PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT ON PROPOSED PROJECT OF MANUFACTURING OF ORGANIC CHEMICALS OF AARTI INDUSTRIES LIMITED (UNIT-V) LOCATED AT Plot 41/1, GIDC Estate, Jhagadia, Bharuch

2 1.0 EXECUTIVE SUMMARY M/s. Aarti Industries Limited (Unit-V)has proposed for manufacturing of Synthetic Organic products mentioned in below table no.1 at Plot 41/1 GIDC Estate, Jhagadia, and Dist.: Bharuch, Gujarat As per EIA notification 2006, the proposed expansion is falling under category 5(f). TABLE NO 1: LIST OF PRODUCTS Sr. Total Quantity Name of Product (MT/Month) 1. Aryl-Dianhydrides Aryl- Phthalimides 920 Total 2270 COST OF PROJECT The proposed project is located in GIDC Estate, Jhagadia. The expected cost of proposed projectis Rs crore. The total plot area of the unit is sq. m. The green belt area after proposed expansion will be approx sq. m. FUEL & ELECTRICITY CONSUMPTION The proposed unit will use imported coal as fuel for one boiler (25 TPH), natural gas for Thermo pack (22 lakh kcal/hr) and diesel for D.G. Set and diesel for D.G. Set(2 Nos of 1500kVA). The connected electricity load will be 3000 KW from DGVCL. WATER CONSUMPTION The unit will use 965 KL/Day fresh water for industrial purpose and 50 KL/Day fresh water for domestic purpose. The unit will reuse 50 KLD of water in gardening from STP. WASTE WATER GENERATION, TREATMENT & DISPOSAL The waste water generation from industrial activities will be 185 KL/Day. The sewage generation will be 50 KL/Day. The industrial waste water will be treated in units own ETP having primary, secondary and tertiary treatment facilitiesand final disposal to NCTL common effluent discharge facility. The sewage of 50 KLD will be treated in STP and the treated wastewater will be used for gardening. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 1

3 GASEOUS EMISSION FLUE GAS EMISSION Flue gas emission will be from 4 stacks; one for boiler (25 TPH) and ESP as APCM, one for thermo pack (22 lakh kcal/hr.) and two for stack D.G. Set (1500 kva each) PROCESS EMISSION Process emission will be from two stacks. One attached to Vessels and Vaccum pumps and one stack attached to storage tanks. The stacks are attached to Water scrubber. HAZARDOUS WASTE MANAGEMENT There will be generation of ETP sludge (270 MT/Month), Used oil (200 L/Month), Discarded container and bags (whatsoever generated), Fly ash (200 MT/Month), Off-specification product (whatsoever generated) and insulation waste (whatsoever generated) 2.0 INTRODUCTION 2.1 THE PROJECT M/s. Aarti Industries Limited (Unit-V) had purchased plot no. 41/1 GIDC Estate, Jhagadia, Bharuch, Gujarat. Proposed production capacity is mentioned in Table no.1. As per EIA notification 2006, the proposed expansion is falling under category 5(f). 2.2 PROJECT PROPONENT The list of Directors is given in Table no.2. TABLE NO 2: CONTACT DETAILS OF DIRECTORS Sr. Name of Director Designation Address Telephone 1. Shri.Rajendra V. Chairman& 1401, Antriksh Gogri Managing Director Murar road, Mulund (w), Mumbai Shri.Rashesh C. Gogri Vice chairman& Managing Director 601,Antriksh Morar Road, Mulund (W) Shri. Parimal H. Desai Whole-Time Director Mumbai A/ TH Floor, Runwal Heights, L.S.B. Marg, Mulund (W) Mumbai M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 2

