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1

PRE FEASIBILITY REPORT

For

PROPOSED DYES, DYE INTERMEDIATES &

AGROCHEMICAL INTERMEDIATES IN EXISTING DYE

FORMULATION UNIT

of

M/s. POLYCHEM INDUSTRIES

PLOT NO: C/387, 388, 389,

GIDC, SAYAKHA,

TAL: VAGARA, DIST: BHARUCH,

GUJARAT

2

CONTENTS

Sr. No. Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 24

3. Project Description 26

4. Site Analysis 31

5. Planning Brief 32

6. Proposed Infrastructure 33

7. Rehabilitation and resettlement (R & R) Plan 34

8. Project Schedule & Cost Estimates 34

9. Analysis of Proposal (Final Recommendations) 35

3

1.0 EXECUTIVE SUMMARY

1.1 COMPANY PROFILE

INTRODUCTION

• M/s Polychem Industries is a Greenfield project init iated by Mr. Dhawal

Bhatia, the project proponent.

• The proponent belongs to a well reputed and highly regarded trading group in Surat

(Gujarat) in the field of textile dyes and chemicals, known as Bhatia Chemicals. This

group has been around for more than 40 years now and is going stronger than ever

in terms of sales volumes and diversification of various verticals in the textile

industry. Another unit of this group has been involved in exports of dyestuff and

printing inks for more than 8 years and has recently achieved a target of Rs. 100

crores of annual export turnover.

• The project proponent, having close to 4 years of experience in this field has realized

the potential and the need for setting up own manufacturing unit due to the

bottlenecks of suppliers and issues with export worthy quality, timely availability

and growing concerns about restricted substances in the products among various

countries.

• Having covered almost every country having a textile base, this project is aimed at

giving a strong platform to the export activities of the group and competing with the

biggest MNCs in this industry.

VISION AND MOTIVATION:

• The proponent has primarily been motivated to initiate this project to reduce the

domestic consumers’ dependency on China for most consumed products. This will

help to improve the Balance of Trade to some extent in this sector.

• Undertaking research at the grassroot level and striving for continuous improvement

in processes and reducing pollution load, minimizing employment of traditional

methods and use of automation wherever necessary are some of the activities

envisioned by the promoter.

• The proponent believes in preserving the nature and has given prime priority to

allocate more coverage for greenbelt and is willing to take measures to conserve

and recycle water as much as possible.

4

1.2 PROJECT DETAILS

LIST OF PRODUCT

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

5

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


6. DIRECT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


200 MT/M 7. DIRECT DYES [CONDENSATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


8. DISPERSE DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


1000 MT/M

9. DISPERSE DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


10. DISPERSE DYES [CYANATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

6

E. Violet Dyes

F. Green Dyes


11. REACTIVE DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


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

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


13. SOLVENT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


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

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


15. PIGMENT DYES [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


75 MT/M

7

16. PIGMENT DYES [ANTHRAQUINONES/CONDENSED]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


17. OPTICAL BRIGHTENERS/ CARBONLESS PAPER DYES/

STAINS [AZO]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


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

STAINS [CONDENSATION]

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


19. VAT & SOLUBLE VAT DYES

A. Yellow Dyes

B. Orange Dyes

C. Red Dyes

D. Blue Dyes

E. Violet Dyes

F. Green Dyes


50 MT/M

20. INTERMEDIATES [AGROCHEMICALS & DYESTUFFS]

A. 2,3-Dibromopropionyl Chloride

B. 2,6-Dibromo Para-toluidine

C. MDEAMS

D. MDPAMS

E. EBA [Ethyl Benzene Aniline]

F. Aldehydes [ EBA,DEA, DEMAP]

G. OBSA / BDSA

H. 2,4-Dichloro Aceto / Valerophenone

I. Dimethyl Sulphide

450 MT/M

8

J. Valeryl Chloride

K. H-Acid

L. DASA

M. Vinyl Sulphone Ester

N. Schaeffer’s Acid

O. Bronner’s Acid

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

LIST OF RAW MATERIAL

SR.

NO.

