Project Pre-feasibility Report PROJECT PRE … Pre-feasibility Report Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants S. No. Particulars Page No. 3.4.3.10.3

Project Pre-feasibility Report

0 Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants

PROJECT PRE FEASIBILITY REPORT

ON

PROPOSED CAPACITY EXPANSION

For

MANUFACTURING OF SURFACTANTS &

SPECIALITY SURFACTANTS

At

Survey No. 193, Khanvel- Udhwa Road,

Village- Kherdi, Silvassa-396230

Submitted to

Ministry of Environment & Forest

By


Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants

CONTENTS S. No. Particulars Page No.

1 Executive Summary 1-3

2 Introduction Of The Project 4-6

2.1 Identification Of The Project And Project Proponent 4

2.1.1 Identification Of The Project 4

2.1.2 Project Proponent 5

2.2 Nature Of The Project 5

2.3 Need Of Project & Demand-Supply Gap 6

2.4 Imports Vs. Indigenous Production 6

2.5 Export Possibility 6

2.6 Domestic / Export Markets 6

2.7 Employment Generation Due To Project 6

3 Project Discription 7-59

3.1 Type & Location Of Project 7

3.1.1 Type 7

3.1.2 Location 7

3.2 Details Of The Alternative Site 9

3.3 Size & Magnitude Of Operation 10

3.4 Project Discription With Process Details 10

3.4.1 So3 Gas Generation 10

3.4.1.1 Manufacturing Process 10

3.4.1.2 Material Balance 11

3.4.2 Group A – Surfactants (100% Purity Basis) 11

3.4.2.1 Alfa Olefin Sulfonate (Aos) 11

3.4.2.1.1 Manufacturing Process 11

3.4.2.1.2 Chemical Reaction 12

3.4.2.1.3 Material Balance 13

3.4.2.2 Sodium Lauryl Sulfate (Sls) / Primary Alcohol Sulfate (Pas) 13




3.4.2.3 Sodium Lauryl Ether Sulfate (Sles) 15




3.4.2.4 Linear Alkyl Benzene Sulfonic Acid (Labsa/Acid Slurry) 16

3.4.2.4.1 Manufacturing Process 16 3.4.2.4.2 Chemical Reaction 17 3.4.2.4.3 Material Balance 17

3.4.2.5 Liquid Detergent (Formulation Product) 17



3.4.2.6 Household Detergents (Formulation Product) 18



3.4.2.7 Ammonium Lauryl Sulfate (Als) 19



S. No. Particulars Page No.




3.4.2.8 Ammonium Lauryl Ether Sulfate (Ales) 20




3.4.3 Group B – Speciality Surfactants 21

3.4.3.1 Fatty Monoethanol Amide 21



3.4.3.1.3 Material Balance 22 3.4.3.2 Fatty Diethanol Amide 22

3.4.3.2.1 Manufacturing Process 22 3.4.3.2.2 Chemical Reaction 23

3.4.3.2.3 Material Balance 23 3.4.3.3 Cocoamidopropyl Betaine 23

3.4.3.3.1 Manufacturing Process 23 3.4.3.3.2 Chemical Reaction 24


3.4.3.4 Coco Betaines 25




3.4.3.5 Amine Oxides 27

3.4.3.5.1 Manufacturing Process 27 3.4.3.5.2 Chemical Reaction 27 3.4.3.5.3 Material Balance 27

3.4.3.6 Sulfosuccinates (Lss Grade) 28




3.4.3.7 Sulfosuccinates (Les Grade) 29




3.4.3.8 Benzalkonum Chloride (Bkc-50) 31




3.4.3.9 Benzalkonum Chloride (Bkc-80) 32




3.4.3.10 Sodium Ether Carboxylate 33







3.4.3.11 Alcohol Ethoxylates (Formulation Product) 34



3.4.3.12 Ethylene Glycol Monostearate 34




3.4.3.13 Ethylene Glycol Distearate 35




3.4.3.14 Sorbitan Monooleate 36




3.5 Raw Material For Finished Products 37

3.5.1 Hazardous Chemical Storage & Handling 39

3.6 Resource Optimization & Availability 43

3.6.1 Land & Building Requirement 43

3.6.2 Equipments 43

3.6.3 Power And Fuel Requirement 44

3.6.4 Water Requirement 44

3.6.5 Man-Power Requirement 45

3.7 Quantity Of Waste To Be Generated 45

3.7.1 Waste Water Generation & Management 45

3.7.2 Waste Water Characteristics 48

3.7.3 Waste Water Treatment & Disposal 48

3.7.4 Air Emissions & Control 54

3.7.4.1 Process Emission 54

3.7.4.2 Utility Emission 54

3.7.4.3 Fugitive Emission 55

3.7.5 Hazardous / Non-Hazardous Wastes Management 56

3.7.6 Noise And Odour Control 56

3.7.7 Health And Safety Measures 57

3.7.8 Environmental Health & Safety Cell 57

3.7.9 Post Project Monitoring Plan 58

4 Site Analysis 60-65

4.1 Connectivity 60

4.2 Land Form, Land Use & Land Ownership 60

4.2.1 Land Form 60

4.2.2 Land Use Pattern 60

4.2.3 Land Ownership 61

4.3 Topography 61

4.4 Salient Features 62

4.5 Existing Infrastructure 62

4.6 Soil Classification 62




4.7 Climate & Meterology 63

4.7.1 Temperature 64

4.7.2 Humidity 64

4.7.3 Cloud Cover 64

4.7.4 Rainfall 64

4.7.5 Wind Pattern 64

4.8 Social Infrastructure 65

4.8.1 Educational Facilities 65

4.8.2 Medical Facilities 65

5 Planning Brief 66-68

5.1 Planning Concept 66

5.2 Population Projection 66

5.3 Area Statement 67

5.4 Assesment Of Infrastructure Demand (Physical & Social) 67

5.5 Amenities/Facilities 67

5.5.1 Drinking Water Facilities 67

5.5.2 Power Supply Facilities 68

5.5.3 Communication & Banking Facilities 68

5.5.4 Transport Facilities 68

5.5.5 Approach To Villages 68

5.5.6 Recreational Facilities 68

6 Proposed Infrastructure 69-70

6.1 Industrial Area 69

6.2 Residential Area 69

6.3 Greenbelt 69

6.4 Social Infrastucure 69

6.5 Connectivity 69

6.6 Drinking Water Management 69

6.7 Sewerage System 70

6.8 Industrial Waste Management 70

6.9 Solid Waste Management 70

6.10 Power Requirement & Source Of Supply 70

7 Rehabilitation & Resettlement (R &R) Plan 71

7.1 Policy To Be Adopted 71

8 Project Schedule & Cost Estimates 72

8.1 Time Schedule Of The Project 72

8.2 Estimated Project Cost 72

9 Analysis Of Proposal 73

9.1 Financial & Social Benefits 73



LIST OF TABLES Table

No.

Topic Page No.

1.1 Project Summary 1

2.1 List Of Proposed Products 4

2.2 Addresses Of Directors 5

3.1 List Of Raw-Materials (Product-Wise) 38

3.2 Storage, Handling & Transport Of Haz. Chemicals 40

3.3 Characteristics Of Raw Materials 41

3.4 Details Of Equipments 43

3.5 Details Of Power & Fuel 44

3.6 Category-Wise Water Requirement (In Kl/D) 45

3.7 Category-Wise Wastewater Generation (In Kl/D) 45

3.8 Characteristics Of Wastewater 48

3.9 Details Of Process Emission 54

3.10 Details Of Utility Emission 55

3.11 Details Of Hazardous Waste Generation & Disposal 56

3.12 Post Project Monitoring Plan 59

4.1 Land Use Distribution Of Dadra & Nagar Haveli (Dnh) 61

4.2 Salient Features Of The Project Site 62

4.3 Summary OF Meteorological Data At Nearest Imd Station - Dahanu 63

4.4 Details Of Educational Facilities 65

4.5 Details Of Medical Facilities 65

5.1 Distribution Of Population 66

5.2 Area Statement 67

5.3 Drinking Water Facilities 67

5.4 Power Supply Facilities 68

5.5 Communication & Banking Facilities 68

8.1 Total Capital Cost Projection 72

8.2 Recurring Cost Provision For Ehs (Per Annum) 72



LIST OF FIGURES

Sr. No. Description Page No.

3.1 Project Site 8

3.2 Satellite Image Of The Project 8

3.3 Project Site Layout With Key Plan 9

3.4 (A) Water Balance Diagram For Existing Operations (In Kld) 46

3.4 (B) Water Balance Diagram For Proposed Operations (In Kld) 47

3.5(a) Treatment Scheme For Existing Operation 49

3.5(b) Treatment Scheme For Proposed Operation 50

3.6 Schematic Diagram Of Effluent Treatment Plant 53

3.7 Organogram Of Ehs Cell 58

LIST OF ANNEXURES

Sr. No. Description

1. Existing Consolidated Consent & Authorization 75-77

2. Drawing Of Apcd With Sulfonation Plant 78

3. Drawing Of Proposed Spray Dryer 79

4. 7 X12 Of Existing LAND 80-82

5. Document in support of the project site being in industrial zone. 83-85


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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants

CHAPTER – 1

EXECUTIVE SUMMARY The project is summarized in the below table:

Table 1.1: Project Summary

PARTICULARS DETAILS

NAME OF THE UNIT

M/s. Aarti Industries Ltd. (Surfactants Specialities Division)

EX.DIRECTOR Shri – C. R. Chowdhury

PRODUCTS Sr. No.

