PRE FEASIBILTY REPORT MANUFACTURING OF ORGANIC PIGMENT M/S PRINCE CHEMICALS

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1 PRE FEASIBILTY REPORT ON PROPOSED PROJECT FOR MANUFACTURING OF ORGANIC PIGMENT OF M/S PRINCE CHEMICALS AT PLOT NO: 9111/3,9111/2/1 GIDC ESTATE, ANKLESHWAR, DIST: BHARUCH, STATE: GUJARAT 1

2 Index Sr no. Description Pg no. 1 Executive Summary 3 2 Introduction Purpose of the report Identification of project & project proponent Nature of project Study of Project Project Description Type of Project Project Location Site Selection Neighboring Industry Size of Project Process Technology Raw material Resource requirement Mitigation measures & EMP Site analysis Connectivity Land use & Land ownership Existing Land use Existing Infrastructure soil Classification Social infrastructure Planning Brief Planning Concept Population Projection Land use planning Proposed infrastructure Processing Area Non Processing Area Green belt area Social Infrastructure Connectivity Drinking water management Industrial water management Solid Waste management Source of Power Rehabilitation and resettlement plan Project schedule & Cost estimation Project implementation schedule Estimated project cost Analysis of Proposal 20 2

3 1.0 Executive Summary: M/s.Prince chemicals, is located at- plot no.9111/3,9111/2/1, GIDC Estate, Ankleshwar, Dist : Bharuch. Unit was produced Flexo ink, Gravure and Pigment But, unit will not continue these products.furthermore, unit will demolish existing building, dismantle existing machineries and construct new building as per plant layout. Plant Layout is attached as ANNEXURE-4 in FORM-I. Unit has proposed to manufacture Pigment Green-7 & Alpha Blue on this plot. Unit is applying EC for manufacturing of 150 MT/Month of Pigment Green-7 & 50 MT/Month Alpha Blue. Total cost of the project is Rs 250 Lacs List of products is given in Table No:-1. Table No. 1: List of Products Name Sr. No. Product Name Existing Production MT/Month Proposed Production MT/Month 01 Pigment Green Pigment Alpha Blue Flexo Ink (Formulation) Gravure Ink (Formulation) Pigment (Drying) Total 200 Total MT/Month COST OF PROJECT The expected cost of project is Rs. 250 lacs.the total plot area of the unit is 1500 sq.mt. FUEL AND ELECTRICITY CONSUMPTION For proposed expansion unit will install TFH based on LDO/ FO, Steam Boiler and Hot air generator and TFH based on Natural gas. D.G.Set will be used only in case of emergency. WATER CONSUMPTION Total water requirement will be 145 KL/Day. Unit will use 1 KL/Day in Domestic activity and 1KL/Day in Gardening Activity. 143 KL/Day used in industrial activity, 104 KL/day used in process. FLUE GAS EMISSION 3

4 TFH, Steam boiler, Hot air generator and D.G.Set will be a source of flue gas emission. PROCESS GAS EMISSION HCl and Cl2 will be a source of process gas emission. Unit will install water scrubber and alkali scrubber to maintain AAQ norms. HAZARDOUS WASTE MANAGEMENT The Hazardous wastes from the unit are ETP sludge, Used Oil,Spent acid,hcl,sodium hypochlorite,discardedcontainers/bags/liners. 4

