FORM-I
for
PROPOSED PROJECT FOR PIGMENTS MANUFACTURING PLANT AT DAHEJ
Of
M/s. GREENPARADISE PIGMENTS LLP
Plot No. D2/CH/31, Dahej-II, Dahej Industrial Estate, Tal: Vagra, Dist: Bharuch, Gujarat
Prepared by:
Aqua -Air Environmental Engineers Pvt. Ltd. (Pollution Control Consultants & Engineers)
Reg. Office: 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat – 395 002, Gujarat, India Fax: +91 261 2707273 / 3987273 Tel: + 91 261 3048586 / 2460854 / 2461241 E-mail: [email protected] Visit us at: www.aqua-air.co.in
Page 1 of 43
APPENDIX I FORM 1 (I) Basic Information Sr. Item Details No. 1. Name of the Project/s M/s. Greenparadise Pigments LLP 2. S.No. in the Schedule 5 (f) 3. Proposed capacity/area/length/tonnage to For proposed production capacity please be handled/command area/lease refer Annexure-I. area/number of wells to be drilled 4. New/Expansion/Modernization New 5. Existing capacity/area etc. N.A. 6. Category of project i.e. ‘A’ or ‘B’ ‘B’ 7. Does it attract the general condition? If yes, N.A. please specify. 8. Does it attract the specific condition? If yes, N.A. please specify. 9. Location Dahej Industrial Area, Dahej, Tal: Vagra, Dist: Bharuch, Gujarat Plot/Survey/Khasra No. Plot. No. D2/CH/31 Village GIDC, Dahej - II Tehsil Vagra District Bharuch State Gujarat 10. Nearest railway station/airport along with Nearest Railway Station : Bharuch: 40 kms distance in kms. Nearest Airport: Surat: 70 kms 11. Nearest Town, city, District Headquarters Nearest town: Bharuch : 40 kms, Nearest along with distance in kms. District Head quarter: Bharuch : 40 kms 12. Village Panchayats, zilla parishad, Municipal Notified Area Authority, Dahej-II corporation, Local body (Complete postal addresses with telephone nos. to be given) 13. Name of the applicant M/s. Greenparadise Pigments LLP 14. Registered address Plot. No. D2/CH/31, Dahej-II, Dahej Industrial Estate, Tal: Vagra, Dist: Bharuch, Gujarat. 15. Address for correspondence: Name Mr. Piyush Dineshbhai Kaswala Designation (Owner/Partner/CEO) Partner Address M/s. Greenparadise Pigments LLP 3rd Floor, Shop No. - 309, Millenium Point, Wing-B, Gulambaba Mill Compound,
Page 2 of 43
Station Road, Surat - 395003 Pin Code 395003 E-Mail [email protected] Telephone No. +919825769755 Fax No. -- 16. Details of Alternative Sites examined, if any No location of these sites should be shown on a topo sheet. 17. Interlinked Projects No 18. Whether separate application of interlinked Not applicable project has been submitted? 19. If Yes, date of submission Not applicable 20. If no., reason Not applicable 21. Whether the proposal involves Not applicable, as the project is located in approval/clearance under: If yes, details of industrial estate. 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? 22. Whether there is any Government No order/policy relevant/relating to the site? 23. Forest land involved (hectares) No 24. Whether there is any litigation pending No 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.
Page 3 of 43
(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. Information/Checklist confirmation Yes Details thereof (with approximate No. /No? quantities / rates, wherever possible) with source of information data 1.1 Permanent or temporary change in land No Proposed Project is within Dahej-II GIDC use, land cover or topography including Estate. increase in intensity of land use (with respect to local land use plan) 1.2 Clearance of existing land, vegetation Yes Minor site clearance activities shall be and buildings? carried out to clear shrubs and weed. 1.3 Creation of new land uses? No Proposed site is located within earmarked industrial estate developed by GIDC. 1.4 Pre-construction investigations e.g. bore No Proposed site is located within houses, soil testing? earmarked industrial estate developed by GIDC. 1.5 Construction works? Yes Approved plan for construction is attached as Annexure: 1. 1.6 Demolition works? No Proposed site is located within earmarked industrial estate developed by GIDC. There is no need for any demolition. 1.7 Temporary sites used for construction No Proposed site is located within workers or housing of construction earmarked industrial estate developed workers? by GIDC and all required workers will be employed from nearby area. 1.8 Above ground buildings, structures or Yes Lay out- plan for construction is Earthworks including linear structures, attached as Annexure: 1. cut and fill or excavations 1.9 Underground works including mining or No Not Required tunneling? 1.10 Reclamation works? No Not Required 1.11 Dredging? No Not Required 1.12 Offshore structures? No Not Required 1.13 Production and manufacturing Yes List of Products attached as Annexure: 2 and manufacturing process attached as Annexure: 3 1.14 Facilities for storage of goods or Yes Dedicated storage area for storage of materials? Raw Materials and finished products,
Page 4 of 43
etc. shall be provided. 1.15 Facilities for treatment or disposal of Yes Details of water consumption & effluent solid waste or liquid effluents? generation with segregation of effluent streams are attached as Annexure: 5. Details of Solid Hazardous waste generation and disposal is attached as Annexure: 6. 1.16 Facilities for long term housing of No Not Concerned operational workers? 1.17 New road, rail or sea traffic during No There will be very minor traffic increase construction or operation? due to proposed project and will not cause any change in locality. 1.18 New road, rail, air waterborne or other No Proposed site is located within airports etc? earmarked industrial estate having very well developed infrastructure facilities. Therefore, there will not be any need of new transportation route/station. 1.19 Closure or diversion of existing No There will not be any closure or transport routes or infrastructure diversion of existing transport routes or leading to changes in traffic infrastructure changes due to proposed movements? expansion project. 1.20 New or diverted transmission lines or No Proposed site is situated in notified pipelines? industrial estate having very well developed transmission lines or pipelines for resources and effluent handling. Therefore, there will not be any need of new or diverted transmission lines or pipelines. 1.21 Impoundment, damming, converting, No Water required will be met through realignment or other changes to the GIDC Water Supply. hydrology of watercourses or aquifers? 1.22 Stream crossings? No Not Required 1.23 Abstraction or transfers or the water Yes The requirement of raw water shall be form ground or surface waters? met through GIDC Water Supply. No ground water shall be used. 1.24 Changes in water bodies or the land No Not Concerned surface affecting drainage or run-off? 1.25 Transport of personnel or materials for Yes Transportation of personnel, raw construction, operation or material and products will be primarily decommissioning? by road only. 1.26 Long-term dismantling or No There is no dismantling of any sort. decommissioning or restoration works? Not applicable. 1.27 Ongoing activity during No No Impact on the Environment.
