Reuse / Sale to PCB

registered party

53 Sodium acetate solution 5.0 Sale to PCB registered

party

54 Sodium Borate solution 15.0 Sale to PCB registered

party


party

56 Column Bottom mass 4.7 Sale to PCB registered

party

57

Sandal Touch

Recovered

MEK+Methanol 45.7

Reuse / Sale to PCB

registered party

58 Spent Aq.Layer

(Pot.acetate) 6.5


party

59 Recovered Catalyst 0.2 Reuse / Sale to PCB

registered party


party


party

62 Recovered 2 -butanol 3.4 Reuse / Sale to PCB

registered party

63

Citronellal

Column Tops 5.9 Reuse / Sale to PCB

registered party


party

65 Recovered catalyst 0.22 Sale to PCB registered



party

66

Cyclocitral (A&B

Mixture)

Aniline recovered 2.0 Reuse / Sale to PCB

registered party

67 Recovered cyclohexane 30.6 Reuse / Sale to PCB

registered party

68 Ammonium sulphate

solution (30-35 %) 47.3


party


party


party

71 Isocitronellene &

Isomer

Column Tops 1.77 Sale to PCB registered

party

72 Column bottom mass 1.24 Sale toMPCB registered

party

73

Citronellyl nitrile

Sodium

sulphate/Ammonium

Sulphate solution (18-28

%)

87.5 Sale to PCB registered

party


party


party

76 White oil residue 8.1 Sale to PCB registered

party

77 A-Pinene from

CST &B-Pinene

from CST &

Limonene from

CST &

Mixed terpenes

from CST OR

DDTO/Carene

60/ 90/98

Terpene bio fuel

Calcium Sulphate OR 181.56 Sale to PCB registered

party

78 Sodium Sulphate OR 189.57 Sale to PCB

registered party

79 CST DMS 85.44 Sale to PCB

registered party

80 CST DMS/DMDS OR 85.44 Sale to PCB registered

party

81

Sodium Sulphide &

Sodium Hydrogen

sulphide solution

250.8 Sale to PCB registered

party

82 Heavy Fractions 105.93 Sale to PCB registered

party



83 Zinc chloride solution 336.43 Sale to PCB registered

party

84 A-Pinene & B-

Pinene (From

GTO)

Dipnetene / Terpene bio

fuel 95.0


registered party

85 Pine tar 51.0 Sale to PCB registered

party

86

Amberfleur


(Fluoboric acid) 109.34


party

87 Spent Phosphoric acid

Layer 42.29


party

88 Recovered Toluene 1.51 Reuse or Sale to PCB

registered party


party


party

91

MI for Soap


party


party

93

Violetone couer


party


party

95

Timber

touch/Timber

forte

Recovered MPK 11.04 Reuse/Sale to PCB

registered party

96 Spent Phosphoric acid 2.32 Reuse/Sale to PCB

registered party

97 Barium hydroxide 1.0 Reuse/Sale to PCB

registered party

98 Recovered Toluene 3.43 Reuse/Sale to PCB

registered party


party


party

101 Recovered Catalyst 0.04 Sale to PCB registered

party



Table 4: Existing By-product details

S.No. By-Products Existing

(MT/M)

Proposed

(MT/M) Utilization

1 Spent Phosphoric Acid

Product- Ionones 2.0 38.2

Sale to PCB

registered party

2. Tops and bottom

Product- Di hydro myrcenol 12.0 17.0

Sale to PCB

registered party

3.

Tops and residue

Products-

A. Ionone

B.Di hydro myrcenol

C. Para Tertiary Butyl Cyclo Hexyl

Acetate(PTBCHA)

D.Ortho Tertiary Butyl Cyclo Hexyl

Acetate(OTBCHA)

E. Terpinyl Acetate

F.Citronellol

G.Geraniol

H. Geranyl Acetate

I. Citronellyl Acetate

J.Timber Touch

10.0 147.3 Sale to PCB

registered party

4. ISO Longifolene

product –Longifolene Ketone 3.0 41.3

Sale to PCB

registered party

5. Spent Sulphuric Acid

product – Dihydromyrcenol 100.0 100.0

Sale to PCB

registered party

6.

Calcium Sulphate

Products-

A. Alpha Pinene

B. Beta Pinene

C. Limonene


registered party

7.

Heavy Fractions

products –

A. Alpha Pinene

B. Beta Pinene

C. Limonene

116.66 116.66 Sale to PCB

registered party

8. Spent Chromium Sulphate

product – Damascone 0.0 75.0

Sale to PCB

registered party



9. Potassium Sulphate


Sale to PCB

registered party

10 MgCl2/Mg(OH)Cl/Mg SO4

solution 0.0 90

Sale to PCB

registered party

11 20%-30 % Ammonium Sulphate


Sale to PCB

registered party

12 Potassium Acetate

product – GPMI 0.0 16.0

Sale to PCB

registered party

13.

spent acetic Acid

product –

A. PTBCHA

B. OTBCHA


registered party

14

Sodium Acetate

product –

A. PTBCHA

B. OTBCHA

C. Geranyl Acetate

D. Citronellyl Acetate

E. Terpinyl Acetate

F. Isobornyl acetate


registered party

7.0 RAW MATERIALS REQUIRED AND STORAGE

Details of raw materials and storage are given below in the table.

Table 5: Action Plan for Consumption, Storage & Transportation of proposed Raw Materials

S.

No Product Raw Materials

Consumpti

on (MT /M) Source Transportation

Storage

Condition

Isobornyl

cyclohexa

nol (IBCH)

1 Camphene 52.71

Self

made/Import/

Domestic

market

Road ways Tank

2 Toluene 135.66 Domestic

market Road ways Tank

3 BF3 etherate 6.2 Domestic

market Road ways Drum



4 Catechol /

Guiacol 72.87

Import/

Domestic

market

Road ways Drum/Bag

5 Sodium

hydroxide 2.52

Domestic

market Road ways Bag

6 Salt 23.64 Domestic


7 Isopropyl

alcohol 3.88

Domestic


8 Catalyst 1.94 Domestic

market Road ways Box

9 Hydrogen 52.71 Domestic

market Road ways Cylinder

10

L-Carvone

D-Limonene 107.09 Domestic


11 Cyclohexane 32.13 Domestic


12 Hydrogen

peroxide 50% 54.62

Domestic


13 PTC 4.28 Domestic


14 Catalyst ST 3.21 Domestic


15 Phosphoric

acid 1.07

Domestic


16 Sodium

Hydroxide 1.07

Domestic


17 CATALYST PBS 2.86 Domestic


18 Sodium

Sulphite 10.71

Domestic


19 AP catalyst 5.19 Domestic


20 Catalyst ZO 5.19 Import/Domesti

c market Road ways Box

21 Aluminium

Isopropoxide 22.32

Import/Domesti

c market Road ways Drum/Tank



22 MEK 135.0 Import/Domesti


23 30 % Sulphuric

Acid 38.41

Domestic




25 Orange oil

& D-

Limonene

Orange oil 138.12 Import/Domesti

c market Road ways Tank

26 Myrcene

Beta -Pinene 402.8

Self

made/Import/

Domestic

market

Road ways Tank

27

Floreol

Isovaleraldeh

yde 59.81

Import/

Domestic

market

Road ways Drum

28 Sulphuric acid 1.79 Domestic


29 Isoprenol 65.79

Import/

Domestic

market

Road ways Drum

30 EDC 23.93

Import/

Domestic

market

Road ways Drum/Tank

31 Sodium

hydroxide 2.33

Domestic


32 A-

Camphole

nic

aldehyde

(ACA)

alpha pinene 57.80

Self

made/Import/

Domestic

market

Road ways Tank

33

Hydrogen

peroxide

(50%)

