By M/S HERCULES PIGMENTS PVT....
Transcript of By M/S HERCULES PIGMENTS PVT....
Prefeasibility Report
New Project: 1 Manufacturing: Organic Azo Pigment
ON
PROPOSED PROJECT FOR THE MANUFACTURE
OF ORGANIC AZO PIGMENTS
Category – 5 (f)
By
M/S HERCULES PIGMENTS PVT. LIMITED
Located at:
Plot No. 1704, Chemical Zone
GIDC Notified Industrial Area, GIDC Sarigam, Dist- Valsad
Gujarat.
Prefeasibility Report M/S HERCULES PIGMENTS PVT. LTD
New Project: Page 2 Manufacturing: Organic Azo pigment
Project prefeasibility report for obtaining prior Environmental Clearance in terms
of provisions of EIA Notification -2006
1. Executive Summary :
Name & Location:
Name of the Project : M/s. Hercules Pigments Pvt. Limited
Location : Plot No.- 1704, GIDC Notified Industrial Sarigam, Ta: Umbergaon,
Dist- Valsad 396 155. Gujarat.
Project M/S Hercules pigments Pvt. limited is a new proposed project to be located in GIDC notified
industrial area, falling under small Scale category & proposes to manufacture Organic Azo
Pigments (Yellow, Orange, Red).
Proposed Project Cost: Rs. 700 Lacs.
Applicability of EIA notification – 2006
Category as per the amended EIA notification- 2006: as proposed products (i.e. Organic Azo
Pigments) are covered under the Category 5 (f) B. Hence, Environmental Clearance is required.
Project Proponent
The company in India comprising 3 Directors
Small Scale Unit
List of finished products & by- products
SR. NO. PRODUCT MT/MONTH
1 Organic Azo Pigments (Orange/Yellow/Red)
150
Manufacturing process with chemical reaction & mass balance is attached as Annexure-3
Resource Requirement
Components Proposed Resources availability
Power, KVA 200 Will be sourced from Dakshin Gujarat Vij Co. Ltd.
Fresh Water, kl/Day 260 Will be sourced from GIDC water supply dept.
Natural gas for Steam Boiler (2.5 TPH) ,
SCM/day
1700 From GSPC Limited
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Natural gas for Hot air dryer (2.5 TPH) ,
SCM/day
800 From GSPC Limited
Fuel (HSD) for D.G.Set (200 KVA) , Kgs/Hr
40 Will be sourced Local Dealer
Raw material Consumption
(1.0) ORGANIC YELLOW PIGMENT
Sr. No. Raw Materials Quantity in MT
Ton per ton of product
Proposed, MT/Month
1.1.1 Base (Amine) 0.405 60.75
1.1.2 Ice 12.0 1800
1.1.3 Sulphamic acid 0.009 1.35
1.1.4 Sodium nitrite 0.69 103.5
1.1.5 Hydro Chloric Acid (30%) 0.96 144
1.1.6 Caustic 0.35 52.5
1.1.7 Acetic acid & others 0.285 42.75
Total 14.699 2204.85
(2.0) ORGANIC RED PIGMENT
2.1 Base (Amine) 0.42 63
2.2 Ice 10.67 1600.5
2.3 Sulphamic acid 0.024 3.6
2.4 Sodium nitrite 0.194 29.1
2.5 Sulphuric acid 2.91 436.5
2.6 Caustic 0.63 94.5
2.7 Hydro Chloric acid 0.97 145.5
2.8 Coupler 0.57 85.5
Total 16.388 2458.2
(3.0) ORGANIC ORANGE PIGMENT
2.3.1 Base (Amine) 0.405 60.75
2.3.2 Ice 9.0 1350
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2.3.3 Sulphamic acid 0.007 1.05
2.3.4 Sodium nitrite 0.24 36
2.3.5 Hydro Chloric Acid (30%) 1.08 162
2.3.6 Caustic 0.32 48
2.3.7 Emulsifier & others 0.02 3
Total 11.072 1660.8
Water and Waste Water Management
Total raw water requirement is 260 M3/day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.
Total Industrial Waste water generation is 250 M3/Day mainly from process, washing, boiler blow down, cooling which will be treated in proposed primary & secondary treatment plant & discharge into underground effluent drainage line of GIDC Sarigam to CETP Sarigam for further treatment & ultimate disposal into Arabian Sea through closed pipe line.
Domestic waste water (5 M3/Day) will be disposed off through septic tank.
Air Emission and its Control Measures
Flue gas emission:
The company proposes to install 2.5 TPH capacity of steam boiler for the requirement of
process steam. The unit shall use 1700 SCM/day of natural gas as a fuel. Adequate height of
stack will be provided. Also the unit shall use natural gas fired hot air dryer having
consumption of natural gas will be 800 SCM/day.
The company shall install one number of new 200 KVA capacity D G set, as standby. It will be
used only during power failure. Average 40 kgs/hr of HSD will be used as a fuel. 11 meters
height of exhaust will be provided.
Process gas emission:
Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers. The process heat is
provided by hot air dryer. The pulverization will be carried out in a closed system includes
cyclone separator & bag filter. (Details of Air pollution control measures are attached as
Annexure-8).
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Hazardous Wastes and its Management
No Type of waste Category Qty. MT/ Year
Treatment Disposal
1 ETP waste 34.3 50.0 Dried, packed in bags
Dispose off into TSDF,
Vapi
2 Used Oil 5.1 0.005 Packed in carboys
Sell to Registered
re-processers
3 Discarded containers 33.3 1.0 De-contaminated,
stored
Sell to authorized
recycler
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2. Introduction of Project / Back Ground Information :
(i) Identification of Project and proponent.
