PROPOSED EXPANSION OF PIGMENT …environmentclearance.nic.in/writereaddata/Online/TOR/18...FORM -I For PROPOSED EXPANSION OF PIGMENT MANUFACTURING IN EXISTING UNIT of M/s. UNITY ORGANICS

FORM -I

For

PROPOSED EXPANSION OF PIGMENT MANUFACTURING

IN EXISTING UNIT

of

M/s. UNITY ORGANICS PVT. LTD.

PLOT NO. 117/6, RAVI INDUSTRIAL ESTATE,

BEHIND PRESTIGE HOTEL,

AHMEDABAD-MEHSANA HIGHWAY,

VILL: BILESHWARPURA, PO: CHHATRAL,

TAL: KALOL, DIST : GANDHINAGAR

(GUJ.)

FORM – I

(I) Basic Information

Sr.

No.

Item Details

1. Name of the Project/s UNITY ORGANICS PVT LTD.

2. S.No. in the Schedule 5(f)

3. Proposed capacity/area/length/tonnage to be

handled/command area/lease area/number of

wells to be drilled

Total after expansion: 15 + 385 = 400 MT/Month

(Please refer Annexure -I). Total plot area: 7,954

m2.

4. New/Expansion/Modernization Expansion

5. Existing capacity/area etc. N.A.

6. Category of project i.e. ‘A’ or ‘B’ ‘A’

7. Does it attract the general condition? If yes,

please specify.

-

8. Does it attract the specific condition? If yes,

please specify.

-

9. Location

Plot/Survey/Khasra No. PLOT NO. 117/6, RAVI INDUSTRIAL ESTATE,

Village BILESHWARPURA, PO: CHHATRAL

Tehsil KALOL

District GANDHINAGAR

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Nearest Railway Station : Gandhinagar: 27 km

Nearest Airport: Ahmedabad: 40 km

11. Nearest Town, city, District Headquarters along

with distance in kms.

Nearest town: Chhatral: 0.5 km

12. Village Panchayats, zillaparishad, Municipal

corporation, Local body (Complete postal

addresses with telephone nos. to be given)

13. Name of the applicant UNITY ORGANICS PVT LTD.

14. Registered address PLOT NO. 117/6, RAVI INDUSTRIAL ESTATE, VILL:

BILESHWARPURA, PO: CHHATRAL, TAL: KALOL,

DIST: GANDHINAGAR-382729

15. Address for correspondence: B/906, Atma House, Opp. Old RBI Bank, Near Sale

Tax Bhavan, Ashram Road, Navrangpura,

Ahmedabad -380009

Name Mr. HIREN HANSRAJBHAI PATOLIYA

Designation (Owner/Partner/CEO) Director

Address PLOT NO. 117/6, RAVI INDUSTRIAL ESTATE, VILL:

BILESHWARPURA, PO: CHHATRAL, TAL: KALOL,

DIST: GANDHINAGAR

Pin Code --

E-Mail [email protected]

Telephone No. +91-2764-233900 / +91-9879212348

Fax No. --

16. Details of Alternative Sites examined, if any

location of these sites should be shown on a

topo sheet.

No

17. Interlinked Projects No

18. Whether separate application of interlinked

project has been submitted?

No interlinked project

19. If Yes, date of submission Not applicable

20. If no., reason Not applicable

21. Whether the proposal involves

approval/clearance under: If yes, details of the

same and their status to be given.

(a) The Forest (Conservation) Act, 1980?

(b) The Wildlife (Protection) Act, 1972?

(c) The C.R.Z Notification, 1991?

Not applicable

22. Whether there is any Government order/policy

relevant/relating to the site?

No

23. Forest land involved (hectares) NA

24. Whether there is any litigation pending against

the project and/or land in which the project is

propose to be set up?

(a) Name of the Court

(b) Case No.

(c) Orders/directions of the Court, if any

and its relevance with the proposed project.

No

• Capacity corresponding to sectoral activity (such as production capacity for

manufacturing, mining lease area and production capacity for mineral production, area

for mineral exploration, length for linear transport infrastructure, generation capacity for

power generation etc.,)

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which

will cause physical changes in the locality (topography, land use, changes in water

bodies, etc.)

Sr.

No.

Information/Checklist confirmation Yes

/No?

Details thereof (with approximate

quantities / rates, wherever possible)

with source of information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase in intensity of land use (with

respect to local land use plan)

No

1.2 Clearance of existing land, vegetation and

buildings?

Yes Minor site clearance activities shall be

carried out to clear shrubs and weed to

conduct soil survey and initial

preparation.

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g. bore

houses, soil testing?

Yes Soil testing and analysis will be done for

detailed engineering before

construction.

1.5 Construction works? Yes The construction work includes process

plants, utility blocks & other

infrastructure which will be in different

stages. Please refer Annexure – II.

1.6 Demolition works? No

1.7

Temporary sites used for construction

workers or housing of construction workers?

Yes Some land portion on the plot will be

provided for temporary housing of

construction workers during

construction stage.

1.8 Above ground buildings, structures or

Earthworks including linear structures, cut

and fill or excavations

Yes All the process plants will have

structures & will require excavation.

