Pre-Feasibility Report Proposed expansion of Synthetic ...environmentclearance.nic.in/writereaddata/Online/TOR/21_Dec_2017... · Prefeasibility Report Roha Dyechem Private Limited

Prefeasibility Report Roha Dyechem Private Limited (Unit II)

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Pre-Feasibility Report

For

Proposed expansion

of

Synthetic Organic Chemical Manufacturing

facility

Schedule 5 (f)

Category A

Prepared By

Roha Dyechem Private Limited (Unit II)

Plot No 23/1/1, MIDC Dhatav,

Tal Roha, Dist Raigad, Maharashtra.

www.roha.com


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Table of Contents

1 EXECUTIVE SUMMARY ............................................................................................................................. 4

2 INTRODUCTION OF THE PROJECT ............................................................................................................. 7

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ........................................................................ 7

MANAGEMENT TEAM ............................................................................................................................................. 7

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ......................................................................................... 7

2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ............................................ 8

2.4 DEMAND – SUPPLY GAP .............................................................................................................................. 8

2.5 IMPORTS VS INDIGENOUS PRODUCTION ........................................................................................................ 8

2.6 EXPORT POSSIBILITY .................................................................................................................................. 8

2.7 DOMESTIC / EXPORT MARKET ..................................................................................................................... 8

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT .................................................... 8

3 PROJECT DESCRIPTION ............................................................................................................................. 9

3.1 TYPE OF PROJECT ...................................................................................................................................... 9

3.2 LOCATION ................................................................................................................................................. 9

3.3 DETAILS OF ALTERNATIVE SITES ............................................................................................................... 10

3.4 SIZE OR MAGNITUDE OF OPERATION ........................................................................................................... 10

3.5 PROJECT DESCRIPTION WITH PROJECT DETAILS .......................................................................................... 10

3.6 RAW MATERIAL REQUIRED........................................................................................................................ 11

3.7 RESOURCE OPTIMIZATION ......................................................................................................................... 12

3.8 WATER, ENERGY / POWER AVAILABILITY AND SOURCE ............................................................................... 12

3.8.1 Water........................................................................................................................................... 12

3.8.2 Energy ......................................................................................................................................... 12 Existing and proposed Air pollution control systems at site ................................................................................ 12

3.8.3 Power .......................................................................................................................................... 13

3.9 WASTE GENERATION, MANAGEMENT AND DISPOSAL ................................................................................... 13

3.9.1 Waste water ................................................................................................................................ 13

3.9.2 Non hazardous waste ................................................................................................................. 13

3.9.3 Hazardous waste ........................................................................................................................ 13

3.10 SCHEMATIC OF EIA PURPOSE .................................................................................................................... 14

4 SITE ANALYSIS ........................................................................................................................................ 15

4.1 CONNECTIVITY ........................................................................................................................................ 15

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................................................... 15

4.3 TOPOGRAPHY & GEOLOGY ........................................................................................................................ 15

4.4 EXISTING LAND USE PATTERN ................................................................................................................... 15

4.5 EXISTING INFRASTRUCTURE ...................................................................................................................... 15

4.6 SOIL CLASSIFICATION ............................................................................................................................... 15

4.7 CLIMATE DATA FROM SECONDARY SOURCES ................................................................................................ 16

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ........................................................................................................ 16

5 PLANNING BRIEF .................................................................................................................................... 17

5.1 PLANNING CONCEPT ................................................................................................................................ 17

5.2 POPULATION PROJECTION ........................................................................................................................ 17

5.3 LAND USE PLANNING ................................................................................................................................ 17

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) .......................................................... 17

5.5 AMENITIES / FACILITIES .......................................................................................................................... 17

6 PROPOSED INFRASTRUCTURE ................................................................................................................ 18

6.1 INDUSTRIAL AREA (PROCESSING AREA) ..................................................................................................... 18

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ............................................................................................ 18

6.3 GREEN BELT ........................................................................................................................................... 18

6.4 SOCIAL INFRASTRUCTURE ......................................................................................................................... 18


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6.5 CONNECTIVITY ........................................................................................................................................ 18

6.6 DRINKING WATER MANAGEMENT .............................................................................................................. 18

6.7 EFFLUENT TREATMENT SYSTEM ................................................................................................................ 18