Name of the project Proponent: M/S Hercules Pigments Pvt. Limited
HERCULES PIGMENTS PVT LTD is a medium scale unit is located in notified industrial
estate, GIDC, Sarigam, Di: Valsad having total plot area 4306 m2 & total investment will
be Rs. 700 Lacs. The proponent wishes to start the production of Organic Pigments (Red,
Yellow and Orange) with capacity of 150 MT per month. The product is especially used in
printing ink, paints and plastic formulation like newspaper inks, magazine, food
packaging, home and industrial paints and plastic master batches as per requirement.
The proposed project site lies on 20018’02.33” N Latitude & 72051’03.43”E Longitude.
M/S HERCULES PIGMENTS PVT LTD is proposing to be located at plot. No. 1704, GIDC
Sarigam, Ta: Umbergaon, Di: Valsad district in Gujarat state and same western part
comes under Daman union Territory. GIDC is located nearby National Highway No. 8
connecting Mumbai and Ahmedabad and is surrounding by Union territories of Daman
in western side. The western Railway Main Line is passing through the area (Double &
Electrified). Nearest town & industrial estate Vapi is the biggest railway station in the
study area; where, almost all the important mail & express trains stop. Entire study area
is well connected with the other major cities of the state and the country.
Beside the rail connectivity, and also well connected by road transport. There is a good
network of roads in the area and contributes for the development and economic growth
of the area. The National Highway No. 8 (Surat – Mumbai) is now six lanes, double
tracked, more elevated and Jam free highway, which is developed by M/s L & T
Company. This highway has given a further boost to the economic growth of this area.
The existing unit is operated by technocrats having more than 30 years of experience in
manufacturing and marketing of various Organic pigments.
The company has been established in 2008 with manufacturing plants in Vapi, Gujarat
having well equipped production plant which is being managed by dedicated, qualified &
skilled persons.
The proponent shall to start production of Organic pigments with total capacity of 150
MT per month and process capabilities to manufacture High Performance pigment
series.
Hercules Pigments Pvt Ltd is established in 2008 and managed by a professional board
of directors. It manufactures and markets a wide range of Organic Pigments. Senior
personnel are available for providing support to the manufacturing unit in the areas of
technology, R&D, manufacturing, quality control and quality assurance. Organic
pigments are manufactured at the company’s 3 manufacturing units located at Vapi
Gujarat for sale in local & international market. It was co-founded by 3 technocrats.
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Identification of the project proponent:
The company is managed by the promoters and whole time directors Mrs. Vatsala
Narendra Desai, Mr. Swetal Narendra Desai and Mr. Anupam Desai having more than 30
years experience & their team members Mr. Pramod Kumar Tandon who is Masters in
Chemical Technology having 45 years experience in chemical industries.
The company emphasis on R & D, quality control, marketing, production, logistics,
import & export.
Company’s strength is commitment, best quality, timely delivery at best prices.
The Directors have good experience and exposure in Azo pigments industries as the
main director has been in this line of business for more than 2 decades. They have
developed wide ranging contacts in the country and abroad and do not foresee any
problem in the marketing the product manufacturing.
(ii) Brief description of nature of the Project :
The proposed project involves the production of “Organic Pigments” which are used in
Printing Inks, Paints, Plastics and cosmetic formulation like newspaper, magazine,
flexible packaging, home and industrial paints, plastic master batches and
cosmetics etc. as per requirement. As per the EIA notification- 2006 as amended
products are covered under any category 5(f) required Prior Environmental Clearance.
For the proposed new project, the company intends to procure the available latest
technology for manufacturing the products.
A typical plant shall house of MS Rubber lined/Stainless Steel reactors, Filter Press,
dryers, multi-mills, jet mills, blenders etc.
(iii) Need for the project and its importance to the country and or region :
The proposed new project provides a potential growth opportunity for the running
business of the company. The company is already engaged in the business of
manufacturing of “Organic Pigments”. The project would increase the overall export
and also increase the foreign revenue. Product is now well established and acceptable
in the international markets.
Additional capacities of product range required over & above our existing capacities, as
the company expect strong growth of exports to the extent of 40-50%. Local market
also showing strong growth potential.
Domestic market concentrated in Pan-India, particularly in West and Northern belt,
making Sarigam as ideal choice. This project will generate employment of up to 100
people.
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(iv) Demand –Supply Gap :
The products have very high specific demand as they are especially used in printing ink
formulation like news paper and flexible packaging as per requirement.
(v) Imports vs. Indigenous production :
Existing products manufacturing in the country will be very much economical as
compared to Import of the same. The export of this pigments will earn revenue for the
county.
(vi) Export Possibility :
Existing products have high export potential. Also these products have very good sab
potential in local market.
Additional capacities of product range required over & above our existing capacities at
Sarigam, as the company expect strong growth of exports to the extent of 40-50%. Local
market also showing strong growth potential.
(vii) Domestic / export Markets :
The company’s product is used as raw material to manufacture various printing inks,
paints and master batches as per the required applications and having very good market
in domestic and also having very good international markets.
(viii) Employment Generation (Direct and Indirect) due to the project :
There will be very good opportunity of employment generation directly and indirectly
due to proposed new project. Due to proposed project there will be ~100 people will be
directly/indirectly employed.
3. Project Description :
(i) Type of Project including interlinked and interdependent projects, If any :
The proposed project is an interdependent project of the company.
(ii) Location (map showing general location, Specific location, and project boundary &
project site layout) with coordinates :
The map showing general location, specific location and project boundary and project
site lay out is enclosed as Annexure-1.Plant layout is attached as Annexure-2.
(iii) Details of alternate sites considered and the basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted :
The proposed activity will be accommodated in the notified industrial area having
proper industrial infrastructure so; there is no alternate site consideration. Proposed
expansion will be carried out in existing premises only. (Land allotment letter is attached
as Annexure-6).
(iv) Size or magnitude of operation :
As per the proposed project cost the project is covered under medium Scale category of
manufacturing industries.
