[Vide Notification dated 14 th September, 2006 Amendment on 1 st December, 2009] For Proposed Expansion Project MANUFACTURING AND SUPPLY OF SYNTHETIC COAL TAR DYES, LAKES & PIGMENTS FOR FOOD, DRUG, COSMETICS, PERSONAL CARE AND INK INDUSTRIES, NATURAL COLOURS & CHEMICALS By M/s. NEELIKON FOOD DYES & CHEMICALS LTD. Plot no. 17, unit no. II, MIDC Dhatav-Roha, Taluka- Roha, District- Raigad, Maharashtra. Prepared By GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers (MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, NABL/17025:2005, OHSAS: 18001 Certified Organization & GPCB approved Environment Auditor Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 24.02.2014 Corp. Office & Environmental Research Laboratory: Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India Tel: 0265-2371269 www.greencircleinc.com E: info@greencircleinc.com ALSO AT BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
INDEX Sr. No. Description Page no. 1.0 Executive Summery 3 2.0 Introduction of project 4 2.1 Project proponent 4 2.2 Brief description of nature of the project 4 2.3 Need for the project & it s important to the country and or region 4 2.4 Demand supply Gap 5 2.5 Employment generation (Direct & Indirect) due to the project 6 3.0 Project description 6 3.1 Products & product capacity 9 3.2 Raw material requirement 11 3.3 Manufacturing process 11 3.4 Resource-utilize & recycling 11 3.4.1 Water Requirement 11 3.4.2 Power requirement 12 3.4.3 Fuel requirement 12 3.5 Waste Management 13 3.5.1 Waste water generation & utilization 13 3.5.2 Solid waste generation & disposal 16 3.6 Schematic representations of the feasibility drawing which give 18 information of EIA purpose 4.0 Site Analysis 19 4.1 Land Form, Land use and Land ownership. 19 4.2 Existing Infrastructure 19 4.3 Soil classification 20 4.4 Climatic data from secondary sources 20 4.5 Social Infrastructure available 20 5.0 Planning Brief 20 6.0 Proposed Infrastructure 20 6.1 Project Area 20 6.2 Residential Area 20 6.3 Green Belt 21 6.4 Social Infrastructure 21 6.5 Occupation health 21 7.0 Rehabilitation and Resettlement (R & R) Plan 21 8.0 Project Schedule & Cost Estimates 22 9.0 Analysis of proposal (Final Recommendations) 22 1
List of Tables & Figures List of Tables Sr. No. Page no. 1 Summary of Proposed Plant 3 2 The details of employment 6 3 The List Product & Production capacity is given below 9 4 water Requirement details 11 5 Non Hazardous Waste Quantity 16 6 Hazardous Waste Quantity 6 Land Use plan 18 7 Project Schedule & Cost Estimates 22 8 Cost of environmental protection measures 22 List of Figures 1 Location Map of the Project site 7 2 Google Image of the Project site 8 3 Google Image of the Project site covering 5 & 10 Km radius 8 5 ETP Flow Chart 14 6 Plant Layout 18 2
1.0 Executive Summery M/s. Neelikon Food Dyes & Chemicals Ltd. is existing manufacturing unit at Plot no. 17, Unit No-II, MIDC Dhatav-Roha, Taluka-Roha, District- Raigad, Maharashtra for food dyes & chemicals. Industry is going for Expansion of project in the Manufacturing and Supply of Synthetic Coal Tar Dyes, Lakes & Pigments for Food, Drug, Cosmetics, Personal Care and Ink Industries, Natural Colors & Chemicals. Table 1: Summary of Proposed Plant Sr. No. Parameter Description 1 Name And Address M/s. Neelikon Food Dyes & Chemicals Ltd. Plot no. 17, unit no. II, MIDC Dhatav-Roha, Taluka- Roha, District- Raigad, Maharashtra 2. Name of Project Expansion in Manufacturing and Supply of Synthetic Coal Tar Dyes, Lakes & Pigments for Food, Drug, Cosmetics, Personal Care and Ink Industries, Natural Colors & Chemicals from 150 to 850 MT/M capacity by M/s. Neelikon Food Dyes & Chemicals. 