by m/s hercules pigments pvt....

Prefeasibility Report

New Project: 1 Manufacturing: Organic Azo Pigment

ON

PROPOSED PROJECT FOR THE MANUFACTURE

OF ORGANIC AZO PIGMENTS

Category – 5 (f)

By

M/S HERCULES PIGMENTS PVT. LIMITED

Located at:

Plot No. 1704, Chemical Zone

GIDC Notified Industrial Area, GIDC Sarigam, Dist- Valsad

Gujarat.

Prefeasibility Report M/S HERCULES PIGMENTS PVT. LTD

New Project: Manufacturing: Organic Azo pigment

Project prefeasibility report for obtaining prior Environmental Clearance in terms

of provisions of EIA Notification -2006

1. Executive Summary :

Name & Location:

Name of the Project : M/s. Hercules Pigments Pvt. Limited

Location : Plot No.- 1704, GIDC Notified Industrial Sarigam, Ta: Umbergaon,

Dist- Valsad 396 155. Gujarat.

Project M/S Hercules pigments Pvt. limited is a new proposed project to be located in GIDC notified

industrial area, falling under small Scale category & proposes to manufacture Organic Azo

Pigments (Yellow, Orange, Red).

Proposed Project Cost: Rs. 700 Lacs.

Applicability of EIA notification – 2006

Category as per the amended EIA notification- 2006: as proposed products (i.e. Organic Azo

Pigments) are covered under the Category 5 (f) B. Hence, Environmental Clearance is required.

Project Proponent

The company in India comprising 3 Directors

Small Scale Unit

List of finished products & by- products

SR. NO. PRODUCT MT/MONTH

1 Organic Azo Pigments (Orange/Yellow/Red)

150

Manufacturing process with chemical reaction & mass balance is attached as Annexure-3

Resource Requirement

Components Proposed Resources availability

Power, KVA 200 Will be sourced from Dakshin Gujarat Vij Co. Ltd.

Fresh Water, kl/Day 260 Will be sourced from GIDC water supply dept.

Natural gas for Steam Boiler (2.5 TPH) ,

SCM/day

1700 From GSPC Limited



Natural gas for Hot air dryer (2.5 TPH) ,

SCM/day

800 From GSPC Limited

Fuel (HSD) for D.G.Set (200 KVA) , Kgs/Hr

40 Will be sourced Local Dealer

Raw material Consumption

(1.0) ORGANIC YELLOW PIGMENT

Sr. No. Raw Materials Quantity in MT

Ton per ton of product

Proposed, MT/Month

1.1.1 Base (Amine) 0.405 60.75

1.1.2 Ice 12.0 1800

1.1.3 Sulphamic acid 0.009 1.35

1.1.4 Sodium nitrite 0.69 103.5

1.1.5 Hydro Chloric Acid (30%) 0.96 144

1.1.6 Caustic 0.35 52.5

1.1.7 Acetic acid & others 0.285 42.75

Total 14.699 2204.85

(2.0) ORGANIC RED PIGMENT

2.1 Base (Amine) 0.42 63

2.2 Ice 10.67 1600.5

2.3 Sulphamic acid 0.024 3.6

2.4 Sodium nitrite 0.194 29.1

2.5 Sulphuric acid 2.91 436.5

2.6 Caustic 0.63 94.5

2.7 Hydro Chloric acid 0.97 145.5

2.8 Coupler 0.57 85.5

Total 16.388 2458.2

(3.0) ORGANIC ORANGE PIGMENT

2.3.1 Base (Amine) 0.405 60.75

2.3.2 Ice 9.0 1350



2.3.3 Sulphamic acid 0.007 1.05

2.3.4 Sodium nitrite 0.24 36

2.3.5 Hydro Chloric Acid (30%) 1.08 162

2.3.6 Caustic 0.32 48

2.3.7 Emulsifier & others 0.02 3

Total 11.072 1660.8

Water and Waste Water Management

Total raw water requirement is 260 M3/day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

Total Industrial Waste water generation is 250 M3/Day mainly from process, washing, boiler blow down, cooling which will be treated in proposed primary & secondary treatment plant & discharge into underground effluent drainage line of GIDC Sarigam to CETP Sarigam for further treatment & ultimate disposal into Arabian Sea through closed pipe line.

Domestic waste water (5 M3/Day) will be disposed off through septic tank.

Air Emission and its Control Measures

Flue gas emission:

The company proposes to install 2.5 TPH capacity of steam boiler for the requirement of

process steam. The unit shall use 1700 SCM/day of natural gas as a fuel. Adequate height of

stack will be provided. Also the unit shall use natural gas fired hot air dryer having

consumption of natural gas will be 800 SCM/day.

The company shall install one number of new 200 KVA capacity D G set, as standby. It will be

used only during power failure. Average 40 kgs/hr of HSD will be used as a fuel. 11 meters

height of exhaust will be provided.

Process gas emission:

Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers. The process heat is

provided by hot air dryer. The pulverization will be carried out in a closed system includes

cyclone separator & bag filter. (Details of Air pollution control measures are attached as

Annexure-8).



Hazardous Wastes and its Management

No Type of waste Category Qty. MT/ Year

Treatment Disposal

1 ETP waste 34.3 50.0 Dried, packed in bags

Dispose off into TSDF,

Vapi

2 Used Oil 5.1 0.005 Packed in carboys

Sell to Registered

re-processers

3 Discarded containers 33.3 1.0 De-contaminated,

stored

Sell to authorized

recycler



2. Introduction of Project / Back Ground Information :

(i) Identification of Project and proponent.

