Sanjivani Paranteral Ltd.

Transcription

1 Pre - Feasibility Report For Sanjivani Paranteral Ltd. Plot no - K-2/1/2, Additional MIDC Mahad, Mahad, Raigad, Maharashtra EIA Consultant M/s. SADEKAR ENVIRO ENGINEERS PVT. LTD. QCI NABET accredited EIA consultancy for schedule 5(f) Cat.- A Certificate No NABET/EIA/1518/RA 020 NABL Accredited Laboratory, Valid up to Lab. Recognized by MoEF& CC, GOI, Valid up to Certified by ISO 9001:2008 & BS OHSAS 18001: , Dempo Towers, EDC Patto, Panaji, Goa state, India. PIN: sadekarenviro@rediffmail.com / prs@sadekarenviro.com Web site:- Telephone : /

2 Table of Content Sr. Title 1 Executive summary 2 Introduction of the project 3 Description of Project 4 Site Analysis 5 Planning 6 Proposed infrastructure 7 Rehabilitation and resettlement 8 Project schedule and cost estimation 9 Analysis of proposal Page Page 2

3 Name & Address of Company Schedule of project as per EIA Notification, 2006 Category of Project Total Plot Area Production details Water Requirement of Project Effluent generation Effluent Treatment 1. Executive summary Salient Features of Project M/s Sanjivani Paranteral Limited Plot no - K-2/1/2, Additional MIDC Mahad, Mahad, Raigad, Maharashtra. PIN: ( (b) 'A' Total Plot Area: Sq. m. Built up area: sq. m. Green Belt Area: 1975 Sq. m. Parking Area: 1437 Sq. m. Proposed Production Capacity: 2469 MT/month. Byproducts capacity : 5837 MT/ month Proposed water requirement : CMD Source of water: MIDC, Mahad Total 93.3 CMD effluent is generated from process containing 11 CMD from manufacturing process, 65 CMD cooling tower blow down and 17.1 CMD boiler blow down. Total 93.3 CMD effluent will be treated in 1000 CMD evaporator Sewage generation 3.6 CMD STP capacity 5 CMD Power requirement of Proposed power demand- 2 MVA project Proposed connected load- 1.5 KW Source: MSEDCL Boiler Details Proposed 1 boiler: 10 TPH steam capacity 1 Thermic fluid heater- 15 Lakh Kcal capacity D.G. Set 500 KVA * 2 nos. (Proposed D.G Set) Fuel Requirement Boiler: 34 MT/d coal/ briquettes Thermic fluid heater: 7 MT/d coal/briquette or, 4 MT/d FO D..G. set : 1000 L/day HSD Stack height Boiler: 39 m Page 3

4 Thermic fluid heater: 32 m D..G. set : as per CPCB guidelines Scrubber : 5m above roof Evaporator capacity 100 CMD Hazardous waste Particulars Category Proposed Sr. No TPM Method of Disposal 3 Aromatic alcoxy compound/ process residue 4 Discarded containers barrels/liners/ plastic bags/ PPE etc 5 Evaporator residue nos../da y CHWTSDF/ sale to MPCB authorised party CHWTSDF / MPCB authorized recycler CHWTSDF/ sale to authorized party Non hazardous waste Ash 150 TPM Sold to registered brick manufacturers Total man power 100 employees EMP cost 284 Lakh rupees Project Cost 3542 Lakh ruppes. Page 4

