PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT For EXPANSION OF DYES INTERMEDIATE UNIT [Schedule 5 (f) Category B as per EIA notification 2006 and its amendment thereof] Plot No. 153/A, 154/1,154/2, Phase-II Notified Industrial Area, GIDC Vapi, Ta: Pardi, Dist- Valsad (Gujarat) At Land/Plot Area: m 2 Production Capacity: TPM to TPM (1512 TPA to TPA) APPLICANT CONSULTANT AROCHEM INDUSTRIES PVT. LTD. ECO CHEM SALES & SERVICES Plot No. 153 /A, 154 /1,154 /2, Phase-II Office Floor, Ashoka Pavilion - A GIDC Vapi, Tal: Pardi, New Civil Road, Surat, Dist: Valsad (Gujarat) NABET/EIA/1720/RA arochem123@yahoo.com eco@ecoshripad.com Mo. No.: Tel No

2 Project pre-feasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification EXECUTIVE SUMMARY Name & Location Name of the Project: M/s. Arochem Industries Pvt. Limited Location Project : Plot No: 153/A, 154/1,154/2, Phase-II, GIDC, Vapi Tal: Pardi, Pin Dist. - Valsad (Gujarat) M/s Arochem Industries Pvt. Limited (Unit I) is located in Notified Industrial Area GIDC Vapi, falling under medium Scale category manufacturing products as mentioned under for which the company had obtained Consent To Establish and Operate from Gujarat Pollution Control Board. The company proposes to enhance the capacity of existing products as well introduce new products under the category Dyes Intermediates. Existing project cost was Rs.3.99 Crores and project cost for expansion is Rs Crores. Total cost after proposed expansion will be Rs Crores. Applicability of EIA Notification 2006 Category as per the amended EIA Notification-2006 as existing and proposed products (i.e. Dyes Intermediates) are covered under the Category-5(f). Hence, Environmental clearance is required from SEAC as project location in Notified Industrial area GIDC Vapi, the public hearing will be exempted. Project Proponent The company comprises of 3 directors in India; company started in the year of Medium scale unit. LIST OF FINISHED PRODUCTS # Product CAS No. Capacity (TPM) Total Capacity Existing Proposed Total after Expansion (TPA) 1. Resist Salt Metanilic Acid ,3 Di nitro Di phenyl sulphone (DNDS) Amino- 4- Chloro Benzoic Acid 5. P- Amino Benzoic acid 6. P- Amino Benzamide Amino Di Methyl Teraphthalate 8. 2,5- Di Methyl-P- Phenylene diamine Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 1

3 9. 2,5 Di Chloro-P Phenylene di amine Chloro-P Phenylene di amine Chloro methyl-p- Phenylene di amine Amino-p- xylene m- Chloro aniline Phenoxy Ethane (2,2- Di Amino Di Phenoxy ethane) Di Amino Di phenyl Sulphone 16. Aniline-2,5- Di Sulphonic acid 17. Nitro Benzene Nitro Di Methyl Teraphthalate Nitro-4 Chloro Benzoic acid 20. 2,5- Di Methyl Nitro Aniline Chloro-5-Methyl Nitro Aniline 22. 2,5 Di Chloro Para Nitro Aniline 23. Nitro P-Xylene Di Calcium Phosphate 25. N-N Di Ethyl-m Amino Phenol 26. Meta Amino Phenol Total Manufacturing process is attached as Annexure 2. RESOURCE REQUIREMENT Components Existing Proposed Total After Proposed Resources Availability Expansion Power, kva Sourced from Dakshin Gujarat Vij Co. Ltd. Fresh Water, Will be sourced from GIDC kl/day water supply Dept. Coal for Thermopak [2.5 lakhs/kcal/h] (tons/day) Local dealer Coal for Thermopak [25 lakhs/kcal/h] (tons/day) Local dealer Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 2

4 Coal for Steam Boiler, 2000 kg/h, (Ton/day) Fuel (HSD) for D.G.Set : (Capacity: 250 kva) Fuel (HSD) for D.G.Set : (Capacity: 500 kva) Cooling Tower, TR Chilling plant, TR Local dealer 20 kg/h 0 20 kg/h Sourced from local dealer 0 40 kg/h 40 kg/h Sourced from local dealer In-house In-house RAW MATERIAL CONSUMPTION # Name of Raw Materials CAS No. Quantity (TPM) Ton/Ton of Product Existing After expansion 1. RESIST SALT I. Nitro Benzene II. Oleum 65% III. Hydrated lime IV. Soda ash Total METANILIC ACID (POWDER) I. Nitro Benzene II. Oleum 65% III. Hydrated lime IV. Soda ash V. Cast Iron Powder VI. Hydrochloric acid (HCl) VII. Sulphuric acid Total ,3 DI NITRO DI PHENYL SULPHONE I. Wet cake of DNDS from Mixture Resist Salt II. Wet cake of DNDS from Mixture Metanilic acid Total AMINO-4- CHLORO BENZOIC ACID I. 4-Chloro-3-nitro benzoic acid II. Palladium on carbon (Pd/C) III. Sodium hydroxide (NaOH) IV. Hydrochloric acid (HCl) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total p- AMINO BENZOIC ACID I. 4- Nitro Benzoic acid II. Palladium on carbon (Pd/C) Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 3

5 III. Sodium hydroxide (NaOH) IV. Hydrochloric acid (HCl) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total P- AMINO BENZAMIDE I. P-Nitro Benzoic acid II. Methanol (Recovered) III. Methanol (Fresh) IV. Catalyst V. Liquor Ammonia VI. Mono Chloro benzene (Recovered) VII. Mono Chloro Benzene (Fresh) VIII. Catalyst : Raney Ni Total AMINO DIMETHYL TERPHTHALATE I. 2-nitro di methyl Teraphthalate II. Palladium on carbon (Pd/C) III. MonoChlorobenzene(MCB) (Recovered) IV. MonoChlorobenzene(MCB) (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total ,5 DI METHYL P- PHENEYL DIAMINE I. 2,5 Di Methyl P- Nitro Aniline II. Palladium on carbon (Pd/C) III. MonoChlorobenzene(MCB) (Recovered) IV. MonoChlorobenzene(MCB) (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total ,5-DICHLORO-P-PHENYLENE DIAMINE I. 2,5-Dichloro-p-nitro aniline II. Palladium on carbon (Pd/C) III. Dimethylformamide (DMF) (Recovered) IV. Dimethylformamide (DMF) (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total CHLORO-P-PHENYLENE DIAMINE I. 2,5-Dichloro-p-nitro aniline II. Palladium on carbon (Pd/C) III. Methanol (Recovered) IV. Methanol (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 4

6 Total CHLORO-5-METHYL-P-PHENYLENE DIAMINE I. 2,5-Dimethyl-p-nitro aniline II. Palladium on carbon (Pd/C) III. MonoChlorobenzene(MCB) (Recovered) IV. MonoChlorobenzene(MCB) (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total AMINO-P-XYLENE I. 2-Nitro-p-xylene II. Raney Ni III. Toluene (Recovered) IV. Toluene (fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total M-CHLORO ANILINE I. m-nitro chloro benzene II. Raney Ni III. Toluene (Recovered) IV. Toluene (Fresh) V. Hydrogen (H 2 ) VI. Nitrogen (N 2 ) Total ,2 -DIAMINO PHENOXY ETHANE (PHENOXY ETHANE) I. Ortho dichloro benzene (ODCB) II. Sodium Hydroxide (NaOH) III. Ethylene Glycol IV. Ethyl Acetate (Recovered) V. Ethyl Acetate (Fresh) VI. Dimethylformamide (DMF) (Recovered) VII. Dimethylformamide (DMF) (Fresh) VIII. Raney Ni Total ,3 DI AMINO DI PHENYL SULPHONE I. Dimethylformamide (DMF) (Recovered) II. Dimethylformamide (DMF) (Fresh) III. 3,3 Di nitro di phenyl sulphone IV. Palladium on carbon (Pd/C) V. Hydrogen (H 2 ) Total ANILINE 2,5-DISULFONIC ACID I. Metanilic acid II. Oleum 65% III. Salt Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 5

7 Total NITRO BENZENE I. Sulphuric acid II. Nitric acid III. Benzene IV. Caustic soda Total NITRO DI METHYL TERAPHTHALATE (NDMT) I. Di Methyl Teraphthalate (DMT) II. Nitric acid III. Sulphuric acid Total NITRO 4 CHLORO BENZOIC ACID I. P- chloro benzoic acid II. Sulphuric acid III. Nitric acid Total ,5 DI METHYL P NITRO ANILINE I. P- Xylidine II. Benzene Sulphonyl Chloride III. Soda ash IV. Toluene (Recovered) V. Toluene (fresh) VI. Sulphuric acid Total CHLORO-5-METHYL-P-NITRO ANILINE I. 2-Chloro-5-methyl aniline II. Benzene sulfonyl chloride III. Soda Ash IV. Toluene (Recovered) V. Toluene (fresh) VI. Nitric Acid VII. Sulphuric acid Total ,5 DI CHLORO PARA NITRO ANILINE I. Acetic Anhydride II. 2,5-Dichloroaniline (2,5 DCA) III. Nitric Acid IV. Sulphuric acid Total NITRO P- XYLENE I. P-Xylene II. Sulphuric Acid Total DI CALCIUM PHOSPHATE I. Rock Phosphate II. Sulphuric Acid (70%) from Nitro benzene, NDMT, 3- nitro 4- chloro benzoic acid, nitro p- Xylene III. Lime Mixture Total META AMINO PHENOL I. Metanilic Acid Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 6