RAW MATERIAL QUANTITY (MT/MT)

1.ACID DYES [AZO]

1. AMINES 0.20

2. HCl 0.40

3. ICE 2.50

4. SODIUM NITRITE 0.10

5. COUPLERS 0.25

6. ALKALIES/ACIDS 0.08

7. AUXILIARIES' FOR STD 0.20

2.ACID DYES [ANTHRAQUINONES / CONDENSED]

1. SOLVENTS 2.50

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

3. COND. PRODUCT 0.50

4. ALKALI/AIDS 0.08

5. AUXILIARIES 0.20

3.ACID DYES [METAL COMPLEX]

1. MONO/TETRA AZO 2.23

2. METALS 0.10


4. AUXILIERIES 0.20

4.BASIC DYES [AZO]

1. AMINES 0.20

2. ACID 0.40

9

3. ICE 2.00


5. COUPLERS 0.25


5.BASIC DYES [ANTHRAQUINONES / CONDENSED]

1. ACETIC ANHYDRIDE 0.30

2. ALDEHYDES 0.15

3. R.M.1 0.15

4. COND. PRODUCT 0.10

5. ACETIC ACID 0.15

6.DIRECT DYES [ AZO ]

1. AMINES 0.15

2. ACID 0.20

3. ICE 1.50


5. COUPLERS 0.10


7.DIRECT DYES [CONDENSATION]

1. R.M. MASS 0.18

2. R.M. 1 0.15

3. CONDN PRODUCT 0.15

4. ALKALI 0.15

5. ICE 0.70

6. AUXILIERIES 0.20

8.DISPERSE DYES [ AZO ]

1. AMINES 0.25

2. ACID 0.40

3. ICE 2.00


5. COUPLERS 0.28

6. ALKALI 2.15

7. AUXILIERIES 0.40

9.DISPERSE DYES [ ANTHRAQUINONES / CONDENSED]

1. SOLVENT 2.00

2. AMINES 0.25

3. A.Q.R.M 1 0.40

4. R.M.2 0.10

5. R.M.3 0.15

6. AUXILIARIES 0.40

10.DISPERSE DYES [ CYANATION ]

1. SOLVENT 1.50

2. MONO/R.M. PRODUCT 0.25

10

3. SODIUM CYANIDE 0.20

4. SODIUM BISULPHITE 0.25

5. ALKALI 0.15

6. WET CAKE 1.40

7. D.A AUXILIARIES 0.20

11.REACTIVE DYES [ AZO ]

1. AMINES 0.15

2. ACID 0.20

3. ICE 1.50


5. COUPLERS 0.10


12. REACTIVE DYES [ ANTHRAQUINONES / CONDENSED]

1. R.M. MASS 0.20

2. R.M. 1 0.15

3. CONDN PRODUCT 0.15

4. ALKALI 0.15

5. AUXILIERIES 0.20

6. ICE 1.00

13.SOLVENT DYES [ AZO ]

1. OR SOLVENT 1.00

2. AMINES 0.28

3. ACID 0.35

4. ICE 1.50


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 SOLVENT 1.00

2. AMINES 0.28

3. ACID 0.35

4. ICE 1.50


6. COUPLERS 0.30

16.PIGMENTS DYES [ ANTHRAQUINONES / CONDENSED]

