environmental impact and risk assessment report for proposed expansion of dyes … ·...

M/S. S.M. INDUSTRIESSURVEY NO. 192/4, VILLAGE : SOKHADA,

TALUKA : KHAMBHAT, DIST. ANAND,

GUJARAT – 388 620

ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT

FOR PROPOSED EXPANSION OF DYEs & NEW PIGMENTS IN

EXISTING UNIT

October to December, 2017

EIA Consultant

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.(Pollution Control Consultants & Engineers)403, Centre Point, Nr. Kadiwala School,

Ring Road, Surat – 395002 (Guj.)

R

ENVIRONMENTAL IMPACT & RISK

ASSESSMENT REPORT

CLIENT

PROJECT TITLE

PROJECT NO.

:

:

:

M/S. S.M. INDUSTRIES

SURVEY NO. 192/4, VILLAGE : SOKHADA,

TALUKA : KHAMBHAT, DIST. ANAND,

Gujarat – 388 620

PROPOSED EXPANSION OF DYES & NEW PIGMENTS IN EXISTING

PREMISES

642000



Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

M/s. S.M. INDUSTRIES ENVIRONMENT IMPACT ASSESSMENT REPORT

Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat I-1

INDEX

SR. NO. TITLE PAGE NO.

1 CHAPTER 1: INTRODUCTION

1.1 INTRODUCTION 1-1

1.1.1 IDENTIFICATION OF THE PROJECT PROPONENT 1-1

1.1.2 STATUTORY REQUIREMENT 1-1

1.2 PROJECT DETAILS 1-2

1.2.1 PROJECT SITE LOCATION 1-2

1.2.2 IMPORTANCE AND BENEFITS OF PROJECT 1-3

1.2.3 TOTAL PROJECT COST 1-3

1.2.4 TOTAL LAND ACCQUIRED AND ITS BREAK-UP 1-4

1.2.5 PRODUCTS DETAILS 1-6

1.2.6 REGULATORY FRAMEWORK 1-8

1.2.7 EXISTING AND ADDITIONAL MAJOR EQUIPMENTS AND

MACHINERIES

1-8

1.3 PROJECT SETTING 1-9

1.3.1 LOCATION 1-9

1.3.2 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1-10

1.3.2.1 METHOD OF DATA PREPARATION 1-10

1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM

PROJECT SITE

1-10

1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1-11

1.4 PURPOSE OF EIA 1-12

1.5 OBJECTIVES OF EIA 1-12

1.6 METHODOLOGIES FOR EIA 1-12

1.6.1 BASE LINE ENVIRONMENTAL CONDITION 1-12

1.6.1.1 AMBIENT AIR ENVIRONMENT 1-12

1.6.1.2 GROUND AND SURFACE WATER ENVIRONMENT 1-13

1.6.1.3 NOISE ENVIRONMENT 1-13

1.6.1.4 SOIL ENVIRONMENT 1-13

1.6.1.5 BIOLOGICAL ENVIRONMENT 1-13

1.6.1.6 SOCIO-ECONOMIC ENVIRONMENT 1-13

1.6.2 IDENTIFICATION OF SOURCE OF POLLUTION 1-14

1.6.3 EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL

MANAGEMENT SYSTEM

1-14

1.6.4 EVALUATION OF IMPACT 1-14

1.6.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 1-14

1.7 STRUCTURE OF REPORT 1-14



2 CHAPTER 2: PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND 2-1

2.2 MANUFACTURING ACTIVITIES 2-2

2.3 RAW MATERIAL STORAGE AND HANDLING 2-101

2.4 INFRASTRUCTURE FACILITIES 2-120

2.4.1 LAND 2-120

2.4.2 TRANSPORTATION FACILITIES 2-120

2.4.3 WATER AND WASTEWATER 2-120

2.4.3.1 TREATMENT PROCESS 2-123

2.4.4 SOURCES OF AIR EMISSION AND AIR POLLUTION CONTROL

EQUIPMENTS

2-129

2.4.5 NOISE LEVEL AND CONTROL SYSTEM 2-130

2.4.6 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL

SYSTEM

2-130

2.4.7 DETAILS OF UTILITIES 2-131

2.5 POWER & FUEL REQUIREMENT 2-131

2.6 DETAILS OF GREENBELT 2-132

2.7 DEPLOYMENT OF QUALIFIED/SKILLED MAN POWER 2-132

2.8 STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS 2-133

3 CHAPTER 3: BASELINE ENVIRONMENTAL STATUS

3.1 MICRO-METEOROLOGY OF THE AREA 3-1

3.1.1 TEMPERATURE DETAILS 3-2

3.1.2 RELATIVE HUMIDITY (RH) 3-3

3.1.3 RAINFALL 3-4

3.1.4 WIND SPEED 3-5

3.2 AIR ENVIRONMENT 3-9

3.2.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING

LOCATIONS

3-9

3.2.2 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 3-9

3.3 NOISE ENVIRONMENT 3-15

3.3.1 METHODOLOGY FOR NOISE MONITORING 3-15

3.4 WATER ENVIRONMENT 3-20

3.4.1 RECONNAISSANCE 3-20

3.4.2 METHODOLOGY FOR WATER QUALITY MONITORING 3-20

3.5 LAND ENVIRONMENT 3-25

3.5.1 METHODOLOGY FOR SOIL MONITORING 3-25

3.6 GEOLOGICAL DATA 3-29

3.6.1 METHOD OF PREPARATION 3-29



3.6.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER

DIFFERENT FORMATIONS

3-29

3.6.3 GEOLOGICAL MAP 3-29

3.7 LAND USE PATTERN 3-32

3.7.1 METHOD OF DATA PREPARATION 3-32

3.7.2 AREA UNDER DIFFERENT LANDUSE 3-32

3.8 ECOLOGICAL INFORMATION 3-35

3.8.1 METHOD OF PREPARATION 3-36

3.8.2 FLORA 3-36

3.8.3 FAUNA 3-38

3.9 DRAINAGE PATTERN 3-40

3.10 SOCIO - ECONOMIC ENVIRONMENT 3-41

3.10.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 3-41

3.10.1.1 SETTLEMENTS 3-41

3.10.1.2 DEMOGRAPHIC DATA WITHIN THE REGION OF INTEREST 3-41

3.10.1.3 LITERACY RATE 3-45

3.10.2 OCCUPATIONAL STRUCTURE 3-47

3.10.3 AMENITIES 3-47

4 CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

4.1 IDENTIFICATION OF IMPACTS 4-1

4.2 PREDICTIONS AND EVALUATION OF IMPACTS 4-8

4.2.1 WATER ENVIRONMENT 4-8

4.2.1.1 IMPACT DURING CONSTRUCTION PHASE 4-8

4.2.1.2 IMPACT DURING OPERATION PHASE 4-9

4.2.2 AIR ENVIRONMENT 4-9

4.2.2.1 CONSTRUCTION PHASE IMPACTS 4-9

4.2.2.2 OPERATION PHASE IMPACTS 4-10

4.2.3 NOISE ENVIRONMENT 4-20

4.2.3.1 CONSTRUCTION PHASE IMPACTS 4-20

4.2.3.2 OPERATION PHASE IMPACTS 4-21

4.2.4 HAZARDOUS/SOLID WASTE DETAILS 4-21

4.2.4.1 CONSTRUCTION PHASE IMPACT AND MITIGATION MEASURES 4-21

4.2.4.2 OPERATION PHASE IMPACT 4-22

4.2.4.3 TRANSPORTATION OF HAZARDOUS WASTE 4-23

4.2.5 INFRASTRUCTURE AND SERVICES 4-23

4.2.6 ENVIRONMENTAL HAZARDS 4-24

4.2.7 HOUSING 4-24

4.2.8 ECOLOGY 4-24



4.2.8.1 NATURAL VEGETATION 4-24

4.2.8.2 CROPS 4-24

4.2.8.3 FISHERIES AND AQUATIC LIFE 4-24

4.2.8.4 AESTHETIC ENVIRONMENT 4-25

4.2.8.5 DEMOGRAPHY, ECONOMICS, SOCIOLOGY AND HUMAN

SETTLEMENT

4-25

4.2.8.6 FOREST, NATIONAL PARKS / SANCTUARIES 4-27

4.2.8.7 PLACES OF ARCHAEOLOGICAL/HISTORICAL/RELIGIOUS/TOURIST

INTEREST

4-27

4.3 MATRIX REPRESENTATION 4-27

4.3.1 CUMULATIVE IMPACT CHART 4-27

5 CHAPTER 5: ENVIRONMENTAL MONITORING PLAN

5.1 PROJECT ENVIRONMENT MONITORING PLAN 5-1

5.1.1 LABORATORY FACILITIES 5-3

5.1.2 DOCUMETATION & RECORDS 5-3

5.1.3 ENVIRONMENTAL MONITORING CELL (EMC) 5-4

5.1.3.1 RESPONSIBILITIES OF EMC 5-5

5.1.4 DETAILED BUDGET 5-5

6 CHAPTER 6: ADDITIONAL STUDIES

6.1 RISK ASSESSMENT 6-1

6.1.1 INTRODUCTION 6-1

6.1.2 APPROACH TO THE STUDY 6-1

6.1.3 METHODOLOGY 6-2

6.1.4 HAZARD IDENTIFICATION 6-4

6.1.4.1 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS 6-4

6.1.4.2 MAJOR HAZARDOUS AREAS 6-4

6.1.5 HANDLING OF CORROSIVE CHEMICALS 6-10

6.1.6 CONSEQUENCE ANALYSIS 6-11

6.1.6.1 DAMAGE CRITERIA 6-12

6.1.6.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS 6-17

6.1.7 RISK ASSESSMENT SUMMARY 6-30

6.1.7.1 PROCESS SAFETY 6-30

6.1.7.2 FOR HAZARDOUS STORAGE TANK FARM 6-31

6.1.7.3 FOR DRUM/CARBOY STORAGE AREA 6-32

6.1.7.4 TRANSPORTATION 6-33

6.1.8 OTHER RISK REDUCTION OPPORTUNITIES 6-33

6.1.9 RECOMMENDATIONS FOR ALARP 6-33

6.1.10 FIRE FIGHTING SYSTEM 6-34



6.2 DISASTER MANAGEMENT PLAN 6-35

6.2.1 DEFIING THE NATURE OF EMERGENCY 6-36

6.2.1.1 LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE CATEGORIES 6-36

6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM 6-36

6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM 6-37

6.2.3.1 CHIEF EMERGENCY CONTROLLER 6-38

6.2.3.2 INCIDENT CONTROLLER (IC) AND DEPUTY INCIDENT CONTROLLER

(DIC)

6-39

6.2.3.3 SITE MAIN CONTROLLER (SMC) 6-40

6.2.3.4 KEY PERSONNELS 6-42

6.2.3.5 ESSENTIAL WORKERS 6-42

6.2.3.6 ASSEMABLY POINT 6-43

6.2.3.7 EMERGENCY CONTROL CENTER (ECC) 6-43

6.2.3.8 FIRE CONTROL ARRANGEMENTS 6-44

6.2.3.9 MEDICAL SERVICES 6-45

6.2.3.10 OTHER ARRANGEMENTS 6-45

6.3 COMMMUNICATION SYSTEM 6-46

6.3.1 RAISING THE ALARM 6-46

6.3.2 DECLARING THE MAJOR EMERGENCY 6-47

6.3.3 TELEPHONE MESSAGES 6-47

6.3.4 COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION 6-47

6.3.4.1 COMMUNICATION OF EMERGENCY 6-47

6.3.4.2 STATUTORY INFORMATION 6-48

6.4 ACTION ON SITE 6-49

6.4.1 PRE-EMERGENCY ACTIVITIES 6-49

6.4.1.1 INTERNAL SAFETY SURVEY 6-49

6.4.1.2 THIRD PARTY SURVEY 6-49

6.4.1.3 PRESSURE VESSEL TESTING/ EXAMINATION 6-50

6.4.1.4 NON-DESTRUCTIVE TESTING (NDT) 6-50

6.4.1.5 SAFETY RELIEF VALVES TESTING 6-50

6.4.1.6 FIRE SYSTEM TESTING 6-51

6.4.1.7 MUTUAL AID SCHEME 6-51

6.4.1.8 MOCK-DRILLS 6-51

6.4.1.9 SAFETY TRAINING 6-52

6.4.1.10 PERSONAL PROTECTIVE EQUIPMENT 6-52

6.4.1.11 COMMUNICATION 6-53

6.4.1.12 EMERGENCY LIGHTS 6-53

6.4.1.13 EMERGENCY CONTROL ROOM 6-53

6.4.1.14 ASSEMBLY POINTS 6-53

6.4.1.15 LIAISON WITH STATE AUTHORITIES 6-53



6.4.1.16 HOSPITAL FACILITIES 6-54

6.4.1.17 OUTSIDE SHELTER 6-54

6.4.1.18 STATUTORY INFORMATION 6-54

6.4.1.19 PROTECTIVE DEVICES & ENGINEERING MAINTENANCE 6-54

6.4.1.20 LIST OF SUPPLIERS OF SAFETY EQUIPMENT 6-55

6.4.1.21 FIRE PREVENTION PLAN 6-55

6.4.2 POST EMERGENCY ACTIVITIES 6-56

6.4.3 EMERGENCY TIME ACTIVITIES 6-56

6.4.3.1 FLAMMABLE RELEASES 6-56

6.4.3.2 TOXIC RELEASES 6-57

6.4.3.3 CHEMICAL SPILL 6-58

6.4.4 EVACUATION & TRANSPORTATION 6-58

6.4.5 SAFE CLOSE-DOWN 6-59

6.4.6 USE OF MUTUAL AID 6-59

6.4.7 HELP OF EXTERNAL AUTHORIES 6-59

6.4.8 MEDICAL TREATMENT 6-59

6.4.9 ACCOUNTING FOR PERSONNEL 6-59

6.4.10 ACCESS TO RECORDS 6-59

6.4.11 PUBLIC RELATIONS 6-60

6.4.12 REHABILITATION 6-60

6.5 OFF – SITE EMERGENCY PLAN 6-60

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN 6-61

6.5.2 STRUCTURE OF THE OFF-SITE EMERGENCY PLAN 6-61

6.5.3 ROLE OF FACTORY MANAGEMENT 6-61

6.5.4 ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO) 6-61

6.5.5 ROLE OF THE FIRE AUTHORITIES 6-62

6.5.6 ROLE OF THE HEALTH AUTHORITIES 6-62

6.5.7 ROLE OF TELEPHONE DEPARTMENT 6-62

6.5.8 ROLE OF POLICE AND EVACUATION AUTHORITIES 6-62

6.5.9 ROLE OF THE MUTUAL-AID AGENCIES 6-63

6.6 OCCUPATIONAL HEALTH AND SAFETY 6-63

6.6.1 OCCUPATIONAL HEALTH 6-63

6.6.1.1 CONSTRUCTION AND ERECTION 6-63

6.6.1.2 OPERATION AND MAINTENANCE 6-64

6.6.1.3 HOSPITAL FACILITIES 6-65

6.6.1.4 FACTORY MEDICAL OFFICER (FMO) 6-65

6.6.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC 6-65

6.6.1.6 AMBULANCE VAN 6-65

6.6.1.7 FIRST AID BOX 6-66

6.6.1.8 PERIODIC MEDICAL EXAMINATION 6-66



6.6.1.9 EMP FOR THE OCCUPATIONAL SAFETY & HEALTH HAZARDS SO

THAT SUCH EXPOSURE CAN BE KEPT WITHIN PERMISSIBLE

EXPOSURE LEVEL (PEL)/THRESHOLD LEVEL VALUE (TLV) SO AS TO

PROTECT HEALTH OF WORKERS

6-66

6.6.1.10 MEDICAL SURVEILLANCE PROGRAM 6-68

6.6.2 SAFETY PLAN 6-69

6.6.3 SAFETY ORGANIZATION 6-71

6.6.4 SAFETY CIRCLE 6-71

6.6.5 SAFETY TRAINING 6-71

6.6.6 HEALTH AND SAFETY MONITORING PLAN 6-72

6.7 TRAINING, REHERASAL & RECORDS 6-72

6.7.1 NEED OF TRAINNING & REHEARASAL 6-72

6.7.2 SOME CHECK POINTS 6-73

6.7.3 RECORDS AND UPDATING THE PLAN 6-73

7 CHAPTER 7: ENVIRONMENTAL MANAGEMENT PLAN

7.1 BACKGROUND 7-1

7.2 ENVIRONMENTAL MANAGEMENT PLAN (EMP) 7-1

7.2.1 OBJECTIVES 7-1

7.2.2 WATER ENVIRONMENT 7-3

7.2.3 AIR ENVIRONMENT 7-4

7.2.3.1 ACTION PLAN TO CONTROL AMBIENT AIR QUALITY AS PER

NAAQES STANDARDS

7-4

7.2.4 NOISE ENVIRONMENT 7-8

7.2.5 HAZARDOUS/SOLID WASTE MANAGEMENT 7-9

7.2.5.1 METHODOLOGY OF DE-CONTAMINATION AND DISPOSAL OF

DISCARDED DRUM AND ITS RECORD KEEPING

7-11

7.2.5.2 IDENTIFICATION OF RECYCLE/REUSE, CLEANER PRODUCTION AND

CO-PROCESSING

7-11

7.2.6 PLAN FOR MANAGEMENT, COLLECTION & DISPOSAL OF WASTE

STREAMS TO BE GENERTED FROM LEAKAGE, SPILLAGE, VESSEL

WASHING & USED CONTAINER WASHING

7-12

7.2.6.1 MEASURES PROPOSED FOR PREVENTING EFFLUENT DISCHARGE

DURING UNFORESEEN CIRCUMSTANCES

7-12

7.2.7 WATER CONSERVATION AND RECHARGING 7-13

7.3 ENVIRONMENTAL MANAGEMENT CELL 7-13

7.3.1 ENVIRONMENTAL POLICY 7-16

7.3.2 CORPORATE ENVIRONMENT RESPONSIBILITY 7-17

7.3.3 MANAGEMENT RESPONSIBILITY 7-17

7.4 GREEN BELT DEVELOPMENT 7-17



7.5 MEASURES FOR CONSERVATION OF ENERGY 7-19

7.6 NATURAL RESOURCES CONSERVATION 7-20

7.7 SKILLED AND TRAINED MANPOWER 7-21

7.8 SOCIO ECONOMIC DEVELOPMENT ACTIVITIES 7-22

7.9 CAPITAL COST FOR ENVIRONMENTAL MANGEMENT 7-23

8 CHAPTER 8: EXECUTIVE SUMMARY OF PROJECT

8.1 SUBJECT 8-1

8.2 NEED AND JUSTIFICATION OF PROPOSED EXPANSION PROJECT 8-1

8.3 PRODUCTS ALONG WITH PRODUCTION CAPACITY 8-1

8.4 WATER REQUIREMENT, WASTE WATER GENERATION AND

TREATMENT & MODE OF DISPOSAL

8-5

8.5 DETAILS OF SOURCE OF EMISSION AND APCM 8-6

8.6 HAZARDOUS/SOLID WASTE GENERATION AND DISPOSAL MODE 8-7

8.7 NOISE LEVEL CONTROL/PREVENTION MEASURES 8-8

8.8 GREEN BELT 8-8

8.9 POWER & FUEL REQUIREMENTS 8-8

8.10 HAZARDOUS CHEMICAL STORAGE AND HANDLING DETAILS 8-9

8.11 CAPITAL AND RECURRING COST EARMARKED FOR

ENVIRONMENTAL PROTECTION MEASURES

8-10

8.12 CONCLUSION 8-10

9 CHAPTER 9: DISCLOSURE OF CONSULTANTS ENGAGED 9-1

ANNEXURES A-1



LIST OF TABLES

TABLE

NO. TITLE PAGE NO.

1.1 PROJECT COST BREAK-UP 1-3

1.2 LAND BREAK-UP 1-3

1.3 LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY 1-6

1.4 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM

PROJECT SITE 1-10

2.1 RAW MATERIALS CONSUMPTION 2-101

2.2 DETAILS OF WATER CONSUMPTION & WASTE WATER GENERATION 2-121

2.3 DETAILS SOURCE OF EMISSION AND AIR POLLUTION CONTROL

EQUIPMENTS 2-129

2.4 DETAILS OF HAZARDOUS/SOLID WASTES GENERATION AND DISPOSAL

MODE 2-130

3.1 TEMPERATURE DATA 3-2

3.2 RELATIVE HUMIDITY DETAILS 3-3

3.3 RAINFALL DATA 3-4

3.4 WIND SPEED DATA 3-5

3.5 SITE SPECIFIC METEOROLOGICAL DATA (PERIOD – OCTOBER TO

DECEMBER, 2017) 3-6

3.6 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 3-10

3.7 AMBIENT AIR QUALITY STATUS (OCTOBER TO DECEMBER, 2017) 3-12

3.8A DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 3-16

3.8B BACKGROUND NOISE LEVELS (OCTOBER TO DECEMBER, 2017) 3-18

3.9 NOISE LEVELS DUE TO TRANSPORTATION 3-18

3.10 SAMPLING LOCATIONS FOR MONITORING SURFACE AND GROUND

WATER QUALITY 3-20

3.11 WATER QUALITY- PHYSICAL PARAMETERS (OCTOBER TO DECEMBER,

2017) 3-22

3.12 SAMPLING LOCATIONS: SOIL QUALITY 3-25



3.13 PHYSICO-CHEMICALS CHARACTERISTICS OF SOIL (OCTOBER TO

DECEMBER, 2017) 3-27

3.14 AREAS UNDER DIFFERENT LANDUSE 3-33

3.15 LIST OF FLORA 3-36

3.16 LIST OF FAUNA 3-38

3.17 DEMOGRAPHIC DATA 3-42

3.18 POPULATION DENSITY 3-43

3.19 LITERACY RATE 3-45

3.20 OCCUPATIONAL STRUCTURE 3-44

3.21 DETAILS OF AMMENITIES AVAILABLE IN STUDY AREA 3-48

4.1 DETAILS OF EMISSION FROM STACK & VENTS 4-11

4.2 SUMMARY OF ISCST3 MODEL OUTPUT 4-18

4.3 PREDICTED AMBIENT AIR QUALITY 4-20

4.4 IMPACT IDENTIFICATION MATRIX 4-28

4.5 CONSTRUCTION & OPERATION STAGE POTENTIAL IMPACTS &

MITIGATIVE MEASURES 4-30

4.6 ENVIRONMENTAL IMPACT MATRIX 4-31

4.7 CUMULATIVE IMPACT CHART 4-32

5.1 PROJECT ENVIRONMENT MONITORING PLAN 5-2

6.1 STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS 6-6

6.2 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES,

SPECIAL HAZARD AND ANTIDOTES 6-7

6.3 OTHER HAZARDS AND CONTROL 6-8

6.4 POSSIBLE ACCIDENT SCENARIOS 6-21

6.5 PROPOSED FACILITIES TO BE MAINTAINED FOR FIRE FIGHTING 6-35

7.1 ENVIRONMENT MANAGEMENT PLAN 7-2



LIST OF FIGURES

FIGURE

NO. TITLE PAGE NO.

