plot no: c/387, 388, 389, gidc, vill: sayakha, tal: vagara,...

1

FORM-1

For

PROPOSED DYES, DYE INTERMEDIATES &

AGROCHEMICAL INTERMEDIATES IN EXISTING DYE

FORMULATION UNIT

of

M/s. POLYCHEM INDUSTRIES

PLOT NO: C/387, 388, 389,

GIDC, VILL: SAYAKHA,

TAL: VAGARA, DIST: BHARUCH

GUJARAT-INDIA

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

2

APPENDIX I

(See paragraph - 6)

FORM 1

(I) Basic Information

Sr.

No.

Item Details

1. Name of the project/s M/s. POLYCHEM INDUSTRIES

2. S. No. in the schedule 5(f) & 5(b)

3. Proposed capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

For detail Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. Formulation of powder dye: 1426 MT/Month

6. Category of Project i.e. ‘A’ or ‘B’ ‘A’

7. Does it attract the general condition? If

yes, please specify.

No

8. Does it attract the specific condition? If

yes, please specify.

No

9. Location

Plot/Survey/Khasra No. Plot No: C/387, 388, 389

Village Sayakha

Tehsil Vagara

District Bharuch

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Railway Station: Bharuch (20 km)

Airport: Vadodara (90 km)

11. Nearest Town, city, District Headquarters

along with distance in kms.

Sayakha Village (7 km)

Bharuch (20 km)

12. Village Panchayats, Zilla Parishad,

Municipal Corporation, local body

(complete postal address with telephone

nos. to be given)

Sayakha, Tal: Vagra, Dist: Bharuch, Gujarat

13. Name of the applicant M/s. POLYCHEM INDUSTRIES

14. Registered Address Plot No: C/387, 388, 389,

GIDC, VILL: Sayakha,

TAL: Vagara, DIST: Bharuch

Gujarat-INDIA

15. Address for correspondence: M/s. POLYCHEM INDUSTRIES

Plot No: A/1/17, 2nd

floor,

Sardar Patel road no. 1,

Udhana Udhyog nagar,

Near Udhana Railway station,

Surat-395210, Gujarat

3

Name Mr. Dhawal Bhatia

Designation (Owner/Partner/Director) Proprietor

Address M/s. POLYCHEM INDUSTRIES

Plot No: A/1/17, 2nd

floor,

Sardar Patel road no. 1,

Udhana Udhyog nagar,

Near Udhana Railway station,

Surat-395210, Gujarat

Pin Code 395210

e-mail [email protected]

Telephone No. +91 9825248492

Fax No. -

16. Details of Alternative Sites examined, if

any.

Location of these sites should be shown

on a topo sheet.

NA

17. Interlinked Projects NA

18. Whether separate application of

interlinked project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

21. Whether the proposal involves

approval/clearance under: if yes, details of

the same and their status to be given.

(a) The Forest (Conservation) Act, 1980?

(b) The Wildlife (Protection) Act, 1972?

(c) The C.R.Z. Notification, 1991?

No

22. Whether there is any Government

Order/Policy relevant/relating to the site?

No

23. Forest land involved (hectares) NA

24. Whether there is any litigation pending

against the project and/or land in which

the project is propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any

and its relevance with the proposed

project.

NA

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,

mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.).

4

(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will

cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes/

No

Details thereof with approximate

quantities frates, wherever possible)

with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase intensity of land use (with respect to local land use plan)

No

1.2 Clearance of existing land, vegetation

and Buildings?

Yes Minor site clearance activities shall be

carried out to clear shrubs and weed.

1.3 Creation of new land uses?

No The project site is located on level ground, which does not require any major land filling for area grading work.

1.4 Pre-construction investigations e.g.

bore Houses, soil testing?

No

1.5 Construction works? Yes For detail Please refer Annexure – II

1.6 Demolition works? No There will not any demolition work at the site.

1.7 Temporary sites used for construction

works or housing of construction

workers?

Yes Some land portion on the plot will be

provided for temporary housing of

construction workers during

construction stage. 1.8 Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

Yes For detail Please refer Annexure – II

1.9 Underground works mining or

tunneling?

No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Off shore structures? No

1.13 Production and manufacturing

processes?

Yes For detail Please refer Annexure -III

1.14 Facilities for storage of goods or

materials?

Yes Area for storage tank farm, raw materials and finished products will be developed for the proposed expansion project.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents?

Yes Facilities for treatment or disposal of liquid effluents are given as Annexure – V & Facilities for treatment or disposal of solid waste is given as Annexure –VI.

1.16 Facilities for long term housing of

operational workers?

No The unit shall be running round the clock. The operational staff will be recruited locally and working in shift, hence no housing for the operational workers.

5

1.17 New road, rail or sea traffic during

Construction or Operation?

No There will not be any new road/rail or sea traffic during construction or operational phase.

1.18 New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No

1.20 New or diverted transmission lines or

Pipelines?

No There will not be said work at the site.

1.21 Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No

1.22 Stream crossings? No

1.23 Abstraction or transfers of water form

ground or surface waters?

No Surface water.

1.24 Changes in water bodies or the land

surface

Affecting drainage or run-off?

No

1.25 Transport of personnel or materials for

construction, operation or

decommissioning?

Yes By road only.

1.26 Long-term dismantling or

decommissioning or restoration works?

No

1.27 Ongoing activity during

decommissioning which could have an

impact on the environment?

No

1.28 Influx of people to an area either

temporarily or permanently?

Yes As the construction party will be on

contract basis, it will temporary increase

population. But after construction stage,

the new recruitment of the employees

will be done which can have minor

impact on the population.

1.29 Introduction of alien species?

No

1.30 Loss of native species or genetic

diversity?

No

1.31 Any other actions? No

6

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sr.

No.

Information/checklist confirmation Yes/

No

Details there of (with approximate

quantities frates, wherever possible) with

source of information data

2.1 Land especially undeveloped or

agricultural land (ha)

No The land is for Industrial Use

2.2 Water (expected source & competing

users) unit: KLD

Yes Water Source – GIDC Water Supply

Water balance is given as Annexure – IV

2.3 Minerals (MT) No

2.4 Construction material - stone,

aggregates,

and / soil (expected source - MT)

Yes Construction materials, like steel, cement,

crushed stones, sand, rubble, etc.

required for the project shall be procured

from the local market of the region.

2.5 Forests and timber (source - MT) No.

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT), energy (MW)

Yes For detail please refer Annexure – IV

2.7 Any other natural resources (use

appropriate standard units)

No

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.

Sr.

No.


No


quantities/rates, wherever possible) with


3.1 Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes For details please refer Annexure – VIII

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No

3.3 Affect the welfare of people e.g. by

changing living conditions?

Yes Direct/Indirect employment

7

3.4 Vulnerable groups of people who could

be affected by the project e.g. hospital

patients, children, the elderly etc.

No

3.5 Any other causes No

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr.

No.


No




4.1 Spoil, overburden or mine wastes

No

4.2 Municipal waste (domestic and or

commercial wastes)

No

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure –VI

4.4 Other industrial process wastes

No

4.5 Surplus product

No

4.6 Sewage sludge or other sludge from

effluent treatment

Yes

Please refer Annexure – VI

4.7 Construction or demolition wastes

No

4.8 Redundant machinery or equipment

No

4.9 Contaminated soils or other materials

No

4.10 Agricultural wastes

No

4.11 Other solid wastes Yes Please refer Annexure –VI

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr.

No.


No


quantities/rates, wherever possible)


5.1 Emissions from combustion of fossil

fuels from stationary or mobile

Yes For details Please refer Annexure – VII.

8

sources

5.2 Emissions from production processes

Yes Stack emission will remain within the

norms prescribed by CPCB. Please refer

Annexure – VII.

5.3 Emissions from materials handling

storage or transport

Yes The construction materials such as stones,

cements, bricks & coal may pollute the air by

dust particles. But it will be controlled by

covering the trucks & trailers by clothes during

transportation.

5.4 Emissions from construction activities

including plant and equipment

Yes During construction work, the Nearby

buildings area will be covered by sheets or

clothes to avoid dust Contamination in air.

5.5 Dust or odors from handling of

materials including construction

materials, sewage and waste

No

5.6 Emissions from incineration of waste No

5.7 Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No

5.8 Emissions from any other sources No

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.


No



with source of information data with


6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes The Noise level will be within the

prescribed limit. Adequate preventive &

control measures will be taken at noisy

area. No significant noise, vibration or

emission of light & heat from the unit.

6.2 From industrial or similar processes Yes -do-

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational

traffic

No

6.6 From lighting or cooling systems No

6.7 From any other sources No

9

7. Risks of contamination of land or water from releases of pollutants into the ground or into

sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No.


No




7.1 From handling, storage, use or spillage

of hazardous materials

Yes For detail please refer Annexure – VIII

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No

7.3 By deposition of pollutants emitted to

air into and or into water

No

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from

these sources?

No

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment

Sr.

No.


No




8.1 From explosions, spillages, fires etc.

from storage, handling, use or

production of hazardous substances

Yes For detail please refer Annexure – VIII

8.2 From any other causes No

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g. floods,

earthquakes, landslides, cloudburst

etc)?

No

10

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. No.

Information/Checklist confirmation

Yes/ No




9.1 Lead to development of supporting. lities, ancillary development or development stimulated by the project which could have impact on the environment e.g.

• Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)

• housing development • extractive industry • supply industry • other

Yes For detail please refer Annexure – IX

9.2 Lead to after-use of the site, which

could have an impact on the

environment

No

9.3 Set a precedent for later

developments

No

9.4 Have cumulative effects due to

proximity to other existing or

planned projects with similar effects

No

11

(II) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance (within 15km.)

Proposed project location boundary

1 Areas protected under international

conventions, national or local legislation

for their ecological, landscape, cultural or

other related value

- No protected area within 5 km from

the proposed project boundary

2 Areas which important for are or sensitive

Ecol logical reasons - Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests

Narmada

River Narmada River: 13 km (approx.) away

from Project Site

3 Area used by protected, important or

sensitive

Species of flora or fauna for breeding,

nesting, foraging, resting, over wintering,

migration

- No protected area or sensitive species

within 5 km from the proposed project

boundary.

4 Inland, coastal, marine or underground

waters

- Narmada River: 13 km (approx.) away

from Project Site

5 State, National boundaries - N.A.

6 Routes or facilities used by the public for

access to recreation or other tourist,

pilgrim areas

- N.A.

7 Defense installations - N.A.

8 Densely populated or built-up area - -

9 Area occupied by sensitive man-made

land uses Hospitals, schools, places of

worship, community facilities)

- N.A.

10 Areas containing important, high quality

or scarce resources (ground water

resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

- N.A.

11 Areas already subjected to pollution

environmental damage. (those where

existing legal environmental standards

are exceeded)or

- N.A.

12 Are as susceptible to natural hazard

which could cause the project to present

environmental problems (earthquake,

subsidence, landslides, flooding erosion,

or extreme or adverse climatic conditions)

- N.A.

IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – X.

12

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products with their Production Capacity

II Layout Map of the Plant

III Brief Manufacturing Process Description

IV Details of Water Consumption & Waste water Generation

V Details of Treatment Scheme and Disposal

VI Details of Hazardous /Solid Waste Generation, Handling and Disposal

VII Details of Stack and Vent

VIII Details of Hazardous Chemical Storage & Handling

IX Socio-Economic Impacts

X Proposed Terms of Reference for EIA studies

13

ANNEXURE-I

___________________________________________________________________________

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

SR.

NO.

