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PrefeasibilityReport–M/s.Aarav Fragrances & Flavors Pvt Ltd

PREFEASIBILITY REPORT

“Expansion of Existing Production Capacity for Fragrances, Flavors &

Manufacturing Chemicals”

By

Aarav Fragrances & FlavorsPvt. Ltd.

Gut No 167, 169, 170, 171, 296, Village. Jamghar -Lakhamapur,

Tal. Wada, District: Thane, Maharashtra

2

Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.

Synopsis

1. Introduction

2. Justification

3. Location

4. Recourses

5. Process

6. Pollution Control

7. Background Study

8. Safety

9. Benefits

10. EIA structure

3


1. Introduction M/s Aarav Fragrances and Flavors Pvt Ltd are desirous to expand to manufacture new products having either raw

material synergy or superior quality and technology to meet demands in India as well as for further producing the

fragrance and flavors at Aarav Fragrances and FlavorsPvt Ltd, Gut No 167,169,170,171,296,Vill. Jamghar -

Lakhamapur, Tal. Wada, District: Thane, Maharashtra

The existing industrial unit is only manufacturing facility for Fragrances and Flavors. The industry now proposes

to enhance the manufacturing capacity of the present Fragrances & Flavors, and further the it is proposed to add

additional capacity to manufacture the chemicals that could be used in house as well as cater to the open Market,

this will reduce the costs of the fragrances and flavors and make them more competitive in the Indian as well as

export markets. Indian and worldwide demand for fragrances, flavors, perfumery chemicals and related specialty

chemicals is increasing steadily.

2. Justification The Indian consumer industry is one of the world’s largest by volume and is likely to lead the manufacturing sector

of India. Several private sector projects with huge amount of investments have been initiated but could not

attend the speed of development for the need of good quality material. Over the last decade, there has been a

sizeable growth in fragrances and flavors sector both in small, medium and large scale units. This has given rise

to many small and medium scale units. There is an ever growing requirement of the consumers in India

and also the world markets. Thus there is a gap in demand and supply. Our efforts of generating products, by-

products, downstream products and recycling - reprocessing are indeed needed. With multinational fragrance and

flavor companies enhancing their presence in India, the long-term prospects of the fragrances and flavors industry

seems verybright. The intermediates proposed will substitute imports and compliment the products in terms of

costs.

The fate of industrialization depends on the proper and effective conjugation of large and medium/small scale

industries each supporting each other in their requirement to bridge the gap between demand and supply. In order

to be competitive in the global market this synergy between large & medium/small scale industries is a prerogative.

Therefore considering the above, large companies do require the help of small units to support them, the main

target is to give the consumer superior quality products at a competitive price. In addition, it is also examined

whether industry had made compliances expected in

Consent to Operate by MPCB for existing production. S.No. Condition Compliance

1 Addressstatus Continuousthesamenochange

2 No. &Validity Validtill30.09.2015

3 Productsize Sr.no. Product Capacity

(TPM)

1 Fragrance/Perfumes &

Flavors

70

4 Waste water

quantity

8.5m3/dpermitted.

5 Waste

waterTreatment

Foundinlimit

6 ECE Presently NA

7 LDAR Leakdetection&repairprogramwith

monitoringprotocolundertakenas consented.No–

towardincident reported.Work zoneambiancecognizes

8 Hazardouswaste MembershipofCHWTSDF to be obtained

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3. Proposal:The Industryproposedtoproduceasunder:

Sr

No

Products Present

MT /M

Proposed

MT/M

Total

MT/M

Field Of Application

1. Fragrances/Perfumes & Flavors 70 210 280 Fragrances & Flavors

2.

Perfumery& Flavor Esters by hot esterification/

addition of organic acid into olefin/ trans

esterification/ reacting alkali halide with sodium

salt of corresponding acid/Cold Esterification -

Ethyl Esters/ Esterification by reaction of

alcohols with anhydride/ Perfumery Esters by

Darzen Condensation

00

300

300

Fragrances & Flavors

3

Perfumery & Flavor Alcohol by Grignard

reaction / by reduction of aldehyde, or ketone by

hydrogen & Reducing Agents / by addition of

water into olefins / by saponification of

esters/Perfumery Compounds by Ring

Reduction

00 Fragrances & Flavors

4

Perfumery & Flavor Aldehyde by ester /

epoxide rearrangement/ dehydrogenation of

alcohols/ reduction of acids/ aldol

condensation& derivatives


5 Dimerization and Trimerization of simple

olefins. 00 Fragrances & Flavors

6 Ketals / Acetals / substituted 1,3-propanediols 00 Fragrances & Flavors

7

Macro cyclic and polycyclic musks derived

from propylene or butadiene and other

propylene derivatives


8 Aldehydes & Ketones by Aldol Condensation 00 Fragrances & Flavors

9 Acetylene and other alkyne derivatives 00 Fragrances & Flavors

10

Cyclo Alkylation/Acetylation ,Diel Alders

Reactions : Cyclization Reaction, Etherification

of Alkyl Halide and Alcohol, Epoxidation of

Alkenes /Friedel Craft Reactions


11 Hydrogenation 00 Fragrances & Flavors

12 Inorganic Salts 00 50 50 Side Stream Products

Total 630

From the list of ProductsSrNos 2 to11 only two to three products will be manufactured simultaneously. The total

quantities to produce for Products Sr No 2 to 11 willbe for any one or all cumulatively up to 300MT

Since many of the products planned are either forward integration or corollary to a known manufacturing process.

