M/S HERCULES PIGMENTS PVT. LIMITED

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1 ON PROPOSED PROJECT FOR THE MANUFACTURE OF ORGANIC AZO PIGMENTS Category 5 (f) By M/S HERCULES PIGMENTS PVT. LIMITED Located at: Plot No. 1704, Chemical Zone GIDC Notified Industrial Area, GIDC Sarigam, Dist- Valsad Gujarat. New Project: 1 Manufacturing: Organic Azo Pigment

2 Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification Executive Summary : Name & Location: Name of the Project : M/s. Hercules Pigments Pvt. Limited Location : Plot No , GIDC Notified Industrial Sarigam, Ta: Umbergaon, Project Dist- Valsad Gujarat. M/S Hercules pigments Pvt. limited is a new proposed project to be located in GIDC notified industrial area, falling under small Scale category & proposes to manufacture Organic Azo Pigments (Yellow, Orange, Red). Proposed Project Cost: Rs. 700 Lacs. Applicability of EIA notification 2006 Category as per the amended EIA notification- 2006: as proposed products (i.e. Organic Azo Pigments) are covered under the Category 5 (f) B. Hence, Environmental Clearance is required. Project Proponent The company in India comprising 3 Directors Small Scale Unit List of finished products & by- products SR. NO. PRODUCT MT/MONTH 1 Organic Azo Pigments (Orange/Yellow/Red) 150 Manufacturing process with chemical reaction & mass balance is attached as Annexure-3 Resource Requirement Components Proposed Resources availability Power, KVA 200 Will be sourced from Dakshin Gujarat Vij Co. Ltd. Fresh Water, kl/day 260 Will be sourced from GIDC water supply dept. Natural gas for Steam Boiler (2.5 TPH), SCM/day 1700 From GSPC Limited New Project: Page 2 Manufacturing: Organic Azo pigment

3 Natural gas for Hot air dryer (2.5 TPH), SCM/day Fuel (HSD) for D.G.Set (200 KVA), Kgs/Hr 800 From GSPC Limited 40 Will be sourced Local Dealer Raw material Consumption (1.0) ORGANIC YELLOW PIGMENT Sr. No. Raw Materials Quantity in MT Ton per ton of product Proposed, MT/Month Base (Amine) Ice Sulphamic acid Sodium nitrite Hydro Chloric Acid (30%) Caustic Acetic acid & others Total (2.0) ORGANIC RED PIGMENT 2.1 Base (Amine) Ice Sulphamic acid Sodium nitrite Sulphuric acid Caustic Hydro Chloric acid Coupler Total (3.0) ORGANIC ORANGE PIGMENT Base (Amine) Ice New Project: Page 3 Manufacturing: Organic Azo pigment

4 2.3.3 Sulphamic acid Sodium nitrite Hydro Chloric Acid (30%) Caustic Emulsifier & others Total Water and Waste Water Management Total raw water requirement is 260 M 3 /day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith. Total Industrial Waste water generation is 250 M 3 /Day mainly from process, washing, boiler blow down, cooling which will be treated in proposed primary & secondary treatment plant & discharge into underground effluent drainage line of GIDC Sarigam to CETP Sarigam for further treatment & ultimate disposal into Arabian Sea through closed pipe line. Domestic waste water (5 M 3 /Day) will be disposed off through septic tank. Air Emission and its Control Measures Flue gas emission: The company proposes to install 2.5 TPH capacity of steam boiler for the requirement of process steam. The unit shall use 1700 SCM/day of natural gas as a fuel. Adequate height of stack will be provided. Also the unit shall use natural gas fired hot air dryer having consumption of natural gas will be 800 SCM/day. The company shall install one number of new 200 KVA capacity D G set, as standby. It will be used only during power failure. Average 40 kgs/hr of HSD will be used as a fuel. 11 meters height of exhaust will be provided. Process gas emission: Drying of % pigment wet cake shall be carried out in tray dryers. The process heat is provided by hot air dryer. The pulverization will be carried out in a closed system includes cyclone separator & bag filter. (Details of Air pollution control measures are attached as Annexure-8). New Project: Page 4 Manufacturing: Organic Azo pigment

5 Hazardous Wastes and its Management No Type of waste Category Qty. MT/ Year Treatment 1 ETP waste Dried, packed in bags 2 Used Oil Packed in carboys 3 Discarded containers Decontaminated, stored Disposal Dispose off into TSDF, Vapi Sell to Registered reprocessers Sell to authorized recycler New Project: Page 5 Manufacturing: Organic Azo pigment

