PREFEASIBILITY STUDY REPORT

Of

Proposed Project for

Manufacturing of Pigments
of

M/s. Nirva Pigments

Located at
PLOT NO. DP-10, Saykha industrial Estate
Ta: Vagra, Dist.: Bharuch

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 Contents
Executive Summary .................................................................................. 3
1.1 Introduction ....................................................................................... 3
1.2 Need of the Project ............................................................................. 4
PROJECT DESCRIPTION ............................................................................. 5
2.1 Location of the Proposed Project: .......................................................... 5
2.2 Product Details: .................................................................................. 6
2.3 Process technology (Manufacturing Process): ......................................... 7
2.3.1 Pigment CPC Blue.............................................................................. 7
2.3.2 Pigment Alpha Blue ............................................................................ 9
2.3.3 Pigment Beta Blue ............................................................................ 11
2.3.4 Pigment Green 7 .............................................................................. 13
2.4 Raw Material requirement .................................................................. 16
2.5 Cost of Project .................................................................................. 19
2.6 Resources Requirements: .................................................................. 19
POLLUTION POTENTIAL AND MITIGATION MEASURE .............................. 20
3.1 Water Pollution: ................................................................................ 20
3.2 Effluent Treatment Plant Detail ........................................................... 22
3.3 Air Emission: .................................................................................... 22
3.4 Hazardous Waste Management: .......................................................... 24
3.5 Noise and Vibration Control:............................................................... 25
3.6 Hazards and Safety Measures:............................................................ 25
3.7 Good Housekeeping: ......................................................................... 25
CONCLUSION ......................................................................................... 27

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 Executive Summary
1.1 INTRODUCTION

M/s. Nirva Pigments Proposes to set up a manufacturing unit of Pigments at PLOT NO.
DP-10, Saykha industrial Estate Ta: Vagra, Dist.: Bharuch in the state of Gujarat. The
total capacity of the proposed project shall by 385 MT / month.

This is our new project with manufacturing of Pigments. Since this establishment attracts
applicability of EIA notification and covered under Category 5(f) B, we are applying to
obtain Environmental Clearance from SEIAA, Gandhinagar for our proposed project.

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1.2 NEED OF THE PROJECT

 Demand and Supply Gap

We have more than 10 years of experience in the field of manufacturing of Pigments. Based on our informal
survey of the market with our current customers, we have found that there is a big potential for the product
we are planning.

 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials, unit will not have to import any raw materials as
they are produced locally. This will make us very competitive against imported finished products and it
will increase the scope of our finished product to all over the country.

 Export possibility
Depending on the international demand of products we will explore the possibility of exporting the
products.

 Employment Generation (Direct and Indirect) due to project

Unit will give direct employment to local people based on qualification and requirement. In addition to
direct employment, indirect employment shall generate ancillary business to some extent for the local
population.

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 PROJECT DESCRIPTION

2.1 LOCATION OF THE PROPOSED PROJECT:

Our company located at Plot No.: PLOT NO. DP-10, Saykha industrial Estate Ta: Vagra, Dist.: Bharuch

Location: 21°47'43.28"N 72°49'37.58"E

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2.2 PRODUCT DETAILS:

Proposed
SR. NO PRODUCT NAME CI Name/CAS No.
MT/Month

1. Pigment CPC Blue Pigment Blue 15:3 300

2. Pigment Alpha Blue Pigment Blue 15:0 40

3. Pigment Beta Blue Pigment Blue 15:3 15

----
4. Pigment Green 7 15

5. Pigment Violet 23 15

TOTAL 385

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2.3 PROCESS TECHNOLOGY (MANUFACTURING PROCESS):