Page 5 of 43
decommissioning which could have an impact on the environment? 1.28 Influx of people to an area in either Yes Direct/Indirect employment shall be temporarily or permanently? provided for proposed operation. 1.29 Introduction of alien species? No Not Concerned 1.30 Loss of native species of genetic No Not Concerned diversity? 1.31 Any other actions? No Not Concerned
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. Information/checklist confirmation Yes/ Details there of (with approximate No. No? quantities/rates, wherever possible) with source of information data 2.1 Land especially undeveloped or No Proposed site is located within agriculture land (ha) earmarked industrial estate developed by GIDC. 2.2 Water (expected source & competing Yes Water requirement will meet through users) unit: KLD the GIDC Water Supply. Detailed water balance is given as Annexure: 4 2.3 Minerals (MT) No Not applicable 2.4 Construction material - stone, Yes Company shall use sand, stone, cement aggregates, sand / soil (expected and structural steel for construction as source MT) required. 2.5 Forests and timber (source - MT) No No wood shall be used as construction material or as a fuel. 2.6 Energy including electricity and fuels Yes Power required from DGVCL is 500 KVA. source, competing users Unit: fuel For Emergency : D.G. Set – 250 KVA x 1 (MT), energy (MW) (Stand-by) Fuel Requirement: Natural Gas = 12,200 SCM/Day or Bio Coal = 8 MT/Day HCD = 120 liter/hr. Any other natural resources (use No 2.7 Not Required appropriates standard units)
Page 6 of 43
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. Information / Checklist confirmation Yes/ Details thereof (with approximate No. No? quantities / rates wherever possible) with source of information data 3.1 Use of substances or materials, which are Yes Please refer Annexure: 7 hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of disease or No Not applicable as site is located in Dahej affect disease vectors (e.g. insect or Industrial Area, Dahej. water borne diseases) 3.3 Affect the welfare of people e.g. by No Not applicable as site is located in Dahej changing living conditions? Industrial Area, Dahej. 3.4 Vulnerable groups of people who could No Not applicable as site is located in Dahej be affected by the project e.g. hospital Industrial Area, Dahej. patients, children, the elderly etc., 3.5 Any other causes No Not Applicable
4. Production of solid wastes during construction or operation or decommissioning MT/month)
Sr. Information/Checklist confirmation Yes/ Details thereof (with approximate No. No? quantities / rates, wherever possible) with source of information data 4.1 Spoil, overburden or mine wastes No Not Applicable 4.2 Municipal waste (domestic and or No Not Concerned commercial wastes) 4.3 Hazardous wastes (as per Hazardous Yes Please refer Annexure: 6 Waste Management Rules) 4.4 Other industrial process wastes Yes Please refer Annexure: 6 4.5 Surplus product No There will not be any surplus product. 4.6 Sewage sludge or other sludge from Yes Please refer Annexure: 6 effluent treatment 4.7 Construction or demolition wastes No Construction waste shall be utilized for leveling, land filling in the premises. 4.8 Redundant machinery or equipment All machinery / equipment will be No installed as per requirement. 4.9 Contaminated soils or other materials No Not Concerned
Page 7 of 43
4.10 Agricultural wastes No Not Concerned 4.11 Other solid wastes No Please refer Annexure: 6
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr. Information/Checklist confirmation Yes/ Details thereof (with approximate No. No? quantities/rates, wherever possible) with source of information data 5.1 Emissions from combustion of fossil Yes Details of emission is attached as fuels From stationary or mobile sources Annexure: 8 5.2 Emissions from production processes No Details of emission is attached as Annexure: 8 5.3 Emissions from materials handling Yes All liquid raw materials shall be including storage or transport procured in bulk tankers and shall be transferred through a closed circuit pipe lines by pumps. Solid raw material shall be handled in closed charging rooms with proper ventilation and charged through close pipeline into reactors. 5.4 Emissions from construction activities No Utmost care will be taken during including plant and equipment construction activity and water sprinklers shall be utilized whenever necessary. 5.5 Dust or odours from handling of No All the waste shall be stored in materials including construction designated places and shall be materials, sewage and waste transported to TSDF Site in their own approved vehicles. 5.6 Emissions from incineration of waste No There will not be generation of any incinerable waste from the proposed unit. 5.7 Emissions from burning of waste in open No No open burning of waste will be air (e.g. slash materials, construction carried out. debris) 5.8 Emissions from any other sources No Not Concerned
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr. Information/Checklist confirmation Yes/ Details there of (with approximate No. No? Quantities /rates, wherever possible) With source of source of information data
Page 8 of 43
