Summary of the Project
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- Brice Hodge
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1 Summary of the Project 1. Introduction M/s. Neogen Chemicals Ltd. is a new unit located at Plot Z/96/B SEZ Dahej, District: Bharuch, Gujarat. Now, the unit proposes to manufacture different type of synthetic organic dyes and pesticide products at above sited address. 2. Total Land Area Total plot area is m Cost of Project: Total Cost of the proposed project is around Rs. 55 crore, out of which 5 crore be used for Environment Management System. 4. Production Capacity Production capacity is prescribe below: List of Products Sr. Name of Products (MT/Year) (MT/month) 1 Bromination and Chlorination of Alcohols 1.1. Ethyl Bromide n-propyl Bromide 1.3. Iso Propyl Bromide 1.4. n-butyl Bromide 1.5. Iso Butyl Bromide 1.6. Sec-Butyl Bromide 1.7. n-hexyl Bromide 1.8. n-heptyl Bromide 1.9. n-octyl Bromide n-decyl Bromide Lauryl Bromide Cetyl Bromide Myristyl Bromide Stearyl Bromide M/s. Neogen Chemicals Ltd. 1
2 Name of Products (MT/Year) (MT/month) ,2 Dibromo Ethane ,3 Dibromo Propane ,4 Dibromo Butane ,5 Dibromo pentane ,6 Dibromo Hexane Chloro 2 Ethyl Hexane Chloro 1 Hexanol Chloro Propanol ,6 Dichloro Hexane Cyclo Propyl Methyl Bromide Cyclo Pentyl Bromide Cyclo Pentyl Chloride 2. Bromination of Organic Acids and Esterification thereof Bromo propionic Acid Bromo Propionyl Bromide Bromo Valeric Acid Bromo Hexanoic Acid 2.5. Sodium 2 Bromo Propionate 2.6. Ethyl 3 Bromo Propionate 2.7. Methyl 2 Bromo Butyrate 2.8. Ethyl 2 Bromo Butyrate 2.9. Ethyl 4 Bromo Butyrate Methyl 2 Bromo Iso Butyrate Ethyl 2 Bromo Iso Butyrate Iso Propyl 2 Bromo Iso Butyrate Ethyl 2 Bromo Valerate Methyl 2 Bromo valerate Ethyl 5 Bromo Valerate Tert-Butyl 2 Bromo Iso Butyrate M/s. Neogen Chemicals Ltd. 2
3 Name of Products Methyl 2 Bromo Caproate (MT/Year) (MT/month) 3. Grignards Formation from Organic Halides 3.1. Methyl Magnesium Chloride 3M in THF Methyl Magnesium Bromide 1.5M in THF 3.3. Ethyl Magnesium Chloride 2M in THF 3.4. Ethyl Magnesium Bromide 2M in THF 3.5. Vinyl Magnesium Bromide in 1M in THF 3.6. Isopropyl Magnesium Chloride 1M in THF 3.7. Phenyl Magnesium Bromide 2M in THF 3.8. n-butyl Magnesium Chloride 1M in THF 3.9. Iso Propyl Magnesium Chloride Li Cl Complex 1.3M in THF Iso Propyl Magnesium Bromide 1M in THF 4. Halogen Exchange Reactions Bromo 2 Chloro Ethane Bromo 4 Chloro Butane Bromo 5 Chloro Pentane Bromo 6 Chloro Hexane Bromo 1 Fluoro Methane 4.6. Dibromo Methane 4.7. Bromo Chloro Methane 4.8. Ethyl 5 Iodo Valerate Bromo Hepta Fluoro Propane 5. Addition of Halogen and Halogen Acids across Double Bonds ,2 Di Bromo Ethane Phenyl Ethyl Bromide Bromo 3 Chloro Propane 5.4. n-hexyl Bromide 5.5. n-octyl Bromide M/s. Neogen Chemicals Ltd. 3
4 Name of Products 5.6. n-decyl Bromide 5.7. Cyclo Pentyl Bromide 5.8. Cyclo Pentyl Chloride ,2 Dibromo 3 Chloro Propane ,2 Dibromo Hexa Fluoro Propane (MT/Year) (MT/month) 6 Bromination or Chlorination of Cyclic and Aromatic Compounds with or Without Functional Groups 6.1. Bromo Benzene Di Bromo Benzene 6.3. Ethyl 4 Bromo Methyl Benzoate Bromo 4 Chloro Benzene 6.5. p- Bromo Toluene Bromo O Xylene Chloro 1,4 Naphthaquinone Bromo 4 Fluoro Benzene Bromo Methyl 2 Cyano Biphenyl (Bromo OTBN) Bromo 3,4 Dichloro Benzene 7 Dehydrohalogenation of Organic Halides Optionally with or without functional Group 7.1. Vinyl Bromide Vinyl Bromide in THF 25% 7.3. Vinyl Chloride Bromo 1 Butene Bromo 1 Hexene Bromo 1 Heptene Bromo 1 Octene 8 Advance Intermediates from Category 1 to Methoxy Naphthaldehyde Fluoro 5 Bromo Benzonitrile M/s. Neogen Chemicals Ltd. 4
