Pre Feasibility- organics division as per form-I by...

PRE-FEASIBILITY REPORT

ON

PROPOSED PROJECT

OF

MANUFACTURING OF

ORGANIC CHEMICALS

OF

AARTI INDUSTRIES LIMITED

(ORGANIC DIVISION)

LOCATED AT

Plot No. 801, 801/23, 806 & 807

Phase-III, GIDC Estate,

Vapi.396 195

M/s.Aarti Industries Limited (Organic Division), Vapi.

Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar i

CONTENTS

SR. NO. CONTENT PAGE

NO.

1. EXECUTIVE SUMMARY 1

2. INTRODUCTION 4

2.1 The Project 4

2.2 Project Proponent 4

2.3 Nature of project 5

2.4 Market Feasibility 5

3. PROJECT DESCRIPTION 6

3.1 Type of Project 6

3.2 Project Location 6

3.3 Site Selection 9

3.4 Neighboring Industries 9

3.5 Size of project 9

3.6 Process Technology 10

3.7 Raw material 10

3.8 Resource optimization/recycling and reuse 10

3.9 Resource requirements 10

3.9.1 Land 10

3.9.2 Building 10

3.9.3 Power and Fuel 10

3.9.4 Water 10

3.9.5 Manpower 11

3.10 Mitigation Measures & EMP 11

3.10.1 Waste water Management 11

3.10.2 Gaseous emission & Control 15

3.10.3 Hazardous waste management 16

3.10.4 Noise control & odour 17

3.10.5 Storage ,handling and transport of Hazardous chemical 17

3.10.6 Health & Safety measures 17

4. SITE ANALYSIS 17

4.1 Connectivity 17

4.2 Land use and land ownership 18

4.3 Existing Land Use 18

4.4 Existing Infrastructure 18


Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar ii

SR. NO. CONTENT PAGE

NO.

4.5 Soil Classification 18

4.6 Climate Data 18

4.7 Social Infrastructure 20

5. PLANNING BRIEF 20

5.1 Planning concept 20

5.2 Population projection 20

5.3 Land use planning 20

5.4 Assessment of infrastructure Demand 20

5.5 Amenities 21

6. PROPOSED INFRASTRUCTURE 21

6.1 Processing Area 21

6.2 Non Processing Area 22

6.3 Green Belt 22

6.4 Social Infrastructure 22

6.5 Drinking Water Management

22

6.6 Sewerage System

22

6.7 Industrial Waste Management 22

6.8 Solid Waste Management

23

6.9 Power Requirement & Supply 23

7. REHABILITATION & RESETTLEMENT (R & R)

PLAN

23

8. PROJECT SCHEDULE & COST ESTIMATES 23

8.1 Project Implementation Schedule 23

8.2 Estimated project cost 23

9. ANALYSIS OF PROPOSAL 23


Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar iii

LIST OF TABLES

SR.

NO.

TABLE NAME PAGE NO.

1. List of Products 1-2

2. Contact details of Directors 4-5

3. Salient Features Of The Project Site 6

4. Details of Neighboring Industries 9

5. Capital Cost Projection 9

6. Power and Fuel Requirement 10

7. Details of Water Consumption 10-11

8. Man Power Requirement 11

9. Details of Wastewater Generation 11

10. Wastewater Characteristics 12

11. ETP Details 13

12. Flue Gas Emissions And Control Measures 15

13. Process Emissions And Control Measures 16

14. Details of The Meteorological Conditions 19

15. Project Implementation Schedule 23

LIST OF FIGURES

FIGURE

NO.

FIGURE NAME PAGE

NO.

1. Location of the Project 7

2. Aerial View Of The 10 Km Radial Periphery

From The Project Site

8

3. Existing ETP Diagram 14

4. Wind rose diagram 19


M/s. Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar. 1

1.0 EXECUTIVE SUMMARY

M/s. Aarti Industries Limited (Organic Division) first obtained CCA order 1616, issued on

24/02/2004. Further it was extended by CCA order no. AWH-50294 dated 22/10/2012 for

manufacturing of Synthetic Organic products mentioned in below table no.1. Now the unit wants to go

for proposed expansion in same plant at Plot No. 801, 801/23,806 & 807 Phase-III, GIDC Estate,

Vapi, and Dist.: Valsad-396 195 Gujarat. The existing products and their proposed expansion are

mentioned in Table no. 1.

List of proposed products is mentioned in table no.1 As per EIA notification 2006, the proposed

expansion is falling under category 5(f).

TABLE NO 1:

LIST OF PRODUCTS

Sr. No.

