PREFEASIBILITY STUDY REPORT

Of

PROPOSED PROJECT

FOR

MANUFACTURING OF DYES AND PIGMENT

Introduced By

M/S. BLUETRON
PLOT NO. C1/373-374, Phase-II
G.I.D.C. ESTATE,
VATVA, AHMEDABAD

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 Contents
1 Executive Summary .............................................................................................................................. 3
1.1 Introduction................................................................................................................................... 3
1.2 Need of the Project........................................................................................................................ 4
2 PROJECT DESCRIPTION ................................................................................................................. 5
2.1 Location of the Proposed Project: ................................................................................................. 5
2.2 Product Details:............................................................................................................................. 6
2.3 Process technology (Manufacturing Process): .............................................................................. 7
2.4 Raw Material requirement .......................................................................................................... 37
2.5 Cost of Project............................................................................................................................. 39
2.6 Resources Requirements:............................................................................................................ 40
3 POLLUTION POTENTIAL AND MITIGATION MEASURE ..................................................... 41
3.1 Water Pollution: .......................................................................................................................... 41
3.2 Effluent Treatment Plant Detail .................................................................................................. 43
3.3 Air Emission: .............................................................................................................................. 44
3.4 Hazardous Waste Management:.................................................................................................. 47
3.5 Noise and Vibration Control:...................................................................................................... 48
3.6 Hazards and Safety Measures: .................................................................................................... 48
3.7 Good Housekeeping:................................................................................................................... 49
4 CONCLUSION................................................................................................................................... 50

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 Executive Summary
1.1 INTRODUCTION

M/s. BLUETRON, Plot no. C1/373-374, phase – II, GIDC Estate, Vatva, Ahmedabad involved in
manufacturing of Dyes since 1998 at this location. We have obtained Consolidated Consent &
Authorization from Gujarat Pollution Control Board vide order number AWH-65505 which is valid up to
25/05/2019. We have more than 17 years of experience in the field of manufacturing of dyes.

Now, looking to the market demand, the unit intends to expand their existing production by addition in
existing quantity as well as by introducing new products within premises. We have proposed Existing
Turquoise Blue product at capacity by 12 MT/Month to 250 MT/Month, and also we have intend Pigment
98 MT/Month and Reactive dye at capacity by 100 MT/Month. This unit will install additional machineries
within plant premises considering this expansion process. Since this expansion attracts applicability of EIA
notification and covered under Category 5(f) B, we are applying to obtain Environmental Clearance from
SEIAA, Gandhinagar for our proposed project.

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1.2 NEED OF THE PROJECT

 Demand and Supply Gap

We have more than 17 years of experience in the field of manufacturing of dye. Based on our informal
survey of the market with our current customers, we have found that there is a big potential for the product
we are planning.

 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials, unit will not have to import any raw materials as
they are produced locally. This will make us very competitive against imported finished products and it
will increase the scope of our finished product to all over the country.

 Export possibility
Depending on the international demand of products we will explore the possibility of exporting the
products.

 Employment Generation (Direct and Indirect) due to project

Unit will give direct employment to local people based on qualification and requirement. In addition to
direct employment, indirect employment shall generate ancillary business to some extent for the local
population.

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 PROJECT DESCRIPTION

2.1 LOCATION OF THE PROPOSED PROJECT:

Our company located at Plot No.: C1/373-374, Phase-II, GIDC Vatva Ahmedabad

Location: 22°57'24.9"N 72°38'04.1"E

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2.2 PRODUCT DETAILS:

Total
SR. Existing Proposed
PRODUCT NAME CI Name/CAS No. Proposed
NO MT/Month MT/Month
MT/Month
1. Reactive Turquoise Blue G Blue-21
2. Reactive Turquoise Blue H5G Blue-25
3. Reactive Turquoise Blue HA Blue-71
4. Reactive Turquoise Blue Blue -77
H2GP 12
5. Reactive Turquoise Blue Blue-38
Green 6B
6. Reactive Turquoise Blue Blue -72
238 250
PGR/PGL
7. Reactive Turquoise Blue Blue -140
MGN
8. Reactive Turquoise Blue BGF Blue-248
9. Direct Dyes Turquoise Blue Blue -86 NIL
(SBL)
10. Direct Dyes Turquoise Blue Blue-199
(FBL)
11. Pigment CPC Blue Pigment Blue 15:3 NIL 80 80
12. Pigment Alpha Blue Pigment Blue 15:0 NIL 13 13
13. Pigment Beta Blue Pigment Blue 15:3 NIL 5 5
14. Reactive Dyes (Crude)
 Reactive Black B Reactive Black 5 NIL 100 100
 Reactive Black WNN --
15. Spray Drier -- NIL 350 350

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2.3 PROCESS TECHNOLOGY (MANUFACTURING PROCESS):

2.3.1 Reactive Turquoise Blue G (21)

1. Sulphonation:
• Copper Phthalo cyanine is taken in a MS vessel and Chloro Sulphonic Acid are charged gradually.
• The temperature is maintained at 50ºc by chilled water circulation.
• Then the mass is stirred for 1 hour.

2. PCL3/TC Charging:
• The temperature of the mass is maintained at 100ºc for 1 hour through indirect steaming.
• Then the temperature is raised up to 128ºc and maintained for 3-3.5 hours.
• Then the mass is cooled to 70ºc by chilled water circulation and PCL3 was added.
• Then the material is heated up to 100ºc and the temperature is maintained for 2 hours.
• Then the mass is cooled up to 70ºc.

3. Dumping in ice.
• The slurry formed is charged into ice maintaining at 0ºc.

4. FILTRATION & WASHING:

• The dumped mass is filtered through press filter.
• Then mass is given chilled water washing using fresh water.

