PIDILITE INDUSTRIES LIMITED - Pidilite Industries limited is located in GIDC notified industrial...

FOR

PROPOSED EXPANSION PROJECT (FOR EXISTING PRODUCT RANGE)

MANUFACTURING OF

ORGANIC PIGMENTS

Category: 5(f)

AT

PIDILITE INDUSTRIES LIMITED

Located at: Plot No. 23, 1st Phase,

GIDC Notified Industrial Area, Vapi, Dist- Valsad (Gujarat).

Prefeasibility Report Pidilite Industries Limited

Expansion project Page 1 Organic Pigments

Project pre feasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification – 2006

1 Executive Summary: Name & Location

Name of the Project: Pidilite Industries Limited Location : Plot No: 23, 1st phase, G.I.D.C, VAPI. Pin Code: 396195 Dist. - Valsad (Gujarat) Project

Pidilite Industries limited is located in GIDC notified industrial area, falling under large Scale category manufacturing products as mentioned under for which the company had obtained Consent To Establish and Operate from Gujarat pollution Control Board.

The company proposes to enhance the capacity of existing products under the category “Organic Pigments” ( Azo Pigments ) as well as “Quinacridone Pigments “ & Pigment Emulsions.

Proposed expansion Project Cost: Rs. 2100 lacs. Total after proposed expansion will be Rs. 14700.25 lacs Applicability of EIA notification – 2006

Category as per the amended EIA notification-2006: as existing and proposed products (i.e. Organic pigments) are covered under the Category-5(f). Hence, Environmental clearance is required.

Project Proponent • The company in India comprises of 12 directors • Large Scale Unit

List of finished products & by- products:

No Product MT/MONTH Existing Proposed Total after

proposed expansion

1 Carbazole Dioxane Violet Pigment

25 0 25

2 Organic Pigment (Azo- Orange/Yellow/ Red)

85 30 115

3 Pigment emulsion 137 33 170

4 Quinacridone Pigment 15 20 35

Total 262 83 345



by-products

1 Phosphoric Acid (10-30%) from Quinacridone Pigment

218.5 291.35 509.85

2 Calcium Sulphate (Gypsum)*

0 110 110

• Gypsum is having 10-15 % moisture in it.

Manufacturing process is attached as Annexure-3.

Resource Requirement:

Components Existing

Proposed Total after proposed expansion

Resources availability

Power, KVA 1600 300 1900

Will be sourced from Dakshin Gujarat Vij Co. Ltd.

Fresh Water, kl/day

1586 -22 1564

Will be sourced from GIDC water supply Dept.

Briquette /Natural Gas for

Steam Boiler (12 Tons/Hr) x 1 Nos

1.45 MT/Hr of Briquette

or 410 SCM/Hr

0.655 MT/Hr Briquette or 180

SCM/Hr

2.105 MT/Hr Briquette or 590

SCM/Hr

GSPC & local dealer

Natural gas for Thermopak (10 lacs & 4 lacs)

2000 SCM/day

0 2000 SCM/day GSPC

Natural gas for steam boiler (8 TPH & 2 TPH)

8750 SCM/day

0 8750 SCM/day GSPC

Fuel (HSD) for D.G.Set

(Capacity: 750 x 2 & 125 KVA)

0 225 kgs/hr 225 kgs/hr Will be sourced from local dealer



Raw material Consumption:

1.0 For Carbazole Dioxane Violet Pigment (Pigment Violet 23)

Sr. No.

Raw Materials Quantity in MT

Ton per

Tone of FG

Per month

Existing Proposed Total after expansion

1.1 Carbazole 0.90 22.52 0 22.52

1.2 Diethyl sulphate 0.81 20.27 0 20.27

1.3 Caustic flakes 0.48 12.11 0 12.11

1.4 Mono Chloro Benzene (Recovered)

3.23 80.86 0 80.86

1.5 Mono Chloro Benzene (Fresh)

0.32 8.11 0 8.11

1.6 Nitric acid 0.93 23.23 0 23.23

1.7 ODCB (Recovered) 17.71 442.68 0 442.68

1.8 ODCB (Fresh) 1.11 27.76 0 27.76

1.9 Catalyst 0.01 0.19 0 0.19

1.10 Nitrogen 0.08 0 1.97 1.97

1.11 Hydrogen 0.04 0 0.99 0.99

1.12 Chloranil 0.52 13.01 0 13.01

1.13 Catalyst RAC 0.21 5.35 0 5.35

1.14 Benzene sulpho chloride

0.37 9.29 0 9.29

1.15 Salt 8.72 217.91 0 217.91

1.16 Di ethyl Glycol 0.16 4.08 0 4.08

1.17 Iron Powder 1.52 37.9 -37.9 0

1.18 Total 36.67 925.27 -34.94 890.33



2.0 For Organic Pigment

2.1 Organic Yellow Pigment

Sr. No.


Ton per ton of FG

Per month


2.1.1 Base (Amine) 0.405 34.425 12.15 46.575

2.1.2 Ice 6 510 180 690

2.1.3 Sulphamic acid 0.009 0.765 0.27 1.035

2.1.4 Sodium nitrite 0.69 58.65 20.7 79.35

2.1.5 Hydro Chloric Acid (30%)

0.96 81.6 28.8 110.4

2.1.6 Caustic 0.35 29.75 10.5 40.25

2.1.7 Acetic acid 0.285 24.225 8.55 32.775

2.1.8 Xylene (Recovered) 0.539 45.815 16.17 61.985

2.1.9 Xylene (Fresh) 0.011 0.935 0.33 1.265

Total 9.249 786.165 277.47 1063.635

2.2 Organic Red Pigment

2.2.1 Base (Amine) 0.42 35.65 12.6 48.23

2.2.2 Ice 14.56 1237.86 436.89 1674.75

2.2.3 Sulphamic acid 0.02 2.06 0.73 2.79

2.2.4 Sodium nitrite 0.19 16.50 5.83 22.33

2.2.5 Sulphuric acid 2.91 247.57 87.38 334.95

2.2.6 Caustic 0.63 53.64 18.93 72.57

2.2.7 Hydro Chloric acid 0.97 82.52 29.13 111.65

Total 19.7 1675.82 591.46 2267.28



Sr. No.


Ton per ton of FG

Per month


2.3 Organic Orange Pigment

2.3.1 Base (Amine) 0.405 34.43 12.15 46.575

2.3.2 Ice 9 765.00 270 1035

2.3.3 Sulphamic acid 0.007 0.60 0.21 0.805

2.3.4 Sodium nitrite 0.24 20.40 7.2 27.6

2.3.5 Hydro Chloric Acid (30%)

1.08 91.80 32.4 124.2

2.3.6 Caustic 0.32 27.20 9.6 36.8

2.3.7 Emulsifier 0.02 1.70 0.6 2.3

2.3.8 Xylene (Recovered) 0.539 45.82 16.17 61.985

2.3.9 Xylene (Fresh) 0.011 0.94 0.33 1.265

Total 11.622 987.87 348.66 1336.53

3.0 For Pigment emulsion (Pigment Black Dispersion) :

3.1 Carbon black pigment 0.105 14.385 3.47 17.85

3.2 Surface active agent 0.015 2.055 0.5 2.55

3.3 Glycols 0.02 2.74 0.66 3.4

3.4 Preservative 0.01 1.37 0.33 1.7

Total 0.15 20.55 4.95 25.5



Sr. No.


Tone per tone

Per month


4.1 For Quinacridone Pigment (Pigment Red 122) :

4.1.1 Aniline 0.04 0.64 0.85 1.50

4.1.2 DMSS 0.71 10.60 14.13 24.74

4.1.3 Para Toludine 0.75 11.31 15.08 26.39

4.1.4 Hydro Chloric acid (30%)

1.97 29.56 39.41 68.98

4.1.5 Methanol (Recovered) 4.49 67.34 89.79 157.13

4.1.6 Methanol (Fresh) 0.44 6.66 8.88 15.54

4.1.7 Resist salt 0.69 10.28 13.7 23.99

4.1.8 Caustic flakes 0.56 8.35 11.13 19.49

4.1.9 PPA or P2O5 4.28 64.27 85.69 149.96

4.1.10 Iso Butanol (Recovered)

4.11 61.70 82.27 143.96

4.1.11 Iso Butanol (fresh) 0.17 2.57 3.43 6.00

4.1.12 Caustic lye 0.03 0.51 0.68 1.20

4.1.13 Total 18.25 273.80 365.08 638.88



4.2 For Quinacridone Pigment (Pigment Violet 19) :

Sr. No.