Name of Product

Existing quantity in MT/Month as per CCA AWH-

50294

Proposed quantity in MT/Month

Total quantity after expansion in MT/Month

1 Para Nitro Chloro Benzene(PNCB) 5000

3900 9000 (Either/Or)

2 Ortho Nitro Chloro Benzene(ONCB)

3 Meta Nitro Chloro Benzene(MNCB) 100

4 2,5 Dichloro Nitro Benzene(2,5 DCNB) 400 0

1500 (Either/Or)

5 3,4 Di Chloro Nitro Benzene(3,4 DCNB) 600

6 2,3 DiChloro Nitro Benzene (2,3 DCNB) 100

7 2,4 DiChloro Nitro Benzene(2,4DCNB) 400

8 2,6 Di Chloro Nitro Benzene (2,6DCNB) 0

9 2,3,4 TrichloroNitro Benzene (2,3,4 TCNB) 0

10 2,4,5 TrichloroNitro Benzene (2,4,5 TCNB) 0

11 2,4 Dichloro 3 Fluoro Nitro Benzene 0

12 2,4 DiNitro Chloro Benzene 200 1300 1500

(Either/Or)

13 Mono Chloro Benzene(MCB) 3800

3000

8000* (Either/Or)

14 Ortho Dichloro Benzene(ODCB) 500

15 Para Dichloro Benzene(PDCB) 500 16 Meta Dichloro Benzene(MDCB) 0 17 1,2,4 Tri Chloro Benzene(1,2,4 TCB)

200 18 1,2,3 Tri ChloroBenzene(1,2,3 TCB)19 TCAN 0

20 Ortho Anisidine 30 0 30

21 Para AniSidine 20 0 20

22 Dichloro Aniline 50 0 50



23 2,5 DiChloro Aniline 35 0 35

24 3,4 DiChloro Aniline 15 0 15

25 Ortho Chloro Aniline 10 0 10

26 PPDA 25 0 25

27 OPDA 225 0 225

28 OCPNA/PCONA 100 0 100 29 ONA/PNA 150 0 150

33 ONCB Para Sulphonic Acid 25 0 25

34 3,3 DiChloro Benzedine Sulphate 10 0 10 35 Dilute Sulphuric Acid 1441 0 1441

Total 13936 8200 22136

By-Product

1. Sulphuric Acid 70% 3627 3027 6654

2. Hydrochloric Acid 30% 6165 7038 13203

3. Thio liquor 136.5 0 136.5

Total 9928.5 10065 19993.5 *NOTE: As such either/or any product will be 8000 MT/MONTH, but 1, 2, 4 TCB, 1, 2, 3 TCB, TCAN not more than 3000MT/Month)

COST OF PROJECT

The expansion will be carried out at existing plot located in GIDC. The expected cost of proposed

expansion is Rs. 52.85 crore. The total plot area of the unit is 45477 sq. m. The green belt area after

proposed expansion will be approx. 9605.22 sq. m.

FUEL & ELECTRICITY CONSUMPTION

As per existing scenario

As per consent, the unit is using 225 lit/hr of diesel as fuel for 2 D.G. Set of 625 KVA and 750 KVA.

The existing electricity load is 2500KVA from DGVCL. The unit is using steam from sister concern

unit M/s. Aarti Industries Limited (Acid Division) which is next to our unit at plot no. 802, 803,

804/1,2,3, Phase-III , GIDC Vapi, Gujarat.

Proposed scenario

Due to proposed expansion diesel of 350 lit/hr will be used for D.G. set of 1100 KVA. The proposed

electricity load from DGVCL will be 1000 KVA. Thus total electricity requirement after proposed

expansion will be 3500 KVA.



WATER CONSUMPTION


The source of water is GIDC. In the existing scenario, the unit is using 545 KLD fresh water for

industrial and domestic purpose.

Proposed scenario

For proposed expansion, the unit has proposed 413 KLD of water consumption for domestic and

industrial purpose. The total fresh water consumption after expansion will be 958 KLD.

WASTE WATER GENERATION, TREATMENT & DISPOSAL


As per consent, the industrial effluent generation is 150 KLD and sewage generation is 50 KLD.

Existing effluent is treated in ETP having primary, secondary and tertiary treatment. Treated water is

sent to CETP.

Proposed scenario

Due to proposed expansion, additional total industrial effluent generation will be 122 KLD. Hence,

after expansion total industrial effluent generation will be 272 KLD (150 KLD existing + 122 KLD

proposed). Due to proposed expansion, additional sewage generation will be 0 KLD. Hence, after

expansion sewage generation will be 50 KLD (50 KLD + 0 KLD).

Existing and proposed effluent will be treated in unit’s own ETP. In which existing waste water is

treated in Effluent treatment plant and after treatment, treated water is sent to CETP - Vapi Waste &

Effluent Management Co. Limited. The Membership Letter is attached as Annexure- XI. We will

discharge additional quantity of effluent in CETP .

GASEOUS EMISSION


FLUE GAS EMISSION

As per CCA order no. AWH- 50294, the unit has two stacks of D.G. Sets of 625 KVA and 750 KVA

having 11 m height each.

Now, the unit has proposed one stack of D.G set of 1100 KVA of 11 m height and one thermo pack of

100,000 Kcal which uses diesel as fuel.



