PROJECT PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-01-19 · project pre-feasibility report and environment management plan on proposed

PROJECT PRE-FEASIBILITY REPORT

AND

ENVIRONMENT MANAGEMENT PLAN

ON

PROPOSED EXPANSION PROJECT

OF

MANUFACTURING OF

DYE/DYE INTERMEDIATE& PESTICIDE

BY EXPANSION

OFAARTI INDUSTRIES LTD.

(ALCHEMIE ORGANICSDIVISION)

LOCATED AT:

Plot no.902,GIDC Estate, Phase -III,Vapi.

Dist: Valsad, Gujarat.

M/s. Aarti Industries Ltd. (Alchemie OrganicsDivision), Vapi.

Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar

CONTENTS

Sr. No. Particulars Page No.

1 EXECUTIVE SUMMARY 1

2 INTRODUCTION 7

2.1 The Project 7

2.2 Project Proponent 7

2.3 Nature of project 9

2.4 Market Feasibility 10

3 PROJECT DESCRIPTION 12

3.1 Type of Project 12

3.2 Project Location 12

3.3 Site selection 14

3.4 Neighbouring Industries 14

3.5 Size of project 15

3.6 Process Technology 15

3.7 Raw material 15

3.8 Resource optimization/recycling reuse 15

3.9 Resource requirement 16

3.9.1 Land 16

3.9.2 Building 16

3.9.3 Power & Fuel 16

3.9.4 Water 16

3.9.5 Man power 17

3.10 Mitigation measures & EMP 18

3.10.1 Waste water Management 18

3.10.2 Gaseous emission & Control 19

3.10.3 Hazardous /non hazardous waste management 20




3.10.4 Noise control & odour 21

3.10.5 Storage ,handling and transport of Hazardous chemical 21

3.10.6 Health & Safety measures 21

4 SITE ANALYSIS 23

4.1 Connectivity 23

4.2 Land use and land ownership 23

4.3 Existing land use 23

4.4 Existing infrastructure 23

4.5 Soil Classification 23

4.6 Climate data 24

4.7 Social Infrastructure 25

5 PLANNING BRIEF 26

5.1 Planning concept 26

5.2 Population projection 26

5.3 Land use planning 26

5.4 Assessment of infrastructure Demand 26

5.5 Ammentities 27

6 PROPOSED INFRASTRUCTURE 28

6.1 Processing area 28

6.2 Non processing area 28

6.3 Green belt 28

6.4 Social Infrastructure 28

6.5 Connectivity 29

6.6 Drinking water management 29

6.7 Sewerage system 29

6.8 Industrial waste managemnt 29




6.9 Solid waste management 29

6.10 Power requirement & Supply 29

7 REHABILITATION & RESETTLEMENT (R & R) PLAN 29

8 PROJECT SCHEDULE & COST ESTIMATES 30

8.1 Project Implementation Schedule 30

8.2 Estimated project cost 30

9 ANALYSIS OF PROPOSAL 30



List of TablesTableNo.

Topic Page No.

1 List of Products as Per CCA 1

2 List of Products as Per Proposed Scenario 2

3 Contact details of the Directors 7

4 Salient features of the Project Site 12

5 Nearby Industries in the vicinity 14

6 Capital cost of projection 15

7 Power and Fuel Requirement 16

8 Category-wise Water Requirement 17

9 Man Power Requirement 17

10 Category-wise Wastewater Generation 18

11 Details of Meteorological conditions 24

12 Project implementation schedule 30

List of Figures

Sr. No. Description Page No.

1. Location of the Project Site 13

2. Aerial view of the 10 km radial periphery from the ProjectSite

14

3. Wind rose diagram for period of March-2013 25

M/s. Aarti Industries Ltd. (Alchemie Organics Division), Vapi.

Jyoti Om Chemical Research Centre Pvt. Ltd., Ankleshwar 1

1.0 EXECUTIVE SUMMARY

M/s.Aarti Industries Ltd. (Alchemie Organics Division) obtained CCA order AWH-53342, issue

on dated 15/04/2013 for manufacturing of Dye/Dye intermediates & Pesticides products

mentioned in below tableno.1at plot no.902,923 Phase-III, GIDC Estate,Vapi-

396195,Dist.Valsad, Gujarat.

Table no.1: List of products as per CCA

Sr.No.

