DYES AND INTERMEDIATES MANUFACTURING UNITenvironmentclearance.nic.in/writereaddata/Online/... ·...
Transcript of DYES AND INTERMEDIATES MANUFACTURING UNITenvironmentclearance.nic.in/writereaddata/Online/... ·...
TECHNO ECONOMIC FEASIBILITY REPORT
FOR
DYES AND INTERMEDIATES MANUFACTURING UNIT
OF
M/s. PARISHI CHEMICALS SHADE / PLOT NO. – C1B/6916-17-18,
GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT-393002
Email: [email protected]
PREPARED BY:
M/s. PARISHI CHEMICALS SHADE / PLOT NO. – C1B/6916-17-18,
GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT-393002
Email: [email protected]
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
EXECUTIVE SUMMARY OF THE REPORT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around 2112 sq.m land is already acquired by M/s. Parishi Chemicals. PROJECT COST Cost of the proposed project would be Rs. 700.0 Lacs. Total capital cost for environmental pollution control measures would be Rs. 25 Lacs and recurring cost per annum would be Rs. 10.50 Lacs. LIST OF EXISTING & PROPOSED PRODUCTS WITH THEIR PRODUCTION CAPACITY
SN PRODUCT (Existing)
Existing MT/Month
Proposed MT/Month
Total MT/Month
End Use
1 Organic Pigments Dyes 1.50 - 1.50 Textile, Paints,
coatings, plastic
industries 2
Standardization of manufactured dyes through
physical process of Mixing/Blending
18.76 -
18.76
3 Drying of Wet cake of dyes 40.00 - 40.00
4 Liquid dyes from wet cake of dyes 80.00 - 80.00
SN PRODUCT (Proposed – EC)
Proposed MT/Month
OR
Proposed MT/Month
End Use
A.
CrudeDyes 60.00 - Textile, Paints,
coatings, plastic
industries
Standardized and formulations crude dyes
- 300.00
B. Dispersing Agent
240.00 - Captive and/or Sell
C. Intermediates 40.00 40.00
D. R & D Products 0.03 0.03 Non-Commercial
Total 340.03 340.03
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
LIST OF PRODUCTS BELOW TABLE:
S.N List of Products CAS No. End Use
QTY (MT/Month)
A. Crude Dyes
1 Acid Yellow 184 70267-73-1 Textile, Plastic and Inks
60 crude dyes and 300
Formulation of crude dyes
2 Acid Yellow 250 93859-32-6 Textile, Plastic and Inks
3 Disperse Black 2RC Mixtures Textile, Plastic and Inks
4 Basic Yellow 40 29556-33-0 Textile, Plastic and Inks
5 Basic Yellow 40:1 35869-60-4 Textile, Plastic and Inks
6 Disperse Blue 148 52239-04-0 Textile, Plastic and Inks
7 Disperse Brilliant Blue CB N/A Textile, Plastic and Inks
8 Disperse Blue 165 41642-51-7 Textile, Plastic and Inks
9 Disperse Blue 183 2309-94-6 Textile, Plastic and Inks
10 Disperse Blue 183:1 2537-62-4 Textile, Plastic and Inks
11 Disperse Blue 281 22578-86-5 Textile, Plastic and Inks
12 Disperse Blue 284 71872-43-0 Textile, Plastic and Inks
13 Disperse Blue 291 56548-64-2 Textile, Plastic and Inks
14 Disperse Blue 291:1 79295-99-1 Textile, Plastic and Inks
15 Disperse Black XF-N Mixtures Textile, Plastic and Inks
16 Disperse Blue 354 74239-96-6 Textile, Plastic and Inks
17 Disperse Blue 364 108948-37-4 Textile, Plastic and Inks
18 Disperse Blue 365 108948-36-3 Textile, Plastic and Inks
19 Disperse Blue 366 84870-65-5 Textile, Plastic and Inks
20 Disperse Black HP-G Mixtures Textile, Plastic and Inks
21 Disperse Blue 373 51868-46-3 Textile, Plastic and Inks
22 Disperse Blue 373:1 85508-41-4 Textile, Plastic and Inks
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
23 Disperse Blue 56 12217-79-7 Textile, Plastic and Inks
24 Disperse Blue 56:1 27312-17-0 Textile, Plastic and Inks
25 Disperse Blue 60 12217-80-0 Textile, Plastic and Inks
26 Disperse Black HP-G Mixtures Textile, Plastic and Inks
27 Disperse Blue 79 3618-72-2 Textile, Plastic and Inks
28 Disperse Blue 79:1 3618-73-3 Textile, Plastic and Inks
29 Disperse Red 126877-06-3 Textile, Plastic and Inks
30 Disperse Black E-MRD Mixtures Textile, Plastic and Inks
31 Disperse Brown 19 59709-38-5 Textile, Plastic and Inks
32 Disperse Red J 70546-12-2 Textile, Plastic and Inks
33 Disperse Green 9 58979-46-7 Textile, Plastic and Inks
34 Disperse Orange 288 96662-24-7 Textile, Plastic and Inks
35 Disperse Orange 37 13301-61-6 Textile, Plastic and Inks
36 Disperse Orange 44 4058-30-1 Textile, Plastic and Inks
37 Disperse Orange 61 55281-26-0 Textile, Plastic and Inks
38 Disperse Reactive Yellow N/A Textile, Plastic and Inks
39 Disperse Red 177 68133-69-7 Textile, Plastic and Inks
40 Disperse Red 278 68248-10-2 Textile, Plastic and Inks
41 Disperse Red 311 70729-65-6 Textile, Plastic and Inks
42 Disperse Red 324 71617-28-2 Textile, Plastic and Inks
43 Disperse Pink BRF N/A Textile, Plastic and Inks
44 Disperse Red 343 68385-96-6 Textile, Plastic and Inks
45 Disperse Red 343:1 72968-82-2 Textile, Plastic and Inks
46 Disperse Red 356 79694-17-0 Textile, Plastic and Inks
47 Disperse Red 4 2379-90-0 Textile, Plastic and Inks
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
48 Disperse Red 60 17418-58-5 Textile, Plastic and Inks
49 Disperse Red 91 34231-26-0 Textile, Plastic and Inks
50 Disperse Red 92 72363-26-9 Textile, Plastic and Inks
51 Disperse Red Violet SR Disperse Violet 3R N/A Textile, Plastic
and Inks
52 Disperse Violet 31 6408-72-6 Textile, Plastic and Inks
53 Disperse Violet 57 1594-08-7 Textile, Plastic and Inks
54 Disperse Violet 77 52549-57-2 Textile, Plastic and Inks
55 Disperse Violet 93 52697-38-8 Textile, Plastic and Inks
56 Disperse Violet SR N/A Textile, Plastic and Inks
57 Disperse Violet 99 52583-54-7 Textile, Plastic and Inks
58 Disperse Yellow 114 59312-61-7 Textile, Plastic and Inks
59 Disperse Yellow 119 57308-41-5 Textile, Plastic and Inks
60 Disperse Yellow 126 61968-70-5 Textile, Plastic and Inks
61 Disperse Violet RL N/A Textile, Plastic and Inks
62 Disperse Yellow 184:1 34564-13-1 Textile, Plastic and Inks
63 Disperse Yellow 211 70528-90-4 Textile, Plastic and Inks
64 Disperse Yellow 231 143067-35-0 Textile, Plastic and Inks
65 Disperse Yellow 232 35773-43-4 Textile, Plastic and Inks
66 Solvent Yellow 160:1 35773-43-4 Textile, Plastic and Inks
67 Disperse Yellow 241 83249-52-9 Textile, Plastic and Inks
68 Disperse Dark Black GR Mixtures Textile, Plastic and Inks
69 Disperse Yellow 82 27425-55-4 Textile, Plastic and Inks
70 Solvent Yellow 145 27425-55-4 Textile, Plastic and Inks
71 Solvent Blue 104 116-75-6 Textile, Plastic and Inks
72 Solvent Blue 122 67905-17-3 Textile, Plastic and Inks
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
73 Disperse Black RLS Mixtures Textile, Plastic and Inks
74 Solvent Blue 128 18038-99-8 Textile, Plastic and Inks
75 Solvent Blue 35 17354-14-2 Textile, Plastic and Inks
76 Solvent Blue 97 32724 - 62 - 2 Textile, Plastic and Inks
77 Disperse Black R Plus Mixtures Textile, Plastic and Inks
78 Solvent Green 28 28198-05-2 Textile, Plastic and Inks
79 Solvent Green 3 128-80-3 Textile, Plastic and Inks
80 Solvent Orange 60 6925-69-5 Textile, Plastic and Inks
81 Disperse Orange 24 6925-69-5 Textile, Plastic and Inks
82 Solvent Orange 63 16294-75-0 Textile, Plastic and Inks
83 Disperse Red 361 16294-75-0 Textile, Plastic and Inks
84 Disperse Black XF Mixtures Textile, Plastic and Inks
85 Solvent Red 135 20749-68-2 Textile, Plastic and Inks
86 Solvent Red 179 6829-22-7 Textile, Plastic and Inks
87 Solvent Red 195 72968-71-9 Textile, Plastic and Inks
88 Solvent Red 196 52372-36-8 Textile, Plastic and Inks
89 Disperse Red 374 52372-36-8 Textile, Plastic and Inks
90 Disperse Pink RL N/A Textile, Plastic and Inks
91 Disperse Red 277 52372-39-1 Textile, Plastic and Inks
92 Solvent Red 197 52372-39-1 Textile, Plastic and Inks
93 Solvent Red 207 15958-68-6 Textile, Plastic and Inks
94 Solvent Red 52 81-39-0 Textile, Plastic and Inks
95 Solvent Violet 13 81-48-1 Textile, Plastic and Inks
96 Solvent Violet 38 63512-14-1 Textile, Plastic and Inks
97 Disperse Black MD Mixtures Textile, Plastic and Inks
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
98 Solvent Yellow 114 7576-65-0 Textile, Plastic and Inks
99 Disperse Yellow 54 7576-65-0 Textile, Plastic and Inks
100 Solvent Yellow 133 51202-86-9 Textile, Plastic and Inks
101 Solvent Yellow 157 27908-75-4 Textile, Plastic and Inks
102 Disperse Black C-RR Mixtures Textile, Plastic and Inks
103 Solvent Yellow 163 13676-91-1 Textile, Plastic and Inks
104 Solvent Yellow 172 68427-35-0 Textile, Plastic and Inks
105 Solvent Yellow 176 10319-14-9 Textile, Plastic and Inks
106 Disperse Yellow 64 10319-14-9 Textile, Plastic and Inks
107 Solvent Yellow 33 8003-22-3 Textile, Plastic and Inks
108 Solvent Yellow 43 19125-99-6 Textile, Plastic and Inks
109 Solvent Yellow 93 4702-90-3 Textile, Plastic and Inks
110 Disperse Black SFGL Mixtures Textile, Plastic and Inks
111 Solvent Yellow 98 27870-92-4 Textile, Plastic and Inks
B. Dispersing Agent
1 Phenol formaldehyde based Dispersing Agent 71342-95-5 Formulation of
Dyes 240
2 Phenol formaldehyde based Dispersing Agent 36290-04-7 Formulation of
Dyes
C. Intermediates
1 Ethyl Benzylacetate 94-02-0 Dyes Intermediate
40
2 3-Oxo-2,3-dihydrobenzo[b]thiophene-1,1-dioxide
1127-35-1 Dyes Intermediate
3 3-(Dicyanomethylidene)-2,3-dihydrobenzothiophene-1,1-dioxide
74228-25-4 Dyes Intermediate
4 N,N-Dihexyl-m-Toluidine 74228-24-3 Dyes Intermediate
5 3-Pyridinecarbonitrile, 1,6-dihydro-2-hydroxy-1,4-dimethyl-6-oxo-
27074-03-9 Dyes Intermediate
6 1-Ethyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile 28141-13-1 Dyes
Intermediate
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
7 1-Butyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile 39108-47-9 Dyes
Intermediate
8 1-(3-Methoxypropyl)-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile
29333-76-4 Dyes Intermediate
