APPLICATION FOR ENVIRONMENTAL CLEARANCE

PRE-FEASIBILITY REPORT

For
‘CHANGE IN PRODUCT MIX OF SURFACTANTS AND
PIGMENTS

By
M/s Ultramarine and Pigments Limited
At
Survey No: 52 & 846
Village: Karai
Taluka: Walajah
District: Vellore
State: Tamil Nadu

Consultant

HUBERT ENVIRO CARE SYSTEMS (P) LTD, CHENNAI

(NABET Accredited vide Certificate No. NABET/EIA/1619/RA0083) &
(MoEF Recognized Lab vide F. No. Q-15018/13/2016-CPW)

MARCH 2019

1
 Contents

1 EXECUTIVE SUMMARY ..................................................................................... 6

1.1 Project Summary .................................................................................................... 6
2 INTRODUCTION OF THE PROJECT ................................................................. 9
2.1 Identification of the Project...................................................................................... 9
2.2 Project Proponent ................................................................................................... 9
2.3 Brief Description of Nature of the Project .............................................................. 10
2.4 Need for the Project and its importance ................................................................ 10
2.5 Demand-Supply Gap ............................................................................................ 10
2.6 Import Possibility................................................................................................... 10
2.7 Domestic/Export Markets ...................................................................................... 10
2.8 Employment Generation ....................................................................................... 11
3 PROJECT DESCRIPTION ................................................................................ 12
3.1 Project location ..................................................................................................... 12
3.2 Details of Alternate sites considered ..................................................................... 18
3.3 Magnitude of Operation ........................................................................................ 22
3.4 Process Description .............................................................................................. 22
3.5 Raw Materials Requirement and storage facility ................................................... 25
3.6 Mode of Transportation......................................................................................... 27
3.7 Resource optimization .......................................................................................... 27
3.8 Recycling /Reuse of Solvents ............................................................................... 27
3.9 Power Requirements ............................................................................................ 27
3.10 Fuel Requirements................................................................................................ 28
3.11 Manpower ............................................................................................................. 28
3.12 Water Requirement............................................................................................... 28
3.13 Liquid waste management .................................................................................... 32
3.13.1 Industrial Effluent Treatment .......................................................................... 32
3.13.2 Sewage Treatment ........................................................................................ 32
3.14 Air Pollution Control Measures.............................................................................. 32
3.15 Waste Management and Disposal Method............................................................ 32
3.15.1 Municipal Solid Waste Management .............................................................. 32
3.15.2 Hazardous Waste Management..................................................................... 33
3.15.3 Non Hazardous Waste Management ............................................................. 34
4 SITE ANALYSIS................................................................................................ 35
4.1 Connectivity .......................................................................................................... 35

2
 4.2 Land Form, Land use&Land ownership................................................................. 35
4.3 Topography of the District ..................................................................................... 36
4.3.1 Drainage ........................................................................................................ 38
4.3.2 Climate and rainfall ........................................................................................ 38
4.3.3 Land use pattern............................................................................................ 38
4.3.4 Soil ................................................................................................................ 40
4.3.5 Flora and Fauna ............................................................................................ 40
4.4 Existing Land use Pattern ..................................................................................... 40
4.5 Environmental Sensitivity of the Project site within 15 km radius........................... 41
4.6 Existing infrastructure ........................................................................................... 41
4.6.1 Land .............................................................................................................. 41
4.6.2 Buildings ........................................................................................................ 42
4.6.3 Plant Machinery & Utilities ............................................................................. 42
4.6.4 Fire &Safety System ...................................................................................... 43
4.6.5 Rain water harvesting facility layout ............................................................... 43
4.7 Social Infrastructure available ............................................................................... 43
5 PLANNING BRIEF ............................................................................................ 44
5.1 Planning concept .................................................................................................. 44
5.2 Transportation....................................................................................................... 44
5.3 Population Projection ............................................................................................ 44
5.4 Land use Planning & Break up.............................................................................. 44
5.5 Assessment of Infrastructure Demand .................................................................. 45
5.6 Amenities/Facilities ............................................................................................... 45
6 PROPOSED INFRASTRUCTURE .................................................................... 46
6.1 Industrial Area....................................................................................................... 46
6.2 Residential Area ................................................................................................... 46
6.3 Social Infrastructure .............................................................................................. 46
6.4 Connectivity .......................................................................................................... 46
6.5 Drinking Water Management ................................................................................ 46
6.6 Sewerage system ................................................................................................. 46
6.7 Industrial Waste& Emissions management: .......................................................... 46
6.8 Municipal Solid Waste Management ..................................................................... 47
6.9 Power and Fuel Requirements and Supply/ Source .............................................. 47
7 REHABILITATION AND RESETTLEMENT (R &R) PLAN ............................... 48
7.1 Policy to be adopted (Central/ State) .................................................................... 48
8 PROJECT SCHEDULE AND COST ESTIMATE .............................................. 49
8.1 Likely date of start of construction and likely date of completion ........................... 49
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 8.2 Project Schedule and Cost Estimate..................................................................... 49
9 ANALYSIS OF PROPOSAL ............................................................................. 50
9.1 Financial and social benefits ................................................................................. 50
9.2 Social Benefit........................................................................................................ 50
9.3 CSR benefit to local community ............................................................................ 50
9.4 Green belt benefits to the environment ................................................................. 50
10 CONCLUSION................................................................................................... 51

List of Tables

Table 1-1 Project Summary................................................................................................................ 6

Table 3-1 Existing and Proposed products with capacities .........................................................12
Table 3-2 Environmental Feature of the existing site within 15 km radius................................18
Table 3-3 List of Raw materials for Existing and Proposed Expansion (Unit MT/Month) .......25
Table 3-4 Power requirement details ..............................................................................................28
Table 3-5 Fuel requirement details (Existing & proposed Expansion).......................................28
Table 3-6 Existing water requirement .............................................................................................28
Table 3-7 Water requirement for proposed expansion.................................................................29
Table 3-8 Effluent generation details for Existing and proposed project ...................................32
Table 3-9 Domestic wastewater generation and Management...................................................32
Table 3-10 Solid waste generation and management..................................................................33
Table 3-11 Hazardous waste generation and management .......................................................33
Table 4-1Connectivity of Project site...............................................................................................35
Table 4-2 Geographical locations of the existing project site......................................................35
Table 4-3 Land area breakup details ..............................................................................................36
Table 4-4 Land use pattern of the district.......................................................................................40
Table 4-5Land use/Land cover statistics of 10km radius of the study area..............................40
Table 4-6List of Machinery &Equipment.........................................................................................42
Table 5-1 Existing and Proposed products with capacities .........................................................44
Table 5-2 Land area breakup details ..............................................................................................45
Table 6-1 Connectivity of the project site .......................................................................................46
Table 6-2 Effluent waste generation for Existing and proposed project ....................................47
Table 6-3 Solid waste generation and management ....................................................................47
Table 6-4 Power requirement details ..............................................................................................47
Table 6-5 Fuel requirement details..................................................................................................47

4
 List of Figure

Figure 3-1 Project location index map ............................................................................................13

Figure 3-2 Satellite image of the project site..................................................................................14
Figure 3-3 Satellite Imagery of 10 km radius of the project site..................................................15
Figure 3-4 Satellite imagery of 5km radius of the project site .....................................................16
Figure 3-5 Environmental Sensitive Areas within 15km of the project site ...............................17
Figure 3-6 Project site layout plan ...................................................................................................21
Figure 3-7 Existing Water Balance Chart .......................................................................................30
Figure 3-8 Proposed Water Balance Chart ....................................................................................31
Figure 4-1 Topo map of the Project site .........................................................................................37
Figure 4-2 Land use pattern of the project influence area...........................................................38
Figure 4-3Land use Land Cover map of the study area...............................................................39
Figure 4-4 Land use pattern of the project study area .................................................................41

List of Annexure

Annexure No Description Page no

1 Land allotment letter by SIPCOT 1
2 Consent to operate (Air and Water) for existing products 10
3 Water bills towards SIPCOT 37
4 Site layout plan 43
5 Raw material MSDS 44
6 Product MSDS 193
7 Air pollution control measure 314
8 Hazardous waste disposal authorization letter 317
9 Fire Hydrant layout 320
10 Topo map of study area 321
11 CEPI for critically polluted Industrial clusters/area 322
12 Water balance diagram for Existing and Proposed 323
project

5
 1 EXECUTIVE SUMMARY

M/s. Ultramarine and Pigments limited (UPL) is a public sector company involved in the
manufacturing of inorganic pigments (Ultramarine Blue – Pigment Blue 29), surfactants &
synthetic detergents, incorporated in the 1975. The unit is located at survey number 52 and
846, Karai village, Walajah Taluka, Vellore district, Tamil Nadu. Land allotment letter is
attached as Annexure 1.

