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GODAVARI BIOREFINERIES LIMITED GUT NOS‐ 158‐165, 167‐178, 180/1, 180/2, 181/1, 181/2, 187/1,

187/2, 188, 189, 199, 511 OF WARI VILLAGE AND 139/2 OF KANHEGAON VILLAGE, SAKARWADI POST, KOPARGAON TEHSIL,

AHMEDNAGAR DISTRICT, MAHARASHTRA

FORM I

Project No. 0917‐21‐01 September 2017

Godavari Biorefineries Limited A/P ‐ Sakarwadi, Tal ‐ Kopargaon, Dist ‐ Ahmednagar, Maharashtra State. Pin No. 413 708 Telephone ‐ (02423) 279308, Fax (02423) 279339 E‐mail: [email protected] [email protected]

STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA, INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Godavari Biorefineries Limited

Form I Page 1

APPENDIX – I (See Paragraph – 6)

FORM I I) Basic Information S.No. Item Details 1 Name of the Project/s Godavari Biorefineries Limited 2 S. No in the Schedule 5 (f) – Synthetic Organic Chemicals 3 Proposed capacity/area/length/tonnage to be

handled/command area/lease area/number of wells to be drilled

Area Existing: 138.387 Ha Area after Expansion: 138.387 Ha (It is proposed to allocate 10 Ha of existing area for expansion)

Existing Capacity: 9070 TPM Capacity after expansion

S. No

Description Capacity (TPM) Existing Proposed Total

after Expansion

1 Synthetic Organic Chemicals

9070 13667 22737

2 R & D ‐‐ 5 5 Total 9070 13672 22742

3 Co‐generation Power

Plant (9.3 MW) ‐‐ 2 x 3.5 2 x 3.5 ‐‐ 1 x 1.5 1 x 1.5 ‐‐ 1 x 0.8 1 x 0.8

4 New/Expansion/Modernization Expansion 5 Existing Capacity/Area etc. Existing Capacity: 9070 TPM

Area Existing: 138.387 Ha 6 Category of Project i.e 'A' or 'B' “A” 7 Does it attract the general condition? If yes,

please specify No

8 Does it attract the Specific condition? If yes, please specify.

No

9 Location Plot/Survey/Khasra No. Enclosed at Annexure Village Sakarwadi Post, Wari and Kanhegaon Villages Tehsil Kopargaon Tehsil District Ahmednagar District State Maharashtra

10 Nearest railway station/airport along with distance in km.

Kanhegaon– 0.3 km Airport : Aurangabad – 82 km

11 Nearest Town, City, District Headquarters along with distance in kms.

Kopargaon ‐ 18 km

12 Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal address with telephone nos. to be given)

Wari (village) A/P ‐ Sakarwadi, Tal ‐ Kopargaon, Dist ‐ Ahmednagar, Maharashtra State. Pin No. 413 708 Telephone ‐ (02423) 279308, Fax (02423) 279339


Form I Page 2

13 Name of the Applicant Godavari Biorefineries Limited 14 Registered Address Godavari Biorefineries Limited

Sakarwadi Post, Kopargaon Tehsil, Ahmednagar District, Maharashtra.

15 Address for Correspondence: Godavari Biorefineries Limited Somaiya Bhavan, 45‐47 , M.G. Road, PO Box No. 384, Fort, Mumbai – 400 001. Phone : (022) 22048272/61702100

Name S. Mohan Designation(Owner/Partner/CEO) Director ‐ Works Address Sakarwadi Post, Wari and Kanhegaon Villages,

Kopargaon Tehsil, Ahmednagar District, Maharashtra Pin Code 413 708 E‐mail [email protected] Telephone Number (02423) 279308, 279396,279397 Fax No. (02423) 279339

16 Details of alternative Sites examined, if any. Location of these sites should be shown on a topo sheet.

NO

17 Interlinked Projects NO 18 Whether separate application of interlinked

project has been submitted? NO

19 If yes, date of submission NO 20 If no, reason NO 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) The C.R.Z Notification, 1991?

NO

22 Whether there is any Government Order/Policy relevant/relating to the site?

NO

23 Forest land involved (hectares) NO 24 Whether there is any location pending against

the project and /or land in which the project is propose to be set up? (a) Name of the Court (b) Case No (c) Orders/directions of the Court, if any and its relevance with the proposed project.

