prefeasibility report for dyes manufacturing …€¦ · prefeasibility report for ... 2.4...

PREFEASIBILITY REPORT

FOR

DYES MANUFACTURING UNIT

PROJECT PROPONENT:MAKEWELL SPECIALITY PRODUCTSNew Survey No. 1808 (Old Survey no. 1070/3/1); RAJPUROpp. Sachin Industries Ltd.Tal: Kadi Dist. Mehsana-382715

APRIL 2017

M/s. Make well Speciality Products Prefeasibility Report

1

CONTENTSCHAPTER 1 ................................................................................................................................................ 21.1 Introduction to the Project................................................................................................................ 2CHAPTER 2 ................................................................................................................................................ 3Project Description....................................................................................................................................... 3

2.1 Project Location ........................................................................................................................... 32.2 Alternate Sites Considered........................................................................................................... 32.3 Products & Raw Material Details ................................................................................................ 44.1 Hazardous Chemicals Details ...................................................................................................... 92.4 Manufacturing Process:.............................................................................................................. 152.5 Utilities Requirement ................................................................................................................. 312.1 Air Pollution Sources ................................................................................................................. 312.2 Water balance............................................................................................................................. 32 Our Unit will be achieving Zero Liquid Discharge. ...................................................................... 322.3 Manpower Requirement............................................................................................................. 32

CHAPTER 3 .............................................................................................................................................. 35Site Analysis .............................................................................................................................................. 33

3.1 Connectivity ............................................................................................................................... 333.2 Existing Land use Pattern .......................................................................................................... 333.3 Topography ................................................................................................................................ 333.4 Social Infrastructure Available: ................................................................................................. 333.5 Detail of CSR activity ................................................................................................................ 343.6 Rehabilitation & Resettlement Plan ........................................................................................... 343.7 Landuse Breakup ....................................................................................................................... 34

CHAPTER 4 .............................................................................................................................................. 35Proposed Environmental Infrastructure ..................................................................................................... 35

4.2 Management of Domestic Waste Water .................................................................................... 354.3 Management of INDUSTRIAL WASTE Water ........................................................................ 354.4 Solid & Hazardous Waste Management .................................................................................... 36

CHAPTER 5 .............................................................................................................................................. 30PROJECT SCHEDULE & COST ESTIMATES....................................................................................... 37

5.1 Proposed Schedule ..................................................................................................................... 37ANNEXURE-I ........................................................................................................................................... 38

Land Document...................................................................................................................................... 38ANNEXURE-II.......................................................................................................................................... 39PLANT LAYOUT ..................................................................................................................................... 39ANNEXURE-III ........................................................................................................................................ 40

PROJECT WITH SURROUNDING AREA ......................................................................................... 40ANNEXURE-IV ........................................................................................................................................ 41


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CHAPTER 11.1 Introduction to the Project

Makewell Speciality Products is Dye manufacturer, exporter and supplier located at NewSurvey No. 1808 (Old Survey no. 1070/3/1), Opposite Sachin Industries Ltd. Rajpur Tal:Kadi Dist. Mehsana-382715 in Gujarat

The Project Proponent procures high grade raw materials from reputed vendors and processthem into a finished range comprising different types of Solvent Dyes. They underline thestandards and norms of Dyes Industry and adhere to the same for quality testing of the product.The Seasoned experts Team keep a vigilant sight at every stage, from raw material procurementtill customized packaging of final products, to attain optimum clients' satisfaction by deliveringa quality-assured product range to clients.

Company is backed by the support of hardworking professionals who hold immense experienceand knowledge of the domain. They understand the varied industrial applications and adaptinnovative approach to serve exact requirements of our clients. They have also constructed amodern infrastructure that forms the base of our successful business growth. Apart from this, wehave a widespread distribution network that helps us ensure prompt delivery schedules in themarket.

Under the leadership of Mr. Dharmendrabhai Bhupatbhai Savani, our company has beenfollowing ethical business practices, transparent dealings and easy payment options to satisfy allour clients beyond their expectations. We strive to continue the same in long run.


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CHAPTER 2Project Description

2.1 Project Location

The Project is located at coordinates 22°57'12.60"N; 72°38'7.38"E at New Survey No. 1808(Old Survey no. 1070/3/1), Opp Sachin Industries Ltd Rajpur Tal: Kadi Dist: Mehsana 382715about 10.45 Km far from Kadi Railway Station and 36 km far from Ahmedabad InternationalAirport. Plant is just a 600 m away from SH-41 (Ahmedabad-Mehsana Highway) that provides aconvenient & competitive trade gateway to domestic market transportation.

Location of the Project with Surroundings

2.2 Alternate Sites Considered

The company has not considered any alternate site; as it already has an existing plant formanufacturing of chemicals at the site. Necessary permissions from State Pollution controlBoard for existing activities have been obtained. The proposed products are addition ofmanufacturing capacity in existing products.

The site is having all required infrastructure facilities in form of; water, electricity, fuel (naturalgas) and Road available for the proposed activities.

Proposed Site

To Mehsana

To Ahmedabad


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2.3 Products & Raw Material Details

2.3.1 Product Details

The Details of Existing products are given in following table:

Sr. no. Name of Product Proposed totalcapacity (MT/Month)

1 Isopropyl Bromide (Pure) 13.52 Nickel Suphate 200.03 Nickel Chloride 8.54 Copper Sulphate 200.05 Textile Auxilary & emulsion by formulation 200.06 Textile sizing blend (power) by formulation/Blending 200.07 Purification Sodium Sulphate (White power) 10.0

Total 832

Looking at volatile market of chemical trading and having good export potential of solvent dyes,now the project proponent proposes to start manufacturing of solvent dyes in place of abovementioned products.

