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TECHNO ECONOMIC FEASIBILITY REPORT

FOR

EXPANSION OF DYES AND CHEMICALS

MANUFACTURING UNIT

AT

SPECTRUM DYES AND CHEMICALS PVT.LTD. BLOCK NO-484, 502, 503-A , 504 & 505,

N.H.NO.8, PALSANA-394315, DIST.: SURAT,

GUJARAT Email: [email protected]

Prepared by M/S. ENVISION ENVIRONMENTAL SERVICES 201 & 301, Union Trade Center (UTC), Near Apple Hospital,

Udhna Darwaja, Surat - 395002, Gujarat. Phone: 0261-2344773, 2344774

Email: [email protected], [email protected] Visit us at www.en-vision.co.in

M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT

2

EXECUTIVE SUMMARY OF THE REPORT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes & Chemicals manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.No.8, Palsana-394315, Dist.: Surat, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around 49824.52 sq. meter non agriculture private land is acquired for proposed project.

PROJECT COST Cost of the proposed project would be Rs. 4,757.83 Lacs. Total capital cost for environmental pollution control measures with the existing plant would be Rs. 3,155.91 Lacs and recurring cost per annum would be Rs. 1,165.38 Lacs. LIST OF PROPOSED PRODUCTS WITH THEIR PRODUCTION CAPACITY 1A: List of Products along with their Production Capacity

SR. NO.

NAME OF PRODUCTS

Existing (MT/ MONTH)

Proposed (MT/ MONTH)

Total after expansion (MT/ MONTH)

1 S.O.Dyes 250 650 900 2 Dispersing Agent 1500 0 1500 3 Textile Auxiliaries 2125 -2125 0 4 Hydros & Speciality

Chemicals 1000 -1000 0

5 Dyes Intermediate 400 350 750 Total 3150

OR 1 Formulated SO

Dyes - 2400 2400


1B.List of Byproducts along with their Production Capacity

SR. NO.

NAME OF BYPRODUCTS Existing (MT/ MONTH)


Total after expansion

(MT/ MONTH) 1 RC DMF (Recovered) 40 0 40

2 RC Methanol (Recovered) 130 0 130

3 RC Acetone (Recovered) 15 0 15

4 RC Sodium Sulphite (Recovered) 15 0 15

5 RC Toluene (Recovered) 7.5 0 7.5

6 Sodium Bromide Solution 15 0 15


3

List of products Sr. No. products Quantity

SO Dyes 1. Cr-Blue

900 MT/ MONTH

2. Cr-Brown 3. Cr-Flavine 4. Cr-Golden Yellow 5. Cr-Navy Blue 6. Cr-Orange 7. Cr-Pink 8. Cr-Red 9. Cr-Rubine 10. Cr-Scarlet 11. Cr-Violet 12. Cr-Yellow 13. Cr-Yellow Brown

Dispersing Agents 14. DYETOL DF

1500 MT/ MONTH 15. SD NKS 16. TK 85

OR Formulated SO Dyes

17. Disperse Black

2400 MT/ MONTH

18. Disperse Blue 19. Disperse Brown 20. Disperse Flavine 21. Disperse Golden Yellow 22. Disperse Mix 23. Disperse Navy Blue 24. Disperse Orange 25. Disperse Pink 26. Disperse Red 27. Disperse Red Violet 28. Disperse Rubine 29. Disperse Scarlet 30. Disperse Violet 31. Disperse Yellow 32. Disperse Yellow Brown

Dyes Intermediates 33. Alkylated Tertiary Amines

750 MT/ MONTH

Benzothiazole / Imidazole Derivatives 34. Cyno Ethylated Tertiary Amines 35. Ethoxylated and Acetylated Tertiary Amines

Formylated Tertiary Amines 36. Methine Derivatives 37. Primary Amines 38. Pyridones Derivatives


4

DETAILS OF RAW MATERIAL (PER MONTH) Details of material consumption are given in annexure-I REQUIREMENTS FOR THE PROJECT Land: Total 49824.52 sq. meter (existing- 46158.23 sq. meter, proposed-3666.29 sq. meter) land Acquired Water: Water requirement will be mainly for the process 1600.0 KL/day, boiler and cooling 950.0 KL/Day approx. (Make up quantity), Domestic 95.0 KL/Day and for gardening 30.0 KL/Day. Domestic sewage (75.0 KLD) generated will be treated in secondary treatment plant. Generated industrial effluents will be treated in existing and proposed ETP. Existing treated effluent is sent to CETP of M/s. New Palsana Industrial Co-operative Society Limited, hence now onward, treated effluents will also be sent to CETP of M/s. NPICSL, Palsana for further treatment and disposal. Membership certificate is attached as annexure-II Electrical Energy: Total power requirement will be 6000 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. sets of (2x380KVA), (2x500KVA) (2x1250KVA), 2nos. of 1250 KVA gas engine and HFO of 760KVA will be provided as standby to fulfill the power requirement. Fuel: For the existing and proposed utilities plant, fuel used for Steam Boiler, Thermic Fluid Heater, Hot Air Generator, Power Plant (stand by) and D.G. Sets (stand by). Total quantity of proposed & existing fuel will be coal- 75.0 MT/day, Gas-10 SCM/hr, Natural Gas-460 SCM/hr, Furnace Oil-200 Lit/hr. Diesel 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 great employment potential providing employment to approximately 122 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY SOURCES, STACK DETAILS AND APCM PROPOSED

A FLUE GAS STACKS : [EXISTING] Stack No.

Stack Attached To

Stack Height

Stack Diameter Fuel Pollutants Permissible

value APC Attached

1

Steam Boiler6 MTPH (Running) 4 MTPH (Stand by) *

36.5 M 1300 mm Coal, Lignite

PM Sox Nox

150mg/Nm ³ 100 ppm 50 ppm

High Efficiency Multi Cyclone Seperator, Bag filter

2 Thermo pack2,00,000 Kcal/Hr

21 M 250 mm NG PM Sox Nox


Sufficient Stack Height

3 HAG 34 M 1000 mm Coal, Lignite

PM Sox Nox


Dual Teema Cyclone Seperator, Bag filter

4

Thermo pack 3,00,000 Kcal/Hr.Heat transfer area 24m2

5 M 305 mm NG PM Sox Nox



5

(LDO/HSD)/NG Based Power Plant (stand by )

30 M 800 mm LDO/ HSD/ NG

PM Sox Nox



6 (LDO/HSD)/NG Based Power Plant on plot

32 M 800 mm LDO/ HSD/ NG

PM Sox Nox




5

no. 484 (stand by)

7 DG Set – 02 Nos stand by (380 KVA)

11 M 150 mm HSD PM Sox Nox











Note - * indicate that in proposed expansion, we will resell our Existing 4 MTPH Boiler (Stand by)

A Flue Gas Stack: [ Proposed] Stack No.

Stack Attached To

Stack Height


value APC Attached

1 Steam Boiler 10 MTPH ** 36 M

1450 mm

Coal,

Lignite

PM Sox Nox


ESP (Combine Stack and APC for boiler and HAG) 2 HAG

Note - ** indicate that in proposed expansion, we will use our Existing 6 MTPH Boiler as a stand by

B PROCESS STACKS :[EXISTING] Stack No.

