PIDILITE INDUSTRIES LIMITED

Transcription

1 FOR PROPOSED EXPANSION PROJECT (FOR EXISTING PRODUCT RANGE) MANUFACTURING OF ORGANIC PIGMENTS Category: 5(f) AT PIDILITE INDUSTRIES LIMITED Located at: Plot No. 23, 1 st Phase, GIDC Notified Industrial Area, Vapi, Dist- Valsad (Gujarat).

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: Location : Plot No: 23, 1 st phase, G.I.D.C, VAPI. Pin Code: Dist. - Valsad (Gujarat) Project Pidilite Industries limited is located in GIDC notified industrial area, falling under large 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 under the category Organic Pigments ( Azo Pigments ) as well as Quinacridone Pigments & Pigment Emulsions. Proposed expansion Project Cost: Rs lacs. Total after proposed expansion will be Rs lacs Applicability of EIA notification 2006 Category as per the amended EIA notification-2006: as existing and proposed products (i.e. Organic pigments) are covered under the Category-5(f). Hence, Environmental clearance is required. Project Proponent The company in India comprises of 12 directors Large Scale Unit List of finished products & by- products: No Product MT/MONTH Existing Proposed Total after proposed expansion 1 Carbazole Dioxane Violet Pigment 2 Organic Pigment (Azo- Orange/Yellow/ Red) 3 Pigment emulsion Quinacridone Pigment Total Expansion project Page 1 Organic Pigments

3 by-products 1 Phosphoric Acid (10-30%) from Quinacridone Pigment 2 Calcium Sulphate (Gypsum)* Gypsum is having % moisture in it. Manufacturing process is attached as Annexure-3. Resource Requirement: Components Existing Proposed Total after proposed expansion Power, KVA Fresh Water, kl/day Briquette /Natural Gas for Steam Boiler (12 Tons/Hr) x 1 Nos Natural gas for Thermopak (10 lacs & 4 lacs) Natural gas for steam boiler (8 TPH & 2 TPH) Fuel (HSD) for D.G.Set (Capacity: 750 x 2 & 125 KVA) MT/Hr of Briquette or 410 SCM/Hr 2000 SCM/day 8750 SCM/day MT/Hr Briquette or 180 SCM/Hr MT/Hr Briquette or 590 SCM/Hr SCM/day GSPC SCM/day GSPC kgs/hr 225 kgs/hr Resources availability Will be sourced from Dakshin Gujarat Vij Co. Ltd. Will be sourced from GIDC water supply Dept. GSPC & local dealer Will be sourced from local dealer Expansion project Page 2 Organic Pigments

4 Raw material Consumption: 1.0 For Carbazole Dioxane Violet Pigment (Pigment Violet 23) Sr. No. Raw Materials Ton per Tone of FG Quantity in MT Per month Existing Proposed Total after expansion 1.1 Carbazole Diethyl sulphate Caustic flakes Mono Chloro Benzene (Recovered) 1.5 Mono Chloro Benzene (Fresh) Nitric acid ODCB (Recovered) ODCB (Fresh) Catalyst Nitrogen Hydrogen Chloranil Catalyst RAC Benzene sulpho chloride Salt Di ethyl Glycol Iron Powder Total Expansion project Page 3 Organic Pigments

5 2.0 For Organic Pigment 2.1 Organic Yellow Pigment Sr. No. Raw Materials Ton per ton of FG Quantity in MT Per month Existing Proposed Total after expansion Base (Amine) Ice Sulphamic acid Sodium nitrite Hydro Chloric Acid (30%) Caustic Acetic acid Xylene (Recovered) Xylene (Fresh) Total Organic Red Pigment Base (Amine) Ice Sulphamic acid Sodium nitrite Sulphuric acid Caustic Hydro Chloric acid Total Expansion project Page 4 Organic Pigments

6 Sr. No. Raw Materials Ton per ton of FG Quantity in MT Per month Existing Proposed Total after expansion 2.3 Organic Orange Pigment Base (Amine) Ice Sulphamic acid Sodium nitrite Hydro Chloric Acid (30%) Caustic Emulsifier Xylene (Recovered) Xylene (Fresh) Total For Pigment emulsion (Pigment Black Dispersion) : 3.1 Carbon black pigment Surface active agent Glycols Preservative Total Expansion project Page 5 Organic Pigments

7 Sr. No. Raw Materials Tone per tone Quantity in MT Per month Existing Proposed Total after expansion 4.1 For Quinacridone Pigment (Pigment Red 122) : Aniline DMSS Para Toludine Hydro Chloric acid (30%) Methanol (Recovered) Methanol (Fresh) Resist salt Caustic flakes PPA or P 2 O Iso Butanol (Recovered) Iso Butanol (fresh) Caustic lye Total Expansion project Page 6 Organic Pigments

8 4.2 For Quinacridone Pigment (Pigment Violet 19) : Sr. No. Raw Materials Quantity in MT Ton per ton of FG Per month Existing Proposed Total after expansion Aniline DMSS Hydro Chloric acid (30%) Methanol (Recovered) Methanol (Fresh) Resist salt Caustic flakes PPA or P 2 O Dimethyl Formamide (Recovered) Dimethyl Formamide (fresh) Caustic lye Total Expansion project Page 7 Organic Pigments

9 Water and Waste Water Management Total Raw Water requirement is 1564 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 1274 KL/Day. Domestic waste water (95 KL/day) will be disposed off through Septic Tank. Air Emission and its Control Measures Flue gas emission: At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers, one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare capacity to supply the steam for proposed expansion. The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA & 125 KVA capacities, as stand by. It will be used only during power failure. Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler. Adequate stack height and stack monitoring facilities is provided. Process gas emission: Presently the unit has installed Two no of multi cyclone separator followed by bag filter attached to pulveriser. After proposed expansion, the unit shall install one additional multi cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent will be provided.(detail of Air pollution control measures is attached as Annexure-10) Hazardous Wastes and its Management Sr. No. Type of hazardous waste Cat egor y Quantity, TPM Existing After proposed expansion Storage Capacity, m2 Disposal 1 ETP waste Dispose off into TSDF, Vapi 2 Used oil Sell to Registered recyclers 3 Discarded containers 4 Distillation Residue ReUse for packing finished product or Sell to Autho. recycler Sell to cement industries for coprocessing. 5 Iron Sludge Spent catalyst Sent for reprocessing Expansion project Page 8 Organic Pigments

10 2. Introduction of the Project and the Proponent. Name of the project Proponent: is a large scale unit is located in notified industrial estate, GIDC, Vapi Di: Valsad, Gujarat having total plot area of m 2 & total investment after proposed expansion will be Rs lacs. The proponent wishes to enhance the Production capacity of Existing Products 33 %. The Organic pigments products are especially used in paint, textiles, plastics, cosmetics, ink, etc. The unit is operated by technocrats having more than 35 years of experience in manufacturing and marketing of various Organic pigments worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proposed expansion proposes to enhance the capacity of all the pigments & Pigment Emulsion to MT per month and process capabilities to manufacture all types of Organic pigments & Emulsions. The proposed expansion project site lies on N Latitude & E Longitude. is located at Plot. No. 23,1 st phase area, GIDC Vapi, Di: Valsad district 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. The western Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with other major cities of the state and the country. 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 now having a six lane, double tracked, more elevated and Jam free highway, developed by L&T Company. 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. About 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 estate, 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 & colleges, community centers, 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 is 180 km from Vapi; whereas, the state capital Gandhinagar is 370 kms away. The district Head Quarter Expansion project Page 9 Organic Pigments