Other buildings, godown, stores, tank

farms, weigh bridges, etc. also require

some excavations work. Please refer

Annexure – II.

1.9

Underground works including mining or

tunneling?

No

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Offshore structures? No

1.13 Production and manufacturing Yes Please refer Annexure –III.

1.14 Facilities for storage of goods or materials? Yes Raw material storage area, Tank farm

area & finished products area will be

developed for proposed project.

1.15

Facilities for treatment or disposal of solid

waste or liquid effluents?

Yes Full-fledged Effluent Treatment Plant

will be installed to treat the effluent so

as to achieve the GPCB norms.

The High TDS effluent shall be

evaporated in proposed Multiple Effect

Evaporation system. The evaporated

salt will be disposed off in the

approved TSDF site. Condensate from

the MEE system shall be reused in

plant premises.

Domestic Waste water will be disposed

by septic tank/soak pit.

Solid waste shall be disposed to

approve TSDF Site.

Details of water consumption

&wastewater generation are attached

as Annexure-IV.

A detail of ETP & MEE is attached as

Annexure-V.

Details of Solid Hazardous waste

generation and disposal is attached as

Annexure-VI.

1.16

Facilities for long term housing of

operational workers?

No

1.17 New road, rail or sea traffic during

construction or operation?

No

1.18 New road, rail, air waterborne or other

airports etc?

No

1.19 Closure or diversion of existing transport

routes or infrastructure leading to changes

in traffic movements?

No

1.20 New or diverted transmission lines or

pipelines?

No

1.21

Impoundment, damming, converting,

realignment or other changes to the

No

hydrology of watercourses or aquifers?

1.22 Stream crossings? No

1.23

Abstraction or transfers or the water form

ground or surface waters?

Yes Ground water shall be used. Company

has applied for withdraw the Ground

Water to CGWA.

1.24

Changes in water bodies or the land surface

affecting drainage or run-off?

No

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes Transportation of personnel or raw

material and products will be primarily

by road only.

1.26 Long-term dismantling or decommissioning

or restoration works?

No

1.27 Ongoing activity during decommissioning

which could have an impact on the

environment?

No

1.28

Influx of people to an area in either

temporarily or permanently?

No

1.29 Introduction of alien species? No

1.30 Loss of native species of genetic diversity? No

1.31 Any other actions? No

2. Use of Natural resources for construction or operation of the Project (such as land,

water, materials or energy, especially any resources which are non-renewable or in short

supply):

Sr.

No

Information/checklist confirmation Yes/

No?

Details there of (with approximate

quantities/rates, wherever possible)


2.1 Land especially undeveloped or agriculture

land (ha)

No

2.2 Water (expected source & competing

users) unit: KLD

Yes Water Source: 215 KLD (45 KLD: bore

well + 170 KLD: Reuse)

Please refer Annexure–IV.

2.3 Minerals (MT) No

2.4

Construction material -stone, aggregates,

sand / soil (expected source MT)

No

2.5 Forests and timber (source - MT) No No wood shall be used as construction

material or as a fuel.

2.6

Energy including electricity and fuels

)source, competing users) Unit: fuel (MT),

energy (MW)

Yes Power:

Power required from GEB is 500 KVA

(existing).

Standby power supply from D.G. set (500

KVA) in emergency case (existing).

Power required from GEB is 2000 KVA

(total after expansion).

Standby power supply from D.G. set

(2000 KVA) in emergency case (total

after expansion).

Fuel:

LDO/FO in THF :700 Liter/Day (Existing)

Fire wood in steam boiler: 3 MT/Day

(Existing)

Total after Proposed Expansion:

Coal: 15 MT/Day

Wood waste/ briquette : 3 MT/Day

HSD: 20 Liter/Hr

2.7 Any other natural resources (use

appropriates standard units)

No

3. Use, storage, transport, handling or production of substances or materials, which could

be harmful to human health or the environment or raise concerns about actual or

perceived risks to human health.

Sr.

No.

Information / Checklist confirmation Yes/

No?


quantities / rates wherever possible)


3.1 Use of substances or materials, which are

hazardous (as per MSIHC rules) to human

health or the environment (flora, fauna,

and water supplies)

Yes

Please refer Annexure: VIII

3.2 Changes in occurrence of disease or affect

disease vectors (e.g. insect or water borne

diseases)

No

3.3 Affect the welfare of people e.g. by

changing living conditions?

No

3.4

Vulnerable groups of people who could be

affected by the project e.g. hospital

patients, children, the elderly, etc.

No

3.5 Any other causes No

4. Production of solid wastes during construction or operation or decommissioning

MT/month)

Sr.

No.

Information/Checklist confirmation Yes/

No? Details thereof (with approximate



4.1 Spoil, overburden or mine wastes No

4.2

Municipal waste (domestic and or

commercial wastes) No

4.3

Hazardous wastes (as per Hazardous Waste

Management Rules)

Yes Please refer Annexure-VI.

4.4 Other industrial process wastes Yes Please refer Annexure-VI.

4.5 Surplus product No

4.6

Sewage sludge or other sludge from

effluent treatment

Yes Please refer Annexure-VI.

