Pre-Feasibility Report

Transcription

1 Pre-Feasibility Report of Asahi Songwon Colors Ltd. (Unit-II) Plot D2/CH/39, GIDC Dahej, Dahej, Tehsil: Vagra, Dist.: Bharuch Proposed Project for Manufacturing of Pigments (1665 TPM) Project Activity: 5(f), Category: B

2 1. INTRODUCTION Asahi Songwon Colors Ltd. is a leading player in the Indian Pigment industry and intends to become a leading manufacturer of pigments around the world. The company is in the manufacturing of CPC Beta Blue and Blue Crude, exporting substantial production to leading MNCs around the world on account of quality of its products. The global dyes and pigments market is projected to reach USD billion by 2021, at a CAGR of 5.0% from 2016 to The growth of the market is primarily due to increasing population, coupled with growing demand for dyes & pigments from various applications, such as textile, paints & coatings, and plastics, among others. Thus, Asahi Songwon Colors Ltd. (Unit-II) proposes to manufacture Pigments at Plot D2/CH/39, GIDC Dahej, Dahej, Tehsil: Vagra, Dist.: Bharuch. The area of the site is 60,000 m 2. Location of the proposed project in industrial estate and 5 km and 10 km radius around the location are shown below. 2. COST OF PROJECT The estimated cost of the project is estimated around Rs crores. Estimated Cost in Rs. Crores Land and Land Development 16 Buildings - Civil & structural work 42.5 Godowns/Engg Stores 5.8 Electric Room 2.55 Plant and Machinery 148 Utility Equipments Miscellaneous Fixed Assets 6.7 ETP plant & Machinery 20 Stores & Spares 2.25 Total Asahi Songwon Colors Ltd. (Unit-II), Dahej 1

3 3. LOCATION OF PROJECT Asahi Asahi Songwon Colors Ltd. (Unit-II), Dahej 2

4 4. PRODUCTION CAPACITY Production capacity is prescribe below: Sr. Product Capacity (MTPM) A Classical Azo Pigments 1000 B High Performance Pigments 45 C CPC-BC 300 D Alpha Blue 100 E Beta Blue 200 F Pigment Blue Total 1665 Sr. Color Name CAS Color Index A Classical Azo Pigments 1. Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red 48: :2 19. Pigment Red 49: :2 20. Pigment Red 53: :2 21. Pigment Red 57: :2 22. Pigment Red 63: :2 23. Pigment Red B High Performance Pigments 1. Pigment Orange Pigment Orange Pigment Orange Pigment Orange Pigment Orange Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Proposed Capacity (MT/month) Asahi Songwon Colors Ltd. (Unit-II), Dahej 3

5 13. Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow Pigment Yellow 191: :1 23. Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red Pigment Red / Pigment Red Pigment Red Pigment Violet Pigment Violet C CPC-BC D Alpha Blue (15:0/ 15:1/15:2/15:3/15:4) E Beta Blue F Pigment Blue Total MANPOWER REQUIREMENTS Total manpower requirement at all level of plant will be ENERGY & FUEL REQUIREMENTS Energy requirement for the proposed project will be 5128 kva, and will be sourced from Dakshin Gujarat Vij Company (DGVCL). Coal requirement will be 60 TPD for boilers and thermic fluid heater. Diesel requirement will be 50 Liter per hour (for each D.G. set of 500 kva each) 7. RAW MATERIALS REQUIREMENTS Sr. A Classical Azo Pigments 1 Pigment Yellow 1 4 methyl 2-nitrobenzeneamine HCl (35%) Sodium nitrite (40%) Sodium hydroxide (50%) Acetoacitanilide Asahi Songwon Colors Ltd. (Unit-II), Dahej 4

6 2 Pigment Yellow 3 4 chloro 2-nitrobenzeneamine HCl (35%) Sodium nitrite (40%) Sodium hydroxide (50%) chloroacetoacitanilide Pigment Yellow 12 Acetoacetanilide Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Sodium nitrite Sodium hydroxide (15%) Pigment Yellow 13 Acetoacet-2:4-dimethylanilide Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Sodium nitrite Sodium hydroxide (15%) Pigment Yellow 14 Acetoacet-2-toluidide Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Sodium nitrite Sodium hydroxide (15%) Pigment Yellow 16 2,5 dichloroaniline HCl (35%) Sodium nitrite (40%) Sodium hydroxide (50%) ,3-dimethylbiphenyl-3 oxybutanamide Sodium acetate Pigment Yellow 17 Acetoacet-2-anisidide Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Sodium nitrite Sodium hydroxide (15%) Pigment Yellow 62 4-amino-2-nitrobenzene HCl (35%) Sodium nitrite (40%) Asahi Songwon Colors Ltd. (Unit-II), Dahej 5