1.1 PROJECT SITE LOCATION (GOOGLE MAP) 1-2

1.2 PLOT LAYOUT 1-4

1.3 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1-11

1.4 E.I.A. PLAN & PROCEDURE 1-16

3.1A WIND ROSE DIAGRAM 3-7

3.1B STABILITY CLASS DISTRIBUTION 3-8

3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 3-11

3.3 LOCATION OF AMBIENT NOISE LEVEL MONITORING STATIONS 3-17

3.4 LOCATIONS OF WATER SAMPLING STATIONS 3-21

3.5 LOCATIONS OF SOIL SAMPLING STATIONS 3-26

3.6 MAJOR GEOLOGICAL FEATURES 3-30

3.7 LANDUSE / LANDCOVER 3-34

3.8 DRAINAGE PATTERN 3-41

3.9 POPULATION DENSITY AND SEX RATIO 3-44

3.10 LITERACY RATE 3-46

4.1 IMPACT NETWORK ON ENVIRONMENT 4-2

4.2 ISOPLETHS (EXISTING & PROPOSED) 4-12

6.1 QRA METHODOLOGY 6-2

6.2 FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT 6-3

6.3 HAZARDOUS CHEMICAL STORAGE AREA 6-5

7.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 7-15



COPY OF TORs FROM MoEFCC, NEW DELHI



COMPLIANCE OF TERMS OF REFERENCES (TORs) – MoEFCC, NEW DELHI

Sr. No ToR Point Status

Specific TOR

1. Details on solvents to be used, measures for solvent

recovery and for emissions control.

Company will not use the solvent for dyes

manufacturing.

2. Details of process emissions from the proposed unit

and its arrangement to control.

There will not process emission from the

proposed unit.

3. Ambient air quality data should include VOC, other

process-specific pollutants* like NH3*, chlorine*,

HCl*, HBr*, H2S*, HF*,etc.,(*-as applicable)

Refer Table 3.7, Chapter-3 in EIA Report (Page

No. 3-12)

4. Work zone monitoring arrangements for hazardous

chemicals.

Hazardous Chemicals are within the TLV/ PEL as

per ACGIH recommendation by using gas

monitor and work place ambient air

monitoring.

5. Detailed effluent treatment scheme including

segregation of effluent streams for units adopting

'Zero' liquid discharge.

M/s. S. M. Industries has ETP, Spray Dryer and

Single Stage Vacuum Evaporation system to

achieve zero discharge of waste water.

6. Action plan for odour control to be submitted. Company will adopt the latest technology to

control odour.

7. A copy of the Memorandum of Understanding

signed with cement manufacturers indicating clearly

that they co-process organic solid/hazardous waste

generated.

Company will make the Memorandum of

Understanding signed with cement

manufacturers after getting EC and CTE.

8. Authorization/Membership for the disposal of liquid

effluent in CETP and solid/hazardous waste in TSDF,

if any.

Please refer Annexure-9 in EIA Report.

9. Action plan for utilization of MEE/dryers salts. Company will sell the dryers salts to Tinting

dyes to end user.

10. Material Safety Data Sheet for all the Chemicals are

being used/will be used.


11. Authorization/Membership for the disposal of

solid/hazardous waste in TSDF.


12. Details of incinerator if to be installed. Company will not install the incinerator.

13. Risk assessment for storage and handling of

hazardous chemicals/solvents. Action plan for

handling & safety system to be incorporated.

Risk assessment is referred as Chapter-6 and

Action plan for handling & safety system is

referred as Section 6.1.4.2, Chapter-6 in EIA

Report (Page No. 6-4).

14. Arrangements for ensuring health and safety of

workers engaged in handling of toxic materials.

Occupational health and safety is referred as

Section 6.6, Chapter-6 in EIA Report (Page No.

6-63).

General TOR

1 Executive Summary Refer Chapter-8

2 Introduction

i Details of the EIA Consultant including NABET

accreditation

Refer Chapter-9 & Annexure - 11

ii Information about the project proponent Refer Section – 1.1.1, Chapter-1, Page No. 1-1

iii Importance and benefits of the project Refer Section 1.2.2, Chapter-1, Page No. 1-3

3 Project Description

i Cost of project and time of completion Total capital investment for the proposed

project activities is Rs. 4.0 crores.

Time of completion: 8 Month after getting EC



and CTE.

ii Products with capacities for the proposed project Refer Section 1.2.5, Chapter-1, Page No. 1-5

iii If expansion project, details of existing products

with capacities and whether adequate land is

available for expansion, reference of earlier EC if

any

Refer Section 1.2.5, Chapter-1, Page No. 1-5

iv List of raw materials required and their source along

with mode of transportation

Refer Section 2.3, Chapter-2, Page No. 2-101

v Other chemicals and materials required with

quantities and storage capacities

Refer Table 6.1, Chapter-6, Page No. 6-6.

vi Details of Emission, effluents, hazardous waste

generation and their management

Details of Emission, effluents - Refer Section

2.4.4, Chapter-2, Page No. 2-129,

Details of effluents - Refer Section 2.4.3,

Chapter-2, Page No. 2-120,

Details of hazardous waste generation and

their management - Refer Section 2.4.6,

Chapter-2, Page No. 2-130

vii Requirement of water, power, with source of

supply, status of approval, water balance diagram,

man-power requirement (regular and contract)

Water:

Source of Water Supply – Ground water

Requirement of water = 31 KL/Day

Water Balance is referred as Section 2.4.3,

Chapter-2, Page No. 2-122,

Power:

Requirement of Power = 80 KVA

Source of Power = MGVCL

Man power requirement = 30 Nos. of person

viii Process description along with major equipments

and machineries, process flow sheet (quantities)

from raw material to products to be provided

Refer Section 2.2, Chapter-2, Page No. 2-1.

ix Hazard identification and details of proposed safety

systems

Refer Section 6.1.4, Chapter-6, Page No. 6-4.

x Expansion/modernization proposals Expansion

a Copy of all the Environmental Clearance(s) including

Amendments thereto obtained for the project from

MoEF/SEIAA shall be attached as an Annexure. A

certified copy of the latest Monitoring Report of the

Regional Office of the Ministry of Environment and

Forests as per circular dated 30th

May, 2012 on the

status of compliance of conditions stipulated in all

the existing environmental clearances including

Amendments shall be provided. In addition, status

of compliance of Consent to Operate for the

ongoing Existing operation of the project from SPCB

shall be attached with the EIA-EMP report

Existing Plant was established before 2006 and

copy of CCA before 2006 is attached as

Annexure – 7.

b In case the existing project has not obtained

environmental clearance, reasons for not taking EC

under the provisions of the EIA Notification 1994

and/or EIA Notification 2006 shall be provided.

Copies of Consent to Establish/No Objection

Certificate and Consent to Operate (in case of units

operating prior to EIA Notification 2006, CTE and

CTO of FY 2005-2006) obtained from the SPCB shall

be submitted. Further, compliance report to the

Existing Plant was established before 2006 and

copy of CCA before 2006 is attached as

Annexure – 7.



conditions of consents from the SPCB shall be

submitted

4 Site Details

i Location of the project site covering village,

Taluka/Tehsil, District and State, Justification for

selecting the site, whether other sites were

considered

Refer Section 1.2 Chapter-1, Page No. 1-2.

Proposed Expansion is within the existing

premises

ii A toposheet of the study area of radius of 10km and

site location on 1:50,000/1:25,000 scale on an

A3/A2 sheet. (including all eco-sensitive areas and

environmentally sensitive places)

Refer Figure – 1.4, Chapter-1, Page No. 1-11

iii Details w.r.t. option analysis for selection of site Proposed Expansion is within the existing

premises

iv Co-ordinates (lat-long) of all four corners of the site longitude 72°35'42.93"E and latitude

22°20'55.82"N

v Google map-Earth downloaded of the project site Refer Figure 1.1, Chapter-1, Page No. 1-2.

vi Layout maps indicating existing unit as well as

proposed unit indicating storage area, plant area,

greenbelt area, utilities etc. If located within an

Industrial area/Estate/Complex, layout of Industrial

Area indicating location of unit within the Industrial

area/Estate

Refer Figure 1.2, Chapter-1, Page No. 1-4.

vii Photographs of the proposed and existing (if

applicable) plant site. If existing, show photographs

of plantation/greenbelt, in particular


premises.

viii Landuse break-up of total land of the project site

(identified and acquired), government/private -

agricultural, forest, wasteland, water bodies,

settlements, etc shall be included. (not required for

industrial area)

Refer Table 1.2, Chapter-1, Page No. 1-3.

ix A list of major industries with name and type within

study area (10km radius) shall be incorporated.

Land use details of the study area


x Geological features and Geo-hydrological status of

the study area shall be included


xi Details of Drainage of the project upto 5km radius

of study area. If the site is within 1 km radius of any

major river, peak and lean season river discharge as

well as flood occurrence frequency based on peak

rainfall data of the past 30 years. Details of Flood

Level of the project site and maximum Flood Level

of the river shall also be provided. (mega green field

projects)


Xii Status of acquisition of land. If acquisition is not

complete, stage of the acquisition process and

expected time of complete possession of the land


premises

xiii R&R details in respect of land in line with State

Government policy


premises.

5 Forest and wildlife related issues (if applicable) Not Applicable

6 Environmental Status

i Determination of atmospheric inversion level at the

project site and site-specific micrometeorological

data using temperature, relative humidity, hourly

wind speed and direction and rainfall.

Refer Section 3.1, Chapter-3, Page No. 3-1 to 3-

6.

ii AAQ data (except monsoon) at 8 locations for PM10,

PM2.5, SO2, NOx, CO and other parameters relevant

Refer Table-3.7, Chapter-3, Page No. 3-12.



to the project shall be collected. The monitoring

stations shall be based CPCB guidelines and take

into account the pre-dominant wind direction,

population zone and sensitive receptors including

reserved forests.

iii Raw data of all AAQ measurement for 12 weeks of

all stations as per frequency given in the NAQQM

Notification of Nov. 2009 along with – min., max.,

average and 98% values for each of the AAQ

parameters from data of all AAQ stations should be

provided as an annexure to the EIA Report


iv Surface water quality of nearby River (100m

upstream and downstream of discharge point) and

other surface drains at eight locations as per

CPCB/MoEF&CC guidelines


v Whether the site falls near to polluted stretch of

river identified by the CPCB/MoEF&CC, if yes give

details

Not Applicable

vi Ground water monitoring at minimum at 8 locations

shall be included


vii Noise levels monitoring at 8 locations within the

study area

Refer Table-3.8B, Chapter-3, Page No. 3-18.

viii Soil Characteristic as per CPCB guidelines Refer Table 3.13, Chapter-3, Page No. 3-27.

ix Traffic study of the area, type of vehicles, frequency

of vehicles for transportation of materials,

additional traffic due to proposed project, parking

arrangement etc

Truck – 2 Nos./Day

Tempo – 5 Nos./Day

Small Tempo -10 Nos./Day

Car – 3 Nos./Day

x Detailed description of flora and fauna (terrestrial

and aquatic) existing in the study area shall be given

with special reference to rare, endemic and

endangered species. If Schedule-I fauna are found

within the study area, a Wildlife Conservation Plan

shall be prepared and furnished.

Refer Section 3.8, Chapter-3, Page No. 3-36 to

3-40.

xi Socio-economic status of the study area Refer Section 3.10, Chapter-3, Page No. 3-42.

7 Impact and Environment Management Plan

i Assessment of ground level concentration of

pollutants from the stack emission based on site-

specific meteorological features. In case the project

is located on a hilly terrain, the AQIP Modelling shall

be done using inputs of the specific terrain

characteristics for determining the potential

impacts of the project on the AAQ. Cumulative

impact of all sources of emissions (including

transportation) on the AAQ of the area shall be

assessed. Details of the model used and the input

data used for modeling shall also be provided. The

air quality contours shall be plotted on a location

map showing the location of project site, habitation

nearby, sensitive receptors, if any

Refer Section 4.2.2.2, Chapter-4, Page No. 4-10

to 4-20.

ii Water Quality modeling – in case of discharge in

water body

Not Applicable as unit is ZLD.

iii Impact of the transport of the raw materials and

end products on the surrounding environment shall

be assessed and provided. In this regard, options for

transport of raw materials and finished products

and wastes (large quantities) by rail or rail-cum road


to 4-26.



transport or conveyor-cum-rail transport shall be

examined

iv A note on treatment of wastewater from different

plant operations, extent recycled and reused for

different purposes shall be included. Complete

scheme of effluent treatment. Characteristics of

untreated and treated effluent to meet the

prescribed standards of discharge under E(P) Rules


v Details of stack emission and action plan for control

of emissions to meet standards


vi Measures for fugitive emission control Refer Section 7.2.3, Chapter-7, Page No. 7-6.

vii Details of hazardous waste generation and their

storage, utilization and management. Copies of

MOU regarding utilization of solid and hazardous

waste in cement plant shall also be included. EMP

shall include the concept of waste-minimization,

recycle/reuse/recover techniques, Energy

conservation, and natural resource conservation.


viii Proper utilization of fly ash shall be ensured as per

Fly Ash Notification, 2009. A detailed plan of action

shall be provided

Not Applicable

ix Action plan for the green belt development plan in

33 % area i.e. land with not less than 1,500 trees

per ha. Giving details of species, width of

plantation, planning schedule etc. shall be included.

The green belt shall be around the project boundary

and a scheme for greening of the roads used for the

project shall also be incorporated


x Action plan for rainwater harvesting measures at

plant site shall be submitted to harvest rainwater

from the roof tops and storm water drains to

recharge the ground water and also to use for the

various activities at the project site to conserve

fresh water and reduce the water requirement from

other sources

Company will make action plan for rainwater

harvesting measures at plant site.

xi Total capital cost and recurring cost/annum for

environmental pollution control measures shall be

included

Total capital investment for the proposed

project activities is Rs. 4.0 crores.

xii Action plan for post-project environmental

monitoring shall be submitted

Refer Table 5.1, Chapter-5 in EIA Report (Page

No. 5-2)

xiii Onsite and Offsite Disaster (natural and Man-made)

Preparedness and Emergency Management Plan

including Risk Assessment and damage control.

Disaster management plan should be linked with

District Disaster Management Plan

Refer Section 6.2, Chapter – 6, Page No. 6-35.

8 Occupational health

i Plan and fund allocation to ensure the occupational

health & safety of all contract and casual workers

Company will allot Rs.10 Lakh for the

occupational health & safety of all contract and

casual workers.

ii Details of exposure specific health status evaluation

of worker. If the workers’ health is being evaluated

by pre designed format, chest x rays, Audiometry,

Spirometry, Vision testing (Far & Near vision, Colour

vision and any other ocular defect) ECG, during pre

placement and periodical examinations give the

details of the same. Details regarding last month



6-63).



analyzed data of above mentioned parameters as

per age, sex, duration of exposure and department

wise

iii Details of existing Occupational & Safety Hazards.

What are the exposure levels of hazards and

whether they are within Permissible Exposure level

(PEL). If these are not within PEL, what measures

the company has adopted to keep them within PEL

so that health of the workers can be preserved



6-63).

iv Annual report of heath status of workers with

special reference to Occupational Health and

Safety.

Once in a period of 6 months, to ascertain

physical fitness of the person to do the

particular job

9 Corporate Environment Policy

i Does the company have a well laid down

Environment Policy approved by its Board of

Directors? If so, it may be detailed in the EIA report

Refer Section 7.3.1, Chapter – 7, Page No. 7-16.

ii Does the Environment Policy prescribe for standard

operating process / procedures to bring into focus

any infringement / deviation / violation of the

environmental or forest norms / conditions? If so, it

may be detailed in the EIA


iii What is the hierarchical system or Administrative

order of the company to deal with the

environmental issues and for ensuring compliance

with the environmental clearance conditions?

Details of this system may be given.


iv Does the company have system of reporting of non

compliances / violations of environmental norms to

the Board of Directors of the company and / or

shareholders or stakeholders at large? This

reporting mechanism shall be detailed in the EIA

report


10 Details regarding infrastructure facilities such as

sanitation, fuel, restroom etc. to be provided to the

labour force during construction as well as to the

casual workers including truck drivers during

operation phase.

Infrastructure facilities such as sanitation,

restroom etc. shall be provided to the labour

force as well as to the casual workers including

truck drivers during operation phase.

11 Enterprise Social Commitment (ESC)

i Adequate funds (at least 2.5 % of the project cost)

shall be earmarked towards the Enterprise Social

Commitment based on Public Hearing issues and

item-wise details along with time bound action plan

shall be included. Socio-economic development

activities need to be elaborated upon

Refer Section 7.8,Chapter – 7 Page No. 7-22

12 Any litigation pending against the project and/or

any direction/order passed by any Court of Law

against the project, if so, details thereof shall also

be included. Has the unit received any notice under

the Section 5 of Environment (Protection) Act, 1986

or relevant Sections of Air and Water Acts? If so,

details thereof and compliance/ATR to the notice(s)

and present status of the case.

There is no any litigation pending against the

project and/or any direction/order passed by

any Court of Law against the project.

13 A tabular chart with index for point wise compliance

of above TORs.

As Above

14 The TORs prescribed shall be valid for a period of

three years for submission of the EIA-EMP reports.

Complied



May 07, 2018

UNDERTAKING

We S.M. INDUSTRIES, own this EIA Report for proposed Expansion of Dyes & New

Pigments in Existing Unit at Survey No. 192/4, Village: Sokhada, Taluka: Khambhat,

Dist: Anand, Gujarat – 388620

Thanking You,

Yours faithfully,



Declaration by Experts Contributing to the EIA Report of

M/s. S.M. INDUSTRIES

SURVEY NO. 192/4, VILLAGE: SOKHADA,

TALUKA: KHAMBHAT, DIST. ANAND,

GUJARAT – 388 620

EIA COORDINATOR

Name Signature

Mr. Chetan R. Kabariya



Declaration by Head of the Organization

I, Jayeshkumar S. Patel hereby confirm that the above mentioned team members were

involved in preparation of EIA Report of M/s. S.M. Industries I also confirm that I shall be

fully accountable for any misleading information mentioned in this statement.


Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat 1-1

CHAPTER – 1

INTRODUCTION

1.1 INTRODUCTION

M/s. S. M. Industries engaged in manufacturing dyes located at Survey No. 192/4, Village:

Sokhada, Taluka: Khambhat, Dist: Anand – 388 620, Gujarat.

Now, company is going for expansion of existing manufacturing unit by increasing

production capacity of existing products and addition of new products within existing

premises.

1.1.1 IDENTIFICATION OF THE PROJECT PROPONENT

The Board of Directors of the company are very experienced industrialists. They are:

Sr. No. Name Designation

1 Mr. Rakesh Shah B.E Chem

2 Mr. Dilip Shah B.Sc

3 Mrs. Jaisriben Shah B.Com

4 Mrs. Kavita Shah B.Com

1.1.2 STATUTORY REQUIREMENT

As per Schedule of the EIA Notification, 2006 as amended till date, the proposed expansion

project is covered under project or activity 5(f) requires prior Environmental Clearance (EC)

and they are categorized as Category ‘A’, requiring Environmental Clearance (EC) from the

EAC, New Delhi.



1.2 PROJECT DETAILS

1.2.1 PROJECT SITE LOCATION

FIGURE - 1.1

PROJECT SITE LOCATION (GOOGLE MAP)



1.2.2 IMPORTANCE AND BENEFITS OF PROJECT

Based on informal survey of the market with various manufacturers and traders, company

has found that there is a big potential for the range of the products that are intended to be

manufactured in domestic as well as in international market. To meet this demand,

company proposes expansion of existing manufacturing unit. The project will also save forex

as certain products import will be reduced. This will also generate direct and indirect

employment opportunity for various levels of people.

1.2.3 TOTAL PROJECT COST

Total capital investment for the proposed project activities is Rs. 4.0 crores.

TABLE-1.1

PROJECT COST BREAK-UP

Sr.

No. Description

Project Cost (Rs in Crore)

Existing Total Proposed

1 Land Cost 0.25 0.25

2 Building 0.1 0.50

3 Plant & Machinery 0.6 2.25

4 Environment Management System 0.1 1.0

Total 1.05 4.0

1.2.4 TOTAL LAND ACCQUIRED AND ITS BREAK-UP

Total Land Area: 4,452 m2

TABLE-1.2

LAND BREAK-UP

SR.

NO. LAND USE

AREA (SQ. MT.)

