PROJECT PRE-FEASIBILITY REPORT ON PROPOSED PROJECT …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/15_Sep... · PROJECT PRE-FEASIBILITY REPORT ON PROPOSED PROJECT FOR MANUFACTURING

RAGESHWARI TEXTILE PVT LTD., PANDESARA, SURAT

PROJECT PRE-FEASIBILITY REPORT

ON

PROPOSED PROJECT

FOR

MANUFACTURING OF PIGMENT

OF

RAGESHWARI TEXTILE PVT. LTD

ATPlot No. 272/C & D, B+F,

GIDC Estate,Pandesara,

Surat 394221.

M/s. RAGESHWARI TEXTILE PVT LTD., PANDESARA, SURAT 1

CONTENTS

S. No. Particulars Page No.

1 SUMMARY 6

2 INTRODUCTION 7

2.1 The Project 7

2.2 Project Proponent 7

2.3 Nature of project 8

2.4 Market Feasibility 9

3 PROJECT DESCRIPTION 9

3.1 Type of Project 9

3.2 Project Location 9

3.3 Site selection 11

3.4 Neighbouring Industries 11

3.5 Size of project 12

3.6 Process Technology 12

3.7 Rawmaterial 25

3.8 Resource requirment 25

3.8.1 Land 25

3.8.2 Building 26

3.8.3 Power & Fuel 26

3.8.4 Water 26

3.8.5 Man power 30

3.9 Mitigation measures & EMP 30



3.9.1 Gaseous emission & Control 30

3.9.1.1 Flue gas emission 30

3.9.1.2 Process emission 31

3.9.2 Hazardous /non hazardous waste managment 31

3.9.3 Noise control& odour 32

3.9.4 Storage ,handling and transport of Hazardous chemical 32

3.9.5 Health & Safety measures 32

4 SITE ANALYSIS

4.1 Connectivity 33

4.2 Land use and land ownership 33

4.3 Existing landuse 33

4.4 Existing infrastructure 33

4.5 Climate data 34

5 PLANNING BRIEF

5.1 Planning concept 35

5.2 Population projection 35

5.3 Land use planning 36

5.4 Assessment of infrastructure Demand 36

6 PROPOSED INFRASTRUCTURE

6.1 Processing area 36

6.2 Non processing area 37

6.3 Green belt area 37

6.4 Social Infrastructure 37

6.5 Connectivity 37



6.6 Drinking water management 37

6.7 Industrial waste managemnt 38

6.8 Solid waste management 38

6.9 Power requirment & Supply 38

7 REHABILITATION & RESETTLEMENT (R & R) PLAN 38

8 PROJECT SCHEDULE & COST ESTIMATES 38

8.1 Project Implementation Schedule 38

8.2 Estimated project cost 38

9 ANALYSIS OF PROPOSAL 39


LIST OF TABLES

Table

No.

Topic Page No.

1. List of Products 6

2. List of Products and By product 7

3. Contact details of the Directors 8

4. Salient features of the Project Site 9

5. Nearby Industries in the vicinity 11

6. Capital cost of projection 12

7. List of Raw Materials-Product wise 25

8. Approximate requirement of Construction Materials 26

9. Power and Fuel Requirement 26

10. Category-wise Water Requirement 27

11. Waste water generation 28

12. Man power requirement 30

13. Flue gas emission 30

14. Process emission 31

15. Details of hazardous waste 31

16. Details of metrological condition from January 2011 to December 2011

34

17. Name of some prominnent industries 36

18. Project implementation schedule 38

19. Capital cost of projection 39


LIST OF FIGURES

Sr. No. Description Page No.

1. Location of the Project Site 10

2. Aerial view of the 5 km radial periphery from the Project Sites 11

3. Water Balance Diagram 29

4.. Wind rose 35


1.0 EXECUTIVE SUMMARY

M/s. Rageshwari Textile Pvt. Ltd. was a textile unit and has been taken over by present

promoters. The unit will be registered as SME.

The promoters are well experienced in manufacturing of pigments. They have proposed to

convert the existing infrastructure into pigment manufacturing unit.

The Rageshwari Textile Pvt Ltd. will engage for manufacturing of Pigment at Plot No. 272/ C &

D,B+F,GIDC Estate, Pandesara, Surat.The production capacity will be 400 MT/Month. As per

EIA notification 2006, the proposed project is falling under category 5(f).

The details of products are given below table 1.

Table 1

List of Products

Sr. no

Name of product Production capacity in MT/Month

1. Copper phthalocyanine Blue 2002. Pigment Alpha Blue 553. Pigment Beta Blue 1454. Ammonium Sulphate (By-Product) 207

COST OF PROJECT

The expected cost of project cost is Rs. 568 Lacs. The plot has been purchased from Rageshwari

Textile Pvt. Ltd. The GIDC has transferred the same to existing owners. The total plot area of the

unit is 4483.05 M2. The green belt area will be 1428.80 M2.

FUEL AND ELECTRICITY CONSUMPTIONThe proposed unit will use natural gas as fuel. The natural gas consumption will be 4000

NM3/Day. The electricity will be purchased from DGVCL. The connected load will be 1000

KWA.

WATER CONSUMPTIONThe expected water consumption will be 205Kl/day in which 98Kl/day will be fresh water and

107Kl/day will be recycled water.

