FORM-1 - Welcome to Environmentenvironmentclearance.nic.in/.../07_Oct_2017_181821747MXCP75D7Form1.pdf · FORM 1 (I) Basic Information Sr. ... 12. Village Panchayats, Zilla Parishad,

0

FORM-1

for

PROPOSED EXPANSION OF EXISTING DYES & DYE

INTERMEDIATES UNIT

of

M/s. COLOURTEX INDUSTRIES PVT. LTD. (UNIT-2)

SURVEY NO. 80, T.P.S. NO. 21, F.P. NO. 5 TO 12, 15, 16, 20, 21, 23,

29, PLOT NOS. 158/1 TO 10, 14 TO 23, 437, 438/1 to 4, 564, 565, &

Survey No. 50-52/1 Paikee, Plot Nos. 17/1 to 17/16,

G.I.D.C., PANDESARA, SURAT -394 221 (GUJ.)

1

APPENDIX I

(See paragraph - 6)

FORM 1

(I) Basic Information

Sr.

No.

Item Details

1. Name of the project/s Colourtex Industries Pvt. Ltd. (Unit-2)

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

Plot area: 2,11,923.45 sq. mt.

For detail Please refer Annexure – I

4. New/Expansion/Modernization Expansion

5. Existing Capacity/Area etc. For detail Please refer Annexure – I

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

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

please specify.

No

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

please specify.

No

9. Location

Plot/Survey/Khasra No. Survey No. 80, T.P.S. No. 21, F.P. No. 5 to 12, 15, 16,

20,21,23,29, Plot Nos. 158/1 to 10, 14 to 23, 437,

438/1 to 4, 564, 565, & Survey No.50-52/1 Paikee

Plot Nos. 17/1 to 17/16,

Village GIDC Estate, Pandesara,

Tehsil Choryasi

District Surat

State Gujarat

10. Nearest railway station/airport along with

distance in kms.

Surat: 10 Km

11. Nearest Town, city, District Headquarters along

with distance in kms.

Surat: 10 Km

12. Village Panchayats, Zilla Parishad, Municipal

Corporation, local body (complete postal

address with telephone nos. to be given)

Not applicable

13. Name of the applicant Colourtex Industries Pvt. Ltd.

14. Registered Address M/s. Colourtex Industries Pvt. Ltd.

Plot No.158, GIDC Estate, Pandesara, Dist: Surat,

Gujarat – 394 221

15. Address for correspondence: M/s. Colourtex Industries Pvt. Ltd.


Gujarat – 394 221

Name Mr. Kirit Gandhi

Designation (Owner/Partner/CEO) General Manager

Address M/s. Colourtex Industries Pvt. Ltd.


Gujarat – 394 221

Pin Code 394 221

E-mail [email protected]

[email protected]

2

Telephone No. 0261-2890122

Fax No. 0261-281011

Mobile +919825056865

16. Details of Alternative Sites examined, if any.

Location of these sites should be shown on a

topo sheet.

Not Applicable

17. Interlinked Projects No

18. Whether separate application of interlinked

project has been submitted?

No

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?

No

22. Whether there is any Government Order/Policy

relevant/relating to the site?

No

23. Forest land involved (hectares) No

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.

3

(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 there of with approximate quantities

frates, wherever possible) with source of

information data

1.1 Permanent or temporary change in land

use, land cover or topography including

increase intensity of land use (with respect

to local land use plan)

No Proposed expansion of existing unit in

Pandesara GIDC Industrial Estate.

1.2 Clearance of existing land, vegetation and

Buildings?

No

1.3 Creation of new land uses?

No Industry is located in the industrial estate of

G.I.D.C., Pandesara.

1.4 Pre-construction investigations e.g. bore

Houses, soil testing?

No

1.5 Construction works?

Yes

1.6 Demolition works? No There will not be any demolition work at the

site.

1.7 Temporary sites used for construction

works or housing of construction workers?

No

1.8 Above ground buildings, structures or

earthworks including linear structures, cut

and fill or excavations

Yes

1.9 Underground works mining or tunneling?

No

1.10 Reclamation works?

No

1.11 Dredging?

No

1.12 Off shore structures? No

1.13 Production and manufacturing processes? Yes For detail Please refer Annexure -II

1.14 Facilities for storage of goods or materials?

Yes Existing areas for storage of raw materials

and finished products will be used for the

proposed expansion project.

1.15 Facilities for treatment or disposal of solid

waste or liquid effluents?

Yes The details of Effluent Treatment Plant,

Multiple Effect Evaporator, Liquid waste

Incinerator and Solid Waste Incinerator are

given as Annexure – IV, V, VI & VII

respectively.

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 No

4

transport infrastructure including new or

altered routes and stations, ports, airports

etc?

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, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No

1.22 Stream crossings?

No

1.23 Abstraction or transfers of water form

ground or surface waters?

Yes Water, which is reserved for industrial

purpose, will be drawn from the Irrigation

Canal.

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 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 either

temporarily or permanently?

No

1.29 Introduction of alien species?

No

1.30 Loss of native species or genetic diversity?

No

1.31 Any other actions? No

5

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

frates, wherever possible) with source of

information data

2.1 Land especially undeveloped or agricultural

land (ha)

No

2.2 Water (expected source & competing users)

unit: KLD

Yes There will not be any additional water

requirement for expansion project. Water,

which is reserved for industrial purpose, will

be drawn from the Irrigation Canal.

The details of total Water consumption &

wastewater generation are given as

Annexure -III.

2.3 Minerals (MT) No

2.4 Construction material - stone, aggregates,

and / soil (expected source - MT)

Yes Construction materials, like steel, cement,

crushed stones, sand, rubble, etc. required

for the project shall be procured from the

local market of the region.

2.5 Forests and timber (source - MT) No.

2.6 Energy including electricity and fuels (source,

competing users) Unit: fuel (MT), energy

(MW)

Yes Additional Power required for proposed

expansion project will be met by Captive

Cogeneration Power Plant & from DGVCL.

The details of fuel consumption are given as

Annexure-IX.

2.7 Any other natural resources (use appropriate

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 Details there of (with approximate

quantities/rates, wherever possible) with

source of information data

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 The details of Hazardous Chemical required

for total Production is given as Annexure – X.

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?

Yes Direct/Indirect employment

3.4 Vulnerable groups of people who could be

affected by the project e.g. hospital patients,

children, the elderly etc.

No

6

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 there of (with approximate

quantities/rates, wherever possible)

with source of information data

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 VIII

4.4 Other industrial process wastes No

4.5 Surplus product No

4.6 Sewage sludge or other sludge from effluent

treatment

No

4.7 Construction or demolition wastes No

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/No Details there of (with approximate



5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources

Yes Please refer as Annexure –XI

5.2 Emissions from production processes Yes Please refer as Annexure –XI

5.3 Emissions from materials handling storage or

transport

Yes

5.4 Emissions from construction activities

including plant and equipment

No

5.5 Dust or odors from handling of materials

including construction materials, sewage and

waste

No

5.6 Emissions from incineration of waste Yes Please refer as Annexure – XI

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

7

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



with source of information data with


6.1 From operation of equipment e.g. engines,

ventilation plant, crushers

Yes The Noise level is within the prescribed

limit. At noisy area, adequate preventive

& control measures are provided. No

significant noise, vibration or emission of

light & heat from the unit.

6.2 From industrial or similar processes Yes Noise generation due to operation of Air

Compressor, Blower and pump are

expected. But it will be confined within

the closed building.

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 Adequate Lighting is provided in unit

and also local ventilation system is

provided.

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:


quantities/rates, wherever possible) with


7.1 From handling, storage, use or spillage of

hazardous materials

Yes Safe handling practices are followed for

handling hazardous chemicals.

For detail please refer Annexure –X.

7.2 From discharge of sewage or other effluents

to water or the land (expected mode and

place of discharge)

Yes The details of wastewater generation are

given at Annexure-III.

Domestic effluent is passed through

septic tank and then is treated with

industrial effluent in the Effluent

Treatment Plant.

The final treated effluent is discharged

into the underground drainage system of

Common Effluent Treatment Plant of

G.I.D.C., Pandesara.

7.3 By deposition of pollutants emitted to air into

the land or into water

Yes

8

7.4 From any other sources No

7.5 Is there a risk of long term build up of

pollutants in the environment from these

sources?

No

8. Risk of accidents during construction or operation of the Project, which could affect human

health or the environment




8.1 From explosions, spillages, fires etc. from

storage, handling, use or production of

hazardous substances

Yes For detail please refer Annexure – X

8.2 From any other causes No

8.3 Could the project be affected by natural

disasters causing environmental damage

(e.g. floods, earthquakes, landslides,

cloudburst etc)?

Yes The earthquake proof design of the plant.

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.

Information/Checklist confirmation

Yes/No

Details there of (with approximate



9.1 Lead to development of supporting. utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.

• Supporting infrastructure (roads, power

supply, waste or waste water treatment,

etc.)

• housing development

• extractive industry

• supply industry

• other

Yes

No

No

Yes

-

For detail please refer Annexure – XII.

9.2 Lead to after-use of the site, which could

have an impact on the environment

No

9.3 Set a precedent for later developments No

9.4 Have cumulative effects due to proximity to

other existing or planned projects with

similar effects

No

9

(II) Environmental Sensitivity

Sr. No. Areas Name/

Identity

Aerial distance (within 15km.) Proposed

project location boundary

1 Areas protected under international

conventions, national or local legislation for

their ecological, landscape, cultural or other

related value

-- No protected area within 5 km from the

proposed expansion project site.

2 Areas which are important or sensitive Ecol

logical reasons - Wetlands, watercourses or

other water bodies, coastal zone, biospheres,

mountains, forests

- N.A.

3 Area used by protected, important or

sensitive Species of flora or fauna for breeding,

nesting, foraging, resting, over wintering,

migration

-- No protected area or sensitive species

within 5 km from the proposed expansion

project site.

4 Inland, coastal, marine or underground waters

- N.A.

5 State, National boundaries

- N.A.

6 Routes or facilities used by the public for

access to recreation or other tourist, pilgrim

areas

- N.A.

7 Defense installations - N.A.

8 Densely populated or built-up area Surat Surat is around 10 km from the proposed

expansion project site.

9 Area occupied by sensitive man-made land

uses Hospitals, schools, places of worship,

community facilities)

- N.A.

10 Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, minerals)

- N.A.

11 Areas already subjected to pollution

environmental damage. (those where existing

legal environmental standards are

exceeded)or

- N.A.

