M/s. Nirma Ltd. Pre Feasibility Report

Transcription

1 Pre Feasibility Report 1

2 1. INTRODUCTION Nirma is one of the few names which is instantly recognized as a true Indian brand, which took on mighty multinationals and rewrote the marketing rules to win the heart of princess, i.e. the consumer. Nirma, the proverbial Rags to Riches saga of Dr. Karsanbhai Patel, is a classic example of the success of Indian entrepreneurship in the face of stiff competition. Starting as a one man operation in 1969, today, it has about 15,000+ employee base and annual turnover is more than 7,000 Crores INR. India is a one of the largest consumer economy, with burgeoning middle class pie. In such a widespread, diverse marketplace, Nirma aptly concentrated all its efforts towards creating and building a strong consumer preference towards its value for money products. It was way back in 60s and 70s, where the domestic detergent market had only premium segment, with very few players and was dominated by MNCs. It was 1969, when Karsanbhai Patel started door to door selling of his detergent powder, priced at an astonishing Rs. 3 per kg, when the available cheapest brand in the market was Rs. 13 per kg. It was really an innovative, quality product with indigenous process, packaging and low profiled marketing, which changed the habit of Indian housewives for washing their clothes. In a short span, Nirma created an entirely new market segment in domestic marketplace, which is, eventually the largest consumer pocket and quickly emerged as dominating market player a position it has never since relinquished. Rewriting the marketing rules, Nirma became a one of the widely discussed success stories between the four walls of the B school classrooms across the world. The performance of Nirma during the decade of 1980s has been labeled as Marketing Miracle of an era. During this period, the brand surged well ahead its nearest rival Surf, which was well established detergent product by Hindustan Lever. It was a severing battering for MNC as it recorded a sharp drop in its market share. Nirma literally captured the market share by offering value based marketing mix of four P s, i.e. a perfect match of product, price, place and promotion. In year 2004 Nirma s annual sales touch 800,000 tones which, makes it one of the largest volume sales with a single brand name in the world. Looking at the FMCG synergies, Nirma stepped into toilet soaps relatively late in 1990 but this did not deter it to achieve a volume of 100,000 per annum. This makes Nirma the largest detergent and the second largest toilet soap brand in India with market share of 38% and 20% respectively. It has been persistent effort of Nirma to make consumer products available to masses at an affordable price. Hence, it takes utmost care to provide finest products at the most affordable prices. To leverage this effort, Nirma has gone for massive backward 2

3 integration along with expansion and modernization of the manufacturing facilities. The focal objective behind modernization plan is of up gradation with resource savvy technology to optimise capabilities. Nirma s eleven production facilities, located at different places, are well equipped with state of art technologies. To ensure regular supply of major raw materials, Nirma had opted for backward integration strategies. These strategic moves allowed Nirma to manage effective and efficient supply chain. Nirma has always been practiced value for money plank. Nirma plans to extend the same philosophy in categories as commodity food products, personal care products and packaged food. Distinct market vision and robust infrastructure allowed Nirma to have cost leadership. Apart from this, lean distribution network, umbrella branding and low profile media promotions allowed it to offer quality products, at affordable prices. Dr. Karsanbhai K. Patel, a marketing legend and philanthropist, is playing role of key strategic decision maker, whereas his next generation has already skilled management capabilities. Shri Rakesh K Patel a qualified management graduate, is spearheading the procurement, production and logistic functions, whereas Shri Hiren K Patel a qualified Chemical engineer and management graduate, heads the marketing and finance functions of the organization with hands on approach. Shri Kalpesh Patel, Executive Director, leads recent diversified sector of Health care, apart from LAB. In recent times, through acquiring manufacturing capabilities in Healthcare, Soda Ash, and Boron production facilities, Nirma has surged new corporate success milestones. In near future, the group is also exploring diversification in Cement sector through a greenfield project. The man behind the success of Nirma phenomenon Dr. Karsanbhai Patel is a recipient of various awards and accolades. He has been bestowed with various awards like Udyog Ratna by Federation of Association of Small Scale Industries of Gujarat, New Delhi. Outstanding Industrialist of Eighties by Gujarat Chamber of Commerce and Industry, Ahmedabad (in 1990). Gujarat Businessman Award in 1998 by Gujarat Chamber of Commerce and Industry, Ahmedabad. Excellence in Corporate Governance Award by Rotary International District A&M Hall of Fame. Shri Karsanbhai has been awarded an Honorary Doctorate by Florida Atlantic University, Florida, USA in the year 2001 in recognition of his exceptional accomplishments as a philanthropist and businessman. His contributions are also acknowledged by Govt. of India, and he has been endowed with Padmshri in

