M/s. DYSTAR INDIA PVT. LTD.

Transcription

1 TECHNO ECONOMIC FEASIBILITY REPORT FOR FORMULATION OF DYES (POWDER & LIQUID), PIGMENTS, INKS, TEXTILE AUXILIARY AND INTERMEDIATES OF TEXTILE AUXILIARY MANUFACTURING UNIT OF M/s. DYSTAR INDIA PVT. LTD. PLOT NO. 3002/A, GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT PREPARED BY: M/s. DYSTAR INDIA PVT. LTD. PLOT NO. 3002/A, GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT

2 EXECUTIVE SUMMARY OF THE REPORT M/s. DyStar India Pvt. Ltd. is planning to set up Formulation Dyes (Power& Liquid), Pigments, Inks, Textile Auxiliary & Intermediate for textile auxiliary manufacturing unit (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/a, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat , Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around sq.m land is already acquired by M/s. DyStar India Pvt. Ltd. PROJECT COST Cost of the proposed project would be Rs Lacs. Total capital cost for environmental pollution control measures would be Rs Lacs and recurring cost per annum would be Rs Lacs. LIST OF PRODUCTS (PER MONTH) Sr. No. Products (Non- EC) Existing Proposed Total Mt/ month 1 Formulation of Powder dyes Formulation of Liquid dyes Formulation and emulsification of Pigment Formulation of Textile Auxiliary Formulation of Inks Total Note: *For the proposed expansion of 1456 T/month, there is a need to synthesis intermediates (760 T/month) which will go for captive consumption. The complete list of intermediates is as mentioned in Below Table: LIST OF SYNTHESIS INTERMEDIATES, WHICH WILL GO FOR CAPTIVE CONSUMPTION FOR FORMULATION OF FINISHED PRODUCTS Sr. No. Name of Product CAS No TPM Existing Proposed Total 1 RSF Intermediate NFF-T Intermediate Atecryl UC 100 Intermediate NP100 Intermediate Sorbitan mono stearate ester Sorbitan mono Oleate ester Sorbitan mono Palmitate ester Sorbitan mono Laurate ester M-ASC ester Intermediate Citric acid ester KEV Intermediate APS New Intermediate BIP phthalimide Intermediate Total M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

3 REQUIREMENTS FOR THE PROJECT Land: Total sq. meter (existing + proposed) land already acquired in Ankleshwar Industrial Estate, GIDC. Water: The total water requirement for formulation of Dyes (Powder+liquid), pigments, inks, textile auxiliary and intermediates of textile auxiliary manufacturing plant is KLD, mainly make-up water in Boiler & cooling tower of plant and domestic requirement. Total water requirement of plant will be met from GIDC water supply. In plant, 24.0 KLD of water is required per day in Boiler & 12.0 KLD in cooling tower as make up water due to evaporation and drift. The 8.0 KLD water required for Domestic purpose. Recycle & Reuse:- 1) Primary ETP+UF+RO+ MEE Treated Water KLD will be reused for Process. 2)84.0 KLD condensate will be recycled back to boiler as make-up water. 3) Domestic 6.8 KLD waste water / sewage will be treated in proposed 10 KLD STP. Treated sewage of 6.6 KLD will be reused in gardening. Hence Total Fresh Water Requirement come down to KLD from KLD total water requirement. 45% of Reuse treated water. Electrical Energy: Total power requirement will be 600 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. set (1 Nos.) of 250 KVA (Existing) and D. G. set (1 Nos.) of 500 KVA (Proposed) will be provided to fulfill the power requirement. Fuel: For the proposed project Natural gas for Steam Boiler will be used at the rate 7452 SCM/day and HSD i.e.107 Lit/Hr. will be required for the D.G. set which will be purchased from local supplier and transported by road only. Manpower: The proposed plant will have employment potential providing employment to approximately 18 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES EXISTING STACK DETAILS STACK ATTACHED Process Plant (10 reactors, 2 mixers and 2 packing stations) STACK HEIGHT (M) STACK DIAMETER (TOP) (M) POLLUTANTS PERMISSIBLE VALUE Process Stack POLLUTION CONTROL SYSTEM 16.3 m 0.3 m PM 150mg/Nm ³ Bag Filters PROPOSED STACK DETAILS STACK ATTACHED STACK HEIGHT (M) STACK DIAMETER (TOP) (M) POLLUTANTS Flue Stack PERMISSIBL E VALUE POLLUTION CONTROL SYSTEM Steam Boiler 4.5 Mt/ Hr Natural gas based PM Sox Nox 150mg/Nm³ 100 ppm 50 ppm Adequate Stack Height M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