Stack Attached To

Stack Height


value APC Attached

1 Spray Dryer No. 3 21.4 M 700 mm

NG / Steam (HAG)

Afer Expansion

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³

Cyclone + Wet Scrubber

2 Spray Dryer No. 4 *** 18.4 M 450 mm Steam

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³


3 Spray Dryer No.5 21.4 M 1200 mm

NG / Steam (HAG)

Afer Expansion

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³


4 Spray Dryer No.6 33.0 M 1100 mm Steam

(HAG)

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³



(HAG)

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³



(HAG)

PM Sox Nox

150 mg/Nm ³ 40 mg/Nm ³ 25 mg/Nm ³


7 Scrubber at Bromide Plant

16.5 M 250 mm -

Cl2 Hcl Br2 Hbr

9 mg/Nm ³ 20 mg/Nm ³ 2 mg/Nm ³ 30 mg/Nm ³

Two Stage venturi scrubbers followed by packed columm scrubber

8 Scrubber At AQ-I Plant

16.5 M 250 mm -

Cl2 Hcl Br2 Hbr

9 mg/Nm ³ 20 mg/Nm ³ 2 mg/Nm ³ 30 mg/Nm ³


9 Scrubber At DD1 16.5 M 250 mm -

Br2 2 mg/Nm ³ 20 mg/Nm ³

Two Stage venturi scrubbers


6

Plant / Mono-Azo #

So2

followed by packed columm scrubber

10 Oleum Storage Tank

6.0 M 50 mm - Sox 40 mg/Nm³ Scrubber

Note - *** indicate that in proposed expansion, we will resell our Existing Spray Dryer No.4 # indicate that in proposed expansion, we will use our existing DD1 scrubber for Mono-Azo plant and install new scrubber for DD1 Plant

B Process Stacks : [Proposed]

Stack No.

Stack Attached To

Stack Height


value APC Attached


(HAG) PM Cyclone + Wet Scrubber

2

Scrubber At NKS Plant

2.5 M 250 mm - So2 -


3

Scrubber At DD2 Plant (Diazo)

6.0 M 250 mm -

Cl2 Hcl Br2 Hbr

-


4 Scrubber At DD2 Plant (Coupling)

5.3 M 650 mm - So2 -


5

Scrubber At Solvent -II Plant

2.0M 250 mm - Br2, So2, Cl2

-


6 Scrubber At MAA Plant

6.0 M 150 mm - Br2, So2, Cl2

- Venturi scrubbers followed by packed columm scrubber

7

Scrubber At Solvent –III Plant Stage-1 Acid

5.6 M 450 mm - So2 Cl2 - Packed columm

scrubber

Scrubber At Solvent –III Plant Stage-2 Alkaline

5.6 M 450 mm - So2 Cl2 - Packed columm

scrubber

8 Scrubber At NEW DD1 Plant (Diazo)

5.5 M 650 mm -

Cl2 Hcl Br2 Hbr

-


9

Scrubber At NEW DD1 Plant (Coupling)

5.5 M 1000 mm -

Cl2 Hcl Br2 Hbr

-


10

Primary Treatment Plant (Equalization tank)

3.5 M 355 mm -

Cl2 Hcl Br2 Hbr

- Packed columm scrubber


7

WASTE WATER GENERATION AND ITS TREATMENT: Domestic sewage (75.0 KLD) generated will be treated in secondary treatment plant. Generated industrial effluents around 2245 KLD will be treated in existing and proposed ETP. Existing process effluent is sent to CETP of M/s. NPICSL, hence now onward, treated effluents will be sent to CETP of M/s. NPICSL, Palsana for further treatment and disposal. 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. S.

No. TYPE OF HAZARD

OUS WASTE

EXISTING

(MT/ month)

PROPOSED (MT/ month)

TOTAL

(MT/ month)

WASTE CATEGO

RY

SOURCE WASTE MANAGEMENT

DETAILS DISPOSAL

1 ETP Sludge 500 750 1250 35.3 Effluent Treatment

Plant

Collection, Storage Transportation,

Disposal at GPCB approved TSDF site

2 Used/spent Oil

1.8 MT/Year

0 1.8 MT/Ye

ar

5.1 Various maintenance processes

Collection, Storage, Transportation,

Disposal by selling to registered re-

refiner 3 Discarded

Containers 60000

MT /Year 0 60000

MT/ Year

33.3 Various production

units

Collection, Storage, Decontamination, Transportation,

Disposal by selling to registered party

4 Process Waste

5 0 5 26.1 Manufacturing process


Disposal at GPCB approved CHWIF

5 Distillation Residue



Disposal at GPCB approved CHWIF

or co/pre- processing

6 GYPSUM 500 0 500 D2 Effluent Treatment

Plan


Disposal by selling to actual user authorized by

GPCB


8

GREEN BELT DEVELOPMENT About 8185 sq.m area i.e. 16.42 % of total project plot area is developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. We have already developed compensatory greenbelt of 5400 sq.m area i.e. 10.83 % of the total project plot area at Udhana-Magdalla Road, Surat and submitted in compliance report of our pervious environment clearance for each half year to the Ministry of Environment, Forest and Climate Change, Regional office-Bhopal. We will develop another 2000 sq. m area i.e 4.06 % of total project area with total investment of Rs.15 Lacs approx. for the green belt plantation. Total Green belt area of total project area would be 31.31 %.


9

INDEX

CHAPTER CONTENT PAGE

1. INTRODUCTION OF THE PROJECT 11

2. PROJECT DESCRIPTION 14

3. SITE ANALYSIS 21

4. PLANNING BRIEF 24

5. PROPOSED INFRASTRUCTURE 25

6. REHABILITATION AND RESETTLEMENT (R & R) PLAN 27

7. PROJECT SCHEDULE & COST ESTIMATES 28

8. ANALYSIS OF PROPOSAL 31


10

LIST OF TABLES

TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 11 2 DETAILS OF EMPLOYMENT REQUIREMENT 13 3 DETAILS OF SIZE OF THE OPERATION 16 4 DETAILS OF WASTEWATER GENERATION 17 5 DETAILS OF SOLID WASTE 20 6 DETAILS OF EXISTING LAND USE 21 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 22 8 TEMPERATURE DATA 22 9 RAINFALL DATA 23 10 PROJECT IMPLEMENTATION SCHEDULE 29 11 TOTAL PROJECT COST AND IT’S BREAK UP 30

LIST OF FIGURES

FIGURE PARTICULAR PAGE

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

14

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

15

3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 29

LIST OF ANNEXURES

ANNEXURE PARTICULAR PAGE

I Raw material consumption 34 II CETP Membership certificate 46 III LAND DOCUMENT 47 IV Solvent recovery system 51 V CGWA Application 61 VI LAYOUT OF THE PLANT 63

M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 11

CHAPTER – 1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT Spectrum Dyes and Chemicals Pvt. Ltd. a company promoted by reputed business families of South Gujarat. The management of “Spectrum Dyes and Chemicals Pvt. Ltd.” have decided to Expansion of Dyes manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, Gujarat. Land document is attached as Annexure- III.

