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ABBREVIATIONS
CGWA Central Ground Water Authority
CPCB Central Pollution Control Board
CRZ Central Regulation Zone
DG Diesel Generator
ESE East of South East
ENE East of North East
EIA Environmental Impact Assessment
ETP Effluent treatment Plant
GIDC Gujarat Industrial Development Corporation
Ha Hectare
HSD High speed Diesel
KLD Kilo Littre Per Day
Kcal Kilo Calories
KM Kilo Meter
KVA Kilo-volt-ampere
KW Kilo Watt
MW Mega Watt
MT Metric Tone
MoEFCC Ministry of Environment, Forest & Climate Change
NH National Highway
NNW North of North West
NE North East
NH National Highway
R&R Rehabilitation and Resettlement
RIICO Rajasthan State Industrial Development and Investment Corporation
RSEB Rajasthan State Electricity Board
SPCB State Pollution Control Board
SE South East
SQ METER Square Meter
SSE South of South East
SW South West
TPH Tonnes Per Hour
TPA Tonnes Per Annum
TSDF Transportation, Storage and Disposal Facility
WNW West of North West
i
INDEX
S. NO. CONTENTS PAGE NO.
1.0 Executive Summary 1
2.0 Introduction of the Project / Background Information 2
(i) Identification of project & project proponent 2
(ii) Brief description of nature of the project 2
(iii) Need for the project & its importance to the country and or region 3
(iv) Demand-Supply Gap 3
(v) Import Vs. Indigenous Production 3
(vi) Export possibility 3
(vii) Domestic / Export Markets 3
(viii) Employment generation (direct and indirect) due to the project 3
3. Project Description 4
(i) Type of project including interlinked and independent projects, if any 4
(ii) Location (Map showing General Location, Specific Location, and Project Boundary &
Project Site Layout) with coordinates 4
(iii) Key Plan 6
(iv) Details of alternative sites consideration and basis of selecting the project site,
particularly the environmental considerations gone into should be highlighted 7
(v) Size or Magnitude of operation 7
(vi) Project description with process details (a schematic diagram/ flow chart showing the
project layout, components of the project etc. should be given)
7
(vii) Raw material required along with estimated quantity, likely source, marketing area of
final products, mode of transport of raw material and finished product 8
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be
briefly outlined 9
(ix) Availability of water its source, energy /power requirement and source should be given 9
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/
disposal 10
4. Site Analysis 13
(i) Connectivity 13
(ii) Land Form, Land Use and Land Ownership 13
(iii) Topography 14
(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
14
ii
S. NO. CONTENTS PAGE NO.
Gazette Notification
(v) Existing Infrastructure 14
(vi) Soil classification 15
(vii) Climatic Data from Secondary Sources 15
(viii) Social Infrastructure Available 15
5. Planning Brief 15
(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and
Country Planning/ Development Authority Classification 15
(ii) Population Projection 15
(iii) Land Use Planning (Break Up along with Green Belt Etc.) 16
(iv) Assessment of Infrastructure Demand (Physical & Social) 16
(v) Amenities/ Facilities 16
6.0 Proposed Infrastructure 16
(i) Industrial Area (Processing Area) 16
(ii) Residential Area (Non-Processing Area) 16
(iii) Green Belt 16
(iv) Social Infrastructure 16
(v) Connectivity 16
(vi) Drinking & Domestic Water 16
(vii) Sewerage System 17
(viii) Industrial Waste Management 17
(ix) Solid Waste Management 17
(x) Power Requirement & Source 17
7. Rehabilitation and Resettlement (R & R) Plan 17
(i) Policy to be adopted (Central/ State) in respect of the Project affected persons including
Home Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 17
8. Project Schedule & Cost Estimates 17
(i) Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the
Project to be given) 17
(ii) Estimated Project Cost 17
9. Analysis of Proposal 17
(i) Financial and Social Benefits with special emphasis on the benefit to the local people
including tribal, population, if any in the area 17
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
M/s. Uma Eximp (India) is proposing for Dyes & Dyes Intermediates Manufacturing Unit (7471.2
TPA) within Existing premises of Ferrous Sulphate Plant at Plot No. E-203, RIICO Growth Centre,
Phase- II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan).
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A. Nature & Size of the Project Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA)
B. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time to
time; this project falls under Category “B”, Project or Activity-5 (f) but as it
attracts the General Condition (Interstate Boundary of Gujarat - Rajasthan
falls within 5.0 km from the plant site), this project will be treated as Category
“A” project.
C. Location Details
Plot no. E-203
Village Maval
Tehsil Abu Road
District Sirohi
State Rajasthan
Latitude 24°25'10.05" N to 24°25'12.04" N
Longitude 72°41'55.88" E to 72°41'59.33" E
Toposheet No. G43S10, G43S11 & G43S15
D. Area Details
Total Plant Area 4231.71 sq. m. (1.04 acres)
Greenbelt / Plantation Area (ha) Approx. 1400 sq. m. (0.34 acres) i.e. (33% of the total plant area) has been
proposed to be developed under greenbelt / plantation.
E. Environmental Setting Details (with approximate aerial distance & direction from the plant site)
1. Nearest Village Maval (1.5 km in NNE direction)
2. Nearest Town / City Abu Road (10.5 km in NE direction)
3. Nearest National Highway / State
Highway
NH- 14 (1.0 km in NW direction)
4. Nearest Railway station Maval Railway Station (1.2 km in NNE direction)
5. Nearest Airport Dabok Airport, Udaipur (122 km in NNE direction)
6. National Parks, Wildlife
Sanctuaries, Biosphere Reserves,
Reserved / Protected Forests
within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserved / Protected
Forests falls within 10 km radius of the plant site.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 2
S. NO. PARTICULARS DETAILS
7. Water Bodies (within 10 km
radius)
o Banas River (2.0 km in NW direction)
o Baisasing Lake (3.5 km in SE direction)
o Dungarpura Lake (4.5 km in SW direction)
o Suket Nadi (1.5 km in NE direction)
o Sewaran Nadi (3.5 km in ENE direction)
o Kaleri Nadi (4.5 km in NW direction)
o Gomti Nadi (6.5 km in WNW direction)
o Mandwari Talav (8.5 km in ENE direction)
o Taliya Nadi (8.5 km in ESE direction)
8. Interstate boundary Rajasthan - Gujarat Interstate boundary (1.2 m in West direction)
9. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]
F. Cost Details
Total Cost of the Project Rs. 1.0 Crores
Cost for Environment Protection
Measures
o Capital Cost: Rs. 50 lacs
o Recurring Cost: 10 lacs /annum
G. Basic Requirements for the project Requirement Source
Water Requirement (KLD) 20 RIICO
Power Requirement (KW) 49 RSEB & Proposed D.G. Set (250 KVA)
Manpower Requirement 10 Skilled - Local / Outside, Unskilled - Local
Source: SOI Toposheet & Google earth
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
M/s Uma Eximp (India) is engaged in manufacturing of Ferrous Sulphate. Company now wishes to
enter in dyes & dyes intermediate products. The company comprises of reputed businessman and
experienced in to the promoter Directors, who are experts in the field of Dyes & Dyes
intermediate manufacturing, who will be guiding the company at every stage of operation from
installation to commissioning. The Unit believes in sustainable development and is equally
concerned about environment preservation and pollution control and proposes to provide
adequate environmental Management System not only to meet desired norms prescribed by
statutory authority but also for sustainable development.
(ii) Brief description of nature of the project
M/s. Uma Eximp (India) is proposing for Dyes & Dyes Intermediates Manufacturing Unit (7471.2
TPA) within Existing premises of Ferrous Sulphate Plant at Plot No. E-203, RIICO Growth Centre,
Phase- II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan).
