Pre-feasibility report for. Expansion of Synthetic Organic Chemical Manufacturing Unit. M/s. Vinati Organics Limited

Transcription

1 Pre-feasibility report for Expansion of Synthetic Organic Chemical Manufacturing Unit By M/s. Vinati Organics Limited PROJECT TERMED UNDER SCHEDULE 5 (f) (SYNTHETIC ORGANIC CHEMICALS) CATEGORY - B Prepared By M/s Vinati Organics Ltd Plot No. A 20 & D 30/2, Lote MIDC, Lote Parshuram Dist: Ratnagiri Maharashtra, India Web: 1

2 Chapter 1 Executive Summary Company Profile Vinati Organics Limited was established in 1989 and is a specialty chemical company producing aromatics, monomers, polymers and other specialty products. The company started operations in its first plant in Mahad in 1992, with its focus on Isobutyl Benzene (IBB). A decade later, in 2002, it started commercial production in its second plant in Lote, producing 2-Acrylamido-2-methyl propane Sulphonic acid. Vinati Organics Limited (VOL) has enhanced the scope of its facilities and now also produces organic intermediates and aromatics. IBB, a specialty organic intermediary, is used as a raw material for the manufacture of Ibuprofen, an anti-inflammatory analgesic bulk drug. 2-Acrylamido-2-methylpropane Sulphonic acid, a specialty monomer finds several applications in oil-field recovery, water treatment, acrylic fibre manufacturing, adhesives, personal care products, medical hydrogel, mining industry, coatings and as dispersing and flocculating agents. Vinati Organics Limited is the world s largest manufacturer of both 2-acrylamido-2- methylpropane Sulphonic acid and IBB. Company also started producing Isobutylene (IB), one of the key components used to manufacture 2-Acrylamido-2-methyl propane sulphonic acid. Apart from being used internally, IB is also sold to agrochemical and antioxidant industry. Vinati Organics Limited (VOL) has always strived for excellence through adopting the best and clean route for manufacturing chemicals. VOL has R & D facilities at both of its plant locations which deal with synthesizing new molecules and optimizing the process promoters. VOL has always emphasized on developing green and cost effective manufacturing techniques for specialty chemicals which have the potential of developing into large scale products in the future. VOL has collaborations with global technology providers like Institut Francais du Petrole (IFP) France, Saipem SpA, Italy, etc. VOL has been closely associated with National Chemical Laboratories (NCL), Indian Institute of Technology, Hyderabad (IICT) for developing cutting edge technologies for commercially manufacturing specialty chemicals. VOL has successfully demonstrated technology absorption from these research organizations in the past. 1

3 Vinati Organics limited now proposes to expand by adding manufacturing unit of synthetic organic chemical (Butyl phenols, Para Tertiary Butyl Benzaldehyde and Lili aldehyde) at its existing facility at plot no-a 20 & D 30/2, Lote- Parshuram MIDC, Dist Ratnagiri. The company got EC for expansion at this site vide letter SEAC 2015/CR-236/TC-2 dated 28 th June 2016 for expansion at the site. With this PFR, the company wish to delete Tertiary Butanol product and wish to include Butyl phenols, Para Tertiary Butyl Benzaldehyde and Lili aldehyde products. The google image of the plot site is at Annexure I Proposed Layout Plan for new establishment is attached as Annexure II. Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide EIA Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic chemicals manufacturing units. This project falls under category B and schedule item no. 5(f): Synthetic organic chemicals. The project brief is summarized in the table below Project summary at a glance Sr. No. Particulars Details 1 Name of Company Vinati Organics Limited 2 Products Butyl phenols, Para Tertiary Butyl Benzaldehyde, Lili- Aldehyde and its by products 3 Location Plot no A20 & D30/2, Lote MIDC area, Dist Ratnagiri, Pin Maharashtra. 4 Name of the project Manufacture of Butyl phenols (39,000MTPA), PTBBAL(2,000MTPA), Lili Aldehyde (2,000MTPA) and its by products 5 Total land area of the 96,570 sq m (~23.86 Acres) plot 6 Total proposed built up 81,797 sq m area 7 Major raw material Refer chapter 3 8 Water Total fresh water requirement shall be approximately 27 CMD. It will be source from MIDC. 2