Ton per ton of

FG

Per month


4.2.1 Aniline 0.79 11.95 15.93 27.89

4.2.2 DMSS 0.71 10.60 14.13 24.74

4.2.3 Hydro Chloric acid (30%)

1.97 29.56 39.41 68.98

4.2.4 Methanol (Recovered)

4.49 67.34 89.79 157.13

4.2.5 Methanol (Fresh) 0.44 6.66 8.88 15.54

4.2.6 Resist salt 0.69 10.28 13.7 23.99

4.2.7 Caustic flakes 0.56 8.35 11.13 19.49

4.2.8 PPA or P2O5 4.28 64.27 85.69 149.96

4.2.9 Dimethyl Formamide (Recovered)

7.47 112.05 261.45 373.5

4.2.10 Dimethyl Formamide (fresh)

0.4 5.94 13.86 19.8

4.2.11 Caustic lye 0.03 0.51 0.68 1.20

4.2.12 Total 21.83 327.45 764.05 1091.5



Water and Waste Water Management

Total Raw Water requirement is 1564 kl/day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

Total industrial Waste Water Generation is 1274 KL/Day. Domestic waste water (95 KL/day) will be disposed off through Septic Tank.

Air Emission and its Control Measures Flue gas emission:

At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers, one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare capacity to supply the steam for proposed expansion.

The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA & 125 KVA capacities, as stand by. It will be used only during power failure.

Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler. Adequate stack height and stack monitoring facilities is provided.

Process gas emission: • Presently the unit has installed Two no of multi cyclone separator followed by bag filter

attached to pulveriser. After proposed expansion, the unit shall install one additional multi cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent will be provided .(Detail of Air pollution control measures is attached as Annexure-10)

Hazardous Wastes and its Management

Sr. No.

Type of hazardous waste

Categor

y

Quantity, TPM Storage Capacity

, m2

Disposal

Existing After proposed expansion

1 ETP waste 34.3 30 40 50 Dispose off into TSDF, Vapi

2 Used oil 5.1 0.1 0.25 5 Sell to Registered recyclers

3 Discarded containers

33.3 1.25 2.0 10 ReUse for packing finished product or Sell to Autho. recycler

4 Distillation Residue

35.1 9 26.6 20 Sell to cement industries for co-

processing .

5 Iron Sludge 35.2 40 0 0 -

6 Spent catalyst 35.2 0 0.19 5 Sent for re-processing



2. Introduction of the Project and the Proponent. Name of the project Proponent: Pidilite Industries Limited Pidilite Industries Limited is a large scale unit is located in notified industrial estate, GIDC, Vapi Di: Valsad, Gujarat having total plot area of 38443.09 m2 & total investment after proposed expansion will be Rs. 2100 lacs. The proponent wishes to enhance the Production capacity of Existing Products by @ 33 %. The Organic pigments products are especially used in paint, textiles, plastics, cosmetics, ink, etc. The unit is operated by technocrats having more than 35 years of experience in manufacturing and marketing of various Organic pigments worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons.

The proposed expansion proposes to enhance the capacity of all the pigments & Pigment Emulsion to 350.0 MT per month and process capabilities to manufacture all types of Organic pigments & Emulsions.

The proposed expansion project site lies on 20021’17.95” N Latitude & 72054’55.15” E Longitude. Pidilite Industries Limited is located at Plot. No. 23 ,1st phase area, GIDC Vapi, Di: Valsad district in Gujarat state. GIDC Vapi is centrally located in the both sides of National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side. The western Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with other major cities of the state and the country.

Beside the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now having a six lane, double tracked, more elevated and Jam free highway, developed by L&T Company. This highway has given a further boost to the economic growth of this area.

The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected to each other by a Pucca road.

About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat – Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for chemical manufacturing industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals, school & colleges, community centers, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchange, hotels, guesthouses etc. The town has got a major face-lift after the completion of national highway . Other links roads are also of good standard. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms away. The district Head Quarter –



Valsad is 30 km from Vapi town.

VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968. The entire estate, which was developed in phases, is now spread over 1140 hectares and houses more than 1400 industries, most of which are small-scale industrial units although some of them have grown into bigger units at later stage. The industrial township is basically a declared “Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related, such as Dyes and Dyes intermediates, pigments, pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s largest common effluent treatment plants has been setup in Vapi industrial estate. Being a major industrial & commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.

PIDILITE INDUSTRIES LIMITED , whose inception dates back to 1959 , has been a pioneer in consumer and specialties chemicals in India. Over two-third of the company’s turn over comes from products and segments it has pioneered in India.

Our product range includes Adhesives and Sealants, Construction and Paint Chemicals, Automotive Chemicals, Art Materials, Industrial Adhesives, Industrial and Textile Resins and Organic Pigments and Preparations. Most of the products have been developed through strong in-house R&D.

The Group's turnover is about 4283 Crores for the year 2013-14.

In a recent report by Economic Times, Pidilite ranked 131st amongst the top 500 listed companies in India.

Pidilite Industries is the market leader in adhesives and sealants, construction chemicals, hobby colours and polymer emulsions in India. Our brand name Fevicol has become synonymous with adhesives to millions in India and is ranked amongst the most trusted brands in India.

Pidilite is also growing it's International presence through acquisitions and setting up manufacturing facilities and sales offices in important regions around the world. Fevicol is now the largest selling adhesives brand in Asia.

We have reached where we are today mainly due to the close team-work of our employees and due to our shared value system which emphasizes commitment to excellence, closeness to customers, and the spirit of innovation.

The management is concerned about Environment and Safety issues and gives utmost importance to these aspects by continuous training & improvement followed by various external Audits. Company is ISO9001:2000, IS0 14001:2004 and OHSAS 18001:2007 certified. We have a strong R&D team which guides us from its Mumbai Centre. We have a small Pilot plant at this site to support the R & D activities which is supported by Mumbai



team.

Award achieved by the company are as under : • 2nd Prize for House Keeping Competition held by DISH under Nirmal Gujarat- District level competition (2006) • 2nd Prize at the National level TPM poster competition organized by CII- TPM club of India (2006) • 1st Prize for House Keeping Competition held by DISH under Nirmal Gujarat- District level competition (2007) • 7 Prizes for State level Safety Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2008) • 1st Prize for State level Road Safety Poster Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2009) • 2nd Prize for State level Road Safety Poster Competition organized by DISH and Gujarat safety Council for posters, slogans, Poems etc. (2010) • The unit has experienced technocrats having more than 35 years of experience in manufacturing and marketing of Organic pigments & chemicals. • The company has prepared well equipped production plan which will be managed by dedicated, qualified & skilled persons.

(i) Identification of the project proponent :

M/S Pidilite industry Limited is a large scale unit is located at notified industrial estate, GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer & marketer of Organic pigments & chemicals especially used in paints, inks industries as

per requirement.

List of Directors :

• Shri M.B.Parekh – Chairman & Managing Director

• Shri N.K.Parekh – Jt. Managing Director

• Shri A.B.Parekh – Whole time Director

• Shri A.N.Parekh – Whole time Director

• Shri R. Sreeram – Whole time Director

All the Board Members are well qualified in Engineering, Management, Accounts,

operations and Marketing field.

Apart from these there are Expert from Field- Industries, Financial Institues and others as a

Part time / Independent Directors on Board for Better Management , They are :

• Shri Uday Khanna

• Shri N.J.Jhaveri

• Shri Bansi Mehta

• Shri Ranjan Kapur

• Shri Yash Mahajan



• Shri Bharat Puri

• Shri Sanjeev Agha

• Smt. Meera Shankar

They help us to achieve & perform better & better.

ii) Brief description of nature of the Project : Pidilite Industries Limited proposes to enhance the production capacity at Plot No. 23, 1st phase, GIDC, Vapi-396195, Dist.- Valsad (Gujarat). The proposed expansion project involves the capacity enhancement of existing Products viz. “Organic Pigments” ( Azo Pigments), Quinacridone Pigments & Pigment Emulsions As per the amended EIA notification- 2006, the proposed products are covered under category 5(f)- A and hence require Prior Environmental Clearance.

iii) Need for the project and its importance to the country and region: The proposed project provides a potential growth opportunity for the ongoing business of the company. The company is engaged in the business of manufacturing of Various Organic Pigments & Pigment Emulsions. The project would also help the company to support the Indian economy in the following way:

• Growth in Export Revenue and there by increasing the inflow of foreign currency which is much needed by our country.