5. Condensation with VS:

• VS is taken in the condensation rector and a clear solution is made by the addition of soda ash and
water.
• Then ice is added to reduce the temperature up to 5ºc.
• Then filtered cake is added gradually.
• Then the pH is maintained at 6 by the addition of soda bi- carbonate & ammonia.
• Then the mass is stirred for 2 hours maintaining the above pH.

6. Then the mass is sending for spray drying.

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 Reactive Turquoise Blue 21 (G)

Mass Balance

Sr. Quantity Kg Sr. Quantity

Input Output
no. per MT No. Kg per MT
1 CPC 350 1 Reactive Turquoise Blue 21 1000
2 Phosphorus trichloride( 160 2 SO2 HCl sent to scrubber 225
PCl3)/ Thionle Chloride
(TC)
3 CSA 1290 3 Spent Acid 18% 4200
4 Ice 5400 4 Spent Acid 7% 2500
5 Water 2000 5 Spray Drying Loss 1870
6 Vinyl Sulphone 420
7 Sodium Bi Carbonate 400
Total 10020 Total 10020

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2.3.2 Reactive Turquoise Blue 25

1. Charging of CPC:
• Copper Phthalo cyanine is taken in a MS vessel and Chloro Sulphonic acid is charged gradually.
• The temperature is maintained at 40ºc by chilled water circulation.
• Then the mass is stirred for 1 hour.

2 Sulphonation:
• The temperature of the mass is maintained at 100ºc for 1 hour.
• Then the temperature is raised up to 120ºc and maintained for 3-3.5 hours.

3. PCL3 charging:
• The mass is cooled to 70ºc by chilled water circulation and PCL3 was added.
• Then the material is heated up to 100ºc & the temperature is maintained for 2 hours.

4. Dumping in ICE:
• The dumped mass is filtered through press filter. Mixed liquor is separated collected.
• Then mass is given chilled water washing using fresh water and ice.

5. Condensation:
• Betachloro is taken in the condensation reactor.
• Then add water and then ice to reduce the temperature up to 50c.
• Ammonia and sodium bi carbonate is added to maintain pH.
• Simultaneously rise temperatures up to 40º c.
• Then the mass is stirred for 2hours. Maintaining the above pH.

6. Isolation:
• Isolate the mass with HCl.

7. Spray Drying
• The solution produced is spray dried and packed.

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 Reactive Turquoise Blue 25

Mass Balance
Sr. Quantity Kg per Sr. Quantity Kg
Input Output
no. MT No. per MT
1 CPC 295 1 Reactive Turquoise Blue 25 1000
2 CSA 1235 2 SO2 HCl sent to scrubber 60
3 PCL3 160 3 Spent Acid 18% 5200
4 Ice 6500 4 Spent Acid 7% 2660
5 Water 1600 5 Spray Drying loss 1760
6 Beta Chloro 90
7 Liq NH3 440
8 HCl 300
9 Soda Ash 60
Total 10680 Total 10680

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2.3.3 Reactive Turquoise Blue 71

STAGE: 1
 Add 2000 Kg Chloro Sulphuric Acid (CSA)
 Add 500 Kg CPC
 Temperature 40 °C for 1 hr
 SO2, HCl gas sent to scrubber for HCl by product

STAGE: 2
 Material dumped in MSRL Vessel
 Add 6000 Kg Ice
 Add 3500 Kg Water

STAGE: 3
 Filtration
 Condensation With
 Add 300 Kg Ethylene Di Amine

STAGE: 4

 Neutralize with Caustic Soda

 Add 440 Kg caustic Soda
 Isolation with 300 Kg hydrochloric Acid (HCl)

STAGE: 6

 Add 600 Kg Wash Water for filtration

 Add 60 Kg Caustic Soda for Neutralization

STAGE: 7

 Spray Drying
 Final product Reactive Turquoise Blue 71 (HA) 1000 Kg

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 Reactive Turquoise Blue 71

Mass Balance

Sr. Quantity Kg per Sr. Quantity Kg

Input Output
no. MT No. per MT
1 CSA 2000 1 Reactive Turquoise Blue 71 1000
2 CPC 500 2 SO2 HCl sent to scrubber 60
3 Ice 6000 3 Spent Acid 18% 6000
4 Water 4100 4 Spent Acid 7% 5000
5 Ethylene Di amine 300 5 Spray Drying Loss 1640
6 Caustic Soda 500
7 HCl 300
Total 13700 Total 13700

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2.3.4 Reactive Turquoise Blue H2GP (77)

1. Sulphonation:
• Copper Phthalo cyanine is taken in a MS vessel and Chloro Sulphonic Acid are charged gradually.
• The temperature is maintained at 50ºc by chilled water circulation.
• Then the mass is stirred for 1 hour.

2. PCL3/ TC Charging:
• The temperature of the mass is maintained at 100ºc for 1 hour through indirect steaming.
• Then the temperature is raised up to 128ºc and maintained for 3-3.5 hours.
• Then the mass is cooled to 70ºc by chilled water circulation and PCL3 was added.
• Then the material is heated up to 100ºc and the temperature is maintained for 2 hours.
• Then the mass is cooled up to 70ºc.

3. Dumping in ice.
• The slurry formed is charged into ice maintaining at 0ºc.

4. FILTRATION & WASHING:

• The dumped mass is filtered through press filter.
• Then mass is given chilled water washing using fresh water.

5. Condensation with SBC:

• Sodium Bi carbonate is taken in the condensation rector and a clear solution is made by the addition of
soda ash and water.
• Then the pH is maintained at 6 by the addition of soda bi- carbonate
• Then the mass is stirred for 2 hours maintaining the above pH.