9 4-(diethylamino)salicylaldehyde 17754-90-4 Dyes Intermediate
10 2,6-Dibromo-4-Methyl Aniline 6968-24-7 Dyes Intermediate
11 Benzothiazole Derivatives 6285-57-0 Dyes Intermediate
12 2,6-Dibromo-4-nitro Aniline 827-94-1 Dyes Intermediate
13 2,6-Dichloro-4-Nitro Aniline 99-30-9 Dyes Intermediate
14 6-Bromo-2,4-Di Nitro Aniline 1817-73-8 Dyes Intermediate
15 6-Chloro-2,4-Di Nitro Aniline 3531-19-9 Dyes Intermediate
16 N-Cyanoethyl Aniline 1075-76-9 Dyes Intermediate
17 N-Cyanoethyl-m-Toluidine 27618-25-3 Dyes Intermediate
18 2-Cyano-6-Bromo-4-Nitro Aniline 17601-94-4 Dyes
Intermediate
19 2-Cyano-6-Chloro-4-Nitro Aniline 20352-84-5 Dyes
Intermediate
20 2-Chloro-6-Bromo-4-Nitro Aniline 99-29-6 Dyes
Intermediate
21 5-Hydroxy-2-oxo-3-phenyl-2,3-dihydro benzofuran NotKnown
Dyes Intermediate
D. R & D 1.0
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
REQUIREMENTS FOR THE PROJECT Land: Total 2112 sq. meter (Existing + Proposed) land already acquired in Ankleshwar Industrial Estate. Water: The total water requirement for Disperse Dyes, Acid dyes, solvent dyes and intermediates manufacturing plant is 105.7 KLD after proposed expansion, mainly in process, make-up water in Boiler & cooling tower, washing of Disperse Dyes plant and domestic& gardening requirement. Total water requirement of Disperse Dyes plant will be met from GIDC water supply. In Disperse Dyes plant, 47.2 KLD water required in process, 10 KLD water required for washing, 4.2 KLD of water is required per day in Boiler as make up water due to evaporation and drift losses and onetime cooling tower water required is 2.5 KL. The 5.0 KLD water required for Domestic purpose and 1.0 KLD required for Gardening purpose. Domestic waste water i.e. 4.5 KL/Day will be generated which will be treated through septic tank and disposed through soak pit/well. However due to reuse/recycle of 55.6 KLD, Total Fresh Water Requirement is 50.1 KLD, which will be meet from GIDC. Electrical Energy: Total power requirement will be 250 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. set of 125 KVA X 2 Nos = 250 KVA will be provided to fulfill the power requirement. Fuel: For the proposed project Diesel/LDO for Steam Boiler, HAG and Thermic Fluid Heater will be used at the rate 7.8 TPD or 3600 SCM Natural Gas and Diesel i.e. 160 Lit/Hr. will be required for the D.G. set which will be purchased from the nearest petrol pump in drum and transported by road only. Manpower: The proposed plant will have employment potential providing employment to approximately 40 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES FLUE & PROCESS GAS EMISSION AND CONTROL MEASURES ARE GIVEN IN FOLLOWING TABLE: EXISTING FLUE GAS STACK DETAILS: STACK Stack attach to Ht. Dia. Fuel Pollutant APCM
1 Steam Boiler ( 0.4 TPH ) 12 1
LDO - 40 lit/hr or NG-
30 m3/hr PM, Sox, Nox Adequate Stack Height
2 HAG
(25,000 Kcal/Hr)
9 0.5 LDO - 40
lit/hr or NG-30 m3/hr
PM, Sox, Nox Adequate Stack Height
EXISTING PROCESS GAS STACK DETAILS: STACK Stack attach to Ht. Dia. Fuel Pollutant APCM
1 Pulverizer 9 0.5 Nil PM Bag Filter
2 Spray Dryer (120 kg/hr) 9 0.5 Nil PM Cyclone Separator
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
PROPOSED FLUE GAS STACK DETAILS: STACK Stack attach
to Ht. Dia. Fuel Pollutant APCM
1 Steam Boiler ( 0.8 TPH )
12 1
LDO - 80 lit/hr or NG-60 m3/hr PM, Sox, Nox Adequate Stack
Height
2 Steam Boiler ( 0.8 TPH )
LDO - 80 lit/hr or NG-60 m3/hr PM, Sox, Nox Adequate Stack
Height
3 HAG
(50,000 Kcal/Hr)
9 0.5 LDO – 1.0 MT/Day PM, Sox, Nox Adequate Stack Height
4
Thermic Fluid Heater
(8,00,000 Kcal/hr)
12 1 LDO - 2.0 MT/Day PM, Sox, Nox Adequate Stack Height
5
D. G. set of 125 KVA X 2
nos. (In Emergency
only)
9 0.5 Diesel 160 Lit./hr approx. PM, Sox, Nox Acoustic Enclosure &
Adequate stack height
PROPOSED PROCESS GAS STACK DETAILS:
STACK Stack attach to Ht. Dia. Fuel Pollutant APCM
1 Spray Dryer (1000 kg/hr) 9 0.5 Nil PM Cyclone Separator + water scrubber
2 Chlorination of Intermediates 9 0.5 Nil CL2 Alkali Scrubber 3 Bromination of Intermediates 9 0.5 Nil Br2 Alkali Scrubber
WASTE WATER GENERATION AND ITS TREATMENT: Domestic wastewater of 4.5 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporators. Residue (1.0 TPD salt) from ATFD will be sent for TSDF. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project:
1. Encasement of noise generating equipment. 2. A thick greenbelt will be developed all around the plant boundary to act as noise attenuator. 3. In addition personnel working near high noise level generating sources will be provided
with ear muffs. 4. Proper and suitable acoustic barrier will also be provided around areas generating high
noise. 5. Effective preventive maintenance and vibration measurement of all rotating equipment will
help in the improvement of plant life and also noise reduction.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes generation and its management are given in the following table.
Sr. No.
Type/Name of Hazardous
waste
Specific Source of
generation
Category and
Schedule as per HW
Rules.
Quantity Management of HW (MT/Annum)
Existing Proposed Total
1 Empty barrels/containe
rs/liners contaminated
with hazardous chemicals/wast
e
Raw Material & Process
33.1 10 (1000 Nos)
50 (5000 Nos)
60 (6000 Nos)
Collected and stored at specified area and sold to approved/ registered vendors.
2 Used or Spent Oil
Maintenance 5.1 0.07 0.8 0.87 Collected in drums and stored at specified area, Reuse in plant for lubrication and Balance will be Selling to authorized recyclers
3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage, Transportation, Disposal at BEIL, TSDF.
4 Distillation residue
(Semi Solid having CV 1500-2000 Kcal/Kg)
In-House Solvent
Recovery Process
or from outside
solvent recovery unit
36.1 Nil 1170 1170 Collection, Storage Transportation, Disposal at GPCB approved CHWIF or co/pre- processing
5 Spent Solvent (Methanol)
Solvent & Disperse
Dyes (Solvent Red 179 , solvent yellow 114,
disperse blue 165, disperse
blue 354, solvent
orange 60 etc)
26.3 Nil 4068 4068 In-House Distillation and recovered solvent will be reuse or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
6 Spent Solvent (DMF)
Solvent & Disperse
Dyes (Solvent
Orange 63, disperse blue 165, disperse
blue 354, disperse red
J, Fluorescent
Red CB, etc)
26.3 Nil 6480 6480 In-House Distillation and recovered solvent will be reuse or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)
7 Spent Solvent ( Xylene)
Solvent Dyes (Solvent red 179 , solvent
red 135, solvent red 179, solvent orange 60,
solvent yellow 157,
solvent yellow 163,
etc)
26.3 Nil 1728 1728 In-House Distillation or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)
8 Spent Solvent (ODCB)
Solvent Dyes (Solvent
Yellow 114, solvent
yellow 33, solvent
yellow 176, etc)
26.3 Nil 2772 2772 In-House Distillation and recovered solvent will be reuse or Collection, Storage & sent for Recovery as per Rule 9 of hazardous and other wastes (Management and transboundary movement) rules,2016 (M/s.Anju Life science or Any others)
9 NaBr Disperse Blue 354
26.3 Nil 4900 4900 Collection, Storage, Transportation & disposal to Actual User under Rule 9
10 Sulphuric Acid 50%
Disperse Blue 354
26.3 Nil 1980 1980 Collection, Storage, Transportation & disposal to Actual User under Rule 9
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
11 Benzoic Acid 40 %
Disperse Blue 354
26.3 Nil 28 28 Collection, Storage, Transportation & disposal to Actual User under Rule 9
12 Salt From ATFD 34.3 Nil 365 365 Collection, Storage, Transportation, Disposal at BEIL, TSDF
13 Contaminated cotton rags or other cleaning materials
Process &
Maintenance
33.2 Nil 0.5 0.5 Collection, Storage, Transportation, Disposal By Incineration at CHWIF of BEIL
14 NaCl Scrubber of CL2
26.3 Nil 18 18 Collection, Storage, Transportation & disposal to Actual User under Rule 9
15 Gypsum Neutralization stage
in Disperse Violet 99
D2 Nil 332 332 Collection, Storage Transportation, Disposal by selling to actual user authorized by GPCB or Cement Industry
GREEN BELT DEVELOPMENT About 852.48 sq.m area i.e. 40 % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 0.90 Lacs approx.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
INDEX
CHAPTER CONTENT PAGE
1. INTRODUCTION OF THE PROJECT 1
2. PROJECT DESCRIPTION 3
3. SITE ANALYSIS 49
4. PLANNING BRIEF 52
5. PROPOSED INFRASTRUCTURE 53
6. REHABILITATION AND RESETTLEMENT (R & R) PLAN
57
7. PROJECT SCHEDULE & COST ESTIMATES 58
8. ANALYSIS OF PROPOSAL 60
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat
LIST OF TABLES
TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 1 2 DETAILS OF EMPLOYMENT REQUIREMENT 2 3 DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) 43 4 DETAILS OF WASTEWATER GENERATION 45 5 DETAILS OF SOLID WASTE 46 6 DETAILS OF EXISTING LAND USE 49 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 50 8 TEMPERATURE DATA 50 9 RAINFALL DATA 51 10 DETAILS OF SOLID WASTE MANAGEMENT 54 11 PROJECT IMPLEMENTATION SCHEDULE 58 12 TOTAL PROJECT COST AND IT’S BREAK UP 59
LIST OF FIGURES
FIGURE PARTICULAR PAGE
1 MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC.
3
2 MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC.
4
3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 58
LIST OF ANNEXURES
ANNEXURE PARTICULAR PAGE
1 LAND AGREEMENT DOCUMENTS 63 2 LAYOUT OF THE PLANT 67
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 1
CHAPTER – 1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed
(a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I.