6 2. Introduction of Project / Back Ground Information : (i) Identification of Project and proponent. Name of the project Proponent: M/S Hercules Pigments Pvt. Limited HERCULES PIGMENTS PVT LTD is a medium scale unit is located in notified industrial estate, GIDC, Sarigam, Di: Valsad having total plot area 4306 m 2 & total investment will be Rs. 700 Lacs. The proponent wishes to start the production of Organic Pigments (Red, Yellow and Orange) with capacity of 150 MT per month. The product is especially used in printing ink, paints and plastic formulation like newspaper inks, magazine, food packaging, home and industrial paints and plastic master batches as per requirement. The proposed project site lies on N Latitude & E Longitude. M/S HERCULES PIGMENTS PVT LTD is proposing to be located at plot. No. 1704, GIDC Sarigam, Ta: Umbergaon, Di: Valsad district in Gujarat state and same western part comes under Daman union Territory. GIDC is located nearby National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounding by Union territories of Daman in western side. The western Railway Main Line is passing through the area (Double & Electrified). Nearest town & industrial estate Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with the other major cities of the state and the country. Beside the rail connectivity, and also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat Mumbai) is now six lanes, double tracked, more elevated and Jam free highway, which is developed by M/s L & T Company. This highway has given a further boost to the economic growth of this area. The existing unit is operated by technocrats having more than 30 years of experience in manufacturing and marketing of various Organic pigments. The company has been established in 2008 with manufacturing plants in Vapi, Gujarat having well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proponent shall to start production of Organic pigments with total capacity of 150 MT per month and process capabilities to manufacture High Performance pigment series. Hercules Pigments Pvt Ltd is established in 2008 and managed by a professional board of directors. It manufactures and markets a wide range of Organic Pigments. Senior personnel are available for providing support to the manufacturing unit in the areas of technology, R&D, manufacturing, quality control and quality assurance. Organic pigments are manufactured at the company s 3 manufacturing units located at Vapi Gujarat for sale in local & international market. It was co-founded by 3 technocrats. New Project: Page 6 Manufacturing: Organic Azo pigment

7 Identification of the project proponent: The company is managed by the promoters and whole time directors Mrs. Vatsala Narendra Desai, Mr. Swetal Narendra Desai and Mr. Anupam Desai having more than 30 years experience & their team members Mr. Pramod Kumar Tandon who is Masters in Chemical Technology having 45 years experience in chemical industries. The company emphasis on R & D, quality control, marketing, production, logistics, import & export. Company s strength is commitment, best quality, timely delivery at best prices. The Directors have good experience and exposure in Azo pigments industries as the main director has been in this line of business for more than 2 decades. They have developed wide ranging contacts in the country and abroad and do not foresee any problem in the marketing the product manufacturing. (ii) Brief description of nature of the Project : The proposed project involves the production of Organic Pigments which are used in Printing Inks, Paints, Plastics and cosmetic formulation like newspaper, magazine, flexible packaging, home and industrial paints, plastic master batches and cosmetics etc. as per requirement. As per the EIA notification as amended products are covered under any category 5(f) required Prior Environmental Clearance. For the proposed new project, the company intends to procure the available latest technology for manufacturing the products. A typical plant shall house of MS Rubber lined/stainless Steel reactors, Filter Press, dryers, multi-mills, jet mills, blenders etc. (iii) Need for the project and its importance to the country and or region : The proposed new project provides a potential growth opportunity for the running business of the company. The company is already engaged in the business of manufacturing of Organic Pigments. The project would increase the overall export and also increase the foreign revenue. Product is now well established and acceptable in the international markets. Additional capacities of product range required over & above our existing capacities, as the company expect strong growth of exports to the extent of 40-50%. Local market also showing strong growth potential. Domestic market concentrated in Pan-India, particularly in West and Northern belt, making Sarigam as ideal choice. This project will generate employment of up to 100 people. New Project: Page 7 Manufacturing: Organic Azo pigment

8 (iv) Demand Supply Gap : The products have very high specific demand as they are especially used in printing ink formulation like news paper and flexible packaging as per requirement. (v) Imports vs. Indigenous production : Existing products manufacturing in the country will be very much economical as compared to Import of the same. The export of this pigments will earn revenue for the county. (vi) Export Possibility : Existing products have high export potential. Also these products have very good sab potential in local market. Additional capacities of product range required over & above our existing capacities at Sarigam, as the company expect strong growth of exports to the extent of 40-50%. Local market also showing strong growth potential. (vii) Domestic / export Markets : The company s product is used as raw material to manufacture various printing inks, paints and master batches as per the required applications and having very good market in domestic and also having very good international markets. (viii) Employment Generation (Direct and Indirect) due to the project : 3. Project Description : There will be very good opportunity of employment generation directly and indirectly due to proposed new project. Due to proposed project there will be ~100 people will be directly/indirectly employed. (i) Type of Project including interlinked and interdependent projects, If any : The proposed project is an interdependent project of the company. (ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates : The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1.Plant layout is attached as Annexure-2. (iii) 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 existing premises only. (Land allotment letter is attached as Annexure-6). (iv) Size or magnitude of operation : As per the proposed project cost the project is covered under medium Scale category of manufacturing industries. New Project: Page 8 Manufacturing: Organic Azo pigment

