Pre-Feasibility Report

Transcription

1 Pre-Feasibility Report For Establishment of Pesticides industry and pesticide specific intermediates (excluding formulations) & Synthetic organic chemicals manufacturing unit By PRASOL CHEMICALS LIMITED Project under Activity 5(b) & 5(f) Category - A Prepared By M/s Prasol Chemicals Limited Plot No. FS-30, Additional MIDC, Mahad Dist: Raigad , India Web: prasolchem.com 1

2 Table of Contents 1 EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT... 7 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT... 7 BRIEF DESCRIPTION OF NATURE OF THE PROJECT... 7 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION... 8 DEMAND SUPPLY GAP... 9 IMPORTS VS INDIGENOUS PRODUCTION... 9 EXPORT POSSIBILITY... 9 DOMESTIC / EXPORT MARKET... 9 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT PROJECT DESCRIPTION TYPE OF PROJECT LOCATION DETAILS OF ALTERNATIVE SITES SIZE OR MAGNITUDE OF OPERATION PROJECT DESCRIPTION WITH PROJECT DETAILS RAW MATERIAL REQUIRED RESOURCE OPTIMIZATION WATER, ENERGY / POWER AVAILABILITY AND SOURCE Water Energy Power WASTE GENERATION, MANAGEMENT AND DISPOSAL Waste water Non Hazardous waste Hazardous waste MANPOWER SITE ANALYSIS CONNECTIVITY LAND FORM, LAND USE AND LAND OWNERSHIP TOPOGRAPHY EXISTING LAND USE PATTERN EXISTING INFRASTRUCTURE SOIL CLASSIFICATION CLIMATE DATA FROM SECONDARY SOURCES SOCIAL INFRASTRUCTURE AVAILABLE PLANNING BRIEF PLANNING CONCEPT POPULATION PROJECTION LAND USE PLANNING ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) AMENITIES / FACILITIES PROPOSED INFRASTRUCTURE INDUSTRIAL AREA (PROCESSING AREA) RESIDENTIAL AREA (NON-PROCESSING AREA) GREEN BELT SOCIAL INFRASTRUCTURE CONNECTIVITY DRINKING WATER MANAGEMENT

3 SEWERAGE SYSTEM INDUSTRIAL WASTE MANAGEMENT SOLID WASTE MANAGEMENT POWER REQUIREMENT AND SUPPLY / SOURCE REHABILITATION & RESETTLEMENT PLAN PROJECT SCHEDULE AND COST ESTIMATES DATE OF START OF CONSTRUCTION AND DATE OF COMPLETION ESTIMATED PROJECT COST ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) List of Annexures Annexure No I II III IV V Description Plot possession letter / Plot allotment letter Google image showing study area Layout plant of the proposed plant Proposed effluent treatment scheme Proposed products, brief description, reaction chemistry, process block diagrams 3

4 E XEC U T IVE SUMMARY Prasol Chemicals Limited (Prasol), form an integral part of the global chemical industry. Prasol is an ISO 9001: 2008, ISO 14001: 2004 and an OHSAS 18001:2007 certified company that is well aligned with its vision "To become a premier manufacturer of Specialty Chemicals and to provide Technical Services globally." Prasol is also BBB+ credit rated by SMERA. Prasol has its own Research and Development and Manufacturing unit, with production facilities for Phosphorous Based, Acetone Based and Hydrogenated products, situated at Khopoli in Raigad district, state. Prasol is prevalent in various sectors spanning Paints, Coatings, Thinners, Flavors & Fragrances, Agrochemicals, Lubricant Additives, Surfactants, Cosmetics and Pharmaceutical Industries. Prasol s global reach spans 40 countries along with local presence through multiple dedicated distribution channels across India. With a team strength of over 275 employees, Prasol enforce its belief of "Customer first, Reputation first", through technical support and after sales service. Prasol has established aggressive growth plans for its business with a well-defined pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term. Prasol Chemicals Limited proposes a Greenfield project for manufacturing of Inorganic & Synthetic Chemicals at Plot No. FS-30, Addl Mahad MIDC situated in Raigad District, state. Few areas were considered in and around and found the existing plot most suitable due to its availability and proximity from the company s existing manufacturing facility. The plot is a vacant plot situated in an additional Mahad MIDC area. Plot area for the project is 45,000 m 2. Total estimated cost of the project will be approx. INR 50.0 Crores (based on present rates). Prasol chemicals proposed to undertake establishment of manufacturing of inorganic phosphorus based chemicals [Phosphorus pentasulfide: 12,000 TPA, Red Phosphorus: 2,000 TPA, & Chlorinated products (Phosphorus Trichloride, Phosphorus Pentachloride, 4