1. SOLVENT 2.00

11

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

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

12

1. TOLUENE 1.00

2. MNA 0.73

3. MSC 0.38

4. ACETIC ACID 0.30

5. METAL POWDER 0.08

6. DES 0.35

D. MDPAMS

1. TOLUENE 0.67

2. MNA 0.48

3. MSC 0.25

4. ACETIC ACID 0.20


6. DPS 0.23

E. EBA [ETHYL BENZENE ANILINE]

1. MEA 0.60

2. ALKALY 0.15

3. BENZOYL CHLORIDE 0.45

F. ALDEHYDES [ EBA,DEA, DEMAP]

1. DMF 0.60

2. ANILINE DERIVATIVES 0.60

3. POCL3 0.20

4. ICE 1.00

5. ALKALI 0.20

G. OBSA / BDSA

1. DCB/OCA 0.46

2. SODIUM BI SULHITE 0.15

3. ALKALI 0.12

4. SPENT ACID 0.35

H. 2,4-DICHLORO ACETO / VALEROPHENONE

1. n-VALERIC ACID 0.90

2. THIONYL CHLORIDE 0.35

I. DIMETHYL SULPHIDE

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

13

3. ICE 1.43

4. PNA 0.21

5. HCL 0.11


7. C.S.LYE 0.18

8. SPENT ACID 1.71

L. DASA

1. H2SO4 1.94

2. OLEUM 2.67

3. NAPTHALENE 0.31

4. NITRIC ACID 0.97

5. LIMESTONE 3.39

6. GLAUBER'S SALT 3.40

7. HCL SPENT 0.75

8. IRON POWDER 0.65

9. CAUSTIC SODA 1.50

10. METHANOL 0.68

11. SPENT ACID 9.50

M. VINYL SULPHONE ESTER

1. C.S.ACID 1.06

2. ACETANILIDE 0.63

3. ICE 3.00

4. SODIUM BISULPHATE 0.60

5. C.S.LYE 0.35

6. H2SO4 0.11

7. ETHYLENE OXIDE 0.33

N. SCHAEFFER’S ACID

1. H2SO4 0.56

2. BETA NAPTHL 0.51

3. ICE 1.64

4. SALT 0.26

O. BRONNER’S ACID

1. LIQ AMMONIA 0.73

2. SCHAFFER'S ACID 0.73

3. SPENT ACID 0.53

21. AUXILIARIES

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

14


B. PHENOL SUPHONATED FORMALDEHYDE CONDENSATE

1. SODIUM SULPHITE 0.30

2. PHENOL 0.54


4. C.S.LYE 0.29


C. MELAMINE SUPHONATED FORMALDEHYDE CONDENSATE

1. SODIUM SULPHITE 0.38

2. MELAMINE 0.41


4. C.S.LYE 0.05


22. TURQUOISE CPC SUPHONATED & CONDENSED DYES

SULPHONATION

1. ACIDS 9.23

2. RAW MATERIAL 4.62

3. ICE 3.10

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

15

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

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

2 Methyl Pyridone HDPE Bags Powder

3 Fischer’s Base HDPE Bags Liquid

4 Gamma Acid HDPE Bags Powder

5 H Acid HDPE Bags Powder

6 J Acid HDPE Bags Powder

16

7 J Acid Urea HDPE Bags Powder

8 Laurent's Acid HDPE Bags Powder

9 MD-01 HDPE Bags Powder


11 MD-07 MS Drums Liquid





16 MD-3A HDPE Bags Powder

17 Mix Cleve's Acid HDPE Bags Powder

18 Mix Xylene MS Drums Liquid

19 Mix Xylidine MS Drums Liquid

20 MPDSA HDPE Bags Powder

21 OAPS Amide HDPE Bags Powder

22 OAPSA HDPE Bags Powder

23 Phenyl J Acid HDPE Bags Powder

24 PMP HDPE Bags Powder

25 R Salt HDPE Bags Powder

26 Resorcinol HDPE Bags Powder

27 Schaffer’s Acid HDPE Bags Powder

28 SPCP HDPE Bags Powder

29 Sulpho Para Base HDPE Bags Powder

30 Super Refined Salt HDPE Bags Powder

31 Tobias Acid HDPE Bags Powder

32 Meta Nitro Aniline HDPE Bags Powder

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

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

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

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

37

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

hydroxyethylamino)phenyl)acetamide HDPE Bags Powder

38

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

Acetanilide PP DRUMS Liquid

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

17

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

18

1.3 GREEN BELT DEVELOPMENT

Company will develop an effective green belt within the factory and on periphery of the

factory. Total Plot Area is 68459 m2, out of which 20654.92 m

2 (30%) will be provided as a

Green Belt Area. In addition to this, majority of the vacant land shall be planted with trees,

shrubs and grasses.

1.4 POWER & FUEL REQUIREMENT

Fuel:

SR.

NO.