1.1 Project Summary

The project summary is given in Table 1-1.

Table 1-1 Project Summary

S. Particulars Details
No
1. Name of the M/s. Ultramarine and Pigments Limited
company
2. Name of the Change in Product Mix of Surfactants and Pigments
project
3. Project M/s. Ultramarine and Pigments Limited,
location Survey No 52 and 846,
Karai Village,
Walajah Taluk,
Vellore District, Tamil Nadu.
4. Site co- 12057’6.66”N
ordinates 79018’57.93”E
(centre co-
ordinates)
5. Project The proposed project falls under Schedule 5(f) Synthetic organic
activity Chemicals.
Schedule, Category ‘B’, However due to applicability of General Conditions the
category as
project to be appraised as A category.
per EIA
notification
2006 &
Amendment

6
6. Product S. Products Capacity (MT/Month)
details No Existing Proposed Total
1. Ultramarine Blue 200 100 300
2. Linear Alkyl 1350 -350 1000
Benzene Sulphonic
acid – LABSA
3. Alpha olefin 1000 Nil 1000
Sulphonate – AOS
4. Synthetic detergents 4000 -2000 2000
5. Mixed Metal Oxide -- 50 50
Pigments
6. Bismuth Vanadate -- 50 50
pigments
7. Sodium Lauryl Ether -- 1500 1500
Sulphate (SLES) or
Sodium Lauryl
Sulphate (SLS)
8. Specialty surfactants -- 500 500
Total 6550 -150 6400
Consent to operate (Air & water) for the existing product is attached as
Annexure 2.
7. Land details The total plot area is 8.6602 Ha.

S. No Description Area Percentage

Hectares Acres Sq. m (%)
1 Built up area 2.10 5.18 21000 24
2 Solid waste 0.20 0.49 2000 2
storage/disposal
are
3 Green belt area 3.10 7.66 31000 36
4 Vacant area 3.26 8.05 32600 38
Total 8.66 21.39 86600 100
Land allotment letter is attached is Annexure 1.

8. Water requirement
The existing fresh water requirement for the project is 106.9 KLD and total water
requirement is 168.4.
After expansion, the fresh water requirement is 329.5 KLD and the total water
requirement is 412.8 KLD.
Source: SIPCOT
Water bill for SIPCOT is attached as Annexure 3.
Water balance for the existing and proposed project is attached as Annexure 12.
9. Domestic wastewater management
Description Domestic Treatment Disposal
waste water units
generation
Existing (KLD) 4.5 STP Water reused for Green belt
Proposed (KLD) - - development & Sludge used as
After expansion 4.5 STP Manure.
10. Industrial wastewater management
Description Industrial Disposal
waste water
generation
Existing (KLD) 9.1 Trade effluent is being treated in RO, MEE &
Proposed (KLD) - VTFD. Condensate water is reused in
After expansion 9.1 process & salt obtained (Na2SO4) is used in
Detergent process.
11. Power requirement

7
 Details Existing (KVA) Proposed After Expansion (KVA)
(KVA)
Power 1425 - 1425
requirement
Back up D.G. 725 x 2 - 725 x 2
set

12. Fuel requirement

S. Details Point of use Unit Existing Proposed After
No expansion

1 Coal Pigment process MT/Day 1.2 -- 1.2

2 Coke Pigment process 3 -- 3
3 SKO Pigment process Lit/Day 1200 -600 600
4 LPG Pigment & spray Kg/Day 400 850 1250
Tower Process
5 HSD DG sets Lit/Day 1000 -- 1000
6 Furnace Boiler & spray MT/Day 3.0 -0.5 2.5
oil Tower process
13. Air Emission Detailed Air emission source and control measures are given in
Source and Annexure 7.
Control
measure
14. Municipal Solid waste Management

S. Waste Quantity (kg/day) Treatment/Disposal

No Existing Proposed After method
expansion
1 Packing 5 - 5 Sent to TNPCB
materials authorized recyclers
2 organic 45 - 45 Vermi compositing
3 STP sludge 0.05 - 0.05 STP sludge is used as
Manure for Green belt.
15. Hazardous waste management

S. Category Type of the Quantity (MT/Year) Mode of

No Hazardous Existing Proposed After Disposal
waste Expansion
1 5.1 Used/ Spent oil 4.5 -- 4.5 Recover and
Reuse- CPCB
Authorized
recyclers
2 5.2 Wastes/ residues 1.2 -- 1.2 TSDF
containing oil
3 17.1 Residues, dusts 6 -- 6 TSDF
or filter cakes
4 17.2 Spent catalyst 0.2 -- 0.2 Buy back with
(V2O5) the
suppliers
5 33.3 Discarded 1.2 -- 1.2 TSDF
containers /
barrels / liners
contaminated
with hazardous
wastes
/chemicals
16. Man power At present, 250 persons are employed in the unit including contract workers.

17. Project Cost 100 lakhs for raw materials

8
 2 INTRODUCTION OF THE PROJECT

2.1 Identification of the Project

M/s. Ultramarine and Pigments limited (UPL) is a public limited company involved in the
manufacturing of inorganic pigment (Ultramarine Blue - Pigment Blue 29), Surfactants &
Synthetic Detergents, incorporated in the year 1975. The unit is located at survey number 52
and 846, Karai village, Walajah Taluka, Vellore district, Tamil Nadu.

UPL focuses on the manufacturing of environmental friendly pigments that can be used
safely across a variety of end users, including paints, plastic, inks, laundry, cosmetic etc.
since 1975, UPL has been manufacturing a menu of Anionic surfactants, used in laundry,
construction fire safety and personal care products. The unit began with Linear Alkyl
Benzene Sulphonic acid as a common surfactant used for detergents, now the unit produces
Alpha Olefine Sulphonate in various concentrations and forms, including liquid, paste,
powder & Noodle.

UPL is a “Responsible Care” logo company & certified towards ISO 9001:2015, ISO
14001:2015 and OHSAS 18001:2007 certifications. The industry manufactures a range of
inorganic pigments, detergents and cosmetic grade surfactants and in the process is the
preferred supplier for most of the clients.

UPL manufactures certified non-toxic (food safe) environmental friendly inorganic pigments
for paints, auto and consumer plastics, and surfactants that are widely used in home and
personal care sectors, agrochemical and construction industries.

M/s. Ultramarine and Pigments limited proposed to enhance the capacity as well as
introduce new products within the existing facility at survey number 52 and 846, Karai
village, Walajah Taluka, Vellore district, Tamil Nadu. The total plot area is 8.66 Hectares.

2.2 Project Proponent

The Board of Ultramarine & Pigments limited has three Executive Directors, Six highly
qualified independent Directors and Non- Executive Directors. The Chairman, Mr. R.
Sampath graduated in Chemistry from the University of Bombay and obtained his chemical
Engineering degree from Washington State University, USA. After a few years working in
USA and India, he joined Ultramarine & Pigments Limited in 1970 as Project Engineer, Since
then, he has worked in various capacities in the company, as Project Manager, Development
Manager and General Manager before being appointed as the Managing Director in 1990
and CMD (Chairman and Managing Director) in 1998. Mr. Sampath held office of CMD up to
March 2016. He is now continuing as Non – Executive Chairman, guiding and advising the
Executive Board and Management regarding business and affairs of the company.
9
2.3 Brief Description of Nature of the Project

M/s. Ultramarine and Pigments limited is engaged in the manufacturing of Ultramarine Blue,
Linear Alkyl Benzene Sulphonic Acid – LABSA, Alpha Olefin Sulphonate (AOS) and
Synthetic detergents. Ultramarine and pigments limited is an India public limited company
listed on the Bombay Stock Exchange. For over fifty years, the industry has offered quality
products with excellent technological expertise. UPL has manufacturing facilities in Chennai
and Ranipet, Tamil Nadu. Ultramarine is a blue pigment consisting primarily of a double
silicate of aluminum and sodium with some sulfides or sulfates. It a very safe, non-
hazardous blue pigment with a variety of application worldwide.