NO


Form I Page 3

(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.) S.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 proposal is for expansion of the existing unit. The land area used for the proposed expansion is 10 Ha.

The topography is in general plain. The entire land is medium to heavy Soil.

1.2 Clearance of existing land, vegetation and buildings?

NO The proposal is for expansion of the existing unit

1.3 Creation of new land uses? NO 1.4 Pre‐construction investigations e.g.

bore houses, soil testing? YES Soil test done and soil load bearing capacity

established. 1.5 Construction works? YES Construction activity involves new production blocks,

additional utilities like boilers, thermic fluid heaters, Hydrogen generator, nitrogen generator and DG sets, storage facility and enhancement of effluent treatment plant.

1.6 Demolition works? NO No structures for demolition 1.7 Temporary sites used for construction

works or housing of construction workers?

NO Facilities are provided available for housing construction workers.

1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations

YES Storage facilities shall be constructed. No major cut and fill or excavation is anticipated.

1.9 Underground works including mining or tunneling?

NO No underground works like mining and tunneling.

1.10 Reclamation works? NO 1.11 Dredging? NO 1.12 Offshore structures? NO 1.13 Production and manufacturing

processes? YES Enclosed in Annexure – I

1.14 Facilities for storage of goods or materials?

NO Raw materials and solvents shall be stored with in factory premises. Materials in bags and drums will be stored in flame proof ware houses. Bulk quantities of raw materials will be stored in Bulk Storage tanks in the tank farms with retention dykes.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

YES Effluents from process and utilities will be treated in effluent treatment plant and treated effluent reused for cooling towers. Domestic wastewater sent to sewage treatment plant and treated wastewater reused for gardening. Details of waste treatment facilities presented in Annexure II

1.16 Facilities for long term housing of NO Residential colony for all the operational workers is


Form I Page 4

operational workers? already available. 1.17 New road, rail or sea traffic during

construction or operation? NO Construction materials shall be transported to the

site. The traffic density of the existing connecting road is less.

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

NO

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

NO

1.20 New or diverted transmission lines or pipelines?

NO

1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?

NO

1.22 Stream crossings? NO All materials and waste streams are pumped through above ground pipe lines.

1.23 Abstraction or transfers of water form ground or surface waters?

YES Water is drawn from Godavari river canal or infiltration well in Godavari river. Present fresh water permitted capacity is 2142 KLD

Total water required after expansion shall be 4838 KLD out of which 3500 KLD will be freshwater and 1338 KLD will be recycled water.

1.24 Changes in water bodies or the land surface affecting drainage or run‐off?

NO

1.25 Transport of personnel or materials for construction, operation or decommissioning?

YES The construction material shall be drawn from local sources within 10 – 15 km. There is no transport of personnel, as the construction workers shall be drawn from local villages.

1.26 Long‐term dismantling or decommissioning or restoration works?

NO

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

NO

1.28 Influx of people to an area in either temporarily or permanently?

YES The proposed project shall increase the employment potential and hence may lead to migration to surrounding villages.

1.29 Introduction of alien species? NO1.30 Loss of native species or genetic

diversity? NO There are no major losses of tree/shrub species.

1.31 Any other actions? NO


Form I Page 5

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): S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities

/rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

No The present proposal is expansion of existing unit within existing site area.

2.2 Water (expected source & competing users) unit: KLD

YES Total water required after expansion shall be 4838 KLD out of which 3500 KLD will be freshwater and 1338 KLD will be recycled water. (Water Balance Enclosed in Annexure III)

2.3 Minerals (MT) NA 2.4 Construction material – stone,

aggregates, sand / soil (expected source – MT)

YES Shall be sourced from the local villages.

2.5 Forests and timber (source – MT) NO 2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel (MT), energy (MW)

YES Existing coal fired boilers are 2 x 18 TPH and 1 x 12 TPH and a standby DG set of 590 kVA. It is proposed to establish 2 x 35 TPH coal fired boilers, 1 x 2 Lac K.Cal/hr and 1 x 10 lac k.cal/hr thermic fluid heaters and 4 x 1000 kVA standby DG sets in addition to existing boilers and DG set.

It is proposed to keep existing 1 x 12 TPH boiler as standby after expansion.

Coal consumption after expansion is 565 TPD. It is proposed to step down the steam pressure by generating power in the order of 9.3 MW by utilizing coal fired boilers installed for process requirement.