12 Are as susceptible to natural hazard which

could cause the project to present

environmental problems (earthquake s,

subsidence ,landslides, flooding erosion, or

extreme or adverse climatic conditions)

- N.A.

IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure – XIII.

Date: 07/10/2017

Place: Surat For Colourtex Industries Pvt. Ltd.

Kirit Gandhi

(General Manager (A & P))

10

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of products with their production capacity

II Brief Manufacturing Process Description with Mass Balance

III Details of Water Consumption Wastewater Generation

IV Details of Effluent Treatment Plant

V Details of Multiple Effect Evaporator

VI Details of Liquid Waste Incinerator

VII Details of Solid Waste Incinerator

VIII Details of Hazardous Waste Generation, Handling and Disposal

IX Details of Fuel Consumption

X Details of Hazardous Chemicals Storage & Handling

XI Details of Air pollution Control System (Stack & Vent)

XII Socio-economic Impacts

XIII Proposed Terms of Reference for EIA studies

IXV Layout Map

XV CSR Activities

XVI A Copy of Permission letter for Drawing Water from Canal

XVII The Copies f Allotment Letters For Land From G.I.D.C.

XVIII � A Copy of Consolidated Consent & Authorization

� A Copy of Amendment To Consolidated Consent & Authorization

IXX Toposheet

XX A Map of 10 Km Radial Distance From Project Site

XXI � A Copy of Environmental Clearance Dated 5-06-2003 Issued By MoEF

� A Copy of Environmental Clearance Dated 17-07-2003 Issued By MoEF

� A Copy of Environmental Clearance Dated 09-11-2009 Issued By State Level

Environment Impact Assessment Authority

XXII Environmental Clearance Compliance Report

11

ANNEXURE – I

LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr.

No.

Product Name Existing Quantity

in MT/Month

Change in

Quantity in

MT/Month

Total Quantity in

MT/Month

1 Synthetic Organic (S.O.) Dyes-1

Azo Disperse Dyes-1(A1) 1375 300 1675

Disperse Dyes-1(A2) 325

200 525

Anthraquinone Acid

Azo Acid & Solvent Dyes 200 0 200

Azo Reactive Dyes-1 300 -300 0

Azo Reactive Dyes-2 (Zero

Discharge)

500 0 500

Synthetic Organic (S.O.) Dyes-2 200 300 500

Azo Disperse Dyes-2 (A3)

Synthetic Organic (S.O.) Dyes-3

335 -135 200 Anthraquinone Disperse Dyes

AQ Solvent Dyes

Vat Dyes


Azo Solvent Dyes


Solvent Dyes for Automotive

Total 3570 365 3935

2 Dye Intermediates

1. Anthraquinone Based

Intermediates

185 -85 100

2. Haloginated Primary Amines 300 100 400

3. Ethylated Tertiary Amines 100 100 200

4. Cyanoethylated Tertiary

Amines

70 0 70

5. Primary Amines

(PABSA,3APBS,3-Amino 4-

Methoxy Acetanilide, Meta

Amino Phonel, MAA,

Anthranilic Acid, DEMAP)

250 0 250

6. PAABSA 5 0 5

7. Quinoline

(Dioxy Quinoline, Hydroxy

Methyl Quinoline)/

50 0 50

12

Sr.

No.

Product Name Existing Quantity

in MT/Month

Change in Quantity

in MT/Month

Total Quantity in

MT/Month

8.Pyrodines

(Butyl Pyridone,

MethylbPyridone,Ethyl Pyridone/

Alkylated Amino Pyridone)

100 0 100

9. BOSA/ E. Acid 40 0 40

10. Sulfonamide 25 0 25

11. Optical Whitener 120 0 120

12. Dispersing Agent SCS/CS-28/

MN/MF/045 2500 2000 4500

13. Disperse DDP

14. Nitrosylsulfuric Acid 250 0 250

Total 3995 2115 6110

3 Ferrous Sulfate including Metal/

Mineral Sulfate

500 0 500

4 Formulation & Spray Drying of

Disperse Wet Press Cake 400 0 400

5 Formulation & Spray Drying of Acid &

Reactive Dyes wpc

6 Disperse/ Vat Dyes/Pigment Ink

Formulation 0 200 200

7 Reactive/Acid/Direct Dyes Ink

Formulation

8 Printex Gum (Printex CRP, Printex CT-

WP, Printex CT-MS, Printex CT-DS,

Printex CT-RT, Printex CT-SA)

0 500 500

9 Textile Auxiliaries

(Levacol CWS, Levacol DS, Levacol

ND, Levacol CWS Liq., Levacol MDWS

Liq., Levacol DS Liq.)

0 500 500

10 Power/Steam 7.5 MW/hour/ 15

TPH

- 7.5 MW/hour/ 15

TPH

6 MW/hour

(Coal/Lignite Based)/

50 TPH*

6 MW/hour

(Coal/Lignite Based)/

50 TPH*

* Steam is also supplied to Colourtex Industries Pvt. Ltd. (Unit-3 & 4) NOTES :-

We also produce mixtures of above dyes (i.e. Black, Brown, Red, Green, Navy, Golden Yellow, Yellow.)

13

ANNEXURE – II

MANUFACTURING PROCESS WITH MASS BALANCE

PROCESS DESCRIPTION

� PROCESS DESCRIPTION FOR DISPERSE AZO DYES

Aromatic Primary Amines are diazotised with Sodium Nitrite in acidic media and coupled with

Tertiary Amines. The products are then isolated and filtered followed by washing with water

and acid to get the desired quality product. The dye product is then grinded in a wet grinding

mill till proper particle sizes are formed. The slurry so formed is spray dried at suitable

temperature to obtain the dry dye product which is finally standardised as required and

packed in drums.

� PROCESS DESCRIPTION FOR AZO ACID & SOLVENT DYES

Different shades of Acid Dyes ( azo, diazo and metal complex ) are manufactured by various

combinations of raw materials.

Primary Amines like Para Amino Azo Benzene 4 Sulfonic Acid (PAAB4S), 4 Nitro Amino Phenol,

Para Nitro Aniline, Aniline Oil, Amino Resorcinol are diazotised with H.Acid, Gamma Acid, 1:2:4

Diazo Acid, NAPSA, Sodium Naphthionate, Metanilic Acid, Sulfanilic Acid in the presence of

sodium nitrite hydrochloric acid. Chemicals like Basic Chromium Sulphate, Caustic Soda Lye,

Soda Ash and Glauber Salt are also added during the diazotisation of amines.

Another set of chemicals like Peri Acid, Beta Naphthol, Resorcinol, Phenyl Peri Acid and Alpha

Napthyl Amine are dissolved to make a coupler solution.

The diazotised mixture and the coupler solution are coupled and stirred well at controlled

temperature. The reaction mass is then hydrolysed. The dye product is isolated from the

mother liquor by salting with Vacuum Salt and dewatered through Filter Press. The filtered

cake is then dried in a spray drier followed by pulverisation in sand mill or ball mill. Before

packing, the pulverised product is ultimately standardised to attain the desired quality of the

acid azo dye.

For acid diazo dyes, the wet cake from filtration is further diazotised with sodium nitrite and

hydrochloric acid and then coupled with other chemicals followed by the subsequent

remaining steps of hydrolysis, isolation / salting, filtration, drying, pulverising and

standardisation.

In case of metal complex dyes, the diazotised & coupled mass is condensed with certain metal

compounds to form the product which is either filtered and dried or directly spray dried.

Solvent Dyes

Aromatic primary Aromatic primary amines are diazotised with sodium nitrite in acidic

medium and coupled with various couplers at optimum temperature. The product is stabilized

and filtered in a filter press. It is washed with water to get quality product and dried. The dry

crude is converted into metal complex formusing required metal salt. The metal complex dye

14

is converted into amine salt, which is filtered at acidic pH and washed with acidic water

followed by hot water. W/C is dried, pulverized and packed in drums.

� PROCESS DESCRIPTION FOR ANTHRAQUINONE ACID

Bromamine Acid condensed with primary amines at require temp. and at atmospheric

pressure in alkaline condition. Drawn in water, filter, washed, dry & packed in drum.

Qunizarine is condensed with primary amine at optimum temp. & at atmospheric pressure.

then filtered, washed and dried. The dry product is sulphonated & dumped in water, filter,

washed up to required pH, dried & packed.

� PROCESS DESCRIPTION FOR REACTIVE DYES-1

(A) Aromatic primary amines are diazotised with sodium nitrite in acidic media than coupled

with couplers in aqueous media than clarified the mass and finally spray dried. Then

standardised against commercial standard.

(B) Aromatic primary amines are diazotised with sodium nitrite in acidic media than coupled

with couplers in aqueous media than isolate the product by salting and filtering. Wetcake

is further cyanurated with cyanuric chloride in aqueous media & then condensed with

amines to get final product, which is clarified and spray dried.

� PROCESS DESCRIPTION FOR REACTIVE DYES-2

Aromatic primary amines are diazotised with sodium nitrite in acidic media then coupled with

couplers in aqueous media then cyanurated with cyanuric chloride in aqueous media & then

condensed with amines to get final product, which is clarified and spray dried.

� PROCESS DESCRIPTION FOR ANTHRAQUINONE DISPERSE DYES

Aromatic primary amines or secondary amines are diazoted with Sodium Nitrite alongwith

Acetic acid below the required temp. The entire diazosolution is stirred for 3-4 hours. At the

same time coupling solution is prepared by taking fishers required water with couplers like

fishers base etc. Then diazo solution is coupled with coupling solution by stirring together for

required time. Then entire solution is heated at required temp. in another vessel by adding

D.M.S. Then entire material is stirred for 24 hours. Then it is dumped in vessel containing

water where it is kept for 2-3 hours. Then material is filtered in wooden press which given the

wet cake. Then it is dried in dryer then pulverised and standardrised after testing powder is

packed in drums.

� PROCESS DESCRIPTION FOR ANTHRAQUINONE SOLVENT DYES

Hydroxy anthraquinone intermediates are condensed with aromatic/ aliphatic amines in

solvent at optimum temperature and pressure using catalyst. The reaction mass is filtered

washed (The mother liq. Is collected for solvent recovery) with water and w/c dumped in

another vessel for purification, where product is heated in acidic medium for 2 to 3 hrs. it is

filtered hot and washed acid free. W/C is dried, pulverized and packed in drums.

