PRE FEASIBILITY REPORT

Transcription

1 PRE FEASIBILITY REPORT For PROPOSED EXPANSION OF SYNTHETIC ORGANIC CHEMICALS IN EXISTING UNIT of M/s. SPAN REMEDIES PVT. LTD. Plot No. 502/15-16, GIDC Industrial Estate, Ankleshwar , Dist. Bharuch, Gujarat, INDIA. 1

2 CONTENTS Sr. No. Description Page No. 1. Executive Summary 3 2. Introduction of the Project/Background information Project Description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation and resettlement (R& R) Plan Project Schedule & Cost Estimates Analysis of Proposal (Final Recommendations) 33 2

3 1.0 EXECUTIVE SUMMARY 1.1 Company Profile M/s. Span Remedies Pvt. Ltd. engages in manufacturing of Bromine and dye intermediates at Plot. No. 502/15-16, GIDC Industrial Estate, Ankleshwar , Dist: Bharuch, Gujarat, India. Now, company is going for new Synthetic Organic Chemicals within existing manufacturing unit. 1.2 Project Details Products along with Production Capacity Sr. Name of Products CAS No. Production Capacity End Use No. (MT/Month) Existing Additional Total 1. Diamino Nil Acid Black Dyes Benzsulfanilide (DASA) 2. Diamino Stilbene Disulphanic Acid (DASDA) Nil Optical Brighteners of fluorescent 3. Ortho Amino Phenol Perasulphanic Acid(OAPSA) 4. DiaminoDiphenylamine -2-Sulphanic Acid(F.C. Acid) whitening agent Nil 6 Nitro Amino 2 Sulphanic Acid Nil Reactive Dyes & Acid Metal Dyes 5. Bromine (Liquid) N-Butyl Bromide & N-Propyl Bromide 6. N-Butyl Bromide (NBBr) and/or Tetra Butyl Ammonium Bromid - 7. N-Propyl Bromide dipropyl aceto (NPBr) and/ or Acetic Ester 8. Bromo Benzene M. Phenoxy Benzaldehyde 9. Hydro Bromic Acid (HBr) For Ethyl Bromide 10. K.Br and/or Photographic 3

4 11. NH 4 Br and/or Developer 12. NaBr and/or Mf N-Butyl 13. CaBr Bromide Oil & Gas Well Bromo Methyl - 2 Cynobipheneyl Or / and Mfg. for Irbesartan, Lasartan, Valsartan M. Bromo Nitro Floro Bennzene (Murpholinomet hyl)aniline Mfg. of Ariprazole 15. Para Bromofloro Benzene Or/and 16. Para Nitro Benzyl Bromide 17. 1, 4 Dibromo Butane Or/and Decyl Bromide Decyl 23 dimethylimidazoli um Bromide 19. Ethyl 2 Bromo Butyrate Ethyl 2 Bromo -4- (E2BB) Or/and Phenyl Butarate 20. Ethyl - 2 Bromo Ethyl 5-Bromo Propionate (E2BP) - (2 Pyridyl), Indol- 2 Carboxylate(Nepr oxine) 21. Bromo Acetaldehyde Dimethylacetal and 2Bromomethyl (1,3) dioxolane Or/and Use in Doxofilline Propyl Pentanoic Acid Mfg. of Valproic Acid 23. Meta Bromo Anisole Tramadol Hydrochloride 24. Tetra Butyl Ammonium Phase Transfer Bromide Or/and Catalyst Tri Ethyl Benzyl Phase Transfer Ammonium Chloride Catalyst Amino 124 Triozole Use in Fluonazole Chloro Salicyclic Acid Glibenclamide 28. Pyridine Sulphur Trioxide 29. Benzyl Bromide Anticoagulation benzyl1,2dimeth ylimidazollium bromide 4