3 Category of Project as per EIA 5 (f) B Notification 4 Project Cost Rs. 114 crore 5 Area of the project Total Area 39569 Sq. M. 6 Latitude & Longitude Latitude: 18 42 52.55 N Longitude: 73 14 95.77 E 7 Product Food Dyes & Chemicals 8 Total Production (Existing-150 + Proposed-400+80+220) =850) MT/M 9 Capacity of Boiler Existing: 1 x 5 TPH & Proposed: 2 x 5 TPH 10 Total water Requirement Existing: 520 m 3 /day & After Proposed expansion: 1750 m 3 /day 11 Waste Water Generation Existing: 436.3 m 3 /day & After Proposed expansion: 1438 m 3 /day 12 Total Power Requirement Total: 1736 KVA (Existing: 736 KVA & Proposed: 1000 KVA) 13 Total Fuel Requirement 1) Coal Existing: 15 MT/Day & Proposed: 30 MT/Day 2) Diesel Total 100 L/Day (Existing: 50 L/Day & Proposed: 50 L/Day) 14 Manpower Construction Phase (60 Existing + 80 Proposed = 140) Operation Phase (397 Existing + 1852 Proposed = 2249) 3
2.0 Introduction/Brief Project Description The objective of this pre feasibility study is to provide information for the Manufacturing and Supply unit of Synthetic Coal Tar Dyes, Lakes & Pigments for Food, Drug, Cosmetics, Personal Care and Ink Industries, Natural Colors & Chemicals by M/s. Neelikon Food Dyes & Chemicals Ltd. at Plot no. 17, unit no. II, MIDC Dhatav, Taluka - Roha, District- Raigad, Maharashtra. The Neelikon Food Dyes & Chemicals Ltd., is 100% Export Oriented Unit (EOU). Company s ranges of specialty dyes are used in foods, pharmaceuticals, cosmetics, personal care, ink-jet inks, writing inks and fluorescent pigments. Its products conform to internationally accepted standards, including those of the US FDA, the EC and Japan. Neelikon exports more than 90% of its production to around 100 countries. The everincreasing demand for the products in India & Abroad has prompted the promoters to undertake expansion in Manufacturing and Supply of Synthetic Coal Tar Dyes, Lakes & Pigments for Food, Drug, Cosmetics, Personal Care and Ink Industries, Natural Colors & Chemicals. As per the provision of EIA Notification No. S.O.1533 (E) dated 14.09.2006 as amended on December 01, 2009, the project comes under Category 5 (f) B 2.1 Project Proponent: In 1983, Mr. Mukund B. Turakhia, the promoter started a proprietary concern, Neelikon Dyestuffs, at Roha, Maharashtra. It initially manufactured fungicides and dye intermediates. In 1987, it started other manufacturing lines (synthetic dyes for food, drugs and cosmetic applications). Neelikon Food Dyes and Chemicals Ltd. was incorporated on April 18, 1994 as a closely held public limited company. The Company was promoted by Mr Mukund Turakhia and his two sons. 2.2 Brief Description of Nature of the Project Neelikon has indigenously developed a range of high quality synthetic dyes for the food, pharmaceutical, Cosmetics, personal care, inkjet ink, writing ink and fluorescent pigment industries. It started with a single plant and expanded operations to fourteen plants in two manufacturing units. The second unit was started in 2002 as a 100% export-oriented unit (EOU). The Company is an ISO 9001: 2008, FSSC 22000 and GMP certified company. Its products have received the clearances from the US Food and Drug Administration (US FDA), Kosher Halal and the ISI (BIS) license. 2.3 Need for the Project & its Importance to the Country & or Region Dyestuff industry plays an important role in the economic development of the country. The Indian Dyestuff Industry, which was primarily started to cater to the needs of domestic textile industry, now not only meets more than 95% requirement of the domestic market, but has gradually also made a dent in the global market. Today, India exports dyes and dye intermediate to the very same countries, on which it was dependant for imports till a decade ago. All ranges of dyes such as disperse, reactive, vats, pigments and leather dyes are now being manufactured in India. Mumbai & Surrounding area has emerged as dye & chemicals manufacturer city with a presence in global market. The Company aims to be one of the top players in the global food, 4
