PRE - FEASIBILITY REPORT

Transcription

1 PRE - FEASIBILITY REPORT for PROPOSED EXPANSION OF BOILER (24 TPH) AS A UTILITY, COAL BASED CPP & CHANGED IN FUEL FROM NATURAL GAS TO COAL IN EXISTING RUBBER & LATTICES MANUFACTURING UNIT of M/S. APCOTEX INDUSTRIES LTD. SURVEY NO. 27, 103 TO 105 & 131 TO 137, VILLAGE:DUNGRI, TAL: VALIA, DIST. BHARUCH, GUJARAT. 1

2 CONTENTS Sr. No. Description Page No. 1. Executive Summary 3 2. Introduction of the Project/Background information 8 3. Project Description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation and resettlement (R& R) Plan Project Schedule & Cost Estimates Analysis of Proposal (Final Recommendations) 19 2

3 1.0 EXECUTIVE SUMMARY 1.1 Project Details M/s. Apcotex Industries Limited proposes expansion of Boiler (24 TPH) as a Utility, Coal Based CPP & Changed in Fuel from Natural Gas to Coal in Existing Rubber & Lattices Manufacturing Unit at Survey No. 27, 103 to 105 & 131 to 137, Village: Dungri, Tal: Valia, Dist. Bharuch, Gujarat Products along with Production Capacity SR. NO. 1. PRODUCTS NAME Acrylonitrile Butadiene Rubber & Lattices EXISTING PRODUCTION IN MT/ANNUM PROPOSED TOTAL AFTER PROPOSED Admixture of NBR Styrene Butadiene Rubber (SBR)& Lattices 4. Admixture of SBR CPP (Natural gas based) 4.93 MW -3.95MW 0.98 MW 6. CPP (Coal Based) MW 3.95 MW 1.2 Raw Material Requirement SR. NO. QUANTITY (KG/KG PRODUCTION) RAW MATERIAL NBR 1. Acrylonitrile Butadiene Styrene Emulsifier Modifier Short Stop Solution Alum / Coagulant Salt Antioxidant emulsion Catalyst Total SBR 3

4 CPP: Sr. Quantity Raw Material No. (MT/Month) 1. Bed Material Lime Stone Addition Oil & Grease Sodium Hydroxide Hydrochloric Acid Hydrazine Phosphate Indian Coal OR Imported Coal OR Total OR Water Requirement, Waste Water Generation and Treatment WATER CONSUMPTION: USAGE EXISTING (KL/DAY) ADDITIONAL (KL/DAY) TOTAL (KL/DAY) (A) Domestic (B) Industrial Process Boiler Cooling Total Industrial (B) Total (A+B) WASTE WATER GENERATION: USAGE EXISTING (KL/DAY) ADDITIONAL (KL/DAY) TOTAL (KL/DAY) (A) Domestic (B) Industrial Process Boiler Cooling Total Industrial (B) Total (A+B)

5 Mode of Waste Water Treatment and Disposal: 1. Water consumption and wastewater generation won t increase/change after amendment and will remain same as existing. 2. Our total effluent is used for land irrigation within premises. 3. Sewage is disposed of through septic tank/soak pit system/ it is treated along with the industrial effluent / it is treated separately. 1.4 Air Pollution Source and Control Management FLUE GAS EMISSON: SR. STACK NO. ATTACHED TO EXISTING Boiler (6 TPH x 2) Co-Generation Plant-2 Boiler (1.2 TPH) D. G. Set (1000 KVA) D. G. Set (520 KVA) HEIGHT (meter) APCM Adequate Stack Height POLLUTANTS PM SO 2 NOX PM SO 2 NOX PM SO 2 NOX PM SO 2 NOX PERMISSIBLE LIMIT 150 mg/nm ppm 50 ppm 150 mg/nm ppm 50 ppm 150 mg/nm ppm 50 ppm 150 mg/nm ppm 50 ppm 5. Flare Stack PM Diesel driven fire SO pump (125 KVA) 2 NOX 7. Diesel driven fire pump (100 KVA) 9.0 Exhaust of powder plant PROPOSED Co-generation 9. Power Plant STACK 50 Boiler 10. (24 TPH) ESP+ Water Scrubber PM SO 2 NOX 150 mg/nm ppm 50 ppm 150 mg/nm ppm 50 ppm PM 150 mg/nm 3 PM SO 2 NOX 150 mg/nm ppm 50 ppm 5

