PRE - FEASIBILITY REPORT. M/s. S. R. CHEMICALS

Transcription

1 PRE - FEASIBILITY REPORT for PROPOSED EXPANSION BULK DRUG AND BULK DRUG INTERMEDIATES PLANT IN EXISTING PREMISES of M/s. S. R. CHEMICALS PLOT NO. 7516, GIDC ESTATE, ANKLESHWAR, DISTRICT: BHARUCH, GUJARAT Prepared By: NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company Aqua-Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat

2 CONTENTS Sr. No. Description Page No. 1. Executive Summary 3 2. Introduction of the Project/Background information Project Description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation and resettlement (R& R) Plan Project Schedule & Cost Estimates Analysis of Proposal (Final Recommendations) 21 2

3 1.0 EXECUTIVE SUMMARY 1.1 Company Profile M/s S. R. Chemicals proposes expansion of manufacturing of Bulk Drugs and Bulk Drug intermediates at Plot No. 7516, G.I.D.C. Estate, Ankleshwar, Dist-Bharuch (Guj.). 1.2 Project Detail Products along with Production Capacity \ Sr No Product Cas No. Existing Capacity (MT/Month) Additional Capacity (MT/Month) Total Capacity (MT/Month) Existing Products 1. Sodium Acetate Sodium Nitrite Di Sodium Phosphate / Mono Sodium Phosphate / Tri- Sodium Phosphate or/and 4. Di Ammonium Phosphate/ Mono Ammonium Phosphate/ Tri-Ammonium Phosphate or/and 5. Di Calcium Phosphate or/and 6. Pottasium Chloride/ Pottasium Nitrate/ Pottasium Sulphate or/and Calcium Nitrate/ Calcium Chloride or/and Sodium Sulphate or/and Boric Acid or/and Zinc Sulphate / Copper Sulphate/ Ferrous Sulphate or/and By-Product Sodium Nitrate (92%)

4 Proposed Products 11. Para Chloro Benzoic Acid Para Nitro Benzoic Acid Ortho Chloro Benzoic Acid Di Chloro Benzoic Acid Para Bromo Benzoic Acid Chloro,3-Nitro Benzoic Acid Chloro,5-Nitro Benzoic Acid Chloro 5-Nitro Benzoic Acid Pure Nitro,4-Methoxy Benzoic Acid 20. Phenoxy Acetic Acid Chloro Salicyclic Acid Di Methyl Amino Ethyl Chloride Hydro Chloride 23. Phenyl Acetic Acid Di Methyl Urea Mono Methyl Urea Nitro Chloro Benzo Phenone (NCBP) 27. Nitro Amino Benzo Phenone (NABP) 28. 3,4-Di Amino Benzo Phenone Total

5 Raw Material Requirement List of Raw Materials And Their Capacity: Sr. Raw Materials No. Existing Products [1] Sodium Acetate Quantity (MT/MONTH) 1. Sodium Acetate soln. (30%) 670 [2] Sodium Nitrite 1. Sodium Nitrite soln. (20%) 1000 [3] Di/Mono/Tri - Sodium Phosphate Di Sodium Phosphate 1. Dilute Phosphoric Acid Sodium Hydroxide 120 Mono Sodium Phosphate 1. Dilute Phosphoric Acid Sodium Hydroxide 120 Tri - Sodium Phosphate 1. Dilute Phosphoric Acid Sodium Hydroxide 120 [4] Di/Mono/Tri - Ammonium Phosphate Di Ammonium Phosphate 1. Liq. Ammonia Dilute Phosphoric Acid 200 Mono Ammonium Phosphate 1. Liq. Ammonia Dilute Phosphoric Acid 200 Tri Ammonium Phosphate 1. Liq. Ammonia Dilute Phosphoric Acid 200 [5] Di Calcium Phosphate 1. Calcium Carbonate Dilute Phosphoric Acid 180 [6] Pottasium Chloride/Nitrate/Sulphate Pottasium Chloride 1. Potassium Chloride soln. (20%)