Name of Finished products Existing Qty

(in MT/Month)

Total Qty after Expansion

(in MT/Month)

Group A – Surfactants (100% Purity Basis)

1. Alfa Olefin Sulfonate (AOS) 250

3000

2. Sodium Lauryl Sulfate (SLS)/ Primary Alcohol Sulfate (PAS)

250

3. Sodium Lauryl Ether Sulfate (SLES) 165

4. Linear Alkyl Benzene Sulfonic Acid (LABSA/Acid Slurry)

650

5. Liquid Detergents 250

6. Household Cleaners 150

7. Ammonium Lauryl Sulfate (ALS) --

8. Ammonium Lauryl Ether Sulfate (ALES) --

Group B - Speciality Surfactants

1. Fatty Monoethanol Amide --

2. Fatty Diethanol Amide --

3. Cocoamidopropyl Betaine --

4. Coco betaines --

5. Amine oxides --

6. Sodium Lauryl Sulfosuccinate (LSS)

--

7. Sodium Lauryl Sulfosuccinate (LES)

8. Benzalkonium Chloride 50%

--


10. Ether Carboxylate, Sodium Salt

11. Alcohol / Amine Ethoxylates --

12. Ethylene Glycol Mono Stearate --

13. Ethylene Glycol Di Stearate --

14. Sorbitan Mono Oleate --

Kindly note that after expansion, we propose to manufacture “Surfactants (Group-A)” & “Speciality Surfactants (Group-B)” @ 3000 MT/M for any one of the products or cumulative production capacity not exceeding more than 3000 MT/M.

LOCATION Survey No. 193, Khanvel-Udhwa Road, Village- Kherdi, Silvassa (U.T.)

NATURE OF PROJECT

Capacity Expansion for Manufacturing of Surfactants & Speciality Surfactants


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PARTICULARS DETAILS

RESOURCES

Resource type Requirement Source

Land Existing land area is 30000 m2 No additional land will be required for proposed project.

Building Existing Built-up area : 10716.06 m2 No additional building is to be constructed.

Raw-materials /Additives (Quantity in MT/MT)

Alfa Olefin, Sulfur , NaOH 48%, Water, Lauryl Alcohol, Ethoxylated Fatty Alcohol, Linear Alkyl Benzene, Liquor Ammonia, Fatty Acid, Monoethanol amine, Diethanol amine, DMAPA, MCA, DMLA, Hydrogen Peroxide, Maleic Anhydride, Sodium Sulfite, Benzyl Chloride, IPA, Mono Ethylene Glycol, Sorbitol, Glycerine For quantity of raw material please refer Chapter-3.

The raw materials are available in Local/ Indian market and are also imported from foreign countries.

Water Existing Scenario: Domestic - 4.0 KLD Industrial - 23.1 KLD Proposed Scenario: Domestic - 18.0 KLD Industrial - 214.0 KLD

Fresh water will be sourced from Borewell/Tanker.

Power Existing Scenario: 1120 KVA Proposed Scenario: 1600 KVA

State Electricity Board Grid D.G. Sets: Existing Scenario: 840 kVA (2 Nos.) Proposed Scenario: 1500 KVA (1 No.) & 750 KVA (1 No.) as Standby facility

Fuel Existing Scenario: Agro Based Fuel ( Baggase, Husk Briquette) –250 kg/hour Furnace oil (FO) – 102 LPH Light Diesel Oil (LDO) – 600 LPH Proposed Scenario: Furnace oil (FO) – 205 LPH (stand by) for 2 TPH boiler 50 LPH for SD burner. Light Diesel Oil (LDO) – 721 LPH Coal /lignite - 1000 kg/hour.

Authorized dealers

Man-power Existing Scenario: Skilled – 43 No (Approx) Unskilled – 59 No (Approx) Proposed Scenario: Skilled – 75 No (Approx) Unskilled – 100 No (Approx)

To be employed from local area

POLLUTION POTENTIAL & MITIGATION MEASURES

Parameter Potential Mitigation

Wastewater Existing Scenario:

Domestic: 3.0 KLD

Industrial: 3.1 KLD Proposed Scenario:

Domestic: 14.0 KLD

Industrial: 50.0 KLD

Existing domestic wastewater is being disposed through septic tank/ soaks pit system. Now we propose to install 20 KLD Sewage Treatment Plant for treatment and recycle of domestic effluent for gardening purpose.

High TDS stream from alkali scrubber, to be converted to Na2SO4 (15%) and reused in process.

In existing streams from washings, boiler and cooling is treated in ETP and treated wastewater is used for gardening.

After proposed expansion streams from process, washings, boiler and cooling will be treated in proposed state-of-the-art ETP and treated wastewater will be sent to RO & MEE then reused in cooling tower makeup.

Air Emissions Emission norms for Boilers, S D Burner, DG set and Process

PM < 150 mg/Nm3

SOx <100 ppm

In existing scenario, the company has two Steam Boilers having capacity of 4 TPH and 2 TPH which works on 50% load capacity.

The company will replaced two D.G. Sets having capacity of 840 KVA each by installing new two D.G. Sets having


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PARTICULARS DETAILS

NOx < 50 ppm

capacity of 1500 & 750 KVA which acts as standby unit

In proposed expansion additional one Thermic fluid heater having capacity of 2 Lakhkcal/hr will be installed and existing steam boiler of 4 TPH will be operated on 100 % load and steam boiler of 2 TPH will be act as standby facility.

Acid Mist & SO2 gas is generated as process emission gases from the Sulfonation plant. The gas is scrubbed out through Alkali scrubber.

In the proposed scenario, 2 Electrostatic precipitators shall be run in series to minimize the acid mist load on scrubber.

After proposed expansion Particulate matter will also be generated as process emission from the Spray Dryer Plant and Bag Filters will be provided as control measures.

Minor quantity of fugitive emissions will be lost as handling losses and some quantity is expected to be released in atmosphere during storage.

Raw Materials & Products are stored in properly designed storage area and under good storage conditions to prevent any volatilities

The fugitive emissions in terms of handling losses get reduced by proper storage and handling.

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

Good housekeeping maintained in the plant.

Adequate stack height is provided to all the utilities.

Hazardous & solid waste

Type of waste & Category

Existing Qty

Total Qty after

proposed expansion

ETP Waste (Cat. 34.3)

4.0 MT/Annum

500.0 MT/Annum

Used Oil (Cat. 5.1)

1.0 KL/Annum

2.0 KL/Annum

Discarded drums (Cat. 33.3)

240 Nos/Annum

30000 Nos/Annum

Used Ion Exchange material

0.05 MT/Annum

0.1 MT/Annum

Spent Catalyst

1.0 MT/Annum

3.0 MT/Annum

Spent Desiccant

0.05 MT/Annum

2.0 MT/Annum

ETP waste is being regularly sent to the PCC approved TSDF (GEPIL site) at Silvassa, for final disposal and the same will be followed for additional quantity.

The used oil is collected and stored separately in closed containers and finally sold to the registered re-refiners.

The discarded drums are stored separately in company premises and are returned back to the supplier / sold to the authorized re-conditioners and same practice will be followed for addn. qty.

Used Ion exchange material generated is stored properly and finally disposed off to GEPIL site, Silvassa.

Spent catalyst generated is stored properly and finally disposed off to GEPIL site, Silvassa.

Spent Desiccant generated will be stored properly and finally disposed off to GEPIL site, Silvassa

Noise Expected levels

Inside the plant: 75 dB(A)

Sturdy foundation to all the noise generating equipments.

D.G. Set installed in closed room

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

Greenbelt will be further developed.


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CHAPTER – 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT

M/s. Aarti Industries Ltd. (Surfactants Specialities Division) located at Survey No. 193,

Khanvel-Udhwa Road, Village- Kherdi; Silvassa (U.T.) is in operation since 2002. Today we are

one of the pioneer and leading companies in the manufacturing of “Surfactants and Speciality

Surfactants”. We propose expansion of the existing unit by way of increasing the production

capacity of the existing products and introducing some new products. Existing CC&A No.

PCC/DDD/O-1594/WA/AA/UR/01-02//346 dated 09/10/2013 is attached as Annexure-1. The

list wise product expansion is as given below:

Table 2.1: List of Proposed Products

Sr. No. Name of Finished products Existing Qty

(in MT/Month)

Total Qty after Expansion

(in MT/Month)

Group A – Surfactants (100% Purity Basis)

1. Alfa Olefin Sulfonate (AOS) 250

3000

2. Sodium Lauryl Sulfate (SLS)/ Primary Alocohol Sulfate (PAS)

250

3. Sodium Lauryl Ether Sulfate (SLES) 165

4. Linear Alkyl Benzene Sulfonic Acid (LABSA/Acid Slurry)

650

5. Liquid Detergents 250

6. Household Cleaners 150

7. Ammonium Lauryl Sulfate (ALS) --

8. Ammonium Lauryl Ether Sulfate (ALES) --

Group B - Speciality Surfactants

1. Fatty Monoethanol Amide --

2. Fatty Diethanol Amide --

3. Cocoamidopropyl Betaine --

4. Coco betaines --

5. Amine oxides --

6. Sodium Lauryl Sulfosuccinate (LSS)

7. Sodium Lauryl Sulfosuccinate (LES)


--

9. Benzalkonium Chloride 80% --

10. Ether Carboxylate, Sodium Salt --

11. Alcohol / Amine Ethoxylates --

12. Ethylene Glycol MonoStearate --


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13. Ethylene Glycol DiStearate --

14. Sorbitan Monooleate --

Kindly note that after expansion, we propose to manufacture “Surfactants (Group-A)” & “Speciality Surfactants (Group-B)” @ 3000 MT/M for any one of the products or cumulative production capacity not exceeding more than 3000 MT/M.