Standby DG sets of 4 x 1000 kVA (proposed) and 1 x 590 kVA (existing) will be provided to meet the power requirement on case of any power shutdown or turbine maintenance.

2.7 Any other natural resources (use appropriate standard units)

NA


Form I Page 6

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. S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate

quantities/rates, wherever possible) with source of information data

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 chemicals shall be used for manufacturing of Synthetic Organic Chemicals. MSIHC rules shall be followed during storage, transportation and handling of raw materials. Hazardous chemicals and solvent shall be stored and handled in closed systems.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases).

NO

3.3 Affect the welfare of people e.g. by changing living conditions?

YES Shall increase the employment potential for locals and affect the living conditions for betterment.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

NO No sensitive receptors are present in the immediate vicinity of the site. The project shall not have any significant impact on vulnerable groups of people.

3.5 Any other causes NO

4. Production of solid wastes during construction or operation or decommissioning (MT/month) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


4.1 Spoil, overburden or mine wastes NO4.2 Municipal waste (domestic and or

commercial wastes) NO Wastes from canteen, other commercial wastes

like paper, empty containers etc. Canteen waste will be composted and reused as manure. Paper waste sent to recyclers.

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

YES Hazardous waste generation during construction shall be limited to waste oils, batteries and containers of paints etc. The quantity of hazardous wastes generated during operation contain salts from evaporators, process residue, and solvent residues, ETP sludge and filtration media etc.

4.4 Other industrial process wastes YES Enclosed at Annexure IV 4.5 Surplus product NO 4.6 Sewage sludge or other sludge from

effluent treatment YES Sludge from Effluent treatment plant, and

evaporation salts shall be sent to TSDF. Sludge from Sewage treatment plant reused as manure after composting.

4.7 Construction or demolition wastes NO 4.8 Redundant machinery or equipment NO 4.9 Contaminated soils or other materials NO All pipe lines including pipe lines of waste

streams are above ground on the pipe rack.


Form I Page 7

Structures of all waste treatment facilities are made of concrete and also above ground to eliminate the possibility of any contamination due to seepage and for ease of maintenance.

4.10 Agricultural wastes NO 4.11 Other solid wastes YES Enclosed at Annexure IV

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

YES Coal Shall be used as fuel. Details are enclosed in Annexure V

5.2 Emissions from production processes YES

Gaseous emissions from process are HCl, SO2, are scrubbed in two stage scrubbers. Water is used as scrubbing media in primary scrubbers and caustic in secondary scrubbers. Effluents from scrubbers are sent to effluent treatment plant.

5.3 Emissions from materials handling including storage or transport

NO Material transfer takes place in closed pipeline systems using pumps with mechanical seals.

5.4 Emissions from construction activities including plant and equipment

YES Dust may rise during transport of material and construction activity. The dust emissions shall be mitigated by water spraying on the roads within the premises.

5.5 Dust or odors from handling of materials including construction materials, sewage and waste

NO Sewage will be treated in sewage treatment plant.

5.6 Emissions from incineration of waste NO Organic waste streams are sent to cement plants for co‐incineration.

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

NO

5.8 Emissions from any other sources NO


Form I Page 8

6. Generation of Noise and Vibration, and Emissions of Light and Heat: S.No. Information/Checklist confirmation 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 Material transport and construction equipment shall be source of noise, while transfer pumps, vacuum systems, DG sets are the sources of noise during operation.

6.2 From industrial or similar processes YES From Turbine and DG sets, and controlled by providing Acoustic Enclosures.

6.3 From construction or demolition YES Noise during construction shall be due to construction equipment and emergency DG sets.

6.4 From blasting or piling NO6.5 From construction or operational

traffic NO The increased traffic shall not have any significant

impact. 6.6 From lighting or cooling systems NO6.7 From any other sources NO

7.Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea: S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates,

wherever possible) with source of information data 7.1 From handling, storage, use or

spillage of hazardous materials NO All pipe lines, storage facilities and waste treatment

facilities are above ground. Local containments with concrete bunds are provided to all process plants, Bulk Storages and ware house.

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

NO All the waste from domestic operations sent to sewage Treatment Plant. Treated wastewater reused for gardening.

7.3 By deposition of pollutants emitted to air into the land or into water

NO All the emissions from process are controlled by providing control equipment like scrubbers, Bag filters and ESP, double stage condensers, etc.

7.4 From any other sources NO 7.5 Is there a risk of long term build up

of pollutants in environment from these sources?