WASTEWATER GENERATION

The total waste water generation will be 68.6Kl/day which will be treated in MEE after

neutralization into neutralization tank.


GASEOUS EMISSION

There will be flue gas emission from Boiler, Thermo-pack, Hot water generator and D.G.sets.

Unit will install adequate APCM to prevent air pollution.

There will be process gas emission from stack attached with reactor. Water scrubber and Ventury

system will be proposed as APCM.

HAZARDOUS WASTE MANAGEMENTThe hazardous waste generation will be Discarded bag/Containers and spent oil. The generation

quantity of Discarded Bag/Containers will be 15000Nos/Month. The spent oil generation will be

50 lit. The total sludge generation will be 465 MT/Month which will be sent into TSDF site.

2. INTRODUCTION

2.1 THE PROJECT

Ragheshwari Textile Pvt Ltd will engage for manufacturing of Pigment at Plot No. 272/ C &

D,B+F,GIDC Estate, Pandesara, Surat.

The list of products and by products is provided in table -2.

TABLE:2

LIST OF PRODUCTS AND BY-PRODUCTS

Sr. no Name of product Production capacityMT/Month

1. Copper Phthalocyanine Blue 2002. Pigment Alpha Blue 553. Pigment Beta Blue 1454. Ammonium Sulphate (By-Product) 207

2.2 PROJECT PROPONENTM/s. Rageshwari Textile Pvt. Ltd. was a textile unit and has been taken over by present

promoters. The unit will be registered as SME.

The promoters are well experienced in manufacturing of pigments. They have proposed to

convert the existing infrastructure into pigment manufacturing unit.

The plant boasts of contemporary infrastructure facilities with advanced machinery and

automated processes. They are conscious of environment protection measures and from the

conception stage itself necessary care has been taken.


QUALITY POLICY

The company’s commitment is to manufacturing of pigment. The company has in house testing

facility with modern testing equipments to ascertain the quality of raw materials as well as

finished products. Continued emphasis towards process and technology up gradation is being

done effectively to enrich the product quality. R & D with initiative & innovative ideas had

resulted into excellent performance in respect of quality products.

ENVIRONMENTAL POLICY

The unit is committed to execute all operations, products and services by environmental

protection activities to the extent possible.

As a means of achieving these, the unit pledge to company with the legal & other requirements

to their core and focus on continually improving products, systems & operations.

TABLE: 3

CONTACT DEAILS OF DIRECTORS

Sr. no

Name of Director Address Telephone no. Designation

1. Mr. Rajendra Babulal Gandhi

Res. Plot no. 406/28, Swagat Society, New Colony, GIDC, Ankleshwar 393002.

992520767402646-222566

Director

2. Mr.Deepakumar Babulal Gandhi

Res. Plot no. 406/28, Swagat Society, New Colony, GIDC, Ankleshwar 393002.

942630453002646-225052

Director

The directors of the company have good experience in handling the production management,

financial management and all the allied areas.

2.3 NATURE OF PROJECT

The proposed unit will engage in manufacturing of Pigment. The production capacity will be 400

MT/Month. As per EIA notification 2006, the proposed project falls under category 5(f)-B.


2.4 MARKET FEASIBILITY

The unit has proposed to manufacture copper phthalocyanine pigments. These pigments are used

in making inks, plastics and polymers. The requirement of printing ink is increasing day by day.

Also export of pigments is taking place and is consistently increasing over a period of time.

The main export is USA and other European companies.

The easy availability of raw materials- mainly urea and phthalic anhydride is major attraction of

manufacturing these pigments in Gujarat. Also the availability of copper is increased due to

number of copper smelting industries in Gujarat. These all factors have resulted in flourishing of

pigment industries in general and copper phthalocyanine industries in particular. The addition of

proposed quantity will be easily absorbed in the market.

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is not including any interlinked and interdependent projects.

3.2 PROJECT LOCATION

The proposed project site is located at plot no 272/C & D, B+F, GIDC Estate, Pandesara, Surat,in the state of Gujarat. The approximate geographical positioning of the project site is at Latitude: 21°08’20.44”N, Longitude: 72°49'14.74”E .It has an average elevation of 14 m. The location of the project site can be identified from the location map shown in Figure-2.

The salient features of the location of the project site are presented in Table 4.

TABLE: 4

SALIENT FEATURES OF THE PROJECT SITE

Particulars Details Distance from Site

Village Pandesara 1.5 KM approx.

Taluka/ Tehsil Surat 3.3 KM approx.

District Surat 3.3 KM approx.

Approx. Geographical positioning Latitude: 21°08’20.44”N

Longitude: 72°49'58.74”E

--

Nearest City Surat. 4 KM approx.

Nearest Town Udhana 4 KM approx.

Nearest Highway National Highway No. 8 15 KM approx.

Nearest State highway State Highway No.6 3 KM approx.


Particulars Details Distance from Site

Nearest Railway line/ Railway station

Udhana 4 KM approx.

Nearest Airport/ Airbase Surat 9.5 KM approx.

Protected Areas/ Sanctuaries ---

FIGURE -1

LOCATION OF THE PROJECT SITE


Figure-2

Aerial view of the 5km radial periphery from the project Site

3.3 SITE SELECTION

The project proponent did not consider any other alternative site for proposed expansion.

