M/s. KASTURI POLYMERS AND PIGMENTS

Transcription

1 TECHNO ECONOMIC FEASIBILITY REPORT FOR DYES AND INTERMEDIATES MANUFACTURING UNIT OF M/s. KASTURI POLYMERS AND PIGMENTS PLOT NO. 4517, GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT PREPARED BY: M/s. KASTURI POLYMERS AND PIGMENTS PLOT NO. 4517, GIDC ESTATE,ANKLESHWAR DIST.: BHARUCH, GUJARAT

2 EXECUTIVE SUMMARY OF THE REPORT M/s. KASTURI POLYMERS AND PIGMENTS is planning to set up Dyes & Intermediate manufacturing unit (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary, Ecologically Sensitive Area within 20 KM radius. Around 1000 sq.m land is already acquired by M/s. Kasturi Polymers and Pigments. PROJECT COST Cost of the proposed project would be Rs Lacs. Total capital cost for environmental pollution control measures would be Rs. 25 Lacs and recurring cost per annum would be Rs Lacs. LIST OF PRODUCTS (PER MONTH) S. PRODUCT PRODUCTION CAPACITY No 1. Crude on Dry Powder Basis or Standardized and formulations of products MT/month 25 OR Intermediate Production (Captive use and/or Sell) R & D Products Ink Formulations OR Digital Ink Formulations (Reactive, Disperse and Vat) Micronization of Dyes and Pigments 5 Total ( ) 65 or 80 LIST OF PROPOSED BY-PRODUCTS WITH THEIR PRODUCTION CAPACITY S. No. By Products Qty ( 5 MT % Sodium Bromide solution % Sulphuric Acid solution 35 M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

3 LIST OF PRODUCTS ARE GIVEN IN FOLLOWING TABLE. Sr. No. CAS No. E U No Chemical Name Commercial Name Molecular Formula 1. Crude dyes on dry Powder basis or Standardized & formulations of products 1,3-Benzenedicarbonitrile, 2-((4-(diethylamino) C19H18N6O3 Disperse Blue DBR -2-methylphenyl)azo)-5-nitro- Disperse Blue 366 2,2'-[[3-cyano-4-[(2,6-dichloro-4-nitrophenyl)azo] Disperse Brown 3 RD C16H15Cl3N3O4S phenyl]imino]bisethanol Disperse Brown 1 Ethanol, 2,2'-((4-(2-(2-bromo-6-chloro-4- C16H15BrCl2N4O4 Disperse Fast Brown D3R nitrophenyl)diazenyl)-3-chlorophenyl)imino)bis- Disperse Brown 4 Propanenitrile, 3-(butyl(4-(2-(4- C19H21N5O3 Disperse Orange SE-RH nitrophenyl)diazenyl)phenyl)imino)- Disperse Orange [[4-[[5,6(or 6,7)-Dichloro-2-benzothiazolyl]azo] C19H16Cl3N5S Disperse Red BS -3-methylphenyl]ethylamino]propanenitrile Disperse Red [[4-[[5,6(or 6,7)-Dichloro-2-enzothiazolyl]azo]phenyl] C19H17Cl2N5S2 Disperse Scarlet GS ethylamino]-propanenitrile Disperse Red 153 N-[5-[Bis[2-(acetyloxy)ethyl]amino]-2-[(2-chloro-4- C22H24ClN5O7 Disperse Dark Red 2B nitrophenyl)azo]phenyl]-acetamide Disperse Red Pyridinecarbonitrile,5-[2-(2-chloro-4- C27H28N8O5Cl nitrophenyl)diazenyl] Disperse Scarlet XF Disperse Red 279-3,6-methoxypropylamino-4-methyl N-[2-[(2-cyano-4-nitrophenyl)azo]-5-(diethylamino) C19H20N6O3S Disperse Violet 3RL phenyl]acetamide Disperse Violet 63 Acetamide,N-[2-[2-(2-Chloro-4,6-dinitrophenyl)diazenyl]- C18H19Cl2N6O5 Disperse Dark Blue 5R 5-(diethylamino)phenyl]- Disperse Violet 93 3-Pyridinecarbonitrile, 1,2-dihydro-6-hydroxy-1,4-dimethyl C20H16N4O4S Disperse Yellow 6GL -2-oxo-5-(3-(4-((phenylsulfonyl)oxy)phenyl)diazenyl)- Disperse Yellow [2-(4-bromo-2-nitrophenyl)diazenyl]-1-methyl-1,2- C15H12ClBrN5O4 Disperse Yellow 4G dihydro-6-hydroxy-4-methyl-2-oxo-3-pyridinecarbonitrile Disperse Yellow hexyl-5-[(2-chloro-4-nitrophenyl)azo]-1,2-dihydro C18H19ClN6O3 Disperse Yellow XF -6-hydroxy-4-methyl-2-oxo-3-Pyridinecarbonitrile Disperse Yellow [7-(diethylamino)-2-oxo-2H-1-benzopyran-3-yl] C20H20N4O5S.Na Acid Brilliant Yellow 8G -1H-benzimidazolesulphonate Acid Yellow 184 End Use Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Nylon H-Benzimidazolium,2-[7-(diethylamino)-2-oxo- Basic Brilliant Yellow C23H25N3O2.Cl Acrylic Quantit y (Tons) 25 (Crude Dyes) OR 40 (Formul ated Dyes) M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

4 H-1-benzopyran-3-yl]-1,3-dimethyl-, chloride 10GFF Basic Yellow 40 2-[7-(Diethylamino)-2-oxo-2H-1-benzopyran-3-yl]-1,3- dimethyl-1h-benzimidazolium methyl sulfate 3-(Diethylamino)-7-imino-7H-[1]benzopyrano[3',4':3,4] pyrido[1,2-a]benzimidazole-6-carbonitrile 3-(Diethylamino)-7-oxo-7H-[1]benzopyrano[3',4':3,4] pyrido[1,2-a]benzimidazole-6-carbonitrile 7-(Diethylamino)-3-(5-chlorobenzoxazol-2-yl)-2- benzopyrone 7-(Diethylamino)-3-(5-methylbenzoxazol-2-yl)-2- benzopyrone Basic Brilliant Yellow 10GFF Disperse Fluorescent Red G Disperse Fluorescent Pink RBSF (2-Benzothiazolyl)-7-(diethylamino)coumarin Coumarine Propanedinitrile,2-[2-[[4-(dihexylamino)-2-methylphenyl] methylene]-1,1-dioxidobenzo[b]thien-3(2h)-ylidene]- 2-methoxyethyl-2-(4-(2,6-dihydro-2,6-dioxo-7-phenyl -1,5-dioxaindacen-3-yl)ethoxy)acetate 4-Amino-N-(2,4-diethylphenyl)naphthalene-1,8- dicarboximide 1,3,3-Trimethyl-2-[(1E,3Z)-3-(1,3,3-trimethyl-1,3-dihydro- 2H-indol-2-ylidene)-1-propen-1-yl]-3H-indolium 2-[2-[4-[(2-Chloroethyl)methylamino]phenyl]ethenyl]-1,3,3- triethyl-3h-indolium chloride 2-[2-[4-[(2-Cyanoethyl)methylamino]phenyl]ethenyl]-1,3,3- trimethyl-3h-indolium chloride N-Methyl-N-Cyanoethyl-4-[2-(1,3,3-triethylindol-1-ium-2- yl) ethenyl]aniline;chloride [2-[[4-[(2-chloro-4- nitrophenyl)azo]phenyl]ethylamino]methyl]triethylammoniu m chloride Disperse Fluorescent Yellow 10GN Disperse Fluorescent Yellow 10GN Disperse Blue SR Disperse Brilliant Scarlet DSF Fluorescent Yellow Y Cationic Astra Phloxine FF Cationic Pink FG Cationic Brilliant Red 4G Cationic Brilliant Red X-B Cationic Red GTL C22H26N3O2.CH3O 4S Basic Yellow 40 C25H19N5O Disperse Red 277 Solvent Red 197 C25H18N4O2 Disperse Red 362 Solvent Red 196 C18H14ClN2O3 Disperse Yellow 232 Solvent Yellow 160:1 C24H20N2O4 Disperse Yellow 184:1 C21H19N2O2S2 Solvent Yellow 196 Disperse Yellow C31H37N3O2S Disperse Blue 354 C27H22O8 Disperse Red 367 C20H16N2O3 Solvent Yellow 44 FD & C Yellow 11 C25H33Cl2N3 Basic Red 12 C25H30Cl2N2 Basic Red 13 C23H31ClN4 Basic Red 14 C26H31Cl2N3 Basic Red 15 C20H29Cl2N5O4 B0asic Red 18 Acrylic Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Polyester Plastics Acrylic Acrylic Acrylic Acrylic Acrylic M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