PROCESS EMISSION

As per CCA order no. AWH- 50294, the unit has two stacks of chlorinator plant of MCB plant and

Nitrator of NCB plant of height 18 m and 12 m attached to two stage water scrubber and caustic

scrubber respectively.

The unit is proposing 5 stacks from HCl storage tank, GLV NCB, Spent acid concentration plant,

Batch nitration plant and DNCB plant of height 11 m respectively.

HAZARDOUS WASTE MANAGEMENT


As per CCA order no. AWH-50294, the hazardous waste generation are ETP waste (75 MT/Month),

Distillation residue (120 MT/Month), Thio Liquor (136.5 MT/Month), Sulfuric acid (3627

MT/Month), Hydrochloric Acid (6165 MT/Month), Spent Carbon (1 MT/Month), Used oil (100

Lit/Year), Discarded material (Plastic bags and drums) (Whatsoever), insulation waste (2 MT/Month)

& Dil. Sulphuric acid (a. 21600 MT/Year) (7500 MT/Year).

Proposed scenario

Due to proposed expansion the additional hazardous waste generation are ETP waste (110

MT/Month), Distillation residue (441 MT/Month), Spent Carbon (1 MT/Month), Used oil (200

Lit/Year), Discarded material (Plastic bags and drums) (Whatsoever) and insulation waste (2

MT/Month).

2.0 INTRODUCTION

2.1 THE PROJECT

M/s. Aarti Industries Limited (Organic Division) first obtained CCA order 1616, issued on

24/02/2004. Further it was extended by CCA order no. AWH-50294 dated 22/10/2012 for

manufacturing of products mentioned in Table 1. The unit has proposed expansion for manufacturing

of existing products and new products. Proposed production capacity is mentioned in Table no.1.

As per EIA notification 2006, the proposed expansion is falling under category 5(f).



2.2 PROJECT PROPONENT

The list of Directors is given in Table no.2.

TABLE NO 2:

CONTACT DETAILS OF DIRECTORS

Sr. No.

Name of Director Designation Address Telephone No.

1.

Shri.Rajendra V. Gogri

Chairman& Managing Director

1401, Antriksh. Murar road, Mulund (w), Mumbai 400080

022-67976666

2.

Shri.Rashesh C. Gogri

Vice chairman& Managing Director

601,Antriksh Morar Road, Mulund (W) Mumbai 400080

022-67976666

3. Shri. Parimal H. Desai

Whole-Time Director

A/1403 14TH Floor, Runwal Heights, L.S.B. Marg, Mulund (W) Mumbai- 400080

022-67976666

4. Shri.Manoj M. Chheda

Whole-Time Director

Dunhill Villa CO.OP.HSG.SOC.Ltd., Besant Road, Santa Cruz (W), Mumbai- 400054

022-67976666

5. Shri.Kirit R. Mehta Whole-Time Director

10, Pushpendra Mension, Feroz shah Mehta Road, Santa Cruz (W), Mumbai– 400054

0260-2400059 2400366

6. Smt. Hetal Gogri Gala

Whole - Time Director

558-B, Gopal Sadan, Block no. 801, 8TH Floor, Jamshed Road, Matunga(E), Mumbai– 400019

022 – 67976666

7. Shri. Renil R. Gogri Whole - Time Director

1401, Antriksh. Murar Road Mulund (W) Mumbai-400080

022 – 67976666

The directors of the company have good experience in handling the production management, financial management and all the allied areas.

2.3 NATURE OF PROJECT

Existing activities involves organic chemical manufacturing unit. The unit has proposed expansion for

organic manufacturing products. Proposed productions scenario is mentioned in Table 1.



2.4 MARKET FEASIBILITY

The unit does contribute towards improving their quality of life since the end users of products are

industries ranging from agrochemicals and dyes to specialty chemicals and pharmaceuticals - markets

that are critical to long-term sustainability. By supplying high quality and good value products to all

customers, the unit indirectly helps people to have access to better medicines, fertilizers and diverse

items of daily use. In other words, greening the supply chain management plays a significant role in

the unit’s business strategy. The products are highly influenced by the market demand and market

rates.

3. PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is not including any interlinked and interdependent projects.

3.2 PROJECT LOCATION

M/s. Aarti Industries Limited (Organic Division) is located at Plot No. 801, 801/23,806, & 807 Phase-

III, GIDC Estate, Vapi, and Dist.: Valsad-396 195 Gujarat. It is approximately 24 km distance from

Dist.: Valsad. The approximate geographical positioning of the project site is at Latitude

20°21'49.38"N, Longitude 72°56'29.91"E. The location of the project site can be identified from the

location map shown in Figure-1.The salient features of the location of the project site are presented in

Table no 3.