4.7 Construction or demolition wastes No Construction waste shall be utilized for

leveling, land filling in the premises.

4.8 Redundant machinery or equipment No

4.9 Contaminated soils or other materials No

4.10 Agricultural wastes No

4.11 Other solid wastes No

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr.

No.

Information/Checklist confirmation Yes/N

o


quantities/rates, wherever possible)


5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources

Yes Please refer Annexure–VII.

5.2 Emissions from production processes Yes Please refer Annexure–VII.

5.3 Emissions from materials handling storage

or transport

Yes The construction materials such as

stones, cements, bricks & coal may

pollute the air by dust particles. But it will

be controlled by covering the trucks &

trailers by clothes during transportation.

Also all the hazardous chemicals storage

tanks will be provided with flame

arrestors & breather valves for safety.

5.4 Emissions from construction activities

including plant and equipment

Yes During construction work, the Nearby

buildings area will be covered by sheets

or clothes to avoid dust contamination in

air.

5.5 Dust or odors from handling of materials

including construction materials, sewage

and waste

No

5.6 Emissions from incineration of waste No

5.7 Emissions from burning of waste in open

air e.g. slash materials, construction

debris)

No

5.8 Emissions from any other sources No

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr.

No.


No?


Quantities /rates, wherever possible)

With source of source of information

data

6.1

From operation of equipment e.g. engines,

ventilation plant, crushers

Yes At noisy areas adequate preventive &

control measures shall be taken to

control the noise level within prescribed

limits. No significant noise, vibration or

emission of light & heat from the unit.

6.2 From industrial or similar processes Yes -do-

6.3 From construction or demolition No

6.4 From blasting or piling No

6.5 From construction or operational traffic No

6.6 From lighting or cooling systems No

6.7 From any other sources No

7. Risks of contamination of land or water from releases of pollutants into the ground or

into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No


No?




7.1

From handling, storage, use or spillage of

hazardous materials

Yes All the raw material shall be stored

separately in designated storage area

and safely. Bund walls shall be

provided around raw materials storage

tanks for containing any liquid spillage.

Other materials shall be stored in bags

/ drums on pallets with concrete

flooring and no spillage is likely to

occur. Please refer Annexure–VIII.

7.2

From discharge of sewage or other

effluents to water or the land (expected

No Sewage effluent shall be treated in

septic tank & soak pit.

mode and place of discharge)

7.3

By deposition of pollutants emitted to air

into the land or into water

No

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term build up of

pollution in the environment from these

sources?

No

Full- fledged Environmental

Management System (EMS) will be

installed. i.e. ETP, Air Pollution Control

systems, Hazardous Waste Handling

and Management as per norms, etc.

which will eliminates the possibility of

building up of pollution.

8. Risks of accident during construction or operation of the Project, which could affect

human health or the environment:

Sr.

No

Information/Checklist confirmation

Yes/

No?




8.1 From explosions, spillages, fires, etc. from

storage, handling, use or production of

hazardous substances

Yes Please refer Annexure – VIII.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by natural

disasters causing environmental damage

(e.g. floods, earthquakes, landslides,

cloudburst etc)?

No There is no history of flood in this area.

The buildings are designed considering

seismic zone III.

The land is plain terrain – no scope of

landslide.

This area is having moderate rainfall and

there is no history of cloudburst.

9. Factors which should be considered (such as consequential development) which could lead

to environmental effects or the potential for cumulative impacts with other existing or

planned activities in the locality

Sr.

No.


No?




9.1 Lead to development of supporting.

laities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.:

Y Site is located near Ahmedabad-Mehsana

Highway, having the entire required

infrastructure.

Local people will be employed and no

housing is required. Please refer

* Supporting infrastructure (roads, power

supply, waste or waste water treatment,

etc.)

• housing development

• extractive industries

• supply industries

• other

Annexure – IX.

9.2

Lead to after-use of the site, which could

have an impact on the environment

No The hazardous waste shall be disposed to

Approved TSDF site.

9.3 Set a precedent for later developments No Not applicable

9.4 Have cumulative effects due to proximity

to Other existing or planned projects with

similar effects

No

(III)Environmental Sensitivity

Sr.

No

Information/Checklist confirmation Name /

Identity

Aerial distance (within 25 km).

Proposed Project Location

Boundary.

1 Areas protected under international conventions

national or local legislation for their ecological,

landscape, cultural or other related value

Nil

2 Areas which are important or sensitive for

Ecological reasons - Wetlands, watercourses or

other water bodies, coastal zone, biospheres,

mountains, forests

Nil

3 Areas used by protected, important or sensitive

species of flora or fauna for breeding, nesting,

foraging, resting, over wintering, migration

Nil

4 Inland, coastal, marine or underground waters Yes River Sabarmati: 73.0 KM

5 State, National boundaries Yes Rajasthan: 128 Km

6 Routes or facilities used by the public for to

recreation or other tourist, pilgrim areas.