5 30. 2,4 Dichloropyrimidine Hydroxy Benzyl Alcohol TOTAL aryl 5 Pyrimidinylimidaz oles Bisoprolol NOTE: - Maximum 330 MT/ Month will be manufactured from the above proposed products. 1.3 Raw Material Requirement Sr. No. Raw Materials Consumption Quantity (MT/MT) CAS No. 1. Diamino Benzsulfanilide (DASA) Para Nitro aniline Iron Powder HCl Soda ash Acetyl Sulphanil Chloride Caustic Soda Dil. H 2 SO Diamino Stilbene Disulphanic Acid (DASDA) PNT Oleum 23% Caustic Lye Chlorine PNTSA Soda ash Sodium Hypo Chloride Spent Acid Salt HCl Iron Powder Ortho Amino Phenol Perasulphanic Acid (OAPSA) ONCB SA Oleum 23% Salt Caustic Flakes Spent Acid Iron Powder HCl , Diamino Diphenylamine-2-Sulphanic Acid (F.C. Acid) 5

6 PNCB Oleum 23% Salt PPD Caustic Spent Acid Iron Powder Bromine (Liquid) NaBr Or KBr Or HBr Or NH 4 Br Chlorine Gas N-Butyl Bromide (NBBr) n-butanol Liquid Bromine Sulphur as Catalyst N-Propyl Bromide (NPBr) n-propanol Liquid Bromine Sulphur as Catalyst Soda Ash Bromo Benzene Benzene Br Soda Ash Crude Bromobenzene Hydro Bromic Acid (HBr) Liquid Bromine Cat. Sulphur Crude HBr Solution Potassium Bromide KOH Soln HBr Soln Ammonium Bromide (NH4) 2 OH Soln HBr Soln Calcium Bromide Calcium hydroxide HBr Soln Sodium Bromide NaOH Soln HBr Soln Soda Ash Bromo Methyl - 2 Cynobipheneyl 6

7 4-Methyl 2-Cynobiphenyl Bromine MDC Catalyst Methanol Para Bromofloro Benzene Fluoro benzene FeCl Bromine Soda Ash Para Nitro Benzyl Bromide (PNBBr.) Para Nitro Toluene Bromine Water IPA , 4 Dibromo Butane Tetra Hydrofurane Bromine Sulfur Caustic Soda Water Decyl Bromide Decanol Bromine Sulfur Soda Ash Ethyl 2 Bromo Butyrate (E2BB) Butyric Acid Catalyst Liquid Bromine Ethanol Sulphuric acid Ethyl - 2 Bromo Propionate (E2BP) Propionic Acid Bromine Sulfuric Acid Ethanol Soda Ash Bromo Acetaldehyde Dimethylacetal and 2Bromomethyl (1,3) dioxolane Vinyl Acetate Methylene Dichloride Liquid Bromine

8 MonoEthyl glycol Pera Toludine Sulphanic Acid Propyl Pentanoic Acid Methyl Aceto Acetate N-Propyl Bromide Catalyst TBAB Caustic Soda Methanol Sulphuric Acid Meta Bromo Anisole Meta Bromo Nitrobenzene KOH Soda Ash Toluene Sulpher Methanol TBAB Water HCl Tetra Butyl Ammonium Bromide Tri N-Butyl Amine NBBr Aceto Nitrile Ethyl Acetate Tri Ethyl Benzyl Ammonium Chloride Toluene Isopropyl Alcohol Benzyl Chloride Tri ethyl Amine Amino 1,2,4 Triozole Hydrogine Hydrate Formic Acid Mix Xyline Methanol Chloro Salicylic Acid Salicylic Acid Ortho Dichloro Benzene Cl2 (Gas) Pyridine Sulfur Trioxide Pyridine Chloroform Chloro Sulphonic Acid

9 Water Benzyl Bromide Benzyl Alcohol Hydro Bromic Acid Catalyst Water Soda ash ,4 Dichloropyridine Uracil Chloroform Phosphorus Oxychloride Water Sodium Bicarbinate Hydroxy Benzyl Alcohol 4-Hydroxy Benzyldehyde Water Caustic Soda Sodium Boro Hydride Acetic Acid Active Carbon Hyflow Water Requirement, Waste Water Generation and Treatment Total water requirement will be 30.5 KL/Day which will be met through GIDC water supply. The wastewater generation will be 32.5 KL/Day. The raw effluent (29.0 KL/day) will be sent to ETP which consists of primary treatment facility and then after sent to CETP of M/s ETL, Ankleshwar (14.5 KL/Day) (Existing) and Common MEE of M/s ACPTCL, Ankleshwar (14.5 KL/Day) (Proposed) for further treatment & disposal. Domestic Wastewater (3.5 KL/Day) will be disposed to soak pit & septic tank. 1.5 Air Pollution Source and Control Management There will be emission from Boilers (2 Nos.), Hot Air/oil Generator, Process Vent (2 Nos.) and D.G. Set (2 Nos.). To control the emission from process vent, adequate Two Stage Water and Caustic scrubber will be installed. 9

