Proposed Dyes & Intermediates manufacturing project of 150 ...

Proposed Dyes & Intermediates manufacturing project of 150 MT/Month (Crude) [{Disperse Azo Dyes (Allcolours) - 100 MT/Month, Coumarine Dyes (All colours)- 25 MT/Month & Methine Dyes (All colours) -25MT/Month}], at Khasara no 670/521 of Revenue Village - Untwalia , Tehsil & District - Churu, (Rajasthan)

PRE- FEASIBILITY REPORT

M/s. Krishnum Dyes & Intermediate Pvt. Ltd. 18

PRE-FEASIBILITY REPORT

1.0 Executive Summary

INTRODUCTION

Krishnum dyes & intermideate pvt. ltd have a very strong and experienced after sales servicewhich are also known as Technical Service Department which guides customer to obtain betterresults from our products. Market for disperse dyes is growing @ 10% per annum, and thereare only two major producers in the Industry. Their continuous technological research andproduct development and superior after sales services will ensure increase in market share andeventually better net sales realization. Strong presence in the value added product. Wide rangeof product to meet customized need. Long standing relationships with leading consumerIndustries.

M/s. Krishnum Dyes & Intermediate Pvt. Ltd. is planning to set up a Proposed Dyes &Intermediates manufacturing project of 150 MT/Month (Crude) [{Disperse Azo Dyes (Allcolours) - 100 MT/Month, Coumarine Dyes (All colours)- 25 MT/Month & Methine Dyes (Allcolours) -25 MT/Month}], located at Khasara no 670/521 of Revenue Village - Untwalia, Tehsil &District - Churu, (Rajasthan).

Table - 1.1Salient Features of the Project

S.NO.

PARTICULARS DETAILS

1 Product Details Manufacturing of Dyes & Intermediates with Total Capacity - 150MT/Month (Crude)

Name of Product Production Capacity MT/Month

Disperse Azo Dyes 100 MT/Month

Coumarine Dyes (All colours) 25 MT/Month

Methine Dyes (All colours) 25 MT/Month

Total Capacity 150 MT/Month (Crude)

2 Boiler Details Steam Boiler (800 kg/hr)

3 Thermic Fluid Heater Thermic Fluid Heater (8, 00,000 Kcal/hr)

4 D.G. Details 2 no. of DG Sets of 125 KVA Capacity

5 ETP 45.0 KLD Capacity

6 Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended fromtime to time; this project falls under category ‘A, Activity -5’(f) -{Synthetic organic chemical industry (dyes &dyes intermediates; bulkdrugs and intermediates excluding drugs formulations; synthetic




rubbers; basic organic chemicals, other synthetic organic chemicalsand chemicals intermediates) Located outside the industrialarea/estate.}

7 Location Details

Plot No. Khasara no 670/521 of Revenue Village - Untwalia

Tehsil Churu

District Churu

State Rajasthan

Latitude 28°24'18.40"N to 28°24'34.40"N

Longitude 75°00'2.94"E to 75°00'3.98"E

Toposheet No. 44P/13, 44P/14, 44L/15 & 44L/16

8 Area Details

Total Plant Area Total plant area: 10000.00 Sq. m. (1.00 ha.) -Private land

Greenbelt / Plantation Area(ha)

33 % (3300.00 sq. m.) of the total plant area will be developed undergreenbelt / plantation. Green belt will be developed along with theroad and plant boundary to reduce noise levels, dust pollution andimprove surrounding environment.

9 Environmental Setting Details (with approximate aerial distance & direction from plant site)

i Nearest Town /City Nearest Village: Untwalita at distance is ~ 2.0 Km in SE direction fromthe project site

Nearest City: Churu at distance is ~ 5.0 Km in NW direction from theproject site

ii. Nearest National Highway /State Highway

SH-37 at a distance of ~3.5 km. in NE direction from the Projectsite.

NH-65 at a distance of ~5.0 km. in West direction from the Projectsite.

iii. Nearest Railway station Churu Railway Station at distance is ~ 6.0 Km in NW direction fromthe project site

Mahansar Railway Station at distance is ~ 5.5 Km in SE directionfrom the project site

iv. Nearest Airport Sanganer International Airport, Jaipur ~175 km in SE direction fromthe project site

v. National Parks, Wild LifeSanctuaries, BiosphereReserves, Tiger/ Elephant

There is no National Park, Wild Life Sanctuaries, Biosphere Reserves,Tiger Reserves, Wildlife Corridors, etc. within 10 km radius




Reserves, Wildlife Corridorsetc. within 10 km radius

vi. Reserved Forests (RF) /Protected Forests (PF) etc.within 10 Km. radius

Jod Bir PF at distance is ~ 5.0 Km in West direction from the projectsite.

vii. River / Water Body (within 10km radius)

Tithrana Johra ~ 1.0 Km in NE direction.

viii. Interstate boundaries None, within 15 km radius area of Project site.

