Ref: Venkys/EC/2017/01-01 Dated: 05/01/2017...

Ref: Venkys/EC/2017/01-01 Dated: 05/01/2017

To,

Shri Manoj Kumar Singh

Joint Secretary (I.A. Division)

Ministry of Environment, Forest & Climate Change

Indira Paryavaran Bhawan, Jor Bagh Road

New Delhi – 110003

Sub: Environment Clearance for proposed modernization of Mash Poultry Feed to Pelletization

and Installation of wood fired boiler of 750kg per hour capacity & DG set (250.0 KVA x 02

Nos. Standby arrangement) by Venky’s (India) Limited at Khasra no. 1050/1, Central Hope

Town, Camp Road, Selaqui Industrial Area, Dehradun, Uttarakhand.

Sir,

With reference to the MoEF & CC Gazette Notification no. 1539 dated 13th December 2007 and Doon

Valley Notification dated 1st February 1989. We are hereby submitting the Form-I along with

Prefeasibility Report (PFR) and Environment Management Plan (EMP) (In hard as well as in soft copy)

for seeking Environment Clearance of aforesaid proposed project. The above project is categorized as

“Orange” under Doon Valley notification 1989 and in the absence of SEIAA/SEAC, Uttarakhand the

application for environment clearance is being submitted to MoEF & CC as per above said notification.

Now, we request your good self to consider our application and grant us the Environment Clearance at

earliest.

Thanking you,

Sincerely yours,

for Venky’s (India) Limited

(Dr. Netrapal Singh)

FORM – 1, PRE-FEASIBILITY REPORT & EMP

FOR PROPOSED MODERNIZATION

OF

MASH POULTRY FEED TO

PALLETIZATION

AND INSTALLATION OF

WOOD FIRED BOILER OF 750 KG PER

HOUR CAPACITY

&

DG SET (250.0 KVA X 02 NOS., STANDBY

ARRANGEMENT)

By

M/S VENKY’S (INDIA) LIMITED

AT

Khasra No. 1050/1, Central Hope Town,

Camp Road, Selaqui Industrial Area,

Dehradun, Uttarakhand

PREPARED BY:

ENVIRONMENTAL MANAGEMENT DIVISION

M/s INDIA GLYCOLS LTD

A – 1, INDUSTRIAL AREA, KASHIPUR,

UTTARAKHAAND

CONTENTS

S. No. Description Page No.

FORM – 1 1 – 21

PRE-FEASIBILITY REPORT 22 – 80

1.0 EXECUTIVE SUMMARY 22 – 23

1.1 Employment Status 22

1.2 Water Balance 22

1.3 Salient Features of the Project 23

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 24 – 29

2.1 Identification of the Project 25

2.1.1 Company Background 25

2.1.2 The Promoters 26

2.2 Nature of Project 26

2.3 Need for The Project and Its Importance To the Country or Region 26

2.4 Demand – Supply Gap 27

2.5 Imports vs. Indigenous Production 27

2.6 Export Possibility 28

2.7 Domestic / Export Markets 29

2.8 Employment Generation - Direct And Indirect 29

3.0 PROJECT DESCRIPTION 29 – 59

3.1 Type of Project 29

3.2 Location of the Project 30

3.3 Site Description 31

3.3.1 Site Selection 31

3.4 Size or Magnitude of Operation 34

3.4.1 Technical Know-How 34

3.5 Manufacturing Process Description and Technology 35

3.5.1 Existing Manufacturing Process 35

3.5.2 Detail of Existing Plant Machinery 37

3.5.3 Proposed Manufacturing Process 39

3.5.4 Detail of Proposed Plant Machinery 45

3.5.5 Proposed Utility Installation 48

A. Wood Fired Boiler 48

B. DG Set 54

3.6 Raw Materials, Quality and Sources 56

3.6.1 Mode of Transport of Raw Material 57

3.7 Resource Optimization 58

3.8 Utilities & Auxiliary Services 58

3.8.1 Water 58

3.8.2 Fuel 59

3.8.3 Energy Requirement 59

3.9 Environment Management 59

4.0 SITE ANALYSIS 59 – 66

4.1 Connectivity 59

4.2 Land Use 59

4.3 Topography 61

4.4 Existing Land Use Pattern 63

4.5 Existing Infrastructures 64

4.6 Soil Classification 65

4.7 Climatic Data 65

4.8 Social Infrastructure 66

5.0 PLANNING BRIEF 66 – 69

5.1 Planning Concept (Type of Industries, Facilities and Transportation etc.) Town

and Country Planning/ Development Authority Classification

66

5.2 Population Projection 66

5.3 Land Use 67

5.4 Assessment of Infrastructure Demand (Physical & Social): 67

5.4.1 System Design for High Productivity 67

5.4.2 Sizing of Critical Equipment- Margins & Redundancy/Standby 68

5.4.3 Design for Efficient Operation 68

5.4.4 Operation Performance Management System (OPMS) 68

5.4.5 Operation & Maintenance Philosophy 68

5.5 Amenities/Facilities 69

5.5.1 In-Plant Facilities 69

5.5.2 Employment Generation 69

5.5.3 Peripheral Developmental Activities 69

6.0 PROPOSED INFRASTRUCTURE 70

7.0 REHABILITATION & RESETTLEMENT (R & R) PLAN 70

8.0 PROJECT COST ESTIMATES 70

9.0 ANALYSIS OF PROPOSAL 70

10.0 STORM WATER/SEWER DETAILS 71

10.1 Sewer Drainage System 71

10.2 Rain Water Harvesting 71

11.0 WASTE WATER MANAGEMENT 75 – 79

11.1 Sewage Treatment Plant (5.0 KLD Capacity) 75

11.2 Process Scheme for STP Unit 78

12.0 AIR / NOISE POLLUTION CONTROL MEASURE 80

13.0 SOLID WASTE MANAGEMENT 80

14.0 HAZARDOUS WASTE MANAGEMENT 80

15.0 SAFETY MEASURES 80

LIST OF TABLES

Table – 01 Employment Status 29

Table – 02 Existing Plant Machinery 37

Table – 03 Proposed Plant Machinery 45

Table – 04 Specification of Proposed Boiler 49

Table – 05 Emissions Summary- Coal & Biomass 52

Table – 06 Annual Raw Material Requirement 56

Table – 07 Total Plant Raw Water Requirement (KLD) 58

Table – 08 Water Balance 58

Table – 09 Land break-up details 60

Table – 10 Soil Classification of Dehradun 65

Table – 11 Climatic Data of Dehradun (Basis of Mean of Last 25 Years) 65

Table – 12 Cost of Project 70

LIST OF FIGURES

Fig – 01 Key map of M/s Venky’s (India) Limited 32

Fig – 02 Topographical map of 10 km radius of M/s Venky’s (India) Limited 33

Fig – 03 Satellite Image of the Project Site 34

Fig – 04 Particle Size Reduction 36

Fig – 05 Process Flow Diagram of Existing Plant 38

Fig – 06 Graphical Representation of Pellet Mill 41

Fig – 07 Die for Pelletization 42

Fig – 08 Prepared Pellets 44

Fig – 09 Graphical Representation of Pelletization Process 46

Fig – 10 Process Flow Diagram After Modernization 47

Fig – 11 Photograph of Horizontal Multi-tubular Shell Type Smoke Tube Boiler 49

Fig – 12 Graphical Representation of Fire (Smoke) Tube Steam Boiler 50

Fig – 13 DG Set System 55

Fig – 14 Layout of existing Poultry Feed Plant 60

Fig – 15 Topographical Map of 05 km radius of Project Site 62

Fig – 16 Seismicity Map of Uttarakhand State 63

Fig – 17 Design of Typical Recharge Pit 72

Fig – 18 Cross section of Recharge Trench 73

Fig – 19 Schematic of Proposed STP 79

LIST OF ANNEXURES

I Copy of DSI, SSI Registration and Memorandum & Articles of Association

II Location of the Project

III Site Lay Out Plan

IV Photographs of Existing Green Belt

V Process Flow Diagram

VI Water Balance

VII Consent to Operate

VIII Copy of Land Detail

IX Copy of Gazette Notification No. 1539, Dated 13 December 2007

X Disclosure of Consultant

XI Authorization & Undertaking

FORM – I

FOR

PROPOSED MODERNIZATION

OF

MASH POULTRY FEED TO PALLETIZATION

AND INSTALLATION OF

WOOD FIRED BOILER OF 750 KG PER HOUR CAPACITY

&

DG SET (250.0 KVA X 02 NOS., STANDBY ARRANGEMENT)

Head Office: Venkateshwara House, S. No. 114/A/2 – Pune Sinhagad Road, Pune – 411030

Registered Office: 330, Phase – II, Vasant Vihar, Dehradun - 248006 Email – [email protected] Phone – 0135 – 2761456, 2694961 Fax – 0135 – 2762535

M/s Venky’s (India) Limited Khasra No. 1050/1, Central Hope Town, Camp Road, Selaqui

Industrial Area, Dehradun, Uttarakhand

mailto:[email protected]

FORM-I

EC FOR PROPOSED MODERNIZATION OF MASH POULTRY FEED TO PALLETIZATION AND

INSTALLATION OF WOOD FIRED BOILER OF 750 KG PER HOUR CAPACITY & DG SET (250.0 KVA X

02 NOS, STANDBY ARRANGEMENT) BY M/S VENKY’S (INDIA) LIMITED

M/s VENKY’S (INDIA) LIMITED P a g e -1

APPENDIX – I

FORM - 1

(1) Basic Information

S.

No.

Item Details

1. Name of the Project/s Proposed Project is for Modernization of Mash

Poultry Feed to Palletization and Installation of

Wood Fired Boiler of 750 kg per hour capacity &

DG Set (250.0 KVA X 02 Nos, standby

arrangement) by M/S Venky’s (India) Limited.

2. S. No. in Schedule NA

3. Proposed Capacity / Area / Length

/ Tonnage to be handled/Command

Area/Lease Area/Number of Wells

to be drilled

Sl Existing Proposed

Product Capacity Product Capacity

1. Mash

Poultry

Feed

1100.00

MT/Month

Poultry

Feed

Pellets

1100.00

MT/Month

Production capacity of proposed Poultry Feed

Pellets shall remain the same as existing Mash

Poultry Feed shall be used for proposed

Pelletization Process as raw material.

Proposed Utility

1. Wood Fired Boiler 750 Kg / hour x 01 No.

2. DG Set 250.0 KVA x 02 Nos.

(standby arrangement)

Western Hatcheries Pvt. Ltd. was incorporated on

01st July, 1976, subsequently It become Public

Company w.e.f. 21st December 1988. It was

renamed by the Deptt. of Company Affairs on 21st

June 2000 as M/s Venky’s (India) Limited.

DSI, SSI Registration & Memorandum of Articles

of Association is attached as per Annexure – I.

FORM-I





Total Land area – 7542.23 Sq. Mt.

No drilling will be done for Bore well as water

requirement will be fulfilled from the existing

sources.

4. New/Expansion/Modernization Modernization

5. Existing Capacity/Area etc Production Capacity – 1100.00 MT/Month

Land area – 7542.23 Sq. Mt

6. Category of Project i.e. “A” or “B” “Orange” as per Doon Valley Notification, 1989.

7. Does it attract the general condition?

If yes, please specify.

NA

8. Does it attract the specific

condition? If’ Yes, please specifies.

NA

9. Location : Selaqui Industrial Area (Annexure-II)

Plot / Survey / Khasra No. Khasra No. 1050/1

Village Central Hope Town, Selaqui

Tehsil Vikas Nagar

District Dehradun

State Uttarakhand

10. Nearest Railway Station/Airport

along with distance in kms.

Dehradun Railway Station – 19.23 Km E

Jolly Grant Airport – 37.77 Km SE

11. Nearest Town, City, District

headquarters along with distance in

kms.

Dehradun– 19.0 Km

12. Village Panchayats, Zilla Parishad,

Municipal Corporation, Local body

(complete postal addresses with

telephone nos. to be given)

Central Hope Town, Camp Road, Selaqui, Distt.

Dehradun, Uttarakhand – 248006

13. Name of the Applicant Dr. Netrapal Singh

14. Registered Address M/s Venky’s (India) Limited

Venkateshwara House,

S.No. 114/A/2 – Pune

Sinhagad Road, Pune – 411030

Email – [email protected]

FORM-I





Phone – 0135 – 2761456, 2694961

Fax – 0135 – 2762535

15. Address for Correspondence

Name Dr. Netrapal Singh

Designation (Owner/Partner/CEO) Deputy General Manager

Address M/s Venky’s (India) Limited

330, Phase – II,

Vasant Vihar, Dehradun, Uttarakhand

Pin Code 248197

E-mail [email protected]

[email protected]

Telephone No. 0135-2761456, 2694961

Fax No. 0135-2762535

16. Details of Alternative Sites

examined, if any.

Location of these sites should be

shown on a topo-sheet.

No alternative site was examined or chosen, as the

proposed modernization will be carried in the

existing Plant Premises.

17. Interlinked Projects There is no Interlinked Project.

18. Whether separate application of

interlinked project has been

submitted?

Not applicable

19. If yes date of submission Not applicable

20. If no, reason Not applicable

21. Whether the proposal involves

approval / clearance under: if yes

details of the same and their status

to be given.

No

(a) The Forest (Conservation) Act,

1980?

No, The Forest (Conservation) Act, 1980 is not

applicable.

(b) The wild life (Protection) Act,

1972?

No, The wild life (Protection) Act, 1972 is not

applicable.

(c) The C.R.Z. Notification, 1991? No, The C.R.Z. Notification, 1991 is not

applicable.


FORM-I





22. Whether there is any Government

Order / Policy relevant / Relating to

the site?

Existing Site is already a Mash Poultry Feed Unit,

proposed Palletization Facility along with the

proposed Utility Facility to be set up at the part

vacant Land.

23. Forest land involves ( hectares) There is no involvement of forest land

24. Whether there is any litigation

pending against the project and / or

land in which the project is propose

to be set up?

(a) Name of Court

(b) Case No.

(c) Orders / directions of the court,

if any and its relevance with the

proposed project.

No litigation is pending against the Project

applicant of this Project in any Court of Law to the

best of knowledge.

25. Expected Cost of the Project Total Project Cost will be Rs. 75.00 Lakh.

II. Activity

1. Construction, operation or decommissioning of the Project involving actions, which

will cause physical changes in the locality (topography, land use, changes in water

bodies, etc.)

S.

No.

Information/Checklist

confirmation

Yes

/No

Details thereof (with approximate

quantities / rates wherever possible) with

sources of information data.

1.1 Permanent or temporary change in

land use, land cover or topography

including increase in intensity of

land use (with respect to local land

use plan).