6. Then the mass is sending for spray drying.

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 Reactive Turquoise Blue H2GP

Mass Balance
Sr. Quantity Kg per Sr. Quantity Kg
Input Output
no. MT No. per MT
1 CPC 350 1 Reactive Turquoise Blue 1000
H2GP
2 PCL3/TC 160 2 SO2 HCl sent to scrubber 225
3 CSA 1290 3 Spent Acid 18% 4200
4 Ice 6000 4 Spent Acid 7% 2525
5 Water 2000 5 Spray Drying loss 2250
6 Sodium Bi 400
carbonate
Total 10200 Total 10200

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2.3.5 Reactive Turquoise Blue 38

1. Sulphonation:
• Nickel phthelocyanine is taken in a MS vessel and Chloro Sulphonic Acid are charged gradually.
• The temperature is maintained at 100ºc by chilled water circulation.
• Then the mass is stirred for 1 hour.

2. Dumping in ice.
• The slurry formed is charged into ice maintaining at 0ºc.

3. FILTRATION & WASHING:

• The dumped mass is filtered through press filter.
• Then mass is given chilled water washing using fresh water.

4. Condensation with VS:

• VS is taken in the condensation rector and a clear solution is made by the addition of soda ash and
water.
• Then ice is added to reduce the temperature up to 5ºc.
• Then filtered cake is added gradually.
• Then the pH is maintained at 6 by the addition of soda bi- carbonate.
• Then the mass is stirred for 2 hours maintaining the above pH.

6. Then the mass is sending for spray drying.

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 Reactive Turquoise Blue 38

Mass Balance
Sr. Quantity Kg Sr. Quantity
Input Output
no. per MT No. Kg per MT
1 NIPC 400 1 Reactive Turquoise Blue 38 1000
2 CSA 2000 2 SO2 HCl sent to scrubber 225
3 Ice 5700 3 Spent Acid 18% 4600
4 Water 2500 4 Spent Acid 7% 3725
5 Vinyl Sulphone 420 5 Spray Drying Loss 1870
6 Sodium Bi Carbonate 400

Total 11420 Total 11420

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2.3.6 Reactive Turquoise Blue 72 (PGR)

STAGE: 1
 Add 500 Kg Copper Phthalocyanine (CPC)
 Add 2000 Kg Chloro Sulphuric Acid (CSA)
 Add 160 Kg Phosphorus trichloride (PCl3)
 Temperature 40 °C for 1 hr
 PCl3 charging 100 °C temperature maintain for 3 to 3.5 hr
 SO2, HCl gas sent to scrubber for HCl by product

STAGE: 2
 Material dumped in MSRL Vessel
 Add 6000 Kg Ice
 Add 550 Cyanuric Chloride

STAGE: 3
 Add 2000 Kg Water in filtration

SATGE: 4
 Condensation with
 Add 300 kg MPDSA
 Add 200 Kg Ice

STAGE: 5

 Neutralize with Sodium bi sulfate

 Add 200 Kg SBC Sodium Bi Carbonate
 Add 400 Kg Liq. Ammonia

STAGE: 6

 Spray Drying
 Final product Reactive Turquoise Blue PGR 1000 Kg

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 Reactive Turquoise Blue 72 (PGR)

Mass Balance
Sr. Quantity Kg Sr. Quantity Kg per
Input Output
no. per MT No. MT
1 CPC 500 1 Reactive Turquoise 1000
Blue 72
2 CSA 2000 2 SO2 HCl sent to 225
scrubber
3 PCI3 160 3 Spent Acid 18% 6000
4 Ice 6200 4 Spent Acid 7% 4160
5 Water 2000 5 Spray Drying loss 575
6 MPDSA 300
7 Sodium Bi carbonate 200
8 Liq. Ammonia 400
Total 12310 Total 12310

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2.3.7 Reactive Turquoise Blue MGN (Blue 140)

STAGE: 1
 Add 2000 Kg Chloro Sulphuric Acid (CSA)
 Add 500 Kg CPC
 Temperature 40 °C for 1 hr
 SO2, HCl gas sent to scrubber for HCl by product

STAGE: 2
 Material dumped in MSRL Vessel
 Add 6000 Kg Ice
 Add 3500 Kg Water

STAGE: 3
 Filtration
 Condensation With
 Add 300 Kg Ethylene Di Amine

STAGE: 4

 Neutralize with Caustic Soda

 Add 440 Kg caustic Soda
 Isolation with 300 Kg hydrochloric Acid (HCl)

STAGE: 6

 Add 600 Kg Wash Water for filtration

 Add 60 Kg Caustic Soda for Neutralization
 Add 400 Kg VS (Vinyl Sulphone)
 Add 200 Kg Sodium Bi carbonate for take PH

STAGE: 7

 Spray Drying
 Final product Reactive Turquoise Blue MGN (140) 1000 Kg

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 Reactive Turquoise Blue MGN (140)

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 CSA 2000 1 Reactive Turquoise Blue 71 1000
2 CPC 500 2 SO2 HCl sent to scrubber 60
3 Ice 6000 3 Spent Acid 18% 6000
4 Water 4100 4 Spent Acid 7% 5000
5 Ethylene Di amine 300 5 Spray Drying Loss 2240
6 Caustic Soda 500
7 HCl 300
8 VS 400
9 Sodium BI carbonate 200
Total 14300 Total 14300

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2.3.8 Reactive Turquoise Blue BGF (Blue 248)
STAGE: 1
 Add 500 Kg Copper Phthalocyanine (CPC)
 Add 2000 Kg Chloro Sulphuric Acid (CSA)
 Add 160 Kg Phosphorus trichloride (PCl3)
 Temperature 40 °C for 1 hr
 PCl3 charging 100 °C temperature maintain for 3 to 3.5 hr
 SO2, HCl gas sent to scrubber for HCl by product