� PROCESS DESCRIPTION FOR VAT DYES

Fusion

The Benzanthrone/cyclised product is subjected to alkali fusion in solvent media at

optimum temperature and the product is subsequently oxidized by either with steam/air

15

or with both. Then the product is isolated, filtered and washed with water for getting

product. The wet cake is dried, pulverized and used for next stage depending upon the

product process requirement.

Hydroxylation

The Fused Product is hydroxylated in Acid media in presence of metal oxide and

subsequently the hydroxylated product is isolated, filtered, washed with water. The wet cake

is dried, pulverized and used for alkylation.

Diazotisation and Reduction

Amino Anthraquinone is diazotised with nitrosyl sulphuric acid and subsequently reduced

with sodium sulfite and the product is isolated, filtered and washed with water for getting

the product product.

Benzoylation and Halogenation

Anthraquinone amines are Benzoylated and or subsequently chlorinated in solvent media and

then the product is subjected to Vacuum/steam distillation to remove the solvent and products

are isolated, filtered and washed with water. The wet cake is dried, pulverized and used for

next stage depending upon the product process requirement.

Condensation

Anthraquinone amines are condensed with halogenated Anthraquinone in solvent media in

presence of metal catalyst at optimum temperature. Then the product is subjected to

Vacuum/steam distillation to remove the solvent and products are isolated, filtered and

washed with water. The wet cake is dried, pulverized and used for next stage depending

upon the product process requirement.

Cyclisation

The condensed/ reduced product is cyclised in acid media/solvent media in presence of

Catalyst at optimum temperature. Then the product is isolated, filtered and washed with

water for getting product.

Alkylation

The Fused/hydroxylated product is alkylated in solvent media at optimum temperature and

solvent is recovered by either steam distillation or vacuum distillation and the product is

isolated, filtered and washed with water (Say alkylated product). The wet cake is dried,

pulverized and used for Acid pasting.

Acid Pasting

The alkylated product is treated in sulphuric acid and isolated, filtered and washed with water.

The wet cake is dried, pulverized and packed in drums.

16

� Anthraquinone Intermediates

Anthraquinone is sulfonated in acidic media at optimum temperature then drawn in water,

isolated by filtering and then ammonolysed with Ammonia at optimum temperature and

pressure. Excess Ammonia gas is recovered and then product is isolated by filtering, washing

with water till purity of the product is achieved.

� Halogenated Primary Amines

Primary Amines are chlorinated or brominated using Chlorine or Bromine or Phosphorus

Oxychloride in acidic media with oxidizing agent. Excess Halogenic gases are scrubbed in alkali

scrubber. The product is isolated by filtering, washing and drying. First the mother liquor is

recycled without any purification. The yield is approximately 90 – 93 % on a theoretical basis.

These products are used in dyestuff.

� Ethylated Tertiary Amines

Primary or Secondary Amines are ehtylated with Ethyl Chloride / D.E.S. / Alkyl Sulfonyl

Chloride in moderately acidic / basic condition at required temperature and pressure. This

product is then filtered, washed, packed in packed in bag as w/c and used in dyestuff.

� Cyanoethylated Tertiary Amines

Primary or Secondary Amines are Cyanoethylated in moderately acidic condition in presence

of anti – polymerizing agent at required temperature and pressure. The product is isolated by

filtering and washing till the purity of the product is achieved.

These products are used as such in further process or manufacturing SO Dyes. The yield is

approximately 90 – 95 % on a theoretical basis.

� Primary Amines

Primary or Secondary Nitro / Methoxy Amines are acetylated with Acetic Acid and Acetic

Anhydride at optimum temperature. The acetylated product is isolated or directly Nitrated

with Nitric Acid at lower temperature. The product is drawn in chilled water, isolated and is

reduced with NaOH at optimum temperature. The product is by filtering and used as

intermediates.

� P-AMINO AZO BENZENE 4-SULFONIC ACID

Sulphanilic acid is deazotied & coupled with primary amine to give intermediate product,

which is then filter & washed. The above w/c is then hydrolised in acidic media filter, dry and

packed.

� Quinolines

Primary Amine is condensed with Methyl Ester / Acetic Anhydride in solvent media at required

temperature. The product is isolated from solvent and is vacuum distilled and reused.

Intermediate product is cyclised in alkali condition at required temperature, then neutralized

17

with acid, filtering the product and purified in acidic condition at required temperature. The

product is isolated by filtering and washing till it is neutral. The product is then dried in a

dryer. The yield is about 55 % on a theoretical basis. This product is used in dyestuff

industries.

� Pyridone

Alkyl Amine is condensed with Methyl Ester and E.C.A. at optimum temperature. The product

is then isolated by acidifying and filtering. These products are used in dyestuff without further

treatment.

� BOSA

Ortho Chloro Benzene is sulfonated with Sodium Bisulfite in moderately alkaline condition at

optimum temperature and pressure. The product is used as such on purity basis. The product

is used in dyestuff.

� Sulfonamide

Chlorosulfonation of O-Nitro-Chloro-Benzene, then isolated by drawning & filtered, washed

till neutral. Above wet cake is then condensed with primary amine or secondary amine.

Then hydrolysed and reduced by Sodium Sulfide. The above reaction mass is then clarified &

isolated by HCL. This product is filtered and sold as is on purity basis. This product is packed in

drums.

� Optical Whitening Agent

Aryl nitrile is chlorinated at optimum temp. Excess chlorine and HCL are scrubbed in alkali

scrubber. Then transfer in condensation vessel & condense with alkyl phosphite at optimum

temp. & then transfer in another vessel and condense with aryl aldehyde in aquase media at

optimum temp. then filter, sand mill & packed.

� Dispersing Agent SCS/DDP /CS-28/MN/MF/045

Naphthalene / Phenol/ 2 Methyl Naphthalene/ Lignine/ CI Oil/ Creoseto Oil is sulphonated

with Sulphuric Acid / Oleum/ Sodium Sulfite and then condensed with Formaldehyde to give

dispersing agent which is then neutralised, clarified and packed in bag or filled directly into the

drum.

� Ferrous Sulphate including Metal/Mineral Sulphate

Iron is treated with spent Sulphuric Acid at required temperature for optimum time and then

cool the mass to RT to isolate the product. Filterate is reused in next batch.

� Disperse/ Vat Dyes/ Pigment Ink Formation

Weight exactly required quantities of Dispersing Agent and charge into water. Subsequently

charge pure dyes/pigment under fast stirring. Mix it properly and start send milling to reduce

particle size. After completion of proper milling and achieving desire particle size check

strength of paste. Transfer this paste in SS tank and add necessary dilution and finally check

18

and confirm strength against standard reference. After approval from QC filter lot through

filter to remove any foreign material and pack it.

� Reactive/Acid/ Direct Dyes Ink Formation

Weight exactly required quantities of Dyes and charge into water, stir to dissolve and start RO.

Periodically check sample for strength and salt content and on approval from QC clarify the lot

and collect it to SS tank. Add all necessary diluting agents as per batch sheet and send sample

for QC check. On approval from QC clarify the lot to remove any foreign material and pack it.

� Printex Gum

Wet Blending

In SS Reactor with Dual Anchor & High speed stirrer, charge ID-215 liquid and start stirrers and

gradually add ID-265. On Completion of addition of ID-265, add ID-174 liquid. Stir 1 hour to a

uniform smooth paste. Unload and fill in carboys.

Dry Blending

Charge ID-265/Tamarind seed Powder/ in SS Blender and charge Vacuum salt/ID-174. Blend

for 1 hour until product is uniform. Unload and fill in bags.

� Textile Auxiliaries

In a clean vessel charge water as require and start stirring. Slowly charge Dispersing

/Wetting /Buffering agent to get clear solution. Stir this clear solution at RT for 1 hr and

clarify through clarifier and fill up in containers and packed.

19

PROCESS FLOW SHEET OF AZO DISPERSE DYES

SODIUM NITRITE PRIMARY

AMINES COUPLING SOLN.

ACID

FILTER PRESS

MOTHER LIQUOR

TO ETP

PUMP

FINISHED

AZO DISPERSE

DYE

SPRAY

DRIER

SAND

MILL

20

MASS BALANCE:

21

22

23

PROCESS FLOW SHEET OF AZO ACID DYES

SODIUM NITRITE


HYDROCHLORIC ACID

SALT

FILTER PRESS

FILTER PRESS

FINAL PRODUCT FOR PACKING

SPRAY

DRIER

BALL

MILL

PULVERISER BLENDING

24

PROCESS FLOW SHEET OF AZO SOLVENT DYES

SODIUM NITRITE

PRIMARY AMINES COUPLING SOLN.

ACID

FILTER PRESS

FILTER PRESS

DRY PRODUCT+ METAL SALT

Water+NaOH+Amine Solution +HCl

FINAL PRODUCT

FOR PACKING

SPRAY

DRIER

REACTION

VESSEL

REACTION

VESSEL DRYER

25

Mass Balance:

26

PROCESS FLOW SHEET FOR REACTIVE DYES-1

(A)



ACID

FILTER PRESS

MOTHER FINISHED

LIQUOR REACTIVE

PUMP TO DYE

ETP

SPRAY

DRIER

27

PROCESS FLOW SHEET FOR REACTIVE DYES-1

(B)



ACID

BASE

CYANURIC

CHLORIDE

FILTER PRESS

FILTER PRESS

PUMP

ML TO ETP FINISHED REACTIVE DYE

SPRAY

DRIER W.C.

28

Mass Balance:

29

PROCESS DESCRIPTION FOR REACTIVE DYES-2



ACID

BASE

AMINE CYANURIC CHLORIDE

FINISED

PUMP REACTIVE DYE

SPRAY

DRIER

30

31

PROCESS FLOW SHEET OF ANTHRAQUINONE DISPERSE DYES

1) Pri. or Sec. Amines 1) Coupling Solution

2) Acid 2) F. base

3) Sodium Nitrite 3) D.M.S. 1) Water

Drawning

To ETP

PROCESS FLOW SHEET OF ANTHRAQUINONE ACID

1) Bromamine acids

2) Primary amine 1) water

3) Alkali

drawning

To ETP

1) Quinizarine

2) Primary amine

1) sulphonating agent water

dryinmg drawning

To ETP To ETP

A

Vessel

B

Vessel

Vessel Filter press

Dryer Produc

Vessel

drying

Vessel

Filter press drying

packed

Vessel

drying

Vessel

Filter

packed

Filter

Vessel

32

Mass Balance:

33

34

35

36

37

PROCESS FLOW SHEET OF DYES INTERMEDIATES

� Anthraquinone Intermediates

1) Anthraquinone

2) Acidic media 1) Water 1) liqour Ammonia

2) Chloronitro benzen or 1-sulphoA. Q.