5 Name of Products 8.3. Ethyl 4- (dimethyl amino) Butyrate 8.4. Bromo Acetal Bromo Hexyl Trimethyl Ammonium bromide Bromo 3 Phenoxy Propane Chloro 2 Hexanone 8.8. n-octyl Amine 8.9. Bifenthrin Alcohol Ethyl 7 Chloro 2 Oxo Heptanoate Bromo 6 Methyl Heptane Methyl 3 Oxo Pentanoate (MT/Year) (MT/month) 9 Lithium Carbonate or Hydroxide reaction with Inorganic or Organic Acids 9.1. Lithium Bromide 55% Lithium Bromide Anhydrous 9.3. Lithium Chloride 40% 9.4. Lithium Chloride Anhydrous 9.5. Lithium Nitrate 9.6. Lithium Sulphate 9.7. Lithium Molybdate 20% 9.8. Lithium Acetate 9.9. Lithium Iodide Lithium Fluoride 10 Hydrobromic Acid from Bromine Hydrogen Bromide 48% to 62% Hydrogen Bromide 20% in IPA Hydrogen Bromide 30% in Acetic Acid Hydrogen Bromide Anhydrous R & D products Total M/s. Neogen Chemicals Ltd. 5
6 Name of Products 11 Co-Products: (MT/Year) (MT/month) Sodium Bromide Zinc Bromide Potassium Bromide Calcium Bromide Magnesium Bromide NaHSO HCl Spent HBr And/or Liquid Bromine (Recovered from above coproduct) List of Raw Materials List of raw materials is given below: Sr. 1. Bromination and Chlorination of Alcohols 1.1. Ethyl Bromide Ethyl Alcohol Hydrobromic Acid (48%) n Propyl Bromide n- Propyl Alcohol Hydrobromic Acid (48%) Iso Propyl Bromide Iso - Propyl Alcohol Hydrobromic Acid (48%) n Butyl Bromide n- Butyl Alcohol Hydrobromic Acid (48%) M/s. Neogen Chemicals Ltd. 6
7 1.5. Iso Butyl Bromide Iso - Butyl Alcohol Hydrobromic Acid (48%) Sec-Butyl Bromide sec-butyl Alcohol Hydrobromic Acid (48%) n-hexyl Bromide n-hexyl Alcohol Hydrobromic Acid (48%) n-heptyl Bromide n-heptyl Alcohol Hydrobromic Acid (48%) n-octyl Bromide n Octyl Alcohol Hydrobromic Acid n-decyl Bromide n- Decyl Alcohol Hydrobromic Acid (48%) Lauryl Bromide Lauryl Alcohol Hydrobromic Acid (48%) Cetyl Bromide Cetyl Alcohol Hydrobromic Acid (48%) Myristyl Bromide Myristyl Alcohol Hydrobromic Acid (48%) Stearyl Bromide Stearyl Alcohol M/s. Neogen Chemicals Ltd. 7
8 Hydrobromic Acid (48%) ,2 Dibromo Ethane Ethylene Glycol Hydrobromic Acid (48%) ,3 Dibromo Propane 1,3 Propanediol Hydrobromic Acid (48%) ,4 Dibromo Butane 1,4 Butanediol Hydrobromic Acid (48%) ,5 Dibromo pentane 1,5 Pentanediol Hydrobromic Acid (48%) ,6 Dibromo Hexane 1,6 Hexanediol Bromine Chloro 2 Ethyl Hexane 2 Ethyl Hexanol Thionyl Chloride Chloro 1 Hexanol 1,6 Hexanediol HCl (20%) Chloro Propanol 1,3 Propanediol Thionyl Chloride ,6 Dichloro Hexane 1,6 Hexanediol Thionyl Chloride Cyclo Propyl Methyl Bromide M/s. Neogen Chemicals Ltd. 8
9 Cyclo Propyl Methyl Alcohol Hydrobromic Acid (48%) Cyclo Pentyl Bromide Cyclo Pentyl Alcohol Hydrobromic Acid (48%) Cyclo Pentyl Chloride Cyclo Pentyl Alcohol Hydrochloric Acid (20%) Bromination of Organic Acids and Esterification thereof Bromo propionic Acid Propionic Acid Bromine Bromo Propionyl Bromide Propionyl Bromide Bromine Bromo Valeric Acid Valerolactone Hydrobromic Acid Bromo Hexanoic Acid n- Hexanoic Acid Bromine Sodium 2 Bromo Propionate Propionic Acid Bromine Sodium Methoxide Ethyl 3 Bromo Propionate Propiolactone Hydrogen Bromide (48%) Ethanol M/s. Neogen Chemicals Ltd. 9