6.8 INDUSTRIAL WASTE MANAGEMENT ............................................................................................................ 19

6.9 POWER REQUIREMENT AND SUPPLY / SOURCE ............................................................................................ 19

7 REHABILITATION & RESETTLEMENT PLAN .............................................................................................. 20

8 PROJECT SCHEDULE AND COST ESTIMATES ............................................................................................ 21

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ............................................... 21

8.2 ESTIMATED PROJECT COST ........................................................................................................................ 21

9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) .................................................................... 22

List of Annexures

Annexure

No

Description Page no

I Plant location / Google image of plant site 23

II Layout plant of the proposed expansion 24

III Proposed effluent treatment scheme 26

IV Process description 27


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1 EXECUTIVESUMMARY

Roha Dyechem Pvt. Ltd. established in 1972, is a leading Indian MNC engaged in

Manufacture and Marketing of colors and food ingredients. It has offices in 22 countries,

13 technical application labs in many time zones globally. Manufacturing facilities are

spread out across 13 countries. Roha dyechem’s products are marketed in more than

130 countries. Its product range includes industrial colors and inks, animal feed

additives, natural extracts (juices and concentrates) and an exclusive range of synthetic

colors for the cosmetics and household goods industries.

At the core of this company is its 300,000 sq. ft., state-of-the-art production facility in

the Roha district of Maharashtra, India, which meets the highest international standards

and norms.

In support are Roha’s 12 other manufacturing centers in the US, UK, Spain, South Africa,

Vietnam, Indonesia, Thailand, China, Egypt, Brazil, Australia & Mexico.

Our Brands:

A comprehensive range of synthetic colors manufactured to meet norms of every individual country

across global markets; it covers a spectrum of food products and drugs & pharmaceuticals. Available

as water soluble & lake colors in a free-flowing powder for dry applications or in granular sizes or

even as dispersions in customized pack sizes, these are a global leader in their category.

As a globally leading manufacturer of food colors, Roha has moved quickly to address the growing

global demand for products that are drawn from nature. Roha has a portfolio of natural colors that

covers the entire spectrum of our clients’ requirements.

Our range comes with the promise of four decades of expertise in customer service and purity

standards. Quality standards that ensure consistency in shades, every time.


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Futurals is a wide range of brilliant and stable shades of coloring foodstuffs & extracts (juices and

concentrates) of fruit, vegetables, herbs, flowers and algae. The entire range of extracts is sourced in

a manner that maintains the natural and essential characteristics without chemical processes or

modifications. The range facilitates ‘clean labels’ that consumers across the globe are favoring.

While Roha is recognized across the world as a leader in colors for the food, cosmetics and

pharmaceuticals industries, there was a gap in the product line.

Simpsons has filled this gap with its range of all kinds of dyes and pigments for industries including

cleaners, plastics, rubber, inks, automobiles and printing to name but a few. A balance of quality,

efficient service and competitive Pricing for business success, Simpsons is ideal for customers in

every part of the world.

Roha understands the art and the science of food & feed color like few others. Through a variety of

choice ingredients sourced from around the world, and rigorous research, we can help you create

animal feeds that make your animal products look as great as they taste.

Roha is one of the most trusted manufacturers of colors for leading Personal Care and Cosmetic

companies across the globe. Marketed under the brand name Adora, it is a range that is designed in

accordance with stringent legislations to meet the highest standards.

Certifications:

In recognition of our consistent efforts towards providing superior quality products and services, we

have been certified by most leading regulatory bodies across the world.


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The facility of Roha dyechem at Plot No 23/1/1 (Unit II) MIDC Dhatav has consent to operate for

50 TPM natural colors.

Due to increased demand of food colors, Roha dyechem wish to expand its manufacturing base

at Plot no 23/1/1 as follows,

The project brief is summarized in the table below Project summary at a glance

Table 1: Brief Project summary

Sr. No Particulars Details

1 Name of Company M/s. Roha Dyechem Pvt. Ltd. (Unit – II)

2 Products Refer section 2

3 Location Plot No 23/1/1, MIDC Dhatav, Tal Roha , Dist Raigad

4 Name of the project Proposed expansion for manufacturing of Synthetic Organic

Chemicals

5 Total land area of the

plot

6,958 sq.m

6 Fresh Water

requirement

Existing requirement (Total) = 30 cmd.

