M/s.

Bhavisha Industries, Vapi

DPR for proposed manufacturing of Synthetic Organic Chemicals

DETAILED PROJECT REPORT

HIGHLIGHT OF PROJECT

The proposed project is for manufacturing of synthetic organic chemicals which is roofed under Category – 5
(f) “B” and excluding public hearing process because the proposed project is to be developed in notified
industrial area, GIDC-Vapi of Gujarat, as per new EIA notification vide gazette no. S.O. 1533 dated 14 th
September 2006 and its amendments till date. Furthermore, the project is covered in category B, but its falls
under critically polluted area as per revised CEPI, hence requires to apply at central level.
The details of the proposed project are summarized as “Highlight of Project” within the subsequent table.
Table 1: Highlight of Project
Sr. No. Particulars DETAILS
1. Company Type & Proprietorship Company
Registered Address C-5/101/4, Near GIDC office, N.H. no.8, GIDC, Vapi-
396195, Gujarat, India.
Tel : 0260-2431587
Fax : 0260-2430487
E-mail : [email protected]
2. Name and Location of project M/s. Bhavisha Industries
Plot No. 1705, Phase - III, G.I.D.C., Vapi - 396 195,
Gujarat, India.
3. Geographical position (Coordinates) Lat: 20°22'16.54"N, Long: 72°56'45.29"E
4. Name of Applicant- Mr. Kishor S. Gupte
(b) Address: (i) Postal Office address: C-5/101/4, Near GIDC office, N.H. no.8,
GIDC, Vapi-396195, Gujarat, India.
(ii) E-mail [email protected]
[email protected]
(c) Phone (i) Land line 0260-2431587
(ii) Mobile 9825142833, 9925100331
(iii) Fax: 0260-2430487
5. Year of Commissioning 2020
6. Nature of project New project Manufacturing Synthetic Organic
Chemicals.
7. Land Type of Project Site Notified Industrial Area (GIDC, Vapi)
8. Is land procured or to be New Plot is procured within Notified Industrial Area,
procured for new project or GIDC Vapi, Gujarat.
For Expansion?
9. Screening category (as per SO 5(f) – “Synthetics Organic Chemicals”
1533 as timely amended) Category: “B”.
10. Total area 6213.00 m2
11. Land for Green belt 1202.00 m2greenbelt will be provided within acquired
land and additional greenbelt (approx. 1300.00 Sq.m.
area) will be developed in outside through GPCB
approved greenbelt developer.

12. Products with capacity EC Product:

1. Dispersing agent, leather chemicals and

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Sr. No. Particulars DETAILS

construction chemicals – 10100.00 MT/Month.
Non EC Product:
2. Admixture for concrete & dyes industries –
3000.00 MT/Month.
13. Cost of project Rs. 1232.44 Lakhs
14. Capital and recurring Cost Capital cost for EMP: Rs. 61.00 Lacs and
earmarked for environmental Recurring cost for EPM+CER: Rs. 32.00 Lacs /Annum
protection measures:
15. Total Fresh Water requirement, 210.50 KL/Day.
sources Source: Water supply will be met from GIDC water
supply dept.
16. Total Power requirement and 600 KVA
source Source: DGVCL
17. D.G.Set (Standby power source) D.G. Set 250 KVA x1 no, 500 KVA x1 no
Fuel requirement Diesel: 140.00 Lit/ Hr (250 KVA- 50.00 lit/hr, 500 KVA-
90.00 lit/hr)
18. Steam Requirement 4.00 TPH
Sources: In-house boilers.
19. Steam Boiler Steam boiler 2.00 TPH x 3 Nos
Fuel Requirement Boiler I – NG@ 120.00 SCM/Hr,
Boiler II & III-NG@ 120.00 SCM/Hr. (one boiler will be
on standby)
20. Thermo Pack Capacity: 10.00 lakhs Kcal/Hr
Fuel Requirement Natural Gas: 100.00 SCM /Hr
21. Hot Air Generator Capacity: 25.00 lakh k. cal/hr
Fuel requirement NG: 270.00 SCM/Hr
22. Man Power Total: 100 nos.
23. Air pollution Control Measures • Adequate stack height connected to utilities
• Two stage Bag filters attached to spray dryers (3 nos.)
• Two stage scrubber attached to sulphonation reactor
24. Waste water Generation Domestic Total: 2.00 KL/Day
Industrial Total: 5.60 KL/Day
25. Solid/Hazardous Wastes • ETP Waste (35.3): 15.00 TPA
• Used Oil (5.1): 0.095 KL/Annum
• Discarded containers/barrels/liners (33.1): 125.0 TPA
• Waste from scrubber(37.1): 290.00TPA
• Used Filter Cloths (33.2):1.00 TPA
• Process Waste (26.1): 400.00 TPA
26. Status of the project New Project- will be established after obtaining
required permissions.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
PROPOSED PRODUCTS DETAILS
The details of the products along with production capacity are presented below in tabular form.

Table 2: List of Products with Capacity

Quantity
Sr.No Name of the Products CAS No. End-use of the products
(MT/Month)
Non-EC Product
Admixture for Concrete and Dyes
1. NA 3000.00 Construction chemicals
Industries
Products requiring Prior EC
2. Dispersing Agents Used to manufacture
Naphthalene Based 9084-06-4 Disperse dyes, construction
Phenol Based 102980-04-1 chemicals, Leather
Sulphonated Alkyl naphthalene chemicals, etc.
6000.00 Used as dispersing agent in
Formaldehyde Condensate 577773-56-9
Sodium Salt Agro formulation and Dyes
Dibutyl Naphthalene sulphonated industry.
25417-70-3
sodium salt
3. Leather Chemicals In Leather processing
Syntans (Powder) NA 500.00 industries.
Fat Liquor (Liquid) NA
PEG Based Polycarboxylate Ether Construction chemicals
4. 70789-60-6 3000.00
(Liquid & Powder)
Biaxial oriented polypropylene For manufacturing BOPP
5. 9003-07-0 300.00
(BOPP) Self Adhesive self-adhesive Taps
Use in Construction
6. Waterproofing polymer 25852-37-3 300.00
chemicals
Total 13100.00 --

JUSTIFICATION& NEED OF PROJECT

Dyestuff industry is one many of the main chemical industries in India. It is correspondingly the second
maximum export phase in chemical business. The Indian dyestuff enterprise is formed of approximately
1000 of small-scale units and 50 large organized units, who produce around 1,30,000 tonnes of dyestuff.
Maharashtra and Gujarat account for 90% of dyestuff production in India because of the accessibility of raw
materials and supremacy of fabric industry in these areas. The key customers of dyes in India are textiles,
paper, plastics, printing ink and foodstuffs. The textiles department consumes around eighty percent of the
entire production due to large call for polyester and cotton, globally.
The requirement for leather chemicals in India is estimated to grow from 406 KTPA in 2018 to 965 KTPA by
2030, demonstrating a CAGR of 7.5% throughout 2019-2030. Rising use of leather chemicals in tanneries,
additionally to expected growth in the demand for specialty leather chemicals in wet-end and finishing
stages of leather goods production, is anticipated to lead the Indian leather chemicals market during
forecast period. Growing demand for leather products in the fashion industry, growing footwear industry
and rising leather exports are numbers of the other factors that may drive the market.
The proposed new project will provide a possible growth opportunity for the company. We have recognised
the demand for the proposed products and they can be developed in-house and produced commercially for

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
domestic market along with increased thrust on export markets. The export of such products also will
increase the foreign revenue. The company’s products are well established and satisfactory in both domestic
and international markets.

Keeping in sight on all above points, company have determined market potential for the particular products
& their demand and with valuable R&D efforts Company is confident that it can develop the merchandise in
very economical route of production and supply at very reasonable price and will benefit the buyer
company. Company has also noticed that the products will be able to substitute the demand of the imported
& costly products which successfully provide a growth potential opportunity to the company& buyers.
Besides, there will be excellent opportunity of employment generation directly and indirectly due to
proposed new project.