4 Process Stack Process exhaust scrubber gas Formaldehyde 0.75 ppm 2 stage packed column scrubber + Bag filter UTILITY EMISSION AND CONTROL MEASURES NO. OF STACK STACK ATTACHED TO 01 D. G. set: 1 No. of 500 KVA (In Emergency only) NAME & QUANTITY OF FUEL USED HSD 107 Lit./hr approx POLLUTION CONTROL EQUIPMENT Acoustic Enclosure STACK HEIGHT & DIA. (M) Ht. 11 m Dia. 0.3 m POLLUTANTS (GPCB LIMIT) SPM < 150 mg/nm 3 SO 2 < 100 ppm NOx < 50 ppm WASTE WATER GENERATION AND ITS TREATMENT: Industrial waste water from process of KL/day will be generated from the proposed project will be treated in in-house ETP+UF+RO & MEE and will be reused in process. Domestic waste water i.e. 6.8 KL/Day will be treated through STP and 6.7 KLD treated water will be used in gardening. 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. Sr. No 1(A) 1(B) Waste Filter & Filter Material Mixed Dyes from Dust Collector Filter & Filter Material Mixed Liquid Cat No Used Oil 5.1 3(A) Discarded Container [Decontaminate 33.1 Quantity Existing Proposed Total Source Facility 30 MT/ 0.5 MT/Yea r 0.5 KL/ 88 MT/ - 2 2KL/year 212 Mt/ 30 MT/ 2.5 MT/Yea r 2.5 KL/ 300 MT/ Dust collector Material collected from filters Various maintenan ce processes Raw material used Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL Collection,Storage,,Transp ortation,,disposal by Selling to Registered reprocess Collection,,Storage,Decont amination,reuse M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

5 d] containers 3(B) Discarded Container /Liners/Bags MT/Yea r 26 Mt/ 50 MT/Yea r Raw material used containers Collection,Storage,,Transp ortation,disposal By incineration at CHWIF of BEIL. 4 MEE Reject MT/Yea r 150 MT/ 240 Mt/ year Equipmen t washings and other porcess activity Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL 5 ETP Sludge MT/Yea r 172 MT/ 180 MT/Yea r Effluent treatment Plant Collection,Storage,Transportation,Disposal at TSDF of BEIL (Landfilling ) 6 Self Life Expired /off Spec Powder - Nil 5 MT/ 5 MT/ Process and old inventory Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL 7 Self Life Expired /off Spec Liquid - Nil 20 MT/ 20 MT/ Process and old inventory/ expired and off spec Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL GREEN BELT DEVELOPMENT About 8675 sq.m area i.e % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 1.5 Lacs approx. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

6 INDEX CHAPTER CONTENT PAGE 1. INTRODUCTION OF THE PROJECT 1 2. PROJECT DESCRIPTION 3 3. SITE ANALYSIS PLANNING BRIEF PROPOSED INFRASTRUCTURE REHABILITATION AND RESETTLEMENT (R & R) PLAN PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL 46 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

7 LIST OF TABLES TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 1 2 DETAILS OF EMPLOYMENT REQUIREMENT 2 3 DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) 33 4 DETAILS OF WASTEWATER GENERATION 34 5 DETAILS OF SOLID WASTE 34 6 DETAILS OF EXISTING LAND USE 36 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 37 8 TEMPERATURE DATA 37 9 RAINFALL DATA DETAILS OF SOLID WASTE MANAGEMENT PROJECT IMPLEMENTATION SCHEDULE TOTAL PROJECT COST AND IT S BREAK UP 45 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 1 LAND AGREEMENT DOCUMENTS 50 2 LAYOUT OF THE PLANT 51 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat

8 INTRODUCTION OF THE PROJECT CHAPTER IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. DyStar India Pvt. Ltd is the Indian arm of DyStar Group and offers the global standard products & services locally to our customers in south Gujarat region and Pan India. DyStar is a leading provider of products and services for the textile and leather industry. The management of M/s. DyStar India Pvt. Ltd. has decided to set up Formulation Dyes (Power & Liquid), Pigments, Inks, Textile Auxiliary & Intermediate for textile auxiliary manufacturing (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/A, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I. TABLE 1: DETAILS OF THE DIRECTORS S. NO. NAME OF THE DIRECTOR DESIGNATION 1. Mr. Yalin Chen Xu Director 22/06/ Mr. Yao Jianfang Director 20/05/ Mr. Manish Kumar P.Kiri Director 25/04/ Mr. Luo Bin Director 11/08/ Mr. Amitava S. Mukharjee Director 25/04/2017 DATE OF APPOINTMENT 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. DyStar India Pvt. Ltd. has decided to set up Formulation Dyes (Power& Liquid), Pigments, Inks, Textile Auxiliary & Intermediate for textile auxiliary manufacturing (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/A, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION 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. Existing Indian production, are not enough to cater the needs of Indian Consumer, hence Chinese products are also making dent in the Indian markets, though they are costly due to logistic cost and are not able to provide wide range of choices to the Indian Customers. Present capacity is negligible in term of overall demand in the world, so a huge market, and considering our high quality products as well customization of product, we don t foresee any hurdle in marketing of product. Our proposed plant will be located near user Industry, hence it provides logistic support as well as customize quantity in small quantities can also be supplied to the customer, which give company a clear edge compared to Chinese Imports, which cannot be supplied in small quantities coupled with time consumed on import. We have a very strong and experienced after sales service which are also known as Technical Service Department (TSD) which guides customer to obtain better results from our products. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 1

9 Market for disperse dyes is 10% per annum, and there are only two major producers in the Industry. Our continuous technological research and product development and superior after sales services will ensure increase in market share and eventually better net sales realization. Strong presence in the value added product Wide range of product to meet customized need. Long standing relationships with leading consumer Industries. 1.4 DEMAND SUPPLY GAP The Indian dyestuff industry is widely fragmented between the organized and unorganized sector. There are approximately 950 dye manufacturing unit in India, of which 50 units are in the organized sector and 900 are in the un-organized sector. The two western states of Maharashtra and Gujarat account for over 90% of the total dyestuff production in the country. The textile industry is the largest user of dye-stuffs in India, It account for 70-75% of the domestic dye consumption. With the increasing pressure on cotton fiber, synthetics like polyester are expected to over perform the overall chemical Industry. The dyestuff Industry worldwide is witnessing a gradual shift of manufacturing facilities from the developed countries to Asia, particularly china and India due to environmental considerations, availability of trained and inexpensive manpower and the relocation of the end-user industries, mainly textile and leather to the Asia-pacific region. India has emerged as a global supplier of dyestuff and dye intermediates, particularly for requirement of the domestic market and has gradually also made a dent in the global market. Indian dyestuff market is in general dominated by Chinese companies, as there are very few large scale manufacturing companies in India who can cater the need of Indian demand. We are expected to be the major recipient of benefits arising out due to expected growth, and consolidation in the Industry. 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 85 excluding contract / casual labour. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break up of the manpower requirement is as under: TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT S. NO. DESCRIPTION EXISTING PROPOSED TOTAL 1 Top Management Managers Specialist/ Engineer/Officers Supervisors Operators/Attendants TOTAL Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. M/s. DyStar India Pvt. Ltd. is going to manufacture formulation dyes and formulation of pigments, formulation of inks, formulation of Textile auxiliaries and its intermediates for mainly textile dyeing and printing industry. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 2

10 CHAPTER 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT M/s. DyStar India Pvt. Ltd. has decided to set up Formulation Dyes (Power& Liquid), Pigments, Inks, Textile Auxiliary & Intermediate for textile auxiliary manufacturing (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/A, GIDC Estate, Ankleshwar, Dist.: Bharuch, 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. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 3

11 COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per the mentioned below: Latitude: N Longitude: E FIGURE 2: MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC. 2.3 DETAILS OF ALTERNATE SITES 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 M/s. DyStar India Pvt. Ltd. has decided to set up Formulation Dyes (Power& Liquid), Pigments, Inks, Textile Auxiliary & Intermediate for textile auxiliary manufacturing (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/A, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 4

