Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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Pre-Feasibility Report
For
Proposed expansion
of
Synthetic Organic Chemical Manufacturing
facility
Schedule 5 (f)
Category A
Prepared By
Roha Dyechem Private Limited (Unit II)
Plot No 23/1/1, MIDC Dhatav,
Tal Roha, Dist Raigad, Maharashtra.
www.roha.com
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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Table of Contents
1 EXECUTIVE SUMMARY ............................................................................................................................. 4
2 INTRODUCTION OF THE PROJECT ............................................................................................................. 7
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ........................................................................ 7
MANAGEMENT TEAM ............................................................................................................................................. 7
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ......................................................................................... 7
2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ............................................ 8
2.4 DEMAND – SUPPLY GAP .............................................................................................................................. 8
2.5 IMPORTS VS INDIGENOUS PRODUCTION ........................................................................................................ 8
2.6 EXPORT POSSIBILITY .................................................................................................................................. 8
2.7 DOMESTIC / EXPORT MARKET ..................................................................................................................... 8
2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT .................................................... 8
3 PROJECT DESCRIPTION ............................................................................................................................. 9
3.1 TYPE OF PROJECT ...................................................................................................................................... 9
3.2 LOCATION ................................................................................................................................................. 9
3.3 DETAILS OF ALTERNATIVE SITES ............................................................................................................... 10
3.4 SIZE OR MAGNITUDE OF OPERATION ........................................................................................................... 10
3.5 PROJECT DESCRIPTION WITH PROJECT DETAILS .......................................................................................... 10
3.6 RAW MATERIAL REQUIRED........................................................................................................................ 11
3.7 RESOURCE OPTIMIZATION ......................................................................................................................... 12
3.8 WATER, ENERGY / POWER AVAILABILITY AND SOURCE ............................................................................... 12
3.8.1 Water........................................................................................................................................... 12
3.8.2 Energy ......................................................................................................................................... 12 Existing and proposed Air pollution control systems at site ................................................................................ 12
3.8.3 Power .......................................................................................................................................... 13
3.9 WASTE GENERATION, MANAGEMENT AND DISPOSAL ................................................................................... 13
3.9.1 Waste water ................................................................................................................................ 13
3.9.2 Non hazardous waste ................................................................................................................. 13
3.9.3 Hazardous waste ........................................................................................................................ 13
3.10 SCHEMATIC OF EIA PURPOSE .................................................................................................................... 14
4 SITE ANALYSIS ........................................................................................................................................ 15
4.1 CONNECTIVITY ........................................................................................................................................ 15
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................................................... 15
4.3 TOPOGRAPHY & GEOLOGY ........................................................................................................................ 15
4.4 EXISTING LAND USE PATTERN ................................................................................................................... 15
4.5 EXISTING INFRASTRUCTURE ...................................................................................................................... 15
4.6 SOIL CLASSIFICATION ............................................................................................................................... 15
4.7 CLIMATE DATA FROM SECONDARY SOURCES ................................................................................................ 16
4.8 SOCIAL INFRASTRUCTURE AVAILABLE ........................................................................................................ 16
5 PLANNING BRIEF .................................................................................................................................... 17
5.1 PLANNING CONCEPT ................................................................................................................................ 17
5.2 POPULATION PROJECTION ........................................................................................................................ 17
5.3 LAND USE PLANNING ................................................................................................................................ 17
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) .......................................................... 17
5.5 AMENITIES / FACILITIES .......................................................................................................................... 17
6 PROPOSED INFRASTRUCTURE ................................................................................................................ 18
6.1 INDUSTRIAL AREA (PROCESSING AREA) ..................................................................................................... 18
6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ............................................................................................ 18
6.3 GREEN BELT ........................................................................................................................................... 18
6.4 SOCIAL INFRASTRUCTURE ......................................................................................................................... 18
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6.5 CONNECTIVITY ........................................................................................................................................ 18
6.6 DRINKING WATER MANAGEMENT .............................................................................................................. 18
6.7 EFFLUENT TREATMENT SYSTEM ................................................................................................................ 18
6.8 INDUSTRIAL WASTE MANAGEMENT ............................................................................................................ 19
6.9 POWER REQUIREMENT AND SUPPLY / SOURCE ............................................................................................ 19
7 REHABILITATION & RESETTLEMENT PLAN .............................................................................................. 20
8 PROJECT SCHEDULE AND COST ESTIMATES ............................................................................................ 21
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ............................................... 21
8.2 ESTIMATED PROJECT COST ........................................................................................................................ 21
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) .................................................................... 22
List of Annexures
Annexure
No
Description Page no
I Plant location / Google image of plant site 23
II Layout plant of the proposed expansion 24
III Proposed effluent treatment scheme 26
IV Process description 27
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1 EXECUTIVESUMMARY
Roha Dyechem Pvt. Ltd. established in 1972, is a leading Indian MNC engaged in
Manufacture and Marketing of colors and food ingredients. It has offices in 22 countries,
13 technical application labs in many time zones globally. Manufacturing facilities are
spread out across 13 countries. Roha dyechem’s products are marketed in more than
130 countries. Its product range includes industrial colors and inks, animal feed
additives, natural extracts (juices and concentrates) and an exclusive range of synthetic
colors for the cosmetics and household goods industries.