4 9 Power Total power requirement is 250 KVA. It will be sourced from MSEDCL Or Cogen Plant as per availability. Proposed additional Coal consumption: 30 TPD 10 Proposed manpower 120 No (permanent 45 & Contract 75) 11 Waste water quantity Trade effluent 18 cmd (estimate) Domestic effluent 7 cmd Total effluent generation 25 cmd Trade effluent and domestic sewage will be treated and recycled. 12 Air emissions The air emissions will be from Thermic fluid heater. Adequate stack height as per statutory norms will be provided to TFH sets. 13 Solid Waste Refer chapter 3 14 Project cost estimate ~ 179 Crores The Land shall be used as Industrial land thus there shall be no change in land use. This industrial plot A 20 & D 30/2 is allotted by MIDC to Vinati Organics limited and existing unit is operational at site. MIDC has provided all basic infrastructures like Electrical Power, water supply, the internal road network, external approach road and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility). There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological monuments, sanctuaries, etc. The land and infrastructure is made available by MIDC and the raw material is easily available through the easy transport via road connectivity by local suppliers as well as imported one. 3

5 Chapter 2 Introduction of the Project 2.1 Identification of the project and Project Proponent This is a new project for the manufacturer of Synthetic organic chemical (Butyl phenols) by wellknown business group Vinati Organics Limited (VOL). Some of the recent achievements of VOL are: Listed consecutively in Forbes Asia s 200 Best Under A Billion companies for 2010 and 2011 Ranked amongst Top 10 Fastest Growing Companies in India for 2009 & 2010 by The Economic Times. Ranked among the Top 30 Fastest Growing Companies by Outlook Business in 2013 In recognition of exemplary growth VOL was awarded Inc 500 Certificate of Excellence in 2012 & 2011 by 99 Media VOL was accorded SILVER by EcoVadis towards Corporate Social Responsibility Rating Vinati Organics limited are the major manufacturer of variety of specialty chemicals, pharmaceutical intermediates and chemicals / additives with expertise in the field of synthetic organic chemicals. 2.2 Need of project with description for region and country Butyl Phenols are intermediates which find applications as raw materials for products that go into a wide variety of industries such as perfumery, inks & resins, plastics and lubricants. Butyl phenols are not directly used for these applications, but act as building blocks for making useful products. VOL is planning to manufacture the following for butyl phenols: a. Para-Tertiary Butyl Phenol (PTBP) b. Ortho-Tertiary Butyl Phenol (OTBP) c. 2,4-Di Tertiary Butyl Phenol (2,4-DTBP) d. 2,6-Di Tertiary Butyl Phenol (2,6-DTBP) Almost all quantity of butyl phenols used in India is imported. Around 35-40% of the total quantity finds application in the perfumery industry. Around 15% is used for plastic additives and the remaining butyl phenols are used for inks/resins and lubricants. 4

6 Quantity MT Pre-Feasibility Report Indian Butyl Phenols Scenario India is a net importer of butyl phenols. By volume, PTBP is the largest product amongst the four butyl phenols. It is mostly imported from Korea, Taiwan, Singapore and Russia. There are majorly 2 grades of PTBP imported into India Technical grade used for perfumery application and Standard grade that is used in resin/ink application. OTBP come second by volume amongst these four butyl phenols. It goes entirely into manufacturing of perfumery products. All leading Indian perfumes manufacturing companies are users of OTBP. This product is imported from Switzerland and Taiwan. The use of 2,4-DTBP and 2,6-DTBP is currently smaller by volume. These two products are used for manufacturing antioxidants which are used as additives for plastics. With increasing use of plastics and composites in India, the use of these butyl phenol based antioxidants is expected to grow rapidly. 2,4-DTBP and 2,6-DTBP are imported into India from Switzerland, Taiwan, Singapore and China. The total demand of these butyl phenols in India is currently 20,500 MTPA. In India, currently, there are no manufacturers for butyl phenols. Previously, companies like Herdillia (Now SI Group), Balmer Lawrie, Naik Naware Chemical Pvt Ltd tried to manufacture these products. However, due to lack of scale, IB supply constraint, they couldn t manufacture products economically. Butyl Phenol import trend in India is as follows: Butyl Phenol India imports Q1 5