6 OR 1. Potassium Carbonate Dilute Hydrochloric Acid 300 Pottasium Sulphate 1. Potassium Sulphate Soln.(20%) 1000 OR 1. Potassium Carbonate Sulphuric Acid 300 Pottasium Nitrate 1. Potassium Nitrate Soln.(20%) 1000 OR 1. Potassium Carbonate/ Potassium Chloride/ 110 Potassium Sulphate 2. Dilute Nitric acid Sodium Hydroxide /Soda Ash 120 [7] Calcium Nitrate/Chloride Calcium Nitrate 1. Calcium Nitrate Soln. (20%) 1000 OR 1. Limestone or Calcium Carbonate Dilute Nitric acid 300 Calcium Chloride 1. Calcium Chloride Soln. (30%) 670 [8] Sodium Sulphate 1. Sodium Sulphate Soln. (30%) 670 OR 1. Sodium Hydroxide Dilute Sulphuric Acid 70.0 [9] Boric Acid 1. Dil. HNO 3 (60%) Borex Penta Hydroxide (Crude Borex) 338 [10] Zinc/Copper/Ferrous Sulphate Zinc Sulphate 1. Zinc Sulphate Soln. (20%) 1000 OR 1. Zinc Oxide Sulphuric Acid 100 6

7 Copper Sulphate 1. Copper Oxide Sulphuric Acid 80.0 Ferrous Sulphate 1. Iron Scrape Dilute Sulphuric Acid By product ( Sodium Nitrate) Sodium Nitrate soln. (20%) 1000 Proposed Products [11] Para Chloro Benzoic Acid MT/MT 1. Para Chloro Toluene (PCT) Nitric Acid (HNO3) 60% NaOH Lye 48% [12] Para Nitro Benzoic Acid 1. Para Nitro Toluene (PNT) Nitric Acid (HNO3) 60% NaOH Lye 48% [13] Ortho Chloro Benzoic Acid 1. Ortho Chloro Toluene (OCT) Nitric Acid (HNO3) 60% NaOH Lye 48% [14] Di Chloro Benzoic Acid 1. Di Chloro Toluene (DCT) Nitric Acid (HNO3) 60% NaOH Lye 48% [15] Para Bromo Benzoic Acid 1. Para Bromo Toluene Nitric Acid NaOH Lye 48% [16] 4-Chloro-3 Nitro Benzoic Acid 1. Para Chloro Benzoic Acid Nitric Acid 98% (CNA) NaOH Lye 48% 0.10 [17] 2 Chloro 5 Nitro Benzoic Acid 1. Ortho Chloro Benzoic Acid

8 2. Nitric Acid 98 % MeOH NaOH Lye 48% 0.10 [18] 2 Chloro 5 Nitro Benzoic Acid Pure 1. 2 Chloro 5 Nitro Benzoic Acid MeOH 1.00 [19] 3 Nitro 4 Metoxy Benzoic Acid 1. 3 Nitro 4 Chloro Benzoic Acid NaOH (lye or Flacks) MeOH HCl [20] Phenoxy Acetic Acid 1. Mono Chloro Acetic Acid Soda Ash NaoH (lye / Flacks) Phenol HCL [21] 5 Chloro Salicylic Acid 1. Salicylic Acid EDC or MDC Chlorine Gas [22] Di Methyle Amino Ethyle Chloride Hydro Chloride 1. DENOL (Di Methyle Amino Ethyle) SOCl Caustic Lye [23] Phenyl Acetic Acid 1. By Product Solution H2So4 98% Toluene [24] Di Methyl Urea 1. Urea Mono Methyle Amine

9 [25] Mono Methyl Urea 1. Urea Mono Methyle Amine [26] Nitro Chloro Benzo Phenone (NCBP) 1. NCBA Thionyl Chloride Benzene DMF AlCl [27] Nitro Amino Benzo Phenone (NABP) 1. NCBP Liq. Ammonia 1.78 [28] 3, 4-Di Amino Benzo Phenone 1. NABP Polysulfide Methanol 2.4 9