PROJECT SITE

The project site is located at plot no. 1705, Phase III, Vapi GIDC notified Industrial Estate. The subject site
consists of a plot of land 6213.00 sq.m. Map showing the project boundary on Google image is shown as
Figure 2-.1 and latitude and longitude of the site is given in Table 2.1. Similarly, the site layout map is
presented as Figure 2.2 and area breakup at site is given in Table 2.3. Nearest National Highway 8- 2.42 Km
W, nearest state highway - Silvassa-Vapi Road: 2.49 Km SW and nearest railway station-Vapi, 3.90 Km NW
away from project site. Via the modernized highway, Mumbai is about 139.85 km to the south and the city of
Surat is about 86.84 km to the north.
Fig.1: Location map

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Fig 2: Map of Project Site (in GIDC etc. showing minimal area of representing land type)

RESOURCE REQUIREMENT

The proposed project is to be developed within the existing developed industrial plot located in notified
industrial estate of GIDC Vapi. The site is already developed with constructed civil structures. Therefore, no
construction works for the proposed project.
The details of the resource requirements of proposed project are presented below in subsequent paragraphs
under respective headings.
LAND & BUILDINGS
The plot which is admeasuring 6213.00 Sq.m. This land is sufficient for proposed project. In 1202.00 Sq. m.
area greenbelt will be developed. The details of the area statement for proposed unit are mentioned
beneath.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Table 3: Area Statement for the Plant Premises
Available area Required area
Area Statement
(Sq. m.) (Sq. m.)
Open & Ground Floor Area (Constructed)
Production Plant/Unit 1130.00 709.00
Raw Material Storage Area 459.00 176.49
Tank Area 463.00 300.00
Finished product Area 459.00 269.36
Utility Area 100.00 100.00
DG SET 100.00 50.00
Parking Area 50.00 50.00
Cooling Area 50.00 50.00
Waste storage Area 100.00 100.00
ETP 100.00 100.00
Offices & Other 26.00 26.00
O.H.C Area 15.00 15.00
Greenbelt Area 1202.00 2502.00 (40% greenbelt)
Other Available 0.00 --
Open Land Area 1959.00 --
Total Area 6213.00 --
Note: 1202 sq. m. greenbelt will be provided within acquired land and additional greenbelt (approx. 1300
Sq.m. area) will be developed in outside through approved greenbelt developer.
1st Floor Area (Constructed)
Production Plant/Unit 1130.00 --
Raw Material Storage Area 457.64 --
Finished Good Storage Area 459.00 --
Utility Area 100.00 --
Offices & Other 52.00 --
Other Available 100.00 --
Total Area 2298.64
2nd Floor Area (Constructed)
Production Plant/Unit 1130.00 --
Raw Material Storage Area 457.64 --
Finished Good Storage Area 459.00 --
Utility Area 50.00 --
Offices & Other 100.00 --
Other Available 100.00 --
Total Area 2296.64
3rd Floor Area (Constructed)
Production Plant/Unit 918.00 --
Raw Material Storage Area 0.00 --
Finished Good Storage Area 0.00 --
Utility Area 50.00 --
Offices & Other 100.00 --
Other Available 100.00 --
Total Area 1168.00
4th Floor Area (Constructed)
Production Plant/Unit 918.00 --
Raw Material Storage Area 0.00 --

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Finished Good Storage Area 0.00 --

Utility Area 50.00 --
Offices & Other 0.00 --
Other Available 0.00 --
Total Area 968.00

Justification for Adequacy of provided production, raw material and product storage area are presented
below:

Raw material Storage Area Requirement, m2

Total area available for storage: 27.00 m (length of the floor) *17.00 m (width of the floor) = 459.00 sq.
m.
Required storage area: 176.49 sq. m. for 477 nos.-drums (286000 kgs), Triple rack with safety
space
Area of a Drum: 0.37 sq. m.
Total Drums to be Stored: The proposed project requires 476.49 sq. m. area for storage of raw
material and 922.00 sq. m. area is already available for raw material
storage area hence it is found that the available area is more than the
required area.
Product Storage Area Requirement, m2
Total area available for storage: 27.00 m (length of the floor) *17.00 m (width of the floor) = 459 sq. m.
Area required for project: 269.36 sq. m. for 728 nos.-drums (436667 kgs), triple rack with safety
space
Adequacy Remark: The proposed project requires 269.36 sq. m. area for storage of product
and 459.00 sq. m. area is already available for product storage area
hence it is found that the available area is more than the required area.
Production Area Requirement of EC product, m2
Total area available for 33.53 m (length of the floor) *27.43 m (width of the floor) = 920.00 sq.
production: m. Production area for inorganic products = 200.00 sq.m.
Total Area= 1130.00 sq. m.
Area required for project: 252 sq. M for Reactor & 274 sq. M for other Production activities = Total
526 sq. M
Production area for inorganic products = 200.00 sq.m.
Adequacy Remark: The proposed project requires 709.00 sq. m. area for production and
1130.00 sq. m. area is already available; hence it is found that the
available area is more than the required area.

Site plan of Ground Floor is shown as fig 2.3 as Site layout plan and First floor to fourth floor plan is give in
annexure- IX (G) Site Layout plan with all floor.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Fig. 3: Plant Layout

WATER
The unit will need 210.50 KLD freshwater, which will be met through Water supply pipeline of GIDC Vapi. The
industrial operation of the unit will require 202.00 KLD, whereas the domestic activities will require 4.00 KLD.
The details with required breakup for water requirement of proposed unit are presented in following table.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Table 4: Breakup of fresh Water Requirement
Category Quantity (in KLD) Remarks
(A) Domestic 4.00 Fresh water
(B) Gardening 4.50 2.50 KLD Fresh water & 2 KLD Reuse from
STP.
(C) Industrial
Process 190.00 Fresh water
Washing 2.00 Fresh water
Boiler & cooling 9.00 Fresh water
Scrubbing 1.00 Fresh water
Industrial Total 202.00 --
Total (A + B + C) 210.50 208.50 KLD Fresh water & 2.00 KLD Reuse.

ENERGY, FUEL & POWER

The details of Fuel & Power requirement is presented in tabular form in subsequent table.
Table 5: Energy, Fuel & Power Requirement
Components Proposed Sources
Power 600 KVA DGVCL
Heat Requirement 29.00 Lakh K.cal/Hr. HAG & Thermo pack
Steam Requirement 4000.00 Kgs/Hr. 2Nos of In-house boilers
Power during power failure 700 KVA 2 Nos of DG Sets
HSD 140.00 Ltr/Hr. Local Pump
Natural Gas 610.00 SCM/Hr. Local dealer

PLANT & MACHINERY

The company will setup its manufacturing unit having following main & foremost machineries & equipment.
The details of the proposed machineries & equipment are presented underneath in tabular form.

Table 6: Major Machineries & Equipment

Sr. Equipment/ Utility Name (Quantity) MOC Capacity

No.
STORAGE
1. Sulphuric Acid MS (1 no.) 25 KL x 1 No.
2. Oleum 23% MS (2 no.) 15 KL x 2 Nos.
3. Formaldehyde PP (2 no.) 25 KL x 2 Nos.
4. Caustic Soda Lye MS (2 no.) 40 KL x 2 Nos.
5. Phenol MS Jacketed (1 no.) 30 KL x 1 No.
6. Naphthalene based dispersing agent liquid MS (9 no.) 40 KL x 4 Nos
60 KL x 4 Nos
30 KL x 1 No
7. Phenol based Disp. Agent liquid MS (3 no.) 30 KL x 3 Nos.
8. PEG Based Polycarboxylate Ether liquid PP (6 no.) 50 KL x 6 Nos.

