Pre-Feasibility Report: Asahi Songwon Colors Ltd. (Unit-II)

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Pre-Feasibility Report

of

Asahi Songwon Colors Ltd. (Unit-II)


Plot No. D2/CH/39, GIDC Dahej,
Dahej, Tehsil: Vagra,
Dist.: Bharuch-392110

Proposed Project for Manufacturing of Pigments (1665 TPM)


Project Activity: 5(f), Category: B
1. INTRODUCTION
Asahi Songwon Colors Ltd. is a leading player in the Indian Pigment
industry and intends to become a leading manufacturer of pigments
around the world. The company is in the manufacturing of CPC Beta Blue
and Blue Crude, exporting substantial production to leading MNCs around
the world on account of quality of its products.
The global dyes and pigments market is projected to reach USD 42.00
billion by 2021, at a CAGR of 5.0% from 2016 to 2021. The growth of the
market is primarily due to increasing population, coupled with growing
demand for dyes & pigments from various applications, such as textile,
paints & coatings, and plastics, among others.
Thus, Asahi Songwon Colors Ltd. (Unit-II) proposes to manufacture
Pigments at Plot No. D2/CH/39, GIDC Dahej, Dahej, Tehsil: Vagra,
Dist.: Bharuch.
The area of the site is 60,000 m2.
Location of the proposed project in industrial estate and 5 km and 10 km
radius around the location are shown below.
2. COST OF PROJECT
The estimated cost of the project is estimated around Rs. 268.55 crores.
Estimated Cost
in Rs. Crores
Land and Land Development 16
Buildings - Civil & structural work 42.5
Godowns/Engg Stores 5.8
Electric Room 2.55
Plant and Machinery 148
Utility Equipments 24.75
Miscellaneous Fixed Assets 6.7
ETP plant & Machinery 20
Stores & Spares 2.25
Total 268.55

Asahi Songwon Colors Ltd. (Unit-II), Dahej 1


3. LOCATION OF PROJECT

Asahi

Asahi Songwon Colors Ltd. (Unit-II), Dahej 2


4. PRODUCTION CAPACITY
Production capacity is prescribe below:
Sr. Product Capacity
No. (MTPM)
A Classical Azo Pigments 1000
B High Performance Pigments 45
C CPC-BC 300
D Alpha Blue 100
E Beta Blue 200
F Pigment Blue-60 20
Total 1665

Proposed
Sr. Color
Color Name CAS No. Capacity
No. Index No.
(MT/month)
A Classical Azo Pigments
1. Pigment Yellow 1 2512-29-0 11680
2. Pigment Yellow 3 6486-23-3 11710
3. Pigment Yellow 12 6358-85-6 21090
4. Pigment Yellow 13 5102-83-0 21100
5. Pigment Yellow 14 5468-75-7 21095
6. Pigment Yellow 16 5979-28-2 20040
7. Pigment Yellow 17 4531-49-1 21105
8. Pigment Yellow 62 12286-66-7 13940
9. Pigment Yellow 65 6528-34-3 11740
10. Pigment Yellow 74 6358-31-2 11741
11. Pigment Red 2 6041-94-7 12310
12. Pigment Red 3 2425-85-6 12120 1000
13. Pigment Red 4 2814-77-9 12085
14. Pigment Red 8 6410-30-6 12335
15. Pigment Red 12 6410-32-8 12385
16. Pigment Red 31 6448-96-0 12360
17. Pigment Red 41 6505-29-9 21200
18. Pigment Red 48:2 7023-61-2 15865:2
19. Pigment Red 49:2 1103-39-5 15630:2
20. Pigment Red 53:2 67990-35-6 15585:2
21. Pigment Red 57:1 17852-98-1 15850:2
22. Pigment Red 63:2 35355-77-2 15880:2
23. Pigment Red 112 6535-46-2 12370
B High Performance Pigments
1. Pigment Orange 05 3468-63-1 12075
2. Pigment Orange 13 3520-72-7 21110
3. Pigment Orange 34 15793-73-4 21115
4. Pigment Orange 36 12236-62-3 11780
5. Pigment Orange 64 72102-84-2 12760
6. Pigment Yellow 83 5567-15-7 21108
45
7. Pigment Yellow 97 12225-18-2 11767
8. Pigment Yellow 110 5590-18-1 56280
9. Pigment Yellow 114 71872-66-7 21092
10. Pigment Yellow 138 56731-19-2 56300
11. Pigment Yellow 139 36888-99-0 56298
12. Pigment Yellow 150 68511-62-6 12764

