FOR SPECTRUM DYES AND CHEMICALS PVT.LTD.

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1 TECHNO ECONOMIC FEASIBILITY REPORT FOR EXPANSION OF DYES AND CHEMICALS MANUFACTURING UNIT AT SPECTRUM DYES AND CHEMICALS PVT.LTD. BLOCK NO-484, 502, 503-A, 504 & 505, N.H.NO.8, PALSANA , DIST.: SURAT, GUJARAT Prepared by M/S. ENVISION ENVIRONMENTAL SERVICES 201 & 301, Union Trade Center (UTC), Near Apple Hospital, Udhna Darwaja, Surat , Gujarat. Phone: , Visit us at

2 EXECUTIVE SUMMARY OF THE REPORT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes & Chemicals manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.No.8, Palsana , Dist.: Surat, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around sq. meter non agriculture private land is acquired for proposed project. PROJECT COST Cost of the proposed project would be Rs. 4, Lacs. Total capital cost for environmental pollution control measures with the existing plant would be Rs. 3, Lacs and recurring cost per annum would be Rs. 1, Lacs. LIST OF PROPOSED PRODUCTS WITH THEIR PRODUCTION CAPACITY 1A: List of Products along with their Production Capacity SR. NO. NAME OF PRODUCTS Existing (MT/ MONTH) Proposed (MT/ MONTH) Total after expansion (MT/ MONTH) 1 S.O.Dyes Dispersing Agent Textile Auxiliaries Hydros & Speciality Chemicals 5 Dyes Intermediate Total 3150 OR 1 Formulated SO Dyes 2 Dyes Intermediate Total B.List of Byproducts along with their Production Capacity SR. NO. NAME OF BYPRODUCTS Existing (MT/ MONTH) Proposed (MT/ MONTH) Total after expansion (MT/ MONTH) 1 RC DMF (Recovered) RC Methanol (Recovered) RC Acetone (Recovered) RC Sodium Sulphite (Recovered) RC Toluene (Recovered) Sodium Bromide Solution M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 2

3 List of products Sr. No. products Quantity SO Dyes 1. Cr-Blue 2. Cr-Brown 3. Cr-Flavine 4. Cr-Golden Yellow 5. Cr-Navy Blue 6. Cr-Orange 7. Cr-Pink 8. Cr-Red 9. Cr-Rubine 10. Cr-Scarlet 11. Cr-Violet 12. Cr-Yellow 13. Cr-Yellow Brown Dispersing Agents 14. DYETOL DF 15. SD NKS 16. TK 85 OR Formulated SO Dyes 17. Disperse Black 18. Disperse Blue 19. Disperse Brown 20. Disperse Flavine 21. Disperse Golden Yellow 22. Disperse Mix 23. Disperse Navy Blue 24. Disperse Orange 25. Disperse Pink 26. Disperse Red 27. Disperse Red Violet 28. Disperse Rubine 29. Disperse Scarlet 30. Disperse Violet 31. Disperse Yellow 32. Disperse Yellow Brown Dyes Intermediates 33. Alkylated Tertiary Amines Benzothiazole / Imidazole Derivatives 34. Cyno Ethylated Tertiary Amines 35. Ethoxylated and Acetylated Tertiary Amines Formylated Tertiary Amines 36. Methine Derivatives 37. Primary Amines 38. Pyridones Derivatives 900 MT/ MONTH 1500 MT/ MONTH 2400 MT/ MONTH 750 MT/ MONTH M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 3

4 DETAILS OF RAW MATERIAL (PER MONTH) Details of material consumption are given in annexure-i REQUIREMENTS FOR THE PROJECT Land: Total sq. meter (existing sq. meter, proposed sq. meter) land Acquired Water: Water requirement will be mainly for the process KL/day, boiler and cooling KL/Day approx. (Make up quantity), Domestic 95.0 KL/Day and for gardening 30.0 KL/Day. Domestic sewage (75.0 KLD) generated will be treated in secondary treatment plant. Generated industrial effluents will be treated in existing and proposed ETP. Existing treated effluent is sent to CETP of M/s. New Palsana Industrial Co-operative Society Limited, hence now onward, treated effluents will also be sent to CETP of M/s. NPICSL, Palsana for further treatment and disposal. Membership certificate is attached as annexure-ii Electrical Energy: Total power requirement will be 6000 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. sets of (2x380KVA), (2x500KVA) (2x1250KVA), 2nos. of 1250 KVA gas engine and HFO of 760KVA will be provided as standby to fulfill the power requirement. Fuel: For the existing and proposed utilities plant, fuel used for Steam Boiler, Thermic Fluid Heater, Hot Air Generator, Power Plant (stand by) and D.G. Sets (stand by). Total quantity of proposed & existing fuel will be coal MT/day, Gas-10 SCM/hr, Natural Gas-460 SCM/hr, Furnace Oil-200 Lit/hr. Diesel will be required for the D.G. set which will be purchased from the nearest petrol pump in drum and transported by road only. Manpower: The proposed plant will have great employment potential providing employment to approximately 122 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY SOURCES, STACK DETAILS AND APCM PROPOSED A FLUE GAS STACKS : [EXISTING] Stack No. 1 2 Stack Attached To Steam Boiler6 MTPH (Running) 4 MTPH (Stand by) * Thermo pack2,00,000 Kcal/Hr Stack Height Stack Diameter 36.5 M 1300 mm Fuel Coal, Lignite 21 M 250 mm NG 3 HAG 34 M 1000 mm Thermo pack 3,00,000 Kcal/Hr.Heat transfer area 24m 2 (LDO/HSD)/NG Based Power Plant (stand by ) (LDO/HSD)/NG Based Power Plant on plot Coal, Lignite 5 M 305 mm NG 30 M 800 mm 32 M 800 mm LDO/ HSD/ NG LDO/ HSD/ NG Pollutants Permissible value APC Attached M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 4 PM So x No x PM So x No x PM So x No x PM So x No x PM So x No x PM So x No x 150mg/Nm ³ 100 ppm 50 ppm 150mg/Nm ³ 100 ppm 50 ppm 150mg/Nm ³ 100 ppm 50 ppm 150mg/Nm ³ 100 ppm 50 ppm 150mg/Nm ³ 100 ppm 50 ppm 150mg/Nm ³ 100 ppm 50 ppm High Efficiency Multi Cyclone Seperator, Bag filter Sufficient Stack Height Dual Teema Cyclone Seperator, Bag filter Sufficient Stack Height Sufficient Stack Height Sufficient Stack Height