TABLE 1: DETAILS OF THE DIRECTORS S.

NO. NAME OF THE DIRECTOR AGE QUALIFICATION EXPERIENCE

1. Mahendrakumar C. Chaudhary 59 Mechanical Engineer 38 years

2. Yogesh R. Gupta 48 Commerce graduate 28 years

3. Avneep V. Bansal 45 Chemical Engineer 24 years

4. Hardat Singh M. Tarar 58 Arts Graduate 28 years

The company is promoted by Shri Mahendrakumar C. Chaudhary having a widespread business interests in Gujarat. He has been in the business of Dyes & Dyes Intermediates for over 27 years and the group has excellent knowledge about the South Gujarat Industrial Environment. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H. No.8, Palsana-394315, Dist.: Surat, Gujarat 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGION The world is changing at a very quick pace. Due to the decline in the availability of the natural resources,

the use of man-made fabrics has increased drastically in the world. This has led to significant increase in the consumption of Synthetic Organic Dyes - Disperse Dyes which is the main ingredient used to colour the man-made (polyester) fabric. The production of disperse dyes was mainly concentrated in the western countries. However, due to the limited availability of resources and increasing costs, the disperse dyes manufacturing has declined in Western countries and is increasing steady in Developing Asian countries like China, India, Indonesia and Thailand.

India is on second position behind China in consumption of disperse dyes market by its 10% share in which around 70,000 MT to 75,000 MT of dyes is being consumed.


India and China have emerged top of the on worldwide market by exporting its Synthetic Organic Dyes, Formulated S. O. Dyes, Intermediate and other raw chemicals which are used by western and other developing countries in textile manufacturing sector.

We at Spectrum Dyes & Chemicals Pvt Ltd are engaged in manufacturing of Synthetic Organic Disperse Dyes since 1991 and have a reputed Brand name in polyester textile industry in India and around the world. Our products are being exported to the South Asian Countries, Middle East Region Countries, USA & Central Americas. We have a huge demand and also see a rise in demand in the coming years.

Foreseeing this situation, we decided to increase our production capacity. We had already purchased a land in Dahej–Saykha GIDC to construct a large scale production plant. But since it is a green-field project, it is expected to take at least 3-4 years for development of infrastructure and starting the construction. Due to this, we are not able to fulfil the requirement of our existing customers and are on the verge of losing them to other domestic and international competitors.

To avoid this, we are looking to maintain a balance to meet the market demand. We want utilize our spare capacity reserved for production of Textile Auxiliaries, Hydros & Specialty Chemicals and also purchase some adjacent land to expand our existing manufacturing capacity of Synthetic Organic Dyes, Dyes Intermediates and Dispersing Agents.

We have a fully functional Effluent Treatment Plant (ETP) to fully treat our existing effluent load of approximately 1 MLD. To overcome the increase in the effluent load, we have planned to upgrade the ETP and invest around 10 crores out of the proposed total project cost of 47.57 crores. The upgraded ETP will be able to treat upto 2.5 MLD of effluent.

Further, we are valid member of Common Effluent Treatment Plant (CETP) developed by New Palsana Industrial Co-Op Society Ltd and are sending our treated effluent for further treatment since the last four years. The CETP is designed to treat 45 MLD of industrial effluent and has provided membership to 32 units as on date. The CETP is connected with 30 textile units and only two chemical industries (M/s. Spectrum Dyes & Chemicals Pvt Ltd and M/s Virdev Intermediate Pvt Ltd).The total permitted load of the both chemicals industries is 5 MLD as per EC issued to CETP. The combined load of effluent sent to CETP by both the chemical units even after our expansion will be less than 3.5 MLD and it will be easily able to cater to the increased load.

Considering all the factors, we intend to go for expansion so that we are able to retain our customers and also continue to contribute to India’s growth in becoming the largest exporter of Synthetic Organic Dyes across the world. 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 122. 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 NUMBER 1 Top Management 0 2 Managers 1 3 Specialist/ Engineer/Officers 5 4 Supervisors 17 5 Operators/Attendants 99

TOTAL 122 Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. Spectrum Dyes and Chemicals Pvt. Ltd. is going to manufacture dyes and chemicals mainly for textile dyeing and printing industry.


CHAPTER – 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no-484, 502, 503-A , 504 & 505 N.H.no.8, Palsana-394315, Dist.: Surat, 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 mentioned below: Latitude: 21°05’46.77” N Longitude: 72°58’31.57” E


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

2.3 DETAILS OF ALTERNATE SITES No alternate site is considered as this is a expansion project on existing premises. The proposed project site is situated at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, Gujarat. The site is about 17.0 km from Surat. 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. 2.4 SIZE OR MAGNITUDE OF OPERATION Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, Gujarat. Details of size of the operation is shown in Table no: 3


3A.List of products along with their Production Capacity

SR. NO.

NAME OF PRODUCTS

Existing (MT/ MONTH)


Total after expansion (MT/ MONTH)

1 S.O.Dyes 250 650 900 2 Dispersing Agent 1500 0 1500 3 Textile Auxiliaries 2125 -2125 0 4 Hydros & Speciality

Chemicals 1000 -1000 0


OR 1 Formulated SO Dyes - 2400 2400 2 Dyes Intermediate 400 350 750

Total 3150

3B.List of Byproducts along with their Production Capacity

SR. NO.

NAME OF BYPRODUCTS Existing (MT/ MONTH)


Total after expansion

(MT/ MONTH) 1 RC DMF (Recovered) 40 0 40

2 RC Methanol (Recovered) 130 0 130

3 RC Acetone (Recovered) 15 0 15

4 RC Sodium Sulphite (Recovered) 15 0 15

5 RC Toluene (Recovered) 7.5 0 7.5

6 Sodium Bromide Solution 15 0 15


2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of disperse dyes is attached as annexure-I.

2.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE We have provided rain water recharging system for the resource optimization. Spent solvent will be recovered through distillation unit and will be reused in process along with fresh solvent. Please refer annexure- IV for details 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 2700 KLD which mainly for process, Boiler & cooling (make up water), Domestic uses and for gardening & others. Total water requirement shall be met from existing 4nos. of bore well and proposed 3 nos. of bore well. 2.7.2 POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 6000 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. sets of (2x380KVA), (2x500KVA) (2x1250KVA), 2nos. of 1250 KVA gas engine and GFO of 760KVA will be provided to fulfill the power requirement.

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

MANAGEMENT / DISPOSAL 2.8.1 WASTEWATER GENERATION Water requirement will be mainly for process, Boiler & cooling (Make up water), Domestic and gardening. Waste water i.e. sewage waste water 75.0 KL/day will be generated which will be treated in secondary treatment plant. Industrial waste water will be 2245 KL/day from process and utilities. Details of water requirement and waste water generation are given in following table.