EXISTING TOTAL

PROPOSED

1 Administration office & lab 65 100

2 Process 525 1250

3 Storage 65 125

4 Parking 0 300

5 Effluent treatment plant 350 500

6 Green Belt 3447 2177

Total 4,452 4,452



FIGURE - 1.2

PLOT LAYOUT



1.2.5 PRODUCTS DETAILS

TABLE-1.3

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr.

No.

Products CAS No. LD50 –

Oral -Rat

(mg/Kg)

End Use Production Capacity

(MT/Month)

Existing Total

after

Proposed

Expansion

1 Azo Dyes (Crude)* -- --

Textile

Industries

5 100

Azo Dyes (Blending & Grinding)* 10

2 AMARANTH 915-67-3 -

3 BISMARK BROWN 8005-77-4 -

4 CARMOSINE 3567-69-9 -

5 CHROM BLACK T 1787-61-7 17590

6 CHRYSODINE 532-82-1 >2000

7 CRYSOPHYNINE 2870-32-8 -

8 MORDENT YELLOW 20 6471-07-4 -

9 SUNSET YELLOW 2783-94-0 -

LIQUID DYES SOLN OF

ABOVE MATERIAL

-- --

PIGMENTS ---

10 PIGMENT ORANGE 5 3468-63-1 980

11 PIGMENT ORANGE 13 3520-72-7 >5000

12 PIGMENT ORANGE 34 15793-73-4 >5000

13 PIGMENT RED 2 6041-94-7 -

14 PIGMENT RED 12 6410-32-8 980

15 PIGMENT RED 48 7023-61-2 -

16 PIGMENT RED 53 5160-02-1 >2000

17 PIGMENT RED 57.1 5281-04-9 -

18 PIGMENT RED 63 6417-83-0 -

19 PIGMENT RED 112 6535-46-2 980

20 PIGMENT RED 170 2786-76-7 >1500

21 PIGMENT VIOLET 23 6358-30-1 >5000

22 PIGMENT YELLOW 1 2512-29-0 -

23 PIGMENT YELLOW 12 6358-85-6 980

24 PIGMENT YELLOW 14 5408-75-7 -



25 PIGMENT YELLOW 17 4531-49-1 11250

26 PIGMENT YELLOW 61 12286-65-6 -

PIGMENT PASTE OF ALL

ABOVE PIGMENTS

-- -

SOLVENT DYES* ---

27 SOLVENT ORANGE 1 2051-85-6 >5000

28 SOLVENT RED 24 85-83-6 -

29 SOLVENT RED 27 1320-06-5 -

30 SOLVENT YELLOW 2 60-11-07 200

31 SOLVENT YELLOW 14 842-07-09 -

ACID DYES* ---

32 ACID RED 1 3734-67-6 800

33 ACID RED 4 2611-82-7 -

34 ACID RED 18 5413-75-2 -

35 ACID RED 73 1658-56-6 -

36 ACID RED 88 10169-02-5 -

37 ACID RED 97 6459-94-5 -

38 ACID RED 114 12220-20-1 -

39 ACID RED 119 6548-30-7 -

40 ACID RED 128 6222-63-5 >5000

41 ACID RED 137 2611-82-7 -

42 ACID RED 214 6656-02-6 -

43 ACID RED 231 6360-06-01 >5000

44 ACID YELLOW 1 846-70-8 -

45 ACID YELLOW 11 6359-82-6 -

46 ACID YELLOW 17 6359-98-4 -

47 ACID YELLOW 23 1934-21-0 -

48 ACID YELLOW 36 587-98-4 5000

49 ACID YELLOW 42 6375-55-9 -

50 ACID YELLOW 59 5601-29-6 -

51 ACID YELLOW 79 12220-70-1 >5000

52 ACID BLACK 1 1064-48-8 2000

53 ACID BLACK 18 6227-09-4 >8000

54 ACID BLACK 21 10142-78-6 >5000

55 ACID BLACK 26 6406-45-7 >5000

56 ACID BLACK 41 5850-37-33 -

57 ACID BLACK 52 5610-64-0 -

58 ACID BLACK 58 12218-

949/

71839-85-5

--

59 ACID BLACK 63 32517-36-5 -

60 ACID BLACK 194 61931-02-0 >5000

61 ACID BLACK 210 99576-15-5 >5000

62 ACID BLUE 158 6370-08-7 -

63 ACID BROWN 14 5850-16-8 -



64 ACID BROWN 28 12238-94-7 -

65 ACID BROWN 121 6487-04-3 >5000

66 ACID GREEN 19 4587-81-2 >2000

67 ACID ORANGE 7 633-96-5 >3200

68 ACID ORANGE 10 1936-15-8 -

69 ACID ORANGE 30 5572-43-0 -

70 ACID ORANGE 72 6408-27-1 >3200

LIQUID DYES SOLN OF

ABOVE MATERIAL

-- -

DIRECT DYES* ---

71 DIRECT BLACK NB -- -

72 DIRECT BLACK 19 6428-31-5 300

73 DIRECT BLACK 22 6473-13-8 -

74 DIRECT BLACK 168 85631-88-5 -

75 DIRECT BLUE G -- -

76 DIRECT BLUE 15 6428-60-0 -

77 DIRECT SKY BLUE FB -- -

78 DIRECT FAST VIOLET

2RL

-- -

79 DIRECT ORANGE 34 12222-37-6 -

80 DIRECT RED 7 70209-93-7 -

81 DIRECT RED 23 3441-14-3 >5000

82 DIRECT RED 26 3617-80-7 -

83 DIRECT RED 80 2610-10-8 -

84 DIRECT RED 81 2610-11-9 1048

85 DIRECT RED 89 12217-67-3 >2000

86 DIRECT RED 239 60202-35-9 -

87 DIRECT YELLOW 4 3051-11-4 -

88 DIRECT BROWN NB -- -

REACTIVE DYES* ---

89 REACTIVE BLACK CNN -- 2000

90 REACTIVE BLACK 5 12225-25-1 2500

91 REACTIVE BLACK 8 12225-26-2 -

92 REACTIVE ORANGE 7 12225-83-1 -

93 REACTIVE ORANGE 122 12220-12-1 -

94 REACTIVE RED 3BS 93050-79-4 >5000

95 REACTIVE RED M 5B 12226-03-

8/ 17804-

49-8

-

96 REACTIVE RED 120 61951-82-4 -

97 REACTIVE YELLOW 15 12226-47-0 -



100 REACTIVE YELLOW 160 129898-77-

7 2000

Total 15 100



1.2.6 REGULATORY FRAMEWORK

For proposed expansion project; following assumptions has been considered:

Total Production Capacity 100 MT/Month – Dyes and Pigments

Project Cost 4.0 Crores

Total Plot Area 4,452 m

2

Total working days in a year 330

Raw material storage facility 01 (one) month

Finished product storage 50 tons

Solvent Storage facility 30 days

1.2.7 EXISTING AND ADDITIONAL MAJOR EQUIPMENTS AND MACHINERIES

Sr. No. Equipments and machineries Nos. Capacity

1 Sprey Dryer 1 1200 lit/hr



1.3 PROJECT SETTING

1.3.1 LOCATION

M/s. S. M. Industries is located at Survey No. 192/4, Village: Sokhada, Taluka: Khambhat,

Dist: Anand – 388 620, Gujarat at longitude 72°35'42.93"E and latitude 22°20'55.82"N.

The industrial estate, wherein M/s. S. M. Industries is located, is near Khambhat, Vadodara

and Ahmedabad which are all important industrial and commercial centers of Gujarat and

India. The nearest large city is Khambhat, which is about 5.0 km away from project site.

Water for industrial purpose is available from bore well (1 no.). Development of

Communication systems is good in the region. Sources of water in the region include cannel,

river, and ground water resources. Common TSDF of M/s. Nandesari Environment Control

Ltd, Nandesari are about 52.0 km away respectively from the project site.

The salient features of the site are as under:

1. Minimum distances:

a) From City : Khambhat (around 5.0 Km away)

(Population 24,33,787 – approx.)

b) Railway station : Khambhat (around 5.0 Km away)

c) Historical Site : None

d) Sanctuaries : None

e) Highway : National highway No. 8, State Highway No. 16

f) Sea coast : approximately 30 km

g) TSDF (BEIL) site : 52 Km (approx.)

2. Use of forest land : None

3. Use of prime agricultural land : None

4. Planned submergence : None

5. Displacement of population : None



• Within 10 km Influence Zone

- No Defense Installation

- No Biosphere Reserve

- No National Park/ Wild Life Sanctuary

- No Ecologically sensitive area

1.3.2 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1.3.2.1 METHOD OF DATA PREPARATION

Key infrastructure features have been extracted from Survey of India (SoI) topographical

maps of 1:50,000 scale. The features have been updated using satellite data and have been

verified with ancillary information derived from TTK maps and guide maps. The locations of

the settlement have been extracted from Census of India (CoI) maps and have been verified

by using SoI topographical maps and satellite data.

1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

The distance of railways and National and State highways are presented in Table 1.4 below:

TABLE 1.4

DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

Sr.

No. Nearest Infrastructure Feature Distance from Project Site

1. State Highway SH 16 2.20 km East

2. Railway Line – Khambhat Railway Station 5.0 km South East

3. Khambhat Town 5.0 km South East

5. Anand City 40.0 Km North East

6. Mahisagar estuary 4.0 km South West

7. Vadodara Airport 60.0 Km East

8. Protected Area None within 15 Km

(Courtesy: Environmental Information Centre, New Delhi)



1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

A map depicting administrative boundaries up to Taluka level, showing locations of towns

and villages along with National and State highways, major and medium roads and railways

is presented as Figure 1.5. The map also shows the water bodies and forest boundaries for

better understanding of project area. The map marks the area within 10 km with the project

site as the center.

FIGURE-1.4

KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS



1.4 PURPOSE OF EIA

The purpose of EIA study is to critically analyze the construction and operation phase

activity of proposed expansion project activity with respect to operation activities, materials

consumption, air emission, hazardous waste generation and control measures to reduce the

pollution and to delineate an environmental management plan along with

recommendations and suggestions based on the finalized TOR by EAC, New Delhi.

1.5 OBJECTIVES OF EIA

The main objectives of the study are

1) To assess the background environmental status.

2) To identify potential sources of pollution.

3) To predict and evaluate the impact on environment along with pollution control

measures taken.

4) To prepare a comprehensive Environment and Disaster Management Plan.

1.6 METHODOLOGIES FOR EIA

Taking into consideration proposed expansion project activities, guidelines and TOR, an area

of 10 km radius from the center of the project has been selected and is designated as the

study area for the purpose of EIA study. Since this is expansion of existing unit, data were

collected and evaluated. All the components of TOR were studied and incorporated in this

report.

1.6.1 Base Line Environmental Condition

The samples of ambient air, ground and surface water and soil are collected and analysed as

per the standard methods for establishing the baseline data and to determine the impact of

proposed activity on the same.

1.6.1.1 Ambient Air Environment

The air environment around the plant was studied by setting up ten locations within the

study area of 10 Km radius from the project site and collection and monitoring the site

specific meteorological data, viz. wind speed and direction, humidity, rainfall and ambient

temperature. Design of network for ambient air quality monitoring location is based on

guidelines provided by CPCB. The ambient air samples were collected and analysed for SPM,

RSPM, SO2 and NOx for prediction, evaluation and assessment of potential impact on

ambient air environment.



1.6.1.2 Ground And Surface Water Environment

The water required for domestic and industrial uses is being made available from ground

water (bore well – 1 no.). Hence, to assess the Physico-chemical quality of the water, a

number of water samples were collected and analyzed for pollution parameters viz., pH,

TDS, TSS, Turbidity, BOD3, COD, Fluorides, Chlorides, Sulphates, Nitrates, Ammonical

Nitrogen, Hardness, Alkalinity, Iron, Oil & Grease, etc. and heavy metals, in order to find out

the contamination, if any.

1.6.1.3 Noise Environment

Noise pollution survey was conducted in the study zone for evaluating existing status. The

anticipated noise sources were automobile activities, which are likely to be increased due to

proposed expansion activity. Noise levels were also recorded at the noise generating places

and in the surrounding villages for evaluating general scenario of the study area. Hourly

equivalent sound levels (Leq) were also recorded for calculating Day and Night noise levels

in the surrounding villages.

1.6.1.4 Soil Environment

Soil sampling and analysis was carried out to assess physico-chemical characteristics of the

soils and delineate existing cropping pattern, existing land use and topography, within the

study area.

1.6.1.5 Biological Environment

Keeping in view, the importance of biological component of total environment due to the

proposed expansion project, biological characterization of terrestrial and aquatic

environments, changes in species diversity of flora and fauna in terrestrial as well as aquatic

systems were studied for impact analysis due to proposed project activity.

1.6.1.6 Socio-economic Environment

Demographic and related socio-economic data was collected from census handbook and EIC

to assess socio-economic status of study area. Assessment of impact on significant

historical, cultural, and archeological sites/places in the area and economic and employment

benefit arisen out from the project is studied.



1.6.2 Identification of Source of Pollution

Detailed study of manufacturing process for existing and proposed scenario is carried out

along with input and output of materials, water, and wastewater as well as infrastructure

facilities available.

1.6.3 Evaluation of Pollution Control and Environmental Management System

The qualitative and quantitative analyses of various pollution sources as well as evaluation

of pollution control system have been carried out.

1.6.4 Evaluation of Impact

A comprehensive evaluation of environmental impact with reference to proposed expansion

activities are carried out.

1.6.5 Preparation of Environmental Management Plan

A comprehensive Environmental Management Plan has been prepared covering all the

aspects of pollution prevention measures, Air and Water Pollution Control measures,

Hazardous Waste Management, Environmental Surveillance and Environmental

Management Plan.

The present EIA report is prepared as per the TOR and monitoring carried out during post

monsoon season of October to December, 2017. The baseline environmental conditions

have been established through field monitoring and literature survey. The contents of EIA

report, details of data collection and source of secondary data are presented in Figure 1.6.

1.7 STRUCTURE OF REPORT

Environment Impact and Risk Assessment (EIRA) study is carried out as per guidelines

prescribed and by TOR given EAC, Ministry of Environment, Forests and Climate Change

(MoEFCC), New Delhi.

• Chapter-1: Introduction provides an Introduction of company, their premises and

surrounding areas. It is also expressing the basic objectives and methodologies for EIA

studies and work to be covered under each Environment component.

• Chapter-2: Project Description and Infrastructural Facilities includes Project Description

and Infrastructure facilities delineating all industrial and environmental aspect of

operation phase activities as well as process details of existing and proposed scenario.

This chapter gives information about storage and handling, water and wastewater

quantitative details, air pollution and control system, sludge storage facility, utilities,

greenbelt and safety measures for existing as well as for proposed expansion. It also



provides information about existing Environmental Management facilities available at

the project site.

• Chapter 3 covers Baseline Environmental Status including meteorological details,

Identification of baseline status of Environmental components of the surrounding area

covering air, water and land environment. Also presents a study of land use pattern,

Biological Environment & Socio-Economic Environment giving details about Bharuch city.

Metropolitan Region and the study area in terms of land use pattern, biological

environment, and socio-economic environment.

• Chapter 4 deals with Identification and Prediction of Impact, which provides

quantification of significant impacts of the proposed expansion project activity of plant

on various environmental components. Evaluation of proposed pollution control

facilities has been presented.

• Chapter 5 deals with Environmental Monitoring Plan.

• Chapter 6 describes additional studies i.e. Risk analysis and Disaster management plan

that shall be adopted by the company.

• Chapter 7 describes Environment Management Plan (EMP) to be adopted for mitigation

of anticipated adverse impacts if any and to ensure acceptable impacts.

• Chapter 8 describes Summary of the Project.

• Chapter 9 describes Details of Consultants Engaged.



FIGURE – 1.5

E.I.A. PLAN & PROCEDURE

RECONNAISSANCE SURVEY OF PLANT ANNUAL REPORT

MARKET ASSESSMENT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS

DATA ON METEOROLOGY, SOCIO-ECONOMIC STATUS &

BASIC AMENITIES

SITE VISITS AND INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS OF INDIA

INDIAN METEOROLOGICAL DEPT

ENVIRONMETAL INFORMATION CENTRE

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED

PLANT

FACILITY DESCRIPTION IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

RISK ASSESSMENT

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR



CHAPTER - 2

PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND

M/s. S. M. Industries engaged in manufacturing dyes located at Survey No. 192/4, Village:

Sokhada, Taluka: Khambhat, Dist: Anand – 388 620, Gujarat.

2.2 MANUFACTURING ACTIVITIES

Manufacturing activities in proposed expansion project include various processes. The

activities also include operation of various utilities. The manufacturing process is described

in details in following sections.

1. AZO DYES (CRUDE)

Manufacturing of all dyes mentioned in products list are known as azodyes.

• AZO DYES

2. AMARANTH

Process Description:

It is mono azo dyes for which first make Sodium Nepthionate is diazotized with sodium

nitrite in presence hydrochloric acid at bellow 5 deg temp and stir for 2 hr. Then dizo

component is coupled with R Salt in alkaline medium at 5 deg temperature. Stir for 5 hr and

isolate at 70 deg then transfer to spray dry.

Chemical Reaction:

C10H9O3SN + NaNO2 + HCl ---------→ C10H7O3SN=NCl

C10H7O3SN=NCl + C10H8O7S2 + Na2CO3 -------→ C20H11O10S3N2Na3 + CO2↑ + NaCl



Mass Balance:

INPUT QTY(Kg) OUTPUT QTY(Kg)

Sodium Nepthionate 0.350 CO2 0.145

HCl 0.500 Washing

Regenerate

3.0

Sodium Nitrite 0.125 Dye 1.00

R.Salt 0.450 Water Evaporated 3.08

Soda Ash 0.500

Salt(NaCl) 0.300

Water 2.500

Ice 2.500

Total 7.225 Total 7.225

3. BISMARK BROWN


It is Poly azo dyes for which first make m-Toludibelenedinamine (MTD) is diazotized with

sodium nitrite in presence hydrochloric acid at bellow 0 deg temp. Then dizo component is

coupled with m.Toludibelenedinamine (MTD) in Acidic medium at 5 deg temperature. Stir

for 5 hr. it is directy intercouple one another.

Chemical Reaction:

(C7H10N2)3 + 2NaNO2 + HCl ---------→ C21H24N8 + NaCl + H2O

Mass Balance:


MTD 0.950 CO2 0.00

HCl 1.500 Washing

Regenerate

4.000

NaNO2 0.360 DYE 1.010

ICE 3.000 Water Evaporated 4.05

SALT 0.250

WATER 3.000

TOTAL 9.06 TOTAL 9.06



4. CARMOSINE



nitrite in presence hydrochloric acid at bellow 5 deg temp. and stir for 2 hr. Then dizo

component is coupled with N W Acid in alkaline medium at 5 deg temperature. Stir for 5 hr

and isolateat 70deg then transfer to spray dry.

Chemical Reaction:


C10H7O3SN=NCl + C10H8O4S + Na2CO3 -------→ C20H13O7S2N2Na2 + CO2↑ + NaCl

Mass Balance:


Sodium Nepthionate 0.525 Co2 0.220

HCl 0.750 Washing

Regenerate

4.0


N W Acid 0.480 Water Evaporated 4.325

Soda Ash 0.750

Salt(NaCl) 0.400

Water 3.500

Ice 3.000




5. CHROME BLACK T


4-Amino-3-Hydroxy-7-Nitronaphthalene-1-sulfonic acid diazo and Naphthalene-1-ol

matches will result in aqueous solution with formic acid chromium. Heating at 115 oC for 2

hr. and then into the same batch of have no complexation half of the dyes and sodium

hydroxide move into alkaline, drying. The component of product is about 2 to 3 moose

single atoms chromium azo dyes.

Chemical Reaction:

C10H6O6N3S+C10H8O+NaOH →C20H13O7N3SNa+NaCl

Mass Balance:


6 nitro diazo 0.285 Washing

Regenerate

1.190

HCl 1.000 Dye 0.590

Alpha Napthol 0..145 Water Evaporated 3.910

Chromium sulphate 0.600

NaOH 0.060

Water 1.500

Ice 2.100




6. CHRYSODINE


It is mono azo dyes for which first make Aniline is diazotized with sodium nitrite in presence

hydrochloric acid at bellow 0 deg temp. and stir for 2 hr. Then dizo component is coupled

with m.Phenylediamine (M.P.D.) in Acidic medium at 5 deg temperature. Stir for 5 hr.

Chemical Reaction:

C6H7N1 + NaNO2 + HCl ---------→ C6H7N=NCl + NaCl

C6H7N=NCl + C6H8N2 + HCl -------→ C12H15N4 + HCl

Mass Balance:


ANILINE 0.415 CO2 0.00

HCl 1.000 Washing

Regenerate

1.000


M.P.D. 0.485 Water Evaporated 6.530

Water 3.200

Ice 3.100




7. CRYSOPHYNINE


This is diazo Dyes in this process DASDA is react with Sodium Nitrite (2 mole) and make it

Diazo in presence of Hcl And ice. Then above Diazo is Coupled with 2 mole of Phenol in

Alkaline medium. Then ethyoxilate the reaction no 2 in Autoclave.

Chemical Reaction:

C14H14N2O6S2 + 2(NaNO2) + HCl --- → C14H10O6S22(N=NCl) + H20

C14H10O6S22(N=NCl) 2(C6H6O)+NaOH --- →C26H18O8S2Na2+H2O+NaCl

Mass Balance:


DASDA 0.418 CO2 0.00

HCl 0.800 Washing

Regenerate

2.775


PHENOL 0.190 Water Evaporated 3.053

NaOH 0.180

Salt(NaCl) 0.200

Water 2.500

Ice 2.100

Ethyle Chloride 0.123




8. MORDENT YELLOW 20


It is mono azo dyes for which first make Amido G.Salt is diazotized with sodium nitrite in

presence hydrochloric acid at bellow 0 deg temp. and stir for 2 hr. Then dizo component is

coupled with Salicylic Acid in alkaline medium at 5 deg temperature. Stir for 5 hr and

isolateat 70deg then transfer to spray dry.