No No Need of Additional Land.

Proposed Modernization of Mash Poultry

Feed to Palletization and Installation of

Wood Fired Boiler of 750 kg per hour

capacity & DG Set (250.0 KVA X 02 Nos,

standby arrangement) will be set up within

the existing Plant Premises located at

Khasra No. 1050/1, Selaqui, Vikas Nagar,

District – Dehradun, Uttarakhand.

Existing Land area is 7542.23 Sq. mt.

FORM-I





Palletization Equipment’s and required

Utility viz. Proposed wood fired Boiler &

DG Sets will be installed in the part area of

existing land. Hence, no change in Land use

is envisaged.

Plant Layout is enclosed as per Annexure –

III.

The present land comprises with covered

area 2055.64 Sq. m

More than 33% of the area is already

developed as Green Belt and being

maintained. This green area also enhances

the aesthetic beauty of the area. Photographs

of existing Green Belt is enclosed as –

Annexure IV.

1.2 Clearance of existing land,

vegetation and buildings?

No There will be no clearance of buildings and

vegetation required for the proposed

modernization of production facility, as the

site required for few Building /

infrastructure is vacant land devoid of any

vegetation & building structure.

1.3 Creation of new land uses? No There would be no change in the land use

pattern of the area in accordance with the

Lay out Plan.

1.4 Pre-construction investigations e.g.

bore houses, soil testing?

Yes Pre-construction investigations will be

carried out before taking up the construction

activities.

1.5

Construction works

Yes

Foundation work for of RCC pedestal for

palletization process & also for supporting

Utilities, required Blenders along with

Pumps / Machinery etc.

Existing Infrastructure will be used, Details

are as below-

FORM-I





S. No. Construction Area (Sq. M)

1. Godowns & Feed

Mill 1872.10

2. Lab & Office 170.22

3. Other Rooms 13.32

Total 2055.64

1.6 Demolition works? No No demolition work would be done.

1.7 Temporary sites used for

construction works or housing of

construction workers?

No There will be no temporary sites created as

the Labour deployed will be local. Thus,

there will be no housing facility or

temporary site required for the same.

Existing Storage Yard will used for the

Storage of Construction Material.

1.8 Above ground buildings, structures

or earthworks including linear

structures, cut And fill or

excavations

Yes The Project will involve excavation of soil

during foundation purposes. The excavated

soil will be utilized within the site by

balancing with scrap and fill operations.

1.9 Underground works including

mining or tunneling?

No Not Required.

1.10 Reclamation works? No Not Required.

1.11 Dredging? No Not Required.

1.12 Offshore structures? No NA.

1.13 Production and manufacturing

Processes?

Yes The proposed manufacturing process will

not contribute any significant change in the

physical environment since proposed

palletization facility along with the Utility

will be installed in the existing Unit. The

proposed unit will manufacture 1100

MT/Month of Poultry Feed Pellets by

utilizing existing mash poultry feed.

Little quantity of solid waste (Approx. 20.0

Kg/day) will be generated during material

sampling, dispensing, handling, production,

FORM-I





processing and packing & eventually reuse

into process.

Solid waste as scrap of Empty Bags, Boxes,

Glass bottles, Plastic Jars, Bottles, and Cans,

will be sold to the respective Dealers.

Ash generated from proposed wood fired

Boiler shall be used for landfilling in low

lying areas.

The manufacturing Process of Poultry Feed

Pellets doesn’t generate any effluent.

Proposed skid mounted STP (5.0 KLPD

Capacity) will be used to treat the waste

water generated (2.50 KLD) from Domestic

Purpose & Miscellaneous i.e. Floor

/Machinery Washing etc.

Treated water shall be further reused into the

Green belt development.

Process Description of manufacturing

process is given in Pre-Feasibility Report

(Page no. 35 to 54).

Process Flow Chart is attached as per

Annexure – V.

1.14 Facilities for storage of goods or

Materials?

Yes Existing facilities for storage of Raw

Material / Products will be used. List of

Raw Material / Product is given in Pre-

feasibility Report (Page No.58) Table – 06.

1.15 Facilities for treatment or disposal

of solid waste or liquid Effluents?

Yes Construction phase:-

Solid Waste:-

Waste will be generated, out of which:-

Recyclable waste (Metal, Plastic Bags etc)

will be segregated & sold to the vendors.

Operation phase: -

Little quantity of solid waste (Approx. 20.0

FORM-I





Kg/day) will be generated during material

sampling, dispensing, handling, production,

processing and packing & eventually reuse

into process.

Approx. 25.0 Kg/day solid waste will be

generated as scrap of Empty sacs, Boxes,

Glass bottles, Plastic Jars, Bottles, and Cans,

which will be sold to the respective Dealers.

Ash generated from proposed wood fired

Boiler shall be used for landfilling in low

lying areas.

Liquid Effluents:-

Proposed skid mounted STP (5.0 KLPD

Capacity) will be used to treat the waste

water generated (2.50 KLD) from Domestic

Purpose & Miscellaneous i.e. Floor

/Machinery Washing etc.

Treated water shall be further reused into the

Green belt development.

Zero discharge shall be achieved.

1.16 Facilities for long term housing of

operational workers?

No Housing provision will not be provided at

the site. No provision made for workers

within the area as the labor employed will be

from local area.

1.17 New road, rail or sea traffic during

construction or operation?

No Not Required.

1.18 New road, rail, air waterborne or

other transport infrastructure

including new or altered routes

and stations, ports, airports etc

No There will be no new Road, Rail or Sea

traffic proposed as the area is well connected

to Road / Rail network.

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

No Not applicable, as no closure or diversion of

existing transport routes or infrastructure

leading to changes in traffic movements is

FORM-I





movements? envisaged.

1.20 New or diverted transmission lines

or pipelines?

No Not applicable.

1.21 Impoundment, damming,

culverting, realignment or other

changes to the Hydrology of

watercourses or aquifers?

No No Impoundment, damming, culverting,

realignment activity is proposed

1.22 Stream crossings? No Stream Crossings are not involved.

1.23 Abstraction or transfers of water

form ground or surface waters?

Yes Water is required for manufacturing process,

drinking, sanitation and Washing of Floor/

Machinery purposes. The daily requirements

of water are estimated at 21.00 KLD. The

water will be source from existing bore well.

Water balance is attached as per Annexure-

VI.

1.24 Changes in water bodies or the

land surface affecting drainage or

run-off?

No Not Applicable, since the proposed Poultry

feed pallet Facility will be set up within

existing plant premises only.

1.25 Transport of personnel or

materials for construction,

operation or decommissioning?

Yes The existing road network will be utilized

for the transportation of materials.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No Not Required. It is a modernization Project

of existing mash Poultry feed to Poultry

Feed Pellets.

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No Not Required.

1.28 Influx of people to an area in

either temporarily or permanently?

Yes Temporary influx of labor force during

construction is anticipated.

1.29 Introduction of alien species? No All the plant / tree species grown in the

project premises are indigenous to the area.

Same will be continued so introduction of

FORM-I





alien species is not envisaged.

1.30 Loss of native species or genetic

diversity?

No The species recorded in the proposed project

area are widely distributed in the area and

not restricted to certain pockets.

No loss of native species or genetic diversity

has been reported so far and is not

anticipated in future.

1.31 Any other actions? No

Not Applicable

2.0 Use of Natural Resources for Construction or Operation of The Project (Such as

Land, Water, Material or Energy, Especially any Resources Which Are Non –

Renewable or in Short Supply):

S.

No.

Information/ Checklist

confirmation

Yes

/

No




2.1 Land especially undeveloped or

agricultural land (ha)

No Existing Unit, Total Land Area – 7542.23

Sq. mt.

Proposed Project will cover part of the

existing land area by covering with thick

Green belt.

Copy of Khatauni for land detail is attached

as Annexure-VIII.

2.2 Water (Expected Source &

Competing Users) Unit : KLD

Yes Water is required for manufacturing process,

drinking, sanitation and Washing of Floor /

Machinery purposes. The daily requirements

of water are estimated at 21.00 KLD. The


2.3 Minerals (MT) No There is no major usage of Minerals in the

proposed Project except Stones and Grit

required for Pedestal Foundation

Construction.

2.4 Construction Material – Stone, Yes Materials like Brick, Steel, Cement, Sand

FORM-I





Aggregates, and / Soil (Expected

Source – MT)

aggregates, Tiles etc shall be procured

locally from the open Market in the desired

quantity as and when required.

2.5 Forests and timber ( source – MT) No Not Applicable.

2.6 Energy including electricity and

fuels (source, competing users)

Unit : fuel ( MT), energy (MW)

Yes The unit at full capacity will demand 300

KVA of power, which shall be supplied by

UPCL.

Steam required during palletization process

shall be fulfilled through proposed wood

fired Boiler (750 Kg/Hr).

Apart from this, the Company proposes 02

No. of Green insulated D.G. sets of 250.0

KVA each (one as standby) in order to have

continuous supply of power.

Fuel consumption: HSD - 60.0 lit / hr.

2.7 Any other natural resources (use

appropriate standard units)

No Not Applicable

3. Use, Storage, Transport, Handling or Production of Substance or Material, Which

Could Be Harmful To Human Health or The Environment or Raise Concern About

Actual or Perceived Risks to Human Health.

S.

No.


confirmation

Yes

/No




3.1

Use of substances or material,

which are hazardous (as per

MSIHC rules) to human health or

the environment (flora, fauna and

water supplies)

No

No hazardous wastes will be released into

the environment.

There will be no Hazardous Waste

generated during the Pelletization Process of

Poultry Feed.

3.2 Changes in occurrences of disease

or affect diseases vectors (e.g.

insect or water born disease)

No There will not be any water stagnation and

the waste water generated from Domestic

purpose & Floor & equipment’s washing

FORM-I





will be treated in the proposed STP.

Proper sanitation facilities will be provided

to avoid insect and water borne disease.

Proper housekeeping will be maintained

also.

3.3 Affect the welfare of people e.g. by

changing living conditions?

Yes The proposed project would have positive

impact on the socioeconomic status, thus

contributing to the marginal growth and

improvement in the living Standards of the

nearby area.

Increased employment opportunities,

Indirect employment for truck drivers,

Periodic medical check-up will be followed.

The proposed project is a Long- term Project

thus, would serve as a stable source of

employment.

3.4 Vulnerable group of people who

could be affected by the project

e.g. hospital patients, children, the

elderly etc.

No Not Applicable

3.5 Any other causes No Not Applicable

4. Production of Solid Wastes During Construction or Operation or Decommissioning

(MT/month)

S.

No.


confirmation

Yes

/No




4.1 Spoil, overburden or mines wastes No Nil.

4.2 Municipal waste (domestic and or

commercial wastes)

Yes Municipal Solid wastes are not generated as

the Plant does not have the residential

colony for workers. The biodegradable

wastes from canteen shall be collected and

dumped in composter to make Bio-Compost

for use in green belt within the premises.

FORM-I





This is ensured that there would be no

wastage of any manufactured or By -

product. Due care & precautions would be

taken at every stage to ensure that no

material will go down to the drain.

4.3 Hazardous wastes (as per

Hazardous waste Management

Rules)

Yes There will be no hazardous waste generated

during the proposed manufacturing of

Poultry Feed Products. Waste / Used Oil

from Proposed DG Set will be sold to the

authorized recyclers only.

4.4 Other industrial process wastes No Nil

4.5 Surplus product No Nil

4.6 Sewage sludge or other sludge

from effluent treatment

Yes STP Sludge shall be generated & shall be

reused as manure for green belt.

4.7 Construction or demolition wastes No Demolition Wastes: There is no structure at

the site; hence no demolition waste will be

generated.

Yes Construction Waste: Construction waste

will be generated out of which recyclable

waste (Metals, Plastic Bags etc) will be sold

to the vendors.

The inert waste (Brick, Concrete, Masonry,

Aggregates etc.) will be used for making of

driveway and pathway within the site.

4.8 Redundant machinery or

equipment

No Not Applicable

4.9 Contaminated soils or other

materials

No Not Applicable

4.10 Agricultural wastes No Not Applicable

4.11 Other solid wastes No Not Applicable

FORM-I





5. Release of Pollutants or any Hazardous, Toxic or Obnoxious Substance to Air

(kg/hr)

S.

No.


confirmation

Yes

/No




5.1 Emissions from combustion of

fossil fuels from stationary or

mobile sources

Yes Exhaust emissions from vehicles and

equipment deployed during the construction

phase.

Wood fired Boiler (750 Kg/hr) with suitable

stack height & Proven APC are proposed.

Green insulated DG set (250 KVA X 02

Nos.) is proposed on stand by basis. HSD

will be used as a fuel for the operation of

DG sets. DG Set shall be operated during

power failure only.

In the proposed unit, emissions from

combustion of fossil fuels will be from D.G.

set and transportation. To control the

emission of exhaust gas following measures

will be adopted.

5.2 Emissions from production

processes

No NA

5.3 Emissions from material handling

including storage or transport

Yes The material handling including storage and

transportation may contribute to fugitive

emissions. The materials will be stored in a

closed room to contain the emission and

adopt upgraded technology. To control the

fugitive emissions in proposed unit,

following measures will be adopted:-

Storage and material handling will be

carried out in closed trucks (1-2 trucks per

week).

Water spraying will be adopted in dust

prone areas & existing Green belt will be

strengthened accordingly.

FORM-I





Ambient air quality and stack emissions will

be regularly monitored to ensure that

ambient air quality standards and suggested

limits of the stack emission loads are met

honestly all the time.

5.4 Emissions from construction

activities including plant and

equipment

Yes Fugitive dusts from various activities of

construction & plying of vehicles are

expected, which will be temporary in nature.

5.5 Dust or odors from handling of

materials including construction

material, sewage and waste

No During the construction / Operation of

Plant area/office area, dust will become air

borne; Adequate precautions shall be taken

to reduce these impacts on construction

workers and the surrounding environment

There will be no odor problem to the best of

knowledge.

5.6 Emissions from incineration of

waste

No Nil

5.7 Emissions from burning of waste

in open air (e.g. slash material,

construction debris)

No No such activity is proposed.

5.8 Emissions from any other sources No Nil.

6. Generation of Noise and Vibration, and Emissions of Light and Heat

S.

No.


confirmation

Yes

/No




6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

Yes All noise producing equipment are enclosed

in Acoustic hoods and in sound proof

buildings. Dense Green belt is planted

around the mill boundary to reduce the

noise escape in surrounding area.

During Operational phase Green insulated

DG sets will be installed, which shall

conform to noise standards set by CPCB.

FORM-I





6.2 From industrial or similar processes Yes During Operational phase enclosure around

Machinery/ Equipments & Green insulated

DG sets will be installed, which shall

conform to noise standards set by CPCB.

