PROJECT PRE-FEASIBILITY REPORT

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1 PROJECT PRE-FEASIBILITY REPORT FOR EXPANSION OF DYES INTERMEDIATE UNIT [Schedule 5 (f) Category B as per EIA notification 2006 and its amendment thereof] At Plot No: 3101,3102, 3108, Phase IV, G.I.D.C, VAPI. Pin Code: Dist. Valsad, Gujarat Land/Plot Area: 10,058 m 2 Production Capacity: 155 TPM to TPM APPLICANT MICAS ORGANICS LIMITED (UNIT: II) Plot No: 3101,3102, 3108, Phase IV, G.I.D.C, VAPI. Pin Code: Dist. Valsad, Gujarat CONSULTANT ECO CHEM SALES & SERVICES Office Floor, Ashoka Pavilion - A New Civil Road, Surat, NABET/EIA/1720/RA eco@ecoshripad.com Tel No

2 Micas Organics Limited (Unit: II) 1.0 EXECUTIVE SUMMARY Name & Location Name of the Project: Location: Plot No: 3101,3102, 3108, phase IV, G.I.D.C,VAPI. Pin Code: Dist. - Valsad (Gujarat) Project M/S 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 as well introduce new similar group of products under the category Dyes intermediates Chemicals. Existing project cost is Rs Crore. Proposed expansion Project Cost: Rs Crore. Total cost after proposed expansion will be Rs Crore 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 Project Proponent The company in India comprises of 5 directors Large scale unit 1.1 LIST OF FINISHED PRODUCTS: S. Product No. 3,3 DCB (3,3 Di 1. Chloro Benzedine Di hydro Chloride) 4- B Acid (4- Amino 2. Toluene 3- Sulphonic acid) 2-B Acid (2 Chloro 3. 4-Amino Meta Sulphonic Acid) CLT Acid (2-4. Chloro 5 - Toludine 4 - Sulphonic acid) 5. Ortho Chloro Aniline (By-product) CAS No. Capacity, TPM Existing Proposed Total Remarks No Change Expansion Total Proposed New Proposed New Proposed new Expansion project- Dyes Intermediates Page 1

3 Micas Organics Limited (Unit: II) Manufacturing process is attached as Annexure-3. Expansion project- Dyes Intermediates Page 2

4 Micas Organics Limited (Unit: II) 1.2 RESOURCE REQUIREMENT: Components Existing Proposed Total after Proposed Expansion Power, KVA Fresh Water, KLD Natural Gas, SCM/Hr for Steam Boiler (3 Tons/Hr) Natural gas, SCM/Hr for Thermopak: I (6 lacs k cal/hr) Natural gas, SCM/Hr for Thermopak: II (20 lacs k cal/hr) Fuel (HSD), kgs/hr for D.G. Set: I (Capacity: 500 KVA) Fuel (HSD), kgs/hr for D.G. Set: II (Capacity: 500 KVA) Resources Availability Sourced from Dakshin Gujarat Vij Co. Ltd. Will be sourced from GIDC Water Supply Dept GSPC GSPC GSPC Sourced from local dealer Sourced from local dealer Cooling Tower, TR In-house Chilling plant, TR In-house 1.3 RAW MATERIAL CONSUMPTION: S. No. 1. Raw Materials 3,3 DI CHLORO BENZIDINE HCl Per ton Raw material consumption, MT Existing After proposed per month expansion per month 1.1 ONCB Toluene (Recycled) Toluene (Fresh) NaOH Catalyst Hydrogen Sulphuric Acid salt Total Expansion project- Dyes Intermediates Page 3

5 Micas Organics Limited (Unit: II) B ACID 2.1 ODCB (Recovered) ODCB (Fresh) Para Toludine Sulphuric acid Caustic lye Hydro Chloric acid Total B ACID 3.1 ODCB (Recovered) ODCB (fresh) Chloro Para Toludine Sulphuric acid Caustic lye Hydro Chloric acid Total CLT ACID 4.1 Toluene Sulphuric acid Chlorine gas Ferric Chloride Nitric acid Dedanol OT Common Salt Soda ash Iron powder Hydro Chloric acid Total WATER AND WASTE WATER MANAGEMENT Total Raw Water requirement after proposed expansion will be 497 kl/day, which supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith. Total industrial Waste Water Generation will be 434 KL/Day, which will be treated in adequately modified existing primary, secondary & tertiary effluent treatment plant and finally treated effluent will be disposed off into CETP Vapi for further treatment and disposal into Arabian Sea. Domestic waste water (9 KLD) will be disposed off through Septic Tank. 1.5 AIR EMISSION AND ITS CONTROL MEASURES Flue Gas Emission: At present, the unit is having one number of natural gas fired 3 TPH capacity of steam boiler, one number of natural gas fired thermopack with capacity 6 lacs k cal/hr. There will be addition of one thermopak having capacity of 20 lacs k cal/hr and natural gas will be used as a fuel. The company is having one D G set of 500 KVA capacities as stand by. One number of additional 500 KVA capacities of D G set will be added. It is used only during power failure. Adequate stack height and stack monitoring facilities is provided. Expansion project- Dyes Intermediates Page 4