5 2. INTRODUCTION 2.1 PURPOSE OF THE REPORT M/s.Prince chemicals, is located at- plot no.9111/3,9111/2/1gidc Estate, Ankleshwar, Dist : Bharuch. Unit was produced Flexo ink, Gravure and Pigment But, unit will not continue these products. Furthermore, unit will demolish existing building, dismantle existing machineries and construct new building as per plant layout. Plant Layout is attached as ANNEXURE-4 in FORM-I. Unit has proposed to manufacture Pigment Green-7 & Alpha Blue on this plot. Unit is applying EC for manufacturing of 150 MT/Month of Pigment Green-7 & 50 MT/Month Alpha Blue. Total cost of the project is Rs 250 Lacs. 2.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT The promoters have well experienced in this field. The plant boasts of contemporary infrastructure facilities with advanced machinery and automated processes. They are conscious of environment protection measures and from the conception stage itself necessary care has been taken. A vision, a mission and a will to succeed are the basic ingredients in the foundation of the company. A team of well-qualified engineers and financial experts supports the company. Main promoters as well as staff of the company have very good industrial as well as business experience. QUALITY POLICY The company s commitment is to manufacturing of pigment. The company will develop in house testing facility with modern testing equipments to ascertain the quality of raw materials as well as finished products. Continued emphasis towards process and technology up gradation will be done effectively to enrich the product quality. R & D with initiative & innovative ideas will be resulted into excellent performance in respect of quality products. ENVIRONMENTAL POLICY The unit is committed to execute all operations, products and services by environmental protection activities to the extent possible. As a means of achieving these, the unit pledges to company with the legal & other requirements to their core and focus on continually improving products, systems & operations. 5

6 Table 2:Contact details of Directors Sr Name Present Residence no. Address 1 Mahesh P Borad Block No.203,Shrushti Co Op Ha Society, Nr GIL Colony, GIDC estate,ankleshwar Designation Contact No. Proprietor The directors of the company have good experience in handling the production management, financial management and all the dyes areas. 2.3 NATURE OF PROJECT As per EIA notification 2006, the proposed project falls under category 5(f)-B. 2.4 SCOPE OF THE STUDY MARKET FEASIBILITY M/s. Prince Chemicals is a leading group in India ventured into manufacture of Synthetic Organic Pigments. This chemical is commonly used as a coloring agent in different substances. The offered chemical is processed by using optimum quality chemical and advanced technology as per set market norms. This product is used into Plastic, Rubber, Textile, Inks, and Paints Industries. 6

7 3.0 PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The proposed expansion project is for manufacturing of synthetic organic pigments Chemicals. 3.2 PROJECT LOCATION M/s.Prince chemicals, is located at- plot no.9111/3,9111/2/1gidc Estate, Ankleshwar, Dist : Bharuch, Gujarat which is one of the fastest growing industrial estate and having all the essential facilities & infrastructure for the management & disposal of effluent discharge. The approximate geographical positioning of the project site is at Latitude: 21 37'52"N Longitude: 73 2'52"E. The location of the project site can be identified from the location map shown in Figure-1. The salient features of the location of the project site are presented in Table 3. TABLE: 3 SALIENT FEATURES OF THE PROJECT SITE Particulars Details Distance from Site Villages Ankleshwar 3 KM Approx. Geographical Latitude: 21 37'52"N positioning Longitude: 73 2'52"E Nearest City Ankleshwar Bharuch 3 KM 15 KM Nearest Railway line/ Ankleshwar 3 KM Railway station Domestic Airport Vadodara 94 KM 7

8 Figure 1: Location of the Project site 8

9 9

10 Aerial view of the 1 km radial periphery from the project Site 3.3 SITE SELECTION The project proponent did not consider any other alternative site for proposedproject. Site is selected as its is within the GIDC of ankleshwar having all infrastructure facility like good road, rail and other connectivity, manpower availability, transportation access and near to Mumbai port and air ports connectivity more over raw material resource are also available bear to proposed location. Uninterrupted power and water supply is available and also the waste water discharge and haz waste disposal scientific approved facilities are available in the vicinity. 3.4 NEIGHBORING INDUSTRIES The industry is located in an area, which is already industrialized. The industries in the vicinity of the proposed project are given in the Table-4 below: TABLE: 4 10