Receiver for Ammonia recovery

Isolation

To ETP

To ETP

� Mass Balance:

�

A

Vessel

Filter press

Vessel

Nutch Product

NH

Vessel

38

� Heloginated Primary Amines

1)Halogenatiing Agent

2)Aromatic nitro amines

3)Oxidizing Agent

4)Acid

1st ML Recycle Wash to ETP

Mass Balance:

Vessel Filter press Drye

r Product

39

� Ethylated Tertiary Amines

1) Primery or secondery amine

2) Ethyl chloride / D.E.S.

3) Moderatly acidic / basic Condition

To ETP

Mass Balance:

Vessel Product Nutch

40

� Cyanoethylated Amines

1) Primary or secondary amines

2) Anti polymerising agent

3) Acid

4) Cyanoethylating Agent

To ETP

Mass Balance:

Vessel

ProducNutch

41

� Dispersing Agent

1) Naphthalene / Lignin/Phenol/ 1) Formaldehyde

2-Methyl Naphthalene/ CI-Oil/

Creoseto oil

2) Sulphuric acid/Oleum/ 2) pH adjusting material

Sodium Sulfite

Mass Balance:

A

Vessel

B

Vessel Clarifier Product

packed

42

� BOSA/E Acid

1) O.C.B.

2) Sodium bisulfite

To ETP

� Mass Balance:

Vessel

Nutch Product

43

Pyridone

1) Alkayl Amine

2) Ester

3) Acid

To ETP

Mass Balance:

Vessel

Nutch Product

44

� Quinoline

1) Primary amine

2) Acetic anhydride 1) Alkali

3) Solvent media 2) Acid

To ETP

� Mass Balance:

A

Vessel Dryer Produc

B

Vessel Nutch

45

� Primary Amines

1) Primary or secondary nitro/ methoxy amines

2) Acetic acid &/or Acetic anhydrided

Aci d

Nitric acid

Drawning

Chilled water

To ETP

2) Iron powder/ NaSH or

3) Hydrochloric acid

Solid Waste to Landfill

To ETP

Vessel

Vessel

PRODUCT Filter press

A

Vessel

Filter press

Vessel

46

Mass Balance:

47

� Optical Whitening Agent

1) Aryl nitrile 1) Aryl aldehyde

2) Chlorine 1) Alkyl phosphite 2) Aquase media

Filter

To ETP

Chlorination Condensation Condensation

Mass Balance:

Vessel

A

Vessel Sand

mill

Produc

B

Vessel Nutch

48

� P-Amino Azo Benzene 4-Sulfonic Acid

1) Sulphanilic acid 1) Primary amines 1) Acidic media

Diazotiation

W/C

Mass Balance:

A

Vessel

B

Vessel

Product Nutch

A

Vessel

49

� Sulphonamide

1) Chlorosulphonic acid

2) ONCB 1) Water 1) Sodium Sulfide 1) HCL

Isolation

To ETP

A

Vessel

Vessel

Nutch Product

Vessel

Filter press

Vessel

50

51

FERROUS SULPHATE INCLUDING METAL/MINERAL SULPHATE

1)spent acid

2)iron oxide waste

Residue to land fill site

ML Iron oxide waste

Residue to land fill site

Vessel Filter press

Product

Vessel

Filter press

Trey for natural cooling

52

Mass Balance:

53

54

55

56

COLOURTEX INDUSTRIES PRIVATE LIMITED,

Mass Balance

Disperse /Vat Dyes/ Pigments Ink Form

ulation:

In Kgs

Disperse D

yes / Vat Dyes/ Pigments W

PC

75

Dispersing agent/W

etting Agent/Surfactant

100

Solvent/DEG/M

EG/PEG/Propylene G

lycol/

Wet Milling

Cellosolve/C

arbitol/Pyrrolidones/G

lycerine/

Dowanol /ethers/

Clarification and Packing

Defoamer

10

Biocides/preservatives

3

Water

620

200

1000 Kgs

Disperse/ Vat Dyes/

Pigment Ink

57

Reactive/Acid /Direct Dyes Ink Form

ulation:

In Kgs

Reactive/Acid D

yes R

/O powder

140

Binder/ID

-3152/C

aprolactum/D

ispersing Agent

80

Solvent/DEG/M

EG/PEG/Propylene G

lycol/

Wet Mixing

Cellosolve/C

arbitol/Pyrrolidones/G

lycerine/

Dowanol /ethers/Sulfolan/SLN

Clarification and Packing

Defoamer

10

Biocides/preservatives

3

Water

620

150

1000 Kgs

Reactive/Acid/ Direct

Dyes Ink

58

59

60

ANNEXURE-III

WATER CONSUMPTION AND WASTEWATER GENERATION

Sr.

No. Description

Water Consumption

Existing Additional Total

KL/Day KL/Day KL/Day

1. Process 5944.0 -157 5787

2. Boiler 1200.0* 00 1200.0 *

3. Cooling 355.5 157 512.5

4. Washing 754.0 00 754.0

Total Industrial 8253.5 00 8253.5

Domestic 124.0 00 124.0

Grand Total 8377.5 00 8377.5

* Steam is also supplied to Colourtex Industries Pvt. Ltd. (Unit-3 & 4), Sister Concerns

61

WASTEWATER GENERATION

Sr.

No. Description

WASTEWATER GENERATION

Existing Additional Total

KL/Day KL/Day KL/Day

1. Process 5970.0# + 22.0* -204.2# +

338** 5765.8 + 360.0**

2. Boiler 612.2 49.7 661.9

3. Cooling 27.80 12.2 40

4. Washing 738.0 00 738.0

Total Industrial 7348.0# +22.0* -142.3# +

338** 7205.7##+360.0**

Domestic 123.0 00 123.0

Grand Total 7471.0# +22.0* -142.3# +

338** 7328.7## + 360.0**

* 22 KL/day of high COD wastewater is treated in Liquid Waste Incinerator

# Out of existing 7471 KL/day of low COD process wastewater, 273 KL/day of wastewater

segregated from process & total 295 KL/day (273 KL/day + 22 KL/day of high COD

Wastewater) of wastewater treated in the Multiple Effects Evaporator & Liquid Waste

Incinerator and 206.5 KL/day of MEE condensate treated in ETP.

## After proposed expansion 7328.7 KL/day of Wastewater generated will be treated in

Effluent Treatment Plant

** After proposed expansion, Out of 360 KL/day of Wastewater, 306 KL/day of Wastewater

segregated [(273 KL/day segregated from existing wastewater & 33 KL/day from

wastewater due to proposed expansion)] & 54 KL/day of high COD wastewater [(22

KL/day of high COD wastewater (existing) & 32 KL/day of high COD wastewater (due to

Proposed expansion)] will be generated.

Thus after proposed expansion, total 360 KL/day of Wastewater will be treated in the

Multiple Effects Evaporator & Spray Dryer/ Liquid Waste Incinerator and 252 KL/day of

MEE condensate will be treated in ETP.

62

ANNEXURE-IV

EXISTING ETP DETAILS & FLOW DIAGRAM

Brief Description of Effluent Treatment

The untreated effluent generating from the various process streams is collected into the Oil

& Grease Trap from where the effluent flows into the Collection Tank where in air is blown

through blowers. From the Collection Tank the effluent is pumped into the Neutralization

Tank. Lime solution is prepared in the Lime Preparation Tank and the slurry is fed from the

Lime Feed Tank into the Neutralization Tank. In order to mix the effluent and Lime solution

homogeneously, agitators are provided in the Neutralization Tank. Ferrous Sulphate (which

acts as a Flocculants) and Polyelectrolyte (Coagulant Aid) are then added to the neutralized

effluent. The effluent is thereafter passed into the Primary Clarifier. Quiescent condition is

provided for the solids to settle down at the bottom of the Primary Clarifier. The clarified

overflow of primary clarifier is taken into Primary lamella. The sludge from the Primary

Clarifier and Primary Lamella is pumped into the Sludge Thickener to reduce the water

content in the sludge. The overflow from the Sludge Thickener is taken back in to the

Primary Clarifier. The overflow of the Primary Lamella is taken into the Aeration Tank.

Nutrients are added into the Aeration tank for the micro – organisms. The effluent from this

tank is taken in to the Secondary Clarifier for further removal of organic sludge / matter

from the effluent. The excess bio-sludge is pumped in to the Sludge Thickener. The sludge

from the Sludge Thickener is taken into the Filter press for reduce the water content in the

sludge. The filtrate water from the filter press is again taken into the Primary clarifier. The

overflow of the secondary clarified effluent is taken in to the Holding Tank/Sand Filter and

Activated Carbon Filter. After that, the treated effluent is discharged in to the underground

drainage system of CETP Pandesara.

63

Details of Effluent Treatment Plant-1

Sr.

No.

Treatment Unit Nos. Dimension Capacity MOC

1 Oil And Grease Trap 4 6.5 x 1.5 x 1.8 m SWD 68 m3 RCC/TL

2 Collection Tank-1 1 16.5 x 8 x 5.5 m SWD 726 m3 RCC/TL

3 Collection Tank-2 1 14.5 x 11.5 x 5.5 m SWD 917 m3 RCC/TL

4 Collection Tank-3&4 1 45.5 x 12.5 x 5.5 m SWD 3128 m3 RCC/TL

5 Old Collection Tank 2 10.0 x 5.0 x 3.5 m SWD 175 m3 RCC/TL

6 High Cod Collection Tank 2 8.0 x 4.0 x 2.5 m SWD 160 m3 RCC/TL

7 Lime Preparation Tank 2 3 dia x 5 m 70.0 m3 MS

8 Lime Feed Tank 2 3 x 3 x 1.25 m 22 m3 MS

9 Feso4 Preparation Tank - 1

Feso4 Preparation Tank - 2

1

1

1.5 dia x 3.4 m

1 dia x 2.5 m

6 m3

2 m3

MSRL

RCC/TL

10 Feso4 Feed Tank 1 2.7 x 1.2 x 0.9 m 3 m3 MSRL

11 Polyelectrolyte Prep. Tank 1 0.9 dia x 3.1 m 2 m3 MS

12 Polyelectrolyte Feed Tank 1 2.1 x 1.2 x 0.9 m 2.3 m3 MS

13 Phosphoric Acid Tank 1 1.1 dia x 1 m 1 m3 HDPE

14 Neutralisation Tank-1 3 5 x 5 x 5.1 m 384 m3 RCC/TL

15 Neutralisation Tank-2 3 3.8 x 3.3 x 5.1 m 192 m3

RCC/TL

16 Primary Clarifier 2 12.5 dia x 2.5 m SWD 613 m3 RCC

17 Primary Lamella 1 2.4 x 1.2 m x 3 m 8.6 m3 MS/EPOXY

18 Aeration Tank-1 1 24 x 19.5 x 6.0 m 2800 m3 RCC

19 Aeration Tank-2 1 23.3 x 10.5 x 5.5 m 1345 m3 RCC

20 Aeration Tank-3 1 22 x 10 x 6 m 1320 m3 RCC

21 Secondary Clarifier 2 11.5 dia x 3.0 m SWD 623 m3 RCC

22 Secondary Clarifier 1 6.0 dia. x 3.0 m SWD 85 m3 RCC

23 Secondary Lamella 2 1.8 x 1.2 x 3.0 m 13 m3 MS/EPOXY

24 Sludge Thickener 1 8 dia x 2.75 m 140 m3 MS/EPOXY

25 Filter Press 4 1.5 x 1.5 m x 60 plates each 540 m2 PP

26 Sand Bed 3 2.25 dia x 3 m 36 m3 MS

27 Carbon Bed 8 2.25 dia x 3 m 96 m3 MS

64

Details of Effluent Treatment Plant-2

Sr.