As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this project falls
under Category “B”, Project or Activity-5 (f) but as it attracts the General Condition (Interstate
Boundary of Gujarat - Rajasthan falls within 5.0 km from the plant site), this project will be treated
as Category “A” project.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 3
(iii) Need for the project and its importance to the country and or region
M/s. Uma Eximp (India) is having small scale manufacturing unit. This product is used in mainly
Dyes & Dyes intermediate. Textile industry accounts for the largest consumption of Dyes. Industry
from being net importer and distributor in the 1950’s, it has emerged as a very strong industry
today and a major foreign exchange earner. India has emerged as a global supplier of dyestuffs
and dye intermediates, particularly for Reactive Dyes, and Direct Dyes. India accounts for 7% of the
world production. There exists wide demand for Dyes.
(iv) Demand- Supply Gap
As stated earlier the major end users of Dyes are the many Dyes Industries. Thus, the demand
for Dye Intermediated is related to the expansion and growth of Dye sector. In 2007-08,
demand grew at 10 per cent in value terms. The growth in exports has resulted in higher
growth, apart from the domestic demand from the textiles sector which accounts for 60 per
cent of the consumption. Demand from other sectors such as leather, paper, food processing,
printing and paints grew at a stable rate of 6-10 per cent. The realizations of Indian players were
affected by the appreciation in rupee, but tight supply has enabled them to increase prices.
Demand for dyes and pigments declined sharply since the beginning of second half of 2008-09
and expected to decline in 2009-10 on the back of declining demand from Textile, leather and
printing industry. The export growth is also expected to get affected by slowdown in the
demand from East, South and West Asia, Africa, USA and the European Countries.
(v) Imports vs. Indigenous Production
Existing manufacturing of the products in the country will be very much economical compare
to Imports of the same and also the export of the same will earn extra revenue generation for
our county. Based on the current cost of indigenous raw materials, it will make very
competitive against imported finished products and the company will be able to increase the
export of our finished products. The project shall enhance the foreign exchange reserves in
view of the proposed products.
(vi) Export Possibility
The finished product of the plant shall cater to both domestic and export markets.
(vii) Domestic / Export Markets
Majority of the products will be sold in local market and some will be exported.
(viii) Employment Generation (Direct and Indirect) due to the project
Direct and indirect employment will be generated due to the project. Manpower required for
proposed manufacturing unit will be 10 persons.
Source: All skilled and unskilled persons will be hired by nearby area.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 4
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any
M/s. Uma Eximp (India) is proposing for Dyes & Dyes Intermediates Manufacturing Unit (7471.2
TPA) within Existing premises of Ferrous Sulphate Plant at Plot No. E-203, RIICO Growth centre,
Phase II, Village: Maval, Tehsil: Abu Road District: Sirohi (Rajasthan).
Interlinked and Independent Projects- There is no interlinked and independent project.
(ii) Location (map showing general location, specific location, and project boundary & project site
layout) with coordinates
Figure - 1: Location Map
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 5
Figure - 2: Plant Layout
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 6
(iii) Key Plan
Figure - 3: Key Plan
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 7
(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
Total plant area is 4231.71 Sq. m. (1.04 acres) Since, the proposed Dyes & Dyes Intermediates
Manufacturing Unit will be set up within the existing premises of Ferrous Sulphate plant; thus, no
additional land will be required; Also, the plant site is situated in Notified RIICO industrial area.
Therefore, no alternative site has been considered.
(v) Size or magnitude of operation
M/s. Uma Eximp (India) is proposing for Dyes & Dyes Intermediates Manufacturing Unit (7471.2
TPA) within Existing premises of Ferrous Sulphate Plant at Plot No. E-203, RIICO Growth Centre,
Phase- II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan).
(vi) Project description with process details (a schematic diagram/ flow chart showing the project
layout, components of the project etc. should be given)
Project Description
M/s. Uma Eximp (India) is proposing for Dyes & Dyes Intermediates Manufacturing Unit (7471.2
TPA) within Existing premises of Ferrous Sulphate Plant at Plot No. E-203, RIICO Growth Centre,
Phase- II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan).
The details of proposed production capacity of Dyes & Dyes Intermediates Manufacturing with
uses of the same are given below:
S. No. Products Name Capacity
(TPA)
Use of Product
1. G- Salt 900 As dyes intermediates for Acid Dyes and Food Color
2. R-Salt 160.8 As dyes intermediates for Acid Dyes and Food Color
3. Schaeffer’s Acid
900
In the manufacturing of Food Colors i.e, Sunset Yellow
& Allura Red
4. K Acid It is used for dyes intermediate
5. Gamma Acid It is used for dyes intermediate
6. Bronner's Acid It is used for dyes intermediate
7. Para Cersidine Ortho Sulphonic Acid
300
It is used can be made food dyes, pigments and so on
8. N-methyl J acid It is used for Intermediate for dyestuffs
9 Vinyl Sulphone Ortho Anisidine Base
(OSVS)
It is used for Intermediate for dyestuffs
10. Vinyl Sulfone Para Cresidine base
(PCVS)
It is used for Reactive Yellow 15 and other dyestuffs.
11.
2-(4-Amino-2,5-Dimethoxy-Phenyl-
Sulphonyl) Ethanol Sulphate Ester
(DMAVS)
It is used for dye intermediate.
12. Sulpho VS 600 It is used for Intermediate for dyestuffs.
13. Meta Phenylene Diamine 4 Sulfonic
Acid Free Acid (MPDSA) 300
It is used for Intermediates and Dyestuff.
14. Neville Winther’s Acid (N.W. Acid) In the manufacturing of Food Colors i.e. Carmoisine,
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 8
ROS-1 Ponceau SX
15. Aniline 2,5 Disulphonic Acid It is used with other intermediate to manufacture
quality products.
16. Tech. Sulphanilic Acid 1200
It is used for formation of optical brighteners for the
paper industry and also in the concrete,
pharmaceutical and food dye industries.
Total 4360.8 -
Proposed Co-Product Capacity
S. No. Co-Products Name Capacity (TPA)
1. Ammonium bi Sulphide 1167.6
2. Sodium Bisulphite 1935.6
3. Sodium Naphthionate 7.2
Total 3110.4
The details manufacturing process of each Dyes & Dyes Intermediates is enclosed as Annexure - 2.
(vii) 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 Requirement
S. No Name of Raw Material Total
(TPA)
Physical
Form Source
Distance / Mode of
Transportation
Raw materials for Dyes & Dyes Intermediates Manufacturing
1. 3 4 DCNB 517.2 Crystals
Chhatral
GIDC &
GIDC,
Ankleshwar
/ Panoli
150 km / road
325 km / Road
2. Sodium Trisulphite 340.8 Solid
3. MGO (Magnesium Oxide) 114 Solid
4. NaCl 1020 Solid
5. Cl Powder 570 Solid
6. Hydrochloric Acid 405.6 Liquid
7. Sulphuric Acid 9963.6 Liquid
8. Soda ash 375.6 Solid
9. Para Cresidine 900 Solid
10. Oleum 3321.6 Liquid
11. Salt 20.4 Solid
12. Sodium Naphthionate 390 Solid
13. Sodium Bisulphite 883.2 Solid
14. Caustic Lye 2216.4 Liquid
15. 2,5 Dichloroaniline 238.8 Solid
16. J- Acid 300 Powder
17. Mono Methylamie 420 Liquid
18. Acetyl Ortho Ansidine 214.8 Liquid
19. Chloro sulphonic acid 8100 Liquid
20. Acetican hydride 192 Liquid
21. Ethylene Oxide 175.2 Gas
22. Amido G-salt 1282.8 Liquid
23. Acetic Anhydride 252 Liquid
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 9
S. No Name of Raw Material Total
(TPA)
Physical
Form Source
Distance / Mode of
Transportation
Raw materials for Dyes & Dyes Intermediates Manufacturing
24. 2:5 DMA 210 Liquid
25. Sodium Sulphate 106.8 Solid
26. Ammonium Sulphate 1125.6 Liquid
27. Vinyl Sulphone 378 Solid
28. KCL 877.2 Solid
29. B Naphth 1899.6 Solid
30. Carbon 31.2 Solid
31. G- Salt ML 6982.8 Liquid
32. Liq. Ammonia 25% 1200 Liquid
33. Schaeffer's Salt 800.4 Liquid
34. Sodium BiSuphonate OR
Ammonium Bi Sulphide 80.4 Liquid
35. Crude Sulphanilic Acid 33.6 Powder
36. Aniline 690 Liquid
Fuel Requirement
S. No. Fuel Total Requirement
(Kg / hr) Source
Distance & Mode of
Transportation
1. Briquettes / Coal (For Boiler) 200
Nearby
areas
15 Km by Road
2. Diesel (For D.G. Set) 60 1 Km by Road
3. Brick/ Coal (For Thermic Heater) 100 15 Km by Road
(a) Marketing Area and Mode of transportation of Final Product
Marketing area Dyes & Dyes intermediate market would be the state of Rajasthan, Gujarat,
Madhya Pradesh and other neighboring states. Mode of transportation for final product will be by
road only.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly
outlined.
o Proposed unit will be based on “Zero Liquid Discharge”.
o The industrial waste water generated will be treated in the Effluent Treatment Plant and
treated waste water will be recycled to process for utilization in cooling/washroom/boiler and
gardening.
o The domestic waste water generated will be disposed through soak pit in septic tank.
o Rainwater harvesting will be done at plant site.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
Water requirement for the proposed manufacturing unit will be 20 KLD.