TABLE NO 3: SALIENT FEATURES OF THE PROJECT SITE

Particulars Details

Taluka/ Tehsil Pardi (approx. 17 KM)

District Valsad (approx. 24 KM)

Approx. Geographical positioning Latitude: 20°21'49.38"N

Longitude: 72°56'29.91"E

Nearest City Valsad (approx. 24 KM)

Nearest Town Vapi (approx. 3 KM)

Nearest Highway NH8 (approx. 2 KM)

Nearest State highway SH 185 (approx. 2 KM)

Nearest Railway line/ Railway station

Vapi (approx. 4 KM)

Nearest Airport/ Airbase Surat (approx. 87 KM)

Protected Areas/ Sanctuaries Vansda National Park, Navsari (approx. 65 KM)

Nearest State/National Boundary Silvassa (9.3 KM) and Daman (5 KM)

M/s.

FL

. Jyoti Om C

FIGURE 1: LOCATION

Chemical Res

N OF THE P

search Centr

PROJECT S

M/s.Aarti

re Pvt. Ltd.,

SITE

i Industries

Ankleshwar

s Limited (O

r.

Organic Div

7

vision), Vap

pi.

M/s

F

A

/s. Jyoti Om Che

FIGURE 2:

AERIAL VIEW

emical Research

W OF THE 10 K

h Centre Pvt. Ltd

KM RADIAL D

d., Ankleshwar.

DISTANCE FR

ROM THE PR

M/s.Aarti I

8

ROJECT SITE

Industries Limmited (Organic Division), Vap

pi.



3.3 SITE SELECTION

The project proponent did not consider any other alternative site for proposed expansion.

3.4 NEIGHBORING INDUSTRIES

The industry is located in an area, which is already industrialized. The industries in the vicinity of the

proposed project are given in the table no-4.

TABLE NO 4:

NEARBY INDUSTRIES IN THE VICINITY

Name of Industry Direction w.r.t project site

Address

Aarti Industries Limited (Alchemie Organic Division)

East Plot No. 902, 923 Phase 3, GIDC, Vapi- 396195 Gujarat, India

M/s. Shah Paper Mills Limited

West Plot no. 5202, Phase 3, GIDC, Vapi- 396195 Gujarat, India

M/s. Bayer Vapi Private Limited

North Plot No. 306/3, II Phase, GIDC, Vapi – 396195 Gujarat, India

M/s. Megafine Pharma (P) Ltd.

South Plot 911-912, Phase 3, GIDC, Phase 3, GIDC, Vapi, Gujarat 396195

3.5 SIZE OF PROJECT

The expected cost of proposed expansion of project is Rs.52.85 crores. New Plant and machinery

installations will also have to be acquired and installed.

Environment Protection and safety systems have also been considered in planning the Cost Projection.

The unit will carry out maintenance and necessary modifications in proposed effluent treatment plant.

The below given table no-5 shows the break-up of the proposed project cost.

TABLE NO 5: CAPITAL COST PROJECTION Sr. No.

Purpose Existing (Rs. in crore)

Proposed (Rs. in crore)

Total (Rs. in crore)

1. Land 96.9 0 96.9 2. Building 85 5 90 3. Plant and Machinery 200 45 245 4. Environment Protection a) Effluent treatment Plant 10 2 12 b) Safety Equipment (PPE,

fire extinguishers, Ventilation, etc.)

10 0.75 10.75

C) Green belt development 0 0.1 0.1 Total 401.9 52.85 454.75



3.6 PROCESS TECHNOLOGY

Details of manufacturing process are attached as an Annexure-V.

3.7 RAW MATERIAL

The proposed raw materials are organic and inorganic chemicals and they will be purchased from the

local/ Indian market. Details of raw-material consumption are attached as Annexure- IV.

3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE

The unit will recover sulphuric acid and will supply it to sister concern unit.

3.9 RESOURCE REQUIREMENTS

3.9.1 LAND

The plot has been purchased by M/s. Aarti Industries Ltd. (Organic Division) from GIDC. The total

plot area of the unit is 45477 sq. m. The existing green belt area is approx. 9605.22 sq. m.

3.9.2 BUILDING

The proposed expansion will take place, and new buildings will be constructed.

3.9.3 POWER AND FUEL

TABLE NO 6: POWER AND FUEL REQUIREMENT Sr. No.

Name Requirement Source Existing as per

CCA AWH-50294 Proposed Total

1 Diesel 225 lit/hr 350 lit/hr 575lit/hr Local market

2 Energy -Electricity 2500KVA 1000KVA 3500KVA DGVCL

3.9.4 WATER

The category wise bifurcation of the water requirement is given in Table no 7. The source of water

will be from GIDC water supply scheme.

TABLE NO 7:

CATEGORY-WISE WATER REQUIREMENT Sr.No.

Purpose Existing fresh Water consumption in KL/day

Proposed fresh Water Consumption in KL/Day

Total fresh water consumption (KL/day)

A Domestic 55 0 55 B Industrial 1) Cooling 334 150 484

2)Process 146 263 409 3) Washing 10 0 10 Total (B) 490 413 903 Total (A+B) 545 413 958



3.9.5 MANPOWER

The manpower required for the project as well as during the construction/ commissioning activities

will be employed from the local area.