5 [2-[[4-[(2-cyano-4- nitrophenyl)azo]phenyl]methylamino]methyl] trimethylammonium chloride N,N-diethyl-4-[2-(1,3,3-trimethylindol-1-ium-2- yl)ethenyl]aniline;chloride 2,4-dimethoxy-N-[(E)-2-(1,3,3-trimethylindol-1-ium-2- yl)ethenyl]aniline;chloride methyl sulfate;n-methyl-n-[(e)-(1,3,3-triethylindol -1-ium-2-yl) methylideneamino]aniline 4-methoxy-N-methyl-N-[(E)-(1,3,3-trimethylindol-1-ium-2- yl)methylideneamino]aniline;methyl sulfate 2-[[[4-[(2-cyanoethyl)methylaminolphenyl]azo]-6-ethoxy-3- methyl]methyl sulfate 4-[(6-chloro-3-methyl-1,3-benzothiazol-3-ium-2- yl)diazenyl]-n,n-dimethylaniline;methyl sulfate 2-[N-ethyl-4-[(6-nitro-3-methyl-1,3-benzothiazol-3-ium -2-yl)diazenyl]anilino]ethanol;methyl sulfate Cationic Brilliant Red 5BL Cationic Red Violet 3R Cationic Yellow 3G Cationic Yellow 5GL Cationic Golden Yellow GL 200 % Cationic Blue X-FRL Cationic Brilliant Blue 2RL Cationic Blue X-GRL C25H33N6O6S Basic Red 24 C23H33ClN2 Basic Violet 16 C25H29ClN2O2 Basic Yellow 11 C23H28N3O4S2 Basic Yellow 51 C21H24N3O.CH3O4 S Basic Yellow 28 C20H23N5O5S2 Basic Blue 162 C18H22N4O6S1 Basic Blue 54 C20H26N4O7S3 Basic Blue 41 Acrylic Acrylic Acrylic Acrylic Acrylic Acrylic Acrylic Acrylic M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

6 Total (A) 25 r List of Intermediates Sr. No. CAS No. Chemical Name Commercial Name End Use Quantity (Tons) Ethyl Benzoyl Aniline EBA Oxo-2,3-dihydrobenzo[b]thiophene-1,1-dioxide 3-OXO (Dicyanomethylidene)-2,3-dihydrobenzothiophene-1,1-dioxide Propanedinitrile Derivative N,N-Dihexyl-m-Toluidine DHMT Pyridinecarbonitrile, 1,6-dihydro-2-hydroxy-1,4-dimethyl-6-oxo- M P Ethyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile E P Butyl-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile B P Captive Use or Production (3-Methoxypropyl)-1,2-dihydro-6-hydroxy-4-methyl-2-oxonicotinonitrile 3-MPA P of Dyes (diethylamino)salicylaldehyde DEMAP Aldehyde 10 N/A Butoxy Mandelic Acid B M Acid Propoxy Mandelic Acid P M Acid Hydroxy-2-oxo-3-phenyl-2,3-dihydrobenzo[1,2-b]furan 1/2 Condensed Mass ,6-Dibromo-4-Methyl Aniline DBPT Benzothiazole Derivatives B T Derivatives TOTAL (B) R & D Products 10 TOTAL (C ) Ink Formulations, Digital Ink Formulations (Reactive, Disperse and Vat) 10 TOTAL (D) Micronization of Dyes and Pigments 05 TOTAL (E) 05 TOTAL (A+B+C+D+E) Tones Per Month 65 or 80 M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

7 REQUIREMENTS FOR THE PROJECT Land: Total 1000 sq. meter (existing + proposed) land already acquired in Ankleshwar Industrial Estate. Water: Water requirement will be mainly for the process KL/day, boiler and cooling 3.0 KL/Day approx. (Make up quantity), Floor & drum washing 1.5 KL/D, Domestic 4.0 KL/Day and for gardening 2.5 KL/Day. Domestic waste water i.e. 3.4 KL/Day will be generated which will be treated through septic tank and disposed through soak pit/well. Industrial effluent will be treated in in-house ETP of capacity 40 KLD and treated effluent will be sent to CETP of M/s. Enviro Technology Limited (ETL), Ankleshwar. Electrical Energy: Total power requirement will be 375 KVA. Power supply shall be taken from DGVCL. In case of Power failure, D. G. set of 125 KVA will be provided to fulfill the power requirement. Fuel: For the proposed project Diesel/LDO for Steam Boiler and Thermic Fluid Heater will be used at the rate 6.0 Ton/day and Diesel i.e. 100 Lit/Hr. will be required for the D.G. set which will be purchased from the nearest petrol pump in drum and transported by road only. Manpower: The proposed plant will have employment potential providing employment to approximately 14 full time persons. SOURCES OF POLLUTION AND CONTROL MEASURES FLUE GAS EMISSION AND CONTROL MEASURES ARE GIVEN IN FOLLOWING TABLE: NO. OF STACK STACK ATTACHED TO 1. Common stack attached to Steam Boiler (800 kg/hr) and Thermic Fluid Heater (8, 00,000 Kcal/hr). POLLUTION CONTROL EQUIPMENT Multi Cyclone STACK HEIGHT & DIAMETER Ht. 30 m Dia m POLLUTANTS (SPCB LIMIT) SPM < 150 mg/nm 3 SO 2 < 100 ppm NOx < 50 ppm UTILITY EMISSION AND CONTROL MEASURES: NO. OF STACK STACK ATTACHED TO 1. D. G. set of 125 KVA (In Emergency only). NAME & QUANTITY OF FUEL USED Diesel 100 Lit./hr approx POLLUTION CONTROL EQUIPMENT Acoustic Enclosure STACK HEIGHT & DIA. (m) Ht. 9 m Dia. 0.3 m POLLUTANTS (APCB LIMIT) SPM < 150 mg/nm 3 SO 2 < 100 ppm NOx < 50 ppm WASTE WATER GENERATION AND ITS TREATMENT: Industrial waste water from process of 17.5 KL/day will be generated from the proposed project will be treated in in-house ETP and will be discharged in to CETP of M/s. Enviro Technology Limited (ETL), Ankleshwar for further treatment. Domestic waste water i.e. 3.4 KL/Day will be generated which will be treated through septic tank and disposed through soak pit/well. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project: 1. Encasement of noise generating equipment. 2. A thick greenbelt will be developed all around the plant boundary to act as noise attenuator. 3. In addition personnel working near high noise level generating sources will be provided with ear muffs. 4. Proper and suitable acoustic barrier will also be provided around areas generating high noise. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

8 5. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also noise reduction. SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes generation and its management are given in the following table. S. NO. NAME OF CATEGORY QTY/MONTH DISPOSAL METHODOLOGY WASTE 1. Spent/Used oil Liters Collected in drums and stored at specified sludge area and sold to approved/registered vendors. 2. Discarded drums/ Containers Nos. Collected and stored at specified area and sold to approved/ registered vendors. 3. Evaporator residue Ton Collected in drums, packed, labeled and stored at specified area and finally transferred to common waste incineration and land fill site facility of BEIL Ankleshwar 4. ETP Sludge Ton ETP sludge will be sent to BEIL Ankleshwar. GREEN BELT DEVELOPMENT About sq.m area i.e % of total plot area shall be developed as green belt at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs Lacs approx. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

9 INDEX CHAPTER CONTENT PAGE 1. INTRODUCTION OF THE PROJECT 1 2. PROJECT DESCRIPTION 3 3. SITE ANALYSIS PLANNING BRIEF PROPOSED INFRASTRUCTURE REHABILITATION AND RESETTLEMENT (R & R) PLAN PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL 77 M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

10 LIST OF TABLES TABLE PARTICULAR PAGE 1 DETAILS OF THE DIRECTORS 1 2 DETAILS OF EMPLOYMENT REQUIREMENT 8 3 DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) 65 4 DETAILS OF WASTEWATER GENERATION 66 5 DETAILS OF SOLID WASTE 67 6 DETAILS OF EXISTING LAND USE 68 7 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 69 8 TEMPERATURE DATA 69 9 RAINFALL DATA DETAILS OF SOLID WASTE MANAGEMENT PROJECT IMPLEMENTATION SCHEDULE TOTAL PROJECT COST AND IT S BREAK UP 76 LIST OF FIGURES FIGURE PARTICULAR PAGE 1 MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC. 2 MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC. 3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL LIST OF ANNEXURES ANNEXURE PARTICULAR PAGE 1 LAND AGREEMENT DOCUMENTS 80 2 LAYOUT OF THE PLANT 85 M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat

11 INTRODUCTION OF THE PROJECT CHAPTER IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. Kasturi Polymers and Pigments, a company promoted by reputed business families of South Gujarat. The management of M/s. Kasturi Polymers and Pigments has decided to set up Dyes & Intermediate manufacturing (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Land document is attached as Annexure- I. TABLE 1: DETAILS OF THE DIRECTORS S. NO. NAME OF THE DIRECTOR AGE QUALIFICATION EXPERIENCE 3. Mr. Jasmin J. Lekhadia 49 years B. Pharm 25 years of Exp. In Dyes and intermediates The company has been promoted by Mr. Jasmin Jyotindra Lekhadia having a widespread business interests in Gujarat. The promoter has been in the business of Dyes & Intermediates for over 26 years and he has excellent knowledge of South Gujarat Industry Environment. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. Kasturi Polymers and Pigments is planning to set up Dyes & Intermediate manufacturing unit (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth. Existing Indian production, are not enough to cater the needs of Indian Consumer, hence Chinese products are also making dent in the Indian markets, though they are costly due to logistic cost and are not able to provide wide range of choices to the Indian Customers. Present capacity is negligible in term of overall demand in the world, so a huge market, and considering our high quality products as well customization of product, we don t foresee any hurdle in marketing of product. Our proposed plant will be located near user Industry, hence it provides logistic support as well as customize quantity in small quantities can also be supplied to the customer, which give company a clear edge compared to Chinese Imports, which cannot be supplied in small quantities coupled with time consumed on import. We have a very strong and experienced after sales service which are also known as Technical Service Department (TSD) which guides customer to obtain better results from our products. Market for disperse dyes is 10% per annum, and there are only two major producers in the Industry. Our continuous technological research and product development and superior after sales services will ensure increase in market share and eventually better net sales realization. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 1