STAGE: 2
 Material dumped in MSRL Vessel
 Add 6000 Kg Ice
 Add 550 Cyanuric Chloride

STAGE: 3
 Add 2000 Kg Water in filtration

SATGE: 4
 Condensation with
 Add 300 kg MPDSA
 Add 200 Kg Ice

STAGE: 5

 Neutralize with Sodium bi sulfate

 Add 200 Kg SBC Sodium Bi Carbonate
 Add 400 Kg Liq. Ammonia
 Add 400 kg VS (Vinyl Sulphone)
 Add 200 KG Sodium Bi carbonate for take PH

STAGE: 6

 Spray Drying
 Final product Reactive Turquoise Blue BGF (Blue 248) 1000 Kg

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 Reactive Turquoise Blue BGF (Blue 248)

Mass Balance
Sr. Quantity Kg Sr. Quantity Kg per
Input Output
no. per MT No. MT
1 CPC 500 1 Reactive Turquoise 1000
Blue 72
2 CSA 2000 2 SO2 HCl sent to 225
scrubber
3 PCI3 160 3 Spent Acid 18% 6000
4 Ice 6200 4 Spent Acid 7% 4160
5 Water 2000 5 Spray Drying loss 575
6 MPDSA 300
7 Sodium Bi carbonate 400
8 Liq. Ammonia 400
9 VS 400
Total 12910 Total 12910

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2.3.9 Direct Blue 86

STAGE: 1
 Add 500 Kg CPC Copper Phthalocyanine
 Add 2750 Kg Oleum
 Temperature 80 °C for 6 hr
 SO2, HCl gas sent to scrubber for HCl by product

STAGE: 2
 Material dumped in MSRL Vessel
 Add 5000 Kg Ice

STAGE: 3
 Add 2500 Kg Water in filtration

SATGE: 4
 Neutralize with caustic flakes/Soda
 Add 375 Kg caustic Soda/flakes

STAGE: 5

 Spray Drying
 Final product Direct Turquoise Blue -86 1000 Kg

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 Direct Blue 86

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg per

Input Output
no. per MT No. MT
1 CPC 500 1 Direct Blue 86 1000
2 Oleum 2750 2 SO2 HCl sent to 187
scrubber
3 Ice 5000 3 Spent Acid 18% 5331
4 Water 2500 4 Spent Acid 7% 3087
5 Caustic soda/flex 375 5 Spray Drying loss 1520
Total 11125 Total 11125

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2.3.10 Direct Blue 199 (FBL)

1. Charging of Copper Phthalo Cyanine:

• Chloro Sulphonic Acid & PCl3 is taken in a MS vessel and CPC are charged gradually.
• The temperature is maintained at 40ºc by chilled water circulation. Then the mass is stirred for
1hour.

2. Sulphonation:
• The temperature of the mass is maintained at 100ºc for 1 hour.
• Then the temperature is raised up to 115ºc and maintained for 1.5 hours.
• Gradually temperature of the mass is raised up to 122ºc and maintained for 2.5 hours.
• This mass is then cooled down to 50ºc.

3. Dumping in ICE:
• The slurry formed is charged into ice maintaining the temperature at 0ºc.

4. Filtration & Washing:

• The dumped mass is filtered through Filter through Filter Press. ML is collected.
• Then mass is given chilled water washing using fresh water and ICE.

5. Condensation:
• Take water in condensation reactor.
• Add ice in this vessel.
• Maintain Ph to 8 to 8.5 by addition of Ammonia. Maintain this pH for 12 hour.
• Increase temperature gradually up to 40ºc.

6. Spray Drying:
• The solution produced is spray dried and packed.

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 Direct Blue 199 (FBL)

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 CPC 588 1 Direct Blue 199 1000
2 PCI3 106 2 SO2 HCl sent to 353
scrubber
3 CSA 2353 3 Spent Acid 18% 6500
4 Ice 10142 4 Spent Acid 7% 5700
5 Water 2353 5 Spray Drying loss 2800
6 Liq.NH3 541
Total 16353 Total 16353

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2.3.11 Pigment CPC Blue

Stage: 1
• Charge Di Chloro Toluene in Glass lined reactor.
• Then add Urea, Phthalic Anhydride, Cuprous Chloride and Ammonium Molyblate to it.
• Raise the temperature up to 180 °C.
• During decomposition of urea ammonia gas as well as carbon dioxide gas is produced. We are
controlling it by providing two stage water scrubber and then after acid scrubber. From the water
scrubber we can obtain ammonium Carbamate as a by product.
• After maintaining sufficient time dump the batch in M.S.Ventulator for vacuum distillation of
solvent.
• By that 95 % of the solvent will be recovered. And transfer the remaining crude in Drawning
vessel containing water.
Stage: 2
• Take above heated crude material into dumping vessel with spent Sulphuric acid (mother liquor
from Alpha Blue).
• Then start heating up to 95 °C and maintain for three hours.
• Then filter in filter press, wash, neutralize, dry and pack the final product as a CPC Blue.
• After filtration process whatever mother liquor will be generated that contains 12-15 % of
Sulphuric Acid. We will treat it into our adequate ETP to become neutral. Then after we will
discharge it into CETP, Vatva.