8 II. Caustic Flakes III. Sulphuric acid Total DEMAP (N-N DI ETHYL-M- AMINO PHENOL) I. Metanilic Acid II. Caustic Flakes III. Di Ethyl Sulphate IV. Caustic flakes V. Sulphuric acid Total WATER AND WASTE WATER MANAGEMENT Total Raw Water requirement is kl/day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith. Total industrial Waste Water Generation is kl/day. Out of which kl/day will be normal effluent will be treated in modified primary, secondary and tertiary effluent treatment plant and finally treated effluent will be disposed off into CETP Vapi for further treatment and disposal into Arabian Sea kl/day of concentrated effluent will be collected separately, neutralized, filtered and sent to common multi effect evaporation system installed at CETP, Vapi. Membership for CETP, Vapi and CMEE, Vapi is enclosed herewith. Domestic waste water (5 kl/day) will be disposed off through Septic Tank and overflow is drained into drainage line. AIR EMISSION AND ITS CONTROL MEASURES Flue gas emission: At present, the unit is having one number of coal fired 2.5 lakh kcal/h capacity of Thermopak. Adequate multi cyclone dust collector and 30 meters height of chimney provided. There will be addition of one coal fired steam boiler of 2 TPH capacity and one 25 lakhs kcal capacity of coal fired thermopack. Adequate multi cyclone dust collector and 30 meters height of chimney will be provided. The company is having one D G set of 250 kva capacity as stand by. One additional D G set of 500 kva capacity will be installed.it is used only during power failure. Adequate stack height and stack monitoring facilities is provided. Process gas emission: At present, Sulphur dioxide process gas is generated from sulphonator and SO 3 gas generated from Oleum storage tank. The unit has provided acid followed by alkali scrubber and 11 meters height of chimney. After proposed expansion, there will be generation of sulphur dioxide and traces of nitrogen dioxide. To Scrub process gases, the unit propose to install additional one number of two stage alkali scrubber having 11 meters height of vent. (Detail of Air pollution control measures is attached as Annexure 9). HAZARDOUS WASTES AND ITS MANAGEMENT # Type of Hazardous waste Category as H/W rules 2016 Generation (TPA) Treatment Disposal Existing Total after Expansion 1. Waste from Sch: I Packed in HDE Sell to Cement Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 7

9 ETP bags, stored Industries for co-processing or dispose off into TSDF, VGEL,VAPI or SEPPL, Kutch 2. Gypsum waste from the process 3. Iron waste from process 4. Distillation Residue from the process Sch: I Packed in HDPE bags Sch:I Packed in HDPE bags Sch: I Packed in HDPE drums 5. Used Oil Sch:I Packed in HDPE drum 6. Discarded containers 7. Salt from the process Sch:I Washed & stored Sch: I Packed in HDE bags, stored 8. Spent Solvent Sch: I Recovered and stored in a storage tank Send Cement Industries for co-processing Send Cement Industries for co-processing Send to GSPL, Palsana for Incineration Sell to registered reprocessers Utilized for packing of hazardous waste or sell to authorized recycler Dispose off into TSDF, VGEL,VAPI or SEPPL, Kutch Recycled in process Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 8

10 2. PROJECT DESCRIPTION AND PROJECT PROPONENT Name of the project Proponent: M/s Arochem Industries Pvt. Limited M/s Arochem Industries Pvt. Limited is a medium scale unit is located in Notified Industrial Area, GIDC, Vapi, Dis: Valsad, Gujarat having total plot area of m 2 and total investment after proposed expansion will be Rs Crores. The proponent wishes to enhance the Production capacity of existing products as well introduce new products. The dyes intermediates products are especially used in Metal Plating, pigment & high performance pigment, Dyes & dyes intermediates, Optical brightener, Pharma industries, high resistance resin, poultry Industry, Single super phosphate as per requirement. The unit is operated by technocrats having more than 30 years of experience in manufacturing and marketing of various Dyes intermediates worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proposed expansion project is to enhance the capacity of all the dyes intermediates to MT per month and process capabilities to manufacture all types of speciality chemicals. The proposed expansion project site lies on Latitude 20 21'41.76"N and Longitude 72 55'49.81"E. M/s Arochem Industries Pvt. Limited is located at Plot. No. 153/A, 154/1,154/2, Phase-II, GIDC Vapi, Dis: Valsad in Gujarat state. GIDC Vapi is centrally located in the both sides of National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side. Vapi is the biggest railway station in the study area. Beside the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat-Mumbai) is a six lane and double tracked. This highway has given a further boost to the economic growth of this area. The other major road is state highway No. 185 (Daman-Vapi-Silvasa Road) which is crosses the NH-8 in Vapi town. Almost every village in the district is now well connected to each other by a Pucca road. Vapi Town Vapi Township has emerged as an Industrial hub on the Gujarat-Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC Area, Vapi has gained a special status on the industrial map of the country mainly for chemical manufacturing industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals, school and colleges, community centres, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchange, hotels, guesthouses etc. The town has got a major face-lift after the completion of national highway. Other links roads are also of good standard. Mumbai, the economic capital of the country Mumbai is 180 km from Vapi whereas the state capital Gandhinagar is 370 km away. The district Head Quarter-Valsad is 30 km from Vapi town. Vapi Industrial Area Vapi Industrial Area came into existence during The entire Area, which was Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 9

11 developed in phases, is now spread over 1140 Ha. and houses more than 1400 industries, most of which are small-scale industrial units although some of them have grown into bigger units at later stage. The industrial township is basically a declared Chemical Area where about 705 of the industrial units are either Chemical or Chemical related, such as Dyes and Dyes intermediates, pigments, pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country s largest common effluent treatment plants has been setup in Vapi industrial Area. Being a major industrial and commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc. M/s was started manufacturing Resist salt and Metanilic acid in the year of Most of the products have been developed through strong in-house R&D. The management is concerned about Environment and Safety issues and gives utmost importance to these aspects by continuous training and improvement followed by various external Audits. We have a strong in-house R&D team. We have a small Pilot plant at this site to support the R&D activities. (I) IDENTIFICATION OF THE PROJECT PROPONENT M/s Arochem Industries Pvt. Limited is a medium scale unit is located at notified industrial Area, GIDC Vapi, Dist: Valsad, a well enthusiastic and professionally managed manufacturer. List of Directors S. No. Name of Directors Addresses 1. Mr. Nilesh S Gandhi 333, Shrinivas Building, 1 st Floor, Opp: UCO Bank, 2. Mr. Manish R Gandhi SVP Road, Mumbai Mr. Milan R Thakkar 402, Joy Residency, Plot. No. 281, 12 th Road, Khar (West), Mumbai- 52 All the directors are well qualified in Engineering, Management, Accounts, operations and Marketing field. Apart from these there are Expert from Field- Industries, Financial Institutes and others as a Part time / Independent technical team for Better Management. They help us to achieve and perform better and better. II) BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s proposes to enhance the production capacity at Plot. No. 153/A, 154 /1,154 /2, Phase-II, GIDC Vapi, Dist: Valsad (Gujarat). The proposed expansion project involves the capacity enhancement of existing Products as well as new products. As per the amended EIA notification- 2006, the proposed products are covered under category 5(f) - B and hence require prior environmental clearance. III) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND REGION The proposed project provides a potential growth opportunity for the ongoing business of the company. The company is engaged in the business of manufacturing of Various Dyes Intermediates. The project would also help the company to support the Indian economy in the following way: Growth in Export Revenue and thereby increasing the inflow of foreign currency Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 10

12 which is much needed by our country. Our products are well accepted by international users and can substitute the international speciality Grades. Thus the Domestic Industry can replace the imported dyes intermediates used by them with ours and there by curtail the outflow of foreign currency spent on speciality chemicals imported by them. Potential increase in Job opportunities for the Local surroundings. Boost to the Local service providers and the overall improvement in the economic activities like Local raw materials Suppliers, Transporters, contractors, clearing and forwarding agents and other allied suppliers. The Company Objective is to achieve: Consolidation of dyes intermediates business. The Proposed expansion will help the company to move towards more specialized products and there by focus on value addition which will improve the shareholder's worth. The Proposed increase in capacity will also assist the company to reduce the costs due to increase in the sale of manufacturing and intern make the company's products more competitive in the market. Considering the nature of dyes intermediates business, the proposed increase in capacity will also help the company to standardize and produce the dyes intermediates with more consistency because higher volumes will help to achieve better control over Physico-chemical conditions while manufacturing. To generate Local Employment IV) DEMAND SUPPLY GAP The dyes intermediates products are especially used in Metal Plating, pigment and high performance pigment, Dyes & dyes intermediates, Optical brightener, Pharma industries, high resistance resin, poultry Industry, Single super phosphate as per requirement. Since our products are approved by quality conscious users which are multinational companies. We can cater to the ever increasing demand in India as well as we are exporting our both products since in west to united state in America, United Kingdom Italy and Germany in Europe. In east we are exporting to Thailand, South Korea, Japan and Australia. V) IMPORTED vs. INDIGENOUS PRODUCTION Existing products manufactured in the country will be very much economical compared to Imports of the same and also the export of the same will earn extra revenue generation for our county. VI) EXPORT POSSIBILITY Existing products have high export potential. Also these products have very good potential in the local market. Additional capacities of product range required over and above the unit s existing capacities, as the company expects strong growth of exports to the extent of 40-50%. Local market also shows strong growth potential. VII) DOMESTIC / EXPORT MARKETS The company s products are used in Metal Plating, pigment and high performance pigment, Dyes & dyes intermediates, Optical brightener, Pharma industries, high resistance resin, poultry Industry, Single super phosphate as per requirement. These are having very good demand in domestic as well as international markets. Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 11

13 VIII) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT There will be very good opportunity of employment generation directly and indirectly due to proposed expansion project. Due to proposed project there will be requirement of manager, supervisor, operator and semi-skilled workers. For this, the company will employ about additional 90 people to fulfil its need to handle the plant. Presently there are 60 Nos. of employees. There will be additional 90 Nos. of employees, thus total 150 Nos. of employees after expansion. 3 PROJECT DESCRIPTION (i) Type of Project including interlinked and interdependent projects, If any : The proposed project is an interdependent project of the company. (ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates: The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1. Plant layout is given as Figure 3 below. (iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted : The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in exiting premises only. (Land allotment letter is attached as Annexure-7). (iv) Size or magnitude of operation: As per the proposed project cost, the project is covered under medium Scale category of manufacturing industries. (v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) : Detailed project description with process details is enclosed as Annexure-2. (vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product : Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products and characteristics of hazardous chemicals are as below: Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 12

