Pravin Industries Dyes Expansion Report
Pravin Industries Dyes Expansion Report
REPORT
For
At
APPLICANT CONSULTANT
Pravin Industries Eco Chem Sales & Services
Plot No: C1-6118, Phase IV, Office Floor, Ashoka Pavilion - A
Notified Industrial Area, GIDC, Vapi - New Civil Road, Surat, 395001
396195 NABET/EIA/1720/RA 051
Tal.: Pardi, Dist.: Valsad, Gujarat E-Mail: eco@[Link]
E-Mail: pravinind@[Link] Tel No.: +91 261 2231630
Mobile No.: +91 93271 22944
August - 2018
Doc. No: 2018_ECSS_EIAI2_18000013
Prefeasibility Report Pravin Industries
Consumption, in MT
S. CAS
Raw Material MT/Month
No. No. Per ton
Existing Proposed Total
For Direct Scarlet 4
1.1
BS
Para Amino Acetanilide 122-80-5 0.15 1.19 -1.19 0
Aniline 62-53-3 0.09 0.74 -0.74 0
Sodium Nitrite 7632-00-0 0.14 1.14 -1.14 0
Ice 7789-20-0 11.70 93.60 -93.60 0
HCL 7647-01-0 0.50 4.00 -4.00 0
Soda Ash 497-19-8 0.13 1.03 -1.03 0
Caustic lye 1310-73-2 0.17 1.35 -1.35 0
JAU 120983-64-4 0.71 5.71 -5.71 0
Common Salt 7647-14-5 0.50 4.00 -4.00 0
1.2 For Direct Red 12 B
HCL 7647-01-0 0.53 4.20 -4.20 0
Sodium Nitrite 7632-00-0 0.15 1.18 -1.18 0
Aniline 62-53-3 0.20 1.58 -1.58 0
Ice 7789-20-0 8.00 64.00 -64.00 0
Soda Ash 497-19-8 0.24 1.88 -1.88 0
Rhoduline Acid 87-03-6 0.93 7.41 -7.41 0
Common Salt 7647-14-5 0.50 4.00 -4.00 0
1.3 For Acid Scarlet MOO
Sodium Nitrite 7632-00-0 0.19 1.56 -1.56 0
HCL 7647-01-0 0.85 6.81 -6.81 0
Para Amino Azo
104-23-4 0.50 3.99 -3.99 0
Benzene
Ice 7789-20-0 4.86 38.89 -38.89 0
Soda Ash 497-19-8 0.26 2.08 -2.08 0
Caustic Soda 1310-73-2 0.26 2.04 -2.04 0
G Salt 842-18-2 0.41 3.27 -3.27 0
For Basic Bismarck
1.4
Brown
Ice 7789-20-0 20.00 160.00 -160.00 0
HCL 7647-01-0 1.05 8.40 -8.40 0
Sodium Nitrite 7632-00-0 0.28 2.24 -2.24 0
MPD 108-45-2 0.65 5.18 -5.18 0
Salt 7647-14-5 0.50 4.00 -4.00 0
1.5 For Chroysidine
Ice 7789-20-0 7.69 61.54 -61.54 0
HCl 7647-01-0 0.78 6.28 -6.28 0
Aniline 62-53-3 0.30 2.39 -2.39 0
Sodium Nitrite 7632-00-0 0.23 1.82 -1.82 0
MPD 108-45-2 0.35 2.77 -2.77 0
S. Quantity, TPA
Type Disposal
No. Existing Proposed Total
Process Residue Sell to actual/authorized
1. (Auramine Sludge) 18.00 391.57 409.57 users or Dispose off into
(Sch: I/26.1) TSDF, Vapi
Process Residue Dispose off into TSDF,
2 0.00 199.90 199.90
(Sch: I/26.1) Vapi
ETP Waste Dispose off into TSDF,
3. 1.80 23.20 25.00
(Sch:I/35.3) Vapi
Used Oil Collection, storage &
4. 0.01 0.01 0.02
(Sch: I/5.1) sell to register recycler
Discarded Containers Collection, storage &
5. 2.00 1.00 3.00
(Sch:I/33.1) sell to register recycler
Sludge from Wet Dispose off into ETP
6. Scrubber 0.00 1.00 1.00 along with scrubbing
(Sch:I/37.1) water
M/S Pravin industries is a small scale unit located in notified industrial estate,
GIDC, Vapi Di: Valsad, Gujarat having total plot area of 806 m2 & total investment
after proposed expansion will be Rs. 163.83 Lakhs. The proponent wishes to
introduce new products. The dyes products are especially used in Paper, Agro
chemicals, paint, textiles, plastics, ink, etc. as per requirement.