6.1 From operation of equipment e.g. Yes Use of PPE like ear plugs and ear muffs engines, ventilation plant, crushers will be made compulsory near the high noise generating machines. Proper and timely oiling, lubrication and preventive maintenance will be carried out for the machineries & equipments to reduce noise generation. D.G. Set will be installed in a closed room and provided with acoustic enclosure. 6.2 From industrial or similar processes Yes All machinery / equipment shall be well maintained, shall be proper foundation with anti vibrating pads wherever applicable and noise levels within permissible limits. Acoustic enclosures shall be provided for DG set. 6.3 From construction or demolition Yes Minor noise will be generated during construction work. No blasting or pilling will be carried out at 6.4 From blasting or piling No project site. There will not be any major impact of 6.5 From construction or operational traffic No noise / vibration due to proposed project. 6.6 From lighting or cooling systems No Not Concerned 6.7 From any other sources No Not Concerned
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. Information/Checklist confirmation Yes/ Details thereof (with approximate No. No? quantities / rates, wherever possible) with source of information data 7.1 From handling, storage, use or spillage No All raw materials shall be stored of hazardous materials separately in designated storage area with safety measures. Bund walls shall be provided around raw materials storage tanks for containing any liquid spillage. Other materials shall be stored in bags / drums on pallets with concrete flooring and no spillage is likely to occur. Please refer Annexure: 7 7.2 From discharge of sewage or other No Sewage effluent shall be treated and effluents to water or the land disposed in Septic Tank & Soak Pit. (expected mode and place of
Page 9 of 43
discharge)
7.3 By deposition of pollutants emitted to No Not Concerned air into the land or into water 7.4 From any other sources No Not Concerned 7.5 Is there a risk of long term build up of No Not Concerned pollution in the environment from these sources?
8. Risks of accident during construction or operation of the Project, which could affect human health or the environment:
Sr. Information/Checklist confirmation Yes/ Details thereof (with approximate No. No? quantities / rates, wherever possible) with source of information data 8.1 From explosions, spillages, fires etc. Yes The risk assessment will be carried out from storage, handling, use or and all mitigative measures shall be production of hazardous substances taken to avoid accidents. 8.2 From any other causes No Not Concerned 8.3 Could the project be affected by natural No Not Concerned disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?
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. Information/Checklist confirmation Details thereof (with approximate Yes/ No. quantities / rates, wherever possible) No? with source of information data 9.1 Lead to development of supporting. No Site is located in Dahej Industrial Area, laities, ancillary development or Dahej, having the entire required development stimulated by the project infrastructure. which could have impact on the This industrial zone is having existing road environment e.g.: infrastructure, power supply, which are to * Supporting infrastructure (roads, be utilized. power supply, waste or waste water Local people will be employed and no treatment, etc.) housing is required. • housing development Please refer Annexure: 9. • extractive industries • supply industries • other
Page 10 of 43
9.2 Lead to after-use of the site, which No could have an impact on the Not Concerned environment 9.3 Set a precedent for later developments No Not Concerned 9.4 Have cumulative effects due to No proximity to Other existing or planned Not Concerned projects with similar effects
(III) Environmental Sensitivity
Sr. Information/Checklist confirmation Name / Aerial distance (within 5 km). Proposed No Identity Project Location Boundary. 1 Areas protected under international Yes Site is located in Dahej Industrial Area, conventions national or local legislation Dahej, Tal. Vagra, Dist. Bharuch, Gujarat. for their ecological, landscape, cultural or other related value 2 Areas which are important or sensitive No Site is located in Dahej Industrial Area, for Ecological reasons - Wetlands, Dahej, Dist. Bharuch, Gujarat. watercourses or other water bodies, coastal zone, biospheres, mountains, forests 3 Areas used by protected, important or No Site is located in Dahej Industrial Area, sensitive species of flora or fauna for Dahej, Tal: Vagra, Dist. Bharuch, Gujarat. breeding, nesting, foraging, resting, over wintering, migration 4 Inland, coastal, marine or underground Yes Arabian Sea = 13.5 kms waters River Narmada = 6.5 kms 5 State, National boundaries No No state or national boundary falls within 5 km aerial distance from the project site. 6 Routes or facilities used by the public Yes Public transportation for to recreation or other tourist, pilgrim areas. 7 Defense installations No Not Applicable 8 Densely populated or built-up area Yes Bharuch city = 4 lakh population 9 Areas occupied by sensitive man-made No Not Applicable land community facilities) 10 Areas containing important, high quality No The project being in industrial area does or scarce resources (ground water not affect agricultural land. resources, surface resources, forestry, agriculture, fisheries, tourism, tourism, minerals)
Page 11 of 43
11 Areas already subjected to pollution or No Site is located in Dahej Industrial Area, environmental damage. (those where Dahej, Tal: Vagra, Dist. Bharuch, Gujarat. existing legal environmental standards are exceeded) 12 Are as susceptible to natural hazard No Not Applicable which could cause the project to present environmental problems (earthquake s, subsidence ,landslides, flooding erosion, or extreme or adverse climatic conditions)
I hereby given undertaking that, the data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage the project will be rejected and clearance give, if any to the project will be revoked at our risk and cost.
