PRE - FEASIBILITY REPORT · 2018. 12. 4. · 1 Electricity Requirement – Contract Demand 1200 KVA 2068 KVA (1000 KVA + 1068 KVA) ... As a global manufacturer of pharmaceuticals,

1

PRE - FEASIBILITY REPORT

for

PROPOSED EXPANSION OF DISTILLERY UNIT

of

M/s. LUNA CHEMICALS IND. PVT. LTD.

R.S. NO. 86, VILLAGE: ASNAD,

TAL: OLPAD, DIST: SURAT-393001,

(Guj.)

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

2

CONTENTS

Sr.

No.

Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 5

3. Project Description 8

4. Site Analysis 13

5. Planning Brief 15

6. Proposed Infrastructure 16

7. Rehabilitation and resettlement (R & R) Plan 17

8. Project Schedule & Cost Estimates 17

9. Analysis of Proposal (Final Recommendations) 18

3

1.0 EXECUTIVE SUMMARY

1.1 Project Details

1.1.1 Products along with Production Capacity

Quantity (MT/Month) Sr.

No.

Name of the

Products

CAS No.

Existing Additional Total

End-use of

Product

1. Rectified Spirit /

Ethanol –

Industrial

Alcohol

64-17-5 90 KL/day 90 KL/day 180 KL/day Raw Material for

Petroleum,

Pesticide

Industries.

2. Fusel Oil 8013-75-0 900 Lit/Day 900 Lit/Day 1800 Lit/Day --

3. Bio Fertilizer -- 1500

MT/Month

1500

MT/Month

3000

MT/Month

As a Fertilizer

4. Ethyl Acetate 141-78-6 0 300

MT/Day

300

MT/Day

Paints, Varnish &

as a Pharma

Intermediate

1.2 Water Requirement, Waste Water Generation and Treatment

Total water requirement will be 2253 KL/Day (Existing: 713 KL/Day + Additional: 1540 KL/Day) out of

which (Industrial: 2216 KL/Day + Domestic: 10 KL/Day + Gardening: 27 KL/Day), out of which Fresh

Water will be 1116 KL/Day (which shall be met through Kakrapar Right Bank Canal) and remaining 1137

KL/Day will be recycled water which shall be reused back in Utilities, Process as well as Gardening. Total

wastewater generation will be 1355 KL/Day (Existing: 471 KL/Day + Additional Proposed: 884 KL/Day)

out of which (Industrial: 1346 KL/Day + Domestic: 9 KL/Day).

Industrial wastewater generation will be 1346 KL/Day (Industrial: 1346 KL/Day + Domestic: 9 KL/Day).

Industrial wastewater shall be given Bio-Methanation Treatment followed by ETP & MEE and ultimately

condensate will be recycled/ reused in Plant Utilities (720 KL/Day), Process (407 KL/Day) as well as

Gardening (10 KL/Day). Domestic wastewater generation will be 9 KL/Day which shall be disposed in

Septic tank & Soak Pit.

1.3 Air Pollution Source and Control Management

There will be emissions from Flue gas Stacks like Dual Fired Boiler (Thermic Fluid Heater), Dual Fired

Boiler (Thermic Fluid Heater = 40 Lac Kcal/Hr x 2), Dual Fired Boiler 32 Lac Kcal/Hr x 2 (MEE) & D.G. Sets

(750 KVA, 380 KVA, 500 KVA, 1250 KVA & 1500 KVA). Multi Cyclone Separator will be provided to control

Air Pollution.

4

1.4 Hazardous Waste

Quantity Sr.

No.

Type/Name

of Hazardous

waste

Source of

generation

Category and

Schedule as

per HW Rules


Disposal Method

1 Used Oil Machineries Sch I-5.1 40

Lit/Year

80

Lit/Year

120

Lit/Year

Collection, Storage,

Transportation and disposal

by selling to registered

refiners.

2 Discarded

barrels/

containers/

liners

Production

Plant

Sch I-33.1 0.167

MT/Annum

0.167

MT/Annum

0.334

MT/Annum

Collection, Storage,

Transportation and disposal to

authorized decontaminator

3 ETP Sludge ETP Sch I-35.3 30

MT/Day

30

MT/Day

60

MT/Day

Bio composting within plant

premises

4 MEE Salt MEE Sch I-37.3 82

MT/Day

60

MT/Day

142

MT/day

Bio composting within plant

premises

1.5 Green Belts

Total 2,27,676 m2

land area is available at site; out of this 75,000 m2 (Existing = 22,500 m

2 + Additional

Proposed = 52,500 m2) (i.e. approx 32.94 % of total area) will be developed as greenbelt and other forms

of greenery.

