01.project feasibility report - welcome to...

1

PRE FEASIBILITY REPORT

FOR

PROPOSED PESTICIDE INTERMEDIATES AND

SPECIALTY CHEMICALS IN EXISTING UNIT

OF

M/s. ACETO CHEM PVT. LTD. (UNIT-II)

PLOT NO. 274/3/1, GIDC ESTATE, PANDESARA,

DIST: SURAT – 394 221, GUJARAT

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CONTENTS

Sr.

No.

Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 9

3. Project Description 10

4. Site Analysis 16

5. Planning Brief 17

6. Proposed Infrastructure 17

7. Rehabilitation and resettlement (R & R) Plan 18

8. Project Schedule & Cost Estimates 19

9. Analysis of Proposal (Final Recommendations) 19

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1.0 EXECUTIVE SUMMARY

1.1 Company Profile

Introduction

M/s. Aceto Chem Pvt. Ltd., established in the year 1976 under the charismatic leadership of Mr.

Jitendra P. Parmar & Mr. Bansilal D. Patel engaged in the manufacturing & marketing of Dyes

Intermediates for Food Color and textiles.

The company has since consolidated its position as major entity. Under the charismatic leadership of

Mr. Jitendra P. Parmar and Mr. Bansilal D. Patel, the company has become a strong force to reckon

with.

In spite of market fluctuations, the company is reporting steady and dynamic progress year after

year. Thanks to our philosophy of believing in team spirit, quality consciousness, innovative

approach, market awareness and foresightedness, we have established a name of repute amongst

our domestic and international clientele.

We started our exports in 1980 and since then gradually expanding our network in various

countries. Currently, we are exporting our products to various European countries besides USA,

Argentina, Brazil, Egypt, South Africa, Japan, Taiwan, Korea, etc.

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1.2 Project Details

Sr.

No. Product Name

Production

Existing Proposed Total

MT/Month MT/Month

1 Nytrosyl Sulphuric Acid (from Sulfur) * 132.08 132.08

2 Nytrosyl Sulphuric Acid (from Sodium Thio

Sulphate Solution and Spent Acid (H2SO4)) ** 468 468

3.1 4-Methoxy Acetophenone 0 60

3.2 4-Methyl Acetophenone

4.1 Diethyl Ketone

0 100 4.2 Methyl Propyl Ketone

4.3 Dipropyl Ketone

4.4 Propiophenone

5 Alpha Nitro Napthalene 0 100

6 Alpha Napthylamine 0 165

7 Phenyl Alpha Naphthylamine (PANA) 0 90

8 Epichlorohydrin Based Polyamide resin 0 116

9 3,5-Dichloroaniline 0 50

10 Bis-(2-Chloroethyl)-amine 0 30

Total 600.08 1311.08

By Products

1 Sulphur 50.74 50.74

2 Sodium Sulphate 242.728 242.728

3 Di Ethyl Ketone Nil 79

4 Acetic Acid Nil 30.5

1.3 Green Belt Development

Company has developed an effective green belt within the factory and on periphery of the factory.

In addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.

1.4 Power & Fuel Requirement

Fuel

Natural Gas: 82 SCM/day (Existing)

Diesel: 30 Lit/Hr (Existing)

Natural Gas: 82 SCM/day (Total Proposed)

Diesel: 75 Lit/Hr (Total Proposed)

Energy:

90 HP from DGVCL

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1.5 Water Requirement and Wastewater Generation & Treatment

Source of water will be met through Surat Municipal Corporation. Total water requirement will be

65 m3/day (Existing: 25.5 m

3/day + Additional Proposed: 39.5 m

3/day). The total wastewater

generations will be 24.0 m3/day (Existing: 7.0 m

3/day + Additional Proposed: 17.0 m

3/day). Total

24.0 m3/day (14 m3/day Industrial + 10 m

3/day domestic) of effluent shall be generated, out of

which 14 KL/Day waste water generated from process (from manufacturing of 3, 5, DCA), cooling,

washing & Scrubber shall be treated in ETP and the treated effluent shall be reused in to utilities.