38.61 Domestic






35

Phenyl

phosphonic

acid

0.91 Domestic




37 Catalyst PBS 1.40 Domestic


38

Sodium

sulphate

anhydrous

1.45 Domestic


39 Sodium

sulphite 0.29

Domestic






42 Zinc Bromide 0.91 Domestic


43

D-

Carvone

L-Limonene 10.7

Self made /

Domestic

market

Road ways Tank



45 Hydrogen

peroxide 50% 5.5

Domestic


46 PTC 0.4 Domestic




48 Phosphoric

acid 0.1

Domestic


49 Sodium

Hydroxide 0.1

Domestic






51 Sodium

Sulphite 1.1

Domestic


52 AP catalyst 0.5 Domestic


53 Catalyst ZO 0.5

Import/

Domestic

market

Road ways Bag

54 Aluminium

Isopropoxide 2.2

Import/Domesti

c market Road ways Box

55 Methyl ethyl

ketone 13.5

Import/Domesti


56 30 % Sulphuric

Acid 3.8

Domestic

market Road ways Drum/Tank



58

Dihydro

carvone

D-Limonene 10.4

Self

made/Import/

Domestic

market

Road ways Tank



60 Hydrogen

peroxide 50% 4.5

Domestic


61 PTC 0.4 Domestic




63 Phosphoric

acid 0.1

Domestic


64 Sodium

Hydroxide 0.2

Domestic




66 Sodium

Sulphite 0.9

Domestic


67 Perchloric

acid 0.01

Domestic




68 EDC 18.3 Domestic




70

Carvomen

thone

Limonene 10.82

Self made/

Domestic

market

Road ways Tank

71 Isopropyl

alcohol 5.41

Domestic








75 Hydrogen

peroxide 50% 6.49

Domestic






78 Phosphoric

acid 0.09

Domestic


79 Sodium

Hydroxide 0.1

Domestic




81 Sodium

Sulphite 0.19

Domestic


82 Perchloric

acid 0.08

Domestic




84 Caustic

solution 0.2

Domestic






86

Nimberol

Citronellal 1.81

Self

made/Domesti

c market

Road ways Drum

87 Acetic

anhydride 2.39

Domestic


88 Triethylamine 1.18 Domestic


89 Sodium

acetate 0.18

Domestic




91 soda ash 0.05 Domestic




93

Ortho

Phosphoric

acid

0.45 Domestic


94 MPK 0.67

Import/

Domestic

market

Road ways Drum

95 Sodium

methoxide 0.13

Import/

Domestic

market

Road ways Bag

96 Acetic acid 0.13 Domestic






99

Dihydrom

yr-cene

Alpha-Pinene 202.1

Self

made/Import/

Domestic

market

Road ways Tank







102

Sandal

fleur &

derivative

A-

Campholenic

aldehyde

22.72

Self

made/Import/

Domestic

market

Road ways Drum

103 Butyraldehyd

e 15.76

Import/

Domestic

market

Road ways Drum



105 Catalyst A 2.98 Domestic




107 30 % HCl 2.39 Domestic


108 Soda ash 0.33 Domestic


109 Sodium

borohydride 1.51

Import/

Domestic

market

Road ways Bag

110 Sodium

hydroxide 0.19

Domestic


111 Methanol 2.65 Domestic


112

Sandal

Touch

A-

Campholenic

aldehyde

6.70

Self

made/Import/

Domestic

market

Road ways Drum

113 MEK 2.11

Import/

Domestic

market

Road ways Tank





116

Salt 0.34 Domestic


117 Acetic acid 1.61 Domestic Road ways Drum



market

118 Potassium

Hydroxide 1.34

Domestic


119 2-butanol 0.20

Self made/

Domestic

market

Road ways Drum

120 Copper

chromite 0.20

Import/

Domestic

market

Road ways Bag



122 Citral

extra pure Citral 30.03

Import/

Domestic

market

Road ways Tank

123

Citronellal

Citral 27.59

Import/

Domestic

market

Road ways Tank




market Road ways Cyclinder





128

Cyclocitra

l (A& B

mixture)

Citral 3.39

Import/

Domestic

market

Road ways Tank

129 Aniline 0.61 Domestic




131 Sulphuric acid 11.9 Domestic

market Road ways Drum/Tank



133 Liq Ammonia 17.5 Domestic




134 Isocitronell

-ylene &

Isomer

DHMOL tops 15.46 Self made Road ways Tank

135 DHM tops 13.95 Self made Road ways Tank

136 DHM bottom

mass 24.45 Self made Road ways Drum

137

Citronellyl

nitrile

Citral 39.13

Import/

Domestic

market

Road ways Tank

138

Hydroxyl

amine

sulphate

22.83 Domestic


139

Soda

ash/Ammonia

solution

22.83 Domestic


140 Sodium

chloride 1.47

Domestic


141 Caustic Soda 0.65 Domestic


142 White oil 2.77 Domestic


143

A-Pinene

from CST &

B-Pinene

from CST &

Limonene

from CST &

Mixed

terpenes

or

DDTO/Car

ene

60/90/98/

terpene

biofuel

Crude

Sulphate

turpentine

(CST Crude)

3050.78 Domestic

market /Import Road ways Tank

144 Lime 98.79 Domestic


145 Sodium

hydroxide 111.12

Domestic


146 Silica 2.2 Domestic

market /Import Road ways Bag

147 Charcoal 2.2 Domestic


148

50 %

Hydrogen

peroxide

67.18 Domestic

market Road ways

Carbouy /

Tank

149 Caustic

solution 5.55 Domestic


150 Nitrogen 320 M3 Domestic Road ways Cyclinder/



market Tank

151

A-Pinene

& B-

Pinene

Gum

turpentine

crude

1032.6

Import/

Domestic

market

Road ways Tank

152

Amberfleu

r

Myrcene 367.5

Self

made/Import/

Domestic

market

Road ways Tank

153 MPO 269

Self made/

Domestic

market

Road ways Tank

154

Boron

trifluoride

etherate

23 Domestic


155 Sodium

chloride (Salt) 3.9

Domestic


156 Antioxidant 0.8 Domestic




158 Phosphoric

acid 42

Domestic


159 Caustic soda 4.5 Domestic


160

Methyl

Ionone for

Soap

NMI crude 5.0

Self made/

Domestic

market

Road ways Drum

161 Violetone

core GMI crude 40.0

Self made/

Domestic

market

Road ways Drum

162

Timber

touch or

Timber

Forte

Citral 5.76

Import/

Domestic

market

Road ways Tank

163 MPK 14.40

Import/

Domestic

market

Road ways Drum

164 Barium

hydroxide 0.69

Import/

Domestic Road ways Bag



market





167 Orthophosph

oric acid 2.27

Domestic






170

Hydrogen 0.17

Self made/

Domestic

market

Road ways Cyclider

171 Catalyst 0.04

Import/

Domestic

market

Road ways Box

8.0 PROCESS DESCRIPTION

Process description with related chemistry per product is given below:

8.1 Isobornyl Cyclohexanol (IBCH) – Capacity 51 MTPM

No Description Details

01 IUPAC NAME 3-(2,3,3-trimethyl-6-bicyclo[2.2.1]heptanyl)cyclohexan-1-ol

4-(1,7,7-trimethyl-6-bicyclo[2.2.1]heptanyl)cyclohexan-1-ol

4-(2,3,3-trimethyl-6-bicyclo[2.2.1]heptanyl)cyclohexan-1-ol

02 CAS NO 3407-42-9,660772-32-0,66068-84-6

03 MT/Month 51 MT

04 MT/Annum 612 MT

Chemical Reaction:



Stage 1:

Stage 2:

Material Balance:

Stage 1:

S.No Input Qty per MT Qty Output Qty Per MT Qty

01 Camphene 1054

Aqueous fluoroboric acid (Fluoboric

acid) 867

02 Toluene 2713 Effluent 1554

03 BF3 etherate 124 Crude weight 5264

04 Catechol / Guiacol 1457 Total 7685

05 Sodium hydroxide 50

06 Water quenching 698

07 water for washing 1589

Total 7685

Distillation:


01 Crude Stage 1

5264

Recovered Toluene 2566

Column Tops 643

Stage 1 Mains 1147

Column Bottom mass 791

Distillation Loss 117

Total 5264 Total 5264



Stage 2

S. No Input Qty per MT Qty Output Qty Per MT Qty

01 Stage 1 Mains 1147 IBCH Crude 1656

02 Isopropyl alcohol 473 Recovered catalyst 78

03 Catalyst 78 Hydrogen loss 3

04 Hydrogen 39 Total 1737

Distillation:

Manufacturing process:

Stage 1& 2

Camphene reacts Catechol or Guiacol in presence of Lewis acid gives Camguiol Crude,

distilled to give Intermediate (Camguiol) which on hydrogenation (Stage 2) in presence of

catalyst gives IBCH crude and Methanol and distilled to give IBCH product.


01 IBCH crude

1656

Recovered IPA 442

Recovered Methanol 101

Column Tops 54

Product 1000


Loss 12




Process Flow diagram for Manufacturing of – IBCH

8.2 L-Carvone – Capacity 50 MTPM

S.No Description Details

01 IUPAC NAME 2-Methyl-5-(1-methylethenyl)-2-cyclohexenone

02 CAS No 6485-40-1

03 MT/Month 50 MT

04 MT/Annum 600 MT



Chemical Reaction

Stage 1:

Stage 2:

Stage 3:

Material Balance:

Stage 1


01 D-Limonene 2142 Effluent 3790

02 Cyclohexane 643 D-Limonene epoxide Crude 3027

03 Hydrogen peroxide 50% 1092 Total 6817

04 PTC 86

05 Catalyst ST 64

06 Phosphoric acid 21

07 Sodium Hydroxide 21

08 Catalyst PBS 57

09 Sodium Sulphite 214

10 Water for quenching 1292

11 Water for Work up 1185



Total 6817

Distillation:

Stage 2


1 Limonene epoxide Mains 2142 D-Carveol crude 2350

2 AP Catalyst 104 Total 2350

3 Catalyst ZO 104

Total 2350

Distillation:

Stage 3


1 Limonene epoxide

crude

3027

Recovered cyclohexane 600

Limonene epoxide Mains 2210

Column bottom mass 164


Total 3027

Total

3027


1 D-Carveol crude 2350

Recovered D-Limonene 413

Column Tops 191

D-Carveol Mains 1349



Total

2350

Total

2350


01

D-Carveol 1349

Spent Aq Layer

(Aluminium Sulphate

+IPA) 1893

02 Aluminium Isopropoxide 446 Effluent 1079

03 Methyl Ethyl Ketone (MEK) 2699 MEK+Butanol rec 2664



Distillation:

Manufacturing Process

Stage1:

D-Limonene (Distilled from Orange oil) undergoes epoxidation with Hydrogen peroxide gives

Crude D-Limonene epoxide crude which subjected to Distillation gives D-Limonene epoxide

product

Stage 2:

D-Limonene epoxide undergoes rearrangement to D-Carveol crude which subjected to

distillation gives D-Carveol.