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 Pigment CPC Blue

Mass Balance

Sr. Quantity Sr. Quantity Kg

Input Output
no. Kg per MT No. per MT
1 Phthalic Anhydride 1075 1 Pigment CPC Blue 1000
2 Ammonium Carbonate 1200 2 Solvent recover 2180
3 Solvent 2200 3 Spent Acid 2500
4 Technical Grade Urea 1400 4 Effluent send to ETP 5000
5 Cuprous Chloride 195 5 Evaporation loss 2173
6 Ammonium Molyblate 3 6 Solvent Loss 20
7 Spent Acid From Alpha Blue 2000 7 NH3 + CO2 1000
(25-30%)
8 Washing Water 6000
9 Water used in Ammonium 500
carbonate
Total 13473 Total 13473

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2.3.12 Pigment Alpha Blue

Stage: 1 (ACID PROCESS)

 Take Sulphuric acid (70 %) in a reaction vessel. Then slowly charge Copper Phthalocyanine slowly
from ball mil.
 Maintaining temperature just below 85 °C so as to dissolve it to completely.
 The mass is transferred to Drawning vessel stirred further for 2-3 hrs at 60 °C and then cooled to
room temperature.
 The CPC separate out in the required form and is filtered off.
 After filtration process whatever mother liquor generated that contains approximate 25-30 % of
Sulphuric acid. We are using that liquor (H2SO4) into the manufacture of CPC Blue. And Filtrate
effluent reuse in next batch alpha blue product

Stage: 2 (PIGMENT PROCESS)

 The CPC cake is charged in another vessel and washed with water and stirred with fresh water.
 The aqueous slurry is neutralized to pH 8 to 8.5 using caustic lye and stirred with emulsifier agent
at 60° C–90°C for 02 hours.
 The above slurry is filtered and the cake is washed with large amount of fresh water.
 The wet cake is dried to obtain Alpha Blue 15.
 The aqueous filtrate goes to ETP. Then after it is discharge it into CETP, Vatva.

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 Pigment Alpha Blue

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg per

Input Output
no. per MT No. MT
1 CPC Crude 1050 1 Pigment Alpha Blue 1000
2 Suphuric Acid (70%) 5000 2 Spent Dilute H2SO4 13000
3 Reuse Water From Filter 5000 3 Effluent Reuse 5000
4 Fresh Water 30000 4 Effluent to ETP 20000
5 Emulsifier 5 5 Evaporation Loss 2085
6 Caustic Flakes 30

Total 41085 Total 41085

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2.3.13 Pigment Beta Blue

Beta Blue is manufactured in two stages.

Stage 1: Milling
Stage 2: Pigmentation.

Milling:
Charge CPC (98 %) in ball mill of capacity 10,000 Liter. Mill the contents for 24 hrs. After grinding
discharge the milled blue for stage II (Pigmentation)

Pigmentation:
• Charge above milled blue into MS vessel, contains caustic water, surfactants and solvent. Reflux
whole mass under stirring for 02 hrs.
• Then recover the solvent. Filter the pigmented mass through filter press; wash with water till neutral
pH. Dry the pressed cake in spin flash dryer at the rate of 150 Kg/Hr.

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 Pigment Beta Blue

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 CPC 1050 1 Pigment Beta Blue 1000
2 Caustic 160 2 Solvent Recover Reuse 3465
in next Batch
3 Water 10000 3 Solvent Loss 35
4 Butyl alcohol(Reuse) 3465 4 Effluent 28400
5 Butyl alcohol(Fresh) 35 5 Organic and inorganic 210
material
6 Washing 20000 6 Moisture Loss 1600
TOTAL 34710 TOTAL 34710

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2.3.14 Reactive Black 5

STAGE: 1
 Add 385 Kg VS in tank 1
 Add 240 Kg HCl
 Add 100 Kg NaNO2
 Add 1900 Kg Ice
 Add 1100 Kg water

STAGE: 2
 Add 205 Kg H Acid
 Add 300 kg Soda Ash
 Add 780 Kg Water
 Add 1000 Ice

SATGE: 4
 Spray Drying
 Total product 1000 Kg

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 Reactive Black 5

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 Vinyl sulphone 385 1 Reactive Black 5 1000
2 HCl 240 2 Spray Drying loss 5010
3 Sodium Nitrite 100
4 H Acid 205
5 Soda Ash 300
6 Water 1880
7 Ice 2900
Total 6010 Total 6010

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2.3.15 Reactive Black WNN

STAGE: 1
 Add 16 Kg sulfo para V.S. in tank 1
 Add 100 Kg HCl
 Add 22 Kg NaNO2
 Add 600 Kg Ice
 Add 348 Kg water

STAGE: 2
 Add 77 Kg J-Acid
 Add 61 Kg MPDSA
 Add 212 Kg V.S. diazo
 Add 27 Kg sodium nitrite
 Add 217 Kg sodium bicarbonate
 Add 132 Kg SPVS diazo
 Add 800 Kg Ice
 Add 200 Kg Water

STAGE: 3
 Add 320 Kg reactive black B
 Add 38 Kg salt

STAGE: 4
 Spray Drying
 Total product 1000 Kg

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 Reactive Black WNN

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 Sodium Nitrite 49 1 Reactive Black WNN 1000
2 Sodium Bi Carbonate 217 2 Spray Drying loss 2170
3 J acid 77
4 Sulfo pera VS 16
5 MPDSA 61
6 SPVS 132
7 VS 212
8 Reactive Black B 320
9 HCl 100
10 Salt 38
11 Water 548
12 Ice 1400
Total 3170 Total 3170

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2.4 RAW MATERIAL REQUIREMENT
We will propose Reactive turquoise Dyes 12 MT/Month to 250 MT/month and we have intend proposed
Pigment manufacture activity by 98 MT/Month and reactive Black dye capacity at 100 MT/Month also we
have intend 350 MT/Month spray drier. The propose quantity of raw material in each type of product in
1000 KG batch is listed as below.