TABLE NO 8: MAN POWER REQUIREMENT

Phase of project

Type of labor

No. of workers (Existing)

No. of workers (Proposed Scenario)

No. of workers (Total)

During construction

Contractual -- 30 30

During commissioning

Contractual -- 20 20

During operations

Managerial 35 5 40Skilled 400 30 430 Un-skilled 265 30 295

Total 700 65 765

3.10 MITIGATION MEASURES & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been proposed by

the company for the control of the anticipated pollution load.

3.10.1 WASTEWATER MANAGEMENT

3.10.1.1 WASTEWATER GENERATION

The category-wise bifurcation of the anticipated wastewater generation details is given in Table 9.

TABLE NO-9: CATEGORY-WISE WASTEWATER GENERATION

Sr.No.

Purpose Existing Waste water generation in KL/day

Proposed Waste water generation in KL/Day

Total wastewater generation in KL/day

A Domestic 50 0 50 B Industrial

1)Cooling 79 41 120 2)Process 61 81 142 3) Washing 10 0 10

Total (B) 150 122 272 Total (A+B) 200 122 322

Note: Our group company M/s. Aarti Industries Limited (Alchemie Organic Division) having discharge of 90 KLD and M/s. Aarti Industries Limited (Amine Division) having discharge of 55 KLD are in the process of achieving zero liquid discharge,already an EC is granted which will reduce the load of CETP.



3.10.1.2 WASTEWATER CHARACTERISTICS

Existing & proposed effluent characteristic before treatment and after treatment in ETP is covered in

Table no. 10.

TABLE NO-10: WATEWATER CHARACTERISTICS

Sr. No

Parameters UnitsBefore

Treatment After

Treatment

1 pH -- 6.5-8.5 6.5-7.5 2 Total Suspended Solids mg/l 150-200 80-100

3 Total Dissolved Solids mg/l 25000-30000

20000-25000

4 Ammonical Nitrogen mg/l 20-25 15-20 6 C.O.D. mg/l 500-800 300-450

3.10.1.3 WASTEWATER TREATMENT & DISPOSAL

EFFLUENT TREATMENT SCHEME (EXISTING& PROPOSED)

ETP Process Description:

Brief Description of Effluent Treatment Plant: The treatment process consists of

Physico - Chemical treatment of effluent.

ii)Bio-logical treatment of Physico -Chemical treated aqueous effluents diluted with domestic effluent.

General waste water & sewage is given anaerobic treatment in the septic tank to reduce organic load &

suspended particles before giving it bio-logical treatment.

Bio-logical Treatment

Physico - Chemically treated aqueous effluent, domestic effluent and non-process effluent are

combined and subject to bio-logical oxidation. General waste combined with the recycled effluent

from sludge dewatering and rain water in dykes area is collected in combined collection sump. All the

above streams are combined and equalized with the help of aeration in equalized tank to obtain same

organics load all times and partly reduction in COD/BOD. The equalized effluent is pumped in to the

primary treatment tank where sludge (settled) is collected in solar dry bed and over flow collected in

aeration tank. Activated sludge treatment as per extended aeration process is carried out in aeration

basin thereby reducing soluble BOD to desired treated effluent quality. Oxygen is supplied to the

aeration tank through fixed, mechanical surface aerator. Effluent from aeration tank enters in to the

secondary classifier where the produced bio-sludge settles allowing classified supernatant to over flow

to carbon filter and sand filter. After tertiary treatment, treated effluent is discharged to CETP pipeline

through continuous sampler. Settled sludge from secondary clarifier scrapped out in to the solar dry

DD



bed. Most of the settled sludge in clarifier is recycled back to the aeration tank to maintain the desired

MLSS/MLVSS concentration in the aeration tank.

DETAILS OF ETP UNITS TABLE NO-11: ETP DETAILS Sr. No.

Treatment Unit Dimension of ETP (in meter)

MOC

Existing ETP Equipments 1. Oil & grease tank 8 kl MS 2. Equalizer Tank -1 150 KL RCC 3. Equalizer Tank -2 150 kl RCC 4. Flash mixture -2 0.500 kl RCC 5. Poly dosing tank 0.458 kl RCC 6. Primary Clarifier 80 KL RCC 7. Bio-Reactor 400 KL RCC 8. Secondary Clarifier 120 KL RCC 9. Secondary sludge tank 5 kl MS 10. Polishing tank-1 3.7 kl RCC 11. Polishing tank-2 3.7 kl rcc 12. Activated Carbon Column --- MS 13. Multigrade sand filter ---- ms 14. Raw Water Tank 5 KL HDPE 15. Final Outlet Tank 1 KL RCC 16. Neutralizer - 1 12 KL MSTL 17. Neutralizer - 2 6 KL HDPE 18. Neutralizer - 3 4 KL SS 19. Lime Preparation Tank - 1 10 KL RCC20. Lime Preparation Tank - 2 10 KL RCC 21. Filter Press --- ---- Proposed ETP Equipments 1. Flash mixture-1 2.5 kl SS 2. Flocculator 2.5 kl MS 3. PAC dosing tank 0.527 kl MS 4. Final Outlet Tank 5 KL HDPE 5. Neutralizer 4 15KL MS 6. Memebrane Filter Press

M/s

F F

E

/s. Jyoti Om Che

FLOW DIAGR

FIGURE 3:

EXISTING ET

emical Research

RAM OF ETP (

TP FLOW DIA

h Centre Pvt. Ltd

(EXISTING &

GRAM

d., Ankleshwar.