4 This world has also recognized his ability, acumen and wisdom and in recognition of the services rendered by him in his various capacities. Dr. Karsanbhai Patel has also served as a Chairman for two terms to the Government of India s Development Council for soaps and detergents, as a Member of Bureau of Indian Standards Committee for Soaps and Detergent Industries and President of Gujarat Detergent Manufacturers Association. 2. COST OF PROJECT Existing cost of project is 1690 crores. The expected cost of the proposed expansion project will be around Rs crores. 3. PRODUCTION CAPACITY Production capacity is prescribe below: List of Products Sr. No. Products/By Products Units Existing Capacity 1 Soda Ash Plant Proposed Capacity Total Capacity after Expansion A Light Soda Ash TPD B Dense Soda Ash TPD C Vacuum Salt TPD Caustic Soda Plant A Product Caustic Soda (100%) TPD Hydrochloric Acid (100%) TPD B By Products Chlorine Gas (100%) TPD Hydrogen (100%) TPD Sodium Hypo Chlorite (100%) TPD Captive Power Plant Power MW Chlorine & Hydrogen Derivatives A Hydrogen Peroxide (100%) TPD B Epichlorohydrine (ECH) TPD C Glycerin TPD D Mono Chloro Acetic Acid (MCAA) By Products TPD

5 Hydrochloric Acid (100%) TPD Mother Liquor of MCAA TPD Sodium Hypo Chlorite (100%) TPD Product E Trichloro Acetyl Chloride (TCAC) By Product TPD Hydrochloric Acid (100%) TPD 9 9 Sodium Hypo Chlorite (100%) TPD 1 1 Sodium Bisulfite Solution (100%) 5 Toilet Soap Plant TPD 3 3 Toilet Soap TPD Detergent Powder TPD Detergent Cake TPD Fatty Acid TPD Glycerin TPD Bromine Plant Bromine TPD

6 List of Raw Materials Sr. No. Name of Raw materials Existing (TPD) Soda Ash Plant 2000 TPD to 2800 TPD Proposed (TPD) M/s. Nirma Ltd. Total (TPD) 1 Salt Lime Stone Ammonia Sodium Sulphide Coke Caustic Soda Plant 480 TPD to 750 TPD 1 Raw Salt Soda Ash Sodium Bi Sulfide Sulphuric Acid Flocculants Alpha Cellulose Captive Power Plant MW to MW 1 Coal Lignite Petcoke Limestone Light Diesel Oil ECH 150 TPD 1 Crude Glycerin NaOH (100 wt% Basis) 3 Oxalic Acid Chlorine Hydrogen H 2 O 2 plant 84 TPD 1 Hydrogen Nm Nm 3 2 Anthraquinone (EAQ) Aromatic Solvent Solvent Solvent Catalyst Phosphoric acid Stabilizer Activated Alumina NaOH (100%) HNO 3 (100%)

7 Sr. No. Name of Raw materials Existing (TPD) Proposed (TPD) M/s. Nirma Ltd. Total (TPD) 13 Activated Carbon Mono Chloro Acetic Acid (MCAA) 120 TPD 1 Acetic Acid Chlorine gas Acetic Anhydride/SMC Hydrogen gas Catalyst Dilute caustic soda Trichloro Acetyl Chloride (TCAC) 10 TPD 1 ML of MCAA Chlorine SMC + Catalyst Soda Ash Solution Caustic Soda Solution MANUFACTURING PROCESS Manufacturing process is given in Annexure II of form WATER BALANCE The total water requirement shall increase from KLD to KLD. The total quantity shall be drawn from sea. Boiler/ Process/ Washings etc. water will be used after treating through RO/DM Plant. DETAILS OF WATER CONSUMPTION Sr. Source Water Consumption (m 3 /day) No. Existing Proposed Total Soda Ash Plant 1. Domestic Process Boiler Cooling Others Toilet soap plant Total (I) Domestic Process Washing Cooling Total (II) Caustic Soda Plant & Captive Power Plant 1. Domestic Process