14 S. No. Product Table 1: Details on Product Transportation Physical State Dispatch 1. Resist Salt solid Local / export 2. Metanilic Acid solid Local / export 3. 3,3 Di nitro Di solid Local / phenyl sulphone export (DNDS) Amino- 4- Chloro solid Local / Benzoic Acid export 5. P- Amino Benzoic solid Local / acid export 6. P- Amino solid Local / Benzamide export Amino Di Methyl solid Local / Teraphthalate export 8. 2,5- Di Methyl-P- solid Local / Phenylene diamine export 9. 2,5 Di Chloro-P- solid Local / Phenylene di amine export Chloro-P- Solid Local / Phenylene di amine Chloro-5- methyl-p- Phenylene di amine export Solid Local / export Amino-p- xylene solid Local / export 13. m- Chloro aniline liquid Local / export 14. Phenoxy Ethane solid Local / (2,2- Di Amino Di export Phenoxy ethane) Di Amino Di phenyl Sulphone Solid Local / export 16. Aniline-2,5- Di solid Local / Sulphonic acid export 17. Nitro Benzene Liquid Local / export Nitro Di Methyl solid Local / Teraphthalate export Nitro-4 Chloro solid Local / Benzoic acid export 20. 2,5- Di Methyl 4- solid Local / Nitro Aniline export Chloro-5-Methyl- solid Local / 4- Nitro Aniline export ,5 Di Chloro Para solid Local / Nitro Aniline export 23. Nitro P-Xylene solid Local / export Packing & Means of transportation Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Tanker container Tanker container Tanker container Tanker container Tanker Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Bags/ truck / container Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 13

15 24. Di Calcium Phosphate solid Local / export 25. N-N Di Ethyl-m- solid Local / Amino Phenol export 26. Meta Amino Phenol solid Local / export Bags/ truck / container Bags/ truck / container Bags/ truck / container Table 2: Details of Raw Material Transportation S. No. Substance Physical State Type of Packing & supply Means of Transportat ion Distance of Supplier from project site (km) 1. Nitro Benzene Liquid tanker Tanker 250km 2. Oleum 65% Liquid tanker Tanker 5-50 km 3. Hydrated lime Solid bags Tanker 5-50 km 4. Soda ash Solid bags Tanker 5-50 km 5. Cast Iron Powder Solid bags Tanker 5-50 km 6. Hydrochloric acid (HCl) Liquid loose Tanker 5-50 km 7. Sulphuric acid Liquid loose Tanker 5-50 km 8. 4-Chloro-3-nitro Solid bags Truck 5-50 km benzoic acid 9. Palladium on carbon Solid bags Truck 5-50 km (Pd/C) 10. Sodium Hydroxide Liquid loose Tanker 5-50 km (NaOH) 11. Hydrogen Gas cylinders Truck 5-50 km 12. Nitrogen Gas cylinders Tanker 5-50 km Nitro Benzoic acid Solid bags Tanker 5-50 km 14. P-Nitro Benzoic acid Solid bags Tanker 5-50 km 15. Methanol Liquid loose Tanker 5-50 km 16. Liquor Ammonia Liquid loose Tanker 5-50 km 17. Mono Chloro benzene Liquid loose Tanker 5-50 km 18. Raney Ni Solid bags Truck 5-50 km nitro di methyl Solid bags Truck 5-50 km Teraphthalate 20. 2,5 Di Methyl P- Nitro Solid bags Truck 5-50 km Aniline 21. 2,5-Dichloro-p-nitro Solid bags Truck 5-50 km aniline 22. Di methyl Formamide (DMF) Liquid loose Tanker 5-50 km Nitro-p-xylene Liquid loose Tanker 5-50 km 24. Toluene Liquid loose Tanker 5-50 km 25. m-nitro chloro Solid bags Truck 5-50 km benzene 26. Orthodichlorobenzene Liquid loose Tanker 5-50 km (ODCB) 27. Ethylene Glycol Liquid loose Tanker 5-50 km 28. Ethyl Acetate Liquid loose Tanker 5-50 km 29. 3,3 Di nitro di phenyl Solid bags Truck 5-50 km Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 14

16 sulphone 30. Metanilic acid Solid bags Truck 5-50 km 31. Salt Solid bags Truck 5-50 km 32. Nitric acid Liquid loose Tanker 250 kms 33. Benzene Liquid loose Tanker 250 kms 34. Caustic soda Solid bags truck 5-50 km 35. Dimethyltryptamine Solid bags truck 5-50 km (DMT) 36. P- chloro benzoic acid Solid bags truck 5-50 km 37. P- Xylidine Liquid loose tanker 5-50 km 38. Benzene Sulphonyl Liquid loose Tanker 5-50 km Chloride Chloro-5-methyl Solid bags truck 5-50 km aniline 40. Acetic Anhydride Liquid loose Tanker 5-50 km 41. 2,5-Dichloroaniline Solid bags truck 5-50 km (2:5 DCA) 42. P-Xylene Liquid loose Tanker 5-50 km 43. Rock Phosphate Solid bags truck 5-50 km 44. Di Ethyl Sulphate Liquid loose Tanker 5-50 km Details of Storage & Handling of Hazardous Chemicals is enclosed as Annexure 11. (vii) Resource optimization/recycling and reuse envisaged in the project, if any, should briefly outlined Resource optimization/recycling and reuse envisaged in the project (solvent recovery system) in detail are as mentioned below. The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses. The solvents are distilled in-house and reused in the manufacturing process. Details of solvent use and recovery are as under. Spent sulphuric acid will be collected separately and utilized to manufacture Di calcium phosphate. Gypsum waste and iron waste will be collected and sent to cement industries for coprocessing. Table 3: Recovery of Solvent S.No. Name of Solvent Quantity (TPM) Tons/ton of product Existing After Expansion 1. P-AMINO BENZAMIDE I. Methanol (Recovered) II. Methanol (Fresh) III. Mono Chloro benzene (Recovered) IV. Mono Chloro Benzene (Fresh) AMINO DIMETHYL TERPHTHALATE I. MonoChlorobenzene(MCB) (Recovered) II. MonoChlorobenzene(MCB) (Fresh) Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 15

17 3. 2,5 DI METHYL P- PHENEYL DIAMINE I. MonoChlorobenzene(MCB) (Recovered) II. MonoChlorobenzene(MCB) (Fresh) ,5-DICHLORO-P-PHENYLENE DIAMINE I. Dimethylformamide (DMF) (Recovered) II. Dimethylformamide (DMF) (Fresh) CHLORO-P-PHENYLENE DIAMINE I. Methanol (Recovered) II. Methanol (Fresh) CHLORO-5-METHYL-P-PHENYLENE DIAMINE I. MonoChlorobenzene(MCB) (Recovered) II. MonoChlorobenzene(MCB) (Fresh) AMINO-P-XYLENE I. Toluene (Recovered) II. Toluene (fresh) M-CHLORO ANILINE I. Toluene (Recovered) II. Toluene (Fresh) ,2 -DIAMINO PHENOXY ETHANE (PHENOXY ETHANE) I. Ethyl Acetate (Recovered) II. Ethyl Acetate (Fresh) III. Dimethylformamide (DMF) (Recovered) IV. Dimethylformamide (DMF) (Fresh) ,3 DI AMINO DI PHENYL SULPHONE I. Dimethylformamide (DMF) (Recovered) II. Dimethylformamide (DMF) (Fresh) ,5 DI METHYL P NITRO ANILINE I. Toluene (Recovered) II. Toluene (fresh) CHLORO-5-METHYL-P-NITRO ANILINE I. Toluene (Recovered) II. Toluene (fresh) Table 4: Solvent Used and Losses after Expansion S.No. Name of the Solvent Total Consumption (TPM) Recovery (TPM) Loss/with residue (TPM) % Recovery 1. Methanol MonoChlorobenzene(MCB) Dimethylformamide (DMF) Toluene Ethyl Acetate (viii) Availability of water its source, Energy/power requirement and source should be given: Availability of water its source, Energy/power required and its source is below. Water will be sourced from GIDC Notified industrial Area, Vapi. Water withdrawal Permission is attached as Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 16

18 Annexure 3. WATER CONSUMPTION Fresh water requirement is 130 KLD after expansion. Product wise water consumption is given below in table 5. Table 5: Product wise Water Consumption & Waste Water Generation per ton and per day of product S. No. Product Proposed Capacity, TPM Water Consumption (m 3 ) Waste water Generation (m 3 ) Per Per day Per Per day tone tone 1. Resist Salt Metanilic Acid ,3 Di nitro Di phenyl sulphone (DNDS) Amino- 4- Chloro Benzoic Acid 5. P- Amino Benzoic acid P- Amino Benzamide Maximum Amino Di Methyl Teraphthalate 8. 2,5- Di Methyl-P Phenylene diamine 9. 2,5 Di Chloro-P- Phenylene di amine Chloro-P- Phenylene di amine Chloro-5- methyl-p- Phenylene di amine Maximum Amino-p- xylene m- Chloro aniline Phenoxy Ethane (2,2- Di Amino Di Phenoxy ethane) Di Amino Di phenyl Sulphone 16 Aniline-2,5- Di Sulphonic acid 17 Nitro Benzene Nitro Di Methyl Teraphthalate Nitro-4 Chloro Benzoic acid 20 2,5- Di Methyl 4- Nitro Aniline 21 2-Chloro-5-Methyl-4- Nitro Aniline 22 2,5 Di Chloro Para Nitro Aniline Maximum Nitro P-Xylene Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 17