The proposed expansion project site lies on 20021’20.07” N Latitude & 72056’30.01”
E Longitude. M/S Pravin Industries is located at Plot No: C1-6118, Phase IV,
Notified Industrial Area, GIDC, Vapi – 396195 Tal.: Pardi, Dist.: Valsad, Gujarat.
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.
Vapi is the biggest railway station in the study area. 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 a six lane and double tracked. 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.
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.
M/S Pravin Industries was started in the year of 1986 by another owner, after
that; we have purchased said unit with entire plant and machineries in the year
of 2013.
Most of the products have been developed through strong in-house R&D. The
Group's turnover is about 3.0 Crores for the year 2017-18.
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.
1.7.1 Identification of the Project Proponent:
M/S Pravin Industries is a small scale unit is located at Notified Industrial Estate,
GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer.
1.7.2 List of Partners:
S.
Name of Directors Addresses
No.
B- 302, Nikunj Co-op. HSG. Society
Mr. Upendra Balubhai
1 Plot no. 83, Nr. Patel Samaj Wadi, Nr. Surya Co-op HSG.
Sheladia
Society, Hariya Hospital Road, G.I.D.C. Vapi-396195.
B- 302, Nikunj Co-op. HSG. Society, Plot no. 83, Nr.
Mr. Ghanshyam
2 Patel Samaj Wadi , Nr. Surya Co-op HSG. Society ,
Balubhai Sheladiya
Hariya Hospital Road, G.I.D.C. Vapi-396195.
Mr. Kamlesh Ratilal C-9, Shivnagar Society, Near Matavadi Police Choki, L.H
3
Senjaliya Road, Surat – 396 006
All the partners are well qualified in Engineering, Management, Accounts, operations
and Marketing field.
Apart from these there are Expert from Field- Industries, Financial Institutes and
others as a Part time / Independent Partners on Board for efficient Management.
They help us to achieve & perform better & better.
The proposed expansion project involves introduction of new products. As per the
amended EIA notification- 2006, the proposed products are covered under category
5(f)- B and appraised at state level expert committee.
1.7.4 Need for the project and its importance to the country and region:
The proposed expansion project provides a potential growth opportunity for the
ongoing business of the company. The company is engaged in the business of
manufacturing of Dyes. The project would also help the company to support the
Indian economy in the following way:
Growth in Export Revenue and thereby 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 speciality Grades. Thus the Domestic Industry can replace the
imported dyes used by them with ours and there by curtail the outflow of foreign
currency spent on dyes 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 raw materials Suppliers, Transporters, contractors, clearing and
forwarding agents and other allied suppliers.