TABLE 4: DETAILS OF WASTEWATER GENERATION

S.NO. PURPOSE WASTE WATER GENERATION (KL/D) EXISTING PROPOSED TOTAL

A. Domestic 15 60 75 B. Industrial 1. Processing 800 1075 1875 2. Boiler and

Cooling 140 130 270

3. Floor and Drum washing

10 15 25

Total (B) 950 1235 2185 C. Green belt 0 0 0 Grand Total (A+B+C) 965 1280 2245

2.8.2 FACILITIES FOR TREATMENT OF LIQUID EFFLUENT (ETP) We propose upgrading/modifying our PTP- Primary Treatment Plant & STP- Secondary Treatment Plant with investment of approximately 10 Crores. In which Primary Treatment is going to have continuous automated neutralization system for charging of lime, ferrous and polyelectrolyte with high efficiency having Thickener which is followed by Two Rotary Vacuum Drum Filters and Paddle Dryer to make moister free Sludge for suitable to fill in Sludge Silo. Secondary treatment plant is going to have the Cyclic Activated Sludge Technology of the ETP. This technology is extensively used for treatment of industrial wastewater to highest possible quality at a very low cost of treatment with minimum space utilization.


Treatment Philosophy of Proposed ETP An equalization tank with mechanical mixing is provided to dampen the variations of flow. Agitators are provided in this tank for proper mixing of effluent and to avoid stagnation of liquid. Pumps have been provided to pump the raw effluent from equalization to pH Correction Tank-1. A Level indicator transmitter is provided in the sump to control proper on/off of the pumps depending upon the water level in the tank. The pumped effluent from Equalization tank is corrected for pH in PPH –FRP neutralization tank 1 followed by Neutralization Tank 2 for increasing pH levels, and will be fed to High Rate Thickener for removal of suspended solids. Hydrated Lime with 80% purity is used to correct the ph. A pH indicator and controllers are installed inside both the tanks to automatically control the dosage of lime and to produce desired pH of effluents. Mechanical agitators are provided in the tank for mixing the lime with effluents inside the tank. The primary object of thickener is to achieve the desired underflow concentration, while maintaining a clear overflow and minimizing the flocculent usage. The fundamental strategy for controlling the underflow concentration is to regulate the time the solids which are present in the thickener and the amount of flocculent used due to which suspended solids gets removed. Clarified effluent from High Rate Thickener and sewage waste water are directed to C-TECH Feed Tank. Effluent is then pumped to C -Tech basins for biological treatment. There are two operating C-Tech basins in the plant. These C-Tech basins work in sequence and the influent flow is distributed using Automatic Gates provided at the Inlet Chamber of C-Tech basins. The C-Tech basins are equipped with air blowers, diffusers, Return Activated Sludge (RAS) pumps, Surplus Activated Sludge (SAS) pumps, Decanters, Auto valves, Programmable Logic Controller (PLC) etc. All cycles will be automatically controlled using PLC. Excess sludge at a consistency level of approx. 0.8% - 1.0% will be pumped intermittently from SAS pump to the sludge sump. Sludge generated from Physico-chemical treatment and biological treatment is collected in common sludge sump. Mechanical mixers are provided to keep the sludge in suspended form. Rotary Vacuum Drum filter is considered to dewater the sludge to the required solid concentration. Screw pumps are used to pump the sludge from sludge sump to RVDF. Dewatering polymer is dosed into the thickener to improve its dewatering characteristics. The dewatered sludge from Rotary Vacuum drum filter is taken to the Paddle Dryer System for max. Solid concentration and to make suitable for filling in the sludge silo whereby the sludge will be dispatch to the TSDF Site. After biological treatment, the treated effluent is directed to CETP. DESIGN CHARACTERISTIC:

Effluent Water Inlet Quality SR.NO. Parameter Unit Inlet Parameters CETP norms

1 pH - 1 to 4 6.5-8.5 2 SS mg/l 1250 300 3 COD mg/l 15000 1000 4 BOD mg/l 6000 400 5 Ammonical Nitrogen mg/l 70 50 6 Phenolic Compound mg/l 2 1 7 Oil & Grease mg/l 15 10

PROPOSED ETP UNIT system: (Design Flow: 2500 KLD)

Equipment name Size/Capacity MOC Quantity

Sludge Handling System Sludge Silo 250 MT MS 2 nos. Paddle Dryer-1 2.5 MT/H SS 304 1 nos. Stand by Paddle Dryer-2 1.5 MT/H SS 304 1 nos. Secondary Treatment Plant C - Tech Basin 3000 m³ RCC 2 sets AERZEN, German make, Hybrid Energy Saving Efficiency Air Blower

2800 Nm³/h @ 0.75 kg/cm² MS 3 nos


Primary Treatment Plant Lime Silo 150 MT MS 1 no. Lime Handling System 2.5 TPH 1 no. Rotary Vacuum Drum Filter 1.8m x 1.8m MS 2 no.

Equalization tank 1000 m³ RCC-AR brick lined 1 no.

Neutralization Tank 41m³ & 44 m³ PP-FRP 1 no. each

Thickener -1 8 m dia MS/painted 1 no. Stand by Thickener -2 8 m dia MS/painted 1 no. Sludge Sump 200 m³ RCC 1 no. Lime Dosing tank 15 m³ RCC 4 nos

FeSO4 Dosing tank 8 m³ RCC-AR brick lined 2 nos

FeSO4 Bulk storage tank 50 m³ RCC-AR brick lined 1 no.

Polymer dosing tank 8 m³ RCC 2 nos Urea/DAP tank 8 m³ RCC 2 nos Air Compressor 220 cfm 1 no. Lift 1.5 MT MS 1 no. Electrical & Instrumentation Piping & Valves

Area available for proposed ETP is 1300 Sq.meter


2.8.2 SOLID WASTE GENERATION Solid waste generated will be Ash from boilers and Sludge from ETP, used/spent oil and discarded bags. The sources of solid wastes, generation and its management are as given in the following table.

TABLE 5: DETAILS OF SOLID WASTE S.

No. TYPE OF

HAZARDOUS WASTE

EXISTING (MT/ month)

PROPOSED (MT/ month)

TOTAL (MT/

month)

WASTE CATEGORY

SOURCE WASTE MANAGEMENT DETAILS

DISPOSAL

1 ETP Sludge 500 750 1250 35.3 Effluent Treatment Plant

Collection, Storage Transportation, Disposal at GPCB approved TSDF site

2 Used/spent Oil 1.8 MT/Year 0 1.8 MT/Year

5.1 Various maintenance

processes

Collection, Storage, Transportation, Disposal by

selling to registered re-refiner 3 Discarded

Containers 60000 MT

/Year 0 60000 MT/

Year 33.3 Various

production units

Collection, Storage, Decontamination,

Transportation, Disposal by selling to registered party

4 Process Waste 5 0 5 26.1 Manufacturing process

Collection, Storage Transportation, Disposal at GPCB approved CHWIF

5 Distillation Residue


Collection, Storage Transportation, Disposal at GPCB approved CHWIF or

co/pre- processing 6 GYPSUM 500 0 500 D2 Effluent

Treatment Plan Collection, Storage

Transportation, Disposal by selling to actual user authorized

by GPCB


CHAPTER – 3 SITE ANALYSIS 3.1 CONNECTIVITY The proposed unit shall be located at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, Gujarat. The site is about 0.05 km from NH-8. 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. 3.1.1 Road Connectivity The plant location is about 0.05 Km (E) from Bombay-Ahmedabad Highway on NH – 8. 3.1.2 Rail The Area is well connected by Railway. The Chalthan Railway Station is about 7.0 km in NNW from the site. 3.1.3 Airport The nearest airport to the project will be Surat at a distance of 24.2 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 49824.52 sq.m. of land at Block no-484, 502, 503-A , 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, Gujarat, is acquired for the proposed plant out of total 46158.23 sq.m existing and 3666.29 sq.m proposed for expansion. Total acquired land is classified as Industrial land. Land document is attached as Annexure – III. 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 0.05 Km E