5 2. Introduction of the project 2.1 Identification of Project Proponent: Sanjivani Paranteral Limited is a research-based, international pharmaceutical company that provides a wide range of high quality products & services, at affordable prices. Sanjivani Paranteral Limited. The core product range of the company s products includes oral solids, small volume paranterals and sterile powder formulations. Sanjivani is the largest supplier of medicine in Indian ARMY hospitals, Indian railway Hospitals, ESIC hospitals, and so many institutions. The company wishes to expand its business area into agrochemicals to capture the present supply gap of insecticides and fungicides in the domestic market. As per the EIA Notification No. S. O dated 4 th September 2006, proposed project is covered under the schedule 5(b) which is pesticides industry and pesticide specific intermediates (excluding formulations). The schedule comes under A category as per EIA notification. The objective of this pre-feasibility study is to provide information for the pesticides and pesticides intermediates manufacturing unit of Sanjivani Paranteral Limited at Plot No. K-2/1/2 Additional MIDC Mahad, Mahad, District Raigad, Maharashtra. 2.2 Nature of project: M/s. Sanjivani Paranteral Ltd. have valid consent to establish no. MPCB/16/10263 for setting up a pharmaceutical formulation plant. The company later decided to shift from formulations to pesticide manufacturing becausee of the change in global demand and supply for formulation products. The proposed project will manufacture range of pesticides including fungicides, herbicides, insecticides and intermediate chemicals. The proposed project will be located at plot no. K-2/1/2, Additional MIDC Mahad, Kalij village, Mahad Tehsil, Raigad, Maharashtra. The land is non agricultural land acquired by MIDC in notified additional MIDC Mahad therefore the land use pattern will be unchanged. Total plot area is sq. m. Total production capacity will be 2469 MT/month and by product capacity will be 5533 MT/ month. 2.3 Need for the project and its importance to the country and or region: India's Chemical industry is the third largest in the world in terms of volume. Its rank is 14 in terms of value. India is also one of the top five active Chemical ingredients producers (with a share of about 6.5%). The ever-increasing demand for Pesticides and Intermediated in India and abroad as well as changing market conditions requisite Indian Chemical industries to grow further. Page 5

6 The company aims to expand its product portfolio further in order to cater to Domestic & International markets by expanding its production capacities. These products will serve to cut the supply of imports from foreign countries thus saving currency and at the same time will earn valuable foreign currency by export of the proposed products. 2.4 Demand supply gap Competition in the Indian Chemical market swelled in recent years, with increasing generic compounds introduction in the domestic market. The price of the products has reduced substantially which led to less supply of highh profit margin products in the market. A demand- supply gas is created due to less supply of products. To capture this newly created gap between demand and supply in the domestic market company wishes to introduce low margin products. 2.5 Import Vs. Indigenous production The proposed products including production of pesticides and chemical intermediate have huge demand in the domestic as well as export market. Production of these pesticides and chemical intermediate are domestically reduces the need to import products along with significant scope for export in these products. 2.6 Export & economic feasibility The Indian crop protection industry is of USD 4.25 billion in FY14 and is expected to grow at a CAGR of 12% to reach USD 7.5 billion by FY19. Exports currently constitute almost 50% of Indian crop protection industry and are expected to grow at a CAGR of 16% to reach USD 4.2 billion by FY19, resulting in 60% share in Indian crop protection industry. Domestic market on the other hand would grow at 8% CAGR, as it is predominantly monsoon dependent, to reach USD 3.3 billion by FY19. Globally, India is fourth largest producer of crop protection chemicals, after United States, Japan and China. The crop protection companies in India can be categorized into three types Multi-National, Indian including public sector companies and small sector units. Page 6

7 Source: Industry Analysis by Tata Strategic 2.7 Domestic/ export markets The finished goods will be sold in domestic market primarily and it would be exported to the Regulated International Market as per demand. 2.8 Employment generation: The company will employ 30 skilled and unskilled personnel for its proposed pesticides manufacturing facility. The skilled employees would be 12 and unskilled employees would be 18. It is expected that proposed plant will generate employment for semi-skilled and unskilled people. Page 7

8 3. Description of Project 3.1 Project type: The proposed pesticides manufacturing project is new project for manufacturing of range of pesticides including insecticides, herbicides and pesticides. 3.2 Location The proposed pesticide manufacturing unit will be located at Plot no. K-2/ 2/1/2, additional MIDC Mahad, Mahad, Mahad, Raigad district, Maharashtra The location is shown in the Google earth image below. Figure 1: Location of Sanjivani Paranteral Ltd. Nearby Industries Sr. Direction Industry 1 North Tulsi Logistics 2 South Nicholas Piramal 3 East Astec Life Sciences Limited 4 West Spider Prints Page 8

