PROJECT PRE-FEASIBILITY REPORT

Transcription

1 PROJECT PRE-FEASIBILITY REPORT Of PROPOSED EXPANSION PROJECT For SYNTHETIC ORGANIC CHEMICALS MANUFACTURING UNIT At Plot No. 1088/B Lamdapura road, Village: Manjusar, Ta: Savli, Dist: Vadodara, Gujarat Project proponent

2 CHAPTER 1 EXECUTIVE SUMMARY The project is summarized in the below table: Table 1.1: Project Summary PARTICULARS NAME OF THE UNIT OCCUPIER PRODUCTS LOCATION NATURE OF PROJECT DETAILS M/s. Universal Ester Ltd. Mr. Vishwas R. Gole, Mr. Mukesh D.Patel, Mr. Dushyant D. Patel S. No. Name of Products Proposed Quantity of Production Quantity in MT / Month Existing Quantity After Phase-I After Phase-II Existing Products* Methyl Anithranilate* Ethyl Salicylate* Ethyl Benzoate* Amyl Salicylate* 3.0 NIL NIL Benzyl Salicylate* Menthyle Salicylate* Amyl Acetate* Or any other type of chemicals in category of organge esters* Octyl Methoxycinnamate Octyl Salicylate Octyl Hydroxystearate Proposed products Homosalate Cosmetic emmolients Ethyl methoxycinnamate Proposed products (Repacking & Reselling) 7. Octocrylene - 8. Benzophenone-3-9. Benzophenone Avobenzone - TOTAL *Note: The company has obtained consolidated consent & Authorization (CC&A) no. H valid up to 24/07/2015 for manufacturing of these products as well, but is not manufacturing them anymore. Plot No. 1088/B, lamdapura road, Village: Manjusar, Ta: Savli, Dist: Vadodara, Gujarat Proposed Expansion Project for Increase in existing production quantities and adding new products in the similar category of products i.e. synthetic organic chemicals 1

3 RESOURCES Resource type Land Building Raw-materials Water Power Fuel Man-power POLLUTION POTENTIAL & MITIGATION MEASURES Parameter Potential Existing After Phase-I Wastewater Industrial: 0.60 Industrial: 7.0 KLD KLD Domestic: 2.0KLD Domestic: 1.20 KLD Air Emissions Requirement Existing m m 2 As given in section Raw Material for finished products. Existing 4.6 KLD 125 KVA Agro waste-500 kg/day Non IBR Boiler 1 no. After Phase-I m m 2 After Phase-I 29.0 KLD 250 KVA Agro waste-800kg/day Diesel-50 LPH TFH 2 Nos. 1 of 6 lakh k.cal/hrs and 1 of 10 lakh kcal/hrs. D.G. Set 125 KVA 1 nos. After Phase-II m m 2 After Phase-II 37 KLD 250 KVA Agro waste-8000 kg/day Diesel-50 LPH 55 After Phase-II Industrial: 10.0 KLD Domestic: 2.2KLD TFH 2 Nos. 1 of 6 lakh k.cal/hrs and 1 of 10 lakh kcal/hrs. D.G. Set 125 KVA 1 nos. Source No additional land is required for expansion project. Only slight modification in the existing infrastructure will be done. The raw materials are available in Local/ Indian market and are also imported from foreign countries. Fresh water is sourced from in-house bore well and same will be the source of supply for the additional quantity. Sourced from MGVCL 1 D.G. Set 125 KVA will be installed as Standby arrangement. Local Suppliers. To be employed from local area Mitigation Measures The domestic effluent is/will be disposedd off through septic tank/ soak pit system. In existing operation Industrial wastewater is treated in ETP and treated water is used for gardning purpose. After proposed expansion wastewater will be treated in ETP. Treated effluent from ETP will be sent to CETP of EICL or will be evaporated in evoporation unit. In existing operations one non IBR Boiler is installed. Agro waste is used as fuel in non IBR Boiler For proposed expansion non IBR Boiler will be replaced by two Thermic Fluid heaters of 6 lakh kcal/hrs and 10lakh kcal/hrs capacities and one D.G. Set of 125 KVA capacities will be installed. Agro waste will be used as fuel in TFH Cyclone separator will be attached to TFH as APCD. Diesel will be used as fuel in D.G. Set. There is no process gas emission from the existing plant as well as proposed expansion project. Raw Materials& Products are/will be 2

4 Hazardous & solid waste ETP Waste (Cat. 34.3) : 0.04MT/Month Distillation Residue (Cat. 20.3): 3.36 MT/Yr Spent Carbon (Cat.35.3 ): 0.05 MT/Month Used Oil (Cat. 5.1): 1.2KL/Yr Discarded Containers (33.3): 120 Nos./Month Non Haz.Waste Fly ash: 13 MT/yr. ETP Waste (Cat. 34.3) : 5.5MT/ Month Distillation Residue (Cat. 20.3): 80MT/Yr Spent Carbon (Cat.35.3 ): 0.1 MT/ Yr Used Oil (Cat. 5.1): 2 KL/Yr Discardedd Containers /Bags (33.3): 9870 Nos./yr Inorganic process waste (28.1): 97 MT/yr Spent solvent (20.2): 210MT/yr. Non Haz.Waste Fly ash: 220 MT/yr. ETP Waste (Cat. 34.3) : 8.5 MT/ Month Distillation Residue (Cat. 20.3): 125 MT/Yr Spent Carbon ( Cat.35.3 ): 0.1 MT/Month Used Oil (Cat. 5.1): 2.5 KL/Yr Discarded Containers/Bags ( 33.3): Nos./yr Inorganic process waste (28.1): 155 MT/yr Spent solvent (20.2): 325 MT/yr. Non Haz.Waste Fly ash: 220MT/yr. stored in properly designed storage area to prevent any volatilities Good housekeeping is/will be maintained in the plant. Regular VOC monitoring will be carried out after proposed expansion. ETP waste: Collection, storage, transportation, disposal at TSDF. Distillation residue: Collection, storage, transportation and disposal by common incinerator at NECL/GEPIL. Spent carbon: Collection, storage, transportation and disposal by incinerator. Used oil: Collection, storage, transportation, disposal by selling to registered re-refiners. Discarded Containers: Collection, storage, transportation, disposal by selling to registered re-refiners. Fly ash to be sold to brick manufacturer In-organic process waste: Collection, storage, transportation, disposal at TSDF Spent solvent will be sold to the actual users. Noise Expected levels Inside the plant: <80 db(a) Expected levels Inside the plant: <80 db(a) Expected levels Inside the plant: < 80 db( (A) The major sourcess of noise generation in plant area are equipment machinary and TFH. Anti vibration pads and flexible bellows is provided wherever applicable. Acousticc Enclosure to D.G. Set will be provided. Ear plug and Ear muff are provided. Regular maintenancee lubrication shall be done. 3