10 1.4 Water Requirement, Waste Water Generation and Treatment Source of water will be met through Anklehwar GIDC Water Supply. Total water requirement will be 14 m 3 /day. Total 6.5 m3/day (5.0 m 3 /day Industrial m 3 /day domestic) of effluent shall be generated. 5.0 m 3 /day of Industrial effluent will be treated in ETP then sent it to ETL, Ankleshwar for further treatment and disposal. Domestic Waste water will be disposed by septic tank & soak pit. 1.5 Air Pollution Source and Control Management There will be flue gas emission from Boiler, THF, Furnace and D.G. Sets and process gas emission from process vent only. Company will install Multi cyclone separator, Bag Filter and Water Scrubber to reduce air pollution. 1.6 Hazardous Waste Sr. Category No No Type of waste Discarded Containers Used/Spent Oil Sodium Nitrate(92%) Sodium Acetate Potassium chloride sol. Existing Proposed Total Disposal Method 17 Nos/Month 4.2 Kg/ Month Nos/ Month 54.2 Kg/ Month Nos/ Month 58.4 Kg/ Month Collection, Storage, Transportation, Disposal by selling to registered recycler Collection, Storage, Transportation, Disposal by selling to registered recycler Collection,Storage, reuse in manufacturing process within plant. Collection, Storage, Transportation, Disposal by selling to registered re-refiners. Reception (From-Gujarat Insecticide Ltd. Ankleshwar),storage, reuse in manufacturing process within plant. 10

11 Distillation Residue ETP sludge Dilute Nitric Acid (25% to 30%) Liqour Ammonia Aqueous Aluminium Chloride Spent HCL Sodium Nitrate/ Nitrite 20 to 30% MT / Month 8.3 MT / Month MT / Month 8.3 MT / Month 50 Collection, Storage, Transportation and dispose to common incineration Site or coprocessing in cement industries Collection, storage, transportation and dispose common TSDF site Collection, Storage and reuse in plant premises and Sell to Registered Party / End User Collection, Storage and reuse in plant premises and Sell to Registered Party / End User Collection, Storage and reuse in plant premises and Sell to Registered Party / End User Collection, Storage and reuse in plant premises and Sell to Registered Party / End User Collection,Storage, reuse in manufacturing process within plant or sell to end user. 1.7 Green Belt Total 980 sq. meter land area is available at site; out of this area about 325 sq. meter area (33% of total land area) will be developed as greenbelt and other forms of greenery. 1.8 Power & Fuel Requirements FUEL: Existing: Wood= 300 kg/day, Agro based bio fuel= 700 kg/day 11

12 Proposed: Biocoal= 3 MT/Day Diesel= 100 Lit./Day (Only for emergency). ENERGY: Existing: Power required from DGVCL is 27 HP. Proposed: Power required from DGVCL will be 98 HP. 1 DG Set= 125 KVA (for Emergency case only) 2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 2.1 Identification of the project and project proponent. In case of mining project, a copy of mining lease/letter of intent should be given. Identification of the project and project proponent S. R. Chemicals proposes expansion of manufacturing of bulk drug and bulk drug intermediates at Plot No. 7516, G.I.D.C. Estate, Ankleshwar, Dist-Bharuch (Guj.). Project Proponent: Ishwarbhai P. Sajjan (Partner) 2.2 Brief description of nature of the Project Proposed expansion of Bulk Drug and bulk drug intermediates manufacturing unit in existing premises. 2.3 Need for the project and its importance to the country and or region The demand for products intended to be manufacture is increasing in the country by setting up this unit, Company will be able to meet the demand of various products locally. The project will save forex as certain products import will be reduced. This will also generate direct and indirect employment opportunity for various levels of people. 2.4 Demands-Supply Gap Based on our informal survey of the market with our current customers and various traders, we have found that there is a big potential for the range of the products we are planning. 12