6.3 From construction or demolition Yes Noise would be generated during

construction activity but adequate

precautions shall be taken to reduce the

noise generation.

6.4 From blasting or piling No No blasting will be involved.

6.5 From construction or operational

traffic

Yes Some noise is generated due to operation/

movement of machines/vehicles but that

will be within the prescribed limit. Minor

noise will be generated during construction

phase, which will be temporary in nature

and for short time only.

More than 33% of Plant area has been under

green cover with local Plant and Trees

Species, which in turn would help reducing

the noise levels.

During operation phase, raw material and

products will be transported at the peak time

of the day.

PUC checked vehicle will be used for

transportation purposes.

6.6 From lighting or cooling system No Not envisaged.

6.7 From any other sources No N.A.

7. Risks of Contamination of Land or Water From Releases of Pollutants in to the

Ground or in to Sewers, Surface Waters, Ground Water, Coastal Waters or the Sea

S.

No.


confirmation

Yes

/No




FORM-I





7.1 From handling storage, use or

spillage of hazardous materials

No There will be no hazardous waste generated

during the proposed manufacturing of

Poultry Feed Pallets except waste / Used

Oil from Proposed DG Set, which will be

sold to the authorized recyclers only.

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No There is not any risk of contamination due

to discharge of sewage or waste water as all

effluent generated will be treated in

proposed skid mounted STP.

7.3 By deposition of pollutant emitted

to air into the land or into water

No No major pollutant emitted from this

project.

7.4 From any other sources No

Not Applicable

7.5 Is there a risk of long term build up

of pollutant in the environment

from these sources?

No Likelihood of such an event is not foreseen

till now and suitable measures will be

adopted so that there will be no such risk in

the coming future from this project.

8. Risks of Accidents During Construction or Operation of the Project, Which Could

Affect Human Health or The Environment

S.

No.


confirmation

Yes

/No




8.1 From explosions , spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes For safe storage, Handling, following

measures will be adopted:-

On-site emergency preparedness plan are

prepared.

Fire extinguisher are installed at strategic

points all over the premises, checked at

regular intervals and a record will be made

and maintained.

First aid facilities are available for the staff

personals.

One vehicle will always be on stand by for

instant mobilization during emergency.

The workers will be provided with the

FORM-I





training for the first aid measures in case of

accident.

However, to meet out the minor incidences

and accidents first aid measures are

available at site.

Medical check-up of the workers is being

done periodically.

Safety items such as hand gloves, mask,

and apron is being providing while dealing

with the raw materials.

Training / Awareness program on safety

will be conducted on regular basis.

No other major risks are involved as no

explosives will be used.

MSDS of HSD shall be kept near storage

site.

8.2 From any other causes No Not Applicable

8.3 Could the project be affected by

natural disasters causing

environmental damage (e.g. floods,

earthquake, landslides, cloudburst

etc)?

Yes Project Site falls in Dehradun district in

Uttarakhand which falls in Seismic IV.

Secondary data reveals that no major natural

calamity has been recorded so far in the

proposed Project area.

9. Factors Which Should be Considered (Such As Consequential Development) Which

Could Lead to Environmental Effects or the Potential for Cumulative Impacts With

Other Existing or Planned Activities in the Locality

S.

No.


confirmation

Yes

/No




9.1 Lead to development of supporting.

Utilities, ancillary development or

development stimulated by the

project which could have impact on

the environment. e.g.

No No such activities will come up in the area

due to this project

FORM-I





Supporting infrastructure (road,

power supply, waste water

treatment etc.)

Housing development

Extractive industries

Supply industries

Other

9.2 Lead to after- use of the site, which

could have an impact on the

environment

No Nil.

9.3 Set a precedent for later

developments

No Nil

9.4 Have cumulative effects due to

proximity to other existing or

planned project with similar effects

No There would not be any negative impact.

Cumulative effect will be noted but will be

within norms/tolerance limit.

III Environmental Sensitivity

S.

No.

Areas Name

/

Identi

ty

Aerial distance (with in 15 km.) Proposed

project location boundary

1. Areas protected under

international conventions, national

or local legislation for their

ecological, landscape, cultural or

other related value

None --

2. Areas which are important or

sensitive for ecological reasons-

Wetland, water courses or other

water bodies, coastal zone,

biosphere, mountains, forests

None --

3. Areas used by protected, important

or sensitive species of flora or

fauna for breeding, nesting,

foraging, resting, over wintering,

Yes Rajaji National Park – 17.90 Km SE

FORM-I





migration

4. Inland, coastal, marine or

underground waters

No Asan Nadi – 150.0 Mtr. SE

Yamuna River – 16.5 KM NW

Ganga River – 52.0 KM SE

5. State , National boundaries No NA

6. Routes or facilities used by the

public for access to recreation or

other tourist, pilgrim areas

No N.H. 72 : 0.84 km (Ponta Sahib Road)

Railway Station: 19.23 Km (Dehradun)

Bus Stand (ISBT): 17.0 Km (Dehradun)

7. Defense installations Yes IMA – 14.8 Km E

8. Densely populated or built up area No Selaqui (Industrial Area)

9. Areas occupied by sensitive man –

made land uses (hospitals, schools,

places of worship, community

facilities)

No Facilities are well developed in Dehradun

City, which is 20.0 KM away from this Site.

10. Areas containing important, high

quality or scarce resources (ground

water resources, surface resources,

forestry, agriculture, fisheries,

tourism, minerals)

None --

11. Areas already subjected to

pollution or environmental

damage. (those where existing

legal environmental standards are

exceeded)

None --

12. Areas susceptible to natural

hazardous which could cause the

project to present environmental

problems. (earthquake, subsidence,

landslides, erosion, flooding

or extreme or adverse climatic

conditions)

None Project Site falls in Dehradun district in

Uttarakhand which occupies Zone IV.

Secondary data reveals that no major natural

calamity has been recorded so far in the

proposed Project area.

FORM-I





“I hereby given undertaking that the data and information given in the application and

enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at stage, the project

will be rejected and clearance and given, if any to the project will be revoked at our risk and cost.

Date: 05 January 2017 Signature of the Applicant

Place: Dehradun


DGM

M/s Venkys India Limited

330, Phase – II, Vasant Vihar, Dehradun - 248006

NOTE:

The projects involving clearance under Coastal Regulation Notification, 1991 shall

submit with the application a C.R.Z. map duly demarcated by one of the authorized

agencies, showing the project activities, w.r.t. C.R.Z ( at the stage of EC).

Simultaneous action shall also be taken to obtain the requisite clearance under the

provisions of the C.R.Z Notification, 1991 for the activities to be located in the CRZ.

The projects to be located within 10 km the National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit

the map duly authenticated by Chief Wildlife Warden showing these features vis – a

– vis the project location and the recommendations or comments of the Chief

Warden “thereon (at the stage of EC)”.

All correspondence with the Ministry of Environment & Forest including submission

of application for TOR / Environment Clearance, subsequent clarification, as may

be required from time to time, participation in the EAC Meeting on behalf of the

project proponent shall be made by the authorized signatory only. The authorized

signatory should also submit a document in support of his claim of being an

authorized signatory for specific project”.

PRE-FEASIBILITY REPORT & EMP

FOR

PROPOSED MODERNIZATION

OF

MASH POULTRY FEED TO PALLETIZATION

AND INSTALLATION OF

WOOD FIRED BOILER OF 750 KG PER HOUR CAPACITY

&

DG SET (250.0 KVA X 02 NOS., STANDBY ARRANGEMENT)

Head Office:

Venkateshwara House,

S. No. 114/A/2 – Pune


Registered Office:

330, Phase – II,

Vasant Vihar, Dehradun - 248006


Phone – 0135 – 2761456, 2694961

Fax – 0135 – 2762535

M/s Venky’s (India) Limited

Khasra No. 1050/1, Central Hope Town, Camp Road, Selaqui

Industrial Area, Dehradun, Uttarakhand


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M/s VENKY’S (INDIA) LIMITED

P F R -22

1.0 EXECUTIVE SUMMARY:

M/s Venky’s (India) Limited is a leading organization in poultry farms and manufacturing

of poultry feed. These products of poultry feed are being used in own hatcheries. Presently

the company is making mash poultry feed (1100 MT/Month) and the Proposed Project is

for Modernization of Mash Poultry Feed to Palletization and Installation of Wood Fired

Boiler of 750 kg per hour capacity & DG Set (250.0 KVA X 02 Nos., standby arrangement)

by M/s Venky’s (India) Limited at Khasra No. 1050/1, Central Hope Town, Camp Road,

Selaqui Industrial Area, Dehradun, Uttarakhand. The proposed project is categorized under

“Orange” of the Doon Valley Notification dated 1stFebruary 1989 & put up to the MoEF &

CC for appraisal due to non-constitution of SEIAA/SEAC, Uttarakhand as per Gazette

Notification No. 1539, Dated 13 December 2007 (Annexure – IX).

1.1 Employment Status:

Sl. No. Category No. of Employees

01. Managerial Staff 02

02. Permanent Staff 19

03. Contract Workers 35

Total 56

1.2 Water Balance:

Total water requirement: 21.00 KLD

Requirement Input Losses Recycled Output

Poultry feed Pelletization process (KLD) 18.00 18.00 0.00 Nil

Domestic (KLD) 2.50 0.50 0.00 *2.00

Miscellaneous i.e. Floor /Machinery

Washing etc. (KLD)

0.50 0.00 0.00 *0.50

Total output to S.T.P. *2.50

Note:


RO Plant reject is being reuse in the existing Green belt.

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P F R -23

Skid mounted STP of 5.0 KLPD capacity is proposed to treat the domestic sewage & other

waste water. Treated water shall be further reused into the Green belt development.

1.3 Salient Features of the Project:

S. No. Parameters Description

(1) Plant Capacity (Proposed) Manufacturing of 1100 MT/Month Pellets from

the existing mashed poultry Feed.

(2) Total area of the Plant 7542.23 Sq. m

(3) Capital Cost Approx. 75.0 Lacs

(4) Location Khasra No. 1050/1,

Central Hope Town, Selaqui Industrial Area,

Dehradun, Uttarakhand

(5) Water Requirement/Source About 21.0 KLD water will be required for

Domestic and manufacturing Purpose.

a) Total water Requirement 21.0 KLD

b) Source of water Existing Bore well

(6) Water Break-up Process : 18.0 KLD

Domestic : 2.50 KLD

Miscellaneous : 0.50 KLD

Total : 21.00 KLD

(7) Waste Water Management Approx. 2.5 KLD of waste water from Domestic

purpose and Equipment’s/Floor cleaning shall be

generate, which shall be utilized in the Green belt

development after treatment through proposed

skid mounted STP of 5.00 KLD capacity.

(8) Employment Generation 56 Person

(9) Alternate Power Green Insulated D.G. Set 250.0 KVA x 02 Nos,

standby arrangement for Alternate Power is

Proposed

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P F R -24

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION:

Poultry feed are mixtures of various ingredients like maize, rice bran, groundnut cake,

molasses, soya bean cake, fish meal etc. The composition of poultry feed can be varied

depending on the availability of various raw materials. Balanced feed is essential for proper

growth of chicks and consequently to increase the output broiler & eggs. The per capita

consumption of poultry products is very low in the north eastern region and there is great

need to increase the production. Development of poultry farms is receiving increasing

attention considering the nutritional requirements of the population as well as large

employment opportunities generated by these activities.

Healthy poultry require a sufficient amount of protein and carbohydrates, along with the

necessary vitamins, dietary minerals, and an adequate supply of water. Certain diets also

require the use of grit, tiny rocks such as pieces of granite, in the feed. Grit aids in digestion

by grinding food as it passes through the gizzard. Grit is not needed if commercial feed is

used. The feed must remain clean and dry; contaminated feed can infect poultry. Damp feed

encourages fungal growth. Mycotoxin poisoning, as an example, is "one of the most

common and certainly most underreported causes of toxicoses in poultry". Diseases can be

avoided with proper maintenance of the feed and feeder.

A feeder is the device that supplies the feed to the poultry. For privately raised chickens, or

chickens as pets, feed can be delivered through jar, trough or tube feeders. The use of

poultry feed can also be supplemented with food found through foraging. In industrial

agriculture, machinery is used to automate the feeding process, reducing the cost and

increasing the scale of farming. For commercial poultry farming, feed serves as the largest

cost of the operation. The term chicken feed is also used as a colloquialism for a small or

insufficient amount, especially a small amount of money. The term was first coined and

used in that sense in 1904.

As reports have indicated, feeding make-up the major cost in raising poultry animals as

birds in general require feeding more than any other animals did particularly due to their

faster growth rate and high rate of productivity. Feeding efficiency is reflected on the birds’

performance and its products. According to National Research Council (1994), poultry

required at least 38% components in their feed. The ration of each feed components,

although differ for each different stage of birds, must include carbohydrates, fats, proteins,

minerals and vitamins. Carbohydrates which are usually supply by grains including corn,

wheat, barley, etc. serve as major energy source in poultry feeds. Fats usually from tallow,

lard or vegetables oil are essentially required to provide important fatty acid in poultry feed

for membrane integrity and hormone synthesis. Proteins are important to supply the

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P F R -25

essential amino acids for the development of body tissues like muscles, nerves, cartilage, etc.

Meals from soybean, canola, and corn gluten are the major source of plant protein in

poultry diets. Supplementations of minerals are often required because grains, which is the

main components of commercial feed contain very little amount of those. Calcium,

phosphorus, chlorine, magnesium, potassium, and sodium are required in larger amounts

by poultry. Vitamins, such as vitamin A, B, C, D, E, and K on the other hand are the

component that required in lower amount by poultry animals.

2.1 IDENTIFICATION OF THE PROJECT:

M/s Venky’s (India) Limited is a team of young professionals, whose collective motto is to

contribute in development of poultry feed and hatchery sector through sharing existing

knowledge/technology/services with those in need of it. The objective to bring the best of

technologies and services available globally to India and extend the cost competitive poultry

feed products.

The difference lies in the endeavor of the group to explore the opportunities available or

work on it to render it suitable for everyone. The group also aspires to contribute actively in

customer education, distant learning program for experts and create awareness among

masses. Though the dream is life-size and the course is easier said than done the group

believes that in whatever minuscule size it achieves, it can present the approach to further

work on.

M/s Venky’s (India) Limited is a leading organization in poultry farms and manufacturing

of poultry feed. These products of poultry feed are being used in own hatcheries. Presently

the company is making mash poultry feed and the Proposed Project is for Modernization of

Mash Poultry Feed to Palletization and Installation of Wood Fired Boiler of 750 kg per

hour capacity & DG Set (250.0 KVA X 02 Nos, standby arrangement). The proposed

project is categorized under “Orange” of the Doon Valley Notification of 1st February 1989.