Asahi Songwon Colors Ltd. (Unit-II), Dahej 3


13. Pigment Yellow 151 61036-28-0 13980
14. Pigment Yellow 152 20139-66-6 21111
15. Pigment Yellow 154 68134-22-5 11781
16. Pigment Yellow 155 68516-73-4 200310
17. Pigment Yellow 168 71832-85-4 13960
18. Pigment Yellow 174 78952-72-4 21098
19. Pigment Yellow 180 77804-81-0 21290
20. Pigment Yellow 181 74441-05-7 11777
21. Pigment Yellow 183 65212-77-3 18792
22. Pigment Yellow 191:1 154946-66-4 18795:1
23. Pigment Red 146 5280-68-2 12485
24. Pigment Red 170 2786-76-7 12475
25. Pigment Red 176 12225-06-8 12515
26. Pigment Red 177 4051-63-2 65300
27. Pigment Red 184 99402-80-9 12487
28. Pigment Red 185 51920-12-8 12516
29. Pigment Red 187 59487-23-9 12486
30. Pigment Red 188 61847-48-1 12467
31. Pigment Red 210 61932-63-6 12477
122390-98-1/
32. Pigment Red 254 56110
84632-65-5
33. Pigment Red 264 88949-33-1 561300
34. Pigment Red 122 980-26-7 73915
35. Pigment Violet 19 1047-16-1 73900
36. Pigment Violet 23 215247-95-3 51319
C CPC-BC 147-14-8 74160 300
Alpha Blue (15:0/
D 147-14-8 74160 100
15:1/15:2/15:3/15:4)
E Beta Blue 147-14-8 74160 200
F Pigment Blue 60 81-77-6 -- 20
Total 1665

5. MANPOWER REQUIREMENTS
Total manpower requirement at all level of plant will be 350.
6. ENERGY & FUEL REQUIREMENTS
 Energy requirement for the proposed project will be 5128 kVA, and
will be sourced from Dakshin Gujarat Vij Company (DGVCL).
 Coal requirement will be 60 TPD for boilers and thermic fluid heater.
 Diesel requirement will be 50 Liter per hour (for each D.G. set of 500
kVA each)
7. RAW MATERIALS REQUIREMENTS
Sr. List of products List of raw materials Quantity
No. (MT/MT)
A Classical Azo Pigments
1 Pigment Yellow 1 4 methyl 2-nitrobenzeneamine 0.521
HCl (35%) 0.700
Sodium nitrite (40%) 0.420
Sodium hydroxide (50%) 0.080
Acetoacitanilide 0.507