19 24 Di Calcium Phosphate N-N Di Ethyl-m- Amino Phenol 26 Meta Amino Phenol Maximum Total Table 6: Product wise Waste Water Generation (normal and concentrated) per day of product S. No. Product Waste water Generation, m 3 /day Normal to ETP Concentrated to MEE 1. Resist Salt Metanilic Acid ,3 Di nitro Di phenyl sulphone (DNDS) Amino- 4- Chloro Benzoic Acid P- Amino Benzoic acid P- Amino Benzamide Maximum Amino Di Methyl Teraphthalate ,5- Di Methyl-P- Phenylene diamine 9. 2,5 Di Chloro-P- Phenylene di amine Chloro-P- Phenylene di amine Chloro-5- methyl-p- Phenylene di amine Maximum Amino-p- xylene m- Chloro aniline Phenoxy Ethane (2,2- Di Amino Di Phenoxy ethane) Di Amino Di phenyl Sulphone Aniline-2,5- Di Sulphonic acid Nitro Benzene Nitro Di Methyl Teraphthalate Nitro-4 Chloro Benzoic acid ,5- Di Methyl 4- Nitro Aniline Chloro-5-Methyl-4- Nitro Aniline ,5 Di Chloro Para Nitro Aniline Maximum Nitro P-Xylene Di Calcium phosphate N-N Di Ethyl-m- Amino Phenol Meta Amino Phenol Maximum Total Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 18

20 Table 7: Overall Water Consumption at Existing and After Expansion S.No. Particulars Water Consumption, m 3 /day Existing Proposed Total 1. Domestic Processing and Product Washing Cooling Boiler Scrubber Floor/container/equipment washing Gardening Total Total Industrial Figure 1: Water Balance Diagram (Existing) Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 19

21 Figure 2: Water Balance Diagram (After Expansion) Table 8: Energy Requirements and Its Source S.No. Particulars Existing kg/h After expansion kg/h Source 1. Steam requirement Will be obtained by proposed 2 TPH boiler, having spare capacity Table 9: Power Requirements and Its Source S.No. Particulars Existing After Source expansion 1. Power Electricity requirement 225 kva 375 kva Sourced from Dakshin Gujarat Vij Co. Ltd. Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 20

22 (ix) Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal: Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure 4. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representation of the feasibility drawing is enclosed as Annexure 8. 4 SITE ANALYSIS (i) Connectivity: The project is located in notified Industrial Area of Vapi which is very well connected to National Highway 8 and Western Railways. The nearest airport is Mumbai which is 150 km away from the project site by road. (ii) Land Form, Land use and Land ownership: The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation. (iii) Topography (along with map) : Topography map showing the elevation of the study area below. The topographical map is enclosed as Annexure 6. (iv) (v) (vi) Existing land use pattern (agriculture, non-agriculture, forest, water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of Gazette notification should be given: The existing land is located in the notified industrial area and a copy of which is enclosed as Annexure 7. Existing Infrastructure: GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system. Soil classification: General soil classification of the area is as under: Soil Characteristics and Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, clay, Red soil. The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose. The land is suitable for industrial development. Damanganga River is located at approx. 2.9 km distance from the site location; both side of the river has mixed soil type (Sand, clay and Basaltic soil). (vii) Climate data from secondary sources: Rainfall Data: The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having coefficient of variation of 65%. There is large spatial and temporal variation Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 21

23 in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives rainfall between mm and generally falls under semi-arid climate. Considering the abnormality of weather particularly rainfall during the monsoon period, the observed and predicted rainfall was then analyzed for its validity. Table 10: Rainfall projection for Project site and Gujarat (June-Oct 2011) S.No. Region Rainfall Projection (mm) June Normal Rainfall (mm) Rainfall Projection (% Departure from normal) Oct Middle Gujarat 2. South Gujarat 3. Project site Saurashtra Gujarat State Source: AAU, Anand, Gujarat (viii) Temperature Data: The site is located in the southern part of Gujarat. The secondary data was collected from free data of Worldclim.org for the year The project site temperature regime for medium to high level temperature (30-32 C) during the seasonal months (June to Sep). Social Infrastructure available: Social Infrastructure in Valsad district is as under: Education: There are 990 primary, 161 secondary and higher secondary schools. There are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature and motor rewinding, electrician, information technology and electronic system maintenance etc., 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, 6 nos. of ITI s with an intake capacity of 360, 1 Nos. of Polytechnic College With 120 seats, there is one Engineering College, Pharmacy College, Arts, Commerce, Science, B. Ed and Law College. Valsad district also has institutes which offer management studies with fulltime MBA. Source: Department of Education, 2007 Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, providing services in general and laproscopic surgery, trauma, orthopedic and urology etc. The hospital is one of the few centres in India offering Uterine Thermochoice Thermal Balloon Therapy for Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 22

24 Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital and Adarsh Hospital are also present in Valsad. Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage center throughout the world. Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the year. The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, which has increased the graph of tourist flow in the district. 5. PLANNING BRIEF (i) Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification: There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi. (ii) Land use Planning (breakup along with green belt etc): The existing as well as proposed expansion project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below. For Green Belt Development as per the revised layout plan, the company proposes total m 2 (Existing 4000 m 2 + Proposed m 2 ), 33% of green belt of the total land, i.e sq. m. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises. While selecting the plants species to be grown in the green belt zone, following points will be taken into account: i. Climatic condition and soil characteristics of the region. ii. The air pollution emitted by the industry gaseous and particulate matter. Plant interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere. iii. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles. iv. Height of the plants should not be too high to be lethal. v. For absorbance of gases, the duration of the foliage should be longer. vi. Vegetation controls soil erosion rates significantly. The decrease of water erosion rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked. Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 23

25 Table 11: Site Plan with Area Table at Existing and After Expansion S.No. Particulars Area (m 2 ) Existing Expansion Total 1. Production Plant Office & Lab Area OHC Area Green Belt Raw Materials & F G Storage Solvent Storage area Utility ETP & Solid Waste Storage area Toilet Block Watchmen Cabin Open Space Total plot Area Figure 3: Site map with Green Belt Development Planning Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 24

26 (iii) (iv) Assessment of Infrastructure demand (Physical and Social): There is no need for any infrastructure demand in terms of physical or social needs for the expansion. Amenities/ Facilities: GIDC notified industrial area of Vapi has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system. 6 PROPOSED INFRASTRUCTURE (i) Industrial Area (Processing Area): The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. (ii) Residential Area (Non-Processing Area): No residential area is involved in the proposed expansion project (iii) Green Belt: Green belt will be provided and maintained at the tune of 33% of the total land area. (iv) Social Infrastructure: Not applicable (v) Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc): The project site is very well connected by road through National Highway no. 8, western railways. (vi) Drinking Water management (Source & Supply of water): Source of water is from GIDC water supply services. (vii) Sewerage System: GIDC has provided sewerage system to dispose the sewage effluent. (viii) Industrial Waste Management: Normal Industrial liquid effluent generated after proposed expansion will be treated in the primary, secondary & tertiary ETP and will be discharged through GIDC underground drainage to CETP, Vapi and concentrated effluent will be evaporated in common multi effect evaporation system installed at CETP, Vapi. (Membership certificate is attached as Annexure 5). Generated domestic liquid waste is being disposed off through septic tank system and overflow taken to final out let of ETP. Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 25

27 S. No. Solid/Hazardous Waste Management: Table 12: Solid/Hazardous Waste Generation and Management Type of Category Generation Treatment Disposal Hazardous as H/W (TPA) waste Rules 2016 Existi Total after 1. Waste from ETP 2. Gypsum waste from the process 3. Iron waste from process 4. Distillation Residue from the process ng Expansion Sch: I Packed in HDE bags, stored Sch: I Packed in HDPE bags Sch:I Packed in HDPE bags Sch: I Packed in HDPE drums 5. Used Oil Sch:I Packed in HDPE drum 6. Discarded containers 7. Salt from the process Sch:I Washed & stored Sch: I Packed in HDE bags, stored 8. Spent Solvent Sch: I Recovered and stored in a storage tank (Membership certificates are attached as Annexure-5). Sell to Cement Industries for coprocessing or dispose off into TSDF, VGEL,VAPI or SEPPL, Kutch Send Cement Industries for coprocessing Send Cement Industries for coprocessing Send to GSPL, Palsana for Incineration Sell to registered re-processers Utilized for packing of hazardous waste or sell to authorized recycler Dispose off into TSDF, VGEL,VAPI or SEPPL, Kutch Recycled in process (x) Power Requirement & Supply / Source: Power requirement for proposed project will be taken from DGVCL. 7. REHABILITATION AND RESETTLEMENT (R&R) PLAN (i) Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given): There will be no rehabilitation and resettlement undertaken as labours and workers from local and nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site. Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 26

28 8. PROJECT SCHEDULE & COST ESTIMATES (i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed minor construction and commissioning of the expansion project. (ii) Estimated project cost along with analysis in terms of economic viability of the project Estimated project cost along with the analysis in terms of economic viability of the project is given as below. Table 13: Capital Cost Projection Cost in INR (Lakhs) S.No. Particulars Existing Expansion Total 1. Land Cost Building Cost Equipment & Machineries Pipes & Fittings Utilities Environmental Management System Total Project Cost Table 14: Utilities and Other Requirement Utilities Boiler, TPH Thermopack, lakh kcal/h Thermopack, lakh kcal/h Cooling Tower, TR Chilling plant, TR D.G. Set (Standby), kva ,500 Power from DGVCL, kva Fuel Coal (MT/day) for thermopak of 2.5 lakhs kcal/h Coal (MT/day) for thermopak of 25 lakhs kcal/h Coal (MT/day) for Steam boiler of 2 TPH HSD (kg/h) for D.G.Set of Capacity: 250 kva HSD (kg/h) for D.G.Set of Capacity: 500 kva Water from GIDC Vapi kl/day Waste Water (Industrial) kl/day Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 27