2.4 Need for the Project and its importance

The proposed project will cater to the need of clients of South India. The project will
contribute towards need of industries which use these as raw materials. As the industry is
situated in Ranipet, it is catering to the needs of Chennai and due to increase in the demand
from industries situated in this region and other part of the country for timely delivery and to
meet the growing demand. Therefore in order to meet the growing demands of the market,
the proponent proposed expansion within the existing facility.

2.5 Demand-Supply Gap

The company generates revenue mainly from four business activities, namely as Pigment,
Surfactant, wind Mill Power Generation business and IT division. Of these four, the pigment
division is the largest contributor of the total turnover of the company followed by the
Surfactant business, IT division and Wind Mill Power generation division. Net Sales for FY
2017-18 stood at Rs. 2825 million of which laundry & allied products segments which
included the Pigments & Surfactants business constituted about 86% of the revenues with
the balance 14% coming in from the IT & Wind Mill Division. Growth in exports for the
pigments and surfactants division and introduction off our new products seem to have
boosted the top line

2.6 Import Possibility

Raw material like Lauryl Alcohol & Lauryl ethoxylates will be imported from other countries
as there is no supply from India.

2.7 Domestic/Export Markets

High supply gap is observed for specialty surfactants and pigments in India. Both products
are imported at higher level from other countries. Particularly, mixed metal oxide and

10
bismuth vanadate requirements in India are fulfilled by 100% import. To capture this UPL is
proposing this change in product mix and quantity.

2.8 Employment Generation

The total employment in the existing facility is 250 persons including contractual workers.

11
 3 PROJECT DESCRIPTION

To cater the needs of the growing market, UPL proposes to increase the production capacity
of the proposed products at its existing unit. The proposed project falls under category ‘B’,
however due to applicability of General Conditions the project to be appraised as ‘A’
category, Schedule 5(f), Synthetic Organic Chemicals Industry as per EIA notification dated
September 14, 2006 and its amendments. There is no interlinked project.

M/s. Ultramarine and Pigment limited (UPL) is an existing unit engaged in the manufacturing
of Ultramarine Blue, Linear Alkyl Benzene Sulphonic acid, Alpha Olefin Sulphonate and
Synthetic detergents. The unit is currently manufacturing Four (4) products with the
production capacity of 6550 MT/Month. The existing capacity of 2 products is decreased
from 5350 MT/Month to 3000 MT/Month. UPL proposes Five (5) new products with a
capacity of 2400 MT/Month. After expansion UPL will produce Eight (8) products with
capacity of 6400 MT/Month (existing 4 products with a capacity of 6550 MT/Month and 5
new products with a capacity of 2400 MT/Month). The details of Existing and proposed
products are given in Table 3-1.

Table 3-1 Existing and Proposed products with capacities

S. No Existing products Capacity (MT/Month)
Existing Proposed Total
1. Ultramarine Blue 200 100 300
2. Linear Alkyl Benzene 1350 -350 1000
Sulphonic acid – LABSA
3. Alpha olefin Sulphonate – 1000 Nil 1000
AOS
4. Synthetic detergents 4000 -2000 2000
5. Mixed Metal Oxide -- 50 50
Pigments
6. Bismuth Vanadate -- 50 50
pigments
7. Sodium Lauryl Ether -- 1500 1500
Sulphate (SLES) or
Sodium Lauryl Sulphate
(SLS)
8. Specialty surfactants -- 500 500
Total 6550 -150 6400

3.1 Project location

The proposed site is located in the SIPCOT Industrial area. The site is situated at Survey No
52 and 846, Karai Village, Walajah Taluk, Vellore district. The site is located adjacent to
State Highway (SH) 124A and National Highway (NH) 4. The center co-ordinates of the plant
area are 12057’7.37” N, 79018’58.58” E. The project location index map is shown in Figure
3-1.Satellite image of the project site is given in Figure 3-2. Satellite imagery around 10 km

12
and 5km radius from the project site is given in Figure 3-3and Figure 3-4.Map showing
environmental sensitive area within 15 km radius of the project site is given in Figure 3-5.

Figure 3-1 Project location index map

13
Figure 3-2 Satellite image of the project site

14
Figure 3-3 Satellite Imagery of 10 km radius of the project site

15
Figure 3-4 Satellite imagery of 5km radius of the project site

16
Figure 3-5 Environmental Sensitive Areas within 15km of the project site

17
 3.2 Details of Alternate sites considered

Since the proposed project will take place within the existing facility, alternate site is not
considered. The environmental setting of the existing site is given in Table 3-2. Project site
layout plan is given in Figure 3-6.

Table 3-2 Environmental Feature of the existing site within 15 km radius

S.
Particulars Details
No.
1. Site Co-ordinates of the 12057’6.66”N
project site (center co- 79018’57.93”E
ordinates)
2. Elevation 188m
3. Present land use Industrial Use
4. Nearest Highway National Highway NH4 is adjacent to the site towards East
direction
5. State Highway State Highway SH 124A is adjacent to the site towards South
West direction.
6. Nearestrailway Station Mukundarayapuram Railway station, at a distance of ~3.94 km
towards NW direction.
7. Nearest Airport Vellore Airport is a distance of ~27.48km towards WSW
direction.
8. Nearest village Karai village at a distance of ~1.69 km towards SW direction.
9. Nearest major city Vellore
10. Type of soil Red Soil
11. Defense Installations Nil
12. Nearest Town Ranipet
13. Nearest River/ S. Distance
Name of the Location Direction
Lakes/Dams No (~km)
Water bodies
1 Ponnai river 4.24 W
2 Ponnai WB main canal 11.24 NW
3 Palar 3.04 S
4 Channasamudram Eri 13.53 SE
5 Kaveri odai 8.02 SSW
6 Mahandravadi channel 10.05 SE
7 Kaveripak main channel 10.22 SE
8 Kaveripak tank 12.52 E
9 Ponnai WB main canal 10.77 NNW
10 Pundi Eri 9.54 SE
Reserve forest
1. Magimandalam RF 9.53 NW
2. Ammur RF 4.92 NNE
3. Tiruvalam RF 4.97 W
4. Kil Minnal RF 7.86 W
5. Punganur RF 10.21 WSW
6. Punganur RF 5.65 SW
7. Vannivedu RF 11.66 SE
8. RF 7.52 W
9. Palamadi RF 13.31 SW
14. Hills & valleys Nil within 15 Km radius of the project

18
 S.
Particulars Details
No.
15. Routes or facilities used
by the public for access to
recreation or other tourist,
pilgrim areas &
Nil
Archeologically Important
Places/ Tourist/Religious
importance