The Details of Proposed Products are given in following table:

Sr. no. Name of Product Proposed total capacity(MT/Month)

1 Solvent Orange 98

100

2 Solvent Green 333 Solvent Yellow 1074 Solvent Yellow 1245 Solvent Yellow 1746 Solvent Yellow 337 Solvent Yellow 1638 Solvent Red 1619 Solvent Red 16410 Solvent Red 19E11 Solvent Red 11112 Solvent Red 20713 Solvent Blue 7914 Solvent Blue 5815 Solvent Blue 9816 Solvent Violet 4417 Blending & Mixing of Dyes 100

Total 200


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2.3.2 Details of Raw Materials With Quantity For Proposed Product:

Sr.no. Product Name Name of Raw Materials Quantity per batch

(Batch Size-1000 kg)

1SOLVENT ORANGE 98

(Crude)

Pera Dodesyl Aniline 265 kgMix Xylidine 110 kgSodium Nitrite 130 kgSulphamic Acid 2 kgResorcinol 100 kgO-xylene/Garasol 150 580 kgKOH 43 kgSoda Ash 160 kgHCl 560 kgIce 500 litWater 710 lit

2.SOLVENT GREEN 33

(Crude)

P- Dodecyl Aniline 510 kgDipropelene Glycol 50 kgO- xylene/ Garasol 150 350 kgLeuco Quinizarine 40 kgAcetic Acid 45 kgBoric Acid 50 kgPure Salt 55 kgWater 200 lit

3.SOLVENT YELLOW 107

(Crude)

OTDH 260 kgSodium Nitrite 130 kgO- xylene/ Garasol 150 420 kgPera Nonyl phenol 430 kgKOH 215 kgSuperis 96/ Casper 5 kgHCl 340 kgIce 2900 litWater 2100 lit

4. SOLVENT YELLOW 124(Crude)

Aniline 200 kgHexa 15/DC 15 400 kgGlypho 8 kgSulphamic Acid 2 kgMono Azo 580 kgGarasol 150 200 kgVinyl Iso butyl Ether 320 kgCatalyst 7 kgSodium Acetate 923 kgSodium Nitrite 150 kgHCl 980 kgIce 4500 litWater 3500 lit

5.SOLVENT YELLOW 174

(Crude)

Methyl Anthranilate 200 kgIahalchem11 260 kgGarasol 150 100 kgToluene 380 kg


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(Batch Size-1000 kg)Resorcinol 70 kgHyflow 8 kgSodium Methoxide 6 kgSodium Nitrite 85 kgSodium Acetate 400 kgNoigen X 100 1 kgHCl 390 kgSalt 340 kgIce 3250 litWater 2530 lit


Ortho Dichloro Benzene 4000 kgPhthalic Anhydride 750 kgQuinaldine 600 kgWater 850 lit

7. SOLVENT RED 161(Crude)

OCPNA 265 kgHexa 15/DC 15 275 kgGarasol 150 300 kgNoigen X 100 1 kgMono Azo 463 kgVinyl Iso Butylether 206 kgSodium Nitrite 100 kgSulphamic Acid 16 kgCatalyst 4 kgHCl 620 kgSalt 275 kgIce 2880 litWater 5680 lit


Butyl Acetate 3270 kg1:8 Dichloro Anthraaquinone 820 kgSodium Hydroxide 900 kgThio Phenol 720 kgWater 18180 lit


Heptene 210 kgBeta Napthol 240 kgMix Xyledine 40 kgOrtho Toludine 170 kgO-xylene/Garasol 150 257 kgZink Chloride 50 kgKOH 20 kgSodium Formate 170 kgSodium Nitrite 185 kgSulphamic Acid 1 kgAniline 57 kgHCl 580 kgSalt 190 kgIce 2400 litWater 1200 lit


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(Batch Size-1000 kg)

10. SOLVENT RED 19E(Crude)

2 EHA 970 kgGarasol 150 363 kgBeta Napthol 1000 kgGarnet GBC 240 kgSodium Bisulphite 850 kgSodium Nitrite 80 kgSulphamic Acid 2 kgKOH 135 kgHCl 450 kgSalt 210 kgIce 4260 litWater 1900 lit


Methanol 6000 kgMono Methyl amine 1100 kg1 Nitro Anthra Quinone 1050 kgWater 10000 lit


Ortho Dichloro Benzene 1300 kgCyclo Hexylamine 1000 kg1:5 Dichloro Anthraquinone 700 kgSodium Hydroxide 320 kgKOH 120 kgSalt 30 kgWater 10200 lit

13. SOLVENT BLUE 79(Crude)

Methanol 60 kgQuinizarine 215 kgLeuco Quinizarine 50 kg2 Ethyl Hexylamine 125 kgn Hexylamine 120 kgN octylamine 120 kgGarasol 150/O xylene 500 kgAcetic Acid 40 kgPure Salt 30 kgWater 200 lit


Methanol 100 kgQuinizarine 205 kgLeuco Quinizarine 50 kg2 Ethyl Hexylamine 225 kgn Butylamine 45 kgMono Methylamine 30 kgGarasol 150/O xylene 430 kgAcetic Acid 20 kgPure Salt 30 kgWater 200 lit


Methanol 60 kgQuinizarine 205 kgLeuco Quinizarine 50 kg2 Ethyl Hexylamine 228 kg


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(Batch Size-1000 kg)n Butylamine 55 kgMono Methylamine 32 kgGarasol 150/O Xylene 485 kgAcetic Acid 15 kgPure Salt 35 kgWater 160 lit

16.