7 Sodium hydroxide (50%) acetic acid acetoacetyl o- toluedide calcium chloride Pigment Yellow 65 HCl (31%) nitro-4-methoxyaniline Sodium nitrite (40%) Sodium hydroxide Acetoacet-2-anisidide Sodium acetate Pigment Yellow 74 HCl (31%) methoxy-4-nitroaniline Sodium nitrite (40%) Sodium hydroxide Acetoacet-2-anisidide Sodium acetate Pigment Red 2 HCl (31%) ,5-dichloroaniline Sodium nitrite (40%) Sodium hydroxide hydroxy-2-naphthanilide Sodium acetate Pigment Red 3 HCl (35%) methyl 2-nitrobenzeneamine Sodium nitrite Sodium hydroxide Naphthalen-2-ol Sodium acetate Pigment Red 4 HCl (35%) chloro 4-nitrobenzeneamine Sodium nitrite Sodium hydroxide Naphthalen-2-ol Pigment Red 8 HCl (35%) methyl-4-nitroaniline Sodium nitrite (40%) Sodium hydroxide '-chloro-3-hydroxy-2'-naphthanilide Sodium acetate Pigment Red 12 HCl (35%) methyl-4-nitrobenzeneamine Sodium nitrite (40%) Sodium hydroxide (50%) Asahi Songwon Colors Ltd. (Unit-II), Dahej 6

8 4'-chloro-3-hydroxy-2'-naphthanilide Sodium acetate Pigment Red 31 N-(3-Amino-4-methoxy phenyl)benzamide Hydrochloric acid (35%) Sodium nitrite (38%) Sodium hydroxide (50%) hydroxy-N-(3-nitro phenyl) naphthamide sodium acetate Pigment Red 41 Sodium hydroxide (50%) phenyl 3-methyl, 5-pyrazoline HCl (35%) acetic acid ,3 dimethoxy benzidine sodium nitrite Pigment Red 48:2 Sodium hydroxide (33%) amino-4-chloro-5-methyl benzenesulfonic acid Hydrochloric acid (31%) Sodium nitrite (38%) hydroxy naphthalene-2- carboxylic acid Calcium Chloride Pigment Red 49:2 Sodium hydroxide (33%) amino naphthalene-1-sulfonic acid Hydrochloric acid (35%) Sodium nitrite (38%) naphthale-2-ol Calcium Chloride Pigment Red 53:2 Sodium hydroxide (33%) amino-5-chloro-4-methyl benzenesulfonic acid Hydrochloric acid (35%) Sodium nitrite (38%) Sodium hydroxide (33%) naphthale-2-ol Calcium Chloride Pigment Red 57:1 Sodium hydroxide (33%) amino-5-methyl benzene sulfonic acid Hydrochloric acid (31%) Sodium nitrite (38%) hydroxynaphthalene-2-carboxylic acid Calcium Chloride Asahi Songwon Colors Ltd. (Unit-II), Dahej 7

9 22. Pigment Red 63:2 HCl (35%) aminonaphthalene 1-sulfonic acid Sodium hydroxide (33%) Sodium nitrite (38%) hydroxy-naphthalen 2-carboxylic calcium chloride Pigment Red 112 HCl (31%) ,4,5-trichloroaniline Sodium nitrite (40%) B 3-hydroxy-2'methyl-2-naphthanilide Sodium acetate High performance Pigments 1. Pigment Orange 05 HCl Sodium Nitrite ,4-Dinitrobenzenamine Napthalan 2 ol Sodium Hydroxide Sodium Acetate Rosin Solution Pigment Orange 13 1-phenyl-3-methyl-5-pyrazoline Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Hydrochloric acid (31%) sodium nitrite Sodium Hydroxide (15%) Pigment Orange 34 1-p-tolyl-3-methyl pyrazol-5-one Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine sodium nitrite Sodium hydroxide (15%) Pigment Orange 36 HCl (31%) chloro-2-nitroaniline Sodium nitrite (40%) Sodium hydroxide acetoacetyl amino benzimidazolone Sodium acetate Pigment Orange 64 HCl (31%) amino-6-methyl-1,3-dihydro-2H benzimidazol-2-one Asahi Songwon Colors Ltd. (Unit-II), Dahej 8