NO


Form I Page 9

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

S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

YES All Inbuilt Safety precautions will be adopted and there will not be any damage to environment or human health

8.2 From any other causes NA 8.3 Could the project be affected by natural disasters

causing environmental damage (e.g. Floods, earthquakes, landslides, cloudburst etc)?

NO

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 S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate


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 • other

YES The project shall enhance the socio economic status of the area by increasing the demand for housing, improving the employment. There are no major support industries required for this plant.

9.2 Lead to after‐use of the site, which could haven impact on the environment

NO

9.3 Set a precedent for later developments NO

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

NO The baseline environmental status of the surrounding areas is within the prescribed limits as observed from the Primary data collected during march to June 2017.


Form I Page 10

(III) Environmental Sensitivity S.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

NA

2 Areas which are important or sensitive for ecological reasons ‐ Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

YES Godavari River ‐ West – 0.6 Km

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

NO

4 Inland, coastal, marine or underground waters NO 5 State, National boundaries NO 6 Routes or facilities used by the public for access to

recreation or other tourist, pilgrim areas NO

7 Defense installations NO 8 Densely populated or built‐up area YES Puntamba is at a distance of 7 km in

southeastt direction.

9 Areas occupied by sensitive man‐made land uses (hospitals, schools, places of worship, community facilities)

NA Nearest school and hospital are located within the residential campus of the industry adjacent to the plant.

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

NO

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)

NO

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

(IV) Proposed Terms of Reference for EIA studies

Scope of Work of EIA The standard terms of reference (page 181‐187) issued by the Ministry of Environment Forest and Climate change shall be followed for preparation of EIA report. Any additional study proposed by the SEAC shall also be completed.

Ref: Standard Terms of Reference (TOR) for EIA/EMPO report for projects/activities requiring environmental clearance under EIA notification, 2006, MoEF & CC, GOI, April 2015.

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ANNEXURES

‘

Project No. 0917‐21‐01 September 2017

Godavari Biorefineries Limited A/P ‐ Sakarwadi, Tal ‐ Kopargaon, Dist ‐ Ahmednagar, Maharashtra State. Pin No. 413 708 Telephone ‐ (02423) 279308, Fax (02423) 279339 E‐mail: [email protected] [email protected]

STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA, INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Godavari Biorefineries Limited Form I Annexures

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Page 3

ANNEXURE - I

Survey No.s M/s. Godavari Biorefineries Limited obtained consent for operation for synthetic organic

chemicals manufacturing at Gut Nos- 158-165, 167-178, 180/1, 180/2, 181/1, 181/2, 187/1,

187/2, 188, 189, 199, 511 of Wari village and 139/2 of Kanhegaon village, Sakarwadi

Post, Kopargaon Tehsil, Ahmednagar District, Maharashtra.

It is proposed to increase the product profile, capacity, utilities considering the

developments in R&D facility and establishment of co-generation power plant of 9.3 MW.

The expansion entails a capital cost of Rs. 250 crores towards additional production blocks,

utilities and enhancement of effluent treatment plant. The manufacturing capacity is

presented in Table A-1.

Table A-1 Manufacturing Capacity S.No Name of Product Capacity (TPM)

Existing Proposed Total after Expansion

Regular Products 1 Acetaldehyde 1500 1300 2800 2 Acetic Acid 598.85 598.85 3 Dilute Acetic Acid 110 110 4 Ethyl Acetate 5400 3300 8700 5 Crude Ethyl Acetate 30 30 6 Crotonaldehyde 500 500 1000 7 Acetaldol 60% 420 420 8 Crotonyldehyde Di- Urea (CDU) 78 78 9 Crotoresin 52 52

10 Paraldehyde 60 0 60 11 Crotonic Anhydride 8.33 1.67 10 12 Crotonitrile 8.33 1.67 10 13 1, 3 Butylene Glycol 41.7 158.33 200.03 14 1-3 Butylene Glycol (Min 40%) 12.9 19.32 32.22 15 Butanol 64.6 53.1 117.7 16 2-Ethyl, 1, 3 Hexane Diol 33.3 33.3 17 3-Methoxy Butanol 25 250 275 18 3 Methoxy Butanol (Min 40%) 30 30 19 3-Methoxy Butyl Acetate 340 340 20 3-Methyl 3- Pentene -One (MPO) 333.3 166.7 500 21 Sodium Sulphate 242 3 245