Name of Products Quantity As Per Consent(MT / Year)

1. DCBH (Di Chloro Benzene Hydro chloride) 3000

2. 2,3/2,5 DCP (Di Chloro Phenol) 300

3. 3,4,5 Tri Flouro Bromo Benzene 40

4. Para Flouro Phenol (PFP) 100

5. 3,5 Di Chloro Nitro Benzene 1050

6. Quinalphose (TECH) (Diethyl 2-Hydroxy ThiophosphorylChloride)

600

7. 1,3 DFB( Di Flouro Benzene) 100

8. 2 Bromo 4 Flouro Acetanilide 74

9. Di Chloro Bromo Benzene 100

10. 3,5/2,6 DFA (Di Flouro Aniline) 30

11. 2,6 DCPNA 25

12. Ortho Chloro Aniline 150

13. Acetic Acid 26

Total 5595

14. Sulphuric Acid (70%) 2310

15. Dilute Sulphuric Acid 51326

16. HBr Solution 87.5

Existing manufacturing involves hydrogenation, diazotization, bromination, condensation and

chlorination products.

The unit obtained Environment Clearance [file no.J-11011/497/2008-IA II (I)] in 2008 from

MOEF but Environment Clearance was not converted to any project and is now lapsed.



Now, the unit has proposed expansion for manufacturing of products by hydrogenation,

diazotization, bromination, condensation and chlorination. Also, the unit has proposed new

products based on hydrolysis. List of proposed new products is mentioned in table no.2.

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

Table no 2: List of products as per proposed scenario

Sr.No.

Products Quantity as per consent(MT / Year)

Quantity as per proposedExpansion(MT / Year)

1 Hydrogenation

1.1 DCBH (Di Chloro BenzeneHydro chloride)

3000 7800

1.2 1,3 D.F.B.(Di FlouroBenzene)

100

1.3 3,5/2,6 DFA (Di FlouroAniline)

30

1.4 OT Base 0

1.5 Di Anisidine 0

1.6 OrthoToluene

0 87

1.7 Ortho Anisidine 0 87

1.8 Ortho Chloro Aniline 150 975

2 Diazotization

2.1 2,3/2,5 DCP (Di ChloroPhenol)

3002400

2.2 3,5 Di Chloro Nitro Benzene 1050

2.3 1,3,5 TCB 0

2.4 Para Flouro Phenol (PFP) 100

3 Bromination

3.1 3,4,5 Tri Flouro BromoBenzene

401000

3.2 2 Bromo 4 FlouroAcetanilide

74

3.3 Di Chloro Bromo Benzene 100

3.4 Acetic Acid 26 29.17

4. Condensation

4.1 Quinalphose (TECH)(Diethyl 2-HydroxyThiophosphoryl Chloride)

600 600



Sr.No.

Products Quantity as per consent(MT / Year)

Quantity as per proposedExpansion(MT / Year)

5. Para Flouro Anisol 0 200

6. Hydrolysis

4 CAP 0 200

2 CAP 0

2,3,4 TFA 0

7. Chlorination

7.1 2,6 DCPNA 25 4000

7.1 2,4,6 TCA 0

Total 5595 17378.17

By Products

1 Sulphuric Acid (70%) 2310 1739.60

2 Dilute Sulphuric Acid 51326 12325.02

3 HBr Solution 87.5 72.91

4 HCl (30%) 0 769.29

COST OF PROJECT

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

proposed expansion is Rs. 1,515Lacs.The total plot area of the unit is 11,970sq.m.Existing green

belt area is approx.2346 sq. m. After expansion, the green belt area will be remaining same.

FUEL & ELECTRICITY CONSUMPTION

As per consent

As per consent, the unit is using 425 L/hr furnace oil as fuel for Incinerator and 100 L/hr diesel

as a fuel for two D.G. sets.

Proposed scenario

The unit has proposed one D.G set. Diesel requirement for one D.G set will be 150 L/hr. Total

diesel consumption will be 250 L/hr. Furnace oil consumption will be nil as the unit will not use

in-house incinerator.



The unit have electricity from Daxin Gujarat Vij Company Ltd. The existing electricity

consumption is 1200 KVA and electricity consumption due to proposed expansion will be 800

KVA. Total electricity requirement after proposed expansion will be 2000 KVA.

WATER CONSUMPTION

As per consent

The source of water is GIDC. As per consent, the unit is using 404 KLD freshwater for industrial

and domestic purpose.

Proposed scenario

For proposed expansion, the unit has proposed additional 195 KLD of fresh water consumption.