drug, cosmetic and fluorescent dyes segments and to develop other specialty dyes such as inkjet and writing ink dyes. Its core strength is the consistent high quality of its products and its development of new products. Neelikon is planning to utilise this strength and target large MNC end-users to obtain their requirements directly. It plans to set up a dedicated sales force in both the domestic and international markets. 2.4 Demands-Supply Gap Textile sector is a major consumer of Dyestuffs. Reactive Dyes, Vat Dyes & Azo Dyes are mainly required for dyeing and printing of cotton fibres. Disperse Dyes are mainly consumed for dyeing synthetic fibers. Acid Dyes are consumed in leather and woolen products. Many Special Dyes & pigments are used in printing inks. Some also have multiple uses in different applications. The production of synthetic fibre achieved during the year 2004-2005 to the extent of 18.86 lakhs MT. The estimated demand of synthetic fibre by terminal year of 11th five year plan may increase to 37.75 lakh tonnes. The demand of cotton textile may also be to the order of 48.19 lakh MT by the end of 11th plan. The Government's policy to promote export of cotton goods and promote blend of polyester fibres with cotton/viscose locally is likely to result in continued high demand for disperse dyes. The industry needs to create a set up to monitor very regularly the growth in exports and take necessary corrective action along the route to achieve the targets. In India, the per capita consumption of dyes is 50 gms., which is very low as compared to a world consumption of 425 gms., which indicates that there is a tremendous potential for growth of this sector in India. Imports Vs Indigenous Production Neelikon is planning to utilise this strength and target large MNC end-users to obtain their requirements directly. It plans to set up a dedicated sales force in both the domestic and international markets. Mr. Turakhia, promoter of the company, was responsible for introducing indigenous technology for the production of food dye in India in 1973-1974. For this, he was presented a National Award from the President of India. He has also received the Highest Export Award from CHEMEXCIL - A Government of India Export Promotion Council, for the export of Synthetic Indigo Dye (1977-1978) and Dun & Bradstreet (D&B) Indian Exporter s Excellence Award 2012. Domestic/ Export Markets The Company aims to be one of the top players in the global food, drug, cosmetic and fluorescent dyes segments and to develop other specialty dyes such as inkjet and writing ink dyes. Its core strength is the consistent high quality of its products has to be backed by large capacities and developing state-of-the-art manufacturing facilities to attract large direct endusers, and building up a wide distribution network. This is 100% EOU unit. Neelikon is selling their products over 100 countries. Increase in production capacity will help Indian government to bring more foreign currency. 5
2.5 Employment Generation (Direct & Indirect) Due to the Project The activities under industry would produce improvement in the socio-economic status of people in the study area in terms of local labor employment & contract basis jobs. The proposed activity might provide employment opportunities to the local populace, especially in business & other services like transportation activity. It is expected to direct or indirect employ about 2000 people of various skills will be required during construction as well as operation phase. The details of employment shown in below Table: 2. Table 2: Employment Details No. of Employees Sr. No. Particular Existing Proposed Total 1 Construction Phase 60 80 140 2 Operation