No. Treatment unit Nos. Dimension Capacity in

m3 MOC

1 Collection tank – 1 1 16.33 m x 12.58 m x 4.50 m SWD 925.00 RCCTL

2 Collection tank – 2 1 16.33 m x 12. 87 m x 4.50 m SWD 945.75 RCCTL

3 Collection tank – 3 1 15.82 m x 12.87 m x 4.50 m SWD 916.21 RCCTL

4 H.acid tank – 1 1 7.88 m x 6.44 m x 4.50 m SWD 228.36 RCCTL




8 Neutralization tank - 1 2 Dia. – 5.50 m x 5.00 m SWD 237.50 RCCTL

9 Neutralization tank - 2 2 Dia. – 5.50 m x 5.00 m SWD 237.50 RCCTL

10 Flash mixer 2 Dia. – 4.00 m x 5.00 m SWD 125.60 RCCTL

11 Flocculation tank 2 Dia. – 5.00 m x 5.00 m SWD 196.25 RCCTL

12 Lime Preparation Tank 2 3.00 m x 3.00 m x 3.00 m SWD 54.00 RCCTL

13 Ferrous Preparation

Tank 1 3.00 m x 2.50 m x 2.30 m SWD 17.25 RCCTL

14 Lime Feed Tank 2 2.50 m x 2.50 m x 2.50 m SWD 31.25 RCC

15 Ferrous Feed Tank 1 2.50 m x 2.50 m x 2.50 m SWD 15.62 RCCTL

16 Primary clarifier 2 Dia - 12.84 m x 3.50 m SWD 906.00 RCC

17 Primary lamella 3 5.05 m x 4.88 m x 3.25 m SWD 240.30 RCC

18 Sludge Thickener 1 Dia. – 12.84 m x 3.5 m SWD 453.00 RCC

19 Filter Press 03 1.5 m x 1.5 m x 50 plates each 337.50 m2 PP

20 Aeration Tank 02 32.0 m x 30.0 m x 8.6 m SWD 16512.00 RCC

21 Secondary Clarifier 03 Dia. 12.0 m x 3.5 m SWD 1187.00 RCC

22 Secondary Holding Tank 02 15.0 m x 14.65 m x 3.50 m SWD 1538.25 RCC

65

FLOW DIAGRAM OF EFFLUEMENT TREATMENT PLANT

To D

rain

age

Syst

em

of

CE

TP

of

GID

C P

and

esar

a

Oil

/Gre

ase

to

Inci

ner

ato

r

Oil

/Gre

ase

Tra

p

Equal

izat

ion T

ank

Neu

tral

izat

ion

Pri

mar

y

Cla

rifi

er

Slu

dge

Thic

ken

er

Aer

atio

n T

ank

Over

Flo

w

Lea

chat

e

Pre

ss C

ake

To S

ecure

Land

fill

Sit

e O

R S

old

to

Cem

ents

Ind

ust

ries

To S

lud

ge

Yar

d

Sec

ondar

y

Cla

rifi

er

Car

bo

n B

ed

San

d B

ed

Fil

ter

Pre

ss

Lim

e

Slu

rry

Tan

k

FeS

O4

Slu

rry

Tan

k

PE

Slu

rry

Tan

k

Rec

ycl

e A

ctiv

ated

Rec

ycl

e fo

r

Slu

rry P

rep

arat

ion

Act

ivat

ed S

lud

ge

Sec

ond

ary

Eff

luent

Ho

ldin

g

Tan

k

Over

Flo

w

Raw

Eff

luen

t

Pri

mar

y L

amel

la

66

ANNEXURE-V

DETAILS OF MULTIPLE EFFECT EVAPORATOR

Description Rate

Feed Rate 17500 Kg/hr + 4440 Kg/hr Recycle

Evaporation Rate 15600 Kg/hr

Concentrate Rate 6340 Kg/hr

67

ANNEXURE-VI

DETAILS OF LIQUID WASTE INCINERATOR

STACK DIAMETER. 1500 MM

STACK HEIGHT 40000 MM

TYPE LIQUID WASTE INCINERATOR

DUCT DIA 900 MM

COMBUSTION ZONE

BURNER 3 Nos.

HEAT GENRATION ( Kcal/Hr.) 51,00,000

LDO/ HSD/ Bio Diesel (Lit./Hr.) 500

LIQUID WASTE (LT/HR)

(DESIGNED CAPACITY)

8000

MATERIAL M.S. F.B.L.

LINING FIRE BRICKS

DIAMETER 3355 MM

HEIGHT 7320 MM

POST COMBUSTION ZONE

BURNER 1 No.

HEAT GENERATION (Kcal/Hr.) 3,35,000

LDO/ HSD/ Bio Diesel (Lit./Hr.) 32

MATERIAL M.S. F.B.L.

LINING FIRE BRICKS

DIAMETER 1830 MM

HEIGHT 5490 MM

SCRUBBER VENTURIMETER

MATERIAL M.S. R.L.

LINING REFACTORY

MEDIA ALKALINE

CIRCULATION PUMP (M3/HR.) 150-200

I.D.FAN CAPACITY (M3/HR.) 55000

F.D. FAN CAPACITY (M3/HR.) 4000 x 4

EMISSION

SPM (MG/NM3) 80-100

SOX (PPM) 20

NOX (PPM) 10

RATE OF EMISSION (NM3/HR) 52,000

68

ANNEXURE-VII

DETAILS OF SOILD WASTE INCINERATORS

Incinerator - 1 Incinerator - 2

Stack Diameter 1500 mm 1500 mm

Stack Height 40000 mm 40000 mm

Type Stationary Grate Rotary

Duct Dia 610 mm 900 mm

Combustion Zone

Burner 1 No. 1 No.

Heat Generation (Kcal/Hr.) 5,10,000 10,20,000

HSD/ Bio Diesel 50 Lit./Hr 150 Lit./Hr

Solid Waste (Tons/Day)

Designed capacity 5 20

Material M.S.F.L. M.S.F.L

Lining Fire Bricks Fire Bricks

Diameter 2440 mm 1525 mm

Height / Length 6135 mm 13420 mm

Post Combustion Zone

Burner 1 No. 1 No.

Heat Generation (Kcal/Hr.) 3,06,000 3,35,000

HSD/ Bio Diesel 30 Lit./Hr 32 Lit./Hr

Material M.S.F.L. M.S.F.L

Lining Fire Bricks Fire Bricks

Diameter 2440 mm 3270 mm

Height 4135 mm 8575 mm

Scrubber Quenching Tower Venturimeter

Material M.S.R.L.B.L. M.S.R.F.L

Lining Acid Bricks Refractory

Media Alkaline Alkaline

Circulation Pump (M3/Hr.) 50 150

I.D.Fan Capacity (M3/Hr.) 12000 55000

F.D. Fan Capacity (M3/Hr.) 8000 4500

Emission

SPM (mg/Nm3) 80-100 80-100

SOx (ppm) 20 20

NOx (ppm) 10 10

Rate Of Emission (Nm3/Hr) 5000 15000

69

ANNEXURE-VIII

DETAILS OF HAZARDOUS WASTE STORAGE, TREATMENT AND DISPOSAL

CAT.

NO.

TYPE OF

SOLID/

HAZARDOUS

WASTES

SOURCE OF

WASTE

QUANTITY GENERATED (MT/Month)

METHOD OF DISPOSAL

EXISTING ADDITIONAL TOTAL

35.3 ETP Sludge From Effluent

Treatment

Plant

2515 1000 3515 Sale to cement manufacturing

industries in India as per their

requirement /used for

manufacturing of bricks/

disposed off at Group companies

own TSDF site / TSDF site of

Saurashtra Enviro Project Pvt.

Ltd., Kutch

26.1 Iron Sludge From Process 220 -- 220

37.2 Incineration

Ash

From

Incinerator

90 165 255 Dispose off at Group companies



Ltd., Kutch

26.1 Organic

Sludge

From Process 68.875

+ 192.8

(Colourtex

Industries

Pvt. Ltd.

(Unit-1,3 & 4)

+ 8.85

(CTX

Lifesciences

Pvt. Ltd.)

-27.15 41.725

+ 192.8

(Colourtex

Industries

Pvt. Ltd.

(Unit-1,3 & 4)

+ 8.85

(CTX

Lifesciences

Pvt. Ltd.)

Receive Collection, Storage,

Transportation, Disposal by

Incineration in the Incinerators /

Sent for Co processing in the

Cement Industries / Sent to Co-

processing to Recycling Solution

Pvt. Ltd., Panoli.

20.3 Distillation

Residue

From

Distillation

579.5

+ 313

(Colourtex

Industries

Pvt. Ltd.

(Unit-1)

+ 223.8 (CTX

Lifesciences

Pvt. Ltd.) =

1116.3

- 48 531.5

+ 313

(Colourtex

Industries

Pvt. Ltd.

(Unit-1)

+ 223.8 (CTX

Lifesciences

Pvt. Ltd.) =

1068.3





Cement Industries/ Sent to Co-


Pvt. Ltd., Panoli.

