Maharashtra Aldehydes & Chemicals Ltd. Plot No: A-17, MIDC, Mahad , India.

Transcription

1 Pre-feasibility report for Expansion of synthetic organic chemical manufacturing unit By M/s. Maharashstra Aldehydes and Chemicals Limited PROJECT TERMED UNDER SCHEDULE 5 (f) (SYNTHETIC ORGANIC CHEMICALS) CATEGORY - B Prepared By Maharashtra Aldehydes & Chemicals Ltd. Plot No: A-17, MIDC, Mahad , India.

2 Chapter 1 Executive Summary Company Profile Maharashtra Aldehydes & Chemicals Ltd. (MACL) is manufacturer of Esters used for perfumery industry and specialty chemicals. MACL (A group company of Laxmi Organics) is the only Indian company that is backward integrated for its raw material. MACL have Ethyl Alcohol manufacturing facilities with two distilleries within the group. The in-house sourcing as well as expertise of our group in alcohol-based chemicals gives us the leverage to use the best quality alcohol for manufacturing compared to our competitors in the market. Considering our proficiency in Alcohol we have successfully developed new range of Ethyl Alcohol based esters, such as Tri Ethyl Citrate (TEC), Ethyl Propionate (EP) & Ethyl Butyrate (EB) and animal feed. In line with our expressed mission, MACL is backed by world class manufacturing facilities, a highly functional R&D department & stringent quality assurance systems. Our long-term relationships with multinational companies bear testimony to our strict adherence to intellectual property. MACL s Product range now accounts for 4 main verticals, which includes Flavors & Fragrance Ingredients, Plasticizers, and Laboratory Chemicals. We are in the process of developing new products that include for the cosmetic, Flavor and Fragrance Industries. We are committed to the Health and Safety of our employees, the welfare of our community & environment protection. MACL has existing plant at Plot no. A-17, MIDC Mahad, dist. Raigad. Plot plan possession receipt / plot possession letter is at Annexure I. The google image of the plot site is at Annexure II. Proposed Layout Plan for expansion is attached as Annexure III. 1

3 Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide EIA Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic chemicals manufacturing units. This project falls under category B and schedule item no. 5(f): Synthetic organic chemicals. The project brief is summarized in the table below Project summary at a glance Sr Particulars Details No 1 Name of Company Maharashtra Aldehydes & Chemicals Ltd. 2 Products (existing and Refer Chapter 2 proposed) 3 Location A-17, Mahad MIDC area, Mahad, Dist Raigad. 4 Name of the project Expansion of Synthetic Organic Manufacturing facility 5 Total land area of the plot 20,000 sq. mtr. 6 Total proposed built up Built up area sq m area Proposed built up area 2500 sq m 7 Major raw material Phthalic Anhydride, SDS, Methanol, Citric acid, Propoinic acid/ethyl Acrylate, Butyric Acid/Ethyl crotonate, Butanol, Formic Acid, Heptanoic acid, valeric acid, capric acid, caproic acid caprylic acid, benzoic acid, adipic acid, lauric acid, Anisole, undecylenic acid, salicylic acid, pelargonic acid, palmitic acid, myristic acid, Crotonic Acid, Cinnamic Acid, Teraphthalic Acid, Guaiacol, Catechol, Heliotropin, Vanillin, Vitamin E, Wet Alcohol etc. 8 Water requirement and 319 cmd (proposed additional requirement) from MIDC source 9 Power requirement and source 770 KVA additional from MSEDCL 10 Existing and proposed Existing 120, Proposed 180, Total 300 No. manpower 11 Waste water quantity 202 cmd, shall be treated and discharged to CETP (estimate) 12 Air emissions SOx, NOx, TPM from proposed boiler and Thermic fluid heater 13 Solid Waste Refer 3.7 below 14 Project cost estimate ~ 50 Crores 2

4 The Land shall be used as Industrial land thus there shall be no change in land use. This industrial plot is allotted by MIDC to Maharashtra Aldehydes and Chemicals limited. (Plot allotment letter / plot possession letter is at Annexure I). MIDC has provided all basic infrastructures like Electrical Power, water supply, the internal road network, external approach road and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility). There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological monuments, sanctuaries, etc. The land and infrastructure is made available by MIDC and the raw material is easily available through the easy transport via road connectivity by local suppliers as well as imported one. 3