11 NEARBY INDUSTRIES IN THE VICINITY SR.NO. INDUSTRIES NAME 1 Seviur chemicals-n 2 Advance dye stuff-s 3 Hubech chemicals-w 3.5 SIZE OF PROJECT Unit is applying EC for the manufacturing of 150 MT/Month Pigment Green-7 and 50 MT/ Month Alpha Blue. New Plant and machinery installations will also have to be acquired and installed. Environment Protection and safety systems have also been considered in planning the Cost Projection. The break-up of the proposed project cost is given in below table 5. TABLE: 5 CAPITAL COST PROJECTION Sr No. Purpose Total Rs.250 (In Lacs) 1 Building 50 2 Plant and Machinery land 50 4 Environment Protection & Safety a) Effluent treatment Plant 15 b) Safety Equipment (PPE, fire 1 extinguishers, Ventilation, etc.) c) Green belt development 3 CSR + 1 in Green belt Total PROCESS TECHNOLOGY Unit is involving in the manufacturing of Synthetic Organic Chemical. These are characterized for their physicochemical properties. Process details like Process description, chemical reactions and mass balance for each product is attached as Annexure 6 in FORM-I. 3.7 RAW MATERIAL Unit is involving in the manufacturing of Synthetic Organic Chemicals and purchasing required raw material from local/indian market. Products wise raw material consumption is attached as Annexure-5 in FORM-I. 3.8 RESOURCE REQUIREMENTS LAND 11

12 The total plot area of the unit is 1500Sq meter FUEL For production activity, fuel requirement and power consumption is as per below Table 6 and Table 7. TABLE: 6 FUEL CONSUMPTION Sr no. Stack attached to capacity Fuel consumption Stack height Fuel used 1 Steam Boiler 3 TPH 130 SCFM 30 Natural Gas 2 Hot Air Generator 10 lacs K cal 90 SCFM 20 Natural Gas 3 Thermic Fluid 5 lacs Kcal 45 SCFM 32 Natural Gas Heater 4 DG Set 125 KVA 2 Litre/Hr 6 HSD TABLE: 7 POWER CONSUMPTION sr no. Electricity In HP Available power for per Existing Consent AWH As per Proposed Expansion TOTAL after Proposed Expansion 1 Electricity 50 HP 50 HP 100 HP WATER WATER CONSUMPTION Water consumption detail is tabulated in Table No:-8. TABLE: 8 WATER CONSUMPTION Application Water Consumption Waste water generation (KL/Day) (KL/Day) Domestic 1 1 Gardening 1 Industrial Process Boiler 35 3 Cooling 10 1 Scrubber total

13 Water Balance Diagramall units are in KL/Day Total Water Consumption = 145 KLD Domestic Gardening Industrial fresh + 36 reuse = 179 KL Sewage 0.75 Process 104 Boiler 35 Cooling 10 Scrubber KL Reuse To Soak Pt/ Septic Tank Effluent 72 Boiler Blow Down 3 Cooling Blow Down 1 Scrubber waste 17 To ETP 40 Spent acid sold to authorized industries having rule 9 permission Discharged 40 KL to ACTPC (Common incineration facility) 13

14 WASTEWATER CHARACTERISTICS Existing & proposed effluent characteristic before treatment and after treatment in ETP is covered in Annexure-7 of FORM I WASTEWATER TREATMENT & DISPOSAL Details of existing & proposed effluent treatment plant (ETP) is covered in Annexure- 7 of FORM I. 3.9 MITIGATION MEASURES & EMP Based on overall manufacturing & operation activities, the mitigation measures have been proposed by the company for the control of the anticipated pollution load GASEOUS EMISSIONS & CONTROL FLUE GAS EMISSION Existing flue gas emission and proposed flue gas emission is mentioned in Table No: 10. TABLE: 10 FLUE GAS EMISSION FLUE GAS EMISSION AFTER PROPOSED EXPANSION Sr no. Stack attached to capacity Fuel consumption Stack height APCM Fuel used 1 Steam Boiler 3 TPH 130 SCFM 30 _ Natural Gas 2 Hot Air Generator 10 lacs K cal 90 SCFM 20 _ Natural Gas 3 Thermic Fluid 5 lacs Kcal 45 SCFM 32 _ Natural Heater Gas 4 DG Set 125 KVA 2 Litre/Hr 6 _ HSD PROCESS EMISSIONS There is a process gas emission from Chlorination reactor and drowning vessel. Unit will install Water scrubber and Alkali scrubber as an APCM to prevent the process gas emission. TABLE: 11 PROCESS GAS EMISSION Sr no. Stack attached APCD system Stack Height Pollutants to 1 Reaction Vessel Water scrubber followed by alkali 11 HCl,Cl2. 14