Source of Water: RIICO Supply & Ground water
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 10
(b) Power Requirement and Source
The total power requirement for the proposed manufacturing unit will be 49 KW.
Source: Rajasthan Rajya Vidyut Vitran Nigam Limited & D.G. Sets for emergency (40 KVA &
Proposed 250 KVA).
Details of D.G. Sets
Existing D.G. set is having capacity 40 KVA & additional 250 KVA DG Set is proposed to be installed
for the power backup. Details regarding the D.G. Sets are mentioned in the table given below:
S. No. Details
1. Type of Fuel High Speed Diesel (HSD)
2. Capacity Existing: 40 KVA and Proposed: - 250 KVA
3. Stack Height (above roof level) As per CPCB/SPCB norms
4. Pollution Control Equipment Measures Adequate stack height / Acoustic
Details of Boiler
M/s. Uma Eximp India is also proposing Boiler (1 TPH) along with Thermic Heater of 2 Lacs Kcal/hr
with will be attached with Multi cyclone Separator.
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
Waste Water Generation:
o ETP sludge will be isolated with the help of Iron Sludge and dried sludge will be collected by
authorized dealers and sent to TSDF Site. Membership Certificate of TSDF site is enclosed as
Annexure - 3.
o Fly ash generated; which will be in very little quantity, will be sold to brick manufacturers/
authorized recycler.
o Proposed unit will be based on “Zero Liquid Discharge”.
o The industrial waste water generated will be treated in the Effluent Treatment Plant and
treated waste water will be recycled to process for utilization in cooling/washroom/boiler and
gardening.
o The domestic waste water generated will be disposed through soak pit in septic tank.
o Rainwater harvesting will be done at plant site.
Description of Effluent Treatment Plant
o Collection cum Equalization Tank
This tank is designed to collect raw effluent generated from the process by gravity. Screen will be
provided at the entry of effluent in the tank for arresting the floating matter and larger size solid
particle. Coagulation and flocculation will be done by addition of chemicals. Course bubble
aeration grid will be provided to equalize the effluent quantitatively as well as qualitatively.
Equalized effluent will be pumped to the primary settling tank.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 11
o Primary Settling Tank with Tube Settler
Equalized effluent will be collected in this tank by gravity. Tank will be provided with hopper
bottom for better sludge settlement and removal of the solids. For enhancing the settling
characteristics and to reduce the volume of tank, tube settler media will be provided in the tank.
Supernatant from this settling tank will flow by gravity into MBBR. Solids settled at the bottom of
the tank will be transferred into the sludge drying beds.
o Moving Bed Bio Reactor (MBBR) or Membrane Bio Reactor
Chemically treated along with sewage from septic tanks will be treated in this tank. Tank consists
of air grids at the bottom of the tank which help to transferring the oxygen through the air blower
and at the same time maintains the bacterial culture in suspension. The bacteria utilize the oxygen
to degrade the organic matter which is present in the wastewater and convert in to the simple
organic compounds. Treated effluent from this tank will flow by gravity into the Secondary
Settling Tank for Bio sludge removal.
o Secondary Settling Tank with Tube Settler
Biologically treated effluent will be collected in this tank by gravity. Tank will be provided with
hopper bottom for better sludge settlement and removal of bio sludge. For enhancing the settling
characteristics and to reduce the volume of tank, tube settler media will be provided in the tank.
Supernatant from this settling tank will flow by gravity into the Filter Feed Tank. Bio sludge settled
at the bottom of the tank will be transferred into the sludge drying beds.
o Sludge Handling System
Sludge Handling System consists sludge collection tank followed by filter press for dewatering of
sludge. Filtrate generates from filter press will be sent to the Collection cum Equalization Tank for
further treatment. Dried sludge will be disposed off as per the norms.
o Filter Feed Tank
This tank is designed to collect the biologically treated effluent after sludge removal. From this
tank, effluent will be pumped to the tertiary filtration system consists of pressure sand filter and
Activated carbon filter with help of high pressured pumps. Chlorination will be done in this tank by
addition of sodium hypochlorite. In case of Membrane Bio reactor will be provided as secondary
treatment, then there is no need of tertiary treatment.
o Pressure Sand Filter and activated carbon Filter
This is the polishing treatment for the effluent. This filtration system is removed the remaining
solid particles, dead microorganisms, colour from the treated effluent. From the activated carbon
filter, treated water will be used for gardening or in other utility applications.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 12
Figure - 4: Process Flow of Effluent Treatment Plant
Capacity of Units
S. No. Name of Unit Qty. Total Volume MOC
1. Collection Cum Equalization Tank 1 25 m3 RCC
2. Flash Mixer and Flocculator 1 3 m3 --
3. Primary Settling Tank (PST) 1 7.5 m3 RCC
4. MBBR / MBR 1 50 m3 RCC
5. Secondary Settling Tank (SST) 1 7.5 m3 RCC
6. Tertiary Feed Tank 1 10 m3 RCC
7. Treated water sump 1 25 m3 RCC
8. Sludge Collection Sump 1 15 m3 RCC
9. Filter Press 1 24” x 24” PP
10. Reverse Osmosis Plant 1 2.5 cum/hr --
11. Steam based Evaporator 1 500 Liters/hr MS
The details of hazardous waste management are given in table below: -
S. No. Description Cat. Quantity (TPA) Management
1. Used/spent Oil 5.1 20 Liter/year
Collection, storage, Transportation
and reuse within premises for
lubrication or disposal to registered
recycler.
2. Discarded
Containers/bags 33.1 2.0 MT/Month
Collection, storage, Transportation &
sell to authorized vendor
3. Spent Carbon 18.2 48 Collection, storage, Transportation
and Disposal to TSDF for Land filling
4. H2SO4 (30-40%) 26.3 11400 Collection, storage, Transportation
Reject will be Evaporated
Activated Carbon Filter
Treated Water
Collection Tank
RO Plant Permeate reuse
in industrial uses
Filter Press
Effluent Collection
Tank
Flash Mixer &
Flocculator
Primary
Settling
Tank
Aeration Tank (MBBR/MBR)
Secondary
Settling
Tank
Tertiary Feed Tank
Pressure Sand Filter
Sludge Tank Sludge to
TSDF
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 13
S. No. Description Cat. Quantity (TPA) Management
5. HCl (30%) 26.3 11400 and reuse for captive consumption or
sell to actual users
6. Process waste 26.1 384 Collection, storage, Transportation
and Disposal to TSDF
7. ETP & Evaporator
Sludge 35.3 300
Collection, storage, Transportation
and Disposal at TSDF
8. Iron Sludge 26.1 780 Collection, storage, Transportation
and sell to cement manufacturing unit
4.0 SITE ANALYSIS
(i) Connectivity
The plant site is well connected to NH - 200 (~1.0 km in NW direction). Nearest town / city is Abu
Road, which is approx. 10.5 km in NE direction from the plant site. Nearest railway station to the
plant site is Maval Railway Station (~1.2 km in NNE direction). Nearest Airport is Dabok Airport,
Udaipur (~122 km in NNE direction). The site is connected with communication facilities like
telephone, fax, wireless and telex, E mail, internet and as such, no constraints are envisaged in this
aspect as the Tehsil.
