PRE-FEASIBILITY REPORT PROPOSED PROJECT FOR MANUFACTURING OF DYES INTERMEDIATES. OF M/s. UMIYA CHEM INTERMEDIATES

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1 PRE-FEASIBILITY REPORT ON PROPOSED PROJECT FOR MANUFACTURING OF DYES INTERMEDIATES OF M/s. UMIYA CHEM INTERMEDIATES AT PLOT NO: 4705/1/1, GIDC ESTATE,ANKLESHWAR, DIST:BHARUCH STATE:-GUJARAT 1

2 1.0 EXECUTIVE SUMMARY M/s. Umiya Chem Intermediates is an existing small scale unit located at Plot No:-4705/1/1, GIDC Estate, Ankleshwar, Dist:-Bharuch. Unit is engaged in the manufacturing of Dye Intermediates.Unit has CCA-AWH-65825, issued on 29/10/2014, valid up to 23/07/2019. List of products is given in Table No:-1. TABLE: 1 LIST OF PRODUCTS Sr. No Name of product CAS No Existing capacity in MT/ Month as per AWH Meta Phenylene Diamine-4- Sulphonic acid-na Salt AND/OR 2. Meta Phenylene Diamine-4- Sulphonic acid- Free acid AND/OR 3. Meta Phenylene Diamine-4- Sulphonic acid- Acetyl AND/OR Proposed capacity in MT/Month Benzoyl H acid AND/OR DNA AND/OR Chloro 2-Amino Phenol AND/OR Total capacity in MT/ Month 75* 7. 5-Chloro 8- Hydroxy Quinoline 8 Meta Nitro Aniline (MNA)**

3 *Unit will manufacture 75 MT/Month productions after proposed expansion. ** Unit will discontinue Meta Nitro Aniline. COST OF PROJECT The expected cost of project is Rs 201 Lacs. The total plot area of the unit is 980 sqmt. FUEL AND ELECTRICITY CONSUMPTION The Unit is using Natural gas as a fuel. The existing consumption of Natural gas is 50 m 3 /day. After proposed expansion it will be 100 m 3 /day. At present the total connected load of power is 50 KVA, which is expected to be increased up to about 99 KVA after proposed expansion. Thus, the additional power requirement for the proposed expansion will be 49 KVA, which will be procured from Dakshin Gujarat Vij Company Ltd. (DGVCL). WATER CONSUMPTION Water consumption for Domestic purpose, Gardening Purpose and Industrial purpose will be 1 KL/Day,1 KL/Day and 9.75 KL/Day respectively. WASTEWATER GENERATION Existing waste water discharge permission as per CCA is 3.5 KL/Day. After proposed expansion it will be 11.5 KL/Day. FLUE GAS EMISSION There is a flue gas emission from the Boiler. There will be no requirement of additional utility for proposed expansion. PROCESS GAS EMISSION Rector will be a source of process gas emission. Unit will install adequate APCM to mitigate it. Gases:-Ammonia and SO 2 APCM-Scrubber with charcoal HAZARDOUS WASTE MANAGEMENT The Hazardous wastes from the unit are ETP sludge, Used Oil, Discarded Containers/Bags/Liners, Iron sludge and Charcoal. 3

4 2. INTRODUCTION 2.1 THE PROJECT M/s. Umiya Chem Intermediates is an existing small scale unit located at Plot No:-4705/1/1, GIDC estate, Ankleshwar, Dist:-Bharuch. Unit is engaged in the manufacturing of Dye intermediates. Unit has CCA-AWH-65825, issued on 29/10/2014, valid up to 23/07/2019. The list of products is mentioned in Table No: PROJECT PROPONENT M/s. Umiya Chem Intermediates is involving in the manufacturing of Dye intermediates. The promoters have well experienced in this field. Now to meet the market demand promoters want to increase the production capacity of the unit. The plant boasts of contemporary infrastructure facilities with advanced machinery and automated processes. They are conscious of environment protection measures and from the conception stage itself necessary care has been taken. A vision, a mission and a will to succeed are the basic ingredients in the foundation of the company. A team of well-qualified engineers and financial experts supports the company. Main promoters as well as staff of the company have very good industrial as well as business experience. QUALITY POLICY The company s commitment is to manufacturing of fiber. The company has in house testing facility with modern testing equipments to ascertain the quality of raw materials as well as finished products. Continued emphasis towards process and technology up gradation is being done effectively to enrich the product quality. R & D with initiative & innovative ideas had resulted into excellent performance in respect of quality products. ENVIRONMENTAL POLICY The unit is committed to execute all operations, products and services by environmental protection activities to the extent possible. As a means of achieving these, the unit pledges to company with the legal & other requirements to their core and focus on continually improving products, systems & operations. 4