5 Chapter 2 Introduction of the Project 2.1 Identification of the project and Project Proponent The project is expansion of synthetic Organic chemicals manufacturing facility at the current location of the plant site. Project proponents are, Directors No Name Address 1 Vasudeo Nathmal Goenka 242-C, Grand Paradi Apartment, August Kranti Marg, Mumbai Ravi Vasudeo Goenka 221-C, Grand Paradi Apartment, August Kranti Marg, Mumbai Rajeev Vasueo Goenka 241-C, 24th Floor, Grand Paradi Apartment, August Kranti Marg, Mumbai Sunil Kumar Gupta E-102, Shanti Nagar - E, Dattamandir Road, Malad (East), Mumbai Aditi Rajeev Goenka 241-C, 24th Floor, Grand Paradi Apartment, August Kranti Marg, Mumbai Anilkumar Govindprasad Lohia 404/A, Meghdoot New D.P.Road, Lokhandwala Complex, Andheri (West), Mumbai Need of project with description for region and country Project is required to products having high export potential & export substitute. Site is situated in the proximity of port. Raw materials are easily available. Job generation in local surrounding area. Easy availability of skilled and unskilled labor. Site is situated in a dedicated chemical zone. 2.3 Brief Description of Project Size : It is proposed to produce following products at the site. The existing products (as per CTO) and proposed products are summarized below, 4

6 Sr. No Product / By product Existing as per CTO MT/M Proposed Add. production capacity (expansion)(mt/m) Total (MT/M) Product 1 Syrindaldehydes Di ethyl Phthalate Di methyl Phthalate 50 4 Ethyl Benzoate 30 5 Esters (Ethyl Formate, Ethyl Butyrate, Triethyl Citrate, Ethyl Propionate, Acetyl Tributyl Citrate, Ethyl Aceto 0 Acetate, Ethyl Caprate, Ethyl Caproate, Ethyl Caprylate, Ethyl Heptanoate, Ethyl Isovalerate) Di Octyl Adipate 0 Di Octyl Phthalate 0 Ethyl Laurate 0 Di Butyl Phthalate 0 Di-iso nonyl Phthalate 0 Di Octyl Terephthalate 0 Ethyl 2-Methyl Pentanoate Ethyl 2-Methyl Butyrate 0 Ethyl Acetate 0 Ethyl Valerate 0 Ethyl Cinnamate 0 Ethyl Crotonate 0 Ethyl Myristate 0 Ethyl Palmitate 0 Ethyl Pelargonate 0 Ethyl Salicylate 0 Ethyl Undecylenate 0 6 Sodium Pyrithione Cyclopentanone & its derivative Trimethyl Hydroquinone & it's formulation 9 Anisole Methoxy Acetophenone Anethol Mono Methyl Ether of Hydroquinone Guaiacol Vanillin Heliotropin Helional Absolute Alcohol 0 50 KLPD 50 KLPD 18 Distillation of Methanol Distillation of Acetonitrile Distillation of Ethyl Acetate Distillation of Toluene 15 5

7 Sr. No Product / By product Existing as per CTO MT/M Proposed Add. production capacity (expansion)(mt/m) Total (MT/M) 22 Distillation of Acetic Acid Distillation of Hexane Distillation of Butanol Distillation of Ethyl Aceto Acetate 0 Formulation Product 1 Vitamin E Blend (MAXVIT) By Products 1 Sodium sulphate Solution Acetic Acid methoxy Acetophenone ,4-Diacetyl toluene Propionic Acid Methoxy-4-Propylbenzene Cis Anethole Export Possibility 70 % - 80 % of the products manufactured, specifically, Esters will be for Export s to Major Global Flavor Houses. Internationally the Flavor market is more developed and advanced and so is the demand. India can compete with the Global manufacturers mainly from Europe and China for these products. 2.5 Domestic / Export Markets Plasticizers: In view of the economic growth of India being projected at 7% to 7.5% PA, the domestic demand for Consumer & Industrial Products viz. All Plastic Products, Vinyl Products, Medical & Surgical Aids, etc. is increasing. We foresee a surge in the demand of close to 12% - 15% annually of such products. This demand translates to an increase in the consumption of Plasticizers in all these segments of Industry. In the International Market, the consumption of such Plasticizers is projected to grow at of 10% - 12% annually as Plastics are replacing traditional metals across the Consumer & Industrial goods spectrum. In India, we have the advantage of availability of local Raw Materials, skilled labour & technology to compete with the best in the world. Esters: India is a major importer of these products except for few manufacturers who may or may not be manufacturing the products in small volumes mainly due to the stricter norms of obtaining Licenses for Ethyl Alcohol. We will be manufacturing the entire range of esters and cater to all the domestic customers and discourage customers to import these materials from China. The Domestic Market is around 20 % to 30% and Export market 6

