1

PRE FEASIBILITY REPORT

for

PROPOSED PROJECT FOR MANUFACTURING DYES,

DYES INTERMEDIATES AND PIGMENTS

of

M/s. NUCHEM DYESTUFF PVT. LTD.

Plot no-C- 284,285,299,& 300

Saykha Industrial Estate

Taluka: Vagra, Dist- Bharuch

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:

2

CONTENTS

Sr.

No.

Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 11

3. Project Description 13

4. Site Analysis 17

5. Planning Brief 19

6. Proposed Infrastructure 20

7. Rehabilitation and resettlement (R & R) Plan 21

8. Project Schedule & Cost Estimates 21

9. Analysis of Proposal (Final Recommendations) 22

3

1.0 EXECUTIVE SUMMARY

1.1 Company Profile

Introduction

Nuchem is involved in the reactive dyes trading and manufacturing since 1962, by the name

of Kishori Lall Rangwala since 1962, initially started off as a trading house in Reactive dyes

locally in Gujarat and Ludhiana area and then putting up a manufacturing unit with a single

spray dryer in 1996. With a vintage of more than 50 years, Nuchem has achieved a name in

the industry of providing value to its customers with guaranteed quality and service.

Nuchem exports more than 80% of its production to Bangladesh, Indonesia and Thailand

and rest to Ludhiana and Ahmedabad.

Nuchem had a turnover over of approximately 19.25 Crore in the last financial year.

Defying the challenges of the external market such as price competitiveness, rising raw

material prices etc, Nuchem has always had stable orders from customers in all the

locations it markets its products, even sometimes orders had to be deferred or cancelled

from export markets due to restriction in production by GPCB due to pollution related

issues in Nuchem’s older unit.

It is due to above reason, Nuchem decided to set up another large unit in the Industrial

Zone, especially set up by Gujarat Government for dyes and allied chemicals production,

with complete provisions for pollution control, utility services and port availability near

industrial zone.

1.2 Project Details

Sr. No. Name of Product Proposed Capacity (MT/Month)

ACID DYES

100 MT/Month

1 Acid Black 210

2 Acid Black 194

3 Acid Black 235

4 Acid Brown 75

5 Acid Brown 165

6 Acid Brown 161

7 Acid Brown 282

8 Acid Brown 355

9 Acid Brown 432

10 Acid Brown 434

4

11 Acid Brown 425

12 Acid Green 68

13 Acid Blue 113

14 Acid Blue 193

15 Acid Red 119

16 Acid Red 97

17 Acid Red 357

18 Acid Violet 90

19 Acid Yellow 42

20 Acid Orange 142

REACTIVE DYES

1000 MT/Month

1 Reactive Black B and Black Mixes

2 Reactive Orange M2R

3 Reactive Red M8B/H8B

4 Reactive Red ME6BL

5 Reactive Orange ME2RL (Orange - 122)

6 Reactive Red ME4BL (Red- 195)

7 Reactive Golden Yellow ME4RL (Yellow

145)

