PROJECT PRE-FEASIBILITY REPORT

Transcription

1 PROJECT PRE-FEASIBILITY REPORT For EXPANSION OF DYE INTERMEDIATES MANUFACTURING UNIT At Plot No: 1712, Phase III, Notified Industrial Area, GIDC, Vapi Tal.: Pardi, Dist.: Valsad, Gujarat Land/Plot Area: 5000 m 2 (0.5 Ha) Production Capacity: 24.8 TPM to TPM [Schedule 5 (f) Category B as per EIA Notification 2006 and its Amendment thereof] APPLICANT SANHI CHEMICALS Plot No: 1712, Phase III, Notified Industrial Area, GIDC, Vapi, Tal.: Pardi, Dist.: Valsad, Gujarat. sales@apurvachem.in Mo. No.: CONSULTANT ECO CHEM SALES & SERVICES Office Floor, Ashoka Pavilion A, Opposite Kapadia Health Club, New Civil Road, Surat, NABET/EIA/1720/RA eco@ecoshripad.com Tel No April Doc. No: 2018_ECSS_EIAI2_

2 1.0 EXECUTIVE SUMMARY Name & Location Project Name of the Project: Location: Plot No: 1712, Phase III, GIDC, Vapi. Pin Code: , Tal.: Pardi, Dist.: Valsad (Gujarat). M/S is located in GIDC Notified Industrial Area, falling under small 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. Existing project cost is Rs lakhs. Proposed expansion Project Cost: Rs lakhs. Total cost after proposed expansion will be Rs lakhs 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 is a proprietary firm. Small Scale Unit. 1.1 LIST OF FINISHED PRODUCTS: # Product Name CAS Number Qty. MT/Month Existing Proposed Total Naphthylamine 4,6,8 tri Sulfonic acid (Sulpho G Acid) Nitro 2 amino phenol 6 Sulfonic acid (4 NAPSA) Nitro 2 amino phenol 4 Sulfonic acid (6 NAPSA) Amino Phenol 4- Sulfonamide (OPSAMIDE) Naphthyl amine 3,6,8 tri Sulfonic acid (KOCH ACID) M-Amino Phenol (MAP) Naphthol 3,6 di Sulfonic acid (Violet Acid) Naphthol 3,8 di Sulfonic acid (EPSILONE ACID) amino 8 Naphthol 4,6 di sulfonic acid (European K Acid) Naphthylamine 4,8 di Sulfonic acid (C Acid) Chloro 5 - Toludine 4 - Sulphonic Expansion project- Dye Intermediates Page 1

3 acid (CLT acid) naphthylamine 8- hydroxy 2,4 di sulfonic acid (Chicago Acid) Amino Benzene Sulphonic acid (Metanilic Acid) ,3 Di Nitro Di Phenyl Sulphone (3 3 DDS) Meta Nitro Benzene Sulphonic acid (Resist salt) or 3,3 Di Nitro Di phenyl Sulphone Nitro 1-Di-Azo 2-Napthol 4-sulfonic acid (6 Nitro 1,2,4 Diazo) Amino 5- Hydroxy Naphthalene-1,7 Di Sulphonic acid (K Acid) Nitro Benzene Meta di Nitro Benzene N-Ethyl-N-Benzyl Aniline m-sulphonic Acid(EBAMSA) Para Phenylene Di amine (PPD) meta Nitro Para Toludine (MNPT) Di phenyl Epsilon Acid Naphthol 8- Sulfonic acid Naphthol 4, 8 sulfonic acid , 5 Di Nitro Benzoic Acid (3,5 DNBA) ,5 Di Amino Benzoic Acid (3,5 DABA) ,4,5 Tri Chloro Aniline Ortho Amino Phenol Meta Nitro Chloro Benzene (MNCB) N-N Di Ethyl -m- Amino Phenol (DEMAP) P-AMINO BENZOIC ACID DI Calcium Phosphate Total Manufacturing process is attached as Annexure RESOURCE REQUIREMENT: Components Existing Proposed Total Resources Availability Power, KVA Sourced from Dakshin Gujarat Vij Co. Ltd. Fresh Water, KLD Will be sourced from GIDC Water Supply Dept. Coal, kg/h for Thermic fluid heater: I Sourced from local dealer (20 lakhs k cal/h) Coal, kg/h for Thermic fluid heater: II Sourced from local dealer (25 lakhs k cal/h) Coal, kg/h for Steam boiler(2 TPH) Sourced from local dealer Fuel (HSD), kg/h for D.G. Set: (Capacity: 500 KVA) Sourced from local dealer Cooling Tower, TR In-House Expansion project- Dye Intermediates Page 2

4 1.3 RAW MATERIAL CONSUMPTION: Consumption in MT # Raw Materials CAS No. After MT/Ton Existing Proposed Expansion 1.0 For 2- Naphthylamine 4,6,8 tri Sulfonic acid (Sulpho G Acid) 1.1 Sulphuric Acid Oleum (65%) G-Acid Salt For 4-Nitro 2 amino phenol 6 Sulfonic acid (4 NAPSA) 2.1 Oleum (23%) PNCB Nitric Acid Caustic soda Salt NaHS For 6-Nitro 2 amino phenol 4 Sulfonic acid (6 NAPSA) 3.1 Oleum (23%) ONCB Nitric Acid Salt Caustic NaHS For 2- Amino Phenol 4- Sulfonamide (OPSAMIDE) 4.1 Chloro Sulfonic acid ONCB ONCB PSA Ammonia Caustic lye Iron Powder HCI For 1 Naphthyl amine 3,6,8 tri Sulfonic acid (KOCH ACID) 5.1 Naphthalene Sulphuric acid (98%) Oleum Nitric Acid Lime Stone Soda Ash Caustic Iron powder HCI For M-Amino Phenol (MAP) 6.1 Metanilic acid Caustic lye For 1-Naphthol 3,6 di Sulfonic acid (Violet Acid) 7.1 Naphthalene Sulphuric Acid 98% Oleum 65 % Lime Stone Sodium sulphate Caustic Flaks Expansion project- Dye Intermediates Page 3

5 7.7 HCI Caustic lye For 1-Naphthol 3,8 di Sulfonic acid (EPSILONE ACID) 8.1 Oleum 65 % Sulphuric Acid (98%) Naphthalene Nitric Acid (98%) Lime Stone MgO Iron powder HCI Caustic lye Sodium Nitrite For 1- amino 8 naphthol 4,6 di sulfonic acid (European K Acid) 9.1 Naphthalene Sulphuric Acid (98%) Oleum 65 % Nitric Acid Lime stone Soda ash HCl Iron Caustic lye For 2- Naphthylamine 4,8 di Sulfonic acid (C Acid) 10.1 Naphthalene Sulphuric acid Oleum Nitric acid MgO HCl Iron Powder Caustic lye For 2 - Chloro 5 - Toludine 4 - Sulphonic acid (CLT acid) 11.1 Toluene Sulphuric acid Chlorine gas Ferric chloride Nitric acid % Dedanol OT Common salt Soda ash Iron HCl (30%) Caustic lye For 1- naphthylamine 8- hydroxy 2,4 di sulfonic acid (Chicago Acid) 12.1 Peri acid Oleum 65 % Sulphuric Acid (98%) Oleum (23%) Lime Soda Ash Caustic flaks Caustic lye Expansion project- Dye Intermediates Page 4

6 12.9 HCI For 3- Amino Benzene Sulphonic acid (Metanilic Acid) 13.1 Nitro Benzene Oleum 65% Hydrated lime Soda ash CI Powder HCl Sulphuric acid For 3,3 Di Nitro Phenyl Sulphone (3 3 DDS) 14.1 Wet cake of 3,3 DDS For Meta Nitro Benzene Sulphonic acid (Resist salt) 15.1 Nitro Benzene Oleum 65% Hydrated lime Soda ash For 6-Nitro 1-Di-Azo 2-Napthol 4-sulfonic acid (6 Nitro 1,2,4 Diazo) 16.1 Caustic Lye Beta Naphthol Sodium Nitrate Sodium bi-sulfite Sulphuric acid Ice Oleum 23% Nitric acid For 4- Amino 5- Hydroxy Naphthalene-1,7 Di Sulphonic acid (K Acid) 17.1 B Naphthol Sulphuric Acid (98%) Oleum (65%) Ice Sodium Sulphate % Ammonia Sodium Bicarbonate Caustic lye For Nitro Benzene 18.1 Sulphuric acid Nitric acid Benzene Caustic soda For Meta di Nitro Benzene 19.1 Nitro Benzene , Nitric Acid Sulphuric acid Caustic lye For EBAMSA 20.1 EBA Oleum Sulphuric Acid Caustic lye For Para Phenylene Di amine (PPD) 21.1 PNA Iron HCl Expansion project- Dye Intermediates Page 5