5 CHAPTER 2 INTRODUCTION OF THE PROJECT 2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT IDENTIFICATION OF THE PROJECT M/s. Universal Ester Ltd. is a Limited company which was established in 1994.The company is engaged in the commercial production of Personal care ingredients, used in various types of formulations, primarily in the Cosmetics industry at its manufacturing facility located at Plot No. 1088/B, Village: Manjusar, Lamdapura road, Ta.: Savli, Dist.: Vadodara. The company is a smalll scale chemicals manufacturing unit. The unit is engaged in manufacturing of (1) Octyl Methoxycinnamate, (2) Octyl Salicylate and (3)Octyl Hydroxystearate. The company has obtained consolidated consent & Authorization (CC&A) no. H valid up to 24/07/2015 for manufacturing of 11 various products but presently the company is manufacturing only above given three products. The existing consent to operate-cca is attached as Annexure-1. Now, the company has planned to increase its existing capacity and add new products in the similar category of products. The list wise products and its production capacity are given in table below: Table 2.1: List of Products S. Name of Products N o. Existing Products* 1. Methyl Anithranilate* 2. Ethyl Salicylate* 3. Ethyl Benzoate* 4. Amyl Salicylate* 5. Benzyl Salicylate* 6 Menthyle Salicylate* 7. Amyl Acetate* 8. Or any other type of chemicals in category of organge esters* 9. Octyl Methoxycinnamate 10 Octyl Salicylate. 11 Octyl Hydroxystearate. Proposed products 4. Homosalate 5. Cosmetic emmolients 6. Ethyl methoxycinnamate Proposed Quantity of Production Quantity in MT / Month Existing Quantity After Phase-I After Phase-II NIL NIL

6 Proposed products (Repacking & Reselling) 7. Octocrylene - 8. Benzophenone-3-9. Benzophenone Avobenzone - TOTAL *Note: The company has obtained consolidated consent & Authorization (CC&A) no. H valid up to 24/07/2015 for manufacturing of these products as well, but is not manufacturing them anymore PROJECT PROPONENT The company is a Limited firm and directors of the company are well educated and professionally qualified; they take every step to ensure that all safety measure to Plant and Environment are fully complied with. Below is a brief profile of the management team. Mr.Vishwas Gole (Director) Mr.Vishwas Gole has done his graduation in Chemistry. He has around 45 years of experiencee in the Chemicals industry. He has worked for over 25 years with renowned companies in USA. Before returning to India, he was Director (R&D) with a leading US company. He mainly looks after Technical and Marketing aspects in the company. Mr. Mukesh Patel (Director) Mr. Mukesh Patel is a Chemical Engineer with over 40 years of experience in the industry. He is in a strategic advisory role in the company. Chemicals Table 2.2: Addresses of Directors Sr. No Name of Directors Mr. Vishwas R. Gole Mr. Mukesh D.Patel Dushyant D. Patel Addresses 4, Kant Flats 7, Suvanapuri Soc. Jetalpur Road, Vadodara 5. 93, Urmi Society. Productivity Road, Vadodara 7. 3& 4, Aakashwan Hsg. Complex. Gotri Sevasi Road, Vadodara 2.2 NATURE OF THE PROJECT The proposed expansion project involves the production of synthetic organic chemicals whichh falls under item no 5(f) i.e. synthetic organic chemicals as per the EIA notification, 14 September 2006 (as amended timely). Since, the project is not located within any notified industrial area/estate; it is to be treated as Category A and needs to obtain the priorr Environmental Clearance from EIAA (MoEF). 5

7 2.3 NEED OF PROJECT & DEMAND-SUPPLY GAP The products are used in various types of formulations, primarily in the Cosmetics industry. All the products are user friendly confirming with international standards. The proposed products range having a good demandd in the market& as per market survey by the company there is a less supply of the product against its demand, to overcome this shortage & to get benefit out of that the company proposed to have this project. 2.4 EXPORT POSSIBILITY As per market survey by the company, these proposed products are having a domestic as well as export market due to its application in various types of formulations, primarily in the Cosmetics industry 2.5 EMPLOYMENT GENERATIONN DUE TO PROPOSED PROJECT The proposed expansion project will provide direct employment opportunityto20 persons and indirect employment to few persons. The man-power required for the project will be employed locally from the nearby areas. 6