8 3. Boiler Cooling Total (III) Salt works 1. Salt works Bromine Plant Total (IV) Process Cooling Chlorine & Hydrogen Derivatives Total (V) Domestic Process + DM Cooling + Chilling Boiler Washing/Others Total (VI) Grand Total (I to VI) M/s. Nirma Ltd. 6. MANPOWER: Total manpower will be approximately 260 nos. 7. SOURCE OF POLLUTION Details of Air Pollution The details of stacks are given below: DETAILS OF STACK EMISSIONS Sr. No. Stack Attached to Stack Height (m) Stack Dia. (m) Air Pollution Control System Pollutant 1 Soda Ash Plant Boiler A, B, C & D (100 TPH each) 100 stack) 5.04 ESP to Each boilers PM SO2 NOx DG Sets (2 nos.) 24 (each) Caustic Soda & CPP Boiler E & F (200 TPH each) 121 Stack) 4.5 ESP PM SO2 NOx Boiler G & H ( ESP PM 8

9 TPH TPH standby) Stack) M/s. Nirma Ltd. SO2 NOx DG Set (1000 KVA) PM DG Set (1500 KVA) Proposed DG Set (1500 KVA) Proposed 3 Toilet Soap SO2 NOx Thermic Heater Fluid PM SO2 NOx DETAILS OF PROCESS EMISSIONS Sr. Vent Attached to Stack Stack Air Pollution Pollutant No. Height (m) Dia. (m) Control System 1 Soda Ash Plant Lime Kilns (A to F) scrubbers and PM, SO2, NOx 6 nos. two ESP in Series Stack) Ammonia Recovery Brine Scrubbers (3 Ammonia System nos.) Stack) Lime Grinding Bag Filter PM System (3 nos.) Calcinations Vessel 29 Each 0.7 Water Scrubber PM (2 nos) Densification Water Scrubber PM Densification Water Scrubber PM Lime Kilns (G & H) One scrubbers and PM, SO2, NOx 2 nos. one ESP in Series Stack) Ammonia Recovery Brine Scrubbers (2 Ammonia 9

10 System (D & E) 2 nos. Stack) nos.) Lime Grinding Bag Filter PM System (2 nos.) Calcinations Vessel (2 nos) 29 vent) 0.7 Water Scrubber PM Densification Water Scrubber PM 2 Caustic Soda and CPP HCl Synthesis Unit Water Scrubbers HCl & Cl2 1 HCl Synthesis Unit Water Scrubbers HCl & Cl2 2 Waste Gas % NaOH Cl2 Dechlorination System 1 Scrubber Waste Gas % NaOH Cl2 Dechlorination Scrubber System 2 HCl Synthesis Unit Water Scrubbers HCl & Cl2 3 HCl Synthesis Unit Water Scrubbers HCl & Cl2 4 Waste Gas % NaOH Cl2 Dechlorination Scrubber System 3 3. Bromine Plant Debromination System Alkali Scrubber Bromine 4. Chlorine & Hydrogen Derivatives 10

11 Solvent Recovery Hydrogenation Plant (purge gas) Incinerator & its scrubber HCl Synthesis Unit Chlorination Plant Chlorination Plant Chlorination Hydrogenation Plant(purge gas) Ceramic + Activated Carbon Filter Aromatic Solvent Ceramic + H2 + Aromatic Activated Carbon Solvent Filter Water Scrubber PM, SO2, CO, NOx, HCl, TOC Water Scrubbers HCl Acidic/Water SO2, HCl, Cl2 Scrubber (3 nos.) Alkali Scrubber (3 Cl2 nos.) Water Scrubber SO2, HCl, Cl H2 8. Source of Wastewater : The main source of the industrial wastewater generation will be from domestic, process, utilities, washing and others. Total qty. of effluent will be increase from KLD to KLD. Entire quantity of wastewater will be treated in separate ETP. Finally reuse or send to solar pan for salt recovery. Source and disposal of solid and Hazardous wastes The main source of hazardous waste generation will increase after proposed expansion. ETP sludge will be dispose to TSDF site. Used oil will be sold to authorized recycler and discarded containers & plastic liners will be sold to registered recyclers. 11