Name of the project Proponent: M/S Hercules Pigments Pvt. Limited

HERCULES PIGMENTS PVT LTD is a medium scale unit is located in notified industrial

estate, GIDC, Sarigam, Di: Valsad having total plot area 4306 m2 & total investment will

be Rs. 700 Lacs. The proponent wishes to start the production of Organic Pigments (Red,

Yellow and Orange) with capacity of 150 MT per month. The product is especially used in

printing ink, paints and plastic formulation like newspaper inks, magazine, food

packaging, home and industrial paints and plastic master batches as per requirement.

The proposed project site lies on 20018’02.33” N Latitude & 72051’03.43”E Longitude.

M/S HERCULES PIGMENTS PVT LTD is proposing to be located at plot. No. 1704, GIDC

Sarigam, Ta: Umbergaon, Di: Valsad district in Gujarat state and same western part

comes under Daman union Territory. GIDC is located nearby National Highway No. 8

connecting Mumbai and Ahmedabad and is surrounding by Union territories of Daman

in western side. The western Railway Main Line is passing through the area (Double &

Electrified). Nearest town & industrial estate Vapi is the biggest railway station in the

study area; where, almost all the important mail & express trains stop. Entire study area

is well connected with the other major cities of the state and the country.

Beside the rail connectivity, and also well connected by road transport. There is a good

network of roads in the area and contributes for the development and economic growth

of the area. The National Highway No. 8 (Surat – Mumbai) is now six lanes, double

tracked, more elevated and Jam free highway, which is developed by M/s L & T

Company. This highway has given a further boost to the economic growth of this area.

The existing unit is operated by technocrats having more than 30 years of experience in

manufacturing and marketing of various Organic pigments.

The company has been established in 2008 with manufacturing plants in Vapi, Gujarat

having well equipped production plant which is being managed by dedicated, qualified &

skilled persons.

The proponent shall to start production of Organic pigments with total capacity of 150

MT per month and process capabilities to manufacture High Performance pigment

series.

Hercules Pigments Pvt Ltd is established in 2008 and managed by a professional board

of directors. It manufactures and markets a wide range of Organic Pigments. Senior

personnel are available for providing support to the manufacturing unit in the areas of

technology, R&D, manufacturing, quality control and quality assurance. Organic

pigments are manufactured at the company’s 3 manufacturing units located at Vapi

Gujarat for sale in local & international market. It was co-founded by 3 technocrats.



Identification of the project proponent:

The company is managed by the promoters and whole time directors Mrs. Vatsala

Narendra Desai, Mr. Swetal Narendra Desai and Mr. Anupam Desai having more than 30

years experience & their team members Mr. Pramod Kumar Tandon who is Masters in

Chemical Technology having 45 years experience in chemical industries.

The company emphasis on R & D, quality control, marketing, production, logistics,

import & export.

Company’s strength is commitment, best quality, timely delivery at best prices.

The Directors have good experience and exposure in Azo pigments industries as the

main director has been in this line of business for more than 2 decades. They have

developed wide ranging contacts in the country and abroad and do not foresee any

problem in the marketing the product manufacturing.

(ii) Brief description of nature of the Project :

The proposed project involves the production of “Organic Pigments” which are used in

Printing Inks, Paints, Plastics and cosmetic formulation like newspaper, magazine,

flexible packaging, home and industrial paints, plastic master batches and

cosmetics etc. as per requirement. As per the EIA notification- 2006 as amended

products are covered under any category 5(f) required Prior Environmental Clearance.

For the proposed new project, the company intends to procure the available latest

technology for manufacturing the products.

A typical plant shall house of MS Rubber lined/Stainless Steel reactors, Filter Press,

dryers, multi-mills, jet mills, blenders etc.

(iii) Need for the project and its importance to the country and or region :

The proposed new project provides a potential growth opportunity for the running

business of the company. The company is already engaged in the business of

manufacturing of “Organic Pigments”. The project would increase the overall export

and also increase the foreign revenue. Product is now well established and acceptable

in the international markets.

Additional capacities of product range required over & above our existing capacities, as

the company expect strong growth of exports to the extent of 40-50%. Local market

also showing strong growth potential.

Domestic market concentrated in Pan-India, particularly in West and Northern belt,

making Sarigam as ideal choice. This project will generate employment of up to 100

people.



(iv) Demand –Supply Gap :

The products have very high specific demand as they are especially used in printing ink

formulation like news paper and flexible packaging as per requirement.

(v) Imports vs. Indigenous production :

Existing products manufacturing in the country will be very much economical as

compared to Import of the same. The export of this pigments will earn revenue for the

county.

(vi) Export Possibility :

Existing products have high export potential. Also these products have very good sab

potential in local market.

Additional capacities of product range required over & above our existing capacities at

Sarigam, as the company expect strong growth of exports to the extent of 40-50%. Local

market also showing strong growth potential.

(vii) Domestic / export Markets :

The company’s product is used as raw material to manufacture various printing inks,

paints and master batches as per the required applications and having very good market

in domestic and also having very good international markets.

(viii) Employment Generation (Direct and Indirect) due to the project :

There will be very good opportunity of employment generation directly and indirectly

due to proposed new project. Due to proposed project there will be ~100 people will be

directly/indirectly employed.

3. Project Description :

(i) Type of Project including interlinked and interdependent projects, If any :

The proposed project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary &

project site layout) with coordinates :

The map showing general location, specific location and project boundary and project

site lay out is enclosed as Annexure-1.Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted :

The proposed activity will be accommodated in the notified industrial area having

proper industrial infrastructure so; there is no alternate site consideration. Proposed

expansion will be carried out in existing premises only. (Land allotment letter is attached

as Annexure-6).