3.4 NEIGHBORING INDUSTRIES

The industry is located in an area, which is already industrialized. The industries in the vicinity

of the proposed project are given in the table-5 below:

TABLE: 5

NEARBY INDUSTRIES IN THE VICINITY

Sr. No. Plot No Industries Name1 272 E Bhagavati Printer2 272 B & F JR & Company3 258/1 Shree Shiv Vijay Processor Pvt. Ltd pvt ltd


3.5 SIZE OF PROJECT

The proposed unit will manufacture Pigment and production capacity is 400 MT/Month. The

expected cost of proposed project is Rs. 568 lacs.

New Plant and machinery installations will also have to be acquired and installed.

Environment Protection and safety systems have also been considered in planning the Cost

Projection. Green belt development, provision of fire extinguishers etc. are also calculated. The

break-up of the proposed project cost is given in below table 6.

TABLE: 6

CAPITAL COST PROJECTION

Sr. No. Purpose Proposed

(Rs. In Lacs)

1. Land 115

2. Building Proposed 50

3. Plant and Machinery 300

4. Q.A. Lab set up 10

5. Env. Protection & Safety

a) Effluent treatment Plant 70

b) Safety Equipment (PPE, fire extinguishers, Ventilation, etc.)

15

c) Green belt development 5

d) Fire 3

Total 568

3.6 PROCESS TECHNOLOGY

The proposed products are “Pigment”. These are characterized for their physicochemical

properties. Process details like Process description, chemical reactions and mass balance for each

product are as below:


MANUFACTURING PROCESS AND MATERIAL BALANCE

1. COPPER PHTHALOCYANINE BLUE CRUDE

Crude copper phthalocyanine is produced by condensing phthalic anhydride, cuprous chloride and Urea in presence of ammonium molybdate as catalyst.

Stage I: ReactionIn glass line reactor kettle having heating arrangement phthalic anhydride, cuprous chloride and Urea are charged. ONT is used as a solvent while ammonium molybdate is used as a catalyst. The reaction mass is heated to temperature. During the reaction ammonia and carbon dioxide gas are evolved due to decomposition of urea, which are scrubbed in a two stage water scrubbing system.

Stage II: Solvent recoveryAfter the condensation reaction over, the product is transferred to Venulath dryer for recovery of solvent, where ONT is distilled out using vacuum and crude copper phthalocyanine blue is obtained as cake.

Stage III: PurificationThis crude product is then stirred with 45 % sulphuric acid and water. The mass is heated using live steam to 900 C. During the process, inorganic impurities get dissolved in water while the product, which is insoluble, remains in the solid form.

Stage IV: FiltrationThe slurry from the purification is taken to the filter press where the dissolved impurities are removed as filtrate, which is taken to the effluent treatment plant. The cake is then washed with water and the washings are also taken for treatment.

Stage V: DryingThe wet cake is then taken to the spin flash dryer. The product is obtained as a fine powder, which is then sent for packing.


CHEMICAL REACTION FOR CPC BLUE CRUDE:


MATERIAL BALANCE FOR CPC CRUDE BLUE

Input Kg. Output Kg.Phthalic Anhydride 1111 Ammonia 200Urea 890 Carbon Dioxide 226Cuprous Chloride 205 Water loss 352.5Ammonium Molybdate 2.5 ONT loss 97ONT 3500 Slurry 4833TOTAL 5708.5 TOTAL 5708.5

Input Kg Output Kg.Mass 4833 ONT 3403

Crude CPC Blue 1430

TOTAL 4833 TOTAL 4833

Input Kg. Output Kg.Steam 1800 Slurry 11430Sulphuric acid(45%) 4700Water 3500Crude CPC Blue 1430TOTAL 11430 TOTAL 11430

Input Kg. Input Kg.Slurry 11430 Mass 2000

Acidic effluent for the manufacturing of Ammonium sulphate(23%sulphuric acid) 9430

TOTAL 11430 TOTAL 11430

Input Kg. Output Kg.Mass 2000 Wet cake 1550Washing water form alpha blue 5000 Effluent 5450TOTAL 7000 TOTAL 7000

Input Kg. Output Kg.Mass 1550 Water loss 550

Product 1000TOTAL 1550 TOTAL 1550

FILTER PRESS-1

DRYING

REACTOR

FILTER PRESS-2

VENULETH

PURIFICATION


MATERIAL BALANCE AT SCRUBBER

Input Kg Output KgWater 4626.5 Water loss 52.5

Ammonia 200CO2 226TOTAL 5052.5 TOTAL 5052.5

SCRUBBERAmmonium Carbonate

solution(13-15 %) 5000

2. PHTHALOCYANINE BETA BLUE (PIGMENT BLUE 15.3 & 15.4) (SOLVENT BASE, WATER BASE)

MANUFACTURING PROCESS FOR PHTHALOCYANINE BETA BLUE (SOLVENT BASE, WATER BASE)Crude CPC Blue is taken into Ball mill for grinding. Here the particle size of the material gets

reduced. Then the grinded material is taken into the reactor with Caustic Flakes. Caustic flakes

are used to get alkaline pH. The alkaline pH results in better dispersion of particles for

pigmentation. The mass is refluxed for pigmentation. Here the colour of the material gets

enhanced due to fine tuning with Xylene / IBA.