About 14 KL/Day of Condensate water (is generated only from the manufacturing of Nytrosyl

Sulphuric Acid (from spent sodium thio sulphate solution and Spent H2SO4 (as a raw material)) is

recycled back in to cooling tower.

1.6 Air Pollution Source and Control Management

The source of air pollution due to the project will be Flue gas emission & Process Vents.

FLUE GAS EMISSION

Sr.

No. Stack Attached To Stack Height

Fuel

Consumption Air Pollution Control System

A EXISTING

1. Thermo pack Unit

Cap.: 600 U

Height - 12 Meter Natural Gas

82 SCM/Hr.

As Natural Gas is used as a fuel,

adequate stack height is provided.

2. D. G. Set (Stand By)

Capacity: 250 KVA

HEIGHT - 7 Meter Diesel:

30 Liter/Hr.

As Diesel is used as a fuel, adequate

stack height is provided.

B ADDITIONAL


Capacity: 365 KVA *


45 Liter/Hr.

As Diesel shall be used as a fuel,


* Industry shall remove the existing D. G. Set having capacity of 250 KVA and will install D. G. Set

having capacity of 365 KVA.

C PROPOSED TOTAL

1. Thermo pack Unit Height - 12 Meter Natural Gas: As Natural Gas is used as a fuel,


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1.7 Hazardous Waste Management

Cap.: 600 U 82 SCM/Hr.


Capacity: 365 KVA


45 Liter/Hr.

As Diesel shall be used as a fuel,


PROCESS GAS EMISSION

Sr.

No. Vent Attached To

Vent Height &

Diameter Pollutants Air Pollution Control System

A Existing

1. Acidification Vessels

12 Meter SO2

Two Stage Scrubber (i.e. Ventury

Scrubber & Vertical column packed

scrubber) is provided. 2. Acidification Vessels

B Additional

There shall be no change in existing process gas emission.

CAT.

NO.

TYPE OF SOLID /

HAZARDOUS

WASTES

SOURCE OF

WASTE

QUANTITY GENERATED

METHOD OF DISPOSAL

Existing Additional Proposed Total

5.1 Used Oil Plant and

Machinery

0.085 MT/Year

i. e.

100 Liters/Year

Nil 0.085 MT/Year

i. e.

100 Liters/Year

Collection / Storage /

Transportation / sent

to registered recycler

33.1 Discarded

containers /

barrels / liners/

Carboys/bags

Raw

material

packaging

4.8 MT/Year

i. e.

600 Nos/Year

1.6 MT/Year

i. e.

200 Nos/Year

6.4 MT/Year

i. e.

800 Nos/Month


Transportation /

Supplier / sent to

registered recycler

35.3 ETP Sludge From ETP 100 Kg/Year 500 Kg/Year 600 Kg/Year Collection / Storage /


to TSDF site for

secured Land Filling

29.5 Catalyst From

Process

Nil 4.1 MT/Month 4.1 MT/Month Collection / Storage /

Transportation /

Given back to

manufacturer for re-

generation

Catalyst shall be generated from the manufacturing of 4 - Methoxy Acetophenone, 4-Methyl Acetophenone &

Alpha Napthylamine.

29.6 Spent Acid

(H2SO4)

---- 286 MT/Month Nil 286 MT/Month * Reception / Storage /

Transportation / used

as a raw material for

the manufacturing of

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Nytrosyl Sulphuric Acid

(from Sodium Thio

Sulphate Solution and

Spent Acid (H2SO4))

From

manufacturi

ng of 3,5-

Dichloroanili

ne

Nil 224 MT/Month 224 MT/Month Reuse for the

manufacturing of

Nytrosyl Sulphuric

Acid (from Sodium

Thio Sulphate

Solution and Spent

Acid (H2SO4))