Proposed additional fresh water requirement = 425 cmd

from MIDC

7 Power Existing- 838 KVA

Proposed additional requirement = 2000 KVA

Source : MSEDCL

8 Waste water quantity Existing Domestic sewage: 1.5 cmd

Existing trade effluent: 8 cmd

Proposed additional domestic sewage: 6 cmd

Proposed additional trade effluent: 226 cmd

9 Project cost Estimate ~ Rs 22.7 Crores


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2 INTRODUCTIONOFTHEPROJECT

2.1 IdentificationoftheProjectandProjectProponent

Roha is a success story scripted by Innovation.

From a small startup in 1972, to a global color-producing behemoth in its present

avatar, manufacturing and distributing synthetic and natural colors for the food,

pharmaceuticals and cosmetics industries, Roha is a sum of all the experiences and

dreams of those associated with it.

Today, Roha’s product range encompasses synthetic and natural products created for a

multitude of applications- Food and Beverages, Pet food, Animal feed, Cosmetics and

Industrial applications. Moreover, Roha is ever collaborating with its associates to

develop new, innovative products.

Based in India with offices in 15 countries, Roha is striding towards the destiny it was

meant to fulfill. A company that governs itself with an eye on the environment; an

organization that champions social causes by giving back to society a share of the profits

it garners through its entity, the JJT Foundation, an arm of Roha’s parent company, the

JJT Group; a force that positively transforms and inspires every life it encounters.

At the core of this company is its 300,000 sq. ft., state-of-the-art production facility in

the Roha district of Maharashtra, India, which meets the highest international standards

and norms. In support are Roha’sten other manufacturing centers in the US, UK, Spain,

South Africa, Vietnam, Indonesia, Thailand, China, Egypt & Mexico.

ManagementTeam

The management team at Roha draw inspiration from its origins and its guiding light,

the late Jagdishprasad Jhabarmal Tibrewala. Roha, the flagship company of the JJT

Group, draws inspiration from the Group’s values and philosophy to return the largest

contribution to the consolidated bottom line.

With the pioneering spirit of JJT guiding the next generation of visionaries at the helm of

the company, the future holds great promise.

2.2 BriefDescriptionofnatureoftheProject

Proposed project is for expansion for manufacturer of synthetic organic chemicals. Existing

products plus new products as per market demand are as follows,

Table2:Existing&proposedProductdetails

Sr.No. NameofProduct/ByproductsExistingasper

CTO*(TPM)

Proposed

quantity

(TPM)

Total

(TPM)

Products

1 Natural colors 50 - 50

2 Tatrazine / Allura red / Sunset yellow/

Ponceau / Amaranth/ Carmosine - 500 500

Byproducts

1 Sodium chloride salt - 500 500


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(*) As Consent order no. BO/MPCB/AST/EIC No-RD-2951-15/HOD-3696 dated 30.03.2015 valid till

31.03.2017 (CTO is under renewal)

2.3 Need of the Project and Its Importance to the country and/or Region

The Indian food industry has portrayed tremendous progress with reference to

infrastructure development, technology base creation and a wide range of production.

India has achieved an eminent global position in food and feed ingredient sector.

The Indian food and feed ingradient industry is estimated to grow at 12-15 %

compound annual growth rate (CAGR) over the next five years and there is tremendous

potential for growth.

2.4 Demand – Supply gap

The demand for food and feed ingredient is a derived demand.

There is a wide gap in the demand and availability of ingredients in India and the world

over.

2.5 Imports vs indigenous production

As it is a well-known fact that Indian products are well accepted abroad for its quality

and marketing flexibility. The exports from the Indian companies to other foreign

countries such as Europe, America, Japan and other African countries has been

increasing every year. This shows the acceptability of the products produced in India.

2.6 Export Possibility

Yes, there is great potential for export of the manufactured products. We are holding

two star certificates for export of our products.

2.7 Domestic / Export market

Refer 2.6 above

2.8 Employment Generation (Direct and indirect) due to the project

The expansion facility will generate direct and indirect employment. Direct employment

will be about 200 persons.


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3 PROJECTDESCRIPTION

3.1 TypeofProject

The project is for manufacture of various food colors which falls under synthetic organic

chemicals manufacturing. The proposed project will be established within existing

manufacturing facility.