• Our products are well accepted by international users and can substitute the international Pigment Grades. Thus the Domestic Industry can replace the imported Pigments used by them with ours and there by curtail the outflow of foreign currency spent on pigments imported by them.

• Potential increase in Job opportunities for the Local surroundings. • Boost to the Local service providers and the overall improvement in the economic

activities like Local RM Suppliers, Transporters , contractors, clearing and forwarding agents and other allied suppliers.

Additional Production capacities are required in Azo, Quinacridone, & Pigment Emulsion as the company expects growth of Exports to the tune of 40-50% in the next 2-3 years. Also the Domestic market is showing Strong Growth Potential as many multinational companies which use pigments as raw material have put up their manufacturing plants in India. Added to this Indian users of Pigments have expanded their own manufacturing capacities to cater to the growing demand of their finished products.

The Company Objective is to achieve :

• Consolidation of Organic Pigments & Pigment Emulsions business. The Proposed expansion will help the company to move towards more specialized products and there by focus on value addition which will improve the shareholder's worth.



• The Proposed increase in capacity will also assist the company to reduce the costs due to increase in the sale of manufacturing and intern make the company's products more competitive in the market.

Considering the nature of Pigment business, the proposed increase in capacity will also help the company to standardize and produce the Pigments with more consistency because higher volumes will help to achieve better control over Physico-chemical conditions while manufacturing.

• To generate Local Employment

iv) Demand –Supply Gap :

Our Organic Pigments & Pigment Emulsions are mainly used by various paint, ink, plastic master batch & textile industries. Though the Global production capacity of Organic Pigments is on the higher side as compared to demand, Customer preference of environment friendly products and high performance Pigment is still not fulfilled satisfactorily. Since our products are approved by quality conscious users which are multinational paint, ink and textile companies. We can cater to the ever increasing demand in India as well as in the Export Market. • ORGANIC PIGMENTS ( AZO PIGMENTS )

Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK, Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia, Indonesia, Australia, China ,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey, Singapore,Uruguay

Potential customers: USA, U.K., France, Italy, switzerland, Holland, Belgium, Luxembourg, Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE etc. New customers in existing countries – Brazil, USA, Australia, Denmark, Italy, Finland, UK, Holland, France ,Belgium, Japan, Philippines,Malaysia, Thailand, Indonesia,Turkey etc. Projected Export demand : USA, Canada & Latin America-1845 MT/Year, Europe – 2475 MT/Year, Japan - 100 MT/Year, Rest of the World (excluding China) – 224 MT/Year. Currently we are exporting about 400-450 MT/Year of AZO class Organic Pigment powder. We expect to acquire 10-15% of the projected export demand. Domestic market for our range of organic pigments is about 900 MT/Year and our market share is about 25%. Market is expected to grow by 20%.

• QUINACRIDONE PIGMENTS :

Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK, Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia, Indonesia, Australia, China ,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey,



Singapore,Uruguay.

Potential customers: USA, U.K., France, Italy, Switzerland, Holland, Belgium, Luxembourg, Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE etc. New customers in existing countries – Brazil, USA, Australia, Denmark, Italy, Finland, UK, Holland, France ,Belgium, Japan, Philippines, Malaysia, Thailand, Indonesia, Turkey etc.

Projected Export demand: USA, Canada & Latin America-1000 MT/Year, Europe – 500 MT/Year, Japan -335 MT/Year, Rest of the World (excluding China) – 400 MT/Year.

Currently we are exporting about 170 MT/Year of QUINACRIDONE class Organic Pigment powder. We expect to acquire 10-15% of the projected export demand. Domestic market for our range of organic pigments is about 300 MT/Year and our market share is about 25%. Market is expected to grow by 20%. • EMULSION:

Current Export to: Bangladesh, Vietnam, Srilanka, Thailand, Phllipens, China, Hongkong, Mauratitus. Potential markets in : Pakistan, Indonesia, Ethiopia, Kenya, Malavi. New customers in existing countries – Vietnam, Bangladesh, Thailand, Phillipens, USA, Projected demand : USA-2000 MT/year, Bangladesh- 1800 MT/year, Pakistan-3000 Mt/yr, Thailand-1500 MT/Year, Vietnam-1000 MT/Year, Phillipens-1200 MT/Year, Mauratious- 500 MT/Year, Srilanka – 800 MT/Year, African countries – 1800 MT/year. Domestic market – Potential-7000 MT/Year. It is expected to grow @ 20% per annum. Our current market share is about 40% of the domestic market. We expect to grow by 25-35 %.

v) Imports vs. Indigenous production :

Existing products manufactured in the country will be very much economical compared to

imports of the same and also the export of the same will earn extra revenue generation for Our county.

vi) Export Possibility:

Existing products have high export potential. Also these products have very good potential

in the local market.

Additional capacities of product range required over & above the unit’s existing capacities,

as the company expects strong growth of exports to the extent of 40-50%. Local market



also shows strong growth potential.

vii) Domestic / export Markets:

The company’s products are used in various in paint & ink industries as per requirement.

These are having very good demand in domestic as well as international markets.

viii) Employment Generation (Direct and Indirect) due to the project:

There will be very good opportunity of employment generation directly and indirectly due

to proposed expansion project. Due to proposed project there will be requirement of

manager, supervisor, operator and semi-skilled workers. For this, the company will employ

about additional 20 people to fulfil it’s need to handle the plant. So that 20 people will be

directly employed and more than 50 will be indirectly employed.



3 Project Description :

(i) Type of Project including interlinked and interdependent projects, If any : The proposed project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates :

The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted :

• The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in exiting premises only. (Land allotment letter is attached as Annexure-8)

(iv) Size or magnitude of operation : As per the proposed project cost, the project is covered under large Scale category of

manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) :

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products & characteristics of hazardous chemicals are as below:

DETAILS ON PRODUCT TRANSPORTATION

Sr. No.

Product Physical State Dispatch Means of transportation

1 Carbazole Dioxane Violet Pigment

(Pigment Violet 23)

Solid Local /export Truck/container

2 Organic Azo Pigment (Orange/Yellow/Red)

Solid Local/export Truck/container

3 Pigment emulsion Paste Local /export Truck/container

4 Quinacridone Pigment

Solid Local /export Truck/container



5 Phosphoric acid Liquid Local/export Truck/container

6 Calcium Sulphate (Gypsum)

Solid Local Truck

DETAILS OF RAW MATERIAL – TRANSPORTATION

Sr. No.

Substance Physical State

Type of packing & supply

Means of Transportati

on

Distance of supplier from project site (km)

1 Carbazole Solid (Powder)

25 Kgs & 400 Kgs

Sea & Road Imported & 350 Kms Local

2 Diethyl sulphate Liquid Tanker Road 300 Kms

3 Caustic flakes SOLID (Flakes)

50 Kg Bags

Road 250 Kms

4 Mono Chloro Benzene (Fresh)

Liquid Tanker Road 200 Kms

5 Nitric acid Liquid Tanker Road 200 Kms

6 ODCB (Fresh) Liquid Tanker Road 5 kms

7 Catalyst Liquid Drums Road 250 Kms

8 Nitrogen Liquid Cylinder Road 40 Kms

9 Hydrogen Liquid Cylinder Bank

Road 200 Kms

10 Chloranil Powder 50 Kg Bag

Road 400 Kms

11 Catalyst RAC Powder 50 Kg Bag

Road 5 Kms

12 Benzene sulpho chloride

Liquid 250 Kg Drums

Road 150 Kms

13 Salt Powder 50 Kg Bag

Road 350 Kms

14 Di ethyl Glycol Liquid Tanker Road 200 Kms

15 Base (Amine) Powder 25 Kg Bag

Road 500 Kms

16 Ice Solid - - Self Manufactured

17 Sulphamic acid Solid (Powder)

50 Kg Bag

Road 200 Kms

18 Sodium nitrite Solid (Powder)

50 Kg Bag

Road 300 Kms



Sr. No.

