0 0 26 Nov 2014 1823468631prefeasibility Report PDF

FOR
PROPOSED EXPANSION PROJECT

(FOR EXISTING PRODUCT RANGE)
MANUFACTURING OF
ORGANIC PIGMENTS
Category: 5(f)
AT
PIDILITE INDUSTRIES LIMITED
Located at:
Plot No. 23, 1st Phase,
GIDC Notified Industrial Area,
Vapi, Dist- Valsad (Gujarat).
Prefeasibility Report Pidilite Industries Limited
Project pre feasibility report for obtaining prior Environmental Clearance in terms of
provisions of EIA Notification – 2006
1 Executive Summary:
Name & Location
Name of the Project: Pidilite Industries Limited

Location : Plot No: 23, 1st phase, G.I.D.C,
VAPI. Pin Code: 396195
Dist. - Valsad (Gujarat)
Project
Ö Pidilite Industries limited is located in GIDC notified industrial area, falling under
large Scale category manufacturing products as mentioned under for which the company
had obtained Consent To Establish and Operate from Gujarat pollution Control Board.
Ö The company proposes to enhance the capacity of existing products under the
category “Organic Pigments” ( Azo Pigments ) as well as “Quinacridone Pigments “ &
Pigment Emulsions.
Ö Proposed expansion Project Cost: Rs. 2100 lacs. Total after proposed expansion will
be Rs. 14700.25 lacs
Applicability of EIA notification – 2006
Ö Category as per the amended EIA notification-2006: as existing and proposed

products (i.e. Organic pigments) are covered under the Category-5(f). Hence,
Environmental clearance is required.
Project Proponent
• The company in India comprises of 12 directors

• Large Scale Unit
List of finished products & by- products:
No Product MT/MONTH
Existing Proposed Total after
proposed
expansion
1 Carbazole Dioxane Violet 25 0 25
Pigment
2 Organic Pigment 85 30 115
(Azo- Orange/Yellow/ Red)
3 Pigment emulsion 137 33 170
4 Quinacridone Pigment 15 20 35
Total 262 83 345
Expansion project Page 1 Organic Pigments

by-products
1 Phosphoric Acid (10-30%) 218.5 291.35 509.85
from Quinacridone Pigment
2 Calcium Sulphate 0 110 110

(Gypsum)*
• Gypsum is having 10-15 % moisture in it.
Manufacturing process is attached as Annexure-3.
Resource Requirement:
Total after
Resources
Components Existing Proposed proposed
availability
expansion
Will be sourced
from Dakshin
Power, KVA 1600 300 1900
Gujarat Vij Co.
Ltd.
Will be sourced
Fresh Water, from GIDC
1586 -22 1564
kl/day water supply
Dept.
Briquette 1.45 MT/Hr 0.655 MT/Hr 2.105 MT/Hr GSPC & local
/Natural Gas for of Briquette Briquette or 180 Briquette or 590 dealer
Steam Boiler or 410 SCM/Hr SCM/Hr
(12 Tons/Hr) x SCM/Hr
1 Nos
Natural gas for 2000 0 2000 SCM/day GSPC
Thermopak (10 SCM/day
lacs & 4 lacs)
Natural gas for 8750 0 8750 SCM/day GSPC
steam boiler (8 SCM/day
TPH & 2 TPH)
Fuel (HSD) for 0 225 kgs/hr 225 kgs/hr
D.G.Set Will be sourced
(Capacity: 750 x from local dealer
2 & 125 KVA)

Raw material Consumption:
1.0 For Carbazole Dioxane Violet Pigment (Pigment Violet 23)
Sr. Raw Materials Quantity in MT

No.
Ton Per month
per
Tone of Existing Proposed Total after
FG expansion
1.1 Carbazole 0.90 22.52 0 22.52
1.2 Diethyl sulphate 0.81 20.27 0 20.27
1.3 Caustic flakes 0.48 12.11 0 12.11
1.4 Mono Chloro 3.23 80.86 0 80.86

Benzene (Recovered)
1.5 Mono Chloro 0.32 8.11 0 8.11

Benzene (Fresh)
1.6 Nitric acid 0.93 23.23 0 23.23
1.7 ODCB (Recovered) 17.71 442.68 0 442.68
1.8 ODCB (Fresh) 1.11 27.76 0 27.76
1.9 Catalyst 0.01 0.19 0 0.19
1.10 Nitrogen 0.08 0 1.97 1.97
1.11 Hydrogen 0.04 0 0.99 0.99
1.12 Chloranil 0.52 13.01 0 13.01
1.13 Catalyst RAC 0.21 5.35 0 5.35
1.14 Benzene sulpho 0.37 9.29 0 9.29

chloride
1.15 Salt 8.72 217.91 0 217.91
1.16 Di ethyl Glycol 0.16 4.08 0 4.08
1.17 Iron Powder 1.52 37.9 -37.9 0
1.18 Total 36.67 925.27 -34.94 890.33

2.0 For Organic Pigment
2.1 Organic Yellow Pigment

No.
Ton per Per month
ton of FG
expansion
2.1.1 Base (Amine) 0.405 34.425 12.15 46.575
2.1.2 Ice 6 510 180 690
2.1.3 Sulphamic acid 0.009 0.765 0.27 1.035
2.1.4 Sodium nitrite 0.69 58.65 20.7 79.35
2.1.5 Hydro Chloric Acid 0.96 81.6 28.8 110.4

(30%)
2.1.6 Caustic 0.35 29.75 10.5 40.25
2.1.7 Acetic acid 0.285 24.225 8.55 32.775
2.1.8 Xylene (Recovered) 0.539 45.815 16.17 61.985
2.1.9 Xylene (Fresh) 0.011 0.935 0.33 1.265
Total 9.249 786.165 277.47 1063.635
2.2 Organic Red Pigment
2.2.1 Base (Amine) 0.42 35.65 12.6 48.23
2.2.2 Ice 14.56 1237.86 436.89 1674.75
2.2.3 Sulphamic acid 0.02 2.06 0.73 2.79
2.2.4 Sodium nitrite 0.19 16.50 5.83 22.33
2.2.5 Sulphuric acid 2.91 247.57 87.38 334.95
2.2.6 Caustic 0.63 53.64 18.93 72.57
2.2.7 Hydro Chloric acid 0.97 82.52 29.13 111.65
Total 19.7 1675.82 591.46 2267.28


No.
Ton per Per month
ton of FG
expansion
2.3 Organic Orange Pigment
2.3.1 Base (Amine) 0.405 34.43 12.15 46.575
2.3.2 Ice 9 765.00 270 1035
2.3.3 Sulphamic acid 0.007 0.60 0.21 0.805
2.3.4 Sodium nitrite 0.24 20.40 7.2 27.6
2.3.5 Hydro Chloric Acid 1.08 91.80 32.4 124.2

(30%)
2.3.6 Caustic 0.32 27.20 9.6 36.8
2.3.7 Emulsifier 0.02 1.70 0.6 2.3
2.3.8 Xylene (Recovered) 0.539 45.82 16.17 61.985
2.3.9 Xylene (Fresh) 0.011 0.94 0.33 1.265
Total 11.622 987.87 348.66 1336.53
3.0 For Pigment emulsion (Pigment Black Dispersion) :
3.1 Carbon black pigment 0.105 14.385 3.47 17.85
3.2 Surface active agent 0.015 2.055 0.5 2.55
3.3 Glycols 0.02 2.74 0.66 3.4
3.4 Preservative 0.01 1.37 0.33 1.7
Total 0.15 20.55 4.95 25.5


No.
Tone per Per month
tone
expansion
4.1 For Quinacridone Pigment (Pigment Red 122) :
4.1.1 Aniline 0.04 0.64 0.85 1.50
4.1.2 DMSS 0.71 10.60 14.13 24.74
4.1.3 Para Toludine 0.75 11.31 15.08 26.39

(30%)
4.1.5 Methanol (Recovered) 4.49 67.34 89.79 157.13
4.1.6 Methanol (Fresh) 0.44 6.66 8.88 15.54
4.1.7 Resist salt 0.69 10.28 13.7 23.99
4.1.8 Caustic flakes 0.56 8.35 11.13 19.49
4.1.9 PPA or P2O5 4.28 64.27 85.69 149.96
4.1.10 Iso Butanol 4.11 61.70 82.27 143.96

(Recovered)
4.1.11 Iso Butanol (fresh) 0.17 2.57 3.43 6.00
4.1.12 Caustic lye 0.03 0.51 0.68 1.20
4.1.13 Total 18.25 273.80 365.08 638.88

4.2 For Quinacridone Pigment (Pigment Violet 19) :

No.
Ton per Per month

ton of
FG

expansion
4.2.1 Aniline 0.79 11.95 15.93 27.89
4.2.2 DMSS 0.71 10.60 14.13 24.74

(30%)
4.2.4 Methanol 4.49 67.34 89.79 157.13

(Recovered)
4.2.5 Methanol (Fresh) 0.44 6.66 8.88 15.54
4.2.6 Resist salt 0.69 10.28 13.7 23.99
4.2.7 Caustic flakes 0.56 8.35 11.13 19.49
4.2.8 PPA or P2O5 4.28 64.27 85.69 149.96
4.2.9 Dimethyl Formamide 7.47 112.05 261.45 373.5

(Recovered)
4.2.10 Dimethyl Formamide 0.4 5.94 13.86 19.8

(fresh)
4.2.11 Caustic lye 0.03 0.51 0.68 1.20
4.2.12 Total 21.83 327.45 764.05 1091.5

Water and Waste Water Management
Ö Total Raw Water requirement is 1564 kl/day supply will be met from GIDC water supply dept.
Copy of GIDC water supply is enclosed herewith.
Ö Total industrial Waste Water Generation is 1274 KL/Day.
Ö Domestic waste water (95 KL/day) will be disposed off through Septic Tank.
Air Emission and its Control Measures