7 22.0 For meta Nitro Para Toludine (MNPT) 22.1 P- Toluene Acetic acid Nitric Acid Caustic lye For Di phenyl Epsilon Acid 23.1 Epsilon Acid Aniline Sulphuric Acid Naphthol 8- Sulfonic acid 24.1 Peri acid Sulphuric Acid NaNO Caustic lye For 1 Naphthol 4, 8 sulfonic acid 25.1 Peri acid Sulphuric Acid NaNO Caustic lye For 3, 5 Di Nitro Benzoic Acid (3,5 DNBA) 26.1 Benzoic Acid Sulphuric acid (98%) Nitric Acid (63%) Oleum (23%) For 3,5 Di Amino Benzoic Acid (3,5 DABA) 27.1 DNBA Iron HCl For 2,4,5 Tri Chloro Aniline 28.1 TCB Sulphuric acid Nitric acid Soda ash Iron HCl Sodium Nitrite Caustic lye For Ortho Amino Phenol 29.1 PNCB Caustic Fe HCI For Meta Nitro Chloro Benzene (MNCB) 30.1 Nitrobenzene , Chlorine Ferric Chloride Lime N-N Di Ethyl -m- Amino Phenol (DEMAP) 31.1 Matanilic acid Caustic Flakes Di Ethyl Sulphate ; Sulphuric acid For P-Amino Benzoic acid Expansion project- Dye Intermediates Page 6

8 Nitro Benzoic acid Pd/C NaOH HCl H N For DI Calcium Phosphate 33.1 Rock Phosphate Spent Sulphuric Acid Lime WATER AND WASTE WATER MANAGEMENT Total Raw Water requirement after proposed expansion will be 150 KLD ( KLD fresh KLD recycled), 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 45.5 KLD, out of which 27.5 KLD of process water will be evaporated in proposed multi effect evaporator and balance 18 KLD of industrial effluent will be treated in existing primary & 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 (5 KLD) will be disposed off through Septic Tank. 1.5 AIR EMISSION AND ITS CONTROL MEASURES Existing: Flue Gas Emission: Presently, we are using 20 lakhs k cal/h capacity of Thermic fluid heater having coal consumption is 500 kg/h and 11 meters height of chimney provided. Process Gas Emission: There is a generation of SO 2 gas from reaction and SO 3 gas from Oleum Storage Tank. To scrub process gas emission, we have provided two stage acid followed by alkali scrubber having 11 meter height of chimney Proposed expansion: Flue Gas Emission: For the proposed expansion, we will utilize existing Thermic fluid heater with increase coal consumption from 500 kg/h to 600 kg/h. Also we shall install one additional Thermic fluid heater of 25 lakhs k cal/h capacity having coal consumption will be 550 kg/h. Adequate capacity of bag filter and 30 meters height of chimney will be provided, we will also install one steam boiler of 2 TPH capacity having 400 kg/h of coal consumption. Adequate capacity of common multi cyclone separator followed by bag filter and 30 meters height of chimney will be provided. Also install one number of D G set with capacity of 500 KVA running on HSD at a fuel rate of 115 kg/h and 11 meters height of chimney will be provided. Process Gas Emission: For the proposed expansion, Cl 2, HCl, SO 3, SO 2, NOx and NH 3 gases will be generated. After proposed expansion we will install total four numbers of two stage scrubbing system. (Detail of Air pollution control measures is attached as Annexure-10). Expansion project- Dye Intermediates Page 7

9 1.6 HAZARDOUS WASTES AND ITS MANAGEMENT # Type Used Oil (Sch: I /5.1) Discarded Containers (Sch: I /33.1) Waste from ETP (Sch: I/ 35.3) Process Waste (Sch: I/26.1) Spent Acid (45-78%) (Sch: I/26.3) Hydro Chloric Acid (30%) (Sch: I/26.3) Sodium Bi Sulphite Soln. 7. (48%) (Sch: II/B23) Ammonium Sulphite 8. (40%) Soln. (Sch: II/B1) Sludge from Wet Scrubber 9. (Sch: (I/37.1) Salt from MEE 10. (Sch: I/35.3) Non Hazardous Solid waste Quantity, TPA Existing Proposed Total Fly Ash Disposal Sell to registered recycler Dispose off into TSDF, Vapi Sell to cement industries or dispose off into TSDF, Vapi Utilize for manufacturing of in-house di calcium phosphate or sell to actual users under hazardous waste rules Recycle in the process or sell to actual users under hazardous waste rules 2016 Sell to actual users under hazardous waste rules 2016 Sell to actual users under hazardous waste rules 2016 Dispose off into ETP/MEE for treatment Dispose off into TSDF, Vapi Sell to Brick manufacturers or cement industry 1.7 INTRODUCTION OF THE PROJECT AND THE PROPONENT. Name of the project Proponent: M/S M/S is a Small Scale unit located in Notified Industrial Area, GIDC, Vapi Tal.: Pardi, Dist.: Valsad, Gujarat having total plot area of 5000 m 2 and total investment after proposed expansion will be Rs. 758 Lakhs. 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 various dyes manufacturer as per requirement. The unit is operated by technocrats having more than 30 years of experience in manufacturing and marketing of dyes, dyes intermediates & chemicals worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. Expansion project- Dye Intermediates Page 8

10 The proposed expansion project is to enhance the capacity of one existing product and addition of new products of same group. At a time 3 to 4 dyes intermediates products will be manufactured and process capabilities to manufacture all types of Dyes intermediates. The proposed expansion project site lies on 20 o N Latitude & E Longitude. M/S is located at Plot. No. 1712, Phase III Notified Industrial Area, GIDC Vapi, Tal.: Pardi, Dist.: 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. M/S was started in the year of 2010.Earlier the unit was known as M/S Solar Dyestuff Pvt. Limited and manufactured Dyes intermediates. We have purchased said premises in the year of 2010 along with land, plant, building and machineries and amend the existing CCA of the board. Most of the products have been developed through strong in-house R&D. The Group's turnover is about 25 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. 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 is a small scale unit is located at Notified Industrial Area, GIDC Vapi, Tal.: Pardi, Dist.: Valsad, managed by enthusiastic and professional manufacturers Name of Personnel: # Name of Partner Qualification 1 Mr. Sanjay Desai Electrical Engineer 2 Mr. Kevin Desai MBA Brief description of nature of the Project: M/S proposes to enhance the production capacity at Plot No. 1712, Phase III, Notified Industrial Area GIDC, Vapi , Tal.: Pardi, 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 and Dye 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 Expansion project- Dye Intermediates Page 9

11 international speciality Grades. Thus the Domestic Industry can replace the imported dyes used by them with ours and there by curtail the outflow of foreign currency spent on dyes 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 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 and dyes intermediates business, the proposed increase in capacity will also help the company to standardize and produce the dyes and dye intermediates 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 dye intermediates products are especially used by dyes manufacturing industries as per requirement. Since our products are approved by quality conscious users which are multinational companies. We shall propose to 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 US 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 dyes intermediates products are especially used by dyes manufacturing 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 its need to handle the plant. Presently there are 20 numbers of employees. There will be additional 30 numbers of employees, thus total 50 numbers of employees after proposed expansion. Expansion project- Dye Intermediates Page 10

12 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 small Scale category of manufacturing industries 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 and characteristics of hazardous chemicals are as below # Product DETAILS ON PRODUCT TRANSPORTATION Physical State Dispatch Packing & Means of Transportation Naphthylamine 4,6,8 tri Sulfonic acid (Sulpho G Acid) Powder Local Bags/Truck 2. 4-Nitro 2 amino phenol 6 Sulfonic acid (4 NAPSA) or Powder Local Bags/Truck 3. 6-Nitro 2 amino phenol 4 Sulfonic acid (6 NAPSA) Powder Local Bags/Truck Amino Phenol 4- Sulfonamide (OPSAMIDE) Powder Local Bags/Truck 5. 1 Naphthyl amine 3,6,8 tri Sulfonic acid (KOCH ACID) Powder Local Bags/Truck 6. M-Amino Phenol (MAP) Powder Local Bags/Truck 7. 1-Naphthol 3,6 di Sulfonic acid (Violet Acid) Powder Local/Export Bags/Container 8. 1-Naphthol 3,8 di Sulfonic acid (EPSILONE ACID) Powder Local/Export Bags/Container Naphthylamine 4,8 di Sulfonic acid Powder Local/Export Bags/Container Expansion project- Dye Intermediates Page 11

