Pre Feasibility Analysis

Prefeasibility Report Shree Pushkar Chemicals and Fertilizers limited
Pre-Feasibility Report
For
Proposed Establishment of Synthetic
Organic Chemicals Manufacturing Facility
By
Shree Pushkar Chemicals & Fertilizers limited

Plot No B-29, Additional Lote Parshuram MIDC,
Tal. Khed, Dist: Ratnagiri 415722,
Maharashtra, India
Web: shreepushkar.com
1
Table of Contents
1 EXECUTIVE SUMMARY ............................................................................................................................. 4

2 INTRODUCTION OF THE PROJECT ............................................................................................................. 6
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ........................................................................ 6
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ......................................................................................... 7
2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ............................................ 7
2.4 DEMAND SUPPLY GAP ................................................................................................................................ 8
2.5 IMPORTS VS INDIGENOUS PRODUCTION ............................................................................................................ 8
2.6 EXPORT POSSIBILITY ..................................................................................................................................... 8
2.7 DOMESTIC / EXPORT MARKET ........................................................................................................................ 9
2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT .............................................................. 9
3 PROJECT DESCRIPTION ........................................................................................................................... 10
3.1 TYPE OF PROJECT ....................................................................................................................................... 10
3.2 LOCATION ................................................................................................................................................ 10
3.3 DETAILS OF ALTERNATIVE SITES..................................................................................................................... 11
3.4 SIZE OR MAGNITUDE OF OPERATION .............................................................................................................. 12
3.5 PROJECT DESCRIPTION WITH PROJECT DETAILS ................................................................................................. 12
3.6 RAW MATERIAL REQUIRED ........................................................................................................................... 12
3.7 RESOURCE OPTIMIZATION ............................................................................................................................ 15
3.8 WATER, ENERGY / POWER AVAILABILITY AND SOURCE ...................................................................................... 15
3.9 WASTE GENERATION, MANAGEMENT AND DISPOSAL ........................................................................................ 16
3.10 MANPOWER REQUIREMENT ........................................................................................................................ 18
3.11 SCHEMATIC OF EIA PURPOSE ....................................................................................................................... 18
4 SITE ANALYSIS ........................................................................................................................................ 19
4.1 CONNECTIVITY .......................................................................................................................................... 19
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP................................................................................................ 19
4.3 TOPOGRAPHY............................................................................................................................................ 20
4.4 EXISTING LAND USE PATTERN........................................................................................................................ 20
4.5 EXISTING INFRASTRUCTURE .......................................................................................................................... 20
4.6 SOIL CLASSIFICATION .................................................................................................................................. 20
4.7 CLIMATE DATA FROM SECONDARY SOURCES .................................................................................................... 22
4.7.1 Temperature ................................................................................................................................ 22
4.7.2 Relative Humidity......................................................................................................................... 22
4.7.3 Rain fall ........................................................................................................................................ 23
4.8 SOCIAL INFRASTRUCTURE AVAILABLE .............................................................................................................. 23
5 PLANNING BRIEF .................................................................................................................................... 24
5.1 PLANNING CONCEPT................................................................................................................................... 24
5.2 POPULATION PROJECTION ........................................................................................................................... 24
5.3 LAND USE PLANNING .................................................................................................................................. 24
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)................................................................... 24
5.5 AMENITIES / FACILITIES ............................................................................................................................... 24
6 PROPOSED INFRASTRUCTURE ................................................................................................................ 25
6.1 INDUSTRIAL AREA (PROCESSING AREA)........................................................................................................... 25
6.2 RESIDENTIAL AREA (NON PROCESSING AREA) ................................................................................................... 25
6.3 GREEN BELT ............................................................................................................................................. 25
6.4 SOCIAL INFRASTRUCTURE ............................................................................................................................ 25
6.5 CONNECTIVITY .......................................................................................................................................... 25
6.6 DRINKING WATER MANAGEMENT .................................................................................................................. 25
6.7 SEWARAGE SYSTEM.................................................................................................................................... 26
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6.8 INDUSTRIAL WASTE MANAGEMENT ................................................................................................................ 26

6.9 SOLID WASTE MANAGEMENT........................................................................................................................ 26
6.10 POWER REQUIREMENT AND SUPPLY / SOURCE ................................................................................................. 26
7 REHABILITATION & RESETTLEMENT PLAN .............................................................................................. 27
8 PROJECT SCHEDULE AND COST ESTIMATES ............................................................................................ 28
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ......................................................... 28
8.2 ESTIMATED PROJECT COST ........................................................................................................................... 28
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) .................................................................... 29
List of Annexures
Annexure Description
I Land allotment / possession letter
II Process chemistry, Block diagram, Description
III Effluent treatment system block diagram
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1 EXEC UT IV E SU MMA RY
Shree Pushkar Chemicals & Fertilizers Ltd(formerly known as Shree Pushkar Petro
Products Ltd.) (SPCFL), founded in 1994 is an established market leader in the
manufacture of Dyes & Dyes Intermediates. We have been a late entrant into
manufacturing of Dyes Intermediates; however, we have created a niche for ourselves in
the dyestuff market. This can be attributed to our dedication to the dyestuff business
and our professional set-up to support our Customers. Today, we have become a force
to reckon with and are on our way of reaching and sustaining a position of leadership.
SPCFL are progressing and growing with a policy of innovation, invention and
consistent quality supplies. Our future development will have emphasis on safety and
harmony with the environment.
SPCFL supply products to a global clientele including major Dyes producers and
Merchant Traders. We also serve our Customers as an integrator of small manufactures
in India offering a "one stop" source of all their chemical requirements.
SPCFL manufacturing facilities are located near the commercial capital of India, i.e.
Mumbai. SPFCL have an aggregate installed capacity of 10000 MT of various Dyes
Intermediates. With a team of highly trained and qualified professionals, we guarantee
our customers not only high quality products, but also 110% service commitments via
our robust Manufacturing, Buy-Cycle and Post sales operational processes.
SPCFL are dedicated to the dyestuff business and set high future goals. We are an
achievement oriented organization and are proud of our track record. Infrastructure
developed by us and with policies that fuel growth, we have a very positive outlook for
the future. Our future plans include consolidating our capacities and enhancing our
product range. We are also in the process of extending our Product Reach capabilities
via Stock & Sale facilities at major consuming & trading centers. Our eventual goal is to
develop long term associations and also engage into Toll manufacturing under secrecy
agreements.
SPCFL is Leading Manufacturers of Dyestuffs, Dye Intermediates, fertilizers,Sulphur

Base Acids, such as Sulphuric Acids, Oleum Acids, Chloro Sulphonic Acid,Manufacturers
of Animal Feed Additives, Manufacturer, Suppliers, and Exporters of Reactive Dyes.
Our Manufacturing facilities are capable of providing a range of Chemical reactions such
as Sulfonation, Reduction, Nitration, Condensation, Isolation, Hydrolysis, Amination,
Fusion, Acetylation etc. These ranges of reactions make us ideal for Toll Manufacturing.
It gives us the flexibility to manufacture a wide range of products. The same is evident
from our product manufacturing capability Tree.
4
SPFCL wishes to establish manufacturing facility of Synthetic Organic Chemicals at

additional Lote MIDC at its newly acquired plot & we will apply for Consent to Establish
from Maharashtra Pollution Control Board Shortly.
The project brief is summarized in the table below Project summary at a glance
Table 2.1.1Brief Project summary
Sr No Particulars Details
1 Name of Company Shree Pushkar Chemicals and
Fertilizers Limited
2 Products Reactive Dyes, H-acid, Vinyl
Sulphone ester, Phthalocyanine
Pigments (Crude CPC Blue, Alpha
blue, Beta Blue, Pigment Green -
7)*
3 Location Plot No B-29, Additional Lote

