PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT for PROPOSED EXPANSION OF SILICA SAND PRODUCTION (GLASS GRADE) & LPG STORAGE CAPACITY FOR GLASS MANUFACTURING UNIT of M/s. GUJARAT GUARDIAN LIMITED VILLAGE: KONDH, VALIA ROAD, TAL: ANKLESHWAR , DIST: BHARUCH (GUJ.) Prepared By: NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company Aqua-Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat

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) 23 2

3 1.0 EXECUTIVE SUMMARY 1.1 Company Profile M/s. Gujarat Guardian Limited proposes expansion of Silica Sand production (Glass Grade) & LPG Storage capacity in Existing Glass Manufacturing Unit at Village: Kondh, Valia Road, Tal: Ankleshwar , Dist: Bharuch (Guj.). Total Cost of the Project is Rs. 624 Crores (Existing = Rs. 584 Crores + Additional Proposed = Rs. 40 Crores). Total Plot Area is 6,55,990.4 m Project Details Products along with Production Capacity Float Plant Details: S. No. Product 1 Float Glass 2 Mirror 3 Lacquered Glass 4 Coater Glass Quantity in Square Meter/Annum Permitted Additional Total 2,50,00,000-2,50,00,000 SR. NO. SR. NO. Proposed Expansion Details: PRODUCT NAME EXISTING CAPACITY (MT/MONTH) PROPOSED CAPACITY (MT/MONTH) 1 Silica Sand (Glass Grade) 13,500 56,225 2 By-Products (Coarse, Fines and rejects) 19,620 30,275 3 Total 33,120 86,500 LPG Storage Tank Details Existing Capacity: LPG Tanks = 4 Nos. (Capacity = MT each) Storage Material No. of Tanks Capacity Total Capacity Tank Dimensions 1 LPG MT (each) 225 MT Length = 16.2 m Diameter = 3200 mm 3

4 Total Proposed Capacity: LPG Tanks = 6 Nos. (Capacity = 120 MT each) Proposed combine capacity: 720 MT Storage No. of Tanks Capacity Total Capacity Tank Dimensions SR. NO. Material 1 LPG MT (each) Sr. No. 720 MT Design Pressure : 21 Kg/cm 2 Overall Length = mm, Tank ID = 4010 mm, Tank Shell = 28 mm thick Dished End = 18 mm Thick Note: M/s. Gujarat Guardian Limited is exploring the option to merge the existing and proposed LPG storage yard for future so that the new LPG yard would be (existing + proposed) with 720 MT capacity. By proposing this we are also proposing that existing yard be demolished and merged with new LPG storage yard in case above is the decision. Existing LPG storage yard: 225 MT Additional Proposed LPG storage: 495 MT Total Storage of LPG onsite: 720 MT Raw Material Requirement Raw Material UOM Consumption Quantity Per Month Proposed Permitted Additions Float Glass 1 Sand MT 14, ,000 2 Soda Ash MT 4, ,500 3 Dolomite MT 3, ,800 4 Limestone MT 1, ,400 5 Feldspar MT Salt Cake MT Carbon MT Cullet MT Wet Coater 1 Raw Glass Sq. Meter 5,83, ,83,000 2 Washing & Polishing Chemicals Kg 2, ,062 3 Tin Sensitizer Litre Palladium Sensitizer Litre Total 5 Silver Solution Litre 2,600 2,600 0 Silver Nitrate Kg 1,088 1,088 6 Reducer/ Litre 4,830 4,830 0 Silver less solution Litre 2,920 2,920 7 GMPA & GMPB Litre 1, ,190 4

5 Consumption Quantity Per Month Sr. Raw Material Proposed No. UOM Permitted Total Additions 8 Paint MT Ortho-Xylene Litre 9, , HCL-32% Litre 11, , Caustic-32% Litre 13, , Ferric Sulfate kg Lacquered Glass 1 Raw Glass Sq. Meter 1,50, ,50,000 2 Washing and polishing chemical Kg Adhesion Promoter Litre Paint MT A GLASSOLUX NG 9003 PURE WHITE Kg 2, ,500 B GLASSOLUX NG 2105 Sapphire Kg 2, ,500 C GLASSOLUX NG 3004 Burgundy Kg 2, ,500 D GLASSOLUX NG 6113 Fluo green Kg 2, ,500 E GLASSOLUX NG 9005 Black Kg 2, ,500 F Ivory Kg 2, ,500 G Red Kg 2, ,500 5 Ortho-Xylene Litre 1, ,000 Sand Beneficiation Plant 1 Raw Silica Sand MT 33,120 53,380 86, Water Requirement, Waste Water Generation and Treatment Total water requirement is 1650 KL/Day at present which is met through Valia Water Supply System (Canal Water). The wastewater generation is 921 KL/Day at present. There will be no increase in Water Consumption as well as Wastewater Generation after proposed expansion. Out of 921 KL/Day of wastewater, 205 KL/day of domestic wastewater is treated in STP and then reused for land irrigation/gardening. 716 KL/day of Industrial waste water (i.e ) is recycled back to Sand Plant for Sand Washing and also is used for irrigation. Ultimately it is a Zero Liquid Discharge Unit and after proposed expansion it will remain ZLD. 5