Therefore, total fresh water consumption after expansion will be 599 KLD. The unit will use 268

KLD recovered water from MEE & R.O. as the unit has proposed zero liquid discharge. Also,

20 KLD recovered water from process will be reused in process itself. The unit will use 30 KLD

of treated water from STP for gardening purpose and 30 KLD treated water from STP for

cooling tower. After expansion, total water consumption will be 867 KLD (599 KLD+288KLD).

WASTE WATER GENERATION, TREATMENT & DISPOSAL

As per consent

As per consent, the industrial effluent generation is 79 KLD and sewage generation is 20 KLD.

Concentrated & toxic effluent stream of 11.7 KLD is sent for in-house incineration.

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

water is sent to CETP.

Proposed scenario

Due to proposed expansion, additional total industrial effluent generation will be 163 KLD.

Hence, after expansion total industrial effluent generation will be 242KLD (79 KLD + 163

KLD).Due to proposed expansion, additional sewage generation will be 40 KLD. Hence, after

expansion sewage generation will be 60 KLD( 20 KLD + 40 KLD).After proposed expansion,

concentrated & toxic effluent stream of 11.7 KLD is sent to common incineration facility for

incineration.

The existing ETP is adequate to treat 167 KLD of effluent. Treated effluent will be subjected to

R.O. followed by MEE to achieve zero liquid discharge for industrial effluent.



Sewage will be treated in STP separately. Treated water from STP will be used for gardening

purpose (30 KLD) and in cooling tower (30KLD).

GASEOUS EMISSION

As per consent

As per CCA order no. AWH 53342, the unit has two stacks of D.G sets.

The process emission is from two stacks. One stack having height 16 m is attached to Reactor of

2-Bromo 4Flouro Acetanilide/ Di Chloro Bromo Benzene Reactor and there is provision ofWater

Scrubber followed by Alkali Scrubber as air pollution control system. Second stack of

incinerator having height 30 m and there is provision of Caustic Scrubber air pollution control

system.

Proposed scenario

Now, the unit has proposed one additional D.G set of 750 KVA. The unit has proposed three

process stacks. One stack having height 11 m attached to chlorinator reactor and there is

provision of water scrubber followed by Alkali Scrubber to control emission of Cl2 &HCl.

Second stack having height 11 m attached to SFD and there is provision of water scrubber to

control emission of PM.Third stack having height 11 m attached to Dizo vessels and there is

provision of water scrubber followed by Alkali Scrubber to control emission of NOx& HCl.

Also, the existing incinerator stack will not be there as the existing incinerator facility will be

dismantled.

HAZARDOUS WASTE MANAGEMENT

As per consent

As per CCA order no. AWH-53342, the hazardous waste generation are ETP waste (1090

MT/Year), Spent solvent heaving water (1.2 MT/Year), Distillation Residue (481.2MT/Year),

Date expired pesticide (2 MT/Year), Used oil (0.6 KL/Year), Spent catalyst (8.4 MT/Year), spent

filter cloth (700 Nos. /year),Incineration ash (160 MT/Year), Discarded containers (8MT/Year)

& Bags/Liners (39.8 MT/Year). ETP waste, spent catalyst & incineration ash are disposed to

TSDF-VWEMCL, Vapi. Spent solvent, Date expired pesticides, Spent filter cloth, Distillation

residue are disposed by sending to common incineration/own incineration. Used oil is sent to



registered recyclers.Discarded containers/Bags/Liners are reused or sale to actual user after

decontamination.

Proposed scenario

For proposed expansion, hazardous waste generation details are covered here. The unit has

proposed 7200 MT/Year of ETP waste, 3675.12MT/Year of Distillation residue, 16 MT/Year of

Discarded containers, 80 MT/Year of liners/bags, 2.4KL/Year of Used oil, 1.2 MT/Year of Spent

solvent, 1500 Nos. /Year of Spent filter cloth, 4 MT/Year of Date expired pesticide, 2640

MT/Year of Gypsum waste, 850.92 MT/Year of Spent catalyst, 83 MT/Year of Spent carbon and

4 MT/Year of Insulation waste.

The unit has proposed to discontinue of in-house incineration facility. Thus there will be no

generation of incineration ash.

ETP waste will be disposed atTSDF Site. Spent solvent, Date expired pesticides, Spent filter

cloth, Distillation residue, Spent carbon are disposed by sending to common incineration. Spent

catalyst will be sent to registered regenerator. Used oil is sent to registered recyclers.Discarded

containers/Bags/Liners are reuse or sale to actual user after decontamination.