11 Valsad is 30 km from Vapi town. VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during The entire estate, which was developed in phases, is now spread over 1140 hectares 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 Estate 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 estate. Being a major industrial & commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc. PIDILITE INDUSTRIES LIMITED, whose inception dates back to 1959, has been a pioneer in consumer and specialties chemicals in India. Over two-third of the company s turn over comes from products and segments it has pioneered in India. Our product range includes Adhesives and Sealants, Construction and Paint Chemicals, Automotive Chemicals, Art Materials, Industrial Adhesives, Industrial and Textile Resins and Organic Pigments and Preparations. Most of the products have been developed through strong in-house R&D. The Group's turnover is about 4283 Crores for the year In a recent report by Economic Times, Pidilite ranked 131st amongst the top 500 listed companies in India. Pidilite Industries is the market leader in adhesives and sealants, construction chemicals, hobby colours and polymer emulsions in India. Our brand name Fevicol has become synonymous with adhesives to millions in India and is ranked amongst the most trusted brands in India. Pidilite is also growing it's International presence through acquisitions and setting up manufacturing facilities and sales offices in important regions around the world. Fevicol is now the largest selling adhesives brand in Asia. We have reached where we are today mainly due to the close team-work of our employees and due to our shared value system which emphasizes commitment to excellence, closeness to customers, and the spirit of innovation. The management is concerned about Environment and Safety issues and gives utmost importance to these aspects by continuous training & improvement followed by various external Audits. Company is ISO9001:2000, IS :2004 and OHSAS 18001:2007 certified. We have a strong R&D team which guides us from its Mumbai Centre. We have a small Pilot plant at this site to support the R & D activities which is supported by Mumbai Expansion project Page 10 Organic Pigments

12 team. Award achieved by the company are as under : 2nd Prize for House Keeping Competition held by DISH under Nirmal Gujarat- District level competition (2006) 2nd Prize at the National level TPM poster competition organized by CII- TPM club of India (2006) 1st Prize for House Keeping Competition held by DISH under Nirmal Gujarat- District level competition (2007) 7 Prizes for State level Safety Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2008) 1st Prize for State level Road Safety Poster Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2009) 2nd Prize for State level Road Safety Poster Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2010) The unit has experienced technocrats having more than 35 years of experience in manufacturing and marketing of Organic pigments & chemicals. The company has prepared well equipped production plan which will be managed by dedicated, qualified & skilled persons. (i) Identification of the project proponent : M/S Pidilite industry Limited is a large scale unit is located at notified industrial estate, GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer & marketer of Organic pigments & chemicals especially used in paints, inks industries as per requirement. List of Directors : Shri M.B.Parekh Chairman & Managing Director Shri N.K.Parekh Jt. Managing Director Shri A.B.Parekh Whole time Director Shri A.N.Parekh Whole time Director Shri R. Sreeram Whole time Director All the Board Members are well qualified in Engineering, Management, Accounts, operations and Marketing field. Apart from these there are Expert from Field- Industries, Financial Institues and others as a Part time / Independent Directors on Board for Better Management, They are : Shri Uday Khanna Shri N.J.Jhaveri Shri Bansi Mehta Shri Ranjan Kapur Shri Yash Mahajan Expansion project Page 11 Organic Pigments

13 Shri Bharat Puri Shri Sanjeev Agha Smt. Meera Shankar They help us to achieve & perform better & better. ii) Brief description of nature of the Project : proposes to enhance the production capacity at Plot No. 23, 1 st phase, GIDC, Vapi , Dist.- Valsad (Gujarat). The proposed expansion project involves the capacity enhancement of existing Products viz. Organic Pigments ( Azo Pigments), Quinacridone Pigments & Pigment Emulsions As per the amended EIA notification- 2006, the proposed products are covered under category 5(f)- A 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 Organic Pigments & Pigment Emulsions. The project would also help the company to support the Indian economy in the following way: Growth in Export Revenue and there by increasing the inflow of foreign currency which is much needed by our country. Our products are well accepted by international users and can substitute the international Pigment Grades. Thus the Domestic Industry can replace the imported Pigments used by them with ours and there by curtail the outflow of foreign currency spent on pigments 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 RM Suppliers, Transporters, contractors, clearing and forwarding agents and other allied suppliers. Additional Production capacities are required in Azo, Quinacridone, & Pigment Emulsion as the company expects growth of Exports to the tune of 40-50% in the next 2-3 years. Also the Domestic market is showing Strong Growth Potential as many multinational companies which use pigments as raw material have put up their manufacturing plants in India. Added to this Indian users of Pigments have expanded their own manufacturing capacities to cater to the growing demand of their finished products. The Company Objective is to achieve : Consolidation of Organic Pigments & Pigment Emulsions 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. Expansion project Page 12 Organic Pigments

14 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 Pigment business, the proposed increase in capacity will also help the company to standardize and produce the Pigments 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 : Our Organic Pigments & Pigment Emulsions are mainly used by various paint, ink, plastic master batch & textile industries. Though the Global production capacity of Organic Pigments is on the higher side as compared to demand, Customer preference of environment friendly products and high performance Pigment is still not fulfilled satisfactorily. Since our products are approved by quality conscious users which are multinational paint, ink and textile companies. We can cater to the ever increasing demand in India as well as in the Export Market. ORGANIC PIGMENTS ( AZO PIGMENTS ) Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK, Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia, Indonesia, Australia, China,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey, Singapore,Uruguay Potential customers: USA, U.K., France, Italy, switzerland, Holland, Belgium, Luxembourg, Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE etc. New customers in existing countries Brazil, USA, Australia, Denmark, Italy, Finland, UK, Holland, France,Belgium, Japan, Philippines,Malaysia, Thailand, Indonesia,Turkey etc. Projected Export demand : USA, Canada & Latin America-1845 MT/Year, Europe 2475 MT/Year, Japan MT/Year, Rest of the World (excluding China) 224 MT/Year. Currently we are exporting about MT/Year of AZO class Organic Pigment powder. We expect to acquire 10-15% of the projected export demand. Domestic market for our range of organic pigments is about 900 MT/Year and our market share is about 25%. Market is expected to grow by 20%. QUINACRIDONE PIGMENTS : Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK, Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia, Indonesia, Australia, China,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey, Expansion project Page 13 Organic Pigments