8 Reactive Golden Yellow HER

9 Reactive Orange H2R

REACTIVE BLUE

1 Blue 3R

2 Blue F4R

3 Blue HERD

4 Blue 221

5 Blue HEGN

6 Blue LFNG

7 Blue BF

8 Blue BFN

5

9 Blue 2B

REACTIVE RED

1 Red mixes

2 Red BS

3 Red RB

4 Red HE3B

5 Red 5B

6 Red F3G

7 Red H7B

8 Red DS4B

9 Red F2B

10 Crimson XLE

11 Red DSGD CONC.

12 Blue Mixes

13 Red SGR

REACTIVE GOLDEN YELLOW

1 Golden Yellow RNL

2 Golden Yellow R

REACTIVE NAVY BLUE

1 NAVY BLUE 2G

2 NAVY RGB

3 NAVY XLE

DIRECT DYES

1 Direct Orange 26

2 Direct Red 31

3 Direct Black 22 100 MT/Month

4 DIRECT BLUE 71

5 DIRECT BLUE 281

6 DIRECT BLUE 218

7 DIRECT RED 239

8 DIRECT BLUE 80

9 DIRECT BLACK 170

6

10 DIRECT BLACK 168

11 DIRECT BLACK 179

12 DIRECT BLACK 80

13 DIRECT BLACK 22

14 DIRECT ORANGE 39

CPC BASE DYES

150 MT/Month

1 Reactive Blue 21

2 Reactive Blue 25

3 DIRECT BLUE 199

4 Reactive blue 72

5 Direct Blue 86

ACRYLIC DYES

100 MT/Month

1 Basic Yellow 28

2 Basic Yellow 13 ( Yellow 8 GL)

3 Basic Blue 54. ( Blue GL).

4 Basic Blue 41( Blue GRL)

5 Basic Blue 3. ( Blue BG).

6 Basic Violate 16. ( Red 2B).

7 Basic Red 18. ( Red GTL).

8 Basic Red 13. ( Pink FG).

9 BASIC RED 14

PIGMENTS 1 Azo Pigments

2 Quinacridone Pigment

200 MT/Month

3 Carbazole Dioxane Violet Pigment

4 CPC Base Pigments

5 Pigment Emulsions

DYES INTERMEDIATES

900 MT/Month

NAPTHANLENE BASE DERIVATIVES

1 H-Acid

2 Vinyl Sulphone

BETA BASE DERIVATIVES

7

1 K-acid

2 Sulfo Tobia Acid

3 Gamma Acid

4 Tobias Acid (SCHAEFFER’S ACID)

5 N Methyl J Acid

CPC BASE DERIVATIVES

1 Amine Base

2 Phthalimide Based

BLUE BASE

Tripheno Dioxazine

Total 2550

LIST OF BY-PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr. No. Name of By-Product Proposed Capacity (MT/Month)

1 Sodium Sulfite salt 130

2 Rec. Acetic Acid 45

1.3 Green Belt Development

Company has developed an effective green belt within the factory and on periphery of the

factory. Total Plot Area is 79603.62 m2, out of which 23873.62 m

2 is Green Belt Area. In

addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.

1.4 Power & Fuel Requirement

Fuel:

Natural Gas 2200 scm / Hr

LDO / FO 560 Liter / Hr

HSD for DG Sets

(for emergency

only.) 80 Liter / Hr

F.O. for lncinerators 40 Liter / Hr

Energy:

4500 KVA from MGVCL

8

DG set - 2500 KVA (In case of Emergency only)

1.5 Water Requirement and Wastewater Generation & Treatment

Source of water requirement will be met through GIDC water supply. Total water

requirement will be 2295 KL/Day. Total 863 KL/Day (835 KL/Day Industrial + 28.0 KL/Day

domestic) of effluent shall be generated; out of which 835 KL/Day will be treated in ETP and

finally Distillate water is reused in to Process & Distillation Residue shall be sent to Captive

Incinerator.

1.6 Air Pollution Source and Control Management

FLUE GAS EMISSION

Sr.

No. Stack Attached to

Height &

Diameter

Fuel

Consumption APCM

A PROPOSED

1. Steam Boiler

Cap. 6 MT/Hr

Height –

30 Meter

Dia.- 800 mm

LDO/FO – 12

MT/Day

Scrubber System

2. Thermic Fluid Heater

Cap. 2.5 MT/hour or 6 Lac

Kcal

Height –

30 Meter

Dia.- 800 mm

Natural Gas -

2200 SCM/Hr

As Natural Gas is used a fuel,

adequate stack height is

provided

3. Incinerator

Height –

35 Meter

Dia.- 1000

mm

FO – 40 Lit/Hr Scrubber System

4. D. G. Set – Stand By

Cap. : 2500 KVA

Height –

11 Meter

Dia.- 150 mm

HSD – 1.6 KL/Day As LDO / HSD are used as a

fuel, adequate stack height is

provided.

9

1.7 Hazardous Waste Management

CAT.

NO.

HAZARDOUS

WASTE

PROPOSED

TOTAL

(MT/Month)

MODE OF

STORAGE METHOD OF DISPOSAL

5.1 Used Oil 0.2 Collected in barrels

& stored in sludge

storage area

Sent to GPCB approved

recycler

33.3 Discarded

barrels/

containers/

liners

5 Stored in sludge

storage area

Sent back to supplier / to

GPCB approved recycler

34.3 ETP Sludge 50 Collected in plastic

/ HDPE bags &

stored in sludge

storage area

Sent to TSDF site for

secured land filling

- MEE Salt * 315 Collected in plastic

/ HDPE bags &

stored in sludge

storage area

Sent to TSDF site for

secured land filling

26.1 Iron Sludge 300 Collected in plastic

/ HDPE bags &

stored in sludge

storage area

Collection, Storage,

Transportation and

Disposal at Nearest TSDF

or sell to Cement Industry

PROCESS GAS EMISSION

Sr.