2.1.1 Company Background:

M/s Venky’s (India) Limited was initially established in July, 1976 with the name of M/s

Western Hatcheries Limited, subsequently it became public company w.e.f. December

1988. In June, 2000 Department of Company Affairs Andhra Pradesh has changed its name

to M/s Venky’s (India) Limited and have passed necessary resolution under section

21/22(1)e/22(1)(b) of Companies Act,1956 and also having approval of the Central

Government vide Latter No.- RAP/TA.VI/sec.21/24870/2000. M/s Venky’s (India)

Limited manufactures Poultry feed and manufacturing facilities are based in Dehradun on

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P F R -26

7542.23 Sq. m land at Khasra No. 1050/1, Central Hope Town, Camp Road, Selaqui,

Dehradun, Uttarakhand.

The Company is a regular tax payer for Income Tax and Service Tax and has never

defaulted.

2.1.2 The Promoters:

The partnership will enable the promoters of M/s Venky’s (India) Limited to charter an

independent growth path for the Company which envisages its entry into Poultry Feed

manufacturing business and expansion in other high potential product lines.

Sr. No. Name Designation

1. Banda Balaji Rao Managing Director

2. Jagapati Rao Chitturi Director

3. Anuradha Jitendra Desai Director

4. Jitendra Moreshwar Desai Director

5. Banda Venkatesh Rao Director

6. Ashok Kumar Mahajan Director

7. Rajeshwar Singh Rathore Director

8. Surinder Kumar Director

9. Amrit Kapur Director

10. Ashok Gambhir Bauskar Company Secretary

2.2 NATURE OF PROJECT:

M/s Venky’s (India) Limited is a leading organization in poultry and manufacturing of

poultry feed. These products of poultry feed are being used in own hatcheries. The Proposed

Project is for Modernization of Mash Poultry Feed to Palletization and Installation of

Wood Fired Boiler of 750 kg per hour capacity & DG Set (250.0 KVA X 02 Nos., standby

arrangement). The proposed Project is categorized under “Orange” of the Doon Valley

Notification of 1st February 1989.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR

REGION:

India has 1.23 billion people and the number is growing every year. The focus is on

“Development” meaning Good Food, Better Health & Living conditions to everyone.

People spend more money on food when they earn more. Healthy food at attractive price

will be the issue in focus. Eggs and chicken are accepted by all communities and are

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P F R -27

available at the most reasonable prices. Within a span of 25 years, the egg production has

gone up to 70 billion from few millions and the broiler production has gone to 3.8 million

tons from nowhere.

India is the third-largest egg producer after China and USA and the fourth-largest chicken

producer after China, Brazil and USA. The per capita eggs consumption has gone up from

30 to 68 and the chicken from 400 gm to 2.5 kg. Human nutritionists recommend 180 eggs

& 10 kg chicken per year. Most of the countries consume over 240 eggs and 20 kg of

chicken. There is scope for enhancing the production. Production is getting more organized

and move ahead of consumption resulting in optimum prices and with minimum profits.

Eggs and chicken were “agriculture produce” few years ago but are “food items” today.

Safe food is very important. Besides maintaining his production efficiency, the producer has

to concentrate on the nutritive values, the adulterants and contaminants of his produce. The

ministry of food processing industries, Centre for Science and Environment and food

inspection authorities started keeping track of eggs and chicken.

Indian Poultry feed industry is a major contributor to the country’s economy. M/s Venky’s

(India) Limited manufactures Poultry Feed. The Proposed Project is for Modernization of

Mash Poultry Feed to Palletization and Installation of Wood Fired Boiler of 750 kg per

hour capacity & DG Set (250.0 KVA X 02 Nos, standby arrangement) in the existing unit to

produce Poultry Feed in pallet form.

2.4 DEMAND – SUPPLY GAP:

With the increased demand for livestock products for domestic consumption as well as

export, the farmers realized maintaining of quality animals with proper feeding and

management. The proportion of crossbred animals or improved strains of birds increased

over the years. This has necessitated higher demand for balanced concentrate feed.

Presently, various poultry corporations/ federations and private companies are supplying

poultry feed of different qualities and forms (mash/ pellets/ crumbles) to the farmers

This market is driven by the high growth in the Poultry Feed manufacturing sector, strong

performance advantage offered by such products and increasing performance standards in

the industrial sectors. M/s Venky’s (India) Limited is the largest manufacturer.

2.5 IMPORTS VS. INDIGENOUS PRODUCTION:

Maize is one of the most important cereals used in animal feed. The annual production of

maize is about 10.5 million tons; about 4 million tons of which are used in the starch

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P F R -28

industry, 4.5 million tons in animal feeds and 2.5 million tons in human consumption and

seed production. Maize production has remained almost static in the past three years while

demand is increasing. The major crop is during the Kharif season (June to October), which

accounts for 90 percent of the total. The remaining 10 percent is harvested in the Rabi

season (November to February)

Sorghum and bajra are very sturdy varieties of millet that can grow under limited rainfall

conditions and are popularly used in animal feeds. Production of sorghum has remained

static. There is no export of sorghum and bajra (millet).

Rice bran and solvent-extracted rice bran are by-products. India is one of the world's largest

producers of rice, producing 87 million tons during 1998/99 (1.7 percent more than in the

previous year), and India produces approximately 2.95 million tonnes of solvent-extracted

rice bran, which is regularly exported.

India produces soybean, groundnut, rapeseed, sunflower, sesame and cotton meals and

these are used as major ingredients in animal feeds. For animal feeds, soybean is the most

frequently used oilseed meal and has completely replaced fishmeal in poultry feeds.

Cottonseed cake and meal are often used in cattle feed throughout the country. Groundnut

meal is less popular because of the afflation problem. Rapeseed meal is second to soybean

meal in production and second to cottonseed cake and meal for cattle feed. Sunflower meal

is commonly used in both cattle and poultry feed. So the indigenous productions are sufficient

to carter the Indian needs.

2.6 EXPORT POSSIBILITY:

As the poultry industry has been expanding beyond the boundaries of these states, there is

ample opportunity for standalone feed players. Poultry feed in India consists of grains like

maize, wheat, sorghum, bajra, ragi and broken rice, grain by-products like rice polish, de-

oiled rice bran and maize gluten meal; oilseed meals from soybeans, mustard, groundnut

and sunflower; animal protein sources like fish meal, whole fish, meat and bone meal,

poultry-by-product meal; vitamins, minerals and various feed additives. So according to

availability of easy raw material and excellent nutrious power Poultry Feed Industries have

very good export potential. However, the poultry feed produced by M/s Venky’s (India)

Limited is being consumed at their own various poultry farms.

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P F R -29

2.7 DOMESTIC/ EXPORT MARKET:

Consumption of commercial feed by the poultry sector at present is 28 million tons/year.

The poultry industry is highly dependent on the feed industry, which is only 35 years old.

The Indian feed industry caters predominantly to the poultry sector. Manufacture of feeds

for other categories of livestock is practically nonexistent. At present, the Indian organized

feed industry produces around 3 million tons of feed/year, which is only 5 percent of its

actual potential. A substantial quantity of feed is prepared by the farmers themselves in

order to reduce the feed cost.

Products i.e. Grand Breeder Chick Feed, Grand Breeder Grower Feed, Grand Breeder

Layer Feed, Grand Breeder Male Feed, Broiler Breeder Chick Feed, Broiler Breeder Grower

Feed, Broiler Breeder Layer Feed, Broiler Breeder Male Feed, Layer Breeder Chick Feed,

Layer Breeder Grower Feed, Layer Breeder Layer Feed, and Layer Breeder Layer Feed

manufacture by M/s Venky’s (India) Limited has good domestic and export markets.

However, the poultry feed produced by M/s Venky’s (India) Limited is being consumed at

their own various poultry farms.

2.8 EMPLOYMENT GENERATION - DIRECT AND INDIRECT:

Total Manpower engaged during operation of the Poultry feed Plant is 56. Apart from

this, 280 – 300 persons are indirectly benefited by this project during the operation

phase for logistic.

Table – 01: Employment Status

Sl. No. Category No. of Employees




Total 56

3.0 PROJECT DESCRIPTION:

3.1 TYPE OF PROJECT:

The Proposed Project is for Modernization of Mash Poultry Feed to Palletization and

Installation of Wood Fired Boiler of 750 kg per hour capacity & DG Set (250.0 KVA X 02

Nos, standby arrangement) to Produce Poultry Feed in pallet form at the Existing Complex

by M/s Venky’s (India) Limited at Khasra No. 1050/1, Central Hope Town, Camp Road,

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P F R -30

Selaqui, Dehradun, Uttarakhand. The proposed expansion project is interlinked and

interdependent with existing plant.

The Proposed Project categorized under “Orange” of the Doon Valley Notification of 1st

February 1989.

3.2 LOCATION OF THE PROJECT:

The plant is located about 19.0 Km from Dehradun City, just outside Municipal limits, in a

scenic location with greenery all around. The land area is 7542.23 Sq. m with plenty of

green land. No alternate site was considered –

The basis of selection of this site is that the State of Uttarakhand is providing suitable

Industrial environment with proper infrastructure support.

The availability of Raw Material, Power and other infrastructure.

Name of the Company M/s Venky’s (India) Limited

Head Office Venkateshwara House,

S.No. 114/A/2 – Pune


Registered Office 330, Phase – II,

Vasant Vihar, Dehradun - 248006


Phone – 0135 – 2761456, 2694961

Fax – 0135 – 2762535

Factory Office

Khasra No. 1050/1, Central Hope Town, Camp Road,

Selaqui, Dehradun, Uttarakhand

The key map and topographical map of 10 km radius of M/s Venky’s (India) Limited is

shown in the Fig. – 01 and Fig. – 02 respectively. The latitudes and longitudes of four

corners of the project site are as follows:

Direction Latitude Longitude

NE 30° 21'20.74"N 77°50'24.77"E

SE 30° 21'18.75"N 77°50'23.18"E

SW 30° 21'20.01"N 77°50'17.26"E

MW 30° 21'23.12"N 77°50'18.83"E


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P F R -31

3.3 SITE DESCRIPTION:

The Existing Plant is located at Khasra No. 1050/1, Central Hope Town, Camp Road,

Selaqui, Dehradun, Uttarakhand. The area is situated in the survey of India Topo Sheet

No. 53 F/15 and Coordinates 30°21'20.74"N 77°50'24.77"E’ to 30°21'23.12"N

77°50'18.83"E. The nearest National Highway NH-72 is 0.84 km away from the site. The

nearest Railway station Dehradun is about 19.0 km away from the site.

3.3.1 Site Selection:

As already stated, Proponent has acquired Land about 7542.23 Sq. mat Khasra No. 1050/1,

Central Hope Town, Camp Road, Selaqui, Dehradun, Uttarakhand for proposed

Modernization of Mash Poultry Feed to Palletization and Installation of Wood Fired Boiler

of 750 kg per hour capacity & DG Set (250.0 KVA X 02 Nos, standby arrangement) to

Produce Poultry Feed in Pellet form.

The main features of the site including environmental considerations that make it suitable

for pellet plant are given below:

Availability of sufficient stretch of land with flat terrain

No habitation in the plant site, hence no direct R&R issues

Sparsely populated surroundings

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

No declared biodiversity parks/sanctuaries are there in the surroundings of the site.

Nearness to source of main raw materials

Location of consumer center

Convenient Rail & Road links.

Perennial & adequate sources of water supply

Availability & closeness to source of adequate power supply

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Fig – 01: Key map of M/s Venky’s (India) Limited

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Fig – 02: Topographical map of 10 km radius of M/s Venky’s (India) Limited

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Fig – 03: Satellite Image of the Project Site

3.4 SIZE OR MAGNITUDE OF OPERATION:

The existing plant is designed for 1100 Tons/Month Mash Poultry Feed production and

the proposed Project is Modernization of Mash Poultry Feed to Palletization and

Installation of Wood Fired Boiler of 750 kg per hour capacity & DG Set (250.0 KVA X 02

Nos., standby arrangement). The plant operations are confined to the existing plant

boundary.

3.4.1 Technical Know-How:

The Company has appointed the Technical Staff; those are qualified as per the provision of

the Rules, separately for manufacturing and quality assessment. The Technical Staff

assisted by the Supporting Staff.

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3.5 MANUFACTURING PROCESS DESCRIPTION AND TECHNOLOGY:

3.5.1 EXISTING MANUFACTURING PROCESS:

Product Description:

Sr. No. Product Quantity (MT/Month)

1. Mash Poultry Feed 1100

The technology of feed processing has undergone substantial improvement in recent years.

It was only sixty years ago that feeds tuffs were mixed on the warehouse floor by the use of

a shovel. Feed processing has progressed from the simple mixing of several ingredients by

hand to mechanical mixing, to continuous mixing, and now to computer controlled mixing

and pelleting. However, the basic concept of mixing ingredients together to result in a

nutritionally balanced feed has remained unchanged.

A. RECEIVING OF RAW MATERIALS

The first operation in the feed processing plant involves the receiving of raw materials into

the plant premises. Feed ingredients arrive in sacks, or other small containers, and in bulk.

Sacked ingredients are checked for identification and condition. They are then logged in

after segregation of drugs and medications. Sacked ingredients must then be stored in a dry

location with proper protection from rodent and insect infestation. Sacked stocks are then

rotated to minimize staleness, product degradation, and insect infestation.

Bulk ingredients are handled according to their physical form. Liquid ingredients, such as

oils and molasses, are generally stored in bulk tanks. Proper storage temperature is

maintained and the filter screens are checked periodically. Solid bulk ingredients such as

grains, oil meals, etc., are cleaned with a scalper to remove foreign material prior to storage

in bins. Bin temperatures are monitored to prevent heating due to grinning respiration.

B. PROCESSING

Material flow during processing includes:

Particle size reduction

Premixing

Mixing

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Packing

i. Particle Size Reduction

Coarse ingredients pass over a permanent magnet which removes tramp metal and then

through a hammer mill which reduces particle size to the desired screen analysis. Ground

material is monitored periodically to ensure size uniformity and to help detect wear of

hammer mill screen and hammers. The ground material is then routed to ingredient holding

bins.

Fig – 04: Particle Size Reduction

ii. Premixing

There are two mixing operations in feed milling. One is for the mixing of micro-nutrients;

the operation is generally termed pre-mixing. The other mixing operation involves the

actual blending of all components of the diet.