10 Source of flue gas emission Sr. No. Stack/Vent attached to Stack Height (meter) Stack Diameter (meter) Fuel name & Quantity Type of Emission APCM Existing 1 Boiler-I (850 Kg/hr) 2 Hot Air /Oil Generator(4 la k cal) 5 D.G. Set* (82 KVA) Wood # (450 Kg/day) or Natural gas (400 m 3 /Day) Wood # (300 Kg/day) or Natural gas (100 Sm 3 /Day) HSD (50 Liter/Month) PM SO 2 NOx PM SO 2 NOx PM SO 2 NOx Adequate Stack Height Adequate Stack Height Adequate Stack Height Proposed 6 D.G. Set* (82 KVA) HSD (50 Liter/Month) PM SO 2 NOx Adequate Stack Height 7 Boiler (1.5 TPH) Natural gas (600 Sm 3 /Day) PM SO2 NOx Adequate Stack Height # Wood will be discontinued after proposed expansion. * To be used in emergency only. Source of process gas emission Sr. no. Source emission of 1 Process Vent-1 (Sulphonation/ Bromination) 2 Process Vent-2 (Bromination) Type of emission HCl Cl 2 Br 2 Stack/Vent Height (meter) Stack/Vent Diameter (meter) Air Pollution Control Measures (APCM) Water Scrubber follow by Two Stage Alkali Scrubber Br Water Scrubber follow by Two Stage Alkali Scrubber 10

11 1.6 Hazardous Waste SR. NO. TYPE OF WASTE SOURCE OF GENERATION SCHEDULE/ QUANTITY CATEGORY EXISTING ADDITIONAL TOTAL NO. DISPOSAL 1 ETP Sludge ETP Sch-I/ Used oil Equipment and Machinery 3 Inorganic Waste 4 Distillation Residue 5 Discarded Containers / Plastic Bags 6 Scrubbing Media (NaBr./Hbr) Process (4-Hydroxy Benzyl Alcohol) Sch-I/ 5.1 Sch-I/ 28.1 Distillation Unit Sch-I/ 36.1 Raw Material & Storage Scrubber 7 Dil. H 2 SO 4 Process (N-Propyl Bromide, Decyl Bromide) Sch-I/ 33.1 Sch-I/ 28.1 Sch-II/ B-15 MT/ Year Collection, Storage, transportation in HWSA and sent to common TSDF site of M/s. BEIL, Ankleshwar for disposal Collection, Storage, transportation in HWSA and sent to GPCB recycler Collection, Storage, transportation in HWSA and sent to common TSDF site of M/s. BEIL/SEPPL/GSPL for disposal Collection, Stores, Transportation in HWSA and sent to M/s. SEPPL/GSPL, Palsana for Disposal Collection, Store, Transportation and sell to GPCB authorized dealer after Decontamination Use for Bromine Recovery in own plant or in mfg. of HBr/NaBr./KBr/NH4Br./CaBr (Reqd Qty: 2500 MT/ year) Use in Acidification of NaBr /KBr/NH 4 Br Solution for Bromine recovery or Neutralize by lime within premises/ or Sale to authorized end user 11