(ii) Land from Land use and Land ownership
The total project area is 4231.71 sq. m (1.04 Acres) and proposed manufacturing unit will be set
within the existing premises of Ferrous Sulphate plant. Land use of the existing land area is
already industrial as the land area falls under notified RIICO Industrial area.
S. No. Particulars Land Area (m2)
1. Existing Plant Facilities 206.80
2. Proposed Plant facilities and Machinery 302.20
3. Utility area 38.80
4. ETP Area 39.10
5. Labour Room 89.70
6. Laboratory 21.50
7. Electric & Security Room 21.50
8. Office & Store Room 57.40
9. Parking area 83.70
10. Waste storage area 108.90
11. Green belt area 1397.20
12. Roads 635.50
13. Open area 1229.41
Total area 4231.71
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 14
(iii) Topography
The topography of the area is almost flat.
(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 - 2
Environmental Settings of the Area
S. No. Particulars Details
(with approximate aerial distance & direction from the plant site)
1. Nearest Village Maval (1.5 km in NNE direction)
2. Nearest Town / City Abu road (10.5 km in NE direction)
3. Nearest National Highway / State Highway NH- 14 (1.0 km in NW direction)
4. Nearest Railway station Maval Railway Station (1.2 km in NNE direction)
5. Nearest Airport Dabok Airport, Udaipur (122 km in NNE direction)
6.
National Parks, Wildlife Sanctuaries,
Biosphere Reserves, Reserved / Protected
Forests within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve,
Reserved / Protected Forests falls within 10 km radius of the
plant site.
7. Water Bodies (within 10 km radius)
o Banas River (2.0 km in NW direction)
o Baisasing Lake (3.5 km in SE direction)
o Dungarpura Lake (4.5 km in SW direction)
o Suket Nadi (1.5 km in NE direction)
o Sewaran Nadi (3.5 km in ENE direction)
o Kaleri Nadi (4.5 km in NW direction)
o Gomti Nadi (6.5 km in WNW direction)
o Mandwari Talav (8.5 km in ENE direction)
o Taliya Nadi (8.5 km in ESE direction)
8. Interstate boundary Rajasthan - Gujarat Interstate boundary (1.2 m in West direction)
9. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]
(v) Existing Infrastructure
Following infrastructure of Ferrous Sulphate plant and associated facilities are available at site is
given below:
• Workshop
A common mechanical and electrical workshop has been installed to take care of the regular
maintenance/ repair jobs in the plant.
• Machinery stores
A store building has been made available for storing tools, spare parts, consumables, etc.
• Time and Security office
At the entrance of the main plant, a time office and a security office has been constructed.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 15
• Weighbridge
Electronic weighbridges are envisaged to take care of the incoming and outgoing materials in
the existing plant premises.
• Storage facilities
Adequate storage facilities have been provided for the storage of raw materials & finished
product.
(vi) Soil classification
Sirohi district is in the shape of an irregular triangle. A large part of the district is a vast semi
desert. Plain, marked by isolated hills and chains of hillocks forming the eastern fringes of the
Thar Desert. The north-eastern, south-western trending Aravali ranges bound it on the east.
The soil type in the Abu road is Loam, sandy clay, saline soil & Kankars.
(vii) Climatic data from secondary sources
Climate of the district can be classified as semi-arid. It is characterized by very hot summer and
very cold winters with fairly good rainfall during south west monsoon period. In May and June,
the maximum temperature may go up to 47°C. The potential evapo transpiration rates are quite
high especially during May and June. Normal annual rainfall of the district is 631mm. Relative
humidity is around 60% during the monsoon but is much lower throughout the rest of the year,
falling to 20-25% in the summer. Winds are generally light and variable during the cool winter
period, and mainly from the north and north-west, and the strongest winds are the south-western
lies that bring the monsoon in June and July.
(viii) Social Infrastructure available
Nearest town is Abu Road. There are primary schools, dispensaries, small hospitals, places of
common facilities in nearby area of the plant site. Most of the villages are electrified.
Telephone, Medical facilities and Telegraph facilities are available in the nearby towns. Almost
all the villages in the buffer zone are electrified.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/
Development authority classification.
The industry is Dyes and Dye-intermediates (Red Category). Facilities required for the Proposed
Dyes & Dyes Intermediates Manufacturing Unit will be provided as per requirement.
Transportation of raw materials and final product will be done via existing road and cement
concrete road will be developed within the plant premises.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will generally
be outsider. A projection may be made by a governmental organization, or by those unaffiliated
with a government.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 16
(iii) Land use planning (breakup along with green belt etc.)
The total project area is 4231.71 sq. m (1.04 acres) and proposed manufacturing unit will be set
within the existing Ferrous Sulphate Production unit. Land use of the existing land area is already
industrial as the land area falls under notified RIICO Industrial area. Approx. 1400 sq. m. (0.35
acres) i.e. (33% of the total plant area) has been proposed to be developed under greenbelt /
plantation.
(iv) Assessment of infrastructure demand (Physical & Social)
The company will assess the demand of infrastructure (physical & social) in nearby area of the
site and will be developed under corporate social responsibilities programs.
(v) Amenities/Facilities
The company will develop the amenities/facilities in nearby area of the plant site as per
requirement of local people under corporate social responsibilities programs.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
The total project area is 4231.71 sq. m and proposed manufacturing unit will be set within the
existing Ferrous Sulphate Production unit. Land use of the existing land area is already industrial
as the land area falls under notified RIICO Industrial area. There will be minor modification require
in existing premises particularly in Process house, Utilities area and ETP section.
(ii) Residential area (Non- Processing area)
There is no provision of residential facility as the manpower hired is/ will be from nearby area.
(iii) Green Belt
Approx. 1400 Sq. m. (0.35 acres) i.e. (33% of the total plant area) has been proposed to be
developed under greenbelt / plantation.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased indirect employment
opportunities in the region including ancillary development and supporting infrastructure.
(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)
The plant site is well connected to NH - 200 (~1.0 km in NW direction). Nearest town / city is Abu
Road, which is approx. 10.5 km in NE direction from the plant site. Nearest railway station to the
plant site is Maval Railway Station (~1.2 km in NNE direction). Nearest Airport is Dabok Airport,
Udaipur (~122 km in NNE direction). The site is connected with communication facilities like
telephone, fax, wireless and telex, E mail, internet and as such, no constraints are envisaged in this
aspect as the Tehsil.
(vi) Drinking Water Management
Total domestic water requirement the project is 2 KLD which will be sourced from RIICO.
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 17
(vii) Sewerage System
The domestic waste water generated will be disposed through soak pit in septic tank.
(viii) Industrial Waste management
The industrial waste water generated will be treated in the Effluent Treatment Plant and treated
waste water will be recycled to process for utilization in cooling/washroom/boiler and gardening.
(ix) Solid Waste Management
o ETP sludge will be isolated with the help of Iron Sludge and dried sludge will be collected by
authorized dealers and sent to TSDF Site.
o Fly ash generated; which will be in very little quantity, will be sold to brick manufacturers/
authorized recycler.
(x) Power requirement and source
The total power requirement for the proposed manufacturing unit will be 49 KW.
Source: Rajasthan Rajya Vidyut Vitran Nigam Limited & D.G. Sets for emergency (40 KVA &
Proposed 250 KVA).
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).
Since, the proposed unit will be set up within the existing premises of Ferrous Sulphate plant & no
additional land will be required for the project; hence R & R plan is not applicable for the proposed
project.
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 project will start only after obtaining Environmental Clearance and all other required
clearances. An implementation period of 6 months for this plant from the date of signing/
effectiveness of the main equipment supply contract will foreseen for this project.
(ii) Estimated project cost along with analysis in term of economic viability of the project.
Total cost of the Project: Rs. 1.0 Crores
Cost for Environment Protection Measures:
� Capital Cost: Rs. 50 Lacs
� Recurring Cost: Rs. 10 Lacs / annum.