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DPR for proposed manufacturing of Synthetic Organic Chemicals

PROCESS PLANT
9. Sulphonator MS (2 no.) 8 KLx 2 Nos.
10. Lead Bonded Reactor MS/LB (4 no.) 16 KL x 4 Nos.
11. Glass Lined MS/GL (3 no.) 16 KL x 3 Nos.
12.5 KL x 1 No.
12. PP Neutralizer PP (2 no.) 25 KL x 2 Nos.
13. MS Mixer MS (7 no.) 25 KL x 3 Nos.
15 KL x 3 Nos.
10 KL x 1 Nos.
5 KL x 1 Nos.
14. SS Mixer SS (4 Nos) 30 KL x 1 Nos.
10 KL x 1 Nos.
5 KL x 2 Nos.
M.S (3 Nos) 20 KL x 1 Nos.
15 KL x 1 Nos.
5 KL x 1 Nos.
15. PP Vessel PP (5 no.) 20 KL x 2 Nos.
30 KL x 3 Nos.
16. SS Reactor SS -316 (10 no.) 10 KL x 4 Nos.
8 KL x 2 Nos.
5 KL x 2 Nos.
2.5 KL * 2 Nos.
17. Spray Dryer SS-316 (3 Nos.) 1000 kg/Hr x 2
500 kg/Hr. X 1
18. Ribbon Blender SS (3 no.) 5 KL x 1
3 KL x 1
1 KL x 1
UTILITY
19. Thermopack - 10 lakh K.cal x 1
20. Boiler - 2000 Kg/H X 3
21. Air Compressor - 7.5 HP x 2
22. D.G Set - 250 KVA x 1, 500 KVA x 1
23. Chilling Plant - 120 TR x 2
24. Hot Air Generator - 25 lakh x 1

HUMAN RESOURCE
The company will deliver employment to 100.00 people in different categories for operation of proposed
project. The details of the projected employment structure are presented below in tabular form.
Table 7: Human Resource Requirement
Sr. Employment Nos.,
Particular
No. Total
1 Managerial 10.00
2 Skilled 55.00
3 Semi-Skilled 20.00
4 Unskilled 15.00
TOTAL 100.00

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
CAPITAL
The capital of proposed project has been assessed & budgeted with costs of Rs. 1232.44 lakhs. The proposed
capital includes Rs. 61.00 Lakhs for environmental protection measures. The details of proposed capital costs
approximation including land, buildings, plant machineries & equipment, environmental protection
measures etc. is presented below in tabulated form.
Table 8: Capital Cost
Proposed Cost
Sr. No. Purpose
(Rs. In Lakhs)
1. Land 361.44
2. Building and Civil Works --
3. Plant, Machinery and other fittings 810.00
4. Environmental protection, Safety & Emergency measures 61.00
TOTAL: 1232.44

DESCRIPTION OF PROCESS & ALLIED DETAILS

The details of Raw Materials & production process of all products are described in subsequent paragraphs
under respective headings.
RAW MATERIALS
All raw materials required for manufacturing of the above said products are easily available indigenously in
local market, which will be transported through road. The details of the raw material requirement are
presented below.
Table- 9: List of Raw Material and its Consumption per Month
Name of the Raw CAS / CI no. of Quantity
Sr. no. Name of the Products
Materials raw materials. MT/Month
1. Admixture for concrete and Dispersing agent/PCE - 2625.00
dyes industries Retarder - 180.00
Foaming agent - 15.00
2. Dispersing Agents
Naphthalene Based Dispersing Napthalene 91-20-3 1053.23
Agent (Liquid & Powder) Oleum (23%) 8014-95-7 432.30
Sulphuric Acid (98%) 7664-93-9 620.93
Formaldehyde 50-00-0 554.34
Caustic Lye 1310-73-2 960.22
Hydrated Lime 1305-62-0 62.00
Soda Ash 497-19-8 15.49
Phenol Based Dispersing Agent Phenol 10895-2 359.79
(Liquid & Powder) Formaldehyde 50-00-0 435.93
Sodium Sulphite 7757-83-7 151.15
Caustic Soda Lye 1310-73-2 235.23
SulphuricAcid(98%) 7664-93-9 103.84
EDTA 6381-92-6 5.76
Sulphonated Alkylnapthalene Alkyl Napthalene 68425-94-5 135.00

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Name of the Raw CAS / CI no. of Quantity

Sr. no. Name of the Products
Materials raw materials. MT/Month
Formaldehyde Condensate, Sulphuric Acid 7664-93-9 144.00
Sodium Salt Formaldehyde 50-00-0 66.00
Caustic Lye 1310-73-2 132.80
Di butyl Naphthalene Naphthalene 91-20-3 100.00
Sulphonated, sodium salt Sulphuric Acid 7664-93-9 150.00
N-Butanol 71-36-3 120.00
Caustic Lye (48 %) 1310-73-2 75.00
3. Leather Chemicals
Leather Chemicals (Powder) PAK liquid 2759-56-0 156.76
Syntan Adipic Acid 124-04-9 5.70
Fumeric Acid 110-17-8 2.85
Pthalic Anhydride 85-44-9 2.85
EDTA 6381-92-6 0.705
Sodium 8061-51-6
28.50
LignoSulphonate
Glauber’s Salt 7757-82-6 172.44
HS Liquid 9084-06-4 17.10
Leather Chemicals (Liquid) Fat Wax Sulpho Chloride 8002-74-2 61.52
Liquor CPW 6474243-4 30.76
SPN 26571-11-9 9.22
Caustic Soda 1310-73-2 10.76
Hypo chlorite 7681-52-9 1.94
Acetic Acid 64-19-7 3.46
Sodium Sulphate 7757-83-7 24.98
4. PEG Based Polycarboxylate Acrylic Acid 79-10-7 96.00
Ether Liquid &Powder PEG 25322-68-3 1800.00
Meth acrylic Acid 79-41-4 44.00
Caustic Lye 1310-73-2 32.80
Soda Ash 497-19-8 1.60
Potassium per sulphate 7727-21-1 9.60
Sulphuric Acid 7664-93-9 16.00
5. BOPP (Biaxial oriented Dainol 25 25155-30-0 1.25
polypropylene) Self Adhesive Butyl acrylate 141-32-2 131.80
Meth acrylic acid 79-41-4 2.75
Noigen DKX-405 67762-27-0 0.10
Soda ash 497-19-8 0.10
Potassium per sulphate 7727-21-1 0.60
Ammonia 7664-41-7 1.10
TBHP(Tent Butyl Hydro 75-91-2
0.05
Peroxide)
Safolite 149-44-0 0.10
Nonyl phenol 9.5 mole 9016-45-9 0.55
Formaldehyde 50-00-0 0.25
6 Waterproofing polymer Dainol 25 2515530-0 1.87
Butyl acrylate 141-32-2 102.50
Meth acrylic acid 79-41-4 2.62
Noigen DKX-405 67762-27-0 2.00
Soda ash 497-19-8 0.25

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DPR for proposed manufacturing of Synthetic Organic Chemicals

Name of the Raw CAS / CI no. of Quantity

Sr. no. Name of the Products
Materials raw materials. MT/Month
Potassium per sulphate 7727-21-1 1.00
Ammonia 7664-41-7 3.00
TBHP 75-91-2 0.08
Safolite 149-44-0 0.13
Styrene 100-42-5 0.75
Formaldehyde 50-00-0 1.25

Table 10: Raw Material Requirement and their Source, Mode of transport& Storage
Distance of
Storage
Sr. Name of Raw Physical Mode of Type of Source
Cap. In Storage
No. Material State Transport Linkage from
MT
Project Site
1. Dispersing agent/PCE 200.00 Liquid - Drums Captive -
2. Retarder 20.00 Liquid Road Drums indigenous 125 km S
3. Foaming agent 2.00 Liquid Road Drums indigenous 125 km S
4. Naphthalene based Liquid Road MS storage tank Captive
Dispersing agent 400.00 -
(liquid)
5. Naphthalene 200.00 Solid Road Warehouse indigenous 125 km S
6. Oleum (23%) Liquid Road MS storage tank indigenous
30.00 125 km S
with scrubber
7. Sulphuric Acid (98%) 20.00 Liquid Road MS storage tank indigenous 125 km S
8. Formaldehyde 40.00 Liquid Road PP storage tank indigenous 125 km S
9. Caustic lye 50.00 Liquid Road MS Storage tank indigenous 125 km S
10. Phenol Liquid Road MS storage with indigenous
30.00 125 km S
jacketed
11. Sodium sulphite 10.00 Solid Road Warehouse indigenous 125 km S
12. EDTA 1.00 Solid Road warehouse indigenous 125 km S
13. Hydrated lime 15.00 Solid Road Ware house indigenous 125 km S
14. Soda ash 5.00 Solid Road warehouse indigenous 125 km S
15. Adipic Acid 2.00 Solid Road warehouse indigenous 125 km S
16. Fumeric acid 1.00 Solid Road warehouse indigenous 125 km S
17. Phthalic anhydride 1.00 Solid Road warehouse indigenous 125 km S
18. Sodium Solid Road Warehouse indigenous
20.00 125 km S
lignosulphonate
19. Glaubber’s salt 10.00 Solid Road Warehouse indigenous 125 km S
20. Wax Sulpho Chloride Liquid Road Drum storage in indigenous
10.00 125 km S
warehouse
21. Chlorinated Paraffin Liquid Road Drum storage indigenous
10.00 125 km S
Wax
22. Acetic acid Liquid Road Drum storage in indigenous
5.00 125 km S
ware house
23. Butyl acrylate 10.00 Liquid Road SS tank indigenous 125 km S
24. Dainol 25 2.00 Liquid Road Drum storage in indigenous 125 km S