10 2.7. Methyl 2 Bromo Butyrate n-butyric Acid Bromine Methanol Ethyl 2 Bromo Butyrate n-butyric Acid Bromine Ethanol Ethyl 4 Bromo Butyrate Butryolactone Hydrogen Bromide (48%) Ethanol Methyl 2 Bromo Iso Butyrate Iso-Butyric Acid Bromine Methanol Ethyl 2 Bromo Iso Butyrate Iso-Butyric Acid Bromine Ethanol Iso Propyl 2 Bromo Iso Butyrate Iso - Butyric Acid Bromine Iso Propyl Alcohol Ethyl 2 Bromo Valerate Valeric Acid Bromine Ethanol Methyl 2 Bromo Valerate M/s. Neogen Chemicals Ltd. 10
11 Valeric Acid Bromine Methanol Ethyl 5 Bromo Valerate Valerolactone Hydrobromic Acid Ethanol Tert-Butyl 2 Bromo Iso Butyrate Iso Butyric Acid Bromine t Butyl Alcohol Methyl 2 Bromo Caproate n- Hexanoic Acid Bromine Methanol Grignards Formation from Organic Halides 3.1. Methyl Magnesium Chloride 3M in THF n-octyl Bromide Magnesium THF Solution Methyl Magnesium Bromide 1.5M in THF Methyl Bromide Magnesium THF Solution Ethyl Magnesium Chloride 2M in THF Ethyl Chloride Magnesium THF Solution Ethyl Magnesium Bromide 2M in THF M/s. Neogen Chemicals Ltd. 11
12 Ethyl Bromide Magnesium THF Solution Vinyl Magnesium Bromide in 1M in THF Vinyl Bromide Magnesium THF Solution Isopropyl Magnesium Chloride 1M in THF Iso Propyl Chloride Magnesium THF Solution Phenyl Magnesium Bromide 2M in THF Phenyl Bromide Magnesium THF Solution n-butyl Magnesium Chloride 1M in THF n-butyl Chloride Magnesium THF Solution Iso Propyl Magnesium Chloride LiCl Complex 1.3M in THF Iso Propyl Chloride Magnesium Lithium Chloride THF Solution Iso Propyl Magnesium Bromide 1M in THF Iso Propyl Bromide Magnesium THF Solution Halogen Exchange Reactions M/s. Neogen Chemicals Ltd. 12
13 Bromo 2 Chloro Ethane 1,2 - Di Bromo Ethane Sodium Chloride Bromo 4 Chloro Butane 1,4 - Di Bromo Butane Sodium Chloride Bromo 5 Chloro Pentane 1,5 - Di Bromo Pentane Sodium Chloride Bromo 6 Chloro Hexane 1,6 - Di Bromo Hexane Sodium Chloride Bromo 1 Fluoro Methane 1,1 - Di Bromo Methane Sodium Fluoride Dibromo Methane Methylene Di Chloride Sodium Bromide Bromo Chloro Methane 1,1 - Di Bromo Methane Sodium Chloride Ethyl 5 Iodo Valerate 5 Bromo Valeric Acid Ethyl Ester Sodium Iodide Bromo Hepta Fluoro Propane 1,2 Dibromo Hexa Fluoro Propane Potassium Fluoride (30%) Addition of Halogen and Halogen Acids across Double Bonds ,2 Di Bromo Ethane M/s. Neogen Chemicals Ltd. 13
14 Vinyl Bromide Hydrogen Bromide Phenyl Ethyl Bromide Phenyl Ethene Hydrobromic Acid Bromo 3 Chloro Propane Allyl Chloride Hydrogen Bromide n-hexyl Bromide n- Hexene Hydrogen Bromide n-octyl Bromide n- Octene Hydrogen Bromide n-decyl Bromide n- Decene Hydrogen Bromide Cyclo Pentyl Bromide Cyclo Pentene Hydrobromic Acid Cyclo Pentyl Chloride Cyclo Pentene Hydrobromic Acid ,2 Dibromo 3 Chloro Propane 2,3 Di Brome Propene Hydrochloric Acid ,2 Dibromo Hexa Fluoro Propane Hexa Fluoro Propane Bromine M/s. Neogen Chemicals Ltd. 14