Stage 3:

D-Carveol undergoes Oxidation in presence of Aluminium Isopropoxide and Methyl Ethyl Ketone

gives L-Carvove crude, which subjected to distillation, gives L-Carvone Product

04 30 % Sulphuric Acid 768 L-Carvone crude 1349

05 Water for quenching 675 Total 6985

06 Water for neutralization 1010

07 Salt 38

Total 6985


1 L-Carvone crude

1349

Column Tops 211

L-Carvone Mains 1000



Total

1349

Total

1349



Process Flow diagram for Manufacturing of L-Carvone

8.3 D-Limonene and Orange Oil Fold

Capacity-D-Limonene- 125 & Orange Oil Folds- 12 MTPM

S.No Description Details 1 IUPAC NAME ------ 2 MT/Month D-Limonene – 125 & Orange oil folds 12 3 MT/Annum D-Limonene – 1500 & Orange oil folds 140

Chemistry

Orange oil is a mixture of D-Limonene and Other aldehydes and alcohols. Major componenet is

D-Limonene and rest is aldehydes and traces of alcohols.



Distillation of Orange oil gives D-Limonene and rest fraction blending gives Orange oil folds.

Material Balance Distillation:

Process Flow diagram for Manufacturing of D-Limonene and Orange Oil Folds

8.4 Myrcene – Capacity 400 MTPM


1 IUPAC NAME 7-Methyl-3-methylene-1,6-octadiene

2 CAS.No 123-35-3

3 MT/Month 400

4 MT/Annum 4800


1 Orange oil 1105

D-LIMONENE 1000 Orange oil fold (Tops & Bottom) 94 Distillation loss 11 Total 1105

Total 1105



Chemical Reaction

Material Balance

Distillation:

Manufacturing Process Beta- Pinene undergoes rearrangement (By thermolysis) at high temperature gives Myrcene

Process Flow diagram for manufacturing of Myrcene

8.5 Floreol – Capacity 80 MTPM

S. No Input Qty per

MT

Qty Output Qty Per MT Qty

1 Beta – Pinene

1007

Myrcene 1000

Bottom mass 4.5

Vapour loss 2.5

Total 1007

Total 1007


01 IUPAC NAME 2-Iso-butyl-4-hydroxy-4-methyltetrahydropyran

02 CAS No 63500-71-0

03 MT/Month 80 MT

04 MT/Annum 960MT



Chemical Reactions

Material Balance:


1 Isovaleraldehyde 748 Effluent 126

2 Sulphuric acid 22 Floreol crude 1869

3 Isoprenol 822 Total 1995

4 EDC 299

5 Water 75


Total 1995

Distillation:

Manufacturing Process:

Cycloaddition of Isovaleraldehyde and Isoprenol in presence of acid gives Floreol crude which

subjected to distillation gives Floreol product.


1 Floreol crude

1869

EDC recovered 284

Column tops 108

DHP 351

Floreol product 1000


Loss 33




Process Flow diagram for manufacturing of Floreol

8.6. Alpha-Campholenic Aldehyde – Capacity 50 MTPM

S. No Description Details

1 IUPAC NAME 1-(2,2,3-trimethyl-1-cyclopent-3-enyl)ethanone

2 CAS No 4501-58-0 , 42370-35-4

3 MT/Month 50 MT

4 MT/Annum 600 MT

Chemical Reactions

Stage 1 & Stage 2

Material Balance:



Stage 1


01 alpha pinene 1156 Effluent 1419

02 Hydrogen peroxide (50%) 772 A-Pinene epoxide crude 1335

03 Catalyst ST 75 Total 2754

04 Phenyl phosphonic acid 18

05 PTC 92

06 Catalyst PBS 28

07 Sodium sulphate anhydrous 29


09 water for washing 462

10 Salt 6

Total 2754

Distillation:

Stage 2


1 A-Pinene epoxide 1137 A-Campholenic aldehyde crude 3410


3 Catalyst 22 Total 3751

4 Water 318

Total 3751

Distillation


1 A-Campholenic

aldehyde crude 3410


Column Tops 84


1 A-Pinene epoxide

crude

1335

Recovered A-Pinene 66

A-Pinene epoxide Mains 1137


Loss 21

Total 1335

Total

1335



A-Campholenic Aldehyde 1000


Loss 35

Total 3410

Total 3410


Stage1:

Alpha- Pinene undergoes epoxidation with Hydrogen peroxide gives Crude A-Pinene epoxide

crude which subjected to Distillation gives A-Pinene epoxide product

Stage 2:

A-Pinene epoxide undergoes rearrangement to gives Alpha-Campholenic aldehyde crude

which subjected to distillation gives Alpha-Campholenic aldehyde.

Process Flow diagram for manufacturing of Alpha-Campholenic Aldehyde



8.7 D-Carvone – Capacity 5 MTPM


1 IUPAC NAME 5-Isopropenyl-2-methyl-2-cyclohexenone

2 CAS No 2244-16-8

3 MT/Month 5 MT

4 MT/Annum 60 MT

Chemical Reactions

Stage 1

Stage 2

Stage 3



Material Balance:

Stage 1


1 L-Limonene 2142 Spent Aq.Layer 2345

2 Cyclohexane 643 Effluent 2038

3 Hydrogen peroxide 50% 1092 L-Limonene epoxide crude 3027

4 PTC 86 Total 7410

5 Catalyst ST 64



8 Catalyst PBS 57




12 Total 7410

Distillation:

Stage 2


1 L-Limonene Epoxide

Mains 2142

L-Carveol crude 2350

2 AP catalyst 104 Total 2350

3 Catalyst ZO 104

Total 2350


1 L-Limonene epoxide

crude

3027


L-Limonene epoxide Mains 2210



Total 3027

Total

3027



Distillation:

Stage 3

Distillation:

S. no Input Qty per MT Qty Output Qty Per MT Qty

1 L-Carveol crude 2350

Recovered D-Limonene 413

Column Tops 191

L-Carveol Mains 1349



Total

2350

Total 2350


1

L-Carveol

1349

Spent Aq Layer

(Aluminium

Sulphate +IPA)

1907

2 Aluminium Isopropoxide 446 Effluent 1443

3 MEK 2699 MEK+Butanol rec 2661

4 30 % Sulphuric Acid 768 D-Carvone crude 1349



7 Salt 39

Total 7360


1 D-Carvone crude

1349

Column Tops 211

D-Carvone Mains 1000



Total

1349

Total

1349




Stage1:

L-Limonene undergoes epoxidation with Hydrogen peroxide gives Crude L-Limonene epoxide

crude which subjected to Distillation gives L- Limonene epoxide product

Stage 2:

L-Limonene epoxide undergoes rearrangement to gives L-Carveol crude which subjected to

distillation gives Carveol.

Stage 3:

Carveol undergoes Oxidation in presence of Aluminium Isopropoxide and Methyl Ethyl Ketone

gives D-Carvove crude, which subjected to distillation, gives D-Carvone Product.

Process Flow diagram for manufacturing of D-Carvone



8.8. Dihydrocarvone – Capacity 5 MTPM


1 IUPAC NAME 2-Methyl-5-prop-1-en-yl cyclohexan-1-one

2 CAS No 7764-50-3

3 MT/Month 5 MT

4 MT/Annum 60 MT

Chemical Reactions

Stage 1

Stage 2

Material Balance

Stage 1


1 D/L-Limonene 2071 Spent Aq.Layer 1944


3 Hydrogen peroxide 50% 905 Limonene epoxide Crude 2509

4 PTC 71 Total 6290

5 Catalyst ST 53





08 CATALYST PBS 47




Total 6290

Distillation:

Stage 2


1 Limonene Epoxide Mains 1831 Dihydrocarvone crude 5494

2 Perchloric acid 3 Effluent 933

3 Ethylene dichloride (EDC) 3663 Total 6427

4 Caustic solution 21

5 Salt 21

6 Water for washing 888

Total 6427

Distillation:


1 Limonene epoxide

Crude

2509


Limonene epoxide Mains 1831



Total 2509

Total

2509


1 Dihydrocarvone

crude

5494

Recovered EDC 3473

Column Tops 269

Dihydrocarvone Mains 1000



Total

5494

Total 5494




Stage1:

D/L-Limonene undergoes epoxidation with Hydrogen peroxide gives Crude D-Limonene epoxide

crude which subjected to Distillation gives Limonene epoxide product

Stage 2:

Limonene epoxide undergoes rearrangement to Dihydrocarvone crude which subjected to

distillation gives Dihydrocarvone

Process Flow diagram for manufacturing of Dihydrocarvone



8.9. Carvomenthone – Capacity 5 MTPM


1 IUPAC NAME 2-Methyl-5-propan-2yl-cyclohexanone or 5-Isopropyl-2-

methylcyclohexanone

2 CAS No 499-70-7 & 59471-80-6

3 MT/Month 5 MT

4 MT/Annum 60 MT

Chemical Reactions:

Stage 1

Stage 2

Stage 3



Material Balance:

Stage 1


1 Limonene 2164 Recovered catalyst 3278

2 IPA 1082 1-p-Menthene Crude 11


4 Hydrogen 32

5 Total 3289

Distillation:

Stage 2


1 1-p-menthene 1855 Spent Aq.Layer 2237


3 Hydrogen peroxide 50% 1299 p-Menthane epoxide Crude 2325

4 PTC 74 Total 5703

5 Catalyst ST 56



8 CATALYST PBS 37




Total 5703


1 1-p-Menthene

Crude

3278

Recovered IPA 1039

Column tops 287

1-p-Menthene 1855


Distillation loss 32

Total

3278 Total 3278



Distillation:

Stage 3

Distillation:


Stage1:

Limonene undergoes hydrogenation in presence of catalyst to give 1-Para-Menthene crude ,

which subjected to distillation gives 1-para-Menthene.