13 (C Acid) amino 8 naphthol 4,6 di sulfonic acid (European K Acid) Powder Local/Export Bags/Container Chloro 5 - Toludine 4 - Sulphonic acid (CLT acid) Powder Local/Export Bags/Container naphthylamine 8- hydroxy 2,4 di sulfonic acid (Chicago Acid) Powder Local/Export Bags/Container Amino Benzene Sulphonic acid (Metanilic Acid) Powder Local/Export Bags/Container 14. 3,3 Di Nitro Phenyl Sulphone (3 3 DDS) Powder Local/Export Bags/Container 15. Meta Nitro Benzene Sulphonic acid (Resist salt) Powder Local/Export Bags/Container Nitro 1-Di-Azo 2-Napthol 4-sulfonic acid (6 Nitro 1,2,4 Diazo) Powder Local/Export Bags/Container Amino 5- Hydroxy Naphthalene-1,7 Di Sulphonic acid (K Acid) Powder Local/Export Bags/Container 18. Nitro Benzene Liquid Local Tanker 19. Meta di Nitro Benzene Powder Local Bags/Truck 20. N-Ethyl-N-Benzyl Aniline m-sulphonic Acid(EBAMSA) Powder Local Bags/Truck 21. Para Phenylene Di amine (PPD) Powder Local Bags/Truck 22. meta Nitro Para Toludine (MNPT) Powder Local Bags/Truck 23. Di phenyl Epsilon Acid Powder Local Bags/Truck Naphthol 8- Sulfonic acid Powder Local Bags/Truck Naphthol 4, 8 sulfonic acid Powder Local Bags/Truck 26. 3, 5 Di Nitro Benzoic Acid (3,5 DNBA) Powder Local Bags/Truck 27. 3,5 Di amino Benzoic Acid (3,5 DABA) Powder Local Bags/Truck 28. 2,4,5 Tri Chloro Aniline Powder Local Bags/Truck 29. Ortho Amino Phenol Powder Local Bags/Truck 30. Meta Nitro Chloro Benzene (MNCB) Powder Local Bags/Truck 31. N-N Di Ethyl -m- Amino Phenol (DEMAP) Powder Local Bags/Truck 32. P-AMINO BENZOIC ACID Powder Local Bags/Truck 33. DI Calcium Phosphate Powder Local Bags/Truck # Substance DETAILS OF RAW MATERIAL TRANSPORTATION Physical State Type of Packing & Supply Means of Transportation Distance of Supplier from Project Site (km) 1. Sulphuric Acid Liquid Tanker Tanker 5-10 kms 2. Oleum (65%) Liquid Tanker Tanker 5-10 kms 3 G-Acid Powder Bags Truck kms 4. Salt Powder Bags Truck kms 5. PNCB Powder Bags Truck kms 6. Nitric Acid Liquid Tanker Tanker 5-10 kms 7. Caustic soda Liquid Tanker Tanker kms 8. NaHS Liquid Tanker Tanker kms 9. ONCB Powder Bags Truck kms 10. Caustic lye Liquid Tanker Tanker kms 11. Chloro Sulfonic acid Liquid Tanker Tanker 5-10 kms 12. ONCB PSA Powder Bags Truck kms 13. Liquor Ammonia Liquid Tanker Tanker 5-10 kms 14. Iron Powder Powder Bags Truck kms Expansion project- Dye Intermediates Page 12

14 15. HCI Liquid Tanker Tanker 5-10 kms 16. Naphthalene Powder Bags Truck kms 17. Lime Stone Powder Bags Truck kms 18. Soda Ash Powder Bags Truck kms 19. Metanilic acid Powder Bags Truck kms 20. Sodium sulphate Powder Bags Truck kms 21. Caustic Flaks Powder Bags Truck kms 22. MgO Powder Bags Truck kms 23. Sodium Nitrite Powder Bags Truck kms 24. Toluene Liquid Drum Truck kms 25. Chlorine gas Liquid Cylinder Truck km 26. Ferric chloride Powder Bags Truck kms 27. Peri acid Powder Bags Truck 5-10 kms 28. Nitro Benzene Liquid Tanker Tanker kms 29. Beta Naphthol Powder Bags Truck kms 30. Sodium bi-sulfite Powder Bags Truck kms 31. Ice slab Bags truck 5-25 kms 32. Sodium Bicarbonate Powder Bags Truck kms 33. EBA Liquid tanker Tanker 150 kms 34. PNA Powder Bags Truck kms 35. P- Toludine liquid Drum truck kms 36. Acetic acid liquid Drum truck kms 37. Epsilon Acid Powder Bags Truck kms 38. Aniline liquid Drum truck kms 39. Benzoic Acid Powder Bags Truck kms 40. DNBA Powder Bags Truck kms 41. TCB Powder Bags Truck kms 42. Matanilic acid Powder Bags Truck kms 43. Di Ethyl Sulphate liquid Drum truck kms Nitro Benzoic acid Powder Bags Truck kms 45. Pd/C Powder Bags Truck kms 46. H2 Gas Cylinder Truck kms 47. N2 Gas Cylinder Truck kms 48. Rock Phosphate Powder Bags Truck kms Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outline: Resource optimization/recycling and reuse envisaged in the project 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. There will be no use of any solvent. Rain water harvesting shall be done and recycled the rain water for cooling and washing purpose to minimize the fresh water consumption. Condensate from MEE will be recycled in the process to minimize the fresh water consumption Availability of water source, Energy/Power requirement and source should be given: Availability of water its source, Energy/power required and its source is below. Expansion project- Dye Intermediates Page 13

15 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, KLD WATER CONSUMPTION # Particulars Water Consumption, KLD Existing Proposed Total A. Domestic B. Industrial 1. Processing, Product Washing & Scrubber Cooling Boiler Floor/Container/Equipment Washing Total Industrial C. Gardeining D. Total (A+B+C) E. Condensate from MEE Net Fresh Water (D-E) Water Balance Diagram at Existing Scenario Total water consumption, 43.0 M3/day sourced from GIDC Vapi Processing, product washing & Scrubber: 17.0 Boiler: 0 Cooling: 20 Washing: 2.0 Domestic: 3.0 Gardening: Blow Down: Septic tank Total effluent: 18.0 Primary and Tertiary ETP CETP, Vapi Tidal zone of River Damanganga to Arabian Sea Expansion project- Dye Intermediates Page 14

16 Water Balance Diagram After proposed Expansion Total water consumption, 150 M3/day (Fresh: Recycled: ) Source from GIDC Processing, product washing & Scrubber: Floor/ container/equipment Washing: Cooling:35.0 Blow Down: 2.0 Boiler: 25.0 Domestic: 5.0 Blow Down: 2.5 Septic tank Gardening: 2.0 ETP: 3.0 ETP: 2.0 ETP: 2.5 High TDS/COD: 27.5 Low TDS/COD: 10.5 Total effluent: 18.0 MEE/Centrifuge: 27.5 Primary and Tertiary ETP Salt: 4.1 Condensate: 22,85 Loss: 0.55 CETP, Vapi TSDF Vapi Recycle in process Tidal zone of River Damanganga to Arabian Sea # Particulars 1. Steam Requirement ENERGY REQUIREMENTS AND ITS SOURCE Quantity, kg/h Existing Proposed Total Source Will be obtained by existing 20 lakhs k cal/h TFH and proposed 2 TPH boiler & 25 lakhs k cal/h TFH # Particulars 1. Power Electricity Requirement POWER REQUIREMENTS AND ITS SOURCE Quantity, KVA Existing Proposed Total 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 -9. Expansion project- Dye Intermediates Page 15

17 1.9 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 Soil Classification: General soil classification of the area is as under: Soil Characteristics and Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, Clay, Red soil. The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose. The land is suitable for industrial development. Damanganga River is located at 1.5 km distance in South direction from the site location; both side of the river has mixed soil type (Sand, clay and 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. Expansion project- Dye Intermediates Page 16

18 Rainfall projection for Project site and Gujarat for 2011 (June-Oct.) # 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) 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 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. Unit had already developed greenbelt area in about 800 m 2 area. After proposed expansion total greenbelt area will be 1500 m 2 (30%) of 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. Expansion project- Dye Intermediates Page 17

19 SITE PLAN WITH AREA TABLE AT EXISTING & AFTER PROPOSED EXPANSION Area in m 2 # Particulars Total after % Area Existing Proposed expansion 1.0 Total Plot Area Production Plant Office and Lab Area Green Belt Raw Materials and F G Storage Solid Waste Storage Area Boiler Shed Area ETP Area Toilet Block Internal road Open Space 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. Expansion project- Dye Intermediates Page 18

20 Amenities/ Facilities: Notified Industrial Area, GIDC - 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 30% 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): 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, Vapi Water Supply services Sewerage System: GIDC, Vapi has provided sewerage system to dispose the sewage effluent Industrial Waste Management: Total industrial Waste Water Generation will be 45.5 KLD, out of which 27.5 KLD of process water will be evaporated in proposed multi effect evaporator and balance 18 KLD of industrial effluent will be treated in existing primary & tertiary effluent treatment plant and finally treated effluent will be disposed off into CETP Vapi for further treatment and disposal into Arabian Sea. (Membership certificate is attached as Annexure-6) Generated domestic liquid waste is being disposed off through septic tank. Expansion project- Dye Intermediates Page 19