No. Vent Attached to

Height &

Diameter Pollutants APCM

PROPOSED

1. Process Vent Height –

11 Meters

Dia – 200 mm

HCl, SO2, Cl2 Two stage Scrubber

10

-- Gypsum 650 Collected in plastic

/ HDPE bags &

stored in sludge

storage area

Collection, Storage,

Transportation and

Disposal at Nearest TSDF

or sell to Cement Industry

36.4 Distillation

Residue

55 Collected in barrels

& stored in haz.

waste

storage area

Collection, Storage,

Transportation and sell to

Cement Industry for Co-

processing or Disposal at

Common Incineration Site

D2 Dilute

Sulphuric Acid

880 Collected in tank &

stored in haz.

waste

storage area

To sell manufacturer

Ferrous Sulphate, Copper

Sulphate and Single Super

Phosphate

-- Sodium Sulfite

salt

130 Collected in plastic

/ HDPE bags &

stored in sludge

storage area

Collection, Storage,

Transportation and Sell to

end user

-- Recovered

Acetic Acid

45 Collected in barrels

& stored in haz.

waste

storage area

Collection, Storage,

Transportation and Sell to

end user

D2 Dilute HCl 1200 Collected in tank &

stored in haz.

waste

storage area

To sell manufacturer of

Calcium Chloride and

Dicalcium phosphate

11

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project and project proponent. In case of mining project, a copy

of mining lease/letter of intent should be given.

Identification of the project

Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.

Identification of the project proponent

Presently following are the Directors of the company:-

(1) Mr. Pawan Kumar Goyal

Managing Director

(2) Mr. Rajendra Chandulal Patel

Whole Time Director

(3) Mr. Shravan Goyal

Director

2.2 Brief description of nature of the Project

Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.

2.3 Need for the project and its importance to the country and or region

The objective is to be achieved by:

• Consolidating Business.

• By constantly upgrading the product range.

• Continuously reducing the Costs & improving Quality.

• To generate local employment.

2.4 Demands-Supply Gap

Based on our informal survey of the market with our current customers and various traders,

we have found that there is a big potential for the range of the products we are planning.

These products will be an addition to the current range of our products.

12

2.5 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials will make us very competitive against

imported finished products and we will be able to increase the export of our finished

products.

2.6 Export possibility

Depending on the international demand of products we shall explore the more possibility of

exporting the products.

2.7 Domestic/Export Markets

Majority of the products will be used for International market and rest will be used for

domestic market.

2.8 Employment Generation (Direct and Indirect) due to project

Employment would be as per prevailing norms of state government for skilled and unskilled

people for the proposed expansion project for manufacturing specialty chemical.

13

3.0 Project Description

3.1 Type of Project including interlinked and interdependent projects, if any.

Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.

Category: B-5(f)

No interlinked project has been submitted.

3.2 Location (map showing general location, specific location and project boundary &

project site layout) with coordinates.

Map showing general location

14

Project Site Layout

15

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Major factors involved in the selection of site are listed below:

• Site is very well connected by road

• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation

• Availability of power evacuation facilities

• Availability of water for industrial use

• Availability of common effluent treatment & disposal facility

Modern infrastructure support and amenities at par with industrial estates in other global

markets, including:

� Efficient transport facilities within the industrial estate and to & fro the city area.

� Environment-friendly zone.

� Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer Section-1.2, Page No. 3

3.5 Project Description with process details (a schematic diagram/flow chart showing the

project layout, components of the project etc. should be given)

Please refer Annexure-III in Form-I.

3.6 Raw material required along with estimated quantity, likely source, marketing area of

final products. Mode of transport of raw materials and finished products.

Raw material requirement is referred as Annexure-I in Form-I.

Raw materials and finished products will be transported by road only.

3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Every possible effort will be made to reduce fresh water requirement.

N

16

3.8 Availability of water its source, energy/power requirement and source should be

given.

Fuel:

Proposed

Natural Gas 2200 scm / Hr

LDO / FO 560 Liter / Hr

HSD for DG Sets

(for emergency

only.) 80 Liter / Hr

F.O. for lncinerators 40 Liter / Hr

Energy:

4500 KVA from MGVCL

DG set - 2500 KVA (In case of Emergency only)

Water Source

Water requirement will be met through GIDC water supply.