15 6. Bromination or Chlorination of Cyclic and Aromatic Compounds with or Without Functional Groups 6.1. Bromo Benzene Benzene Bromine Di Bromo Benzene Benzene Bromine Ethyl 4 Bromo Methyl Benzoate 4 Methyl Benzoic Acid Bromine Ethanol Bromo 4 Chloro Benzene Chloro Benzene Bromine p- Bromo Toluene Toluene Bromine Bromo O Xylene O - Xylene Bromine Chloro 1,4 Naphthaquinone 1,4 Naphthaquinone Chlorine Bromo 4 Fluoro Benzene Fluoro Benzene Bromine Bromo Methyl 2 Cyano Biphenyl (Bromo OTBN) OTBN Bromine M/s. Neogen Chemicals Ltd. 15
16 Methylene Dichloride Hydrogen peroxide (30%) Ethyl Acetate Bromo 3,4 Dichloro Benzene 1,2 Dichloro Benzene Bromine Dehydro-halogenation of Organic Halides Optionally with or without functional Group 7.1. Vinyl Bromide 1,2 Dibromo Ethane NaOH Methanol Vinyl Bromide in THF 25% 1,2 Dibromo Ethane NaOH Methanol THF Vinyl Chloride 1,2 Dichloro Ethane NaOH Methanol Bromo 1 Butene 1,4 Dibromo Butane NaOH Methanol Bromo 1 Hexene 1,6 Dibromo Hexane NaOH Methanol Bromo 1 Heptene M/s. Neogen Chemicals Ltd. 16
17 1,7 Dibromo Heptane NaOH Methanol Bromo 1 Octene 1,8 Dibromo Octane NaOH Methanol Advance Intermediates from Category 1 to Methoxy Naphthaldehyde Naphthaldehyde Bromine Sodium Methoxide Oxygen Methanol Fluoro 5 Bromo Benzonitrile 2 Chloro Benzonitrile Potassium Fluoride (30%) Bromine Ethyl 4- (dimethyl amino) Butyrate Ethyl 4 Bromo Butyrate Dimethyl Amine Ethyl Acetate Bromo Acetal Vinyl Acetate Methanol Bromine Soda solution Bromo Hexyl Trimethyl Ammonium bromide 1,6-Dibromohexane M/s. Neogen Chemicals Ltd. 17
18 Trimethyl amine Gas Ethyl Acetate Bromo 3 Phenoxy Propane 1,3 Dibromo Propane Phenol Sodium Hydroxide (40%) Chloro 2 Hexanone Methyl Acetoacetate Bromo 3 Chloro Propane Potassium Carbonate (30%) IPA HCl (40%) n-octyl Amine n Octyl Bromide Ammonia (20%) Bifenthrin Alcohol Dichloro Toluene Magnesium Bromo Benzene Formaldehyde (60%) THF Ethyl 7 Chloro 2 Oxo Heptanoate Ethyl Acetoacetate Bromo 5 Chloro Pentane Potassium Carbonate Nitrosyl Sulphuric Acid Toluene Formaldehyde (35%) Bromo 6 Methyl Heptane M/s. Neogen Chemicals Ltd. 18
19 1,5 Di Bromo Pentane Iso Propyl Magnesium Methyl 3 Oxo Pentanoate Butyl methyl ketone Chlorine Sodium Cyanide Sulphuric Acid (65%) Methanol Lithium Carbonate or Hydroxide reaction with Inorganic or Organic Acids 9.1. Lithium Bromide 55% Lithium Carbonate Hydrobromic Acid (48%) Lithium Bromide Anhydrous Lithium Carbonate Hydrobromic Acid (48%) Lithium Chloride 40% Lithium Carbonate Hydrobromic Acid (30%) Lithium Chloride Anhydrous Lithium Carbonate Hydrobromic Acid (30%) Lithium Nitrate Lithium Carbonate Nitric Acid (68%) Lithium Sulphate Lithium Carbonate Sulphuric Acid Lithium Molybdate 20% Lithium Hydroxide Monohydrate M/s. Neogen Chemicals Ltd. 19
20 Molybdenum Trioxide Lithium Acetate Lithium Carbonate Acetic acid Lithium Iodide Lithium Carbonate Hydro Iodic Acid (48 %) Lithium Fluoride Lithium Carbonate Hydrofluoric Acid (48%) Hydrobromic Acid from Bromine Hydrogen Bromide 48% to 62% Bromine Hydrogen Hydrogen Bromide 20% in IPA Bromine Hydrogen Iso propyl alcohol Hydrogen Bromide 30% in Acetic Acid Bromine Hydrogen Acetic acid Hydrogen Bromide Anhydrous Bromine Hydrogen Co - Products Sodium Bromide Sodium Hydroxide (50%) Hydrobromic Acid (48%) M/s. Neogen Chemicals Ltd. 20