This is only a physical process and does not involve any chemical reaction. After completion

of reflux, the mass is distilled for recovery of Xylene / IBA. After recovery of Xylene / IBA, the

mass is neutralized with hydrochloric acid to increase the particle size of beta blue. The whole

mass is washed and filtered in filter press. Filtrate and washing are use for manufacturing of CPC

Blue Crude. Wet cake from filter press is dried in dryer / SFD.

CHEMICAL REACTION FOR PHTHALOCYANINE BETA BLUE (SOLVENT BASE, WATER BASE)


MATERIAL BALANCE FOR PIGMENT BETA BLUE(SOLVENT BASE, WATER BASE)

Input Kg Output Kg

copper phthalocyanine Blue 1.030 Reaction mass 1.030

Total 1.030 Total 1.03

Input Kg Output KgMass 1.03 Mass 3.358Dilute HCL 0.013Caustic soda flakes 0.015Water 1.8IBA/Xyalene 0.5


Input Kg Output KgMass 3.358 Mass 2.858

Recovered IBA/Xylene 0.490Atmosphere solvent loss 0.010


Input Kg Output KgMass 2.858 Mass 2.307Water for washing 3.451 Effluent 4.002


Input Kg Output KgMass 2.307 Beta Blue 1

Evaporation loss 1.307


BALL MILL

REACTION VESSEL

DRYER

PULVERIRE & PACKING

DISTILLATION

FILTER PRESS


3. PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1)

MANUFACTURING PROCESS FOR PIGMENT ALPHA BLUE (BLUE 15.0 & 15.1)

MANUFACTURING PROCESS:

Stage-I: Charging of C.P.C. with H2SO4 :

Initially H2SO4 is charge in the reactor and start the cooling up to room temperature by raw water

circulation. Then CPC crude is charge slowly in the reactor and stirring it. Maintain the

temperature below 70 ºC during whole reaction for 5 to 6 hours. Then cool the reaction mass up

to room temperature by raw water circulation.

Stage-II: Drowning:

1st washing water of previous batch is recycling and takes in the MSRLBL vessel. Then dump

the reaction mass in MSRLBL vessel slowly.

Stage-III: Filtration & Washing:

Then filter the above reaction mass in the filter press-1 and separate the cake and spent sulfuric

acid. This spent sulfuric acid is using as a raw-material in the manufacturing process of CPC

Blue. Now, the cake is washing by water up to neutral pH. The whole quantity of washed water

is stored in separate storage tank and then recycles in drowning section for next batch.

Stage-IV: Charging of Rosin or Caustic Lye and T. L.S.:

2nd washing of previous batch and wet cake are charging in the reactor and maintain the pH of

reaction mixture is 8 to 8.5 by charging the Caustic lye in the reactor. Then heating the reaction

mass up to 60 ºC by steam and charging the TLS. Again heat the reaction mass up to 90 ºC and

add rosin and stir it for 2 hours.

Stage-V: Filtration and Washing:

Filter the above reaction mass through filter press-2 and separate the cake. Then cake is washing

with fresh water. Total waste water from filter press-2 and 2nd washing reuse in the

manufacturing process of CPC Blue.


Stage-VI: Drying, Pulverizing and Packing:

Dry the wet cake in tray dryer or by natural drying and then pulverize the cake and

pulverized dry product is packed in fiber TLS drum or laminated HDPE bags.


Input Kg Output Kg

CPC Crude 250Sulfuric acid(98%) 2000

Total 2250 Total 2250

Input Kg Output KgReaction Mass 2250 Reaction mass 6250Washing water of previous batch 5000 Water loss 1000Total 7250 Total 7250

Input Kg Output KgReaction mass 6250 Wet cake 1950

Spent sulphuric acid(45%) 4300


Input Kg Output KgWet Cake 1950 Wet cake 1900

Water 5000

washing water recycle to drowning process for next batch 5050


Input Kg Output KgWet cake 1900Rosin 9.6TLS 19Caustic Soda 36.7 Water 5000TOTAL 6965.3 Total 6965.3

Input Kg Output KgReaction mass 6965.3 Wet cake 1600

Effluent 5365.3


Input Kg Output KgWet cake 1600 Wet cake 1500Fresh water 2400 Effluent 2500TOTAL 4000 TOTAL 4000

CPC ALPHA BLUE MATERIAL BALANCE

Reaction mass 2250

FILTER PRESS-2

2nd WASHING

6965.3

1st WASHING

REACTOR-1

DROWING

FILTER PRESS-I

REACTOR-2 Reaction mass


Input Kg Output KgWet cake 1500 Dry Cake 240

Water loss 1260TOTAL 1500 TOTAL 1500

Input Kg Output KgDry cake 240 Product 240

TOTAL 240 TOTAL 240

Input Kg Output KgProduct 240 Final product 240TOTAL 240 TOTAL 240

DRYING

PULVERISING

PACKING

4. MANUFACTURING PROCESS OF AMMONIUM SULPHATE

Manufacturing Process for Ammonium Sulphate:

Take ammonium carbonate solution (15%) in reactor. Add sulphuric acid (23%) . Provide steam

to reactor for 4-5 hrs. This process is carried out under vacuum system.