21 Solid/Hazardous Waste Management: # Type Used Oil (Sch: I /5.1) Discarded Containers (Sch: I /33.1) Waste from ETP (Sch: I/ 35.3) Process Waste (Sch: I/26.1) Spent Acid (45-78%) (Sch: I/26.3) Hydro Chloric Acid (30%) (Sch: I/26.3) Sodium Bi Sulphite Soln. 7. (48%) (Sch: II/B23) Ammonium Sulphite 8. (40%) Soln. (Sch: II/B1) Sludge from Wet Scrubber 9. (Sch: (I/37.1) Salt from MEE 10. (Sch: I/35.3) Non Hazardous Solid waste Quantity, TPA Existing Proposed Total Fly Ash Disposal Sell to registered recycler Dispose off into TSDF, Vapi Sell to cement industries or dispose off into TSDF, Vapi Utilize for manufacturing of in-house di calcium phosphate or sell to actual users under hazardous waste rules Recycle in the process or sell to actual users under hazardous waste rules 2016 Sell to actual users under hazardous waste rules 2016 Sell to actual users under hazardous waste rules 2016 Dispose off into ETP/MEE for treatment Dispose off into TSDF, Vapi Sell to Brick manufacturers or cement industry (Membership certificate is attached as Annexure-6) 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- Dye Intermediates Page 20

22 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. CAPITAL COST PROJECTION # Particulars Amount (Lakhs) Existing Proposed Total 1.0 Land 5000 m Building Equipment and Machineries Pipes and Fittings Utilities Environmental Management System Total Project Cost UTILITIES REQUIREMENT # Particulars Existing Proposed Total 1.0 Utilities 1. Thermic fluid heater, lakhs k cal/h Thermic fluid heater, lakhs k cal/h Boiler, TPH Cooling Tower, TR DG Set (Standby), KVA Power from DGVCL, KVA Fuel 1. Coal (kg/h) HSD (kg/h) Fresh Water from GIDC Vapi, KLD Waste Water (Industrial) KLD PROJECT VIABILITY # PARTICULARS AMOUNT (INR Lakhs) 1. Proposed Sale Raw Material Cost Power & Fuel Labour Cost Environmental Management System Maintenance Cost Selling, packing & Office Expenses Proposed Profit 120 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. Expansion project- Dye Intermediates Page 21

23 RECURRING/OPERATING COST PER ANNUM # Component Proposed (Rs. in Lakhs/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- Dye Intermediates Page 22

24 ANNEXURES Expansion project- Dye Intermediates Page 23

25 ANNEXURE: 1 Location map showing the Project site and inter-state boundary within 10 kms radius Expansion project- Dye 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. (1) Mass Balance for 2- Naphthylamine 4,6,8 tri Sulfonic acid (Sulpho G Acid) Sulphuric Acid : 3300 Kgs Oleum (65%) : 3000 Kgs G-Acid : 1050 Kgs SULPHONATION SO2 gas: 27 kgs Water: 100 kgs Caustic: 50 kgs Scrubber Sulfo mass : 7323 Kgs Water : 7000 Kgs DRAWNING To ETP: 177 kgs Drowning mass : Kgs Salt : 1500 Kgs ISOLATION FILTERATION Waste Water to MEE : Kgs CENTRIFIGE Wet Cake of Sulpho G Acid: 1700 kgs Expansion project-dyes Intermediates Page 26

28 (2) Mass Balance of 4-Nitro 2 amino phenol 6 Sulfonic acid (4 NAPSA) Oleum (23%) : 1000 Kgs PNCB : 350 Kgs Sulfonation SO2 gas: 12 kg Water: 100 kgs Caustic: 50 kgs Sulfo mass : 1338 Kgs Nitric Acid : 300 Kgs Nitration NOx gas: 9 kgs Alkali Scrubber To ETP: 171 kgs Nitro mass : 1629 Kgs Water : 1500 Kgs Salt : 500 Kgs Drowning Drowning mass : 3629 Kgs Filtration Centrifuge Waste water to MEE: 2429 kgs Nitro wet cake : 1200 Kgs Caustic : 300 Kgs NaHS : 800 Kgs Hydrolysis mass : 2300 Kgs Nitro Wet cake: 1200 Kgs Hydrolysis & reduction Filtration Centrifuge Waste water to MEE: 1700 kgs Wet cake of 4 NAPSA: 600 kgs Expansion project-dyes Intermediates Page 27

29 (3) Mass Balance for 6-Nitro 2 amino phenol 4 Sulfonic acid (6 NAPSA) Oleum (23%) : 1000 Kgs ONCB : 350 Kgs Sulfonation SO2 gas: 12 kg Water: 100 kgs Caustic: 50 kgs Sulfo mass : 1338 Kgs Nitric Acid : 300 Kgs Nitration NOx gas: 9 kgs Alkali Scrubber To ETP: 171 kgs Nitro mass : 1629 Kgs Water : 1500 Kgs Salt : 500 Kgs Drowning Drowning mass : 3629 Kgs Filtration Centrifuge Waste water to MEE: 2429 kgs Nitro wet cake : 1200 Kgs Caustic : 300 Kgs NaHS : 800 Kgs Hydrolysis mass : 2300 Kgs Nitro Wet cake: 1200 Kgs Hydrolysis & reduction Filtration Centrifuge Waste water to MEE: 1700 kgs Wet cake of 4 NAPSA: 600 kgs Expansion project-dyes Intermediates Page 28

30 (4) Mass Balance for 2- Amino Phenol 4- Sulfonamide (OPSAMIDE) Chloro Sulfonic acid : 2400 Kgs ONCB : 1100 Kgs Sulfo mass : 2971 Kgs Water : 3000 Kgs Drowning mass : 5971 Kgs Sulfonation Drowning Filtration HCl gas: 529 kgs Scrubber Water: 1234 kgs 30% HCl: 1763 kgs Water to ETP : 3771 Kgs ONCB PSA : 2200 Kgs Ammonia : 700 Kgs Water : 1000 Kgs Amidation Mass : 3900 Kgs 1 Amino 2 -Nitro P-S Acid : 2500 Kgs Caustic lye : 700 Kgs Centrifuge: 2200 kgs Amidation Filtration & Centrifuge Hydrolysis Water to ETP : 1400 Kgs 1 Amino 2 Nitro Para Sulphonic acid: 2500 kgs Hydrolysis mass : 3200 Kgs Iron Powder : 1000 Kgs HCI : 50 Kgs Reduction Isolation Iron sludge : 2000 Kgs Water (ETP) : 550 Kgs Centrifuge: 1700 kgs Product ( OPSAMIDE): 1700 kgs Expansion project-dyes Intermediates Page 29

31 (5) Mass Balance For 1 Naphthyl amine 3,6,8 tri Sulfonic acid (KOCH ACID) Naphthalene : 1000 Kgs Sulphuric acid (98%): 1100 Kgs Oleum : 1500 Kgs Sulfonation SO2 gas: 12 kg Water: 100 kgs Caustic: 50 kgs Alkali Scrubber Sulfo mass : 3588 Kgs Nitric Acid : 800 Kgs Nitration NOx gas: 9 kgs To ETP: 171 kgs Nitro mass : 4379 Kgs Water : 5000 Kgs Lime Stone : 4500 Kgs Soda Ash : 500 Kgs Neutralization mass : Kgs Water wash (Recycled) : 3000 Kgs Nitro Liquer : 5379 Kgs Iron powder : 900 Kgs HCI : 100 Kgs Water wash (Recycled) : 2000 Kgs Reduction mass : 4379 Kgs Sulphuric acid : 600 Kgs Neutralization Filtration Reduction Isolation Filteration Gypsum : 9000 kgs Water reuse : 3000 Kgs Sludge : 2000 Kgs Water reuse : 2000 Kgs Water to ETP : 1979 Kgs Centrifuge Product (KOCH Acid): 3000 kgs Expansion project-dyes Intermediates Page 30

32 (6) Mass Balance for M-Amino Phenol (MAP) Metanilic acid: 1250 kgs Caustic lye: 625 kgs Water: 1250 kgs FUSION DRAWNING Drowning Mass: 3125 kgs FILTERATION WET CAKE: 1125 KGS Filtrate to ETP: 2000 kgs ( 750 kgs NaHSO Water) DISTILLATION Process waste: 607 kgs PRODUCT: 518 KGS Expansion project-dyes Intermediates Page 31

33 (7) Mass Balance for 1-Naphthol 3,6 di Sulfonic acid (Violet Acid) Naphthalene : 500 Kgs Sulphuric Acid 98% : 1000 Kgs Oleum 65 %: 1500 Kgs Sulfonation SO2 gas: 32 kg Water: 100 kgs Caustic: 50 kgs Alkali Scrubber Sulfo mass : 2968Kgs Water : 3000 Kgs Lime Stone : 3000 Kgs Sodium sulphate : 900 Kgs Drowning To ETP: 182 kgs Drowning mass : 9868 Kgs Filtration Gypsum : 5500 Kgs Evaporation Water evaporate : 2368Kgs Caustic Flaks : 1000 Kgs Evaporation Mass : 2000 Kgs Fusion mass : 3000 Kgs Water : 2000 Kgs HCI : 500 Kgs Fusion Drowning Waste water to MEE: 4875 kgs Centrifuge: 625 kgs Product: 625 kgs Expansion project-dyes Intermediates Page 32