15 scrubber 2 Reaction Vessel Water scrubber followed by alkali scrubber 3 Drowning Vessel Water scrubber followed by alkali scrubber 11 HCl,Cl2. 11 HCl,Cl HAZARDOUS WASTE MANAGEMENT The following types of hazardous wastes will be generated during the operational activities. All the wastes will be stored separately in a designated storage area. The details of hazardous waste are below given Table 12. TABLE 12 DETAILS OF HAZARDOUS WASTE Sr no. Type of hazardous waste Source Cat. No. Quantity Management 1 ETP sludge ETP MT/Month 2 HCl (Hydrochloric Acid) Pigment Green 7-Bleed liquor from scrubber Sch.2 Class B MT/month 3 Spent Acid(20-22%) Alpha Blue Mt/Month 4 Sodium Hypochloride Pigment Green 7 5 Aluminium Chloride Pigment Green 7 6 Discarded bags/ Containers/ Drums Production of all products 7 Used Oil Maintenance of plant machineries and DG set Sch.2 Class B 7 Sch.2 Class 422 MT/month 705 MT/Month B nos./year Liter/Year Collection, Storage, Transportation, Disposal to TSDF site Will be sold to authorized industries having rule 9 permission Reused in manufacturing of CPC blue in own premises and balanced qty will be sold to actual user having rule 9 permission in case when there is no production of those products in which spent acid is used. Will be sold to authorized industries having rule 9 permission Will be sold to authorized industries having rule 9 permission Used for packing of ETP Waste or return back to raw material supplier or selling to vendors Storage into carboys and ultimately sell to registered refiners 15

16 3.9.3 NOISE CONTROL & ODOUR Unit is following below steps to Noise control and Odour. Raw-material feeding will be carried out by pumps. All reactions will be taken in closed reactor system. Roof top ventilation will be installed in the entire plant area. Regular monitoring of piping and fittings will be carried out to prevent the leakages. Guidelines of for odor control will be followed STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS The storage and mode of transport of chemicals will be done as per detailed MSDS and chemical hazards guide (NIOSH) for the hazardous chemicals. Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in HEALTH AND SAFETY MEASURES Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of large volumes of gas or toxic or flammable gases or vapours. According to Schedule 2 & 3 of MSIHC Rules. Moreover transport activity will be done through drums, so there is a manual loading and unloading and no unloading through pipe at the site. Hence, the risk of static charge generation during transfer of such chemicals is not significant MAN POWER The manpower required for the project as well as during the construction/ commissioning activities will be employed from the local area. TABLE NO:-13 MAN POWER REQUIREMENT Phase of Project Type of Labour No of worker Total During construction Contractual Existing Proposed During operations Managerial 1 1 Supervisor 2 2 Clerical 2 2 Un-Skilled

17 4.0 SITE ANALYSIS 4.1 CONNECTIVITY Ankleshwar is known for Pigment and Pharmaceutical Industry. Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by the Western Railway Division of Indian Railways. The railway division runs the broad gauge train services to Rajpipla. The 133-year-old Golden Bridge connects Ankleshwar to Bharuch across the Narmada on the station front while a new bridge connects the highway, the other bridge on the highway is now ready to use. Ankleshwar railway station is centrally located at the intersection of NH8 & Station Road. Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western section).development projects of Ankleshwar Airport & City Bus are in last stage. 4.2 LAND USE AND LAND OWNERSHIP M/s.Prince chemicals, is located at- plot no.9111/3,9111/2/1gidc Estate, Ankleshwar, Dist : Bharuch. The total plot area of the unit is 1500 sq meter. Unit will develop 100 sq.mt green belt area. 4.3 EXISTING LAND USE The proposed project site is located at plot No: 9111/3,9111/2/1GIDC Estate, Ankleshwar, Dist : Bharuch. The total plot area of the unit is 1500sq meter. The plot is notified by GIDC for industrial purpose which will be having 6.5% green belt area of the total plant area. 4.4 EXISTING INFRASTRUCTURE The plant is located in a well-developed industrial zone, which has all essential facilities such as internal roads, arrangement for supply of water and power to industries, effluent disposal facilities, gas etc. The proposed project is relatively small in size and will be employing some skilled and unskilled people. First preference will be given to local people, so there will be no change in population pattern due to the proposed project. 4.5 SOIL CLASSIFICATION The soil of the district can be classified as light, medium and heavy according to depth, texture and location. There is sandy loam to loamy in texture, brownish black in color. 4.6 SOCIAL INFRASTRUCTURE 17