12 8 Dil. HBr Process (4 Bromo Methyl - 2 Cynobipheneyl, Ethyl - 2 Bromo Propionate, Bromo Acetaldehyde Dimethyl acetal Sch-I/ B-36 9 Dil. HCl (20%) Scrubber Sch-I/ B Spent Solvent Process Sch-I/ Spent Catalyst Process (Para Bromofloro Benzene) Sch-I/ Use in Mfg. of HBr/NaBr /KBr/NH4Br/CaBr or use in Bromine Recovery in our plant within premises. (Reqd Qty: 2500 MT/ year) Use in bromine Recovery plant or ph Adjustment of NaBr Soln Collection, Storage, Transportation & Recovery and re-use within premises Collection, Storage, transportation in HWSA and sent to common TSDF site of M/s. BEIL/SEPPL/GSPL for disposal. 1.7 Green Belt Total area is 1740 sq meter and green belt of 170 sq meter will be provided. 1.8 Power & Fuel Requirements Power required from GEB is 100 KVA (Existing) Power required from GEB will 164 KVA (Total Proposed) 2 D.G. Set 82 KVA (Existing: 1 + Proposed: 1) (For Emergency Only) Fuel: Wood = 750 Kg/Day (Existing) Natural Gas = 1100 Nm 3 /Day(Total Proposed) HSD = 100 Liter/ Day (Total Proposed) (For Emergency Only) 12

13 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 Synthetic Organic Chemicals in existing unit. Identification of the project proponent SR. NO. NAME DESIGNATION 1. Mr. Maganbhai Suhagia Director 2.2 Brief description of nature of the Project Proposed Expansion of Synthetic Organic Chemicals in existing unit. 2.3 Need for the project and its importance to the country and or region The Indian pharmaceutical, pesticides & dyes industries currently tops amongst India s science based industries with wide ranging capabilities in the complex field of pharmaceutical, pesticides & dyes. The pharmaceutical, pesticides & dyes industries in India meet around 60% of the country s demand. But in world market also Indian pharmaceutical, pesticides & dyes products are well accepted. There is a good potential for us to fulfill the need of domestic market as well as contribute in earning foreign Exchange. 2.4 Demands-Supply Gap Based on our informal survey of the market with our current customers and various traders, we have found that there is a big potential for the range of the products we are planning. 2.5 Imports vs. Indigenous production Based on the current cost of indigenous raw materials and the non availability of some materials, we will have to import, if required, some of the key raw materials as they are not 13

14 available indigenously. This will make us very competitive against imported finished products and we will export our finished products in the international market. 2.6 Export possibility We shall explore the possibility of export the products. 2.7 Domestic/Export Markets Our products have good demand in international and local market. We shall explore the possibility of export the products. 2.8 Employment Generation (Direct and Indirect) due to project. M/s. Span Remedies Pvt. Ltd. will give direct employment, if required, to local people based on qualification and requirement after proposed expansion. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. 3.0 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any. Proposed Expansion of Synthetic Organic Chemicals in existing unit. Category: B-5(f) No interlinked project. 14

15 3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates. Map showing general location (Courtesy: Environmental Information Center, New Delhi) 15

16 Specific location and project boundary 23

17 Google image showing 10kms. radius 24

18 Plot Layout 25

19 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: Existing operational industry Site is very well connected by road Proximity to Raw Material suppliers Availability of sufficient land free from cultivation Availability of power evacuation facilities Availability of water for industrial use Availability of CETP, CHWIF, common MEE, common TSDF, etc. Modern infrastructure support and amenities at par with industrial estates in other global markets, including: Efficient transport facilities within the industrial estate and to & fro the city area. Environment-friendly zone. Uninterrupted power supply. 3.4 Size or Magnitude of Operation Please refer Section-1.2.1, Page No Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project, etc. should be given) Please refer Please refer Form-I, Annexure Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product. For raw material required along with quantity; Please refer Section-1.3, Page No. 3. We shall procure the raw material as much as possible from domestic market and if there is no availability of any raw material we will import. We shall explore the possibility of export the finished products. 26

20 3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. Resource optimization/recycling and reuse shall be envisaged 3.8 Availability of water its source, energy/power requirement and source should be given. Water Source Present water requirement is met through GIDC water supply and will be the same after proposed expansion. Power & Fuel Requirement Power required from GEB is 100 KVA (Existing) Power required from GEB will 164 KVA (Total Proposed) 2 D.G. Set 82 KVA (Existing: 1 + Proposed: 1) (For Emergency Only) Fuel: Wood = 750 Kg/Day (Existing) Natural Gas = 1100 Nm3/Day (Total Proposed) HSD = 100 Liter/ Day (Total Proposed) (For Emergency Only) 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. Please refer Form-I, Annexure-IV & V. 27