1.8.6 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
S. Physica Packing & Means of
Product Dispatch
No. l State transportation
Domestic & Sack Bags or Jumbo
1. Direct Scarlet 4 BS Solid
Export Market Bags through Truck
Domestic & Sack Bags or Jumbo
2. Direct Red 12 B Solid
Export Market Bags through Truck
Domestic & Sack Bags or Jumbo
3. Acid Scarlet MOO Solid
Export Market Bags through Truck
Domestic & Sack Bags or Jumbo
4. Basic Bismarck Brown Solid
Export Market Bags through Truck
Domestic & Sack Bags or Jumbo
5. Chroysidine Solid
Export Market Bags through Truck
Domestic & Sack Bags or Jumbo
6. Acid Orange-II Solid
Export Market Bags through Truck
Basic Auramine-O (Basic Domestic & Sack Bags or Jumbo
7. Solid
Yellow-2) Export Market Bags through Truck
Methyl Violet Liquid
OR
Malachite Green Liquid
OR
Domestic &
8. Diamond Green Liquid Liquid Drums through Truck
Export Market
OR
Victoria Blue Liquid
OR
Auramine Liquid
Methyl Violet Crystal
(Crude)
OR
Malachite Green Crystal
(Crude)
OR
Domestic & Sack Bags or Jumbo
9. Diamond Green Crystal Solid
Export Market Bags through Truck
(Crude)
OR
Victoria Blue Crystal
(Crude)
OR
Auramine-OF (Crude)
May cause
Paste at respiratory and PPEs
7. JAU 5.0 1.0 Drums NA NA
STP digestive tract provided
irritation.
Hazardous in case
Glaubber’s Normal at of skin contact of PPE’S
8. 5.0 1.0 Bags 100 33
salt STP ingestion, of provided
inhalation
May cause
Rhoduline Powder at respiratory and PPEs
9. 7.0 1.0 bags NA NA
acid STP digestive tract provided
irritation.
This chemical is
highly toxic and
Para Amino Powder at may be fatal by PPEs
10. 4.0 1.0 Bags 360 123
Azo Benzene STP ingestion, provided
inhalation or skin
absorption.
May cause
Powder at
respiratory and PPEs
11. G Salt 3.0 1.0 Bags - - STP
digestive tract provided
irritation.
Hazardous in case
of skin contact
(irritant,
sensitizer), of eye
contact (irritant),
Powder at of ingestion, of
PPEs
12. MPD 2.0 0.5 Bags 284 62 STP inhalation. Slightly
provided
hazardous in case
of skin contact
(permeator).
Severe over-
exposure can
result in death
Powder at
Sulphanilic Causes skin PPEs
13. 1.0 0.5 Bags - 288 STP
acid irritation. provided
May be harmful if
Powder at
inhaled. Causes PPEs
14. B- Naphthol 3.0 0.5 Bags 285 120 STP
respiratory tract provided
irritation.
Liquid at Causes skin PPEs
15. Formalin 0.5 0.2 Drums - 96
STP irritation. provided
Causes severe
skin irritation and
Normal at PPE’S
16. Sulphuric acid 1 0.5 Drums 330 -1.1 burns. Continued
STP Provided
contact can cause
tissue necrosis.
Di Methyl Normal at Hazardous in case PPEs
17. 5.0 1.0 Drums 194 2.5
Aniline STP of skin contact provided
Hazardous in case
of skin contact
Normal at (irritant), of eye PPEs
18. T G urea 6.0 1.0 Bags NA 132
STP contact (irritant), provided
of ingestion, of
inhalation
Normal at Causes serious PPEs
19. Sulphur 0.6 0.1 Bags 444 112
STP eye irritation provided
Cylind Normal at High pressure PPEs
20. Oxygen 0.6 0.09 - -
er STP oxidizing gas provided
Expansion project- Dyes Page 14
Prefeasibility Report Pravin Industries
Absorbed through
skin. Dermal
Normal at contact. Eye PPE’s
21. Acetic acid 10 2 Liquid 118 16.6
STP contact. Provided
Inhalation.
Ingestion
Hazardous in case
Di Ethyl Normal at of skin contact of PPE’S
22. 8.0 2.0 Drums 216 -38
Aniline STP ingestion, of provided
inhalation
Hazardous in case
Normal at
Benzaldehyd of Eye contact. PPE’s
23. 4 2 Drums 179 -26 STP
e Inhalation. Provided
Ingestion
Flammable.