2. Nearest State Highway SH-168 at around 1.1 Km S

3. Nearest city Surat at around 17.0 Km

4. Nearest River Mindhola at around 2.6 Km SE

5. Nearest Railway station Chalthan at around 7.0 Km NNW

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 17.8 Km

2. Colleges 1.2 Km

3. Govt. & Pvt. Schools 0.8 Km

4. Temple 1.5 Km 3.6 CLIMATIC DATA The climate of the area is humid and tropical. A hot and humid pre-monsoon from March to mid May, a prolonged southwest monsoon or rainy season from mid May to September, a pleasant post-monsoon or retreating monsoon from October to November and a cold pleasant winter from December to February are the characteristics of the general climate. Summer runs concurrently with the later part of the pre-monsoon season and continues throughout the monsoon season. 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

Sometimes, the monsoon commences in mid-June and ends in mid-September. Therefore, the boundaries between the seasons are not very rigid. Surat is the meteorological observatory, to whom the meteorological data (Temperature, Relative Humidity, Rainfall, Wind speed and Wind direction) for the year January 2014 to December 2014 were collected from Indian Meteorological Department (IMD) in Ahmedabad. 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 Surat station for the period of Jan’14 to Dec’14 are given in following table.

TABLE 8: TEMPERATURE DATA

S. NO.

MONTHS OF

YEAR 2014

MONTHLY MEAN

MINIMUM (0C)

MONTHLY MEAN

MAXIMUM (0C) 1. January 15.0 30.0 2. February 17.0 32.0 3. March 21.0 35.0 4. April 24.0 37.0 5. May 27.0 36.0 6. June 27.0 34.0 7. July 26.0 31.0 8. August 26.0 31.0 9. September 25.0 32.0

10. October 23.0 35.0 11. November 20.0 34.0 12. December 17.0 32.0

(Courtesy: Indian Meteorological Department)


3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Bharuch 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)

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)

S. NO.

MONTHS OF YEAR 2016

MONTHLY TOTAL(MM)

1. January 13.4 2. February 1.8 3. March 0.0 4. April 0.0 5. May 0.4 6. June 22.7 7. July 398.9 8. August 158.5 9. September 216.8 10. October 4.5 11. November 0.0 12. December 0.0

TOTAL 817.0


CHAPTER – 4 PLANNING BRIEF 4.1 PLANNING CONCEPT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes & Chemicals manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana-394315, Dist.: Surat, 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 For the proposed Expansion of plant 46158.23 sq. meter existing land acquired and purchase 3666.29 sq. meter new land, Hence Total 49824.52 sq. meter land Required for proposed Expansion. 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 For the proposed Expansion of plant 46158.23 sq. meter existing land acquired and purchase 3666.29 sq. meter new land, Hence Total 49824.52 sq. meter land Required for proposed Expansion. 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 top soil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About 8185 sq.m area i.e. 16.42 % of total project plot area is developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. We have already developed compensatory greenbelt of 5400 sq.m area i.e. 10.83 % of the total project plot area at Udhana-Magdalla Road, Surat and submitted in compliance report of our pervious environment clearance for each half year to the Ministry of Environment, Forest and Climate Change, Regional office-Bhopal. We will develop another 2000 sq. m area i.e 4.06 % of total project area with total investment of Rs.15 Lacs approx. for the green belt plantation. Total Green belt area of total project area would be 31.31 %. In Green belt area about 1700 tree 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 4 nos. of existing Bore well and 3 nos. of proposed bore well. CGWA application submitted for use of bore well. A copy of CGWA application attached as annexure-V. 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 75.0 KL/day sewage will be generated which will be treated by our secondary treatment plant and final treated waste water disposed to CETP of NPICSL 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 Water will be required for Process, Boiler & Cooling purpose, Domestic and Green belt development. Maximum recycling of water will be done. 2245.0 KL/day industrial wastewater generated from process & utilities of the proposed project. Same will be treated in in-house ETP and treated effluents are finally discharged in to CETP of NPICSL for further treatment and disposal. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the table no. 5.


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 18 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 10: PROJECT IMPLEMENTATION SCHEDULE S.NO. WORK IMPLEMENTATION TIME

1. Construction work 9 Months 2. Machinery installation 4 Months 3. Recruitment process 1 Month 4. Commissioning 2 Month 5. Operation and functions 2 Month

Total 18 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

UNSKILLED WORKERS


7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs.4757.83 Lacs. Break up of proposed project cost is given in following table:

TABLE 11: TOTAL PROJECT COST AND IT’S BREAK UP S. NO. COST OF PROJECT COST (RS. IN LACS)

1 Land and Site development 300.0 2 Factory Building 698.76 3 Plant & Machineries 3389.52 4 Furnitures 173.04 5 Greenbelt Development 15.0 6 Preliminary & Pre-operative Exp. 89.99 7 Total Capital Cost of Project 4666.31 8 CSR Project Activity 91.53 9 Total Cost of project 4757.83

7.3 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The capital expenditure is Rs.3155.91 Lacs and recurring (Rs 1165.38 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 122 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 122. 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. 4757.83 Lacs for the construction of factory building and installation of plant machinery along with required auxiliary and balancing facilities for the production 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 300.0 2 Factory Building 698.76 3 Plant & Machineries 3389.52 4 Furnitures 173.04 5 Greenbelt Development 15.0 6 Preliminary & Pre-operative Exp. 89.99 7 Total Capital Cost of Project 4666.31 8 CSR Project Activity 91.53 9 Total Cost of project 4757.83 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

LACS 1 Capital Expenditure 3,155.91 2 Recurring expenditure on environmental management cell and on pollution control

systems per annum 1,165.38

ECONOMIC VIABILITY STATEMENT SHOWING PROFITABILITY AND CASH ACCRUALS

Particulars Quantity Rate per kg Total

Rs. in Lacs

SALES Value of Dyes and Intermediate Product 2,10,00,000 276.75 58 117.75

If we will produce… Total Cost of Dyes & Intermediate Product

2,10,00,000 256.56 53,877.20

Net Earnings Per Kg. 2,10,00,000 20.19 4 240.55

Estimated Sales / Day 57 534.25 20.19 11.62

Estimated Sales / Monthly 17 26 027 20.19 348.54 Estimated Sales / Quarterly 51 78 082 20.19 1 045.62 Estimated Sales / Yearly 2 10 00 000 20.19 4 240.55