Flue gas emission:
Ö At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers,
one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired
thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new
boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare
capacity to supply the steam for proposed expansion.
Ö The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA &
125 KVA capacities, as stand by. It will be used only during power failure.
Ö Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler.
Adequate stack height and stack monitoring facilities is provided.
Process gas emission:

• Presently the unit has installed Two no of multi cyclone separator followed by bag filter
attached to pulveriser. After proposed expansion, the unit shall install one additional multi
cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent
will be provided .(Detail of Air pollution control measures is attached as Annexure-10)
Hazardous Wastes and its Management
Sr. Type of Cat Quantity, TPM Storage Disposal

No. hazardous waste egor Capacity
Existing After
y , m2
proposed
expansion
1 ETP waste 34.3 30 40 50 Dispose off into
TSDF, Vapi
2 Used oil 5.1 0.1 0.25 5 Sell to Registered

recyclers
3 Discarded 33.3 1.25 2.0 10 ReUse for

containers packing finished
product or Sell to
Autho. recycler
4 Distillation 35.1 9 26.6 20 Sell to cement

Residue industries for co-
processing .
5 Iron Sludge 35.2 40 0 0 -
6 Spent catalyst 35.2 0 0.19 5 Sent for re-

processing

2. Introduction of the Project and the Proponent.

Name of the project Proponent: Pidilite Industries Limited
Pidilite Industries Limited is a large scale unit is located in notified industrial estate,
GIDC, Vapi Di: Valsad, Gujarat having total plot area of 38443.09 m2 & total investment
after proposed expansion will be Rs. 2100 lacs. The proponent wishes to enhance the
Production capacity of Existing Products by @ 33 %. The Organic pigments products are
especially used in paint, textiles, plastics, cosmetics, ink, etc.
The unit is operated by technocrats having more than 35 years of experience in

manufacturing and marketing of various Organic pigments worldwide.
The company has established well equipped production plant which is being managed by
dedicated, qualified & skilled persons.
The proposed expansion proposes to enhance the capacity of all the pigments & Pigment
Emulsion to 350.0 MT per month and process capabilities to manufacture all types of
Organic pigments & Emulsions.
The proposed expansion project site lies on 20021’17.95” N Latitude & 72054’55.15” E
Longitude. Pidilite Industries Limited is located at Plot. No. 23 ,1st phase area, GIDC
Vapi, Di: Valsad district in Gujarat state. GIDC Vapi is centrally located in the both sides of
National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union
territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side. The
western Railway Main Line passes through the area (Double & Electrified). Vapi is the
biggest railway station in the study area; where, almost all the important mail & express
trains stop. Entire study area is well connected with other major cities of the state and the
country.
Beside the rail connectivity, the site is also well connected by road transport. There is a good
network of roads in the area and contributes for the development and economic growth of the
area. The National Highway No. 8 (Surat – Mumbai) is now having a six lane, double tracked,
more elevated and Jam free highway, developed by L&T Company. This highway has given
a further boost to the economic growth of this area.
The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is
crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected to
each other by a Pucca road.
About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat –
Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of
GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for
chemical manufacturing industrial units. Over the years, it has emerged as a major
cosmopolitan industrial township equipped with hospitals, school & colleges, community
centers, temples, churches, mosques, cinema house, fire stations, blood banks, water
filtration plants, police stations, post offices, banks, telephone exchange, hotels, guesthouses
etc. The town has got a major face-lift after the completion of national highway . Other links
roads are also of good standard. Mumbai, the economic capital of the country is 180 km from
Vapi; whereas, the state capital “Gandhinagar” is 370 kms away. The district Head Quarter –

Valsad is 30 km from Vapi town.
VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968.
The entire estate, which was developed in phases, is now spread over 1140 hectares and houses
more than 1400 industries, most of which are small-scale industrial units although some of
them have grown into bigger units at later stage. The industrial township is basically a declared
“Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical
related, such as Dyes and Dyes intermediates, pigments, pesticides, fine chemicals,
pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics,
engineering, textiles, paints, food processing, printing, etc. One of the country’s largest
common effluent treatment plants has been setup in Vapi industrial estate. Being a major
industrial & commercial centre, it caters to other peripheral industrial estates like Daman,
Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.
PIDILITE INDUSTRIES LIMITED , whose inception dates back to 1959 , has been a
pioneer in consumer and specialties chemicals in India. Over two-third of the company’s turn
over comes from products and segments it has pioneered in India.
Our product range includes Adhesives and Sealants, Construction and Paint Chemicals,
Automotive Chemicals, Art Materials, Industrial Adhesives, Industrial and Textile Resins and
Organic Pigments and Preparations. Most of the products have been developed through
strong in-house R&D.
The Group's turnover is about 4283 Crores for the year 2013-14.
In a recent report by Economic Times, Pidilite ranked 131st amongst the top 500 listed
companies in India.
Pidilite Industries is the market leader in adhesives and sealants, construction chemicals,
hobby colours and polymer emulsions in India. Our brand name Fevicol has become
synonymous with adhesives to millions in India and is ranked amongst the most trusted
brands in India.
Pidilite is also growing it's International presence through acquisitions and setting up
manufacturing facilities and sales offices in important regions around the world.
Fevicol is now the largest selling adhesives brand in Asia.
We have reached where we are today mainly due to the close team-work of our employees
and due to our shared value system which emphasizes commitment to excellence, closeness
to customers, and the spirit of innovation.
The management is concerned about Environment and Safety issues and gives utmost
importance to these aspects by continuous training & improvement followed by various
external Audits. Company is ISO9001:2000, IS0 14001:2004 and OHSAS 18001:2007
certified. We have a strong R&D team which guides us from its Mumbai Centre. We have a
small Pilot plant at this site to support the R & D activities which is supported by Mumbai
team.
Award achieved by the company are as under :

• 2nd Prize for House Keeping Competition held by DISH under Nirmal Gujarat-
District level competition (2006)
• 2nd Prize at the National level TPM poster competition organized by CII- TPM club
of India (2006)
• 1st Prize for House Keeping Competition held by DISH under Nirmal Gujarat-
District level competition (2007)
• 7 Prizes for State level Safety Competition organized by DISH and Gujarat safety
Council for posters, slogans, Poems etc. (2008)
• 1st Prize for State level Road Safety Poster Competition organized by DISH and
Gujarat safety Council for posters, slogans, Poems etc. (2009)
• 2nd Prize for State level Road Safety Poster Competition organized by DISH and
Gujarat safety Council for posters, slogans, Poems etc. (2010)
• The unit has experienced technocrats having more than 35 years of experience in
manufacturing and marketing of Organic pigments & chemicals.
• The company has prepared well equipped production plan which will be managed by
dedicated, qualified & skilled persons.
(i) Identification of the project proponent :
M/S Pidilite industry Limited is a large scale unit is located at notified industrial estate,
GIDC Vapi, Di: Valsad, a well enthusiastic & professionally managed manufacturer & marketer
of Organic pigments & chemicals especially used in paints, inks industries as
per requirement.
List of Directors :
• Shri M.B.Parekh – Chairman & Managing Director
• Shri N.K.Parekh – Jt. Managing Director
• Shri A.B.Parekh – Whole time Director
• Shri A.N.Parekh – Whole time Director
• Shri R. Sreeram – Whole time Director
All the Board Members are well qualified in Engineering, Management, Accounts,
operations and Marketing field.
Apart from these there are Expert from Field- Industries, Financial Institues and others as a
Part time / Independent Directors on Board for Better Management , They are :
• Shri Uday Khanna
• Shri N.J.Jhaveri
• Shri Bansi Mehta
• Shri Ranjan Kapur
• Shri Yash Mahajan

• Shri Bharat Puri

• Shri Sanjeev Agha
• Smt. Meera Shankar
They help us to achieve & perform better & better.
ii) Brief description of nature of the Project :
Pidilite Industries Limited proposes to enhance the production capacity at Plot No. 23, 1st
phase, GIDC, Vapi-396195, Dist.- Valsad (Gujarat).
The proposed expansion project involves the capacity enhancement of existing Products viz.
“Organic Pigments” ( Azo Pigments), Quinacridone Pigments & Pigment Emulsions As per
the amended EIA notification- 2006, the proposed products are covered under category 5(f)-
A and hence require Prior Environmental Clearance.
iii) Need for the project and its importance to the country and region:
The proposed project provides a potential growth opportunity for the ongoing business of
the company. The company is engaged in the business of manufacturing of Various
Organic Pigments & Pigment Emulsions. The project would also help the company to
support the Indian economy in the following way:
• Growth in Export Revenue and there by increasing the inflow of foreign currency which
is much needed by our country.
• Our products are well accepted by international users and can substitute the
international Pigment Grades. Thus the Domestic Industry can replace the imported
Pigments used by them with ours and there by curtail the outflow of foreign currency
spent on pigments imported by them.
• Potential increase in Job opportunities for the Local surroundings.
• Boost to the Local service providers and the overall improvement in the economic
activities like Local RM Suppliers, Transporters , contractors, clearing and forwarding
agents and other allied suppliers.
Additional Production capacities are required in Azo, Quinacridone, & Pigment Emulsion as
the company expects growth of Exports to the tune of 40-50% in the next 2-3 years. Also
the Domestic market is showing Strong Growth Potential as many multinational companies
which use pigments as raw material have put up their manufacturing plants in India. Added
to this Indian users of Pigments have expanded their own manufacturing capacities to cater
to the growing demand of their finished products.
The Company Objective is to achieve :

• Consolidation of Organic Pigments & Pigment Emulsions business. The Proposed
expansion will help the company to move towards more specialized products and there
by focus on value addition which will improve the shareholder's worth.
• The Proposed increase in capacity will also assist the company to reduce the costs due
to increase in the sale of manufacturing and intern make the company's products more
competitive in the market.
Considering the nature of Pigment business, the proposed increase in capacity will also help
the company to standardize and produce the Pigments with more consistency because higher
volumes will help to achieve better control over Physico-chemical conditions while
manufacturing.
• To generate Local Employment
iv) Demand –Supply Gap :
Our Organic Pigments & Pigment Emulsions are mainly used by various paint, ink, plastic
master batch & textile industries. Though the Global production capacity of Organic
Pigments is on the higher side as compared to demand, Customer preference of environment
friendly products and high performance Pigment is still not fulfilled satisfactorily. Since our
products are approved by quality conscious users which are multinational paint, ink and
textile companies. We can cater to the ever increasing demand in India as well as in the
Export Market.
• ORGANIC PIGMENTS ( AZO PIGMENTS )

Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK,
Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia,
Indonesia, Australia, China ,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey,
Singapore,Uruguay
Potential customers: USA, U.K., France, Italy, switzerland, Holland, Belgium,

Luxembourg, Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE
etc.
New customers in existing countries – Brazil, USA, Australia, Denmark, Italy, Finland, UK,
Holland, France ,Belgium, Japan, Philippines,Malaysia, Thailand, Indonesia,Turkey etc.
Projected Export demand : USA, Canada & Latin America-1845 MT/Year, Europe – 2475
MT/Year, Japan - 100 MT/Year, Rest of the World (excluding China) – 224 MT/Year.
Currently we are exporting about 400-450 MT/Year of AZO class Organic Pigment powder.
We expect to acquire 10-15% of the projected export demand.
Domestic market for our range of organic pigments is about 900 MT/Year and our market
share is about 25%. Market is expected to grow by 20%.
• QUINACRIDONE PIGMENTS :
Current Export : USA, Brazil, Canada, Denmark, France, Italy, Portugal, Holland, UK,
Russia, Germany, Pakistan, Finland, South Africa, Srilanka, Bangladesh, Thailand, Malaysia,
Indonesia, Australia, China ,Mexico, Luxembourg, Belgium, Philippines, Japan,Turkey,

Singapore,Uruguay.
Potential customers: USA, U.K., France, Italy, Switzerland, Holland, Belgium, Luxembourg,
Japan, Australia, Korea, Taiwan, Vietnam, Saudi Arabia, Turkey, Egypt, UAE etc.
New customers in existing countries – Brazil, USA, Australia, Denmark, Italy, Finland, UK,
Holland, France ,Belgium, Japan, Philippines, Malaysia, Thailand, Indonesia, Turkey etc.
Projected Export demand: USA, Canada & Latin America-1000 MT/Year, Europe – 500
MT/Year, Japan -335 MT/Year, Rest of the World (excluding China) – 400 MT/Year.
Currently we are exporting about 170 MT/Year of QUINACRIDONE class Organic Pigment
powder. We expect to acquire 10-15% of the projected export demand.
Domestic market for our range of organic pigments is about 300 MT/Year and our market
share is about 25%. Market is expected to grow by 20%.
• EMULSION:
Current Export to: Bangladesh, Vietnam, Srilanka, Thailand, Phllipens, China, Hongkong,
Mauratitus.
Potential markets in : Pakistan, Indonesia, Ethiopia, Kenya, Malavi.
New customers in existing countries – Vietnam, Bangladesh, Thailand, Phillipens, USA,
Projected demand : USA-2000 MT/year, Bangladesh- 1800 MT/year, Pakistan-3000

Mt/yr, Thailand-1500 MT/Year, Vietnam-1000 MT/Year, Phillipens-1200 MT/Year,
Mauratious- 500 MT/Year, Srilanka – 800 MT/Year, African countries – 1800 MT/year.
Domestic market – Potential-7000 MT/Year. It is expected to grow @ 20% per annum.

Our current market share is about 40% of the domestic market. We expect to grow by 25-
35 %.
v) Imports vs. Indigenous production :

Existing products manufactured in the country will be very much economical compared to
imports of the same and also the export of the same will earn extra revenue generation for
Our county.
vi) Export Possibility:

Existing products have high export potential. Also these products have very good potential
in the local market.
Additional capacities of product range required over & above the unit’s existing capacities,
as the company expects strong growth of exports to the extent of 40-50%. Local market

also shows strong growth potential.

vii) Domestic / export Markets:
The company’s products are used in various in paint & ink industries as per requirement.
These are having very good demand in domestic as well as international markets.
viii) Employment Generation (Direct and Indirect) due to the project:
There will be very good opportunity of employment generation directly and indirectly due
to proposed expansion project. Due to proposed project there will be requirement of
manager, supervisor, operator and semi-skilled workers. For this, the company will employ
about additional 20 people to fulfil it’s need to handle the plant. So that 20 people will be
directly employed and more than 50 will be indirectly employed.

3 Project Description :
(i) Type of Project including interlinked and interdependent projects, If any :

The proposed project is an interdependent project of the company.
(ii) Location (map showing general location, Specific location, and project boundary &
project site layout) with coordinates :
The map showing general location, specific location and project boundary and project site lay
out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.
(iii) Details of alternate sites considered and the basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted :
• The proposed activity will be accommodated in the notified industrial area having proper
industrial infrastructure so; there is no alternate site consideration. Proposed expansion
will be carried out in exiting premises only. (Land allotment letter is attached as
Annexure-8)
(iv) Size or magnitude of operation :

As per the proposed project cost, the project is covered under large Scale category of
manufacturing industries.
(v) Project description with process details (a schematic diagram/ flow chart showing the
project layout components of the project etc. should be given) :
Detailed project description with process details is enclosed as Annexure-3
(vi) Raw material required along with estimated quantity, likely source, marketing area of
final products/s, mode of transport of raw Material and finished product :
Detailed raw material requirement along with estimated quantity, likely source, marketing
of final products, mode of transport of raw materials and finished products & characteristics
of hazardous chemicals are as below:
DETAILS ON PRODUCT TRANSPORTATION
Sr. Product Physical State Dispatch Means of

No. transportation
1 Carbazole Dioxane Solid Local /export Truck/container
Violet Pigment
(Pigment Violet 23)
2 Organic Azo Pigment Solid Local/export Truck/container
(Orange/Yellow/Red)
3 Pigment emulsion Paste Local /export Truck/container
4 Quinacridone Solid Local /export Truck/container

Pigment

5 Phosphoric acid Liquid Local/export Truck/container
6 Calcium Sulphate Solid Local Truck

(Gypsum)
DETAILS OF RAW MATERIAL – TRANSPORTATION

Sr. Substance Physical Type of Means of Distance of supplier
No. State packing Transportati from project site (km)
& supply on
1 Carbazole Solid 25 Kgs Sea & Road Imported &
(Powder) & 400 350 Kms Local
Kgs
2 Diethyl sulphate Liquid Tanker Road 300 Kms
3 Caustic flakes SOLID 50 Kg Road 250 Kms

(Flakes) Bags
4 Mono Chloro Liquid Tanker Road 200 Kms

Benzene (Fresh)
5 Nitric acid Liquid Tanker Road 200 Kms
6 ODCB (Fresh) Liquid Tanker Road 5 kms
7 Catalyst Liquid Drums Road 250 Kms
8 Nitrogen Liquid Cylinder Road 40 Kms
9 Hydrogen Liquid Cylinder Road 200 Kms

Bank
10 Chloranil Powder 50 Kg Road 400 Kms
Bag
11 Catalyst RAC Powder 50 Kg Road 5 Kms
Bag
12 Benzene sulpho Liquid 250 Kg Road 150 Kms
chloride Drums
13 Salt Powder 50 Kg Road 350 Kms

Bag
14 Di ethyl Glycol Liquid Tanker Road 200 Kms
15 Base (Amine) Powder 25 Kg Road 500 Kms

Bag
16 Ice Solid - - Self Manufactured
17 Sulphamic acid Solid 50 Kg Road 200 Kms

(Powder) Bag
18 Sodium nitrite Solid 50 Kg Road 300 Kms

(Powder) Bag

Sr. Substance Physical Type of Means of Distance of supplier

No. State packing Transportation from project site (km)
& supply
19 Hydro Chloric Liquid Tanker Road 300 Kms
Acid (30%)
20 Caustic Lye Liquid Tanker Road 300 Kms
21 Acetic acid Liquid Tanker Road 200 Kms
22 Xylene (Fresh) Liquid 200 Kg Road 250 Kms

Drums
23 Sulphuric acid Liquid Tanker Road 5 Kms
24 Emulsifier Liquid 50 Kg Road 20 Kms

Drum
25 Carbon black Solid 25 Kg Road 5 Kms
pigment (Powder) Bag
26 Surface active SOLID 30 Kg Road 300 Kms

agent (Powder) Bag
27 Glycols Liquid Tanker Road 300 Kms
28 Preservative Liquid 50 Kg Road 400 Kms

carboy
29 Aniline Liquid Tanker Road 200 Kms
30 DMSS Solid 100 Kg Sea + road Imported

(Powder) Drum
31 Para Toludine Solid 210 Kg Sea + Road Imported

Drum
32 Methanol Liquid Tanker Road 300 Kms
(Fresh)
33 Resist salt Solid 50 Kg Road 5 Kms

(Powder) Bag
34 Caustic flakes Solid 50 Kg Road 250 Kms

(Powder) Bag
35 PPA or P2O5 Liquid/ 300 Kg Road +Sea 25 Kms & Imported
Solid Drum
36 Iso Butanol Liquid Tanker Road 300 Kms

(fresh)

vii) Resource optimization/ recycling and reuse envisaged in the project, if any,
should briefly outlined:
Resource optimization/recycling and reuse envisaged in the project (solvent recovery
system) in detail are as mentioned below.
• The raw materials will be stored in closed containers and will be handled through closed
system to avoid the handling losses.
• The solvents are reused in the manufacturing of Pigment Violet, Quinacridone & Azo
pigments. Details of solvent use & recovery are as under.
• Wash water is also recycled in process as shown in the process flow diagram.
PRODUCT WISE SOLVENT USED/RECOVERED PER TONE OF PRODUCT

FOR EXISTING & PROPOSED EXPANSION
Sr. Product Solvent Quantity Loss Quantity Loss,