18 As of 2011 India census, Ankleshwar had a population of 140,839. Males constitute 53% of the population and females 47%. 13% of the population is under 6 years of age. 5.0 PLANNING BRIEF 5.1 PLANNING CONCEPT: Ankleshwar is largely an industrial area dominated by large scale industries, especially chemical Plants. Government agencies provide many basic facilities likeuninterrupted water supply, power and road network. 5.2 POPULATION PROJECTION. As of 2011 India census, Ankleshwar had a population of 140,839. Males constitute 53% of the population and females 47%. 13% of the population is under 6 years of age. 5.3 LAND USE PLANNING The names of prominent industries are shown in table no: 15 SR.NO. INDUSTRIES NAME 1 M/s. SUBHASRI PIGMENTS PVT LTD. 2 M/s. JAYSHREE INDUSTRIES 3 M/s. DYNAMIC DYE CHEM 4 M/s. HEMDEEP 5 M/s. A-ONE CHEMICALS 6.0 PROPOSED INFRASTRUCTURE 6.1 PROCESSING AREA The process area is covered plant area, raw material storage area, hazardous waste storage area, workshop and utilities. 6.2 NON PROCESSING AREA The non process area is covered Admin Building, toilet blocks, change room and security cabin. 6.3 GREEN BELT AREA Total plot area of the unit is 1500Sq-meter. Unit has allotted 100 Sq-meter area for green belt. There will be provision of budget of 1 lakh rupees for green belt development. 18

19 6.4 SOCIAL INFRASTRUCTURE The availability of basic amenities is covered as under: Training & Education: All the employees will be trained and educated periodically about the hazardous nature of chemicals used in the process. Also, training for firefighting, work permits system, first aid, safe handling of hazardous chemicals and integrating safety, in all activities. Medical facility: Pre-employment medical checkup at the time of employment. In order to safe guard the health of the employees, all the employees undergo periodic health checkup. Drinking water: Unit has provided Aqua Guard/R.O at different places for purified water. Transportation: The unit will provide basic transportation facility to workers. Telegraph & Post: Unit has all the facilities like telephone, fax and internet for the employees. 6.5 CONNECTIVITY This industrial estate is well connected to Ahmadabad/Mumbai/Vadodara through the Ankleshwar. Rail services and Road services are available in Ankleshwar. 6.6 DRINKING WATER MANAGEMENT Average daily domestic water consumption of unit will be 145 KL/day. GIDC water will be a source of domestic water. 6.7 INDUSTRIAL WASTE MANAGEMENT The hazardous waste management and disposal is shown in table SOLID WASTE MANAGEMENT The Solid waste management and disposal is shown in table SOURCE OF POWER DGVCL is a main source of Power. 19

20 7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN The proposed project is located in GIDC Estate, Ankleshwar. There will be no any human settlement affected by proposed project. So, there is no requirement of any R & R Plan. 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 PROJECT IMPLEMENTATION SCHEDULE The details of project Implementation Schedule is given in below table. TABLE: 16 PROJECT IMPLEMENTATION SCHEDULEProject implementation schedule after getting NOC from GPCB Sr. No. Activity Required Period 1 Civil work Immediately after getting CTE of GPCB 2 Procurement of machinery 1 month after getting CTE of GPCB 3 Erection & installation of machinery Immediately after competition of activity no.2 4 Trial of machinery & Within 1 months after competition of equipment activity no.3 5 Commercial activity After obtaining CTO from GPCB 8.2 ESTIMATED PROJECT COST The details of Capital cost projection will be Rs 250 lacs 9.0 ANALYSIS OF PROPOSAL First preference will be given to local people for employment and Company will also try to provide indirect employment opportunities by availing local contract services during transportation and operational phase. The company intents to donate 0.5 % of the profit to agencies like NGOs or social welfare societies for projects carried out in nearby villages for their welfare and upliftment. 20