5 Phosphoryl Trichloride, Thiophosphoryl chloride): 10,000 TPA] used in lubricant oil which does not falls under EIA notification, Company has applied Consent to establish from Pollution control board for above products. The plant shall be operated for 24 hrs., a day, seven days a week and 300 days / annum. The balance 65 days will be utilized for product change-over preparation and annual maintenance shutdown. It is proposed to manufacture various synthetic organic products. Plot plan possession receipt / plot possession letter is at Annexure I The Google image of the plot site is presented at Annexure II Proposed Layout Plan for new establishment is attached as Annexure III. 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 Pesticide and Pesticide intermediates manufacturing unit. This project falls under Project activity 5 (b) & 5 (f)- A category. The project brief is summarized in the table below Project summary at a glance Table : Brief Project summary Sr No Particulars Details 1 Name of Company Prasol Chemicals Limited 2 Products Refer section 2 (Introduction of the project) 3 Location Plot No FS-30, Additional Mahad MIDC, Dist Raigad 4 Name of the project Manufacture of Phosphorus Based Chemicals (Category: Pesticide and Pesticide intermediate manufacturing unit) 5 Total land area of the plot 45,000 sq m 6 Raw material Refer section Water (estimate) / Source 200 CMD, from MIDC 8 Power Requirement / Source Proposed 1,200 KVA Source: MSEDCL 9 Manpower Proposed: (Permanent + Contract) = 100 Nos 10 Waste water quantity 24 CMD (refer section 3.9 for details) (estimate) 11 Air emissions Refer section 3.9 below 12 Solid Waste Refer section 3.9 below 12 Approx. Project cost Estimate 5,000 Lakhs 5

6 (estimate) 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 Prasol 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. 6

7 INTRODUCTION OF THE P RO JECT Identification of the Project and Project Proponent Prasol Chemicals Limited (PCL) is one of the leading & fastest growing chemical manufacturing companies in India. Incorporated in 1992, the manufacturing of unsaturated polyester resins was commissioned. In the year 1995, Prasol Chemicals became a deemed Public limited company and set up a manufacturing unit at Khopoli near Mumbai, India. PCL is an ISO 9001: 2008, ISO 14001: 2004 and an OSHAS 18001:2007 certified company. PCL has an in-house R & D and manufacturing facility, with production plants for Phosphorous based; Acetone based and hydrogenated products, situated at Khopoli, with their own warehouse for storage and distribution of specialty chemicals. The total occupied area at Khopoli is 16 Acres (around 64,000 sq. meters) with production plants for Phosphorous Pentasulphide, Diacetone Alcohol, Isophorone, Mesityl Oxide, Lubricant Additives, Phenol Acetone and various Hydrogenated Products. PCL are prevalent in various sectors spanning Paints, Coatings, Thinners, Flavors & Fragrances, Agrochemicals, Lubricant Additives, Surfactants, Cosmetics, and Pharmaceutical Industries. PCL s global reach spreads over 40 countries along with local presence in India through multiple dedicated distribution channels. PCL has established aggressive growth plans for its business with a well-defined pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term. Prasol team is headed by Technical and commercial skilled professionals. Brief Description of nature of the Project Proposed project is a Greenfield project consisting of manufacturing of Phosphorous based products which will be widely used as intermediates in the manufacture of agrochemicals and pesticides. List of Proposed Products and Production Capacity S. No. Product / By Products Capacity (MT/Year) Products 1 Diethyl Thiophosphoric Acid (DETA) 12,000 (Combined 2 Diethyl Thiophosphoryl Chloride (DETC) 3 Dimethyl Thiophosphoryl Chloride (DMTC) capacity will be manufactured on Campaign basis) 4 Dimethyl Phosphoramidothioate (DMPAT) 1,000 5 Dithio phosphates 7