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DPR for proposed manufacturing of Synthetic Organic Chemicals

Distance of
Storage
Sr. Name of Raw Physical Mode of Type of Source
Cap. In Storage
No. Material State Transport Linkage from
MT
Project Site
ware house
25. HS Liquid Liquid Road Drum storage in indigenous
10.00 125 km S
ware house
26. Acrylic Acid 20.00 Liquid Road SS tank indigenous 125 km S
27. Alkyl Naphthalene Liquid Road Drum storage in indigenous
10.00 125 km S
ware house
28. Ammonia Liquid Road Drum storage in indigenous
5.00 125 km S
ware house
29. Hypo chlorite Liquid Road Drum storage in indigenous
1.00 125 km S
ware house
30. Meth acrylic Acid Liquid Road Drum storage in indigenous
2.00 125 km S
ware house
31. N-Butanol 10.00 Liquid Road SS tank indigenous 125 km S
32. Noigen DKX-405 Liquid Road Drum storage in indigenous
1.00 125 km S
ware house
33. Nonyl phenol Liquid Road Drum storage in indigenous
1.00 125 km S
ware house
34. PAK liquid Liquid Road Drum storage in indigenous
5.00 125 km S
ware house
35. PEG 500.00 solid Road Ware house indigenous 0.5 Km S
36. Potassium per solid Road Ware house indigenous
1.00 125 km S
sulphate
37. Safolite 1.00 Solid Road Ware house indigenous 125 km S
38. SPN (sulphonated Liquid Road Drum storage in indigenous
1.00 125 km S
nonylphenol) ware house
39. Styrene 10.00 Liquid Road SS tank indigenous 125 km S
40. TBHP Liquid Road Drum storage in indigenous
1.00 125 km S
ware house

The products of proposed project are described in earlier section with required raw materials. The company
shall use the latest available process technology for the production. This section includes the manufacturing
process of the product, chemical reactions, and mass balance of each product.
1. PRODUCT : ADMIXTURE FOR CONCRETE AND DYES INDUSTRIES:
Capacity: 3000.00 MT/Month
Manufacturing Process:
Dispersing agent/PCE, Retarder, Foaming agent and water are mixed in a mixer as per the required quantity.
After proper mixing, materials packed for dispatch.
During the manufacturing product water is consumed for manufacturing product and process water is
consumed along with product and there is no process waste water generation. There is no hazardous waste
generation. Also there is no flue gas and process gas emission generated.
During the manufacturing process there is no any chemical reaction. There is no any flue gas stack and
process stack installed for product manufactured.
Process water is consumed along with product and there is no any process waste generation.

Detailed of Project
2-14
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

Mass Balance:
Sr.No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK
1. Dispersing 2625.00 Admixture For Concrete 3000.00 Product
agent/PCE And Dyes Industries
2. Retarder 180.00
3. Foaming agent 15.00
4. water 180.00
Total 3000.00 3000.00

2. PRODUCT : DISPERSING AGENT

Capacity: 6000.00 MT/Month
a) Naphthalene Based Dispersing Agent (Liquid& Powder) - Capacity: 4000.00 MT/Month
Manufacturing process:
Naphthalene is charged in a reactor and heated up to 90 °C. 23 % Oleum and/or Sulphuric Acid is then
added. Raise the temperature till Sulphonation reaction is completed. After testing for the completion of
reaction, add 37 % Formaldehyde and water is added and the mass is stirred at 110 ºC for 10 hours. Then
neutralized with Caustic Lye and water is added. Finally the liquid is packed in a drum as a final product for
liquid one. For Powder product the mass is neutralized with Caustic Lye and Hydrated Lime to bring the pH
to about 7. The mass is then filtered and washed. The wet cake is collected and stored as a solid waste. The
wash water is recycled back in the neutralization process. The filtrate is further reacted with Soda Ash. Again
the wet cake is collected and stored as solid waste. Finally the filtrate is taken to the Spray Drier for drying.
The dry powder as a result is packed in HDPE bags for dispatch.

Detailed of Project
2-15
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

Oleum (23%): 3675 kg Alkali

SULPHONATION Vapour loss: 50 kg
H2SO4 (98%): 1325 kg Scrubber
10000 kg
Naphthalene: 5000 kg

CONDENSATION Chilled Brine

Water: 2500 kg
15450 kg Reflux Condenser
Formaldehyde: 3000 kg

Water: 5800 kg
Caustic Lye: 4500 kg NEUTRALIZATION
Soda Ash: 170 kg 26600 kg
Hydrated Lime: 680 kg

FILTRATION Wet Cake Waste: 100 kg

(26600 kg) (80% solid-20% Moisture)

LIQUID PRODUCT:
(26500 kg)

Drying
(26500) 15428 kg Drying loss
(

POWDER PRODUCT
(11172 kgs)

Chemical reaction:
• SULPHONATION
SO3H
H2SO4
+ Oleum + H2O

Napthalene 2 Sulphonic 18
Napthalene: 128
Acid: 208

Detailed of Project
2-16
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

• CONDENSATION
SO3H HO 3S CH2 SO3H
2 + HCHO + H2O

428 18
Napthalene 2 Sulphonic 30
Acid: 416
• NEUTRALIZATION
HO 3S NaO 3S CH2 SO3Na
CH2 SO3H
2NaOH/Ca(OH) 2
+ 2 H 2O
80
428 472 36
Na Salt of B-Napthalene
Sulphuric Acid Condensate

Mass Balance:
Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK
1. Oleum (23%) 3675.00 Dispersing Agent Based On 26500.00 Product*
Naphthalene (Liquid)
2. Sulphuric Acid (98%) 1325.00 Vapour loss 50.00
3. Naphthalene 5000.00 Process waste 100.00
4. Water 8300.00
5. Formaldehyde 3000.00
6. Caustic Lye 4500.00
7. Soda Ash 170.00
8. Hydrated Lime 680.00
Total 26650.00 26650.00
Note: * In case of solid powder product 15428 kg will be drying loss & 11172 kg will be solid product.

b) Phenol Based Dispersing Agent (Liquid) - Capacity: 1350.00 MT/Month

Manufacturing process:
Phenol is first reacted with Sulphuric Acid in a Sulphonator Reactor at 90 °C for 10 hours. This is
condensed with Formaldehyde and Sodium Sulphite at 110 °C and maintained for 10 hours. After the
reaction is over, the liquid product is neutralized to pH 7 with Caustic Soda lye. The liquid mass is then
spray dried in a Spray Drier. Finally, the dry powder is packed in bags as a final product.

Detailed of Project
2-17
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

Sulphuric Acid (98%): 1800 kg SULPHONATOR

Phenol: 2300 kg 4100 kg

Water: 4000 kg CONDENSATION Brine Chilled Reflux

Formaldehyde: 2800 kg 10900 kg Condenser w

EDTA: 100 kg NEUTRALIZATION

Caustic Soda Lye: 2000 kg 13000 kg

Liquid product SPRAY DRYING Drying loss: 7561 kg

13000 kg 13000 kg

PRODUCT: 5439 kg

Chemical reaction:

• SULPHONATION

OH OH

+ H2SO4 + H2O
SO3H

Phenol: 94 98 174 18

Detailed of Project
2-18
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

• CONDENSATION
OH

OH

SO 3H
2 + HCHO CH2 + H2O
30
SO3H
174
SO3H
OH
• NEUTRALIZATION

HO CH2 OH + 2 NaOH

SO3H
SO3H

HO CH2 OH + 2H 2O

SO 3Na
SO3Na

Mass Balance:
Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK
1. Sulphuric Acid (98%) 1800.00 Dispersing Agent Based On 13000.00 Product
Phenol (Liquid)
2. Phenol 2300.00
3. Water 4000.00
4. Formaldehyde 2800.00
5. EDTA 100.00
6. Caustic Soda Lye 2000.00
Total 13000.00 13000.00
Note: * In case of solid powder product 7561kg will be drying loss & 5439 kg will be solid product.

c) Sulphonated alkyl naphthalene formaldehyde condensate sodium salt- Capacity: 300.00 MT/Month
Manufacturing process:

• After charge raw materials, slowly heat to 120oC temperature.