34 (8) Mass Balance for 1-Naphthol 3,8 di Sulfonic acid (EPSILONE ACID) Oleum 65 % : 1000 Kgs Sulphuric Acid (98%) : 1200 Kgs Naphthalene : 2000 Kgs Sulfonation SO2 gas: 38 kg Water: 100 kgs Caustic: 50 kgs Sulfo mass : 4162 Kgs Nitric Acid (98%) : 800 Kgs Nitro mass : 4953 Kgs Lime Stone : 7000 Kgs MgO : 800 Kgs Water : Kgs Neutralization mass : Kgs Water wash : 5000 Kgs Nitro Liquer : 7950 Kgs Iron powder : 2000 Kgs HCI : 100 Kgs Water wash : 2000 Kgs Amino liquor : 6050 Kgs Sul. Acid : 500 Kgs W/C : 2200 Kgs Sodium Nitrite: 230 Kgs HCI : 200 Kgs Nitration Neutralization Filtration Reduction Isolation Centrifuge: 2200 kgs Diazotization Filteration NOx gas: 9 kgs Sludge : Kgs Wash water : 5000 Kgs Iron Sludge : 4000 Kgs Water reuse : 2000 Kgs Water to ETP : 4350 Kgs Alkali Scrubber To ETP: 188 kgs Water to ETP : 2030 Kgs Centrifuge: 600 kgs Product: 600 kgs Expansion project-dyes Intermediates Page 33

35 (9) Mass balance for 1- amino 8 naphthol 4,6 di sulfonic acid (European K Acid) Naphthalene : 1000 Kgs Oleum 65 %: 1500 Kgs Sulfonation SO2 gas: 38 kg Water: 100 kgs Caustic: 50 kgs Sulfo mass : 2462 Kgs Nitric Acid : 800 Kgs Nitro mass : 3246 Kgs Water: 2000 kgs Lime Stone: 1800 kgs Soda ash: 400 kgs Water: 2000 kgs Nitration Neutralization Filter NOx gas: 16 kgs Water: 1946 kgs recycle Gypsum sludge: 4000 kgs Alkali Scrubber To ETP: 204 kgs Filtrate: : 3500 Kgs HCI : 100 Kgs Iron: 900 Kgs Water: 1500 kgs Reduction mass : 2500 Kgs Caustic lye: 600 kgs Fusion mass : 3100 Kgs Sulphuric acid : 200 Kgs Water: 700 kgs Reduction Filtration Fusion Drowning Filteration Centrifuge Product: 1350 kgs Iron sludge : 2000 Kgs Water recycle: 1500 kgs Waste water to ETP: 2650 kgs Expansion project-dyes Intermediates Page 34

36 (10) Mass Balance for 2- Naphthylamine 4,8 di Sulfonic acid (C Acid) Naphthalene : 625Kgs Sulphuric Acid (98%) :2500 Kgs Oleum 65 %: 2400 Kgs Sulfonation SO2 gas: 38 kg Water: 100 kgs Caustic: 50 kgs Sulfo mass : 5487 Kgs Nitric Acid : 350 Kgs Water : 4000 Kgs MgO : 325 Kgs Nitration Drowning NOx gas: 12 kgs Alkali Scrubber To ETP: 191 kgs Filter Waste water to ETP: 8050 Kgs Centrifuge Nitro Wet cake: 2100 kgs Water : 3000 Kgs HCI : 35 Kgs Iron: 500 Kgs Reduction mass : 5635 Kgs Amino mass : 4135 Kgs Sulphuric acid : 200 Kgs Isolation mass : 4335 Kgs Reduction Filtration Isolation Filteration Centrifuge Product: 1000 kgs Iron sludge : 1500 Kgs Waste water to ETP: 3335 kgs Expansion project-dyes Intermediates Page 35

37 (11) Mass Balance for 2 - Chloro 5 - Toludine 4 - Sulphonic acid (CLT acid) Toluene: 500 kgs Sulphuric acid: 735 kgs Chlorine gas: 385 kgs Ferric chloride: 3.2 kgs Sulphuric acid: 1530 kgs Nitric acid: 353 kgs 20% Dedanol OT: 64 kgs Common salt: 1152 kgs Water: 3550 kgs SULPHONATION at C CHLORINATION at C NITRATION at C ISOLATION Chlorine gas: 193 kgs Nitrous oxide: 239 kgs Spent acid (32%): 4640 kgs Water: 450 kgs Scrubber HCl (30%): 643 kgs Caustic soln (20%): 1000 kgs Scrubber Waste water to ETP: 1239 kgs 30% brine water wash: 5400 kgs Nitro Wet cake: 3200 kgs Soda ash: 20 kgs Iron: 350 kgs HCl (30%): 80 kgs Water: 3000 kgs Water: 1000 kgs Mother Liquor for Isolation: 7100 kgs 30% HCl: 395 kgs Water: 500 kgs FILTERATION REDUCTION FILTERATION ISOLATION FILTERATION Wash water: 5400 kgs Nitro Wet cake: 3200 kgs Ferric Oxide Sludge: 550 kgs Mother Liquor for Isolation: 7100 kgs ML to ETP: 7588 kgs CLT- ACID: 407 kgs (70% purity) Expansion project-dyes Intermediates Page 36

38 (12) Mass Balance for 1- naphthylamine 8- hydroxy 2,4 di sulfonic acid (Chicago Acid) Peri acid : 250 Kgs Oleum 65 % : 500 Kgs Sulphuric Acid (98%): 1500 Kgs Oleum : (23%) : 600 kgs Sulfonation SO2 gas: 38 kg Water: 100 kgs Caustic: 50 kgs Sulfonation mass : 2812 Kgs Water : 3000 Kgs Lime : 2000 Kgs Soda Ash : 150 Kgs Drowning Alkali Scrubber To ETP: 188 kgs Drowning Mass : 7962 Kgs Filtration Gypsum : 3462 Kgs Filtrate: 4500 Kgs Evaporator liq. : 2000 Kgs Caustic flaks : 100 Kgs Caustic : 150 Kgs Evaporation Fusion Water evaporation : 2500 Kgs Fusion mass : 2250 Kgs Water : 1500 Kgs HCI : 300 Kgs Drowning Centrifuge Water ETP : 3750 Kgs Product: 300 kgs Expansion project-dyes Intermediates Page 37

39 (13) MASS BALANCE FOR 3- Amino Benzene Sulphonic acid (Metanilic Acid) Nitro Benzene: 1250 kgs Oleum 65%: 1320 kgs Sulpho Mass: 2570 kgs water: 3000 kgs SULPHONATION DRAWNING Drowning Mass: 5570 kgs FILTERATION Wet cake of 3,3 Di nitro Di phenyl sulphone: 79 kgs FILTRATE : 5491 kgs Drying Vapour loss: 16 kgs Hydrated lime: 750 kgs Soda ash: 625 kgs Wash water: 1000 kgs CI Powder: 1250 kgs HCl: 50 kgs Sulphuric acid: 600 kgs NEUTRALIZATION FILTERATION/WASHING REDUCTION FILTERATION ISOLATION 3,3 Di nitro Di phenyl sulphone: 63 kgs Wet cake of Gypsum: 1930 kgs Iron Sludge: 1250 kgs FILTERATION & CENTRIFUGING Mother liquor: 5002 kgs recycled DRYNIG Evaporation loss: 334 kgs METANILIC ACID: 1250 KGS (14) MASS BALANCE FOR 3,3 Di Nitro Phenyl Sulphone (3 3 DDS) Nitro Benzene: 1250 kgs Oleum 65%: 1320 kgs Sulpho Mass: 2570 kgs water: 3000 kgs Drowning Mass: 5570 kgs SULPHONATION DRAWNING FILTERATION FILTRATE : 5491 kgs for Metanilic acid & Resist Salt Wet cake of 3,3 Di nitro Di phenyl sulphone: 79 kgs Drying Vapour loss: 16 kgs Product: 3,3 Di nitro Di phenyl sulphone: 63 kgs Expansion project-dyes Intermediates Page 38

40 (15) Mass Balance for Meta Nitro Benzene Sulphonic acid (Resist salt) Nitro Benzene: 1250 kgs Oleum 65%: 1320 kgs SULPHONATION Sulpho Mass: 2570 kgs Recycled water: 3000 kgs DRAWNING Drowning Mass: 5570 kgs FILTERATION Wet cake of 3,3 Di nitro Di phenyl sulphone: 79 kgs FILTRATE : 5491 kgs Drying Vapour loss: 16 kgs Hydrated lime: 750 kgs Soda ash: 625 kgs NEUTRALIZATION 3,3 Di nitro Di phenyl sulphone: 63 kgs Wash water: 1000 kgs FILTERATION/WASHING Wet cake of Gypsum: 1930 kgs EVAPORATION Water: 3000 kgs recycled DRYING in SFD Evaporation loss: 936 kgs RESIST SALT: 2000 kgs Expansion project-dyes Intermediates Page 39