8 around 70% to 80%. Over a period of time we would try to capture 45 % to 50 % of the market share. Distilled Solvents: India is emerging on the world map as a major producer of High Value Chemicals & the demand for Distilled Solvents is increasing by the day as these are used in the R & D Facilities of all such Industrial Units. We plan to cater to the rising demand. Acceptance by MNCs in India opens up the doors for us to venture into the International Market. 2.6 Employment Generation due to Project (Direct and indirect) Once the project is fully operational we expect to create approx new job opportunities for Technical, Clerical, and Skilled & Semi Skilled Labor. With the expansion in capacities of our Plant, we would also be upgrading our Infrastructure thereby creating a demand for Industrial Equipment & raw Materials. This will create a ripple effect & help in employment generation at our suppliers side as well. 7

9 Chapter 3 Project Description 3.1 Type of Project: Expansion of existing products with new products 3.2 Location of the Project Details of Nearest Infrastructure Facilities Sr. No Destination App. Distance of Project Site 01 Nearest Town Mahad 7 km 02 Nearest National Highway (Mumbai Goa) NH-66 7 km 03 Nearest Airport Mumbai 177 km 04 Nearest Railway Station Karanjadi 17 km 05 Nearest Port JNPT 190 km The project expansion is proposed at Plot No A - 17, Mahad MIDC, Dist. Raigad Maharashtra. The Geographical Location of this plot is at N Latitude and E Longitude with an elevation of 20 meter above sea level MSL. Site coordinates are as follows: Direction Latitude Longitude North east corner North west corner South east corner South west corner This site is in premises of MIDC Estate which is meant for these types of Industries. GPS Location on Google Imagery of the proposed site is attached as Annexure II. Land Form: Land is on plain contour, it is flat terrain. 8

10 Land Ownership: Land ownership is with project proponents (Maharashtra Aldehydes and Chemicals limited) Existing Land use Pattern: The Land is reserved for Industrial use & the proposed project shall be at the same plot. Existing Infrastructure: Presently there is an existing Infrastructure around the site. Infrastructure like water, electricity, telephone facility, roads already available. Other Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at Mahad Town (Which is at distance of about 7 km) Mahad MIDC provides many basic facilities like uninterrupted water supply, power and Road Network. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure. There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological monuments. The location justification for the project is as under a. Availability of required land and infrastructure for locating the establishment for the synthetic organic chemical manufacturing. b. Suitability of land from topography & geological aspects, synergy and business point of view c. Proximity to rail / road to facilitate transport of equipment / materials/ product d. Availability of adequate quantity of water to meet water requirements. Lay-Out Refer Annexure III for the proposed plant site layout plan. 3.3 Project Description with Processes Details: The project is expansion project for manufacture of Synthetic Organic chemicals Refer Annexure IV for product description with process details. 9