ESTIMATE OF MEANS OF FINANCE 1. Capital & Reserve 1 325.59 2. Share application money - 3. Unsecured loan (Shareholders) - 4. Member’s deposit - 5. Central & state subsidy - 6. Loan from Financial Institutions 3 432.24

TOTAL 4 757.83

S.No. Raw MaterialQty

((MT / MT))

1 CR-YELLOW 54 0.830

2 Sulfuric Acid 6.570

3 Iodine 0.001

4 Bromine Liquid 0.590

5 H E D P 0.030

1 CR-YELLOW 3G 0.316

2 DYETOL DF 0.086

3 Dispersing Agent 0.606

4 O P A (Ortho Phosphoric Acid) 0.006

5 C 20 FKI (DEFOAMER) 0.001

6 LUMINOUS YELLOW 10GN 0.015

1 GP BASE 0.530

2 E.P. 0.650

3 H C L 0.990

4 Sodium Nitrite 0.240

5 DIATOMITE SUPERCELL 935 (HYFLOW) 0.010

6 Sulfamic Acid 0.040

7 Sodium Acetate Crystal ( Tri ) 1.050


1 CR-G. Y. GNN 0.324

2 DYETOL DF 0.104


4 H E D P 0.004


1 P N A 0.390

2 H M Q 0.770

3 H C L 1.230





8 Soda Ash 0.570

9 Sodium Bi Carbonate 0.070

1 CR-YELLOW C4G 0.200

2 DYETOL DF 0.090


CR-YELLOW 3G

DISPERSE YELLOW 3G 200%

CR-G. Y. GNN

DISPERSE GOLDEN YELLOW W3RN

CR-YELLOW C4G

DISPERSE YELLOW C4G H/CONC.

ANNEXURE-I

34

4 H E D P 0.005


1 P N A 0.450

2 SD 08 0.611

3 H2SO4 (30%) 1.200




7 Sodium acetate Crystal 0.419

8 Surfactant 0.011


1 CR-ORANGE RL 0.360

2 DYETOL DF 0.120


4 H E D P 0.010


1 O C P N A 0.515

2 N,N-DCNE Aniline 0.588

3 HCl (30%) 1.271




7 Surfactant 0.012


1 CR-ORANGE 3R 0.340

2 DYETOL DF 0.130


4 H E D P 0.010


1 P N A 0.375

2 Coupler 0.655

3 HCl (30%) 1.009




7 Surfactant 0.009

1 CR-ORANGE 80 0.428

2 DYETOL DF 0.122

CR-ORANGE RL

DISPERSE ORANGE RL

CR-ORANGE 3R

DISPERSE ORANGE 3R

CR-ORANGE 80

DISPERSE ORANGE 80

ANNEXURE-I

35


4 H E D P 0.010


1 2:6 DCPNA 0.525

2 SD 07 0.615

3 N.S.A. 35% 0.958



6 CO – 40 0.025

7 Acetic Acid 0.200


1 CR-Y BROWN 2RC 0.280

2 DYETOL DF 0.145


4 Acetic Acid 0.001


1 2:6 DCPNA 0.530

2 SD - 37 0.490

3 N.S.A. 35% 0.970



6 CO – 40 0.018

7 HCl 0.200


1 CR - BROWN 2 0.276

2 DYETOL DF 0.145


4 Acetic Acid 0.001


1 2:6 DBPNA 0.720

2 SD 01 0.380

3 N.S.A. 35% 0.764



6 Acetic Acid 0.160


1 CR-BROWN 3RSF 0.55

2 DYETOL DF 0.124

CR-YELLOW BROWN 2RFL

DISPERSE YELLOW BROWN 2RFL

CR- BROWN 2

DISPERSE BROWN 2

CR-BROWN 3RSF

DISPERSE BROWN 3RSF H/CONC

ANNEXURE-I

36


4 Acetic Acid 0.004


1 O C P N A 0.540

2 TK 8 0.540

3 H C L 1.440






1 CR-SCARLET 3R 0.330

2 DYETOL DF 0.115


4 H E D P 0.002


1 O C P N A 0.350

2 SD 3A 0.650

3 H C L 1.200






1 CR- RED 2B 0.350

2 DYETOL DF 0.150


4 H E D P 0.010


1 SD 3.2 0.690

2 2 Cyno PNA 0.377

3 N.S.A. 35% 0.580

4 Suphuric acid 0.230


1 CR-RUBINE XF2G 0.384

2 DYETOL DF 0.080



CR-SCARLET 3R

DISPERSE SCARLET 3R 150%

CR-RED 2B

DISPERSE RED 2B

CR-RUBINE XF - 2G

DISPERSE RUBINE XF 2G

ANNEXURE-I

37

1 CRUDE RED 34 (MONO) 1.5402 D M F 0.3503 Zinc Cyanide 0.2604 Copper cyanide 0.050

1 CR-RED 34 0.3402 DYETOL DF 0.0953 Dispersing Agent 0.5654 O P A (Ortho Phosphoric Acid) 0.0065 C 20 FKI (DEFOAMER) 0.006

1 Phenol Liquid 1.186

2 Pottasium Carbonate (Granules) 0.956

3 Di chloro di amino AQ 0.956

4 Soda Ash 0.523


1 INT-VIOLET 26 0.444

2 DYETOL DF 0.104




1 2 Cyno PNA 0.488

2 3-( N,N DIETHYL ) AMINO ACETANILIDE 0.767

3 N.S.A. 35% 0.743


5 H C L 0.366


7 CO 20 0.016



10 T.B.A.B. 0.008

1 INT-VIOLET 3R 0.264

2 DYETOL DF 0.084


4 Acetic Acid 0.004


1 2 Cyno PNA 0.389

2 3-(N,N-dimethoxyethyl) amino acetanilide 0.632

CR - VIOLET 3R

DISPERSE VIOLET 3R CONC.

