PRE FEASIBILITY REPORT

Transcription

1 PRE FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY AND INTRODUCTION OF THE PROJECT The Proposed Th Proposed Food Colours and Lake Colours Manufacturing Unit will be established on Plot 22/1 - B, Dhatav, MIDC Roha Tal.: Roha, Dist.: Raigad, (Maharashtra). The location of the Industry is towards west side and at a distance of about 3.5 Km from Roha City. 1.1 Need of the Project The basic application of synthetic food colours or artificial food colours include colouring of food items, pharmaceutical and cosmetic industries, personal care products, dairy products, confectionary, bakery, sweet meats etc. Addition of a suitable colour enhanced the appearance of fresh and process foods. Presently, there is global trend towards the more usage of natural colours in food, pharmaceutical and personal care industries. Due to adverse effect of synthetic dyes, all countries have made strict regulations about the permitted colours to be used as food additives. Most of the countries have prohibited the use of several synthetic dyes as food colouring agents and permitted a limited number of synthetic colours under specified maximum limits. The ever-increasing demand for food colours as well as lake colours in India and abroad has encouraged the promoters to go for food colours and lake colours manufacturing unit. 2.0 PROJECT DESCRIPTION 2.1 Location Site selection for setting up a project is governed by some criteria which includes certain conditions. The same are proximity to sources, proximity to end users, and availability of infrastructure like land free of encumbrance, railway, road, power, water and manpower. The proposed site is well connected by roads. The site is 3.5 Km from the city Roha. The Roha Railway Station is 3.61 Km and Mumbai Airport is Km from proposed project site. 2.2 Alternative Site No any alternative sites were examined since the proposed site is located in Dhatav area, Roha MIDC at Raigad and plot was allotted for same by the Govt. 2.4 The Products The different products considered for manufacture & its maximum production quantities are as under.. Table 1 List of Products 1. Food Colours: 9.5 MT/Day Quantity Name of Product a. Carmoisine 2000 Kg/Batch b. Ponceau 4R 2020 Kg/Batch 1

2 Quantity Name of Product C. Sunset Yellow FCF 2300 Kg/Batch d. Tartrazine 1800 Kg/Batch e. Green 2000 Kg/ Batch Solvent Green 7(Green 8) f. Red Pigment Red 57 (Red 6) 1100 Kg/Batch Red Kg/Batch Solvent Red 43(Red 21) 900 Kg/Batch Acid Phloxine B (Red 27) 770 Kg/Batch Acid Red 92(Red 28) Acid Red 33 (Red 33) g. Violet Acid Violet 49(Violet 2) h. Yellow C.I.Solvent Yellow 172(Yellow172) 480 Kg/Batch 1350 Kg/Batch 1470 Kg/Batch 2250 Kg/Batch Note: Total 9.5 MT/Day of Food Colours shall be manufactured. Thereunder, daily one batch each from above products from (a) to (h) shall be carried out. 2. Lake Colours: 2.5 MT/Day Name of Product 1. Lake Colours 2. Ponceau 4R Aluminium 3. Sunset yellow Aluminium 4. Tartrazine Aluminium 5. Red Pigment Red 57(Red 6 Barium Lake) Red 7 calcium lake Acid Phloxine B (Red 27 Aluminium) Acid Red 92(Red 28 Aluminium) Acid Red 33(Red 33 Aluminium) 6. Yellow yellow 6 Aluminium Quantity 2010 Kg/ Batch 192 Kg/ Batch 165 Kg/ Batch 500 Kg/ Batch 592 Kg/ Batch 610 Kg/ Batch 600 Kg/ Batch 3. Intermediates: 7 MT/Day Quantity Name of Product Intermediates a. Sulphanilic Acid 1750 Kg/Batch 2