2.0 INTRODUCTION

2.1 The project

M/s.Aarti Industries Ltd. (Alchemie Organics Division) obtained CCA order AWH-53342, issue

on dated 15/04/2013 for manufacturing of products mentioned in Table 1. Existing

manufacturing involves hydrogenation, diazotization, bromination, condensation and

chlorination.

The unit obtained Environment Clearance [file no.J-11011/497/2008-IA II (I)] in 2008 from

MOEF but Environment Clearance was not converted to any project and is now lapsed.

The unit has proposed expansion for manufacturing of products by hydrogenation, diazotization,

bromination, condensation and chlorination. Also, the unit has proposed new products based on

hydrolysis. Proposed productions scenario in mentioned in Table no 2.

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

2.2 Project Proponent

Table no 3: Contact details of directors

Sr.No.

NameofDirector

Designation Address Telephone No.

1. Shri.rajendra V.

Gogri

Chairman&

Managing Director

1401, Antriksh.

Murar road,

Mulund (w),

Mumbai 400080

022-67976666

2. Shri.Rashesh C.

Gogri

Vice chairman&

Managing Director

601,Antriksh

Morar Road,

Mulund (W)

Mumbai 400080

022-67976666

3. Shri.Parimal H.

Desai

Whole-Time Director A/1403 14TH Floor,

Runwal Heights,

L.S.B. Marg,

Mulund (W)

Mumbai- 400080

022-67976666



Sr.No.

NameofDirector

Designation Address Telephone No.

4. Shri.Manoj M.

Chheda

Whole-Time Director Dunhill Villa

CO.OP.HSG.SOC.Ltd.,

Besant Road,

Santacruz (W),

Mumbai- 400054

022-67976666

5. Shri.Kirit R.

Mehta

Whole-Time Director 10, Pushpendra Mension,

Phirojshah Mehta Road,

Santacruz (W),

Mumbai– 400054

0260-2400059

2400366

6. Smt.Hetal

GOGRI GALA

Whole - Time

Director

558-B, Gopal Sadan,

Block no. 801, 8TH Floor,

Jamshed Road,

Matunga(E),

Mumbai– 400019

022 - 67976666

7. Shri. Renil R.

Gogri

Whole - Time

Director

1401, Antriksh. Murar

Road Mulund (W)

Mumbai-400080

022 - 67976666

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

QUALITY POLICY & ENVIRONMENTAL POLICY

QUALITY POLICY

Aarti Industries Ltd., leading manufacturer of intermediates and specialty Chemicals, is

committed to provide quality products and services leading to Total Customer Satisfaction.

While conducting business, we shall comply with all applicable regulations and shall strive to

continually improve performance, processes and systems with an aim to be world class in terms

of Productivity, Safety, and Occupational Health and Environmental performance by harnessing

the competence of employees and ensuring their involvement.



SAFETY, HEALTH AND ENVIRONMENT POLICY

We, at Aarti Industries Limited, engaged in the Business of Manufacturing Chemicals, shall

strive to ensure Safety, Health and Environment (SHE) performance related to our Processes,

Products, and Services through an Effective Implementation, Monitoring and Periodic Review of

the Designed SHE Objectives, Targets and Management Programs.

Company is committed to continuous improvement of its performance and ensures that the

Employees at all levels are familiar with and apply this Policy in all their Industrial and

Commercial activities.

Company shall comply with all the Applicable Regulatory and Statutory requirements and

recommendations of the Regulatory Authorities and implements the best Industrial Practices.

Company periodically assesses the Risks involved in its Operation(s) and during

Change/Modification(s) of the Processes to evaluate impact on Health, Safety and Environment.

Company also communicates all relevant information to its Customers, Vendors the General

Public and Authorities. It advises its customers about the handling, use and disposal of its

products.

Company strengthen Pollution Prevention and Waste abatement Practices and strive to provide a

Safe and Healthy Environment.

Company implements an Effective and Standard SHE Practices at Work Place, among

employees and concerned Stake Holders to prevent Injuries and ill Health of employees

The Company shares its experience wherever possible with other members of Industries.

2.3 Nature of project

Existing manufacturing involves hydrogenation, Diazotization, Bromination, Condensation and

Chlorination.