12 Strong presence in the value added product Wide range of product to meet customized need. Long standing relationships with leading consumer Industries. 1.4 DEMAND SUPPLY GAP The Indian dyestuff industry is widely fragmented between the organized and unorganized sector. There are approximately 950 dye manufacturing unit in India, of which 50 units are in the organized sector and 900 are in the un-organized sector. The two western states of Maharashtra and Gujarat account for over 90% of the total dyestuff production in the country. The textile industry is the largest user of dye-stuffs in India, It account for 70-75% of the domestic dye consumption. With the increasing pressure on cotton fiber, synthetics like polyester are expected to over perform the overall chemical Industry. The dyestuff Industry worldwide is witnessing a gradual shift of manufacturing facilities from the developed countries to Asia, particularly china and India due to environmental considerations, availability of trained and inexpensive manpower and the relocation of the end-user industries, mainly textile and leather to the Asia-pacific region. India has emerged as a global supplier of dyestuff and dye intermediates, particularly for requirement of the domestic market and has gradually also made a dent in the global market. Indian dyestuff market is in general dominated by Chinese companies, as there are very few large scale manufacturing companies in India who can cater the need of Indian demand. We are expected to be the major recipient of benefits arising out due to expected growth, and consolidation in the Industry. PRODUCT PROFILE Our products are backed by unique technology and or process, and are not readily available with the competitor. These products play an important role in the production process of the user and hence user do not compromise or shift from tested products and user industry TECHNOLOGY Technology is typically developed in-house with the critical equipment being out-sourced. We have in-house independent R & D, equipped with latest state of art technologies and facilities. 1.5 EMPLOYMENT GENERATION DUE TO THE PROJECT The manpower requirement for the project is estimated at about 85 excluding contract / casual labour. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break up of the manpower requirement is as under: TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT S. NO. DESCRIPTION EXISTING PROPOSED 1 Top Management Managers Specialist/ Engineer/Officers Supervisors Operators/Attendants 4 6 TOTAL 9 14 Thus, from the viewpoint of infrastructural facilities, no major constraints are envisaged. M/s. Kasturi Polymers and Pigments is going to manufacture dyes and dye intermediate product for mainly textile dyeing and printing industry. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 2

13 PROJECT DESCRIPTION CHAPTER TYPE OF PROJECT M/s. Kasturi Polymers and Pigments is planning to set up Dyes & Intermediate manufacturing unit (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Our proposed products are Import substitute and almost consumed in the Indian market only. We believe that Indian consumption growth will continue to be there, considering demographic ratio in favor of youth. 2.2 LOCATION WITH COORDINATES A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure 1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 3

14 COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per the mentioned below: Latitude: N Longitude: E FIGURE 2: MAP SHOWING LOCATION OF THE PROJECT SITE, BOUNDARIES, LANDMARK FEATURES, ROADS, RAILWAYS, ETC. 2.3 DETAILS OF ALTERNATE SITES The proposed project site is situated at Plot no. 4517, GIDC, Ankleshwar, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labours are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 2.4 SIZE OR MAGNITUDE OF OPERATION M/s. Kasturi Polymers and Pigments is planning to set up Dyes & Intermediate manufacturing unit (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 4

15 DETAILS OF PRODUCTION AND MANUFACTURING PROCESS: 1-INTRODUCTION Disperse dyes manufactured by M/s. Kasturi Polymers & Pigments is essentially low molecular weight derivatives of azo compounds. They generally melt at above 130 C and are crystalline materials which are ground with dispersing agents to produce particles smaller than two micron. The aqueous paste obtained by grinding is spray dried. Important requirement for spray dried powders are the storage stability and the ease with which the powders can be re-dispersed in water. The actual dye content of commercial products may vary from 20 to 60%. To manufacture crude disperse azo dyestuff primary aromatic amine is diazotized and coupled with tertiary aromatic amines. 2. MANUFACTURING PROCESS 1. Disperse Blue 366 (Step 1) 1) Diazotization of C6H4Br2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake dried and used in next step. C6H4Br2N2O2 + H2SO4 + Nitrosyl Sulphuric Acid + C11H17N C19H18N4O2Br2 Disperse Blue 366, step-1 C6H4Br2N2O2 880 kg Sulphuric Acid 2750 kg Sodium Nitrite 215 kg Diazotization 3845 kgs Water 500 kg C11H17N 735 kg HCL 600 kg Coupling ICE 7500 kg kgs Water 3700 kg Filtration and Washing 4880 kgs Wet Cake for Drying 3515 kgs Dry Crude C17H18Br2N4O2 (1365 kg) kg Water for ETP M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 5

16 Disperse Blue 366 (Step 2) 1) Cyanation of above monoazo dyes is carried out in solvent. 2) Prepared solution of dyes and then added metal cyanide. 3) Closed the vessel and reaction is carried out at elevated temperature. 4) Isolation is done by cooling and addition of Methanol. 5) Filter the product and wash with water. 6) Re-slurry the wet cake in 5 % ammonia solution. 7) Filter the wet cake and ML sent to recovery plant. C19H18N6O2 + Metal Cyanide + DMF C19H18N6O2 + DMF Disperse Blue 366, STEP-2 DMF 3000 kg First step 1365 kg Zn (CN) 300 kg Reaction Vessel CuCN 25 kg 4690 kgs MeOH 3200 kg Isolation MeOH 1000 kg 7890 kgs Filtration and Washing 2500 kgs Wet Cake for Drying 1500 kgs Dry Crude (1000kg) C17H18Br2N4O2 DMF and MeOH 6390 kg for Distillation M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 6

17 2. Disperse Brown 1 1) Diazotization of C6H4Cl2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C6H4Cl2N2O2 + H2SO4 + NSA + C10H14ClNO2 + HCl C16H15Cl3N4O2 + HCl + Surfactant Disperse Brown 1 C6H4Cl2N2O2 525 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite 180 kg 3205 kgs Water 500 kg C10H14ClNo2 615 kg Coupling HCL300 kg Ice 7500 kg kgs Water 3000 kg Filtration and Washing 3000 kgs kg Water for ETP Wet Cake for Drying 2000 kgs Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 7

18 3. Disperse Brown 4 1) Diazotization of C6H4Cl2N2O2 is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C6H4BrClN2O2 + H2SO4 + NSA + C10H14ClNO2 + HCl C16H15BrCl2N4O2 + HCl + Surfactant Disperse Brown 4 C6H4BrClN2O2 575 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite 180 kg 3255 kgs Water 500 kg C10H14ClNO2 550 kg Coupling HCL300 kg Ice 7500 kg kgs Water 3000 kg Filtration and Washing 3000 kgs kg Water for ETP Wet Cake for Drying 2000 kgs Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 8

19 4. Disperse Orange 288 1) Here C6H6N2O2 is diazotized in sulphuric acid with sodium nitrite and ice. 2) Transfer the diazo slowly to coupler solution and stir. 3) Check the completion of coupling and filter and wash the wet cake with water. 4) Wet cake sent to sand milling and spray drying. C6H6N2O2 + H2SO4 + NaNO2 + C16H16N2 C22H22N5O2 + H2SO4 Disperse Orange 288 C6H6N2O2 420 kg HCL 1050 kg Sodium Nitrite 215 kg Diazotization ICE 4000 kg Water 500 kg 6185 kgs Water 500 kg C16H16N2 615 kg Coupling HCL300 kg Ice 3500 kg kgs Water 3000 kg Filtration and Washing 4000 kgs Wet Cake for Drying 3000 kgs kg Water for ETP Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 9

20 5. Disperse Red 152 1) Diazotization of C7H4Cl2N2OS is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H4Cl2N2OS + H2SO4 + NSA + C12H16N2 + Surfactant C19H20Cl2N5OS + H2SO4 +Surfactant Disperse Red 152 C7H4Cl2N2S 555 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite 185kg 3240 kg Water 500 kg C12H16N2 500 kg Coupling HCL 250 kg Ice 7500 kg kg Water 3000 kg Filtration and Washing 3000 kg kg Water for ETP Wet Cake for Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 10

21 6. Disperse Red 153 1) Diazotization of C7H4Cl2N2OS is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add surfactant, sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C 7 H 4 Cl 2 N 2 S + H 2 SO 4 + NSA + C 11 H 14 N 2 + Surfactant C 18 H 19 Cl 2 N 5 OS + H 2 SO 4 +Surfactant Disperse Red 153 C7H4Cl2N2S 600 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite kg Water 500 kg C11H14N2 630 kg Coupling HCL 300 kg Ice 7500 kg kg Water 3500 kg Filtration and Washing 3500 kg Wet Cake for Drying 2500 kg Dry Crude 1000 kg kg Water for ETP M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 11

22 7. Disperse Red 167 1) Diazotization of C6H5ClN2O2S is carried out in hydrochloric and sodium nitrite. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C6H5ClN2O2S + HCl + NaNO2 + C16H18N2O C22H24ClN5O4S Disperse Red 167 C6H5ClN2O2 600 kg HCL 1450 kg Sodium Nitrite 150 kg Diazotization Water 500 kg Ice 3500 kg 6200 kg Water 500 kg C16H18N2O 675 Coupling HCL 300 kg Ice 4000 kg kg Water 3000 kg Filtration and Washing 3000 kg kg Water for ETP Wet Cake for Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 12

23 8. Disperse Red 279 1) Diazotization of C7H5N3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5N3O2 + H2SO4 + NSA + C14H18N4O3 C22H23N7O4S Disperse Red 279 C7H5N3O2 400 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite 175 kg 3075 kg Water 500 kg C14H18N4O3 715 kg Coupling HCL 300 kg Ice 8000 kg kg Water 4000 kg Filtration and Washing 3500 kg kg Water for ETP Wet Cake for Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 13