No. used ton /tone per ton /month MT/
MT
Fresh Recycle Fresh Recycle Month
1 Quinacridone Methanol 0.443 4.489 0.443 15.505 157.11 15.5
Iso Butanol 0.171 4.113 0.171 5.985 143.95 5.985
DMF 0.396 7.47 0.396 13.860 261.45 13.86
2 Carbazole MCB 0.32 3.23 0.32 8.000 80.75 8.0
ODCB 1.11 17.71 1.11 27.750 442.75 27.75
Methanol 0.59 3.14 0.59 14.750 78.43 14.75
3 Azo Pigment Xylene 0.011 0.539 0.011 1.265 61.985 1.265
Total 3.041 40.691 3.041 73.200 964.98 73.2

viii) Availability of water its source, Energy/power requirement and source should be given :
Availability of water its source, Energy/power required and its source is below. Water withdrawal
Permission is attached as Annexure: 4
Sr. No. Particulars Water consumption, m3/day

expansion
1 Domestic 95 0 95
2 Processing & 1100 -185 915
washing
3 Boiler 116 28 144
4 Cooling 125 35 160
5 Floor/container 100 50 150
washing
6 Gardening 50 50 100
7 Total 1586 -22 1564
WATER CONSUMPTION (m3/DAY)
ENERGY REQUIREMENTS AND ITS SOURCE

Sr. Particulars Existing After Source

No Kgs/hr Proposed
. expansion
Kgs/Hr
1 Steam 5500 8000 Will be obtained by installation of
requirement Briquette Fired Boiler having
Steam generation capacity of 12
TPH .Existing 8 TPH will be
standby.
POWER REQUIREMENTS AND ITS SOURCE
Sr. Particulars Existing After Source

No Proposed
. expansion
1 Power – Electricity 1600 KVA 1900 KVA Sourced from
requirement Dakshin Gujarat
Vij Co. Ltd.
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their
Management/disposal:
Quantity of waste to be generated (liquid and solid) and scheme for their Management/
disposal is enclosed as Annexure-5.
(x) Schematic representations of the feasibility drawing which give information of EIA
purpose:
A schematic representation of the feasibility drawing is enclosed as Annexure -9.

4 Site Analysis
(i) Connectivity :
The project is located in notified Industrial Estate of Vapi which is very well connected to
National Highway no.8 and Western Railways. The nearest airport is Mumbai which is 150
KM away from the project site by road.
(ii) Land Form, Land use and Land ownership :

The land is in the form of industrial shed owned by Gujarat Industrial Development
Corporation.
(iii) Topography (along with map) :

Topography map showing the elevation of the study area below. The topographical map is
enclosed as Annexure-7.
(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including
area under CRZ)), shortest distances from the periphery of the project to periphery of
the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance
from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette
notification should be given :
The existing land is located in the notified industrial area and a copy of which is enclosed as
Annexure-8
(v) Existing Infrastructure :

GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads,
rail, transportation, availability of raw material and drainage system.
(vi) Soil classification :

General soil classification of the area is as under :
• Soil Characteristics & Land use classification: The study area is located at outer part
of Dadra. Northern part of the site is fully developed for settlement with cropping
pattern. Eastern part of the site location has Loamy, clay, Red soil.
• The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil.
This type of soil is not suitable for cultivation purpose.
• The land is suitable for industrial development.
Damanganga River is located at 3 km distance from the site location; both side of the river has
mixed soil type (Sand, clay & Basaltic soil).
(vii) Climate data from secondary sources :
Rainfall Data :
The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having
coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the
study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch
district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot
and Surendranagar districts. These are also characterized by arid climate. The high rainfall (>
1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar
Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the
state receives rainfall between 500-1000 mm and generally falls under semi-arid climate.
Considering the abnormality of weather particularly rainfall during the monsoon period, the
observed and predicted rainfall was then analyzed for its validity.
Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)
Sr. Region Rainfall Normal Rainfall Projection

No Projection Rainfall (In (% Departure from
(in mm) June - mm) normal)
Oct
1 Middle Gujarat 905.3 796 13.7
2 South Gujarat 696.3 575 21.0
3 Project site 2071.7 1433.7 44.5
4 Saurashtra 767.1 580.4 32.2
5 Gujarat State 1110.1 846.5 31.1
Source: AAU, Anand, Gujarat
Temperature Data:
The site is located in the southern part of Gujarat. The secondary data was collected from free
data of Worldclim.org for the year 2010. The project site temperature regime for medium to
high level temperature (30-32 °C) during the seasonal months (June to Sep).
(viii) Social Infrastructure available :
Social Infrastructure in Valsad district is as under :
Education: There are 990 primary, 161 secondary and higher secondary schools.
There are 6 ITIs offering several industrial training Institutes programs which includes, fitting,
armature & motor rewinding, electrician, information technology and electronic system
maintenance etc., 166 Higher Secondary School, One Government polytechnic College is
present in the district offering courses in civil, chemical, electrical, mechanical and plastic
engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nos of Polytechnic College With
120 seats, there is one Engineering College, Pharmacy College, Arts, Commerce, Science, B.
Ed and Law College. Valsad district also has institutes which offers management studies with
fulltime MBA.
Source: Department of Education, 2007
Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10
Government and 1 Municipal hospital present in the district. Valsad has several private
specialized hospitals to provide a comprehensive range of tertiary and secondary care services
backed by state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch
of Nadkarni Group of Hospitals) is present in Vapi, providing services in general and
laproscopic surgery, trauma, orthopedic and urology etc. The hospital is one of the few centers
in India offering Uterine Thermochoice Thermal Balloon Therapy for Dysfunctioning Uterine
Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital,
Bhatia General Hospital and Adarsh Hospital are also present in Valsad.
Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is
also known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage
center throughout the world. Dharampur is surrounded on three sides by the Sahyadri
Mountains which grace the town with pleasant climate throughout the year. The collection at
the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the
local culture. Besides this, District Science Centre is also present in Valsad Proximity of

Valsad with Daman & Diu, which has increased the graph of tourist flow in the district.
5. Planning Brief :
Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country
Planning /Development authority Classification :
There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged
in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper
mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the
Gujarat Industrial Development Corporation (GIDC) notified area of Vapi.
Population Projection :
• Not applicable
Land use Planning (breakup along with green belt etc) :
The existing as well as proposed expansion project is located within the Notified Industrial
Area by Government of Gujarat and due to the proposed project there will not be any change
in the land use pattern of the region. Proposed Green belt planning in the project area is as
below.
For Green Belt Development as per the revised layout plan, the company proposes 33% green
belt of the total land, i.e. 12686 sq. meter. The company shall develop green belt along the
periphery of the proposed site and in common premises available outside the company
premises.
While selecting the plants species to be grown in the green belt zone, following points will be
taken into account:
1. Climatic condition and soil characteristics of the region.
2. The air pollution emitted by the industry – gaseous and particulate matter. Plant
interaction with both gaseous and particulate pollutants and to a great extent absorbs
them and thus, removes them from the atmosphere.
3. Characteristics of plants including shapes of crowns considered necessary for
effective absorption of pollutant gases and removal of dust particles.
4. Height of the plants should not be too high to be lethal.
5. For absorbance of gases, the duration of the foliage should be longer.
6. Vegetation controls soil erosion rates significantly. The decrease of water erosion
rates with increasing vegetation cover is exponential. This review reveals that the
decrease in water erosion rates with increasing root mass is also exponential. Plant
species having good root system are selected, so that soil erosion can be checked.

Site Plan with Area Table at Existing & After proposed expansion
Sr. No Particulars Area in m2

expansion
1.0 Total plot Area 38443 0 38443
1.1 Production Plant 14635 200 14835

1.2 Office & lab area 515 0 515
1.3 OHC Area 50 0 50
1.4 Green Belt 11734 952 12686
1.5 Raw materials & other Storage 2032 0 2032
1.6 Solvent storage area 529 0 529
1.7 Utility 285 0 285
1.8 Boiler shed area 500 0 500
1.9 ETP & solid waste storage area 784 0 784
1.10 Toilet block 112 20 132
1.11 Open space 7267 -1172 6095
Site map with Green Belt Development Planning

(iv) Assessment of Infrastructure demand ( Physical & Social) :
There is no need for any infrastructure demand in terms of physical or social needs for the
proposed expansion.
(v) Amenities/ Facilities :
GIDC notified industrial area of Vapi has the available infrastructure like water, electricity,
roads, rail, transportation, availability of raw material and drainage system.
6 Proposed Infrastructure:
(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standard
engineering design considering all the relevant parameters related to environment, health
and safety.
(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project
(iii) Green Belt :

Green belt will be provided and maintained at the tune of 33% of the total land area.
(iv) Social Infrastructure :

Not applicable
(v) Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc):
The project site is very well connected by road through National Highway no. 8, western
railways.
(vi) Drinking Water management ( Source & Supply of water ) :

Source of water is from GIDC water supply services.
(vii) Sewerage System :

GIDC has provided sewerage system to dispose the sewage effluent.
(viii) Industrial Waste Management :

Industrial liquid effluent generated after proposed expansion will be treated in the primary &
secondary ETP and will be discharged through GIDC underground drainage to
CETP.(Membership certificate is attached as Annexure-6)
Generated domestic liquid waste is being disposed off through soak pit system to
drainage.

(ix) Solid/Hazardous Waste Management :

Sr. Type of Cat Quantity, TPM Storage Disposal
No. hazardous waste egor Capacity
Existing After
y , m2
proposed
expansion
1 ETP waste 34.3 30 40 50 Dispose off into
TSDF, Vapi
2 Used oil 5.1 0.1 0.25 5 Sell to Registered

recyclers
3 Discarded 33.3 1.25 2.0 10 ReUse for

containers packing finished
product or Sell to
Autho. recycler
4 Distillation 35.1 9 26.6 20 Sell to cement

Residue industries for co-
processing .
5 Iron Sludge 35.2 40 0 0 -
6 Spent catalyst 35.2 0 0.19 5 Sent for re-

processing
(Membership certificate is attached as Annexure-6)
(x) Power Requirement & Supply / Source :

Power requirement for proposed project will be taken from DGVCL.
7. Rehabilitation and Resettlement (R&R) Plan:
(i) Policy to be adopted (Central/ State) in respect of the project affected persons
including home oustees, land oustees and landless laborers (a brief outline to be
given):
There will be no rehabilitation and resettlement undertaken as labours and workers from
local & nearby areas for the proposed construction activity which will be minor as the
proposed expansion activity is to be undertaken at the existing site.