10 Sodium nitrite (40%) Sodium acetate Barbituric acid Pigment Yellow 83 Acetoacet-2:5-dimethoxy-4-chloroanilide Sodium Hydroxide (50%) Acetic acid Hydrochloric acid (35%) ,3-dichlorobenzidine Sodium nitrite Sodium hydroxide (15%) Pigment Yellow 97 HCl Sodium Nitrite Amine Coupler Sodium Hydroxide Sodium Acetate Pigment Yellow 110 o-dichlorobenzene ,4-Diaminobenzene ,3,4,5,6,7-Hexachloro-2,3-dihydro-1Hisoindol-1-one Methanol Pigment Yellow 114 N-Acetoacetyl-4-methylaniline Acetoacetanilide Sodium Hydroxide Acetic Acid HCl ,3-dichlorobenzidine Sodium Nitrite Sodium Acetate Pigment Yellow 138 ODCB aminoquinaldine Tetra chloro phthalic anhydride Methanol Pigment Yellow 139 Sodium methoxide (30%) ,2-Dicynobenzene Barbituric acid Acetic acid MCB Surfactant Pigment Yellow 150 Aminoguanidine bicarbonate Hydrochloric acid (30%) Potassium nitrite (37%) Barbituric acid Potassium hydroxide Asahi Songwon Colors Ltd. (Unit-II), Dahej 9

11 Melamine Nickel chloride (6.5%) Pigment Yellow aminobenzoic acid Hydrochloric acid (31%) Sodium nitrite (40%) Sodium hydroxide (25%) Acetoacetylamino-benzimidazolone Acetic acid Sodium Hydroxide (10%) Xylene Caustic Pigment Yellow 152 N-(4-ethoxyphenyl)-3-oxo butanamide Sodium Hydroxide Acetic Acid HCl ,3-dichlorobenzidine Sodium Nitrite Pigment Yellow (trifluoromethyl)aniline Hydrochloric acid (31%) Sodium nitrite (40%) Sodium hydroxide (25%) Acetoacetylamino-benzimidazolone acetic acid Sodium Hydroxide (10%) Xylene Caustic Pigment Yellow 155 HCl (31%) Dimethyl-2-amino-terephthalate Sodium nitrite (40%) ,4-bis (aceto acetylamino) benzene sodium acetate HCl (31%) Dimethyl-2-amino-terephthalate Pigment Yellow 168 Sodium Nitrite Amino-3-nitro benzenesulfonic acid Acetic acid N-(2-chloro phenyl)-3-oxo butanamide Sodium Hydroxide Calcium Chloride Pigment Yellow 174 HCl (31%) ,3-dichlorobenzidine Sodium nitrite (40%) Sodium hydroxide Asahi Songwon Colors Ltd. (Unit-II), Dahej 10

12 Acetoacet-2-methylanilide Acetoacet-2:4-dimethylanilide Pigment Yellow (Ethylene dioxy) dianiline acid Sodium Nitrite HCl Acetic acid aceto acetyl amino benzimidazolone Sodium Hydroxide Caustic Xylene Pigment Yellow (4-Aminobenz amido)benzamide Sodium Nitrite HCl Acetic acid aceto acetyl amino benzimidazolone Sodium Hydroxide Caustic Xyline (4-Aminobenz amido)benzamide Pigment Yellow 183 Sodium hydroxide (33%) Pigment Yellow 191:1 2-Amino-4,5-dichloro-benzenesulfonic acid Hydrochloric acid (31%) Sodium nitrite (38%) (3'-Sulfophenyl)-3-methyl pyrazolone Calcium Chloride Sodium hydroxide (33%) amino-4chloro-5-methylbenzenesulfonic acid Hydrochloric acid (31%) Sodium nitrite (38%) (3'-sulfophenyl)-3-methyl pyrazolone Ammonium Chloride Pigment Red 146 HCl (31%) amino-4-methoxybenzanilide Sodium nitrite (40%) '-chloro-3-hydroxy-2-5'dimethoxy naphthanilide sodium acetate HCl (31%) Asahi Songwon Colors Ltd. (Unit-II), Dahej 11