Asahi Songwon Colors Ltd. (Unit-II), Dahej 4


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Sodium acetate 0.020
2 Pigment Yellow 3 4 chloro 2-nitrobenzeneamine 0.529
HCl (35%) 0.700
Sodium nitrite (40%) 0.420
Sodium hydroxide (50%) 0.080
2-chloroacetoacitanilide 0.519
Sodium acetate 0.020
3 Pigment Yellow 12 Acetoacetanilide 0.595
Sodium Hydroxide (50%) 0.300
Acetic acid 0.023
Hydrochloric acid (35%) 1.077
3,3-dichlorobenzidine 0.410
Sodium nitrite 0.220
Sodium hydroxide (15%) 0.095
4 Pigment Yellow 13 Acetoacet-2:4-dimethylanilide 0.614
Sodium Hydroxide (50%) 0.130
Acetic acid 0.017
Hydrochloric acid (35%) 1.201
3,3-dichlorobenzidine 0.387
Sodium nitrite 0.204
Sodium hydroxide (15%) 0.087
5. Pigment Yellow 14 Acetoacet-2-toluidide 0.595
Sodium Hydroxide (50%) 0.287
Acetic acid 0.022
Hydrochloric acid (35%) 1.031
3,3-dichlorobenzidine 0.407
Sodium nitrite 0.212
Sodium hydroxide (15%) 0.091
6. Pigment Yellow 16 2,5 dichloroaniline 0.475
HCl (35%) 0.945
Sodium nitrite (40%) 0.557
Sodium hydroxide (50%) 0.108
3,3-dimethylbiphenyl-3 oxybutanamide 0.526
Sodium acetate 0.024
7. Pigment Yellow 17 Acetoacet-2-anisidide 0.616
Sodium Hydroxide (50%) 0.273
Acetic acid 0.021
Hydrochloric acid (35%) 0.981
3,3-dichlorobenzidine 0.387
Sodium nitrite 0.202
Sodium hydroxide (15%) 0.086
8. Pigment Yellow 62 4-amino-2-nitrobenzene 0.534
HCl (35%) 0.558
Sodium nitrite (40%) 0.307

Asahi Songwon Colors Ltd. (Unit-II), Dahej 5


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Sodium hydroxide (50%) 0.189
acetic acid 0.023
acetoacetyl o- toluedide 0.412
calcium chloride 0.473
9. Pigment Yellow 65 HCl (31%) 1.020
2-nitro-4-methoxyaniline 0.450
Sodium nitrite (40%) 0.452
Sodium hydroxide 0.102
Acetoacet-2-anisidide 0.553
Sodium acetate 0.032
10. Pigment Yellow 74 HCl (31%) 1.020
2-methoxy-4-nitroaniline 0.453
Sodium nitrite (40%) 0.452
Sodium hydroxide 0.102
Acetoacet-2-anisidide 0.553
Sodium acetate 0.032
11. Pigment Red 2 HCl (31%) 0.903
2,5-dichloroaniline 0.385
Sodium nitrite (40%) 0.400
Sodium hydroxide 0.090
3-hydroxy-2-naphthanilide 0.618
Sodium acetate 0.022
12. Pigment Red 3 HCl (35%) 1.220
4-methyl 2-nitrobenzeneamine 0.554
Sodium nitrite 0.225
Sodium hydroxide 0.288
Naphthalen-2-ol 0.458
Sodium acetate 0.025
13. Pigment Red 4 HCl (35%) 0.800
2-chloro 4-nitrobenzeneamine 0.527
Sodium nitrite 0.355
Sodium hydroxide 0.288
Naphthalen-2-ol 0.458
Sodium acetate 0.020
14. Pigment Red 8 HCl (35%) 0.850
2-methyl-4-nitroaniline 0.331
Sodium nitrite (40%) 0.377
Sodium hydroxide 0.193
4'-chloro-3-hydroxy-2'-naphthanilide 0.645
Sodium acetate 0.026
15. Pigment Red 12 HCl (35%) 0.940
2-methyl-4-nitrobenzeneamine 0.426
Sodium nitrite (40%) 0.417
Sodium hydroxide (50%) 0.214