PRODUCT NAME QUANTITY

(MT/MONTH)

EXISTING

1. FORMULATION OF POWDER DYE

(Through mixing/blending & Spray Drying only)

1426 MT/M

PROPOSED

1. ACID DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes

G. Black Dyes

75 MT/M

2. ACID DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes

G. Black Dyes

3. ACID DYES [METAL COMPLEX]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes

G. Black Dyes & Mixtures

4. BASIC DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes

G. Black Dyes

100 MT/M

5. BASIC DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


14

6. DIRECT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


200 MT/M 7. DIRECT DYES [CONDENSATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


8. DISPERSE DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


1000 MT/M

9. DISPERSE DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


10. DISPERSE DYES [CYANATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


11. REACTIVE DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


200 MT/M 12. REACTIVE DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

15

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


13. SOLVENT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


75 MT/M 14. SOLVENT DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


15. PIGMENT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


75 MT/M

16. PIGMENT DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


17. OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES/

STAINS [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


150 MT/M 18. OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES/

STAINS [CONDENSATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

16

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


19. VAT & SOLUBLE VAT DYES

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


50 MT/M

20. INTERMEDIATES [AGROCHEMICALS & DYESTUFFS]

A. 2,3-Dibromopropionyl Chloride

B. 2,6-Dibromo Para-toluidine

C. MDEAMS

D. MDPAMS

E. EBA [Ethyl Benzene Aniline]

F. Aldehydes [ EBA,DEA, DEMAP]

G. OBSA / BDSA

H. 2,4-Dichloro Aceto / Valerophenone

I. Dimethyl Sulphide

J. Valeryl Chloride

K. H-Acid

L. DASA

M. Vinyl Sulphone Ester

N. Schaeffer’s Acid

O. Bronner’s Acid

450 MT/M

21. AUXILIARIES

A. Naphthalene suphonated formaldehyde condensate

B. Phenol suphonated formaldehyde condensate

C. Melamine suphonated formaldehyde condensate

150 MT/M

22. TURQUOISE CPC SUPHONATED & CONDENSED DYES 75 MT/M

TOTAL 4026 MT/M

17

LIST OF RAW MATERIALS

SR.

NO.

RAW MATERIAL QUANTITY (MT/MT)

1.ACID DYES [AZO]

1. AMINES 0.20

2. HCl 0.40

3. ICE 2.50

4. SODIUM NITRITE 0.10

5. COUPLERS 0.25

6. ALKALIES/ACIDS 0.08

7. AUXILIARIES' FOR STD 0.20

2.ACID DYES [ANTHRAQUINONES / CONDENSED]

1. SOLVENTS 2.50

2. A.Q/R.M./AMINES 0.60

3. COND. PRODUCT 0.50

4. ALKALI/AIDS 0.08

5. AUXILIARIES 0.20

3.ACID DYES [METAL COMPLEX]

1. MONO/TETRA AZO 2.23

2. METALS 0.10


4. AUXILIERIES 0.20

4.BASIC DYES [AZO]

1. AMINES 0.20

2. ACID 0.40

3. ICE 2.00


5. COUPLERS 0.25


5.BASIC DYES [ANTHRAQUINONES / CONDENSED]

1. ACETIC ANHYDRIDE 0.30

2. ALDEHYDES 0.15

3. R.M.1 0.15

4. COND. PRODUCT 0.10

5. ACETIC ACID 0.15

6.DIRECT DYES [ AZO ]

1. AMINES 0.15

2. ACID 0.20

3. ICE 1.50


5. COUPLERS 0.10


7.DIRECT DYES [CONDENSATION]

1. R.M. MASS 0.18

2. R.M. 1 0.15

18

3. CONDN PRODUCT 0.15

4. ALKALI 0.15

5. ICE 0.70

6. AUXILIERIES 0.20

8.DISPERSE DYES [ AZO ]

1. AMINES 0.25

2. ACID 0.40

3. ICE 2.00


5. COUPLERS 0.28

6. ALKALI 2.15

7. AUXILIERIES 0.40

9.DISPERSE DYES [ ANTHRAQUINONES / CONDENSED]

1. SOLVENT 2.00

2. AMINES 0.25

3. A.Q.R.M 1 0.40

4. R.M.2 0.10

5. R.M.3 0.15

6. AUXILIARIES 0.40

10.DISPERSE DYES [ CYANATION ]

1. SOLVENT 1.50

2. MONO/R.M. PRODUCT 0.25

3. SODIUM CYANIDE 0.20

4. SODIUM BISULPHITE 0.25

5. ALKALI 0.15

6. WET CAKE 1.40

7. D.A AUXILIARIES 0.20

11.REACTIVE DYES [ AZO ]

1. AMINES 0.15

2. ACID 0.20

3. ICE 1.50


5. COUPLERS 0.10


12. REACTIVE DYES [ ANTHRAQUINONES / CONDENSED]

1. R.M. MASS 0.20

2. R.M. 1 0.15

3. CONDN PRODUCT 0.15

4. ALKALI 0.15

5. AUXILIERIES 0.20

6. ICE 1.00

13.SOLVENT DYES [ AZO ]

1. OR SOLVENT 1.00

2. AMINES 0.28

3. ACID 0.35

4. ICE 1.50

19


6. COUPLERS 0.30

14.SOLVENT DYES [ ANTHRAQUINONES / CONDENSED]

1. SOLVENT 2.00

2. AMINES 0.25

3. A.Q.R.M-1 0.40

4. R.M.-2 0.10

5. R.M.-3 0.15

6. AUXILIARIES 0.40

15.PIGMENT DYES [ AZO ]

1. OR 1.00

2. AMINES 0.28

3. ACID 0.35

4. ICE 1.50


6. COUPLERS 0.30

16.PIGMENTS DYES [ ANTHRAQUINONES / CONDENSED]

1. SOLVENT 2.00

2. AMINES 0.25

3. A.Q.R.M-1 0.40

4. R.M.-2 0.10

5. R.M.-3 0.15

6. AUXILIARIES 0.40

17.OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES /STAINS[AZO]

1. R.M.MASS 0.25

2. R.M.1 0.25

3. COND PRODUCT 0.30

4. ALKALI 0.15

5. ICE 1.00

6. WET CAKE 1.50

18.OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES /STAINS

[CONDENSATION]

1. SOLVENTS 2.00

2. SULPHONIC ACID 0.35

3. AMINES/ALDEHYDES 0.30

4. ANILINE COMP. 0.30

5. ALKALI 0.05

6. METHANOL 1.00

19.VAT & SOLUBLE VAT DYES

1. SOLVENTS 2.00

2. SULPHONIC ACID 0.35

3. AMINES/ALDEHYDES 0.30

4. ANILINE COMP. 0.30

5. ALKALI 0.05

6. PYRIDINE 1.20

7. PARENT VAT 0.40

20

8. CHLORO S.ACID 0.35

9. METAL POEWDER 0.20

10. ICE 3.00

11. C.S.LYE 0.50

12. SALT 0.30

20.INTERMEDIATES [ AGROCHEMICALS & DYESTUFFS]