13 24. Pigment Red 170 HCl (31%) aminobenzamide Sodium nitrite (40%) N-(2-ethoxyphenyl) hydroxynaphthalene-2-carboxamide sodium acetate HCl (31%) aminobenzamide Sodium nitrite (40%) Pigment Red 176 HCl (31%) Amine Sodium nitrite (40%) Coupler Pigment Red 177 Polyethylene glycol Potassium hydroxide Sodium chlorate amino-4-bromo anthracene-9,10-dione Pigment Red 184 N-(3-amino methoxyphenyl)benzamide Sodium Nitrite HCl Chloro-2-methylphenyl ) methanone Pigment Red Methyl-4-amino-5-methoxy-N-methyl benzene sulfonamide Sodium Nitrite HCl Hydroxy-N-2-naphthamide Pigment Red Amino-4-methoxy-4-carbamoyl benzanilide Sodium Nitrite HCl Hydroxy-5-chloro-2,4-dimethoxy naphthanilide 30. Pigment Red 188 2,5 -Dichloro-3-amino-4-methoxy Asahi Songwon Colors Ltd. (Unit-II), Dahej 12

14 carbonylbenzanilide Sodium Nitrite HCl Methoxy-3-hydroxy-2-naphthanilide Pigment Red 210 HCl (31%) aminobenzamide Sodium nitrite (40%) hydroxy-N-(2-methoxy phenyl) naphthalene-2-carboxamide 32. Pigment Red 254 Tert-amyl alcohol p-chlorobenzonitrile Potassium tert-butoxide Di-isopropylsuccinate Methanol Pigment Red 264 Tert-amyl alcohol phenylbenzylnitrile Potassium tert-butoxide Di-isopropylsuccinate Methanol Pigment Red 122 HCl (31%) ,4,5-trichloroaniline Sodium nitrite (40%) hydroxy-2'methyl-2-naphthanilide Sodium acetate Pigment Violet 19 Succinyl-succinic acidsimethylester Aniline Methanol HCl Pigment Violet 23 ODCB aminoethylcarbazole sodium acetate chloranil benzene sulpho chloride C CPC-BC Cuprous Chloride Phthalic Anhydrous solvent Urea Ammo. Molybdate Spent Acid from alpha blue Asahi Songwon Colors Ltd. (Unit-II), Dahej 13

15 D Caustic lye Alpha Blue(15:0/15:1 /15:2/15:3/15:4) CPC(grinded) Sulphuric Acid Surfactant/Additive Caustic E Beta blue CPC Sulphuric acid Caustic Flacks IBA Dispersing Agent F Pigment Blue 60 polyethylene glycol potassium hydroxide sodium chlorate MANUFACTURING PROCESS 2-aminoanthraquinone sodium chlorate Detailed manufacturing process is given in Annexure-II of Form-I. 9. WATER REQUIREMENTS AND WASTEWATER GENERATION The total fresh water requirement will be 555 KL/day, which will fulfill by GIDC water supply. The breakup of water consumption and wastewater generation is given below. Sr. Source Water Consumption (KLD) Wastewater Generation (KLD) I Domestic 10 8 II Gardening 50 0 III Industrial a) Process b) Scrubber 6 0 c) Boiler d) Cooling e) Water treatment f) Lab 5 5 g) Washing Total Industrial Total (I+II+III) Recycle water Actual fresh water requirement Asahi Songwon Colors Ltd. (Unit-II), Dahej 14

16 Water Balance Diagram Total water consumption= 1955 KLD [555 (Fresh water) * (recycle)] Domestic 10 Lab 5 Scrubber 6 Process 1289 Washing 100 Utility 495 Greenbelt 50 Soak pit 8 liquid amm (20%) 17 Ice 3.0 Water retained RM 39 Live Steam 60 Water treatment 495 Reject 40 Total Volume 1391 Boiler 255 Cooling Make up D. L Blow down 25 Bleed Off 50 ETP =1510 RO 1510 OR Permeate 975* W/w 1510 To CETP- Dahej Reject 535 MEE 535 Condensate 425* Loss 90 Spray Dryer 110 Salt 20 Asahi Songwon Colors Ltd. (Unit-II), Dahej 15