4 Sr. Name of Director Designation Address Telephone 4. Shri.Manoj M. Whole-Time Dunhill Villa Chheda Director CO.OP.HSG.SOC.Ltd., Besant Road, Santa Cruz (W), Mumbai Shri.Kirit R. Mehta Whole-Time Director 10, Pushpendra Mension, Feroz shah Mehta Road, Santa Cruz (W), Smt. Hetal Gogri Gala Whole - Time Director 7. Shri. Renil R. Gogri Whole - Time Director Mumbai B, Gopal Sadan, Block no. 801, 8 TH Floor, Jamshed Road, Matunga(E), Mumbai , Antriksh. Murar Road Mulund (W) Mumbai The directors of the company have good experience in handling the production management, financial management and all the allied areas. 2.3 NATURE OF PROJECT The unit will be manufacturing synthetic organic chemical in the proposed project. 2.4 MARKET FEASIBILITY The proposed products will be used in polymer manufacturing industry. The products are highly influenced by the market demand and market rates. 3. PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The proposed project is not including any interlinked and interdependent projects. 3.2 PROJECT LOCATION M/s. Aarti Industries Limited (Unit-V) has purchased Plot 41/1 GIDC Estate, Jhagadia Dist.: Bharuch, Gujarat from GIDC Jhagadia. It is approximately 18 km distance from Dist.: Bharuch The approximate geographical positioning of the project site is at Latitude 21 36'49.30"N, Longitude 73 8'10.28"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 no 3. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 3

5 TABLE NO 3: SALIENT FEATURES OF THE PROJECT SITE Particulars Taluka/ Tehsil District Approx. Geographical positioning Nearest City Nearest Town Nearest Highway Nearest State highway Nearest Railway line/ Railway station Nearest Airport/ Airbase Protected Areas/ Sanctuaries -- Nearest State/National Boundary -- Details Jhagadia (approx. 12 KM) Bharuch (approx. 18 KM) Latitude: 21 36'49.30"N Longitude: 73 8'10.28"E Ankleshwar (approx. 15 KM) Ankleshwar (approx. 15 KM) NH8 (approx. 9.5 KM) SH 165 (approx. 2 KM) Ankleshwar (approx. 14 KM) Vadodara (approx. 80 KM) M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 4

6 FIGURE 1: LOCATION OF THE PROJECT SITE M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 5

7 FIGURE 2: AERIAL VIEW OF THE 10 KM RADIAL DISTANCE FROM THE PROJECT SITE 3.3 SITE SELECTION The project proponent did not consider any other alternative site for proposed project. 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 no-4. TABLE NO 4: NEARBY INDUSTRIES IN THE VICINITY Name of Industry Direction w.r.t Address project site Britannia Industries Limited South Plot 23, G.I.D.C., Jhagadia Industrial Estate Jhagadia Gujarat Shell and Pearl Ceramics Ltd. South East Plot No : 19, Jhagadia Gidc Estate. Taluka M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 6

8 Air Liquide India Holding Pvt. Ltd. 3.5 SIZE OF PROJECT North Jhagadia, Bharuch, Gujarat, PLOT NO:- 38/1, JHAGADIA INDUSTRIAL ESTATE, GIDC JHAGADIA, Bharuch The expected cost of proposed project is Rs crores. 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 below given table no-5 shows the break-up of the proposed project cost. TABLE NO 5: CAPITAL COST PROJECTION Sr. Purpose Total (Rs. in crore) 1. Land Building Plant and Machinery Environment Protection a) Effluent treatment Plant 3 b) Safety Equipment (PPE, 3 fire extinguishers, Ventilation, etc.) C) Green belt development 0.2 Total PROCESS TECHNOLOGY Details of manufacturing process are attached as an Annexure-V. 3.7 RAW MATERIAL The proposed raw materials are organic and inorganic chemicals and they will be purchased from the local/ Indian market. Details of raw-material consumption are attached as Annexure- IV. 3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE The unit will reuse 50 KLD of wastewater from STP to Gardening. 3.9 RESOURCE REQUIREMENTS LAND The plot has been purchased by M/s. Aarti Industries Ltd. (Unit-V) from GIDC Estate, Jhagadia. The total plot area of the unit is sq. m. The green belt area will be approx sq. m. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 7

9 3.9.2 BUILDING New buildings will be constructed for proposed project POWER AND FUEL TABLE NO 6: POWER AND FUEL REQUIREMENT Sr. Name Requirement Source Total 1. Coal 5 MT/Hr. Imported Coal 2. Natural Gas 300 Nm 3 /Hr. Gujarat 3. Diesel 660 Litre/Hr. Local Market 4. Energy - Electricity 3000 kva DGVCL WATER The category wise bifurcation of the water requirement is given in Table no 7. The source of water will be from GIDC water supply scheme. TABLE NO 7: CATEGORY-WISE WATER REQUIREMENT Sr. Purpose Total fresh water Recycled Total Water consumption (KL/day) Water (KL/day) Consumption (KL/day) A Domestic B Industrial 1)Process ) Washing ) D.M. Plant * 4) Boiler 252 (Water from DM 0 252(*) Plant) 5) Softener * 5) Cooling 505(Water from 0 505(*) Softener) 6) Gardening Total (B) Total (A+B) MANPOWER The manpower required for the project as well as during the construction/ commissioning activities will be employed from the local area. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 8

