CLASSIC OIL LTD. PFR for Environmental Clearance (EC) of Proposed Greenfield project of Manufacturing of speciality Chemicals& intermediates at Plot No.: B-14 MIDC Mahad, District: Raigad, Maharashtra Goldfinch Environmental Engineering Systems Private Limited ( Goldfinch ), Augestl 2016 This report is released for the use of the M/s Classic oil Ltd (Classic oil). Regulators and relevant stakeholders solely as part of the subject EC of Proposed Greenfield project of Manufacturing of Speciality Chemicals& intermediate at Plot No.: B-14, MIDC Mahad, District: Mahad, Maharashtra. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Goldfinch/Classic Oil. QUALITY CONTROL Name of Publication Proposed Greenfield project of Manufacturing of Synthetic Organic Chemicals, at Plot No.: B-14 MIDC Mahad, Taluka: Mahad, District: Raigad, Maharashtra Project Number No. 1 Version 1 Released September, 2016 Prepared By Reviewed By Released By Dr. Nivedita Kulkarni & Mr. Vishal Jasal Mr. K. N. Sharma Mr. Anand Apte DISCLAIMER Goldfinch has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Goldfinch also believes that the facts presented in the report are based on information submitted by Classic oil and based on the technical expertise of Goldfinch as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Goldfinch therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation. Page 1
CONTENTS 2.0 PROJECT DESCRIPTION... 9 2.1 Type of Project... 9 2.2 Project Location... 10 2.3 Details of alternate sites considered and the basis of selecting the proposed site... 12 2.5 Process Description... 14 1. CYCLOHEXANOL... 14 2. 2 METHYL CYCLOHEXANOL... 15 3. N-BUTYL CHLORIDE (NBC)... 17 4. ISO BUTYL CHLORIDE (IBC)... 18 5. TERTIARY BUTYAL CHLORIDE (TBC)... 20 6. TRIOCTYL PHOSPHATE / TRI (ETHYL HEXYL) PHOSPHATE)... 21 7. TRIPHENYL PHOSPHITE... 23 8. TRIETHYL PHOSPHITE... 25 9. TRIMETHYL PHOSPHITE... 27 10. TRIBUTYL PHOSPHATE... 28 11. 2 METHYL CYCLOHEXYL ACETATE... 30 12. DI-ISO BUTYL CARBINOL (DIBC)... 33 13. 2- ETHYL ANTHRAQUINONE... 35 14. INDOSOL-V... 36 15. TYRAMINE/ TYRAMINE HCl... 38 2.6 Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product... 40 Raw Materials:... 40 Source for Raw Material Procurement... 40 Mode of Transport of Raw Materials... 40 Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of storage yard is demarcated in Layout Plan.... 40 2.7 Resource optimization/recycling and reuse envisaged in the project... 41 2.8 Availability of water its source, energy/power requirement and source... 41 2.8.1 Water Requirement and Source... 41 2.8.2 Power Requirement... 41 Page 2
2.8.3 Fuel Requirement... 42 2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal... 42 2.9.1 Gaseous Emissions... 42 2.9.2 Liquid Effluent... 43 2.9.3 Details of Hazardous wastes... 45 2.10 Schematic representations of the feasibility drawing which give information of EIA purpose.... 46 3.0 SITE ANALYSIS... 47 3.1 Connectivity... 47 3.2 Land Form, Land use and Land ownership... 47 3.3 Topography... 47 Figure 3.1: Toposheet Showing Project site and 10Km of area... 47 3.4 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.... 48 The proposed land for setting new unit is located in Notified Industrial Estate. The land is acquired by Classic Oil Ltd.The proposed site is an undeveloped land which does not include agricultural, forestry, water bodies (including CRZ) etc.... 48 3.5 Soil classification... 48 3.6 Climatic data from secondary sources... 48 Climate Classification... Error! Bookmark not defined. Temperature... Error! Bookmark not defined. Rainfall:... Error! Bookmark not defined. Humidity:... Error! Bookmark not defined. 3.7 Social Infrastructure Availability... 48 4.0 PLANNING IN BRIEF... 48 4.1 Planning Concept... 48 4.3 Assessment of Infrastructure Demand (Physical & Social)... 49 4.4 Amenities/Facilities... 49 5.0 PROPOSED INFRASTRUCTURE... 50 5.1 Industrial area... 50 5.2 Residential Area... 51 5.3 Green Belt... 51 Page 3
5.4 Social Infrastructure... 51 5.5 Connectivity... 51 The proposed site is well connected with the roads connecting SH-70 at an aerial distance of 2 kms towards South. Nearest railway station is located at Veer at an aerial distance of 10 kms. Nearest airport is located at Mumbai at an aerial distance of 170 kms.... Error! Bookmark not defined. 5.6 Drinking Water Management... 51 5.7 Sewage System... 51 5.8 Industrial Water Management... 51 5.9 Solid Waste Management... 51 5.10 Power Requirement & Supply / source... 51 6.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN... 51 6.1 Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless.... 51 7.0 PROJECT SCHEDULE & COST ESTIMATES... 52 7.1 Likely date of start of construction and likely date of completion... 52 7.2 Estimated project cost along with analysis in terms of economic viability of the project... 52 Economic Viability... 52 8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)... 52 Page 4
LIST OF FIGURES Fig. 2-3 : Photographs of Site Location of proposed project of Classic Oil Ltd 10 Figure 2-2 : Plot on MIDC plan...11 Fig. 2-3 : Photographs of Site Location of proposed project of Classic Oil Ltd 12 LIST OF TABLES Table 2-1: Size/Magnitude of Proposed Production Capacity..13 Table 2-2: Details of Raw material Quantity 40 Table 2-3: Details of Raw water consumption 41 Table 2-4: Details of emissions from process and flue gas. 42 Table 2-5: Details of stacks along with their mitigation methods..43 Table 2-6: Details of effluent Genration.43 Table 2-7: Design Parameters for ETP 44 Table 2-8: Details of Proposed Hazardous Solid waste along with the Category and disposal method 45 Table 4-1: Land use Break Up. 49 Table 7-1: Cost Break Up.. 52 LIST OF ANNEXURES Annexure 1: Site Layout Map Page 5