6 Micas Organics Limited (Unit: II) Process Gas Emission: Presently, the unit has installed one number 500 kgs/hr capacity of incinerator to incinerate process residue. After proposed expansion, existing incinerator will be discontinued and send process residue will be sent to M/S RSPL, Panoli for coprocessing. There is no process gas emission from the existing products. Permission of RSPL is enclosed in Annexure-5. After proposed expansion; there will be generation of process gas like chlorine fumes and nitrous fumes. To scrub, process gas emission, we will install two stage scrubbing system along with 11 meters height of vent.(detail of Air pollution control measures is attached as Annexure-10) 1.6 HAZARDOUS WASTES AND ITS MANAGEMENT S. No Type Process Residue (26.1) Incineration Ash (37.2) ETP waste (35.3) Quantity, TPA Existing Proposed Total Discontinued Disposal Sent for co-processing to M/S RSPL, Panoli Dispose off into TSDF, Vapi 4. Used oil (5.1) Used filter cloth (36.2) Discarded containers (33.1) Inorganic Acid (Spent Sulphuric acid)(sch: II B 15) Iron (26.1) Oxide Hydro Chloric acid (30%) from Scrubber (Sch: II B 15) Collection, storage & sell to register refineries Dispose off into TSDF, Vapi Partly recycle for packing of hazardous waste and partly Sell to authorized recycler Sell to M/s Pharmavet Industries, GIDC Vapi for the manufacture of Di calcium phosphate and applied under Rule-9 of the H/W 2016 Sell to cement industries or dispose off into TSDF Vapi Recycled in the process Expansion project- Dyes Intermediates Page 5

7 Micas Organics Limited (Unit: II) 1.7 INTRODUCTION OF THE PROJECT AND THE PROPONENT. Name of the project Proponent: M/S Micas Organics Limited (Unit: II) M/S Micas Organics Limited (Unit: II) is a large scale unit 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 crore. The proponent wishes to enhance the Production capacity of Existing Products as well introduce new similar group of products. The dyes intermediates products are especially used by Pigment manufacturers which serve to Paints, Inks & Plastic industries as per requirement The unit is operated by technocrats having more than years of experience in manufacturing and marketing of dyes intermediates chemicals 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 one existing product and addition of new products of same group. All the dyes intermediate to MT per month and process capabilities to manufacture all types of Dyes intermediates. The proposed expansion project site lies on N Latitude & E Longitude. M/S Micas Organics Limited (Unit: II) is located at Plot. No. 3102, 3101, 3108, Phase: IV area, GIDC Vapi, Di: 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 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. Expansion project- Dyes Intermediates Page 6

8 Micas Organics Limited (Unit: II) M/S Micas Organics Limited (UNIT: II) was started in the year of Most of the products have been developed through strong in-house R&D. The Group's turnover is about 85 Crores for the year 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 ISO 9001:2015 certified. We have a strong in-house R&D team. We have a small Pilot plant at this site to support the R & D activities Identification of the Project Proponent: M/S Micas Organics Limited (UNIT:II) is a large scale unit is located at notified industrial estate, GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer List of Directors: S. No. Name of Directors Addresses 1 Mr. Rajul A. Shah 60, II Main Rd, 11 th Cross, JP Nagar, 3 rd Phase, Banglore , Karnataka, India 2 Mr. Pranav R. Shah 60, II Main Rd, 11 th Cross, JP Nagar, 3 rd Phase, Banglore , Karnataka, India 3 Mr. Mukesh N. Patel At. Post- Tigra, Tal & Di.: Valsad, Gujarat, India. 4 Mr. Harshad V. Patel At. Post- Tigra, Tal & Di.: Valsad, Gujarat, India. 5 Mr. Urmil Shah Flat No, 11, Laxmi Darshan, Bajar Road, Vile Parle, Mumbai, Maharashtra, 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 Directors on Board for efficient Management, They are : Dr. Anil Inamdar (Product Development consultant from UDCT) Mr. Anil Patel (R & D head) Mr. Sharad Kadam (Production Manager) Mr. Ankur Patel (Engineer) Mr. Jignesh Oza ( EHS head) Mr. Anil Patel (Quality control & Quality assurance) They help us to achieve & perform better & better. Expansion project- Dyes Intermediates Page 7

9 Micas Organics Limited (Unit: II) Brief description of nature of the Project: M/S Micas Organics Limited (UNIT:II) proposes to enhance the production capacity at Plot No. 3102,3101,3108, phase IV, 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 appraised at state level expert committee 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 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 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 chemicals used by them with ours and there by curtail the outflow of foreign currency spent on dyes intermediates 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 chemicals 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 chemicals business, the proposed increase in capacity will also help the company to standardize and produce the dyes intermediates chemicals with more consistency because higher volumes will help to achieve better control over Physico-chemical conditions while manufacturing. To generate Local Employment Demand Supply Gap: Our dyes intermediates chemicals are mainly used by Pigment manufacturers which serve to Paints, Inks & Plastic industries 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 in the Export Market like Canada, Srilanka, Thailand, Pakistan, Kenya, Bangladesh, UAE, Saudi Arabia, Indonesia and Nigeria. Expansion project- Dyes Intermediates Page 8