8 CHAPTER 3 PROJECT DESCRIPTION 3.1 TYPE & LOCATION OF PROJECT TYPE The proposed project is an expansion for increase in existing production capacity and manufacturing of new range of products falling in the similar category of products, i.e. Synthetic Organic Chemicals LOCATION M/s. Universal Esters Ltd. is located at Plot No.1088/B, Village: Manjusar, Lamdapura road, Ta: Savli, Dist: Vadodara. Savli is a village near Vadodara, Gujarat in Western India. One of the Gujarat Industrial Development Corporation centers is very near to it; the branch of Santram temple is also located in this village near the Mahisagar River. The population in Savli comprises Baniaa (Vaishnava), Patel, Brahmin and Raj puts, Muslims also are part of the village. The main crop of this village is tobacco. Savli is also becoming an educational hub with an educational campus including the K. J. Institute of Engineering and Technology. In addition to this college there are arts & commerce colleges and a homeopathic medical college. The site is approximately kms SSW from Vadodara - the third largest city in the Indiann State of Gujarat, after Ahmadabad and Surat. It is the administrative headquarters of Vadodaraa District. It is located on the banks of the Vishwamitri river, southeast of Ahmadabad, 139 km from state capital, Gandhinagar. Both the railway line and national highway connecting Delhi and Mumbai pass through Vadodara. It is also the home of the Maharaja Sayajirao University of Baroda, which is the largest university in Gujarat. Major industriess include petrochemicals, engineering, chemicals,pharmaceuticals, plastics and Forex. 7

9 Figure 3.1: Project Site 8

10 Figure 3.2: Satellite Image of the Project Site 9

11 Figure 3.3: Project Site layout Table 3.1: Area Statement S. No Description Total Plot Area Built-up area Greenbelt area Open Area Approx. Area (m 2 )

12 3.2 DETAILS OF THE ALTERNATIVE SITE The proposed expansion is to be carried out in the existing industrial plot. So no alternativee study for site selection has been conducted. The present land is adequate to cater the requirement of the proposed expansion project. Further the existing infrastructure & machinery availability is very helpful to avoid installation of many infrastructure & machinery for the proposed project. These together justify the use of existing premises for proposed project. Hence only existing site is considered for the proposed project. Some more benefits of the existing site are shown below. Site is very well connected by road. Proximity to Raw Material suppliers Availability of power from MGVCL SIZE & MAGNITUDE OF OPERATION The total magnitude of operation after proposed expansion will be 2400 MT/A. 3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS It is noteworthy that the company is proposing change in process in terms of change of catalystt and raw-material for manufacturing of its existing 2 nos. of products, viz. octylmethoxycinamate and octyl salicylate. Details of both existing and proposed process are provided in subsequent sections. Moreover, some of the products (viz. Octocrylene e, Benzophenone-3, Benzophenone -4, and Avobenzone) are only to be purchased, repacked and sold out. 111

13 3.4.1 Existing Products Scenario OCTYL METHOXYCINAMATE ( EXISTING PROCESS) Chemical Reaction Manufacturing Process Into an S.S. Reactor para Anisic Aldehyde, catalyst & 2-ethyl hexyl acetatee are charged. & masss is heated to 190 C 0-200C 0 for 48 hours. Then masss is cooled to 70C 0-80C 0 & filter through filter press. Mother liquor is distilled under high vacuum to get 98% octyl methoxycinamate. Recovered 2-ethyl hexyl acetate is recycled in the next batch Material Balance 12

14 OCTYL METHOXYCINAMATE ( PROPOSED PROCESS) Chemical Reaction Manufacturing Process Into an S.S. Reactor para Anisic Aldehyde, inorganic catalyst & 2-ethyl hexyl acetate are charged. & mass is heated to 190 C 0-200C 0 for 48 hours. Then mass is cooled to 70C 0-80C 0 & filter through filter press. Mother liquor is distilled under high vacuum to get 98% octyl methoxycinamate. Recovered 2-ethyl hexyl acetate is recycled in the next batch Material Balance 13

15 OCTYL SALICYLATE (EXISTING PROCESS) Chemical Reaction Manufacturing Process Into a glass lined reactor salicylic acid (1100 kgs), catalyst (60 kgs) 2-ethyl hexanol (1140 kgs) are charged. & mass is slowly heated to 120 c & hold for 3 hours. Apply low vacuum & slowly raise temp, to 150 c for 8 hours & sample is given to check G.C. Then crude is transferred to distillation tank. Crude is distilled under high vacuum to get 99% octyl salicylate Material Balance 14

16 OCTYL SALICYLATE (PROPOSED PROCESS) Chemical Reaction Manufacturing Process Into a glass lined reactor methyl salicylate, catalyst and 2-ethyl hexanol are charged. & mass is slowly heated to 120C 0 & hold for 3 hours. Slowly raise temp, to 150 C 0 for 8 hours & sample is given to check GC. Then crude is transferred to distillation tank. Crude is distilled under highh vacuum to get 99% octyl salicylate Material Balance 15

17 OCTYL HYDROXYSTEARATE Chemical Reaction Manufacturing Process Into a glass line reactor 12HAS, catalysts& 2-ethyl hexanol are charged. & mass is heated to 180 C 0 for 24 hours & water is removed. Check the acid value. If the acid value is <1.5% stop the reaction & slowly apply vacuum & then under high vacuum remove 2-ethyl hexanol. If GC of 2-ethyl hexanol is <2.0% stop the vacuum and heat. Cool down to 80 c & filter product Material Balance 16

18 3.4.2 Proposed Products Scenario HOMOSALATE Chemical Reaction Manufacturing Process Into an S.S. Reactor methyl salicylate, catalyst & homo Menthyl alcohol are charged& mass is heated to 180 C for 24 hours & check GC. If methyl salicylate is <1.5% stop the reaction. Cool down to 80 C & transfer crude to distillation unit. Crude is distilled in Column distillation to get 99% purity & colorless product Material Balance 17

19 ETHYLE METHOXYCINNAMATE Chemical Reaction Manufacturing Process Into (200 ltr) glasss lined reactor paraanisic aldehyde (40 kgs), & ethyl acetate (120kgs) are charged. Mass is cooled to 10 C. 16 kgs catalyst is added over the period of 2 hours. Keeping temp. < 30 C. Reaction mixture is kept stirring around 30 C for 3 hours. Sample is taken to check unreacted p-anisic aldehyde which is <1.0% %. 25% acetic acid is added to neutralize the catalyst. Organic and water layer is separated. Organic layer is taken for distillation to get 98% purity of ethyl methoxycinnamate. Water layer is taken for distillation in distillation/evaporation unit Material Balance 18

