PRE FEASIBILITY REPORT FOR

Transcription

1 - PRE FEASIBILITY REPORT FOR PROPOSED EXPANSION OF SYNTHETIC ORGANIC CHEMICALS AND PESTICIDE INTERMEDIATES IN EXISTING UNIT of M/s. ORGANIC INDUSTRIES PVT. LTD. PLOT NO. S/163, GIDC, DAHEJ-I, TALUKA: VAGRA, DISTRICT: BHARUCH , GUJARAT 1

2 CONTENTS Sr. No. Description Page No. 1. Executive Summary 3 2. Introduction of the Project/Background information 9 3. Project Description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation and resettlement (R & R) Plan Project Schedule & Cost Estimates Analysis of Proposal (Final Recommendations) 25 2

3 SR. NO. 1.0 EXECUTIVE SUMMARY 1.1 Company Profile M/s. Organic Industries Pvt Ltd is a leading polymer processing products and chemicals manufacturing company in india Driven by state of the art Production facility having multiple products at multiple locations. The Company has been a Customer-Oriented organization ever since its inception in Project Details Plant-01 (Existing) PRODUCT NAME EXISTING CAPACITY (MT/Annum) ADDITIONAL PROPOSED CAPACITY (MT/Annum) TOTAL PROPOSED CAPACITY (MT/Annum) 1 Potassium Permanganate Boric Acid Technical (All Grades) Borax Decahydrate (All Grades) Di-Sodium Octaborate Tetrahydrate Plant-02 (Existing) 5 Herbal Products by Herbal Extracts (Water Based) i. Aswagandha Withania Somanifera ii. Brami Bacopa Monnieri iii. Andhrographis Pariculata Kalmegh iv. Asphalt Shilajit v. Azartica Indica Neem vi. Asparagus Racemogus Shatavari vii. Boswllia Serrata Salaji Guggal viii. Commiphora Mukal Guggal ix. Garcinia Combogia x. Glycyrliza Glabra Mulethi xi. Gymnema Sylvester Gurmar xii. Lagastrolmia Splciosa Karela xiii. Momordica Pureins Kaunch xiv. Mucana Pureins kaunch xv. Ocimum Santium Tulsi xvi. Terminalia Arjuna Arjuna xvii. Tribulus Terestris - Gokharu Plant-03 (Existing) 6 Roasted Bentonite Granules Soil Conditioner Plant Growth Regulator NPK Mixed Granulated Fertilizer Plant-02-A (Proposed) 10 Herbal Products by Herbal Extract (Solvent based) Plant-04-A (Proposed) - ETHOXILATES & PROPOXYLATES and there condensates 11 Ethylene Oxide / Propylene Oxide Condensate

4 - Direct Sale - Internal Consumption 12 Anionic Surfactants Cationic Surfactants Blended Surfactants (using Intermediates) Powder Surfactants Plant-04-B (Proposed) 16 Sulphocuecinated Products Phosphatised Products Plant-04-C (Proposed) 18 Alkonol Amines (Methyl Diethanol Amines) Plant-04-D (Proposed) 19 Single Compound Double Compound 21 CBS (50%, 60% & 70%) Plant-05 (Proposed) 22 Di-Ethyl-Phthalate Di-Methyl Phthalate Di-Methyl Sulphate Di-Methyl - Aniline Di-Ethyl-Aniline N-Ethyl-Aniline Ethyl Benzyl Aniline Di-Ethyl-Ether Plant-06 (Proposed) 30 Sodium Saccharine Lasamide ,3 DINITRODIPHENYL SULFONE Plant-07 (Proposed) Pesticide Intermediates Chloro 6- Nitro Benzonitrile Amino Dimethyl Pyridine Amino-2,5-dimethylphenol Chloro-2,6-dimethylbromobenzene (CLDMBB) - TOTAL ,320 1,27,260 List of By-Products By-Products Existing Quantity Proposed Quantity Total Quantity Manganese -Silicon Gypsum Calcium Sulphate sludge generated during the production of CABS 70%