EXECUTIVE SUMMARY Classic Oil Ltd. (COL) is sister concern of M/s. Indo Amines Ltd. (IAL) having corporate office at Plot No. W44, MIDC, Phase-II, Dombivli (E) 421203. IAL is one of the India's Largest Independent manufacturers of Fine, Specialty & Performance Chemicals providing a comprehensive package of products & technical services for Indian & Global markets. IAL has come forward for revamping COL with all the technical support for manufacturing, of Cr.2MCNOL and Cr.DIBC. Classic oils Ltd, propose green field project to produce Speciality Chemicals & intermediates at Plot nob-14, MIDC Mahad, District Mahad, Maharashtra. The proposed project falls under classification 5(f) of schedules listed in EIA notification SO1533 dated 14/09/2006. Its appraisal category is B-1. Project Synopsis: Sr. No Parameters Description 1. Category as per EIA Notification 5 (f ) B 2. Longitude 18.009793 N 3. Latitude 73.490087 E 4. Proposed Production Capacity 2620 MT/M, and By-products 854.54 MT/M 5. Total Plot Area 4050.00 sq. m. 6. Green Belt Area 668.25 sq. m. 7. Fresh Water Requirement 245 CMD 8. Effluent Quantity (Trade + Domestic) 62CMD +3.8CMD = 65.8 CMD 9. 10. Trade Effluent Treatment 62 CMD effluent will be treated in ETP of capacity 75 CMD.It will be consists of primary, secondary and tertiary treatment. Treated water will be discharged to CETP Mahad for final disposal into sea. Domestic Waste water Treatment 3.8 CMD Treatment in soak pit followed by septic tank Fuel requirement at full load Boiler: 5TPH X 1 no : 315 kg/hr 11. Thermopac 10 lac Kcal/hr X 1no = 126 kg/hr D G set = 500 KVA X 1 no 138 kg/hr 12. Power Requirement 1100 KW 13. Dispersion of emission for Boiler and thermopac Stack Height : 40 m common stack for boiler and thermo Pac. 14. Dispersion of emission DG Sets, Stack Height : 5 m above enclosure 15. Work Force 65 16. Total Capital Cost the project (Cr) Rs 17.25 Cr. Page 6
1.0 INTRODUCTION OF THE PROJECT 1.1 Introduction of the Project Classic Oil Ltd (Hereafter being referred as Classic or COL for brevity in this text) intends to start a new project to manufacture specialty Chemicals & intermediates for example 2-MCA and DIBC. These are used as a plasticizers and solvents for high temperature reaction; especially for the production of hydrogen peroxide. These also finds application in flavors and fragrances manufacturing processes. The proposed manufacturing unit is to come up in MIDC Mahad which is approved chemical manufacturing zone of MIDC. COL has taken over plot no B-14 in MIDC for this purpose. The plot originally belonged to Mr.R.K. Govil under the name of Classic Oil Ltd. for Oil processing facility. This company turned inoperative because of financial problems. As per the EIA Notification S.O. 1533 dated 14th September 2006, proposed activity is covered under Synthetic Organic Chemical Industry 5 (f) and needs prior environmental clearance. Further, as the proposed industry is under category B. Since it is located in a notified industrial area the project will not need public approval and is under category B. 1.2 Introduction of the Project Proponent Classic Oil Ltd, is sister concern of Indo Amines Ltd. (IAL). IAL is one of the India's Largest Independent manufacturers of Fine, Specialty & Performance Chemicals providing a comprehensive package of products & technical services for Indian & Global markets. IAL manufacturing unit is located at MIDC Dombivli. IAL has come forward for revamping COL with all the technical support for manufacturing, of Cr.2MCNOL and Cr.DIBC List of Directors and their designations S.No. Name Designation 1 Mr. Vijay Bhalchandra Palkar Director 2 Mrs. Bharati Vijay Palkar Director 3 Mr. Rahul Vijay Palkar Director 4 S K Chaugule Director 5 Sudhakar Patil Director 6 Mr. Pandurang Kokitkar Director Page 7
1.3 Brief description of nature of the project COL aims to set up the facility of production of various speciality chemicals required for manufacturing hydrogen peroxide, woth provision for stage wise capacity enhancement in the near future. The main products to be manufactured includes 2- methyle cyclohexyl Acetate ( 2-MCA), Di- isobutyl Carbinol (DIBC), 2-Ethyl Antraquionone (2-EAQ), Indosol-V etc. 1.4 Need for the project and its importance to the country and or region 2-MCA and DIBC is used as a plasticizer and solvent for high temperature reaction; especially for the production of hydrogen peroxide. It also finds application in flavors and fragrances manufacturing processes. In the changing scenario the demand of hydrogen peroxide is not only limited to pulp and paper industries. Consumption of hydrogen peroxide as an oxidizing agent in the environmental segment has grown significantly in the last five years. Hydrogen peroxide has the reputation of being an environmentally friendly and efficient product. As environmental awareness is increasing globally and legislative requirements are becoming more stringent, this market is expected to remain important in the forecast period and result in increasing consumption of hydrogen peroxide. Specialty grades of hydrogen peroxide are being used in food, cosmetics and the electronics industry, and have been growing in line with growth in the respective areas. For the forecast period it is expected that increases in world population, average wealth and disposable incomes will continue to result in growth for hydrogen peroxide in the respective sectors. In view of this ever increasing hydrogen peroxide demand in domestic and international market, IAL has clear opportunity to enhance 2-MCA and DIBC business. The first stage of manufacturing 2-MCA and DIBC is planned to carry out at COL and further processing will be done at existing IAL Dombivli setup. 1.5 Demands-Supply Gap Competition in the Indian Chemical market swelled in recent years, with increasing generic penetration. This had many companies opting out of low-margin segments, as competition resulted in lower prices. This created a gap between demand and supply. Such unusual price hikes take place when there is withdrawal of some of the key competitors, which leads to demand override and as a consequence prices start soaring in a free-pricing market. 1.6 Imports vs. Indigenous Production The proposed products including production of speciality chemicals having high in demand in the export market. Also their demand is increasing in the domestic market. Production of these products are domestically reduces the need to import these in future along with significant scope for export in these products. 1.7 Domestic /Export Markets The finished goods will be sold in domestic market and would be largely exported to the Regulated International Market as per demand in Europ, Africa etc. 1.8 Employment Generation due to the project The new project will generate direct employment opprtunity around 65 no. Page 8