24 9. Disperse Violet 63 1) Diazotization of C7H5N3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5N3O2S + H2SO4 + NSA + C12H18N2O C19H23N7O4S Disperse Violet 63 C7H5N3O2 555 kg Sulphuric Acid 2900 kg Diazotization Sodium Nitrite kg Water 500 kg C12H18N2O 540 kg Coupling HCL 300 kg Ice 8000 kg kg Water 4000 kg Filtration and Washing 3500 kg kg Water for ETP Wet Cake for Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 14

25 10. Disperse Violet 93 1) Diazotization of C7H5ClN3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5ClN3O2S + H2SO4 + NSA + C12H18N2O C20H23ClN6O3S Disperse Violet 93 C7H5N3O2 555 kg Sulphuric Acid 2500 kg Diazotization Sodium Nitrite 185 kg 3240 kg Water 500 kg C12H18N2O 540 kg Coupling HCL 300 kg Ice 8000 kg kg Water 4000 kg Filtration and Washing 3500 kg kg Water for ETP Wet Cake for Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 15

26 11. Disperse Yellow 211 1) Diazotization of C7H5ClN2O2 is carried out in hydrochloric acid and sodium nitrite. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5ClN2O2 +HCl + NaNO2 + C10H12N2O2 C17H18ClN5O4 Disperse Yellow 211 C6H5ClN2O2 465 kg HCL 1850 kg Diazotization Sodium Nitrite 210 Water 500 kg ICE 5000 kg 8025 kg Water 500 kg C9H12N2O2 520 kg Coupling Soda Ash 750 kg Ice 4000 kg kg Water 3500 kg Filtration and Washing 4000 kg Wet Cake for Drying 3000 kg Dry Crude 1000 kg kg Water for ETP M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 16

27 12. Disperse Yellow 235 1) Diazotization of C7H5ClN2O2 is carried out in hydrochloric acid and sodium nitrite. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5ClN2O2 +HCl + NaNO2 + C9H12N2O2 C17H18ClN5O4 Disperse Yellow 235 C6H5ClN2O2 465 kg HCL 1850 kg Diazotization Sodium Nitrite 200 Water 500 kg ICE 5000 kg 8015 kg Water 500 kg C9H12N2O2 560 kg Coupling Soda Ash 750 kg Ice 4000 kg kg Water 3000 kg Filtration and Washing 4000 kg Wet Cake for Drying 3000 kg Dry Crude 1000 kg kg Water for ETP M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 17

28 13. Acid Yellow 184 1) C20H19N3O2 is sulfonated at ambient temperature in oleum. 2) Drawing and isolation by cooling and filter it. C20H19N3O2 + Oleum C20H20N3O5 Acid Yellow 184 C20H19N3O2 900 Oleum 5400 kg Reaction Vessel 6300 kg NaOH 7500 kg Ice kg Neutrallizer kg Filtration 4000 kg kg Water for ETP Wet Cake For Drying 3000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 18

29 14. Disperse Red 277(Solvent Red 197) 1) C20H19N3O2 and C3H2N2 were mixed in solvent and reaction carried out in ambient temperature. 2) Cool the reaction mass to 25 C and isolate the product. 3) Filtered and wash C20H19N3O2 + Solvent + C3H2N2 C23H19N4O2 Disperse Red 277 C20H19N4O 1000 C3H2N2 240 kg Reaction Vessel DMF 5000 kg 6240 kg MeOH 6000 kg Isolation kg MeOH 1000 kg Filtration 3240 kg kg DMF and Methanol For Distilation Wet Cake For Drying 2240 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 19

30 15. Disperse Red 362(Solvent Red 196) 1) C23H19N4O2 is treated with diluted sulphuric acid at ambient temperature. 2) ph adjusts to 3.5 with alkali and filter the product. C20H19N3O2 + Diluted H2SO4 C23H19N4O3 Disperse Red 362 C23H17N5O 1000 Sulphuric Acid 5% 10000kg Reaction Vessel kg NaOH 100 kg Ice 6000 kg Water 3000 kg Neutrallizer kg Filtration 4000 kg kg Water for ETP Wet Cake For Drying 3000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 20

31 16. Disperse Yellow 232(Solvent Red 160:1) 1) C6H6ClNO2, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete. 2) Cool to 20 C and filter the product. C6H6ClNO2 + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H20ClN3O2 Disperse Yellow 232 C6H6ClNO 600 kg MeOH 3000kg Reaction Vessel PCL3 300kg C5H7NO2 390kg C11H15NO2 750kg Water 6000 kg 5040 kg Filtration and Washing 3540 kg 2500 kg MeOH for Distillation and 5000 kg water to Wet Cake For Drying 2540 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 21

32 17. Disperse Yellow 184:1 1) C7H9NO, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete. 2) Cool to 20 C and filter the product. C7H9NO + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H21N3O2 Disperse Yellow 184:1 C7H9NO 530 kg MeOH 3000kg Reaction Vessel PCL3 300kg C5H7NO2 390kg C11H15NO2 750kg Water 6000 kg 4970 kg Filtration and Washing 3470 kg 2500 kg MeOH for Distillation and 5000 kg water to ETP Wet Cake For Drying 2470 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 22

33 18. Solvent Yellow 196(Disperse Yellow) 1) C6H7NS, Solvent, PCl3, C6H7NO2 and C12H15NO2 were mixed and stir at ambient temperature till reaction is complete. 2) Cool to 20 C and filter the product. C6H7NS + PCL3 + C6H7NO2 + C12H15NO2 + Solvent C22H20N3O2S Disperse Yellow 196 C6H7NS 530 kg MeOH 3000kg Reaction Vessel PCL3 300kg C5H7NO2 390kg C11H15NO2 750kg Water 6000 kg 4970 kg Filtration and Washing 3470 kg 2500 kg MeOH for Distillation and 5000 kg water to ETP Wet Cake For Drying 2470 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 23

34 19. Disperse Red 367 1) Step 1 C6H6O2 is reacted with C8H8O4 in sulphuric acid at ambient temperature. Product is isolated and filtered. C6H6O2 + C8H8O4 + Sulphuric Acid C14H10O2 Disperse Red 367 Step - 1 Sulphuric Acid 2000 C6H6O2 350kg Reaction Vessel C8H8O30 485kg Water 5000 kg Water 1000 kg 7835 kg Filtration and Washing 2550 kg Wet Cake For Drying 6285 kg water for ETP 1700 kg Dry Crude 850 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 24

35 2) Step 2 C8H8O4 is reacted with C2H3ClO2 in alkali at ambient temperature. Product is isolated and filtered. C8H8O4 + C2H3ClO2 + NaOH C15H12O5 Disperse Red 367 Step -2 Caustic 320 kg C2H3ClO2 675 kg Reaction Vessel C8H8O kg Water 6000 kg HCL 975 kg Water 3000 kg 7995 kg Drawing and ph adjustment kg Filtration 3500 kg 8470 kg Water for ETP Wet Cake For Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 25

36 3) Step 3 Step 1 and Step 2 are reacted in solvent to produce the intermediate stage. C14H10O2 + C15H12O5 + Solvent C29H23O7 + Solvent Disperse Red 367 Step -3 1st Step 700 kg Acetic Acid 4900 kg Reaction Vessel 2nd Step 700 kg Ammonium Sulphate 715 kg ICE 2500 kg Water 2500 kg Water 5000 kg 7015 kg Drawing kg Filtration 4500 kg kg Water for ETP Wet Cake For Drying 3300 kg Dry Crude 1200 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 26

37 4) Step 4 Ester is reacted with step 3 in solvent to produce the dye which isolated and filtered. C29H23O7 + Ester + Solvent + H2SO4 C33H26O9 Disperse Red 367 Step -4 Ester 9000 kg Step kg Reaction Vessel Sulphuric Acid 50 kg MeOH 1000 kg kg Filtration and washing 8000 kg Ester 3050 kg Wet Cake For Drying 2050 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 27

38 20. Solvent Yellow 44 (FD & C Yellow 11) 1) C12H5ClO3 is reacted with C7H11N in presence of Solvent to produce the dye. 2) Dye is isolated and filtered. 3) This dye is then treated with ammonia to produce the final colour. 4) Wet cake is then given to formulation department. C12H5ClO3 + Solvent + C7H11N + NH3 C21H17N2O2 Solvent Yellow 44 C12H5ClO3 785 kg MCB kg Reaction Vessel C4H11N 1250 kg NH kg MeOH 3000 kg kg Filtration and washing 4785 kg Wet Cake For Drying 9000 kg MCB for Distillation and 2500 kg MeOH to ETP 3785 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 28

39 21. Basic Yellow 40 1) C20H19N3O2 was treated in Solvent with C2H6O4S in buffer solution. 2) Filter the product and collect the solvent. 3) Wet cake slurry in water and isolated by salting. 4) Wet is given to formulation department. C20H19N3O2 + C2H6O4S + Solvent C23H27N3O6S Basic Yellow 40 MCB 8050 kg C20H19N3O2 670 kg C2H6O4S 1170 kg Reaction Vessel Sodium Acetate 400 kg Water 6000 kg Filtration & Washing kg 4000 kg Wet Cake for Drying 3000 kg 7500 kg MCB for Recovery & 4790 kg water for ETP Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 29

40 22. Basic Red 12 1) C12H15N and C13H15NO is reacted in presence of Acetic acid and Acetic Anhydride at ambient temperature. 2) Dye is isolated and filtered. 3) Wet cake is given to formulation department. C12H15N + C13H15NO + CH3COOH + A A C25H29ClN3 Basic Red 12 C12H15N 500 kg C13H15NO 580kg Reaction Vessel Acetic Acid 800kg Acetic Anhydride 600kg 2480 kg Water 6000 kg Salt 500 kg Isolation 8980 kg Filtration 3500 kg 5480 kg Water for ETP Wet Cake For Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 30

