10 PF Resin (liquid) PF Resin (powder) Silver refining Hexamine Hardener Hexamine Tablet

Size: px
Start display at page:

Download "10 PF Resin (liquid) PF Resin (powder) Silver refining Hexamine Hardener Hexamine Tablet"

Transcription

1 PREFEASBILITY REPORT: 1.0 INTRODUCTION : M/s.Simalin Chemicals Pvt. Ltd.. is an existing unit located at plot no. 13, GIDC, Nandesari, Dist. Vadodara which is a chemical notified zone. The unit is involved in manufacture of synthetic organic chemicals. In view of the expanding market, the unit wants to increase the production of of its products. The expansion will be carried out on the existing plot admeasuring 37,152 sq. mts. The unit is holding a valid Consolidated Consent and Authorisation (CC&A) issued by Gujarat Pollution Control Board (GPCB) vide no. AWH valid till 1/12/2020. The list of products are given below: Table No. 1: LIST OF PRODUCTS: Sr.No. Name of Product Existing Quantity (MT/Month) Quantity for expansion (MT/Month) Total Quantity after expansion (MT/Month) 1 Formaldehyde Hexamine Paraformaldehyde Hexalye Urea / Melamine Formaldehyde (liquid Resin) Powder Resin (Urea / Melamine Formaldehyde) Urea Formaldehyde Concentrate Methylal Foundry Resins (Powder / liquid) and sand quoted resin PF Resin (liquid) PF Resin (powder) Silver refining Hexamine Hardener Hexamine Tablet The existing manufacturing capacity of the plant is 13,450 MT/Month. The Total Manufacturing capacity of the plant after expansion will be 45,327 MT/Month.

2 Table No. 2: Details of Project in brief: Mode of Operation Continuous Process Fuel used LG/FO will be used in the boiler at a rate of 30,000 scm/hr or FO at 38 KL/day. HSD will be used in the DG sets in case of power fuel at 300 Lt/hr Water Requirement 1541 KL/Day from GIDC Water Supply Scheme (permission taken) Waste water Generation 713 KL/day. Domestic Waste Water 8 KL/hr will be sent to the Soak Pit. The industrial Waste Water 705 KL/day the which will be treated in the ETP and passed through RO. 175 KL/day will be recycled and 530 KL/day will be sent to the CETP as per the inlet norms. (membership of CETP for additional discharge taken) Hazardous waste ETP sludge (5.76 MT/Yr) will be disposed off in TSDF of NECL. Used oil generation (2 KL/Yr) will be sold off to authorized recycler. Discarded containers / liner (20 MT/Yr) will be sold off to authorized recycler after decontamination. Filter Cloth (1.92 MT/Yr) will be sent for CHWI for incineration Power requirement 2MW from MGVCL after expansion Cost of Project expansion Rs. 75 Crores Table No. 3: Summary: Parameter Existing For Proposed Plant Remarks 1. Land requirement (sq.mts) 37,152 - Additional land is not required 2. Water requirement (KL/day) Source is GIDC Water supply scheme 3. Power requirement (KVA) Will be sourced from MGVCL 4. Waste water generation (KL/day) Domestic Waste water (8 KL/day) will be sent to Soak pit. 175 KL/day will be recycled and 530 KL/day will be sent to CETP of NIA, Nandesari for its further treatment and disposal. 5. Air pollution Control a) Fuel Burning i) Lean Gas (Nm 3 /hr) iv) Process Emissions Lean gas used in boiler No process emissions 6. Hazardous Waste a. Used /Spent oil (MT/Yr.) b. Discarded containers/ barrels / liners(mt/yr.) Will be sold to authorized recycler or sent to NECL Will be sold to authorized scrap dealer Will be sent to NECL for its disposal