7 In FY and FY , India spent around $ 45 million and $ 35 million respectively for importing the butyl phenols. VOL will help save so much foreign exchange in case the plant is operational. In addition to this, because of the availability of raw materials like 2,4-DTBP and 2,6-DTBP, there will be an increased manufacturing of antioxidants and UV stabilizers in India. These antioxidants which are currently being imported into India will be manufactured in India eventually adding to the self-sufficiency and additional foreign currency savings besides generating employment opportunities. Global Butyl Phenol market and past trends: Globally, Butyl Phenols are well known compounds widely used in numerous applications. While, in India PTBP and OTBP are large volume products, globally, 2,6-DTBP and 2,4-DTBP are large volume products. Globally, these di-tertiary butyl phenols are widely used in lubricants, plastic additives and fuel additives The use of 2,6-DTBP as a jet fuel additive is a large volume application globally. Globally, PTBP is also used in poly carbonate manufacturing. Some companies that are large volume manufacturers of butyl phenols are SI Group, BASF, Songwon, Oxiris, Chemtura/ Addivant, Eutec, Kaoching, Tasco, DIC. Almost all these butyl phenol manufacturers are forward integrated and they also manufacture antioxidants for plastics and lubricants from di tertiary butyl phenols. The estimated capacity of butyl phenols globally is close to TPA. However, since a large quantity of butyl phenols are captively consumed, estimating the exact production of butyl phenols globally is not possible. Market Scenario for Lili aldehyde: Lily Aldehyde Lilial is a chemical compound commonly used as a perfume in cosmetic preparations and laundry powders. The name of the compound is p-tert-butyl-alpha-methylhydrocinnamic aldehdye (BMHCA) or (2-(4-tert-butylbenzyl) propionaldehyde).[cas no ] The product is known based on brand names of global manufacturers like Lysmeral [BASF], Lilestralis [Kalama] and Lilial [Kuraray]. The R enantiomer of the compound has a strongly diffusive fresh, light, green floral, reminiscent of lily (Also called Lily of the valley) Applications: 6

8 Its strong diffusivity makes it invaluable for use in soaps and detergents. Leading FMCG soaps and detergent manufacturers are the users of formulated lily aldehyde. Other than soaps and detergents, the product is also used in cleaning agents, fine fragrances, cosmetics and air fresheners. It may also be used as a perfumery ingredient is various coatings and paints, fillers/plasters, ink/toners, polishes/wax blends and scented articles (clothes, eraser, toys, paper articles, CD). While most of the applications of lily aldehyde are related to personal care and perfume applications, there is a small demand of this product in agrochemical industry as an intermediate to make weedicide. Indian market and global market At present, there is no manufacturer of lily aldehyde in India and current imports of this product in India are close to 800 metric tons per annum. In India, all the lily aldehyde that is imported is used in the personal care industry in the form of perfume/ fragrance. In India, the product is not currently used in agrochemical industry. The global market for this product is close to metric ton per annum. The global demand of this product is estimated to remain stable or slightly decline. The Indian market of this product is expected to remain constant or grow moderately. The raw materials for this product are p-tertiary butyl benzaldehyde, propionaldehyde and hydrogen. Propionaldehyde is a widely traded product in India and is readily available. VOL is going to establish a plant to make p-tertiary butyl benzaldehyde and hydrogen plant is also proposed to be established by VOL. VOL is proposing to establish a plant of close to 2000 Ton per annum of which half will be used for import substitution and other half will be for exports. 2.3 Brief Description of Project Size: It is proposed to produce following products at the existing site at lote after removal of plan to produce Tertiary Butyl Alcohol due to place constraints which was considered in recently issued EC letter to this site Ref. SEAC-2015/CR-236/TC-2 dated The proposed products are summarized below Sr. No Product / By product Proposed production capacity (TPA) Product 1 Butyl Phenols 39,000 2 Para tertiary Butyl Benzaldehyde 2,000 3 Lili-Aldehyde 2,000 Total 43,000 By Products 1 Aluminum Sulphate (Solution)

9 2.4 Export Possibility VOL would like to install a capacity of 39,000 MTPA for the 4 butyl phenols put together. Out of these around 20,500 MTPA is the current Indian demand while the remaining 18,500 MTPA will be for exports. Since 2,4-DTBP and 2,6-DTBP have huge demand globally, it will be possible to export these products. Some of the target customers for di tertiary butyl phenols could be Cytec, Everspring, Omnova, Adeka, etc. Due to the availability of butyl phenols in India, eventually, there will be an increased production of downstream derivatives of butyl phenol which will lead to more export possibilities. 2.5 Employment Generation due to Project (Direct and indirect) The proposed establishment of plant at plot A-20 MIDC, Lote will certainly lead to increase in employment generation. We will have employment generation for operation, maintenance, Packaging, Dispatch, administration etc. We estimate that there will be a net generation of around 120 jobs on account of this project. Also there is great potential for employment in the downstream industries. 8