1 p-Menthane epoxide

Crude 2325


Column tops 232

p-Menthane epoxide Mains 1646



Total

2325 Total 2325


1 P-Menthane Epoxide Mains 1646 Carvomenthone crude 4495

2 Perchloric acid 17 Effluent 961

3 Cyclohexane 2848 Total 5456

4 Caustic solution 11

5 Salt 6


Total 5456


1 Carvomenthone

crude 4495

Recovered Cyclohexane 2776

Column Tops 310

Carvomenthone 1000



Total

4495 Total 4495



Stage2:

1-P-Menthene undergoes epoxidation with Hydrogen peroxide to give Crude 1-P-Menthane

epoxide crude which subjected to Distillation gives 1-p-Menthane epoxide product

Stage 3:

1-p-menthane epoxide undergoes rearrangement to give Carvomenthone crude which

subjected to distillation gives Carvomenthone product.

Process Flow diagram for manufacturing of Carvomenthone



8.10. Nimberol – Capacity 01 MTPM


1 IUPAC NAME 1-(2,2,6-Trimethyl Cyclohexyl)-hexan-3-ol

2 CAS No 70788-30-6

3 MT/Month 01 MT

4 MT/Annum 12 MT

Chemical Reactions:

Stage 1A

Stage 1B

Stage 2

Stage 3



Material Balance

Stage 1A


01 Citronellal 1806 Spent Aq.Layer (27% Acid) 3847

02 Acetic anhydride 2393 Effluent 1651

03 Triethylamine 1185 CAL Diacetate Crude 6605

04 Sodium acetate 181 Total 12103

05 Toluene 3612

06 soda ash 27



09 Salt 9

Total 12103

Stage 1B


01 CAL Diacetate crude 6605 Spent acid layer solution 484

02 Ortho Phosphoric acid 452 acetic acid solution (50-60%) 3794

03 Soda ash 27 DCC crude 5109

04 Sodium chloride 181 Effuent 948

05 water for Hydrolysis 2167 Total 10335

06 water for neutralization 903

Total 10335

Distillation:


1 DCC crude 5109


Column Tops 128

DCC Mains 1279



Total 5109

Total 5109



Stage 2


01 DCC mains 1279 Recovered MPK 2507

02 MPK 3180 Aq.layer (Sodium acetate solution) 1621

03 Sodium methoxide 128 Effluent 752

04 Acetic acid 131 DNEI Crude 1833

05 Sodium chloride 57 Loss 29



Total 6742

Distillation:

S

t

a

Stage 3


01 DNEI mains 1195 Recovered catalyst 11

02 Hydrogen 26 Nimberol Crude 1216

03 Catalyst 11 Hydrogen loss 5


Distillation:


1 DNEI crude 1833

Column Tops 348

DNEI Mains 1195



Total 1833

Total 1833


1 Nimberol crude 1216

Column Tops 134

Nimberol Mains 1000


Distillation loss 8

Total 1216

Total 1216




Stage1A:

Citronellal reacts with acetic anhydride in presence of Triethyl amine and Toluene as solvent

gives Citronellyl Diacetate crude

Stage1B:

Citronellyl diacetate undergoes cyclisation in presence of Phosphoric acid followed by hydrolysis

gives acetic acid and Dihydrocyclocitral crude which on distillation gives Dihydrocyclocitral

product

Stage 2:

Dihydrocyclocitral product undergoes condensation with MPK in presence of base catalyst

gives DNEI crude which subjected to distillation gives DNEI mains.

Stage 3;

Hydrogenation of DNEI gives Nimberol crude which subjected to distillation gives Niberol product

Process Flow diagram for manufacturing of Nimberol



8.11 Dihydromyrcene (DHM) – Capacity 150 MTPM


1 IUPAC NAME 3,7-dimethylocta-1,6-diene

2 CAS No 2436-90-0

3 MT/Month 150 MT

4 MT/Annum 1800 MT

Chemical Reactions:

Stage 1

Stage 2

Material Balance

Stage 1


01 Alpha-Pinene 1347 Recovered catalyst 1

02 Hydrogen 20 Cis-Pinane Crude 1367


Total 1368

Stage 2


01 Cis-Pinane 1367 DHM crude 1362



Loss 5


Distillation:


Alpha-Pinene undergoes hydrogenation in presence Hydrogen and catalyst to give Cis-Pinane.

Cis-Pinane undergoes rearrangement (by pyrolysis) at high temperature to

Diydromyrcene(DHM) crude which is subjected to distillation gives Dihydromyrcene (DHM) mains

Process Flow diagram for manufacturing of Dihydromyrcene


1 DHM crude 1362

Column Tops 130

DHM Mains 1000


Loss 17

Total 1362

Total 1362



8.12 Sandal Fleur & Derivatives– Capacity 20 MTPM


1 IUPAC NAME 2-Ethyl-4-(2, 2, 3-Trimethyl-3-Cyclopenten-1-yl) 2-Buten-1-ol

2 CAS No 28219-61-6

3 MT/Month 20 MT

4 MT/Annum 240 MT

Chemical Reactions:

Stage 1

Stage 2

Material Balance

Stage 1


01 A-Campholenic aldehyde 1136 Recovered Cyclohexane 1441

02 Butyraldehyde 788 Spent Aq.Layer 672


04 Catalyst A 149 CABAL Crude 1824

05 Acetic acid 119 Loss 37

06 30 % HCl 119 Total 4680

07 Soda ash 26


09 Water for neutralisation 568

Total 4680



Distillation:

Stage 2


01 Cabal mains 1143 Recovered methanol 2152

02 Sodium borohydride 76 Effluent 1790

03 Sodium hydroxide 10 Sandal fleur Crude 1173

04 Acetic acid 152 Total 5115

05 Methanol 2286

06 Soda ash 19


08 Water for neutralisation 1048

Total 5115

Distillation:


1 CABAL crude 1824

Column Tops 497

Cabal Mains 1143



Total 1824

Total 1824


1 Sandal fleur crude 1173

Column Tops 69

Sandal fleur Product 1000



Total 1173

Total 1173




A-Campholenic aldehyde undergoes aldol reaction with Butyraldehyde in presence of weak

base to and Cyclohexane as solvent gives CABAL crude which is subjected to distillation give

CABAL mains.

Reduction of CABAL mains by using Sodium Borohydride in presence of methanol and water

gives Sandal fleur crude which is subjected to distillation gives Sandal fleur Products.

Process Flow diagram for manufacturing of Sandal Fleur & Derivatives



8.13. Sandal Touch– Capacity 05 MTPM


1 IUPAC NAME 5-2,2,3-Trimethyl-3-cyclopentenyl)-3-methylpentan-2-ol

2 CAS No 65113-99-7

3 MT/Month 05 MT

4 MT/Annum 60 MT

Chemical Reactions:

Stage 1

Stage 2:

Material Balance:

Stage 1


01 A-Campholenic aldehyde 1340 Recovered MEK+Methanol 9139

02 MEK 1005 Spent Aq.Layer (Pot.acetate) 1303

03 Methanol 8780 Effluent 2332

04 Soda ash 13 CAMEK Crude 1702

05 Salt 67

06 Acetic acid 322 Total 14476

07 Potassium Hydroxide 268


09 Water 2011

Total 14476



Distillation:

Stage 2


01 Camek 1214 Copper chroimite rec 40

02 2-butanol 729 Crude 1975.33

03 Copper chromite 40 Total 2015.33

04 Hydrogen 32

05 Methanol 0.3

06 soda ash 0.03

Total 2015.33

Distillation:


A-Campholenic aldehyde undergoes aldol condensation with MEK in presence of base and

Methanol as solvent to give CAMEK crude which is subjected to give CAMEK mains.

CAMEK mains undergoes hydrogenation in presence of catalyst and 2-Butanol as solvent to give

Sandal Touch crude which is subjected to distillation to give Sandal Touch product


1 CAMEK Crude 1702

Column Tops 265

CAMEK Mains 1214



Total 1702

Total 1702


1 Sandal Touch crude 1975.33

Recovered 2 -butanol 689

ColumnTops 166

Sandal Touch Mains 1000

Column bottom mass 91.33


Total 1975.33

Total 1975.33



Process Flow diagram for manufacturing of Sandal Touch

8.14 Citral Extra Pure – Capacity 30 MTPM


1 IUPAC NAME 3,7-DIMETHYL-2,6-OCTADIENAL

2 CAS No 5392-40-5

3 MT/Month 30 MT

4 MT/Annum 360 MT



Material Balance:

Stage 1


01 Citral 1000.1 Citral extra Pure 1000

Loss 0.1

Total 1000.1 Total 1000


Citral is purged with Nitrogen to improve the odour & filtered to get Citral extra pure .