10 Cost Details

Total Cost of the Project Rs. 20.21 Crores

Environment Protection CostCapital Cost of EMP: Rs. 50.00 Lac

Recurring Cost of EMP: Rs. 5.00 Lac/annum

11 Basic Requirements for the project

Water Requirement (KLD) 49.50 KLD (Fresh: 24.5 KLD + Ice: 10.3 KLD + Recycle: 14.7 KLD)Source: Freshwater will be sourced from ground water after approvalfrom CGWA.

Power Requirement (MW) 500 KVASource: JDVVNL Rajasthan2 no. of DG Sets of 125 KVA Capacity for power back up

Man Power Requirement(Persons)

Total - 99 PersonSource: Unskilled/semi-skilled manpower sourced from the local areaand skilled manpower sourced from outside/local.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

The Rajasthan region is expected to continue with increased focus on industrial

development and infrastructure activity. The current growth trends are expected to

continue. The proposed products are Import substitute and almost consumed in the

Indian market only, Indian consumption growth will continue to be there, considering

demographic ratio in favour of youth.

Existing Indian production, are not enough to cater the needs of Indian Consumer, hence

Chinese products are also making dent in the Indian markets, though they are costly due

to logistic cost and are not able to provide wide range of choices to the Indian

Customers. Present capacity is negligible in terms of overall demand in the world, so a

huge market, and considering our high quality products as well customization of product,

we don’t foresee any hurdle in marketing of product. The proposed plant will be located




near user Textile Industry, hence it provides logistic support as well as customize

quantity in small quantities can also be supplied to the customer, which give company a

clear edge compared to Chinese Imports, which cannot be supplied in small quantities

coupled with time consumed on import.

The demand for products intended to be manufactured is increasing in the country and in

global market also. By setting up this unit of M/s. Krishnum Dyes & Intermediate Pvt. Ltd,

shall be able to meet the demand of various products locally and globally. This will also

generate direct and indirect employment opportunity for various levels of people

including local area employment. Some by-products/waste shall be utilized as alternate

fuel in cement industry, thus reducing environment pollution load.

The company has been promoted by Mahesh Kumar Prajapat having a widespread

business interests in Rajasthan. The promoter has been in the business of Dyes for over

17 years and the group has excellent knowledge of Rajasthan Industry Environment

Identification of Project Proponent:

1. Bajrang Sharma- S/o Shri. Ramavtar

Address: 228, Near Residence of Dr. Narender Kumar, Ward No. 38, Churu- 331001

2. Vivek Goenka – S/o Shri. Ramensh Kumar Goenka

Address: 170, Near Naiyon Temple, Ward no. 39, Churu- 331001

3. Mahesh Kumar Prajapat – S/o Shri. Kishan Lal

Address: Near Khemka Sati Temple, ward No. 28, Churu - 331001

(ii) Brief description of nature of the project

M/s. Krishnum Dyes & Intermediate Pvt. Ltd. is planning to set up a Proposed Dyes &Intermediates manufacturing project of 150 MT/Month (Crude) [{Disperse Azo Dyes (Allcolours) - 100 MT/Month, Coumarine Dyes (All colours)- 25 MT/Month & Methine Dyes(All colours) -25 MT/Month}], at Khasara no 670/521 of Revenue Village - Untwalia , Tehsil& District - Churu, (Rajasthan).

The proposed unit is dyes & dyes intermediate manufacturing unit covered under thecategory of 5(f) in schedule “Synthetic organic chemicals industry (dyes & dyeintermediates; bulk drugs and intermediates excluding drug formulations; syntheticrubbers; basic organic chemicals, other synthetic organic chemicals and chemicalintermediates)” of EIA Notification-2006 and as amended time to time. As the project siteis located outside the Notified Industrial area hence this will be treated as category ‘A’




Project and shall be appraised at Ministry of Environment, Forest and Climate Change(MoEF&CC), Central Level.

(iii) Need for the project and its importance to the country and or region

The unit will engaged with development, manufacturing & marketing of Dyes & Dyesintermediates like Synthetic Organic Dyes [Liquid Direct Dyes] & [Direct Dyes) &Synthetic Organic Dyes [Disperse Dyes]. The broad objective is to start said syntheticorganic dyes unit having considerable export potential & domestic good market tofulfilment of markets demand. The survey of the market with various traders, we havefound that there is a big potential for the range of the products we are planning.

(iv) Demand supply gap:-

Krishnum dyes & intermideate pvt. ltd have a very strong and experienced after sales

service which are also known as Technical Service Department which guides customer to

obtain better results from our products. Market for disperse dyes is growing @ 10% per

annum, and there are only two major producers in the Industry. Their continuous

technological research and product development and superior after sales services will

ensure increase in market share and eventually better net sales realization. Strong

presence in the value added product. Wide range of product to meet customized need.

Long standing relationships with leading consumer Industries.

