PROJECT PRE-FEASIBILITY REPORT For THE PROPOSED ORGANIC CHEMICALS MANUFACTURING IN EXISTING IN FORMULATION OF PESTICIDE, AGROCHEMICAL AND BIO FERTILIZERS MANUFACTURING UNIT AT M/S. SULPHUR MILLS LTD. PLOT NO. 2, GIDC PANOLI, TALUKA:ANKLESHWAR DIST: BHARUCH, GUJARAT Submitted by: M/S. SULPHUR MILLS LTD.
EXECUTIVE SUMMARY M/s. SULPHUR MILLS PVT.LTD. is planning to manufacture organic products in the existing formulation products manufacturing unit at Plot no. 2 GIDC Panoli, Taluka: Ankleshwar, Dist: Bharuch, Gujarat. Project Cost The total cost of the project after proposed expansion will be around Rs. 7.00 crores. Details of Products Details of existing and proposed products are given in following table. LIST OF PRODUCTS Sr No. Name Of Product Existing Quantity Propose Quantity Total Quantity (MT/M) (MT/M) (MT/M) 1 Pesticides, Agrochemicals, Fertilizers, Bio Fertilizers Formulation And Repacking (Own Manufacturing and job work) 2 Naphthalene based dispersing Agent 3. Phenol Based Dispersing Agent 4 Liquid Dispersing Agent (only Mixing) 12000.00 000 12000.00 0.00 1000.00 1000.00 000 2000.00 2000.00 0.00 3000.00 3000.00 Since, the project is covered under the Category 5(f) of the new EIA notification-2006; we are applying for obtaining Environment Clearance for the same.
COST OF PROJECT The expected cost of proposed project is 7.00 crore. The plot has been purchased by M/s. Sulphur Mills ltd from GIDC. The total plot Area of the unit is 28201 sq. m. the green belt area will be 9000 Sq.m. FUEL & ELECTRICITY CONSUMPTION The proposed unit will use Natural gas as fuel for boiler while Diesel will be used as fuel in DG set. The connected electricity load will be 1000 KVA from DGVCL. WATER CONSUMPTION The unit will use 256 KL/Day water for industrial purpose and domestic purpose. WASTE WATER GENERATION The waste water generation from industrial activities will be 2 KL/Day. The sewage generation will be 16 KL/Day which will be goes to septic tank to soak pit. The industrial waste water will be treated in units own ETP having primary and tertiary treatment facilities. The treated water will be evaporate in Spray dryer and achieved the Zero liquid discharge for our unit. GASEOUS EMISSION There will be Two stack of Boiler (Capacity: 0.8 Tone/Hr), One thermic fluid heater (Capacity: 4 lacks K cal/hr).there is no process gas emission of proposed products. HAZARDOUS WASTE MANAGEMENT There will be generation of ETP Sludge (10 MT/Y). Waste /residue containing pesticide (10 MT/Y) Used Oil (1.08 MT/Y) HDPE Containers (395 MT/Y) Solid Waste (15 MT/Y) Date Expired materials (10 MT/Y).
INDEX Chapter No. Content 1 Introduction of The Project 2 Project Description 3 Site Analysis 4 Planning Brief 5 Proposed Infrastructure 6 Rehabilitation and Resettlement (R & R) Plan 7 Project Schedule & Cost estimates 8 Analysis of Proposal
CHAPTER - 1 Introduction of the Project 1.1 Identification of Project and Project Proponent M/s. Sulphur Mills ltd. is planning to manufacture organic products in the existing Formulation products manufacturing unit at plot no. 2, GIDC Panoli, Taluka: Ankleshwar, Dist: Bharuch,Gujarat. 1.2 Brief Description of Nature of the Project List of Products LIST OF EXISTING AND PROPOSED PRODUCT. Sr. No. Name of Product 1. Pesticide, Agrochemicals, Fertilizers, Bio Fertilizers Formulation & Repacking (Own manufacturing & Job work) Existing Quantity (MT/M) Proposed Quantity (MT/M) Total Quantity (MT/M) 12000.00 0.00 12000.00 2. Naphthalene based dispersing agent 0.00 1000.00 1000.00 3. Phenol Based Dispersing agent 0.00 2000.00 2000.00 4. Liquid Dispersing Agent (only Mixing) 0.00 3000.00 3000.00 1.3 Employment Generation: For the proposed expansion project, additional 15 nos. of personnel (existing 30 nos.) will be employed.