In addition the project will increase business opportunities to local population in the areas of transportation, hotels and restaurents, kirana merchants, housing, banking, stationary suppliers etc. Since the project will need 18660 kg/tone of products as a raw materials. it will increase business opportunity to suppliers of these items and in turn employment benefits and other benefits to their areas as well.the activities under proposed industry would produce improvement in the socioeconomic status of people in the study area in terms of local labor employment and contract basis jobs. The proposed activity might provide employment opportunities to the local populace, especially in business and other services like transportation activity.it is expected to direct or indirect employ about 180 people of various skills will be required during operation phase. 2.0 PROJECT DESCRIPTION 2.1 Type of Project Proposed project is a greenfield project to manufacture Speciality chemicals and intermeditates falling in category 5(f) B of EIA notification 2006. Page 9
2.2 Project Location Proposed manufacturing unit will come up at Plot No. B-14, in MIDC Mahad, District:Mahad, State:Maharashtra The proposed site is well connected by road to Mumbai by Mumbai Goa (NH-66) National Highway at 2 Km. It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Mahad for public transport. Nearest railway station is at Veer which is 10 Km away from site. The nearest airport is at Pune 130 km and at Mumbai 170 km.. Figure 2-1 : Google Image of the Site Page 10
Figure 2-2 : Classic oill Plot on Mahad MIDC plan Page 11
Fig. 2-3 : Photographs of Site Location The project site is situated in MIDC Mahad. It is a notified industrial area where the land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity.the detail plant lay out is attched as Annexure-I Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company for 99 years. 2.3 Details of alternate sites considered and the basis of selecting the proposed site COL is a sister concern of Indo amines Ltd who have a manufacturing unit in MIDC Dombivli. Line of production is also similar. As a part of growth IAL needed more space to expand their activities. Since there is no space in DOmbivli, this alternate site is chosen to conduct operations in name of classic oils ltd. The reasons for selection of this alternate site are: Location is within the established notified industrial estate Availability of common infrastructural facilities of the industrial estate Availability of water supply in the industrial estate Availability of un-interrupted power supply in the industrial estate Page 12
Nearby availability of CETP for the disposal of treated effluent 2.4 Size or Magnitude of Operation The products manufactured and their capacities proposed are shown in below Table 2.1. Table 2-1: Size/Magnitude of Proposed Production Capacity S. No. Products Quantity (MTM) 1 CYCLOHEXANOL 20 2 2 METHYL CYCLOHEXANOL 40 3 N - BUTYL CHLORIDE(NBC) 20 4 ISOBUTYL CHLORIDE (IBC) 10 5 TERTIARY BUTYL CHLORIDE (TBC) 10 6 TRIOCTYL PHOSPHATE / TRI (ETHYL HEXYL) PHOSPHATE) 400 7 TRIPHENYL PHOSPHITE 20 8 TRIETHYL PHOSPHITE 50 9 TRIMETHYL PHOSPHITE 30 10 TRIBUTYL PHOSPHATE 100 11 2 METHYL CYCLOHEXYL ACETATE 300 12 DI-ISO BUTYL CARBINOL (DIBC) 100 13 2- ETHYL ANTHRAQUINONE 100 14 INDOSOL-V 1400 15 TYRAMINE/ TYRAMINE HCl 20 Total /Month 2620 Size/Magnitude of Proposed By-Production Capacity S. No. Products Quantity (MTM) 1 Spent Acid (HCl 25%) 776 2 Dilute Acetic Acid 71 3 Sodium Acetate 7.54 Total 854.54 Note: The total production capacity will not exceed to 1000MT/M Page 13
2.5 PROCESS DESCRIPTION 1. Cyclohexanol A. Chemical Reaction: OH OH + H 2 RNC Phenol Cycl ohexanol M.Wt = 94.00 M.Wt = 100 B. Brief Manufacturing Process: PHENOL is hydrogenated in presence of RNC to produce CYCLOHEXANOL. C List of Raw Material: 1. CYCLOHEXANONE 2. HYDROGEN 3. RANEY NICKEL CATALYST C. Flow Chart: Page 14
d. Mass Balance Remark INPUT MATERIAL OUTPUT MATERIAL Sr. No. Name Quantity Name 1 CYCLOHEXANONE 983 Kg CYCLOHEXANOL : 1000 Kg Product 2 HYDROGEN 27 Kg RECOVERED RNC : 2.0 Kg Recycle 3 RANEY NICKEL CATALYST 2.0 Kg Water from reactor Washing : 250kg ETP Water for reactor Washing & 4 equipment washing (After complete 250 kg campaign of 20 MT water required for reactor washing is 5kl ) Total 1252 KG Total : 1252KG 2. 2 METHYL CYCLOHEXANOL Molecular Weight:114.19 g/mole CAS No. :583-59-5 Chemical Reaction: OH OH CH 3 + H 2 RNC CH 3 O - Cresol 2 - Methyl Cycl ohexanol M.Wt = 108.00 M.Wt = 116.0 Brief Manufacturing Process: O- Cresol is hydrogenated in presence of Raney Nickel catalyst to produce 2 Methyl Cyclohexanol List of Raw Material: 1. O-CRESOL 2. Hydrogen 3. RNC Page 15
Flow Chart: Mass Balance: Sr. No. 1 ORTHO-CRESOL INPUT MATERIAL OUTPUT MATERIAL Name Quantity Name Remark 950 Kg Cr. 2MCNOL 1000 Kg Product 2 HYDROGEN 50 kg Spent RNC : 1.1 Kg Recycle 3 RNC 1.1 Kg Water from reactor Washing : 125kg ETP 4 Water for reactor Washing & equipment washing (After complete campaign of 125 40MT water required for reactor washing is 5kl ) Total 1126.1 kg Total : 1126.1 kg Page 16
3. N-BUTYL CHLORIDE (NBC) Molecular weight:92.57 g/mole CASNo:109-69-3 Chemical Reaction: + H 3 C OH HCl H 3 C Cl + H 2 O n - Butanol M.Wt = 74.12 n - Butyl Chloride M.Wt = 92.57 Raw Materials: 1. n - Butanol 2. Dry HCl gas Brief Manufacturing Process: Reaction of n-butanol in presences of Dry HCl gas at desired temperature gives product n -Butyl Chloride which is then distilled out to get required purity and residue is recycled for the next batch. Flow Chart: Page 17