20 Cosmetic Emollients Chemical Reaction Manufacturing Process Into (200 ltr) glass lined reactor carboxylic acid, alcohol & catalyst are charged. Keeping temp.< 30 C. Reaction mixture is kept stirring around 30 C for 3 hours. Aqueous layer is separated which is sent to ETP. Then it is taken into high vaccum distillation. Alcohol is separated and minor loss occurred. Sample is taken to check for GC and cooled down. Then mixture is passed from filtration unit where process waste is separated. Finally 98% pure cosmetic emollients is obtained Material Balance 19

21 3.5 RAW MATERIAL FOR FINISHED PRODUCTS The raw materials for the proposed range of products will be indigenously available and will be also imported. Table 3.2(a): List of Raw Materials Product Octyl Methoxycinnamate Octyl Salicylate Octyl HydroxyStear rate Homosalate Ethyl methoxycinnamate Name of Raw Material P-Anisic Aldehyde 2-Ethyl Hexylacetate Catalyst Salicylic acid Methyl Salicylate 2-Ethyl Hexanol Catalyst 12 H.S.A. 2-Ethyl Hexanol Catalyst Methyl Salicylate Homo Menthyl Alcohol Catalyst P-Anisic Aldehyde Ethyl Acetate Catalyst Acetic acid (25%) Requirement (MT/Month) Existing After Phase I After Phase II Or Or Or And HAZARDOUS CHEMICAL STORAGE & HANDLING Hazardous chemicals are/willl be used as raw material in the manufacturing process. Storage, handling & transport of Hazardous Chemicals are given in table 3.2(b). Table 3.2(b): Storage, Handling & Transport of Hazardous Chemicals Raw Material/ finished goods Raw Material P-Anisic Aldehyde 2-EthylHexylacetatee Methyl Salicylate 2-EthylHexanol 12 H.S.A. Source CAS No Local Local Local/Imported Local/Imported Local Means of storage Drums Drums Drums Drums Drums Means of transport Truck Truck Truck Truck Truck Max. Qty. stored MT

22 Raw Material/ finished goods Homo Menthyl Alcohol Ethyl Acetate Acetic acid Products Octyl Methoxycinnamate Octyl Salicylate Octyl HydroxyStearate Homosalate Ethyl methoxycinnamate Source CAS No Local Local Local product product product product product Means of storage Drums Drums Drums Drums Drums Drums Drums Drums Means of transport Truck Truck Truck Truck Truck Truck Truck Truck Max. Qty. stored MT RESOURCE OPTIMIZATION & AVAILABILITY The major resources for the proposed project are/will be raw-materials, water, man-power, etc LAND & BUILDING REQUIREMENT Total existing plot area is m 2 and total constructed areaa is m 2. No additional land will be required for proposed project expansion. Minor construction and fabrication work will be carried out. Land Possession Document is attached as Annexure EQUIPMENTS Some additional equipment will be needed for the proposed expansion. Table 3.3: List of Equipments Sr. No. Equipments Existing 1 Glass line Reactor (3 KL) 2 SS 316 Reactor (3 KL) 3 SS 316 Distillation Vessel (800L) 4 SS 316 Distillation Vessel (2 KL) 5 SS 316 Reactor (1.5 KL) 6 SS 316 Reactor (2 KL) 7 SS 316 (1 KL) 8 SS 316 Reactor (4 KL) 9 SS 316 Reactor (5 KL ) 10 SS 316 Reactor (6 KL) 11 Advanced Continuous Distillation Unit 12 Nutche Filter 13. Non IBR Boiler Proposed additional 1 Vacuum pumps 2 SS 316 Reactor (5 KL ) 3 SS 316 Reactor (6 KL) 4 Thermic fluid heater (6& 10lakh. k.cal/hrs.) 5 Deep Freezer Chilling Unit No

23 3.6.3 POWER AND FUEL REQUIREMENT Total power requirement for existing project is 125 kva and after proposed expansion it will be kva, sourced from Madhya Gujarat Vij Company Ltd. (MGVCL) In existing 500 kg/ /day Agro waste is used as fuel for non IBR boiler. After proposed expansionn 8000 kg/day Agro waste will be used in proposed Thermic fluid heaters. Diesel will be used as fuel in D.G. Set. Table 3.4: Details of Power & Fuel Sr. No. Power 1 Power Requirement Fuel 1 Particulars Fuel & it s consumptionn Requirement Existing Scenario 125 kva Agro 500 kg/day Phase I 250 kva Agro 8000 kg/day Diesel@ 50 LPH Phase II 250 kva Agro kg/day Diesel@ 50 LPH Source Madhya Gujarat Vij Company Ltd (MGVCL.) Local Suppliers WATER REQUIREMENT For existing project, water is required for domestic, process and utility purpose, whichh is sourced from in house, bore well. Total fresh water requirement for existing project is 4.6KLD which will be 29.0 KLD after phase l and 37.0 KLD after phase II which will be sourced from in house bore well. The category wise bifurcation of the water requirement is given in the Water Balance Data in Table 3.5 Table 3.5: Category-wise Water Requirement (in KL/D) S.No Particulars Domestic Gardening Industrial Process Boiler Cooling (Make-up) washing Sub-Total: Industrial Grand Total Requirement (KLD) Existing scenario After Phase I NIL After Phase II NIL