13 2.5 Imports vs. Indigenous production Based on the current cost of indigenous raw materials and the non availability of some materials, we will have to import some of the key raw materials as they are not available indigenously. This will make us very competitive against imported finished products and we will export of our finished products in the international market. 2.6 Export possibility We shall explore the possibility of export the products. 2.7 Domestic/Export Markets Our products have good demand in international market. We shall explore the possibility of export the products. 2.8 Employment Generation (Direct and Indirect) due to project. M/s. S. R. Chemicals will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. 3.0 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any. No interlinked project has been submitted. Location (map showing general location, specific location and project boundary & project site layout) with coordinates. 13

14 Map showing general location. PROJECT SITE 14

15 Specific location and project boundary Project Site (Google Map) 15

16 Project Site (Google Map of 10 km ) 16

17 Plant Layout 17

18 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Looking to the international market demand of the products it was decided by M/s. S. R. Chemicals to expand existing facility. Major factors involved in the selection of site are listed below: Minor site clearance activities shall be carried out to clear shrubs and weed. The project site is located on level ground, which does not require any major land filling for area grading work. Proximity to Raw Material suppliers. Site is very well connected by road and railway. Availability of Fuel, Power, CETP, TSDF, etc. within the estate. Modern infrastructure support and amenities at par in other global markets, including: Efficient transport facilities. Environment-friendly zone. Uninterrupted power supply. 3.4 Size or Magnitude of Operation Please refer Section-1.2.1, Page No Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project, etc. should be given) Please refer Please refer Form-I, Annexure-III. 3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product. For raw material required along with quantity; Please refer Section-1.3, Page No. 3. We shall procure the raw material as much as possible from domestic market and if there is no 18

19 availability of any raw material we will import. We shall explore the possibility of export the finished products. 3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. Company will explore the possibility of reuse & recycle. 3.8 Availability of water its source, energy/power requirement and source should be given. Water Source Total water requirement shall be met through Ankleshwar G.I.D.C Water Supply. FUEL: EXISTING: Wood= 300 kg/day, Agro based bio fuel= 700 kg/day PROPOSED: Biocoal= 3 MT/Day Diesel= 100 Lit./Day (Only for emergency). ENERGY: EXISTING: Power required from DGVCL is 27 HP. PROPOSED: Power required from DGVCL will be 98 HP. 1 DG Set= 125 KVA (for Emergency case only) 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. Please refer Please refer Form-I, Annexure-IV & VI. 19

20 3.10 Schematic representations of the feasibility drawing which give information of EIA purpose. ACTIVITIES OVERVIEW OF E. I. A. STUDIES SOURCE OF INFORMATION RECONNAISSANCE SURVEY OF EXISTING PLANT MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS INTRODUCTION BASELINE ENVIRONMENTAL STATUS SOCIOECONOMIC STATUS & INFRASTRUCTURE PROPOSED PLANT ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. INDIAN METEOROLOGICAL DEPT. IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX METHOD DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM IMPACTS METHODOLOGY OF IMPACT ASSESSMENT ENVIRONMENTAL MANAGEMENT PLAN FACILITY DESCRIPTION CONSEQUENCE ANALYSIS PREPARATION OF DISASTER MANAGEMENT PLAN RISK ANALYSIS STUDIES & DISASTER MANAGEMENT PLAN SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. 4.0 Site Analysis 4.1 Connectivity Site is very well connected by road Availability of fuel, power, CETP, TSDF, etc. within the estate. 4.2 Land Form, Land Use and Land Ownership Land Use will be incorporated in the EIA Study. 4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the 20