(v) Imports vs. Indigenous production:-

Existing Indian production, are not enough to cater the needs of Indian Consumer, hence

Chinese products are also making dent in the Indian markets, though they are costly due

to logistic cost and are not able to provide wide range of choices to the Indian

Customers. Present capacity is negligible in terms of overall demand in the world, so a

huge market, and considering our high quality products as well customization of product,

we don’t foresee any hurdle in marketing of product. The proposed plant will be located

near user Textile Industry, hence it provides logistic support as well as customize

quantity in small quantities can also be supplied to the customer, which give company a

clear edge compared to Chinese Imports, which cannot be supplied in small quantities

coupled with time consumed on import.

(vi) Export possibility:-

The proposed plant will be located near user Textile Industry, hence it provides logistic

support as well as customize quantity in small quantities can also be supplied to the

customer, which give company a clear edge compared to Chinese Imports, which cannot

be supplied in small quantities coupled with time consumed on import.




(vii) Domestic/export Markets:-

The products which will be manufactured will be as per customer’s specifications. This

will have acceptability in the domestic markets. The product also has an export potential.

The export market can also be explored in future.

(viii) Employment Generation (Direct and Indirect) due to the project:-

The company will be employed approx 99 workers and staff directly and indirectly in

manufacturing units. Business approach is directed towards better interactions with the labour

and development of human resources.

Sr.No.

Particulars Manpower requirement (Persons)

1 Skilled 14

2 Unskilled 24

3 Semi skilled 61

Total manpower 99

Unskilled/ semi skilled manpower can be sourced from the local area and skilled manpower shall

have to be sourced from where it is available.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any

No interlinked / interdependent project is involved.

(ii) Location (map showing general location, specific location, and project boundary &project site layout) with coordinates




Figure 1: Location Map




Figure 2: Key Plan




Figure 3: Current site Photographs of project site




Figure 4: Google Image Showing the 500 mtr. Area surrounding project site




iii) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Site has been taken into consideration as the proposed site has been acquired by the

company keeping in mind following mentioned factors:

Following factors were considered while selecting the site:-

Site is well connected through air, water and roadways. There is no any wildlife sanctuary

and national parks within 10 km radius from the proposed site. All basic and

infrastructure facilities are available. Manpower is also easily available from the nearby

area. Proximity to the agriculture field surrounding the area & availability of ground

water Location in rural area ensures adequate availability of manpower at marginally

lower rates, compared to other area. Good road connectivity which makes easy transport

of raw material and products.

(iv) Size or magnitude of operation

This is a proposal for environmental clearance for Proposed Dyes & Intermediates

manufacturing project of 150 MT/Month (Crude) [{Disperse Azo Dyes (All colours) - 100

MT/Month, Coumarine Dyes (All colours)- 25 MT/Month & Methine Dyes (All colours) -25

MT/Month}], at Khasara no 670/521 of Revenue Village - Untwalia , Tehsil & District -

Churu, (Rajasthan) by M/s. Krishnum Dyes & Intermediate Pvt. Ltd.

The process includes basic raw material requirement, sizing of equipment, utilities &

services, infrastructure facilities & sources of waste generation, their quantity, treatment

& safe disposal of the waste.

(v) Project Description with Process Details (a schematic diagram/ flow chart showing the

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

M/s. Krishnum Dyes & Intermediate Pvt. Ltd. has planning for Proposed Dyes &

Intermediates manufacturing project of 150 MT/Month (Crude) [{Disperse Azo Dyes (All

colours) - 100 MT/Month, Coumarine Dyes (All colours)- 25 MT/Month & Methine Dyes

(All colours) -25 MT/Month}], at Khasara no 670/521 of Revenue Village - Untwalia , Tehsil

& District - Churu, (Rajasthan) .




Process Flow Chart




Process Flow Chart




Process Flow Chart




Process:

Disperse dyes are traditionally non-ionic chemicals with sparing solubility in water which,

consequently, are able to retain comparatively better substantivity for hydrophobic

fibres, such as polyester, nylon and acetate. For the sake of efficient diffusion into

textiles, the particles of disperse dye should be as fine as possible comprising low

molecular weight molecules in the range of 400 – 600. It is essential for disperse dyes to

be able to withstand various dyeing conditions, pH and temperature, resulting in

negligible changes in shade and fastness.

Disperse dyes are often substituted azo, anthraquinone or diphenylamine compounds

which are non-ionic and contain no water solubilising groups. The dye particles are thus

held in dispersion by the surface-active agent and the dyes themselves are called

disperse dyes. They are marketed in the form of either an easily dispersible powder or a

concentrated aqueous dispersion and are now the main class of dye for certain synthetic

fibres

Diazotization: Taken stirrable water in small HDPE Tank charged PCONA (para

choroOrtho Nitro Aniline), charged HCl (31 %) stirring- cooling O °C by ice addition of

NaNO2 solution C.R S.T positive prepare diazo.

Coupling: In HDPE tank taken stirrable water and charged soda ash heated to 70 °C and

charged HMQ (n methyl 4 hydroxyQuinoline) stirring cooling and received diazo from

small wooden vet adjusted pH -7 to 8 by soda – heated to 90 °C cooling filtration

Washing- sand milling -spray drying and packing.