Harmful by
Ethyl Normal at PPE’S
24. 1 0.5 drums 135 -100 inhalation, in
Cellosolve STP provided
contact with skin
and if swallowed.
Hazardous in case
Phenyl Alpha of skin contact ,
Normal at PPE’S
25. Naphthalene 2 2 bags 226 60 irritan), of
STP provided
amine ingestion, of
inhalation.
Very hazardous in
Para
Normal at case of skin PPEs
26. Formaldehyd 2 2 Bags NA 120
STP contact, irritant, provided
e
corrosive
cause skin
Mono Methyl Normal at irritation. Harmful PPE’s
27. 3 5 Drums 195 -57
Aniline STP if absorbed Provided
through the skin.
cause skin
Normal at irritation. Harmful PPE’s
28. Oxalic Acid 15 2 Bags 149 101
STP if absorbed Provided
through the skin.
Hazardous in case
of ingestion.
Slightly hazardous
Sodium Normal at in case of skin PPE’s
29. 23 2 Bags 380 308
nitrate STP contact (irritant), Provided
of eye contact
(irritant), of
inhalation.
Slightly hazardous
in case of skin
contact (irritant,
Normal at PPE’s
30. Glycerin 2 0.5 Drum 290 19 permeator), of eye
STP Provided
contact (irritant),
of ingestion, of
inhalation.
Slightly hazardous
in case of skin
contact (irritant,
Hydro Normal at PPE’s
31. 0.25 0.1 Bags - 53 permeator), of eye
sulphide STP Provided
contact (irritant),
of ingestion, of
inhalation.
1.8.7 Resource optimization/ recycling and reuse envisaged in the project, if any,
should briefly outline:
Resource optimization/recycling and reuse envisaged in the project in detail are as
mentioned below.
The raw materials will be stored in closed containers and will be handled through
closed system to avoid the handling losses.
1.8.8 Availability of water source, Energy/Power requirement and source should be
given:
Availability of water its source, Energy/power required and its source is below.
Water will be sourced from GIDC Notified industrial estate, Vapi.
Water withdrawal Permission is attached as Annexure: 4
OVERALL WATER CONSUMPTION AT EXISTING & AFTER EXPANSION (KLD)
S. Water Consumption, KLD
Particulars
No. Existing Proposed Total
A. Domestic 2.0 0 2.0
B. Industrial
1. Processing, Washing & Scrubber 8.0 21.58 29.58
2. Boiler 1.0 2.0 3.0
3. Cooling 2.0 1.0 3.0
4. Floor/Container Washing 1.0 0.5 1.5
Total Industrial 12.0 25.08 37.08
C. Gardening 1.0 0 1.0
Grand Total (A+B+C) 15.0 25.08 40.08
D. Recycle as MEE Condensate 0 26.46 26.46
Net Fresh Water (A+B+C-D) 15.0 -1.38 13.62
9 M3/Day
CETP, VAPI
Total Water Consumption, 40.08 KL/Day ( Fresh: 13.62 KL/day + Recycle: 26.46 KL/Day) source from GIDC Water supply
27.16 6.5
MEE/Centrifuge
9 M3/Day
MEE Salt to TSDF: 0.55 Loss: 0.15 Condensate Primary & Tertiary ETP
Recycle: 26.46
CETP, VAPI
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.)
Rainfall Projection
S. Rainfall Projection Normal Rainfall
Region (% Departure from
No. (in mm) June - Oct (In mm)
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 [Link] 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).
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 offer 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 laparoscopic surgery, trauma, orthopaedic and
urology etc. The hospital is one of the few centres 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.
1.10 PLANNING BRIEF
1.10.1 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.
1.10.2 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
150.00 m2 (18.6%) of green belt of the total land, i.e. 806 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.