3 2.5 Investment The expected cost of the proposed project will be around Rs. 8.5 Crores. 2.6 Process Details The manufacturing of food colours and lake colours comprises of a number of operations and processes involving various chemical reactions of basic raw materials. Eventually, the desired products are formed which are refined and separated. Water The daily water requirement for various process operations in proposed project activity would be to the tune of 375 M 3 /Day Out of which 227 M 3 /Day would be Fresh Water & 148 M 3 /day recycle condensate water. Fuel In the proposed project, Coal, Furnace Oil and Diesel would be used as fuel for Boiler, Thermic Fluid Heaters and D.G Set respectively. Coal Diesel Fuel Table 2 Fuel Consumption Total Quantity 28.5 MT/Day 60 Lit./Hr Manpower In the proposed project about 50 skilled and 25 unskilled workers would be appointed. Preference shall be given to persons from local area thereby creating better employment opportunities. 2.7 Environmental Aspects under the Project A) The Effluents i) Domestic Effluent - Domestic effluent to be generated from proposed activity would be 10 M 3 /Day and same shall be treated in proposed Sewage Treatment Plant (STP) i) Industrial Effluent - The effluent generated from the proposed activity would be segregated in two different Streams viz. Stream I and Stream II. Further, the effluent from above streams would be treated in Effluent Treatment Plant comprising of Multiple Effect Evaporator Systems. The details w.r.t effluents considered under Stream I and Stream II are as follows: Stream I Comprises of Process Effluent 70 M 3 / Day and Washing would be evaporated in Multiple Effect Evaporator (MEE) Systems installed to process plant. Stream II Comprises of lake colours 86 M 3 /Day, and Washing of equipments and floors- 10 M 3 /Day (Total 96 M 3 /Day). This effluent would be given primary treatment of Neutralization and Settling. 3

4 The details of wastewater generation under proposed operations is as follows- Table 3 Details of Effluent Generation Description 1. Domestic 2. Industrial Effluent Generation (M 3 /Day) Losses (M 3 /Day) 8 2 a) Process b) Washing of 70 M 3 /Day Equipment 10 (Strong Stream i.e Filtrate from Nil s & Floors Food Colour & Intermediates c) Cooling Industrial Total (a+b+c) 3. Gardening & others 5 96 M 3 /Day + Weak Stream i.e Filtrate 120 from Lake & Washing Nil 50 In proposed STP In proposed ETP Installation of Multiple Effect Evaporation System for evaporating the trade effluent generated from proposed activities would result in ZERO DISCHARGE of effluent as per the CREP Norms. B) The Emissions In the proposed Food and Lake Colourant Manufacturing Unit, main source of emissions would be the boiler house from where steam for operations in the plant would be taken. A boiler of 3 TPH capacity will be installed in the proposed project. Imported Coal to the tune of 20 MT/Day would be used as fuel for boiler. The boiler stack emissions would mainly contain SPM/TPM and SO 2. APC equipment in the form of pulse jet bag filter will be provided for the 3 TPH boiler. One DG sets of capacity 500 KVA and two thermic fluid heaters of 10 Lakh Kcal/Kg and 4 lakh Kcal/ Kg respectively will be installed onsite. Diesel to the tune of 60 Lit/ day will be used as fuel for D.G set and Coal will be used for Thermic Fluid Heater. DG set will be used only during power failure. Table 4 Details of Stack Description Details 1. Stack number (s) Thermic Thermic D.G.Set Attached to Boiler Fluid Heater Fluid Heater Lakh 4 Lakh 500 KVA Capacity 3 TPH Kcal/Kg Kcal/Kg 4. Fuel type Imported Imported Imported HSD 4

5 Description Details Coal Coal Coal 5. Fuel Quantity 20 MT/Day 6 MT/ Day 2.5 MT/Day 60 lit/hr 6. Material of construction M.S. M.S. M.S Shape -- Round Round Round (round/rectangular) 8. Height, m (above ground level) 33 M 35 M 30 M 5 M ARL 9. Diameter/size, in meters 0.5 M 0.5 M 0.5 M Internal Diameter of the 0.45 M 0.45 M 0.45 M -- stack at the top in meters 11. Gas flow rate in Nm 3 /Hour Nm 3 /Hour Nm 3 /Hour Nm 3 /Hour 12. Stack diameter at 0.45 M 0.45 M 0.45 M -- sampling port in meters 13. Calorific value 7000 kcal/ kg / kcal/ kg 7000 kcal/ kg / kcal/ kg 7000 kcal kg / kcal kg 14. Ash content 10% 10% 10% Sulphur content 0.5%/4.5% 0.5%/ 4.5% 0.5%/4.5% Control Equipment Pulse Jet type Bag Filter Pulse Jet type Bag Filter -- C) Fugitive Emissions There would be chances of fugitive emissions due to handling of process emissions, chemicals as well as solvents. However to prevent and control same, adequate and efficient systems shall be provided. The same would comprises of scrubbing arrangements to absorb the process gases, carrying out entire process in the closed reactors, handling of solvents in close circuits etc. D) Noise Pollution Aspect There would be no major noise generating sources in the proposed project. The probable sources shall be Boiler, Thermic Fluid Heaters, Reactors, Compressors and D.G.Set. The same would be kept in isolated areas. Further, proper acoustic treatments wherever required would also be provided to have the ambient noise levels as per CPCB standards. The workers would be provided with earmuffs and other Personal Protective Equipments (PPE) which would give the reduction of 30 db (A). The D.G. set would not be a continuous source of noise as it would be operated only during power failure. As per the Noise Pollution Regulation and Control Amendment Rules; 2010, the DG set would be properly and adequately provided with acoustic enclosures E) Solid Wastes Solid wastes generated from the proposed project are categorized as Hazardous and Non-Hazardous Wastes. Solid waste generated would be in the form of Boiler Ash of imported coal to the tune of 1.5 MT / Day and same would be forwarded to brick manufacturers. -- 5