29 S.No. Table 15: Project Viability S.No. Particulars Amount (Crore) 1. Proposed Sale Raw Material Cost Power & Fuel Labour Cost Environmental Management System Maintenance Cost Selling, packing & Office Expenses Proposed Profit The company will provide budgetary provision for the recurring/operating expenses for environmental issues while planning the allocation of funds during the annual budgetary planning. Table 16: Budget for Proposed EMP Component 1. Air Pollution Control 2. Water Pollution Control 3. Solid/Hazardous Waste Management 4. Occupational Health & Safety 5. Noise Pollution Control including greenbelt development & maintenance Capital Cost (Lakhs) Recurring Cost (Lakhs/annum) Analysis of Proposal (Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people including tribal population in the area: Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Local people will get direct financial benefit by way of employment. Local people will get some contracts of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby area Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 28

30 ANNEXURES Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 29

31 ANNEXURE: 1 LOCATION MAP SHOWING THE PROJECT SITE AND INTER-STATE BOUNDARY WITHIN 10 KM RADIUS Expansion Project at GIDC Vapi- Dyes Intermediates 5(f) Cat B Page 30

32 ANNEXURE: 2 MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product. MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE (1 & 3) CHEMICAL REACTION OF RESIST SALT NO 2 NO 2 Nitro Benzene MW: 123 NO 2 + H 2 SO 4.SO 3 Oleum MW: 178 SO 3 H + H 2 SO 4 NO 2 H 2 SO 4 + Na 2 CO 3 + Ca(OH) 2 + CaSO H 2 O + CO 2 + NaOH SO 3 H SO 3 Na Resist Salt MW: 225 NO 2 NO 2 NO 2 Nitro benzene + H 2 S 2 O 7 O + H 2 O +H 2 SO 4 S O 3,3'-Dinitro diphenyl sulfone Expansion Project- Dyes Intermediates Page 31

33 (1 & 3) MASS BALANCE OF RESIST SALT Nitro Benzene: 1250 kgs Oleum 65%: 1320 kgs SULPHONATION Sulpho Mass: 2570 kgs Recycled water: 3000 kgs DRAWNING Drowning Mass: 5570 kgs FILTERATION Wet cake of 3,3 Di nitro Di phenyl sulphone: 79 kgs FILTRATE : 5491 kgs Drying Vapour loss: 16 kgs Hydrated lime: 750 kgs Soda ash: 625 kgs NEUTRALIZATION 3,3 Di nitro Di phenyl sulphone: 63 kgs Wash water: 1000 kgs FILTERATION/WASHING Wet cake of Gypsum: 1930 kgs EVAPORATION Water: 3000 kgs recycled DRYING in SFD Evaporation loss: 936 kgs RESIST SALT: 2000 kgs Expansion Project- Dyes Intermediates Page 32

34 (2 & 3) CHEMICAL REACTION OF METANILIC ACID (POWDER) NO 2 NO 2 + H 2 SO 4.SO 3 + H 2 SO 4 SO 3 H NO 2 NO 2 SO 3 H H 2 SO 4 + Na 2 CO 3 + Ca(OH) 2 SO 3 Na + CaSO 4 + 2H 2 O + CO 2 + NaOH NO 2 NH 2 SO 3 Na + 2Fe + 2HCl SO 3 Na + 2FeO + FeCl 3 Expansion Project- Dyes Intermediates Page 33

35 (2 & 3) MASS BALANCE OF METANILIC ACID (POWDER) Nitro Benzene: 1250 kgs Oleum 65%: 1320 kgs Sulpho Mass: 2570 kgs water: 3000 kgs SULPHONATION DRAWNING Drowning Mass: 5570 kgs FILTERATION Wet cake of 3,3 Di nitro Di phenyl sulphone: 79 kgs FILTRATE : 5491 kgs Drying Vapour loss: 16 kgs Hydrated lime: 750 kgs Soda ash: 625 kgs Wash water: 1000 kgs CI Powder: 1250 kgs HCl: 50 kgs Sulphuric acid: 600 kgs NEUTRALIZATION FILTERATION/WASHING REDUCTION FILTERATION ISOLATION 3,3 Di nitro Di phenyl sulphone: 63 kgs Wet cake of Gypsum: 1930 kgs Iron Sludge: 1250 kgs FILTERATION & CENTRIFUGING Mother liquor: 5002 kgs recycled DRYNIG Evaporation loss: 334 kgs METANILIC ACID: 1250 KGS Expansion Project- Dyes Intermediates Page 34

36 (4) CHEMICAL REACTION OF 3- AMINO-4- CHLORO BENZOIC ACID COOH COOH 201 gms/mole + 3 H 2 + Pd/C NO 2 Cl 4-Chloro-3-nitro benzoic acid +2 H 2 O NH 2 Cl 4-Chloro-3-amino benzoicacid 171 gms/mole (4) MASS BALANCE OF 3-AMINO-4-CHLORO BENZOIC ACID 4-Chloro-3-nitro benzoic acid : 1000 Kg Pd/C: 6 Kg Water: 4000Kg+ NaOH 451 Kg HCl : 575 Kg H 2 : 30Kg N 2 : 16 Kg AUTO CLAVE FILTERATION Pd/C: 6 Kg Recycle Waste water to MEE: 4901 kgs 3-Amino-4-chloro benzoic acid-1171 Kg DRYING Drying Loss Kg 3-Amino-4-chloro benzoic acid: 820 Kg Expansion Project- Dyes Intermediates Page 35

37 (5) CHEMICAL REACTION OF P-AMINO BENZOIC ACID O 2 N COOH + H 2 + Reny Ni H 2 N COOH +H 2 O p-nitro benzoic acid p-amino benzoic acid (5) MASS BALANCE OF P- AMINO BENZOIC ACID 4-Nitro Benzoic acid : 1000 Kg Pd/C: 6 Kg Water: 4000Kg+ NaOH 451 Kg HCl : 575 Kg H 2 : 30Kg N 2 : 16 Kg Autoclave Filtration Pd/C: 6 Kg Recycle Waste water: 4901 kgs 3-Amino-4-chloro benzoic acid-1171 Kg DRYING Drying Loss Kg 3-Amino-4-chloro benzoic acid-820 Kg Expansion Project- Dyes Intermediates Page 36

38 (6) CHEMICAL REACTION OF P- AMINO BENZAMIDE O 2 N COOH + CH 3 OH + Catalyst O 2 N COOCH 3 + H 2 O p-nitro benzoic acid p-nitro methyl benzoate O 2 N COOCH 3 + NH 3 O 2 N CONH 2 + CH 3 OH p-nitro methyl benzoate p-nitro benzamide O 2 N CONH 2 + H 2 + Reny Ni p-nitro benzamide H 2 N CONH 2 +H 2 O p-amino benzamide Expansion Project- Dyes Intermediates Page 37

39 (6) FLOW DIAGRAM OF p-amino Benzamide P-Niro Benzoic acid 600Kgs Methanol : 2500 Kgs Catalyst- 100 Kgs Esterification Methanol Recovered 2200 Kg Methanol loss: 100 kgs Filtration Catalyst recovered : 100 Kgs Stage -1: 800 Kgs [85%] Liquor Ammonia: 1900 kgs Amidation Effluent : 2340 Kgs Mono Chloro benzene :1250 Kgs Catalyst : Reny Ni: 10 Kgs P-Nitro Benzamide:360 Kgs Hydrogenation P-Amino Benzamide: 215 Kgs Recovered MCB :1230 Kgs Recovered Catalyst: 10 Kgs Waste water:165 Kgs Expansion Project- Dyes Intermediates Page 38

40 (7) CHEMICAL REACTION OF 2-AMINO DI METHYL TERAPHALATE O O H 3 CO C H 3 CO C NO 2 NH 2 + 3H 2 + Pd/C + 2H 2 O H 3 CO C Mol. Wt. 2 H 3 CO C Mol. Wt. 18 O O 2-nitro Dimethyl Teraphthalate 2-Amino Dimethyl Teraphthalate Mol. Wt. 239 Mol. Wt. 209 MASS BALANCE OF 2-AMINO DIMETHYL TERPHTHALATE 2-nitro dimethyl terphthalate : 1000 Kg Pd/C: 8 Kg MCB: 4000Kg H 2 : 28 Kg N 2 : 16 Kg Autoclave Filtration Filtration ANFD DISTILLATION Rec. Pd/C recycled: 8 Kg 2-Amino dimethyl terphthalate : 835 Kg MCB recovered: 3860 kgs Distillation Loss: 156 kg Dist. Residue to incineration : 17.9 Kg Waste water: kgs Expansion Project- Dyes Intermediates Page 39

41 (8) CHEMICAL REACTION OF 2,5-Dimethyl-p-phenylene diamine NH 2 CH 3 NH 2 CH 3 H 3 C + 3 H 2 + Pd/C +2 H 2 O H 3 C NO 2 2,5-Dimethyl-p-nitro aniline 166 gms/mole NH 2 2,5-Dimethyl-p-phenylene diamine 136 gms/mole (8) MASS BALANCE OF 2,5-DIMETHYL-P-PHENYLENE DIAMINE 2,5-Dimethyl-p-nitro aniline : 1000 kg Pd/C: 7 kg MCB: 4000 kg H 2 : 40 Kg N 2 : 16 kg Autoclave Filtration Rec. Pd/C recycled: 7 kg Filtration ANFD DISTILLATION 2,5-Dimethyl-p-phenylene diamine : 780 kg MCB recovered: 3860 kgs Dist. Loss: 156 kg Dist. residue to incineration : 19.3 kg Waste water: kgs Expansion Project- Dyes Intermediates Page 40