The above mentioned process based chemicals are important chemicals in the vast field of fragrances and flavors

where many such routed chemicals are required to make a fragrances and flavors. None of these chemicals are

banned for production in developed countries nor is banned for use. The chemicals produced have the following

merits:

- Import /Cost Substitution

- Minimizepollutantsatsource

- Maximizerecycle of recovered RMs and Water

- Treatto MPCBnorms

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General formulas limited to groups of manufacture

Sr

No Products

General Reaction(s) Field Of Application

1. Fragrances/Perfumes & Flavors Formulation Fragrances& Flavors.

2.

Perfumery& Flavors Esters by

hot esterification/ addition of

organic acid into olefin/ trans

esterification/ reacting alkali

halide with sodium salt of

corresponding acid/Cold

Esterification -Ethyl Esters/

Esterification by reaction of

alcohols with anhydride/

Perfumery Esters by Darzen

Condensation


3

Perfumery& Flavors Alcohol

by Grignard reaction / by

reduction of aldehyde, or

ketone by hydrogen &

Reducing Agents / by addition

of water into olefins / by

saponification of

esters/Perfumery Compounds

by Ring Reduction


4

Perfumery &FlavorsAldehyde

by ester / epoxide

rearrangement/

dehydrogenation of alcohols/

reduction of acids/ aldol

condensation and Derivatives


5

Dimerization and Trimerization

of simple olefins.


6

Ketals / Acetals / substituted

1,3-propanediols


7

Macrocyclic and polycyclic

musks derived from propylene

or butadiene/and other

propylene Derivatives


8

Aldehydes & ketones by

Condensation with vinyl ether


9

Acetylene and other alkyne

derivatives

RC≡CR + R'C≡CR' 2 RC≡CR'


6


10

Cyclo Alkylation Reactions

/Acetylation ,Diel Alders

Reactions : Cyclization

Reaction, Etherification of

Alkyl Halide and Alcohol,

Epoxidation of Alkenes/Friedel

Craft Reactions

3.


11

Hydrogenation


12

Inorganic Salts

NaCl, AlCl3, MgCl.HSO4, KCl, BaSO4

Inorganic Salts Side Stream Products

Total

From the list of Products SrNo 2 to11 only two to three products will be manufactured simultaneously. The total

quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT

List of Raw Materials and Source:

The list of raw materials along with monthly consumption is given in table, However there will be only 2-3 products

being manufactured at the same time hence the requirement of the raw materials will be low, however the below

raw material quantities are reflected based on single product manufacturing.

Sr.

No.

Raw Material Required Consumption

in MT /M

1 Acetic Acid Glacial 182.00

2 Acetic Anhydride 53.00

3 Acid Catalyst 17.00

4 Aldehyde 85.00

5 Caryophellene 4.00

6 Phase transfer Catalyst 1.10

7 Caustic lye 1.04

8 Citronellol 17.03

9 Benzylledene Acetone 105.00

10 D’limonene/Orange Terpenes 98.00

11 Di Ethanol Amine 1.00

12 Dicyclopentadiene 240.00

13 Ethyl Chloro Acetate 22.05

14 Benzyl chloride 27.60

15 Halide (Pentyl Bromide/ Chloride) 106.00

16 HCL 45% 1.00

17 Iodine 0.05

18 Iso Amyl Alcohol 10.00

19 Isobutyric Acid 60.00

20 Methanol 15.00

21 Methyl Heptanone 69.00

22 Methyl Magnesium Bromide /

Chloride

31.61

23 Hexyl Alcohol 52.00

24 Mg Turnings 12.74

25 Pentanol mixture 77.14

26 Propionic Acid 46.00

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27 Salicylic Acid 160.00

28 Soda Ash 12.24

29 Sodium Acetate 21.30

30 Sodium Methoxide 15.00

31 Sulphuric Acid 10.00

32 Terpineol 68.18

33 Tetra hydro Furon 200.00

34 Toluene 28.03

35 Sodium salicylate 35.70

36 Zn Chloride 0.52

37 Propylene 5.00

38 Acetylene 5.00

39 Hydrogen 6.00

40 Benzaldehyde 100.00

41 N Pentanol 96.00

42 Propionaldehyde 142.00

43 Pthalic Acid 5.00

44 Vinyl Ethyl Ether 5.00

45 Sodium Hydride 5.00

46 Aluminum Trichloride 5.00

47 Di Chloro Methane 5.00

48 N Butyl Aldehyde 5.00

49 Tertiary Butyl Methyl Ether 5.00

50 N ,O Dimethyl Hydroxyl Amine

Hydrochloride

5.00

51 Geraniol 5.00

52 Linalool 5.00

53 Meta Chloro Pre Benzoic Acid 5.00

54 1 Phenyl Ethanol ( Styrallyl

Alcohol)

5.00

55 Furan 5.00

56 Allyl Alcohol 5.00

57 Aroma & Flavor Ingredients For

Formulation

80.00

Source:

Raw material will be sourced locally and also from countries like Japan, USA and Germany.

