PLOT NO: C/387, 388, 389, GIDC, VILL: SAYAKHA, TAL: VAGARA,...
Transcript of PLOT NO: C/387, 388, 389, GIDC, VILL: SAYAKHA, TAL: VAGARA,...
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FORM-1
For
PROPOSED DYES, DYE INTERMEDIATES &
AGROCHEMICAL INTERMEDIATES IN EXISTING DYE
FORMULATION UNIT
of
M/s. POLYCHEM INDUSTRIES
PLOT NO: C/387, 388, 389,
GIDC, VILL: SAYAKHA,
TAL: VAGARA, DIST: BHARUCH
GUJARAT-INDIA
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
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APPENDIX I
(See paragraph - 6)
FORM 1
(I) Basic Information
Sr.
No.
Item Details
1. Name of the project/s M/s. POLYCHEM INDUSTRIES
2. S. No. in the schedule 5(f) & 5(b)
3. Proposed capacity/area/length/tonnage to
be handled/command area/lease
area/number of wells to be drilled
For detail Please refer Annexure – I
4. New/Expansion/Modernization Expansion
5. Existing Capacity/Area etc. Formulation of powder dye: 1426 MT/Month
6. Category of Project i.e. ‘A’ or ‘B’ ‘A’
7. Does it attract the general condition? If
yes, please specify.
No
8. Does it attract the specific condition? If
yes, please specify.
No
9. Location
Plot/Survey/Khasra No. Plot No: C/387, 388, 389
Village Sayakha
Tehsil Vagara
District Bharuch
State Gujarat
10. Nearest railway station/airport along with
distance in kms.
Railway Station: Bharuch (20 km)
Airport: Vadodara (90 km)
11. Nearest Town, city, District Headquarters
along with distance in kms.
Sayakha Village (7 km)
Bharuch (20 km)
12. Village Panchayats, Zilla Parishad,
Municipal Corporation, local body
(complete postal address with telephone
nos. to be given)
Sayakha, Tal: Vagra, Dist: Bharuch, Gujarat
13. Name of the applicant M/s. POLYCHEM INDUSTRIES
14. Registered Address Plot No: C/387, 388, 389,
GIDC, VILL: Sayakha,
TAL: Vagara, DIST: Bharuch
Gujarat-INDIA
15. Address for correspondence: M/s. POLYCHEM INDUSTRIES
Plot No: A/1/17, 2nd
floor,
Sardar Patel road no. 1,
Udhana Udhyog nagar,
Near Udhana Railway station,
Surat-395210, Gujarat
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Name Mr. Dhawal Bhatia
Designation (Owner/Partner/Director) Proprietor
Address M/s. POLYCHEM INDUSTRIES
Plot No: A/1/17, 2nd
floor,
Sardar Patel road no. 1,
Udhana Udhyog nagar,
Near Udhana Railway station,
Surat-395210, Gujarat
Pin Code 395210
e-mail [email protected]
Telephone No. +91 9825248492
Fax No. -
16. Details of Alternative Sites examined, if
any.
Location of these sites should be shown
on a topo sheet.
NA
17. Interlinked Projects NA
18. Whether separate application of
interlinked project has been submitted?
NA
19. If yes, date of submission NA
20. If no, reason NA
21. Whether the proposal involves
approval/clearance under: if yes, details of
the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z. Notification, 1991?
No
22. Whether there is any Government
Order/Policy relevant/relating to the site?
No
23. Forest land involved (hectares) NA
24. Whether there is any litigation pending
against the project and/or land in which
the project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
NA
• Capacity corresponding to sectoral activity (such as production capacity for manufacturing,
mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.).
4
(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will
cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes/
No
Details thereof with approximate
quantities frates, wherever possible)
with source of information data
1.1 Permanent or temporary change in land use, land cover or topography including increase intensity of land use (with respect to local land use plan)
No
1.2 Clearance of existing land, vegetation
and Buildings?
Yes Minor site clearance activities shall be
carried out to clear shrubs and weed.
1.3 Creation of new land uses?
No The project site is located on level ground, which does not require any major land filling for area grading work.
1.4 Pre-construction investigations e.g.
bore Houses, soil testing?
No
1.5 Construction works? Yes For detail Please refer Annexure – II
1.6 Demolition works? No There will not any demolition work at the site.
1.7 Temporary sites used for construction
works or housing of construction
workers?
Yes Some land portion on the plot will be
provided for temporary housing of
construction workers during
construction stage. 1.8 Above ground buildings, structures or
earthworks including linear structures,
cut and fill or excavations
Yes For detail Please refer Annexure – II
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Off shore structures? No
1.13 Production and manufacturing
processes?
Yes For detail Please refer Annexure -III
1.14 Facilities for storage of goods or
materials?
Yes Area for storage tank farm, raw materials and finished products will be developed for the proposed expansion project.
1.15 Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes Facilities for treatment or disposal of liquid effluents are given as Annexure – V & Facilities for treatment or disposal of solid waste is given as Annexure –VI.
1.16 Facilities for long term housing of
operational workers?
No The unit shall be running round the clock. The operational staff will be recruited locally and working in shift, hence no housing for the operational workers.
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1.17 New road, rail or sea traffic during
Construction or Operation?
No There will not be any new road/rail or sea traffic during construction or operational phase.
1.18 New road, rail, air waterborne or other
transport infrastructure including new
or altered routes and stations, ports,
airports etc?
No
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No
1.20 New or diverted transmission lines or
Pipelines?
No There will not be said work at the site.
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water form
ground or surface waters?
No Surface water.
1.24 Changes in water bodies or the land
surface
Affecting drainage or run-off?
No
1.25 Transport of personnel or materials for
construction, operation or
decommissioning?
Yes By road only.
1.26 Long-term dismantling or
decommissioning or restoration works?
No
1.27 Ongoing activity during
decommissioning which could have an
impact on the environment?
No
1.28 Influx of people to an area either
temporarily or permanently?
Yes As the construction party will be on
contract basis, it will temporary increase
population. But after construction stage,
the new recruitment of the employees
will be done which can have minor
impact on the population.
1.29 Introduction of alien species?
No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
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2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No.
Information/checklist confirmation Yes/
No
Details there of (with approximate
quantities frates, wherever possible) with
source of information data
2.1 Land especially undeveloped or
agricultural land (ha)
No The land is for Industrial Use
2.2 Water (expected source & competing
users) unit: KLD
Yes Water Source – GIDC Water Supply
Water balance is given as Annexure – IV
2.3 Minerals (MT) No
2.4 Construction material - stone,
aggregates,
and / soil (expected source - MT)
Yes Construction materials, like steel, cement,
crushed stones, sand, rubble, etc.
required for the project shall be procured
from the local market of the region.
2.5 Forests and timber (source - MT) No.
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel
(MT), energy (MW)
Yes For detail please refer Annexure – IV
2.7 Any other natural resources (use
appropriate standard units)
No
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes For details please refer Annexure – VIII
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
Yes Direct/Indirect employment
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3.4 Vulnerable groups of people who could
be affected by the project e.g. hospital
patients, children, the elderly etc.
No
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
4.1 Spoil, overburden or mine wastes
No
4.2 Municipal waste (domestic and or
commercial wastes)
No
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure –VI
4.4 Other industrial process wastes
No
4.5 Surplus product
No
4.6 Sewage sludge or other sludge from
effluent treatment
Yes
Please refer Annexure – VI
4.7 Construction or demolition wastes
No
4.8 Redundant machinery or equipment
No
4.9 Contaminated soils or other materials
No
4.10 Agricultural wastes
No
4.11 Other solid wastes Yes Please refer Annexure –VI
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
5.1 Emissions from combustion of fossil
fuels from stationary or mobile
Yes For details Please refer Annexure – VII.
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sources
5.2 Emissions from production processes
Yes Stack emission will remain within the
norms prescribed by CPCB. Please refer
Annexure – VII.
5.3 Emissions from materials handling
storage or transport
Yes The construction materials such as stones,
cements, bricks & coal may pollute the air by
dust particles. But it will be controlled by
covering the trucks & trailers by clothes during
transportation.
5.4 Emissions from construction activities
including plant and equipment
Yes During construction work, the Nearby
buildings area will be covered by sheets or
clothes to avoid dust Contamination in air.
5.5 Dust or odors from handling of
materials including construction
materials, sewage and waste
No
5.6 Emissions from incineration of waste No
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No
5.8 Emissions from any other sources No
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data with
source of information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes The Noise level will be within the
prescribed limit. Adequate preventive &
control measures will be taken at noisy
area. No significant noise, vibration or
emission of light & heat from the unit.
6.2 From industrial or similar processes Yes -do-
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational
traffic
No
6.6 From lighting or cooling systems No
6.7 From any other sources No
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7. Risks of contamination of land or water from releases of pollutants into the ground or into
sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or spillage
of hazardous materials
Yes For detail please refer Annexure – VIII
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No
7.3 By deposition of pollutants emitted to
air into and or into water
No
7.4 From any other sources No
7.5 Is there a risk of long term build up of
pollutants in the environment from
these sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
Sr.
No.
Information/Checklist confirmation Yes/
No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
8.1 From explosions, spillages, fires etc.
from storage, handling, use or
production of hazardous substances
Yes For detail please refer Annexure – VIII
8.2 From any other causes No
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No
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9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr. No.
Information/Checklist confirmation
Yes/ No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
9.1 Lead to development of supporting. lities, ancillary development or development stimulated by the project which could have impact on the environment e.g.
• Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)
• housing development • extractive industry • supply industry • other
Yes For detail please refer Annexure – IX
9.2 Lead to after-use of the site, which
could have an impact on the
environment
No
9.3 Set a precedent for later
developments
No
9.4 Have cumulative effects due to
proximity to other existing or
planned projects with similar effects
No
11
(II) Environmental Sensitivity
Sr.
No.
Areas Name/
Identity
Aerial distance (within 15km.)
Proposed project location boundary
1 Areas protected under international
conventions, national or local legislation
for their ecological, landscape, cultural or
other related value
- No protected area within 5 km from
the proposed project boundary
2 Areas which important for are or sensitive
Ecol logical reasons - Wetlands,
watercourses or other water bodies,
coastal zone, biospheres, mountains,
forests
Narmada
River Narmada River: 13 km (approx.) away
from Project Site
3 Area used by protected, important or
sensitive
Species of flora or fauna for breeding,
nesting, foraging, resting, over wintering,
migration
- No protected area or sensitive species
within 5 km from the proposed project
boundary.
4 Inland, coastal, marine or underground
waters
- Narmada River: 13 km (approx.) away
from Project Site
5 State, National boundaries - N.A.
6 Routes or facilities used by the public for
access to recreation or other tourist,
pilgrim areas
- N.A.
7 Defense installations - N.A.
8 Densely populated or built-up area - -
9 Area occupied by sensitive man-made
land uses Hospitals, schools, places of
worship, community facilities)
- N.A.
10 Areas containing important, high quality
or scarce resources (ground water
resources, surface resources, forestry,
agriculture, fisheries, tourism, minerals)
- N.A.
11 Areas already subjected to pollution
environmental damage. (those where
existing legal environmental standards
are exceeded)or
- N.A.
12 Are as susceptible to natural hazard
which could cause the project to present
environmental problems (earthquake,
subsidence, landslides, flooding erosion,
or extreme or adverse climatic conditions)
- N.A.
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – X.
12
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products with their Production Capacity
II Layout Map of the Plant
III Brief Manufacturing Process Description
IV Details of Water Consumption & Waste water Generation
V Details of Treatment Scheme and Disposal
VI Details of Hazardous /Solid Waste Generation, Handling and Disposal
VII Details of Stack and Vent
VIII Details of Hazardous Chemical Storage & Handling
IX Socio-Economic Impacts
X Proposed Terms of Reference for EIA studies
13
ANNEXURE-I
___________________________________________________________________________
LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY
SR.
NO.
PRODUCT NAME QUANTITY
(MT/MONTH)
EXISTING
1. FORMULATION OF POWDER DYE
(Through mixing/blending & Spray Drying only)
1426 MT/M
PROPOSED
1. ACID DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes
75 MT/M
2. ACID DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes
3. ACID DYES [METAL COMPLEX]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
4. BASIC DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes
100 MT/M
5. BASIC DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
14
6. DIRECT DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
200 MT/M 7. DIRECT DYES [CONDENSATION]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
8. DISPERSE DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
1000 MT/M
9. DISPERSE DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
10. DISPERSE DYES [CYANATION]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
11. REACTIVE DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
200 MT/M 12. REACTIVE DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
15
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
13. SOLVENT DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
75 MT/M 14. SOLVENT DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
15. PIGMENT DYES [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
75 MT/M
16. PIGMENT DYES [ANTHRAQUINONES/CONDENSED]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
17. OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES/
STAINS [AZO]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
150 MT/M 18. OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES/
STAINS [CONDENSATION]
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
16
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
19. VAT & SOLUBLE VAT DYES
A. Yellow Dyes
B. Orange Dyes
C. Red Dyes
D. Blue Dyes
E. Violet Dyes
F. Green Dyes
G. Black Dyes & Mixtures
50 MT/M
20. INTERMEDIATES [AGROCHEMICALS & DYESTUFFS]
A. 2,3-Dibromopropionyl Chloride
B. 2,6-Dibromo Para-toluidine
C. MDEAMS
D. MDPAMS
E. EBA [Ethyl Benzene Aniline]
F. Aldehydes [ EBA,DEA, DEMAP]
G. OBSA / BDSA
H. 2,4-Dichloro Aceto / Valerophenone
I. Dimethyl Sulphide
J. Valeryl Chloride
K. H-Acid
L. DASA
M. Vinyl Sulphone Ester
N. Schaeffer’s Acid
O. Bronner’s Acid
450 MT/M
21. AUXILIARIES
A. Naphthalene suphonated formaldehyde condensate
B. Phenol suphonated formaldehyde condensate
C. Melamine suphonated formaldehyde condensate
150 MT/M
22. TURQUOISE CPC SUPHONATED & CONDENSED DYES 75 MT/M
TOTAL 4026 MT/M
17
LIST OF RAW MATERIALS
SR.