5 no. 484 (stand by) DG Set 02 Nos PM 150mg/Nm ³ Sufficient Stack 7 stand by ( M 150 mm HSD So x 100 ppm Height KVA) No x 50 ppm DG Set 02 Nos PM 150mg/Nm ³ Sufficient Stack 8 stand by ( M 150 mm HSD So x 100 ppm Height KVA) No x 50 ppm DG Set 02 Nos PM 150mg/Nm ³ Sufficient Stack 9 stand by ( M 150 mm HSD So x 100 ppm Height KVA) No x 50 ppm Note - * indicate that in proposed expansion, we will resell our Existing 4 MTPH Boiler (Stand by) Stack No. 1 A Flue Gas Stack: [ Proposed] Stack Stack Stack Attached To Height Diameter Fuel Steam Boiler 10 MTPH ** 36 M 1450 mm Coal, Lignite 2 HAG Pollutants PM So x No x Permissible value 150mg/Nm ³ 100 ppm 50 ppm APC Attached ESP (Combine Stack and APC for boiler and HAG) Note - ** indicate that in proposed expansion, we will use our Existing 6 MTPH Boiler as a stand by Stack No Stack Attached To Spray Dryer No. 3 Spray Dryer No. 4 *** Spray Dryer No.5 Spray Dryer No.6 Spray Dryer No.7 Spray Dryer No.8 Scrubber at Bromide Plant Scrubber At AQ-I Plant Scrubber At DD1 Stack Height B PROCESS STACKS :[EXISTING] Stack Fuel Pollutants Diameter 21.4 M 700 mm NG / Steam (HAG) Afer Expansion 18.4 M 450 mm Steam 21.4 M 1200 mm 33.0 M 1100 mm 33.0 M 1200 mm 33.0 M 1200 mm NG / Steam (HAG) Afer Expansion Steam (HAG) Steam (HAG) Steam (HAG) 16.5 M 250 mm M 250 mm M 250 mm - PM So x No x PM So x No x PM So x No x PM So x No x PM So x No x PM So x No x Cl 2 Hcl Br 2 Hbr Cl 2 Hcl Br 2 Hbr Br2 Permissible value 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 150 mg/nm ³ 40 mg/nm ³ 25 mg/nm ³ 9 mg/nm ³ 20 mg/nm ³ 2 mg/nm ³ 30 mg/nm ³ 9 mg/nm ³ 20 mg/nm ³ 2 mg/nm ³ 30 mg/nm ³ 2 mg/nm ³ 20 mg/nm ³ APC Attached Cyclone + Wet Scrubber Cyclone + Wet Scrubber Cyclone + Wet Scrubber Cyclone + Wet Scrubber Cyclone + Wet Scrubber Cyclone + Wet Scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 5

6 10 Plant / Mono-Azo # Oleum Storage So2 followed by packed columm scrubber 6.0 M 50 mm - Sox 40 mg/nm³ Scrubber Tank Note - *** indicate that in proposed expansion, we will resell our Existing Spray Dryer No.4 # indicate that in proposed expansion, we will use our existing DD1 scrubber for Mono-Azo plant and install new scrubber for DD1 Plant Stack No Stack Attached To Spray Dryer No.9 Scrubber At NKS Plant Scrubber At DD2 Plant (Diazo) Scrubber At DD2 Plant (Coupling) Scrubber At Solvent -II Plant Scrubber At MAA Plant Scrubber At Solvent III Plant Stage-1 Acid Scrubber At Solvent III Plant Stage-2 Alkaline Scrubber At NEW DD1 Plant (Diazo) Scrubber At NEW DD1 Plant (Coupling) Primary Treatment Plant (Equalization tank) Stack Height B Process Stacks : [Proposed] Stack Diameter 33.0 M 1200 mm Fuel Steam (HAG) Pollutants PM Permissible value 2.5 M 250 mm - So2-6.0 M 250 mm - Cl 2 Hcl Br 2 Hbr 5.3 M 650 mm - So2-2.0M 250 mm M 150 mm M 450 mm M 450 mm M 650 mm M 1000 mm M 355 mm - Br2, So2, Cl2 Br2, So2, Cl2 So2 Cl2 So2 Cl2 Cl 2 Hcl Br 2 Hbr Cl 2 Hcl Br 2 Hbr Cl 2 Hcl Br 2 Hbr APC Attached Cyclone + Wet Scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Venturi scrubbers followed by packed columm scrubber Packed columm scrubber Packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Two Stage venturi scrubbers followed by packed columm scrubber Packed columm scrubber M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 6

7 WASTE WATER GENERATION AND ITS TREATMENT: Domestic sewage (75.0 KLD) generated will be treated in secondary treatment plant. Generated industrial effluents around 2245 KLD will be treated in existing and proposed ETP. Existing process effluent is sent to CETP of M/s. NPICSL, hence now onward, treated effluents will be sent to CETP of M/s. NPICSL, Palsana for further treatment and disposal. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project: 1. Encasement of noise generating equipment. 2. A thick greenbelt will be developed all around the plant boundary to act as noise attenuator. 3. In addition personnel working near high noise level generating sources will be provided with ear muffs. 4. Proper and suitable acoustic barrier will also be provided around areas generating high noise. 5. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also noise reduction. SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes generation and its management are given in the following table. S. No. TYPE OF HAZARD OUS WASTE EXISTIN G (MT/ month) PROPOS ED (MT/ month) TOTA L (MT/ month) WASTE CATEGO RY SOURCE WASTE MANAGEMENT DETAILS DISPOSAL 1 ETP Sludge Effluent Treatment Plant 2 Used/spent Oil 3 Discarded Containers 4 Process Waste 5 Distillation Residue 1.8 MT/Year MT /Year MT/Ye ar MT/ Year 5.1 Various maintenanc e processes 33.3 Various production units Manufacturi ng process Manufacturi ng process 6 GYPSUM D2 Effluent Treatment Plan Collection, Storage Transportation, Disposal at GPCB approved TSDF site Collection, Storage, Transportation, Disposal by selling to registered rerefiner Collection, Storage, Decontamination, Transportation, Disposal by selling to registered party Collection, Storage Transportation, Disposal at GPCB approved CHWIF Collection, Storage Transportation, Disposal at GPCB approved CHWIF or co/preprocessing Collection, Storage Transportation, Disposal by selling to actual user authorized by GPCB M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 7

8 GREEN BELT DEVELOPMENT About 8185 sq.m area i.e % of total project plot area is developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. We have already developed compensatory greenbelt of 5400 sq.m area i.e % of the total project plot area at Udhana-Magdalla Road, Surat and submitted in compliance report of our pervious environment clearance for each half year to the Ministry of Environment, Forest and Climate Change, Regional office-bhopal. We will develop another 2000 sq. m area i.e 4.06 % of total project area with total investment of Rs.15 Lacs approx. for the green belt plantation. Total Green belt area of total project area would be %. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 8

9 INDEX CHAPTER CONTENT PAGE 1. INTRODUCTION OF THE PROJECT PROJECT DESCRIPTION SITE ANALYSIS PLANNING BRIEF PROPOSED INFRASTRUCTURE REHABILITATION AND RESETTLEMENT (R & R) PLAN PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL 31 M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 9

10 LIST OF TABLES TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 11 2 DETAILS OF EMPLOYMENT REQUIREMENT 13 3 DETAILS OF SIZE OF THE OPERATION 16 4 DETAILS OF WASTEWATER GENERATION 17 5 DETAILS OF SOLID WASTE 20 6 DETAILS OF EXISTING LAND USE 21 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 22 8 TEMPERATURE DATA 22 9 RAINFALL DATA PROJECT IMPLEMENTATION SCHEDULE TOTAL PROJECT COST AND IT S BREAK UP 30 LIST OF FIGURES FIGURE PARTICULAR PAGE 1 MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC. 2 MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC. 3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL LIST OF ANNEXURES ANNEXURE PARTICULAR PAGE I Raw material consumption 34 II CETP Membership certificate 46 III LAND DOCUMENT 47 IV Solvent recovery system 51 V CGWA Application 61 VI LAYOUT OF THE PLANT 63 M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 10