16. Areas occupied by S. Distance

sensitive man-made land No Hospitals (~km) Direction
uses 1. Thirumalai mission
a). Hospitals hospital 0.86 ESE
2. Scudder Memorial
Hospital 2.13 SSE
3. Anjukam Hospital 2.47 SSE
4. Rupa nursing home 2.71 SE
5. Ramya dental clinic 3.61 SSE
6. Rajeshwari hospital 3.60 SSE
7. Apollo KH hospital 5.29 SW
8. Government Hospital 5.44 SW
9. Melvisharam primary
health center 5.43 SW
10. G.K. hospital 1.90 NW
11. Dr. L. Shanthi Vimala
clinic 2.49 SE
b). Schools and colleges S. Distance
No Schools and collages (~KM) Direction
1. Government ITI college 1 SE
2. B.ed college, Vadagal 4.23 NW
3. Dav Bhel School 3.66 NW
4. Sri Ramachandra ITI
college 0.40 SE
5. Navelpur bharathiyar
nursing college 2.46 SE
6. Govt. teacher training
institute for Women 2.67 SE
7. Bharathi institute of
Catering & Hotel
Management 2.36 SSE
8. Sunrise College, Ranipet 3.39 SSE
9. SSS college of Arts,
Science & Management 4.32 S
10. M.M.E.S. women’s Arts &
Science College 5.14 SW
11. The Geekay world school 3.62 ENE
12. Municipal central school,
walajapet 5.83 SE
13. Walajapet womens college 7.18 SE
14. V.K.V.matriculate school 6.38 SE
15. Bright Minds vidyodaya 5.69 E
16. RTI- polytechnic college 9.33 SE
17. Ranippettai Engineering
college 9.35 SE
18. Ranipet institute of
Technology 9.35 SE
19. Little Flower convent 2.50 SSE
c). Industries S.No Distance
Schools and collages (~KM) Direction

19
S.
Particulars Details
No.
1. Sathvik springs 2.84 NE
2. Citizen industries 3.29 E
3. Indira industries 0.42 NE
4. United foundries
private limited 0.81 N
5. Mitsubishi heavy
industries 0.85 N
6. SNAP Industries 1 N
7. Balaji oil industries
limited 1.91 NNW
8. Sviss labs private
limited 2.54 NW
9. Saroj leathers 2.58 NW
10. Same Deutz- Fahr
private limited 2.50 NNW
11. Indira Damper
industries 3.47 NNW
17. Ecologically sensitive
areas (National
Parks/Wild Life Nil
sanctuaries/Bio Sphere
reserves)
18. Reserved/Protected S. No Reserve forest Distance Direction
Forests within 15Km (~km)
radius 1. Magimandalam RF 9.53 NW
2. Ammur RF 4.92 NNE
3. Tiruvalam RF 4.97 W
4. Kil Minnal RF 7.86 W
5. Punganur RF 10.21 WSW
6. Punganur RF 5.65 SW
7. Vannivedu RF 11.66 SE
8. RF 7.52 W
9. Palamadi RF 13.31 SW
19. Areas susceptible to The project location is falls under Zone III (Moderate risk
natural hazard which category). As per the IS:1893 (Part-1) 2002 of Bureau of Indian
could cause the project to Standards (BIS) There is no susceptible to natural hazards like
present environmental subsidence, landslides, erosion, flooding or extreme or adverse
problems climatic conditions.
(earthquakes, Note :
subsidence, landslides, Seismic Zone-II : Low risk
erosion, flooding or Seismic Zone-III : Moderate Risk
extreme or adverse Seismic Zone-IV : High Risk
climatic conditions) Seismic Zone-V Very high Risk

20
Figure 3-6 Project site layout plan

21
3.3 Magnitude of Operation

M/s. Ultramarine and Pigments limited is engaged in the manufacturing of inorganic

pigments and organic surfactants. UPL’s manufacturing units are in Chennai, Ranipet in
Tamil Nadu. Under the surfactants division, the key products encompass Linear Alkyl
Benzene Sulphonic Acid, Alpha Olefin Sulphonate, as well as Detergents. In view of fulfilling
the market demand, the unit proposes for change in product mix and quantities within the
existing facilities. The existing and proposed production detail along with capacities is given
in Table 3-1. Raw material MSDS and Product MSDS are enclosed as Annexure 5 and
Annexure 6.

3.4 Process Description

The detailed process description is given below:

A. Sulphonation:
Sulphonation is having the following steps.

1. Air Compression & Drying

2. Sulphur Melting
3. SO2 Production
4. SO3 Production
5. Sulphonating required Organic.
6. Ageing and Hydrolyzing.
7. Neutralizing if required.
8. Effluent Treatment.
9. Drying of Finished Products.

1. Air Compression & Drying:

Atmospheric air is compressed using screw or twin lube compressor to feed the air in to
the system to the required pressure and volume. During compression heat is generated
which is cooled using pre chilled glycol solution using chilling compressors. After chilling
the moisture is removed using cyclone separator and adsorbent beds. These adsorbent
beds are regenerated by heating with hot air produced during sulphonation process and
by cooling using cooling water and chilled glycol solution. The dry air is passed to the
oven where SO2 is produced.

2. Sulphur Melting:

22
 Sulphur pellets received from refineries are melted in Sulphur melting chambers which
heated using steam. Required quantity of molten Sulphur is pumped to oven using
metering pumps for producing SO2.

3. SO2 Production:

The oven is preheated using dried air, to the required temperature before pumping
molten Sulphur. After preheating the molten Sulphur pumped to the oven get ignited due
availability of air & heat which produces the SO2 gas. During SO2 production the heat
generated due exothermic reaction was recovered using waste heat recovery units.

4. SO3 Production:

SO2 produced from the oven is passed through catalyst bed to covert this SO2 in to SO3.
The catalyst used was V2O5 which is converting SO2 gas in to SO3 gas which is an
exothermic reaction. The heat generated during this was recovered using waste heat
recovery units and series of heat exchanger. After cooling SO3 was diluted to the
required concentration level using dried air. Then this diluted SO3 is passed to the
reactor.

5. Sulphonation:

During Sulphonation the pre cooled organic (LAB / AO / LA / LEO) is pumped to the
“Multi tube or Single Tube Falling Film Reactor” depending on the products. During
Sulponation, organic will fall from top to bottom as thin film having thickness of 100
microns along with SO3 gas. Because of the residence time SO3 get reacted with organic
and forming corresponding sulphonic acid which is taken to next step.

6. Ageing &Hydrolysis:

This step is applicable only for LABSA production. As LABSA is stable by its nature we
have to do ageing to increase the active matter by allowing the free SO3 to react with
available organic. After this reaction we have to stop the further reaction by adding
small quantity of water to convert the free SO3 in to sulphuric acid otherwise the color of
the final product will be changed due to over sulphonation.

7. Neutralizing:

Other than LABSA all other products (AOA, LEOA, LAA) has to be neutralized after
sulphonation as the corresponding sulphonic acid are weak acid and tend decompose
to produce SO3 and organic. During neutralization diluted caustic soda is reacting with
corresponding sulphonic acid to form sodium salt of corresponding acid. (Alpha olefin
sulphonate for AO, Sodium Lauryl Ethoxy sulphate for LEO, Sodium lauryl sulphate for
LA).
23
8. Effluent Treatment:

During this process acid mist along with SO2& SO3 gas will generate as effluents. Acid
mist is separated using “Electro Static Precipitator” and the gases are treated with
Caustic Soda lye solution in “Wet Alkali Scrubber”. The water generated from Scrubber
operation will be treated in RO plant to recover usable water and the reject is being sent
to evaporator for evaporation.

9. Drying of Final Products:

Final products of Alpha Olefin sulphonate and Sodium Lauryl Sulphate can be dried
using Vacuum dryers / Spray dryers to get desired moisture level and physical form the
FG like Noodle , Needle , Paste or Powder.

B. Specialty Surfactants:
Specialty Surfactants are mild surfactant which is normally produced by reaction of base
raw materials with required functional group amine / chloride / calcium etc. These
compounds are produced by heating the base raw materials in the reactors (SS / Glass
lined) and by addition functional group base materials followed by cooling / Solidification
/ filtration etc.

C. Ultramarine Blue Pigment:

Raw materials like china Clay, Sulphur, Soda Ash, Silica Powder and Tar pitch are mixed
and grinded to the required particle size in dry ball mill using grinding media like pebble
or ceramic balls. After grinding, this raw mix is filled in refractory pots and loaded in the
batch kilns.

These kilns are heated using fuels like coal &Coke to the required temperature and the
temperature is maintained to particular time. After this the kiln is allowed for natural
cooling which will take min 25 to 30 days depending upon the atmospheric conditions.
Then the kilns are opened to unload raw blue (Pigment + By Product) and washed in the
washing tanks / equipment’s to remove the water soluble salts.