A. 2,3-DIBROMOPROPIONYL CHLORIDE

1. ACRYLIC ACID 0.27

2. LIQ BROMINE 0.31

3. THIONYL CHLORIDE 0.31

B. 2,6-DIBROMO PARA-TOLUIDINE

1. PARA TOLUDINE 0.35

2. LIQ BROMINE 0.18

C. MDEAMS

1. TOLUENE 1.00

2. MNA 0.73

3. MSC 0.38

4. ACETIC ACID 0.30

5. METAL POWDER 0.08

6. DES 0.35

D. MDPAMS

1. TOLUENE 0.67

2. MNA 0.48

3. MSC 0.25

4. ACETIC ACID 0.20


6. DPS 0.23

E. EBA [ETHYL BENZENE ANILINE]

1. MEA 0.60

2. ALKALY 0.15

3. BENZOYL CHLORIDE 0.45

F. ALDEHYDES [ EBA,DEA, DEMAP]

1. DMF 0.60

2. ANILINE DERIVATIVES 0.60

3. POCL3 0.20

4. ICE 1.00

5. ALKALI 0.20

G. OBSA / BDSA

1. DCB/OCA 0.46

2. SODIUM BI SULHITE 0.15

3. ALKALI 0.12

4. SPENT ACID 0.35

H. 2,4-DICHLORO ACETO / VALEROPHENONE

1. n-VALERIC ACID 0.90

2. THIONYL CHLORIDE 0.35

I. DIMETHYL SULPHIDE

21

1. MDCB 0.67

2. ALLUMINIUM CHLORIDE 0.10

3. ACETYL/VELERIC CHLORIDE 0.43

4. ICE 0.95

J. VALERY CHLORIDE

1. SODIUM SULPHIDE 0.70

2. DIMETHYL SULPHATE 0.30

K. H-ACID

1. C.S.ACID 0.71

2. ACETANILIDE 0.32

3. ICE 1.43

4. PNA 0.21

5. HCL 0.11


7. C.S.LYE 0.18

8. SPENT ACID 1.71

L. DASA

1. H2SO4 1.94

2. OLEUM 2.67

3. NAPTHALENE 0.31

4. NITRIC ACID 0.97

5. LIMESTONE 3.39

6. GLAUBER'S SALT 3.40

7. HCL SPENT 0.75

8. IRON POWDER 0.65

9. CAUSTIC SODA 1.50

10. METHANOL 0.68

11. SPENT ACID 9.50

M. VINYL SULPHONE ESTER

1. C.S.ACID 1.06

2. ACETANILIDE 0.63

3. ICE 3.00

4. SODIUM BISULPHATE 0.60

5. C.S.LYE 0.35

6. H2SO4 0.11

7. ETHYLENE OXIDE 0.33

N. SCHAEFFER’S ACID

1. H2SO4 0.56

2. BETA NAPTHL 0.51

3. ICE 1.64

4. SALT 0.26

O. BRONNER’S ACID

1. LIQ AMMONIA 0.73

2. SCHAFFER'S ACID 0.73

3. SPENT ACID 0.53

AUXILIARIES

22

A. NAPHTHALENE SUPHONATED FORMALDEHYDE CONDENSATE

1. H2SO4 0.16

2. OLEUM 23% 0.43

3. NEPTHALENE 0.60

4. FORMALDEHYDE 0.35

5. C.S.LYE 0.55


B. PHENOL SUPHONATED FORMALDEHYDE CONDENSATE

1. SODIUM SULPHITE 0.30

2. PHENOL 0.54


4. C.S.LYE 0.29


C. MELAMINE SUPHONATED FORMALDEHYDE CONDENSATE

1. SODIUM SULPHITE 0.38

2. MELAMINE 0.41


4. C.S.LYE 0.05


TURQUOISE CPC SUPHONATED & CONDENSED DYES

1. ACIDS 9.23

2. RAW MATERIAL 4.62

3. ICE 3.10

23

ANNEXURE (A) - DETAILS OF AMINES, ALDEHYDES, CONDENSE PRODUCTS, COUPLERS &

SOLVENTS

SR.NO. RAW MATERIAL NAME STORAGE

PHYSICAL

FORM

A. AMINES

1 DTPTSA HDPE Bags Powder

2 DCPNA HDPE Bags Powder

3 OCPNA HDPE Bags Powder

4 DBPNA HDPE Bags Powder

5 PNA HDPE Bags Powder

6 Meta Amino Phenol HDPE Bags Powder

7 PAABSA HDPE Bags Powder

8 PAAB 3,4 DSA HDPE Bags Powder

9 Tobias Acid HDPE Bags Powder

10 3,3’-Diamino Diphenyl Sulphone HDPE Bags Powder

11 Sulpho tobias Acid HDPE Bags Powder

12 Aniline HDPE Bags Powder

13 Ortno Nitro Aniline HDPE Bags Powder

14 4-NAP HDPE Bags Powder

15 5-NAP HDPE Bags Powder

16 4-NAPSA HDPE Bags Powder

17 5-NAPSA HDPE Bags Powder

18 4-CAP HDPE Bags Powder

19 Meta Phenylene Diamine MS DRUMS Powder

20 Meta Toluene Diamine MS DRUMS Powder

21 Meta Toluidine MS DRUMS Liquid

22 Meta Xylidine Sulphonic Acid HDPE Bags Powder

23 Metanilic Acid HDPE Bags Powder

B. ALDEHYDES

1 DEA Aldehyde MS DRUMS Powder

2 EBA Aldehyde MS DRUMS Powder

3 Fischer’s Aldehyde MS DRUMS Powder

4 Dichlro benzaldehyde MS DRUMS Powder

5 Ortho Chloro Benzaldehyde MS DRUMS Powder

C. CONDENSE PRODUCTS

1 Bromamine acid HDPE Bags Powder

2 M-Acid HDPE Bags Powder

3 DABA HDPE Bags Powder

4 Dahl’s Acid HDPE Bags Powder

5 DASA HDPE Bags Powder

6 Diphenyl Amine HDPE Bags Powder

7 F C Acid HDPE Bags Powder

8 Fast Black B Base HDPE Bags Powder

9 Fast Blue B Base HDPE Bags Powder

10 PNAOSA HDPE Bags Powder

24

11 PNCBOSA HDPE Bags Powder

12 PNTOSA HDPE Bags Powder

13 Quinaldine MS Drums Liquid

14 Quinizarine HDPE Bags Powder

15 Fast Red B Base HDPE Bags Powder

D. COUPLERS

1 Ethyl Pyridone HDPE Bags Powder

2 Methyl Pyridone HDPE Bags Powder

3 Fischer’s Base MS Drums Liquid

4 Gamma Acid HDPE Bags Powder

5 H Acid HDPE Bags Powder

6 J Acid HDPE Bags Powder

7 J Acid Urea HDPE Bags Powder

8 Laurent's Acid HDPE Bags Powder

9 MD-01 HDPE Bags Powder


11 MD-07 MS Drums Liquid





16 MD-3A HDPE Bags Powder

17 Mix Cleve's Acid HDPE Bags Powder

18 Mix Xylene MS Drums Liquid

19 Mix Xylidine MS Drums Liquid

20 MPDSA HDPE Bags Powder

21 OAPS Amide HDPE Bags Powder

22 OAPSA HDPE Bags Powder

23 Phenyl J Acid HDPE Bags Powder

24 PMP HDPE Bags Powder

25 R Salt HDPE Bags Powder

26 Resorcinol HDPE Bags Powder

27 Schaffer’s Acid HDPE Bags Powder

28 SPCP HDPE Bags Powder

29 Sulpho Para Base HDPE Bags Powder

30 Super Refined Salt HDPE Bags Powder

31 Tobias Acid HDPE Bags Powder

32 Meta Nitro Aniline HDPE Bags Powder

33 [P-1] NN-Bis(2-hydroxyethyl)-m-chloroaniline HDPE Bags Powder

34 [P-1A] N,N-diacetoxyethyl-m-chloro aniline PP DRUMS Liquid

35 [P-2] N,N-diacetoxyethyl-m-chloro aniline HDPE Bags Powder

36 [P-2A] N,N-Diacetoxyethyl-M-Toluidine PP DRUMS Liquid

37

[P-3 ] 1N-(3-Bis(2-

hydroxyethylamino)phenyl)acetamide HDPE Bags Powder

38

[P-3A] 3-(N,N-Diacetoxyethyl)Amino

Acetanilide PP DRUMS Liquid

25

39

[P-5 ] 3'-[bis(2-hydroxyethyl)amino]-4'-

methoxyacetamilde PP DRUMS Liquid

40 [P-7] N-Cyanoethyl-N-Acetoxyethyl Aniline PP DRUMS Liquid

41 [P-8]3-(N-Ethyl-N-phenylamino)propionitrile PP DRUMS Liquid

42 1,3 SPMP HDPE Bags Powder

43 1,4 SPMP HDPE Bags Powder

44 1.6 Clevs Acid HDPE Bags Powder

45 1.7 Clevs Acid HDPE Bags Powder

46 8-Hydroxy Quinoline HDPE Bags Powder

47 Aceto Acetanilide HDPE Bags Powder

48 Aceto Acetanisidine 4-Methyl 5-Sulphonic Acid HDPE Bags Powder

49 Alpha Naphthylamine HDPE Bags Lumps

50 Beta Naphthol HDPE Bags Flakes

51 Bronner's Acid HDPE Bags Powder

52 C Acid HDPE Bags Powder

53 Chloro MPD HDPE Bags Powder

54 3-(Dimethylamino) Benzoic Acid HDPE Bags Powder

E. SOLVENTS

1 Methanol MS TANKS Liquid

2 Dimethyl Formamide MS TANKS Liquid

3 Xylene MS TANKS Liquid

4 Toluene DRUM STORAGE Liquid

5 Heptane MS TANKS Liquid

26

ANNEXURE-II

___________________________________________________________________________

LAYOUT MAP OF THE PLANT

27

ANNEXURE-III

BRIEF PROCESS DESCRIPTION

1. ACID DYES [AZO ]

1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:

DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines as

mentioned in Raw Material list Annexure (A) is charged. Then required quantity of HCL is

added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium Nitrite is

slowly added keeping Congo red paper positive & S.I. paper slightly positive now diazo is

ready for coupling.

2. Preparation of Coupler compound:

In Coupling reaction vessel, required quantity of Process / DM water is taken & required

quantity of coupler as mentioned in Raw Material list Annexure (A) is added. Then crushed

ICE is added to reduce temperature 15 to 20 Deg.C

3. Coupling:

Now in above coupling reaction vessel previously prepared diazo mass is slowly received

keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction.

Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for further

treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if powder require,

it is directly straightway Spray Dried to dispatch as a Powder form.

4. Tetrazo:

For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5 Deg.C

temperature & coupling with required further coupler products as mentioned in Raw Material

list Annexure (A) in require parameters.

Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for further

treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if powder require,

it is directly straightway Spray Dried to dispatch as a Powder form.

FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:

INPUT IN KGS OUTPUT IN KGS

Water 2000 kg

Amines 200 kg

Acid Hcl 400 kg

ICE 2000 kg

Sodium Nitrite 100kg

Water 1000 kg

Couplers 250 kg

Alkalies / Acids 75 kg

ICE 500 kg

4500 kg ML to ETP

Auxiliaries’ 1225 kg Water evaporation

For STD 200Kg 1000 kg Finish Product

Total 6725 kg 6725 kg

Diazotization

Diazo Reaction

Vessel

I Coupling

Reaction Vessel

Reverse Osmosis

Unit

Spray Drying Unit

28

2. ACID DYES [ANTHRAQUINONES / CONDENSED]

DM / Process water OR Solvent like ODCB / Xylene is taken in Reaction vessel. Then require

quantity of Anthraquinones/ Or Other R.M. as mentioned in Raw Material list Annexure (A) is

added & mass is further condensed to complete the reaction. Solvent is recovered for re-use

Now the mass is eighter directly converted in Liquid for by formulating to Dispatch as A

Liquid Dyes OR if powder require, mass is filtered, Washed. Filtrate & washing is send to ETP

for further treatment. & press cake is directly straightway Spray Dried to dispatch as a Powder

form.

FLOW CHART & MATERIAL BALANCE:

Condensation:


Solvent 2500kg

A.Q /R.M. 600kg

Amines /

Condn Product 500 kg

Alkali / Acid 75 kg 2375 kg Solvent Recovery for

reuse

4000 kg ML to ETP

Water for washing 4000 kg 1300 kg Press cake

Water 500kg 1000 kg Water evaporation in

Press Cake 1300 kg Spray drying

Auxiliaries 200Kg 1000 kg Finish Product


Condensation

Reaction Vessel

Filter Press/

R.O.Unit

Spray Drying Unit

Solvent Recovery

System

29

3. ACID DYES [METAL COMPLEX]

Mono/tetra azo mass/ Condensed mass is further Metalized in require parameters with

Require Metals products as mentioned in Raw Material list Annexure (A)

Now the mass is eighter directly converted in Liquid For by concentrating in Reverse Osmosis

Unit & standardization to Dispatch as A Liquid Dyes OR if powder require, it is directly

straightway Spray Dried to dispatch as a Powder form. R.O.Permite is send to ETP for further

treatment.


Metallization:


Mono /Tetra Azo 2225kg

Water 500 kg

Metal 100 kg

Alkalies / Acids 75 kg

1600 kg ML to ETP

Water 500kg 1300 Press Cake

Auxiliaries 200kg 1000 kg Water

Press Cake 1300Kg evaporation in Spray

Drying 1000 kg Finish product


Reaction Vessel

Filter Press / Reverse

Osmosis Unit

Spray Drying Unit

30

4.BASIC DYES [AZO ]


DM water/ Process water is charged in Reaction vessel. Then required quantity of

Amines as mentioned in Raw Material list Annexure (A) is charged. Then required

quantity of HCL is added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C.

Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I. paper

slightly positive now diazo is ready for coupling.


In Coupling reaction vessel, required quantity of Process / DM water is taken &

required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.

Then crushed ICE is added to reduce temperature 15 to 20 Deg.C

3. Coupling:

Now in above coupling reaction vessel previously prepared diazo mass is slowly

received keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction

& directly spray dried and dispatch as a Powder form.



Water 1500 kg

Amines 200 kg

Acid 400 kg

ICE 1000 kg

Sodium Nitrite 100kg

Water 700 kg

Coupler 250 kg

Alkali / Acid 75 kg

32 25 kg water evaporation in

Spray drying

1000 kg Finish Product


Diazotization

Diazo Reaction

Vessel

I Coupling

Reaction Vessel

Spray Dryer

31

5.BASIC DYES [ANTHRAQUINONES / CONDENSED]

In a Reaction vessel, require quantity of acetic anhydride is taken .Then require Aldehydes is

added & condensing 2 or 3 more compounds R.M. as mentioned in Raw Material list Annexure

(A) is added & mass is further condensed to complete the reaction. Then reaction mass is

diluted & standardize with acetic acid & water. Now the mass is directly converted in Liquid for

by formulating to Dispatch as A Liquid Dyes .

In This Process No any filtration, washing carried out hence effluent is Zero


Condensation:


Acetic Anhydride 300kg

Aldehydes. 150kg

R.M.-1 150kg


Acetic Acid 150 kg

Water 150kg No any Effluent



Condensation

Reaction Vessel

Clarifier

32

6. DIRECT DYES [AZO ]


DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines

as mentioned in Raw Material list Annexure (A) is charged. Then required quantity of HCL is

added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium Nitrite

is slowly added keeping Congo red paper positive & S.I. paper slightly positive now diazo is

ready for coupling.



Required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.


3. Coupling:

Now in above coupling reaction vessel previously prepared diazo mass is slowly received 3


Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for

further treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if

powder require, it is directly straightway Spray Dried to dispatch as a Powder form.

4. Tetrazo:

For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5

Deg.C temperature & coupling with required further coupler products as mentioned in

Raw Material list Annexure (A) in require parameters.






Water 800 kg

Amines 150 kg

Acid 200 kg

ICE 1000 kg

Sodium Nitrite 50kg

Cold Water Wash 1000 kg 2000 kg ML to ETP

1200 kg Press cake

Water 500 kg

Press Cake 1200 kg

Couplers 100kgs

ICE 500 kg

700 kg water recycled to first stage

Auxiliaries’



Diazotization

Diazo Reaction

Vessel

Reverse Osmosis

Unit

Standardization

Filter press

I Coupling

Reaction Vessel

33

7.DIRECT DYES [CONDENSED]

In a Reaction vessel, require quantity of Water is taken .Then require quantity of Monoazo /

condendn / CPC suphonated mass is added & amine / di-/tri-chlorinated R.M. as mentioned

in Raw Material list Annexure (A) is added & mass is further condensed to complete the

reaction. Then reaction mass is diluted & standardize with Auxiliaries & water. Now the mass is

directly concentrating on Reverse Osmosis & formulating to Dispatch as A Liquid Dyes . Permit

of R.O. is send to ETP for further Treatment OR if powder require, it is directly straightway

Spray Dried to dispatch as a Powder form.


Condensation:


Water 1000kg

R.M. mass 175kg

R.M.-1 150kg


Alkali 150 kg

Water 500kg

ICE 700kg

1000 kg ML to ETP

Auxiliaries 200kgs 1025kg Water Evaporation



Condensation

Reaction Vessel

Reverse Osmosis

/Filter Press

Spray Drying

34

8. DISPERSE DYES [AZO ]


DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines as

mentioned in Raw Material list Annexure (A) is charged. Then required quantities add Acid

[HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to form good suspension of

Hydrochloride. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium

Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly positive &stirred

for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.



required quantity of coupler as mentioned in Raw Material list Annexure is added. Then little

quantity of eighter alkali or acid is added to make soluble & buffer to maintain coupling

condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C

3. Coupling:

Now in above coupling reaction vessel previously prepared diazo mass is slowly received in 2-

3 hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.

Reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further

treatments

4. Grinding in Sand / Beed Mills / Homozinizer

Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /

Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to

Dispatch as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to

dispatch as a Powder form.