Or (b) Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day
Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I.
TABLE 1: DETAILS OF THE DIRECTORS
S. NO.
NAME OF THE DIRECTOR AGE QUALIFICATIO
N EXPERIENCE
1. Mr. Garshill J. Lekhadia 49 Years B. Pharm 25 years of Exp. In Dyes and intermediates
The company has been promoted by Mr. Garshill Jyotindra Lekhadia having a widespread business interests in Gujarat. The promoter has been in the business of Dyes & Intermediates for over 26 years and he has excellent knowledge of South Gujarat Industry Environment. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth.
Existing Indian production, are not enough to cater the needs of Indian Consumer, hence
Chinese products are also making dent in the Indian markets, though they are costly due to logistic cost and are not able to provide wide range of choices to the Indian Customers.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 2
Present capacity is negligible in term of overall demand in the world, so a huge market, and considering our high quality products as well customization of product, we don’t foresee any hurdle in marketing of product.
Our proposed plant will be located near user Industry, hence it provides logistic support as well as customize quantity in small quantities can also be supplied to the customer, which give company a clear edge compared to Chinese Imports, which cannot be supplied in small quantities coupled with time consumed on import.
We have a very strong and experienced after sales service which are also known as Technical Service Department (TSD) which guides customer to obtain better results from our products.
Market for disperse dyes is growing @ 10% per annum, and there are only two major producers in the Industry.
Our continuous technological research and product development and superior after sales services will ensure increase in market share and eventually better net sales realization.
Strong presence in the value added product Wide range of product to meet customized need. Long standing relationships with leading consumer Industries.
1.4 DEMAND – SUPPLY GAP The Indian dyestuff industry is widely fragmented between the organized and unorganized sector. There are approximately 950 dye manufacturing unit in India, of which 50 units are in the organized sector and 900 are in the un-organized sector. The two western states of Maharashtra and Gujarat account for over 90% of the total dyestuff production in the country. The textile industry is the largest user of dye-stuffs in India, It account for 70-75% of the domestic dye consumption. With the increasing pressure on cotton fiber, synthetics like polyester are expected to over perform the overall chemical Industry. The dyestuff Industry worldwide is witnessing a gradual shift of manufacturing facilities from the developed countries to Asia, particularly china and India due to environmental considerations, availability of trained and inexpensive manpower and the relocation of the end-user industries, mainly textile and leather to the Asia-pacific region. India has emerged as a global supplier of dyestuff and dye intermediates, particularly for requirement of the domestic market and has gradually also made a dent in the global market. Indian dyestuff market is in general dominated by Chinese companies, as there are very few large scale manufacturing companies in India who can cater the need of Indian demand. We are expected to be the major recipient of benefits arising out due to expected growth, and consolidation in the Industry. PRODUCT PROFILE Our products are backed by unique technology and or process, and are not readily available with
the competitor. These products play an important role in the production process of the user and hence user do not
compromise or shift from tested products and user industry TECHNOLOGY Technology is typically developed in-house with the critical equipment being out-sourced. We have in-house independent R & D, equipped with latest state of art technologies and
facilities.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 3
1.5 EMPLOYMENT GENERATION DUE TO THE PROJECT The manpower requirement for the project is estimated at about 40 excluding contract / casual labour. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break – up of the manpower requirement is as under:
TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT
S. NO. DESCRIPTION EXISTING PROPOSED 1 Top Management 2 4 2 Managers 2 4 3 Specialist/ Engineer/Officers 2 4 4 Supervisors 4 10 5 Operators/Attendants 8 18
TOTAL 18 40
Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. M/s. Parishi Chemicals is going to manufacture dyes and dye intermediate product for mainly textile dyeing and printing industry.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 4
CHAPTER – 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth. 2.2 LOCATION WITH COORDINATES A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure – 1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE
HIGHWAYS, RAILWAY LINES, ROADS ETC.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 5
COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per the mentioned below: Latitude: 21°38’37.58” N Longitude: 73°04’51.95” E FIGURE 2: MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC.
2.3 DETAILS OF ALTERNATE SITES The proposed project site is situated at Plot no. 4517, GIDC, Ankleshwar, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labours are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 2.4 SIZE OR MAGNITUDE OF OPERATION M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R &
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 6
D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. DETAILS OF PRODUCTION AND MANUFACTURING PROCESS: 1-INTRODUCTION Disperse dyes manufactured by M/s. Parishi Chemicals is essentially low molecular weight derivatives of azo compounds. They generally melt at above 130°C and are crystalline materials which are ground with dispersing agents to produce particles smaller than two micron. The aqueous paste obtained by grinding is spray dried. Important requirement for spray dried powders are the storage stability and the ease with which the powders can be re-dispersed in water. The actual dye content of commercial products may vary from 20 to 60%. To manufacture crude disperse azo dyestuff primary aromatic amine is diazotized and coupled with tertiary aromatic amines. 2. MANUFACTURING PROCESS
1. Disperse Blue 366 (Step – 1) 1) Diazotization of C6H4Br2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake dried and used in next step.
C6H4Br2N2O2 + H2SO4 + Nitrosyl Sulphuric Acid + C11H17NC19H18N4O2Br2
Disperse Blue 366, step-1
Diazotization
Filtration and Washing
Wet Cake for Drying
Dry Crude C17H18Br2N4O2 (1365 kg)
ICE 7500 kg
13180 kgs
3845 kgs
4880 kgs
3515 kgs
C6H4Br2N2O2 880 kg
Sulphuric Acid 2750 kg
Sodium Nitrite 215 kg
Coupling
Water 500 kg
C11H17N 735 kg
HCL 600 kg
12000 kg Water for ETP Water 3700 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 7
Disperse Blue 366 (Step – 2)
1) Cyanation of above monoazo dyes is carried out in solvent. 2) Prepared solution of dyes and then added metal cyanide. 3) Closed the vessel and reaction is carried out at elevated temperature. 4) Isolation is done by cooling and addition of Methanol. 5) Filter the product and wash with water. 6) Re-slurry the wet cake in 5 % ammonia solution. 7) Filter the wet cake and ML sent to recovery plant.
C19H18N6O2 + Metal Cyanide + DMF C19H18N6O2 + DMF
Reaction Vessel
Isolation
Filtration and Washing
DMF 3000 kg
Wet Cake for Drying
DMF and MeOH 6390 kg for Distillation
Dry Crude C17H18Br2N4O2
1000 kg
First step 1365 kg
Zn (CN) 300 kg
MeOH 3200 kg
MeOH 1000 kg
7890 kgs
4690 kgs
2500 kgs
1500 kgs
CuCN 25 kg
Disperse Blue 366, STEP-2
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 8
2. Disperse Brown 1 1) Diazotization of C6H4BrCl2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric
acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.
C6H4BrCl2N2O2 + H2SO4 + NSA + C10H14ClNO2 + HCl C14H19NO4 + HCl + Surfactant
Diazotization
Coupling
Filtration and Washing
C6H4BrCl2N2O2 525 kg
Wet Cake for Drying
12120 kg Water for ETP
Dry Crude 1000 kg
Sulphuric Acid 2500 kg
Sodium Nitrite 180 kg
Water 500 kg
C14H19No4 615 kg
HCL300 kg
Water 3000 kg
12120 kgs
3205 kgs
3000 kgs
2000 kgs
Disperse Brown 1
Ice 7500 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 9
3. Disperse Orange 288 1) Here C6H6N2O2 is diazotized in sulphuric acid with sodium nitrite and ice. 2) Transfer the diazo slowly to coupler solution and stir. 3) Check the completion of coupling and filter and wash the wet cake with water. 4) Wet cake sent to sand milling and spray drying.
C6H6N2O2 + H2SO4 + NaNO2 + C16H16N2 C22H22N5O2 + H2SO4
Diazotization
Coupling
Filtration and Washing
C6H6N2O2 420 kg
Wet Cake for Drying
10100 kg Water for ETP
Dry Crude 1000 kg
HCL 1050 kg
ICE 4000 kg
Water 500 kg
C16H16N2 615 kg
HCL300 kg
Water 3000 kg
11100 kgs
6185 kgs
4000 kgs
3000 kgs
Disperse Orange 288
Ice 3500 kg
Sodium Nitrite 215 kg
Water 500 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 10
4. Disperse Red 278
1) Diazotization of C6H6N2O2 is carried out in Hydrochloric acid and nitrosyl Hydrochloric acid.
2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.
C6H6N2O2 + HCl + NSA + C16H22N2O5 C22H29N5O7S
C6H6N2O2 300 kgHCl 1000 kgNaNO2 152 kgIce 5000 kg
6452 kg
C16H22N2O5 700 kgHCl 350 kgIce 6000 kgWater Washing 3000 kg
3800 kg
2800 kg
Disperse Red 278
Diazotization
Coupling&
Filtration
12702 kgWater forETP Plant
Wet Cakefor
Drying
Dry Crude1000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 11
5. Disperse Violet 93
1) Diazotization of C7H5ClN3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.
C7H5ClN3O2S + H2SO4 + NSA + C12H18N2O C20H23ClN6O3S
6-Br-2,4-DNA 595 kgH2SO4 3600 kgSodium Nitrite 160 kg
4355 kg
M-12 470 kgHCl 250 kgIce + Water 7000 kgWater 4000 kg
4000 kg
3000 kg
Wet Cakefor
Drying
Dry Crude1000 kg
Disperse Violet 93
Diazotization
Coupling &
Filtration
12075 kgwater for ETP
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 12
6. Disperse Yellow 211
1) Diazotization of C7H5ClN2O2 is carried out in hydrochloric acid and sodium nitrite. 2) Prepared coupler solution in hydrochloric acid then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying.
C7H5ClN2O2 +HCl + NaNO2 + C10H12N2O2 C17H18ClN5O4
C6H5ClN2O2 465 kgWater 500 kgHCl 1850 kgIce 5000 kgSodium Nitrite 210 kg
8025 kg
C9H12N2O2 520 kg
Water 500 kg
Soda Ash 750 kgIce 3000 kg
12795 kg
Water 2500 kg
4000 kg
3000 kg
Disperse Yellow 211
Diazotization
Coupling
Filtrationand
Washing
11295 kgWater for
ETP
Wet Cakefor
Drying
Dry Crude1000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 13
7. Acid Yellow 184 Manufacturing process: 1) C20H19N3O2 is sulfonated at ambient temperature in oleum. 2) Drawing and isolation by cooling and filter it.
Chemical reaction: C20H19N3O2 + Oleum C20H20N3O5 Mass Balance:
Yellow 82 900 kgOleum 1250 kgSulphuric Acid 1250 kg
3400 kg
NaOH Lye 4500 kgIce 4000 kg
11900 kg
Water 5000 kgSalt 1000 kg
5000 kg
4000 kg
Wet cakefor Drying
Dry Crude1000 kg
Acid Yellow 184
ReactionVessel
12900 kg water toETP Plant
ReactionVessel
Isolation and
Re-slurry
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 14
8. Disperse Red 277 Manufacturing Process:
1) C20H19N3O2 and C3H2N2 were mixed in solvent and reaction carried out in ambient temperature.