11 INTRODUCTION OF THE PROJECT CHAPTER IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT Spectrum Dyes and Chemicals Pvt. Ltd. a company promoted by reputed business families of South Gujarat. The management of Spectrum Dyes and Chemicals Pvt. Ltd. have decided to Expansion of Dyes manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat. Land document is attached as Annexure- III. TABLE 1: DETAILS OF THE DIRECTORS S. NO. NAME OF THE DIRECTOR AGE QUALIFICATION EXPERIENCE 1. Mahendrakumar C. Chaudhary 59 Mechanical Engineer 38 years 2. Yogesh R. Gupta 48 Commerce graduate 28 years 3. Avneep V. Bansal 45 Chemical Engineer 24 years 4. Hardat Singh M. Tarar 58 Arts Graduate 28 years The company is promoted by Shri Mahendrakumar C. Chaudhary having a widespread business interests in Gujarat. He has been in the business of Dyes & Dyes Intermediates for over 27 years and the group has excellent knowledge about the South Gujarat Industrial Environment. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no- 484, 502, 503-A, 504 & 505, N.H. No.8, Palsana , Dist.: Surat, Gujarat 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The world is changing at a very quick pace. Due to the decline in the availability of the natural resources, the use of man-made fabrics has increased drastically in the world. This has led to significant increase in the consumption of Synthetic Organic Dyes - Disperse Dyes which is the main ingredient used to colour the man-made (polyester) fabric. The production of disperse dyes was mainly concentrated in the western countries. However, due to the limited availability of resources and increasing costs, the disperse dyes manufacturing has declined in Western countries and is increasing steady in Developing Asian countries like China, India, Indonesia and Thailand. India is on second position behind China in consumption of disperse dyes market by its 10% share in which around 70,000 MT to 75,000 MT of dyes is being consumed. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 11

12 India and China have emerged top of the on worldwide market by exporting its Synthetic Organic Dyes, Formulated S. O. Dyes, Intermediate and other raw chemicals which are used by western and other developing countries in textile manufacturing sector. We at Spectrum Dyes & Chemicals Pvt Ltd are engaged in manufacturing of Synthetic Organic Disperse Dyes since 1991 and have a reputed Brand name in polyester textile industry in India and around the world. Our products are being exported to the South Asian Countries, Middle East Region Countries, USA & Central Americas. We have a huge demand and also see a rise in demand in the coming years. Foreseeing this situation, we decided to increase our production capacity. We had already purchased a land in Dahej Saykha GIDC to construct a large scale production plant. But since it is a green-field project, it is expected to take at least 3-4 years for development of infrastructure and starting the construction. Due to this, we are not able to fulfil the requirement of our existing customers and are on the verge of losing them to other domestic and international competitors. To avoid this, we are looking to maintain a balance to meet the market demand. We want utilize our spare capacity reserved for production of Textile Auxiliaries, Hydros & Specialty Chemicals and also purchase some adjacent land to expand our existing manufacturing capacity of Synthetic Organic Dyes, Dyes Intermediates and Dispersing Agents. We have a fully functional Effluent Treatment Plant (ETP) to fully treat our existing effluent load of approximately 1 MLD. To overcome the increase in the effluent load, we have planned to upgrade the ETP and invest around 10 crores out of the proposed total project cost of crores. The upgraded ETP will be able to treat upto 2.5 MLD of effluent. Further, we are valid member of Common Effluent Treatment Plant (CETP) developed by New Palsana Industrial Co-Op Society Ltd and are sending our treated effluent for further treatment since the last four years. The CETP is designed to treat 45 MLD of industrial effluent and has provided membership to 32 units as on date. The CETP is connected with 30 textile units and only two chemical industries (M/s. Spectrum Dyes & Chemicals Pvt Ltd and M/s Virdev Intermediate Pvt Ltd).The total permitted load of the both chemicals industries is 5 MLD as per EC issued to CETP. The combined load of effluent sent to CETP by both the chemical units even after our expansion will be less than 3.5 MLD and it will be easily able to cater to the increased load. Considering all the factors, we intend to go for expansion so that we are able to retain our customers and also continue to contribute to India s growth in becoming the largest exporter of Synthetic Organic Dyes across the world. PRODUCT PROFILE Our products are backed by unique technology and or process, and are not readily available with the competitor. These products play an important role in the production process of the user and hence user do not compromise or shift from tested products and user industry TECHNOLOGY Technology is typically developed in-house with the critical equipment being out-sourced. We have in-house independent R & D, equipped with latest state of art technologies and facilities. 1.5 EMPLOYMENT GENERATION DUE TO THE PROJECT The manpower requirement for the project is estimated at about 122. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break up of the manpower requirement is as under: M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 12

13 TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT S. NO. DESCRIPTION NUMBER 1 Top Management 0 2 Managers 1 3 Specialist/ Engineer/Officers 5 4 Supervisors 17 5 Operators/Attendants 99 TOTAL 122 Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. Spectrum Dyes and Chemicals Pvt. Ltd. is going to manufacture dyes and chemicals mainly for textile dyeing and printing industry. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 13

14 PROJECT DESCRIPTION CHAPTER TYPE OF PROJECT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no- 484, 502, 503-A, 504 & 505 N.H.no.8, Palsana , Dist.: Surat, Gujarat. The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth. 2.2 LOCATION WITH COORDINATES A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure 1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC. COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per mentioned below: Latitude: N Longitude: E M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 14

15 FIGURE 2: MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC. 2.3 DETAILS OF ALTERNATE SITES No alternate site is considered as this is a expansion project on existing premises. The proposed project site is situated at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat. The site is about 17.0 km from Surat. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labors are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 2.4 SIZE OR MAGNITUDE OF OPERATION Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes manufacturing unit at Block no- 484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat. Details of size of the operation is shown in Table no: 3 M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 15

16 3A.List of products along with their Production Capacity NAME OF PRODUCTS Existing (MT/ MONTH) Proposed (MT/ MONTH) 1 S.O.Dyes Dispersing Agent Textile Auxiliaries SR. NO. Total after expansion (MT/ MONTH) 4 Hydros & Speciality Chemicals 5 Dyes Intermediate Total 3150 OR 1 Formulated SO Dyes Dyes Intermediate Total B.List of Byproducts along with their Production Capacity SR. NO. NAME OF BYPRODUCTS Existing (MT/ MONTH) Proposed (MT/ MONTH) Total after expansion (MT/ MONTH) 1 RC DMF (Recovered) RC Methanol (Recovered) RC Acetone (Recovered) RC Sodium Sulphite (Recovered) RC Toluene (Recovered) Sodium Bromide Solution M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 16