Sr.

No

Raw Material Quantity

in MT/M

Storage

At a

time

during

the

month

Physical

Form

Stored In MOC

1 Acetic Acid Glacial 182.00 10.00 Liquid Tank SS304

2 Acetic Anhydride 53.00 4.00 Liquid Drums HDPE

3 Acid Catalyst 17.00 2.00 Liquid Carboy/ Drums HDPE

4 Aldehyde 85.00 6.00 Liquid Drums HDPE

5 Caryophellene 4.00 1.00 Liquid Drums GI

6 Phase transfer

Catalyst

1.10 0.10 Liquid Drum HDPE

7 Caustic lye 1.04 1.00 Liquid Carboy HDPE

8


8 Citronellol 17.03 2.00 Liquid Drums MS Epoxy

9 Benzylledene

Acetone

105.00 10.00 Liquid Drums GI

10 D’limonene/Orange

Terpenes

98.00 10.00 Liquid Drums MS Epoxy

11 Di Ethanol Amine 1.00 1.00 Liquid Drums MS Epoxy

12 Dicyclopentadiene 240.00 20.00 Liquid Tank SS304

13 Ethyl Chloro Acetate 22.05 5.00 Liquid Drums HDPE

14 Benzyl chloride 27.60 2.50 Liquid Drums HDPE

15 Halide (Pentyl

Bromide/ Chloride)

106.00 10.00 Liquid Drums HDPE

16 HCL 45% 1.00 1.00 Liquid Carboys HDPE

17 Iodine 0.05 0.05 Solid Can GI

18 Iso Amyl Alcohol 10.00 2.00 Liquid Drums HDPE

19 Isobutyric Acid 60.00 10.00 Liquid Drums HDPE

20 Methanol 15.00 3.00 Liquid Drums MS

21 Methyl Heptanone 69.00 10.00 Liquid Drums HDPE

22 Methyl Magnesium

Bromide / Chloride

31.61 2.50 Liquid Drums MS

23 Hexyl Alcohol 52.00 2.80 Liquid Drums MS Epoxy

24 Mg Turnings 12.74 2.00 Solid Bags PP

25 Pentanol mixture 77.14 20.00 Liquid Tanks MS

26 Propionic Acid 46.00 5.00 Liquid Drums HDPE

27 Salicylic Acid 160.00 16.00 Solid Bags PP

28 Soda Ash 12.24 2.00 Solid Bags PP

29 Sodium Acetate 21.30 2.20 Solid Bags PP

30 Sodium Methoxide 15.00 2.00 Solid Can GI

31 Sulphuric Acid 10.00 1.20 Liquid Carboys HDPE

32 Terpineol 68.18 5.00 Liquid Drums GI

33 Tetra hydro Furon 200.00 6.00 Liquid Drums MS

34 Toluene 28.03 3.00 Liquid Drums MS

35 Sodium salicylate 35.70 3.50 Solid Containers HDPE

36 Zn Chloride 0.52 0.05 Solid Can GI

37 Propylene 5.00 1.00 Gas Capsules SS304

38 Acetylene 5.00 1.00 Gas Capsules SS304

39 Hydrogen 6.00 1.00 Gas Capsules SS304

40 Benzaldehyde 100.00 10.00 Liquid Drums MS

41 N Pentanol 96.00 10.00 Liquid Drums MS

42 Propionaldehyde 142.00 10.00 Liquid Tank SS304

43 Pthalic Acid 5.00 1.00 Liquid Drums MS

44 Vinyl Ethyl Ether 5.00 1.00 Liquid Drums MS

45 Sodium Hydride 5.00 1.00 Liquid Drums MS

46 Aluminum

Trichloride


47 Di Chloro Methane 5.00 1.00 Liquid Drums MS

48 N Butyl Aldehyde 5.00 1.00 Liquid Drums MS

49 Tertiary Butyl Methyl

Ether


50 N ,O

Dimethylhydroxylam

ine Hydrochloride


51 Geraniol 5.00 1.00 Liquid Drums MS

9


52 Linalool 5.00 1.00 Liquid Drums MS

53 Meta Chloro Pre

Benzoic Acid


54 1 Phenyl Ethanol (

Styrallyl Alcohol)


55 Furan 5.00 1.00 Liquid Drums MS

56 Allyl Alcohol 5.00 1.00 Liquid Drums MS

57 Aroma & Flavor

Ingredients

80.00 50.00 Liquid &

Solids

Drums/Cans/Boxes

/Containers

MS/HDPE

/Aluminu

m

Location- For theproposed project the company will use its spare land from the existing plotsat Gut No 167, 169, 170,

171, 296, Village. Jamghar Lakhamapur, Tal. Wada, District: Thane, Maharashtra.

Thissiteisin onallfoursides wearesurroundedby industriesandnonuisance isspread.The immediate

surroundingneighborsare:

East :Abhinav Pharmaceuticals Pvt Ltd, Mumbai Wada Jawahar Highway

West: Agricultural Land, Village Lakhmapur

South: A g r i c u l t u r a l L a n d , V i l l a g e L a k h m a p u r

North: AFFPL Green Belt, Village Road, Residential Building

Locationtooisjustifiable.Unitsizeiskeptcorrectfor easeofhandling andenvironmentalcontrol.