SOLVENT VIOLET 44(Crude)

1,8 Dichloro Anthraquinone 55 kgPera Dodesyl Aniline 200 kgPotassium Carbonate 65 kgOrtho Xylene 750 kgCopper acetate 0.1 kgAcetic Acid 30 kgGarasol 150 650 kgOrtho Xylene 750 kg

17. BLENDING & MIXING OFDYES

Mixture of multiple products 100 MTSolvents 10 MT

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4.1 Hazardous Chemicals Details

Properties of Major Raw Materials

Sr.No

Raw MaterialsQuantity InMT/Annum

StateSolid,LiquidOr Gas

Main properties (refer MSDS, Sch-9 of MSIHC Rules)B.P.°C

F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)

Vapourdensity(air=1)

Odourthreshold

ppm

Flammability

1. 1,5-Dichloroanthraquinone

Powder Solid N.A N.A N.A N.A N.A N.A N.A N.A N.A

2. 1,8-Dichloroanthraquinone

Solid N.A N.A N.A N.A N.A N.A N.A N.A N.A

3. 1-Nitroanthraquinone Solid N.A N.A N.A N.A ipr-rat LD50:1050 mg/kgorl-mus LD50:1540 mg/kg

N.A N.A N.A N.A

4. 2-Ethylhexyl Acrylate Liquid approx. 216 °C 86 °C LEL:0.9%(V)

UEL; 6.0%(V)

N.A Oral:LD50/rat: 4,435 mg/kgDermal:LD50/rat: > 12,000mg/kg

N.A N.A N.A Flammable

5. 2-Ethyl-1-Hexylamine Liquid 169 °C (336 °F) 50 °C (122 °F)- Closed Cup

LEL: 1.6%(V) UEL;7.7 %(V)

N.A LD50 Oral - rat - 450 mg/kgLD50 Dermal - rabbit - 474mg/kg


6. Acetic Acid Liquid 118.1°C Closed Cup:39°C

(102.2°F).Open Cup:

43°C(109.4°F)

N.A N.A ORAL (LD50): Acute: 3310 mg/kg[Rat]. 4960 mg/kg [Mouse].3530 mg/kg[Rat]. DERMAL (LD50): Acute:1060 mg/kg [Rabbit]. VAPOR(LC50): Acute: 5620 ppm 1 hours[Mouse]

1.049 N.A N.A Flammable

7. Aniline Liquid 184.1°C(363.4°F)

Closed Cup:70°C (158°F).

N.A TWA:7.6

(mg/m3)from

ACGIH(TLV)

ORAL (LD50): Acute: 250 mg/kg[Rat.]. 464 mg/kg [Mouse].DERMAL (LD50):Acute: 820 mg/kg [Rabbit.].1400 mg/kg [Rat].

1.0216 3.22 2.4 ppm FlammableLower: 1.3%Upper: 23%

8. Beta Naphthol Solid 285 - 286 °C(545 - 547 °F)

153 °C (307°F) - Closed

Cup

N.A N.A LD50 Oral - rat - 1,960 mg/kgLD50 Oral - rat - 1,960 mg/kgLD50 Dermal - rabbit - > 10,000

N.A N.A N.A N.A


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Sr.No




F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)


Odourthreshold

ppm

Flammability

mg/kgLD50 Dermal - rabbit - > 10,000mg/kg

9. Boric Acid Solid 300°C (572°F) N.A N.A N.A ORAL (LD50): Acute: 2660 mg/kg[Rat]. 3450 mg/kg [Mouse].

1.435 N.A N.A Non-Flammable

10. N-Butyl Acetate Liquid 126.5°C(259.7°F)

Closed Cup:23.9°C (75°F).

(Tag) OpenCup: 37°C(98.6°F)

N.A N.A ORAL (LD50): Acute: 10768mg/kg [Rat]. DERMAL (LD50):Acute:17601 mg/kg [Rabbit]

0.9 4.01 0.31 ppm FlammableLOWER: 1.7%UPPER: 7.6%

11.Casper Granular

N.A N.A N.A N.A Oral:LD50 = >2,000 mg/kgDermal:LD50 = >2,000 mgLC50 = >5,400 mg/m3(prosulfuron)LC50 = 4.46 mg/L (dicamba)

N.A N.A N.A N.A

12. Cyclohexylamine Liquid 134 °C 27 °C (ClosedCup)

LEL: 1.6%(V)UEL;

9.4%(V)

N.A For Rat (Oral-LD50 :303 mg/kgInhalation-LD50 :> 32.9 mg/lDermal-LD50:> 631 - < 1,000mg/kg )


13. Garnet GBC Solid. ~407.7° C at760 mmHg

200 .4 °C N.A N.A Oral (rat) LDLo: 1500 mg/kgOral (Rat) LD: 1500 mg/kg

N.A N.A N.A N.A

14. Glyphosate Liquid Approx. 100°C N.A N.A N.A N.A 1.2 N.A N.A Non-Flammable

15. Heptene Liquid 205 F (96 C) 21 F (-6 C)(Cc)

N.A N.A >3 g/kg skin-rabbit LD50; >5 g/kgoral-rat LD50

0.7030 3.4 N.A Flammable

16. Hexa Liquid 100 C N.A N.A N.A N.A N.A N.A N.A N.A

17. Hydrochloric Acid Liquid 108.58 C GAS (LC50): Acute: 4701 ppm 1.1- 1.267 0.25 to 10 Non-


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Sr.No




F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)


Odourthreshold

ppm

Flammability

0.5 hours [Rat] 1.19 ppm Flammable18. Hyflo Solid 2230 °C / 4046

°F1710 °C /3110 °F

N.A N.A N.A N.A N.A N.A N.A

19. Potassium Hydroxide Solid Decompositiontemp: 1384°C

(2523.2°F)

N.A N.A N.A ORAL (LD50): Acute: 273 mg/kg[Rat].