• After that maintain 4 hours at 120-125oC to get complete Sulphonation.
• First charge water in lead bonding reactor, than slowly charge sulphonated mass under cooling.
• Temperature should be below 80oC during drowning of acidic mass.
• After that charge formaldehyde in 3 hours at 70-80o.
• After addition of formaldehyde, slowly heat to 100-105o& maintain 8 hours at same temperature to get
complete condensation.
• After condensation charge water & slowly add caustic lye under fast cooling.

Detailed of Project
2-19
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

• Temperature should not go above 80o during neutralization.

• After complete neutralization (PH 7.0 – 7.5), mix further 1 hour to get homogeneous solution. Sample
send to QC lab for quality evaluation.
• If sample okay, then material hand over to spray dryer unit.
• Run SANFC liquid 50% into spray dryer through feed pump & keep inlet/outlet temperature.
• Power sample send to QC lab for quality evaluation. If sample okay, then pack in 25 kg bags.
Process flow diagram:

Water: 2042 kg
Sulphonation
Formaldehyde: 1100 Kg
+
Alkyl Naphthalene: 2250
kg Condensation
Caustic Lye( 48%):2208 kg
Sulphuric Acid: 2400 Kg

SANFC: 10000 Kg (50%)

Spray Drying: 10000 kg Vapour loss: 5000 kg

SANFC POWDER: 5000 Kg (Powder)

Mass Balance:

Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Alkyl Naphthalene 2250.00 Sulphonated alkyl 5000.00 Product

naphthalene formaldehyde
condensate sodium salt
2. Suphuric Acid 2400.00 Vapour loss 5000.00 Due to Spray
drying
3. Formaldehyde 1100.00
4. Caustic Lye (48 %) 2208.00
5. Water 2042.00
Total 10000.00 Total 10000.00

Detailed of Project
2-20
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Chemical reaction:

H
R

Sulphuric Acid SO3M

Alkyl Napthalene
Alkyl Napthalene Sulphuric Acid

SO3X R SO3X
R

CH2
H3C
n

Final Product

d) Di butyl Naphthalene Sulphonated, sodium salt - Capacity: 350.00 MT/Month

Manufacturing process:
• After charge raw materials, cool to 12-16°C temperature.
• After that maintain 20 hours at 12-16oC to get complete sulphonation.
• After sulphonation charge water & slowly add caustic lye under fast cooling.
• Temperature should not go above 90o during neutralization.
• After complete neutralization (PH 7.0 – 7.5), mix further 1 hour to get homogeneous solution. Sample
send to QC lab for quality evaluation.
• If sample okay, then material hand over to spray dryer unit.
• Run DNS (Dibutyl Naphthalene sulphonate) liquid 50% into spray dryer through feed pump & keep
inlet/outlet temperature.
• Power sample send to QC lab for quality evaluation. If sample okay, then pack in 25 kg bags.
Process flow diagram:

Detailed of Project
2-21
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Mass Balance:
Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK
1 Naphthalene 2000.00 Di butyl Naphthalene 7000.00 Product
Sulphonated, sodium salt
2 Suphuric Acid 3000.00 Vapour loss 7000.00 Due to Spray
drying
3 N-Butanol 2400.00
4 Caustic Lye (48 %) 5100.00
5 Water 1500.00
Total 14000.00 Total 14000.00

Chemical reaction:

+ H2SO4 + C4H10O

Napthalene Sulphuric Acid Butanol

C4H9
SO3Na

C4H9

Dibutyl Napthalene Sulphonate, Sodium Salt

3. PRODUCT 3: LEATHER CHEMICALS

Capacity: 500.00 MT/Month
a) Leather Chemicals (Powder) Syntan - Capacity: 300.00 MT/Month
Manufacturing process:
PAK Liquid, Adipic Acid, Fumeric Acid, Phthalic Anhydride, EDTA, Sodium Lingo, Glaubbers Salt and H S
Liquid are mixed in a reactor as per the required quantity. After proper mixing, the liquid mass is taken
into the Spray Dryer. The drier powder is packed in bags for dispatch.

Detailed of Project
2-22
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

PAK Liquid:2750kg EDTA: 12.5 kg

Adipic Acid: 100 kg Sodium Lingo: 500 kg

Reactor
Fumeric Acid: 50 kg Glaubber’s Salt: 3025 kg

Phthalic Anhydride: 50 kg H S Liquid: 300 kg

Dying: 6787.5 kg
Vapor loss: 1525 kg

Product: 5262.5 kg

Chemical reaction: No Chemical reaction only mixing and spray drying process

Mass Balance:
Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. PAK liquid 2750.00 Leather Chemicals (Powder) 5262.50 Product

2. Adipic Acid 100.00 Vapour loss 1525.00
3. Fumeric Acid 50.00
4. Phthalic Anhydride 50.00
5. EDTA 12.50
6. Sodium Lingo 500.00
7. Glauber’s Salt 3025.00
8. H.S. liquid 300.00
Total 6787.50 6787.50

b) Leather Chemicals (Liquid) Fat Liquor

Capacity: 200.00 MT/ Month
Manufacturing process:
Wax Sulpho Chloride, CPW, SPN, Caustic Soda, Sodium Hypochlorite, Acetic Acid, Sodium Sulphate and
water are mixed in a reactor as per the required quantity. The reactor is fitted with a stirrer for proper
mixing. The mass is heated up to 60 – 70 °C. Finally, the mixture is packed into drums as a final product.

Detailed of Project
2-23
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

Wax Sulpho Chloride: 1600 Hypo chlorite: 50 kg

kg
CPW: 800 kg Acetic Acid: 90 kg
Reactor Heat
SPN: 240 kg Sodium Sulphate: 650
kg
Caustic Soda: 280 kg Water: 1490kg

Product: 5200 kg

Chemical reaction: no Chemical reaction only mixing and blending process

Mass Balance:

Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Wax Sulpho Chloride 1600.00 Leather Chemicals 5200.00 Product
(Liquid) Fat Liquor
2. CPW 800.00
3. SPN 240.00
4. Caustic Soda 280.00
5. Hypo chlorite 50.00
6. Acetic Acid 90.00
7. Sodium Sulphate 650.00
8. Water 1490.00
Total 5200.00 5200.00

4. Product 4: PEG BASED POLYCARBOXYLATE ETHER (LIQ. & POWDER)

Capacity: 3000.00 MT/Month

Manufacturing process:

• After charge raw materials, heat the reactor to 70oC & start addition of emulsion & potassium per
sulphate solution.
• Charge both solutions simultaneously in 3 hours at 90oC to 95oC.
• After complete addition, maintain further 1 hour at 90 oC to 95oC.
• After that cool to 50oC& charge caustic soda lye.
• Further mix 20 min. & sample send to QC lab for quality evaluation.
If sample okay, then pack in drums.

Detailed of Project
2-24
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Process flow diagram:

Water: 5000 kg Caustic Lye: 82 kg

Acrylic Acid: 240 kg Soda ash: 4 kg

Emulsion
polymerization
PEG: 4500 kg Potassium per sulphate: 24 kg

Meth Acrylic Acid: 110 kg Sulphuric Acid: 40 kg

Poly Carboxylate Ether:

10000 Kg (Liquid)

Spray Drying: 10000 kg Vapour loss: 5000 kg

Poly Carboxylate Ether: 5000 Kg (Powder)

Sulphuric Acid: 3000 Kg

Chemical reaction:

CH3 CH3
-
H2O2 Vc
H2C CH + H2C CH + H2C C * CH2 CH a CH2 CH
b
CH2 C
c
C O 70 C C O
Rx COOH Rx
O COOH O
CH2 CH2
CH2 CH2
-
H2C Cl H2C CH2
+ -
O H3C N CH3 O Cl +
H3C N CH3
CH2 CH3 CH2
CH3
CH2 CH2
O O
m m
CH2 CH2

HC CH3 HC CH3
O O
n n
H H

Polycarboxylate
ether

Detailed of Project
2-25
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Mass Balance:

Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Acrylic acid 240.00 Poly carboxylate ether 5000.00 Product

2. PEG 4500.00 Vapour Loss 5000.00
3. Meth acrylic acid 110.00
4. Caustic Lye 82.00
5. Soda ash 4.00
Potassium per 24.00
6.
sulphate
7. Sulphuric acid 40.00
8. water 5000.00
Total 10000.00 10000.00

5. PRODUCT 5: BOPP SELF ADHESIVE (Capacity: 300.00 MT/Month)

Manufacturing process:
• After charge raw materials, heat the reactor to 70oC & start addition of emulsion & potassium per
sulphate solution.
• Charge both solution simultaneously in 2 hours at 70 oC to 75oC.
• After complete addition, maintain further 1 hour at 70oC to 75oC.
• After that cool to 50oC& charge ammonia.
• Further mix 20 min. & sample send to QC lab for quality evaluation.
If sample okay, then pack in drums.