Phase 397 1852 2249 3 No. of Employee live in the colony (If Applicable) 06 12 18 3.0 Project Description M/s. Neelikon Food Dyes & Chemicals Ltd. located at Plot no. 17, unit no. II, MIDC Dhatav-Roha, Taluka-Roha, District- Raigad, Maharashtra Location map is shown in below Figure. The Co-ordinates (Latitude and Longitude) of the project site are 18 42 52.55 N, 73 14 95.77 E with an elevation of 12.8 m (42ft) above mean sea level MSL There are no archaeological, historical sites located near project site, the proposed expansion project is located in Notified Industrial Area by Maharashtra Industrial Development Corporation (MIDC). Therefore, the project site does not offer any negative impact on the local area. But rather have a positive impact on socio economic conditions of the habitants around it. The plant is well connected with National Highway No.17 (NH-17) and it is 130 Km away from Mumbai from Site & Railway line at Roha Railway station at 5 km away from project site. The total of about 39569 Sq. Mt. of land is acquired for this project. 6
Figure 1: Location Map of the Project site 7
Figure 2: Google Image of the Project site (500 m radius) Figure 3: Google Image of the Project site covering 5 & 10 Km radius 8
3.1 The List Product & Production capacity is given below in Table 3. Sr. No. Table 3: Existing & Proposed Product details Product Name Quantity (Mt/month) Storage Condition 1 Synthetic coal tar dyes or Azo colours for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application 2 Aluminium Lakes for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application 3 D&C Lakes for Drug, Cosmetics,Personal Care, Ink and Industrial application 4 Quinoline/Quinoline Yellow /D&C yellow 10 for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application 5 Pyrene/Solvent Green 7/ SAPT4 for Drug, Cosmetics,Personal Care, Ink and Industrial application 6 Qumarin/D&C Violet 2/Ext D&C Violet 2 for Drug, Cosmetics,Personal Care, Ink and Industrial application 7 Tri-Phenol Methyl/ Brilliant Blue FCF/Fast Green FCF/Patent Blue v/green S for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application 8 Dispersions of water/sugar/oil for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application 9 Salt Free Dyes for Specialty Ink application Existing Proposed Total 60 140 200 Fill in Poly bag and packed in. 50 100 150 Fill in Poly bag and packed in 05 45 50 Fill in Poly bag and packed in 10 10 20 Fill in Poly bag and packed in 04 06 10 Fill in Poly bag and packed in 01 09 10 Fill in Poly bag and packed in 00 50 50 Fill in Poly bag and packed in 00 30 30 Fill and packed in HDPE drum//hdpe buckets and store at cool and 00 10 10 Fill in Poly bag and packed in 9
10 Indigo/Indigo Carmine for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application (Job Work) 11 Xanthene/ Erythrosine/Phloxine/ Eosine/Uranine for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application (Job Work) 12 Synthetic coal tar dyes or Azo colours for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application (Job Work) 13 Xanthene/ Erythrosine/Phloxine/ Eosine/Uranine for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application (Out Source) 14 Organic Pigments for Drug, Cosmetics,Personal Care, Ink and Industrial application (Out Source) 15 In-Organic Pigments for Drug, Cosmetics,Personal Care, Ink and Industrial application (Out Source) 16 Natural colours for Food, Drug, Cosmetics,Personal Care, Ink and Industrial application (Out Source) 17 Mixture of above Above in any combin ation 00 10 10 Fill in Poly bag and packed in 00 10 10 Fill in Poly bag and packed in 00 200 200 Fill in Poly bag and packed in 00 10 10 Fill in Poly bag and packed in 00 10 10 Fill in Poly bag and packed in 00 50 50 Fill in Poly bag and packed in 00 10 10 Fill in Poly bag and packed in Above in any combinati on Abo ve in any com binat ion 18 Excess Capacity 20 00 20 Total 150 700 850 Fill in Poly bag and packed in 3.2 Raw material requirement All the raw materials required for manufacturing of above products will be sourced from local market- List is attached as Exhibit 1. 10