2.1.2 PROJECT PROPONENT The company is a limited firm and is promoted by board of directors.

Shri. Rajendra Gogari and Shri. Parimal Desai- UDCT Graduate Engineers are associated with

this group right from the inception and setting of various operations and is having vast

experience in the field of marketing, finance and administration.

Shri. Rashesh Gogri is also associated with all the group operations for more than last 18 years

and is having thorough experience in marketing, administration and technicalities.

All other directors are also having ample experience of marketing, finance and administration.

Table 2.2: Addresses of Directors

Sr. No.

Name of Director Designation Address Telephone No.

1.

Shri. Rajendra V. Gogri Chairman & Managing Director

1401,Antriksh Morar 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. Uarg, Mulund (W) Mumbai-400080

022-67976666

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

2.2 NATURE OF THE PROJECT

The proposed expansion project of the manufacturing of “Surfactants and Speciality

Surfactants” falls under the item no. 5(f) i.e. Synthetic Organic Chemicals Category “B” as

per the EIA notification, 2006 (as amended timely).


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Due to the applicability of “General Conditions”, and presence of interstate boundary of

Maharashtra within 5 km areal distance, the project is to be appraised at the central level.

2.3 NEED OF PROJECT & DEMAND-SUPPLY GAP

M/s. Aarti Industries Ltd. (Surfactants Specialties Division) is engaged in manufacturing of

Surfactants and Specialty Surfactants. In a developing nation like ours, surfactant plays an

important role in providing hygienic conditions by virtue of its cleaning and disinfectant

properties. Surfactants are used in the manufacturing of various household products like

shampoos, hand wash, face wash, liquid detergents, laundry detergents, etc. In the growing

need of domestic and overseas market for surfactants and specialty surfactants and due to

demand-supply gap, we propose expansion of the existing unit by way of increasing the

production capacity of the existing products and introducing some new products.

2.4 IMPORTS VS. INDIGENOUS PRODUCTION

In the existing project, all the raw materials are available indigenously and are also imported.

The raw materials for the proposed range of products will be indigenously available and will also

be imported.

2.5 EXPORT POSSIBILITY

There is a very good potential if we can produce and offer more quantities and multiple

products.

2.6 DOMESTIC / EXPORT MARKETS

Surfactant plays an important role in providing hygienic conditions by virtue of its cleaning and

disinfectant properties. Surfactants are used in the manufacturing of various household products

like shampoos, hand wash, face wash, liquid detergents, laundry detergents, etc. which will fulfill

the growing need of domestic market.

2.7 EMPLOYMENT GENERATION DUE TO PROJECT

Employment will be generated by the proposed project. 175 persons will be employed for the

proposed expansion project. The man-power required for the project will be employed locally

from the nearby areas. Skilled as well as unskilled labour will be employed for the project.


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CHAPTER – 3

PROJECT DISCRIPTION

3.1 TYPE & LOCATION OF PROJECT

3.1.1 TYPE

The proposed project is the type of capacity enhancement project of manufacturing of

Surfactant and Specialty Surfactants.

3.1.2 LOCATION

The industry named M/s. Aarti Industries Ltd. falling under Large Scale category proposes

expansion in existing production capacity and addition of new products at Survey No. 193,

Khanvel-Udhwa Road, and Village- Kherdi Silvassa (U.T.)

There are more than 1,600 S.S.I. units, which include Cottage, Village Industries and 430

Medium Scale/Large Scale Industries in Textiles, Engineering, Plastics, Electronics, Chemicals,

Pharmaceuticals, etc., employing more than 43,100 persons.

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

supply, arrangements for power, streetlights & other common facilities like Hospitals, Hotels,

Banks, Meeting Halls, etc.

Location of project site, satellite image of project site & Layout are shown in figure 3.1, 3.2 &

figure 3.3.


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Figure 3.1: Project Site

Figure 3.2: Satellite image of the project


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Figure 3.3: Project Site layout with key plan

3.2 DETAILS OF THE ALTERNATIVE SITE

The major reason for selection of the particular site is because it has sufficient land to

accommodate the proposed expansion project and also our major purchasers are located in the

vicinity of the region. Secondly; there is no Octroi Duty and power is available at subsidized

rates in the region. The territory’s vicinity to well developed industrial estate in Vapi, Daman &

Sarigam also plays an important role in the site selection.

Based on the above reasons, this location is most suitable for the proposed project and hence

no other alternative site is selected.

THE LOCATION JUSTIFICATION FOR THE PROJECT IS AS UNDER:

Availability of well connected roads to the plant site for movement of equipments, raw

material, finished products etc.

Availability of the resources like water, fuel, power etc.

Suitability of land and topographical and geological considerations.

Environmental and ecological impacts.


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3.3 SIZE & MAGNITUDE OF OPERATION

The total magnitude of operation will be @ 3000 MT/M for any one of the products or cumulative

production capacity not exceeding more than 3000 MT/M of Surfactant & Specialty Surfactants.

3.4 PROJECT DISCRIPTION WITH PROCESS DETAILS

The proposed products process details like Process description, Material Balance and Chemical

reactions for each grade of products are as below.

The manufacturing of Surfactants and Speciality Surfactants involves a major process which is

SO3 Gas Generation for which the company has a separate plant. The SO3 gas is used at a

primary stage of the process. The manufacturing process and mass balance for SO3 Gas

Generation is shown below along with the manufacturing process, chemical reactions and mass

balance for each product.

3.4.1 SO3 GAS GENERATION

3.4.1.1 MANUFACTURING PROCESS

Raw Sulfur is available in solid form. This is melted in a melter. The molten sulfur is fed to the

burner along with dry air. The liquid sulfur is oxidized to Sulfur dioxide.

Sulfur dioxide is cooled to ~400 - 450oC and passed through Vanadium pentoxide catalyst bed

where SO2 is converted to SO3.

This SO3 is further provided to reactors for carrying out sulfonation and sulfation reactions to

produce Surfactants.

This is intermediate product. It is produced and used instantaneously.


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3.4.1.2 MATERIAL BALANCE

3.4.2 GROUP A – SURFACTANTS (100% PURITY BASIS)

3.4.2.1 ALFA OLEFIN SULFONATE (AOS)

3.4.2.1.1 MANUFACTURING PROCESS

Alfa Olefin is sulfonated using gaseous sulfur trioxide in continuous process reactor. The acid

formed is unstable and immediately neutralized with Sodium Hydroxide (48%) and diluted with

water using a highly efficient mixing and recycle pump.


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The neutralized product is further hydrolyzed at high temperature (130 -150oC) for 30 -90

minutes to convert any un-reacted part into finished product. The product formed is transferred

to storage tank using mechanical pump.

The product is available as 70% Active Paste. The same can be diluted with water to produce

37 -39% Active Liquid. The paste / liquid can be further dried to produce solid (Powder or

Needle) form. Needle formed is achieved by using Mixer / Plodder.

3.4.2.1.2 CHEMICAL REACTION


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3.4.2.1.3 MATERIAL BALANCE

3.4.2.2 SODIUM LAURYL SULFATE (SLS) / PRIMARY ALCOHOL SULFATE (PAS)


Lauryl Alcohol is sulfated using gaseous sulfur trioxide in continuous process reactor. The acid

formed is highly unstable and immediately neutralized with Sodium Hydroxide (48%) and diluted

with water using a highly efficient mixing and recycle pump.


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The product formed is transferred to storage tank using mechanical pump. The liquid is further

dried to produce solid (Powder or Needle) form of Sodium Lauryl Sulfate. Needle formed is

achieved by using Mixer / Plodder.




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3.4.2.3 SODIUM LAURYL ETHER SULFATE (SLES)


Ethoxylated Lauryl Alcohol is sulfated using gaseous sulfur trioxide in continuous process

reactor. The acid formed is highly unstable and immediately neutralized with Sodium Hydroxide

(48%) and diluted with water using a highly efficient mixing and recycle pump. The Product

formed is transferred to storage tank using mechanical pump.

This product is available as 70% active paste and same can be diluted with water to produce 27

-28% active liquid product.



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3.4.2.4 LINEAR ALKYL BENZENE SULFONIC ACID (LABSA/ACID SLURRY)


Linear Alkyl Benzene (LAB) is sulfonated using gaseous sulfur trioxide in continuous process

reactor. The acid formed is passed through digester and then aging is provided. During aging

water is added to stabilize the product.

This is stable acid and is used as finished product containing 96% Active Matter.


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MATERIAL BALANCE

3.4.2.5 LIQUID DETERGENT (FORMULATION PRODUCT)


This is a simple blended or formulated product. Surfactants like Sodium Lauryl Ether Sulfate,

Sodium Lauryl Sulfate, Alfa Olefin Sulfonate are mixed as per the requirement. Speciality

Surfactants like CDEA, CAPB and BKC are added as required.


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The product is properly mixed and adjusted as per the customer requirement. Sufficient Water is

added to adjust the active content or solids. The product is filled in container.