20. Leucoquinizarin Solid N.A N.A N.A N.A N.A N.A N.A N.A N.A

21. Methyl Alcohol Liquid 64.5°C(148.1°F)

Closed Cup:12°C (53.6°F).

Open Cup:16°C (60.8°F).

N.A N.A ORAL (LD50): Acute: 5628 mg/kg[Rat]. DERMAL (LD50): Acute:15800mg/kg [Rabbit]. VAPOR (LC50):Acute: 64000 ppm 4 hours [Rat].

0.7915 1.11 100 ppm FlammableLOWER: 6%

UPPER: 36.5%

22. Methyl 2-Anthranilate Solid 256°C (492.8°F) Closed Cup:100°C

(212°F).

N.A N.A ORAL (LD50): Acute: 2910 mg/kg[Rat]. 3900 mg/kg [Mouse].2780 mg/kg [Guinea pig].DERMAL (LD50): Acute: 5001mg/kg [Rabbit].

1.168 N.A N.A May BeCombustible

At HighTemperature.

23. Mix Xylidine Liquid 216 °C – 228 °C 90-98 °C(194-208 Of)

LEL: 1%(V)UEL; 7%(V)

N.A skn-rbt LD50:1500 mg/kgivn-cat LDLo:120 mg/kgivn-rbt LDLo:240 mg/kgorl-rat LDLo:610 mg/kg

N.A N.A 0.5 ppm Flammable

24. MONOAZO Mono Azo N.A N.A N.A N.A N.ALD50 (ORAL (LD50 rat):>5000 mg/kg N.A N.A N.A N.A

25. Monomethylamine Gas -6.3 °C / 20.6 °F 32 °F / 0 °C LEL:4.9%(V)

UEL;20.7%(V)

N.A Inhalation:7000 ppm/1 hr(Mouse)

N.A 1.07 N.A N.A

26. Hexylamine Liquid 130°C (266°F) -132 C


N.A N.A ORAL (LD50): Acute: 670 mg/kg[Rat]

0.766 3.5 N.A Flammable


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Sr.No




F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)


Odourthreshold

ppm

Flammability

27. Octylamine Liquid 175°C (347°F) -177 C

Closed Cup:62°C

(143.6°F)

N.A N.A N.A 0.78 4.5 N.A FlammableLOWER: 1.6%UPPER: 8.2%

28. Ortho Chloro ParaNitro Aniline

Solid 200°C (392°F) 205°C (401°F) N.A N.A orl-rat LD50:6430 mg/kgipr-mus LDLo:500 mg/kgivn-mus LD50:56 mg/kg

N.A N.A N.A N.A

29. Ortho-Dichlorobenzene

Liquid 180C (356F) 66c (151f) Cc lel: 2.2;uel: 9.2

N.A Oral rat LD50: 500 mg/kg. 1.30 @20C/4C

5.1 25 ppm Flammable

30. Ortho-Toluidine Liquid 200.2°C(392.4°F)


N.A N.A ORAL (LD50): Acute: 670 mg/kg[Rat.]. DERMAL (LD50): Acute:3245 mg/kg [Rabbit.]

1 3.69 N.A FlammableLower: 1.5%

31. O-Xylene Liquid 144.4°C(291.9°F)


N.A N.A N.A 0.88 3.7 0.05 ppm FlammableLOWER: 0.9%UPPER: 6.7%

32. P- Dodecyl Aniline Solid 220.0 - 221.0°C

302 °F 150 °CClosed Cup

N.A N.A N.A N.A N.A N.A N.A

33. P-Nonylphenol Liquid 293-297°C 141°C /285.8°F

N.A N.A Oral-LD50 :580 mg/kg (rat)Inhalation-LD50 :>=2031 mg/lkg(rabbit)

0.940 N.A N.A N.A

34. Phthalic Anhydride Solid 295°C (563°F) Closed Cup:151.67°C

(305°F). OpenCup: 165°C

(329°F).

N.A N.A ORAL (LD50): Acute: 1530 mg/kg[Rat]. 1500 mg/kg [Mouse].DERMAL (LD50): Acute:>10000 mg/kg [Rabbit]. DUST(LC50): Acute: >210 mg/m 1hours [Rat].

1.53 6.6 N.A May BeCombustible

At HighTemperature.LOWER: 1.7%UPPER: 10.4%

35. Propylene Glycol Liquid 188°C (370.4°F) Closed Cup:99°C

(210.2°F).Open Cup:

107°C(224.6°F)

N.A N.A ORAL (LD50): Acute: 20000mg/kg [Rat]. 22000 mg/kg[Mouse].DERMAL (LD50): Acute: 20800mg/kg [Rabbit].


At HighTemperature.LOWER: 2.6%UPPER: 12.5%


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Sr.No




F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)


Odourthreshold

ppm

Flammability

36. Quinaldine Liquid 248.5°C(479.3°F)

Closed Cup:79.4°C

(174.9°F).