9.0 ANALYSIS OF PROPOSAL
(i) Financial and social benefits with special emphasis on the benefit to the local people including
tribal population, if any, in the area.
Nearby people will get opportunity to improve their livelihood. Proposed Manufacturing
Proposed Dyes & Dyes Intermediates Manufacturing Unit (7471.2 TPA) within Existing premises of Ferrous Sulphate Plant
At Plot No. E-203, RIICO Growth Centre, Phase-II, Village: Maval, Tehsil: Abu Road, District: Sirohi (Rajasthan)
Pre - feasibility Report
M/s. Uma Eximp (India) 18
Project will result in growth of the surrounding areas by enhancing opportunity in indirect
employment in the region including ancillary development and supporting infrastructure. No
additional land will be required, existing land is sufficient for the proposed manufacturing
project; hence there will be no impact on the land use pattern of the project study area.
Adequate measures will be adhered to keep the pollution level within prescribed standards.
Thus, the project of M/s. Uma Eximp (India) will be proved beneficial to the local economy and
society and will not lead to any adverse impact on the environment.
Annexure- 1
Plot Allotment Certificate from RIICO
(Rajasthan State Industrial Development and Investment Corporation)
Annexure – 2
Manufacturing Process
1. G- Salt
Manufacturing process, reaction chemistry, mass balance diagram and process flow diagram of G-Salt is presented here;
a) Manufacturing Process:
In Sulphonator take Sulphuric acid. Cool it to required temperature. Add Beta Naphthol Free stire. Slowly
add oleum (23%) with controlling of temperature. Heat it to elevated temperature Maintain for Hrs. Dump
the mass in ice water. Add MOP salt and heat to boil. Scrub the generated HCL in scrubber and stir for Hrs.
Cool it. Filter it. Collect wet cake as finished product and filtrate for recovery of R-salt.
b) Chemical Reaction:
c) Material Balance:
OH
H2SO4
Oleum
SO3H
OH
SO3H
OH
SO3H SO3H
B Naphthol
R Salt
G Salt
Sulphonation H2SO4 : 2300 Kg
B Napthol: 2000 Kg
Oleum : 3500 Kg 7800 Kg
Isolation HCl (30%): 4900 Kg
Filter/CF
ML from G Salt: 16830 Kg (Reuse for
R-Salt)
G-Salt: 4500 KG
KCl Salt: 3000 Kg
Water : 15430 Kg
d) Mass Balance:
G- Salt 75 Mt/Month
Batch Size 4500 Kg
Input Particular Kg/Batch
H2SO4 2300.0
B Naphthol 2000.0
Oleum 23% 3500.0
KCL 3000.0
Water 15430.0
Total 26230.0
Output Product 4500.0
HCL 30% 4900.0
ML from G-Salt 16830.0
Total 26230.0
2. R-Salt
Manufacturing process, reaction chemistry, mass balance diagram and process flow diagram of R-Salt is
presented here;
a) Manufacturing Process:
Collect filtrate form G-salt plant. Heat and Add aniline oil add salt and free spirit. Cool it. Filter the mass.
Collect wet cake as R-complex. Take it in reactor with water and caustic lye and make alkaline. Heat it to
boil collect Aniline oil. Add carbon filter it. Collect filtrate and add acid for isolation. Cool it. Filter it. Collect
wet cake as finished product. b) Chemical Reaction:
SO4H
OH
SO3H
+ H2SO4
40% +
NH2
NH2
+
R Salt
SO3H
OH
SO3H SO3H
SO3H
O
NH
NaOH
c) Material Balance:
d) Mass Balance:
R- salt 13.4 MT/Month
Batch Size 800 Kg
Input
Particular Kg/Batch
G- Salt ML 16830.0
Aniline 150.0
Salt 2000.0
Caustic lye 500.0
Carbon 50.0
H2SO4 500.0
Water 5500.0
Total 25530.0
R - Complex G-Salt Ml: 16830 Kg
Aniline : 150 Kg
Salt : 1500 kg 18480 Kg
Centrifuge
Filter
Waste Water: 16980 kg
1500 Kg
Aniline Distillation Aniline: 150 kg
Waste Water: 300 kg
6100 kg
Caustic Lye: 500 Kg
Water : 4500 Kg
Carbon : 50 kg
Clarify Spent Carbon: 75 kg Water Wash: 1000 kg
Isolation
7025 kg
H2SO4: 500 kg
Salt: 500 kg
8025 kg
Filter/CF H2SO4 (30-40) %: 6525 kg (Reuse
for Gamma Acid: 4000 Kg)
Finished Product: R Salt
1500 kg
Drying Drying loss: 700 kg
Product: 800 Kg
Output
Product 800.0
Aniline 150.0
Spent Carbon 75.0
Reuse in Gamma Acid 4000.0
Wastewater 19805.0
Drying Loss 700.0
Total 25530.0
3. Schaeffer’s Acid a) Manufacturing Process:
In sulphonate or take Sulphuric acid. Cool it to required temp. Add Beta Naphthol. Heat it to elevated temp.
Maintain for hours. Dump the mass in water. Add activated carbon Filterer. Collect filtrate add soda ash or
caustic lye and make neutral. Cool it and filterer. Collect wet cake as finished product-
b) Chemical Reaction:
d) Material Balance:
H2SO4 Salt
NaOH
OH
OH
SO3H
OH
SO3H
e) Mass Balance:
Schaeffer's Acid 75 MT/Month
Batch Size 2160 Kg
Input
Particular Kg/Batch
H2SO4 1980.0
B Naphthol 1800.0
Carbon 50.0
Caustic Lye/ Soda 1500.0
Salt 200.0
Water 8000.0
Total 13530.0
Output Product 2160.0
Spentb Carbon 75.0
Wastewater 11295.0
Total 13530.0
2160 kg
Spent Carbon: 75 kg
Sulphonation
Dumping
Clarify
Nutch Filter
Water: 2000 Kg Caustic
Lye/Soda Ash: 1500 kg
Salt: 200kg Isolation
Finishes Product:
Schaeffer’s Acid
Wet Cake: 2950
Centrifuge
Waste Water: 790 Kg
H2SO4: 1980 kg B Naphthol: 1800 kg
Water: 6000 kg
Carbon: 50 kg
3780
9830
9755
13455
2950
4. K Acid a) Manufacturing Process:
Amino G-Acid is charged in sulfonator containing Oleum & Sulfuric acid. The mass is heated at 1450C
temp and stirred for 20 hours. The sulfonated mass is drowned in isolation vessel. Ammonium Sulfate
is added to isolate the final mass. The product is filtered. Spent acid generated from filtration is reused
in the process. From nutch filter mass is transferred to centrifuge filter. Mother liquor generated from
centrifuge filter is sent to effluent treatment plant. Centrifuged mass is packed as final product. The
chemical reaction of the process is as under.
b) Chemical Reaction:
c) Material Balance
d) Mass Balance:
K Acid 75 MT/Month
Batch Size 1600 Kg
Particular Kg/Batch
Amido G Salt
SO3H
NH2
SO3H
Acid/Oleum + H2S2O7
SO3H
NH2
SO3H
SO3H
K- Acid
+ H2SO4
Sulfonator
Isolation
Waste Water: 4000 Kg Filtration
Centrifuge
Evaporation loss: 700 kg
Waste Water: 500 kg
K- Acid: 1600 Kg
Amido G Salt: 1250 Kg
Sulfuric Acid: 750 Kg
Oleum : 2800 kg
Ammonium Sulphate:
2000kg
5. Gamma Acid
a) Manufacturing Process:
Fusion
After animation caustic is to be added into the reactor and the mass is to be stirred on elevated temp until Amido G is fully converted. Isolation
Dump the mass into mass into water and product will come out on cooling Filter, Centrifuge, Crushing and Packing.