Water 1000 kg

Amines 250 kg

Acid 400 kg

ICE 1000 kg

Sodium Nitrite 95kg

Water 500 kg

Coupler 275 kg

Alkali / Acid 150 kg

ICE 1000 kg

Water for Washing 4670 kg ML to ETP

2000 kg 2000 kg wet cake

Auxiliaries 400Kg

Press Cake 2000 kg

1400 kg Water evaporation

in Spray Drying



Diazotization

Diazo Reaction

Vessel

I Coupling

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Sand Mills Unit

35

9.DISPERSE DYES [ANTHRAQUINONES / CONDENSED ]:

In suitable reaction vessel, require quantity water Or suitable solvent like Dimethyl Form

amide / Toluene / Xylene is taken .Then mono azo mass or condensing Product is condensed

with require condensed products as mentioned in raw material list Annexure (A) at require

parameters .After completion of condensation, Solvents are Distilled out for Re-Use &

remaining reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for

further treatments


Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to


dispatch as a Powder form



Solvent 2000 kg

Amines 250 kg

A.Q.R.M.-1 400 kg

R.M.-2 100kg

R.M.-3 150 kg

1900kg Solvent recover for

reuse recycle



Auxiliaries 400Kg

Press Cake 1800 kg


in Spray Drying



Condensation

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Sand Mills Unit

Filtration &

Washing

36

10. DISPERSE DYES [CYANATION ]:

In a suitable reaction vessel require quantity water OR suitable Solvents like Dimethyl Form

amide / Methanol taken. Then mono azo OR AQ Product mass is charged & further

condensed with Sodium Cyanide. After Completion Of complete consumption of Sodium

Cyanide, Solvent is distilled out for Re-Use & reaction mass is filtered. ML is collected in

separate Vessel for Killing / Detoxification of traces cyanide with Sodium Bisulphite. Again it is

filtered. Ml is send to ETP for further treatment


Homozinisers. Now the mass is eighter directly converted in Liquid & standardization to


dispatch as a Powder form

FLOW CHART WITH MATERIAL BALANCES [Cyanation]:

INPUT IN KGS

OUTPUT IN KGS

Solvent 1500 kg

Mono/R.M.Product 250 kg

Sodium Cyanide 200 kg

Water 750 kg

1425 kg solvent recycle

Water 500 kg

Sodium Bisulphite 250 kg

Alkali 150 Kg

1400 kg Wet cake

Water 1000kg Reslury

Wet Cake 1400kg

Water for Washing

2500 kg 775 kg ML to ETP

3300 kg ML to ETP

1600 kg wet cake for Sand

D.A Auxiliaries 200Kg mill

Press Cake 1600 kg


in Spray Drying


Total 10300 kg 10300 kg

Reaction Vessel

Detoxification

Vessel

Sand Mills Unit

Spray drying Unit

Solvent recovery

system

Re-Slurry

Filter Press

Filter press Filter press

37

11. REACTIVE DYES [ AZO ]


DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines

as mentioned in Raw Material list Annexure(A) is charged. Then required quantity of HCL

is added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium

Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly positive now

diazo is ready for coupling.



Required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.


3. Coupling:






4. Tetrazo:

For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5

Deg.C temperature & coupling with required further coupler products as mentioned in

Raw Material list Annexure (A) in require parameters.






Water 800 kg

Amines 150 kg

Acid 200 kg

ICE 1000 kg

Sodium Nitrite 50kg

Cold Water Wash 1000 kg 20 kg Sludge

Water 500 kg

Press Cake 500 kg

Couplers 100kgs

ICE 500 kg

1000 kg Water To ETP

Auxiliaries’ 2980 kg water evaporation



Diazotization

Diazo Reaction

Vessel

Reverse Osmosis

Unit

Standardization

Filter press

I Coupling

Reaction Vessel

38

12.REACTIVE DYES [CONDENSED/ BIFUNCTINAOL]

In a Reaction vessel, require quantity of Water is taken .Then require quantity of Monoazo /

condendn / CPC suphonated mass is added & amine / di-/tri-chlorinated R.M. as mentioned

in Raw Material list Annexure (A) is added & mass is further condensed to complete the

reaction.

Then reaction mass further condensed with Vinyl sulphone derivatives Or 2,3 Dibromo

propionyl Chloride & maintain reaction to complete the condensation .

Now the mass is directly concentrate on Reverse Osmosis & formulating to Dispatch as A

Liquid Dyes . Permit of R.O. is send to ETP for further Treatment OR if powder require, it is

directly straightway Spray Dried to dispatch as a Powder form.


Condensation:

INPUT IN KGS OUTPUT IN

KGS

Water 1000kg

R.M. mass 200kg

R.M.-1 150kg


Alkali 150 kg

Water 1000kg

ICE 1000kg

1000 kg ML to ETP

Auxiliaries’ 200kgs 1850 kg Water Evaporation


Total 3850 kg Total 3850 kg

Condensation

Reaction Vessel

Reverse Osmosis

/Filter Press

Spray Drying

39

13.SOLVENT DYES [AZO ]


DM water/ Process water OR suitable solvent charged in Reaction vessel. Then required

quantity of Amines as mentioned in Raw Material list Annexure (A) is charged. Then

required quantities add Acid [HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to

form good suspension of Hydrochloride. Now Crushed ICE is added to reduce temperature

0 to 5 Deg.C. Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I.

paper slightly positive &stirred for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.



required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.

Then little quantity of eighter alkali or acid is added to make soluble & buffer to maintain

coupling condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C

3. Coupling:


in 2-3 hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.


treatments

Press cake is mixed with water Now the mass is eighter directly converted in Liquid &

standardization to Dispatch as A Liquid Dyes OR if powder require, it is directly

straightway Spray Dried to dispatch as a Powder form.



Water 1000 kg/

OR Solvent 1000kg

Amines 275 kg

Acid 350 kg 950

ICE 1000 kg

Sodium Nitrite 75

Water 500 kg

Coupler 300 kg

ICE 500 kg



Water 500kg

Press Cake 1800 kg


in Spray Drying



Diazotization

Diazo Reaction

Vessel

Coupling

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Slurry making Unit

Solvent recovery

system

40

14.SOLVENT DYES [ANTHRAQUINONES / CONDENSED ]:

In suitable reaction vessel, require quantity water OR suitable solvent like ODCB / Dimethyl

Form amide / Toluene / Xylene is taken .Then mono azo mass or Anthraquinones derivatives

Product is added. Then condensed require Amines / condensed products as mentioned in

raw material list Annexure (A) at require parameters .After completion of condensation,

Solvents are Distilled out for Re-Use & remaining reaction mass is filtered, washed with

Water. Filtrate & Washing is send to ETP for further treatments

Press cake is mixed with water directly it is directly straightway Dried to dispatch as a

Powder form



Solvent 2000 kg

Amines 250 kg

A.Q.R.M.-1 400 kg

R.M.-2 100kg

R.M.-3 150 kg

1900kg Solvent recover for re-

use recycle



Auxiliaries 400Kg

Press Cake 1800 kg


in Spray Drying


Total 8900 kg 8900kg

Condensation

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Slurry making Unit

Solvent Recovery

System

41

15.PIGMENT DYES [AZO ]


DM water/ Process water OR suitable solvent charged in Reaction vessel. Then required

quantity of Amines as mentioned in Raw Material list Annexure (A) is charged. Then required

quantities add Acid [HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to form good

suspension of Hydrochloride. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C.

Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly

positive &stirred for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.


In Coupling reaction vessel, required quantity of Process / DM water is taken & required

quantity of coupler as mentioned in Raw Material list Annexure (A) is added. Then little

quantity of eighter alkali or acid is added to make soluble & buffer to maintain coupling

condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C

3. Coupling:

Now in above coupling reaction vessel previously prepared diazo mass is slowly received in 2-3

hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.


treatments Press cake is mixed with water directly it is directly straightway Dried to dispatch

as a Powder form



Water 1000 kg/

OR Solvent 1000kg

Amines 275 kg

Acid 350 kg

ICE 1000 kg

Sodium Nitrite 75 950 kg Solvent recover for

reuse recycle

Water 500 kg

Coupler 300 kg

ICE 500 kg



Water 500kg

Press Cake 1800 kg


in Spray Drying



Diazotization

Diazo Reaction

Vessel

Coupling

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Slurry making Unit

Solvent Recovery

System

42

16.PIGMENT DYES [ANTHRAQUINONES / CONDENSED ]:

In suitable reaction vessel, require quantity water OR suitable solvent like ODCB / Dimethyl

Form amide / Toluene / Xylene is taken .Then mono azo mass or Anthraquinones derivatives

Product is added. Then condensed require Amines / condensed products as mentioned in raw

material list Annexure (A) at require parameters .After completion of condensation, Solvents are

Distilled out for Re-Use & remaining reaction mass is filtered, washed with Water. Filtrate &

Washing is send to ETP for further treatments

Press cake is mixed with water directly it is directly straightway Dried to dispatch as a

Powder form



Solvent 2000 kg

Amines 250 kg

A.Q.R.M.-1 400 kg

R.M.-2 100kg

R.M.-3 150 kg

1900 kg Solvent recover for re-

use recycle



Auxiliaries 400Kg

Press Cake 1600 kg


in Spray Drying



Condensation

Reaction Vessel

Filtration &

Washing

Spray drying Unit

Slurry making Unit

Solvent

Recovery

System

43

17.OPTICAL BRIGHTENERS ,CARBONLESS PAPER DYES /STAINS [ WATER BASE ]:

In a suitable reaction vessel, require quantity of DM /process water is taken .Then require

quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned in Raw Material list

Annexure (A) is react with amines / cyanuric chloride.

Then condensed mass is further condensed with aniline derivatives as mentioned in Raw

Material list Annexure (A).

Then reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further

treatments

Press cake is mixed with water directly it is directly straightway Dried to dispatch as a Powder

form


Condensation:


Water 1000kg

R.M. mass 250kg

R.M.-1 250kg


Alkali 150 kg

Water 1000kg

ICE 1000kg

2000 kg ML to ETP

Water washing 1000kg

Water ’ 1000kgs 2950kg Water Evaporation



Condensation

Reaction Vessel

Filter Press

Spray Drying

44

18.OPTICAL BRIGHTENERS ,CARBONLESS PAPER DYES /STAINS [ SOLVENT BASE ]:

In a suitable reaction vessel, require quantity of Solvent like ODCB / Xylene / Toluene is tis taken

.Then require quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned in

Raw Material list Annexure (A) is react with amines / Aldehydes as mentioned in Raw Material

list Annexure (A).

Then condensed mass is further condensed with aniline derivatives as mentioned in Raw

Material list Annexure (A). After completion Of reaction, Solvent is distilled out for Re-Use.

Then reaction mass is isolated in methanol / Acetone. Then isolated mass is filtered. Filtetrate is

collected & used Methanol / Acetone is distilled out for Re-Use .

The Press cake is washed with hot Water. Washing is send to ETP for further treatments

Press cake is mixed with water directly it is directly straightway dried to dispatch as a Powder

form


Condensation:


Solvent 2000kg 1900kg Solvet Re-Use

Sulphonic Acids 350kg

Amine/Aldehyde 300kg

Aniline comp. 300 kg

Alkali 50 kg

Methanol 1000kg 950kg Methanol Re-Use

Water Washing 1600kgs

1550 kg ML to ETP

200kg Water Evaporation



Condensation

Reaction

Vessel

Drying

Solvent recovery

system

Filter Press

Solvent recovery

system

45

19. VAT & SOLUBLE DYES:

In a suitable reaction vessel, require quantity of Solvent like ODCB / Xylene / Toluene is

taken .Then require quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned

in Raw Material list Annexure (A) is react with amines / Aldehydes as mentioned in Raw

Material list Annexure (A). Then reaction mass is maintained till completion Of reaction, Then

Solvent is distilled out for Re-Use

Then reaction mass is isolated in Water. Then isolated mass is filtered. Filtetrate is

collected

The Press cake is washed with hot Water. Washing is send to ETP for further treatments

Press cake is mixed with water directly it is directly straightway dried to dispatch as a

Powder form OR Used to make soluble vat dyes as follows

In a suitable reaction vessel required quantity of Pyridine is taken .Then required quantity

of chlorosulphonic acid is slowly added. Then parent dry vat powder is added. Then metal

powder is added to reduce vat powder. After completion of reaction, mass is drowned in Ice &

neutralized by c.s.lye.