Substance Physical State

Type of packing & supply

Means of Transportation

Distance of supplier from project site (km)

19 Hydro Chloric Acid (30%)


20 Caustic Lye Liquid Tanker Road 300 Kms

21 Acetic acid Liquid Tanker Road 200 Kms

22 Xylene (Fresh) Liquid 200 Kg Drums

Road 250 Kms

23 Sulphuric acid Liquid Tanker Road 5 Kms

24 Emulsifier Liquid 50 Kg Drum

Road 20 Kms

25 Carbon black pigment

Solid (Powder)

25 Kg Bag

Road 5 Kms

26 Surface active agent

SOLID (Powder)

30 Kg Bag

Road 300 Kms

27 Glycols Liquid Tanker Road 300 Kms

28 Preservative Liquid 50 Kg carboy

Road 400 Kms

29 Aniline Liquid Tanker Road 200 Kms

30 DMSS Solid (Powder)

100 Kg Drum

Sea + road Imported

31 Para Toludine Solid 210 Kg Drum

Sea + Road Imported

32 Methanol (Fresh)


33 Resist salt Solid (Powder)

50 Kg Bag

Road 5 Kms

34 Caustic flakes Solid (Powder)

50 Kg Bag

Road 250 Kms

35 PPA or P2O5 Liquid/ Solid

300 Kg Drum

Road +Sea 25 Kms & Imported

36 Iso Butanol (fresh)




vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outlined: Resource optimization/recycling and reuse envisaged in the project (solvent recovery system) in detail are as mentioned below. • The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses. • The solvents are reused in the manufacturing of Pigment Violet, Quinacridone & Azo pigments. Details of solvent use & recovery are as under. • Wash water is also recycled in process as shown in the process flow diagram.

PRODUCT WISE SOLVENT USED/RECOVERED PER TONE OF PRODUCT FOR EXISTING & PROPOSED EXPANSION

Sr. No.

Product Solvent used

Quantity ton /tone

Loss per MT

Quantity ton /month

Loss, MT/

Month Fresh Recycle Fresh Recycle

1 Quinacridone Methanol 0.443 4.489 0.443 15.505 157.11 15.5

Iso Butanol 0.171 4.113 0.171 5.985 143.95 5.985

DMF 0.396 7.47 0.396 13.860 261.45 13.86

2 Carbazole MCB 0.32 3.23 0.32 8.000 80.75 8.0

ODCB 1.11 17.71 1.11 27.750 442.75 27.75

Methanol 0.59 3.14 0.59 14.750 78.43 14.75

3 Azo Pigment Xylene 0.011 0.539 0.011 1.265 61.985 1.265

Total 3.041 40.691 3.041 73.200 964.98 73.2



viii) Availability of water its source, Energy/power requirement and source should be given : Availability of water its source, Energy/power required and its source is below. Water withdrawal Permission is attached as Annexure: 4 Sr. No. Particulars Water consumption, m3/day


1 Domestic 95 0 95 2 Processing &

washing 1100 -185 915

3 Boiler 116 28 144 4 Cooling 125 35 160 5 Floor/container

washing 100 50 150

6 Gardening 50 50 100 7 Total 1586 -22 1564

WATER CONSUMPTION (m3/DAY)

ENERGY REQUIREMENTS AND ITS SOURCE



Sr. No.

Particulars Existing Kgs/hr

After Proposed expansion Kgs/Hr

Source

1 Steam requirement

5500 8000 Will be obtained by installation of Briquette Fired Boiler having Steam generation capacity of 12 TPH .Existing 8 TPH will be standby.

POWER REQUIREMENTS AND ITS SOURCE

Sr. No.

Particulars Existing After Proposed expansion

Source

1 Power – Electricity requirement

1600 KVA 1900 KVA Sourced from Dakshin Gujarat

Vij Co. Ltd. (ix) Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal: Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure-5. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representation of the feasibility drawing is enclosed as Annexure -9.



4 Site Analysis

(i) Connectivity : The project is located in notified Industrial Estate of Vapi which is very well connected to

National Highway no.8 and Western Railways. The nearest airport is Mumbai which is 150 KM away from the project site by road.

(ii) Land Form, Land use and Land ownership : The land is in the form of industrial shed owned by Gujarat Industrial Development

Corporation.

(iii) Topography (along with map) : Topography map showing the elevation of the study area below. The topographical map is

enclosed as Annexure-7.

(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given :

The existing land is located in the notified industrial area and a copy of which is enclosed as Annexure-8

(v) Existing Infrastructure : GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads,

rail, transportation, availability of raw material and drainage system.

(vi) Soil classification : General soil classification of the area is as under :

• Soil Characteristics & Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.

• The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose.

• The land is suitable for industrial development.

Damanganga River is located at 3 km distance from the site location; both side of the river has mixed soil type (Sand, clay & Basaltic soil).

(vii) Climate data from secondary sources : Rainfall Data :

The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives rainfall between 500-1000 mm and generally falls under semi-arid climate. Considering the abnormality of weather particularly rainfall during the monsoon period, the



observed and predicted rainfall was then analyzed for its validity. Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

Sr. No

Region Rainfall Projection

(in mm) June - Oct

Normal Rainfall (In mm)

Rainfall Projection (% Departure from normal)

1 Middle Gujarat 905.3 796 13.7

2 South Gujarat 696.3 575 21.0

3 Project site 2071.7 1433.7 44.5

4 Saurashtra 767.1 580.4 32.2

5 Gujarat State 1110.1 846.5 31.1

Source: AAU, Anand, Gujarat

Temperature Data: The site is located in the southern part of Gujarat. The secondary data was collected from free data of Worldclim.org for the year 2010. The project site temperature regime for medium to high level temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available : Social Infrastructure in Valsad district is as under :

Education: There are 990 primary, 161 secondary and higher secondary schools.

There are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature & motor rewinding, electrician, information technology and electronic system maintenance etc., 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nos of Polytechnic College With 120 seats, there is one Engineering College, Pharmacy College, Arts, Commerce, Science, B. Ed and Law College. Valsad district also has institutes which offers management studies with fulltime MBA.

Source: Department of Education, 2007

Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, providing services in general and laproscopic surgery, trauma, orthopedic and urology etc. The hospital is one of the few centers in India offering Uterine Thermochoice Thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital and Adarsh Hospital are also present in Valsad.

Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage center throughout the world. Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the year. The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also present in Valsad Proximity of



Valsad with Daman & Diu, which has increased the graph of tourist flow in the district.

5. Planning Brief :

Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification : There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi. Population Projection :

• Not applicable

Land use Planning (breakup along with green belt etc) : The existing as well as proposed expansion project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below.

For Green Belt Development as per the revised layout plan, the company proposes 33% green belt of the total land, i.e. 12686 sq. meter. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises.

While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

1. Climatic condition and soil characteristics of the region. 2. The air pollution emitted by the industry – gaseous and particulate matter. Plant

interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal. 5. For absorbance of gases, the duration of the foliage should be longer. 6. Vegetation controls soil erosion rates significantly. The decrease of water erosion

rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.



Site Plan with Area Table at Existing & After proposed expansion

Sr. No Particulars Area in m2


1.0 Total plot Area 38443 0 38443

1.1 Production Plant 14635 200 14835 1.2 Office & lab area 515 0 515

1.3 OHC Area 50 0 50

1.4 Green Belt 11734 952 12686 1.5 Raw materials & other Storage 2032 0 2032 1.6 Solvent storage area 529 0 529 1.7 Utility 285 0 285 1.8 Boiler shed area 500 0 500 1.9 ETP & solid waste storage area 784 0 784 1.10 Toilet block 112 20 132 1.11 Open space 7267 -1172 6095

Site map with Green Belt Development Planning



(iv) Assessment of Infrastructure demand ( Physical & Social) : There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion.

(v) Amenities/ Facilities :

GIDC notified industrial area of Vapi has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.

6 Proposed Infrastructure:

(i) Industrial Area (Processing Area). The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety.

(ii) Residential Area (Non Processing Area) : No residential area is involved in the proposed expansion project

(iii) Green Belt : Green belt will be provided and maintained at the tune of 33% of the total land area.

(iv) Social Infrastructure : Not applicable

(v) Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc): The project site is very well connected by road through National Highway no. 8, western railways.

(vi) Drinking Water management ( Source & Supply of water ) : Source of water is from GIDC water supply services.

(vii) Sewerage System : GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management : Industrial liquid effluent generated after proposed expansion will be treated in the primary & secondary ETP and will be discharged through GIDC underground drainage to CETP.(Membership certificate is attached as Annexure-6)

Generated domestic liquid waste is being disposed off through soak pit system to drainage.



(ix) Solid/Hazardous Waste Management : Sr. No.