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(v) Project description with process details (a schematic diagram/ flow chart showing the
project layout components of the project etc. should be given) :
Detailed project description with process details is enclosed as Annexure-3
(vi) Raw material required along with estimated quantity, likely source, marketing area of
final products/s, mode of transport of raw Material and finished product :
Detailed raw material requirement along with estimated quantity, likely source,
marketing are of final products mode of transport of raw material and finish product &
characteristics of hazardous chemicals are as below:
DETAILS ON PRODUCT/BY-PRODUCTS TRANSPORTATION
Sr. No.
Product Physical State Dispatch Means of Transportati
on 1 Organic Azo Pigments
(Red/Yellow/Orange) Solid Local/Export Truck/contai
ners
DETAILS ON RAW MATERIAL TRANSPORTATION
Sr. No.
Substance Physical State
Source of Supply & packing
Means of Transportation
Distance of supplier
from project site
(km) 1 Base (Amine) Powder Local, 25 kgs
bags container 200 kms
2 Ice solid Local, 50 kgs bags
tractor 10 kms
3 Sulphamic acid
Powder Local, 25 kgs bags
container 200 kms
4 Sodium nitrite
Powder Local, 25 kgs bags
container 200 kms
5 Hydro Chloric Acid
(30%)
liquid Local, tanker tanker 25 kms
6 Caustic lye liquid Local, tanker tanker 25 kms
7 Acetic acid & others
liquid Local, tanker tanker 25 kms
8 Sulphuric acid
liquid Local, tanker tanker 25 kms
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(vii)
DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS
No Name of the Raw
Materials
Quantity stored, MT
BP. 0C
MP 0C
Place of its
Storage
State operati
ng pressur
e temperature
Possible type of hazards
Control measures provided
Max Actual
1 DCB 46 20 Bags N.A 132 Solid Avoid
contact with
skin & eye.
Avoid
breathing
dust, mist or
gas.
Use Chemical
goggles,
Gloves, Apron,
Purifying
respirator.
2 AAA 46 20 Bags Does
not
bil
up
to
200
85 -
86
Solid May cause
Eye and Skin
irritation,
respiratory
and
digestive
tract
irritation.
Ingestion of
large
amount may
cause
gastrointesti
nal irritation.
Use chemical
safety goggles,
Wear
appropriate
protective
gloves and
clothing to
prevent skin
exposure.
Always use a
NIOSH or
European
Standard
EN149
approved
respirator.
3 Caustic
lye
36 10 Stor
age
tank
/Dru
ms
13
88
318 Liqui
d
Skin
irritation
with greater
skin
exposure,
eye contact
causes
destructive
to eye
tissue.
Contact
lenses
should not
be worn
when
working with
this
Employee
should be
provided with
impervious
clothe, gloves,
face
shield(eight-
inch
minimum),dus
t and splash
proof safety
goggles,
chemically
resistant
safety shoes,
eyewash
station and
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chemical.
Swallowing
Sodium
Hydroxide
may cause
severe burns
of mouth,
throat,
esophagus
and
stomach.
safety showers
must be
available.
4 Hydro
Chloric
acid
124 20 St
or
ag
e
ta
nk
53 -74 Liqui
d
Corrosive
Liquid. Mist
causes
severe
burns to all
body
tissue, may
be fatal if
swallowed
or inhaled,
inhalation
may cause
lung
damage.
Use chemical
safety goggles
or full face
shield, Rubber
or neoprene
gloves and
additional
protection
including
impervious
boots, apron.
NIOSH
approved
Respirators.
5 Sulpha
mic
acid
2 1 Ba
gs
N.
A
N.A Solid Irritant. Use Chemical
safety face
shield, Rubber
hand gloves,
Rubber or PVC
apron.
6 Napht
hol AS
50 10 Ba
gs
N.
A
240-
244
Solid In case of
Skin and
Eye contact
(Slightly
irritanting)
Use chemical
Goggles,
Gloves and
Respirators,
avoid contact
with eyes and
skin.
7 Sodiu
m
nitrite
80 10 Ba
gs
32
0
271 Solid Toxic if
swallowed,
very toxic
on
inhalation,
irritation to
eyes,
possible
skin
sensitizer.
Use Chemical
goggles, full
face shield,
Wear PVC
gloves, Rubber
safety
footwear or
gumboots. The
material may
produce skin
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Resource optimization/ recycling and reuse envisaged in the project , if any , should
briefly outlined
Contact
with
combustibl
e material
may cause
fire.
sensitization in
predisposed
individuals,
care must be
taken, when
removing
gloves and
other PPE, to
avoid all
possible skin
contact.
8 PMP 50 10 Ba
gs
28
7
126
–
130
Solid Causes
Irritation in
case of Skin
and Eye
contact.
Use splash
resistant
safety goggles,
appropriate
chemical
resistant
clothing and
gloves.
Resource optimization/recycling and reuse envisaged in the project in detail are as
mentioned below:
The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses.
Proper earthing shall be provided were ever hazardous material handling is done.
Entire plant will be flameproof.
Wash water will be recycled to minimize the fresh water consumption.
(viii) Availability of water its source, Energy/power requirement and source should be given
:
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Availability of water its source, Energy/power required and its source is below. Water
withdrawal permission is attached as Annexure-4.