Pyridine is distilled out for re-use & mass is extracted in water& filtered. Sludge is Sold to

authorized vender & Filtrate is isolated with salt, again filtered .ML send to ETP& press cake

dried, Standardize to finish product



Solvent 2000kg 1900kg Solvet Re-Use

Sulphonic Acids 350kg

Amine/Aldehyde 300kg

Aniline comp. 300 kg

Alkali 50 kg 2200 kg ML to ETP

Water 1000kg 1500kg Drying loss

400kg vat output

Water Washing’ 2000kgs

Pyridine 1200 kg 1140kg Pyridine Recycle

Parent Vat 400 kg

Chloro S.Acid 350kg

Metal Powder 200kg

ICE 3000Kg

C.S. Lye 500kg

Water 2000kg

Salt 300kg 200kg sludge

2710 kg ML to ETP

2900kg drying loss

1000kg finish Product

Condensation

Reaction

Vessel

Solvent recovery

system

Filter Press

Dryer

Neutralization

Reaction Vessel

Filtration

Extraction &

Isolation

Pyridine Recovery

for Reuse

Drying &

Standardization

Filtration

Total 13950kg Total 13950kg

46

20. INTERMEDIATES [AGROCHEMICAL & DYESTUFFS]

i) 2,3DIBROMO PROPIONYL CHLORIDE:

In a Glasslinned Reaction Vessel required quantity of Water added, then required quantity Of

Acrylic Acid is added. Then required quantity of Liquid Bromine is added & it stirr for 14 Hrs,

Then required quantity of Thionyl chloride is charged & reaction mass is heated. Vapours are

scrubbed in effective scrubbing system. Then Product is distilled out & used. There is no effluent

except scrubbing system.

In This Process, there is no any Filtration, decantation, Washing. So There is No Any Effluent

FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:

Chlorination & Bromination

Acrylic Acid Thionyl Chloride

C3H4O2 + SOCI2

Chlorination

Step-I Product

C3H3OCI + SO2 + HCI

M.W. 126 119 M.W.90.5 64 36.5

Step-I Product Liquid Bromine

C3H3OCI + Br2

Bromination

2,3-DBPC

C3H3Br2CI

90.5 160 250.5



Water 400kg

Acrylic Acid 350kg 50gs vapors scrubbed

Liquid Bromine 400 kg

Thionyl Chloride 400kg

200kg Intercut Re-cycled

Distillation 1200kg [1000kg real]

83% purity finish Product


Glass-linned

Reaction Vessel

Effective

Scrubbing

System

47

ii) 2,6DIBROMO PARA TOLUIDINE:

In a Tile-lining reaction vessel, required quantity of water is taken .Then required quantity

of Para toluidine is charged & it is stirred. Now required quantity of liquid bromine is charged &

mass is heated up to 50deg.C to complete the reaction.

Then reaction mass is filtered.ML is sent to ETP for further treatment. & press cake is

washed by water & aired. Wet cake is directly used for further reaction OR Sale out.


Bromination

Para Toluidine Bromine

C7H9N + Br2

Bromination

2,6 DBPT

C7H7N.Br2 + H2

M.W. 107 160 M.W.265 2



Water 660kg

Para Toludine 528 kg 33 kg vapors scrubbed

Liquid Bromine 264 kg

Water washing 1320 kg 1239 kg ML to ETP

1520 kg Finish

Product


Tile-linned

Reaction Vessel

Effective

Scrubbing

System

Filter Press

48

iii) MDEAMS [ META-DIETHYLAMINO,METHYL-SULFONAMIDE]:

In a Glass-lining reaction vessel, required quantity of Toluene is taken .Then required

quantity of MNA [Meta Nitro Aniline] is charged & it is stirred. Now required quantity of Methyl

Sulphonyl chloride is charged & mass is heated up to 50deg.C to complete the reaction.Toulene

is distilled out for re-use water is added. Then reaction mass is filtered.ML is sent to ETP for

further treatment. & press cake is charged in same vessel. Then required quantity of Acetic Acid

is added & Metal powder is added to reduce it .Now mass is filtered & ML is isolated by cooling.

Then isolated mass is filtered & Wet cake is condensed with Diethyl Sulphate in same reaction.

Then Mass is Filtered & wet cake is used for further process or sale out.


Methylation

M-Nitro aniline Methyl Sulphonyl

Chloride

C6H6O2N2 + CH3SO2CI

Chlorination

Step-I Product

C7H8O4N2S + + HCI

M.W. 138114.5 Tolenen M.W.216 36.5

Reduction

Step-I Product + Iron Powder

C7H8O4N2S + H2

Reduction

Step-2

C7H10O2 N2S + O2

216 2 HCI 186 32

Condensation

Step-2 DES

C7H10O2 N2S + [C2H5]2SO4

Condensation

MDEAMS

C11H18O2 N2S H2SO4

186 154 242 98

Flow Chart & Material Balance:-


Step-1

Toulene 1000kg

MNA 725kg 950kgs Toluene Recycled

MSC 375 kg

Water 800kg

Water washing 750kg 1500 kg ML to ETP

1200 kg Press cake use for next step

Total 3650kg Total 3650 kg

Tile-lined Reaction

Vessel

Filter Press

49

Step-2

Press cake 1200kg

Acetic Acid 300kg

Metal Powder 80kg

Water 750kg 2230kg Liquid taken for isolation for

next step

100kg sludge


Step-3

2230 kg ML for Isolation

1300kg Press cake used for

Condensation

. 930kg ML to ETP


Step-4

DES 350kg

Water 1300kg

1500kg Finish Water for Washing 500kg

Product

650 kg ML to ETP


Tile-lined Reaction

Vessel

Filter Press

Tile-lined Reaction

Vessel

Filter Press

Filter Press

Tile-lined Reaction

Vessel

50

iv) MDPAMS [ META-DIETHYLAMINO,METHYL-SULFONAMIDE]:

In a Glass-lining reaction vessel, required quantity of Toluene is taken .Then required

quantity of MNA [Meta Nitro Aniline] is charged & it is stirred. Now required quantity of Methyl

Sulphonyl chloride is charged & mass is heated up to 50deg.C to complete the reaction.Toulene

is distilled out for re-use water is added. Then reaction mass is filtered.ML is sent to ETP for

further treatment. & press cake is charged in same vessel. Then required quantity of Acetic Acid

is added & Metal powder is added to reduce it .Now mass is filtered & ML is isolated by cooling.

Then isolated mass is filtered & Wet cake is condensed with Dipropyl Sulphate in same reaction.

Then Mass is Filtered & wet cake is used for further process or sale out.


Methylation

M-Nitro aniline Methyl Sulphonyl

Chloride

C6H6O2N2 + CH3SO2CI

Chlorination

Step-I Product

C7H8O4N2S + + HCI

M.W. 138 114.5 Tolenen M.W.216 36.5

Reduction

Step-I Product + Iron Powder

C7H8O4N2S + H2

Reduction

Step-2

C7H10O2 N2S + O2

216 2 HCI 186 32

Condensation

Step-2 DPS

C7H10O2 N2S + [C3H7]2SO4

Condensation

MDEAMS

C13H22O2 N2S H2SO4

186 182 270 98



Step-1

Toulene 1000kg

MNA 725kg 950kgs Toluene Recycled

MSC 375 kg

Water 800kg

Water washing 750kg 1520kg ML to ETP

1200 kg Press cake use for next step


Step-2

Press cake 1200kg

Acetic Acid 300kg

Metal Powder 80kg

Water 750kg 2230kg Liquid taken for isolation for

next step

100kg sludge

Tile-lined Reaction

Vessel

Filter Press

Tile-lined Reaction Vessel

Filter Press

51


Step-3

2330 kg ML for Isolation

1300kg Press cake used for

Condensation

. 1030kg ML to ETP


Step-4

DPS 350kg

Water 1000kg

1500kg [67%] 1000 kg real Finish

Water for Washing500kg Product

350 kg ML to ETP



Filter Press

Filter Press

Tile-lined Reaction

Vessel

52

V). ETHYL BENZENE ANILINE [EBA]

I a SS316 reaction vessel, required quantity of Mono ethyl aniline is taken. Then required

quantity of Benzoyl Chloride is added at alkaline condition. Then Mass is heated & maintain till

completion of reaction,& Product is distilled out .Residual sludge is sold as authorized vendor.


MEA Benzoyl Chloride

C8H11N + C7H7CI

Benzoylation

EBA

C15H17N + HCI

M.W. 121 126.5 M.W. 211 26.5



KGS

MEA 600kg

Alkaly 150kg 50gs vapors scrubbed

Benzoyl Chloride 450 kg

100kg Intercut Re-

cycled

Distillation 1050kg [1000kg real]


Galss-linned

Reaction Vessel

Effective

Scrubbing

System

53

VI). VARIOUS ALDEHYDES:

In a Glass lined reaction vessel required quantity of Dimethyl Formamide is added.

Then required quantity of aniline derivatives as mentioned in Raw Material list Annexure (A)

taken. Now required quantity of Phosphorus Trichloride is slowly added & maintains to complete

the reaction. Then reaction mass is dumped in Ice & isolated by alkali. Then mass is filtered &

press cake is dehydrate & used for further process OR sale out.ML is send to ETP for further

process.


DMF + POCI 3 +EBA + NaOH + H2O

C3H7NOC15H17N

EBA Aldehydes

C16H17NO+PO2CI2 + HCI+CH3COONa.NH + 4H

M.W. 73 +153.5 + 211+ 40 + 18 M.W. 23913436.5 + 82 + 4



DMF 600kg

Aniline derivatives 600kg

POCL3 200 kg

540 kg DMF Recycle

ICE 1000 kg

Water 1000 kg

Alkali 200kg

1260 kg ML to ETP

1800 kg Press cake use to

Di-hydration

1000kg Finish Product

Press cake 1800kg 800 kg drying loss


SS316 Reaction Vessel

Dumping /

Quenching vessel

Effective Scrubbing

System

Filtration &

Washing

De-Hydration

54

VII). BDSA & OBSA:

In a SS316 reaction vessel required quantity of water taken. Then required quantity of

Di-Chloro benzaldehyde OR Ortho Chloro benzaldehyde is added. Then required quantity of

Sodium B-Sulphite is added. Now reaction is maintained to complete the reaction. Then

reaction mass is is neutralized by soda ash & isolated by spent acid .Then mass is filtered & press

cake is used for further process OR sale out.ML is send to ETP for further process.


DCB+ 2[NaHSO3]

C7H4CI2O C10H15N

BDSA

C7H6S2O7 + 2 [NaCI ]

M.W.175 + 208 M.W. 266 + 117



Water 1000kg

DCB /OCA 600kg

Sodium Bi sulphite 200 kg

Alkali 150kg

Spent Acid 450kg

1100 kg ML to ETP

1300 kg [77%] 1000kg Finish



Filtration

55

VIII). N-VALERIC CHLORIDE :

In a Glass lined reaction vessel required quantity of n-Valeric Acid is charged . Then

required quantity of Thionyl chloride is slowly added.. Now reaction is maintained to complete

the reaction. Then reaction mass is distilled out & directly use for further process. There is no

ML in effluent except scrubbing system.

In This Process, there is no any Filtration, decantation, Washing. So There is No Any

Effluent


Chlorination

Valeric Acid Thionyl Chloride

C5H10O2 + SOCI2

Chlorination

Step-I Product

C5H9OCI + SO2 + HCI

M.W. 102 119 M.W.120.5 64 36.5



n-Valeric Acid 900kg 50 kg vapour loss in scrubbing system

Thionyl Chloride 350kg 1100kg [91%]=1000kg real finish mass

100kg intercut recycled



56

IX). DICHLORO ACETO /VALERO PHENONES

In a Glass lined reaction vessel, require quantity of Meta Dichloro benzene is taken .Then

required quantity of aluminum chloride is added .Now required quantity of Acetyl / Valeric

Chloride is slowly added. Then reaction mass is heated & maintain to completion of reaction

Then it is dumped in ICE & aqueous layer is separated & send to ETP for further treatment.

Organic layer is distilled out .Intercut is recycled in next batch & Main product is used for further

process OR Sale out.