5 TABLE: 2 LIST OF PARTNERS Sr. No Name Present Residential Address 1. Mr.Vinodbhai K Patel 408/12,Sardar Patel Society, GIDC, Ankleshwar 2. Mr.Pratik V Patel 408/12,Sardar Patel Society, GIDC, Ankleshwar Designation Contact No. Partner Partner The Partners of the company have good experience in handling the production management, financial management and all the dyes areas. 2.3 NATURE OF PROJECT The existing plant capacity of the unit is 48 MT/Month for the production of Meta Nitro Aniline & Meta Phenylene Diamine 4-sulphonic acid (MPDSA). After proposed expansion total production capacity of unit will reach at 75 MT/Month. Unit has decided to withdraw one existing product Meta Nitro Aniline. As per EIA notification 2006, the proposed project falls under category 5(f)-B. 2.4 MARKET FEASIBILITY This dye intermediates are widely used across the globe. These dye intermediates are commonly used as a coloring agent in different substances. The offered chemical is processed by using optimum quality chemical and advanced technology as per set market norms. These products are used into dye industries. 3.0 PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The proposed project is not including any interlinked and interdependent project 3.2 PROJECT LOCATION The proposed project site is located at Plot No:-4705/1/1, GIDC industrial Estate, Ankleshwar , Dis: - Bharuch, Gujarat which is one of the fastest growing industrial estate and having all the essential facilities & infrastructure for the management & disposal of effluent discharge. The approximate geographical positioning of the project site is at Latitude: 21 36'59.88"N 5

6 Longitude: 73 01'59.18"E. The location of the project site can be identified from the location map shown in Figure-1. The salient features of the location of the project site are presented in Table 3. TABLE: 3 SALIENT FEATURES OF THE PROJECT SITE Particulars Details Distance from Site Villages Ankleshwar 3 KM Approx. Geographical positioning Nearest City Nearest Railway line/ Railway station Latitude: Longitude: Ankleshwar Bharuch Ankleshwar 21 36'59.88"N 73 01'59.18"E 3 KM 15 KM 3 KM Domestic Airport Vadodara 94 KM 6

7 FIGURE -1 LOCATION OF THE PROJECT SITE 7

8 ANKLESHWAR 8

9 9

10 FIGURE-2 Aerial view of the 5km radial periphery from the project Site 3.3 SITE SELECTION The project proponent did not consider any other alternative site for proposed project. 3.4 NEIGHBORING INDUSTRIES The industry is located in an area, which is already industrialized. The industries in the vicinity of the proposed project are given in the table-4 below: 10

11 TABLE: 4 NEARBY INDUSTRIES IN THE VICINITY SR.NO. INDUSTRIES NAME 1 M/s. JAYSHREE INDUSTRIES 2 M/s. DYNAMIC DYE CHEM 3. M/s. HEMDEEP 4. M/s. A-ONE CHEMICALS 11

12 3.5 SIZE OF PROJECT The existing plant capacity of the unit is 48 MT/Month for the production of Meta Nitro Aniline & Meta Phenylene Diamine 4-sulphonic acid (MPDSA). After proposed expansion total production capacity of unit will reach at 75 MT/Month. Unit has decided to withdraw one existing product Meta Nitro Aniline. The expected cost of proposed project is Rs.201 lacs. New Plant and machinery installations will also have to be acquired and installed. Environment Protection and safety systems have also been considered in planning the Cost Projection. The break-up of the proposed project cost is given in below table 5. TABLE: 5 CAPITAL COST PROJECTION Sr. No. Purpose 1. Land EXISTING (In Lacs) PROPOSED (In Lacs) --- TOTAL AFTER EXPANSION (In Lacs) 2. Building Plant and Machinery QA Lab Environment Protection & Safety 226 a) Effluent treatment Plant 30 b) Safety Equipment (PPE, 15 fire extinguishers, Ventilation, etc.) c) Green belt development 1 d) Hazardous waste 10 management e) Air Pollution Control 5 GRAND TOTAL PROCESS TECHNOLOGY Unit is involving in the manufacturing of Dye Intermediate. These are characterized for their physicochemical properties. Process details like Process description, chemical reactions and mass balance for each product is attached as Annexure 6 in FORM-I. 12

