Proposed Project for Manufacturing of Pigments

Transcription

1 PREFEASIBILITY STUDY REPORT Of Proposed Project for Manufacturing of Pigments of M/s. Nirva Pigments Located at PLOT NO. DP-10, Saykha industrial Estate Ta: Vagra, Dist.: Bharuch P a g e 1 27

2 Contents Executive Summary Introduction Need of the Project... 4 PROJECT DESCRIPTION Location of the Proposed Project: Product Details: Process technology (Manufacturing Process): Pigment CPC Blue Pigment Alpha Blue Pigment Beta Blue Pigment Green Raw Material requirement Cost of Project Resources Requirements: POLLUTION POTENTIAL AND MITIGATION MEASURE Water Pollution: Effluent Treatment Plant Detail Air Emission: Hazardous Waste Management: Noise and Vibration Control: Hazards and Safety Measures: Good Housekeeping: CONCLUSION P a g e 2 27

3 Executive Summary 1.1 INTRODUCTION M/s. Nirva Pigments Proposes to set up a manufacturing unit of Pigments at PLOT NO. DP-10, Saykha industrial Estate Ta: Vagra, Dist.: Bharuch in the state of Gujarat. The total capacity of the proposed project shall by 385 MT / month. This is our new project with manufacturing of Pigments. Since this establishment attracts applicability of EIA notification and covered under Category 5(f) B, we are applying to obtain Environmental Clearance from SEIAA, Gandhinagar for our proposed project. P a g e 3 27

4 1.2 NEED OF THE PROJECT Demand and Supply Gap We have more than 10 years of experience in the field of manufacturing of Pigments. Based on our informal survey of the market with our current customers, we have found that there is a big potential for the product we are planning. Imports vs. Indigenous production Based on the current cost of indigenous raw materials, unit will not have to import any raw materials as they are produced locally. This will make us very competitive against imported finished products and it will increase the scope of our finished product to all over the country. Export possibility Depending on the international demand of products we will explore the possibility of exporting the products. Employment Generation (Direct and Indirect) due to project Unit will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. P a g e 4 27

5 PROJECT DESCRIPTION 2.1 LOCATION OF THE PROPOSED PROJECT: Our company located at Plot No.: PLOT NO. DP-10, Saykha industrial Estate Ta: Vagra, Dist.: Bharuch Location: 21 47'43.28"N 72 49'37.58"E P a g e 5 27

6 2.2 PRODUCT DETAILS: SR. NO PRODUCT NAME CI Name/CAS No. Proposed MT/Month 1. Pigment CPC Blue Pigment Blue 15: Pigment Alpha Blue Pigment Blue 15: Pigment Beta Blue Pigment Blue 15: Pigment Green Pigment Violet TOTAL 385 P a g e 6 27

7 2.3 PROCESS TECHNOLOGY (MANUFACTURING PROCESS): Pigment CPC Blue Stage: 1 Charge Di Chloro Toluene in Glass lined reactor. Then add Urea, Phthalic Anhydride, Cuprous Chloride and Ammonium Molyblate to it. Raise the temperature up to 180 C. During decomposition of urea ammonia gas as well as carbon dioxide gas is produced. We are controlling it by providing two stage water scrubber and then after acid scrubber. From the water scrubber we can obtain ammonium Carbamate as a by product. After maintaining sufficient time dump the batch in M.S.Ventulator for vacuum distillation of solvent. By that 95 % of the solvent will be recovered. And transfer the remaining crude in Drawning vessel containing water. Stage: 2 Take above heated crude material into dumping vessel with spent Sulphuric acid (mother liquor from Alpha Blue). Then start heating up to 95 C and maintain for three hours. Then filter in filter press, wash, neutralize, dry and pack the final product as a CPC Blue. After filtration process whatever mother liquor will be generated that contains % of Sulphuric Acid. We will treat it into our adequate ETP to become neutral. Then after we will discharge it into CETP, Vatva. P a g e 7 27

8 Pigment CPC Blue Mass Balance Sr. no. Input Quantity Kg per MT Sr. No. Output Quantity Kg per MT 1 Phthalic Anhydride Pigment CPC Blue Ammonium Carbonate Solvent recover Solvent Spent Acid Technical Grade Urea Effluent send to ETP Cuprous Chloride Evaporation loss Ammonium Molyblate 3 6 Solvent Loss 20 7 Spent Acid From Alpha Blue NH3 + CO (25-30%) 8 Washing Water Water used in Ammonium 500 carbonate Total Total P a g e 8 27