Micro-nutrients, such as vitamins and trace minerals, are accurately weighed with carrier

material which has a density approximating that of the predominant micro-ingredient. The

materials are then mixed in a batch mixer for a period of time specified by the equipment

manufacturer to ensure homogeneity. The premix is finally routed to the premix holding

bin.

iii. Mixing

Diet mixing begins when augers are set in motion to deliver; the correct amounts of each

ingredient including the premix, according to the formula, into the mixer. Where manual

changing of the mixer is done, ingredients are weighed out in sacks or hopper carts. The

mixing period is according to the equipment manufacturer's specifications, but final mix is

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checked periodically with a tracer to ensure homogeneity of the mix. If the mixed diet is to

undergo pelleting, it is routed to the pelleting bin.

iv. Packing

Most finish mash feed are sacked. The sacking operation includes: weighing, sacking,

taping, coding, and sewing. The sacked bags are then sent to the warehouse for distribution.

3.5.2 Detail of Existing Plant Machinery:

Table – 02: Existing Plant Machinery

Sr. No. Plant Section Name of Equipment Quantity (Nos.)

1. Premixing Section Mineral Mixer 01

Medicine Mixer 01

Grinder 01

2. Grinding Section Intake Elevator 01

Hammer Mill 01

Ratler (Conveyer) 01

Batch Elevator 01

Medicine Trolley 01

Mixer 01

Pedal Conveyer 01

Air Compressor 01

Molasses Elevator 01

Bag Conveyer 01

Bag Stitching 01

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Fig – 05: PROCESS FLOW DIAGRAM OF EXISTING PLANT

BAGGED / PACKEDGED RECEIVAL & STORAGE

Viz. Vitamins, Minerals, Salts, Pre-Mixes

BULK RECEIVALS & STORAGE

Viz. Grains, Oilseed meals, Meat & Bone meal

PRE – MIXING MILLING / GRINDING

Viz. Grains

WEIGHING / BATCHING

MIXING

BULK LOADING

LIQUID RECEIVAL & STORAGE

Viz. Vegetable oils, Tallow,

Feed enzymes

WEIGHING

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3.5.3 PROPOSED MANUFACTURING PROCESS:

Presently, M/s Venky’s (India) Limited is manufacturing Mash Poultry Feed Products and

proposing the Pelletizatin Process of the Mashed Poultry Feed which requires steam

conditioning. To fulfill the steam requirement of Pelletization Process, company has

proposed Installation of Wood Fired Boiler of 750 kg per hour capacity and DG Set (250.0

KVA x 02Nos, standby arrangement).

1. PELLETIZATION:

Product Description:

Sr.

No. Product Quantity (MT/Month)

1. Poultry Feed (Pellets) 1100

The transformation of a soft, often dusty feed into a hard pellet is accomplished by

compression, extrusion, and adhesion. The general process involves passing a feed mixture

through a conditioning chamber where 4 to 6 percent steam may be added. Moisture

provides lubrication for compression and extrusion and in the presence of heat causes some

gelatinization of raw starch present on the surface of vegetative ingredients, resulting in

adhesion. Within 20 seconds of entering the pellet mill, feed goes from an air-dry (about 10-

12 percent moisture) condition at ambient temperature, to 15-16 percent moisture at 80-

90°C. During subsequent compression and extrusion through holes in a ring' die, friction

further increases feed temperature to nearly 92°C. Pellets discharged onto a screen belt of a

horizontal tunnel drier or into a vertical screened hopper are air-cooled within 10 minutes to

slightly above ambient temperatures and dried to below 13 percent moisture.

Contrary to early belief, finished pellets contain practically all the nutrients found in

feedstuffs and additives as compounded. The loss of thermo labile vitamins used in

additives, which may be slight or extensive in the case of vitamin C, may be compensated

for by extra supplementation of these in the vitamin premix to comply with formula

requirements. Di static enzymes (alpha and beta amylase) present in whole grains and cereal

byproducts are still active after processing by grinding and pelleting, although powdered

enzymes added as an ingredient are inactivated.

Mechanically, the process of pelleting involves forcing soft feed through holes in a metal

ring-type die. These holes are round. Double rolls mounted inside the die ring on a cam or

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eccentric; turn on a rotating shaft as friction develops (due to the presence of feed between

roll and die). Feed is forced through the die holes in increments so that dissection of a

finished pellet shows tight layers of feed mixture. The die is driven by a motor and the rolls

turn only as feed between rolls and die develops friction.

To make dry feed particles pliable for close compression and to decrease friction and absorb

mechanical heat, water is often added in form of steam to the feed, either as the formula is

mixed or in the conditioning chamber of the pellet mill. Water is provided in the form of

steam, two objectives are accomplished:

1. A high volume of water vapour condenses on the surface of feed particles, wetting and

softening them for better compression, and

2. The high temperatures of this steam cause some gelatinization of raw starch present in all

vegetative ingredients, providing the necessary adhesion for firm pellets.

Overall, the texture of a soft feed mixture is changed from a meal-like material with bulk

density approximately 0.4 g/cc, to a pellet with bulk density of 0.5 – 0.6 g/cc. Within the

ring die, pressures of 75 – 600 kg/cm2 are attained.

Variables resulting from mechanical operation of the equipment may be listed here:

Pellet die thickness as related to diameter of hole is a factor in pellet quality.

Speed of rotation should also be considered for each die thickness/hole diameter

combination.

The speed at which feed is introduced into the feed-conditioning chamber affects the

moisture/temperature relationship which in turn relates to pellet quality.

The amount of steam added to a given volume of feed should be in balance such that

the drive motor on the pellet mill is operating at its maximum amperage. The

opening of the steam valve at the pellet mill has a direct relation to the amount of

water entering the feed as steam at any given steam pressure.

Atmospheric conditions in the factory, especially relative humidity, which pre-

condition the ingredients before processing, will affect die selection and operational

settings.

All of the above items must be examined for each feed formula, which shows that pelleting

is more of an art than a science. It should be emphasized again that the pellet mill operates

most efficiently when the motor amperage use is optimum for the voltage available. It is

important to watch the ammeter gauge frequently during pelleting. At the start of a pelleting

operation, a small amount of soft dry feed enters the pellet chamber for compression and the

gauge will respond to the load with less than optimum results. The addition of steam results

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in a lowered reading, showing the lubricating effect. More dry feed may now enter the

conditioning chamber and, as it reaches the die, the ammeter will move to a higher reading.

Additional steam will lower this. By adjusting the dry feed intake and the steam valve

opening, a stable condition will result where the motor is operating at its maximum rated

amperage and pellet production will be at maximum capacity. These operational conditions

normally coincide with maximum pellet quality afforded by the composition of the feed mix

Fig – 06: Graphical Representation of Pellet Mill

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Fig – 07: Die for Pelletization

A control valve introduces dry steam into a header from which, through several port-holes,

steam enters the conditioning chamber in contact with dry feed. Between this valve and the

steam generator or boiler are a strainer and trap to remove condensate, providing only dry

steam in the mill. At the discharge end of the conditioning chamber is a gate to restrict feed

from immediately leaving and allows more time for moisture to be absorbed into the feed. A

chute or funnel usually guides moisture-conditioned feed into the pellet chamber where

compression and extrusion occur. If the ammeter goes much above the optimum reading,

this chute may be quickly raised to prevent a choke-up of feed in the die holes. From the

pellet chamber, feed may be directed by means of a butterfly valve to the cooler or on the

floor for inspection.

Another variable that may be introduced into the operation of a pellet mill is the rotational

speed of the die. For the production of small diameter pellets (i.e., 3 mm or less) high

rotation speeds are used. This results in a thinner layer of soft feed inside the die ring ahead

of the rolls, and for a given volume of feed the efficiency of pelleting and pellet hardness are

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improved. Die speeds may be changed by replacing the pulley on the main motor shaft of

the pellet mill. Speeds generally range from 130-400 rpm. Feeds-of low bulk density are

formed best in dies rotating at higher speeds.

Influence of Feed Composition:

Additional factors known to influence pellet quality include bulk density of the soft feed, its

texture, chemical composition (fat, fibre, carbohydrate, protein, and moisture) and

prevailing ambient conditions of temperature and relative humidity. Grinding improves

pellet quality by reducing air spaces between particles, allowing closer surface to surface

contact for a given volume of feed; i.e., it increases bulk density. Large pieces of any

ingredient in a feed formula result in weak spots in the pellet, especially if these are fibrous

or bony. Grinding also increases the total surface area of a given weight of feed, thereby

allowing more space for steam condensation during the conditioning process. This results in

a higher feed temperature and more water absorption which together, within the time

available, increases gelatinization of raw starch. Starch gelatinization has been mentioned

previously (Section 3), but since it is the key to water-stable pellets, further discussion may

be beneficial. Starch gelatinization is the rupture of starch granules, thereby allowing the

linear and cyclic molecules to hydrate and become sticky in the presence of water.

Gelatinization occurs by mechanical means such as grinding, pressure, and by hot water.

Soft feed at an environmental temperature of 25°C can be brought to a temperature of 85°C

by the addition of 4 to 6 percent moisture from steam. Frictional heat due to passage of feed

through the pellet mill adds 2 or 3 degrees of temperature. The moisture, temperature, and

time involved combine to impart a sticky surface to starch-containing ingredients which,

when subsequently dried, improved pellet hardness and water stability.

Since fat and moisture lubricate the soft feed as it passes through holes in the ring die,

reducing friction of compression and extrusion, a certain level of these are necessary for

pelleting. If the total crude fat in a feed formula is much more than 8-10 percent or the

moisture is much above 15 percent, too much lubrication is provided and a poor quality

pellet in terms of hardness results. Dies may be designed to accommodate high-fat feeds by

tapering or slanting the Holes or by increasing the hole depth in relation to its diameter.

Dietary fat in the final feed may be increased beyond that in the formula by spraying liquid

fat or oil onto pellets or crumbles after they leave the pellet mill. An external coating of 5-6

percent stabilized fat does not appreciably soften the pellet except externally, and this may

be a lure both in odour and texture for chickens.

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Cooling and Drying:

The temperature imparted to pellets in the process of their manufacture assists the removal

of moisture by the air-drying process. Generally, within ten minutes after extrusion, hard

pellets are cooled to ambient temperature and brought to moisture content slightly above

that of the entering soft feed. This may be done by spreading pellets in a thin layer on the

floor and blowing air over them. Commercially, it is done by passing the hot pellets through

a vertical or a horizontal chamber designed to bring air at ambient temperature into intimate

contact with the outer surface of the pellets.

Mixed feed mash for pelleting is first conditioned with steam in the steam conditioner

section of the pellet mill, after which it enters the die where it is finally extruded. Freshly

extruded pellets are hot and contain excess moisture which is removed during passage

through the cooler. Fines are then screened from the cooled pelleted feed and returned for

repeating. Fish oil, if added, is now applied prior to the routing of the finished pellets into

the packer bins.

Fig – 08: Prepared Pellets

Packing:

Most finish feed pellets will be sacked. The sacking operation includes: weighing, sacking,

taping, coding, and sewing. The sacked bags will be then sent to the warehouse for

distribution.

https://www.google.co.in/url?url=https://www.pinterest.com/pin/470133648571509984/&rct=j&frm=1&q=&esrc=s&sa=U&ved=0ahUKEwjYupiUpJnRAhUFNY8KHQMWBJ84jAEQwW4IIzAH&usg=AFQjCNErFoYkMwurtkOlgw2GKVpiWJ8_xg

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3.5.4 Detail of Proposed Plant Machinery:

Table – 03: Proposed Plant Machinery

1. Pelleting Section Feeder Conditioner 03

Pellet Machine 01

Cooler 01

Crumbler 02

Blower 01

Cyclone 01

Bag Conveyer 01

Bag Stitching 01

2. Boiler Wood Fired Boiler of 750 kg

per hour capacity

01

3. DG Set 250.0 KVA standby arrangement

02

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Fig – 09: Graphical Representation of Pelletization Process

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Proposed Process

Fig – 10: PROCESS FLOW DIAGRAM AFTER MODERNIZATION


e.g. Vitamins, Minerals, Salts, Pre-Mixes


e.g. Grains, Oilseed meals, Meat & Bone meal


e.g. Grains

WEIGHING / BATCHING

MIXING

PELLETING

COOLING

POST – PELLETING ADDITIONS & MIXING

e.g. Oil, Tallow, Enzymes, Whole grain

BULK LOADING


e.g. Vegetable oils, Tallow,

Feed enzymes

WEIGHING

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3.5.5 PROPOSED UTILITY INSTALLATION:

A. WOOD FIRED BOILER:

Industrial boilers are commonly used to make process steam. These boilers can use wood

fuels as an alternative to fossil fuels such as natural gas, coal, and fuel oil.

One important component of a boiler is the super heater, an array of tubes that uses hot

combustion gases to raise the temperature of steam, converting it from a saturated or wet

state to a dry state.

Biomass as a Fuel:

Biomass, the oldest source for heat energy, has been used for thousands of years. However,

with the emergence of fossil fuels, its relative share of use has declined over past years.

Currently some 13% of the world’s primary energy supply is from biomass, though there are

strong regional differences. Developed countries source around 3% of their energy from

biomass while, in Africa it ranges between 70-90%. With adverse environmental effects on

the environment such as climate change coming to the forefront, people everywhere are

rediscovering the advantages of biomass.

Potential benefits of biomass:

Reducing carbon emissions if managed (produced, transported, used) in a sustainable manner

Enhancing energy security by diversifying energy sources & utilizing local resources Reduced problem of biomass waste management Possible additional revenues for the agricultural and forestry sectors

Plant Capacity:

Proposed Wood fired Boiler Capacity – 750 Kg/Hr

To fulfill the steam requirement for the Pelletization process of existing mashed Poultry

Feed, the Horizontal Multi-tubular Shell Type Smoke Tube Boiler is proposed (Wood Fired

Boiler). The specification of proposed boiler is as below-

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Table – 04: Specification of Proposed Boiler

Sr. No. Operating Parameter Unit

1. Boiler Type - Horizontal Multi-tubular Shell

Type Smoke Tube Boiler

2. Max. Steam Output (F&A 100˚C) Kg/h 750.00

3. Design Pressure (SVLOP) Kg/cm2(g) 7.00

4. Fuel Type - Wood Logs

5. Fuel Consumption @ 100% Load Kg/h 191.00

6. Connected Power Load KW 7.80

7. Design Code (IBR 1950 with

latest amendments)

- IBR

Fig – 11: Photograph of Horizontal Multi-tubular Shell Type Smoke Tube Boiler

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The Proposed boiler is shell type smoke tube steam boiler. Shell boilers may be defined as

those boilers in which the heat transfer surfaces are all contained within a steel shell. Shell

boilers may also be referred to as 'fire tube' or 'smoke tube' boilers because the products of

combustion pass through the boiler tubes, which in turn transfer heat to the surrounding

boiler water. To control the boiler an automatic system is provided for control of capacity as

per requirement of steam in the plant. Bag filter will be provided with for maintaining the

required pollution norms for air and will maintain less than 100 mg/nm3 of air.