3 c. ETP Sludge (MT/Yr.) d. Filter Cloth (MT/Yr.) e. Activated Carbon (MT/Yr) Will be sent to NECL for its disposal. Will be sent to NECL for its disposal 2.0 INTRODUCTION: 2.1 THE PROJECT: M/s. Simalin Chemical Industries Pvt. Ltd. located on plot ono. 13, GIDC, Nandesari was established by Shri Vishubhai Patel in The unit is holding a valid Consolidated Consent and Authorisation (CC&A) issued by Gujarat Pollution Control Board (GPCB) vide no. AWH valid till 01/12/2021 for manufacturing Formaldehyde, Hexamine, Para Formaldehye and Hexalye. The unit now intends to increase the manufacturing capacity from 13,450 MT/Month to 45,327 MT/Month. 2.2 PROJECT PROPONENT: The Industry is run by a group of directors who are actively involved in Production, Adminstration and Sales. The list of directors are given below in Table No. 4 Table No. 4: List of Directors: Sr.No. Name of the directors 1 Shri. Vishubhai B. Patel 2 Shri. Ashokbhai V. Patel 3 Shri. Sunilbhai V. Patel Designation Address Mobile No. Director Director Director 1, Shriram Society, Gotri Road, Vadodara. 2, Shriram Society, Gotri Road,Vadodara. 2, Shriram Society, Gotri Road, Vadodara NATURE OF PROJECT: The unit is involved in the manufacturing of Formaldehyde, Hexamine, Paraformaldehyde and Hexaline and located in the Notified Chemical Zone of GIDC, Nandesari falls under the category 5(f)b. The unit intends to increase the production of its present products from 13,450 MT/Month to 45,327 MT/Month. 2.4 MARKET FEASBILITY: The products manufactured by M/s. Simalin Chemical Industries Pvt. Ltd. have a high market potential. Simalin Chemicals Industries Limited, Vadodara, India was set-up under the technical collaboration from

4 Chematur, Sweden, the world leaders in Formaldehyde technologies. The installed capacity of Formaldehyde, Hexamine and Paraformaldehyde are one of the highest in India. Now the unit wants to increase the manufacturing capacity of these products and wants to manufaacture different type of resins. There is regular demand of these chemicals in the local market. Also it has a good export potential. The expansion will help to meet the demand and will generate additional employment. 2.5 EMPLOYMENT GENERATION DUE TO PROJECT: The expansion project will generate employment for the local and nearby population. A total of 100 nos. of personnel (Skilled as well as unskilled) will be employed to carry out the proposed production after expansion. 3.0 PROJECT DESCRIPTION: 3.1 TYPE OF PROJECT: M/s. Simalin Chemical Industries Pvt. Ltd., located in the Chemical Notified Zone of GIDC, Nandesari will be manufacturing Organic Chemical and the proposed expansion is not interlinked or interdependent on any other projects. 3.2 PROJECT LOCATION: The project is located at Plot No. 13 in the Chemical Notified Zone of GIDC, Nandesari. The area of the plot is 37,152 sq mts. GIDC Nandesari is located about 17 km NW of city of Vadodara. Table No. 5: Salient features of the site Particulars Taluka/Tehsil District Geographic Location Nearest city Nearest Town Nearest Highway Nearest Airport Protected Areas/Sanctuaries Elevation above mean sea level Details Vadodara Vadodara 22 o N, 73 o E Vadodara (17 kms in the SW direction) Vadodara Ahmedabad Vadodara NH 8 Highway Vadodara NA 34 mts

5 Location of Site on GIDC Map

6 Landmarks in the 10 km radius circle

7 3.3 SITE SELECTION: The expansion activities will be carried out in the existing plot. 3.4 NEIGHBOURING INDUSTRIES The proposed site is already in the chemical Notified Zone of GIDC. Table no. 6 shows the neighbouring industries Table no. 6 Neighbouring Industries Name of industry Deepak Nitrite Ltd. GIDC Internal Road Deepak Nitrite Ltd. Farmson Pharma Ltd. Direction w.r.t project site South West East North 3.5 SIZE OF THE PROJECT: The existing capacity of the plant is 13,450 MT/Month which the unit intends to increase to 45,327 MT/Month. The total cost of expansion is expected to be about Rs. 75 Crores. The expansion will be carried in the existing plot. Additional land is not required for expansion. However, new machinery will be procured and erected. The ETP will also be expanded for additional waste water treatment load. A breakdown of the cost of expansion is given below in Table No. 7. Table No. 7. Breakup of cost of expansion Sr. No Purpose Projected Investment (Rs in Crores) 1 Land -- 2 Building Plant and machinery Effluent treatment plant Fire and safety equipment Green belt development Air pollution control measures -- 8 Hazardous waste storage area Utilities 15.0 Total 75.0

8 3.6 PROCESS TECHNOLOGY: The project involves expansion of the existing product. The unit is already manufacturing the products (process technology indigenous) since RAW MATERIAL: The list of raw materials is given in table no. 8. Table 8. List of Raw Materials Raw Material Qty (MT/Month) Ammonia Formaldehyde Caustic Soda 7.5 Methanol Urea 1500 Hexamine 725 Calcium Stearate 175 Camphor RESOURCE OPTIMIZATION / RECYCLE & REUSE: All the process are continuous process. The addition of chemicals are by metering pumps. The organic vapours generated during the manufacturing process are fed back into the boiler as fuel 3.9 RESOURCE REQUIREMENT: LAND: The expansion will be carried out on the existing plot of land. Additional land will not be required for expansion. The total plot area is Sq Mts BUILDING: Additional building structures will be constructed to house the new plant, raw material and finished material storage sheds and effluent treatment plant, hazardous waste storage yard.