After completion of reaction, entire mass will be sent to distillation where the water and slurry

will be separated from each other. Separated water will be sent for the re-use purpose in the

manufacturing process of alpha blue. Ammonium sulfate solution will be sent in to crystallizer.

Then transfer mass to centrifuge. Liquid will come out from centrifuge and will be reused for

preparation of next batch of ammonium sulfate and the Solid mass coming out of will be sent in

to dryer, where we will get our Final product-Ammonium Sulfate.


FLOW DIAGRAM

Semi solid ammonium sulfate crystal

Ammonium carbonate solution

Reaction vessel

Water (reused )

Conc. - H2SO4 (23%)

Crystallizer

Dryer

Centrifuge

Distillation

Dry product

Steam


MATERIAL BALANCE OF AMMONIUM SULFATE

Input Kg. Output Kg.

Ammonium Carbonate Solution

4.83

Sulfuric Acid 23% 3.21TOTAL 8.04 TOTAL 8.04

Input Kg Output Kg.Water 6.935Ammonium Sulphate Solution 1.105

TOTAL 8.04 TOTAL 8.04


Wet Ammonium Sulphate 1.055Evaporation Loss 0.05

TOTAL 1.105 TOTAL 1.055

Input Kg. Input Kg.

Ammonium Sulphate 1.025

Water 0.03TOTAL 1.055 TOTAL 1.055


Ammonium Sulphate 1.025 Dry Product 1

Evaporation Loss 0.025TOTAL 1.025 TOTAL 1.025

DRYER

Reaction Mass 8.04

Reaction Mass 8.04

Ammonium Sulphate Solution

1.105

Wet Ammonium Sulphate

1.055

REACTOR

DISTILLATION

CRYSTALIZATION

CENTRIFUGE


SOLVENT RECOVERY SYSTEM

Solvents to be used: O-Nitro Toluene/ISOL/Nitro Benzene/IBA/Xylene

FIGURE NO:

Drawing of Solvent Recovery System

Reactor Vessel

Primary condenser

Secondary condenser

Receiver Vessel

Steam Inlet

Steam Outlet

Reflux lineDistribution box

Cooling water Inlet

Cooling water Outlet

Vapour Inlet

Vapor Inlet

Cooling water Outlet

Cooling water Inlet

Solvent vapour


3.7 RAW MATERIAL

The proposed products are organic chemicals and the required raw materials will be purchased

from the local/ Indian market. Details of raw-material consumption are as shown in table no.7.

TABLE: 7

LIST OF RAW MATERIALS-PRODUCT WISE

Sr. no

Name of product Production capacity

MT/Month

Sr. No.

Name of Raw Material

Consumption quantity

MT/Month1. Copper

Phthalocyanine Blue

200 1. Phthalic anhydrides 2232. Urea 1783. Ammonium

Molybdate 0.504. Cuprous Chloride 505. TCB or ONT 7006. Sulfuric acid 940

Total 2091.52. Copper

Phthalocyanine Beta Blue

145 1. Copper phthalocyanine 149.35

2. Dilute HCL 1.893. Caustic Soda 2.204. IBA/Xylene 72.50

Total 225.943. Copper

Phthalocyanine Alpha Blue

55 1. Copper Phthalocyanine Blue 57.2

2. Sulfuric acid (98%) 458.153. Rosin 2.204. TLS 4.355. Caustic Soda 8.41

Total 530.31Total (1+2+3) 1907.75

4. Ammonium Sulphate (By-Product)

207 1. Ammonium carbonate solution 1000

2. H2SO4 (23%) 665Total 1665

3.8 RESOURCE REQUIREMENTS

3.8.1 LAND

The Rageshwari Textile Pvt. Ltd. has been taken over by the present promoters. The GIDC has

transferred the same to present promoters. The total plot area of the unit is 4483.05 Sq. Mtrs.


3.8.2 BUILDING

There is one existing building. It is in good condition. There will be extra floor on the existing

building. Also additional construction will be done to accommodate utility block, workshop, and

solvent storage area besides effluent treatment plant. The approximate requirement of

construction materials is given table 8.

TABLE: 8

APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS

Sr. No. Construction material Proposed Quantity

1. Bricks 140000 Nos

2. TMT Steel 100 MT

3. Grit 1550 MT

4. Cement 15600 Bags

5. Sand 2000 MT

6 Rubble stone 350 MT

3.8.3 POWER AND FUEL

TABLE: 9

POWER AND FUEL REQUIREMENT

FUEL

Sr. no. Particulars Remarks1. Type of Fuel Natural gas

Consumption rate 4000 M3/DaySource of supply Gujarat Gas

ENERGY – Electricity.Sr. No. Particulars Remarks1. Type of Energy Electricity.2. Consumption rate 1000 KVA 3. Source of supply Dakshin Gujarat Vij Company Ltd.

3.8.4 WATER

WATER CONSUMPTION

The expected total water requirement of the unit will be 205Kl/day.

Unit will use 98Kl/day fresh water and 107Kl/day recycle water for the fulfillment of total

water requirement.


GIDC water will be a source of fresh water.

60Kl/day water will be required for utility in which 40Kl/day will be used for boiler and

20Kl/day will be used in cooling tower.

6Kl/day water will be used for washing.

10Kl/day water will be used for domestic purpose

5 Kl/day water will be used for gardening purpose

The bifurcation of water consumption is given below in Table No: 10.