b) Chemical Reaction:
c) Material Balance
Input Amido G-Salt 1250.0
Sulfuric Acid 98% 750.0
Oleum 65% 2800.0
Ammonium Sulphate 2000.0
Output Total 6800.0
Product 1600.0
Evaporation Loss 700.0
Waste Water 4500.0
Total 6800.0
C10H9NO4S + 2H2SO4 + H2 H2SO4 + C10H8O + H2S2O7 + NH3
Fusion
Isolation & Centrifugation &
Filtration H2SO4 (30-40) %: 4000 Kg Waste Water: 5825 kg
Drying Drying Loss: 600 kg
Gamma Acid: 1000 kg
Amido G- Salt: 1425 Kg
Caustic Soda: 1700 Kg
Water : 300 kg
d) Mass Balance:
Gamma Acid 75
MT/Month
Batch Size 1000 Kg
Input Particular Kg/Batch
Amido G-Salt 1425.0
Caustic Soda 1700.0
ML from G- Salt 4000.0
Water 300.0
Total 7425.0
Output Product 1000.0
Waste Water 5825.0
Drying loss 600.0
Total 7425.0
6. Bronner's Acid
a) Manufacturing Process
In reactor Schaeffer’s acid is aminated with 23 % Liquid Ammonia and Sodium Bi Sulphate at high temperature
and pressure in autoclave. The aminated mass is drowned in water and neutralized with Sulphuric acid,
Bronner’s acid is precipitated, filtered in nutch. Centrifuged and dried in tray drier and future processed or
sold in market.
b) Chemical Reaction:
(NH4)2SO3NH3
CnHn-OH CNHN-NH2
Aryl Phenolic Aromatic Aryl Aromatic Amine
c) Material Balance
OH
SO3Na
NH2
HO3S
Schaeffer’s Acid Na-
Salt
+ NaHSO3 AmidationNH3
Bonner’s Acid
d) Mass Balance
Bronner's Acid 75 MT/Month
Batch Size 1125 Kg
Input Particular Kg/Batch
Schaeffer's Salt 1000.0
Liq. Ammonia 25% 1500.0
Sodium BiSuphonate OR Ammonium Bi Sulphide 100.0
Sulphuric Acid 98% 210.0
Ice 650.0
Water 1500.0
Total 4960.0
Output Product 1125.0
Ammonium bi Sulphide 1460.0
Drying Loss 350.0
Wastewater 2025.0
Total 4960.0
7. Para Cersidine Ortho Sulphonic Acid
Manufacturing process, reaction chemistry, mass balance diagram and process flow diagram of Para Cersidine Ortho Sulphonic Acid is presented here;
a) Manufacturing Process:
In a sulphonator charge sulphuric acid and add PCD. Cool the mass and slowly charge Oleum 23% at elevated
Drying Loss: 360 kg
Auto Clave
Isolation
Final Product: 1125
Kg
Water: 2150 Kg
Sulfuric Acid 98%: 210 Kg
Filtration
Schaeffer’s Salt: 1000kg Liq. Ammonia: 1500 kg
Waste Water: 2025 kg
Sodium Bi-Sulphonate: 100 Kg
OR Ammonium Bi- Sulphide 7%:
1460 Kg
Drying
temp. Stir for a hr. and heat to required temp. Dump the mass in ice water. Free stir and filter the mass. Collect wet cake as finished product.
b) Chemical Reaction:
C) Mass Balance:
CH3
NH2
OCH3
H2SO4
Oleum 23%
OCH3
CH3
NH2
SO3H
Sulphonation
2405 Kg
Drowning
7705Kg
Nutch Filtration
Waste Water: 6755 kg
Centrifuge
Drying
950 kg
Drying loss: 250
kg
Finished Product: Para
Cersidine Ortho Sulphonic
Acid: 700 kg
Para Cresidine: 500 Kg
H2SO4 : 550 Kg
Oleum 23% : 1355 kg
Salt : 300 Kg
Ice : 4000 Kg
Water : 1000 kg
d) Material Balance
Para Cresidine Ortho Sulfonic Acid 25
MT/Month
Batch Size 700 Kg
Input Particular Kg/Batch
Para Cresidine 500.0
H2SO4 550.0
Oleum 23% 1355.0
Salt 300.0
Ice 4000.0
Water 1000.0
Total 7705.0
Output Product 700.0
Waste Water 6755.0
Drying loss 250.0
Total 7705.0
8. N-methyl J acid
a) Manufacturing Process:
Take 20% Sodium Bi Sulphite solution and 40% Mono Methyl Amine solution in SS reactor. Then charged J Acid into it. PH is maintained between 5 - 7 and then methylated at 104°C for 15 hrs. After reaction, ammonia is recovered by distillation process. The mass is then isolated in water and N-methyl J Acid is precipitated out using Sulphuric Acid. N.M.J. Acid is centrifuged and then purified using caustic lye and Hydrochloric Acid. Purified N.M.J. Acid is packed.
b) Chemical Reaction:
J- Acid N- Methyl J- Acid
NH2
OH
SO3H
CH3NH2 + NAHSO3
NH-CH3
OH
SO3H
c) Material Balance:
d) Mass Balance:
N-methyl J Acid 25 MT/Month
Batch Size 500 Kg
Input
Particular Kg/Batch
J- Acid 500.0
Mono Methylamie 700.0
Sodium Bisulphite 560.0
H2SO4 700.0
Cauctic Flakers 100.0
HCl 50.0
Water 2250.0
Total 4860.0
Output
Product 500.0
Ammonia Liquor 300.0
Drying Loss 700.0
Waste Water 3360.0
Total 4860.0
Reaction Ammonia liquor: 300 Kg
Isolation
Purification
Effluent: 3060 Kg
Final Product: 500 Kg
Waste Water: 300 kg
J-- Acid : 500 Kg
Mono Methyl Amine: 700 kg
Sodium Bi-Sulfite : 560 Kg
Water : 750 kg
Sulphuric Acid: 700 Kg
Water : 750 kg
Drying Loss: 700 Kg Caustic Flakers: 100 Kg
Water : 750 kg
HCl : 50 Kg
9. Vinyl Sulphone Ortho Anisidine Base (OAVS)
a) Manufacturing Process: Acetyl ortho anisidine is charged in to Chloro sulphonic acid below 300C. After the addition the temperature
is raised to 50-550C and maintained for 4 hours. It is cooled and drowned over ice and filtered. The Sulpho
chloride is charged into slurry of sodium bi sulphate and made neutral with caustic and the pH is maintained
at 7. Ethylene oxideis passed in to the solution maintaining pH 7 by adding H2SO4. When there action is
complete, it is filtered and dried. It is further clarified by heating with calculated quantity of H2SO4 and then
pulverized.
b) Chemical Reaction:
2ClSO2H +
OCH3
Sulphonation
NHCOCH3
H2SO4
NHCOCH3
OCH3
SO2Cl
+ + HCl
+
OCH3
Reduction
NHCOCH3
NaHSO3 + 3NaOH 2H2O
NHCOCH3
OCH3
SO2NA
+ + NaCl
SO2Cl
H2SO4
2CH2CH2O2 +
OCH3
Condensation
NHCOCH3
2 H2SO4
NHCOCH3
OCH3
SO2CH2CH2OH
+ + H2O
SO2Na
2 + H2SO4
+
OCH3
Esterification
NHCOCH3
H2SO4
NHCOCH3
OCH3
SO2CH2CH2OSO3H SO2CH2CH2OH
+ CH3COOH
C) Mass Balance:
c) Material Balance:
OAVS 25 MT/Month
Batch Size 1000 Kg
Input Particular Kg/Batch
Acetyl Ortho Ansidine 715.0
Chloro sulphonic acid 3033.0
Sodium Bisulphite 650.0
Caustic Lye 1191.0
Ethylene Oxide 585.0
H2SO4 1386.0
Ice 1950.0
Water 364.0
Total 9874.0
Output Product 1000.0
HCl 30% 520.0
H2SO4 (30-40) % 4270.0
Acetic Acid (20-25%) 209.0
Wastewater 3875.0
Total 9874.0
H2SO4 (30-40) %: 4270 Kg
Sulphonation HCl 30%: 520 Kg
Dumping
Sodium Bi-Sulfite: 650 Kg Reduction
Waste Water: 3875 Kg
Ethoxylation
Estrification Acetic Acid: 209 kg
Acetyl Ortho Ansidine: 715 Kg Chloro
Sulphonic Acids: 3033 kg
Ice: 1950 kg
Caustic lye: 1191 Kg
Ethylene Oxide: 585 Kg
Sulfuric Acid: 1069 Kg
Pulverization
OAVS: 1000 Kg
Sulfuric Acid: 317 Kg
Water: 364 kg
10. Vinyl Sulfone Para Cresidine base (PCVS) a) Manufacturing Process: Acetyl para cresidine is charged in to Chloro sulphonic acid below 30oC. Afte the addition the temperature is
raised to 50-55oC and maintained for 4 hours. It is cooled and drowned over ice and filtered. The Sulpho chloride
is charged in to slurry of sodium bisulphate and made neutral with caustic and the pH is maintained at 7.