11 3.4 Raw Material for finished Product: Raw Materials: The basic raw material for the proposed production capacity is submitted herein below. Source for Raw Material Procurement: Raw Material is easily available in the local market. Mode of Transport of Raw Materials: Mode of transport to site is by road truck/tankers. Sr. No. Raw Material Unit List of Major Raw Material & Storage Total consumption Qty. per year (existing) Total consumption Qty. per year (proposed) Total 1 Phthalic Anhydride Ton Citric acid Ton Methyl Butyric acid Ton Methyl Pentanoic acid Ton Benzoic Acid Ton Butyric Acid Ton Capric acid Ton Caproic acid Ton caprylic acid Ton Formic Acid Ton Heptanoic Acid Ton Iso Butyric Acid Ton Iso Valeric Acid Ton Lauric Acid Ton Propionic Acid Ton Valeric Acid Ton Adipic Acid Ton Teraphthalic Acid Ton Cinnamic Acid Ton Crotonic Acid Ton Myristic acid Ton Palmitic acid Ton Pelargonic acid Ton Salicylic acid Ton undecylenic acid Ton Phenol Ton Anisole Ton

12 Sr. No. Raw Material Unit Total consumption Qty. per year (existing) Total consumption Qty. per year (proposed) Total 28 Guaiacol Ton Catechol Ton Heliotropin Ton Wet Alcohol(SDS) KL methanol KL Acetonitrile Ton Ethyl Acetate Ton Ethyl Aceto Acetate Ton Acetic Acid Ton Hexane Ton Butanol Ton Toluene Ton Chloro Pyridene Ton Vitamin E Ton Trimethyl Phenol Ton Vanillin Ton Ethyl Hexanol Ton Iso Nonyl Alcohol Ton Acetic Anhydride Ton Prop ionic Anhydride Ton % Glyoxylic acid Ton Silicon Dioxide Ton Existing and Proposed major bulk liquid storages at site are as follow: Sr. No Raw material Number of tanks (existing) Number of tanks (proposed) Liquid storage capacity (existing)( KL) Liquid storage capacity (proposed)(kl ) 1 SDS Methanol Acetic Anhydride Hexane Ethyl Hexanol Iso Nonyl Alcohol Propionic Anhydride 8 Acetonitrile Ethyl Acetate Ethyl

13 Acetoacetate 11 Acetic acid Butanol Toluene Resource Optimization: Maharashtra Aldehyde and Chemicals limited are desirous to expand the manufacturing facilities for the product indicated above. The resource optimization shall be carried out at the site in order to reduce wastage and minimum transport needs. 3.6 Availability of Resources (Water, Energy/Power Requirement): Power: Existing power requirement of the site is 370 KVA. The proposed power requirement for the expansion is 770 KVA which will be source from MSEDCL grid. It is proposed to install 1 Nos of DG sets of 250 KVA capacity based on HSD as fuel as emergency backup in case of power outage. Water: The total water requirement for the expansion is about 319 cmd mainly for domestic, process, Boiler/cooling purpose. It will be source from MIDC water works. Fresh water requirement and waste water generation for proposed establishment shall be as follows: Fresh water intake No. Description Existing as per CTO (cmd) Proposed water input (cmd) for expansion Total (cmd) 1 Domestic Industrial cooling/boilers 3. Processing whereby water gets polluted and pollutants are easily biodegradable 4. Gardening Total

14 Waste water No. Description Existing as per CTO Proposed generation (cmd) Disposal 1. Trade effluent Domestic effluent 8 Total Manpower: Expected additional manpower requirement for the expansion shall be as follows: Description Existing Proposed, No Total (approx.) Permanent Contract Total Steam / Process heat Requirement: Existing steam and thermic fluid heater details are as follows, Sr. No. Equipment Capacity Status Fuel name & Quantity 1 Boiler 2 TPH Existing Coal & 7 TPD 2 Thermic Fluid Heater 4 lakh Kcal/hour Existing FO 1.2 KL/day (FO) & 2.8 TPD(coal) 3 DG 62 KVA Existing HSD & 0.5KL/day For expansion requirement following utility boiler and TFH are proposed to be added, Sr. No. Equipment Capacity Status Fuel name & Quantity 1 Boiler 6TPH New Coal, 30 TPD 2 Thermic Fluid Heater 8 lakh Kcal/hour New Coal, 5.6 TPD 3 DG 250 KVA New HSD, 1.5 KL/hour 3.7 Waste Generation and its treatment, disposal I. Solid Waste (a) Non Hazardous Solid Waste: Sr Type of Waste Quantity UOM Mode of Disposal No Existing as per CTO 1 Coal Ash 0.7 MT /D Sale to Bricks manufacture Additional Proposed for the expansion