2) Cool the reaction mass to 25° C and isolate the product. 3) Filtered and wash
Chemical Reaction: C20H19N3O2 + Solvent + C3H2N2 C23H19N4O2 Mass Balance:
Reaction Vessel
Isolation
Filtration
C20H19N4O 1000
Wet Cake For Drying
10000 kg DMF and Methanol For Distilation
Dry Crude 1000 kg
DMF 5000 kg
12240 kg
6240 kg
3240 kg
2240 kg
Disperse Red 277
MeOH 6000 kg
C3H2N2 240 kg
MeOH 1000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 15
9. Disperse Red 362 Manufacturing Process:
1) C23H19N4O2 is treated with diluted sulphuric acid at ambient temperature. 2) pH adjusts to 3.5 with alkali and filter the product.
Chemical Reaction: C20H19N3O2 + Diluted H2SO4 C23H19N4O3 Mass Balance:
C23H17N5O 1000 kg
Sulphuric Acid 7000 kg
8000 kg
NaOH 100 kg
Ice 4000 kg
12100 kg
Water 3000 kg
4000 kg
3000 kg
Neutralizer
Filtration
11100 kgWater
for ETP
Wet Cakefor
Drying
Dry Crude1000 kg
Disperse Red 362
ReactionVessel
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 16
10. Disperse Yellow 232
1) C6H6ClNO2, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete.
2) Cool to 20° C and filter the product. C6H6ClNO2 + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H20ClN3O2
Reaction Vessel
Filtration and Washing
C6H6ClNO 600 kg
Wet Cake For Drying
2500 kg MeOH for Distillation and 5000 kg water to ETP
Dry Crude 1000 kg
5040 kg
3540 kg
2540 kg
Disperse Yellow 232
MeOH 3000kg
Water 6000 kg
PCL3 300kg
C5H7NO2 390kg
C11H15NO2 750kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 17
11. Disperse Yellow 184:1
1) C7H9NO, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete.
2) Cool to 20° C and filter the product. C7H9NO + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H21N3O2
Reaction Vessel
Filtration and Washing
C7H9NO 530 kg
Wet Cake For Drying
2500 kg MeOH for Distillation and 5000 kg water to ETP
Dry Crude 1000 kg
4970 kg
3470 kg
2470 kg
Disperse Yellow 184:1
MeOH 3000kg
Water 6000 kg
PCL3 300kg
C5H7NO2 390kg
C11H15NO2 750kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 18
12. Solvent Yellow 43 Manufacturing Process:
1) C12H5ClO3Br is reacted with C5H11N in presence of Solvent (DMF) to produce the dye. 2) Dye is isolated and filtered. 3) This dye is then treated with ammonia to produce the final color. 4) Wet cake is then given to formulation department.
Chemical Reaction: C12H5ClO3Br + Solvent (DMF) + C5H11N C21H17N2O2 Mass Balance:
C12H5ClO3Br 1000 kgC5H11N 1000 kgDMF 3000 kg
5000 kg
2500 kg
MeOH 6000 kg
3000 kg
2000 kg
Wet Cakefor
Drying
Dry Crude1000 Kg
Solvent Yellow 43
ReactionVessel
Distillationof
Dioxine
2500 kgDMF
Reused in next Batch
Isolation5500 kg
DMF and MeOHfor Recovery
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 19
13. Disperse Blue 354 1) C6H10O3 is treated with C6H5COCl and then treated with C3H2N2 in the presence of
solvent to produce Step – 1. 2) C7H9N, C6H13N and POCl3 is treated in DMF to form Step – 2. 3) Step – 1 and Step – 2 are treated in solvent to form the dye. 4) Dye is isolated by cooling and filtered. 5) Wet cake sent to formulation department.
Step – 1 C6H10O3 + C6H5COCl + C3H2N2 + H2SO4 Step – 1 + 50 % H2SO4
2175 kg
Step - 1 6013 kgC6H10O3 725 kgC6H5OCl 850 kgCaustic 1500 kgWater 2525 kg 5600 kg
Oleum 5200 kgWater 1500 kg
7787 kg1500 kg
Water 1500 kg
MeOH 3000 kgC3H2N2 375 kg
4100 kg
MeOH 800 kg
1200 kg
Reaction Vessel
Reaction Vesseland
Isolation4513 kg water
5562 kg 50 %Sulphuric Acid
For SellFiltration&
Washing 5263 kg Water for
ETP
Product A725 kg
Acidification
Disperse Blue 354
Benzoic Acid2250 kg
75 kg DryBenzoic Acid
Reaction Vessel
Wet Cake for Drying3700 kg
MeOH forRecovery
Step - 1800 kg
For Sale
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 20
Step – 2 C7H9N + C6H13N + NaOH C19H33N + NaBr C19H33N + DMF + POCl3 Step – 2 Final Dye Step – 1 + Step – 2 + Solvent C32H38N3O3S
Step - 2
C7H9N 425 kgC6H13Br 1325 kgCaustic 2500 kgWater 3500 kg
7750 kg
1036 kg
POCl3 635 kgDMF 775 kg
2446 kg
Disperse Blue 354
ReactionVessel
Oil Separation6714 kg NaBr
solution as Byproduct and Sell
ReactionVessel
Step - 22446 kg
Step - 3
Step - 1 800 kgStep - 2 2446 kgMeOH 3000 kg
MeOH 800 kg
2000 kg
1000 kg
Dry Crude1000 kg
Disperse Blue 354
ReactionVessel
Filtrationand
Washing
5046 kgMeOH and DMF for
Recovery
Wet Cakefor
Drying
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 21
14. Disperse Yellow 114 Manufacturing Process:
1) C6H7NO is reacted with Acetic Anhydride and then reacted with C6H5SO2Cl to form the diazo component which is then hydrolysed and diazotized with Hydrochloric Acid and Sodium Nitrite.
2) Coupling is carried with C8H8N2O2in alkaline condition to make the final crude dyes. 3) Dye is filtered and wash then sent to formulation department.
Chemical Reaction: Step – 1 C6H7NO + (CH3CO)2+NaOH C14H13NO4S C14H13NO4S + HCl C12H11NO3S Step – 2 C12H111NO3S + NaNO2 + HCl + C8H8N2O2 C20H19N4O5S + NaCl + H2O Mass Balance:
Water 5500 kgMAP 600 kgAcetic Acid 815 kgBSc 1170 kgSoda Ash 1350 kg
9435 kg
Water For Washing 1000 kg
ReactionVessel
ReactionVessel
6935 kgwater forETP Plant
Wet Cake2500 kg
Step - 1
Disperse Yellow 114
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 22
Wet Cake 1250 kgWater 1500 kgHCl 1000 kg
3750 kg
NaNO2 200 kgIce 4000 kg
7950 kg
MP 430 kgWater 1500 kgNaOH 300 kgIce 5000 kgWater 2000 kg 4500 kg
3500 kg
ReactionVessel
ReactionVessel
Wet Cakefor
Drying
Dry Crude1000 kg
12680 kgwater forETP Plant
Disperse Yellow 114Step - 2
ReactionVessel
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 23
15. Disperse Red 343: Mass
Balance:
Step - 1
C6H4Br2N2O2 725 kg
HCL 3000 kgICE 5000 kgSodium Nitrite 200 kg
8925 kgs
Water 500 kg
C11H17N 635 kg
Ice 5000 kg15060 kgs
Water 2000 kg
4500 kgs
3120 kgs
Wet Cakefor
Drying
Dry Crude1380 kg
Disperse Red 343
Diazotization
Coupling
Filtrationand
Washing
12560 kgWater for
ETP
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 24
Step - 2
DMF 2750 kg
1st Step 1380 kgZn(CN)2 315 kgCuCN 30 kg
4475 kg
MeOH 4000 kg
3500 kg
2500 kg
DMF and MeOH4975 kg forDistillation
Wet Cakefor
Drying
Dry Crude1000 kg
Disperse Red 343
ReactionVessel
Isolation
16. Solvent Orange 60 Manufacturing process: Naphthalic anhydride is reacted with 1:8 Diamino Naphthalene using Xylene as a solvent. The product is isolated using methanol. It is then filtered and washed with water. The wet cake is dried and pulverized to get the finished product. Chemical reaction:
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 25
1,8-DAN 660 kgPA 620 kgXylene 3000 kgDPG 450 kg
4730 kg
MeOH 3000 kg
MeOH Washing 1000 kg2200 kg
1200 kg
Solvent Orange 60
ReactionVessel
Isolation,Filtration
andWashing
Wet Cakefor
Drying
6530 kgXylene + MeOH
for Recovery
Dry Crude1000 kg
17. Solvent Red 135: Manufacturing process: Tetra Chloro Phthalic Anhydride is reacted with 1:8 Di Amino Naphthalene using Xylene as a solvent. The product is filtered and washed with methanol & water. The wet cake is dried and pulverized to get the finished product. Chemical reaction:
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 26
Mass Balance:
1,8 DAN 435 KgTCPA 870 KgXylene 3000 KgDPG 435 Kg
4740 kg
2240 kg
MeOH 3000 kg
2500 kg
1500 kg
Dry Crude1000 Kg
Solvent Red 135
ReactionVessel
Isolation&
Filtration
2500 kgXylene forRecovery
Washing2740 kg
Xylene + MeOHfor Recovery
Wet Cakefor
Drying
18. Solvent red 179: Manufacturing Process: Condensation: Naphthalene-1,8-diamine and 1H, 3H benzo [de] isochromene-1,3-dione is suspended in ODCB at room temperature. Stir it for 1 hour and. then heat it to 150 temperatures. Maintain for 6 hours. Cool to room temperature for filtration. Filtration and washing: Filter the slurry and wash with methanol and then water up to salt free. Filtrate and methanol wash sent to solvent recovery. Water wash sent to ETP. Drying and Packaging: Wet cake us then dried and pulverized and then sent to packaging.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 27
Chemical Reaction:
Mass Balance:
Xylene 3000 kg1,8 DAN 650 kgDPG 200 kg1,8 Naph Anhy. 735 kg
4635 kg
MeOH 6000 kgMeOH Washing 1000 kg
3500 kg
2500 kg
Solvent Red 179
Reaction Vessel
Isolation&
Washing
Wet Cakefor
Drying
Dry Crude1000 kg
8135 kgXylene + MeOH
for Recovery
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 28
19. Disperse red 60 Manufacturing process: 1. In glass reactor 94% phenol and potassium carbonate charge. 2. Dehydration of the above mixture at 120 0C. 3. Then cool to the 500C and charge 1 Amino 2 Bromo 4 Hydroxy AQ and heat the reaction mass 130- 1350C for 10 Hrs. 4. Reaction mass filter and wash till salt free. 5. Crude wet cake handover to the formulation unit. 6. Mother liquor sends to recovery unit for phenol recovery. Chemical Reaction:
Mass Balance:
C14H8ClNO3 990 kgC6H6O 360 kgC6H5Cl 4000 kgKOH 220 kgC16H36BrN 170 kg 5740 kg
Steam 5000 kg
5540 kg
Water 3000 kg
3500 kg
2500 kg
Disperse Red 60
ReationVessel
SteamDistiilation
Filtration&
Washing
Wet Cakefor
Drying
Dry Crude1000 kg
3700 kg MCB distilled out and
1500 lit waterfor ETP
5040 kgWater for
ETP
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 29
20. Disperse blue GSL (Disperse blue 165): Manufacturing process: Diazotization: DBPNA is charged with N.S.A. and sulphuric acid for diazotization, liberating water. Coupling: Water, ice and sulphuric acid are coupled with KD12. After that product is tray dried. Cyanuration: After tray drying, product is Cynurated with copper cyanide, sodium cyanide and DMF to get crude product. Filtration: Water and ammonia are added for reaction mass and crude product is filtrate out. ML is sent to ETP for treatment. Dyfol and Acetic acid are added to crude product. Spray Drying: The standardized dye liquid of Disperse Blue GSL will be transferred to the spray drying Holding Tank and spray dry. Packing: The final product is then packed in HDPE bags/M.S. Drums/Plastic Carboys / Paper cartoon boxes. Chemical reaction:
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 30
Mass Balance:
Step - 1
C6H4Br2N2O2 790 kg
Sulphuric Acid 2500 kg
Sodium Nitrite 188 kg3478 kgs
Water 500 kg
C11H17N 556 kg
Hydrochloric Acid 325 kgIce 8000 kg
12859 kgs
Water 4000 kg
5460 kgs
4095 kgs
Wet Cakefor
Drying
Disperse Blue 165
Diazotization
Coupling
Filtrationand
Washing
11399 kgWater for
ETP
Dry CrudeC17H18Br2N4O2
1365 kg
Step - 2
DMF 2500 kg
1st Step 1365 kgZn(CN)2 295 kgCuCN 25 kg
4185 kg
MeOH 5000 kg
3000 kg
2000 kg
Wet Cakefor
Drying
Dry Crude1000 kg
DMF and MeOH6185 kg forDistillation
Disperse Blue 165
ReactionVessel
Isolation
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 31
LIST OF INTERMEDIATES: 1. ETHYL BENZYLACETATE
2. 3-OXO
6675 kg water to ETP Plant
EBA 1000 kg
Reaction Vessel
Separation
C6H5OCl 1175 kg
C6H10O3 1000 kg
Caustic 2000 kg
EBA
Water 3500 kg
7675 kg
2000 kg water to ETP Plant
Product 1000 kg 3-Oxo-2, 3-
dihydrobenzothiophene-1, 1-dioxide
Reaction Vessel
and Isolation
Filtration and Washing
25% Oleum 7200 kg
3-Oxo 910 kg
3-Oxo-2, 3-dihydrobenzo[b]thiophene-1, 1-dioxide
Water 700 kg
10400 kg 50 % Sulphuric Acid For Sell
Water 5590 kg
8810 kg