At the core of this company is its 300,000 sq. ft., state-of-the-art production facility in
the Roha district of Maharashtra, India, which meets the highest international standards
and norms.
In support are Roha’s 12 other manufacturing centers in the US, UK, Spain, South Africa,
Vietnam, Indonesia, Thailand, China, Egypt, Brazil, Australia & Mexico.
Our Brands:
A comprehensive range of synthetic colors manufactured to meet norms of every individual country
across global markets; it covers a spectrum of food products and drugs & pharmaceuticals. Available
as water soluble & lake colors in a free-flowing powder for dry applications or in granular sizes or
even as dispersions in customized pack sizes, these are a global leader in their category.
As a globally leading manufacturer of food colors, Roha has moved quickly to address the growing
global demand for products that are drawn from nature. Roha has a portfolio of natural colors that
covers the entire spectrum of our clients’ requirements.
Our range comes with the promise of four decades of expertise in customer service and purity
standards. Quality standards that ensure consistency in shades, every time.
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Futurals is a wide range of brilliant and stable shades of coloring foodstuffs & extracts (juices and
concentrates) of fruit, vegetables, herbs, flowers and algae. The entire range of extracts is sourced in
a manner that maintains the natural and essential characteristics without chemical processes or
modifications. The range facilitates ‘clean labels’ that consumers across the globe are favoring.
While Roha is recognized across the world as a leader in colors for the food, cosmetics and
pharmaceuticals industries, there was a gap in the product line.
Simpsons has filled this gap with its range of all kinds of dyes and pigments for industries including
cleaners, plastics, rubber, inks, automobiles and printing to name but a few. A balance of quality,
efficient service and competitive Pricing for business success, Simpsons is ideal for customers in
every part of the world.
Roha understands the art and the science of food & feed color like few others. Through a variety of
choice ingredients sourced from around the world, and rigorous research, we can help you create
animal feeds that make your animal products look as great as they taste.
Roha is one of the most trusted manufacturers of colors for leading Personal Care and Cosmetic
companies across the globe. Marketed under the brand name Adora, it is a range that is designed in
accordance with stringent legislations to meet the highest standards.
Certifications:
In recognition of our consistent efforts towards providing superior quality products and services, we
have been certified by most leading regulatory bodies across the world.
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The facility of Roha dyechem at Plot No 23/1/1 (Unit II) MIDC Dhatav has consent to operate for
50 TPM natural colors.
Due to increased demand of food colors, Roha dyechem wish to expand its manufacturing base
at Plot no 23/1/1 as follows,
The project brief is summarized in the table below Project summary at a glance
Table 1: Brief Project summary
Sr. No Particulars Details
1 Name of Company M/s. Roha Dyechem Pvt. Ltd. (Unit – II)
2 Products Refer section 2
3 Location Plot No 23/1/1, MIDC Dhatav, Tal Roha , Dist Raigad
4 Name of the project Proposed expansion for manufacturing of Synthetic Organic
Chemicals
5 Total land area of the
plot
6,958 sq.m
6 Fresh Water
requirement
Existing requirement (Total) = 30 cmd.
Proposed additional fresh water requirement = 425 cmd
from MIDC
7 Power Existing- 838 KVA
Proposed additional requirement = 2000 KVA
Source : MSEDCL
8 Waste water quantity Existing Domestic sewage: 1.5 cmd
Existing trade effluent: 8 cmd
Proposed additional domestic sewage: 6 cmd
Proposed additional trade effluent: 226 cmd
9 Project cost Estimate ~ Rs 22.7 Crores
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2 INTRODUCTIONOFTHEPROJECT
2.1 IdentificationoftheProjectandProjectProponent
Roha is a success story scripted by Innovation.
From a small startup in 1972, to a global color-producing behemoth in its present
avatar, manufacturing and distributing synthetic and natural colors for the food,
pharmaceuticals and cosmetics industries, Roha is a sum of all the experiences and
dreams of those associated with it.
Today, Roha’s product range encompasses synthetic and natural products created for a
multitude of applications- Food and Beverages, Pet food, Animal feed, Cosmetics and
Industrial applications. Moreover, Roha is ever collaborating with its associates to
develop new, innovative products.
Based in India with offices in 15 countries, Roha is striding towards the destiny it was
meant to fulfill. A company that governs itself with an eye on the environment; an
organization that champions social causes by giving back to society a share of the profits
it garners through its entity, the JJT Foundation, an arm of Roha’s parent company, the
JJT Group; a force that positively transforms and inspires every life it encounters.
At the core of this company is its 300,000 sq. ft., state-of-the-art production facility in
the Roha district of Maharashtra, India, which meets the highest international standards
and norms. In support are Roha’sten other manufacturing centers in the US, UK, Spain,
South Africa, Vietnam, Indonesia, Thailand, China, Egypt & Mexico.