Parshuram MIDC, Tal. Khed, Dist:
Ratnagiri 415722,Maharashtra,
India
4 Name of the project Establishment of Synthetic Organic
Chemicals Manufacturing Facility
5 Total land area of the plot 40,000 Sq. m
6 Raw material Refer Section 3.6
7 Water Water shall be sourced from MIDC.
Requirement ~ 412cmd (Fresh
plus recycled)
8 Power Power requirement is around
1250 KW ( 1250 KW from
MSEDCL)
9 Manpower During operation phase ~ 115Nos
(65 Permanent &50 Contract
workmen)
10 Waste water quantity (estimate) Refer section 3.9
11 Air emissions Emission shall be from Boiler,
Thermic Fluid heater, Emergency
DG set (SO2, NOx & Particulate
matter) and Process stacks (SO2,
acid mist/SO3, etc)
12 Solid Waste Refer section 3.9
13 Project cost ~ Rs. 72 Crores (Estimate)
*Note : SPCFL proposed to undertake establishment of manufacturing of inorganic Products
sulphuric acid 98 % (150 TPD), Oleum 65 % (30 TPD), Chlorosulphonic acid (30 TPD), Thionyl chloride
(3000 TPA) along with captive power plant of 750 kw which does not falls under EIA notification,
2006. Company will apply for Consent to establish from Maharashtra Pollution control board for
above products shortly.
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2 INT RODUCT IO N OF TH E PROJ ECT
2.1 Identification of the Project and Project Proponent

M/s. Shree Pushkar Chemicals & Fertilizers Limited (SPCFL) is a public Limited company
promoted by Shri Punit Makharia and has its Registered office at 301/302, 3rd Floor,
Atlanta Center, Opp. Udyog Bhawan, Goregaon East, Mumbai - 400063.
SPCFL has its manufacturing plants located at MIDC Industrial Area, Lote-Parshuram
Tal. Khed, Dist Ratnagiri Maharashtra as under:
1. Unit I Chemical Division: at Plot Nos. B-102-103 at MIDC Lote Parshuram,

manufacturing Dye- intermediates, Sulphur Based Acids and Cattle Feed
Supplement.
2. Unit II Fertilizer Division: at Plot Nos. D-25 at MIDC Lote Parshuram,

manufacturing Single Super Phosphate, Mixed NPK fertilisers and Soil
Conditioner.
3. Unit III Reactive Dyes Division: at plot No B-97 at MIDC Lote Parshuram,
manufacturing Reactive dyes. It also has 2 plants for the manufacture of H-Acid
and Vinyl Sulphone for captive consumption in the manufacture of reactive Dyes.
4. Unit IV SOP Division: at plot No B-18 at MIDC Lote Parshuram, manufacturing

Sulphate of Potash a soluble Potassic fertilizer along with a granulated Calcium
Chloride plant manufactured out of the waste HCl generated in the manufacture
of SOP.
PROJECT DESCRIPTION
SPCFL is already into the manufacture of Dye Intermediates and Reactive Dyes.
Based on SPCFLs presence in the market for nearly a decade, its base of existing
& prospective customers, the present orders and enquiries in hand as also
looking to the demand for its products SPCFL is confident of an optimistic market
situation, which is expected to persist in the foreseeable future.
SPCFL is thus in the process securing a firm place for itself in this emerging
scenario, and has therefore planned to expand its activities with state of the art
manufacturing plants, in key product areas which have significant growth in
demand.
SPCFL thus proposes to expand its activities into setting up the new plants on a
new plot of land admeasuring 40,000 M2 allotted to it within the additional Lote
Parshuram MIDC Industrial Area.
The company has already paid a sum of Rs. 70 Lacs and is in the process of
paying the balance amount and taking possession of the plot.
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2.2 Brief Description of nature of the Project

SPCFL thus proposes to set up the following plant,
Sr. Item Capacity

No.
Products
1 Reactive Dyes 12,000 TPA
2 H-Acid 3,000 TPA
3 Vinyl Sulphone ester 5,000 TPA
4 Phthalocyanine Pigments (Crude CPC Blue 7,800 TPA
5400 TPA, Alpha blue 900 TPA, Beta
Blue 600 TPA, Pigment Green -7 900
TPA)
By products
1 Copper Sulfide 48.TPA
2 Ammonium Sulphate 3000 TPA
3 HYPO(Sodium Hypo Chlorite NaOCl ) 12 TPA
4 Copper 24 TPA
5 Poly Aluminum Chloride (PAC) 900 TPA
Note : SPCFL proposed to undertake establishment of manufacturing of inorganic
Products sulphuric acid 98 % (150 TPD), Oleum 65 % (30 TPD), Chlorosulphonic acid (30
TPD), Thionyl chloride (3000 TPA) along with captive power plant of 750 kw which does
not falls under EIA notification, 2006. Company has applied for Consent to establish from
Maharashtra Pollution control board for above products.
2.3 Need of the Project and Its Importance to the country and/or
Region
The products proposed (Dyes, Pigments etc) above are imported to India on a regular
basis. The quantum of imports varies from product to product but the manufactured
goods will be import substitutes.
The products proposed are expansion of the companys current product range
(manufactured at other sites) as also backward integration into manufacture of some
items of raw material, and have a great demand both global and domestic. The demand
is envisaged to increase rapidly in the domestic market.
BUSINESS PROSPECTS
Healthy demand for dyes & bright prospects for dye intermediate industry
After remaining sluggish for two years, the volume growth of the nearly Rs 400 bn
domestic dyes and pigments industry has bounced back in FY14 which has led to a pick-
up in export demand. The industry has healthy prospects in the medium to long term,
driven by
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(a) Scope for increase in penetration of dyes in India,

(b) Revival in demand from the domestic textile industry, which accounts for 65-70% of
domestic dye consumption, and
(c) Reduction in dye imports from China and healthy growth in dye exports driven by
increasing competitiveness of Indian manufacturers in the global markets. This, in turn,
is expected to benefit the domestic dye intermediates industry.
Indian dye manufacturers are becoming more competitive in global markets:

Global production of dyes and pigments has shifted from regions such as Europe, the US
and Japan to Asian countries such as China, India, Thailand, Indonesia and Taiwan on
account of implementation of strict environmental norms in the former regions, lower
cost of production in Asia and the regions growing prominence in textile export
markets. China and India are leading producers and exporters of dyes. With a current
global market share of 10-15%, India exports 65-70% of its production (in volume
terms). As in the textile industry, Indian dye manufacturers have become more
competitive vis--vis their Chinese counterparts over the past few years due to
appreciation of Chinese Yuan, persistent wage inflation in China and cut-back of export
incentives by the Chinese government. This is expected to lead to reduction in Chinese
imports to India and increase in demand for Indian dyes in the global market.
Global short supply has led to pick-up in exports, increase in margins of local dye
intermediate players
Implementation of tough environmental control norms in China has led to the shutdown
of a number of polluting units of dye intermediates. The same has also been observed in
the domestic market wherein a number of small/ unorganized units which were unable
to comply with the pollution control norms have been shut down. This has led to supply
shortage globally and a sharp increase in the prices of key dye intermediates. This has
benefited organized Indian players as
(a) Exports of key dye intermediates have increased over FY14-H1FY15, and
(b) Increase in sales price has led to an increase in operating profitability.
2.4 Demand Supply gap

All the products in the product list have higher demands than the domestic supply and
hence are imported into the country. The addition of domestic production capacity will
provide a local source for the domestic market.
2.5 Imports vs indigenous production

All the products mentioned in the above product list are imported into India in
substantial quantities. The production will lead to an additional domestic source for the
local market.
2.6 Export Possibility

The products can be exported thus leading to Forex revenues for the country.
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2.7 Domestic / Export market

SPCFL has a well-established presence in the domestic as well as international market.
The products specified cater to the needs of the customers and provide them with a
complete product basket from a single source. These products can be sold in the
domestic market as well as can be exported.
2.8 Employment Generation (Direct and indirect) due to the project

During the construction phase around 75 - 100 workers and during the operational
phase around 115 workers including contractors will be required. Local skilled and
semiskilled workers will be engaged during construction phase.
The positives impact includes enhanced direct employment for technical/

administrative works and indirect employment opportunities for transporters of raw
materials and finished goods and downstream industries.
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3 PROJ ECT DESC RIPT ION
3.1 Type of Project

(including interlinked and interdependent projects, if any)
The project is for manufacture of Dyes, Pigments, and intermediates as follows,
Sr. Item Capacity