FUEL QUANTITY USE

1 COAL (EXISTING) 10 MT/DAY HOT AIR GENERATOR

2 COAL/AGROWASTE

(PROPOSED)

20 MT/DAY HOT AIR GENERATOR (5 MT/DAY)

+

STEAM BOILER (15 MT/DAY)

3 HSD (PROPOSED) 100 L/Hr D.G.SET

4 OIL (PROPOSED) 20 L/Hr TFH

Energy:

2000 KVA from DGVCL

1500 KVA (750 KVA x 2 No.) FROM D.G.SET

1.5 Water Requirement and Wastewater Generation & Treatment

• Source of water is met through GIDC water supply. After expansion total water

requirement will be 725 KL/Day. 388 KL/Day effluents will be generated after the

expansion. Low COD stream (228 KL/Day) will be treated in proposed effluent

treatment consisting Primary, Secondary & Tertiary treatment & R.O. Permeate 140

KL/Day will be reused. High TDS Stream (160 KL/Day) will be treated in own MEE and

condensate will be reused.

• 28 KL/Day domestic wastewater generated will be treated in STP and treated water

will be reused for gardening.

19

WATER BALANCE:

20

1.6 AIR POLLUTION SOURCE AND CONTROL MANAGEMENT

The source of air pollution from the existing project & proposed expansion is summarized

bellow.

EXISTING

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

SOURCES OF GASESOUS EMISSIONS STACK

Fuel Used Coal – 15 MT / Day

Capacity 30 Lac Kcal/Hr

Type of Emissions SO2 NOx SPM

Permissible Limits 262 mg/Nm3 94 mg/Nm

3 150 mg/Nm

3

Stack Height 30 meters

Stack Diameter at the Top 0.5 m

Air Pollution Control System Bag Filter

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

SOURCES OF PROCESS EMISSIONS VENT

Source of emission Process Vent-1

Type of Emissions Particulate matter

Permissible Limits 150 mg/Nm3

Stack Height 32 m

Air Pollution Control System Water scrubber

PROPOSED

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


Fuel Used Coal/Agrowaste – 15 MT/Day

Capacity 5 MT/Hr



3 150 mg/Nm

3


Stack Diameter at the Top 800 MM

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

21

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


Fuel Used Oil – 20 Lit/ Hr

Capacity 2 Lac Kcal/Hr



3 150 mg/Nm

3


Stack Diameter at the Top 800

Air Pollution Control System Scrubber

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


Fuel Used HSD = 100 Liter/Hr

Capacity 750 x 2 KVA



3 150 mg/Nm

3


Stack Diameter at the Top 0.2 meter

Air Pollution Control System --

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





Stack Height 32 m


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





Stack Height 32 m


22

(F)STACK ATTACHED TO PROCESS VENT-3



Type of Emissions HCl




Air Pollution Control System Two Stage scrubber

(G)STACK ATTACHED TO PROCESS VENT-4



Type of Emissions SO2




Air Pollution Control System Two Stage scrubber(Water + Alkali)

(H)STACK ATTACHED TO PROCESS VENT-5



Type of Emissions NH3




Air Pollution Control System Two Stage scrubber (Water + Acid)

(I) STACK ATTACHED TO PROCESS VENT-6



Type of Emissions HBr




Air Pollution Control System Two Stage scrubber(Water + Alkali)

23

1.7 HAZARDOUS WASTE MANAGEMENT

CAT.

NO.

HAZARDOUS

WASTE

PROPOSED

TOTAL

(MT/Month)

METHOD OF DISPOSAL

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

for secured land filling

33.1 Discarded barrels/

containers/ liners

100

Nos./Month

Collection, Storage, Transportation and Sent back to

supplier / to GPCB approved recycler

33.1 HDPE Bags 500

Nos./Month

Collection, Storage, Transportation and Sent back to

supplier / to GPCB approved recycler

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

Industries for Co-processing or Disposal at Common

Incineration Site

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

approved recycler

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


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

Nearest TSDF or sell to Cement Industries

26.1 Gypsum 3659 Collection, Storage, Transportation and Disposal at

Nearest TSDF or sell to Cement Industries

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


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

26.3 Sulphuric Acid 1850

Collection, Storage, Transportation and Reuse in H-Acid

(2300)

- CaCl2 2 Collection, Storage, Transportation and sell to

Pharmaceutical Industry, Food Industry, For the Water

Treatment & In Fabric Industries.

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

industries & Glass Industries.