Chemical Reaction:

C10H9S2O6N1 + NaNO2 + HCl ---------→ C10H9S2O6N=NCl

C10H9S2O6N=NCl + C7H6O3 + NaOH -------→ C17H97S2N2Na3O9 + NaCl

Mass Balance:


Amido G.Salt 0.700 CO2 0.150

HCl 0.450 Washing

Regenerate

2.005


Salicylic Acid 0.345 Water Evaporated 3.447

Soda Ash/NaOH 0.350

Salt(NaCl) 0.300

Water 2.200

Ice 2.100




9. SUNSET YELLOW


It is mono azo dyes for which first make Sulphanilic Acid is diazotized with sodium nitrite in

presence hydrochloric acid at bellow 5 deg temp. and stir for 3hr. Then dizo component is

coupled with 1mole of Schaeffers Acid in alkaline medium at 5 deg temperature. Stir for 5

hr and isolate at 60 deg. celcius then transfer to spray dry.

Chemical Reaction:

C6H7O3S1N1 + NaNO2 + HCl ---------→ C6H5O3S1N=NCl

C6H5O3S1N=NCl + C10H8O4S + NaOH + Na2Co3 -------→ C16H10O7S2N2Na2 + NaCl +

CO2↑

Mass Balance:

INPUT QTY (Kg) OUTPUT QTY (Kg)

Sulphanilic Acid 0.300 CO2 0.135

HCl 0.500 Washing

Regenerate

4.600


Schaeffers Acid 0.390 Water Evaporated 2.760

NaOH 0.165

Salt(NaCl) 0.300

Water 2.600

Ice 3.700

Na2CO3 0.220




• PIGMENTS:

10. PIGMENT ORANGE 5


2,4-Dinitrobenzenamine diazotization, and Naphthalen-2-ol coupling.

Chemical Reaction:

C6H5N3O4 + NaNO2 → C6H3N2O4N=N + H2O

C6H3N2O4N=N + C10H8O → C16H10N4O5 + NaCl

Mass Balance:


2-5 dinitro aniline 0.183 CO2 0.000

HCl 0.575 Washing

Regenerate

1.005


Β Napthol 0.144 Water Evaporated 5.027

NaOH 0.100

Water 3.200

Ice 2.100






4-(4-Amino-3-chlorophenyl)-2-chlorobenzenamine double nitrogen, and P.M.P. (2 Moore)

coupling.

Chemical Reaction:

C12H8Cl2N2 + 2* NaNO2 + HCl → C12H6Cl2 ( N=NCl)*2 + NaCl

C12H8Cl2 ( N=NCl)*2 + 2*(C9H7ON2) + NaOH → C30H20Cl2N8O2 + NaCl

Mass Balance:


DICHLORO

BENZEDINE

0.249 Washing

Regenerate

1.005

HCl 0.375 Dye 0.610

Sodium Nitrite 0.140 Water Evaporated 5.997

PMP 0.348

NaOH 0.200

Water 4.200

Ice 2.100






4-(4-Amino-3-chlorophenyl)-2-chlorobenzenamine double nitrogen, and 3-Methyl-1-p-tolyl-

1H-pyrazol-5(4H)-one (2 Moore) coupling.

Chemical Reaction:


C12H8Cl2 ( N=NCl)*2 + 2*(C11H11ON2) + NaOH → C34H28Cl2N8O2 + NaCl

Mass Balance:


DI CHLOROBENZEDINE 0.249 Washing

Regenerate

1.005

HCl 0.375 Dye 0.652


PTMP 0.390

NaOH 0.200

Water 4.200

Ice 2.100




13. PIGMENT RED 2


2,5-Dichlorobenzenamine diazotization, and 3-Hydroxy-N-phenyl-2-naphthamide coupling.

Chemical Reaction:

C6H5Cl2N + NaNO2 + HCl → C6H5Cl2N=NCl + NaCl

C6H5Cl2N=NCl + C17H12O2N + NaOH → C23H15Cl2N3O2 + NaCl

Mass Balance:


2 5 dichloroaniline 0.162 Washing

Regenerate

1.005

HCl 0.375 Dye 0.440


3 Hydroxy Neptelinamide 0.260

NaOH 0.150

Water 4.200

Ice 2.100




14. PIGMENT RED 12


2-Methyl-4-nitrobenzenamine diazotization, and 3-Hydroxy-N-o-tolyl-2-naphthamide

coupling.

Chemical Reaction:

C7H8O2N2 + NaNO2 + HCl → C7H6O2NN=NCl + NaCl

C7H6O2NN=NCl + C18H15O2N + NaOH → C25H20N4O4 + NaCl

Mass Balance:


P-Nitro Toludine 0.152 Washing

Regenerate

1.005

HCl 0.375 Dye 0.440


Hydroxy Nepthio

toudide

0.305

NaOH 0.150

Water 4.200

Ice 2.100




15. PIGMENT RED 48


2-Amino-4-chloro-5-methylbenzenesulfonic acid diazotization, and 3-Hydroxy-2-naphthoic

acid coupling, and then into calcium salt.

Chemical Reaction:

C7H8O3NSO3Cl + NaNO2 + HCl → C7H6 O3SClN=NCl + NaCl

C7H6 O3SClN=NCl + C11H10O3+NaOH → C18H15ClN2O6S + NaCl

Mass Balance:


Chlorosulpho

toludine

0.220

HCl 0.500 Washing

Regenerate

1.005


3 hydroxy nepthionic

acid

0.188 Water Evaporated 5.048

NaOH 0.200

Water 3.200

Ice 2.100




16. PIGMENT RED 53


2-Amino-5-chloro-4-methylbenzenesulfonic acid diazotization, and Naphthalen-2-ol

coupling, and then into barium salt.

Chemical Reaction:

C10H9ON + NaNO2 + HCl → C10H7 ON=NCl + NaCl

C10H7 ON=NCl + C7H7O3SCl + NaOH → C17H13ClN2O4S + NaCl

Mass Balance:


Chlorosulpho

toludine

0.220

HCl 0.500 Washing

Regenerate

1.005


Β Napthol 0.144 Water Evaporated 5.154

NaOH 0.100

Water 3.200

Ice 2.100

Barium Salt 0.200




17. PIGMENT RED 57.1


2-Amino-5-methylbenzenesulfonic acid diazotization, and 3-Hydroxy-2-naphthoic acid

coupling, and then into calcium salt.

Chemical Reaction:

C11H8O3N + NaNO2 + HCl → C11H6 O3N=NCl + NaCl

C11H6 O3N=NCl + C7H9O3S + NaOH → C18H14N2O6S + NaCl

Mass Balance:


6 amino tolune

sulphonic acid

0.187

HCl 1.000 Washing

Regenerate

1.005



acid


NaOH 0.200

Water 3.200

Ice 2.100




18. PIGMENT RED 63


2-Aminonaphthalene-1-sulfonic acid diazotization, and 3-Hydroxy-2-naphthoic acid

coupling, and then into calcium salt.

Chemical Reaction:

C11H8O2N + NaNO2 + HCl → C11H6 O2N=NCl + NaCl

C11H6 O2N=NCl + C10H9O3S + NaOH → C21H14N2O6S + NaCl

Mass Balance:


Tobias acid 0.224

HCl 0.500 Washing

Regenerate

1.005



acid


NaOH 0.100

Water 3.200

Ice 2.100

Calcium Salt 0.080




19. PIGMENT RED 112


2,4,5-Trichloroaniline diazotization, and 3-Hydroxy-N-o-tolyl-2-naphthamide coupling.

Chemical Reaction:

C7H8ON2 + NaNO2 + HCl → C7H6ONN =NCl + NaCl

C7H6ONN =NCl + C19H17O3N + NaOH → C26H22N4O4 + NaCl

Mass Balance:


TriChloro Aniline 0.193

HCl 0.500 Washing

Regenerate

1.005


2 Nepthol o toludide 0.280 Water Evaporated 4.953

NaOH 0.100

Water 3.200

Ice 2.100




20. PIGMENT RED 170


4-Aminobenzamide diazotization, and N-(2-ethoxyphenyl)-3-hydroxy-2-naphthamide

coupling.

Chemical Reaction:

C7H8ON2 + NaNO2 + HCl → C7H6ONN =NCl + NaCl

C7H6ONN =NCl + C19H17O3N + NaOH → C26H22N4O4 + NaCl

Mass Balance:


Amino benzamide 0.136

HCl 0.300 Washing

Regenerate

1.015


Ethoxi phynine

nepthionic acid


NaOH 0.100

Water 3.200

Ice 2.100




21. PIGMENT VIOLET 23


Carbazole is condensed with Di Ethyle Sulphate and make Ester Then make Nitration of

Ester in presence of nitrite Then filter the residue Take filter cake and Condensed with

Chloranil in presence of Ortho di Chloro benzene take residue and wash and remove excess

chloranil by distillation filter it and dry the cake grind it which is ready for dye pigment.

Mass Balance:


Carbazole 0.100 CO2 0.060

DES 0.100 Dyes 0.121

HCl 0.150 Solvent regenerate 0.100

NaOH 0.060 Water Evaporated 4.829

MCB 0.030

DCB 0.060

CHLORNIL 0.100

H2O 3.500

Ice 1.000

DEG 0.010




22. PIGMENT YELLOW 1


Make diazo of 2 Nitro P Toludine in presence of Hcl and sodium Nitrite and coupled it with

Aceto Acitanilide in basic Medium stir for some hr and make it neutral by Acid then filter

and make wash with water dry it grind which is ready for dye.

Chemical Reaction:

C7H8N2O2 + NaNO2 + HCl → C7H6O2N N=NCl + NaCl

C7H6O2N N=NCl + C10H11NO2 + NaOH → C17H16N4O4 + NaCl

Mass Balance:


2-Nitro P Toludine 0.152

HCl 0.175 Washing

Regenerate

1.005


Aceto acetanilide 0.168 Water Evaporated 4.620

NaOH 0.100

Water 3.200

Ice 2.100






Make Diazo of 3 3 di Chloro Benzidine and coupled it with 2 mole of Aceto Xylidine in Basic

Medium Filter it And dry and Grind it Which is ready for Dye.

Chemical Reaction:


C12H8Cl2 ( N=NCl)*2 + 2*(C10H11O2N) + NaOH → C32H26Cl2N6O4 + NaCl

Mass Balance:


DI CHLORO BENZEDINE 0.249

HCl 0.375 Washing

Regenerate

1.005


Aceto Xylidide 0.355 Water Evaporated 5.984

NaOH 0.200

Water 4.200

Ice 2.100






4-(4-Amino-3-chlorophenyl)-2-chlorobenzenamine double nitrogen, and 3-Oxo-N-o-

tolylbutanamide (2 Moore) coupling.

Chemical Reaction:


C12H8Cl2 ( N=NCl)*2 + 2*(C11H12O2N2) + NaOH → C34H30Cl2N6O4 + NaCl

Mass Balance:



HCl 0.375 Washing

Regenerate

1.005


Acetoacetatoludide 0.385 Water Evaporated 5.984

NaOH 0.200

Water 4.200

Ice 2.100






4-(4-Amino-3-chlorophenyl)-2-chlorobenzenamine double nitrogen, and N-(2-

methoxyphenyl)-3-oxobutanamide (2 Moore) coupling.

Chemical Reaction:


C12H8Cl2 ( N=NCl)*2 + 2*(C11H12O3N2) + NaOH → C34H30Cl2N6O6 + NaCl

Mass Balance:



HCl 0.375 Washing

Regenerate

1.005


Acetoacetaniside 0.415 Water Evaporated 5.984

NaOH 0.200

Water 4.200

Ice 2.100






4-Amino-2-nitrobenzenesulfonic acid diazotization, and 3-Oxo-N-phenylbutanamide

coupling, then use Calcium chloride translate into Calcium salt.

Chemical Reaction:

C6H6O5N2S + NaNO2 + HCl → C6H4 O3SN N=NCl + NaCl

C6H4 O3SN N=NCl + C10H11O4N + NaOH → C16H14N4O7S + NaCl

Mass Balance:


2Nitro p amino sulphonic

acid

0.218

HCl 0.375 Washing

Regenerate

1.005


Oxo phynile butamide 0.175 Water Evaporated 5.053

NaOH 0.100

Water 3.200

Ice 2.100

Calcium chloride 0.230




PIGMENT PASTE

It can be done by making 40 to 50% pigment powder in water or we can make

directly from batch.



• SOLVENT DYES

27. SOLVENT ORANGE 1




with Resorcinol in Acidic medium at 5 deg temperature. Stir for 5 hr.

Chemical Reaction:


C6H7N=NCl + C6H6O2 + HCl -------→ C12H1N2O2 + HCl

Mass Balance:


ANILINE 0.415

HCl 1.000 Washing

Regenerate

1.005


Resorcinol 0.490 Water Evaporated 10.565

Water 5.200

Ice 5.100




28. SOLVENT RED 24


It is mono azo dyes for which first make Garnet GBC is diazotized with sodium nitrite in

presence hydrochloric acid at bellow 0 deg temp. and stir for 2 hr. Then dizo component is

coupled with β Nepthol in alkaline medium at 5 deg temperature. Stir for 5 hr.

Chemical Reaction:

C14H15N3 + NaNO2 + HCl ---------→ C14H15N2N=NCl + NaCl

C14H15N2N=NCl + C10H8O1 + NaOH -------→ C24H23N4O1 + NaCl

Mass Balance:


Garnet GBC 0.590

HCl 0.700 Washing

Regenerate

2.005


β Nepthol 0.380 Water Evaporated 6.355

Soda Ash/NaOH 0.200

Water 4.200

Ice 3.100




29. SOLVENT RED 27


It is mono Azo Dyes it can be done by firsy make dizo of mix xylidine and mix tolidine And

inter couple it And make Agiain diazo of mix and coupled with β Napthol.

Chemical Reaction:

C8H11N + NaNO2 + HCl → C8H9N=NCl+ NaCl

C8H9N=NCl + C8H11N → C16H20N3 + HCl

C16H20N3 + NaNO2 + HCl → C16H19N2N=NCl + H2O

C16H19N2N=NCl + C10H8O + NaOH → C26H26N4O + NaCl

Mass Balance:


XYLIDINE 0.124

HCl 0.500 Washing

Regenerate

1.005


TOLUDINE 0.107 Water Evaporated 3.407

NaOH 0.100

Β NAPTHOL 0.144

Water 2.200

Ice 1.500




30. SOLVENT YELLOW 2




with Di MethylAniline (D.M.A.) in Acidic medium at 5 deg temperature. Stir for 5 hr.

Chemical Reaction:


C6H7N=NCl + C8H11N1 + HCl -------→ C14H15N3 + HCl

Mass Balance:


ANILINE 0.415

HCl 1.000 Washing

Regenerate

1.005


D.M.A. 0.545 Water Evaporated 10.570

Water 5.200

Ice 5.100




31. SOLVENT YELLOW 14




with β Napthol in Alkaline medium at 5 deg temperature. Stir for 5 hr.

Chemical Reaction:


C6H7N=NCl + C10H8O1 + NaOH -------→ C16H14N2O + NaCl + H2O

Mass Balance:


ANILINE 0.415

HCl 1.000 Washing

Regenerate

2.000


β Napthol 0.642 Water Evaporated 5.747

Soda Ash/NaOH 0.200

Water 3.200

Ice 3.100




• ACID DYES

32. ACID RED 1


Aniline diazo, and 4-Acetamido-5-hydroxynaphthalene-2,7-disulfonic acid coupling.

Chemical Reaction:

C6H7N + NaNO2 + HCl → C6H7N=N Cl + H20

C6H7N=N Cl + C12H9NO8S2 + Na2CO3 → C18H13N3Na2O8S2 + CO2↑ + NaCl

Mass Balance:


ANILINE 0.095 CO2 0.060

HCl 0.300 Washing

Regenerate

1.0


ACETYLE H ACID 0.360 Water Evaporated 3.835

Soda Ash 0.300

Salt(NaCl) 0.300

Water 1.500

Ice 2.500




33. ACID RED 4


It is mono azo dyes for which first O-Anisidine is diazotized with sodium nitrite in presence


with N W Acid in alkaline medium at 5 deg temperature. Stir for 5 hr and isolateat 70deg

then transfer to spray dry.

Chemical Reaction:

C7H9ON + NaNO2 + HCl ---------→ C7H7ON=NCl + HCl

C7H7ON=NCl + C10H8O4S + Na2CO3 -------→ C17H13O2SN2Na + CO2↑ + NaCl

Mass Balance:


O-Anisidine 0.123 CO2 0.044

HCl 0.220 Washing

Regenerate

1.0


N W Acid 0.224 Water Evaporated 3.158

Soda Ash 0.250

Salt(NaCl) 0.200

Water 1.500

Ice 2.000




34. ACID RED 18




component is coupled with G Salt in alkaline medium at 5 deg temperature. Stir for 5 hr and

isolateat 70deg then transfer to spray dry.

Chemical Reaction:


C10H7O3SN=NCl + C10H8O7S2 + Na2CO3 -------→ C20H11O10S3N2Na3 + CO2↑ + NaCl

Mass Balance:


Sodium Nepthionate 0.350 CO2 0.145

HCl 0.500 Washing

Regenerate

3.0


G.Salt 0.450 Water Evaporated 3.08

Soda Ash 0.500

Salt(NaCl) 0.300

Water 2.500

Ice 2.500




35. ACID RED 73


It is mono azo dyes for which first make Paraamino Azo Benzene(PAAB) is diazotized with

sodium nitrite in presence hydrochloric acid at bellow 5 deg temp. and stir for 2 hr. Then

dizo component is coupled with G Salt in alkaline medium at 5 deg temperature. Stir for 5

hr and isolate at 70deg then transfer to spray dry.

Chemical Reaction:

C12H11N3 + NaNO2 + HCl ---------→ C12H9N2 N=NCl

C12H9N2 N=NCl + C10H8O7S2 + Na2CO3 -------→ C22H147S2N4Na3O7 + CO2↑ + NaCl

Mass Balance:


PAAB 0.350 CO2 0.50

HCl 0.700 Washing

Regenerate

3.775



Soda Ash 1.050

Salt(NaCl) 0.200

Water 3.200

Ice 3.100




36. ACID RED 88




component is coupled with β Napthol in alkaline medium at 5 deg temperature. Stir for 5 hr


Chemical Reaction:


C10H7O3SN=NCl +C 10H8O1 + NaOH -------→ C20H13O4S1N2Na + NaCl

Mass Balance:


Sodium Nepthionate 0.580

HCl 0.700 Washing

Regenerate

3.500



NaOH 0.300

Salt(NaCl) 0.300

Water 3.000

Ice 3.000




37. ACID RED 97


It is mono azo dyes for which first make 22 Disulphobenzedine(BDSA) is diazotized with

sodium nitrite in presence hydrochloric acid at bellow 5 deg temp. and stir for 3hr. Then

dizo component is coupled with 2 mole of β Napthol in alkaline medium at 5 deg

temperature. Stir for 5 hr and isolateat 70deg then transfer to spray dry.

Chemical Reaction:

C12H12O6S2N2 + NaNO2 + HCl ---------→ C12H12O6S2N2(N=NCl)2

C12H12O6S2N2(N=NCl)2 + (C10H8O1 )2 + NaOH -------→ C22H20O8S2N4Na2 + NaCl

Mass Balance:


BDSA 0.350

HCl 0.750 Washing

Regenerate

3.000



NaOH 0.230

Salt(NaCl) 0.300

Water 3.200

Ice 3.000




38. ACID RED 114


It is di diazo dyes. first O Dianisidine is Diazotized with2 Mole of Sodium Nitrite And This

DIazo salt is coupled wih H-Acid in Alkline Medium.

Chemical Reaction:

C14H16N2O2 + 2*(NaNO2) + HCl ----→ C14H12O2 2*(N=NCl) + H2O

C14H12O2 2*(N=NCl) + 2*(C10H9NO7S2) ----→ C34H28O16N6S24Na4

Mass Balance:


O Di anisidine 0.244 CO2 0.120

HCl 0.400 Washing

Regenerate

1.00


H acid 0..638 Water Evaporated 4.652

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




39. ACID RED 119


3-Aminobenzenesulfonic acid diazo, and Naphthalen-1-amine coupling, product to diazo,

and 3-(Ethyl(phenyl)amino)methyl)benzenesulfonic acid coupling.

Chemical Reaction:

C6H7NSO3 + NaNO2 +HCl → C6H5SO3 N=NCl + H2O + NaCl

C6H5SO3 N=NCl + C10H9N → C16H13SO3N3 + H20 + HCl

C16H13SO3N3 + NaNO2 + HCl → C16H13SO3N2N=NCl + HCl

C16H13SO3N2N=NCl + C15H15O3SN + Na2CO3 → C31H25N5Na2O6S2 + CO2↑ + H2O

Mass Balance:


Sulphanilic acid 0.173 Co2 0.120

HCl 1.500 Washing

Regenerate

1.100


Amine 0.144 Water Evaporated 3.946

Hydrobenzenesulfonic

acid

0.290

Soda Ash 0.400

Salt(NaCl) 0.500

Water 1.200

Ice 1.500




40. ACID RED 128


It is di diazo dyes first O Dianisidine is Diazotized with2 Mole of Sodium Nitrite And This

DIazo salt is coupled wih Phenol And G ACid in Alkline Medium. Then Eateryfy with PTS

Chloride and we got product

Chemical Reaction:


C14H12O2 2*(N=NCl) + C6H6O + C10H8O7S2 → C30H24N4O10S2Na2 + H2O + CO2↑

Mass Balance:


O Di anisidine 0.244 Co2 0.120

HCl 0.400 Washing Regenerate 1.00


G acid 0.304 Water Evaporated 4.702

Phenol 0.094

Pts Chloride 0.250

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




41. ACID RED 137


It is mono azo Dyes first p Aminoacetanilide is diazotized with sodium nitrite in presence of

HCl. This diazo is coupled with N acetyle J-acid in alkaline medium.