--- Sodium Thio

Sulfate Solution

---- 501 MT/Month Nil 501 MT/Month* Reception / Usage /

Storage /

Transportation / use

as a raw material for

the manufacturing

of Nytrosyl Sulphuric

Acid (from Sodium

Thio Sulphate

Solution and Spent

Acid (H2SO4))

From

manufacturi

ng of 3,5-

Dichloroanili

ne

Nil 384 MT/Month 384 MT/Month Reuse for the

manufacturing of

Nytrosyl Sulphuric

Acid (from Sodium

Thio Sulphate

Solution and Spent

Acid (H2SO4)) / 3, 5

DCA

* Presently, Industry has applied under the Rule 11 [i.e. utilization of the hazardous wastes as a supplementary

resource or for energy recovery, or after processing under Rule 11 of the Hazardous Waste (Management,

Handling & Transboundary) Rules, 2008] for the reception (from actual generator) & usage of Spent H2SO4 &

Spent Sodium Thio Sulphate Solution as a raw material for the manufacturing of Nytrosyl Sulphuric Acid from

Sodium Thio Sulphate Solution & Spent H2SO4 on dated 9/3/2016. Permission for the same is awaited.

Now as per proposed proposal, industry has proposed to manufacture about 50 MT/Day of 3, 5 Di Chloro

Aniline. From the manufacturing of this product Spent H2SO4 and Spent Sodium Thio Sulphate Solution shall be

generate. If industry will manufacture 3, 5 Di Chloro Aniline within premises, in such case industry will receipt

the balance quantity (as per manufacturing of 3, 5, Di Chloro Aniline quantity). If industry will manufacture 50

MT/Day of 3, 5 Di Chloro Aniline, than industry will receipt about balance quantity i. e. 62 MT/Month of Spent

H2 SO4 and 117 MT/Month of Spent Sodium Thio Sulphate Solution from actual generator.

29.4 Spent Solvent

(Anisol)

From the

manufacturi

ng of 4 -

Methoxy

Acetopheno

ne

Nil 161 MT/Month 161 MT/Month Collection / Storage /

Reuse in to next

batch in same

process

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29.4 Spent Solvent

(IPA OR

Methanol)

From

manufacturi

ng of Alpha

Napthylami

ne

Nil 274 MT/Month 274 MT/Month


Reuse in to next

batch in same

process

OR

Spent Solvent

(Aniline OR

ODCB)

From

manufacturi

ng of Alpha

Napthylami

ne

Nil 386 MT/Month 386 MT/Month

If industry will use IPA / Methanol as a raw material for the manufacturing of Alpha Napthylamine, then IPA /

Methanol shall be recovered, accordingly if industry will use Aniline / ODCB, then only Aniline / ODCB shall be

recovered.

29.4 Spent Solvent

(MCB)

From

manufacturi

ng 3,5-

Dichloroanili

ne


reuse in to next

batch in same

process

29.4 Spent Solvent

(Aniline)

From

manufacturi

ng Phenyl

Alpha

Naphthylam

ine


reuse in to next

batch in same

process

29.4 Spent Solvent

(Toluene)

From

manufacturi

ng of 4-

Methyl

Acetopheno

ne


reuse in to next

batch in same

process

29.4 Spent Solvent

(EDC)

From

manufacturi

ng of Bis-(2-

Chloroethyl)

-amine


reuse in to next

batch in same

process

29.1 Distillation

Residue

From

Process



to Cement industries

for co-processing of

CHWIF

Distillation residue generated from the manufacturing of 4-Methoxy Acetophenone, 4-Methyl Acetophenone,

Alpha Napthylamine, Phenyl Alpha Naphthylamine (PANA), 3,5-Dichloroaniline

--- Acetic

Anhydride

From

manufacturi

ng of 4-


Transportation /

reuse in to next

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2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project and project proponent. In case of mining project, a copy of mining

lease/letter of intent should be given.