N.A N.A ORAL (LD50): Acute: 1230 mg/kg[Rat]. DERMAL (LD50): Acute:1978.5mg/kg [Rabbit (converted fromthe actual figure of 1870 ul/kgreported in RTECS)].

1.058 N.A N.A Combustible.

37. Quinizarin Solid N.A N.A N.A N.A Rat LD50 (oral) >5000mg/kgRat LD50 (intraperitoneal)2100mg/kgMouse LD50 (intravenous)320mg/kg

N.A 8.3 N.A N.A

38. Resorcinol Solid. 281°C (537.8°F) Closed Cup:127.22°C(261°F).

N.A N.A ORAL (LD50): Acute: 301 mg/kg[Rat]. 200 mg/kg [Mouse].DERMAL(LD50): Acute: 3360 mg/kg[Rabbit]


At HighTemperature.CLOSED CUP:

127.22°C(261°F).

39. Sodium Carbonate Solid N.A N.A N.A N.A ORAL (LD50): Acute: 4090 mg/kg[Rat]. 6600 mg/kg [Mouse].DUST(LC50): Acute: 2300 mg/m 2hours [Rat]. 1200 mg/m 2 hours[Mouse].


40. Sodium Acetate Solid N.A N.A N.A N.A Acute oraltoxicity (LD50): 3530 mg/kg[Rat]. Acute dermal toxicity(LD50): >10000 mg/kg [Rabbit].Acute toxicity of the dust (LC50):>30000 mg/m 1 hours [Rat].

1.528 N.A N.A May BeCombustible

At HighTemperature.

41. Sodium Bisulfite Solid N.A N.A N.A N.A ORAL (LD50): Acute: 2000 mg/kg 1.48 N.A N.A Non-


14

Sr.No




F.P.°C

LEL, UEL%

TLVmg/m3

LD50 mg/KgLC50 mg/l

Sp. Gr.(water

=1)


Odourthreshold

ppm

Flammability

[Rat]. Flammable42. Sodium Formate Solid N.A N.A N.A N.A ORAL (LD50): Acute: 11200

mg/kg [Mouse].1.92 N.A N.A N.A

43. Sodium Hydroxide Solid 1388°C(2530.4°F)

N.A N.A N.A LDL [Rabbit] - Route: Oral; Dose:500 mg/kg


44. Sodium Methoxide Liquid 64.5°C(148.1°F)


N.A N.A ORAL (LD50): Acute: 2037 mg/kg[Rat].

1.1 1.11 160 ppm Flammable.LOWER: 7.3%UPPER: 36%

45. Sodium Nitrite Solid 320°C (608°F) N.A N.A N.A ORAL (LD50): Acute: 180 mg/kg[Rat]. 175 mg/kg [Mouse].


46. Sulphamic Acid Solid N.A N.A N.A N.A ORAL (LD50): Acute: 3160 mg/kg[Rat]


47. Thiophenol Liquid. 168.3°C(334.9°F

)


N.A N.A ORAL (LD50): Acute: 46.2 mg/kg[Rat]. 267 mg/kg [Mouse].DERMAL(LD50): Acute: 134 mg/kg[Rabbit]. VAPOR (LC50): Acute:33 ppm 4 hours [Rat]. 28 ppm 4hours [Mouse].

3.8 N.A N.A Flammable

48. Toluene Liquid. 110.6°C(231.1°F)

Closed Cup:4.4444°C

(40°F)Open Cup:

16°C (60.8°F).

N.A N.A ORAL (LD50): Acute: 636 mg/kg[Rat]. DERMAL (LD50): Acute:14100 mg/kg[Rabbit]. VAPOR (LC50): Acute:49000 mg/m 4 hours [Rat]. 440ppm 24 hours [Mouse].

0.8636 3.1 1.6 ppm FlammableLOWER: 1.1%UPPER: 7.1%

49. Isobutyl Vinyl Ether Liquid 82-83℃ -15℃ N.A N.A N.A 0.768 N.A N.A Flammable50. Zinc Chloride Solid 732°C

(1349.6°F)N.A N.A N.A ORAL (LD50): Acute: 350 mg/kg

[Rat]. 329 mg/kg [Mouse].2.907 4.7 N.A Non-

Flammable

M/s. Make well speciality products Feasibility Report

15

2.4 Manufacturing Process:

2.4.1 Solvent Orange 98

PROCESS:Charge Water, Ice, HCL, PDA, mix xylediene in Reactor. Add Sodium Nitrite and carry outdiazotization reaction and then after coupling with resorcinol at temp. 0 °C to 8°C . Nowadd KOH to Get PH 8.5 - 9.5 Start heating & get 50-60°C and remove Aqu. layer from theBottom of reactor. Remove traces of water at 105-130 °C standardize the product andpacked in the drums.