17 2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of disperse dyes is attached as annexure-i. 2.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE We have provided rain water recharging system for the resource optimization. Spent solvent will be recovered through distillation unit and will be reused in process along with fresh solvent. Please refer annexure- IV for details 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed project will be 2700 KLD which mainly for process, Boiler & cooling (make up water), Domestic uses and for gardening & others. Total water requirement shall be met from existing 4nos. of bore well and proposed 3 nos. of bore well POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 6000 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. sets of (2x380KVA), (2x500KVA) (2x1250KVA), 2nos. of 1250 KVA gas engine and GFO of 760KVA will be provided to fulfill the power requirement. 2.8 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND ITS MANAGEMENT / DISPOSAL WASTEWATER GENERATION Water requirement will be mainly for process, Boiler & cooling (Make up water), Domestic and gardening. Waste water i.e. sewage waste water 75.0 KL/day will be generated which will be treated in secondary treatment plant. Industrial waste water will be 2245 KL/day from process and utilities. Details of water requirement and waste water generation are given in following table. TABLE 4: DETAILS OF WASTEWATER GENERATION S.NO. PURPOSE WASTE WATER GENERATION (KL/D) EXISTING PROPOSED TOTAL A. Domestic B. Industrial 1. Processing Boiler and Cooling 3. Floor and Drum washing Total (B) C. Green belt Grand Total (A+B+C) FACILITIES FOR TREATMENT OF LIQUID EFFLUENT (ETP) We propose upgrading/modifying our PTP- Primary Treatment Plant & STP- Secondary Treatment Plant with investment of approximately 10 Crores. In which Primary Treatment is going to have continuous automated neutralization system for charging of lime, ferrous and polyelectrolyte with high efficiency having Thickener which is followed by Two Rotary Vacuum Drum Filters and Paddle Dryer to make moister free Sludge for suitable to fill in Sludge Silo. Secondary treatment plant is going to have the Cyclic Activated Sludge Technology of the ETP. This technology is extensively used for treatment of industrial wastewater to highest possible quality at a very low cost of treatment with minimum space utilization. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 17

18 Treatment Philosophy of Proposed ETP An equalization tank with mechanical mixing is provided to dampen the variations of flow. Agitators are provided in this tank for proper mixing of effluent and to avoid stagnation of liquid. Pumps have been provided to pump the raw effluent from equalization to ph Correction Tank-1. A Level indicator transmitter is provided in the sump to control proper on/off of the pumps depending upon the water level in the tank. The pumped effluent from Equalization tank is corrected for ph in PPH FRP neutralization tank 1 followed by Neutralization Tank 2 for increasing ph levels, and will be fed to High Rate Thickener for removal of suspended solids. Hydrated Lime with 80% purity is used to correct the ph. A ph indicator and controllers are installed inside both the tanks to automatically control the dosage of lime and to produce desired ph of effluents. Mechanical agitators are provided in the tank for mixing the lime with effluents inside the tank. The primary object of thickener is to achieve the desired underflow concentration, while maintaining a clear overflow and minimizing the flocculent usage. The fundamental strategy for controlling the underflow concentration is to regulate the time the solids which are present in the thickener and the amount of flocculent used due to which suspended solids gets removed. Clarified effluent from High Rate Thickener and sewage waste water are directed to C-TECH Feed Tank. Effluent is then pumped to C -Tech basins for biological treatment. There are two operating C-Tech basins in the plant. These C-Tech basins work in sequence and the influent flow is distributed using Automatic Gates provided at the Inlet Chamber of C-Tech basins. The C-Tech basins are equipped with air blowers, diffusers, Return Activated Sludge (RAS) pumps, Surplus Activated Sludge (SAS) pumps, Decanters, Auto valves, Programmable Logic Controller (PLC) etc. All cycles will be automatically controlled using PLC. Excess sludge at a consistency level of approx. 0.8% - 1.0% will be pumped intermittently from SAS pump to the sludge sump. Sludge generated from Physico-chemical treatment and biological treatment is collected in common sludge sump. Mechanical mixers are provided to keep the sludge in suspended form. Rotary Vacuum Drum filter is considered to dewater the sludge to the required solid concentration. Screw pumps are used to pump the sludge from sludge sump to RVDF. Dewatering polymer is dosed into the thickener to improve its dewatering characteristics. The dewatered sludge from Rotary Vacuum drum filter is taken to the Paddle Dryer System for max. Solid concentration and to make suitable for filling in the sludge silo whereby the sludge will be dispatch to the TSDF Site. After biological treatment, the treated effluent is directed to CETP. DESIGN CHARACTERISTIC: Effluent Water Inlet Quality SR.NO. Parameter Unit Inlet Parameters CETP norms 1 ph - 1 to SS mg/l COD mg/l BOD mg/l Ammonical Nitrogen mg/l Phenolic Compound mg/l Oil & Grease mg/l PROPOSED ETP UNIT system: (Design Flow: 2500 KLD) Equipment name Size/Capacity MOC Quanti ty Sludge Handling System Sludge Silo 250 MT MS 2 nos. Paddle Dryer MT/H SS nos. Stand by Paddle Dryer MT/H SS nos. Secondary Treatment Plant C - Tech Basin 3000 m³ RCC 2 sets AERZEN, German make, Hybrid Energy Saving Efficiency Air Blower kg/cm² MS 3 nos M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 18

19 Primary Treatment Plant Lime Silo 150 MT MS 1 no. Lime Handling System 2.5 TPH 1 no. Rotary Vacuum Drum Filter 1.8m x 1.8m MS 2 no. Equalization tank 1000 m³ RCC-AR brick lined Neutralization Tank 41m³ & 44 m³ PP-FRP 1 no. 1 no. each Thickener -1 8 m dia MS/painted 1 no. Stand by Thickener -2 8 m dia MS/painted 1 no. Sludge Sump 200 m³ RCC 1 no. Lime Dosing tank 15 m³ RCC 4 nos FeSO4 Dosing tank 8 m³ RCC-AR brick lined 2 nos FeSO4 Bulk storage tank 50 m³ RCC-AR brick lined 1 no. Polymer dosing tank 8 m³ RCC 2 nos Urea/DAP tank 8 m³ RCC 2 nos Air Compressor 220 cfm 1 no. Lift 1.5 MT MS 1 no. Electrical & Instrumentation Piping & Valves Area available for proposed ETP is 1300 Sq.meter M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 19

20 2.8.2 SOLID WASTE GENERATION Solid waste generated will be Ash from boilers and Sludge from ETP, used/spent oil and discarded bags. The sources of solid wastes, generation and its management are as given in the following table. S. No. TYPE OF HAZARDOUS WASTE EXISTING (MT/ month) TABLE 5: DETAILS OF SOLID WASTE PROPOSED TOTAL WASTE SOURCE (MT/ month) (MT/ CATEGORY month) WASTE MANAGEMENT DETAILS DISPOSAL 1 ETP Sludge Effluent Treatment Plant 2 Used/spent Oil 1.8 MT/Year MT/Year 3 Discarded Containers MT /Year MT/ Year 5.1 Various maintenance processes 33.3 Various production units 4 Process Waste Manufacturing process 5 Distillation Residue Manufacturing process 6 GYPSUM D2 Effluent Treatment Plan Collection, Storage Transportation, Disposal at GPCB approved TSDF site Collection, Storage, Transportation, Disposal by selling to registered re-refiner Collection, Storage, Decontamination, Transportation, Disposal by selling to registered party Collection, Storage Transportation, Disposal at GPCB approved CHWIF Collection, Storage Transportation, Disposal at GPCB approved CHWIF or co/pre- processing Collection, Storage Transportation, Disposal by selling to actual user authorized by GPCB M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 20