Mass Balance: Sr. No. INPUT MATERIAL OUTPUT MATERIAL Remarks Name Quantity Name Quantity 1 N - BUTANOL 801.3 kg N-Butyl Chloride 1000 kg Product 2 HCl 394.5 kg Effluent Water 195.8 kg ETP 3 Water for reactor Washing & equipment washing (After complete campaign of 20MT water required for reactor washing is 5kl ) 250 kg Water from reactor Washing 250kg Total 1445.8 kg Total 1445.8 kg ETP 4. ISO BUTYL CHLORIDE (IBC) Molecular weight:92.57 g/mole CASNo:513-36-0 Chemical Reaction: OH H 3 C CH 3 + HCl Cl + H 2 O H 3 C CH 3 Isobutanol M.Wt = 74.12 Iso Butyl Chloride M.Wt = 92.57 Raw Materials: 1. Isobutanol 2. HCl Brief Manufacturing Process: Reaction of Isobutanol in presences of HCl at desired temperature gives product Iso Butyl Chloride which is then distilled out to get required purity and residue is recycled for the next batch. Page 18
Flow Chart: Mass Balance: Sr. No. INPUT MATERIAL OUTPUT MATERIAL Remark Name Quantity Name Quantity 1 ISOBUTANOL 801.3 kg 2 HCl 394.5 kg 3 Water for reactor Washing & equipment washing (After complete campaign of 10MT water required for reactor washing is 5kl ) 500 kg ISOBUTYL CHLORIDE EFFLUENT WATER Water from reactor Washing 1000 kg Product 195.8 kg ETP 500kg Total 1695.8 kg Total 1695.8 kg ETP Page 19
5. TERTIARY BUTYAL CHLORIDE (TBC) Molecular weight:92.57 g/mole CAS No: 507-20-0 Chemical Reaction: C H 3 CH 3 OH HCl C CH3 + H 3 CH 3 Cl CH3 + H 2 O Raw Materials: M.Wt = 74.07 Tertiary Butyl Chloride M.Wt = 92.57 1. Tertiary Butanol 2. Dry HCl gas Brief Manufacturing Process: Reaction of tertiary butanol in presences of HCl at desired temperature gives product Tertiary Butyl Chloride which is then distilled out to get required purity and residue is recycled for the next batch. Flow Chart: Page 20
Mass Balance: Sr. No. INPUT MATERIAL OUTPUT MATERIAL Remark Name Quantity Name Quantity 1 TERTIARY BUTANOL 801.3 kg TERTIARY CHLORIDE 1000 kg Product 2 HCL 394.5 kg EFFLUENT WATER 195.8 kg ETP 3 Water for reactor Washing & equipment washing (After complete campaign of 10MT water required for reactor washing is 5kl ) 500kg Water from reactor Washing 500kg Total 1695.8 kg Total 1695.8 kg ETP 6. TRIOCTYL PHOSPHATE / TRI (ETHYL HEXYL) PHOSPHATE) Molecular Weight: 434.63 g/mole CAS No. : 1806-54-8 Reaction Scheme: H 3 C CH 3 O 3 H 3 C OH H 3 C O P O CH 3 + POCl 3 + 3 HCl O H 3 C TOP M.Wt = 434.63 2 - Ethylhexanol M. Wt = 130.23 CH 3 CH 3 Brief Manufacturing Process: Reaction of 2-Ethyl Hexanol with POCl3 at desired temperature under Nitrogen gives crude TOP. Crude TOP on distillation under vacuum gives pure TOP. Page 21
List of Raw Material : 1. 2- Ethyl Hexanol 2. Phosphorous oxychloride (POCl 3 ) Flow Chart: Mass Balance: Sr. No. Input Material Output Material Remark Name Quantity Name Quantity 1 2-Ethyl Hexanol 899 TOP 1000 Product 2 POCl3 352 HCl (25%) 1011 By-Product 3 3 Water for reactor Washing & equipment washing (After complete campaign of 400 water required for reactor washing is 15kl ) Water used to scrub out HCl 37.5 760 Water from reactor Washing Total 2048.5 kg Total 2048.5 kg 37.5 ETP Page 22
7. TRIPHENYL PHOSPHITE Molecular Weight:310.28 g/mole CAS No. :101-02-0 Reaction Scheme: OH 3 + POCl 3 O + 3 HCl O P O Phenol M.Wt = 94.11 Brief Manufacturing Process: Tri Phenyl Phosphite M.Wt = 310.28 Reaction of Phenol with PCl3 at desired temperature gives crude TPPI. Crude TPPI on purification under vacuum distillation gives pure TPPI. List of Raw Material : 1] Phenol 2] Phosphorous Trichloride Flow Chart: Page 23
Mass Balance: Input Material Output Material Sr. No. Name Quantity in Kg Name Quantity 1 Phenol 888 TPPI 1000 kg Product 2 PCl3 444 HCl 25% 332 By-product 3 Water for reactor Washing & equipment washing (After complete campaign of 20 MT 250 Water from reactor Washing 250 ETP water required for reactor washing is 5kl ) 4 Water used to scrub out HCl 1059 Total 2641 Total 2641 kg Page 24
8. TRIETHYL PHOSPHITE Molecular Weight:166.16g/mole CAS No. :122-52-1 Reaction Scheme: H 3 C 3 H 3 C + OH Ethanol M.Wt = 46.06 PCl 3 O P O O + 3 HCl H 3 C CH 3 Triethyl Phosphite M.Wt = 166.16 Brief Manufacturing Process: Reaction of Ethanol with PCl3 at desired temperature gives crude TEPI.Crude TEPI on purification under vacuum gives pure TEPI. List of RawMaterial: 1] Ethanol 2] Phosphorous Trichloride Flow Chart: Page 25
Mass Balance: Total Input Qty Kg Total Output Qty Kg Remark Ethanol 836.3 TEPI 1000 Product PCl3 832 HCl 668.3 Water for reactor Washing & equipment washing (After complete campaign of 50MT water required for reactor washing is 5kl ) Water used to scrub out HCl 100 1977 Water from reactor Washing Total 3745.3 Total 3745.3 100 Sold to authorized party Page 26
9. TRIMETHYL PHOSPHITE Molecular Weight:124.08 g/mole CAS No. :121-45-9 Reaction Scheme: CH 3 H 3 C OH PCl 3 Methanol + O O P O CH 3 + 3 HCl M.Wt = 32.00 CH 3 Trimethyl Phosphite M.Wt = 124.08 Brief Manufacturing Process: Reaction of Methanol with PCl3 at desired temperature gives crude TMPI.Crude TMPI on purification under vacuum gives pure TMPI. List of RawMaterial: 1] Methanol 2] Phosphorous Trichloride Flow Chart: Page 27
Mass Balance: Total Input Qty Kg Total Output Qty Kg Remark Methanol 775.4 TMPI 1000 Product PCl3 1110.8 HCl 886.2 Sold to authorized party Water for reactor Washing & equipment washing (After complete campaign of 30mmmmmMT water required for reactor washing is 5kl ) 167 Water from reactor Washing 167 ETP Water used to scrub out HCl 2647.5 Total 1886.2 Total 1886 10. TRIBUTYL PHOSPHATE Molecular Weight:266.31 g/mole CAS No. :126-73-8 Reaction Scheme: 3 H 3 C n - Butanol M.Wt = 74.12 OH + POCl 3 C H 3 O TBP M.Wt = 266.31 O P O O CH 3 + 3 HCl CH 3 List of RawMaterial: 1] n- Butanol 2] Phosphorous oxychloride Page 28