12 DETAILS OF PRODUCTION AND MANUFACTURING PROCESS: 1. RSF Intermediate Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of Formaldehyde into the clean vessel, followed by Urea and Glyoxal 40% and diethylene glycol. The temperature is increased to C under constant stirring. The process is continued for 5-6 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Formaldehyde 0.40 RSF Urea 0.20 Reaction Vessel 1.00 Intermediate Glyoxal 0.40 Total 1.00 Total 1.00 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 5

13 Process Flow Diagram M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 6

14 2. NFF-T Intermediate Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of glyoxal 40%and water into the clean vessel under constant stirring. Cool the vessel and add N, N-dimethyl urea until homogenous mixture is achieved. The temperature is maintained below ambient temperature and reaction is further continued for 2-4 hours under catalytic concentration of citric acid. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Dimethyl Urea 0.40 NFF-T Reaction Vessel 1.00 Glyoxal 40% 0.60 Intermediate Total 1.00 Total 1.00 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 7

15 Process Flow Diagram M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 8

16 3. Atecryl 1467 Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity of Formalin under constant stirring. Then add required quantity of Melamine and maintain ph at required level using formic acid. Raise temperature to C and continue reaction for around 2-3 hrs. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2 hr and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Formaldehyde 0.55 Melamine 0.25 Reaction Vessel Atecryl Formic acid 0.20 Total 1.00 Total 1.00 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 9

17 Process Flow Diagram M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 10

18 4. UC 100 Intermediate Manufacturing process: Check and maintain a clean and dry vessel. Charge required quantity of stearic acid and maintain temperature at 55-80C under constant stirring. Then add required quantity of Diethylenetriamine and ethanolamine. Raise temperature up to 160C-170C and continue reaction for around 3-4 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2hour and again check for quality. Maintain required ph using acetic acid and If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Stearic acid 0.80 UC 100 Diethylenetriamine 0.15 Reaction Vessel intermediate Monoethanolamine Acetic acid 0.08 Water Loss 0.09 Total 1.09 Total 1.09 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 11

19 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 12

20 5. NP 100 Intermediate Manufacturing process: Check and maintain a clean and dry vessel. Charge required quantity of stearic acid and maintain temperature up to 55-80C under constant stirring. Then add required quantity of diethanolamine and mono ethanolamine. Raise temperature up to C and continue reaction for around 3-4 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2 hr and again check for quality. Maintain required ph using acetic acid and If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Stearic acid 0.78 NP Diethanol amine 0.19 Reaction Vessel intermediate Monoethanolamine 0.07 Water Loss 0.04 Total 1.04 Total 1.04 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 13

21 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 14

22 6. Sorbitan mono stearate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and Stearic Acid in to a clean reactor under continuous stirring maintained at temperature to 50-60C. Raise the temperature to C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If theacid value is within specification cool the mass to 40 C and unload in to therequired pack size for further formulation. Chemical Reaction Material Balance Input Output Sorbitol 70% 0.5 Sorbitan Stearic Acid 0.7 mono stearate 1.00 Reaction Vessel ester Water Loss 0.20 Total 1.20 Total 1.20 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 15

23 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 16

24 7. Sorbitan mono Oleate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and oleic Acid in to a clean reactor under continuous stirring maintained at temperature to 50-60C. Raise the temperature to C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If the acid value is within specification cool the mass to 40 C and unload in to therequired pack size for further formulations. Chemical Reaction Material Balance Input Output Sorbitol 70% 0.5 Sorbitan Oleic Acid 0.7 mono oleate 1.00 Reaction Vessel ester Water Loss 0.20 Total 1.20 Total 1.20 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 17

25 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 18

26 8. Sorbitan mono Palmitate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and palmitic Acid in to a clean reactor under continuous stirring maintained at temperature to 50-60C. Raise the temperature to C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If the acid value is within specification cool the mass to 40 C and unload in to therequired pack size for further formulation. Chemical Reaction Material Balance Input Output Sorbitol 70% 0.55 Sorbitan Palmitic Acid 0.65 mono Reaction Vessel Palmitate 1.00 ester Water Loss 0.20 Total 1.20 Total 1.20 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 19

27 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 20

28 9. Sorbitan mono Laurate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and lauric Acid in to a clean reactor under continuous stirring maintained at temperature to 50-60C. Raise the temperature to C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If the acid value is within specification cool the mass to 40 C and unload in to the required pack size for further formulation. Chemical Reaction Material Balance Input Output Sorbitol 70% 0.58 Sorbitan Lauric Acid 0.62 mono Laurate 1.00 Reaction Vessel ester Water Loss 0.20 Total 1.20 Total 1.20 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 21