8 a Zinc Dialkyl Dithiophosphate (ZDDP) 6,000(Combined capacity b Alkyl Sodium Dithiophosphate will be manufactured on c Sodium Dithiophosphate Campaign basis) 6 Organic Acetates 5,000 (Combined capacity a 2-Methyl Adrohol Acetate will be manufactured on b Trimethyl Cyclohexyl Acetate Campaign basis) c Styrallyl Acetate d Phenethyl Acetate 7 Hydrogenated Products 5,000 (Combined capacity a O-Methyl Cyclohexanol will be manufactured on b O-Methyl Cyclohexanone Campaign basis) c Styrallyl Alcohol d 3,3,5 Trimethyl Cyclohexanol e 3,3,5 Trimethyl Cyclohexanone Sub Total (Products) 29,000 By-Products 1 Sodium Hydrogen Sulphide (NaHS) 8,500 2 Hydrochloric Acid (HCl) 19,500 3 Wettable Sulphur 3,000 4 Ammonium Hydroxide (NH4OH) Sodium Sulphite Na2SO Dil. Acetic Acid 3000 Sub Total (By Products) 34,800 Grand Total (Products + By products) 63,800 Prasol chemicals proposed to undertake establishment of manufacturing of inorganic phosphorus based chemicals [Phosphorus Pentasulphide: 12,000 TPA, Red Phosphorus: 2,000 TPA, & Chlorinated products (Phosphorus Trichloride, Phosphorus Pentachloride, Phosphoryl Trichloride, Thiophosphoryl chloride): 10,000 TPA] used in lubricant oil which does not falls under EIA notification, Company has applied Consent to establish from Pollution control board for above products. In addition, Trading activities will be carried out for products suitable to the product basket to the tune of 5000 MT per annum and around 1000 MT per Annum Formulated products prepared by blending of various Solvents, Thinners or other products is proposed to be made. Need of the Project and Its Importance to the country and/or Region All the products proposed above are imported to India on a regular basis. The quantum of imports varies from product to product but the manufactured goods will be import substitutes. Amongst the products proposed, hydrogenated products, Phosphorus Pentasulphide and ZDDP are already being manufactured at the company s current facility near Khopoli, Dist: Raigad,. 8

9 The additional products proposed are forward integration of the company s current products and have a great demand both global and domestic. The demand is envisaged to increase rapidly in the domestic market. Demand Supply gap All the products in the product list have higher demands than the domestic supply and hence are imported into the country. The addition of domestic production capacity will provide a local source for the domestic market. Imports vs indigenous production All the products mentioned in the above product list are imported into India in substantial quantities. The production will lead to an additional domestic source for the local market. Export Possibility The products can be exported thus leading to Forex revenues for the country. Domestic / Export market Prasol has a well-established presence in the domestic as well as international market. It exports to more than 50 countries across the globe in addition to over 400 customers in the domestic market. The products specified cater to the needs of the customers and provide them with a complete product basket from a single source. These products can be sold in the domestic market as well as can be exported Employment Generation (Direct and indirect) due to the project During the construction phase around 60 workers and during the operational phase around 100 workers including contractors will be required. Local skilled and semiskilled workers will be engaged during construction phase. The positives impact includes enhanced direct employment for technical/ administrative works and indirect employment opportunities for transporters of raw materials and finished goods and downstream industries. 9

10 P RO JECT DESCRIPTION Type of Project The project is for manufacture of Prosperous based Chemicals as follows, as follows: S. No. Product / By Products Capacity (MT/Year) Products 1 Diethyl Thiophosphoric Acid (DETA) 12,000 (Combined 2 Diethyl Thiophosphoryl Chloride (DETC) 3 Dimethyl Thiophosphoryl Chloride (DMTC) capacity will be manufactured on Campaign basis) 4 Dimethyl Phosphoramidothioate (DMPAT) 1,000 5 Dithio phosphates a Zinc Dialkyl Dithiophosphate (ZDDP) 6,000(Combined capacity b Alkyl Sodium Dithiophosphate will be manufactured on c Sodium Dithiophosphate Campaign basis) 6 Organic Acetates 5,000 (Combined capacity a 2-Methyl Adrohol Acetate will be manufactured on b Trimethyl Cyclohexyl Acetate Campaign basis) c Styrallyl Acetate d Phenethyl Acetate 7 Hydrogenated Products 5,000 (Combined capacity a O-Methyl Cyclohexanol will be manufactured on b O-Methyl Cyclohexanone Campaign basis) c Styrallyl Alcohol d 3,3,5 Trimethyl Cyclohexanol e 3,3,5 Trimethyl Cyclohexanone Sub Total (Products) 29,000 By-Products 1 Sodium Hydrogen Sulphide (NaHS) 8,500 2 Hydrochloric Acid (HCl) 19,500 3 Wettable Sulphur 3,000 4 Ammonium Hydroxide (NH4OH) Sodium Sulphite Na2SO Dil. Acetic Acid 3000 Sub Total (By Products) 34,800 Grand Total (Products + By products) 63,800 Prasol chemicals proposed to undertake establishment of manufacturing of inorganic phosphorus based chemicals [Phosphorus pentasulfide: 12,000 TPA, Red Phosphorus: 2,000 TPA, & Chlorinated products (Phosphorus Trichloride, Phosphorus Pentachloride, Phosphoryl Trichloride, Triphosphoryl chloride): 10,000 TPA] used in lubricant oil which does not falls under EIA notification, Company has applied Consent to establish from Pollution control board for above products. 10