Identification of the project

Proposed Pesticide Intermediates and Specialty Chemicals in Existing Unit

Identification of the project proponent

Presently following are the directors of the company:-

1. Mr. Bansilal D. Patel

2. Mr. Jitendra P. Parmar

2.2 Brief description of nature of the Project

Proposed Pesticide Intermediates and Specialty Chemicals in Existing Unit

2.3 Need for the project and its importance to the country and or region

The objective is to be achieved by:

• Consolidating Business.

• By constantly upgrading the product range.

• Continuously reducing the Costs & improving Quality.

• To generate local employment

2.4 Demands-Supply Gap

Based on our informal survey of the market with our current customers and various traders, we have

found that there is a big potential for the range of the products we are planning. These products will

be an addition to the current range of our products.

2.5 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials and the non availability of some materials, we

will have to import some of the key raw materials as they are not available indigenously. This will

Methyl

Acetopheno

ne

batch in same

process

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make us very competitive against imported finished products and we will be able to increase the

export of our finished products.

2.6 Export possibility

There is export potential of our proposed products.

2.7 Domestic/Export Markets

There is export potential as well as demand in local market.

2.8 Employment Generation (Direct and Indirect) due to project.

Employment would be as per prevailing norms of state government for skilled and unskilled people

for the proposed expansion project.

3.0 Project Description

3.1 Type of Project including interlinked and interdependent projects, if any.

Proposed Pesticide Intermediates and Specialty Chemicals in Existing Unit.

Category: A-5 (b) & 5(f)

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3.2 Location (map showing general location, specific location and project boundary & project site

layout) with coordinates.

Map showing general location

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Layout

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3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly

the environmental considerations gone into should be highlighted.

Major factors involved in the selection of site are listed below:

• Site is very well connected by road

• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation

• Availability of power evacuation facilities

• Availability of water for industrial use

Modern infrastructure support and amenities at par with industrial estates in other global markets,

including:

� Efficient transport facilities within the industrial estate and to & fro the city area.

� Environment-friendly zone.

� Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer Annexure-I of Form-I.

3.5 Project Description with process details (a schematic diagram/flow chart showing the project

layout, components of the project etc. should be given)

Please refer Annexure-III in Form-I.

3.6 Raw material required along with estimated quantity, likely source, marketing area of final

products. Mode of transport of raw materials and finished products.

Please refer Annexure-I in Form-I

3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Out of total 28 KL/Day of effluent ...

1. About 14 KL/Day of Condensate water (generated only from the manufacturing of Nytrosyl

Sulphuric Acid (from spent sodium thio sulphate solution and Spent H2SO4 (as a raw material)) is

recycled back in to cooling tower.

14

And remaining 14 KL/Day waste water generated from process (from manufacturing of 3, 5, DCA),

cooling, washing & Scrubber shall be treated in ETP and the treated effluent shall be reused in to

utilities.

3.8 Availability of water its source, energy/power requirement and source should be given.

Power & Fuel Requirement

Fuel

Natural Gas: 82 SCM/day (Existing)

Diesel: 30 Lit/Hr (Existing)

Natural Gas: 82 SCM/day (Total Proposed)

Diesel: 75 Lit/Hr (Total Proposed)

Energy:

90 HP from DGVCL

Water Source

The entire water requirement will be met through Surat Municipal Corporation (SMC).

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/disposal.

Liquid Waste:

Source of water will be met through SMC. Total water requirement will be 65 m3/day (Existing: 25.5

m3/day + Additional Proposed: 39.5 m

3/day). The total wastewater generations will be 24.0 m

3/day

(Existing: 7.0 m3/day + Additional Proposed 17.0 m

3/day). Total 24.0 m3/day (14 m

3/day Industrial +

10 m3/day domestic) of effluent shall be generated, out of which 14 KL/Day waste water generated

from process (from manufacturing of 3, 5, DCA), cooling, washing & Scrubber shall be treated in ETP

and the treated effluent shall be reused in to utilities. About 14 KL/Day of Condensate water

(generated only from the manufacturing of Nytrosyl Sulphuric Acid (from spent sodium thio sulphate

solution and Spent H2SO4 (as a raw material)) is recycled back in to cooling tower.