INPUT : 3160 kgs OUTPUT: 1000 kgs (Final Product) Water: 7035 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 313 kgs Approximately

SOLVENT

AQUEOUSLAYER

Waste WaterTo ETP

Water100 litReusein nextBatch

CONDENSATION

RECEIVER TANKWaste Water 1602

Distilled water 145

DIAZOTISATION&

COUPLING

Pera dodesyl Aniline 265Mix Xylidine 110Sodium Nitrite 130Sulphamic Acid 2Resorcinol 100O-xylene/Garasol 150 580KOH 43Soda Ash 160HCl 560Ice 500Water 710

FINAL PRODUCTSolvent Orange 98 1000

DRYING


16

2.4.2 Solvent Green 33

INPUT : 1300 kgs OUTPUT: 1000 kgs (Final Product)

Water: 200 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 100 kgs Approximately

DIAZOTISATION&

COUPLING

P- Dodecyl Aniline 510Dipropelene Glycol 50O- xylene/ Garasol 150 350Leuco Quinizarine 40Acetic Acid 45Boric Acid 50Pure Salt 55Water 200

FINAL PRODUCTSolvent Green 33 1000

DRYING

SOLVENT

AQUEOUSLAYER

Waste WaterTo ETP


CONDENSATION


Distilled water 145


17

2.4.3 Solvent Yellow 107


Water: 2100 Lit & Ice: 2900 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 800 kgs Approximately

FINAL PRODUCTSolvent Yellow 107 1000DRYING

Waste WaterTo ETP


CONDENSATION


Distilled water 145

DIAZOTISATION&

COUPLING

OTDH 260Sodium Nitrite 130O- xylene/ Garasol 150 420Pera Nonyl phenol 430KOH 215Superis 96 5HCl 340Ice 2900Water 2100

SOLVENT

AQUEOUSLAYER


18



Water: 3500 Lit & Ice: 4500 Lit (will be vaporize) Process Loss & Moisture loss in Dryer: 2770 kgs Approximately

FILTRATION

DIAZOTISATION&

COUPLING

Aniline 200Hexa 15/DC 15 400Glypho 8Sulphamic Acid 2Sodium Acetate 923Sodium Nitrite 150HCl 980Ice 4500Water 2000

Water 1500

FINAL PRODUCTSolvent Yellow 124 1000

DRYING

CONDENTATION

Mono Azo 580Garasol 150 150Vinyl Iso butyl Ether 320Catalyst 7


19


DIAZOTISATION&

COUPLING

CONDENTATION

Methyl Anthranilate 200Iahalchem 11 260Toluene 380Sodium Methoxide 6Hyflow 8Water 1200

Toluene 380Resorcinol 70Noigen X 100 1Sodium Nitrite 85Sodium Acetate 400HCL 390Ice 3250Water 1330

Water


DRYINGGarasol 150 100




20

FILTRATION

CONDENTATION

Water for rinsing 850 lit


DRYING

PULVERIZATION

Water (To ETP) 100

Water (To ETP) 850

Solvent for recovery & reusein next batch 3920 kg

Loss80 kg

(SolventRecovery

2%)

Ortho Dichloro Benzene 4000Phthalic Anhydride 750Quinaldine 600

INPUT : 6200 kgs OUTPUT: 1000 kgs (FinalProduct) Water:950 Lit (will be evaporated in spray dryer after adequate treatment in ETP)Moisture loss in Dryer during drying: 250 kgs ApproximatelyPROCESS:

In Reactor take ODCB, Quinaldine and Phthalic Anhydride. Heat to reflux temp. 1800C.Maintain for 15 hrs and check reaction completion by TLC. Then filter, wash with methanol anddry, pulverize and pack in bags/drums.



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CONDENTATION

Butyl Acetate 32701:8 Dichloro Anthraquinone 820Sodium Hydroxide 900Thio Phenol 720

Water for rinsing 9180


DRYING

PULVERIZATION

FILTRATION

Water (To ETP) 100

Water (To ETP) 9180


Loss65 kg

(SolventRecovery

2%)

INPUT : 14890 kgs OUTPUT: 1000 kgs (FinalProduct) Water: 9280 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 1340 kgs Approximately

PROCESS: In reactor take Butyl Acetate, 1:8 dichloro anthraquinone, sodium hydroxide and thiophenol.

Heat to 1000C temp. and maintain for 8 hr. check. Reaction completion test by TLC. Thencool to R.T and filter, wash with water, dry, pulverize and pack in bags/drums.


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2.4.8 Solvent Red 161

FILTRATION

DRYING

OCPNA 265Noigen X 100 1Sodium Nitrite 100Sulphamic Acid 16Hexa 15/DC 15 275HCl 620Salt 275Ice 2880Water 3650

FINAL PRODUCTSolvent Red 161 1000

Water 2030

CONDENTATION

DIAZOTISATION&

COUPLING

Mono Azo 463Garasol 150 300Vinyl Iso Butyl Ether 206Catalyst 4




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1ST COUPLING

2nd COUPLING

MIXING

Heptene 210Beta Napthol 240O-xylene/Garasol 150 157Zink Chloride 50Salt 90Water 300

Aniline 57Ortho Toludine 170

Sodium Nitrite 100KOH 20Mix Xyledine 40Sulphamic Acid 1HCL 380Salt 100Ice 1400Water 700


Sodium Nitrite 85HCL 200Sodium Formate 170O-Xylene 100Ice 1000Water 200

DRYING




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2.4.10 Solvent Red 19E

COUPLING

INTERMEDIATE 19E

2 EHA 970Beta Napthol 1000Sodium Bisulphite 850Salt 210Water 1000

Garasol 150 363Sodium Nitrite 80Sulphamic Acid 2Garnet GBC 240HCl 450Ice 4260

FINAL PRODUCTSolvent Red 19E 1000

KOH 135Salt 210Water 900

DRYING

INPUT : 10460 kgs OUTPUT: 1000 kgs (Final Product) Water: 1900 Lit & Ice: 4260 Lit (will be vaporize) Process Loss & Moisture loss in Dryer: 3300 kgs Approximately


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FILTRATION

CONDENTATIONMethanol 6000Mono Methyl Amine 11001 Nitro Anthra Quinone 1050

Water for rinsing 9000


DRYING

PULVERIZING

INPUT : 17150 kgs OUTPUT: 1000 kgs (FinalProduct) Water: 9150 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 1000 kgs ApproximatelyPROCESS:In reactor take methanol, 1 Nitro Anthraquinone and mono methyl amine. Heat to 100º c temp.and maintain for 8 hr. check Reaction completion test by TLC. Then cool to R.T and filter, washwith water, dry, pulverize and pack in bags/drums.