2.3.1 Pigment CPC Blue

Stage: 1
• Charge Di Chloro Toluene in Glass lined reactor.
• Then add Urea, Phthalic Anhydride, Cuprous Chloride and Ammonium Molyblate to it.
• Raise the temperature up to 180 °C.
• During decomposition of urea ammonia gas as well as carbon dioxide gas is produced. We are
controlling it by providing two stage water scrubber and then after acid scrubber. From the water
scrubber we can obtain ammonium Carbamate as a by product.
• After maintaining sufficient time dump the batch in M.S.Ventulator for vacuum distillation of
solvent.
• By that 95 % of the solvent will be recovered. And transfer the remaining crude in Drawning
vessel containing water.
Stage: 2
• Take above heated crude material into dumping vessel with spent Sulphuric acid (mother liquor
from Alpha Blue).
• Then start heating up to 95 °C and maintain for three hours.
• Then filter in filter press, wash, neutralize, dry and pack the final product as a CPC Blue.
• After filtration process whatever mother liquor will be generated that contains 12-15 % of
Sulphuric Acid. We will treat it into our adequate ETP to become neutral. Then after we will
discharge it into CETP, Vatva.

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 Pigment CPC Blue

Mass Balance

Sr. Quantity Sr. Quantity Kg

Input Output
no. Kg per MT No. per MT
1 Phthalic Anhydride 1075 1 Pigment CPC Blue 1000
2 Ammonium Carbonate 1200 2 Solvent recover 2180
3 Solvent 2200 3 Spent Acid 2500
4 Technical Grade Urea 1400 4 Effluent send to ETP 5000
5 Cuprous Chloride 195 5 Evaporation loss 2173
6 Ammonium Molyblate 3 6 Solvent Loss 20
7 Spent Acid From Alpha Blue 2000 7 NH3 + CO2 1000
(25-30%)
8 Washing Water 6000
9 Water used in Ammonium 500
carbonate
Total 13473 Total 13473

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2.3.2 Pigment Alpha Blue

Stage: 1 (ACID PROCESS)

 Take Sulphuric acid (70 %) in a reaction vessel. Then slowly charge Copper Phthalocyanine slowly
from ball mil.
 Maintaining temperature just below 85 °C so as to dissolve it to completely.
 The mass is transferred to Drawning vessel stirred further for 2-3 hrs at 60 °C and then cooled to
room temperature.
 The CPC separate out in the required form and is filtered off.
 After filtration process whatever mother liquor generated that contains approximate 25-30 % of
Sulphuric acid. We are using that liquor (H2SO4) into the manufacture of CPC Blue. And Filtrate
effluent reuse in next batch alpha blue product

Stage: 2 (PIGMENT PROCESS)

 The CPC cake is charged in another vessel and washed with water and stirred with fresh water.
 The aqueous slurry is neutralized to pH 8 to 8.5 using caustic lye and stirred with emulsifier agent
at 60° C–90°C for 02 hours.
 The above slurry is filtered and the cake is washed with large amount of fresh water.
 The wet cake is dried to obtain Alpha Blue 15.
 The aqueous filtrate goes to ETP. Then after it is discharge it into CETP, Vatva.

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 Pigment Alpha Blue

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg per

Input Output
no. per MT No. MT
1 CPC Crude 1050 1 Pigment Alpha Blue 1000
2 Suphuric Acid (70%) 5000 2 Spent Dilute H2SO4 13000
3 Reuse Water From Filter 20000 3 Effluent Reuse 20000
4 Fresh Water 15000 4 Effluent to ETP 5000
5 Emulsifier 5 5 Evaporation Loss 2085
6 Caustic Flakes 30

Total 41085 Total 41085

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2.3.3 Pigment Beta Blue

Beta Blue is manufactured in two stages.

Stage 1: Milling
Stage 2: Pigmentation.

Milling:
Charge CPC (98 %) in ball mill of capacity 10,000 Liter. Mill the contents for 24 hrs. After grinding
discharge the milled blue for stage II (Pigmentation)

Pigmentation:
• Charge above milled blue into MS vessel, contains caustic water, surfactants and solvent. Reflux
whole mass under stirring for 02 hrs.
• Then recover the solvent. Filter the pigmented mass through filter press; wash with water till neutral
pH. Dry the pressed cake in spin flash dryer at the rate of 150 Kg/Hr.