9 (v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) : Detailed project description with process details is enclosed as Annexure-3 (vi) 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 are of final products mode of transport of raw material and finish product & characteristics of hazardous chemicals are as below: Sr. No. DETAILS ON PRODUCT/BY-PRODUCTS TRANSPORTATION Product Physical State Dispatch Means of Transportati on 1 Organic Azo Pigments (Red/Yellow/Orange) Solid Local/Export Truck/contai ners Sr. No. Substance DETAILS ON RAW MATERIAL TRANSPORTATION Physical State Source of Supply & packing 1 Base (Amine) Powder Local, 25 kgs bags 2 Ice solid Local, 50 kgs bags 3 Sulphamic Powder Local, 25 kgs acid bags Means of Transportation container tractor container Distance of supplier from project site (km) 200 kms 10 kms 200 kms 4 Sodium nitrite Powder Local, 25 kgs bags container 200 kms 5 Hydro Chloric Acid (30%) liquid Local, tanker tanker 25 kms 6 Caustic lye liquid Local, tanker tanker 25 kms 7 Acetic acid & others 8 Sulphuric acid liquid Local, tanker tanker 25 kms liquid Local, tanker tanker 25 kms New Project: Page 9 Manufacturing: Organic Azo pigment

10 DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS No Name of the Raw Materials Quantity stored, MT Max Actual BP. 0 C MP 0 C Place of its Storage State operati ng pressur e temper ature Possible type of hazards Control measures provided (vii) 1 DCB Bags N.A 132 Solid Avoid Use Chemical contact withgoggles, skin & eye. Gloves, Apron, Avoid breathing Purifying respirator. dust, mist or gas. 2 AAA Bags Does not bil up to Caustic lye Stor age tank /Dru ms New Project: Page 10 Manufacturing: Organic Azo pigment Liqui d Solid May causeuse Eye and Skin irritation, respiratory and digestive tract irritation. chemical safety goggles, Wear appropriate protective gloves and clothing to prevent skin Ingestion ofexposure. large Always use a amount mayniosh or cause European gastrointesti nal irritation. Standard EN149 approved respirator. Skin irritation with greater skin exposure, tissue. Contact lenses should be when Employee should be provided with impervious clothe, gloves, eye contactface causes shield(eightinch destructive to eyeminimum),dus t and splash proof safety goggles, notchemically worn resistant safety shoes, working witheyewash this station and

11 chemical. safety showers Swallowing must be Sodium Hydroxide available. may cause severe burns of mouth, throat, esophagus and stomach. 4 Hydro Chloric acid St or ag e ta nk Liqui d Corrosive Liquid. Mist causes severe burns to all body tissue, may be fatal if swallowed or inhaled, inhalation may cause lung damage. Use chemical safety goggles or full face shield, Rubber or neoprene gloves and additional protection including impervious boots, apron. NIOSH approved Respirators. 5 Sulpha mic acid 2 1 Ba gs N. A N.A Solid Irritant. Use Chemical safety face shield, Rubber hand gloves, Rubber or PVC apron. 6 Napht hol AS Ba gs N. A Solid In case of Skin and Eye contact (Slightly irritanting) Use Goggles, Gloves chemical and Respirators, avoid contact with eyes and skin. 7 Sodiu m nitrite Ba gs Solid Toxic if swallowed, very toxic on inhalation, irritation to eyes, possible skin sensitizer. Use Chemical goggles, full face shield, Wear PVC gloves, Rubber safety footwear or gumboots. The material may produce skin New Project: Page 11 Manufacturing: Organic Azo pigment

12 Contact with combustibl e material may cause fire. sensitization in predisposed individuals, care must be taken, when removing gloves and other PPE, to avoid all possible skin contact. 8 PMP Ba gs Solid Causes Irritation in case of Skin and Eye contact. Use splash resistant safety goggles, appropriate chemical resistant clothing and gloves. Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outlined 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. Proper earthing shall be provided were ever hazardous material handling is done. Entire plant will be flameproof. Wash water will be recycled to minimize the fresh water consumption. (viii) Availability of water its source, Energy/power requirement and source should be given : New Project: Page 12 Manufacturing: Organic Azo pigment

13 Availability of water its source, Energy/power required and its source is below. Water withdrawal permission is attached as Annexure-4. PRODUCTWISE WATER CONSUMPTION M 3 PER TONE OF PROPOSED PRODUCT INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING Sr. No. Product Processing Boiler (Live Steam) Cooling (Ice) Product Washing Total 1 Organic Red Pigment 2 Organic Yellow Pigment 3 Organic Orange Pigment Maximum PRODUCTWISE EFFLUENT GENERATION M 3 PER TONE OF PROPOSED PRODUCT INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING Sr. No. Product Processing Boiler (Live Steam) Cooling (Ice) Product Washing Total 1 Organic Red Pigment 2 Organic Yellow Pigment 3 Organic Orange Pigment Maximum New Project: Page 13 Manufacturing: Organic Azo pigment