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FILTRATION

CONDENTATION

Ortho Dichloro Benzene 1300Cyclo Hexyl Amine 10001:5 Dichloro Anthra quinine 700Sodium Hydroxide 320KOH 120Salt 30Water 3200

Water 7000


DRYING

PULVERIZING

Water (To ETP) 35


Loss26 kg

(SolventRecovery

2%)Water (To ETP) 7000

INPUT :13670 kgs OUTPUT: 1000 kgs (FinalProduct) Water: 7035 Lit (will be evaporated in spray dryer after adequate treatment in ETP) Process Loss & Moisture loss in Dryer: 4335 kgs ApproximatelyPROCESS:

In reactor take ODCB, 1:5 dichloro anthraquinone, sodium hydroxide and Cyclo Hehyl amine.Heat to 100⁰C temp. and maintain for 8 hr. check. Reaction completion test by TLC. Then cool toR.T and filter, wash with water, dry, pulverize and pack in bags/drums.


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2.4.13 Solvent Blue 79

CONDENTATION

Methanol 60Quinizarine 215Leuco Quinizarine 502 Ethyl Hexylamine 125n Hexylamine 120N octylamine 120Garasol 150/O xylene 500Acetic Acid 40Pure Salt 30Water 200

FINAL PRODUCTSolvent Blue 79 1000

DRYING


Water: 200 Lit (will be vaporize) Process Loss & Moisture loss in Dryer: 260 kgs Approximately


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CONDENTATION

Methanol 100Quinizarine 205Leuco Quinizarine 502 Ethyl Hexylamine 225n Butylamine 45Mono Methylamine 30Garasol 150/O xylene 430Acetic Acid 20Pure Salt 30Water 200


DRYING




29


CONDENTATION

Methanol 60Quinizarine 205Leuco Quinizarine 502 Ethyl Hexylamine 228n Butylamine 55Mono Methylamine 32Garasol 150/O xylene 485Acetic Acid 15Pure Salt 35Water 160


DRYING




30

2.4.16 Solvent Violet 44

CONDENTATION

1,8 Dichloro Anthraquinone 55Pera Dodesyl Aniline 200Potassium Carbonate 65Ortho Xylene 750Copper Acetate 0.1Acetic Acid 30

FILTRATION

Oxylene 800

FINAL PRODUCTSolvent Violet 44 1000

DRYING

Ortho Xylene 50

Garasol 150 650

INPUT : 1800.1 kgs OUTPUT: 1000 kgs (Final Product)


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2.5 Utilities Requirement

All utilities required for the project would be developed in the existing facility and the utility

requirements are as under.

Sr.No.

Particulars Consumption Source

1 Power Consumption 95 KW UGVCL2 Proposed total fresh water

Requirement16.900 KL/Day Borewell

3 White coal/BriquettesDiesel

1200 kg/Day0.500 KL/Hour

Local suppliers

2.1 Air Pollution Sources

2.1.1 Details of Existing Air Pollution Sources

FLUE GAS EMISSION ParameterSr.No.

Type of Emission Fuel APCM Detailsof Stack

1. Thermic Fluid Heater-(Capacity- 1 Lac Kcal)

WhiteCoal/Briquettes

200 kg/day

ProperVentilation &

Exhaust system 12.0 m(commonStack) PM<150 mg/ NM3

SO2 < 100 ppmNOx < 50 ppm

2. Steam Boiler(Capacity- 1 MT)


500 kg/day--

3. Hot Air Generator(Capacity- 3 Lac Kcal)


500 kg/day-- 12.0 m

4. D. G. Set(Capacity- 350 KVA)

Diesel0.500 KL/Hour -- 6.0 m

PROCESS GAS EMISSION ParameterSr.No.

Type of Emission APCM Details ofStack

1.Spray Drier(300 Lit/hour evaporation)with HAG

Dust collector and Scrubber -- PM<150 mg/ Nm3

2. Distillation Column Column condenser -- --

3. Reaction Vessel Alkali Scrubber 15.0 mSO2 < 40 mg/ NM3

NO2 < 25 mg/ NM3

HCl < 20 mg/ NM3

Note: Through the scrubber, Sodium sulphate and sodium chloride are being generated whichused in the manufacturing of dyes. There is wide market for selling of these two by products.


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2.2 Water balance

(Category-wise water consumption and wastewater generation)

Sr.No. Source

Water Consumption (L/Day) Waste Water Generation (L/Day)

ExistingQuantity

ProposedQuantity

TotalQuantity

ExistingQuantity

ProposedQuantity

TotalQuantity

1. Domestic 2300 -- 2300 1500 --1500(discharge

via Soak pitsystem )

2. Industrial

3. Process 1200 10000 11200(Consumption)

Nil Nil Nil

4.Scrubber

500 -- 500 Nil NilNil(reuse in nextbatch process)

905. Cooling 200 -- 200 (make up) Nil -- Nil6. Washing 700 2000 2700 700 2000 2700

Domestic Total 2300 -- 2300 1500 --1500 (Discharge

via soak pitsystem)

Industrial Total2600 12000 14600 700 2000 2700

Total 4900 12000 16900 2200 2000 4200

Our Unit will be achieving Zero Liquid Discharge by evaporation of generatedwastewater.

