PRE FEASIBILITY REPORT FOR OBTAINING PRIOR ENVIRONMENT CLEARANCE FOR MANUFACTURING OF SYNTHETIC ORGANIC CHEMICALS OF M/s. MAYUR COLOUR AND CHEMICALS LOCATED AT Plot No. 5148, GIDC Industrial Estate, Ankleshwar 393002, Dist Bharuch, State: Gujarat.
INDEX CHAPTER NO. TITLE PAGE NO. 1. Executive Summary 1 2. Introduction of Project / Background Information 3 3. Project Description 5 4. Site Analysis 13 5. Planning Brief 16 6. Proposed Infrastructure 18 7. Rehabilitation and Resettlement (R & R) Plan 19 8. Project Schedule & Cost Estimates 20 9. Analysis of Proposal 21 [2]
1. EXECUTIVE SUMMARY is involved in manufacturing of synthetic organic products (Agrochemical Industry, Dyes, Glass, Paper, Textile Industry). It is going for expansion by addition of new products within existing premises located at Plot No. 5148, GIDC Industrial Estate, Ankleshwar 393002, Dist Bharuch, State: Gujarat. Project is located within GIDC area. The unit is going for expansion in synthetic organic chemical activity. Therefore, project falls under category B of schedule 5(f), as per the EIA Notification, September 2006. Therefore, it requires prior Environment Clearance. There shall be no forest, wild life sanctuary, eco sensitive area present within 10 km area from the project site. Electric power requirement for existing project is 60 HP, which is procured from DGVCL. It is estimated that the additional power requirement for the proposed project will be 330 HP, which will be also procured from DGVCL. One D. G. Set of capacity 50 KVA is exist, which is use in case of power failure. HSD is used as a fuel in D. G. Set. At present one Steam Boiler of capacity 600 kg/hr, one Hot Air Generator of capacity 300 kg/hr & one no. of Pulverizer-1 are exist. Adequate stack height is provided for Steam Boiler and Hot Air Generator and Bag filter is provided with Pulverizer-1. In addition of these, one Pulverizer-2 will be installed for proposed production activity. Bag filter will be provided with Pulverizer-2. Natural Gas is used as a fuel for Steam Boiler and Hot Air Generator. At present, GIDC is supplying water to unit. For proposed activity, water required for domestic & industrial purpose will be also sourced from GIDC. Domestic effluent shall be disposed in to existing Septic tank / Soak pit system. Effluent generated from manufacturing process and other ancillary operations will be treated into in-house ETP. After primary treatment, treated wastewater will be passed through RO system from RO, RO permeates water will be again reused in process and washing section and RO rejected water will be evaporated by allowing it into spray dryer. Hazardous/solid waste generated from the process and other industrial activity will be stored in a separate hazardous waste storage area and then it will be disposed at nearest TSDF site for secured land filling or disposed by selling to registered re-cyclers/re-refiners or incineration. Unit will get TSDF site membership for disposal of extra quantity of hazardous waste. [1]
Proper safety will be provided during storage, handling and use of hazardous substance. Portable Fire Extinguishers shall be provided at key location. Total area of project site is 1811.10 m 2. Existing green belt area is approx. 380.00 m 2 and proposed 217.66 m 2 area will be developed as a green belt. Therefore, total green belt area will be 597.66 m 2. Due to expansion by addition of new products, employment generation will be more than 33 people. There is already 23 employees (22 men + 01 woman) working at existing plant. Therefore total employment from this project will be 56 people (52 men + 04 women). Total Workers in all Shifts Shift Existing Proposed Male Female Total Male Female Total General Shift 04 01 05 06 03 09 1 st Shift 06 0 06 08 0 08 2 nd Shift 06 0 06 08 0 08 3 rd Shift 06 0 06 08 0 08 Sub Total 22 01 23 30 3 33 Total Male 52, Female 04 [2]
2. INTRODUCTION OF PROJECT / BACKGROUND INFORMATION 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT is involved in manufacturing of synthetic organic chemicals (Agrochemical Industry, Dyes, Glass, Paper, Textile Industry). It is going for expansion by addition of new products within existing premises located at Plot No. 5148, GIDC Industrial Estate, Ankleshwar 393002, Dist Bharuch, State: Gujarat. List of existing product and new products to be manufactured within existing premises is as under; Sr. No. Name of Product LIST OF PRODUCT [3] Quantity (MT/Month) Existing Product End-Use of Products 1. Copper Sulphate In Agrochemical Industry 100.00 2. Sodium Nitrate In Dyes, Glass Industry 3. Dyes (Grinding, Ball Milling, Sieving And Packing of Dyes) 4. Acid Black 