14 PRODUCTWISE WATER CONSUMPTION M 3 PER DAY OF PROPOSED PRODUCT INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING Sr. No. Product Processing Boiler (Live Steam) Cooling (Ice) Product Washing Total 1 Organic Red Pigment 2 Organic Yellow Pigment 3 Organic Orange Pigment Maximum PRODUCTWISE EFFLUENT GENERATION M 3 PER DAY OF PROPOSEDPRODUCT INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING Sr. No. Product Processing Boiler (Live Steam) Cooling (Ice) Product Washing Total 1 Organic Red Pigment 2 Organic Yellow Pigment 3 Organic Orange Pigment Maximum New Project: Page 14 Manufacturing: Organic Azo pigment

15 OVERALL WATER CONSUMPTION & EFFLUENT GENERATION(M 3 /DAY) Sr. No. Particulars Water Consumption Effluent generation 1. Domestic Processing Boiler ( Live steam) Boiler blow down & DM rejection Product Washing Cooling as ice Floor/container washing Gardening Grand Total Total Industrial Note: Average 260 M 3 /day fresh water will be used for proposed plant and source from GIDC authority. Domestic effluent shall be passed through adequate capacity of septic tank/soak pit. Process effluent shall be sent ETP. Boiler blow down, D M rejection & live steam comes out as an effluent. Ice water comes out as effluent. Floor/container & vessel washing comes out as effluent. Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through under ground drainage line for further treatment & ultimate disposal into Arabian Sea. New Project: Page 15 Manufacturing: Organic Azo pigment

16 Sr. No. 1 Steam requirement ENERGY REQUIREMENT AND ITS SOURCE Particulars Proposed Source 2500 kgs./hrs. Will be obtained from proposed NG fired steam boiler of 2.5 TPH capacity POWER REQUIREMENT AND ITS SOURCE Sr. Particulars Proposed Source No. 1 Power Electricity requirement 200 KVA Will be sourced from Dakshin Gujarat Vij Co. Ltd. (ix) Quantity of waste to be generated ( liquid and solid) and scheme for their Management/disposal : Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure-4. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representations of the feasibility drawing is attached as Annexure-7 Site Analysis (i) Connectivity : The project is to be located in notified Industrial Estate of Sarigam which is very well connected to National Highway no.8, Western Railways. And the nearest air port (Mumbai) and port are 150 KM away from the project site by road. New Project: Page 16 Manufacturing: Organic Azo pigment

17 4. (ii) Land Form, Land use and Land ownership : The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation. (iii) Topography (along with map) : Topography map showing the elevation of study area is below; The catchment area of the proposed project site altitude is 35 m (a.m.s.l) consists of the near site is flat topped, highly dissected plateaus and dyke ridges running in a west to east direction. The Main River (Daman Ganga) in the catchment area flows in incised meanders forming steep geomorphologically V shaped valleys with steep sides. The entire catchment has a rectangular and trellis pattern of drainage depicting the influence of the structures on the drainage development. (iv) Topography map showing the elevation of the study area below. The topographical map is enclosed as Annexure-5. 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 possession letter and gazette notification is enclosed as Annexure-6. (v) Existing Infrastructure : GIDC notified industrial area of Sarigam has the entire available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system. (vi) Soil classification : General soil classification of the area is as under : The area, being of basaltic formation, falls under the broad soil group of red loams and black clay soils. The transmission of water through similar parent material seems to have influenced the development of different physiographic characteristics of the soils in the area. The area in between the hills with sloping lands contains dark yellowish brown to very dark grayish brown gravelly clay loam to clayey soils of shallow to moderate thickness. The dissected hill and steep slopes suffer from severe erosion hazards. The steep hill slopes are almost devoid of soil. (vii) Climate data from secondary sources : Rainfall Data : The project site location receives annual rainfall of to 1300 mm in 35 rainy days with 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 New Project: Page 17 Manufacturing: Organic Azo pigment

18 comprised of Kutch district and western parts of Banaskantha and Patan district 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 rest part of the state receives rainfall between mm and generally fall under semi-arid climate. Temperature & Climate Data: Proposed project site falls under seismic zone-iii, which h is not highly earthquake prone area. Aside from the monsoon season, the climate is dry. The average maximum temperature o C and Minimum temperature, o C. The average humidity ranges from nearly 84% in August to about 31% in February. (viii) Social Infrastructure available : Social Infrastructure in Valsad district is as under : Education : There are 990 primary and 161 secondary and higher secondary Table 5: List of Educational Institutes schools in the district Educational Total With over 1,250 seats, there are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature & motor rewinding, Primary School 990 electrician, information technology and electronic system maintenance Secondary School etc 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, ITI s 6 with an intake capacity of 360 Polytechnic 1 College With 120 seats, there is one Degree Engineering College present in Pharmacy College 2 Valsad offering engineering courses in mechanical and chemical Engineering 1 branches College Located in Vapi, G. M. Bilakhia Pharmacy College has an intake Management 1 College capacity of 60 students per year Other Colleges Rofel Institute of Management studies in Valsad offers full time MBA Other Colleges: Arts, Commerce, Science, B.Ed and Law College course and takes 120 students per annum Source: Department of Education, 2007 Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of- the- art technology and trained medicos A multi-specialty 21 st Century Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, giving services in general and laparoscopic surgery, trauma, orthopedic and urology etc. the hospital is one of the few centers in India offering Uterine Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital, and Adarsh Hospital are also present in Valsad Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also known Fire Temple as Mecca for the Parsi community in India, makes the city a famous pilgrimage center throughout the world Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the years The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also New Project: Page 18 Manufacturing: Organic Azo pigment