CR - VIOLET 77

DISPERSE RED F3BS 400%

CR-VIOLET 26

DISPERSE RED VIOLET FBL 200%

CR-RED 34

ANNEXURE-I

38

3 N.S.A. 35% 0.828


5 H C L 0.118


7 CO 20 0.009



10 T.B.A.B. 0.014

1 INT-VIOLET 77 0.425

2 DYETOL DF 0.084


4 Acetic Acid 0.001


1 CRUDE BLUE GSL (MONO) 1.480

2 D M F 1.220

3 Zinc Cyanide 0.550

4 Copper Cyanide 0.153

5 METHANOL 1.111

1 CR-BLUE GSL 0.450

2 DYETOL DF 0.080




1 6 Chloro 2:4 DNA 0.432

2 TK 5 0.720

3 N.S.A. 35% 0.734



6 Acetic Acid 0.040

1 CR-N BLUE 3G 0.410

2 DYETOL DF 0.245


4 Acetic Acid 0.004


1 6 Bromo 2:4 DNA 0.552

2 Coupler 0.463

3 N.S.A. 35% 0.747


DISPERSE BRILL BLUE GSL 400%

CR-N BLUE 3G

DISPERSE NAVY BLUE 3G 200%

CR- BLUE 2R

DISPERSE VIOLET 77

CR-BLUE GSL

ANNEXURE-I

39


1 CR- BLUE 2R 0.475

2 DYETOL DF 0.171


4 Acetic Acid 0.004


1 PABA RE (ME) 0.686

2 Ethyl Pyridone 0.514

3 HCl 0.828




8 Caustic lye (48%) 0.283


10 Surfactant 0.014

1 INT-FLAVIN XF 0.350

2 DYETOL DF 0.130


4 Acetic Acid 0.010


1 SD 36 0.900

2 DMP 0.640

3 Acetic Anhydride 1.700

4 METHANOL 2.010

1 CR-PINK BR 0.130

2 DYETOL DF 0.054




6 Ammonium Sulphate (G Salt) 0.014

1 Orange 3R 0.160

2 Navy Blue 3G 0.195

3 Dark Red 2B 0.450

4 DYETOL DF 0.150



DISPERSE BLACK R - Plus

CR - FLAVIN XF

DISPERSE FLAVIN XF

CR-PINK BR

DISPERSE BRILL. PINK BRF 300%

DISPERSE BLACK 3GNS

DISPERSE BLUE 2R

ANNEXURE-I

40

1 Orange 288 0.075

2 Blue 4G 0.200

3 Blue 4R 0.225

4 DYETOL DF 0.075



1 INT-BLUE 1224 0.220

2 INT-ORANGE 8L 0.170

3 DYETOL DF 0.070




7 BLUE M-5R 0.028

DISPERSE BLACK E-MRD

ANNEXURE-I

41

S.N Raw Material MT/MT

1 Phenol 0.500

2 Formaldehyde 0.440

3 Sodium Sulphite 0.280

4 Caustic lye 0.070

5 Water 0.425

1 Napthalene 0.380


3 Oleum 0.320

4 Caustic lye 0.380

1 Lignin 0.500


3 Sulfonating Agent 0.350

4 Caustic lye 0.050

TK - 85 /Dispersing Agent

NKS / Dispersing Agent

Dyetol DF / Dispersing Agent

ANNEXURE-I

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S.N Raw Material MT/MT

1 M P D A 0.800

2 Sodium Bi Sulphite 0.010

3 H C L 2.160


5 Caustic Soda Lye 0.400



3 H C L 5.410

4 Hydrogen Peroxide (H2O2) 0.240

5 P N A 0.470

1 H C L 8.410

2 2 Cyno PNA 0.750



1 2,4-DNCB 1.125

2 Liquid Ammonia (23%) 3.000

1 2,4 DNCB 0.800

2 Liquid Ammonia 23% 2.500

3 Bromine 0.340

4 Hydrogen Peroxide 0.075

5 HCL 2.000


2 Para Toluidine 0.400



2 DCBTC 1.060



1 Methyl cyano acetate 0.650

2 OPDA 0.700

3 H2SO4 1.500

1 3 – AMA 0.530

2 EO 0.315

3 Catalyst 0.005

4 Acetic acid 0.525


ADC Liquid

Cyanomethyl Benzimidazole (CMB)

TK - 05

SD - 14

Bromo PTI

M A A

DBPNA

Bromo Cyno PNA

DNA

Bromo DNA

ANNEXURE-I

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1 Aniline 0.470

2 Acrylonitrile 0.700

3 Catalyst 0.005

4 Acetic acid 0.500

1 MT 0.400

2 Hexyl Bromide 1.250

3 Caustic lye 0.630

1 DEMAP 0.900

2 POCl3 0.900

3 DMF 2.000

4 Caustic lye 0.400

5 Sod. Acetate 0.300

1 ECA 0.640

2 MAA Ester 0.653

3 Ethyl amine 0.275

1 EAA ester 0.820

2 Benzyl chloride 0.850

3 Caustic lye 0.500

4 Oleum (23 – 25%) 2.350

5 H2SO4 0.500

1 Soda ash 0.900

2 MAA 0.780

3 DES 1.110

1 Soda ash 0.890

2 M A M S 0.800

3 DES 1.100

4 Acetic acid 1.000

1 Aniline 0.450

2 TBAB 0.030

3 Hydroquinone 0.002


5 Nitrogen gas 0.001

6 Acetic acid 0.840

7 Ethylene Oxide 0.250


1 Meta Chloro aniline (MCA) 0.600


3 Sulphuric acid 0.010

SD - 07

SD - 01

SD - 34B

TK - 31

SD - 35

Ethyl pyridone

SD - 30

SD - 12

ANNEXURE-I

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4 Acid Slurry 0.003


1 MAA (HCl) 0.600


3 Acetic acid 1.000

4 Caustic lye (48%) 0.250



1 SD - 7CN 0.630

2 Soda ash 0.230

3 Benzyle Chloride 0.545

1 Meta Toluidine 0.358

2 TBAB 0.010




6 Soda ash 0.308

7 Ethylene Chloride 0.375

1 Aniline 0.560

2 TBAB 0.010




6 Soda ash 0.330

7 Ethylene Chloride 0.400

1 Soda ash 0.300

2 MAA Ester 0.650

3 Benzoyl chloride 0.800

1 Soda ash 0.450

2 3-AMA 0.710

3 Allyl chloride 0.650

TK - 08

TK - 28

SD - 24

TK - 3A

SD - 38

SD - 37

ANNEXURE-I

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ANNEXURE-II

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ANNEXURE-III

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ANNEXURE-III

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ANNEXURE-III

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ANNEXURE-III

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SOLVENT RECOVERY SYSTEM

Recovery Plant Distillation Unit & Solvent

Stripper System

Flowcharts of the recovery process, flowcharts of both the system workings and Mass Balances of the batch, the processes and the solvents – Methanol & DMF

ANNEXURE-IV

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Solvent Recovery & Mass Balance

We carry out the recovery of the solvents used (Methanol & DMF) in two separate systems. We have explained

below the recovery process and the system used. We have also enclosed the plant layouts of both the systems.

The raw materials including the solvents are added to the reactor as per the required batch size. After completion

of reaction, the product is filtered and mother liquor (ML) is collected in the storage tank 1. The further treatments

on ML is carried out in recovery plant distillation unit. The washing water of wet cake is collected in storage tank

2 and sent to solvent stripper to remove the solvent traces with the help of effective cooling facility at different

temperature and under vacuum.

Flow Diagram of Mother Liquor and Wet Cake Washing Water

Mass Balance of the Batch

INPUTS OUTPUTS

Item Kgs Litres Item Kgs Litres

DMF 1990.00 2110.00 Product Wet Cake 3800.00

Metal Cyanide 450.00 Mother Liquor (Storage Tank 1) 6880.00 7500.00

Mono Azo 2727.00 Washing ML (Storage Tank 2) 8237.00 610.00

Methanol 4750.00 6000.00 Water in wet cake 0.00

Washing Water 9000.00

Total 18917.00 8110.00 Total 18917.00 8110.00

Washing

Filtration

Wet Cake

Reactor

Mother Liquor Water Storage Tank 1

Storage Tank 2 Recovery Plant

Distillation Unit

Solvent Stripper

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Recovery Plant Distillation Unit & Solvent Stripper System

We have installed 4 distillation units and 1 solvent stripper system. Both Recovery Plant Distillation Unit & The

Solvent Stripper System are provided with Main condenser, Vertical condenser (distillation column), vent

condenser & sub-cooler condenser.