The unit has proposed expansion for manufacturing of products by hydrogenation, Diazotization,

Bromination, Condensation and chlorination. Also, the unit has proposed new products based on

hydrolysis. Proposed productions scenario in mentioned in Table 2.



2.4 Market Feasibility

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

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

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

products to our customers, the unit indirectly helps people to have access to better medicines,

fertilizers and diverse items of daily use. In other words, greening the supply chain management

plays a significant role in the unit business strategy. The products are highly influenced by the

market demand and market rates

Various products listed above are used in manufacturing of:

Inks- used in manufacturing of sheet –fed offset, web offset, News Paper, UV screen, gravure

and Flexo.

Paints- used in manufacturing of Air drying enamel, stoving paints, Acrylic paints, and

Automotive paints Industrial paints and Cement Paints.

Plastics- used in manufacturing of LDPE, HDPE,PVC,Polypropylene,Poly carbonate,

Polystyrene.

Textile- used in manufacturing of Emulsion paste for Pigment printing

Agrochemicals

The Golden corridor of Gujarat from Dahej to Vapi has presence of lots of industries

manufacturing Organic chemicals. Hence, local market is already available.

AARTI has privilege of catering to its export customers in countries such as USA, UK,

Germany, Spain, Italy, Switzerland, Belgium, Japan, Korea, China, Russia, etc





3. PROJECT DESCRIPTION

3.1 Type of project

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

3.2 Project location

M/s.Aarti Industries Ltd.(Alchemie Organics Division) is located at plot no 902,923 Phase-III,

GIDC Estate, Vapi-396195, Dist.Valsad, and Gujarat. It is approximately 26 km distance from

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

20°21’47.26”N, Longitude 72°56'29.93” E. It has an average elevation of 5 m. The location of

the project site can be identified from the location map shown in Figure-1.

The salient features of the location of the project site are presented in Table no 4.

Table no 4: Salient features of the project site

Particulars DetailsTaluka/ Tehsil Pardi

District Valsad

Approx. Geographical positioning Latitude: 20°21’47.26”NLongitude: 72°56'29.93” E

Nearest City Valsad

Nearest Town Vapi

Nearest Highway NH8

Nearest State highway

Nearest Railway line/ Railwaystation

Vapi

Nearest Airport/ Airbase Mumbai

Protected Areas/ Sanctuaries ---------



Figure 1: Location of the project site

Project site



Figure 2: Aerial view of the 10 km radial distance from the project site

3.3 Site selection

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

3.4 Neighboring Industries

The industry is proposed to be located in an area, which is already industrialized. The industries

in the vicinity of the proposed project are given in the table no-5:

Table no5: Nearby Industries in the vicinity

Name of Industry Direction W.R.Tproject site

Address

Aarti Industries Limited(organic division)

North Plot No801/23,Phase III ,GIDC Vapi.

Megafine Pharma Pvt. Ltd. East Plot No911,Phase III ,GIDC Vapi.NR Agarwal Paper industry West Plot No901,Phase III,GIDC Vapi.MWV North Plot No789/4,Phase III, GIDC Vapi.



3.5 Size of Project

The expected cost of proposed expansion of project is Rs.1515 lacs.New Plant and machinery

installations will also have to be acquired and installed.

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

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

treatment plant. The below given table no-6 shows the break-up of the proposed project cost.

Table no 6: Capital Cost projection

Sr.No.

Purpose Existing(Rs. InLacs)

Proposed(Rs. In Lacs)

Total(Rs. In Lacs)

1. Land 39.50 0 39.502. Building 351.04 150 501.043. Plant and Machinery 5000.46 500 5500.464. Env. Protection & Safety

a) Effluent treatment Plant 3250 800 4050b) Safety Equipment (PPE,fire extinguishers, Ventilation,etc.)

500 50 550

C) Green belt development 15 15 30

d) Fire 45 0 45Total 9201 1515 10716

3.6 Process Technology

Process details like process description, chemical reactions and mass balance for each grade of

products are attached as Annexure-IV.

3.7 Raw-Materials

The proposed products are organic and inorganic chemicals and the required raw materials will

be purchased from the local/ Indian market. Details of raw-material consumption are attached as

Annexure- III.

3.8 Resource optimization/recycling and reuse

The unit will use 268 KL/day of recovered water of cooling tower and 20 KL/day recovered

water for process.



3.9 Resource Requirements

3.9.1 Land

The plot had been purchased by M/s. Aarti Industries Ltd. (Alchemie Organics Division) from

GIDC. The total plot area of the unit is 11,970 sq.m.