5 Dil. H2SO Sodium Phthalate Poly Liquor Ammonia Ammonium Chloride Cuprous Chloride Green Belt Development M/s. Organic Industries Pvt. Ltd. has develop an effective green belt within the factory and on periphery of the factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses. 1.4 Power & Fuel Requirement Power requirement: Existing: Power requirement= 1300 KVA from DGVCL and D.G.Set= 125 KVA After Proposed Expansion: Power requirement= 4500 KVA from DGVCL and D.G.Set= 1500 KVA Fuel Requirement EXISTING Sr. No. Fuel Requirement 1. Coal 100 MT/Day 2. HSD 12 Lit/Hr AFTER PROPOSED EXPANSION 1. Coal 200 MT/Day 2. HSD 35 Lit/Hr 5

6 1.5 Water Requirement and Wastewater Generation & Treatment After Proposed Expansion, fresh water requirement will be met through GIDC, Dahej. Total water requirement after proposed expansion will 655 m 3 /day (Fresh= 526 m 3 /day + Recycle= 129 m 3 /day). Total wastewater generation after proposed expansion will be 193 m 3 /day. The Low COD= effluent (50 m 3 /day) shall be treated in proposed effluent treatment plant consisting of primary treatment and secondary treatment & dispose it to GIDC Drain. The High COD & High TDS-effluent (138 m 3 /day) shall be treated in proposed effluent treatment plant consisting of primary treatment, MEE and Secondary & Tertiary Treatment & send it to plant for reuse purpose. Domestic Effluent (17 m 3 /day) will be disposed through septic tank & soak pit. 1.6 Air Pollution Source and Control Management Particulars Fuel Fuel Quantity Stack height Emission APCM Norms Existing scenario Boiler Coal 100 MT/Day 31 m PM<150 mg/nm3 SO2< 100 ppm Thermic Fluid NOx< 50 ppm Heater (2 Nos) D.G.Set (125 KVA) Diesel 12 lit/hr. 11 m PM<150 mg/nm3 SO2< 100 ppm NOx< 50 ppm Proposed Scenario after expansion (Flue Gas Emission) Dust Collector + Bag filter Cyclone Separator + Bag Filter Boiler -1 Coal 100 MT/Day 31 m PM<150 mg/nm3 SO2< 100 ppm Thermic Fluid NOx< 50 ppm Heater (2 Nos) Boiler -2 Coal 100 MT/Day 31 m PM<150 mg/nm3 (7 MT/Hr) SO2< 100 ppm NOx< 50 ppm Dust Collector + Bag filter Cyclone Separator + Bag Filter Multi Cyclone Separator + Bag filter 31 m Cyclone Separator + Bag Filter Thermic Fluid Heater (1 Nos) D.G.Set (500 KVA) Diesel 83 lit/hr. 11 m PM<150 mg/nm3 SO2< 100 ppm NOx< 50 ppm Proposed Scenario (Process Gas Emission) Process Vent m HCl < 20 mg/nm3 Two Stage 6