21 SITE ANALYSIS CHAPTER CONNECTIVITY The proposed unit shall be located at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat. The site is about 0.05 km from NH-8. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labors are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access Road Connectivity The plant location is about 0.05 Km (E) from Bombay-Ahmedabad Highway on NH Rail The Area is well connected by Railway. The Chalthan Railway Station is about 7.0 km in NNW from the site Airport The nearest airport to the project will be Surat at a distance of 24.2 Km in NWW Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP About sq.m. of land at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat, is acquired for the proposed plant out of total sq.m existing and sq.m proposed for expansion. Total acquired land is classified as Industrial land. Land document is attached as Annexure III. 3.3 TOPOGRAPHY Topography of the area is plain. 3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table: TABLE 6: DETAILS OF EXISTING LAND USE S.NO. PARTICULAR NAME & ITS DISTANCE 1. Nearest National Highway NH-8 at around 0.05 Km E 2. Nearest State Highway SH-168 at around 1.1 Km S 3. Nearest city Surat at around 17.0 Km 4. Nearest River Mindhola at around 2.6 Km SE 5. Nearest Railway station Chalthan at around 7.0 Km NNW 6. National park/reserve Forest, Biosphere, etc. None within a radius of 10 Km 6. Seismicity Zone III 3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table: M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 21

22 TABLE 7: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE S. NO. PARTICULAR DISTANCE 1. Civil Hospital 17.8 Km 2. Colleges 1.2 Km 3. Govt. & Pvt. Schools 0.8 Km 4. Temple 1.5 Km 3.6 CLIMATIC DATA The climate of the area is humid and tropical. A hot and humid pre-monsoon from March to mid May, a prolonged southwest monsoon or rainy season from mid May to September, a pleasant post-monsoon or retreating monsoon from October to November and a cold pleasant winter from December to February are the characteristics of the general climate. Summer runs concurrently with the later part of the pre-monsoon season and continues throughout the monsoon season. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months: Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February Sometimes, the monsoon commences in mid-june and ends in mid-september. Therefore, the boundaries between the seasons are not very rigid. Surat is the meteorological observatory, to whom the meteorological data (Temperature, Relative Humidity, Rainfall, Wind speed and Wind direction) for the year January 2014 to December 2014 were collected from Indian Meteorological Department (IMD) in Ahmedabad TEMPERATURE DETAILS The hottest months were May to September with mercury reaching 37 ºC during June. The coldest months were December, January and February when temperature drops to 15 ºC. The months, November and March, can also be quite cold in some years. During the other months, temperature was more or less moderate in nature and pleasant to bear. Monthly mean Minimum and Maximum Temperatures of Surat station for the period of Jan 14 to Dec 14 are given in following table. TABLE 8: TEMPERATURE DATA S. NO. MONTHS OF YEAR 2014 MONTHLY MEAN MINIMUM ( 0 C) MONTHLY MEAN MAXIMUM ( 0 C) 1. January February March April May June July August September October November December (Courtesy: Indian Meteorological Department) M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 22

23 3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Bharuch station was recorded for 08:30 hrs and 17:30 hrs. Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period RAINFALL Monthly total rainfall data for Surat station is presented in following table. S. NO. TABLE 9: RAINFALL DATA MONTHS OF YEAR 2016 MONTHLY TOTAL(MM) 1. January February March April May June July August September October November December 0.0 TOTAL (Courtesy: Indian Meteorological Department) WIND SPEED AND WIND DIRECTION The April Sept Month, have winds from South West to North East. From October-March is a period mixed with calm conditions and winds mainly from North East to South East. The winter months, November to February, experience frequent calm conditions. The maximum number of calm periods observed is in the month of December and February. (Source: M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 23

24 PLANNING BRIEF CHAPTER PLANNING CONCEPT Spectrum Dyes and Chemicals Pvt. Ltd. is planning to Expansion of Dyes & Chemicals manufacturing unit at Block no-484, 502, 503-A, 504 & 505, N.H.no.8, Palsana , Dist.: Surat, Gujarat. Proposed project is envisaged as existing Dyes & Intermediates facilities in Gujarat are not adequate to handle new development activities as well for the industries in Surat, Ankleshwar, Jhagadia, Panoli, Vapi, Navsari, Vadodara, others. 4.2 LAND USE PLANNING For the proposed Expansion of plant sq. meter existing land acquired and purchase sq. meter new land, Hence Total sq. meter land Required for proposed Expansion. 4.3 AMENITIES / FACILITIES At the project site first aid centre will be set up. Company will provide drinking water to the workers in the factory premises. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 24

25 PROPOSED INFRASTRUCTURE CHAPTER INDUSTRIAL AREA For the proposed Expansion of plant sq. meter existing land acquired and purchase sq. meter new land, Hence Total sq. meter land Required for proposed Expansion. 5.2 RESIDENTIAL AREA There will be no residential area proposed for the project. 5.3 GREEN BELT The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of top soil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About 8185 sq.m area i.e % of total project plot area is developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. We have already developed compensatory greenbelt of 5400 sq.m area i.e % of the total project plot area at Udhana-Magdalla Road, Surat and submitted in compliance report of our pervious environment clearance for each half year to the Ministry of Environment, Forest and Climate Change, Regional office-bhopal. We will develop another 2000 sq. m area i.e 4.06 % of total project area with total investment of Rs.15 Lacs approx. for the green belt plantation. Total Green belt area of total project area would be %. In Green belt area about 1700 tree shall be planted. The selection of tree species suitable for plantation at the industry shall be governed by guiding factors as stated below: The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in primary and secondary attenuation zone. The trees should possess extensive foliar area to provide maximum impinging surface for continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution indicator. It is also recommended to carry out extensive plantation within premises. Keeping in view the climatic conditions, status of soils and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE No new social infrastructure facility will be developed as the plot is located in notified industrial area having well developed infrastructure. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 25

26 5.5 CONNECTIVITY ROAD CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation. 5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the 4 nos. of existing Bore well and 3 nos. of proposed bore well. CGWA application submitted for use of bore well. A copy of CGWA application attached as annexure-v. 5.7 WASTE WATER MANAGEMENT STORM WATER DRAINAGE Storm water drainage system shall consist of well-designed open surface drains network so that all the storm water is efficiently drained of without any water logging. Based on the rainfall intensity of the proposed area drainage system shall be design on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow. Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations. For crossing roads, culverts shall be provided SEWERAGE WATER SYSTEM The sanitary sewerage system shall be designed to cater the sanitary sewerage from plant premises. The design of facial sewerage system shall be designed based on no. of person to be served and average daily consumption of water. Only 75.0 KL/day sewage will be generated which will be treated by our secondary treatment plant and final treated waste water disposed to CETP of NPICSL For inspection, cleaning and maintenance of sewer lines, manholes of reinforced concrete constructions shall be provided at every bend, junction point of change in slope or diameter and on straight sections of pipes at interval not exceeding 30 meters INDUSTRIAL WASTE WATER MANAGEMENT Water will be required for Process, Boiler & Cooling purpose, Domestic and Green belt development. Maximum recycling of water will be done KL/day industrial wastewater generated from process & utilities of the proposed project. Same will be treated in in-house ETP and treated effluents are finally discharged in to CETP of NPICSL for further treatment and disposal. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the table no. 5. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 26

27 REHABILITATION AND RESETTLEMENT (R & R) PLAN CHAPTER 6 Proposed project is located on industrial land, which is already acquired and there is no habitat. So proposed project proposal does not involve any Rehabilitation & Resettlement. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 28