No.
Products
2 H-Acid 3,000 TPA
4 Phthalocyanine Pigments (Crude CPC Blue 7,800 TPA
5400 TPA, Alpha blue 900 TPA, Beta
Blue 600 TPA, Pigment Green -7 900
TPA)
By products
1 Copper Sulfide 48TPA
4 Copper 24 TPA
Note : SPCFL proposed to undertake establishment of manufacturing of inorganic Products

sulphuric acid 98 % (150 TPD), Oleum 65 % (30 TPD), Chlorosulphonic acid (30 TPD), Thionyl
chloride (3000 TPA) along with captive power plant of 750 kw which does not falls under EIA
notification, 2006. Company will apply for Consent to establish from Maharashtra Pollution
control board for above products shortly.
There is no interlinked and interdependent project.
3.2 Location
(Map showing general location, specific location, and project boundary and
project site layout) with co ordinates
The proposed project site is at additional Lote Parshuram MIDC. The plot is in
allotted by MIDC, However the plot layout is not yet submitted by MIDC to
SPCFL, which is in process.
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Details of Nearest Infrastructure Facilities
App. Distance of Project

Sr. No Destination
Site
01 Nearest Town
Chiplun 7 km
02 Nearest National Highway
NH-66 0.5 km
03 Nearest Airport
Mumbai 250 km
04 Nearest Railway Station
Chiplun 7 km
05 Nearest Port
JNPT 200 km
The project is proposed at Plot No B-29, Additional MIDC Lote Parshuram, Dist.
Ratnagiri, Maharashtra.
This site is in premises of additional MIDC (Lote Parshuram) area which is meant for
these types of Industries.
3.3 Details of Alternative sites

(Sites considered and the basis of selecting the proposed site, particularly the
environmental considerations gone into should be given)
Additional MIDC Lote Parshuram has proximity to 3 sea ports as under:
1. JSW Port, Jaigadh, Ratnagiri. 120 Kms

2. Dharamtar Port, Raigad 180 Kms
3. Dighi Port, Raigad 150 Kms.
SPCFL is currently importing various raw material including bulk items through these ports.
SPCFL has its own EXIM & Logistics departmentfor transportation of the Raw material &
Finished goods from factory to the port &vice versa.
The plot is thus most suitable for the products proposed specifically considering a complex
catering to in-house availability of some of the key Raw Materials such as Dye Intermediates
and Sulphuric Acid, as also from the point of view of ease in Management & control within
in the same locality.
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3.4 Size or magnitude of operation

Sr. No. Item Capacity
Products
2 H-Acid 3,000 TPA
4 Phthalocyanine Pigments (Crude CPC Blue 5400 TPA, 7,800 TPA
Alpha blue 900 TPA, Beta Blue 600 TPA, Pigment Green
-7 900 TPA)
By products
1 Copper Sulfide 48 TPA
4 Copper 24 TPA
Note : SPCFL proposed to undertake establishment of manufacturing of inorganic Products sulphuric

acid 98 % (150 TPD), Oleum 65 % (30 TPD), Chlorosulphonic acid (30 TPD), Thionyl chloride (3000
TPA) along with captive power plant of 750 kw which does not falls under EIA notification, 2006.
Company has applied for Consent to establish from Maharashtra Pollution control board for above
products.
3.5 Project description with Project details

(A schematic diagram / flow chart showing the project layout, components of the
project etc should be given)
Please refer Annexure I for process block diagram and description.
3.6 Raw material required

(Raw materials along with estimated quantity, likely source, marketing area of final
product/s, mode of transport of raw material and finish products.)
Raw Materials:
The basic raw material for the product capacity is submitted herein below.
Source for Raw Material Procurement:

Raw Material is easily available in the localmarket.
Mode of Transport of Raw Materials: Few of the raw materials will be transported
Locally and few will be imported from the International Market. Mode of transport to
site is by road truck/tankers.
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List of Raw Material required (Major)
Estimated
Sr. Physical Storage
Item consumption Unit Source / Vendor Name
No. state means
MTA
1 H-Acid 3240 MT solid bags Self Manufactured
2 Vinyl Sulphone Ester 6000 MT solid bags Self Manufactured
RCF/ Indian Oxalate/ R.R.
3 Sodium Nitrite 624 MT solid bags Enterprises, Mumbai./
Triveni Chemicals, Vapi
4 Cynauric Chloride 2208 MT solid drums Desmo Exports. Mumbai.
5 Aromatic Amines 1920 MT solid bags Hind Prakash
Shri Ram Industries
6 Lime Stone Powder. 9990 MT Solid bags
(Jodhpur)
Sodium Bi Sulphite Shalibhadra Intermediates
7 7450 MT Solid bags
22.0 % Pvt Ltd(Ahmedabad)
Dhruvika Chemicals Trading
8 Phthalic Anhydride 5832 MT Solid bags
P. Ltd.
Hazel Mercantile Ltd /M K
9 Caustic Flakes 4080 MT Solid bags Trading
Corporation(Mumbai)
10 Urea 3618 MT Solid bags
HurisonPharma
11 Naphthalene 2010 MT Solid bags First Chemicals(Mumbai)
12 Iron Powder 2010 MT Solid bags Dyechem Industries (Karad)
Pesticides &Brevers Ltd / P
13 Soda Ash 1710 MT Solid bags
G Exim Pvt Ltd(Mumbai)
AnmolColourChemChattral,
14 Aluminum Chloride 1413 MT Solid bags
Gujrat
Shalibhadra Intermediates
15 Na2SO4 1320 MT Solid bags
Pvt Ltd(Ahmedabad)
16 Cuprous Chloride 972 MT Solid bags Swami Narayan Industries,
Chattral , Gujrat
17 Vacume Salt 360 MT Solid bags Ravji Salt Suppliers
AmmonuimMolybdate
18 54 MT Solid bags
(Catalyst) Ganesh Trading
19 Cupric Chloride 45 MT Solid bags Ganesh Trading
20 Surfactant 33 MT Solid bags HitelChem, Mumbai
Gujarat Narmada Valley
Fertilisers& Chemicals Ltd /
21 Aniline Oil 4950 MT Liquid tank
Amos Corporation
(Ahmedabad)
22
Thionyl Chloride 2260 MT Liquid tank Self Manufactured
13
Estimated
Sr. Physical Storage
Item consumption Unit Source / Vendor Name
No. state means
MTA
Excel Industries / Atharv
52
HCl MT liquid tank Chemicals(Lote), Mamta
23 Enterprises(Pune)
Hazel Mercantile Ltd /M K
24 Caustic Lye 5000 MT Liquid tank Trading
Corporation(Mumbai)
Shri Ram Industries
25 Hydrated Lime 3990 MT Solid Bags
(Jodhpur)
26 Acetic Acid 3550 MT Liquid tank Fertilisers& Chemicals Ltd
/Urmi Chemicals(Mumbai)
Deepak Fertilisers&
27 Nitric Acid 2250 MT Liquid tank Petrochemicals / Sulphocid
(Mumbai)
Nandadeep Chemicals Pvt
28 Methanol 1590 MT Liquid Barrels
Ltd (Mumbai)
Reliance Industries Limited
29 Ethylene Oxide 1400 MT Liquid tank
(Mumbai)
30 Acetic Acid 660 MT Liquid tank Fertilisers& Chemicals Ltd
/Urmi Chemicals(Mumbai)
BenzoChem Industries P.
31 Dichloro Toluene 162 MT Liquid tank
Ltd.
Kempar Energy /
32 Xylene 28 MT Liquid Barrels
SksGlochem (Mumbai)
33 Mono Chloro Benzene 27 MT Liquid Barrels Chemie Organic Chemicals
Antares Chem P. Ltd.
34 Solvent Butanol 24 MT Liquid Barrels
Ghatkopar
35 Ice 23400 MT Solid Open Local Supplier
Proposed bulk storages at site (Major) for raw material and finished goods shall be as
follows,
No Particular Physical state Storage Stored in

capacity
1 Hydrochloric Acid Liquid 25 KL FRP tank
2 Nitric Acid Liquid 60 KL SS Tank
3 Aniline Liquid 50 KL MS Tank
4 Acetic Acid Liquid 15 KL SS Tank
5 Caustic Lye Liquid 30 KL MS Tank
6 Ethylene Oxide Liquid 10 KL MS Tank
7 Spent Sulphuric acid Liquid 150 KL PP Tank
8 Lime slurry Liquid 15 KL MS Tank
9 Solvent Liquid 15 KL MS Tank
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3.7 Resource optimization