CHAPTER - 2 Project Description 2.1 Type of Project M/s. Sulphur Mills Ltd. is planning to manufacture organic products in the existing unit of Formulation products manufacturing unit at plot no. 2,GIDC Panoli, Taluka: Ankleshwar, Dist: Bharuch, Gujarat. 2.2 Location M/s. Sulphur Mills Ltd. located at plot no.2, GIDC Panoli, Taluka: Ankleshwar, Dist: Bharuch, Gujarat. Total Plot area of 28000 sq. mm is sufficient for proposed expansion. It is situated at 21 0 33.42.77 North latitude and 72 0 59 25.28 East longitude. A map showing project site is given in following figure-1 & a detailed map of the project site & surrounding is showing in following figure. Site Location Map
2.3 Size or Magnitude of Operation Details of production capacity is discussed in section 1.2 2.4 Process Description Manufacturing process: PART A ] NAPHTHALENE BASE Take 1 mole of Naphthalene (M.W. = 128) + 1.3 mole of Sulphuric acid (M.W.=98) in a clean and dry reactor. Heat it to 155 to 160 deg Celcius. And maintain for 6 hrs. The product obtain is 1 mole of Naphthalene Sulphonate (M.W.= 208) + 1 mole of water (M.W.=18) Add 0.65 mole of formaldehyde (M.W.= 30) into it at 75-80 deg c. The Product obtain is 1 mole of Naphthalene sulphonate formaldehyde condensate (M.W.= 222) + 1 mole of water (M.W.=18). The 1 mole of Naphthalene sulphonate formaldehyde condensate (M.W.= 222) is self polymerise to give one polymer of molecular weight 2220. Finally, the product is neutralised with 2 mole of Caustic soda. The product obtained is 1 mole of Sodium salt of Naphthalene sulphonate formaldehyde condensate + 1 mole water. Total molecular weight of product is approx 2280. PART B ] PHENOL BASE Take 1 mole of Phenol (M.W. = 94) + 1.15 mole of Sulphuric acid (M.W.=98) in a clean and dry reactor. Heat it to 102 to 105 deg Celcius. And maintain for 3 hrs. The product obtain is 1 mole of Phenol Sulphonate (M.W.= 174) + 1 mole of water (M.W.=18) Add 1.2 mole of Urea (M.W.=60) into it at 65-70 deg c. Add 2.20 mole of formaldehyde (M.W.= 30) into it at 75-80 deg c. The Product obtain is 1 mole of Phenol sulphonate formaldehyde condensate (M.W.= 204) + 1 mole of Urea formaldehyde condensate (M.W. = 89) + 1 mole of water (M.W.=18). The 1 mole of Phenol sulphonate formaldehyde condensate (M.W.=174 ) is self polymerise to give one polymer of molecular weight 714 + 1 mole of Urea formaldehyde condensate (M.W. = 89) ) is self polymerise to give one polymer of molecular weight 312. Now, add 2 mole of Phenol + 2 mole of formaldehyde to obtain 1 mole of Phenol formaldehyde condensate (M.W.= 124), Which polymerise to give molecular weight 248. Finally, the product is neutralised with 3 mole of Caustic soda. The product obtained is 1 mole of Sodium salt of Phenol sulphonate formaldehyde condensate + 1 mole of Urea formaldehyde condensate + 1 mole of Phenol formaldehyde condensate + 1 mole of water. Total Molecular of product is Approx. 1450.
LIQUID DISPERSING AGENT i) RAW MATERIALS : - ( in Kgs ) a) PART B (PHENOL BASE) = 2350. 00 b) PART A (NAPHTHALENE BASE) = 900. 00 c) Water = 400. 00 ii) OPERATING INSTRUCTIONS :- Charge 2350 kgs of PART B liquid into a clean & dry reactor. Heat it to a temp. 50 55 o C. To this add 900 kgs of PART A + 400 kgs of water & stir well. Send sample to Q.C. to check for its ph & solids. If o.k. Cool & unload by filtering it through nylon cloth of 100 mesh.