(iv) Size or magnitude of operation :

As per the proposed project cost the project is covered under medium Scale category of

manufacturing industries.



(v) Project description with process details (a schematic diagram/ flow chart showing the

project layout components of the project etc. should be given) :

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of

final products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source,

marketing are of final products mode of transport of raw material and finish product &

characteristics of hazardous chemicals are as below:

DETAILS ON PRODUCT/BY-PRODUCTS TRANSPORTATION

Sr. No.

Product Physical State Dispatch Means of Transportati

on 1 Organic Azo Pigments

(Red/Yellow/Orange) Solid Local/Export Truck/contai

ners

DETAILS ON RAW MATERIAL TRANSPORTATION

Sr. No.

Substance Physical State

Source of Supply & packing

Means of Transportation

Distance of supplier

from project site

(km) 1 Base (Amine) Powder Local, 25 kgs

bags container 200 kms

2 Ice solid Local, 50 kgs bags

tractor 10 kms

3 Sulphamic acid

Powder Local, 25 kgs bags

container 200 kms

4 Sodium nitrite

Powder Local, 25 kgs bags

container 200 kms

5 Hydro Chloric Acid

(30%)

liquid Local, tanker tanker 25 kms

6 Caustic lye liquid Local, tanker tanker 25 kms

7 Acetic acid & others


8 Sulphuric acid




(vii)

DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS

No Name of the Raw

Materials

Quantity stored, MT

BP. 0C

MP 0C

Place of its

Storage

State operati

ng pressur

e temperature

Possible type of hazards

Control measures provided

Max Actual

1 DCB 46 20 Bags N.A 132 Solid Avoid

contact with

skin & eye.

Avoid

breathing

dust, mist or

gas.

Use Chemical

goggles,

Gloves, Apron,

Purifying

respirator.

2 AAA 46 20 Bags Does

not

bil

up

to

200

85 -

86

Solid May cause

Eye and Skin

irritation,

respiratory

and

digestive

tract

irritation.

Ingestion of

large

amount may

cause

gastrointesti

nal irritation.

Use chemical

safety goggles,

Wear

appropriate

protective

gloves and

clothing to

prevent skin

exposure.

Always use a

NIOSH or

European

Standard

EN149

approved

respirator.

3 Caustic

lye

36 10 Stor

age

tank

/Dru

ms

13

88

318 Liqui

d

Skin

irritation

with greater

skin

exposure,

eye contact

causes

destructive

to eye

tissue.

Contact

lenses

should not

be worn

when

working with

this

Employee

should be

provided with

impervious

clothe, gloves,

face

shield(eight-

inch

minimum),dus

t and splash

proof safety

goggles,

chemically

resistant

safety shoes,

eyewash

station and



chemical.

Swallowing

Sodium

Hydroxide

may cause

severe burns

of mouth,

throat,

esophagus

and

stomach.

safety showers

must be

available.

4 Hydro

Chloric

acid

124 20 St

or

ag

e

ta

nk

53 -74 Liqui

d

Corrosive

Liquid. Mist

causes

severe

burns to all

body

tissue, may

be fatal if

swallowed

or inhaled,

inhalation

may cause

lung

damage.

Use chemical

safety goggles

or full face

shield, Rubber

or neoprene

gloves and

additional

protection

including

impervious

boots, apron.

NIOSH

approved

Respirators.

5 Sulpha

mic

acid

2 1 Ba

gs

N.

A

N.A Solid Irritant. Use Chemical

safety face

shield, Rubber

hand gloves,

Rubber or PVC

apron.

6 Napht

hol AS

50 10 Ba

gs

N.

A

240-

244

Solid In case of

Skin and

Eye contact

(Slightly

irritanting)

Use chemical

Goggles,

Gloves and

Respirators,

avoid contact

with eyes and

skin.

7 Sodiu

m

nitrite

80 10 Ba

gs

32

0

271 Solid Toxic if

swallowed,

very toxic

on

inhalation,

irritation to

eyes,

possible

skin

sensitizer.

Use Chemical

goggles, full

face shield,

Wear PVC

gloves, Rubber

safety

footwear or

gumboots. The

material may

produce skin



Resource optimization/ recycling and reuse envisaged in the project , if any , should

briefly outlined

Contact

with

combustibl

e material

may cause

fire.

sensitization in

predisposed

individuals,

care must be

taken, when

removing

gloves and

other PPE, to

avoid all

possible skin

contact.

8 PMP 50 10 Ba

gs

28

7

126

–

130

Solid Causes

Irritation in

case of Skin

and Eye

contact.

Use splash

resistant

safety goggles,

appropriate

chemical

resistant

clothing and

gloves.

Resource optimization/recycling and reuse envisaged in the project in detail are as

mentioned below:

The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses.

Proper earthing shall be provided were ever hazardous material handling is done.

Entire plant will be flameproof.

Wash water will be recycled to minimize the fresh water consumption.

(viii) Availability of water its source, Energy/power requirement and source should be given

:



Availability of water its source, Energy/power required and its source is below. Water

withdrawal permission is attached as Annexure-4.