Brief Manufacturing Process: Reaction of n- Butanol with POCl3 at desired temperature gives crude TBP.Crude TBP on purification under vacuum gives pure TBP. Flow Chart: Mass Balance: Total Input Qty Kg Total Output Qty Kg Remark n- Butanol 835 TBP 1000 Product POCl3 575 HCl 25% 1640 By-Product Water for reactor Washing & equipment washing (After complete campaign of 100MT water required for reactor washing is 10kl ) 100 Water from reactor Washing 100 ETP Water used to scrub out HCl 1230 Total 2740 Total 2740 Page 29
11. 2 METHYL CYCLOHEXYL ACETATE Molecular Weight:156.22 g/mole CAS No. :5726-19-2 Chemical Reaction: O OH Ortho Cresol CH 3 + H 2 RNC M.Wt = 108.00 M.Wt = 114.00 OH O CH 3 + H 3 C OH Acetic acid 2 - Methyl Cyclohexanol M.Wt = 60 O CH 3 CH 3 Dil Acetic acid + 2 - MCA M.Wt = 156.22 Brief Manufacturing Process : O- Cresol is on hydrogenation give Crude 2 MCNOL which on again esterification we get Crude 2 Methyl cyclohexyl acetate, which is on further distillation get distilled 2 Methyl cyclohexyl acetate. List Of Raw Material: Stage-I 1. ORTHO-CRESOL 2. HYDROGEN 3. RNC Stage-II 1. Cr. 2 MCNOL 2. ACETIC ACID 3. TOLUENE 4. ACETIC ANHYDRIDE 5. MSA 6. SODA ASH Stage-III 1. Cr. MCA 2. SODA ASH Page 30
Flow Chart: Stage - I Stage - II Stage - III Page 31
Mass Balance: Stage I Remark Input Material Output Material Sr. No. Name Quantity Name ORTHO-CRESOL 786 Kg Cr. 2MCNOL 825 Kg For purification 2 HYDROGEN 39 KG Spent RNC : 1.0 Kg Recycle 3 RNC 1 Kg Total 826 kg Total : 826 kg Stage II Input Material Sr. No. Name Quantity Name Output Material Remark 1 Cr. 2 MCNOL 825 Kg Cr. 2MCA : 1190 Kg For purification 2 ACETIC ACID 494 Kg Dil,. Acid: 273 Kg By-product 3 TOLUENE 150 Kg Sodium Acetate : 29 Kg By-product 6 SODA ASH 23 Kg Total 1492 Kg Total : 1492 kg Stage III Remark Input Material Output Material Sr. No. Name Quantity Name 1 Cr. 2 MCA 1190 Kg 2-MCA : 1000 Kg Product Recovered Toluene: 95 Kg Recovered Water for reactor Washing & equipment washing (After complete campaign 300 MT water required for reactor washing is 10 kl ) 33.3 kg MF/LP & RP : 92 Kg Residue : 3 Kg Water from reactor Washing : 33.3 kg Reuse Disposal to MWM(CHWTSDF) ETP Total 1223.3 Kg Total : 1223.3 kg Page 32
12. DI-ISO BUTYL CARBINOL (DIBC) Molecular Weight:144.25 g/mole CAS No. :108-82-7 Chemical Reaction : CH 3 O CH 3 CH 3 OH CH 3 H 3 C CH 3 + H 2 RNC H 3 C CH 3 Diisobutyl Ketone Diisobutyl Carbinol M.Wt = 143.25 M.Wt = 144.25 Brief Manufacturing Process : Hydrogenation reaction of Di-isobutyl ketone in presence of RNC to give Di-isobutyl carbinol. List Of Raw Material: 1. DI-ISO BUTYL KETONE 2. HYDROGEN 3. RNC Flow Chart: Page 33
Mass Balance: Input Material Sr. No. Name Quantity Name 1 DIBK 980 KG DIBC : 1000 KG Output Material Remark For purification 2 HYDROGEN 20 KG RNC Recycle :2 KG Recycle 3 RNC 2 KG 4 Water for reactor Washing & equipment washing (After complete campaign of 100MT water required for reactor washing is 10kl ) 100 kg Total 1102 Kg Total : 1102 KG Water from reactor Washing : 100 kg ETP Page 34
13. 2- ETHYL ANTHRAQUINONE Molecular Weight:236.27g/mole CAS No. :84-51-5 Chemical Reaction: O O CH 3 Distillation CH 3 Residue O Crude 2 - Ethyl Antraquinone M.Wt = 236.27 O Pure 2 - Ethyl Antraquinone M.Wt = 236.27 Brief Manufacturing Process : Distillation of crude 2 - Ethyl Anthraquinone at high vacuum and desired temperature it gives pure 2 - Ethyl Anthraquinone. List of Raw Material : Crude 2- EAQ Flow Chart: Page 35
Mass balance: Input Material Output Material Remark Sr. No. Name Quantity Name 1 Crude 2-EAQ 1030kg Pure 2-EAQ=1000Kg Product Water for reactor Washing & equipment 2 washing (After Water from reactor Washing : complete campaign 50 kg 50kg 100MT water required ETP for reactor washing is 5kl ) Total 1080 kg 1080 kg 14. INDOSOL-V Molecular Weight:279 g/mole CAS No.: 64742-94-5 Chemical Reaction: R R + H 2 RNC H 3 C CH 3 M.Wt = 279.00 Brief Manufacturing Process: Indosol crude is hydrogenated to get technical grade Indosol V which is then subjected to fractional distillation to get pure Indosol V. List of RawMaterial: 1. Crude Indosol 2. Hydrogen gas 3. RNC Page 36
Flow Chart: MASS BALANCE: Sr. No. 1 Input Material Output Material Remark Name Quantity Name Crude Indosol 1020 kg Indosol V pure: 1000 kg Product 2 Hydrogen gas 5 Kg Residue : 20 Kg Disposal 3 RNC 4.0 Kg Loss:5 kg Recovered RNC : 4 kg 4 Water for reactor Washing & equipment washing (After complete campaign water required for reactor washing is 5kl ) 250 kg Water from reactor Washing : 250kg Total 1279 kg Total 1279 kg ETP Page 37
15. TYRAMINE/ TYRAMINE HCl Molecular weight of Tyramine : 137.18 g/mole Molecular weight of TyramineHCl: 173.64 g/mole CAS No of Tyramine : 51-67-2 CAS No of TyramineHCl : 60-19-5 Chemical Reaction: NH 2 NH 2.HCl + 30 % HCl + CH 3 Cl O CH3 NH 2.HCl OH Tyramine HCl M.Wt = 173.64 NH 2 + NaOH + H 2 O + NaCl OH T yramine HCl M.Wt = 173.64 OH Tyramine M.Wt = 137.18 Brief Manufacturing Process: 4-Methoxy Beta Phenyl Ethyl Amine is reacted Hydrochloric acid to give TyramineHCl. Further when this TyramineHCl is neutralized with Caustic Lye Tyramine Base is formed. Raw Materials: 1.4 MBPEA 2. 30% HCL 3. CAUSTIC LYE 4. WATER 5. ACTIVATED CARBON Page 38
Flow Chart: Mass Balance: Input MATERIAL Output MATERIAL Remark Name Quantity Name Quantity 4 MBPEA 1300 kg TYRAMINE 1000 kg Product 30% HCL 3000 kg ML TO ETP 1718 kg ETP CAUSTIC LYE 715 kg Spent Carbon 2.5 kg ACTIVATED CARBON 2.5 kg SOLID WASTE 3.5 kg Water for reactor 250 Recovered HCl 2346 kg Disposal Washing & equipment washing (After complete campaign water required for reactor washing is 5kl ) Water from reactor Washing : 250 kg Sold to authorized party TOTAL 5467.5 kg TOTAL 5467.5 kg Page 39