26.1 Organic

Sludge

containing

Metal salt

From Process 40 60 100 Incineration in the Incinerators/




Pvt. Ltd., Panoli./ Sell to

Authorized Agency/ disposed off

at TSDF site.

35.4 Oily Sludge From Effluent

Treatment

Plant

2.88 + 8.95

(Colourtex

Industries

Pvt. Ltd.

-- 2.88 + 8.95

(Colourtex

Industries

Pvt. Ltd.



Incineration in the Incinerators

70

(3&4) +

Bhavin

Textiles)

= 11.83

(3&4) +

Bhavin

Textiles)

= 11.83

5.1 Used Oil Oil used as

lubricant in

various

applications

1.8

+ 1.5

(Colourtex

Industries

Pvt. Ltd.

(Unit-3 &

Bhavin

Textiles) = 3.3

-- 1.8

+ 1.5

(Colourtex

Industries

Pvt. Ltd.

(Unit-3 &

Bhavin

Textiles) = 3.3



Incineration in the Incinerators/

Sale to registered Re-processor /

Burn in the incinerators as a

fuel/ reuse

5.2 Waste/Resid

ues

Containing

Oil

0.8

+ 0.5

(Colourtex

Industries

Pvt. Ltd.

(Unit-3) = 1.3

-- 0.8

+ 0.5

(Colourtex

Industries

Pvt. Ltd.

(Unit-3) = 1.3




33.1 Discarded

Containers &

barrels

Raw material

packaging

4800 Nos. -- 4800 Nos. Sale to authorized recycler/

reuse

liners Raw material

packaging

98 -- 98 Sale to authorized recycler/

reuse/ Send for Co-processing in

the Cement Industries/ Sent to

Co-processing to Recycling

Solution Pvt. Ltd., Panoli.

26.3 Spent Acid

(Inorganic

Acid)

From Process 1200 -- 1200 Reuse in the Process & transfer

at our Sister concern Units,

Colourtex Industries Pvt. Ltd.

(Unit-1, 3 & 4) for reuse in the

process

20.2 Spent

Solvent

From Process 20.85

(Colourtex

Industries

Pvt. Ltd.(Unit-

1)

- 20.85

(Colourtex

Industries

Pvt. Ltd.(Unit-

1)




Send for Co-processing in the



Pvt. Ltd., Panoli.

28.6 141.6

(CTX

Lifesciences

Pvt. Ltd.)

- 141.6

(CTX

Lifesciences

Pvt. Ltd.)

35.3 Spent Carbon From Process 8.58

(Colourtex

Industries

Pvt. Ltd.

(Unit-1))

- 8.58

(Colourtex

Industries

Pvt. Ltd.

(Unit-1))

28.2 56.28

(CTX

Lifesciences

Pvt. Ltd.)

- 56.28

(CTX

Lifesciences

Pvt. Ltd.)

71

28.3 Off

Specification

Product

0.3 - 0.3 Receive Collection, Storage,



28.4 Date Expired

Discarded &

Off

Specification

Drugs

0.3 - 0.3

35.3 MEE Salt

(Inorganic

Salt)

After Drying of

MEE

Concentrate in

Dryer

- 980 980 Dispose off at Group companies



Ltd., Kutch

72

ANNEXURE –IX

DETAILS OF FUEL CONSUMPTION

Sr.

No.

Description Existing Quantity

Additional

Quantity

Total Quantity

1 For 7.5 MW CPP-1 Natural Gas: 2400

Nm3/hr

- Natural Gas: 2400

Nm3/hr

2 For Steam Boiler

(8 TPH)-1

Natural Gas: 640

Nm3/hr

- Natural Gas: 640

Nm3/hr

3 For Steam Boiler

(12 TPH)-2

Natural Gas: 960

Nm3/hr

- Natural Gas: 960

Nm3/hr

4 For Steam Boiler

(8 TPH)-3

Coal: 1280 Kg/hr - Coal: 1280 Kg/hr

5 For Steam Boiler

(6 TPH)-4


6 For Steam Boiler

(25TPH)-5


7 For Steam Boiler (50

TPH)-6 For one unit of 6

MW Power Plant

Coal: 10 MT/hr

- Coal: 10 MT/hr

8 For Hot Air Generator-1 Natural Gas: 125

Nm3/hr

- Natural Gas: 125

Nm3/hr

9 For Hot Air Generator-2 Natural Gas: 125

Nm3/hr

- Natural Gas: 125

Nm3/hr

10 For Incinerators HSD/LDO: 794

Lit./hr

Bio Diesel:

794 Lit./hr

HSD/LDO/ Bio

Diesel: 794 Lit./hr

11 For HRSG Boilers of CPP-

1

Flue Gas: 70000

Nm3/hr

- Flue Gas: 70000

Nm3/hr

12 For Thermopack

(3000 U)-1


13 For Thermopack

(3000 U)-2


14 For Thermopack

(1500 U)-3

Natural Gas: 180

Nm3/hr

- Natural Gas: 180

Nm3/hr

15 For Hot Air Generator

(45 Lacs Kcal/hr Capacity)


16 For D. G. Sets HSD: 1380 Lit./hr 420 Lit./hr HSD: 1800 Lit./hr

17 For Hot Air Generator-1


- Coal: 1750

Kg/hr

Coal: 1750 Kg/hr

18 For Hot Air Generator-2


- Coal: 1750

Kg/hr

Coal: 1750 Kg/hr

73

ANNEXURE –X

DETAILS OF HAZARDOUS CHEMICALS STORAGE & HANDLING

Sr. No. Name of the Hazardous

Substance (Mention

Concentration if any)

Quantity

Max.

that

can be

stored

M.T.

Type &

No. of

Containers

(M.T.)

**

Quantity

Actually

Stored

(Including

in process

& handling

M.T

Type of

hazards

Possible

(Fire, Explosion

,Toxic

Release,

Spill etc.

1. Sulphuric Acid

12.50 T:12.5 x1 10.00 Corrosive & Spill, if

leak from tank 50.00

12.50

08.00

12.50

T: 50 x 1

T: 12.5x1

T: 08 x 1

T:12.5 x 2

50.00

10.00

08.00

20.00

2. Phosphoric acid 20.00 T: 20 x 1 20.00 -Do

3. Caustic Lye 10.00

10.00

02.00

50.00

T: 10x1

T: 10x2

T: 02x1

T: 50x1

10.00

20.00

02.00

50.00

-Do-

12.5

12.5

T: 12.5X1

T: 12.5X1

10.00

10.00

4. Spent Acid 25.00

25.00

10.00

T: 25 x 1

T: 25 x 1

T: 10 x 1

25.00

25.00

10.00

-Do-

5. Nash 12.50 T: 12.5x1 12.50 -Do-

6. Oleum (23%)

50.00

12.50 T: 50 x1

T: 12.5X2

50.00

20.00

-Do-

7. Oleum (65%) 12.50 T: 12.5X1 12.00 -Do-

8. Nitric Acid 09.00

09.00

20.00

09.00

07.00

T:08 x 1

T:09 x 1

T:20X 1

T:09X 1

T:07X1

8.00

18.00

20.00

9.00

7.00

Corrosive & Spill, if

leak from tank

9. Hydro Chloric Acid 10.00

20.00

20.00

50.00

35.00

T:10 x 2

T:20 x 1

T:20X 2

T:50X3

T:35X0

20.00

20.00

40.00

150.00

70.00


leak from tank

10 Nitrosyl Sulphuric Acid 25.00

5.00

5.00

6.00

5.00

T: 25 x 1

T: 5.0 x 1

T: 5.0 x 1

T: 6.0 x 1

T: 5.0 x 1

25.00

5.00

5.00

6.00

5.00


leak from tank

11 DES 10.00 T: 10 x 1 10.00 -Do-

12 Chloro Sulphonic Acid 10.00 T: 10X1 10.00 Corrosive, Spill &

Toxic gas release, if

leak from tank

13.

Acetic Acid 10.00 T: 8.5 x 1 08.50 Combustible if spill

from tank & comes

in contact with heat

& spark

10.00 T: 10 X 1 10.00

14 Methyl Aceto Acetate 10.00 T: 10 X 1 10.00 -Do-

15. Phenol 50.00 T: 50 x 1 50.00

74

12.50 T:12.5X3 30.00

16. DMF 15.00

12.00

T: 15 x 2

T: 12 x 2

30.00

12.00

-Do-

17. Metsol 200 12.50 T: 12.5x 1 10.00 -Do-

18. Nitro Benzene 12.50 T:12.5X2 20.00 -Do-

19. Aniline Oil 12.50 T:12.5X1 10.00 -Do-

20. ODCB 12.50 T:12.5X1 10.00 -Do-

21. DNCB 25.00 T:12.5X2 20.00 -Do-

22. CI Liquid 25.00 T: 25 x 3 75.00 -Do-

23. Xylene 14.00 T: 14 x 4 56.00 -Do-

24. P-Xylene 25.00 T: 25 x 1 21.00 -Do-

25 Heptene 25.00 T: 25 x 3 75.00 -Do-

26 Methanol 20.00 T: 20 x 13 260.00 -Do-

25.00 T: 25 X 7 175.00

27 Ethanol 20.00 T: 20 X 3 60.00 -Do-

28 HSD 25.00 T: 25 x 2 50.00 -Do-

29 Automate Red 1 20.00 T: 20 x 2 40.00 -Do-

30 Automate Yellow 1 20.00 T: 30 x 1 20.00 -Do-

31 Automate Blue 1 20.00 T: 30 x 1 20.00 -Do-

32 Formaldehyde (37%) 35.00 T: 35 x 2 70.00 -Do-

33 Ammonia (24%) 10.00

25.00

T: 10 x 1

T: 25 x 3

10.00

75.00

-Do-

34 Acetic Anhydride 20.00 T: 20 x 1 20.00 -Do-

35 Mono Methyl Amine 10.00 T: 10 x 1 10.00 -Do-

36 Di Ethylene Glycol 10.00 T: 10 x 1 10.00 -Do-

37 Ethyl chloride 0.6 Cy: 0.6

x 24

14.4 Fire, if Leak from

Cylinder & come in

contact with spark

& Toxic gas release

during ECL

combustion

38 Hydrogen 7

Quebec

Cy:

x 5

-- Fire, if Leak from

Cylinder & come in

contact with spark

39 Acetylene - Cy:

x 10

-- Fire, if Leak from

Cylinder & come in

contact with spark

40 LPG .00145 Cy: 0.0014514.5

x 4

0.058 Fire, if Leak from

Cylinder & come in

contact with spark

41 Chlorine 0.900 Cy: 0.900

x 36

32.40 Toxic gas release, if

Leak from Cylinder

or CL2 handling

system

42 Ammonia 0.05 Cy: 0.050

x 72

16.93


leak from Cylinder

43 Nitrogen 0.05 Cy: 0.050

x 10

0.5


leak from Cylinder

75

44 Liquid Ammonia 0.350 CR:

0.350 x 8

receivers +

0.450 x

21receivers +

0.150 x 3

receiver

(in RAC)

13.33 Toxic gas release, if

Leak from Cylinder

or NH3 chilling

system

45 Phosph-orous Oxychloride 15.00 C: 0.05 x 300 15.00 Corrosive & Spill, if

leak from Carboy/

Drum

46 Hydrogen Peroxide 10.00 C: 0.050 x 200 10.00 -Do-

47 Benzoyl chloride 25.00 D: 0.200x125 25.00 -Do-

48 Petroleum Class “A” &

Class “B” Drum storage

(Toluene,

Acetone,

Sodium Methoxilate

Xylene)

40.00 D: 0.200

x 200

40.00 Fire, if spill from

drum & comes in

contact with spark.