9 2.3.2 Pigment Alpha Blue Stage: 1 (ACID PROCESS) Take Sulphuric acid (70 %) in a reaction vessel. Then slowly charge Copper Phthalocyanine slowly from ball mil. Maintaining temperature just below 85 C so as to dissolve it to completely. The mass is transferred to Drawning vessel stirred further for 2-3 hrs at 60 C and then cooled to room temperature. The CPC separate out in the required form and is filtered off. After filtration process whatever mother liquor generated that contains approximate % of Sulphuric acid. We are using that liquor (H2SO4) into the manufacture of CPC Blue. And Filtrate effluent reuse in next batch alpha blue product Stage: 2 (PIGMENT PROCESS) The CPC cake is charged in another vessel and washed with water and stirred with fresh water. The aqueous slurry is neutralized to ph 8 to 8.5 using caustic lye and stirred with emulsifier agent at 60 C 90 C for 02 hours. The above slurry is filtered and the cake is washed with large amount of fresh water. The wet cake is dried to obtain Alpha Blue 15. The aqueous filtrate goes to ETP. Then after it is discharge it into CETP, Vatva. P a g e 9 27

10 Pigment Alpha Blue Mass Balance Sr. no. Input Quantity Kg per MT Sr. No. Output Quantity Kg per MT 1 CPC Crude Pigment Alpha Blue Suphuric Acid (70%) Spent Dilute H2SO Reuse Water From Filter Effluent Reuse Fresh Water Effluent to ETP Emulsifier 5 5 Evaporation Loss Caustic Flakes 30 Total Total P a g e 10 27

11 2.3.3 Pigment Beta Blue Beta Blue is manufactured in two stages. Stage 1: Milling Stage 2: Pigmentation. Milling: Charge CPC (98 %) in ball mill of capacity 10,000 Liter. Mill the contents for 24 hrs. After grinding discharge the milled blue for stage II (Pigmentation) Pigmentation: Charge above milled blue into MS vessel, contains caustic water, surfactants and solvent. Reflux whole mass under stirring for 02 hrs. Then recover the solvent. Filter the pigmented mass through filter press; wash with water till neutral ph. Dry the pressed cake in spin flash dryer at the rate of 150 Kg/Hr. P a g e 11 27

12 Pigment Beta Blue Mass Balance Sr. no. Input Quantity Kg per MT Sr. No. Output Quantity Kg per MT 1 CPC Pigment Beta Blue Caustic Solvent Recover Reuse 3465 in next Batch 3 Water Solvent Loss 35 4 Butyl alcohol(reuse) Effluent Butyl alcohol(fresh) 35 5 Organic and inorganic 210 material 6 Washing Moisture Loss 1600 TOTAL TOTAL P a g e 12 27

13 2.3.4 Pigment Green 7 Manufacturing Process: CPC Green is produced by Chlorination of Copper Phthalocyanine Blue (CPC). The basic Mfg. process involves two distinct steps. Synthesis of crude CPC green from CPC Blue and purification with solvent. In a glass lined reactor, CPC Blue is charged with sodium chloride, Cupric Chloride and anhydrous Aluminum Chloride with their respective proportion. Whole mixture is maintained at elevated temperature. Then pass chlorine gas into the mixture. During the reaction gaseous HCl mist and unreacted chlorine gas are evolved. HCl gas and unreacted chlorine gas are scrubbed by water and caustic spray in consecutive packed column scrubber. These can result in dilute HCl and NaOCl (Sodium Hypo Chlorite) generation, which are used in ETP for treating trade effluent. After completion of chlorination, the eutectic melt contain sodium chloride, Aluminium Chloride, Cupric Chloride and CPC Green is drowned in water in a rubber lined vessel. Aluminium Chloride will be converted into Aluminium Hydroxides and HCl gas is released and it will be also sent to alkali scrubber. The slurry containing crude CPC green is filtered through filter press, followed by washing with water, until ph of the cake become neutral. Mother liquor is sent to Aluminium Hydroxide recovery and then to ETP. The cake is purified by solvent treatment, In which the cake is refluxed in closed reactor containing solvent, emulsifier and water containing NaOH. The slurry is then filtered and washed with water and dematerialized water till ph is Neutral The filtrate separate into two layers consisting of the organic layer containing impurities and the alkaline aqueous layer containing Aluminium salt along with emulsifier etc. The solvent is used for further purification. The wet cake of CPC Green is dried in spin flash dryer to get required mesh size of final product CPC Green for final packing P a g e 13 27