29 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 22

30 10. M-ASCester Intermediate Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity ethyl hexanol and maleic acid anhydride along with catalytic concentration of sulfuric acid. Under continuous stirring raise the temperature to C and maintain for 3-4 hours, water of reaction is collected in receiver. Further charge sodium bisulphite solution and continue reaction for 2-3 hours followed by addition of mono ethylene glycol. Check if required specification Values are achieved. If required acid value is not achieved continue reaction further for 1-2 hours If required specification achieved, cool the mass to 40 C and unload in to the required pack size for further formulation. Chemical Reaction Material Balance Input Output Ethyl hexanol 0.47 M-ASC ester Maleic acid Intermediate anhydride Reaction Vessel Sodium bisulfite 0.40 Water Loss 0.03 solution Total 1.03 Total 1.03 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 23

31 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 24

32 11. Citric acid ester Manufacturing process: Check and maintain a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing.charge the required quantity Citric acid and Lauryl alcohol ethoxylate in to a clean reactor under continuous stirring maintained at temperature to 60-80C. continue mixing for 1 hour and raise the temperature to C and maintain for 3-4 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If the acid value is within specification cool the mass to 40 C and unload in to the required pack size for further formulation. Chemical Reaction Material Balance Input Output Citric acid 0.40 Citric acid 1.00 ester Reaction Vessel Lauryl alcohol 0.69 Water Loss 0.09 ethoxylate Total 1.09 Total 1.09 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 25

33 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 26

34 12. KEV Intermediate Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of butyl diglycolinto the clean vessel, followed by slow addition of phosphorous pentoxide in small proportions maintaining temperature below 30-40C. The temperature is increased to 40-50C under constant stirring and reaction is continued for 3-4 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. Neutralise above reaction mixture using potassium hydroxide aqueous solution. If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Butyl diglycol 0.62 Phosphorous 0.18 KEV pentoxide Reaction Vessel 1.00 Intermediate KOH 50% 0.20 solution Total 1.00 Total 1.00 Process Flow Diagram M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 27

35 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 28

36 13. APS new Intermediate Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of isodecanol ethoxylate into the clean vessel and raise temperature to 120C to distil out water, once distillate is stopped cool product to 60C. further add phosphorous pentoxide in small proportions maintaining temperature below 25-30C. The temperature is increased to 80-90C under constant stirring and reaction is continued for 5-6 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. Neutralise above reaction mixture using potassium hydroxide aqueous solution. If specification is reached fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Isodecanol APS new ethoxylate Intermediate Reaction Vessel Phosphorous 0.10 Water loss pentoxide Total 1.00 Total 1.00 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 29

37 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 30

38 14. BIP phthalimide intermediate Manufacturing process: Check and prepare a clean and dry vessel. Charge the required quantity of Phthalic anhydride flakes. The temperature of the reaction is maintained at C followed by addition of isopropyl amine and butylamine. Under slow stirring continue mixing for 1-2 hours followed by raising the temperature to 150C to distilled out water of reaction. The process is continued for 2-3 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. If specification is reached cool the batch to 30-35C and fill product in containers, to be used for further formulations of finished product. Chemical Reaction Material Balance Input Output Phthalic BIP anhydride phthalimide 1.00 isopropylamine Reaction Vessel intermediate n-butylamine Water loss 0.08 Total 1.08 Total 1.08 M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 31

39 Process Flow Diagram Water distillate ETP M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 32

40 2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of Formulation of Textile Auxiliary are listed below: TABLE 3: DETAILS OF RAW MATERIAL REQUIREMENTS S. No. CAS No. Name of Raw Material Qty (MT)/Month Formaldehyde Dimethyl Urea Diethylene glycol Glyoxal 40% Melamine Formic acid Stearic acid Diethylenetriamine Monoethanolamine Acetic acid Diethanol amine Sorbitol 70% Oleic acid Palmitic acid Lauric acid Ethylhexanol Maleic acid anhydride Sodium Bisulfite C12-15 alcohol ethoxylate Citric acid anhydrous Butyldiglycol Phosphorous Pentoxide Potassium hydroxide isodecanol ethoxylate Phthalic anhydride flakes Isoporpylamine Butylamine RESOURCE OPTIMIZATION / RECYCLING AND REUSE We will be provided rain water recharging for the resource optimization. Spent Oil i.e. 2.5 KL/year will be generated from various maintenance processes which will be reused as lubricant within premises or sell to MoEF approved re-processor. 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE WATER REQUIREMENT AND ITS SOURCE The total water requirement for formulation of Dyes (Powder+liquid), pigments, inks, textile auxiliary and intermediates of textile auxiliary manufacturing plant is KLD, mainly make-up water in Boiler & cooling tower of plant and domestic requirement. Total water requirement of plant will be met from GIDC M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 33