PROPOSED):

:

M/s.Aarti I

14

Industries Limmited (Organic Division), Vappi.



3.10.2 GASEOUS EMISSIONS & CONTROL

3.10.2.1 FLUE GAS EMISSIONS

As per CCA order no. AWH- 50294, the unit has two stacks of D.G. Sets of 625 KVA and 750 KVA

having 11 m height each.

Now, the unit has proposed one stack of D.G set of 1100 KVA of 11 m height and one thermo pack of

100,000 Kcal.

TABLE NO-12: FLUE GAS EMISSION Sr. No.

Stack Attached To Stack Height in Meter

APCM Fuel Type of Emission

Permissible Limit

Existing as per CCA (AWH-50294) 1. D.G.set

(1 no. 625 KVA) 11 None Diesel PM

SO2

NOX

150mg/ Nm3 100 ppm 50ppm

2. D.G.set (1 no. 750 KVA)

11 None Diesel PM SO2

NOX


Proposed 1. D.G.set

(1 no. 1100KVA) 11 None Diesel PM

SO2

NOX


2. Thermo pack 100000 KCal

11 None Diesel PM SO2

NOX


3.10.2.2 PROCESS EMISSION

As per CCA order no. AWH- 50294, the unit has two stacks of chlorinator plant of MCB plant and

Nitrator of NCB plant of height 18 m and 12 m attached to two stage water scrubber and caustic

scrubber respectively.

The unit is proposing 5 stacks from HCl storage tank, GLV NCB, Spent acid concentration plant,

Batch nitration plant and DNCB plant of height 11 m respectively.



TABLE NO-13: PROCESS GAS EMISSION

Sr. No.

Stack attached to Stack Height in Meter

APCM Parameter Permissible Limit

Existing as per CCA (AWH-50294) 1. Chlorinator for MCB

plant 18 Two stage water

scrubber+Caustic scrubber

HCl Cl2

20 mg/Nm3 9 mg/Nm3

2. Nitrator of NCB plant 12 Two Stage Caustic scrubber

NOX 25 mg/Nm3

Proposed 1. Connected to Hcl

storage tank 11 Water

scrubber+Caustic scrubber

HCL

2. Connected to GLV NCB 11 Caustic scrubber NOX 25 mg/Nm3 3. Spent acid

Concentration plant 11 Caustic scrubber

4. Batch Nitration plant 11 Caustic scrubber 5. DNCB Plant 11 Water scrubber

followed by Caustic scrubber

3.10.2.3 FUGITIVE EMISSIONS

There will be no volatile or low boiling chemicals to be used in the process. Hence, chances of fugitive

emissions are reduced to a great extent by providing proper control measures.

However, following steps will be taken to reduce chances of fugitive emissions:

All raw-materials will be stored in drums/ bags in a well-ventilated raw material storage area.

All reactions will be taken in closed reactor system.

The fugitive emissions in terms of handling losses will be reduced by proper storage and handling.

Raw-material feeding will be carried out by pumps.

Regular monitoring will be done of piping and fittings for checking of any leakages.

Good housekeeping will be maintained in the plant

3.10.3 HAZARDOUS/ NON-HAZARDOUS WASTE MANAGEMENT

The following type of hazardous waste will be generated from the operational activities. All the waste

will be stored separately in a designated storage area. The details about quantity of hazardous waste

generation, storage, and disposal for existing and proposed are attached as Annexure-IX.

In addition to the provision of above, we will ensure proper management for hazardous waste as

below:



(A) Transportation of hazardous waste to the TSDF Site will be governed as per the guidelines and

accompanied with Form-13.

(B) Annual returns of the disposal of wastes in Form-4 will be uploaded online and submitted

regularly to the local office of the GPCB.

3.10.4 NOISE CONTROL & ODOUR

The major noise generation is from D.G. Set. It is installed in a closed room, acoustic enclosure is

provided around it. Ear plugs are provided to the operating personnel in boiler room.

The following steps will be taken for Odour control.

(A) Raw-material feeding will be carried out by pumps.

(B) All reactions will be taken in closed reactor system.

(C) Roof top ventilation will be provided in the entire plant area.

Regular monitoring will be done of piping and fittings for checking of any leakages.