2.5 Raw Materials requirement Details of Raw material consumption and Mode of transportation are given in following table. LIST OF RAW MATERIALS LIST OF PROPOSED PRODUCT WISE RAW MATERIAL Sr. Name Of Product No. 1 Naphthalene based dispersing agent 2 Phenol Based Dispersing agent 3 Liquid Dispersing Agent (only Mixing) Quantity MT/M Sr. No. Name Of Raw Material Quantity MT/M 1000.00 1 Naphthalene 207.47 2 Formaldehyde 94.02 3 Caustic Lye 246.67 2000.00 1 Phenol 400.60 2 Formaldehyde 501.60 3 Sulphuric Acid 280.00 4 Urea 176.72 5 Caustic Lye 241.00 3000.00 1 Naphthalene based 739.80 dispersing agent 2 Phenol Based Dispersing 1931.40 agent
2.6 Availability of water its source, energy / power requirement and source Water The water requirement for the Formulation is 200 KLD and for the proposed organic products will be 56 KLD. This would be sourced from GIDC Panoli. Power Requirement Scenario Project HP Source Existing 1000 KVA Existing power requirement is/will source from Daxin Gujarat Vij Company Limited (DGVCL) Proposed 1500 KVA Additional power requirement is/will source from Daxin Gujarat Vij Company Limited (DGVCL) Fuel Requirement Sr. Fuel Daily Fuel Consumption Source & Mode of No. Existing Proposed Total Transportation 1 Natural Gas 1300 M 3 /hr 1500 M 3 /hr 2800 M 3 /hr From GGCL through direct pipe line 2.7 Air Pollution Emission from Combustion of Fossil fuels from stationary or Mobile Sources Sr. no. FLUE GAS EMISSION (EXISTING) Existing Details of Stacks and Air pollution Control equipments Flue Gas Emission: Stack attached to Stack Height in Mtr. From Ground Fuel used and rate of consumption Parameters Permissible Limits 1. Hot Air Generator at Spray drier-v Capacity 1400000 K Cal/Hr 30 Natural Gas 100 NM 3 /Hr. Particulate Matter SO 2 2. Hot Air Generator at Spray drier-vi Capacity 1400000 K Cal/Hr 30 Natural Gas 100 NM 3 /Hr. Particulate Matter SO 2 3. Hot Air Generator at Spray drier-vii Capacity 1400000 K Cal/Hr 30 Natural Gas 100 NM 3 /Hr. Particulate Matter SO 2 4. Hot Air Generator at Spray drier-viii Capacity 1400000 K Cal/Hr 30 Natural Gas 100 NM 3 /Hr. Particulate Matter SO 2 5. Hot Air Generator at Spray drier-ix Capacity 1400000 K Cal/Hr 30 Natural Gas 100 NM 3 /Hr. Particulate Matter SO 2 6. Hot Air Generator at Spray 30 Natural Gas Particulate Matter
drier-x Capacity 1400000 K Cal/Hr 7. Hot Air Generator at Spray drier-xi Capacity 1400000 K Cal/Hr 8. Hot Air Generator at Spray drier-xii Capacity 1400000 K Cal/Hr 9. Thermic Fluid Heater at Spray drier-v & VI Capacity 700000 K Cal/Hr 10. Thermic Fluid Heater at Spray drier-vii & VIII Capacity 700000 K Cal/Hr 11. Thermic Fluid Heater at Spray drier-ix & X Capacity 700000 K Cal/Hr 12. Thermic Fluid Heater at Spray drier-xi & XII Capacity 700000 K Cal/Hr 13 Diesel Generator 250 KVA X 2=500 KVA 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 30 Natural Gas Particulate Matter 100 NM 3 /Hr. SO 2 14 Diesel 100 ltr/hr. Particulate Matter SO 2 Proposed Details of Air pollution Control measures: Sr. No. Stack Attached to Type of Fuel and Consumption 1 Boiler 800 kg/hr Natural Gas: 500 NM 3 /Hr 2 Boiler 800 kg/hr Natural Gas: 500 NM 3 /Hr 3 Thermic Fluid Heater 4 lakh K.cal Natural Gas: 500 NM 3 /Hr Air Pollution control measures Flue gas Chimney 15 mtr. Flue gas Chimney 15 mtr. Flue gas Chimney 15 mtr. Parameters PM<150 mg/nm 3 SO x <40 mg/nm 3 <25 mg/nm 3 PM<150 mg/nm 3 SO x <40 mg/nm 3 <25 mg/nm 3 PM<150 mg/nm 3 SO x <40 mg/nm 3 <25 mg/nm 3
PROCESS GAS EMISSION Existing Process Gas Emission: Process Emission from Production Activities Stack No. Stack attached to 1. Spray Drier-V Capacity 1.2 Ton/Hr 2. Spray Drier-VI Capacity 1.2 Ton/Hr 3. Spray Drier-VII Capacity 1.2 Ton/Hr 4. Spray Drier-VIII Capacity 1.2 Ton/Hr 5. Spray Drier-IX Capacity 1.2 Ton/Hr 6. Spray Drier-X Capacity 1.2 Ton/Hr 7. Spray Drier-XI Capacity 1.2 Ton/Hr 8. Spray Drier-XII Capacity 1.2 Ton/Hr Stack Height in Mtr. From Ground Control Measures provided 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator 30 Cyclone Separator Followed by Ventury Scrubber And then Drop let Separator Parameters Permissible Limits SPM 150 mg/ NM 3 SPM 150mg/ NM 3 SPM 150 mg/ NM 3 SPM 150 mg/ NM 3 SPM 150 mg/ NM 3 SPM 150 mg/ NM 3 SPM 150 mg/ NM 3 SPM 150 mg/ NM 3
Waste Water Generation and it s Treatment: From the proposed expansion project, domestics waste water and process water will be generated. Domestic waste water will be disposed through the septic tank following by soak pit. Industrial waste water approximately 2 KLD will be treated as primary treatment and treated water will be Evaporated in Spray Dreyer, so our unit is Zero Liquid Discharge. Noise Pollution and Control Measures: From the existing and proposed expansion manufacturing unit noise pollution will generate which will be controlled by adopting different types of noise pollution control measures. Main sources of the noise pollution are machineries, Electric motors, dryers and heaters, etc. Encasement of noise generating equipment. Greenbelt will be developed all around the plant boundary to act as noise attenuator. In addition personnel, working near high noise level generating sources, will be provided with ear muffs. Proper and suitable acoustic barrier will also be provided around, areas generating high noise. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also noise reduction.