42 (9) CHEMICAL REACTION OF 2,5-Dichloro-p-phenylene diamine NH 2 Cl NH 2 Cl Cl + 3 H 2 + Pd/C +2 H 2 O Cl NO 2 2,5-Dichloro-p-nitro aniline 207 gms/mole NH 2 2,5-Dichloro-p-phenylene diamine 177 gms/mole (9) MASS BALANCE OF 2,5-DICHLORO-P-PHENYLENE DIAMINE 2,5-Dichloro-p-nitro aniline: 1000 kg Pd/C: 8 kg DMF: 2000 Kg H 2 : 30 Kg N 2 : 16 kg Autoclave Filtration Rec. Pd/C recycled: 8 kg Filtration ANFD 2,5-Dichloro-p-phenylene diamine : 825 kg DISTILLATION DMF recovered: 1930 kgs Dist. Loss: 86 Kg Dist. residue to incineration : 6.8 Kg Waste water: kgs Expansion Project- Dyes Intermediates Page 41

43 (10) CHEMICAL REACTION OF 2-Chloro-p-phenylene diamine NH 2 Cl + 3 H 2 + Pd/C NH 2 Cl +2 H 2 O NO 2 2-Chloro-p-nitro aniline gms/mole NH 2 2-Chloro-p-phenylene diamine gms/mole (10) MASS BALANCE OF 2-CHLORO-P-PHENYLENE DIAMINE 2,5-Dichloro-p-nitro aniline: 1000 kg Pd/C: 8 kg Methanol: 3000 Kg H 2 : 30 Kg N 2 : 16 kg Autoclave Filtration Rec. Pd/C recycled: 8 kg Filtration ANFD DISTILLATION 2-Chloro-p-phenylene diamine: 795 Kg Methanol recovered: 2985 kgs Dist. Loss: 121 Kg Dist. residue to incineration : 24.4 Kg Waste water: kgs Expansion Project- Dyes Intermediates Page 42

44 (11) Chemical Reaction of 2-Chloro-5-methyl-p-phenylene diamine NH 2 NH 2 H 3 C Cl + 3H 2 + Pd/C H 3 C Cl + 2 H 2 O O 2 N 2-Chloro-5-methyl-p-nitro aniline M.Wt g/m H 2 N 2-Chloro-5-methyl-p-phenylene diamine M.Wt g/m (11) MASS BALANCE OF 2-CHLORO-5-METHYL-P-PHENYLENE DIAMINE 2,5-Dimethyl-p-nitro aniline : 1000 kg Pd/C: 7 kg MCB: 4000 kg H 2 : 40 Kg N 2 : 16 kg Autoclave Filtration Rec. Pd/C recycled: 7 kg Filtration ANFD 2,5-Dimethyl-p-phenylene diamine : 780 kg DISTILLATION MCB recovered: 3860 kgs Dist. Loss: 156 kg Dist. residue to incineration : 19.3 kg Waste water: kgs Expansion Project- Dyes Intermediates Page 43

45 Expansion Project- Dyes Intermediates Page 44

46 (13) Chemical Reaction of m-chloro Aniline NO NH H 2 + Pd/C + 2H 2 O Cl m-niro chloro benzene Mol. Wt Mol. Wt. 2 m-chloro aniline Mol. Wt Cl Mol. Wt. 18 (13) MASS BALANCE OF M-CHLORO ANILINE m-nitro chloro benzene : 1000 kg Raney Ni: 7 Kg Toluene: 1000 Kg H 2 : 45 Kg N 2 : 16 kg Autoclave Filtration DISTILLATION H 2 : 7.3 Kg N 2 : 16 kg Rec. Pd/C recycled: 7 kg Rec. Toluene: 965 kg Dist. Loss: 35Kg Lower Cut MCA : 80.4Kg Water of Reaction Kg m-chloro Aniline: 721 kg Expansion Project- Dyes Intermediates Page 45

47 (14) Chemical Reaction of Phenoxy Ethane (2,2-Di Amino Di Phenoxy Ethane) NO 2 O 2 N OH Cl + HO + Cl +2NaOH Ethylene Glycol 2-Nitro chloro benzene [ ONCB ] 2-Nitro chloro benzene [ ONCB ] NO 2 o O 2 N o 2,2'-Dinitro diphenoxy ethane [Stage-1 - Phenoxy Ethane Nitro ] NH 2 o H 2 N o 2,2'-Diamino diphenoxy ethane [Stage-1 - Phenoxy Ethane ] Expansion Project- Dyes Intermediates Page 46

48 (14) Mass Balance of 2,2 -Diamino Phenoxy Ethane (Phenoxy Ethane) ODCB: 380 kgs Water: 760 kgs NaOH: 152 kgs Ethylene Glycol: 80 kgs CONDENSATION FILTERATION Waste water: 1022 kgs Ethyl Acetate : 1215 kgs Ethyl Acetate (F): 35 kgs DMF : 440 kgs DMF (F): 10 kgs Reny Ni: 12 kgs STAGE: I: 350 kgs HYDROGENATION DMF Recovered: 440 kgs Ethyl Acetate Recovered: 1215 kgs Catalyst recovered: 12 kgs Water: 86 kgs 2,2 -Diamino Phenoxy Ethane:309 Kgs Expansion Project- Dyes Intermediates Page 47

49 (15) Chemical Reaction of 3,3 Di Amino Di Phenyl Sulphone NO 2 NO 2 NH 2 NH 2 O + H 2 + Catalyst S O 3,3'-Dinitro diphenyl sulfone O S O 3,3'-Diamino diphenyl sulfone (15) Mass Balance of 3,3 Di Amino Di Phenyl Sulphone DMF (recovered): 2850 kgs DMF (fresh): 150 kgs HYDROGENATION 3,3 Di nitro di phenyl sulphone: 1000 kgs Pd/c: 10 kgs H2: 38 kgs FILTERATION Catalyst recovered: 10 kgs CRYSTALIZATION & FILTER DADS: 1104 kgs DMF ML: 2934 kgs Distillation Residue: 10 kgs Loss:74 kgs DMF recovery: 2850 kgs Expansion Project- Dyes Intermediates Page 48

50 (16) Chemical Reaction of Aniline 2,5 Di Sulphonic Acid NH 2 NH 2 SO 3 H + H 2 SO 4 + H 2 O SO 3 H HO 3 S C 6 H 7 O 3 NS C 6 H 7 NS 2 O 6 m-amino benzene sulfonic acid Anilin-2,5-disulfonic acid [ Metanilic acid ] [ 173 g/mole ] [ 253 g/mole ] (16) MASS BALANCE OF ANILINE 2,5-DISULFONIC ACID Metanilic acid Kgs Oleum 65% : 3600 Kgs Sulfonator Vessel Water: 6670 kgs Salt: 600 kgs Drawning Filtration Waste Water: kgs Aniline 2,5-disulfonic acid : 1860 Kgs Expansion Project- Dyes Intermediates Page 49

51 (17) Chemical Reaction of Nitro Benzene NO 2 + H 2 SO 4 + HNO 3 +H 2 SO 4 +H 2 O Benzene Nitro benzene (17) Mass Balance of Nitro Benzene Sulphuric acid: 1650 kgs Nitric acid: 600 kgs MIX ACID REACTOR Benzene: 530 kgs REACTOR NOx fumes to alkali scrubber Spent Sulphuric acid 978%): 2029 kgs Caustic soda: 50 kgs NEUTRALIZATION NITRO BENZENE: 800 kgs Expansion Project- Dyes Intermediates Page 50

52 (18) CHEMICAL REACTION OF 2- NITRO DI METHYL TERAPHTHALATE (NDMT) H 3 COOC + HNO 3 H 2 SO 4 + H 2 O H 3 COOC COOCH 3 COOCH 3 NO 2 DMT (194) (63) NDMT (239) (18) (18) MASS BALANCE OF 2- NITRO DI METHYL TERAPHTHALATE (NDMT) DMT: 100 kgs Nitric acid: 34 kgs Sulphuric acid: 350 kgs Ice Water: 200 kgs NITRATION DRAWNING FILTERATION Spent acid:(63%): 520 kgs Water: 502 kgs CENTRIFUGE Effluent to ETP: 516 kgs WET CAKE: 150 KGS DRYING Vapour loss: 28 kgs NDMT: 122 KGS Expansion Project- Dyes Intermediates Page 51

53 (19) CHEMICAL REACTION OF 3- NITRO 4 CHLORO BENZOIC ACID COOH COOH + H 2 SO 4 +HNO 3 Cl 4-Chloro benzoic acid + H 2 SO 4 + H 2 O NO 2 Cl 4-Chloro-3-nitro benzoic acid (19) MASS BALANCE OF 3- NITRO 4 CHLORO BENZOIC ACID P- chloro benzoic acid: 1560 kgs Sulphuric acid: 2500 kgs Nitric acid: 635 kgs Water: 1200 kgs NITRATION FILTERATION Spent Sulphuric Acid (69.5%): 3595 kgs 3- NITRO-4- CHLORO BENZOIC ACID: 2300 kgs Expansion Project- Dyes Intermediates Page 52

54 (20) CHEMICAL REACTION OF 2,5 DI METHYL P NITRO ANILINE CH 3 NH 2 + Cl O S O + Na 2 CO 3 CH 3 NH S O O CH 3 2-Amino-p-xylene Benzene sulfonyl chloride CH 3 2',5'-Dimethyl benzene sulfanilide [Stage - 1] CH 3 NH S O O +HNO 3 O 2 N CH 3 NH S O O +H 2 O O 2 N CH 3 2',5'-Dimethyl benzene sulfanilide [Stage - 1] CH 3 NH S O O +H 2 SO 4 CH 3 2',5'-Dimethyl-4'-nitro benzene sulfanilide [Stage - 2] CH 3 2',5'-Dimethyl-4'-nitro benzene sulfanilide [Stage - 2] H 2 N H 3 C CH 3 NO 2 2,5-Dimethyl-4-nitro aniline Expansion Project- Dyes Intermediates Page 53