(Recycling and reuse envisaged in the project, if any, should be briefly outlined)
SPCFL desirous to establish the manufacturing capacity of products. The resource

optimization shall be carried out at the site and with other site in order to reduce
wastage and minimum transport needs.
3.8 Water, Energy / Power availability and source

(Availability of water, its source, Energy/power and requirement and source should
be given)
1) Water
The total water requirement is 412 cmd for domestic, process, Boiler and cooling
and green belt maintenance purpose.
The source of water shall be from water works of MIDC.
Water requirement for proposed establishment is tabulated as below:
No Purpose Total, cmd

1 Domestic 12
2 Industrial
2.1 Industrial cooling / boiler feed 360
2.2 Industrial processing 35
3 Green belt / Gardening 5
Grand Total(#) 412
2) Energy
Steam / Process heat Requirement: The steam requirement and process heat
requirement for the proposed set up shall be met from the steam generating boilers and
Thermic Fluid heaters.
It is proposed to install 1 No of boilers of 6 TPH steam capacity each, and 1 Thermic

Fluid heater of 3 Lac Kcal/hr capacity.
In addition to above, there will be one hot air generator (coal fired).
Coal is proposed to be used as fuel its requirement for above.
The estimated fuel requirement for above shall be as follows:
15
No Capacity Fuel requirement Source of fuel supply

(Coal)
1 Boilers : 1 No x 6 TPH 26 TPD Imported
steam capacity each
2 Thermic Fluid Heater : 1 2.5 TPD Imported
No x 3 Lac kcal/hr
capacity each
3 Hot air Generators 24 TPD Imported
Total 52.5 TPD
Stacks of requisite heights and air pollution control devices for above shall be provided
as per statutory norms.
Following no of stacks are expected at site
No Stack for No of stacks Expected Pollutants

1 Boilers 1 PM, SO2, NOx
2 Thermic Fluid Heaters 1 PM, SO2, NOx
3 Hot Air generator 1 PM, SO2, NOx
4 Pigment Plant 1 PM, SO2, Cl2
5 Dyes Plant 1 PM
6 Spray Drying 1 PM
7 Emergency DG sets 1 PM, SO2, NOx
Note: APC and stack height shall be provided as per statutory requirement/norms.
3) Power
Proposed power requirement is 1250 KW for the proposed site operation which will be
supplied by MSEDCL.
For emergency power requirement, it is proposed to install 1 DG set of 500 KW

capacity.
No Capacity Nos Fuel requirement Source of fuel supply

1 DG : 500 KW 1 HSD : 125Litres/hr From local supplier
(Emergency use only)
3.9 Waste generation, Management and disposal

(Quantity of waste to be generated (liquid and solid) and scheme of their
management/disposal)
1) Waste Water
Proposed waste water generation, treatment and disposal shall be as follows,
No Description Quantity Disposal

1 Domestic effluent 8 Septic tank with Soak pit shall
be provided. Overflow if any
16
shall be used for onsite

gardening/ Green belt
maintenance purpose.
2 Trade effluent 300 Effluent treatment comprising
of Primary treatment followed
by Multiple effect evaporator
shall be installed at site.
The recovered condensate will
be reused to the maximum
extent.
And balance will be sent to
CETP for further treatment /
disposal.(*)
Total 308
(*) The estimated discharge to CETP shall be ~ 50 cmd of treated trade effluent.
The quantification of non-hazardous and hazardous waste estimated to be generated

from proposed activities is tabulated as below:
2) Non Hazardous waste
No Waste Type Quantity (*) Disposal

1 Fly ash 13 TPD Sold to brick
manufacturer/ sent for
landfilling
2 Lagging waste 300 kg/month Authorized Recycler
3 Iron scrap 400 kg/month Authorized Recycler
(*) Note: Above quantities are rough estimate, will be firmed up during EIA study
Ash content is based on 15 % ash in coal.
3) Hazardous waste
Category Type of Waste Quantity UOM Mode of Disposal
5.1 Used Oil 16 TPM Authorized
reprocesser/CHWTSDF Taloja
21.1 Process residue 50 TPM CHWTSDF Taloja
Spray Dryer
21.1 Process residue 25 TPM CHWTSDF Taloja
Pigment Plant
26.1 Gypsum 1500 TPM Cement manufacturers
26.1 Iron sludge 400 TPM CHWTSDF Taloja
33.1 Drums/ Barrels 500 No.PM Cleaned and Reused a site
35.3 ETP sludge 200 TPM CHWTSDF Taloja
(*) Note: Above quantities are rough estimate, will be firmed up during EIA study
17
3.10 Manpower Requirement

Manpower: Expected manpower requirement for the establishment (during operation
phase) shall be as follows:
Description Proposed nos (approx.)

Permanent 65
Contract workmen 50
Total 115
3.11 Schematic of EIA Purpose

(Schematic representations of the feasibility drawing which give information of EIA
purpose)
Figure 3.11.1Schematic reprsentation of the feasibility drawing which gives EIA

purpose
18
4 S IT E A NALYS IS
4.1 Connectivity
Proposed establishment project is planned at its newly acquired plot at additional Lote
Parshuram MIDC of the company. The nearest town / cities are Khed (21kms)/ Chiplun
(about 10 kms)/Pune approx. 250 kms and Panvel/Mumbai 210/250 kms respectively.
The industrial area are provided with good infrastructure like road connectivity to
National Highways (NH-66, old NH-17), railways (nearest station is Khed/Chiplun about
18/10 kms) / un-interrupted power supply as well water supply.
The land in possession with the company. The land doesnt fall under CRZ.
Existing land use pattern, Forest, water bodies details are as follows
Sr. No. Particulars Details
1. Town Lote MIDC
2. Taluka Khed
3. District Ratnagiri
4. Nearest water bodies River Vashishti (about 4 km in southwest direction)
5. Nearest Highway NH 66 = 1 km towards West
6. Nearest Railway Khed / Chiplun on Konkan railway which is
station approximately 18/10 km
7. Nearest Airport/ Mumbai International Airport 250 KM towards NW
Airbase Pune Lohegaon Airport / Airbase 134.5 KM towards NE
4.2 Land form, Land use and land ownership

Land Form: Land is on plain contour, it is flat terrain.
Land Ownership: Land ownership is with project proponents (Shree Pushkar

Chemicals and Fertilizers limited)
Existing Land use Pattern: The Land is reserved for Industrial use & the proposed
project shall be at the same plot.
Existing Infrastructure: Presently there is an existing Infrastructure around the site.
19
Infrastructure like water, electricity, telephone facility, roads already available in the
area. Other Infrastructure like, hospital, school, housing, entertainment, daily needs are
available easily at nearby Chiplun Town.
Additional Lote Parshuram MIDC provides many basic facilities like uninterrupted
water supply, power and Road Network. When various sites were seen, this site
appeared to be environmentally best as also from the business angle and therefore this
option was finally adopted. This site is inside the campus of the MIDC and means safe
transportation, less need of Utilities, less constructing buildings and roads, less water
with optimization of infrastructure.
There is no sensitive establishment in the vicinity such as health resort, hospital, and
archaeological monuments.
4.3 Topography
District Ratnagiri is one of the coastal districts of Konkan region of Maharashtra, spread
over an area of 8208 km2. It shows variation in topography from high altitudinal
Sahyadri hill ranges to coastal plains. The most predominant rock formation of the
district is the Konkan laterite, formed from the original trap and so the soils produced
from it is predominantly Lateritic. According to location and, extent of admixture of
different rocks, soils in Ratnagiri are graded as Rice, Varkas, Garden and Coastal Alluvial
soils. District receives average 3029 mm annual rainfall mostly contributed by
southwesterly monsoon. These climatic and edaphic conditions support different types
of forests. As per Champion and Seths classification, following forest types are generally
found in the district.
According to bio-geographic zone classification of India, study area falls under Deccan
Peninsula Central Plateau.
4.4 Existing land use pattern

It is MIDC Plot for industrial use.
4.5 Existing infrastructure

Vacant MIDC plot. Infrastructure is provided by additional Lote MIDC
4.6 Soil classification