11 There is no interlinked /interdependent project. Location The proposed project site is at additional Mahad MIDC. Map showing location of Mahad MIDC Add. Mahad MIDC Map showing location of Prasol Chemical 11

12 Details of Nearest Infrastructure Facilities Sr. No. Particulars Details 1. Town Addl. Mahad MIDC 2. Taluka Mahad 3. District Raigad 4. Latitude Latitude: N 5. Longitude Longitude: ' 0" E 6. Nearest water River Savitri bodies 7. Nearest Highway NH 66 = 2 km towards West 8. Nearest Railway Veer on Konkan railway which is approximately 16.3 km station 9. Nearest Airport/ Airbase Mumbai International Airport KM towards NW Pune Lohegaon Airport / Airbase KM towards NE The project is proposed at Plot No FS-30, Additional Mahad MIDC, Dist. Raigad. The Geographical Location of this plot is at Latitude N and 73 32' 16" E with an elevation of 39 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 additional MIDC area which is meant for these types of Industries. GPS Location on Google Imagery of the proposed site is attached as Annexure I. Land Form: Land is on plain contour, it is flat terrain. Land Ownership: Land ownership is with project proponents (Prasol 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 nearby Mahad Town (Which is at distance of about 7 km) Additional 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. 12

13 There is no sensitive establishment in the vicinity such as health resort, hospital, and archaeological monuments. The project site is located at 2.7 KM of village Matwan which is listed as Eco sensitive Area by MoEF Lay-Out Refer Annexure III for the proposed plant site layout plan. Details of Alternative sites Company has an operative facility in the name of Prasol Chemicals limited in Khopoli, Raigad, making similar products. The Company felt the necessity of setting up a new facility looking at future market demand. The western part of India is an obvious choice for the new project considering its proximity to both, raw material sources as well as captive markets. Within western India, apart from Mahad, Lote Parshuram MIDC, Roha MIDC and Dahej GIDC were evaluated as all are industrial areas, have excellent infrastructure including infrastructure required for management of Environment. However, based on the availability, and the proximity from the existing unit, the above mentioned plot was found most suitable. a. Availability of required land and infrastructure for locating the establishment for the Pesticide and Pesticide intermediate 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. Size or magnitude of operation Plot area of the project consists of ~45000 m 2 area. The design capacity of the plant as given in the table below will be on the basis of running the plant for 24 hrs., a day, seven days a week and 300 days / annum. The balance 65 days will be utilized for product change-over preparation and annual maintenance shutdown. It is proposed to manufacture Phosphorous based products which will be widely used as intermediates in the manufacture of agrochemicals and pesticides. Details of all the proposed products are listed in table above, Project description with Project details Proposed products, Brief description, Process Chemistry, Process Block diagram are given at Annexure V. 13

14 Raw material required Raw Materials: The basic raw material for the product 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: Few of the raw materials will be transported locally and few will be imported from the International Market. Mode of transport to site is by road truck/tankers. Table: List of Raw Material required S.N. Raw Material Consumption Physical (MTPA) State Means of Storage Source 1 Phosphorous 9000 Pentasulphide S Silos / Tote Bins In-house 2 Ethanol 8000 # L Tanks Local 3 Methanol 8000 # L Tanks Local 4 Octanol 4000* L Tanks Local 5 Isobutanol 4000* L Tanks Local 6 Isopropanol 4000* L Tanks Local 7 N-butanol 4000* L Tanks Local 8 Pentanol 4000* L Tanks Local 9 Caustic Soda 5000 S/L Bags/Tanks Local 10 Base Oil 600 L Tanks Local 11 Zinc Oxide 800 S Bags Local 12 Chlorine Gas 7500 G Tonners Local 13 Ammonia Gas 100 G Cylinders Local 14 Nitrogen Gas 1000 G Tanks/ Cylinders Local 15 Hydrogen Gas 225 G Cylinders Local 16 Filter Aid 50 S Bags Local 17 Acetic Acid 4000 L Tanks Local 18 Acetic Anhydride 1000 L Tanks Local 19 O-Cresol 5000 L Tanks Local 20 Styrene Oxide 5000 L Tanks Local 21 Isophorone 5000 L Tanks Local/Imports 22 Cyclohexane 1000 L Tanks Local NOTE: *RM requirement can be on the basis of the grade of Dithiophosphates manufactured, the figure indicates maximum quantity per annum # RM required can be on the basis of the category of the product (DETC/DMTC/DMPAT) manufactured. Proposed bulk storages at site shall be as follow for finished goods and raw materials Finished product storage details for Inorganic & Synthetic based products, 14