15 Singapore,Uruguay. Potential customers: USA, U.K., France, Italy, Switzerland, Holland, Belgium, Luxembourg, Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE etc. New customers in existing countries Brazil, USA, Australia, Denmark, Italy, Finland, UK, Holland, France,Belgium, Japan, Philippines, Malaysia, Thailand, Indonesia, Turkey etc. Projected Export demand: USA, Canada & Latin America-1000 MT/Year, Europe 500 MT/Year, Japan -335 MT/Year, Rest of the World (excluding China) 400 MT/Year. Currently we are exporting about 170 MT/Year of QUINACRIDONE class Organic Pigment powder. We expect to acquire 10-15% of the projected export demand. Domestic market for our range of organic pigments is about 300 MT/Year and our market share is about 25%. Market is expected to grow by 20%. EMULSION: Current Export to: Bangladesh, Vietnam, Srilanka, Thailand, Phllipens, China, Hongkong, Mauratitus. Potential markets in : Pakistan, Indonesia, Ethiopia, Kenya, Malavi. New customers in existing countries Vietnam, Bangladesh, Thailand, Phillipens, USA, Projected demand : USA-2000 MT/year, Bangladesh MT/year, Pakistan-3000 Mt/yr, Thailand-1500 MT/Year, Vietnam-1000 MT/Year, Phillipens-1200 MT/Year, Mauratious- 500 MT/Year, Srilanka 800 MT/Year, African countries 1800 MT/year. Domestic market Potential-7000 MT/Year. It is expected to 20% per annum. Our current market share is about 40% of the domestic market. We expect to grow by %. v) Imports 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 & above the unit s existing capacities, as the company expects strong growth of exports to the extent of 40-50%. Local market Expansion project Page 14 Organic Pigments

16 also shows strong growth potential. vii) Domestic / export Markets: The company s products are used in various in paint & ink industries as per requirement. These are having very good demand in domestic as well as international markets. 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 20 people to fulfil it s need to handle the plant. So that 20 people will be directly employed and more than 50 will be indirectly employed. Expansion project Page 15 Organic Pigments

17 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) (iii) 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 attached as Annexure-2. 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-8) (iv) Size or magnitude of operation : As per the proposed project cost, the project is covered under large Scale category of manufacturing industries. (v) (vi) 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-3 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 & characteristics of hazardous chemicals are as below: DETAILS ON PRODUCT TRANSPORTATION Sr. No. Product Physical State Dispatch Means of transportation Solid Local /export Truck/container 1 Carbazole Dioxane Violet Pigment (Pigment Violet 23) 2 Organic Azo Pigment (Orange/Yellow/Red) Solid Local/export Truck/container 3 Pigment emulsion Paste Local /export Truck/container 4 Quinacridone Pigment Solid Local /export Truck/container Expansion project Page 16 Organic Pigments

18 5 Phosphoric acid Liquid Local/export Truck/container 6 Calcium Sulphate (Gypsum) Solid Local Truck Sr. No. Substance DETAILS OF RAW MATERIAL TRANSPORTATION Physical State 1 Carbazole Solid (Powder) Type of packing & supply 25 Kgs & 400 Kgs Means of Transportati on Sea & Road Distance of supplier from project site (km) Imported & 350 Kms Local 2 Diethyl sulphate Liquid Tanker Road 300 Kms 3 Caustic flakes SOLID (Flakes) 50 Kg Bags Road 250 Kms 4 Mono Chloro Benzene (Fresh) Liquid Tanker Road 200 Kms 5 Nitric acid Liquid Tanker Road 200 Kms 6 ODCB (Fresh) Liquid Tanker Road 5 kms 7 Catalyst Liquid Drums Road 250 Kms 8 Nitrogen Liquid Cylinder Road 40 Kms 9 Hydrogen Liquid Cylinder Bank 10 Chloranil Powder 50 Kg Bag 11 Catalyst RAC Powder 50 Kg 12 Benzene sulpho chloride Liquid Bag 250 Kg Drums Road Road Road Road 200 Kms 400 Kms 5 Kms 150 Kms 13 Salt Powder 50 Kg Road 350 Kms Bag 14 Di ethyl Glycol Liquid Tanker Road 200 Kms 15 Base (Amine) Powder 25 Kg Road 500 Kms Bag 16 Ice Solid - - Self Manufactured 17 Sulphamic acid Solid (Powder) 50 Kg Bag Road 200 Kms 18 Sodium nitrite Solid (Powder) 50 Kg Bag Road 300 Kms Expansion project Page 17 Organic Pigments

19 Sr. No. Substance 19 Hydro Chloric Acid (30%) Physical State Type of packing & supply Means of Transportation Distance of supplier from project site (km) Liquid Tanker Road 300 Kms 20 Caustic Lye Liquid Tanker Road 300 Kms 21 Acetic acid Liquid Tanker Road 200 Kms 22 Xylene (Fresh) Liquid 200 Kg Road 250 Kms Drums 23 Sulphuric acid Liquid Tanker Road 5 Kms 24 Emulsifier Liquid 50 Kg Drum 25 Carbon black Solid 25 Kg pigment (Powder) Bag Road Road 20 Kms 5 Kms 26 Surface active agent SOLID (Powder) 30 Kg Bag Road 300 Kms 27 Glycols Liquid Tanker Road 300 Kms 28 Preservative Liquid 50 Kg Road 400 Kms carboy 29 Aniline Liquid Tanker Road 200 Kms 30 DMSS Solid (Powder) 100 Kg Drum Sea + road Imported 31 Para Toludine Solid 210 Kg Sea + Road Imported Drum 32 Methanol (Fresh) Liquid Tanker Road 300 Kms 33 Resist salt Solid (Powder) 50 Kg Bag Road 5 Kms 34 Caustic flakes Solid (Powder) 50 Kg Bag Road 250 Kms 35 PPA or P 2 O 5 Liquid/ Solid 300 Kg Drum Road +Sea 25 Kms & Imported 36 Iso Butanol (fresh) Liquid Tanker Road 300 Kms Expansion project Page 18 Organic Pigments

20 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 reused in the manufacturing of Pigment Violet, Quinacridone & Azo pigments. Details of solvent use & recovery are as under. Wash water is also recycled in process as shown in the process flow diagram. PRODUCT WISE SOLVENT USED/RECOVERED PER TONE OF PRODUCT FOR EXISTING & PROPOSED EXPANSION Sr. No. Product Solvent used Quantity ton /tone Loss per MT Quantity ton /month Fresh Recycle Fresh Recycle Loss, MT/ Month 1 Quinacridone Methanol Iso Butanol DMF Carbazole MCB ODCB Methanol Azo Pigment Xylene Total Expansion project Page 19 Organic Pigments

21 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 withdrawal Permission is attached as Annexure: 4 Sr. No. Particulars Water consumption, m3/day Existing Proposed Total after expansion 1 Domestic Processing & washing 3 Boiler Cooling Floor/container washing 6 Gardening Total WATER CONSUMPTION (m 3 /DAY) ENERGY REQUIREMENTS AND ITS SOURCE Expansion project Page 20 Organic Pigments

22 Sr. No. Particulars 1 Steam requirement Existing Kgs/hr After Proposed expansion Kgs/Hr Source Will be obtained by installation of Briquette Fired Boiler having Steam generation capacity of 12 TPH.Existing 8 TPH will be standby. Sr. No. POWER REQUIREMENTS AND ITS SOURCE Particulars Existing After Proposed expansion 1 Power Electricity requirement Source 1600 KVA 1900 KVA Sourced from Dakshin Gujarat Vij Co. Ltd. (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-5. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representation of the feasibility drawing is enclosed as Annexure -9. Expansion project Page 21 Organic Pigments