PRODUCTWISE WATER CONSUMPTION M3 PER TONE OF PROPOSED PRODUCT
INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING
Sr. No. Product Processing Boiler
(Live
Steam)
Cooling
(Ice)
Product
Washing
Total
1 Organic Red
Pigment
6.5 4.0 11.0 20.0 41.5
2 Organic
Yellow
Pigment
7.0 4.0 12.0 20.0 43.0
3 Organic
Orange
Pigment
7.5 4.0 9.0 20.0 40.5
4 Maximum 7.0 4.0 12.0 20.0 43.0
PRODUCTWISE EFFLUENT GENERATION M3 PER TONE OF PROPOSED PRODUCT
INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING
Sr. No. Product Processing Boiler
(Live
Steam)
Cooling
(Ice)
Product
Washing
Total
1 Organic Red
Pigment
6.5 3.9 11.0 20.0 41.39
2 Organic
Yellow
Pigment
6.9 3.9 12.0 20.0 42.8
3 Organic
Orange
Pigment
6.7 3.9 9.0 20.0 39.6
4 Maximum 6.9 3.9 12.0 20.0 42.8
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PRODUCTWISE WATER CONSUMPTION M3 PER DAY OF PROPOSED PRODUCT
INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING
Sr. No. Product Processing Boiler
(Live
Steam)
Cooling
(Ice)
Product
Washing
Total
1 Organic Red
Pigment
37.5 23.1 63.5 115.4 239.4
2 Organic
Yellow
Pigment
40.4 23.1 69.2 115.4 248.1
3 Organic
Orange
Pigment
43.3 23.1 51.9 115.4 233.7
4 Maximum 40.4 23.1 69.2 115.4 248.1
PRODUCTWISE EFFLUENT GENERATION M3 PER DAY OF PROPOSEDPRODUCT
INCLUDES PROCESSING, STEAM, COOLING & PRODUCT WASHING
Sr. No. Product Processing Boiler
(Live
Steam)
Cooling
(Ice)
Product
Washing
Total
1 Organic Red
Pigment
37.5 22.5 63.5 115.4 238.8
2 Organic
Yellow
Pigment
39.8 22.5 69.2 115.4 246.9
3 Organic
Orange
Pigment
38.7 22.5 51.9 115.4 228.5
4 Maximum 39.8 22.5 69.2 115.4 246.9
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OVERALL WATER CONSUMPTION & EFFLUENT GENERATION(M3/DAY)
Sr. No.
Particulars Water Consumption
Effluent generation
1. Domestic 5.0 4.0
2. Processing 40.4 39.8
3. Boiler ( Live steam)
Boiler blow down &
DM rejection
27.0 24.0
4. Product Washing 115.4 115.4
5. Cooling as ice 69.0 69.0
6. Floor/container
washing
2.0 2.0
7. Gardening 1.0 0
8. Grand Total 259.8 254.2
9. Total Industrial 253.8 250.2
Note:
Average 260 M3/day fresh water will be used for proposed plant and source from GIDC authority.
Domestic effluent shall be passed through adequate capacity of septic tank/soak pit.
Process effluent shall be sent ETP.
Boiler blow down, D M rejection & live steam comes out as an effluent.
Ice water comes out as effluent.
Floor/container & vessel washing comes out as effluent.
Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through under ground drainage line for further treatment & ultimate disposal into Arabian Sea.
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ENERGY REQUIREMENT AND ITS SOURCE
Sr. No.
Particulars Proposed Source
1 Steam requirement
2500 kgs./hrs. Will be obtained from proposed NG fired steam boiler of 2.5 TPH capacity
POWER REQUIREMENT AND ITS SOURCE
Sr. No.
Particulars Proposed Source
1 Power –Electricity requirement
200 KVA Will be sourced from Dakshin Gujarat Vij Co. Ltd.
(ix) Quantity of waste to be generated ( liquid and solid) and scheme for their
Management/disposal :
Quantity of waste to be generated (liquid and solid) and scheme for their Management/
disposal is enclosed as Annexure-4.
(x) Schematic representations of the feasibility drawing which give information of EIA
purpose: A schematic representations of the feasibility drawing is attached as
Annexure-7
Site Analysis
(i) Connectivity :
The project is to be located in notified Industrial Estate of Sarigam which is very well
connected to National Highway no.8, Western Railways. And the nearest air port
(Mumbai) and port are 150 KM away from the project site by road.
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4. (ii) Land Form, Land use and Land ownership :
The land is in the form of industrial shed owned by Gujarat Industrial Development
Corporation.
(iii) Topography (along with map) :
Topography map showing the elevation of study area is below;
The catchment area of the proposed project site altitude is 35 m (a.m.s.l) consists of the
near site is flat topped, highly dissected plateaus and dyke ridges running in a west to
east direction. The Main River (Daman Ganga) in the catchment area flows in incised
meanders forming steep geomorphologically ‘V’ shaped valleys with steep sides. The
entire catchment has a rectangular and trellis pattern of drainage depicting the
influence of the structures on the drainage development.
Topography map showing the elevation of the study area below. The topographical map
is enclosed as Annexure-5.
(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including
area under CRZ)), shortest distances from the periphery of the project to periphery of
the forest, national park, wild life sanctuary , eco sensitive areas, water bodies
(distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of
Gazette notification should be given :
The existing land is located in the notified industrial area and a copy of possession letter
and gazette notification is enclosed as Annexure-6.
(v) Existing Infrastructure :
GIDC notified industrial area of Sarigam has the entire available infrastructure like
water, electricity, roads, rail, transportation, availability of raw material and drainage
system.
(vi) Soil classification :
General soil classification of the area is as under :
The area, being of basaltic formation, falls under the broad soil group of red loams and
black clay soils. The transmission of water through similar parent material seems to have
influenced the development of different physiographic characteristics of the soils in the
area.
The area in between the hills with sloping lands contains dark yellowish brown to very
dark grayish brown gravelly clay loam to clayey soils of shallow to moderate thickness.
The dissected hill and steep slopes suffer from severe erosion hazards. The steep hill
slopes are almost devoid of soil.
(vii) Climate data from secondary sources :
Rainfall Data :
The project site location receives annual rainfall of 2010 – 1200 to 1300 mm in 35 rainy
days with coefficient of variation of 65 %. There is large spatial and temporal variation in
rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are
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comprised of Kutch district and western parts of Banaskantha and Patan district and
parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by
arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad,
Navsari and Surat, Dadra & nagar haveli and Daman & Diu) are characterized as sub
humid climate. The rest part of the state receives rainfall between 500-1000 mm and
generally fall under semi-arid climate.
