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Project Prefeasibility Report

Project: Proposed expansion project for manufacturing of Synthetic Organic Chemicals 0

PROJECT PRE-FEASIBILITY REPORT

Of

PROPOSED EXPANSION PROJECT

For

MANUFACTURING OF SYNTHETIC ORGANIC CHEMICALS

(EPOXIDISED SOYABEAN OIL, METHYL SOYATE& PLASTICIZERS)

At

Plot No. 16-19

Phase-I, GIDC Vapi-396195

Dist: Valsad, Gujarat

Project proponent

M/s. Consumers Plastics Pvt. Ltd.

Project Prefeasibility Report M/s.Consumers Plastics Pvt, Ltd


CHAPTER – 1 EXECUTIVE SUMMARY The project is summarized in the below table: Table 1.1: Project Summary

PARTICULARS DETAILS

NAME OF THE UNIT

M/s. Consumers Plastics Pvt. Ltd.

DIRECTOR Mr.Ajay G. Gandhi, Mr. Pradeep G. Gandhi, Mr. Shamit A. Gandhi, Mr. Gulabrai V. Gandhi PRODUCTS

Sr. No.

Name of Finished products Quantity in MT/Month Existing Proposed Total

1. PVC/ HDPE Pipes 40.0 NIL 40.0 2. EpoxidisedSoyabean Oil

200.0

400.0

600.0 3. Methyl Soyate 4. Di Octyl Phthalate (DOP)

NIL 1000.0 1000.0 5. Di-Iso-Nonyl Phthalate (DINP) 6. Di-IsoDecyl Phthalates (DIDP) 7. Di Butyle Phthalates (DBP) 8. Di Octyl Maleate (DOM) 9. Di Butyl Maleate (DBM) 10 Di (2-Ethylhexyl) Adipate (DOA) 11. Polymer Compound& Master Batch NIL 500.0 500.0 12. Plastic Extruded & molded Products NIL 500.0 500.0

Total 240.0 2400.0 2640.0 By Products* 1. Sodium Formate *15.0 *-15.0 Nil 2. Glycerol *25.4 *50.8 *76.2

Total 280.4 2450.8 2716.2 Note: *In existing operations, Sodium Formate is being generated as by product during manufacturing of Epoxidised Soyabean Oil. After proposed project, new manufacturing process of Epoxidised Soyabean Oil will adopted, where Sodium Formate will not be generated. (1) Consolidated Consent and Authorization (CC&A) No: AWH-65840, dated: 30/10/2014 (2) Environment Clearance No.: F.No. J-11011/871/2008- IA II (I), dated: 10/02/2009

LOCATION Plot No. 16-19, Phase-1,GIDC Estate,Vapi396195,Ta: Pardi, Dist. Valsad. Gujarat NATURE OF PROJECT

Proposed Expansion Project forIncrease in existing production quantities of products. i.e. Synthetic Organic Chemicals

RESOURCES Resource type Requirement Source

Existing Proposed Additional

Total

Land 6761.00 m2 Nil 6761.00m2 No additional land is required for expansion project.

Building 1725.00m2 750.00 m2 2475.00 m2 The existing built up area will be utilized after necessary modifications also some new sheds will be constructed and ETP will have to be modified.

Raw-materials

As given in Chapter-3 section 3.5 - Raw Material for finished products.

The raw materials are available in Local/ Indian market.Andarealso imported from foreign countries. Details are explained in chapter 3

Water Industrial 17.0 KLD Domestic 5.0 KLD

Industrial 30.0 KLD Domestic 3.0 KLD

Industrial 47.0 KLD Domestic 8.0 KLD

Fresh water is/ will be sourced from GIDC water supply



PARTICULARS DETAILS

Power 150 kVA 200 kVA 350 kVA Sourced from DGVCL Fuel Natural Gas

@290 SCM/day Natural Gas @2205 SCM/day

Natural Gas @2495 SCM/day

Local Suppliers.

Man-power 24 16 40 To be employed from local area POLLUTION POTENTIAL & MITIGATION MEASURES Parameter Potential Mitigation Measures

Existing Proposed Additional

Total

Wastewater Industrial: 2.2 KLD Domestic: 4.0 KLD

Industrial: 48.8KLD Domestic: 2.4KLD

Industrial: 51.0KLD Domestic: 6.4KLD

• The domestic effluent is/will be disposed of through septic tank/ soak pit system.

• In existing operations, Industrial effluent is given primary treatment and utilized for gardening purpose.

• After proposed expansion,necessary modifications will be made in existing ETP.

• Industrial effluent generated will be treated in ETP and treated effluent will be reused for cooling & gardening purpose.

Air Emissions • Boiler-1 Nos. 600 kg/h.

• Thermic Fluid Heater 10 lakh Kcal/h.

• Boiler-1 Nos. 600 kg/h.

• Thermic Fluid Heater 10 lakh Kcal/h.

• In existing operations one Boiler of 600 kg/Hr. is installed. Natural gasis used as fuel in Boiler

• For Proposed expansion additionally one thermic fluid heater having capacity of 10Lakh Kcal/Hr. will be installed.

• Natural gas is/will be used as fuel in boiler & thermic fluid heater.

• Adequate chimney height is/will be provided.

Hazardous & solid waste

• ETP waste (34.3): 0.037MT/Month

• Used Oil (5.1): 30 L/Year

• Discarded Bags (33.3):100Nos./Month

• Discarded Containers (33.3): 1800 Nos./Month

• ETP waste (34.3): 9.963 MT/Month


• Discarded Bags (33.3): 11500 Nos./Month

• Discarded Containers (33.3):2285 Nos./Month

• ETP waste (34.3): 10 MT/Month


• Discarded Bags (33.3):11780 Nos./Month

• Discarded Containers (33.3): 4285Nos./Month

• ETP waste is/will be stored properly & disposed of to CSW site of VWEMCL, Vapi.