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
S. Area in m2
Particulars Area in %
No. Existing Proposed Total
1.0 Total plot Area 806 0 806 100
1.1 Production Plant 200 50 250 31.01
1.2 Office & lab area 100 0 100 12.40
1.3 Green Belt 150 0 150 18.61
1.4 Raw materials & F G storage 50 50 100 12.40
1.5 ETP area 40 0 40 4.96
1.6 Boiler shed area 20 0 20 2.48
1.7 solid waste storage area 20 0 20 2.48
1.8 Toilet block 10 0 10 1.24
1.9 Open space 216 -100 116 14.39
1.11.5 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.
S. Quantity, TPA
Type Disposal
No. Existing Proposed Total
Process Residue Sell to actual/authorized
1. (Auramine Sludge) 18.00 391.57 409.57 users or Dispose off into
(Sch: I/26.1) TSDF, Vapi
Process Residue Dispose off into TSDF,
2 0.00 199.90 199.90
(Sch: I/26.1) Vapi
ETP Waste Dispose off into TSDF,
3. 1.80 23.20 25.00
(Sch:I/35.3) Vapi
Used Oil Collection, storage &
4. 0.01 0.01 0.02
(Sch: I/5.1) sell to register recycler
Discarded Containers Collection, storage &
5. 2.00 1.00 3.00
(Sch:I/33.1) sell to register recycler
Sludge from Wet Dispose off into ETP
6. Scrubber 0.00 1.00 1.00 along with scrubbing
(Sch:I/37.1) water
(Membership certificate is attached as Annexure-6)
The company will provide budgetary provision for the recurring/operating expenses
for environmental issues while planning the allocation of funds during the annual
budgetary planning.
RECURRING/OPERATING COST PER ANNUM
S. Proposed
Component
No. (Rs. in Lacs/annum)
1. Environment & Safety Management System 10.00
2. Greenbelt Maintenance 0.25
3. Solid waste Disposal 7.00
Total 17.25
ANNEXURES
ANNEXURE: 1
Location map showing the Project site and inter-state boundary within 10 kms
radius
ANNEXURE: 2
Plant Layout
ANNEXURE: 3
Steam condensate
Steam loss as effluent
Steam
COUPLING
Common Salt Time- 12.0 Hrs
Steam [Link] effluent Steam loss
WET CAKE
TRAY DRYING
Time- 48 Hrs Water vapors
CRUDE MATERIAL
Soda Ash
Water Sodium Nitrite : Steam loss:
Rhodulene Acid DISSOLUTION OF
DIAZOTIZATION Aniline Ice
HCL COUPLER
Time- 4.0 Hrs Ice
Water Steam as effluent:
Time- 8.0 Hrs
Steam
Common Salt
COUPLING
Steam as effluent To ETP
FILTRATION Filtrate
WET CAKE
Water vapours
TRAY DRYING
CRUDE MATERIAL
Sodium Nitrite
HCL Caustic Soda
Water DIAZOTIZATION G Salt
Water
Para Amino Azo Benzene 9548 Kg Ice
DISSOLUTION OF COUPLER
Ice
Time – 4.0 Hrs Soda Ash Time – 4.0 Hrs
Soda Ash
Salt: COUPLING
Time – 4.0 Hrs
FILTRATION Filtrate
WET CAKE
Water vapours
TRAY DRYING
Salt
Filtrate to ETP