3.2 Location

The proposed project will be at existing facility of the company at MIDC Dhatav.

Figure1:LocationofproposedprojectwithinMIDC

Location and details of nearest infrastructure facilities,

No Destination Approx.distancefrom

projectsite(km)

1 Nearest town – Roha 4

2 Nearest state highway (NH-66) 5.4

3 Nearest airport – Mumbai 130

4 Nearest railway station - Roha 4

The proposed project is on the existing location at plot no. 23/1/1, MIDC Dhatav, Roha.

The Geographical Location of this Industry is 18°25'45.17"N Latitude and 73°9'21.43"E Longitude with an elevation of 12 meter above sea level MSL.

GPS Location on Google Imagery of the proposed site is attached for as (AnnexureI)


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Land Form: Land is on plain contour, it is flat terrain.

Land Ownership: Land ownership is with project proponents (Roha Dye chem pvt ltd).

Existing Land use Pattern: The Land is reserved for Industrial use & proposed project is

within existing facility.

Existing Infrastructure: Presently there is an existing Infrastructure at the site. Infrastructure

like water, electricity, telephone facility, roads already available as this is an existing Industrial

area.

MIDC Dhatav provides basic facilities like uninterrupted water supply, power and Road

Network. When various alternatives sites were examined, this site appeared to be

environmentally best as also from the business angle and therefore this option was finally

adopted. This site is inside the campus of the MIDC and means safe transportation, less need of

Utilities, less constructing buildings and roads, less fuel, less water with optimization of

infrastructure.

There is no sensitive establishment in the vicinity such as health resort, hospital, and

archaeological monuments.

The location justification for the project is as under

a. Availability of required land and infrastructure for locating the proposed synthetic

organic chemical manufacturing facility b. Suitability of land from topography & geological aspects, synergy and business point

of view c. Proximity to rail / road to facilitate transport of equipment / materials/ product d. Availability of adequate quantity of water to meet water requirements.

Lay-Out

Refer Annexure II for the plant site layout plan.

3.3 Details of Alternative sites

Refer above.

3.4 Size or magnitude of operation

Plot area of the site is ~ 6958 sq.m area.

Proposed production quantities are mentioned in section 2.2 above

3.5 Project description with Project details

Proposed products, Brief description, Process Chemistry, Process Block diagram are given at

Annexure IV.


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3.6 Raw material required

Raw Materials: The basic raw material for the product capacity (existing and proposed) is submitted herein

below.

Source for Raw Material Procurement: Raw Material is easily available in the local market

and some are imported.

Mode of Transport of Raw Materials: Few of the raw materials will be transported locally

and few will be imported from the International Market. Mode of transport to site is by road

truck/tankers.

Table 3: List of major Raw Material

Sr.

No. Name of Raw Material Consumption per month

EXISTING

1 Beat root 900 MT

2 Malto 190 MT

3 Citric acid 500 kg

4 Ascorbic acid 500 kg

PROPOSED FOR PROJECT

1 HCl(30 %) 519.1 KL

2 Sulphanilic Acid 422.00 MT

3 Sodium Nitrite 204.14 MT

4 Soda Ash 349.00 MT

5 Caustic Soda Flakes 77.00 MT

6 Dimethyl Acetyl Succinate 220.00 MT

7 Vacuum Salt 77.00 MT

8 Schaeffer's acid 50.00 MT

9 Pcosa 55.00 MT

10 scheffer's acid 104.00 MT

11 Sodium Naphthionate 62.00 MT

12 NW acid 17.00 MT

13 G Salt 19.00 MT

14 Sulphuric acid 4.00 KL

15 H Acid 7 MT

Proposed bulk storages at site will be as follow:

Bulk storage details

No Particular Unit Physica

l state

Existing

storage

capacity

Proposed

storage

capacity

Stored in

1 HCl MT Liquid - 3 x 20 KL Tank


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3.7 Resource optimization

It will be carried out within and with other sites of the company.

3.8 Water, Energy / Power availability and source

3.8.1 Water

The total water requirement is for Domestic, Process, Utilities and Green belt maintenance

purpose.

The source of water is from MIDC and the same is adequate and satisfactory.