13 3.7 RAW MATERIAL Unit is involving in the manufacturing of Dye Intermediates and purchasing required raw material from local/indian market. Products wise raw material consumption is attached as Annexure-5 in FORM-I. 3.8 RESOURCE REQUIREMENTS LAND The total plot area of the unit is 980 Sq meter FUEL For production activity, fuel requirement and power consumption is as per below Table 6 and Table 7. TABLE: 6 FUEL CONSUMPTION SR. FUEL QUANTITY QUANTITY TOTAL NO (As per current CCA (As per proposed No:-AWH-65825) expansion) 1. Natural Gas 50 M 3 /day 50 M 3 /day 100 M 3 /day TABLE: 7 POWER CONSUMPTION SR. NO POWER QUANTITY (As per current CCA No:-AWH-65825) QUANTITY (As per proposed expansion) TOTAL QUANTITY 1. Electricity 50 KVA 49 KVA 99 KVA 13

14 3.8.3 WATER WATER CONSUMPTION Existing water and Proposed water consumption is incorporated in Table No:-8. TABLE: 8 WATER CONSUMPTION Sr. No Particulars Existing Water Consumption KL/Day (As per CCA- No:-AWH ) Proposed Water Consumption KL/Day (As per proposed expansion) Total Water Consumption KL/Day Fresh Total 1. Domestic Process Boiler Cooling Gardening Wash water Total Industrial TOTAL (Industrial + Domestic )

15 3.8.4 WASTEWATER MANAGEMENT The category-wise bifurcation of the wastewater generation is given in Table 9. TABLE: 9 WASTE WATER GENERATION Sr. No. Particulars Existing Waste Water Generation in KL/Day (As per CCA-No:-AWH ) Proposed Waste Water Generation in KL/Day Final waste Water Generation in KL/Day 1. Domestic Industrial 2. Process Boiler Cooling Tower Washing Total Industrial Total (Industrial + Domestic) * 15

16 WATER BALANCE DIAGRAM TOTAL WATE REQUIREMENT (11.75 GIDC WATER) Waste Water from Chemicals-2.75 KL/Day PROCESS WATER (7 KL/Day) EFFLUENT GENERATION (8.5 KL/DAY) LOSS (1.25 KL/Day) WASHING (0.75 KL/DAY) BOILER (1 KL/Day) LOSS (0.25 KL/Day) COOLING TOWER LOSS (0.5 KL/Day) DOMESTIC (1 KL/Day) GARDENING (1 KL/Day) Effluent (0.75 KL/Day) BLOW DOWN (0.75 KL/DAY) BLOW DOWN (0.5 KL/DAY) SEWAGE (1 KL/DAY) 8.5 KL/Day Treatment collection Tank (11.5 KL/Day) CETP M/s. ETL for further treatment (11.5 KL/Day) 16

17 WASTEWATER CHARACTERISTICS Existing & proposed effluent characteristic before treatment and after treatment in ETP is covered in Annexure-7 of FORM I WASTEWATER TREATMENT & DISPOSAL Details of existing & proposed effluent treatment plant (ETP) is covered in Annexure-7 of FORM I. 3.9 MITIGATION MEASURES & EMP Based on overall manufacturing & operation activities, the mitigation measures have been proposed by the company for the control of the anticipated pollution load GASEOUS EMISSIONS & CONTROL FLUE GAS EMISSION Existing flue gas emission and proposed flue gas emission is mentioned in Table No: 10. TABLE: 10 FLUE GAS EMISSION Sr. No Stack Attached To Stack Height in Meter Type Fuel APCM Parameter Permissible Limit 1. Small Industrial Boiler (600 Kg) EXISTING EQUIPMENTS (As per CCA-No:-AWH-65825) 11 Natural Gas --- Particulate Matter Sox Nox - No additional utility will be required for proposed activity. 1. Small Industrial Boiler (600 Kg) AFTER PROPOSED EXPANSION 11 Natural Gas --- Particulate Matter Sox Nox 150mg/NM ppm 50 ppm 150mg/NM ppm 50 ppm 17