24 3.6.5 MAN-POWER REQUIREMENT The total number of man power for existing project is 35 persons, for proposed expansionn project additional 20 persons will be required. Hencee the total man-power will be 55 The man-power equired for the project is/ will be employed locally from the nearby areas. Skilled as well as unskilled labour will be employed for the project. Table 3.6: Man Power Requirement Phase of project Existing During operations Phase I During operations Phase II During operations Type of Labour Managerial Skilled Un-skilled Managerial Skilled Un-skilled Managerial Skilled Un-skilled General M No. of workers 1 st Shift M nd Shift M rd Shift M QUANTITY OF WASTE TO BE GENERATED WASTE WATER GENERATION & MANAGEMENT The category wise bifurcation of the waste water generation is given in Table 3.7. Table 3.7:Category-wise Wastewater Generation (in KL/D) S.No Particulars Domestic Industrial Process water Cooling (Blow down) Boiler (Blow down) Washing Sub-Total: Industrial Grand Total Waste Water Generation Existing Scenario After Phase I NIL NIL After Phase II NIL

25 Fig-3.4(a): Water Balance Diagram (in KLD) for Existing Scenario Fig-3.4(b): Water Balance Diagram (in KLD) for Phase - I 24

26 Fig-3.4(c): Water Balance Diagram (in KLD) for Phase II WASTE WATER CHARACTERISTICS The tentative wastewater characteristic of effluent is given below in Table No Table 3.8: Characteristics of Wastewater Sr. No Parameterr ph Suspended Solids (SS) Chemical Oxygen Demand (COD) Biochemical Oxygen Demand (BOD) Oil & Grease Total Dissolved Solids (TDS) Characteristics Untreated Effluent Treated Effluent < < <100 <10 < < WASTE WATER TREATMENT & DISPOSAL In existing operations, the domestic effluent is disposed through septic tank/ soakss pit system and the industrial effluent is provided primary treatment and the treated effluent is used for gardening. After proposed expansion the domestic effluent will be disposed throughh septic tank/ soak pit system. For the industrial effluent from the proposed production activities, necessary maintenance and modifications will be made in the existing ETP. 25

27 The effluent coming from the process, washing and cooling tower blow down will diverted to the collection cum neutralization tank and neutralization will be carried out. After neutralization, the effluent will be pumped out to the primary settling tank; sludge from the bottom of the primary settling tank will be diverted into the sludge drying bed. The overflow of the primary settling tank will be passed through mix bed filter and diverted into the holding tank and the effluent from this tank will either be sent to CETP of EICL or will be evaporated in evaporation unit. The salts/ residue from evaporation unit along with ETP primary sludge will be disposed throughh TSDF site. ETP Scheme: Fig-3.5 (a): Existing ETP flow diagram Fig-3.5 (b): Proposed ETP flow diagram 26

28 3.7.4 AIR EMISSIONS & CONTROL Process Emission There is/will be no process emissions fromthe manufacturing activities Utility Emission In existing scenario, the company has one non IBR boiler. Agro waste is used as fuel in the boiler. Cyclone separator is provided as air pollution control measure with the boiler. For proposed expansion IBR boiler will be replaced by two thermic fluid heaters having capacity of 6 lakh k.cal/hrs& &10 lakh k.cal/hrs. Agro waste will be used as fuel in the thermic fluid heaters. Additionally a D.G. Set of 125 KVA will be installed as standby unit and will be utilized only in case of power failure and Diesel will used as fuel in the D.G. Set. The details regarding utility emissions and control measures are mentioned in the below table no Table 3.9: Details of Utility Emission Particulars Existing scenario Non IBR boiler. Fuel Agro waste Fuel Quantity 500 Kg/day Proposed Scenario for Phase I Thermic fluid heater 2 No.- one of 6 lakh k.cal/hrs and one of 10 lakh kcal/hrs. D.G. Set 125 KVA (Stand by) Agro waste Diesel Kg/day 50 LPH Proposed Scenario for Phase II Thermic fluid heater 2 No.- one of 6 lakh k.cal/hrs and one of 10 lakh kcal/hrs. D.G. Set 125 KVA (Stand by) Agro waste Diesel Kg/day 50 LPH Fugitive Emission APCD Cyclone separator Cyclone separator Cyclone separator Emission Norms PM<150 mg/nm 3 SO 2 < 100 ppm NOx< 50 ppm PM<150 mg/nm 3 SO 2 < 100 ppm NOx< 50 ppm PM<150 mg/nm 3 SO 2 < 100 ppm NOx< 50 ppm PM<150 mg/nm 3 SO 2 < 100 ppm NOx< 50 ppm PM<150 mg/nm 3 SO 2 < 100 ppm NOx< 50 ppm Minor quantity of fugitive emissions will occur during handling of the raw materials. Fugitive emissions are also likely to occur from storage area. 27

29 Following measures will be practiced to reduce the fugitive emissions: Raw Materials & Products are/will be stored in properly designated storage area and under good storage conditions to prevent any volatilities Raw Materials & Products are/will be stored in closed containers The fugitive emissionss in terms of handling losses will get reduced by proper storage and handling. Regular monitoring is/will be done of piping and fittings for checking of any leakages. Hazardous chemicals are/will be stored as per standardd criteria. Good housekeeping will be maintained in the plant HAZARDOUS/NON-HAZARDOUS WASTE MANAGEMENT Hazardous wastess generated is in the form of ETP waste, Distillation residue, spent carbon and used oil Company has provided adequate storage area for proper storage of wastes. The details of the hazardous waste and its management is given in below table 3.10 Table 3.10: Details of Hazardous Waste Generation & Disposal Type of waste & Category ETP Waste (Cat. 34.3) Distillation residuee (Cat.36.4) Spent carbon (Cat 35.3) In organic process waste (Cat. 28.1) Used Oil (Cat. 5.1) Discarded Containers/ bags (Cat. 33.3) Spent solvent (Cat. 20.2) Source ETP Process Process Process Maintenancee Raw material 120 storage Nos/Month Process... Existing 0.04 MT/Month 3.36 MT/ /Yr 0.05 MT/Month KL/Yr After Phase l After Phase ll MT/Month MT/Month 80 MT/Yr 125 MT/Yr MT/Month MT/Month 97 MT/Yr 155 MT/Yr 2.0 KL/Yr 2.5 KL/Yr 9870 Nos./Yr Nos./Yr 210 MT/Yr 325MT/Yr Disposal Method Collection, storage, transportation and disposal to TSDF site. Collection, storage, transportation and disposal by incineration at NECL/GEPIL. Collection, storage, transportation and disposal by incineration Collection, storage, transportation and disposal to TSDF site. Collection, storage, transportation, disposal by selling to registered re- storage, refiners. Collection, transportation, disposal by selling to registered resolvent sell refiners. Spent to the actual users. 28