Type of hazardous waste

Categor

y

Quantity, TPM Storage Capacity

, m2

Disposal

Existing After proposed expansion

1 ETP waste 34.3 30 40 50 Dispose off into TSDF, Vapi

2 Used oil 5.1 0.1 0.25 5 Sell to Registered recyclers

3 Discarded containers

33.3 1.25 2.0 10 ReUse for packing finished product or Sell to Autho. recycler

4 Distillation Residue

35.1 9 26.6 20 Sell to cement industries for co-

processing .

5 Iron Sludge 35.2 40 0 0 -

6 Spent catalyst 35.2 0 0.19 5 Sent for re-processing

(Membership certificate is attached as Annexure-6)

(x) Power Requirement & Supply / Source : Power requirement for proposed project will be taken from DGVCL.

7. Rehabilitation and Resettlement (R&R) Plan:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless laborers (a brief outline to be given): There will be no rehabilitation and resettlement undertaken as labours and workers from local & nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site.



8. Project Schedule & Cost Estimates :

(i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) : After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed construction and commissioning of the project.

(ii) Estimated project cost along with analysis in terms of economic viability of the project : Estimated project cost along with the analysis in terms of economic viability of the project is given as below.



CAPITAL COST PROJECTION

Cost in INR (Crore) Sr. No.

Particulars Existing Proposed Total

1.0 Land 38443 m2 4.0 0 4.0 2.0 Building 12.0 2.0 14.0 3.0 Plant & Machinery 3.1 Equipment & machineries 67.74 10.0 77.74 3.2 Pipes & fittings 12.40 2.0 14.4 3.3 Utilities 22.24 3.0 25.24 4.0 Environmental Management

System 7.87 4.0 11.87

5.0 Total Project Cost 126.25 21.0 147.25 6.0 Utilities 6.1 Boiler, TPH 12+8 + 2 0 12 + 8 + 2 (8

- Standby) Thermopack, k cal/hr 10 +4 0 10 +4 6.2 Cooling Tower, TR 1300 650 1950 6.3 D.G. Set (Standby) 0 750, 750,

125 750, 750, 125

7.0 Power from DGVCL, KVA 1600 300 1900 8.0 Fuel 8.1 Briquette /Natural Gas for

Steam Boiler (12 Tons/Hr)

1.45 MT/Hr of Briquette or 410 SCM/Hr

0.655 MT/Hr Briquette or 180 SCM/Hr

2.105 MT/Hr Briquette or 590 SCM/Hr

8.2 Natural gas for Thermopak (10 lacs & 4 lacs)

2000 SCM/day 0 2000 SCM/day

8.3 Natural gas for steam boiler (8 TPH & 2 TPH)

8750 SCM/day 0 8750 SCM/day

8.4 Fuel (HSD) for D.G.Set

(Capacity: 750 x 2 & 125 KVA)

0 225 kgs/hr 225 kgs/hr

9.0 Water from GIDC Vapi kl/day

1586 -22 1564

10.0 Waste Water (Industrial) kl/day

1358 -84 1274



PROJECT VIABILITY

Sr. No.

PARTICULARS AMOUNT (INR Crore)

1 Proposed Sale 254 2 Raw Material Cost 150.5 3 Power & Fuel 34 4 Labour Cost 15 5 Environmental Management System 1.5 6 Maintenance Cost 15 7 Selling, packing & Office Expenses 15 8 Proposed Profit 23

The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning.

RECURRING COST PER ANNUM

Sr. No. Component Proposed (Rs. in Lacs/annum)

1. Environment & Safety Management System 68

2. Greenbelt Maintenance 12

3. Solid waste Disposal 70

Total 150

8. Analysis of Proposal ( Final Recommendations):

(i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare.

• Local people will get direct financial benefit by way of employment.

• Local people will get some contracts of supply and services to get indirect income.

• Company will contribute in improving education and health facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius



ANNEXURE: 2

Plant Layout



ANNEXURE: 3

Detailed project description with process details - MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product.

MANUFACTURING PROCESS IN BRIEF

• Azo Pigments (Organic Yellow/Orange/Red): (a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c. Solution is maintained at this temp. (b) Coupler Dissolution : Water , Caustic Lye & Coupler is taken in stirred vessel. This mixture is heated to required temp. to make uniform solution. And cooled back to room temp. (c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution. Take out the wet cake. Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material Balance is enclosed. • Quinacridone Pigment (PR-122 /PV-19) : In PR-122 Manufacture ,P- Toludine is condensed with Dimethyl Succino succinate to form a DTA . It is further oxidised with Resist Salt to form Quinacridone Molecule. This is further cyclised to get the required Molecule in presence of Poly Phosphoric Acid. Finally the Pigmentation is done in presence of IBA / DMF as per the Quinacridone, PR-122 OR PV-19. Detailed Reaction, Flow Diagram as well as Material Balance is enclosed. In PV-19 , in place of P-Toludine , Aniline is used.

• Carbazole Dioxane Violet Pigment: Manufacturing Process is carried out in 5 Stages as per the attched sheet. Carbazole is a Main Raw Material. In First Step , Carbazole Alkylation is carried out with Diethyl Sulfate . Salt is separated by Addition of Caustic Flakes . Impurities are washed with MCB and water. In second Step , Resultant Ethyl Carbazole is Nitrated with 65% Nitirc Acid to form Nitro Ethyl Carbazole. This Nitro Ethyl Carbazole is reduced with Hydrogen to form Amino Ethyl Carbazole in third Step. Further it is condensed with Choranil and subsequently cyclised to form Crude Violet. Till this it is Synthesis Process. In Final Step Crude Violet , Pigmentation is done by various Methods to make Pigment Violet. There are lot of Physical changes done to get Pigmentation Properties. Detail Flow Diagram as well as Material Balance is also enclosed.

• Pigment Emulsions: There are No chemical reaction involved in Pigment Emulsion process. There are only Unit Operations of Kneading, Pulverising , Milling etc in Emulsion /Dispersion preparations. Pigments are dispersed in Water to make it compatible for end use. To make it dispersible it is milled and surface Active Agents , Glycols , Preservative and Other Auxiliaries, additives are added in water to make the dispersion stable.



CHEMICAL REACTION

( 1 ) Organic Yellow Pigment

HCl

NaNO2NH2 NH2

Cl Cl

Cl N=N N=N Cl

Cl Cl

2CH3COCH2CONHC6H5 + 2 NaOH

+ 2 NaCl + 4 H2O

Cl N=N N=N Cl

Cl Cl

CH3COCH2CONHC6H4 - N=N

Cl Cl

N=N-C6H4NHCOCH2COCH3 + 2 NaCl + 2 H2O

3 3’ DichlorobenzidineMol.wt. 253

Diazo

AcetoAcetanilideMol. Wt. 177

Yellow pigmentMol. Wt. 618

+

Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG



ORGANIC YELLOW PIGMENT

DIAZOTIZATION

12064 Kgs + 3990 kgs

Hours: 1 ½+11/2=3hr

Water: 4000 KgsBase (Amine) : 405 kgs

Ice: 6000 kgs

HCl: 960 kgsNa Nitrite: 690 kgs

Sulphamic acid: 9 kgsDISSOLUTION

3990 KgsHours: ½ hr

Water: 3000 lits

Coupler : 640 kgs

Caustic: 350 kgs

COUPLING & TREATMENT26339 kgs, Time: 6 Hrs

WASHING ,43400 kgs , Time: 6HrsWater: 30000 kgs Fresh

10000 Kgs Recycle

Filtrate 39900 (10000 (recycle) + 29900 kgs to ETP

TRAY DRYING ( 24 Hrs)3500 kgs

Water Vapors: 2498 kgs

PULVERIZER & PACKING(Time: 6 Hrs)