18 PROCESS EMISSIONS TABLE: 11 PROCESS GAS EMISSION Sr. No Stack Attached To Stack Height in Meter Air Pollution Control System 1 Reactor 15 Scrubber with charcoal Parameter NH 3 SO 2 Permissible Limit 175 mg/nm ppm HAZARDOUS WASTE MANAGEMENT The following types of hazardous wastes are being generated during the operational activities. All the wastes are being stored separately in a designated storage area. The details of hazardous waste are below given Table 12. TABLE 12 DETAILS OF HAZARDOUS WASTE Sr. No. Waste Category Quantity/ Month (As per existing CCA-AWH ) Quantity/ Month (As per Proposed Expansion) Total/ Month Facility 1 Iron Sludge MT 245 MT 275 MT Collection, Storage, Transportation, and final disposal at common TSDF by BEIL. 2 Discarded Containers Bags/Liners Nos. 220 Nos 420 Nos Collection, Storage, Transportation, Decontamination 3 Used Oil Lit 0.06 Lit 0.08 Lit Collection, Storage, reuse sell to registered re-processors. 4 ETP Sludge MT 3 MT Collection, Storage, Transportation and 18

19 send to available TSDF site M/s. BEIL 5 Charcoal MT MT Collection, Storage, Transportation and send to available TSDF site M/s. BEIL NOISE CONTROL & ODOUR To reduce the effect of noise, unit has provided ear plugs to the operating person of Boiler room. Unit is following below steps to Noise control and Odour. Raw-material feeding is being carried out by pumps. All reactions are being taken in closed reactor system. Roof top ventilation is installed in the entire plant area. Regular monitoring of piping and fittings is carried out to prevent the leakages STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS The storage and mode of transport of chemicals are being done as per detailed MSDS and chemical hazards guide (NIOSH) for the hazardous chemicals. Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in HEALTH AND SAFETY MEASURES Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of MSIHC Rules, Moreover transport activity is being done through drums, so there is a manual loading and unloading and no unloading through pipe at the site. Hence, the risk of static charge generation during transfer of such chemicals is not significant. 19

20 3.9.6 MAN POWER The manpower required for the project as well as during the construction/ commissioning activities will be employed from the local area. TABLE NO:-13 MAN POWER REQUIREMENT Phase of project Type of Labor No of Workers Total During construction Contractual Existing Proposed During operations Managerial 2-2 Supervisor Clerical Un-Skilled SITE ANALYSIS 4.1 CONNECTIVITY Ankleshwar is known for Pigment and Pharmaceutical Industry. Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by the Western Railway Division of Indian Railways. The railway division runs the broad gauge train services to Rajpipla. The 133-year-old Golden Bridge connects Ankleshwar to Bharuch across the Narmada on the station front while a new bridge connects the highway, the other bridge on the highway is now ready to use. Ankleshwar railway station is centrally located at the intersection of NH8 & Station Road. Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western section).development projects of Ankleshwar Airport & City Bus are in last stage. 4.2 LAND USE AND LAND OWNERSHIP The proposed project site is located at plot No: 4705/1/1,GIDC Estate, Ankleshwar,Dist: Bharuch. The total plot area of the unit is 980 sq meter 20

21 4.3 EXISTING LAND USE The proposed project site is located at plot No: 4705/1/1,GIDC Estate, Ankleshwar,Dist: Bharuch. The total plot area of the unit is 980 sq meter.the plot is notified by GIDC for industrial purpose. 4.4 EXISTING INFRASTRUCTURE The plant is located in a well-developed industrial zone, which has all essential facilities such as internal roads, arrangement for supply of water and power to industries, effluent disposal facilities, gas etc. The proposed project is relatively small in size and will be employing some skilled and unskilled people. First preference will be given to local people, so there will be no change in population pattern due to the proposed project. 4.5 SOIL CLASSIFICATION The soil of the district can be classified as light, medium and heavy according to depth, texture and location. There is sandy loam to loamy in texture, brownish black in color. 4.6 CLIMATE DATA Based on the meteorological data, wind rose is prepared for the summer season period between the Dec 2017 to Feb The wind rose diagram prepared from same data is shown in Figure 3. TABLE: 14 METEOROLOGICAL DATA (Data from Indian Meteorological Department, Ahmadabad, Station:-Baroda) Month Temperature( o C) Humidity (%) Rain fall (mm) Maximum Minimum Maximum Minimum Maximum Minimum December January February