PRODUCTWISE WATER CONSUMPTION M3 PER TONE OF PROPOSED PRODUCT

INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING

Sr. No. Product Processing Boiler

(Live

Steam)

Cooling

(Ice)

Product

Washing

Total

1 Organic Red

Pigment

6.5 4.0 11.0 20.0 41.5

2 Organic

Yellow

Pigment

7.0 4.0 12.0 20.0 43.0

3 Organic

Orange

Pigment

7.5 4.0 9.0 20.0 40.5

4 Maximum 7.0 4.0 12.0 20.0 43.0

PRODUCTWISE EFFLUENT GENERATION M3 PER TONE OF PROPOSED PRODUCT



(Live

Steam)

Cooling

(Ice)

Product

Washing

Total

1 Organic Red

Pigment

6.5 3.9 11.0 20.0 41.39

2 Organic

Yellow

Pigment

6.9 3.9 12.0 20.0 42.8

3 Organic

Orange

Pigment

6.7 3.9 9.0 20.0 39.6

4 Maximum 6.9 3.9 12.0 20.0 42.8



PRODUCTWISE WATER CONSUMPTION M3 PER DAY OF PROPOSED PRODUCT



(Live

Steam)

Cooling

(Ice)

Product

Washing

Total

1 Organic Red

Pigment

37.5 23.1 63.5 115.4 239.4

2 Organic

Yellow

Pigment

40.4 23.1 69.2 115.4 248.1

3 Organic

Orange

Pigment

43.3 23.1 51.9 115.4 233.7

4 Maximum 40.4 23.1 69.2 115.4 248.1

PRODUCTWISE EFFLUENT GENERATION M3 PER DAY OF PROPOSEDPRODUCT



(Live

Steam)

Cooling

(Ice)

Product

Washing

Total

1 Organic Red

Pigment

37.5 22.5 63.5 115.4 238.8

2 Organic

Yellow

Pigment

39.8 22.5 69.2 115.4 246.9

3 Organic

Orange

Pigment

38.7 22.5 51.9 115.4 228.5

4 Maximum 39.8 22.5 69.2 115.4 246.9



OVERALL WATER CONSUMPTION & EFFLUENT GENERATION(M3/DAY)

Sr. No.

Particulars Water Consumption

Effluent generation

1. Domestic 5.0 4.0

2. Processing 40.4 39.8

3. Boiler ( Live steam)

Boiler blow down &

DM rejection

27.0 24.0

4. Product Washing 115.4 115.4

5. Cooling as ice 69.0 69.0

6. Floor/container

washing

2.0 2.0

7. Gardening 1.0 0

8. Grand Total 259.8 254.2

9. Total Industrial 253.8 250.2

Note:

Average 260 M3/day fresh water will be used for proposed plant and source from GIDC authority.

Domestic effluent shall be passed through adequate capacity of septic tank/soak pit.

Process effluent shall be sent ETP.

Boiler blow down, D M rejection & live steam comes out as an effluent.

Ice water comes out as effluent.

Floor/container & vessel washing comes out as effluent.

Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through under ground drainage line for further treatment & ultimate disposal into Arabian Sea.



ENERGY REQUIREMENT AND ITS SOURCE

Sr. No.

Particulars Proposed Source

1 Steam requirement

2500 kgs./hrs. Will be obtained from proposed NG fired steam boiler of 2.5 TPH capacity

POWER REQUIREMENT AND ITS SOURCE

Sr. No.

Particulars Proposed Source

1 Power –Electricity requirement

200 KVA Will be sourced from Dakshin Gujarat Vij Co. Ltd.

(ix) Quantity of waste to be generated ( liquid and solid) and scheme for their

Management/disposal :

Quantity of waste to be generated (liquid and solid) and scheme for their Management/

disposal is enclosed as Annexure-4.

(x) Schematic representations of the feasibility drawing which give information of EIA

purpose: A schematic representations of the feasibility drawing is attached as

Annexure-7

Site Analysis

(i) Connectivity :

The project is to be located in notified Industrial Estate of Sarigam which is very well

connected to National Highway no.8, Western Railways. And the nearest air port

(Mumbai) and port are 150 KM away from the project site by road.



4. (ii) Land Form, Land use and Land ownership :

The land is in the form of industrial shed owned by Gujarat Industrial Development

Corporation.

(iii) Topography (along with map) :

Topography map showing the elevation of study area is below;

The catchment area of the proposed project site altitude is 35 m (a.m.s.l) consists of the

near site is flat topped, highly dissected plateaus and dyke ridges running in a west to

east direction. The Main River (Daman Ganga) in the catchment area flows in incised

meanders forming steep geomorphologically ‘V’ shaped valleys with steep sides. The

entire catchment has a rectangular and trellis pattern of drainage depicting the

influence of the structures on the drainage development.

Topography map showing the elevation of the study area below. The topographical map

is enclosed as Annexure-5.

(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including

area under CRZ)), shortest distances from the periphery of the project to periphery of

the forest, national park, wild life sanctuary , eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of

Gazette notification should be given :

The existing land is located in the notified industrial area and a copy of possession letter

and gazette notification is enclosed as Annexure-6.

(v) Existing Infrastructure :

GIDC notified industrial area of Sarigam has the entire available infrastructure like

water, electricity, roads, rail, transportation, availability of raw material and drainage

system.

(vi) Soil classification :

General soil classification of the area is as under :

The area, being of basaltic formation, falls under the broad soil group of red loams and

black clay soils. The transmission of water through similar parent material seems to have

influenced the development of different physiographic characteristics of the soils in the

area.

The area in between the hills with sloping lands contains dark yellowish brown to very

dark grayish brown gravelly clay loam to clayey soils of shallow to moderate thickness.

The dissected hill and steep slopes suffer from severe erosion hazards. The steep hill

slopes are almost devoid of soil.