• The used oil will be collected & stored separately andreused as lubricant in plant operation.

• The discarded bags & drums are/will be stored separately in company premises and returned back to supplier/sold to the recognized re-conditioners.

Noise Expected levels

Inside the plant: <75 dB(A)

Expected levels


Expected levels


• The major sources of noise generation in plant area are equipment machinary and boiler

• Anti-vibrationpads are/will be provided wherever applicable.

• Regular maintenance lubrication is/will be done.



CHAPTER – 2 INTRODUCTION OF THE PROJECT 2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 2.1.1 IDENTIFICATION OF THE PROJECT

M/s. Consumers Plastics Pvt. Ltd. which is an existing unit located at Plot No. 16-19, Phase I,

GIDC Estate, Vapi–396 195 is engaged in manufacturing “HDPE, PVC Plastic Pipes,

Epoxidised Soyabean Oil and Methyl Soyate. Due to market demand and availability of all the

required infrastructure/facilities in the existing premises, we plan to increase the production

capacity of the existing product and introduction of new range of plasticizers product. The

proposed expansion will be carried out within the existing unit. For this proposed expansion

project, the industry intends to procure the latest available technology.

The list wise products and its production capacity are given in table below:

Table 2.1: List of Products Sr. No.

Name of Finished products Quantity in MT/Month

Existing Proposed Total 1. PVC/ HDPE Pipes 40.0 NIL 40.0 2. Epoxidised Soyabean Oil

200.0

400.0 600.0 3. Methyl Soyate 4. Di Octyl Phthalate (DOP)

NIL 1000.0 1000.0

5. Di-Iso-Nonyl Phthalate (DINP) 6. Di-IsoDecyl Phthalates (DIDP) 7. Di Butyle Phthalates (DBP) 8. Di Octyl Maleate (DOM) 9. Di Butyl Maleate (DBM) 10. Di (2-Ethylhexyl) Adipate (DOA) 11. Polymer Compound&Master Batch NIL 500.0 500.012. Plastic Extruded & Molded Products NIL 500.0 500.0

Total 240.0 2400.0 2640.0By Products* 1. Sodium Formate *15.0 *-15.0 Nil2. Glycerol *25.4 *50.8 *76.2

Total 280.4 2450.8 2716.2Note: *In existing operations, Sodium Formate is being generated as by product during manufacturing of Epoxidised Soyabean Oil. After proposed project, new manufacturing process of Epoxidised Soyabean Oil will adopted, where Sodium Formate will not be generated. (1) Consolidated Consent and Authorization (CC&A) No: AWH-65840, dated: 30/10/2014 (2) Environment Clearance No.: F. No. J-11011/871/2008- IAII (I), dated: 10/02/2009



2.1.2 PROJECT PROPONENT

The company is a private limited and is promoted by 4 directors. Table 2.2: Addresses of Directors

Sr.No. Name of Directors Addresses

1. Mr. Ajay G. Gandhi B-252,25th Floor, Grand Paradi, August KrantiMarg, Mumbai– 400 036.

2. Mr. Pradeep G. Gandhi 21, Vallabh Appts., 87, Bhulabhai Desai Road, Mumbai–400 036.

3. Mr. Shamit A. Gandhi B-252,25th Floor, Grand Paradi, August KrantiMarg, Mumbai – 400 036.

4. Mr. Gulabrai V. Gandhi 21, Vallabh Appts.,87, Bhulabhai Desai Road, Mumbai–400 026

2.2 NATURE OF THE PROJECT The proposed Polymer Compound & Master Batch and Plastic Extruded & Molded Products do not require prior environmental clearance as the process/type of process is not covered under the provisions of EIA-notification-2006 (as amended timely). However, the manufacturing of Plasticizers, Epoxidised Soyabean Oil and Methyl Soyate falls under the item no. “5(f) category” i.e. Synthetic Organic Chemicals and “Category B” as per the EIA notification, since the project is located in GIDC Vapi.However, due to the presence of interstate boundary of D&NH and Daman within 5 km radial periphery, it is to be treated as “Category A” and needs to obtain the prior Environmental Clearance from the Ministry of Environment and Forests MoEF (EIAA).

2.3 NEED OF PROJECT & DEMAND-SUPPLY GAP The proposed products range is having a good demand in the market as per market survey by the company. 2.4 EXPORT POSSIBILITY As per market survey by the company, these proposed products are having a domestic as well as export market.

2.5 EMPLOYMENT GENERATION DUE TO PROPOSED PROJECT

The proposed expansion project will provide direct employment opportunity to16 persons the

man-power required for the project will be employed locally from the nearby areas.



CHAPTER – 3

PROJECT DESCRIPTION 3.1 TYPE & LOCATION OF PROJECT

3.1.1 TYPE

The proposed expansion project involves manufacturing of “Synthetic Organic Chemical” falls under the item no. “5(f) category i.e. Synthetic Organic Chemicals and “Category B” as per the EIA notification, 2006 (as amended timely), since the project is located in GIDC Vapi and presence of interstate boundary of D&NH and Daman within 5 km radial periphery it is to be treated as “Category A”, and needs to obtain the prior Environmental Clearance from the MoEF (EIAA).

3.1.2 LOCATION

M/s. Consumers Plastics Pvt. Ltd. falling under Small Scale category proposes expansion in

existing production capacity and addition of new product at Plot No. 16-19, Phase I, GIDC

Estate, Vapi – 396 195.

There is cluster of profuse large-scale, medium scale and small-scale industries, engaged in

manufacturing of various products, bulk drugs, organic pigments, Organic and Inorganic

Chemicals, Pharmaceuticals, Pesticides etc.