Valeric ChlorideM-Dichloro Benzene

C5H10O2 + C6H4CI2

Ali.Chloride

2,4 Dichlrovalerophenone

C11H12OCI2 + H2O

M.W. 102 147 M.W.231 18



MDCB 700kg

Allumi. Chloride 100kg

Acetyl/ Valeric chloride 450kg

ICE 1000 kg 100 kg HCL Re-Use

Water 1000 kg 2000kg ML to ETP

100kg Intercut to re-use

1050kg [95%] 1000kg finish


Glass linned Reactor

Dumping /

Quenching vessel

Effective HCL Recovery

Scrubbing System

Distillation

57

x). Dimethyl Sulphide:

In a SS316 reaction vessel, require quantity of water is taken. Then require quantity of Sodium

sulphide flakes is added & mass is stirred. Then require quantity of Dimethyl sulphate is slowly

added & reaction is maintained . Now reaction mass is heated & product get distilled out .Is is

collected & used for further process OR sale out..residual mass is send to ETP for further

treatment


Potassium /Na,Sulphide DMS

2x K/Na2S + [CH3]2SO4

Dimethyl Sulphide

[CH3]2S + K/Na2SO4

M.W. 110 126 M.W. 62 284



KGS

Water 800kg

Sodium Sulphide 700kg 1000kg finish product

Dimethyl sulphate 300 kg 800kg residual mass to

TSDF


xi).DASA [4,4-Diamino Sulphonamide]:

Step-1:-

In MS reaction vessel, required quantity of Chlorosulphonic acid is taken. Then require

quantity of Acetanilide is charged.gas is scrubbed in HCL recovery system to recover HCI for re-

use. Reaction mass is dumped in ICE. & filtered on Press. ML is collected as a spent Acid for Re-

Use. Press cake is use in step-3

Step-2:-

In Tile linned rector, require quantity of water taken & require Para Nitro Aniline is

charged.

The HCI is charged & iron powder is added to reduce it as PPD.Now mass is clarified ML is used

in step-3.& Iron sludge sale-out to authorized customer.

Step-3

In Rubber-linned reactor, require quantity of step-2 ML is taken. Then Step-1 press cake

is charged to condense with each other. Then product is hydrolyzed with c.s.lye & isolated by

spent Acid. Then reaction mass is filtered. Ml send to ETP for further treatment & Press cake is

used for further process OR sale out.

SS316 Reactor

58


Step-1

Acetanilide + C.S.Acid

C8H9ON CISO3H

Sulphonation

Sulpho mass

C8H8SNO3.CI + H2O

M.W.135 + 116.5 M.W. 233.5 + 18

Step-2

PNA + HCI + Fe

C6H6N2O2

Reduction

PPD + 2[H2O]

C6H8N2

138 108 36

Step-3

Sulpho mass PPD

C8H8SNO3.CI + C6H8N2

Condensation

Condensed mass

C14H15S.N3O3. + HCI

233.5 + 108 305 36.5

Step-4

Condensed mass + NaOH

C14H15S.N3O3

Hydrolysis

Isolation

DASA

C12H13N3O2 + CH3COOH + H2O

305 40 Spent acid 263 60 + 18



Step-1

C.S. Acid 1000kg

Acetanilide 450kg

250kg HCI re-use

ICE 2000kg

2400kg ML re-use as spent acid

800 kg Press cake use for step-3


Step-2

Water 1000kg

PNA 300kg

HCL 150 kg

Metal Powder 150kg 1450kg Liquid taken for Condn for

Step-3

150kg sludge


Tile-lined Reaction

Vessel

Filter Press

Tile-lined Reaction

Vessel

Clarifier

HCL recovery

system


59

Step-3

Step-1 Product 800kg

Step-3 ML 1450 kg

C.S.Lye 250kg

Spent Acid 2400kg

1400kg finished product

3500kg ML to ETP


Tile-lined Reaction

Vessel

Filter Press

60

xii). H-Acid:-

Step-1 Sulphonation:-

In Cast Iron reaction vessel, required quantity of Sulphuric acid & Oleum is taken. Then

require quantity of Naphthalene is charged. Reaction mass is heated up-to 170 Deg.C to

complete the reaction.SO2Gas is scrubbed in effective scrubbing system.

Step-2 Nitration:-

In SS316 reactor, required quantity is taken .Then sulpho mass is received from

sulphonator & mass is nitrated. Then mass is taken for neutralization.

Step-3 Neutralization & filtration:-

In Rubber- Tile/ Brick linned reactor, require quantity of step-2 mass is taken. Then

excess acid is neutralize with Lime stone to form Gypsum..It is then separate out by filtering on

vacuum nutch.Filtrate is taken for reduction step. Gypsum is sale out to authorized vendor.

Step-4 Reduction:-

Nitro mass from Step-3 is reduced in tile/ brick linned reaction vessel by iron powder &

HCL in warm condition & then is clarify to remove iron oxide.& clarified ml is concentrate .

Step-5 Hydrolysis:-

Concentrate mass from step is hydrolyzed with caustic soda in autoclave 6-7kg pressure

& at 170 Deg.C temp.after completion of reaction ,mass is transfer for isolation

Step-6 Isolation:-

Hydrolyzed mass is isolated by adding spent acid at 2 pH.It get precipitate. Then it is

filtered & washed to obtained press cake of H-Acid for use for further process to make dyestuffs

OR sale-out.


Step-1

Naphthalene + H2SO4 + Oleum

C10H8

Sulphonation

Sulpho mass

C10H8[SO3]3 + 3 X [H2O]

M.W.128 + 98 M.W. 368 + 54

Step-2

Sulpho mass + HNO3

C10H8[SO3]3

Nitration

Nitro mass + H2O

C10H7[SO3]3 .NO2

368 63 413 18

Step-3

Nitro mass HCL+ Fe

C10H7[SO3]3 .NO2 +

Reduction

Koch Acid

C10H7[SO3]3.NH2. + O2

413 383 32

Step-4

Koch Acid + 3 X [NaOH]

C10H7[SO3]3 .NH2

Hydrolysis

Amino Mass

C10H4[SO3.Na]2.ONa + SO2 +3X[ H2O]

383 120 384 64 + 54

Step-5

Amino Mass + 3[ HCI]

C10H4[SO3.Na]2.ONa

Isolation

H-Acid

C10H4[SO3.Na]2.ONa 3X [ NaCI]

383 109.5 Spent acid 319 175.5

61

FLOW CHART & MATERIAL BALANCE FOR H- ACID :


Step-1,2 & 3

Sulphuric Acid 1937kg

Oleum 2670kg

Naphthalene 910kg

Nitric Acid 965kg

1634 kg NOx/CO2/ water vapourloss

Water 2500kg

Limestone 3385kg

Glauber’Salt 3400kg

8133kg Gypsum

6000 kg Filtrate use for step-4


Step-4

Nitro Mass 6000kg

HCL Spent 750 kg

lron Powder 650kg

Water for washing 3000kg 750kg Iron Oxide sludge

9650kg Amino ML for next step.


Step-5,6

Amino Product 9650kg 7000kg water evopration

Caustic Soda 1500kg 570kg Methanol recovery

Methanol 680kg 1260kg water loss

Spent Acid 9500kg Spent 3500 kg

7000kg ML to ETP

Water for washing 4000kg

5000 Drying Loss



Cast Iron Reaction

Vessel

Filter Press

Evaporation Reaction Vessel

Autoclave Reaction Vessel


Clarifier

Effective

scrubbing system

SS/CI Reaction

Vessel

TL/Brick line

Neutralizer

Isolation Reaction Vessel



62

xiii).Vinyl Sulphone Esters:-

Step-1 Chlorosulphonation of Acetanilide:-

In a MS sulphonator, required quantity is taken & required quantity of acetanilide is

charged. Mass is heated up to 55 Deg.C & maintained 4-5 Hrs. Vapours converted in HCL in HCL

recovery system. Mass is dumped in ICE & filtered Filtrate is send in Spent Acid storage tank for

Re-use.& press cake is used in step-2

Step-2 Ehylation, Filtration, Drying & Pulverizing:-

In SS condensation, require quaintly of water taken,& Sodium Bisulphate is charged

.Then sulpho mass is charged & 7 pH is done by adding caustic .Then mass is condensed with

Ethylene Oxide keeping pH neutral by adding spent acid. Then mass is filtered. Press cake is

dried & use to make dyestuffs OR sale out.


Step-1

Acetanilide + C.S.Acid

C8H9ON CISO3H

Sulphonation

Sulpho mass

C8H8SNO3.CI + H2O

M.W.135 + 116.5 M.W. 233.5 + 18

Step-2

Sulpho mass

C8H8SNO3.CI + 2x [NaOH] + NaHSO3

Neutralisation

Neutralized Mass

C8H9NO4.SNa + Na2SO4 + HCL

233.5 80 104 238 142 36.5

Step-3

Neutralized Mass + Ethylene Oxide

C8H9NO4.SNa CH2CH2O

Condensation

H2

Condensed mass

C10H14S.NO4. + NaOH

233.5 + 108 24440

Step-4

Condensed mass + H2SO4

C10H14S.NO4

Hydrolysis

Isolation

Vinyl Sulphone Ester

C8H11NO6S2 + CH3COOH + H2O

305 40 281 61 + 18



Step-1

C.S. Acid 1600kg

Acetanilide 625kg

400kg HCI re-use

ICE 3000kg


800 kg Press cake use for step-2


Tile-lined Reaction

Vessel

Filter Press

HCL recovery

system

Tile-lined Reaction

Vessel

63

Step-2

Water 1500kg

Na Bisuphate 600kg

Step-1 Press cake 800kg

C.S.Lye 350kg

H2SO4 110kg

Ethylene Oxide 330kg 2000kg ML to ETP

690kg drying loss



Tile-lined Reaction

Vessel

Filter Press

Clarifier

64

ivx). Schaeffer’s Acid:-

In a MS /CI sulphonator, require quantity of Sulphuric Acid is taken & beta Naphthol is

charged.

Now mass is allow to sulphonate. Then it is dumped in ICE & clarified .Then isolated by adding

salt Then filtered. ML is collected in spent acid storage for reuse.& press cake is use for making

dyestuffs OR Sale out.


Beta Naphthol + Sulphuric Acid

C10H8O H2SO4

Sulphonation

Schaeffer’s Acid

C10H8O4S + H2O

M.W.144 + 98 M.W. 224 + 18



Step-1


Beta naphthol 770kg

ICE 2500kg

Salt 400kg


1520 kg Press cake of 66%

xx Real1000kg



Filter Press

Effective Scrubbing system

Tile-lined Reaction

Vessel

65

xv). Bronner’s Acid:-

In a CI autoclave liquor Ammonia is taken % Schaeffer’s acid is charged. Then mass is heated

up to 130 Deg.C at 6-7kg pressure. Then mass is drown in Water & isolated by spent acid then

filtered .Press cake is used to make dyestuffs OR sale out.


Schaeffer’s Acid + Liquor

Ammonia

C10H8O4S NH3

Ammonination

Bronner’s Acid

C10H9NO3S + H2O

M.W.144 + 17 M.W. 223 + 18



Step-1

Liquor Ammonia 1100kg

Schaeffer’s Acid 1100kg

Water 1500kg

Spent acid 800kg


1500 kg product


Tile-lined Reaction

Vessel

Filter Press

Tile-lined Reaction

Vessel

66

AUXILIARIES

SYNTHETICORGANIC Tanning Agent / Dispersing Agents

(Naphthalene, Phenol Melamine Sulphonated, Formaldehyde condensed Products )

Average Production of Following & Similar Type Other Dyes Products = 150 MT Per Month]: -

1.Naphthalene Base Dispersing / Tanning [ Syntans] Agents [ Powder ] Dytol DF / SNF / NBN

Manufacturing Process: -

1.Naphthalene is Sulphonated by 101% Sulphuric Acid [ 23% Oleum + H2SO4]

2.2 Mol of above Sulpho mass is condensed with Formaldehyde

3.Then Reaction mass is Neutralize by C.S. Lye

3. Then Water & Glauber’s Salt is Added for adjust viscosity.

4. Then Product is Spray dried .Then Directly Used to Dilution Or To Make Blend Product &

Finally

Packed.