Nil Not applicable

7 Defense installations Nil NIL

8 Densely populated or built-up area Yes Gandhinagar city: 2.00 lakh

population

9 Areas occupied by sensitive man-made land

community facilities)

Nil

10 Areas containing important, high quality or scarce

resources (ground water resources, surface

resources, forestry, agriculture, fisheries, tourism,

tourism, minerals)

Yes

The project shall use ground water.

The project being in outside

industrial area does not affect

agricultural land.

No tourist location in the vicinity of

30 Km.

11 Areas already subjected to pollution or

environmental damage. (those where existing legal

environmental standards are exceeded)

Nil

12

Areas susceptible to natural hazard which could

cause the project to present environmental

problems (earthquakes, subsidence, landslides,

erosion, flooding or extreme or adverse climatic

conditions)

Nil

Proposed expansion site falls in

seismic zone III. So, all the structures

are constructed as per the IS code

for earthquake resistant structures.

There is no heavy rain in the area. So

erosion of land is very little.

The area has no history of flooding.

The climate of area is moderate.

made by the authorized signatory only. The authorized signatory should also submit a

document in support of his claim of being an authorized signatory for the specific project.

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products with their Production Capacity

II Layout of Plant

III Brief Manufacturing Process Description

IV Details of water consumption & waste water generation

V Description of Effluent Treatment Plant & MEE

VI Details of Hazardous Waste Generation and Disposal

VII Details of Stacks and Vents

VIII Details of Hazardous Chemicals Storage & Handling

IX Socio-economic Impacts

X Proposed Terms of Reference for EIA studies

ANNEXURE – I

LIST OF PRODUCTS & RAW MATERIALS AND THEIR CAPACITY

LIST OF PRODUCTS AND THEIR CAPACITY

Sr. No. Product Name Existing Capacity

(MT/Month)

Additional

Capacity

(MT/Month)

Total Capacity

(MT/Month)

1. Copper Phthalocynine Blue 15 285 300

2. Beta Blue -- 50 50

3. Alpha Blue -- 50 50

Total 15 385 400

By-Products

4. Spent Ammonium Carbonate 75 -75 00

5. Ammonium Sulphate -- 450 450

List of Raw Material Along with Quantity

SR.

NO.

NAME OF

PRODUCT

RAW MATERIAL Existing

QUANTITY

(MT/MONTH)

Proposed

QUANTITY

(MT/MONTH)

1. Copper

Phthalocynine

Blue

Phthalic Anhydride 16 320

T. G. Urea 24 480

Cuprous Chloride 2.88 57.6

Ammonia Molybdate 0.04 0.8

Nitro Benzene 35.2 704

Sulphuric Acid 9.6 192

Caustic Soda 1.6 32

TOTAL 89.32 1786.4

2. Alpha BLUE Copper Phthalocynine

Blue

52.08

Sulphuric Acid 425.69

Emulsified 5.78

Caustic Flake 2.54

TOTAL 486.09

3. Beta BLUE Copper Phthalocynine

Blue

52.5

Xylene 2.5

Caustic Flake 2.5

TOTAL 57.5

ANNEXURE – II

LAYOUT OF THE PLANT

ANNEXURE –III

MANUFACTURING PROCESS

1) Copper Phthalocynine Blue

MANUFACTURING PROCESS AND FLOW DIAGRAM:

The manufacturing process can be broadly divided in to four parts. The various process steps

involved are as under.

1. Charging of reactant & Reaction:

Nitrobenzene is charged at room temperature to the glass -lined reactor. The temperature is

maintained at 120 o C to remove the moisture present in the Nitrobenzene mixture. Now 2-3

bags of urea are added, the reaction temperature falls to around 100o C Kg of phthalic

anhydride is slowly charged to the reactor and the temperature further falls to 89 -90o C. Now

remaining urea is added Ammonium Molybdate is then charged and 178 KG of cuprous chloride

(CU 2CL2) is then charged to the reactor. The temperature of the reactor is now maintained to

120 o C for 2 hours and then slowly it is increased up to 170o C at a temperature interval of 5 o

C per hour. The mass is maintained at 170o C for 6 hours then it is heated to 180 o C within

hours and then maintained at 180o C for 6 hours. At the end of the reaction CPC Slurry is

produced and Ammonia and Carbon dioxide gas is produced during the reaction. Heating is

provided using hy-therm fluid, which is circulated in the jacked heated by furnace oil, provides

the temperature in the reactor. Initially Nitrobenzene vapor of about 100 kgs are liberated

which is condensed using cooling water circulation in jacked and collected in the receiver. The

ammonia carbon dioxide gas goes to scrubber system. Ammonia gas is scrubbed using weak

solution of ammonia, which is continuously re -circulated from ammonia receiver tank counter

currently. The weak solution of ammonia is cooled in lead lined condenser before it is pumped

to the scrubber. The un –scrubbed ammonia vapour is charged to a receiver capacity of 3000

litters containing water before if is vented to air though the stack. This water containing very

less traces of dissolved ammonia is also sent to weak ammonia liquor storage tank usually once

in a month and sold as weak solution of ammonia. After 3 batched the concentrated ammonia

solution is sent of ammonia storage tank and sold as weak solution of ammonia (Containing

ammonium carbonate).