30 3.7.6 NOISE AND ODOUR CONTROL There is/will be no major activities due to which noise would be generated other than Air compressors, TFH & pumps. However, Noise level generation would be limited to 80 db(a) within plant. The equipments resulting in noise generation is/will be Air compressor and Diesel generator. No offensive odour is/will be generated from the process. The control measures to be taken for reduction in noise levels are as below: Ear Plugs and Ear muffs are provided to the workers in Utility Section. Anti vibration pads and flexible bellows is provided wherever applicable. Acoustic Enclosure to D.G. Set will be provided. Regular maintenance & lubrication shall be done HEALTH AND SAFETY MEASURES The following key safety measures shall be implemented in the proposed project: The industry is responsible for health and safety of the workers. The industry is doing a periodical medical examination of its employees and the health records are maintained. The industry has provided first aid box containing cotton, bandage, soframycine tubes, burnol, dettol, tincture iodine, eyes and eardrops. This is to cure the injuries from chemical burns, eye injuries and electrical shocks. Goggles, Gloves, Gum boots, Helmets, Skin Cream, Earplugs, Face Masks, and clothing are provided to the workers. The industry is taking all precautionary measures to control the hazardous associated with the industry. The industry has providedd good lighting and ventilation arrangements. Fire buckets are provided to withstand the fire or explosion condition. Emergency alarm will be installed for the communication for the emergency condition. Fire extinguishers will be installed wherever necessary. Work place monitoring will be done on regular basis ENVIRONMENTAL HEALTH & SAFETY CELL The company has an environment cell in order to keep a close watch on the performance of the pollution control equipment, emissionss from the sources and the quality of surrounding environment in accordance with the monitoring program. The cell is also entrusted with the responsibilities of regulating the safety measures inside the plant campus. The cell is also responsible for maintaining the records of all data, documents and information in line within the legislative requirement. 29

31 3.7.9 POST PROJECT MONITORING PLAN The company has developedd in-house facilities for monitoring certain components. Where it is not possible to establish such facilities, the same will be done by appointing external recognized/approved agencies. The proposed post-project monitoring plan is given below: Table 3.11: Post Project Monitoring Plan Components Parameters Frequency of in house monitoring Frequency of third party monitoring Drinking water IS-10500: Once in a month Waste water Air-ambient BOD, COD, ph, TSS, TDS SPM, SOx, NOx. VOC Daily (At all ETP) -- stages of Once in a month (treated and untreated) Quarterly Stack monitoring SPM, SO 2, NOx -- Quarterly Noise monitoring db (A) -- Once in a month 30

32 CHAPTER 4 SITE ANALYSIS 4.1 CONNECTIVITY The Industry is located at Plot No. 1088/ /B, Lamdapura road, Village: Manjusar, Ta: Savli, Dist. : Vadodara. This proposed expansion project will be accommodated in the existing site. The site is very well connected by national highway and railway. Efficient transport facilities will be available nearby the project site. 4.2 LAND FORM, LAND USE & LAND OWNERSHIP LAND FORM The proposed expansion is to be carried out in the existing industrial facility LAND USE PATTERN It is a non-agricultural land and developed industrial facility outside notified industrial area. at existing industrial unit located LAND OWNERSHIP The plot is owned by the company. Land ownership document is attached as Annexure TOPOGRAPHY The topography of Vadodaraa is divided into two distinct regions, viz. western regions and the eastern regions. The western region of the city possesses a number of educational institutions, residential complexes, railway station, shopping malls, multiplexes, business districts and modern buildings. The business districtt centers at Alkapuri, Old Padraa Road and R C Duttt Road. The eastern region houses bazaars, various shrines and various shanty buildings. The eastern region also contains some of the landmarks such as Nyay Mandir, Mandvi and Laxmi Vilas Palace and the General Post Office. The eastern bank of river Vishvamitri also houses the fortified city of Vadodara. 31

33 4.4 SALIENT FEATURES The salient features of the project site are given in the table below: Table 4.1: Salient Features of the Project Site Particulars Details Co-ordinates Center: 22 28'02.92"N, 73 12'22.43"E Village Manjusar Taluka/ Tehsil Savli Districtt Vadodara Nearest Water body Mahi River 9.37 km (NW) Nearest Highway State highway 1.16 km (W) Nearest Railway station & Railway line Samlayaa railway station (ENE) Vadodara Railway Station km SSW Nearest Airport/ Airbase Vadodara Airport km (SSE) Ahmedabad Airport km (NW) State/ National borders None within 10 kms Protected Area/ Sanctuaries No CRZ applicability No Seismicity Seismic Zone III (Moderate) Note: All the above mentioned distances are the aerial distance from the project site. 4.5 EXISTING INFRASTRUCTURE The plot is located in village: Manjusar outside notified industrial area. infrastructure is developed by the company itself. The entiree necessary 4.6 CLIMATE & METEROLOGY The climate is characterized by oppressive summer dampness in the atmosphere nearly throughout the year, heavy south west monsoon rainfall and a mild winter. The year can be divided into four seasons. The cold season from December to February is followed by the summer season from March to May. The south-west monsoon season is from June to September. The post-monsoon season constitutes the months of October and November. The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of IMD, Vadodara published by IMD. 32