10 Chapter 3 Project Description 3.1 Type of Project: The project is for manufacture of Synthetic organic chemical (Butyl Phenols) as follows: Sr. No Product / By product Proposed production capacity (TPA) Product 1 Butyl Phenols 39,000 2 Para Tertiary Butyl Benzaldehyde 2,000 3 Lili-Aldehyde 2,000 Total 43,000 By Products 1 Aluminum Sulphate (25% Solution) 1, Location of the Project Details of Nearest Infrastructure Facilities Sr. No Destination App. Distance of Project Site 01 Nearest Town Chiplun: 10 km 02 Nearest National Highway NH-66: 1 km (Mumbai Goa) 03 Nearest Airport Mumbai International Airport: 257 km 04 Nearest Railway Station Chiplun Railway Station: 10 km 05 Nearest Port JNPT: 270 km The project is proposed at Plot No A20 & D 30/2, Lote MIDC, Dist. Ratnagiri, Maharashtra. The Geographical Location of this plot is at 17 35'44.43 "N Latitude and 73 29'14.697"E Longitude with an elevation of 16 meter above sea level MSL. This site is in premises of MIDC Estate which is meant for these types of Industries. GPS Location on Google Imagery of the proposed site is attached as Annexure I. Land Form: Land is on plain contour; it is flat terrain. Land Ownership: Land ownership is with project proponents (Vinati Organics limited) 9

11 Existing Land use Pattern: The Land is reserved for Industrial use & the proposed project shall be at the same plot. Existing Infrastructure: Presently there is an existing Infrastructure around the site. Infrastructure like water, electricity, telephone facility, roads already available. Other Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at Chiplun Town (Which is at distance of about 10 km) Lote MIDC provides many basic facilities like uninterrupted water supply, power and Road Network. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure. There is no sensitive establishment in the vicinity such as health resort, hospital, and archaeological monuments. The location justification for the project is as under a. Existing well established plant of Vinati organics is already running successfully at said location, also one of the raw materials for Butyl phenols i.e IB is available here. b. Availability of required land and infrastructure for locating the establishment for the synthetic organic chemical manufacturing. c. Suitability of land from topography & geological aspects, synergy and business point of view d. Proximity to rail / road to facilitate transport of equipment / materials/ product e. Availability of adequate quantity of water to meet water requirements. Lay-Out Refer Annexure II for the proposed plant site layout plan. 3.3 Project Description with Processes Details: For Butyl Phenols:- Manufacturing Process: Broad manufacturing process of the chemical (Butyl Phenols) is described and depicted below. 10

12 Ortho tertiary Butyl Phenol & 2, 6 Di tertiary butyl phenols:- Phenol dehydration followed by Aluminum phenoxide preparation & Alkylation of phenol with Iso-butylene to form maximum of OTBP (Ortho tertiary butyl phenol) & 2,6 DTBP( 2,6 di tertiary butyl phenol). In this process there is release of H2 gas & formation of Aluminum sulphate as by product during reactive extraction with dilute sulphuric acid. Para tertiary Butyl Phenol:- In this process catalytic alkylation of phenol with Isobutylene in continuous vertical catalytic reactor to form maximum of PTBP(Para Tertiary Butyl Phenol). There is no downstream process for this reaction; product mixture will be sent directly to separation section. 11

13 2,4 di Butyl Phenol:- In this process catalytic alkylation of Phenol with Iso butylene followed by extraction of liquid catalyst with DM water & product stream will go to distillation / Separation section. Downstream separation:- Product mix from PTBP will be directly go to separation section where unreacted Phenol & heavies will be separated to get pure PTBP as liquid form. This molten PTBP will be further send to flakers & packing section. Product mix generated from OTBP/2,6 DTBP reaction scheme & 2, 4, DTBP scheme will be mixed together & then separation of desired product from product mix will be done with removal of unreacted phenol & heavies to get pure OTBP,2,6DTBP & 2,4DTBP as pure product which will be stored in respective storage tanks. All the 3 products will be stored & supply in liquid form only. For PTBBAL:- VOL has already received EC for Manufacturing of p-tert Butyl Toluene (PTBT) from Isobutylene and Toluene and also manufacturing of p-tert Butyl Benzoic Acid (PTBBA) by Air Oxidation of PTBT. VOL subsequently worked out with IICT Hyderabad (who have developed the PTBT & PTBBA process) for partial oxidation process of PTBT. Partial Oxidation process results in formation of p-tert Butyl Benzaldehyde also along with p- tert Butyl Benzoic Acid. The brief process description is as follows Desired quantity of PTBT/Acetic Acid / Catalysts and co-catalysts is charged in the reactor. The mix is heated to desired temperature and then air is introduced for oxidation purpose. Partial oxidation is achieved by reducing the reaction time. 12