Solid and Hazardous Waste Generation and its Disposal Method The sources of solid wastes, generation and its management are as given in the following table. List of Existing And Proposed Hazardous Waste Generation and Management Type Of Waste Category As per Schedule II Existing Generation MT/Y Proposed Generatio n MT/Y Total Generation MT/M Source of generation Storage Facility Mode of Disposal Discarded Containers/ Empty bags & liners 33.3 88 MT/Y 307 MT/Y 395 MT/Y Raw Material Covered Shed with RCC flooring Sale it to GPCB approved merchant/reuse Used Oil 5.1 0.580 MT/Y 0.500 MT/Y 1.08 MT/Y Machinery Store in separate Area Sale it to CPCB or MOEF approved recycler or reprocessor/reuse for machine lubrication Waste /residue containing pesticide 29.1 10 MT/Y --- 10 MT/Y Process Store in separate Area Reuse for next batch/send to BEIL Date Expired materials 29.3 10 MT/Y --- 10 MT/Y From Market/ Ware house/stoc k Store in separate Area Reuse after testing and modification Solid Waste 6.1 15 MT/Y --- 15 MT/Y From Laboratory water after spray Drying ETP 35.3 --- 10 MT/Y 10 MT/Y Waste water treatment Plant Covered Shed with RCC flooring Specified Storage Area Sent to BEIL Sent to BEIL Green Belt Development Company is having total 9000 m 2 land area is available. Around 33% out of total plot area will be developed as green belt.
CHAPTER - 3 SITE ANALYSIS 3.1 Connectivity 3.1.1 Rail The nearest railway station is Sanjali Railway station, Which is around 1.5 km in North direction from the project site. 3.1.2 Road The site is well connected by road network to all the key places. The major highway passing near the project site is NH-8 which is around 1.0 kms east direction from the project site. 3.1.3 Air The nearest airport from the project site is Surat Airport. The distance of airport site is around 55.0 kms in South-west direction. 3.1.4 Communication Panoli GIDC is well connected with telephone, telefax etc. all communications facilities are well developed in the district. 3.2 Topography Topography of the land is plane. 3.3 Existing land use Pattern There is no Forest, National Park, and Wild life sanctuary within a radius of 10 km. Details of existing land use is given in the following table: DETAILS OF EXISTING LAND USE Sr. No. Particular Name & its Distance 1. Nearest National Highway NH- 8 at around 1.0 km in East 2. Nearest city Panoli at around 3.00 in south 3. Nearest River Narmada river at around 13.00 km in north 4. Nearest Railway station Sanjali Railway Station 1.5 km in North 5. National park/reserve Forest, Biosphere, etc. None within 20 km 3.4 Existing Social Structure Project site is located at a distance of around 10.00 km from Ankleshwar city. All the infrastructures are available within city like schools, Hospitals & community Facilities.
CHAPTER - 4 Planning Brief 4.1 Planning Concept Type of industries: M/s Sulphur Mills ltd. is planning to introduce new organics products in existing unit at Plot no. 2, GIDC Panoli, Taluka: Ankleshwar, Dist: Bharuch, Gujarat. 4.2 Land Use planning The Plant general Layout has been planned considering production facilities, auxiliary and ancillary facilities and plant utilities & services. The total plot area is 28201 sq.m. 4.3 Amanitas / facilities Adequate storage facilities for Chemicals, machinery spares and consumables shall be provided. A small mechanical and electrical/instrument workshop facilities for repairs and maintenance shall be provided. Time and security offices shall be provided in the plant. To avoid fire hazard, internal fire hydrants system in all major plant unit will be provided.