15 List of Proposed Product storage details No Particular Physical storage Stored in state capacity 1 Diethyl Thiophosphoric Acid (DETA) Liquid 100 MT Tanks/ Drums 2 Diethyl Thiophosphoryl Chloride (DETC) Liquid 300 MT Tanks/ Drums 3 Dimethyl Thiophosphoryl Chloride (DMTC) Liquid 100 MT Tanks/Drums 4 Dimethyl Phosphoramidothioate (DMPAT) Liquid 50 MT Tanks/Drums 5 Zinc Diorgano Dithiophosphate (ZDDP) Liquid 200 MT Tanks/ Drums 6 Alkyl Sodium Dithiophosphate Liquid 50 MT Tanks/ Drums 7 Sodium Dithiophosphate Liquid 50 MT Tanks/ Drums 8 Phosphorous Trichloride Liquid 200 MT Tanks/ Drums 9 Phosphorous Pentachloride Liquid 200 MT Tanks/ Drums 10 Phosphoryl Trichloride Liquid 100 MT Tanks/ Drums 11 Thiophosphoryl Chloride Liquid 100 MT Tanks/ Drums 12 2-Methyl Adrohol Acetate Liquid 200 MT Tanks/ Drums 13 Styrallyl Acetate Liquid 200 MT Tanks/ Drums 14 Trimethyl Cyclohexyl Acetate Liquid 200 MT Tanks/ Drums 15 Phenethyl Acetate Liquid 200 MT Tanks/ Drums 16 O-Methyl Cyclohexanol Liquid 100 MT Tanks/ Drums 17 O-Methyl Cyclohexanone Liquid 100 MT Tanks/ Drums 18 Styrallyl Alcohol Liquid 100 MT Tanks/ Drums 19 3,3,5 Trimethyl Cyclohexanol Liquid 100 MT Tanks/ Drums 20 3,3,5 Trimethyl Cyclohexanol Liquid 100 MT Tanks/ Drums 21 Sodium Hydrogen Sulphide (NaHS) Liquid 300 MT Tanks/ Drums 22 Hydrochloric Acid (HCl) Liquid 500 MT Tanks/ Drums 23 Wettable Sulphur Solid 50 MT Tanks/ Drums 24 Ammonium Hydroxide (NH4OH) Liquid 10 MT Tanks/ Drums List of Raw material storage details No Particular Physical storage state capacity Stored in 1 Phosphorous Pentasulphide Solid 1000 MT Silos / Tote Bins 2 Ethanol Liquid 500 MT Tanks 3 Methanol Liquid 500 MT Tanks 4 Octanol Liquid 200 MT Tanks 5 Isobutanol Liquid 200 MT Tanks 6 Isopropanol Liquid 200 MT Tanks 7 N-butanol Liquid 200 MT Tanks 8 Pentanol Liquid 200 MT Tanks 9 Caustic Soda Solid/Liquid 100 MT Bags/Tanks 10 Base Oil Liquid 20 MT Tanks 11 Zinc Oxide Solid 20 MT Bags 12 Chlorine Gas Gas 50 MT Tonners 13 Ammonia Gas Gas 100 NM 3 Cylinders 14 Nitrogen Gas Gas 1000 NM 3 Tanks/Cylinders 15

16 15 Hydrogen Gas Gas 500 NM 3 Cylinders 16 Filter Aid Solid 5 MT Bags 17 Acetic Acid Liquid 250 MT Tanks 18 Acetic Anhydride Liquid 50 MT Tanks 19 O-Cresol Liquid 100 MT Tanks 20 Styrene Oxide Liquid 100 MT Tanks 21 Isophorone Liquid 100 MT Tanks 22 Cyclohexane Liquid 100 MT Tanks Resource optimization Prasol Chemicals limited intend to establish the manufacturing capacity of the above mentioned products. The resource optimization shall be carried out at the site and with other Prasol sites in order to reduce wastage and minimize the transport needs. Water, Energy / Power availability and source (Availability of water, its source, Energy/power and requirement and source should be given) Water The total water requirement is 200 cmd for domestic, process, Boiler and cooling and greenbelt maintenance purpose. The source of water shall be from existing water works of MIDC and the same shall be adequate for the facility. Water requirement for proposed establishment is tabulated as below: Table : Water requirement No Purpose Total, cmd 1 Domestic 10 2 Industrial Industrial cooling / boiler feed Industrial processing 45 3 Gardening 5 Grand Total 200 Energy Steam / Process heat Requirement: The steam requirement and process heat requirement for the proposed set up shall be met from the steam generating boilers It is proposed to install 1 No of boilers of 10 TPH steam capacity. FO is proposed to be used as fuel its requirement at rated capacity of boiler shall be 25 TPD (Ton per day). The fuel requirement shall be as follows: S. No. Type of Fuel Used in Quantity Source 1 FO 10 TPH Capacity 25 T/Day Local Suppliers Stacks of requisite heights and air pollution control devices for above shall be provided as per statutory norms. 16