Process flow diagram:

Water: 5328 kg Potassium per sulphate: 28.8

kg
Dainol: 60.28 kg
Ammonia: 67.2
kg
Butyl acrylate: 6328.52 Emulsion
kg TBHP: 2.4
Polymerisation Kg
Meth Acrylic Acid: 132 kg
Safolite: 4.8 Kg

Noigen DKX-405: 4.8 kg

Nonyl Phenol 9.5 mole: 26.4 Kg

Soda ash: 4.8 kg

Formaldehyde: 12 Kg

Noigen DKX-405:
4.8 kg

Detailed of Project
2-26
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Chemical reaction:

Mass Balance:

Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Dainol 25 60.28 BOPP Self Adhesive 12000.00 Product
2. Butyl acrylate 6328.52
3. Meth acrylic acid 132.00
4. Noigen DKX-405 4.80
5. Soda ash 4.80
6. Potassium per sulphate 28.80
7. Ammonia 67.20
8. TBHP 2.40
9. Safolite 4.80
10. Nonyl phenol 9.5 mole 26.40
11. Formaldehyde 12.00
12. Water 5328.00
Total 12000.00 12000.00

6. Waterproofing polymer - Capacity: 300.00 MT/Month

Manufacturing process:
• After charge raw materials, heat the reactor to 70°C & start addition of emulsion & potassium per
sulphate solution.
• Charge both solution simultaneously in 2 hours at 70 oC to 75oC.
• After complete addition, maintain further 1 hour at 70 oC to 75oC.
• After that cool to 50oC& charge ammonia.
• Further mix 20 min. & sample send to QC lab for quality evaluation.
If sample okay, then pack in drums.

Detailed of Project
2-27
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Process flow diagram:

Water: 4711 kg Soda ash: 10 kg

Noigen DKX-405: 80 kg Ammonia: 120 kg

Butyl acrylate: 4100 kg TBHP: 3.5 Kg

Emulsion
Styrene: 2700 kg Polymerisation Safolite: 5.5 Kg

Meth Acrylic Acid: 105 kg Dainol: 75 Kg

kg
Formaldehyde: 50 Kg
Potassium per sulphate: 40 kg

Waterproofing polymer: 12000 Kg

Chemical reaction:

F.R.
CH CH2
Water
+ BuO 2C emulsion

CH CH2 CH CH2

BuO 2C
m

Waterproofing Polymer

Detailed of Project
2-28
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Mass Balance:
Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK
1 Dainol 25 75.00 Waterproofing polymer 12000.00 Product
2 Butyl acrylate 4100.00
3 Meth acrylic acid 105.00
4 Noigen DKX-405 80.00
5 Soda ash 10.00
Potassium per 40.00
6
sulphate
7 Ammonia 120.00
8 TBHP 3.50
9 Safolite 5.50
10 Styrene 2700.00
11 Formaldehyde 50.00
12 Water 4711.00
Total 12000.00 12000.00

POLLUTION POTENTIALS & CONTROL MEASURES

Air Pollution Sources & Control

There will be total 4 kinds of utilities are identified as source of stationary emission. The utilities are 3 nos. of
Boilers (one in standby), 1 no. of Thermo Pack, 2nos. of DG sets and one Hot Air Generator. Company is using
NG and Diesel for operating their Utilities. All utilities are going to be given adequate stack height to regulate
the air pollution because of emission. The details of the Utility Emission & Control Measures are presented in
tabular form beneath.

Table 11: Details of Utility Emission & Control Measures

Stack Type of fuel Air Pollution Applicable norms

Sr.No.
Attached and consumption Control Measures for CPA
Thermo pack PM <120 mg/Nm3
(10.00 Lakh K.cal/hr) NG: 100.00 SCM/Hr Adequate stack height 15 m SO2 <80 ppm
1.
NOx<40 ppm
D.G. Sets: Adequate stack height 11m PM <120 mg/Nm3
1 X 200 KVA Diesel:140.00 Lit/hr and operated only during SO2 < 80 ppm
2.
1 X 500 KVA power break down. NOx< 40 ppm
Steam boiler
Adequate stack height 15 PM <120 mg/Nm3
2.00 TPH (3 Nos.) NG@ 240.00 SCM/Hr
3. m. SO2 < 80 ppm
(one boiler will be
NOx< 40 ppm
on standby)

PM <120 mg/Nm3
Hot Air Generator NG@ 270.00 SCM/Hr Adequate stack height 15
4. SO2 < 80 ppm
25.00 Lakh k. cal/hr m.
NOx< 40 ppm

Detailed of Project
2-29
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
In addition to the stationary emission two sources of process emissions are also identified which are spray
dryer and SS Reactor. Mainly PM is anticipated from spray dryer, SO2 is anticipated from SS Reactor. The
details of the process emission and the APCD planed are presented below in tabular form.

Table 12: Details of Process Emission & Control Measures

Probable Air Pollution
Stack Ht.
Sr. No. Product Name Stack attached to pollutants & Control
(in mtr.)
Limits System
1. Phenol Based Spray dyer -1(Cap.- 600 PM<120
Dispersing Agent 15 Bag filter
kgs/hrx1) mg/Nm3
Di butyl Naphthalene
Sulphonated & PEG Spray dyer -2 PM<120
15 Bag filter
based (Cap.200x1kgs/hr) mg/Nm3
polycarboxylate ether
Sulphonated alkyl
naphthalene Spray dyer -3 PM<120
15 Bag filter
formaldehyde (Cap.900x1kgs/hr) mg/Nm3
condensate
2. Naphthalene Based Process Vent (Sulphonator Two stage
SOx<32
Dispersing Agent & Oleum Storage Tank) 11 Alkali-
mg/Nm3
scrubber

Fig. 4: Detailed diagram of scrubbing system:

Detailed of Project
2-30
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Fugitive Emissions
Fugitive emissions are anticipated to be produced during installation and operational phases of the project.
During installation stage, key source of fugitive emission is dust which is predicted mainly due to the
movement of vehicles carrying machineries and equipment used for installation.
During operation stage, seepage through valves, pumps, emission from open drum having chemicals, open
feeding; storage tanks, etc. are the main causes of fugitive emissions of organic chemicals and VOCs. VOC is
also expected from the storage of formaldehyde and process.
Following actions will be implemented to avert and regulate the fugitive emissions:
➢ Airborne dust at all transfers actions/ points will be controlled either by spurting water or providing
enclosures.
➢ To control fugitive emission from formaldehyde storage, Brine chilled reflux condenser will be
provided
➢ Raw materials loading and unloading will be done in roofed area.
➢ All the raw materials will be pneumatically transfer to the reactor.
➢ Plantation will be done around the project area and along the roads.
➢ Adequate aeration will be provided.
➢ Regular maintenance of valves, pumps and other equipment will be done to avoid leakages and thus
curtailing the fugitive emissions of VOCs.
➢ Entire process will be carried out in the closed reactors with appropriate maintenance of pressure
and temperature.
➢ Intervallic monitoring of work area will be carried out to check the fugitive emission as per the
norms of Gujarat Factory Rules.

Fig. 5: Detailed diagram of Chilled Brine Reflux Condenser

Detailed of Project
2-31
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Action Plan for Odour control:

• Raw material and Finished good will be transferred and Processed/Stored into closed system, there is
no expose of the raw material and finished good into the atmosphere air.
• Green belt development inside the periphery of the plant, open area and also along the road area. It
helps to reduce the concentration of pollutant in the ambient air and source emissions. Weight age
should be given to the species which are used to counteracting the odour.
• Covering the Water supply, pipelines, roads storm water drainage, sewerage, temporary waste storage
facility, common facility etc.
• Gas detector in Storage & Process Area to detect the Leakage of gases.
• Auto Sprinkle system in the storage area to dilute the impact of hazardous gases during the major
leakage.
• Adequate Stack height to disperse the release odour into the atmosphere.