22 FIGURE: 3 WIND ROSE DIAGRAM FOR PERIOD OF DECEMBER-2016 TO FEBRUARY-2017 Observation: It was observed that wind is blowing mainly towards the SW direction from NE. average wind speed was 2.90 m/s with calm winds recorded to be 5.97%. 4.7 SOCIAL INFRASTRUCTURE As of 2011 India census, Ankleshwar had a population of 140,839. Males constitute 53% of the population and females 47%. 13% of the population is under 6 years of age. 5.0 PLANNING BRIEF 5.1 PLANNING CONCEPT: Panoli is largely an industrial area dominated by large scale industries, especially chemical Plants. Government agencies provide many basic facilities like uninterrupted water supply, power and road network. 5.2 POPULATION PROJECTION. As of 2011 India census, Ankleshwar had a population of 140,839. Males constitute 53% of the population and females 47%. 13% of the population is under 6 years of age. 5.3 LAND USE PLANNING The names of prominent industries are shown in table no: 15 22

23 TABLE: 15 NAME OF SOME PROMINENT INDUSTRIES SR.NO. INDUSTRIES NAME 1 M/s. JAYSHREE INDUSTRIES 2 M/s. DYNAMIC DYE CHEM 3. M/s. HEMDEEP 4. M/s. A-ONE CHEMICALS 6.0 PROPOSED INFRASTRUCTURE 6.1 PROCESSING AREA The process area is covered plant area, raw material storage area, hazardous waste storage area, workshop and utilities. 6.2 NON PROCESSING AREA The non process area is covered Admin Building, toilet blocks, change room and security cabin. 6.3 GREEN BELT AREA Total plot area of the unit is 980 Sq-meter. Total Plant/Process area of the unit is 882 Sq-meter. Unit has allotted 98 Sq-meter area for green belt. There will be provision of budget of 1 lakh rupees for green belt development. 6.4 SOCIAL INFRASTRUCTURE The availability of basic amenities is covered as under: Training & Education: All the employees are being trained and educated periodically about the hazardous nature of chemicals used in the process. Also, training for fire fighting, work permits system, first aid, safe handling of hazardous chemicals and integrating safety, in all activities. Medical facility: Pre-employment medical checkup at the time of employment. In order to safe guard the health of the employees, all the employees undergo periodic health checkup. 23

24 Drinking water: Unit has provided Aqua Guard/R.O at different places to provide purified water for drinking purpose. Transportation: The unit is providing basic transportation facility to workers. Telegraph & Post: Unit has all the facilities like telephone, fax and internet for the employees. 6.5 CONNECTIVITY This industrial estate is well connected to Ahmadabad/Mumbai/Vadodara through the Ankleshwar. Rail services and Road services are available in Ankleshwar. 6.6 DRINKING WATER MANAGEMENT Average daily domestic water consumption of unit is 1 KL/day. GIDC water is a source of domestic water. 6.7 INDUSTRIAL WASTE MANAGEMENT The hazardous waste management and disposal is shown in table SOLID WASTE MANAGEMENT The Solid waste management and disposal is shown in table SOURCE OF POWER DGVCL is a main source of Power. 7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN The proposed project is located in GIDC Estate, Ankleshwar. There will be no any human settlement affected by proposed project. So, there is no requirement of any R & R Plan. 24

25 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 PROJECT IMPLEMENTATION SCHEDULE The details of project Implementation Schedule is given in below table. TABLE: 15 PROJECT IMPLEMENTATION SCHEDULE Project implementation schedule after getting NOC from GPCB Sr. No. Activity Required Period 1. Civil work Immediately after getting NOC 2. Procurement of machinery 1 month after getting NOC 3. Eraction & installation of Immediately after competition of activity no.2 machinery 4. Trial of machinery & equipment Within 1 months after competition of activity no.3 5. Commercial activity 1 months after competition of activity no ESTIMATED PROJECT COST The details of Capital cost projection are given in table no ANALYSIS OF PROPOSAL First preference will be given to local people for employment and Company will also try to provide indirect employment opportunities by availing local contract services during transportation and operational phase. The company intents to donate 0.5 % of the profit to agencies like NGOs or social welfare societies for projects carried out in nearby villages for their welfare and upliftment. 25