Sr No. Name of the Product Raw Material Per MT

CPC 350
Phosphorus trichloride( PCl3)/ 160
Thionle Chloride (TC)
Reactive Turquoise CSA 1290
1.
Blue G (21) Ice 5400
Water 2000
Vinyl Sulphone 420
Sodium Bi Carbonate 400
CPC 295
CSA 1235
PCL3 160
Ice 6500
Reactive Turquoise
2. Water 1600
Blue 25
Beta Chloro 90
Liq NH3 440
HCl 300
Soda Ash 60
CSA 2000
CPC 500
Ice 6000
Reactive Turquoise
3. Water 4100
Blue 71
Ethylene Di amine 300
Caustic Soda 500
HCl 300
CPC 350
PCL3/TC 160
Reactive Turquoise CSA 1290
4.
Blue H2GP Ice 6000
Water 2000
Sodium Bi carbonate 400
NIPC 400
CSA 2000
Reactive Turquoise Ice 5700
5.
Blue 38 Water 2500
Vinyl Sulphone 420
Sodium Bi Carbonate 400

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 CSA 2000
CPC 500
Ice 6000
Water 4100
Reactive Turquoise
6. Ethylene Di amine 300
Blue 140
Caustic Soda 500
HCl 300
VS 400
Sodium BI carbonate 200
CPC 500
CSA 2000
PCI3 160
Ice 6200
Reactive Turquoise
7. Water 2000
Blue 248
MPDSA 300
Sodium Bi carbonate 400
Liq. Ammonia 400
VS 400
CPC 500
CSA 2000
PCI3 160
Reactive Turquoise Ice 6200
8.
Blue 72 Water 2000
MPDSA 300
Sodium Bi carbonate 200
Liq. Ammonia 400
CPC 500
Oleum 2750
9. Direct Blue 86 Ice 5000
Water 2500
Caustic soda 375
CPC 588
PCI3 106
CSA 2353
10. Direct Blue 199
Ice 10142
Water 2353
Liq.NH3 541
Phthalic Anhydride 1075
Ammonium Carbonate 1200
Solvent 2200
11. Pigment CPC Blue
Technical Grade Urea 1400
Cuprous Chloride 195
Ammonium Molyblate 3

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 Spent Acid From Alpha Blue 2000
(25-30%)
Washing Water 6000
Water for Ammonia carbonate 500
CPC Crude 1050
Suphuric Acid (70%) 5000
Reuse Water From Filter 5000
12. Pigment Alpha Blue
Fresh Water 30000
Emulsifier 5
Caustic Flakes 30
CPC 1050
Caustic 160
Water 10000
13. Pigment Beta Blue
Butyl alcohol(Reuse) 3465
Butyl alcohol(Fresh) 35
Washing 20000
Vinyl sulphone 385
HCl 240
Sodium Nitrite 100
14. Reactive Black 5 H Acid 205
Soda Ash 300
Water 1880
Ice 2900
Sodium Nitrite 49
Sodium Bi Carbonate 217
J acid 77
Sulfo pera VS 16
MPDSA 61
SPVS 132
15. Reactive Black WNN
VS 212
Reactive Black B 320
HCl 100
Salt 38
Water 548
Ice 1400

2.5 COST OF PROJECT

The approx. cost of the proposed project will be 6.5 cr. The details of the cost of the project is given here:
Land & Building 2.5 Cr.
Plant & Machinery 4.0 Cr.

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2.6 RESOURCES REQUIREMENTS:
As the proposed project will be required resource for production. The details of their sources given
hereunder,

Land: The proposed project is in exiting unit area 1408 sq. m. located at Ahmedabad hence there will be
no additional land is required for this proposed expansion.

Water: The total fresh water requirement for various activities like industrial, domestic and gardening will
105.55 KLD after this proposed expansion including Industrial process, utilities, domestic and gardening
from which 5.0 KLD fresh water will be utilized as Domestic and remaining 100.55 KLD in which 2.6
KLD will be Reuse from Process Waste water and remaining 97.95 KLD water will be received from GIDC.

Power: Total power requirement for the after proposed project will be 450 KWA. Power demand will
satisfied by Torrent Power Ltd., Ahmedabad.

Fuel: At present we are utilizing LDO 0.01 KL/hr and fire Wood 0.5 MT/hr as fuel in existing boiler and
spray Dryer. We have Addition 4900 SCM/Day as fuel in proposed Spray Dryer and Boiler we have also
proposed HSD 30 liter/hr as a fuel in D.G. Set (150 KVA)for emergency power supply.

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 POLLUTION POTENTIAL AND MITIGATION
MEASURE

3.1 WATER POLLUTION:

The water requirements for the after expansion project will be 105.55 KLD from which 5.0 KLD
fresh water will be utilized as Domestic and remaining 100.55 KLD in which 2.6 KLD will be
Reuse from Process Waste water and remaining 97.95 KLD water will be received from GIDC.