Temperature & Climate Data:
Proposed project site falls under seismic zone-III, which h is not highly earthquake prone
area. Aside from the monsoon season, the climate is dry. The average maximum
temperature 35 - 41 oC and Minimum temperature, 12 -15
oC. The average humidity ranges
from nearly 84% in August to about 31% in February.
(viii) Social Infrastructure available :
Social Infrastructure in Valsad district is as under :
Education : There are 990 primary and 161 secondary and higher secondary Table 5: List
of Educational Institutes schools in the district Educational Total With over 1,250 seats,
there are 6 ITIs offering several industrial training Institutes programs which includes,
fitting, armature & motor rewinding, Primary School 990 electrician, information
technology and electronic system maintenance Secondary School etc 166 Higher
Secondary School, One Government polytechnic College is present in the district
offering courses in civil, chemical, electrical, mechanical and plastic engineering, ITI’s 6
with an intake capacity of 360 Polytechnic 1 College§ With 120 seats, there is one
Degree Engineering College present in Pharmacy College 2 Valsad offering engineering
courses in mechanical and chemical Engineering 1 branches College§ Located in Vapi, G.
M. Bilakhia Pharmacy College has an intake Management 1 College capacity of 60
students per year Other Colleges Rofel Institute of Management studies in Valsad offers
full time MBA Other Colleges: Arts, Commerce, Science, B.Ed and Law College course
and takes 120 students per annum Source: Department of Education, 2007
1. Health: There are 43 primary healthcare centres, 10 community healthcare
centres, 10 Government and 1 Municipal hospital present in the district. Valsad has
several private specialized hospitals to provide a comprehensive range of tertiary and
secondary care services backed by state-of- the- art technology and trained medicos§ A
multi-specialty 21st Century Hospital, (branch of Nadkarni Group of Hospitals) is present
in Vapi, giving services in general and laparoscopic surgery, trauma, orthopedic and
urology etc. the hospital is one of the few centers in India offering Uterine
Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB)
patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General
Hospital, and Adarsh Hospital are also present in Valsad
2. Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also
known Fire Temple as Mecca for the Parsi community in India, makes the city a famous
pilgrimage center throughout the world§ Dharampur is surrounded on three sides by
the Sahyadri Mountains which grace the town with pleasant climate throughout the
years The collection at the Lady Wilson Museum in Dharampur includes tribal art and art
crafts that highlights the local culture. Besides this, District Science Centre is also
Prefeasibility Report M/S HERCULES PIGMENTS PVT. LTD
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present in Valsad Proximity of Valsad with Daman & Diu, has increased the graph of
tourist flow in the district.
5. Planning Brief :
(i) Planning Concept ( Type of industries, facilities, transportation etc) Town and Country
Planning /Development authority Classification :
There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in manufacture of variety of products, for example pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Sarigam.
(ii) Population Projection :
Not applicable
(iii) Land use Planning (breakup along with green belt etc) :
The proposed project is located within the Notified Industrial Area by Government of
Gujarat and due to the proposed project there will not be any change in the land use
pattern of the region. Proposed Green belt planning in the project area is as below.
For Green Belt Development, the company proposes to develop a green belt in 22% of the total plot area. i.e. 4306 sq. meter. In addition to this company shall also develop green belt along the periphery of the proposed site and in common premises available outside the company premises.
Site plan with Area table for proposed plant
Sr. No Particulars Area in m2
1 Production area 700
2 Raw material storage area 150
3 Finished product storage 50
4 Office & laboratory area 100
5 Toilet block & others 150
6 Utility & boiler 330
7 Solid waste storage 40
8 ETP 60
9 Gardening & plantation 980
10 Open space 1736
12 Watchman cabin 10
13 Total 4306
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Site plan & Key Plan
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(iv) Assessment of Infrastructure demand ( Physical & Social) :
There is no need for any infrastructure demand in terms of physical or social needs for
proposed expansion.
(v) Amenities/ Facilities :
GIDC notified industrial area of Sarigam has the entire available infrastructure like CETP,
water, electricity, roads, rail, transportation, availability of raw material and drainage
system.
6. Proposed Infrastructure :
(i) Industrial Area (Processing Area).
The proposed infrastructure to manufacture products will be built with standard
engineering design considering all the relevant parameters related to environment,
health and safety.
(ii) Residential Area (Non Processing Area) :
No residential area is involved in the proposed project.
(iii) Green Belt :
Green belt will be provided and maintained at the tune of 22% of the total land area.
(iv) Social Infrastructure :
Not applicable
(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) :
The project site is very well connected by road through National Highway no. 8,
railways.
(vi) Drinking Water management ( Source & Supply of water ) :
Source of water is from GIDC water supply services.
(vii) Sewerage System :
GIDC has provided sewerage system to dispose the sewage effluent.
(viii) Industrial Waste Management :
Average 250 M3/day of Industrial liquid effluent generation during the
manufacturing of proposed products will be treated in proposed primary &
secondary effluent treatment plant and sent to CETP Sarigam through under
ground effluent drainage line of GIDC Sarigam.
Generated domestic liquid waste is being disposed off through soak pit system
to drainage.
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(ix) Solid Waste Management :
No Type of waste Category Qty. MT/ Year
Treatment Disposal
1 ETP waste 34.3 50.0 Dried, packed in bags
Dispose off into TSDF,
Vapi
2 Used Oil 5.1 0.005 Packed in carboys
Sell to Registered
re-processers
3 Discarded containers 33.3 1.0 De-contaminated,
stored
Sell to authorized
recycler
(x) Power Requirement & Supply / Source :
Power requirement for proposed project will be taken from DGVCL.
