PREFEASIBILITY REPORT FOR Proposed Manufacturing of ...environmentclearance.nic.in/writereaddata/Online/... · Prefeasibility Report For Proposed Manufacturing Of Synthetic Organic

PREFEASIBILITY REPORT FOR

Proposed Manufacturing of Synthetic Organic

chemicals, API, Pesticide Technical. At Plot No. W-156, TTC Industrial Area,

Pawane, Navi Mumbai 400710, Maharashtra.

Prepared By Paxchem Ltd. Plot No. A-34, TTC Industrial Area,

Pawane, Navi Mumbai 400710, Maharashtra.

CONTENTS

Sr. No. Element Page No.

* Executive summary 1 1.0 Introduction of the project 2 2.0 Project description 3 3.0 Process Description 5 4.0 Raw Material 13 5.0 Existing infrastructure 14 6.0 Rehabilitation and resettlement (R and R) plan 16 7.0 Analysis of proposal (final recommendations) 16

Prefeasibility Report For Proposed Manufacturing Of Synthetic Organic Chemicals, Pesticide Technical. At Plot No. W-156, Ttc Industrial Area, Pawane, Navi Mumbai 400710, Maharashtra.

Prepared By: Paxchem Ltd. Plot No. A-34, TTC Industrial Area, Pawane, Navi Mumbai 400710,Maharashtra P a g e 1 | 16

EXECUTIVE SUMMARY Paxchem Ltd. (an ISO 9000 and 14000, OHSAS 18000,cGMP, GLP Certified Company) has been manufacturing and marketing Specialty Chemicals such as Industrial Biocides, Preservatives, Anti-microbial and Disinfectant Actives for over 37 years. With more than 1,200 Customers located in 18 Countries, catering to over 25 different applications areas, Paxchem is presently one of the largest and most competent Regional Companies in its area of operation. Paxchem Ltd.’s proposed expansion project for manufacturing of synthetic organic Chemicals, Active Pharmaceutical Ingredients and Pesticide Technical – which are its raw materials for its existing finished products; in its existing manufacturing facility located at Plot No. W-156, TTC Industrial Area, Pawane, Navi Mumbai 400710, Maharashtra. The proposed expansion project products fall under classification 5f and 5b schedules listed in EIA notification SO1533 dated 14/09/2006. Its appraisal category is B-1. Project Synopsis:

Sr.No. Parameters Description 1. Category as per EIA Notification 5f and 5b 2. Longitude 19 0 05’ 30.73” 3. Latitude 730 01 33.17

4. Total Production Capacity after expansion

Total =700 Mton Existing = Nil Proposed =700 MT

5. Total Plot Area 1150 SqM 6 Fresh Water Requirement 15 cum

7. Effluent Quantity (Trade + Domestic) 11.9 +1.9 cum

8. Trade Effluent Treatment

Proposed effluent 11.9 CMD after treatment will be reuse for utilities. High TDS stream will be fed to MEE followed by ATFD. Low TDS stream along with condensate from MEE will be treated in conventional ETP consisting of primary reatment. After primary treatment this effluent is discharged into the Common Effluent Treatment Plant (CETP) of the MIDC.

9. Domestic Waste Water Treatment Sewage treatment plant of capacity 2.0 CMD will be proposed.

10. Fuel requirement at full load

Existing Boiler: 400 kg PH Total Boiler 1 no. Total fuel required 13 Lit/Hr (Type Fuel:) LDO

11. Power Requirement Existing: 12. Dispersion of emission for Boiler Stack Height:11.0 M 13. Dispersion of emission DG Sets, NA 14. Work Force Total=(44)

15. Total Capital Cost the project (Cr) Rs.= Nil



1.0 INTRODUCTION OF THE PROJECT Paxchem Ltd. intends to expand its existing operations and commence manufacturing of synthetic organic chemicals, Active Pharmaceutical Intermediates and Pesticides Technical. The existing manufacturing unit is in Navi Mumbai, TTC Industrial Area MIDC; which is approved chemical manufacturing zone of MIDC. Paxchem Ltd. is located at, Plot No. W-156 and Plot No. A-34. The proposed manufacturing capacity of the unit will be 700 MT/M As per the EIA Notification S.O. 1533 dated 14th September 2006, proposed activity is covered under 5f and 5band need prior environmental clearance. Since it is located in a notified industrial area the project will not need public approval