- Sodium

Sulfite/Sodium Bi

sulfite

20 Collection, Storage, Transportation and sell to Pulp &

Paper Industries / Food Industries.

SOLID WASTE

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

manufacturer.

24

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project and project proponent. In case of mining project, a copy

of mining lease/letter of intent should be given.

Identification of the project

Proposed expansion in existing Dye Formulation Plant

Identification of the project proponent

• Mr. Dhawal Bhatia

2.2 Brief description of nature of the Project

Proposed expansion in existing dye Plant.

2.3 Need for the project and its importance to the country and or region

The objective is to be achieved by:

• Consolidating Business.

• Continuously reducing the Costs & improving Quality.

• By constantly upgrading the product range.

2.4 Demands-Supply Gap

Based on our informal survey of the market with our current customers and various

traders, we have found that there is a big potential for the range of the products we are

planning. These products will be expansion of the current range of our products.

2.5 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials and the non availability of some

materials, we will have to import some of the key raw materials as they are not available

indigenously. This will make us very competitive against imported finished products and we

will be able to increase the export of our finished products.

25

2.6 Export possibility

Depending on the international demand of products we shall explore the more possibility of

exporting the products.

2.7 Domestic/Export Markets

We will sale our products in domestic & international markets.

2.8 Employment Generation (Direct and Indirect) due to project.

Employment would be as per prevailing norms of state government for skilled and unskilled

people for the proposed expansion project.

26

3.0 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any.

Proposed expansion in existing Dye Formulation Plant

Category: B-5(f) & B-5(b)

3.2 Location (map showing general location, specific location and project boundary &

project site layout) with coordinates.

Map showing general location

27

PLANT LAYOUT

28

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Major factors involved in the selection of site are listed below:

• Site is very well connected by road

• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation

• Availability of power evacuation facilities

• Availability of water for industrial use

Modern infrastructure support and amenities at par with industrial estates in other global

markets, including:

� Efficient transport facilities within the industrial estate and to & from the city area.

� Uninterrupted power supply.

3.4 Size or Magnitude of Operation

The detail of product capcity & major raw material consumption is furnised in section 1.2 of

PFR. (Page No. 4)

3.5 Project Description with process details (a schematic diagram/flow chart showing the

project layout, components of the project etc. should be given)

Please refer Annexure-III in Form-I (Page No. 27)

3.6 Raw material required along with estimated quantity, likely source, marketing area of

final products. Mode of transport of raw materials and finished products.

Please refer Section 1.2 of PFR (Page No. 8)

3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be

briefly outlined.

340 KL/day of treated wastewater will be reused. Discarded barrels/ containers/ liners and

HDPE Bags will be sent back to supplier / to GPCB approved recycler. Distillation residue will

29

be sent for Co-processing in cement industries or disposed at Common Incineration Site.

Iron sludge and gypsum sludge will be sold to cement industries or disposed at nearest

TSDF. HCl (32%) and Sulphuric Acid will be reused within premises. CaCl2 will be sold to

Pharmaceutical Industry or Food Industry for water treatment or Fabric Industries. K2CO3

will be sold to detergent industries or Glass Industries. Sodium Sulfite/Sodium Bi sulfite will

be sold to Pulp & Paper Industries or Food Industries. Fly Ash will be sold to brick

manufacturers.

3.8 Availability of water and source should be given.

Water Source

The entire water requirement will be met through GIDC water supply.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/disposal.

Liquid Waste:

• Source of water will be met through GIDC water supply. Total water requirement will

be 725 KL/Day (385 KL/Day fresh + 340 KL/Day Recycled)

• 388 KL/Day effluents will be generated after the expansion.

• Out of 388 KL/Day, High TDS Stream (160 KL/Day) will be treated in MEE and

condensate will be reused & Low COD Stream (200 KL/Day) will be treated in ETP

consisting primary, Secondary & tertiary treatment and R.O. Permeate will be reused .

• 28 KL/Day domestic wastewater generated shall be treated in STP and treated water

will be reused for gardening.

Solid Waste:

The detail is furnished in section-1.7 of PFR (Page No. 23)

30

3.10 Schematic representations of the feasibility drawing which give information of EIA

purpose.