2000 kg
Wet cake for Drying
1000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 32
3. PROPANEDINITRILE DERIVATIVE
4. N, N-DIHEXYL-M-TOLUIDINE
3500 kg MeOH for Recovery
Wet cake for drying
Reaction Vessel
Filtration and Washing
C3H2N2 375 kg
MeOH 3500 kg
C11H12O3 910 kg
PROPANEDINITRILE DERIVATIVE
MeOH 1300 kg
3-(Dicyanomethyllidene)-2, 3-dihydrobenzothiophen-11-dioxide
1000 kg
7360 kg NaBr solution as Byproduct and Sell
N,N-Dihexyl-m-Toluidine 1000 kg
Reaction Vessel
Oil Separation
C6H13Br 1430 kg
C7H9N 460 kg
Caustic 2700 kg
N, N-DIHEXYL-M-TOLUIDINE
Water 3770 kg
4785 kg
2585 kg
1585 kg
8360 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 33
5. DBPT
3920 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Filtration and Washing
HCL 2100 kg
C7H9N 430 kg
H2O2 120 kg
DBPT
Water 4000 kg
Dry Crude 1000 kg
Br2 770 kg
3420 kg
3500 kg
2500 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 34
6. DEMAP ALDEHYDE
16210 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Filtration and Washing
DMF 3100 kg
C10H15NO 1110 kg
Ice + Water 10000 kg
DEMAP ALDEHYDE
Water 2000 kg
DEMAP Aldehyde1000 kg
POCl3 2000 kg
19210 kg
5000 kg
4000 kg
NaOH 3000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 35
7. BENZOTHIAZOLE DERIVATIVE
11530 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Filtration and Washing
Acetic Acid 3300
C7H10NO 820 kg
Bromine 1170 kg
BENZOTHIAZOLE DERIVATIVE
Water 3000 kg
Benzothiazole Derivative 1000 kg
NH4SCN 1040 kg
13030 kg
4500 kg
3500 kg
NaOH 6700 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 36
8. METHYL PYRIDONE
6090 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Isolation and Washing
ECA 700 kg
Methyl Amine 510 kg
METHYL PYRIDONE
HCl 1500 kg
Dry Crude 1000 kg
Methyl Ester 800kg
2090 kg
3500 kg
2500 kg
NaOH 80 kg
Water + Ice 6000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 37
9. ETHYL PYRIDONE
5675 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Isolation and Washing
ECA 650 kg
Ethyl Amine 275 kg
ETHYL PYRIDONE
HCl 1500 kg
Dry Crude 1000 kg
Methyl Ester 650kg
1675 kg
3500 kg
2500 kg
NaOH 100 kg
Water + Ice 6000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 38
10. BUTYL PYRIDONE
6200 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Isolation and Washing
ECA 620 kg
Butyl Amine 840 kg
BUTYL PYRIDONE
HCl 1500 kg
Dry Crude 1000 kg
Methyl Ester 640kg
2200 kg
3500 kg
2500 kg
NaOH 100 kg
Water + Ice 6000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 39
11. 3-MPA PYRIDONE
7120 kg Water for ETP Plant
Wet cake for drying
Reaction Vessel
Isolation and Washing
ECA 770 kg
3-MP Amine 1400 kg
3-MPA PYRIDONE
HCl 1500 kg
Dry Crude 1000 kg
Methyl Ester 850kg
3120 kg
3500 kg
2500 kg
NaOH 100 kg
Water + Ice 6000 kg
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 40
UNIT PROCESSES INVOLVED IN R&D PRODUCTS A) Dyes: Dyes are classified according to the functional group and method of preparation as follows 1) Synthetic Organic Dyes – 1
i) Azo Disperse Dyes (T – 1) ii) Disperse Dyes (T – 2)
2)Synthetic Organic Dyes – 2
i) Azo Disperse Dyes (T – 3) 3) Synthetic Organic Dyes – 3
i) Anthraquinone Disperse Dyes ii) Anthraquinone Solvent Dyes
The brief description of synthesis route of each class as follows 1) Synthetic Organic Dyes – 1 i) Azo Disperse Dyes (T – 1): Azo disperse dyes prepared by two different routes due to the reactivity during diazotization. a) HCl Base Diazotization is a reaction that converts an -NH2 group connected to a phenyl ring to a diazonium salt. For example Nitrous acid is generated in situ by using Hydrochloric acid and Sodium Nitrite. Diazotization reactions are extremely useful in organic synthesis. The nitrous acid provides NO+ which replaces a hydrogen on the -NH3+ group to produce -NH2NO+ and water; a second water is eliminated to produce the - N2+ group. The amine is dissolved in suitable volume of water containing 2.5 – 3 mole of HCl by the application of heat if necessary, and the solution is cooled in ice when the amine hydrochloride usually crystallizes. The temperatures is maintained at 0 – 10°C and an aqueous solution of sodium nitrite is added and stirred until all amine converts into diazo then diazo is clarified and used to couple with tertiary amine. b) NSA Base The diazotization of Primary aromatic weekly basic amines is effected by adding the stoichiometrical amount of nitrosyl sulfuric acid (NSA) or some time ortho phosphoric acid, acetic acid along with NAS at a temperature of about minus 10° C to 20° C and atmospheric Pressure. In some cases it is advantageous to work at temperatures to about 40° C and stirred until all amine converts into diazo then diazo is used to
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 41
couple with tertiary amine. Coupling: Specific tertiary amine is dissolved in suitable acidic / alkaline or neutral aqueous solution and coupled with diazo at 0 – 20°C. Sometimes excess acidity is partially neutralized with suitable alkaline buffer. Disperse azo dyestuffs being hydrophobic in nature, precipitate out and are collected by filtration. Filtered wet cake is washed with water till neutral pH. Then aired well and dumped in to the wet grinding mill to obtain proper particle size distribution. The slurry so formed is spray dried at suitable temperature to obtain the dry dye product which is finally standardized as required and packed in drums. ii) Disperse Dyes (T – 2) In this class dyes were prepared after the condensation in suitable media and condition may be in single step or multistep. For example: a) Single Step: Dyes were prepared using two or more component in one step. Disperse Yellow 184 is prepared by the condensation of DEMAP Aldehyde, ECA, 4-CAP in presence of TEDA in one step. b) Multistep Step: Disperse Yellow 64 is prepared in two steps. In first step condensation between the 3-Hydroxy-2-methyl-4-quinolinecarboxylic acid and Phthalic anhydride. After completion of reaction material is isolated and dried then used in to bromination in methanol as a media. 2) Synthetic Organic Dyes – 2 i) Azo Disperse Dyes (T – 3) Dyes having the halogenated moiety (Bromine and Chlorine) which prepared in Azo Disperse Dyes (T – 1) is dried. Cyanation of the dry crude in DMF using copper cyanide and Sodium cyanide in presence of metal catalyst at suitable temperature is carried out. After completion of reaction methanol is use in isolation of product. Isolated product filters and ML send to the solvent recovery and detoxification. Treatment on the isolated material by liquid ammonia carried out before handover to the formulation. 3) Synthetic Organic Dyes – 3
i) Anthraquinone Disperse Dyes Aromatic and/or aliphatic primary amines or phenols or metal cyanide are condensed with Dihydroxy derivative or halogenated derivative of Anthraquinone in solvent as a media with suitable temp. & pressure in presence of base or catalyst to get desire product. After completion of reaction product is isolated either by cooling or by diluting it with solvent & filter to get wet press cake of the
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 42
product. Then it is further standardized & milled to get desire quality in wet slurry formis spray dried to get final product.
ii) Anthraquinone Solvent Dyes Aromatic and/or aliphatic primary amines or phenols are condensed with Dihydroxy derivative or halogenated derivative of Anthraquinone in solvent media at suitable temp. & pressure to get desire product. After completion of reaction product is isolated either by cooling or by diluting it with solvent & filter to get wet press cake of the product. The wet press cake mill and standardized in presence of suitable solvent. Fusion At the optimum temperature with or without solvent media, Benzanthrone/cyclised product is subjected to alkali is subsequently oxidized by either with steam/air or with both. Then the product is isolated, filtered and washed with water till neutral pH then further dried, pulverized and used for next stage depending upon the product process requirement. Hydroxylation The Fused Product is hydroxylated in Acid media in presence of metal oxide and sub-sequently the hydroxylated product is isolated, filtered, washed with water. The wet cake is dried, pulverized and used for alkylation. Diazotization and Reduction The diazotization of primary amine of anthraquinone is diazotized with nitrosyl sulphuric acid and subsequently reduced by sodium sulphite. After completion of reaction product is isolated, filtered and washed with water for getting the product. Benzoylation and Halogenation Amino Anthraquinone are Benzoylated and / or subsequently chlorinated in solvent media at suitable temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material filtered and washed with water till neutral pH. The wet cake is dried, pulverized and used for next stage depending upon the product process requirement. Condensation Amino Anthraquinone are condensed with halogenated Anthraquinone in solvent media at suitable temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material filtered and washed with water till neutral pH. The wet cake is dried, pulverized and used for next stage depending upon the product process requirement. Cyclisation The condensed/ reduced material is cyclised in presence of catalyst and acid media/solvent media at optimum temperature. Then the product is isolated, filtered and washed with water for getting product. Alkylation The Fused/hydroxylated product is alkylated in solvent media at optimum temperature and then the product is isolated after the Vacuum/steam distillation to remove the solvent. The isolated material
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 43
filtered and washed with water till neutral pH (Say alkylated product). The wet cake is dried, pulverized and used for Acid pasting. Acid Pasting After the treatment of sulphuric acid on alkylated product is isolated, filter and wash till neutral pH by water. The wet cake is dried, pulverized and packed in drums. Anthraquinone Intermediates As per requirements of anthraquinone intermediates, operation performed on the starting material. For example: 1-amino anthraquinone and 1-chloro anthraquinone. Both are prepared using same starting material by different operation. In first step sulphonation of Anthraquinone in acidic media at optimum temperature then drawn in water, isolated by filtering and then ammonolysis gives 1-amino while chlorination gives 1-chloro AQ at optimum temperature and pressure. Excess Ammonia gas and chlorine is recovered and then product is isolated by filtering, washing with water till purity of the product is achieved. Primary Amines There are so many way to prepare a primary amine. Few are describe below,
At optimum temperature and pressure, ammonolysis using liquid ammonia of Chloro Nitro Benzene &Dichloro Nitro Benzene is carried out. The excess ammonia is recovered and then product is isolate, filtering & washing with water till neutral pH is achieved.