Table No 1.1 List of Directors and their designations

Sr.No. Name Designation 1. Mr. Xerxes Pervez Batliwala Director 2. Mr. Shreyas Alias Ashok Narayan Pathare Managing Director 3. Mr. Pervez Minocher Batliwala Director

Need for the project and its importance to the country and / or region India's pharmaceutical industry is the third largest in the world in terms of volume. It ranks 14 in terms of value. India is also one of the top five active pharmaceutical ingredients (API) producers (with a share of about 6.5%). The ever-increasing demand for Bulk Drugs and Intermediated in India and abroad as well as changing market conditions requisite Indian pharmaceutical industries to grow further. Pax aims to manufacture high purity Active Pharmaceutical Intermediates which are being used for the preparation of Disinfectants and Sanitizers. The Pesticide Active Manufacturing Industry in India is one of the largest in the world. Pax aims to manufacture Pesticide technical grades which are also used in manufacturing of personal care products. Pax aims to maximize their existing project in order to cater to Domestic and International markets. These products will serve to cut the supply of imports from foreign countries thus saving currency and at the same time will earn valuable foreign currency by export of the proposed products. The population of India as well as the population internationally is increasing at an alarming rate. This has created a huge gap between demand and supply of API, Pesticides and finally the finished dosage form globally. To fulfill this gap, Pax is proposing to increase the range and production capacity to meet the market requirement. The products manufactured will be sold both in domestic and export markets. The major thrust in the export market will earn foreign currency for the country. The foreign currency earned will be utilized to import raw materials used to manufacture these products and save valuable foreign exchange for the country. The proposed products have high in demand in the export market. Also, their demand is increasing in the domestic market. Production of these chemicals domestically reduces

https://www.zaubacorp.com/director/XERXES-PERVEZ-BATLIWALA/01761873

https://www.zaubacorp.com/director/SHREYAS-ALIAS-ASHOK-NARAYAN-PATHARE/00306149

https://www.zaubacorp.com/director/PERVEZ-MINOCHER-BATLIWALA/00306191



the need to import these in future along with significant scope for export in these products. The finished goods will be sold in domestic market and would be largely exported to the Regulated International Market as per demand all over the world. Existing employees are (44) nos. and no additionally manpower is required. 2.0 PROJECT DESCRIPTION The proposed project is an expansion in manufacturing operations of its existing products to include manufacture of products in the category of synthetic organic chemicals and Pesticides in its existing manufacturing facility located at MIDC Navi Mumbai. Existing manufacturing unit is located at Plot No. W-156, TTC Industrial Area, Pawane, Navi Mumbai 400710, Maharashtra. Major factories adjacent to the manufacturing unit are on North side, Jeevan Chemical industries on South side Pax Chem Ltd second unit on East side National rubbers, West side Eco firend Industries. The site is well connected by road to Mumbai Pune Highway at 20 Km. The nearest railway station is KoparKhairne3.0Km. The nearest airport is at Mumbai 30 Km. The project site is situated in MIDC, Navi Mumbai. It is a notified industrial area where the land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity. Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company for 99 years.

Figure 1 Google image of the site.

The proposal is for expansion of existing products in the same manufacturing unit using existing infrastructure only hence consideration of alternate site is not required.