55 (20) MASS BALANCE OF 2,5 DI METHYL P NITRO ANILINE P- Xylidine: 1190 kgs Benzene Sulphonyl Chloride: 1765 kgs Soda ash: 636 kgs Water: 9000 kgs CONDENSATION FILTERATION Waste water: 9591 kgs Toluene (Recovered): 4850 kgs Toluene (fresh): 150 kgs HNO3: 650 kgs Water: 1500 kgs STAGE: I: 3000 kgs NITRATION STAGE: II: 3495 kgs Toluene (Recovered): 4850 kgs Waste water: 1805 kgs Sulphuric acid: 6000 kgs Water: 6000 kgs HYDROLYSIS Waste water: kgs 2,5 DI METHYL P- NITRO ANILINE: 1561 kgs Expansion Project- Dyes Intermediates Page 54

56 (21) Chemical Reaction of 2-Chloro-5-methyl-p-nitro aniline Cl NH 2 + Cl O S O + Na 2 CO 3 Cl NH S O O CH 3 2-Chloro-5-methyl aniline Benzene sulfonyl chloride CH 3 2'-Chloro-5'-methyl benzene sulfanilide [Stage - 1] Cl NH S O O +HNO 3 O 2 N Cl NH S O O +H 2 O CH 3 2'-Chloro-5'-methyl benzene sulfanilide [Stage - 1] Cl O NH S +H 2 SO 4 O O 2 N CH 3 2'-Chloro-5'-methyl-4'-nitro benzene sulfanilide [Stage - 2] CH 3 2'-Chloro-5'-methyl-4'-nitro benzene sulfanilide [Stage - 2] H 2 N Cl CH 3 NO 2 2-Chloro-5-methyl-4-nitro aniline Expansion Project- Dyes Intermediates Page 55

57 (21) Mass Balance of 2-Chloro-5-methyl-p-nitro aniline 2-Chloro-5-methyl aniline: 1445 Kgs Benzene sulfonyl chloride: 1765Kg Soda Ash: 636 Kgs Water : 9000 Condensation Filtration Waste water: 9576 Kgs Stage Kgs [85%] Toluene (Recovered) : 4850 kgs Toluene (fresh): 150 kgs HNO3: 650 kgs Water : 1500 Kgs Nitration Stage-2:3700 Kgs [ 85% ] Toluene Recovery 4850 Kgs Waste water: 1870 Kgs Sulphuric acid: 6000 kgs Water: 6000 kgs HYDROLYSIS Waste water: kgs 2,5-Dimethyl-p-nitro aniline 1900Kgs[ 80% ] Expansion Project- Dyes Intermediates Page 56

58 1. Acetylation: - (22) Chemical Reaction of 2:5 Di chloro Para Nitro Aniline NH 2 Cl + (C H 3 CO) 2O Cl 2,5-DichloroanilineAcetic anhydride NHCOCH 3 Cl + H 2 SO 4 +HNO 3 Cl 2,5-Dichloro acetanilide NHCOCH 3 Cl + CH 3 COOH Cl 2,5-Dichloro acetanilide NHCOCH 3 Cl + H 2 SO 4 +H 2 O Cl NO 2 2,5-Dichloro-4-nitro acetanilide NHCOCH 3 Cl NH 2 Cl Cl +NaOH NO 2 2,5-Dichloro-4-nitro acetanilide + CH Cl 3 COONa NO 2 2,5-Dichloro-4-nitroaniline Expansion Project- Dyes Intermediates Page 57

59 (22) MASS BALANCE of 2:5 DI CHLORO PARA NITRO ANILINE Acetic Anhydride: 64 kgs 2:5 DCA: 101 kgs ACETYLATION : 165 kgs Distilled Acetic Acid (99%) Under vacuum :37 kgs (Recycled) DISTILLATION : 165 kgs Nitric Acid: 40 Kgs H2SO4: 600 Kgs NITRATION 2:5 DCA Acetyl Body: 128 kgs Kgs = 768 kgs Water: 200 Kgs DRAWINING 768 kgs Kgs = 968 kgs CENTRIFUGE : 968 kgs Spent Acid (75%) : 750 Kgs ( 558 kgs: H2SO4 + 2 Kgs:HNO kgs: Water) WASHING 218 kgs kgs= 2246 kgs Effluent: 2047 kgs ( contains 37 kgs Acid) Water: 2028 Kgs DRYER : 199 kgs (Wet Cake) Evaporation loss: 49 kgs PRODUCT ( 2:5 DCPNA): 150 Kgs Expansion Project- Dyes Intermediates Page 58

60 (23) Chemical Reaction of 2- NITRO P- XYLENE CH 3 CH 3 + H 2 SO 4 +HNO 3 + H 2 SO 4 +H 2 O CH 3 p-xylene CH 3 NO 2 2-Nitro-p-xylene (23) Mass Balance of 2- NITRO P- XYLENE P-Xylene: 1060 Kgs Sulfuric Acid : 2500 Kgs Water : 1200 Kgs Nitration Water : 610 Kgs Separation & Washing 2-Nitro-p- Xylene: 1070 Kgs Spent sulphuric acid (80%): 3100 kgs Waste water: 1200 kgs Expansion Project- Dyes Intermediates Page 59

61 (24) Chemical Reaction of DI Calcium Phosphate Ca 3 (PO 4 ) 2. CaCO3 + 4H 2 SO 4 + 7H 2 O - 2H 3 PO 4 + 4CaSO 4 2H 2 O + CO (24) Mass Balance of DI Calcium Phosphate Rock Phosphate: 2181 kgs Water (Fresh): 715 kgs Water (recycled): 7490 kgs Sulphuric Acid (70%) from Nitro benzene, NDMT, 3- nitro 4- chloro benzoic acid, nitro p- xylene: 1661 kgs ML: 7630 kgs (H3PO4: 570 kgs + Water: 7060 kgs Lime: 430 kgs Water: 430 kgs Reactor Filteration Reactor CO2: 128 kgs Silica: 289 kgs Gypsum (50%) wet cake: 4000 kgs ML: 7630 kgs (H3PO4: 570 kgs + Water: 7060 kgs Water: 1000 kgs Filteration & Washing Effluent recycle : 7490 kgs Drying Moisture loss: 1000 kgs Pulveriser Di Calcium Phosphate: 1000 kgs Expansion Project- Dyes Intermediates Page 60

62 (25) Chemical Reaction of m- Amino Phenol NH 2 NH NaOH + Na 2 SO 3 SO 3 H Na H 2 SO 4 (25) Mass Balance of m-amino Phenol NH 2 Matanilic acid: 173 kgs Caustic Flakes: 130 kgs Water: 50 liters Fusion OH + Na 2 SO 4 Filteration Salt: 110 kgs to TSDF Sulphuric acid: 100 kgs Water: 100 kgs Isolation Traces of SO2 gas: 8 kgs Filteration Effluent to ETP: 339 kgs Product: Meta Amino Phenol: 96 kgs Expansion Project- Dyes Intermediates Page 61

63 (26) Chemical Reaction of N-N Di Ethyl -m- Amino Phenol (DEMAP) NH 2 SO 3 H Metanilic acid + (C 2 H 5 ) 2 SO 4 Di ethyl sulphate + 2 NaOH N SO 3 Na + Na 2 SO 4 N NaOH N ONa + H 2 SO 4 + Na 2 SO 3 OH DEMAP (N-N Di Ethyl m- Amino Phenol) Expansion Project- Dyes Intermediates Page 62

64 (26) Mass Balance of N-N Di Ethyl -m- Amino Phenol (DEMAP) Matanilic acid: 173 kgs Caustic Flakes: 60 kgs Water: 50 liters Di Ethyl Sulphate: 154 kgs Ethylation Caustic Flakes: 130 kgs Fusion Filter Salt: 110 kgs Sulphuric acid: 100 kgs Water: 61 kgs Acidification Traces of SO2 gas: 8 kgs Filteration Ef f luent to ETP: 465 kgs Product: DEMAP: 145 kgs Expansion Project- Dyes Intermediates Page 63

65 ANNEXURE: 3 WATER REQUIREMENT LETTER FROM NOTIFIED INDUSTRIAL AREA Expansion Project- Dyes Intermediates Page 64

66 ANNEXURE 4 WASTE WATER MANAGEMENT Quantity of Waste Water (liquid waste) generation and its management : Table: 1 Effluent Generation # Particulars Effluent Generation (m 3 /day) Existing Proposed Total Normal Concentrated Normal Concentrated Normal Concentrated 1. Domestic Processing & product washing 3. Cooling Boiler Scrubber Floor/container/ equipment washing 7. Total Total Industrial Mode of ETP MEE ETP MEE ETP MEE treatment 10. Mode of Disposal CETP CMEE CETP CMEE CETP CMEE Note: Thus after proposed expansion, total fresh water consumption will be 130 m 3 /day. After proposed expansion, total industrial Waste water generation will be m 3 /day, out of which m 3 /day of concentrated effluent will segregated and sent to CMEE, Vapi and balance m 3 /day of normal effluent will be treated in proposed primary, secondary and tertiary effluent treatment plant and discharge into under-ground effluent drainage line to CETP, Vapi for further treatment. 5 m 3 /day of domestic effluent will be passed through adequate capacity of septic tank and overflow will be discharged into under-ground drainage line to CETP, Vapi. Expansion Project- Dyes Intermediates Page 65

67 DETAILS OF EFFLUENT TREATMENT PLANT Design Criteria : Product : Dyes Intermediates Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : kl/day Max.(Normal: kl/day + Concentrated: kl/day) Design Parameters : As under Effluent Characteristics: # Effluent parameters Process + washing Boiler + cooling Equip + floor + container washing Combined normal effluent Effluent Concentr ated effluent 1. ph Temperature 0 C Colour (Pt-Co) SS, mg/l TDS, mg/l COD, mg/l BOD, mg/l Chlorides, mg/l Sulphates, mg/l O & G, mg/l NH3-N, mg/l 40 ND Phosphates, mg/l 6.2 ND Phenolic, mg/l ND ND ND N.D. ND Expansion Project- Dyes Intermediates Page 66