NO.
RAW MATERIAL QUANTITY (MT/MT)
1.ACID DYES [AZO]
1. AMINES 0.20
2. HCl 0.40
3. ICE 2.50
4. SODIUM NITRITE 0.10
5. COUPLERS 0.25
6. ALKALIES/ACIDS 0.08
7. AUXILIARIES' FOR STD 0.20
2.ACID DYES [ANTHRAQUINONES / CONDENSED]
1. SOLVENTS 2.50
2. A.Q/R.M./AMINES 0.60
3. COND. PRODUCT 0.50
4. ALKALI/AIDS 0.08
5. AUXILIARIES 0.20
3.ACID DYES [METAL COMPLEX]
1. MONO/TETRA AZO 2.23
2. METALS 0.10
3. ALKALIES/ACIDS 0.08
4. AUXILIERIES 0.20
4.BASIC DYES [AZO]
1. AMINES 0.20
2. ACID 0.40
3. ICE 2.00
4. SODIUM NITRITE 0.10
5. COUPLERS 0.25
6. ALKALIES/ACIDS 0.08
5.BASIC DYES [ANTHRAQUINONES / CONDENSED]
1. ACETIC ANHYDRIDE 0.30
2. ALDEHYDES 0.15
3. R.M.1 0.15
4. COND. PRODUCT 0.10
5. ACETIC ACID 0.15
6.DIRECT DYES [ AZO ]
1. AMINES 0.15
2. ACID 0.20
3. ICE 1.50
4. SODIUM NITRITE 0.05
5. COUPLERS 0.10
6. AUXILIARIES' FOR STD 0.20
7.DIRECT DYES [CONDENSATION]
1. R.M. MASS 0.18
2. R.M. 1 0.15
18
3. CONDN PRODUCT 0.15
4. ALKALI 0.15
5. ICE 0.70
6. AUXILIERIES 0.20
8.DISPERSE DYES [ AZO ]
1. AMINES 0.25
2. ACID 0.40
3. ICE 2.00
4. SODIUM NITRITE 0.10
5. COUPLERS 0.28
6. ALKALI 2.15
7. AUXILIERIES 0.40
9.DISPERSE DYES [ ANTHRAQUINONES / CONDENSED]
1. SOLVENT 2.00
2. AMINES 0.25
3. A.Q.R.M 1 0.40
4. R.M.2 0.10
5. R.M.3 0.15
6. AUXILIARIES 0.40
10.DISPERSE DYES [ CYANATION ]
1. SOLVENT 1.50
2. MONO/R.M. PRODUCT 0.25
3. SODIUM CYANIDE 0.20
4. SODIUM BISULPHITE 0.25
5. ALKALI 0.15
6. WET CAKE 1.40
7. D.A AUXILIARIES 0.20
11.REACTIVE DYES [ AZO ]
1. AMINES 0.15
2. ACID 0.20
3. ICE 1.50
4. SODIUM NITRITE 0.05
5. COUPLERS 0.10
6. AUXILIARIES' FOR STD 0.20
12. REACTIVE DYES [ ANTHRAQUINONES / CONDENSED]
1. R.M. MASS 0.20
2. R.M. 1 0.15
3. CONDN PRODUCT 0.15
4. ALKALI 0.15
5. AUXILIERIES 0.20
6. ICE 1.00
13.SOLVENT DYES [ AZO ]
1. OR SOLVENT 1.00
2. AMINES 0.28
3. ACID 0.35
4. ICE 1.50
19
5. SODIUM NITRITE 0.08
6. COUPLERS 0.30
14.SOLVENT DYES [ ANTHRAQUINONES / CONDENSED]
1. SOLVENT 2.00
2. AMINES 0.25
3. A.Q.R.M-1 0.40
4. R.M.-2 0.10
5. R.M.-3 0.15
6. AUXILIARIES 0.40
15.PIGMENT DYES [ AZO ]
1. OR 1.00
2. AMINES 0.28
3. ACID 0.35
4. ICE 1.50
5. SODIUM NITRITE 0.08
6. COUPLERS 0.30
16.PIGMENTS DYES [ ANTHRAQUINONES / CONDENSED]
1. SOLVENT 2.00
2. AMINES 0.25
3. A.Q.R.M-1 0.40
4. R.M.-2 0.10
5. R.M.-3 0.15
6. AUXILIARIES 0.40
17.OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES /STAINS[AZO]
1. R.M.MASS 0.25
2. R.M.1 0.25
3. COND PRODUCT 0.30
4. ALKALI 0.15
5. ICE 1.00
6. WET CAKE 1.50
18.OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES /STAINS
[CONDENSATION]
1. SOLVENTS 2.00
2. SULPHONIC ACID 0.35
3. AMINES/ALDEHYDES 0.30
4. ANILINE COMP. 0.30
5. ALKALI 0.05
6. METHANOL 1.00
19.VAT & SOLUBLE VAT DYES
1. SOLVENTS 2.00
2. SULPHONIC ACID 0.35
3. AMINES/ALDEHYDES 0.30
4. ANILINE COMP. 0.30
5. ALKALI 0.05
6. PYRIDINE 1.20
7. PARENT VAT 0.40
20
8. CHLORO S.ACID 0.35
9. METAL POEWDER 0.20
10. ICE 3.00
11. C.S.LYE 0.50
12. SALT 0.30
20.INTERMEDIATES [ AGROCHEMICALS & DYESTUFFS]
A. 2,3-DIBROMOPROPIONYL CHLORIDE
1. ACRYLIC ACID 0.27
2. LIQ BROMINE 0.31
3. THIONYL CHLORIDE 0.31
B. 2,6-DIBROMO PARA-TOLUIDINE
1. PARA TOLUDINE 0.35
2. LIQ BROMINE 0.18
C. MDEAMS
1. TOLUENE 1.00
2. MNA 0.73
3. MSC 0.38
4. ACETIC ACID 0.30
5. METAL POWDER 0.08
6. DES 0.35
D. MDPAMS
1. TOLUENE 0.67
2. MNA 0.48
3. MSC 0.25
4. ACETIC ACID 0.20
5. METAL POWDER 0.05
6. DPS 0.23
E. EBA [ETHYL BENZENE ANILINE]
1. MEA 0.60
2. ALKALY 0.15
3. BENZOYL CHLORIDE 0.45
F. ALDEHYDES [ EBA,DEA, DEMAP]
1. DMF 0.60
2. ANILINE DERIVATIVES 0.60
3. POCL3 0.20
4. ICE 1.00
5. ALKALI 0.20
G. OBSA / BDSA
1. DCB/OCA 0.46
2. SODIUM BI SULHITE 0.15
3. ALKALI 0.12
4. SPENT ACID 0.35
H. 2,4-DICHLORO ACETO / VALEROPHENONE
1. n-VALERIC ACID 0.90
2. THIONYL CHLORIDE 0.35
I. DIMETHYL SULPHIDE
21
1. MDCB 0.67
2. ALLUMINIUM CHLORIDE 0.10
3. ACETYL/VELERIC CHLORIDE 0.43
4. ICE 0.95
J. VALERY CHLORIDE
1. SODIUM SULPHIDE 0.70
2. DIMETHYL SULPHATE 0.30
K. H-ACID
1. C.S.ACID 0.71
2. ACETANILIDE 0.32
3. ICE 1.43
4. PNA 0.21
5. HCL 0.11
6. METAL POWDER 0.11
7. C.S.LYE 0.18
8. SPENT ACID 1.71
L. DASA
1. H2SO4 1.94
2. OLEUM 2.67
3. NAPTHALENE 0.31
4. NITRIC ACID 0.97
5. LIMESTONE 3.39
6. GLAUBER'S SALT 3.40
7. HCL SPENT 0.75
8. IRON POWDER 0.65
9. CAUSTIC SODA 1.50
10. METHANOL 0.68
11. SPENT ACID 9.50
M. VINYL SULPHONE ESTER
1. C.S.ACID 1.06
2. ACETANILIDE 0.63
3. ICE 3.00
4. SODIUM BISULPHATE 0.60
5. C.S.LYE 0.35
6. H2SO4 0.11
7. ETHYLENE OXIDE 0.33
N. SCHAEFFER’S ACID
1. H2SO4 0.56
2. BETA NAPTHL 0.51
3. ICE 1.64
4. SALT 0.26
O. BRONNER’S ACID
1. LIQ AMMONIA 0.73
2. SCHAFFER'S ACID 0.73
3. SPENT ACID 0.53
AUXILIARIES
22
A. NAPHTHALENE SUPHONATED FORMALDEHYDE CONDENSATE
1. H2SO4 0.16
2. OLEUM 23% 0.43
3. NEPTHALENE 0.60
4. FORMALDEHYDE 0.35
5. C.S.LYE 0.55
6. GLAUBER'S SALT 0.22
B. PHENOL SUPHONATED FORMALDEHYDE CONDENSATE
1. SODIUM SULPHITE 0.30
2. PHENOL 0.54
3. FORMALDEHYDE 0.65
4. C.S.LYE 0.29
5. GLAUBER'S SALT 0.20
C. MELAMINE SUPHONATED FORMALDEHYDE CONDENSATE
1. SODIUM SULPHITE 0.38
2. MELAMINE 0.41
3. FORMALDEHYDE 0.70
4. C.S.LYE 0.05
5. GLAUBER'S SALT 0.20
TURQUOISE CPC SUPHONATED & CONDENSED DYES
1. ACIDS 9.23
2. RAW MATERIAL 4.62
3. ICE 3.10
23
ANNEXURE (A) - DETAILS OF AMINES, ALDEHYDES, CONDENSE PRODUCTS, COUPLERS &
SOLVENTS
SR.NO. RAW MATERIAL NAME STORAGE
PHYSICAL
FORM
A. AMINES
1 DTPTSA HDPE Bags Powder
2 DCPNA HDPE Bags Powder
3 OCPNA HDPE Bags Powder
4 DBPNA HDPE Bags Powder
5 PNA HDPE Bags Powder
6 Meta Amino Phenol HDPE Bags Powder
7 PAABSA HDPE Bags Powder
8 PAAB 3,4 DSA HDPE Bags Powder
9 Tobias Acid HDPE Bags Powder
10 3,3’-Diamino Diphenyl Sulphone HDPE Bags Powder
11 Sulpho tobias Acid HDPE Bags Powder
12 Aniline HDPE Bags Powder
13 Ortno Nitro Aniline HDPE Bags Powder
14 4-NAP HDPE Bags Powder
15 5-NAP HDPE Bags Powder
16 4-NAPSA HDPE Bags Powder
17 5-NAPSA HDPE Bags Powder
18 4-CAP HDPE Bags Powder
19 Meta Phenylene Diamine MS DRUMS Powder
20 Meta Toluene Diamine MS DRUMS Powder
21 Meta Toluidine MS DRUMS Liquid
22 Meta Xylidine Sulphonic Acid HDPE Bags Powder
23 Metanilic Acid HDPE Bags Powder
B. ALDEHYDES
1 DEA Aldehyde MS DRUMS Powder
2 EBA Aldehyde MS DRUMS Powder
3 Fischer’s Aldehyde MS DRUMS Powder
4 Dichlro benzaldehyde MS DRUMS Powder
5 Ortho Chloro Benzaldehyde MS DRUMS Powder
C. CONDENSE PRODUCTS
1 Bromamine acid HDPE Bags Powder
2 M-Acid HDPE Bags Powder
3 DABA HDPE Bags Powder
4 Dahl’s Acid HDPE Bags Powder
5 DASA HDPE Bags Powder
6 Diphenyl Amine HDPE Bags Powder
7 F C Acid HDPE Bags Powder
8 Fast Black B Base HDPE Bags Powder
9 Fast Blue B Base HDPE Bags Powder
10 PNAOSA HDPE Bags Powder
24
11 PNCBOSA HDPE Bags Powder
12 PNTOSA HDPE Bags Powder
13 Quinaldine MS Drums Liquid
14 Quinizarine HDPE Bags Powder
15 Fast Red B Base HDPE Bags Powder
D. COUPLERS
1 Ethyl Pyridone HDPE Bags Powder
2 Methyl Pyridone HDPE Bags Powder
3 Fischer’s Base MS Drums Liquid
4 Gamma Acid HDPE Bags Powder
5 H Acid HDPE Bags Powder
6 J Acid HDPE Bags Powder
7 J Acid Urea HDPE Bags Powder
8 Laurent's Acid HDPE Bags Powder
9 MD-01 HDPE Bags Powder
10 MD-04 HDPE Bags Powder
11 MD-07 MS Drums Liquid
12 MD-12 HDPE Bags Powder
13 MD-15 HDPE Bags Powder
14 MD-22 HDPE Bags Powder
15 MD-23 HDPE Bags Powder
16 MD-3A HDPE Bags Powder
17 Mix Cleve's Acid HDPE Bags Powder
18 Mix Xylene MS Drums Liquid
19 Mix Xylidine MS Drums Liquid
20 MPDSA HDPE Bags Powder
21 OAPS Amide HDPE Bags Powder
22 OAPSA HDPE Bags Powder
23 Phenyl J Acid HDPE Bags Powder
24 PMP HDPE Bags Powder
25 R Salt HDPE Bags Powder
26 Resorcinol HDPE Bags Powder
27 Schaffer’s Acid HDPE Bags Powder
28 SPCP HDPE Bags Powder
29 Sulpho Para Base HDPE Bags Powder
30 Super Refined Salt HDPE Bags Powder
31 Tobias Acid HDPE Bags Powder
32 Meta Nitro Aniline HDPE Bags Powder
33 [P-1] NN-Bis(2-hydroxyethyl)-m-chloroaniline HDPE Bags Powder
34 [P-1A] N,N-diacetoxyethyl-m-chloro aniline PP DRUMS Liquid
35 [P-2] N,N-diacetoxyethyl-m-chloro aniline HDPE Bags Powder
36 [P-2A] N,N-Diacetoxyethyl-M-Toluidine PP DRUMS Liquid
37
[P-3 ] 1N-(3-Bis(2-
hydroxyethylamino)phenyl)acetamide HDPE Bags Powder
38
[P-3A] 3-(N,N-Diacetoxyethyl)Amino
Acetanilide PP DRUMS Liquid
25
39
[P-5 ] 3'-[bis(2-hydroxyethyl)amino]-4'-
methoxyacetamilde PP DRUMS Liquid
40 [P-7] N-Cyanoethyl-N-Acetoxyethyl Aniline PP DRUMS Liquid
41 [P-8]3-(N-Ethyl-N-phenylamino)propionitrile PP DRUMS Liquid
42 1,3 SPMP HDPE Bags Powder
43 1,4 SPMP HDPE Bags Powder
44 1.6 Clevs Acid HDPE Bags Powder
45 1.7 Clevs Acid HDPE Bags Powder
46 8-Hydroxy Quinoline HDPE Bags Powder
47 Aceto Acetanilide HDPE Bags Powder
48 Aceto Acetanisidine 4-Methyl 5-Sulphonic Acid HDPE Bags Powder
49 Alpha Naphthylamine HDPE Bags Lumps
50 Beta Naphthol HDPE Bags Flakes
51 Bronner's Acid HDPE Bags Powder
52 C Acid HDPE Bags Powder
53 Chloro MPD HDPE Bags Powder
54 3-(Dimethylamino) Benzoic Acid HDPE Bags Powder
E. SOLVENTS
1 Methanol MS TANKS Liquid
2 Dimethyl Formamide MS TANKS Liquid
3 Xylene MS TANKS Liquid
4 Toluene DRUM STORAGE Liquid
5 Heptane MS TANKS Liquid
26
ANNEXURE-II
___________________________________________________________________________
LAYOUT MAP OF THE PLANT
27
ANNEXURE-III
BRIEF PROCESS DESCRIPTION
1. ACID DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines as
mentioned in Raw Material list Annexure (A) is charged. Then required quantity of HCL is
added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium Nitrite is
slowly added keeping Congo red paper positive & S.I. paper slightly positive now diazo is
ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken & required
quantity of coupler as mentioned in Raw Material list Annexure (A) is added. Then crushed
ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received
keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for further
treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if powder require,
it is directly straightway Spray Dried to dispatch as a Powder form.
4. Tetrazo:
For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5 Deg.C
temperature & coupling with required further coupler products as mentioned in Raw Material
list Annexure (A) in require parameters.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for further
treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if powder require,
it is directly straightway Spray Dried to dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 2000 kg
Amines 200 kg
Acid Hcl 400 kg
ICE 2000 kg
Sodium Nitrite 100kg
Water 1000 kg
Couplers 250 kg
Alkalies / Acids 75 kg
ICE 500 kg
4500 kg ML to ETP
Auxiliaries’ 1225 kg Water evaporation
For STD 200Kg 1000 kg Finish Product
Total 6725 kg 6725 kg
Diazotization
Diazo Reaction
Vessel
I Coupling
Reaction Vessel
Reverse Osmosis
Unit
Spray Drying Unit
28