6 SR. NO. PROCESS GAS EMISSON: There is and shall not be process gas emission in existing and after proposed amendment. 1.5 Hazardous Waste TYPE OF HAZARDOUS WASTE CATEGORY 1. Used Oil SCH-I (5.1) Discarded Containers Discarded Bags/ Liners Waste Insulating glass wool Spent Resin from water treatment. Discarded Asbestos containing roof sheet/insulatio n liners Spent carbon from waste water treatment SCH-I (33.1) SCH-I (34.2) SCH-I (15.2) SCH-I (35.3) QUANTITY EXISTING PROPOSED TOTAL 21 MT /YEAR Nos./Year Nos./Year As and when 4000 Ltrs /YEAR. As and when As and when MT /YEAR Nos./Year MT /YEAR Nos./Year Nos./Year Ltrs /YEAR. - - As and when 5200 Ltrs /YEAR. As and when As and when TREATMENT & DISPOSAL storage, transportation, Disposal by selling to Registered reprocesses. Storage, Decontaminati on, disposal by sell to authorized vendors storage, Transportation, & Disposal at TSDF- BEIL storage, transportation & disposal by sell to Registered Reprocesses. storage, transportation & disposal at TSDF-BEIL storage, transportation & disposal at TSDF-BEIL 8. ETP waste

7 Oil contaminated cotton waste. Oil Contaminated filter i.e. at TSDF-BEIL cotton, metal filters Sludge/residue during emptying cleaning petroleum storage tanks Discarded florescent bulb, tube containing mercury E-Waste 12. Bed Ash SCH-I (35.4) SCH-I (3.2) SCH-I (31) SCH-I (35.1) MT/YEAR 3000 Kgs/year 250 Kgs/year 1500 ltrs/year 400 kgs/year - As and when 13. Fly Ash MT/YEAR storage, transportation & disposal at TSDF-BEIL 3000 Kgs/year 250 Kgs/year ltrs/year MT/Year MT/Year 400 kgs/year As and when 3157 MT/Year MT/Year storage, transportation & disposal at TSDF-BEIL storage, transportation & Disposal by sell to Registered Reprocesses storage, transportation & disposal at TSDF-BEIL storage, transportation & Disposal by sell to Registered Reprocesses storage & sell to brick manufactures storage & sell to brick manufactures 1.6 Green Belt Total 4,57,580 m 2 land area is available at site; out of this 1,51,000 m 2 (i.e. 30% of total area) will be developed as greenbelt and other forms of greenery. 7

8 1.7 Power & Fuel Requirements Power Requirement CPP (Natural Gas): 4.93 MW (Existing)-3.95MW = 0.98 MW (Total Proposed) CPP (Coal Based): 3.95 MW (Proposed) DG Set: 1000 KVA (Existing) DG Set: 520 KVA (Existing) Fuel Requirement SR. NO. FUEL 1. Natural Gas EXISTING M 3 /day (Co- Generation Plant)OR 4500 M 3 /day (Boiler I & II) QUANTITY ADDITIONAL M 3 /day (Co-Generation Plant) TOTAL AFTER PROPOSED 13000M3/d for Co- Generation plant or 4500 M 3 /day (Boiler I & II) 2. Diesel 374 Liters/Day Liters/Day 3. Indian Coal MT/DAY MT/DAY 4. Imported Coal MT/DAY MT/DAY 2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 2.1 Identification of the project and project proponent. In case of mining project, a copy of mining lease/letter of intent should be given. Identification of the project M/s. Apcotex Industries Limited proposes expansion of Boiler (24 TPH) as a Utility, Coal Based CPP & Changed in Fuel from Natural Gas to Coal in Existing Rubber & Lattices Manufacturing Unit at Survey No. 27, 103 to 105 & 131 to 137, Village: Dungri, Tal: Valia, Dist. Bharuch, Gujarat. Identification of the project partners SR. NO. NAME DESIGNATION CORRESPONCE ADDRESS WITH CONTACTS 1. Mr. Atul Champaklal Choksey Director Geetanjali, 9 N Gamadia Road, Off Peddar Road, Mumbai Tel: Mr. Abhiraj Atul Choksey Director Geetanjali, 9 N Gamadia Road, Off Peddar Road Mumbai Tel:

9 3. Mr. Girish CHampaklal Choksey 4. Mr. Amit Champaklal Choksey 5. Mr. Manubhai Gokalbhai Patel 6. Mr. Shailesh Shankarlal Vaidya Director Director Director Director Geetanjali, 9 N Gamadia Road, Off Peddar Road Mumbai Tel: Geetanjali, 9 N Gamadia Road, Off Peddar Road Mumbai Tel: , Sahyog, Sardar Patel Nagar, Behind Navrang-Pura Telephone Exchange, Ellisbridge, Ahmedabad Tel: , Sumer Heights, K.M. Munshi Marg, Chowpatty, Mumbai Tel: Mr. Swaminathan Sivram Director Apartment No. 10, Gulmohar Glory-5 Gulmohar Park lti Road Aundh Pune Tel: Mr. Kamlesh Shivji Vikamsey 9. Mr. Yashodhan Bhargao Gadgil 10. Mr. Priyamvada Ashesh Bhumkar Director Director Director 194,Kalpataru Habitat, Tower-A Dr. S. S Rao Road, Parelo Mumbai Tel: Sonakshi Plot No R-16 Sudarshan Nagar, Dombivli East Tel: Vasant Vihar Complex, Row House, 33/34, Pokhran Road No.2, Majiwade, Thane- Ees T Mumbai Tel: Brief description of nature of the Project M/s. Apcotex Industries Limited proposes expansion of Boiler (24 TPH) as a Utility, Coal Based CPP & Changed in Fuel from Natural Gas to Coal in Existing Rubber & Lattices Manufacturing Unit at Survey No. 27, 103 to 105 & 131 to 137, Village: Dungri, Tal: Valia, Dist. Bharuch, Gujarat. 2.3 Need for the project and its importance to the country and or region The demand for products intended to be manufacture is increasing in the country. By this expansion, M/s. Apcotex Industries Limited will be able to meet the demand of various products internationally and locally. This will also generate direct and indirect employment opportunity for various levels of people. 9

10 2.4 Demands-Supply Gap Based on our informal survey of the market with our current customers and various traders, we have found that there is a big potential for the products we are planning. These products will be an addition to the current products. 2.5 Imports vs. Indigenous production Based on the current cost of indigenous raw materials, it will make us very competitive against imported finished products and we will be able to increase the export of our finished products. 2.6 Export possibility We shall explore the possibility of export the products. 2.7 Domestic/Export Markets Majority of the products will be sold in local market. We shall explore the possibility of export the products. 2.8 Employment Generation (Direct and Indirect) due to project. M/s. Apcotex Industries Limited will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. 10

11 3.0 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any. No interlinked project has been submitted. MAP SHOWING GENERAL LOCATION Project Site 11

12 PLANT LAYOUT 12

13 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Looking to the market demand of the products in International market, it was decided by M/s. Apcotex Industries Limited for the expansion. Major factors involved in the selection of site are listed below: Existing operational facility. Site is well connected by road & Rail. Proximity to raw material suppliers. Availability of power and cleaner fuel - natural gas. Availability of water from GIDC water supply. Availability of skilled workmen. Proximity to cities like Bharuch and Ankleshwar, ensure access to already existing social and commercial infrastructure. Modern infrastructure support and amenities at par in other global markets, including: Efficient transport facilities. Environment-friendly zone. Uninterrupted power supply. 3.4 Size or Magnitude of Operation Total Area = 4,57,580 m 2 For Production capacity, please refer Section Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project, etc. should be given) Please refer Form-I, Annexure III. 3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product. For raw material required along with quantity; Please refer Section 1.2. Majority of the raw materials will procure as much as possible from the local market and if there is no availability, will be imported. We shall explore the possibility of export the products. 3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. Total effluent is used for land irrigation within premises. 13

14 3.8 Availability of water its source, energy/power requirement and source should be given. Water Source Total water requirement shall meet through GIDC water supply. Power Requirement CPP (Natural Gas): 4.93 MW (Existing)-3.95MW = 0.98 MW (Total Proposed) CPP (Coal Based): 3.95 MW (Proposed) DG Set: 1000 KVA (Existing) DG Set: 520 KVA (Existing) Fuel Requirement SR. NO. FUEL 1. Natural Gas EXISTING M 3 /day (Co- Generation Plant)OR 4500 M 3 /day (Boiler I & II) QUANTITY ADDITIONAL M 3 /day (Co-Generation Plant) TOTAL AFTER PROPOSED 13000M3/d for Co- Generation plant or 4500 M 3 /day (Boiler I & II) 2. Diesel 374 Liters/Day Liters/Day 3. Indian Coal MT/DAY MT/DAY 4. Imported Coal MT/DAY MT/DAY 3.9 Quantity of wastes to be (liquid and solid) and scheme for their management/disposal. For Effluent generation, Please refer Section 1.3. For Hazardous Waste, Please refer Section