6 Sr. No. 1.4 Air Pollution Source and Control Management There is no addition or changes in the Flue Gas Stacks & Process Vents Flue Gas Stacks Stack Attached To No. of Stacks Height From Ground (m) Fuel Used 1. Melting Furnace 1 91 Natural Gas, LPG 2. DG Set (2.5 MW) 3. DG Set (2.5 MW) 4. DG Set (500 KVA) 5. LPG Hot water generator exhaust 6. Diesel Engine 1 (155 KVA) 7. Diesel engine 2 (155 KVA) 8. Diesel engine 3 (155 KVA) 9. Diesel engine 4 (155 KVA) 10. Glass Edge Burner Air Pollution Control System Low NOx Burner, Stack height Expected Pollutants PM,TF 1 30 Diesel NA PM, NOx, NMHC, CO 1 30 Diesel NA PM, NOx, NMHC, CO 1 14 Diesel NA PM, NOx, NMHC, CO 1 12 LPG NA PM, SO 2, NOx 1 12 Diesel NA PM, NOx, CO 1 12 Diesel NA PM, NOx, CO 1 11 Diesel NA PM, NOx, CO 1 11 Diesel NA PM, NOx, CO 1 16 Natural Gas, LPG NA PM, SO 2, NOx Process Vents S. No. Stack attached to No. of Stacks Stack height (m) Pollutant Emitted Air Pollution Control Measures Attached 1. Main Melting Furnace 1 91 PM, TF Stack 2. Ammonia Cracking Plant 1 21 PM, Ammonia 3. Mirror Line Plant 7 12 VOC, Ammonia Stack, Nitrogen Purging Stack 4. SO 2 Vent 2 17 SO 2 Stack 5. Batch House Raw PM Dust Collector 6

7 Materials DCF Vents 6. Batch House Raw Materials DCF Vents at Basement PM Dust Collector 7. Batch House Unloading 1 6 PM Dust Collector DCF Vent 8. Cullet Return System DCF Vent 1 3 PM Dust Collector 9. Hot Air Exhaust 5 16 PM Not Required 1.5 Hazardous Waste Management S. No. Items Category Existing Additional Total 1 Used Oil KL/Year 2 Chemical Sludge from Wastewater Treatment 3 Waste residue containing oil 4 Process wastes, residues & debris from production and/or industrial use of paints, pigments, lacquers, varnishes, plastics and inks 5 Spent solvents from the production and/or industrial use of solvents 7 Discarded Containers & barrels contaminated with hazardous wastes/chemicals KL/Year Treatment and Disposal Method Transportation & Sending to Registered Refiners for recycle / reuse Transportation & Disposal by landfill at authorized TSDF Transportation & Sent to GPCB registered TSDF for land Filling or Incineration Transportation & Sent to licensed disposal company Recycle as a fuel or Incineration Transportation & Sent to licensed disposal company Recycle as a fuel or Incineration Transportation & Disposal by selling to Registered Vendors 7

8 8 Furnace/reactor residue and debris from pyrolytic operations 9 Inorganic Tin compounds 10 Spent catalyst and molecular sieves 11 Spent ion exchange resin containing toxic metal D1 60 B Transportation & Disposal by landfill at authorized TSDF Transportation & Sent to licensed disposal company for Recycling Transportation & Sent to licensed disposal company for Recycling Transportation & Disposal by landfill at authorized TSDF Solid (Non-Hazardous) Wastes: S.No Waste Type Permitted Additional Total Disposal Method 1. Mirror Cullet Transportation & Sold as non-hazardous waste for recycling / reuse 2. Bad Batch, Gcore, other NH organic chemicals G-Core 100 Kg/Month 4. Waste sand Cullet Sludge Generation from STP Kg/Month Transportation & Recycling/Reuse/Landfill Transportation & Reuse inhouse for water neutralization Transportation & Recycling in house / Landfill & Recycled in house Transportation & Recycling in house / Landfill Transportation & Using as manure in-house 7. Furnace refractory waste, 10 MT/ 0 10 MT/ 8