Wastewater Generation & Management

Domestic effluent (2.00 KLD) will be sent to septic tank to Holding Tank & Disinfection system & the
disinfected sewage to be reused for gardening. The industrial effluent generation will be @ 5.60 KLD
generated from floor washing, scrubbing, boiler and cooling only which will be treated using adequate in-
house ETP then, will be send to through spray dryer to achieve ZLD.
The details of wastewater generation are tabulated below whereas the water balance diagram is shown in
subsequent figure.
Table 13: Details of Waste water Generation
Proposed Quantity Treatment
Sr. No. Particulars
(KL per day) Facility
2.00 To septic tank to Disinfection system &
1 Domestic Holding Tank & the disinfected sewage
to be reused for gardening.
2 Industrial
Process 0.00 -
Floor/container/Equipment 1.80 To ETP
Washing
Boiler & Cooling 3.00 To ETP
Scrubbing 0.80 To ETP
Sub Total Industrial 5.60
Total 7.60

Table 14: Stream wise quality of waste water generation (to ETP)
Sr. No Parameters Unit Stream I Stream II Stream III
1 pH -- 7.12 7.30 7.05
2 Total Dissolved Solid mg/lit <2500 <1350 <1200
3 Total Suspended Solid mg/lit <1100 <135 <800
4 Chemical Oxygen Demand mg/lit <1350 <100 <2000
5 Biochemical Oxygen Demand mg/lit <450 <35 <650
Stream I-Washing - 1.80 KLD, Stream II- Boiler & Cooling - 3.00 KLD, Stream III- Scrubbing- 0.80 KLD

o Untreated Composite Effluent sample was analysed for relevant parameters and was taken for the
treatability study.

Detailed of Project
2-32
M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
INITIAL ANALYSIS:
Table 15: Sample Particulars: Untreated Effluent Sample (Composite) Qty: 5.00 Lit.
Sr. No. Test Parameters Unit Results
1. pH -- 6.0
2. Total Dissolved Solids mg/lit 1750
3. Total Suspended Solids mg/lit 570
4. COD Value mg/lit 785
5. BOD Value (3 days at 27o c) mg/lit 270

As can be observed from above analysis results that the sample needs treatment for some relevant
parameters like pH & Suspended Solids. Hence the study has been carried out as follows to achieve the
treated waste water norms laid down by GPCB.

Details of Proposed Sewage Effluent Treatment Plant and Effluent Treatment Scheme:

❖ Design Criteria of STP

• Source of Effluent: Domestic Sewage effluent.
• Effluent Generation: 2.00 KLD Max.
• Capacity of STP: 3.00 KLD Max
Domestic effluent (2.00 KLD) will be sent to septic tank to Holding Tank & Disinfection system & the
disinfected sewage to be reused for gardening.

Domestic Collection Reuse for

Septic Holding
Wastewater / Tank/ Gardening
Tank Tank
Inlet Chamber Disinfectant

❖ Design Criteria of ETP

• Source of Effluent: process, washing and utility etc.
• Effluent Generation: 5.60 KLD Max.
• Capacity of ETP: 10.00 KLD Max

Primary Treatment:
The effluent was taken and hydrated lime was added to make the effluent alkaline up to pH 10.0. Then Non
ferric alum solution was added to neutralize the effluent. After neutralization, Polyelectrolyte (coagulant) is
added for proper settling of flocks to reduce the suspended solid concentration, color and COD in the
effluent. Then neutral effluent will be filtered through filter paper and a clear effluent was analyzed and the
results of the same are as below.
Table 16: Analysis Report after primary treatment

Sr. No. Test Parameters Unit Results % reduction

1. pH -- 7.3 --
2. Total Dissolved Solids -- 1785 --
3. Total Suspended Solids mg/lit 84 85 %
4. COD Value mg/lit 635 19 %
5. BOD Value (3 days at 27o c) mg/lit 223 17 %

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals

Tertiary Treatment:
After Primary treatment clear effluent was passed through Pressure Sand Filter & Activated Carbon Filter
and outlet effluent was analyzed as follows.

Table 17: Analysis Report after tertiary treatment

Sr. No. Test Parameters Unit Results % reduction
1. pH -- 7.2
2. Total Dissolved Solids mg/lit 1790 --
3. Total Suspended Solids mg/lit 67 20 %
4. COD Value mg/lit 552 13 %
5. BOD Value (3 days at 27o c) mg/lit 197 11 %

• As can be observed from above results, almost all the parameters are observed well within the desired
limit suitable for evaporation of treated wastewater in Spray Dryer to achieve ZLD.
Table 18: Details of Effluent Treatment Plant
SR
ITEM MOC CAPACITY NOS
NO.
1 Oil/ Grease Trap RCC 0.5 KL 2
2 Collection Tank RCC 11 KL 1
3 P.E. Dosing Tank HDPE 0.5 KL 1
4 Flocculator MS 2.0 KL 1
Primary Lamella separator with tube deck
5 packing MS 3.0 KL 1
6 Holding Tank RCC 5 KL 1
7 Pressure sand Filter MS 1.0 m3/hr. 1
3
8 Activated Carbon Filter MS 1.0 m /hr. 1
9 Sludge Drying Beds BM 1.0 x 1.0 x 1.0 3
10 Sludge storage Area BM 2.0 x 2.0 x 1.0 1

Economic Viability of ETP:

ETP Installation cost – 7 Lakh
ETP Maintenance Cost –
o ETP Chemical Cost – 12240 Rs. /Yr.
o Energy Cost – 42000 Rs. /Yr.
o Man Power Cost – 180000 Rs. /Yr.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Fig. 6: Hydraulic Flow Diagram

Spray Dryer Details

In the proposed project, effluent from the process is zero, hence no volatile organic compound is going to be
present in the effluent. The effluent is generated from washing, scrubbing & utility operation only. Because
of volatile organic compounds absence any kind of evaporator will works for the proposed project, therefore
the company choose spray dryer with bag filter for evaporation, as it is more environmental friendly and
more sustainable.
Adequacy of Spray Dryer Capacity:

• Total quantity of effluent need to be evaporated- 5.60 KLD

• Maximum hours anticipated for evaporation operation- 10 hrs./Day
• Evaporation rate of proposed Spray Dryer- 1000 Kg/Hr.
Therefore, number of hours required to evaporate the effluent quantity is
= Quantity of effluent (lit)/Evaporation rate per hour
= 5600/1000
= 5.6 Hrs.
i.e = 6 Hrs.
From above calculation the proposed spray dryer required only maximum 6 hrs to evaporate the effluent,
which is more than adequate as the spray dyer has capacity of 1000 kg/hr. Also it has been noticed that the
spray dryer will have significantly high spare operational hours (4 hrs more than anticipated operation hours
and 18 Hrs. more than the daily max operation hours). Hence the proposed spray dryer capacity is adequate
for the proposed project.

Environmental Impact Potential:

• In the proposed project, effluent from the process is zero, hence no volatile organic compound will
be present in the final effluent to be evaporated in spray dryer. Hence no potential impact on

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
surrounding environment as well as human health due VOC from evaporation of effluent through
spray dryer is anticipated.
• Evaporation salt from the spray dry will be in a dry form, which can have impacts on surrounding
environment & human health may occur. Considering this, company has planned to provide bag
filter along with the proposed spray dryer with 99% efficiency. After such control measure for
control of PM emission, PM emission will significantly reduce and the probable impacts on
environment & human health will be almost nullified.
• The evaporation salt will be stored along with ETP waste after necessary stabilization of mix waste in
a dedicated hazardous waste storage area and will send to TSDF. Hence there will no impact on
environment & human health is anticipated due to the management & disposal of evaporation salt.

Details & adequacy study report of spray dyer is attached as Annexure-VIII.

Fig. 7: Water Balance Diagram

Total Water 210.50 KLD

(Fresh – 208.50 KLD + Reuse- 2.00 KLD)

4.00 KLD 190.00 KLD 2.00 KLD 1.00 KLD 9.00 KLD 4.50 KLD

Domestic Process Washing Scrubbing Boiler & Cooling Gardening

(Fresh- 2.50 KLD
2.00 KLD 190.00 KLD Losses*:
1.80 KLD + Reuse 2.00
0.80 KLD 6.00 KLD
KLD)
Septic tank Consumed as product-
78.50 KLD
2.00 KLD Drying Loss 111.50 KLD
3.00 KLD
Proposed
STP Wastewater: Nil
To Proposed Effluent Treatment Plant
2.00 KLD
5.60 KLD
Reuse for
5.60 KLD
Gardening
STP To Spray Dryer

Note: *Losses includes Evaporation & drift loss in cooling and Steam Loss from boiler.