41 23. Basic Red 13 1) C12H15N and C10H12Cl2NO is reacted in the presence of Acetic acid and Acetic Anhydride at ambient temperature. 2) Dye is then isolated and filtered. 3) Wet cake is given to formulation department. C12H15N + C10H13Cl2NO + Acetic Acid + A A C22H27Cl2N3 Basic Red 13 C12H15N 500 kg C10H12Cl2NO 580kg Reaction Vessel Acetic Acid 800kg Acetic Anhydride 600kg 2485 kg Water 6000 kg Salt 500 kg Isolation 8985kg Filtration 3000 kg 5985 kg Water for ETP Wet Cake For Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 31

42 24. Basic Red 14 1) C11H15N and C11H12N2O is treated in presence of Acetic acid and acetic anhydride at ambient temperature. 2) Dye is isolated and filtered. 3) Wet cake is given to formulation department. C11H15N + C11H12N2O + Acetic acid + A A C24H27ClN3 Basic Red 14 C12H15N 500 kg C11H12N2O 555 kg Acetic Acid 800kg Reaction Vessel Acetic Anhydride 600kg 2455 kg Water 6000 kg Salt 500 kg Isolation 8955kg Filtration 3000 kg 5955 kg Water for ETP Wet Cake For Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 32

43 25. Basic Red 15 1) C11H15N and C13H16N2O2 is treated with Acetic acid and acetic anhydride at ambient temperature to produce a dye. 2) Dye is isolated and filtered. 3) Wet cake is given to formulation department. C11H15NO + C13H16N2O2 + Acetic Acid + A A C25H30Cl2N3 Basic Red 15 C12H15N 500 kg C13H16N2O2 685 kg Reaction Vessel Acetic Acid 800kg Acetic Anhydride 600kg 2585 kg Water 6000 kg Salt 500 kg Isolation 9085 kg Filtration 3000 kg 6085 kg Water for ETP Wet Cake For Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 33

44 26. Basic Red 18 1) C6H5ClN2O2 is diazotized with Hydrochloric acid and sodium nitrite at ambient temperature. 2) Diazo solution is then transfer slowly to coupler solution. 3) Dye is then isolated, filtered. 4) Wet cake given to formulation department. C6H5ClN2O2 + HCl + NaNO2 + C13H23ClN2 C19H25Cl2N5O2 Basic Red 18 C6H5ClN2O2 500 kg ICE 4000 kg Diazotization HCL 1060 kg NaNO2 205 kg Water 500 kg Water 500 kg C12H23ClN kg Coupling ICE 4500 kg HCL 360 kg kg Filtration 3000 kg 9345 kg Water for ETP Wet Cake For Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 34

45 27. Basic Red 24 1) Diazotization of C7H5N3O2S is carried out in Sulphuric acid and nitrosyl sulphuric acid. 2) Prepared coupler solution in hydrochloric acid then then used in coupling. 3) Add sulfamic acid and then transfer the diazo in coupler solution while cooling. 4) After filter the wet cake submitted to send milling and spray drying. C7H5N3O2S + H2SO4 + NSA + C13H23ClN2 C22H29N6O6S Basic Red 24 C7H5N3O2 500 kg Sulphuric Acid 3200 kg Diazotization NaNO2 215 kg 3915 kg Water 500 kg C14H26N2O4S 980 Coupling ICE 9000 kg HCL 600 kg kg Filtration 4000 kg kg Water for ETP Wet Cake For Drying 2950 kg Dry Crude 1050 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 35

46 28. Basic Violet 16 1) C11H15NO is treated with C11H15NO in acetic acid and Acetic anhydride at ambient temperature. 2) Dye is then isolated and filtered. 3) Wet cake sent to formulation department. C11H15NO + C11H15NO + Acetic acid + A A C23H30ClN2 Basic Violet 16 C12H15N 600 kg C11H15NO 615 kg Acetic Acid 800 kg Reaction Vessel Acetic Anhydride kg Water 6000 kg Isolation Salt 500 kg 9115 kg Filtration 2500 kg 6615 kg Water for ETP Wet Cake For Drying 1500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 36

47 29. Basic Yellow 51 1) C6H7N is diazotized with hydrochloric acid and sodium nitrite at ambient temperature. 2) Diazo is then transfer to coupler solution. 3) Wet cake is then treated with C2H6O4S in buffer solution. 4) Dye is isolated filtered. 5) Wet cake given to formulation department. C6H7N + HCl + NaNO2 + C13H15NO + C2H6O4S C20H25N3O4S Basic Yellow 51 Step-1 C6H7N 350 kg HCL 1375 kg Diazotization Sodium Nitrite 265 kg ICE 5000 kg 6990 kg Water 500 kg C13H15NO 760 kg Coupling ICE 4000 kg Acetic Acid 1900 kg kg Filtration 3900 kg kg Water for ETP Wet Cake For Drying 2800 kg Dry Crude 1100 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 37

48 Basic Yellow 51 Step-2 MCB kg 1 St STEP 1000 kg Quaternization DMS 930 kg kg Filtration 2930 kg kg MCB for Recovery Wet Cake For Drying 1930 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 38

49 30. Basic Yellow 28 1) C6H9NO is diazotized with hydrochloric acid and sodium nitrite at ambient temperature. 2) Diazo is then transfer to coupler solution. 3) Wet cake is then treated with C2H6O4S in buffer solution. 4) Dye is isolated filtered. 5) Wet cake given to formulation department. C7H9NO + HCl + NaNO2 + C13H15NO + C2H6O4S C21H28N3O2S Basic Yellow 28 Step-1 C7H9NO 460 kg HCL 1375 kg Diazotization Sodium Nitrite 265 kg ICE 5000 kg 7100 kg Water 500 kg C13H15NO 760 kg Coupling ICE 4000 kg Acetic Acid kg Filtration 4000 kg kg Water for ETP Wet Cake For Drying 2900 kg Dry Crude 1100 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 39

50 Basic Yellow 28 Step-2 MCB kg 1 St STEP 1000 kg Quaternization DMS 930 kg kg Filtration 2930 kg kg MCB for Recovery Wet Cake For Drying 1930 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 40

51 31. Basic Blue 41 1) C8H8N2OS is diazotised with sulphuric acid and nitrosyl sulphuric acid at ambient temperature. 2) Prepared coupler solution in hydrochloric acid. 3) It is then transferred to coupler solution slowly and stir. 4) Dye is then filtered and dry crude treated with C2H6O4S in solvent. 5) Wet given to formulation department. C8H8N2OS + H2SO4 + NaNO2 + C10H15NO + C2H6O4S C20H28N4O6S2 Basic Blue 41 Step-1 C8H8N2OS 560 kg Sulphuric Acid 2240 Diazotization Sodium Nitrite 220 kg 3020 kg Water 500 kg C10H15NO 515 kg Coupling ICE 8000 kg HCL 250 kg kg Water 3000 kg Filtration 3200 kg kg Water for ETP Wet Cake For Drying 2200 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 41

52 Basic Blue 41Step-2 MCB kg 1 St STEP 1000 kg Quaternization C2H6O4S 885 kg kg Filtration 2885 kg kg MCB for Recovery Wet Cake For Drying 1885 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 42

53 32. Basic Blue 54 1) C8H8N2OS is diazotised with sulphuric acid and nitrosyl sulphuric acid at ambient temperature. 2) Prepared coupler solution in hydrochloric acid. 3) It is then transferred to coupler solution slowly and stir. 4) Dye is then filtered and dry crude treated with C2H6O4S in solvent. 5) Wet given to formulation department. C8H8N2OS + H2SO4 + NaNO2 + C8H11N + C2H6O4S C19H22N4O4S2 Basic Blue 54 Step-1 C8H8N2OS 630 kg Sulphuric Acid 2800 kg Diazotization Sodium Nitrite 245 kg 3675 kg Water 500 kg C8H11N 425 kg Coupling ICE 9000 kg HCL 250 kg kg Water 3000 kg Filtration 3500 kg kg Water for ETP Wet Cake For Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 43

54 Basic Blue 54 Step-2 MCB kg 1 St STEP 1000 kg Quaternization DMS 1000 kg kg Filtration 3000 kg kg MCB for Recovery Wet Cake For Drying 2000 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 44

55 33. Basic Blue 162 1) C8H8N2OS is diazotised with sulphuric acid and nitrosyl sulphuric acid at ambient temperature. 2) Prepared coupler solution in hydrochloric acid. 3) It is then transferred to coupler solution slowly and stir. 4) Dye is then filtered and dry crude treated with C2H6O4S in solvent. 5) Wet given to formulation department. C8H8N2OS + H2SO4 + NaNO2 + C10H12N + C2H6O4S C20H25N4O5S2 Basic Blue 162 Step-1 C8H8N2OS 560 kg Sulphuric Acid 2240 Diazotization Sodium Nitrite 220 kg 3020 kg Water 500 kg C10H12N 515 kg Coupling ICE 8000 kg HCL 250 kg kg Water 3000 kg Filtration 3200 kg kg Water for ETP Wet Cake For Drying 2200 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 45

56 Basic Blue 162 Step-2 MCB kg 1 St STEP 1000 kg Quaternization DMS 885 kg kg Filtration 2885 kg kg MCB for Recovery Wet Cake For Drying 1885 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 46