3.3 Manufacturing Process: The manufacturing process of food dyes & chemicals consisting of chemical synthesis extending to stages of processing involving different type of chemical reactions. The generalized flow chart for food dyes & chemical manufacturing and mass balance is shown in Flow chart List attached as Exhibit-2. 3.4 Resource Utility & Recycling 3.4.1 Water Requirement Water requirement for the existing facility is 520 m 3 /day, which is met from MIDC water supply. Total Water requirement of the project after expansion for domestic & Industrial activity during operation phase will be 1750 m 3 /day. Water requirement for expansion will also be met from MIDC water supply. The detailed water requirement shown in below Table 4. Sr. No. Table 4: Water Requirement details Water Consumption Equipment KL/Day E P T 1 Process 150 488 638 2 Cooling Tower 15 45 60 3 Boiler 30 60 90 4 R.O 0 25 25 5 Domestic 55 145 200 6 Green Belt 05 15 20 7 Equipment and Floor Washing 265 452 717 Total 520 1230 1750 Note: E = Existing, P = Proposed, T = Total after the expansion 3.3.2 Power Requirement The Total power requirement will be 1736 KVA. The main source of power is MSEDCL. The back-up will be provided from DG Sets having capacity of 1500 KVA in case of power failure. Table 5: Power Requirements Sr. No. Particulars Source Existing Proposed Total 1 Total MSEDCL 736 KVA 1000 KVA 1736 KVA Demand 2 Back-up D.G. set 1x750 KVA 1x750 KVA 1500 KVA 11
3.4.3 Fuel Requirement Existing Details: Sr. No. Stack attached to Capacity Status Stack Height (m) Stack Dia (mm) Fuel name & Quantity Stack Gas Temp. ( 0 C) Air Pollution Control Measure 1 Boiler 5 TPH Existing 30 500 Coal/10T per day 90-110 Cyclone with wet scrubber 2 D.G. Set 750 KVA Existing 5.5 200 Diesel/ 50 L per day 60-80 Sufficient Height Stack 3 HAG 14000 CFM Existing 20.0 500 Coal/ 5 T per day 90-110 Sufficient Height Scrubber Stack with Proposed Details: Sr. No. Stack attached to Capacity Stack Height (m) Stack Dia. (mm) Fuel name & Quantity Stack Gas Temp. ( 0 C) Air Pollution Control Measure 1 Boiler No. 2 5 TPH 30 500 Coal/10T per day 90-110 Cyclone with Bag filter 2 Boiler No. 3 5 TPH 30 500 Coal/10T per day 90-110 Cyclone with Bag filter 3 D.G. Set No. 2 750 KVA 5.5 200 Diesel/ 50 L per day 60-80 Sufficient Stack Height will be provided 4 HAG No. 2 14000 CFM 20.0 500 Coal/ 5 T per day 90-110 Sufficient Stack Height with Scrubber will be provided 5 HAG No. 3 14000 CFM 20.0 500 Coal/ 5 T per day 90-110 Sufficient Stack Height with Scrubber will be provided 3.5 Waste Management 3.5.1 Waste Water Generation, Utilization & Treatment Total existing effluent (Domestic + Industrial) generated in the project is 436.3 M 3 /day. The treated water will be recycled for plant operations and reused for Gardening. The wastewater is being sent to RIA CETP for further treatment since 2003. After expansion, the total wastewater generation will be 1438 m 3 /day. The MoU has been attached in Annexure. Sr. No. Equipment Waste Water Generation KL/Day E P T 1 Process 120 390 510 2 Cooling Tower 0.6 1.8 2.4 3 Boiler 1.2 2.4 3.6 4 R.O 0 25 25 12