Ethylene oxideis passed in to the solution maintaining pH 7 by adding H2SO4. When there action is complete, it
is filtered and dried. It is further clarified by heating with calculated quantity of H2SO4 and then pulverized.
a) Chemical Reaction:
OCH3
Acetylation
NH2
+ +
CH3
2CH3COOH (CH3CO)2C + CH3COOH
NHCOCH3
OCH3
CH2
2ClSO3H +
OCH3
Chloro Sulphonation
NHCOCH3
+ HCl
CH3
+ H2SO4
NHCOCH3
OCH3
SO2Cl
CH3
NaHSO3 +
OCH3
Reduction
NHCOCH3
+ NaCl
CH3
+ Na2SO4
SO2Cl
+ 3NaOH
OCH3
NHCOCH3
SO2Na
CH3
+ H2O
(CH2)2O +
OCH3
Condensation
NHCOCH3
+
CH3
Na2SO4
SO2Na
+ H2SO4 + H2O
OCH3
NHCOCH3
SO2CH2CH2OH
CH3
c) Material Balance:
+
OCH3
Esterification
NHCOCH3
H2SO4
NHCOCH3
OCH3
SO2CH2CH2OSO3H SO2CH2CH2OH
+ CH3COOH
CH3 CH3
Acetylation
HCl 30%: 300 Kg
Dumping
Process Waste: 10 Kg
Reduction
Waste Water: 4000 Kg
Condensation
Drying Drying loss: 310 kg
Para Cresidine: 500 Kg
Aceticanhydrie: 640 kg
Ice: 9500 kg
H2SO4 (30-40) %:
16500 Kg
Waste Water: 3000 Kg
Dil. H2SO4: 600 Kg
Ethylene Oxide: 400 Kg
Estrification
PCVS: 1000 Kg
Sulfuric Acid (98%): 300 Kg
Sulphonation Chloro Sulphonic Acid: 1950 kg
Spent Acid: 2800 kg
Filtration Washing: 2000 kg
Filtration
SBS : 400 Kg Water
: 1350 kg Caustic lye:
1200 Kg
Filtration Wash Water: 1800 Kg
Acetic Acid: 180 kg
Water: 210 kg
d) Mass Balance:
PCVS 25 MT/Month
Batch Size 1000 Kg
Input
Particular Kg/Batch
Para Cresidine 500.0
Acetican hydride 640.0
Chloro Sulphonic acid 3600.0
Sodium Bisulphite 400.0
Sodium Sulphate 98% 300.0
Dil. H2SO4 600.0
Ethylene Oxide 400.0
Spent acid 2800.0
Caustic Lye 1200.0
Water 5360.0
Ice 9500.0
Total 25300.0
Output
Product 1000.0
HCl 30% 300.0
H2SO4 (30-40) % 16500.0
Acetic Acid (20-25%) 180.0
Process Waste 10.0
Waste water 7000.0
Drying Loss 310.0
Total 25300.0
11. 2-(4-Amino-2, 5-Dimethoxy-Phenyl-Sulphonyl) Ethanol Sulphate Ester (DMAVS)
a) Manufacturing Process:
Dimethoxy Aniline is charge dintochloro sulphonic acid bellow 300C. After the addition the temperature is
raised to 50-550C and maintained for 4 hours it is cooled and drowned over ice and filtered. The Sulpho
chloride is charged into slurry of sodium bi sulphate and made natural with caustic and the pH is maintained
at 7. Ethylene oxide is passed into solution maintaining pH 7 by adding H2SO4. When there action is
complete, it is filtered and dried. It is further clarified by heating with calculated quantity of H2SO4 and then
pulverized.
b) Chemical Reaction:
OCH3
Acetylation
NH2
+ +
CH3O
2CH3COOH (CH3CO)2O + CH3COOH
NHCOCH3
OCH3
CH3O
CH3O
2ClSO3H +
OCH3
Chloro Sulphonation
NHCOCH3
+ HCl + H2SO4
NHCOCH3
OCH3
SO2Cl
CH3O
NaHSO3 +
OCH3
Reduction
NHCOCH3
+ NaCl
CH3O
+ Na2SO4
SO2Cl
+ 3NaOH + H2O
OCH3
NHCOCH3
SO2Na
CH3O
(CH2)2O +
OCH3
Condensation
NHCOCH3
+
CH3O
Na2SO4
SO2Na
+ H2SO4 + H2O
OCH3
NHCOCH3
SO2CH2CH2OH
CH3O
+
OCH3
Esterification
NHCOCH3
H2SO4
NHCOCH3
OCH3
SO2CH2CH2OSO3H SO2CH2CH2OH
CH3O CH3O
a) Material Balance:
d) Mass Balance
DMAVS 25 MT/Month
Batch Size 1000 Kg
Particular Kg/Batch
Input Acetic Anhydride 840.0
2:5 DMA 700.0
Chloro sulphonic acid 4500.0
Sodium Bisulphite 550.0
HCl 30%: 424 Kg
Process Waste: 10 Kg
Effluent: 7700 Kg
Evap. Loss: 610 kg
H2SO4 (30-40) % : 17000 Kg
Acetic Acid: 200 kg
Acetylation
Drowning
Reduction
Condensation
Drying
Ice: 11550 kg
Dil. H2SO4: 600 Kg
Ethylene Oxide: 400 Kg
Estrification
DMAVS: 1000 Kg
Sulfuric Acid: 357 Kg
Filtration
Chloro Sulphonic Acid: 4500 kg
Filtration Washing: 3500 kg
Filtration
SBS : 550 Kg
Water : 1500 kg
Caustic lye: 1150 Kg
Filtration Wash Water: 1000 Kg
2:5 DMA : 700 Kg
Aceticanhydrie: 840 kg
Water: 297 kg
Sodium Sulphate 357.0
Dil. H2SO4 600.0
Caustic lye 1150.0
Ethylene Oxide 400.0
Ice 11550.0
Water 6297.0
Total 26944.0
Output Product 1000.0
HCl 30% 424.0
H2SO4 (30-40) % 17000.0
Acetic acid (20-25%) 200.0
Evaporation Loss 610.0
Process Waste 10.0
Waste Water 7700.0
Total 26944.0
12. Sulpho VS
a) Manufacturing Process:
Vinyl Sulphone Esteris charged in to sulphuric acid below 30oC. Then charge Oleum 65% in it & dumps this sulpho mass in ice and water & salted out by potassium chloride. Then filter it and centrifuge it. The final product is packed as a Sulpho VS.
b) Chemical Reaction:
SO3H
H2SO4
NH3
SO2OCH2CH2SO3H
+ + H2S2O7
NH3
SO2OCH2CH2SO3H
c) Material Balance:
d) Mass Balance
Sulpho VS 50 Mt/Month
Batch Size 1000 Kg
Input Particular Kg/Batch
Vinyl Sulphone 629.0
Oleum 65% 629.0
H2SO4 810.0
KCL 461.0
Ice 1396.0
Total 3925.0
Output Product 1000.0
H2SO4 (30-40) % 2925.0
Total 3925.0
H2SO4 (30-40) % : 2925 kg
Sulphonation
Drowning
Final Product: 1000 Kg
Ice: 1396Kg KCL: 461
Kg
Nutch& CF
Vinyl Sulphone: 629kg Oleum Acid 65%: 629 kg Sulphuric Acid: 810 Kg
13. Meta Phenylene Diamine 4 Sulfonic Acid Free Acid (MPDSA)
a) Manufacturing Process:
Step-1: Sulphonation - Dechlorination
3,4 DNCB is converted in 2,4 dinitrophenyl sulphonic acid with the help of sodium sulfite (prepared by sod.