ManagementTeam
The management team at Roha draw inspiration from its origins and its guiding light,
the late Jagdishprasad Jhabarmal Tibrewala. Roha, the flagship company of the JJT
Group, draws inspiration from the Group’s values and philosophy to return the largest
contribution to the consolidated bottom line.
With the pioneering spirit of JJT guiding the next generation of visionaries at the helm of
the company, the future holds great promise.
2.2 BriefDescriptionofnatureoftheProject
Proposed project is for expansion for manufacturer of synthetic organic chemicals. Existing
products plus new products as per market demand are as follows,
Table2:Existing&proposedProductdetails
Sr.No. NameofProduct/ByproductsExistingasper
CTO*(TPM)
Proposed
quantity
(TPM)
Total
(TPM)
Products
1 Natural colors 50 - 50
2 Tatrazine / Allura red / Sunset yellow/
Ponceau / Amaranth/ Carmosine - 500 500
Byproducts
1 Sodium chloride salt - 500 500
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(*) As Consent order no. BO/MPCB/AST/EIC No-RD-2951-15/HOD-3696 dated 30.03.2015 valid till
31.03.2017 (CTO is under renewal)
2.3 Need of the Project and Its Importance to the country and/or Region
The Indian food industry has portrayed tremendous progress with reference to
infrastructure development, technology base creation and a wide range of production.
India has achieved an eminent global position in food and feed ingredient sector.
The Indian food and feed ingradient industry is estimated to grow at 12-15 %
compound annual growth rate (CAGR) over the next five years and there is tremendous
potential for growth.
2.4 Demand – Supply gap
The demand for food and feed ingredient is a derived demand.
There is a wide gap in the demand and availability of ingredients in India and the world
over.
2.5 Imports vs indigenous production
As it is a well-known fact that Indian products are well accepted abroad for its quality
and marketing flexibility. The exports from the Indian companies to other foreign
countries such as Europe, America, Japan and other African countries has been
increasing every year. This shows the acceptability of the products produced in India.
2.6 Export Possibility
Yes, there is great potential for export of the manufactured products. We are holding
two star certificates for export of our products.
2.7 Domestic / Export market
Refer 2.6 above
2.8 Employment Generation (Direct and indirect) due to the project
The expansion facility will generate direct and indirect employment. Direct employment
will be about 200 persons.
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3 PROJECTDESCRIPTION
3.1 TypeofProject
The project is for manufacture of various food colors which falls under synthetic organic
chemicals manufacturing. The proposed project will be established within existing
manufacturing facility.
3.2 Location
The proposed project will be at existing facility of the company at MIDC Dhatav.
Figure1:LocationofproposedprojectwithinMIDC
Location and details of nearest infrastructure facilities,
No Destination Approx.distancefrom
projectsite(km)
1 Nearest town – Roha 4
2 Nearest state highway (NH-66) 5.4
3 Nearest airport – Mumbai 130
4 Nearest railway station - Roha 4
The proposed project is on the existing location at plot no. 23/1/1, MIDC Dhatav, Roha.
The Geographical Location of this Industry is 18°25'45.17"N Latitude and 73°9'21.43"E Longitude with an elevation of 12 meter above sea level MSL.
GPS Location on Google Imagery of the proposed site is attached for as (AnnexureI)
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Land Form: Land is on plain contour, it is flat terrain.
Land Ownership: Land ownership is with project proponents (Roha Dye chem pvt ltd).
Existing Land use Pattern: The Land is reserved for Industrial use & proposed project is
within existing facility.
Existing Infrastructure: Presently there is an existing Infrastructure at the site. Infrastructure
like water, electricity, telephone facility, roads already available as this is an existing Industrial
area.
MIDC Dhatav provides basic facilities like uninterrupted water supply, power and Road
Network. When various alternatives sites were examined, this site appeared to be
environmentally best as also from the business angle and therefore this option was finally
adopted. This site is inside the campus of the MIDC and means safe transportation, less need of
Utilities, less constructing buildings and roads, less fuel, less water with optimization of
infrastructure.
There is no sensitive establishment in the vicinity such as health resort, hospital, and
archaeological monuments.
The location justification for the project is as under
a. Availability of required land and infrastructure for locating the proposed synthetic
organic chemical manufacturing facility b. Suitability of land from topography & geological aspects, synergy and business point
of view c. Proximity to rail / road to facilitate transport of equipment / materials/ product d. Availability of adequate quantity of water to meet water requirements.
Lay-Out
Refer Annexure II for the plant site layout plan.
3.3 Details of Alternative sites
Refer above.
3.4 Size or magnitude of operation
Plot area of the site is ~ 6958 sq.m area.
Proposed production quantities are mentioned in section 2.2 above
3.5 Project description with Project details
Proposed products, Brief description, Process Chemistry, Process Block diagram are given at
Annexure IV.
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3.6 Raw material required
Raw Materials: The basic raw material for the product capacity (existing and proposed) is submitted herein
below.
Source for Raw Material Procurement: Raw Material is easily available in the local market
and some are imported.