23 4 Site Analysis (i) Connectivity : The project is located in notified Industrial Estate of Vapi which is very well connected to National Highway no.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-7. (iv) 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-8 (v) Existing Infrastructure : GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system. (vi) Soil classification : General soil classification of the area is as under : Soil Characteristics & 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 3 km distance from the site location; both side of the river has mixed soil type (Sand, clay & 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 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 Expansion project Page 22 Organic Pigments

24 observed and predicted rainfall was then analyzed for its validity. Rainfall projection for Project site and Gujarat for 2011 (June-Oct.) Sr. No Region Rainfall Projection (in mm) June - Oct Normal Rainfall (In mm) Rainfall Projection (% Departure from normal) 1 Middle Gujarat South Gujarat Project site Saurashtra Gujarat State Source: AAU, Anand, Gujarat 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). (viii) 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 & 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 offers 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 centers in India offering Uterine Thermochoice Thermal Balloon Therapy for 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 Expansion project Page 23 Organic Pigments

25 Valsad with Daman & Diu, which has increased the graph of tourist flow in the district. 5. Planning Brief : Not 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. Population Projection : applicable 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 33% green belt of the total land, i.e sq. meter. 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: 1. Climatic condition and soil characteristics of the region. 2. 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. 3. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles. 4. Height of the plants should not be too high to be lethal. 5. For absorbance of gases, the duration of the foliage should be longer. 6. 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 Page 24 Organic Pigments

26 Site Plan with Area Table at Existing & After proposed expansion Sr. No Particulars Area in m 2 Existing Proposed Total after expansion 1.0 Total plot Area Production Plant Office & lab area OHC Area Green Belt Raw materials & other Storage Solvent storage area Utility Boiler shed area ETP & solid waste storage area Toilet block Open space Site map with Green Belt Development Planning Expansion project Page 25 Organic Pigments

27 (iv) Assessment of Infrastructure demand ( Physical & Social) : There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion. (v) 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 : Industrial liquid effluent generated after proposed expansion will be treated in the primary & secondary ETP and will be discharged through GIDC underground drainage to CETP.(Membership certificate is attached as Annexure-6) Generated domestic liquid waste is being disposed off through soak pit system to drainage. Expansion project Page 26 Organic Pigments

28 Sr. No. (ix) Solid/Hazardous Waste Management : Type of Quantity, TPM hazardous waste Cat egor y Existing After proposed expansion Storage Capacity, m2 Disposal 1 ETP waste Dispose off into TSDF, Vapi 2 Used oil Sell to Registered recyclers 3 Discarded containers 4 Distillation Residue ReUse for packing finished product or Sell to Autho. recycler Sell to cement industries for coprocessing. 5 Iron Sludge Spent catalyst Sent for reprocessing (Membership certificate is attached as Annexure-6) (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 laborers (a brief outline to be given): There will be no rehabilitation and resettlement undertaken as labours and workers from local & 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 Page 27 Organic Pigments

29 8. Project Schedule & Cost Estimates : (i) (ii) 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 construction and commissioning of the project. 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. Expansion project Page 28 Organic Pigments

30 CAPITAL COST PROJECTION Cost in INR (Crore) Sr. Particulars Existing Proposed Total No. 1.0 Land m Building Plant & Machinery 3.1 Equipment & machineries Pipes & fittings Utilities Environmental Management System 5.0 Total Project Cost Utilities 6.1 Boiler, TPH (8 - Standby) Thermopack, k cal/hr Cooling Tower, TR D.G. Set (Standby) 0 750, 750, , 750, Power from DGVCL, KVA Fuel 8.1 Briquette /Natural Gas for Steam Boiler (12 Tons/Hr) 8.2 Natural gas for Thermopak (10 lacs & 4 lacs) 8.3 Natural gas for steam boiler (8 TPH & 2 TPH) 8.4 Fuel (HSD) for D.G.Set (Capacity: 750 x 2 & 125 KVA) 9.0 Water from GIDC Vapi kl/day 10.0 Waste Water (Industrial) kl/day 1.45 MT/Hr of Briquette or 410 SCM/Hr MT/Hr Briquette or 180 SCM/Hr MT/Hr Briquette or 590 SCM/Hr 2000 SCM/day SCM/day 8750 SCM/day SCM/day kgs/hr 225 kgs/hr Expansion project Page 29 Organic Pigments

31 PROJECT VIABILITY Sr. PARTICULARS AMOUNT (INR Crore) No. 1 Proposed Sale Raw Material Cost Power & Fuel 34 4 Labour Cost 15 5 Environmental Management System Maintenance Cost 15 7 Selling, packing & Office Expenses 15 8 Proposed Profit 23 The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning. RECURRING COST PER ANNUM Sr. No. Component 1. Environment & Safety Management System Greenbelt Maintenance Solid waste Disposal 70 Total 150 Proposed (Rs. in Lacs/annum) 8. Analysis of Proposal ( Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, 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 Page 30 Organic Pigments

32 ANNEXURES Expansion project Page 31 Organic Pigments

33 ANNEXURE: 1 Location map showing the Project site and inter-state boundary within 10 kms radius Expansion project Page 32 Organic Pigments

34 ANNEXURE: 2 Plant Layout Expansion project Page 33 Organic Pigments

35 ANNEXURE: 3 Detailed project description with process details - 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 IN BRIEF Azo Pigments (Organic Yellow/Orange/Red): (a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c. Solution is maintained at this temp. (b) Coupler Dissolution : Water, Caustic Lye & Coupler is taken in stirred vessel. This mixture is heated to required temp. to make uniform solution. And cooled back to room temp. (c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution. Take out the wet cake. Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material Balance is enclosed. Quinacridone Pigment (PR-122 /PV-19) : In PR-122 Manufacture,P- Toludine is condensed with Dimethyl Succino succinate to form a DTA. It is further oxidised with Resist Salt to form Quinacridone Molecule. This is further cyclised to get the required Molecule in presence of Poly Phosphoric Acid. Finally the Pigmentation is done in presence of IBA / DMF as per the Quinacridone, PR-122 OR PV-19. Detailed Reaction, Flow Diagram as well as Material Balance is enclosed. In PV-19, in place of P-Toludine, Aniline is used. Carbazole Dioxane Violet Pigment: Manufacturing Process is carried out in 5 Stages as per the attched sheet. Carbazole is a Main Raw Material. In First Step, Carbazole Alkylation is carried out with Diethyl Sulfate. Salt is separated by Addition of Caustic Flakes. Impurities are washed with MCB and water. In second Step, Resultant Ethyl Carbazole is Nitrated with 65% Nitirc Acid to form Nitro Ethyl Carbazole. This Nitro Ethyl Carbazole is reduced with Hydrogen to form Amino Ethyl Carbazole in third Step. Further it is condensed with Choranil and subsequently cyclised to form Crude Violet. Till this it is Synthesis Process. In Final Step Crude Violet, Pigmentation is done by various Methods to make Pigment Violet. There are lot of Physical changes done to get Pigmentation Properties. Detail Flow Diagram as well as Material Balance is also enclosed. Pigment Emulsions: There are No chemical reaction involved in Pigment Emulsion process. There are only Unit Operations of Kneading, Pulverising, Milling etc in Emulsion /Dispersion preparations. Pigments are dispersed in Water to make it compatible for end use. To make it dispersible it is milled and surface Active Agents, Glycols, Preservative and Other Auxiliaries, additives are added in water to make the dispersion stable. Expansion project Page 34 Organic Pigments