The GIDC area has a Disaster management cell set up by Vapi Industrial Association. Common

Effluent Treatment Plant and Common Hazardous Waste Disposal Site is set up by Vapi Waste

&Effluent Management Co. Ltd. Vapi also having the drainage system for the disposal of the

treated effluent from individual industry to the CETP for further treatment and disposal into the

saline region of the Damanganga River.

Location map of the project site is given in the Figure 3.1.



Figure 3.1: Project Site

Project Site



Figure 3.2: Satellite Image of the Project Site



Figure 3.3: Project Site layout

Table 3.1: Area Statement

S. No. Description Area (m2) Existing Scenario Proposed Scenario

1. Construction Area 1725.00 2475.00

2. Greenbelt area 1600.00 1600.00

3. Open land area 3436.00 2686.00

Total plot area 6761.00 6761.00



3.2 DETAILS OF THE ALTERNATIVE SITE The proposed expansion is to be carried out in the existing plot located in GIDC Vapi,so no

alternative study for site selection has been conducted. The present land is adequate to cater

the requirement of the proposed expansion project. Further the existing infrastructure &

machinery availability is very helpful for the proposed project. These together justify the use of

Existing premises for proposed project. Hence, only existing site is considered for the proposed

project.

The main advantages for expansion at existing site are shown below. • Existing site land area is adequate for production to the required quantities.

• Availability of proper approach to the plant site for movement of raw materials, finished

products, etc.

• Availability of resources such as water, fuel, power etc.

• Existing site already employs trained manpower. Additional manpower will be available

locally.

. 3.3 SIZE & MAGNITUDE OF OPERATION The total magnitude of operation after proposed expansion will be 2716.2MT/Month with by-

products.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS The proposed products details like process description, material balance and chemical reaction

are given below.



3.4.1 Existing Products Scenario

3.4.1.1 EPOXIDISED SOYABEAN OIL (Existing Process)

3.4.1.1.1 Chemical Reaction 3.4.1.1.2 Manufacturing Process Epoxidised Soyabean Oil is manufactured by oxidizing Soyabean Oil by Hydrogen Peroxide in presence of catalyst Formic Acid. In this process initially Soyabean Oil is charged in reactor and catalyst Formic acid is added. Then the required quantity of Hydrogen Peroxide is added in six to seven installments with constant stirring.

After the reaction is completed, the mass is transferred to the settling tank where aqueous layer is removed and remaining oily layer is final product Epoxidised Soyabean Oil, which is dried out by heating under vacuum condition. Whereas the aqueous layer is treated with Sodium Hydroxide and after evaporation, used as byproduct Sodium Formate

H2C O CO

CH

H2C O CO

CH

H2C O CO

CH

CH

CH

CH

R

R

R+ H2O2

Formic Acid

HCOOH(Catalyst)

Epoxidised Soyabean Oil

+ OH2

Hydrogen Perodxide WaterSoyabean Oil

H2C O CO

C

H2C O CO

C

H2C O CO

C

C

C

C

R

R

R

O

O

O



3.4.1.1.3 Material Balance



3.4.1.2EPOXIDISED SOYABEAN OIL (Proposed Process) 3.4.1.2.1 Chemical Reaction

3.4.1.1.2 Manufacturing Process

In the proposed change in process, we propose giving stage wise washing for remaining organic layer to achieve required reduction in the acidity. The wash water is also diverted to ETP. Finally, the Epoxidised Soyabean Oil will dry in dryer.

H2C O CO

CH

H2C O CO

CH

H2C O CO

CH

CH

CH

CH

R

R

R+ H2O2

Formic Acid

HCOOH(Catalyst)


+ OH2

Hydrogen Perodxide WaterSoyabean Oil

H2C O CO

C

H2C O CO

C

H2C O CO

C

C

C

C

R

R

R

O

O

O



3.4.1.3METHYL SOYATE

3.4.1.3.1 Chemical Reaction

3.4.1.3.2 Manufacturing Process Methyl Soyate is manufactured by esterification of Soyabean Oil by Methanol in presence of catalyst. In this process initially Soyabean Oil is charged in reactor and catalyst Sodium Methoxide and Methanol are added. Then the mixture is heated up to 65oC to 75oC with constant stirring, and refluxed.

After completion of esterification reaction, Methyl Soyate is distilled out and remaining oily mass is byproduct Glycerol.


H2C O CO

R

HC O CO

R

H2C O CO

R

Soyabean Oil

+ CH3 OH3

Methanol

R CO

O CH3 +

H2C OH

HC OH

H2C OH

3

Methyl Soyate Glycerol

Catalyst

NaOCH 3



3.4.1.4 Di-Octyl Phthalate (DOP)


C6H4(CO)2O + 2 (C8H17OH) C6H4(COOC8H17)2 + H2O

148.12 2 x 130.23 390.56 18.02

3.4.1.4.2 Manufacturing Process Esterification / Separation

Esterification is an equilibrium chemical reaction which is carried out as a batch process in the reactor containing an agitator and other equipment – particularly for water separation and removal which is formed during chemical reaction.

First Phthalic anhydride and the 2-ethylhexanol are mixed in the reactor in order to form the monoester – mono-2-ethylhexylphthalate. The reaction takes place at about 150oC. Further the reaction mixture is heated to 170-180oC. At this point the catalyst tetrabutyl-titanate is added. Before the addition, care is taken to separate all the water formed during chemical reaction from the system. The evolution of reaction takes place and water formed is continuously & carefully separated in the alcohol water separator. The temperature in the reactor is further increased upto 220-235oC to terminate the Esterification and the Raw DOP is obtained.

Neutralization

After esterification process, neutralization is carried out with Sodium carbonate (caustic soda flakes) wherein small amount of water is added in order to neutralize the traces of monoester.