41 (16) Mass Balance for 6-Nitro 1-Di-Azo 2-Napthol 4-sulfonic acid (6 Nitro 1,2,4 Diazo) Water : 1000 lit Caustic Lye : 300kg Beta Naphthol : 450 kgs Sodium Nitrate : 220 kg Sodium bi-sulfite : 850 kg Sulfuric acid 98% : 1010 kg Ice : 40 Slabs Sulfonation Filtration in Nutsch Effluent : 6604 kg Water : 2150 kg 1:2:4 Acid : 500 kg Ice : 10 Slabs Sodium Nitrite : 170 kg Sulphuric acid: 410 kg Wet Cake : 500 kg 1:2:4 Acid Di-Azotization Filtration In Nutsch Effluent : 3576 kg Product: 6 Nitro 1:2:4 acid: 820 kgs Centrifuge Centrifuge Filtration In Nutsch Effluent : 4737 kg Centrifuge Cake : 650 kg 1 Di -Azo Water : 2020 kg Ice : 15 Slabs Drawing In Sintex Vessel Sulfuric acid : 450 kg Oleum 23% : 308 kg Sulphuric acid: 940 kg Nitric acid: 172 kg Nitration In S.S Vessel Expansion project-dyes Intermediates Page 40

42 B Napthol : 1330 kgs Sulphuric Acid (98%) : 2270 Kgs Oleum (65%) : 5675 Kgs (17) Mass Balance for 4- Amino 5- Hydroxy Naphthalene-1,7 Di Sulphonic acid (K Acid) Ice : Kgs Water : 1000 Kgs Sodium Sulphate : 4500 Kgs Sulphonation Drowning Isolation SO 2 : 555 Kgs Water: 300 kgs Caustic: 346 kgs Alkali Scrubber Sodium bi sulphite soln (48%): 1201 kgs Wash water: 2500 kgs Filtration Centrifuge Spent Sulphuric acid: 60%: Kgs Spent Sulphuric acid (60%): 2750 Kgs 24 % Ammonia : 6830 Kgs Sodium Bicarbonate : 920 Kgs Amidation NH3 : 445 Kgs Water: 2336 kgs Liq. Ammonia: 2781 kgs Sulphuric acid: 1165 kgs Isolation SO2 : 1650 Kgs Water: 424 kgs Scrubber Wash water : 840 Kgs Filtration & Nutch Centrifuge ML to MEE : 7685 Kgs ML to MEE : 950 Kgs Ammonium Sulphate Soln (40%): 4855 kgs Drying Loss: 675 kgs Product: 1000 kgs (18) Mass Balance for Nitro Benzene Sulphuric acid: 1650 kgs Nitric acid: 600 kgs MIX ACID REACTOR NO2 : 55 Kgs Water: 100 kgs Caustic: 46 kgs Benzene: 530 kgs REACTOR Spent Sulphuric acid (78%): 1975 kgs Alkali Scrubber Caustic soda: 50 kgs NEUTRALIZATION Effluent to ETP: 201 NITRO BENZENE: 800 kgs Expansion project-dyes Intermediates Page 41

43 (19) Mass Balance for Meta di Nitro Benzene Nitro Benzene : 1000 kgs Nitric Acid : 600kgs Sulphuric acid : 1200 kgs Water : 210 Kgs NITRATOR C Traces of Nitrous fumes: 10 kgs Caustic: 10 kgs Water: 20 kgs Alkali Scrubber Effluent to ETP: 40 kgs Water : 1500 Kgs SPENT ACID SEPARATION WASHING OF CRUDE MDNB Spent Acid (78%): 1640 kgs sell to actual users having permission under Rule 9 Wash Water : 750 Kgs Caustic lye: 60 kgs NEUTRALIZATION Waste water to ETP: 870 kgs MDNB (Crude): 1300 kgs (20) Mass Balance for EBAMSA EBA : 1000 Kgs Oleum : 1000 Kgs Sulphuric Acid : 1000 kgs Sulpho mass : 2973 kgs Water : 5000 Kgs Sulphonation Drowning SO2 gas: 27 kgs Water: 100 kgs Caustic: 50 kgs Scrubber To ETP: 177 kgs Filtration Centrifuge: 2200 Kgs Waste water to MEE : 5773 kgs Drying Loss: 1000 kgs Product: 1200 kgs Expansion project-dyes Intermediates Page 42

44 (21) Mass Balance for Para Phenylene Di amine (PPD) PNA : 1000 Kgs Water : 1000 kgs Iron : 1000 Kgs HCl: 50 Kgs Reduction Reduction mass : 3000 Kgs Filtration Iron sludge : 1500 Kgs Filtrate mass : 1550 Kgs Distilation Water reused : 550 Kgs Product : 1000 Kgs (22) Mass Balance for meta Nitro Para Toludine (MNPT) P- Toludine : 500 Kgs Acetic acid: 60 Kgs Acetylation Acetylation mass : 560 Kgs Nitric Acid : 200 Kgs Nitration Nitrous oxide: 8 kgs Caustic soln (20%): 32 kgs Scrubber Nitro mass : 752 Kgs Water : 1000 Caustic lye : 400 Drowning Filtration Waste water to ETP: 40kgs Waste water to MEE: 1152 kgs Centrifuge Product: 1000 kgs Expansion project-dyes Intermediates Page 43

45 (23) Mass Balance for Di phenyl Epsilon Acid Epsilon Acid : 1000 Kgs Aniline : 800 Kgs Condensation Reflux Condensation mass : 1800 Kgs Water : 1000 kgs Drowning Filtration Filtration mass : 2800 Kgs Sulphuric Acid : 200 Kgs Isolation Mother liquor reuse: 1000 kgs Centrifuge Drying Water evaporate : 1000 Kgs Product: 1000 kgs Expansion project-dyes Intermediates Page 44

46 (24) Mass Balance for 1 - Naphthol 8- Sulfonic acid Peri acid : 500 Kgs Sulphuric Acid : 200 Kgs NaNO2 : 250 Kgs Water : 500 Kgs Diazolation Diazo mass : 1450 Kgs Caustic lye : 200 Kgs Filtration Waste water to MEE : 750 Kgs Centrifuge Drying Loss: 400 kgs Product: 350 kgs Expansion project-dyes Intermediates Page 45

47 Peri acid : 500 Kgs Sulphuric Acid : 200 Kgs NaNO2 : 250 Kgs Water : 500 Kgs (25) Mass Balance for 1 Naphthol 4, 8 sulfonic acid Diazolation Diazo mass : 1450 Kgs Filtration Centrifuge Drying Waste water to MEE : 550 Kgs Loss: 550 kgs 1 Naphthol 8 Sulphonic Acid: 350 kgs Sulphuric Acid : 500 Kgs Sulpho mass: 850 kgs Water: 500 kgs Caustic lye: 500 kgs Sulphonation Dissolution Filteration Waste water to MEE : 850 Kgs Centrifuge Drying Loss: 600 kgs 1 Naphthol 4, 8 Sulphonic Acid: 400 kgs Expansion project-dyes Intermediates Page 46

48 (26) Mass Balance for 3, 5 Di Nitro Benzoic Acid (3,5 DNBA) Benzoic Acid : 1000 Kgs H2SO4 : 6000 Kgs 2HNO3: 1800 Kgs Oleum : 2500 Kgs Nitration Nitrous oxide: 68 kgs Caustic : 50 kgs Water: 250 kgs Scrubber Nitro mass : Kgs Drowning Spent sulphuric acid (70%): 9232 kgs Waste water to ETP: 318 kgs Centrifuge Product: 2000 kgs Expansion project-dyes Intermediates Page 47

49 (27) Mass Balance for 3,5 Di Amino Benzoic Acid (3,5 DABA) DNBA: 1000 kgs Water: 3000 kgs Iron: 2000 kgs HCl: 200 kgs Reduction mass: 6200 kgs Wash water: 1000 kgs Reduction Filteration Iron sludge: 4000 kgs Water recycle: 1000 kgs Filtrate: 2200 kgs HCl: 200 kgs Isolation Filteration Filtrate to MEE: 1400 kgs Centrifuge Drying Vapour loss: 400 kgs Product: 600 kgs Expansion project-dyes Intermediates Page 48

50 (28) Mass Balance for 2,4,5 Tri Chloro Aniline TCB: 1000 kgs Sulphuric acid: 1600 kgs Nitric acid: 600 kgs Soda ash: 60 kgs Nitro Mass: 3250 kgs Water: 3000 kgs Nitration Drowning Traces of Nitrous fumes: 10 kgs Caustic: 10 kgs Water: 20 kgs Alkali Scrubber Effluent to ETP: 40 kgs Filteration Spent acid: 4750 kgs Water: 3000 kgs Iron: 1000 kgs HCl: 50 kgs Sodium Nitrite: 50 kgs TCNB: 1500 kgs Reduction Filteration Iron Sludge: 2000 kgs HCl: 200 kgs Isolation Spent acid: 4760 kgs Filteration Waste water to ETP: 2100 kgs Centrifuge Product: 1700 kgs Expansion project-dyes Intermediates Page 49