The most predominant rock formation of the district is the Konkan laterite, formed
from the original trap. It is an argillo-ferrugenous deposit and covers the major
portion of the land surface forming undulating plateaus with a general elevation of
200 to 300 feet Laterisation has taken place under the hot humid conditions. Due to
heavy rainfall, the bases have been leached away along with the silicic acid and hence
the resulting rock is acidic in reaction and rich in iron and aluminium oxides with a
silica-sesquioxide ratio of less than two. The hydrated iron oxides impart the red
colour to the soils. Due to these geological formations the soils of the district are
mostly lateritic which are found mixed with trappean soils in the north and shallow
20
soils in the south. Along the coast are the alluviums. There are small patches of salt
lands developed near the creeks.
Lateritic Soils
Lateritic soils which are predominant in the district, vary in color from bright red to
brownish red owing to the preponderance of hydrated iron oxides. They are always
acidic, the PH value ranging from 4.5 to 6.5. Lime is deficient or almost absent.
Usually they have very low phosphorus and potash content, but are fairly well
supplied with nitrogen and organic matter. Their texture is loamy and depth varies
from one foot to three feet. They are porous and not retentive of moisture and are
found all over the district except in Mandangad taluka which consists mainly of
forests. These soils, however, are found in several grades, which depend upon their
(soils) location and the extent of admixture of different rocks. The following of these
grades are of special significance.
Rice Soil
These soils have various names which are identified with their location. Those
situated at higher levels are usually known as mal, while those at slightly lower levels
are called kuryat soils. Near the water courses, which have a fair supply of water
during the rabi season, are the panthal or vaingan soils. All these soils benefit by
liming and give high response to the application of phosphatic and potassic
fertilisers. Only a kharif crop of paddy can be taken on these soils. On the panthal
soils, however, a crop of rabi pulse (wal) or summer (vaingan) paddy can also be
taken.
Varkas Soil
These soils are situated on the slopes of the hills and are partly eroded, yellowish red
and poor in fertility. Further, they are shallow in depth and coarse in texture. Ragi
(nagli) is the principal crop in these soils and it responds well to supplies of nitrogen
and phosphate. Cashewnut grows in plenty in this area. It is on these soils that the
world renowned Alphonso mangoes are grown. On the mountain tops are the
perennial forests, where the soils are rich in humus because of their being protected
from erosion. They are reddish-brown in colour.
Garden Soil
These soils are usually of mixed origin, varying from yellow-red to brown and are
located in the basins at the bottom of the hill ranges. They are light, easily workable,
well-drained and fairly fertile. Arecanut and cocoanut gardens thrive well in these
soils and are located in areas which have plenty of water supply and good drainage.
These crops respond well to application of nitrogen, phosphorus and potash.
Coastal Alluvium
The coastal strips in Dapoli, Guhagar, Ratnagiri and Rajapurtalukas are covered with
soils of recent deposits and are locally known as pulanwat. They are deep sandy
loams and cocoanut gardens and arecanut gardens thrive well in them. Paddy is also
taken here to some extent.
21
Salt Land
Due to the inundation of the sea, a part of the coastal soils has "become salty. They
are locally known by several names like khar, khajan, kharvat, etc. In Deogad, Malvan
and Vengurlatalukas, the entire western strips are salty while in other coastal talukas
only salt patches which are suited to the coarser types of paddy are to be noticed.
Since these salt lands have not yet become alkaline, they can be reclaimed for
cultivation. With a view to making khar lands fit for cultivation Government enacted
the Bombay Khar Lands Act, 1948 and passed the Bombay Khar Lands Rules, 1949 to
provide for protection and improvement of khar and khajan lands and reclamation of
tidal lands in the State by construction and maintenance of and repairs to
embankments of the lands. The act was brought into force with effect from 11th July
1949 in the district. Under the provisions of the Act, the Government established the
Khar Lands Development Board on 11th July 1949. The Revenue Department
administers the Act, and sanctions individual Khar Lands Scheme thereunder
approved and prepared by the Board. The schemes so sanctioned are executed and
completed by the Board. The Act provides for a Government subsidy of 40 per cent,
of the cost of the schemes; the remaining 60 per cent, to be contributed by the
beneficiaries. The Board also recovers a small annual cess called "Khar BandistiAkar"
from the beneficiaries, being the cost of maintenance of the embankments
constructed under the scheme. By 1958, the Board had reclaimed in this district
about 1,959 acres covered by 13 schemes at a cost of Rs. 1,51,305.
4.7 Climate data from secondary sources

4.7.1 Temperature
Meteorological data are available for four stations in the district, viz., Harnai,
Ratnagiri, Deogad and Vengurla. Being a coastal district the variation of temperature
during the day and through the seasons is not large.
In the hot season temperature rises slowly from March, and May is the hottest
month. With the onset of the monsoon, temperature drops by three to four degrees.
Day temperatures during the monsoon are lower than those in the cold season. In the
post monsoon months of October and November, day temperatures increase and
days in November are as hot as in May. Night temperatures are the lowest in January.
Areas within 20 to 25 kilometres of the coast are the most pleasant particularly in
the hot months with the sea breeze blowing, nearly throughout the day. Further
inland during the hot months both days and nights can be oppressive and more so in
the tract at the foot of the Western Ghats. Along the coast the maximum temperature
rarely goes beyond 38C but in the interior may reach 40 or 41C.
4.7.2 Relative Humidity

Owing to the proximity of the sea, the district is on the whole very humid. Even
during the winter and summer the relative humidity seldom goes below 50 per cent.
Cloudiness:
22
During the monsoon, skies are heavily clouded to overcast. But in the rest of the year
skies are clear or very lightly clouded.
Winds:
Winds are very strong and are mainly westerly or south westerly during the
monsoon. In the rest of the year winds blow from directions between north and east
in the mornings and between west and north-west in the afternoons.
Special weather phenomenon
During the pre and post monsoon months the district experiences very strong winds
sometimes reaching gale force particularly near the coast and heavy rain in
association with cyclonic storms which develop in the Arabian Sea and move in close
proximity to the coast. Thunderstorms are common in the post monsoon months and
the latter part of the hot season.
4.7.3 Rain fall
The regional distribution of rainfall is mainly explained by the relief of the land and
the direction of the rain bearing winds. The supply of rain to the inland areas is
considerably more than to the coastal areas. It becomes heavier or lighter, according
to the nearness or otherwise of the station to the great Sahyadri range which
powerfully attracts the rain clouds. Mandangad is, however, an exception though its
distance from the sea-is just about 14 miles. The average rainfall recorded by this
station appears to be quite high as compared to the averages of Deorukh, Chiplun,
Rajapur and Khed which are so near the Sahyadri hills.
Ante-monsoon or "mango" showers occur in April-May. Although the amount of
precipitation is small, these showers have great value in so far as the preliminary
kharif operations are concerned. The south-west monsoon is the main rainy season,
commencing by about the middle of June and lasting till the end of September.
Winter fall, resulting from the retreating monsoon, is almost negligible, which
explains why rabi cultivation is practiced on an insignificant scale. Most of the rabi
crops are brought to maturity mainly by irrigation.
The length of the rainy season has an important bearing on the agricultural
operations and output of the district. In a normal rainy season, there are about 100
rainy days. A substantial portion of which runs to waste because of its extreme
concentration during a certain part of the season which reduces the effectiveness of
the rainfall commensurately. From the point of view of agriculture, effectiveness of
rainfall depends on many factors such as, the normal rainfall, length of the rainy
season, occurrence of rain at the right time during the agricultural season, its spacing
during the season, nature of the soil, rate of evaporation, etc.
4.8 Social infrastructure available

Nearest town is Chiplun which is about 7 km from site. Social infrastructure such as
schools, Hospitals, market place and other amenities are easily available. Transport
facilities by rail and road are available.
23
5 PL A NNING B RIEF
5.1 Planning Concept

Plot is at well-established MIDC Parshuram Lote area
Purified Water supply from MIDC
Road facility with illumination is available
Infrastructure facilities available at the established MIDC site
Integration with the existing manufacturing facility within area
Raw material availability
5.2 Population Projection