DNCB is Methoxylated with sodium Methoxide, isolate the product by filtering and then reduced by reducing agent.
Meta nitro Aniline is acetylated using acetic anhydride isolated the product by drowning and filtering and then reduced by reducing agent.
M.D.N.B., Nitro Anisole, Nitro Chloro Benzene, Nitro Acetanilide, Nitro Methoxy Acetanilide are reduced using reducing Agent like Iron filling & Sodium Hydrosulfite, isolate the product by salting & filtering.
Halogenated Primary Amines Halogenation (Bromination or Chlorination) of the primary amine using chlorine gas or bromine gas or HBr in presence of hydrogen peroxide in acidic media at optimum temperature. After completion of reaction quench excess bromine by using SBS and then filter and wash with water till neutral pH. The isolated material used as such or dried as per the requirements. Tertiary amines: There are so many way to prepare a tertiary amine. Few are describe below, i) Alkylated tertiary amines Primary and Secondary Amines are alkylated in aqueous / solvent media with or without inert atmosphere at optimum parameters (pressure & temperature). Finally, the product is isolated by filtration or separation. ii) Ethoxylated and Acetylated Tertiary Amines
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 44
Primary and Secondary Amines are Ethoxylated in aqueous media under inert atmosphere at optimum parameters (pressure & temperature). Finally, the product is isolated by filtration and separation. Ethoxylated tertiary amines are dried under vacuum and acetylated with acetic anhydride at required temperature. After cooling material is diluted by minimum amount of acetic acid stored in to the storage tank. iii) Cyanoethylated Amines Primary or secondary amines are Cyanoethylated in mild acidic condition in presence of anti polymerizing agent at optimum temperature and pressure. Isolate the product by filtering & washed till neutral pH. Some of these products are further used in ethoxylation / alkylation process & some of these products are directly used in S.O. Dyes. Other Intermediates: Other intermediates are prepared by followed different operations like sulphonation, halogenation, ammonolysis, reduction, condensations, cyclisation, cyanation, nitration, acetylation, alkylation, formylation etc as per the reactive sites of functional group conversation possibilities in to the starting material. For example: a) Pyridones: Cyanoacetic ester, suitable amine and Alkyl acetoacetate are condensed in an autoclave at 80-120°C and 1 – 3kg/cm2 pressure for 4 – 20 hrs. Pyridones so formed are either used as such or isolated by drowning into acidic solution. Isolated pyridine is filtered and washed with water and pressed well to obtain the wet cake of Pyridone. b) CMB: Cyclisation of OPDA and ECA in presence of catalyst in solvent media at high temperature. After completion of reaction material is isolated by natural cooling, filter and wash till removed the solvent. c) Quinoline are prepared by multi steps reaction which having secondary (–N=) or tertiary nitrogen atom. The most common examples in our industries are HMQ, DHQ, 3 Hydroxy Quinaldine, 2,4-dihydroxy quinoline etc. C) Dispersing Agents Dispersing agent is the main constituent of the finish dye. In our industry we produce a different kind of dispersing agent like solid, liquid and sometime semi liquid. i) Solid Dispersing Agent
a) Naphthalene base b) Creosote oil / Wash Oil c) Butanol d) Lignin
ii) Liquid Dispersing agent a) Phenol b) Cresol
i) Solid Dispersing Agent
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 45
The above mention solid dispersing agents are prepared in similar manner. Naphthalenesulphonic acid–formaldehyde Condensate Naphthalene is sulphonated by sulfuric acid and oleum at 100 – 150°C for 1 – 10 hrs at 0 – 4 kg/cm2 to get naphthalene-2-sulphonic acid 85% and naphthalene-1-sunphonic acid 15%. ii) Liquid Dispersing agent Liquid dispersing agents are prepared by using the same process which used in solid dispersing agent. Phenol–formaldehyde Condensate (Liquid Dispersing Agent) Phenol is condensed with Polymerization agent at 100 – 150°C at 0–4kg / cm2 along with sulfonating agent and water to get Liquid Dispersing agent. D) NSA / NOHSO4 Nitrosyl sulphuric acid is widely used in the azo dyes for diazotization. Nitrosyl sulphuric acid is used for the diazotization of the primary amines which having less basicity. NSA / NOHSO4 are prepared by the reaction between H2SO4, HNO3 and Water in presence of catalyst.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 46
2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of disperse dyes are listed below:
TABLE 3: DETAILS OF RAW MATERIAL REQUIREMENTS S.No. Raw Material Qty (MT)/Month CAS No.
1 2-Ethylhexyl Bromide 4.0 18908-66-2 2 Acetic acid 4.0 64-19-7 3 Acetic Anhydride 6.0 108-24-7 4 Acetone 7.0 67-64-1 5 Ammonium peraSulphate 2.3 7727-54-0 6 Ammonium Thiocyanate 2.3 1762-95-4 7 Aniline Derivatives (Tertiary
Aromatic Amines) 25.0 91-67-8 (N,N DEMT)
92-00-3 (M-1) 148-69-6 (M-17)
6375-46-8 (M-12) 27059-08-1 (M-3A) 51560-72-6 (M-279)
8 Benzoyl Chloride 7.0 98-88-4 9 Bromine 2.5 7726-95-6 10 Caustic Flask 10.0 1310-73-2 11 Cuprous Cyanine 3.0 7782-50-5 12 DEMAP Aldehyde 7.0 544-92-3 13 Dibutylamine 4.0 17754-90-4 14 Diethylamine 4.0 1192-2 15 Dimethyl Sulfate 5.0 109-89-7 16 Dimethylformamide (DMF) 10.0 77-78-1 17 Dioxane 5.0 68-12-2 18 Ethyl Cyano Acetate 7.0 105-56-6 19 Fisher's Aldehyde 5.0 111-25-1 20 Fisher's base 5.0 7647-01-0 21 Hexyl Bromide 6.0 67-63-0 22 Hydrochloric Acid 20.0 1305-62-0 23 Isopropyl alcohol (IPA) 7.5 108-44-1 24 Lime 5.0 109-77-3 25 m - Toluidine 4.0 868-54-2 26 Malodinitrile 5.0 67-56-1 27 Malononitrile Dimer 5.0 74-87-3 28 Methanol 15.0 74-88-4 29 Methyl Chloride 3.0 1126-78-9 30 Methyl Iodide 3.0 7782-78-7 31 n-Butyl Aniline 5.0 8014-95-7 32 Ortho Pheneline Diamine 6.0 95-54-5 33 p - Toluidine 4.0 106-49-0
34 Aniline Derivatives (Primary Aromatic Amines)
25.0 827-94-1 (DBPNA)
99-29-6 (2-CN PNA)
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 47
100-01-6 (PNA) 24072-75-1 (Dichloro
BT) 3531-19-9 (6-Cl-2,4-
DNA) 1817-73-8 (6-Br-2,4-
DNA) 35 Pentyl Bromide 5.0 110-53-2 36 Phenylhydrazine 3.0 100-63-0 37 Phosphorus Oxy Chloride 10.0 10025-87-3 38 Phosphorus Penta Chloride 7.5 10026-13-8 39 Soda Ash 15.0 497-19-8 40 Sodium Chloride 3.0 7647-14-5 41 Sodium Cyanide 3.0 143-33-9 42 Sodium Nitrite 3.0 7632-00-0 43 Sulfamic acid 3.0 5329-14-6 44 sulphur 0.3 7704-34-9 45 Sulphuric Acid 20.0 7664-93-9 46 Tributylamine 5.0 102-82-9 47 Triethylamine 5.0 121-44-8 48 Zinc Chloride 3.0 7646-86-7 49 Zinc Cyanide 3.0 557-21-1 50 Ammonium Chloride 3.0 12125-02-9 51 Naphthalene 21 91-20-3 52 Formaldehyde 12 50-00-0 53 Phenol 21 108-95-2 54 Cresol 12 95-48-7; 106-44-5 55 Sodium bisulfite 20 7631-90-5 56 Thiophenol 6 108-98-5 57 Phenylmethyl pyrazolone (PMP) 5 89-25-8 58 Quinizarine 7 81-64-1 59 Leuco-Quinizarine 3 476-60-8 60 p-Toluidine 4 106-49-0 61 p-Amino Acetanilide 3 122-80-5 62 1,8-Dichloro Anthraquinone 4 82-43-9
63 1,4-Diamino-2,3-Dichloro Anthraquinone 3 81-42-5
64 2,4,6-Trimethyl Aniline 4 88-05-1 65 2,6-Dimethyl-4-Ethyl Aniline 3 4150-37-2
66 1,4-Diamino-5,8-Dihydroxy Anthraquinone 4 145-49-3
67 4-Butyl Aniline 4 104-13-2 68 1-Amino Anthraquinone 5 82-45-1 69 1-Methyl amino Anthraquinone 3 82-38-2 70 Chlorine 5 7782-50-5 71 Naphthaleic Anhydride 4 81-84-5
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 48
72 4-Chloro Naphthalic Anhydride 4 8/1/4053 73 1,8-Diamino Anthraquinone 8 479-27-6 74 Quinaldine 3 91-63-4 75 Phthalic Anhydride 6 85-44-9 76 Tetra Chloro Phthalic Anhydride 3 117-08-8
77 3-Hydroxy quinaldine-4-carboxylic Acid 4 118-13-8
78 Methyl Ester 5 105-45-3 79 n-Butanol 8 71-36-3 80 Xylene 8 95-47-6; 1330-20-7 81 Oleum 75 8014-95-7 82 NitrocylSulphuric Acid 20 7782-78-7 83 Phosphorus Trichloride 3 (7719-12-2) 84 m-Amino acetanilide 5 102-28-3 85 4-Methoxy-m-Amino acetanilide 6 6375-47-9
2.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE We will be provided rain water recharging for the resource optimization. Spent Oil i.e. 10 Lit/month will be generated from prime movers which will be reused as lubricant within premises or sell to MoEF approved re-processor. 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT
AND SOURCE 2.7.1 WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed project will be 105.7 KLD which mainly for process, Boiler & cooling (make up water), Domestic uses and for gardening & others, however due to reuse/recycle of 55.6 KLD, Total Fresh Water Requirement will be 50.1 KLD. Total water requirement shall be met from GIDC. 2.7.2 POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 250 KVA. Power supply shall be taken from DGVCL. In case of emergency or power failure D.G. set of 125 KVA X 2 Nos = 250 KVA will be used. It will be used to fulfill emergency power requirement.
