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TECHNO ECONOMIC FEASIBILITY REPORT

FOR

DYES AND INTERMEDIATES MANUFACTURING UNIT

OF

M/s. PARISHI CHEMICALS SHADE / PLOT NO. – C1B/6916-17-18,

GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT-393002

Email: [email protected]

PREPARED BY:

M/s. PARISHI CHEMICALS SHADE / PLOT NO. – C1B/6916-17-18,

GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT-393002

Email: [email protected]

mailto:[email protected]

mailto:[email protected]

M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat

EXECUTIVE SUMMARY OF THE REPORT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around 2112 sq.m land is already acquired by M/s. Parishi Chemicals. PROJECT COST Cost of the proposed project would be Rs. 700.0 Lacs. Total capital cost for environmental pollution control measures would be Rs. 25 Lacs and recurring cost per annum would be Rs. 10.50 Lacs. LIST OF EXISTING & PROPOSED PRODUCTS WITH THEIR PRODUCTION CAPACITY

SN PRODUCT (Existing)

Existing MT/Month

Proposed MT/Month

Total MT/Month

End Use

1 Organic Pigments Dyes 1.50 - 1.50 Textile, Paints,

coatings, plastic

industries 2

Standardization of manufactured dyes through

physical process of Mixing/Blending

18.76 -

18.76

3 Drying of Wet cake of dyes 40.00 - 40.00

4 Liquid dyes from wet cake of dyes 80.00 - 80.00

SN PRODUCT (Proposed – EC)

Proposed MT/Month

OR

Proposed MT/Month

End Use

A.

CrudeDyes 60.00 - Textile, Paints,

coatings, plastic

industries

Standardized and formulations crude dyes

- 300.00

B. Dispersing Agent

240.00 - Captive and/or Sell

C. Intermediates 40.00 40.00

D. R & D Products 0.03 0.03 Non-Commercial

Total 340.03 340.03


LIST OF PRODUCTS BELOW TABLE:

S.N List of Products CAS No. End Use

QTY (MT/Month)

A. Crude Dyes

1 Acid Yellow 184 70267-73-1 Textile, Plastic and Inks

60 crude dyes and 300

Formulation of crude dyes

2 Acid Yellow 250 93859-32-6 Textile, Plastic and Inks

3 Disperse Black 2RC Mixtures Textile, Plastic and Inks

4 Basic Yellow 40 29556-33-0 Textile, Plastic and Inks

5 Basic Yellow 40:1 35869-60-4 Textile, Plastic and Inks

6 Disperse Blue 148 52239-04-0 Textile, Plastic and Inks

7 Disperse Brilliant Blue CB N/A Textile, Plastic and Inks



10 Disperse Blue 183:1 2537-62-4 Textile, Plastic and Inks





15 Disperse Black XF-N Mixtures Textile, Plastic and Inks





20 Disperse Black HP-G Mixtures Textile, Plastic and Inks







26 Disperse Black HP-G Mixtures Textile, Plastic and Inks



29 Disperse Red 126877-06-3 Textile, Plastic and Inks

30 Disperse Black E-MRD Mixtures Textile, Plastic and Inks

31 Disperse Brown 19 59709-38-5 Textile, Plastic and Inks

32 Disperse Red J 70546-12-2 Textile, Plastic and Inks

33 Disperse Green 9 58979-46-7 Textile, Plastic and Inks

34 Disperse Orange 288 96662-24-7 Textile, Plastic and Inks




38 Disperse Reactive Yellow N/A Textile, Plastic and Inks

39 Disperse Red 177 68133-69-7 Textile, Plastic and Inks




43 Disperse Pink BRF N/A Textile, Plastic and Inks


45 Disperse Red 343:1 72968-82-2 Textile, Plastic and Inks







51 Disperse Red Violet SR Disperse Violet 3R N/A Textile, Plastic

and Inks

52 Disperse Violet 31 6408-72-6 Textile, Plastic and Inks




56 Disperse Violet SR N/A Textile, Plastic and Inks


58 Disperse Yellow 114 59312-61-7 Textile, Plastic and Inks



61 Disperse Violet RL N/A Textile, Plastic and Inks

62 Disperse Yellow 184:1 34564-13-1 Textile, Plastic and Inks




66 Solvent Yellow 160:1 35773-43-4 Textile, Plastic and Inks


68 Disperse Dark Black GR Mixtures Textile, Plastic and Inks


70 Solvent Yellow 145 27425-55-4 Textile, Plastic and Inks

71 Solvent Blue 104 116-75-6 Textile, Plastic and Inks



73 Disperse Black RLS Mixtures Textile, Plastic and Inks



76 Solvent Blue 97 32724 - 62 - 2 Textile, Plastic and Inks

77 Disperse Black R Plus Mixtures Textile, Plastic and Inks

78 Solvent Green 28 28198-05-2 Textile, Plastic and Inks

79 Solvent Green 3 128-80-3 Textile, Plastic and Inks

80 Solvent Orange 60 6925-69-5 Textile, Plastic and Inks


82 Solvent Orange 63 16294-75-0 Textile, Plastic and Inks


84 Disperse Black XF Mixtures Textile, Plastic and Inks

85 Solvent Red 135 20749-68-2 Textile, Plastic and Inks





90 Disperse Pink RL N/A Textile, Plastic and Inks





95 Solvent Violet 13 81-48-1 Textile, Plastic and Inks

96 Solvent Violet 38 63512-14-1 Textile, Plastic and Inks

97 Disperse Black MD Mixtures Textile, Plastic and Inks






102 Disperse Black C-RR Mixtures Textile, Plastic and Inks








110 Disperse Black SFGL Mixtures Textile, Plastic and Inks


B. Dispersing Agent

1 Phenol formaldehyde based Dispersing Agent 71342-95-5 Formulation of

Dyes 240

2 Phenol formaldehyde based Dispersing Agent 36290-04-7 Formulation of

Dyes

C. Intermediates

1 Ethyl Benzylacetate 94-02-0 Dyes Intermediate

40

2 3-Oxo-2,3-dihydrobenzo[b]thiophene-1,1-dioxide

1127-35-1 Dyes Intermediate

3 3-(Dicyanomethylidene)-2,3-dihydrobenzothiophene-1,1-dioxide


4 N,N-Dihexyl-m-Toluidine 74228-24-3 Dyes Intermediate

5 3-Pyridinecarbonitrile, 1,6-dihydro-2-hydroxy-1,4-dimethyl-6-oxo-


6 1-Ethyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile 28141-13-1 Dyes

Intermediate


7 1-Butyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile 39108-47-9 Dyes

Intermediate

8 1-(3-Methoxypropyl)-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile


9 4-(diethylamino)salicylaldehyde 17754-90-4 Dyes Intermediate

10 2,6-Dibromo-4-Methyl Aniline 6968-24-7 Dyes Intermediate

11 Benzothiazole Derivatives 6285-57-0 Dyes Intermediate

12 2,6-Dibromo-4-nitro Aniline 827-94-1 Dyes Intermediate

13 2,6-Dichloro-4-Nitro Aniline 99-30-9 Dyes Intermediate

14 6-Bromo-2,4-Di Nitro Aniline 1817-73-8 Dyes Intermediate

15 6-Chloro-2,4-Di Nitro Aniline 3531-19-9 Dyes Intermediate

16 N-Cyanoethyl Aniline 1075-76-9 Dyes Intermediate

17 N-Cyanoethyl-m-Toluidine 27618-25-3 Dyes Intermediate

18 2-Cyano-6-Bromo-4-Nitro Aniline 17601-94-4 Dyes

Intermediate

19 2-Cyano-6-Chloro-4-Nitro Aniline 20352-84-5 Dyes

Intermediate

20 2-Chloro-6-Bromo-4-Nitro Aniline 99-29-6 Dyes

Intermediate

21 5-Hydroxy-2-oxo-3-phenyl-2,3-dihydro benzofuran NotKnown

Dyes Intermediate

D. R & D 1.0


REQUIREMENTS FOR THE PROJECT Land: Total 2112 sq. meter (Existing + Proposed) land already acquired in Ankleshwar Industrial Estate. Water: The total water requirement for Disperse Dyes, Acid dyes, solvent dyes and intermediates manufacturing plant is 105.7 KLD after proposed expansion, mainly in process, make-up water in Boiler & cooling tower, washing of Disperse Dyes plant and domestic& gardening requirement. Total water requirement of Disperse Dyes plant will be met from GIDC water supply. In Disperse Dyes plant, 47.2 KLD water required in process, 10 KLD water required for washing, 4.2 KLD of water is required per day in Boiler as make up water due to evaporation and drift losses and onetime cooling tower water required is 2.5 KL. The 5.0 KLD water required for Domestic purpose and 1.0 KLD required for Gardening purpose. Domestic waste water i.e. 4.5 KL/Day will be generated which will be treated through septic tank and disposed through soak pit/well. However due to reuse/recycle of 55.6 KLD, Total Fresh Water Requirement is 50.1 KLD, which will be meet from GIDC. Electrical Energy: Total power requirement will be 250 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. set of 125 KVA X 2 Nos = 250 KVA will be provided to fulfill the power requirement. Fuel: For the proposed project Diesel/LDO for Steam Boiler, HAG and Thermic Fluid Heater will be used at the rate 7.8 TPD or 3600 SCM Natural Gas and Diesel i.e. 160 Lit/Hr. will be required for the D.G. set which will be purchased from the nearest petrol pump in drum and transported by road only. Manpower: The proposed plant will have employment potential providing employment to approximately 40 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES FLUE & PROCESS GAS EMISSION AND CONTROL MEASURES ARE GIVEN IN FOLLOWING TABLE: EXISTING FLUE GAS STACK DETAILS: STACK Stack attach to Ht. Dia. Fuel Pollutant APCM

1 Steam Boiler ( 0.4 TPH ) 12 1

LDO - 40 lit/hr or NG-

30 m3/hr PM, Sox, Nox Adequate Stack Height

2 HAG

(25,000 Kcal/Hr)

9 0.5 LDO - 40

lit/hr or NG-30 m3/hr

PM, Sox, Nox Adequate Stack Height

EXISTING PROCESS GAS STACK DETAILS: STACK Stack attach to Ht. Dia. Fuel Pollutant APCM