An official Census 2011 detail of Ratnagiri, a district of Maharashtra has been released
by Directorate of Census Operations in Maharashtra. Enumeration of key persons was
also done by census officials in Ratnagiri District of Maharashtra.
In 2011, Ratnagiri had population of 1,615,069 of which male and female were 761,121
and 853,948 respectively. In 2001 census, Ratnagiri had a population of 1,696,777 of
which males were 794,498 and remaining 902,279 were females. Ratnagiri District
population constituted 1.44 percent of total Maharashtra population. In 2001 census,
this figure for Ratnagiri District was at 1.75 percent of Maharashtra population.
There was change of -4.82 percent in the population compared to population as per
2001. In the previous census of India 2001, Ratnagiri District recorded increase of 9.89
percent to its population compared to 1991.
5.3 Land use planning

The Land is already as Industrial thus there is no change in land use. This is allotted by
MIDC in the year 2016.
5.4 Assessment of Infrastructure Demand (Physical and social)

No major infrastructure demand is envisaged as the proposed site is in well-developed
MIDC area.
5.5 Amenities / Facilities

No major amenities / facilities demand is envisaged as the proposed site is in
welldeveloped MIDC area, and Mahad is major town near the site.
24
6 PROPOS ED INF RASTRU CT U RE

Since the establishment is planned at new site in developed notified industrial area, no
special/specific development is anticipated. Company will have to do site development.
Company has not planned any residential area at the proposed site as MIDC has already
existing Residential areas earmarked for housing colonies.
6.1 Industrial Area (Processing area)

SPCFL at plot no B-29, additional Lote Parshuram MIDC proposes to set up plant for
manufacture of Chemicals, Dyes and pigments based on demand and market projection.
6.2 Residential area (non processing area)

No Residential area is proposed within the plant site.
6.3 Green Belt

Green belt of adequate area within and around the project site shall be carried out as
per industries norms and requirement.
6.4 Social Infrastructure

Local people will be given preference wherever found suitable for all the jobs in the
plant, direct as well as indirect. Thus the project shall have a positive impact on the
employment pattern of the region. Economic status of the local population will improve
due to increased ancillary/business opportunities, thereby making positive impact.
Educational, medical & housing facilities will improve due to the proposed project.
6.5 Connectivity
Refer 4.1 above
6.6 Drinking water management

Drinking water and water for industrial usage shall be supplied by MIDC.
The total water requirement is about 412cmd (fresh & recycled) for Domestic,
boiler/cooling, Greenery and process. The source of water shall be from MIDC.
25
6.7 Sewarage System

Septic tank with Soak pit shall be provided for seweage. Overflow if any shall be used for
onsite gardening/ Green belt maintenance purpose.
Effluent treatment comprising of Primary treatment followed by Multiple effect

evaporator shall be installed at site. The recovered condensate will be reused to the
maximum extent, and balance will be sent to CETP for further treatment / disposal.
6.8 Industrial waste management

Refer 3.9 above
6.9 Solid waste management

There is no specific infrastructure is required for the proposed expansion for solid
waste management. Refer 3.9 above for additional waste generation and its disposal
management.
6.10 Power requirement and supply / source

Power requirement shall be sourced from MSEDCL. Refer above 3.8 for power
requirement / source details
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7 REHAB IL ITAT ION & RES ET TL EMENT

PL A N
(Policy to be adopted (center/state) in respect of project affected persons including home
oustees, land oustees and landless labors(a brief outline to be given)
The proposed activities are in the newly acquired plot of the company which is located
in additional Lote Parshuram MIDC area. It does not require acquisition of Land and the
Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement
carried out.
27
8 PROJ ECT SCH ED UL E A ND COST

EST IMAT ES
8.1 Likely date of start of construction and likely date of

completion
(Time schedule of the project to be given)
The various plants are expected to be commissioned one after the other starting from
November 2018 onwards and are expected to be fully operational by December 2019.
8.2 Estimated project cost

(Along with analysis in terms of economic viability of of the project)
Estimated cost of the Project is ~ 72 Crores
28
9 A NA LYS IS OF TH E PRO P O SAL (FINAL

RECOMMENDAT IO N)
(Financial and social benefits with special emphasis on the benefit tothe local people
including tribal population, if any, in the area)
The proposed manufacturing project envisages
- For the growing domestic market and as Import substitution

- Direct employment to locals and will prompt ancillary business
- Export benefits
29
Annexure I
30
31
32
33
34
Annexure II
Brief Manufacturing Process description & Flow Diagram
PROCESS OF MANUFACTURE
The manufacturing processes for the aforesaid products are as under:
1. Vinyl Sulphone:The Manufacturing process for Vinyl Sulphone consists of six main
stages namely:
Sulphonation
Filtration
Reduction
Filtration and Centrifuge
Esterification
Drying & Packing
Sulphonation:
Acetanilide is Sulphonated with Chloro sulphonic Acid & Thionyl Chloride in a sulphonator
at controlled temperature.
The mass is then transferred to a dumping vessel and washed. The washed mass is charged
with required quantity of crushed ice so as to maintain the temperature within 00 to 30C; the
mass is then transferred to filtration.
Filtration:
The dumping mass is filtered in a Nutche filter where the cake is separated. The filtrate
containing spent acid (dilute Sulphuric acid) is transferred to the storage tank from where it is
taken for manufacture 1 Amino 3-6 Disulphonic 8 Napthalene Acid. The Cake containing
ASC is further taken for reduction and. Pre-determined quantity of Sodium Bi-Sulphite is
dissolved in water in the reduction vessel. The cake (Acetyl Sulphonyl Chloride) is added to
the reactor for about 6 hours along with Caustic Lye to maintain the PH at 7.
Reduction:
The Sulphonyl chloride wet cake is slowly added to an aqueous solution of sodium bisulphite
in a S.S. jacketed reduction tank. Caustic lye (48%) is added simultaneously to maintain the
pH at 7.5. The mass is stirred till pH stabilizes at 7.5 and then it is heated to 50C and
maintained at that temperature.The mass is then transferred to Ethoxylation vessel where
Ethylene oxide gas is passed at a controlled rate and the PH is maintained at 7 by continuous
addition of Sulphuric acid.
Filtration and Centrifuge:

The Ethoxylated mass is filtered in a Nutche filter. The cake is further dried with centrifuge
and finally in tray driers, while filtrate containing spent acid is transferred to storage tank for
further use in 1 Amino 3-6 Disulphonic 8 Napthalene Acid plant.
Esterification:
35
The dried cake together with Sulphuric acid is charged in an Esterification vessel and heated
to 1700C. After the Esterification reaction is complete the mass is filtered.
Drying & Packing

The cake containing Vinyl Sulphone is separated, dried, pulverized to fine powder and
packed in plastic bags. The fumes generated in the Esterification reaction containing Acetic
Acid is collected in the condenser and transferred to storage tank.
The Reaction steps for manufacture of Vinyl Sulphone Ester are as follows
36
37
2. Manufacturing process for 1 Amino 3-6 Di-sulphonic 8 Naphthalene Acidconsists of

six main stages as follows:
i. Sulphonation .
ii. Nitration.
iii. Neutralization & Filtration.
iv. Reduction & Concentration
v. Methanol Fusion
vi. Isolation& Filtration.
Sulphonation
Naphthalene is Sulphonated by conc. Sulphuric Acid & 65% Oleum in a Cast Iron jacketed
Vessel at controlled temperature & PH.
Nitration
The Sulphonated mass obtained as above is thereafter Nitrated using 60% Nitric Acid in a SS
jacketed Vessel at controlled temperature & PH.
Neutralization & Filtration
The Amino mass obtained as above is taken in a brick lined MS reactor, where it is washed &
the PH adjusted using Lime slurry. The mass is then heated & thereafter neutralised at
controlled temperature with Sodium Sulphate.
The neutralised mass is thereafter filtered in a Nutche Filter under Vacume to obtain the Nitro
Solution.
The solute Gypsum containing 30% moisture is dumped in the gypsum yard for sale to
Cement manufacturers.
Reduction & Concentration
The Nitro solution obtained as above is taken in a brick lined MS reactor,
& the PH of the Nitro mass is adjusted using 30%Hydrochloric Acid/ 25% Acetic Acid. The
temperature of the mass is thereafter raised & the mass reduced with slow addition of cast
iron powder for reduction. After completion of reduction the mass is treated with Soda Ash to
raise the PH to slightly alkaline & thereafter the mass is filtered in filter presses with
Continuous washing with hot water to obtain the Amino Solution which is concentrated
through Multi effect evaporator leading to recycling of more than 50% of the water.
The Residual Iron Sludge from the filter press is stored in pits where from it is sent for
land fill to SWMP, Taloja.
Hydrolysis & Fusion
The concentrated Amino Solution obtained as above is taken in a MS Jacketed autoclave & is
charged with Caustic soda flakes and Methanol and the temperature & Pressure of the Auto
clave raised to 1800 C & 28 Kgs/mm2 pressure & maintained for about 11/2 hrs.
The reaction mass is thereafter cooled & discharged into a MS Jacketed Fusion Mass Holder
where it is steamed to ensure completion of reaction and distill out Methanol completely for
recirculation in subsequent batches.
Isolation of 1 Amino 3-6 Di-sulphonic 8 Naphthalene Acid & Filtration