10 TABLE NO 8: MAN POWER REQUIREMENT Phase of project Type of labor of workers (Total) During Contractual 50 construction During Contractual 50 commissioning During Managerial 10 operations Skilled 27 Un-skilled 30 Total During Operations 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 WASTEWATER MANAGEMENT WASTEWATER GENERATION The category-wise bifurcation of the anticipated wastewater generation details is given in Table 9. TABLE NO-9: CATEGORY-WISE WASTEWATER GENERATION Sr. Purpose Total wastewater generation in KL/day A Domestic 50 B Industrial 1)Process 30 2) Washing 5 3) Boiler 40 4) Cooling 72 5) DM Plant 28 6) Softener 10 Total (B) 185 Total (A+B) WASTEWATER CHARACTERISTICS Existing & proposed effluent characteristic before treatment and after treatment in ETP is covered in Table no. 10. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 9

11 TABLE NO-10: WATEWATER CHARACTERISTICS Sr. Parameters Units No After Treatment Before Treatment 1 ph Total Suspended Solids mg/l Total Dissolved Solids mg/l C.O.D. mg/l WASTEWATER TREATMENT & DISPOSAL EFFLUENT TREATMENT SCHEME The dilute effluent from the process plant is collected in a collection sump from which it is taken to oil & grease trap for separation, oil and grease is skimmed 0ff from the top. Effluent is then pumped to neutralization tank where ph is neutralized between 7.00 to 8.00 and compressed air is used for agitation. Then it is transferred to decanter for sludge dewatering then it is take to equalization tank after that effluent is pumped to primary settling tank where suspended solids are settled and the sludge is taken into membrane filter to separate the solid. Dried sludge is stored in a sludge storage tank. Clear water from settling tank is taken into aeration tank In this tank, extended type aeration system is adopted. Biological treatment is given to the effluent. Overflow is taken into secondary settling tank for excess sludge settling, biomass is recirculated in aeration tank if required or sent to membrane filter press. Overflow from secondary settling tank is passed through two stage activated carbon filter and then taken into collection tank for final disposal to NCTL common effluent discharge facility GASEOUS EMISSIONS & CONTROL FLUE GAS EMISSIONS Flue gas emission will be from 4 stacks; one for boiler (25 TPH) and ESP as APCM, one for thermo pack (22 lakh kcal/hr.) and two for stack D.G. Set (1500 kva each). Details of stacks number, stack height, pollutants emitted are covered in following table-11. TABLE NO-12: FLUE GAS EMISSION Sr. Stack Attached To Stack Height in Meter Fuel APCM Type of Emission Boiler-1 (25 TPH) Thermo pack Coal Natural ESP -- PM SO 2 NO X (22 LAKH Kcal/hr) Gas 3. D.G. Set (Standby) 11 Diesel -- Permissible Limit 150mg/ Nm ppm 50ppm M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 10

12 Sr. Stack Attached To (2 Nos) Capacity= 1500 KVA (Each) Stack Height in Meter Fuel APCM Type of Emission Permissible Limit PROCESS EMISSION The process emissions from the manufacturing activities are given in following Table. The details of air pollution control system are also mentioned in table-13. TABLE NO-13: PROCESS GAS EMISSION Sr. Stack attached to Stack Height in Meter APCM Parameter Permissible Limit 1. Vessels & 11 Water VOCs -- Vacuum Pumps Scrubber 2. Storage Tanks FUGITIVE EMISSIONS There will be no volatile or low boiling chemicals to be used in the process. Hence, chances of fugitive emissions are reduced to a great extent by providing proper control measures. However, following steps will be taken to reduce chances of fugitive emissions: All raw-materials will be stored in drums/ bags in a well-ventilated raw material storage area. All reactions will be taken in closed reactor system. The fugitive emissions in terms of handling losses will be reduced by proper storage and handling. Raw-material feeding will be carried out by pumps. Regular monitoring will be done of piping and fittings for checking of any leakages. Good housekeeping will be maintained in the plant HAZARDOUS/ NON-HAZARDOUS WASTE MANAGEMENT The following type of hazardous waste will be generated from the operational activities. All the waste will be stored separately in a designated storage area. The details about quantity of hazardous waste generation, storage, and disposal for existing and proposed are attached as Annexure-VIII. In addition to the provision of above, we will ensure proper management for hazardous waste as below: (A) Transportation of hazardous waste to the TSDF Site will be governed as per the guidelines and accompanied with Form-13. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 11