3.9 Schematic representations of the feasibility drawing which give information of EIA

purpose.

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC

STATUS & BASIC AMENITIES. SITE VISITS BY AND

INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT.

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED

EXPANSION PLANT

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

RISK ANALYSIS

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

17

4.0 Site Analysis

4.1 Connectivity

• Site is very well connected by road & rail

• Availability of power evacuation facilities

• Availability of water for industrial use

4.2 Land Form, Land Use and Land Ownership

It will be incorporated in EIA Studies.

4.3 Topography (along with map)

We will be incorporated topography in EIA Studies.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from

HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette

notification should be given.

It will be incorporated in EIA Studies.

18

4.5 Existing Infrastructure

Existing Infrastructures facilities are listed below:

Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free form cultivation

Availability of power evacuation facilities

Availability of common effluent treatment & disposal facility

4.6 Soil Classification

It will be incorporated in EIA Studies.

4.7 Climatic data from secondary sources

Secondary Sources – Indian Meteorological Department, Ahmedabad and our own weather

station.

4.8 Social infrastructure available

Depending on the growth of the company the required social infrastructure will be

provided.

19

5.0 Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

planning/Development authority classification.

Type of Industry: Proposed Project For Manufacturing Dyes, Dyes Intermediates And

Pigments

Facility: Canteen, Administration, Transportation

5.2 Population Projection

It will be incorporated in EIA Studies.

5.3 Land use planning (breakup along with green belt etc.)

Total Area – 79603.62 m2

Plant Area – 21300 m2

Open Area – 6700 m2

Green Belt Area – 23873.62 m2

5.4 Assessment of Infrastructure Demand (Physical & Social)

It will be incorporated in EIA Studies.

5.5 Amenities/Facilities

It will be incorporated in EIA Studies.

20

6.0 Proposed Infrastructure

Sr.

NO.

PARTICULARS LAND AREA (Sq. m) % OF LAND AREA

USE

1 Plant Area 21300 26.76

2 Storage Area (Raw material & finish

goods) & Administration, Lab &

Other Buildings

22600 28.39

3 Utilities 3000 3.77

4 ETP Area 1130 1.42

5 HW Storage Area 1000 1.26

6 Open Area 6700 8.42

7 Green Belt Area 23873.62 29.99

Total 79603.62 100.00

6.3 Green Belt

Company has developed an effective green belt within the factory and on periphery of the

factory. Total Plot Area is 79603.2 m2, out of which 23873.62 m

2 (30%) is Green Belt Area. In

addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.

6.4 Social Infrastructure

Depending on the growth of the company the required social infrastructure will be

provided.

6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc)

Site is very well connected by road & railway.

6.6 Drinking water Management (Source & Supply of water)

Water requirement will be met through GIDC water supply.

21

6.7 Sewerage System

Sewage pipes would be laid in entire company for the removal and disposal of mainly non-

harmful liquid wastes from the offices, canteen and domestic waste coming from different

sections. These liquid wastes would be treated and disposed by septic tank and soak pit.

6.8 Solid Waste Management

Please refer Section 1.7, Page No. 8.

7.0 Rehabilitation and Resettlement (R & R) Plan

7.1 Policy to be adopted (central/state) in respect of the project affected including home

ousters, land ousters and landless laborers (a brief outline to be given)

There is no habitation on the proposed expansion project area and it is industrial land which

is purchased by company for development of Company, so that R & R policy is not

applicable to this project.

There shall be no displacement of any population in project area.

8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for

the project to be given).

We shall start construction after getting environmental clearance and consent to establish.

We shall start production upon making application for CCA.

8.2 Estimated Project cost along with analysis in terms of economic viability of the

project.

Total costs of the project will Rs. 140 Crore. Capital cost of air & water pollution control

system and environmental monitoring equipments will be Rs. 8 Crore.

22

9. Analysis of Proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to be local people

including tribal population, if any, in the area.

• Employment would be as per prevailing norms of state government for skilled and

unskilled people for the proposed expansion project.

• Social Welfare shall be done.

• Cordial relation with the industry shall be established and representation shall be made

to villagers for help for creation of facilities related to health, education, etc.