10 Micas Organics Limited (Unit: II) 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 country 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 also shows strong growth potential Domestic / export Markets: The company s products are used by Pigment manufacturers which serve to Paints, Inks & Plastic industries as per requirement. These are having very good demand in domestic as well as international markets 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 30 people to fulfil it s need to handle the plant. Presently there are 62 numbers of employees. There will be additional 30 numbers of employees, thus total 92 numbers of employees after proposed expansion. 1.8 PROJECT DESCRIPTION: Type of Project including interlinked and interdependent projects, If any : The proposed project is an interdependent project of the company 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 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) Size or magnitude of operation : As per the proposed project cost, the project is covered under large Scale category of manufacturing industries. Expansion project- Dyes Intermediates Page 9

11 Micas Organics Limited (Unit: II) 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 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: S. No S. No. Product 3,3 DCB (3,3 Di Chloro Benzedine Di hydro Chloride) 4- B Acid (4- Amino Toluene 3- Sulphonic acid) 2-B Acid (2 Chloro 4- Amino Meta Sulphonic Acid) CLT Acid (2 - Chloro 5 - Toludine 4 - Sulphonic acid) Ortho Chloro Aniline (By-product) Substance 1. ONCB 2. Toluene 3. Catalyst 4. Hydrogen 5. Sulphuric Acid 6. Salt 7. ODCB 8. Para Toludine DETAILS ON PRODUCT TRANSPORTATION Physical State Solid Solid Solid Solid Liquid Dispatch Domestic & Export Market Domestic & Export Market Domestic & Export Market Domestic & Export Market Domestic Market DETAILS OF RAW MATERIAL TRANSPORTATION Physical State Liquid Liquid Solid Gas Liquid Solid Liquid Type of packing & supply Means of Transportation Packing & Means of transportation Sack Bags or Jumbo Bags through Truck Sack Bags or Jumbo Bags through Truck Sack Bags or Jumbo Bags through Truck Sack Bags or Jumbo Bags through Truck HDPE Drum through Truck Distance of supplier from project site (km) ISO tanker Road Transport 150 ISO tanker Road Transport HDPE Drum with inner liner Gas Cylinder Bank Road Transport 700 Road Transport 200 ISO tanker Road Transport HDPE Bags Road Transport 600 ISO tanker Road Transport 350 Liquid MS Drum Road Transport Expansion project- Dyes Intermediates Page 10

12 Micas Organics Limited (Unit: 9. Caustic lye Liquid ISO tanker Road Transport Hydro Chloric acid 2- Chloro Para Toludine 12. Chlorine gas 13. Ferric Chloride 14. Nitric acid 15. Dedanol OT 16. Soda ash 17 Iron powder Liquid Liquid Gas ISO tanker Road Transport 10 MS Drum Road Transport Cylinder Road Transport Solid Bags Road Transport 20 Liquid Liquid Solid Solid ISO tanker Road Transport 200 Drum Road Transport 380 Bags Road Transport 200 Bags Road Transport Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outline: 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 & recovery are as under. PRODUCT WISE SOLVENT USED/RECOVERED PER TONE, PER MONTH OF PRODUCT FOR EXISTING & PROPOSED EXPANSION S. No. Raw Materials Per tone Raw material consumption, MT Existing per month After proposed expansion per month 1. 3,3 DI CHLORO BENZIDINE HCl 1.2 Toluene (Recycled) Toluene (Fresh) B ACID 2.1 ODCB (Recovered) ODCB (Fresh) B ACID 3.1 ODCB (Recovered) ODCB (fresh) Expansion project- Dyes Intermediates Page 11

13 Micas Organics Limited (Unit: II) S. No. SUMMARY OF OVERALL SOLVENT USE & LOSSES AFTER PROPOSED EXPANSION Name of the solvent 1 Toluene 2 ODCB Total Consumption, TPM Recovery, TPM Loss/with residue, TPM % Recovery Availability of water source, Energy/Power requirement and source should be given: 98.3 Availability of water its source, Energy/power required and its source is below. Water will be sourced from GIDC Notified industrial estate, Vapi. Water withdrawal Permission is attached as Annexure: 4 OVERALL WATER CONSUMPTION AT EXISTING & AFTER EXPANSION, M 3 /DAY WATER CONSUMPTION Water Consumption, M 3 /Day S. Particulars No. After proposed Existing Proposed expansion 1. Domestic Processing, Washing & Scrubber 3. Cooling Boiler Floor/container/equipment washing 6. Gardening & Safety Total Total Industrial Expansion project- Dyes Intermediates Page 12