19 present in Valsad Proximity of Valsad with Daman & Diu, has increased the graph of tourist flow in the district. 5. Planning Brief : (i) 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 manufacture of variety of products, for example 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 Sarigam. (ii) Population Projection : Not applicable (iii) Land use Planning (breakup along with green belt etc) : The proposed project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below. For Green Belt Development, the company proposes to develop a green belt in 22% of the total plot area. i.e sq. meter. In addition to this company shall also develop green belt along the periphery of the proposed site and in common premises available outside the company premises. Site plan with Area table for proposed plant Sr. No Particulars Area in m 2 1 Production area Raw material storage area Finished product storage 50 4 Office & laboratory area Toilet block & others Utility & boiler Solid waste storage 40 8 ETP 60 9 Gardening & plantation Open space Watchman cabin Total 4306 New Project: Page 19 Manufacturing: Organic Azo pigment

20 Site plan & Key Plan New Project: Page 20 Manufacturing: Organic Azo pigment

21 (iv) Assessment of Infrastructure demand ( Physical & Social) : There is no need for any infrastructure demand in terms of physical or social needs for proposed expansion. (v) Amenities/ Facilities : GIDC notified industrial area of Sarigam has the entire available infrastructure like CETP, water, electricity, roads, rail, transportation, availability of raw material and drainage system. 6. Proposed Infrastructure : (i) Industrial Area (Processing Area). The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. (ii) Residential Area (Non Processing Area) : No residential area is involved in the proposed project. (iii) Green Belt : Green belt will be provided and maintained at the tune of 22% of the total land area. (iv) Social Infrastructure : Not applicable (v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) : The project site is very well connected by road through National Highway no. 8, railways. (vi) Drinking Water management ( Source & Supply of water ) : Source of water is from GIDC water supply services. (vii) Sewerage System : GIDC has provided sewerage system to dispose the sewage effluent. (viii) Industrial Waste Management : Average 250 M 3 /day of Industrial liquid effluent generation during the manufacturing of proposed products will be treated in proposed primary & secondary effluent treatment plant and sent to CETP Sarigam through under ground effluent drainage line of GIDC Sarigam. Generated domestic liquid waste is being disposed off through soak pit system to drainage. New Project: Page 21 Manufacturing: Organic Azo pigment

22 (ix) Solid Waste Management : No Type of waste Category Qty. MT/ Year Treatment 1 ETP waste Dried, packed in bags 2 Used Oil Packed in carboys 3 Discarded containers Decontaminated, stored Disposal Dispose off into TSDF, Vapi Sell to Registered reprocessers Sell to authorized recycler (x) Power Requirement & Supply / Source : Power requirement for proposed project will be taken from DGVCL. 7. Rehabilitation and Resettlement (R&R) Plan: (i) Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless laborers (a brief outline to be given): There will be no rehabilitation and resettlement undertaken as labours and workers from local & nearby areas for the proposed construction activity which will be minor as the proposed activity is to be undertaken at the existing plot/shed. 8. Project Schedule & Cost Estimates : (i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) : After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed construction and commissioning of the project. (ii) 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; Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads considered in the Capital Cost Projection for the proposed project. Environment Protection has also been considered in planning the Cost Projection, which New Project: Page 22 Manufacturing: Organic Azo pigment

23 will include Green belt development, safety systems, etc. CAPITAL COST PROJECTION Sr. No. Particulars Cost in Rs.(Lacs) for proposed project 1.0 Land 4306 Sq. meters Building Plant & Machinery Utility Environmental Management 50 System 5.0 Total Project Cost Utilities 6.1 Steam Boiler, TPH Hot air dryer Three Nos. (Direct firing) 6.3 D.G. Set (Standby), KVA Power from DGVCL, KVA Fuel 8.1 Natural gas for steam boiler 2500 & hot air dryer, SCM/day 8.2 HSD, kgs/hr Water from GIDC Sarigam Waste Water (Industrial) PROJECT VIABILITY Sr. No. PARTICULARS AMOUNT INR Lacs/Anum 1 Proposed Sale Raw Material Cost Power & Fuel Labor Cost Environmental Management System 85 6 Maintenance Cost 50 7 Selling, packing & Office Expenses Proposed Profit 195 The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning. New Project: Page 23 Manufacturing: Organic Azo pigment