8. Project Schedule & Cost Estimates :
(i) Likely date of start of construction and likely date of completion ( Time schedule
for the project to be given ) :
After obtaining Environmental clearance and Consent to Establish from GPCB, the
company shall start the proposed construction and commissioning of the project.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project :
Estimated project cost along with the analysis in terms of economic viability of the
project is given as below.

CAPITAL COST PROJECTION
Cost in INR (Crore)

Sr. Particulars Existing Proposed Total
No.
1.0 Land 38443 m2 4.0 0 4.0
2.0 Building 12.0 2.0 14.0
3.0 Plant & Machinery
3.1 Equipment & machineries 67.74 10.0 77.74
3.2 Pipes & fittings 12.40 2.0 14.4
3.3 Utilities 22.24 3.0 25.24
4.0 Environmental Management 7.87 4.0 11.87
System
5.0 Total Project Cost 126.25 21.0 147.25
6.0 Utilities
6.1 Boiler, TPH 12+8 + 2 0 12 + 8 + 2 (8
- Standby)
Thermopack, k cal/hr 10 +4 0 10 +4
6.2 Cooling Tower, TR 1300 650 1950
6.3 D.G. Set (Standby) 0 750, 750, 750, 750, 125
125
7.0 Power from DGVCL, KVA 1600 300 1900
8.0 Fuel
8.1 Briquette /Natural Gas for 1.45 MT/Hr of 0.655 2.105 MT/Hr
Steam Boiler (12 Tons/Hr) Briquette or 410 MT/Hr Briquette or
SCM/Hr Briquette 590 SCM/Hr
or 180
SCM/Hr
8.2 Natural gas for Thermopak (10 2000 SCM/day 0 2000
lacs & 4 lacs) SCM/day
8.3 Natural gas for steam boiler (8 8750 SCM/day 0 8750
TPH & 2 TPH) SCM/day
8.4 Fuel (HSD) for D.G.Set 0 225 kgs/hr 225 kgs/hr
(Capacity: 750 x 2 & 125
KVA)
9.0 Water from GIDC Vapi 1586 -22 1564
kl/day
10.0 Waste Water (Industrial) 1358 -84 1274
kl/day

PROJECT VIABILITY
Sr. PARTICULARS AMOUNT (INR Crore)

No.
1 Proposed Sale 254
2 Raw Material Cost 150.5
3 Power & Fuel 34
4 Labour Cost 15
5 Environmental Management System 1.5
6 Maintenance Cost 15
7 Selling, packing & Office Expenses 15
8 Proposed Profit 23
The company will provide budgetary provision for the recurring expenses for
environmental issues while planning the allocation of funds during the annual budgetary
planning.
RECURRING COST PER ANNUM
Proposed
Sr. No. Component
(Rs. in Lacs/annum)
1. Environment & Safety Management System 68
2. Greenbelt Maintenance 12
3. Solid waste Disposal 70
Total 150
8. Analysis of Proposal ( Final Recommendations):
(i) Financial and social benefits with special emphasis on the befit to the local people
including tribal population, if any, in the area:
Proposed expansion activity will provide benefits to the local people in terms of financial and
social welfare.
• Local people will get direct financial benefit by way of employment.

• Local people will get some contracts of supply and services to get indirect income.
• Company will contribute in improving education and health facilities in nearby
area.

ANNEXURES

ANNEXURE: 1
Location map showing the Project site and inter-state boundary within 10 kms radius

ANNEXURE: 2
Plant Layout

ANNEXURE: 3
Detailed project description with process details - MANUFACTURING PROCESS

The company is using the latest available process technology for the production. This
chapter includes the manufacturing process of the product, chemical reactions, and material
mass balance & mole balance for the product.
MANUFACTURING PROCESS IN BRIEF
• Azo Pigments (Organic Yellow/Orange/Red):

(a) Preparation of Diazo solution. Water & Hydrochloric Acid is recd in Stirred tank. Primary
Aromatic Amine is added along with Ice. Later Sodium Nitrite is slowly added at 0-5 Deg c.
Solution is maintained at this temp.
(b) Coupler Dissolution : Water , Caustic Lye & Coupler is taken in stirred vessel. This
mixture is heated to required temp. to make uniform solution. And cooled back to room temp.
(c) Coupling reaction : Receive Diazo Solution or Coupler into coupling reactor. Then add
another component at reaction condition in 2-3 Hrs. Heat reaction mass to desired elevated
temp. Check end Point. Stirrer for further 3-4 Hrs till reaction completion. Filter the Solution.
Take out the wet cake.
Filtrate is let out to ETP for treatment. Wet cake is Azo pigment which is further taken for
drying, Pulverizing, blending and packing. Detailed Reaction, Flow Diagram with Material
Balance is enclosed.
• Quinacridone Pigment (PR-122 /PV-19) :
In PR-122 Manufacture ,P- Toludine is condensed with Dimethyl Succino succinate to form
a DTA . It is further oxidised with Resist Salt to form Quinacridone Molecule. This is further
cyclised to get the required Molecule in presence of Poly Phosphoric Acid. Finally the
Pigmentation is done in presence of IBA / DMF as per the Quinacridone, PR-122 OR PV-19.
Detailed Reaction, Flow Diagram as well as Material Balance is enclosed. In PV-19 , in place
of P-Toludine , Aniline is used.
• Carbazole Dioxane Violet Pigment:

Manufacturing Process is carried out in 5 Stages as per the attched sheet. Carbazole is a Main
Raw Material. In First Step , Carbazole Alkylation is carried out with Diethyl Sulfate . Salt is
separated by Addition of Caustic Flakes . Impurities are washed with MCB and water. In
second Step , Resultant Ethyl Carbazole is Nitrated with 65% Nitirc Acid to form Nitro Ethyl
Carbazole. This Nitro Ethyl Carbazole is reduced with Hydrogen to form Amino Ethyl
Carbazole in third Step. Further it is condensed with Choranil and subsequently cyclised to
form Crude Violet. Till this it is Synthesis Process. In Final Step Crude Violet , Pigmentation
is done by various Methods to make Pigment Violet. There are lot of Physical changes done
to get Pigmentation Properties. Detail Flow Diagram as well as Material Balance is also
enclosed.
• Pigment Emulsions:
There are No chemical reaction involved in Pigment Emulsion process. There are only Unit
Operations of Kneading, Pulverising , Milling etc in Emulsion /Dispersion preparations.
Pigments are dispersed in Water to make it compatible for end use. To make it dispersible it is
milled and surface Active Agents , Glycols , Preservative and Other Auxiliaries, additives are
added in water to make the dispersion stable.

CHEMICAL REACTION
( 1 ) Organic Yellow Pigment
Cl Cl
Cl Cl HCl
NH 2 NH2 Cl N=N N=N Cl + 2 NaCl + 4 H2O
NaNO2
3 3’ Dichlorobenzidine
Mol.wt. 253
Diazo
Cl Cl
Cl N=N N=N Cl + 2CH3COCH2CONHC6H5 + 2 NaOH
AcetoAcetanilide
Mol. Wt. 177
Cl Cl
CH3COCH2CONHC6H4 - N=N N=N-C6H4NHCOCH2COCH3 + 2 NaCl + 2 H2O
Yellow pigment
Mol. Wt. 618
Base like: DCB, Fast red G Base, PCONA, MNPT & Coupler like Arylanilides, AAA, Napthol ASIRG

ORGANIC YELLOW PIGMENT
Water: 4000 Kgs

DIAZOTIZATION
Base (Amine) : 405 kgs
Ice: 6000 kgs DISSOLUTION Water: 3000 lits
12064 Kgs + 3990 kgs Coupler : 640 kgs
Sulphamic acid: 9 kgs 3990 Kgs
Na Nitrite: 690 kgs Hours: ½ hr Caustic: 350 kgs
Hours: 1 ½+11/2=3hr
HCl: 960 kgs
Total: 3990 kgs
Total: 12064 kgs
Ice: 6000 kgs
Acetic Acid & Others: 285 kgs COUPLING &
Crude Pigment Slurry: 26339 kgs
Diazotization + Dissolution 16054 kgs TREATMENT
Live steam: 4000 kgs 26339 kgs, Time: 6 Hrs Total : 26339 kgs
Total: 26339 kgs
Filtrate as effluent: 22939 kgs to ETP
FILTERATION
Crude Pigment Slurry: 26339 kgs 26339 kgs, Time: 3 Hrs Wet cake: 3400 kgs
Total: 26339 kgs Total: 26339kgs
Wet cake: 3400 kgs WASHING , Filtrate 39900 (10000 (recycle) + 29900 kgs to ETP
Water: 30000 kgs Fresh 43400 kgs , Time: 6Hrs Wet cake: 3500 kgs
10000 Kgs Recycle
Total: 43400 kgs Total: 43400 kgs
Xylene: 11 kgs Fresh SOLVENT
539 Kgs Recycle Wet cake: 3500 kgs
TREATMENT,
Water:1140 kgs 12 HRS Effluent:26000 kgs
Wet cake: 3500 kgs
Total: 5190 kgs Water + Xylene: 1690 kgs
Water: 26000 FILTERATION & WASHING Xylene recovered: 539

Distillation + Loss: 11 kg +
Effluent: 1140
TRAY DRYING ( 24 Hrs) Water Vapors: 2498 kgs
Wet cake: 3500 kgs 3500 kgs Dry Powder: 1002 kgs
PULVERIZER & PACKING

Dry Powder: 1002 kgs ORGANIC YELLOW PIGMENT: 1000 kgs
(Time: 6 Hrs)