Water surrounds the tubes through which hot combustion gases pass before venting

to atmosphere through gas uptakes.

Water converted into high pressure steam by transfer of heat from very high

temperature combustion gases on water.

Hot combustion gases produced by burning diesel oil, town gas etc. in the furnace.

Boilers are of fully automatic design.

Essential mountings include safety valve, steam pressure switch, pressure gauge,

gauge glass, valve fittings, low-water level cut-off and alarm devices etc.

The pressure & temperature of boiler is 7.0 kg/cm 2, & 180°C respectively.

The bag filters are stainless steel cage tight vertical hanging bags filter, it has

automatic cleaning of bag filter by way of pneumatic switches which at a regular

interval clean the ash. The above bags are mounted on header which is enclosed with

mild steel tank having conical bottom to remove the fly ash

.

Fig – 12: Graphical Representation of Fire (Smoke) Tube Steam Boiler

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Biomass Based Shell Type Fire (Smoke) Tube Steam Boiler:

Fire tube boiler consists of boiler shell which is filled with water and perforated with tubes,

there are different configurations of these tubes but horizontal configuration is the common

one. Water is partially filled in the water tank and volume is left inside the tank to

accommodate the steam. Long horizontal tubes arc called flues and these carry the hot

combustion gases through the water tank and heating the water. The furnace is situated at

one end of a fire tube which elongates the path of the hot gases, thus expanding the heating

surface which can be further increased by making the gases reverse direction through a

second tube or bundle of multiple tubes.

The water and steam in fire-tube boilers contained within a large diameter drum or shell,

and such unit arc often referred to as 'shell type boiler'. Heat from the products of

combustion is transferred to the boiler water by tubes and it goes out from the smokestack.

Fire-tube boilers are approximated to 360psi of steam pressure. In case of fire tube boiler the

whole lank is under pressure so if tanks burst it creates a major explosion and if one need to

increase the steam pressure of fire-tube boiler then it is necessary to increase the thickness of

the shell and material of tube sheet.

The water is confined by the outer shell of boiler. To avoid the need for a thick outer shell

fire-tube boilers are used for lower pressure applications. Generally, he heat input capacities

for fire-tube boilers are to 50mbtu per hour or less, but in recent years the size of fire-tube

boilers has increased. Fire-tube boilers are subdivided into three groups; horizontal return

tubular (HRT) boilers typically have horizontal self-contained fire-tubes with a separate

combustion chamber. Scotch, scotch marine, or shell boilers have the fire-tubes and

combustion chamber housed within the same shell. Firebox boilers have a water-jacketed

firebox and employ at most three passes of combustion gases.

Most modern fire-tube boilers have cylindrical outer shells with a small round combustion

chamber located inside the bottom of the shell. Depending on the constructions details,

these boilers have tubes configured in one, two, three or four pass arrangements, because the

design of fire-tube boilers is simple, they are easy to construct in a shop and can be shipped

fully assembled as a package unit. Fire-tube boilers typically have a lower initial cost, are

more fuel efficient and are easier to operate.

Advantages of Fire-Tube Boilers;

Low cost.

Fluctuations of steam demand can be met easily.

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It is compact in size. C boilers give efficiency of as high as 80-82% and can be used

for a wide variety of fuels.

Environmental Benefits of Biomass based Boiler:

The benefits of biomass use as a source of fuel in cogeneration systems, besides energy

security & independence of the industries, include several environmental benefits, mainly in

terms of GHG reduction.

Social Benefits of Biomass based Boiler:

Biomass based fuel undoubtedly leads to several social benefits as below:

Biomass steam generating plants monetize the heat value of biomass, which brings in

additional income to various players in the biomass supply chain.

It creates additional employment in collection and transportation of biomass.

In countries like India the employment generation, in fuel collection and logistics,

have excellent gender mix in favor of women, which, is lacking in many employment

generation schemes of the government and in other sectors such as infrastructure

building (roads, highways etc.).

It would reduce the equivalent fossil fuel import bill of the government & thereby

improve the balance of payment position.

Biomass based steam generating projects have given impetus to technology

development, by encouraging use of different agro and woody biomass in plants. It

would also give impetus to technology development at the farm level, by introducing

farm level machinery, to facilitate collection and baling.

Biomass Issues:

Emissions - the Primary Concern

Pollutant Emissions

• SO2 Nil

• PM Low

• CO Moderate

• NOx Moderate/High

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NOx and CO are main pollutants

Table – 05: Emissions Summary- Coal & Biomass

lb/MBtu Coal Biomass

Uncontrolled Controlled Uncontrolled Controlled

NOX 0.32 to >1.5 0.035 to 0.15 0.15 to 0.48 0.05 to 0.075

SO2 0.8 to >6.0 0.03 to 0.06 <0.08 <0.08

CO 0.04 to >0.15 0.04 to 0.15 0.15 to 0.45 0.075 to 0.10

PM 3.0 to 15 0.012 to 0.02 0.20 to >1.0 0.010 to 0.015

Operating Advantages and Disadvantages:

Fire (Smoke) Tube Steam Boilers have specific operating advantages and disadvantages

with biomass fuels depending on the fuel characteristics and site requirements. Biomass

fuels are extremely variable in terms of heating value, moisture content, and other factors

that affect combustion. Wood and most other biomass fuels are composed primarily of

cellulose and moisture. As discussed previously, the high proportion of moisture is

significant because it acts as a heat sink during the combustion process. The latent heat of

evaporation depresses flame temperature, taking heat energy away from steam production,

and contributing to the difficulty of efficiently burning biomass fuels. Cellulose, in addition

to containing the chemical energy released in combustion, contains fuel-bound oxygen. This

oxygen decreases the theoretical air requirements for combustion and, accordingly, the

amount of nitrogen included in the products of combustion. A few general guidelines for

direct firing of wood and biomass in boilers include:

Maintain stable combustion, which can be achieved in most water-cooled boilers

with fuel moisture contents as high as 65 percent by weight, as received.

Use of preheated combustion air reduces the time required for fuel drying prior to

ignition and is essential to spreader stoker combustion systems. Design air

temperatures will vary directly with moisture content.

A high proportion of the combustible content of wood and other biomass fuels burns

in the form of volatile compounds. A large proportion of the combustion air

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requirement, therefore, is added above the fuel in stoker and other conventional

combustion boilers as over fire air.

Solid chars produced in the initial stages of combustion of biomass fuels are of very

low density. Conservative selection of furnace section size is used to reduce gas

velocity and keep char entrainment into the flue gases and possibly out the stack at

acceptable levels.

B. DG SET:

Presenting, an exclusive variety of high grade Diesel Engine Generating Set that is highly

reliable in nature. Fabricated from quality components, these sets are known for their longer

functional life. Robust in design, these sets have combustion engines that comply with the

latest Central Pollution Control Board emission norms. Owing to their sophisticated

designs, these sets are widely used in small and big industries, commercial buildings, IT

parks, hospitals, hotels and cold storages.

A diesel generator is the combination of a diesel engine with an electric generator (often an

alternator) to generate electrical energy. This is a specific case of engine-generator.

Diesel generating sets are used in places without connection to the power grid, as

emergency power-supply if the grid fails, as well as for more complex applications such as

peak-lopping, grid support and export to the power grid. Sizing of diesel generators is

critical to avoid low-load or a shortage of power and is complicated by modern electronics,

specifically non-linear loads.

Diesel engine is the prime mover, which drives an alternator to produce electrical energy. In

the diesel engine, air is drawn into the cylinder and is compressed to a high ratio (14:1 to

25:1). During this compression, the air is heated to a temperature of 700–900°C. A metered

quantity of diesel fuel is then injected into the cylinder, which ignites spontaneously because

of the high temperature. Hence, the diesel engine is also known as compression ignition (CI)

engine. DG set can be classified according to cycle type as: two stroke and four stroke.

However, the bulk of IC engines use the four stroke cycle.

Acoustic Enclosure:

The silent series is a Super Silent DG set with a sound proof acoustic enclosure. It offers a

cost effective and perfect solution to the problem of noise pollution. The advanced acoustic

engineering employed in attenuating noise also saves on the expenses for building up a

separate room for the DG set.

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DG Set as a System:

Successful operation of a diesel generating set depends on the well-matched performance of

the components, namely:

a) The diesel engine and its accessories.

b) The AC Generator.

c) The control systems and switchgear.

d) The foundation and power house civil works.

e) The connected load with its own components like heating, motor drives, lighting etc.

Process Flow Diagram of DG Set System:

Fig – 13: DG SET SYSTEM

Energy Saving Measures for DG Sets:

Ensure steady load conditions on the DG set, and provide cold, dust free air at intake

(use of air washers for large sets, in case of dry, hot weather, can be considered).

Improve air filtration.

Ensure fuel oil storage, handling and preparation as per manufacturers'

guidelines/oil company data.

Consider fuel oil additives in case they benefit fuel oil properties for DG set usage.

Calibrate fuel injection pumps frequently.

Ensure compliance with maintenance checklist.

Ensure steady load conditions, avoiding fluctuations, imbalance in phases, harmonic

loads.

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In case of a base load operation, consider waste heat recovery system adoption for

steam generation or refrigeration chiller unit incorporation. Even the Jacket Cooling

Water is amenable for heat recovery, vapour absorption system adoption.

In terms of fuel cost economy, consider partial use of biomass gas for generation.

Ensure tar removal from the gas for improving availability of the engine in the long

run.

Consider parallel operation among the DG sets for improved loading and fuel

economy.

Carryout regular field trials to monitor DG set performance, and maintenance

planning as per requirements.

3.6 RAW MATERIALS, QUALITY AND SOURCES:

Source of major raw material are as follows:

Table – 06: ANNUAL RAW MATERIAL REQUIREMENT

POULTRY FEED PLANT

RAW MATERIALS QUANTITY (TPA) SOURCE

Bentonite Powder 88.15 From open market

Di – Calcium Phosphate (DCP) 342.52 From open market

De – Oiled Rice Bran 1715.41 From open market

Lime Stone Coarse Powder 728.72 From open market

Lime Stone Powder 314.08 From open market

Maize 9806.49 From open market

Rice Bran Oil 65.15 From open market

Rice Gluton 262.44 From open market

Rice Polish 802.56 From open market

Soya Bean Refined Oil 23.14 From open market

Soya bean Doc 2855.52 From open market

MAJOR RAW MATERIALS:

BENTONITE POWDER

Requirement of Bentonite Powder is 88.15 TPA and sourced from open market.

DI – CALCIUM PHOSPHATE (DCP)

Requirement of Di – Calcium Phosphate (DCP) is 342.52 TPA and sourced from open

market.

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DE – OILED RICE BRAN

Requirement of De – Oiled Rice Bran is 1715.41 TPA and sourced from open market.

LIME STONE COARSE POWDER

Requirement of Lime Stone Coarse Powder is 728.72 TPA and sourced from open

market.

LIME STONE POWDER

Requirement of Lime Stone Coarse Powder is 314.08 TPA and sourced from open

market.

MAIZE

Requirement of Maize is 9806.49 TPA and sourced from open market.

RICE BRAN OIL

Requirement of Rice Bran Oil is 65.15 TPA and sourced from open market.

RICE GLUTON

Requirement of Rice Gluton is 262.44 TPA and sourced from open market.

RICE POLISH

Requirement of Rice Polish is 802.56 TPA and sourced from open market.

SOYA BEAN REFIND OIL

Requirement of Soya Bean Refined Oil is 23.14 TPA and sourced from open market.

SOYABEAN DOC

Requirement Soya bean Doc is 2855.52 TPA and sourced from open market.

3.6.1 Mode of Transport of Raw Material:

It has been assumed that major raw materials like Bentonite Powder, Di – Calcium

Phosphate (DCP), De – Oiled Rice Bran, Lime Stone Coarse Powder, Lime Stone Powder,

Maize, Rice Bran, Oil Rice Gluton, Rice Polish, Soya Bean Refined Oil, Soya bean Doc are

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brought to the plant from outside sources by rail/road and road facility is being availed to

supply the final products to own poultry farms.

3.7 RESOURCE OPTIMIZATION:

No waste water is generated from the process. The plant is designed in zero discharge

concept. Presently domestic effluent is subjected to septic tank/soak pit. However Skid

mounted STP of 5.0 KLPD capacity is proposed to treat the domestic sewage.

3.8 UTILITIES & AUXILIARY SERVICES:

3.8.1 Water:

Water is required for manufacturing process, drinking, sanitation and Washing of Floor /

Machinery purposes. The daily requirements of water are estimated at 21.00 KLD. The


Table – 07: Total Plant Raw Water Requirement (KLD)

Sr. No. Particulars Total water requirement (KLD)

1. Poultry Feed Pelletization Process 18.00

2. Domestic Purpose 2.50

3. Miscellaneous Purpose i.e. Floor

/Machinery Washing

0.50

Total 21.00

WATER BALANCE: Total water requirement – 21.00 KLD

Table – 08: Water Balance



Domestic (KLD) 2.50 0.50 0.00 *2.00


Washing etc. (KLD)

0.50 0.00 0.00 *0.50


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Note:



Skid mounted STP of 5.0 KLPD capacity is proposed to treat the domestic sewage &

other waste water. Treated water shall be further reused into the Green belt

development.

3.8.2 Fuel:

The Plant requires around 69.75 TPA of wood logs which will be sourced from various

local wood logs traders.

3.8.3 Energy Requirement:

Uttarakhand Power Corporation Limited (UPCL), Dehradun District is major source to

electricity (300 KVA).

DG Set (250.0 KVA x 02 Nos., standby arrangement) are proposed for alternate source of

power for essential services.

3.9 ENVIRONMENT MANAGEMENT:

The Poultry Feed Plant is designed with Zero Discharge concept with no solid or liquid

waste disposal. The dusts generated from the proposed Wood Fired Boiler will be collected

through bag filters and utilize for land filling in low line areas.

4.0 SITE ANALYSIS:

4.1 Connectivity:

The plant is located about 19.0 Kms from Dehradun City, just outside Municipal limits, in a

scenic location with greenery all around. The land area is 7542.23 Sq. m with plenty of

green land.The nearest National Highway NH-72 is 0.84 km away from the site. The


4.2 Land Use:

Proponent has acquired Land about 7542.23 Sq. m at Khasra No. 1050/1, Central Hope

Town, Camp Road, Selaqui, Dehradun, Uttarakhand for Expansion/ Installation of Wood

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Fired Boiler of 750 kg per hour capacity and DG Set (250.0 KVA x 02 Nos, standby

arrangement) to Produce Poultry Feed.