Date: July 7, 2017 Place: Dahej
NOTE:
1. The projects involving clearance under Coastal Regulation Zone Notification, 1991 shall submit with the application a C.R.Z. map duly demarcated by one of the authorized agencies, showing the project activities, w.r.t. C.R.Z. (at the stage of TOR) and the recommendations of the State Coastal Zone Management Authority (at the stage of EC). Simultaneous action shall also be taken to obtain the requisite clearance under the provisions of the C.R.Z. Notification, 1991 for the activities to be located in the CRZ.
2. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden thereon (at the stage of EC).
3. All correspondence with the Ministry of Environment & Forests including submission of application for TOR/Environmental Clearance, subsequent clarifications, as may be required from time to time, participation in the EAC Meeting on behalf of the project proponent shall be made by the authorized signatory only. The authorized signatory should also submit a document in support of his claim of being an authorized signatory for the specific project.
Page 12 of 43
ANNEXURES
1 Plant layout
2 List of products with production capacity and raw materials
3 Brief manufactring process, chemical reaction and mass balance with flow diagram 4 Details of Water consumption and Wastewater Generation
5 Details of Effluent Treatment Plant (ETP)
6 Details of hazardous solid waste management and disposal
7 Details hazardous chemical storage facility
8 Details of flue & process gas emission
9 Socio - economic impacts
10 Proposed terms of references
11 Copy of Plot Allotment Letter
12 Copy of GIDC Water Supply Certificate
13 Membership Certificate of Common Solid Waste Disposal Facility (M/s. BEIL)
14 Toposheet
Page 13 of 43
ANNEXURE: 1 PLANT LAYOUT
Page 14 of 43
ANNEXURE: 2 LIST OF PRODUCTS WITH PRODUCTION CAPACITY
Sr. PRODUCTS CAS No. QTY No. MT/MONTH 1 Pigment green-7 1328-53-6 200 2 Pigment green-36 14302-13-7 30 3 Pigment beta blue 15:3 147-14-8 100 4 Pigment alpha blue 15:1 147-14-8 90 5 CPC blue 147-14-8 100 Total 520
Page 15 of 43
LIST OF RAW MATERIALS Sr. No. Raw Material Quantity (MT/Month)
Pigment green-7 (200 MT/month) 1 Aluminum Chloride 360 2 Copper phthalo cyanine blue 106 3 Chlorine 244 4 CUCl2 16 5 Salt 77 6 Caustic Lye (98%) 18 7 MCB 698 8 Dispersing Agent 6 Pigment green-36 (30 MT/Month) 1 Aluminum Chloride 65.33 2 Copper phthalo cyanine blue 10.33 3 Chlorine 7.6 4 Bromine 33.16 5 Salt 8.16 6 Caustic Lye (98%) 3.73 7 MCB 62.5 8 Dispersing Agent 1.16 Pigment beta blue 15:3 (100 MT/Month) 1 Copper phthalo cyanine blue 100 2 Caustic Flakes - 98% 3 3 Iso butyl alcohol/ Ortho xylene 100 4 Dispersing Agent 1 Pigment alpha blue 15:1 (90 MT/Month) 1 Sulphuric Acid (98%) 700 2 Solvent - 121 20 3 Copper phthalo cyanine blue 100 4 Dispersing Agent 1 5 O-Xylene 1.5 CPC Blue (100 MT/Month) 1 Phthalic Anhydride 107.5 2 Carbomide Salt / NH3 Gas 150.5 3 Cuprous Chloride 19.3 4 ONT 215 5 Dilute H2SO4 (25-30%) 250
Page 16 of 43
ANNEXURE: 3 BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH FLOW DIAGRAM
PIGMENTS
(1) Pigment green-7
Manufacturing Process: In GLV first charge Aluminum Chloride, Sodium Chloride and Cupric chloride. Melt this by giving heat through thermic fluid heater after melting is take place charge Copper Phthalocyanine blue. This is main Raw Material for Green-7 Product. Pass the chlorine gas with maintaining temperature between 160°C to 190°C temperature because this process is exothermic reaction & for that do the cooling through hytherm cooling system for maintaining temperature. Around 30 to 40 hrs chlorination is required for making the green- 7 crude but end point results given by lab only. For above all activity, scrubbing system is required for excess chlorine gas & hydrochloric acid. After lab approval do the drowning of all GLV mass in drowning vessel & thanfilter, wash & keep for finishing the green. For finishing the final green, SS reactor required with steam heating system. In this vessel charge solvent, emulsifier & do reflux than distilled solvent than filter, wash & dry in SFD. After drying, making the 5 mt lot as per lab instruction.