9 3.9.3 POWER AND FUEL: The power and fuel requirement is given in table no. 9. Table No. 9 Fuel and power requirements Sr. No. Stack Attached to Fuel Fuel Consumption Stack Height (m) Stack dia. (mm) Source Existing Flue gas stack 1 Boiler (GT-7019) Capacity 10 TPH LG/ FO scm/hr or 10 KL/day 31 mts 1500 Process plant 2 Boiler (GT-2597) FO 8.0 KL/day 30 mts 750 Capacity 4 TPH 3 DG Set (1500 KVA) HSD 250 Lt/hr 7.5 mts DG Set (250 KVA) HSD 50 Lt/hr 7.5 mts 400 Proposed Flue gas stack 5 Boiler 10 TPH LG/ FO scm/hr or 10 KL/day 31 mts 1500 Process Plant 6 Boiler 4 TPH FO 8.0 KL/day 30 mts 750 Power Requirement 7 Energy - Electricity Existing 750 KVA Proposed 2 MW MGVCL WATER: The water will be sourced from GIDC Water supply scheme. For expansion additional water consumption will be 1581 KL/day. Permission to procure water has already been taken from Water Utilities Department. The Total water requirement will be 2274 KL/day. Total waste water generation from the plant will be 713 KL/Day, of which 8 KL/Day will be from domestic activities and rest 705 KL/Day from industrial activities. The waste water will be taken to ETP plant for its treatment and further disposed to CETP of NIA. The domestic waste water will be sent to the soak pit. The waste water after treatment will be passed through RO. 175 KL/day will be recycled and 530 KL/day will be sent to CETP for final disposal.

10 Table 10: Existing Water Consumption and Waste water generation Details: No. Usages Existing Water Consumption (m 3 /day) Proposed Water Consumption (m 3 /day) 1 Domestic Gardening Industrial RO + DM Water a) Process b) Boiler c) Washing d) RO Reject SW Water a) Cooling Tower b) Backwash & Regeneration Total Industrial Total Total Water Consumption (m 3 /day)

11 Table No. 11: Proposed Water Consumption and Waste Water Generation Details : No. Usages Existing Wastewater generation (m 3 /day) Proposed Wastewater generation (m 3 /day) Total Wastewater generation (m 3 /day) 1 Domestic Gardening -- Industrial RO + DM Water a) Process b) Boiler c) Washing d) RO Reject SW Water a) Cooling Tower b) Backwash & Regeneration Total Industrial Total The total waste water quantity generated will be about 705 m 3 /day. This will be passed through filter press and stored in treated water tank. Then it will be passed through RO unit to recover the waste water. 175 m 3 /day will be recycled back to the plant and 530 m 3 /day having high TDS will be sent to CETP

12 3.10 EMISSIONS AND MITIGATION MEASURES: PROPOSED WASTE WATER TREATMENT SCHEME: Quality of Untreated Effluent: The quality of effluent produced by the unit is as follows. ph ~6.8 COD 100 ~ 150 mg/lit. BOD - 35 ~ 50 mg/lit SS 34 ~ 50 mg/lit. The waste water from different sources will be collected in the collection tank. It will be then pumped through a settling tank and collected in Final collection tank. From the final collection tank it will be pumped to the CETP inlet collection tanks via pipeline. We are already discharging to the CETP by pipeline and the treated water COD is always less than 250 mg/l. We will be installing the online COD meter as per the instructions of CETP authorities GASEOUS EMISSIONS AND CONTROL: The only sources of emissions are from utility stacks of boiler. Natural gas will be used as fuel in the boiler. There are no process emissions Flue Gas Emission: Sr. No. Stack Attached to Fuel Existing fuel Consumption Existing Flue gas stack 1 Boiler (GT-7019) LG/ scm/hr Capacity 10 TPH FO or 10 KL/day 2 Boiler (GT-2597) Capacity 4 TPH Stack Height (m) Stack dia. (mm) 31 mts 1500 FO 8.0 KL/day 30 mts DG Set (1500 KVA) HSD 250 Lt/hr 7.5 mts DG Set (250 KVA) HSD 50 Lt/hr 7.5 mts 400 Proposed Flue gas stack 5 Boiler 10 TPH LG/ scm/hr 31 mts 1500 FO or 10 KL/day 6 Boiler 4 TPH FO 8.0 KL/day 30 mts 750 LG Lean Gas