The land break-up details are shown in Table – 08

Table – 09: Land break-up details

S. No. Construction Area (Sq m.)

1. Built up area for Plant & Facilities 2055.64.

2. Roads and Drains 1502.14

3. Greenbelt 2490.00

4. Open Area 1494.45

Total Land 7542.23

Fig – 14: Layout of existing Poultry Feed Plant

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4.3 Topography:






The main features of the site including environmental considerations that make it suitable

for pellet plant are given below:

Availability of sufficient stretch of land with flat terrain

No habitation in the plant site, hence no direct R&R issues

Sparsely populated surroundings

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

No declared biodiversity parks/sanctuaries are there in the surroundings of the site.

Nearness to source of main raw materials

Location of consumer center

Convenient Rail & Road links.

Perennial & adequate sources of water supply

Availability & closeness to source of adequate power supply

The site lies in seismic zone IV as per Seismic zonation & intensity Map of India and has

the lowest seismic potential.

There is no Capable Fault within the study area. The seismic zone map of Uttarakhand is

shown in the Fig. – 16.

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Fig – 15: Topographical Map of 05 km radius of Project Site

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Fig – 16: Seismicity Map of Uttarakhand State

4.4 EXISTING LAND USE PATTERN:

Proponent has acquired Land about 7542.23 Sq. m at Khasra No. 1050/1, Central Hope

Town, Camp Road, Selaqui, Dehradun, Uttarakhand for Modernization of Mash Poultry

Feed to Palletization and Installation of Wood Fired Boiler of 750 kg per hour capacity &

DG Set (250.0 KVA X 02 Nos, standby arrangement).The proposed Modernization project

is interlinked and interdependent with existing plant which is situated in Selaqui Industrial

Area Dehradun and categorized under “Orange” of the Doon Valley Notification of 1st

February 1989.

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4.5 EXISTING INFRASTRUCTURES:

The proposed Expansion/Installation is in existing plant so infrastructure such as housing

facility, Drinking water facility, First-aid facility, Toilet facility is already available. Internal

roads are developed inside the plant premises once all the statutory clearances are

obtained.

Land:

Proponent has acquired Land about 7542.23 Sq. m, whose building is converted through

modular modifications to suit to Poultry Feed Products at Khasra No. 1050/1, Central

Hope Town, Camp Road, Selaqui, Dehradun, Uttarakhand

Power:

The total connected load for smooth operation of the Unit is being sourced from UPCL (300

KVA).

The Company proposes for installation of Green Insulated DG Set for Alternate Power of

arrangement (250.0 KVA x 02 Nos, standby arrangement) for continuous supply of power

in the manufacturing of proposed Pelletization of Poultry Feed Products during Failure /

Shutdown of power at any point of time will adversely affect the production and quality of

Finished Product.

Water:

Total water requirement for Pelletization of Poultry Feed Products shall be 21.0 KLD,

which shall be sourced from existing bore wells. Necessary provision for storage of water

and water supply has been made in project cost.

Storage:

Company has already developed storage facility for raw material & finished goods by

providing adequate safety measures.

Transportation:

Promoters have adequate resources for transportation of Raw Material and Finished Goods.

Connectivity:

The Project site is well connected with road as well as Rail route.

All the other infrastructural facilities are expected to be adequately available to the Unit.

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4.6 SOIL CLASSIFICATION:

Table – 10: Soil Classification of Dehradun

Sr.

No.

Agro ecological

situation

Characteristics Block covered Altitude

(m) MSL

1. Doon valley Deep soil, Tarai soil,

Irrigated,

Fertile, Clay soil

Doiwala,

Vikas Nagar

250-400

2. Foot hills/ Semi

hills

Sandy to Sandy loam

soil

Vikas Nagar,

Sahaspur

400-600

3. Mid hills Dry soil, Rain fed,

rocky soil

Raipur, Kalsi 600-800

4. High hills Dry soil, Rainfed,

Rocky soil,

Snow fall

Chakrata 1200-

2300

4.7 CLIMATIC DATA:

The Climate of the district is generally temperate. It varies greatly from tropical to severe

cold depending upon the altitude of the area. The district being hilly, temperature variations

due to difference in elevation are considerable. In the hilly regions, the summer is pleasant,

but in the Doon, the heat is often intense, although not to such degree as in the plains of the

adjoining district. The temperature drops below freezing point not only at high altitude but

even at places like Dehradun during the winters, when the higher peaks are also under

snow. The area receives an average annual rainfall of 2073.3 mm. Most of the annual

rainfall in the district is received during the months from June to September, July and

August being rainiest. Climate Data of Doon Valley for all the months is as under on the

basis of mean of last 25 years

Table – 11: Climatic Data of Dehradun (Basis of Mean of Last 25 Years)

Month Rainfall

(mm)

Relative

Humidity

(%)

Temperature Mean (°C)

Max Min Avg

January 46.9 91 19.3 3.6 10.9

February 54.9 83 22.4 5.6 13.3

March 52.4 69 26.2 9.1 17.5

April 21.2 53 32 13.3 22.7

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May 54.2 49 35.3 16.8 25.4

June 230.2 65 34.4 29.4 27.1

July 630.7 86 30.5 22.6 25.1

August 627.4 89 29.7 22.3 25.3

September 261.4 83 29.8 19.7 24.2

October 32.0 74 28.5 13.3 20.5

November 10.9 82 24.8 7.6 15.7

December 2.8 89 21.9 4.0 12.0

Average

Annual

2051.4 76 27.8 13.3 20.0

4.8 SOCIAL INFRASTRUCTURE:

The Project site comes under the Selaqui Industrial Area Dehradun District. Project area

has education, drinking water facilities, transport facilities, School etc.

5.0 PLANNING BRIEF:

5.1 Planning Concept (Type of Industries, Facilities and Transportation etc.) Town

and Country Planning/ Development Authority Classification:






5.2 Population Projection:

Total Manpower engaged during operation of the Poultry feed Plant is 56. Apart from

this, 280 – 300 persons are indirectly benefited by this project during the operation

phase for logistic.

Employment Status:

Sl. No Category No. of Employees



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Total 56

5.3 Land Use:

The Project is over an area of 7542.23 Sq. m there is no forest land was involved in the

project site. The entire land is now in the name of the plant and situated in Selaqui

Industrial area.

Green Belt Development

Local native species suitable for this region are planted in compliance of conditions of

environmental clearance. With a view to attenuate air pollutants, to resist noise propagation

from power generation units and uptake of treated effluent to some extent, the green belt all

around the periphery of project sites and in vacant areas (33% of the total acquired land) is

being developed. Tree plantation has been undertaken in a large scale on land vacated after

cessation of construction activities. Open spaces, where tree plantation is not possible are

planted with flowering herbs and grass which act as soil binders and also helpful in

preventing erosion of topsoil. Existing green belt is being strengthened regularly.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL):

The social infrastructure likes school and Primary Health Centre is developed in this area.

However, the following facilities are installed within the plant site;

a. Electricity supply

b. Water supply

c. Administrative Building, Service Building

d. Construction offices and stores

e. Time and security offices

f. First Aid and firefighting station

g. Canteen

h. Toilets and change rooms

i. Car parks and cycle/ scooter stands

5.4.1 System Design for High Productivity:

The productivity of the Unit and associated auxiliary objectives are achieved by adopting

the following principles;

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Use of equipment and systems of design, performance and high availability which has been

fully established by a considerable record of successful operation for similar service

conditions in all plant facilities. Use of only proven design concepts and conservative

designs. Strict implementation of quality assurance norms during design, manufacture as

well as installation and commissioning stage. Strict compliance with the project company

approved pre-commissioning and commissioning procedures as well as standard checklists

forming a part of commissioning documents for the project.

5.4.2 Sizing of Critical Equipment- Margins & Redundancy/Standby:

Adequate margins are provided while sizing all important auxiliaries and sub-systems to

ensure operation of the Unit at ultimate capacity under the worst conditions and taking into

consideration normal wear & tear.

5.4.3 Design for Efficient Operation:

Centralized maintenance system is followed. All repairs of capital nature, heavy

maintenance jobs, refractory maintenance and plant civil maintenance are done by engaging

specialized external agencies.

Implementation of computer systems including local area network (LAN) with standard

user friendly software’s in the field of financial management, personnel management,

materials management, order scheduling, sales and marketing management, management

information systems (MIS), production planning and control, maintenance and spares

planning, etc. has been considered to increase work efficiency and to reduce manpower

requirement.

5.4.4 Operation Performance Management System (OPMS):

The operation of the plant will be optimized by implementation of OPMS. This system will

clearly define the responsibilities of all key O & M personnel including the shift-in-charge.

This will also cover the system of daily reporting to the project company Corporate Office

and monthly O&M review meetings.

5.4.5 Operation & Maintenance Philosophy:

Most of the key positions in operation and maintenance of the proposed plant at different

categories are manned by the qualified persons having experience in the similar field.

However, depending on the type of equipment /facilities along with the degree of

automation contemplated, the operation and maintenance personnel of the plant so

recruited will require specific need based training which is carried out on site by the

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respective equipment supplier during equipment erection, start up and commissioning of

different plant units.

5.5 AMENITIES/FACILITIES:

5.5.1 In-Plant Facilities:

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and firefighting station

e. Canteen

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training Centre

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in relevant factories act. The above facilities shall also be

adequately furnished and equipped.

5.5.2 Employment Generation:

Total Manpower engaged during operation of the Poultry feed Plant is 56.

Establishment of small and medium scale engineering ancillaries, with cascading

employment opportunities;

Increased revenue to the state by way of taxes and duties;

Improved green cover;

Better communication and transport facilities;

The project has enhanced the prospects of employment. Recruitment for the unskilled

workers for the plant is from the nearby villages. The basic amenities viz. roads,

transportation, electricity, drinking water, proper sanitation, educational institutions,

medical facilities, entertainment, etc. are developed as far as possible.

5.5.3 Peripheral Developmental Activities:

M/s Venky’s (India) Limited has undertaken various activities already made around the

plant as a mark of their Corporate Social Responsibilities viz. Education, Water Supply,

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including Drinking Water, HealthCare, Environment, Social Empowerment and Sports

and Culture.

6.0 PROPOSED INFRASTRUCTURE:

Not Applicable

7.0 REHABILITATION & RESETTLEMENT (R & R) PLAN:

Not Applicable

8.0 PROJECT COST ESTIMATES:

Initiated Project cost was estimated as under:

Table – 12: Cost of Project

Details Rs. in Lakh

Land : 0.00

Building / Shed : 5.00

Plant & Machinery : 65.00

Others : 5.00

Total : 75.00

Means of Finance:

Details Rs. in Lakh

Internal Accrual (Self) : 75.00

Total : 75.00

9.0 ANALYSIS OF PROPOSAL:

Project will create direct & indirect employment opportunities within the surrounding

region. Unit will use good faith efforts to employ local people from the nearby villages

depending upon the availability of skilled & un-skilled man-power surrounding the project

site.

In operation phase, the proposed project would require significant workforce of non-

technical and technical persons. Migration of highly education and skilled experience will

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result in increase of literacy in the surrounding villages. In addition, the proposed project

shall enhance the prospects of employment.

Additional government revenue expected from royalty, taxes, duties and other fees. An

added benefit to the proposed project will result in considerable growth of stimulating the

industrial and commercial activities in the state.

10.0 STORM WATER/SEWER DETAILS:

The Factory Land is small with Plot area of just 7542.23 Sq. m. The open land surrounding

the building is paved with concrete, except for green belt & garden.

Being a small land, there is no storm water drain, as the rain water flows out onto the front

road.

10.1 Sewer Drainage System:

The land has two toilet rooms in front office building for office staff and one toilet rooms for

workers in the rear side of the land. The drainage leads to a septic tank. There is no disposal

of sewage.

10.2 Rain Water Harvesting:

Rainwater harvesting in the present scenario holds vast potential in controlling runoff and

resulting water logging problems besides assuring an alternative source of water and a

supplement to existing natural resources in a wide variety of circumstances.

A rainwater harvesting system comprises components of various stages namely-

Transporting rainwater through pipes or drains.

Filtration

Storage in tanks for reuse or recharge.

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\

Fig – 17: Design of Typical Recharge Pit

Two major systems that are ideal for industrial developed areas of are artificial ground

water recharge, and roof top rainwater harvesting (The mode NBC-2005). The mode of

harvesting are basically site specific and depends the amount of precipitation, availability of

total number of rainy days, nature of storage structures, nature of aquifers etc.

In general CGWB norm suggest not to artificially recharging if water table is less than 05 M.

Also recharging is not recommended for aquifers with TDS levels higher than 4000 mg/L or

high levels of chemical composition like Nitrate, Fluoride, and Arsenic etc.

In this project it has been planned to provide 02 Nos. rainwater harvesting recharge pit

(Trench) and 02 No. rain water harvesting tank. Rainwater collected from the rooftop

would be diverted by drain pipes to a settlement / filtration tank, from which it would flow

into the recharge pit. Water filters would be provided prior to the chamber to arrest and

separate any suspended matter present in the rain water. The recharge pits are designed with

three concentric circular chambers in which the outer chamber is filled with sand, the

middle one with coarse aggregate and the inner most layer with pebbles.

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Fig – 18: Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the unpaved

areas and allowed to get absorbed. Also there would be proper storm water drainage

network to collect the excess storm water runoff.

Rain Water Harvesting (RWH) System Calculation

Based on the area statement, the total roof/surface area receiving the rainfall is as follows:

Total plot Area: 7542.23 m2

Proposed ground coverage area of the unit receiving: 1502 m2

Proposed covered area of the unit: 2055 m2

As per data available, the annual rainfall in Dehradun: 2073.3 mm

Total rainy days in a year: 80 days

Average rainfall per day: 2073.3/80 = 25.91 mm/day

The intensity of rainfall considered is 25.91 mm/hr, (Heavy rain fall) which generally occurs

in one hour (for the purpose of calculations, the higher value of rainfall intensity is being

considered in view of unpredictable nature of rainfall for arriving at total storage volume)

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Therefore, intensity of rainfall: 25.91 mm/hr

RUN-OFF (Discharge)

Q = 10*C*I*A

Where:

Q: run off in cubic meters/hr

C: Co-efficient/Impermeability factor of the surface

I: Intensity of rainfall (25.91 mm/hr)

A: Total drainage area in hectare

Co-efficient of Run off/Impermeability Factor [C]

S. No. Description of Surface Value of run off coefficient

factor of the surface (C)

1. Terraces, Hard paved surfaces 0.9-0.95

2. Paved Surfaces, roads 0.85-0.90

3. Gravel path, loosely paved walk, rocky surface 0.70-0.85

4. Brick paved, Compact ground 0.50-0.70

5. General Ground 0.50-0.60

6. Natural Ground, sloping ground 0.20-0.50

Run Off Calculation:

(i) Run off from ground coverage area of the proposed unit

Q1 = 10*0.8*25.91*1502/10000 (since 1 hectare = 10000 m2)

= 31.13 m3/hr

(ii) Run off from covered area (above mixers) of the propsed unit

Q2 = 10*0.9*25.91*2055/10000

= 47.92 m3/hr

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Total run off discharge (Q): Q1 + Q2 = 31.13 + 47.92 = 79.05 m3/hr

Considering the first flush of rainwater after a dry period shall be allowed to run to waste as

it will be contaminated with dust, bird droppings etc.