Existing and proposed water requirement is tabulated below,

Table 5: Water requirement

No Purpose Existing

requirement

Propose

d

require

ment

Total

(existing +

proposed)

Quantity in CMD

1 Domestic 2 7 9

2 Processing 28 198 226

3 Industrial cooling / boiler feed 0 220 220

Grand Total 30 425 455

3.8.2 Energy

There is 1 Boilers at site. The boilers has fuel coal / FO( 5 TPD coal / 1 TPD FO)

There is proposal to add one boiler, one hot air generator and one DG set at site.

Existing and proposed Air pollution control systems at site

No Stack attached to APC system Fuel used

with quantity

Ht. from ground level

(m)

EXISTING

1 Boiler / HAG Cyclone dust

collector

Coal 5 TPD /

FO 1 TPD

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PROPOSED

1 Boiler ( 6 TPH) As per

statutory

requirement

Coal 28.8 TPD

12 TPD

As per statutory

requirement

2 Hot air generator (HAG) As per

statutory

requirement

Coal 30 TPD

15 TPD

As per statutory

requirement

3 DG set (1010 KVA) As per

statutory

requirement

HSD: 200

lit/hr

As per statutory

requirement


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3.8.3 Power

Existing power requirement of the site is 838 KVA which is sourced from MSEDCL.

Additional power requirement for proposed expansion is 2000 KVA which shall be sourced

from MSEDCL.

3.9 Waste generation, Management and disposal

3.9.1 Waste water

Existing and proposed waste water generation, treatment and disposal is as follows

Table 6: Existing & Proposed effluent generation

No Description

Existing

waste water

(*), cmd

Proposed

waste

water, cmd

Total (existing

+ proposed),

cmd

Disposal (*)

1 Domestic

effluent

1.5 6 7.5 Domestic sewage

treated in Septic tank.

2 Trade

effluent

8.0 220 228 Treated effluent will

be partly used for

gardening and

balance sent to CETP

Total 9.5 226 235.5

3.9.2 Non hazardous waste

Nonhazardous waste quantity as per existing consent to operate & proposed is presented

below.

No Description Existing* Proposed Total Method of Disposal

1 ETP sludge 100

kg/day

100

Kg/day

200

kg/day

Use as manure

2 HDPE Bags - 6 TPM 6 TPM By sale

3.9.3 Hazardous waste

Hazardous waste quantity as per existing consent to operate & proposed is presented below.

Table 7: Existing & Proposed Hazardous waste generation & disposal

No Description Category UOM Existin

g*

Propos

ed

Total Method of

Disposal

1 ETP Sludge 35.3 MT/Y - 40 40 CHWTSDF

2 Empty containers 33.3 Nos/M - 125 125 Sale to

authorized re

processor

3 Used oil 5.1 Lit/Y - 150 150 Sale to

authorized re

processor


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3.10 Schematic of EIA Purpose

Figure 2: Schematic reprsentation of the feasibility drawing which gives EIA purpose


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4 SITEANALYSIS

4.1 Connectivity

MIDC Dhatav, where the plant is located, comes in Taluka Roha of Raigad district in

Konkan, near west coast of Maharashtra. Site is well connected by rail and road. Nearest

railway station is Roha 4 km NW of site and Kolad-Roha road is 300 m to North from

site which meets National Highway-66 (Panvel- Edappalli). Site is at a distance of 100

km from Mumbai. The plant facility is located in well-developed notified industrial

estate and there is no human habitation in immediate vicinity of the plant.

4.2 Landform,Landuseandlandownership

LandForm:Land is on plain contour, it is flat terrain

LandOwnership:Land ownership is with project proponent (Roha Dyechem provate limited)

4.3 Topography&Geology

The Raigad district is divided into three parts on the basis of its topography.

The rock of the district is trap. In the plains it is found in tabular masses a few feet

below the soil and sometimes standing out from the surface. In the hills it is tabular and

is also found in irregular masses and shapeless boulders varying from a few inches to

several feet in diameter. In many places the surface of the trap has a rusty hue showing

the presence of iron. River on North of the plant site is the main line of drainage which

on going further meets Sea near village Korlai. This river flows east to west and helps in

replenishment of ground water table.

4.4 Existinglandusepattern

The existing land is used for the existing facility is for manufacture of Natural colors.

4.5 Existinginfrastructure

Presently there is an operative plant/Infrastructure at the site.