68 Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: Details of effluent treatment plant for normal industrial effluent stream (42.52 kl/day): S. No. Name of Equipment Capacity in (kl) MOC 1. Oil & Grease Chamber 0.5 RCC 2. Collection Tank 2 Nos each RCC/TL 3. Neutralization Tank 2 Nos. 5.0 MSRL 4. Lime Dozing Tank 1.0 HDPE 5. FeSO4 Dozing Tank 0.2 HDPE 6. P. E. Dozing Tank 0.05 HDPE 7. Floculator 1 MSRL 8. Primary Settling Tank 15 MSRL 9. Aeration Tank with Diffuser & 100 RCC Surface Aerator 10. Secondary settling Tank 15 MSRL 11. Secondary Holding Tank 15 HDPE 12. Carbon Sand Filter Bed 2.0 MS 13. Sand Filter Bed 2.0 MS 14. Air Blower with Condenser for 500 CFM - Diffuser 15. Transfer Pump 6 Nos. CI 16. Filter Press 36 plates PP 17. Final Holding Tank 10.0 RCC 18. Energy Meter 1 No Flow Meter 1 No Online ph meter 1 No. - Details of effluent treatment plant for concentrated effluent stream (15.91 kl/day): S. No. Name of the unit Capacity MOC 1. Collection tank 15 kl RCC/TL 2. Neutralization tank 2 kl HDPE with stirrer 3. Filter nutsch 0.5 kl MSRL 4. Holding tank for treated effluent to be sent to MEE 15 kl HDPE Expansion Project- Dyes Intermediates Page 67

69 Figure 2: Schematic diagram of Effluent Treatment Plant EFFLUENT TREATMENT SCHEME 1. PRIMARY TREATMENT: UNITS: Oil & Grease removal Tank Collection cum Neutralization Tank Primary settling and sludge removal The effluent coming from the plant is initially passed through the Oil & Grease removal system. The oil free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank various chemicals like None Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added to ensure proper settling which reduces the suspended solid concentration, colour and COD in the effluent. The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling tank is charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into the sludge drying beds/filter press and leached of the sludge drying beds is going back to collection tank. Expansion Project- Dyes Intermediates Page 68

70 2. SECONDARY TREATMENT (BIOLOGICAL TREATMENT): UNITS: Aeration Tank Secondary settling The primary treated clear effluent is passed through the aeration tank where the biodegradation of the organic matter is taken place in presence of active microorganism and required Dissolved Oxygen level. During the biological treatment BOD Value and COD Value are reduced. After the biological treatment (aeration tank) the effluent with the biomass is passed through secondary settling tank where biomass is settled and settled biomass is recycle back to aeration tank or if excess is discharged into the sludge drying beds. And clear effluent is collected into the holding tank. 3. TERTIARY TREATMENT: UNIT: Sand and Carbon Filter (Mixed bed) After secondary treatment the effluent is passed through the mixed bed filter for further reduction of COD Value, BOD Value and Colour. Treated water is collected into the treated water tank above the roof. Finally the treated effluent confirming the treated water discharge norms laid down by board will be discharged for plantation or into the drainage to CETP, Vapi as and when permitted. Expansion Project- Dyes Intermediates Page 69

71 ANNEXURE: 5 MEMBERSHIP CERTIFICATE OF CETP, VAPI Expansion Project- Dyes Intermediates Page 70

72 MEMBERSHIP OF CMEE, Vapi FOR CONCENTRATED EFFLUENT Expansion Project- Dyes Intermediates Page 71

73 ACCEPTANCE LETTER FOR CETP AUTHORITY FOR ADDITIONAL EFFLUENT Expansion Project- Dyes Intermediates Page 72

74 MEMBERSHIP OF TSDF & CHWIF Expansion Project- Dyes Intermediates Page 73

75 Expansion Project- Dyes Intermediates Page 74

76 ANNEXURE: 6 Expansion Project- Dyes Intermediates Page 75

77 Expansion Project- Dyes Intermediates Page 76

78 ANNEXURE: 7 COPY OF PLOT ALLOTMENT LETTER ISSUED BY GIDC Expansion Project- Dyes Intermediates Page 77

79 Expansion Project- Dyes Intermediates Page 78

80 Expansion Project- Dyes Intermediates Page 79

81 COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA Expansion Project- Dyes Intermediates Page 80

82 ANNEXURE: 8 A SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING Expansion Project- Dyes Intermediates Page 81

83 ANNEXURE: 9 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED EXPANSION Flue gas emission: At present, the unit is having one number of coal fired 2.5 lakh kcal/h capacity of Thermopak. Adequate multi cyclone dust collector and 30 meters height of chimney provided. There will be addition of one coal fired steam boiler of 2 TPH capacity and one 25 lakhs kcal capacity of coal fired thermopack. Adequate multi cyclone dust collector and 30 meters height of chimney will be provided. The company is having one D G set of 250 kva capacity as stand by. One additional D G set of 500 kva capacity will be installed.it is used only during power failure. Adequate stack height and stack monitoring facilities is provided. Process gas emission: At present, Sulphur dioxide process gas is generated from sulphonator and SO 3 gas generated from Oleum storage tank. The unit has provided acid followed by alkali scrubber and 11 meters height of chimney. After proposed expansion, there will be generation of sulphur dioxide and traces of nitrogen dioxide. To Scrub process gases, the unit propose to install additional one number of two stage alkali scrubber having 11 meters height of vent. The details of which are as under; S. No. Particulars Details Remarks Existing Proposed Total after expansion FLUE GAS EMISSION 1. Steam Boiler 0 2 TPH 2 TPH Proposed i. Fuel used 0 Coal Coal ii. Fuel Consumption 0 1 MT/day 1MT/day iii. APC 0 Multi Cyclone separator and Chimney Multi Cyclone separator and Chimney iv. Height & Dia of chimney 0 30 meter/900 mm 30 meter/900 mm 2. Thermopak 2.5 lakh k cal lakh k cal i. Fuel used Coal 0 Coal ii. Fuel Consumption 1 MT/day 0 1 MT/day iii. APC Multi Cyclone 0 Multi Cyclone separator and separator Chimney and Chimney Existing iv. Height & Dia of chimney 30 meter/450 mm 30 meter/450 mm 3. Thermopak 0 25 lakh 25 lakh kcal Proposed kcal i. Fuel used 0 Coal Coal Expansion Project- Dyes Intermediates Page 82

84 ii. Fuel Consumption MT/day iii. APC 0 Multi Cyclone separator and Chimney iv. Height & Dia of 0 30 chimney meter/ MT/day Multi Cyclone separator and Chimney 30 meter/450 mm mm 4. D G Set: I 250 kva kva Standby i. Fuel used HSD 0 HSD ii. Fuel Consumption 20 kg/h 0 20 kg/h iii. APC Exhaust 0 Exhaust iv. Height of exhaust 11 meters 0 11 meters 5. D G Set: II kva 500 kva Standby i. Fuel used 0 HSD HSD ii. Fuel Consumption 0 40 kg/h 40 kg/h iii. APC 0 Exhaust Exhaust iv. Height of exhaust 0 11 meters 11 meters Process gas emission 6. Stack attached to Sulphonator & Oleum storage tank 0 Sulphonator & Oleum storage tank i. Pollutants SO 3 & SO 2 0 SO 3 & SO 2 ii. APC provided Acid followed by alkali scrubber 0 Acid followed by alkali scrubber iii. Height of vent 11 meter 0 11 meter 7. Stack attached to 0 Sulphona tor & Nitrator i. Pollutants 0 SO 2 & NO x ii. APC provided 0 Two stage alkali scrubber Sulphonator & Nitrator SO 2 & NO x Two stage alkali scrubber iii. Height of vent 0 11 meter 11 meter Existing Proposed Details of Multi Cyclone Separator attached to Thermopak and Boiler ( Existing & Proposed) Cyclone tube diameter 150 dia Height of tube Standard No of tubes 16 Dia of tubes 150 mm Dimensions 1220 x1220 x ( ) Expansion Project- Dyes Intermediates Page 83

85 Details of Acid followed by Alkali Scrubber attached to Oleum storage and sulphonator (Existing) S. No. Particulars Details 1. Stack attached to Oleum storage tank & sulphonator 2. APC provided Acid pot followed by alkali scrubber 3. Vent provided 11 meters 4. Scrubber size PP/FRP with poll ring packing, 500 mm dia x 6 meter height 5. Circulation tank 1000 liter, PPFRP 6. Blower capacity 3 HP, 1440 rpm ACID & ALKALI SCRUBBER ATTACHED TO OLEUM STORAGE & SULPHONATOR Blower Alkali Scrubber Sulphonator Oleum Storage Tank Sulfuric Acid Trap Tank 500 Lit, HDPE Caustic Solution, 100 Lit, HDPE Alkali circulation pump Expansion Project- Dyes Intermediates Page 84

86 Details of Scrubbing System attached to sulphonator and Nitrator (proposed) S. No. Particulars Details 1 Size of Primary scrubber 300 mm dia x 2000 mm height 2 MOC of scrubber PP/FRP 3 Capacity of Caustic circulation tank 2000 liters, HDPE 4 Size of Ventury Scrubber 200 mm x 1500 mm 5 MOC of ventury scrubber PP/FRP 6 Capacity of circulation tank 1000 liters, HDPE 7 Capacity of circulation pump 3 HP, PP 8 Capacity of blower 5 HP, 2000 cfm 9 Height of vent 11 meter VENTURY SCRUBBER PG STACK PACKED COLUMN SCRUBBER Di. NaOH DILUTE NaOH NRV BLOWER reactor Expansion Project- Dyes Intermediates Page 85

87 ANNEXURE 10 COPY OF EXISTING CCA Expansion Project- Dyes Intermediates Page 86

88 Expansion Project- Dyes Intermediates Page 87

89 Expansion Project- Dyes Intermediates Page 88

90 Expansion Project- Dyes Intermediates Page 89

91 Expansion Project- Dyes Intermediates Page 90