Chemical Reaction:
C32 H16 N8 Cu + 14 Cl 2 = C32 N8 Cu H2 Cl 14 + 14 HCl ( 575.5 ) ( 994 ) ( 1058.5 ) ( 511 ) [ CPC - Blue ] [ CPC - Green ]
(Reaction takes place in the presence of AlCl3 + NaCl + CuCl2 - as catalysts & reaction carriers)
Page 17 of 43
Mass Balance:
IN – PUT OUT – PUT S.N. Raw Materials kg Product / Byproduct Kg 1) ALCL3 3600 Product 2000 2) CPC 1060 Gas emission 1080 3) Chlorine 2440 AlCl3 Soln. (ML) 16720 4) CUCL 2 160 Washing 41740 5) Caustic Lye (98%) 180 MCB 6860 6) MCB 6980 Waste Water 8240 7) Dispersing Agent 60 Waste Water (ETP) 16910 8) Water 75470 Evaporation loss 1350 9) Steam 4180 10) Salt 770 Total 94900 Total 94900
Page 18 of 43
(2) Pigment green-36
Manufacturing Process: In GLV first charge Aluminum Chloride, Sodium Chloride & Cupric Chloride. Melt this by giving heat through thermic fluid heater after melting is take place charge Copper Phthalocyanine blue. This is main Raw Material for Green-36 Product. Charge the Bromine gas with maintaining temperature between 160 and 180 °C temperature. Because this reaction is exothermic, so that do the cooling through hytherm cooling system for maintaining temperature around 800 kg to 1000 kg of bromine required for making the Green-36 & after that pass chlorine for removing the excess bromine from reaction. End point check in UV by lemda value for making the green-36 crude but end point results given by lab only. For above all activity, scrubbing system is required for excess Bromine gas & hydrogen bromide gas. After lab approval do the drowning of all GLV mass in drowning vessel & than filter, wash & keep for finishing the green. For finishing the final green MS reactor required with steam heating system .in this vessel charge solvent, emulsifier & do reflux than distilled solvent than filter, wash & dry in SFD After drying, making the 5 mt lot as per lab instruction.
Chemical Reaction
AlCl 3 + NaCl
CPC Blue + Cl 2 CPC Green-36 + HCl + Br 2
Br 2
Page 19 of 43
Mass Balance:
IN – PUT OUT – PUT S.N. Raw Materials kg Product / Byproduct Kg 1) ALCL3 1960 Product 900 2) CPC 310 Gas emission 677 3) Chlorine 228 Alcl3 Soln. (ML) 13210 4) Bromine 995 Washing 19570 5) Caustic Lye (98%) 112 MCB 1795 6) MCB 1875 Waste Water (ML) 4470 7) Dispersing Agent 35 Waste Water (ETP) 13050 8) Water 48280 Evaporation loss 1998 9) Steam 1630 10) Salt 245 Total 55670 Total 55670
Page 20 of 43
(3) Pigment beta blue 15:3
Manufacturing Process: • Ball Milling: Charge 1000 kg CPC in 10 KL Ball mill. Grind it for 22hr. Then discharge the ball mill and crude fill in the bag. • Pigmentation: Take 4000 liter Water in reactor. Add 30 kg caustic flakes, 6 kg DA-B, 800 Kg grinded CPC and 1000 1iter Solvent. After addition of above all raw material close the main hole and start jacket Heating by steam till reflux and note the reflux temperature. Reflux for 4 hrs. After completing reflux start solvent distillation. After distillation takes 200 liter water and bring the pH 7.5- 8.0 by adding MCI. After the reaction mass in filter press and give the washing till salt free. Unload the filter press and keep it in dryer for drying. After drying Pulverizing in pulverize. Do the Blending for final dispatch.
Mass Balance:
IN – PUT OUT – PUT S.N. Raw Materials kg Product / Byproduct Kg 1) CPC 1000 Product 1000 2) Caustic Flakes (98%) 30 Evaporation loss 1350 3) IBN or O-Xylene 1000 IBN or O-Xylene 995 4) Dispersing Agent 10 Waste Water (ML) 7695 5) Water 15000 Waste Water (ETP) 8500 6) Steam 2500 Total 19540 Total 19540
Page 21 of 43
(4) Pigment alpha blue 15:1
Manufacturing Process: • Acid Process: Take sulphuric acid (98%) in a reaction vessel. Then slowly charge Copper Phthalocyanine crude. Maintain temperature just below 80°C. So that as to dissolve it too completely. The mass is stirred further for 2-3 hrs. at 65°C and then cooled to room temperature by external circulation of water in jacket. Recycled water is then introduced as a thin spray into the vessel slowly; take care to maintain the temperature below 65°C. The CPC separate out in the required form and is filtered off. After filtration process whatever mother liquor generated that contains approximate 25% of sulphuric acid. We will sell that liquor (H2SO4) to the manufacture of CPC blue and H-Add. • Pigmentation Process: The CPC cake is charged in another vessel and aqueous slurry is neutralized to H 8 to 8.5 using ammonia solution and caustic lye and stirred with emulsifier at 60°C - 90°C for 2 Hrs. The above slurry is filtrated and the cake is washed with large amount of fresh water. The wet cake is dried and pulverized to obtain CPC alpha blue. The aqueous filtrate goes to ETP. Then after it is discharged.
Mass Balance:
IN – PUT OUT – PUT S.N. Raw Materials kg Product / Byproduct Kg 1) Sulphuric Acid (98%) 7000 Product 1000 2) Solvent - 121 200 Sulphuric Acid (22-25%) 26000 3) CPC 1000 Waste Water (ETP) 38165 4) DA-B 10 Acidic fumes Scrubbing system 50 5) O-Xylene 15 Evaporation loss 1860 6) Water 51450 7) Steam 7400 Total 67075 Total 67075
Page 22 of 43
(5) CPC Blue
Manufacturing Process: Phthalic Anhydride, Urea and solvent (TCB/NB/ONT) are mixed in the vessel equipped with heating arrangement (by Thermopack Boiler for circulation of high temperature oil) and stirrer. Cuprous Chloride and ammonium Molybdate are then added. The mixture is heated up slowly for 20 hours at 180 C temperatures. Ammonia gas and carbon dioxide gas is liberated with the formation of Phtahlamide at 135 C temp. Formation of Copper phthalocyanine takes place at a temp. 185 C with release of Ammonia gas & carbon dioxide gas. The Ammonia gas & carbon dioxide gas is scrubbed through series of scrubbers under water circulation. The reaction mass is stirred till formation of Copper Pthalocyanine is completed. The reaction mass is then transferred to rotary vacuum drier and solvent is recovered completely under vacuum from rotary drier. The dried powder of Copper phthalocyanine is then purified in MSRL brick lined vessel by treating it with acidic effluent (diluted sulphuric Acid) generated during manufacture of pigment Apha Blue. The resulting mixture is filtered in filter press and wet cake is washed with either the effluent generated during Beta Blue manufacture and finally with fresh water till the soluble Salt are removed. Filtrate is transferred to ETP for treatment, while the wet press cake of CPC Blue is dried in tray dryer/spin flash dryer, pulverized and packed into HDPE bags.