14 Micas Organics Limited (Unit: II) WATER BALANCE DIAGRAM WATER BALANCE AT EXISTING SCENARIO TOTAL WATER CONSUMPTION, 97.5 M 3 /Day Domestic: 5.0 Processing & Washing: 54.5 Cooling: 10 Boiler: 18.0 Other washing: 3 Gardening & Safety: 7.0 Septic tank Primary, Secondary & tertiary Treatment Plant Under Ground drainage line to CETP Vapi WATER BALANCE AFTER PROPOSED EXPANSION TOTAL WATER CONSUMPTION, 497 M 3 /Day Domestic: 9.0 Processing & Washing: 418 Cooling: 20 Boiler: 30.0 Floor washing /container: 10 Gardening & Safety: 10.0 Septic tank M3/Day Primary, Secondary & tertiary Treatment Plant Under Ground drainage line to CETP Vapi Expansion project- Dyes Intermediates Page 13

15 Micas Organics Limited (Unit: II) S. No 1. Particulars Steam requirement ENERGY REQUIREMENTS AND ITS SOURCE Existing Kgs/Hr After Proposed expansion Kgs/Hr Source Will be obtained by existing 3 TPH boiler, having spare capacity S. No. 1. Particulars Power Electricity requirement POWER REQUIREMENTS AND ITS SOURCE Existing After Proposed expansion 500 KVA 1000 KVA Source Sourced from Dakshin Gujarat Vij Co. Ltd 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 Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representation of the feasibility drawing is enclosed as Annexure SITE ANALYSIS 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 Land Form, Land use and Land ownership : The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation Topography (along with map) : Topography map showing the elevation of the study area below. The topographical map is enclosed as Annexure 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 Existing Infrastructure : GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system. Expansion project- Dyes Intermediates Page 14

16 Micas Organics Limited (Unit: II) 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) 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 observed and predicted rainfall was then analyzed for its validity. Rainfall projection for Project site and Gujarat for 2011 (June-Oct.) S. No. 1 Region Middle Gujarat Rainfall Projection (in mm) June - Oct Normal Rainfall (In mm) Rainfall Projection (% Departure from normal) 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). Expansion project- Dyes Intermediates Page 15

17 Micas Organics Limited (Unit: II) 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 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 laparoscopic surgery, trauma, orthopaedic and urology etc. The hospital is one of the few centres 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 Valsad with Daman & Diu, which has increased the graph of tourist flow in the district PLANNING BRIEF : 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. Expansion project- Dyes Intermediates Page 16

18 Micas Organics Limited (Unit: 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 m 2 (33% ) of 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. 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. SITE PLAN WITH AREA TABLE AT EXISTING & AFTER PROPOSED EXPANSION Area in m 2 S. No. Particulars Total after Existing Proposed 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 Internal road Open space Expansion project- Dyes Intermediates Page 17

19 Micas Organics Limited (Unit: II) Site map with Green Belt Development Planning: 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 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 PROPOSED INFRASTRUCTURE: 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 Residential Area (Non Processing Area): No residential area is involved in the proposed expansion project Green Belt: Green belt will be provided and maintained at the tune of 16.19% of the total land area. Additional green belt shall be developed at other land in GIDC to meet the criteria of 33% greenbelt of total plot area Social Infrastructure: Not applicable Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc): Expansion project- Dyes Intermediates Page 18

20 Micas Organics Limited (Unit: II) The project site is very well connected by road through National Highway no. 8, western railways Drinking Water management (Source & Supply of water) : Source of water is from GIDC water supply services Sewerage System: GIDC has provided sewerage system to dispose the sewage effluent Industrial Waste Management: Industrial liquid effluent generated after proposed expansion will be treated in modified existing ETP of primary, secondary & tertiary treatment unit and will be discharged through GIDC underground drainage to CETP Vapi for further treatment and disposal into Tidal zone of River Damanganga to Arabian sea.(membership certificate is attached as Annexure-6) Generated domestic liquid waste is being disposed off through septic tank Solid/Hazardous Waste Management: S. No Waste Category Process Residue (26.1) Incineration Ash (37.2) ETP waste (35.3) Quantity in MT/Year Existing Proposed Total Disposal Sent for co-processing to M/S RSPL, Panoli Discontinued Used oil (5.1) Used filter cloth (36.2) Discarded containers (33.1) Dispose off into TSDF, Vapi Collection, storage & sell to register refineries. Dispose off into TSDF, Vapi Partly recycle for packing of hazardous waste and partly Sell to authorized recycler Inorganic Acid Sell to M/s Pharmavet 7 (Spent Sulphuric Industries, GIDC Vapi for acid)(sch: II B the manufacture of Di 15) calcium phosphate Sell to cement industries 8 Iron Oxide (26.1) or dispose off into TSDF Vapi Hydro Chloric 9 acid (30%) from Scrubber (Sch: II Recycled in the process B 15) (Membership certificate is attached as Annexure-6) Expansion project- Dyes Intermediates Page 19

21 Micas Organics Limited (Unit: II) Power Requirement & Supply / Source: Power requirement for proposed project will be taken from DGVCL REHABILITATION AND RESETTLEMENT (R&R) PLAN: 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 & 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- Dyes Intermediates Page 20