1.6 Power & Fuel Requirements

TOTAL POWER REQUIREMENT

Note: DG Set will be kept for emergency power back up.

DETAILS ON FUEL & SOURCE

Sr.

No.

Type of Fuel Existing Additional Total Requirement

1 Coal/ Lignite 14.8 MT/Day 79.8 MT/Day 94.6 MT/Day

2 Diesel 276 Lit/Hr 350 Lit/Hr 626 Lit/Hr

3 Gas 38000 m3/day 38000 m

3/day 76000 m

3/day

Requirement Sr.

No.

Description


Source

1 Electricity Requirement

– Contract Demand

1200 KVA 2068 KVA

(1000 KVA + 1068 KVA)

3268 KVA DGVCL

2 D.G. Set 750 KVA

380 KVA

500 KVA

1250 KVA

1500 KVA

4380 KVA --

5

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

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

lease/letter of intent should be given.

Identification of the project

RLG Group began its journey in 1974, when the company was established and formed by Sh. Ram Lal

Goyal as a Plasticizer manufacturing company. Today, the company has grown into a large & dynamic

business house, which currently occupies a leading position in the field of Chemical Manufacturing,

Pharmaceutical’s Manufacturing, Power Plant, Marketing & Exports in the Domestic as well as the

International Market. The corporation also includes hard work & dedication by Mr. Raman Goyal, and

Mr. Rahul Goyal.

As a global manufacturer of pharmaceuticals, chemicals & power the vision and leadership of those at

the helm is critical to success. The team of approx 800 people (as counted in the year 2015), comprises

of skilled and experienced professionals, who are technically sound and enterprising. Foreseeing the

standards that would be expected for manufacturing of world class quality, they implement the same

ahead of time. It is because of this focused dedication and hard work that RLG had accounted total

revenue of 60 Million Dollars in the year 2014-15.

The team in the organization has been carefully handpicked to provide right mix of diverse skills that

complement each other. Under the guidance of RLG’ management, the technical team and support

personnel have achieved exceptional levels of productivity and success in product development, quality

control, quality assurance and all aspects of business and operations.

The Corporate Headquarters at New Delhi, India, houses capable staff that is thoroughly dedicated in

understanding the requirements of RLG’s partners and provides realistic customer solutions. With this

balanced mix of young dynamism and experienced perspective, the company has unfurled its flag across

the globe and is doggedly stepping into new territories, widening the customer across the globe.

Over a period of years, RLG has grown as a company and achieved greater heights. Today, the business

has 9 state-of-the-art manufacturing facilities which includes chemical manufacturing units for

production of Acetic Anhydride, Monochloro Acetic Acid, Acetanilide Flakes, Power Alcohol, Aniline Oil,

and Nitro Benzene.

The group has around 50% market share of total production of Acetic Anhydride in India and is one of

the top 10 manufacturers of Acetanilide Flakes in the world. The group has a combined Cycle Power

Plant of 225 MW at Kashipur is the 1st Gas Based power Plant of Uttrakhandand is one of the leading

power supplier to Uttrakhand government, the power plant cost about Rs. 850.00 cr.

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The Board of Directors of the Company are very experienced industrialists, they are:

Sr. No. Name of Directors Residential Address & Phone Nos. CONTACT NO.

1. OM PRAKASH

AGGARWAL

C-122, Mahendra Enclave

Azadpur, Delhi : 110033 0265-2326673

2. SOBH NATH VIBHUTI

SHUKLA

B/15, GIDC Colony

Nandesari, Baroda : 391320 0265-2326673

3 SATPAL SINGH

DHANDA

A4, Jaganath Puram

Refinery Road

Gorwa, Baroda : 390016

0265-2326673

2.2 Brief description of nature of the Project

Proposed Expansion of Distillery Unit.

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

Molasses is a raw material for production of alcohol which gains importance for its use as a fuel in

admixture with petrol, as main ingredients in beverages and as a starting raw material for various

organic chemicals. Molasses is a renewable resource and dispense the use of petroleum for fuel and

organic chemicals. Alcohol has assumed very important place in the country economy. It is vital raw

material for a number of chemicals. It has been a source of large amount of revenue by way of excise

duty levied by state government. Ethanol has a potentiality as fuel in the form of “power alcohol” for

blending with petrol in the ratio of 10:90. This trend is continuing and will continue in the view of the

fact that potable liquor has larger revenue generating potential for the governments. The demand for

alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will

enhance the demand for alcohol. Other than the above mention major requirement, alcohol is also

being used in the production of many downstream chemicals including drugs, polymers, plastic. The

proposed expansion project will create additional employment opportunities in terms of factory

employment, transportation, petty shops etc.