7. Rehabilitation and Resettlement (R&R) Plan:
(i) Policy to be adopted (Central/ State) in respect of the project affected persons
including home oustees, land oustees and landless laborers (a brief outline to be
given):
There will be no rehabilitation and resettlement undertaken as labours and workers
from local & nearby areas for the proposed construction activity which will be minor as
the proposed activity is to be undertaken at the existing plot/shed.
8. Project Schedule & Cost Estimates :
(i) Likely date of start of construction and likely date of completion ( Time schedule for
the project to be given ) :
After obtaining Environmental clearance and Consent to Establish from GPCB, the
company shall start the proposed construction and commissioning of the project.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project:
Estimated project cost along with the analysis in terms of economic viability of the
project is given as below;
Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the
major heads considered in the Capital Cost Projection for the proposed project.
Environment Protection has also been considered in planning the Cost Projection, which
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will include Green belt development, safety systems, etc.
CAPITAL COST PROJECTION
Sr. No. Particulars Cost in Rs.(Lacs) for proposed project
1.0 Land 4306 Sq. meters 350
2.0 Building 125
3.0 Plant & Machinery 150
4.0 Utility 25
5.0 Environmental Management System
50
5.0 Total Project Cost 700
6.0 Utilities
6.1 Steam Boiler, TPH 2.5
6.2 Hot air dryer Three Nos. (Direct firing)
6.3 D.G. Set (Standby), KVA 200
7.0 Power from DGVCL, KVA 200
8.0 Fuel
8.1 Natural gas for steam boiler & hot air dryer, SCM/day
2500
8.2 HSD, kgs/hr 40
9.0 Water from GIDC Sarigam 259.8
10.0 Waste Water (Industrial) 250.2
PROJECT VIABILITY
Sr. No. PARTICULARS AMOUNT INR Lacs/Anum
1 Proposed Sale 5000
2 Raw Material Cost 4000
3 Power & Fuel 300
4 Labor Cost 120
5 Environmental Management System 85
6 Maintenance Cost 50
7 Selling, packing & Office Expenses 250
8 Proposed Profit 195
The company will provide budgetary provision for the recurring expenses for
environmental issues while planning the allocation of funds during the annual budgetary
planning.
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Recurring Cost per annum
Sr. No. Component Proposed (Rs. In
Lacs/annum)
1. Environment & Safety Management System 4.0
2. Greenbelt Maintenance 1.0
3. Solid waste Disposal 0.5
Total 5.5
9.
Analysis of Proposal ( Final Recommendations):
(i) Financial and social benefits with special emphasis on the befit to the local people
including tribal population, if any, in the area:
Proposed expansion activity will provide benefits to the local people in terms of financial
and social welfare.
Local people will get direct financial benefit by way of employment.
Local people will get some contracts of supply and services to get indirect
income.
Company will contribute in improving education and health facilities in nearby
area.
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ANNEXURES
ANNEXURES
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ANNEXURE-1 The map showing general location, specific location and project boundary and project site layout of M/S. Hercules Pigments Pvt. Limited , located at Plot No. 1704, GIDC,Sarigam-396155, Dist- Valsad (Gujarat). The location of the project site can be viewed in Figure 1.1
Fig. 1.1: Location map showing the Project site and inter-state boundary with 10 kms radius
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ANNEXURE-2
Site Layout Plan & Key Plan
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GOOGLE MAP SHOWING PROPOSED PLOT.
Proposed plant
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ANNEXURE-3
Detailed project description with process details - MANUFACTURING PROCESS The company will use the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance for the product. Manufacturing process:
Azo Pigments (Organic Yellow/Orange/Red): (a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c. Solution is maintained at this temp.
(b) Coupler Dissolution : Water , Caustic Lye & Coupler is taken in stirred vessel. This mixture is heated to required temp. to make uniform solution. And cooled back to room temp.
(c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution. Take out the wet cake.
Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material Balance is enclosed.
CHEMICAL REACTION
( 1 ) Organic Yellow Pigment
HCl
NaNO2
NH2 NH2
Cl Cl
Cl N=N N=N Cl
Cl Cl
2CH3COCH2CONHC6H5 + 2 NaOH
+ 2 NaCl + 4 H2O
Cl N=N N=N Cl
Cl Cl
CH3COCH2CONHC6H4 - N=N
Cl Cl
N=N-C6H4NHCOCH2COCH3 + 2 NaCl + 2 H2O
3 3’ Dichlorobenzidine