5. In This Process, there is no any Filtration, decantation, Washing. So There is No Any

Effluent

Sulphonation

Naphthalene 101% Sulphuric

Acid

C10H8 + H2SO4

Sulphonation

Sulpho mass

C10H8SO3 + H2O

M.W. 128 98 M.W.208 18

Condensation

Sulpho mass + Formaldehyde

2X[ C10H8SO3 ] n [HCHO]n

Condensation

D.A. /T,A. / SNF/ NBN

[C21H16S2O6] + [H2O]n

M.W.416 30 [428]n

Raw Material Consumption & Mass Balance for One TON Product: -

Condensation, Solvent Recvery,Filtration ,Washing &-drying


Oleum 23% 432kg

Naphthalene 600kg

Formaldehyde 351kg

Water 975kg

C.S.Lye 550kg

Glauber’salt 200kg

ML in Effluent NIL

Water Evaporation

during Reaction 20kg

Water Evaporation

during Spray Drying 2244kg

Finish Product 1000kg


67

2.Phenol Base Dispersing / Tanning [ Syntans] Agents [ Powder ] Dytol DA / SNF / DLL


1.Phenol isReact with C.S. Lye to form Sodium Phenolate

2. Then it is condensed with Formaldehyde &Sulphonated withSodium Sulphite



5.Then Product is Spray dried .Then Directly Used to Dilution Or To Make Blend Product &

Finally

Packed.

6.Then Directly Packed

7.In This Process, there is no any Filtration, decantation, Washing . So There is No Any

Effluent

Condensation & Sulphonation

Phenol C.S.lye Formaldehyde Na,

Sulphite

n X [C6H6O] + n X[NaOH] + n X [CHCHO] + n X

[Na2SO3]

Condensation

Sulphonation

Sulpho mass

n X [C7H8O2Na2SO3] H2O

M.W. 94 40 32 126 M.W.250 18



Sodium Sulphite 300kg

Phenol 540kg

Formaldehyde 652kg

Water 552kg

C.S.Lye 285kg

Glauber’salt 200kg

ML in Effluent NIL

Water Evaporation

during Reaction 20kg

Water Evaporation

during Spray Drying 1609kg

Finish Product 1000kg


68

3.Melamine Base Dispersing / Tanning [ Syntans] Agents [ Powder] Dytol DA /DLL


2. Melamine is condensed with Formaldehyde & Sulphonated with Sodium Sulphite



5.Then Product is Spray dried. Then Directly Used to Dilution Or To Make Blend Product &

Finally

Packed.

6.Then Directly Packed

7.In This Process, there is no any Filtration, decantation, Washing. So There is No Any

Effluent

Condensation & Sulphonation

Melamine Formaldehyde Na, Sulphite

n X [C6H6N6] + n X [CHCHO] + n X [Na2SO3]

Condensation

Sulphonation

Sulpho mass

n X [C7H8O2Na2SO3] NaSO3

M.W. 126 32 126 M.W.303 103



Sodium Sulphite

383kg

Melamine 405kg

Formaldehyde

700kg

Water 462kg

C.S.Lye 50kg

Glauber’salt

200kg

ML in Effluent NIL

Water Evaporation

during Reaction

20kg

Water Evaporation

during Spray Drying

1180kg

Finish Product

1000kg


69

CPC SULPHONATED

Sulphonation:[CPC ,Naphthalene, Phenol, Anthraquinones]

In a MS reaction vessel, require quantity of Sulphuric / Chlorosulphonic Acid/ Oleum is taken

.Then require of R.M.as mentioned in Raw Material list Annexure (A) is added .Then reaction

mass is heated & maintain to completion of reaction Then it is dumped in ICE & filtered &

washed .Filtrate is used as Spent Acid in Other products & washing is send to ETP for further

treatment. Press cake is used for further stage.



Acid 1200kg

Raw Material 600 kg

ICE 4000 kg 500 kg HCL Re-Use

Water 1000 kg

Water 5000 kg Spent Acid ML re -use

for washing 3000 kg 3000 kg ML to ETP

1300 kg Press cake use to

Further process


Sulphonator

Dumping /

Quenching vessel

Effective HCL Recovery

Scrubbing System

Filtration &

Washing

70

ANNEXURE - IV

WATER CONSUMPTION

SR.

NO. SOURCES

WATER CONSUMPTION (KL/DAY)

EXISTING

PROPOSED

TOTAL

1 Domestic 15 20 35

2 Industrial

A Process 20 365 385

B Boiler - 70 70

C Cooling 5 60 65

D Washing - 10 10

E Scrubber - 10 10

F Ice Formation - 70 70

G Liq. Dyes

Formation -

80 80

TOTAL 40 685 725

WASTEWATER GENERATION

SR.

NO. SOURCES

WASTE WATER GENERATION (KL/DAY)

EXISTING

PROPOSED

TOTAL

1 Domestic 12 16 28

2 Industrial

A Process - 330 330

B Boiler - 5 5

C Cooling - 5 5

D Washing - 10 10

E Scrubber - 10 10

F Ice Formation - - -

G Liq. Dyes

Formation -

- -

TOTAL 12 376 388

71

WATER BALANCE DIAGRAM

Note: Only fresh water will be used for Ice Formation, Liq. Formulation & Domestic purpose.

72

ANNEXURE - V

(A) EFFLUENT TREATMENT PLANT (ZLD)

M/s. POLY CHEM INDUSTRIES shall have a ZLD Effluent treatment plant consisting of primary,

secondary, tertiary treatment and advance treatment units. The details of ETP are as follows.

STREAM I (Low COD & TDS Stream)

First all non-toxic and biodegradable streams (low & medium COD& TDS) of wastewater shall

pass through Screen Chamber (SC-01) where floating material shall be removed with help of

Screen (S-01). Then effluent shall be passed through Oil & Grease Removal Tank (OGRT-01).

Automatic mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and

grease from the wastewater to Oil & Grease Collection Tank (OGCT-01). Then effluent shall be

collected in Collection cum Equalization tank-1 (CET-01). Pipe grid is provided at bottom of the

CET-01 to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air

Blowers (1W+1 stand-by) shall supply air through to pipe grid.

Then after, equalized wastewater shall be pumped to Neutralization Tank-1 (NT-01) where the

continuous addition and stirring of Lime solution is done to maintain neutral pH of wastewater

from Lime Dosing Tanks (CDT-01) as per requirement by gravity. Then after, neutralized

wastewater shall go to Flash Mixer-1 (FM-01) by gravity. Alum and Polyelectrolyte shall be dosed

from Alum Dosing Tank (ADT-01) and Polyelectrolyte Dosing Tank (PEDT-01) respectively by

gravity into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated

wastewater shall be settled in Primary Clarifier (PCF-01). Clear supernatant from PCL shall be

passed in Aeration Tank (AT-01)

Here, biodegradation of organic matter of the wastewater shall be carried out by bacteria

(suspended growth) in the AT-01 and for that oxygen shall be supplied by 2 nos. of air blowers

(B-02) through diffusers. Air blowers also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Clarifier-1 (SCL-01) from AT-1. Here, the suspended

solids shall be settled. Sludge shall be removed from bottom of SCL-01 and pumped to AT-1 to

maintain MLSS and excess activated sludge shall be sent to Sludge Sump (SS-01).

Clear supernatant from SCL-01 shall go to Aeration Tank-2 (AT-02). Here biodegradation of left out

organic matter of the wastewater shall be carried out by bacteria (suspended growth) and for that

oxygen shall be supplied by two nos. of blowers (B-03) with help of diffusers. Then after,

wastewater shall go to Secondary Clarifier-2 (SCL-02) from AT-2. Here, the suspended solids shall be

settled. Activated sludge shall be removed from bottom of SCL-02 and pumped to AT-02 to maintain

MLSS and remaining will be sent to SS. Nutrients will be added from NDTs to Aeration Tank-1& 2 for

growth of Bacteria. Clear effluent is the collected in of Intermediate Sump (IS-01) by gravity.

Thereafter, the wastewater shall be passed through Multi Grade Filter (MGF-01) to remove left

out TSS and Activated Carbon Filter (ACF-01) for final effluent polishing. After tertiary

treatment, effluent shall be collected in RO Feed Tank(ROFT-01) before treat in UF & RO

73

units.RO permeate shall be reuse in process. RO reject shall be collected in ME Feed Tank(MFT-

01) for further treatment.

Sludge settled in PCL-01 and excess sludge from SCL-01/02 & PTS-01 shall be collected in Sludge

Sump then sludge shall be pumped to Centrifuge (CFG-01) where, dewatering shall be carried

out before storage in HWSA and ultimate disposal to TSDF. Leachate from CFG and backwash

from MGF-01 and ACF-01 shall be collected in Drain Pit and pumped back to CET-01 for further

treatment.

STREAM II (High TDS stream)

All High TDS streams of wastewater shall be collected in Collection cum Equalization Tank-2

(CET-02). Pipe grid is provided at bottom of the CET-02 to keep all suspended solids in

suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1 stand-by) shall supply air

through to pipe grid. Then effluent shall be pumped to Neutralization Tank-2(NT-02) where

Lime shall be added from Lime Dosing tank. Then after, effluent shall have sent to Flash Mixer-2

(FM-2) where Alum and poly shall be added from ADT and PDT respectively. Then after,

coagulated wastewater shall be settled in Primary Tube Settler (PTS-01).

Clear effluent from PTS shall be collected in Holding Tank (HT-01) before pumped to strippers.

Effluent from stripper shall be then collected in MEE Feed Tank (MFT-01) where RO reject shall

be mixed. Then effluent shall be sent to Multiple Effect Evaporator (MEE-01) for further

treatment followed by Agitated Thin Film Dryer (ATFD-01) for solids dewatering. Condensate

from MEE shall reuse in washing and utilities and solids from ATFD-01 shall be collected and

stored in HWSA for disposal in TSDF.

SIZE OF TANKS (Stream I and Stream II)

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

.

MOC/ Remark

Stream I (Low COD & TDS Stream) 200 M3/D

1 Screen Chamber (SC-01) 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.

Lining

2 Oil & Grease Removal Tank

(OGRT-01)

3.5 x 1.0 x (1.0 LD +0.5

FB)

1 RCC M25+A/A Bk.

Lining

3 Oil & Grease Collection

Tank (OGRT-01)

1.4 x 1.5 x (0.9 LD +0.8FB) 1 RCC M25 + RCC

M25+A/A Bk. Lin.

4 Collection cum Equalization

Tank-1 (CET-01)

5.0 x4.0 x (2.5 LD+0.7 FB) 2 RCC M25+A/A Bk.

Lining

5 Neutralization Tank (NT-01) 1.5 x 1.5 x (3.0LD +0.5 FB) 1 RCC M25+A/A Bk.

Lining

6 Flash Mixer-1 (FM-01) 1.5 x 1.5 x (2.8 LD +0.7

FB)

1 RCC M25

7 Primary Clarifier (PCL-01) 4.6 dia x (3.0 SWD +0.5

FB)

1 RCC M25

8 Aeration Tank-1 (AT-01) 16 x 9.0 x (5.0 LD +0.5 FB) 1 RCC M25

9 Secondary Clarifier-1 (SCL- 5.0 dia x (3.0 SWD +0.5 1 RCC M25

74

01) FB)

10 Aeration Tank-2 (AT-02) 12.0 x 9.0 x (5.0 LD +0.5

FB)

1 RCC M25

11 Secondary Clarifier (SCL-

02)

4.5 dia x (3.0 SWD +0.5

FB)

1 RCC M25

12 Intermediate Sump (IS-01) 3.0 m x 3.0 m x (3.0 m +

0.5)

1 RCC M25

13 Multi Grade Filter(MGF-01) 10 m3/hr 1 MSEP/FRP

14 Activated Carbon Filter

(ACF-01)

10 m3/hr 1 MSEP/FRP

15 RO Feed Tank (ROFT-01) 7.0 x4.5 x (3.0 LD+0.5 FB) 1 RCC M25

16 UF Unit & RO Unit (two

stage)

200 M3/D 1 SS

17 Lime Dosing Tank (CDT-01) 1500 lit 1 HDPE

18 Alum Dosing Tank (ADT-01) 1000 lit 1 HDPE

19 Poly Dosing Tank (PDT-01) 1000 lit 1 HDPE

20 Nutrient Dosing Tank (NDT-

01)

1000 lit 2 HDPE

21 Sludge Sump (SS-01) 3.0 m x 3.0 m x (3.0 m +

0.5)

1 RCC M25

22 Centrifuge (CFG-01) 50 M3 / day 1 SS

Stream II (High TDS stream) 160 m3/D+ RO Reject 60 m3/D

23 Collection cum Equalisation

Tank-2 (CET-02)

5.0 x 3.0 x (3.0 LD+

0.5 FB)

2 RCC M25+A/A Bk.

Lining

24 Neutralization Tank (NT-01) 1.5 x 1.5 x (3.0LD +0.5

FB)

1 RCC M25+A/A Bk.

Lining

25 Flash Mixer-2 (FM-02) 1.5 x 1.5 x (2.8 LD+

0.7 FB)

1 RCC M25

26 Primary Tube Settler(PTS-

01)

3.0 x 2.4 x (2.0 LD+1.0

HB+ 0.5 FB)

1 RCC M25

27 Holding Tank (HT-01) 7.0 x 4.0 x (3.0 LD+

0.5 FB)

1 RCC M25

28 Strippers (ST-01) 160 M3/D 1 SS316

29 MEE Feed Tank (MFT-01) 7.0 x 5.2 x (3.0 LD+

0.5 FB)

1 RCC M25

30 Multi Effect Evaporator

(MEE-01) with Agitated

Thin Film Dryer (ATFD-01)

220 M3/D 1 SS316

RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

PCC = PLAIN CEMENT CONCRETE

PP = POLYPROPELENE

MSEP = MILD STEEL EPOXY PAINTED

SS = STAINLESS STEEL

75

BLOCK DIAGRAM FOR EFFLUENT TREATMENT PLANT

*NOTE: COMPANY WILL ADOPT THIS OPTION UNTIL THE CETP WILL BECOME OPERATIONAL.