EXISTING WATER CONSUMPTION & WASTE WATER GENERATION DETAILS

Water Waste Water
Sr No Category
Consumption Generation
1. Domestic Purpose 5.0 4.0
INDUSTRIAL
Process 11.00 5.0
2. Washing 5.0 4.8
Boiler 3.0 0.0
Cooling 1.0 0.2
Total water Consumption & Generation
5.0 4.0
( Domestic)
Total water Consumption & generation
20.0 10.0
(Industrial )

TOTAL PROPOSED WATER CONSUMPTION & WASTE WATER GENERATION DETAILS

Water Waste Water

Sr No Category
Consumption Generation
1. Domestic Purpose 5.0 4.0
INDUSTRIAL
Process water 84.00 43.08
Washing 5.0 4.8
2.
Boiler 6.0 0.6
Cooling 2.0 0.4
Scrubber 3.55 5.5*
Total water Consumption & Generation
5.0 4.0
(Domestic)
Total water Consumption & generation
100.55 48.88
(Industrial)
Note: 5.5* KLD Scrubber Spent HCl Send to Authorized Agencies

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 Water Balance Diagram

Total Water consumption

105.55 KLD

Industrial Domestic
100.55 KLD 5.00 KLD

Process Boiler Washing Cooling Scrubber Sewage

84.00 KLD 4 KLD 5 KLD 2 KLD 3.55 KLD 4.0 KLD

spent acid sell to

Spent Acid generation Effluent Blow Down Washing Blow Down
Athorized
from process 43.08 0.2 KLD 4.8 KLD 0.4 KLD Agencies
**86.76 KLD *5.5 KLD

Spent Acid Reuse spent acid sell to effluent reuse in alph

in CPC Athorized blue (filteration) Low COD waste
Agencies Water 5.8 KLD
6.4 KLD 2.6 KLD
80.36 KLD 46.28 KLD

Send to CETP Send to inhouse send to Common

spray Dryer spary dryer
10 KLD 16.28 KLD
20.00 KLD

Note:-
*5.5 KLD Spent HCl Acid Send to Authorized Agencies
**86.36 KLD Spent Sulphuric Acid Send to Authorized Agencies

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Note: There will no change in existing sewage generation and its mode of disposal. The generated sewage
will be disposed through soak pit/septic tank.

The total industrial wastewater generation from Manufacturing process and other ancillary process will be
48.88 KLD. From the total wastewater generation, 2.6 KLD will be reused in alpha blue product filtration
and the remaining 10 KLD primary treated waste water will be sent to CETP for further treatment. From
the remaining 36.28 KLD of wastewater, 20.00 KLD will be disposed through in house Spray Dryer and
16.28 KLD Send to Common Spray Dryer for the Evaporation. The unit is having CC&A to discharge
10.00 KLD wastewater to CETP Vatva.

The total spent Sulphuric acid generation from manufacturing process will be 109.3 KLD from which 6.4
KLD spent acid reuse in CPC process. The remaining 102.9 KLD Spent Acid sell to Authorized agencies
or actual users which are having permission under Rule 9. The spent HCL generation will be 5.4 KLD
which disposed by selling to Authorized agencies or actual users which are having permission under Rule
9.

3.2 EFFLUENT TREATMENT PLANT DETAIL

Sr. Name of Unit Capacity

No.
1 Collection Tank 2 Nos. 6 m3 and 10m3
2 Neutralization Tank 10 m3
3 Settling Tank 25 m3 and 10 m3
4 Holding Sump 7.5 m3 and 10 m3
5 C.E.T.P Overhead Tank 30 m3
6 Sludge Drying Bed 1.5×1.5 (4 Nos.)

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  CPC plant effluent treatment plant

Collection Neutralization primary Settling

Aeration Tank Discharge
tank Tank Tank

Sr. Name of Unit Capacity

No.
1 Collection tank 12 m3
2 Neutralization Tank 10 m3
3 Primary Settling Tank 12 m3
4 Aeration Tank 10 m3

3.3 AIR EMISSION:

We will use LDO 0.01 KL/hr and Fire Wood or Agro waste 0.5 MT/hr as fuel in Existing Boiler and Hot
air generator. Adequate stack height of 12.00 m from ground level will be provided for Boiler.

 Flue gas Emission data

Stack
Sr.
Stack attached to height in Fuel Consumption APCM Remark
no
meter
Small Industrial
1. 12.00 LDO 0.01 KL/hr Cyclone
Boiler (800kg)
Separator
2. Hot Air generator-1 20.00
Existing
Fire Wood Cyclone followed
Spray Dryer (600 0.5 MT/hr
3. 12.00 /Agro Waste by Ventury
LPH)
Scrubber
Spray Dryer (1500 2500
4 12.00 PNG NA
LPH) SCM/Day
1500
5 Hot Air Generator-2 20.00 PNG NA
SCM/Day Proposed
Thermic fluid
6 11.00 PNG 900 SCM/Day NA
heater(TFH)
7 D.G Set (250 KVA) 11.00 HSD 30 Liter/hr. NA

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  Process Gas Emission Data
Stack Final
Sr Stack
height in APCM Pollutant Concentration of Remark
no attached to
meter Pollutant
Chloro
Three Stage
Sulphonation HCL <20 mg/Nm3
1. 18.00 Packed Column HCl & SO2 Existing
Reactor (4 SO2 <40 mg/Nm3
Scrubber
Nos.)
Bag filter +
Spin Flash PM< 150 Mg/Nm3
2. 11.00 Cyclone PM & SO2 Proposed
Dryer (SFD) SO2<150 Mg/Nm3
Separator
Two stage water
Reaction
3. 11.00 scrubber with NH3 < 175 mg/Nm3 Proposed
Vessel
Acid Scrubber
Two stage water
Reaction
4. 11.00 scrubber with NH3 < 175 mg/Nm3 Proposed
Vessel
Acid Scrubber
Two stage water
Reaction
5. 11.00 scrubber with NH3 < 175 mg/Nm3 Proposed
Vessel
Acid Scrubber
Two stage water
Reaction
6. 11.00 scrubber with NH3 < 175 mg/Nm3 Proposed
Vessel
Acid Scrubber

Fuel Requirement
Sr
Name of Fuel Existing Proposed Total
no
1 LDO 0.01 KL/hr. NIL 0.01 KL/hr.
Fire Wood /Agro
2 0.5 MT/hr. NIL 0.5 MT/Hr.
waste
3 HSD NIL 30 liter/hr. 30 liter/hr.
4 PNG NIL 4900 SCM/Day 4900 SCM/Day

There will be a chance of fugitive emission from the manufacturing process as well as due to storage &
handling of raw materials and products. The unit will take following adequate precautions for the control
of fugitive emission;
 The entire manufacturing activities will be carried out in the closed reactors and regular checking and
maintenance of reactors will be carried out to avoid any leakages.
 Replacing the low pressure mixing head with high pressure system will eliminate emission of VOCs.
 The tank vents will be equipped with either a carbon filter or an oil trap to prevent water vapor from
entering the tank as it breathes.