2. Solvent recovery:

The CPC slurry of temperature around 180 o C is taken to RVD (Rotary Vacuum Distillation Unit).

It is further heated to 210 o C using Thermic fluid hytherm oil circulation in the jacked. The unit

is operated at a vacuum of about 700 mmHg and hence the boiling point of nitrobenzene is

lowered to 115 o C and this nitrobenzene vapor is recovered in receiver, which is kept under

vacuum, using pump. Rotary vacuum Distillation unit is rotated at 16 rpm. It takes 7 -8 hours for

this process. The nitrobenzene about2030 kg is recovered. The crude dried product CPC blue

approximately 1230 kg containing about 70 kg Nitrobenzene and other impurities are charged

for further purification.

3. Purification – Acidic Treatment:

The crude CPC product, of about 1230 kg, is charged to an open wooden vat brick lined vessel.

It is charged manually, l after 500 KG of 98% sulphuric acid is charged. 1400 lit of reuse water

and live steam 300 kg. is charged to vessel to make a 10% solution add sulphuric acid. It is

stirred for 8 hours and temperature of 90 o C is maintained using lice steam.

4. Filtration & Washing :

The slurry material from purification vessel about (3430 kg .) is charged to filter press (1 nos.)

having 36 plates of size 3’ x 3’. The wet cake about 1260 kg. is then taken to alkali treatment

vessel. The filtrate about 4170 (1170 mother liquor + 300 0 washing) litters it sent to EPT

collection Tank,

5. Purification – Alkali Treatment:

The wet cake around 1260 kg. (Containing 900 kg product & 360 kg. moisture) is charged to

alkali treatment vessel. 100 kg. of sodium hydroxide flakes is charged to form a solution of 2.5%

sodium hydroxide, around 1400 Kg of reuse water is added and live steam 300 KG is charge to

achieve a temperature of about 80 -90o C for 7-8 hours.

6. Filtration & Washing:

The slurry material from purification vessel about (3060 kg.) is charged to filter press (1 Nos.)

having 36 pates of size 0.91 m x 0.91 m (3’ x 3’). The wet cake, of about 1250 kgs. Is then taken

for drying in rotary vacuum dryer. The filtrate about 4810 (1810 mother liquor + 3000 washing)

liters is sent to ETP collection tank.

7. Drying :

The wet cake, of about 1250 kg, (850 kg product + 400 kg moisture) is now charged to spin flash

dryer, which is heated by hytherm oil circulated in jacket. The material is charged from the top

manually and product is discharged from the bottom, the time for drying is about 2-3 hours.

8. Packing:

The dried product of about 850 kg. The material is packed into polyethylene (LDPE of HDPE)

bags in 25 Kgs or 500Kgs quantity per bag.

2

3

To

ATM

To

MEE

MATERIAL BALANCE

REACTOR

Nitro Benzene –2200

Phthalic Anhydride –990

Urea -1479

Cuprous Chloride –170.88

Ammonium Molybdate

– 2.50

Impurities – 38.12

Total : 4880.50

Carbon Dioxide – 882.96

Ammonia - 479.60

Nitrobenzene - 100.00

Total 1462.56

NITRO BENZENE

RECEIVER

Nitro Benzene–100

Total - 100

Carbon Dioxide - 882.96

Ammonia - 479.60

Total 1362.56

SCRUBBER CPC - 481.20

CPC-Cl - 510.05

Cuprous

Cloride - 5.33

Ammonium

Chloride - 44.73

Biuret&Impurities-

276.63

Nitro Benzene -2100.00

Total - 3417.94

Ammonium

Carbonate - 67.76

Ammonia – 420.00

Ammonium

Carbomate – 55.06

Water - 2987.30

Total - 3530.12

R.V.D.

Vapour - 2030

Total - 2030

Water – 3000

Total - 3000

Handling Loss

- 7.94

Total - 1.59

CPC - 991.25

Impurities- 326.69

Nitro Benzene-

70.00

1387.94

ACID

WASHING

Slurry – 3580.00

Total - 3580.00

Live Steam - 300

98% Sulfuric Acid

(OR Alpha Spent

Acid -4500)