CHAPTER - 5 Proposed infrastructure 5.1 industrial Area The company already has land of 28201 m 2 in which Land Company will expand their production capacity. 5.2 Residential Area There is no provision of housing for the employees at site. 5.3 Green Belt The main objective of the green belt is to provide a barrier between the sources of pollution and the Surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise Generated apart from improving the aesthetics. Development of green belt and other forms of greenery Shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional Ecosystem and further to make the climate more conducive and to restore water balance. The functional Ecosystem and further to make climate conducive and to restore water balance. The company has green belt area with lawn, plants and flowers spread across about 33 of the total area. Green belt shall be developed at plant boundary, road side, around office & buildings and stretch of open Land. The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in primary and secondary attenuation zone. The trees should posses extensive foliar area to provide maximum impinging surface for continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution indicator. It is also recommended top carry out extensive plantation within premises. Keeping in view the climatic conditions, status of solid and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE Drinking water facility, canteen, proper sanitation, etc will be provided to the working in plant. 5.5 CONNECTIVITY As discussed earlier, proposed location of the plant is already well be connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation. 5.6 WASTE WATER MANAGEMENT From the proposed expansions project, domestic waste water and process waste will be generated. Domestic waste water will be disposed through the septic tank followed by soak pit. Industrial waste water approximately 2 KLD will be Treatment as primary and treated water will be evaporate in Spray dryer, so our unit is Zero Liquid Discharge.
5.8 INDUSTRIAL SOLID/HAZARDOUS WASTE MANAGEMENT The source of solid wastes, generation and its management are as given in the following table. Type Of Waste Category As per Schedule II Existing Generation MT/Y Proposed Generatio n MT/Y Total Generation MT/M Source of generation Storage Facility Mode of Disposal Discarded Containers/ Empty bags & liners 33.3 88 MT/Y 307 MT/Y 395 MT/Y Raw Material Covered Shed with RCC flooring Sale it to GPCB approved merchant/reuse Used Oil 5.1 0.580 MT/Y 0.500 MT/Y 1.08 MT/Y Machinery Store in separate Area Sale it to CPCB or MOEF approved recycler or reprocessor/reuse for machine lubrication Waste /residue containing pesticide 29.1 10 MT/Y --- 10 MT/Y Process Store in separate Area Reuse for next batch/send to BEIL Date Expired materials 29.3 10 MT/Y --- 10 MT/Y From Market/ Ware house/stoc k Store in separate Area Reuse after testing and modification Solid Waste 6.1 15 MT/Y --- 15 MT/Y From Laboratory water after spray Drying ETP 35.3 --- 10 MT/Y 10 MT/Y Waste water treatment Plant Covered Shed with RCC flooring Specified Storage Area Sent to BEIL Sent to BEIL
CHAPTER - 6 Rehabilitation and Resettlement [R & R] Plan The project is in notified industrial area, which is already acquired and there is no habitat. So the project Proposal does not involve any Rehabilitation & Resettlement.
Project Schedule & Cost CHAPTER - 7 7.1 Time Schedule for the project The implementation of the project will involve major activities like preparation of specification / drawing, Issue of tenders, receipt of quotations, scrutiny of tenders, placing of orders, civil & structural Construction, delivery & erection of equipment, test trial runs of various items of equipment and Commissioning of the plant & equipment and completion of the project will take about 6 month after the necessary clearances are available, and the funding for the project has been tied up. 7.2 Estimated Project Cost The total cost of proposed expansion will be around Rs. 7.00 crores. 7.3 Budgetary Provisions for EMP Adequate budgetary provisions have been made by the management for execution of environmental Management plans. The details of capital and recurring [per annum] budget earmarked for pollution Control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance. Cost of environmental Protection measures Sr. No. Particulates Rs. In Lacs 1. Capital Expenditure 100 2. Recurring expenditure on environmental management cell and on pollution control system per annum 25
CHAPTER - 8 Analysis of proposal 8.1 Financial and Social Benefits The capital cost of the expansion synthetic organic chemicals manufacturing in existing premises is estimated at about Rs.7.00 crore for the installation of plant & machinery along with required auxiliary and balancing facilities for the production. The project is evaluated fully from the financial point of view and found to be viable in long run. By further expansion, it will help the country to accumulate foreign Currency and will contribute in reduction in fiscal deficit a bit. For the coming of this project surrounding area will get developed due to this project and through the corporate social Responsibility [CRS] activities, socio-economic status of the region will also get developed. It will also create employment helping the society at large.