15 1 Coal Ash 2.8 MT /D Sale to Bricks manufacture 2 Metal scrap 200 Kg/ M Sale to Authorized party 3 Insulating waste 100 Kg/M Sale to Authorized party 4 Canteen waste 900 Kg/Y Composting 5 Rubber hand gloves, PVC shoes, 300 Kg/Y Recycle/sale after tarpoline, paper waste decontamination 6 Broken discarded glass 200 Kg/Y sale after decontamination (b) Hazardous Waste: The quantification of hazardous solid waste generated from present activity and proposed activities is presented as follows: Sr No Type of Waste Category Quantity UOM Mode of Disposal Existing as per CTO 1 Chemical sludge MT/M CHWTSDF form waste water treatment 2 Residue And KL/M Sale to Authorized party wastes 3 Spent Organic KL/M Sale to Authorized party solvent 4 Process sludge / residue KL/M Sale to Authorized party Additional Proposed for the expansion 1 Chemical sludge MT/M MWML, Taloja form waste water treatment 2 Residue And KL/M Sale to Authorized party wastes 3 Spent Organic KL/M Sale to Authorized party solvent 4 Process sludge / KL/M Sale to Authorized party residue 5 Discarded No s/y Sale to Authorized party barrels/liners 6 Discarded Kg/Y Sale to Authorized party Asbestos 7 Spent oil(waste/used oil) Kg/M Sale to Authorized party 8 Oil soaked Kg/M Sale to Authorized party gaskets and cotton waste 14

16 9 Filter &filter MT/Y MWML, Taloja material Note: additional proposed quantities are estimate, Quantity shall be worked out during EIA stage. 15

17 Chapter 4 Site Analysis 4.1 Connectivity: This proposed expansion of Maharashtra Aldehydes and Chemicals limited shall be located at Plot A-17, Mahad MIDC in Raigad district, Maharashtra. The Site is 7 km from Mahad. The land and infrastructure is made available by MIDC and the raw material is easily available through the easy transport via road connectivity. 4.2 Land form, Land use and Land ownership: Land Form: Land is on plain contour, it is flat terrain. Land Ownership: Land ownership is with project proponents (Maharashtra Aldehyde and Chemicals limited) 4.3 Topography: The district has three physiographic divisions i.e. (i) Coastal zone in west covers about 20% percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting of fertile land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude and covered with forest. This hill range is characterized by ruggedness and uneven topography, with crestline of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three main rivers in northern part. Kundalika River is the main river in central part whereas in the southern part Savitri River is the main river. The soils in the district 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 and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation. 4.4 Existing land use pattern: Industrial use 4.5 Existing Infrastructure: Infrastructure is provided by additional Mahad MIDC. 4.6 Soil Classification: 16

18 SOILS: The soils of the district are formed from the Deccan trap which is the predominating rock formation of this district with small out-crops of laterite at a few places in the Poladpur taluka and in the Matheran hills. Various types of these soils are marked out as per topographical situation and location. They ' are generally grouped as forest, varkas, rice, khar or salt, coastal alluvial and laterite soils. Forest soils: These soils are not used for agricultural purposes but yield valuable forest products such as teak-wood, hirda (myrobalan), beheda, pepper, etc. However, these soils are heavily eroded due to grazing and cutting of the forest trees. Varkas soils: These soils are located just below the forest soils all along the steeper slopes. They are shallow in depth, which varies only between a foot and a foot and a half, heavily eroded and sandy in texture and yellowish red to yellowish grey in colour with acidic reaction. They are poor in organic matter and nitrogen and possess very little retentivity of moisture. They yieldkharif millets but the production thereof could be increased with the addition of bulky manures, lime and nitrogenous and phosphatic fertilisers. Rice soils. The district is the second largest producer of rice in the Maharashtra State. The region is peculiarly terraced and, though the small strips in between the two terraces are levelled, it is difficult to get even a few gunthas of land in one piece in a levelled condition. The depth varies between two and six feet. They are loamy in texture, yellowish or reddish grey in colour, neutral in reaction and almost devoid of lime. They are formed from the trap rock from the Sahyadri ranges under heavy rainfall and humid climatic conditions. The linear response of rice to the application of nitrogenous, phosphatic and potassic fertilisers is observed in these soils. Addition of bulky manures in these soils is also found to be advantageous from the point of view of yield. There are some patches of manat soils in Mangaon taluka which are rich in clay and silt and which become stiff and hard when dry. 17