TABLE: 10

WATER CONSUMPTION

Sr. No. Section Water Consumption KL/Day

1 Domestic 10Gardening 5

2. IndustrialProcess (124 fresh + 186 recycle water

from process)Washing 6Boiler 40cooling 20 TOTAL 205 KL/Day( 98 FRESH

+107 RECYCLE)

WASTE WATER GENERATION, TREATMENT & DISPOSAL

92.8Kl/day effluent will be generated from the CPC blue manufacturing process in which 48.8Kl/day will be acidic effluent and 44Kl/day will be aqueous effluent. Aqueous effluent will be reused in the manufacturing process of pigment alpha blue and acidic effluent will be neutralized in neutralization tank.

The total effluent generation form the pigment alpha blue will be a 120.8Kl/day from which 72Kl/day will be sent in CPC blue manufacturing process, 46Kl/day will be reused in next batch of pigment alpha blue and 1.8Kl/day will be sent in neutralization tank for neutralization purpose.

The total effluent generation from the pigment beta blue will be a 23Kl/day from which 14Kl/day will be reused into pigment alpha blue production and 9Kl/day will be reused into CPC blue production.

The boiler blow down water and cooling tower blow down will be 8Kl/day and 4Kl/day.


The effluent generation from the washing will be 6Kl/day.

The total effluent generation will be 68.6Kl/day which will be treated into MEE after neutralization into neutral tank.

The recovered water from MEE will be 50Kl/day which will be reused into plant.

TABLE: 11

WASTE WATER GENERATION

Sr. No. Section Waste Water generation KL/Day

1 Domestic 7.52. Industrial

Process 50.6Washing 6Boiler 8cooling 4TOTAL 68.6

RAGESHWARI TEXTILE PVT LTD., PANDESARA, SURAT

FIGURE:4

WATER FLOW DIAGRAM

GIDC Water (205 KL/Day)(98 KL/Day Fresh water + 107 KL/Day Recycle water)

Washing (6 KL/Day) Process(124 Fresh+186 Recycle)

Domestic(10

KL/Day)

Gardening(5

KL/Day)

Utility(60

KL/Day)

Ammonium Carbonate plant(37 KL/Day)

CPC Blue(82 KL/Day)(Recycle)

Pigment beta blue(31 KL/Day fresh water)

Pigment alpha blue (160 KL/Day)(56 KL fresh +104 recycle)

Effluent(92.8 KL/Day)(44 KL Recycle +48.8Kl for neutralization)

Effluent(120.8 KL/Day)(119 KL Recycle +1.8 for neutralization

Effluent(23 KL/Day)(14 KL in alpha blue+9 KL in CPC Blue)

Ammonium sulfate Plant(57 KL/Day)(Recycle)

46 KL/Day73 KL/Day 14 KL/Day

9 KL/Day

44 KL/Day

Soak pit(7.5 KL/Day)

Acidic effluent(48.8 KL/Day)

Acidic effluent(1.8 KL/Day)

Floor/Plant(6 KL/Day)

Cooling(20 KL/Day)

Boiler(40 KL/Day)

Boiler(8 KL/Day)

Cooling(4 KL/Day)

Water Loss(16 KL/Day)

Water Loss(32 KL/Day)

Total effluent (68.6 KL/Day)

Neutralization (68.6 KL/Day)

Water (50 KL/Day) MEE (56.6 KL/Day)

12 KL/Day

MEE Salt 6.6 KL/Day

Recycle water (50 KL/Day)

Recycle water 57 KL/Day


3.8.5 MANPOWER

The manpower required for the project as well as during the construction/ commissioning

activities will be employed from the local area.

TABLE 12

MAN POWER REQUIREMENT

Phase of project Type of labor No. of workers(Proposed Scenario)

During construction Contractual 30During commissioning Contractual 15During operations Managerial 3

Skilled 12Un-skilled 30-35

3.9 MITIGATION MEASURES & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been

proposed by the company for the control of the anticipated pollution load.

3.9.1 GASEOUS EMISSIONS & CONTROL

3.9.1.1 FLUE GAS EMISSION

There will be flue gas emission from boiler, thermic fluid heater and hot air generator. The air pollution control measures are covered under table 13.TABLE: 13

FLUE GAS EMISSION

Stack No.

Source of emission

Stackheight(m)

Stack Diameter in mm

Pollutioncontrol equipment

Type of emission

PermissibleLimit

1. Boiler- I & II(6 TPH)

30 900 -- PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

2. Thermopack I & II(15 lacs K Cal)

30 Common stack

900 -- PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

3. Hot Water Generator (6 lac K Cal)

-- PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm

4. D.G. Sets(2 Nos. of 380 KVA )

7 m each

-- -- PMSO2

NOx

150 mg/Nm3

100 ppm50 ppm


3.9.1.2 PROCESS EMISSIONS

The process emissions in the existing scenario from the proposed manufacturing activities are

given in Table 14.

TABLE 14

PROCESS EMISSIONS

3.9.2 HAZARDOUS MANAGEMENT

The following type of hazardous waste will be generated from the operational activities. All the

waste will be stored separately in a designated storage area. The details of hazardous waste are

below given Table 15.

TABLE 15

DETAILS OF HAZARDOUS WASTE

Sr. No.