[2] Organic Orange Pigment
Cl Cl Cl Cl
HCl
NH2 NH2 Cl N=N N=NCl + 2 NaCl + 2 H2O
NaNO2
3 3’dichlorobenzidine CH3
CH2 C
Mol wt. 253
Cl Cl
O =C
Cl N=N N=NCl + 2 N + 2 NaOH
N
PMP
Mol wt. 173
Cl Cl
CH3CH CH-N=N N=N- CH CH-CH3

+ 2 NaCl + 2 H2 O
N O=C N
C=O
N N
Orange 13 pigment
Mol .wt. 610
Base like: DCB, Coupler like PMP, MPMP

ORGANIC ORANGE PIGMENT
Water: 2600 Kgs

DIAZOTIZATION
Base (Amine) : 405 kgs
Ice: 5000 kgs DISSOLUTION Water: 4900 lits
9332 Kgs + 5800 kgs Coupler : 580 kgs
Sulphamic acid: 7 kgs 5800 Kgs
Na Nitrite: 240 kgs Hours: ½ hr Caustic: 320 kgs
Hours: 1 ½+11/2=3hr
HCl: 1080 kgs
Total: 5800 kgs
Total: 9332 kgs
Ice: 4000 kgs
Emulsifier & Others: 20 kgs COUPLING &
Crude Pigment Slurry: 23152 kgs
Diazotization + Dissolution 15132 kgs TREATMENT
Live steam: 4000 kgs 23152 kgs, Time: 6 Hrs Total : 23152 kgs
Total: 23152 kgs
Filtrate as effluent: 19752 kgs to ETP
FILTERATION
Crude Pigment Slurry: 23152 kgs 23152 kgs, Time: 3 Hrs Wet cake: 3400 kgs
Wet cake: 3400 kgs WASHING , Filtrate 39900 (10000 (recycle) + 29900 kgs to ETP
Water: 30000 kgs Fresh 43400 kgs , Time: 6Hrs Wet cake: 3500 kgs
10000 Kgs Recycle
Xylene: 11 kgs Fresh SOLVENT
539 Kgs Recycle Wet cake: 3500 kgs
TREATMENT,
Water:1500 kgs 12 HRS Effluent:28800 kgs
Wet cake: 3500 kgs
Total: 5550 kgs Water + Xylene: 2050 kgs
Water: 28800 FILTERATION & WASHING Xylene recovered: 539

Distillation + Loss: 11 kg +
Effluent: 1500
TRAY DRYING ( 24 Hrs) Water Vapors: 2498 kgs
Wet cake: 3500 kgs 3500 kgs Dry Powder: 1002 kgs
PULVERIZER & PACKING

Dry Powder: 1002 kgs ORGANIC YELLOW PIGMENT: 1000 kgs
(Time: 6 Hrs)

[3] Organic Red 2 Pigment
Cl N=NCl
NH 2
Cl
HCl
2H2 O + NaCL
NaNO2 +
Cl
Cl Diazo
2:5 Dichloro Aniline
Mol Wt.162
OH
N=NCl O
Cl
+ NH
C17 H12NO2
( Naphthol AS)
Mol wt.263
O
Cl OH C NH
N=N
Cl
Base like: TCA, DCA, Scarlet G base, Coupler like Naphols
Organic Red 2 Pigment
Mol wt. 436

(3) ORGANIC RED PIGMENT (TOTAL TIME: 48.5Hrs)
Water: 1500 lits

Water: 6000 lits
Base: 432 kgs DIAZOTIZATION Coupler: 590 kgs
11157 Kgs + DISSOLUTION Caustic: 650 kgs
Ice: 6000 kgs
Sulphamic acid: 25 kgs 14240 kgs 14240 Kgs Steam: 1000 kgs
Hours: 1 hr Ice: 6000 kgs
Na Nitrite: 200 kgs
H2SO4: 3000kgs Hours: 6 hrs
Total: 14240 kgs
Total: 11157 kgs
Diazotization + Dissolution:25397 kgs

COUPLING
Ice :3000kgs
Live steam: 3000kgs
32397 kgs, Coupler: 32397 kgs
Time: 10 Hrs
HCL: 1000 kgs Total: 32397 kgs
Total: 32397 kgs
FILTERATION Filtrate as effluent: 27397 kgs to ETP

Coupler: 32397 kgs 32397 kgs, Time: 3 Hrs
Total: 32397 kgs Wet cake: 5000 kgs
Total: 32397kgs
Wet cake: 5000 kgs WASHING ,
60000 kgs Filtrate as effluent: 55000 kgs to ETP
Water: 55000 liters Time: 6Hrs Wet cake: 5000 kgs
Total: 60000 kgs Total: 60000-kgs
Water Vapours: 3970 kgs

Wet cake: 5000 kgs TRAY DRYING ( 24 Hrs)
5000 kgs Dry Powder: 1030 kgs
Total: 5000 kgs
Total: 5000 kgs
Dry Powder: 1030 kgs PULVERIZER & PACKING PRODUCT
(Time: 6 Hrs) (ORGANIC RED PIGMENT: 1030 kgs )

(4) Quinacridone Pigment

NH 2 H
H H
H H
CH 3 OOC OH
+
H 3 COO N Oxidation
2
-H 2 O
HO COOCH 3
H N COOCH3 CH3
H CH 3
H H
P-Methyl Aniline
H
Dimethyl succinosuccinate MW: 406
MW: 2 x 107
C10 H12O6 H
MW: 228 H
CH3 HOOC N PPA(Polyphosphoric Acid)
CH3
CH3OOC N H+
Cyclisation
COOH CH3
COOCH3 CH3 N
N
MW: 376 H Step B
H
C24 H24O4N2
MW: 404 H
O
H N
O
CH 3 N Reflux CH3
N
with Solvent IBA O
CH3 H
N
O Pigment Red 122
Step D P.R.122
H
Step C
C22 H16N2O2 MW: 340
MW: 340 2, 9 Dimethyl Quinacridone
QUINACRIDONE PIGMENT (PIGMENT RED 122)
STEP: I (CONDENSATION)
Aniline: 50 kgs
DMSS 825 KGS
For step-B
Para Toludine 880 KGS ( Reactor ) 2,5
diarylamino
CONDENSATION
-3,6-
HCl (30%) 100 KGS 9612 dihydrotere
phthalate
Methanol 5757 KGS (Recovered From 9612 Kg
Step II: 5239 kgs Fresh 518 kgs )
Water: 2000

STEP: II (OXIDATION)
From Step: I :(9612 kgs) Recycled in Step: I
Resist Salt (800 Kgs)

( Reactor )
Recovered Methanol (5239 kgs)
Caustic Flakes (650 Kgs) OXIDATION
Water:- 14000(KGS) Filtrate: 14129 kgs

Methanol: 5757kg
30%HCI :2300 kg Aques
30% HCl (2200 kgs) Precipitation laye
Water: 5000 lit
8468
Organic impurities kg
:422Kg
Filtration / Centrifuge Caustic:650Kg
Water: 89000 kgs Washing Residue 422

Kg
Wet cake: 3808 kgs Wash water: 97525 lit
Dryer Vapour loss: 2475 kgs
Di toludinoterephthalic acid:
1333 Kg
STEP: III (CYCLIZATION)
From Step:II : 1333 kgs
PPA: 5000 kgs OR

(Phospheric Acid + 4000
REACTOR
Kgs+ P2o5 - 1000 Kgs) 20533
Water:- 14710 KGS
Phosphoric acid (10‐30%)
recovered as by‐product :
FILTERATION 17000 kgs
Filtrate: 104000 kgs

PPA: 30 kg
Water:- 106000 KGS WASHING Organics impurities: 125 kgs
Water: 103845 kgs

Wet cake: 6043 kgs

STEP: IV (PIGMENTATION)
Wet Crude Pigment Red: 6043 kgs

Iso-Butanol: 5000 kgs
Fresh: 200 kgs
Recovered: 4800 kgs
REACTOR Recovered IBA: 4800 kgs
Water:- 8770 KGS
Caustic lye: 40 kgs

WASHING & Filtrate: 15220 kgs
Water:- 106000 KGS FILTERATION IBA: 200 kgs
Water:114938 kgs
Impurities: 42 kgs
Wet cake: 5833 kgs Caustic lye: 40 kgs
Dryer Vapour loss: 4666 kgs
Quinacridone Pigment
(Pigment Red 122): 1167 kgs
In Pigment Violet 19 ( Quinacridone) :
1. In First Condensation Stage – Aniline is used in place of ParaToludiene.

2. In Final Pigmentation Stage DMF is used as Solvent in place of IBA. 9180 Kg
is used, we are distilling DMF and Recovery is 8721 Kgs.
3. Here @ 164 Kgs residue is generated after Distillation.