5 Domestic 49.5 130.5 180 6 Green Belt 0 0 0 7 Equipment and Floor Washing 265 452 717 Total 436.3 1001.7 1438 Note: E = Existing, P = Proposed, T = Total after the expansion Figure 5 ETP Flow Chart Waste Water Treatment Effluent generated from the project will be treated through effluent treatment plant. Existing ETP having Capacity 500 KLD and it is proposed to be expanded to 1500 KLD capacity. Total Effluent generation after expansion will be 1438 KLD [436.3 KLD (Existing) + 1001.7 KLD (expansion)], which after treatment in ETP, will be sent to CETP. It is proposed to recycle/ reuse the treated water partly for process, cooling Tower and /or For Floor Wash and excess, if any, to be discharged to Gardening. Process of the Effluent water treatment: Industry had provided Full-fledged E.T.P. consisting of Following Units. Additional Effluent after Expansion will also be treated in this Facility. Existing E.T.P. is designed for 500 KLD and it is proposed to be expanded to 1500 KLD capacity. 13
I. Equalization Cum Neutralization Tank: Two No.(One Stand by) The effluent is collected & equalized here to equalize the whole mass of the effluent to the average concentration. All the floating material also being separated here by Course screen & Fine screen. The online screens installed for the same. As the most efficient digestion occurs at neutral ph, it is necessary to neutralize the incoming waste to a ph of 7. II. Primary Clarifier Tank with Flash Mixing Tank: One no. After Neutralization, the effluent is pumped to Flash Mixer Tank. The Alum & Poly Electrolyte dosing is added for the Sedimentation & coagulation. After Equalization & Neutralization, the industrial waste water enters the Primary Clarifier Tank through Flash Mixer. To avoid the Turbulence created due to the Pressure Pumping Flash Mixing Tank provided Here the Suspended Particles heavier than water settles down at the bottom. The Settled Solid is Separated as Sludge & dewatered to Sludge drying Bed. After sludge drying, the sludge is sent to CHWSTDF. III. Anaerobic Digester: After Primary Clarification, the Effluent enters to Anaerobic Digester. Here the effluent is treated with anaerobic culture. IV. Bioreactor Tank /Aeration Tank: 1 No After Anaerobic digester, the effluent enters to the Aeration Tank. Here the activated sludge process achieved, to reduce the Organic load to the desired standards by providing a sufficient detention time & activating the Bacterial culture. For Oxygenation (aeration) of waste water these tanks provided with fixed Air Blowers. These Air Blowers are capable of providing sufficient amount of Dissolved Oxygen (D.O.) required by the micro organisms for synthesis or degradation of organic matter. V. Secondary Settling Tank: For the settlement of the mixed liquor, the waste led to a Secondary Clarifier tank. Waste led to the tank through a pipe to centre feed well from where it flow downwards and then outwards launder. The settled mixed liquor returned back to aeration tank to improve mixed liquor in the tank and the excess mixed liquor drained to the existing sludge drying beds VI. Clarified Water Tank: The Clear effluent from Secondary Clarifier Tank is collected here. From this Tank, the Effluent is pumped to the Sand & Activated Carbon Filter. 14
VII. Pressure Sand & Activated Carbon Filter: The Clarified supernant effluent is then passed through the Sand & Carbon filter for Final Purification. To remove the suspended solids from Sand & Carbon Filter, back wash operation to be carried out. The effluent is then transferred to Treated Water Tank VIII. Treated Water Tank: Such Treated Clear Effluent is then sent to CETP. It is proposed to recycle/ reuse the treated water partly for process, cooling Tower and /or For Floor Wash and excess, if any, to be discharged to Gardening. IX. Sludge Drying Beds: The Waste sludge is drained to Sludge Drying Bed and after drying, sent to CHWSTDF 3.5.2 Solid waste generation & disposal The types of Hazardous and non Hazardous wastes are generated from the project. Method of handling and disposal is shown in below table The Solid waste will be classified into hazardous waste and other waste which is being handled