Spent Sulphuric Acid (circulated from the VS plant)is taken in a brick lined MS reactor and
heated to 900C. The Hydrolysed mass obtained as above is thereafter charged slowly in the
acid bath by controlling the PH& temperature. The excess SO2 is removed by direct purging
of steam. The mass is thereafter cooled to 750C & the volume maintained by addition of raw
water.
38
The 1 Amino 3-6 Di-sulphonic 8 Naphthalene Acid slurry obtained is drained in a Nutche
filter & given 2 to 3 washes to obtain 1 Amino 3-6 Di-sulphonic 8 Naphthalene Acidwet cake
which is subjected to Flash Drying.
Packing
The 1 Amino 3-6 Di-sulphonic 8 Naphthalene Acidof consistent quality is then packed in
poly lined plastic bags for dispatch.
Reaction steps for manufacture of1 Amino 3-6 Di-sulphonic 8 Naphthalene
Acid
39
3. The general process for manufacture of Reactive Dyes consists of five main stages:
i. Diazotization.
ii. Preparation of Coupler.
40
iii. Coupling.
iv. Condensation
v. Concentration & spray drying.
Diazotization
The reactive component, an Aromatic Amine, is diazotized by adding sodium nitrite solution
and HCl at lower temperatures (00 to 50 C - crushed ice is directly used to maintain
temperature).
Preparation of Coupler
i. The coupler an Aromatic Amine is neutralised with caustic Lye and then acetylated by
using acetic Anhydride at 300 to 350 C,
In another process the Coupler organic component containing hydroxy/ sulphonic/ amino
group is cynurated with Cyanuric chloride at 00 to 50 C.
Coupling
The coupler is thereafter coupled with the diazotized base. The same is neutralised with light
solution of soda Bi Carb and soda ash resulting into the Dye solution.
Condensation
In the case of cynurated coupler the reaction mass is condensed with a third aromatic amine
at 500 to 600 C resulting into the Dye solution
Concentration & spray drying.
The Dye solution is thereafter concentrated to slurry in multi effect evaporators and is finally
spray dried to yield the final product. (Removing extra water which is recirculated)
Blending &Sieving
The final Reactive Dye obtained from different batches are blended and sieved for product
consistency and are finally send to the packing line.
Packing
The dye of consistent quality is then packed initially in plastic bags and thereafter in poly
lined cartons.
Typical Reaction steps for manufacture of Reactive Dyes

STEP 1 CYNAURATION
STEP 2 DIAZOTIZATION
41
STEP 3 COUPLING
STRUCTURE - A
STEP -4 CONDENSATION
A typical flow diagram for manufacture can be depicted as under:
42
43
4. Manufacturing process for Phthalocyanine Pigments.

Copper phthalocyanine, a blue pigment, is manufactured by heating phthalonitrile,
derived from Phthalic anhydride, with a copper (cuprous) salt. For a high-grade pigment
quality, the raw pigment is subjected to special conditioning processes to achieve the
required physical form. Valuable green pigments are obtained from copper
phthalocyanine by halogenation processes.
The phthalocyanine is synthesized using Phthalic anhydride, urea, metallic salt and
ammonium molybdate as raw materials in the absence of a solvent. The appropriate
reaction temperatures ranges between 200-2800C, the mole ratio of urea to phthalic
anhydride is 1:5, the yields are improved by adding a suitable dosage of sodium carbonate
and ammonium chloride.
1. Manufacturing Process CPC Blue (Crude):
Stage 1:
Phthalic Anhydride, Ammonium Carbonate and Di Chloro toluene Solvent are heated in a
vessel to 1300 C.
The above charge is taken in a M.S. Jacketed Glass lined reactor, to which is charged
Urea, Cuprous Chloride and Ammonium Molybdate in proper proportion and heated
upto 1900 C
During the heating process part of the urea Decomposes releasing ammonia & carbon
dioxide gas.Which is scrubbed through a two-stage water scrubber and thereafter through
acid scrubber. From the water scrubbing we obtain ammonium carbonate which is
recirculated.
After maintaining the batch for sufficient time the charge is dumped into a M.S. venulator
for vacuum distillation by which nearly 95 % of the solvent is recovered.
The residual crude is then transferred to a MSRLTL vessel containing water.
Stage 2:
The above heated crude material in the dumping vessel is charged with spent sulphuric
acid (mother liquor from Alpha Blue) and further water added to the desired consistency.
The charge is then heated up to 95 deg C and maintained for 3 hrs.
The mass is then filtered through filter press, washed, Neutralized, dried in a spin flash
drier, pulverized & packed to obtain the final product CPC blue (Crude).
the mother liquor generated from the filtration process, is concentrated from which copper
sulphate is isolated dried and packed for sale the residual Mother liquor is further
concentrated through Multi Effect Evaporator to remove water which is recycled, and
Ammonium Sulphate is harvested, the residual water containing 6-8 % of sulphuric acid,
is neutralized & treated in the ETP where after the same is discharged into the CETP.
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF CPC (CRUDE)
44
2. Alpha Blue:
Stage 1 (Acid process):
98 % Sulphuric acid is taken in a jacketed reaction vessel, to which crude Copper
Phthalocyanine is charged slowly. The temperature is maintained just below 85 deg C so
as to dissolve it completely.
The mass is stirred further for 2-3 hrs at 60 deg C and then cooled to room temp by
external circulation of water in jacket.
Recycled water is then introduced as a thin spray into the vessel slowly, taking care to
maintain the temp below 60 deg C.
The CPC separates out in the required form and is filtered off.
During filtration process the mother liquor generated contains 20 % sulphuric acid,
which is used in the manufacture of CPC blue.
Stage 2 (Pigmentation Process):
45
The CPC cake obtained in stage 1 is taken in another vessel and washed with water. It
is then stirred with fresh water to obtain an aqueous slurry which is acidic in nature. The
same is neutralized using ammonia solution and caustic lye to a pH of 8 to 8.5 and stirred
with emulsifier at 60 - 90 deg C for 2 Hrs.
The above slurry is filtered and the cake is washed with large amount of fresh water.
The wet cake is dried and pulverized to obtain CPC Alpha Blue.
The aqueous filtrate goes to ETP. Where after it is discharged into CETP.
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF ALPHA BLUE
46
3. Beta Blue:
Stage 1 (Milling) :
The 98 % CPC is charged in a ball mill. The crude is milled for 24 Hrs. After grinding the
milled blue is discharged for Pigmentation. (Stage 2)
Stage 2 (Pigmentation):
The milled blue obtained above is charged into a MS vessel, containing caustic water,
Surfactants and solvent. The mass is heated under stirring and refluxed for 2 Hrs.
The solvent is thereafter recovered. The pigmented mass is filtered through filter
press, washed with water till the pH is neutral. The pressed cake is dried in spin flash
dryer.
4. Phthalocyanine Green G
Step 1
AlCl3 and Vacume salt are taken in a glass lined reactor, and heated upto 1600C for
melting of the mass. CPC and Cupric Chloride are charged in the molten mass and the
temperature maintained at 1700C.
Take water in the dumping vessel and drown the above mass.
Filter the mass in filter press and wash upto neutral PH.
Step2
The filtered cake is mixed with water in a vessel to which is added caustic Lye, a
surfactant and solvent (butyl Alcohol). The mass is heated upto reflux and is kept in
reflux mode for 5 Hrs.
The mass is thereafter put on distillation mode to recover the entire solvent. Thereafter
water is added to the mass and is subjected to filtration in the filter press, with hot water
washing till neutral PH. The cake is thereafter dried in a spin flash dryer and packed.
PROCESS FLOW DIAGRAM FOR PIMENT GREEN-7
47
48
RAW MATERIAL
For manufacture of Reactive Dyes the main Raw materials required are various types of
Dye-intermediates mainly different aromatic Amines such as VS, 1 Amino 3-6
Disulphonic 8 Napthalene Acid, Gamma Acid, MUA etc.
A major portion of these Intermediates would be manufactured in-house by the