9 Proposed unit is well connected by Mumbai- Goa highway (NH 66). The national highway is approximately 9 km away and can be reached by state road network. The nearest railway station is Veer which is approximately 18 km away from site. The MIDC map is given in figure 2 showing location of plot in MIDC. M/s. Sanjivani Paranteral Ltd. Plot no K-2/1/2 Figure 2: Additional MIDC Mahad The plot layout of proposed unit of Sanjivani Paranteral Ltd. is given in figure 3. Total plot area is sq. m. the location of plant building, utility building, ware house, internal roads, parking area is shown in the layout. Figure 3 : Plot layout of Sanjivani Paranteral Ltd. Area statement of M/s. Sanjivani Paranteral Ltd. Sr. Particulars Area (sq. m.) 1 Total plot area Page 9

10 2 Built up area 3 Green belt area 4 Parking area 5 Total open area Details of alternate sites considered: The additional MIDC Mahad is situated near Mahad MIDC. The land rates are cheaper to promote the industrializationn and the MIDC have all adequate facilities viz. good road and rail network, 24 hour electricity, water supply, MIDC roads, CETP etc. 3.4 Size of operation The production capacity with byproducts is given in following table. Sr. No. Name of product Quantity /month Unit Group A Fungicide 1 Propiconazoleonazole 300 MT 2 Cyproconazole 126 MT 3 Metconazole 102 MT Group B Herbicide/Insecticide 4 Transfluthrin 88 MT Group C Intermediate 5 2,4 Dichloracetophenone 502 MT 6 Valerylphenonelphenone 171 MT 7 2-Chloro (4-chlorophenixy) acetophenone) 106 MT 8 Tri chloroacetophenone 234 MT 9 Valeryl l chloride 230 MT 10 m-chlorobenzene 200 MT 11 Flurochloro acetophenone 165 MT 12 Dinonyl diphenyl amine TOTAL MT MT List of byproducts: Page 10

11 Sr. No. Name of Byproduct MT/Month Remarks Sale to MPCB authorized Potassium bromide solution vendors/ in-house use Sale to MPCB authorized 48 2 Inorganic salt(naoh) vendors / in-house use Sale to MPCB authorized Poly aluminium chloride solution vendors Sale to MPCB authorized HCl ( 30%) vendors Sale to MPCB authorized Phosphorus acid vendors Sale to MPCB authorized 4 6 Mono chloro benzenee vendors Sale to MPCB authorized Aromatic alkoxy compounds vendors Total Project description with process detail. The process details and material balance for Propiconazole Technical is given in following table. Manufacturing process of other products is given in annexure-1. PRODUCT NAME : Propiconazole Technical PRODUCT DETAILS : For Grade MT/Day MT/Month Months MT/Year Application Tech Fungicide RAW MATERIALS : Input output data per day. Reaction INPUTS OUTPUTS Role in Name of Qty Sr. No. Name MT/Day Reaction Sr. No. outputs MT Recover 1.00 Bromoketal Reactant 1.00 Solvent Dimethyl Acetamide Solvent 2.00 Sodium Bromide 5.09 Organic 3.00 Triazole 3.23 Reactant 3.00 Layer Potassium Hydroxide 3.23 Catalyst Total Page 11

12 Fractionation 1.00 Organic layer Cut l Main Cut Residue 2.02 Total CHEMICAL FORMULAE : Cl Cl CH 2 Br O + O H N N N CMD, KOH Cl Cl O O N N N CHEMICA EQUITION: C13H15O2CL2Br + C2H3N3 +KOH C15H17Cl2N3O2 + KBr + H BRIEF PROCESS DESCRIPTION : Charge Dimethyl acetamide, PIOL-ll, Triazole and Potassium Hydroxide under Stirring at room temperature. Then heat mass up to 140 C and maintain up to Complete reaction. Then Filter reaction mass to separate sodium bromide and recover solvent. Crude organic take to fractionation. FLOW SHEET & MASS BALANCE : Raw Materials Qty Product Qty PIOL-ll Dimethyl acetamide Recovered Solvent Potassium bromide Triazole 3.23 solution 5.09 Potasium Hydroxide 3.23 Organic Layer Total Total Organic Layer Cut-l 0.30 Main cut PIOL-lll Residue 2.02 Page 12