Mode of Transport of Raw Materials: Few of the raw materials will be transported locally
and few will be imported from the International Market. Mode of transport to site is by road
truck/tankers.
Table 3: List of major Raw Material
Sr.
No. Name of Raw Material Consumption per month
EXISTING
1 Beat root 900 MT
2 Malto 190 MT
3 Citric acid 500 kg
4 Ascorbic acid 500 kg
PROPOSED FOR PROJECT
1 HCl(30 %) 519.1 KL
2 Sulphanilic Acid 422.00 MT
3 Sodium Nitrite 204.14 MT
4 Soda Ash 349.00 MT
5 Caustic Soda Flakes 77.00 MT
6 Dimethyl Acetyl Succinate 220.00 MT
7 Vacuum Salt 77.00 MT
8 Schaeffer's acid 50.00 MT
9 Pcosa 55.00 MT
10 scheffer's acid 104.00 MT
11 Sodium Naphthionate 62.00 MT
12 NW acid 17.00 MT
13 G Salt 19.00 MT
14 Sulphuric acid 4.00 KL
15 H Acid 7 MT
Proposed bulk storages at site will be as follow:
Bulk storage details
No Particular Unit Physica
l state
Existing
storage
capacity
Proposed
storage
capacity
Stored in
1 HCl MT Liquid - 3 x 20 KL Tank
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3.7 Resource optimization
It will be carried out within and with other sites of the company.
3.8 Water, Energy / Power availability and source
3.8.1 Water
The total water requirement is for Domestic, Process, Utilities and Green belt maintenance
purpose.
The source of water is from MIDC and the same is adequate and satisfactory.
Existing and proposed water requirement is tabulated below,
Table 5: Water requirement
No Purpose Existing
requirement
Propose
d
require
ment
Total
(existing +
proposed)
Quantity in CMD
1 Domestic 2 7 9
2 Processing 28 198 226
3 Industrial cooling / boiler feed 0 220 220
Grand Total 30 425 455
3.8.2 Energy
There is 1 Boilers at site. The boilers has fuel coal / FO( 5 TPD coal / 1 TPD FO)
There is proposal to add one boiler, one hot air generator and one DG set at site.
Existing and proposed Air pollution control systems at site
No Stack attached to APC system Fuel used
with quantity
Ht. from ground level
(m)
EXISTING
1 Boiler / HAG Cyclone dust
collector
Coal 5 TPD /
FO 1 TPD
28
PROPOSED
1 Boiler ( 6 TPH) As per
statutory
requirement
Coal 28.8 TPD
12 TPD
As per statutory
requirement
2 Hot air generator (HAG) As per
statutory
requirement
Coal 30 TPD
15 TPD
As per statutory
requirement
3 DG set (1010 KVA) As per
statutory
requirement
HSD: 200
lit/hr
As per statutory
requirement
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3.8.3 Power
Existing power requirement of the site is 838 KVA which is sourced from MSEDCL.
Additional power requirement for proposed expansion is 2000 KVA which shall be sourced
from MSEDCL.
3.9 Waste generation, Management and disposal
3.9.1 Waste water
Existing and proposed waste water generation, treatment and disposal is as follows
Table 6: Existing & Proposed effluent generation
No Description
Existing
waste water
(*), cmd
Proposed
waste
water, cmd
Total (existing
+ proposed),
cmd
Disposal (*)
1 Domestic
effluent
1.5 6 7.5 Domestic sewage
treated in Septic tank.
2 Trade
effluent
8.0 220 228 Treated effluent will
be partly used for
gardening and
balance sent to CETP
Total 9.5 226 235.5
3.9.2 Non hazardous waste
Nonhazardous waste quantity as per existing consent to operate & proposed is presented
below.
No Description Existing* Proposed Total Method of Disposal
1 ETP sludge 100
kg/day
100
Kg/day
200
kg/day
Use as manure
2 HDPE Bags - 6 TPM 6 TPM By sale
3.9.3 Hazardous waste
Hazardous waste quantity as per existing consent to operate & proposed is presented below.
Table 7: Existing & Proposed Hazardous waste generation & disposal
No Description Category UOM Existin
g*
Propos
ed
Total Method of
Disposal
1 ETP Sludge 35.3 MT/Y - 40 40 CHWTSDF
2 Empty containers 33.3 Nos/M - 125 125 Sale to
authorized re
processor
3 Used oil 5.1 Lit/Y - 150 150 Sale to
authorized re
processor
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3.10 Schematic of EIA Purpose
Figure 2: Schematic reprsentation of the feasibility drawing which gives EIA purpose
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4 SITEANALYSIS
4.1 Connectivity
MIDC Dhatav, where the plant is located, comes in Taluka Roha of Raigad district in
Konkan, near west coast of Maharashtra. Site is well connected by rail and road. Nearest
railway station is Roha 4 km NW of site and Kolad-Roha road is 300 m to North from
site which meets National Highway-66 (Panvel- Edappalli). Site is at a distance of 100
km from Mumbai. The plant facility is located in well-developed notified industrial
estate and there is no human habitation in immediate vicinity of the plant.