Sulphate +caustic lye) isolated and filtered.
Step 2: Reduction
Nitro mass converted in amino mass by reduction with HCl + iron powder. Di-nitro phenyleneis converted into
Meta. Phenylenedi amino sulfonic acid by reduction with iron + HCl. Filter to remove iron sludge. Filtrate is
isolated with HCl. Productis filtered, centrifuge dried for packing. Mother Liquoris send to ETP.
b) Chemical Reaction:
Drawing
Reduction
Sulphodichlorination
Na2SO4 2Na2SO3 +
SO2H
NO2
NO2 3,4Dinito Sulphoni acid
+ NaCl MGO Catalyst
+
NO2 3,4DNCB
NO2
Cl
NO2 3,4Dinito Sulphoni acid
H2O
SO2H
NO2
+ +
NO2 3,4DNCB
NO2
Cl
Fe + HCl
Iron Powder
FeCl2 + H2O
SO2H
NO2
NO2 3,4Dinito Sulphoni acid
+
SO2H
NH2
NH2 Meta phynylene diamine 4-sulphonic acid
+
c) Material Balance:
Wash water
OUTPUT
KG 1725 1135 380 2200
INPUT 3 4 DCNB Sodium Trisulphite MGO Water
1200 2000
KG
CI Powder HCl (30%) Soda Ash
Sulpho Di
Chlorination
Filtration
Drowning NaCl Water
1200
3000
1900 140 150
Dilute washing M/L
Effluent water
Reduction
Filtration
Drowning
Wash water 1300
NaCl 2200
Filtration
Iron Sludge
Waste Water
3800
1500 4500
Centrifuge
Drying
Final Product
Drying Loss
MPDSA
430
16530
1000
16530
1000 Water
Dilute washing M/L 2300
d) Mass Balance
MPDSA 25 MT/Month
Batch Size 1000 Kg
Input
Particular Kg/Batch
3 4 DCNB 1725.0
Sodium Trisulphite 1135.0
MGO 380.0
NaCl 3400.0
Cl Powder 1900.0
HCl (30%) 140.0
Soda ash 150.0
Water 7700.0
Total 16530.0
Output
Product 1000.0
Waste water 11300.0
Iron sludge 3800.0
Drying loss 430.0
Total 16530.0
14. Neville Winther’s Acid (N.W.Acid)ROS-1
Manufacturing process, reaction chemistry, mass balance diagram and process flow diagram of Neville Winther’s Acid (N.W.Acid) ROS-1is presented here;
b) Manufacturing Process:
Sodium Naphthionate is condensed with Sodium Bisulphite at reflux temp for 48hrs. Followed by Hydrolysis
with Sulphuric acid to remove SO2. SO2 is scrubbed in soda ash solution and reuse for further batch.
Hydrolyzed mass is neutralize and alkaline with Sodium Hydroxide (Caustic Lye) boiler for removal of
Ammonia. Cool it and remove isolated salt. Than isolate N.W. acid with disulphuric acid/ Hydrochloric acid.
Filter it. Collect W/C and than dry the mass as N.W. Acid.
b) Chemical Reaction:
NH2
SO3H
+
OH
SO3H
NaHSO3 H2SO4
NaO4
c) Material Balance:
Reuse
SS Vessel
22250 Kg
Hydrolysis
Reflux SBS: 12900 Kg
Water + Soda 8000
+ 2200 Kg 25350 Kg
25300Kg
Separation SN
SN: 50 kg
28300 kg
Expel of NH3 Ammonia liquor: 700 Kg
Concentration
27860 kg
Waste Water: 12000 kg
Hydrochloric acid: 2500 kg
15860 kg
Filter Salt: 2500 Kg
Isolation
13360kg
Filter/ CF Waste water: 12660 kg
W/c: 3200 Kg Drying Loss: 1200 kg
SN : 2600 Kg SBS
: 3650 Kg Water :
16000 kg
11970 Kg
Reuse
H2SO4 (38%): 5800 Kg
Reuse Filter
Caustic Lye 48%: 1500 Kg Water
: 1760 Kg
15860kg
Final Product 2000 Kg Dry
d) Mass Balance
Neville Winther's Acid ROS-1 25 MT/Month
Batch Size 2000 Kg
Input Particular Kg/Batch
Sodium Naphthionate 2600.0
Sodium Bisulphite 3650.0
H2SO4 38% 5800.0
Caustic lye 48% 1500.0
Water 25760.0
Hydrochloric Acid 2500.0
Soda Ash 2200.0
Total 44010.0
Output Product 2000.0
Sodium Bisulphite 12900.0
Sodium Naphthionate 50.0
Ammonia liquor 700.0
Salt 2500.0
WasteWater 24660.0
Drying 1200.0
Total 44010.0
15. Aniline 2,5 Disulphonic Acid
a) Manufacturing Process:
2,5 dichloro aniline is sulphonated by 23% Oleum and 98% Sulphuric acid. Dump this sulpho mass in water.
Then filter it and centrifuge it. Then final product is packed as a Aniline 2,5 Disulphonic Acid.
b) Chemical Reaction:
H2S2O7 H2SO4
Cl
NH2
Cl
NH2
SO3H
SO3H
c) Mass Balance:
d) Mass Balance
Aniline 2,5 Disulphonic Acid 25 MT/Month
Batch Size 1000 Kg
Input Particular Kg/Batch
2,5 Dichloroaniline 795.0
Oleum 23% 2635.0
Sulphuric Acid 98% 320.0
Water 11980.0
Total 15730.0
Output Product 1000.0
H2SO4 (30-40) % 11630.0
Waste Water 2425.0
Drying loss 675.0
Total 15730.0
Waste Water: 1995 Kg
Sulphonation H2SO4 (30-40) %: 11630 Kg
Drowning
Wash Water: 670 Kg Nutch
Waste Water: 430 Kg Centrifuge
Final Product: 1000 Kg Drying loss: 675 kg
2,5 Dichloro aniline: 795 Kg
Oleum 23% : 2635 kg
Sulphuric Acid (98%): 320Kg
Water: 11310 kg
16. Tech. Sulphanilic Acid
a) Manufacturing Process:
Sulphuric Acid and Aniline are charged in a ball mill and heated to 100°C to form Aniline Sulphate. This is then
heated to 280°C to convert Aniline Sulphate to Sulphanilic Acid. During reaction, the vapours mainly consisting
of water and traces of Aniline are generated which are scrubbed. Sulphanilic Acid produced is cooled and
packed.
b) Chemical Reaction:
c) Mass Balance:
NH2
H2SO4 +
Aniline
+
Aniline 2,4,5,
Disulphonic Acid
H2O
SO3H
NH2
Evaporation Loss: 135 kg
Ball Mill
Heating 1000C Aniline
Sulphate
Sulphanilic Acid: 900
Kg
Water: 4 Kg
H2SO4: 16 Kg
Heating 2800C Sulphanilic
Acid
Sulfuric Acid: 520 Kg Aniline : 495 Kg Crude Sulphanilic Acid: 25 Kg
Crude Sulphanilic Acid: 25 Kg
Aniline Gas: 5 Kg
Acid Scrubber: 20 Kg
d) Mass Balance
Technical Sulfanilic acid 100 MT/Month
Batch Size 900 Kg
Input Particular Kg/Batch
Sulphuric Acid 520.0
Aniline 495.0
Crude Sulphanilic Acid 25.0
H2SO4 16.0
Water 4.0
Total 1060.0
Output Product 900.0
Evaporation loss 135.0
Crude Sulphanilic Acid 25.0
Total 1060.0
Annexure –3
TSDF Certificate