P a g e 45 | 50
 All the motors of pumps for the handling of hazardous chemicals will be flame proof and provided with
suitable mechanical seal with stand-by arrangement.
 Control of all parameters on a continuous basis will be done by adequate control valves, pressure release
valves and safety valves etc.
 All the flange joints of the pipe lines will be covered with flange guards.
 All the raw materials will be stored in isolated storage area and containers tightly closed.
 There will also be provision of adequate ventilation system in process plant and hazardous chemical
storage area.
 A regular preventive maintenance will be planned to replace or rectify all gaskets, joints etc.
 The unit will also develop green belt within the factory premises to control the fugitive emission from
spreading into surrounding environment.

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3.4 HAZARDOUS WASTE MANAGEMENT:

Types of
Sr.
Hazardous Category Existing Propose Ultimate Disposal
No
Waste
Collection, storage,
20 40 60
1 ETP Sludge 35.3 Transportation and Dispose
MT/Month MT/Month MT/Month
to Active TSDF Site

0.010 0.010 0.020 Collection, storage, Reuse

2 Used Oil 5.1
KL/year KL/year KL/year within premises.
Discarded 3 4 7
Container MT/Month MT/Month MT/Month Collection, storage,
Liners / 2400 6000 8400 Transportation and Dispose
3 33.1
Bags Nos./Month Nos./Month Nos./Month by selling to Registered
500 500 Recycler
carboys --
Nos./Month Nos./Month
Collection, Storage,
Spent
150 1859 2009 Transportation & sell to
4 Sulphuric 26.3
MT/month MT/Month MT/Month (Rule -9) authorized
Acid
agencies or actual users
80 MT/Month will be utilize
in CPC production and
remaining 80 MT/Month
Ammonium 160 160 Ammonium Carbonate will
5 26.1 NIL
Carbonate MT/month MT/Month be utilized in mfg. of
Ammonium sulfate or will
be Send to Actual User
(rule-9)
Collection, Storage,
Spent HCl 110 110 Transportation & sell to
6 26.3 NIL
acid MT/Month MT/Month (Rule -9) authorized
agencies or actual users

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3.5 NOISE AND VIBRATION CONTROL:
The following adequate precautions will be taken for control of noise & vibration;
 The unit will install latest technology based low noise DG Set with acoustic enclosures.
 Proper and timely oiling, lubrication and preventive maintenance will be carried out for the
machineries and equipment to reduce noise generation.
 The noise generation will be mitigated by installing noise barriers/absorbers around stationery noise
sources. Adequate noise control measures such as anti-vibration pad for equipment with high
vibration will be provided.
 All the vibrating parts will be checked periodically and serviced to reduce the noise generation.
The equipment, which generates excessive noise, will be provided with enclosures etc.
 To minimize the adverse effect on the health, ear muffs / earplugs will be provided to the working
under high noise area.

3.6 HAZARDS AND SAFETY MEASURES:

 All the personnel at the plant will be made aware about the operation hazards and risk associated
with them.
 Safe work practices will be adopted to ensure the control of hazards during operation and
maintenance.
 The workers will be made aware about the hazards associated with manual handling and operation.
 Safety measures in the form of ‘DO’ and ‘Don’t Do’ will be displayed at strategic locations
especially in local language.
 Good housekeeping will be maintained in the Mining area.
 The required PPEs for each area/operation should be identified and the necessary PPEs, like,
helmets, goggles, hand gloves, mask, suit, safety belts, ear muff and plug, etc. will be provided to
the personnel.
 The plant will check and ensure that all instruments provided in the plant are in good condition and
documented.
 First Aid box will be provided within the plant.
 List of important telephone numbers will be displayed at prominent location in the plant. Lease
Holder Machine Operator Helper/ Labor.
 All the accidents and incidents if any will be recorded, investigated and analyzed in the proposed
plant.
 Safety awareness programs and trainings of the worker will be carried out to motivate the workers
to increase the safety level at personal level.

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3.7 GOOD HOUSEKEEPING:

The term Good Housekeeping is often loosely understood as simple floor cleaning or broom
Stick operation. But it has even wider meaning including up keeping of all industrial activities in orderly
manner to minimize the accidents due to improper planning, placement, arrangement, handling, etc.
everywhere in industrial premises. “Place for everything and everything on proper place”. So, Good
housekeeping at quarry site will greatly reduce unsafe conditions and so risk of accidents.

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 CONCLUSION
This is existing unit proposed for made an expansion in existing unit for production of Dyes and Dyes
intermediate and Pigment. The unit will provide adequate measures for the prevention and control of
pollution for its proposed project. With the execution and operation of such control measures along with
proper Environmental Management System, there will not be any major potential for negative impact on
the environment due to proposed project.

There will be positive impact on the socio-economic environment since proposed project will generate
some permanent and secondary employment. The unit will also establish Cordial relation with the nearby
villagers and will carry out social welfare activities according to their needs.

The proposed project will also boosts up ancillary industrial and commercial activity. Thus, it will improve
the economic condition of the area.

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