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 Pigment Beta Blue

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 CPC 1050 1 Pigment Beta Blue 1000
2 Caustic 160 2 Solvent Recover Reuse 3465
in next Batch
3 Water 10000 3 Solvent Loss 35
4 Butyl alcohol(Reuse) 3465 4 Effluent 28400
5 Butyl alcohol(Fresh) 35 5 Organic and inorganic 210
material
6 Washing 20000 6 Moisture Loss 1600
TOTAL 34710 TOTAL 34710

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2.3.4 Pigment Green 7

Manufacturing Process:
CPC Green is produced by Chlorination of Copper Phthalocyanine Blue (CPC).
The basic Mfg. process involves two distinct steps. Synthesis of crude CPC green from CPC Blue and
purification with solvent.
In a glass lined reactor, CPC Blue is charged with sodium chloride, Cupric Chloride and anhydrous
Aluminum Chloride with their respective proportion.
Whole mixture is maintained at elevated temperature. Then pass chlorine gas into the mixture.
During the reaction gaseous HCl mist and unreacted chlorine gas are evolved.
HCl gas and unreacted chlorine gas are scrubbed by water and caustic spray in consecutive packed column
scrubber. These can result in dilute HCl and NaOCl (Sodium Hypo Chlorite) generation, which are used in
ETP for treating trade effluent.
After completion of chlorination, the eutectic melt contain sodium chloride, Aluminium Chloride, Cupric
Chloride and CPC Green is drowned in water in a rubber lined vessel.
Aluminium Chloride will be converted into Aluminium Hydroxides and HCl gas is released and it will be
also sent to alkali scrubber.
The slurry containing crude CPC green is filtered through filter press, followed by washing with water,
until pH of the cake become neutral.
Mother liquor is sent to Aluminium Hydroxide recovery and then to ETP.
The cake is purified by solvent treatment, In which the cake is refluxed in closed reactor containing solvent,
emulsifier and water containing NaOH.
The slurry is then filtered and washed with water and dematerialized water till pH is Neutral
The filtrate separate into two layers consisting of the organic layer containing impurities and the alkaline
aqueous layer containing Aluminium salt along with emulsifier etc.
The solvent is used for further purification.
The wet cake of CPC Green is dried in spin flash dryer to get required mesh size of final product CPC
Green for final packing

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 Chemical Reaction

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 Pigment Green 7

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 Aluminium Chloride 1825 1 Pigment Green 7 1000
2 Cupric Chloride 80 2 Cl2 + HCl 621
3 Vaccum Salt 397 3 Vapot Loss 825
4 CPC Blue Crude 555 4 Aluminium Chloride soln 4697
5 MCB Solvent 3400 5 MCB Recover 3340
6 Emulsifier 40 6 MCB Loss 60
7 Caustic Flakes 79 7 Effluent Send to ETP 3525
8 Water 13575 8 Effluent reuse 5590
9 Evaporation Loss 1563
Total 21221 Total 21221

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2.3.5 Pigment Violet 23
Reaction: In reactor charge aminoethylcarbazole, sodium acetate and chloranil at 50 temp. in ODCB. stir
for 3 hrs at 60-65 temp. The batch is heated to 115 temp. for 5 hrs and then further heated to 150 temp. and
add benzene sulphochloride at this temp. The batch is then heated to 176-180 and maintain for 8 hrs. Then
batch is cooled to 100 temp.
Filtration and washing: filter the pigment slurry. Wash with ODCB. ML and Wash water is sent to Solvent
Recovery.
Steam Distillation: Wet cake us then charge into reactor with water and start steam distillation to remove
ODCB completely.
Filtration and washing: Filter the pigment slurry. Wash with water. ML and Wash water is sent to ETP.
Drying and Packaging: Wet cake is then dried and pulverized and then sent to packaging.

Chemical Reaction:

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 Pigment Violet 23

Mass Balance

Sr. Quantity Kg Sr. Quantity Kg

Input Output
no. per MT No. per MT
1 ODCB 6000 1 Pigment Violet 23 1000
2 Aminoethylcarbazole 732 2 ODCB Recovery 6700
3 Sodium Acetate 25 3 Effluent 5897
4 Chloranil 425 4 Drying Loss 1610
5 Benzene Sulphochloride 25 5 MCB Recover 3340
6 Water 7000
Total 14207 Total 14207

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2.4 RAW MATERIAL REQUIREMENT
We will propose manufacturing Activity Various Types of Pigment at capacity by 385 MT/Month. The
propose quantity of raw material in each type of product in 1000 KG batch is listed as below.