- 500

Reuse H2O - 1400

Total 2200

FILTRATION

MEE Reuse water –

3000

Carbon Dioxide –820.84

Ammonia - 11.60

Total 832.44

WATER TANK Water - 150

Total - 150

Carbon Dioxide –

820.84

Ammonia – 1.60

Total 822.44

Ammonia – 10

Water - 150

Total - 160

AMMONIA

TANK

CPC - 18.00

Nitro Benzene – 50.0

Dissolved Impurities &

Salts - 694.00

Water - 4320.0

Total 5082.00

Water -3137.30

Ammonium

Carbonate -67.76

Ammonia - 430.0

Ammonium

Carbomate–55.06

Total -

3690.12

Send to

neutralization

tank

2

VACUUM NITRO

BENZENE RECEIVER

Nito benzene Vapour- 2030.00

NITRO BENZENE

CONDENSER

Vapour – 2030

VACUUM SEAL LINE

WATER TANK

Nitrobenzene Liquid

–2029.00

Total 405.8

Nitrobenzene Tank

Nitro benzene Liquid

– 2200

Nitro Benzene Liquid

– 1.00

Total 0.2

USED FOR

NEXT

BATCH

Nitro Benzene Make Up

70.0

Nitro Benzene –

100.00

4

To

MEE

CPC 966.00

Nitro Benzene 20.00

Impurities & Salts 32.00

Water 480.0

Total 1498.00

ALKALI WASHING

FILTRATION CPC - 16.00

Nitro Benzene - 5.00

Impurities & Salts –116.00

Water - 4780.0

Total - 4917.00 CPC -950.00

Nitrobenzene- 15.00

Impurities - 16.00

Water - 400.00

Total - 1381.00

SPIN FLASH DRYER

CPC - 950.00

Impurities - 31.00

Moisture - 40.0

Total

1021.00

PACKING

Water Vapour -

360.00

Total 360.00

Handling - 5.0

Losses

Product CPC –

1016.00

3

NaOH -100

CPC Slurry - 1400.00

Live steam -300.00

Total 1800.00

Chemical Reaction:

MATERIAL BALANCE

CPC – 1,000 Kg. CPC - H2SO4 Paste 8,000 Kg

H2SO4 – 7,000 Kg.

CPC H2SO4 Paste

8,000 Kg.

H2O 25,000 Kg.

Spent Sulphuric Acid

Wash Water 29,000 Kg. (13%-14%)

20,000 Kg. (Recycled to CPC-Blue)

Wet

Cake Wash Effluent 20,000 Kg.

4000 Kg.

Liquor – 40 Kg. Effluent 6,610 Kg.

Ammonia TLS (pH – 8.5)

70 Kg. (25-30%)

(Triloraal Sulphate)

MEE

Water 5,000 Kg.

Evaporation 1,500 Kg.

Dry Alpha Blue

Product – 1000 Kg.

Sulphonation

Dumping

(Drawning)

Filteration

Alkali Treatment

SPIN FLASH

DRYER

2) ALPHA BLUE :


Ball milled CPC blue is charged in glass limed kettle with 70% H2SO4 & agitated. The thick mss

formed is then transferred to MSRL vessel captaining cold water & maintained for 2 Hrs. Then

the slurry is filtered in filter press & washed with water until it is acid free.

Neutral wet cake is taken back to pigmentation vessel in presence of surfactant (TLS),

maintained for 2 Hrs. at 90OC, filtered, washed, dried, pulverized & packed final Alpha Blue

product.

MATERIAL BALANCE

Xylene

CPC – 1,000 Kg.

NaOH – 7,000 Kg.

Reflux for 4 hrs.

Xylene is recovered

HCl Or H2SO4

Washed with hot water

Dry cake for Packing

Sulphonation

Steam

Distillation

Agitation

MSRL Tank

Filter press

SPIN FLASH

DRYER

(3) BETA BLUE


Ball milled CPC Blue is charged in S.S. jacketed vessel with vertical column containing Sodium

Hydroxide solvent and xylene. Solvent vapor is refluxed for 4 Hrs. After 4 Hrs., xylene is

recovered by Steam Distillation. Agitated slurry is transferred to MSRL and is made acidic with

HCl or H2SO4 till pH becomes 2. Slurry is then filtered in filter press, washed with hot water. Wet

cake produced is dried, pulverized & packed.

ANNEXURE – IV

DETAILS OF WATER CONSUMPTION & WASTE WATER GENERATION

Existing:

Water Balance (KL/Day)

Sr. No. Section Water

Consumption

Waste Water

Generation

1 Process 12.8 12.8

2 Boiler + Cooling 1.2 0.2

3 Scrubber 3 --

Total Industrial 14.6 13.0

4 Domestic 1 0.8

5 Gardening 0.3 --

Total 15.9 13.8

Total after Proposed Expansion:

Water Balance (KL/Day)

Sr. No. Section Water

Consumption

Waste Water

Generation

1 Process 175 170

2 Boiler 10 1

3 Cooling 15 1

4 Washing 5 5

5 Scrubber 5 5

Total Industrial 210 182

6 Domestic 3 2.4

7 Gardening 2 --

Total 215 184.4

Water Balance (After Proposed Expansion):

Fresh Water (215 KL/Day)

Domestic (3 KL/Day) Industrial (210 KL/Day) Gardening (2 KL/Day)

Septic Tank/Soak

Pit (2.4 KL/Day)

Process (175 KL/Day) Washing

(5 KL/Day)

Boiler (10 KL/Day) Cooling (15KL/Day)

Effluent Treatment Plant – Primary

Treatment (182 KL/Day)

5

KL/Day

1KL/Day 1 KL/Day 5 KL/Day

Multiple Effective Evaporators

(Capacity: 100 KL/Day – 2 Nos.)