Page 4

22 Ketone Mixture 131.7 65.8 197.5 23 Absolute Alcohol (Fuel Grade from RS/IS) 3000 3000 24 Acetaldehyde Oxime 175 175 25 Ammonium Sulphate 139.7 139.7 26 n- Hexanol 42 42 27 Acetaldehyde Diethyl Acetal 250 250 28 Ethyl Vinyl Ether 100 100 29 Phenyl Ethyl Alcohol 100 100 30 Styrene Oxide 117 117 31 Styrene Polymer 42 42 32 Acetophenone 175 175 33 Phenyl Methyl Carbinol 44.80 44.8 34 Benzoic Acid or Sodium Benzoate 36.93 36.93 35 Acetonitrile 425 425 36 Diethyl Oxalate 175 175 37 Gbamber 100 100 38 Polyol 100 100 39 Styrallyl Acetate 100 100 40 M-Toluic Acid 100 100 41 Crude M-Toluic Acid 17 17 42 Propyl Acetate or Butyl Acetate 1000 1000 43 Crude Propyl Acetate or Crude Butyl

Acetate 17 17

44 Sorbic Acid or Potassium Sorbate 500 500 Total - I 9070 13526 22596.1

Campaign Basis 1 Ethyl Crotonate 7.5 7.5 2 Tri-Ethoxy Butane (Somsal 65%) 21 21 3 Forskolin 0.3 0.3 4 Methyl Crotonate 9 9 5 Methyl Beta Amino Crotonate 15 15 6 Ethyl Beta Amino Crotonate 30 30 7 Acetaldehyde Dimethyl Acetal 15 15 8 Formaldehyde Dimethyl Acetal 15 15 9 Formaldehyde Diethyl Acetal 15 15

10 Acetaldehyde Dibutyl Acetal 15 15 11 Acetaldehyde di-Iso Propyl Acetal 15 15 12 Acetaldehyde di-iso amyl acetal 15 15 13 Crotonaldehyde Diethyl Acetal 15 15 14 Butyraldehyde Dimethyl Acetal 15 15 15 Cinnamaldehyde Diethyl acetal 15 15 16 Tri Methoxy Butane 15 15 17 Acetaldehyde Propylene Glycol Acetal 15 15 18 Butane Diol polyester 15 15 19 Ethyl Levulinate 15 15 20 Ethyl Butyrate 15 15


Page 5

21 Diethyl Succinate 15 15 22 Dimethyl Phthalate 15 15 23 Isopropyl Crotonate 15 15 24 Hexyl Acetate 15 15 25 Hexyl Salisilate 15 15 26 Valerolactone 15 15 27 Diethyl Phthalate 15 15 28 Ethyl Formate 15 15 29 Butaraldehyde Oxime 20 20 30 Methyl Ethyl Ketone Oxime 20 20 31 Butyraldehyde 20 20 32 2-Ethyl butyraldehyde 20 20 33 2-Ethyl Hexenal 20 20 34 2-Ethyl Hexanal 20 20 35 2- Ethyl Crotonaldehyde 20 20 36 Cinnamaldehyde 20 20 37 Sorbaldehyde 20 20 38 Butyric acid 20 20 39 Crotonic acid 20 20 40 Levulinic acid 2 2 41 Formic acid 1.5 1.5 42 Styrene Phosphonic acid 1.25 1.25 43 Hydrochloric acid 1.25 1.25 44 2-ethyl Butanol 20 20 45 2-Ethyl Hexanol 20 20 46 Hexanol 20 20 47 Sorbic Alcohol 20 20 48 Crotyl Alcohol 20 20 49 Cinnamic Alcohol 20 20 50 Polycosonol 20 20 51 Trimethylol Propane 20 20 52 Sorbic Alcohol (Min 30%) 1.78 1.78 53 Crotyl Alochol (Min 30%) 2.46 2.46 54 Cinnamyl Alcohol (Min 30%) 7.84 7.84 55 Isobutanol 14 14 56 2,5 Furan Dimethanol 20 20 57 Propionitrile 20 20 58 Butyronitrile 20 20 59 Butyl Nitrite 20 20 60 Isobutyro nitrile 20 20 61 Valeronitrile 9 9 62 Acetone 20 20 63 3-Methyl 2-Pentanone 20 20 64 Methyl Ethyl Ketone 20 20 65 Diethyl Ketone 20 20 66 Isopropenyl Acetate 20 20