Total run off = 0.9 * 79.05 = 71.14 m3/hr

Considering retention storage of rain water harvesting is 30 min

Total capacity of RWH storage: 19.35 *30/60 = 35.57 m3

The total no. of RWH proposed: 2

Capacity of each RWH: 17.78 m3 (approx. 18 kl)

11.0 WASTE WATER MANAGEMENT:

No waste water will generate from the manufacturing process of Poultry feed products.

Only 2.5 KLD of waste water will be generated from Domestic & Floor/ Equipment’s

cleaning, which will be treated through proposed skid mounted STP of 5.0 KLPD capacity.

Treated water shall be further reused into the Green belt development.

11.1 Sewage Treatment Plant (5.0 KLD Capacity):

An external sewage network shall collect the sewage from septic tanks, and pumped to the

proposed sewage treatment plant.

Following are the benefits of providing the Sewage Treatment Plant in the present

circumstances:

Reduced net daily water requirements, source for Horticultural purposes by

utilization of the treated waste water.

Reduced dependence on the public utilities for water supply and sewerage systems.

Sludge generated from the Sewage Treatment Plant shall be rich in organic content

and an excellent fertilizer for horticultural purposes.

a. Waste Water Details:

(a) Daily load : 2.5 KLD

(b) Duration of flow to STP : 24 hours

(c) Temperature : Maximum 32oC

(d) pH : 7 to 9.5

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(e) Colour : Turbid

(f) T.S.S. (mg/l) : 100-400 mg/l

(g) BOD (mg/l) : 200-300 mg/l

(h) COD (mg/l) : 500-700 mg/l

b. Treated Water Characteristics:

(a) pH : 6.5 to 7.5

(b) Oil & Grease : <10 mg/l

(c) B.O.D. : <20 mg/l

(d) C.O.D. : <100 mg/l

(e) Total Suspended Solids : <10 mg/l

c. Treatment Technology:

The technology is based on attached growth aerobic treatment followed by clarification by a

tube settler. Lime will be dosed in for suppression of foaming tendencies. The clarified water

will be filtered in a pressure sand filter after dosing of coagulant (alum) for removal of

unsettled suspended impurities. This water will be passed through an activated carbon filter

for removal of organics. The filtered water from ACF will be utilize in Green Belt.

The attached growth fluidized aerobic bed reactor (FAB) process combines the biological

processes of attached & suspended growth. It combines submerged fixed film with extended

aeration for treatment of the waste water.

The waste water after screening is collected in an equalization tank. The equalization tank is

required for preventing surges in flow & facilitating equalization of characteristics over the

entire quantity of effluent in a given time. A provision for pre-aeration is made in the

equalization tank in order to ensure mixing & to prevent the sewage from going septic.

The equalized sewage is then pumped into the RBC reactor for biological processing. The

water enters the bottom of the reactor & flows up through media which grossly enhances the

hydraulic retention time & provides a large surface area for growth of biological micro –

organisms. The RBC reactor is aerated by fine pore sub – surface diffusers which provide the

oxygen for organic removal. The synthetic media floats on the water & the air agitation

ensures good water to micro-organism contact.

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The RBC treatment is an attached growth type biological treatment process where in, the

majority of biological activity takes place on the surface of the PVC media. Continuous

aeration ensures aerobic activity on the surface of the media. Micro – organisms attach

themselves on the media & grow into dense films of a viscous jelly like nature. Waste water

passes over this film with dissolved organics passing into the bio-film due to concentration

gradients within the film. Suspended particles & colloid may get retained on this sticky

surface where they are decomposed into soluble products. Oxygen from the aeration process

in the waste water provides oxygen for the aerobic reactions at the bio-film surface. Waste

products from the metabolic processes diffuse outward & get carried away by the waste

water or air currents through the voids of the media.

The aerated effluent passes into a tube deck settler for clarification. The theory of gravity

tube settler system is that the carrier fluid maintains laminar flow in the settling media at

specified maximum viscosity. These two parameters of a carrier fluid, flowing through a

hydraulic configuration, will determine the velocity gradients of the flow, the height of

boundary layer at the inclined surface and the residence time within the media.

The carrier fluid must be viscous Newtonian, exhibiting a Reynolds number of less than

1000 and preferably, a number under 400. The laminar flow, through the inclined tubes, will

produce velocity gradients sufficiently large to form an adequate boundary layer, where the

velocity of fluid approaches zero. Boundary layers are necessary in functioning tube settlers,

to allow suspended solids to separate from the viscous carrier fluid. Under gravitational

forces, they will settle to the hydraulic surface of the tube and subsequently from the clarifier

media.

Since the tubes are inclined at 60 degrees, solids settled on the tubes are continually

discharged down. This downward rolling action increases particle contact and hence further

agglomeration, which increases the sludge settle ability. Studies show that these

agglomerated sludge particles can have a settling rate in excess of ten times the settling rate

of the individual floc particles in the influent. These heavy agglomerated masses quickly

slide down the 60 degree inclined tube and settle at the bottom of the tank.

At the bottom of the Tube deck, where the sludge leaves the Tube surface, the larger

agglomerated captures smaller particles in the upcoming stream. This solid contact

phenomenon greatly enhances the capture efficiency.

Stages of Treatment: The treatment process consists of the following stages:

Equalization

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Bio- Degradation

Clarification & Settling

Filtration

11.2 Process Scheme for STP Unit:

The STP treatment process will consist of following stages:

Stage 1: Primary Treatment:

Septic Tank, Screening cum Oil & Grease Trap, Raw sewage septic cum collection sump

(Equalization Tank).

Stage 2: Secondary or biological treatment:

Aeration Tank, Clarifier

Stage 3: Tertiary Treatment:

Supernatant Sump, Pressure Sand Filter Column, Activated Carbon Filter Column, and

Disinfection

Stage 4: Sludge Dewatering:

Filter press with accessories (Mechanical sludge dewatering)

Primary

Treatment

Secondary

Treatment

Tertiary

Treatment

Sludge

Dewatering

PFR





P F R -79

Fig – 19: SCHEMATIC OF PROPOSED STP

Slu

dge

Rec

ycli

ng

De

wat

eri

ng

Dry Sludge

Equalization Tank Multi Stage

Bar Screen Aeration Tank

Clarifier

Sludge

Holding

Tank

Pressure

Sand Filter

Column

Activated

Carbon

filter

Column

Treated Water

Tank

Filter Press Unit

Inlet Sewage

Supernatant

Sump

Reuse in Green

belt

Disinfection

PFR





P F R -80

12.0 AIR / NOISE POLLUTION CONTROL MEASURE:

As Green insulated DG Set will be installed, although an acoustic enclosure will be

provided on the DG Set.

All noise producing equipment are enclosed in Acoustic hoods.

Bag Filter shall be provided to arrest dust from proposed wood fired Boiler. Adequate Stack

height shall be provided as per CPCB Norms.

Ambient air quality and stack emissions will be regularly monitored to ensure ambient air

quality standards.

Dense Green belt is available and being strengthening around the boundary to reduce the

noise escape in surrounding area.

13.0 SOLID WASTE MANAGEMENT:

The solid ingredients grind and mixed in closed manufacturing equipment therefore a little

quantity of solid waste (Approx. 20.0 Kg/day) will be generated during material sampling,

dispensing, handling, production, processing and packing & eventually reuse into process.

Approx. 25.0 Kg/day solid waste will be generated as scrap of Empty sacs, Boxes, Glass

bottles, Plastic Jars, Bottles, and Cans, which will be sold to the respective Dealers.

Ash generated from proposed wood fired Boiler shall be used for landfilling in low lying

areas.

14.0 HAZARDOUS WASTE MANAGEMENT:

There will be no hazardous waste generated during the proposed manufacturing of Poultry

Feed Products except waste / Used Oil from Proposed DG Set, which will be sold to the

authorized recyclers only.

15.0 SAFETY MEASURES:

Company will provided full proof fire hydrant system & all kinds of fire extinguishers to

ensure the safe working environment. The workers shall be provided with face-mask, hand

gloves, moreover the production halls shall be fitted with exhaust fans etc.

The Organization will establish, implement & maintain documented Occupational health &

safety objectives, at relevant functions & levels within the organization and training /

awareness program will be conducted on regular basis.

EC FOR PROPOSED MODERNIZATION OF PALLETIZATION PROCESS OF POULTRY FEED AND



Annexures


ANNEXURE – I




Annexures





Annexures


ANNEXURE – II




Annexures





Annexures


Topographical map of 10 km radius of M/s Venky’s (India) Limited




Annexures


Satellite Image of the Project Site




Annexures


ANNEXURE – III

Site Lay Out Plan




Annexures


ANNEXURE – IV




Annexures





Annexures


ANNEXURE – V


e.g. Vitamins, Minerals, Salts, Pre-Mixes


e.g. Grains, Oilseed meals, Meat & Bone meal


e.g. Grains

WEIGHING / BATCHING

MIXING

PELLETING

COOLING

POST – PELLETING ADDITIONS & MIXING

e.g. Oil, Tallow, Enzymes, Whole grain

BULK LOADING


e.g. Vegetable oils, Tallow,

Feed enzymes

WEIGHING




Annexures


ANNEXURE - VI

WATER BALANCE:

Total water requirement – 21.00 KLD



Domestic (KLD) 2.50 0.50 0.00 *2.00


Washing etc. (KLD)

0.50 0.00 0.00 *0.50


Note:



Skid mounted STP of 5.0 KLPD capacity is proposed to treat the domestic sewage &

other waste water. Treated water shall be further reused into the Green belt

development.




Annexures


ANNEXURE – VII




Annexures


DISCLOSURE OF CONSULTANTS ENGAGED

INTRODUCTION

India Glycols Limited (IGL) is a leading Company that manufactures Green technology based Bulk,

Specialty and Performance Chemicals and Natural Gums, Spirit, Industrial Gases, Sugar and

Nutraceuticals. India Glycols Limited (IGL) is a Company with three sister concerns located in Uttar

Pradesh & Uttarakhand, with Corporate Office at A – 1, Industrial Area, Bazpur Road, Kashipur –

244713, District Udham Singh Nagar (Uttarakhand) and Head Office at Plot No. 2 – B, Sector – 126,

Noida – 201304, District Gautam Budh Nagar, Uttar Pradesh.

Besides this, India Glycols Limited (IGL) has spread their work towards Environmental Consultancy

Services. A number of EIA studies carried by India Glycols Limited (IGL) in various sectors viz.

Industrial Projects, Chemical Industries, Thermal Power Plants, Sugar & Distilleries and Mining Projects.

India Glycols Limited (IGL) is also offering the consultancy services for Environmental Monitoring,

NOC / Consent, Environmental Report, Risk Assessment and Disaster Management Plan, Consultancy for

Rain Water Harvesting, Preparation of Environmental Statement Reports (Environmental Clearance

Condition wise Compliances), etc.

As Head of Environment Management Division, Dr. Ashutosh Gautam, Doctor of Philosophy from the

H. N. B. Garhwal University, Srinagar, Uttarakhand has a vast experience in the field of ETP, STP

Designing & Operation, Distillery Operation, Sugar and Power Plant operation & Mining Sector. Dr.

Gautam has more than 15 EIA studies in his account for various Projects.

EIA TEAM:

India Glycols Limited has highly qualified experts, constituting Environment Management Division as

are under:

Sr. No. Name Qualification

1. Dr. Ashutosh Gautam Doctor of Philosophy from the H. N. B. Garhwal University,

Srinagar, Uttarakhand

2. Mr. Shashikant Sharma M.Sc. Botany from Meerut University Meerut, U.P.

3. Mr. A.K. Shahi B.Sc. from the University of Allahabad, U.P.

4. Mr. J. K. Jawla M.Sc. Botany from CCS University Meerut

PG Degree in Environmental Science & Engineering from

VSI Pune (MH)

5. Mr. Pankaj Kumar B.Sc. from CCS University Meerut

PG Degree in Environmental Science & Engineering from

VSI Pune (MH)

6. Mr. Sunil Kumar Sharma Graduation from Kumaon University Nainital, Uttarakhand

MBA from U.P. Technical University, Lucknow, U.P.

7. Mr. Rahul Kumar B.SC. from M. J. P. Rohilkhand University Bareilly, U.P.

MBA from Uttarakhand Technical University, Roorkee,

Uttarakhand.

8. Dr. Chakresh Pathak MSc. , Ph.D. (Environment) – Environmental Science from

Gurukula Kangri University, Haridwar, Uttarakhand

9. Mr. Pradeep Pathak Graduation from Kumaun University, Nainital.

AUTHORIZATION LETTER

January 5, 2017

M/s Venky’s (India) Limited wish to authorize M/s India Glycols Ltd. A – 1 Industrial area

Bazpur road, Kashipur, District Udham Singh Nagar, Uttarakhand to undertake all the

proceeding of Environmental Clearance of Proposed Modernization of Mash Poultry Feed to

Pelletization and Installation of wood fired boiler of 750kg per hour capacity & DG set (250.0

KVA x 02 Nos. Standby arrangement) at Khasra no. 1050/1, Central Hope Town, Camp Road,

Selaqui Industrial Area, Dehradun, Uttarakhand under Environmental Consultancy Services.

Thanking you,

Sincerely yours,



UNDERTAKING

January 5, 2017

M/s Venky’s (India) Limited give this undertaking that all the pertinent Documents for Proposed

Modernization of Mash Poultry Feed to Pelletization and Installation of wood fired boiler of

750kg per hour capacity & DG set (250.0 KVA x 02 Nos. Standby arrangement) at Khasra no.

1050/1, Central Hope Town, Camp Road, Selaqui Industrial Area, Dehradun, Uttarakhand have

been submitted & The Data & information presented in this Report are factually correct & based

on the Documents given by us.

I also confirm that I shall be fully accountable for any mis-leading information mentioned in this

Statement.

Thanking you,

Sincerely yours,



Ref: Venkys/EC/2017/01-01 Dated: 05/01/2017...

Documents

Transcript of Ref: Venkys/EC/2017/01-01 Dated: 05/01/2017...