2. ACID DYES [ANTHRAQUINONES / CONDENSED]
DM / Process water OR Solvent like ODCB / Xylene is taken in Reaction vessel. Then require
quantity of Anthraquinones/ Or Other R.M. as mentioned in Raw Material list Annexure (A) is
added & mass is further condensed to complete the reaction. Solvent is recovered for re-use
Now the mass is eighter directly converted in Liquid for by formulating to Dispatch as A
Liquid Dyes OR if powder require, mass is filtered, Washed. Filtrate & washing is send to ETP
for further treatment. & press cake is directly straightway Spray Dried to dispatch as a Powder
form.
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN KGS
Solvent 2500kg
A.Q /R.M. 600kg
Amines /
Condn Product 500 kg
Alkali / Acid 75 kg 2375 kg Solvent Recovery for
reuse
4000 kg ML to ETP
Water for washing 4000 kg 1300 kg Press cake
Water 500kg 1000 kg Water evaporation in
Press Cake 1300 kg Spray drying
Auxiliaries 200Kg 1000 kg Finish Product
Total 9675 kg 9675 kg
Condensation
Reaction Vessel
Filter Press/
R.O.Unit
Spray Drying Unit
Solvent Recovery
System
29
3. ACID DYES [METAL COMPLEX]
Mono/tetra azo mass/ Condensed mass is further Metalized in require parameters with
Require Metals products as mentioned in Raw Material list Annexure (A)
Now the mass is eighter directly converted in Liquid For by concentrating in Reverse Osmosis
Unit & standardization to Dispatch as A Liquid Dyes OR if powder require, it is directly
straightway Spray Dried to dispatch as a Powder form. R.O.Permite is send to ETP for further
treatment.
FLOW CHART & MATERIAL BALANCE:
Metallization:
INPUT IN KGS OUTPUT IN KGS
Mono /Tetra Azo 2225kg
Water 500 kg
Metal 100 kg
Alkalies / Acids 75 kg
1600 kg ML to ETP
Water 500kg 1300 Press Cake
Auxiliaries 200kg 1000 kg Water
Press Cake 1300Kg evaporation in Spray
Drying 1000 kg Finish product
Total 4900 kg 4900 kg
Reaction Vessel
Filter Press / Reverse
Osmosis Unit
Spray Drying Unit
30
4.BASIC DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of
Amines as mentioned in Raw Material list Annexure (A) is charged. Then required
quantity of HCL is added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C.
Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I. paper
slightly positive now diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken &
required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.
Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly
received keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction
& directly spray dried and dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 1500 kg
Amines 200 kg
Acid 400 kg
ICE 1000 kg
Sodium Nitrite 100kg
Water 700 kg
Coupler 250 kg
Alkali / Acid 75 kg
32 25 kg water evaporation in
Spray drying
1000 kg Finish Product
Total 4225 kg 4225 kg
Diazotization
Diazo Reaction
Vessel
I Coupling
Reaction Vessel
Spray Dryer
31
5.BASIC DYES [ANTHRAQUINONES / CONDENSED]
In a Reaction vessel, require quantity of acetic anhydride is taken .Then require Aldehydes is
added & condensing 2 or 3 more compounds R.M. as mentioned in Raw Material list Annexure
(A) is added & mass is further condensed to complete the reaction. Then reaction mass is
diluted & standardize with acetic acid & water. Now the mass is directly converted in Liquid for
by formulating to Dispatch as A Liquid Dyes .
In This Process No any filtration, washing carried out hence effluent is Zero
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN KGS
Acetic Anhydride 300kg
Aldehydes. 150kg
R.M.-1 150kg
Condn Product 100 kg
Acetic Acid 150 kg
Water 150kg No any Effluent
1000 kg Finish Product
Total 1000 kg 1000 kg
Condensation
Reaction Vessel
Clarifier
32
6. DIRECT DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines
as mentioned in Raw Material list Annexure (A) is charged. Then required quantity of HCL is
added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium Nitrite
is slowly added keeping Congo red paper positive & S.I. paper slightly positive now diazo is
ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken &
Required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.
Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received 3
keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for
further treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if
powder require, it is directly straightway Spray Dried to dispatch as a Powder form.
4. Tetrazo:
For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5
Deg.C temperature & coupling with required further coupler products as mentioned in
Raw Material list Annexure (A) in require parameters.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for
further treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if
powder require, it is directly straightway Spray Dried to dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 800 kg
Amines 150 kg
Acid 200 kg
ICE 1000 kg
Sodium Nitrite 50kg
Cold Water Wash 1000 kg 2000 kg ML to ETP
1200 kg Press cake
Water 500 kg
Press Cake 1200 kg
Couplers 100kgs
ICE 500 kg
700 kg water recycled to first stage
Auxiliaries’
For STD 200Kg 1800 kg Finish Product
Total 5700 kg 5700 kg
Diazotization
Diazo Reaction
Vessel
Reverse Osmosis
Unit
Standardization
Filter press
I Coupling
Reaction Vessel
33
7.DIRECT DYES [CONDENSED]
In a Reaction vessel, require quantity of Water is taken .Then require quantity of Monoazo /
condendn / CPC suphonated mass is added & amine / di-/tri-chlorinated R.M. as mentioned
in Raw Material list Annexure (A) is added & mass is further condensed to complete the
reaction. Then reaction mass is diluted & standardize with Auxiliaries & water. Now the mass is
directly concentrating on Reverse Osmosis & formulating to Dispatch as A Liquid Dyes . Permit
of R.O. is send to ETP for further Treatment OR if powder require, it is directly straightway
Spray Dried to dispatch as a Powder form.
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN KGS
Water 1000kg
R.M. mass 175kg
R.M.-1 150kg
Condn Product 150 kg
Alkali 150 kg
Water 500kg
ICE 700kg
1000 kg ML to ETP
Auxiliaries 200kgs 1025kg Water Evaporation
1000 kg Finish Product
Total 3025 kg 3025 kg
Condensation
Reaction Vessel
Reverse Osmosis
/Filter Press
Spray Drying
34
8. DISPERSE DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines as
mentioned in Raw Material list Annexure (A) is charged. Then required quantities add Acid
[HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to form good suspension of
Hydrochloride. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium
Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly positive &stirred
for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken &
required quantity of coupler as mentioned in Raw Material list Annexure is added. Then little
quantity of eighter alkali or acid is added to make soluble & buffer to maintain coupling
condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received in 2-
3 hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.
Reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further
treatments
4. Grinding in Sand / Beed Mills / Homozinizer
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to
Dispatch as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to
dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 1000 kg
Amines 250 kg
Acid 400 kg
ICE 1000 kg
Sodium Nitrite 95kg
Water 500 kg
Coupler 275 kg
Alkali / Acid 150 kg
ICE 1000 kg
Water for Washing 4670 kg ML to ETP
2000 kg 2000 kg wet cake
Auxiliaries 400Kg
Press Cake 2000 kg
1400 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 9070 kg 9070 kg
Diazotization
Diazo Reaction
Vessel
I Coupling
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Sand Mills Unit
35
9.DISPERSE DYES [ANTHRAQUINONES / CONDENSED ]:
In suitable reaction vessel, require quantity water Or suitable solvent like Dimethyl Form
amide / Toluene / Xylene is taken .Then mono azo mass or condensing Product is condensed
with require condensed products as mentioned in raw material list Annexure (A) at require
parameters .After completion of condensation, Solvents are Distilled out for Re-Use &
remaining reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for
further treatments
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to
Dispatch as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to
dispatch as a Powder form
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Solvent 2000 kg
Amines 250 kg
A.Q.R.M.-1 400 kg
R.M.-2 100kg
R.M.-3 150 kg
1900kg Solvent recover for
reuse recycle
Water for Washing 3000 kg ML to ETP
3800 kg 1800 kg wet cake
Auxiliaries 400Kg
Press Cake 1800 kg
1200 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 8900 kg 8900 kg
Condensation
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Sand Mills Unit
Filtration &
Washing
36
10. DISPERSE DYES [CYANATION ]:
In a suitable reaction vessel require quantity water OR suitable Solvents like Dimethyl Form
amide / Methanol taken. Then mono azo OR AQ Product mass is charged & further
condensed with Sodium Cyanide. After Completion Of complete consumption of Sodium
Cyanide, Solvent is distilled out for Re-Use & reaction mass is filtered. ML is collected in
separate Vessel for Killing / Detoxification of traces cyanide with Sodium Bisulphite. Again it is
filtered. Ml is send to ETP for further treatment
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinisers. Now the mass is eighter directly converted in Liquid & standardization to
Dispatch as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to
dispatch as a Powder form
FLOW CHART WITH MATERIAL BALANCES [Cyanation]:
INPUT IN KGS
OUTPUT IN KGS
Solvent 1500 kg
Mono/R.M.Product 250 kg
Sodium Cyanide 200 kg
Water 750 kg
1425 kg solvent recycle
Water 500 kg
Sodium Bisulphite 250 kg
Alkali 150 Kg
1400 kg Wet cake
Water 1000kg Reslury
Wet Cake 1400kg
Water for Washing
2500 kg 775 kg ML to ETP
3300 kg ML to ETP
1600 kg wet cake for Sand
D.A Auxiliaries 200Kg mill
Press Cake 1600 kg
800 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 10300 kg 10300 kg
Reaction Vessel
Detoxification
Vessel
Sand Mills Unit
Spray drying Unit
Solvent recovery
system
Re-Slurry
Filter Press
Filter press Filter press
37
11. REACTIVE DYES [ AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines
as mentioned in Raw Material list Annexure(A) is charged. Then required quantity of HCL
is added. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium
Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly positive now
diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken &
Required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.
Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received
keeping temperature 5 to 10 Deg.C& is stirred to complete coupling reaction.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for
further treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if
powder require, it is directly straightway Spray Dried to dispatch as a Powder form.
4. Tetrazo:
For Tetrazo, Monoazo mass is diazotized as above with Acid & Sodium Nitrite at 0 to 5
Deg.C temperature & coupling with required further coupler products as mentioned in
Raw Material list Annexure (A) in require parameters.
Now the mass is concentrate in Reverse Osmosis Unit. R.O.Permite is send to ETP for
further treatment. Concentrate mass is standardize to Dispatch as A Liquid Dyes OR if
powder require, it is directly straightway Spray Dried to dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 800 kg
Amines 150 kg
Acid 200 kg
ICE 1000 kg
Sodium Nitrite 50kg
Cold Water Wash 1000 kg 20 kg Sludge
Water 500 kg
Press Cake 500 kg
Couplers 100kgs
ICE 500 kg
1000 kg Water To ETP
Auxiliaries’ 2980 kg water evaporation
For STD 200Kg 1000 kg Finish Product
Total 5000 kg 5000 kg
Diazotization
Diazo Reaction
Vessel
Reverse Osmosis
Unit
Standardization
Filter press
I Coupling
Reaction Vessel
38
12.REACTIVE DYES [CONDENSED/ BIFUNCTINAOL]
In a Reaction vessel, require quantity of Water is taken .Then require quantity of Monoazo /
condendn / CPC suphonated mass is added & amine / di-/tri-chlorinated R.M. as mentioned
in Raw Material list Annexure (A) is added & mass is further condensed to complete the
reaction.
Then reaction mass further condensed with Vinyl sulphone derivatives Or 2,3 Dibromo
propionyl Chloride & maintain reaction to complete the condensation .
Now the mass is directly concentrate on Reverse Osmosis & formulating to Dispatch as A
Liquid Dyes . Permit of R.O. is send to ETP for further Treatment OR if powder require, it is
directly straightway Spray Dried to dispatch as a Powder form.
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN
KGS
Water 1000kg
R.M. mass 200kg
R.M.-1 150kg
Condn Product 150 kg
Alkali 150 kg
Water 1000kg
ICE 1000kg
1000 kg ML to ETP
Auxiliaries’ 200kgs 1850 kg Water Evaporation
1000 kg Finish Product
Total 3850 kg Total 3850 kg
Condensation
Reaction Vessel
Reverse Osmosis
/Filter Press
Spray Drying
39
13.SOLVENT DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water OR suitable solvent charged in Reaction vessel. Then required
quantity of Amines as mentioned in Raw Material list Annexure (A) is charged. Then
required quantities add Acid [HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to
form good suspension of Hydrochloride. Now Crushed ICE is added to reduce temperature
0 to 5 Deg.C. Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I.
paper slightly positive &stirred for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken &
required quantity of coupler as mentioned in Raw Material list Annexure (A) is added.
Then little quantity of eighter alkali or acid is added to make soluble & buffer to maintain
coupling condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received
in 2-3 hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.
Reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further
treatments
Press cake is mixed with water Now the mass is eighter directly converted in Liquid &
standardization to Dispatch as A Liquid Dyes OR if powder require, it is directly
straightway Spray Dried to dispatch as a Powder form.
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 1000 kg/
OR Solvent 1000kg
Amines 275 kg
Acid 350 kg 950
ICE 1000 kg
Sodium Nitrite 75
Water 500 kg
Coupler 300 kg
ICE 500 kg
Water for Washing 3250 kg ML to ETP
2000 kg 1800 kg wet cake
Water 500kg
Press Cake 1800 kg
2300 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 9300 kg 9300 kg
Diazotization
Diazo Reaction
Vessel
Coupling
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Slurry making Unit
Solvent recovery
system
40
14.SOLVENT DYES [ANTHRAQUINONES / CONDENSED ]:
In suitable reaction vessel, require quantity water OR suitable solvent like ODCB / Dimethyl
Form amide / Toluene / Xylene is taken .Then mono azo mass or Anthraquinones derivatives
Product is added. Then condensed require Amines / condensed products as mentioned in
raw material list Annexure (A) at require parameters .After completion of condensation,
Solvents are Distilled out for Re-Use & remaining reaction mass is filtered, washed with
Water. Filtrate & Washing is send to ETP for further treatments
Press cake is mixed with water directly it is directly straightway Dried to dispatch as a
Powder form
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Solvent 2000 kg
Amines 250 kg
A.Q.R.M.-1 400 kg
R.M.-2 100kg
R.M.-3 150 kg
1900kg Solvent recover for re-
use recycle
Water for Washing 3000 kg ML to ETP
3800 kg 1800 kg wet cake
Auxiliaries 400Kg
Press Cake 1800 kg
1200 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 8900 kg 8900kg
Condensation
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Slurry making Unit
Solvent Recovery
System
41
15.PIGMENT DYES [AZO ]
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water OR suitable solvent charged in Reaction vessel. Then required
quantity of Amines as mentioned in Raw Material list Annexure (A) is charged. Then required
quantities add Acid [HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to form good
suspension of Hydrochloride. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C.
Then Sodium Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly
positive &stirred for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken & required
quantity of coupler as mentioned in Raw Material list Annexure (A) is added. Then little
quantity of eighter alkali or acid is added to make soluble & buffer to maintain coupling
condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received in 2-3
hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.
Reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further
treatments Press cake is mixed with water directly it is directly straightway Dried to dispatch
as a Powder form
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 1000 kg/
OR Solvent 1000kg
Amines 275 kg
Acid 350 kg
ICE 1000 kg
Sodium Nitrite 75 950 kg Solvent recover for
reuse recycle
Water 500 kg
Coupler 300 kg
ICE 500 kg
Water for Washing 4450 kg ML to ETP
2200 kg 1800 kg wet cake
Water 500kg
Press Cake 1800 kg
1300 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 9500 kg 9500kg
Diazotization
Diazo Reaction
Vessel
Coupling
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Slurry making Unit
Solvent Recovery
System
42
16.PIGMENT DYES [ANTHRAQUINONES / CONDENSED ]:
In suitable reaction vessel, require quantity water OR suitable solvent like ODCB / Dimethyl
Form amide / Toluene / Xylene is taken .Then mono azo mass or Anthraquinones derivatives
Product is added. Then condensed require Amines / condensed products as mentioned in raw
material list Annexure (A) at require parameters .After completion of condensation, Solvents are
Distilled out for Re-Use & remaining reaction mass is filtered, washed with Water. Filtrate &
Washing is send to ETP for further treatments
Press cake is mixed with water directly it is directly straightway Dried to dispatch as a
Powder form
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Solvent 2000 kg
Amines 250 kg
A.Q.R.M.-1 400 kg
R.M.-2 100kg
R.M.-3 150 kg
1900 kg Solvent recover for re-
use recycle
Water for Washing 3200 kg ML to ETP
3800 kg 1600 kg wet cake
Auxiliaries 400Kg
Press Cake 1600 kg
1000 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 8700 kg 8700kg
Condensation
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Slurry making Unit
Solvent
Recovery
System
43
17.OPTICAL BRIGHTENERS ,CARBONLESS PAPER DYES /STAINS [ WATER BASE ]:
In a suitable reaction vessel, require quantity of DM /process water is taken .Then require
quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned in Raw Material list
Annexure (A) is react with amines / cyanuric chloride.
Then condensed mass is further condensed with aniline derivatives as mentioned in Raw
Material list Annexure (A).
Then reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further
treatments
Press cake is mixed with water directly it is directly straightway Dried to dispatch as a Powder
form
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN KGS
Water 1000kg
R.M. mass 250kg
R.M.-1 250kg
Condn Product 300 kg
Alkali 150 kg
Water 1000kg
ICE 1000kg
2000 kg ML to ETP
Water washing 1000kg
Water ’ 1000kgs 2950kg Water Evaporation
1000 kg Finish Product
Total 5950 kg Total 5950 kg
Condensation
Reaction Vessel
Filter Press
Spray Drying
44
18.OPTICAL BRIGHTENERS ,CARBONLESS PAPER DYES /STAINS [ SOLVENT BASE ]:
In a suitable reaction vessel, require quantity of Solvent like ODCB / Xylene / Toluene is tis taken
.Then require quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned in
Raw Material list Annexure (A) is react with amines / Aldehydes as mentioned in Raw Material
list Annexure (A).
Then condensed mass is further condensed with aniline derivatives as mentioned in Raw
Material list Annexure (A). After completion Of reaction, Solvent is distilled out for Re-Use.
Then reaction mass is isolated in methanol / Acetone. Then isolated mass is filtered. Filtetrate is
collected & used Methanol / Acetone is distilled out for Re-Use .
The Press cake is washed with hot Water. Washing is send to ETP for further treatments
Press cake is mixed with water directly it is directly straightway dried to dispatch as a Powder
form
FLOW CHART & MATERIAL BALANCE:
Condensation:
INPUT IN KGS OUTPUT IN KGS
Solvent 2000kg 1900kg Solvet Re-Use
Sulphonic Acids 350kg
Amine/Aldehyde 300kg
Aniline comp. 300 kg
Alkali 50 kg
Methanol 1000kg 950kg Methanol Re-Use
Water Washing 1600kgs
1550 kg ML to ETP
200kg Water Evaporation
1000 kg Finish Product
Total 5600 kg Total 5600 kg
Condensation
Reaction
Vessel
Drying
Solvent recovery
system
Filter Press
Solvent recovery
system
45
19. VAT & SOLUBLE DYES:
In a suitable reaction vessel, require quantity of Solvent like ODCB / Xylene / Toluene is
taken .Then require quantity of Naphthalene/ benzene sulphonic acid derivatives as mentioned
in Raw Material list Annexure (A) is react with amines / Aldehydes as mentioned in Raw
Material list Annexure (A). Then reaction mass is maintained till completion Of reaction, Then
Solvent is distilled out for Re-Use
Then reaction mass is isolated in Water. Then isolated mass is filtered. Filtetrate is
collected
The Press cake is washed with hot Water. Washing is send to ETP for further treatments
Press cake is mixed with water directly it is directly straightway dried to dispatch as a
Powder form OR Used to make soluble vat dyes as follows
In a suitable reaction vessel required quantity of Pyridine is taken .Then required quantity
of chlorosulphonic acid is slowly added. Then parent dry vat powder is added. Then metal
powder is added to reduce vat powder. After completion of reaction, mass is drowned in Ice &
neutralized by c.s.lye.
Pyridine is distilled out for re-use & mass is extracted in water& filtered. Sludge is Sold to
authorized vender & Filtrate is isolated with salt, again filtered .ML send to ETP& press cake
dried, Standardize to finish product
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Solvent 2000kg 1900kg Solvet Re-Use
Sulphonic Acids 350kg
Amine/Aldehyde 300kg
Aniline comp. 300 kg
Alkali 50 kg 2200 kg ML to ETP
Water 1000kg 1500kg Drying loss
400kg vat output
Water Washing’ 2000kgs
Pyridine 1200 kg 1140kg Pyridine Recycle
Parent Vat 400 kg
Chloro S.Acid 350kg
Metal Powder 200kg
ICE 3000Kg
C.S. Lye 500kg
Water 2000kg
Salt 300kg 200kg sludge
2710 kg ML to ETP
2900kg drying loss
1000kg finish Product
Condensation
Reaction
Vessel
Solvent recovery
system
Filter Press
Dryer
Neutralization
Reaction Vessel
Filtration
Extraction &
Isolation
Pyridine Recovery
for Reuse
Drying &
Standardization
Filtration
Total 13950kg Total 13950kg
46
20. INTERMEDIATES [AGROCHEMICAL & DYESTUFFS]
i) 2,3DIBROMO PROPIONYL CHLORIDE:
In a Glasslinned Reaction Vessel required quantity of Water added, then required quantity Of
Acrylic Acid is added. Then required quantity of Liquid Bromine is added & it stirr for 14 Hrs,
Then required quantity of Thionyl chloride is charged & reaction mass is heated. Vapours are
scrubbed in effective scrubbing system. Then Product is distilled out & used. There is no effluent
except scrubbing system.