Chemical Reaction:
Page 23 of 43
Mass Balance:
IN – PUT OUT – PUT S.N. Raw Materials kg Product / Byproduct Kg 1) Phthalic Anhydride 1075 Product 1000 2) Carbomide Salt / NH3 Gas 1505 Gas emission 884 3) Cuprous Chloride 193 Mass 14649 4) Ammonium Molybdate 3 Ammonium Carbonate 4884 5) ONT (Solvent) 2150 Recovered ONT (Solvent) 2130 6) Mass 10607 Solvent Loss 20 7) Dilute H2SO4 (22 to 25%) 2500 Effluent to ETP 6632 8) Washing Water 8432 Evaporation Loss 1150 9) Water for Scrubber 4000 10) Gas (NH3 + CO2) 884 Total 31349 Total 31349
Page 24 of 43
ANNEXURE: 4 DETAILS OF WATER CONSUMPTION & WASTEWATER GENERATION
Sr. Sources Water Wastewater No. consumption KLD generation KLD 1. Domestic 10 8 2. Gardening 15 0 3. Industrial (i Process 523 294 (ii Boiler 35 5 (iii Cooling 40 5 (iv Scrubber 5 2 (v Washing 20 20 Total industrial 623 326 Total 648 334
Note: • At present, unit has planned to install MEE for ZLD. However, in future as & when function of CETP in this area will improved / installed & if GPCB will grant permission to discharge effluent into CETP, mode of disposal will be of CETP after getting its permission.
• Industrial wastewater generated from proposed manufacturing process and other ancillary operation shall be allowed into in-house ETP for primary treatment. Treated water will be sent to MEE from where water will be evaporated and condensed water will be reused in process.
• Domestic effluent shall be disposed in to Septic tank / Soak pit system.
Page 25 of 43
WATER BALANCE DIAGRAM
Raw Water 648 KLD
Industrial: 623 KLD Gardening: Domestic: m3/Day m3/Day 15 KLD 10 KLD
Process: Boiler: Cooling: Scrubber: Washing: 523 KLD 35 KLD 40 KLD 5 KLD 20 KLD
8 KLD 294 KLD 5 KLD 5 KLD 2 KLD 20 KLD Septic Tank & Soak Pit 278 KLD
16 KLD ETP :
310 KLD
RO Permeate – 190 KLD RO
RO Rejected: 120 KLD HPRO Rejected HPRO Permeate: 55 KLD MEE: HPRO 81 KLD 65 KLD Unit
MEE Condensate: 73 KLD MEE Salt
Page 26 of 43
ANNEXURE: 5 DETAILS OF EFFLUENT TREATMENT PLANT (ETP)
Design flow
Stream I (Low COD & TDS) = 310 m3/day (Average) Stream II (High COD & TDS) = 16 m3/day (Average)
Untreated Effluent Characteristics (Low COD & TDS) Sr. No. Parameters Value 1. pH = 5.0-7.0 2. Total Dissolved Solids < 6000 mg/L 3. Suspended Solids < 500 mg/L
4. BOD 3 < 6000 mg/L 5. COD < 15000 mg/L 6. O & G < 100 mg/L
Treated Water Characteristics Sr. No. Parameters Value 1. pH = 6.5 – 7.5 2. Total Dissolved Solids < 6000 mg/L 3. Suspended Solids < 50 mg/L 4. BOD3 < 100 mg/L 5. COD < 250 mg/L 6. O & G < 10 mg/L
Untreated Effluent Characteristics (High COD & TDS) Sr. No. Parameters Value 1. pH = 5.0-7.0 2. Total Dissolved Solids < 1,50,000 mg/L 3. Suspended Solids < 700 mg/L
4. BOD 3 < 6000 mg/L 5. COD < 45,000 mg/L
Page 27 of 43
TREATMENT PHILOSOPHY:
Stream I (Low COD & TDS Stream)
First all non-toxic and biodegradable streams (low & medium COD& TDS) of wastewater shall be collected in Collection cum Equalization Tanks-01 (CETs-01). Pipe grid is provided at bottom of the CETs-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-B) where the continuous addition and stirring of Lime solution is done to maintain neutral pH of wastewater from Lime Dosing Tanks (LDT-01-A/B) as per requirement with help of Lime Dosing Pumps. Then after, neutralized wastewater shall go to Flash Mixer (FM-01) by gravity. Alum and Polyelectrolyte shall be dosed from Alum Dosing Tanks (ADT-01-A/B) & Polyelectrolyte Dosing Tank-1 (PEDT-01) respectively with help of Dosing Pumps. Then after, coagulated wastewater shall be settled in Primary Clarifier-1 (PCL-01). Clear supernatant from PCL-01 shall be passed in Aeration Tank-1 (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. Nutrients will be added from Nutrient Dosing Tanks (NDTs-01) to Aeration Tank-1 for growth of Bacteria.