24 Sr. No. Component Recurring Cost per annum Proposed (Rs. In Lacs/annum) 1. Environment & Safety Management System Greenbelt Maintenance Solid waste Disposal 0.5 Total Analysis of Proposal ( Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area: Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Local people will get direct financial benefit by way of employment. Local people will get some contracts of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby area. New Project: Page 24 Manufacturing: Organic Azo pigment

25 ANNEXURES ANNEXURES New Project: Page 25 Manufacturing: Organic Azo pigment

26 ANNEXURE-1 The map showing general location, specific location and project boundary and project site layout of M/S. Hercules Pigments Pvt. Limited, located at Plot No. 1704, GIDC,Sarigam , Dist- Valsad (Gujarat). The location of the project site can be viewed in Figure 1.1 Fig. 1.1: Location map showing the Project site and inter-state boundary with 10 kms radius New Project: Page 26 Manufacturing: Organic Azo pigment

27 New Project: Page 27 Manufacturing: Organic Azo pigment

28 ANNEXURE-2 Site Layout Plan & Key Plan New Project: Page 28 Manufacturing: Organic Azo pigment

29 GOOGLE MAP SHOWING PROPOSED PLOT. Proposed plant New Project: Page 29 Manufacturing: Organic Azo pigment

30 ANNEXURE-3 Detailed project description with process details - MANUFACTURING PROCESS The company will use the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance for the product. Manufacturing process: Azo Pigments (Organic Yellow/Orange/Red): (a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c. Solution is maintained at this temp. (b) Coupler Dissolution : Water, Caustic Lye & Coupler is taken in stirred vessel. This mixture is heated to required temp. to make uniform solution. And cooled back to room temp. (c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution. Take out the wet cake. Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material Balance is enclosed. ( 1 ) Organic Yellow Pigment CHEMICAL REACTION Cl NH 2 NH 2 Cl HCl NaNO 2 Cl N=N Cl Cl N=N Cl + 2 NaCl + 4 H 2 O 3 3 Dichlorobenzidine Mol.wt. 253 Diazo Cl Cl Cl N=N N=N Cl + 2CH 3 COCH 2 CONHC 6 H NaOH AcetoAcetanilide Mol. Wt. 177 Cl Cl CH 3 COCH 2 CONHC 6 H 4 - N=N N=N-C 6 H 4 NHCOCH 2 COCH NaCl + 2 H 2 O Yellow pigment Mol. Wt. 618 Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG New Project: Page 30 Manufacturing: Organic Azo pigment

31 ORGANIC YELLOW PIGMENT Water: 4000 Kgs Base (Amine) : 405 kgs Ice: 6000 kgs Sulphamic acid: 9 kgs Na Nitrite: 690 kgs HCl: 960 kgs Total: kgs Ice: 6000 kgs Acetic Acid & Others: 285 kgs Diazotization + Dissolution kgs Live steam: 4000 kgs Total: kgs DIAZOTIZATION Kgs kgs Hours: 1 ½+11/2=3hr COUPLING & TREATMENT kgs, Time: 6 Hrs DISSOLUTION 3990 Kgs Hours: ½ hr Water: 3000 lits Coupler : 640 kgs Caustic: 350 kgs Total: 3990 kgs Crude Pigment Slurry: kgs Total : kgs Crude Pigment Slurry: kgs Total: kgs Wet cake: 3400 kgs Water: kgs Total: kgs Wet cake: 3500 kgs Dry Powder: 1002 kgs FILTERATION kgs, Time: 3 Hrs WASHING, kgs, Time: 6Hrs TRAY DRYING ( 24 Hrs) 3500 kgs PULVERIZER & PACKING (Time: 6 Hrs) Filtrate as effluent: kgs to ETP Wet cake: 3400 kgs Total: 26339kgs Filtrate kgs to ETP Wet cake: 3500 kgs Total: kgs Water Vapors: 2498 kgs Dry Powder: 1002 kgs loss: 2 kgs ORGANIC YELLOW PIGMENT: 1000 kgs New Project: Page 31 Manufacturing: Organic Azo pigment