2.6 Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product Raw Materials: The detailed raw material list for proposed products as per selected capacity is detailed below for all reactants, solvents and support chemicals. Source for Raw Material Procurement: Raw Materials are easily available in the local market, from Mumbai and Gujarat. Part of the raw materials are generated In-house and used internally and some raw material will be imported Viz. Di-Iso butyl Ketone, O- Cresol,2-EAQ, Tertiary Butanol. Mode of Transport of Raw Materials: Raw Materials will be transported through Trucks/ Tankers from suppliers factories or traders go-downs. Those which are in house will be transported through internal pipelines as per the requirements. Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of storage yard is demarcated in Layout Plan. Table 2-2: Details of Raw material Quantity Sr.No Name of the Raw Materials Consumption in Kg/ MT of Product State Source Mode of transport 1 2-ETHYL HEXANOL 899 Liquid Local Road 2 4-METHOXY BETA PHENYL 1300 Local Road Liquid ETHYL AMINE (4-MBPEA) 3 ACETIC ACID 494 Liquid Local Road 4 ACTIVATED CARBON 2.5 Solid Local Road 5 CRUDE 2-ETHYL 1030 Local Road Liquid ANTRAQUINONE 6 CRUDE INDOSOL 1020 Liquid Local Road 7 CYCLOHEXANONE 983 Liquid Local Road 8 DI-ISOBUTYL KETONE (DIBK) 980 Liquid Local Road 9 HCl 4133.5 Liquid Local Road 10 HYDROGEN 141 Gas Local Road 11 ORTHOCRESOL 1736 Semi-liquid Local Road 12 PHENOL 888 Solid Local Road 13 PHOSPHOROUS OXYCHLORIIDE 927 Local Road Liquid (POCl3) 14 PHOSPHOROUS TRICHLORIDE 2386.8 Local Road Liquid (PCl3) 15 RANEY NICKEL CATALYST (RNC) 10.1 Slurry Local Road 16 SODA ASH 23 Solid Local Road 17 SODIUM HYDROXIDE 905 Solid Local Road 18 TERTIARY BUTANOL 801.3 Liquid Local Road TOTAL 18660.2 Page 40
Details of Solvent Quantity Sr.no Name of the Raw Materials Consumption Kg/ MT of Product State Source Mode of transport 1 ETHANOL 836.3 Liquid Local Road 2 ISOBUTANOL 801.3 Liquid Local Road 3 METHANOL 775.4 Liquid Local Road 4 N-BUTANOL 1636.3 Liquid Liquid Road 5 TOLUENE 150 Liquid Liquid Road TOTAL 4199.3 These solvents will be recycled and repetitively used. 2.7 Resource optimization/recycling and reuse envisaged in the project To conserve the water, various recycle/ reuse schemes will be implemented. Most energy efficient technology is selected. 2.8 Availability of water its source, energy/power requirement and source 2.8.1 Water Requirement and Source Proposed fresh water requirement of the project for domestic and industrial activity during operation phase will be 245 CMD. The water requirement will be sourced from MIDC. The details of water requirement are given below Table 2-3: Details of Raw water consumption S. No. Units Raw Water Qty.(KLD) A Process 36 B Utilities 1 Cooling water make up 175 2 Boiler make up 26 C Domestic 5 D Gardening 3 Total 245 2.8.2 Power Requirement Power requirement of proposed project will be made available through State Electricity Board. Power requirement of proposed plant is expected to be 1100 KW. Page 41
2.8.2.1 Emergency power One no D. G. set of capacity 500 KVA is proposed to meet emergency power requirement of the plant. 2.8.3 Utility requirement Sr No Item Quantity Capacity Rating 1 Boiler 1 5 TPH 10 kg/cm2 2 Thermopac 1 10 lac KCal/hr 280-300 0 C Fuel Requirement Sr No Item Fuel Quantity required at full load Fuel consumption at 1 Boiler F. O. 315 kg/hr @at full load 2 Thermopac F.O 190 kg/hr @at full load 3 D G set HSD 138 kg/hr @at full load 2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal 2.9.1 Gaseous Emissions Details of gaseous emissions from Process and Flue gas are given in Table 2-4 Table 2-4: Details of emissions from process and flue gas S. No. Pollutant Source of Emission Emission rate if operated at full load 1. SPM Boiler Negligible 2. SPM Thermopac Negligible 3. SPM DG Negligible 4. SO 2 Boiler 28.35 kg/hr 5. SO 2 Thermopac 17.1 kg/hr 6. SO 2 DG 0.7 kg/hr Details of stack are given in Table 2-5. Page 42
Table 2-5: Details stacks along with their mitigation methods Boiler Thermopac DG Capacity 5.0 TPH 15 lac Kcal/hr 500 KW Fuel type FO FO HSD Fuel /consumption @full lad F O. 315 kg/hr F O. 190 kg/hr HSD 138 kg/hr. MOC MS MS MS Shape Round Round Round Height 40 m 5 m Mitigation Measures Common Stack Stack 2.9.2 Effluent The quantity of effluent generated proposed project is given in Table 2.5 S. No. Units Table 2-6: Details of Effluent Generation Effluent generation (KLD) A Process 16 B Utilities 1 Cooling water make up 40 2 Boiler water make up 6 C Domestic 3.8 Total 65.8 Trade effluent generated will be 62 KLD and will be treated in proposed ETP. Domestic effluent will be treated separately in soak pit followed by septic tank. Treatment Scheme for Trade Effluent Primary Treatment The system will be designed to treat 75m3/day of waste water. Wastewaters from different streams of process along with wastewater from cooling tower, boiler blow down etc. will be collected in the Equalization Tank and air stripped. This effluent will then be pumped to the Flash Mixer where it will be dosed with alum for coagulation. Flash Mixer will be followed by a flocculator where poly will be dosed for bigger flock formation. This effluent will overflow into the settling tank where the solids will settle down and will be removed. Page 43
Secondary (Aerobic) Treatment: The system will be designed to treat 75m3/day of waste water. The neutralized effluent will enter the bioreactor @ 3.125m3 / hr. In the bio reactor, dissolved organic material is degraded by the micro organisms present in the bio reactor. Oxygen required for the oxidation of organic matter will be provided by means of proposed diffuser aeration system which will mix the contents of the bioreactor also. The mixed liquor will overflow into Secondary Settling Tank (SST). In the secondary settling tank, solid-liquid separation takes place and solids i.e. biomass will settle at the bottom of the tank. Settled biomass will be recycled to the bio reactor for maintaining the MLVSS concentration by using proposed sludge recycle pumps and excess biomass will be wasted periodically to the sludge sump. Two stage treatments are proposed where the overflow from the 1 st stage clarifier will enter the 2 nd stage bioreactor where the non-degraded organics from the 1 st stage bioreactor will be treated. The clear overflow from the 2 nd stage Secondary Settling Tank will be collected in the intermediate sump. Tertiary Treatment: The system