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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.





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




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.





(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.





3.0 PROJECT DESCRIPTION

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


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





Figure - 2: Plant Layout





(iii) Key Plan

Figure - 3: Key Plan





(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




(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




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,





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





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





(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.





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.





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





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





(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.





• 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.





(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.





(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





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;


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


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-


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


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.


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


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.


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


Amido G-Salt 1425.0

Caustic Soda 1700.0

ML from G- Salt 4000.0

Water 300.0

Total 7425.0


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.


(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


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


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;


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


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.


C) Mass Balance:

CH3

NH2

OCH3

H2SO4

Oleum 23%

OCH3

CH3

NH2

SO3H

Sulphonation

2405 Kg

Drowning

7705Kg

Nutch Filtration


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


Para Cresidine 500.0

H2SO4 550.0

Oleum 23% 1355.0

Salt 300.0

Ice 4000.0

Water 1000.0

Total 7705.0


Waste Water 6755.0

Drying loss 250.0

Total 7705.0

8. N-methyl J acid


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.


J- Acid N- Methyl J- Acid

NH2

OH

SO3H

CH3NH2 + NAHSO3

NH-CH3

OH

SO3H


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.


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:


OAVS 25 MT/Month

Batch Size 1000 Kg


Acetyl Ortho Ansidine 715.0

Chloro sulphonic acid 3033.0


Caustic Lye 1191.0

Ethylene Oxide 585.0

H2SO4 1386.0

Ice 1950.0

Water 364.0

Total 9874.0


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


Pulverization

OAVS: 1000 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


+

OCH3

Esterification

NHCOCH3

H2SO4

NHCOCH3

OCH3


+ CH3COOH

CH3 CH3

Acetylation

HCl 30%: 300 Kg

Dumping

Process Waste: 10 Kg

Reduction


Condensation

Drying Drying loss: 310 kg

Para Cresidine: 500 Kg

Aceticanhydrie: 640 kg

Ice: 9500 kg

H2SO4 (30-40) %:

16500 Kg


Dil. H2SO4: 600 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 Sulphate 98% 300.0

Dil. H2SO4 600.0


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)


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.


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


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


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


Estrification

DMAVS: 1000 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


Ice 11550.0

Water 6297.0

Total 26944.0


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


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.


SO3H

H2SO4

NH3

SO2OCH2CH2SO3H

+ + H2S2O7

NH3

SO2OCH2CH2SO3H


d) Mass Balance

Sulpho VS 50 Mt/Month

Batch Size 1000 Kg


Vinyl Sulphone 629.0

Oleum 65% 629.0

H2SO4 810.0

KCL 461.0

Ice 1396.0

Total 3925.0


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)


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.


Drawing

Reduction

Sulphodichlorination

Na2SO4 2Na2SO3 +

SO2H

NO2

NO2 3,4Dinito Sulphoni acid

+ NaCl MGO Catalyst

+

NO2 3,4DNCB

NO2

Cl


H2O

SO2H

NO2

+ +

NO2 3,4DNCB

NO2

Cl

Fe + HCl

Iron Powder

FeCl2 + H2O

SO2H

NO2


+

SO2H

NH2

NH2 Meta phynylene diamine 4-sulphonic acid

+


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.


NH2

SO3H

+

OH

SO3H

NaHSO3 H2SO4

NaO4


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


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


Sodium Naphthionate 2600.0


H2SO4 38% 5800.0

Caustic lye 48% 1500.0

Water 25760.0

Hydrochloric Acid 2500.0

Soda Ash 2200.0

Total 44010.0



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


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.


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


2,5 Dichloroaniline 795.0

Oleum 23% 2635.0

Sulphuric Acid 98% 320.0

Water 11980.0

Total 15730.0


H2SO4 (30-40) % 11630.0

Waste Water 2425.0

Drying loss 675.0

Total 15730.0


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


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.


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


Sulphuric Acid 520.0

Aniline 495.0

Crude Sulphanilic Acid 25.0

H2SO4 16.0

Water 4.0

Total 1060.0


Evaporation loss 135.0

Crude Sulphanilic Acid 25.0

Total 1060.0

Annexure –3

TSDF Certificate

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