2.3 Manpower Requirement

Required specialized man power & talent would be recruited / hired locally and supportingservices would be made available from our existing plant. Approximately 15 people will beemployed.


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CHAPTER 3

Site Analysis3.1 Connectivity

Site is approx 600 m from Ahmedabad-Mehsana State highway that provides a convenient &

competitive trade gateway to domestic market transportation..

Nearest city and district head quarter, Mehshana is well connected by rail, road transport.

Site is connected to nearest railway station by 10.45 Km approx (Kadi Railway Station)

Air: Site is approx 35.99 km away from Ahmedabad Airport.

3.2 Existing Land use Pattern

Currently the land (3845.0 m2) is occupied by Project Proponent. No agricultural activities aredone on this land. The particular plot is under the possession of the company. There will not beany additional requirement of land.

3.3 Topography

The area is flat in nature. It is a build up plot. The average elevation above mean sea level is 76m. Toposheet of the area covering site is as follows:

3.4 Social Infrastructure Available:

The social infrastructure available at Mehsana/Kadi is listed below.

• Housing colonies


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• Public School

• ITI center

• Healthcare Centre

• Children’s Park

• Community Centers

• Pharmacy

• Market

And all very well developed urban facilities

3.5 Detail of CSR activity

It will be ensured that the unit contributes to the locally arranged Social welfare activities.

3.6 Rehabilitation & Resettlement Plan

The land is already in the possession of the project proponent. The NA permission for the land isobtained. Therefore, resettlement and rehabilitation is not involved.

3.7 Landuse Breakup

This plant will be located at New Survey No. 1808 (Old Survey no. 1070/3/1); vill: RAJPUR

Sr. No. Land Break up Area (m2)

1 Storage of raw material 295.002 Plant and machineries 850.003 Storage of product 450.004 Roads 170.005 Green belt 620.006 Office Building 199.757 Parking 443.758 Open space 816.50

Total Land sq. m 3845.00


35

CHAPTER 4Proposed Environmental InfrastructureCompany has already obtained Consent from Gujarat Pollution Control Board for the existingunit. The company will take into account all environmental aspects for expansion also so that nopollution hazard is ever created in and around the plant. Every effort is being made to keep zeroair pollution as well as water pollution. In addition to the above, care has been taken to providegreen belt around the plant.

4.2 Management of Domestic Waste Water

The domestic effluent (1500 Liter/day) shall be disposed through septic tank/ soak pit.

4.3 Management of INDUSTRIAL WASTE Water

The industrial effluent (2700 Liter/day) shall be treated in ETP (meeting GPCB norms) Will beevaporated in spray drying.

SprayDrying


36

Air Quality Management:

The source of air pollution is Steam Boiler, Hot air Generator (2 Nos.), Thermic Fluid Heater anstand-by D. G. Set; which consumes White Coal/briquettes: 1200 kg/Day. Plant area has wellventilated, cross air flow and exhaust fans have been provided for extra air flow.

4.4 Solid & Hazardous Waste Management

The details of hazardous wastes generation from the proposed project & its management &Handling are listed in the following tables. All the requirements of hazardous waste rules shallbe complied with.

Details of Hazardous & Other Waste Rules

Sr.No.

Type of waste Category

Total proposedQuantity

Management

1. ETP Waste 35.3 6.0 MT/yearCollection, Storage,

Transportation and disposal toTSDF

2.Solution of Alkali MediaScrubber or sludge of wet

scrubber37.1 1.8 MT/year

Collection, Storage,Transportation and disposal to

Common CHWIF

3. Discarded Container 33.1 3.0 MT/yearCollection, Storage,

Transportation and disposal toregistered recycler

4. Used Oil 5.1 0.1 MT/yearCollection, Storage,

Transportation and disposal toregistered recycler

5. Distillation residues 20.3 1.2 MT/yearCollection, Storage,

Transportation and disposal toCommon CHWIF

Waste Minimization Measures

Metering and control of quantities of active ingredients to minimize waste. Reuse of by-products from the process as raw materials or as raw material substitutes

in other processes. Use of automated filling to minimize spillage. Use of Close Feed system into batch reactors. Venting equipment through vapour recovery system. Use of high pressure hoses for equipment clearing to reduce wastewater generation

for reuse.


37

CHAPTER 5

PROJECT SCHEDULE & COST ESTIMATES5.1 Proposed Schedule

The industry seeks Environmental Clearance (EC) and intends to start production activities fromDecember 2017.

Sr. No. Activity Schedule

1 Application for Environmental Clearance 01/04/2017

2 TOR Meeting 10/05/2017

3 Baseline study for EIA June 2017

4 Application for appraisal 15/08/2017

5 Appraisal meeting 15/09/2017

6 Avail Environmental Clearance 10/10/2017

7 Procure CTO 01/12/2017

8 Start Production Activities 10/12/2017


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ANNEXURE-ILand Document


39

ANNEXURE-IIPLANT LAYOUT


40

ANNEXURE-IIIPROJECT WITH SURROUNDING AREA

PROJECT WITH SURROUNDING 5 KM RADIUS AREA

PROJECT WITH SURROUNDING 500 Meter RADIUS AREA


41

ANNEXURE-IVLETTER FROM GAM PANCHAYAT

prefeasibility report for dyes manufacturing …€¦ · prefeasibility report for ... 2.4...

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