28 PROJECT SCHEDULE & COST ESTIMATES CHAPTER PROJECT IMPLEMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. We are giving here under the details of the Project Implementation. From the date of start, the implementation schedule envisages completion of project in 18 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows: TABLE 10: PROJECT IMPLEMENTATION SCHEDULE S.NO. WORK IMPLEMENTATION TIME 1. Construction work 9 Months 2. Machinery installation 4 Months 3. Recruitment process 1 Month 4. Commissioning 2 Month 5. Operation and functions 2 Month Total 18 months PROPOSED ORGANISATION CHART In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to ensure its effective implementation. Hence, company will create a team consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level etc. either permanently or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried - out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in figure 3. FIGURE 3: AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL DIRECTORS GENERAL MANAGER OFFICE ASSISTANTS WAREHOUSE INCHARGE WORKS MANAGER ACCOUNTANT SUPERVISORS OPERATORS UNSKILLED WORKERS M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 29

29 7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs Lacs. Break up of proposed project cost is given in following table: TABLE 11: TOTAL PROJECT COST AND IT S BREAK UP S. NO. COST OF PROJECT COST (RS. IN LACS) 1 Land and Site development Factory Building Plant & Machineries Furnitures Greenbelt Development Preliminary & Pre-operative Exp Total Capital Cost of Project CSR Project Activity Total Cost of project BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The capital expenditure is Rs Lacs and recurring (Rs Lacs per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance. M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 30

30 ANALYSIS OF PROPOSAL CHAPTER FINANCIAL AND SOCIAL BENEFITS The industrial activity of the proposed project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region. 8.2 DIRECT BENEFITS TO THE NATIONAL AND STATE EXCHEQUER Employment generation, Income tax from individual as well as corporate taxes from company and ancillary units, Transportation reduction. 8.3 OTHER BENEFITS Most of the work force required for construction and operation of the proposed project will be drawn from the surrounding villages. During the construction phase, no family is required to rehabilitate from the core zone. The economic growth of the area in terms of employment generation, consumption of goods and marketgrowth are expected outcome of the project. The project has an employment generation prospect on skilled manpower. The direct employment potential of the project is estimated as 122 persons, the share of local people in this is expected to be significant. It is assumed that the generation of indirect employment would be multiple of direct employment. The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. This will have impact on the current literacy level, primary and middle level education and on existing health facilities. A new awareness generated will have positive impact on the social pattern, which at this stage, is caste and community oriented. The long-term implications of this change are definitely progressive. 8.4 EMPLOYMENT Due to proposed project, there will be development of communication facilities in the area. The total manpower requirement will be 122. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities etc. During operation, plant will generate direct employment as explained in the previous paragraph. The preference will be given for local population for employment in the semi-skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods. Moreover, permanent supply of electricity in the area will support to improve other type of industries. 8.5 HEALTH AND SAFETY MEASURES The workers engaged in high pollution generation area will be equipped with appropriate protective equipment. Following measures will be adopted in the plant to keep check on the safety measures and health: - Inspection and maintenance of pollution control systems regularly - All safety measures such as provision of safety appliances, training, and giving-of safety awards. - The workers exposed to noisy sources will be provided with ear muffs/plugs - Adequate facilities for drinking water and sufficient toilets will be provided to the employees 8.6 SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY The firm shall earmark funds for social development and welfare measures in the surrounding villages. These measures will include funding for: 1) Education Facilities 2) Health Care and Family Welfare 3) Infrastructure Developments 4) Social Causes M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 31

31 The details of peripheral development plan including development in infrastructure, health, education and socio cultural aspects which will be carried out are as follows under the Corporate Responsibility: 1 The firm will organize free medical camps at least twice in a year for the benefit of the villagers. 2 The firm will organize cultural programmes in connection for the sake of local villagers every year. 3 The firm will provide chairs and cooking vessels on returnable basis to all the villagers for marriages. ESTIMATED COST OF PROJECT AND PROJECT VIABILITY The capital cost of the project is estimated at about Rs Lacs for the construction of factory building and installation of plant machinery along with required auxiliary and balancing facilities for the production of Dyes & Intermediate product. The breakup of the same is shown below: S. No. Cost of Project Cost (Rs. in Lacs) 1 Land and Site development Factory Building Plant & Machineries Furnitures Greenbelt Development Preliminary & Pre-operative Exp Total Capital Cost of Project CSR Project Activity Total Cost of project BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control/monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance will be as given in following table: S. NO. ITEM RS. IN LACS 1 Capital Expenditure 3, Recurring expenditure on environmental management cell and on pollution control systems per annum 1, ECONOMIC VIABILITY STATEMENT SHOWING PROFITABILITY AND CASH ACCRUALS Particulars Quantity Rate per kg Total Rs. in Lacs SALES Value of Dyes and Intermediate Product 2,10,00, If we will produce Total Cost of Dyes & Intermediate Product 2,10,00, , Net Earnings Per Kg. 2,10,00, Estimated Sales / Day Estimated Sales / Monthly Estimated Sales / Quarterly Estimated Sales / Yearly M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 32

32 ESTIMATE OF MEANS OF FINANCE 1. Capital & Reserve Share application money - 3. Unsecured loan (Shareholders) - 4. Member s deposit - 5. Central & state subsidy - 6. Loan from Financial Institutions TOTAL M/S. SPECTRUM DYES AND CHEMICALS PVT. LTD; PALSANA DIST: SURAT 33

33 ANNEXURE-I S.No. Raw Material Qty ((MT / MT)) CR-YELLOW 3G 1 CR-YELLOW Sulfuric Acid Iodine Bromine Liquid H E D P DISPERSE YELLOW 3G 200% 1 CR-YELLOW 3G DYETOL DF Dispersing Agent O P A (Ortho Phosphoric Acid) C 20 FKI (DEFOAMER) LUMINOUS YELLOW 10GN CR-G. Y. GNN 1 GP BASE E.P H C L Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid Sodium Acetate Crystal ( Tri ) C 20 FKI (DEFOAMER) DISPERSE GOLDEN YELLOW W3RN 1 CR-G. Y. GNN DYETOL DF O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-YELLOW C4G 1 P N A H M Q H C L Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid C 20 FKI (DEFOAMER) Soda Ash Sodium Bi Carbonate DISPERSE YELLOW C4G H/CONC. 1 CR-YELLOW C4G DYETOL DF O P A (Ortho Phosphoric Acid)

34 ANNEXURE-I 4 H E D P Dispersing Agent CR-ORANGE RL 1 P N A SD H2SO4 (30%) Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid Sodium acetate Crystal Surfactant C 20 FKI (DEFOAMER) DISPERSE ORANGE RL 1 CR-ORANGE RL DYETOL DF O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-ORANGE 3R 1 O C P N A N,N-DCNE Aniline HCl (30%) Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid Surfactant C 20 FKI (DEFOAMER) DISPERSE ORANGE 3R 1 CR-ORANGE 3R DYETOL DF O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-ORANGE 80 1 P N A Coupler HCl (30%) Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid Surfactant DISPERSE ORANGE 80 1 CR-ORANGE DYETOL DF