13 (B) Annual returns of the disposal of wastes in Form-4 will be uploaded online and submitted regularly to the local office of the GPCB NOISE CONTROL & ODOUR The major noise generation is from D.G. Set. It will be installed in a closed room, acoustic enclosure is provided around it. Ear plugs are provided to the operating personnel in boiler room. The following steps will be taken for Odour control. (A) Raw-material feeding will be carried out by pumps. (B) All reactions will be taken in closed reactor system. (C) Roof top ventilation will be provided in the entire plant area. Regular monitoring will be done of piping and fittings for checking of any leakages 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 vapors. According to Schedule 2 & 3 of MSIHC Rules, Moreover transport activity will be through drums, so there will be 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. 4.0 SITE ANALYSIS 4.1 CONNECTIVITY The site is located at Plot 41/1 GIDC Estate, Jhagadia Dist.: Bharuch , Gujarat. The site is 18 km from Bharuch district. The land and Infrastructure is already available. The raw materials are easily available through the easy transport via road connectivity. Ankleshwar city has railway station and connected to Mumbai- Ahmedabad rail line. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 12

14 4.2 LAND USE AND LAND OWNERSHIP The proposed project site is into the GIDC Estate, Jhagadia Gujarat which is meant for this type of industries. The land is on Plot No41/1 GIDC Estate, Jhagadia, and Dist.: Bharuch Gujarat. The total plot area of the unit is sq. m. The green belt area will be approx sq. m. Land ownership is with M/s. Aarti Industries Limited. 4.3 EXISTING INFRASTRUCTURE The plant is located in a well-developed industrial zone, which have all essential facilities such as well-connected road network with ease of transportation, arrangement for supply of water and power to industries, effluent disposal facilities etc. Infrastructure is made available through Govt. approved authorized agencies. 4.4 SOIL CLASSIFICATION The soils of the district are derived from the Deccan trap which is main rock formation of the district. 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. 4.5 CLIMATE DATA (SECONDARY SOURCES) The climate is characterized by oppressive summer dampness in the atmosphere nearly throughout the year, heavy south- west monsoon rainfall and a mild winter. The year may be divided in to four seasons. From December to February is known as winter or cold season. The summer or hot season is from March to May and south- west monsoon season is from June to September, while October and November is the post monsoon season. Based on the meteorological data, wind rose have been prepared for the summer season period between the Dec-2016 to Feb-2017 of Ankleshwar region. The wind rose diagram prepared from same data is given in Table no. 14. TABLE NO 14: MICRO METEOROLOGICAL DATA Month Temperature( o C) Humidity (%) Rain fall (mm) Maximum Minimum Maximum Minimum Maximum Minimum December January February M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 13

15 FIGURE 5: WIND ROSE DIAGRAM FOR PERIODOF DECEMBER 2016 TO FEBRUARY SOCIAL INFRA STRUCTURE There are 41 villages in Jhagadia Taluka. Population density and sex ratio of Jhagadia Taluka was reported 212 persons/sq.km. and 937 females per 1000 males respectively in 2001 census report. Total literacy of Jhagadia Taluka was found %.The basic amenities like primary and secondary education schools, community health workers, primary health sub centre, private practitioners, primary health centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital, drinking water, transportation facilities, electricity, telephone etc. are available. 5.0 PLANNING BRIEF 5.1 PLANNING CONCEPT Jhagadia is largely an industrial area dominated by medium and large scale industries, especially chemical plants. Agencies provide many basic facilities like uninterrupted water supply, power and road network. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 14