Azo disperse dyes

Azo dyes are defined as compounds containing at least one azo group attached to sp²-

hybridized carbon atoms, such as benzene, naphthalene, thiazole and thiophene. Under

normal conditions, azo dyes exist in the more stable planar tras-form so that the

carbonnitrogen bond angle is approximately 120 (Gordon & Gregory, 1983).

Azo dyes are by far the most important class and account for more than 50% of the total

commercialized disperse dyes in the world. There are several reasons why azo dyes have

dominated the markets and have replaced many of the conventional anthraquinone

dyes. In principal, the azo group is an inherently intense chromophore in terms of the

tinctorial strength, when compared with the comparatively weak anthraquinone




chromogen, normally 2 or 3 times stronger in tinctorial strength. By virtue of their

simplicity and the ease of manufacture, unlike the other types of dyestuffs such as

anthraquinone and styryl, the cost of manufacturing azo dyes is comparatively lower

than the expensive anthraquinone dyes.

Azo dyes cover a whole gamut of colours, from yellow to blue-green hues, by varying the

intermediates especially when heterocyclic diazo components are coupled to

aminobenzene couplers substituted with powerful electron donating groups, giving

bright blue-green colours. Although some deficiencies of azo dyes are not easily

overcome, such as duller shades, lower fastness to light and breakdown into

carcinogenic amines derived from the cleavage of the azo linkage, and have somewhat

restricted their extensive usage against anthraquinone dyes, the cost effectiveness

undoubtedly compensates for the drawbacks mentioned above

Coumarin Synthesis

The Pschorr coumarin synthesis involves the reaction of phenols with ββ-keto esters in

the presence of a condensing agent. The history of coumarin's synthesis began in the mid

of 19th century by W.H. Perkin in his famous first synthesis of a vegetable perfume.

Coumarin is prepared by treating the sodium salt of ortho-hydroxybenzqaldehyde with

acetic anhydride. It involves other methods which has been developed by Pechmann

Claisen, Knoevenagal, Reformatsky and Wittig for the synthesis of pyrone-ring moieties

in coumarins.

Methine dyes -

Methine dyes with longer chains are obtained by reaction with malonaldehyde,

glutaconaldehyde, or their derivatives. Diazamethine dyes are prepared from

heterocyclic azo dyes that are obtained by diazotizing heterocyclic amines and coupling

with aromatic or heterocyclic coupling components.




Figure - 5: Site Layout Plan




DG Set

M/s. Krishnum Dyes & Intermediate Pvt. Ltd. has also proposed to install 2 no. of DG

Sets of 125 KVA Capacity.

Process of Power Generation:

Fuel handling & storage.

The fuel oil is heated for free flow to D.G. Set.

It is transferred for settling to settling tank to remove unwanted material. Fuel oil

is further centrifuged.

After centrifuging, the fuel oil is transferred to another service tank, heated,

filtered and injected into engine for combustion.

The engine generates power and produces electricity.

PLANT LAYOUT

The features of the layout are as follows:

Sufficient space will be provided for ease of operation and maintenance;

Sufficient space will be provided for parking of vehicles used for transportation

of raw materials.

Inward & outward movements of the vehicles for carrying raw materials from

customers/suppliers and dispatch from AOS plant, will be segregated and routed

for internal plant traffic control.

Safety requirements will be kept in mind while locating the workshops and

vehicular movement inside the plant.

33% of the area will be covered under green belt development.

Connectivity with railway siding & approach road.

(vi) Raw material required along with estimated quantity, likely source, marketing area of

final products, mode of transport of raw material and finished product.

Raw Material Requirements:

Raw material requirement for the Proposed Dyes & Intermediates manufacturing project

of 150 MT/Month (Crude) [{Disperse Azo Dyes (All colours) - 100 MT/Month, Coumarine

Dyes (All colours)- 25 MT/Month & Methine Dyes (All colours) -25 MT/Month}] are as

given below:

Table: 3.3




Raw Material Requirements

Sr.No.