7 Particulars Fuel Fuel Quantity Stack height Emission APCM Norms Scrubber Process Vent m SO 2 < 40 mg/nm3 Two Stage Scrubber Process Vent m NH 3 < 175 mg/nm3 Two Stage Scrubber 1.7 Hazardous Waste Management Sr. No. Type of Waste 1. Discarded Containers/Barrels/Carboys Category No Nos/Year Quantity Existing Additional Total 2000 Nos/Year Bags/Liners Nos/Year 2. Used Oil KL/Year 0.6 i.e. KL/Year 50 i.e. Liter/Month 50 Liter/Month 3. ETP Sludge MT/Year i.e. 50 Kg/Month 4. Resin from softening plant DM plant Lit/year i.e. 38 Liter/Month MT/Year i.e Lit/year i.e. 20 Liter/Month 5. Distillation Residue MT/Year i.e Manganese -Silicon MT/Year i.e Gypsum A Calcium Sulphate sludge generated during the production of CABS 70% MT/Year i.e Nos/Year 2500 Nos/Year 1.2 KL/Year i.e. 100 Liter/Month 120 MT/Year i.e Lit/Year i.e. 58 Liter/Month 392 MT/Year i.e MT/Year i.e MT/Year i.e. 100 Method of Disposal Collection, Storage, Reuse or sale to authorized vendor Collection, Storage, Transportation, disposal by sale to registered recycler Collection, Storage, Transportation, disposal at TSDF site of BEIL, Ankleshwar Collection, Storage, Transportation, disposal at TSDF site of BEIL, Ankleshwar Collection, Storage, Transportation, sale to cement industries for co-processing or disposal at common incineration site of BEIL, Ankleshwar Sell to end user Sell to end user White calcium salt CaSO 4 used especially as a 7

8 9. Dil. HCl MT/Year i.e Dil. H2SO Sodium Phthalate Poly Liquor Ammonia Ammonium Chloride Cuprous Chloride Solid Waste: 1. Fly Ash MT/Year i.e MT/Year i.e MT/Year i.e. 300 diluent in tablets and in hydrated form as plaster of Paris. White salt CaSO 4 that occurs especially as anhydrite, gypsum, and plaster of Paris and that in hydrated form is used as a building material and in anhydrous form is used as a drying agent. Sell to end user Sell to end user Sell to end user Sell to end user Sell to end user Sell to end user Sell to end user Sell to brick manufacturer 8

9 2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 2.1 Identification of the project and project proponent. In case of mining project, a copy of mining lease/letter of intent should be given. Identification of the project Proposed expansion of Organic Specialty Chemicals and Pesticide Intermediates in Existing Unit. Identification of the project proponent The company is managed by Directors. Name of the directors are given below: Sr Name of Directors Designation Address No. 1 Mr. Anand M Shetty Director 1801, Odyssey 1, 18 th Floor, Hiranandani Gardens, A.S. Marg, Powai, Mumbai Mrs. Shashirekha A Shetty Director 1801, Odyssey 1, 18 th Floor, Hiranandani Gardens, A.S. Marg, Powai, Mumbai Mr. Pravir A Shetty Director 1801, Odyssey 1, 18 th Floor, Hiranandani Gardens, A.S. Marg, Powai, Mumbai Mr. Adish A Shetty Director 1801, Odyssey 1, 18 th Floor, Hiranandani Gardens, A.S. Marg, Powai, Mumbai Brief description of nature of the Project The proposed expansion project involves the production of Organic Specialty Chemicals & Pesticide Intermediates which falls under item no 5(f) - synthetic organic chemicals & 5(b) Pesticide Intermediates as per the EIA notification, Sept. 14, 2006 (as amended time to time), Since The project is located in Dahej-I, GIDC and due to pesticide intermediates, it is to be treated as Category 'A', and needs to obtain the prior Environmental Clearance from MoEFCC, New Delhi. 9

10 2.3 Need for the project and its importance to the country and or region The products are widely used in pesticide industries, pharma industries and construction chemicals. The proposed products range having good demand in the Market & as per market survey by the company there is a less supply of the products against its demand, to overcome this shortage & to bridge demand-supply gap, the company proposed to have this expansion. 2.4 Demand-Supply Gap Based on our informal survey of the market with our current customers and various traders, we have found that there is a big potential for the range of the products we are planning. These products will be an addition to the current range of our products. 2.5 Imports vs. Indigenous production Based on the current cost of indigenous raw materials, it will make us very competitive against imported finished products and we will be able to increase the export of our finished products. 2.6 Export possibility As per market survey by the company, these proposed products are having a domestic as well as export market due to its application in various types of pesticide industries, pharma industries and construction chemicals. 2.7 Domestic/Export Markets According to our principal customer, there is very good possibility of export of the products. 2.8 Employment Generation (Direct and Indirect) due to project. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed expansion project. 10