After washing or before washing the pigment is grinded using wet mills to get desired
particle size followed by natural settling to separate the pigment based on the particle
size. After settling separation wet pigment is taken to the different type of dryers where
hot air or oil is circulated to remove the moisture.

Final dried pigment is de-agglomerated using high speed turbo’s and blended to get the
desired tone and strength. Then the final product is packed based on the customer
requirement.

24
 D. Ultramarine Violet Pigment:

Ultramarine violet is produced by heating the Ultramarine Blue pigment along with
Ammonium Chloride to the specific temperature in a Heating equipment like Tray dryer
or Blender. During heating sodium is removed from Ultramarine Blue pigment and
producing Ultramarine Violet which is washed, dried, grinded and blended to get desired
shades.

E. Bismuth Vanadate Pigment:

Bismuth vanadate pigment is produced by high temp calcination of Bismuth Tri Oxide
with Vanadium Pentoxide. After calcination the raw yellow pigment is wet grinded in the
wet mill / bead mills to get desired particle size and shade. After grinding the pigment is
filtered using vacuum filters followed by drying in tray dryers. Dried pigment is pulverized
to disintegrate the particles and then blended to get desired shade.

F. Mixed Metal Oxide (MMO) Pigments:

Mixed metal oxide pigments are produced by calcinating the parent metal oxide powder
along with coloring metal oxide (Chromophores / Dopants) at very high temperature of
1100 deg C plus. During calcinations the dopants are doped inside the lattice of parent
metal oxides and thus color is obtained. The color of the final product will vary based on
the parent metal oxide, dopants and their quantity.

After calcinations the raw pigment is wet grinded using ball mills / bead mills to get
desired color shade and particle size followed by filtration and drying. Drying is done
using tray driers / drying cum blending equipment’s which is preheated using Thermic
Fluid Heaters. After drying pigment in disintegrated using high speed Turbo Mills and
then blended to get desired color shade.

3.5 Raw Materials Requirement and storage facility

Raw materials like LAB, Sulphonic acid – LABSA, benzyl chloride, Sodium Chloride are
required for the production process. A detailed list of raw materials required is summarized
in Table 3-3.

Table 3-3 List of Raw materials for Existing and Proposed Expansion (Unit MT/Month)
S. Raw material Monthly consumption Principle Use Storage
No Existing Proposed After
expansion
1. China clay 113.76 90.18 203.94 Raw material Bags
2. Sulphur 254.4 190.09 444.49 Raw material Bulk quantity
in civil
building
3. Sodium -- 118.69 118.69 Raw material Bags
carbonate

25
4. Silica 12.24 35.24 47.48 Raw material Bags
5. Tarpitch 12.24 6.49 18.73 Raw material Bags
6. LAB 1080 -340.96 739.04 For LABSA Tanks
manufacturing
7. AO 960 -293.26 666.74 For AOS Tanks
manufacturing
8. Caustic Soda 15.27 514.29 529.56 Neutralizing Tanks
9. Lauryl alcohol 1000.11 For Tanks
(LA) SLS/SLES
Lauryl manufacturing
Ethoxylate
(LEO)
10. Cobalt -- 33.60 33.60 Raw material Bags/drums
carbonate
CaCO3
11. Aluminum -- 44.05 44.05 Raw material Bags
Hydroxide
Al(OH)3
12. Potassium -- 3.309 3.309 Raw material Bags
Chloride –
KCL
13. Nickel oxide - -- 13.80 13.80 Raw material Bags/ drums
NiO
14. Titanium di -- 709.80 709.80 Raw material Bags
oxide – TiO2
15. Zinc Oxide - -- 12.66 Raw material Bags
12.66
ZnO
16. Nickel -- 5.70 Raw material Bags/ Drums
Carbonate - 5.70
NiCO3
17. Sodium -- 3.30 Raw material Bags
Chloride - 3.30
NaCl
18. Antimony Tri -- 121 Raw material Bags
Oixde - 121.00
Sb2O3
19. Chromium Tri -- 4.17 Raw material Bags/Drums
Oxide - 4.17
Cr2O3
20. Tungsten Tri -- 5.16 Raw material Bags
5.16
Oxide - WO3
21. Potassium -- 5.16 Raw material Bags
Carbonate - 5.16
K2CO3
22. Bismuth Tri -- 35.93 Raw material Bags /
Oxide – 35.93 Drums
Bi2O3
23. Vanadium -- 14.16 Raw material Drums
Pentoxide – 14.16
V2O5
24. Sulphonic 240 Active Tanks
303.03 -63.03
Acid - LABSA detergent
25. Sulphuric -- 9.43 Raw material Tanks
9.43
Acid - H2SO4
26. Calcium -- 87.67 Raw material Bags
87.67
Chloride /
26
 Cal.
Carbonate
27. Diluents as -- 943.45 Raw material Bags /
943.45
Required Drums
28. Distilled -- 443.85 Raw material Drums/
Cocoa Fatty 443.85 Tanks
Acid
29. Mono -- 93.84 Raw material Drums/
93.84
Ethanolamine Tanks
30. Dimethyl -- 314.16 Raw material Drums/
314.16
Lauryl Amine Tanks
31. Benzyl -- 185.84 Raw material Drums/Tanks
185.84
Chloride
32. Hydrogenated -- 382.75 Raw material Drums/
Coco Fatty 382.75 Tanks
Acid (C12-18)
33. Dimethyl -- 149.12 Raw material Drums/
Amino Propyl 149.12 Tanks
Amine
34. Sodium -- 169.58 Raw material Drums
MonoChloro 169.58
Acetic Acid
35. Di -- 141.51 Raw material Drums
141.51
Ethanolamine
36. Stearic Acid -- 435.58 435.58 Raw material Bags
37. Mono -- 95.09 Raw material Drums
Ethylene 95.09
Glycol

3.6 Mode of Transportation

All raw materials, axillary materials & finished goods will be transported using road tankers &
trucks based on the quantity being handled.

3.7 Resource optimization

Sodium sulphate produced as by product in ultramarine blue pigment process will be

washed off using water and the same water will treated in RO & MEE to get solid “Sodium
Sulphate “ which will be reused in detergent production as Sodium sulphate was the major
filler for any detergent.

3.8 Recycling /Reuse of Solvents

No solvent being used in the process

3.9 Power Requirements

The existing power requirement of 1425 kVA is sufficient for the proposed expansion project.
So no additional power is required. The power supply is from. D.G. sets will be used as
alternative source of power and will be used during power failure. The power requirement for
existing and proposed expansion is summarized in Table 3-4.
27
 Table 3-4 Power requirement details
Details Existing Proposed After Expansion (kVA)
(kVA) (kVA)
Power 1425 - 1425
requirement
Back up D.G. 725 x 2 -- 725 x 2
set

3.10 Fuel Requirements

The major fuel used in the production process included Coal, Coke, SKO (Super Kerosene
Oil), LPG, HSD and Furnace oil. The details of Fuel used are given in Table 3-5.

Table 3-5 Fuel requirement details (Existing & proposed Expansion)

S. No Details Point of use Unit Existing Proposed After

expansion
1 Coal Pigment process MT/Day 1.2 -- 1.2
2 Coke Pigment process 3 -- 3
3 SKO Pigment process Lit/Day 1200 -600 600
4 LPG Pigment & spray Tower Kg/Day 400 850 1250
Process
5 HSD DG sets Lit/Day 1000 -- 1000
6 Furnace oil Boiler & spray Tower process MT/Day 3 -0.5 2.5

3.11 Manpower

The total employment in the existing facility is 250 persons including contractual workers

3.12 Water Requirement

The total water requirement for the existing facility is 168.4 KLD. Water requirement for the
proposed expansion process is 412.8 KLD. Water requirement for the project will be met
from SIPCOT. Water bills towards SIPCOT are attached as Annexure 3. Water balance for
the existing and proposed expansion project is attached as Annexure 12.The existing water
requirement and breakup details are given in Table 3-6.

Water requirement and breakup detail for the proposed expansion is given in Table 3-7.