Details of Raw Material

Name of Raw material Quantity(TONS)/Month

Mode of Transportation & Distance

1 Acetic acid 10.0 ~ 950.0 Km from Bharuch by Road

2 Aniline Derivatives 40.0 ~ 1100.0 Km from Vapi by Road

3 Benzoyl Chloride 5.0 ~ 900.0 Km from Khambhat by Road

4 Bromine 5.0 ~ 950.0 Km from Ankleshwar by Road

5 Caustic Flakes 15.0 ~ 200 km from Jaipur Supplier by Road

6 Cuprous Cyanide 5.0 ~ 850.0 Km from Baroda By Road

7 Dimethyl Sulfate 10.0 ~ 950.0 Km from Ankleshwar by Road

8 Dimethylformamide (DMF) 25.0 ~ 1300 Km from Mumbai by Road

9 Ethyl Cyano Acetate 6.0 ~ 1300 Km from Mumbai by Road

10 Hydrochloric Acid 30.0 ~200 Km from Jaipur Supplier by Road

11 Lime 5.0 ~ 50.0 Km from Sardarsahar by Road

12 Malononitrile 5.0 ~ 1300.0 Km from Mumbai by Road

13 Methanol 20.0 ~ 850.0 Km from Barod by Road

14 Para Nitro Aniline Derivatives 35.0 ~ 1100.0 Km from Vapi by Road

15 Phosphorus Oxy Chloride 7.5 ~ 1100.0 Km from Vapi By Road

16 Soda Ash 20.0 ~ 200.0 km from Jaipur by Road

17 Sodium Chloride 5.0 ~ 200.0 km from Jaipur by Road

18 Sodium Cyanide 3.0 ~ 850.0 Km from Baroda By Road

19 Sodium Nitrite 5.0 ~ 850.0 Km from Baroda By Road

20 Sulfamic acid 3.0 ~ 200 km from Jaipur by Road

21 Sulphuric Acid 40.0 ~ 200 km from Jaipur by Road

22 Zinc Cyanide 6.0 ~ 850.0 Km from Baroda by Road

23 Meta- Toluidine 6.0 ~ 1100.0 Km from Vapi by Road

24 Pera –Toluidine 6.0 ~ 1100.0 Km from Vapi by road.

Total 317.5

Raw Material Storage and Transportation

Raw material for Disperse Dyes unit will be purchased from the different sources and it

will be stored in chemical storage area in Carboys, Drums, bags and some are in storage

tanks. Only following chemicals are to be stored in tanks are given in below:

Sr.No.

Name & MOC Dimensions No. ofTanks

Monthlyrequirements

(Tons)

Tank CapacityProposed

(Tons)




1. Horizontal Sulphuric AcidTank (MS)

2.0 m dia.3.4 m long

1 20 10

2. Under Ground MethanolTank (MS)


1 10 4

3. Horizontal HydrochloricAcid (Rubber lined)


1 20 4

Marketing Area and Mode of transportation of Final Product

Because of good transport system available in Churu area, M/s. Krishnum Dyes &

Intermediate Pvt. Ltd. can easily cater markets of U.P., Delhi, Haryana, Punjab

Uttarakhand and M.P. etc. M/s. Krishnum Dyes & Intermediate Pvt. Ltd. can also start

selling our products in availability of good means of transport.

(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

No waste water will be generated from the Dyes manufacturing process.

Domestic effluents generated from plant office will be only 4 KL, same will be

disposed in soak pit via septic tank.

There will be no industrial effluent discharge inside/ outside from the project

premises, Proposed Plant will be Zero Liquid Discharge (ZLD) project.

(viii) Availability of water its source, energy /power requirement and source should

Be given.

(a) Water Requirement and Source

The total water requirement for the proposed Dyes & Intermediates Manufacturing

Unit has been estimated as 49.50 KLD. Out of which 24.5 KLD will be Fresh, 10.3 KLD

will be Ice & 14.7 KLD will be Recycle. Freshwater will be sourced from ground water

after approval from CGWA.

Sr. No. Particulars Water requirement in KLD1 Fresh Water 24.52 Ice Water 10.33 Recycle Water 14.7Total Water requirement 49.50 KLD

Source Freshwater will be sourced from ground waterafter approval from CGWA.




(b) Power Requirement and Source

The maximum power demand for the proposed dyes and manufacturing unit has been

estimated as about 500 KVA. The power requirement is proposed to be sourced from

Jodhpur Vidhyut Vitran Nigam Limited (JDVVNL). However, in case of emergency & to

meet the power requirement, 2 no. of DG Sets of 125 KVA Capacity is also envisaged.

A Steam Boiler (800 kg/hr) is also proposed.

Power Requirement Total Power Requirement will be 500 KVASource: JDVVNL Rajasthan2 no. of DG Sets of 125 KVA Capacity for power back up

(c) Fuel Requirement and Source

Sr.No.

Fuel requirement

Particulars FUEL CONSUMPTION MODE OF TRANSPORTATION

1 Bio-Fuel (Pellets) 10.0 Ton/ Day Import by Indonesia

2 Diesel

(in emergency only)

80 Lit/ Hr Local Supplier by Road

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

Description ofhazardous waste

Wastecategory

Wastegenerating

processes/Step

Totalproposedquantity

Method of disposal

Fly ash ---- Boilers area 5.0Ton/month

Sent to brick manufacturer

Used /Spent oil 10.2 From DG Set 20Liters/month

Collected in drums and stored atspecified area and sold toapproved /registered vendors

Discardeddrums/Containers/PP Liners/Bags

33.3 FromManufacturing

1.5Ton/Month

Collected and stored at specifiedarea and sold to approved/registered vendors

Evaporatorresidue

---- From MEE 2.5Ton/Month

Collected in drums packed,labelled and stored at specifiedarea and finally transferred tocommon waste incineration andlandfill site

ETP sludge 34.3 From ETP 10.0Ton/Month

ETP sludge will be sent to landfillsite.