12 Sr. No. The details of Solid & hazardous waste are given below: SOLID WASTE GENERATION AND DISPOSAL: Sr. No. Solid Waste Quantity (TPD) Mode of Disposal 1 Settling Pond Sludge Existing Proposed After Expansion Shall be used in road construction, salt works bund preparation Shall be used in boilers for desulphurization in boilers 2 Lime stone rejects /under size 3 Brine Sludge Nonhazardous; Shall be used dumped in identified area 4 Fly ash/ Bottom ash Brick manufacturing, bund preparation, road making etc 5 Incineration Ash Brick manufacturing, bund preparation, road making etc HAZARDOUS WASTE GENERATION & DISPOSAL: Hazardous Waste 1 Soda Ash Plant Waste Oil/ Lub. Oil from Spent ion exchange resins Discarded bags/drums/con tainers etc 2. Caustic Soda Plant Waste Oil/ Lub. Oil from Category Quantity (MTPA) Mode of Disposal Existing Proposed Total After Expansion Collection, Storage, Transportation & disposal by selling to Registered Recyclers L cation & L anion Collection, Storage, (once in 10 years) Disposal by selling to authorized recyclers or sent to NECL Nandesari for Incineration Collection, Storage, Disposal by selling to authorized recyclers Collection, Storage, Transportation & disposal by selling to Registered Recyclers 12

13 Spent ion exchange resins Residue/ Sludge & Filter sludge M/s. Nirma Ltd Collection, Storage, Disposal by selling to authorized recyclers or sent to NECL Nandesari for Incineration Collection, Storage, Disposal at TSDF ETP sludge Collection, Storage, Disposal at TSDF Spent Sulphuric Acid (80%) 3. Toilet Soap Plant D Collection, Storage, reuse as raw material for Nirma Ltd. Moraiya and other end users. Waste Oil/ Lub Collection, Storage, Oil from Transportation & disposal by selling to Registered Recyclers ETP sludge Collection, Storage, Disposal at TSDF Glycerin foot D6 II Collection, Storage, Transportation & disposal by selling to M/s. Ultratech Cement for Co incineration in cement kiln/necl for Incineration. Spent Sulphuric Acid (80%) 4 Chlorine & Hydrogen Derivatives Waste Oil/ Lub. Oil Discarded containers/ Barrels/empty drums/empty bags D Collection, Storage, reuse as raw material for Nirma Ltd. Moraiya and other end users Collection, Storage, Transportation & disposal by selling to Registered Recyclers Collection, Storage and disposal by selling to authorized recyclers. 13

14 ETP sludge Collection, Storage, Disposal at TSDF Glycerin foot D6 II Collection, Storage & incineration in plant incinerator. Catalyst from Collection, Storage, regeneration Disposal at Common Haz. Waste Spent Carbon from solvent recovery Spent Carbon from ETP Distillation Residue incineration facility Collection, Storage, Disposal at Common Haz. Waste incineration facility Collection, Storage, Disposal at TSDF Collection, Storage, Disposal at Common Haz. Waste incineration facility 9. FUNDS FOR POLLUTION CONTROL MEASURES The management is quite conscious of its responsibility for maintaining clean environment. Adequate funds will be provided for the pollution control measures as a part of overall project financing. Necessary provision for Environmental management system is in practice and will be part of practice in future expansion project. 10. MONITORING FACILITIES Company is ready to carry out any other kind of monitoring proposed by Pollution Control Board from time to time through outside agency. 11. CONCLUSION There is no adverse impact on the water environment due to the operation of the project. The air environment has negligible effect due to the activities related to the operation of the project. After implementation of pollution control measures there will be no emission from the plant beyond the norms specified by the Board. The project is not contributing to any adverse impact on the surrounding soil, as the pollutants emitted are of the negligible amount. The project has generated direct and indirect employment. 14