210 And Proposed Product 500.00 In Paper, Textile Industry 45.00 In Textile, Leather Industry 5. Acid Brown 161 In Textile, Leather Industry 6. Acid Brown 355 7. Acid Brown 425 8. Acid Brown 432 9. Acid Green 68 10. Acid Red 97 11. Acid Yellow 42 12. Solvent Yellow 14 13. Solvent Red 24 14. Acid Orange 142 15. Acid Black 234 16. Acid Yellow 36 17. Solvent Yellow 2 18. Direct Yellow 12 Total 645.00 In Textile, Leather Industry In Textile, Leather Industry In Textile, Leather Industry In Textile, Leather Industry In Textile, Leather Industry In Textile, Leather Industry In Plastic, Paint Industry In Textile, Leather Industry In Textile, Leather Industry In Textile, Leather Industry In Textile, Paper Industry In Plastic, Paint Industry In Textile, Paper Industry
Note: Unit shall continue to manufacture its all existing products. Proposed products will be manufactured on basis and its production capacity will not exceed 45 MT/Month. After expansion total production capacity shall not exceed 645.00 MT/month. PROJECT PROPONENT is a private limited firm. Mr. Mathurbhai R. Savalia is a Partner of the company. He has experience in this field. 2.2 NATURE OF THE PROJECT is a small scale unit. It covers under the category of synthetic organic chemical industry. At present, unit is manufacturing 03 products and intends to expand the production by adding 15 new products of same category. 2.3 NEED FOR THE PROJECT had engaged in production of inorganic products since last many years and due to increase in market demand, unit wants to expand the production capacity by addition of synthetic organic chemical industry category products. 2.4 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT Due to expansion by addition of new products, employment will be increased. The unit will hire local people from the nearby villages. Due to expansion by addition of new products, employment generation will be more than 33 people. There is already 23 employees (22 men + 01 woman) working at existing plant. Therefore total employment from this project will be 56 people (52 men + 04 women). Total Workers in all Shifts Shift Existing Proposed Male Female Total Male Female Total General Shift 04 01 05 06 03 09 1 st Shift 06 0 06 08 0 08 2 nd Shift 06 0 06 08 0 08 3 rd Shift 06 0 06 08 0 08 Sub Total 22 01 23 30 3 33 Total Male 52, Female 04 [4]
3. PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The unit is engaged in manufacturing of synthetic organic products and intends to expand the present production capacity by addition of new products within existing premises. At present, there are 03 products manufacturing at project site and 15 new products will be manufactured with existing premises. 3.2 LOCATION The site is located at about 21 36'35.92"N latitude and 73 2'15.14"E longitude. LOCATION OF THE PROJECT [5]
3.3 DETAILS OF ALTERNATE SITES No alternative sites examined as proposed project is located within GIDC area. 3.4 SIZE / MAGNITUDE OF OPERATION is a small scale unit. No alternative sites examined as expansion of project will be carried out within existing premises. [6]
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS Project description with process, chemical reaction and mass balance is attached in Annexure 6 of EC application. 3.6 RAW MATERIAL WITH REQUIRED QUANTITY, SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT For Product and Raw material with required quantity, please refer Annexure 4 of EC application and for its source, marketing area of final products and mode of transportation, please refer Annexure 5 of EC application. 3.7 RESOURCE OPTIMIZATION / RECYCLING AND REUSE Unit shall implement the concept of waste minimization. Good Housekeeping practice makes the system easier and less costly. Some of these are as follows: Cleaner production technology shall be adopted for the resource conservation and pollution control. Utilization of water & fuel as per standard operating procedure and avoid its excess use can indirectly conserve our natural resources. All electric motors shall be connected with inverter drive. 3.8 AVAILABILITY OF WATER, ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE Water Availability & Its Source Source of Water: GIDC, Ankleshwar Sr. No. Category WATER CONSUMPTION [7] WATER CONSUMPTION (KL/day) Existing Additional Total i. Domestic 2.00 0.50 2.50 ii. Industrial Process 1.30 13* 14.30 Washing 0.40 1.60 2.00 Boiler 1.00 7.00 8.00 Total 2.70 21.60 24.30 iii. Gardening 0.30 2.10 2.40 GRAND TOTAL (i + ii + iii) 5.00 24.20 29.20 NOTE: Above calculation are based on considering worst case scenario. *Maximum Water consumption will be in Product No. 17 (Solvent Yellow 2).