Table 3-6 Existing water requirement

S. Particulars Total Effluent/ Treated Loss Remarks
No water Req. sewage water used
1 Domestic 4.5 4.5 0 0 Sent to STP
2 DM plant 4 4 0 0 Sent to RO
regeneration
3 Boiler 24 1.2 22 0.8 Blow down sent to
RO
4 Cooling Tower 24 3 0 21 Blow down sent to
RO
5 Process 111.2 31.2 35.5 80 sent to RO
6 Floor washing 0.7 0.7 0 0 sent to RO
7 Green belt 0 0 4 0
Total 168.4 44.6 61.5 101.8
28
 Table 3-7 Water requirement for proposed expansion
S. No Particulars Total Fresh Effluen Treated Loss Remarks
water water t/sewa water
Req. req. ge used
1 Domestic 4.5 4.5 4 0 0.5 Sent to STP
Sent to RO II for
2 Boiler 45 4.5 2.5 40.5 2
treatment
Sent to RO II for
3 Cooling Tower 40 40 4 0 36
treatment
RO I Rejects+
Treated Water
+Boiler Condensate
4 Process 307.6 269.5 27 84.1 280.6
is considered in
treated water

Sent to RO II
5 Floor washing 0.7 0 0.7 0 0
treatment
Treated water from
6 Green belt 10 6 0 4 6
STP used
7 MEE cleaning 5 5 5 0 0 --
Total 412.8 329.5 43.2 129.3 325.1 --

29
Figure 3-7 Existing Water Balance Chart

30
 Water Balance – Proposed
Total water Req.
412.8
Fresh Water
Treated / Recycled Water
140 Fresh water Req
Effluent / Sewage
329.5
Evaporation Loss

6 4.5 129.5 RO Treatment

46 189.5

Fresh Water RO Reject RO Permeate

46 143.5

46 Process
124.5
Loss
0.5 Drying Loss 99 4.5 Evap. 40 Evap
2 36
16.6
Domestic
4.5 Process 2 Process1 Cooling Tower
Boiler

Condensate
Treated
water for
38.1 165KLD of 208.6 100%
retained

Blow down
Retained in

40.5
4 Re use

Blow down
product
MEE Cleaning

2.5
STP

4
0.7 27
5

4
Floor
Collection Tank
Washing
To Green Belt
10
RO
39.2
MEE Cleaning

9.1 30.1
30.1 Treated
38.8
5

Reject Permeate water for

Re use
9.1
Condensate
MEE
7.5
1.6
Salt recovered & reused in
VTFD
Condensate
process – 0.433 MT/Day
1.2

Figure 3-8 Proposed Water Balance Chart

31
3.13 Liquid waste management

3.13.1 Industrial Effluent Treatment

Industrial Effluent generation details are given in Table 3-8.

Table 3-8 Effluent generation details for Existing and proposed project
Description Industrial waste Disposal
water generation
Existing (KLD) 9.1 Treated using RO & MEE
Proposed (KLD) - followed by VTFD. Salt
Generated (Na2SO4) will be
After expansion 9.1
reused in Detergent Process.

3.13.2 Sewage Treatment

The existing domestic wastewater is being sent to STP. The existing and proposed Domestic
wastewater disposal details are given in Table 3-9.

Table 3-9 Domestic wastewater generation and Management

Description Domestic Treatment Disposal
waste water units
generation
Existing (KLD) 4.5 STP Domestic waste water is being
Proposed (KLD) - - treated in “Sewage Treatment
After expansion 4.5 STP Plant” of 60 KLD and treated
water is being reused for green
belt development.

3.14 Air Pollution Control Measures

 The discharge of emission from air pollution sources will be passed through stack
and adequate stack height is provided for better dispersion of pollutants.
 Ambient Air quality of the premises will be maintained within the National Ambient Air
Quality standards.
 Emissions are analyzed on regular basis.
 Detailed description on Air pollution control measures is given in Annexure7.

3.15 Waste Management and Disposal Method

3.15.1 Municipal Solid Waste Management

3.15.1.1 Construction Phase

Since the proposed project involves change in product mix and will take place within the
existing facility, no additional construction works are proposed.

32
3.15.1.2 Operation Phase

Municipal Solid waste generation for existing facility is 45 kg/day (STP Sludge is 0.05 kg/day
and will be used as manure for green belt) will be generated and will be disposed off into
local municipal bins. Salt recovered from the effluent treatment will be reused in detergent
production process.

Table 3-10 Solid waste generation and management

S. Waste Quantity (kg/day) Collection Treatment/Disposal
No Existing Proposed After method method
expansion
1 Packing 5 - 5 Bins Sent to TNPCB
materials authorized recyclers
2 Organic 45 - 45 -- Vermi compositing
3 STP 0.05 - 0.05 Sludge Will be used as
sludge drying bedmanure in green belt
development
Note: existing Manpower is 250, no additional man power is required for the proposed
expansion.

3.15.2 Hazardous Waste Management

The Hazardous waste will be stored in isolated area above concrete platform under roofed
shed. These waste will be segregated & stored and will be disposed off by giving it to the
TNPCB authorized dealers/recyclers/TSDF within a stipulated period of time (90 days).

Hazardous waste materials will be properly disposed as per the Hazardous and other
waste/Management Handling and Transboundary Movement) Rules 2016.The type of
hazardous waste and the quantity generated are detailed in Table 3-11. Hazardous waste
authorization letter is attached as Annexure 8.

Table 3-11 Hazardous waste generation and management

S. No Catego Type of the Quantity (MT/Year) Mode of Disposal

ry Hazardous waste Existing Proposed After
Expansion
1 5.1 Used/ Spent oil 4.5 - 4.5 Recover and
Reuse- CPCB
Authorized recyclers
2 5.2 Wastes/ residues 1.2 - 1.2 TSDF
containing oil
3 17.1 Residues, dusts or 6 - 6 TSDF
filter cakes
4 17.2 Spent catalyst 0.2 - 0.2 Buy back with the
(V2O5) suppliers
5 33.3 Discarded 1.2 - 1.2 TSDF
containers / barrels
/ liners
contaminated with
hazardous wastes
/chemicals

33
3.15.3 Non Hazardous Waste Management

Sodium Sulphate will be produced as Solid waste from the VTFD which will be reused in
Detergent Production process.

34
 4 SITE ANALYSIS

4.1 Connectivity

The project site is located in SIPCOT industrial area at survey no 52 and 846, Karai village,
Walajah Taluka, Vellore district Tamil Nadu and project connectivity is shown in Table 4-1.
Project site boundary co-ordinates are given in Table 4-2.
Table 4-1Connectivity of Project site
S. Description Name of Distance Direction
No Connectivity (~km)
1 Nearest Highway NH-1 Adjacent to the SW
project site
2 Nearest state Highway SH 124A Adjacent to the E
project site
3 Nearest Railway station Mukundarayapuram ~3.94 NW
4 Nearest Airport Vellore Airport ~27.48 WSW
5 Nearest major city Ranipet ~1.54 NW

Table 4-2 Geographical locations of the existing project site

S. No Site Point Geographical co-ordinates
Latitude Longitude
0
1. Center co- 12 57’6.66”N 79018’57.93”E
ordinates
2. A 12°57'2.81"N 79°19'3.93"E
3. B 12°57'2.02"N 79°19'2.93"E
4. C 12°57'1.52"N 79°19'2.09"E
5. D 12°57'1.51"N 79°19'1.42"E
6. E 12°57'4.72"N 79°18'50.56"E
7. F 12°57'7.22"N 79°18'52.35"E
8. G 12°57'8.07"N 79°18'52.88"E
9. H 12°57'8.39"N 79°18'53.54"E
10. I 12°57'9.08"N 79°18'54.71"E
11. J 12°57'9.61"N 79°18'55.35"E
12. K 12°57'10.40"N 79°18'55.80"E
13. L 12°57'11.15"N 79°18'56.01"E
14. M 12°57'12.30"N 79°18'56.24"E
15. N 12°57'13.83"N 79°18'56.30"E
16. O 12°57'15.33"N 79°18'56.80"E
17. P 12°57'15.63"N 79°18'57.11"E
18. Q 12°57'15.73"N 79°18'57.28"E

4.2 Land Form, Land use & Land ownership

The proposed expansion project is situated at Survey no 52 and 846, Karai village, Walajah
Taluka, Vellore district, Tamil Nadu. The total land area is 8.66 Ha. Land allotment letter is
attached as Annexure 1. The project site is located in SIPCOT industrial area. The area
breakup details of the project site are given in Table 4-3.