Company.
Whereas for Manufacture of H-Acid& VS the main raw material requirement would be
Naphthalene & Aniline oil. In addition the other items required are Nitric Acid, Oleum
65%, Sulphuric Acid 98%, Acetic Acid, Methanol, HCl, Iron powder, Caustic Flakes &,
Hydrated Lime As regards Sulphuric Acid, Oleum & Chloro Sulphonic Acid the same
would be met internally from the proposed Acid Complex (inorganic Products to be
manufactured under Consent to establish from MPCB) . The Company is already using
all the aforesaid raw material for its existing activities and as such has a well set
procurement system and no difficulty is envisaged in this regard.
All the raw materials are available indigenously from the open market without any difficulty.
At its existing plants at B-102/103, SPCFL is already manufacturing Dye Intermediates like
Gamma Acid, K-Acid, H- Acid, MUA, VS, etc. As also a Reactive dye manufacturing unit at
B-97. Further it also has an acid complex manufacturing Sulphuric and its derivative acids
Oleum & Chloro Sulphonic Acid with a nominal Capacity of 125 MT /day. As such the
existing procurement set up would be utilized for the raw material procurement.
The proposed plants for VS and H-Acid, are mainly to meet captive needs. The residual
portion would be sold in the market.
The details of sources of raw material are as under:

As regards the main raw material namely Dye Intermediates SPCFL is already in the
manufacture of Dye Intermediates and has existing 6 plants for the manufacture of
intermediates and nearly 90 % of the requirement of intermediates can be met in-house. The
balance Dye Intermediates would be procured locally or could also be imported from China.
The other raw material like acids, alkalies and other reagents are available indigenously
without any difficulty. SPCFL is already procuring these chemicals for its existing activities
and as such has a well set procurement system and no difficulty is envisaged in this regard.
The sources of individual items of raw material are as under:

Sr. No. Item Source / Vendor Name
1 Dye Intermediates Self-Manufactured
2 Sulphuric Acid Self-Manufactured
3 Oleum 65% Self-Manufactured
4 Thionyl Chloride Self-Manufactured
Gujarat Narmada Valley Fertilisers & Chemicals Ltd /Urmi
5 Acetic Acid Glacial
Chemicals(Mumbai)
Excel Industries / Atharv Chemicals(Lote Parshuram),Mamta
Hydrochloric Acid 30%
6 Enterprises(Pune)
7 Caustic Soda Lye Hazel Mercantile Ltd /M K Trading Corporation(Mumbai)
8 Nitric Acid 72% Deepak Fertilisers & Petrochemicals / Sulphocid (Mumbai)
9 Aniline Oil Gujarat Narmada Valley Fertilisers & Chemicals Ltd / Amos
49
Corporation(Ahmedabad)
Kempar Energy / Sks Glochem (Mumbai)
10 Ethylene Oxide Reliance Industries Limited(Mumbai)
11 Methanol Nandadeep Chemicals Pvt Ltd (Mumbai)
12 Hydrated Lime 90% Shri Ram Industries (Jodhpur)
13 Soda Ash Pesticides & Brevers Ltd / P G Exim Pvt Ltd(Mumbai)
14 Sodium Nitrite RCF/ Indian Oxalate/ R.R. Enterprises, Mumbai.
15 Cyanuric Chloride Desmo Exports. Mumbai.
16 Cast Iron Powder Dyechem Industries (Karad)
17 Refined Naphthalene First Chemicals(Mumbai)
18 Sodium Bi Sulphite Powder Shalibhadra Intermediates Pvt Ltd(Ahmedabad)
19 Phthalic Anhydride Dhruvika Chemicals Trading P. Ltd.
20 Technical grade Urea Hurison Pharma
21 Cuprous Chloride Swami Narayan Industries, Chattral , Gujrat
22 Cupric Chloride Ganesh Trading
23 Ammonium Molybdate Ganesh Trading
24 Aluminum chloride Anmol Colour Chem Chattral, Gujrat
25 Xylene Kempar Energy / Sks Glochem (Mumbai)
26 Butyl Alcohol Antares Chem P. Ltd. Ghatkopar
27 Solvents CHEMIEORGANIC CHEMICALS
28 Surfactants Local Supplier
29 Ice Local Supplier
50
ANNEXURE III
Proposed Effluent treatment Plant block flow diagram
51

Pre Feasibility Analysis

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Prefeasibility Report Shree Pushkar Chemicals and Fertilizers limited

Shree Pushkar Chemicals & Fertilizers limited

1 EXECUTIVE SUMMARY ............................................................................................................................. 4

6.8 INDUSTRIAL WASTE MANAGEMENT ................................................................................................................ 26

SPCFL is Leading Manufacturers of Dyestuffs, Dye Intermediates, fertilizers,Sulphur

SPFCL wishes to establish manufacturing facility of Synthetic Organic Chemicals at

Table 2.1.1Brief Project summary

3 Location Plot No B-29, Additional Lote

2 INT RODUCT IO N OF TH E PROJ ECT

2.1 Identification of the Project and Project Proponent

1. Unit I Chemical Division: at Plot Nos. B-102-103 at MIDC Lote Parshuram,

2. Unit II Fertilizer Division: at Plot Nos. D-25 at MIDC Lote Parshuram,

4. Unit IV SOP Division: at plot No B-18 at MIDC Lote Parshuram, manufacturing

2.2 Brief Description of nature of the Project

Sr. Item Capacity

(a) Scope for increase in penetration of dyes in India,

Indian dye manufacturers are becoming more competitive in global markets:

2.4 Demand Supply gap

2.5 Imports vs indigenous production

2.6 Export Possibility

2.7 Domestic / Export market

2.8 Employment Generation (Direct and indirect) due to the project

The positives impact includes enhanced direct employment for technical/

3 PROJ ECT DESC RIPT ION

3.1 Type of Project

The project is for manufacture of Dyes, Pigments, and intermediates as follows,

Sr. Item Capacity

Note : SPCFL proposed to undertake establishment of manufacturing of inorganic Products

There is no interlinked and interdependent project.

Details of Nearest Infrastructure Facilities

App. Distance of Project

3.3 Details of Alternative sites

Additional MIDC Lote Parshuram has proximity to 3 sea ports as under:

1. JSW Port, Jaigadh, Ratnagiri. 120 Kms

3.4 Size or magnitude of operation

Note : SPCFL proposed to undertake establishment of manufacturing of inorganic Products sulphuric

3.5 Project description with Project details

Please refer Annexure I for process block diagram and description.

3.6 Raw material required

Source for Raw Material Procurement:

List of Raw Material required (Major)

No Particular Physical state Storage Stored in

3.7 Resource optimization

SPCFL desirous to establish the manufacturing capacity of products. The resource

3.8 Water, Energy / Power availability and source

The source of water shall be from water works of MIDC.

Water requirement for proposed establishment is tabulated as below:

No Purpose Total, cmd

It is proposed to install 1 No of boilers of 6 TPH steam capacity each, and 1 Thermic

Coal is proposed to be used as fuel its requirement for above.

The estimated fuel requirement for above shall be as follows:

No Capacity Fuel requirement Source of fuel supply

Following no of stacks are expected at site

No Stack for No of stacks Expected Pollutants

For emergency power requirement, it is proposed to install 1 DG set of 500 KW

No Capacity Nos Fuel requirement Source of fuel supply

3.9 Waste generation, Management and disposal

Proposed waste water generation, treatment and disposal shall be as follows,

No Description Quantity Disposal

shall be used for onsite

The quantification of non-hazardous and hazardous waste estimated to be generated

2) Non Hazardous waste

No Waste Type Quantity (*) Disposal

3.10 Manpower Requirement