Distillation

The neutralized DOP is then transferred to the distillation section which consists of a reactor equipped with the stirrer, vapors condenser, cooler and alcohol water separator. The alcohol is distilled first under mild vacuum distillation and at the end with vacuum distillation and steam stripping. Further, DOP is dried under vacuum.

Filtration

In this phase, solids formed during neutralization and hydrolysis of the catalyst is removed by filtration process and finished product is obtained.

Note: Other types of Plasticizers as shown in product list – table are produced using same methodology &equipment using different raw materials.



3.4.1.5 Di-Iso Decyl Phalate (DIDP)



148.12 2 x 158.28 446.67 18.02




3.4.1.6 Di-IsoNonylPhalate (DINP)



148.12 2 x 144.257 418.61 18.02




3.4.1.7 Di-Butyl Phalate (DBP)


C6H4(CO)2O + 2 (CH3(CH2)3OH) C6H4(COO(CH2)3CH3)2 + H2O

148.12 2 x 74.12 278.34 18.02




3.4.1.8 Di-Octyl Maleate (DOM)


CHCOOCHCO + 2 (C8H17OH) C2H2(COOC8H17)2 + H2O

98.058 2 x 130.23 340.50 18.02




3.4.1.9 Di-Butyl Maleate (DBM)


CHCOO:CHCO + 2 [(CH3)2CHCH2OH] C2H2(COOC4H9)2 + H2O

98.058 2 x 74.123 228.29 18.02




3.4.1.10 Di-Octyl Adipate (DOA)


COOH(CH2)4COOH + 2 (C8H17OH) (CH2)4(COOC8H17)2 + 2 H2O

146.143 2 x 130.23 370.58 36.023




3.4.1.11Polymer Compound& Master Batch

3.4.1.11.1Manufacturing Process

• Firstly, take Polymer resin, additives, plasticizers & pigments and add into mixer for uniformly mixing.

• After the adequate mixing, granular of Polymer compounds& Master batch can be extracted from the extruder & cool it adequately.

3.4.1.11.2Material Balance



3.4.1.12 Plastic Extruded & Moulded Products

3.4.1.12.1Manufacturing Process

• Firstly, take Polymer resin, additives, plasticizers & pigments and add into mixer for uniformly mixing.

• After adequate mixing, granular of Polymer compounds can be extracted from the extruder & cool it adequately.

• Furthermore, haul & coiling has been done. • Finally, cutting it in various size & supply it to market.




3.5 RAW MATERIAL FOR FINISHED PRODUCTS The raw materials for the proposed range of products will be indigenously available and will be also imported. Table 3.2: List of Raw Materials

Product Name of Raw Material Requirement (MT/Month) Existing Proposed

Additional Total


Soyabean Oil 190 380 570Formic Acid 12 24 36Hydrogen Peroxide 79 160 239Sodium Hydroxide 8 16 24

OR Methyl Soyate Soyabean Oil 199 400 599

Methanol 22 40 62Sodium Methoxide 6 12 18

And Di Octyl Phthalate (DOP)

Phthalic Anhydride Nil 380 3802 Ethyl Hexanol Nil 800 800Catalyst TITP Nil 0.3 0.3Caustic Nil 0.3 0.3

OR Di Butyl Phthalate (DBP)

Phthalic Anhydride Nil 535 535Iso Butyl Alcohol Nil 625 625Catalyst PTSA Nil 416 416Caustic Nil 208 208

OR Di Iso Butyl Phthalate (DIDP)

Phthalic Anhydride Nil 332 332IsoDecyl Alcohol Nil 886 886Catalyst TIPT Nil 0.35 0.35Caustic Nil 0.35 0.35

OR Di Octyl Maleate (DOM)

Maleic Anhydride Nil 288 2882 Ethyl Hexanol Nil 103 103Catalyst PTSA Nil 5.5 5.5Caustic Nil 1.1 1.1

OR Di Butyl Maleate (DBM)

Maleic Anhydride Nil 430 430N-Butyl Alchohol Nil 914 914Catalyst TITP Nil 0.5 0.5Caustic Nil 1 1

OR Di OctylAdipate (DOA) Adipic Acid Nil 395 395

2 Ethyl Alcohol Nil 914 914Catalyst TITP Nil 0.5 0.5Caustic Nil 1 1

And



3.5.1 HAZARDOUS CHEMICAL STORAGE & HANDLING Hazardous chemicals are/will be used as raw material in the manufacturing process. Storage, handling & transport of Hazardous Chemicals are given in table 3.3 Table 3.3: Storage, Handling & Transport of Hazardous Chemicals Raw Material Source CAS/CS No Means

of storage

Means of transport

Max. Qty.

stored MT

Raw Material Soyabean Oil Indian/ Imported 801-22-7 Tank By road 40Formic Acid Indian/ Imported 64-18-6 Tank By road 10Hydrogen Peroxide Indian/ Imported 7722-84-1 Tank By road 20Sodium Hydroxide Indian/ Imported 1310-73-2 Bags By road 1Methanol Indian/ Imported 67-56-1 Drum By road 1Sodium Methoxide Indian/ Imported 124-41-4 Bags By road 1Polymer Resin Indian/ Imported -- Bags By road 20Polymer Compound Indian/ Imported -- Bags By road 10Master Batch Indian/ Imported -- Bags By road 2Stabilizer Indian/ Imported -- Bags By road 5HDPE Indian/ Imported 9002-88-4 Bags By road 10Phthalic Anhydride Indian/ Imported 85-84-9 Bags By road 202 Ethyl Hexanol Indian/ Imported 140-76-7 Tank By road 20Normal Butanol (NBA) Indian/ Imported 71-36-1 Tank By road 20Iso-Butanol Indian/ Imported 78-83-1 Tank By road 20Maleic Anhydride Indian/ Imported 108-31-6 Bags By road 10Adipic Acid Indian/ Imported 124-04-9 Drum By road 1

Polymer Compound & Master Batch

Polymer Resin Nil 250 250Additives Nil 12.5 12.5Plasticizers Nil 225 225Pigments Nil 12.5 12.5

And Plastic Extruder & Molded Products

Polymer Resin Nil 250 250Additives Nil 12.5 12.5Plasticizers Nil 225 225Master Batch Nil 12.5 12.5

Project Prefeasibility Report


3.6 RESOURCE OPTIMIZATION & AVAILABILITY The major resources for the proposed project are/will be raw-materials, water, man-power, etc. 3.6.1 LAND & BUILDING REQUIREMENT Total existing plot area is 6761.00 m2 and total existing constructed area is 1725.00 m2. No

additional land will be required for proposed project expansion.