Chemical Reaction:

C8H10ON2 + NaNO2 + HCl ------→ C8H8ON N=NCl + H2O

C8H8ON1 N=NCl + C12H9O5NS + Na2CO3 → C20H15O6N4SNa

Mass Balance:

Input Qty Output Qty

P.A.A. 0.150 CO2 0.044

HCl 0.240 DYES 0.445

NaNO2 0.070 WATER EVAPORTED 2.976

N Ace. J Acid 0.255

SALT 0.250

WATER 1.500

ICE 1.000




42. ACID RED 214


3-Amino-4-hydroxy-5-nitrobenzenesulfonic acid diazo, and Quinoline-2,4-diol coupling, and

then in water solution and sulfuric acid chromium heating, in 125 °C keep 2 hours to form

chromium complex.

Chemical Reaction:

C6H6N2O6S + NaNO2 + HCl → C6H4NO6SN=NCl + NaCl + H2O

C6H6NO6SN=NCl + C9H7NO2 + Na2CO3 → C15H9N4NaO8S + CO2↑ + NaCl

Mass Balance:


m-Aminonitrophenol

Sulphonic acid

0.235 CO2 0.060

HCl 0.340 DYES 0.450


Quinoline 0.175

SALT 0.250

WATER 1.500

ICE 1.000

Soda 0.300




43. ACID RED 231


It is mono azo Dyes first p-Aminoacetanilide is diazotized with sodium nitrite in presence of

HCl. This diazo is coupled with Gama Acid

Chemical Reaction:

C8H10ON2 + NaNO2 + HCl ------→ C8H8ON N=NCl + H2O

C8H8ON1 N=NCl + C10H9O4NS+NaCl +HCl → C18H16O5N4SNa + H2O

Mass Balance:


P.A.A. 0.150

HCl 0.240 DYES 0.450


GAMA ACID 0.240

SALT 0.250

WATER 1.500

ICE 1.000




44. ACID YELLOW 1


It is Nitro Dyes in Which α Naphthol is react with Sulphuric Acid in M S vessel and convert it

into the α-Naphthol tri Sulphonic Acid. Then α-Naphthol tri-Sulphonic Acid is react with

Nitric Acid by which it is converted into Acid yellow 1. Then run above soln. in soda ash to

convert in sodium salt which is known as ACID YELLOW 1.

Chemical Reaction:

C10H8O1 + 3(H2SO4) ------→ C10H8O10S3 + H2O

C10H8O10S3 + 2(HNO3) -----→ C10H6O8N2 + H2O

C10H6O8N2 + Na2CO3 -----→ C10H4O8N2Na2 + CO2↑

Mass Balance:


α Naphthol 0.400 CO2 0.125

H2SO4 0.850 Washing

Regenerate

1.0

HNO3 0.360 Dye 0.950

SODA 0.350 Water Evaporated 3.385

WATER/ICE 3.500




45. ACID YELLOW 11




with S.P.M.P. in alkaline medium at 5 deg temperature. Stir for 5 hr and isolateat 70deg

then transfer to spray dry

Chemical Reaction:

C6H7N1 + NaNO2 + HCl ---------→ C6H7N=NCl

C6H7N=NCl + C10H10O4S1N2 + Na2CO3 -------→ C16H15S1N4NaO4 + CO2↑ + NaCl

Mass Balance:


ANILINE 0.215 CO2 0.450

HCl 0.550 Washing

Regenerate

3.200


S.P.M.P. 0..587 Water Evaporated 3.337

Soda Ash 0.750

Salt(NaCl) 0.300

Water 2.200

Ice 3.100




46. ACID YELLOW 17




coupled with 1 mole of 2-5 Dichloro 5 Pyrozolon in alkaline medium at 5 deg C

temperature. Stir for 5 hr and isolate at 60 deg C then transfer to spray dry.

Chemical Reaction:


C6H5O3S1N=NCl + C10H8O4S1Cl2N2 + NaOH + Na2Co3 ----→ C16H13O7S2N4Cl2Na2 + NaCl +

CO2↑

Mass Balance:



HCl 0.500 Washing

Regenerate

2.500


2-5 dichlo.spmp 0.580 Water Evaporated 4.395

NaOH 0.175

Salt(NaCl) 0.300

Water 2.700

Ice 3.200

Na2CO3 0.200




47. ACID YELLOW 23




coupled with 1mole of S.P.C.PAYROZOLONE in alkaline medium at 5 deg temperature. Stir

for 5 hr and isolateat 60deg then transfer to spray dry.

Chemical Reaction:


C6H5O3S1N=NCl + C10H8O6S1N2 + NaOH + Na2Co3 ---→ C16H13O7S2N4Cl2Na2

+ NaCl + co2↑

Mass Balance:



HCl 0.500 Washing

Regenerate

4.500


SPCP 0.315 Water Evaporated 2.660

NaOH 0.175

Salt(NaCl) 0.300

Water 2.700

Ice 3.700

Na2CO3 0.220




48. ACID YELLOW 36


It is mono azo dyes for which first make Metanilic Acid is diazotized with sodium nitrite in


coupled with 1 mole of Di Phynyle Amine(DPA) in alkaline medium at 5 deg temperature.

Stir for15 hr and isolateat 40deg then transfer to spray dry

Chemical Reaction:


C6H5O3S1N=NCl + C12H11N1 + Na2CO3 -------→ C16H11OS1N2Na2 + NaCl + CO2↑

Mass Balance:


Metanilic Acid 0.540 Co2 0.750

HCl 0.950 Washing

Regenerate

3.200


D.P.A. 0.525 Water Evaporated 4.170

Na2CO3 1.000

Salt(NaCl) 0.200

Water 2.700

Ice 3.000




49. ACID YELLOW 42


2,2′-Disulfo-4,4,diaminobibenzene double nitriding, and 3-Methyl-1-phenyl-1H-pyrazol-

5(4H)-one (2 Moore) coupled.

Chemical Reaction:

C12H12N2S2O6 + 2(NaNO2) + HCl → C12H8S2O6 2(N=NCl) + NaCl

C12H8S2O6 2(N=NCl) + 2(C10H9N2O) + Na2CO3 → C32H24N8Na2O8S2 + CO2↑ + NaCl

Mass Balance:


BDSA 0.344 CO2 0.145

HCl 0.500 Washing

Regenerate

1.0


P.M.P 0.380 Water Evaporated 3.219

Soda Ash 0.500

Salt(NaCl) 0.300

Water 1.500

Ice 1.500




50. ACID YELLOW 59


C.I. Acid Yellow 121 (C.I. 18690) method: 2-Aminobenzoic acid diazo, and 3-Methyl-1-

phenyl-1H-pyrazol-5(4H)-one coupling, and then into a chrome complex.

Chemical Reaction:

C7H7O2N + NaNO2 + HCl → C7H5O2N=NCl + NaCl

C7H5O2N=NCl + C10H9N2O + NaOH → C17H14N4O3 + NaCl + H2O

Mass Balance:


Amino benzoic acid 0.137 CO2 0.020

HCl 0.200 Washing

Regenerate

0.500


PMP 0.170 Water Evaporated 2.837

NaOH 0.105

Salt(NaCl) 0.100

Water 1.700

Ice 1.200




51. ACID YELLOW 79


1,1- dimethyl 4,4 ‘-dihydroxydiphenyl methane and 4-Aminophenol (2 Moore) reaction, its

product diazo, and 1-(3-Sulfophenyl)-3-methyl-5-pyrazolone (2 Moore) coupled.

Chemical Reaction:

C3H6 2*C6H6O2S + 2*C6H7NO → C3H6 2*(C12H11O3NS)

C3H6 2*(C12H11O3NS) + 2*NaNO2 + HCl → C3H6 2*(C12H11O3SN=NCl) + NaCl

C3H6 2*(C12H11O3SN=NCl) + 2*(C10H11N3SO3) + Na2CO3 → C47H40N10Na2O12S4 + CO2↑ +

NaCl

Mass Balance:


MAP 0.245 CO2 0.145

HCl 0.500 Washing

Regenerate

1.111


SPMP 0.750 Water Evaporated 5.225

Soda Ash 0.500

Salt(NaCl) 0.300

Water 1.500

Ice 3.500

ester 0.160




52. ACID BLACK 1


It is di diazo dyes first PNA is Diazotized with Sodium Nitrite And This DIazo salt is coupled

wih HAcid in Acidic Medium. Then Aniline is Diazotized with Sodium Nitrite and it is Coupled

With Reaction No 1 in Alkaline Medium.

Chemical Reaction:

C6H6N2O2 + NaNO2 + HCl ----→ C6H6O2N1N=NCl + H2O

C6H6O2N1N=NCl + C10H9NO7S2 ----→ C16H14O9N4S2 (Reaction - 1)


C6H7N=NCl + C16H14O9N4S2 + Na2CO3------→ C22H18O9N6S2Na2 + CO2↑

Mass Balance:


PNA 0.280 CO2 0.120

HCl 1.000 Washing

Regenerate

1.005


H Acid 0..640 Water Evaporated 6.380

ANILINE 0.200

Soda Ash 0.400

Salt(NaCl) 0.500

Water 3.200

Ice 2.100




53. ACID BLACK 18


First Make Diazo Of Sulphanilic acid And Coupled With ! napthyle amine thane make Again

make Diazo of mixture and coupled with H acid in alk. Media.

Chemical Reaction:

C6H7O3S1N1 + NaNO2 + HCl ---------→ C6H5O3S1N=NCl + NaCl

C6H5O3S1N=NCl + C10H9N --→ C16H13O3SN3 + HCl

C16H13O3SN3 + NaNO2 + HCl → C16H11O3SN2 N=NCl + H2O

C16H11O3SN2 N=NCl + C10H9NO7S2 + NaOH → C26H16O10S3N5Na3 + NaCl

Mass Balance:


Sulphanilic Acid 0.173

HCl 0.500 Washing

Regenerate

0.500


1-napthyle amine 0.144 Water Evaporated 5.001

H.Acid 0.319

NaOH 0.160

Salt(NaCl) 0.300

Water 2.000

Ice 2.500




54. ACID BLACK 21


First make diazo of 5amino naptiosulphonic acid and coupled with 1 napthyle amine

Make again diazo of reaction no 1 and coupled with n p toly peri acid.

Chemical Reaction:

C10H9O3SN + NaNO2 + HCl ---------→ C10H7O3SN=NCl + NaCl

C10H7O3SN=NCl + C10H9N --→ C20H16O3SN3 + HCL (REACTION 1)


C20H14O3SN2 N=NCl + C17H15O3SN + NaOH → C37H26O6S2N5Na2 + NaCl + H2O

Mass Balance:


5amino

naptiosulphonic acid

0.245

HCl 0.500 Washing

Regenerate

0.0


1 napthyle amine 0.144 Water Evaporated 5.544

N p toly peri acid 0.315

NaOH 0.160

Salt(NaCl) 0.300

Water 2.000

Ice 2.500




55. ACID BLACK 26


First make diazo of 5 amino Anilino benz sulphonic acid and coupled with 1 napthyle amine

Make again diazo of reaction no 1 and coupled with n p toly peri acid.

Chemical Reaction:

C12H11O3SN2 + NaNO2 + HCl ---------→ C12H9O3SN N=NCl + NaCl

C12H9O3SN N=NCl + C10H9N --→ C22H17O3SN4 + HCL (REACTION 1)


C22H15O3SN3 N=NCl + C10H8O4S + NaOH → C32H20O6S2N5Na2 + NaCl + H2O

Mass Balance:


5-amino Anilino benz

sulphonic acid

0.263 CO2 0.00

HCl 0.500 Washing

Regenerate

0.500


1 napthyle amine 0.144 Water Evaporated 5.021

Schaeffers acid 0.224

NaOH 0.160

Salt(NaCl) 0.300

Water 2.000

Ice 2.500




56. ACID BLACK 41


It is di diazo dyes first PNA is Diazotized with Sodium Nitrite And This DIazo salt is coupled

wih HAcid in Acidic Medium. Then Sulphanilic Acid is Diazotized with Sodium Nitrite and it is

Coupled With Reaction No 1 in Alkaline Medium.

Chemical Reaction:


C6H6O2N1N=NCl + C10H9NO7S2 ----→ C16H14O9N4S2 (REACTION 1)

C6H7SO3N1 + NaNO2 + HCl ---------→ C6H6SO3N=NCl + NaCl

C6H6SO3N=NCl + C16H14O9N4S2 + Na2CO3 ------→ C22H17O12N6S3Na3 + CO2↑

Mass Balance:


PNA 0.280 CO2 0.120

HCl 1.000 Washing

Regenerate

1.100



ANILINE 0.372

Soda Ash 0.400

Salt(NaCl) 0.500

Water 3.200

Ice 2.000




57. ACID BLACK 52


4-Amino-3-hydroxy-7-nitronaphthalene-1-sulfonic acid diazo, and Naphthalen-2-ol matches,

will result in aqueous solution with formic acid chromium common heating, in 115 ℃ keep 2

hours, and then into the same batch of have no complexation half of the dyes, and sodium

hydroxide move into alkaline, drying. The component of product is about 2 to 3 Moore

single atoms chromium azo dyes.

Chemical Reaction:

C10H6O6N3S + C10H8O+NaOH → C20H13O7N3SNa + NaCl

Mass Balance:


6 nitro diazo 0.285

HCl 1.000 Washing

Regenerate

1.190

Bita Napthol 0..145 Dye 0.590

Chromium sulphate 0.600 Water Evaporated 3.910

NaOH 0.060

Water 1.500

Ice 2.100




58. ACID BLACK 58


2-Amino-4-(methylsulfonyl)phenol diazo, and N-(7-hydroxynaphthalen-1-yl)acetamide

coupling, and then turn it into 1:2 chromium complex.

Chemical Reaction:

C7H9O3SN + NaNO2 + HCl → C7H7O3SN=NCl + NaCl

C7H7O3SN=NCl + C12H11O2N + NaOH → C19H17N3O5S + NaCl

Mass Balance:


Sulpho methyl amino

phenol

0.186 CO2 0.020

HCl 0.200 Washing

Regenerate

0.500


1 napthyle acetonamide 0.202 Water Evaporated 2.843

NaOH 0.105

Salt(NaCl) 0.100

Water 1.700

Ice 1.200




59. ACID BLACK 63


It is metalcomplex dyes first make diazo of 2 Amino Nitro Phenol And Coupled with β

Napthol and make acroumium complex of Dyes.

Chemical Reaction:

C6H6O3N2 + NaNO2 + HCL → C6H4O3N=NCl + NaCl + H2O

C6H4O3N1N=NCl + C10H8O + NaOH → C16H12O4 + NaCl

Mass Balance:


2-Amino nitro phenol 0.154

HCl 0.500 Washing

Regenerate

0.800



Cromium Sulphat 0.372

NaOH 0.400

Salt(NaCl) 0.500

Water 1.200

Ice 1.000




60. ACID BLACK 194


In this process there is ready available of 6 NITRO DIAZO Compound which is dissolved in

Water then add β Napthol Solution inthis mixture and bring Ph 10 then stir for 3 hr and

make nutral by acid then filter it transfer wet cake in vessel and make chromium complex

by chromium sulphate solution stir and salt out and filter and dry for powder which is Acid

Black 194.

Chemical Reaction:

C10H6O6N3S + C10H8O + NaOH → C20H13O7N3SNa

C20H13O7N3SNa + Cr2So4 → C20H13O7N3Cr

Mass Balance:

Sr.

No. Input Kg Output Kg

1 WATER 3400 ACID BLACK 194 2400

2 BETA NAPTHOL 500 EVAPORATE 7670

3 6-NITRO 1,2,4,DIAZO 1000

4 C.LYE 670

5 SALICYLIC ACID 50

6 BASIC CHROMIUM

SULFATE 450

7 ICE 4000

TOTAL 10070 TOTAL 10070



61. ACID BLACK 210


It is poly Azo Dyes First PNA is diazotized with Sodium Nitrite and Coupled Diazo With H

acid. Then make diazo of of DASA with 2 mole of Sodium Nitrite then Coupled Reaction

No 1 to this DASA diazo. Now reaction no 2 is coupled wit meta phyniline di amine (MPD) so

which is converted into ACID BLACK 210.

Chemical Reaction:



C12H13N3O2S + 2(NaNO2) + HCl ----→ C12H13N3O2S(N==NCl)2 + H2O

C12H13N3O2S(N==NCl)2 + C16H14O9N4S2 ----→ C28H26N8O11S3(N=NCl) (REACTION NO 2)

C28H26N8O11S3(N=NCl) + C6H8N2 + Na2CO3 ----→ C34H25N11O11S3Na2 + CO2↑

Mass Balance:


PNA 0.250 CO2 0.050

HCl 0.700 Washing

Regenerate

3.100


DASA 0.185 Water Evaporated 3.745

MPD 0.100

H.ACID 0.210

NaOH/Na2CO3 0.350

Salt(NaCl) 0.200

Water 3.700

Ice 2.000




62. ACID BLUE 158


4-Amino-3-hydroxynaphthalene-1-sulfonic acid diazo, and 8hydroxynaphthalene-1-sulfonic

acid coupling, and then with excessive sulfuric acid aqueous acid chromium solution

common heating, in 115 ℃ keep 7 hours, make dye create chromium complex.

Chemical Reaction:

C10H9SO4N + NaNO2 + HCl → C10H7SO4N=NCl + NaCl

C10H7SO4N=NCl + C10H8SO4 + NaOH → C20H13S2O8N2Na + NaCl

Mass Balance:


Gama Acid 0.239 CO2 0.060

HCl 0.600 Washing

Regenerate

2.100


Schaffer Acid 0.224 Water Evaporated 3.648

Na2CO3 0.275

Salt(NaCl) 0.200

Water 2.700

Ice 2.000




63. ACID BROWN 14


Make diazo of sodium Neppthionate(2 Mole) with Sodium Nitrite in Presence of HCl and

Coupled with Resorcinol (1Mole) in Alkline Medium.

Chemical Reaction:

2*(C10H9SO3N) + 2*(NaNO2) + HCl → 2*( C10H7SO3N=NCl) + NaCl

2*( C10H7SO3N=NCl) + C6H6O2 + NaOH → C26H16N4Na2O8S2 + NaCl

Mass Balance:


Sodium Nepthionate 0.490

HCl 0.750 Washing

Regenerate

2.100


Resorcinol 0.110 Water Evaporated 4.935

NaOH 0.275

Salt(NaCl) 0.200

Water 2.700

Ice 3.000




64. ACID BROWN 28


2-Amino-4-nitrophenol diazo, and N-(2-hydroxy-5-methylphenyl)acetamide coupling, and

then turn it into 1:2 chromium complex.

Chemical Reaction:

C6H6O3N2 + NaNO2 + HCl → C6H4O3NN=NCl + NaCl

C6H4O3NN=NCl + C9H11O2 + NaOH → C15H14N4O5 + NaCl

Mass Balance:


m-Amino Nitro

Phenol

0.155

HCl 0.450 Washing

Regenerate

1.100


2oh 5mit.acetoamide 0.183 Water Evaporated 4.598

NaOH 0.275

Salt(NaCl) 0.200

Water 2.700

Ice 2.000




65. ACID BROWN 121


It is di diazo dyes first PNA is Diazotized with Sodium Nitrite And This Diazo salt is coupled

with HAcid in Acidic Medium. Then Again Make Diazo of reaction No 1 And coupled with

Resorcinol. Then Make Diazo of M anino nirophenol and Coupled with Reaction no 2 to

produce product.

Chemical Reaction:


C6H6O2N1N=NCl + C10H9NO7S2 ----→ C16H14O9N4S2

Mass Balance:


PNA 0.138 CO2 0.044

HCl 1.000 Washing

Regenerate

1.005


H Acid 0.319 Water Evaporated 4.278

resorcinol 0.110

2amino nitrophenol 0.150

Soda Ash 0.400

Salt(NaCl) 0.500

Water 1.200

Ice 2.100




66. ACID GREEN 19


It is di diazo dyes first 2-5 Di Chloro Aniline(2-5DCA) is Diazotized with Sodium Nitrite And

This DIazo salt is coupled wih HAcid in Acidic Medium. Then 1-Nepthyle Amine is Diazotized

with Sodium Nitrite and it is Coupled With Reaction No 1 in Alkaline Medium.

Chemical Reaction:

C6H5NCl2 + NaNO2 + HCl ----→ C6H3Cl2N=NCl + H2O

C6H3Cl2N=NCl + C10H9NO7S2 ----→ C16H11O7N3S2Cl2 (REACTION 1)


C10H7N=NCl + C16H11O7N3S2Cl2 + Na2CO3------→ C26H15O7N5S2Cl2Na2 + CO2↑

Mass Balance:


(2-5DCA) 0.230 CO2 0.120

HCl 1.000 Washing

Regenerate

1.195



ANILINE 0.130

Soda Ash 0.400

Salt(NaCl) 0.500

Water 3.500

Ice 2.100




67. ACID ORANGE 7



presence hydrochloric acid at bellow 5 deg temp.and stir for 3hr. Then dizo component is

coupled with 1 mole of β Napthol in alkaline medium at 5 deg temperature. Stir for 5 hr


Chemical Reaction:


C6H5O3S1N=NCl + C10H8O1 + NaOH -------→ C16H11OS1N2Na2 + NaCl

Mass Balance:


Sulphanilic Acid 0.540

HCl 0.750 Washing

Regenerate

3.100



NaOH 0.275

Salt(NaCl) 0.200

Water 2.700

Ice 3.000




68. ACID ORANGE 10




with G Salt in alkaline medium at 5 deg temperature. Stir for 5 hr and isolateat 70deg then

transfer to spray dry

Chemical Reaction:

C6H7N1 + NaNO2 + HCl ---------→ C6H7N=NCl

C6H7N=NCl + C10H8O7S2 + Na2CO3 -------→ C16H137S2N2Na2O7 + CO2↑ + NaCl

Mass Balance:


ANILINE 0.215 CO2 0.450

HCl 0.550 Washing

Regenerate

3.005



Soda Ash 0.750

Salt(NaCl) 0.300

Water 2.200

Ice 3.100




69. ACID ORANGE 30


Aniline diazo, and 6-(2-Chloroacetamido)-1-naphthol-3-sulfonic acid coupling.