3.10.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS

The storage and mode of transport of chemicals will be done as per detailed MSDS and Chemical

hazards guide (NIOSH) for the hazardous chemicals.

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

3.10.6 HEALTH AND SAFETY MEASURES

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of large

volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of MSIHC Rules,

Moreover transport activity will be through drums, so there will be manual loading and unloading and

no unloading through pipe at the site. Hence, the risk of static charge generation during transfer of

such chemicals is not significant.

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

The site is located at Plot No. 801, 801/23,806, & 807 Phase-III, GIDC Estate, Vapi, and Dist.:

Valsad-396 195 Gujarat. The site is 3 km from Vapi town and 2 Km from National highways. The

land and Infrastructure is already available. The raw materials are easily available through the easy



transport via road connectivity. The Vapi has railway station and connected to Mumbai- Amadavad

rail line. The site is in the existing unit compound.

4.2 LAND USE AND LAND OWNERSHIP

The proposed project site is into the GIDC Estate, Vapi, and Gujarat which is meant for this type of

industries. The land is on Plot No. 801, 801/23,806, & 807 Phase-III, GIDC Estate, Vapi, and Dist.:

Valsad-396 195 Gujarat. The total plot area of the unit is 45477 sq. m. The existing green belt area is

approx. 9605.22 sq. m.

Land ownership is with project proponents.

4.3 EXISTING LAND USE

Proposed expansion will be in present plot only. The same land use status will be maintained.

4.4 EXISTING INFRASTRUCTURE

The plant is located in a well-developed industrial zone, which have all essential facilities such as

well-connected road network with ease of transportation, arrangement for supply of water and power

to industries, effluent disposal facilities etc. Infrastructure is made available through Govt. approved

authorized agencies.

4.5 SOIL CLASSIFICATION

The soils of the district are derived from the Deccan trap which is main rock formation of the district.

The soil of the district can be classified as light, medium and heavy according to depth, texture and

location. There is sandy loam to loamy in texture, brownish black in color.

4.6 CLIMATE DATA (SECONDARY SOURCES)

The climate is characterized by oppressive summer dampness in the atmosphere nearly throughout the

year, heavy south- west monsoon rainfall and a mild winter.

The year may be divided in to four seasons. From December to February is known as winter or cold

season. The summer or hot season is from March to May and south- west monsoon season is from

June to September, while October and November is the post monsoon season.

Valsad is the nearest meteorological observatory station to the project site. Based on the

meteorological data, wind rose have been prepared for the summer season period between the Oct-

2016 to Dec-2016. The wind rose diagram prepared from same data is given in Table no. 14.

M/s.

T

M(D

M

O

N

D

F

W

. Jyoti Om C

TABLE NO

MICRO MEData from In

Month

October-16

November-1

December-1

FIGURE 5:

WIND ROSE

Chemical Res

14:

ETEOROLOndian Meteo

--

Min. Max. Averag

16 Min. Max. Averag

6 Min. Max. Averag

E DIAGRA

search Centr

OGICAL Dorological D

Tem

23 35

ge 29 20 34

ge 27 17 32

ge 24.

AM FOR PE

M/s.Aarti

re Pvt. Ltd.,

DATA epartment, A

mp. (°C)

5

ERIODOF O

i Industries

Ankleshwar

Ahmadabad

Relative Humidity (

28 94 61 24 51 37.5 23 52 37.5

OCTOBER

s Limited (O

r.

, Station:-VA

(%) Winkm

0 136.50 105 0 115.5

R 2016 TO D

Organic Div

19

ALSAD)

nd Speed m/hr

DECEMBE

vision), Vap

9

ER 2016

pi.



4.7 SOCIAL INFRA STRUCTURE

The Vapi city falls at Pardi Taluka of Gujarat. It is positioned on the bank of River Daman Ganga. It is

situated to east of Daman (Central Territory) and to the West of Dadra and Nagar Haveli. Vapi is

largely an industrial area dominated by small scale industries, especially chemical plants.

Infrastructure like Airport is at the distance of 87 km (Surat) in north direction. Nearest habitation is

Vapi Town, 3 km away from project site in West direction. All the required infrastructure facilities are

available in this town. National highway no.8 is 2 km away in west direction from project site.

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT

Vapi is largely an industrial area dominated by small scale industries, especially chemical plants.

Vapi in Gujarat has a largest industrial area with common effluent treatment plant and land fill site.

Govt. agencies provide many basic facilities like uninterrupted water supply, power and road network.

5.2 POPULATION PROJECTION

As per provisional reports of Census India, Population of Vapi in 2011 is 1, 63,605 of which male and

female are 94,338 and 69,267 respectively. The sex ratio of Vapi city is 734 per 1000 males.

In education section, total literates in Vapi city are 1, 43,706 of which 83,720 are males while 59, 986

are females. Average literacy rate of Vapi city is almost 100 Percent.