9 Kwool, Mud, Cement etc. Year Year Transportation & Sent for Construction earth-filling 8. Cullet Dust E-waste Trash and Packaging material waste Kg / Month Metal Scrap Kg / Month Transportation & Sold To GPCB approved recycler Transportation & Sold to scrap vendor Transportation & Sold to scrap vendor Transportation & Sold as non-hazardous waste for recycling / reuse (increase in scrape would be because of demolish of existing sand beneficiation plant) 1.6 Green Belt Company has developed an effective green belt within the factory and on periphery of the factory. Total Plot Area is 6,55,990.4 m 2 out of which 80, m 2 is Green Belt Area. 1.7 Power & Fuel Requirements TOTAL POWER REQUIREMENT & SOURCE OF POWER Power requirement will be 6.5 MW which will be taken from GEB. 4 Nos. of (155 KVA each) & 3 Nos. of (2.5 MW, 2.5 MW & 500 KVA) DG Sets will be kept for emergency power back up. FUEL REQUIREMENT S.No Fuel Quantity Existing Proposed Total 1 Natural Gas 6600 m 3 /hr m 3 /hr 9

10 2 LPG 4 MT/hr* - 4 MT/hr* 3 Diesel 1515 Ltrs /Hr 60 Ltrs/Hr 1575 Ltrs /Hr 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 M/s. Gujarat Guardian Limited proposes expansion of Silica Sand production (Glass Grade) & LPG Storage capacity in Existing Glass Manufacturing Unit at Village: Kondh, Valia Road, Tal: Ankleshwar , Dist: Bharuch (Guj.). Identification of the project proponent Sr. Name of No. the Director 1 Mr. Vinay Kumar Modi 2 Mr. Kevin William Baird 3 Mr. Emad Al Ebrahim Designation Date of Address PAN Birth Chairman 13/06/1943 Gujarat Guardian Ltd., AAEPM1414A 4/7C DDA Shopping Centre, New Friends Colony, New Delhi Director 09/12/1961 Guardian Industries Non-resident Corpn., 2300 Harmon Road, Auburn Hills, Michigan, USA Director 05/11/ C Al Khazan Street, Al Non-resident HazmSafwa 31892, Saudi Arabia 4 Mr. Alok Joint 18/06/1966 Gujarat Guardian Ltd., ADQPM0674F 10

11 K. Modi Managing 4/7C DDA Shopping Director Centre, New Friends Colony, New Delhi Mr. A. M. Surana 6 Mr. P. K. Gera, IAS 7 Mr. Arun Kumar Solanki, IAS 8 Mr. Vincent Pringiers 9 Mr. Thomas V Jacobs 10 Mr. Douglas Alan Girdier Finance 02/08/1950 Gujarat Guardian Ltd., AGBPS5137R Director Valia Road, Village: Konth, Ankleshwar, Guj Nominee 26/11/1959 Gujarat Alkalies & AATPG0400D Director Chemicals Ltd., PO: Petrochemicals, Baroda Additional 14/02/1967 Gujarat Min. AGEPS0663H Director Development Corp. Ltd., Khanij Bhavan, 132 ft. Ring Road, University Ground, Ahmedabad-52 Director 31/12/ , Kohlenberg, L-1870, Non-resident Luxembourg-1870 Director 04/06/1961 Guardian Industries Non-resident Corpn., 2300 Harmon Road, Auburn Hills, Michigan, USA Director 29/09/1966 Guardian Industries Non-resident Corpn., 2300 Harmon Road, Auburn Hills, Michigan, USA 11 Mr. Independent 01/07/1960 Flat 1102, Tower 1, AABPA1222F 11

12 Govind Director Sumer Trinity Towers, Agrawal New Prabhadevi Road, Mumbai Ms. Independent 26/06/1953 C-191, Grand Paradi, AACPD4427C Bhavna Director Kemps Corner, Mumbai- Doshi Brief description of nature of the Project Proposed expansion of Silica Sand production (Glass Grade) & LPG Storage capacity in Existing Glass Manufacturing Unit 2.3 Need for the project and its importance to the country and or region The demand for products intended to be manufacture is increasing in the country by expanding this; M/s Gujarat Guardian Limited will be able to meet the demand of the product locally. This will also generate direct and indirect employment opportunity for various levels of people. 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 Shall be envisaged. 2.6 Export possibility Shall be envisaged. 2.7 Domestic/Export Markets Major portion of the product will be used for domestic market and some portion of the product may be exported depending on the international market. 12