In This Process, there is no any Filtration, decantation, Washing. So There is No Any Effluent
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Chlorination & Bromination
Acrylic Acid Thionyl Chloride
C3H4O2 + SOCI2
Chlorination
Step-I Product
C3H3OCI + SO2 + HCI
M.W. 126 119 M.W.90.5 64 36.5
Step-I Product Liquid Bromine
C3H3OCI + Br2
Bromination
2,3-DBPC
C3H3Br2CI
90.5 160 250.5
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Water 400kg
Acrylic Acid 350kg 50gs vapors scrubbed
Liquid Bromine 400 kg
Thionyl Chloride 400kg
200kg Intercut Re-cycled
Distillation 1200kg [1000kg real]
83% purity finish Product
Total 1550kg Total 1550kg
Glass-linned
Reaction Vessel
Effective
Scrubbing
System
47
ii) 2,6DIBROMO PARA TOLUIDINE:
In a Tile-lining reaction vessel, required quantity of water is taken .Then required quantity
of Para toluidine is charged & it is stirred. Now required quantity of liquid bromine is charged &
mass is heated up to 50deg.C to complete the reaction.
Then reaction mass is filtered.ML is sent to ETP for further treatment. & press cake is
washed by water & aired. Wet cake is directly used for further reaction OR Sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Bromination
Para Toluidine Bromine
C7H9N + Br2
Bromination
2,6 DBPT
C7H7N.Br2 + H2
M.W. 107 160 M.W.265 2
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Water 660kg
Para Toludine 528 kg 33 kg vapors scrubbed
Liquid Bromine 264 kg
Water washing 1320 kg 1239 kg ML to ETP
1520 kg Finish
Product
Total 2772 kg Total 2772 kg
Tile-linned
Reaction Vessel
Effective
Scrubbing
System
Filter Press
48
iii) MDEAMS [ META-DIETHYLAMINO,METHYL-SULFONAMIDE]:
In a Glass-lining reaction vessel, required quantity of Toluene is taken .Then required
quantity of MNA [Meta Nitro Aniline] is charged & it is stirred. Now required quantity of Methyl
Sulphonyl chloride is charged & mass is heated up to 50deg.C to complete the reaction.Toulene
is distilled out for re-use water is added. Then reaction mass is filtered.ML is sent to ETP for
further treatment. & press cake is charged in same vessel. Then required quantity of Acetic Acid
is added & Metal powder is added to reduce it .Now mass is filtered & ML is isolated by cooling.
Then isolated mass is filtered & Wet cake is condensed with Diethyl Sulphate in same reaction.
Then Mass is Filtered & wet cake is used for further process or sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Methylation
M-Nitro aniline Methyl Sulphonyl
Chloride
C6H6O2N2 + CH3SO2CI
Chlorination
Step-I Product
C7H8O4N2S + + HCI
M.W. 138114.5 Tolenen M.W.216 36.5
Reduction
Step-I Product + Iron Powder
C7H8O4N2S + H2
Reduction
Step-2
C7H10O2 N2S + O2
216 2 HCI 186 32
Condensation
Step-2 DES
C7H10O2 N2S + [C2H5]2SO4
Condensation
MDEAMS
C11H18O2 N2S H2SO4
186 154 242 98
Flow Chart & Material Balance:-
INPUT IN KGS OUTPUT IN KGS
Step-1
Toulene 1000kg
MNA 725kg 950kgs Toluene Recycled
MSC 375 kg
Water 800kg
Water washing 750kg 1500 kg ML to ETP
1200 kg Press cake use for next step
Total 3650kg Total 3650 kg
Tile-lined Reaction
Vessel
Filter Press
49
Step-2
Press cake 1200kg
Acetic Acid 300kg
Metal Powder 80kg
Water 750kg 2230kg Liquid taken for isolation for
next step
100kg sludge
Total 2330kg Total 2330kg
Step-3
2230 kg ML for Isolation
1300kg Press cake used for
Condensation
. 930kg ML to ETP
Total 2230kg Total 2230kg
Step-4
DES 350kg
Water 1300kg
1500kg Finish Water for Washing 500kg
Product
650 kg ML to ETP
Total 2150kg Total 2150kg
Tile-lined Reaction
Vessel
Filter Press
Tile-lined Reaction
Vessel
Filter Press
Filter Press
Tile-lined Reaction
Vessel
50
iv) MDPAMS [ META-DIETHYLAMINO,METHYL-SULFONAMIDE]:
In a Glass-lining reaction vessel, required quantity of Toluene is taken .Then required
quantity of MNA [Meta Nitro Aniline] is charged & it is stirred. Now required quantity of Methyl
Sulphonyl chloride is charged & mass is heated up to 50deg.C to complete the reaction.Toulene
is distilled out for re-use water is added. Then reaction mass is filtered.ML is sent to ETP for
further treatment. & press cake is charged in same vessel. Then required quantity of Acetic Acid
is added & Metal powder is added to reduce it .Now mass is filtered & ML is isolated by cooling.
Then isolated mass is filtered & Wet cake is condensed with Dipropyl Sulphate in same reaction.
Then Mass is Filtered & wet cake is used for further process or sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Methylation
M-Nitro aniline Methyl Sulphonyl
Chloride
C6H6O2N2 + CH3SO2CI
Chlorination
Step-I Product
C7H8O4N2S + + HCI
M.W. 138 114.5 Tolenen M.W.216 36.5
Reduction
Step-I Product + Iron Powder
C7H8O4N2S + H2
Reduction
Step-2
C7H10O2 N2S + O2
216 2 HCI 186 32
Condensation
Step-2 DPS
C7H10O2 N2S + [C3H7]2SO4
Condensation
MDEAMS
C13H22O2 N2S H2SO4
186 182 270 98
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Step-1
Toulene 1000kg
MNA 725kg 950kgs Toluene Recycled
MSC 375 kg
Water 800kg
Water washing 750kg 1520kg ML to ETP
1200 kg Press cake use for next step
Total 3650 kg Total 3650 kg
Step-2
Press cake 1200kg
Acetic Acid 300kg
Metal Powder 80kg
Water 750kg 2230kg Liquid taken for isolation for
next step
100kg sludge
Tile-lined Reaction
Vessel
Filter Press
Tile-lined Reaction Vessel
Filter Press
51
Total 2330kg Total 2330kg
Step-3
2330 kg ML for Isolation
1300kg Press cake used for
Condensation
. 1030kg ML to ETP
Total 2330kg Total 2330kg
Step-4
DPS 350kg
Water 1000kg
1500kg [67%] 1000 kg real Finish
Water for Washing500kg Product
350 kg ML to ETP
Total 1850kg Total 1850kg
Tile-lined Reaction Vessel
Filter Press
Filter Press
Tile-lined Reaction
Vessel
52
V). ETHYL BENZENE ANILINE [EBA]
I a SS316 reaction vessel, required quantity of Mono ethyl aniline is taken. Then required
quantity of Benzoyl Chloride is added at alkaline condition. Then Mass is heated & maintain till
completion of reaction,& Product is distilled out .Residual sludge is sold as authorized vendor.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
MEA Benzoyl Chloride
C8H11N + C7H7CI
Benzoylation
EBA
C15H17N + HCI
M.W. 121 126.5 M.W. 211 26.5
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN
KGS
MEA 600kg
Alkaly 150kg 50gs vapors scrubbed
Benzoyl Chloride 450 kg
100kg Intercut Re-
cycled
Distillation 1050kg [1000kg real]
Total 1200kg Total 1200kg
Galss-linned
Reaction Vessel
Effective
Scrubbing
System
53
VI). VARIOUS ALDEHYDES:
In a Glass lined reaction vessel required quantity of Dimethyl Formamide is added.
Then required quantity of aniline derivatives as mentioned in Raw Material list Annexure (A)
taken. Now required quantity of Phosphorus Trichloride is slowly added & maintains to complete
the reaction. Then reaction mass is dumped in Ice & isolated by alkali. Then mass is filtered &
press cake is dehydrate & used for further process OR sale out.ML is send to ETP for further
process.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
DMF + POCI 3 +EBA + NaOH + H2O
C3H7NOC15H17N
EBA Aldehydes
C16H17NO+PO2CI2 + HCI+CH3COONa.NH + 4H
M.W. 73 +153.5 + 211+ 40 + 18 M.W. 23913436.5 + 82 + 4
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
DMF 600kg
Aniline derivatives 600kg
POCL3 200 kg
540 kg DMF Recycle
ICE 1000 kg
Water 1000 kg
Alkali 200kg
1260 kg ML to ETP
1800 kg Press cake use to
Di-hydration
1000kg Finish Product
Press cake 1800kg 800 kg drying loss
Total 5400 kg 5400 kg
SS316 Reaction Vessel
Dumping /
Quenching vessel
Effective Scrubbing
System
Filtration &
Washing
De-Hydration
54
VII). BDSA & OBSA:
In a SS316 reaction vessel required quantity of water taken. Then required quantity of
Di-Chloro benzaldehyde OR Ortho Chloro benzaldehyde is added. Then required quantity of
Sodium B-Sulphite is added. Now reaction is maintained to complete the reaction. Then
reaction mass is is neutralized by soda ash & isolated by spent acid .Then mass is filtered & press
cake is used for further process OR sale out.ML is send to ETP for further process.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
DCB+ 2[NaHSO3]
C7H4CI2O C10H15N
BDSA
C7H6S2O7 + 2 [NaCI ]
M.W.175 + 208 M.W. 266 + 117
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Water 1000kg
DCB /OCA 600kg
Sodium Bi sulphite 200 kg
Alkali 150kg
Spent Acid 450kg
1100 kg ML to ETP
1300 kg [77%] 1000kg Finish
Total 2400 kg 2400 kg
SS316 Reaction Vessel
Filtration
55
VIII). N-VALERIC CHLORIDE :
In a Glass lined reaction vessel required quantity of n-Valeric Acid is charged . Then
required quantity of Thionyl chloride is slowly added.. Now reaction is maintained to complete
the reaction. Then reaction mass is distilled out & directly use for further process. There is no
ML in effluent except scrubbing system.
In This Process, there is no any Filtration, decantation, Washing. So There is No Any
Effluent
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Chlorination
Valeric Acid Thionyl Chloride
C5H10O2 + SOCI2
Chlorination
Step-I Product
C5H9OCI + SO2 + HCI
M.W. 102 119 M.W.120.5 64 36.5
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
n-Valeric Acid 900kg 50 kg vapour loss in scrubbing system
Thionyl Chloride 350kg 1100kg [91%]=1000kg real finish mass
100kg intercut recycled
Total 1250 kg 1250 kg
SS316 Reaction Vessel
56
IX). DICHLORO ACETO /VALERO PHENONES
In a Glass lined reaction vessel, require quantity of Meta Dichloro benzene is taken .Then
required quantity of aluminum chloride is added .Now required quantity of Acetyl / Valeric
Chloride is slowly added. Then reaction mass is heated & maintain to completion of reaction
Then it is dumped in ICE & aqueous layer is separated & send to ETP for further treatment.
Organic layer is distilled out .Intercut is recycled in next batch & Main product is used for further
process OR Sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Valeric ChlorideM-Dichloro Benzene
C5H10O2 + C6H4CI2
Ali.Chloride
2,4 Dichlrovalerophenone
C11H12OCI2 + H2O
M.W. 102 147 M.W.231 18
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
MDCB 700kg
Allumi. Chloride 100kg
Acetyl/ Valeric chloride 450kg
ICE 1000 kg 100 kg HCL Re-Use
Water 1000 kg 2000kg ML to ETP
100kg Intercut to re-use
1050kg [95%] 1000kg finish
Total 3250kg Total 3250kg
Glass linned Reactor
Dumping /
Quenching vessel
Effective HCL Recovery
Scrubbing System
Distillation
57
x). Dimethyl Sulphide:
In a SS316 reaction vessel, require quantity of water is taken. Then require quantity of Sodium
sulphide flakes is added & mass is stirred. Then require quantity of Dimethyl sulphate is slowly
added & reaction is maintained . Now reaction mass is heated & product get distilled out .Is is
collected & used for further process OR sale out..residual mass is send to ETP for further
treatment
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Potassium /Na,Sulphide DMS
2x K/Na2S + [CH3]2SO4
Dimethyl Sulphide
[CH3]2S + K/Na2SO4
M.W. 110 126 M.W. 62 284
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN
KGS
Water 800kg
Sodium Sulphide 700kg 1000kg finish product
Dimethyl sulphate 300 kg 800kg residual mass to
TSDF
Total 1800 kg Total 1800 kg
xi).DASA [4,4-Diamino Sulphonamide]:
Step-1:-
In MS reaction vessel, required quantity of Chlorosulphonic acid is taken. Then require
quantity of Acetanilide is charged.gas is scrubbed in HCL recovery system to recover HCI for re-
use. Reaction mass is dumped in ICE. & filtered on Press. ML is collected as a spent Acid for Re-
Use. Press cake is use in step-3
Step-2:-
In Tile linned rector, require quantity of water taken & require Para Nitro Aniline is
charged.