14 After the reaction is over the mixture is splashed in crystallizer where PTBBA is crystallized out and purified by washing/filtration and drying. The mother liquor after PTBBA removal contains unreacted PTBT, acetic acid, dissolved PTBBA and catalysts, p-tert Butyl Benzaldehyde (PTBBAL) formed. This is subject to distillation to recover and recycle acetic acid and soluble PTBBA + Catalyst, PTBT and PTBBAL in last column. For Lili Aldehyde:- The major use of PTBBAL formed by partial oxidation is in manufacturing of Lilialdehyde (lilial) which has main application in perfumery industry. Lilial is manufactured from PTBBAL in two stage synthesis. In first step PTBBAL is reacted with Propionaldehyde to form an intermediate aldehyde which on hydrogenation gets converted to Lilial / Lili aldehyde. The reaction mixture is separated/purified by Distillation to get pure Liliakdehyde. Process block diagram for the manufacturing of:- Butyl Phenols:- 13

15 For PTBBAL :- 14

16 For Lilialdehyde:- 3.4 Raw Material for finished Product: Raw Materials: The basic raw material for the proposed production capacity is submitted herein below. Source for Raw Material Procurement: Raw Material is easily available in the local market. Mode of Transport of Raw Materials: Few of the raw materials will be transported locally and few will be imported from the International Market. Mode of transport to site is by road truck/tankers. 15

17 List of Major Raw Material & Storage Sr. No. Raw Material Unit Total consumption Qty. per year (proposed) 1 Phenol Tons Isobutylene Tons Liquid catalyst Tons Sulphuric acid Tons Aluminum turnings (Igots) Tons 424 Proposed major bulk storages at site are as follow: Sr. No Raw material/ Products Physical state (Liquid/ solid) No. of tanks Proposed liquid storage capacity of tank (KL) Proposed liquid storage (KL) at site 1 Phenol Liquid catalyst Ortho tertiary Butyl Phenol 4 2,4 di-tertiory butyl phenol Liquid 5 2,4 di-tertiory butyl phenol 6 Al2(SO4)3, solution PTBBAL Lili aldhyde Resource Optimization: Vinati Organics limited are desirous to establish the manufacturing facilities for the product indicated above. The resource optimization shall be carried out at the site and with other plants within the site and other VOL sites in order to reduce wastage and minimum transport needs. 3.6 Availability of Resources (Water, Energy/Power Requirement): Power: The proposed power requirement for the facility is 250 KVA which will be source from Our Existing power inputs to site & newly installed Cogen plant. Heating utility: - Heating utility like steam about 2 Tons/hr will be made available from Co-gen plant & TFH plant of capacity 30LacKcal/hr of plant to be installed additionally for this project. Water: The total water requirement is about 27 cmd for domestic, process, and Boiler /cooling purpose. It will be source from MIDC water works. 16

18 Fresh water requirement and waste water generation for proposed establishment shall be as follows: Water requirement No. Description Existing water input* (cmd) Proposed water input (cmd) 1 Domestic Industrial cooling/boilers Processing whereby water gets polluted and pollutants are easily biodegradable Total requirement (cmd) 4. Gardening Total = * - As per EC SEAC 2015 / CR 236/TC 2 dated 28 th June cmd is fresh water from MIDC and 216 cmd is recycled water (after treatment). Waste water No. Description Existing generation# (cmd) Proposed generation (cmd) Total Disposal 1. Trade effluent Proposed trade effluent shall be treated (primary, secondary and tertiary treatment) and will be recycled. 2. Domestic Proposed domestic effluent effluent shall be treated at STP and treated effluent shall be recycled. Total # - As per EC SEAC 2015 / CR 236/TC 2 dated 28 th June 2016 Existing discharge to CETP is 23 cmd which will be maintained (ZLD for proposed expansion) Manpower: Expected manpower requirement for the establishment shall be as follows: Description Proposed, No (approx.) Permanent 45 Contract 75 Total