Asahi Songwon Colors Ltd. (Unit-II), Dahej 6


Sr. List of products List of raw materials Quantity
No. (MT/MT)
4'-chloro-3-hydroxy-2'-naphthanilide 0.577
Sodium acetate 0.030
16. Pigment Red 31 N-(3-Amino-4-methoxy 0.352
phenyl)benzamide
Hydrochloric acid (35%) 0.800
Sodium nitrite (38%) 0.355
Sodium hydroxide (50%) 0.090
3-hydroxy-N-(3-nitro phenyl)-2 0.678
naphthamide
sodium acetate 0.025
17. Pigment Red 41 Sodium hydroxide (50%) 0.415
1-phenyl 3-methyl, 5-pyrazoline 0.590
HCl (35%) 0.050
acetic acid 0.025
3,3 dimethoxy benzidine 0.428
sodium nitrite 0.233
18. Pigment Red 48:2 Sodium hydroxide (33%) 0.266
2-amino-4-chloro-5-methyl benzene- 0.486
sulfonic acid
Hydrochloric acid (31%) 0.684
Sodium nitrite (38%) 0.300
3-hydroxy naphthalene-2- carboxylic 0.417
acid
Calcium Chloride 0.534
19. Pigment Red 49:2 Sodium hydroxide (33%) 0.276
2-amino naphthalene-1-sulfonic acid 0.505
Hydrochloric acid (35%) 0.710
Sodium nitrite (38%) 0.310
naphthale-2-ol 0.327
Calcium Chloride 0.555
20. Pigment Red 53:2 Sodium hydroxide (33%) 0.138
2-amino-5-chloro-4-methyl benzene- 0.505
sulfonic acid
Hydrochloric acid (35%) 0.710
Sodium nitrite (38%) 0.310
Sodium hydroxide (33%) 0.138
naphthale-2-ol 0.333
Calcium Chloride 0.555
21. Pigment Red 57:1 Sodium hydroxide (33%) 0.288
2-amino-5-methyl benzene sulfonic acid 0.445
Hydrochloric acid (31%) 0.740
Sodium nitrite (38%) 0.323
3-hydroxynaphthalene-2-carboxylic acid 0.445
Calcium Chloride 0.578

Asahi Songwon Colors Ltd. (Unit-II), Dahej 7


Sr. List of products List of raw materials Quantity
No. (MT/MT)
22. Pigment Red 63:2 HCl (35%) 0.684
2 aminonaphthalene 1-sulfonic acid 0.486
Sodium hydroxide (33%) 0.266
Sodium nitrite (38%) 0.299
3-hydroxy-naphthalen 2-carboxylic 0.411
calcium chloride 0.534
23. Pigment Red 112 HCl (31%) 0.800
2,4,5-trichloroaniline 0.405
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
3-hydroxy-2'methyl-2-naphthanilide 0.567
Sodium acetate 0.030
B High performance Pigments
1. Pigment Orange 05 HCl 1.220
Sodium Nitrite 0.225
2,4-Dinitrobenzenamine 0.554
Napthalan 2 ol 0.458
Sodium Hydroxide 0.288
Sodium Acetate 0.025
Rosin Solution 0.002
2. Pigment Orange 13 1-phenyl-3-methyl-5-pyrazoline 0.590
Sodium Hydroxide (50%) 0.265
Acetic acid 0.035
Hydrochloric acid (35%) 0.050
3,3-dichlorobenzidine 0.428
Hydrochloric acid (31%) 1.080
sodium nitrite 0.233
Sodium Hydroxide (15%) 0.100
3. Pigment Orange 34 1-p-tolyl-3-methyl pyrazol-5-one 0.648
Sodium Hydroxide (50%) 0.315
Acetic acid 0.025
Hydrochloric acid (35%) 1.130
3,3-dichlorobenzidine 0.441
sodium nitrite 0.233
Sodium hydroxide (15%) 0.100
4. Pigment Orange 36 HCl (31%) 0.800
4-chloro-2-nitroaniline 0.363
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.182
5-acetoacetyl amino benzimidazolone 0.491
Sodium acetate 0.175
5. Pigment Orange 64 HCl (31%) 0.800
5-amino-6-methyl-1,3-dihydro-2H 0.726
benzimidazol-2-one