41 water supply. In plant, 24.0 KLD of water is required per day in Boiler & 12.0 KLD in cooling tower as make up water due to evaporation and drift. The 8.0 KLD water required for Domestic purpose. Recycle & Reuse:- 1) Primary ETP+UF+RO+ MEE Treated Water KLD will be reused in Process. 2) 84.0 KLD condensate will be recycled back to boiler as make-up water. 3) Domestic 6.8 KLD waste water / sewage will be treated in proposed 10 KLD STP. Treated sewage of 6.6 KLD will be reused in gardening. Hence, Total Fresh Water Requirement comes down to KLD from KLD total water requirement. 45% of Reuse treated water POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 600 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. set (1 Nos.) of 250 KVA (Existing) and D. G. set (1 Nos.) of 500 KVA (Proposed) 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, washing, Boiler & cooling (Make up water), Domestic and gardening. Waste water i.e. sewage waste water 6.8 KL/day will be treated in STP and 6.7 KLD of treated water will be reused in gardening. Industrial waste water will be KL/day from process, washing and utilities. Details of water requirement and waste water generation are given in following table. TABLE 4: DETAILS OF WASTEWATER GENERATION S. PURPOSE EXISTING PROPOSED WASTE Total NO. WASTE WATER WATER (KL/D) (KL/D) A. Domestic B. Industrial 1 Processing Boiler (make up) Cooling (make up) Floor and Drum washing Grand Total SOLID WASTE GENERATION Solid waste generated will be 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. Sr. No 1(A) Waste Filter & Filter Material Mixed Dyes from Dust Collector Cat No TABLE 5: DETAILS OF SOLID WASTE Quantity Existing Proposed Total Source Facility 30 MT/ - 30 MT/ Dust collector Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 34

42 1(B) Filter & Filter Material Mixed Liquid MT/Yea r MT/ Material collected from filters Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL 2 Used Oil KL/ 2KL/year 2.5 KL/ Various maintenance processes Collection,Storage,,Transportati on,,disposal by Selling to Registered reprocess 3(A) Discarded Container [Decontamin ated] MT/ 212 Mt/ 300 MT/ Raw material used containers Collection,,Storage,Decontamin ation,reuse 3(B) Discarded Container /Liners/Bags MT/Yea r 26 Mt/ 50 MT/ Raw material used containers Collection,Storage,,Transportati on,disposal By incineration at CHWIF of BEIL. 4 MEE Reject MT/Yea r 150 MT/ 240 Mt/ year Equipment washings and other porcess activity Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL 5 ETP Sludge MT/Yea r 172 MT/ 180 MT/ Effluent treatment Plant Collection,Storage,Transportation,Disposal at TSDF of BEIL ( Landfilling ) 6 Self Life Expired /off Spec Powder - Nil 5 MT/ 5 MT/ Process and old inventory Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL 7 Self Life Expired /off Spec Liquid - Nil 20 MT/ 20 MT/ Process and old inventory/ expired and off spec Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 35

43 SITE ANALYSIS CHAPTER CONNECTIVITY The proposed project site is situated at Plot no. 3002/A, GIDC, Ankleshwar, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.75 km in NW and SH64 (Ankleshwar-Rajpipala) road is about 0.38 km in North direction. 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 Road Connectivity The Plant is near NH-8 (Mumbai-Delhi road) is about 0.75 km in NW direction and SH64 (Ankleshwar- Rajpipala) road is about 0.38 km in North direction Rail The Area is well connected by Railway. Ankleshwar railway Station is about 3.08 km in SW Airport The nearest airport to the project will be Surat at around 64.0 km. in SSW 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 Plot no. 3002/A, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. DyStar India Pvt. Ltd. This is already in operation. Total acquired land is classified as Industrial land. Land document is attached as Annexure I. 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 0.75 Km 2. Nearest State Highway SH-64 at around 0.38 Km 3. Nearest city Ankleshwar at around 1.61 Km 4. Nearest River Narmada at around 6.68 Km 5. Nearest Railway station Ankleshwar at around 3.08 Km 6. National park/reserve Forest, Biosphere, etc. None within a radius of 10 Km 6. Seismicity Zone III M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 36