13 DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL: The details of hazardous waste generation and its disposal is given in table no. 13. Table No. 11. Hazardous waste generation and its disposal: Sr No Waste Description Cat. Existing Proposed Expansion ETP Sludge MT/Year MT/Year Filter Cloth MT/Year Discarded Bags & containers MT/Year Used Oil KL/Year Activated Carbon 1.44 MT/Year 8.96 MT/Year 1.94 KL/Year Total 5.76 MT/Yr 1.92 MT/Yr 20 MT/Yr 25 MT/Yr 10 MT/Yr 35 MT/Yr Mode of Disposal Collection, Storage, Transportation and disposal at TSDF, Nandesari. Collection, Storage, Transportation and disposal by incineration at CHWI. Collection, Storage, Decontamination to authorized vendor. 2 KL/Yr Collection, Storage, Transportation and disposal to registered recycler Collection, Storage, Transportation and disposal at TSDF, Nandesari.

14 3.11 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE: 4.0 SITE ANALYSIS: 4.1 CONNECTIVITY: The unit is located in a Designated Chemical Zone of Gujarat Industrial Development Corporation at Nandesari. GIDC, Nandesari is the only Chemical Estate in Gujarat where all the roads are of concrete with paved sidings. A very good and efficient network of transport facilities exists for transport of

15 incoming raw material and outgoing finished goods, since the site is already located in an industrial estate. The site is only 4 Km from the NH8 connecting Vadodara and Ahmedabad and is only 1 Km away from Nandesari Railway station and 15 km from Vadodara railway station. 4.2 LANDUSE AND OWNERSHIP The expansion project will be carried out in the existing plot of land. Additional land is not required for expansion activities. The land is already owned by the promoters of the company. 4.5 SOIL CLASSIFICATION: Alluvial sandy loam to sandy clay soils are found in the region. 4.6 CLIMATE DATA: Vadodara district area, in general, being located south of Tropic of Cancer and in transition zone of heavy rainfall areas of South Gujarat and arid areas of North Gujarat plains, have sub-tropical climate with moderate humidity. The various season of the year are (a) monsoon - middle of June to October, (b) winter - November to February, and (c) summer March to June. From March onwards the temperature starts rising till it reaches maximum, as high as 41 C in some parts of the district. January is the coldest month of the year. 4.7 SOCIAL INFRASTRUCTURE: The entire region including urban as well as rural area show the signs of modernization and development. The basic parameters like education, water, medicine, post and telegraph communication road development and power supply are available which decide the measure of this development. Educational facilities are available to 100% of the population. All the villages have a minimum of one primary school. higher secondary education is available with 10 km of any village. There are several colleges, polytechnic, industrial training schools and other employment oriented training centres. All the villages and towns have potable water supply and in 100% area the drinking water is supplied through taps. 100% of the villages are connected to main commercial and industrial centres by pucca roads. There is 100% electrification in the area.

16 The medical facilities are available at almost 100% of the human settlements. These facilities are available in the from of hospital, dispensary, primary health centre, family welfare centres and child welfare centre. 5.0 PLANNING BRIEF: 5.1 PLANNING CONCEPT: The unit is located in a Designated Chemical Zone of Gujarat Industrial Development Corporation at Nandesari. GIDC, Nandesari is the only Chemical Estate in Gujarat where all the roads are of concrete with paved sidings. The CETP in Nandesari, operated by Nandesari Industries Association, is the only CETP running on advance oxidation technologies of Hydrodynamic Cavitation which has been authenticated by NEERI, Nagpur.. This CETP has received the permission to treat 12 MLD of waste water. Now the CETP is expanding its facility from 12 MLD to 20 MLD. The TSDF facility at GIDC, Nandesari is operated by Nandesari Environment Control Ltd., a subsidiary company of Nandesaari Industries Association. The TSDF facilities comprises of Landfill facilities and hazardous waste destruction by Plasma pyrolysis, the only facility in Gujarat. The TSDF facility also possess the permission to send the hazardous waste for coprocessing to M/s. Gujarat Ambuja Cement Ltd., Kodinar. Table No. 13: Type of Industries in Nandesari GIDC Estate: Dye and Dye intermediates manufacturing units 32% Pharma and Pharma Intermediate manufacturing units 23% Synthetic Organic Chemical manufacturing Units 22% Inorganic Chemical manufacturing Units 14% Recovery Units 4% Pesticide manufacturing units 3% Engineering Units 3%

17 5.2 POPULATION PROJECTION: Since the 10 Kmradius circle covers part of Vadodara and Anand, the demographic profile of both the districts is given below: The details of Vadodara and Anand districts are summarised in the table below: Table No. 14 District wise Census Details Table No 15 Percentage Decadal Variation in Population for State and Districts: District Code State/Districts Percentage Decadal Variation 15 Anand Vadodara Table No 16 Sex-Ratio for State and Districts : District Code State/Districts Sex-ratio since (Number of females per 1000 males) Anand Vadodara LAND USE PLANNING : The proposed expansion will be carried out in existing plot which is located in the Chemical Notified Zone of GIDC, Nandesari.