34 Table 4.2: Summary of Meteorologicall Data at nearest IMD Station Vadodara Location: At the Physics Department, MS University, Vadodara Gujarat ( Lat: N , Long: E 73 o 15 ) Aerial Dist from Project Site: Approx.16 Km SSW Height of installation: 34 m above MSL, Month Temperature Relativee Cloud Cover Mean Wind Pre-dominant Rainfall (mm) ( o C) Humidity (Oktas) Speed Wind Direction (%) (km/hr) Max. Min. Mor. Eve. Mor. Eve. January February March April May June July August September October November December NE CALM CALM NW SW SW SW SW SW CALM CALM NE Seasonal Average Values Period Temperature Relative Cloud Cover Mean Wind Avg. PDW Total Rainfall (mm) ( o C) Humidity (Oktas) Speed Direction (%) (m/s) Avg. Avg. Avg. Avg. Avg. Avg. Max. Min. Mor. Eve. Mor. Eve. Summer Winter Monsoonn Post monsoonn Annual Total or Mean NW,SW NE SW CALM SW Note: Winter: December, January & February, Summer: March, April & May, Monsoon: June, July, August & September, Post monsoon: October & November (Source: Book Climatological tables of Observatories in India ( ) published by IMD) TEMPERATURE The summer season from March to May is a one of continuous increase in temperatures whichh decreases during monsoons, increasess slightly during the post-monsoon season and again decreases during the winter. The south-wesmonths are generally pleasant. May is generally the hottest month with the mean daily maximum temperature recorded at 40.9 o C and mean daily minimumm temperature recorded at 12.0 o C. January is the coldest month with the mean daily maximumm temperature as 30.3 o C and mean daily minimum temperature observed as 12.0 o monsoon from June to September brings copious rain to the area. The winter C. 333

35 HUMIDITY The climate of the region is characterized by a humid summer because of the closeness to coastline. Humidity is usually high during the monsoon months, with average relative humidity generally exceeding 85%. Humidity decreases gradually during the post-monsooaverage relative humidity ranges around months and for rest of the year i.e. the period of December to April, the 20-70% CLOUD COVER During the South-wescover decreases during the post monsoon months. In the rest of the year the skies are mostly monsoon months, the skies are usually heavily clouded or overcast. Cloud clear RAINFALLL About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to September, July being the month with highest rainfall. The average annual rainfall observed from the data is mm WIND PATTERN The annual resultant vector for wind direction shows winds blowing from SW. During summer and monsoon, the winds blow mostly from the sea i.e. the NW or SW direction. The winter season experiencee a change in direction, with the winds blowing from NE. The post-monsoonn season experiencee calm winds. The wind speed is high during monsoon and summer seasons, slightly moderate during winter and post monsoon seasons. 4.7 SOCIAL INFRASTRUCTURE The infrastructure available in the study area denotes the economic well-being of the region EDUCATIONAL FACILITIES As per census 2001, Out of 136 villages, all villages have educational facilities, details of whichh are given below. 34

36 Table 4.3: Details of Educational facilities Sr.No Particulars 1. Primary Schools 2. Middle Schools 3. Secondary School 4. Senior Secondary School 5. College (Source: Primary Census s Abstract Census of India, 2001) Observed values in Savli Taluka MEDICAL FACILITIES As per census 2001, Details of medical facilities available in the study areaa are given below. Table 4.4: Details of Medical facilities Sr.No. Particulars 1 Dispensaries 2 Primary Health Centers 3 Primary Health sub centre 4 Allopathic Hospital 5 Allopathic dispensary 6 Maternity and Child welfare Centree 7 Community Health Workers (Source: Primary Census s Abstract Census of India, 2001) Observed values in Savli Taluka

37 CHAPTER 5 PLANNING BRIEF 5.1 PLANNING CONCEPT The proposed project is located at Manjusar, Savli. The nearest city is Vadodara- the third largest city in the Indian State of Gujarat, after Ahmedabadd and Surat. Major raw materials are/will be sourced locally. RM cost as many input suppliers are located nearby which will bring reduction in transportation cost. The region is well planned with all the basic infrastructural facilities like internal roads, water supply, arrangements for power, streetlights, solid waste disposal sites etc. 5.2 POPULATION PROJECTION As per census 2001, the average household size is around 5 persons. The demographic profile of study area within Savli Taluka is presented below. Table 5.1: Distribution of population Sr. No. Particulars 1 Total Population 2 No. of Households 3 Avg. household size (person) 4 Male population 5 Male population (in %) 6 Female population 7 Female population (in %) 8 Sex ratio (Source: Primary Census s Abstract Census of India, 2001) Observed values in Savli Taluka AREA STATEMENT The total area of the plot is m 2 out of which constructed area of the plant is m ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) This is an expansion project which is to be developed in the existing premises. No additional land or building is required for the proposed project except few installations and modifications. So there will be no demand of major change in physical infrastructure and social infrastructure. 5.5 AMENITIES/FACILITIES DRINKING WATER FACILITIES As per census 2001 following drinking facilities are available in study region. 36

38 Table 5.2: Drinking Water Facilities Sr. No. Particulars 1 Tap 2 Well water 3 Tank water 4 Tube well water 5 Hand pump 6 River water 7 Canal 8 Lakes 9 Spring 10 Other drinking water sources (Source: Primary Census s Abstract Census of India, 2001) Observed values in Savli Taluka POWER SUPPLY FACILITIES As per census 2001, all the villages have power supply facilities in the study region COMMUNICATION& BANKING FACILITIES As per census 2001, Distribution of facilities such as post office, post & telegraph office, banks, and telephone connections in the study area are illustrated in table below. Table 5.3: Communication & Banking Facilities Sr. No. Particulars 1 Post Office 2 Post and telegraph office 3 Telephone connection 4 Commercial Bank (Source: Primary Census s Abstract Census of India, 2001) Observed values in Savli Taluka TRANSPORT FACILITIES As per census 2001, Bus service is available in all the villages of the study region within Savli Taluka and most preferable mode of transport in the region. Second option for transport is railway; railway line is available in 4 villages. 136villages are connected with paved roads. Theree is 100% electrification in the area APPROACH TO VILLAGES As per census 2001, 109 villages have paved road, 98 villages mud road and 73 villages have foot path. 37