44 3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table: TABLE 7: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE S. NO. PARTICULAR DISTANCE 1. Civil Hospital Within 10 Km 2. Colleges 3. Govt & Pvt Schools 4. Hari Mandir 3.6 CLIMATIC DATA The main characteristic of this region is hot summer and severe winter with a small spell of rainy season. The rainy season generally commence at the beginning of July and last till mid-october. The period from October to November constitutes the post monsoon season and winter prolong from December to February which last till March before the summer season begins. 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 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 Bharuch station for the period of Jan 15 to Dec 015 are given in following table. TABLE 8: TEMPERATURE DATA S. NO. MONTHS OF YEAR 2015 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) RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Surat 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. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 37

45 3.6.3 RAINFALL Monthly total rainfall data for Surat station is presented in following table. TABLE 9: RAINFALL DATA S.NO. MONTHS OF YEAR 2015 MONTHLY TOTAL (MM) 1. January February March April May June July August September October November December 00 TOTAL (Courtesy: Indian Meteorological Department) The rainy season in the area extends from June to October. The mean total rainfall, during the monsoon period (June to September), has been recorded as mm. The average number of rainy days per month varies from 8 to 18 in monsoon months. The rainfall data indicates that the rainfall is limited to monsoon season for four months of the year 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. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 38

46 PLANNING BRIEF CHAPTER PLANNING CONCEPT M/s. DyStar India Pvt. Ltd. is planning to set up Formulation Dyes & Intermediate manufacturing unit (Proposed (a) Formulation of Textile Auxiliary 1456 MT/month (b) Formulation of Inks 100 MT/month and (C) Intermediates for Formulation of Textile Auxiliary 760 MT/month) at plot no. 3002/a, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat Proposed project is envisaged as existing Formulation 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 About sq.m. of land at Plot no.3002/a, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. DyStar India Pvt. Ltd. which is already in operation. Total acquired land is classified as Industrial land. 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. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 39

47 PROPOSED INFRASTRUCTURE CHAPTER INDUSTRIAL AREA About sq.m. of land at Plot no.3002/a, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. DyStar India Pvt. Ltd. which is already in operation. Total acquired land is classified as Industrial land. 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 topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About 8675 sq.m area i.e % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. In Green belt area about 1445 trees 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. 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. M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 40

48 5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the GIDC Ankleshwar located within premises after getting necessary clearance. 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 6.8 KL/day will be generated which will be treated through STP & 6.7 KLD treated will be reused in gardening. 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 The total water requirement for formulation of Dyes (Powder+liquid), pigments, Inks, textile auxiliary and intermediates of textile auxiliary manufacturing plant is KLD, mainly make-up water in Boiler & cooling tower of plant and domestic requirement. Total water requirement of plant will be met from GIDC water supply. In plant, 24.0 KLD of water is required per day in Boiler & 12.0 KLD in cooling tower as make up water due to evaporation and drift. The 8.0 KLD water required for Domestic purpose. Recycle & Reuse:- 1) Primary ETP+UF+RO+ MEE Treated Water KLD will be reused in Process. 2) 84.0 KLD condensate will be recycled back to boiler as make-up water. 3) Domestic 6.8 KLD waste water / sewage will be treated in proposed 10 KLD STP. Treated sewage of 6.6 KLD will be reused in gardening. Hence Total Fresh Water Requirement come down to KLD from KLD total water requirement. 45% of Reuse treated water. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the following table. Sr. No 1(A) Waste Filter & Filter Material Mixed Dyes from Dust Collector TABLE 10: DETAILS OF SOLID WASTE MANAGEMENT Cat Quantity No. Existing Proposed Total Source Facility MT/ - 30 MT/ Dust collector Collection,Storage,Transportation,Disposal By Incineration at CHWIF of BEIL M/s. DyStar India Pvt. Ltd., GIDC Ankleshwar, Gujarat 41