The products manufactured and their capacities proposed are shown in below: Table 2.2. Size/Magnitude of Proposed Production and By-product

Sr. No. List of Products Capacity Tons / Month Existing Proposed Total

1. 5,5- Dimethylhydantoin (DMDMH – 55)

000 100 100

2. bis(2-pyridylthio)zinc 1,1'-dioxide (Zinc Pyrthione)

000 50 50

3. Iodo Propynyl Butyl Carbamate (IPBC)

000 50 50

4. Mixture of 5-Chloro-2-methyl-4-isothiazolin-3-one and Methylchloroisothiazolinone (CMIT and MIT)

000 50 50

5. Chloroxylenol (PCMX) 000 100 100 6. Benzalkonium Chloride 000 200 200 7. Para Chloro Meta Cresol (PCMC) 000 100 100 8. Bronopol 000 50 50 Total 000 700 700



3.0 PROCESS DESCRIPTION 1. 5,5-Dimethylhydantoin (DMDMH - 55)

Product Details Sr. No. Parameter Details

1. Product Name Dimethyl Dimethyl Hydantoin

2. IUPAC Name 1,3-Bis(hydroxymethyl)-5,5-dimethyl-imidazolidine-2,4-dione

3. CAS No. 6440-58-0

4. Molecular Weight 188.18 g/mol

5 Structure

Bill of Materials Sr. No. Raw Material Name Typical BOM Quantity (KG)

1 Dimethyl Hydantoin 37.50

2 Paraformaldehyde 46.50

3 Caustic Soda 0.30

4 Water 15.70 Output 100.00

Manufacturing Details

This process is conducted in a closed reactor type SS 316 / FRP Vessel.

Reaction Steps

1. Charge Paraformaldehyde into assembly. 2. Charge Caustic soda solution in assembly to adjust pH 9 to 9.5. 3. Draw sample for pH. 4. Dimethyl Hydantoin slowly addition started through manhole under stirring. 5. Batch under digestion for 12 hours.



2. bis(2-pyridylthio)zinc 1,1’-dioxide (Zinc Pyrithione)


1 Product Name Zinc Pyrithione

2 IUPAC Name bis(2-pyridylthio)zinc 1,1’-dioxide

3 CAS No. 13463-41-7

4 Molecular Weight 317.70 g/mol

5 Structure


1. Sodium Pyrithione 234.72

2. Zinc Chloride 216.05 Output 100.00


This process is conducted in a closed reactor type SS 316 / FRP vessel.

Reaction Steps

1. Charge water in the reaction vessel and start stirring. 2. Charge Sodium pyrithione into water stir for 30 mins. 3. Start addition of Zinc chloride solution (20%); complete the addition in 2-3 hrs. 4. Stir for one more hour. 5. Centrifuge the reaction mass and dry in FBD.



3. Iodo Propynyl Butyl Carbamate (IPBC) Product Details

Sr. No. Parameter Details

1. Product Name Iodo Propynyl Butyl Carbamate (IPBC)

2. IUPAC Name 3-Iodoprop-2-yn-1-yl butylcarbamate

3. CAS No. 55406-53-6


5. Structure


1. Prop-2-yl N-Carbamate 56.07

2. Caustic Soda 14.64

3. Sodium Iodide 54.18

4. Sodium Hypochlorite 31.78

5 Water 1335.00 Output 100.00


This process is conducted in a closed reactor type SS 316 / FRP vessel.

Reaction Steps

1. Charge Water in to reactor with an agitator, limpet, addition vessel. 2. Charge Caustic and start agitation. 3. Add first step purified product Prop-2-ynl N-Carbamate and maintain temperature at 10°C. 4. Charge sodium iodide into reaction mixture and maintain temperature at 10-15°C. 5. Start addition of Sodium Hypochlorite and complete it in 120 minutes. 6. Once all the Sodium Hypochlorite is added take the temperature slowly to 60°C and agitate for 2 hours. 7. Remove solvent and purify the product. 8. Received the finished product.



4. Mixture of 5-Chloro-2-methyl-4-isothiazolin-3-one & Methylchloroisothiazolinone(CMIT & MIT)

Product Details


1. Product Name Chloromethyl isothiazolinone & Methyl isothiazolinone (CMIT & MIT)

2. IUPAC Name 5-Chloro-2-methyl-2H-isothiazol-3-one & 2-Methyl-2H-isothiazol-3-one

3. CAS No. 55965-84-9

4. Molecular Weight 149.60 g/mol & 115.15 g/mol

5. Structure

CMIT & MIT


1. N,N-Dimethyl-3,3-dithiopropionamide 10.96

2. Chlorine Gas 3.25

3. Toluene 44.10

4. Water 87.72 Output 100.00


This process is conducted in a closed reactor type SS 316.