13 2.8 Employment Generation (Direct and Indirect) due to project. M/s Gujarat Guardian Limited will give direct employment to local people based on qualification and requirement. 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 Silica Sand production (Glass Grade) & LPG Storage capacity in Existing Glass Manufacturing Unit Category: A-2(b) & 6(b) No interlinked project has been submitted. 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) 13

14 Project Site (Google Map) 14

15 Plot Layout 15

16 LPG STORAGE LAYOUT (EXISTING) 16

17 LPG STORAGE LAYOUT (PROPOSED) 17

18 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. It is expansion within existing premises. No alternate site is considered. Major factors involved in the selection of site are listed below: Minor site clearance activities shall be carried out to clear shrubs and weed. The project site is located on level ground, which does not require any major land filling for area grading work. Proximity to Raw Material suppliers. Site is very well connected by road and railway. Availability of Power, Water, etc. Modern infrastructure support and amenities at par in other global markets, including: Efficient transport facilities. Environment-friendly zone. Uninterrupted power supply. 3.4 Size or Magnitude of Operation Please refer Section-1.2.1, Page No. 1 to 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-III. 3.6 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-1.2.2, Page No Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. It is a Zero Liquid Discharge Unit. 18

19 3.8 Availability of water its source, energy/power requirement and source should be given. Water Source Total water requirement is met through Valia Water Supply System (canal water). Power & Fuel Requirement For Power & Fuel Requirement; Please refer Section-1.7, Page No Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. Please refer Please refer Form-I, Annexure-V & VI 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. 19

20 4.0 Site Analysis 4.1 Connectivity Site is very well connected by road Availability of water, power facilities 4.2 Land Form, Land Use and Land Ownership It will be incorporated in EIA Studies. 4.3 Topography (along with map) We will be incorporated topography in EIA Studies. 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. It will be incorporated in EIA Studies. CRZ Clearance is not applicable. 4.5 Existing Infrastructure Existing Infrastructures facilities are listed below: Site is very well connected by road Proximity to sugar cane growers Availability of sufficient land free form cultivation Availability of power evacuation facilities 4.6 Soil Classification It will be incorporated in EIA Studies. 20

21 4.7 Climatic data from secondary sources Primary source: our own weather station & Secondary Sources: Indian Meteorological Department, Ahmedabad. 4.8 Social infrastructure available Depending on the growth of the company the required social infrastructure will be provided. 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 Silica Sand production (Glass Grade) & LPG Storage capacity in Existing Glass Manufacturing Unit. 5.2 Population Projection It will be incorporated in EIA Studies. 5.3 Land use planning (breakup along with green belt etc.) Sr. No. Land Use Proposed Area (m 2 ) 1 Production Plants Parking Security Building Effluent Treatment plant NA 5 Utility + Tank Tank Farm Area 7 Raw Material and Finished Products Storage Gas Tonner Storage Green Belt Road Total

22 5.4 Assessment of Infrastructure Demand (Physical & Social) It will be incorporated in EIA Studies. 5.5 Amenities/Facilities It will be incorporated in EIA Studies. 6.0 Proposed Infrastructure 6.1 Processing Zone = 5,75, m Non- Processing Zone = 80, m Green Belt Company has developed an effective green belt within the factory and on periphery of the factory. Total Plot Area is 6,55,990.4 m 2 out of which 80, m 2 is Green Belt Area. 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 sugar cane growers Availability of sufficient land free from cultivation Availability of power facilities Availability of water 6.6 Drinking water Management (Source & Supply of water) Total water requirement is met through Valia Water Supply System (Canal Water). 22

23 6.7 Sewerage System Sewage pipes are laid in entire factory for the removal and disposal of mainly non-harmful liquid wastes from the offices, canteen and domestic waste coming from different sections. These liquid wastes are treated in STP and reused back in land irrigation/gardening. 6.8 Solid Waste Management Please refer Section 1.5 (Page No. 7). 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 expansion 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. 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 shall start construction of sand beneficiation plant only after getting environmental clearance and consent to establish. We shall start production of new sand beneficiation plant upon making application for CCA. Note: In the existing premises, we already have operational float glass manufacturing unit and existing old sand beneficiation plant since

24 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total Cost of the Project is Rs. 624 Crores (Existing = Rs. 584 Crores + Additional Proposed = Rs. 40 Crores). Break up of Additional Project Cost Sr.No. Particulars Estimated Cost (Inr In Lakhs) 1 Land and Site Development Building Plant and Machineries 4 Environment protection measures (includes cost of ETP, Tree Plantation, 1000 Evaporator System and Rain Water Harvesting etc.) TOTAL 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 expansion 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. 24