Sr No. Name of the Product Raw Material Per MT

Phthalic Anhydride 1075
Ammonium Carbonate 1200
Solvent 2200
Technical Grade Urea 1400
Cuprous Chloride 195
1. Pigment CPC Blue
Ammonium Molyblate 3
Spent Acid From Alpha Blue 2000
(25-30%)
Washing Water 6000
Water for Ammonia carbonate 500
CPC Crude 1050
Suphuric Acid (70%) 5000
Reuse Water From Filter 20000
2. Pigment Alpha Blue
Fresh Water 15000
Emulsifier 5
Caustic Flakes 30
CPC 1050
Caustic 160
Water 10000
3. Pigment Beta Blue
Butyl alcohol(Reuse) 3465
Butyl alcohol(Fresh) 35
Washing 20000
Aluminium Chloride 1825
Cupric Chloride 80
Vaccum Salt 397
CPC Blue Crude 555
4. Pigment Green 7
MCB Solvent 3400
Emulsifier 40
Caustic Flakes 79
Water 13575
ODCB 6000
Aminoethylcarbazole 732
Sodium Acetate 25
5. Pigment Violet 23
Chloranil 425
Benzene Sulphochloride 25
Water 7000

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2.5 COST OF PROJECT
The approx. cost of the proposed project will be 3.0cr. The details of the cost of the project is given here:
Land & Building 1.4 Cr.
Plant & Machinery 1.6 Cr.

2.6 RESOURCES REQUIREMENTS:

As the proposed project will be required resource for production. The details of their sources given
hereunder,

Land: The proposed project is in new unit 7182 sq. m located at Saykha GIDC.

Water: The water requirements for the after expansion project will be 203.2 KLD from which 5.0 KLD
fresh water will be utilized as Domestic and remaining 198.2 KLD in which 84.4 KLD will be Reuse from
Process Waste water and remaining 113.8 KLD water will be received from GIDC.

Power: Total power requirement for the after proposed project will be 245 KW. Power demand will
satisfied by Electricity Board/Authority.

Fuel: At present we are utilizing Coal or Lignite 9 MT/Day or 7 MT/Day as fuel in Proposed Boiler and
Hot air generator. Adequate stack height of 30.00 m from ground level will be provided for Boiler.

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 POLLUTION POTENTIAL AND MITIGATION
MEASURE

3.1 WATER POLLUTION:

The water requirements for the after expansion project will be 203.2 KLD from which 5.0 KLD
fresh water will be utilized as Domestic and remaining 198.2 KLD in which 84.4 KLD will be
Reuse from Process Waste water and remaining 113.8 KLD water will be received from GIDC.

WATER CONSUMPTION DETAILS

Sr No Category Water Consumption

1. Domestic Purpose 5.0

INDUSTRIAL
Process 173.0 (88.6 F+84.4 R)
Washing 5.0
2.
Boiler 5.0
Cooling 1.0
Scrubber 14.20
Total water Consumption & Generation (Domestic) 5.0
Total water Consumption & generation (Industrial ) 198.2

WASTE WATER GENERATION DETAILS

Waste Water
Sr No Category
Generation
1. Domestic Purpose 4.0
INDUSTRIAL
Process water 126
Washing 4.8
2.
Boiler 0.5
Cooling 0.5
Scrubber 26.7
Total water Consumption & Generation
4.0
(Domestic)
Total water Consumption & generation (Industrial) 131.8

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 Water Balance Diagram

Total Water consumption

203.2 KLD

Industrial Domestic
198.2 KLD 5.00 KLD

Process Boiler Washing Cooling Scrubber Sewage

173.5 KLD 5 KLD 5 KLD 1 KLD 14.20 KLD 4.0 KLD

spent HCl acid sell

Spent (H2SO4) Acid Effluent Blow Down Washing Blow Down
to Athorized
generation from process 126 0.5 KLD 4.8 KLD 0.5 KLD Agencies
**50.8 KLD *1.1 KLD
effluent reuse in
spent acid sell to alph blue, CPC Blue 5.8 KLD
Spent Acid Reuse and CPC Green Low COD waste Ammonium
in CPC Athorized Water
Agencies (filteration) and Carbonate Partialy
Reuse in CPC Sodium
20.8 KLD Ammonium Sulfate 41.6 KLD
10.0 KLD Hypochloride
84.4 KLD 24.0 KLD
2.8 KLD

ETP
47.4

Send To CETP

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Note: The generated sewage will be disposed through soak pit/septic tank.