Reaction Steps

1. Charge water with N,N-Dimethyl-3,3-dithiopropionamide and stir for 30 minutes. 2. Add Chlorine and maintain the temperature below 35°C. 3. Keep Chlorine adding rate slow as to monitor the reaction. 4. Monitor reaction on GC / HPLC the rate of disappearance of N,N-Dimethyl-3,3-dithiopropionamide and formation of CMIT and MIT. 5. Check the pH of reaction, if the pH of the reaction mass is 1 to 4 then start adding buffer. 6. Stir the mixture for 4 to 6 hours.



5. Chloroxylenol (PCMX)


1. Product Name Chloroxylenol (PCMX)

2. IUPAC Name 4-chloro-3,5-dimethylphenol

3. CAS No. 88-04-0


5. Structure


1. 3,5-Xylenol 78.00

2. Sulfuryl Chloride 86.18

3. Ethylene Dichloride 187.20 Output 100.00


This process is conducted in a closed SS 316 type reactor.

Reaction Steps

1. Charge Ethylene Dichloride. 2. Charge 3,5-Xylenol slowly by manhole, start stirrer. 3. Transfer Sulphuryl Chloride from storage tank to batch tank. 4. Charge Sulphuryl Chloride for about 2 hours. 5. Batch is allowed to stand for digestion at a temperature of 15 to 25°C for 1 hr. 6. Batch temperature is raised by hot water circulation up to 58 to 64°C. 7. Cool at Temp 15 to 20°C by ice water circulation. 8. Charge 450 kg Ice chilled water. Stir for 30 minutes. 9. Charge the material in centrifuge. 10. Receive the finished product.



6. Benzalkonium chloride

Product Details


1. Product Name Benzalkonium chloride

2. IUPAC Name N-Alkyl-N-benzyl-N,N-dimethylammonium chloride

3. CAS No. 63449-41-2


5. Structure


1. Alkyl dimethyl amine 32.00

2. Benzyl Chloride 17.70

3. Alcohol (Isopropyl / Ethanol) 3.00

4. Sodium Bicarbonate 0.15

5. Water 47.15 Output 100.00


This process is conducted in a closed reactor type SS 316 / FRP vessel / GLR, Centrifuge and FBD.

Reaction Steps

1. Charge alkyl dimethyl amine by charging pump. 2. Charge water by charging pump by opening the marked charging valve/charging by manhole of the assembly. 3. Charge Benzyl chloride by charging pump by opening the marked charging valve. 4. Charge Sodium Bicarbonate by hopper & agitate the reaction mass. 5. Charge ethanol by hopper via opening the marked valve. Continue agitation. 6. Cool the assembly. Drop the material in nutch filter and remove the material from the nutch filter in charge in centrifuge. 7. After the centrifuge unload the material in clean HDPE bag, record the weight of material. Powder dries in FBD.



7. Para Chloro Meta Cresol (PCMC) Product Details


1 Product Name Chlorocresol (PCMC)

2 IUPAC Name 4-chloro-3-methylphenol

3 CAS No. 59-50-7

4 Molecular Weight 142.58 g/mol

5 Structure


1. Ethylene Dichloride 182.00

2. Metacresol 75.87

3. Sulphuryl Chloride 94.67 Output 100.00


This process is conducted in a closed reactor type SS 316 / FRP vessel, Centrifuge and FBD.

Reaction Steps

1. Charge Ethylene Dichloride into clean and dry reactor. 2. Charge Metacresol slowly by main hole. Start stirrer, chilling plant, and scrubber. 3. Start addition of Sulphuryl Chloride. Batch is allowed to stand for Digestion at a temperature of 15-25°C for 1 hr. 4. After attaining a temperature of 15 – 20°C, add 450 kg ice chilled water stirrer 30 minutes. 5. Lower (bottom) layer charge settles in the nutsch filter. Filter the EDC. Record the filtrate weight. After removing the EDC, wash the material with water up to neutral pH. 6. Remove the material from nutsch filter and charge in Centrifuge. Spin the material in centrifuge with two water washing. (Top layer is water layer passes by nutsch filter. If some product is present in the water layer, it is separated by filter.) 7. Powder dries in FBD.