FILTRATION
WET CAKE
Water vapours
TRAY DRYING
CRUDE MATERIAL
Ice
HCI Water
DIAZO OF ANILINE COUPLER SOLUTION Steam
Aniline
Sodium Nitrile MPD
Water
FILTRATION To ETP
DRYING
Wet cake Water vapours
CRUDE
PULVERISING, BALLMILLING
Sodium Nitrite
HCL Caustic Soda
Water DIAZOTIZATION Beta Napthol
Water
Sulphanilic Acid
Ice
9548 Kg Ice
DISSOLUTION OF COUPLER
Charcoal Time – 4.0 Hrs Soda Ash Time – 4.0 Hrs
Soda Ash
Salt COUPLING
Time – 4.0 Hrs
FILTRATION Filtrate
WET CAKE
Water vapours
TRAY DRYING
CRUDE MATERIAL
Di. Acid
METHANE BASE Caustic
Water
Methane Base
T G Urea REACTOR Process Gas to Scrubber Scrubber
Sulphur
Di methyl aniline
Para foprmaldehyde
Monomethyl Aniline
Catalyst:
Reactor
Oxygen
Acetic Acid
Heating 600C
Di methyl aniline
Benzaldehyde
Hydro Chloric acid
Acetic acid Reactor
Catalyst
Ethyl Cellosolve
Oxygen
Heating 60 0C
Heating 60 0C
Dimethyl Aniline
Para Formaldehyde
Phenyl Alpha Naphthalene Amine
Catalyst Reaction
Oxygen
Acetic Acid
Heating 60 0C
Auramine – OF
Acetic acid
Glycerin
Hydro Reaction
Heating 60 0C
Water Heating
Clarification Sludge
Caustic Neutralisation
Wet cake
Wet cake
Di methyl aniline
Benzaldehyde (3.2) Mass Balance for Malachite Green Crystal
Hydro Chloric acid
Acetic acid Reactor
Catalyst
Ethyl Cellosolve
Oxygen
Wet cake
Wet cake
Water Heating
Caustic Precipitation
Wet cake
Sulphuric Acid
Glauber Salt Salting
Water
Filtration Filtrate to ETP
Wet cake
Dimethyl Aniline
Para Formaldehyde
Phenyl Alpha Naphthalene
Amine
Catalyst Reaction
Oxygen
Acetic Acid
Water Heating
Caustic Precipitation
Wet cake
Sulphuric Acid
Glaubers Salt Salting
Water
Filtration Filtrate to ETP
Wet cake
Formalin
H2SO4 CONDENSATION
Di Methyl Aniline
Di. Acid
METHANE BASE Caustic
Water
Methane Base
T G Urea REACTOR Process Gas to Scrubber Scrubber
Sulphur
ANNEXURE: 4
Water requirement letter from Notified industrial estate
ANNEXURE: 5
9 M3/Day
CETP, VAPI
Total Water Consumption, 40.08 KL/Day ( Fresh: 13.62 KL/day + Recycle: 26.46 KL/Day) source from GIDC Water supply
27.16 6.5
MEE/Centrifuge
9 M3/Day
MEE Salt to TSDF: 0.55 Loss: 0.15 Condensate Primary & Tertiary ETP
Recycle: 26.46
CETP, VAPI
Details of Effluent Treatment Plant for concentrated effluent stream (27.16 Kl/Day)
(proposed) (27.16 Kl/Day):
S.
Name of the unit Capacity, M3 MOC
No.
1. Collection tank 2.0 RCC/TL
2. Caustic dosing tank 0.1 HDPE
3. Neutralization tank 1.0 HDPE
4. Final Holding tank 5.0 HDPE
Details of Multi Effect evaporator
S. Retention time
No. Name of Equipment ID MOC Capacity
Req. Prov.