Energy / Power Requirement & Its Source Electric power requirement for existing project is 60 HP, which is procured from Dakshin Gujarat Vidyut Company Ltd. (DGVCL). There will additional more 330 HP electric power requirement for proposed project, which will also procured from DGVCL. Unit will install one D. G. Set of capacity 50 KVA, which will be use in case of power failure. 3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT / DISPOSAL (A) Quantity of Liquid Waste to be Generated & Its Management / Disposal: Sr. No. Category WASTEWATER GENERATION WASTEWATER GENERATION (KL/day) Existing Additional Total i. Domestic 0.80 0.40 1.20 ii. Industrial Process -- 22** 22 Washing -- 1.50 1.50 Boiler -- 0.50 0.50 iii. Gardening -- -- -- GRAND TOTAL (i + ii + iii) 0.80 24.00 24.80 NOTE: Above calculation are based on considering worst case scenario. **Maximum waste water generated from Product No. 10 (Acid Red 97). DISPOSAL OF WASTEWATER: Existing: 1. Domestic effluent is disposed in to Septic tank / Soak pit system. 2. Unit is ZLD. Proposed: 1. Domestic effluent shall be disposed in to Septic tank / Soak pit system. 2. Industrial effluent generated from manufacturing process and other ancillary operations will be treated into in-house ETP. After primary treatment, treated wastewater will be passed through RO system from RO, RO permeates water will be again reused in process and washing section and RO rejected water forwarded to common MEE facility, managed by BEIL, Ankleshwar for evaporation. [8]
DESCRIPTION OF EFFLUENT TREATMENT PLANT The Raw Effluent coming from the different stream will be collected in to collection tank. Then after, effluent will be transferred into Reaction tank where dosing will be done with hydrated lime and alum. The neutralized & flocculated effluent will be then transferred in a primary settling tank (PST). In PST, sludge will be settled at bottom of the PST which will be sprayed on sludge drying bed, while clear over flow will be carried out in treated water sump. Industrial effluent generated from manufacturing process and other ancillary operations will be treated into in-house ETP. After primary treatment, treated wastewater will be passed through RO system from RO, RO permeates water will be again reused in process and washing section and RO rejected water forwarded to common MEE facility, managed by BEIL, Ankleshwar for evaporation. DESIGN DATA OF EFFLUENT TREATMENT PLANT CAPACITY (30 KLD) Sr. No. Name of the Unit Nos. Capacity 1. Collection Tank 01 30.00 m 3 2. Reaction tank 01 500 Lit 3. Chemical Dosing Tanks 02 250 Lit each 4. Primary Settling Tank 01 25.00 m 3 5. Treated Water Sump 01 50.00 m 3 6. Sludge Drying Bed 02 2x1x1 7. R.O Plant 01 2 m 3 /hr 8. R.O. Rejected water Collection Tank 01 12 m 3 9. R.O Permeate water Collection Tank 01 20 m 3 [9]
(B) Quantity of Hazardous/Solid Waste to be Generated & Its Management / Disposal: Hazardous/Solid waste generated from the process, effluent treatment plant and other industrial activity will be stored in a separate hazardous waste storage area and it will be disposed at nearest TSDF site for further treatment and disposal. The municipal solid wastes generated during operation phase will be disposed to bin of GIDC HAZARDOUS/SOLID WASTE GENERATION & ITS MANAGEMENT Sr. No. Type of Waste Category Source of Generation Quantity (MT/Year) Existing Additional Total After Expansion Disposal 1. Empty Barrels / Containers / Liners Contaminated with Hazardous Chemicals / Wastes 33.1 Sch I Raw Materials & Product 15 35 50 Collection, Storage, Transportation, by send it to authorized decontamination facility / recycler or reuse or send back to supplier who is having authorization with valid CCA and rule 6 permission to receive this waste [10]
2. 3. Process Waste Used / Spent Oil 4. ETP Sludge 26.1 Sch I Process 5 -- 5 5.1 Sch I D G Set 1.32 -- 1.32 35.3 Sch I Effluent Treatment Plant -- 65.00 65.00 Collection, Storage, Transportation and Disposal at TSDF, BEIL Ankleshwar. Collection, Storage, Transportation, Disposal by selling to Registered re-processor. Collection, Storage, Transportation and Disposal at TSDF. (C) Stack Details: Stack Attached to Steam Boiler (Capacity: 600 Kg/Hr) Hot Air Generator (Capacity: 300 Kg/Hr) D. G Set 01 Nos. (Stand By) (Capacity: 50 KVA) Pulverizer-1 Pulverizer-2 Stack Height & Dia. 11.0 m & Fuel Consumption Existing 0.35 m Natural Gas 11.0 m & 0.35 m 5.00 m & 0.10 m 09.0 m & 0.15 m 09.0 m & 0.15 m 2000 m 3 /Month HSD 16 Lit/hr Air Pollution Control System Adequate stack height is provided Parameters PM SO 2 NO x Permissible Limit 150 mg/nm 3 100 ppm 50 ppm -- Bag Filter SPM 150 mg/nm 3 Additional -- Bag Filter PM 150 mg/nm 3 3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE SCHEMATIC REPRESENTATIONS OF PROJECT Location of Project Activity Project is located within GIDC area. Thus, project falls under category B. Production of synthetic organic chemicals. Thus, falls under schedule 5(f). Thus, overall project require EIA as per MoEF notification. [11]