FILTERATION26339 kgs, Time: 3 Hrs

Filtrate as effluent: 22939 kgs to ETP

Total: 12064 kgsTotal: 3990 kgs

Diazotization + Dissolution 16054 kgs

Total: 26339 kgs

Crude Pigment Slurry: 26339 kgs

Total : 26339 kgs


Total: 26339 kgs

Wet cake: 3400 kgs

Total: 26339kgs

Total: 43400 kgs

Wet cake: 3500 kgs

Total: 43400 kgs

Wet cake: 3500 kgs Dry Powder: 1002 kgs

Dry Powder: 1002 kgs ORGANIC YELLOW PIGMENT: 1000 kgs

Live steam: 4000 kgs

Acetic Acid & Others: 285 kgs

Wet cake: 3400 kgs

SOLVENT TREATMENT,

12 HRS

Xylene: 11 kgs Fresh539 Kgs RecycleWater:1140 kgs

Wet cake: 3500 kgs

FILTERATION & WASHINGWater: 26000

Wet cake: 3500 kgs

DistillationXylene recovered: 539 + Loss: 11 kg + Effluent: 1140

Effluent:26000 kgs

Total: 5190 kgs Water + Xylene: 1690 kgs

Ice: 6000 kgs



[2] Organic Orange Pigment

NH2 NH2

Cl ClHCl

NaNO2Cl N=N

Cl Cl

N=NCl

N

N

CCH2

+ 2 NaCl + 2 H2O

Cl N=N

Cl Cl

N=NCl + 2 C + 2 NaOH

C=O

N

CH-N=NCH3CH

Cl Cl

N=N-

N N

N

CH-CH3CH

O=C

+ 2 NaCl + 2 H2O

3 3’dichlorobenzidineMol wt. 253

CH3

O =

PMP Mol wt. 173

Orange 13 pigmentMol .wt. 610

Base like: DCB, Coupler like PMP, MPMP



ORGANIC ORANGE PIGMENT

DIAZOTIZATION

9332 Kgs + 5800 kgs

Hours: 1 ½+11/2=3hr

Water: 2600 KgsBase (Amine) : 405 kgs

Ice: 5000 kgs

HCl: 1080 kgsNa Nitrite: 240 kgs

Sulphamic acid: 7 kgsDISSOLUTION

5800 KgsHours: ½ hr

Water: 4900 lits

Coupler : 580 kgs

Caustic: 320 kgs

COUPLING & TREATMENT23152 kgs, Time: 6 Hrs

WASHING ,43400 kgs , Time: 6HrsWater: 30000 kgs Fresh

10000 Kgs Recycle

Filtrate 39900 (10000 (recycle) + 29900 kgs to ETP


Water Vapors: 2498 kgs




Total: 9332 kgsTotal: 5800 kgs

Diazotization + Dissolution 15132 kgs

Total: 23152 kgs


Total : 23152 kgs


Total: 23152 kgs

Wet cake: 3400 kgs

Total: 23152 kgs

Total: 43400 kgs

Wet cake: 3500 kgs

Total: 43400 kgs

Wet cake: 3500 kgs Dry Powder: 1002 kgs

Dry Powder: 1002 kgs ORGANIC YELLOW PIGMENT: 1000 kgs

Live steam: 4000 kgs

Emulsifier & Others: 20 kgs

Wet cake: 3400 kgs

SOLVENT TREATMENT,

12 HRS

Xylene: 11 kgs Fresh539 Kgs RecycleWater:1500 kgs

Wet cake: 3500 kgs

FILTERATION & WASHINGWater: 28800

Wet cake: 3500 kgs

DistillationXylene recovered: 539 + Loss: 11 kg + Effluent: 1500

Effluent:28800 kgs

Total: 5550 kgs Water + Xylene: 2050 kgs

Ice: 4000 kgs



NH2

[3] Organic Red 2 Pigment

HCl

NaNO2 +2H2O + NaCL

2:5 Dichloro AnilineMol Wt.162

N=NCl

Cl

N=NCl

NH

C17H12NO2

( Naphthol AS)Mol wt.263

+

Cl

Cl

N=N

C NH

O

Organic Red 2 PigmentMol wt. 436

Cl

Cl

Diazo

O

Cl

Cl

OH

OH

Base like: TCA, DCA, Scarlet G base, Coupler like Naphols



(3) ORGANIC RED PIGMENT (TOTAL TIME: 48.5Hrs)

DIAZOTIZATION11157 Kgs + 14240 kgs

Hours: 6 hrs

Water: 1500 lits

Base: 432 kgs

Ice: 6000 kgs

H2SO4: 3000kgs

Na Nitrite: 200 kgs

Sulphamic acid: 25 kgs

DISSOLUTION14240 Kgs

Hours: 1 hr

Water: 6000 litsCoupler: 590 kgsCaustic: 650 kgsSteam: 1000 kgsIce: 6000 kgs

COUPLING 32397 kgs, Time: 10 Hrs

WASHING ,60000 kgs

Time: 6HrsWater: 55000 liters Filtrate as effluent: 55000 kgs to ETP


Water Vapours: 3970 kgs




Total: 11157 kgs Total: 14240 kgs

Diazotization + Dissolution:25397 kgs

Total: 32397 kgs

Coupler: 32397 kgs

Total: 32397 kgs

Coupler: 32397 kgs

Total: 32397 kgs Wet cake: 5000 kgs

Total: 32397kgs Wet cake: 5000 kgs

Total: 60000 kgs Wet cake: 5000 kgs

Total: 60000-kgs

Wet cake: 5000 kgs

Total: 5000 kgs Dry Powder: 1030 kgs

Total: 5000 kgs

Dry Powder: 1030 kgs PRODUCT (ORGANIC RED PIGMENT: 1030 kgs )

Ice :3000kgs

HCL: 1000 kgs

Live steam: 3000kgs



Dimethyl succinosuccinate

Pigment Red 122

(4) Quinacridone Pigment

H HOH

COOCH 3

CH 3 OOC

HOH H

+NH 2

CH 3

2

P-Methyl Aniline

- H 2 O

N

HH H

N

H

H 3 COO

COOCH3

H HOxidation

CH3

CH3OOC

COOCH3

H

N

H

N

CH3

H +CH3

CH3

H

N

H

N

CH3 HOOC

COOH

PPA

Cyclisation

(Polyphosphoric Acid)

Step B

Step C

CH3

N

H

N

H

CH3

O

O

Reflux

with Solvent IBAN

H

H

N

O

O

CH3

Step D P.R.122

2, 9 Dimethyl Quinacridone

C10H12O6

MW: 228

MW: 2 x 107 MW: 406

C24H24O4N2

MW: 404

MW: 376

MW: 340C22H16N2O2

MW: 340

DMSS 825 KGS

Para Toludine 880 KGS

HCl (30%) 100 KGS

Methanol 5757 KGS (Recovered FromStep II: 5239 kgs Fresh 518 kgs )

( Reactor )CONDENSATION

9612

For step-B2,5

diarylamino-3,6-

dihydroterephthalate9612 Kg

QUINACRIDONE PIGMENT (PIGMENT RED 122)

STEP: I (CONDENSATION)

Water: 2000

Aniline: 50 kgs



Water:- 14000(KGS)

Caustic Flakes (650 Kgs)

Resist Salt (800 Kgs)

Precipitation30% HCl (2200 kgs)

Filtration / Centrifuge

Washing

Dryer

Filtrate: 14129 kgsMethanol: 5757kg30%HCI :2300 kgWater: 5000 litOrganic impurities :422KgCaustic:650Kg

Recovered Methanol (5239 kgs)( Reactor )

OXIDATION

From Step: I :(9612 kgs)

Water: 89000 kgs

Di toludinoterephthalic acid: 1333 Kg

Wet cake: 3808 kgs

Vapour loss: 2475 kgs

Recycled in Step: I

STEP: II (OXIDATION)

Wash water: 97525 lit

Residue 422 Kg

Aques laye 8468

kg

Water:- 14710 KGS

PPA: 5000 kgs OR(Phospheric Acid + 4000 Kgs+ P2o5 - 1000 Kgs)

FILTERATION

WASHING

Filtrate: 104000 kgsPPA: 30 kgOrganics impurities: 125 kgs

Water: 103845 kgs

REACTOR20533

From Step:II : 1333 kgs

Wet cake: 6043 kgs

STEP: III (CYCLIZATION)

Phosphoric acid (10‐30%) recovered as by‐product : 17000 kgs

Water:- 106000 KGS



Water:- 8770 KGS

Iso-Butanol: 5000 kgsFresh: 200 kgs

Recovered: 4800 kgs

WASHING & FILTERATION

Dryer

Filtrate: 15220 kgsIBA: 200 kgsWater:114938 kgsImpurities: 42 kgsCaustic lye: 40 kgs

REACTOR

Wet Crude Pigment Red: 6043 kgs

Quinacridone Pigment (Pigment Red 122): 1167 kgs

Wet cake: 5833 kgs

Vapour loss: 4666 kgs

STEP: IV (PIGMENTATION)

Recovered IBA: 4800 kgs

Water:- 106000 KGS

Caustic lye: 40 kgs

In Pigment Violet 19 ( Quinacridone) :

1. In First Condensation Stage – Aniline is used in place of ParaToludiene. 2. In Final Pigmentation Stage DMF is used as Solvent in place of IBA. 9180 Kg

is used, we are distilling DMF and Recovery is 8721 Kgs. 3. Here @ 164 Kgs residue is generated after Distillation.