11 3.0 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any. Proposed expansion of Organic Specialty Chemicals and addition of Pesticide Intermediates in Existing Unit. Category: 'A'-5(f) & 5(b). 3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates. Map showing general location 11

12 Project Site: 12

13 Plant Layout 13

14 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Major factors involved in the selection of site are listed below: Site is very well connected by road Proximity to Raw Material suppliers Availability of sufficient land free from cultivation Availability of power evacuation facilities Availability of abundant water for industrial use Availability of Port, common MEE, common TSDF & CETP Modern infrastructure support and amenities at par with industrial estates in other global markets, including: Efficient transport facilities within the industrial estate. Environment-friendly zone. Uninterrupted power supply. 3.4 Size or Magnitude of Operation Please refer section 1.2 of PFR. 3.5 Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project etc. should be given) Please refer Annexure-III in Form-I. 3.6 Raw material required along with estimated quantity, likely source, marketing area of final products. Mode of transport of raw materials and finished products. Please refer Annexure-II in Form-I. 3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. There will not be resource optimization/recycling and reuse envisaged in the proposed expansion project. 14

15 3.8 Availability of water its source, energy/power requirement and source should be given. Water Source After proposed expansion, quantity of water consumption will be 655 KL/Day. The entire water requirement will be met through GIDC Water Supply. Power & Fuel Requirement Power requirement: Existing: Power requirement= 1300 KVA from DGVCL and D.G.Set= 125 KVA After Proposed Expansion: Power requirement= 4500 KVA from DGVCL and D.G.Set= 1500 KVA FUEL REQUIREMENT EXISTING Sr. Fuel Requirement No. 1. Coal 100 MT/Day 2. HSD 12 Lit/Hr AFTER PROPOSED EXPANSION 1. Coal 200 MT/Day 2. HSD 35 Lit/Hr 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. After Proposed Expansion, fresh water requirement will be met through GIDC, Vapi. Total water requirement after proposed expansion will 655 m 3 /day (Fresh= 526 m 3 /day + Recycle= 129 m 3 /day). Total wastewater generation after proposed expansion will be 193 m 3 /day. The Low COD effluent (50 m 3 /day) shall be treated in proposed effluent treatment plant consisting of primary treatment and secondary treatment & dispose it to GIDC Drain. 15

16 The High COD & High TDS-effluent (138 m 3 /day) shall be treated in proposed effluent treatment plant consisting of primary treatment, MEE and Secondary & Tertiary Treatment & send it to plant for reuse purpose. Domestic Effluent (17 m 3 /day) is disposed through septic tank & soak pit Schematic representations of the feasibility drawing which give information of EIA purpose. ACTIVITIES OVERVIEW OF E. I. A. STUDIES SOURCE OF INFORMATION RECONNAISSANCE SURVEY OF EXISTING PLANT MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS INTRODUCTION BASELINE ENVIRONMENTAL STATUS SOCIOECONOMIC STATUS & INFRASTRUCTURE PROPOSED EXPANSION PLANT ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. INDIAN METEOROLOGICAL DEPT. IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX METHOD DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM IMPACTS METHODOLOGY OF IMPACT ASSESSMENT ENVIRONMENTAL MANAGEMENT PLAN FACILITY DESCRIPTION CONSEQUENCE ANALYSIS PREPARATION OF DISASTER MANAGEMENT PLAN RISK ANALYSIS STUDIES & DISASTER MANAGEMENT PLAN SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. 16

17 4.0 Site Analysis 4.1 Connectivity Site is very well connected by road Availability of power evacuation facilities Availability of abundant water for industrial use 4.2 Land Form, Land Use and Land Ownership 17