(vii) Climate data from secondary sources :

Rainfall Data :

The project site location receives annual rainfall of 2010 – 1200 to 1300 mm in 35 rainy

days with coefficient of variation of 65 %. There is large spatial and temporal variation in

rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are



comprised of Kutch district and western parts of Banaskantha and Patan district and

parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by

arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad,

Navsari and Surat, Dadra & nagar haveli and Daman & Diu) are characterized as sub

humid climate. The rest part of the state receives rainfall between 500-1000 mm and

generally fall under semi-arid climate.

Temperature & Climate Data:

Proposed project site falls under seismic zone-III, which h is not highly earthquake prone

area. Aside from the monsoon season, the climate is dry. The average maximum

temperature 35 - 41 oC and Minimum temperature, 12 -15

oC. The average humidity ranges

from nearly 84% in August to about 31% in February.

(viii) Social Infrastructure available :

Social Infrastructure in Valsad district is as under :

Education : There are 990 primary and 161 secondary and higher secondary Table 5: List

of Educational Institutes schools in the district Educational Total With over 1,250 seats,

there are 6 ITIs offering several industrial training Institutes programs which includes,

fitting, armature & motor rewinding, Primary School 990 electrician, information

technology and electronic system maintenance Secondary School etc 166 Higher

Secondary School, One Government polytechnic College is present in the district

offering courses in civil, chemical, electrical, mechanical and plastic engineering, ITI’s 6

with an intake capacity of 360 Polytechnic 1 College§ With 120 seats, there is one

Degree Engineering College present in Pharmacy College 2 Valsad offering engineering

courses in mechanical and chemical Engineering 1 branches College§ Located in Vapi, G.

M. Bilakhia Pharmacy College has an intake Management 1 College capacity of 60

students per year Other Colleges Rofel Institute of Management studies in Valsad offers

full time MBA Other Colleges: Arts, Commerce, Science, B.Ed and Law College course

and takes 120 students per annum Source: Department of Education, 2007

1. Health: There are 43 primary healthcare centres, 10 community healthcare

centres, 10 Government and 1 Municipal hospital present in the district. Valsad has

several private specialized hospitals to provide a comprehensive range of tertiary and

secondary care services backed by state-of- the- art technology and trained medicos§ A

multi-specialty 21st Century Hospital, (branch of Nadkarni Group of Hospitals) is present

in Vapi, giving services in general and laparoscopic surgery, trauma, orthopedic and

urology etc. the hospital is one of the few centers in India offering Uterine

Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB)

patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General

Hospital, and Adarsh Hospital are also present in Valsad

2. Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also

known Fire Temple as Mecca for the Parsi community in India, makes the city a famous

pilgrimage center throughout the world§ Dharampur is surrounded on three sides by

the Sahyadri Mountains which grace the town with pleasant climate throughout the

years The collection at the Lady Wilson Museum in Dharampur includes tribal art and art

crafts that highlights the local culture. Besides this, District Science Centre is also



present in Valsad Proximity of Valsad with Daman & Diu, has increased the graph of

tourist flow in the district.

5. Planning Brief :

(i) Planning Concept ( Type of industries, facilities, transportation etc) Town and Country

Planning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in manufacture of variety of products, for example pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Sarigam.

(ii) Population Projection :

Not applicable

(iii) Land use Planning (breakup along with green belt etc) :

The proposed project is located within the Notified Industrial Area by Government of

Gujarat and due to the proposed project there will not be any change in the land use

pattern of the region. Proposed Green belt planning in the project area is as below.

For Green Belt Development, the company proposes to develop a green belt in 22% of the total plot area. i.e. 4306 sq. meter. In addition to this company shall also develop green belt along the periphery of the proposed site and in common premises available outside the company premises.

Site plan with Area table for proposed plant

Sr. No Particulars Area in m2

1 Production area 700

2 Raw material storage area 150

3 Finished product storage 50

4 Office & laboratory area 100

5 Toilet block & others 150

6 Utility & boiler 330

7 Solid waste storage 40

8 ETP 60

9 Gardening & plantation 980

10 Open space 1736

12 Watchman cabin 10

13 Total 4306



Site plan & Key Plan



(iv) Assessment of Infrastructure demand ( Physical & Social) :

There is no need for any infrastructure demand in terms of physical or social needs for

proposed expansion.

(v) Amenities/ Facilities :

GIDC notified industrial area of Sarigam has the entire available infrastructure like CETP,

water, electricity, roads, rail, transportation, availability of raw material and drainage

system.

6. Proposed Infrastructure :

(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standard

engineering design considering all the relevant parameters related to environment,

health and safety.

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed project.

(iii) Green Belt :

Green belt will be provided and maintained at the tune of 22% of the total land area.

(iv) Social Infrastructure :

Not applicable

(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) :

The project site is very well connected by road through National Highway no. 8,

railways.

(vi) Drinking Water management ( Source & Supply of water ) :

Source of water is from GIDC water supply services.

(vii) Sewerage System :

GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management :

Average 250 M3/day of Industrial liquid effluent generation during the

manufacturing of proposed products will be treated in proposed primary &

secondary effluent treatment plant and sent to CETP Sarigam through under

ground effluent drainage line of GIDC Sarigam.

Generated domestic liquid waste is being disposed off through soak pit system

to drainage.



(ix) Solid Waste Management :


Treatment Disposal



Vapi


Sell to Registered

re-processers


stored

Sell to authorized

recycler

(x) Power Requirement & Supply / Source :

Power requirement for proposed project will be taken from DGVCL.