19 Khar soils. These soils are situated on the flat, levelled land near the sea at the point of creeks formed due to the rivers. They are flat clay to clay loam in texture and reddish or yellowish grey in colour. These soils contain hardly more than one per cent of soluble salts. These soils are formed due to the deposition of salts by the sea or from lands reclaimed from the sea. Large tracts of land are going out of cultivation due to the ingress of the sea and, in order to reclaim these lands, the Government have formed the Khar Land Development Board which has undertaken ambitious projects of the reclamation of khar lands. Coastal alluvium soils. These soils are found all along the coast and at places where there are no creeks. They are deep soils developed on flat land and loamy in texture with reddish grey colour. They are devoid of clay fraction or humus and are open in nature. The profile is difficult to differentiate and is excessively drained. Calcium carbonate is found in abundance throughout the profile but calcium has not entered the clay complex. The sub-soil water level is only from ten to fifteen feet deep. The salt contents of the well water are higher in the proximity of the sea; but due to excellent drainage, its use has not produced any deleterious effects. The soils are almost neutral or slightly on the alkaline side of neutrality. Good garden crops like coconut, areca-nut, plantain, etc., are grown in these soils, depending upon the availability of water. Laterite soils. Out-crops of laterite rock are observed amongst the Sahyadri ranges amidst the trap rock mainly at Matheran and in the Poladpur taluka. These soils mostly occur on the mountain peaks. They are coarser in texture, wherever there are no forests. They are yellowish-red in colour and shallow in depth and yield coarse millets and niger. The heavy rains in the mountainous regions thoroughly leach the soils turning them acidic in reaction and devoid of calcium carbonate. They are rich in sesquioxides, the ratio of silica to sesquioxides being less than two. But they are generally poor in exchangeable bases or in fertility constituents. However, the soils from the forest region are well-supplied with nitrogen and organic matter. 18

20 4.7 Climate data from secondary sources: Climate: Mahad comes in Raigad district of Maharashtra. The climate of this district is typical of that on the west coast of India, with plentiful and regular seasonable rainfall, oppressive weather in the hot months and high humidities throughout the year. The summer season from March to May is followed by the south-west monsoon season from June to September. October and November form the post-monsoon or the retreating monsoon season. The period from December to February is the cold season. Rainfall: The district has a network of eleven rain gauge stations with records extending to 82 years for most of the stations. The south-west monsoon commences by about the first week of June and the rains continue till about the beginning of October. The average annual rainfall for the district as a whole is 3,028.9 mm. (119.25"). The rainfall increases rapidly from the coast Howards the Western Ghats on the eastern border of the district. In the coastal strip the annual rainfall decreases from south to north. Uran and Alibag at the northern end of the coast get annually 2,072.3 mm. (81.58") and 2,080.8 mm. (81.92") of rain, respectively, Matheran gets as much as 5,167.5 mm. (203.45") of rain annually. Nearly 95 per cent, of the annual rainfall is received during the south-west monsoon months, and the rainfall in October forms the major portion of the rest. July is the month with the heaviest rainfall, the same being 38 per cent of the annual rainfall. Temperature: Being a coastal district the diurnal (daily) and seasonal variations of temperature are not large. The period from March to May is one of increasing temperatures. May is the hottest month with a mean daily maximum temperature at 31.7 C (89.1 F) and the mean daily minimum temperature at 26.4 C (79.5 F). Fresh breezes from the sea relieve the oppressive heat particularly in the coastal regions in the afternoons. The onset of the south-west monsoon early in June brings down the temperatures slightly. After the withdrawal of the south-west monsoon by the end of September the day temperatures increase slightly and the weather in October and November is almost like the summer months. In the period from December to February the weather is cooler than in the post-monsoon months. 19