3.9.2 Building

No new building will be constructed.

3.9.3 Power and Fuel

Table no 7: Power and fuel requirement

Sr.No.

Name Requirement Source

Existing Quantityas per consent NoAWH-53342

ProposedQuantity

TotalQuantity

1. Diesel 100 Lit/Hr 150 L/Hr 250 L/Hr Local supplier

2. FurnaceOil

425 Lit/Hr - 425 L/Hr 000 L/Hr Local supplier

3. Energy -Electricity

1200 KVA 800 KVA 2000 KVA DGVCL

3.9.4 Water

The category wise bifurcation of the water requirement is given in Table no 8. The source of

water will be from GIDC water supply scheme.



Table no 8: Category-wise water requirement

Sr. No. Section Water Consumption KL/Day

Existing As Per CCANo AWH-53342

WaterConsumption AsPer ProposedExpansion

Total

Domestic 30 40 70

Industrial

Process129

198( Fresh)+ 20 (Recovered)

327 ( Fresh)+ 20 (Recovered)

Washing 10 20 30

DM plant 0 15 15

Cooling215

-58 (fresh) +268(Recovered)

157 (Fresh)+

268 (Recovered)

Gardening 20 -20 0

Total( Industrial)

374155(Fresh)

+288(Recovered)529 (Fresh)

+288 (Recovered)

Total( Domestic+Industrial)

404195 (Fresh)

+288 (Recovered)

599 (Fresh)+288

(Recovered)

3.9.5 Manpower

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

activities will be employed from the local area.

Table no 9: Man Power Requirement

Phase ofproject

Type oflabor

No. of workers(Existing)

No. of workers(Proposed Scenario)

No. of workers(Total)

Duringconstruction

Contractual -- -- --

Duringcommissioning

Contractual -- -- --

Duringoperations

Managerial 12 8 20Skilled 18 20 38Un-skilled 160 140 300

Total 190 168 358



3.10 Mitigation Measures & EMP

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

proposed by the company for the control of the anticipated pollution load.

3.10.1 Wastewater Management

3.10.1.1 Wastewater Generation

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

10.

Table No-10:Category-Wise Wastewater Generation

Sr.No.

Section Waste Water Generation KL/Day

Existing Quantity Asper Consent No AWH-53342

Waste water ConsumptionAs Per ProposedExpansion

Total

1. Domestic 20 40 602. Industrial

Process 62.3 74.7 137Washing 10 20 30DM plant 0 5 5Cooling 6.7 63.3 70Total(Industrial)

79 163 242

Total( Domestic +Industrial)

99 203 302

** The unit has become already zero- liquid discharge unit.

3.10.1.2 Wastewater Characteristics

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

covered in Annexure-VI.

3.10.1.3 Wastewater Treatment & Disposal

Existing Effluent Treatment Scheme

The company is generating two types of effluents i.e. highly concentrated effluent stream and

dilute effluent stream.

Domestic4.0

Soak pit4.0

Domestic4.0

Soak pit4.0



The concentrated effluent stream alkaline in nature is separately collected in collection tank and

directly incinerated in incineration system of 500 liters per hour capacity.

The dilute effluent from the process plant is collected in a collection sump from which it is taken

to oil & grease trap for separation, oil and grease is skimmed off from the top. Effluent is then

pumped to neutralization tank where pH is neutralized between 7 to 8 and compressed air is used

for agitation.

Then it is transferred to decanter for sludge dewatering then it is taken to equalization tank after

that effluent is pumped to primary settling tank where suspended solids are settled and the sludge

is taken into sludge drying bed. Leachate is collected and sent back to equalization cum

neutralization tank.

Dried sludge is stored in a sludge storage tank. Clear water from settling tank is taken into

aeration tank no. 1. In this tank, extended type aeration system is adopted. Biological treatment is

given to the effluent. Overflow is taken into primary lamella separator for excess sludge settling,

Biomass is recirculated in aeration tank if required or sent to SDB. Then further it is taken into

second stage bioreactor and second stage settling tank. Overflow from secondary settling tank is

passed through two stage activated carbon filter and then drain into underground effluent

drainage line to CETP, Vapi.

Proposed Effluent Treatment Scheme

The unit is having effluent treatment plant consisting of primary, secondary, and tertiary

treatment. The effluent is treated in ETP. Treated water will be further treated in RO followed by

MEE. The condensate water from MEE and permeate water from RO is reused and the residue

from MEE is send to TSDF site. The unit will be zero liquid discharge for industrial effluent.