35 ANNEXURE-I 3 O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-YELLOW BROWN 2RFL 1 2:6 DCPNA SD N.S.A. 35% Sulfuric Acid Sulfamic Acid CO Acetic Acid Sodium Acetate Crystal ( Tri ) DISPERSE YELLOW BROWN 2RFL 1 CR-Y BROWN 2RC DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR- BROWN 2 1 2:6 DCPNA SD N.S.A. 35% Sulfuric Acid Sulfamic Acid CO HCl C 20 FKI (DEFOAMER) DISPERSE BROWN 2 1 CR - BROWN DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR-BROWN 3RSF 1 2:6 DBPNA SD N.S.A. 35% Sulfuric Acid Sulfamic Acid Acetic Acid C 20 FKI (DEFOAMER) DISPERSE BROWN 3RSF H/CONC 1 CR-BROWN 3RSF DYETOL DF

36 ANNEXURE-I 3 O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR-SCARLET 3R 1 O C P N A TK H C L Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid C 20 FKI (DEFOAMER) Sodium Acetate Crystal ( Tri ) DISPERSE SCARLET 3R 150% 1 CR-SCARLET 3R DYETOL DF O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-RED 2B 1 O C P N A SD 3A H C L Sodium Nitrite DIATOMITE SUPERCELL 935 (HYFLOW) Sulfamic Acid C 20 FKI (DEFOAMER) Sodium Acetate Crystal ( Tri ) DISPERSE RED 2B 1 CR- RED 2B DYETOL DF O P A (Ortho Phosphoric Acid) H E D P Dispersing Agent CR-RUBINE XF - 2G 1 SD Cyno PNA N.S.A. 35% Suphuric acid Sulfamic Acid DISPERSE RUBINE XF 2G 1 CR-RUBINE XF2G DYETOL DF Dispersing Agent O P A (Ortho Phosphoric Acid)

37 ANNEXURE-I CR-RED 34 1 CRUDE RED 34 (MONO) D M F Zinc Cyanide Copper cyanide DISPERSE RED F3BS 400% 1 CR-RED DYETOL DF Dispersing Agent O P A (Ortho Phosphoric Acid) C 20 FKI (DEFOAMER) CR-VIOLET 26 1 Phenol Liquid Pottasium Carbonate (Granules) Di chloro di amino AQ Soda Ash Sulfuric Acid DISPERSE RED VIOLET FBL 200% 1 INT-VIOLET DYETOL DF Dispersing Agent O P A (Ortho Phosphoric Acid) C 20 FKI (DEFOAMER) CR - VIOLET 3R 1 2 Cyno PNA ( N,N DIETHYL ) AMINO ACETANILIDE N.S.A. 35% Sulfuric Acid H C L Sulfamic Acid CO Sodium Acetate Crystal ( Tri ) C 20 FKI (DEFOAMER) T.B.A.B DISPERSE VIOLET 3R CONC. 1 INT-VIOLET 3R DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR - VIOLET Cyno PNA (N,N-dimethoxyethyl) amino acetanilide

38 ANNEXURE-I 3 N.S.A. 35% Sulfuric Acid H C L Sulfamic Acid CO Sodium Acetate Crystal ( Tri ) C 20 FKI (DEFOAMER) T.B.A.B DISPERSE VIOLET 77 1 INT-VIOLET DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR-BLUE GSL 1 CRUDE BLUE GSL (MONO) D M F Zinc Cyanide Copper Cyanide METHANOL DISPERSE BRILL BLUE GSL 400% 1 CR-BLUE GSL DYETOL DF Dispersing Agent O P A (Ortho Phosphoric Acid) C 20 FKI (DEFOAMER) CR-N BLUE 3G 1 6 Chloro 2:4 DNA TK N.S.A. 35% Sulfuric Acid Sulfamic Acid Acetic Acid DISPERSE NAVY BLUE 3G 200% 1 CR-N BLUE 3G DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR- BLUE 2R 1 6 Bromo 2:4 DNA Coupler N.S.A. 35% Sulfuric Acid

39 ANNEXURE-I 5 Sulfamic Acid DISPERSE BLUE 2R 1 CR- BLUE 2R DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR - FLAVIN XF 1 PABA RE (ME) Ethyl Pyridone HCl Sodium Nitrite Sulfamic Acid DIATOMITE SUPERCELL 935 (HYFLOW) Caustic lye (48%) C 20 FKI (DEFOAMER) Surfactant DISPERSE FLAVIN XF 1 INT-FLAVIN XF DYETOL DF O P A (Ortho Phosphoric Acid) Acetic Acid Dispersing Agent CR-PINK BR 1 SD DMP Acetic Anhydride METHANOL DISPERSE BRILL. PINK BRF 300% 1 CR-PINK BR DYETOL DF O P A (Ortho Phosphoric Acid) Dispersing Agent C 20 FKI (DEFOAMER) Ammonium Sulphate (G Salt) DISPERSE BLACK 3GNS 1 Orange 3R Navy Blue 3G Dark Red 2B DYETOL DF O P A (Ortho Phosphoric Acid) Dispersing Agent DISPERSE BLACK R - Plus 40

40 ANNEXURE-I 1 Orange Blue 4G Blue 4R DYETOL DF O P A (Ortho Phosphoric Acid) Dispersing Agent DISPERSE BLACK E-MRD 1 INT-BLUE INT-ORANGE 8L DYETOL DF O P A (Ortho Phosphoric Acid) C 20 FKI (DEFOAMER) Dispersing Agent BLUE M-5R

41 ANNEXURE-I S.N Raw Material MT/MT Dyetol DF / Dispersing Agent 1 Phenol Formaldehyde Sodium Sulphite Caustic lye Water NKS / Dispersing Agent 1 Napthalene Formaldehyde Oleum Caustic lye TK - 85 /Dispersing Agent 1 Lignin Formaldehyde Sulfonating Agent Caustic lye

42 ANNEXURE-I S.N Raw Material MT/MT M A A 1 M P D A Sodium Bi Sulphite H C L Acetic Anhydride Caustic Soda Lye DBPNA 1 Bromine Liquid Caustic Soda Lye H C L Hydrogen Peroxide (H2O2) P N A Bromo Cyno PNA H C L Cyno PNA Bromine Liquid Hydrogen Peroxide (H2O2) DNA 2,4-DNCB Liquid Ammonia (23%) Bromo DNA 1 2,4 DNCB Liquid Ammonia 23% Bromine Hydrogen Peroxide HCL Bromo PTI 1 Bromine Liquid Para Toluidine Hydrogen Peroxide (H2O2) ADC Liquid Sulfuric Acid DCBTC Bromine Liquid Caustic Soda Lye Cyanomethyl Benzimidazole (CMB) Methyl cyano acetate OPDA H2SO TK AMA EO Catalyst Acetic acid Acetic Anhydride SD

43 ANNEXURE-I 1 Aniline Acrylonitrile Catalyst Acetic acid TK MT Hexyl Bromide Caustic lye SD DEMAP POCl DMF Caustic lye Sod. Acetate Ethyl pyridone 1 ECA MAA Ester Ethyl amine SD EAA ester Benzyl chloride Caustic lye Oleum (23 25%) H2SO SD Soda ash MAA DES SD - 34B 1 Soda ash M A M S DES Acetic acid SD Aniline TBAB Hydroquinone Acrylonitrile Nitrogen gas Acetic acid Ethylene Oxide Acetic Anhydride SD Meta Chloro aniline (MCA) Ethylene Oxide Sulphuric acid