The HCI is charged & iron powder is added to reduce it as PPD.Now mass is clarified ML is used
in step-3.& Iron sludge sale-out to authorized customer.
Step-3
In Rubber-linned reactor, require quantity of step-2 ML is taken. Then Step-1 press cake
is charged to condense with each other. Then product is hydrolyzed with c.s.lye & isolated by
spent Acid. Then reaction mass is filtered. Ml send to ETP for further treatment & Press cake is
used for further process OR sale out.
SS316 Reactor
58
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Step-1
Acetanilide + C.S.Acid
C8H9ON CISO3H
Sulphonation
Sulpho mass
C8H8SNO3.CI + H2O
M.W.135 + 116.5 M.W. 233.5 + 18
Step-2
PNA + HCI + Fe
C6H6N2O2
Reduction
PPD + 2[H2O]
C6H8N2
138 108 36
Step-3
Sulpho mass PPD
C8H8SNO3.CI + C6H8N2
Condensation
Condensed mass
C14H15S.N3O3. + HCI
233.5 + 108 305 36.5
Step-4
Condensed mass + NaOH
C14H15S.N3O3
Hydrolysis
Isolation
DASA
C12H13N3O2 + CH3COOH + H2O
305 40 Spent acid 263 60 + 18
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Step-1
C.S. Acid 1000kg
Acetanilide 450kg
250kg HCI re-use
ICE 2000kg
2400kg ML re-use as spent acid
800 kg Press cake use for step-3
Total 3450kg Total 3450kg
Step-2
Water 1000kg
PNA 300kg
HCL 150 kg
Metal Powder 150kg 1450kg Liquid taken for Condn for
Step-3
150kg sludge
Total 1600kg Total 1600kg
Tile-lined Reaction
Vessel
Filter Press
Tile-lined Reaction
Vessel
Clarifier
HCL recovery
system
Tile-lined Reaction Vessel
59
Step-3
Step-1 Product 800kg
Step-3 ML 1450 kg
C.S.Lye 250kg
Spent Acid 2400kg
1400kg finished product
3500kg ML to ETP
Total 4900kg Total 4900kg
Tile-lined Reaction
Vessel
Filter Press
60
xii). H-Acid:-
Step-1 Sulphonation:-
In Cast Iron reaction vessel, required quantity of Sulphuric acid & Oleum is taken. Then
require quantity of Naphthalene is charged. Reaction mass is heated up-to 170 Deg.C to
complete the reaction.SO2Gas is scrubbed in effective scrubbing system.
Step-2 Nitration:-
In SS316 reactor, required quantity is taken .Then sulpho mass is received from
sulphonator & mass is nitrated. Then mass is taken for neutralization.
Step-3 Neutralization & filtration:-
In Rubber- Tile/ Brick linned reactor, require quantity of step-2 mass is taken. Then
excess acid is neutralize with Lime stone to form Gypsum..It is then separate out by filtering on
vacuum nutch.Filtrate is taken for reduction step. Gypsum is sale out to authorized vendor.
Step-4 Reduction:-
Nitro mass from Step-3 is reduced in tile/ brick linned reaction vessel by iron powder &
HCL in warm condition & then is clarify to remove iron oxide.& clarified ml is concentrate .
Step-5 Hydrolysis:-
Concentrate mass from step is hydrolyzed with caustic soda in autoclave 6-7kg pressure
& at 170 Deg.C temp.after completion of reaction ,mass is transfer for isolation
Step-6 Isolation:-
Hydrolyzed mass is isolated by adding spent acid at 2 pH.It get precipitate. Then it is
filtered & washed to obtained press cake of H-Acid for use for further process to make dyestuffs
OR sale-out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Step-1
Naphthalene + H2SO4 + Oleum
C10H8
Sulphonation
Sulpho mass
C10H8[SO3]3 + 3 X [H2O]
M.W.128 + 98 M.W. 368 + 54
Step-2
Sulpho mass + HNO3
C10H8[SO3]3
Nitration
Nitro mass + H2O
C10H7[SO3]3 .NO2
368 63 413 18
Step-3
Nitro mass HCL+ Fe
C10H7[SO3]3 .NO2 +
Reduction
Koch Acid
C10H7[SO3]3.NH2. + O2
413 383 32
Step-4
Koch Acid + 3 X [NaOH]
C10H7[SO3]3 .NH2
Hydrolysis
Amino Mass
C10H4[SO3.Na]2.ONa + SO2 +3X[ H2O]
383 120 384 64 + 54
Step-5
Amino Mass + 3[ HCI]
C10H4[SO3.Na]2.ONa
Isolation
H-Acid
C10H4[SO3.Na]2.ONa 3X [ NaCI]
383 109.5 Spent acid 319 175.5
61
FLOW CHART & MATERIAL BALANCE FOR H- ACID :
INPUT IN KGS OUTPUT IN KGS
Step-1,2 & 3
Sulphuric Acid 1937kg
Oleum 2670kg
Naphthalene 910kg
Nitric Acid 965kg
1634 kg NOx/CO2/ water vapourloss
Water 2500kg
Limestone 3385kg
Glauber’Salt 3400kg
8133kg Gypsum
6000 kg Filtrate use for step-4
Total 15767kg Total 17267kg
Step-4
Nitro Mass 6000kg
HCL Spent 750 kg
lron Powder 650kg
Water for washing 3000kg 750kg Iron Oxide sludge
9650kg Amino ML for next step.
Total 10400kg Total 10400kg
Step-5,6
Amino Product 9650kg 7000kg water evopration
Caustic Soda 1500kg 570kg Methanol recovery
Methanol 680kg 1260kg water loss
Spent Acid 9500kg Spent 3500 kg
7000kg ML to ETP
Water for washing 4000kg
5000 Drying Loss
1000kg Finish Product
Total 25330kg Total 25330kg
Cast Iron Reaction
Vessel
Filter Press
Evaporation Reaction Vessel
Autoclave Reaction Vessel
Tile-lined Reaction Vessel
Clarifier
Effective
scrubbing system
SS/CI Reaction
Vessel
TL/Brick line
Neutralizer
Isolation Reaction Vessel
Isolation Reaction Vessel
Isolation Reaction Vessel
62
xiii).Vinyl Sulphone Esters:-
Step-1 Chlorosulphonation of Acetanilide:-
In a MS sulphonator, required quantity is taken & required quantity of acetanilide is
charged. Mass is heated up to 55 Deg.C & maintained 4-5 Hrs. Vapours converted in HCL in HCL
recovery system. Mass is dumped in ICE & filtered Filtrate is send in Spent Acid storage tank for
Re-use.& press cake is used in step-2
Step-2 Ehylation, Filtration, Drying & Pulverizing:-
In SS condensation, require quaintly of water taken,& Sodium Bisulphate is charged
.Then sulpho mass is charged & 7 pH is done by adding caustic .Then mass is condensed with
Ethylene Oxide keeping pH neutral by adding spent acid. Then mass is filtered. Press cake is
dried & use to make dyestuffs OR sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Step-1
Acetanilide + C.S.Acid
C8H9ON CISO3H
Sulphonation
Sulpho mass
C8H8SNO3.CI + H2O
M.W.135 + 116.5 M.W. 233.5 + 18
Step-2
Sulpho mass
C8H8SNO3.CI + 2x [NaOH] + NaHSO3
Neutralisation
Neutralized Mass
C8H9NO4.SNa + Na2SO4 + HCL
233.5 80 104 238 142 36.5
Step-3
Neutralized Mass + Ethylene Oxide
C8H9NO4.SNa CH2CH2O
Condensation
H2
Condensed mass
C10H14S.NO4. + NaOH
233.5 + 108 24440
Step-4
Condensed mass + H2SO4
C10H14S.NO4
Hydrolysis
Isolation
Vinyl Sulphone Ester
C8H11NO6S2 + CH3COOH + H2O
305 40 281 61 + 18
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Step-1
C.S. Acid 1600kg
Acetanilide 625kg
400kg HCI re-use
ICE 3000kg
4025kg ML re-use as spent acid
800 kg Press cake use for step-2
Total 5225kg Total 5225kg
Tile-lined Reaction
Vessel
Filter Press
HCL recovery
system
Tile-lined Reaction
Vessel
63
Step-2
Water 1500kg
Na Bisuphate 600kg
Step-1 Press cake 800kg
C.S.Lye 350kg
H2SO4 110kg
Ethylene Oxide 330kg 2000kg ML to ETP
690kg drying loss
1000kg Finish Product
Total 3690kg Total 3690kg
Tile-lined Reaction
Vessel
Filter Press
Clarifier
64
ivx). Schaeffer’s Acid:-
In a MS /CI sulphonator, require quantity of Sulphuric Acid is taken & beta Naphthol is
charged.
Now mass is allow to sulphonate. Then it is dumped in ICE & clarified .Then isolated by adding
salt Then filtered. ML is collected in spent acid storage for reuse.& press cake is use for making
dyestuffs OR Sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Beta Naphthol + Sulphuric Acid
C10H8O H2SO4
Sulphonation
Schaeffer’s Acid
C10H8O4S + H2O
M.W.144 + 98 M.W. 224 + 18
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Step-1
Sulphuric Acid 850kg
Beta naphthol 770kg
ICE 2500kg
Salt 400kg
3000kg ML re-use as spent acid
1520 kg Press cake of 66%
xx Real1000kg
Total 4520kg Total 4520kg
Tile-lined Reaction Vessel
Filter Press
Effective Scrubbing system
Tile-lined Reaction
Vessel
65
xv). Bronner’s Acid:-
In a CI autoclave liquor Ammonia is taken % Schaeffer’s acid is charged. Then mass is heated
up to 130 Deg.C at 6-7kg pressure. Then mass is drown in Water & isolated by spent acid then
filtered .Press cake is used to make dyestuffs OR sale out.
FLOW CHART & MATERIAL BALANCE & CHEMICAL REACTION:
Schaeffer’s Acid + Liquor
Ammonia
C10H8O4S NH3
Ammonination
Bronner’s Acid
C10H9NO3S + H2O
M.W.144 + 17 M.W. 223 + 18
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Step-1
Liquor Ammonia 1100kg
Schaeffer’s Acid 1100kg
Water 1500kg
Spent acid 800kg
3000kg ML re-use as spent acid
1500 kg product
Total 4500kg Total 4500kg
Tile-lined Reaction
Vessel
Filter Press
Tile-lined Reaction
Vessel
66
AUXILIARIES
SYNTHETICORGANIC Tanning Agent / Dispersing Agents
(Naphthalene, Phenol Melamine Sulphonated, Formaldehyde condensed Products )
Average Production of Following & Similar Type Other Dyes Products = 150 MT Per Month]: -
1.Naphthalene Base Dispersing / Tanning [ Syntans] Agents [ Powder ] Dytol DF / SNF / NBN
Manufacturing Process: -
1.Naphthalene is Sulphonated by 101% Sulphuric Acid [ 23% Oleum + H2SO4]
2.2 Mol of above Sulpho mass is condensed with Formaldehyde
3.Then Reaction mass is Neutralize by C.S. Lye
3. Then Water & Glauber’s Salt is Added for adjust viscosity.
4. Then Product is Spray dried .Then Directly Used to Dilution Or To Make Blend Product &
Finally
Packed.
5. In This Process, there is no any Filtration, decantation, Washing. So There is No Any
Effluent
Sulphonation
Naphthalene 101% Sulphuric
Acid
C10H8 + H2SO4
Sulphonation
Sulpho mass
C10H8SO3 + H2O
M.W. 128 98 M.W.208 18
Condensation
Sulpho mass + Formaldehyde
2X[ C10H8SO3 ] n [HCHO]n
Condensation
D.A. /T,A. / SNF/ NBN
[C21H16S2O6] + [H2O]n
M.W.416 30 [428]n
Raw Material Consumption & Mass Balance for One TON Product: -
Condensation, Solvent Recvery,Filtration ,Washing &-drying
Sulphuric Acid 156kg
Oleum 23% 432kg
Naphthalene 600kg
Formaldehyde 351kg
Water 975kg
C.S.Lye 550kg
Glauber’salt 200kg
ML in Effluent NIL
Water Evaporation
during Reaction 20kg
Water Evaporation
during Spray Drying 2244kg
Finish Product 1000kg
Total 3264kg Total 3264kg
67
2.Phenol Base Dispersing / Tanning [ Syntans] Agents [ Powder ] Dytol DA / SNF / DLL
Manufacturing Process: -
1.Phenol isReact with C.S. Lye to form Sodium Phenolate
2. Then it is condensed with Formaldehyde &Sulphonated withSodium Sulphite
3.Then Reaction mass is Neutralize by C.S. Lye
4. Then Water & Glauber’s Salt is Added for adjust viscosity.
5.Then Product is Spray dried .Then Directly Used to Dilution Or To Make Blend Product &
Finally
Packed.