The total industrial wastewater generation from Manufacturing process and other ancillary process will be
126 KLD out of which 84.4 KLD will be reused in alpha blue, CPC Blue, CPC Green Product and
remaining 47.4 KLD primary treated waste water will be sent to CETP for further treatment and ultimate
disposal.

3.2 EFFLUENT TREATMENT PLANT DETAIL

Sr. Name of Unit Capacity

No.
1 Collection Tank 2 Nos. 6 m3 and 10m3
2 Neutralization Tank 10 m3
3 Settling Tank 25 m3 and 10 m3
4 Holding Sump 7.5 m3 and 10 m3
5 C.E.T.P Overhead Tank 30 m3
6 Sludge Drying Bed 1.5×1.5 (4 Nos.)

3.3 AIR EMISSION:

We will use Coal or Lignite 9 MT/Day as fuel in Proposed Boiler and Hot air generator. Adequate stack
height of 30.00 m from ground level will be provided for Boiler.

 Flue gas Emission data

Stack
Sr.
Stack attached to height in Fuel Consumption APCM
no
meter
Multi cyclone Dust
Coal or 5 MT/Day or 4
1 Steam Boiler (3 TPH) 30 Collector and Bag
Lignite MT/Day
Filter

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 Multi cyclone Dust
Hot Air Generator (4 Coal or 2 MT/Day or
2 30 Collector and Bag
Lac kcl) Lignite 1.5 MT/Day
Filter
Multi cyclone Dust
Thermic Fluid Heater (3 Coal or 2 MT/Day or
3 30 Collector and Bag
Lac KCl) Lignite 1.5 MT/Day
Filter

 Process Gas Emission Data

Stack height in
Sr no Stack attached to APCM Pollutant
meter
Spray Dryer (2000 Bag Filter Followed By
1. 11.0 PM
LPH) Water Scrubber
Spin Flash Dryer Bag filter + Cyclone
2. 11.00 PM
(SFD) Separator
Reaction Vessel (CPC
3. 11.00 Two stage water scrubber NH3 & CO2
Blue )
Reaction Vessel Two stage water scrubber
4. 11.00 Cl2 & HCl
(Pigment Green) with Alkali Scrubber

There will be a chance of fugitive emission from the manufacturing process as well as due to storage &
handling of raw materials and products. The unit will take following adequate precautions for the control
of fugitive emission;
 The entire manufacturing activities will be carried out in the closed reactors and regular checking and
maintenance of reactors will be carried out to avoid any leakages.
 Replacing the low pressure mixing head with high pressure system will eliminate emission of VOCs.
 The tank vents will be equipped with either a carbon filter or an oil trap to prevent water vapor from
entering the tank as it breathes.
 All the motors of pumps for the handling of hazardous chemicals will be flame proof and provided with
suitable mechanical seal with stand-by arrangement.
 Control of all parameters on a continuous basis will be done by adequate control valves, pressure release
valves and safety valves etc.
 All the flange joints of the pipe lines will be covered with flange guards.
 All the raw materials will be stored in isolated storage area and containers tightly closed.
 There will also be provision of adequate ventilation system in process plant and hazardous chemical
storage area.
 A regular preventive maintenance will be planned to replace or rectify all gaskets, joints etc.
 The unit will also develop green belt within the factory premises to control the fugitive emission from
spreading into surrounding environment.