44 ANNEXURE-I 4 Acid Slurry Nitrogen gas TK - 3A 1 MAA (HCl) Ethylene Oxide Acetic acid Caustic lye (48%) Nitrogen gas Acetic Anhydride SD SD - 7CN Soda ash Benzyle Chloride SD Meta Toluidine TBAB Hydroquinone Acrylonitrile Nitrogen gas Soda ash Ethylene Chloride TK Aniline TBAB Hydroquinone Acrylonitrile Nitrogen gas Soda ash Ethylene Chloride TK Soda ash MAA Ester Benzoyl chloride SD Soda ash AMA Allyl chloride

45 ANNEXURE-II 46

46 ANNEXURE-III 47

47 ANNEXURE-III 48

48 ANNEXURE-III 49

49 ANNEXURE-III 50

50 ANNEXURE-IV SOLVENT RECOVERY SYSTEM Recovery Plant Distillation Unit & Solvent Stripper System Flowcharts of the recovery process, flowcharts of both the system workings and Mass Balances of the batch, the processes and the solvents Methanol & DMF 51

51 Solvent Recovery & Mass Balance ANNEXURE-IV We carry out the recovery of the solvents used (Methanol & DMF) in two separate systems. We have explained below the recovery process and the system used. We have also enclosed the plant layouts of both the systems. The raw materials including the solvents are added to the reactor as per the required batch size. After completion of reaction, the product is filtered and mother liquor (ML) is collected in the storage tank 1. The further treatments on ML is carried out in recovery plant distillation unit. The washing water of wet cake is collected in storage tank 2 and sent to solvent stripper to remove the solvent traces with the help of effective cooling facility at different temperature and under vacuum. Flow Diagram of Mother Liquor and Wet Cake Washing Water Filtration Reactor Washing Water Wet Cake Mother Liquor Storage Tank 1 Storage Tank 2 Recovery Plant Distillation Unit Solvent Stripper Mass Balance of the Batch INPUTS OUTPUTS Item Kgs Litres Item Kgs Litres DMF Product Wet Cake Metal Cyanide Mother Liquor (Storage Tank 1) Mono Azo Washing ML (Storage Tank 2) Methanol Water in wet cake 0.00 Washing Water Total Total Page 2 of 8 52

52 ANNEXURE-IV Recovery Plant Distillation Unit & Solvent Stripper System We have installed 4 distillation units and 1 solvent stripper system. Both Recovery Plant Distillation Unit & The Solvent Stripper System are provided with Main condenser, Vertical condenser (distillation column), vent condenser & sub-cooler condenser. All the condensers & the sub-coolers are Horizontal, Shell and tube type in SS 304 construction. The Utility in the Main Condenser is cooling water while vent condenser is provided with Chilled Water. The distillation column is in SS 304 construction. Its internals include liquid distributer, Packing supports, Structured packing & liquid collector, all in SS 304. The structured packing used is Mellapak 250Y. The solvent vapours condense in main condenser via vertical condenser. The uncondensed vapours from main condenser get condensed in vent condenser. Both the condensed streams are collected in two Receivers through sub cooler condenser. This arrangement ensures the solvent recovery efficiency of up to 99%. We have also enclosed the layout of both the systems for your reference. Page 3 of 8 53

53 ANNEXURE-IV i) Solvent Recovery from ML in Recovery Plant Distillation Unit. Process with flow diagram of Solvent recovery through column condenser Storage Tank (Mixture of solvent + Salts + Products etc) Distillation Reactor Vertical condenser Main condenser Vent condenser Sub cooler condenser Intercut Receiver Pure solvent Receiver Typical Batch Process: Charge Mother Liquor (Storage Tank 1) in 10 KL distillation vessel. (ML contains 5400 litres Methanol; 2100 litres DMF). Depending upon the boiling point of solvent, distillation is set up in two stages. In first stage, 5240 litres methanol is distilled out at ⁰C without vacuum due to its low boiling point. After that, condensation is stopped, temperature is increased to ⁰C, vacuum is applied and intercut 122 litres Methanol litres DMF is collected. Then, 1640 litres DMF recover under same temperature and vacuum. During recovery, 25 litres Methanol and 5 litres DMF vapour loss. The remaining solvents (13 litres methanol litres DMF) remain unrecovered in the incinerable sludge. Intercut of the significant number of batches are redistilled out. Page 4 of 8 54

54 ANNEXURE-IV Mass Balance of the Recovery Plant Distillation Unit INPUTS OUTPUTS Mother Liquor Kgs Litres Kgs Litres (Storage Tank 1) Real ASIS (Real) Methanol in ML Methanol pure (99%) DMF in ML Intercut methanol (90%) Salts Methanol Vapour loss Dissolved products Methanol in sludge Water DMF pure (99%) Intercut DMF (80%) DMF Vapour loss DMF in sludge Balance Sludge containing salts, product (except solvents) Total Total % Recovery Methanol: 99.30% % Recovery DMF: 88.81% Page 5 of 8 55

55 ANNEXURE-IV ii) Solvent Recovery from washing effluent through solvent stripper. Process with flow diagram of Solvent Stripper Recovered Solvent Storage Tank 2 Neutralization Reactor 10KL Filter Press 2MT Storage Tank 100KL Solvent Stripper Outlet to CETP Tertiary Treatment Secondary Treatment Effluent on Line Primary Washing ML collected in Storage Tank 2 is pumped to solvent stripper plant neutralization reactor. The washing ML is first neutralized and then filtered through Zero leakage filter press. Solid sludge is separated and the remaining liquid is transferred to storage tank. From the storage tank, the effluent is distilled by continuous distillation process in solvent stripper column where solvent get separated from effluent. The solvents are collected in the receivers and the remaining effluent is transferred to ETP Primary division. The above effluent gets mixed with other streams in Equalization tank of primary system. After doing Primary Treatment, the effluent is transferred to Secondary Treatment Plant and finally to tertiary treatment plant. The above effluent is then sent to Common Effluent Treatment Plant as per Gujarat Pollution Control Board norms. Page 6 of 8 56

56 ANNEXURE-IV Mass Balance of the Solvent Stripper System INPUTS OUTPUTS Mother Liquor Kgs Kgs Litres Material (Storage Tank 1) Real ASIS Litres Methanol in washing Methanol pure DMF in washing Intercut methanol (90%) Salts Methanol Vapour loss Water DMF pure Intercut DMF (80%) DMF Vapour loss Methanol in final ML to ETP DMF in final ML to ETP ML contain water, salts and solvent traces Total Total % Recovery Methanol: 80.17% % Recovery DMF: 80.00% Page 7 of 8 57

57 ANNEXURE-IV OVERALL EFFICIENCY Methanol (Batch Input Quantity 4750 Kgs 6000 Litres) OUTPUT Recovery plant Stripper Total Total Kgs Litres Kgs Litres Kgs Litres % Methanol pure Intercut methanol Methanol Vapour loss Methanol in final ML to ETP Methanol in sludge Total DMF (Batch Input Quantity 1990 Kgs 2110 Litres) OUTPUT Recovery plant Stripper Total Total Kgs Litres Kgs Litres Kgs Litres % DMF pure Intercut DMF DMF Vapour loss DMF in final ML to ETP DMF in sludge Total Page 8 of 8 58

58 ANNEXURE-IV 59

59 ANNEXURE-IV PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 60

60 ANNEXURE-V 61

61 ANNEXURE-V 62

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