Sewage will be treated separately in STP and treated water will be used for gardening purpose

and reused in cooling tower.

3.10.2 Gaseous emissions & control

3.10.2.1 Flue gas emissions

As per CCA order no. AWH 53342, the unit has two stacks of D.G sets.Now, the unit has

proposed one D.G set of 750 KVA.



3.10.2.2 Process emission

As per Consent, the process emission is from two stacks. One stack having height 16 m is

attached to Reactor of 2-Bromo 4Flouro Acetanilide/ Di Chloro Bromo Benzene Reactor and

there is provision of Water Scrubber followed by Alkali Scrubber as air pollution control system.

Second stack of incinerator having height 30m and there is provision of Caustic Scrubber air

pollution control system.

The unit has proposed three process stacks. One stack having height 11 m attached to chlorinator

reactor and there is provision of water scrubber followed by Alkali Scrubber to control emission

of Cl2 & HCl. Second stack having height 11 m attached to SFD and there is provision of water

scrubber to control emission of PM. Third stack having height 11 m attached to Dizo vessels and

there is provision of water scrubber followed by Alkali Scrubber to control emission of NOx &

HCl. Also the existing incinerator stack will be not there as the existing incinerator facility will

be dismantled.

3.10.2.3 Fugitive emissions

Volatile or low boiling chemicals to be used in the process. Hence, chances of fugitive emissions

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

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

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

All reactions will be taken in closed reactor system.

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

handling. Raw-material feeding will be carried out by pumps.

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

Good housekeeping will be maintained in the plant

3.10.3 Hazardous/ Non-hazardous waste management

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

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

hazardous waste generation, storage, and disposal for existing and proposed are attached as

Annexure-IX.



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

below:

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

and accompanied with Form-13.

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

regularly to the local office of the GPCB.

3.10.4 Noise Control & Odour

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

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

The following steps will be taken for odour control.

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

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

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

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

3.10.5 Storage, Handling and Transport of Hazardous Chemicals

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

Chemical hazards guide (NIOSH) for the hazardous chemicals.

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

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

3.10.6 Health and Safety measures

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

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

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

large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of

MSIHC Rules,



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

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

during transfer of such chemicals is not significant.

Below mentioned is the summary proposed safety measures to be taken at site for control of

anticipated hazards.



4.0 SITE ANALYSIS

4.1 Connectivity

The site is located at plot no. 902,923 Phase –III, GIDC Estate, Vapi- 396 195, Dist. Valsad. The

site is 4.37 km from Vapi town and 3 Km from National highways. The land and Infrastructure is

already available. And the raw material is easily available through the easy transport via road

connectivity. The district headquarter has railway station. The site is in the existing unit

compound.

4.2 Land use and land ownership

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

of industries. The Geographical Location of this industry is 20o 21’47. 26’ N Latitude and 72o

56’ 29. 93”E Longitude with an elevation of 5 m. above mean sea level (AMSL).

The land is on plot no. 902,923 Phase –III, GIDC Estate, Vapi- 396 195, Dist. Valsad. The total

plot area of the unit is 11970 sq.m.

Land ownership is with project proponents.

4.3 Existing Land use

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

4.4 Existing Infrastructure

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

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

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

approved authorized agencies.

4.5 Soil Classification

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

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

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



4.6 Climate data (Secondary Sources)

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

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

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

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

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

Surat is the nearest meteorological observatory station to the project site. The various

meteorological details of Surat station for the year March to May, 2013are given in table 11.

Table no 11: Micro meteorological Data

(Data from Indian Meteorological Department, Ahmadabad, Station:-Surat)

Month Temperature(oC) Humidity (%) Rain fall (mm)

Maximum Minimum Maximum Minimum Maximum Minimum

March- 13 38.4 17.8 95 11 0 0

April – 13 39 22.4 92 16 0 0

May -13 39 18 93 24 0 0



Figure 3: Wind rose diagarm for peroid of March 2013 to May 2013

4.7 Social Infra structure

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

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

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

chemical plants.

Infrastructure like Airport is at the distance of 90 km in North-waste direction. Nearest habitation

is Vapi Town, 4.37 km away from project site in West direction. All the required infrastructure

facilities are available in this town. National highway no.8 is 3km away in west direction from

project site.