21 3.10 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 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. 4.0 Site Analysis 4.1 Connectivity Site is very well connected by road Availability of water, power, etc. 4.2 Land Form, Land Use and Land Ownership It will be incorporated in EIA Report. 28

22 4.3 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given. It will be incorporated in EIA Report. 4.4 Existing Infrastructure Processing Area (Plant facilities, R&D, ETP Area and Engineering / Utility Services) = 1040 m 2 Non Processing Area (Green belt, Raw material storage area, finished storage area, Administration Building, Parking, road and open area) = 700 m Soil Classification It will be incorporated in EIA Report. 4.6 Climatic data from secondary sources. Climatic data from primary & secondary sources will be incorporated in EIA Study. 4.7 Social infrastructure available. Various Programs/ Projects related to Social & Economic development of surrounded area has been planned, which are as follows. A) Natural Resource Management The main focus of this program will be to maximize the yield returns of the farmers through efficient management of existing resources & extension of new agricultural practices. 1) Integrated Agricultural Growth Project For improvement and use of the modern techniques and thereby would certainly contribute to prosperity in the agriculture sector and reduce the rural poverty by programs like Farmers Training, Nursery Growing Trainings, Modern agriculture equipment distribution programs etc. 2) Animal Husbandry Projects Various programs like health checkups & treatment, vaccination program, Anti sterility camps, breed improvement etc. will be carried out. 29

23 B) Income Generation Program - 1) Establishment of Self help groups. 2) Rural Entrepreneurship Development Program 3) Handcrafts Development Program 4) Vocational Training 5) Business process outsourcing C) Health, Education & Infrastructure 1) Aids Awareness Program 2) General Health Camps 3) Innovative Teaching Methods 4) Adult Education 5) Sanitation 6) Infrastructure Development Projects 5.0 Planning Brief 5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country planning/development authority classification. Expansion of existing manufacturing unit by addition of new products (Synthetic Organic Chemicals & Bromide Derivatives) within existing premises. 5.2 Population Projection Population data will be incorporated in EIA Study. 5.3 Land use planning (breakup along with green belt etc.) Total 1740 m 2 land area is available at site; out of this area about 170 m 2 areas will be covered as greenbelt and other forms of greenery. 30

24 5.4 Assessment of Infrastructure Demand (Physical & Social) Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project activity. 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 Report. 6.0 Proposed Infrastructure 6.1 Industrial Area (Processing Area) Processing Area (Plant facilities, R&D, ETP Area and Engineering / Utility Services) = 1040 m Residential Area (Non Processing Area) Non Processing Area (Green belt, Raw material storage area, finished storage area, Administration Building, Parking, road and open area) = 700 m Green Belt Total 1740 m 2 land area is available at site; out of this area about 170 sq. meter area will be covered as greenbelt and other forms of greenery. 6.4 Social Infrastructure Water Supply by GIDC Power supply by DGVCL 31

25 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 facilities Availability of water for industrial use 6.6 Drinking water Management (Source& Supply of water) Total water requirement shall be met through GIDC supply. 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 of industry. These liquid wastes are sent to septic tank & soak pit. 6.8 Solid Waste Management Please refer Form-I, Annexure-V. 6.9 Power Requirement & Supply/Source Please refer Section 1.8, Page No.6 of this report. 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 oustees and landless laborers (a brief outline to be given) There is no habitation on the proposed project activity area and it is open industrial land, so R & R policy is not applicable to this project. There shall not be displacement of any population in project area. The increasing industrial activity will boost the commercial and economical status of the locality up to some extent. 32

26 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 are already having CC&A. We shall start manufacturing after getting environmental clearance and CTE. 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total Project Cost for proposed project activity is Rs. 5 Crores. Capital cost of air & water pollution control system and environmental monitoring equipments will be Rs. 50 Lakhs. Recurring Cost towards Environment Management System will be Rs. 50 Lakhs/ Annum. 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. 33