17 Power Proposed power requirement is 1,200 KVA which will be sourced from MSEDCL. For emergency power requirement, It is proposed to install 1 DG sets (400 KVA capacity each). Sr No Capacity Nos Fuel requirement Source KVA each (emergency use only) 1 HSD: 200 lit/hr From local supplier Waste generation, Management and disposal Waste water Proposed waste water generation, treatment and disposal shall be as follows, No Description Quantity, Disposal cmd 1 Domestic effluent 5 Septic tank with Soak pit shall be provided. Supernatant water shall be treated in the ETP at site. 2 Trade effluent 70 ETP with primary, Secondary & tertiary treatment shall be installed. The treated effluent will be reused to the maximum extent. Some of the treated effluent will be sent to CETP Total 75 The quantification of non-hazardous and hazardous waste estimated to be generated from proposed activities is tabulated as below: Non Hazardous waste No Waste Type Quantity Disposal (*) 1 Ion Exchange Resins (DM Plant / Other Plant) 1.5 TPA Landfill 2 Sand from Water Filtration 10 TPA Landfill 3 Used Cotton Hand gloves 5000 Pairs/ Landfill Year 4 Miscellaneous (Rubber & Teflon Gasket/Packing/ Transmission Belt /V-Belts / Packing, PP /FRP/ material, suction air filter of compressor/ packing 0.75 TPA Sale to Authorized Parties / Landfill (*) Note: Above quantities are rough estimate, will be firmed up during EIA study. Hazardous waste No Waste Type Category Quantity (*) Disposal 1 Distillation TPA Disposal to MWML / Sale to Residue Authorized party 2 Residue from TPA Disposal to MWML / Sale to ZDDP Authorized party manufacture 17

18 No Waste Type Category Quantity (*) Disposal 3 ETP Sludge TPA Disposal to MWML 4 Used Oil TPA Recycler 5 Spent Catalyst TPA Disposal to MWML / Sale to Authorized party 6 Used Empty Barrels / Liners No/Yr Sale to Authorized party (*) Note: Above quantities are rough estimate, will be firmed up during EIA study. Air Emissions: Environmental issues associated with proposed pesticides manufacturing, formulation and packaging includes: The principal air pollutants will be volatile organic compounds (VOCs) and particulate matter (PM). Likely air pollutants from proposed project shall be PM, H2S, NOx, SO2 & HC from various (~15 m to 35 m) process vents, boiler stack and DG Sets as point source. Adequate APC equipment like scrubbers stacks & vents with adequate height will be provided. Vehicular Emissions like CO & HC s will be generated as line source emissions. Fugitive emissions are also envisaged from proposed project. Manpower Manpower: Expected manpower requirement for the establishment (during operation phase) shall be as follows: Description Proposed, No (approx.) Permanent 60 Contract 40 Total

19 S ITE ANALYS IS Connectivity This proposed Prasol Chemicals limited new facility shall be located at Plot FS-30, Additional Mahad MIDC in Raigad district,. The Site is about 13 km from Mahad city. The land and infrastructure is made available by MIDC and the raw material is easily available through the easy transport via road connectivity. 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 proponent (Prasol Chemicals Limited) 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. Existing land use pattern It is vacant MIDC plot allocated to Prasol Chemicals Limited. Existing infrastructure Vacant MIDC plot. Infrastructure is provided by additional Mahad MIDC SOIL: Soil classification 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 19

20 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 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. 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 20

21 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 wellsupplied with nitrogen and organic matter. Typical soil analysis is as follows Description of Soils Chemical Coastal Analysis Loamy Varkas Laterite Alluvial (1) (2) (3) (4) (5) (6) Yellowish Yellowish red Reddish Colour to reddish to yellowish Yellowish red grey grey. grey. Salt land or Khar land Reddish or yellowish grey. Depth 1' 3' 1' - 2' 3' 5' 5' 10' 5' 10' Per cent on oven drv matter Organic matter Calcium Carbonate Nil 0.01 Trace Trace Sand (Coarse and fine) Silt Clay Textural class Loam Sandy Sandy loam Clay loam Clay to Clay loam Total soluble salts Trace Trace Organic carbon Total Nitrogen C/N PH value Mgm. per cent drv matter on oven Available P Trace Available K

22 Description of Soils Loamy Varkas Laterite Coastal Alluvial (1) (2) (3) (4) (5) (6) millie Chemical Analysis Exchangeable Ca Exchangeable Mg Exchangeable Na Exchangeable K Exchangeable H Total Exchangeable bases Base Exchange Capacity Climate: equivalent per cent on oven. dry matter Salt land or Khar land Climate data from secondary sources Mahad comes in Raigad district of. 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. 22