Name of Waste

Waste categorySchedul

e-I

Source ofwaste

generation

Mode ofdisposal

Quantityin month

1 Discarded bag container

33.1 Raw material handling

Given to Authorized vendors by GPCB

15000 Nos.

2 Spent oil 5.1 Lubrication Collect, Storage and sell to register re-processors

50 lit

3 Sludge 35.3 MEE Collection, Storage, Transportation and disposal to TSDF site.

465 MT

Sr. No.

Stackattached

to

Stack Height

in meter

Stack diameter

(mm)

APCM Probable Pollutants

Permissible Limit

1. Reactor 25 300 Water scrubber & Ventury

system

Ammonia 175 mg/Nm3


In addition to the provision of above, we will ensure proper management for hazardous waste as

below:

Transportation of hazardous waste to the TSDF Site will be governed as per the guidelines

and accompanied with Form-9.

Annual returns of the disposal of wastes in Form-4 and Form-13 will be submitted regularly

to the local office of the GPCB.

3.9.3 NOISE CONTROL & ODOUR

The major noise generating installation will be the D.G. Set. It will be installed in a closed room,

acoustic enclosure will be provided around it. Ear plugs will also be provided to the operating

personnel in boiler room.

The following steps will be taken for odour control.

Raw-material feeding will be carried out by pumps.

All reactions will be taken in closed reactor system.

Roof top ventilation will be provided in the entire plant area.

Regular monitoring of piping and fittings will be done to prevent the leakages.

3.9.4 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS

The storage and mode of transport of chemicals will be done as per detailed MSDS and chemical

hazards guide (NIOSH) for the hazardous chemicals.

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

3.9.5 HEALTH AND SAFETY MEASURES

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of

large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of

MSIHC Rules,


Moreover transport activity will be through drums, so there will be manual loading and

unloading and no unloading through pipe at the site. Hence, the risk of static charge generation

during transfer of such chemicals is not significant.

Below mentioned is the summary proposed safety measures to be taken at site for control of

anticipated hazards.

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

The Pandesara estate is connected to Surat and Udhana. Surat is a district head quarter and is

known for textile industries. It is connected with Mumbai by rail. Almost all trains on

Ahmadabad- Mumbai route stops at Surat. It also has six lane road up to Mumbai. Surat has its

Air Port and connected with Delhi and Mumbai. The major distances by road from Pandesara to

Mumbai is 263 KM, while for Ahmadabad the distance is 255 KM. Vadodara is another

important city located at 142 KM north of Pandesara.

4.2 LAND USE AND LAND OWNERSHIP

The proposed project site is located at plot no 272/C & D, B +F, GIDC Estate, Pandesara, Surat.

The plot has been purchased by Rageshwari Textilie Pvt Ltd from GIDC. The total plot area of

the unit is 4483.05 Sq. Mtrs.

4.3 EXISTING LAND USE

The proposed project site is located at plot no 272/ C & D, B +F, GIDC Estate, Pandesara, Surat.

The plot is notified by GIDC for industrial purpose. The land use pattern is as under:

4.4 EXISTING INFRASTRUCTURE

The plant is located in a well-developed industrial zone, which has all essential facilities such as

internal roads, arrangement for supply of water and power to industries, effluent disposal

facilities, gas etc.

The proposed project is relatively small in size and will be employing around 50 skilled and

unskilled people. First preference will be given to local people, so there will be no change in

population pattern due to the proposed project.


4.5 SOIL CLASSIFICATION

The soils of the district are derived from the Deccan trap which is main rock formation of the

district. The soil of the district can be classified as light, medium and heavy according to depth,

texture and location. There is sandy loam to loamy in texture, brownish black in color.

4.6 CLIMATE DATA

The climate is characterized by oppressive summer dampness in the atmosphere nearly

throughout the year, heavy south- west monsoon rainfall and a mild winter.

The year may be divided in to four seasons. From December to February is known as winter or

cold season. The summer or hot season is from March to May and south- west monsoon season

is from June to September, while October and November is the post monsoon season.

Valsad is the nearest meteorological observatory station to the project site. The various

meteorological details of Valsad station for the year March 2014 to May 2014are given in table

no: 16.

TABLE NO 16

MICRO METEOROLOGICAL DATA

(Data from Indian Meteorological Department, Ahmadabad, Station:-Surat)

Month -- Temp. (°C) Relative Humidity (%) Rainfall mm

March-14 Min 12.8 24 0.0

Max 33.6 85

Average 23.2 54.5

Apr-14 Min 19.2 33 0.0

Max 40 84

Average 29.6 58.5

May-14 Min 19.2 39 0.0

Max 36.6 81

Average 27.9 60


WIND ROSE DIAGRAM FOR PERIOD OF MARCH 2014 TO MAY 2014

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT

Surat is largely an industrial area dominated by small scale industries, especially chemical plants.

Surat in Gujarat has a largest industrial area with common effluent treatment plant and land fill

site. Govt. agencies provide many basic facilities like uninterrupted water supply, power and

road network.

5.2 POPULATION PROJECTION.

According to recent estimates from Census of India, Population of Surat in 2015 was 5,754,035.