3.4.2.6 HOUSEHOLD DETERGENTS (FORMULATION PRODUCT)


This is a simple blended or formulated product. Surfactants like Sodium Lauryl Ether Sulfate,

Sodium Lauryl Sulfate, Alfa Olefin Sulfonate are mixed as per the requirement. Speciality

Surfactants like CDEA, CAPB and BKC are added as required.

The product is properly mixed and adjusted as per the customer requirement. Sufficient Water is

added to adjust the active content or solids. The product is filled in container.


19



3.4.2.7 AMMONIUM LAURYL SULFATE (ALS)


Lauryl Alcohol is sulfated using gaseous sulfur trioxide in continuous process reactor. The acid

formed is highly unstable and immediately neutralized with Ammonia Solution (25%) and diluted

with water using a highly efficient mixing and recycle pump.

The Product formed is transferred to storage tank using mechanical pump. The product is used

as 70% Active Paste or can be diluted with water to produce 25 -27% Active Liquid Product.



20



3.4.2.8 AMMONIUM LAURYL ETHER SULFATE (ALES)


Ethoxylated Lauryl Alcohol is sulfated using gaseous sulfur trioxide in continuous process

reactor. The acid formed is highly unstable and immediately neutralized with Ammonia solution

(25%) and diluted with water using a highly efficient mixing and recycle pump.

The Product formed is transferred to storage tank using mechanical pump. This product is

available as 70% active paste and same can be diluted with water to produce 24 -26% active

liquid product.



21



3.4.3 GROUP B – SPECIALITY SURFACTANTS

3.4.3.1 FATTY MONOETHANOL AMIDE


Esterification of Fatty acid with Mono ethanolamine is carried out at 140 -160oC. The product is

allowed to age for completion of reaction for 5-6 hrs.

The liquid product formed can be allowed to pass through flaker / prilling to produce flakes or

prills / granules.


22




3.4.3.2 FATTY DIETHANOL AMIDE


Esterification of Fatty acid with Di ethanolamine is carried out at 140 -160oC. The product is

allowed to age for completion of reaction for 5-6 hrs. The liquid product formed is directly filled in

containers.


23




3.4.3.3 COCOAMIDOPROPYL BETAINE


Amidation of Fatty acid is carried out with Dimethylamine propylamine at 140 -160oC. The amide

formed is quaternized with Monochloroacetic acid and Sodium Hydroxide 48%. Water is added

to make the product in liquid form.


24


After the quaternization is over, pH of the product is adjusted if required. The Liquid product is

directly filled in containers.



25



3.4.3.4 COCO BETAINES


Alkylation of Dimethyl Lauryl amine is done with Mono-chloro acetic acid in presence of

equivalent amount of Sodium Hydroxide 48%. Sufficient Water is added to make the product in

liquid form. This process is also referred as quaternization.

After the quaternization is over, pH of the product is adjusted if required. The Liquid product is



26





27


3.4.3.5 AMINE OXIDES


Oxidation reaction of Dimethyl Lauryl amine is carried out by using Hydrogen peroxide (50%) at

atmospheric pressure. After the oxidation is over, product is digested and then cooled. The

product is suitably diluted with water and filled in containers.




28


3.4.3.6 SULFOSUCCINATES (LSS GRADE)


Esterification of Fatty alcohol and Maleic anhydride is carried out. The half ester is formed.

Sulfitation reaction of half ester is carried out using Sodium Sulfite.

Sufficient water is added to produce the product is liquid form. This product is soft, waxy semi-

solid at normal temperature.



29



3.4.3.7 SULFOSUCCINATES (LES GRADE)


Esterification of Ethoxylated Fatty alcohol and Maleic anhydride is carried out. The half ester is

formed. Sulfitation reaction of half ester is carried out using Sodium Sulfite.

Sufficient water is added to produce the product in liquid form. This product is a clear viscous

liquid at normal temperature.


30



3.4.16.1 MATERIAL BALANCE


31


3.4.3.8 BENZALKONUM CHLORIDE (BKC-50)


Dimethyl Lauryl Amine is quaternized with Benzyl chloride at controlled temperature. The

product is digested and sufficiently diluted to produce finished product containing 50% Active.

The Liquid Product is directly filled in containers.




32


3.4.3.9 BENZALKONUM CHLORIDE (BKC-80)


Dimethyl lauryl amine is quaternized with Benzyl chloride at controlled temperature. The product

is digested and sufficiently diluted to produce finished product containing 50% Active.

Solvent is also added to the product to keep the product in flow able form. The Liquid Product is





33


3.4.3.10 SODIUM ETHER CARBOXYLATE


Carboxylation of Ethoxylated Fatty alcohol is carried out using Monochloroacetate. Sufficient

water is added to produce the product is liquid form. This product is a clear viscous liquid at

normal temperature.




34


3.4.3.11 ALCOHOL ETHOXYLATES (FORMULATION PRODUCT)


Crude Ethoxylated Alcohol is adjusted with Sodium Hydroxide solution or Acetic acid. The

product is properly mixed and filled in containers. This is available as 100% Active Product.


3.4.3.12 ETHYLENE GLYCOL MONOSTEARATE


Ethylene Glycol Mono Stearate is an organic compound with the molecular formula C20H40O3. It

is theester of stearic acid and ethylene glycol. It is used as an ingredient in many types of

personal care products and cosmetics including shampoos, hair conditioners, and skin lotions.


35




3.4.3.13 ETHYLENE GLYCOL DISTEARATE


Ethylene Glycol Di Stearate is an organic compound. It is the ester of 2 moles of Stearic acid

and 1 mole ofethylene glycol. It is used as an ingredient in many types of personal care

products and cosmetics including shampoos, hair conditioners, and skin lotions.


36




3.4.3.14 SORBITAN MONOOLEATE


Sorbitan Mono Oleate is produced by direct reaction of sorbitol with fatty acid in the molar ratio

of 1:0.9.

This is a simple esterification / condensation reaction and the temperature of 220 -250 0C and

the product is in the form of 100% Active Ingredient.


37




3.5 RAW MATERIAL FOR FINISHED PRODUCTS

The existing products are widely manufactured and are old and steady products. All the raw

materials are available indigenously and are also imported. The raw materials for the proposed

range of products are also indigenously available and will be imported. The product-wise raw-

material consumption is given in Table 3.1.


38


Table 3.1 List of Raw-materials (Product-wise)

Sr. No. Raw Materials Quantity (in MT/MT)

SO3 Gas Generation

1. Sulfur 0.402

Alfa Olefin Sulfonate

1. Alfa Olefin 0.689

2. Sulfur trioxide 0.291

3. NaOH (48%) 0.303

Sodium Lauryl Sulfate (SLS) – 95% (Powder/Needle Form)

1. Fatty Alcohol 0.678


3. NaOH (48%) 0.297

Sodium Lauryl Ether Sulfate (SLES) – 70% (Paste Form)

1. Ethoxylated Fatty Alcohol 0.551


3. NaOH (48%) 0.219

Liquid Detergents

1. Surfactants 0.750

2. Sp. Surfactants 0.150

Linear Alkyl Benzene Sulfonic Acid

1. Linear Alkyl Benzene 0.722


Household Detergents

1. Surfactants 0.520

2. Sp. Surfactants 0.380

Ammonium Lauryl Sulfate

1. Lauryl Alcohol 0.70


3. Ammonia 0.175

Ammonium Lauryl Ether Sulfate

1. Ethoxylated Lauryl Alcohol 0.8


3. Ammonia 0.151

Fatty Monoethanol Amide

1. Fatty Acid 0.771

2. Monoethanol Amine 0.229

Fatty Diethanol Amide

1. Fatty Acid 0.657

2. Monoethanol Amine 0.343

Cocoamidopropyl Betaine

1. Fatty Acid 0.185

2. DAPA 0.100

3. MCA 0.091

4. NaOH (48%) 0.080

Coco Betaine

1. DMLA 0.225

2. CAA 0.105


39


Sr. No. Raw Materials Quantity (in MT/MT)

3. NaOH (48%) 0.092

Amine Oxides

1. DMLA 0.303

2. Hydrogen Peroxide 0.096

Sulfosuccinates – Sodium Lauryl Sulfosuccinate (LSS grade)

1. Fatty Alcohol 0.199

2. Maleic Anhydride 0.101

3. Sodium Sulfide 0.132

Sulfosuccinates – Sodium Lauryl Sulfosuccinate (LES grade)


2. Maleic Anhydride 0.078

3. Sodium Sulfide 0.107

Benzalkonium Chloride (BKC-50)

1. Dimethyl Fatty Amine 0.326

2. Benzyl Chloride 0.183

Benzalkonium Chloride (BKC-80)

1. Dimethyl Fatty Amine 0.516

2. Benzyl Chloride 0.290

3. Solvent (IPA) 0.050

Sodium Ether Carboxylate


2. MCA 0.045

3. NaOH (48%) 0.084

Ethixylated Lauryl Alcohol

1. Crude Ethoxylated Fatty Alcohol 0.253

2. MCA 0.045

3. NaOH (48%) 0.084

Ethylene Glycol Monostearate

1. Fatty Acid 0.870

2. Ethylyne Glycol 0.190

Ethylene Glycol Distearate

1. Fatty Acid 0.960

2. Ethylyne Glycol 0.100

Sorbitan Mono Oleate

1. Fatty Acid 0.610

2. Sorbitol 0.390

3.5.1 HAZARDOUS CHEMICAL STORAGE & HANDLING

Hazardous chemicals will be used as raw material in the manufacturing process. The details of

the raw materials are given below in table 3.2.