Asahi Songwon Colors Ltd. (Unit-II), Dahej 8


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Sodium nitrite (40%) 0.335
Sodium acetate 0.025
Barbituric acid 0.278
6. Pigment Yellow 83 Acetoacet-2:5-dimethoxy-4-chloroanilide 0.928
Sodium Hydroxide (50%) 0.315
Acetic acid 0.018
Hydrochloric acid (35%) 1.370
3,3-dichlorobenzidine 0.441
Sodium nitrite 0.233
Sodium hydroxide (15%) 0.100
7. Pigment Yellow 97 HCl 0.800
Sodium Nitrite 0.650
Amine 0.618
Coupler 0.339
Sodium Hydroxide 0.080
Sodium Acetate 0.070
8. Pigment Yellow 110 o-Dichlorobenzene 0.225
1,4-Diaminobenzene 0.220
3,3,4,5,6,7-Hexachloro-2,3-dihydro-1H- 0.970
isoindol-1-one
Methanol 0.200
9. Pigment Yellow 114 N-Acetoacetyl-4-methylaniline 0.434
Acetoacetanilide 0.494
Sodium Hydroxide 0.415
Acetic Acid 1.500
HCl 1.419
3,3-dichlorobenzidine 0.441
Sodium Nitrite 0.233
Sodium Acetate 0.070
10. Pigment Yellow 138 ODCB 0.150
8-aminoquinaldine 0.261
Tetra chloro phthalic anhydride 0.800
Methanol 0.200
11. Pigment Yellow 139 Sodium methoxide (30%) 0.075
1,2-Dicynobenzene 0.457
Barbituric acid 0.634
Acetic acid 0.025
MCB 0.050
Surfactant 0.005
12. Pigment Yellow 150 Aminoguanidine bicarbonate 0.050
Hydrochloric acid (30%) 0.560
Potassium nitrite (37%) 0.064
Barbituric acid 0.820
Potassium hydroxide 0.020

Asahi Songwon Colors Ltd. (Unit-II), Dahej 9


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Melamine 0.025
Nickel chloride (6.5%) 1.500
13. Pigment Yellow 151 2-aminobenzoic acid 0.292
Hydrochloric acid (31%) 0.590
Sodium nitrite (40%) 0.325
Sodium hydroxide (25%) 0.100
5-Acetoacetylamino-benzimidazolone 0.485
Acetic acid 0.020
Sodium Hydroxide (10%) 0.100
Xylene 0.005
Caustic 0.005
14. Pigment Yellow 152 N-(4-ethoxyphenyl)-3-oxo butanamide 0.928
Sodium Hydroxide 0.415
Acetic Acid 0.025
HCl 1.370
3,3-dichlorobenzidine 0.441
Sodium Nitrite 0.233
15. Pigment Yellow 154 2-(trifluoromethyl)aniline 0.409
Hydrochloric acid (31%) 0.715
Sodium nitrite (40%) 0.393
Sodium hydroxide (25%) 0.121
5-Acetoacetylamino-benzimidazolone 0.587
acetic acid 0.024
Sodium Hydroxide (10%) 0.121
Xylene 0.006
Caustic 0.006
16. Pigment Yellow 155 HCl (31%) 1.200
Dimethyl-2-amino-terephthalate 0.707
Sodium nitrite (40%) 0.650
Sodium hydroxide 0.080
1,4-bis (aceto acetylamino) benzene 0.291
sodium acetate 0.025
HCl (31%) 1.200
Dimethyl-2-amino-terephthalate 0.707
17. Pigment Yellow 168 Sodium Nitrite 0.325
4-Amino-3-nitro benzenesulfonic acid 0.590
Acetic acid 0.020
N-(2-chloro phenyl)-3-oxo butanamide 0.518
Sodium Hydroxide 0.300
Calcium Chloride 0.500
18. Pigment Yellow 174 HCl (31%) 0.800
3,3-dichlorobenzidine 0.536
Sodium nitrite (40%) 0.710
Sodium hydroxide 0.050