1 Pulverizer 9 0.5 Nil PM Bag Filter

2 Spray Dryer (120 kg/hr) 9 0.5 Nil PM Cyclone Separator


PROPOSED FLUE GAS STACK DETAILS: STACK Stack attach

to Ht. Dia. Fuel Pollutant APCM

1 Steam Boiler ( 0.8 TPH )

12 1

LDO - 80 lit/hr or NG-60 m3/hr PM, Sox, Nox Adequate Stack

Height

2 Steam Boiler ( 0.8 TPH )

LDO - 80 lit/hr or NG-60 m3/hr PM, Sox, Nox Adequate Stack

Height

3 HAG

(50,000 Kcal/Hr)

9 0.5 LDO – 1.0 MT/Day PM, Sox, Nox Adequate Stack Height

4

Thermic Fluid Heater

(8,00,000 Kcal/hr)

12 1 LDO - 2.0 MT/Day PM, Sox, Nox Adequate Stack Height

5

D. G. set of 125 KVA X 2

nos. (In Emergency

only)

9 0.5 Diesel 160 Lit./hr approx. PM, Sox, Nox Acoustic Enclosure &

Adequate stack height

PROPOSED PROCESS GAS STACK DETAILS:

STACK Stack attach to Ht. Dia. Fuel Pollutant APCM

1 Spray Dryer (1000 kg/hr) 9 0.5 Nil PM Cyclone Separator + water scrubber

2 Chlorination of Intermediates 9 0.5 Nil CL2 Alkali Scrubber 3 Bromination of Intermediates 9 0.5 Nil Br2 Alkali Scrubber

WASTE WATER GENERATION AND ITS TREATMENT: Domestic wastewater of 4.5 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporators. Residue (1.0 TPD salt) from ATFD will be sent for TSDF. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project:

1. Encasement of noise generating equipment. 2. A thick greenbelt will be developed all around the plant boundary to act as noise attenuator. 3. In addition personnel working near high noise level generating sources will be provided

with ear muffs. 4. Proper and suitable acoustic barrier will also be provided around areas generating high

noise. 5. Effective preventive maintenance and vibration measurement of all rotating equipment will

help in the improvement of plant life and also noise reduction.


SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes generation and its management are given in the following table.

Sr. No.

Type/Name of Hazardous

waste

Specific Source of

generation

Category and

Schedule as per HW

Rules.

Quantity Management of HW (MT/Annum)

Existing Proposed Total

1 Empty barrels/containe

rs/liners contaminated

with hazardous chemicals/wast

e

Raw Material & Process

33.1 10 (1000 Nos)

50 (5000 Nos)

60 (6000 Nos)

Collected and stored at specified area and sold to approved/ registered vendors.

2 Used or Spent Oil

Maintenance 5.1 0.07 0.8 0.87 Collected in drums and stored at specified area, Reuse in plant for lubrication and Balance will be Selling to authorized recyclers

3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage, Transportation, Disposal at BEIL, TSDF.

4 Distillation residue

(Semi Solid having CV 1500-2000 Kcal/Kg)

In-House Solvent

Recovery Process

or from outside

solvent recovery unit

36.1 Nil 1170 1170 Collection, Storage Transportation, Disposal at GPCB approved CHWIF or co/pre- processing

5 Spent Solvent (Methanol)

Solvent & Disperse

Dyes (Solvent Red 179 , solvent yellow 114,

disperse blue 165, disperse

blue 354, solvent

orange 60 etc)

26.3 Nil 4068 4068 In-House Distillation and recovered solvent will be reuse or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)


6 Spent Solvent (DMF)

Solvent & Disperse

Dyes (Solvent

Orange 63, disperse blue 165, disperse

blue 354, disperse red

J, Fluorescent

Red CB, etc)


7 Spent Solvent ( Xylene)

Solvent Dyes (Solvent red 179 , solvent

red 135, solvent red 179, solvent orange 60,

solvent yellow 157,

solvent yellow 163,

etc)

26.3 Nil 1728 1728 In-House Distillation or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)

8 Spent Solvent (ODCB)

Solvent Dyes (Solvent

Yellow 114, solvent

yellow 33, solvent

yellow 176, etc)


9 NaBr Disperse Blue 354

26.3 Nil 4900 4900 Collection, Storage, Transportation & disposal to Actual User under Rule 9

10 Sulphuric Acid 50%

Disperse Blue 354



11 Benzoic Acid 40 %

Disperse Blue 354


12 Salt From ATFD 34.3 Nil 365 365 Collection, Storage, Transportation, Disposal at BEIL, TSDF

13 Contaminated cotton rags or other cleaning materials

Process &

Maintenance

33.2 Nil 0.5 0.5 Collection, Storage, Transportation, Disposal By Incineration at CHWIF of BEIL

14 NaCl Scrubber of CL2


15 Gypsum Neutralization stage

in Disperse Violet 99

D2 Nil 332 332 Collection, Storage Transportation, Disposal by selling to actual user authorized by GPCB or Cement Industry

GREEN BELT DEVELOPMENT About 852.48 sq.m area i.e. 40 % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 0.90 Lacs approx.


INDEX

CHAPTER CONTENT PAGE

1. INTRODUCTION OF THE PROJECT 1

2. PROJECT DESCRIPTION 3

3. SITE ANALYSIS 49

4. PLANNING BRIEF 52

5. PROPOSED INFRASTRUCTURE 53

6. REHABILITATION AND RESETTLEMENT (R & R) PLAN

57

7. PROJECT SCHEDULE & COST ESTIMATES 58

8. ANALYSIS OF PROPOSAL 60


LIST OF TABLES

TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 1 2 DETAILS OF EMPLOYMENT REQUIREMENT 2 3 DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) 43 4 DETAILS OF WASTEWATER GENERATION 45 5 DETAILS OF SOLID WASTE 46 6 DETAILS OF EXISTING LAND USE 49 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 50 8 TEMPERATURE DATA 50 9 RAINFALL DATA 51 10 DETAILS OF SOLID WASTE MANAGEMENT 54 11 PROJECT IMPLEMENTATION SCHEDULE 58 12 TOTAL PROJECT COST AND IT’S BREAK UP 59

LIST OF FIGURES

FIGURE PARTICULAR PAGE

1 MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC.

3

2 MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC.

4

3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 58

LIST OF ANNEXURES

ANNEXURE PARTICULAR PAGE

1 LAND AGREEMENT DOCUMENTS 63 2 LAYOUT OF THE PLANT 67

M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 1

CHAPTER – 1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed

(a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I.

Or (b) Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day

Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I.

TABLE 1: DETAILS OF THE DIRECTORS

S. NO.

NAME OF THE DIRECTOR AGE QUALIFICATIO

N EXPERIENCE

1. Mr. Garshill J. Lekhadia 49 Years B. Pharm 25 years of Exp. In Dyes and intermediates

The company has been promoted by Mr. Garshill Jyotindra Lekhadia having a widespread business interests in Gujarat. The promoter has been in the business of Dyes & Intermediates for over 26 years and he has excellent knowledge of South Gujarat Industry Environment. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth.

Existing Indian production, are not enough to cater the needs of Indian Consumer, hence

Chinese products are also making dent in the Indian markets, though they are costly due to logistic cost and are not able to provide wide range of choices to the Indian Customers.


Present capacity is negligible in term of overall demand in the world, so a huge market, and considering our high quality products as well customization of product, we don’t foresee any hurdle in marketing of product.

Our proposed plant will be located near user Industry, hence it provides logistic support as well as customize quantity in small quantities can also be supplied to the customer, which give company a clear edge compared to Chinese Imports, which cannot be supplied in small quantities coupled with time consumed on import.

We have a very strong and experienced after sales service which are also known as Technical Service Department (TSD) which guides customer to obtain better results from our products.

Market for disperse dyes is growing @ 10% per annum, and there are only two major producers in the Industry.

Our continuous technological research and product development and superior after sales services will ensure increase in market share and eventually better net sales realization.

Strong presence in the value added product Wide range of product to meet customized need. Long standing relationships with leading consumer Industries.

1.4 DEMAND – SUPPLY GAP The Indian dyestuff industry is widely fragmented between the organized and unorganized sector. There are approximately 950 dye manufacturing unit in India, of which 50 units are in the organized sector and 900 are in the un-organized sector. The two western states of Maharashtra and Gujarat account for over 90% of the total dyestuff production in the country. The textile industry is the largest user of dye-stuffs in India, It account for 70-75% of the domestic dye consumption. With the increasing pressure on cotton fiber, synthetics like polyester are expected to over perform the overall chemical Industry. The dyestuff Industry worldwide is witnessing a gradual shift of manufacturing facilities from the developed countries to Asia, particularly china and India due to environmental considerations, availability of trained and inexpensive manpower and the relocation of the end-user industries, mainly textile and leather to the Asia-pacific region. India has emerged as a global supplier of dyestuff and dye intermediates, particularly for requirement of the domestic market and has gradually also made a dent in the global market. Indian dyestuff market is in general dominated by Chinese companies, as there are very few large scale manufacturing companies in India who can cater the need of Indian demand. We are expected to be the major recipient of benefits arising out due to expected growth, and consolidation in the Industry. PRODUCT PROFILE Our products are backed by unique technology and or process, and are not readily available with

the competitor. These products play an important role in the production process of the user and hence user do not

compromise or shift from tested products and user industry TECHNOLOGY Technology is typically developed in-house with the critical equipment being out-sourced. We have in-house independent R & D, equipped with latest state of art technologies and

facilities.


1.5 EMPLOYMENT GENERATION DUE TO THE PROJECT The manpower requirement for the project is estimated at about 40 excluding contract / casual labour. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break – up of the manpower requirement is as under:

TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT

S. NO. DESCRIPTION EXISTING PROPOSED 1 Top Management 2 4 2 Managers 2 4 3 Specialist/ Engineer/Officers 2 4 4 Supervisors 4 10 5 Operators/Attendants 8 18

TOTAL 18 40

Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. M/s. Parishi Chemicals is going to manufacture dyes and dye intermediate product for mainly textile dyeing and printing industry.