40


Table 3.2: Storage, Handling & Transport of Haz. Chemicals

Raw Material Source Means of

storage

Means of

transport

Storage conditions Max. Qty. to be

stored

(In MT) Press., Kg/m2

Temp (ºC)

Alfa Olefin Imp Storage Tank By road Atm Ambient 300

Sulfur trioxide In-house -- - 1 45 -

NaOH (48%) Ind Storage Tank By road Atm Ambient 70

Fatty Alcohol Ind / Imp Storage Tank By road Atm Ambient 200

Ethoxylated Fatty Alcohol Ind / Imp Storage Tank By road Atm Ambient 200

Surfactants In-house Storage Tank By road Atm Ambient 500

Sp. Surfactants In-house Storage Tank By road Atm Ambient 100

Linear Alkyl Benzene Ind / Imp Storage Tank By road Atm Ambient 200

Ammonium hydroxide (25%) Ind Storage Tank By road Atm Ambient 30

Fatty Acid Ind / Imp Drums By road Atm Ambient 100

Monoethanol amine (MEA) Ind / Imp Drums By road Atm Ambient 70

Diethanol amine (DEA) Ind / Imp Drums By road Atm Ambient 20

Dimethyl amine propyl amine (DMAPA)

Ind / Imp Drums By road Atm Ambient 40

Monochloro Acetic Acid (MCA)

Ind / Imp Bags By road Atm Ambient 20

Dimethyl Lauryl Amine (DMLA)

Imp Drums By road Atm Ambient 70

Hydrogen Peroxide Ind / Imp Drums By road Atm Ambient 20

Maleic Anhydride Ind / Imp Bags By road Atm Ambient 25

Sodium Sulfite Ind Bags By road Atm Ambient 20

Benzyl Chloride Ind / Imp Drums By road Atm Ambient 50

IPA Ind / Imp Drums By road Atm Ambient 5

Crude Ethoxylated Fatty Alcohol

Ind / Imp Storage Tank By road Atm Ambient 25

Chloro Acetic Acid Ind Drums By road Atm Ambient 10

Hydrochloric Acid Ind Drums By road Atm Ambient 2

Phosphoric Acid Ind / Imp Drums By road Atm Ambient 5

Sorbitol Ind / Imp Drums By road Atm Ambient 5

Glycerine Ind / Imp Drums By road Atm Ambient 2

Monoethylene Glycol (MEG) Ind / Imp Drums By road Atm Ambient 5



Table 3.3: Characteristics of Raw Materials

SR No.

NAME OF CHEMICAL

CAS No. HAZARD

FLASH POINT0 C (CC)

BP 0 C

MP 0 C

LEL %

UEL %

SP.GR. 20 0 C

VD SOLUBILITY WITH WATER at 25 0 C

NFPA

TLV ppm/ mg/m3 TWA

IDLH LC50 mg/m3

CARCINOGENIC CHARACTERISTIC

H F R

1. Alfa Olefin 1120-36-1

F >107 251 -13.9 0.5 5.4 0.77 (15.60

C)

6.8 In Soluble 0 1 0 NA NA 9900 NA

2. Sulfur trioxide 7446-11-9

H & R NA* 45 16.8 NA NA 1.92 2.8 Very Soluble 3 0 2 NA NA NA YES

3. NaOH 48% 1310-73-2

H & R NA 1390 318 NA NA 2.13 >1.0 Soluble 3 0 1 2 NA NA NA

4. Lauryl Alcohol 112-53-8 H & F 129 254-259

23 0.6 5.1 NA 6.4 In Soluble 2 2 0 NA NA 1.01 NA

5. Ethoxylated Fatty Alcohol

68439-45-2

H & F NA 100 9.9-10.8

NA NA 0.902 NA Soluble 1 1 0 1 ppm NA 1-10 YES

6. Surfactants Mixture H NA 100 10.36 NA NA 1.03 3.4 Easily Soluble 3 0 0 1 TWA NA NA YES

7. Sp. Surfactants 9003-11-6

H & F NA NA NA NA NA 0.99-1.03

NA Soluble 1 1 0 NA NA NA NA

8. Linear Alkyl Benzene

6774-74-7

F 140 278-314

NA NA NA 0.858 8.4 Slightly Soluble 0 1 0 NA* NA* NA* NO

9. Ammonia 7664-41-7

H & F -- -33.3 NA 16 25 NA 0.62 Very Soluble 3 1 0 25 NA 2000 --

10. Fatty Acid 67701-05-7

--- 100 239.7-365.2

20-28 NA NA NA NA In Soluble --- NA NA NA NA

11. Monoethanol amine

141-43-5 H & F 86 170.8 10.3 3 23.5 1.018 2.1 Soluble 3 2 0 6 ppm NA NA NA

12. Diethanol amine

111-42-2 H & F 165.6 268 28 NA NA 1.1 3.6 Soluble 1 1 0 0.46 ppm

NA NA NA

13. Dimethyl amine propyl amine

109-55-7 H & F 32 133 60 2-3 12-35

8120 3.5 Soluble 3 3 0 NA NA 4 ppm (Rats)

NO

14. MCA 79-11-8 H & F 150 189 63 8 --- 1.4043 NA Soluble 3 1 0 NA NA 254.6 ppm (Rats)

NA

15. DMLA 112-18-5/112-75-4

H & F 118 110-112

-20 NA NA 7870 7.36 NA 3 1 0 NA NA 1.1 g/kg (Rats)

NO

16. Hydrogen Peroxide

7732-18-5

H & R NA 108 -33 NA NA 1.2 1.1 Easily Soluble 3 0 1 1.42 TWA

NA NA YES


42


SR No.

NAME OF CHEMICAL

CAS No. HAZARD

FLASH POINT0 C (CC)

BP 0 C

MP 0 C

LEL %

UEL %

SP.GR. 20 0 C

VD SOLUBILITY WITH WATER at 25 0 C

NFPA

TLV ppm/ mg/m3 TWA

IDLH LC50 mg/m3

CARCINOGENIC CHARACTERISTIC

17. Maleic Anhydride

108-31-6 F T R 103.3 202 NA 1.4 7.1 1.48 3.4 Soluble 3 1 2 0.25 ppm

10 NA* NO

18. Sodium Sulfide 1313-82-2

H & F NA NA 1180 NA NA 1.86 NA Soluble 3 1 1 NA NA NA NA

19. Benzyl Chloride

100-44-7 H & F 67.2 179 -43 1.1 14 1.1 4.36 Partially soluble 3 2 1 --- NA 1231 (Rat)

YES

20. IPA 67-63-0 H & F 11.667 82.5 -88.5 2 12.7 0.78 2.07 Easily Soluble 1 3 0 400 ppm

NA 3600 (Mouse)

NO

21. Phosphoric Acid

7664-38-2

H NA 158 21 NA NA 1.685 3.4 Easily Soluble 1 0 0 1 TWA NA NA NA

22. Acetic Acid 64-19-7 H &F 39 118.1 16.7 NA NA 1.049 2.07 Soluble 3 2 0 10 ppm NA 5620 NA

23. Hydrochloric Acid

7647-01-0

H & R NA 108.5 -62.25

NA NA 1.1 -1.19

1.267 Soluble 3 0 1 NA NA 1108 NA

24. Sorbitol 50-70-4 H & F 100 296 NA NA NA 1.489 NA Soluble 2 1 0 NA NA NA NA

25. Glycerine 56- 81 -5 H & F 189 290 20 NA NA 1.26 NA Soluble 1 1 0 NA NA NA NA

26. Monoethylene Glycol (MEG)

107 -21 -1

H & F 111 197 NA NA NA 1.115 NA Soluble 1 1 0 NA NA NA NA

Note: NA = Not available, NA* = Not Applicable, M.P.=Melting Point, B.P.=Boiling Point, F.P.=Flash Point, TLV=Threshold Limit Value, LC50= Median Lethal Concentration, UEL= Upper flammable limit, LEL= Lower flammable limit, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million, ND = Not Detectabl



3.6 RESOURCE OPTIMIZATION & AVAILABILITY

The major resources for the proposed project will be plant & machinery, raw-materials, power,

fuel, water, man-power, etc.

3.6.1 LAND & BUILDING REQUIREMENT

Total plot area of existing unit is 30000 m2. No additional land will be required for proposed

expansion. The existing built-up area is 10716.06 m2 .

3.6.2 EQUIPMENTS

Based on process necessity, list of the proposed machinery is shown in the table given below:

Table 3.4: Details of Equipments

S. No. Equipment Existing (Nos.) Proposed (Nos.) Total (Nos.)

1. Sulfur melter 1 1

2. Sulfur Burner 1 1

3. Catalyst tower 1 1

4. Cascade cooler 1 1

5. Mist Eliminator 1 1

6. Acid Absorber 1 1

7. ESP 1 1 2

8. Alkali Scrubber 1 1

9. Falling Film Reactor 2 2

10. Neutralizer pump 2 2

11. Hydrolyser 2 2

12. Digester 2 2

13. Turbo tube dryer 2 2

14. Stripper 1 1

15. Steam Boiler 2 2

16. Air Compressor 1 1 2

17. Regeneration Air Blower 2 2

18. ADP Cooling air blower 2 2

19. ADP Drying Bed 2 2 4

20. Air Chiller 1 1 2

21. Cooling Tower 2 2 4

22. Product Adjustment tank 20KL 3 3

23. Product Adjustment tank 10KL 3 3

24. Bucket Filter 2 2 4

25. Spray Drying Tower 0 1 1

26. Stirred Reactors 3 3 6


44


3.6.3 POWER AND FUEL REQUIREMENT

The total existing power requirement is 1120 KVA which is sourced from State Electricity Board

Grid. After the proposed expansion total power required will be 1600 KVA which will be sourced

from State Electricity Board Grid.