21 Humidity: The air is humid throughout the year. Relative humidity is on an average over 80 per cent during the south-west monsoon season. In the rest of the year the relative humidity is between 65 per cent and 75 per cent. Cloudiness: During the south-west monsoon season skies are heavily clouded to overcast. In May and October the clouding is moderate. Clear or very lightly clouded skies are common in the rest of the year. Winds: Winds are very strong and blow from west or south-west during monsoon season. During the period from October to December winds are generally moderate but sometimes strong in October and blow from directions between north-east and south-east. In the three months from January to March the winds continue to be moderate and are predominantly from directions between north and east. In April while there is a slight strengthening of wind, the direction is variable. In May there is a further strengthening of winds and the directions are between south-west and north-west. Special weather phenomena: In association with cyclonic storms in the Arabian sea in the post-monsoon months and to a lesser extent in May, the district experiences very strong winds, sometimes reaching gale force, particularly very near the coast and also heavy widespread rain. Occasionally these storms may cross the coast in the northern part of the district and cause heavy damage. Thunderstorms occur in April and May and just before the onset of the monsoon and in the late September to the middle of November. 20

22 Chapter 5 Planning Brief 5.1 Planning Concept: Plot is at well-established Mahad MIDC area Purified Water supply from MIDC Well-developed roads and connectivity. Infrastructure facilities available established MIDC site Integration with the existing plant of MACL manufacturing facility 5.2 Population Projection: In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345 and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which males were 1,117,628 and remaining 1,090,301 were females. Raigad District population constituted 2.34 percent of total Maharashtra population. In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population. There was change of percent in the population compared to population as per In the previous census of India 2001, Raigad District recorded increase of percent to its population compared to The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas. 5.3 Assessment of Infrastructure Demand (Physical and Social): No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC area. 21

23 Chapter 6 Proposed Infrastructure Since the establishment is planned at existing plant site in developed industrial area, no special/specific development is anticipated. Company will have to do internal site development only. Company has not planned any residential area at the proposed site as MIDC has already existing Residential areas earmarked for housing colonies. 6.1 Industrial area: Maharashtra Aldehydes and Chemicals Limited Plot no A 17, MIDC Mahad proposes to expand manufacture of synthetic organic chemicals based on demand and market projection. 6.2 Residential Area: No Residential area has been proposed within the plant site. 6.3 Green Belt: Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement. 6.4 Social Infrastructure: Local people will be given preference wherever found suitable for all the jobs in the plant, direct as well as indirect. Thus the project shall have a positive impact on the employment pattern of the region. Economic status of the local population will improve due to increased ancillary/business opportunities, thereby making positive impact. Educational, medical & housing facilities will improve due to the proposed project. 6.5 Connectivity: This proposed expansion project facility shall be located at Mahad MIDC area, in Raigad district, Maharashtra. The Site is 7 km from Mahad town and 17 km from nearest railway Station. The land and infrastructure is made available by MIDC and the raw material is easily available through the easy transport via road connectivity. 6.6 Water Management: 22

24 The total water requirement is about 481.5cmd for Domestic, boiler/cooling, and process. The source of water shall be from MIDC. The water supply will be through the good offices of MIDC. We will not be encroaching on anybody s water source. 6.7 Sewage and waste water treatment system: Existing Effluent treatment scheme: The treatment of effluent arising from plant is achieved through multiple stages as follows, A. Primary treatment B. Secondary Treatment C. Tertiary Treatment Total 91.5 m3/day effluent will undergo three stages of treatment involving following steps. A. Primary Treatment:- This step includes neutralization and physical separation incorporating the following: Neutralization Tank Equalization Tank Chemical dosing system(lime/alum) Primary Clarifier The effluent will collected in neutralization tank. Provision is made for alkali dosing as required for neutralization. Uniform mixing will be achieved by providing aeration grid (air sparing) in the tank. After completion of neutralization, the effluent will be pumped to equalization tank. Effluent from equalization tank feed to primary clarifier tank for solid liquid separation in primary treatment. Overflow from primary clarifier will be gravitate to Evaporation Pond & then it pumped to Aeration tank for further Biological treatment. B.Secondary Treatment: Secondary treatment includes single stage degradation of effluent. Aeration Tank Secondary Clarifier Sludge dewatering system The effluent will be uniformly gravity to Aeration tank to biologically degrade the organic matter. The Oxygen required for the biological growth was supplied through Surface Aerator System. The overflow from Aeration tank will gravities to Secondary Clarifier. The settled sludge will be pumped back to the Aeration Tank to maintain the bacterial concentration in the tank. The excess sludge in the system will be sent to Sludge Drying Beds for sludge dewatering. The dried sludge will be sent to Hazardous Waste Facility. Overflow from Secondary Clarifier will be send to tertiary treatment. 23