(X) Schematic representation of the feasibility drawing which give information of EIA purpose.

Environmental Clearance is required As per EIA Notification dated 14th Sept., 2006 & as amended

from time to time; this project falls under category ‘A, Activity -5’(f) - {Synthetic organic chemical

industry (dyes &dyes intermediates; bulk drugs and intermediates excluding drugs formulations;

synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemicals

intermediates) Located outside the industrial area/estate.}

(IX) Effluent Treatment Plant

Total 45.0 KLD capacity of Effluent Treatment Plant will be installed by M/s. Krishnum Dyes &

Intermediate Pvt. Ltd. Effluent Treatment Plant design is done considering worst case scenario in

terms of high Organic load generating products and high hydraulic load generating products at a

time. Considering One batch (2000 kg/day) of Disperse red 167 (Azo Dyes) and one batch (2000

kg/day) of Disperse Yellow 82 (Coumarine Dyes), bench scale study in pilot plant and based on

detailed treatability study, We will provide online continuous pH meter, TOC analyzer and flow

meter at the final outlet of the ETP.

Domestic waste water will be disposed off through septic tank/soak pits. Industrial effluents will

be treated in proposed ETP. After treatment of effluent in ETP, Part of the treated effluent will be

taken in to MEE.

ETP UNIT SYSTEM AND SIZE

Sr.no Name of unit Size (M) NOS HRT(HRS)1 Equalization of tank 2.50x2.50x2.50+0.50FB 1 9.002 Neutralization of tank 0.80x0.80x1.00+0.50FB 1 0.53 Primary settling tank 1.50x1.50x(2.00+1.00HB+0.50FB) 1 3.04 Dosing tanks 50 Liters 1+1 -5 Aeration tank 6.00x5.00x4.00+0.50FB 1 20.06 Secondary clarifier 2.00m Dia x (2.50 SWD+0.50 FB) 1 3.07 Intermediate sump 1.50X1.50X(2.00+0.50 FB) 1 -8 Sludge sump 1.50X1.50X(2.00+0.50 FB) 1 -9 Treated water sump 1.50X1.50X(2.00+0.50FB) 1 -10 PSF & ACF 2 M3/Hr 1+1 -11 Sludge Drying Beds 1.50X1.50 1+1 -12 MCC panel Room 1.50X1.50 1

INLET NORMS OF CETP QUALITY

Before treatment mg/l After TREATMENT mg/l6.5-8.5 5.28 7.5-8.0

300mg/L 3316mg/L <300mg/L1500mg/L 6300mg/L <1500mg/L4000mg/L 18440mg/L <4000mg/L




Figure 5: Process Flow Diagram of ETP




4.0 SITE ANALYSIS

(i) Connectivity

The project site is well connected to State Highway SH -37 (~3.5 Km in NE direction) & SH-

65 (~5.0 km in West direction). The nearest railway station _Mahansar Railway Station at

distance is ~ 5.5 Km in SE direction from the project site and Churu Railway Station at

distance is ~ 6.0 Km in NW direction from the project site, nearest airport is Sanganer

International Airport, Jaipur ~175 km in SE direction from the project site. The site is

suitably located with respect to availability of land, water, road network, skilled/semi

skilled/unskilled and professional manpower etc. All communication facilities such as

telephone, telefax & internet are available in the vicinity of the project site.

(ii) Land Form Land use and Land ownership

The considered land for the Proposed Plant for Manufacturing of Dyes & Intermediates

unit is generally flat. Total Project area is 10000 sq.m. (1.0 ha) and the same has been

acquired by the company. Out of total land 33% area will be developed under plantation /

greenbelt development.

(iii) Topography (along with map).

Topography of the core zone of the proposed project is almost flat will be followed;therefore drainage pattern will not be changed during construction phase.

The topography of the area will have localized changes; however except the site, the

overall topography will be same as the present.

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

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

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of

the Gazette notification should be given

Table: 4.1

Environmental Settings of the Area

S. No. Particular Details

1.Nearest Village Untwalita at distance is ~ 2.0 Km in SE direction from the

project site

2. Nearest city/ town Churu at distance is ~ 5.0 Km in NW direction from the




project site

3.

Nearest Railway Station Churu Railway Station at distance is ~ 6.0 Km in NWdirection from the project site

Mahansar Railway Station at distance is ~ 5.5 Km in SEdirection from the project site

4.Nearest Airport Sanganer International Airport, Jaipur ~175 km in SE

direction from the project site

5. Archaeological Important Place None, within 15 km radius area of Project site.

6. Ecological Sensitive Areas(National Park, Wildlife Sanctuary,Biosphere Reserve etc.)

There is no National Park, Wild Life Sanctuaries, BiosphereReserves, Tiger Reserves, Wildlife Corridors, etc. within 10km radius

7. Reserved/Protected Forest within10 km radius

Jod Bir PF at distance is ~ 5.0 Km in West direction from theproject site.