Astherea r e o t he r indus t r i e s inthe neighborhoodw i t h similarn a t u r e , there is compatibility.

Thelanduseisalreadyas“Industrial land/Non Agriculture Land”.Thus,thereisnochangeinthestatus.Thisisaflat

landwhereby cutting- f i l l i n g balancesand the rewillbeNoLowBorrowingfromNature.

Tansa wildlife Sanctuary is about 8.3 kms North West of the site and the plot is located in

private industrial land hence requires Environment Clearance from the Ministry Of

Environment, Forest and Climate Change with Public Consultation.

Geographical Location Items:

Latitude : Approx. 19° 5'9.63"N

Longitude : Approx. 73°10'9.86"E

Terrain : Flat terrain Climate : Semi-Arid

4. Resources Site

AFFPL is desirous to establish and it requires following resources,

• Area 48900sq. mts

• Water Input Ground Water for existing 2 No’s bore wells and 1 No Well.

New Two No’s Borewell proposed with Rain Harvesting

Facility will be put in place.

• Work force 65

• Raw Materials Commensurate with product, as also work up chemicals

Solvents& catalysts

•Effluent Facility High COD and TDS sub stream segregated self-treatment

And Later CETP (membership is sought)/Gardening

• Haz. Waste Facility CSWTSDF at Taloja, Maharashtra

• Process Machinery Developed by self available locally maintained sophisticated

Laboratory Attendants, cooling tower, hot water generations,

Steam Boilers

• Units Instrumentation Precision and accurate

• Total InvestmentRs.19.3408Crores (Rs 9.3408Crores Present + Rs 10.00Crores Expansion)

• Environment Fund 2 %

• Proponents Law abiding. No litigation pending.

Site

1. Existing industrial premises and land area: 48900sq mts

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2. Climatic condition suitable for finer adjustments of control, making it fit for processing Conditions.

3. Well connected for transportation through Mumbai Wada-Jawahar Highway

4. Leveled ground and load bearing soil

Technology Selection

1. The products proposed are in the same manufacturing range for which the technology is already developed,

and well known.

2. The process used is based on raw materials that are available, without any bottleneck. Thus, Excess storage

also means wastage. Here, we can follow easily the principle of JIT (Just in Time).

3. The process used is developed by AFFPL them in house and hence we are aware aboutthesensitivepoints

needing careful attention in advance.

4. The process is cost effective, safe and environmentally friendly.

5. There is no elevated pressure condition in processing.

6. Solvents used that are recoverable, and are so recovered.

7. The steam & hot water from boilers will be used for process

Instrumentation

1. Latestelectronicinstrumentationwithhighaccuracyandreliability

2. 100% redundancy forcontrolandpowersupply.

3. EmergencyShutdownSystemforensuringsafetyofplantandpersonnel.

4. Streamflow,feedwaterflowismeasurable(indicatingandrecording)

5. Waterlevelandliquidmateriallevelismeasurable(indicatingand recording)

6. Multipointtemperaturescannerwiththermocouple.Allpointsindicatingandrecordingallforsteam,feedwater

,fluegasandair)

7. Pressuregaugesatreactors.

8. Multi-channeldataloggertoinputs likecurrents,mv,T/Cam recordingwith columneddotmatrixprinter.

9. Hootersfortrips,lowlevels,highlevelsandhightemperatures.

Machinery & Hardware:

1. ModernClosed Pump transfer system isused toavoid any risks in human being handling the production.

2. All processing equipment likereactors material of construction will be compatible to process.

3. Generally, will be of SS316/GLR quality and will be kept validated as per strict international guidelines

prescribed.

4. The condensers are in SS316.

5. Wherever water is used, will be specially purified for process and cleaning- washing.

6. Help of sophisticated configuration may be taken, if necessary.

Project proponents

AARAV Fragrances & Flavors Pvt.Ltd. (AFFPL) was incorporated in 2007. The promoters of the company have

more than 20 years of experience and profound understanding of the fragrance & flavor industry to provide

strategic inputs into key business decisions and developing long term goals.

AFFPL have developed strategic partnership with key global & local suppliers of synthetic and Natural ingredients

to provide consistent supply of fragrances & flavors to our valued customers.

AFFPL proudly service a wide range of SME's as well as multinational companies, both global & Indian.

To experience a great fragrance is to experience magic, fragrance has the power to captivate the senses and

transport our mind to new realm of imagination. AFFPL excels in the art and science of great fragrance creation.

Guided by our principles of Balance, Clarity and Integrity, we put our expertise behind your brand to create

signature fragrances. AFFL fragrances create unique, consistent and lasting experience for all consumers.

AFFL takes pride in partnering with their customers to ensure that when a product is picked off the self, customer

brand promise is fulfilled to the utmost satisfaction of the consumers from various categories

Some of the most profound memories are attached with food customer’s taste. We develop unique flavor

experiences that deliver your brand promise to consumers.

AFFL experts are constantly researching trends and focusing on the magic that consumers are looking for in the

market. AFFL development team works closely with the clients on specific briefs to deliver unique flavours within

stipulated deadlines for various categories.