36 ( 1 ) Organic Yellow Pigment CHEMICAL REACTION Cl NH 2 NH 2 Cl HCl NaNO 2 Cl N=N Cl Cl N=N Cl + 2 NaCl + 4 H 2O 3 3 Dichlorobenzidine Mol.wt. 253 Diazo Cl Cl Cl N=N N=N Cl + 2CH 3 COCH 2 CONHC 6 H NaOH AcetoAcetanilide Mol. Wt. 177 Cl Cl CH 3 COCH 2 CONHC 6 H 4 -N=N N=N-C 6 H 4 NHCOCH 2 COCH NaCl + 2 H 2 O Yellow pigment Mol. Wt. 618 Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG Expansion project Page 35 Organic Pigments

37 Water: 4000 Kgs Base (Amine) : 405 kgs Ice: 6000 kgs Sulphamic acid: 9 kgs Na Nitrite: 690 kgs HCl: 960 kgs Total: kgs Ice: 6000 kgs Acetic Acid & Others: 285 kgs Diazotization + Dissolution kgs Live steam: 4000 kgs Total: kgs ORGANIC YELLOW PIGMENT DIAZOTIZATION Crude Pigment Slurry: kgs Total: kgs Wet cake: 3400 kgs Water: kgs Fresh Kgs Recycle Total: kgs Xylene: 11 kgs Fresh 539 Kgs Recycle Water:1140 kgs Wet cake: 3500 kgs Total: 5190 kgs Kgs kgs Hours: 1 ½+11/2=3hr Water: Wet cake: 3500 kgs COUPLING & TREATMENT kgs, Time: 6 Hrs FILTERATION kgs, Time: 3 Hrs WASHING, kgs, Time: 6Hrs SOLVENT TREATMENT, 12 HRS FILTERATION & WASHING TRAY DRYING ( 24 Hrs) 3500 kgs DISSOLUTION 3990 Kgs Hours: ½ hr Water: 3000 lits Coupler : 640 kgs Caustic: 350 kgs Filtrate as effluent: kgs to ETP Wet cake: 3400 kgs Total: 26339kgs Filtrate (10000 (recycle) kgs to ETP Wet cake: 3500 kgs Water Vapors: 2498 kgs Total: 3990 kgs Crude Pigment Slurry: kgs Total : kgs Total: kgs Wet cake: 3500 kgs Effluent:26000 kgs Water + Xylene: 1690 kgs Distillation Dry Powder: 1002 kgs Xylene recovered: Loss: 11 kg + Effluent: 1140 Dry Powder: 1002 kgs PULVERIZER & PACKING (Time: 6 Hrs) ORGANIC YELLOW PIGMENT: 1000 kgs Expansion project Page 36 Organic Pigments

38 [2] Organic Orange Pigment Cl NH 2 NH 2 Cl HCl NaNO 2 Cl N=N Cl Cl N=NCl + 2 NaCl + 2 H 2 O Cl N=N Cl 3 3 dichlorobenzidine Mol wt. 253 Cl CH 2 O = C N=NCl + 2 N C N CH NaOH PMP Mol wt. 173 Cl Cl CH 3 CH N N CH-N=N C=O N=N- CH O=C N CH-CH 3 N + 2 NaCl + 2 H 2 O Base like: DCB, Coupler like PMP, MPMP Orange 13 pigment Mol.wt. 610 Expansion project Page 37 Organic Pigments

39 Water: 2600 Kgs Base (Amine) : 405 kgs Ice: 5000 kgs Sulphamic acid: 7 kgs Na Nitrite: 240 kgs HCl: 1080 kgs Total: 9332 kgs Ice: 4000 kgs Emulsifier & Others: 20 kgs Diazotization + Dissolution kgs Live steam: 4000 kgs Total: kgs ORGANIC ORANGE PIGMENT DIAZOTIZATION Crude Pigment Slurry: kgs Total: kgs Wet cake: 3400 kgs Water: kgs Fresh Kgs Recycle Total: kgs Xylene: 11 kgs Fresh 539 Kgs Recycle Water:1500 kgs Wet cake: 3500 kgs Total: 5550 kgs 9332 Kgs kgs Hours: 1 ½+11/2=3hr Water: Wet cake: 3500 kgs COUPLING & TREATMENT kgs, Time: 6 Hrs FILTERATION kgs, Time: 3 Hrs WASHING, kgs, Time: 6Hrs SOLVENT TREATMENT, 12 HRS FILTERATION & WASHING TRAY DRYING ( 24 Hrs) 3500 kgs DISSOLUTION 5800 Kgs Hours: ½ hr Water: 4900 lits Coupler : 580 kgs Caustic: 320 kgs Filtrate as effluent: kgs to ETP Wet cake: 3400 kgs Total: kgs Filtrate (10000 (recycle) kgs to ETP Wet cake: 3500 kgs Water Vapors: 2498 kgs Total: 5800 kgs Crude Pigment Slurry: kgs Total : kgs Total: kgs Wet cake: 3500 kgs Effluent:28800 kgs Water + Xylene: 2050 kgs Distillation Dry Powder: 1002 kgs Xylene recovered: Loss: 11 kg + Effluent: 1500 Dry Powder: 1002 kgs PULVERIZER & PACKING (Time: 6 Hrs) ORGANIC YELLOW PIGMENT: 1000 kgs Expansion project Page 38 Organic Pigments

40 [3] Organic Red 2 Pigment Cl NH 2 Cl N=NCl HCl NaNO 2 + Cl 2H 2 O + NaCL Cl N=NCl Cl 2:5 Dichloro Aniline Mol Wt O NH OH Diazo C 17 H 12 NO 2 ( Naphthol AS) Mol wt.263 O Cl OH C NH N=N Cl Base like: TCA, DCA, Scarlet G base, Coupler like Naphols Organic Red 2 Pigment Mol wt. 436 Expansion project Page 39 Organic Pigments

41 (3) ORGANIC RED PIGMENT (TOTAL TIME: 48.5Hrs) Water: 1500 lits Base: 432 kgs Ice: 6000 kgs Sulphamic acid: 25 kgs Na Nitrite: 200 kgs H2SO4: 3000kgs Total: kgs DIAZOTIZATION Kgs kgs Hours: 6 hrs DISSOLUTION Kgs Hours: 1 hr Water: 6000 lits Coupler: 590 kgs Caustic: 650 kgs Steam: 1000 kgs Ice: 6000 kgs Total: kgs Diazotization + Dissolution:25397 kgs Ice :3000kgs Live steam: 3000kgs HCL: 1000 kgs Total: kgs COUPLING kgs, Time: 10 Hrs Coupler: kgs Total: kgs Coupler: kgs Total: kgs Wet cake: 5000 kgs Water: liters Total: kgs FILTERATION kgs, Time: 3 Hrs WASHING, kgs Time: 6Hrs Filtrate as effluent: kgs to ETP Wet cake: 5000 kgs Total: 32397kgs Filtrate as effluent: kgs to ETP Wet cake: 5000 kgs Total: kgs Wet cake: 5000 kgs Total: 5000 kgs Dry Powder: 1030 kgs TRAY DRYING ( 24 Hrs) 5000 kgs PULVERIZER & PACKING (Time: 6 Hrs) Water Vapours: 3970 kgs Dry Powder: 1030 kgs Total: 5000 kgs PRODUCT (ORGANIC RED PIGMENT: 1030 kgs ) Expansion project Page 40 Organic Pigments