will be designed to treat 75 m3/day of waste water. The clear effluent from the intermediate sump will be pumped by tertiary Feed pumps through the pressure sand filter (PSF) & activated carbon filters. The final treated effluent will be collected in the final collection tank from where it will be discharge to proposed upgraded CETP. Sludge Handling: Primary sludge, excess biomass from the secondary treatment and backwash water from PSF will be collected in the sludge sump. From the sludge sump the sludge will be pumped to the decanter for dewatering. The solid cake from the decanter will be sent for disposal to Hazardous waste disposal site. The filtrate from the Filter press will be drained to the collection tank. Table 2-6: Design details and Performance Projection of ETP Table 2-7 Design Parameters for ETP S. No. Parameters Unit Inlet Effluent Characteristics Outlet Effluent Characteristics Effluent discharge standards (MPCB) 1 Design Quantity M 3 /day 75 75 2 ph ---- 3-4 7.5 8.5 6.5-9.0 3 BOD3 27 0 C mg/l 2000-3000 70-80 <100 4 COD mg/l 5000-6000 200-240 <250 Page 44
5 TSS mg/l 300-350 50-80 <100 6 Oil & Grease mg/l 10 20 5-6 <10 Treatment Scheme for Domestic Wastewater The sewage generated due to domestic activities will be treated separately in soak pit followed by septic tank. 2.9.3 Details of Hazardous wastes The types of Hazardous wastes generated from the project, method of disposal is shown in below table below Table 2-8: Details of Proposed Hazardous Solid waste along with the Category and disposal method S. Waste Name No. Hazardous Waste Category Quantity MTPA Source 1 Distillation Residue 20.3 11.64 Process 2 ETP Sludge 34.3 780 ETP 3 Spent Carbon 28.2 0.6+7 Process + ETP 4 Discarded drums and containers 33.3 100 Process Disposal Method Collection, Storage, transportation and send to MWML, Taloja CHWTSDF for incineration. Collection, Storage, transportation and send to MWML, Taloja CHWTSDF Collection, Storage, transportation and send to MWML, Taloja CHWTSDF Collection, decontaminations, storage, reuse/sale to authorized recycler Page 45
2.10 Schematic representations of the feasibility drawing which give information of EIA purpose. Project Identification What environmental impacts are normally associated with such type of projects being proposed? Pre-feasibility Analysis Is the Project feasible from an environment point of view? Project Design (a) What negative environmental impacts could arise if the proposed project is implemented with proposed design? (b) Is there alternative design with less environmental impacts? Project Appraisal Have all the environmental concerns associated with the project been eliminated? Project Implementation What environmental concerns might arise at the implementation phase of the project? Preparation of an Environment Monitoring and Evaluation Plan (b) (a) What environment monitoring indicators are required to ensure that the implementation of components of the project will be executed within environmentally sound limits? What is required to ensure that the recommended environmental control measures will be implemented and enforced? Post EIA Monitoring and Environment Audit (a) Is the implementation of components of the project being executed in an environmentally sound manner? (b) Are all the recommended environmental control measures being implemented and enforced? Page 46
3.0 SITE ANALYSIS 3.1 Connectivity Proposed unit is planned at Plot No Plot no. B-14, MIDC, Mahad, Maharashtra. The nearest city from the site is Mahad at a distance of 8.0 Km The nearest railway station is Veer at a distance of 10 Km from the site on Mumbai Goa Manglore Kokan railway. The nearest airport is at Pune 130 km and at Mumbai 170 km. National Highway NH 66 (previously known as NH 17) passes through Mahad. It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Mahad for public transport. 3.2 Land Form, Land use and Land ownership The proposed land is situated in approved chemical zone of MIDC where land use is industrial. Land is owned by MIDC and is leased for 99 years. 3.3 Topography The proposed industry is located at Latitude -18.099752 N and Longitude- 73.490014E. Elevation above mean sea level is: 16m. Toposheet of the site is shown below. The study area (10 km radius) around the project site exhibits flat terrain in the east and relatively elevated terrain in the west side. Figure 3.1: Toposheet Showing Project site and 10Km of area Page 47
3.4 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. The proposed land for setting new unit is located in Notified Industrial Estate developed by MIDC. The land is already classified as for industrial use and land use does not change. 3.5 Soil classification 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. Generally soil is Medium Black and Deep Black soil. 3.6 Climatic data from secondary sources The climate of the district is typical of west coast and characterized with plentiful and regular seasonal rainfall, oppressive weather in summer and high humidity throughout the year. The mean minimum temperature is 17.7 C and mean maximum temperature is 31.8 C. The analysis of long term rainfall data indicates that normal annual rainfall over the district ranges from 2200 mm to more than 3000 mm in the plains and it is above 5000 mm in the hills. The minimum rainfall is in the northwest around Uran (2197 mm) and maximum around Mahad (3360 mm). The annual rainfall data for the period 2002-2012 is also compiled and is given in Table 3. The average rainfall for given 10 years ranges from 2253 (Uran) to 7598 mm (Poladpur). 3.7 Social Infrastructure Availability Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. 4.0 Planning In Brief 4.1 Planning Concept Proposed plant activities will be started after getting statutory clearance form related authorities. The project will be completed within one year. Further proposed project activities will take care of all the rules and regulation of statutory authority and provide the control measure and devices to achieve the standard norms Mahad MIDC has provided all infrastructure like assured electrical power, continuous water supply with purification from water works like disinfection, the internal road network, external approach road, and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility), MWML at Taloja in vicinity established with support of MIDC and MPCB. All nearby villages are provided with drinking water from wells or Government Water Supply Schemes. Hence we do not encroach upon their supply. Page 48