Thecompany hasadoptedfollowingcertifications

1. ISO 9001

2. ISO 22000

3. ISO27001( Under Implementation)

4. Food Safety Standards Authority Certification.

The Board of Directors represents an optimum mix of knowledge, experience and expertise to guide the long-

term success of the company.Theproponentsare

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Sr.No. Name Designation

1. Mr. Ajit Suresh Vaze

Master Of Science Organic Chemistry

Engineer

CEO/ManagingDirector

2. Ms. AnuradhaAjitVaze Director

3. Mr. AjitDeshmukh Director

4. Mr. Jean Louis Matthey Director

5. Mr. HolgerHauenschild Director

5. Process Products

AFFPL proposes to establish a plant to produce synthetic organic chemicals catering to the perfumery & Flavor

industry. These products serve as raw material to the fragrance and flavors industries. As season changes the

demand for a fragrance /flavor changes, hence the demand for particular chemical ingredients also changes, the

industry has thus to be in readiness to change the product suitability as well as the application and be prepared to

mitigate the corresponding customer requirement challenges.

The utilities required will be steam which will be provided by the existing steamer and a new IBR Boiler will be

installed. Other will be provided by newer fresh technologies for cooling, vacuum etc. The multi-product facility

will be operated as normal chemical industry but the reactors will be used by different combination and sequence.

From the list of Products Sr Nos 2 to11 only two to three products will be manufactured simultaneously. The total

quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT

It may be seen that,

There is a capability of making these products

Production process is batch process with “Cleaner Production” strategy with effluents recycles

Machineries, utilities will be installed according to the requirement of the plant and products.

Schematic Process Flow for Proposed Products

COMPLIANCE TO MSIHC RULES:

According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical Rules, 1989), data on the

toxicity and flammable characteristics for the chemicals involved is as presented below in the form of tables.

12


Storage details for Raw Materials to be used in manufacturing activities:

Sr.

No.

Raw Material Quantity in

MT/M

Storage At

a time

during the

month

Physical

Form

Stored In MOC

1 Acetic Acid Glacial 182.00 10.00 Liquid Tank SS304

2 Acetic Anhydride 53.00 4.00 Liquid Drums HDPE

3 Acid Catalyst 17.00 2.00 Liquid Carboy/Drums HDPE

4 Aldehyde 85.00 6.00 Liquid Drums HDPE

5 Caryophellene 4.00 1.00 Liquid Drums GI

6 Phase transfer Catalyst 1.10 0.10 Liquid Drum HDPE

7 Caustic lye 1.04 1.00 Liquid Carboy HDPE

8 Citronellol 17.03 2.00 Liquid Drums MS Epoxy

9 Benzylledene Acetone 105.00 10.00 Liquid Drums GI

10 D’limonene/Orange Terpenes 98.00 10.00 Liquid Drums MS Epoxy

11 Di Ethanol Amine 1.00 1.00 Liquid Drums MS Epoxy

12 Dicyclopentadiene 240.00 20.00 Liquid Tank SS304

13 Ethyl Chloro Acetate 22.05 5.00 Liquid Drums HDPE

14 Benzyl chloride 27.60 2.50 Liquid Drums HDPE

15 Halide (Pentyl Bromide/

Chloride)