13 Total Total Total outlet Byproduct Potassium bromide Type solid Qty /Day 5.09 Remark KBr for sale Total 5.09 Solid Waste Empty Containers 2.02 CHWTSDF,Nos. 3.6 Raw material details 72 Recycle All basic raw material details with its quantity is given below. The raw materials are available in domestic market and they will be transported by road to the manufacturing unit. Bags, carbuoys and drums will be stored in storage area and larger quantity raw materials like solvents will be stored in tanks. The gases will be stored in the cylinders as per storage specifications. Product 1 Propiconazole 2 Cyproconazole 3 Metconazole 4 Valerophenone Input Max Storage Name of RM MT/Day Storage Facility Bromoketal Tank Dimethyl acetamide Tank Triazole Godown Potasium Hydroxide Godown Oxirane Godown Dimethyl Acetamide Tank Triazole Godown Hexane Tank Sodium Hydoxide Godown Oxirane Godown Dimethyl Acetamide Tank Triazole Godown Methanol Tank Sodium Hydroxide Godown m-chlorobenzene Tank Phosporous Tri chloride Godown N-valeric acid Godown Valeryl chloride Godown Page 13

14 2,4 5 Dichloracetophen one 2-Chloro (4-6 (chlorophenixy)ac etophenone) Tri chloro 7 acetophenone 8 Fluorchloroacetop henone 9 m- Dichlorobenzene 10 Valeryl chloride 11 DiNonyl diphenyl amine 12 Transfluthrin Alluminium chloride Godown m-chlorobenzene Tank Acetic acid Godown Phosphorus trichloride Godown Alluminium chloride Godown Acetyl chloride Godown 4 Chlorophinoxy 3 chlorophinyl ether Tank Acetyl chloride Godown Alluminium chloride Godown Dichloroethane Godown m-dichlorobenzene Tank Chloro acetic acid Godown Alluminium chloride Godown p-fluorobenzene Godown Chloro acetic acid Godown Alluminium chloride Godown Alluminium chloride Godown O/P-Chlorobenzene Tank Valeric acid Godown Phspurus trichloride Godown Diphenyl amine Godown Nonene Godown Alluminium chloride Godown t-permethric acid Godown Tetrafluro Benzyl alcohol Godown Sulphuric acid Godown Toluene Godown 3.7 Resource optimization ( recycle/ reuse): 1. The effluent generated from process and scrubber will be sold as byproduct. The need of ETP is thus eliminated. 2. The treated domestic sewage will be reused for gardening which will reduce daily fresh water need for gardening. 3. The company will employ rooftop rain water harvesting and the harvested rain water will be stored in dedicated underground water tank. In rainy season the fresh water need will be reduced. 4. The 93.3 CMD cooling tower and boiler blowdown effluent will be treated at evaporation system and 80.6 CMD water will be recycled back to the process. Page 14

15 5. The 5 CMD STP will be provided to treat the sewage. The treated sewage will be used for gardening. 3.8 Availability of water, energy fuel: The water will be supplied by additional MIDC Mahad. Daily fresh water need for domestic and process water requirement will be CMD. A 2 MVA capacity transformerr will be installed in the company for connected load of equal amount. The power demand will be around 1.5 MW for proposed unit. Total 41 T/day foreign grade coal or briquettes will be required for running boiler and thermic fluid heater. Fuel oil will be used as an alternative fuel for thermic fluid heater. The quantity of FO will be around 4 T/day. Page 15

16 3.9 Quantity of waste to be generated Total 93.3 CMD process waste will be generated. It will be treated in evaporation system and 80.6 CMD water will be recycled to process. 3.6 CMD domestic sewage e will be treated in STP and treated sewage will be used for gardening. Parameter Requirement, CMDLosses, CMD Effluent, CMD Remark Domestic Process Byproduct Domestic % HCL And Pac Process Solution CMD Cooling Cooling Tower -- Tower Blowdown Condensate Boiler -- Recovery Gardening Total Solid hazardous waste which will be generated from the manufacturing activity will be, Particularsrs Category Proposed Method of Disposal Sr. No TPM 1 Aromatic alcoxy compound/ process residue CHWTSDF/ sale to MPCB authorized party 2 Discarded containers barrels/liners/ plastic bags/ PPE PE etc nos./ day CHWTSDF / MPCB authorized recycler 3 Evaporator residue CHWTSDF/ sale to authorized party Non hazardous waste generation will be given as, Sr. No Particularsars Proposed TPM Ash management at site Method of Disposal 1 Fly ash 150 Silo will be provided Sale to brick manufacturer Page 16