This figure was recorded to be 5,461,466 in 2014 and 5,170,655 in 2013. According to last

Census of India in 2011, Surat recorded a population of 4,591,246. Population growth in Surat is


considered to be descent as compared with other metro cities in India. Surat with a Literacy rate

of 89% is one of the best cities to live in India. The city’s literacy rate is much higher than

national average of 79.5%. In Surat, Male and female literacy rate stands at 93% and 84%

respectively. This figure is far better than other cities of Gujarat. The city offers a range of

Education facilities in the form of universities, colleges and schools at par with national and

international standards.

5.3 LAND USE PLANNING

It has been developed on out skirts of Surat by GIDC for promotion of industrial development.

The names of prominent industries are shown in table no: 17

Table: 17

NAME OF SOME PROMINENT INDUSTRIES

Sr. No. Name of industry

1 Colourtex Industries Pvt Ltd

2 Nova Dyestuff Industries Pvt. Ltd.

3 Pandesara Industries Pvt. Ltd.

4 L.D.Chemicals Interchem

5 Ashim products

6 Narayan Oil and Gas Burner Company

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

The Rageshwari Textile Pvt. Ltd. shall get water from GIDC water supply scheme. So there will

be no additional stress on ground water resources and there will be no adverse effect on the

ground water resources available in the nearby area. The unit has proposed 1000 KWA

connected load form DGVCL. The transportation facilities will also expect to improve due to

increase in the movement of workers and raw material and finished products.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

The process area will cover plant area, raw material storage area, hazardous waste storage area,

workshop and utilities.


6.2 NON PROCESSING AREA

The non process area will cover Admin Building, toilet blocks, change room and security cabin.

6.3 GREEN BELT AREA

Out of the total land area about 4483.05 M2 approximately 31% will be utilized for green belt

development.The proposed greenbelt area is 1427.80 M3. Species like Baval, Kadam, Bili,

Neem, Gulmahor, Ashoka, Ambo, Badam, Pipro, Vad etc are suggested for plantation. There

will be provision of budget of 5 lakh rupees for green belt development .The unit will plant 150-

200 trees and shrubs in green belt area.

6.4 SOCIAL INFRASTRUCTURE

The availability of basic amenities is covered as under:

Training & Education: All the employees will be trained and educated periodically about the

hazardous nature of chemicals used in the process. Also, training for fire fighting, work

permits system, first aid, safe handling of hazardous chemicals and integrating safety, in all

activities.

Medical facility: Pre-employment medical check up at the time of employment. In order to

safe guard the health of the employees, all the employees undergo periodic health checkup.

Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide

purified water for drinking purpose.

Transportation: The unit will provide basic transportation facility for workers.

Telegraph & Post: There will be provision of telephone, fax and internet facility for the

workers.

Power supply: There will be connected load of 1000 KWA from DGVCL.

6.5 CONNECTIVITY

This industrial estate is well connected to Ahmadabad/Mumbai/Vadodara through the district

headquarter Surat. Rail services, Road services and Air services are available in GIDC.

6.6 DRINKING WATER MANAGEMENT

Average daily water consumption of unit will be 10 KL/day for domestic purpose. The entire

water requirement will be meeting through Surat Municipal Corporation water supply system.


6.7 INDUSTRIAL WASTE MANAGEMENT

The hazardous waste like discarded bag /containers and used oil will be generated from the

proposed activity. The hazardous waste management and disposal is shown in table 15.

6.8 SOLID WASTE MANAGEMENT

The record of hazardous waste and non hazardous solid waste like, discarded bag containers

and spent oil etc. will be maintained.

6.9 SOURCE OF POWER

The unit will used total 1000 KWA electricity connected load from DGVCL.

7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

The proposed project is located in GIDC Estate, Pandesara, Surat. There will be no any human

settlement affected by proposed project. So, there is no requirement of any R & R Plan.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

The details of project Implementation Schedule is given in below table.

TABLE: 18

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule after getting NOC from GPCBSr.No.

Activity Required Period

1 Civil work Immediately after getting NOC2 Procurement of machinery 1 month after getting NOC3 Erection & installation of

machinery Immediately after competition of activity no.2

4 Trial of machinery & equipments

Within 1 months after competition of activity no.3

5 Commercial activity 1 months after competition of activity no.4

8.2 ESTIMATED PROJECT COST

The details of Capital cost projection are given in below table 19.


TABLE: 19

CAPITAL COST PROJECTION

Sr. No. Purpose Proposed(Rs. In Lacs)

1. Land 1152. Building Proposed 503. Plant and Machinery 3004. Q.A. Lab set up 105. Env. Protection & Safetya) Effluent treatment Plant 70b) Safety Equipment (PPE, fire

extinguishers, Ventilation, etc.)15

c) Green belt development 5d) Fire 3

Total 568

9.0 ANALYSIS OF PROPOSAL

All the manpower will be utilized from local region around Pandesara, Surat. First preference

will be given to local people for employment and Company shall also try to provide indirect

employment opportunities by availing local contract services during transportation and

operational phase.

The company intents to donate 0.5 % of the profit to agencies like NGOs or social welfare

societies for projects carried out in nearby villages for their welfare and upliftment.

Documents

PROJECT PRE-FEASIBILITY REPORT ON PROPOSED PROJECT …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/15_Sep... · PROJECT PRE-FEASIBILITY REPORT ON PROPOSED PROJECT FOR MANUFACTURING