22 Micas Organics Limited (Unit: II) 1.13 PROJECT SCHEDULE & COST ESTIMATES : 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 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. S. No. Particulars CAPITAL COST PROJECTION Cost in INR (Crore) Existing Proposed Total 1.0 Land m Building Equipment & machineries Pipes & fittings Utilities Environmental Management System Total Project Cost UTILITIES REQUIREMENT S. No. Particulars Existing Proposed Total 1.0 Utilities 1. Boiler, TPH Thermopack, k cal/hr Cooling Tower, TR Chilling plant, TR D.G. Set (Standby), KVA Power from DGVCL, KVA Fuel 1. Natural Gas (SCM/Hr) Steam Boiler (3 Tons/Hr) 2. Natural gas (SCM/Hr) for Thermopak: I (6 lacs) Natural gas (SCM/Hr)for Thermopak: II (26 lacs) Fuel (HSD) kgs/hr for D.G.Set: I, (Capacity: KVA) 5. Fuel (HSD) kgs/hr for D.G.Set: II, (Capacity: KVA) 4.0 Water from GIDC Vapi kl/day Waste Water (Industrial) kl/day Expansion project- Dyes Intermediates Page 21

23 Micas Organics Limited (Unit: II) PROJECT VIABILITY S. No. PARTICULARS AMOUNT (INR Crore) 1. Proposed Sale Raw Material Cost Power & Fuel Labour Cost Environmental Management System Maintenance Cost Selling, packing & Office Expenses Proposed Profit 8.05 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. S. No. RECURRING/OPERATING COST PER ANNUM Component Proposed (Rs. in Lacs/annum) 1. Environment & Safety Management System Greenbelt Maintenance Solid waste Disposal Total ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS): 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 social upliftment programs by the way of improving education and health facilities in nearby area. Expansion project- Dyes Intermediates Page 22

24 Micas Organics Limited (Unit: II) ANNEXURES Expansion project- Dyes Intermediates Page 23

25 Micas Organics Limited (Unit: II) ANNEXURE: 1 Location map showing the Project site and inter-state boundary within 10 kms radius Expansion project- Dyes Intermediates Page 24

26 ANNEXURE: 2 Plant Layout Expansion project- Dyes Intermediates Page 25

27 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, CHEMICAL REACTION & MASS BALANCE CHEMICAL REACTION FOR 3,3 DI CHLORO BENZIDINE DI HYDRO CHLORIDE (3,3 DCB) Cl NO 2 Cl NO Cl NHOH Cl NH 2 +2e+2[H]-H 2 O +2e + 2[H] +2e+2[H]-H 2 O ONCB Ortho Chloro Aniline -H 2 O Cl O Cl N + = N 2,2' Di Chloro Azoxy Benzene +2e+2[H]-H 2 O Cl Cl N = N +2e+2[H] Cl H H Cl N - N 2,2' Di Chloro Hydrazo Benzene Re-arrangement of 2,2 Di Chloro Hydrazo Benzene Cl H Cl H Cl Cl H N - N + 2H 2 SO 4 N H N + 2H 2 O (253) (196) SO 3 H SO 3 H Sulphomass (413) Isolation of Sulphomass to 3,3 Di Chloro Hydrazo Benzene Di Hydro Chloride H N SO 3 H Cl Cl H N + 2H 2 O + 2 NaCl SO 3 H Sulphomass (413) H N HCl Cl Cl H N HCl + Na 2 SO 4 + H 2 SO 4 3,3 DCBH ( 326) (142) (98) Expansion project- Dyes Intermediates Page 26

28 ONCB Toluene (Recycled) NaOH Water Catalyst Hydrogen MASS BALANCE FOR 3,3 DI CHLORO BENZIDINE HYDRO CHLORIDE HYDROGENATION Reaction mass Toluene (Recycled) Toluene (fresh) Water FILTERATION Hydrazo contains Toluene Catalyst ML to ETP Hydrazo Toluene (Recovered) Water Organic Layer Hydro chloric acid Water Caustic lye SEPARATION OCA EXTRACTION, SEPARATION & NEUTRALIZATION Organic layer Aq. Layer Sulpho mass OCA (Co- Product) Aqueous layer Organic Layer Sulphuric acid Water Catalyst ISOLATION & RE- ARRANGEMENT Sulpho Mass Toluene Distillation Sulpho mass Salt Water ISOLATION :19602 KGS Spent acid (20-22%): sell Toluene (Recovery) Residue Loss 3,3 DCB Expansion project- Dyes Intermediates Page 27

29 CHEMICAL REACTION FOR 4 -B ACID (4- AMINO TOLUENE 3- SULPHONIC ACID) CH 3 NH 2 P- Toludine (107) 4-B ACID (4-AMINO TOLUENE 3-SULPHONIC ACID) CH 3 + H 2 SO 4 + H 2 O (98) Sulphonation NH 2 SO 3 H 4- Amino Toluene 3- Sulphonic acid (187) (18) Sodium Salt CH 3 NH 2 + SO 3 H 4- Amino Toluene 3- Sulphonic acid (187) NaOH (40) CH 3 NH 2 SO 3 Na + H 2 O (18) 4- Amino Toluene -3 Sodium Sulphonate (209) Isolation CH 3 CH 3 + HCl + NaCl NH 2 SO 3 Na (36.5) 4- Amino Toluene -3 Sodium Sulphonate (209) SO 3 H (58.5) NH 2 4- Amino Toluene 3 -sulphonic acid (187) Expansion project- Dyes Intermediates Page 28