CHAPTER – 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth. 2.2 LOCATION WITH COORDINATES A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure – 1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE

HIGHWAYS, RAILWAY LINES, ROADS ETC.


COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per the mentioned below: Latitude: 21°38’37.58” N Longitude: 73°04’51.95” E FIGURE 2: MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC.

2.3 DETAILS OF ALTERNATE SITES The proposed project site is situated at Plot no. 4517, GIDC, Ankleshwar, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labours are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 2.4 SIZE OR MAGNITUDE OF OPERATION M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R &


D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. DETAILS OF PRODUCTION AND MANUFACTURING PROCESS: 1-INTRODUCTION Disperse dyes manufactured by M/s. Parishi Chemicals is essentially low molecular weight derivatives of azo compounds. They generally melt at above 130°C and are crystalline materials which are ground with dispersing agents to produce particles smaller than two micron. The aqueous paste obtained by grinding is spray dried. Important requirement for spray dried powders are the storage stability and the ease with which the powders can be re-dispersed in water. The actual dye content of commercial products may vary from 20 to 60%. To manufacture crude disperse azo dyestuff primary aromatic amine is diazotized and coupled with tertiary aromatic amines. 2. MANUFACTURING PROCESS

1. Disperse Blue 366 (Step – 1) 1) Diazotization of C6H4Br2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake dried and used in next step.

C6H4Br2N2O2 + H2SO4 + Nitrosyl Sulphuric Acid + C11H17NC19H18N4O2Br2

Disperse Blue 366, step-1

Diazotization

Filtration and Washing

Wet Cake for Drying

Dry Crude C17H18Br2N4O2 (1365 kg)

ICE 7500 kg

13180 kgs

3845 kgs

4880 kgs

3515 kgs

C6H4Br2N2O2 880 kg

Sulphuric Acid 2750 kg

Sodium Nitrite 215 kg

Coupling

Water 500 kg

C11H17N 735 kg

HCL 600 kg

12000 kg Water for ETP Water 3700 kg


Disperse Blue 366 (Step – 2)

1) Cyanation of above monoazo dyes is carried out in solvent. 2) Prepared solution of dyes and then added metal cyanide. 3) Closed the vessel and reaction is carried out at elevated temperature. 4) Isolation is done by cooling and addition of Methanol. 5) Filter the product and wash with water. 6) Re-slurry the wet cake in 5 % ammonia solution. 7) Filter the wet cake and ML sent to recovery plant.

C19H18N6O2 + Metal Cyanide + DMF C19H18N6O2 + DMF

Reaction Vessel

Isolation


DMF 3000 kg

Wet Cake for Drying

DMF and MeOH 6390 kg for Distillation

Dry Crude C17H18Br2N4O2

1000 kg

First step 1365 kg

Zn (CN) 300 kg

MeOH 3200 kg

MeOH 1000 kg

7890 kgs

4690 kgs

2500 kgs

1500 kgs

CuCN 25 kg

Disperse Blue 366, STEP-2


2. Disperse Brown 1 1) Diazotization of C6H4BrCl2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric

acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.

C6H4BrCl2N2O2 + H2SO4 + NSA + C10H14ClNO2 + HCl C14H19NO4 + HCl + Surfactant

Diazotization

Coupling


C6H4BrCl2N2O2 525 kg

Wet Cake for Drying

12120 kg Water for ETP

Dry Crude 1000 kg



Water 500 kg

C14H19No4 615 kg

HCL300 kg

Water 3000 kg

12120 kgs

3205 kgs

3000 kgs

2000 kgs

Disperse Brown 1

Ice 7500 kg


3. Disperse Orange 288 1) Here C6H6N2O2 is diazotized in sulphuric acid with sodium nitrite and ice. 2) Transfer the diazo slowly to coupler solution and stir. 3) Check the completion of coupling and filter and wash the wet cake with water. 4) Wet cake sent to sand milling and spray drying.

C6H6N2O2 + H2SO4 + NaNO2 + C16H16N2 C22H22N5O2 + H2SO4

Diazotization

Coupling


C6H6N2O2 420 kg

Wet Cake for Drying

10100 kg Water for ETP

Dry Crude 1000 kg

HCL 1050 kg

ICE 4000 kg

Water 500 kg

C16H16N2 615 kg

HCL300 kg

Water 3000 kg

11100 kgs

6185 kgs

4000 kgs

3000 kgs

Disperse Orange 288

Ice 3500 kg


Water 500 kg


4. Disperse Red 278

1) Diazotization of C6H6N2O2 is carried out in Hydrochloric acid and nitrosyl Hydrochloric acid.

2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.

C6H6N2O2 + HCl + NSA + C16H22N2O5 C22H29N5O7S

C6H6N2O2 300 kgHCl 1000 kgNaNO2 152 kgIce 5000 kg

6452 kg

C16H22N2O5 700 kgHCl 350 kgIce 6000 kgWater Washing 3000 kg

3800 kg

2800 kg

Disperse Red 278

Diazotization

Coupling&

Filtration

12702 kgWater forETP Plant

Wet Cakefor

Drying

Dry Crude1000 kg


5. Disperse Violet 93

1) Diazotization of C7H5ClN3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.

C7H5ClN3O2S + H2SO4 + NSA + C12H18N2O C20H23ClN6O3S

6-Br-2,4-DNA 595 kgH2SO4 3600 kgSodium Nitrite 160 kg

4355 kg

M-12 470 kgHCl 250 kgIce + Water 7000 kgWater 4000 kg

4000 kg

3000 kg

Wet Cakefor

Drying

Dry Crude1000 kg

Disperse Violet 93

Diazotization

Coupling &

Filtration

12075 kgwater for ETP


6. Disperse Yellow 211

1) Diazotization of C7H5ClN2O2 is carried out in hydrochloric acid and sodium nitrite. 2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.

C7H5ClN2O2 +HCl + NaNO2 + C10H12N2O2 C17H18ClN5O4

C6H5ClN2O2 465 kgWater 500 kgHCl 1850 kgIce 5000 kgSodium Nitrite 210 kg

8025 kg

C9H12N2O2 520 kg

Water 500 kg

Soda Ash 750 kgIce 3000 kg

12795 kg

Water 2500 kg

4000 kg

3000 kg

Disperse Yellow 211

Diazotization

Coupling

Filtrationand

Washing

11295 kgWater for

ETP

Wet Cakefor

Drying

Dry Crude1000 kg


7. Acid Yellow 184 Manufacturing process: 1) C20H19N3O2 is sulfonated at ambient temperature in oleum. 2) Drawing and isolation by cooling and filter it.

Chemical reaction: C20H19N3O2 + Oleum C20H20N3O5 Mass Balance:

Yellow 82 900 kgOleum 1250 kgSulphuric Acid 1250 kg

3400 kg

NaOH Lye 4500 kgIce 4000 kg

11900 kg

Water 5000 kgSalt 1000 kg

5000 kg

4000 kg

Wet cakefor Drying

Dry Crude1000 kg

Acid Yellow 184

ReactionVessel

12900 kg water toETP Plant

ReactionVessel

Isolation and

Re-slurry


8. Disperse Red 277 Manufacturing Process:

1) C20H19N3O2 and C3H2N2 were mixed in solvent and reaction carried out in ambient temperature.

2) Cool the reaction mass to 25° C and isolate the product. 3) Filtered and wash

Chemical Reaction: C20H19N3O2 + Solvent + C3H2N2 C23H19N4O2 Mass Balance:

Reaction Vessel

Isolation

Filtration

C20H19N4O 1000

Wet Cake For Drying

10000 kg DMF and Methanol For Distilation

Dry Crude 1000 kg

DMF 5000 kg

12240 kg

6240 kg

3240 kg

2240 kg

Disperse Red 277

MeOH 6000 kg

C3H2N2 240 kg

MeOH 1000 kg


9. Disperse Red 362 Manufacturing Process:

1) C23H19N4O2 is treated with diluted sulphuric acid at ambient temperature. 2) pH adjusts to 3.5 with alkali and filter the product.

Chemical Reaction: C20H19N3O2 + Diluted H2SO4 C23H19N4O3 Mass Balance:

C23H17N5O 1000 kg


8000 kg

NaOH 100 kg

Ice 4000 kg

12100 kg

Water 3000 kg

4000 kg

3000 kg

Neutralizer

Filtration

11100 kgWater

for ETP

Wet Cakefor

Drying

Dry Crude1000 kg

Disperse Red 362

ReactionVessel


10. Disperse Yellow 232

1) C6H6ClNO2, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete.

2) Cool to 20° C and filter the product. C6H6ClNO2 + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H20ClN3O2

Reaction Vessel


C6H6ClNO 600 kg

Wet Cake For Drying

2500 kg MeOH for Distillation and 5000 kg water to ETP

Dry Crude 1000 kg

5040 kg

3540 kg

2540 kg

Disperse Yellow 232

MeOH 3000kg

Water 6000 kg

PCL3 300kg

C5H7NO2 390kg

C11H15NO2 750kg


11. Disperse Yellow 184:1

1) C7H9NO, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete.

2) Cool to 20° C and filter the product. C7H9NO + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H21N3O2

Reaction Vessel


C7H9NO 530 kg

Wet Cake For Drying

2500 kg MeOH for Distillation and 5000 kg water to ETP

Dry Crude 1000 kg

4970 kg

3470 kg

2470 kg

Disperse Yellow 184:1

MeOH 3000kg

Water 6000 kg

PCL3 300kg

C5H7NO2 390kg

C11H15NO2 750kg


12. Solvent Yellow 43 Manufacturing Process:

1) C12H5ClO3Br is reacted with C5H11N in presence of Solvent (DMF) to produce the dye. 2) Dye is isolated and filtered. 3) This dye is then treated with ammonia to produce the final color. 4) Wet cake is then given to formulation department.