The existing built up area will be utilized after necessary modifications also some new sheds will

be constructed and ETP will have to be modified. After necessary modification & construction,

constructed area will be 2475.00 m2. Plot allotment document is attached as Annexure-3.

3.6.2 EQUIPMENT Some additional equipment will be needed for the proposed expansion. Table 3.4: List of Equipment Sr. No. Equipment Capacity No.Existing 1 SS 316 11 MT 12 SS 316 7 MT 13 SS 316 3.6 MT 14 SS 304 10 MT 15 Vaccum pump --- 16 Filter press --- 1Proposed additional 1 SS 316 15 MT 22 Thermo pack 10 Lakh K cal/Hr. 13 Receiver SS 316 --- 34 Condenser SS 316 --- 2



3.6.3 POWER AND FUEL REQUIREMENT Total power requirement for existing project is 150 kVA and after proposed expansion it will be -

350 kVA, sourced from Dakshin Gujarat Vij Company Ltd. (DGVCL)

In existing operations one Boiler of 600 kg/Hr. is installed. Natural gas@290 SCM/day is used

as fuel in Boiler; additionally one Thermic Fluid Heater having Capacity of 10 lakh Kcal/Hr. will

be installed for proposed expansion. Natural gas @2410 SCM/day will be used as fuel in

Thermic Fluid Heater.

Table 3.5: Details of Power & Fuel

Sr. No.

Particulars Requirement Source Existing Proposed

Additional Total

Power 1 Power

Requirement 150 kVA 200 kVA 350 kVA Dakshin Gujarat Vij

Company Ltd (DGVCL.) Fuel 1 Fuel & it’s

consumption Natural Gas @290 SCM/day



GSPC Gas Supply.

3.6.4 WATER REQUIREMENT The water requirement for the project is/will is fulfilled by GIDC’s piped water supply. Total fresh

water requirement for existing project is 25.8 KLD which will be 55.0 KLD after proposed

expansion.

The category wise bifurcation of the water requirement is given in the Table 3.6

Table 3.6: Category-wise water requirement (in KL/D)

S.No. Particulars Requirement (KLD) Existing Proposed

Additional Total

1. Domestic 5.0 3.0 8.02. Gardening* 3.8 -3.8 0.03. Industrial 4. Process Nil 40.0 40.05. Boiler 1.0 2.0 3.06. Cooling (Make-up) 15.0 -15.0 0.07. washing 1.0 3.0 4.08. Sub-Total: Industrial 17.0 30.0 47.09. Grand Total 25.8 29.2 55.0

*Presently, out of 6.0 KLD water used for gardening 3.8 KLD is fresh water and 2.2 KLD is ETP treated water. After the proposed expansion, the total cooling water and gardening water requirement will be met by recycling the ETP treated water.



3.6.5 MAN-POWER REQUIREMENT The total number of man power for existing project is 24 persons, for proposed expansion

project additional 16persons will be required. Hence, the total man-power will be 40.

The man-power required for the project is/will be employ locally from the nearby areas. Skilled

as well as unskilled labour will be employed for the project.

3.7 QUANTITY OF WASTE TO BE GENERATED

3.7.1 WASTEWATER GENERATION & MANAGEMENT The category wise bifurcation of the wastewater generation is given in Table 3.7. Table 3.7:Category-wise Wastewater Generation (in KL/D)

S.No. Particulars Waste Water Generation Existing Proposed

Additional Total

1. Domestic 4.0 2.4 6.42. Industrial 3. Process water Nil 43.4 43.44. Cooling (Blow down) 1.0 2.0 3.05. Boiler (Blow down) 0.2 0.4 0.66. Washing 1.0 3.0 4.07. Sub-Total: Industrial 2.2 48.8 51.08. Grand Total 6.2 51.2 57.4

Domestic wastewater generated from the plant is/will be disposed of through septic tank/soak

pit system.

The wastewater from the utility section is given primary treatment. The wastewater after pH

correction is passed through netuch filter and thereafter collected into the collection tank. The

treated water is then utilized for gardening purpose. Hence, there is no discharge of treated

effluent.

There is no industrial wastewater generated from existing industrial activity.

After proposed expansion, industrial effluent generated will be treated in Effluent Treatment

Plant and treated effluent will be reused in cooling & gardening purpose. Hence, there will be no

discharge of treated effluent outside the company premises.

The category wise bifurcation of the waste water generation is given in Table 3.7



Fig-3.4(a): Water Balance Diagram (in KLD) for Existing Scenario

Fig-3.4(b): Water Balance Diagram (in KLD) for Proposed Scenario



3.7.2 AIR EMISSIONS & CONTROL 3.7.2.1 Process Emission There is/will be no process emissions from the manufacturing activities.

3.7.2.2 Utility Emission In existing operations one boiler of 600 kg/Hr. is installed. Natural gas@290 SCM/day is used

as fuel in boiler. Additionally, one boiler having capacity of 600 kg/Hr. & one thermic fluid heater

having Capacity of 10 lakh Kcal/Hr. will be installed for proposed expansion. Natural gas @495

SCM/day & @2000 SCM/day will be used as fuel in boiler & thermic fluid heater respectively.