57 34. Basic Yellow 11 1) C8H11NO2 is diazotized with hydrochloric acid and sodium nitrite at ambient temperature. 2) Diazo is then transfer to coupler solution. 3) Wet cake is then treated with C2H6O4S in buffer solution. 4) Dye is isolated filtered. 5) Wet cake given to formulation department. C8H11NO2 + HCl + NaNO2 + C13H15NO + C2H6O4S C21H26ClN2O2 Basic Yellow 11 Step-1 C8H11NO2 440 kg HCL 1050 kg Diazotization Sodium Nitrite 205 kg ICE 5000 kg 6695 kg Water 500 kg C13H15NO 580 kg Coupling ICE 4000 kg Acetic Acid kg Filtration 3500 kg kg Water for ETP Wet Cake For Drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 47

58 Basic Yellow 11 Step-2 MCB kg 1 St STEP 1000 kg Quaternization DMS 865 kg kg Filtration 2865 kg kg MCB for Recovery Wet Cake For Drying 1865 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 48

59 35. Disperse Blue 354 1) C6H10O3 is treated with C6H5COCl and then treated with C3H2N2 in the presence of solvent to produce Step 1. 2) C7H9N, C6H13N and POCl3 is treated in DMF to form Step 2. 3) Step 1 and Step 2 are treated in solvent to form the dye. 4) Dye is isolated by cooling and filtered. 5) Wet cake sent to formulation department. Step 1 C6H10O3 + C6H5COCl + C3H2N2 + H2SO4 Step % H2SO4 C6H10O3 725 kg Disperse Blue 354 Step-1 C6H5OCl 850 kg Caustic 1500 kg Reaction Vessel Water 2525 kg Water 1500 kg 25 % Oleum 5200 kg Water 1500 kg MeOH 3000 kg C3H2N2 375 kg MeOH 800 kg Separation Product A 725 kg Filtration and washing 5600 kg Reaction Vessel and Isolation Filtration and washing Reaction Vessel 1087 kg 7787 kg 1450 kg 4100 kg 1200 kg 4513 kg Water for ETP plant 7062 kg 50 % Sulphuric Acid For Sell 775 kg Water for ETP 3700 kg MeOH for Recovery Wet Cake for Drying Step kg 400 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 49

60 Note: By Product List % Sodium Bromide solution: 6714 kg % Sulphuric Acid solution: 7062 kg 3. MeOH from Step 1: 5046 kg Step 2 C7H9N + C6H13N + NaOH C19H33N + NaBr C19H33N + DMF + POCl3 Step 2 Final Dye Step 1 + Step 2 + Solvent C32H38N3O3S Disperse Blue 354 Step-2 C7H9N 425 kg C6H13Br 1325 kg Reaction Vessel Caustic 2500 kg Water 3500 kg POCl3 635 kg DMF 775 kg 7750 kg Oil Seperation 1036 kg Reaction Vessel 2446 kg Step 2: 2446 kg 6714 kg 12.3 %NaBr Solution as Byproduct and Sell Disperse Blue 354 Step-3 Step kg Step kg MeOH 3000 kg Reaction Vessel MeOH 800 kg Filtration and washing 2000 kg 5046 kg MeOH & DMF for Recovery Wet Cake for Drying Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 50

61 36. Disperse Yellow 114 1) C6H7NO is reacted with Acetic Anhydride and then reacted with C6H5SO2Cl to form the diazo component which is then hydrolysed and diazotized with Hydrochloric Acid and Sodium Nitrite. 2) Coupling is carried with C8H8N2O2in alkaline condition to make the final crude dyes. 3) Dye is filtered and wash then sent to formulation department. Step 1 C6H7NO + (CH3CO)2+NaOH C14H13NO4S C14H13NO4S + HCl C12H11NO3S Step 2 C12H111NO3S + NaNO2 + HCl + C8H8N2O2 C20H19N4O5S + NaCl + H2O Disperse Yellow 114 Step-1 C6H7NO 300 kg Water 600 kg Reaction Vessel Acetci Anhydride 410 kg 1310 kg Water 2500 kg C6H5SO2CL 585 kg Soda Ash 675 kg Reaction Vessel 5070 kg Water 1000 kg Filtration and Washing 5070 kg Water for ETP Wet Cake 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 51

62 Disperse Yellow 114 Step-2 Wet Cake Step kg Water 1500 kg HCL 2000 kg Ice 6000 kg Diazotization NaNo2 195 kg kg Water 500 kg C8H8N2O2 430 kg NaOH 500 kg Coupling Ice 5000 kg kg Water 3000 kg Filtration and Washing kg Water for ETP 4500 kg Wet Cake For Drying 3500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 52

63 LIST OF INTERMEDIATES 1. ETHYL BENZOYL ANILINE EBA C6H10O C6H5OCl 1175 Reaction Vessel Caustic 2000 Water 3500 kg Separation 6675 kg water to ETP Plant EBA 1000 kg 2. 3-OXO 3-Oxo-2, 3-dihydrobenzo[b]thiophene-1, 1-dioxide 3-Oxo 910 kg 25% Oleum 7200 kg Water 700 kg Water 5590 kg Reaction Vessel and Isolation 7675 kg 8810 kg Filtration and Washing 2000 kg Wet cake for Drying 1000 kg kg 50 % Sulphuric Acid For Sell 2000 kg water to ETP Plant Product 1000 kg 3-Oxo-2, 3- dihydrobenzothiophene-1, 1-dioxide M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 53

64 3. PROPANEDINITRILE DERIVATIVE PROPANEDINITRILE DERIVATIVE MeOH 3500 kg C3H2N2 375 kg C11H12O3 910 kg MeOH 1300 kg Reaction Vessel Filtration and Washing 4285 kg 1585 kg Wet cake for drying 585 kg 3500 kg MeOH for Recovery 3-(Dicyanomethyllidene)-2, 3- dihydrobenzothiophen-11-dioxide 1000 kg 4. N, N-DIHEXYL-M-TOLUIDINE N, N-DIHEXYL-M-TOLUIDINE C7H9N 460 kg C6H13Br 1430 kg Reaction Vessel Caustic 2700 kg Water 3770 kg 8360 kg Oil Separation 7360 kg NaBr solution as Byproduct and Sell N,N-Dihexyl-m-Toluidine 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 54

65 5. 1/2 CONDENSED MASS 1/2 CONDENSED MASS Sulphuric Acid 2800 kg C6H6O2 565 kg C8H8O3 780 kg Reaction Vessel Water 5000 kg 9145 kg Water 1500 kg Filtration and Washing 3600 kg 7045 kg Water for ETP Plant Wet cake for drying 2600 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 55

66 6. P M ACID P M ACID Caustic 450 kg C3H7Cl 910 kg C8H8O4 950 kg Reaction Vessel Water 5000 kg 7310 kg HCL 1500 kg Water 3000 kg Drawing and ph adjustment kg Filtration 8310 kg Water for ETP Plant 3500 kg Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 56

67 7. B M ACID B M ACID Caustic 450 kg C4H9Cl 1010 kg C8H8O4 950 kg Reaction Vessel Water 5000 kg 7410 kg HCL 1500 kg Water 3000 kg Drawing and ph adjustment kg Filtration 8410 kg Water for ETP Plant 3500 kg Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 57

68 8. DBPT DBPT C7H9N 430 kg HCL 2100 kg Br2 770 kg Reaction Vessel H2O2 120 kg 3420 kg Water 4000 kg Filtration and Washing 3500 kg 3920 kg Water for ETP Plant Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 58

69 9. DEMAP ALDEHYDE DEMAP ALDEHYDE C10H15NO 1110 kg DMF 3100 kg POCl kg Reaction Vessel Ice + Water kg NaOH 3000 kg kg Water 2000 kg Filtration and Washing 5000 kg kg Water for ETP Plant Wet cake for drying 4000 kg DEMAP Aldehyde1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 59

70 10. BENZOTHIAZOLE DERIVATIVE BENZOTHIAZOLE DERIVATIVE C7H10NO 820 kg Acetic Acid 3300 NH4SCN 1040 kg Reaction Vessel Bromine 1170 kg NaOH 6700 kg kg Water 3000 kg Filtration and Washing 4500 kg kg Water for ETP Plant Wet cake for drying 3500 kg Benzothiazole Derivative 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 60

71 11. METHYL PYRIDONE METHYL PYRIDONE Methyl Amine 510 kg ECA 700 kg Methyl Ester 800kg Reaction Vessel NaOH 80 kg HCl 1500 kg Water + Ice kg Isolation and Washing 3500 kg 6090 kg Water for ETP Plant Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 61

72 12. ETHYL PYRIDONE ETHYL PYRIDONE Ethyl Amine 275 kg ECA 650 kg Methyl Ester 650kg Reaction Vessel NaOH 100 kg HCl 1500 kg Water + Ice 6000 kg 1675 kg Isolation and Washing 3500 kg 5675 kg Water for ETP Plant Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 62

73 13. BUTYL PYRIDONE BUTYL PYRIDONE Butyl Amine 840 kg ECA 620 kg Methyl Ester 640kg Reaction Vessel NaOH 100 kg HCl 1500 kg Water + Ice 6000 kg 2200 kg Isolation and Washing 3500 kg 6200 kg Water for ETP Plant Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 63

74 14. 3-MPA PYRIDONE 3-MPA PYRIDONE 3-MP Amine 1400 kg ECA 770 kg Methyl Ester 850kg Reaction Vessel NaOH 100 kg HCl 1500 kg Water + Ice 6000 kg 3120 kg Isolation and Washing 3500 kg 7120 kg Water for ETP Plant Wet cake for drying 2500 kg Dry Crude 1000 kg M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 64