In existing, the company has 2 Nos of D.G. Sets of 840 KVA capacity which acts as standby

facility and is used only in case of power failure. For proposed scenario, existing D.G. sets will

be replaced by 2 Nos. of D.G. sets of 1500 kVA and 750 kVA capacities which will act as

standby facility and will be used only in case of power failure.

Agro Based Fuel (Baggase, Husk Briquette) ,Furnace oil (FO) ,Light Diesel Oil (LDO) are used

as fuel for existing operations which are obtained from authorized dealers.

Coal/Lignite, Furnace oil (FO),Light Diesel Oil (LDO) will be used as fuel for proposed

operations which will be obtained from authorized dealers.

Table 3.5: Details of Power & Fuel

Sr. No. Particulars Existing Requirement Requirement after Proposed

Expansion

Power

1. Power Requirement 1120 kVA 1600 kVA

2. Source of supply State Electricity Board Grid and D.G. Set – 2 no. (840 KVA) – Standby facility

State Electricity Board Grid and D.G. Set – 2 no. (1500 &750 KVA) – Standby facility

Fuel

1. Fuel & it’s consumption

Briquettes – 250 kg/Hr Furnace oil (FO) – 102 LPH LDO – 600 LPH

Coal/lignite – 1000 kg/Hr Furnace oil (FO) –for 2 TPH boiler 205 LPH stand by & for SD burner 50 LPH. LDO – 721 LPH

2. Source of supply Authorised dealers Authorised dealers

3.6.4 WATER REQUIREMENT

The source of fresh water is/will be the Bore-well/Tanker water supply. Other than the general

water requirements for domestic usage, water will also be required in the process & washing

section. The total fresh water consumption for existing unit is 27.1KL/D. Total water

consumption after proposed expansion will be 232.0 KL/D. The category wise bifurcation of the

water requirement is given in the Water Balance Data in Table 3.6.


45


Table 3.6: Category-wise Water Requirement (in KL/D)

Particulars Existing Scenario Proposed Scenario

Domestic 4.0 18.0

Gardening -- --

Industrial

Softener (reject) -- 10.0

Process 8.4 64.0

Washing 0.5 4.0

Boiler 9.3 45.0

Cooling 4.9 91.0

Sub-Total: Industrial 23.1 214.0

Grand Total 27.1 232.0

3.6.5 MAN-POWER REQUIREMENT

The existing man-power requirement is 102 no. The total number of man power after the

proposed expansion project will be 175 persons.

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

3.7 QUANTITY OF WASTE TO BE GENERATED

3.7.1 WASTE WATER GENERATION & MANAGEMENT

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

Table 3.7: Category-wise Wastewater Generation (in KL/D)

Particulars Existing Scenario Proposed Scenario

Domestic 3.0 14.0

Industrial

Softener reject -- 10.0

Process 0.0 6.0

Washing 0.5 4.0

Boiler 2.1 5.0

Cooling 0.5 25.0

Sub-Total: Industrial 3.1 50.0

Grand Total 6.1 64.0


46


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


47


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


48


3.7.2 WASTE WATER CHARACTERISTICS

In existing domestic wastewater is being disposed through septic tank/ soaks pit system. After

proposed expansion domestic wastewater will be treated in the proposed 20 KLD Sewage

Treatment Plant and treated water from STP will be used for gardening purpose.

For the industrial effluent from the proposed production activities, necessary maintenance and

modifications will be made in the existing ETP.

The wastewater characteristic of effluent before and after treatment in ETP is given below in

Table No. 3.8.

Table 3.8: Characteristics of Wastewater

Sr. No.

Parameter

Characteristics

Untreated Treated Permissible limit

1. pH 9 – 11 < 6.5 to 8.5 6.5-8.5

2. Suspended Solids (SS) 650-850 < 100 100

3. Total Dissolved Solids 2000-2500 < 2100 < 2100

4. Chemical Oxygen Demand (COD)

4500-5000 < 250 250

5. Biochemical Oxygen Demand (BOD)

1800-2000 < 100 100

6. Oil & Grease 160-180 < 10 10

Note: All above values in mg/ lit except pH or where specified.

3.7.3 WASTE WATER TREATMENT & DISPOSAL

The high TDS effluent stream generated from Alkali scrubber attached to the SO3 generation

plant containing Na2SO3 to be segregated and oxidized with H2O2 to form Na2SO4. The Na2SO4

(15 %) generated to be used for captive consumption for manufacturing of product AOS. The

treatment scheme is given below:

The packed tower SO2 absorber or caustic scrubber is the final piece of effluent gas

conditioning apparatus.

The system will consist of following equipments:

1. PP / FRP packed tower packed with PP pall rings,

2. 2.0 No HDPE recycle tank (One Std By and One Operational ) ,

3. Recycle pump,

4. PH / Temperature / Pressure monitoring & alarm system


49


A dilute caustic solution (10 -11%) is circulated in the packed column to absorb the

incoming SO2 gas along with the air from the sulfonation system. These absorption

leads to the formation of Sodium Sulfite solution. PH of the dilute caustic solution is

maintained between 9 – 11 (more than 8) for better absorption and optimum performance.

A low pH alarm system will help to maintain and replenish the Caustic Solution. After

the solid content of re-circulating solution is reached to 15 -16%, the second HDPE

recycle tank is taken into operations.

The sulfite liquor from the first tank will be treated with Hydrogen peroxide solution to

oxidize sulfite into Sulfate. The Sodium Sulfate Liquor thus formed, will then be used in

the finished product specification adjustment.

Fig-3.5(a): Treatment Scheme for Existing Operation


50


Fig-3.5(b): Treatment Scheme for Proposed Operation

The low TDS effluent stream generated from the process, Utility, cooling and washing section

will be treated in proposed Full fledged Effluent Treatment Plant, R.O.Plant and MEE. Treated

water from ETP will be diverted to the R.O., Reject water from R.O will be diverted to the MEE.

Permeate water from R.O. and condensate water from MEE will be reused as cooling tower

make up water. Salt generated from the MEE will be sent to TSDF site for disposal.

Proposed ETP details & scheme is given below:

Oil and Grease Removal

The effluent will enter into oil & grease removal pit. Oily masses will separate out and float on

the surface. Floating matter (mainly oily mass) will be removed by manually skimming and will

be filled in barrels. The effluent will be free of oil and grease at the outlet of this pit.

Collection Tank

The effluent from oil & grease trap will be collected into the Collection Tank. The incoming

effluent will be alkaline in nature having higher values of COD, BOD, Suspended Solids and

Colors.


51


Neutralization

Then in order to neutralize and give chemical treatment of the effluent, various chemicals will be

added depending upon the influent characteristics. Here, the effluent will be neutralized by

using lime and then will react with Alum Solution. Neutralization will be done continuously in

tank. These tanks will be provided with efficient agitator. Effluent from collection tank will be

pumped to the tank, from where it will flow to the each compartment by gravity (overflow). Lime

and alum slurry will be added in controlled manner in tank by dosing pumps. The effluent

leaving neutralization tank will be of pH value between 6.5- 8.5.

Flocculation

Suspended solids should be removed from effluent before feeding it to the biological reactors.

The suspended solids will be removed by settling them. Colloidal solids hinder the settling

process and they cannot be removed by simple settling to overcome these difficulties,

flocculants will be added in an appropriate quantity.

Primary Settling

Effluent from neutralization tank will be pumped to primary settling tank for solids removal. The

solids settled at the bottom of the tank will be diverted to sludge drying beds, while the clear

effluent will overflow to the aeration tank.

Biological Treatment

The clear effluent of primary settling tank will be fed to the Aeration Tank by gravity flow. The

oxygen required for the metabolic activity of the microorganisms will be supplied by means of

surface aerator. In the Aeration tank, the wastewater will be degraded by activated sludge to

reduce the BOD and COD concentrations. Urea and DAP will be added in the aeration tank in

calculated amount daily for proper bacterial growth. A constant feed rate will be maintained in

the aeration tank. A sludge percentage of around 25 to 30 % by volume will be maintained in

the aeration tank. Also MLSS and MLVSS ratio will be maintained to ensure active

microorganism growth. The dissolved oxygen content in the aeration tank will be maintained in

between 0.5 to 2.0 mg/lit. The overflow of the aeration tank will be discharged into the

Secondary settling tank for biomass separation.

Secondary Settling

The overflow from the aeration tank will enter into the secondary settling tank. where the bio

mass sludge will be settled at the bottom of the secondary settling tank. The function of

secondary settling tank is to reduce the amount of suspended solids. An appropriate retention

time will be given to the effluent to ensure proper settling. The settled sludge will be

continuously recycled back to the aeration tank to maintain the desired concentration of mixed


52


liquor suspended solids and the excess sludge will be diverted to the sludge drying beds. The

clear overflow from the top of the secondary clarifier will be collected into the Clarified water

tank.