42 (4) Quinacridone Pigment CH 3 OOC CH 3 HO H H H H OH Dimethyl succinosuccinate C 10 H 12 O 6 MW: 228 CH3OOC COOCH 3 H N + NH 2 2 -H 2 O CH 3 P-Methyl Aniline MW: 2 x 107 H + CH 3 HOOC H H 3 COO N H H H N H H N Oxidation COOCH3 CH 3 H MW: 406 PPA(Polyphosphoric Acid) Cyclisation N COOCH3 CH3 N COOH CH 3 H MW: 376 H Step B C 24 H 24 O 4 N 2 MW: 404 O H CH 3 O H N N O H Step C C 22 H 16 N 2 O 2 MW: 340 CH 3 Reflux with Solvent IBA N CH 3 N O H Pigment Red 122 Step D P.R.122 MW: 340 2, 9 Dimethyl Quinacridone QUINACRIDONE PIGMENT (PIGMENT RED 122) STEP: I (CONDENSATION) Aniline: 50 kgs DMSS 825 KGS Para Toludine 880 KGS HCl (30%) 100 KGS Methanol 5757 KGS (Recovered From Step II: 5239 kgs Fresh 518 kgs ) ( Reactor ) CONDENSATION 9612 For step-b 2,5 diarylamino -3,6- dihydrotere phthalate 9612 Kg Water: 2000 Expansion project Page 41 Organic Pigments

43 From Step: I :(9612 kgs) Resist Salt (800 Kgs) Caustic Flakes (650 Kgs) STEP: II (OXIDATION) ( Reactor ) OXIDATION Recycled in Step: I Recovered Methanol (5239 kgs) Water: (KGS) 30% HCl (2200 kgs) Precipitation Filtration / Centrifuge Filtrate: kgs Methanol: 5757kg 30%HCI :2300 kg Water: 5000 lit Organic impurities :422Kg Caustic:650Kg Aques laye 8468 kg Water: kgs Washing Residue 422 Kg Wet cake: 3808 kgs Dryer Wash water: lit Vapour loss: 2475 kgs Di toludinoterephthalic acid: 1333 Kg STEP: III (CYCLIZATION) From Step:II : 1333 kgs PPA: 5000 kgs OR (Phospheric Acid Kgs+ P2o Kgs) Water: KGS Water: KGS REACTOR FILTERATION WASHING Wet cake: 6043 kgs Phosphoric acid (10 30%) recovered as by product : kgs Filtrate: kgs PPA: 30 kg Organics impurities: 125 kgs Water: kgs Expansion project Page 42 Organic Pigments

44 STEP: IV (PIGMENTATION) Wet Crude Pigment Red: 6043 kgs Iso-Butanol: 5000 kgs Fresh: 200 kgs Recovered: 4800 kgs Water: KGS REACTOR Recovered IBA: 4800 kgs Caustic lye: 40 kgs Water: KGS WASHING & FILTERATION Wet cake: 5833 kgs Filtrate: kgs IBA: 200 kgs Water: kgs Impurities: 42 kgs Caustic lye: 40 kgs Dryer Vapour loss: 4666 kgs Quinacridone Pigment (Pigment Red 122): 1167 kgs In Pigment Violet 19 ( Quinacridone) : 1. In First Condensation Stage Aniline is used in place of ParaToludiene. 2. In Final Pigmentation Stage DMF is used as Solvent in place of IBA Kg is used, we are distilling DMF and Recovery is 8721 Kgs Kgs residue is generated after Distillation. Expansion project Page 43 Organic Pigments

45 (5) Carbazole Dioxane Violet Pigment (Pigment Violet 23) H 3 C H N DES, MCB H 2 N HNO 3 N Carbazole C 12 H 9 N MW: 167 Alkylation (C 2 H 5 O) 2 SO 2 MW: 154 N ethyl carbazole C 14 H 13 N MW: Nitro 9 ethyl carbazole N 2+ OO C 14 H 12 N 2 O 2 MW: 240 Hydrogenation N N N O Cl Cl O N N Cl O Cl Cl O Cl + Benzene Sulpho Chloride + NH 2 3 Amino N Ethyl Carbazole Pigment Violet - 23 MW: 589 Chloranil MW: 246 MW: C 14 H 12 N 2 H 2 MW: 210 Expansion project Page 44 Organic Pigments

46 Carbazole Dioxane Violet Pigment (Pigment Violet 23) STEP: I (N-Ethyl Carbazole) Carbazole 800 Diethylsulfate 720 NaOH flkes 430 ALKYLATION, 4350 kgs Monochlorobenzene (recovered & recycle: 2182 kgs DISTILLATION RESIDUE (624) Incineration Monochlorobenzene 2400 Recovered 2182 Fresh 218 DISTILLATION (MCB Loss: 48 Kgs) Waste water: 1278 Water: kgs FILTRATION Kgs Layer Separation: kgs MCB + Water: 4132 kgs N-ETHYLCARBAZOLE : 890 Kgs FILTRATE to ETP:27328 kgs Water:27313 Organic: 10 Caustic: 5 Expansion project Page 45 Organic Pigments

47 STEP: II (3- Nitro-N- Ethyl Carbazole) N-Ethylcarbazole (890) Monochlorobenzene (760) Recovered 690 Fresh 70 Nitric acid (825) Water: kgs NITRATION SS Reactor, 2475 kgs LAYER SEPARATION SOLVENT LAYER (1770) FILTRATION & WASHING ACID LAYER (To ETP) (705) Nitric acid (42) Water (662.5) Organics: 0.5 FILTRATE (50690) Water:49857 N-Ethyl carbazole (22.5 ) + Monochlorobenzene (810) Effluent: kgs Wet cake 3-NITRO-N- ETHYL CARBAZOLE (1130) DISTILLATION Monochlorobenzene (recovered) (690) N ethyl carbazole or impurities 2.5 Residue (40 kgs) Incinerator STEP: III (3- Amino-N- Ethyl Carbazole) 3-Nitro-N-ethylcarbazole(1130) ( Water) O-Dichlorobenzene (7260) Recovered 6944 Fresh 316 Catalyst: 6.7 kgs N 2 : 70 kgs H 2 : 35 kgs REDUCTION, kgs Reprocessing & recycle Spent Catalyst: 6.7 kgs Water of reaction: 314 kgs to ETP ( ) N 2 loss : 70 kgs H 2 loss : 19.3 kgs Solvent loss: 146 kgs ORGANIC LAYER SEPARATION PARTIAL DISTILLATION o-dichlorobenzene (recovered)(380) FILTRATION DISTILLATION o-dichlorobenzene (recovered) (6564) Amino carbazole AMINO CARBAZOLE : 775 ODCB : 150 TOTAL : 925 Distillation residue ( 65) (as solid waste) CHWIF Expansion project Page 46 Organic Pigments