17 3.10 Schematic representation of feasibility drawing for EIA purpose RESOURCE CONSUMPTION (WATER) POWER CONSUMPTION RAW MATERIAL PRODUCTION ACTIVITY WASTE GENERATION FINISHED PRODUCTS POLLUTION ABATEMENT EMPLOYMENT MARKET ECONOMY CLEAN ENVIRONMENT Page 17

18 4. Site Analysis 4.1 Connectivity: The project is located in additional industrial area Mahad which is easily accessible from Mumbai- by Goa highway, further connecting to the project site by internal access roads developed MIDC. Nearest Railway Station: Veer, approximately at a distance of 18 km. Nearest Airport: Chatrapati Shivaji International Airport approximately at a distance of 166 km Location and Access The industrial area is centrally located and easily accessible through all modes of transport. Road: The entire industrial area is well connected by internal roads. Available Road Network: Mumbai Goa highway (NH 66) at a distance of approximately 4 km from the project site. 4.2 Land Form, Land use and Land Ownership The Project location & the surrounding environs being located in the notified industrial area prevails industrial land use form. 4.3 Topography: The co-ordinates of the project site are 18 6'46.07"N and 73 31'2.91"E. the toposheet is given below to show the topography of surrounding area. Page 18

19 M/s. Sanjivani Paranteral Ltd. Location: Plot no. K-2/1/2, additional MIDC Mahad, Kalij, Mahad, Raigad, Maharashtra Co-ordinates: 18 6'46.07"N & 73 31'2.91"E Toposheet no. 47F/12 Page 19

20 Environmentally sensitive features within 15 km radius of the plant The environmentally sensitive features exist around 15 km radial distance from the plant is, 1. Kal river is 850 m away and Savitri river is 3.5 km away from the project site. River distance certificate is attached as annexure Meeting point of Kal and Savitri river is 5.8 km away from plant aerially. 3. Some part of Western Ghats denoted as reserved forest in toposheet is lying within 15 km radial distance from project site. 4. Nira-Devghar Jalayshay (backwaters) is 13.3 km away aerially from project site. 5. Savitri dam backwaters is km away aerially from project site 6. Raigadh fort is 14.8 km away and Shivathar ghal is 12 km away aerially. 4.4 Existing land use pattern The proposed project is located in the notified industrial area which has been developed for industrial development. The existing land use pattern in the 10 km radial distance of the project site comprises of Industrial, human habitations/settlements, small agricultural/ crop lands, quarrying land use classes. 4.5 Existing infrastructure: Presently construction of office building, UG water tank and internal roads is started on the project site because the proponent has valid consent to establish from MPCB. No other industrial infrastructure is being constructed at site. 4.6 Soil classification: The soils in the area are formed from the Deccan Trap which is predominating rock formation with small out crops of Laterite at a few places in the Poladpur taluka. The soils are medium black and black soil which can be further grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation. At proposed site soil analysis has been carried out by M/s. Paresh Constructions & Foundations Pvt. Ltd, Competent Agency for soil testing. Climatic data from secondary sources The climate in proposed area is characterized by hot summer and general dryness throughout the year except the south west monsoon season. Climate Classification: Project site features a semi arid climate. In rainy season the climate is very Page 20

21 humid. Temperature: annual average max. Temperature is 32 C and min. temperature is 17 C Rainfall: The analysis of long term rainfall data indicates that normal annual rainfall over the district ranges from 2200 mm to more than 3000 mm in the plains and it is above 5000 mm in the hills. The average rainfall around Mahad area is 3360 mm in rainy season. 4.7 Social infrastructure available: Social infrastructure like schools, s, road, hospitals, is available near additional MIDC Mahad. Page 21