6.Then Directly Packed
7.In This Process, there is no any Filtration, decantation, Washing . So There is No Any
Effluent
Condensation & Sulphonation
Phenol C.S.lye Formaldehyde Na,
Sulphite
n X [C6H6O] + n X[NaOH] + n X [CHCHO] + n X
[Na2SO3]
Condensation
Sulphonation
Sulpho mass
n X [C7H8O2Na2SO3] H2O
M.W. 94 40 32 126 M.W.250 18
Raw Material Consumption & Mass Balance for One TON Product: -
Condensation, Solvent Recvery,Filtration ,Washing &-drying
Sodium Sulphite 300kg
Phenol 540kg
Formaldehyde 652kg
Water 552kg
C.S.Lye 285kg
Glauber’salt 200kg
ML in Effluent NIL
Water Evaporation
during Reaction 20kg
Water Evaporation
during Spray Drying 1609kg
Finish Product 1000kg
Total 2629kg Total 2629kg
68
3.Melamine Base Dispersing / Tanning [ Syntans] Agents [ Powder] Dytol DA /DLL
Manufacturing Process: -
2. Melamine is condensed with Formaldehyde & Sulphonated with Sodium Sulphite
3.Then Reaction mass is Neutralize by C.S. Lye
4. Then Water & Glauber’s Salt is Added for adjust viscosity.
5.Then Product is Spray dried. Then Directly Used to Dilution Or To Make Blend Product &
Finally
Packed.
6.Then Directly Packed
7.In This Process, there is no any Filtration, decantation, Washing. So There is No Any
Effluent
Condensation & Sulphonation
Melamine Formaldehyde Na, Sulphite
n X [C6H6N6] + n X [CHCHO] + n X [Na2SO3]
Condensation
Sulphonation
Sulpho mass
n X [C7H8O2Na2SO3] NaSO3
M.W. 126 32 126 M.W.303 103
Raw Material Consumption & Mass Balance for One TON Product: -
Condensation, Solvent Recvery,Filtration ,Washing &-drying
Sodium Sulphite
383kg
Melamine 405kg
Formaldehyde
700kg
Water 462kg
C.S.Lye 50kg
Glauber’salt
200kg
ML in Effluent NIL
Water Evaporation
during Reaction
20kg
Water Evaporation
during Spray Drying
1180kg
Finish Product
1000kg
Total 2200kg Total 2200kg
69
CPC SULPHONATED
Sulphonation:[CPC ,Naphthalene, Phenol, Anthraquinones]
In a MS reaction vessel, require quantity of Sulphuric / Chlorosulphonic Acid/ Oleum is taken
.Then require of R.M.as mentioned in Raw Material list Annexure (A) is added .Then reaction
mass is heated & maintain to completion of reaction Then it is dumped in ICE & filtered &
washed .Filtrate is used as Spent Acid in Other products & washing is send to ETP for further
treatment. Press cake is used for further stage.
FLOW CHART & MATERIAL BALANCE:
INPUT IN KGS OUTPUT IN KGS
Acid 1200kg
Raw Material 600 kg
ICE 4000 kg 500 kg HCL Re-Use
Water 1000 kg
Water 5000 kg Spent Acid ML re -use
for washing 3000 kg 3000 kg ML to ETP
1300 kg Press cake use to
Further process
Total 9800 kg 9800 kg
Sulphonator
Dumping /
Quenching vessel
Effective HCL Recovery
Scrubbing System
Filtration &
Washing
70
ANNEXURE - IV
WATER CONSUMPTION
SR.
NO. SOURCES
WATER CONSUMPTION (KL/DAY)
EXISTING
PROPOSED
TOTAL
1 Domestic 15 20 35
2 Industrial
A Process 20 365 385
B Boiler - 70 70
C Cooling 5 60 65
D Washing - 10 10
E Scrubber - 10 10
F Ice Formation - 70 70
G Liq. Dyes
Formation -
80 80
TOTAL 40 685 725
WASTEWATER GENERATION
SR.
NO. SOURCES
WASTE WATER GENERATION (KL/DAY)
EXISTING
PROPOSED
TOTAL
1 Domestic 12 16 28
2 Industrial
A Process - 330 330
B Boiler - 5 5
C Cooling - 5 5
D Washing - 10 10
E Scrubber - 10 10
F Ice Formation - - -
G Liq. Dyes
Formation -
- -
TOTAL 12 376 388
71
WATER BALANCE DIAGRAM
Note: Only fresh water will be used for Ice Formation, Liq. Formulation & Domestic purpose.
72
ANNEXURE - V
(A) EFFLUENT TREATMENT PLANT (ZLD)
M/s. POLY CHEM INDUSTRIES shall have a ZLD Effluent treatment plant consisting of primary,
secondary, tertiary treatment and advance treatment units. The details of ETP are as follows.
STREAM I (Low COD & TDS Stream)
First all non-toxic and biodegradable streams (low & medium COD& TDS) of wastewater shall
pass through Screen Chamber (SC-01) where floating material shall be removed with help of
Screen (S-01). Then effluent shall be passed through Oil & Grease Removal Tank (OGRT-01).
Automatic mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and
grease from the wastewater to Oil & Grease Collection Tank (OGCT-01). Then effluent shall be
collected in Collection cum Equalization tank-1 (CET-01). Pipe grid is provided at bottom of the
CET-01 to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air
Blowers (1W+1 stand-by) shall supply air through to pipe grid.
Then after, equalized wastewater shall be pumped to Neutralization Tank-1 (NT-01) where the
continuous addition and stirring of Lime solution is done to maintain neutral pH of wastewater
from Lime Dosing Tanks (CDT-01) as per requirement by gravity. Then after, neutralized
wastewater shall go to Flash Mixer-1 (FM-01) by gravity. Alum and Polyelectrolyte shall be dosed
from Alum Dosing Tank (ADT-01) and Polyelectrolyte Dosing Tank (PEDT-01) respectively by
gravity into FM-1 to carry out coagulation by using a Flash Mixer. Then after, coagulated
wastewater shall be settled in Primary Clarifier (PCF-01). Clear supernatant from PCL shall be
passed in Aeration Tank (AT-01)
Here, biodegradation of organic matter of the wastewater shall be carried out by bacteria
(suspended growth) in the AT-01 and for that oxygen shall be supplied by 2 nos. of air blowers
(B-02) through diffusers. Air blowers also keep MLSS in suspension.
Then after, wastewater shall go to Secondary Clarifier-1 (SCL-01) from AT-1. Here, the suspended
solids shall be settled. Sludge shall be removed from bottom of SCL-01 and pumped to AT-1 to
maintain MLSS and excess activated sludge shall be sent to Sludge Sump (SS-01).
Clear supernatant from SCL-01 shall go to Aeration Tank-2 (AT-02). Here biodegradation of left out
organic matter of the wastewater shall be carried out by bacteria (suspended growth) and for that
oxygen shall be supplied by two nos. of blowers (B-03) with help of diffusers. Then after,
wastewater shall go to Secondary Clarifier-2 (SCL-02) from AT-2. Here, the suspended solids shall be
settled. Activated sludge shall be removed from bottom of SCL-02 and pumped to AT-02 to maintain
MLSS and remaining will be sent to SS. Nutrients will be added from NDTs to Aeration Tank-1& 2 for
growth of Bacteria. Clear effluent is the collected in of Intermediate Sump (IS-01) by gravity.
Thereafter, the wastewater shall be passed through Multi Grade Filter (MGF-01) to remove left
out TSS and Activated Carbon Filter (ACF-01) for final effluent polishing. After tertiary
treatment, effluent shall be collected in RO Feed Tank(ROFT-01) before treat in UF & RO
73
units.RO permeate shall be reuse in process. RO reject shall be collected in ME Feed Tank(MFT-
01) for further treatment.
Sludge settled in PCL-01 and excess sludge from SCL-01/02 & PTS-01 shall be collected in Sludge
Sump then sludge shall be pumped to Centrifuge (CFG-01) where, dewatering shall be carried
out before storage in HWSA and ultimate disposal to TSDF. Leachate from CFG and backwash
from MGF-01 and ACF-01 shall be collected in Drain Pit and pumped back to CET-01 for further
treatment.
STREAM II (High TDS stream)
All High TDS streams of wastewater shall be collected in Collection cum Equalization Tank-2
(CET-02). Pipe grid is provided at bottom of the CET-02 to keep all suspended solids in
suspension and to provide proper mixing. 2 nos. of Air Blowers (1W+1 stand-by) shall supply air
through to pipe grid. Then effluent shall be pumped to Neutralization Tank-2(NT-02) where
Lime shall be added from Lime Dosing tank. Then after, effluent shall have sent to Flash Mixer-2
(FM-2) where Alum and poly shall be added from ADT and PDT respectively. Then after,
coagulated wastewater shall be settled in Primary Tube Settler (PTS-01).
Clear effluent from PTS shall be collected in Holding Tank (HT-01) before pumped to strippers.
Effluent from stripper shall be then collected in MEE Feed Tank (MFT-01) where RO reject shall
be mixed. Then effluent shall be sent to Multiple Effect Evaporator (MEE-01) for further
treatment followed by Agitated Thin Film Dryer (ATFD-01) for solids dewatering. Condensate
from MEE shall reuse in washing and utilities and solids from ATFD-01 shall be collected and
stored in HWSA for disposal in TSDF.
SIZE OF TANKS (Stream I and Stream II)
S.N. Name of unit Size (m x m x m) No
.
MOC/ Remark
Stream I (Low COD & TDS Stream) 200 M3/D
1 Screen Chamber (SC-01) 2.5 x 1.0 x (0.05 +0.3 FB) 1 RCC M25+A/A Bk.
Lining
2 Oil & Grease Removal Tank
(OGRT-01)
3.5 x 1.0 x (1.0 LD +0.5
FB)
1 RCC M25+A/A Bk.
Lining
3 Oil & Grease Collection
Tank (OGRT-01)
1.4 x 1.5 x (0.9 LD +0.8FB) 1 RCC M25 + RCC
M25+A/A Bk. Lin.
4 Collection cum Equalization
Tank-1 (CET-01)
5.0 x4.0 x (2.5 LD+0.7 FB) 2 RCC M25+A/A Bk.
Lining
5 Neutralization Tank (NT-01) 1.5 x 1.5 x (3.0LD +0.5 FB) 1 RCC M25+A/A Bk.
Lining
6 Flash Mixer-1 (FM-01) 1.5 x 1.5 x (2.8 LD +0.7
FB)
1 RCC M25
7 Primary Clarifier (PCL-01) 4.6 dia x (3.0 SWD +0.5
FB)
1 RCC M25
8 Aeration Tank-1 (AT-01) 16 x 9.0 x (5.0 LD +0.5 FB) 1 RCC M25
9 Secondary Clarifier-1 (SCL- 5.0 dia x (3.0 SWD +0.5 1 RCC M25
74
01) FB)
10 Aeration Tank-2 (AT-02) 12.0 x 9.0 x (5.0 LD +0.5
FB)
1 RCC M25
11 Secondary Clarifier (SCL-
02)
4.5 dia x (3.0 SWD +0.5
FB)
1 RCC M25
12 Intermediate Sump (IS-01) 3.0 m x 3.0 m x (3.0 m +
0.5)
1 RCC M25
13 Multi Grade Filter(MGF-01) 10 m3/hr 1 MSEP/FRP
14 Activated Carbon Filter
(ACF-01)
10 m3/hr 1 MSEP/FRP
15 RO Feed Tank (ROFT-01) 7.0 x4.5 x (3.0 LD+0.5 FB) 1 RCC M25
16 UF Unit & RO Unit (two
stage)
200 M3/D 1 SS
17 Lime Dosing Tank (CDT-01) 1500 lit 1 HDPE
18 Alum Dosing Tank (ADT-01) 1000 lit 1 HDPE
19 Poly Dosing Tank (PDT-01) 1000 lit 1 HDPE
20 Nutrient Dosing Tank (NDT-
01)
1000 lit 2 HDPE
21 Sludge Sump (SS-01) 3.0 m x 3.0 m x (3.0 m +
0.5)
1 RCC M25
22 Centrifuge (CFG-01) 50 M3 / day 1 SS
Stream II (High TDS stream) 160 m3/D+ RO Reject 60 m3/D
23 Collection cum Equalisation
Tank-2 (CET-02)
5.0 x 3.0 x (3.0 LD+
0.5 FB)
2 RCC M25+A/A Bk.
Lining
24 Neutralization Tank (NT-01) 1.5 x 1.5 x (3.0LD +0.5
FB)
1 RCC M25+A/A Bk.
Lining
25 Flash Mixer-2 (FM-02) 1.5 x 1.5 x (2.8 LD+
0.7 FB)
1 RCC M25
26 Primary Tube Settler(PTS-
01)
3.0 x 2.4 x (2.0 LD+1.0
HB+ 0.5 FB)
1 RCC M25
27 Holding Tank (HT-01) 7.0 x 4.0 x (3.0 LD+
0.5 FB)
1 RCC M25
28 Strippers (ST-01) 160 M3/D 1 SS316
29 MEE Feed Tank (MFT-01) 7.0 x 5.2 x (3.0 LD+
0.5 FB)
1 RCC M25
30 Multi Effect Evaporator
(MEE-01) with Agitated
Thin Film Dryer (ATFD-01)
220 M3/D 1 SS316
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PCC = PLAIN CEMENT CONCRETE
PP = POLYPROPELENE
MSEP = MILD STEEL EPOXY PAINTED
SS = STAINLESS STEEL
75
BLOCK DIAGRAM FOR EFFLUENT TREATMENT PLANT
*NOTE: COMPANY WILL ADOPT THIS OPTION UNTIL THE CETP WILL BECOME OPERATIONAL.