48 STEP: IV (Crude Pigment Violet 23) 3-Amino-N-ethyl carbazole 775 kgs ODCB: 150 Kgs Chloranil (462) CONDENSATION & CYCLISATION o-dichlorobenzene(recovered) (8780) ODCB Loss : 180 Kgs o-dichlorobenzene (9300) Recovered 8780 Fresh 520 Catalyst RAC (190) MSGL Temp. 160 O C Distillation residue (640) CHWIF Benzene sulfochloride (330) Water (56000) FILTRATION Filtrate (to ETP) (54010) Sodium Chloride (172) Organics (424) Other Salt (112) Water (53302) ETP DRYING Drying loss: 2700 kgs PIGMENT VIOLET 23 CRUDE: 897 STEP: V (Pigmentation) Crude Violet pigment 23: 897 kgs Salt: 7740 kgs GRINDING Di-ethyl Glycol: 145 kgs Water: kg Mixing & Washing Filtrate: kgs (Salt: 7740 kgs + DEG 145 kgs) + water: kgs Drying Drying loss: 2500 kgs Pigment Violet-23: 888 Kg Expansion project Page 47 Organic Pigments

49 Pigment Black Dispersions Premix (1) Carbon Black Pigment (105) (2) Surface active agent (15) (3) Glycols (20) (4) Preservative (10) (5) Water(850) Grinding Packing(1000 Kgs) Expansion project Page 48 Organic Pigments

50 ANNEXURE: 4 Water requirement letter from Notified industrial estate: Expansion project Page 49 Organic Pigments

51 ANNEXURE: 5 Quantity of Waste Water (liquid waste) generation and its management : Sr. No. Particulars Effluent generation, m3/day Existing Proposed Total after expansion 1 Domestic Processing & washing Boiler Cooling Floor/container washing Total Total Industrial The generated waste water will be treated in existing adequate effluent treatment plant (ETP). The details of the same is given on Next Page. We have reduced Water consumption and Effluent Generation Qty by following 3R Principle. (1) Final Wash water of Filter Press is recycled for Initial washings. (2) Use of Membrane Press in place of Ordinary Plate & Frame Filter Press (3) Pulse washing in Filter Press, where ever Plate & Frame Press is existing. (4) Increasing Batch Size in Same Volume there by reducing water Dilution. (5) Use of DM Water in place of Raw Water in Final Washings. (6) Use of treated Effluent in Water Jet Ejectors. Expansion project Page 50 Organic Pigments

52 Details of Effluent Treatment Plant Design Criteria : Product : Organic Pigments ( Azo, Quina & Violet ) + Pigment Emulsion Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 1369 KL/day Max. Design Parameters : As under Effluent Characteristics: No Effluent parameters Combined Effluent Process + washing Boiler + cooling Equip + floor + container washing/scrubber 1 ph Temperature 0 C Colour (Pt-Co) SS, mg/l TDS, mg/l COD value, mg/l BOD value, mg/l Chlorides, mg/l Sulphates, mg/l O & G, mg/l NH3-N, mg/l 20 ND Phosphates, mg/l 6.2 ND Phenolic, mg/l ND ND ND N.D. Expansion project Page 51 Organic Pigments

53 Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: No Name of the unit Existing Capacity MOC Detention time in hrs Adequacy, m3 Reqd Prov. 1 Oil/grease trap 2 RCC Adequate 2 Equalization cum neutralization tank (2 Nos.) 1586 RCC 8 27 Adequate 3 Flash mixer 2.7 RCC Adequate 4 Clarifloculator 339 RCC Adequate 5 Aeration tank (2 Nos.) 6 Secondary clarifier 7 Sludge thicker with agitator 8 Sludge mixing sump 3120 RCC Adequate 530 RCC Adequate 125 RCC Adequate 34 RCC Adequate 9 Filter press 48 PP - - Adequate 10 Lime slurry tank (3 Nos.) 11 Ferrous sulphate tank 72 RCC - - Adequate 8 RCC - - Adequate 12 Air blower (2 Nos) 13 Sludge pump (2 Nos.) 692 m3/hr 110 m3/hr CI - - Adequate CI - - Adequate 14 Effluent transfer pump (2 Nos.) 55 m3/hr CI - - Adequate Expansion project Page 52 Organic Pigments

54 EFFLUENT TREATMENT SCHEME FOR EFFLUENT The company has put up a full-scale elaborate effluent treatment plant with a total investment of nearly 2.5 crores. The plant occupies nearly 3200 M2 land area. The plant is designed by M/S. Environmental Engineering Consultants, Bombay, and has capacity of treating a maximum of 2200 M3/day effluent. Here the combined wastes from various plants are collected into two Equalization-cum- Neutralization Tanks, alternately, which are provided with aeration grids. The effluent is neutralized here with lime solution prepared in lime slurry tank situated in the chemical house. After neutralization, it is pumped into the Clarifloculator. Here ferrous sulphate solution is added. The solution of ferrous sulphate is made in the tank located in the Chemical House. The clear supernatant liquid from Clarifloculator goes to the Biodegradation aerator tanks, provided with 4 nos. aerators of 50 HP each. The overflow from the biodegradation tanks goes to the clarifier where after settling, the clear liquid overflows into the GIDC common drainage system. A Thickener is also provided for settling the calcium sulphate sludge. The treated waste water from GIDC common drainage goes to the CETP from where it is discharged to the river Daman Ganga (down stream) & finally meeting to Arebian Sea. The settled bio mass in clarifier is either recirculated to the aeration tank or filtered by membrane filter press. The sludge from bottom of the thickener is also taken to the Filter Press for dewatering. The effluent treatment plant is a separate unit by itself. The plant also has an elaborate Chemical House with complete provision of MCC room, Laboratory, Raw Material storage, Lime and Ferrous Sulphate Tanks. It also has provision of proper material movement with an electrical hoist. Separate KWH meter certified by Gujarat State Electricity Board ( DGVCL ) is provided to know the electrical consumption. Expansion project Page 53 Organic Pigments

55 Chemical House FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT Reuse of treated water for lime solution preparation Lime Solution Tanks 8 m 3 each L -1 L -2 L -3 F -1 Ferrous Solution Tanks : 8 m 3 P-3 From ETP E/N - 1 E/N - 2 Main Equalization cum Neutralization tank 793 m 3 P-1 B-1 Air Blower 692 m 3 /hr each B-2 Nutrients Urea & DAP Aeration Tank Clariflocuulator 1560 m 3 each 339 m 3 SA-1 SA-2 AT-1 Surface aerators P-4 PT PT-2 PT-3 P m 3 /hr each Overflow water to E/N tank Flash Mixer 2.7 m 3 Thickener 125 m 3 PT-4 AT-2 Diffuser b lowers 30 HP each Biomass recycle to aeration tanks P-5 Secondary 530 m 3 Water washing line Filter press P-11 Water Tank P-9 Excess biomass disposal 34 m 3 Sludge mixing P-7 P-6 PT-5 V-notch PT-6 P-10 P-8 Treated Water outlet to CETP Expansion project Page 54 Organic Pigments