4.2 Landform,Landuseandlandownership
LandForm:Land is on plain contour, it is flat terrain
LandOwnership:Land ownership is with project proponent (Roha Dyechem provate limited)
4.3 Topography&Geology
The Raigad district is divided into three parts on the basis of its topography.
The rock of the district is trap. In the plains it is found in tabular masses a few feet
below the soil and sometimes standing out from the surface. In the hills it is tabular and
is also found in irregular masses and shapeless boulders varying from a few inches to
several feet in diameter. In many places the surface of the trap has a rusty hue showing
the presence of iron. River on North of the plant site is the main line of drainage which
on going further meets Sea near village Korlai. This river flows east to west and helps in
replenishment of ground water table.
4.4 Existinglandusepattern
The existing land is used for the existing facility is for manufacture of Natural colors.
4.5 Existinginfrastructure
Presently there is an operative plant/Infrastructure at the site.
4.6 Soilclassification
There are four chief varieties of soil in Raigad district: ailuvial and alluvia, powdered
laterite and trap, clayey mould resting on trap, and soil containing marine deposits with,
much sand and other matter in concretion.
The soil in the Roha taluka is sandy loam and clay-slit. Sandy loam is ideal for plants that
need more soil drainage than usual. Chronic incurable "overwater" will appreciate the
drainage benefits sandy loam soil provides, since good drainage in soil decreases the
chance of plant disease. The large soil particles of sand in sandy loam soil increase the
soil's capacity to let water flow through, making it easier for fresh water to move
through the planting media.
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4.7 Climate data from secondary sources
Overall climate of this region is equable with high rainfall in monsoon season and very
few days of extreme temperatures. The mean annual temperature ranges from 300C to
330C. The maximum temperature of the hottest month in this area varies from 350C –
400C in April-May while minimum temperature of coldest month varies from 15oC to
20oC. Extremes of temperatures, like 46-48oC in summer and 10-120C in winter, may be
experienced for a day or two in respective season. The area has humid climate. Relative
humidity varies from 25% to 85%. Driest days being in summer and wettest ones
experienced in July. The rainy season is mostly confined to southwest monsoon & is
responsible for fresh water supply.
4.8 Social infrastructure available
Nearest town is Roha which is about 4 km from site. Social infrastructure such as schools,
Hospitals, market place and other amenities are available. Transport facilities by rail and road
are available.
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5 PLANNINGBRIEF
5.1 PlanningConcept
The plot is in well-established MIDC Dhatav area.
Purified Water supply from MIDC, Road facility with illumination, Infrastructure facilities
available in the established MIDC. The proposed project shall be integrated with the existing
manufacturing facility.
5.2 PopulationProjection
An official Census 2011 detail of Raigad, a district of Maharashtra has been released by
Directorate of Census Operations in Maharashtra.
In 2011, Raigad had population of 1,07,562 of which male and female were 55,553 and 52,009
respectively. The proportion of urban & rural population of study area stood at 32.34 (34786)
and 67.66 (72776) percent respectively.
There was change of 3.20% in the population compared to population as per 2001. In
the previous census of India 2001, study area recorded increase of 18.78 percent to its
population compared to 1991.
5.3 Landuseplanning
The existing land use is industrial as it is within MIDC area.
5.4 AssessmentofInfrastructureDemand(Physicalandsocial)
At Roha Dyechem, in proposed expansion project there will be increase in production of the
synthetic organic chemicals. There will be no major demand of physical and social
infrastructure.
5.5 Amenities/Facilities
No major amenities / facilities demand is envisaged as the proposed site is in well-developed
MIDC area.
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6 PROPOSEDINFRASTRUCTURE
6.1 IndustrialArea(Processingarea)
Roha dyechem, MIDC Dhatav proposed to expand its manufacturing base at existing
site.
6.2 Residentialarea(non-processingarea)
No Residential area has been proposed within the plant site.
6.3 GreenBelt
Green belt has been carried out along the boundary of the plot. And will be
maintained as per guidelines.
6.4 SocialInfrastructure
The project shall have a positive impact on the employment pattern of the region.
Economic status of the local population will improve due to increased ancillary/
business opportunities, thereby making positive impact. Educational, medical &
housing facilities will improve due to the proposed project.
6.5 Connectivity
This proposed project facility is located at MIDC Dhatav area, in Raigad district,
Maharashtra. The Site is 4 km from Roha town. The land and infrastructure is
made available by MIDC and the raw material is easily available through the easy
transport via road connectivity.
6.6 Drinkingwatermanagement
The source of water is already availability from existing water works of MIDC and
the same is adequate and satisfactory. The water supply will be through the good
offices of MIDC.
6.7 Effluenttreatmentsystem
Roha Dyechem is manufacturer of beet root powder from fresh beet root
& water from cleaning of beet root during manufacturing is sent to
Effluent Treatment Plant, capacity of 10 m3.
Effluent Treatment Plant is consisting of primary Treatment Unit such as
Collection tank & Settling Tank as effluent is non- toxic.
Settled sludge is get collected and used as manure for Gardening.