14 Chemical Reaction P a g e 14 27

15 Pigment Green 7 Mass Balance Sr. no. Input Quantity Kg per MT Sr. No. Output Quantity Kg per MT 1 Aluminium Chloride Pigment Green Cupric Chloride 80 2 Cl2 + HCl Vaccum Salt Vapot Loss CPC Blue Crude Aluminium Chloride sol n MCB Solvent MCB Recover Emulsifier 40 6 MCB Loss 60 7 Caustic Flakes 79 7 Effluent Send to ETP Water Effluent reuse Evaporation Loss 1563 Total Total P a g e 15 27

16 2.3.5 Pigment Violet 23 Reaction: In reactor charge aminoethylcarbazole, sodium acetate and chloranil at 50 temp. in ODCB. stir for 3 hrs at temp. The batch is heated to 115 temp. for 5 hrs and then further heated to 150 temp. and add benzene sulphochloride at this temp. The batch is then heated to and maintain for 8 hrs. Then batch is cooled to 100 temp. Filtration and washing: filter the pigment slurry. Wash with ODCB. ML and Wash water is sent to Solvent Recovery. Steam Distillation: Wet cake us then charge into reactor with water and start steam distillation to remove ODCB completely. Filtration and washing: Filter the pigment slurry. Wash with water. ML and Wash water is sent to ETP. Drying and Packaging: Wet cake is then dried and pulverized and then sent to packaging. Chemical Reaction: P a g e 16 27

17 Pigment Violet 23 Mass Balance Sr. no. Input Quantity Kg per MT Sr. No. Output Quantity Kg per MT 1 ODCB Pigment Violet Aminoethylcarbazole ODCB Recovery Sodium Acetate 25 3 Effluent Chloranil Drying Loss Benzene Sulphochloride 25 5 MCB Recover Water 7000 Total Total P a g e 17 27

18 2.4 RAW MATERIAL REQUIREMENT We will propose manufacturing Activity Various Types of Pigment at capacity by 385 MT/Month. The propose quantity of raw material in each type of product in 1000 KG batch is listed as below. Sr No. Name of the Product Raw Material Per MT Phthalic Anhydride 1075 Ammonium Carbonate 1200 Solvent 2200 Technical Grade Urea Pigment CPC Blue Cuprous Chloride 195 Ammonium Molyblate 3 Spent Acid From Alpha Blue 2000 (25-30%) Washing Water 6000 Water for Ammonia carbonate 500 CPC Crude 1050 Suphuric Acid (70%) Pigment Alpha Blue Reuse Water From Filter Fresh Water Emulsifier 5 Caustic Flakes 30 CPC 1050 Caustic Pigment Beta Blue Water Butyl alcohol(reuse) 3465 Butyl alcohol(fresh) 35 Washing Aluminium Chloride 1825 Cupric Chloride 80 Vaccum Salt Pigment Green 7 CPC Blue Crude 555 MCB Solvent 3400 Emulsifier 40 Caustic Flakes 79 Water ODCB 6000 Aminoethylcarbazole Pigment Violet 23 Sodium Acetate 25 Chloranil 425 Benzene Sulphochloride 25 Water 7000 P a g e 18 27

19 2.5 COST OF PROJECT The approx. cost of the proposed project will be 3.0cr. The details of the cost of the project is given here: Land & Building 1.4 Cr. Plant & Machinery 1.6 Cr. 2.6 RESOURCES REQUIREMENTS: As the proposed project will be required resource for production. The details of their sources given hereunder, Land: The proposed project is in new unit 7182 sq. m located at Saykha GIDC. Water: The water requirements for the after expansion project will be KLD from which 5.0 KLD fresh water will be utilized as Domestic and remaining KLD in which 84.4 KLD will be Reuse from Process Waste water and remaining KLD water will be received from GIDC. Power: Total power requirement for the after proposed project will be 245 KW. Power demand will satisfied by Electricity Board/Authority. Fuel: At present we are utilizing Coal or Lignite 9 MT/Day or 7 MT/Day as fuel in Proposed Boiler and Hot air generator. Adequate stack height of m from ground level will be provided for Boiler. P a g e 19 27