Chemical Reaction:

C6H7N + NaNO2 + HCl → C6H5N=NCl + NaCl

C6H5N=NCl + C12H9ClNO5S + Na2CO3 → C18H13ClN3NaO5S + CO2 ↑ + NaCl

Mass Balance:


Aniline 0.093 CO2 0.060

HCl 0.350 Washing

Regenerate

1.005


Chloro acetyle j acid 0.380 Water Evaporated 4.328

Soda Ash 0.350

Salt(NaCl) 0.300

Water 2.200

Ice 2.100




70. ACID ORANGE 72


3-Amino-4-hydroxy-5-nitrobenzenesulfonic acid diazo, and 3-Methyl-1-phenyl-1H-pyrazol-

5(4H)-one coupling, and then and sulfuric acid chromium and chromium acid in aqueous

solution heating, in 130 ℃ : maintain 6 hours, and make them into chromium complexation.

Chemical Reaction:

C6H6N2O6S + NaNO2 + HCl → C6H4O6NSN=NCl + NaCl

C6H4O6NSN=NCl + C10H10N2O + Na2CO3 → C16H12N5NaO7S + CO2↑ + NaCl

Mass Balance:


3-Amino-4-hydroxy-5-

nitrobenzenesulfonic

acid

0.235 CO2 0.060

HCl 0.450 Washing

Regenerate

1.005


P.M.P 0.174 Water Evaporated 3.535

Soda Ash 0.350

Salt(NaCl) 0.300

Water 2.200

Ice 2.100




• DIRECT DYES

71. DIRECT BLACK NB


In this Process D.A.B.A. is diazotized and Coupled with H AcId in Acid Medium And make

Diazo of Aniline And Coupled with Reaction No 1 in Alk Medium then Coupled MPD.

Chemical Reaction:

C13H13N3O + 2*NaNO2 + HCl → lCN=NC13H9NO3N=NCl + NaCl + H2O

lCN=NC13H9NO3N=NCl+C10H9NO7S2 → C23H19N4O10S2N=NCl (Reaction no 1)


C23H19N4O10S2N=NCl + C6H5N=NCl +Na2CO3 → C29H22N6O10S2Na2N=NCl + CO2↑ (REACTION

2)

C29H22N6O10S2N=NCl + C6H8N2 → C35H30N10O10S2Na2 + H2O (FINAL PRODUCT)

Mass Balance:


DABA 0.227 CO2 0.060

HCl 0.600 Washing

Regenerate

1.05


H ACID 0.319 Water Evaporated 4.687

ANILINE 0..093

M.P.D. 0.108

Na2CO3 0.300

Salt(NaCl) 0.200

Water 2.500

Ice 2.100




72. DIRECT BLACK 19


It is poly -azo dyes first PNA is Diazotized with Sodium Nitrite And This DIazo salt is coupled

with H Acid in Acidic Medium. Then again make Diazo of PNA (para nitro aniline) with

Sodium Nitrite in presence of HCl. Make alkaline to Reaction no 1 and Coupled with Other

Diazo of PNA in alk. medium. Then reduced the nitro group to amine group by reduction.

Make Diazo of Reaction no 2 with Sodium Nitrite And make Poly Azo compound And

coupled with 2mole of MetaPhyniline Di amine(MPD) which is direct black 19by making

Sodium Salt.

Chemical Reaction:




C16H14O9N4S2 + C6H6O2N1N=NCl + Na2CO3 -→ C22H16O11S2N6Na2 + NaCl + CO2↑

C22H16O11S2N6Na2 + HCl (reduction) ----→ C22H22O7S2N6 (REACTION2)

C22H22O7S2N6+NaNO2 + HCl ----→ C22H18O7S2N4(N=NCl)2 + NaCl + H2O

C22H18O7S2N4(N=NCl)2 + 2(C6H8N2) ---→ C22H32O7S2N12Na2 + NaCl

Mass Balance:


PNA 0.220 Co2 0.220

Sodium Nitrite 0.220 Dyes 1.007

HCl 1.500 Water regenerate 3.020

H.Acid 0.240 Water Evaporated 5.660

Soda 0.800

MPD 0.127

Salt 0.300

H2O 3.500

Ice 3.000




73. DIRECT BLACK 22


5-Amino-2-(4-aminophenylamino)benzenesulfonic acid double nitriding, in alkaline

conditions and 6-Amino-4-hydroxynaphthalene-2-sulfonic acid (2 Moore) coupled, then

double nitriding, and Benzene-1,3-diamine (2 Moore) coupled.

Chemical Reaction:

C12H1306N3S + 2(NaNO2) + HCl → C12H9NO6S 2(N=NCl) + NaCL

C12H9NO6S 2(N=NCl) + 2*C10H9SO4N + Na2CO3 → C32H23N7O14S3 + NaCl

C32H23N7O14S3 + 2(NaNO2) + HCl → C32H19N5O14S3 2(N=NCl) + NaCl

C32H19N5O14S3 2(N=NCl) + 2C6H8N2 + Na2CO3 → C44H32N13Na3O11S3 + NaCl

Mass Balance:


DASA 0.309 CO2 0.220



Gama Acid 0.478 Water Evaporated 7.729

Soda 0.800

MPD 0.216

Salt 0.300

H2O 3.500

Ice 3.000




74. DIRECT BLACK 168


In this process make diazo of FC acid and coupled with H Acid then Make diazo of aniline

and coupled with above mixture and after 1 hr charge M.P.D.

Chemical Reaction:

C12H13N3SO3 + 2*(NaNO2) + HC l → C12H9NSO3 2(N=NCl) + NaCl


C12H9NSO3 2(N=NCl) + C10H9NO7S2 → C22H17N3S3O10 N=NCL + H2O

C22H17N3S3O10 N=NCL + C6H5N=NCl + Na2CO3 → C28H21N5S3O10Na3N=NCl

+ CO2↑ + NaCl

C28H21N5S3O10Na3N=NCl + C6H8N2 → C34H28N9S3O10Na3 + H2O (Final Dyes)

Mass Balance:


FC Acid 0.279 CO2 0.120



H.Acid 0.319 Water Evaporated 6.419

Soda 0.300

MPD 0.108

Aniline 0.093

Salt 0.300

H2O 2.500

Ice 3.000




75. DIRECT BLUE G


It is diazo dyes first O Dianisidine is Diazotized with 2 Mole of Sodium Nitrite and This Di

azo salt is coupled with Scaffer Acid in Alkline Medium.

Chemical Reaction:


C14H12O2 2*(N=NCl) + 2*(C10H9NO4S) ----→ C34H28O10N6S24Na4

Mass Balance:



HCl 0.400 Washing

Regenerate

1.00


Scaffer Acid 0.448 Water Evaporated 4.652

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




76. DIRECT BLUE 15


It is diazo dyes first O Dianisidine is Diazotized with2 Mole of Sodium Nitrite And This DIazo

salt is coupled with H-Acid in Alkline Medium.

Chemical Reaction:



Mass Balance:



HCl 0.400 Washing

Regenerate

1.00


H acid 0.638 Water Evaporated 4.652

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




77. DIRECT SKY BLUE FB


It is diazo dyes first O Dianisidine is Diazotized with 2 Mole of Sodium Nitrite And This Diazo

salt is coupled with CHIGO ACID in Alkline Medium

Chemical Reaction:



Mass Balance:



HCl 0.400 Washing

Regenerate

1.00


Chikago Acid 0.638 Water Evaporated 4.652

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




78. DIRECT FAST VIOLET 2RL


Mix xylidine is diazotized wit sodium nitrite and coupled with p cresidine then Again make

diazo of this mixture and coupled with phinyle j Acid.

Chemical Reaction:

C8H11O3SN + NaNO2 + HCl → C8H9O3SN=NCl + NaCl

C8H9O3SN=NCl + C8H11N + Na2CO3 → C16H19N3O3S + CO2↑ + NaCl

C16H19N3O3S + NaNO2 + HCl → C16H17O3S N2N=NCl + NaCl

C16H17O3S N2N=NCl + C16H12O4NS + Na2CO3 → C32H26N5O7S2Na2 + CO2↑ + NaCl

Mass Balance:


Mix xylidine

sulphonate

0.200 Co2 0.120

HCl 0.400 Washing

Regenerate

1.00


Pera Cresidine 0.136 Water Evaporated 4.623

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200

Phinyle J Acid 0.330




79. DIRECT ORANGE 34


In reflux conditions, sodium hydroxide solution in (E)-2-(2-sulfo-4-nitrostyryl)-5-

nitrobenzenesulfonic acid sodium salt with 4-Aminobenzenesulfonic acid sodium diazo with

aniline coupled with product heating (40215). In reflux conditions, sodium hydroxide

solution in (E)-2-(2-sulfo-4-nitrostyryl)-5-nitrobenzenesulfonic acid sodium salt with 4-

Aminobenzenesulfonic acid sodium diazotization and a product matches m-Toluidine,

molecular than 1:1.

Chemical Reaction:


C6H5SO3N=NCl + C7H9N → C13H13SO3N3

C6H5SO3N=NCl + C6H7N → C12H10SO3N3

Mass Balance:


Sulphanilic acid 0.346 Co2 0.00

HCl 0.400 Washing

Regenerate

1.00


Aniline 0.093 Water Evaporated 3.124

Soda Ash/NaOH 0.150

Salt(NaCl) 0.100

Water 1.200

Ice 2.200

toludine 0.107




80. DIRECT RED 7


It is di diazo dyes. First O Dianisidine is Diazotized with 2 Mole of Sodium Nitrite and this

Diazo salt is coupled wih Napthionic Acid in Alkline Medium.

Chemical Reaction:

C14H16N2O2+2*(NaNO2)+HCl----→C14H12O2 2*(N=NCl)+H2O

C14H12O2 2*(N=NCl)+2*(C10H8NO3S)----→C34H26O8N6S2Na2

Mass Balance:


O Di anisidine 0.244 Co2 0.120

HCl 0.400 Washing

Regenerate

1.00


Napthionic Acid 0.444 Water Evaporated 4.628

Soda Ash 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




81. DIRECT RED 23


In this process J acid Urea is coupled with 1 mole of Diazo of Aniline and 1mole of P amino

Acetinalide.

Chemical Reaction:

(C6H7N) + (NaNO2) + (HCL) → (C6H5N=NCl) + NaCl

C10H12N2O2 + NaNO2 + (HCL) → C10H10O2N N==NCL + NaCl

(C6H5N=NCl) + C21H14N2O9S2 + NaOH + C10H10O2N N==NCL →

C37H27N7O11S2Na2 + NaCl + H2O

Mass Balance:


Aniline 0.093 CO2 0.000

HCl 0.400 Washing

Regenerate

1.00


JAcid Urea 0.505 Water Evaporated 4.798

P-AMINO ACETANILIDE 0.195

NaOH 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




82. DIRECT RED 26


In this process J acid Urea is coupled with @ mole of Diazo of Aniline.

Chemical Reaction:

2* (C6H7N) + 2(NaNO2) + 2(HCL) → 2*( C6H5N=NCl) + NaCl

2*( C6H5N=NCl) + C21H14N2O9S2 + NaOH → C33H22N6O9S2Na2 + NaCl + H2O

Mass Balance:


Aniline 0.186 Co2 0.000

HCl 0.400 Washing

Regenerate

1.00


JAcid Urea 0.505 Water Evaporated 4.766

NaOH 0.500

Salt(NaCl) 0.400

Water 2.200

Ice 2.200




83. DIRECT RED 80


(a) 3,4′-Disulfo-4-aininoazobenzene diazo, and 7-Amino-4-hydroxynaphthalene-2-sulfonic

acid coupling, and then hydrolysis acetyl amino and light gasification; (b) 3,4′-Disulfo-4-

aininoazobenzene (2 Moore) diazo, coupled with N,N’-bis(4-hydroxy-2-sulfonaphthalene-7-

yl)urea.

Chemical Reaction:

2(C12H12S2O6N4) + 2(NaNO2) + HCl → 2*(C12H8S2O6N2 N=NCl) + NaCl

2*(C12H8S2O6N2 N=NCl) + C21H12S2O9N2 + Na2CO3 → C45H26N10Na6O21S6 + CO2↑ + NaCl

Mass Balance:


Disulpho PAAB 0.716 Co2 0.50

HCl 0.700 Washing

Regenerate

1.005


J Acid Urea 0.505 Water Evaporated 5.126

Soda Ash 0.650

Salt(NaCl) 0.200

Water 3.000

Ice 2.100




84. DIRECT RED 81


It is mono azo dyes for which first make Paraamino Azo BenzeneSulphonic Acid(PAABSA) is

diazotized with sodium nitrite in presence hydrochloric acid at bellow 5 deg temp. and stir

for 2 hr. Then dizo component is coupled with Benzoyl J Acid in alkaline medium at 5 deg

temperature. Stir for 5 hr and isolateat 70deg then transfer to spray dry

Chemical Reaction:

C12H11N3SO3 + NaNO2 + HCl ---------→ C12H9SO3N2 N=NCl

C12H9SO3N2 N=NCl + C23H13O5N2S + Na2CO3 -------→ C35H19S2N5Na2O8 + CO2↑+ NaCl

Mass Balance:


PAABSA 0.278 CO2 0.50

HCl 0.700 Washing

Regenerate

2.775


Benzoyl J Acid 0.435 Water Evaporated 3.484

Soda Ash 0.750

Salt(NaCl) 0.200

Water 3.000

Ice 2.100




85. DIRECT RED 89


3-Amino-4-methoxybenzenesulfonic acid diazo, and 7-Amino-4-hydroxynaphthalene-2-

sulfonic acid coupled to get A single accidentally nitrogen compounds. 4-Amino-5-

hydroxynaphthalene-2,7-disulfonic aciddiazo, and 2-Amino-4-methylanisole coupling, get

single accidentally nitrogen compounds B, and then A, B and aniline and 2,4,6-Trichloro-

1,3,5-triazine condensation chlorine.

Chemical Reaction:

2*(C7H9O4SN) + 2*(NaNO2) + HCl → 2*(C7H5O4S N=NCl) + NaCl

2*(C7H5O4S N=NCl) + 2*(C10H8O4S) + Na2CO3 → 2*(C17H13O8S2 N2)

C6H7N+C4N6H3 + 2*(C17H13O8S2 N2) → C44H32N10Na4O16S4 + NaCl

Mass Balance:


Aniline 0.093 CO2 0.50

HCl 0.700 Washing

Regenerate

1.775


H Acid 0.319 Water Evaporated 4.583

Scaffer Acid 0.224

Methyle Anisol 0.122

Sulpho BEnzoyle

amine

0.205

Cynuric chloride 0.185

Soda Ash 0.750

Salt(NaCl) 0.200

Water 3.000

Ice 2.100




86. DIRECT RED 239


Bronners acid diazotized and couple with J-Acid in alkaline medium and spray dry it.

Chemical Reaction:


C10H7SO3N=NCl + C10H8SO4N + NaOH → C20H13S2O7N3 + NaCl

2*(C20H13S2O7N3) → C40H24S4O15N6

CONDENTATION

Mass Balance:


Water + Ice 6000 Evaporate 6064

Bonners Acid 200 Product 600

J-Acid 113

HCl 30% 155

Sodium Nitrite 38

Sodium Bicarbonate 120

Caustic Lye 38

Total 6664 Total 6664



87. DIRECT YELLOW 4


This is diazo Dyes in this process DASDA is react with Sodium Nitrite (2 mole) and make it

Diazo in presence of Hcl And ice. Then above Diazo is Coupled with 2 mole of Phenol in

Alkaline medium.

Chemical Reaction:

C14H14N2O6S2 + 2(NaNO2) + HCl ---→ C14H10O6S2 2(N=NCl) + H20

C14H10O6S2 2(N=NCl) + 2(C6H6O) + NaOH ---→ C26H18O8S2Na2 + H2O + NaCl

Mass Balance:


DASDA 0.418 Co2 0.00

HCl 0.800 Washing

Regenerate

2.775


PHENOL 0.190 Water Evaporated 3.053

NaOH 0.180

Salt(NaCl) 0.200

Water 2.500

Ice 2.100




88. DIRECT BROWN NB


In this Process D.A.B.A. is diazotized and Coupled with Salicylic acid and gama acid in Alkline

medium

Chemical Reaction:

C13H13N3O + 2*NaNO2 + HCl → ICN=NC13H9NO3N=NCl + NaCL + H2O

C7H6O3 + lCN=NC13H9NO3N=NCl + C10H9NO4S + Na2CO3 C30H22N6O10SNa2 + CO2↑

Mass Balance:


DABA 0.227 Co2 0.060

HCl 0.500 Washing

Regenerate

1.05


GAMA 0.239 Water Evaporated 4.534

SALICYLIC ACID 0.138

Na2CO3 0.300

Salt(NaCl) 0.200

Water 2.500

Ice 2.100




• REACTIVE DYES

89. REACTIVE BLACK CNN


Acetanilide VS diazotized, and couple with J-Acid than with MPDSA and H-Acid first in acidic

medium and then in neutral by sodium bicarbonate and spray dryer it.

Chemical Reaction:

C8H11O6S2N + NaNO2 + HCl → C8H9O6S2N=NCl + NaCl (2 Mole)

C8H9O6S2N=NCl + C10H9O7S2N + Na2CO3 → C18H13O13S4N3Na4 + CO2↑ + NaCl

Mass Balance:


Water + ICE 7960 Product 5200

Acetanilide VS 2300 Evaporation 8800

H-Acid 785

HCl 30% 920

Sodium Nitrite 576


J-Acid 194

Caustic Lye 40




90. REACTIVE BLACK 5


Acetanilide VS diazotized, and couple with H-Acid in acidic medium and then in neutral by

sodium bicarbonate and spray dryer it.

Chemical Reaction:

C8H11O6S2N + NaNO2 + HCl → C8H9O6S2N=NCl + NaCl (2 Mole)


Mass Balance:


Water + ICE 6800 Product 3675

Acetanilide VS 1776 Evaporation 7901

H-Acid 975

HCl 30% 680

Sodium Nitrite 445





91. REACTIVE BLACK 8


2-Amino-4-nitrophenol diazo, and 4-Amino-5-hydroxynaphthalene-2,7-disulfonic

acid coupling, chromium complexation, and 2,4,6-Trichloro-1,3,5-triazine condensation,

with four ammonia, and salting-out.

Chemical Reaction:

C3N5H4Cl + C10H9O7S2N → C13H12O7S2N6Cl

C6H6O3N2 + NaNO2 + HCl → C6H4O3N N=NCl + NaCl

C6H4O3N N=NCl + C13H12O7S2N6Cl + Na2CO3 → C19H11ClN8Na2O10S2 + CO2↑ + NaCl

Mass Balance:


CYNURIC CJHLORIDE 0.185 CO2 0.060


HCl 0.150 Water Evaporated 5.368

M.amino nitro

Phenol

0.154

Soda 0.500

H.Acid 0.319

Salt 0.300

H2O 2.500

Ice 2.000




92. REACTIVE ORANGE 7


2-(3-Aminophenylsulfonyl)ethyl hydrogen sulfate diazo, and 6-Acetamido-4-

hydroxynaphthalene-2-sulfonic acid coupling.

Chemical Reaction:

C8H11O6S2N + NaNO2 + HCl → C8H9O6S2N=NCl + NaCl

C8H9O6S2N=NCl + C12H11O5N + Na2CO3 → C20H17N3Na2O11S3 + CO2↑ + NaCl

Mass Balance:


V S 0.266 CO2 0.020


HCl 0.550

Aceto S N 0.310 Water Evaporated 5.840

Soda 0.500

Salt 0.300

H2O 2.500

Ice 2.000




93. REACTIVE ORANGE 122


2-Aminonaphthalene-1,5-disulfonic acid diazo, and 7-Amino-4-hydroxynaphthalene-2-

sulfonic acid coupling, its products and 2,4,6-Trichloro-1,3,5-triazine and 2-(3-

Aminophenylsulfonyl)ethyl hydrogen sulfate condensation.

Chemical Reaction:

C8H11O6S2N + C3N5H4Cl → C11H14O6S2N6Cl


C10H7O6S2N=NCl + C10H8O4S + Na2CO3 → C20H11O10S3N3Na3 + CO2↑ + NaCl

C20H11O10S3N3Na3 + C11H14O6S2N6Cl → C31H20ClN7Na4O16S5

Mass Balance:




HCl 0.550 Water regenerate 0

VS 0.266 Water Evaporated 5.818

Soda 0.500

2-5 DISULPHO 2

ANAPTHYLE

0.303

Salt 0.300

H2O 2.500

Ice 2.000

Gama 0.239




94. REACTIVE RED 3BS


4-Amino-5-hydroxynaphthalene-2,7-disulfonic acid and 2,4,6-Trichloro-1,3,5-triazine first

condensation, and a second time between ester condensation, 2-Aminonaphthalene-1,5-

disulfonic acid diazo, and the generation of condensation products coupled, then salting-

out.

Chemical Reaction:




C20H11O13S4N3Na4 + C11H14O6S2N6C → C31H19ClN7Na5O19S6 + NaCl

Mass Balance:


CYNURIC CHLORIDE 0185 CO2 0.120



H.Acid 0.319

Soda 0.500

2AMINO DI SULPHONIC

ACID

0.288

Salt 0.300

H2O 2.500

Ice 2.000

ESTER 0.266




95. REACTIVE RED M 5B


Aniline diazo, in alkaline conditions and 4-Amino-5-hydroxynaphthalene-2,7-disulfonic

acid coupling, and then and 2,4,6-Trichloro-1,3,5-triazine condensation .