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6.8 Industrial waste management
Refer 3.9 above
6.9 Power requirement and supply / source
Power requirement shall be sourced from MSEDCL.
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7 REHABILITATION&RESETTLEMENT
PLAN
The proposed activities shall be in the existing plot of the company which is located in Dhatav
MIDC area. It does not require acquisition of Land and the Infrastructure so there is no any kind
of activity of Rehabilitation and Resettlement planned to be carried out.
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8 PROJECTSCHEDULEANDCOST
ESTIMATES
8.1 Likelydateofstartofconstructionandlikelydateofcompletion
It is expected that the expansion project shall be completed within 1.5 to 2 years from date
of grant of Environmental clearance.
8.2 Estimatedprojectcost
Total estimated project cost is around Rs. 22.7 Crores
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9 ANALYSIS OF THE PROPOSAL (FINAL
RECOMMENDATION)
The proposed expansion of products is due to increase in market demand of the product
range. As described earlier nearly 80% of products are getting exported to different
countries which are certainly increasing the foreign exchange for the nation.
Also many of products are equal or better in quality to that of certain imported
products. This reduces the dependency as well as money of customers by importing the
products. The project will definitely open an avenue for the young generation of our
nation by generating employment at project site.
We will be hiring the local residents nearby our project site for employment, as per
their competency. This will create employment to these people & thereby will improve
their living standard. The proposed expansion project shall be at MIDC area so area
development will be carried out as per MIDC, which will improve the living standards of
the local people.
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Annexure – I
Google image of site with 1 km radius
Google image of site with 10 km radius
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Annexure – II Layout plant of the proposed expansion project
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Annexure – III Existing Effluent Treatment Scheme
Anoxic
clarifier
Primary
Treatment
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Proposed Effluent Treatment Scheme
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Annexure – IV
1. Tatrazine
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Tatrazine Manufacturing process brief :
The diazotization of sulphanilic acid solution with sodium nitrate is being carried out in acid
condition in water medium. The sulphanilic acid solution and nitrite solution are prepared in
separate vessels. Then both the solutions are added to make the final diazo.
The Diazo slurry will undergo coupling with DMAS and followed by hydrolysis using Soda Ash
solution.
The coupled solution is isolated using salt. The product is separated by filter. The filtrate is sent to
ETP and the cake is the purified product which is spray dried.
The final product undergoes milling, sieving operation before packing.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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2. Allura Red
Allura Red process flow chart
WATER
ICE SODIUM NITRITE SOLN.
HCL (30%)
SCHAEFFERS ACID
PCOSA SODA ASH SOLN.
SODIUM CHLORIDE
DIAZOTIZATION
COUPLING
ISOLATION
FILTRATION
DISSOLUTION AND
CLARIFICATION
SPRAY DRYING
POWDER COOLING AND
PACKING
FILTRATE TO ETP
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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ALLURA RED MANUFACTURING PROCESS
1. Diazotization: - Take measured quantity of water through flow meter of water line.
Add measured quantity of (31.5%) HCl, stir for 15 min.
Charge Schaeffer’s acid and stir for 10 min.
Add ice to take temp up to 00C to (-5)0C.
Prepare solution of sodium nitrite in Nitrite tank as follow.
� Water
� Ice
� Sodium Nitrite
Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.
Temperature of Diazo should be below 5°C.
Stir the reaction for 30 to 40 min.
Transfer final Diazo to precooled (15°C via jacket) coupling vessel.
2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.
Add PCOSA through pump in 1 Hr.
Start soda ash solution and complete addition within 110-130 min
Check pH it should be 4.0 to 4.5.
Simultaneously start adding second soda solution and complete it in 120-150 min.,
approximately.
Adjust pH 8.0 to 8.5.
Start coupling through 2nd diazo addition below 200C temp.
Check pH & it must be 6-6.5
Add Caustic soda flakes and start heating.
Heat it up to 700C to 800C (by steam from Jacket only.)
Maintain under stirring for 1 Hr. at 80°C.
2. Isolation: - Check vessel is clean & empty.
Receive material of batch.
Adjust pH 4.5 to 5.5 by adding HCl.
Start cooling via both internal coil & external jacket circulation of chilled water.
After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then
restart chilling circulation till temperature reaches to 17°C.
3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)
Collect all filtrate and send to Effluent Treatment Plant
Collect all wet cake and its total weight send sample for moisture and purity analysis.
4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the
required water quantity to make 30 - 35% solution. Charge required quantity of water (by
considering water quantity formation during live steam heating to 75-80°C.) and start
stirring and heating with live steam. Charge total weighted wet cake under stirring.
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After clear solution formation send sample for GPL analysis. Filter through filter press,
transfer to LST for spray drying.
5. Spray Drying:- Spray Dry the solution at 320°C Inlet and 140°C Outlet temperature.
Collect Allura Red powder and pack with using dust free packing machine system.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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3. Sunset Yellow
Sunset Yellow process flow chart
WATER
ICE SODIUM NITRITE SOLN.
HCL
SULPHANILIC ACID
SCHAEFFER ACID SODA ASH SOLN.