20 POLLUTION POTENTIAL AND MITIGATION MEASURE 3.1 WATER POLLUTION: The water requirements for the after expansion project will be KLD from which 5.0 KLD fresh water will be utilized as Domestic and remaining KLD in which 84.4 KLD will be Reuse from Process Waste water and remaining KLD water will be received from GIDC. WATER CONSUMPTION DETAILS Sr No Category Water Consumption 1. Domestic Purpose 5.0 INDUSTRIAL Process (88.6 F+84.4 R) 2. Washing 5.0 Boiler 5.0 Cooling 1.0 Scrubber Total water Consumption & Generation (Domestic) 5.0 Total water Consumption & generation (Industrial ) WASTE WATER GENERATION DETAILS Sr No Category Waste Water Generation 1. Domestic Purpose 4.0 INDUSTRIAL Process water Washing 4.8 Boiler 0.5 Cooling 0.5 Scrubber 26.7 Total water Consumption & Generation (Domestic) 4.0 Total water Consumption & generation (Industrial) P a g e 20 27

21 Water Balance Diagram Total Water consumption KLD Industrial KLD Domestic 5.00 KLD Process KLD Boiler 5 KLD Washing 5 KLD Cooling 1 KLD Scrubber KLD Sewage 4.0 KLD Spent (H2SO4) Acid generation from process **50.8 KLD Effluent 126 Blow Down 0.5 KLD Washing 4.8 KLD Blow Down 0.5 KLD spent HCl acid sell to Athorized Agencies *1.1 KLD Spent Acid Reuse in CPC 20.8 KLD spent acid sell to Athorized Agencies 10.0 KLD effluent reuse in alph blue, CPC Blue and CPC Green (filteration) and Ammonium Sulfate 84.4 KLD Low COD waste Water 41.6 KLD 5.8 KLD Ammonium Carbonate Partialy Reuse in CPC 24.0 KLD Sodium Hypochloride 2.8 KLD ETP 47.4 Send To CETP P a g e 21 27

22 Note: The generated sewage will be disposed through soak pit/septic tank. The total industrial wastewater generation from Manufacturing process and other ancillary process will be 126 KLD out of which 84.4 KLD will be reused in alpha blue, CPC Blue, CPC Green Product and remaining 47.4 KLD primary treated waste water will be sent to CETP for further treatment and ultimate disposal. 3.2 EFFLUENT TREATMENT PLANT DETAIL Sr. No. Name of Unit Capacity 1 Collection Tank 2 Nos. 6 m 3 and 10m 3 2 Neutralization Tank 10 m 3 3 Settling Tank 25 m 3 and 10 m 3 4 Holding Sump 7.5 m 3 and 10 m 3 5 C.E.T.P Overhead Tank 30 m 3 6 Sludge Drying Bed (4 Nos.) 3.3 AIR EMISSION: We will use Coal or Lignite 9 MT/Day as fuel in Proposed Boiler and Hot air generator. Adequate stack height of m from ground level will be provided for Boiler. Sr. no Flue gas Emission data Stack attached to Stack height in meter 1 Steam Boiler (3 TPH) 30 Fuel Consumption APCM Coal or Lignite 5 MT/Day or 4 MT/Day Multi cyclone Dust Collector and Bag Filter P a g e 22 27

23 2 3 Hot Air Generator (4 Lac kcl) Thermic Fluid Heater (3 Lac KCl) Coal or Lignite Coal or Lignite 2 MT/Day or 1.5 MT/Day 2 MT/Day or 1.5 MT/Day Multi cyclone Dust Collector and Bag Filter Multi cyclone Dust Collector and Bag Filter Sr no Process Gas Emission Data Stack attached to Spray Dryer (2000 LPH) Spin Flash Dryer (SFD) Reaction Vessel (CPC Blue ) Reaction Vessel (Pigment Green) Stack height in meter APCM Bag Filter Followed By Water Scrubber Bag filter + Cyclone Separator Pollutant PM PM Two stage water scrubber NH3 & CO Two stage water scrubber with Alkali Scrubber Cl2 & HCl There will be a chance of fugitive emission from the manufacturing process as well as due to storage & handling of raw materials and products. The unit will take following adequate precautions for the control of fugitive emission; The entire manufacturing activities will be carried out in the closed reactors and regular checking and maintenance of reactors will be carried out to avoid any leakages. Replacing the low pressure mixing head with high pressure system will eliminate emission of VOCs. The tank vents will be equipped with either a carbon filter or an oil trap to prevent water vapor from entering the tank as it breathes. All the motors of pumps for the handling of hazardous chemicals will be flame proof and provided with suitable mechanical seal with stand-by arrangement. Control of all parameters on a continuous basis will be done by adequate control valves, pressure release valves and safety valves etc. All the flange joints of the pipe lines will be covered with flange guards. All the raw materials will be stored in isolated storage area and containers tightly closed. There will also be provision of adequate ventilation system in process plant and hazardous chemical storage area. A regular preventive maintenance will be planned to replace or rectify all gaskets, joints etc. The unit will also develop green belt within the factory premises to control the fugitive emission from spreading into surrounding environment. P a g e 23 27