6 The entire quantity of hazardous waste will be handled and disposed as per Hazardous Waste (Management, Handling and Trans boundary Movement) Rules Hazardous Waste in the form of Process Residue, ETP Sludge and Discarded Containers and Drums will be generated. The unit would provide dedicated and isolated storage arrangement for the hazardous wastes. The area shall have leachate collection system, impervious floor and covered roof. Trained and experienced staff shall be employed for collection and handling of the wastes. Category Table 5 List of Hazardous Waste Generation Type of hazardous waste/ By Product Quantity (Kg/M) Process Residues and wastes 2 MT/M Chemical sludge from waste water treatment 150 MT/M Disposal Would be forwarded to CHWTSDF Discarded Drums / Containers 2200 / M Would be sale to Authorized re-processor Table 6 List of Solid Waste Generation Solid waste Type of Waste Disposal generation 1. Boiler Ash 1.5 MT/Day Sold to brick manufacturers for secondary use 3.0 SITE ANALYSIS 3.1 Connectivity The proposed activity is scheduled to commence at a site in Roha MIDC, Dist.: Raigad. The site is located at a rural surrounding and its nearest railway station is Roha railway station, located at about 3.61 Km and nearest airport is Mumbai airport, located at about Km from the proposed site. 3.2 Land Form, Land Use and Ownership: The premises have a gentle terrain. Soil is mostly, Yellowish Red colour and loamy in texture. Land use is industrial as the area has been developed by MIDC for industrial activity 3.3 Topography Raigad is a coastal district situated on the west coast of India. It is slightly elongated in the North - South direction and has a long indented coastline. The length of the coasts is about 160 Km and the length of the coast line is about 240 Km with a number of creeks and inlets. 3.4 Existing Land Use Pattern The total geographical area of Raigad district is about Sq. Km. It can be visualized that about 30.1 % is cultivable area of total land area. 6

7 3.5 Existing Infrastructure MIDC has acquired Hectares of land for the development of industrial belt. Basic infrastructure viz. good roads, water supply, storm water system, street lights, common facility centers, recreation, communication facilities, bank, post office, telephone exchange etc. are available in this area. 3.6 Soil Classification The soil found in the district is forest soil, varkas soil, rice soil, khar or salt soil, coastal alluvium and laterite soil. A thin layer of soil containing humus and organic materials are found in the deep-forested area, which yields valuable forest products and are not used for agriculture. These soils are heavily eroded due to grazing and cutting of forest trees. 3.7 Climate The climate of the district is typical of that on the west coast of India, with plentiful, regular and seasonal rainfall during the monsoon season. The year may be divided into four seasons; the summer season from March to May, the rainy season from June to September, the post-monsoon season in October and November, and the winter season from December to February. The average annual rainfall for the district as a whole is mm. The air is humid throughout the year. Winds are very strong during the monsoon season and blow from west or south-west. 3.8 Social Infrastructure Available The area is well served with infrastructural facilities such as road, rail, power station, and telecommunications. Fire Station: - MIDC has developed a Fire Station which is run by Roha Manufacturers Association. Truck Terminus and Bus Stop: - A truck terminus is available in the region to be developed. Common Facility Centre: - This facility centre houses includes post office and rest house. Many other facilities are planned to develop in the centre. Connectivity:- MIDC has developed a telephone exchange building in this area. Power Supply: MIDC has developed MSEB. This ensures the supply of electricity to the region. 4.0 PLANNING BRIEF 4.1 Planning Concept There are about 915 Nos. of industries in Raigad Region. Out of which 336 Nos. falls under red category, 202 orange category & remaining falls under green category. Availability of amenities like education, medical, water supply, communication, road network, electricity etc. significantly reflects the level of development of the area. 7