Process Flow diagram for manufacturing of Citral extra Pure

8.15 Citronellal– Capacity 20 MTPM

S. No Description Details 1 IUPAC NAME 3,7-DIMETHYL-2,6-OCTADIENAL 2 CAS No 106-23-0 3 MT/Month 20 MT 4 MT/Annum 240 MT

Chemical Reactions:



Material Balance: Stage 1

S No Input Qty per MT Qty Output Qty Per MT Qty 01 Citral 1379 Catalyst recovered 11 02 Catalyst 11 CAL Crude 1414 03 Hydrogen 23 Total 1425 04 Methanol 10 05 soda ash 2

Total 1425

Distillation:

Process Flow diagram for manufacturing of Citronellal


1 CAL Crude 1414

Column Tops 294 Citronellal Product 1000 Column bottom mass 90 Distillation loss 30




8.16. Cyclocitral– Capacity 02 MTPM


1 IUPAC NAME Cyclocitral

2 CAS No 432-25-7

3 MT/Month 02 MT

4 MT/Annum 24 MT

Chemical Reactions:

Stage 1

Stage 2

Aniline recovery:

Material Balance

Stage 1


01 Citral 1694 Effluent 208

02 Aniline 1093 Anitral Crude 4765

03 Cyclohexane 2186




Stage 2


01 Anitral crude 4765

Spent Aq. Layer (Aniline sulphate

solution) 15885


03 Sulphuric acid 5956 Cyclocitral crude 17175

04 water for digestion 8934 Total 36922

05 soda ash 273

06 water for neutralisation 3415

Total 36922

Distillation:

Recovery of Aniline from Spent acid layer


01 Spent acid layer 15885 Aniline recovered 984

02 Liq Ammonia 8743 Ammonium sulphate solution (30-35 %) 23644

Total 24628

Total 24628


Citral reacts with aniline forms adduct (Anitral), which undergoes cyclisation and hydrolysis gives

Cyclocitral (A & B) and Aniline sulphate.

Aniline sulphate neutralized with liquid ammonia gives Aniline and Ammonium sulphate.


1 Cyclocitral crude 17175


Column Tops 251

Cyclocitral product 1000



Total 17175

Total 17175



Process Flow diagram for manufacturing of Cyclocitral

8.17 Isocitronellene & Isomer – Capacity 30 MTPM


1 IUPAC NAME ISOCITRONELLENE;Einecs 285-035-1;(R)-5,7-dimethylocta-

1,6-diene;R(+)-5,7-DIMETHYL-1,6-OCTADIENE

2 CAS No 85006-04-8

3 MT/Month 30 MT

4 MT/Annum 360 MT



Material Balance:

Stage 1

Distillation:


Isocitronellene Isomer is prepared from Blending of DHMOL tops (contains small qty of DHMOL,

other terpenes) and DHM tops & Bottom mass also contains Isocitronellene & other terpenes. The

bled is distilled to remove tops & other fractions are blended to get Isocitronellene Isomer.

Process Flow diagram for manufacturingg of Isocitronellene & Isomer


01 DHMOL tops 309 Mixture blend 1077

02 DHM tops 279 Total 1077

03 DHM bottom mass 489

Total 1077


1 Mixture blend 1077

Column Tops 35

Isocitronellene & Isomer Product 1000



Total 1077

Total 1077



8.18 Citronellyl Nitrile – Capacity 30 MTPM


1 IUPAC NAME 3,7-Dimethyl-6-octenenitrile

2 CAS No 51566-62-2

3 MT/Month 30 MT

4 MT/Annum 360 MT

Chemical Reactions:

Stage 1

Stage 2

Material Balance:

Stage 1


01 Citronellal 1304 Sodium sulphate solution (18-28 %) 2915

02 Hydroxyl amine sulphate 761 Effluent 701

03 Soda ash 761 Carbon dioxide 158

04 Sodium chloride 49 Citral oxime Crude 1492


06 Water for washing 652 Total 5266

Total 5266



Stage 2


01 CAL oxime crude 1492 CN rapid mains 1120

02 Caustic soda 22 Reaction bottom mass 293

03 white oil 92 Water generated during process 151

Loss 42


Distillation:


Citronellal reacts with Hydroxylamine sulphate in presence of Sodium carbonate gives CAL

Oxime crude. CAL oxime undergoes dehydration in presence of Sodim hydroxide at particular

temperature gives Citronellyl nitrile which is subjected to distillation gives Citronellyl nitrile.


1 CN rapid mains 1120

Column Tops 43

Citronellyl nitrile Product 1000



Total 1120

Total 1120



Process Flow diagram for manufacturing of Citronellyl Nitrile

8. 19 A-Pinene & B-Pinene & Limonene & Mixed Terpenes or DDTO/Carene 60 / Carene 90/Carene98/ Terpene biofuel (From CST crude) – 1611.66 & 504.86 &41.32 & 744 or 679.15 Capacity MTPM

S. No Description Details 1 IUPAC NAME Mixture 2 CAS No Mixture

Brief description:

CST is collected as by-product from pine wood based paper mills. Various paper mills

collect the separated oil during its pulp making and store in the tanks for disposal.

Depending on the season, nature and species of wood the composition of the oil varies

quite a bit in its Alpha & Beta Pinene & Other Terpenes content and also in its impurity

levels. It contains very small amount of dissolved & volatile sulfides like Dimethyl Sulfide

and Dimethyl Disulfide etc.

CST contain different sulfurous impurities and it is essential to remove these impurities

totally (as low as 1 ppm) because the Alpha & Beta Pinene are further processed for

hydrogenation and are used to make perfumery ingredients.

Continuously sulphur compounds removed from Stripper column (C1) lower sulfides like

Dimethyl sulphide etc collected & sold as CST DMS or Stripper vapour passed to

Incinerator followed by scrubber which is burnt immediately and subsequent scrubbing

after heat recovery of the gases. The generated Sulphur dioxide gas absorbs in scrubber



which contains Lime (Calcium hydroxide)/Sodium hydroxide solution to form Calcium

sulphate / Sodium sulphate .

The stripped CST called TCST is cooled & treated with Sodium hydroxide solution & Stored

in storage tank for further processing.

TCST crude is feed to C2 Column (A-Pinene) from top A-Pinene collected & from bottom

Beta -450 collected (B-Pinene, Carene, limonene etc) & stored in tank for further

purification.

Beta-450 is feed to C3 column from top B-Pinene collected & from bottom Limonene 350

collected ( Carenes ,limonene & other terpenes) & stored in tank for further processing.

Mixed Terpenes is feed to distillation column & to get DDTO (Mixture of Carene, limonene

& other terpenes), further purification to get Carene 60/Carene90

Treatment

A-Pinene treatment to remove sulphur below 1PPM,1st process A-Pinene treated with Zinc

chloride , cooled washed with caustic solution & feed to Silica column followed by

charcoal column & stored for further processing.

B-Pinene & Mixed Terpenes treatment to remove sulphur is treatment of hydrogen

peroxide, cooled, washed & crude feed to distillation column to get Beta-Pinene

product & DDTO/Carene 60 / Carene 90 /98/Terpene biofuel product.

Material Balance:

CST DMS

OR

118.67 Kg/hr Tops Incinerator Scrubber 127/137 kg/hr Lime or NaOH

Spray Dryer 233/244 kg/hr CaSO4/Na2SO4

4118.53 Kg/hr TCST Crude

CST Crude 4237.20 Kg/hr

Alkali washing

10.45 Kg/hr Column tops

2239.83 Kg/hr A‐Pinene

TCST Bottom 4118.53 Kg/hr 1868.25 Kg/hr Beta 450

17.24 Kg/hr Column tops

Beta 450 1868.25 Kg/hr 706.10 Kg/hr B‐Pinene

1144.91 Kg/hr Mixed Terpenes

1033.38 Kg/hr Mixed Terpenes mains

Mixed Terpenes 1144.91 Kg/hr 111.53 Kg/hr Column Bottom mass

Stripper C1

Column

A‐Pinene C2

Column

B‐Pinene C2

Column

Distillation

CST CRUDE PROCESSING



A‐Pinene (32 PPM) 53755.97 Kg

ZnCl2 213.26 Kg

20 % Caustic soltion 721.00 Kg 53755.71 Kg A‐Pinene

934.52 Kg Zinc Hydroxide solution

A‐Pinene 53755.71 Kg/hr 53755.71 Kg/hr A‐Pinene

53755.71 Kg/hr A‐Pinene

A‐Pinene 53755.71 Kg/hr

Nitrogen 320 m3/M 320 m3/M Nitrogen

Regeneration of Silica & Charcoal Column by Using Nitrogen

Silica/Charcoal

Column

A‐Pinene Treatment (Sulphur reduction)

Charcoal

column

Neutralisation

Sulphur

reduction

Reactor

Silica column



B‐Pinene 16946.06 Kg

H2O2 831.26 Kg

Caustic solution 72.18 Kg 16946.06 Kg B‐Pinene crude

Water 333.25 Kg 1236.70 Kg Aq.layer used for Scrubber

45.01 Kg Column Tops

16828.69 Kg B‐Pinene

B‐Pinene crude 16946.06 67.08 Kg Column bottom mass

5.28 Kg Distillation Loss

B‐Pinene Treatment (Sulphur reduction)

Sulphur

reduction

Reactor

Neutralisation

Distillation



Mixed Terpenes 24801.15 Kg

H2O2 1407.83 Kg

Caustic solution 112.62 Kg 24801.15 Kg Mixed Terpenes crude

Water 623.95 Kg 2144.41 Kg Aq.layer used for Scrubber

Mixed Terpenes crude 24801.15 Kg

1377.20 Kg Limonene

742.11 Kg Column Bottom mass

43.38 Kg Distillation Loss

Distillation

Sulphur

reduction

Reactor

Neutralisation

Mixed Terpenes Treatment (Sulphur reduction)

22638.34

DDTO/Carene 60/90/98

Note: Mixed terpene crude distillation based on requirement of DDTO/Carene 60/90/98 or Terpene biofuel

8.20 A-Pinene & B-Pinene (From GTO) – Capacity 537.0 & 334.0 MTPM


1 IUPAC NAME 2,6,6-Trimethylbicyclo[3.1.1]hept-2-ene &

BICYCLO[3.1.1]HEPTANE; 6,6-DIMETHYL-2-METHYLENE

2 CAS No 80-56-8 & 18172-67-3

3 MT/Month 537 & 334

4 MT/Annum 6444 & 4008



Material Balance:

Stage 1

S.No Input Qty per MT Qty

01 Gum turpentine crude

(GTO) 1033

Total 1033

Distillation:


Gum turpentine oil is a mixture of alpha-Pinene, beta-Pinene and mixture of Dipentene (mixture

of Limonene, Terpinolene, other Terpenes) subjected to distillation gives Alpha-Pinene, and Beta-

pinene and Dipentene and Pine tar.