Sand Filter & Carbon Filter

The clear water from clarified water tank will be pumped to pressure sand filter and activated

carbon filter respectively for removal of suspended solids and COD, BOD & color. The effluent

will enter into the sand filter from the top and clear treated effluent will be fed to the activated

carbon filter. A back wash facility will be provided to the sand filter and activated carbon filter to

wash out suspended solids. The backwash will be given periodically to remove the suspended

solids, which are deposited at the top of the filter media. The outlet of the activated carbon filter

will be diverted to the holding tank. Backwash of the filters will be taken to Collection tank.

Sludge drying beds

Sludge from primary settling tank and the excess sludge from the secondary settling tank will be

taken to Sludge Drying Beds. Sludge Drying Beds will be used alternatively. Leachate of the

sludge will be collected in to collection cum neutralization tank and cake will be collected and

packed in plastic bags and stored in sludge storage area.


53


Fig-3.6: Schematic Diagram of Effluent Treatment Plant


54


3.7.4 AIR EMISSIONS & CONTROL

3.7.4.1 Process Emission

In existing Acid Mist and SO2 are generated from the process of Sulfonation. The company has

provided ESP and Alkali Scrubber as an Air Pollution Control Device. The same will be the

control measures for the proposed project. Drawing of APCD with Sulfonation Plant is given in

Annexure-2. For proposed expansion project Process emission will occur from the

manufacturing process so; the company will install a Spray Dryer Plant with Bag Filter as an Air

pollution control device in order to control the particulate matter. Drawing of proposed spray

dryer is given in Annexure-3.

Table 3.9: Details of Process Emission

Sr. No. Particulars Parameters Control Measures

Existing Scenario

1. Sulfonation Plant Acid Mist & SO2 ESP and Alkali Scrubber

Proposed Scenario

1. Sulfonation Plant Acid Mist & SO2 ESP and Alkali Scrubber

2. S.D. Burner (Spray dryer plant)

Particulate matter Bag Filter

3.7.4.2 Utility Emission

In existing scenario, the company has two Steam Boilers having capacity of 4 TPH and 2 TPH

which works on 50% load capacity. The company has two D.G. Sets having capacity of 840

KVA each which acts as standby unit and is used only in case of power failure. Adequate

chimney height is provided to the existing utilities.

In proposed expansion additional one Thermic fluid heater having capacity of 2 lakhkcal/hr will

be installed and will be operated on 100% load and existing steam boiler of 4 TPH will be

operated on 100 % load and steam boiler of 2 TPH will act as standby facility. Existing D.G. sets

will be replaced by 2 Nos. of D.G. sets of 1500 kVA and 750 kVA capacities which will act as

standby unit and will be used only in case of power failure.


55


Table 3.10: Details of Utility Emission

Particulars Details Fuel & its Qty Stack

Details(m) Emission Norms

Existing Scenario

Steam Boiler 1 No.

Capacity: 4.0 TPH (50 % load)

Agro Based Fuel ( Baggase, Husk Briquette) –250 kg/hour

H: 30 m D: 500 mm

SPM<150mg/Nm3

SOX< 100 ppm NOx< 50 ppm

Steam Boiler 1 No.


Furnace oil (FO) – 102 LPH (Stand by)

H: 30 m D: 500 mm

SPM<150mg/Nm3


D.G.Set- 2 No.

840 kVA

Light Diesel Oil (LDO) – 600 LPH

H: 12 m D: 200 mm

SPM<150mg/Nm3


Proposed Scenario

Steam Boiler 1 No.


Coal/Lignite –1000 kg/hour

H: 30 m D: 500 mm

SPM<150mg/Nm3


Steam Boiler 1 No.

Capacity: 2.0 TPH (100 % load) (Standby)

Furnace oil (FO) – 205 LPH (Stand by)

H: 30 m D: 500 mm

SPM<150mg/Nm3


D.G.Set- 2 No.

1500 KVA 750 KVA

Light Diesel Oil (LDO) =700 LPH

H: 12 m D: 200 mm

SPM<150mg/Nm3


Thermo pack Boiler

Capacity: 2 Lakh K.Cal/Hr (100% load)

LDO = 21 LPH

H: 30 m D: 500 mm

SPM<150mg/Nm3


S.D. Burner (Spray dryer plant)

800 K.Cal/Hr FO = 50 LPH.

H: 30 m D: 500 mm

SPM<150mg/Nm3


*Common chimney will be provided for Steam Boiler and Thermo pack Boiler.

3.7.4.3 Fugitive Emission

Minor quantity of fugitive emissions will occur during handling of the raw materials. Fugitive

emissions are also likely to occur from storage drums.

Following measures will be practiced to reduce the fugitive emissions:

Raw Materials & Products are stored in properly designated storage area and under

good storage conditions to prevent any volatilities

Raw Materials & Products are stored in closed containers

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

handling.

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

Good housekeeping maintained in the plant.


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3.7.5 HAZARDOUS / NON-HAZARDOUS WASTES MANAGEMENT

Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,

Used oil from gear boxes of the machineries & D.G. Set, discarded drums, Used Ion exchange

& resin, spent desiccant and catalyst. Company has provided adequate storage area for proper

storage of wastes.

Table 3.11: Details of Hazardous/Non-Hazardous Waste Generation & Disposal

Type of waste & Category

Existing Qty Total Qty after proposed expansion

Disposal Method

Hazardous waste

ETP Waste (Cat. 34.3)

4.0 MT/Annum 500.0 MT/Annum

Company has provided adequate storage area. The ETP waste generated is stored properly and finally disposed off to GEPIL site, Silvassa and same practice will be followed for addn. qty.

Used Oil (Cat. 5.1)

1.0 KL/Annum 2.0 KL/Annum The used oil is collected and stored separately in closed containers and finally sold to the registered re-refiners. and same practice will be followed for addn. qty.

Discarded drums (Cat. 33.3)

240 Nos/Annum

30000 Nos/Annum

The discarded drums are stored separately in company premises and are returned back to the supplier / sold to the authorized reconditioners and same practice will be followed for addn. qty.

Used Ion Exchange material

0.05 MT/Annum

0.1 MT/Annum

Used Ion exchange material generated is stored properly and finally disposed off to GEPIL site, Silvassa. and same practice will be followed for addn. qty.

Spent Catalyst 1.0 MT/Annum 3.0 MT/Annum Spent catalyst generated is stored properly and finally disposed off to GEPIL site, Silvassa. and same practice will be followed for addn. qty.

Spent Desiccant

0.05 MT/Annum

2.0 MT/Annum

Spent Desiccant generated will be stored properly and finally disposed off to GEPIL site, Silvassa.

Non-Hazardous waste

Fly ash 60.0 MT/Annum

2700.0 MT/ Annum

Fly ash will be collected, stored and sold off to brick manufacturers.

Insulation waste

NIL 24.0 MT/Annum

Insulation waste will be collected, stored and sold off to scrape dealer.

3.7.6 NOISE AND ODOUR CONTROL

There are no major activities due to which noise would be generated other than compressors &

gear boxes. There is no major generation of bad odour as process will be carried out in closed

reactors. The control measures to be taken for reduction in noise & odour levels are as below:


57


Sturdy foundation to all the noise generating equipments.

D.G. Set installed in closed room

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

Closed reactors and vessels for odour control.

Greenbelt will be further developed.

3.7.7 HEALTH AND SAFETY MEASURES

The company is concerned about occupational health and safety among its

work force as the man power is the biggest asset to the company. The Off-site Emergency Plan

is available with the Collectorate Office, Silvassa.

The following key safety measures are implemented in the existing plant and the same shall be

a part of proposed expansion project:

Safety Training is provided to the employees.

Safety Sirens & Hooter Alarm System is provided for use, in case of emergency.

Fire Extinguishers are installed at identified locations in the premises.

Assembly point is provided in the plant.

First Aid Facility and training is provided to the workers.

Personal protective equipments are provided to employees.

Health check up is organized at regular intervals.

Safety / Health records and MSDS are maintained.

3.7.8 ENVIRONMENTAL HEALTH & SAFETY CELL

The company has a separate environment cell in order to keep a close watch on the

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

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

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

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

the legislative requirement. The organogram of the EHS cell is given below in Figure 3.6.


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Fig-3.7: Organogram of EHS Cell

3.7.9 POST PROJECT MONITORING PLAN

As an existing company, the company gets monitored the components like bore well water,

waste water, flue gas and process emissions, ambient air and noise monitoring.

The company is also developing in-house facilities for monitoring certain components. Where it

is not possible to establish such facilities, the same is done by appointing external

recognized/approved agencies. The proposed post-project monitoring plan is given below:


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Table 3.12: Post Project Monitoring Plan

Components Parameters Frequency of in house monitoring

Frequency of third party monitoring

No. of sample

Drinking water IS-10500:1991 -- Quarterly One sample

Waste water BOD, COD, pH, TSS, TDS

Daily Once in a month At all stage

Air-ambient SPM, SOx, NOx, RSPM, CO, etc.

-- Quarterly 2 stations within premises

Stack monitoring SPM, SO2, NOx

-- Quarterly 3 stacks

Process stack monitoring

Acid Mist & SO2 -- Quarterly 1 stack

Noise monitoring

dB (A) -- Once in a month Main plant, utility area & boundaries

Workplace monitoring

RSPM, SPM, SOx & Lux Level

-- Half Yearly Factory Building


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CHAPTER – 4

SITE ANALYSIS

4.1 CONNECTIVITY

This proposed project is located at survey no.193 in village-Kherdi, Silvassa. The Site is 9.18

km from Dadra and Nagar Haveli .The site is 12.3 km from National highway and 6.3 km from

state highway. The land and infrastructure is already available. And the raw material is easily

available through the easy transport via road connectivity. The nearest Railway station is Sanjan

railway station which is 22.75 km and Daman Coast Guard Airbase is 41.92 km from the project

site.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP

The Region of Dadra and Nagar Haveli is located on the western coast of India between the

parallels of 20 o - 0’ to 20 o - 22’ of North latitude and between the meridian 72o - 50’ and 73 o -

15’ of East longitude of Greenwich.