56 ANNEXURE: 6 MEMBERSHIP CERTIFICATE OF CETP, VAPI Expansion project Page 55 Organic Pigments

57 MEMBERSHIP CERTIFICATE OF CHWIF Expansion project Page 56 Organic Pigments

58 Expansion project Page 57 Organic Pigments

59 Expansion project Page 58 Organic Pigments

60 ANNEXURE: 7 Expansion project Page 59 Organic Pigments

61 ANNEXURE: 8 Copy of plot allotment letter issued by GIDC Expansion project Page 60 Organic Pigments

62 COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA Expansion project Page 61 Organic Pigments

63 ANNEXURE: 9 A schematic representation of the feasibility drawing Expansion project Page 62 Organic Pigments

64 ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED EXPANSION At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers, one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare capacity to supply the steam for proposed expansion. The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA & 125 KVA capacities, as stand by. It will be used only during power failure. Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler. Adequate stack height and stack monitoring facilities is provided. Process gas emission: Presently the unit has installed Two no of multi cyclone separator followed by bag filter attached to pulveriser. After proposed expansion, the unit shall install one additional multi cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent will be provided The details of which are as under; Sr. Particulars Details Remarks No. Existing Proposed Total after expansion FLUE GAS EMISSION 1.0 Steam Boiler 8TPH 0 8 TPH Standby 1.1 Fuel used Natural Gas 0 Natural Gas 1.2 Fuel Consumption 7000 SCM/d SCM/d 1.3 APC Chimney 0 Chimney 1.4 Height & Dia of 30 meter/900 chimney mm 0 30 meter/900 mm 2.0 Steam boiler 2 TPH 0 2 TPH Standby 2.1 Fuel used Natural gas 0 Natural gas 2.2 Fuel Consumption 1750 SCM/day SCM/day 2.3 APC Chimney 0 Chimney 2.4 Height & Dia of chimney 30 meter/800 mm 0 30 meter/800 mm 3.0 Thermopak: I 10 lacs k cal 0 10 lacs k cal 3.1 Fuel used Natural gas 0 Natural gas 3.2 Fuel Consumption 1500 SCM/day SCM/day 3.3 APC Chimney 0 Chimney 3.4 Height & Dia of chimney 30 meter/450 mm 30 meter/450 mm No Change Expansion project Page 63 Organic Pigments

65 4.0 Thermopak:II 4 lacs k cal 0 4 lacs k cal No Change 4.1 Fuel used Natural gas 0 Natural gas 4.2 Fuel Consumption 500 SCM/day SCM/day 4.3 APC Chimney 0 Chimney 4.4 Height & Dia of chimney 30 meter/450 mm 0 30 meter/450 mm Common chimney with TP:I 5.0 Steam boiler 12 TPH 0 12 TPH Only 5.1 Fuel used Briquetes Briquetes Briquetes 5.2 Fuel Consumption 1.45 MT/Hr MT/Hr MT/Hr 5.3 APC MDC followed by bag filter & online SEMS - MDC followed by bag filter & online SEMS increase the operating hours & fuel 5.4 Height & Dia of chimney 30 meter/800 mm - 30 meter/800 mm 6.0 D G Set: I KVA 750 KVA Standby 6.1 Fuel used 0 HSD HSD 6.2 Fuel Consumption kgs/hr 100 kgs/hr 6.3 APC 0 Exhaust Exhaust 6.4 Height of exhaust 0 11 meters 11 meters 7.0 D G Set: II KVA 750 KVA Standby 7.1 Fuel used 0 HSD HSD 7.2 Fuel Consumption kgs/hr 100 kgs/hr 7.3 APC 0 Exhaust Exhaust 7.4 Height of exhaust 0 11 meters 11 meters 8.0 D G Set: III KVA 125 KVA Standby 8.1 Fuel used 0 HSD HSD 8.2 Fuel Consumption 0 25 kgs/hr 25 kgs/hr 8.3 APC 0 Exhaust Exhaust 8.4 Height of exhaust 0 11 meters 11 meters 9.0 Pulveriser Cyclone separator followed by Cyclone separator followed by bag Cyclone separator followed by Total three numbers Expansion project Page 64 Organic Pigments

66 bag filter filter bag filter 9.1 Height of vent 11 meters 11 meters 11 meter 9.2 Gases emission PM: < 150 mg/nm3 PM: < 150 mg/nm3 PM: < 150 mg/nm3 DETAILS OF AIR POLLUTION CONTROL SYSTEM ATTACHED TO BRIQUETTES FIRED BOILER 1. Boiler: kg of steam/hour. Briquettes consumption : 70 MT/day Calorific value : 4200 kcal/kg Inlet to dust collector : 280 C Stack temp : 180 C Diameter of chimney : 750mm Flue Gas Volume : 6107Am3/hr I.D. Fan : m3/hr Stack diameter : 850Ømm Stack height provided : 30 meters Efficiency : Thermal Efficiency of Boiler 82±2% 1.0 Air Pollution control System: Multi Cyclone Dust Collector (Grit Arrestor) Cyclone tube diameter : 2.5 Ø mm Height of tube : 2500 mm No of tubes : 4no Dia of tubes : 587Ø mm Dimensions : 2.5 m x 2.5 m x 9 m height Collection efficiency : 60-70% (over 40micron) Expected outlet dust load : 150 < mg/nm 3 at out let of bag filter Inlet Dust load : gms/nm 3 Density : 600kg/ m 3 Fines : (< 1 mm) 2.0 Air Pollution control System: Bag filter Size of Bag filter : 12 m x 10 m x 10 m MOC : Mild steel Size of Gas inlet : 400 X 1000 mm Size of gas out let : 850 Ømm Total unit weight : 4.1MT Hopper volume : 3.9m 3 Designed gas volume : Am 3 /hr Maximum designed temp. : C Number of filter bags : 96 Nos (500 gms/m2 filter glass) Size of filter bags : 160mm dia x 3600m length No. of cages : 96 Pressure drop : mm Air to cloth ratio : 1.01 m3/min/m2 Expansion project Page 65 Organic Pigments

67 Expected emission : PM: < 100 mg/nm3 : SOx: < 100 ppm : NOx: < 50 ppm Drying of Pigment: Details of Air pollution control measures attached to Pulveriser Drying of % pigment wet cake shall be carried out in tray dryers/spin flash dryer. The process heat is provided by Hot Oil Thermopak system based on natural gas. The Thermopak exhaust flue gas is connected to a chimney. Pulverization of pigments: This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This consists of following parts: Hopper feed box. Screw feeder. Closed grinder with box cyclone separator Bag filter. I.D. fan. Vent line. Rotary valve for outlet of product. The pulverized material is collected in bags, weighed and dispatched. The material collected from bag filter is also mixed with the final product. Thus this is a completely dry process and does not involve any consumption or discharge of effluent. There is no solid waste as even the floor spillage is collected and recycled. Expansion project Page 66 Organic Pigments

68 Expansion project Page 67 Organic Pigments