Solid & Hazardous Waste Generation & Management

The hazardous waste from the unit will be generated in form of waste from scrubber, process, Used Oil,
Discarded/Empty containers/Barrels/Liner, used filter cloths and ETP waste. The details of all wastes & their
management are tabulated below.
The details of all wastes & their management are tabulated below.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Table 19: Details of Solid/Hazardous Waste Generation & Management
Specific Source of
Type/Name Category and
generation Quantity
Sr. no. of Hazardous Schedule as Management of HW
(Name of the Activity, (MT/Annum)
waste per HW Rules.
Product etc.)
1 ETP Waste ETP operation & Spray 35.3 15.00 Collection, Storage,
dryer Transportation, Disposal
at TSDF Site.
2 Spent/ Used Machinery 5.1 0.095 Collection, Storage,
Oil Transportation, disposal
by selling to registered
recyclers.
3 Discarded Raw Materials 33.1 125.00 Collection, Storage,
materials Decontamination,
Drum, Liners/ Disposal on sell to actual
Bags/ users.
Carboys
4 Process Mfg. Process 26.1 400.00 Collection, storage,
Waste (Product-Naphthalene transportation, disposal at
based Dispersing TSDF Site.
agent)

5 Scrubber Process Scrubber 37.1 290.00 To be managed with other

Bleedoff (Product-Naphthalene wastewater using ETP.
based Dispersing
agent)
6 Used Filter Mfg. Process 33.2 1.00 Collection, Storage,
Cloths Transportation, disposal
to Co-Processing.

Noise & Vibration Generation & Control

Noise & Vibration generation is predicted in utility & production area along with from operation of pumps,
motor & compressors etc. installed at altered site within premises. Mainly the high noise & vibration is
probably going to be generated in utility area. The amplitude in premises ranges from 50 dB(A) to 80 dB(A)
depending up on the abreast of the space from the noise sources. Noise level outside of production & utility
area will never cross the permissible limit for industrial unit as mostly remains below 75 dB(A). All noises are
going to be managed by providing of suitable PPEs for working people in the corresponding areas. Vibrations
will be managed by provision of proper fitting, shunting and sturdy non-vibrating foundation with rubber
pads.
Greenbelt Development & Rainwater Harvesting
Green belt act as a surface, which is capable of engrossing air pollutants and sinks for pollutants. Other than
functioning as a pollutant sink, green belts provide other benefits like:
• Green belt helps in noise diminution for the surroundings area. Thus, it is recommended as noise fences.
• Green belt helps in achieving bio diversity by providing possible habitats for birds and animal, thus restoring
welcoming nature in drab urban industrial scene.
• Green belts upsurge the aesthetic worth of the site.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Company has acquired plot admeasuring 6213 Sq. Mt. The sufficient greenbelt will be developed at the
periphery of plant premises also in some open area within the site which admeasures 1202 Sq. Mt. (19 % of
total plot area). Greenbelt is/will be maintained by regular fertilization, irrigation & replantation to provide
thick pasture view considering the guideline of CPCB for three tiers greenbelt development. Besides this
company will do plantation outside the company premises.
The proposed project would have about 2583 m2 area as rooftop which might have potential of rainwater
harvesting with runoff co-efficient of 0.85.
The long term average rainfall of the area is perceived to be around 2100 mm, which may have great
potential of rainwater harvesting resulting in 6119.37 m3/annum. The harvested rain water shall never be
used to recharge ground water or to release in surface water.

Occupational Health & Safety

Hazardous Materials Management & Safety

There will be total 16 hazardous materials in the proposed project. All of these materials are identified as
hazardous as per MSIHC Rules (2000) the list of hazardous chemicals are shown in table 2.20
Table 20: Hazardous Raw materials identified as per MSIHC Rule 2000

Threshold
Sr. Storage Storage Classification as per
Name of Raw material
No. Cap. In MT as per MSIHC Schedule of MSIHC Rule
Rule
1. Naphthalene 400.00 -- Sh-I,Part-II,417
2. Oleum (23%) 30.00 -- Sh-I,Part-II,444
3. Sulphuric Acid (98%) 20.00 -- Sh-I,Part-II,591
4. Formaldehyde 40.00 5t Sh-I,Part-II,285
5. Caustic lye 50.00 -- Sh-I,Part-II,571
6. Phenol 30.00 -- Sh-I,Part-II,481
7. EDTA (Ethylene di amine tetra acetic acid) 1.00 -- Sh-I, Part-I, (a)2
8. Phthalic anhydride 1.00 -- Sh-I,Part-II,508
9. Acetic acid 5.00 -- Sh-I,Part-II,2
10. N-Butanol 10.00 -- Sh-I,Part-II,412
11. Acrylic Acid 20.00 15,000 t Sh-I, Part-I, b(v)
12. Methacrylic acid 2.00 15,000 t Sh-I, Part-I, b(v)
13. Butyl acrylate 10.00 10,000 t Sh-I, Part-I, b (iv)
14. Ammonia 5.00 50 t Sh-I,Part-II,31
15. TBHP(Tent Butyl Hydro Peroxide) 1.00 10,000 t Sh-I, Part-I, b(iv)
16. Styrene 10.00 -- Sh-I,Part-II,583

All hazardous materials are going to be managed in accordance with national & state regulations. Detailed
RA study will be conducted for storage and handling of the hazardous materials and all essential measures as
recommended in RA report will be implemented for avoidance of hazards related with the hazardous
chemicals of the project.

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M/s. Bhavisha Industries, Vapi
DPR for proposed manufacturing of Synthetic Organic Chemicals
Primarily proponent has got to implement the subsequent general risk reduction measures for Handling,
Storage of Hazardous Materials (Drums & Tanks) to sustain safe work place & hazard free areas in the
proposed unit.

• Adequate aeration in godown & production area to avoid toxic chemical vapour exposure built-up in
workplace and to maintained area below PEL/TLV limits. Air change ratio in these areas are managed
around 1.
• Appropriate label and identification board /stickers in storage & production area for all chemicals
• Conductive drum pallets are going to be provided.
• Trolley / stackers/fork lift for heavy goods/drum/bag handling.
• Storage of Materials as per compatibility
• Separate storage area for combustible, scarring and toxic chemical storage.
• Prohibition/constraint on smoking and other spark/ flame causing item.
• Lower level ventilation exhaust system will be provided in drum storage area.
• Material safety data sheets at storage along with process and chemical handling area.
• Fire hydrant system & firefighting equipment in unit as per TAC/NFPA Norms.
• Plant should meet provisions of the Manufacture, storage & Import of Hazardous Chemicals Rules,
1986 & the factories Act, 1948 and also the Chemical Accidents (Emergency Planning, Preparedness
and Response) Rules, 1996 (As amended timely).
• Static grounding to any or all process vessels and equipment
• Caution note board for all hazardous chemicals
• Safety valve provision to be made on reactor.
• Periodic On Site Emergency, Mock Drills so as to coach the staff and make them mentally prepared to
challenge any emergency
• Safety devices and control instruments should be calibrated once in an exceedingly year.
• Proper coloring as per IS 2379 in plant to pipeline network, tank and equipment to protect it from
corrosion.
• Preventive maintenance agenda for all the equipment and colour code or tagging
• Permit to work system on 100 % basis for hazardous work to be dispensed within the plant
• Automated Fire detection system &/or manual call points for fire location identification in storage
area as well as plant area
• Obligatory Induction safety course and training of all new employees
• Empty drums & bags will be stored in separate devoted empty drum & bag storage area. All drums &
bags will be neutralized/decontaminated before send it to recyclers.
Management of Occupational Health & Safety
The company is dedicated towards ensuring high level of health & safety of its employee and every one
necessary implementation & actions are going to be observed well in place in the proposed unit. Company
will follows all constitutional guidelines related with occupational health & safety and all necessary facilities
& procedures will be provided within the unit. Health check-up programs are dole out regularly and all
records & documents related with employee health check-up program will be maintained. All necessary risk
control & prevention measures are going to be implemented in unit. Management will provide required
PPEs, safety equipment/ materials as mentioned in above section of risk reduction to ensure healthy & safe
work conditions. Consistent inspection for the safety procedures and use of PPEs & Safety

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DPR for proposed manufacturing of Synthetic Organic Chemicals
equipment/material will be done by the management/safety cell. Premedical examination and periodical
examination are going to be carried out once in a very six month and record are maintained in Form No-32 &
33 as per GFR. Training programs & safety audit shall be done on regular basis to avoid impacts of the
operational activities on occupational health as well as to progress workplace condition & safe work system.

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