Mol.wt. 253Diazo
AcetoAcetanilide
Mol. Wt. 177
Yellow pigment
Mol. Wt. 618
+
Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG
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ORGANIC YELLOW PIGMENT
DIAZOTIZATION
12064 Kgs + 3990 kgs
Hours: 1 ½+11/2=3hr
Water: 4000 Kgs
Base (Amine) : 405 kgs
Ice: 6000 kgs
HCl: 960 kgs
Na Nitrite: 690 kgs
Sulphamic acid: 9 kgs
DISSOLUTION
3990 Kgs
Hours: ½ hr
Water: 3000 lits
Coupler : 640 kgs
Caustic: 350 kgs
COUPLING &
TREATMENT
26339 kgs, Time: 6 Hrs
WASHING ,
23400 kgs , Time: 6HrsWater: 20000 kgs
Filtrate 19900 kgs to ETP
TRAY DRYING ( 24 Hrs)
3500 kgs
Water Vapors: 2498 kgs
PULVERIZER & PACKING
(Time: 6 Hrs)
FILTERATION
26339 kgs, Time: 3 Hrs
Filtrate as effluent: 22939 kgs to ETP
Total: 12064 kgsTotal: 3990 kgs
Diazotization + Dissolution 16054 kgs
Total: 26339 kgs
Crude Pigment Slurry: 26339 kgs
Total : 26339 kgs
Crude Pigment Slurry: 26339 kgs
Total: 26339 kgs Wet cake: 3400 kgs
Total: 26339kgs
Total: 23400 kgs
Wet cake: 3500 kgs
Total: 23400 kgs
Wet cake: 3500 kgs Dry Powder: 1002 kgs
Dry Powder: 1002 kgs
ORGANIC YELLOW PIGMENT: 1000 kgs
Live steam: 4000 kgs
Acetic Acid & Others: 285 kgs
Wet cake: 3400 kgs
Ice: 6000 kgs
loss: 2 kgs
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[2] Organic Orange Pigment
NH2 NH2
Cl Cl
HCl
NaNO2
Cl N=N
Cl Cl
N=NCl
N
N
CCH2
+ 2 NaCl + 2 H2O
Cl N=N
Cl Cl
N=NCl + 2C
+ 2 NaOH
C=O
N
CH-N=NCH3CH
Cl Cl
N=N-
N N
N
CH-CH3CH
O=C
+ 2 NaCl + 2 H2O
3 3’dichlorobenzidine
Mol wt. 253
CH3
O =
PMP
Mol wt. 173
Orange 13 pigment
Mol .wt. 610Base like: DCB, Coupler like PMP, MPMP
ORGANIC ORANGE PIGMENT
DIAZOTIZATION
9332 Kgs + 5800 kgs
Hours: 1 ½+11/2=3hr
Water: 2600 Kgs
Base (Amine) : 405 kgs
Ice: 5000 kgs
HCl: 1080 kgs
Na Nitrite: 240 kgs
Sulphamic acid: 7 kgs
DISSOLUTION
5800 Kgs
Hours: ½ hr
Water: 4900 lits
Coupler : 580 kgs
Caustic: 320 kgs
COUPLING &
TREATMENT
23152 kgs, Time: 6 Hrs
WASHING ,
23400 kgs , Time: 6HrsWater: 20000 kgs
Filtrate 19900 kgs to ETP
TRAY DRYING ( 24 Hrs)
3500 kgs
Water Vapors: 2498 kgs
PULVERIZER & PACKING
(Time: 6 Hrs)
FILTERATION
23152 kgs, Time: 3 Hrs
Filtrate as effluent: 19752 kgs to ETP
Total: 9332 kgsTotal: 5800 kgs
Diazotization + Dissolution 15132 kgs
Total: 23152 kgs
Crude Pigment Slurry: 23152 kgs
Total : 23152 kgs
Crude Pigment Slurry: 23152 kgs
Total: 23152 kgs
Wet cake: 3400 kgs
Total: 23152 kgs
Total: 23400 kgs
Wet cake: 3500 kgs
Total: 23400 kgs
Wet cake: 3500 kgs Dry Powder: 1002 kgs
Dry Powder: 1002 kgs
ORGANIC YELLOW PIGMENT: 1000 kgs
Live steam: 4000 kgs
Emulsifier & Others: 20 kgs
Wet cake: 3400 kgs
Ice: 4000 kgs
loss: 2 kgs
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NH2
[3] Organic Red Pigment
HCl
NaNO2+
2H2O + NaCL
2:5 Dichloro Aniline
Mol Wt.162
N=NCl
Cl
N=NCl
NH
C17H12NO2
( Naphthol AS)
Mol wt.263
+
Cl
Cl
N=N
C NH
O
Organic Red Pigment
Mol wt. 436
Cl
Cl
Diazo
O
Cl
Cl
OH
OH
Base like: TCA, DCA, Scarlet G base, Coupler like Naphols
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(3) ORGANIC RED PIGMENT
DIAZOTIZATION9157 Kgs + 11240 kgs
Hours: 6 hrs
Water: 1500 lits
Base: 432 kgs
Ice: 4000 kgs
H2SO4: 3000kgs
Na Nitrite: 200 kgs
Sulphamic acid: 25 kgs
DISSOLUTION
11240 KgsHours: 1 hr
Water: 4000 lits
Coupler: 590 kgs
Caustic: 650 kgs
Steam: 1000 kgs
Ice: 5000 kgs
COUPLING 26397 kgs, Time: 10 Hrs
WASHING ,
25000 kgs
Time: 6HrsWater: 20000 liters Filtrate as effluent: 20000 kgs to ETP
TRAY DRYING ( 24 Hrs)
5000 kgs
Water Vapours: 3970 kgs
PULVERIZER & PACKING
(Time: 6 Hrs)
FILTERATION
26397 kgs, Time: 3 Hrs
Filtrate as effluent: 21397 kgs to ETP
Total: 9157 kgsTotal: 11240 kgs
Diazotization + Dissolution:20397 kgs
Total: 26397 kgs
Coupler: 26397 kgs
Total: 26397 kgs
Coupler: 26397 kgs
Total: 26397 kgs Wet cake: 5000 kgs
Total: 26397kgs Wet cake: 5000 kgs
Total: 25000 kgs
Wet cake: 5000 kgs
Total: 25000 kgs
Wet cake: 5000 kgs
Total: 5000 kgs Dry Powder: 1030 kgs
Total: 5000 kgs
Dry Powder: 1030 kgs PRODUCT
(ORGANIC RED PIGMENT: 1030 kgs )
Ice :2000 kgs
HCL: 1000 kgs
Live steam: 3000 kgs
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ANNEXURE-4
Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal.
Quantity of Waste Water (liquid waste) generation and its management :
Sr. No.
Particulars Water Consumption
Effluent generation
1. Domestic 5.0 4.0
2. Processing 40.4 39.8
3. Boiler ( Live steam)
Boiler blow down &
DM rejection
27.0 24.0
4. Product Washing 115.4 115.4
5. Cooling as ice 69.0 69.0
6. Floor/container
washing
2.0 2.0
7. Gardening 1.0 0
8. Grand Total 259.8 254.2
9. Total Industrial 253.8 250.2
Note:
Average 260 M3/day fresh water will be used for proposed plant and source from GIDC authority.
Domestic effluent shall be passed through adequate capacity of septic tank/soak pit.
Process effluent shall be sent ETP.