Chemical Reaction: C12H5ClO3Br + Solvent (DMF) + C5H11N C21H17N2O2 Mass Balance:

C12H5ClO3Br 1000 kgC5H11N 1000 kgDMF 3000 kg

5000 kg

2500 kg

MeOH 6000 kg

3000 kg

2000 kg

Wet Cakefor

Drying

Dry Crude1000 Kg

Solvent Yellow 43

ReactionVessel

Distillationof

Dioxine

2500 kgDMF

Reused in next Batch

Isolation5500 kg

DMF and MeOHfor Recovery


13. Disperse Blue 354 1) C6H10O3 is treated with C6H5COCl and then treated with C3H2N2 in the presence of

solvent to produce Step – 1. 2) C7H9N, C6H13N and POCl3 is treated in DMF to form Step – 2. 3) Step – 1 and Step – 2 are treated in solvent to form the dye. 4) Dye is isolated by cooling and filtered. 5) Wet cake sent to formulation department.

Step – 1 C6H10O3 + C6H5COCl + C3H2N2 + H2SO4 Step – 1 + 50 % H2SO4

2175 kg

Step - 1 6013 kgC6H10O3 725 kgC6H5OCl 850 kgCaustic 1500 kgWater 2525 kg 5600 kg

Oleum 5200 kgWater 1500 kg

7787 kg1500 kg

Water 1500 kg

MeOH 3000 kgC3H2N2 375 kg

4100 kg

MeOH 800 kg

1200 kg

Reaction Vessel

Reaction Vesseland

Isolation4513 kg water

5562 kg 50 %Sulphuric Acid

For SellFiltration&

Washing 5263 kg Water for

ETP

Product A725 kg

Acidification

Disperse Blue 354

Benzoic Acid2250 kg

75 kg DryBenzoic Acid

Reaction Vessel

Wet Cake for Drying3700 kg

MeOH forRecovery

Step - 1800 kg

For Sale


Step – 2 C7H9N + C6H13N + NaOH C19H33N + NaBr C19H33N + DMF + POCl3 Step – 2 Final Dye Step – 1 + Step – 2 + Solvent C32H38N3O3S

Step - 2

C7H9N 425 kgC6H13Br 1325 kgCaustic 2500 kgWater 3500 kg

7750 kg

1036 kg

POCl3 635 kgDMF 775 kg

2446 kg

Disperse Blue 354

ReactionVessel

Oil Separation6714 kg NaBr

solution as Byproduct and Sell

ReactionVessel

Step - 22446 kg

Step - 3

Step - 1 800 kgStep - 2 2446 kgMeOH 3000 kg

MeOH 800 kg

2000 kg

1000 kg

Dry Crude1000 kg

Disperse Blue 354

ReactionVessel

Filtrationand

Washing

5046 kgMeOH and DMF for

Recovery

Wet Cakefor

Drying


14. Disperse Yellow 114 Manufacturing Process:

1) C6H7NO is reacted with Acetic Anhydride and then reacted with C6H5SO2Cl to form the diazo component which is then hydrolysed and diazotized with Hydrochloric Acid and Sodium Nitrite.

2) Coupling is carried with C8H8N2O2in alkaline condition to make the final crude dyes. 3) Dye is filtered and wash then sent to formulation department.

Chemical Reaction: Step – 1 C6H7NO + (CH3CO)2+NaOH C14H13NO4S C14H13NO4S + HCl C12H11NO3S Step – 2 C12H111NO3S + NaNO2 + HCl + C8H8N2O2 C20H19N4O5S + NaCl + H2O Mass Balance:

Water 5500 kgMAP 600 kgAcetic Acid 815 kgBSc 1170 kgSoda Ash 1350 kg

9435 kg

Water For Washing 1000 kg

ReactionVessel

ReactionVessel

6935 kgwater forETP Plant

Wet Cake2500 kg

Step - 1

Disperse Yellow 114


Wet Cake 1250 kgWater 1500 kgHCl 1000 kg

3750 kg

NaNO2 200 kgIce 4000 kg

7950 kg

MP 430 kgWater 1500 kgNaOH 300 kgIce 5000 kgWater 2000 kg 4500 kg

3500 kg

ReactionVessel

ReactionVessel

Wet Cakefor

Drying

Dry Crude1000 kg

12680 kgwater forETP Plant

Disperse Yellow 114Step - 2

ReactionVessel


15. Disperse Red 343: Mass

Balance:

Step - 1

C6H4Br2N2O2 725 kg

HCL 3000 kgICE 5000 kgSodium Nitrite 200 kg

8925 kgs

Water 500 kg

C11H17N 635 kg

Ice 5000 kg15060 kgs

Water 2000 kg

4500 kgs

3120 kgs

Wet Cakefor

Drying

Dry Crude1380 kg

Disperse Red 343

Diazotization

Coupling

Filtrationand

Washing

12560 kgWater for

ETP


Step - 2

DMF 2750 kg

1st Step 1380 kgZn(CN)2 315 kgCuCN 30 kg

4475 kg

MeOH 4000 kg

3500 kg

2500 kg

DMF and MeOH4975 kg forDistillation

Wet Cakefor

Drying

Dry Crude1000 kg

Disperse Red 343

ReactionVessel

Isolation

16. Solvent Orange 60 Manufacturing process: Naphthalic anhydride is reacted with 1:8 Diamino Naphthalene using Xylene as a solvent. The product is isolated using methanol. It is then filtered and washed with water. The wet cake is dried and pulverized to get the finished product. Chemical reaction:


1,8-DAN 660 kgPA 620 kgXylene 3000 kgDPG 450 kg

4730 kg

MeOH 3000 kg

MeOH Washing 1000 kg2200 kg

1200 kg

Solvent Orange 60

ReactionVessel

Isolation,Filtration

andWashing

Wet Cakefor

Drying

6530 kgXylene + MeOH

for Recovery

Dry Crude1000 kg

17. Solvent Red 135: Manufacturing process: Tetra Chloro Phthalic Anhydride is reacted with 1:8 Di Amino Naphthalene using Xylene as a solvent. The product is filtered and washed with methanol & water. The wet cake is dried and pulverized to get the finished product. Chemical reaction:


Mass Balance:

1,8 DAN 435 KgTCPA 870 KgXylene 3000 KgDPG 435 Kg

4740 kg

2240 kg

MeOH 3000 kg

2500 kg

1500 kg

Dry Crude1000 Kg

Solvent Red 135

ReactionVessel

Isolation&

Filtration

2500 kgXylene forRecovery

Washing2740 kg

Xylene + MeOHfor Recovery

Wet Cakefor

Drying

18. Solvent red 179: Manufacturing Process: Condensation: Naphthalene-1,8-diamine and 1H, 3H benzo [de] isochromene-1,3-dione is suspended in ODCB at room temperature. Stir it for 1 hour and. then heat it to 150 temperatures. Maintain for 6 hours. Cool to room temperature for filtration. Filtration and washing: Filter the slurry and wash with methanol and then water up to salt free. Filtrate and methanol wash sent to solvent recovery. Water wash sent to ETP. Drying and Packaging: Wet cake us then dried and pulverized and then sent to packaging.


Chemical Reaction:

Mass Balance:

Xylene 3000 kg1,8 DAN 650 kgDPG 200 kg1,8 Naph Anhy. 735 kg

4635 kg

MeOH 6000 kgMeOH Washing 1000 kg

3500 kg

2500 kg

Solvent Red 179

Reaction Vessel

Isolation&

Washing

Wet Cakefor

Drying

Dry Crude1000 kg

8135 kgXylene + MeOH

for Recovery


19. Disperse red 60 Manufacturing process: 1. In glass reactor 94% phenol and potassium carbonate charge. 2. Dehydration of the above mixture at 120 0C. 3. Then cool to the 500C and charge 1 Amino 2 Bromo 4 Hydroxy AQ and heat the reaction mass 130- 1350C for 10 Hrs. 4. Reaction mass filter and wash till salt free. 5. Crude wet cake handover to the formulation unit. 6. Mother liquor sends to recovery unit for phenol recovery. Chemical Reaction:

Mass Balance:

C14H8ClNO3 990 kgC6H6O 360 kgC6H5Cl 4000 kgKOH 220 kgC16H36BrN 170 kg 5740 kg

Steam 5000 kg

5540 kg

Water 3000 kg

3500 kg

2500 kg

Disperse Red 60

ReationVessel

SteamDistiilation

Filtration&

Washing

Wet Cakefor

Drying

Dry Crude1000 kg

3700 kg MCB distilled out and

1500 lit waterfor ETP

5040 kgWater for

ETP


20. Disperse blue GSL (Disperse blue 165): Manufacturing process: Diazotization: DBPNA is charged with N.S.A. and sulphuric acid for diazotization, liberating water. Coupling: Water, ice and sulphuric acid are coupled with KD12. After that product is tray dried. Cyanuration: After tray drying, product is Cynurated with copper cyanide, sodium cyanide and DMF to get crude product. Filtration: Water and ammonia are added for reaction mass and crude product is filtrate out. ML is sent to ETP for treatment. Dyfol and Acetic acid are added to crude product. Spray Drying: The standardized dye liquid of Disperse Blue GSL will be transferred to the spray drying Holding Tank and spray dry. Packing: The final product is then packed in HDPE bags/M.S. Drums/Plastic Carboys / Paper cartoon boxes. Chemical reaction:


Mass Balance:

Step - 1

C6H4Br2N2O2 790 kg


Sodium Nitrite 188 kg3478 kgs

Water 500 kg

C11H17N 556 kg

Hydrochloric Acid 325 kgIce 8000 kg

12859 kgs

Water 4000 kg

5460 kgs

4095 kgs

Wet Cakefor

Drying

Disperse Blue 165

Diazotization

Coupling

Filtrationand

Washing

11399 kgWater for

ETP

Dry CrudeC17H18Br2N4O2

1365 kg

Step - 2

DMF 2500 kg

1st Step 1365 kgZn(CN)2 295 kgCuCN 25 kg

4185 kg

MeOH 5000 kg

3000 kg

2000 kg

Wet Cakefor

Drying

Dry Crude1000 kg

DMF and MeOH6185 kg forDistillation

Disperse Blue 165

ReactionVessel

Isolation


LIST OF INTERMEDIATES: 1. ETHYL BENZYLACETATE

2. 3-OXO

6675 kg water to ETP Plant

EBA 1000 kg

Reaction Vessel

Separation

C6H5OCl 1175 kg

C6H10O3 1000 kg

Caustic 2000 kg

EBA

Water 3500 kg

7675 kg

2000 kg water to ETP Plant

Product 1000 kg 3-Oxo-2, 3-

dihydrobenzothiophene-1, 1-dioxide

Reaction Vessel

and Isolation


25% Oleum 7200 kg

3-Oxo 910 kg

3-Oxo-2, 3-dihydrobenzo[b]thiophene-1, 1-dioxide

Water 700 kg

10400 kg 50 % Sulphuric Acid For Sell

Water 5590 kg

8810 kg

2000 kg

Wet cake for Drying

1000 kg


3. PROPANEDINITRILE DERIVATIVE

4. N, N-DIHEXYL-M-TOLUIDINE

3500 kg MeOH for Recovery

Wet cake for drying

Reaction Vessel


C3H2N2 375 kg

MeOH 3500 kg

C11H12O3 910 kg

PROPANEDINITRILE DERIVATIVE

MeOH 1300 kg

3-(Dicyanomethyllidene)-2, 3-dihydrobenzothiophen-11-dioxide

1000 kg

7360 kg NaBr solution as Byproduct and Sell

N,N-Dihexyl-m-Toluidine 1000 kg

Reaction Vessel

Oil Separation

C6H13Br 1430 kg

C7H9N 460 kg

Caustic 2700 kg

N, N-DIHEXYL-M-TOLUIDINE

Water 3770 kg

4785 kg

2585 kg

1585 kg

8360 kg


5. DBPT

3920 kg Water for ETP Plant

Wet cake for drying

Reaction Vessel


HCL 2100 kg

C7H9N 430 kg

H2O2 120 kg

DBPT

Water 4000 kg

Dry Crude 1000 kg

Br2 770 kg

3420 kg

3500 kg

2500 kg


6. DEMAP ALDEHYDE


Wet cake for drying

Reaction Vessel


DMF 3100 kg

C10H15NO 1110 kg

Ice + Water 10000 kg

DEMAP ALDEHYDE

Water 2000 kg

DEMAP Aldehyde1000 kg

POCl3 2000 kg

19210 kg

5000 kg

4000 kg

NaOH 3000 kg


7. BENZOTHIAZOLE DERIVATIVE


Wet cake for drying

Reaction Vessel


Acetic Acid 3300

C7H10NO 820 kg

Bromine 1170 kg

BENZOTHIAZOLE DERIVATIVE

Water 3000 kg

Benzothiazole Derivative 1000 kg

NH4SCN 1040 kg

13030 kg

4500 kg

3500 kg

NaOH 6700 kg


8. METHYL PYRIDONE


Wet cake for drying

Reaction Vessel

Isolation and Washing

ECA 700 kg

Methyl Amine 510 kg

METHYL PYRIDONE

HCl 1500 kg

Dry Crude 1000 kg

Methyl Ester 800kg

2090 kg

3500 kg

2500 kg

NaOH 80 kg

Water + Ice 6000 kg


9. ETHYL PYRIDONE


Wet cake for drying

Reaction Vessel


ECA 650 kg

Ethyl Amine 275 kg

ETHYL PYRIDONE

HCl 1500 kg

Dry Crude 1000 kg

Methyl Ester 650kg

1675 kg

3500 kg

2500 kg

NaOH 100 kg

Water + Ice 6000 kg


10. BUTYL PYRIDONE


Wet cake for drying

Reaction Vessel


ECA 620 kg

Butyl Amine 840 kg

BUTYL PYRIDONE

HCl 1500 kg

Dry Crude 1000 kg

Methyl Ester 640kg

2200 kg

3500 kg

2500 kg

NaOH 100 kg

Water + Ice 6000 kg


11. 3-MPA PYRIDONE


Wet cake for drying

Reaction Vessel


ECA 770 kg

3-MP Amine 1400 kg

3-MPA PYRIDONE

HCl 1500 kg

Dry Crude 1000 kg

Methyl Ester 850kg

3120 kg

3500 kg

2500 kg

NaOH 100 kg

Water + Ice 6000 kg


UNIT PROCESSES INVOLVED IN R&D PRODUCTS A) Dyes: Dyes are classified according to the functional group and method of preparation as follows 1) Synthetic Organic Dyes – 1

i) Azo Disperse Dyes (T – 1) ii) Disperse Dyes (T – 2)

2)Synthetic Organic Dyes – 2

i) Azo Disperse Dyes (T – 3) 3) Synthetic Organic Dyes – 3

i) Anthraquinone Disperse Dyes ii) Anthraquinone Solvent Dyes

The brief description of synthesis route of each class as follows 1) Synthetic Organic Dyes – 1 i) Azo Disperse Dyes (T – 1): Azo disperse dyes prepared by two different routes due to the reactivity during diazotization. a) HCl Base Diazotization is a reaction that converts an -NH2 group connected to a phenyl ring to a diazonium salt. For example Nitrous acid is generated in situ by using Hydrochloric acid and Sodium Nitrite. Diazotization reactions are extremely useful in organic synthesis. The nitrous acid provides NO+ which replaces a hydrogen on the -NH3+ group to produce -NH2NO+ and water; a second water is eliminated to produce the - N2+ group. The amine is dissolved in suitable volume of water containing 2.5 – 3 mole of HCl by the application of heat if necessary, and the solution is cooled in ice when the amine hydrochloride usually crystallizes. The temperatures is maintained at 0 – 10°C and an aqueous solution of sodium nitrite is added and stirred until all amine converts into diazo then diazo is clarified and used to couple with tertiary amine. b) NSA Base The diazotization of Primary aromatic weekly basic amines is effected by adding the stoichiometrical amount of nitrosyl sulfuric acid (NSA) or some time ortho phosphoric acid, acetic acid along with NAS at a temperature of about minus 10° C to 20° C and atmospheric Pressure. In some cases it is advantageous to work at temperatures to about 40° C and stirred until all amine converts into diazo then diazo is used to


couple with tertiary amine. Coupling: Specific tertiary amine is dissolved in suitable acidic / alkaline or neutral aqueous solution and coupled with diazo at 0 – 20°C. Sometimes excess acidity is partially neutralized with suitable alkaline buffer. Disperse azo dyestuffs being hydrophobic in nature, precipitate out and are collected by filtration. Filtered wet cake is washed with water till neutral pH. Then aired well and dumped in to the wet grinding mill to obtain proper particle size distribution. The slurry so formed is spray dried at suitable temperature to obtain the dry dye product which is finally standardized as required and packed in drums. ii) Disperse Dyes (T – 2) In this class dyes were prepared after the condensation in suitable media and condition may be in single step or multistep. For example: a) Single Step: Dyes were prepared using two or more component in one step. Disperse Yellow 184 is prepared by the condensation of DEMAP Aldehyde, ECA, 4-CAP in presence of TEDA in one step. b) Multistep Step: Disperse Yellow 64 is prepared in two steps. In first step condensation between the 3-Hydroxy-2-methyl-4-quinolinecarboxylic acid and Phthalic anhydride. After completion of reaction material is isolated and dried then used in to bromination in methanol as a media. 2) Synthetic Organic Dyes – 2 i) Azo Disperse Dyes (T – 3) Dyes having the halogenated moiety (Bromine and Chlorine) which prepared in Azo Disperse Dyes (T – 1) is dried. Cyanation of the dry crude in DMF using copper cyanide and Sodium cyanide in presence of metal catalyst at suitable temperature is carried out. After completion of reaction methanol is use in isolation of product. Isolated product filters and ML send to the solvent recovery and detoxification. Treatment on the isolated material by liquid ammonia carried out before handover to the formulation. 3) Synthetic Organic Dyes – 3

i) Anthraquinone Disperse Dyes Aromatic and/or aliphatic primary amines or phenols or metal cyanide are condensed with Dihydroxy derivative or halogenated derivative of Anthraquinone in solvent as a media with suitable temp. & pressure in presence of base or catalyst to get desire product. After completion of reaction product is isolated either by cooling or by diluting it with solvent & filter to get wet press cake of the


product. Then it is further standardized & milled to get desire quality in wet slurry formis spray dried to get final product.

ii) Anthraquinone Solvent Dyes Aromatic and/or aliphatic primary amines or phenols are condensed with Dihydroxy derivative or halogenated derivative of Anthraquinone in solvent media at suitable temp. & pressure to get desire product. After completion of reaction product is isolated either by cooling or by diluting it with solvent & filter to get wet press cake of the product. The wet press cake mill and standardized in presence of suitable solvent. Fusion At the optimum temperature with or without solvent media, Benzanthrone/cyclised product is subjected to alkali is subsequently oxidized by either with steam/air or with both. Then the product is isolated, filtered and washed with water till neutral pH then further dried, pulverized and used for next stage depending upon the product process requirement. Hydroxylation The Fused Product is hydroxylated in Acid media in presence of metal oxide and sub-sequently the hydroxylated product is isolated, filtered, washed with water. The wet cake is dried, pulverized and used for alkylation. Diazotization and Reduction The diazotization of primary amine of anthraquinone is diazotized with nitrosyl sulphuric acid and subsequently reduced by sodium sulphite. After completion of reaction product is isolated, filtered and washed with water for getting the product. Benzoylation and Halogenation Amino Anthraquinone are Benzoylated and / or subsequently chlorinated in solvent media at suitable temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material filtered and washed with water till neutral pH. The wet cake is dried, pulverized and used for next stage depending upon the product process requirement. Condensation Amino Anthraquinone are condensed with halogenated Anthraquinone in solvent media at suitable temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material filtered and washed with water till neutral pH. The wet cake is dried, pulverized and used for next stage depending upon the product process requirement. Cyclisation The condensed/ reduced material is cyclised in presence of catalyst and acid media/solvent media at optimum temperature. Then the product is isolated, filtered and washed with water for getting product. Alkylation The Fused/hydroxylated product is alkylated in solvent media at optimum temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material


filtered and washed with water till neutral pH (Say alkylated product). The wet cake is dried, pulverized and used for Acid pasting. Acid Pasting After the treatment of sulphuric acid on alkylated product is isolated, filter and wash till neutral pH by water. The wet cake is dried, pulverized and packed in drums. Anthraquinone Intermediates As per requirements of anthraquinone intermediates, operation performed on the starting material. For example: 1-amino anthraquinone and 1-chloro anthraquinone. Both are prepared using same starting material by different operation. In first step sulphonation of Anthraquinone in acidic media at optimum temperature then drawn in water, isolated by filtering and then ammonolysis gives 1-amino while chlorination gives 1-chloro AQ at optimum temperature and pressure. Excess Ammonia gas and chlorine is recovered and then product is isolated by filtering, washing with water till purity of the product is achieved. Primary Amines There are so many way to prepare a primary amine. Few are describe below,

At optimum temperature and pressure, ammonolysis using liquid ammonia of Chloro Nitro Benzene &Dichloro Nitro Benzene is carried out. The excess ammonia is recovered and then product is isolate, filtering & washing with water till neutral pH is achieved.