30 MASS BALANCE FOR 4 -B ACID (4- AMINO TOLUENE 3- SULPHONIC ACID) ODCB ODCB (F) Para Toludine H2SO4 SULPHONATION 90 o C Reaction water To ETP 48 % C.lye Water 4 - B ACID SODIUM 80 o C Layer separation Filteration ODCB Recovered ODCB loss 30 % HCl 80 o C Hot water wash Washing/Filteration & Centrifuge Waste water to ETP Drying & Pulverizing Drying loss Product: 4 B Acid Expansion project- Dyes Intermediates Page 29

31 CHEMICAL REACTION FOR 2 B ACID (2-CHLORO 4- AMINO META SULPHONIC ACID) 2-B ACID (2-CHLORO 4-AMINO META SULPHONIC ACID) Sulphonation CH 3 Cl + H 2 SO 4 NH (98) 2 2- Chloro Para Toludine (141.5) Cl CH 3 NH 2 SO 3 H + H 2 O 2 Chloro 4- Amino Meta Sulphonic acid (221.5) (18) Sodium Salt Cl CH 3 NH 2 + SO 3 H 2 Chloro 4- Amino Meta Sulphonic Acid (221.5) NaOH (40) Cl CH 3 NH 2 + SO 3 Na H 2 O (18) 2 Chloro 4- Amino Meta Sodium Sulphonate (243.5) Isolation Cl CH 3 + SO 3 Na HCl (36.5) Cl CH 3 + NaCl SO 3 H (58.5) NH 2 NH 2 2 Chloro 4- Amino Meta Sodium Sulphonate (243.5) 2 Chloro 4- Amino Meta Sulphonic Acid (221.5) Expansion project- Dyes Intermediates Page 30

32 MASS BALANCE FOR 2 B ACID (2-CHLORO 4- AMINO META SULPHONIC ACID) ODCB ODCB (F) 2- Chloro para Toludine H2SO4 Condenser 0 C 90 o C Reaction water 48 % Caustic lye Water o C Layer separation Filteration ODCB Recovered ODCB loss Filter Press 30 % HCl 80 o C Hot water wash Washing/Filteration & Centrifuge Waste water to ETP Drying & Pulverizing: Drying loss Product: 4 B Acid Expansion project- Dyes Intermediates Page 31

33 CHEMICAL REACTION OF CLT- ACID (2 - Chloro 5 - Toludine 4 - Sulphonic acid) Step: 1 (Sulfonation) CH 3 CH 3 + H 2 SO 4 + H 2 O Toluene (92) (98) SO 3 H PTSA (172) (18) Step: 2 (Chlorination) CH 3 CH 3 + Cl 2 FeCl 3 Cl + HCl SO 3 H PTSA (172) (71) SO 3 H 2- Chloro PTSA (206.5) (36.5) Step: 3 (Nitration) CH 3 Cl SO 3 H 2- Chloro PTSA (206.5) + 2HNO H 2 SO 4 (126) (294) Cl CH 3 SO 3 H NO 2 2-Chloro 6-Nitro PTSA (251.5) + 2H 2 O + 3 H2 SO 4 + HN 2 O (36) (294) (45) Cl CH 3 SO 3 H + NO 2 2-Chloro 6-Nitro PTSA (251.5) Fe + 2HCl (55.5) (73) Step: 4 (Reduction) CH 3 Cl + FeCl 2 + O 2 NH 2 (126.5) (32) SO 3 H 2 Chloro 5- Toludine 4 Sulphonic acid (221.5) Expansion project- Dyes Intermediates Page 32

34 MASS BALANCE OF CLT- ACID (2 - Chloro 5 - Toludine 4 - Sulphonic acid) Toluene Sulphuric acid Chlorine gas Ferric chloride Sulphuric acid Nitric acid 20% Dedanol OT Common salt Water SULPHONATION at C CHLORINATION at C NITRATION at C ISOLATION Chlorine gas Nitrous oxide Spent acid (32%) Water Scrubber HCl (30%) Caustic soln (20%) Scrubber Waste water to ETP 30% brine water wash Nitro Wet cake Soda ash Iron HCl (30%) Water Water Mother Liquor for Isolation 30% HCl Water FILTERATION REDUCTION FILTERATION ISOLATION FILTERATION Wash water Nitro Wet cake Ferric Oxide Sludge Mother Liquor for Isolation ML to ETP CLT- ACID Expansion project- Dyes Intermediates Page 33