Table 3.8: Details of Utility Emission

Particulars Fuel Working Hour

Fuel Quantity Stack Details Emission Norms

Existing scenario Boiler. 600 kg/Hr. (100% Load)

Natural Gas 14.0 @290 SCM/day

Stack Ht: 11m PM<150 mg/Nm3 SO2< 100 ppm NOx< 50 ppm

Proposed scenario

Boiler. 600 kg/Hr. (100% Load)

Natural Gas 24.0 @ 495 SCM/day


Thermic Fluid Heater. 10 lakh Kcal/Hr.

Natural Gas 20.0 @2000 SCM/day


3.7.2.3 Fugitive Emission Minor quantity of fugitive emissions will occur during handling of the raw materials. Fugitive emissions are also likely to occur from storage area.

Following measures will be practiced to reduce the fugitive emissions:

• Raw Materials & Products are/will be stored under good storage conditions to prevent any volatilities

• Raw Materials & Products are/will be stored in closed containers • The fugitive emissions in terms of handling losses will get reduced by proper storage

and handling. • Regular monitoring is/will be done of piping and fittings for checking of any leakages. • Hazardous chemicals are/will be stored as per standard criteria. • Good housekeeping maintained in the plant.



3.7.3 HAZARDOUS/NON-HAZARDOUS WASTE MANAGEMENT Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,

Used oil from gear boxes of the machineries and discarded bags/drums. Company has provided

adequate storage area for proper storage of wastes.

Table 3.9: Details of Hazardous Waste Generation & Disposal

Type of waste & Category

Existing Scenario

Proposed Scenario

Disposal Method

ETP Waste (Cat. 34.3)

0.037 MT/Month 10 MT/Month Company has provided adequate storage area. The ETP waste generated is/will be stored properly and finally disposed of to CSWD site of VWEMCL, Vapi.

Used Oil (Cat. 5.1)

30 L/Year 30 L/Year The used oil is/will be collected & stored separately and reused as lubricant in plant operation.

Discarded bags (Cat. 33.3)

280Nos/Month 11500Nos/Month The discarded bags are/will be stored separately in company premises and are/will be reused for packing / sold to the authorized scrap dealers.

Discarded drums (Cat. 33.3)

2000Nos/Month 2285Nos/Month The discarded drums are/will be stored separately in company premises are/will be returned back to the supplier / sold to the authorized re-conditioners.

3.7.4 NOISE AND ODOUR CONTROL There is/will be no major activities due to which noise would be generated other than

equipment’s, boiler & pumps. However, Noise level generation would be limited to 75dB (A)

within plant. No offensive odour is/will be generated from the process.

The control measures to be taken for reduction in noise levels are as below:

Ear Plugs and Ear muffs are provided to the workers in Utility Section.

Anti-vibration pads are/will be provided wherever applicable.

Regular maintenance & lubrication shall be done.



3.7.5 HEALTH AND SAFETY MEASURES The company is concerned about occupational health and safety among its

work force as the man power is the biggest asset to the company. The following key safety

measures are implemented in the existing plant and the same shall be a part of proposed

expansion project:

Safety Training is provided to the employees.

Assembly point is established.

Fire Extinguishers are installed.

First Aid Facility and training is imparted to the employees.

Personal protective equipment is provided to employees.

Health checkup are organized at regular intervals.

Safety / Health records and MSDS are maintained.

3.7.6 ENVIRONMENTAL HEALTH & SAFETY CELL The company has an environment cell in order to keep a close watch on the performance of the

pollution control equipment, emissions from the sources and the quality of surrounding

environment in accordance with the monitoring program. The cell is also entrusted with the

responsibilities of regulating the safety measures inside the plant campus. The cell is also

responsible for maintaining the records of all data, documents and information in line within the

legislative requirement.

3.7.7 POST PROJECT MONITORING PLAN

The company is developing in-house facilities for monitoring certain parameters. Where it is not

possible to establish such facilities, the same is to be done by appointing external

recognized/approved agencies.



CHAPTER – 4

SITE ANALYSIS 4.1 CONNECTIVITY

The Industry is located at Plot No. 16-19 GIDC Vapi, Dist. Valsad. This proposed expansion

project will be accommodated in the existing site. The site is very well connected by national

highway and railway. Efficient transport facilities will be available nearby the project site.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP 4.2.1 LAND FORM The proposed expansion project will be accommodated in the existing site located in GIDC Vapi. 4.2.2 LAND USE PATTERN It is a developed industrial estate for industrial development.

4.2.3 LAND OWNERSHIP The plot is located in GIDC Vapi. The company has obtained it on lease from GIDC. 4.3 TOPOGRAPHY

The Topography of the region consists of flat topped, highly dissected plateaus and dyke ridges

running in a west to east direction. The Main River (Damanganga) in the catchment area flows

in incised meanders forming steep geomorphologic ally ‘V’ shaped valleys with steep sides. The

entire catchment has a rectangular and trellis pattern of drainage depicting the influence of the

structures on the drainage development. The piedmonts at the base of the steep plateaus and

dyke ridges are covered with thin soils, which support agriculture in very few areas. The river

valley, wherever flat, has good quality soil and is mostly cultivated based on the availability of

water. The river valley fills with thick alluvium provides the only area for cultivation.



4.4 SALIENT FEATURES The salient features of the project site are given in the table below: Table 4.1: Salient Features of the Project Site Particulars Details Co-ordinates 20°21'2.76"N, 72°54'47.79"E Village Vapi Town≈ 2.50 km (NW) Taluka/ Tehsil Pardi District Valsad Nearest Water body Damanganga River Nearest Highway N.H.- 8≈ 0.42 km Nearest Railway station & Railway line Vapi Railway Station ≈ 2.43 km (NW) Nearest Airport/ Airbase Daman Coast Guard ≈ 11.40 km (NW) State/ National borders Daman & Dadra Nagar Haveli(D&NH) Protected Area/ Sanctuaries None within 15 km CRZ applicability Not applicable Seismicity Seismic Zone III Note: All the above mentioned distances are the aerial distance from the project site.