All the condensers & the sub-coolers are Horizontal, Shell and tube type in SS 304 construction. The Utility in

the Main Condenser is cooling water while vent condenser is provided with Chilled Water.

The distillation column is in SS 304 construction. Its internals include liquid distributer, Packing supports,

Structured packing & liquid collector, all in SS 304. The structured packing used is Mellapak 250Y.

The solvent vapours condense in main condenser via vertical condenser. The uncondensed vapours from main

condenser get condensed in vent condenser. Both the condensed streams are collected in two Receivers through

sub cooler condenser. This arrangement ensures the solvent recovery efficiency of up to 99%.

We have also enclosed the layout of both the systems for your reference.

ANNEXURE-IV

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i) Solvent Recovery from ML in Recovery Plant Distillation Unit.

Process with flow diagram of Solvent recovery through column condenser

Typical Batch Process:

Charge Mother Liquor (Storage Tank 1) in 10 KL distillation vessel. (ML contains 5400 litres Methanol;

2100 litres DMF).

Depending upon the boiling point of solvent, distillation is set up in two stages.

In first stage, 5240 litres methanol is distilled out at 65 – 70 ⁰C without vacuum due to its low boiling

point.

After that, condensation is stopped, temperature is increased to 80 – 85 ⁰C, vacuum is applied and intercut

122 litres Methanol + 225 litres DMF is collected.

Then, 1640 litres DMF recover under same temperature and vacuum.

During recovery, 25 litres Methanol and 5 litres DMF vapour loss.

The remaining solvents (13 litres methanol + 230 litres DMF) remain unrecovered in the incinerable

sludge.

Intercut of the significant number of batches are redistilled out.

Storage Tank

(Mixture of solvent +

Salts + Products etc)

Distillation

Reactor Vertical

condenser

Main

condenser

Sub cooler

condenser

Vent

condenser

Intercut

Receiver

R

Pure solvent

Receiver

ANNEXURE-IV

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Mass Balance of the Recovery Plant Distillation Unit

INPUTS OUTPUTS

Mother Liquor

(Storage Tank 1) Kgs Litres

Kgs Litres

(Real) Real ASIS

Methanol in ML 4275.00 5400.00 Methanol pure (99%) 4155.00 4197.00 5240.00

DMF in ML 1980.00 2100.00 Intercut methanol (90%) 90.00 100.00 122.00

Salts 225.00 Methanol Vapour loss 20.00 20.00 25.00

Dissolved products 300.00 Methanol in sludge 10.00 10.00 13.00

Water 100.00 DMF pure (99%) 1550.00 1565.00 1640.00

Intercut DMF (80%) 210.00 262.00 225.00

DMF Vapour loss 5.00 5.00 5.00

DMF in sludge 215.00 215.00 230.00

Balance Sludge containing

salts, product (except solvents) ------ 506.00 ------

Total 6880.00 7500.00 Total ---- 6880.00 7500.00

% Recovery Methanol: 99.30%

% Recovery DMF: 88.81%

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ii) Solvent Recovery from washing effluent through solvent stripper.

Process with flow diagram of Solvent Stripper

Washing ML collected in Storage Tank 2 is pumped to solvent stripper plant neutralization reactor.

The washing ML is first neutralized and then filtered through Zero leakage filter press. Solid sludge is

separated and the remaining liquid is transferred to storage tank.

From the storage tank, the effluent is distilled by continuous distillation process in solvent stripper column

where solvent get separated from effluent.

The solvents are collected in the receivers and the remaining effluent is transferred to ETP Primary

division.

The above effluent gets mixed with other streams in Equalization tank of primary system.

After doing Primary Treatment, the effluent is transferred to Secondary Treatment Plant and finally to

tertiary treatment plant.

The above effluent is then sent to Common Effluent Treatment Plant as per Gujarat Pollution Control

Board norms.

Storage Tank

2 Neutralization

Reactor 10KL

Filter Press

2MT

Storage

Tank 100KL

Solvent

Stripper

Recovered

Solvent

Effluent on

Line Primary

Secondary

Treatment Tertiary

Treatment Outlet to

CETP

ANNEXURE-IV

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Mass Balance of the Solvent Stripper System

INPUTS OUTPUTS

Mother Liquor

(Storage Tank 1) Kgs Litres Material

Kgs Litres

Real ASIS

Methanol in washing 475.00 600.00 Methanol pure 310.00 313.00 391.00

DMF in washing 10.00 10.00 Intercut methanol (90%) 71.00 80.00 90.00

Salts 252.00 Methanol Vapour loss 3.00 3.00 4.00

Water 7500.00 DMF pure 0.00 0.00 0.00

Intercut DMF (80%) 8.00 10.00 8.00

DMF Vapour loss 1.00 1.00 1.00

Methanol in final ML to ETP 91.00 91.00 115.00

DMF in final ML to ETP 1.00 1.00 1.00

ML contain water, salts and solvent traces ----- 7738.00 -----

Total 8237.00 610.00 Total ----- 8237.00 610.00

% Recovery Methanol: 80.17%

% Recovery DMF: 80.00%

ANNEXURE-IV

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OVERALL EFFICIENCY

Methanol

(Batch Input Quantity – 4750 Kgs | 6000 Litres)

OUTPUT

Recovery plant Stripper Total Total %

Kgs Litres Kgs Litres Kgs Litres

Methanol pure 4155.00 5240.00 310.00 391.00 4465.00 5631.00 93.85

Intercut methanol 90.00 122.00 71.00 90.00 161.00 212.00 3.53

Methanol Vapour loss 20.00 25.00 3.00 4.00 23.00 29.00 0.48

Methanol in final ML to ETP 0.00 0.00 91.00 115.00 91.00 115.00 1.92

Methanol in sludge 10.00 13.00 0.00 0.00 10.00 13.00 0.22

Total 4275.00 5400.00 475.00 600.00 4750.00 6000.00 100.00

DMF

(Batch Input Quantity – 1990 Kgs | 2110 Litres)

OUTPUT

Recovery plant Stripper Total Total %

Kgs Litres Kgs Litres Kgs Litres

DMF pure 1550.00 1640.00 0.00 0.00 1550.00 1640.00 77.73

Intercut DMF 210.00 225.00 8.00 8.00 218.00 233.00 11.04

DMF Vapour loss 5.00 5.00 1.00 1.00 6.00 6.00 0.28

DMF in final ML to ETP 0.00 0.00 1.00 1.00 1.00 1.00 0.05

DMF in sludge 215.00 230.00 0.00 0.00 215.00 230.00 10.90

Total 1980.00 2100.00 10.00 10.00 1990.00 2110.00 100.00

ANNEXURE-IV

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ANNEXURE-IV

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PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRO

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PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

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ANNEXURE-V

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ANNEXURE-V

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ANNEXURE VI LAYOUT OF PROPOSED PLAN

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