DNCB is Methoxylated with sodium Methoxide, isolate the product by filtering and then reduced by reducing agent.

Meta nitro Aniline is acetylated using acetic anhydride isolated the product by drowning and filtering and then reduced by reducing agent.

M.D.N.B., Nitro Anisole, Nitro Chloro Benzene, Nitro Acetanilide, Nitro Methoxy Acetanilide are reduced using reducing Agent like Iron filling & Sodium Hydrosulfite, isolate the product by salting & filtering.

Halogenated Primary Amines Halogenation (Bromination or Chlorination) of the primary amine using chlorine gas or bromine gas or HBr in presence of hydrogen peroxide in acidic media at optimum temperature. After completion of reaction quench excess bromine by using SBS and then filter and wash with water till neutral pH. The isolated material used as such or dried as per the requirements. Tertiary amines: There are so many way to prepare a tertiary amine. Few are describe below, i) Alkylated tertiary amines Primary and Secondary Amines are alkylated in aqueous / solvent media with or without inert atmosphere at optimum parameters (pressure & temperature). Finally, the product is isolated by filtration or separation. ii) Ethoxylated and Acetylated Tertiary Amines


Primary and Secondary Amines are Ethoxylated in aqueous media under inert atmosphere at optimum parameters (pressure & temperature). Finally, the product is isolated by filtration and separation. Ethoxylated tertiary amines are dried under vacuum and acetylated with acetic anhydride at required temperature. After cooling material is diluted by minimum amount of acetic acid stored in to the storage tank. iii) Cyanoethylated Amines Primary or secondary amines are Cyanoethylated in mild acidic condition in presence of anti polymerizing agent at optimum temperature and pressure. Isolate the product by filtering & washed till neutral pH. Some of these products are further used in ethoxylation / alkylation process & some of these products are directly used in S.O. Dyes. Other Intermediates: Other intermediates are prepared by followed different operations like sulphonation, halogenation, ammonolysis, reduction, condensations, cyclisation, cyanation, nitration, acetylation, alkylation, formylation etc as per the reactive sites of functional group conversation possibilities in to the starting material. For example: a) Pyridones: Cyanoacetic ester, suitable amine and Alkyl acetoacetate are condensed in an autoclave at 80-120°C and 1 – 3kg/cm2 pressure for 4 – 20 hrs. Pyridones so formed are either used as such or isolated by drowning into acidic solution. Isolated pyridine is filtered and washed with water and pressed well to obtain the wet cake of Pyridone. b) CMB: Cyclisation of OPDA and ECA in presence of catalyst in solvent media at high temperature. After completion of reaction material is isolated by natural cooling, filter and wash till removed the solvent. c) Quinoline are prepared by multi steps reaction which having secondary (–N=) or tertiary nitrogen atom. The most common examples in our industries are HMQ, DHQ, 3 Hydroxy Quinaldine, 2,4-dihydroxy quinoline etc. C) Dispersing Agents Dispersing agent is the main constituent of the finish dye. In our industry we produce a different kind of dispersing agent like solid, liquid and sometime semi liquid. i) Solid Dispersing Agent

a) Naphthalene base b) Creosote oil / Wash Oil c) Butanol d) Lignin

ii) Liquid Dispersing agent a) Phenol b) Cresol

i) Solid Dispersing Agent


The above mention solid dispersing agents are prepared in similar manner. Naphthalenesulphonic acid–formaldehyde Condensate Naphthalene is sulphonated by sulfuric acid and oleum at 100 – 150°C for 1 – 10 hrs at 0 – 4 kg/cm2 to get naphthalene-2-sulphonic acid 85% and naphthalene-1-sunphonic acid 15%. ii) Liquid Dispersing agent Liquid dispersing agents are prepared by using the same process which used in solid dispersing agent. Phenol–formaldehyde Condensate (Liquid Dispersing Agent) Phenol is condensed with Polymerization agent at 100 – 150°C at 0–4kg / cm2 along with sulfonating agent and water to get Liquid Dispersing agent. D) NSA / NOHSO4 Nitrosyl sulphuric acid is widely used in the azo dyes for diazotization. Nitrosyl sulphuric acid is used for the diazotization of the primary amines which having less basicity. NSA / NOHSO4 are prepared by the reaction between H2SO4, HNO3 and Water in presence of catalyst.


2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of disperse dyes are listed below:

TABLE 3: DETAILS OF RAW MATERIAL REQUIREMENTS S.No. Raw Material Qty (MT)/Month CAS No.

1 2-Ethylhexyl Bromide 4.0 18908-66-2 2 Acetic acid 4.0 64-19-7 3 Acetic Anhydride 6.0 108-24-7 4 Acetone 7.0 67-64-1 5 Ammonium peraSulphate 2.3 7727-54-0 6 Ammonium Thiocyanate 2.3 1762-95-4 7 Aniline Derivatives (Tertiary

Aromatic Amines) 25.0 91-67-8 (N,N DEMT)

92-00-3 (M-1) 148-69-6 (M-17)

6375-46-8 (M-12) 27059-08-1 (M-3A) 51560-72-6 (M-279)

8 Benzoyl Chloride 7.0 98-88-4 9 Bromine 2.5 7726-95-6 10 Caustic Flask 10.0 1310-73-2 11 Cuprous Cyanine 3.0 7782-50-5 12 DEMAP Aldehyde 7.0 544-92-3 13 Dibutylamine 4.0 17754-90-4 14 Diethylamine 4.0 1192-2 15 Dimethyl Sulfate 5.0 109-89-7 16 Dimethylformamide (DMF) 10.0 77-78-1 17 Dioxane 5.0 68-12-2 18 Ethyl Cyano Acetate 7.0 105-56-6 19 Fisher's Aldehyde 5.0 111-25-1 20 Fisher's base 5.0 7647-01-0 21 Hexyl Bromide 6.0 67-63-0 22 Hydrochloric Acid 20.0 1305-62-0 23 Isopropyl alcohol (IPA) 7.5 108-44-1 24 Lime 5.0 109-77-3 25 m - Toluidine 4.0 868-54-2 26 Malodinitrile 5.0 67-56-1 27 Malononitrile Dimer 5.0 74-87-3 28 Methanol 15.0 74-88-4 29 Methyl Chloride 3.0 1126-78-9 30 Methyl Iodide 3.0 7782-78-7 31 n-Butyl Aniline 5.0 8014-95-7 32 Ortho Pheneline Diamine 6.0 95-54-5 33 p - Toluidine 4.0 106-49-0

34 Aniline Derivatives (Primary Aromatic Amines)

25.0 827-94-1 (DBPNA)

99-29-6 (2-CN PNA)


100-01-6 (PNA) 24072-75-1 (Dichloro

BT) 3531-19-9 (6-Cl-2,4-

DNA) 1817-73-8 (6-Br-2,4-

DNA) 35 Pentyl Bromide 5.0 110-53-2 36 Phenylhydrazine 3.0 100-63-0 37 Phosphorus Oxy Chloride 10.0 10025-87-3 38 Phosphorus Penta Chloride 7.5 10026-13-8 39 Soda Ash 15.0 497-19-8 40 Sodium Chloride 3.0 7647-14-5 41 Sodium Cyanide 3.0 143-33-9 42 Sodium Nitrite 3.0 7632-00-0 43 Sulfamic acid 3.0 5329-14-6 44 sulphur 0.3 7704-34-9 45 Sulphuric Acid 20.0 7664-93-9 46 Tributylamine 5.0 102-82-9 47 Triethylamine 5.0 121-44-8 48 Zinc Chloride 3.0 7646-86-7 49 Zinc Cyanide 3.0 557-21-1 50 Ammonium Chloride 3.0 12125-02-9 51 Naphthalene 21 91-20-3 52 Formaldehyde 12 50-00-0 53 Phenol 21 108-95-2 54 Cresol 12 95-48-7; 106-44-5 55 Sodium bisulfite 20 7631-90-5 56 Thiophenol 6 108-98-5 57 Phenylmethyl pyrazolone (PMP) 5 89-25-8 58 Quinizarine 7 81-64-1 59 Leuco-Quinizarine 3 476-60-8 60 p-Toluidine 4 106-49-0 61 p-Amino Acetanilide 3 122-80-5 62 1,8-Dichloro Anthraquinone 4 82-43-9

63 1,4-Diamino-2,3-Dichloro Anthraquinone 3 81-42-5

64 2,4,6-Trimethyl Aniline 4 88-05-1 65 2,6-Dimethyl-4-Ethyl Aniline 3 4150-37-2

66 1,4-Diamino-5,8-Dihydroxy Anthraquinone 4 145-49-3

67 4-Butyl Aniline 4 104-13-2 68 1-Amino Anthraquinone 5 82-45-1 69 1-Methyl amino Anthraquinone 3 82-38-2 70 Chlorine 5 7782-50-5 71 Naphthaleic Anhydride 4 81-84-5


72 4-Chloro Naphthalic Anhydride 4 8/1/4053 73 1,8-Diamino Anthraquinone 8 479-27-6 74 Quinaldine 3 91-63-4 75 Phthalic Anhydride 6 85-44-9 76 Tetra Chloro Phthalic Anhydride 3 117-08-8

77 3-Hydroxy quinaldine-4-carboxylic Acid 4 118-13-8

78 Methyl Ester 5 105-45-3 79 n-Butanol 8 71-36-3 80 Xylene 8 95-47-6; 1330-20-7 81 Oleum 75 8014-95-7 82 NitrocylSulphuric Acid 20 7782-78-7 83 Phosphorus Trichloride 3 (7719-12-2) 84 m-Amino acetanilide 5 102-28-3 85 4-Methoxy-m-Amino acetanilide 6 6375-47-9

2.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE We will be provided rain water recharging for the resource optimization. Spent Oil i.e. 10 Lit/month will be generated from prime movers which will be reused as lubricant within premises or sell to MoEF approved re-processor. 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT

AND SOURCE 2.7.1 WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed project will be 105.7 KLD which mainly for process, Boiler & cooling (make up water), Domestic uses and for gardening & others, however due to reuse/recycle of 55.6 KLD, Total Fresh Water Requirement will be 50.1 KLD. Total water requirement shall be met from GIDC. 2.7.2 POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 250 KVA. Power supply shall be taken from DGVCL. In case of emergency or power failure D.G. set of 125 KVA X 2 Nos = 250 KVA will be used. It will be used to fulfill emergency power requirement.