2.4 Demands-Supply Gap

Based on their informal survey of the market with their current customers and various traders, they

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

will be an addition to the current range of their products.

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2.5 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials will make them very competitive against

imported finished products and they will be able to increase the export of their finished products.

2.6 Export possibility

We shall explore the possibility to export the products.

2.7 Domestic/Export Markets

Majority of the products will be used for domestic market and some products will be exported

depending on the international market.

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

M/s. Luna Chemicals Ind. Pvt. Ltd. will give direct employment to (Direct 25 & Indirect 15) local people

based on qualification and requirement. In addition to direct employment, indirect employment shall

generate ancillary business to some extent for the local population.

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3.0 Project Description

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

No interlinked project has been submitted.

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

layout) with coordinates.

Map showing general location

9

Google map: Specific location and project boundary

10

Plot Layout

11

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

environmental considerations gone into should be highlighted.

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

Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free from cultivation

Availability of power evacuation facilities

Availability of surface water for industrial use

Modern infrastructure support and amenities at par with nearest city in global markets, including:

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

Environment-friendly zone.

Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer Section-1.1.1, Page No. 3

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

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

Please refer Please refer Form-I, Annexure-III.

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

product/s, mode of transport of raw material and Finished product.

For raw material required along with quantity; Please refer Form-I, Annexure-III. Majority of the

products will be used for domestic market and some products will be exported depending on the

international market.

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

outlined.

Industrial wastewater generation will be 1346 KL/Day (Industrial: 1346 KL/Day + Domestic: 9 KL/Day).

Industrial wastewater shall be given Bio-Methanation Treatment followed by ETP & MEE and ultimately

condensate (1137 KL/Day) will be recycled/reused in Plant Utilities (720 KL/Day), Process (407 KL/Day)

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as well as Gardening (10 KL/Day). Domestic wastewater generation will be 9 KL/Day which shall be

disposed in Septic tank & Soak Pit.

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

Water Source

Total water requirement shall be met through Kakrapar Right Bank Canal.

Power & Fuel Requirement

TOTAL POWER REQUIREMENT

Note: DG Set will be kept for emergency power back up.

DETAILS ON FUEL & SOURCE

Sr.

No.

Type of Fuel Existing Additional

Proposed

Total Requirement

1 Coal/ Lignite 14.8 MT/Day 79.8 MT/Day 94.6 MT/Day

2 Diesel 276 Lit/Hr 350 Lit/Hr 626 Lit/Hr

3 Gas 38000 m3/day 38000 m

3/day 76000 m

3/day

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal.

Please refer Please refer Form-I, Annexure-V.

Requirement Sr.

No.

Description


Source

1 Electricity Requirement

– Contract Demand

1200 KVA 2068 KVA

(1000 KVA + 1068 KVA)

3268 KVA DGVCL

2 D.G. Set 750 KVA

380 KVA

500 KVA

1250 KVA

1500 KVA

2750 KVA --

13

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

4.0 Site Analysis

4.1 Connectivity


Availability of fuel, water, power, etc.

4.2 Land Form, Land Use and Land Ownership

AREA (SQ. MT.) SR.

NO.

LAND USE

Existing Proposed Total

1 Production Plants 2331.00 2000.00 4331.00

2 Parking 99.30 - 99.30

3 Security Building 53.40 - 53.40

4 Effluent Treatment plant 19369.90 1000.00 20369.90

5 Utility 2426.90 500.00 2926.90

6 Raw Material and Finished Products Storage 8035.75 - 8035.75

7 Gas Tonner Storage 405.00 - 405.00

8 Tank Farm Area 4900.00 500.00 5400.00

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS

& BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH

LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT.

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED EXPANSION

PLANT

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT,

GREEN BELT DEVELOPMENT MONITORING PROGRAM

RISK ANALYSIS

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY

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

PREPARATION OF DISASTER MANAGEMENT PLAN

14

9 Green Belt 22500.00 52500.00 75000.00

10 Road 14800.00 - 14800.00

11 Open Area 96254.75 - 96254.75

Total 171176.00 56500.00 227676.00

4.3 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under

CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park,

wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of

the notified industrial area, a copy of the Gazette notification should be given.

4.4 Existing Infrastructure

AREA (SQ. MT.) SR.

NO.