under the agency of Pollution Control Board. The industry entered into an agreement with Mumbai Waste Management Limited where the waste is characterized and scientifically disposed off in a secured Landfill after Stabilization to prevent any sought of impact on environment. Table 5: Non Hazardous Waste Quantity Sr. Name of solid waste Quantity (Mt/month) Management No E P T 1 Lime sludge of PTSA To authorized vendor for 50 75 125 further processing/use 2 Lead sludge of TPM To authorized vendor for 0 10 10 further processing/use 3 Plastic Scrap 3rd Quality To authorized vendor for 0.3 1 1.3 further processing/use 4 Scrap Plastic & M S Drums Cap.35Ltr To 50Ltrs 2nd Quality 100 Nos. 300 Nos. 400 Nos. To authorized vendor for further processing/use 5 Scrap HDPE & LDPE Bags To authorized vendor for 3 7 10 further processing/use 6 Scrap Rubber To authorized vendor for 0.2 0.8 1 further processing/use 7 Charcoal To authorized vendor for 1 4 5 further processing/use 8 Coal Ash To authorized vendor for 1 4 5 further processing/use 9 Lab Chemicals 0.1 0.4 0.5 To ETP for treatment 15
Table 6: Hazardous Waste Quantity Sr. Name of Hazardous Category Quantity (Mt/ Month) Management No. material No. E P T 1 ETP Sludge 26.2 50 150 200 To Mumbai Waste Management, Taloja 2 Process Sludge of MnO2 from TPM 26.1 0 50 50 To Mumbai Waste Management, Taloja 3 Process Sludge of Lime from Quinoline 26.1 40 40 80 To Mumbai Waste Management, Taloja 4 Spent Oil 5.1 0 0.5 0.5 To Mumbai Waste Management, Taloja 5 Glass Wool -- 0 0.2 0.2 To Mumbai Waste Management, Taloja 6 Glass -- 0 0.2 0.2 To Mumbai Waste Management, Taloja 7 Hyflo/Silica -- 0 0.5 0.5 To Mumbai Waste Management, Taloja 3.6 Schematic representations of the feasibility drawing which give information of EIA purpose. The applicability of the S.O. 1533 for the proposed project was explored by considering different possibilities & provision made in the said Notification. Considering the products & project location of the proposed project it is noticed that the proposed project falls under category 5 (F) B of the Schedule I of EIA Notification S.O. 1533. 16
Figure 6: Plant Layout 18
4.0 Site Analysis M/s. Neelikon Food Dyes & Chemicals Ltd. is located at Plot No.17, MIDC, Dhatav, Tal.Roha, Dist.Raigad, Maharashtra. The nearest habitation from the site is Roha at a distance of 4 KM. The nearest railway station is Roha Railway Station at a distance of 5 KMs from the site. The nearest airport is Mumbai Air port at a distance of 143 KMs from site. The Nearest road ways National (NH 17), around 8 km away from site at Kolad. 4.1 Land Form, Land use and Land ownership. The proposed expansion project land food dyes & chemicals unit is in area of 39569 m 2. The land is acquired by M/s. Neelikon Food Dyes & Chemicals Ltd. for their Manufacturing Facility. The land use break-up is given below Table 7- Sr. Details of Land Existing Land Proposed Area Total Land No. Area(m 2 ) (m 2 ) (m 2 ) 1. Total Plot Area 39569-39569 2. Main plant Building (Production 17174.3 17092.5 34266.8 Area) 3. Storage area 2078.25 2332.7 4411.0 4. Solid Waste Storage Area 360 625 985 5. Administration and Research 218.8 952.5 1171.3 buildings (office + Wm area) 6. Utility area (utility room, weigh 823 1200 2023 bridge, electrical rooms etc) 7. Parking Area 540-540 8. Road Area 4768.2-4768.2 9. Greenbelt Area 5541.51-5541.51 10. Open Area 11657-11657 11. Permissible Built up area at all floors 22501 17043.2 39544.2 12. Permissible F.S.I 0.57 0.43 1.0 13. Total built up area of plan (plinth) 8858.6 10925.9 19784.5 4.2 Existing Infrastructure. The Industry is having existing Infrastructure at this site and going for Expansion in the same in- House Facility. Some area of the existing infrastructure will be demolished and new infrastructure will be constructed.