Figure 6.19: Process Flow diagram for manufacturing of A-Pinene & B-Pinene


1 GTO 1033.0

A-Pinene 537

B-Pinene 334

Dipentene 95

Pine tar 51


Total 1033.0 Total 1033



8.21 Methyl Ionone (MI) FOR SOAP– Capacity 01 MTPM


1 IUPAC NAME 1-(2,6,6-trimethyl-1-cyclohex-2-enyl)pent-1-en-3-one

2 CAS No i) 1335-46-2

3 MT/Month 01MT

4 MT/Annum 12 MT

Material Balance:

Stage 1

S. No Input Qty per MT Qty

01 NMI crude 2513

Total 2513

Distillation:


NMI crude or MI crude subjected to distillation gives NMI product / MI product along with Methyl

Ionone for soap (MI for Soap) product.


1 NMI crude 2513

Column Tops 156

NMI 1131

MI for soaps product 1000






Process Flow diagram for manufacturing of Methyl Ionone (MI)

8.22 Violetone Couer – Capacity 02 MTPM


1 IUPAC NAME 4-(2,6,6-Trimethyl-2-cyclohexen-1-yl)-3-buten-2-one

2 CAS No ii) 127-51-5

3 MT/Month 02 MT

4 MT/Annum 24 MT

Material Balance:

Stage 1

S. No Input Qty per MT Qty

01 GMI crude 20000

Total 20000

Distillation:


1 GMI crude 20000

Column Tops 600

Violetene couer 1000

GMI mains 16800







GMI crude subjected to distillation gives GMI product along with Viletone couer product (High

Gamma methyl Ionone percentage)

Process Flow diagram for manufacturing of Violetone Couer

8.23 Amberfleur– Capacity 400 MTPM


1 IUPAC NAME (1,2,3,4,5,6,7,8-octahydro-2,3,8,8-tetramethyl-2-

naphthalenyl)-ethan-1-one

2 CAS No iii) 54464-57-2

3 MT/Month 400 MT

4 MT/Annum 4800 MT

Chemical Reaction:




Stage1:

Myrcene undergoes Diels-Alder reaction with MPO gives PCM crude which subjected to

Distillation gives PCM product (Intermediate)

Stage 2:

PCM product undergoes cyclisation in presence of acid catalyst gives Amberfleur crude which

subjected to distillation gives Amberfluer.

Note;

Amber fleur product is manufactured at Unit 1, blending, packing and sale (dispatch) from uint -

2. So no production activity of Amberfleur on plot no. C-3/4/5/6, 6/1, 8, 9 and C33/1, X-9, X-10, X-

11 hence no water input / effluent is generated.

Material Balance:

Stage 1


01 Myrcene 919


(Fluoboric acid) 273

02 MPO 672 Effluent 1350

03 Boron trifluoride etherate 57 PCM crude 1571

04 Salt 6 Total 3194

05 Antioxidant 2



Total 3194

Distillation:


1 PCM Crude

1571

PCM Tops 283

PCM Mains 1099

Column Bottom 161


Total 1571

Total 1571



Stage 2


01 PCM Mains 1099 Amberfleur crude 1388

02 Toluene 290 Spent Phosphoric acid Layer 106

03 Phosphoric acid 105 Effluent 1004

04 Water 989 Total 2498

05 Caustic soda 11

06 Salt 4

Total 2498

Distillation:


1 AF crude 1388


Column Tops 39

Amberfleur 1000

Column Bottom 56

Loss 14

Total 1388

Total 1388



Process Flow diagram for manufacturing of Amberfleur

8.24 Timber Touch / Timber forte – Capacity 05 MTPM


1 IUPAC NAME 1-(2,2,6-Trimethyl Cyclohexyl)-hexan-3-ol

2 CAS No 70788-30-6

3 MT/Month 05 MT

4 MT/Annum 60 MT

Project: PrDeveloper:

Green Cir

Chemica

Stage 1

Stage 2

Stage 3

Material

Stage 1

S

0

0

0

0

0

0

0

roposed ExpansM/s. Privi Org

cle, Inc.

al Reactions:

Balance

S.No Inp

01 Citr

02 MP

03 Bar

04 Ace

05 wa

06 Sod

07 Tota

sion & Additionganics Ltd.

:

ut Qty per M

ral

K

rium Hydroxid

etic acid

ter

dium chloride

al

n of Aroma Che

Pre

MT Q

11

28

de 13

40

92

e 2

51

emical Manufac

e Feasibility Re

Qty Outp

152 Reco

879 Efflue

38 NPEI

0 Loss

21 Total

132

cturing Capacit

eport

put Qty Per M

overed MPK

ent

crude

ty in Unit II

MT Qty

2209

1243

1659

21

5132

86



Distillation:

Stage 2


01 NPEI 1288 Spent Phosphoric acid 463

02 Phosphoric acid 454 NEI crude 2009


04 Soda ash 17 Total 3364

05 Water 884

06 Salt 2

Total 3364

Distillation:


1 NPEI crude 1659

Column Tops 160

NPEI Mains 1288



Total 1659

Total 1659


1 NEI crude 2009

Recovered toluene 687

Column Tops 73

NEI Mains 1158






Stage 3


01 NEI mains 1158 Recovered catalyst 7.4

02

Hydrogen 33

Timber touch/Forte Crude 1189

03 Catalyst 7 Hydrogen loss 1.6


Distillation:


Stage1A:

Citral reacts with MPK in presence of base gives NPEI crude which on distillation gives NPEI

mains

Stage1B:

NPEI undergoes cyclisation in presence of Phosphoric acid gives NEI crude which on distillation

gives NEI mains

Stage 3;

Hydrogenation of NEI gives Timber touch / Timber forte crude which subjected to distillation

gives Timber touch / Timber forte product


1 Timber touch / Timber

forte crude 1189

Column Tops 70

Timber touch/Forte Mains 1000



Total 1189

Total 1189



Process Flow diagram for manufacturing of Timber touch / Timber

8.25 Effluent reduction in existing process of DHMOL

Existing Consent effluent is 83 m3/day, by changing existing process, washing method/process

(minimizing water wash) & Applying resin technology effluent has reduced drastically to 63.13

m3/day. As per Existing Consent Alcohol group products are

DHMOL/COL/GOL&NOL/TERPENIOL/DMO / Damascons capacity is 445 MT/M out of which

COL/GOL&NOL/DMO are the zero effluent process.



Major reduction of effluent is achieved in DHMOL product (for capacity of 400 MT/M) from 25.75

to 5.88 m3/day by using Resin technology (19.87 m3/day effluent reduction is achieved).

Material Balance:

Stage1

S. No Input Qty per MT Qty Output Qty Per MT Qty 01 Dihydromyrcene 1152 Sulphuric acid (27-35 %) 1385 02 Sulphuric acid 70 % 691 Effluent 441 03 Ferrous Sulphate 3 DHMOL crude 1192 04 Emulifier 1 Total 3018 05 Water for quenching 730 06 Water for washing 230

07 Caustic water for resin column neutralization 211

Total 3018

Distillation:

Note:

1).Sulfuric acid will send for in-house concentration process.

2). Water wash & Neutralized resin column effluent will send to Effluent treatment.

S. No Input Qty per MT Qty Output Qty Per MT

Qty

1 DHMOL Crude

1192

Column Tops 118 DHMOL Mains 1000 Column Bottom 58 Distillation loss 16

Total 1192

Total 1192



9.0 RECOVERY OF CONCENTRATED SULFURIC ACID AT PLOT NO. C33/1, X-9, 10, 11

Spent Sulfuric acid (27%) will be utilize to generate 70% concentrated sulfuric acid through

multiple effect evaporation system. 27% Spent Sulfuric acid will be generate from DHMOL

process plant. The dilute acid then goes to the multiple effect evaporation system where

water gets evaporated and collected into a tank (50KL) for recycling in DHMOL process

plant and 70% concentrated sulfuric acid collected in a tank of capacity 50 KL and

transfer to DHMOL plant for hydration system.

Table 6: Details and Quantity of Sulfuric acid

S.no. Description Quantity (Kg/day)

1. Spent acid (27%) generation 36250

2. Quantity of acid in Spent 9788

3. Quantity of water in Spent 26463

4. Conc. Sulfuric acid (70%) 13594

5. Quantity of water in Sulfuric acid (70%) 3806

6. Quantity of water evaporated 22656

Table 7: Process Standard for Sulfuric acid Plant

S.no. Parameters Standards Unit

1. Spent acid feed rate 2000 LPH

2. Steam Inlet 4.0 Kg/cm2

3. System Vacuum 700 mm of Hg

4. Conc. H2SO4 (70%) outlet rate 750 LPH

5. Spent water separated rate 1250 LPH

6. 3 Nos. resin column capacity 1200 (each) LPH

7. Cooling Tower 200 TR



Figure 2: Layout of Sulfuric acid concentration and polishing unit



Proposed recovery option

The units will also implement the concept of waste minimization:

1. Solvents will be recovered and reused.

2. Proper Housekeeping practices make the system easier and less costly.

Some of this are follows:

1. Liquid wastes from various section should be collected and treated with effluent.

2. Rain water harvesting system will be adopted to reduce the fresh water requirement.

3. Cleaner production technology will be adopted for the resource conservation and

pollution control.