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC

STATUS & BASIC AMENITIES. SITE VISITS BY AND

INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT.

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PLANT

EXPANSION

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

RISK ANALYSIS

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

31

4.0 SITE ANALYSIS

4.1 Connectivity

• Site is very well connected by road

• Availability of power evacuation facilities

• Availability of water for industrial use

4.2 Land Form, Land Use and Land Ownership

It will be incorporated in EIA Studies.

4.3 Topography (along with map)

We will incorporate topography map in EIA Studies.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from

HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette

notification should be given.

It will be incorporated in EIA Studies. CRZ Clearance is not applicable to us.

4.5 Existing Infrastructure

Existing Infrastructures facilities are listed below:

Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free form cultivation

Availability of power evacuation facilities

Availability of port for export

Availability of Common TSDF & Common MEE facility

Availibility of CETP in near future

32

4.6 Soil Classification


4.7 Climatic data from secondary sources.

Primary source: Our own weather station and Secondary Source: Indian Meteorological

Department, Ahmedabad.

4.8 Social infrastructure available.

Depending on the growth of the company the required social infrastructure will be

provided.

5.0 PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

planning/Development authority classification.

Type of Industry: Expansion in existing dye formulation plant

5.2 Population Projection


5.3 Land use planning (breakup along with green belt etc.)

Total Plot Area: 68,459 m2 (Green Belt: 20,654.92 m

2)

5.4 Assessment of Infrastructure Demand (Physical & Social)

• Employment would be as per prevailing norms of state government for skilled and

unskilled people for the proposed expansion project.

• Social Welfare

• Cordial relation with the industry shall be established and representation shall be made

to villagers for help for creation of facilities related to health, education, etc.

33

5.5 Amenities/Facilities

It will be incorporated in the EIA Studies.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

Processing Area (Processing Zone and Utility Area): 40,000 m2

6.2 Residential Area (Non Processing Area)

Non Processing Area (Green belt, Raw material storage area, finished storage area): 28,459

m2

6.3 Green Belt

Company will develope green belt within the factory and on periphery of the factory. In

addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.

6.4 Social Infrastructure

Depending on the growth of the company the required social infrastructure will be

provided.

6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc)

Site is very well connected by road & railway

6.6 Drinking water Management (Source & Supply of water)

Water requirement is meeting through the GIDC water supply.

6.7 Sewerage System

Sewage pipes will be laid in entire company for the removal and disposal of mainly non-

harmful liquid wastes from the offices, canteen and domestic waste coming from different

sections. These liquid wastes would be treated in STP & treated water will be reused in

gardening.

34

6.8 Solid Waste Management

Details of Hazardous Waste Generation & Disposal is furnished in section-1.7 of PFR (Page

No. 23)

6.9 Power Requirement & Supply/Source

Energy:

2000 KVA from DGVCL

1500 KVA (750 KVA x 2 No.) FROM D.G.SET

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected including home

oustees, land ouatees and landless laborers (a brief outline to be given)

There is no habitation on the proposed expansion project area and it is industrial land which

is purchased by company from GIDC for development of Company, so R & R policy is not

applicable to this project.

There shall be no displacement of any population in project area.

8. PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion (Time schedule for

the project to be given).

Unit has obtained CTE only. We will start expansion work after getting environmental

clearance and CTE-Amendment.

35

8.2 Estimated Project cost along with analysis in terms of economic viability of the

project.

SR

NO

PARTICULARS COST (Rs. in Lakhs)

Existing Proposed Total After

Expansion

1 LAND 1131 NIL 1131

2 BUILDING 816.78 2481.22 3298

3 PLANT & MACHINERY 377.52 3000 3377.52

4 ENVIRONMENTAL

PROTECTION MEASURES

NOT APPLICABLE 500 500

5 WORKING CAPITAL 250 1500 1750

TOTAL 2575.30 7481.22 10056.52

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and social benefits with special emphasis on the benefit to be local people

including tribal population, if any, in the area.

• Employment would be as per prevailing norms of state government for skilled and

unskilled people for the proposed expansion project.

• Social Welfare shall be done.

• Cordial relation with the industry shall be established and representation shall be made

to villagers for help for creation of facilities related to health, education, etc.

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