35 ANNEXURE: 4 Water requirement letter from Notified industrial estate Expansion project- Dyes Intermediates Page 34

36 ANNEXURE: 5 Quantity of Waste Water (liquid waste) generation and its management : S. No. Particulars Water Consumption, M 3 /Day Effluent Generation, M 3 /Day Existing After proposed expansion Existing After proposed expansion 1 Domestic Processing, Washing & Scrubber 3 Cooling Boiler Floor/container/equipm ent washing 6 Gardening & Safety Total Total Industrial WATER BALANCE AT EXISTING SCENARIO TOTAL WATER CONSUMPTION, 97.5 M 3 /Day Domestic: 5.0 Processing & Washing: 54.5 Cooling: 10 Boiler: 18.0 Other washing: 3 Gardening & Safety: 7.0 Septic tank Primary, Secondary & tertiary Treatment Plant Under Ground drainage line to CETP Vapi Expansion project- Dyes Intermediates Page 35

37 WATER BALANCE AFTER PROPOSED EXPANSION TOTAL WATER CONSUMPTION, 497 M 3 /Day Domestic: 9.0 Processing & Washing: 418 Cooling: 20 Boiler: 30.0 Floor washing /container: 10 Gardening & Safety: 10.0 Septic tank M3/Day Primary, Secondary & tertiary Treatment Plant Under Ground drainage line to CETP Vapi Expansion project- Dyes Intermediates Page 36

38 Details of Effluent Treatment Plant with proposed modification Design Criteria : Product : Dyes intermediates Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 434 KL/day Max. Design Parameters : As under Effluent Characteristics: No Effluent parameters Process + washin g Boiler + coolin g Equip + floor + container washing Combine d normal effluent Effluent After ETP treatm ent CETP inlet norms 1 ph to Temperature 0 C Colour (Pt-Co) <100 4 SS, mg/l <300 5 TDS, mg/l COD value, mg/l 7 BOD value, mg/l < <400 8 Chlorides, mg/l Sulphates, mg/l O & G, mg/l <10 11 NH3-N, mg/l 20 ND <50 12 Phosphates, mg/l 1.2 ND Phenolic, mg/l ND ND ND N.D. ND <1 Expansion project- Dyes Intermediates Page 37

39 Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: Details of effluent treatment plant for industrial effluent stream with proposed modification: Sr. Equipment Dimensions Capacity in m 3 MOC No. meters Proposed Total Existing 1. Oil & Grease 10*2* RCCTL tank/collection tank 2. Collection cum 7.5*7.5* RCCTL equalization Tank 4. Lime preparation 1.85 dia* MS dosing tank 5. Neutralization tank 2.2 dia* MS 6. Primary clarifier 4 x 4 x MSRL 7. Intermediate Storage 5*8* RCC tank 8. Bio Reactor ( Aeration 12*12* RCC Tank) 9. Secondary clarifier 3.5* RCC 10. Holding tank 5*5* RCC 11. Activated carbon 3 dia x 2 ht MSRL Filter 12. Pressure Sand filter 3 dia x 2 ht MSRL 13. Sludge Drying Bed 14*10* Brick 14. Filter Press 900*900* PP/CI 15. plates Final treated effluent 2.2 dia*4 holding tank HDPE Expansion project- Dyes Intermediates Page 38