10.0 INSTALLATION OF 4 MW THERMAL POWER PLANT

A Captive power plant of capacity 4MW is proposed to install, to save the energy

demand. The thermal power plant will be coal based which is mainly divided into four

parts.

1. Coal Handling Plant

2. Boiler with ESP and ash handling system

3. Turbine

4. Generator

S.no. Description Requirement Unit

1. Coal 120 MT/day

2. Steam 30 MT/hr @ 67Kg/cm2 pressure

3. Boiler 30 TPH @ 68 atm pressure

1. Coal Handling Plant: The capacity of coal handling plant is 20 MT/hr. As the coal

consumption is about 120 MT/day, the coal handling plant should be simple, reliable and

low maintenance. Coal is feeded on coal conveyer belt through vibrating feeder.

Feeders are of electromagnetic type and controls the rate of feeding required for

bunkering (150 MT). By the various combinations of conveyor belts, coal is conveyed to

the surge hopper of a crusher house. Before the coal comes to the crusher house, the

ferrous material which comes along with the coal is taken out with the help of suspended

and rotating type magnetic separators. Non-ferrous materials like stones. Shells, wood



etc. are removed manually. Here coal is crushed to the size of 6 to 8 mm.

This size of coal is then sent to coal bunkers through various belts and finally coal trippers

and stored for further processing of coal for combustion in boiler furnace. This cycle is

known as bunkering cycle.

2. Boiler: Boiler is used for generation of steam for power generation. In thermal power

plant water tube boilers are used. Type of a boiler: Natural circulation, natural draft,

tangentially fired, radiant, reheat type, dry bottom and pulverized fuel fired. A 30 TPH

boiler will be use from which 30 MT/hr @67 kg/cm2 of steam will generate to produce

power. The consumption of imported coal is about 120 MT/day.

ESP: Electrostatic precipitator will be used to control the flue gas. Three field high voltage

transformer with rectifier, emitting and collecting electrodes with inbuilt rapping and

draining arrangement. The capacity of ESP is 70 NM3/hr, having the inlet velocity is about

10 M/sec and outlet (inside ESP) velocity is 0.5 M/sec.

Ash Handling: Ash handling will be done with the help of ash cello of capacity 90M3

having pneumatic handling system and having automatic drop down system in vehicles.

The bottom ash quantity is approximately 1.44 MT (on basis of 120 MT/day) falls in the

bottom hopper and after crushing it is transferred to ash handling plant .Fly ash

approximately 5.76 MT (on basis of 120 MT/day) along with the flue gases goes through

ESP where fine ash is taken out by ionization with help of high voltage transformer

/rectifier and send to the ash handling plant for further processing to the ash bunds.

3. Turbine: A 4 MW turbine is used, which is three cylinder, horizontal, disc and diaphragm

type with nozzle governing and regenerating feed water heating. Live steam from boiler

enters two emergency stop valves (ESV) of high-pressure turbine (HPT) Excess exhaust

steam after fulfillment of plant demand condenses in the surface condenser which

welded directly to the exhaust part of turbine. The turbine is equipped with barring gear

which rotates the rotors of turbine at a speed nearly 3.4 rpm for providing uniform

heating during starting and uniform cooling during shut down.

4. Generator: The steam enters in steam turbine and due to the heat energy of steam,

turbine rotates at about 7000 to 8000 rpm. The turbine is coupled to the generator rotor

through gear box by reduction in RPM up to 3000 RPM and Electricity is generated.

Electricity produced in the stator is then passed through bus ducts to the generator

transformer.



Figure 3 : Block diagram of 4 MW thermal power plant

11.0 LAND REQUIREMENT DETAILS

Total land area of the plant is 50675.0 M2 and 5081.0 M2 respectively. Thus the total plot area is

55756.0 M2.

Table8 Area Statement of Plots

S.no Area Details (Plot no. C-3,4,5,6, 6/1,7, 8, 9)

Area (m2)

Description Existing Propose

1 Plant 4013.0 66.0

2 Storage 7167.20 468.50

3 RM/BSR/Store 2623.12 -



4 Utility 492.55 109.70

5 Boiler 313 .70 -

6 DG/ PCC/Transformer 680.0 -

7 Administrative Building 116.70 -

8 Effluent treatment plant 678.25 -

9 Approach roads 8329.20 3574.80

10 Parking 736.15 -

11 Security/Change room 153.84 -

12 Open Shed 851.18 -

13 Green belt 1920.0 -

14 Open space 11892.01

15 Office/R&D/Workshop 2438.90 -

Total 42406.0 4219.0

Grand Total 46625.0

Area Details (Plot no. C-7)

1 Storage - 1197.54

2 Green belt & open space 2852.45 -

Grand Total 4050.0

Existing area + Proposed area = 45258.45+5416.54 = 50675.0 m2

Table 9: Area Statement of Plots

Sl.no. Description Area (m2) Remarks

A Area of Plot no. - C33/1 3906 Existing

B Area of Plot no. – X-9, X-10, X-11 1175 Existing

Total 5081 Existing

Area Details

Area (m2)

Description Existing Propose

1 Plant 97.76 -

2 DM water plant 95.90 -

3 Storage 55.95 -

4 Boiler 8TPH 198.40 -

5 Boiler 18 TPH 418.80 -

6 Boiler 30 TPH - 460.0



7 ESP - 108.0

8 Turbine - 80.0

9 Toilet Block 12.04 -

10 DG Room 81.47 -

11 Transformer area 69.0 -

12 Septic tank 3.13 -

13 Chimney 4.5 -

14 Coal Shed 180.0 -

15 U/G water Tank 81.75 -

16 HT breaker room 18.0 -

17 Scrap area 65.79 -

18 Security 9.0 -

19 Road area 976.0 -

20 Green belt 161.0 -

21 open space 1900.51

Total 4433.0 648.0

Existing area + Proposed area = 4433.0 + 648.0 = 5081.0 m2



6" Steam Line

6.0M wide road

Figure 4: Plant Layout of proposed expansion project



Figure5: Layout Plan of proposed expansion project



12.0 UTILITY AND REQUIREMENTS

12.1 WATER REQUIREMENTS

Construction Phase:

The total water requirement for domestic purpose and for construction activity is about

60 M3/day and 5.5 M3/day respectively. The source of required water will be from MIDC,

Mahad. The waste generation from the domestic use will be disposed into septic tank.

Operation Phase:

The total water requirement during the operation phase is 927.2 m3/day for dry season

and 899.2 m3/day for wet season and main supply source of water is from MIDC, Mahad

water supply. Details of water consumption and effluent generation are tabulated in

Table 10 & 11.

Table 10 Water Consumption and Waste water generation details for Dry Season

Note:

Sr.

No. Details

Water Consumption – M3 / day Waste Water generation – M3/day

Existing as

per consent

Current

Actual Proposed Total

Existing as per

consent

Current

actual Proposed Total

1 Domestic 40 40 9 49 28 28 7 35

*2 Industrial

Processing 190 190 2 192 83.0 75 9 84.0

3

Industrial

Cooling

& Boiler

Feed

468 468 218.2 686.2 24.0 18 3 21

4

Agricultural

/

gardening

24 24 11 0# 0 0 0 0

Total 722 722 240.2 927.2 135.0 121 19 140



* No major increase in water consumption and effluent generation of industrial

processing though new addition of products as we are going to use resin technology in

process instead of water wash.

@ Boiler & cooling tower effluent generation reduced due to the use of demineralization

plant which have better feed quality which results low effluent discharge in compare to

existing softener and incorporation of online filters which removes foreign particles and

decreases the effluent quantity and also increases the performance of cooling tower.

# recycling/ reused of effluent will be used for gardening after treatment.

Table 11: Water Consumption and Waste water generation details for Wet Season

Sr.

No. Details

Water Consumption – M3 / day Waste Water generation – M3/day

Existing as per consent

Current Actual Proposed

Proposed water consumption in wet season

Total Existing as per consent

Current actual Proposed Total

1 Domestic 40 40 9 9 49 28 28 7 35

2 Industrial Processing

190 190 2 2 192 83.0 75 9 84.0

3 Industrial Cooling & Boiler Feed

468 468 218.2 190.2 658.2 24.0 18 3 21

4 Agricultural/gardening

24 24 11 0 0 0 0 0 0

Total 722 722 240.2 201.2 899.2 135.0 121 19 140

Note: Avg rain water harvesting is 28-29 m3/day will be used for cooling tower and RO water will

be recycled for gardening purpose.

Write up on Effluent Treatment Plan

A. Source of Effluent water:

The effluent is generated from sources:

iv) Boiler Blow Down

v) Cooling Tower Purging



vi) Domestic Purpose

vii) Process

The quantity per day is as mentioned in Water Balances.

B. Treatment Scheme:

The Effluent Stream obtained from the above sources is subjected to Pre-treatment

followed by MEE.

The Scheme is as mentioned below.

1. Pre-treatment prior to MEE

The effluent as mentioned in `A’ above is collected in Equalization Tank, where

pH is adjusted to 7- 7.5.

The equalized effluent is taken in to Aeration Tank where the same is subjected to

aeration.

The Effluent from Aeration Tank is taken in to clarifier from which the de-cantate is

taken to collection tank.

Effluent from collection tank is subjected to filtration through multi-media filter

followed by, R.O.

2. MEE

Rejected RO effluent is taken in to receiving tank for MEE.

The effluent from the receiving tank is subjected to triple effect evaporation.

