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.
Plot No.158, GIDC Estate, Pandesara, Dist: Surat,
Gujarat – 394 221
Name Mr. Kirit Gandhi
Designation (Owner/Partner/CEO) General Manager
Address M/s. Colourtex Industries Pvt. Ltd.
Plot No.158, GIDC Estate, Pandesara, Dist: Surat,
Gujarat – 394 221
Pin Code 394 221
E-mail [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
quantities/rates, wherever possible)
with source of information data
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:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data with
source of information data
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:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
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
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
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
quantities/rates, wherever possible)
with source of information data
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
Synthetic Organic (S.O.) Dyes-4 35 0 35
Azo Solvent Dyes
Synthetic Organic (S.O.) Dyes-5 300 0 300
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
AMINES COUPLING SOLN.
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)
SODIUM NITRITE PRIMARY
AMINES COUPLING SOLN.
ACID
FILTER PRESS
MOTHER FINISHED
LIQUOR REACTIVE
PUMP TO DYE
ETP
SPRAY
DRIER
27
PROCESS FLOW SHEET FOR REACTIVE DYES-1
(B)
SODIUM NITRITE PRIMARY
AMINES COUPLING SOLN.
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
SODIUM NITRITE PRIMARY
AMINES COUPLING SOLN.
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
5 H.acid tank – 2 1 7.88 m x 5.89 m x 4.50 m SWD 208.85 RCCTL
6 H.acid tank – 3 1 7.65 m x 6.44 m x 4.50 m SWD 221.70 RCCTL
7 H.acid tank – 4 1 7.65 m x 5.89 m x 4.50 m SWD 202.75 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
own TSDF site / TSDF site of
Saurashtra Enviro Project Pvt.
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
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.
26.1 Organic
Sludge
containing
Metal salt
From Process 40 60 100 Incineration in the Incinerators/
Sent for Co processing in the
Cement Industries/ Sent to Co-
processing to Recycling Solution
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.
Receive Collection, Storage,
Transportation, Disposal by
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
Receive Collection, Storage,
Transportation, Disposal by
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
Receive Collection, Storage,
Transportation, Disposal by
Incineration in the Incinerators
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)
Receive Collection, Storage,
Transportation, Disposal by
Incineration in the Incinerators /
Send for Co-processing in the
Cement Industries/ Sent to Co-
processing to Recycling Solution
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,
Transportation, Disposal by
Incineration in the Incinerators
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
own TSDF site / TSDF site of
Saurashtra Enviro Project Pvt.
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
Coal: 960 Kg/hr - Coal: 960 Kg/hr
6 For Steam Boiler
(25TPH)-5
Coal: 5000 Kg/hr - Coal: 5000 Kg/hr
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
Coal: 720 Kg/hr - Coal: 720 Kg/hr
13 For Thermopack
(3000 U)-2
Coal: 720 Kg/hr - Coal: 720 Kg/hr
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)
Coal: 1020 Kg/hr - Coal: 1020 Kg/hr
16 For D. G. Sets HSD: 1380 Lit./hr 420 Lit./hr HSD: 1800 Lit./hr
17 For Hot Air Generator-1
(80 Lacs Kcal/hr Capacity)
- Coal: 1750
Kg/hr
Coal: 1750 Kg/hr
18 For Hot Air Generator-2
(80 Lacs Kcal/hr Capacity)
- 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
Corrosive & Spill, if
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
Corrosive & Spill, if
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
Toxic gas release, if
leak from Cylinder
43 Nitrogen 0.05 Cy: 0.050
x 10
0.5
Toxic gas release, if
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 &
Toxic gas release, if
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 &
Toxic gas release, if
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
8. Thermopack (3000 U) –
Vertical
SPM: 150 mg/Nm3
SO2: 100 ppm
Nox: 50 ppm
Coal Multicyclone Separator/
Teema Cyclone
9. Thermopack (1500 U) –
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
Coal Multicyclone Separator/
Teema Cyclone
12. Steam Boiler-4 (6 TPH) 39.624 SPM: 150 mg/Nm3
SO2: 100 ppm
Nox: 50 ppm
Coal Multicyclone Separator/
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.
2. Spray Drier-2 (P1/2) 14.64 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
3. Spray Drier-3 (P1/3) 24.64 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
4. Spray Drier-4 (P1/4) 24.64 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
5. Spray Drier-5 (P1/5) 28.9 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
6. Spray Drier-6 (P1/6) 28.9 SPM: 150 mg/Nm3 -- Water scrubber &
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
13. Spray Drier-1 (P3/1) 13.725 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
14. Spray Drier-2 (P3/2) 13.115 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
15. SFD-I (P3/3) 12.22 SPM: 150 mg/Nm3 -- Bag Filter
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
21. SFD-I (P4/5) 14.44 SPM: 150 mg/Nm3 -- Bag Filter
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
31. Chlorinator (P5/4) 9.150 HCl: 20 mg/Nm3
Cl2: 9 mg/Nm3
-- Two Stage Alkali
Scrubbing System
32. SFD-I (P5/5) 15.25 SPM: 150 mg/Nm3 -- Bag Filter
33. Sulfonator (P5A/1) 9.15 HCl: 20 mg/Nm3
SO2: 40 mg/Nm3
-- Two Stage Alkali
Scrubbing System
34. Chlorinator (P6/1) 10.675 HCl: 20 mg/Nm3
Cl2: 9 mg/Nm3
-- Two Stage Alkali
Scrubbing System
35. Chlorinator (P6/2) 10.675 HCl: 20 mg/Nm3
Cl2: 9 mg/Nm3
-- Two Stage Alkali
Scrubbing System
36. Chlorinator (P6/3) 11.00 HCl: 20 mg/Nm3
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.
5. Spray Drier-4 20.00 SPM: 150 mg/Nm3 -- Water scrubber &
cyclone.
6. Spray Drier-5 20.00 SPM: 150 mg/Nm3 -- Water scrubber &
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
11. Reactor Diazotisation 11.0 SO2: 40 mg/Nm3
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
19. Reactor Diazotisation 11.0 SO2: 40 mg/Nm3
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
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