32 [2] Organic Orange Pigment Cl NH 2 NH 2 Cl HCl NaNO 2 Cl N=N Cl Cl N=NCl + 2 NaCl + 2 H 2 O Cl N=N Cl 3 3 dichlorobenzidine Mol wt. 253 Cl CH 2 O = C N=NCl + 2 N C N CH NaOH PMP Mol wt. 173 Cl Cl CH 3 CH N N CH-N=N C=O N=N- CH O=C N CH-CH 3 N + 2 NaCl + 2 H 2 O Base like: DCB, Coupler like PMP, MPMP Orange 13 pigment Mol.wt. 610 Water: 2600 Kgs Base (Amine) : 405 kgs Ice: 5000 kgs Sulphamic acid: 7 kgs Na Nitrite: 240 kgs HCl: 1080 kgs Total: 9332 kgs Ice: 4000 kgs Emulsifier & Others: 20 kgs Diazotization + Dissolution kgs Live steam: 4000 kgs Total: kgs ORGANIC ORANGE PIGMENT DIAZOTIZATION Crude Pigment Slurry: kgs Total: kgs Wet cake: 3400 kgs Water: kgs Total: kgs 9332 Kgs kgs Hours: 1 ½+11/2=3hr COUPLING & TREATMENT kgs, Time: 6 Hrs FILTERATION kgs, Time: 3 Hrs WASHING, kgs, Time: 6Hrs DISSOLUTION 5800 Kgs Hours: ½ hr Water: 4900 lits Coupler : 580 kgs Caustic: 320 kgs Filtrate as effluent: kgs to ETP Filtrate kgs to ETP Total: 5800 kgs Crude Pigment Slurry: kgs Wet cake: 3400 kgs Total: kgs Wet cake: 3500 kgs Total: kgs Total : kgs Wet cake: 3500 kgs Dry Powder: 1002 kgs TRAY DRYING ( 24 Hrs) 3500 kgs PULVERIZER & PACKING (Time: 6 Hrs) Water Vapors: 2498 kgs Dry Powder: 1002 kgs loss: 2 kgs ORGANIC YELLOW PIGMENT: 1000 kgs New Project: Page 32 Manufacturing: Organic Azo pigment

33 [3] Organic Red Pigment Cl NH 2 Cl N=NCl HCl NaNO 2 + Cl 2H 2 O + NaCL Cl N=NCl Cl 2:5 Dichloro Aniline Mol Wt O NH OH Diazo C 17 H 12 NO 2 ( Naphthol AS) Mol wt.263 O Cl OH C NH N=N Cl Base like: TCA, DCA, Scarlet G base, Coupler like Naphols Organic Red Pigment Mol wt. 436 New Project: Page 33 Manufacturing: Organic Azo pigment

34 (3) ORGANIC RED PIGMENT Water: 1500 lits Base: 432 kgs Ice: 4000 kgs Sulphamic acid: 25 kgs Na Nitrite: 200 kgs H2SO4: 3000kgs Total: 9157 kgs DIAZOTIZATION 9157 Kgs kgs Hours: 6 hrs DISSOLUTION Kgs Hours: 1 hr Water: 4000 lits Coupler: 590 kgs Caustic: 650 kgs Steam: 1000 kgs Ice: 5000 kgs Total: kgs Diazotization + Dissolution:20397 kgs Ice :2000 kgs Live steam: 3000 kgs HCL: 1000 kgs Total: kgs COUPLING kgs, Time: 10 Hrs Coupler: kgs Total: kgs Coupler: kgs Total: kgs Wet cake: 5000 kgs Water: liters Total: kgs Wet cake: 5000 kgs Total: 5000 kgs Dry Powder: 1030 kgs FILTERATION kgs, Time: 3 Hrs WASHING, kgs Time: 6Hrs TRAY DRYING ( 24 Hrs) 5000 kgs PULVERIZER & PACKING (Time: 6 Hrs) Filtrate as effluent: kgs to ETP Wet cake: 5000 kgs Total: 26397kgs Filtrate as effluent: kgs to ETP Wet cake: 5000 kgs Total: kgs Water Vapours: 3970 kgs Dry Powder: 1030 kgs Total: 5000 kgs PRODUCT (ORGANIC RED PIGMENT: 1030 kgs ) New Project: Page 34 Manufacturing: Organic Azo pigment

35 ANNEXURE-4 Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal. Quantity of Waste Water (liquid waste) generation and its management : Sr. No. Particulars Water Consumption Effluent generation 1. Domestic Processing Boiler ( Live steam) Boiler blow down & DM rejection Product Washing Cooling as ice Floor/container washing Note: 7. Gardening Grand Total Total Industrial Average 260 M 3 /day fresh water will be used for proposed plant and source from GIDC authority. Domestic effluent shall be passed through adequate capacity of septic tank/soak pit. Process effluent shall be sent ETP. Boiler blow down, D M rejection & live steam comes out as an effluent. Ice water comes out as effluent. Floor/container & vessel washing comes out as effluent. Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through underground drainage line for further treatment & ultimate disposal into Arabian Sea. New Project: Page 35 Manufacturing: Organic Azo pigment

36 DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT Design Criteria : Product : Organic Azo Pigment Source of Effluent : process, washing, Utilities & floor/container. Design Flow of Effluent : 260 KL/day Max. Design Parameters : As under Effluent Characteristics: No Effluent Parameter Untreated combined normal effluent Expected Results GPCB norms 1 ph to Color pt. Co <100 3 Suspended solids, Mg/L 4 Total dissolved solids, Mg/L < < Oil and grease, Mg/L <10 6 NH 3 -N, Mg/L <50 7 BOD, Mg/L <100 8 COD, Mg/L <250 9 Heavy metal, Mg/L Nil Nil < Phenolic Compounds, Mg/L Nil Nil <1 New Project: Page 36 Manufacturing: Organic Azo pigment