8 4.2 Population Projection According to Census 2001, district Raigad has a total population 2,207,929, comprising of 1,117,628 males and 1,090,301 females. The population of the district in Census 2001 is 21% higher than the district population of 1,824,816 in 1991 Census. The average growth rates for the rural and urban areas of the district are 11.8 % and 62.7 % respectively. The proportion of urban to total population in Raigad district stands at 24.2 % in 2001 as it was 18 % in 1991 indicating a slow pace of urbanization in the district. 5.0 PROPOSED INFRASTRUCTURE 5.1 Industrial Area As mentioned above, MIDC has acquired Ha of land for the development of industrial belt. The total land acquired by the project proponent in MIDC is 1.7 Ha. Under the proposed activity a systemic green belt would be developed in consultation with the district forest officer. The detailed area statement for the proposed project is as follows- 5.2 Greenbelt & Rain water Harvesting A plot admeasuring of 17,990 Sq.M. i.e. 1.7 Ha is been allotted to M/s. Arjun Food Colourant Mfg. Pvt. Ltd. by MIDC. As per MoEF norms, an area of about Sq. M. would be developed under the green belt which accounts 33% of the open area of the industry. 5.3 Social Infrastructure MIDC has developed internal roads, as well as it is provided with good connectivity facilities. 5.4 Connectivity The proposed activity is scheduled to commence at a site in MIDC Roha, Dist.: Raigad. The site is located at a rural surrounding and nearest railway station is Roha, located at about 3.66 Km and nearest Airport is Mumbai, located at about Km. 5.5 Drinking Water Management The main source of the water for processing as well as domestic purpose in proposed unit will be water supply scheme of MIDC. 5.6 Sewerage System The domestic effluent would be treated separately in proposed STP Plant. 5.7 Industrial Waste Management Industrial Effluent Industrial Effluent The trade effluent generated from the industry would passes through the physicochemical treatment, biological Treatment and tertiary treatment. Further, the treated effluent would be recycled for various in plant purposes. 8

9 Emissions - The unit proposes to install Pulse Jet Type Bag Filters as an Air Pollution Control Equipment. Hazardous Waste - The quantity of hazardous waste generated would be forwarded to CHWTSDF. Solid Waste - Solid waste generated in proposed unit would be sold to brick Manufacturer. 5.8 Solid Waste Management Solid waste in the form of boiler ash would be generated and the same would be given to brick manufacturer. 5.9 Power Requirement & Supply / Source The power requirement would be fulfil through MSEB. In case of a power failure, DG set would used to provide and uninterrupted power supply to emergency facilities provided. 6.0 REHABILITATION & RESETTLEMENT (R& R) PLAN 6.1 Policy to Be Adopted As the project site is located in approved industrial area developed by MIDC, there are no rehabilitation & resettlement issues involved 7.0 PROJECT SCHEDULE & COST ESTIMATES 7.1 Date of Start The construction work w.r.t. proposed project would be initiated after grant of Environmental Clearance. 7.2 Estimated Project Cost The expected cost of the proposed project will be around Rs. 8.5 Crores. The capital as well as O & M Costs towards Environmental aspects in the industry is as follows Table - 7 Operation & Maintenance Costs Description Cost Component Capital (Rs. Lakhs) O & M per Year (Rs. Lakhs) 1. Capital Cost of the ETP Cost towards APC Equipment in the form of 30 5 Pulse Jet type Bag Filter and stack 3. Cost incurred on the Green Belt Development Environmental Management Plan and -- 5 Monitoring 5. Cost towards Noise Pollution Control CSR Activities for next Three years

10 Description Cost Component Capital (Rs. Lakhs) O & M per Year (Rs. Lakhs) Total ANALYSIS OF PROPOSAL The proposed food colours and lake colours manufacturing unit has low pollution potential. Water use will be minimized to improve the process. Water pollution potential of the project will be mitigated by treatment of effluent in Effluent Treatment Plant and thereafter it will be recycled for in plant process. The air pollution potential of the project will be mitigated by providing Pulse Jet Type Bag Filter as air pollution control system. For minimization/prevention of the fugitive emission, regular maintenance of valves, pumps and other equipments will be done. To prevent leakage entire process will be carried out in the closed vessel as well as would provide with adequate scrubbing system for efficient absorption of process gas. Adequate arrangement for handling and disposal of Hazardous Solid waste will be made. Fire protection and safety measures would be provided to take care of fire and explosion hazard. Direct and indirect employment opportunities would be extended to the nearby resident. The proposed project would be implemented by adopting latest technologies and equipments thereby minimizing the pollution load in Environment. 10