21 11.2. Zinc Bromide Zinc Hydroxide (45%) Hydrobromic Acid (48%) Potassium Bromide Potassium Hydroxide (45%) Hydrobromic Acid (48%) Calcium Bromide Calcium Hydroxide (45%) Hydrobromic Acid (48%) Magnesium Bromide Magnesium Hydroxide (40%) Hydrobromic Acid (48%) Liquid Bromine (Recovered from above co-products) 6. Details of manpower Total manpower requirement at all level of plant will be Water Consumption & Waste Water Generation Sr. Source Water Consumption (KLD) Wastewater Generation (KLD) 1. Domestic 45 40* 2. Green Belt 12+40* Industrial A Water treatment B Process C Scrubber D Boiler E Cooling Tower Total Industrial TOTAL ( ) Reuse water 40* - Fresh water requirements M/s. Neogen Chemicals Ltd. 21
22 * Treated Sewage 8. Details of Air Pollution Air pollution is mainly from flue gas stack attached to Boiler & stand by D G Set. PNG is used as a fuel in boiler, whereas HSD in D.G. Set. And main emissions from flue gas stack are SPM, SO 2 & NO X. Air pollution process gas stack is from stack attached to Halogen Specific Reaction Plant, Bromine recovery plant, Common Reaction & Multi-purpose plant, Distillation/ Rectification Plant, Ejector vents from Distillation/Rectification plant, Drying, Packing & Finishing Plant & Common stack attached to suction of work place area. Caustic scrubber is used as APCM. And main emissions from Process gas stack are HBr, HCl, Br 2 & Cl 2. Details of stack are given below: Sr. Stack attached to Flue gas stacks Stack Height in m Fuel Used Fuel Consumption Rate APC measure Pollutant 01 Boiler (3 nos.) (2 TPH each) 02 D G set (250 KVA x 3) Process vent 30 (common stack) PNG SCM/day 21 HSD 60 Lit/hrs. each -- SPM<150 mg/nm 3 -- SO 2 <100 ppm NO X <50 ppm 01 Halogen Specific Reaction Plant Caustic Scrubber 02 Bromine recovery Caustic Scrubber 03 Common Reaction & Multi-purpose Plant 04 Distillation/ Rectification Plant 05 Ejector vents from Distillation / Rectification Plant 06 Drying, Packing & Finishing Plant 07 Common stack attached to suction of work place area Caustic Scrubber Caustic Scrubber Caustic Scrubber Caustic Scrubber Caustic Scrubber HBr<20 mg/nm 3 HCl<20 mg/nm 3 Br 2 <2 mg/nm 3 Cl 2 <9 mg/nm 3 M/s. Neogen Chemicals Ltd. 22
23 Source and disposal of wastewater Source of wastewater generation is mainly from water treatment, process, scrubber, boiler & cooling. Entire quantity of w/w is sent to ETP. In-house treated effluent is sent to SEZ Drainage line for final disposal. Domestic effluent is send to STP and then used for greenbelt. Source and disposal of Hazardous wastes Summary of waste and ultimate disposal are summarized below: Sr. Type of Waste Category as per HWM rules, ETP waste MT/month Method of Disposal Collection, storage & disposal at TSDF site approved by GPCB. 2. Process/distillation residue 3. Discarded containers/ barrels/ liners 29.1 / MT/month 33.3 Barrels-5000 nos./month Liner-500 kg/month Collection, storage & disposal at CHWIF or co-processing. Collection, storage and reuse for packing of products or disposal by selling to approved recycler or traders. 4. Used Lubricating Oil Kl/year Collection, storage & use within premises as lubricant/sell to registered recycler. M/s. Neogen Chemicals Ltd. 23
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