106.00 10.00 Liquid Drums HDPE

16 HCl 45% 1.00 1.00 Liquid Carboys HDPE

17 Iodine 0.05 0.05 Solid Can GI

18 Iso Amyl Alcohol 10.00 2.00 Liquid Drums HDPE

19 Isobutyric Acid 60.00 10.00 Liquid Drums HDPE

20 Methanol 15.00 3.00 Liquid Drums MS

21 Methyl Heptanone 69.00 10.00 Liquid Drums HDPE

22 Methyl Magnesium Bromide

/ Chloride


23 Hexyl Alcohol 52.00 2.80 Liquid Drums MS Epoxy

24 Mg Turnings 12.74 2.00 Solid Bags PP

25 Pentanol mixture 77.14 20.00 Liquid Tanks MSEpoxy

26 Propionic Acid 46.00 5.00 Liquid Drums HDPE

27 Salicylic Acid 160.00 16.00 Solid Bags PP

28 Soda Ash 12.24 2.00 Solid Bags PP

29 Sodium Acetate 21.30 2.20 Solid Bags PP

30 Sodium Methoxide 15.00 2.00 Solid Can GI

31 Sulphuric Acid 10.00 1.20 Liquid Carboys HDPE

32 Terpineol 68.18 5.00 Liquid Drums GI

33 Tetra hydro Furon 200.00 6.00 Liquid Drums MSEpoxy

34 Toluene 28.03 3.00 Liquid Drums MSEpoxy

35 Sodium salicylate 35.70 3.50 Solid Containers HDPE

36 Zn Chloride 0.52 0.05 Solid Can GI

37 Propylene 5.00 1.00 Gas Capsules SS304

38 Acetylene 5.00 1.00 Gas Capsules SS304

39 Hydrogen 6.00 1.00 Gas Capsules SS304

40 Benzaldehyde 100.00 10.00 Liquid Drums MS

41 N Pentanol 96.00 10.00 Liquid Drums MSEpoxy

42 Propionaldehyde 142.00 10.00 Liquid Tank SS304

43 Pthalic Acid 5.00 1.00 Liquid Drums MSEpoxy

44 Vinyl Ethyl Ether 5.00 1.00 Liquid Drums MS Epoxy

13


45 Sodium Hydride 5.00 1.00 Liquid Drums MS Epoxy

46 Aluminum Trichloride 5.00 1.00 Liquid Drums MSEpoxy

47 Di Chloro Methane 5.00 1.00 Liquid Drums MSEpoxy

48 N Butyl Aldehyde 5.00 1.00 Liquid Drums MSEpoxy

49 Tertiary Butyl Methyl Ether 5.00 1.00 Liquid Drums MS

50 N ,O Dimethylhydroxylamine

Hydrochloride


51 Geraniol 5.00 1.00 Liquid Drums MS

52 Linalool 5.00 1.00 Liquid Drums MS

53 Meta Chloro Pre Benzoic

Acid


54 1 Phenyl Ethanol ( Styrallyl

Alcohol)


55 Furan 5.00 1.00 Liquid Drums MS

56 Allyl Alcohol 5.00 1.00 Liquid Drums MS

57 Aroma & Flavor Ingredients 80.00 50.00 Liquid &

Solids

Drums/Cans/

Boxes/Contain

ers

MS/HDPE/

Aluminum

Storage Details For Products Proposed to be Manufactured

Sr.

No

Raw Material Quantity

in MT/M

Storage

At a time

in MT/M

Physical

Form

Stored In MOC

1 Fragrances/Perfumes & Flavors

(formulation) 210.00 50.00 Liquid Cans/Drums Aluminum/MS

2 Perfumery & Flavors Esters

300.00 35.00

Liquid Cans/Drums Aluminum/MS

3 Perfumery & Flavors Alcohol Liquid Cans/Drums Aluminum/MS

4 Perfumery & Flavors Aldehyde &

Aldehyde Derivatives Liquid Cans/Drums Aluminum/MS

5 Dimerization and Trimerization of

simple olefins. Liquid Cans/Drums Aluminum/MS

6 Ketals / Acetals / substituted 1,3-

propanediols Liquid Cans/Drums Aluminum/MS

7

Macrocyclic and polycyclic musks

derived from propylene or

butadiene/ and other propylene

derivatives


8 Aldehydes & Ketones by Aldol

Condensation Cans/Drums Aluminum/MS

9 Acetylene and other alkyne

derivatives Liquid Cans/Drums Aluminum/MS

10

Cyclo Alkylation/Acetylation, Diel

Alders Reactions ,Friedel Craft

Reactions


11 Hydrogenation Compounds Liquid Cans/Drums Aluminum/MS

12 Inorganic Salts 50.00 20.00 Solids Bags HDPE/PP

560.00 105.00

Overall Environmental Significance:

Unit Operation/

Process

Peculiarities Environmental significance

1.IncomingRaw Materials Selected from known vendor’s

transportation enclosed

tankers/Drums in limited low

volumes.

Prompt use and storage in closed

containers prevent spillages and loss of

strength. Fewer emissions.

14


2.Weighingand strict

Quality control

Load Cell based weighing system

provided

Better check on mass balance, purer

material and less rejections.

3.Inprocess Solvents Recovered and reused

Byproducts Recovered and sold to parties, when in

demand

Process waste residue To be sent on common facility for

disposal by incineration.

4.Instrumentation Control system for accurate

process controls

Facilitates monitoring of quality of the

product and safety aspects.

5.Control Excellent system of

documentation and control of

critical stages in production

process

Better operation and retrievable records

for better checks.

6.Solvent Recovery Proper recovery systems with

vapor condenser and chilled unit.

Vapor and Product Condensers with Step

down chilling and cooling systems

6. Pollution control

Clean production technology adopted byensuringfollowing a t design a n d e n g i n e e r i n g stage.

- All Products & their reactions selected after considering the friendliness of these products on the

- environment

- Minimize pollutants at source

- Recovering and recycle of the RM

- Maximize recycle of water resources.

- Tertiary ETP System will be erected and operated

- Treat to PCB norms

- 100% recycle of increased effluents for process for defined cycles.

- Procure CEPT Membership when available

- Use with Priority Environment Friendly Fuels Like Ground Shells Briquettes, Agricultural Waste.

- Reduction of VOC at every processing stage by providing vents condensers and scrubbers.

- Use of mainly clean fuels like agricultural waste/FO/LDO.

- All Process Transfers will be conducted in enclosed systems by pumps.

The process where varies based on Esterification of organic acid and alcohol producing water. The

recovery system will be designed in such a way that entire water is used for process application there by

replacing fresh water input.

The boiler is provided with cyclone separator, bag filter/ ESP to control emission within prescribed limits.

The stack height will be up to 30 meters to control ground level clearance within limits.

Process vents are controlled by condensers followed by water cooling and chilling systems and with

which the organics are recovered and recycled.