4.5 EXISTING INFRASTRUCTURE The plot is located in the industrial estate. It has been developed for industrial purpose. Existing

infrastructure includes provisions of water, power, storage facilities for raw-material and

products and production, utility sheds and administrative office

4.6 CLIMATE & METEROLOGY 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 can be

divided into four seasons. The winter season from December to February is followed by the

summer season from March to May. The South-West monsoon season is from June to

September. The post-monsoon season constitutes the months of October and November.

The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of

Indian Meteorological Department (IMD), Dahanu and is taken from the book “Climatological

tables of Observatories in India (1951 - 1980)” published by IMD.



Table 4.2: Summary of Meteorological Data at nearest IMD Station –Dahanu.

Location: Dahanu Gujarat ( Lat: N 19o 58’, Long: E 72o 43’) Aerial Dist from Project Site: Approx.37 Km SSW Height of installation: 29 m above MSL, Month Temperature

(oC) Relative Humidity

(%) Cloud Cover

(Oktas) Mean Wind

Speed (km/h)

Pre-dominant Wind

Direction

Rainfall (mm)

Max. Min. Mor. Eve. Mor. Eve. January 27.7 16.5 67 69 1.3 1.1 11.3 N 0.2 February 28.3 17.4 66 69 1.1 0.8 11.7 N 0.2 March 30.3 20.7 68 67 1.4 1.1 12.9 N 0.1 April 32.2 24.0 74 69 2.1 1.4 13.7 W 0.1 May 33.1 26.8 77 73 3.8 2.3 15.5 W 5.2 June 32.2 26.3 85 80 6.1 5.6 17.7 SW 522.1 July 30.1 25.0 89 84 7.1 6.8 22.6 SW 771.7 August 29.5 24.7 88 83 6.9 6.7 22.6 W 502.3 September 30.0 24.0 87 79 5.4 4.9 14.6 W 319.1 October 32.1 23.1 77 72 2.8 2.4 10.0 E 44.4 November 32.1 20.5 67 71 1.9 1.9 9.4 N 17.1 December 29.8 18.0 67 71 1.6 1.5 10.0 N 0.3 Seasonal Average Values Period Temperature

(oC) Relative Humidity

(%) Cloud Cover

(Oktas) Mean Wind

Speed (km/h)

Avg. PDW Direction

Total Rainfall (mm)

Avg. Max.

Avg. Min.

Avg. Mor.

Avg. Eve.

Avg. Mor.

Avg. Eve.

Summer 31.9 23.8 73.0 69.7 2.4 1.6 14.0 W 5.4 Winter 28.6 17.3 66.7 69.7 1.3 1.1 11.0 N 0.7 Monsoon 30.5 25.0 87.3 81.5 6.4 6.0 19.4 SW 2115.2 Post monsoon 32.1 21.8 72.0 71.5 2.4 2.2 9.7 N/E 61.5 Annual Total or Mean

30.7 21.9 74.7 73.1 3.1 2.7 13.5 W 2182.8

Note: Winter: December, January & February, Summer: March, April & May, Monsoon: June, July, August & September, Post monsoon: October & November (Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)

4.6.1. TEMPERATURE

The summer season from March to May is a one of continuous increase in temperatures which

decreases during monsoons, increases slightly during the post-monsoon season and again

decreases during the winter.

4.6.2. HUMIDITY

The climate of the region is characterized by a humid summer because of the closeness to

coastline. Humidity is usually high during the monsoon months, with average relative humidity

generally exceeding 80%. Humidity decreases gradually during the post-monsoon months and

for rest of the year i.e. the period of December to April, the average relative humidity ranges

around 50-70%.



4.6.3. CLOUD COVER

During the South-west monsoon months, the skies are usually heavily clouded or overcast.

Cloud cover decreases during the post monsoon months. In the rest of the year the skies are

mostly clear

4.6.4. RAINFALL

About 95% of the annual rainfall is received during the southwest monsoon season i.e. from

June to September, July being the month with highest rainfall. The total annual rainfall observed

from the historical data of year 1951-1980 is 2182 mm.

4.6.5. WIND PATTERN The annual resultant vector for wind direction shows winds blowing from WSW. During

summers and monsoon, the winds blow mostly from the sea i.e. the SW or WSW direction. The

post-monsoon & winter seasons experience a change in direction, with the winds blowing from

NE, ENE or NNE. The wind speed is high during monsoon and post monsoon seasons, slightly

moderate during summer and winter seasons.

4.7 SOCIAL INFRASTRUCTURE The village boundaries for 5km and 10 km radial periphery from the project site are provided in

the Village maps as figure 2.2. The data has been collected from Census 2001 (since 2011 data

is provisional) for establishing the demographic pattern for the study area and details of

available amenities is delineated as below.



Figure 4.1: Village Map of Study Area

4.7.1 EDUCATIONAL FACILITIES

As per Census 2001 Educational facilities are available and the literacy rate is above 72% within

5 km periphery. All the villages have a minimum of one primary school.

4.7.2 MEDICAL FACILITIES As per census 2001, Details of medical facilities available in the study area are given below.

Table 4.3: Details of Medical facilities

Sr.No. Particulars Observed values in 5 km radius1 Dispensaries 02 Primary Health Centers 13 Primary Health sub centre 84 Allopathic Hospital 05 Allopathic dispensary 26 Maternity and Child welfare Centre 17 Community Health Workers 4

(Source: Primary Census Abstract – Census of India, 2001)



CHAPTER – 5 PLANNING BRIEF 5.1 PLANNING CONCEPT The proposed project is located at GIDC Vapi. Major raw materials are/will be sourced locally.