35
 Table 4-3 Land area breakup details
S. No Description Area Percentage
Hectares Acres Sq. m (%)
1 Built up area 2.10 5.18 21000 24
2 Solid waste 0.20 0.49 2000 2
storage/disposal
area
3 Green belt area 3.10 7.66 31000 36
4 Vacant area 3.26 8.05 32600 38
Total 8.66 21.39 86600 100

4.3 Topography of the District

The district covers a geographical area of 6077 sq. km and lies between 12015’ to 13015’
North latitude and 78020’ to 79050’ East longitudes in Tamil Nadu. Vellore the district Head
Quarter is well connected by rail and road to the entire neighboring district, other major town
and to the nearby states. Topo map of the project site is given in Figure 4-1.

36
Figure 4-1 Topo map of the Project site

37
4.3.1 Drainage
The district has the following important rivers: Palar, South Pennar, Cheyyar and Ponnai.
'Palar' is the most important river of the district. Rising near Nandidurg in Karnataka state,
Palar enters the district in the western part through Vaniyambadi taluk. It flows then in an
east-north-easterly direction in the taluk and is joined by some jungle streams like Malattar
flowing in Gudiyattam taluk.

4.3.2 Climate and rainfall

The district has a moderate climate. Some taluks like Arakkonam, parts of Walajapet and
Gudiyattam that are interspersed by hills and mountains are exposed to different climatic
conditions and having very hot weather during the summer seasons.
The district receives rainfall due to southwest and northeast monsoons. The actual level of
rainfall in the district ranges from 570.6 milli meter (mm) in 2002-03, the lowest level in the
last 13 years, to the highest level of 1297.7 mm in 2005-06.

4.3.3 Land use pattern

The nature of irrigation practiced in a region is capable of affecting the cropping pattern,
agricultural income and the standard of living in a rural society. Table 4-4 presents the
dataon the land utilization pattern in Vellore district. The table shows that the total
geographical area of the district is 6077 sq. km out of which 42.68 % was under
agricultural crop land.Land use pattern of the project influence area is given in Figure
4-2.Land use land covermap of the study area is given Figure 4-3.

Figure 4-2 Land use pattern of the project influence area

38
Figure 4-3 Land use Land Cover map of the study area

39
 Table 4-4 Land use pattern of the district
LULC Class Area LULC class Area (Sq.
(Sq. Km)
Km)
Built-up, Urban 110.98 Built-up, Rural 97.8
Built-up, Mining 13.03 Agricultural Crop land 2593.47
Agricultural plantation 416.87 Agriculture, Fallow 486.59
Forest Evergreen/Semi 237.63 Forest deciduous 1111.98
evergreen
Forest, forest plantation 15.3 Forest scrub forest 309
Barren/unculturable/wasteland, 9.38 Barren/unculturable/wastelands, 271.01
salt affected land scrub land
Barren/unculturable/wastelands, 0.81 Barren/unculturable/waste land, 10.77
sandy area Barren rocky
Wasteland/water bodies, 11.16 Wetlands/ water bodies, 281.2
River/Stream/canals reservoir/lakes/ponds
Total 6077.00

4.3.4 Soil
Soil of the district is not uniform and one can observe different varieties of soil. The soil is
mostly of the red femginous variety both sandy and loamy, with black area accounting for
about 16 per cent. The black soil is found mostly in the neighborhood of the rivers of Palar,
Ponnai and in the anaicuts of a few big tanks.

4.3.5 Flora and Fauna

Some varieties of flora and fauna, most of which are unique to the region are found in
Javadi region. On flora, no distinguishing variety is observed in the district. The hilly areas
belong to the 'dry deciduous' type. In the lower areas, plants like tamarind trees, teak wood,
sandal wood, ven-teak, casurina, bamboo etc., can be found. With regard to fauna, no
special and distinguishing variety is available in the district.

4.4 Existing Land use Pattern

The present land is used for the industrial purpose. The land allotment letter is attached as
Annexure 1.The project study area is 8.66 Hectare i.e. 21.39 acres. The land use/Land
cover statistics of 10km radius of the study area is given in Table 4-5. Land use land pattern
of the project study area is shown in Figure 4-4.
Table 4-5Land use/Land cover statistics of 10km radius of the study area
Description Total project study area : 322.29 sq. km
Sq. km Acres Ha. Percentage
Cropland 131.35 32457.24 13135 40.76
Fallow land 55.77 13781.05 5577 17.30
River /Stream/Canals 20.81 5142.255 2081 6.46
Reservoirs /Lakes/Ponds 21.26 5253.452 2126 6.60
Scrub forest 15.14 3741.17 1514 4.70
Deciduous 14.84 3667.038 1484 4.60
Scrub land 14.37 3550.899 1437 4.46
Rural 13.88 3429.817 1388 4.31
Urban 17.3 4274.917 1730 5.37
40
Plantation 11.2 2767.576 1120 3.48
Evergreen/ semi 1.57 387.9549 157 0.42
evergreen
Forest plantation 1.35 333.5918 135 0.42
Salt affected land 0.36 88.9578 36 0.11
Barren rocky area 0.3.6 88.9578 258 0.80
Mining 2.58 637.5309 258 0.80
Sandy area 0.15 37.06575 15 0.05
Total 322.29 79639.47 32229 100

Figure 4-4 Land use pattern of the project study area

4.5 Environmental Sensitivity of the Project site within 15 km radius

Environmental Sensitivity areas of the project site within the 15 Km radius of the project site
are summarized in Table 3-2.

4.6 Existing infrastructure

4.6.1 Land
The total area of the project site is 8.66 Ha. The proposed expansion will takes place in the
existing facility, no construction is proposed.

The area break up detail is given in Table 4-3. The site layout is shown in Figure 3-6.

41
4.6.2 Buildings
Total factory footprint is divided into various sections like Production Blocks, Engineering,
Warehouses, Administration, Toilets etc.

4.6.3 Plant Machinery & Utilities

The Plant Facilities have been designed and set up with the objective to carry out almost all
chemical reactions and processes. As the proposed expansion project will be carried out in
the existing premises, the existing infrastructure facilities will also be utilized with the addition
of some new machinery and utilities for the proposed project. The list of Plant and
Machineries for existing and proposed project are given Table 4-6.
Table 4-6 List of Machinery &Equipment
S. Machinery & Equipment
Plant
No Existing Proposed
1. Film Sulphonation Plant 1. Storage Tanks.
2. Reactors
3. Blowers
4. Compressors
5. Pumps.
6. Filters
7. Oven
8. Catalyst Tower
9. Heat Exchanger
10. Agitating Tanks
11. Instruments Same as present
12. Electrical Panels.
13. Electrostatic
Precipitator.
14. Scrubber
15. Chimney
16. Spray Drier
17. Vacuum Drier
18. Vacuum Pumps /
Ejectors

2 Pigment Plant 1. Storage Tanks

2. Ball Mills
3. Kilns
4. Cyclone Separator
5. Scrubber
6. Chimney
7. Agitating Tanks
8. Settling Tanks
9. Filters
10. Blenders Same as present
11. Dryers
12. Mixers
13. Vibrators
14. Attritor
15. Thermic Fluid Heaters
16. Burners
17. Multi Mills
18. Turbo Grinders

42
3 Detergent Plant 1. Mixer
2. Bucket Elevator
3. Cage Mills
4. Vibratos Same as present
5. Storage Tanks
6. Packing Machines
7. Plodders

4.6.4 Fire & Safety System

Fire hydrant is installed across the plant & required firefighting equipments like
extinguishers, fire buckets etc are provided where ever required. Trained people are
available to mitigate the fire during emergency and regular mock drills are conducted to
enrich the knowledge of the people. Fire Hydrant layout is attached as Annexure-9.