51 (29) Mass Balance for Ortho Amino Phenol PNCB : 1000 Kgs Caustic : 400 Kgs Water : 1000 Kgs Hydrolysis Filtrate : 2400 Kgs Fe : 1000 Kgs HCI : 100 Kgs Reduction Mass : 1500 kgs Reduction Isolation Iron Sludge : 2000 Kgs Centrifuge Waste water to ETP : 600 Kgs Product: 900 Kgs (30) Mass Balance for Meta Nitro Chloro Benzene (MNCB) Water: 655 kgs Nitrobenzene : 950 kgs Chlorine :570 Kgs Ferric Chloride: 75 Kgs 1 st water wash : 1000 Kgs 2 nd & 3 rd water wash: 1000 kgs Reactor : 1595 Kgs Washing : 3292 kgs Excess Chlorine 22 Kg, scrubbed in Nitro Benzene trap (next batch chlorination) 1 st Wash water: 1075 kgs Neutralization 2 nd & 3 rd wash water: 1000 kgs to ETP HCl (g) : 281 Kgs Lime: 60 kgs Filteration Scrubber HCl (30 %):: 936 kgs For product Solid waste: 70 kgs TDSF Filtrate: 1065 kgs to MEE Fractional Distillation : 1217 Kgs Handling Loss : 13 Kgs MNCB: 1010 Kgs (99% purity) & PNCB/ONCB : 194 Kgs Expansion project-dyes Intermediates Page 50

52 (31) Mass Balance of N-N Di Ethyl -m- Amino Phenol (DEMAP) Matanilic acid: 173 kgs Caustic Flakes: 60 kgs Water: 50 liters Di Ethyl Sulphate: 154 kgs Ethylation Caustic Flakes: 130 kgs Fusion Filter Salt: 110 kgs Caustic : 10 kgs Water: 50 kgs Sulphuric acid: 100 kgs Water: 61 kgs Acidification Traces of SO2 gas: 8 kgs Scrubber Waste water to ETP:68 kgs Filteration Effluent to ETP: 465 kgs Product: DEMAP: 145 kgs (32) Mass Balance for P-AMINO BENZOIC ACID 4-Nitro Benzoic acid : 1000 Kg Pd/C: 6 Kg Water: 4000Kg+ NaOH 451 Kg HCl : 575 Kg H 2 : 30Kg N 2 : 16 Kg Autoclave Filtration Pd/C: 6 Kg Recycle Waste water: 4901 kgs 3-Amino-4-chloro benzoic acid-1171 Kg DRYING Drying Loss Kg 3-Amino-4-chloro benzoic acid-820 Kg Expansion project-dyes Intermediates Page 51

53 (33) Mass Balance for DI Calcium Phosphate Rock Phosphate: 2181 kgs Water (Fresh): 715 kgs Water (recycled): 7490 kgs Sulphuric Acid (70%) : 1661 kgs ML: 7630 kgs (H3PO4: 570 kgs + Water: 7060 kgs Lime: 430 kgs Water: 430 kgs Reactor Filteration Reactor CO2: 128 kgs Silica: 289 kgs Gypsum (50%) wet cake: 4000 kgs ML: 7630 kgs (H3PO4: 570 kgs + Water: 7060 kgs Water: 1000 kgs Filteration & Washing Effluent recycle : 7490 kgs Drying Moisture loss: 1000 kgs Pulveriser Di Calcium Phosphate: 1000 kgs Expansion project-dyes Intermediates Page 52

54 ANNEXURE: 4 Water requirement letter from Notified Industrial Estate Expansion project-dyes Intermediates Page 53

55 ANNEXURE: 5 Quantity of Waste Water (liquid waste) generation and its management: # Particulars Effluent generation, M3/day Existing Proposed Total Low High Low High Low High TDS/COD TDS/COD TDS/COD TDS/COD TDS/COD TDS/COD A. Domestic B. Industrial 1. Processing, product washing and scrubber 2. Cooling Boiler Floor/container/eq uipment washing Total Industrial Total (A+B) Mode of treatment ETP - ETP MEE ETP MEE Net Discharge to CETP Water Balance Diagram at Existing Scenario Total water consumption, 43.0 M3/day sourced from GIDC Vapi Processing, product washing & Scrubber: 17.0 Boiler: 0 Cooling: 20 Washing: 2.0 Domestic: 3.0 Gardening: Blow Down: Septic tank Total effluent: 18.0 Primary and Tertiary ETP CETP, Vapi Tidal zone of River Damanganga to Arabian Sea Expansion project-dyes Intermediates Page 54

56 Water Balance Diagram After proposed Expansion Total water consumption, 150 M3/day (Fresh: Recycled: ) Source from GIDC Processing, product washing & Scrubber: Floor/ container/equipment Washing: Cooling:35.0 Blow Down: 2.0 Boiler: 25.0 Domestic: 5.0 Blow Down: 2.5 Septic tank Gardening: 2.0 ETP: 3.0 ETP: 2.0 ETP: 2.5 High TDS/COD: 27.5 Low TDS/COD: 10.5 Total effluent: 18.0 MEE/Centrifuge: 27.5 Primary and Tertiary ETP Salt: 4.1 Condensate: 22,85 Loss: 0.55 CETP, Vapi TSDF Vapi Recycle in process Tidal zone of River Damanganga to Arabian Sea Details of Effluent Treatment Plant for normal effluent Design Criteria : Product Source of Effluent Design Flow of Effluent Design Parameters Effluent Characteristics: # Effluent Parameters : Dyes intermediates : Process, Washing and Utilities. : 18 KLD Max. : As under Concentrat ed Effluent from Process Combined Normal Effluent (Product washing, scrubber, Boiler, Floor Washing, Cooling) After ETP Treatment CETP Inlet Norms 1. ph to 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 < Phenolic, mg/l 1.5 N.D. ND <1 Expansion project-dyes Intermediates Page 55

57 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: # Equipment Capacity in m 3 Existing Proposed Total MOC 1. Oil and Grease Tank/Collection Tank RCCTL 2. Collection Cum Equalization Tank RCCTL 4. Lime Preparation Dosing Tank HDPE 4. FeSO4 Preparation Dosing Tank HDPE 5 P E Dosing Tank HDPE 6. Neutralization Tank MS 7. Floculator MSRL 8. Primary Settling Tank MSRL 9. Filter Press PP/FRP 10. Activated Carbon Filter MSRL 11. Pressure Sand Filter MSRL 12. Final Treated Effluent Holding Tank HDPE Details of Effluent Treatment Plant and MEE for Concentrated effluent Design Criteria : Product : Dyes intermediates Source of Effluent : Process. Design Flow of Effluent : 27.5 KLD Max. Design Parameters : As under Details of effluent treatment plant for concentrated effluent stream: # Name of the unit Capacity MOC 1 Collection Tank 10 kl RCC/TL 2 Neutralization Tank 1 kl MSRL 3 Filter Nutsch 0.5 kl HDPE 4 Holding Tank for treated Effluent to MEE 10 kl HDPE Expansion project-dyes Intermediates Page 56

58 DETAILS OF MULTI EFFECT EVAPORATOR FOR HIGH TDS/COD EFFLUENT # Name of Equipment ID MOC Capacity Retention time Req. Prov. 1. Storage Tank V - 1 HDPE 30 KL 2 day 7 hr. 2. Condensate Collection Vessel V - 2 M.S 500 L 1 hr. 2 hr. 3. Salt Collection Vessel V - 3 M.S. 500 L 3 hr. 10 hr. 4. Crystallizer V - 4 SS 6 KL 2 hr. 10 hr. 5. CALENDRIA-1 CL - 1 Titanium 28 M2 1 hr. 2 hr. 6. CALENDRIA-2 CL - 2 Titanium 28 M2 1 hr. 2 hr. 7. CALENDRIA-3 CL - 3 Titanium 28 M2 1 hr. 2 hr. 8. PRE-HEATER PHE-1 Titanium 2.2 M PRE-HEATER PHE-2 Titanium 2.2 M PRE-HEATER PHE-3 Titanium 2.2 M Pump - 1 P - 1 CI 3 HP Pump - 2 P - 2 CI 5 HP Pump - 3 [ VCP ] P - 3 CI 10 HP Pump - 4 P - 4 CI 5 HP Nutsch Filter N - 1 MSRL 2.25 M Centrifuge CF-1 SS Expansion project-dyes Intermediates Page 57