49 Allyl Chloride 50.00 D: 0.2 x 250 50.00 -Do-

50 Mono Ethyl Amine 12.00 D: 0.200

x 60

12.00 -Do-

51 Mono Chloro Benzene 12.00 D: 0.200

x 60

12.00 -Do-

52 N-Butyl Amine 15.00 D: 0.200

x 75

15.00 -Do-

53 3 Methoxy Propile Amine 10.00 D: 0.200

x 50

10.00 -Do-

54 Pyridine 2.00 D: 0.200

x 10

2.00 -Do-

55 Piperidine 2.00 D: 0.200

x 10

2.00 -Do-

56 Methane sulfonyl chloride 40.00 D: 0.200

x 200

40.00 Fire, if spill from

drum & comes in

contact with spark &


leak from drum

57 Benzene sulphonyl chloride

(BSC)

20.00 D: 0.200

x 100

20.00 -Do-

58 Melonitrile 20.00 D: 0.200

x 100

20.00 -Do-

59 Dimethyl Sufate 25.00 D: 0.2 x 125 25.00 -Do-

60 Diethyl Sufate 25.00 D: 0.2 x 125 25.00 -Do-

61 2:4 Xylidine 20.00 D: 0.2 x 20 4.00 -Do-

62 2:5 Xylidine 20.00 D: 0.2 x 20 4.00 -Do-

63 2:6 Xylidine 20.00 D: 0.2 x 20 4.00 -Do-

64 Mix Xylidine 10.00 D: 0.2 x 50 10.00 -Do-

65 3 Chloro propionyl chloride 05.00 D: 0.2 x 25 5.00 -Do-

66 2Amino Thio Phenol 05.00 D: 0.2 x 25 5.00 -Do-

67 3 Ethoxy Propyl Amine 10.00 D: 0.2 x 50 10.00 -Do-

68 Acrylic Acid 2.00 D: 0.2 x 10 2.00 -Do-

69 Anisole 2.00 D: 0.2 x 10 2.00 -Do-

70 Iso Butanol 2.00 D: 0.2 x 10 2.00 -Do-

76

71 Octanol 2.00 D: 0.2 x 10 2.00 -Do-

72 Cresylic Acid 10.00 D: 0.2 x 50 10.00 -Do-

73 Dawanol DPM 5.00 D: 0.2 x 25 5.00 -Do-

74 Ethylene Di Chloride 2.00 D: 0.2 x 10 2.00 -Do-

75 Methyl Acrylate 6.00 D: 0.2 x 30 6.00 -Do-

76 Propynyl Chloride 5.00 D: 0.2 x 25 5.00 -Do-

77 N Propyl Bromide 5.00 D: 0.2 x 25 5.00 -Do-

78 Mono Methyl Cyclo Hexyl

Amine

8.00 D: 0.2 x 40 8.00 -Do-

79 M Toludine 1.00 D: 0.2 x 5 1.00 -Do-

80 2 Ethylhexylamine 15.00 D: 0.2 x 75 15.00 -Do-

81 Trimethyl phosphite 25.00 D: 0.200 x 125 25.00 Toxic gas release, if

leak from drum

82 Benzyl Chloride 25.00 D: 0.200 x 125 25.00 -Do-

83 Cychlo Hexyl Amine 5.00 D: 0.2 x 25 5.00 -Do-

84 Di Ethyl Amine 2.00 D: 0.2 x 10 2.00 -Do-

85 Di Methyl Aniline 2.00 D: 0.2 x 10 2.00 -Do-

86 Di Methyl Amine 2.00 D: 0.2 x 10 2.00 -Do-

87 Di N-Butyl Amine 2.00 D: 0.2 x 10 2.00 -Do-

88 Mono Ethyl Amine 10.00 D: 0.2 x 50 10.00 -Do-

89 Ortho Toludine 20.00 D: 0.2 x 100 20.00 -Do-

90 Ortho Chloro Benzene 20.00 D: 0.2 x 100 20.00 -Do-

91 Para Cresol 3.00 D: 0.2 x 15 3.00 -Do-

92 Para Toludine 20.00 D: 0.2 x 100 20.00 -Do-

93 Thionyl Chloride 5.00 D: 0.2 x 25 5.00 -Do-

94 Thiophene 2.00 D: 0.2 x 10 2.00 -Do-

95 Phosphorus trichloride 1.00 D: 0.2 x 5 1.00 -Do-

96 Hydrogen Bromide 1.00 D: 0.2 x 5 1.00 -Do-

97 Naphthalene 1000.00 B: 0.05

x 20000

1000.00 Combustible if

Splatter from bags &

comes in contact

with heat & spark.

98 Hydroquinone 00.40 B 0.05 x 8 00.40 -Do-

99 Sodium nitrite 80.00 B: 0.050

x 1600

80.00 -Do-

100 Para Chloro Aniline 06.00 B: 0.050

x 120

06.00 Cyanosis, if splatter

from bags & comes

in contact skin or

inhalation of dust

101 Para Nitro Aniline 120.0 B: 0.050

X 2400

120.00 -Do-

102 Phthalic anhydride 15.00 B: 0.050

x 300

15.00 Corrosive & Spill, if

splatter from bags

103 Potassium hydroxide 20.00 B: 0.050

x 400

20.00 -Do-

104 Caustic soda flakes 20.00 B: 0.050

x 400

20.00 -Do-

105 Sodium sulfide flakes 10.00 B: 0.050

x 200

10.00 -Do-

106 2 Chloro Acetamide 5.00 B: 0.050

x 100

5.00 -Do-

77

107 Mono Chloro Acetic Acid 5.00 B: 0.050

x 100

5.00 -Do-

108 Meta Amino Phenol 10.00 B: 0.050

x 200

10.00 -Do-

109 Para Anisidine 150.0 B: 0.050

x 3000

150.00 -Do-

110 Para Toluene Sulfonic Acid 1.00 B: 0.050

x 20

1.00 -Do-

111 Copper Chloride 20.00 B: 0.050

x 400

20.00 -Do-

112 Anthraquinone 30.00 B: 0.050

x 600

30.00 -Do-

113 Venyl Sulphone 50.00 B: 0.050

x 1000

50.00 -Do-

114 Ortho Nitro Chloro

Benzene

20.00 B: 0.050

x 400

20.00 -Do-

115 Aluminum chloride 10.00 B: 0.050 x 200 10.00 -Do-

116 Sodium Sulphite 100.0 B: 0.050

x 2000

100.00 -Do-

117 Vanadium Pentoxide 1.0 B: 0.0025

x 40

1.0 -Do-

118 Bromine 19.63

5

(3.5 kg x 6

bottle= 21kg in

1 box) 0.021 x

935 boxes

19.635 Corrosive, Spill &


leak from bottle

119 Benzoyl peroxide 0.400 FD: 0.04

x 10

1.0 -Do-

120 Aluminum Powder 0.250 FD: 0.025

x 10

0.250 -Do-

121 Sodium Chlorate 6.00 B: 0.050

x 120

6.00 Combustible if

Splatter from drums

& Bags in contact

with heat & spark.

122 Sodium Cyanide, Copper

Cyanide &

Zinc Cyanide

6.00 D: 0.050

x 120

6.00 Poison, if splatter

from drums & comes

in contact skin or

inhalation of dust

78

ANNEXURE – XI

DETAILS OF STACK AND VENT

EXISTING

A FLUE GAS EMISISON (EXISTING)

Sr

No Stack attached to

Stack Height

in Meter Parameters

Fuel

Consumption

Air Pollution Control

System

1. Steam Boiler-1 (8 TPH)

(Gas Fired )

32 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas --

2. Steam Boiler-2 (12 TPH)

(Gas Fired )

SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas --

3. Heat Recovery Steam

Generation Boiler

(HRSG)-1 (13.9 TPH)

36 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Flue Gas --

4. Captive Co-generation

Power Plant-1 (7.5 MW)

(Gas Based)

36 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas SoloNox System

5. Incinerator 1, 2, 3 40 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

LDO/HSD Cyclone & Ventury

Scrubber

6. Hot Air Generator-I 23.3 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas --

7. Thermopack (3000 U) –

Vertical

32.05

SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal Multicyclone Separator/

Teema Cyclone


Vertical

SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm


Teema Cyclone


Horizantal

SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas --

10. Hot Air Generator 18.9 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Natural Gas --

11. Steam Boiler-3 (8 TPH) 39.624 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm


Teema Cyclone

12. Steam Boiler-4 (6 TPH) 39.624 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm


Teema Cyclone

13. Steam Boiler-5 (25 TPH) 42 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal ESP

14. Steam Boiler (50 TPH) for

Captive Power Plant-(6

MWH) (Coal Fired)

60 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal ESP

15. Hot Air Generator

(45 Lac Kcal/hr) (Coal

Fired)

34 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal Teema Cyclone

79

16.

to

23.

D.G. Sets-8 Nos.

(725 KVA each)

11 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

HSD -

24. D.G. Sets-1 Nos.

(1500 KVA )

11 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

HSD -

B FLUE GAS EMISISON (PROPOSED)

1. Hot Air Generator-1

(80 Lacs Kcal/Hr)

35 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal Cyclone

2. Hot Air Generator-2

(80 Lacs Kcal/Hr)

35 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

Coal Cyclone

3. D. G. Set

(2000 KVA)

11 SPM: 150 mg/Nm3

SO2: 100 ppm

Nox: 50 ppm

HSD -

80

C PROCESS EMISSION (EXISTING)

Sr

No Vent attached to

Stack Height

(m) Pollutants Fuel

Air Pollution Control

System

1. Spray Drier-1 (P1/1) 14.64 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.


cyclone.


cyclone.


cyclone.


cyclone.


cyclone.