16 5.2 POPULATION PROJECTION Population of Jhagadia Taluka was reported to be in 2011, Census. Entire Jhagadia area is all set for massive industrialization. There is large scale migrant population is anticipated in this area. The proposed project is relatively small in size and will be employing Around 300 skilled and unskilled people.almost 80% of this will be selected from local people. Even though the population of Jhagadia Taluka will have some increase due to this project. 5.3 LAND USE PLANNING The proposed project is in the established GIDC industrial area. This is not a prime agriculture land. 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND M/s. Aarti Industries Ltd. (Unit-V) will get water from GIDC water supply scheme. So there will be no additional stress on ground water resources and there will be no adverse effect on the ground water resources available in the nearby area. The unit will be having 3000 kva connected load form DGVCL. 5.5 AMENITIES All of the villages have primary schools, 4 villages have both primary and secondary education schools. 10 villages have adult education facility, 1 villages has higher secondary and intermediate. There is no training school in any village. 10 villages have other education institution. 35 villages have community health workers, 15 villages have primary health sub centre, 5 villages have registered private practitioners while 4 villages have family planning centre, 1 village has primary health centre. 1 maternity home, 1 child welfare centers, 1 dispensary and one hospital are also available in the impact zone. Primary source of water in villages are tap and well. Tank and hand pump are also used in the villages. Villages are connected with paved road. Bus is the main source of transportation. Broad guage rail line conversion work is under progress. Most of the villages have post office and phones. All the villages have availability of electricity supply. The villages have connectivity of mobile phone facility. All the surrounding area is covered with 108 emergency facilities. Source: 2011, Census. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 15

17 6.0 PROPOSED INFRASTRUCTURE 6.1 PROCESSING AREA The process area will cover Plant, Raw material storage area, Hazardous waste storage area, ETP and utilities. The process area covered by the unit at ground level will be sq. m. 6.2 NON PROCESSING AREA The non process area will cover Admin Building, Canteen and security cabin. The non process area covered by unit at ground level will be sq.m. 6.3 GREEN BELT Out of the total land area of sq. m. approximately sq. m. is utilized for green belt development that is approx. 33% of total plant area. There will be provision of budget of 20 lakh rupees for green belt development. 6.4 SOCIAL INFRASTRUCTURE The availability of basic amenities is covered as under: (A) 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 permit system, first aid, safe handling of hazardous chemicals and integrating safety, in all activities. (B) 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. (C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide purified water for drinking purpose. (D) Transportation: The unit will provide basic transportation facility for workers. (E) Telegraph & Post: There will be provision of telephone, fax & internet facility. (F) Power supply: There will be connected load of 3000KVA from DGVCL. 6.5 DRINKING WATER MANAGEMENT The source of water will be GIDC and the same is adequate and satisfactory. The unit will provide 50 KL/Day water for domestic purpose. 6.6 SEWERAGE SYSTEM The sewage will be sent to Sewage treatment plant. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 16

18 6.7 INDUSTRIAL WASTE MANAGEMENT The hazardous waste like ETP waste, used oil, discarded containers/bags/liners, Fly Ash & Insulation waste. The hazardous waste management and disposal is shown in Annexure-VIII. 6.8 SOLID WASTE MANAGEMENT The record of non-hazardous solid waste like, Fibber board drum, Polyethylene bag, Rubber Hose pipe, glass, wooden waste etc. will be mentioned. 6.9 POWER REQUIREMENT & SUPPLY The unit will require 3000 kva of connected load. 7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN The proposed project is located in Jhagadia Industrial Estate, Tal. Jhagadia, Dist.: Bharuch. 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 TABLE 15: PROJECT IMPLEMENTATION SCHEDULE Project implementation schedule after getting NOC from GPCB Sr. Activity Required Period 1. Civil work Immediately after getting NOC 2. Procurement of 1 month after getting NOC machinery 3. Eraction& installation of Immediately after competition of activity no.2 machinery 4. Trial of machinery & Within 1 months after competition of activity no.3 equipments 5. Commercial activity 1 months after competition of activity no ESTIMATED PROJECT COST Details for estimated project cost is covered in table no ANALYSIS OF PROPOSAL All the manpower is utilized from local region around Jhagadia. Company shall also try to provide indirect employment opportunities by availing local contract services during transportation during operational phase. The company intends to carryout CSR activity as applicable to nearby village for their welfare and upliftment. M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 17