76

(B) SEWAGE TREATMENT PLANT

TREATMENT SCHEME

First all non-toxic and biodegradable streams of sewage shall be passed through Screen

Chamber(SC-01) where Screen (S-01) is provided to remove floating material from sewage

manually. Then effluent shall be passed through Oil & Grease Removal Trap (OGRT-01) from

where floating O & G shall be removed from top manually. Then after, the sewage is collected in

Collection Tank (CT-01). Then sewage shall be pump to Moving Bed Bio-Reactor (MBBR) with

help of submersible pump (P-01).

In MBBR tank dissolved organics are removed with the help of bacteria in presence of oxygen

provided by blower (B-01) through diffused aeration system. MBBR tank is loaded with special

media which inhibits attached bacterial growth. Due to this attached growth the quantity of

sludge generation is very little and also the treatment is more effective in a very less retention

time. The biggest advantage of this system is it does not require recirculation of activated

sludge. This treated sewage shall be transferred to Tube Settler Tank (TST-01), where Sludge

settles in TST-01 shall be sludge is discarded in sludge drying beds (SDBs) for drying. Leachate

from SDBs is sent back to Collection tank for treatment and dry sludge is used as manure.

The treated sewage shall be then collect in Intermediate Sump (IS-01) where for disinfection of

sewage; Sodium Hypochlorite shall be added from Sodium Hypochlorite Dosing Tank with help

of Dosing Pump.

This treated water shall be pump to Dual Media filter (DMF-01) with help of Centrifugal pump

(P-02) to ensure total removal of suspended particles and for polishing treatment. Treated water

is then collected in Treated Water Sump (TWS-01) before used for irrigation.

77

SIZE OF TANKS

S.

N. Name of unit

Size (m x m x m)

L x B x (LD+FB) No. MOC/ Remark

1 Screen Chamber (SC-01) 1.5 m x 0.7 m

(0.05 m+0.5 FB)

1 RCC M25

2 Oil & grease removal tank

(OGRT-01)

2.5 m x 0.7 m

(0.05 m+0.7 FB)

1 RCC M25

4 Collection cum Equalization

Tank (CET-01)

3.0 m x2.5 m x

(2.0 m+0.9 FB)

1 RCC M25

5 Moving Beds Bio Reactor

(MBBR-01)

4.0 m x 3.0 m x

(3.5 m+1.0HB+0.3 FB)

1 MSEP

6 Tube Settle Tankr-1(TST-01) 2.0 m x1.7 m x

(2.0 m+1.0 HB+0.3 FB)

1 MSEP

7 Intermediate Sump (IS-01) 2.0 m x1.7 m x

(1.5 m+0.5 HB+0.3 FB)

1 MSEP

8 Dual Media Filter (DMF-01) 2 m3/hr 1 MSEP

9 Treated Water Sump (TWS-

01)

3.0 m x 2.5 m x

(2.5 m + 0.5)

1 RCC M25

10 Sludge Drying Beds (SDBs-

A/B)

2.5 m x 1.5 m

2 Brick Mas. With PCC

Bedding

11 Sodium hypochlorite dosing

tank (SHDT-01)

1000 Liter 1 HDPE

78

BLOCK DIAGRAM OF STP

79

ANNEXURE-VI

DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL

CAT.

NO.

HAZARDOUS

WASTE

PROPOSED

TOTAL

(MT/Month)

METHOD OF DISPOSAL

35.3 ETP Sludge 69 Collection, Storage, Transportation and Sent to TSDF site

for secured land filling

33.1 Discarded barrels/

containers/ liners

100

Nos./Month Collection, Storage, Transportation and Sent back to

supplier / to GPCB approved recycler

33.1 HDPE Bags 500

Nos./Month Collection, Storage, Transportation and Sent back to

supplier / to GPCB approved recycler

20.3 Distillation Residue 25 Collection, Storage, Transportation and sell to Cement

Industries for Co-processing or Disposal at Common

Incineration Site

5.1 Used Oil 0.5 Collection, Storage, Transportation and Sent to GPCB

approved recycler

26.1 Process Waste 60 Collection, Storage, Transportation and Sent to TSDF site


26.1 Iron Sludge 338 Collection, Storage, Transportation and Disposal at

Nearest TSDF or sell to Cement Industries

26.1 Gypsum 3659 Collection, Storage, Transportation and Disposal at

Nearest TSDF or sell to Cement Industries

35.3 MEE Salt 60 Collection, Storage, Transportation and Sent to TSDF site


26.3 HCl (32%) 180 Collection, Storage, Transportation and Reuse in Process

26.3 Sulphuric Acid 1850

Collection, Storage, Transportation and Reuse in H-Acid

(2300)

- CaCl2 2 Collection, Storage, Transportation and sell to

Pharmaceutical Industry, Food Industry, For the Water

Treatment & In Fabric Industries.

- K2CO3 7 Collection, Storage, Transportation and sell to Detergent

industries & Glass Industries.

- Sodium

Sulfite/Sodium Bi

sulfite

20 Collection, Storage, Transportation and sell to Pulp &

Paper Industries / Food Industries.

SOLID WASTE

1 Fly Ash 48 Collection, Storage, Transportation and sell to brick

manufacturer.

80

ANNEXURE-VII

DETAILS OF STACK AND VENTS

EXISTING

(A) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO HOT AIR GENERATOR

SOURCES OF GASESOUS EMISSIONS STACK

Fuel Used Coal – 15 MT / Day

Capacity 30 Lac Kcal/Hr

Type of Emissions SO2 NOx SPM

Permissible Limits 262 mg/Nm3 94 mg/Nm

3 150 mg/Nm

3

Stack Height 30 meters

Stack Diameter at the Top 0.5 m

Air Pollution Control System Bag Filter

(B) STACK ATTACHED TO PROCESS VENT-1 (SPRAY DRYER)

SOURCES OF PROCESS EMISSIONS VENT

Source of emission Process Vent-1

Type of Emissions Particulate matter

Permissible Limits 150 mg/Nm3

Stack Height 32 m

Air Pollution Control System Water scrubber

PROPOSED

(A) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO STEAM BOILER


Fuel Used Coal/Agrowaste – 15 MT/Day

Capacity 5 MT/Hr



3 150 mg/Nm

3


Stack Diameter at the Top 800 MM

Air Pollution Control System Multi Cyclone Separator, Bag filter & Scrubber

81

(B) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO THERMIC FLUID HEATER


Fuel Used Oil – 20 Lit/ Hr

Capacity 2 Lac Kcal/Hr



3 150 mg/Nm

3


Stack Diameter at the Top 800

Air Pollution Control System Scrubber

(C) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO D.G.SET


Fuel Used HSD = 100 Liter/Hr

Capacity 750 x 2 KVA



3 150 mg/Nm

3


Stack Diameter at the Top 0.2 meter

Air Pollution Control System --

(D) STACK ATTACHED TO PROCESS VENT-1 (SPRAY DRYER NO. - 2)





Stack Height 32 m


(E) STACK ATTACHED TO PROCESS VENT-2 (SPRAY DRYER NO. - 3)





Stack Height 32 m


82

(F)STACK ATTACHED TO PROCESS VENT-3



Type of Emissions HCl




Air Pollution Control System Two Stage scrubber

(G)STACK ATTACHED TO PROCESS VENT-4



Type of Emissions SO2





(Water + Alkali)

(H)STACK ATTACHED TO PROCESS VENT-5



Type of Emissions NH3





(Water + Acid)

(I) STACK ATTACHED TO PROCESS VENT-6



Type of Emissions HBr





(Water + Alkali)

83

ANNEXURE-VIII

STORAGE DETAILS OF HAZARDOUS CHEMICALS

SR.

NO

NAME OF THE MATERIAL TYPE OF

HAZARD

NUMER OF

TANKS

MAXIMUMA

QTY TO STORE

TANK STORAGE 1 ACETIC ACID CORROSIVE 25 KL X 1 25 KL

2 ACETIC ANHYDRIDE FLAMMABLE 25 KL X 1 25 KL

3 H2SO4 (98%) CORROSIVE 25 KL X 2 50 KL

4 OLEUM (23%) CORROSIVE 25 KL X 1 25 KL

5 OLEUM (65%) CORROSIVE 25 KL X 1 25 KL

6 CHLORO SULPHONIC ACID CORROSIVE 25 KL X 1 25 KL

7 NITRIC ACID CORROSIVE 25 KL X 1 25 KL

8 HCL CORROSIVE 25 KL X 1 25 KL

9 SPENT HCL (32%) CORROSIVE 25 KL X 1 25 KL

10 H2SO4 (70%) SPENT COOROSIVE 25 KL X 2 50 KL

11 C.S.LYE CORROSIVE 25 KL X 2 50 KL

12 METHANOL FLAMMABLE 25 KL X 1 25 KL

13 DIMETHYL FORMAMIDE FLAMMABLE 25 KL X 1 25 KL

14 XYLENE FLAMMABLE 25 KL X 1 25 KL

15 HEXANE FLAMMABLE 25 KL X 1 25 KL

DRUMS

1 SODIUM CYANIDE TOXIC 50 X 40 2 MT

2 TOLUENE FLAMMABLE 50 X 20 1 MT

CYLINDER 1 CHLORINE GAS TOXIC 1 TONN X 1 1 TONN

2 NITROGEN TOXIC 1 TONN X 1 1 TONN

3 AMMONIA GAS TOXIC 1 TONN X 1 1 TONN

84

ANNEXURE-IX

___________________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement for the proposed project is being expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to some

extent for the local population.

This phase is expected to create a beneficial impact on the local socio-economic environment.

2) INDUSTRIES

Required raw materials and skilled and unskilled laborers will be utilized maximum from the

local area. The increasing industrial activity will boost the commercial and economical status of

the locality, to some extent.

3) PUBLIC HEALTH

The company regularly examines, inspects and tests its emission from sources to make sure that

the emission is below the permissible limit. Hence, there will not be any significant change in the

status of sanitation and the community health of the area, as sufficient measures have been

taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the existing factory is having proper linkage for the transport and communication, the

development of this project will not cause any additional impact.

In brief, as a result of the proposed project there will be no adverse impact on sanitation,

communication and community health, as sufficient measures have been proposed to be taken

under the EMP. The proposed project is not expected to make any significant change in the

existing status of the socio - economic environment of this region.

85

ANNEXURE-X

___________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 5 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

• List of Products and their capacity

• List of hazardous chemicals with their toxicity levels.

• Mass balance of each product along with the batch size

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5

km area.

• Study of Data from secondary sources.

• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.

For SPM, RSPM, SO2, NOx.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in the

study area were surveyed.

4. Impacts Identification and Mitigatory Measures.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

86

6. Risk Assessment

• Details on storage facilities

• Identification of hazards

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Occupational Health and Safety Program for the Project.

plot no: c/387, 388, 389, gidc, vill: sayakha, tal: vagara,...

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