4.6 Soilclassification

There are four chief varieties of soil in Raigad district: ailuvial and alluvia, powdered

laterite and trap, clayey mould resting on trap, and soil containing marine deposits with,

much sand and other matter in concretion.

The soil in the Roha taluka is sandy loam and clay-slit. Sandy loam is ideal for plants that

need more soil drainage than usual. Chronic incurable "overwater" will appreciate the

drainage benefits sandy loam soil provides, since good drainage in soil decreases the

chance of plant disease. The large soil particles of sand in sandy loam soil increase the

soil's capacity to let water flow through, making it easier for fresh water to move

through the planting media.


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4.7 Climate data from secondary sources

Overall climate of this region is equable with high rainfall in monsoon season and very

few days of extreme temperatures. The mean annual temperature ranges from 300C to

330C. The maximum temperature of the hottest month in this area varies from 350C –

400C in April-May while minimum temperature of coldest month varies from 15oC to

20oC. Extremes of temperatures, like 46-48oC in summer and 10-120C in winter, may be

experienced for a day or two in respective season. The area has humid climate. Relative

humidity varies from 25% to 85%. Driest days being in summer and wettest ones

experienced in July. The rainy season is mostly confined to southwest monsoon & is

responsible for fresh water supply.

4.8 Social infrastructure available

Nearest town is Roha which is about 4 km from site. Social infrastructure such as schools,

Hospitals, market place and other amenities are available. Transport facilities by rail and road

are available.


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5 PLANNINGBRIEF

5.1 PlanningConcept

The plot is in well-established MIDC Dhatav area.

Purified Water supply from MIDC, Road facility with illumination, Infrastructure facilities

available in the established MIDC. The proposed project shall be integrated with the existing

manufacturing facility.

5.2 PopulationProjection

An official Census 2011 detail of Raigad, a district of Maharashtra has been released by

Directorate of Census Operations in Maharashtra.

In 2011, Raigad had population of 1,07,562 of which male and female were 55,553 and 52,009

respectively. The proportion of urban & rural population of study area stood at 32.34 (34786)

and 67.66 (72776) percent respectively.

There was change of 3.20% in the population compared to population as per 2001. In

the previous census of India 2001, study area recorded increase of 18.78 percent to its

population compared to 1991.

5.3 Landuseplanning

The existing land use is industrial as it is within MIDC area.

5.4 AssessmentofInfrastructureDemand(Physicalandsocial)

At Roha Dyechem, in proposed expansion project there will be increase in production of the

synthetic organic chemicals. There will be no major demand of physical and social

infrastructure.

5.5 Amenities/Facilities

No major amenities / facilities demand is envisaged as the proposed site is in well-developed

MIDC area.


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6 PROPOSEDINFRASTRUCTURE

6.1 IndustrialArea(Processingarea)

Roha dyechem, MIDC Dhatav proposed to expand its manufacturing base at existing

site.

6.2 Residentialarea(non-processingarea)

No Residential area has been proposed within the plant site.

6.3 GreenBelt

Green belt has been carried out along the boundary of the plot. And will be

maintained as per guidelines.

6.4 SocialInfrastructure

The project shall have a positive impact on the employment pattern of the region.

Economic status of the local population will improve due to increased ancillary/

business opportunities, thereby making positive impact. Educational, medical &

housing facilities will improve due to the proposed project.

6.5 Connectivity

This proposed project facility is located at MIDC Dhatav area, in Raigad district,

Maharashtra. The Site is 4 km from Roha town. The land and infrastructure is

made available by MIDC and the raw material is easily available through the easy

transport via road connectivity.

6.6 Drinkingwatermanagement

The source of water is already availability from existing water works of MIDC and

the same is adequate and satisfactory. The water supply will be through the good

offices of MIDC.

6.7 Effluenttreatmentsystem

Roha Dyechem is manufacturer of beet root powder from fresh beet root

& water from cleaning of beet root during manufacturing is sent to

Effluent Treatment Plant, capacity of 10 m3.

Effluent Treatment Plant is consisting of primary Treatment Unit such as

Collection tank & Settling Tank as effluent is non- toxic.

Settled sludge is get collected and used as manure for Gardening.


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6.8 Industrial waste management

Refer 3.9 above

6.9 Power requirement and supply / source

Power requirement shall be sourced from MSEDCL.