75 INK FORMULATIONS OR DIGITAL INK FORMULATIONS (REACTIVE, DISPERSE VAT AND SUBLIMATION) Colorant SN. Reactive Disperse Vat Sublimation 1 Black Black Black Black 2 Blue Blue Blue Blue 3 Cyan Cyan Cyan Cyan 4 Grey Grey Grey Grey 5 Magenta Magenta Magenta Magenta 6 Orange Orange Orange Orange 7 Pink Pink Pink Pink 8 Red Red Red Red 9 Yellow Yellow Yellow Yellow MICRONIZATION OF PIGMENTS SN Colorant Pigments 1 Black 2 Blue 3 Cyan 4 Grey 5 Magenta 6 Orange 7 Pink 8 Red 9 Yellow M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 65

76 FLOW DIAGRAM FOR INK FORMULATION SR. NO. CHEMICALS USED IN KG 1 COLOURANT 7 TO 15 2 WETTING AGENT 5 TO 10 3 DEFOAMER 2 TO 3 4 EMULSIFIER 5 TO 8 5 ANT CLOGGING AGENT 2 TO 3 6 WATER BY DIFFERENCE 7 TOTAL 100 Water Emulsifier Auxiliaries Colorant Nano Grinding In Case of Disperse and Vat Dyes Filter Micro Filter Nano Filter Standardization Formulation Packing M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 66

77 FLOW DIAGRAM FOR MICRONIZATION OF PIGMENTS Sr. No. Chemicals Used In Kg 1 Colourant 10 to 15 2 Wetting Agent 5 to 10 3 Defoamer 2 to 3 4 Emulsifier 5 to 8 5 Ant Clogging Agent 2 to 3 6 Dispersing Agent 5 to 8 7 Water By Difference 8 Total 100 Water Emulsifier Auxiliaries Colorant Nano Grinding Filter Micro Filter Nano Filter Standardization Formulation Packing M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 67

78 2.5 RAW MATERIALS REQUIREMENT (PER MONTH) Raw materials required for the manufacturing of disperse dyes are listed below: TABLE 3: DETAILS OF RAW MATERIAL REQUIREMENTS S. No. CAS No. Raw Material Qty (MT)/Month Ethylhexyl Bromide Acetic acid Acetic Anhydride Acetone Ammonium per Sulphate Ammonium Thiocyanate (DBPNA) (2-CN PNA) (PNA) (Dichloro BT) Aniline Derivatives (6-Cl-2,4-DNA) (6-Br-2,4-DNA) Benzoyl Chloride Bromine Caustic Flask Cuprous Cyanine DEMAP Aldehyde Dibutylamine Diethylamine Dimethyl Sulfate Dimethylformamide (DMF) Dioxane Ethyl Cyano Acetate Fisher's Aldehyde Fisher's base Hexyl Bromide Hydrochloric Acid Isopropyl alcohol (IPA) Lime m Toluidine Malodinitrile Malononitrile Dimer Methanol Methyl Chloride Methyl Iodide n-butyl Aniline Ortho Pheneline Diamine p Toluidine (N,N DEMT) (M-1) (M-17) (M-12) (M-3A) (M-279) Para Nitro Aniline Derivatives 15.0 M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 68

79 Pentyl Bromide Phenylhydrazine Phosphorus Oxy Chloride Phosphorus Penta Chloride Soda Ash Sodium Chloride Sodium Cyanide Sodium Nitrite Sulfamic acid sulphur Sulphuric Acid Tributylamine Triethylamine Zinc Chloride Zinc Cyanide RESOURCE OPTIMIZATION / RECYCLING AND REUSE We will be provided rain water recharging for the resource optimization. Spent Oil i.e. 10 Lit/month will be generated from prime movers which will be reused as lubricant within premises or sell to MoEF approved reprocessor. 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed project will be 27.5 KLD which mainly for process, Boiler & cooling (make up water), Domestic uses and for gardening & others. Total water requirement shall be met from GIDC POWER REQUIREMENT AND ITS SOURCE Total power requirement will be 375 KVA. Power supply shall be taken from DGVCL. In case of emergency or power failure D.G. set of 125 KVA will be used. It will be used to fulfill emergency power requirement. 2.8 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND ITS MANAGEMENT / DISPOSAL WASTEWATER GENERATION Water requirement will be mainly for process, Boiler & cooling (Make up water), Domestic and gardening. Waste water i.e. sewage waste water 3.4 KL/day will be generated which will be treated through septic tank and disposed through soak pit/well. Industrial waste water will be 17.5 KL/day from process and utilities. Details of water requirement and waste water generation are given in following table. TABLE 4: DETAILS OF WASTEWATER GENERATION S.NO. PURPOSE WATER CONSUMPTION (KL/D) WASTE WATER GENERATION (KL/D) A. Domestic B. Industrial 1 Processing (Fresh water + Ice) 2 Boiler and Cooling (make up) C. Other uses M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 69

80 1 Green Belt Floor and Drum washing Grand Total (B + C) SOLID WASTE GENERATION Solid waste generated will be Ash from boilers and Sludge from ETP, used/spent oil and discarded bags. The sources of solid wastes, generation and its management are as given in the following table. TABLE 5: DETAILS OF SOLID WASTE S. NO. NAME OF CATEGORY QTY/MONTH DISPOSAL METHODOLOGY WASTE 1. Spent/Used oil Liters Collected in drums and stored at specified sludge area and sold to approved/registered vendors. 2. Discarded drums/ Containers Nos. Collected and stored at specified area and sold to approved/ registered vendors. 3. Evaporator residue Ton Collected in drums, packed, labeled and stored at specified area and finally transferred to common waste incineration and land fill site facility of BEIL Ankleshwar 4. ETP Sludge Ton ETP sludge will be sent to BEIL Ankleshwar. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 70

81 SITE ANALYSIS CHAPTER CONNECTIVITY The proposed project site is situated at Plot no. 4517, GIDC, Ankleshwar, Gujarat. The site is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar-Rajpipala) road is about1.23 km in North direction. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labors are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc Road Connectivity The Plant is near NH-8 (Mumbai-Delhi road) is about 0.76 km in West direction and SH64 (Ankleshwar- Rajpipala) road is about1.23 km in North direction Rail The Area is well connected by Railway. Ankleshwar railway Station is about 1.35 km in SE Airport The nearest airport to the project will be Surat at around km. in NWW Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP About 1000 sq.m. of land at Plot no. 4517, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Kasturi Polymers which is already in operation. Total acquired land is classified as Industrial land. Land document is attached as Annexure I. 3.3 TOPOGRAPHY Topography of the area is plain. 3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table: TABLE 6: DETAILS OF EXISTING LAND USE S.NO. PARTICULAR NAME & ITS DISTANCE 1. Nearest National Highway NH-8 at around 0.76 Km 2. Nearest State Highway SH-64 at around 1.23 Km 3. Nearest city Surat at around 62.0 Km 4. Nearest River Narmada at around 6.92 Km 5. Nearest Railway station Ankleshwar at around 1.35 Km 6. National park/reserve Forest, Biosphere, etc. None within a radius of 10 Km 6. Seismicity Zone III M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 71

82 3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table: TABLE 7: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE S. NO. PARTICULAR DISTANCE 1. Civil Hospital Within 15 Km 2. Colleges 3. Govt & Pvt Schools 4. Hari Mandir 3.6 CLIMATIC DATA The main characteristic of this region is hot summer and severe winter with a small spell of rainy season. The rainy season generally commence at the beginning of July and last till mid-october. The period from October to November constitutes the post monsoon season and winter prolong from December to February which last till March before the summer season begins. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months: Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February TEMPERATURE DETAILS The hottest months were May to September with mercury reaching 37 ºC during June. The coldest months were December, January and February when temperature drops to 15 ºC. The months, November and March, can also be quite cold in some years. During the other months, temperature was more or less moderate in nature and pleasant to bear. Monthly mean Minimum and Maximum Temperatures of Bharuch station for the period of Jan 15 to Dec 015 are given in following table. TABLE 8: TEMPERATURE DATA S. NO. MONTHS OF YEAR 2015 MONTHLY MEAN MINIMUM ( 0 C) MONTHLY MEAN MAXIMUM ( 0 C) 1. January February March April May June July August September October November December (Courtesy: Indian Meteorological Department) M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 72

83 3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Surat station was recorded for 08:30 hrs and 17:30 hrs. Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period RAINFALL Monthly total rainfall data for Surat station is presented in following table. TABLE 9: RAINFALL DATA S.NO. MONTHS OF YEAR 2015 (Courtesy: Indian Meteorological Department) MONTHLY TOTAL (MM) 1. January February March April May June July August September October November December 00 TOTAL The rainy season in the area extends from June to October. The mean total rainfall, during the monsoon period (June to September), has been recorded as mm. The average number of rainy days per month varies from 8 to 18 in monsoon months. The rainfall data indicates that the rainfall is limited to monsoon season for four months of the year WIND SPEED AND WIND DIRECTION The April Sept Month, have winds from South West to North East. From October-March is a period mixed with calm conditions and winds mainly from North East to South East. The winter months, November to February, experience frequent calm conditions. The maximum number of calm periods observed is in the month of December and February. (Source: M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 73