19 Heating utility: - Heating utility like steam about 2 Tons/hr will be made available from Co-gen plant so no need for additional boiler. Thermic Fluid Heater (TFH) of capacity 30 LacKcal/hr is proposed be installed additionally for this expansion project. Coal will be fuel for the proposed Thermic fluid heater (30 Lac Kcal/hr duty) Type of Fuel Coal Quantity 30 MTPD DG Set: There is no DG set required for this proposed Expansion. 3.7 Waste Generation and its treatment, disposal I. Solid Waste (a) Non Hazardous Solid Waste: Sr Type of Waste Quantity UOM Mode of Disposal No 1 Fly Ash 9 TPD Sale to offsite recycling brick making or for landfill 2 Rubber, Hand gloves, PVC 0.15 TPA Sale for offsite recycling/ shoes, Tarpaulin, Hose pipes CHWTSDF 3 Insulating material 0.25 TPA Sale to authorized vendor/ CHWTSDF 4 Iron scrap, Glass, Paper, Plastic bottles etc 0.15 TPA Sold to scrap dealer for recycle (b) Hazardous Waste: The quantification of hazardous solid waste generated from present activity and proposed activities is presented as follows: Sr No Category Type of Waste Quantity* UOM Mode of Disposal Used/ Spent Oil 0.25 KLPA CHWTSDF/ Sale to Authorized party approved by MOEF/CPCB/MPCB 18

20 Discarded 0.25 MTPA CHWTSDF Asbestos (AC sheets) (one time generation) Discarded 25 Nos/annum Authorized MPCB Drum Drums, carbuoys Recycler etc Paint cans, brush etc 0.5 MTPA CHWTSDF * Estimate, Quantity shall be worked out during EIA stage. 19

21 Chapter 4 Site Analysis Proposed projects are planned in existing spare land of company. The nearest town / cities are Khed (21kms)/ Chiplun (about 10 kms)/pune approx. 250 kms and Panvel/Mumbai 210/250 kms respectively. Company has already taken adjacent plot D-30/2 admeasuring almost 9000 Sq M. This project will be accommodated at the site. The industrial area are provided with good infrastructure like road connectivity to National Highways (NH-66, old NH-17), railways (nearest station is Khed/Chiplun about 18/10 kms) / un-interrupted power supply as well water supply. The land in possession with the company is lease hold land & the lease with MIDC is for 99 years with nominal lease charges. The land doesn t fall under CRZ. Location of MIDC Lote 20

22 Existing land use pattern, Forest, water bodies details are as follows Sr. No. Particulars Details 1. Town Lote MIDC 2. Taluka Khed 3. District Ratnagiri 4. Latitude Latitude: N 5. Longitude Longitude: E 6. Nearest water bodies River Vashishti (about 4 km in southwest direction) 7. Nearest Highway NH 66 = 1 km towards West 8. Nearest Railway Khed / Chiplun on Konkan railway which is station 9. Nearest Airport/ Airbase approximately 18/10 km Mumbai International Airport 250 KM towards NW Pune Lohegaon Airport / Airbase KM towards NE Proposed land use is allotted for industrial use by MIDC, Lote. The project site does not come in range of Eco sensitive Area by MoEF The project is not covered under CRZ. The estate is located at sufficient distance from reserved forests and sanctuaries, archeological sites and historical sites to ensure that there is no impact of industrial activities. The land is in notified industrial area MIDC which is developed by Govt of Maharashtra. Hence it has fully developed infrastructure required for running the chemical manufacturing units. Company s existing unit is running since in same MIDC area. The site/land/location is well connected by Rail/Road and also has all possible communication networks. Manpower (technical/ non-technical) is easily available. Social infrastructures like schools/markets/residential areas/entertainment/medical facilities are well developed. 4.1 Climate: Lote comes in Ratnagiri district of Maharashtra. The location climate is similar to that on the west coast of India, with plentiful and regular seasonable rainfall, oppressive weather in the hot months and high humidities throughout the year. The summer season from March to May is followed by the south-west monsoon season from June to September. October and November form the post-monsoon or the retreating monsoon season. The period from December to February is the cold season. 21