1. Storage Tank V-1 HDPE 30 KL 2 day 7 hrs
2. Condensate collection Vessel V-2 M.S 500 L 1h 2 hrs.
3. Salt Collection vessel V-3 M.S. 500 L 3 hrs 10 hrs
4. Crystallizer V-4 SS 6 KL 2 hrs 10 hrs
5. CALENDRIA-1 CL - 1 Titanium 28 M2 1h 2 hrs
6. CALENDRIA-2 CL - 2 Titanium 28 M2 1h 2 hrs
7. CALENDRIA-3 CL - 3 Titanium 28 M2 1h 2 hrs
8. PRE-HEATER PHE-1 Titanium 2.2 M2 - -
9. PRE-HEATER PHE-2 Titanium 2.2 M2 - -
10. PRE-HEATER PHE-3 Titanium 2.2 M2 - -
11. Pump - 1 P-1 CI 3 HP - -
12. Pump - 2 P-2 CI 5 HP - -
13. Pump - 3 [ VCP ] P-3 CI 10 HP - -
14. Pump - 4 P-4 CI 5 HP - -
15. Nutsch Filter N-1 MSRL 2.25 M2 - -
16. Centrifuge CF-1 SS 48 - -
ANNEXURE: 6
ANNEXURE: 7
ANNEXURE: 8
Copy of plot allotment letter issued by GIDC
ANNEXURE: 9
A schematic representation of the feasibility drawing
ANNEXURE: 10
DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING &
PROPOSED EXPANSION
Details
S.
Particulars After proposed Remarks
No. Existing
Expansion
1.0 Capacity of D G set 0 82.5 KVA Proposed
1.1 Fuel used 0 HSD
1.2 Consumption 0 15 lits/hr
1.3 APC provided 0 11 meters chimney
Existing will be
utilized for
proposed expansion
Capacity of Steam
2.0 300 kgs/hr 300 kgs/hr by increase the
boiler
working hours
(Presently operating
for 6 hrs)
2.1 Fuel used Natural gas Natural gas
2.2 Consumption 20 SCM/hr 60 SCM/Hr
11 meters
2.3 APC provided 11 meters chimney
chimney
Thermopak
3.1 Fuel Used Natural gas Natural gas
3.2 Consumption 20 SCM/Hr 60 SCM/Hr
11 meters
3.3 APC Provided 11 meters chimney
chimney
Capacity of Steam
5.0 0 600 kgs/hr Proposed
boiler
5.1 Fuel used 0 Natural gas
5.2 Consumption 0 60 SCM/Hr
5.3 APC provided 0 11 meters chimney
Details
Sr.
Particulars After proposed Remarks
No. Existing
Expansion
5.0 Stack attached to Reactor Reactor
Three stage Three stage
Alkali followed Alkali followed
5.1 APC provided Existing will be modified
by Water and by Water and
acid scrubber acid scrubber
5.2 Height of vent 11 meters 11 meters
NH3: <175 mg/Nm3
5.3 Expected Emission
H2S : < 10 mg/Nm3
Spin Flash Spin Flash
6.0 Stack attached to
dryer dryer
Cyclone Cyclone
separator separator Existing
6.1 APC provided
followed by followed by bag
bag filter filter
6.2 Height of vent 11 meters 11 meters
6.3 Expected emissision PM: <150 mg/Nm3
The only process emission is that from the production of Auramine-O. This
process generates simultaneous emission of Ammonia & hydrogen sulphide
gas.
The company has provided a two stage absorption system to control the air
pollution by this process emission.
In the first stage a ventury scrubber absorbs the hydrogen sulphide gas into the
caustic soda solution to generate sodium hydrosulphide solution as per the
following reaction.
H2S+ NaOH NaHS + H2O
The gas now has only ammonia gas which enters the packed tower in which
the cold water is circulated to absorb this gas and makes liquor Ammonia
solution and finally traces of ammonia gas is passes through acid scrubber.
The specifications of ventury scrubber and packed tower are given below: -
1. Ventury Scrubber :-
MOC : PP/FRP
Diameter: 150 mm
Length: 1650 mm
Throat Dia: 50 mm
Nozzle Dia: 15 mm
2. Packed Tower :-
MOC: PP/FRP
Diameter: 300 mm
Height: 2500 mm
Packed height: 1500 mm
Packing: 20 mm NB Ceramic racing ring
3. Acid scrubber:
MOC: PP/FRP
Diameter: 300 mm
Height: 2500 mm
Packed height: 1500 mm
Packing: 20 mm NB Ceramic racing ring
STACK
PG
H2 S + NH 3
Packed
Ventury column
Scrubber
NRV
DILUTE NaOH
Blower
REACTOR
Water Di. Acid