Chemical Reaction:


C6H7N+NaNO2 + HCl → C6H7N=NCl + NaCl

C13H14O7S2N6Cl + C6H7N=NCl + Na2CO3 → C19H18O7S2N8Cl + CO2↑ + NaCl

Mass Balance:


CYNURIC CJHLORIDE 0.185 Co2 0.060


HCl 0.150

Aniline 0.093 Water Evaporated 5.437

Soda 0.500

H.Acid 0.319

Salt 0.300

H2O 2.500

Ice 2.000




96. REACTIVE RED 120


2-Aminobenzenesulfonic acid diazo, and 4-Amino-5-hydroxynaphthalene-2,7-disulfonic

acid coupling, and 2,4,6-Trichloro-1,3,5-triazine first condensation, its product (2 Moore)

and Benzene-1,4-diamine second condensation.

Chemical Reaction:



C6H5SO3N=NCl + C13H14O7S2N6Cl + Na2CO3 → C19H15O10S3N8ClNa3

2*(C19H15O10S3N8ClNa3) + C6H8N2 → C44H36O20S6N18Cl2Na6

Mass Balance:


CYNURIC CHLORIDE 0.370 CO2 0.040



H.ACID 0.638

Soda 0.500

1 AMINE

SULPONEPTH.

0.490

Salt 0.300

H2O 2.500

Ice 2.000

P.P.D 0.108




97. REACTIVE YELLOW 15


2-(4-Amino-2-methoxy-5-methylphenylsulfonyl)ethyl hydrogensulfate diazo, and 4-(3-

Methyl-5-oxo-4,5-dihydropyrazol-1-yl)benzenesulfonic acid coupling.

Chemical Reaction:


C10H13O7S2N=NCl + C10H9O4SN2 + Na2CO3 → C20H20N4Na2O11S3 + NaCl

Mass Balance:





VS 0.266

Soda 0.500

Benzene Sulphonic

Acid

0.158

Salt 0.300

H2O 2.500

Ice 2.000






2-Aminonaphthalene-1,5-disulfonic acid diazo, and 3-Methyl-1-(4-(vinylsulfonyl)phenyl)-1H-

pyrazol-5(4H)-one coupling.

Chemical Reaction:

C10H9S2O6N + NaNO2 + HCl → C10H7O6S2N=NCl + NaCl

C10H7O6S2N=NCl + C12H10O3SN2 + Na2CO3 → C22H16N4Na2O9S3 + NaCl

Mass Balance:





2 AMINO 2 5 DI

SULPHON

0.325

Soda 0.500

VS PY ZO 0.168

Salt 0.300

H2O 2.500

Ice 2.000






1-(3-Aminophenyl)urea and 2,4,6-Trichloro-1,3,5-triazine first condensation, 7-

Aminonaphthalene-1,3,6-trisulfonic acid diazo, and condensation products coupled, again

with a between, 2-(3-Aminophenylsulfonyl)ethyl hydrogen sulfate condensation, and then

salting-out.

Chemical Reaction:


C10H9S3O9N + NaNO2 + HCl → C10H7O9S3N=NCl + NaCl

C10H7O9S3N=NCl + C7H8ON2 → C17H13O10S3N4 + HCl

H14O6S2N6Cl + C17H13O10S3N4 + Na2CO3 → C28H20ClN9Na4O16S5 + NaCl

Mass Balance:





VS 0.266

Soda 0.500

1 Nepthyle amine

Trisulphophonic Acid

0.383

Salt 0.300

H2O 2.500

Ice 2.000

Aminophynyle urea 0.150






2,4-Diaminobenzenesulfonic acid diazo, and 6-hydroxy-1,4-dimethyl-2-oxo-1,2-

dihydropyridine-3-carboxamide coupling, and 2,4,6-Trichloro-1,3,5-triazine condensation,

and then and registration, 2-(3-Aminophenylsulfonyl)ethyl hydrogen sulfate condensation.

Chemical Reaction:

C8H9O6S2 + C3N5H4Cl → C11H13O6S2N5Cl

C7H7SO3N + NaNO2 + HCl → C7H5O3S N=NCl + NaCl

C7H5O3S N=NCl + C7H9O3N2 + Na2CO3 → C14H12O6S N4 + NaCl

C11H13O6S2N5Cl + C14H12O6S N4 → C25H22ClN9Na2O12S3

Mass Balance:




HCl 0.550

VS 0.266 Water Evaporated 6.000

Soda 0.500

2 4 diamino benzene

sulphonic acid

0.180

Salt 0.300

H2O 2.500

Ice 2.000

easter 0.330




2.3 RAW MATERIAL STORAGE AND HANDLING

Raw materials are received in drums, carboys, bags, tankers. All storage tanks of hazardous

flammable substances are located within premises in separate storage area and stored with

all precautionary process instrumentation and safety appliances. Large area is covered by

well-designed warehouse which contains store office, raw materials store, finished products

store, etc. The personnel protective equipments like hand gloves, safety shoes, goggles,

helmet, clothing, etc. are provided to those handling hazardous chemicals as per

requirement. All the motors and electrical connections are flame proof. This existing system

and process for raw materials storage and handling will follow after proposed expansion

also. List of raw materials are given in Table-2.1.

TABLE – 2.1

RAW MATERIALS CONSUMPTION

Sr. No. Raw Material Consumption

(MT/MT)

CAS No.

AZO DYES (BLENDING & GRINDING)