23 4.2 Rainfall: The regional distribution of rainfall is mainly explained by the relief of the land and the direction of the rain bearing winds. The supply of rain to the inland areas is considerably more than to the coastal areas. It becomes heavier or lighter, according to the nearness or otherwise of the station to the great Sahyadri range which powerfully attracts the rain clouds. Mandangad is, however, an exception though its distance from the sea-is just about 14 miles. The average rainfall recorded by this station appears to be quite high as compared to the averages of Deorukh, Chiplun, Rajapur and Khed which are so near the Sahyadri hills. Ante-monsoon or "mango" showers occur in April-May. Although the amount of precipitation is small, these showers have great value in so far as the preliminary kharif operations are concerned. The south-west monsoon is the main rainy season, commencing by about the middle of June and lasting till the end of September. Winter fall, resulting from the retreating monsoon, is almost negligible, which explains why rabi cultivation is practiced on an insignificant scale. Most of the rabi crops are brought to maturity mainly by irrigation. The length of the rainy season has an important bearing on the agricultural operations and output of the district. In a normal rainy season, there are about 100 rainy days. A substantial portion of which runs to waste because of its extreme concentration during a certain part of the season which reduces the effectiveness of the rainfall commensurately. From the point of view of agriculture, effectiveness of rainfall depends on many factors such as, the normal rainfall, length of the rainy season, occurrence of rain at the right time during the agricultural season, its spacing during the season, nature of the soil, rate of evaporation, etc. 4.3 Temperature: Meteorological data are available for four stations in the district, viz., Harnai, Ratnagiri, Deogad and Vengurla. Being a coastal district the variation of temperature during the day and through the seasons is not large. In the hot season temperature rises slowly from March, and May is the hottest month. With the onset of the monsoon, temperature drops by three to four degrees. Day temperatures during the monsoon are lower than those in the cold season. In the post monsoon months of October and November, day temperatures increase and days in November are as hot as in May. Night temperatures are the lowest in January. Areas within 20 to 25 kilometres of the coast are the most pleasant particularly in the hot months with the sea breeze blowing, nearly throughout the day. Further inland during the hot months both days and nights can be oppressive and more so in the tract at the foot of the Western Ghats. Along the coast the maximum temperature rarely goes beyond 38 C (100.4 F) but in the interior may reach 40 or 41 C (104 0 or F). Winds: Winds are very strong and are mainly westerly or south westerly during the monsoon. In the rest of the year winds blow from directions between north and east in the mornings and between west and north-west in the afternoons. 22

24 4.4 SOILS The most predominant rock formation of the district is the Konkan laterite, formed from the original trap. It is an argillo-ferrugenous deposit and covers the major portion of the land surface forming undulating plateaus with a general elevation of 200 to 300 feet Laterisation has taken place under the hot humid conditions. Due to heavy rainfall, the bases have been leached away along with the silicic acid and hence the resulting rock is acidic in reaction and rich in iron and aluminium oxides with a silica-sesquioxide ratio of less than two. The hydrated iron oxides impart the red colour to the soils. Due to these geological formations the soils of the district are mostly lateritic which are found mixed with trapping soils in the north and shallow soils in the south. Along the coast are the alluviums. There are small patches of salt lands developed near the creeks. Lateritic Soils Lateritic soils which are predominant in the district, vary in color from bright red to brownish red owing to the preponderance of hydrated iron oxides. They are always acidic, the ph value ranging from 4.5 to 6.5. Lime is deficient or almost absent. Usually they have very low phosphorus and potash content, but are fairly well supplied with nitrogen and organic matter. Their texture is loamy and depth varies from one foot to three feet. They are porous and not retentive of moisture and are found all over the district except in Mandangad taluka which consists mainly of forests. These soils, however, are found in several grades, which depend upon their (soils) location and the extent of admixture of different rocks. The following of these grades are of special significance. Rice Soil These soils have various names which are identified with their location. Those situated at higher levels are usually known as mal, while those at slightly lower levels are called kuryat soils. Near the water courses, which have a fair supply of water during the rabi season, are the panthal or vaingan soils. All these soils benefit by liming and give high response to the application of phosphatic and potassic fertilisers. Only a kharif crop of paddy can be taken on these soils. On the panthal soils, however, a crop of rabi pulse (wal) or summer (vaingan) paddy can also be taken. Varkas Soil These soils are situated on the slopes of the hills and are partly eroded, yellowish red and poor in fertility. Further, they are shallow in depth and coarse in texture. Ragi (nagli) is the principal crop in these soils and it responds well to supplies of nitrogen and phosphate. Cashewnut grows in plenty in this area. It is on these soils that the world renowned Alphonso mangoes are grown. On the mountain tops are the perennial forests, where the soils are rich in humus because of their being protected from erosion. They are reddish-brown in colour. 23