23 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. 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 southeast. 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. Social infrastructure available Nearest town is Mahad which is about 13 km from site. Social infrastructure such as schools, Hospitals, market place and other amenities are easily available. Transport facilities by rail and road are available. 23

24 P LANNIN G BRIEF Planning Concept Plot is at well-established Additional Mahad MIDC area Purified Water supply from MIDC Well-developed roads and connectivity. Infrastructure facilities available established MIDC site Integration with the existing nearby Prasol s manufacturing facility 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 population. In 2001 census, this figure for Raigad District was at 2.28 percent of 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. For Industrial use Land use planning Assessment of Infrastructure Demand (Physical and social) No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC area. Amenities / Facilities No major amenities / facilities demand is envisaged as the proposed site is in welldeveloped MIDC area, and Mahad is major town near the site. 24

25 P RO POSED IN F R ASTRU CT U R E Since the establishment is planned at new site in developed industrial area, no special/specific development is anticipated. Company will have to do 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. Company has already housing colony in that area. For additional essential manpower company may decide at later date about building additional colony building. Industrial Area (Processing area) Prasol Chemicals limited, Plot no FS-30, Additional Mahad proposes to set up plant for manufacture of Pesticide and pesticide intermediates based on demand and market projection. Residential area (non-processing area) No Residential area is proposed within the plant site. Green Belt Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement. 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. Connectivity This proposed project facility shall be located at Additional Mahad MIDC area, in Raigad district,. The Site is 13 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. Drinking water management The total water requirement is about 350 cmd for Domestic, boiler/cooling, Greenery and process. The source of water shall be from MIDC. The water supply will be through the good offices of MIDC. 25

26 Sewerage System Refer Annexure IV Industrial waste management Refer 3.9 above Solid waste management There is no specific infrastructure is required for the proposed expansion for solid waste management. Refer 3.9 above for additional waste generation and its disposal management. Power requirement and supply / source Power requirement shall be sourced from MSEDCL. Refer above for power requirement details. 26

27 REHABIL ITAT ION & RESETTLEMENT P LAN The proposed new facility shall be at plot of the company which is located in Additional 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. 27

28 P RO JECT SCHEDULE AND COST E ST IM AT ES Date of start of construction and Date of completion It is expected that the expansion project shall be completed within 24 months from date of grant of Environmental clearance. Estimated project cost Total estimated project cost is around 5000 Lacs 28

29 A NALYS IS OF T HE PRO P O SAL (F INAL RECO MMENDAT ION) The proposed manufacturing project envisages - For the growing domestic market and as Import substitution - Direct employment to locals and will prompt ancillary business - Export benefits

30 Annexure I Plot plan possession letter

31 Plot sanction order

32

33

34 Annexure II Goggle image of site with 1 km radius Goggle image of site with 10 km radius

35 Annexure III Proposed plant site layout

36 Annexure - IV Proposed Effluent treatment scheme

37 Annexure - V Proposed products, Brief description, Process Chemistry, Process Block diagram Zinc Diorgano Dithiophosphate (ZDDP) Manufacturing Process Zinc Diorgano-DithioPhosphate (ZDDP) is manufactured in two major steps. Step 1: Synthesis Step: The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-Alkyl Dithiophosphate Acid with release of Hydrogen Sulphide gas. In this step, the oxo-alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is added to this mass with continuous stirring which results in the evolving of gases which are to be absorbed in the 2 stage caustic scrubber. Step 2: Neutralization Step: The neutralization of the acid is carried out with zinc oxide. Once neutralization is complete, the product mass is dried. Filter aid is added and the batch is filtered to obtain the product of desired quality. The residue is then removed from the filter in the form of solid cakes. The ZDDP product is then stored, packed and dispatched as required. Reaction involved and process flow diagram is shown below: S 1) 4R OH + P2S5 2 (RO)2 P = SH + H2S Oxo-Alcohol Phosphorous Reaction Hydrogen Pentasulphide Intermediate Sulphide S S S 2) 2 (RO)2 P = SH + ZnO (RO)2 P = S Zn -S= P (OR)2 + H2O Reaction Zinc ZDDP Water Intermediate Oxide Scrubbing of Hydrogen Sulfide H2S + NaOH NaHS + H2O Hydrogen Sulfide Sodium Hydroxide Sodium Hydrosulfide Water