(a) Water & waste water:

The water and waste water generated in the factory will be as follows;

i. Water Requirements:

Details Of Fresh Water Consumption

Sr

No

Water Break Up Existing Water

Consumption

( KL/Day)

Proposed Water

Consumption

(KL/Day)

Total Water

Consumption

(KL/Day)

I Domestic 5.00 5.00 10.00

II Gardening 0.00 80.00 80.00

III Industrial

1)Process 0.00 5.00 5.00

2)Cooling Water Make up 0.00 9.00 9.00

3) Boiler Make Up 3.50 13.50 16.00

4) Washings 0.00 3.00 3.00

Total Industrial 8.50 115.50 124.00

Details Of Waste Water

Sr Waste Water Break Up Existing Waste Proposed Waste Total Waste

15


No. Water

Generation

(KL/Day)

Water Generation

(KL/Day)

WaterGeneration

(KL/Day)

I Domestic 3.60 3.60 7.20

II Industrial

1)Process 0.00 5.00 5.00

2)Cooling Water 0.00 9.00 9.00

3) Boiler Blow Down & Cooling 2.70 12.00 12.00

4) Washings 0.00 3.00 3.00

Total Industrial 7.30 32.6 36.20

The industry will obtain membership of CETP.

Water Balance Diagram:

Fresh Water From Borewells/Well 124 kl/Day

Gardening Domestic Cooling

Tower

RO

Fresh 80kl/Day 10kl/Day 9kl/Day 28kl/day

Recycled 3kl/Day

Recycled 12.8kl/Day

Recycled 8kl/Day

Total 103.8kl/Day

Sewage

Treatment

Plant

Cooling

Tower

Blow

Down

RO Reject RO Water

to Boiler

Feed

3kl/day 9kl/Day 11.2kl/Day 16.8kl/Day

Process Washings

5kl/Day 3kl/Day

8KL Recovered to ETP

Boiler

Blow

Down

12.8kl/Day

Recylce back to garden/

Or CEPT Effluent Treatment Plant

Schematic Diagram for Fresh Water Requirement and Waste Water Flow

Proposed ETP Flow Sheet:

Oil & Grease Trap

Equalisation and

Neutral ization Tank

Primary Settl ing Tank

1st Stage

Aeration Tank

1st Stage

Secondary

Settl ing Tank

2nd Stage

Aeration Tank

2nd Stage

Secondary Settl ing Tank

Intermediate

Collection

Tank

Inlet

Outlet

Pressure Sand

Fil ter

Final Dishcarge

Tank

16


(b) Air Pollution:

The existing plant comprises of 1 small industrial boiler (Steamer). The fuel used in the existing boiler is

furnace oil. Two DG Sets a.63kva for emergency and power failures & b. 160kva exclusively for fire

alarms & firefighting hydrant systems is already installed, which is used only during power failures.

Proposed Scenario: For the proposed expansion unit, the existing steam boiler will be kept as stand by. A new 5 MT IBR

Boiler and a new thermic fluid heater will be installed. The details of the boiler and thermic Fluid heater

are given below:

Details of Boiler and Thermic Fluid heater Capacity

Details of Air Pollution Control unit:

The proposed plant will not produce any significant air pollution load. The major sources of air pollution

will be:

Boiler

Thermic Fluid Heater

D.G. Set Emissions

Fugitive emissions

Process emissions

To control the fly ash particles / particulate emissions from the boiler, cyclone will be installed in the

proposed project. There are no process emissions from the proposed project.

Schematic diagram of cyclone

The existing D.G. Set shall be used only in case of emergencies / Power failure & Fire Related

emergencies. A New DG will be installed replacing the 63KVA

Details of D.G. Set

Sources of gaseous emissions

Existing D.G.Set

(63 KVA)

Existing D.G.Set

(160 KVA)

Proposed D.G.Set

(500 KVA)

Fuel used Diesel Diesel Diesel

Sources of Gaseous

Emissions

Boiler (1x 5MT/Hr) Thermic Fluid Heater (1x 3Lac kcals/

hr)

Fuel used Agricultural Waste /Bio Coal/ Furnace

oil/Coal / NG

Agricultural Waste /Bio Coal/ Furnace Oil

/Coal /NG

Quantity of fuel 22 mt/Day / 22mt/day/10 mt/day

/22mt/day/8500 m3/Day

5mt/Day/5mt/day/2.5mt/day/5mt/day/

2500m3/day

Type of emissions SO2, NOX, PM SO2, NOX, PM

Stack height 30 mts 13 mts

Stack dia. at the top 0.505 mts 0.505 mts

17


Quantity of fuel (Will depend on

Power Failure & Emergencies)

11lits/Hr 35lits/Hr 105 lts/hr

Type of emissions PM, SO2& NOX PM, SO2& NOX PM, SO2& NOX

Stack height 3 meters 3 meters 3 meters

Capacity of D.G.Set 63 KVA 160 KVA 300 KVA

Noise :

There is no major noise generating sources. Only those Vehicles with PUC's and spark arresters will be

allowed inside the premises. Green belt facilities have also been provided in the plant premises.

Details of Hazardous Waste Generation and Disposal:

The plant will have the maximum solid waste generation from the ETP, which will be sent to CHWTSDF,

Taloja, Maharashtra for its disposal applied for membership.

Details of Hazardous waste generation and disposal:

Sr.

No.

Type of Waste Category Existing

Quantity

MT/Annum

Proposed

Quantity

MT/month

Mode of disposal

1 ETP Sludge 34.3 0.060 100.00 Collection, storage,

transportation and disposal to

TSDF.

2 Used Oil 5.1 0.00 2.40 Collection, storage,

transportation and disposal by

sale to registered recyclers.