24 3.4 HAZARDOUS WASTE MANAGEMENT: Sr. No Types of Hazardous Waste Sources Category Propose MT/Month Disposal 1 ETP Sludge ETP Area MT/Month Collection, storage, Transportation and Dispose to Active TSDF Site 2 Used Oil Plant Machinery KL/Month Collection, storage, Reuse within premises Discarded Container Spent Sulphuric Acid (12-20%) Ammonium Carbonate Spent HCl acid Sodium Hypochloride Material handling and Storage CPC Blue and Alpha Blue CPC Blue 26.1 Pigment Green Water Scrubber Pigment Green Alkali Scrubber MT/Month 1270 MT/Month 600 MT/month 27.5 MT/Month 42.0 MT/Month Collection, storage, Transportation and Dispose by selling to Registered Recycler 520 MT/Month will be utilize in CPC production remaining 750 MT/Month send to (Rule -9) authorized agencies or actual users 300 MT/Month will be utilize in CPC production and remaining 300 MT/Month Ammonium Carbonate will be utilized in mfg. of Ammonium sulfate or will be Send to Actual User (rule-9) Collection, Storage, Transportation & sell to (Rule -9) authorized agencies or actual users Collection, Storage, And Send to Actual User (rule-9) 8 Solvent Residue Distillation Unit MT/Month Collection, Storage, And Send to Actual User (rule-9) 9 Solvent Recovery CPC Blue, Beta Blue, and Pigment Green, Pigment violet MT/Month Collection, Storage, And Send to Actual User (rule-9) P a g e 24 27

25 3.5 NOISE AND VIBRATION CONTROL: The following adequate precautions will be taken for control of noise & vibration; The unit will install latest technology based low noise DG Set with acoustic enclosures. Proper and timely oiling, lubrication and preventive maintenance will be carried out for the machineries and equipment to reduce noise generation. The noise generation will be mitigated by installing noise barriers/absorbers around stationery noise sources. Adequate noise control measures such as anti-vibration pad for equipment with high vibration will be provided. All the vibrating parts will be checked periodically and serviced to reduce the noise generation. The equipment, which generates excessive noise, will be provided with enclosures etc. To minimize the adverse effect on the health, ear muffs / earplugs will be provided to the working under high noise area. 3.6 HAZARDS AND SAFETY MEASURES: All the personnel at the plant will be made aware about the operation hazards and risk associated with them. Safe work practices will be adopted to ensure the control of hazards during operation and maintenance. The workers will be made aware about the hazards associated with manual handling and operation. Safety measures in the form of DO and Don t Do will be displayed at strategic locations especially in local language. Good housekeeping will be maintained in the Mining area. The required PPEs for each area/operation should be identified and the necessary PPEs, like, helmets, goggles, hand gloves, mask, suit, safety belts, ear muff and plug, etc. will be provided to the personnel. The plant will check and ensure that all instruments provided in the plant are in good condition and documented. First Aid box will be provided within the plant. List of important telephone numbers will be displayed at prominent location in the plant. Lease Holder Machine Operator Helper/ Labor. All the accidents and incidents if any will be recorded, investigated and analyzed in the proposed plant. Safety awareness programs and trainings of the worker will be carried out to motivate the workers to increase the safety level at personal level. 3.7 GOOD HOUSEKEEPING: The term Good Housekeeping is often loosely understood as simple floor cleaning or broom P a g e 25 27

26 Stick operation. But it has even wider meaning including up keeping of all industrial activities in orderly manner to minimize the accidents due to improper planning, placement, arrangement, handling, etc. everywhere in industrial premises. Place for everything and everything on proper place. So, Good housekeeping at quarry site will greatly reduce unsafe conditions and so risk of accidents. P a g e 26 27

27 CONCLUSION This is our new unit proposed for manufacturing of various Pigments. The unit will provide adequate measures for the prevention and control of pollution for its proposed project. With the execution and operation of such control measures along with proper Environmental Management System, there will not be any major potential for negative impact on the environment due to proposed project. There will be positive impact on the socio-economic environment since proposed project will generate some permanent and secondary employment. The unit will also establish Cordial relation with the nearby villagers and will carry out social welfare activities according to their needs. The proposed project will also boosts up ancillary industrial and commercial activity. Thus, it will improve the economic condition of the area. P a g e 27 27