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7 REHABILITATION&RESETTLEMENT

PLAN

The proposed activities shall be in the existing plot of the company which is located in Dhatav

MIDC area. It does not require acquisition of Land and the Infrastructure so there is no any kind

of activity of Rehabilitation and Resettlement planned to be carried out.


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8 PROJECTSCHEDULEANDCOST

ESTIMATES

8.1 Likelydateofstartofconstructionandlikelydateofcompletion

It is expected that the expansion project shall be completed within 1.5 to 2 years from date

of grant of Environmental clearance.

8.2 Estimatedprojectcost

Total estimated project cost is around Rs. 22.7 Crores


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9 ANALYSIS OF THE PROPOSAL (FINAL

RECOMMENDATION)

The proposed expansion of products is due to increase in market demand of the product

range. As described earlier nearly 80% of products are getting exported to different

countries which are certainly increasing the foreign exchange for the nation.

Also many of products are equal or better in quality to that of certain imported

products. This reduces the dependency as well as money of customers by importing the

products. The project will definitely open an avenue for the young generation of our

nation by generating employment at project site.

We will be hiring the local residents nearby our project site for employment, as per

their competency. This will create employment to these people & thereby will improve

their living standard. The proposed expansion project shall be at MIDC area so area

development will be carried out as per MIDC, which will improve the living standards of

the local people.


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Annexure – I

Google image of site with 1 km radius

Google image of site with 10 km radius


24

Annexure – II Layout plant of the proposed expansion project


25

Annexure – III Existing Effluent Treatment Scheme

Anoxic

clarifier

Primary

Treatment


26

Proposed Effluent Treatment Scheme


27

Annexure – IV

1. Tatrazine


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Tatrazine Manufacturing process brief :

The diazotization of sulphanilic acid solution with sodium nitrate is being carried out in acid

condition in water medium. The sulphanilic acid solution and nitrite solution are prepared in

separate vessels. Then both the solutions are added to make the final diazo.

The Diazo slurry will undergo coupling with DMAS and followed by hydrolysis using Soda Ash

solution.

The coupled solution is isolated using salt. The product is separated by filter. The filtrate is sent to

ETP and the cake is the purified product which is spray dried.

The final product undergoes milling, sieving operation before packing.


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2. Allura Red

Allura Red process flow chart

WATER

ICE SODIUM NITRITE SOLN.

HCL (30%)

SCHAEFFERS ACID

PCOSA SODA ASH SOLN.

SODIUM CHLORIDE

DIAZOTIZATION

COUPLING

ISOLATION

FILTRATION

DISSOLUTION AND

CLARIFICATION

SPRAY DRYING

POWDER COOLING AND

PACKING

FILTRATE TO ETP


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ALLURA RED MANUFACTURING PROCESS

1. Diazotization: - Take measured quantity of water through flow meter of water line.

Add measured quantity of (31.5%) HCl, stir for 15 min.

Charge Schaeffer’s acid and stir for 10 min.

Add ice to take temp up to 00C to (-5)0C.

Prepare solution of sodium nitrite in Nitrite tank as follow.

� Water

� Ice

� Sodium Nitrite

Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.

Temperature of Diazo should be below 5°C.

Stir the reaction for 30 to 40 min.

Transfer final Diazo to precooled (15°C via jacket) coupling vessel.

2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.

Add PCOSA through pump in 1 Hr.

Start soda ash solution and complete addition within 110-130 min

Check pH it should be 4.0 to 4.5.

Simultaneously start adding second soda solution and complete it in 120-150 min.,

approximately.

Adjust pH 8.0 to 8.5.

Start coupling through 2nd diazo addition below 200C temp.

Check pH & it must be 6-6.5

Add Caustic soda flakes and start heating.

Heat it up to 700C to 800C (by steam from Jacket only.)

Maintain under stirring for 1 Hr. at 80°C.

2. Isolation: - Check vessel is clean & empty.

Receive material of batch.

Adjust pH 4.5 to 5.5 by adding HCl.

Start cooling via both internal coil & external jacket circulation of chilled water.

After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then

restart chilling circulation till temperature reaches to 17°C.

3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)

Collect all filtrate and send to Effluent Treatment Plant

Collect all wet cake and its total weight send sample for moisture and purity analysis.