25 Coastal Alluvium The coastal strips in Dapoli, Guhagar, Ratnagiri and Rajapur talukas are covered with soils of recent deposits and are locally known as pulanwat. They are deep sandy loams and cocoanut gardens and arecanut gardens thrive well in them. Paddy is also taken here to some extent. Salt Land Due to the inundation of the sea, a part of the coastal soils has "become salty. They are locally known by several names like khar, khajan, kharvat, etc. In Deogad, Malvan and Vengurla talukas, the entire western strips are salty while in other coastal talukas only salt patches which are suited to the coarser types of paddy are to be noticed. 4.5 Planning in Brief The expansion is planned at existing plot of the company, so no new specific / additional planning is envisaged. The Green Belt area statement is attached herewith. 4.6 Proposed Infrastructure There is no specific additional infrastructure required for the proposed expansion. Power / Water required for existing as well new proposed plants will be supplied by MSEB/MIDC respectively. Company already has uninterrupted and stable power supply through Express Feeder Lines however power will also be generated & utilized as per the need from proposed Co-gen plant. For solid waste disposal Company is already member of Hazardous Waste disposal center run by agencies authorized by local state government / pollution control board. 4.7 Rehabilitation and Resettlement Plan Since expansion doesn t involve relocation/shifting of any existing settlements on land, the rehabilitation and resettlement is not applicable for this expansion. 24

26 Chapter 5 Planning Brief 5.1 Planning Concept: Plot is at well-established MIDC Lote Parshuram industrial area Purified Water supply from MIDC Well-developed roads and connectivity. Infrastructure facilities available established MIDC site Utilities Integration with existing unit 5.2 Population Projection An official Census 2011 detail of Ratnagiri, a district of Maharashtra has been released by Directorate of Census Operations in Maharashtra. Enumeration of key persons was also done by census officials in Ratnagiri District of Maharashtra. In 2011, Ratnagiri had population of 1,615,069 of which male and female were 761,121 and 853,948 respectively. In 2001 census, Ratnagiri had a population of 1,696,777 of which males were 794,498 and remaining 902,279 were females. Ratnagiri District population constituted 1.44 percent of total Maharashtra population. In 2001 census, this figure for Ratnagiri District was at 1.75 percent of Maharashtra population. There was change of percent in the population compared to population as per In the previous census of India 2001, Ratnagiri District recorded increase of 9.89 percent to its population compared to Assessment of Infrastructure Demand (Physical and Social) No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC area. 25

27 Chapter 6 Proposed Infrastructure Since the expansion is planned at existing site in developed MIDC industrial area, no special/specific development is anticipated. Company has not planned any additional residential area at the proposed site as MIDC has already existing Residential areas earmarked for housing colonies. For additional essential manpower company may decide at later date about building additional colony building. 6.1 Industrial area: Vinati Organic Ltd., Plot no A20 & D 30/2, Lote MIDC proposes to expand existing plant for manufacture of synthetic organic chemical (Butyl Phenols) based on demand and market projection. 6.2 Residential Area: No Residential area has been proposed within the plant site. 6.3 Green Belt: Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement. 6.4 Social Infrastructure: Local people will be given preference wherever found suitable for all the jobs in the plant, direct as well as indirect. Thus the project shall have a positive impact on the employment pattern of the region. Economic status of the local population will improve due to increased ancillary/business opportunities, thereby making positive impact. Educational, medical & housing facilities will improve due to the proposed project. 6.5 Water Management: The total water requirement is about 27cmd for Domestic, boiler/cooling, Greenery and process. The source of water shall be from MIDC. The water supply will be through the good offices of MIDC. VOL will not be encroaching on anybody s water source. 6.7 Sewage and waste water treatment system: Existing Vinati organics plot (A20) is well developed & has existing ETP facility to cater the waste water treatment generated from this plant. Detailed ETP & STP process description for treatment will be submitted in EIA report of subjected expansion plans. 26

28 Chapter 7 Rehabilitation and Resettlement Plan Since expansion doesn t involve relocation/shifting of any existing settlements on land, the rehabilitation and resettlement is not applicable for this expansion. 27

29 Chapter 8 Project Schedule & Cost Estimate Project Schedule is given below and Cost estimate/feasibility is given in tabulated form below The following schedule is based on assumption that Company gets Environmental Clearance by Sep, Time frame is to be considered Project Likely Start Likely Completion Butyl Phenols Oct, 2016 Oct, 2017 (PTBP, OTBP, 2, 4 DTBP, 2,6DTBP) PTBBAL Oct, 2016 Apr, 2017 Lili Aldehyde Apr, 2017 Oct, 2017 The approximate Project Costs (Figures in Lacs) Sr. No. Description BUTYL PHENOLS PTBBAL Total 1 Civil Cost 1, ,146 2 Plant & Machineries including Utilities 11,660 2,340 14,000 3 Margin Money 1, ,742 4 Total Project Cost 14,636 3,252 17,888 28

30 Annexure I Site google image Site & surrounding study area of 1 km Site & surrounding study area of 10 km 29

31 Annexure II Proposed Layout Plan 30

32 Proposed area statement for Plot no A20 & D 30/2 31