2.8 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND ITS
MANAGEMENT / DISPOSAL 2.8.1 WASTEWATER GENERATION Domestic wastewater of 3.4 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporator. Residue (1.0 TPD salt) from ATFD will be sent for TSDF. Details of water requirement and waste water generation are given in following table.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 49
TABLE 4: DETAILS OF WASTEWATER GENERATION
Category Existing Proposed (Additional)
Total after Expansion
Domestic (A) 1 3.5 4.5 Industrial (B)
Process 0.65 46.2 46.85
Washing 1.9 7.8 9.7 Boiler 0.4 3.2 3.6
Cooling 0.05 0.6 0.65 Total (B) 3 57.8 60.8
Total (A) + (B) 4 61.3 65.3 2.8.2 SOLID WASTE GENERATION Solid waste generated will be Sludge from ETP, used/spent oil and discarded bags/drums etc.. The sources of solid wastes, generation and its management are as given in the following table.
TABLE 5: DETAILS OF SOLID WASTE
Sr. No.
Type/Name of Hazardous
waste
Specific Source of
generation
Category and
Schedule as per
HW Rules.
Quantity Management of HW (MT/Annum)
Existing Proposed Total
1 Empty barrels/containe
rs/liners contaminated
with hazardous chemicals/wast
e
Raw Material &
Process
33.1 10 (1000 Nos)
50 (5000 Nos)
60 (6000 Nos)
Collected and stored at specified area and sold to
approved/ registered vendors.
2 Used or Spent Oil
Maintenance
5.1 0.07 0.8 0.87 Collected in drums and stored at
specified area, Reuse in plant for
lubrication and Balance will be
Selling to authorized recyclers
3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage,
Transportation, Disposal at BEIL,
TSDF.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 50
4 Distillation residue
(Semi Solid having CV 1500-2000 Kcal/Kg)
In-House Solvent
Recovery Process
or from
outside solvent
recovery unit
36.1 Nil 1170 1170 Collection, Storage
Transportation, Disposal at
GPCB approved CHWIF or
co/pre- processing
5 Spent Solvent (Methanol)
Solvent & Disperse
Dyes (Solvent
Red 179 , solvent
yellow 114, disperse blue 165, disperse blue 354, solvent
orange 60 etc)
26.3 Nil 4068 4068 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for Recovery as per
Rule 9 of hazardous and other wastes
(Management and transboundary
movement) rules,2016
(M/s.Anju Life science or Any
others) 6 Spent Solvent
(DMF) Solvent & Disperse
Dyes (Solvent
Orange 63, disperse blue 165, disperse blue 354,
disperse red J,
Fluorescent Red CB,
etc)
26.3 Nil 6480 6480 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for Recovery as per
Rule 9 of hazardous and other wastes
(Management and transboundary
movement) rules,2016
(M/s.Anju Life science or Any
others) 7 Spent Solvent
( Xylene) Solvent
Dyes (Solvent red
26.3 Nil 1728 1728 In-House Distillation or
Collection,
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 51
179 , solvent red 135, solvent
red 179, solvent
orange 60, solvent
yellow 157, solvent
yellow 163, etc)
Storage & sent for Recovery as per
Rule 9 of hazardous and other wastes
(Management and transboundary
movement) rules,2016
(M/s.Anju Life science or Any
others) 8 Spent Solvent
(ODCB) Solvent
Dyes (Solvent Yellow
114, solvent yellow 33,
solvent yellow 176,
etc)
26.3 Nil 2772 2772 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for Recovery as per
Rule 9 of hazardous and other wastes
(Management and transboundary
movement) rules,2016
(M/s.Anju Life science or Any
others) 9 NaBr Disperse
Blue 354 26.3 Nil 4900 4900 Collection,
Storage, Transportation &
disposal to Actual User under Rule 9
10 Sulphuric Acid 50%
Disperse Blue 354
26.3 Nil 1980 1980 Collection, Storage,
Transportation & disposal to Actual User under Rule 9
11 Benzoic Acid 40 %
Disperse Blue 354
26.3 Nil 28 28 Collection, Storage,
Transportation & disposal to Actual User under Rule 9
12 Salt From ATFD
34.3 Nil 365 365 Collection, Storage,
Transportation,
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 52
Disposal at BEIL, TSDF
13 Contaminated cotton rags or other cleaning materials
Process &
Maintenance
33.2 Nil 0.5 0.5 Collection, Storage,
Transportation, Disposal By
Incineration at CHWIF of BEIL
14 NaCl Scrubber of CL2
26.3 Nil 18 18 Collection, Storage,
Transportation & disposal to Actual User under Rule 9
15 Gypsum Neutralization stage
in Disperse Violet 99
D2 Nil 332 332 Collection, Storage
Transportation, Disposal by
selling to actual user authorized
by GPCB or Cement Industry
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 53
CHAPTER – 3 SITE ANALYSIS 3.1 CONNECTIVITY The proposed project site is situated at at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labors are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 3.1.1 Road Connectivity The Plant is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. 3.1.2 Rail The Area is well connected by Railway. Ankleshwar railway Station is about 1.35 km in SE. 3.1.3 Airport The nearest airport to the project will be Surat at around 62.08 km. in NWW. 3.1.4 Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. Land document is attached as Annexure – I. 3.3 TOPOGRAPHY Topography of the area is plain. 3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table:
TABLE 6: DETAILS OF EXISTING LAND USE S.NO. PARTICULAR NAME & ITS DISTANCE
1. Nearest National Highway NH-8 at around 0.76 Km 2. Nearest State Highway SH-64 at around 1.23 Km
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 54
3. Nearest city Surat at around 62.0 Km 4. Nearest River Narmada at around 6.92 Km
5. Nearest Railway station Ankleshwar at around 1.35 Km 6. National park/Reserve Forest, Biosphere,
etc. None within a radius of 10 Km
6. Seismicity Zone III 3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table:
TABLE 7: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE S. NO. PARTICULAR DISTANCE
1. Civil Hospital Within 15 Km
2. Colleges
3. Govt & Pvt Schools
4. Hari Mandir 3.6 CLIMATIC DATA The main characteristic of this region is hot summer and severe winter with a small spell of rainy season. The rainy season generally commence at the beginning of July and last till mid-October. The period from October to November constitutes the post monsoon season and winter prolong from December to February which last till March before the summer season begins. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months:
Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February
3.6.1 TEMPERATURE DETAILS The hottest months were May to September with mercury reaching 37 ºC during June. The coldest months were December, January and February when temperature drops to 15 ºC. The months, November and March, can also be quite cold in some years. During the other months, temperature was more or less moderate in nature and pleasant to bear. Monthly mean Minimum and Maximum Temperatures of Bharuch station for the period of Jan’18 to Dec’018 are given in following table.
TABLE 8: TEMPERATURE DATA S.
NO. MONTHS OF
YEAR 2015 MONTHLY MEAN
MINIMUM (0C) MONTHLY MEAN
MAXIMUM (0C) 1. January 10 33 2. February 9 38 3. March 11 37 4. April 22 39
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 55
S. NO.
MONTHS OF YEAR 2015
MONTHLY MEAN MINIMUM (0C)
MONTHLY MEAN MAXIMUM (0C)
5. May 23 40 6. June 21 36 7. July 20 34 8. August 23 38 9. September 21 36 10. October 18 36 11. November 15 34 12. December 11 33
(Courtesy: Indian Meteorological Department) 3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Surat station was recorded for 08:30 hrs and 17:30 hrs. Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period. 3.6.3 RAINFALL Monthly total rainfall data for Surat station is presented in following table.
TABLE 9: RAINFALL DATA
(Courtesy: Indian Meteorological Department) The rainy season in the area extends from June to October. The mean total rainfall, during the monsoon period (June to September), has been recorded as 1165.1 mm. The average number of rainy days per month varies from 8 to 18 in monsoon months. The rainfall data indicates that the rainfall is limited to monsoon season for four months of the year.
S.NO.
MONTHS OF YEAR 2015
MONTHLY TOTAL (MM)
1. January 00 2. February 00 3. March 00 4. April 0.1 5. May 00 6. June 144.7 7. July 348.6 8. August 154.2 9. September 474.8
10. October 42.7 11. November 00 12. December 00
TOTAL 1165.1
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 56
3.6.4 WIND SPEED AND WIND DIRECTION The April – Sept Month, have winds from South West to North East. From October-March is a period mixed with calm conditions and winds mainly from North East to South East. The winter months, November to February, experience frequent calm conditions. The maximum number of calm periods observed is in the month of December and February. (Source: http://www.windfinder.com/windstats/windstatistic_surat_gujarat.htm)
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 57
CHAPTER – 4 PLANNING BRIEF 4.1 PLANNING CONCEPT M/s. PARISHI CHEMICALS is planning to set up Dyes & Intermediate manufacturing unit Proposed (a) 60 MT/month dyes Crude dyes (b) 240 MT/month Dispersing Agent (c) 40 MT/Month Intermediates, (d) 1 Tons R & D Products, - Total Quantum – 341 MT/Month Or Proposed (a) 300 MT/month Standardized and formulations crude dyes (c) 40 MT/day Intermediates, (d) 1 Tons R & D Products -- Total Quantum – 341 MT/Month at plot no. CB1/6916-17-18, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Proposed project is envisaged as existing Dyes & Intermediates facilities in Gujarat are not adequate to handle new development activities as well for the industries in Surat, Ankleshwar, Jhagadia, Panoli, Vapi, Navsari, Vadodara, others. 4.2 LAND USE PLANNING About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. 4.3 AMENITIES / FACILITIES At the project site first aid centre will be set up. Company will provide drinking water to the workers in the factory premises.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 58
CHAPTER – 5 PROPOSED INFRASTRUCTURE 5.1 INDUSTRIAL AREA About 2112 sq.m. of land at plot no. CB1/6916-17-18, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Parishi Chemicals which is already in operation. Total acquired land is classified as Industrial land. 5.2 RESIDENTIAL AREA There will be no residential area proposed for the project. 5.3 GREEN BELT The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About 852.48 sq.m area i.e. 40 % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 0.90 Lacs approx. In Green belt area about 1000 tree per acre of land shall be planted. The selection of tree species suitable for plantation at the industry shall be governed by guiding factors as stated below: The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having
minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in
primary and secondary attenuation zone. The trees should possess extensive foliar area to provide maximum impinging surface for
continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and
hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution
indicator. It is also recommended to carry out extensive plantation within premises.