76
(B) SEWAGE TREATMENT PLANT
TREATMENT SCHEME
First all non-toxic and biodegradable streams of sewage shall be passed through Screen
Chamber(SC-01) where Screen (S-01) is provided to remove floating material from sewage
manually. Then effluent shall be passed through Oil & Grease Removal Trap (OGRT-01) from
where floating O & G shall be removed from top manually. Then after, the sewage is collected in
Collection Tank (CT-01). Then sewage shall be pump to Moving Bed Bio-Reactor (MBBR) with
help of submersible pump (P-01).
In MBBR tank dissolved organics are removed with the help of bacteria in presence of oxygen
provided by blower (B-01) through diffused aeration system. MBBR tank is loaded with special
media which inhibits attached bacterial growth. Due to this attached growth the quantity of
sludge generation is very little and also the treatment is more effective in a very less retention
time. The biggest advantage of this system is it does not require recirculation of activated
sludge. This treated sewage shall be transferred to Tube Settler Tank (TST-01), where Sludge
settles in TST-01 shall be sludge is discarded in sludge drying beds (SDBs) for drying. Leachate
from SDBs is sent back to Collection tank for treatment and dry sludge is used as manure.
The treated sewage shall be then collect in Intermediate Sump (IS-01) where for disinfection of
sewage; Sodium Hypochlorite shall be added from Sodium Hypochlorite Dosing Tank with help
of Dosing Pump.
This treated water shall be pump to Dual Media filter (DMF-01) with help of Centrifugal pump
(P-02) to ensure total removal of suspended particles and for polishing treatment. Treated water
is then collected in Treated Water Sump (TWS-01) before used for irrigation.
77
SIZE OF TANKS
S.
N. Name of unit
Size (m x m x m)
L x B x (LD+FB) No. MOC/ Remark
1 Screen Chamber (SC-01) 1.5 m x 0.7 m
(0.05 m+0.5 FB)
1 RCC M25
2 Oil & grease removal tank
(OGRT-01)
2.5 m x 0.7 m
(0.05 m+0.7 FB)
1 RCC M25
4 Collection cum Equalization
Tank (CET-01)
3.0 m x2.5 m x
(2.0 m+0.9 FB)
1 RCC M25
5 Moving Beds Bio Reactor
(MBBR-01)
4.0 m x 3.0 m x
(3.5 m+1.0HB+0.3 FB)
1 MSEP
6 Tube Settle Tankr-1(TST-01) 2.0 m x1.7 m x
(2.0 m+1.0 HB+0.3 FB)
1 MSEP
7 Intermediate Sump (IS-01) 2.0 m x1.7 m x
(1.5 m+0.5 HB+0.3 FB)
1 MSEP
8 Dual Media Filter (DMF-01) 2 m3/hr 1 MSEP
9 Treated Water Sump (TWS-
01)
3.0 m x 2.5 m x
(2.5 m + 0.5)
1 RCC M25
10 Sludge Drying Beds (SDBs-
A/B)
2.5 m x 1.5 m
2 Brick Mas. With PCC
Bedding
11 Sodium hypochlorite dosing
tank (SHDT-01)
1000 Liter 1 HDPE
78
BLOCK DIAGRAM OF STP
79
ANNEXURE-VI
DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL
CAT.
NO.
HAZARDOUS
WASTE
PROPOSED
TOTAL
(MT/Month)
METHOD OF DISPOSAL
35.3 ETP Sludge 69 Collection, Storage, Transportation and Sent to TSDF site
for secured land filling
33.1 Discarded barrels/
containers/ liners
100
Nos./Month Collection, Storage, Transportation and Sent back to
supplier / to GPCB approved recycler
33.1 HDPE Bags 500
Nos./Month Collection, Storage, Transportation and Sent back to
supplier / to GPCB approved recycler
20.3 Distillation Residue 25 Collection, Storage, Transportation and sell to Cement
Industries for Co-processing or Disposal at Common
Incineration Site
5.1 Used Oil 0.5 Collection, Storage, Transportation and Sent to GPCB
approved recycler
26.1 Process Waste 60 Collection, Storage, Transportation and Sent to TSDF site
for secured land filling
26.1 Iron Sludge 338 Collection, Storage, Transportation and Disposal at
Nearest TSDF or sell to Cement Industries
26.1 Gypsum 3659 Collection, Storage, Transportation and Disposal at
Nearest TSDF or sell to Cement Industries
35.3 MEE Salt 60 Collection, Storage, Transportation and Sent to TSDF site
for secured land filling
26.3 HCl (32%) 180 Collection, Storage, Transportation and Reuse in Process
26.3 Sulphuric Acid 1850
Collection, Storage, Transportation and Reuse in H-Acid
(2300)
- CaCl2 2 Collection, Storage, Transportation and sell to
Pharmaceutical Industry, Food Industry, For the Water
Treatment & In Fabric Industries.
- K2CO3 7 Collection, Storage, Transportation and sell to Detergent
industries & Glass Industries.
- Sodium
Sulfite/Sodium Bi
sulfite
20 Collection, Storage, Transportation and sell to Pulp &
Paper Industries / Food Industries.
SOLID WASTE
1 Fly Ash 48 Collection, Storage, Transportation and sell to brick
manufacturer.
80
ANNEXURE-VII
DETAILS OF STACK AND VENTS
EXISTING
(A) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO HOT AIR GENERATOR
SOURCES OF GASESOUS EMISSIONS STACK
Fuel Used Coal – 15 MT / Day
Capacity 30 Lac Kcal/Hr
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 30 meters
Stack Diameter at the Top 0.5 m
Air Pollution Control System Bag Filter
(B) STACK ATTACHED TO PROCESS VENT-1 (SPRAY DRYER)
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-1
Type of Emissions Particulate matter
Permissible Limits 150 mg/Nm3
Stack Height 32 m
Air Pollution Control System Water scrubber
PROPOSED
(A) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO STEAM BOILER
SOURCES OF GASESOUS EMISSIONS STACK
Fuel Used Coal/Agrowaste – 15 MT/Day
Capacity 5 MT/Hr
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 30 meters
Stack Diameter at the Top 800 MM
Air Pollution Control System Multi Cyclone Separator, Bag filter & Scrubber
81
(B) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO THERMIC FLUID HEATER
SOURCES OF GASESOUS EMISSIONS STACK
Fuel Used Oil – 20 Lit/ Hr
Capacity 2 Lac Kcal/Hr
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 30 meters
Stack Diameter at the Top 800
Air Pollution Control System Scrubber
(C) DETAILS OF FLUE GAS STACK; STACK ATTACHED TO D.G.SET
SOURCES OF GASESOUS EMISSIONS STACK
Fuel Used HSD = 100 Liter/Hr
Capacity 750 x 2 KVA
Type of Emissions SO2 NOx SPM
Permissible Limits 262 mg/Nm3 94 mg/Nm
3 150 mg/Nm
3
Stack Height 11 meters
Stack Diameter at the Top 0.2 meter
Air Pollution Control System --
(D) STACK ATTACHED TO PROCESS VENT-1 (SPRAY DRYER NO. - 2)
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-1
Type of Emissions Particulate matter
Permissible Limits 150 mg/Nm3
Stack Height 32 m
Air Pollution Control System Water scrubber
(E) STACK ATTACHED TO PROCESS VENT-2 (SPRAY DRYER NO. - 3)
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-1
Type of Emissions Particulate matter
Permissible Limits 150 mg/Nm3
Stack Height 32 m
Air Pollution Control System Water scrubber
82
(F)STACK ATTACHED TO PROCESS VENT-3
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-1
Type of Emissions HCl
Permissible Limits 20 mg/Nm3
Stack Height 15 meters
Stack Diameter at the Top 200 MM
Air Pollution Control System Two Stage scrubber
(G)STACK ATTACHED TO PROCESS VENT-4
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-2
Type of Emissions SO2
Permissible Limits 40 mg/Nm3
Stack Height 15 meters
Stack Diameter at the Top 200 MM
Air Pollution Control System Two Stage scrubber
(Water + Alkali)
(H)STACK ATTACHED TO PROCESS VENT-5
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-3
Type of Emissions NH3
Permissible Limits 175 mg/Nm3
Stack Height 15 meters
Stack Diameter at the Top 200 MM
Air Pollution Control System Two Stage scrubber
(Water + Acid)
(I) STACK ATTACHED TO PROCESS VENT-6
SOURCES OF PROCESS EMISSIONS VENT
Source of emission Process Vent-3
Type of Emissions HBr
Permissible Limits 5 mg/Nm3
Stack Height 15 meters
Stack Diameter at the Top 200 MM
Air Pollution Control System Two Stage scrubber
(Water + Alkali)
83
ANNEXURE-VIII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
SR.
NO
NAME OF THE MATERIAL TYPE OF
HAZARD
NUMER OF
TANKS
MAXIMUMA
QTY TO STORE
TANK STORAGE 1 ACETIC ACID CORROSIVE 25 KL X 1 25 KL
2 ACETIC ANHYDRIDE FLAMMABLE 25 KL X 1 25 KL
3 H2SO4 (98%) CORROSIVE 25 KL X 2 50 KL
4 OLEUM (23%) CORROSIVE 25 KL X 1 25 KL
5 OLEUM (65%) CORROSIVE 25 KL X 1 25 KL
6 CHLORO SULPHONIC ACID CORROSIVE 25 KL X 1 25 KL
7 NITRIC ACID CORROSIVE 25 KL X 1 25 KL
8 HCL CORROSIVE 25 KL X 1 25 KL
9 SPENT HCL (32%) CORROSIVE 25 KL X 1 25 KL
10 H2SO4 (70%) SPENT COOROSIVE 25 KL X 2 50 KL
11 C.S.LYE CORROSIVE 25 KL X 2 50 KL
12 METHANOL FLAMMABLE 25 KL X 1 25 KL
13 DIMETHYL FORMAMIDE FLAMMABLE 25 KL X 1 25 KL
14 XYLENE FLAMMABLE 25 KL X 1 25 KL
15 HEXANE FLAMMABLE 25 KL X 1 25 KL
DRUMS
1 SODIUM CYANIDE TOXIC 50 X 40 2 MT
2 TOLUENE FLAMMABLE 50 X 20 1 MT
CYLINDER 1 CHLORINE GAS TOXIC 1 TONN X 1 1 TONN
2 NITROGEN TOXIC 1 TONN X 1 1 TONN
3 AMMONIA GAS TOXIC 1 TONN X 1 1 TONN
84
ANNEXURE-IX
___________________________________________________________________________
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
The manpower requirement for the proposed project is being expected to generate some
permanent jobs and secondary jobs for the operation and maintenance of plant. This will
increase direct / indirect employment opportunities and ancillary business development to some
extent for the local population.
This phase is expected to create a beneficial impact on the local socio-economic environment.
2) INDUSTRIES
Required raw materials and skilled and unskilled laborers will be utilized maximum from the
local area. The increasing industrial activity will boost the commercial and economical status of
the locality, to some extent.
3) PUBLIC HEALTH
The company regularly examines, inspects and tests its emission from sources to make sure that
the emission is below the permissible limit. Hence, there will not be any significant change in the
status of sanitation and the community health of the area, as sufficient measures have been
taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
Since the existing factory is having proper linkage for the transport and communication, the
development of this project will not cause any additional impact.
In brief, as a result of the proposed project there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be taken
under the EMP. The proposed project is not expected to make any significant change in the
existing status of the socio - economic environment of this region.
85
ANNEXURE-X
___________________________________________________________________
PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Project location and Plant layout.
• Existing infrastructure facilities
• Water source and utilization including proposed water balance.
• List of Products and their capacity
• List of hazardous chemicals with their toxicity levels.
• Mass balance of each product along with the batch size
• Storage and Transportation of raw materials and products.
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5
km area.
• Study of Data from secondary sources.
• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.
For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in the
study area were surveyed.
4. Impacts Identification and Mitigatory Measures.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
86
6. Risk Assessment
• Details on storage facilities
• Identification of hazards
• Consequence analysis
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Occupational Health and Safety Program for the Project.