Asahi Songwon Colors Ltd. (Unit-II), Dahej 10


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Acetoacet-2-methylanilide 0.220
Acetoacet-2:4-dimethylanilide 0.430
Sodium acetate 0.020
19. Pigment Yellow 180 2’-(Ethylene dioxy) dianiline acid 0.522
Sodium Nitrite 0.325
HCl 0.590
Acetic acid 0.020
5- aceto acetyl amino benzimidazolone 0.485
Sodium Hydroxide 0.200
Caustic 0.005
Xylene 0.095
20. Pigment Yellow 181 4-(4-Aminobenz amido)benzamide 0.522
Sodium Nitrite 0.325
HCl 0.590
Acetic acid 0.020
5- aceto acetyl amino benzimidazolone 0.485
Sodium Hydroxide 0.200
Caustic 0.005
Xyline 0.005
4-(4-Aminobenz amido)benzamide 0.522
21. Pigment Yellow 183 Sodium hydroxide (33%) 0.546
2-Amino-4,5-dichloro-benzenesulfonic 0.511
acid
Hydrochloric acid (31%) 0.640
Sodium nitrite (38%) 0.280
1-(3'-Sulfophenyl)-3-methyl-5- 0.568
pyrazolone
Calcium Chloride 0.250
22. Pigment Yellow Sodium hydroxide (33%) 0.540
191:1 2-amino-4chloro-5-methyl- 0.478
benzenesulfonic acid
Hydrochloric acid (31%) 0.640
Sodium nitrite (38%) 0.280
1-(3'-sulfophenyl)-3-methyl-5- 0.512
pyrazolone
Ammonium Chloride 0.250
23. Pigment Red 146 HCl (31%) 0.800
3-amino-4-methoxybenzanilide 0.502
Sodium nitrite (40%) 0.330
Sodium hydroxide 0.080
4'-chloro-3-hydroxy-2-5'dimethoxy-2- 0.738
naphthanilide
sodium acetate 0.020
HCl (31%) 0.800

Asahi Songwon Colors Ltd. (Unit-II), Dahej 11


Sr. List of products List of raw materials Quantity
No. (MT/MT)
24. Pigment Red 170 HCl (31%) 0.800
4-aminobenzamide 0.280
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
N-(2-ethoxyphenyl)-3- 0.630
hydroxynaphthalene-2-carboxamide
sodium acetate 0.095
HCl (31%) 0.800
4-aminobenzamide 0.280
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
25. Pigment Red 176 HCl (31%) 0.800
Amine 0.495
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
Coupler 0.652
Sodium acetate 0.020
26. Pigment Red 177 Polyethylene glycol 1.000
Potassium hydroxide 0.300
Sodium chlorate 0.025
1-amino-4-bromo anthracene-9,10-dione 1.300
27. Pigment Red 184 N-(3-amino-4- 0.502
methoxyphenyl)benzamide
Sodium Nitrite 0.355
HCl 0.800
Sodium hydroxide 0.080
5-Chloro-2-methylphenyl ) methanone 0.726
Sodium acetate 0.020
28. Pigment Red 185 2-Methyl-4-amino-5-methoxy-N-methyl 0.412
benzene sulfonamide
Sodium Nitrite 0.355
HCl 0.800
Sodium hydroxide 0.080
3-Hydroxy-N-2-naphthamide 0.544
Sodium acetate 0.020
29. Pigment Red 187 3-Amino-4-methoxy-4-carbamoyl 0.439
benzanilide
Sodium Nitrite 0.355
HCl 0.800
Sodium hydroxide 0.080
3-Hydroxy-5-chloro-2,4-dimethoxy-2- 0.738
naphthanilide
Sodium acetate 0.020
30. Pigment Red 188 2′,5′-Dichloro-3-amino-4-methoxy 0.531

Asahi Songwon Colors Ltd. (Unit-II), Dahej 12


Sr. List of products List of raw materials Quantity
No. (MT/MT)
carbonylbenzanilide
Sodium Nitrite 0.355
HCl 0.800
Sodium hydroxide 0.080
2′-Methoxy-3-hydroxy-2-naphthanilide 0.450
Sodium acetate 0.020
31. Pigment Red 210 HCl (31%) 0.800
4-aminobenzamide 0.382
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
3-hydroxy-N-(2-methoxy phenyl) 0.600
naphthalene-2-carboxamide
Sodium acetate 0.020
32. Pigment Red 254 Tert-amyl alcohol 0.400
p-chlorobenzonitrile 0.985
Potassium tert-butoxide 0.070
Di-isopropylsuccinate 0.556
Methanol 0.320
33. Pigment Red 264 Tert-amyl alcohol 0.400
4-phenylbenzylnitrile 1.132
Potassium tert-butoxide 0.050
Di-isopropylsuccinate 0.638
Methanol 0.320
34. Pigment Red 122 HCl (31%) 0.800
2,4,5-trichloroaniline 0.405
Sodium nitrite (40%) 0.355
Sodium hydroxide 0.080
3-hydroxy-2'methyl-2-naphthanilide 0.567
Sodium acetate 0.030
35. Pigment Violet 19 Succinyl-succinic acidsimethylester 0.600
Aniline 0.500
Methanol 0.200
HCl 0.320
36. Pigment Violet 23 ODCB 0.300
aminoethylcarbazole 0.732
sodium acetate 0.025
chloranil 0.425
benzene sulpho chloride 0.025
C CPC-BC Cuprous Chloride 0.178
Phthalic Anhydrous 1.050
solvent 0.050
Urea 1.400
Ammo. Molybdate 0.005
Spent Acid from alpha blue 1.500