21 forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given. Existing land use pattern will be incorporated in the EIA Study. CRZ is not applicable. 4.5 Existing Infrastructure This is proposed expansion project. Site is very well connected by road Availability of fuel, power, CETP, TSDF, etc. within the estate. 4.6 Soil Classification Soil Classification will be incorporated in the EIA Study. 4.7 Climatic data from secondary sources. Climatic data will be incorporated in the EIA Study. 4.8 Social infrastructure available. Various Programs/ Projects related to Social & Economic development of surrounded area has been planned, which are as follows. A) Natural Resource Management The main focus of this program will be to maximize the yield returns of the farmers through efficient management of existing resources & extension of new agricultural practices. 1) Integrated Agricultural Growth Project For improvement and use of the modern techniques and thereby would certainly contribute to prosperity in the agriculture sector and reduce the rural poverty by programs like Farmers Training, Nursery Growing Trainings, Modern agriculture equipment distribution programs etc. 2) Animal Husbandry Projects Various programs like health checkups & treatment, vaccination program, Anti sterility camps, breed improvement etc. will be carried out. B) Income Generation Program - 21

22 1) Establishment of Self help groups. 2) Rural Entrepreneurship Development Program 3) Handcrafts Development Program 4) Vocational Training 5) Business process outsourcing C) Health, Education & Infrastructure 1) Aids Awareness Program 2) General Health Camps 3) Innovative Teaching Methods 4) Adult Education 5) Sanitation 6) Infrastructure Development Projects 5.0 Planning Brief 5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country planning/development authority classification. Type of Industry: Proposed expansion project of Bulk Drug and bulk drug intermediates in existing unit. 5.2 Population Projection Population Projection will be incorporated in the EIA Study. 5.3 Land use planning (breakup) Total Plot Area- 980 sq mt. Processing Area-450 sq mt Non-Processing area- 530 sq mt 22

23 5.4 Assessment of Infrastructure Demand (Physical& Social) Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed activity. Social Welfare Cordial relation with the villages shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 5.5 Amenities/Facilities Details of amenities available in study area Population Projection will be incorporated in the EIA Study. 6.0 Proposed Infrastructure 6.1 Industrial Area (Processing Area) Processing Area (Plant facilities, ETP Area and Utility Services) = 450 m Residential Area (Non Processing Area) Non Processing Area (Raw material storage area, finished storage area, Workshop and Engg. Store, Canteen, security cabin, green belt and open area) =530 m Green Belt Total 980 sq. meter land area is available at site; out of this area about 325 (33% of total land area) sq. meter area will be developed as greenbelt and other forms of greenery. Green Belt: 325 m Social Infrastructure Water requirement will be met through G.I.D.C Water Supply. Power supply by DGVCL. 6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways, etc.) Major factors involved in the selection of site are listed below: 23

24 Site is very well connected by road Proximity to Raw Material suppliers Availability of sufficient land free from cultivation Availability of power facilities Availability of fuel 6.6 Drinking water Management (Source & Supply of water) Total water requirement shall met through Ankleshwar, G.I.D.C. Water Supply. 6.7 Sewerage System Sewage pipes are laid in entire company for the removal and disposal of mainly nonharmful liquid wastes from the offices, canteen and domestic waste coming from different section of industry. These liquid wastes are sent to septic tank & soak pit. 6.8 Solid Waste Management Please refer Form-I, Annexure-VI. 6.9 Power Requirement & Supply/Source Please refer Section 1.8, Page No. 5 of this report. 7.0 Rehabilitation and Resettlement (R& R) Plan 7.1 Policy to be adopted (central/state) in respect of the project affected including home oustees, land oustees and landless laborers (a brief outline to be given) There is no habitation on the proposed project activity area and it is open industrial land, so R & R policy is not applicable to this project. There shall not be displacement of any population in project area. Any major activity that may lead to resettlement of the people is considered as permanent impact. Hence, there is no permanent impact on this account. The increasing industrial activity will boost the commercial and economical status of the locality up to some extent. 24

25 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given). We shall start construction of proposed expansion project after getting EC and we shall start production after applying for CCA. 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total Project Cost for proposed project activity is Rs. 4.0 Crores. 9. Analysis of Proposal (Final Recommendations) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project. Social Welfare shall be done. Cordial relation with the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 25