5.3 LAND USE PLANNING

The proposed project is in the established GIDC industrial area. This is not a prime agriculture land.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

M/s. Aarti Industries Ltd. (Organic Division) shall get water from GIDC water supply scheme. So

there will be no additional stress on ground water resources and there will be no adverse effect on the

ground water resources available in the nearby area. The unit has 2500 KVA connected load form

DGVCL as per CCA. Additional requirement for proposed expansion will 1000 KVA. Thus the total

requirement of electricity will be 3500 KVA. The transportation facilities will also expect to improve

due to increase in the movement of workers and raw material and finished products.



5.5 AMENITIES

The available basic amenities are as under:

(A) Education Facilities:

Education Facilities are available and the literacy rate is about 45.67 % within 5 km periphery. All the

villages have a minimum of one primary school.

(B) Medical Facilities:

The medical facilities are available in satisfactory amount in study area. These facilities are available

in form of child welfare Centre, primary health sub Centre, and allopathic dispensary, maternity &

child welfare centers, registered private medical practitioners and family welfare Centre within the

range.

(C) Drinking water Facilities & Power Supply:

All the villages have potable water supply and in 100% area the drinking water is supplied through

taps, wells and tube wells. All the villages have power supply facilities in the study region.

(D) Post, Telegraph & Telephone facilities

The information collected clearly indicates that the infrastructural facilities are provided by respective

government agencies for the development of this area. For communication purpose, post office and

phones are available in most of the villages. The villages having Non-availability of these facilities can

get these facilities within 5-10km distance.

(E) Transport Facilities:

Bus services are available in all the villages of the study region within 5 km area and are the most

preferable mode of transport in the region. Auto-rickshaw is also used as transport facility. Villages

are connected with paved roads.

Source: 2011, Census.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

The process area will cover Plant, Raw material storage area, Hazardous waste storage area, ETP and

utilities. The process area covered by the unit at ground level will be 10904.57 sq. m.



6.2 NON PROCESSING AREA

The non process area will cover Admin Building, Canteen and security cabin. The non process area

covered by unit at ground level will be 1222.6 sq.m.

6.3 GREEN BELT

Out of the total land area of 45477 sq. m. approximately 9605.22 sq. m. is utilized for green belt

development. There will be provision of budget of 10 lakh rupees for green belt development.

6.4 SOCIAL INFRASTRUCTURE

The availability of basic amenities is covered as under:

(A) Training & Education: All the employees will be trained and educated periodically about the

hazardous nature of chemicals used in the process. Also, training for firefighting, work permit

system, first aid, safe handling of hazardous chemicals and integrating safety, in all activities.

(B) Medical facility: Pre-employment medical checkup at the time of employment. In order to safe

guard the health of the employees, all the employees undergo periodic health checkup.

(C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide purified

water for drinking purpose.

(D) Transportation: The unit will provide basic transportation facility for workers.

(E) Telegraph & Post: There will be provision of telephone, fax & internet facility.

(F) Power supply: There will be connected load of 3500KVA from DGVCL.

6.5 DRINKING WATER MANAGEMENT

The source of water is already availability from existing water works of GIDC and the same is

adequate and satisfactory. The unit has total 50 KL/Day water for domestic purpose.

6.6 SEWERAGE SYSTEM

The sewage will be sent to Sewage treatment plant.

6.7 INDUSTRIAL WASTE MANAGEMENT

The hazardous waste like ETP waste, used oil, discarded containers/bags/liners, Process waste

containing organic complex will be generated from proposed project activity. The hazardous waste

management and disposal is shown in Annexure-IX.



6.8 SOLID WASTE MANAGEMENT

The record of non-hazardous solid waste like, Fibber board drum, Polyethylene bag, Rubber Hose

pipe, glass, wooden waste etc. will be mentioned.

6.9 POWER REQUIREMENT & SUPPLY

At present, the unit has 2500 KVA connected load. Additional 1000 KVA connected load for

proposed expansion.

7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

The proposed project is located in Vapi Industrial Estate, Tal. Pardi, Dist.: Valsad and the project is.

There will be no any human settlement affected by proposed project. So, there is no requirement of

any R & R Plan.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

TABLE 15:

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule after getting NOC from GPCB Sr. No.

Activity Required Period

1. Civil work Immediately after getting NOC 2. Procurement of

machinery 1 month after getting NOC

3. Eraction& installation of machinery

Immediately after competition of activity no.2

4. Trial of machinery & equipments

Within 1 months after competition of activity no.3

5. Commercial activity 1 months after competition of activity no.4

8.2 ESTIMATED PROJECT COST

Details for estimated project cost is covered in table no 6.

9.0 ANALYSIS OF PROPOSAL

All the manpower is utilized from local region around Vapi. Company shall also try to provide indirect

employment opportunities by availing local contract services during transportation during operational

phase. The company intends to carryout CSR activity as applicable to nearby village for their welfare

and upliftment.

Pre Feasibility- organics division as per form-I by...

Documents

Transcript of Pre Feasibility- organics division as per form-I by...