18 4.3 Topography (along with map) 18

19 4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given. CRZ Clearance is not applicable to our industry. 19

20 4.5 Existing Infrastructure Major factors involved in the selection of site are listed below: Site is very well connected by road Proximity to Raw Material suppliers Availability of sufficient land free form cultivation Availability of power evacuation facilities 4.6 Soil Classification It will be incorporated in EIA Studies. 4.7 Climatic data from secondary sources. Primary source: Our own weather station & Secondary Source: Indian Meteorological Department. 4.8 Social infrastructure available. Depending on the growth of the company the required social infrastructure will be provided. 20

21 5.0 Planning Brief 5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country planning/development authority classification. Type of Industry: Proposed expansion of Organic Specialty Chemicals & addition of Pesticide intermediates in Existing Unit. 5.2 Population Projection It will be incorporated in EIA Studies. 5.3 Land use planning (breakup along with green belt etc.) Total Plot Area: 1,71,579 m Assessment of Infrastructure Demand (Physical & Social) Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed expansion project. Social Welfare Cordial relation with the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 5.5 Amenities/Facilities It will be incorporated in EIA Studies. 21

22 6.0 Proposed Infrastructure 6.1 Industrial Area (Processing Area) Processing Area (Processing Zone, ETP Area and Utility Area): m Residential Area (Non Processing Area) Non Processing Area (Green belt, Raw material storage area, finished storage area and open area): m Green Belt M/s. Organic Industries Pvt. Ltd. has developed an effective green belt within the factory and on periphery of the factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses. 6.4 Social Infrastructure Depending on the growth of the company the required social infrastructure will be provided. 6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc) Major factors involved in the selection of site are listed below: Site is very well connected by road Proximity to Raw Material suppliers Availability of sufficient land free from cultivation Availability of power evacuation facilities Availability of abundant water for industrial use 6.6 Drinking water Management (Source & Supply of water) Water requirement will meet through GIDC Water Supply. 22

23 6.7 Sewerage System Sewage pipes are laid in entire company for the removal and disposal of mainly nonharmful liquid wastes from the offices, canteen and domestic waste coming from different sections. These liquid wastes are treated and disposed of by septic tank & soak pit. 6.8 Solid Waste Management Details of Hazardous Waste Generation & Disposal Please refer Topic No. 1.7 of PFR. 6.9 Power Requirement & Supply/Source Power requirement: Existing: Power requirement= 1300 KVA from DGVCL and D.G.Set= 125 KVA After Proposed Expansion: Power requirement= 2800 KVA from DGVCL and D.G.Set= 1500 KVA Fuel Requirement EXISTING Sr. Fuel Requirement No. 1. Coal 100 MT/Day 2. HSD 12 Lit/Hr AFTER PROPOSED EXPANSION 1. Coal 200 MT/Day 2. HSD 35 Lit/Hr 23

24 7.0 Rehabilitation and Resettlement (R & R) Plan 7.1 Policy to be adopted (central/state) in respect of the project affected including home oustees, land ouatees and landless laborers (a brief outline to be given) There is no habitation on the proposed expansion project area and it is within existing industry, so that R & R policy is not applicable to this project. There shall be no displacement of any population in the project area. Any major activity that may lead to resettlement of the people is considered as permanent impact. Hence, there is no permanent impact on this account. The increasing industrial activity will boost the commercial and economical status of the locality up to some extent. 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given). We hereby state that the existing plant is operating as per present CC&A and will seek revised CC&A only after obtaining the environmental clearance & CTE as per this application. Project can be implemented in 8 months after obtaining EC & CTE. 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total costs of the project will Rs Crore (Proposed Expansion). Capital cost of air & water pollution control system and environmental monitoring equipments will be Rs. 2.5 Crore (Proposed Expansion). 24

25 9. Analysis of Proposal (Final Recommendations) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project. Social Welfare shall be done. Cordial relation with the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 25