Scrubber (5 KL/Day)

170

KL/Day

MEE Salt to

nearest TSDF

Condensate (170 KL/Day)

Treated Effluent will be

reused in plant premises

Effluent Treatment Plant – Secondary &

Tertiary Treatment (170 KL/Day)

ANNEXURE – V

DETAILS OF EFFLUENT TREATMENT PLANT AND MEE

Proposed:

• 182 KL/Day effluents (low COD & High TDS) shall be collected in Collection Tanks. The

effluent is pumped to equalization cum Neutralization Tank, where the continuous addition

and stirring of ammonium carbonate/lime is done to maintain the pH of wastewater. Then

after, neutralized wastewater shall go to Flash Mixer (FM) by gravity. Alum shall be dosed

from Alum Dosing Tank (ADT) and Polyelectrolyte shall be added from Polyelectrolyte

Dosing Tank (PEDT) into FM to carry out coagulation by using a Flash Mixer mechanism.

Effluent from Flash Mixer shall go to Primary Clarifier (PCL) where the suspended solids are

allowed to settle down. Then after, effluent shall be evaporated in MEE and salt will be

separated out and condensate will be treated in aeration tank and then go to Secondary

Clarifier (SCL) where the suspended solids are allowed to settle down. And give tertiary

treatment. Then treated effluent will be reused in plant premises.

• 2.4 KL/Day Domestic wastewater will be treated in soak pit/septic tank.

Characteristics of Effluent:

Sr.No. Parameter Raw Effluent Treated Effluent

1 pH 3-10 6.5 to 8.5

2 TDS 135400 250

3 COD 5511 100

4 BOD 1210 30

5 Total Hardness (as CaCO3) 1850 30

6 Total Suspended Solid 5191 50

ETP Unit Size:

For Low COD & High TDS Stream

SR.NO Name of Unit Nos. of

Unit Size/Capacity

1 Equalization Tank 02 3.86 m X3.86 mX 3.2 m (95 m

3 )

2 Neutralization Tank 02 2.2 mX 2.2 mX 4.4 m (20 m

3)

3 Primary Clarifier 01 7.0 m X 5.0m (35 m3)

4 Multiple Effect Evaporator

02 100 KL/Day

5 Aeration Tank 02 5.4 mX 5.4 mX 3.0 m(87.48 m

3)

6 Secondary Clarifier 02 3m X 2.5m (17.66 m

3)

7 Storage Tank 02 100 m

3

8 Sludge drying beds 02 4.4 mX 4.25 mX 2.2 m (82.28 m

3)

9 Activated Carbon Filter 02 100 KL/Day

10 Sand Filter 02 100 KL/Day

Flow Diagram of ETP

Low COD &

High TDS

Effluent

Neutralization

Tank

Equalization

Tank

Primary

Clarifier

Secondary

Clarifier

MEE Solid Waste Solid Waste

Alum &

Polyelectrolyte Flocculation Tank

Activated

Carbon Filter

Aeration Tank

Sand Filter

Treated

effluent

will be

reused

ANNEXURE – VI

DETAILS OF SOLID & HAZARDOUS WASTE GENERATION AND DISPOSAL

Sr.

No. Name of waste Category

Existing

(MT/Mont

h)

Additional

(MT/Mon

th)

Total

(MT/Month)

Mode of Disposal

1 ETP Sludge

35.3 9 15 24 Collection, Storage,

Transportation and

Disposal to nearest

TSDF site

2 Residue from

Distillation

20.3 -- 10 10 Collection, Storage,

Transportation and co-

processing in cement

industries or dispose at

Common Incineration

Site

3

Discarded

Drum/container

33.3 15 # 18 # 33 # Collection, Storage,

Transportation and Sell

to GPCB authorized

Vendor

4

Used Oil 5.1 1.25 Lit. 2.25 Lit. 3.5 Lit. Collection, Storage,

Transportation and Sell

to GPCB registered re-

processor.

5

Process Waste 26.1 -- 20 20 Collection, Storage,

Transportation and co-

processing in cement

industries or dispose at

Common Incineration

Site

6 Ammonium

Sulphate

-- -- 450 450 Sell to end user

7 Spent

Ammonium

Carbonate

-- 75 -75 00

8 MEE Salt -- -- 60 60 Collection, Storage,

Transportation and

Disposal to nearest

TSDF site

ANNEXURE – VII

DETAILS OF STACK & VENT

Flue Gas Emission (Existing)

Sr.

No.

Source of

Emission

Type of

Emission

Stack

Height

(M)

Stack

Diameter

(M)

Pollution Control

Equipment

Fuel

Name

1 Boiler PM, SO2,

NOx

22 1.0 Dust Collector Fire Wood

2 Thermic

Fluid Heater

PM, SO2,

NOx

22 1.0 -- LDO/FO

3 DG Sets

(500 x 1

KVA)

PM, SO2,

NOx

12 0.1 -- LDO/FO

Process Emission (Existing)

Sr.

No.

Source of

Emission

Type of

Emission

Stack

Height

(M)

Stack

Diameter

(M)

Pollution Control

Equipment

Fuel Name

& Qty. /

Hr.

3 Process Vent HCl, SO2, Cl2 22 0.5 Packed column water

scrubber followed by

lead condenser acid

deeping vessel

NA

Total:

Flue Gas Emission

Sr.

No.