15 3.10 Schematic representations of the feasibility drawing which give information of EIA purpose. ACTIVITIES OVERVIEW OF E. I. A. STUDIES SOURCE OF RECONNAISSANCE SURVEY OF EXISTING PLANT INTRODUCTION ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT BASELINE ENVIRONMENT AL STATUS SOCIOECONOM IC STATUS & PROPOSED PLANT IMPACTS METHODOLOG Y OF IMPACT ASSESSMENT ENVIRONMENT AL MANAGEMENT PLAN ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. FACILITY DESCRIPTION CONSEQUENCE ANALYSIS PREPARATION OF DISASTER MANAGEMENT PLAN RISK ANALYSIS STUDIES & DISASTER MANAGEMENT PLAN SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. 15

16 4.0 Site Analysis 4.1 Connectivity Site is well connected by road & Rail Proximity to raw material suppliers Availability of power and cleaner fuel - natural gas. Availability of water from GIDC water supply Availability of common TSDF and common incineration sites in nearby estate. Availability of skilled workmen Proximity to cities like Bharuch and Ankleshwar, ensure access to already existing social and commercial infrastructure. 4.2 Land Form, Land Use and Land Ownership Land use will be incorporated in EIA Study. 4.3 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given. Land use map will be incorporated in EIA Study. CRZ clearance is not applicable. 4.4 Soil Classification Soil Characteristics under Project Area will be incorporated in EIA studies. 4.6 Climatic data from secondary sources. Shall be incorporated in the EIA Study. 4.7 Social infrastructure available. Depending on the growth of the company the required social infrastructure will be provided. 16

17 5.0 Planning Brief 5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country planning/development authority classification. Type of Industry: M/s. Apcotex Industries Limited proposes expansion of Boiler (24 TPH) as a Utility, Coal Based CPP & Changed in Fuel from Natural Gas to Coal in Existing Rubber & Lattices Manufacturing Unit at Survey No. 27, 105, , 103, 104, Village-Dungri, Tal- Valia, Dist. Bharuch, Gujarat. 5.2 Population Projection Shall be incorporated in the EIA Study. 5.3 Land use planning (breakup along with green belt etc.) Total 4,57,580 m 2 land area is available at site; out of this 1,51,000 m 2 (i.e. 30% of total area) will be developed as greenbelt and other forms of greenery. 5.4 Assessment of Infrastructure Demand (Physical & Social) Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project activity. Social Welfare Cordial relation with the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 5.5 Amenities/Facilities It will be incorporated in EIA Studies. 6.0 Proposed Infrastructure Proposed expansion is in GIDC Panoli. 6.1 Green Belt M/s. Apcotex Industries Limited have develop an effective green belt within the factory and on periphery of the factory. In addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses. 6.2 Social Infrastructure Depending on the growth of the company the required social infrastructure will be provided. 17

18 6.3 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc) Major factors involved in the selection of site are listed below: Site is well connected by road & Rail Proximity to raw material suppliers Availability of power and cleaner fuel - natural gas. Availability of water from GIDC water supply Availability of skilled workmen Proximity to cities like Bharuch and Ankleshwar, ensure access to already existing social and commercial infrastructure. 6.4 Drinking water Management (Source & Supply of water) Total water requirement shall be met through GIDC water supply. 6.5 Sewerage System Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful liquid wastes from the offices, canteen and domestic waste coming from different sections of the industry. These liquid wastes are sent to septic tank & soak pit. 6.6 Solid Waste Management Please refer Form-I, Annexure-V. 6.7 Power Requirement & Supply/Source Please refer Section 3.8 of this report. 7.0 Rehabilitation and Resettlement (R & R) Plan 7.1 Policy to be adopted (central/state) in respect of the project affected including home oustees, land oustees and landless laborers (a brief outline to be given) Expansion will be carried out within existing premises. 18

19 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given). We shall start construction of proposed expansion project after getting EC & CTE and we shall start production after applying for CCA. 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total cost of proposed project will be 3.0 Crores. Existing Cost of project is Crores. 9. Analysis of Proposal (Final Recommendations) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project. Social Welfare shall be done. Cordial relation with the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 19