37 Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install. DETAILS OF EFFLUENT TREATMENT PLANT Average hydraulic load, M 3 /Day : 250 M 3 /Day Design hydraulic load, M 3 /Day : 260 M 3 /Day Average Inlet BOD, mg/l : Average Inlet COD, mg/l : No Name of the unit Size in meters Capacity in m 3 MOC No Detention time Remarks Reqd. provided Adequacy 1 Oil/grease trap 0.6 x 0.6 x RCC 1 1 min 1.44 min Adequate 2 Collection with sparger 7 x 5 x 5 m 175 RCC 1 8 hrs 16 hrs Adequate 3 Reaction tank 2.0 ø x MS 1 10 min 25 min Adequate 4 Floculator 2.0 ø x MS 1 10 min 25 min Adequate 5 Chemical dosing tanks HDPE Primary Lamella separator with tube deck packing 7 Secondary Aeration Tank with build in clarifier with tube deck 1.5 x 1.5 x x 5.0 x MS 1 15 min 32 min Adequate 200 RCC 1 12 hrs 18 hrs Adequate 8 Twin Lobe Air Blower 6500 mmwg 500 nm3/hr CI Adequate 9 Holding tank 5 x 5 x 5 m 125 RCC 1 6 hrs 12 hrs Adequate 10 Filter Press 24 x 24 PP Adequate New Project: Page 37 Manufacturing: Organic Azo pigment

38 FLOW DIAGRAM OF PROPOSED EFFLUENT TREATMENT PLANT LIME SLURRY TANKS FeSO 4 /PE tanks TWIN LOBE AIR BLOWER Primary Lamella Separator EFFLUENT O/G TRAP Collection/Equ tank Reaction. Tank FLOCCULATOR FILTER PRESS DIFFUSER SECONDARY AERATION TANK WITH BUILT IN SECONDARY CLARIFIER Holding Tank To GIDC Drain to CETP New Project: Page 38 Manufacturing: Organic Azo pigment

39 Quantity of Hazardous Waste generation and its management No Type of waste Category Qty. MT/ Year Treatment 1 ETP waste Dried, packed in bags 2 Used Oil Packed in carboys 3 Discarded containers Decontaminated, stored Disposal Dispose off into TSDF, Vapi Sell to Registered reprocessers Sell to authorized recycler Note: The unit will obtain membership of approved TSDF site of M/S VGEL, Vapi, for disposal of Hazardous waste. New Project: Page 39 Manufacturing: Organic Azo pigment

40 ANNEXURE-5 The topographical map New Project: Page 40 Manufacturing: Organic Azo pigment

41 Annexure-6 PLOT ALLOTMENT LETTER ISSUED BY THE GIDC New Project: Page 41 Manufacturing: Organic Azo pigment

42 New Project: Page 42 Manufacturing: Organic Azo pigment

43 Notification for Sarigam Notified industrial estate New Project: Page 43 Manufacturing: Organic Azo pigment

44 New Project: Page 44 Manufacturing: Organic Azo pigment

45 ANNEXURE-7 A schematic representation of the feasibility drawing New Project: Page 45 Manufacturing: Organic Azo pigment

46 ANNEXURE: 8 DETAILS OF PROPOSED AIR POLLUTION & ITS CONTROL MEASURES The utility emissions will be from the 2.5 TPH capacity of steam boiler. Natural gas (green fuel) as fuel will be used in the boiler. Also we will install a D.G. Set of 200 KVA capacity to use in case of power failure and HSD shall be used as a fuel. There will be no process gas emission. Details of which are as under; Sr. No. Particulars Details 1.0 Capacity of Steam boiler 2.5 TPH 1.1 Fuel Used Natural gas 1.2 Fuel Consumption 1700 SCM/Day 1.3 APC provided Chimney 1.4 Height/dia of chimney 11 meters 2.0 Capacity of D G set 200 KVA (Standby) 2.1 Fuel Used HSD 2.2 Fuel Consumption 40 liters/hr 2.3 APC provided Exhaust 2.4 Height/dia of Exhaust 11 meters 3.0 Hot air Dryer Direct firing through burner (3 Nos.) 3.1 Fuel used Natural gas 3.2 Fuel consumption 800 SCM/Day 3.3 APC Not required Drying of Pigment: Details of Air pollution control measures attached to Pulveriser Drying of % pigment wet cake shall be carried out in tray dryers. The process heat is provided by Hot air dryer system based on natural gas. Pulverization of pigments: This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This consists of following parts: 1. Hopper feed box. 2. Screw feeder. 3. Closed grinder with box 4. cyclone separator 5. Bag filter. 6. Rotary valve for outlet of product. The pulverized material is collected in bags, weighed and dispatched. The material collected from bag filter is also mixed with the final product. Thus this is a completely closed system and does not involve any process gas emission. New Project: Page 46 Manufacturing: Organic Azo pigment

47 DETAILS OF AIR POLLUTION CONTROL EQUIPMENTS FOR PULVERISER Dried Material wet cake Bag Filter Tray Dryer Pulveriser Cyclone Separator Pulverized dyes New Project: Page 47 Manufacturing: Organic Azo pigment

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