4. SITE ANALYSIS 4.1 CONNECTIVITY The project site is well connected with all infrastructures like National Highway, Railway, Airport, telephone, internet, fax, post, etc. Nearest city is Ankleshwar located 2.93 km in NW direction from the proposed project site. National Highway-8 is located 3.75 km in N direction. Nearest railway station is Ankleshwar Railway Station is located 4.10 WNW directions from the proposed project site. Nearest airport is Surat Airport is located 62.20 km in SW direction from the proposed project site. 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP The land is non agriculture and allotted by GIDC. The land is totally flat. The ownership of the land is unit itself. Sr. No. Title LAND AREA BIFURCATION Existing Ground Floor Area (m 2 ) Proposed First Floor Second Floor Total After Expansion 1) Plant area 200.00-200.00 100.00 500.00 2) Raw material Storage area 310.00-310.00-620.00 3) Office area 70.00 - - - 70.00 4) Utility area 79.60 22.40 - - 102 5) Finished Goods Storage area 205.00-205.00-410.00 6) ETP area - 95.00 - - 95.00 7) Hazardous waste Storage area 94.00 - - - 94.00 8) Greenbelt area 380.00 165.00 - - 545.00 9) Open area 387.50 - - - 105.10 10) Tank area 85.00 - - - 85.00 TOTAL 1811.10 4.3 TOPOGRAPHY For Topography map, please refer Annexure 1 of EC application. [12]
4.4 EXISTING LAND USE PATTERN, SHORTEST DISTANCE FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FOREST, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREA, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ The land is non agriculture. The project site is located in GIDC area. There shall be no forest, wild life sanctuary, eco sensitive area within 10 km from the project site. The details of water bodies and nearest park are mentioned below: Arabian Sea is 45.90 km in W direction. Narmada River is 10.60 km in N direction. Sarthana National Park is 44.40 km in SSW direction. Shoolpaneshwar Wildlife Sanctuary is 80.15 km in ENE direction. Jambughoda Wildlife Sanctuary is 105.35 km in NE direction. 4.5 EXISTING INFRASTRUCTURE Proposed expansion activity will be carried out within existing premises and infrastructure is already available for proposed production activity. Some construction activity will be carried out for the proposed project. G + 2 floor with Roof type shed is already constructed for existing production and existing infrastructure is sufficient to manufacture proposed products. The project site is well connected with all infrastructures like Highway, Railway, Airport, telephone, internet, fax, post, etc. Nearest city is Ankleshwar is located 2.93 km in NW direction from the proposed project site. National Highway-8 is located 3.75 km in N direction. Nearest railway station is Ankleshwar Railway Station located 4.10 km in WNW direction from the proposed project site. Nearest airport is Surat Airport located 62.20 km in SW direction from the proposed project site. 4.6 SOCIAL INFRASTRUCTURE AVAILABLE The project is located in GIDC area. GIDC has already developed power supply, water supply, pucca road, telephone & other communication network, transporters godown & drainage network in the area. Skilled & unskilled manpower available within area. Ambulance and emergency fire & medical service available round the clock. [13]
5. PLANING BRIEF 5.1 PLANNING CONCEPT is existing unit and involved in manufacturing of synthetic organic products. Unit is going for expansion by addition of new products within existing premises located at Plot No. 5148, GIDC Industrial Estate, Ankleshwar 393002, Dist Bharuch, State: Gujarat. G + 2 floor & Roof type shed is already exist. All the basic facilities like tap water, sanitation & drinking water, lunch space & First aid box is provided within premises. The project site is well connected with the road, railway and airport. Finished products and raw materials will be transported through road. There is no requirement for the development of other road or railway. 5.2 POPULATION PROJECTION Due to expansion by addition of new products, employment generation will be more than 33 people. There is already 23 employees (22 men + 01 woman) working at existing plant. Therefore total employment from this project will be 56 people (52 men + 04 women). 5.3 LAND USE PLANNING The breakup of the land area is mentioned in the below table: LAND AREA BIFURCATION Sr. No. Title Existing Ground Floor Area (m 2 ) Proposed First Floor Second Floor Total After Expansion 11) Plant area 200.00-200.00 100.00 500.00 12) Raw material Storage area 310.00-310.00-620.00 13) Office area 70.00 - - - 70.00 14) Utility area 79.60 22.40 - - 102 15) Finished Goods Storage area 205.00-205.00-410.00 16) ETP area - 95.00 - - 95.00 17) Hazardous waste Storage area 94.00 - - - 94.00 18) Greenbelt area 380.00 165.00 - - 545.00 19) Open area 387.50 - - - 105.10 [14]