25 C.Tertiary Treatment. The treated effluent of 91.5 m3 after primary and secondary treatment will undergo tertiary treatment. Overflow from Secondary Clarifier will be collected to intermediate tank and effluent will be pumped to Sand Filter and Activated Carbon Filter. After Tertiary Treatment effluent collected in HDPE tank and from this tank 24 m3 effluents recycle to cooling tower makeup remaining send to CETP through flow meter to Lock & Key tank, as per MPCB guideline and then effluent disposed off to MIDC common drainage system for further treatment to CETP. Expected Effluent Characteristics Sr. No. Parameter Before Treatment After Treatment 1 ph BOD 2750 mg/l Less than 100 mg/l 3 COD 4950 mg/l Less than 250 mg/l 4 TDS 3400 mg/l Less than 2100 mg/l 5 SS 250 mg/l Less than 100 mg/l 6 Oil & Grease 8 mg/l BDL i.e. less than 10mg/L 7 Sulphate 2450 mg/l Less than 1000 mg/l 8 Total Ammonical nitrogen 31 mg / l Less than 50 mg /l 9 Chlorides 885 mg/l Less than 600 mg/l 24

26 Chapter 7 Rehabilitation and Resettlement (R & R Plan) The proposed expansion facility shall be at plot of the company which is located in Mahad MIDC area. It does not require acquisition of Land and the Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement carried out. 25

27 Chapter 8 Project schedule and cost estimates 8.1 Time schedule of the Project It is expected that the project shall be completed within 18 months from date of grant of Environmental clearance. 8.2 Estimated project cost (Economic Viability of the Project) Total estimated project cost is Approx. 50 Crores 26

28 Chapter 9 Analysis of Proposal 9.1 Financial and Social Benefits With an increased capacity, we shall be creating new jobs thereby empowering the local population with additional spending power. As industries grow in a hub, the social structure of the area improves with additional facilities such as schools, technical training centers, hospitals, etc being made available in the smaller towns. This has a long term impact on the financial & social improvement thereby reducing the migration of population to urban centers in search of livelihood & better living conditions. 27

29 Annexure I Land allotment letter 28

30 Annexure II Site & surrounding study area of 1 km 29

31 Site & surrounding study area of 10 km 30

32 Annexure III Proposed Layout Plan 31

33 Structure no in Layout Area statement Details of Existing built up area Structure name Existing Area in sq.meter 1 Main Plant Building A Column Area b DEP extended area 123 1C Dryer room D DEP extended area 80 2 Raw material Store Explosive tank farm Effluent Treatment plant Monoester Plant 123 5A Monoester Plant expansion Meter room A PCC room 42 7 Transformer yard 50 8 Admin building &QC lab TR cooling tower A 40TR cooling tower 4 9B 75 TR cooling tower 6 9c 120TR cooling tower 8 10 Water storage tank A Process Water storage tank Utility Building A Extended utility building PAN store area Acid storage tank farm collection sump ETP Tank DEP finish product tank farm DEP process storage tank farm finish product Packing shed Security cabin old security cabin Alcohol storage tank farm old security cabin Alcohol storage tank farm Condensed collection tank 4 27A Condensed collection tank 4 28 Boiler

34 Pipe rack Total Existing Built-up area Total Permissible Area in (Sq.Meter) 20,000 1 Total Existing built up area(sq.meter) Total proposed built up area(sq.m) 2500 Parking area (Sq.meter) 1 Near Main security gate 55 2 Near store Loading unloading area Near Old security cabin 70 4 Near Alcohol unloading point 56 5 Near ETP area 70 6 Near PAN store area 105 Total Parking area (Sq.meter)