Then after, wastewater shall go to Secondary Clarifier-1 (SCL-01). 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 be collected in Intermediate Sump (IS-01) by gravity.
Thereafter, the wastewater shall be passed through Pressure Sand Filter (PSF-01) to remove left out TSS and Activated Carbon Filter (ACF-01) for final effluent polishing. After tertiary treatment, effluent shall be collected in Treated Effluent Sump (TES-01) before sent to RO-01 for further treatment. RO-01 permeate water shall be collected in RO Permeate Tank (ROPT- 01). RO-01 reject shall be sent to HPRO for further treatment. Permeate from HPRO-01 shall be collected in ROPT-01 and reject shall be sent to MEE Feed tank (MFT-01) for further treatment.
Sludge settled in PCL-01, PTS-01 and excess sludge from SCL-01 shall be collected in Sludge Sumps (SSs-01) then sludge shall be pumped to Centrifuge (CFs-01) where poly shall be mixed from poly Dosing Tank-2 (PDT-02) with sludge to increase efficiency of centrifuge sludge dewatering. Then, dewatered sludge shall be stored in in HWSA and then ultimate disposal to TSDF. Leachate from CFs-01 and backwash from MGF-01 and ACF-01 shall be collected in Drain Pit and pumped back to CET-01-A/B for further treatment.
Page 28 of 43
Stream II (High TDS stream) (300 KLD Process)
All High TDS streams of wastewater shall be collected in Equalization cum Neutralization Tank (ENT-01). Here Lime shall be added from Lime Dosing tank (LDTs-01) with help of Dosing Pumps. Pipe grid is provided at bottom of the ENT-01 to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers B-04 (1W+1 stand-by) shall supply air through to pipe grid. Then effluent shall be pumped to Flash Mixer-2 (FM-02) where Alum and poly shall be added from ADT and PDT-01 respectively. Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST-01). Sludge settled in PST-01 shall be sent to SS-01.
Clear effluent from PST-01 shall be collected in MEE Feed Tank (MFT-01). Here reject from HPRO-01 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 & ATFD shall collect in Condensate Storage Tank (CST-01) before reuse. Solids from ATFD-01 shall be collected and stored in HWSA for disposal in TSDF.
DETAILS OF UNITS: (FOR LOW COD & TDS STREAMS) (310 KLD):
Size in Meters Sr. No. Name of Unit Tag No. Nos. MOC (L X B X (LD+FB) Inlet Units
Collection cum RCC M30+ 1. CETs-01-A/B 7.75 x 5.0 x (4.0+0.5) 2 A/A Bk. Equalization Tanks Lining Primary Treatment 2. Neutralization Tank NT-01 2.0 x 2.0 x (3.0 + 0.5) 1 RCC M30 3. Flash Mixer-1 FM-01 2.0 x 2.0 x (3.0 + 0.5) 1 RCC M30 6.0 Dia x (3.0 SWD + RCC M30 4. Primary Clarifier -1 PCL-01 1 0.5) Secondary Treatment 5. Aeration Tank-1 AT-01 18.0 x 9.0 (5.0 + 0.5) 1 RCC M30 6.5 Dia x (3.0 SWD + RCC M30 6. Secondary Clarifier-1 SCL-01 1 0.5) Tertiary + sludge dewatering Treatment+ Dosing Tanks 7. Intermediate Sump TES 5.0 x 3.5 (3.0 + 0.5) 1 RCC M30 8. Pressure Sand Filter PSF-01 16 M3/hr 1 MSEP 9. Activated Carbon Filter ACF-01 16 m3/hr 1 MSEP 10. Treated Effluent Sump TESs-01 7.75 x 5.0 x (4.0+0.5) 2 RCC M30 11. Sludge Sump SS-01 3.0 x 3.0 x (3.0+0.5) 1 RCC M30
Page 29 of 43
12. Centrifuge CFG-01/02 30 m3/D 1 SS304 13. Drain Pit DP-01 2.0 x 2.0 x (3.0+0.3) 1 RCC M30 14. Lime Dosing Tanks LDTs-01 1500Lit 2 HDPE/PP 15. Alum Dosing Tank ADT-01 1500 Lit 1 HDPE/PP 16. Poly Dosing Tanks PDT-01/02 1000 Lit 2 HDPE 17. Nutrient Dosing Tank NDT-01 1000 Lit 1 HDPE
DETAILS OF UNITS: (FOR HIGH TDS STREAMS) (16 KLD Process)
Size in Meters Sr. No. Name of Unit Tag No. Nos. MOC (L X B X (LD+FB) Inlet Units Equalization cum RCC M30+ A/A Bk. 1. Neutralization ENT-01 3.0 x 3.0 (3.0 + 0.5) 1 Lining Tank Primary Treatment 2. Flash Mixer-2 FM-02 2.0 x 2.0 x (2.8 LD +0.3 FB) 1 RCC M30 Primary Settling 6.0 dia x (3.0 SWD + 0.5 RCC M30 3. PST-01 1 Tank FB) Advance Treatment 6.0 m x 5.0 m x (3.0 m + 4. MEE Feed Tank MFT-01 1 RCC M30 0.5) Multi Effect Evaporator (MEE-01) with MEE-01/ 5. 81 m3/D 1 SS316L Agitated Thin ATFD-01 Film Dryer (ATFD-01) Condensate 4.0 m x 5.0 m x (3.0 m + 6. CST-01 1 RCC M30 Storage Tank 0.5)
Page 30 of 43
Flow Diagram of Effluent Treatment Plant (ETP):
Page 31 of 43
ANNEXURE: 6 DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL
SR. NAME OF WASTE TOTAL QTY. MODE OF DISPOSAL NO. WASTE CATEGORY