8. Bronopol


1. Product Name Bronopol

2. IUPAC Name 2-Bromo-2-nitro-1,3-propanediol

3. CAS No. 52-51-7


5. Structure


1. Nitromethane 54.50

2. Formaldehyde 36.00

3. Bromine 60.00

4. Calcium oxide 21.50

5. Ethylene chloride 500.00

6. Sodium hydroxide 25.00

7. Water 700.00 Output 100.00


This process is conducted in a closed reactor type SS 316 / FRP vessel, Centrifuge and FBD.

Reaction Steps

1. Charge Filtered / Treated – Processed Water in the vessel. 2. Charge Nitromethane & Formaldehyde Derivative in the vessel along with caustic soda flakes. 3. Bromine is added to the mixture and forms crude Bronopol with NaBr as a byproduct. 4. The isolated crude bronopol is treated with activated charcoal and filtered. This releases spent carbon which is used as solid waste. 5. The treated product is crystallized, isolated and washed with water. The mother and wash liquors released as byproducts are transferred to the Distillation unit for water recovery and the water is reused in Step 2 and 4. 6. The finished product Bronopol of suitable purity is obtained after it gets dried.



Raw materials required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product. 4.0 Raw Materials: The detailed raw material list for product mixed products as per selected capacity is detailed below for all reactants, solvents and support chemicals. Source for Raw Material Procurement: Raw Materials are easily available in the local market, from Mumbai and some raw material will be imported. Table 2-2: List of Raw Material

Sr. No. Name of Product Existing Quantity (MT/Month)

Proposed Quantity (MT/Month)

Total Quantity (MT/Month)

5,5- Dimethylhydantoin (DMDMH – 55) 1. Dimethyl Hydantoin 000 37.50 37.50 2. Paraformaldehyde 000 46.50 46.50 3. Caustic Soda 000 0.30 0.30 4. Water 000 15.70 15.70

bis(2-pyridylthio)zinc 1,1'-dioxide (Zinc Pyrthione) 1. Sodium Pyrithione 000 234.72 234.72 2. Zinc Chloride 000 216.05 216.05

IodoPropynyl Butyl Carbamate (IPBC) 1. Prop-2-yl N-

Carbamate 000 56.07 56.07

2. Caustic Soda 000 14.64 14.64 3. Sodium Iodide 000 54.18 54.18 4. Sodium Hypochlorite 000 31.78 31.78 5. Water 000 1335.00 1335.00

Mixture of 5-Chloro-2-methyl-4-isothiazolin-3-one and Methylchloroisothiazolinone(CMIT and MIT)

1. N,N-Dimethyl-3,3-dithiopropionamide

000 10.96 10.96

2. Chlorine Gas 000 3.25 3.25 3. Toluene 000 44.10 44.10 4. Water 000 87.72 87.72

Chloroxylenol (PCMX) 1. 3,5-Xylenol 000 78.00 78.00 2. Sulfuryl Chloride 000 86.18 86.18 3. Ethylene Dichloride 000 187.20 187.20

Benzalkonium Chloride 1. Alkyl dimethyl amine 000 32.00 32.00 2. Benzyl Chloride 000 17.70 17.70 3. Alcohol (Isopropyl /

Ethanol) 000 3.00 3.00

4. Sodium Bicarbonate 000 0.15 0.15 5. Water 000 47.15 47.15

Para Chloro Meta Cresol (PCMC) 1. Ethylene Dichloride 000 182.00 182.00



2. Metacresol 000 75.87 75.87 3. Sulphuryl Chloride 000 94.67 94.67

Bronopol 1. Nitromethane 00 54.50 54.50 2. Formaldehyde 000 36.00 36.00 3. Bromine 000 60.00 60.00 4. Calcium Oxide 000 21.50 21.50 5. Ethylene Chloride 000 500.00 500.00 6. Sodium Hydroxide 000 25.00 25.00 7. Water 000 700.00 700.00