17 10. SOURCES OF POLLUTION AND MITIGATION MEASURES A. Air Pollution Flue gas emission will be from stack attached with boiler & Thermic Fluid Heater (TFH), where coal/briquettes will be used as fuel; and D.G. Set, in which Diesel will be used as fuel. Process emissions will be from process vents and spin flash dryer. Most probable pollutants will be SPM, SO 2, NOx and NH 3. Adequate stack height will be provided to control & disperse the air pollutants within the satisfactory levels. Furthermore, facility for sampling such as ladder and sampling point will be provided as per the GPCB guidelines. The details of stacks with their APC measures & height are given in below. Sr. Stack attached to Flue Gas Stacks Fuel Type 1 Boiler - 1 (10 TPH) Coal/ Briquettes Fuel consumption rate 60 MT/day Stack Height in (m) APC measures 30 Electrostatic Precipitator (ESP) 2 Boiler - 2 (10 TPH) 30 Electrostatic Precipitator (ESP) 3 Thermic Fluid heater (25 Lakhs K.cal/hr) 4 D.G. set- 4 Nos. (500 KVA each) Process Gas Stacks 5 Process vents (4 Nos.) 6 Process vents (1 Nos.) 7 Spin Flash Dryers (5 Nos.) HSD 50 lit/hr each 30 Electrostatic Precipitator (ESP) Two stage water scrubber followed by an acid scrubber Two stage water and alkali scrubber In built Cyclone and Bag Filters Probable emission SPM <150 mg/nm 3 SO 2 <100 ppm NOx <50 ppm NH 3 <175 mg/nm 3 SO 2 < 40 mg/nm 3 SPM <150 mg/nm 3 Asahi Songwon Colors Ltd. (Unit-II), Dahej 16

18 B. Water Pollution Main source of effluent generation will be from process, utilities & washing. Scheme for Wastewater Treatment Process effluent (Concentrated stream) along with wastewater of lab, washing and utility will be taken to RO after primary treatment. RO reject will be sent to MEE; RO permeate and condensate of MEE will be reused. MEE reject will be further spray dried in spray dryer. Domestic wastewater will be disposed off to soak pit. Thus, achieving zero liquid discharge (ZLD). After the commencement of CETP, Industrial effluent will be disposed to CETP. C. Hazardous Wastes Sr. Entire quantity of hazardous waste will be handled & disposed as per Hazardous & Other waste (Management & Transboundary Movement) Rules, The unit will provided isolated area with impervious flooring & roof cover for the storage of hazardous waste. Details of hazardous waste and disposal are given below. Type of Waste Category of Waste as per HWM Rules 2016 Quantity 1. ETP Sludge MT/Month 2. Evaporation salt MT/Month 3. Copper sulphide (Sludge) 4. Ammonia Solution (10%) MT/Month MT/Month Disposal facility Collection, Storage, Transportation and disposal at TSDF site approved by GPCB Collection, Storage, Transportation and disposal at TSDF site approved by GPCB Collection, Storage, Transportation and sold to actual end users/registered recyclers Collection, Storage, Transportation and sold to actual end users. 5. Discarded Drum/Container /Bags/liners Nos./month Collection, Storage, Transport, Decontamination and used for sludge packaging or if in excess sold to actual end users. 6. Spent Oil KL/year Collection, Storage, Transportation and sell to GPCB approved recycler 7. Process residues MT/Month Collection, Storage, Transportation and disposal at CHWIF facility for co-processing 8. Filter Material -- 8 MT/Month Collection, Storage, Transportation and disposal at TSDF site approved by GPCB Asahi Songwon Colors Ltd. (Unit-II), Dahej 17

19 Details of Solid waste Sr. Type of Waste Quantity 1. Fly Ash 125 MT/Month Disposal facility Collection, Storage, Transportation and sell to brick manufacturer /used for land filling 11. GREEN BELT DEVELOPMENT The unit proposes to earmarked space for development of green belt along the plan periphery to arrest noise pollution and fugitive emissions as well as to improve aesthetics. 12. FUNDS FOR POLLUTION CONTROL MEASURES The management is quite conscious of its responsibility for maintaining clear environment. Thus, around Rs. 18 crores will be provided for the pollution control measures as a part of overall project financing. 13. MONITORING FACILITIES Company is ready to carry out monitoring proposed by pollution control board from time to time through outside agency. 14. CONCLUSION On the basis of information presented here on pollution control measures and its implementation, there will be no emission from the plant beyond the norms specified by the Board as per the provisions of Water (Prevention and Control of Pollution) Act, 1974 and Air (Prevention and Control of Pollution) Act, Asahi Songwon Colors Ltd. (Unit-II), Dahej 18