NH

Carbazole

N

CH3

N

N2+

O

O

N

NH2

N ethyl carbazole

HNO3

3 Nitro 9 ethyl carbazole

Alkylation

DES, MCB

H2

OO

ClCl

ClCl

Chloranil

3 Amino N Ethyl Carbazole

Hydrogenation

+ Benzene Sulpho Chloride +

N

Cl

Cl

N

N

O

O

N

Pigment Violet - 23

C12H9NMW: 167

(C2H5O)2SO2

MW: 154C14H13NMW: 195

C14H12N2O2

MW: 240

C14H12N2H2

MW: 210MW: 176.5

MW: 246

MW: 589

(5) Carbazole Dioxane Violet Pigment (Pigment Violet 23)



STEP: I (N-Ethyl Carbazole)

ALKYLATION,4350 kgs

Carbazole 800

NaOH flkes 430

Monochlorobenzene 2400 Recovered 2182Fresh 218

Diethylsulfate 720

FILTRATION 32350 Kgs

N-ETHYLCARBAZOLE : 890 KgsFILTRATE to ETP:27328 kgsWater:27313Organic: 10Caustic: 5

DISTILLATION(MCB Loss: 48 Kgs)

Monochlorobenzene(recovered & recycle: 2182 kgs

DISTILLATION RESIDUE (624) Incineration

Carbazole Dioxane Violet Pigment (Pigment Violet 23)

Water: 28000 kgsLayer Separation: 31460 kgs

Waste water: 1278

MCB + Water: 4132 kgs



NITRATION

SS Reactor, 2475 kgs

N-Ethylcarbazole (890)

Monochlorobenzene (760)Recovered 690Fresh 70

Nitric acid (825)

LAYER SEPARATION

ACID LAYER (To ETP) (705)Nitric acid (42)Water (662.5)Organics: 0.5

SOLVENT LAYER (1770)

FILTRATION & WASHING

Wet cake 3-NITRO-N-ETHYL CARBAZOLE (1130)

FILTRATE (50690)Water:49857N-Ethyl carbazole (22.5 ) +Monochlorobenzene (810)

DISTILLATION Monochlorobenzene (recovered) (690)N ethyl carbazole or impurities 2.5

Residue (40 kgs) Incinerator

STEP: II (3- Nitro-N- Ethyl Carbazole)

Water: 50000 kgs

Effluent: 49907 kgs

REDUCTION,8501.7 kgs

3-Nitro-N-ethylcarbazole(1130) (960 +170 Water)

O-Dichlorobenzene (7260)Recovered 6944Fresh 316

Catalyst: 6.7 kgs

N2: 70 kgs

H2: 35 kgs

ORGANIC LAYER SEPARATION

PARTIAL DISTILLATION

FILTRATION

3 – AMINO CARBAZOLE : 775ODCB : 150 TOTAL : 925

DISTILLATION

o-Dichlorobenzene(recovered) (6564)Amino carbazole 1.0

Distillation residue ( 65)(as solid waste) CHWIF

o-Dichlorobenzene(recovered)(380)

STEP: III (3- Amino-N- Ethyl Carbazole)

Spent Catalyst: 6.7 kgs

Water of reaction: 314 kgs to ETP (144 +170)

N2 loss : 70 kgs

H2 loss : 19.3 kgs

Solvent loss: 146 kgs

Reprocessing & recycle



CONDENSATION&

CYCLISATION

MSGL

Temp. 160 O C

3-Amino-N-ethyl carbazole 775 kgsODCB: 150 Kgs

Chloranil (462)

o-Dichlorobenzene (9300) Recovered 8780Fresh 520

Catalyst RAC (190)

Benzene sulfochloride (330)

FILTRATION

PIGMENT VIOLET 23 CRUDE: 897

o-Dichlorobenzene(recovered) (8780) ODCB Loss : 180 Kgs

Water (56000)

Distillation residue (640) CHWIF

ETP

Filtrate (to ETP) (54010)Sodium Chloride (172)Organics (424)Other Salt (112)Water (53302)

STEP: IV (Crude Pigment Violet 23)

DRYING Drying loss: 2700 kgs

Mixing &

Washing

Pigment Violet-23: 888 Kg

Water: 142315 kg

STEP: V (Pigmentation)

GRINDING

Crude Violet pigment 23: 897 kgs

Salt: 7740 kgs

Di-ethyl Glycol: 145 kgs

Filtrate: 147709 kgs(Salt: 7740 kgs + DEG 145 kgs) +water: 139824 kgs

Drying Drying loss: 2500 kgs



Pigment Black Dispersions

Premix (1) Carbon Black Pigment (105)(2) Surface active agent (15)(3) Glycols (20)(4) Preservative (10)(5) Water(850)

Grinding

Packing(1000 Kgs)



ANNEXURE: 4 Water requirement letter from Notified industrial estate:



ANNEXURE: 5

• Quantity of Waste Water (liquid waste) generation and its management :

Sr. No. Particulars Effluent generation, m3/day


1 Domestic 95 0 95

2 Processing & washing

1050 -165 885

3 Boiler 111 0 111

4 Cooling 100 28 128

5 Floor/container washing

100 50 150

6 Total 1456 -87 1369

7 Total Industrial 1361 -87 1274

• The generated waste water will be treated in existing adequate effluent treatment plant (ETP).

The details of the same is given on Next Page.

• We have reduced Water consumption and Effluent Generation Qty by following 3R Principle. (1) Final Wash water of Filter Press is recycled for Initial washings .

(2) Use of Membrane Press in place of Ordinary Plate & Frame Filter Press

(3) Pulse washing in Filter Press, where ever Plate & Frame Press is existing.

(4) Increasing Batch Size in Same Volume there by reducing water Dilution.

(5) Use of DM Water in place of Raw Water in Final Washings.

(6) Use of treated Effluent in Water Jet Ejectors.



Details of Effluent Treatment Plant • Design Criteria :

Product : Organic Pigments ( Azo, Quina & Violet ) + Pigment Emulsion Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 1369 KL/day Max. Design Parameters : As under Effluent Characteristics:

No Effluent parameters

Process +

washing

Boiler +

cooling

Equip + floor + container

washing/scrubber

Combined Effluent

1 pH 1.52 8.1 6.5 2.56

2 Temperature 0 C. 32 30 30 31

3 Colour (Pt-Co) 600 60 180 400

4 SS, mg/l 417 121 456 356

5 TDS, mg/l 6322 3400 2850 5300

6 COD value, mg/l 3650 10 1448.8 3108

7 BOD value, mg/l 1020 124 350 988

8 Chlorides, mg/l 820 120 280 636

9 Sulphates, mg/l 1050 210 850 684

10 O & G, mg/l 5.12 13.6 8.9 4.6

11 NH3-N, mg/l 20 ND 22.2 19

12 Phosphates, mg/l 6.2 ND 1.2 5.4

13 Phenolic , mg/l ND ND ND N.D.



Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install:

No Name of the unit Existing Capacity

, m3

MOC Detention time in hrs

Adequacy

Reqd Prov.

1 Oil/grease trap 2 RCC 0.01 0.035 Adequate

2 Equalization cum neutralization tank (2 Nos.)

1586

RCC 8 27 Adequate

3 Flash mixer 2.7 RCC 0.03 0.04 Adequate

4 Clarifloculator 339 RCC 2 5.9 Adequate

5 Aeration tank (2 Nos.)

3120 RCC 24 54 Adequate

6 Secondary clarifier

530 RCC 4 9.2 Adequate

7 Sludge thicker with agitator

125 RCC 1 1.06 Adequate

8 Sludge mixing sump

34 RCC 0.03 0.59 Adequate

9 Filter press 48” PP - - Adequate

10 Lime slurry tank (3 Nos.)

72 RCC - - Adequate

11 Ferrous sulphate tank

8 RCC - - Adequate

12 Air blower (2 Nos)

692 m3/hr

CI - - Adequate

13 Sludge pump (2 Nos.)

110 m3/hr

CI - - Adequate

14 Effluent transfer pump (2 Nos.)

55 m3/hr CI - - Adequate



EFFLUENT TREATMENT SCHEME FOR EFFLUENT The company has put up a full-scale elaborate effluent treatment plant with a total

investment of nearly 2.5 crores. The plant occupies nearly 3200 M2 land area. The plant is

designed by M/S. Environmental Engineering Consultants, Bombay, and has capacity of

treating a maximum of 2200 M3/day effluent.