Keeping in view the climatic conditions, status of soils and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE No new social infrastructure facility will be developed as the plot is located in notified industrial area having well developed infrastructure.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 59
5.5 CONNECTIVITY 5.5.1 ROAD CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 60
5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the GIDC Ankleshwar located within premises after getting necessary clearance. 5.7 WASTE WATER MANAGEMENT 5.7.1 STORM WATER DRAINAGE Storm water drainage system shall consist of well-designed open surface drains network so that all the storm water is efficiently drained of without any water logging. Based on the rainfall intensity of the proposed area drainage system shall be design on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow. Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations. For crossing roads, culverts shall be provided. 5.7.2 SEWERAGE WATER SYSTEM The sanitary sewerage system shall be designed to cater the sanitary sewerage from plant premises. The design of facial sewerage system shall be designed based on no. of person to be served and average daily consumption of water. Only 4.5 KL/day will be generated which will be treated through septic tank and disposed through soak pit/well. For inspection, cleaning and maintenance of sewer lines, manholes of reinforced concrete constructions shall be provided at every bend, junction point of change in slope or diameter and on straight sections of pipes at interval not exceeding 30 meters. 5.7.3 INDUSTRIAL WASTE WATER MANAGEMENT Domestic wastewater of 4.5 KLD will be discharged through septic tank/ soak pit. Industrial waste water 60.80 will be treated in in-house ETP of capacity 70.0 KLD. After treatment in ETP, 35.0 KLD will be sent to CETP of M/s. Ankleshwar Waste Management Ltd; Ankleshwar & 4.0 KLD will be send to CETP of M/s. ETL for further treatment and disposal. 20.8 KLD will be taken in to multiple effect evaporator. residue (1.0 TPD salt) from ATFD will be sent for TSDF. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the following table.
TABLE 10: DETAILS OF SOLID WASTE MANAGEMENT Sr. No
.
Type/Name of Hazardous waste
Specific Source of
generation
Category and
Schedule as per
HW Rules.
Quantity Management of HW (MT/Annum)
Existing Proposed
Total
1 Empty barrels/containers/liners contaminated
with hazardous chemicals/waste
Raw Material &
Process
33.1 10 (1000 Nos)
50 (5000 Nos)
60 (6000 Nos)
Collected and stored at specified area and sold to
approved/ registered vendors.
2 Used or Spent Oil Maintenance
5.1 0.07 0.8 0.87 Collected in drums and stored at
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 61
specified area, Reuse in plant for
lubrication and Balance will be
Selling to authorized recyclers
3 ETP Sludge ETP 35.3 12 365 377 Collection, Storage, Transportation,
Disposal at BEIL, TSDF.
4 Distillation residue (Semi Solid having
CV 1500-2000 Kcal/Kg)
In-House Solvent
Recovery Process
or from
outside solvent
recovery unit
36.1 Nil 1170 1170 Collection, Storage Transportation,
Disposal at GPCB approved
CHWIF or co/pre- processing
5 Spent Solvent (Methanol)
Solvent & Disperse
Dyes (Solvent
Red 179 , solvent
yellow 114, disperse blue 165, disperse blue 354, solvent
orange 60 etc)
26.3 Nil 4068 4068 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for
Recovery as per Rule 9 of hazardous
and other wastes (Management and
transboundary movement) rules,2016
(M/s.Anju Life science or Any
others) 6 Spent Solvent
(DMF) Solvent & Disperse
Dyes (Solvent
Orange 63, disperse blue 165, disperse blue 354,
26.3 Nil 6480 6480 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for
Recovery as per Rule 9 of hazardous
and other wastes
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 62
disperse red J,
Fluorescent Red CB,
etc)
(Management and transboundary
movement) rules,2016
(M/s.Anju Life science or Any
others)
7 Spent Solvent ( Xylene)
Solvent Dyes
(Solvent red 179 ,
solvent red 135, solvent
red 179, solvent
orange 60, solvent
yellow 157, solvent
yellow 163, etc)
26.3 Nil 1728 1728 In-House Distillation or
Collection, Storage & sent for
Recovery as per Rule 9 of hazardous
and other wastes (Management and
transboundary movement) rules,2016
(M/s.Anju Life science or Any
others) 8 Spent Solvent
(ODCB) Solvent Dyes
(Solvent Yellow
114, solvent yellow 33,
solvent yellow 176,
etc)
26.3 Nil 2772 2772 In-House Distillation and
recovered solvent will be reuse or
Collection, Storage & sent for
Recovery as per Rule 9 of hazardous
and other wastes (Management and
transboundary movement) rules,2016
(M/s.Anju Life science or Any
others) 9 NaBr Disperse
Blue 354 26.3 Nil 4900 4900 Collection, Storage,
Transportation & disposal to Actual User under Rule 9
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 63
10 Sulphuric Acid 50%
Disperse Blue 354
26.3 Nil 1980 1980 Collection, Storage, Transportation &
disposal to Actual User under Rule 9
11 Benzoic Acid 40 % Disperse Blue 354
26.3 Nil 28 28 Collection, Storage, Transportation &
disposal to Actual User under Rule 9
12 Salt From ATFD
34.3 Nil 365 365 Collection, Storage, Transportation,
Disposal at BEIL, TSDF
13 Contaminated cotton rags or other cleaning materials
Process &
Maintenance
33.2 Nil 0.5 0.5 Collection, Storage, Transportation,
Disposal By Incineration at
CHWIF of BEIL 14 NaCl Scrubber of
CL2 26.3 Nil 18 18 Collection, Storage,
Transportation & disposal to Actual User under Rule 9
15 Gypsum Neutralization stage
in Disperse Violet 99
D2 Nil 332 332 Collection, Storage Transportation,
Disposal by selling to actual user authorized
by GPCB or Cement Industry
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 64
CHAPTER – 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN Proposed project is located on industrial land, which is already acquired and there is no habitat. So proposed project proposal does not involve any Rehabilitation & Resettlement.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 65
CHAPTER – 7 PROJECT SCHEDULE & COST ESTIMATES 7.1 PROJECT IMPLEMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. We are giving here under the details of the Project Implementation. From the date of start, the implementation schedule envisages completion of project in 12 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows:
TABLE 11: PROJECT IMPLEMENTATION SCHEDULE S.NO. WORK IMPLEMENTATION TIME
1. Construction work 6 Months 2. Machinery installation 3 Months 3. Recruitment process 1 Month 4. Commissioning 1 Month 5. Operation and functions 1 Month
Total 12 months 7.1.1 PROPOSED ORGANISATION CHART In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to ensure its effective implementation. Hence, company will create a team consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level etc. either permanently or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried - out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in figure – 3.
FIGURE 3: AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL
DIRECTORS
GENERAL MANAGER
WORKS MANAGER OFFICE ASSISTANTS
WAREHOUSE INCHARGE
SUPERVISORS ACCOUNTANT
OPERATORS
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 66
7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs. 700.00 Lacs. Break up of proposed project cost is given in following table:
TABLE 12: TOTAL PROJECT COST AND IT’S BREAK UP S.NO. PARTICULARS AMT. (RS. IN LACS)
1 Land and Site Development 0.00 2 Factory Building 300.00 3 Plant & Machineries 400.00 4 Franchises Deposits/ Non CA 0.00 5 Investment/ Non CA 0.00 6 Other Misc. Assets 0.00 7 Preliminary & Pre-operative Exp. 0.00 8 Margin Money for working capital 0.00
TOTAL COST OF PROJECT 700.00 7.3 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The of capital Rs. 25 Lacs and recurring (Rs 10.50 Lacs per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance.
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 67
CHAPTER - 8
ANALYSIS OF PROPOSAL 8.1 FINANCIAL AND SOCIAL BENEFITS The industrial activity of the proposed project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region. 8.2 DIRECT BENEFITS TO THE NATIONAL AND STATE EXCHEQUER
Employment generation, Income tax from individual as well as corporate taxes from company and ancillary units, Transportation reduction.
8.3 OTHER BENEFITS Most of the work force required for construction and operation of the proposed project will be drawn from the surrounding villages. During the construction phase, no family is required to rehabilitate from the core zone. The economic growth of the area in terms of employment generation, consumption of goods and market-growth are expected outcome of the project. The project has an employment generation prospect on skilled manpower. The direct employment potential of the project is estimated as 40 persons, the share of local people in this is expected to be significant. It is assumed that the generation of indirect employment would be multiple of direct employment. The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. This will have impact on the current literacy level, primary and middle level education and on existing health facilities. A new awareness generated will have positive impact on the social pattern, which at this stage, is caste and community oriented. The long-term implications of this change are definitely progressive. 8.4 EMPLOYMENT Due to proposed project, there will be development of communication facilities in the area. The total manpower requirement will be 85. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities etc. During operation, plant will generate direct employment as explained in the previous paragraph. The preference will be given for local population for employment in the semi-skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods. Moreover, permanent supply of electricity in the area will support to improve other type of industries. 8.5 HEALTH AND SAFETY MEASURES The workers engaged in high pollution generation area will be equipped with appropriate protective equipment. Following measures will be adopted in the plant to keep check on the safety measures and health:
- Inspection and maintenance of pollution control systems regularly - All safety measures such as provision of safety appliances, training, and giving-of safety
awards. - The workers exposed to noisy sources will be provided with ear muffs/plugs - Adequate facilities for drinking water and sufficient toilets will be provided to the employees
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 68
8.6 SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY The firm shall earmark funds for social development and welfare measures in the surrounding villages. These measures will include funding for:
1) Education Facilities 2) Health Care and Family Welfare 3) Infrastructure Developments 4) Social Causes
The details of peripheral development plan including development in infrastructure, health, education and socio cultural aspects which will be carried out are as follows under the Corporate Responsibility:
1 The firm will organize free medical camps at least twice in a year for the benefit of the villagers.
2 The firm will organize cultural programmes in connection for the sake of local villagers every year.
3 The firm will provide chairs and cooking vessels on returnable basis to all the villagers for marriages.
ESTIMATED COST OF PROJECT AND PROJECT VIABILITY The capital cost of the project is estimated at about Rs. 700.00 Lacs for the installation of plant & machinery along with required auxiliary and balancing facilities for the production capacity of 341 T/Month of Dyes & Intermediate product. The breakup of the same is shown below: S. NO. COST OF PROJECT COST (RS. IN LACS)
1 Land and Site Development 0.00 2 Factory Building 300.00 3 Plant & Machineries 400.00 4 Franchises Deposits/ Non CA 0.00 5 Investment/ Non CA 0.00 6 Other Misc. Assets 0.00 7 Preliminary & Pre-operative Exp. 0.00 8 Margin Money for working capital 0.00 9 Total Cost of project 700.00
BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control/monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance will be as given in following table: S. NO. ITEM RS. IN
LAKHS 1 Capital Expenditure 25.00 2 Recurring expenditure on environmental management cell and on pollution
control systems per annum 10.50
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 69
ECONOMIC VIABILITY STATEMENT SHOWING PROFITABILITY AND CASH ACCRUALS
PARTICULARS QUANTITY RATE PER KG
TOTAL RS. IN LAKHS
Purchase Value of Dyes and Intermediate Product
-- 625.00 --
If we will produce, Production Cost of Dyes & Intermediate Product
-- 510.00 --
Net Saving Per Kg. -- 115.00 -- Actual Consumption / Day 2435.00 115.00 2.80 Actual Consumption / Monthly 63310.00 115.00 72.80 Actual Consumption / Quarterly 189930.00 115.00 218.40 Actual Consumption / Yearly 759720.00 115.00 873.60 ESTIMATE OF MEANS OF FINANCE 1. Capital & Reserve 0.00 2. Share application money 0.00 3. Unsecured loan (Shareholders) 700.00 4. Member’s deposit 0.00 5. Central & state subsidy 0.00
TOTAL 700.00
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 70
ANNEXURE – I LAND AGREEMENT DOCUMENTS :
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 71
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 72
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 73
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 74
ANNEXURE – II
LAYOUT OF THE PLANT Ground Floor Plan
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 75
First & Second Floor Plan
M/s. Parishi Chemicals, GIDC Ankleshwar, Gujarat 76
Second & Terrace Floor Plan