4.6.5 Rain water harvesting facility layout

UPL is having rain water collection system in Sulponation plant and rain water collection &
recharging pits across the plant.
Total no of rain water collection & recharge pits – 8 Nos

Total rain collection area in Sulponation plant – 1068 Sq.M

4.7 Social Infrastructure available

Social infrastructure like religious places, school and colleges and common places within 15
km radius of the project site is given in Table 3-2.

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 5 PLANNING BRIEF

5.1 Planning concept

M/s. Ultramarine and Pigment limited (UPL) is an existing unit engaged in the manufacturing
of Ultramarine Blue, Linear Alkyl Benzene Sulphonic acid, Alpha Olefin Sulphonate and
Synthetic detergents. The proposed project involves change in product mix and will take
place with the existing premises situated at Survey No 52 & 846, Karai village, Walajah
Taluk, Vellore district, Tamil Nadu. The existing production capacity with 4 products is 6550
MT/Month. The proposed production capacity with 8 products is 6400 MT/Month. The
production details are given in Table 5-1.

Table 5-1 Existing and Proposed products with capacities

S. No Products Capacity (MT/Month)
Existing Proposed Total
1. Ultramarine Blue 200 100 300
2. Linear Alkyl Benzene 1350 -350 1000
Sulphonic acid – LABSA
3. Alpha olefin Sulphonate – 1000 Nil 1000
AOS
4. Synthetic detergents 4000 -2000 2000
5. Mixed Metal Oxide -- 50 50
Pigments
6. Bismuth Vanadate -- 50 50
pigments
7. Sodium Lauryl Ether -- 1500 1500
Sulphate (SLES) or
Sodium Lauryl Sulphate
(SLS)
8. Specialty surfactants -- 500 500
Total 6550 -150 6400

5.2 Transportation
 The workforce is sourced locally who come to the factory in their own transport
arrangement by road.
 Raw materials, finished products are transported through Trucks by road.

5.3 Population Projection

The total employment for the existing facility is 250 persons including workers on contractual
basis.

5.4 Land use Planning & Break up

The proposed project is situated at Survey No 52 and 846, Karai village, Walajah Taluk,
Vellore district. The total plot area is 8.66 Hectares utilized for Building, solid waste

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storage/disposal area, and Green belt/irrigation area. Land breakup details are given in
Table 5-2.
Table 5-2 Land area breakup details
S. No Description Area Percentage
Hectares Acres Sq. m (%)
1 Built up area 2.10 5.18 21000 24
2 Solid waste 0.20 0.49 2000 2
storage/disposal are
3 Green belt area 3.10 7.66 31000 36
4 Vacant area 3.26 8.05 32600 38
Total 8.66 21.39 86600 100

5.5 Assessment of Infrastructure Demand

As the proposed project involves change in product mix and quantities, no additional
infrastructure facilities are proposed. The existing road facilities are will be used and
maintained. Medical facilities are available near the project site.

5.6 Amenities/Facilities
The existing site is having all sanitary facilities, Drinking water facility for employees.

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 6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area

The project site is located in SIPCOT Industrial Complex.

6.2 Residential Area

The proposed project involves expansion and change in product mix within the existing
facility. The project is situated at Survey No 52 & 846, SIPCOT industrial complex, Karai
village, Walajah Taluka, Vellore, Tamil Nadu.
The total project area is 8.66 Hectares. The land devoted for greenbelt is 3.10 Hectares i.e.
35.79% of the total project area.

6.3 Social Infrastructure

The project will provide employment to local youth and good supply of products to Domestic
& Commercial purposes, thus increasing their standard of living and thus helping strengthen
the social infrastructure of the region.

6.4 Connectivity
The project site is well connected by road to the nearby locations. The site is adjacent to
State Highway (SH 124A) and to the National Highway (NH 1). The connectivity of the
project site is given in Table 6-1.
Table 6-1 Connectivity of the project site
S. Description Name of Distance Direction
No Connectivity (~km)
1 Nearest Highway NH-1 Adjacent to the SW
project site
2 Nearest state Highway SH 124A Adjacent to the E
project site
3 Nearest Railway station Mukundarayapuram ~3.94 NW
4 Nearest Airport Vellore Airport ~27.48 WSW
5 Nearest major city Ranipet ~1.54 NW

6.5 Drinking Water Management

Drinking water facility is available for the employees with the project site.

6.6 Sewerage system

4.5 KLD of Domestic waste is generated in the existing facility and it is treated in STP.

6.7 Industrial Waste& Emissions management:

Industrial waste effluent generation is given in Table 6-2.

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 Table 6-2 Effluent waste generation for Existing and proposed project
Description Industrial Disposal
waste water
generation
Existing (KLD) 9.1 Treated using RO & MEE followed
Proposed - by VTFD. Salt Generated (Na2SO4)
(KLD) will be reused in Detergent Process.
After 9.1
expansion

6.8 Municipal Solid Waste Management

The solid waste generation and management are given in Table 6-3.
Table 6-3 Solid waste generation and management
S. Waste Quantity (kg/day) Collection Treatment/Disposal
No Existing Proposed After method method
expansion
1 Paper 5 - 5 Bins Sent to TNPCB
materials authorized recyclers
2 organic 45 - 45 Bins Vermi composting
3 STP 0.05 - 0.05 Sludge Will be used as
sludge drying bed manure in green belt
development

6.9 Power and Fuel Requirements and Supply/ Source

The existing power requirement of 1425 kVA is sufficient for the proposed expansion project.
So no additional power is required. D.G. sets will be used in case of emergency during the
power failure. Power and Fuel requirement are given in Table 6-4 and Table 6-5.
Table 6-4 Power requirement details
Details Existing (kVA) Proposed (kVA) After Expansion (kVA)
Power 1425 - 1425
requirement
Back up D.G. 725x2 -- 725x2
set

Table 6-5 Fuel requirement details

Details Point of use Unit Existing Proposed After
expansion
Coal Pigment process MT/Day 1.200 - 1.200
Coke Pigment process 3 - 3
SKO Pigment process Lit/Day 1200 -600 600
LPG Pigment & spray Kg/Day 400 850 1250
Tower Process
HSD DG sets Lit/Day 1000 -- 1000
Furnace oil Boiler & spray MT/Day 3.0 -0.5 2.5
Tower process

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 7 REHABILITATION AND RESETTLEMENT (R &R) PLAN

7.1 Policy to be adopted (Central/ State)

Not applicable as proposed project involves change in product mix and quantities within the
existing facility.

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 8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely date of completion

As the proposed expansion will take place within the industry so no construction activity is
envisaged.

8.2 Project Schedule and Cost Estimate

The overall project cost is 1 Crores for raw materials only.

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 9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits

Existing Annual Turnover: 350 Crores.
Proposed projected Annual Turnover: 400 Crores

9.2 Social Benefit

The project will provide employment to local youth and good supply of products to the
Domestic and commercial purposes, thus helping strengthen the social infrastructure of the
region.

9.3 CSR benefit to local community

Promotion of education and possible infrastructure development in nearby villages will be
undertaken possibly.

9.4 Green belt benefits to the environment

The main objective of the green belt is to provide a barrier between the source of pollution
and the surrounding areas. The green belt helps to capture the fugitive emission and to
attenuate the noise generated apart from improving the aesthetics. M/s. Ultramarine &
Pigments limited will maintain green belt inside the factory premises and also plant trees at
the periphery of the boundary for environmental protection.

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 10 CONCLUSION

 Since the proposed project is expansion within the existing site, there will not be any
change in land use pattern.
 There are no new/additional construction activities.
 Socio – economic benefit to the local people as it would provide both direct
employment and indirect employment.
 Increase in supply of products for commercial purpose will improve the standard of
living and thus helps in strengthen the social infrastructure of the region.
 Marginal impacts if any due to proposed project will be fully mitigated by the
Environmental Management Plan (EMP).

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