5.0 PLANNING BRIEF

5.1 Planning Concept

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

At present, the unit is manufacturing 5595MT/Year involves hydrogenation, Diazotization,

Bromination, Condensation and Chlorination products.

Now the unit has proposed to manufacture of products by hydrogenation, Diazotization,

Bromination, Condensation and Chlorination. Also, the unit has proposed new products based on

hydrolysis.

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

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

road network.

5.2 Population projection

As per provisional reports of Census India, Population of Vapi in 2011 is 163 605 of which male

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

In education section, total literates in Vapi city are 143,706 of which 83, 720 are males while 59,

986 are females. Average literacy rate of Vapi city is 100.00 percent.

5.3 Land use planning

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

land.

5.4 Assessment of Infrastructure Demand

The M/s. Aarti Industries Ltd. (Alchemie Organics Division) shall get water from GIDC water

supply scheme. So there will be no additional stress on ground water resources and there will be

no adverse effect on the ground water resources available in the nearby area. The unit has 1200

KVA connected load form DGVCL as per CCA. Additional requirement for proposed expansion

will 800 KVA. The transportation facilities will also expect to improve due to increase in the

movement of workers and raw material and finished products.



5.5 Amenities

The available basic amenities are as under:

(A)Education Facilities:

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

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

(B) Medical Facilities:

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

are available in form of child welfare centre, primary health sub centre, and allopathic

dispensary, maternity & child welfare centers, registered private medical practitioners

and family welfare centre within the range.

(C)Drinking water Facilities & Power Supply:

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

supplied through taps, wells and tube wells. All the villages have power supply facilities

in the study region.

(D)Post, Telegraph & Telephone facilities

The information collected clearly indicates that the infrastructural facilities are provided

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

purpose, post office and phones are available in most of the villages. The villages having

non-availability of these facilities can get these facilities within 5-10km distance.

(E) Transport Facilities:

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

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

transport facility. Villages are connected with paved roads.

Source: 2001, Census.



6.0 Proposed Infrastructure

6.1 Processing Area

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

and utilities. The process area covered by the unit at ground level will be 4862 sq.m.

6.2 Non Processing Area

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

area covered by unit at ground level will be 7,108sq.m.

6.3 Green Belt

Out of the total land area of 11,970 Sq. m. approximately 2,346 sq.m is utilized for green belt

development. There will be provision of budget of 15 lakh rupees for green belt development .

6.4 Social Infrastructure

The availability of basic amenities is covered as under:

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

hazardous nature of chemicals used in the process. Also, training for fire fighting, work

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

activities.

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

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

Drinking water: There will be provision of Aqua

(C) Guard/R.O. at different places to provide purified water for drinking purpose.

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

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

(F) Power supply: There will be connected load of 2000 KVA from DGVCL.



6.5 Connectivity

6.6 Drinking water Management

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

adequate and satisfactory. The unit has proposed 40 KL/Day water for domestic purpose.

6.7 Sewerage system

The sewage will be treated in STP. Treated water will be used in gardening purpose and cooling

tower.

6.8 Industrial waste management

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

residue, spent solvents, Date expired pesticide, spent catalyst, incineration waste, spent carbon

and spent filter cloth will be generated from proposed project activity. The hazardous waste

management and disposal is shown in Annexure-IX.

6.9 Solid waste management

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

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

6.10 Power requirement & supply

At present, the unit has 1200 KVA connected load. As per CCA, and additional 800 KVA

connected load for proposed expansion. The unit will use total 2000 KVA electricity connected

load from DGVCL.

7.0 Rehabilitation and Resettlement(R &R) Plan

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

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

requirement of any R & R Plan.



8.0 Project Schedule & cost estimates

8.1 Project implementation Schedule

Table 12: Project Implementation Schedule

Project implementation schedule after getting NOC from GPCBSr.No.

Activity Required Period

1 Civil work Immediately after getting NOC2 Procurement of

machinery1 month after getting NOC

3 Eraction & installation ofmachinery

Immediately after competition of activity no.2

4 Trial of machinery &equipments

Within 1 months after competition of activity no.3

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

8.2 Estimated project cost

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

9.0 Analysis of proposal

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

indirect employment opportunities by availing local contract services during transportation

during operational phase.

The company intends to donate 2% of the profit to agencies like NGOs or social welfare

societies for projects carried out in nearby village for their welfare and upliftment.

Documents

PROJECT PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-01-19 · project pre-feasibility report and environment management plan on proposed