84 PLANNING BRIEF CHAPTER PLANNING CONCEPT M/s. Kasturi Polymers and Pigments; is planning to set up Dyes & Intermediate manufacturing unit (Proposed (a) 25 Tons Crude on Dry Powder Basis or 40 Tons Standardized and formulations of products, (b) 15 Tons Intermediates, (c) 10 Tons R & D Products, (d) 10 Tons Ink Formulations OR Digital Ink Formulations & (e) 05 Tons Micronization of Dyes and Pigments) at plot no. 4517, GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat. Proposed project is envisaged as existing Dyes & Intermediates facilities in Gujarat are not adequate to handle new development activities as well for the industries in Surat, Ankleshwar, Jhagadia, Panoli, Vapi, Navsari, Vadodara, others. 4.2 LAND USE PLANNING About 1000 sq.m. of land at Plot no. 4517, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Kasturi Polymers and Pigments which is already in operation. Total acquired land is classified as Industrial land. 4.3 AMENITIES / FACILITIES At the project site first aid centre will be set up. Company will provide drinking water to the workers in the factory premises. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 74

85 PROPOSED INFRASTRUCTURE CHAPTER INDUSTRIAL AREA About 1000 sq.m. of land at Plot no. 4517, GIDC, Ankleshwar, Gujarat, is already acquired for the proposed plant; allotted to M/s. Kasturi Polymers & Pigments which is already in operation. Total acquired land is classified as Industrial land. 5.2 RESIDENTIAL AREA There will be no residential area proposed for the project. 5.3 GREEN BELT The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. About % area of total plant area i.e sq. m shall be developed as green belt at plant boundary, road side, around offices & buildings and Stretch of open land. In Green belt area about 1000 tree per acre of land shall be planted. The selection of tree species suitable for plantation at the industry shall be governed by guiding factors as stated below: The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in primary and secondary attenuation zone. The trees should possess extensive foliar area to provide maximum impinging surface for continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution indicator. It is also recommended to carry out extensive plantation within premises. Keeping in view the climatic conditions, status of soils and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE No new social infrastructure facility will be developed as the plot is located in notified industrial area having well developed infrastructure. 5.5 CONNECTIVITY ROAD CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 75

86 5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the GIDC Ankleshwar located within premises after getting necessary clearance. 5.7 WASTE WATER MANAGEMENT STORM WATER DRAINAGE Storm water drainage system shall consist of well-designed open surface drains network so that all the storm water is efficiently drained of without any water logging. Based on the rainfall intensity of the proposed area drainage system shall be design on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow. Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations. For crossing roads, culverts shall be provided SEWERAGE WATER SYSTEM The sanitary sewerage system shall be designed to cater the sanitary sewerage from plant premises. The design of facial sewerage system shall be designed based on no. of person to be served and average daily consumption of water. Only 3.4 KL/day will be generated which will be treated through septic tank and disposed through soak pit/well. For inspection, cleaning and maintenance of sewer lines, manholes of reinforced concrete constructions shall be provided at every bend, junction point of change in slope or diameter and on straight sections of pipes at interval not exceeding 30 meters INDUSTRIAL WASTE WATER MANAGEMENT Water will be required for process, Boiler & cooling purpose, Domestic and Green belt development. Maximum recycling of water will be done KL/day industrial wastewater generated from process & utilities of the proposed project. Same will be treated in in-house ETP and treated effluents are finally discharged in to CETP of M/s. Enviro Technology Limited (ETL), Ankleshwar for further treatment and disposal. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the following table. TABLE 10: DETAILS OF SOLID WASTE MANAGEMENT S. NO. NAME OF CATEGORY QTY/MONTH DISPOSAL METHODOLOGY WASTE 1. Spent/Used oil Liters Collected in drums and stored at specified sludge area and sold to approved/registered vendors. 2. Discarded drums/ Containers Nos. Collected and stored at specified area and sold to approved/ registered vendors. 3. Evaporator residue Ton Collected in drums, packed, labeled and stored at specified area and finally transferred to common waste incineration and land fill site facility of BEIL Ankleshwar 4. ETP Sludge Ton ETP sludge will be sent to BEIL Ankleshwar. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 76

87 REHABILITATION AND RESETTLEMENT (R & R) PLAN CHAPTER 6 Proposed project is located on industrial land, which is already acquired and there is no habitat. So proposed project proposal does not involve any Rehabilitation & Resettlement. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 77

88 PROJECT SCHEDULE & COST ESTIMATES CHAPTER PROJECT IMPLEMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. We are giving here under the details of the Project Implementation. From the date of start, the implementation schedule envisages completion of project in 12 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows: TABLE 11: PROJECT IMPLEMENTATION SCHEDULE S.NO. WORK IMPLEMENTATION TIME 1. Construction work 6 Months 2. Machinery installation 3 Months 3. Recruitment process 1 Month 4. Commissioning 1 Month 5. Operation and functions 1 Month Total 12 months PROPOSED ORGANISATION CHART In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to ensure its effective implementation. Hence, company will create a team consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level etc. either permanently or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried - out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in figure 3. FIGURE 3: AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL DIRECTORS GENERAL MANAGER OFFICE ASSISTANTS WAREHOUSE INCHARGE WORKS MANAGER ACCOUNTANT SUPERVISORS OPERATORS UNSKILLED M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 78

89 7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs Lacs. Break up of proposed project cost is given in following table: TABLE 12: TOTAL PROJECT COST AND IT S BREAK UP S.NO. PARTICULARS AMT. (RS. IN LACS) 1 Land and Site Development Factory Building Plant & Machineries Franchises Deposits/ Non CA Investment/ Non CA Other Misc. Assets Preliminary & Pre-operative Exp Total Capital Cost of Project Margin Money for working capital 0.00 TOTAL COST OF PROJECT BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The of capital Rs. 25 Lacs and recurring (Rs 3.15 Lacs per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance. M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 79

90 ANALYSIS OF PROPOSAL CHAPTER FINANCIAL AND SOCIAL BENEFITS The industrial activity of the proposed project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region. 8.2 DIRECT BENEFITS TO THE NATIONAL AND STATE EXCHEQUER Employment generation, Income tax from individual as well as corporate taxes from company and ancillary units, Transportation reduction. 8.3 OTHER BENEFITS Most of the work force required for construction and operation of the proposed project will be drawn from the surrounding villages. During the construction phase, no family is required to rehabilitate from the core zone. The economic growth of the area in terms of employment generation, consumption of goods and marketgrowth are expected outcome of the project. The project has an employment generation prospect on skilled manpower. The direct employment potential of the project is estimated as 85 persons, the share of local people in this is expected to be significant. It is assumed that the generation of indirect employment would be multiple of direct employment. The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. This will have impact on the current literacy level, primary and middle level education and on existing health facilities. A new awareness generated will have positive impact on the social pattern, which at this stage, is caste and community oriented. The long-term implications of this change are definitely progressive. 8.4 EMPLOYMENT Due to proposed project, there will be development of communication facilities in the area. The total manpower requirement will be 85. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities etc. During operation, plant will generate direct employment as explained in the previous paragraph. The preference will be given for local population for employment in the semi-skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods. Moreover, permanent supply of electricity in the area will support to improve other type of industries. 8.5 HEALTH AND SAFETY MEASURES The workers engaged in high pollution generation area will be equipped with appropriate protective equipment. Following measures will be adopted in the plant to keep check on the safety measures and health: - Inspection and maintenance of pollution control systems regularly - All safety measures such as provision of safety appliances, training, and giving-of safety awards. - The workers exposed to noisy sources will be provided with ear muffs/plugs - Adequate facilities for drinking water and sufficient toilets will be provided to the employees 8.6 SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY The firm shall earmark funds for social development and welfare measures in the surrounding villages. These measures will include funding for: 1) Education Facilities 2) Health Care and Family Welfare 3) Infrastructure Developments 4) Social Causes M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 80

91 The details of peripheral development plan including development in infrastructure, health, education and socio cultural aspects which will be carried out are as follows under the Corporate Responsibility: 1 The firm will organize free medical camps at least twice in a year for the benefit of the villagers. 2 The firm will organize cultural programmes in connection for the sake of local villagers every year. 3 The firm will provide chairs and cooking vessels on returnable basis to all the villagers for marriages. ESTIMATED COST OF PROJECT AND PROJECT VIABILITY The capital cost of the project is estimated at about Rs Lacs for the installation of plant & machinery along with required auxiliary and balancing facilities for the production capacity of 80 T/Month of Dyes & Intermediate product. The breakup of the same is shown below: S. NO. COST OF PROJECT COST (RS. IN LACS) 1 Land and Site Development Factory Building Plant & Machineries Franchises Deposits/ Non CA Investment/ Non CA Other Misc. Assets Preliminary & Pre-operative Exp Total Capital Cost of Project Margin Money for working capital Total Cost of project BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control/monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance will be as given in following table: S. NO. ITEM RS. IN LAKHS 1 Capital Expenditure Recurring expenditure on environmental management cell and on pollution control systems per annum 3.15 ECONOMIC VIABILITY STATEMENT SHOWING PROFITABILITY AND CASH ACCRUALS PARTICULARS QUANTITY RATE TOTAL PER KG RS. IN LAKHS Purchase Value of Dyes and Intermediate Product If we will produce, Production Cost of Dyes & Intermediate Product Net Saving Per Kg Actual Consumption / Day Actual Consumption / Monthly Actual Consumption / Quarterly Actual Consumption / Yearly M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 81

92 ESTIMATE OF MEANS OF FINANCE 1. Capital & Reserve Share application money Unsecured loan (Shareholders) Member s deposit Central & state subsidy 0.00 TOTAL M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 82

93 ANNEXURE I LAND AGREEMENT DOCUMENTS : M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 83

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98 LAYOUT OF THE PLANT Ground Floor Plan ANNEXURE II M/s. Kasturi Polymers and Pigments, GIDC Ankleshwar, Gujarat 88