Page 6

67 Acrylic ester 20 20 68 Ketene 5 5 69 Isobutyl Vinyl ether 20 20 70 1-ethoxy Ethyl Acetate 20 20 71 Methyl vinyl Ether 20 20 72 Butyl Vinyl Ether 20 20 73 Diethyl Ether 20 20 74 NaturoWax 20 20 75 Hexyl cinnamaldehyde 20 20 76 Crude Hexyl Cinnamaldehyde 8 8 77 Ethyl propionate 20 20 78 Tri-Ethyl Phosphate (TEP) 20 20 79 Tri n Butyl Phosphate (TBP) 20 20

Total - II (Any 6 product at a time) 141 141 80 R & D Products 5 5

Total - III 5 5 Grand Total (I+II+III) - Total 44 from regular, 6 products from campaign products and R&D products.

9070 13672 22742

81 Co-Generation Power Plant 2 x 3.5 MW 2 x 3.5 MW 1 x 1.5 MW 1 x 1.5 MW 1 x 0.8 MW 1 x 0.8 MW


Page 7

Process Description of Ethyl Acetate

Ethyl acetate is produced by esterification of acetic acid and ethanol in presence of Para

Toluene Sulphonic Acid as catalyst.

PTSA CH3COOH + C2H5OH CH3COOC2H5 +H2O Glacial acetic acid, 95% ethanol and 1% PTSA are mixed and continuously feed into the esterification kettle. Suitable amount of ternary azeotrope is withdrawn from the top of the esterification column, by maintaining optimum top temperature and is then fed into the decanter. Fresh De-mineralized water is also fed in to the decanter to separate 94% ester as upper heterogeneous phase. This ester is fed to the drying (Ester Purification) column where the ternary distillation (water-ethanol-ethyl acetate) occurs. Final pure ethyl acetate is drawn continuously from the middle of the distillation column, cooled in the product cooler and sent to storage tank. The product purity is 99.5% to 99.9% pure. The top vapour outlet is again mixed with excess water is fed to another decanter. Small amount of ester separated is refluxed to the column. The bottom product of the two decanters is sent to the alcohol recovery column. From it the recovered vapor is sent to the reaction kettle.

Process Flow Diagram of Ethyl Acetate


Page 8

ANNEXURE – II: Wastewater Treatment Facilities

The effluent generated from the proposed expansion of is mainly from process, washings,

scrubbers, cooling towers & boiler blow downs, RO/DM rejects from pre-treatment of

water and domestic wastewater. It is proposed to treat effluent from process, washings,

scrubbers and R&D in biological treatment plant followed by RO. Blow downs are sent to

settling tank followed by RO. Rejects from RO sent to MEE and permeate is used for

cooling towers as make up. Total Effluent generated and mode of treatment after

expansion is presented in Table A-3.

Table A-3 Quantity of Effluent Generated and Mode of Treatment after expansion - Tentative

Description Quantity (KLD)

Mode of Treatment

Process 650 Sent to biological treatment plant followed by RO. RO rejects sent to MEE and permeate reused for cooling towers make-up

Washings 50 Scrubber Effluent 30 DM rejects 120 R & D 5 Boiler Blow downs 35 Sent to settling tank followed by RO. RO rejects sent to

MEE and permeate reused for cooling towers make-up. Cooling Tower Blow downs

380

Domestic 188 Sent to Sewage treatment plant and treated wastewater is reused for gardening.

Total 1458


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ANNEXURE – III: Water Balance

The total water requirement shall increased from 2134 KLD to 4838 KLD out of which 3500

KLD will be fresh water requirement and 1338 KLD is recycled water. The total fresh

water requirement shall be met from Godavari river canal or infiltration well in Godavari

river. The water balance for daily consumption after expansion is presented in Table .A-4.