AMARANTH

Sodium Nepthionate 0.35 1338-24-5

HCl 0.50 7647-01-0

Sodium Nitrite 0.13 7632-00-0

R. Salt 0.45 117-43-1

Soda Ash 0.50 497-19-8

Salt (NaCl) 0.30 7647-14-5

BISMARK BROWN

MTD 0.94 97-80-7

HCl 1.50 7647-01-0

NaNO2 0.36 7632-00-0

Salt 0.25 7647-14-5

CARMOSINE


HCl 0.75 7647-01-0


N W Acid 0.48 84-87-7

Soda Ash 0.75 497-19-8

Salt (NaCl) 0.40 7647-14-5

CHROM BLACK T

6 Nitro Diazo 0.48 1328-53-6

HCl 1.69 7647-01-0

Alpha Napthol 0.25 90-15-3



Chromium sulphate 1.02 12306-95-7

NaOH 0.10 1310-73-2

CHRYSODINE

ANILINE 0.42 62-53-3

HCl 1.02 7647-01-0


M.P.D. 0.49 108-45-2

CRYSOPHYNINE

DASDA 0.51 81-11-8

HCl 0.97 7647-01-0


PHENOL 0.23 108-95-2

NaOH 0.22 1310-73-2

Salt(NaCl) 0.24 7647-14-5

Ethyl Chloride 0.15 75-00-3

MORDENT YELLOW 20

Amido G.Salt 0.69 842-16-0

HCl 0.45 7647-01-0


Salicylic Acid 0.34 69-72-7

Soda Ash/NaOH 0.35 497-19-8

Salt(NaCl) 0.30 7647-14-5

SUNSET YELLOW

Sulphanilic Acid 0.38 121-57-3

HCl 0.63 7647-01-0


Schaeffers Acid 0.49 93-01-6

NaOH 0.21 1310-73-2

Salt(NaCl) 0.38 7647-14-5

Na2CO3 0.28 497-19-8

PIGMENTS

PIGMENT ORANGE 5

2-5 dinitro aniline 0.54 95-82-9

HCl 1.69 7647-01-0


Β Napthol 0.42 135-19-3

NaOH 0.29 1310-73-0

PIGMENT ORANGE 13

DICHLORO BENZEDINE 0.41 106-46-7

HCl 0.61 7647-01-0




PMP 0.57 89-25-8

NaOH 0.33 1310-73-0

PIGMENT ORANGE 34

DI CHLOROBENZEDINE 0.38 91-94-1

HCl 0.58 7647-01-0


PTMP 0.60 288-13-1

NaOH 0.31 1310-73-0

PIGMENT RED 2

2 5 dichloroaniline 0.37 95-82-9

HCl 0.85 7647-01-0


3 Hydroxy Neptelinamide 0.59 7473-98-5

NaOH 0.34 1310-73-0

PIGMENT RED 12

P-Nitro Toludine 0.35 89-62-3

HCl 0.85 7647-01-0


Hydroxy Nepthio toudide 0.69 92-70-6

NaOH 0.34 1310-73-0

PIGMENT RED 48

Chlorosulpho toludine 0.52 95-69-2

HCl 1.18 7647-01-0


3 Hydroxy Nepthionic Acid 0.44 92-70-6

NaOH 0.47 1310-73-0

PIGMENT RED 53

Chlorosulpho toludine 0.59 95-69-2

HCl 1.33 7647-01-0


Β Napthol 0.38 135-19-3

NaOH 0.27 1310-73-0

Barium Salt 0.53 7727-43-7

PIGMENT RED 57.1

6 amino tolune sulphonic acid 0.48 104-15-4

HCl 2.59 7647-01-0


3 hydroxy nepthionic acid 0.49 92-70-6

NaOH 0.52 1310-73-0



PIGMENT RED 63

Tobias acid 0.53 81-16-3

HCl 1.18 7647-01-0


3 hydroxy nepthionic acid 0.44 92-70-6

NaOH 0.24 1310-73-0

Calcium Salt 0.19 10043-52-4

PIGMENT RED 112

TriChloro Aniline 0.40 636-30-6

HCl 1.03 7647-01-0


2 Nepthol o toludide 0.58 2425-85-6

NaOH 0.21 1310-73-0

PIGMENT RED 170

Amino benzamide 0.30 2835-68-9

HCl 0.66 7647-01-0


Ethoxi phynine nepthionic acid 0.66 279262-28-1

NaOH 0.22 1310-73-0

PIGMENT VIOLET 23

Carbazole 0.83 86-74-8

DES 0.83 64-67-5

HCl 1.24 76-47-01-0

NaOH 0.50 1310-73-0

MCB 0.25 108-90-7

DCB 0.50 108-90-7

CHLORNIL 0.83 118-21-2

DEG 0.08 107-21-1

PIGMENT YELLOW 1

2 Nitro P Toludine 0.45 89-62-3

HCl 0.51 7647-01-0


Aceto acetanilide 0.49 102-01-2

NaOH 0.29 1310-73-0

PIGMENT YELLOW 12

DI CHLORO BENZEDINE 0.40 106-47-2

HCl 0.60 7647-01-0


Aceto Xylidide 0.56 104-46-2



NaOH 0.32 1310-73-0

PIGMENT YELLOW 14


HCl 0.57 7647-01-0


Acetoacetatoludide 0.58 16634-82-5

NaOH 0.30 1310-73-0

PIGMENT YELLOW 17


HCl 0.54 7647-01-0


Acetoacetaniside 0.60 102-01-2

NaOH 0.29 1310-73-0

PIGMENT YELLOW 61

2Nitro p amino sulphonic acid 0.53 96-67-3

HCl 0.91 7647-01-0


Oxo phynile butamide 0.43 2713-85-1

NaOH 0.24 1310-73-0

Calcium chloride 0.56 10043-52-4

SOLVENT DYES

SOLVENT ORANGE 1

ANILINE 0.44 62-53-3

HCl 1.05 7647-01-0


Resorcinol 0.52 108-46-3

SOLVENT RED 24

Garnet GBC 0.59 101-89-3

HCl 0.70 7647-01-0


β Nepthol 0.38 135-19-3

Soda Ash/NaOH 0.20 497-19-

8/1310-73-0

SOLVENT RED 27

XYLIDINE 0.31 87-59-2

HCl 1.24 7647-01-0


TOLUDINE 0.27 108-88-3

NaOH 0.25 1310-73-0



Β NAPTHOL 0.36 135-19-3

SOLVENT YELLOW 2

ANILINE 0.42 62-53-3

HCl 1.00 7647-01-0


D.M.A. 0.55 95-68-1

SOLVENT YELLOW 14

ANILINE 0.37 62-53-3

HCl 0.89 7647-01-0


β Napthol 0.57 135-19-3


8/1310-73-0

ACID DYES

ACID RED 1

ANILINE 0.18 62-53-3

HCl 0.57 7647-01-0


ACETYLE H ACID 0.68 16698-16-1

Soda Ash 0.57 497-19-8

Salt(NaCl) 0.57 7647-14-5

ACID RED 4

O-Anisidine 0.32 90-04-0

HCl 0.57 7647-01-0


N W Acid 0.58 84-87-7

Soda Ash 0.65 497-19-8

Salt(NaCl) 0.52 7647-14-5

ACID RED 18


HCl 0.50 7647-01-0


G.Salt 0.45 578-85-8

Soda Ash 0.50 497-19-8

Salt(NaCl) 0.30 7647-14-5

ACID RED 73

PAAB 0.35 60-09-3

HCl 0.69 7647-01-0




G.Salt 0.56 578-85-8

Soda Ash 1.04 84-87-7

Salt(NaCl) 0.20 7647-14-5

ACID RED 88


HCl 0.70 7647-01-0


β Napthol 0.35 135-19-3

NaOH 0.30 1310-73-0

Salt(NaCl) 0.30 7647-14-5

ACID RED 97

BDSA 0.33 117-61-3

HCl 0.71 7647-01-0


β Napthol 0.28 135-19-3

NaOH 0.22 1310-73-0

Salt(NaCl) 0.28 7647-14-5

ACID RED 114

O Di anisidine 0.26 90-04-0

HCl 0.42 7647-01-0


H acid 0.67 90-20-0

Soda Ash 0.53 497-19-8

Salt(NaCl) 0.42 7647-14-5

ACID RED 119

Sulphanilic acid 0.25 121-57-3

HCl 2.20 7647-01-0


Amine 0.21 75-04-7

Hydrobenzenesulfonic acid 0.43 98-11-3

Soda Ash 0.59 497-19-8

Salt(NaCl) 0.73 7647-14-5

ACID RED 128


HCl 0.44 7647-01-0


G acid 0.33 578-85-8

Phenol 0.10 108-95-2

Pts Chloride 0.27 98-59-9

Soda Ash 0.55 497-19-8



Salt(NaCl) 0.44 7647-14-5

ACID RED 137

P.A.A. 0.34 122-80-5

HCl 0.54 7647-01-0

NaNO2 0.16 7632-00-0

N Ace. J Acid 0.57 6334-97-0

SALT 0.56 7647-14-5

ACID RED 214

m-Aminonitrophenol Sulphonic acid 0.52 96-93-5

HCl 0.76 7647-01-0

NaNO2 0.16 7632-00-0

Quinoline 0.39 91-22-5

SALT 0.56 7647-14-5

Soda 0.67 497-19-8

ACID RED 231

P.A.A. 0.33 122-80-5

HCl 0.53 7647-01-0

NaNO2 0.16 7632-00-0

GAMA ACID 0.53 39496-87-2

SALT 0.56 7647-14-5

ACID YELLOW 1

α Naphthol 0.42 90-15-3

H2SO4 0.89 7664-93-9

HNO3 0.38 7697-67-2

SODA 0.37 497-19-8

ACID YELLOW 11

ANILINE 0.24 62-53-3

HCl 0.63 7647-01-0


S.P.M.P. 0.67 119-17-5

Soda Ash 0.85 497-19-8

Salt(NaCl) 0.34 7647-14-5

ACID YELLOW 17


HCl 0.48 7647-01-0


2-5 dichlo.spmp 0.55 84-57-1

NaOH 0.17 1310-73-2

Salt(NaCl) 0.29 7647-14-5

Na2CO3 0.19 497-19-8



ACID YELLOW 23


HCl 0.48 7647-01-0


SPCP 0.30 118-47-8

NaOH 0.17 1310-73-2

Salt(NaCl) 0.29 7647-14-5

Na2CO3 0.21 497-19-8

ACID YELLOW 36

Metanilic Acid 0.53 121-41-1

HCl 0.94 7647-01-0


D.P.A. 0.52 122-39-4

Na2CO3 0.99 497-19-8

Salt(NaCl) 0.20 7647-14-5

ACID YELLOW 42

BDSA 0.43 117-61-3

HCl 0.63 7647-01-0


P.M.P 0.48 89-25-8

Soda Ash 0.63 497-19-8

Salt(NaCl) 0.38 7647-14-5

ACID YELLOW 59

Amino benzoic acid 0.42 10541-83-0

HCl 0.62 7647-01-0


PMP 0.52 89-25-8

NaOH 0.32 1310-73-2

Salt(NaCl) 0.31 7647-14-5

ACID YELLOW 79

MAP 0.22 591-27-5

HCl 0.45 7647-01-0


SPMP 0.67 119-17-5

Soda Ash 0.45 497-19-8

Salt(NaCl) 0.27 7647-14-5

Ester 0.14 95481-62-2

ACID BLACK 1

PNA 0.25 93-58-3



HCl 0.88 7647-01-0


H Acid 0.57 90-20-0

ANILINE 0.18 62-53-3

Soda Ash 0.35 497-19-8

Salt(NaCl) 0.44 7647-14-5

ACID BLACK 18


HCl 0.68 7647-01-0


1-napthyle amine 0.20 134-32-7

H.Acid 0.43 90-20-0

NaOH 0.22 1310-73-2

Salt(NaCl) 0.41 7647-14-5

ACID BLACK 21

5-Amino Naptiosulphonic acid 0.32 120-98-5

HCl 0.66 7647-01-0



N p toly peri acid 0.41 139-90-8

NaOH 0.21 1310-73-2

Salt(NaCl) 0.39 7647-14-5

ACID BLACK 26

5-amino Anilino benz sulphonic acid 0.37 121-57-3

HCl 0.70 7647-01-0



Schaeffers acid 0.32 93-01-6

NaOH 0.23 1310-73-2

Salt (NaCl) 0.42 7647-14-5

ACID BLACK 41

PNA 0.25 93-58-3

HCl 0.88 7647-01-0


H Acid 0.56 90-20-0

ANILINE 0.33 63-53-3

Soda Ash 0.35 497-19-8

Salt(NaCl) 0.44 7647-14-5

ACID BLACK 52

6 Nitro diazo 0.48 1328-53-6



HCl 1.69 7647-01-0

Bita Napthol 0.25 135-19-3

Chromium sulphate 1.02 12306-95-7

NaOH 0.10 1310-73-2

ACID BLACK 58

Sulpho methyl amino phenol 0.47 19803-97-7

HCl 0.50 7647-01-0


1-Napthyle Acetonamide 0.51 86-86-2

NaOH 0.26 1310-73-2

Salt(NaCl) 0.25 7647-14-5

ACID BLACK 63

2-Amino Nitro Phenol 0.39 603-87-2

HCl 1.25 7647-01-0


β Napthol 0.36 135-19-3

Cromium Sulphate 0.93 12306-95-7

NaOH 1.00 1310-73-2

Salt(NaCl) 1.25 7647-14-5

ACID BLACK 194

Beta Napthol 0.21 135-19-3

6-Nitro 1,2,4,Diazo 0.42 1328-53-6

Caustic Lye 0.28 1310-73-2

Salicylic Acid 0.02 69-72-7

Basic Chromium Sulfate 0.19 12306-95-7

ACID BLACK 210

PNA 0.26 93-58-3

HCl 0.74 7647-01-0


DASA 0.19 16803-97-7

MPD 0.11 108-45-2

H. ACID 0.22 90-20-0

NaOH/Na2CO3 0.37 1310-73-

2/497-19-8

Salt(NaCl) 0.21 7647-14-5

ACID BLUE 158

Gama Acid 0.48 39496-87-2

HCl 1.20 7647-01-0


Schaffer Acid 0.45 93-01-6



Na2CO3 0.55 497-19-8

Salt(NaCl) 0.40 7647-14-5

ACID BROWN 14


HCl 1.19 7647-01-0


Resorcinol 0.17 108-46-3

NaOH 0.44 1310-73-2

Salt(NaCl) 0.32 7647-14-5

ACID BROWN 28

m-Amino Nitro Phenol 0.46

HCl 1.34 7647-01-0


2oh 5mit.acetoamide 0.55 50772-59-3

NaOH 0.82 1310-73-2

Salt(NaCl) 0.60 7647-14-5

ACID BROWN 121

PNA 0.17 93-58-3

HCl 1.25 7647-01-0


H Acid 0.40 90-20-0

resorcinol 0.14 108-46-3

2amino nitrophenol 0.19 603-87-2

Soda Ash 0.50 497-19-8

Salt(NaCl) 7647-14-5

ACID GREEN 19

(2-5DCA) 0.21 95-82-9

HCl 0.89 7647-01-0


H Acid 0.57 90-20-0

ANILINE 0.12 62-53-3

Soda Ash 0.36 497-19-8

Salt(NaCl) 0.45 7647-14-5

ACID ORANGE 7


HCl 0.74 7647-01-0


β Napthol 0.45 135-19-3

NaOH 0.27 1310-73-2

Salt (NaCl) 0.20 7647-14-5



ACID ORANGE 10

ANILINE 0.22 62-53-3

HCl 0.55 7647-01-0


G. Salt 0.72 578-85-8

Soda Ash 0.75 497-19-8

Salt (NaCl) 0.30 7647-14-5

ACID ORANGE 30

Aniline 0.21 62-53-3

HCl 0.78 7647-01-0


Chloro acetyle j acid 0.84 6334-97-0

Soda Ash 0.78 497-19-7

Salt(NaCl) 0.67 7647-14-5

ACID ORANGE 72

3-Amino-4-hydroxy-5-nitrobenzenesulfonic

acid

0.52 98-37-3

HCl 1.00 7647-01-0


P.M.P 0.39 89-25-8

Soda Ash 0.78 497-19-8

Salt(NaCl) 0.67 7647-14-5

DIRECT DYES

DIRECT BLACK NB

DABA 0.26 785-30-5

HCl 0.70 7647-01-0


H ACID 0.37 90-20-0

ANILINE 0.11 62-53-3

M.P.D. 0.13 108-45-2

Na2CO3 0.35 497-19-8

Salt(NaCl) 0.23 7647-14-5

DIRECT BLACK 19

PNA 0.22 93-58-3


HCl 1.50 7647-01-0

H. Acid 0.24 90-20-0

Soda 0.80 497-19-8

MPD 0.13 108-45-2

Salt 0.30 7647-14-5



DIRECT BLACK 22

DASA 0.28 16108-97-7


HCl 1.08 7647-01-0

Gama Acid 0.43 39496-87-2

Soda 0.72 497-19-8

MPD 0.19 108-45-2

Salt 0.27 7647-14-5

DIRECT BLACK 168

FC Acid 0.27 119-70-0


HCl 1.43 7647-01-0

H. Acid 0.30 90-20-0

Soda 0.29 497-19-8

MPD 0.10 108-45-2

Aniline 0.09 62-53-3

Salt 0.29 7647-14-5

DIRECT BLUE G


HCl 0.53 7647-01-0


Scaffer Acid 0.59 93-01-6

Soda Ash 0.66 497-19-8

Salt(NaCl) 0.53 7647-14-5

DIRECT BLUE 15


HCl 0.42 7647-01-0


H acid 0.67 90-20-0

Soda Ash 0.53 497-19-8

Salt(NaCl) 0.42 7647-14-5

DIRECT SKY BLUE FB


HCl 0.42 7647-01-0


Chikago Acid 0.67 82-47-3

Soda Ash 0.53 497-19-8

Salt(NaCl) 0.42 7647-14-5

DIRECT FAST VIOLET 2RL



Mix xylidine sulphonate 0.26 1300-73-8

HCl 0.52 7647-01-0


Pera Cresidine 0.18 120-71-8

Soda Ash 0.66 497-19-8

Salt(NaCl) 0.52 7647-14-5

Phinyle J Acid 0.43 119-40-4

DIRECT FAST VIOLET 2RL

Mix xylidine sulphonate 0.26 133-73-8

HCl 0.52 7647-01-0


Pera Cresidine 0.18 120-71-8

Soda Ash 0.66 497-19-8

Salt(NaCl) 0.52 7647-14-5

Phinyle J Acid 0.43 119-40-4

DIRECT ORANGE 34

Sulphanilic acid 0.57 121-57-3

HCl 0.65 7647-01-0


Aniline 0.15 62-53-3


8/1310-73-2

Salt(NaCl) 0.16 7647-14-5

toludine 0.17 108-88-3

DIRECT RED 7


HCl 0.51 7647-01-0


Napthionic Acid 0.57 1338-24-5

Soda Ash 0.64 497-19-8

Salt(NaCl) 0.51 7647-14-5

DIRECT RED 23

Aniline 0.11 62-53-3

HCl 0.46 7647-01-0


JAcid Urea 0.58 134-47-4

P-Amino Acetanilide 0.23 122-80-5

NaOH 0.58 1310-73-2

Salt(NaCl) 0.46 7647-14-5

DIRECT RED 26



Aniline 0.24 62-53-3

HCl 0.52 7647-01-0


JAcid Urea 0.66 134-47-4

NaOH 0.65 1310-73-2

Salt(NaCl) 0.52 7647-14-5

DIRECT RED 80

Disulpho PAAB 0.52 104-23-4

HCl 0.51 7647-01-0


J Acid Urea 0.37 134-47-4

Soda Ash 0.47 497-19-8

Salt(NaCl) 0.14 7647-14-5

DIRECT RED 81

PAABSA 0.36 104-23-4

HCl 0.90 7647-01-0


Benzoyl J Acid 0.56 132-87-6

Soda Ash 0.97 497-19-8

Salt(NaCl) 0.26 7647-14-5

DIRECT RED 89

Aniline 0.08 62-53-3

HCl 0.59 7647-01-0


H Acid 0.27 90-20-0

Scaffer Acid 0.19 93-01-6

Methyle Anisol 0.10 104-93-8

Sulpho BEnzoyle amine 0.17 100-46-9

Cynuric chloride 0.16 108-77-0

Soda Ash 0.64 497-19-8

Salt(NaCl) 0.17 7647-14-5

DIRECT RED 239

Bonners Acid 0.33

J-Acid 0.19 87-02-5

HCl 30% 0.26 7647-01-0


Sodium Bicarbonate 0.2 144-55-8

Caustic Lye 0.05 1310-73-2

DIRECT YELLOW 4

DASDA 0.60 81-11-8



HCl 1.14 7647-01-0


PHENOL 0.27 108-95-2

NaOH 0.26 1310-73-2

Salt(NaCl) 0.29 7647-14-5

DIRECT BROWN NB

DABA 0.32 785-30-8

HCl 0.71 7647-01-0


GAMA 0.34 39496-87-2

SALICYLIC ACID 0.20 69-72-7

Na2CO3 0.43 497-19-8

Salt(NaCl) 0.29 7647-14-5

REACTIVE DYES

REACTIVE BLACK CNN

Acetanilide VS 0.44 2494-89-5

H-Acid 0.15 90-20-0

HCl 30% 0.18 7647-01-0


Sodium Bicarbonate 0.24 144-55-8

J-Acid 0.04 87-02-5

Caustic Lye 0.01 1310-73-2

REACTIVE BLACK 5

Acetanilide VS 0.48 2494-89-5

H-Acid 0.27 1310-73-2

HCl 30% 0.19 7647-01-0


Sodium Bicarbonate 0.24

REACTIVE BLACK 8

CYNURIC CJHLORIDE 0.25 108-77-0


HCl 0.20 7647-01-0

M.amino nitro Phenol 0.21

Soda 0.67 497-19-8

H.Acid 0.43 90-20-0

Salt 0.40 7647-14-5

REACTIVE ORANGE 7

V S 0.42 77-77-0


HCl 0.86 7647-01-0



Aceto S N 0.49 1338-24-5

Soda 0.79 497-19-8

Salt 0.47 7647-14-5

REACTIVE ORANGE 122



HCl 0.53 7647-01-0

VS 0.26 77-77-0

Soda 0.48 497-19-8

2-5 DISULPHO 2 ANAPTHYLE 0.29

Salt 0.29 7647-14-5

Gama 0.23 39496-87-2

REACTIVE RED 3BS

CYNURIC CHLORIDE 0.13 108-77-0


HCl 0.68 7647-01-0

H.Acid 0.22 90-20-0

Soda 0.34 497-19-8

2AMINO DI SULPHONIC ACID 0.20 99-44-2

Salt 0.21 7647-14-5

REACTIVE RED M 5B



HCl 0.24 7647-01-0

Aniline 0.15 62-53-3

Soda 0.81 497-19-5

H.Acid 0.51 90-20-0

Salt 0.48 7647-14-5

REACTIVE RED 120

CYNURIC CHLORIDE 0.21 108-77-0


HCl 0.31 7647-01-0

H.ACID 0.36 90-20-0

Soda 0.29 497-19-8

1-AMINE SULPONEPTH 0.28

Salt 0.17 7647-14-5

P.P.D. 0.06 88-53-9

REACTIVE YELLOW 15





HCl 0.82 7647-01-0

VS 0.40 77-77-0

Soda 0.75 497-19-8

Benzene Sulphonic Acid 0.24 27176-87-0

Salt 0.45 7647-14-5

REACTIVE YELLOW 37

Cynuric Chloride 0.26 108-77-0


HCl 0.76 7647-01-0

2 AMINO 2 5 DI SULPHON 0.45 24605-36-5

Soda 0.70 497-19-8

VS PY ZO 0.23 88054-14-2

Salt 0.42 7647-14-5

REACTIVE YELLOW 145



HCl 0.51 7647-01-0

VS 0.25 77-77-0

Soda 0.47 497-19-8

1 Nepthyle amine Trisulphophonic Acid 0.36 1429-50-1

Salt 0.28 7647-14-5

Aminophynyle urea 0.17 91711-44-5

REACTIVE YELLOW 160



HCl 0.67 7647-01-0

VS 0.32 77-77-0

Soda 0.61 497-19-8

2 4 diamino benzene sulphonic acid 0.22 88-63-1

Salt 0.37 7647-14-5

Easter 0.40 95481-62-2



2.4 INFRASTRUCTURE FACILITIES

2.4.1 LAND

Total 4,452 m2

land area is available at site; out of this area about 2,600 m2 (58.4 %) area is

covered as greenbelt and other forms of greenery.

2.4.2 TRANSPORTATION FACILITIES

Transportation of all raw material/s and Product/s are and will be primarily by road only.

2.4.3 WATER AND WASTEWATER

Existing:

Total raw water requirement is 13.5 KL/day (Industrial: 11.2 KL/day + Domestic: 0.3 KL/day +

Gardening: 2.0 KL/day) which is met through ground water (bore well). Total waste water

generation is 3.6 KL/day (Industrial: 3.3 KL/day + Domestic: 0.3 KL/day). Waste water is

treated in existing Effluent Treatment Plant (ETP) of primary treatment (neutralization)

facility. Treated effluent is sent to Spray Dryer/Single Stage Vacuum Evaporation system to

achieve zero discharge of waste water. Waste water converted in steam/converted in clean

water through condenser of single stage evaporation system is recycled in process or used

for makeup water in cooling tower. Domestic waste water is disposed through septic tank &

soak pit.

Total after proposed expansion:

Total raw water requirement will be is 31.0 KL/day (Industrial: 24.5 KL/day + Domestic: 3.0

KL/day + Gardening: 3.5 KL/day) which will also be met through ground water (existing bore

well). No additional bore well will be drilled within premises after proposed expansion. Total

waste water generation will be 16.3 KL/day (Industrial: 13.3 KL/day + Domestic: 3.0 KL/day).

Treatment and disposal of waste water will be done through same way as existing.



TABLE – 2.2

DETAILS OF WATER CONSUMPTION & WASTE WATER GENERATION

SR.

NO. DESCRIPTION

EXISTING TOTAL AFTER PROPOSED

EXPANSION

WATER

CONSUMPTION

(KL/Day)

WASTE WATER

GENERATION

(KL/Day)

WATER

CONSUMPTI

ON (KL/Day)

WASTE

WATER

GENERATION

(KL/Day)

1 Process 3.5 2.5 15.0 12.0

2 Boiler 1.0 0.1 2.0 0.2

3 Cooling 6.0 0.3 6.0 0.3

4 Washing 0.5 0.4 1.0 0.8

5 Scrubber 0.2 -- 0.5 --

Total Industrial 11.2 3.3 24.5 13.3

5 Domestic * 0.3 0.3 3.0 3.0

6 Gardening 2.0 -- 3.5 --

Grand Total 13.5 3.6 31.0 16.3

* Domestic waste water will be disposed through septic tank & soak pit.



• WATER BALANCE DIAGRAM - TOTAL AFTER PROPOSED EXPANSION

(All quantities are in KL/Day)

Total Water Requirement

31.0

Process

12.0

Boiler

2.0

Cooling

6.0

Washing

1.0 Scrubber

0.5

Gardening

3.5

Domestic

3.0

Domestic

wastewater:

3.0 � Septic

Tank/Soak

Pit

Process

W/W

12.0

Boiler

W/W

0.2

Cooling

W/W

0.3

Washing

W/W

0.8

ETP

(Primary and Tertiary Treatment)

Spry Dryer/Single Stage Vacuum

Evaporation

13.3

Treated Water

Recycled in process or

used for makeup water in

cooling tower



2.4.3.1 TREATMENT PROCESS

2.4.3.1.1 EFFLUENT CHARACTERISTICS

Sr. No. Parameter Inlet Outlet

1 pH 6.0 – 9.5 7.0 – 7.5

2 COD (mg/L) 2,000 - 2,500 1,500 - 1,600

3 BOD (mg/L) 1,600 - 1,800 600 - 800

4 TDS (mg/L) 4,000 3,500

2.4.3.1.2 EFFLUENT TREATMENT PLANT, SPRAY DRYER AND SINGLE STAGE VACUUM

EVAPORATION SYSTEM FACILITY

M/s. S. M. Industries has ETP, Spray Dryer and Single Stage Vacuum Evaporation system to

achieve zero discharge of waste water.

• Effluent Treatment Plant (ETP) Details

First all non-toxic and biodegradable streams of wastewater is collected in Collection Tank

(CT-01). Then effluent is pumped to Neutralization Tank (NT-01) where the continuous

addition and stirring of Caustic solution is done to maintain neutral pH of wastewater from

Caustic Dosing Tank (CDT-01) as per requirement by gravity. Mixer is provided in NT-01 for

mixing.

Thereafter, neutralized wastewater is passed through Sludge Drying Beds (SDBs-A/B) for

removal of suspended solids and filter rate from SDB-01 is collected in Treated Effluent

Sump (TES-01) before sent to Spray Dryer (SD-01) / Singe Stage Vacuum Evaporation System

for further treatment.

Unit Name and Size

S.N. Name of unit Size (m x m x m) No. MOC/ Remark

Flow = 15 KLD

1 Collection Tank (CT-01) 3.0 x 3.0 x 2.0 1 RCC M25

2 Neutralization Tank (NT-01) 4.0 x 4.0 x 2.0 1 RCC M25

3 Treated Effluent Sump (TES-01) 1.0 x 1.0 x 1.5 1 RCC M25

4 Spray Dryer (SD-01) 15 KLD 1 SS

5 Single Stage Vacuum

Evaporation System

1 KL/hr. 1 --

6 Caustic Dosing Tank (CDT-01) 500 lit 1 HDPE

7 Sludge Drying Beds (SDBs-A/B) 3.0 x 3.0 2 Bk. Mas. With PCC



Bedding+ filling Media

ETP Process Flow Diagram:

Spray Dryer / Single Stage

Vacuum Evaporation System



Spray Dryer

Spray Dryer is of 1.2 KL/hr capacity. Effluent is directly spray dried in spray dryer. Solid

waste generate from process is either disposed to common TSDF site or sell as a by-product.

Finally company achieves zero discharge.

Existing spray dryer capacity is adequate to spray dried additional effluent to be generated

after proposed expansion.

SPRAY DRYER UNITS:

Sr. No. Unit Name Sr. No. Unit Name

1 Feed Tank 13 Drying Chamber

2 Water Funnel 14 Cyclone Separator

3 Feed Pump 15 Rotary Valve

4 Rotary Atomizer 16 Ventury Duct

5 Air Filter Unit for DHAG-01 17 Wet Scrubber

6 F.D. Blower for DHAG-01 18 Scrubber Tank

7 Direct Fired Air Heater 19 Scrubber Pump

8 Gas Burner 20 I.D. Blower

9 Air Filter Unit for DHAG-02 21 Secondary Scrubber

10 F.D. Blower for DHAG-02 22 Exhaust Chimney

11 Direct Wood/Agrowaste 23 Control Panel

Fired HAG

12 Air Distributor



PROCESS FLOW DIAGRAM:



• Single Stage Vacuum Evaporation System - Capacity: 1 KL/hr.


Waste water if feed to evaporator vessel from feed tank. Steam is supplied to calandria for

heating the water inside vessel. Due to thermo siphon, water starts heating uniformly.

Cooling water feed pump with spraying system in barometric condenser create vacuum in the

system.

Now, the top surface of water in vessel is heated to enough temperature to start vaporizing

under vacuum. This vapor passes through moisture separator and enters in to direct cooling

barometric condenser and comes in contact with cooled water circulated through cooling tower

through feed pump.

Waste water converted in steam/converted in clean water through condenser which is recycled

in process or use for makeup water in cooling tower. Thus, this will reduce fresh water demand.

Now, due to constant evaporation, TDS level in the vessel is increased slowly and reaches to

crystallization stage. This high TSD sludge is drained out of vessel and kept in open crystallizer

pan. After crystallization, solid sludge is centrifuged for further drying and sends to TSDF site for

disposal. The residue comes out from centrifuge is recycled in next batch (feed tank).

UNITS:

Sr. No. Unit Name

1 Evaporator vessel with steam heated calandria

2 Feed Tank

3 Moisture Separator

4 Direct Cooling Barometric Condenser

5 Cooling Tower

6 Cooling water feed pump



PROCESS FLOW DIAGRAM:



2.4.4 SOURCES OF AIR EMISSION AND AIR POLLUTION CONTROL EQUIPMENTS

TABLE – 2.3

DETAILS SOURCE OF EMISSION AND AIR POLLUTION CONTROL EQUIPMENTS

Sr.

No. Stack/Vent

attached to

Stack

Height

(meter)

Stack

Diameter

(meter)

Fuel name &

Quantity

Type of

Emission APCE

Existing

1. Boiler

(1 TPH) 12 0.6

Agro waste /

Biofuel (White coal)

(175 Kg/hr.)

PM

SO2

NOx

Multicyclone

Separator

and Dust

Collector

2 Hot Air Generator 12 0.3 PNG

(10 m3/hr)

PM

SO2

NOx

Dust

Collector

Proposed

3 Boiler

(1 TPH) 12 0.6

Agro waste /

Biofuel (White coal)

(175 Kg/hr.)

PM

SO2

NOx

Cyclone

Separator

4 Spray Dryer

(1.2 KL/hr.) 15 0.5

PNG

(55 m3/hr)

PM

SO2

NOx

Water

immersed

Cyclone

separator

for Dust

Collection

5

D.G. Set*

(Capacity – 75

KVA)

10 0.3 Diesel

(30 Liter/hr)

PM

SO2

NOx

-

* To be used in emergency only.



2.4.5 NOISE LEVEL AND CONTROL SYSTEM

Extensive oiling and lubrication and preventive maintenance are carried out to reduce noise

generation at source to the permissible limit. Manufacturers/suppliers of major noise

generating equipment/machines like compressors, generators should be asked to take required

measures for minimizing the noise levels generated by machines by using noise absorbing

material for various enclosures or using appropriate design/technology for

fabricating/assembling the machines. However, at place where noise levels can exceed the

permissible limit, Earplugs and Earmuffs are provided to those working in such area.

Audiometric tests should be conducted periodically for the employees working close to the high

noise sources. This system will follow after proposed expansion. Adequate plantation has done

to control noise level at site.

2.4.6 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM

Six categories of Hazardous/Solid Wastes are generated from existing unit and total Four

categories of Hazardous/Solid Wastes to be generated after proposed expansion. Hazardous

waste generation quantity, physical characteristics and mode of disposal are given in Table-2.4.

TABLE – 2.4

DETAILS OF HAZARDOUS/SOLID WASTES GENERATION AND DISPOSAL MODE

SR.

NO. TYPE OF WASTE

CATEGOR

Y NO.

QUANTITY

DISPOSAL MODE EXISTING

TOTAL AFTER

PROPOSED

EXPANSION

1 ETP Sludge 35.3/Sch-I 0.416

MT/Month 1.2 MT/Month

Collection, Storage,

Transportation and sent to

common TSDF site for

disposal.

2 Used Oil 5.1/Sch-1 -- 20 Liter/Month


Transportation and sell to

GPCB registered reprocess

or/refiner

3

Discarded

Drums/Container

s /Bags

33.1/Sch-I -- 1000 Nos./Month


Decontamination,

Transportation & sell to GPCB

authorized Vendor.

4 MEE Salt 37.3/Sch-I -- 10 MT/Month Collection, Storage,




common TSDF site for

disposal/reuse.

5 Spry Dryer

Sludge 35.3/Sch-I -- 20 MT/Month

Collection, Storage and sell as

Tinting dyes to end user.

6 Fly Ash from

Boilers -- -- 10 MT/Month



brick manufacturer/common

TSDF site for disposal /used

for land filling.

7 Spent Solvent 26.4/Sch-I -- 1 MT/Month


Transportation and sell to

end user.

2.4.7 DETAILS OF UTILITIES

Various utilities required for proper functioning of manufacturing plants. These utilities include

boiler, cooling plant, cooling tower, DM water plant, Chilling Plant & Brine Unit, Air compressor,

High Vacuum System, etc.

2.5 POWER & FUEL REQUIREMENT

• Power Requirement

Sr.

No.

Requirement Source

Existing

Total After

Proposed

Expansion

Existing After Proposed Expansion

1. 60 KVA 80 KVA • MGVCL

• MGVCL

• D.G. Set - 1 no.

- 75 KVA capacity (emergency

standby)



• Fuel Requirement

Sr.

No. Fuel

Requirement

Existing Total After Proposed Expansion

1 Agro waste /

Biofuel (White coal) 175 Kg/hr. 350 Kg/hr.

2 PNG 10 m3/hr. 65 m

3/hr.

3 Diesel - 30 Liter/hr.

2.6 DETAILS OF GREENBELT

Total 4,452 m2

land area is available at site; out of this area about 2,600 m2 (58.4 %) area is

covered as greenbelt and other forms of greenery.

2.7 DEPLOYMENT OF QUALIFIED/SKILLED MAN POWER

Particular Existing Total after Proposed Expansion

Regular 10 15

Contract 0 5

Total 10 20



2.8 STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS

Sr.

No.

Name of

Hazardous

chemical

Quantity Places of

its

Storage

(Storage

tank

/drums

/cylinders

/barrels)

No. of

Storages

Places

of its

Storage

State Type of

Hazards

Control measures

provided

Max.

that

Can

be

Stored

Actually

stored

(Including

in

process

&

handling)

1. HCl (30 %) 15 KL 12 KL Tank 3.0 Tank

Farm

Area

Liquid Corrosive • Closed handling and transferring

systems for Hazardous chemicals.

• Dyke wall and material collection

systems are provided to all material

storage tank/s.

• Fire Extinguishers and absorbents

will be available near storage tanks

and storage area.

• Drums to be stored on pallet with

the suitable trap.

2 H2SO4

(98%)

1 KL 0.2 KL Drum 1.0 # Storage

Area

Liquid Corrosive

environmental impact and risk assessment report for proposed expansion of dyes … ·...

Documents