59 ANEXURE: 6 MEMBERSHIP CERTIFICATE OF CETP, VAPI Expansion project-dyes Intermediates Page 58

60 MEMBERSHIP OF TSDF Expansion project-dyes Intermediates Page 59

61 ANNEXURE: 7 Expansion project-dyes Intermediates Page 60

62 ANNEXURE: 8 Copy of plot allotment letter issued by GIDC Expansion project-dyes Intermediates Page 61

63 COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA Expansion project-dyes Intermediates Page 62

64 ANNEXURE: 9 A schematic representation of the feasibility drawing Expansion project-dyes Intermediates Page 63

65 ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED EXPANSION Existing: Flue Gas Emission: Presently, we are using 20 lakhs k cal/h capacity of Thermic fluid heater having coal consumption is 500 kg/h and 11 meters height of chimney provided. Process Gas Emission: There is a generation of SO 2 gas from reaction and SO 3 gas from Oleum storage tank. To scrub process gas emission, we have provided two stage acid followed by alkali scrubber having 11 meter height of chimney. Proposed Expansion: Flue Gas Emission: For the proposed expansion, we will utilize existing Thermic fluid heater with increase coal consumption from 500 kg/h to 600 kg/h. Also we shall install one additional Thermic fluid heater of 25 lakhs k cal/h capacity having coal consumption will be 550 kg/h. Adequate capacity of bag filter and 30 meters height of chimney will be provided, we will also install one steam boiler of 2 TPH capacity having 400 kg/h of coal consumption. Adequate capacity of common multi cyclone separator followed by bag filter and 30 meters height of chimney will be provided. Also install one number of D G set with capacity of 500 KVA running on HSD at a fuel rate of 115 kg/h and 11 meters height of chimney will be provided. Process Gas Emission: For the proposed expansion, Cl 2, HCl, SO 3, SO 2, NOx and NH 3 gases will be generated. After proposed expansion we will install total four numbers of two stage scrubbing system. Flue Gas Emission: Details # Particulars After Proposed Remarks Existing Expansion 1.0 Capacity of D G set: I KVA Proposed 1.1 Fuel Used 0 HSD 1.2 Consumption kg/h APC Provided 0 11 m chimney Capacity of Thermic Fluid Heater 20 lakh k cal/h 20 lakh k cal/h 2.1 Fuel Used Coal Coal 2.2 Consumption 500 kg/h 600 kg/h 2.3 APC Provided Multi cyclone Multi cyclone & bag filter 2.4 Height of Chimney 30 meters 30 m 3.0 Capacity of Steam Boiler 0 2 TPH 3.1 Fuel Used 0 Coal 3.2 Consumption kg/h 3.3 APC Provided 0 MDC and bag filter Existing, only increase fuel consumption Proposed New Expansion project-dyes Intermediates Page 64

66 3.4 Height of Chimney 0 30 meters 4.0 Capacity of Thermic Fluid Heater 0 25 lakh k cal/h Proposed New 4.1 Fuel Used 0 Coal 4.2 Consumption kg/h 4.3 APC Provided 0 Multi cyclone & bag filter 4.4 Height of Chimney 0 30 m Process Gas Emission: # Particulars 1.0 Expected Pollutants from Details Existing After Proposed Expansion Sulphonation Sulphonation Reaction & Reaction & Oleum Oleum Storage Storage 1.1 Pollutants SO 2 SO APC Provided Two Stage Acid followed by Alkali Scrubber Two Stage Acid followed by Alkali Scrubber 1.3 Height of vent 11 m 11 m 2.0 Expected Pollutants Chlorination 0 from Reactor Two Stage Water 2.1 APC provided 0 followed by Alkali Scrubber 2.2 Height of vent 0 11 m Remarks Existing will be utilized Proposed 2.3 Expected emission 0 HCl: <20 mg/m 3 Cl2: < 5 mg/m Stack Attached to 0 Nitrator Proposed 3.1 Pollutant 0 NOx 3.2 APC Provided 0 Two Stage Alkali Scrubber 3.3 Height of Vent 0 11 m 3.4 Expected Emission 0 NOx: <25 mg/m3 4.0 Stack Attached to 0 Amidator Proposed 4.1 Pollutant 0 NH3 4.2 APC Provided 0 Two Stage Water Scrubber followed by Acid Scrubber 4.3 Height of Vent 0 11 m 4.4 Expected Emission 0 NH3: <175 mg/m3 Expansion project-dyes Intermediates Page 65

67 Specifications of Falling Film Graphite HCl Scrubber: Type : Parallel flow falling film type Tube side : HCl gas, Cl 2 gas, water, HCl solution Shell side : cooling water HCl/Cl2 gas /hour : 100 kg/h Scrubbing media : water Heat of solution kcal/h : kcal/h Cooling water required at 40 approach : 2.5 m 3 /h No of tubes required : 65 tubes, 20 dia x 2.5 m length HTA required : 10 m 2 Diameter of scrubber : 350 mm Overall length : 3000 mm MOC tubes : Glass MOC shell : 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 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 : 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 : kg/h : 2 kg/h : 10 % dilute alkali : 150 dia x 1250 mm ht. : FRP : 2000 liter HDPE : 2.5 m 3 /h S/S : 150 mm : 11 meters Specification of SO 2 Gas scrubbing system # Name of the Equipment Capacity 1. Scrubber size 420 mm dia x 5000 mm 2. MOC of scrubber HDPE 3. Type of packing PP Racing ring 4. Height of packing 3500 mm 5. Alkali Circulation tank 5 m3, HDPE 6. Alkali circulation pump 3 HP 7. ventury scrubber 300 dia x Alkali circulation tank 1 m 3 9. Alkali circulation pump 10 m 3 /h 10. Height of vent 11 meter 11. Dia of vent 150 mm Expansion project-dyes Intermediates Page 66

68 Specification of Ammonia gas scrubbing system # Name of the Equipment Capacity 1. Ammonia Gas Cooler 5 m 2, with cooling water 2. Height of Scrubber 420 mm dia x 2500 mm height 3. MOC of Scrubber PP/FRP 4. Type of Packing PP Racing ring 5. Height of Packing 2500 mm 6. Water Circulation Tank 5m3, MS jacketed with chilled water cooling 7. Water Circulation Pump 3 HP 8. Liquor Ammonia Cooler 10 m 2 9. Capacity of Blower 3 HP 10. Height of Vent 11 meter 11. Dia of Vent 150 mm 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. Specification of Scrubber attached to Oleum Storage tank: # Details of Two stage Scrubber Size 1. Acid pot 500 liters, HDPE 2. Packed height in meters 2 mt. 3. Dia in meters Circulating liquid Dilute caustic 5. Size of tank 100 liters, HDPE 6. Capacity of the pump,m 3 /h 3 HP 7. Capacity of the blower, Nm 3 /h Vent diameter in mm Height of the vent from ground 11 mt 10. Sampling arrangement provided Details of Multicyclone separator followed by bag filter attached to Boiler Particular Details Capacity of Boiler 2 tones/h Type of fuel used Steam coal Quantity used 200 kg/h Gas volume Am 3 /h Size of MDC 915 x 915 x 1350 mm MOC MS Number of clones 16 Size of clones 125 x 80 NB Gas temperature 150 0C Expansion project-dyes Intermediates Page 67

69 Dust load 15 gms/m 3 Particle size Above 5 microns Filtration area 160 m 2 Actual filter rate 1.04 m 3 /m 2 /min Pressure drop 150 mm Wg Nos. of Bag filter 121(Ryton) Size of bags 116 mm dia x 3660 mm length Rotary valve 200 mm, CI Rotor rpm 20 Height of Chimney 35 meters ( common) Dia of chimney 900 mm 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 68

70 Gas From Plant Header Primary HCl SCRUBBER Tail SCRUBBER For HCl Un Condense d HCl gas To Atmosphere V E N T U R Y Primary Circulation Tank Secondary Circulation Tank NaHSO3 Manufacturing Reactor Caustic Lye Circulation Tank PROPOSED HCl & SO2 SCRUBBER SYSTEM Expansion project-dyes Intermediates Page 69

71 VENT Ammonia Gas NH 3 SCRUBBER PACKED TOWER PG CHW VENTURY SCRUBBER REACTOR 22 % AMMONIA DILUTE Acid Reactor Liquor ammonia Storage tank Use for making Ammonium Sulphite TWO STAGE AMMONIA SCRUBBING SYSTEM Expansion project-dyes Intermediates Page 70

72 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 71

73 ACID & ALKALI SCRUBBER ATTACHED TO OLEUM STORAGE Blower Alkali Scrubber Sulphonator Oleum Storage Tank Sulfuric Acid Trap Tank 500 Lit, HDPE Caustic Solution, 100 Lit, HDPE Alkali circulation pump Expansion project-dyes Intermediates Page 72

74 COPY OF EXISTING CCA Expansion project-dyes Intermediates Page 73

75 Expansion project-dyes Intermediates Page 74

76 Expansion project-dyes Intermediates Page 75

77 Expansion project-dyes Intermediates Page 76

78 Expansion project-dyes Intermediates Page 77