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3.4 HAZARDOUS WASTE MANAGEMENT:

Types of
Sr. Propose
Hazardous Sources Category Disposal
No MT/Month
Waste

40 Collection, storage, Transportation

1 ETP Sludge ETP Area 35.3
MT/Month and Dispose to Active TSDF Site

Plant 0.010 Collection, storage, Reuse within

2 Used Oil 5.1
Machinery KL/Month premises.
Material Collection, storage, Transportation
Discarded 4
3 handling 33.1 and Dispose by selling to
Container MT/Month
and Storage Registered Recycler
Spent 520 MT/Month will be utilize in
CPC Blue
Sulphuric 1270 CPC production remaining 750
4 and Alpha 26.3
Acid (12- MT/Month MT/Month send to (Rule -9)
Blue
20%) authorized agencies or actual users
300 MT/Month will be utilize in
CPC production and remaining
Ammonium 600 300 MT/Month Ammonium
5 CPC Blue 26.1
Carbonate MT/month Carbonate will be utilized in mfg.
of Ammonium sulfate or will be
Send to Actual User (rule-9)
Pigment
Collection, Storage,
Spent HCl Green 27.5
6 26.3 Transportation & sell to (Rule -9)
acid Water MT/Month
authorized agencies or actual users
Scrubber
Pigment
Sodium Green 42.0 Collection, Storage, And Send to
7 --
Hypochloride Alkali MT/Month Actual User (rule-9)
Scrubber

Solvent Distillation 12.0 Collection, Storage, And Send to

8 26.4
Residue Unit MT/Month Actual User (rule-9)

CPC Blue,
Beta Blue,
and
Solvent 841.5 Collection, Storage, And Send to
9 Pigment --
Recovery MT/Month Actual User (rule-9)
Green,
Pigment
violet

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3.5 NOISE AND VIBRATION CONTROL:
The following adequate precautions will be taken for control of noise & vibration;
 The unit will install latest technology based low noise DG Set with acoustic enclosures.
 Proper and timely oiling, lubrication and preventive maintenance will be carried out for the
machineries and equipment to reduce noise generation.
 The noise generation will be mitigated by installing noise barriers/absorbers around stationery noise
sources. Adequate noise control measures such as anti-vibration pad for equipment with high
vibration will be provided.
 All the vibrating parts will be checked periodically and serviced to reduce the noise generation.
The equipment, which generates excessive noise, will be provided with enclosures etc.
 To minimize the adverse effect on the health, ear muffs / earplugs will be provided to the working
under high noise area.

3.6 HAZARDS AND SAFETY MEASURES:

 All the personnel at the plant will be made aware about the operation hazards and risk associated
with them.
 Safe work practices will be adopted to ensure the control of hazards during operation and
maintenance.
 The workers will be made aware about the hazards associated with manual handling and operation.
 Safety measures in the form of ‘DO’ and ‘Don’t Do’ will be displayed at strategic locations
especially in local language.
 Good housekeeping will be maintained in the Mining area.
 The required PPEs for each area/operation should be identified and the necessary PPEs, like,
helmets, goggles, hand gloves, mask, suit, safety belts, ear muff and plug, etc. will be provided to
the personnel.
 The plant will check and ensure that all instruments provided in the plant are in good condition and
documented.
 First Aid box will be provided within the plant.
 List of important telephone numbers will be displayed at prominent location in the plant. Lease
Holder Machine Operator Helper/ Labor.
 All the accidents and incidents if any will be recorded, investigated and analyzed in the proposed
plant.
 Safety awareness programs and trainings of the worker will be carried out to motivate the workers
to increase the safety level at personal level.

3.7 GOOD HOUSEKEEPING:

The term Good Housekeeping is often loosely understood as simple floor cleaning or broom

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Stick operation. But it has even wider meaning including up keeping of all industrial activities in orderly
manner to minimize the accidents due to improper planning, placement, arrangement, handling, etc.
everywhere in industrial premises. “Place for everything and everything on proper place”. So, Good
housekeeping at quarry site will greatly reduce unsafe conditions and so risk of accidents.

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CONCLUSION
This is our new unit proposed for manufacturing of various Pigments. The unit will provide adequate
measures for the prevention and control of pollution for its proposed project. With the execution and
operation of such control measures along with proper Environmental Management System, there will
not be any major potential for negative impact on the environment due to proposed project.

There will be positive impact on the socio-economic environment since proposed project will generate
some permanent and secondary employment. The unit will also establish Cordial relation with the
nearby villagers and will carry out social welfare activities according to their needs.

The proposed project will also boosts up ancillary industrial and commercial activity. Thus, it will
improve the economic condition of the area.

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