40 FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT Expansion project- Dyes Intermediates Page 39

41 ANNEXURE: 6 MEMBERSHIP CERTIFICATE OF CETP, VAPI Expansion project- Dyes Intermediates Page 40

42 ACCEPTANCE LETTER FOR CETP AUTHORITY FOR ADDITIONAL EFFLUENT Expansion project- Dyes Intermediates Page 41

43 MEMBERSHIP CERTIFICATE FOR CO-PROCESSING OF PROCESS RESIDUE Expansion project- Dyes Intermediates Page 42

44 MEMBERSHIP OF TSDF Expansion project- Dyes Intermediates Page 43

45 Expansion project- Dyes Intermediates Page 44

46 ANNEXURE: 7 Expansion project- Dyes Intermediates Page 45

47 ANNEXURE: 8 Copy of plot allotment letter issued by GIDC Expansion project- Dyes Intermediates Page 46

48 Expansion project- Dyes Intermediates Page 47

49 Expansion project- Dyes Intermediates Page 48

50 COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA Expansion project- Dyes Intermediates Page 49

51 ANNEXURE: 9 A schematic representation of the feasibility drawing Expansion project- Dyes Intermediates Page 50

52 ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED EXPANSION Flue gas emission: At present, the unit is having one number of natural gas fired 3 TPH capacity of steam boiler, one number of natural gas fired thermopack with capacity 6 lacs k cal/hr. There will be addition of one thermopak having capacity of 20 lacs k cal/hr and natural gas will be used as a fuel. The company is having one D G set of 500 KVA capacity as stand by. One number of 500 KVA capacity of D G set will be added. It is used only during power failure. Adequate stack height and stack monitoring facilities is provided. Process gas emission: Presently, the unit has install one number 500 kgs/hr capacity of incinerator to incinerate process residue. After proposed expansion, existing incinerator will be discontinued and send process residue to M/S RSPL, Panoli for co-processing. Thus there is no process gas emission from the existing products. After proposed expansion; there will be generation of process gas like chlorine and nitrous fumes. To scrub, process gas emission, we will install two stage scrubbing system along with 11 meters height of vent Flue Gas emission S. No. Particulars Details Remarks Existing After proposed Expansion 1.0 Capacity of D G set: I 500 KVA 500 KVA Existing 1.1 Fuel used HSD HSD 1.2 Consumption 75 lits/hr 75 lits/hr 1.3 APC provided 11 meters chimney 11 meters chimney 2.0 Capacity of D G set: II KVA Proposed new 2.1 Fuel used 0 HSD 2.2 Consumption 0 75 lits/hr 2.3 APC provided 0 11 meters chimney Capacity of Steam boiler Fuel used 3000 kgs/hr Natural gas 3000 kgs/hr Natural gas Existing will be utilized for proposed expansion by increase 3.2 Consumption 137 SCM/hr 137 SCM/Hr the working hours 3.3 APC provided 11 meters chimney 11 meters chimney (Presently operating for 10 hrs) 4.0 Capacity of 6 Lacs K Cal 6 Lacs K Cal Existing Expansion project- Dyes Intermediates Page 51

53 Thermopak: I 4.1 Fuel Used Natural gas Natural gas 4.2 Consumption 55 SCM/Hr 55 SCM/Hr 4.3 APC Provided 11 meters chimney 11 meters chimney 5.0 Capacity of 0 20 Lacs K Cal Proposed new Thermopak: II 5.1 Fuel Used 0 Natural gas 5.2 Consumption SCM/Hr 5.3 APC Provided 0 11 meters chimney Process Gas emission: S. No. Particulars Details Remarks Existing After proposed Expansion 1.0 Capacity of incinerator 500 kgs/hr 0 Discontinued 1.1 Fuel used Natural gas Fuel Consumption 20 SCM/day APC provided Ventury 0 scrubber 1.4 Height of vent 30 meter Expected pollutants from 0 Chlorination reaction of CLT-acid 2.1 Expected pollutants 0 Chlorine gas 2.2 APC to be provided 0 Two stage water followed by alkali scrubber 2.3 Height of vent 0 11 meters 4.0 Expected pollutants from 0 Nitration reaction of CLT-acid 4.1 Expected pollutants 0 Nitrous oxide gas 4.2 APC to be provided 0 Two stage alkali scrubber 4.3 Height of vent 0 11 meters Proposed New Proposed New Expansion project- Dyes Intermediates Page 52

54 DETAILS OF SCRUBBING SYSTEM 1. Specifications of Falling Film Graphite HCl Scrubber: Type Tube side Shell side Scrubbing media Heat of solution kcal/h Cooling water required at 40 approach No of tubes required HTA required Diameter of scrubber Overall length MOC tubes MOC shell : Parallel flow falling film type : HCl gas, Cl 2 gas, water, HCl solution : cooling water : water : kcal/h : 2.5 m3/h : 65 tubes, 20 dia x 2.5 m length : 10 m2 : 350 mm : 3000 mm : Glass : HDPE/Graphite Specifications of tails tower Inlet HCl Inlet Cl2 gas Scrubbing media Tower dia Packed length Overall length MOC Packing dia Outlet HCl Chlorine gas : 50 kg/h : 2 kg/h : Water, 58 kg /h, to be fed to main scrubber : 350 mm : 1500 mm : 2000 mm : FRP : 40 mm PP : KG/h : 6 kg/h Specifications of Alkali Ventury Inlet HCl Inlet Cl2 gas Scrubbing media Size of Ventury MOC Alkali circulation tank Circulation pump Vent diameter Height of vent : kg/h : 2 kg/h : 10 % dilute alkali : 150 dia x 1250 mm ht. : FRP : 2000 liter HDPE : 2.5 m3/h S/S : 150 mm : 11 meters 1. Specification of NOx scrubbing system: Scrubber dia Packed length Overall scrubber height MOC of scrubber Scrubbing media Dilute alkali circulation tank Alkali circulation pump Vent size : 400 mm : 3000 mm : 4500 mm : PP/FRP : 10 % NaOH : 2000 liter HDPE : 3 m3/h, SS, 10 m head : 200 mm, 11 m height. Expansion project- Dyes Intermediates Page 53

55 Gas From Plant Header Primary HCl SCRUBBER Tail SCRUBBER For HCl Un Condensed HCl gas To Atmosphere V E N T U R Y Primary Circulation Tank Secondary Circulation Tank Caustic Lye Circulation Tank EXISTING HCl/CL2 SCRUBBER SYSTEM Expansion project- Dyes Intermediates Page 54

56 NO x FUMES PACKED COLUMN NO x SCRUBBER VENTURY SCRUBBER MIXED ACID PG STACK NITRATION REACTOR 10 % NaOH NaOH LYE DILUTE NaOH NRV BLOWER NITRATION REACTORS TWO STAGE NO x SCRUBBING SYSTEM FOR NITRATION REACTORS Expansion project- Dyes Intermediates Page 55