Here the combined wastes from various plants are collected into two Equalization-cum-

Neutralization Tanks, alternately, which are provided with aeration grids. The effluent is

neutralized here with lime solution prepared in lime slurry tank situated in the chemical

house. After neutralization, it is pumped into the Clarifloculator. Here ferrous sulphate

solution is added. The solution of ferrous sulphate is made in the tank located in the

Chemical House. The clear supernatant liquid from Clarifloculator goes to the

Biodegradation aerator tanks, provided with 4 nos. aerators of 50 HP each. The overflow

from the biodegradation tanks goes to the clarifier where after settling, the clear liquid

overflows into the GIDC common drainage system. A Thickener is also provided for

settling the calcium sulphate sludge.

The treated waste water from GIDC common drainage goes to the CETP from where it is

discharged to the river Daman Ganga (down stream) & finally meeting to Arebian Sea.

The settled bio mass in clarifier is either recirculated to the aeration tank or filtered by

membrane filter press. The sludge from bottom of the thickener is also taken to the Filter

Press for dewatering.

The effluent treatment plant is a separate unit by itself. The plant also has an elaborate

Chemical House with complete provision of MCC room, Laboratory, Raw Material storage,

Lime and Ferrous Sulphate Tanks. It also has provision of proper material movement with

an electrical hoist. Separate KWH meter certified by Gujarat State Electricity Board (

DGVCL ) is provided to know the electrical consumption.



E/N - 1 E/N - 2

L - 1 L - 2 L - 3 F - 1

Main

PT

PT-2 PT-3

B-1

B-2

P-2

P-1

Chemical House

Lime Solution

Tanks8 m3 each

FromETP

FerrousSolution

Tanks : 8 m3

Equalization cum Neutralization tank

793 m3

Flash Mixer2.7 m3

Air Blower692 m3/hr each

110 m3/hr each

Clariflocuulator339 m3

SA-1 SA-2AT-1

AT-2

Aeration Tank1560 m3 each

PT-4P-5

P-6

P-7

P-8

Sludgemixing

P-3

P-4

PT-5

NutrientsUrea & DAP

Surfaceaerators

Diffuser b lowers30 HP each

Biomassrecycle to aeration

tanks

34 m3

V-notch

Treated Wateroutlet

to CETP

Thickener125 m3

Excessbiomassdisposal

Filter press

PT-6

P-9

P-10

Water Tank

P-11

Water washing line

Overflow water to E/N tank

Secondary 530 m3

Reuse of treated water for lime solution preparation

FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT



ANNEXURE: 6

MEMBERSHIP CERTIFICATE OF CETP, VAPI



MEMBERSHIP CERTIFICATE OF CHWIF



ANNEXURE: 7



ANNEXURE: 8 Copy of plot allotment letter issued by GIDC



COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA



ANNEXURE: 9 A schematic representation of the feasibility drawing



ANNEXURE: 10 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING &

PROPOSED EXPANSION

At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers, one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare capacity to supply the steam for proposed expansion.

The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA & 125 KVA capacities, as stand by. It will be used only during power failure.

Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler. Adequate stack height and stack monitoring facilities is provided.

Process gas emission: • Presently the unit has installed Two no of multi cyclone separator followed by bag filter

attached to pulveriser. After proposed expansion, the unit shall install one additional multi cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent will be provided The details of which are as under;

Sr. No.

Particulars Details Remarks


FLUE GAS EMISSION 1.0 Steam Boiler 8TPH 0 8 TPH Standby 1.1 Fuel used Natural Gas 0 Natural Gas 1.2 Fuel Consumption 7000 SCM/d 0 7000

SCM/d

1.3 APC Chimney 0 Chimney 1.4 Height & Dia of

chimney 30 meter/900

mm 0 30

meter/900 mm

2.0 Steam boiler 2 TPH 0 2 TPH Standby 2.1 Fuel used Natural gas 0 Natural gas 2.2 Fuel Consumption 1750 SCM/day 0 1750

SCM/day



mm 0 30

meter/800 mm

3.0 Thermopak: I 10 lacs k cal 0 10 lacs k cal

No Change

3.1 Fuel used Natural gas 0 Natural gas 3.2 Fuel Consumption 1500 SCM/day 0 1500

SCM/day



mm 30

meter/450 mm



4.0 Thermopak:II 4 lacs k cal 0 4 lacs k cal No Change 4.1 Fuel used Natural gas 0 Natural gas 4.2 Fuel Consumption 500 SCM/day 0 500

SCM/day



mm 0 30

meter/450 mm

Common chimney with TP:I

5.0 Steam boiler 12 TPH 0 12 TPH Only increase

the operating hours &

fuel

5.1 Fuel used Briquetes Briquetes Briquetes 5.2 Fuel Consumption 1.45 MT/Hr 0.655

MT/Hr 2.105

MT/Hr 5.3 APC MDC followed

by bag filter & online SEMS

- MDC followed by bag filter &

online SEMS

5.4 Height & Dia of chimney

30 meter/800 mm

- 30 meter/800

mm

6.0 D G Set: I 0 750 KVA 750 KVA Standby

6.1 Fuel used 0 HSD HSD

6.2 Fuel Consumption 0 100 kgs/hr 100 kgs/hr

6.3 APC 0 Exhaust Exhaust

6.4 Height of exhaust 0 11 meters 11 meters

7.0 D G Set: II 0 750 KVA 750 KVA Standby





8.0 D G Set: III 0 125 KVA 125 KVA Standby





9.0 Pulveriser Cyclone separator

followed by

Cyclone separator followed by bag

Cyclone separator

followed by

Total three numbers



bag filter filter bag filter

9.1 Height of vent 11 meters 11 meters 11 meter

9.2 Gases emission PM: < 150 mg/Nm3

PM: < 150 mg/Nm3

PM: < 150 mg/Nm3

DETAILS OF AIR POLLUTION CONTROL SYSTEM ATTACHED TO BRIQUETTES FIRED BOILER

1. Boiler: 12000 kg of steam/hour.

Briquettes consumption : 70 MT/day Calorific value : 4200 kcal/kg Inlet to dust collector : 280°C Stack temp : 180°C Diameter of chimney : 750mm Flue Gas Volume : 6107Am3/hr I.D. Fan : 15254 m3/hr Stack diameter : 850Ømm Stack height provided : 30 meters Efficiency : Thermal Efficiency of Boiler 82±2% 1.0 Air Pollution control System: Multi Cyclone Dust Collector (Grit Arrestor) Cyclone tube diameter : 2.5 Ø mm Height of tube : 2500 mm No of tubes : 4no Dia of tubes : 587Ø mm Dimensions : 2.5 m x 2.5 m x 9 m height Collection efficiency : 60-70% (over 40micron) Expected outlet dust load : 150 < mg/nm3

at out let of bag filter

Inlet Dust load : 25-40 gms/nm3 Density : 600kg/ m3

Fines : (< 1 mm) 2.0 Air Pollution control System: Bag filter Size of Bag filter : 12 m x 10 m x 10 m MOC : Mild steel Size of Gas inlet : 400 X 1000 mm Size of gas out let : 850 Ømm Total unit weight : 4.1MT Hopper volume : 3.9m3 Designed gas volume : 10704 Am3/hr Maximum designed temp. : 1900C Number of filter bags : 96 Nos (500 gms/m2 filter glass) Size of filter bags : 160mm dia x 3600m length No. of cages : 96 Pressure drop : 125-150mm Air to cloth ratio : 1.01 m3/min/m2



Expected emission : PM: < 100 mg/Nm3 : SOx: < 100 ppm : NOx: < 50 ppm

Details of Air pollution control measures attached to Pulveriser

• Drying of Pigment: Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers/spin flash dryer. The process heat is provided by Hot Oil Thermopak system based on natural gas. The Thermopak exhaust flue gas is connected to a chimney.

• Pulverization of pigments: This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This consists of following parts:

• Hopper feed box. • Screw feeder. • Closed grinder with box • cyclone separator • Bag filter. • I.D. fan. • Vent line. • Rotary valve for outlet of product.

The pulverized material is collected in bags, weighed and dispatched. The material collected from bag filter is also mixed with the final product. Thus this is a completely dry process and does not involve any consumption or discharge of effluent. There is no solid waste as even the floor spillage is collected and recycled.

PIDILITE INDUSTRIES LIMITED - Pidilite Industries limited is located in GIDC notified industrial...

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