Solid Waste:

Please Annexure- VI in Form-I.

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3.10 Schematic representations of the feasibility drawing which give information of EIA purpose.

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC

STATUS & BASIC AMENITIES. SITE VISITS BY AND

INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT.

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED

EXPANSION PLANT

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

RISK ANALYSIS

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

16

4.0 Site Analysis

4.1 Connectivity

• Site is very well connected by road & rail

• Availability of power evacuation facilities

• Availability of water for industrial use

4.2 Land Form, Land Use and Land Ownership

It will be incorporated in EIA Studies.

4.3 Topography (along with map)

We will incorporate topography in EIA Studies.

4.4 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. In case of the notified industrial area, a copy of the Gazette notification should be

given.


4.5 Existing Infrastructure

Existing Infrastructures facilities are listed below:

Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free form cultivation.

Availability of power evacuation facilities

4.6 Soil Classification


4.7 Climatic data from secondary sources.

Primary source: our own weather station & Secondary Sources: Indian Meteorological Department,

Ahmedabad.

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4.8 Social infrastructure available.

Depending on the growth of the company the required social infrastructure will be provided.

5.0 Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

planning/Development authority classification.

Type of Industry: Proposed Pesticide Intermediates and Specialty Chemicals in Existing Unit

Facility: Canteen, Administration, Transportation, OHC

5.2 Population Projection


5.3 Land use planning (breakup along with green belt etc.)

Plot Area: 2700 m2

Total Factory area: 1413 m2

Green belt area: 540 m2

Total Open Area: 747 m2

5.4 Assessment of Infrastructure Demand (Physical & Social)


5.5 Amenities/Facilities


6.0 Proposed Infrastructure

6.1 Industrial Area (Processing Area)

Processing Area (Processing Zone, ETP Area and Utility Area): 1413 m2

6.2 Residential Area (Non Processing Area)

Non Processing Area (Green belt, Raw material storage area, Finished storage area, road, Open

Area): 1287 m2

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6.3 Green Belt

Company has developed an effective green belt within the factory and on periphery of the factory.

In addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.

6.4 Social Infrastructure

Depending on the growth of the company the required social infrastructure will be provided.

6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc)

Site is very well connected by road & railway.

6.6 Drinking water Management (Source & Supply of water)

Water requirement will meet through SMC.

6.7 Sewerage System

Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful liquid

wastes from the offices, canteen and domestic waste coming from different sections. These liquid

wastes is treated and disposed by septic tank and soak pit.

6.8 Solid Waste Management

Please refer Section 1.7, Page No. 7 in Pre-Feasibility Report.

6.9 Power Requirement & Supply/Source

Energy:

90 HP from DGVCL

7.0 Rehabilitation and Resettlement (R & R) Plan

7.1 Policy to be adopted (central/state) in respect of the project affected including home ousters,

land ousters and landless laborers (a brief outline to be given)

There is no habitation on the proposed expansion project area and it is industrial land which is

purchased by company for development of Company, so that R & R policy is not applicable to this

project.

There shall be no displacement of any population in project area.

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8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for the project

to be given).

We shall start construction after getting environmental clearance and consent to establish. We shall

start production upon making application for CCA.

8.2 Estimated Project cost along with analysis in terms of economic viability of the project.

Total costs of the project will Rs. 50 Lakh. Capital cost of air & water pollution control system and

environmental monitoring equipments will be Rs. 5 Lakh.

9. Analysis of Proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to be local people including

tribal population, if any, in the area.

• Employment would be as per prevailing norms of state government for skilled and unskilled

people for the proposed project.

• Social Welfare shall be done.

• Cordial relation with the industry shall be established and representation shall be made to

villagers for help for creation of facilities related to health, education, etc.

01.project feasibility report - welcome to...

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