2.8 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND ITS

MANAGEMENT / DISPOSAL 2.8.1 WASTEWATER GENERATION Domestic wastewater of 3.4 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporator. Residue (1.0 TPD salt) from ATFD will be sent for TSDF. Details of water requirement and waste water generation are given in following table.


TABLE 4: DETAILS OF WASTEWATER GENERATION

Category Existing Proposed (Additional)

Total after Expansion

Domestic (A) 1 3.5 4.5 Industrial (B)

Process 0.65 46.2 46.85

Washing 1.9 7.8 9.7 Boiler 0.4 3.2 3.6

Cooling 0.05 0.6 0.65 Total (B) 3 57.8 60.8

Total (A) + (B) 4 61.3 65.3 2.8.2 SOLID WASTE GENERATION Solid waste generated will be Sludge from ETP, used/spent oil and discarded bags/drums etc.. The sources of solid wastes, generation and its management are as given in the following table.

TABLE 5: DETAILS OF SOLID WASTE

Sr. No.

Type/Name of Hazardous

waste

Specific Source of

generation

Category and

Schedule as per

HW Rules.


Existing Proposed Total

1 Empty barrels/containe

rs/liners contaminated

with hazardous chemicals/wast

e

Raw Material &

Process

33.1 10 (1000 Nos)

50 (5000 Nos)

60 (6000 Nos)

Collected and stored at specified area and sold to

approved/ registered vendors.

2 Used or Spent Oil

Maintenance

5.1 0.07 0.8 0.87 Collected in drums and stored at

specified area, Reuse in plant for

lubrication and Balance will be

Selling to authorized recyclers

3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage,

Transportation, Disposal at BEIL,

TSDF.


4 Distillation residue

(Semi Solid having CV 1500-2000 Kcal/Kg)

In-House Solvent

Recovery Process

or from

outside solvent

recovery unit

36.1 Nil 1170 1170 Collection, Storage

Transportation, Disposal at

GPCB approved CHWIF or

co/pre- processing


Solvent & Disperse

Dyes (Solvent

Red 179 , solvent

yellow 114, disperse blue 165, disperse blue 354, solvent

orange 60 etc)

26.3 Nil 4068 4068 In-House Distillation and

recovered solvent will be reuse or

Collection, Storage & sent for Recovery as per

Rule 9 of hazardous and other wastes

(Management and transboundary

movement) rules,2016

(M/s.Anju Life science or Any

others) 6 Spent Solvent

(DMF) Solvent & Disperse

Dyes (Solvent

Orange 63, disperse blue 165, disperse blue 354,

disperse red J,

Fluorescent Red CB,

etc)









( Xylene) Solvent

Dyes (Solvent red

26.3 Nil 1728 1728 In-House Distillation or

Collection,


179 , solvent red 135, solvent

red 179, solvent

orange 60, solvent

yellow 157, solvent

yellow 163, etc)

Storage & sent for Recovery as per






(ODCB) Solvent

Dyes (Solvent Yellow

114, solvent yellow 33,

solvent yellow 176,

etc)








others) 9 NaBr Disperse

Blue 354 26.3 Nil 4900 4900 Collection,

Storage, Transportation &

disposal to Actual User under Rule 9


Disperse Blue 354

26.3 Nil 1980 1980 Collection, Storage,

Transportation & disposal to Actual User under Rule 9

11 Benzoic Acid 40 %

Disperse Blue 354



12 Salt From ATFD


Transportation,


Disposal at BEIL, TSDF


Process &

Maintenance

33.2 Nil 0.5 0.5 Collection, Storage,

Transportation, Disposal By

Incineration at CHWIF of BEIL

14 NaCl Scrubber of CL2





D2 Nil 332 332 Collection, Storage

Transportation, Disposal by

selling to actual user authorized

by GPCB or Cement Industry


CHAPTER – 3 SITE ANALYSIS 3.1 CONNECTIVITY The proposed project site is situated at at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labors are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 3.1.1 Road Connectivity The Plant is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. 3.1.2 Rail The Area is well connected by Railway. Ankleshwar railway Station is about 1.35 km in SE. 3.1.3 Airport The nearest airport to the project will be Surat at around 62.08 km. in NWW. 3.1.4 Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. Land document is attached as Annexure – I. 3.3 TOPOGRAPHY Topography of the area is plain. 3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table:

TABLE 6: DETAILS OF EXISTING LAND USE S.NO. PARTICULAR NAME & ITS DISTANCE

1. Nearest National Highway NH-8 at around 0.76 Km 2. Nearest State Highway SH-64 at around 1.23 Km


3. Nearest city Surat at around 62.0 Km 4. Nearest River Narmada at around 6.92 Km

5. Nearest Railway station Ankleshwar at around 1.35 Km 6. National park/Reserve Forest, Biosphere,

etc. None within a radius of 10 Km

6. Seismicity Zone III 3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table:

TABLE 7: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE S. NO. PARTICULAR DISTANCE

1. Civil Hospital Within 15 Km

2. Colleges

3. Govt & Pvt Schools

4. Hari Mandir 3.6 CLIMATIC DATA The main characteristic of this region is hot summer and severe winter with a small spell of rainy season. The rainy season generally commence at the beginning of July and last till mid-October. The period from October to November constitutes the post monsoon season and winter prolong from December to February which last till March before the summer season begins. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months:

Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February

3.6.1 TEMPERATURE DETAILS The hottest months were May to September with mercury reaching 37 ºC during June. The coldest months were December, January and February when temperature drops to 15 ºC. The months, November and March, can also be quite cold in some years. During the other months, temperature was more or less moderate in nature and pleasant to bear. Monthly mean Minimum and Maximum Temperatures of Bharuch station for the period of Jan’18 to Dec’018 are given in following table.

TABLE 8: TEMPERATURE DATA S.

NO. MONTHS OF

YEAR 2015 MONTHLY MEAN

MINIMUM (0C) MONTHLY MEAN

MAXIMUM (0C) 1. January 10 33 2. February 9 38 3. March 11 37 4. April 22 39


S. NO.

MONTHS OF YEAR 2015

MONTHLY MEAN MINIMUM (0C)

MONTHLY MEAN MAXIMUM (0C)

5. May 23 40 6. June 21 36 7. July 20 34 8. August 23 38 9. September 21 36 10. October 18 36 11. November 15 34 12. December 11 33

(Courtesy: Indian Meteorological Department) 3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Surat station was recorded for 08:30 hrs and 17:30 hrs. Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period. 3.6.3 RAINFALL Monthly total rainfall data for Surat station is presented in following table.

TABLE 9: RAINFALL DATA

(Courtesy: Indian Meteorological Department) The rainy season in the area extends from June to October. The mean total rainfall, during the monsoon period (June to September), has been recorded as 1165.1 mm. The average number of rainy days per month varies from 8 to 18 in monsoon months. The rainfall data indicates that the rainfall is limited to monsoon season for four months of the year.

S.NO.

MONTHS OF YEAR 2015

MONTHLY TOTAL (MM)

1. January 00 2. February 00 3. March 00 4. April 0.1 5. May 00 6. June 144.7 7. July 348.6 8. August 154.2 9. September 474.8

10. October 42.7 11. November 00 12. December 00

TOTAL 1165.1


3.6.4 WIND SPEED AND WIND DIRECTION The April – Sept Month, have winds from South West to North East. From October-March is a period mixed with calm conditions and winds mainly from North East to South East. The winter months, November to February, experience frequent calm conditions. The maximum number of calm periods observed is in the month of December and February. (Source: http://www.windfinder.com/windstats/windstatistic_surat_gujarat.htm)

http://www.windfinder.com/windstats/windstatistic_surat_gujarat.htm)


CHAPTER – 4 PLANNING BRIEF 4.1 PLANNING CONCEPT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Proposed project is envisaged as existing Dyes & Intermediates facilities in Gujarat are not adequate to handle new development activities as well for the industries in Surat, Ankleshwar, Jhagadia, Panoli, Vapi, Navsari, Vadodara, others. 4.2 LAND USE PLANNING About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. 4.3 AMENITIES / FACILITIES At the project site first aid centre will be set up. Company will provide drinking water to the workers in the factory premises.


CHAPTER – 5 PROPOSED INFRASTRUCTURE 5.1 INDUSTRIAL AREA About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. 5.2 RESIDENTIAL AREA There will be no residential area proposed for the project. 5.3 GREEN BELT The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About 852.48 sq.m area i.e. 40 % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 0.90 Lacs approx. In Green belt area about 1000 tree per acre of land shall be planted. The selection of tree species suitable for plantation at the industry shall be governed by guiding factors as stated below: The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having

minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in

primary and secondary attenuation zone. The trees should possess extensive foliar area to provide maximum impinging surface for

continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and

hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution

indicator. It is also recommended to carry out extensive plantation within premises.

Keeping in view the climatic conditions, status of soils and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE No new social infrastructure facility will be developed as the plot is located in notified industrial area having well developed infrastructure.