22 5. Planning Brief 5.1 Planning concept: M/s. Sanjivani Paranteral Ltd. has valid consent to establish no. MPCB/16/10263 for setting up a pharmaceutical formulation plant. The company later decided to shift from formulations to pesticide manufacturing because of the change in global demand and supply for formulation products. Based on respective consent to establish the company has started to build internal road network, green belt development and office building. The manufacturing plant will be constructed after issue of EC. The additional MIDC Mahad have road network and water will be provided by MIDC, therefore company will not be relied on ground water in the MIDC area. Electricity will be provided by MSEDCL and transformer and substation will be constructed. The construction material is available locally and it will be transported through road network. 5.2 Population projection: As per the 2011 census data, the Mahad region have 1,80,191, of which 88,734 are males and 91,457 are females. Total population equal to 19,044 is lied in 0-6 year age group. Area according to census data total literates are 1,31,981. The data published by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. It is assumed that due to proposed project minor migration of skilled labour in the region is expected after commissioning of the project. 5.3 Land use planning: The proposed manufacturing unit will be established in plot K/1/2, Additional MIDC Mahad. The land is acquired by MIDC and the land use will be industrial type. No cultivated land or forest land will be utilized for the proposed unit. 5.4 Assessment of Infrastructure demand The major physical infrastructure like road, water supply is provided by additional MIDC Mahad. The electricity will be supplied by MSEDCL by means of continuous feeder substation. The industrial infrastructure will be constructed after grant of EC. The need of social infrastructure is not presently envisaged. 5.5 Amenities: Basic amenities like road, electricity, process water will be available at site. The drinking water will be provided by further purification of process water by RO purification unit. In the plant personal hygiene facilities will be provided to workers as per the rule. Page 22

23 6. Proposed infrastructure: 6.1 Industrial area The proposed pesticide manufacturing unit of Sanjivani Paranteral Ltd. will be established on plot no. K 2/1/2. Total built up area for manufacturing and allied processes will be sq. m. 6.2 Residential area The unit is pesticide manufacturing unit and situated at notified additional MIDC Mahad therefore there will be no need of residential infrastructure. 6.3 Green belt The proposed unit will be provided with 1975 sq. m. of green belt area around the boundary and inside of the plot. 6.4 Social infrastructure: The project site is approximately 8 km from Mahad city. All basic social infrastructure facilities are available in the study area. 6.5 Connectivity The site can be accessed by national highway and connecting state highway from Mahad to Solamkund village. The additional MIDC Mahad have excellent internal and connecting road network therefore no additional connectivity infrastructure will be constructed. 6.6 Sewerage system The sewage will be treated at proposed STP with 5 cu. M capacity. The treated sewage will be utilized for gardening purposes. 6.7 Industrial waste management 203 CMD process mother liquor will be sold as byproduct. Total 93.3 CMD process waste will be generated. It will be treated in evaporation system and 80.6 CMD water will be recycled to process. 3.6 CMD domestic sewagee will be treated in STP and treated sewage will be used for gardening. 6.8 Solid waste management The hazardous waste will be segregated as per category in schedule I of Hazardous and Other Wastes (Management and Tran s-boundary Movement) Rules, 2016 and it will be stored in demarcated area. The hazardous waste will be treated at CHWTSD facility or it will be sold to MPCB authorized re-processor. The fly ash will be sold to brick manufacturers or authorized vendours. Page 23

24 6.9 Power requirement/ supply/ source A 2 MVA capacity transformer will be installed in the company for connected load of equal amount. The power demand will be around 1.5 MW for proposed unit. Electrical power will be supplied by MSEDCL. Total 41 T/day foreign grade coal or briquettes will be required for running boiler and thermic fluid heater. Fuel oil will be used as an alternative fuel for thermic fluid heater. The quantity of FO will be around 4 T/day. Fuel will be arranged from local vendours. Total 1000 L/day HSD will be used for running D.G. sets in case of power failure. Page 24

25 7. Rehabilitation and resettlement: The unit will be established in notified industrial area of additional MIDC Mahad. No rehabilitation and resettlement will be incorporated. 8. Project schedule and cost estimation It is proposed that the project will be commissioned after 24 months from grant of EC. The cost estimation is presented in CA certificate attached as annexure Analysis of proposal Proposed production activity will provide employment to the local residents, resulting financial and social benefits of the nearby people. Indirect employment will be generated by the proposed unit like canteen, transportation facilities to workers. The export will result in generation of foreign exchangee to the country. Page 25