4.2 Land Use Planning Existing land is barren and undeveloped which will be converted for industrial purpose. The land is located in a designated industrial area. The total plot area is 4050 Sq.m Table 4-1: Land Use Break Up Sr.no Particular Area in Sq.m 1 Plant Area 346.3 2 Raw material storage area 743.9 3 ETP 47.5 4 Office Building 98.3 5 Parking (12% of total area) 486 6 Internal road 360.2 7 Open Space 1299.6 8 Green Belt (33% of unbuild area) 668.2 Total 4050 4.3 Assessment of Infrastructure Demand (Physical & Social) Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. 4.4 Amenities/Facilities In proposed site many basic facilities like uninterrupted water supply, Power and Road Network & solids disposal facility if feasible are available. 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 and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal facility), MWML, Taloja in vicinity established with support of MIDC and MPCB. 4.5 Population Projection Mahad is a Municipal Council city in district of Raigarh, Maharashtra. The Mahad Municipal Council has population of 27,536 of which 14,025 are males while 13,511 are females as per report released by Census India 2011. Population of Children with age of 0-6 is 2817 which is 10.23 % of total population of Mahad. In Mahad Municipal Council, Female Sex Ratio is of 963 against state average of 929. Moreover Child Sex Ratio in Mahad is around 897 compared to Maharashtra state average of 894. Literacy rate of Mahad city is 94.32 % higher than state average of 82.34 %. In Mahad, Male literacy is around 96.19 % Page 49
while female literacy rate is 92.40 %. Mahad Municipal Council has total administration over 6,430 houses to which it supplies basic amenities like water and sewerage. It is also authorized to build roads within Municipal Council limits and impose taxes on properties coming under its jurisdiction. Mahad population was 24,276 and its estimated 2012 population was 30,379. While as per 2011 cesus Population has grown up to 27,536 only. It means population has grown up by 13.4% only as against expectation of 25.1%. A short fall of 11.7% from prediction.assuming population cone as in previous continues to grow at same rate as in previous decade it is likely To reach 31,256 souls by 2021. 5.0 Proposed infrastructure 5.1 Industrial area Industrial Area (Processing area) Utilities Cooling towers HSD unloading/storage area Boilers DM water plant Cooling towers Hydrogen trolley area Non- Processing Area Weighbridge Administrative Buildings Security cabins Workers restroom Vehicle Shed Water reservoirs Temporary storage sites Works block etc. Page 50
5.2 Residential Area There is no any residential area has been proposed. 5.3 Green Belt The project is built on an MIDC plot with plot area of 4050sq. m. and green belt area 668.2 sq. m. Green belt will be developed at proposed project site and details will be provided in EIA report. 5.4 Social Infrastructure The basic amenities within the study area include primary schools, dispensaries, water supply, electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training institute and entertainment etc. 5.5 Connectivity The nearest railway station is Veer at a distance of 10 Km from the site on Mumbai Goa Manglore Kokan railway. The nearest airport is at Pune 130 km and at Mumbai 170 km. National Highway NH 66 (previously known as NH 17) passes through Mahad. It connects Panvel (south of Mumbai city) to Kanyakumari, passing through the states of Maharashtra, Goa, Karnataka, Kerala and Tamil Nadu. Maharashtra State Road Transport Corporation has a Bus Depot at Mahad for public transport. 5.6 Drinking Water Management The source of water supply is from MIDC Mahad. 5.7 Sewage System The domestic effluent will be treated in soak pit followed by septic tank 5.8 Industrial Water Management Treated Industrial effluent after meeting the MPCB norms for discharge will be sent to CETP for final disposal. 5.9 Solid Waste Management Hazardous solid waste generated from the process will be collected, stored, transported and send to MWML, Taloja CHWTSDF as per Hazardous waste (Management, Handling and Transboundry Movement) Rules 2008. 5.10 Power Requirement & Supply / source The Total Power required for the proposed project is 1100 KW. 6.0 Rehabilitation And Resettlement (R & R) Plan 6.1 Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless. Rehabilitation and Resettlement (R&R) plan is not applicable for the proposed project. Page 51
7.0 PROJECT SCHEDULE & COST ESTIMATES 7.1 Likely date of start of construction and likely date of completion The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized committee and will be completed within one year. 7.2 Estimated project cost along with analysis in terms of economic viability of the project The total investment envisaged is Rs. 17.25 Crore with the break-up as given belowtable 7-1 Table 7-1: Cost Break-Up S. No Item Cost (Rs in Crore) 1 Land Cost 0.25 3 Building 3 4 Plant & Machinery 14 Total Approx. 17.25 Economic Viability The project has been conceived assuming that there will be a growth in demand for the proposed products, leading to a reasonable rate of return in the medium term. The project is considered bankable. 8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Local people will get direct financial benefit by way of employment. Local people will get some contract of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby area. Page 52
Annexure -I Plant Lay out Page 53