5.5 CONNECTIVITY 5.5.1 ROAD CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation.


5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the GIDC Ankleshwar located within premises after getting necessary clearance. 5.7 WASTE WATER MANAGEMENT 5.7.1 STORM WATER DRAINAGE Storm water drainage system shall consist of well-designed open surface drains network so that all the storm water is efficiently drained of without any water logging. Based on the rainfall intensity of the proposed area drainage system shall be design on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow. Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations. For crossing roads, culverts shall be provided. 5.7.2 SEWERAGE WATER SYSTEM The sanitary sewerage system shall be designed to cater the sanitary sewerage from plant premises. The design of facial sewerage system shall be designed based on no. of person to be served and average daily consumption of water. Only 4.5 KL/day will be generated which will be treated through septic tank and disposed through soak pit/well. For inspection, cleaning and maintenance of sewer lines, manholes of reinforced concrete constructions shall be provided at every bend, junction point of change in slope or diameter and on straight sections of pipes at interval not exceeding 30 meters. 5.7.3 INDUSTRIAL WASTE WATER MANAGEMENT Domestic wastewater of 4.5 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporator. residue (1.0 TPD salt) from ATFD will be sent for TSDF. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the following table.

TABLE 10: DETAILS OF SOLID WASTE MANAGEMENT Sr. No

.

Type/Name of Hazardous waste

Specific Source of

generation

Category and

Schedule as per

HW Rules.


Existing Proposed

Total

1 Empty barrels/containers/liners contaminated

with hazardous chemicals/waste

Raw Material &

Process

33.1 10 (1000 Nos)

50 (5000 Nos)

60 (6000 Nos)

Collected and stored at specified area and sold to

approved/ registered vendors.

2 Used or Spent Oil Maintenance

5.1 0.07 0.8 0.87 Collected in drums and stored at


specified area, Reuse in plant for

lubrication and Balance will be

Selling to authorized recyclers

3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage, Transportation,

Disposal at BEIL, TSDF.

4 Distillation residue (Semi Solid having

CV 1500-2000 Kcal/Kg)

In-House Solvent

Recovery Process

or from

outside solvent

recovery unit

36.1 Nil 1170 1170 Collection, Storage Transportation,

Disposal at GPCB approved

CHWIF or co/pre- processing


Solvent & Disperse

Dyes (Solvent

Red 179 , solvent

yellow 114, disperse blue 165, disperse blue 354, solvent

orange 60 etc)



Collection, Storage & sent for

Recovery as per Rule 9 of hazardous

and other wastes (Management and

transboundary movement) rules,2016



(DMF) Solvent & Disperse

Dyes (Solvent

Orange 63, disperse blue 165, disperse blue 354,





and other wastes


disperse red J,

Fluorescent Red CB,

etc)




others)

7 Spent Solvent ( Xylene)

Solvent Dyes

(Solvent red 179 ,

solvent red 135, solvent

red 179, solvent

orange 60, solvent

yellow 157, solvent

yellow 163, etc)

26.3 Nil 1728 1728 In-House Distillation or







(ODCB) Solvent Dyes

(Solvent Yellow

114, solvent yellow 33,

solvent yellow 176,

etc)








others) 9 NaBr Disperse

Blue 354 26.3 Nil 4900 4900 Collection, Storage,




Disperse Blue 354

26.3 Nil 1980 1980 Collection, Storage, Transportation &


11 Benzoic Acid 40 % Disperse Blue 354

26.3 Nil 28 28 Collection, Storage, Transportation &


12 Salt From ATFD

34.3 Nil 365 365 Collection, Storage, Transportation,

Disposal at BEIL, TSDF


Process &

Maintenance

33.2 Nil 0.5 0.5 Collection, Storage, Transportation,

Disposal By Incineration at

CHWIF of BEIL 14 NaCl Scrubber of

CL2 26.3 Nil 18 18 Collection, Storage,




D2 Nil 332 332 Collection, Storage Transportation,

Disposal by selling to actual user authorized

by GPCB or Cement Industry


CHAPTER – 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN Proposed project is located on industrial land, which is already acquired and there is no habitat. So proposed project proposal does not involve any Rehabilitation & Resettlement.


CHAPTER – 7 PROJECT SCHEDULE & COST ESTIMATES 7.1 PROJECT IMPLEMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. We are giving here under the details of the Project Implementation. From the date of start, the implementation schedule envisages completion of project in 12 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows:

TABLE 11: PROJECT IMPLEMENTATION SCHEDULE S.NO. WORK IMPLEMENTATION TIME

1. Construction work 6 Months 2. Machinery installation 3 Months 3. Recruitment process 1 Month 4. Commissioning 1 Month 5. Operation and functions 1 Month

Total 12 months 7.1.1 PROPOSED ORGANISATION CHART In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to ensure its effective implementation. Hence, company will create a team consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level etc. either permanently or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried - out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in figure – 3.

FIGURE 3: AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL

DIRECTORS

GENERAL MANAGER

WORKS MANAGER OFFICE ASSISTANTS

WAREHOUSE INCHARGE

SUPERVISORS ACCOUNTANT

OPERATORS


7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs. 700.00 Lacs. Break up of proposed project cost is given in following table:

TABLE 12: TOTAL PROJECT COST AND IT’S BREAK UP S.NO. PARTICULARS AMT. (RS. IN LACS)

1 Land and Site Development 0.00 2 Factory Building 300.00 3 Plant & Machineries 400.00 4 Franchises Deposits/ Non CA 0.00 5 Investment/ Non CA 0.00 6 Other Misc. Assets 0.00 7 Preliminary & Pre-operative Exp. 0.00 8 Margin Money for working capital 0.00

TOTAL COST OF PROJECT 700.00 7.3 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The of capital Rs. 25 Lacs and recurring (Rs 10.50 Lacs per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance.


CHAPTER - 8

ANALYSIS OF PROPOSAL 8.1 FINANCIAL AND SOCIAL BENEFITS The industrial activity of the proposed project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region. 8.2 DIRECT BENEFITS TO THE NATIONAL AND STATE EXCHEQUER

Employment generation, Income tax from individual as well as corporate taxes from company and ancillary units, Transportation reduction.

8.3 OTHER BENEFITS Most of the work force required for construction and operation of the proposed project will be drawn from the surrounding villages. During the construction phase, no family is required to rehabilitate from the core zone. The economic growth of the area in terms of employment generation, consumption of goods and market-growth are expected outcome of the project. The project has an employment generation prospect on skilled manpower. The direct employment potential of the project is estimated as 40 persons, the share of local people in this is expected to be significant. It is assumed that the generation of indirect employment would be multiple of direct employment. The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. This will have impact on the current literacy level, primary and middle level education and on existing health facilities. A new awareness generated will have positive impact on the social pattern, which at this stage, is caste and community oriented. The long-term implications of this change are definitely progressive. 8.4 EMPLOYMENT Due to proposed project, there will be development of communication facilities in the area. The total manpower requirement will be 85. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities etc. During operation, plant will generate direct employment as explained in the previous paragraph. The preference will be given for local population for employment in the semi-skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods. Moreover, permanent supply of electricity in the area will support to improve other type of industries. 8.5 HEALTH AND SAFETY MEASURES The workers engaged in high pollution generation area will be equipped with appropriate protective equipment. Following measures will be adopted in the plant to keep check on the safety measures and health:

- Inspection and maintenance of pollution control systems regularly - All safety measures such as provision of safety appliances, training, and giving-of safety

awards. - The workers exposed to noisy sources will be provided with ear muffs/plugs - Adequate facilities for drinking water and sufficient toilets will be provided to the employees


8.6 SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY The firm shall earmark funds for social development and welfare measures in the surrounding villages. These measures will include funding for:

1) Education Facilities 2) Health Care and Family Welfare 3) Infrastructure Developments 4) Social Causes

The details of peripheral development plan including development in infrastructure, health, education and socio cultural aspects which will be carried out are as follows under the Corporate Responsibility:

1 The firm will organize free medical camps at least twice in a year for the benefit of the villagers.

2 The firm will organize cultural programmes in connection for the sake of local villagers every year.

3 The firm will provide chairs and cooking vessels on returnable basis to all the villagers for marriages.

ESTIMATED COST OF PROJECT AND PROJECT VIABILITY The capital cost of the project is estimated at about Rs. 700.00 Lacs for the installation of plant & machinery along with required auxiliary and balancing facilities for the production capacity of 341 T/Month of Dyes & Intermediate product. The breakup of the same is shown below: S. NO. COST OF PROJECT COST (RS. IN LACS)

1 Land and Site Development 0.00 2 Factory Building 300.00 3 Plant & Machineries 400.00 4 Franchises Deposits/ Non CA 0.00 5 Investment/ Non CA 0.00 6 Other Misc. Assets 0.00 7 Preliminary & Pre-operative Exp. 0.00 8 Margin Money for working capital 0.00 9 Total Cost of project 700.00

BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control/monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance will be as given in following table: S. NO. ITEM RS. IN

LAKHS 1 Capital Expenditure 25.00 2 Recurring expenditure on environmental management cell and on pollution

control systems per annum 10.50


ECONOMIC VIABILITY STATEMENT SHOWING PROFITABILITY AND CASH ACCRUALS

PARTICULARS QUANTITY RATE PER KG

TOTAL RS. IN LAKHS

Purchase Value of Dyes and Intermediate Product

-- 625.00 --

If we will produce, Production Cost of Dyes & Intermediate Product

-- 510.00 --

Net Saving Per Kg. -- 115.00 -- Actual Consumption / Day 2435.00 115.00 2.80 Actual Consumption / Monthly 63310.00 115.00 72.80 Actual Consumption / Quarterly 189930.00 115.00 218.40 Actual Consumption / Yearly 759720.00 115.00 873.60 ESTIMATE OF MEANS OF FINANCE 1. Capital & Reserve 0.00 2. Share application money 0.00 3. Unsecured loan (Shareholders) 700.00 4. Member’s deposit 0.00 5. Central & state subsidy 0.00

TOTAL 700.00


ANNEXURE – I LAND AGREEMENT DOCUMENTS :


ANNEXURE – II

LAYOUT OF THE PLANT Ground Floor Plan


First & Second Floor Plan


Second & Terrace Floor Plan

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