Asahi Songwon Colors Ltd. (Unit-II), Dahej 13


Sr. List of products List of raw materials Quantity
No. (MT/MT)
Caustic lye 0.150
D Alpha CPC(grinded) 1.000
Blue(15:0/15:1 Sulphuric Acid 6.000
/15:2/15:3/15:4) Surfactant/Additive 0.030
Caustic 0.100
E Beta blue CPC 1.050
Sulphuric acid 0.405
Caustic Flacks 0.150
IBA 0.100
Dispersing Agent 0.010
F Pigment Blue 60 polyethylene glycol 1.350
potassium hydroxide 0.270
sodium chlorate 0.112
2-aminoanthraquinone 1.023
sodium chlorate 0.045

8. MANUFACTURING PROCESS
Detailed manufacturing process is given in Annexure-II of Form-I.
9. WATER REQUIREMENTS AND WASTEWATER GENERATION
The total fresh water requirement will be 555 KL/day, which will fulfill by
GIDC water supply. The breakup of water consumption and wastewater
generation is given below.
Sr. Source Water Wastewater
No. Consumption Generation
(KLD) (KLD)
I Domestic 10 8
II Gardening 50 0
III Industrial
a) Process 1289 1290
b) Scrubber 6 0
c) Boiler 255 25
d) Cooling 200 50
e) Water treatment 40 40
f) Lab 5 5
g) Washing 100 100
Total Industrial 1895 1510
Total (I+II+III) 1955 1518
Recycle water 1400 --
Actual fresh water 555 --
requirement

Asahi Songwon Colors Ltd. (Unit-II), Dahej 14


Water Balance Diagram
Total water consumption= 1955 KLD
[555 (Fresh water) + 1400* (recycle)]

Domestic Lab Scrubber Process Washing Utility Greenbelt


10 5 6 1289 100 495 50

Ice
Soak pit Live Steam Water
3.0 Reject
8 liquid 60 treatment
amm Water 495 40
(20%) retained
17 RM
39

Boiler Cooling
Total Volume Make up
255
1391 200

5 D. L.
101 Blow
down Bleed
25 Off
100 50
1290

ETP
5+1290+100+25+50+40=1510

OR
W/w To CETP-
1510 Dahej
RO
Permeate
1510 975*

Reject
535

MEE Condensate
535 425*

Loss Spray Dryer Salt


90 110 20

Asahi Songwon Colors Ltd. (Unit-II), Dahej 15


10. SOURCES OF POLLUTION AND MITIGATION MEASURES
A. Air Pollution
Flue gas emission will be from stack attached with boiler & Thermic Fluid
Heater (TFH), where coal/briquettes will be used as fuel; and D.G. Set, in
which Diesel will be used as fuel. Process emissions will be from process
vents and spin flash dryer. Most probable pollutants will be SPM, SO2,
NOx and NH3.
Adequate stack height will be provided to control & disperse the air
pollutants within the satisfactory levels. Furthermore, facility for sampling
such as ladder and sampling point will be provided as per the GPCB
guidelines. The details of stacks with their APC measures & height are
given in below.
Sr. Stack attached to Fuel Fuel Stack APC Probable
No. Type consumption Height in measures emission
rate (m)
 Flue Gas Stacks
1 Boiler - 1 (10 TPH) Coal/ 60 30 Electrostatic SPM <150
Briquettes MT/day Precipitator mg/Nm3
(ESP) SO2 <100 ppm
2 Boiler - 2 (10 TPH) 30 Electrostatic NOx <50 ppm
Precipitator
(ESP)
3 Thermic Fluid 30 Electrostatic
heater (25 Lakhs Precipitator
K.cal/hr) (ESP)
4 D.G. set- 4 Nos. HSD 50 lit/hr 15 ---
(500 KVA each) each
 Process Gas Stacks
5 Process vents -- -- 21 Two stage NH3 <175
(4 Nos.) water mg/Nm3
scrubber
followed by
an acid
scrubber
6 Process vents -- -- 11 Two stage SO2 < 40
(1 Nos.) water mg/Nm3
and alkali
scrubber
7 Spin Flash Dryers -- -- 11 In built
SPM <150
(5 Nos.) Cyclone and
mg/Nm3
Bag Filters