20) Tank area 85.00 - - - 85.00 TOTAL 1811.10 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) The project is located in GIDC area. GIDC will develop power supply, water supply, pucca road, telephone & other communication network, transporters godown & drainage network in the area. Skilled & unskilled manpower available within area Ambulance and emergency fire & medical service available round the clock. Local people will be hired for proposed project and they will be trained within unit. Thus, no social infrastructure will require. 5.5 AMENITIES / FACILITIES All the basic facilities like tap water, sanitation & drinking water, lunch space will be provided within premises. First aid box, free medicines & doctor service (on call basis) will be provided. Adequate PPE s will be provided to all workers. [15]
6. PROPOSED INFRASTRUCTURE 1. Industrial Area 1811.10 m 2 2. Residential Area Residential area is located 2.55 km in S direction. 3. Green Belt 380.00 m 2 (Existing) + 165.00 m 2 (Proposed) = 545.00 m 2 (Total) 4. Social Infrastructure Social infrastructure available within 10-15 km from project site. 5. Connectivity National Highway-8 is located 3.75 km in N direction. 6. Drinking Water Management Ankleshwar Railway Station located 4.10 km in WNW direction. Surat Airport located 62.20 km in SW direction Source of water for domestic & industrial purpose is to be from GIDC. 7. Sewerage System Domestic effluent shall be disposed in to Septic tank / Soak pit system. 8. Industrial Waste Management 9. Solid Waste Management 10. Power Requirement & Supply / Source Industrial effluent generated from manufacturing process and other ancillary operations will be treated into in-house ETP. After primary treatment, treated wastewater will be passed through RO system from RO, RO permeates water will be again reused in process and washing section and RO rejected water will be evaporated by allowing it into spray dryer. Empty Barrels / Containers / Liners Contaminated with Hazardous Chemicals / Wastes Collection, Storage, Transportation, by send it to authorized decontamination facility / recycler or reuse or send back to supplier who is having authorization with valid CCA and rule 6 permission to receive this waste Process Waste Collection, Storage, Transportation and Disposal at TSDF, BEIL Ankleshwar Used or Spent Oil Collection, Storage, Transportation, Disposal by selling to Registered re-processor. Chemical Sludge from Waste Water Treatment Collection, Storage, Transportation and Disposal at TSDF MSW disposed to bin of GIDC. Source: Dakshin Gujarat Vidyut Company Ltd. (DGVCL) Existing Power requirement: 60 HP Proposed power requirement: 330 HP Total Power requirement: 390 HP [16]
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN The project is located within GIDC area therefore no Rehabilitation & Resettlement (R & R) plan is involved in proposed project. [17]
8. PROJECT SCHEDULE & COST ESTIMATES 8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION M/S. Mayur Colour and Chemicals has valid CC&A for existing products. Expansion in existing products & Production of new products shall be started after getting Environment Clearance & Consent. 8.2 PROJECT COST ESTIMATION Estimated cost for the proposed project is as under; Details Approximate Capital Cost (Rs. in Lacs) Land -- Building 20.00 Machinery 50.00 ETP & HWM 5.00 Greenbelt Development 3.00 Occupational Health & Safety 10.00 TOTAL 88.00 [18]
9. ANALYSIS OF PROPOSAL 9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA Project is located in GIDC area. Therefore, No R & R plan involved in proposed project. Due to proposed project it is expected that employment will increase for people who reside nearby project area. Approx. 33 people will get employment directly. Due to increase in raw material and product transportation activity, indirect employment will generate. As local people will get job, their living status will increase. Due to green belt development, aesthetic value of local environment will improve. [19]