SODIUM CHLORIDE
DIAZOTIZATION
COUPLING
ISOLATION
FILTRATION
DISSOLUTION AND
CLARIFICATION
SPRAY DRYING
POWDER COOLING AND
PACKING
FILTRATE TO ETP
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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SUNSET YELLOW MANUFACTURING PROCESS
1. Diazotization: - Take measured quantity of water through flow meter of water line.
Add measured quantity of (31.5%) HCl, stir for 15 min.
Charge Sulphanilic acid and stir for 10 min.
Add ice to take temp up to 00C to (-5)0C.
Prepare solution of sodium nitrite in Nitrite tank as follow.
� Water
� Ice
� Sodium Nitrite
Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.
Temperature of Diazo should be below 5°C.
Stir the reaction for 30 to 40 min.
Transfer final Diazo to precooled (15°C via jacket) coupling vessel.
2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.
Add Schaeffer’s Acid in 1 Hr.
Start soda ash solution and complete addition within 110-130 min
Check pH it should be 4.0 to 4.5.
Simultaneously start adding second soda solution and complete it in 120-150 min.,
approximately.
Adjust pH 8.0 to 8.5.
Start coupling through 2nd diazo addition below 200C temp.
Check pH & it must be 6-6.5 and start heating.
Heat it up to 700C to 800C (by steam from Jacket only.)
Maintain under stirring for 1 Hr. at 80°C.
2. Isolation: - Check vessel is clean & empty.
Receive material of batch.
Adjust pH 4.5 to 5.5 by adding HCl.
Start cooling via both internal coil & external jacket circulation of chilled water.
After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then
restart chilling circulation till temperature reaches to 17°C.
3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)
Collect all filtrate in storage tank and send to Effluent Treatment Plant
Collect all wet cake and its total weight send sample for moisture and purity analysis.
4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the
required water quantity to make 30 - 35% solution. Charge required quantity of water (by
considering water quantity formation during live steam heating to 75-80°C.) and start
stirring and heating with live steam. Charge total weighted wet cake under stirring.
After clear solution formation send sample for GPL analysis. Filter through filter press,
transfer to LST for spray drying.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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5. Spray Drying:- Spray Dry the solution at appropriate Inlet and Outlet temperature.
Collect Sunset Yellow powder and pack with using dust free packing machine system.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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4. Ponceau
Ponceau process flow chart
WATER
ICE SODIUM NITRITE SOLN.
HCL
SODIUM NAPTHONATE
G-SALT SODA ASH SOLN.
SODIUM CHLORIDE
DIAZOTIZATION
COUPLING
ISOLATION
FILTRATION
DISSOLUTION AND
CLARIFICATION
SPRAY DRYING
POWDER COOLING AND
PACKING
FILTRATE TO ETP
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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PONCEAU MANUFACTURING PROCESS
1. Diazotization: - Take measured quantity of water through flow meter of water line.
Add measured quantity of (31.5%) HCl, stir for 15 min.
Charge Sodium Naphthionate and stir for 10 min.
Add ice to take temp up to 00C to (-5)0C.
Prepare solution of sodium nitrite in Nitrite tank as follow.
� Water
� Ice
� Sodium Nitrite
Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.
Temperature of Diazo should be below 5°C.
Stir the reaction for 30 to 40 min.
Transfer final Diazo to precooled (15°C via jacket) coupling vessel.
2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.
Add G-Salt in 1 Hr. Start soda ash solution and complete addition within 110-130 min
Check pH it should be 4.0 to 4.5. Simultaneously start adding second soda solution and
complete it in 120-150 min., approximately. Adjust pH 8.0 to 8.5.
Start coupling through 2nd diazo addition below 200C temp.
Check pH & it must be 6-6.5 and start heating.
Heat it up to 700C to 800C (by steam from Jacket only.)
Maintain under stirring for 1 Hr. at 80°C.
2. Isolation: - Check vessel is clean & empty.
Receive material of batch.
Adjust pH 4.5 to 5.5 by adding HCl.
Start cooling via both internal coil & external jacket circulation of chilled water.
After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then
restart chilling circulation till temperature reaches to 17°C.
3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)
Collect all filtrate and send to Effluent Treatment Plant
Collect all wet cake and its total weight send sample for moisture and purity analysis.
4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the
required water quantity to make 30 - 35% solution. Charge required quantity of water (by
considering water quantity formation during live steam heating to 75-80°C.) and start
stirring and heating with live steam. Charge total weighted wet cake under stirring.
After clear solution formation send sample for GPL analysis. Filter through filter press,
transfer to LST for spray drying.
5. Spray Drying:- Spray Dry the solution at appropriate Inlet and Outlet temperature.
Collect Ponceau powder and pack with using dust free packing machine system.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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5. Amaranth
Amaranth process flow chart
WATER
ICE SODIUM NITRITE SOLN.
HCL (30%)
SODIUM NAPHTHIONATE
H Acid SODA ASH SOLN.