RM cost as many input suppliers are located nearby which will bring reduction in transportation

cost. The region is well planned with all the basic infrastructural facilities like internal roads,

water supply, arrangements for power, streetlights, solid waste disposal sites etc.

5.2 POPULATION PROJECTION As per census 2001, the average household size is around 4 persons. The demographic profile

of study area presented below.

Table 5.1: Distribution of population

Sr. No. Particulars Observed values in 5 km radius1 Total Population 2171332 No. of Households 514033 Avg. household size (person) 4.224 Male population 1270535 Male population (in %) 58.516 Female population 900807 Female population (in %) 41.498 Sex ratio 709.00

(Source: Primary Census Abstract – Census of India, 2001)

5.3 AREA STATEMENT The total area of the plot is 6759.68m2 out of which constructed area of the plant is 1722.60 m2. After additional construction in existing land area constructed area will be 2427.60 m2. 5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) This is an expansion project which is to be developed in the existing premises. No additional

land is required for the proposed project except few installations and modifications. So there will

be no demand of major change in physical infrastructure and social infrastructure.



5.5AMENITIES/FACILITIES 5.5.1 DRINKING WATER FACILITIES All the villages have potable water supply through taps and also potable water is sourced from wells and tube wells as secondary source. 5.5.2 POWER SUPPLY FACILITIES As per census 2001, all the villages have power supply facilities in the study area. 5.5.3 COMMUNICATION& BANKING FACILITIES As per census 2001, the information collected clearly indicates that the infrastructural facilities

are provided by respective government agencies for the development of this area. For

communication purposes, post office and phones are available in most of the villages. The

villages having non-availability of these facilities within 5km distance.

5.5.4 TRANSPORT FACILITIES As per census 2001, bus service is available in all the villages of the study region within 5 km

area and is the most preferable mode of the transport in the region Second option for transport

is auto rickshaw.Villages connected with paved roads.

5.5.5 APPROACH TO VILLAGES As per census 2001, most of the villages have paved road in the study region.



CHAPTER – 6

PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREA The total area of the plot is 6761.00 m2 out of which constructed area of the plant is 1725.00 m2

and proposed construction 750.00 m2 will be done in existing area. The total production capacity

will be 2716.2 MT/month with byproducts after proposed project.

6.2 RESIDENTIAL AREA In the said proposal no residential area has been proposed for workers and/or for staff. 6.3 GREENBELT In existing operation company has developed a healthy green belt in1600 m2 area. Maximum

possible open land will be allotted for green belt development.

6.4 SOCIAL INFRASTUCURE Existing infrastructure will be sufficient to accommodate the existing load from the proposed

project which is very low.

6.5 CONNECTIVITY This proposed expansion project will be accommodated in the existing site. The site is very well

connected by national highway and railway. Efficient transport facilities will be available nearby

the project site.

6.6 DRINKING WATER MANAGEMENT Drinking water is/will be sourced from GIDC Water supply.

6.7 SEWERAGE SYSTEM Domestic wastewater generated from the existing and proposed project is/will be disposed of

through septic tank/Soak pit system, which is @4.0 KL/D for existing plant and @6.4 KL/D after

proposed expansion.



6.8 INDUSTRIAL WASTE MANAGEMENT In existing operations industrial effluent is given primary treatment and is be utilized as

gardening purpose. After proposed expansion necessary modifications will be made in existing

ETP and treated effluent will be utilized gardening. There is/will be no discharge of industrial

effluent outside the company premises. Details are explained in Chapter 03, 3.7.3

6.9 SOLID WASTE MANAGEMENT Solid wastes generated are/will be in the form of ETP waste, and discarded containers from

storage of raw materials. Company is/will provide adequate storage area for proper storage of

wastes. Details are explained in Chapter 03, 3.5.1

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY Total power requirement for existing project is 150 kVA and after proposed expansion it will be -

350 kVA, sourced from Dakshin Gujarat Vij Company Ltd. (DGVCL).



CHAPTER – 7

REHABILITATION &RESETTLEMENT (R &R) PLAN 7.1 POLICY TO BE ADOPTED The proposed project is to be developed in the existing premises.Hence, no displacement of

any population is proposed for the project. Therefore, detailed Social Impact Assessment

studies or R&R action study has not been proposed.



CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE OF THE PROJECT At present we are not proposing any additional production at the site. It will start only after

getting all the statutory permission from respective authorities.

8.2 ESTIMATED PROJECT COST The company has made budgetary provision for the recurring expenses for the environmental

issues and Environment Protection has also been considered in planning the cost projection.

The existing cost projection is 97.2Lakh and after proposed project expansion project the

estimated cost bifurcation table is given below:

Table 8.1: Total Capital Cost Projection

Sr. No. Purpose Proposed Expansion Cost (Rs. in Lakhs)

1. Land Nil2. Building 203. Plant & Machinery 2504 Electrification and Administrative set-up 105. ETP 50

Air pollution control device 106. Safety instruments 57. Chartered services/ Government fees 5 TOTAL 350



CHAPTER – 9

ANALYSIS OF PROPOSAL 9.1 FINANCIAL & SOCIAL BENEFITS M/s. Consumers Plastics Pvt. Ltd. is located at Plot No. 16-19 GIDC Vapi, Dist.: Valsad.

Currently Consumers Plastics Pvt. Ltd has built its reputation as a preferred supplier to the

customers. The company focuses on providing quality products to the industry.

For the proposed project, the company intends to donate 2% of the profit margin for the social

benefit as Corporate Social Responsibility.



Annexures



Annexure‐ 1 Existing Environmental Clearance



Annexure‐ 2 Consolidated Consent and Authorization (CC&A)



Annexure‐ 3 Plot Allotment Certificate

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