7. SFD-I (P1/7) 14.44 SPM: 150 mg/Nm3 -- Bag Filter

8. Chlorinator

Sulfonator (P2/1)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

9. Chlorinator

Sulfonator (P2/2)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

10. Chlorinator

Sulfonator (P2/3)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

11. Chlorinator

Sulfonator (P2/4)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

12. Chlorinator

Sulfonator (P2/5)

11.0 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System


cyclone.


cyclone.


16. Detoxification (P3/1-1) 9.760 Cl2: 9 mg/Nm3

NOx: 25 mg/Nm3

-- Packed Tower with Alkali

Scrubber

17. Chlorinator

Brominator (P4/1)

9.150 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

HBr: 30 mg/Nm3

Br2: 2 mg/Nm3

-- Two Stage Alkali

Scrubbing System

18. Chlorinator

Brominator (P4/2)

9.150 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

HBr: 30 mg/Nm3

Br2: 2 mg/Nm3

-- Two Stage Alkali

Scrubbing System

19. Reaction Vessel (P4/3) 11 NOx: 25 mg/Nm3 -- Two Stage Alkali

Scrubbing System

20. Reaction Vessel A-14,

B-21, B-24 (P4/4)

13.42 HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System


22. Sulfonator(P4-1/1) 12.81 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

23. Spray Drier-1(P4-1/2) 19.215 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

81

24. Spray Drier-2 (P4-1/3) 16.775 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

25. Spray Drier-3 (P4-1/4) 32 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

26. Chlorinator (P4-2/1) 9.150 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System + Four

Stage Alkali Scrubbing

System

27. Reaction Vessel(P4-2/2) 11.00 HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System

28. Brominator (P5/1) 9.150 HBr: 30 mg/Nm3

Br2: 2 mg/Nm3

-- Two Stage Alkali

Scrubbing System

29. Brominator (P5/2) 9.760 HBr: 30 mg/Nm3

Br2: 2 mg/Nm3

-- Two Stage Alkali

Scrubbing System

30. Chlorinator (P5/3) 9.150 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System


Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System


33. Sulfonator (P5A/1) 9.15 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System


Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System


Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System


Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

37. SFD-I (P6/4) 15.00 SPM: 150 mg/Nm3 -- Two Stage Alkali

Scrubbing System

38. SFD-2 (P6/5) 15.00 SPM: 150 mg/Nm3 -- Two Stage Alkali

Scrubbing System

39. Sulfonator (J1/1&2) 9.45 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Four Stage Alkali

Scrubbing System

40. Sulfonator (J1/3) 11.0 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

41. Chlorosulfonator (J1/4) 11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

42. Chlorosulfonator

(J1/5&6)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

H2S: 5 mg/Nm3

-- Two Stage Alkali

Scrubbing System

43. Chlorosulfonator

(J1/7&8)

11 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System

44. Amminolysis (J1/9) 17.08 NH3: 175 mg/Nm3 -- One Stage water

scrubbing system

45. Sulfonator (J1/10) 9.45 SO2: 40 mg/Nm3 -- One Stage Alkali

Scrubbing System

46. SFD-I (J1/11) 10.675 SPM: 150 mg/Nm3 -- Bag Filter

47. Cyclisation (J2Vat/1) 9.75 HCl: 20 mg/Nm3

-- Three Stage Alkali

Scrubbing System

48. Chlorinator (J2Vat/2) 11.0 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

49. Spray Drier-1 (J3/1) 15.25 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

82

50. Spray Drier-2 (J3/2) 18.25 SPM: 150 mg/Nm3 -- Water scrubber & cyclone

with multicyclone dust

collector

51. Spray Drier-3 (J3/3) 21.228 SPM: 150 mg/Nm3 -- Water scrubber & cyclone

with multicyclone dust

collector

D PROCESS EMISSION (Proposed)

1. Pulverizer 11.0 SPM: 150 mg/Nm3 -- Dust Collector

2. Spray Dryer-1 35.0 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

3. Spray Dryer-2 35.0 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.

4. Spray Drier-3 20.00 SPM: 150 mg/Nm3 -- Water scrubber &

cyclone.


cyclone.


cyclone.

7. SFD-I 20.00 SPM: 150 mg/Nm3 -- Bag Filter

8. SFD-2 20.00 SPM: 150 mg/Nm3 -- Bag Filter

9. SFD-3 20.00 SPM: 150 mg/Nm3 -- Bag Filter

10. Reactor Diazotisation 11.0 SO2: 40 mg/Nm3

NOx: 25 mg/Nm3

HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System


NOx: 25 mg/Nm3

HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System

12. Chlorinator 11.0 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

13. Condensation 11.0 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

14. Nitraion 11.0 Nox: 25 mg/Nm3

-- Two Stage Alkali

Scrubbing System

15. Amminolysis 11.0 NH3: 175 mg/Nm3 -- One Stage water

scrubbing system

16. Oxidation 11.0 SO2: 40 mg/Nm3

Nox: 25 mg/Nm3

-- Two Stage Alkali

Scrubbing System

17. Sulfonator 11.0 SO2: 40 mg/Nm3

Nox: 25 mg/Nm3

HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System

18. Chlorinator

Sulfonator

11.0 HCl: 20 mg/Nm3

SO2: 40 mg/Nm3

-- Two Stage Alkali

Scrubbing System


Nox: 25 mg/Nm3

HCl: 20 mg/Nm3

-- Two Stage Alkali

Scrubbing System

20. Detoxification 11.0 Cl2: 9 mg/Nm3

NOx: 25 mg/Nm3

-- Packed Tower with Alkali

Scrubber

21. Chlorinator 11.0 SO2: 40 mg/Nm3

HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

83

22. Condensation 11.0 HCl: 20 mg/Nm3

Cl2: 9 mg/Nm3

-- Two Stage Alkali

Scrubbing System

23. Nitraion 11.0 Nox: 25 mg/Nm3

-- Two Stage Alkali

Scrubbing System

24. Amminolysis 11.0 NH3: 175 mg/Nm3 -- One Stage water

scrubbing system

25. Halogenations 11.0 Nox: 25 mg/Nm3

HCl: 20 mg/Nm3

Two Stage Alkali

Scrubbing System

26. Oxidation 11.0 Nox: 25 mg/Nm3

-- Two Stage Alkali

Scrubbing System

Note: Stack no. 1 will be used for proposed expansion.

Stack No. 2 & 3 (Spray Dryer-1 & 2) is proposed for treatment of MEE concentrate.

We have already got the Environmental clearance issued vide the letter no. SEIAA/GUJ/EC/5(f)&1(d)/283/2009

dated 9/11/2009 for manufacturing existing products and to install stack no. 4 to 26 for the same.

We have got the CCA for existing products, but we have not installed the stack no. 4 to 26. So, stack no. 4 to 26 are

included in proposed stack, which will be used for existing as well as proposed production capacity.

84

ANNEXURE-XII

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 existing factory is 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 project 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 project is not expected to make any significant change in the

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

85

ANNEXURE-XIII

PROPOSED TORs

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.

• Existing infrastructure facilities

• Water source and utilization including proposed water balance.

• List of Products and their capacity

• List of hazardous chemicals with their toxicity levels.

• Mass balance of each product along with the batch size

• Storage and Transportation of raw materials and products.

2. Description of the Environment and Baseline Data Collection

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

area.

• Study of Data from secondary sources.

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

For SPM, RSPM, SO2, NOx.

• 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.

• 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

• Details on storage facilities

• Identification of hazards

86

• Consequence analysis

• Recommendations on the basis of risk assessment done

• Disaster Management Plan.

7. Information for Control of Fugitive Emissions

8. Post Project Monitoring Plan for Air, Water, Soil and Noise.

9. Occupational Health and Safety Program for the Project.

87

ANNEXURE-IXV

LAYOUT OF THE PLANT

88

ANNEXURE-XV

CSR ACTIVITIES

CONTRIBUTION FOR ECO DEVELOPMENT & SOCIAL WELFARE

BY COLOURTEX GROUP OF COMPANIES

Year Education Social Welfare Health &

Environment

1990-1995 Rs. 10,05,001 Rs. 4,71,688 -

1996-2000 Rs. 63,31,294 Rs. 30,68,332 Rs. 29,49,605

2001-2005 Rs. 51,86,484 Rs. 99,44,083 Rs. 39,04,781

2006-2010 Rs. 47,03,111 Rs. 47,93,711 Rs. 13,45,599

2011-2017 Rs. 3,25,60,698 Rs. 4,08,66,496 Rs. 1,17,05,001

Total Rs. 49786588 Rs. 59144310 Rs. 19904986

Grand Total Rs. 128835884.0

89

ANNEXURE-XVI

A COPY OF PERMISSION LETTER FOR DRAWING WATER FROM CANAL

90

91

ANNEXURE-XVII

THE COPIES OF ALLOTMENT LETTERS FOR LAND FROM G.I.D.C.

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

ANNEXURE-XVIII

A COPY OF CONSOLIDATED CONSENT & AUTHORIZATION

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

ANNEXURE-IXX

TOPOSHEET

141

ANNEXURE-XX

MAP OF 10 KM RADIAL DISTANCE FROM PROJECT SITE

Bhestan

Talangpor

Sachin

Pandesara

Kansad

Vanjh

Bhatha Pal

Palanpor

Rundh

Magdalla

Vesu Bharthana

Sarsana

Abhuva Khajod

Bhimrad

Bamroli

Dipli Jiav Sonari

Budia

Gabheni

Ubher Pali

Sachin

Bhanodra

Kharwasa

Saniya Kande

Goja

Mohni Karadva

Deladva

Dindoli

Godadara Dakhanw

aada

Dumbhal

Parvat Kumbharia

Puna

Saroli Sania Hemad

Magob

Vadod

Eklera

Devadh

Althan

Udhana

Un

Bhatar

Umra

Adajan

RanderKatargam

Documents

FORM-1 - Welcome to Environmentenvironmentclearance.nic.in/.../07_Oct_2017_181821747MXCP75D7Form1.pdf · FORM 1 (I) Basic Information Sr. ... 12. Village Panchayats, Zilla Parishad,