8. Nearest River / water body Tithrana Johra ~ 1.0 Km in NE direction.

9. Interstate boundaries No interstate boundary is within 15 km radius of the projectsite.

(v) Existing Infrastructure

Presently no industrial infrastructure exists, as the proposed site is a vacant land.

(vi) Soil classification

The soil is mostly lateritic, light in texture and acidic in nature. The fertility status is also

very low. The soil is light and porous in nature with low organic matter and low water

holding capacity. However eastern and southern part of this district is more productive

than western part.

(vii) Climatic data from secondary sources

The seasons in Churu are generally distributed as ‘hot summer’ (April-May), ‘monsoon’

(June-September) and ‘Cold season’ (November-February). The humidity is usually low to

medium throughout the year and the rainfall, though not heavy, is usually well

distributed. The average annual rainfall to the district is around 220 mm. The rainy

months are generally July and August.

(viii) Social Infrastructure available

Nearest city/town/village is Churu (~5.0 km in NW direction) & Village Untwalyia (~ 2.0

km in SE from project site.

All basic amenities such as school, hospital, market, etc. are available in nearby area.




Telephone, medical facilities and telegraph facilities are available in the nearby area.

Transportation of raw material and final product will be done via existing road

network and cement concrete road will be developed within the proposed project

area.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country

Planning/ Development authority classification.

Facilities required for the proposed project will be provided as per requirement.

Transportation of raw material and final product will be done via existing road network

and cement concrete road will be developed within the proposed project area.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will

generally be outsider.

(iii) Land use planning (breakup along with green belt etc)

Total Project area is 10000 sq.m. (1.0 ha) and the same has been acquired by the company.

Out of total land 33% area will be developed under plantation / greenbelt development.

(iv) Assessment of infrastructure demand (Physical & Social)

The Company will assess the demand of infrastructure (Physical & Social) in nearby area of

the proposed site and will be developed in under corporate social responsibilities

programs

(v) Amenities/Facilities

The Company will be developed the Amenities/Facilities in nearby area of the proposed

project site as per requirement of local people of the nearby area under corporate social

responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area

The 10000 sq. m land will be required for proposed manufacturing unit.

Following infrastructure will be provided as following:

Workshop

The mechanical and electrical workshop will be provided to take care of the regular

maintenance/ repair jobs in the plant.




Machinery stores

A store building needed for storing tools, spare parts, consumables, etc. Open area

for storing machinery and construction materials for the proposed plant.

Time and Security office

At the entrance of the main plant, a time office and a security office will be

constructed.

First Aid facility

A first aid facility will be provided in the plant premises.

Weighbridge

Electronic weighbridges will be provided to take care of the incoming and outgoing

materials at the plant.

Bags Go down

Space will be provided in the packing plant area for the storage of bags.

Parking

Adequate parking space will be provided in the plant premises for the parking of

vehicles.

(ii) Residential Area (Non processing area)

No residential colony has been envisaged for plant employees. However, guest house &

resting shelter will be provided at project site for plant official and labourers.

(iii) Green Belt

The total project area will be 10000 sq. m out of which 33% area will be covered under

green belt. Local species will be selected for green belt development.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and

indirect employment opportunities in the region including ancillary development and

supporting infrastructure.

(v) Connectivity (traffic and transportation road/rail/metro/water ways etc)

The project site is well connected to State Highway SH -37 (~3.5 Km in NE direction) & SH-

65 (~5.0 km in West direction). The nearest railway station _Mahansar Railway Station at

distance is ~ 5.5 Km in SE direction from the project site and Churu Railway Station at

distance is ~ 6.0 Km in NW direction from the project site, nearest airport is Sanganer




International Airport, Jaipur ~175 km in SE direction from the project site. The site is

suitably located with respect to availability of land, water, road network, skilled/semi

skilled/unskilled and professional manpower etc. All communication facilities such as

telephone, telefax & internet are available in the vicinity of the project site.

(vi) Drinking Water Management (Source & Supply of water)

The total water requirement for the proposed Dyes & Intermediates Manufacturing Unit

has been estimated as 49.50 KLD. Out of which 24.5 KLD will be Fresh, 10.3 KLD will be

Ice & 14.7 KLD will be Recycle. Freshwater will be sourced from ground water after

approval from CGWA.

(vii) Effluent Treatment System/Plan

The effluent generate from proposed project would be 43.5 KLD; same will be treated in

ETP proposed within project site. Treated water will be reutilized within site and no

effluent will be discharge outside the plant area. Domestic waste water will be disposed

off through septic tank/soak pits.

(viii) Industrial Waste / Hazardous Waste management

Hazardous waste will be generated which will be given to the authorised vendor

approved by CPCB and dried sludge will be generated from ETP will be given to TSDF, for

proper disposal of these hazardous waste.

(ix) Solid Waste Management

Description ofSolid/Hazardous waste

Method of disposal

Fly ash Sent to brick manufacturerUsed /Spent oil Collected in drums and stored at specified sludge area and

sold to approved /registered vendorsDiscardeddrums/Containers/PPLiners/Bags

Collected and stored at specified area and sold to approved/registered vendors

Evaporator residue Collected in drums packed, labelled and stored at specifiedarea and finally transferred to common waste incinerationand landfill site.