7. Rehabilitation and Resettlement (R&R) Plan:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be

given):

There will be no rehabilitation and resettlement undertaken as labours and workers

from local & nearby areas for the proposed construction activity which will be minor as

the proposed activity is to be undertaken at the existing plot/shed.

8. Project Schedule & Cost Estimates :

(i) Likely date of start of construction and likely date of completion ( Time schedule for

the project to be given ) :

After obtaining Environmental clearance and Consent to Establish from GPCB, the

company shall start the proposed construction and commissioning of the project.

(ii) Estimated project cost along with analysis in terms of economic viability of the

project:

Estimated project cost along with the analysis in terms of economic viability of the

project is given as below;

Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the

major heads considered in the Capital Cost Projection for the proposed project.

Environment Protection has also been considered in planning the Cost Projection, which



will include Green belt development, safety systems, etc.

CAPITAL COST PROJECTION

Sr. No. Particulars Cost in Rs.(Lacs) for proposed project

1.0 Land 4306 Sq. meters 350

2.0 Building 125

3.0 Plant & Machinery 150

4.0 Utility 25

5.0 Environmental Management System

50

5.0 Total Project Cost 700

6.0 Utilities

6.1 Steam Boiler, TPH 2.5

6.2 Hot air dryer Three Nos. (Direct firing)

6.3 D.G. Set (Standby), KVA 200

7.0 Power from DGVCL, KVA 200

8.0 Fuel

8.1 Natural gas for steam boiler & hot air dryer, SCM/day

2500

8.2 HSD, kgs/hr 40

9.0 Water from GIDC Sarigam 259.8

10.0 Waste Water (Industrial) 250.2

PROJECT VIABILITY

Sr. No. PARTICULARS AMOUNT INR Lacs/Anum

1 Proposed Sale 5000

2 Raw Material Cost 4000

3 Power & Fuel 300

4 Labor Cost 120

5 Environmental Management System 85

6 Maintenance Cost 50

7 Selling, packing & Office Expenses 250

8 Proposed Profit 195

The company will provide budgetary provision for the recurring expenses for

environmental issues while planning the allocation of funds during the annual budgetary

planning.



Recurring Cost per annum

Sr. No. Component Proposed (Rs. In

Lacs/annum)

1. Environment & Safety Management System 4.0

2. Greenbelt Maintenance 1.0

3. Solid waste Disposal 0.5

Total 5.5

9.

Analysis of Proposal ( Final Recommendations):

(i) Financial and social benefits with special emphasis on the befit to the local people

including tribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms of financial

and social welfare.

Local people will get direct financial benefit by way of employment.

Local people will get some contracts of supply and services to get indirect

income.

Company will contribute in improving education and health facilities in nearby

area.



ANNEXURES

ANNEXURES



ANNEXURE-1 The map showing general location, specific location and project boundary and project site layout of M/S. Hercules Pigments Pvt. Limited , located at Plot No. 1704, GIDC,Sarigam-396155, Dist- Valsad (Gujarat). The location of the project site can be viewed in Figure 1.1

Fig. 1.1: Location map showing the Project site and inter-state boundary with 10 kms radius



ANNEXURE-2

Site Layout Plan & Key Plan



GOOGLE MAP SHOWING PROPOSED PLOT.

Proposed plant



ANNEXURE-3

Detailed project description with process details - MANUFACTURING PROCESS The company will use the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance for the product. Manufacturing process:

Azo Pigments (Organic Yellow/Orange/Red): (a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c. Solution is maintained at this temp.

(b) Coupler Dissolution : Water , Caustic Lye & Coupler is taken in stirred vessel. This mixture is heated to required temp. to make uniform solution. And cooled back to room temp.

(c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution. Take out the wet cake.

Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material Balance is enclosed.

CHEMICAL REACTION

( 1 ) Organic Yellow Pigment

HCl

NaNO2

NH2 NH2

Cl Cl

Cl N=N N=N Cl

Cl Cl

2CH3COCH2CONHC6H5 + 2 NaOH

+ 2 NaCl + 4 H2O

Cl N=N N=N Cl

Cl Cl

CH3COCH2CONHC6H4 - N=N

Cl Cl

N=N-C6H4NHCOCH2COCH3 + 2 NaCl + 2 H2O

3 3’ Dichlorobenzidine

Mol.wt. 253Diazo

AcetoAcetanilide

Mol. Wt. 177

Yellow pigment

Mol. Wt. 618

+

Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG



ORGANIC YELLOW PIGMENT

DIAZOTIZATION

12064 Kgs + 3990 kgs

Hours: 1 ½+11/2=3hr

Water: 4000 Kgs

Base (Amine) : 405 kgs

Ice: 6000 kgs

HCl: 960 kgs

Na Nitrite: 690 kgs

Sulphamic acid: 9 kgs

DISSOLUTION

3990 Kgs

Hours: ½ hr

Water: 3000 lits

Coupler : 640 kgs

Caustic: 350 kgs

COUPLING &

TREATMENT

26339 kgs, Time: 6 Hrs

WASHING ,

23400 kgs , Time: 6HrsWater: 20000 kgs

Filtrate 19900 kgs to ETP

TRAY DRYING ( 24 Hrs)

3500 kgs

Water Vapors: 2498 kgs

PULVERIZER & PACKING

(Time: 6 Hrs)