38 Figure 9-1: Block Diagram for ZDDP Manufacturing Environmental Aspects of ZDDP Manufacture The hydrogen sulfide generated during acid preparation will be absorbed in two stage caustic scrubber system. The NaHS (30%) thus formed, shall be sold. Emissions of H2S from the scrubber vent shall be within the prescribed limits. No water is required as part of production process. Hazardous waste generated will be Category C5 and C14 Schedule II of HW Rules, This HW shall be sent to TSDF. Membership certificate shall be obtained. Mass Balance Input S. Input/MT of /Day of No Raw Materials Product (MT) Product. (MT) 1 Phosphorus Pentasulphide Alcohols Zinc Oxide Base Oil Caustic Water for Scrubbing Total

39 S. No. Output/MT of Product Materi al / Item Product / Byprodu ct Liquid Efflue nt Air Emissio n Recove ry HW Output/D ay of Product MT Remarks 1 ZDDP Product 2 NaHS (30%) H2S Filter Residu e Total By Product To Scrubbe r To CHWTS DF DATC (DETA/DETC/DMTC) Manufacturing Process Dialkyl Thiophosphoryl Chloride (DATC) is produced using a series of Unit Processes and Operations. The steps involved in the production process are as given below: Manufacture of DATA; Chlorination; Hydrolysis; Distillation of crude DATC; By-product Sulphur Recovery Step 1: Manufacture of Dialkyl Thiophosphoric Acid (DATA) DATA is manufactured by batch process in a CSTR. Predetermined quantity of phosphorus pentasulphide is charged into the reactor containing a measured quantity of Acid as heel. Alcohol is then added in a controlled manner maintaining reaction mass temperature. Reaction is exothermic in nature with evolution of hydrogen sulphide gas which is absorbed in caustic solution in a packed bed scrubber system to form sodium hydrogen sulphide as by-product. Step 2: Chlorination

40 In this step, chlorine gas is purged into the Acid in control manner. The reaction mass obtained at the end of this step is a mixture of Dialkyl Thiophosphoryl Chloride, Sulphur mono chloride and Hydrochloric Acid which is then purified in the subsequent steps Step 3: Hydrolysis For washing of crude product, water hydrolysis method is preferred. After addition and maintaining the temperature, first wash of aqueous is to be used for HCL preparation. After washing, organic material is drained from reactor along with washing aqueous mass. This mass (high COD) is then separated and sent to the ETP for further treatment. The Crude free of the washing aqueous mass is then sent for purification. Step 4: Distillation of Crude DATC In this process hydrolyzed mass of crude product is purified by removing high boiling impurities to get DATC product. Step 5: By-product Sulphur Recovery In this step, the sulphur obtained from the hydrolyzed mass of crude product is purified and made suitable for sale or reuse. Reaction involved and process flow diagram is shown below: Part 1 Formation of DATA P2S5 + 4 ROH 2 R2P=S + H2S Phosphorus Alcohol DETA/DMTA Hydrogen Pentasulphide Sulphide SH Part 2 Chlorination of DATA to DATC SH Cl 2 R2P=S + 3 Cl2 2R2P=S + S2Cl2 + 2 HCl Acid Chlorine DETC/DMTC Sulphur Hydrochloric Mono chloride Acid

41 H 2S ALCOHOL P 2S 5 To H 2S Scrubber Reactor HCl DATA CHLORINE To HCl Scrubber Chlorination Crude DATC Acidic Effluent Washing Agents Water Washing Washing Effluent & Sulfur To ETP (High COD Treatment) Losses Distillation Impure Sulfur Sulfur for sale and reuse DATC Product Distillation Bottom To CHWTSDF Figure : Block Diagram for DATC Manufacturing

42 Environmental Aspects of DATC Manufacture The hydrogen sulfide generated during acid preparation will be absorbed in two stage caustic scrubber system. The NaHS (30%) thus formed, shall be sold. Emissions of H2S from the scrubber vent shall be within the prescribed limits. The hydrochloric acid generated during chlorination process will be absorbed in two stage water scrubber system. The HCl (30%) thus formed, shall be sold. Emissions of HCl from the scrubber vent shall be within the prescribed limits. Waster water of higher COD shall be generated and shall be treated into ETP. Hazardous waste generation as distillation residue in the form of sludge (HW Category 20.3, Schedule I) during the distillation stage. This HW shall be sent to TSDF. Membership certificate shall be obtained. Mass Balance S. No. Raw Materials Input/MT of Product (MT) Input /Day of Product (MT) 1 Phosphorus Pentasulphide Ethanol/Methanol Chlorine Caustic Sodium Sulphite Water Total Output/MT of Product Output/Day S. Material / Product / Liquid Air of Product Remarks No. Recovery HW Item Byproduct Effluent Emission MT 1 DATC Product 2 H2S To Scrubber 3 HCl To (Emission) Scrubber 4 NaHS By (30%) Product 5 HCl By Product 6 Sulphur Sold / Recycled 7 Waste Water To ETP