ETP sludge ETP sludge will be sent to TSDF site

(x) Power requirement & supply/ source

The maximum power demand for the proposed dyes and manufacturing unit has been

estimated as about 500 KVA. The power requirement is proposed to be sourced from

Jodhpur Vidhyut Vitran Nigam Limited (JDVVNL). However, in case of emergency & to

meet the power requirement, 2 no. of DG Sets of 125 KVA Capacity is also envisaged.




7.0 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 labourers (a brief outline to be given).

As there is no major population displacement has been evolved. Land losers have been

compensated as per the mutual agreements. Hence R&R Plan is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the

project to be given).

The Manufacturing of Dyes & Intermediates will be started after obtaining Environmental

Clearance from SEIAA, Rajasthan

(ii) Estimated Project Cost Along With Analysis In Terms Of Economic Viability of the

Project

Total Project Cost : Rs. 20.21 Crores

Environment Protection Cost : Capital Cost of EMP: Rs. 50.00 Lac

: Recuring Cost of EMP: Rs. 5.00 Lac/annum

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area.

Proposed Project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on financial and social benefits will be given to the local

people including tribal population, if any, in the area. Development of social amenities will be in

the form of medical facilities, education to underprivileged and creation of self help groups

10.0 ENVIRONMENTAL MANAGEMENT PLAN

(i) Air Pollution Control

All major sources of air Pollution (burning of fossil fuels, particulate matter and SO2

fumes) will be maintaining the height of the stack of boiler and DG.In the production

line Electrostatic Precipitator (ESP) is installed to minimize the emission of particulate

matter in the ambient air and SO2 Scrubber to avoid the escape of SO2 in Ambient air.




Water spraying will be provided around raw material handling area and on the haul

roads for dust suppression.

All the roads within the plant premises will be concreted and regular sweeping by

vacuum sweeping machine.

Periphery of plant and surrounding areas of office building will be covered by thick

green belt to attenuate the pollutants.

Proper maintenance of vehicles will be done to reduce gaseous emissions.

Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.

Air emission from stackSTACK

ATTACHED TOFUEL POLLUTION

CONTROLEQUIPMENT

STACKHEIGHT &DIAMETER

POLLUTANTS(CPCB LIMIT)

Steam Boiler(800Kg/Hr)

Thermic Fluidand Heater

BIO Fuel(Pellets) 10.0

Tons/DAY

Multi cyclonewith bag filter

Ht-30 mDia-0.51 m

SPM < 150MG/NM3

SO2 < 100 PPMNOx < 50 PPM

D.GSET OF 125KVA (IN

EMERGENCYONLY)

Diesel 40Liter/Hrapprox

AcousticEnclosure

Ht-11 mDia -0.3 m

(ii) Water Pollution Control

No industrial effluent will be generated from manufacturing process.

Waste water from water treatment plant will be recycled back in dust suppression

after proper mixing/diluting.

Domestic effluent will be treated in STP

No waste water will be discharged inside/outside the plant premises.

Rain water harvesting system will be provided for storm water drains and rooftop.

(iii) Rain water Harvesting

In the plant premises water harvesting system is proposed to harvest the rain water as a

green initiative to increase the efficiency of plant in respect of water.

(iv) Hazardous Waste Management

Hazardous waste will be generated which will be given to the authorised vendor




approved by CPCB and dried sludge will be generated from ETP will be given to TSDF, for

proper disposal of these hazardous waste.

Hazardous waste generated will be collected in plastic drum and stored temporarily for

proper disposal system.

(v) Noise Pollution Control

All equipment considered in technical concept shall be designed to operate

within the prescribed noise levels as defined by relevant standards. Where necessary

special sound enclosures shall be considered or the buildings shall be designed with

noise protection.

Silencers for compressor house and acoustic stack for DG Set will be provided.

Proper maintenance, oiling and greasing of machines at regular intervals will be done

to reduce generation of noise.

Personal Protective Equipments like earplugs and earmuffs will be provided to the

workers exposed to high noise level.

Green Belt of appropriate width all along with plant boundary wall will be developed.

Regular monitoring of noise level will be carried out.

(vi) Green Belt Development/Plantation

About 33% area of the total land will be developed under green belt area all along with

plant boundary wall & plantation in side plant premises so as to reduce dust & noise

levels & to increase aesthetic beauty of the area.

11. CONCLUSION

Proposed Project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on financial and social benefits will be given to the local

people including tribal population, if any, in the area. Development of social amenities will be in

the form of medical facilities, education to underprivileged and creation of self help groups.

No adverse effect on environment is envisaged as proper mitigation measure will be taken up

for the same.

Proposed Dyes & Intermediates manufacturing project of 150 ...

Documents

Transcript of Proposed Dyes & Intermediates manufacturing project of 150 ...