Boiler blow down, D M rejection & live steam comes out as an effluent.
Ice water comes out as effluent.
Floor/container & vessel washing comes out as effluent.
Entire industrial effluent will be treated in primary & secondary effluent treatment plant & sent to CETP through underground drainage line for further treatment & ultimate disposal into Arabian Sea.
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DETAILS OF PROPOSED EFFLUENT TREATMENT PLANT
Design Criteria :
Product : Organic Azo Pigment
Source of Effluent : process, washing, Utilities & floor/container.
Design Flow of Effluent : 260 KL/day Max.
Design Parameters : As under
Effluent Characteristics:
No Effluent Parameter Untreated combined normal
effluent
Expected Results GPCB
norms
1 pH 7.0- 8.0 7.0-8.0 6.5 to 8.5
2 Color pt. Co 600-800 40-50 <100
3 Suspended solids ,
Mg/L
150-200 60-70 <100
4 Total dissolved solids,
Mg/L
4000-4500 4000-4500 <2100
5 Oil and grease, Mg/L 2-3 1-2 <10
6 NH3-N, Mg/L 10-12 5-10 <50
7 BOD , Mg/L 800-900 80-90 <100
8 COD , Mg/L 3000-3500 200-210 <250
9 Heavy metal, Mg/L Nil Nil <0.1
10 Phenolic Compounds,
Mg/L
Nil Nil <1
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Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to
install.
DETAILS OF EFFLUENT TREATMENT PLANT
Average hydraulic load, M3/Day : 250 M3/Day
Design hydraulic load, M3/Day : 260 M3/Day
Average Inlet BOD, mg/l : 800-900
Average Inlet COD, mg/l :3000-3500
No Name of the
unit
Size in
meters
Capacity
in m3
MOC No Detention time Remarks
Reqd. provided Adequacy
1 Oil/grease trap 0.6 x 0.6 x
0.6
0.2 RCC 1 1 min 1.44 min Adequate
2 Collection with
sparger
7 x 5 x 5 m 175 RCC 1 8 hrs 16 hrs Adequate
3 Reaction tank 2.0 ø x 2.5 7.8 MS 1 10 min 25 min Adequate
4 Floculator 2.0 ø x 2.5 7.8 MS 1 10 min 25 min Adequate
5 Chemical
dosing tanks
- 0.2 HDPE 3 - -
6 Primary Lamella
separator with
tube deck
packing
1.5 x 1.5 x
2.0
4.5 MS 1 15 min 32 min Adequate
7 Secondary
Aeration Tank
with build in
clarifier with
tube deck
10 x 5.0 x
4.0
200 RCC 1 12 hrs 18 hrs Adequate
8 Twin Lobe Air
Blower
6500 mmwg 500
nm3/hr
CI 1 - - Adequate
9 Holding tank 5 x 5 x 5 m 125 RCC 1 6 hrs 12 hrs Adequate
10 Filter Press 24 x 24 PP 1 - - Adequate
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FLOW DIAGRAM OF PROPOSED EFFLUENT TREATMENT PLANT
O/G TRAP
Collection/Equ tank
Reaction . Tank
FLOCCULATOR
LIME SLURRYTANKS
FeSO4/PEtanks
EFFLUENT
Primary LamellaSeparator
Holding Tank
To GIDCDrain to CETP
SECONDARY AERATION TANK WITH BUILT IN SECONDARY CLARIFIER
TWIN LOBE AIR BLOWER
DIFFUSER
FILTER PRESS
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Quantity of Hazardous Waste generation and its management
No Type of waste Category Qty. MT/ Year
Treatment Disposal
1 ETP waste 34.3 50.0 Dried, packed in bags
Dispose off into TSDF,
Vapi
2 Used Oil 5.1 0.005 Packed in carboys
Sell to Registered
re-processers
3 Discarded containers 33.3 1.0 De-contaminated,
stored
Sell to authorized
recycler
Note: The unit will obtain membership of approved TSDF site of M/S VGEL, Vapi, for disposal of
Hazardous waste.
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ANNEXURE-5
The topographical map
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Annexure-6
PLOT ALLOTMENT LETTER ISSUED BY THE GIDC
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Notification for Sarigam Notified industrial estate
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ANNEXURE-7
A schematic representation of the feasibility drawing
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ANNEXURE: 8
DETAILS OF PROPOSED AIR POLLUTION & ITS CONTROL MEASURES
The utility emissions will be from the 2.5 TPH capacity of steam boiler. Natural gas (green fuel) as fuel will
be used in the boiler. Also we will install a D.G. Set of 200 KVA capacity to use in case of power failure and
HSD shall be used as a fuel.
There will be no process gas emission. Details of which are as under;
Sr. No. Particulars Details
1.0 Capacity of Steam boiler 2.5 TPH
1.1 Fuel Used Natural gas
1.2 Fuel Consumption 1700 SCM/Day
1.3 APC provided Chimney
1.4 Height/dia of chimney 11 meters
2.0 Capacity of D G set 200 KVA (Standby)
2.1 Fuel Used HSD
2.2 Fuel Consumption 40 liters/hr
2.3 APC provided Exhaust
2.4 Height/dia of Exhaust 11 meters
3.0 Hot air Dryer Direct firing through burner (3 Nos.)
3.1 Fuel used Natural gas
3.2 Fuel consumption 800 SCM/Day
3.3 APC Not required
Details of Air pollution control measures attached to Pulveriser
Drying of Pigment:
Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers. The process heat is provided by Hot air dryer system based on natural gas.
Pulverization of pigments:
This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This consists
of following parts:
1. Hopper feed box. 2. Screw feeder. 3. Closed grinder with box 4. cyclone separator 5. Bag filter. 6. Rotary valve for outlet of product.
The pulverized material is collected in bags, weighed and dispatched. The material collected from bag filter
is also mixed with the final product.
Thus this is a completely closed system and does not involve any process gas emission.