1 ETP Waste 35.3 120 Collection, Storage, Transportation & MT/Month disposal at nearest TSDF site 2 Used Oil 5.1 40 Collection, Storage, Transportation & Lit./Month disposal by selling to registered re-
refiners 3 Discarded 33.1 750 Collection, Storage, Decontamination Containers/ Nos./Month and reuse or disposal by Liners / Bags selling to approved vendors 4 MEE Salt 35.3 80 Collection, Storage, Transportation & MT/Month and Disposal to nearest TSDF site
5 Gypsum Sludge -- 60 Collection, Storage, Disposal to nearest MT/Month TSDF or sell to cement industries
6 Spent H2SO 4 -- 2340 Collection, Storage, Treatment, (22-25%) MT/Month reuse in process (CPC Blue) and remaining shall be sell to end users 7 Aluminum -- 2110 Collection, storage, treatment & Chloride MT/Month transportation by selling to end users
Page 32 of 43
ANNEXURE: 7 DETAILS HAZARDOUS CHEMICAL STORAGE FACILITY
Sr. Hazardous Type of Hazard MOC of Storage Actual Size Stored Quantity No. Chemicals 1 Sulphuric Acid Corrosive CS Tank 10 MT 20 MT (2 Nos.) 2 Chlorine Corrosive MS Tonner 900 kg 9 MT (10 Nos.) 3 Aluminium Chloride Corrosive Poly Bags 25 kg 5 MT (200 Nos.) 4 Monochloro Flammable MS Tank 10 MT 20 MT Benzene (2 Nos.) 5 Bromine Toxic Bottle 2 kg 200 kg (100 Nos.) 6 Iso Butyl Alcohol Flammable MS Tank 10 MT 10 MT (1 Nos.) 7 Ortho Nitro Toluene Corrosive MS Tank 10 MT 10 MT (1 Nos.) 8 Copper Phthalo Corrosive Poly Bags 25 kg 10 MT Cyanine (400 Nos.)
Page 33 of 43
ANNEXURE: 8 DETAILS OF FLUE & PROCESS GAS EMISSION Sr. Stack attached to Fuel Fuel Stack APC Probable No. Type Consum Height measures emission ption in m rate Flue Gas Stacks 1. Steam Boiler Natural 6100 30 -- or PM<150 mg/Nm 3 (3.5 T/hr.) Gas or scm/day or Multicyclone SO 2<100 ppm Bio Coal 4 MT/Day Separator with NOx<50 ppm Bag Filter
Page 34 of 43
2. Thermic Fluid Heater Natural 2500 12 -- or (10 lakhs k cal / Hr.) Gas or scm/day or Multicyclone Bio Coal 2 MT/Day Separator with Bag Filter 3. Thermic Fluid Heater Natural 3600 12 -- or (6 lakhs k cal / Hr.) Gas or scm/day or Multicyclone Bio Coal 2 MT/Day Separator with Bag Filter 4. D.G. Set (250 kVA) HSD 120 9 -- lit/hr Process stacks 1. Reaction vessel -- -- 15 Two stage HCl<20 mg/Nm 3 System (CPC green- water scrubber Cl 2<9 mg/Nm 3 7 / CPC green-36) followed by 3 HBr/Br 2<5 mg/Nm alkali scrubber 3 2. Reaction vessel -- -- 12 Alkali scrubber SO 2<40 mg/Nm System (Alpha blue) 3. Spin Flash dryer -- -- 12 Bag filter PM<150 mg/Nm 3 3 SO 2<40 mg/Nm NO x<25 mg/Nm 3
Page 35 of 43
ANNEXURE: 9 SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES The manpower requirement for the proposed project is 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.
Page 36 of 43
ANNEXURE – 10 PROPOSED DRAFT TERMS OF REFERENCE
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 • Water source and utilization including proposed water balance • Product spectrum (proposed products along with production capacity) and process • List of hazardous chemicals • Mass balance of each product • 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 • Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the
project site. For SPM, RSPM, SO 2, 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 • Identification of impacting activities from the proposed project during construction and operational phase. • 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
Page 37 of 43
5. Environmental Management Plan • Details of pollution control measures • Environment management team • Proposed schedule for environmental monitoring including post project
6. Risk Assessment • Objectives and methodology of risk assessment • Details on storage facilities • Process safety, transportation, fire fighting systems, safety features and emergency capabilities to be adopted • Identification of hazards • Consequence analysis through occurrence & evaluation of incidents • Disaster Management Plan
7. Information for Control of Fugitive Emissions 8. Post Project Monitoring Plan for Air, Water, Soil and Noise 9. Information on Rain Water Harvesting 10. Green Belt Development plan
Page 38 of 43
ANNEXURE – 11 COPY OF PLOT ALLOTMENT LETTER
Page 39 of 43
Page 40 of 43
ANNEXURE – 12 COPY OF GIDC WATER SUPPLY CERTIFICATE
Page 41 of 43
ANNEXURE – 13 MEMBERSHIP CERTIFICATE OF COMMON SOLID WASTE DISPOSAL FACILITY (M/s. BEIL)
Page 42 of 43
ANNEXURE – 14 TOPOSHEET
Page 43 of 43