(5) Carbazole Dioxane Violet Pigment (Pigment Violet 23)
H3C
H2
H
N
DES, MCB N HNO3 N
Alkylation 2+
N O
Carbazole O
N ethyl carbazole
C14H12N2O2
C12H9N (C2H5O)2SO2 C14H13N 3 Nitro 9 ethyl carbazole MW: 240
MW: 167 MW: 154 MW: 195
Hydrogenation
Cl Cl Cl NH2
N O N
O O + Benzene Sulpho Chloride +
3 Amino N Ethyl Carbazole
N O N
Cl Cl
Cl
Chloranil MW: 176.5 C14H12N2H2
MW: 210
Pigment Violet - 23
MW: 246
MW: 589

Carbazole Dioxane Violet Pigment (Pigment Violet 23)
STEP: I (N-Ethyl Carbazole)
Carbazole 800
Monochlorobenzene
Diethylsulfate 720 (recovered & DISTILLATION
ALKYLATION, recycle: 2182 kgs RESIDUE (624) Incineration
NaOH flkes 430 4350 kgs
Monochlorobenzene 2400 DISTILLATION

Recovered 2182 (MCB Loss: 48 Kgs) Waste water: 1278
Fresh 218
FILTRATION 32350 Layer Separation:
Water: 28000 kgs MCB + Water:
Kgs 31460 kgs
4132 kgs
N-ETHYLCARBAZOLE : 890 Kgs

FILTRATE to ETP:27328 kgs
Water:27313
Organic: 10
Caustic: 5

STEP: II (3- Nitro-N- Ethyl Carbazole)
N-Ethylcarbazole (890)
Monochlorobenzene (760)
Recovered 690 NITRATION
Fresh 70
SS Reactor,
2475 kgs
Nitric acid (825)
ACID LAYER (To ETP) (705)
Nitric acid (42)
LAYER SEPARATION
Water (662.5)
Organics: 0.5
SOLVENT LAYER (1770)
FILTRATE (50690)
Water:49857 Effluent: 49907 kgs
N-Ethyl carbazole (22.5 ) +
Water: 50000 kgs FILTRATION & Monochlorobenzene (810)
WASHING
DISTILLATION Monochlorobenzene
(recovered) (690)
Wet cake 3-NITRO-N- N ethyl carbazole
ETHYL or impurities 2.5
CARBAZOLE (1130)
Residue (40 kgs) Incinerator
STEP: III (3- Amino-N- Ethyl Carbazole)
3-Nitro-N-ethylcarbazole(1130) Reprocessing
(960 +170 Water)
& recycle
REDUCTION,
O-Dichlorobenzene (7260)
8501.7 kgs
Recovered 6944 Spent Catalyst: 6.7 kgs
Fresh 316
Catalyst: 6.7 kgs Water of reaction: 314 kgs to

ETP (144 +170)
N2: 70 kgs
N2 loss : 70 kgs
H2: 35 kgs
H2 loss : 19.3 kgs
ORGANIC LAYER SEPARATION

o-Dichlorobenzene
(recovered)(380)
Solvent loss: 146 kgs PARTIAL DISTILLATION
o-Dichlorobenzene
FILTRATION DISTILLATION (recovered) (6564)
Amino carbazole 1.0
3 – AMINO CARBAZOLE : 775 Distillation residue ( 65)

ODCB : 150 CHWIF
(as solid waste)
TOTAL : 925

STEP: IV (Crude Pigment Violet 23)
o-Dichlorobenzene(recovered) (8780)
3-Amino-N-ethyl carbazole 775 kgs ODCB Loss : 180 Kgs
ODCB: 150 Kgs
CONDENSATION
Chloranil (462) &
CYCLISATION
o-Dichlorobenzene (9300) MSGL
Recovered 8780
Fresh 520 Temp. 160 O C Distillation residue (640) CHWIF
Catalyst RAC (190)
Benzene sulfochloride (330)
Filtrate (to ETP) (54010)

Water FILTRATION Sodium Chloride (172)
(56000) Organics (424) ETP
Other Salt (112)
Water (53302)
DRYING Drying loss: 2700 kgs
PIGMENT VIOLET 23 CRUDE: 897
STEP: V (Pigmentation)
Crude Violet pigment 23: 897 kgs
Salt: 7740 kgs

GRINDING
Di-ethyl Glycol: 145 kgs
Mixing
& Filtrate: 147709 kgs
Water: 142315 kg
(Salt: 7740 kgs + DEG 145 kgs) +
Washing water: 139824 kgs
Drying Drying loss: 2500 kgs
Pigment Violet-23: 888 Kg

Pigment Black Dispersions
Premix (1) Carbon Black Pigment (105)
(2) Surface active agent (15)
(3) Glycols (20)
(4) Preservative (10)
(5) Water(850)
Grinding
Packing(1000 Kgs)

ANNEXURE: 4
Water requirement letter from Notified industrial estate:

ANNEXURE: 5
• Quantity of Waste Water (liquid waste) generation and its management :
Sr. No. Particulars Effluent generation, m3/day
Existing Proposed Total after expansion
1 Domestic 95 0 95
2 Processing & 1050 -165 885

washing
3 Boiler 111 0 111
4 Cooling 100 28 128
5 Floor/container 100 50 150

washing
6 Total 1456 -87 1369
7 Total Industrial 1361 -87 1274
• The generated waste water will be treated in existing adequate effluent treatment plant (ETP).
The details of the same is given on Next Page.
• We have reduced Water consumption and Effluent Generation Qty by following 3R Principle.
(1) Final Wash water of Filter Press is recycled for Initial washings .
(2) Use of Membrane Press in place of Ordinary Plate & Frame Filter Press
(3) Pulse washing in Filter Press, where ever Plate & Frame Press is existing.
(4) Increasing Batch Size in Same Volume there by reducing water Dilution.
(5) Use of DM Water in place of Raw Water in Final Washings.
(6) Use of treated Effluent in Water Jet Ejectors.

Details of Effluent Treatment Plant

• Design Criteria :
Ö Product : Organic Pigments ( Azo, Quina & Violet ) + Pigment Emulsion
Ö Source of Effluent : Process, washing & Utilities.
Ö Design Flow of Effluent : 1369 KL/day Max.
Ö Design Parameters : As under
Ö Effluent Characteristics:
No Effluent Process Boiler Equip + floor + Combined
parameters + + container Effluent
washing cooling washing/scrubber
1 pH 1.52 8.1 6.5 2.56
2 Temperature 0 C. 32 30 30 31
3 Colour (Pt-Co) 600 60 180 400
4 SS, mg/l 417 121 456 356
5 TDS, mg/l 6322 3400 2850 5300
6 COD value, mg/l 3650 10 1448.8 3108
7 BOD value, mg/l 1020 124 350 988
8 Chlorides, mg/l 820 120 280 636
9 Sulphates, mg/l 1050 210 850 684
10 O & G, mg/l 5.12 13.6 8.9 4.6
11 NH3-N, mg/l 20 ND 22.2 19
12 Phosphates, mg/l 6.2 ND 1.2 5.4
13 Phenolic , mg/l ND ND ND N.D.

Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to
install:
No Name of the unit Existing MOC Detention time in Adequacy
Capacity hrs
, m3
Reqd Prov.
1 Oil/grease trap 2 RCC 0.01 0.035 Adequate
2 Equalization cum 1586 RCC 8 27 Adequate

neutralization
tank (2 Nos.)
3 Flash mixer 2.7 RCC 0.03 0.04 Adequate
4 Clarifloculator 339 RCC 2 5.9 Adequate
5 Aeration tank 3120 RCC 24 54 Adequate

(2 Nos.)
6 Secondary 530 RCC 4 9.2 Adequate

clarifier
7 Sludge thicker 125 RCC 1 1.06 Adequate

with agitator
8 Sludge mixing 34 RCC 0.03 0.59 Adequate

sump
9 Filter press 48” PP - - Adequate
10 Lime slurry tank 72 RCC - - Adequate

(3 Nos.)
11 Ferrous sulphate 8 RCC - - Adequate

tank
12 Air blower 692 CI - - Adequate

(2 Nos) m3/hr
13 Sludge pump 110 CI - - Adequate

(2 Nos.) m3/hr
14 Effluent transfer 55 m3/hr CI - - Adequate

pump (2 Nos.)



EFFLUENT TREATMENT SCHEME FOR EFFLUENT
The company has put up a full-scale elaborate effluent treatment plant with a total
investment of nearly 2.5 crores. The plant occupies nearly 3200 M2 land area. The plant is
designed by M/S. Environmental Engineering Consultants, Bombay, and has capacity of
treating a maximum of 2200 M3/day effluent.
Here the combined wastes from various plants are collected into two Equalization-cum-
Neutralization Tanks, alternately, which are provided with aeration grids. The effluent is
neutralized here with lime solution prepared in lime slurry tank situated in the chemical
house. After neutralization, it is pumped into the Clarifloculator. Here ferrous sulphate
solution is added. The solution of ferrous sulphate is made in the tank located in the
Chemical House. The clear supernatant liquid from Clarifloculator goes to the
Biodegradation aerator tanks, provided with 4 nos. aerators of 50 HP each. The overflow
from the biodegradation tanks goes to the clarifier where after settling, the clear liquid
overflows into the GIDC common drainage system. A Thickener is also provided for
settling the calcium sulphate sludge.
The treated waste water from GIDC common drainage goes to the CETP from where it is
discharged to the river Daman Ganga (down stream) & finally meeting to Arebian Sea.
The settled bio mass in clarifier is either recirculated to the aeration tank or filtered by
membrane filter press. The sludge from bottom of the thickener is also taken to the Filter
Press for dewatering.
The effluent treatment plant is a separate unit by itself. The plant also has an elaborate
Chemical House with complete provision of MCC room, Laboratory, Raw Material storage,
Lime and Ferrous Sulphate Tanks. It also has provision of proper material movement with
an electrical hoist. Separate KWH meter certified by Gujarat State Electricity Board (
DGVCL ) is provided to know the electrical consumption.

FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT

Chemical House
Reuse of treated water for lime solution preparation
Lime Ferrous
Solution Solution
Tanks L- 1 L- 2 L- 3 F- 1 P-3
Tanks : 8 m3
8 m3 each
Equalization cum
P-4
Neutralization tank
793 m3
Nutrients
E/N - 1 E/N - 2
From B-1 Urea & DAP
Air Blower
ETP
692 m3 /hr each
B-2 Aeration Tank
Clariflocuulator 1560 m3 each
339 m3 Surface
P-1 SA-1 SA-2
aerators
Main AT-1
P-2
PT AT-2
110 m3/hr each Flash Mixer
2.7 m3
Diffuser b lowers
30 HP each
PT-2 PT-3 Biomass Secondary
recycle to aeration
530 m3
Thickener tanks
125 m3 P-5
PT-4
Overflow water to E/N tank
Excess
Water biomass 34 m3
Water washing line P-6
Tank disposal Sludge
P-11 mixing V-notch
Filter press PT-5

P-9 P-7
P-10 P-8
PT-6 Treated
Water
outlet
to CETP

ANNEXURE: 6
MEMBERSHIP CERTIFICATE OF CETP, VAPI

MEMBERSHIP CERTIFICATE OF CHWIF



ANNEXURE: 7

ANNEXURE: 8
Copy of plot allotment letter issued by GIDC

COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED

INDUSTRIAL AREA

ANNEXURE: 9
A schematic representation of the feasibility drawing

ANNEXURE: 10
DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING &
PROPOSED EXPANSION
Ö At present, the unit is having two number of natural gas fired 8 TPH & 2 TPH steam boilers,
one number of briquettes fired boiler of 12 TPH capacity and two numbers of gas fired
thermopack with capacity 10 lacs kcal & 4 lacs kcal. There will be no addition of any new
boiler or thermopak for proposed expansion, as existing boilers & thermopak having spare
capacity to supply the steam for proposed expansion.
Ö The company shall install three numbers of D G sets having capacity of 750 KVA, 750 KVA &
125 KVA capacities, as stand by. It will be used only during power failure.
Ö Adequate multi cyclone separator followed by bag filter provided to briquettes fired boiler.
Adequate stack height and stack monitoring facilities is provided.
Process gas emission:

• Presently the unit has installed Two no of multi cyclone separator followed by bag filter
attached to pulveriser. After proposed expansion, the unit shall install one additional multi
cyclone separator followed by bag filter attached to pulveriser. Adequate height of process vent
will be provided The details of which are as under;
Sr. Particulars Details Remarks

No. Existing Proposed Total after
expansion
FLUE GAS EMISSION
1.0 Steam Boiler 8TPH 0 8 TPH Standby
1.1 Fuel used Natural Gas 0 Natural Gas
1.2 Fuel Consumption 7000 SCM/d 0 7000
SCM/d
1.3 APC Chimney 0 Chimney
1.4 Height & Dia of 30 meter/900 0 30
chimney mm meter/900
mm
2.0 Steam boiler 2 TPH 0 2 TPH Standby
2.1 Fuel used Natural gas 0 Natural gas
2.2 Fuel Consumption 1750 SCM/day 0 1750
SCM/day
2.4 Height & Dia of 30 meter/800 0 30
mm
3.0 Thermopak: I 10 lacs k cal 0 10 lacs k No Change
cal
SCM/day
3.4 Height & Dia of 30 meter/450 30
mm
4.0 Thermopak:II 4 lacs k cal 0 4 lacs k cal No Change

SCM/day
4.4 Height & Dia of 30 meter/450 0 30 Common
chimney mm meter/450 chimney
mm with TP:I
5.0 Steam boiler 12 TPH 0 12 TPH Only
5.1 Fuel used Briquetes Briquetes Briquetes increase
5.2 Fuel Consumption 1.45 MT/Hr 0.655 2.105 the
MT/Hr MT/Hr operating
5.3 APC MDC followed - MDC hours &
by bag filter & followed by fuel
online SEMS bag filter &
online
SEMS
5.4 Height & Dia of 30 meter/800 - 30
mm
6.0 D G Set: I 0 750 KVA 750 KVA Standby
6.1 Fuel used 0 HSD HSD
6.2 Fuel Consumption 0 100 kgs/hr 100 kgs/hr
6.3 APC 0 Exhaust Exhaust
6.4 Height of exhaust 0 11 meters 11 meters
7.0 D G Set: II 0 750 KVA 750 KVA Standby
8.0 D G Set: III 0 125 KVA 125 KVA Standby
9.0 Pulveriser Cyclone Cyclone Cyclone Total three

separator separator separator numbers
followed by followed followed by
by bag
bag filter filter bag filter
9.1 Height of vent 11 meters 11 meters 11 meter
9.2 Gases emission PM: < 150 PM: < 150 PM: < 150
mg/Nm3 mg/Nm3 mg/Nm3
DETAILS OF AIR POLLUTION CONTROL SYSTEM ATTACHED TO BRIQUETTES

FIRED BOILER
1. Boiler: 12000 kg of steam/hour.
Briquettes consumption : 70 MT/day

Calorific value : 4200 kcal/kg
Inlet to dust collector : 280°C
Stack temp : 180°C
Diameter of chimney : 750mm
Flue Gas Volume : 6107Am3/hr
I.D. Fan : 15254 m3/hr
Stack diameter : 850Ømm
Stack height provided : 30 meters
Efficiency : Thermal Efficiency of Boiler 82±2%
1.0 Air Pollution control System: Multi Cyclone Dust Collector (Grit Arrestor)
Cyclone tube diameter : 2.5 Ø mm
Height of tube : 2500 mm
No of tubes : 4no
Dia of tubes : 587Ø mm
Dimensions : 2.5 m x 2.5 m x 9 m height
Collection efficiency : 60-70% (over 40micron)
Expected outlet dust load : 150 < mg/nm3 at out let of bag filter
Inlet Dust load : 25-40 gms/nm3
Density : 600kg/ m3
Fines : (< 1 mm)
2.0 Air Pollution control System: Bag filter
Size of Bag filter : 12 m x 10 m x 10 m
MOC : Mild steel
Size of Gas inlet : 400 X 1000 mm
Size of gas out let : 850 Ømm
Total unit weight : 4.1MT
Hopper volume : 3.9m3
Designed gas volume : 10704 Am3/hr
Maximum designed temp. : 1900C
Number of filter bags : 96 Nos (500 gms/m2 filter glass)
Size of filter bags : 160mm dia x 3600m length
No. of cages : 96
Pressure drop : 125-150mm
Air to cloth ratio : 1.01 m3/min/m2

Expected emission : PM: < 100 mg/Nm3

: SOx: < 100 ppm
: NOx: < 50 ppm
Details of Air pollution control measures attached to Pulveriser
• Drying of Pigment:
Drying of 60- 70 % pigment wet cake shall be carried out in tray dryers/spin flash dryer. The process
heat is provided by Hot Oil Thermopak system based on natural gas. The Thermopak exhaust flue
gas is connected to a chimney.
• Pulverization of pigments:
This is carried out in a closed circuit grinding equipment, pulverizer as shown in the drawing. This
consists of following parts:
• Hopper feed box.
• Screw feeder.
• Closed grinder with box
• cyclone separator
• Bag filter.
• I.D. fan.
• Vent line.
• Rotary valve for outlet of product.
The pulverized material is collected in bags, weighed and dispatched. The material collected from
bag filter is also mixed with the final product.
Thus this is a completely dry process and does not involve any consumption or discharge of effluent.
There is no solid waste as even the floor spillage is collected and recycled.


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FOR

PROPOSED EXPANSION PROJECT

PIDILITE INDUSTRIES LIMITED

Name of the Project: Pidilite Industries Limited

Applicability of EIA notification – 2006

Ö Category as per the amended EIA notification-2006: as existing and proposed

• The company in India comprises of 12 directors

List of finished products & by- products:

Expansion project Page 1 Organic Pigments

2 Calcium Sulphate 0 110 110

• Gypsum is having 10-15 % moisture in it.

Manufacturing process is attached as Annexure-3.

Expansion project Page 2 Organic Pigments

Raw material Consumption:

1.0 For Carbazole Dioxane Violet Pigment (Pigment Violet 23)

Sr. Raw Materials Quantity in MT

1.1 Carbazole 0.90 22.52 0 22.52

1.2 Diethyl sulphate 0.81 20.27 0 20.27

1.3 Caustic flakes 0.48 12.11 0 12.11

1.4 Mono Chloro 3.23 80.86 0 80.86

1.5 Mono Chloro 0.32 8.11 0 8.11

1.6 Nitric acid 0.93 23.23 0 23.23

1.7 ODCB (Recovered) 17.71 442.68 0 442.68

1.8 ODCB (Fresh) 1.11 27.76 0 27.76

1.9 Catalyst 0.01 0.19 0 0.19

1.10 Nitrogen 0.08 0 1.97 1.97

1.11 Hydrogen 0.04 0 0.99 0.99

1.12 Chloranil 0.52 13.01 0 13.01

1.13 Catalyst RAC 0.21 5.35 0 5.35

1.14 Benzene sulpho 0.37 9.29 0 9.29

1.15 Salt 8.72 217.91 0 217.91

1.16 Di ethyl Glycol 0.16 4.08 0 4.08

1.17 Iron Powder 1.52 37.9 -37.9 0

1.18 Total 36.67 925.27 -34.94 890.33

Expansion project Page 3 Organic Pigments

2.0 For Organic Pigment

2.1 Organic Yellow Pigment

Sr. Raw Materials Quantity in MT

2.1.1 Base (Amine) 0.405 34.425 12.15 46.575

2.1.2 Ice 6 510 180 690

2.1.3 Sulphamic acid 0.009 0.765 0.27 1.035

2.1.4 Sodium nitrite 0.69 58.65 20.7 79.35

2.1.5 Hydro Chloric Acid 0.96 81.6 28.8 110.4

2.1.6 Caustic 0.35 29.75 10.5 40.25

2.1.7 Acetic acid 0.285 24.225 8.55 32.775

2.1.8 Xylene (Recovered) 0.539 45.815 16.17 61.985

2.1.9 Xylene (Fresh) 0.011 0.935 0.33 1.265

Total 9.249 786.165 277.47 1063.635

2.2 Organic Red Pigment

2.2.1 Base (Amine) 0.42 35.65 12.6 48.23

2.2.2 Ice 14.56 1237.86 436.89 1674.75

2.2.3 Sulphamic acid 0.02 2.06 0.73 2.79

2.2.4 Sodium nitrite 0.19 16.50 5.83 22.33

2.2.5 Sulphuric acid 2.91 247.57 87.38 334.95

2.2.6 Caustic 0.63 53.64 18.93 72.57

2.2.7 Hydro Chloric acid 0.97 82.52 29.13 111.65

Total 19.7 1675.82 591.46 2267.28

Expansion project Page 4 Organic Pigments

Sr. Raw Materials Quantity in MT

2.3 Organic Orange Pigment

2.3.1 Base (Amine) 0.405 34.43 12.15 46.575

2.3.2 Ice 9 765.00 270 1035

2.3.3 Sulphamic acid 0.007 0.60 0.21 0.805