Source of

Emission

Type of

Emission

Stack

Height

(M)

Stack

Diameter

(M)

Pollution Control

Equipment

Fuel Name

1 Steam

Boiler: 4

MT/Hr

PM, SO2,

NOx

22 1.0 Multicyclone

separator + bag filter

Wood waste

or

Briquette/Coal

2 Thermic

Fluid

Heater: 8

Lakh

KCal/Hr

PM, SO2,

NOx

30 1.0 Multicyclone

separator + bag filter

+ scrubber

Coal

3 DG Sets

(500 x 4

PM, SO2,

NOx

12 0.1 -- LDO/FO

KVA)

Process Emission

Sr.

No.

Source of

Emission

Type of

Emission

Stack

Height

(M)

Stack

Diameter

(M)

Pollution Control

Equipment

Fuel Name

& Qty. /

Hr.

3 Process Vent

(Existing)

HCl, SO2, Cl2 22 0.5 Packed column water

scrubber followed by

lead condenser acid

deeping vessel

NA

ANNEXURE – VIII

DETAILS OF HAZARDOUS CHEMICALS STORAGE & HANDLING

Sr.

No

Name of

Hazardou

s

Quantity

Max.

that

Can be

Stored

(MT)

Places of its

Storage

(Storage

tank

/drums/cyli

nders/barre

ls)

No. of

Tank Operating

Pressure &

Temp.

Type of

Hazards

Possible (Fire,

explosive,

toxic release,

spillage etc.

Control measures

provided

1. Nitrobenz

ene

20 Tank 1 Atm.

Pressure &

Room

Temp.

Flammable • Flame proof plant, pumping

transfer, close process, etc.

• Double Static earthing

• Dyke Wall

• Tanker unloading procedure

• Jumper clips on flanges

• Fire Extinguishers

• Fencing and No Smoking and

prohibited area.

• Tanker unloading procedure.

• Flame arrestor provided on

vent line of the tank

• Hydrant system

2. Xylene 2 Drum 10

drum x

200 Kg

Atm.

Pressure &

Room

Temp.

Flammable

3. H2SO4 20 KL Tank 2 Atm.

Pressure &

Room

Temp.

Corrosive • Level guage provided

• Scrubber provided

• Required PPEs provided to all

employees

• Double drain valve will be

provided to sulphuric acid

storage tank

• Full body protection will be

provided to operator

• Caution note will be displayed

and train for the same to all

employees.

• Safety shower and eye wash

will be provided Total close

process will be adopted for

sulphuric acid handling.

• Dyke wall will be provided to

storage tank

ANNEXURE – IX

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

The manpower requirement for the proposed project is being expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to

some extent for the local population.

This phase is expected to create a beneficial impact on the local socio-economic environment.

2) INDUSTRIES

Required raw materials and skilled and unskilled laborers will be utilized maximum from the

local area. The increasing industrial activity will boost the commercial and economical status of

the locality, to some extent.

3) PUBLIC HEALTH

The company regularly examines, inspects and tests its emission from sources to make sure

that the emission is below the permissible limit. Hence, there will not be any significant change

in the status of sanitation and the community health of the area, as sufficient measures have

been taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the factory will be having proper linkage for the transport and communication, the

development of this project will not cause any additional impact.

In brief, as a result of the proposed there will be no adverse impact on sanitation,

communication and community health, as sufficient measures have been proposed to be taken

under the EMP. The proposed scenario is not expected to make any significant change in the

existing status of the socio - economic environment of this region.

ANNEXURE-X

______________________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1. Project Description

• Justification of project.

• Promoters and their back ground

• Project site location along with site map of 5 km area and site details providing various

industries, surface water bodies, forests etc.

• Project cost

• Project location and Plant layout.

• Water source and utilization including proposed water balance.

• List of Products & their capacity

• Details of manufacturing process of proposed products

• List of hazardous chemicals

• Mass balance of each product

2. Description of the Environment and Baseline Data Collection

• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5

km area.

• Other industries in the impact area

• Prevailing environment quality standards

• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project

site.

• Ground water quality at 5 locations within 5 km.

• Complete water balance

3. Socio Economic Data

• Existing socio-economic status, land use pattern and infrastructure facilities available in the

study area were surveyed.

4. Impacts Identification And Mitigatory Measures

• Identification of impacting activities from the proposed project during construction and

operational phase.

• Impact on air and mitigation measures including green belt

• Impact on water environment and mitigation measures

• Soil pollution source and mitigation measures

• Noise generation and control.

• Solid waste quantification and disposal.

• Control of fugitive emissions

5. Environmental Management Plan

• Details of pollution control measures

• Environment management team

• Proposed schedule for environmental monitoring including post project

6. Risk Assessment

• Objectives and methodology of risk assessment

• Details on storage facilities

• Process safety, transportation, fire fighting systems, safety features and emergency

capabilities to be adopted.

• Identification of hazards

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

Information for Control of Fugitive Emissions

Information on Rain Water Harvesting

Green Belt Development plan

Documents

PROPOSED EXPANSION OF PIGMENT …environmentclearance.nic.in/writereaddata/Online/TOR/18...FORM -I For PROPOSED EXPANSION OF PIGMENT MANUFACTURING IN EXISTING UNIT of M/s. UNITY ORGANICS