4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the

required water quantity to make 30 - 35% solution. Charge required quantity of water (by

considering water quantity formation during live steam heating to 75-80°C.) and start

stirring and heating with live steam. Charge total weighted wet cake under stirring.


31

After clear solution formation send sample for GPL analysis. Filter through filter press,

transfer to LST for spray drying.

5. Spray Drying:- Spray Dry the solution at 320°C Inlet and 140°C Outlet temperature.

Collect Allura Red powder and pack with using dust free packing machine system.


32

3. Sunset Yellow

Sunset Yellow process flow chart

WATER


HCL

SULPHANILIC ACID

SCHAEFFER ACID SODA ASH SOLN.

SODIUM CHLORIDE

DIAZOTIZATION

COUPLING

ISOLATION

FILTRATION

DISSOLUTION AND

CLARIFICATION

SPRAY DRYING

POWDER COOLING AND

PACKING

FILTRATE TO ETP


33

SUNSET YELLOW MANUFACTURING PROCESS



Charge Sulphanilic acid and stir for 10 min.



� Water

� Ice

� Sodium Nitrite






Add Schaeffer’s Acid in 1 Hr.

Start soda ash solution and complete addition within 110-130 min

Check pH it should be 4.0 to 4.5.

Simultaneously start adding second soda solution and complete it in 120-150 min.,

approximately.

Adjust pH 8.0 to 8.5.


Check pH & it must be 6-6.5 and start heating.










Collect all filtrate in storage tank and send to Effluent Treatment Plant









34

5. Spray Drying:- Spray Dry the solution at appropriate Inlet and Outlet temperature.

Collect Sunset Yellow powder and pack with using dust free packing machine system.


35

4. Ponceau

Ponceau process flow chart

WATER


HCL

SODIUM NAPTHONATE

G-SALT SODA ASH SOLN.

SODIUM CHLORIDE

DIAZOTIZATION

COUPLING

ISOLATION

FILTRATION

DISSOLUTION AND

CLARIFICATION

SPRAY DRYING

POWDER COOLING AND

PACKING

FILTRATE TO ETP


36

PONCEAU MANUFACTURING PROCESS



Charge Sodium Naphthionate and stir for 10 min.



� Water

� Ice

� Sodium Nitrite






Add G-Salt in 1 Hr. Start soda ash solution and complete addition within 110-130 min

Check pH it should be 4.0 to 4.5. Simultaneously start adding second soda solution and

complete it in 120-150 min., approximately. Adjust pH 8.0 to 8.5.












Collect all filtrate and send to Effluent Treatment Plant









Collect Ponceau powder and pack with using dust free packing machine system.


37

5. Amaranth

Amaranth process flow chart

WATER


HCL (30%)

SODIUM NAPHTHIONATE

H Acid SODA ASH SOLN.

SODIUM CHLORIDE

DIAZOTIZATION

COUPLING

ISOLATION

FILTRATION

DISSOLUTION AND

CLARIFICATION

SPRAY DRYING

POWDER COOLING AND

PACKING

FILTRATE TO ETP


38

AMARANTH MANUFACTURING PROCESS






� Water

� Ice

� Sodium Nitrite






Add H Acid in 1 Hr. Start soda ash solution and complete addition within 110-130 min






Add Caustic Flakes. Maintain under stirring for 1 Hr. at 80°C.








Collect all filtrate and send to Effluent Treatment Plant.









Collect Amaranth powder and pack with using dust free packing machine system.


39

6. Carmosine

Carmoisine process flow chart

WATER


HCL

SODIUM NAPTHONATE

NW ACID SODA ASH SOLN.

SODIUM CHLORIDE

DIAZOTIZATION

COUPLING

ISOLATION

FILTRATION

DISSOLUTION AND

CLARIFICATION

SPRAY DRYING

POWDER COOLING AND

PACKING

FILTRATE TO ETP


40

CARMOISINE MANUFACTURING PROCESS






� Water

� Ice

� Sodium Nitrite






Add NW Acid in 1 Hr. Start soda ash solution and complete addition within 110-130 min














Collect all filtrate and send to Effluent Treatment Plant.









Collect Ponceau powder and pack with using dust free packing machine system.

Documents

Pre-Feasibility Report Proposed expansion of Synthetic ...environmentclearance.nic.in/writereaddata/Online/TOR/21_Dec_2017... · Prefeasibility Report Roha Dyechem Private Limited