SODIUM CHLORIDE
DIAZOTIZATION
COUPLING
ISOLATION
FILTRATION
DISSOLUTION AND
CLARIFICATION
SPRAY DRYING
POWDER COOLING AND
PACKING
FILTRATE TO ETP
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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AMARANTH MANUFACTURING PROCESS
1. Diazotization: - Take measured quantity of water through flow meter of water line.
Add measured quantity of (31.5%) HCl, stir for 15 min.
Charge Sodium Naphthionate and stir for 10 min.
Add ice to take temp up to 00C to (-5)0C.
Prepare solution of sodium nitrite in Nitrite tank as follow.
� Water
� Ice
� Sodium Nitrite
Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.
Temperature of Diazo should be below 5°C.
Stir the reaction for 30 to 40 min.
Transfer final Diazo to precooled (15°C via jacket) coupling vessel.
2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.
Add H Acid in 1 Hr. Start soda ash solution and complete addition within 110-130 min
Check pH it should be 4.0 to 4.5. Simultaneously start adding second soda solution and
complete it in 120-150 min., approximately. Adjust pH 8.0 to 8.5.
Start coupling through 2nd diazo addition below 200C temp.
Check pH & it must be 6-6.5 and start heating.
Heat it up to 700C to 800C (by steam from Jacket only.)
Add Caustic Flakes. Maintain under stirring for 1 Hr. at 80°C.
2. Isolation: - Check vessel is clean & empty.
Receive material of batch.
Adjust pH 4.5 to 5.5 by adding HCl.
Start cooling via both internal coil & external jacket circulation of chilled water.
After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then
restart chilling circulation till temperature reaches to 17°C.
3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)
Collect all filtrate and send to Effluent Treatment Plant.
Collect all wet cake and its total weight send sample for moisture and purity analysis.
4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the
required water quantity to make 30 - 35% solution. Charge required quantity of water (by
considering water quantity formation during live steam heating to 75-80°C.) and start
stirring and heating with live steam. Charge total weighted wet cake under stirring.
After clear solution formation send sample for GPL analysis. Filter through filter press,
transfer to LST for spray drying.
5. Spray Drying:- Spray Dry the solution at appropriate Inlet and Outlet temperature.
Collect Amaranth powder and pack with using dust free packing machine system.
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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6. Carmosine
Carmoisine process flow chart
WATER
ICE SODIUM NITRITE SOLN.
HCL
SODIUM NAPTHONATE
NW ACID SODA ASH SOLN.
SODIUM CHLORIDE
DIAZOTIZATION
COUPLING
ISOLATION
FILTRATION
DISSOLUTION AND
CLARIFICATION
SPRAY DRYING
POWDER COOLING AND
PACKING
FILTRATE TO ETP
Prefeasibility Report Roha Dyechem Private Limited (Unit II)
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CARMOISINE MANUFACTURING PROCESS
1. Diazotization: - Take measured quantity of water through flow meter of water line.
Add measured quantity of (31.5%) HCl, stir for 15 min.
Charge Sodium Naphthionate and stir for 10 min.
Add ice to take temp up to 00C to (-5)0C.
Prepare solution of sodium nitrite in Nitrite tank as follow.
� Water
� Ice
� Sodium Nitrite
Add this Sodium Nitrite solution to diazotization vessel in approximately 45 min.
Temperature of Diazo should be below 5°C.
Stir the reaction for 30 to 40 min.
Transfer final Diazo to precooled (15°C via jacket) coupling vessel.
2. Coupling & Hydrolysis:- Receive first diazo slurry in approximately 60 min.
Add NW Acid in 1 Hr. Start soda ash solution and complete addition within 110-130 min
Check pH it should be 4.0 to 4.5. Simultaneously start adding second soda solution and
complete it in 120-150 min., approximately. Adjust pH 8.0 to 8.5.
Start coupling through 2nd diazo addition below 200C temp.
Check pH & it must be 6-6.5 and start heating.
Heat it up to 700C to 800C (by steam from Jacket only.)
Maintain under stirring for 1 Hr. at 80°C.
2. Isolation: - Check vessel is clean & empty.
Receive material of batch.
Adjust pH 4.5 to 5.5 by adding HCl.
Start cooling via both internal coil & external jacket circulation of chilled water.
After getting temperature 25-26°C, stop chilling water circulation, stir for 30 min, then
restart chilling circulation till temperature reaches to 17°C.
3. Filtration:- Filter it on squeezing filter press (Moisture in wet cake should be less than 35%)
Collect all filtrate and send to Effluent Treatment Plant.
Collect all wet cake and its total weight send sample for moisture and purity analysis.
4. Dissolution of wet cake/Clarification:- Collect all moisture and purity analysis of wet cake with its total weight and calculate the
required water quantity to make 30 - 35% solution. Charge required quantity of water (by
considering water quantity formation during live steam heating to 75-80°C.) and start
stirring and heating with live steam. Charge total weighted wet cake under stirring.
After clear solution formation send sample for GPL analysis. Filter through filter press,
transfer to LST for spray drying.
5. Spray Drying:- Spray Dry the solution at appropriate Inlet and Outlet temperature.
Collect Ponceau powder and pack with using dust free packing machine system.