3 Discarded

Containers

33.3 0.00 12.25 Collection, storage,

decontamination,


sale to authorized recycler

4 FO / LDO &

Oil Bottoms

Sludge

--

0.00

3.36

Collection, storage,



5 Distillation

Residue

20.3 0.00 16.200


transportation and disposal to

CHWI.

6 Grease 5.2 0.00 0.012




7 Fly ash (Boiler

& TF Ash)

- 0.00 482.00 Will be sold to brick

manufacturers.

8 Low purity

fractions

C8 0.00 72.00

Will be sold.

9 Spent acid -- 0.00 16.00

Will be sold.

Hazardous Waste Storage Room:

A hazardous waste storage room measuring 100sqmts will be provided with impervious RCC flooring and

leachate collection pit. The distillation residue will be stored in carboys in Hazardous waste storage room

and will be finally disposed of to CHWTDFS, Taloja, Maharashtra. The Fly ash will be stored in a defined

area and precautionary measure will take for avoid carryover of the ash by wind/breeze/water etc.

Dispersion:

Sr

No

Source Pollutant Measures Control Equipment

1 Proposed 5MTBoiler. SPM, CO,SO2,

NOx

Dust Collectors,, ESP,

Dust extraction with Bag

filters, fogging.

Tall stack of 30 m.

2 In process VOC Closed loop transfer Vent condensers,

Extraction and scrubbing

3 ETP COD, TDS Segregation of Streams Fully aerobic

18


Point Emissions are coming from one boiler, thermic fluid heater &3 DG hence proper stacks will be

provided for the same. Please note DG 3 Nos will be used only in emergency & during power failures.

The stacks will be fitted with port-holes, ladder and platform for facility of taking samples.

Fugitive:

A number of mitigation measures will be taken to control fugitive emissions

Engineering, the plant layout will be in such a way so as to virtually eliminate need of using heavy

Equipment for material handling in the main plant

Internal roads paved, leveled, no undulations, no sharp curves, slow speed.

No open storage of materials involved

Fumes extraction and vacuum system will provided for extraction of fumes

from the reactors and the process plant areas.

Fugitive Emissions and its control:

There are no emissions from the manufacturing process. For control of fugitive emissions, chilled

water traps will be installed on the vent of the unit to arrest any escape of vapors from the reaction

and distillation unit. Fugitive emission could occur from the storage yard of raw materials and

finished products. The storage quantity is very low and proper handling methods will be adopted.

Emissions from transport of vehicles would occur to a certain extent. The emissions from traffic

movements is controlled by proper planning of the transport of raw materials and finished

products to and fro from the factory premises. Since the quantities involved are very less,

movement of vehicles will be occasional. All the roads inside the plant will be concreted to reduce

any dust emissions.

Details of Solvent recovery Plan and monitoring of vents:

The solvent recovery system for the proposed expansion project is shown in the figure below.

The vents of the reactors will be connected to 2 stage condenser system, where chilled water will be

recalculated. The receiver will also be jacketed with circulation of chilled water. The recovered solvents

will then be stored and reused. All the units will be under nitrogen blanketing through cylinders. Proper

planning and maintenance will control the extent of fugitive emissions. During the production, the

industry will carry out regular monitoring of fugitive emissions as per the factories act.

Details of Solvent Recovery Plan

Aesthetics:

There will be no nuisance from noise. DG 3 Nos will be used only in emergency & during power failures

to keep plant under safe conditions. If Coal is used as fuel for boiler there will crushing and pulverizing

19


operations for coal handling. Dust suppression system is provided. Dust extraction with dust collection

will be provided. Labor strength will also be limited.

7. Background Study: 1.a)

LAND ENVIRONMENT:

Area : Study area (10km)

Details: Topography of the area indicating gradients, aspects and altitude.

Establishment of Land Use Pattern. Locations of National Park/

Sanctuary/Biosphere Reserve/ Monument /Heritage site/Reserve

Forests.

Soil Samples : Soil Analysis to cover 7 locations in the project area.

Parameters : pH, EC (mhos/cm2), Organic Carbon, Phosphorous as P (kg/Ha),

Potassium as K (kg/Ha), Sulphate as SO4 (%), Textural

classification, Available nitrogen (kg/Ha).

1.b)

AIR ENVIRONMENT:

BASELINE AAQ:

Number of stations : 6 in study area

Frequency : 2 days per week

Duration : One season.

Parameters : PM10, NOx, SO2, NMHC, CO, Primary Meteorological data,

(WS/WD/DB Temp. / RH), Review frequency of inversion,

Frequency of cyclones/ tornadoes/ cloud burst from Climatological

Tables & other available secondary data.

1.c) NOISE ENVIRONMENT:

Number of station

locations

: Same as AAQ locations

Frequency : Hourly measurements to determine day time / night time Leq. as per

Environment Protection Act.

Duration : Once in the season

Method of sampling

and analysis

: Continuous sound level meter

1.e) WATER ENVIRONMENT:

Number of locations : 7 locations for Ground/ Surface water within study area.

Frequency : One sample per location.

Duration : One season.

Parameters : As per ISO 10500-2012

1.f) SOCIOECONOMIC DATA:

Area : study area

Details

: Demographic Pattern (literacy Rate, Male to Female Ratio),

Occupational Pattern, Socioeconomic Status etc.

Documents

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