39 CHAPTER 6 PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREAA The total area of the plot is m 2 out of which constructed area of the plant The total production capacity will be 2580 MTA after proposed project. is 1500m RESIDENTIAL AREA In the said proposal no Residential area has been proposed for workers and/or for staff. 6.3 GREENBELT Maximum possible open land is/will be allotted for green belt development. If required, experts will also be consulted for selection of species for the development of the greenbelt. 6.4 SOCIAL INFRASTUCURE Existing infrastructure will be sufficient project which is very low. to accommodate the existing load from the proposed 6.5 CONNECTIVITY This proposed expansion project will be accommodated in the existing site. The site is very well connected by national highway and railway. Efficient transportt facilities will be available nearby the project site. 6.6 DRINKING WATER MANAGEMENT Drinking water is/will be sourced from in house bore well for the proposed project. 6.7 SEWERAGE SYSTEM Domestic waste water generated from the existing and proposed project is/will be disposed offf throughh septic tank/soak pit system, which 1.20KL/D for existing plant 2.0 KL/D after phase I and 2.2 KLD after phase II. 6.8 INDUSTRIAL WASTE MANAGEMENT Industrial effluent generated after proposed project will be treated in ETP, treated water from ETP will be will be sent to EICL/CETP or will be evaporated in evaporation unit. Details are explained in Chapter 03, Section and

40 6.9 SOLID WASTE MANAGEMENT Solid wastes generated are in the form of ETP waste, spent carbon, Distillation residue, used oil and discarded containers from storage of raw materials. Company will provide adequate storage area for proper storage of wastes. Details of solid waste generation are given in table 6.1. Table 6.1: Solid waste generation and disposal Type of waste & Category ETP Waste (Cat. 34.3) Distillation residuee (Cat.36.4) Spent carbon (Cat 35.3) In organic process waste (Cat. 28.1) Used Oil (Cat. 5.1) Discarded containers/ bags (Cat. 33.3) Spent solvent (Cat. 20.2) Source ETP Process Process Process Maintenance Raw material storage Process Existing 0.04 MT/Month 3.36 MT/Yr 0.05 MT/Month KL/Yr 120 Nos/Month... After Phase l After Phase ll 5.5 MT/ /Month 8.5 MT/Month 80 MT/Yr 125 MT/Yr MT/Month MT/Month 97 MT/Yr 155 MT/Yr 2.0 KL/Yr 2.5 KL/Yr 9870 Nos/Yr 15210Nos/Yr 210 MT/Yr 325 MT/Yr Disposal Method Collection, storage, transportation and disposal to TSDF site. Collection, storage, transportation and disposal by incineration at NECL/GEPIL. Collection, storage, transportation and disposal by incineration Collection, storage, transportation and disposal to TSDF site. Collection, storage, transportation, disposal by selling to registered re- storage, refiners. Collection, transportation, disposal by selling to registered resolvent sell refiners. Spent to the actual users POWER REQUIREMENT & SOURCE OF SUPPLY Total power requirement for existing project is 125 KVA and after proposed expansion it will be - 250KVA, sourced from Madhya Gujarat Vij Company Ltd. (MGVCL) 39

41 CHAPTER 7 REHABILITATION &RESETTLEMENT (R &R) PLAN 7.1 POLICY TO BE ADOPTED The proposed project is to be developed in the existing premises.hence, no displacement of any population is proposed for the project. Therefore, detailed Social Impact Assessment studies or R&R action study has not been proposed. 40

42 CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE OF THE PROJECT At present we are not proposing any additional production at the site. getting all the statutory permission from respective authorities. It will start only after 8.2 ESTIMATED PROJECT COST The company has made budgetary provision for the recurring expenses for the environmental issues and Environment Protection has also been consideredd in planning the cost projection. Green belt development is also considered. The estimated project cost after proposed project will be approximately Rs Lakhs. Table 8.1: Total Capital Cost Projection Sr. No. Purpose Capital Cost (Rs. in Lakhs) Existing Proposed additional Land Building Plant & Machinery Electrification and Administrative set-up Environment Protection (including ETP, APCD etc.) ETP Air pollution control device Safety instruments Chartered services/ Government fees Green belt development TOTAL Total Table 8.2: Recurring cost provision for EHS Sr. No. Purpose Environment Protection (including ETP, APCD etc.) Air pollution control device Fees for Common disposal facilities Env. Monitoring expenses Safety instruments maintenancee Environment & safety training Green belt maintenance Medical surveillancee TOTAL Recurring Cost per annum Existing Proposed additional (in Lakhs) Total

43 CHAPTER 9 ANALYSISS OF PROPOSAL 9.1 FINANCIAL & SOCIAL BENEFITS M/s. Universal Esters Ltd. is located at Plot No. 1088/B, Village: Manjusar, Ta: Savli, Dist: Vadodara. Currently Universal Esters has become one of the leading manufacturers of Personal Care Ingredients in India. With stringent quality standards and good manufacturing practices, Universal has built its reputation as a preferred supplier to companies all over the world. The company focuses on providing quality products to the Personal Care industry. Finally in the days of acute Deficit of Foreign Exchange in our Country, Universal contributed to the earning of Foreign Exchange in Hard Currency. Esters has For the proposed project, the company intends to benefit as Corporate Social Responsibility. donate 2% of the capital cost for the social 42

44 Annexure 1: Existing CC&A A1

45 A2

46 A3

47 A4

48 A5

49 Annexure 2: Land Ownership Document A6

50 A7

51 A8

52 A9

53 A10

54 A11

55 A12

56 A13

57 A14

58 A15

59 A16