Asahi Songwon Colors Ltd. (Unit-II), Dahej 16


B. Water Pollution
Main source of effluent generation will be from process, utilities &
washing.
Scheme for Wastewater Treatment
Process effluent (Concentrated stream) along with wastewater of lab,
washing and utility will be taken to RO after primary treatment. RO reject
will be sent to MEE; RO permeate and condensate of MEE will be reused.
MEE reject will be further spray dried in spray dryer. Domestic
wastewater will be disposed off to soak pit. Thus, achieving zero liquid
discharge (ZLD). After the commencement of CETP, Industrial
effluent will be disposed to CETP.
C. Hazardous Wastes
Entire quantity of hazardous waste will be handled & disposed as per
Hazardous & Other waste (Management & Transboundary Movement)
Rules, 2016. The unit will provided isolated area with impervious flooring
& roof cover for the storage of hazardous waste. Details of hazardous
waste and disposal are given below.
Sr. Type of Waste Category of Quantity Disposal facility
No. Waste as per
HWM Rules
2016
1. ETP Sludge 35.3 150 Collection, Storage, Transportation
MT/Month and disposal at TSDF site approved
by GPCB
2. Evaporation salt 35.3 520 Collection, Storage, Transportation
MT/Month and disposal at TSDF site approved
by GPCB
3. Copper sulphide -- 10.5 Collection, Storage, Transportation
(Sludge) MT/Month and sold to actual end
users/registered recyclers
4. Ammonia -- 435 Collection, Storage, Transportation
Solution (10%) MT/Month and sold to actual end users.
5. Discarded 33.1 2400 Collection, Storage, Transport,
Drum/Container Nos./month Decontamination and used for
/Bags/liners sludge packaging or if in excess
sold to actual end users.
6. Spent Oil 5.1 1 KL/year Collection, Storage, Transportation
and sell to GPCB approved recycler
7. Process 26.1 35 Collection, Storage, Transportation
residues MT/Month and disposal at CHWIF facility for
co-processing
8. Filter Material -- 8 MT/Month Collection, Storage, Transportation
and disposal at TSDF site approved
by GPCB

Asahi Songwon Colors Ltd. (Unit-II), Dahej 17


Details of Solid waste
Sr. Type of Quantity Disposal facility
No. Waste
1. Fly Ash 125 Collection, Storage, Transportation
MT/Month and sell to brick manufacturer /used
for land filling

11. GREEN BELT DEVELOPMENT


The unit proposes to earmarked space for development of green belt
along the plan periphery to arrest noise pollution and fugitive emissions
as well as to improve aesthetics.
12. FUNDS FOR POLLUTION CONTROL MEASURES
The management is quite conscious of its responsibility for maintaining
clear environment. Thus, around Rs. 18 crores will be provided for the
pollution control measures as a part of overall project financing.
13. MONITORING FACILITIES
Company is ready to carry out monitoring proposed by pollution control
board from time to time through outside agency.
14. CONCLUSION
On the basis of information presented here on pollution control measures
and its implementation, there will be no emission from the plant beyond
the norms specified by the Board as per the provisions of Water
(Prevention and Control of Pollution) Act, 1974 and Air (Prevention and
Control of Pollution) Act, 1981.

Asahi Songwon Colors Ltd. (Unit-II), Dahej 18

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