LAND USE

Existing Proposed Total

1 Production Plants 2331.00 2000.00 4331.00

2 Parking 99.30 - 99.30

3 Security Building 53.40 - 53.40

4 Effluent Treatment plant 19369.90 1000.00 20369.90

5 Utility 2426.90 500.00 2926.90

6 Raw Material and Finished Products Storage 8035.75 - 8035.75

7 Gas Tonner Storage 405.00 - 405.00

8 Tank Farm Area 4900.00 500.00 5400.00

9 Green Belt 22500.00 52500.00 75000.00

10 Road 14800.00 - 14800.00

11 Open Area 96254.75 - 96254.75

Total 171176.00 56500.00 227676.00

4.5 Soil Classification

It will be incorporated in the EIA Report.

15

4.6 Climatic data from secondary sources.

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

Ahmedabad.

4.7 Social infrastructure available.

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

5.0 Planning Brief

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

planning/Development authority classification.

Type of Industry: Proposed Expansion of Distillery Unit.

5.2 Population Projection


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

Total 2,27,676 m2

land area is available at site; out of this 75,000 m2 (Existing = 22,500 m

2 + Additional

Proposed = 52,500 m2) (i.e. approx 32.94% of total area) will be developed as greenbelt and other forms

of greenery.

5.4 Assessment of Infrastructure Demand (Physical & Social)

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

for the proposed expansion project activity.

Social Welfare

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

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

5.5 Amenities/Facilities


16

6.0 Proposed Infrastructure

Depending on the growth of the company the required infrastructure will be developed within premises

as well as region.

6.1 Green Belt

M/s. Luna Chemicals India Pvt. Ltd. shall develop an effective green belt within the factory and on

periphery of the factory. Total 2,27,676 m2

land area is available at site; out of this 75,000 m2 (Existing =

22500 m2

+ Additional Proposed = 52500 m2) (i.e. approx 32.94% of total area) will be developed as

greenbelt and other forms of greenery.

6.2 Social Infrastructure

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

6.3 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways, etc.)

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

Already existing operating unit


Proximity to Raw Material suppliers

Availability of sufficient land free from cultivation

Availability of power evacuation facilities

Availability of surface water for industrial use

6.4 Drinking water Management (Source & Supply of water)

Total water requirement shall be met through Kakrapar Right Bank Canal.

6.5 Sewerage System

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

wastes from the offices, canteen and domestic waste coming from different section of industry.

6.6 Solid Waste Management

Please refer Form-I, Annexure-V.

17

6.7 Power Requirement & Supply/Source

Please refer Section 3.8, Page No. 11 of this report.

7.0 Rehabilitation and Resettlement (R & R) Plan

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

oustees and landless laborers (a brief outline to be given)

There is no habitation on the proposed project area and it is open industrial land within premises, so

that R & R policy is not applicable to this project. There shall not be displacement of any population in

project area. Any major activity that may lead to resettlement of the people is considered as permanent

impact. Hence, there is no permanent impact on this account. The increasing industrial activity will

boost the commercial and economical status of the locality up to some extent.

8. Project Schedule & Cost Estimates

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

be given).

We shall start construction of the project after getting EC and CTE.

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

Total Project Cost for Proposed Project will be Rs. 5918.66 Lakhs (Existing = Rs. 1918.66 Lakhs +

Additional Proposed = Rs. 4000 Lakhs). Cost for EMS will be Rs. 1493.10 Lakhs (included in Project Cost)

(Existing = Rs. 493.10 Lakhs + Additional Proposed = Rs. 1000 Lakhs). Recurring Cost for EMS will be Rs.

125 Lakhs/ Annum.

BREAK-UP PROJECT COST

Estimated Cost (Rs. in Lakhs) Sr.

No.

Particulars


1 Land and Site Development 215.50 200 415.50

2 Building 193.43 300 493.43

3 Plant and Machineries 1016.63 2500 3516.63

4 Environment protection measures (includes cost of ETP, Tree

Plantation, Evaporator System and Rain Water Harvesting etc.)

493.10 1000 1493.10

TOTAL 1918.66 4000 5918.66

18

EMS Cost & Recurring Cost/Annum to be given for EMS

S. No. Description Capital Cost

(Rs. in Lakhs)

Recurring Cost

(Rs. in Lakhs)

1. Air Pollution Control 470 5

2. Water Pollution Control 320 105

3. Solid waste Management 50 1

4. Environmental Monitoring and Management -- 10

5. Rainwater Harvesting 100 1

6. Occupational Health 40 2

7. Greenbelt Development 20 1

Total 1000 125

9. Analysis of Proposal (Final Recommendations)

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

tribal population, if any, in the area.

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

for the proposed expansion project.

Social Welfare activities shall be done.

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

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

Documents

PRE - FEASIBILITY REPORT · 2018. 12. 4. · 1 Electricity Requirement – Contract Demand 1200 KVA 2068 KVA (1000 KVA + 1068 KVA) ... As a global manufacturer of pharmaceuticals,