18 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND: There will be no impact on land resources since the proposed project is coming up in a notified chemical zone of GIDC, Nandesari. Additional land is not required for the proposed expansion. During the operation phase, the water requirement will increase from existing 693 KL/day to 2274 KL/day. The water requirement will be met from GIDC Water Supply Scheme. Permission for additional water has already been taken. The power requirement will increase from 750 KVA to 2000 KVA. The demand will be met from MGVCL. The unit will provide employment to 80 nos of skilled and unskilled workers. 5.5 AMENITIES/ FACILITIES: The available basic amenities are as under. a. Education facilities : The education facility is available in each nearby Nandesari village. The school comprising of primary and secondary school is run by Nandesari Industries Association b. Medical facility: The medical facility are available in the study area. Deepak Medical foundation is running a full fledged hospital in the estate. Doctors are available round the clock. The advanced medical treatment is available in nearby Anand and Vadodara Cities c. Drinking water facility & power supply: All the villages have potable water supply and in 100 % area the drinking water is supplied through taps, wells, and tube wells. d. Post, Telegraph and Telephone facilities: The government has provided providedpost and telegraph services to most of the village around. Being a industrialised estate, facilities of Internet, courier services are also available in the Estate e. Transport facility: The proposed area has a good connectivity via state road transport facility due to its closeness to the national highway

19 6.0 PROPOSED INFRASTRUCTURE: 6.1 PROCESSING AREA: For the proposed expansion, the processing area will cover 5000 sq mts. 6.2 NON PROCESSING AREA The non-processing area will cover admin building, security cabin, canteen, open space which will be GREEN BELT A total of 1000 sq mt will be used for developing of greenbelt 6.4 SOCIAL INFRASTRUCTURE: The basic infrastructure facilities provided is as under: (A) Training & Education: All the employees will be trained and educated periodically about the hazardous nature of chemicals used in the process. Also, training will be provided for firefighting, first aid, safe handling of hazardous chemicals. (B) Medical facility: Pre-employment medical checkup will be undertaken at the time of employment. In order to safe guard the health of the employees, all the employees undergo periodic health checkup as the factory act rules. (C) Drinking water: RO drinking water will be provided to all the employees (D) Transportation: The unit will provide basic transportation facility for workers. (E) Telegraph & Post: There is provision of telephone, fax & internet facility. (F) Power supply: 2 MW electric load will be sourced from MGVCL. 6.5 DRINKING WATER MANAGEMENT: The employees will be provided with RO water for drinking. 6.6 SEWAGE SYSTEM The domestic sewage (8 KL/day) will be sent to the soak pit. 6.7 INDUSTRIAL WASTE MANAGEMENT The waste water generated will be first treated inhouse ETP and will then be sent to CETP as per the inlet norms.

20 6.8 SOLID WASTE MANAGEMENT The solid hazardous waste management details are provided in Table No POWER REQUIREMENT & SUPPLY The unit will use total 2000 KVA electricity which will be sourced from MGVCL. 7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN: The Project is located in the GIDC Estate of Nandesari and does not involve any displacement of human population 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 PROJECT IMPLEMENTATION S Table No. 17 Project Implementation Schedule Sr. No. Activity Required Period 1. Civil work After getting CTE and EC 2. Procurement of machinery After getting EC 3. Erection & installation of machinery After receiving CTE from GPCB 4 Application for CCA 15days before commencement of Trial 5. Commercial activity After receipt of CC&A from GPCB 8.2 ESTIMATED PROJECT COST The Estimated cost of Expansion Project is Rs. 75 Crores. 9.0 ANALYSIS OF PROPOSAL It is a proposed expansion project at plot no. 13,GIDC, Nandesari. Dist. Vadodara. The unit intends to increase the capacity of one of the existing products and introduce additional products. Lean Gas will be used as a fuel for the proposed project. The domestic waste water will be sent to soak pit and industrial waste water will be given primary treatment before being discharged to the CETP of NIA, Nandesari. The solid waste generated from the ETP and other residue and waste from process will be sent to NECL, whereas recyclable waste will be sent to authorized recyclers. The local manpower will be used as far as possible.