The distillate from MEE is recycled plant for Process use.

Figure 6: Schematic Diagram of ETP



Table 2.12: Waste Water Characteristics

Sr.

No.

Parameters Effluent

After Treatment

1 pH 6.5 -8.5

2 Suspended Solids (mg/l) 100

3 BOD (mg/l) 100

Figure 7: Flow Diagram for STP



Figure 8: Flow Diagram for MEE

12.2 POWER REQUIREMENT

Source of Electricity shall be MSEDCL.

Construction Phase:

Quantity : 30KVA

DG set for Backup

(Quantity and capacity) : 1x 1000KVA

1x 750 KVA

1x 380 KVA



Operation Phase:

Table 13: Details of Power Consumption

S.No. Particulars Source Power Consumption (KVA)

Existing Proposed Total

1 Administration MSEDCL 100 50 150

2 Plant MSEDCL 1600 1545 3145

Total 1700 1595 3295

12.3 FUEL CONSUMPTION

Diesel Oil and coal will be used as a fuel for DG sets and Boilers. Boiler is required for steam

generation which is supplying heating requirement in all synthesis section. DG sets will be used as

power back up as required.

Requirement of fuels is as below:

Table 14: Fuel requirement details

Sl.No Particulars Name of

fuel

Quantity required

(existing)

Quantity required

(proposed)

Remark

1.

DG set Diesel 250 Lt/hrs -

For Existing-

1000KVA, 380 KVA

750 KVA

2. Boiler Coal 90 TPD 120 TPD For propose- 30 TPH

3. Boiler FO/ Bio-Fuel FO = 4.1 KLPD FO/ Bio-Fuel =5.9

KLPD

-

4 Thermo

pack

FO/ Bio-

Fuel/Coal

FO-0.3 KLD/

Biofuel = 650 LPD Coal = 3.624 TPD

For Proposed- 6 Lacs

Kcal



12.4 STACK DETAILS

Stack will be attached to Boiler and DG sets. The stack attached to them will be as per Factories

Act, 1948. Details of stacks are shown in Table 15.

Table 15: Details of Stack

S.N Details Capacity Stack Ht. Fuel/Fuel consumption Stack Dia(mm) Stack gas

temp(˚C)

1. Boiler

Exist. 18 TPH

& 8 TPH

Pro. 30

TPH

Exit. 42 m

Pro. 46 m

Exit. 90 TPD (Coal)

Pro. 120 TPD

(coal)

Exit. 1300

Pro. 2000

Exit. 136

Pro. 160

2 Boiler

6 TPH (coal)&

6 TPH (FO) - 30 m -

Coal include

in 90 TPD FO-

4.1KLPD

FO- 4.1KLPD or 5.9 KLPD biofuel

550 - 120 -

3. DG set

Exist 1000, 750

380 KVA

Pro. -

Exit.

12m & 10 m

Pro. -

Exit.

125 L/hr &

80 L/hr & 45 L/hr

Pro. -

Exit. 177.8

Pro. -

Exit.

185

Pro. -

4. Incinerator

Exist 75

Kg/hr

- 30 m - 240 L/Day

(Diesel)

- 1100/500

- 93.5 -

5. Thermic

Fluid Heater

Exist 6 lac Kilo

Calorie/Hr

Pros 6 lac Kilo

Calorie/Hr

Exist

30.0

Pro.

30

FO/Biofuel 650

L/Day

Pro. Coal 3.624

Exist

250

Pro.

550

Exit.

158

Pro.

158

12.5 ACTION PLAN FOR DISPOSAL OF FLY ASH GENERATED FROM BOILER Coal will be used for boiler and generated fly ash shall be collected and sold to nearest brick

manufacturer and land filling.



Table 16: Fly ash generation and disposal facility

Sr. No.

Details Capacity(TPH) Fuel/Fuel consumption (TPD)

Flyash generation (MT/M)

Disposal option

1. Boiler

Exit. 18, 8 & 6

Prop. 30

Exit. 90

Prop. 120

Exit. 85.5

Prop. 288.0

Exit. Sale to brick

manufacture/ land filling

Prop. Sale to brick

manufacture/ land filling

2. Thermo pack

- 6.0 Lacs Kcal

- 3.624 - 5.5 - Sale to brick manufacture/ land filling

12.6 MANPOWER REQUIREMENT

Construction Phase

During construction phase, around 60 laborers will be hired for construction activity.

Operation phase

Around 50 people will work directly in the facility other than sale and marketing team and

indirect employment will be around 13 making total employment generation to 63 people. The

details are as shown in Table 17.

Table 17: Employment Details

Sr. No. Descriptions Approx. Numbers

1 Skilled 50

2 Un-skilled 13

A Proposed Total Employments 63

B Existing Total Employments 395

C Total Employments after expansion 458



13.0 SOLID WASTE MANAGEMENT

13.1 Construction Phase:

Waste generated during the construction will be properly handled, stored and disposed off in

accordance with relevant Waste Management Rules (Municipal Waste Management Rules,

Hazardous Waste Management & Handling Rules etc.) enacted by the government of India.

Total Waste generated during construction phase will be about 4000 kg/day. The Construction

waste like, debris, excavated soil will be used for land filling on same site and other unused

construction materials and construction equipment will be removed from the site after the

construction. Used plastics, LDPE, HDPE, gunny bags/cement bags will be collected, stored and

disposed of properly. Plastics and similar material will not be allowed to dispose outside the plant

boundary.

13.2 Operation Phase:

Total domestic waste will be generated during the operation phase is about 65.1kg/day. The

generated waste that is bio degradable waste (35.1 kg/day) and Non bio degradable waste

(30 kg/day) will be hand over to authorize vendors.

14.0 HAZARDOUS WASTE DETAILS

Details of Hazardous Waste generation, storage and disposal facility are shown in Table 18.

Table 18: Hazardous Waste Handling and Disposal Details

S.

No.

Category

No.

Particulars Existing Proposed Total Qty Disposal

1 34.3

Chemical Sludge

from Waste Water

Treatment

8.0 MT/M 32.0 MT/M 40 MT/M CHWTSDF

2 5.1

Spent oil

0.4 MT/M 0.1 MT/M 0.5 MT/M

Sale to

Authorised

recyclers

3 33.3

Discarded

Containers

MS / HDPE Drums

IBC’s

Carboys

83 nos/M

0 nos/M

0 nos/M

118 nos/M

25 nos/M

50 nos/M

201 nos/M

25 nos/M

50 nos/M

Sale to

Authorised

recyclers



4 36.1

Sludge from

Concentration

Techniques (MEE) Nil 20.4 MT/M 20.4 MT/M

CHWTSDF/Sal

e to

Authorised

recyclers

5

Batteries

Rules,

2002

Lead Acid Batteries Nil 30 Nos /A 30 Nos /A

Sale to

Authorised

recyclers

6 15.2 Discarded Asbestos 8.3 kg/M 0 8.3 kg/M CHWTSDF

7 35.2 Spent Catalyst 0.2 MT/M 0.3MT/M 0.5 MT/M

Sale to

Authorised

recyclers

8 5.2

Waste or residue

containing oil (Oil

soaked gaskets

and cotton waste)

Nil 150 kg/M 150 kg/M CHWTSDF

9

E- waste

Rules,

2011

e-Waste Nil 57 kg/M 57 kg/M

Sale to

Authorised

recyclers

10 35.3 Carbon/Charcoal Nil 2.2 MT/M 2.2 MT/M Incineration

in boiler

11

Silica Nil 2.2 MT/M 2.2 MT/M

Sale to

authorize

party/Land

filling

12 Resin Nil 0.1 MT/M 0.1 MT/M CHWTSDF

15.0 GREEN BELT DEVELOPMENT

Adequate land will be available for green belt development. There is total 2286 m2 areas have

been taken for green cover / lawn development in the proposed expansion facility. Suitable

plant species of local varieties will be planted with adequate spacing and density for their fast

growth and survival. Proponent will also developed green belt in outside of project premises and

nearby area due to very small plot area.

16.0 RAIN WATER HARVESTING

Rainwater harvesting is proposed in the project to conserve the rain water. Adequate care has

been taken while making efficient planning for percolation of rainwater into the sub-surface



without directly draining it outside the Project and conserving maximum extent of rain water

within the facility. In order to allow percolation of rainwater into the ground, rainwater harvesting

structures along the boundary of the project has been proposed. These will enhance the

groundwater potential while raising the water Tables in the area.

Run off from the proposed project site is calculated using rational formula:

Q= C x I X A

Q = Run-off in m3/hr

A = Catchment Area (ha)

C = Coefficient of Run-off

I = intensity of Rainfall in mm/hr

Table 19: Annual Runoff

Land use type Area (M2) Coefficient runoff Rainfall (m) Quantity of rain

water (M3)

Roof top area 2686.00 0.9 3.413 8250.5

Green Area 18.00 0.3 3.413 18.4

Total 2704.00 8268.9

Harvested water will be collected in underground tanks of 350 KL and 150 KL. The stored water

shall be used for firefighting as well process.

17.0 Storm Water-Collection and Disposal

Storm water drains is constructed according to municipal regulations. Storm water from the

entire plot will be collected through network of storm drains. Storm water from plot area will be

collected in the rainwater harvesting pits provided for this purpose. The overflow from these pits,

if any, will be then discharged in the proposed drains. The dimension of the drain is 10.5 x 15.0 x

2.25 M.

18.0 Air Pollution Control Measures

Air pollution control measures include adequate stack height, installation of cyclone, dust

collectors and incinerator.

form - i unit ii 17.11.14 -...

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