FILTERATION


Filtrate as effluent: 22939 kgs to ETP

Total: 12064 kgsTotal: 3990 kgs

Diazotization + Dissolution 16054 kgs

Total: 26339 kgs

Crude Pigment Slurry: 26339 kgs

Total : 26339 kgs


Total: 26339 kgs Wet cake: 3400 kgs

Total: 26339kgs

Total: 23400 kgs

Wet cake: 3500 kgs

Total: 23400 kgs

Wet cake: 3500 kgs Dry Powder: 1002 kgs

Dry Powder: 1002 kgs

ORGANIC YELLOW PIGMENT: 1000 kgs

Live steam: 4000 kgs

Acetic Acid & Others: 285 kgs

Wet cake: 3400 kgs

Ice: 6000 kgs

loss: 2 kgs



[2] Organic Orange Pigment

NH2 NH2

Cl Cl

HCl

NaNO2

Cl N=N

Cl Cl

N=NCl

N

N

CCH2

+ 2 NaCl + 2 H2O

Cl N=N

Cl Cl

N=NCl + 2C

+ 2 NaOH

C=O

N

CH-N=NCH3CH

Cl Cl

N=N-

N N

N

CH-CH3CH

O=C

+ 2 NaCl + 2 H2O

3 3’dichlorobenzidine

Mol wt. 253

CH3

O =

PMP

Mol wt. 173

Orange 13 pigment

Mol .wt. 610Base like: DCB, Coupler like PMP, MPMP

ORGANIC ORANGE PIGMENT

DIAZOTIZATION

9332 Kgs + 5800 kgs

Hours: 1 ½+11/2=3hr

Water: 2600 Kgs

Base (Amine) : 405 kgs

Ice: 5000 kgs

HCl: 1080 kgs

Na Nitrite: 240 kgs


DISSOLUTION

5800 Kgs

Hours: ½ hr

Water: 4900 lits

Coupler : 580 kgs

Caustic: 320 kgs

COUPLING &

TREATMENT


WASHING ,

23400 kgs , Time: 6HrsWater: 20000 kgs

Filtrate 19900 kgs to ETP


3500 kgs

Water Vapors: 2498 kgs


(Time: 6 Hrs)

FILTERATION




Diazotization + Dissolution 15132 kgs

Total: 23152 kgs


Total : 23152 kgs


Total: 23152 kgs

Wet cake: 3400 kgs

Total: 23152 kgs

Total: 23400 kgs

Wet cake: 3500 kgs

Total: 23400 kgs

Wet cake: 3500 kgs Dry Powder: 1002 kgs

Dry Powder: 1002 kgs

ORGANIC YELLOW PIGMENT: 1000 kgs


Emulsifier & Others: 20 kgs

Wet cake: 3400 kgs

Ice: 4000 kgs

loss: 2 kgs



NH2

[3] Organic Red Pigment

HCl

NaNO2+

2H2O + NaCL

2:5 Dichloro Aniline

Mol Wt.162

N=NCl

Cl

N=NCl

NH

C17H12NO2

( Naphthol AS)

Mol wt.263

+

Cl

Cl

N=N

C NH

O

Organic Red Pigment

Mol wt. 436

Cl

Cl

Diazo

O

Cl

Cl

OH

OH

Base like: TCA, DCA, Scarlet G base, Coupler like Naphols



(3) ORGANIC RED PIGMENT

DIAZOTIZATION9157 Kgs + 11240 kgs

Hours: 6 hrs

Water: 1500 lits

Base: 432 kgs

Ice: 4000 kgs

H2SO4: 3000kgs

Na Nitrite: 200 kgs


DISSOLUTION

11240 KgsHours: 1 hr

Water: 4000 lits

Coupler: 590 kgs

Caustic: 650 kgs

Steam: 1000 kgs

Ice: 5000 kgs

COUPLING 26397 kgs, Time: 10 Hrs

WASHING ,

25000 kgs

Time: 6HrsWater: 20000 liters Filtrate as effluent: 20000 kgs to ETP


5000 kgs

Water Vapours: 3970 kgs


(Time: 6 Hrs)

FILTERATION




Diazotization + Dissolution:20397 kgs

Total: 26397 kgs

Coupler: 26397 kgs

Total: 26397 kgs

Coupler: 26397 kgs

Total: 26397 kgs Wet cake: 5000 kgs

Total: 26397kgs Wet cake: 5000 kgs

Total: 25000 kgs

Wet cake: 5000 kgs

Total: 25000 kgs

Wet cake: 5000 kgs

Total: 5000 kgs Dry Powder: 1030 kgs

Total: 5000 kgs

Dry Powder: 1030 kgs PRODUCT

(ORGANIC RED PIGMENT: 1030 kgs )

Ice :2000 kgs

HCL: 1000 kgs




ANNEXURE-4

Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal.

Quantity of Waste Water (liquid waste) generation and its management :

Sr. No.

Particulars Water Consumption

Effluent generation

1. Domestic 5.0 4.0

2. Processing 40.4 39.8

3. Boiler ( Live steam)

Boiler blow down &

DM rejection

27.0 24.0

4. Product Washing 115.4 115.4

5. Cooling as ice 69.0 69.0

6. Floor/container

washing

2.0 2.0

7. Gardening 1.0 0

8. Grand Total 259.8 254.2

9. Total Industrial 253.8 250.2

Note:

Average 260 M3/day fresh water will be used for proposed plant and source from GIDC authority.

Domestic effluent shall be passed through adequate capacity of septic tank/soak pit.

Process effluent shall be sent ETP.

Boiler blow down, D M rejection & live steam comes out as an effluent.

Ice water comes out as effluent.

Floor/container & vessel washing comes out as effluent.

Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through underground drainage line for further treatment & ultimate disposal into Arabian Sea.



DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT

Design Criteria :

Product : Organic Azo Pigment

Source of Effluent : process, washing, Utilities & floor/container.

Design Flow of Effluent : 260 KL/day Max.

Design Parameters : As under

Effluent Characteristics:

No Effluent Parameter Untreated combined normal

effluent

Expected Results GPCB

norms

1 pH 7.0- 8.0 7.0-8.0 6.5 to 8.5

2 Color pt. Co 600-800 40-50 <100

3 Suspended solids ,

Mg/L

150-200 60-70 <100

4 Total dissolved solids,

Mg/L

4000-4500 4000-4500 <2100

5 Oil and grease, Mg/L 2-3 1-2 <10

6 NH3-N, Mg/L 10-12 5-10 <50

7 BOD , Mg/L 800-900 80-90 <100

8 COD , Mg/L 3000-3500 200-210 <250

9 Heavy metal, Mg/L Nil Nil <0.1

10 Phenolic Compounds,

Mg/L

Nil Nil <1



Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to

install.

DETAILS OF EFFLUENT TREATMENT PLANT

Average hydraulic load, M3/Day : 250 M3/Day

Design hydraulic load, M3/Day : 260 M3/Day

Average Inlet BOD, mg/l : 800-900

Average Inlet COD, mg/l :3000-3500

No Name of the

unit

Size in

meters

Capacity

in m3

MOC No Detention time Remarks

Reqd. provided Adequacy

1 Oil/grease trap 0.6 x 0.6 x

0.6

0.2 RCC 1 1 min 1.44 min Adequate

2 Collection with

sparger

7 x 5 x 5 m 175 RCC 1 8 hrs 16 hrs Adequate

3 Reaction tank 2.0 ø x 2.5 7.8 MS 1 10 min 25 min Adequate

4 Floculator 2.0 ø x 2.5 7.8 MS 1 10 min 25 min Adequate

5 Chemical

dosing tanks

- 0.2 HDPE 3 - -

6 Primary Lamella

separator with

tube deck

packing

1.5 x 1.5 x

2.0

4.5 MS 1 15 min 32 min Adequate

7 Secondary

Aeration Tank

with build in

clarifier with

tube deck

10 x 5.0 x

4.0

200 RCC 1 12 hrs 18 hrs Adequate

8 Twin Lobe Air

Blower

6500 mmwg 500

nm3/hr

CI 1 - - Adequate

9 Holding tank 5 x 5 x 5 m 125 RCC 1 6 hrs 12 hrs Adequate

10 Filter Press 24 x 24 PP 1 - - Adequate



FLOW DIAGRAM OF PROPOSED EFFLUENT TREATMENT PLANT

O/G TRAP

Collection/Equ tank

Reaction . Tank

FLOCCULATOR

LIME SLURRYTANKS

FeSO4/PEtanks

EFFLUENT

Primary LamellaSeparator

Holding Tank

To GIDCDrain to CETP

SECONDARY AERATION TANK WITH BUILT IN SECONDARY CLARIFIER

TWIN LOBE AIR BLOWER

DIFFUSER

FILTER PRESS



Quantity of Hazardous Waste generation and its management


Treatment Disposal



Vapi


Sell to Registered

re-processers


stored

Sell to authorized

recycler

Note: The unit will obtain membership of approved TSDF site of M/S VGEL, Vapi, for disposal of

Hazardous waste.



ANNEXURE-5

The topographical map



Annexure-6

PLOT ALLOTMENT LETTER ISSUED BY THE GIDC



Notification for Sarigam Notified industrial estate



ANNEXURE-7

A schematic representation of the feasibility drawing



ANNEXURE: 8

DETAILS OF PROPOSED AIR POLLUTION & ITS CONTROL MEASURES

The utility emissions will be from the 2.5 TPH capacity of steam boiler. Natural gas (green fuel) as fuel will

be used in the boiler. Also we will install a D.G. Set of 200 KVA capacity to use in case of power failure and

HSD shall be used as a fuel.

There will be no process gas emission. Details of which are as under;

Sr. No. Particulars Details

1.0 Capacity of Steam boiler 2.5 TPH

1.1 Fuel Used Natural gas

1.2 Fuel Consumption 1700 SCM/Day

1.3 APC provided Chimney

1.4 Height/dia of chimney 11 meters

2.0 Capacity of D G set 200 KVA (Standby)

2.1 Fuel Used HSD

2.2 Fuel Consumption 40 liters/hr

2.3 APC provided Exhaust

2.4 Height/dia of Exhaust 11 meters

3.0 Hot air Dryer Direct firing through burner (3 Nos.)

3.1 Fuel used Natural gas

3.2 Fuel consumption 800 SCM/Day

3.3 APC Not required

Details of Air pollution control measures attached to Pulveriser

Drying of Pigment:

Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers. The process heat is provided by Hot air dryer system based on natural gas.

Pulverization of pigments:

This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This consists

of following parts:

1. Hopper feed box. 2. Screw feeder. 3. Closed grinder with box 4. cyclone separator 5. Bag filter. 6. Rotary valve for outlet of product.

The pulverized material is collected in bags, weighed and dispatched. The material collected from bag filter

is also mixed with the final product.

Thus this is a completely closed system and does not involve any process gas emission.



wet cake

Tray Dryer

Dried Material

Pulverized dyes

PulveriserCyclone

Separator

DETAILS OF AIR POLLUTION CONTROL EQUIPMENTS FOR PULVERISER

Bag Filter

by m/s hercules pigments pvt....

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