4.3 Soil classification The soil near the project site is mainly sandy loam to clay in texture, yellowish in color and under laid with murum derived from the basic rock basalt. 4.4 Climatic data (from secondary sources) The climate of Roha district is characterized by hot summer and dryness except in the south-west monsoon season. The year may be divided into four seasons, the cold season from December to February followed by the hot season from March to May and the south-west monsoon season from June to September followed by the post-monsoon season during October and November. Temperature Maximum: 37 C Minimum: 14 C Average annual rainfall 3038.2 mm 4.5 Social Infrastructure available As the proposed expansion project site is in the notified industrial area - Dhatav MIDC. Basic facilities like uninterrupted water supply, Power and Road Network & solid waste disposal facilities are available. Also, 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 has been established with support of MIDC and MPCB. 5.0 Planning Brief The Already Existing Production activity are going on at Plant Level and the construction and production related to the Proposed Product in Expansion will be started after getting statutory clearance form related authorities. Further Activities related to the Expansion in Production will take care of all the rules and regulation of statutory authority and provide the control measure and devices to achieve the standard norms. 6.0 Proposed Infrastructure: 6.1 Project Area Basic infrastructure already exists in the total plot area of 39569 m 2. The proposed expansion is to be done by demolition of 2820 Sq. Meter Area of the existing plot and the construction for infrastructure required in expansion of production will be developed along with installation of required machineries. 6.2 Residential Area No residential area is involved in the project area as it is a notified industrial estate. The employees are accommodated in nearby Residential areas. 20
6.3 Green Belt: The unit has already developed green belt area @ 5541.51 sq. m within and on the surrounding of the existing premises, which will not only improve the soil conditioning but will also prevent soil erosion and the landscape will help for conservation of environment & give slight beneficial impact on the land usage. 6.4 Social Infrastructure The Neelikon Food Dyes & Chemicals Ltd. project has generated a fair amount of direct and indirect employment in the study region and due to expansion, the company will generate employment of almost 2000 new employees. The local economy has received a boost due to employee spending and services generated by Neelikon Food Dyes & Chemicals Ltd. Migration into the existing area or displacement of existing population is insignificant. Housing, transport, water, power supply, medical, educational and other civic amenities are not adversely affected nor appear to get affected in future. 6.5 Occupation health Various precautions have been taken by the unit to reduce health hazards and medical checkup is also carried out regularly to avoid occupational hazard. Drinking water supply for the employees is provided by the project proponent and the standard of the drinking water is as per WHO guidelines. Proper sanitary facilities are made available by the project proponent so that employees do not suffer from any health ailments. Training includes information on accident prevention, proper control and maintenance of equipment and safe material handling practices. MSDS of the chemical used are made available at the place of use. Storage and process areas are posted with No Smoking signs. Smoking is prohibited throughout the factory. All management staff, Executives on their rounds to factory ensures the compliance. Pre-employment medical check-up at the time of employment. The unit has appointed the medical officer cum industrial hygienist for the regular medical examination and treatment of the employee. Certificate of fitness of employ is maintained. Equipment required for personal safety like water jet blankets, gloves, helmets, safety belts, first aid boxes etc. are provided. 7.0 Rehabilitation and Resettlement (R & R) Plan Rehabilitation & Resettlement (R&R) plan is not applicable as already the unit is Existing and no any Rehabilitation is causing due to this Expansion Activity 21
8.0 Project Schedule & Cost Estimates The unit is already established and the expansion activities will be started after getting statutory clearance from concerned authorities. The cost estimate is given below in Table 8 - Sr. No. Particulars Amount (INR) in Crore 1 Production 77.95 2 Ware house 10.00 3 ETP / STP Expansion 12.00 4 Canteen, Office construction 03.00 5 Strom drains & Roads 04.20 6 Toilets & Change room 00.80 7 Utility ( Boiler, cooling tower, Ice 03.50 plant ) 8 Open area development 01.00 9 Pollution control 01.62 Total : Crore Rs.114.07 Table 9 Cost of environmental protection measures (Rs. Lakhs) No. ITEM Capital Cost (Rs, Lacs) Recurring Cost per annum (Lacs) 1 Pollution Control Measures 12 0.5 3 Solid Waste Management 216 1 4 Environment Monitoring and Management 35 1 5 Rain Water Harvesting 25-7 Green Belt 16 0.25 8 Occupational Health and Safety 10-9 ETP & STP 600 1 Total 914.0 3.75 9.0 Analysis of proposal (Final Recommendations) Already the Existing Unit is beneficial to the local People. After expansion activity will also provide additional 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 contracts of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby area. 22