Mode of Transport of Raw Materials: Raw Materials will be transported through Trucks/ Tankers from the Supplier’s factories or traders go-downs. Storage at the site: Raw Materials are stored in Raw material storage area at the project site. Water Requirement and Source Fresh water requirement of the project for domestic and industrial activity during operation phase will be 15 CMD. The water supply is from MIDC. Power Requirement Existing power requirement is 600 KW and additionally 400 KW will be required for expansion. Total power requirement will be 1000 KW. Source is State Electricity Board. Effluent Generation: The quantity of effluent generated proposed project is given in Table below Table: Details of Effluent Generation

Sr. No. Units Effluent generation(CMD) A Process 10.2 B Utilities 1.2 Trade effluent Total 11.4

C Domestic 1.9 Trade effluent generated from the expansion project will be 11.4 CMD. This will be treated in ETP plant consisting primary treatment and will be discharged in the Common Effluent Treatment Plant. 5.0 Existing Infrastructure The MIDC has allotted a plot of area 1150sqm. Built up area is 321 sqm. 6.0 SITE ANALYSIS • This unit is at Plot No. W-156, TTC Industrial Area, Pawane, Navi Mumbai 400710. • The nearest city from the site is Vashi at distance of 3.5 Km • The nearest railway station is Kopar Khairne at distance of 3.0Km from the site • The nearest airport is at Mumbai 30 km. • National Highway Mumbai Pune highway is at 2.5 Km from project site.



The proposed land is situated in approved chemical zone of MIDC where land use is industrial. Land is owned by MIDC and is leased for 99 years. The proposed industry is located at Latitude 19 0 05’ 30.73” N and Longitude 73 0 01’ 33.49” E. Elevation above mean sea level is: 13 m. Soil classification The basic type of soil found in the area varies from brown and black. The black type of soil is found in the eastern part. The fertility of the soil increases as it goes from red to black. Climate Temperature: Annual maximum and minimum temperature in Navi Mumbai range from max. 38°C and min. 11°C. Rainfall: Most of the rainfall occurs in the monsoon season from June to September. Average annual rainfall is 2500 mm. Humidity: Annually relative humidity ranged from 61 % to 96% and during summer season the humidity ranged from 56 % to 75%. Social Infrastructure Availability MIDC Industrial area, Navi Mumbai provides many basic facilities like uninterrupted water supply, power and road network and solids disposal facility if feasible. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure. There are few Hospitals within 10 Km radius. Land Use Planning Existing land is converted for industrial purpose. The land is located in a designated industrial area. No change in land use. In the site, many basic facilities like uninterrupted water supply, Power and Road Network and solids disposal facility if feasible are available. This site is inside the campus of the MIDC and means safe transportation, less need of utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure and networking with TTWMA (Trans Thane Creek Waste Management Association) and CETP (Common Effluent Treatment Plant) in vicinity established with support of MIDC and MPCB. All nearby villages are provided with drinking water from wells or Government Water Supply Schemes RWS. Hence, we do not encroach upon their supply. Social Infrastructure The basic amenities within the study area include primary schools, dispensaries, water supply, electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training institute and entertainment etc. Drinking Water Management The source of water supply is from MIDC, Navi Mumbai. Sewage System The domestic effluent will be treated in proposed sewage treatment plant. Industrial Water Management Existing effluent 2.0 CMD will be discharged to CETP after primary treatment and propose effluent 11.9 CMD will be discharged to CETP after primary treatment.



Solid Waste Management Hazardous solid waste generated from the process will be collected, stored, transported (Trans boundary Movement) Rules 2008. 7.0 Rehabilitation and Resettlement (R and R) Plan Proposed activity will be at existing manufacturing unit located at MIDC area. Hence, there is no any kind of activity of Rehabilitation and resettlement carried out over it. 8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Company will contribute in improving education and health facilities in nearby area.

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PREFEASIBILITY REPORT FOR Proposed Manufacturing of ...environmentclearance.nic.in/writereaddata/Online/... · Prefeasibility Report For Proposed Manufacturing Of Synthetic Organic