Table A-4 Total Water Balance - Tentative Purpose INPUT (KLD) OUTPUT (KLD)

Fresh Water Recycled Water Loss Effluent Process 580 650 Washings 50 50 Scrubber 30 30 Boiler Feed 280 245 35 Cooling Tower 2200 1150 2970 380 DM Regenration 120 120 R & D 5 5 Domestic 235 47 188** Gardening 188 188 Gross Total 3500 1338 3450 1458 Total 4838 4908 * Includes water formed during reaction and water in raw material ** Includes residential


Page 10

ANNEXURE – IV: Solid Waste Generation and Mode of Disposal

Table A-5 Solid Waste Details – After Expansion (Tentative) S.No. Description of waste Unit After

Expansion Disposal method

1 Process/Distillation residue TPD 22 TSDF / Cement Industry 2 Spent Carbon TPD 0.3 TSDF / Cement Industry 3 Hyflow Kg/day 20 TSDF 4 Catalyst Kg/day 180 TSDF 5 Mixed Spent Solvents KLD 2 TSDF / Cement Industry 6 Boiler Ash TPD 145 TSDF to use as a stabilizing

agent / Brick manufactures 7 Used Oil KLPA 3 Authorized recyclers 8 Lead acid batteries No's/Year 80 Authorized recyclers 9 Softner / DM Plant Resins TPA 2 TSDF

10 Forced Evaporation Salts TPD 12.8 TSDF 11 ETP Sludge TPD 0.35 TSDF 12 STP Sludge TPD 0.4 Composted and used as

manure 13 Used/Discarded Filter Bags Nos /year 100 TSDF for Incineration 14 Used / Discarded RO Membranes TPA 0.2 TSDF for Incineration 15 HDPE containers No's/

Month 100 Detoxified and reuse

16 Liners & Bags TPM 0.5 Authorized recyclers 17 Used Filters (HEPA filters, Oil Filters

etc) Nos /year 100 TSDF for Incineration

18 Insulation and Glass wool Waste TPM 1 TSDF 19 Discarded PPE TPA 0.5 TSDF for Incineration 20 Glass Bottles No's/

Month 100 Dispose off to outside

agencies after detoxification 21 Paper, cotton waste & Packing

materials i.e. wood, carton , ropes TPA 5 Sale to out side agencies/

recyclers 22 Waste packing wood/ broken glass

etc TPA 5 Sale to out side agencies/

recyclers 23 Metal scrap TPA 30 Sale to out side agencies/

recyclers 24 Bio Medical Waste TPA 0.8 Sen to Bio Meidcal Waste

Treatment Facility 25 E- Waste TPA 2 Authorized recyclers 26 Canteen Waste Kg/day 40 Composted and used as

manure 27 Plastic Waste TPA 0.5 Authorized recyclers


Page 11

ANNEXURE – V: Stack Emissions Details

The sources of air pollution in the plant are from the existing 2 x 18 TPH, 1 x 12 TPH Coal

fired boilers and standby DG set of 1 x 590 kVA. It is proposed to establish 2 x 35 TPH

coal fired boilers, 1 x 2 Lac K.Cal/hr and 1 x 10 lac. K.cal/hr thermic fluid heaters and 4 x

1000 kVA standby DG sets in addition to existing boilers and DG set. Electro static

precipitators (ESP) will be provided for 2 x 35 TPH coal fired boilers Boiler as air

pollution control equipment. DG sets shall be provided with stack heights based on the

CPCB formula for effective stack height. The emission rates of PM, SO2, and NOx from

each stack are presented in Table A-6.

Table A-6 Stack Emission Details S.

No

Stack Connected to Stack Ht (m)

Dia of stack at top(m)

Temp. of exhaust

gases (0C)

Exit Velocity (m/sec)

Pollutant Emission Rate (g/sec)

PM SO2 NOx

Existing 1 2 x 18 TPH Coal fired

Boilers 30 1.2 190 10.25 0.61 1.2 1.4

2 12TPH Coal fired Boiler*

30 1.0 140 8.1 0.5 0.42 0.15

3 590KVA DG Set** 9 0.2 165 6.8 0.04 0.12 0.22 Proposed

1 2 x 35 TPH Coal fired Boilers

45 2.2 200 15 2.52 4.7 5.4

2 1 x 2 Lakh Kcal Thermic Fluid Heater

20 0.4 170 6.5 0.08 0.14 0.19

3 1 x 10 Lakh Kcal Thermic Fluid Heater

30 0.5 190 9.0 0.12 0.24 0.31

4 4 x 1000 KVA DG Set**

10 0.2 170 10 0.09 0.25 0.38

* 1 x 12 TPH coal fired boiler shall be kept as standby after expansion **DG sets will be used during load shut down period only.




STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants QCI: MoE&F OM, List A‐1, S.No.25. (An ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 Certified Organization) B‐115, Annapurna Block, Aditya Enclave Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/616, Telefax: 040‐23748666 Email: [email protected]

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