4.2.1 LAND FORM

The proposed expansion will be carried out in existing premises. No additional land will be

required for proposed expansion project. The land is owned by the company located at

industrial zone of DN & H. land documents is attached as Annexure-4. And Documents in

Support of the Project Site being in Industrial Zone is attached as Annexure-5.

4.2.2 LAND USE PATTERN

The existing land-use as per the State of Environment Report -2005, for all the 70 villages and 2

urban centers namely Silvassa and Amli in the Region. Land use categories are as follows:

a) Built-up area which includes urban and rural areas

b) Industry

c) Mixed uses such as commercial, mixed urban built-up

d) Agriculture

e) Irrigation command area

f) Tourism

g) Forest

h) Roads and Water body


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Forest and agriculture are the predominant land-uses, which are followed by the industrial use

and built-up structures. The share of the forest is the largest amounting to 39.85% of the total

area followed by 32.17% under agriculture use; Irrigation command area together with water

bodies covers 20.63% of the total area of the region. The predominance of rural activities in the

region is reflected by the land-use pattern. Gaunthan and urban built-up constitutes 1.69% of

the region. The area under industries is 3.73% of the gross total area and 6.90% of the net

available area i.e. excluding the reserved forest area and water bodies.

Table 4.1: Land use Distribution of Dadra & Nagar Haveli (DNH)

Major Land-use Classification

Gross Total Area in Sq. Km.

Percent to Gross Total Area

Net Developable Area

Percent to Net Developable

Area

Built-up 8.08 2% 8.08 3%

Industries 17.82 4% 17.82 7%

Agriculture 153.64 32% 153.64 59%

Irr. Command Area 69.48 15% 69.48 27%

Res. Forest 190.35 40% -- --

Roads 9.19 2% 9.19 4%

Water bodies 29.04 6% -- --

Total 477.61 100% 258.22 100% (Source: State of Environment Report, 2005 for DNH)

4.2.3 LAND OWNERSHIP

The proposed project will be sited on the existing plot located notified industrial zone of Dadra &

Nagar Havili.

4.3 TOPOGRAPHY

The topography is undulating and rolling. The territory has a hilly terrain, especially in the

northeast part, which is surrounded by the ranges of Sahyadri Mountains (Western Ghats). The

central and remaining part of the Region is fairly plain. The highest point in the Region is 423

mtrs. above the sea level.


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4.4 SALIENT FEATURES

Table 4.2: Salient Features of the Project Site

Particulars Details

Co-ordinates 73° 1' 03.1” E, 20° 05' 52.9" N

Village Kherdi

Taluka/ Tehsil Dadra and Nagar Haveli

District Dadra and Nagar Haveli

Nearest Settlement Village - Kherdi

Nearest Reservoir River Damanganga @ 16.8 km

Nearest Highway State Highway @ 6.3 km National Highway 8 @ 12.3 km

Nearest Railway station & Railway line Sanjan Railway station @ 22.75 km Railway line @ 22.3 km

Nearest Airport/ Airbase Daman Coast Guard Airbase @ 41.92 km

State/ National borders Maharashtra border within 1 km

Tourist places Gardens in Khanvel and Dadra

Sites of Historical/ Archaeological importance Structures constructed during Portuguese rule.

Protected Area/ Sanctuaries None within 10km radius

CRZ applicability Not applicable

4.5 EXISTING INFRASTRUCTURE

The existing infrastructure is sufficient to accommodate the proposed expansion project and

also our major purchasers are located in the vicinity of the region. Secondly; there is no Octroi

Duty and power is available at subsidized rates in the region. The territory’s vicinity to well

developed industrial estate in Vapi, Daman & Sarigam also plays an important role in the site

selection.

The major factors involved in the selection of site are:

Availability of well connected roads to the plant site for movement of equipments, raw

material, finished products etc.

Availability of the resources like water, fuel, power etc.

Suitability of land and topographical and geological considerations.

Environmental and ecological impacts.

4.6 SOIL CLASSIFICATION

Shallow Black Cotton Soil: The soils of subdued hillocks and undulated valley plains are either

having no diagnostic horizon or have tendency of alteration to give rise to cambric horizon.

These are subjected to high erosion menace and have lost the top soil fully or partially. These

are medium textured soils with gravels and pebbles and hard rock is met early below the soil

restricted free movement of water and air. Through the soil are permeable enough but low


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moisture holding capacity of the soil calls for specific moisture management for sustainable land

use under cultivation. These soils need permanent vegetation to protect them from further

deterioration. These soils are medium to low in fertility and are placed either in entisol or

inceptisol order. These soils call for specific conservation measures for their protection and are

advised for no tilling or occasional tilling for their sustainability. Mostly these soils developed

over basaltic basic parent material occur in the central part of the territory extending in N-S

direction.

(Courtesy: Environmental Information Centre, New Delhi)

4.7 CLIMATE & METEROLOGY

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

throughout the year, heavy south–west monsoon rainfall and a mild winter. The year can be

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

summer season from March to May. The south-west monsoon season is from June to

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

The summary of yearly meteorological data for a period of 10 years recorded at the nearest

observatory of IMD at Dahanu has been taken from the National Data Centre of Indian

Meteorological Department at Pune.

Table 4.3: Summary of Meteorological Data at nearest IMD Station - Dahanu

Location: In the compound of the old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o 58’, Long: E 72o 43’) Height of installation: 11m above MSL

Month PDW Direction

Avg. W. Speed (kmph)

Temperature (oC)

Relative Humidity (%)

Cloud Cover (Oktas)

Rainfall (mm)

Max. Min. Morn. Even. Morn. Even.

JANUARY N 1-19 27.7 16.5 67 69 1.3 1.1 0.2

FEBRUARY N 1-19 28.3 17.4 66 69 1.1 0.8 0.2

MARCH N 1-19 30.3 20.7 68 67 1.4 1.1 0.1

APRIL W 1-19 32.2 24.0 74 69 2.1 1.4 0.1

MAY W 1-19 33.1 26.8 77 73 3.8 2.3 5.2

JUNE SW 1-19 32.2 26.3 85 80 6.1 5.6 522.1

JULY SW 1-19 30.1 25.0 89 84 7.1 6.8 771.7

AUGUST W 1-19 29.5 24.7 88 83 6.9 6.7 502.3

SEP W 1-19 30.0 24.0 87 79 5.4 4.9 319.1

OCT E 1-19 32.1 23.1 77 72 2.8 2.4 44.4

NOV N 1-19 32.1 20.5 67 71 1.9 1.9 17.1

DEC N 1-19 29.8 18.0 67 71 1.6 1.5 0.3

Seasonal Average Values

Period Avg. PDW Direction

Avg. WS

Avg. Max.

Avg. Min.

Avg. Morn.

Avg. Even.

Avg. Morn.

Avg. Even.

Total

Summer W 1-19 31.9 23.8 73.0 69.7 2.4 1.6 5.4

Winter N 1-19 28.6 17.3 66.7 69.7 1.3 1.1 0.7


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Monsoon SW 1-19 30.45 25.0 87.3 81.5 6.4 6.0 2115.2

Post monsoon W/E 1-19 32.1 21.8 72 71.5 2.35 2.15 61.5

Annual W 1-19 30.8 22.0 74.7 73.1 3.1 2.7 2182.8 (Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)

4.7.1 TEMPERATURE

The climate of Dadra and Nagar Haveli is warm and humid during the summer months but less

warm during the monsoon months. The south-west monsoon from June to September brings

copious rain to the territory. The winter months are generally pleasant. May is generally the

hottest month with the mean daily maximum temperature recorded at 33.1 Co and mean daily

minimum temperature recorded at 26.8 Co. January is the coldest month with the mean daily

maximum temperature as 27.7 and mean daily minimum temperature observed as 16.5.

4.7.2 HUMIDITY

Humidity is usually high during the monsoon months, generally exceeding 80%. Humidity

decreases during the post-monsoon months. For rest of the year i.e. the period of December to

April, the relative humidity ranges around 60-70%.

4.7.3 CLOUD COVER

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

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

mostly clear.

4.7.4 RAINFALL

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

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

observed from the data is 2182.8 mm.

4.7.5 WIND PATTERN

The annual predominant wind direction comes to West, followed by North and South-west.

Winds blows mostly from the West/North-West during summers and Monsoons are usually

South-west. The post-monsoon & winter seasons experience a change in the wind blowing from

North and North-east.

The wind speed is high during summer and monsoon seasons, slightly moderate during winter

and low during post-monsoon phase.


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4.8 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well being of the region.

4.8.1 EDUCATIONAL FACILITIES

Out of 71 villages, 69 villages have educational facilities, details of which are given below.

Table 4.4: Details of Educational facilities

Sr. No Particulars No of villages in UT of D&NH

1 Primary Schools 69

2 Middle Schools 36

3 Secondary School 11

4 Senior Secondary School 5

5 College 1 (Source: Primary Census Abstract – Census of India, 2001)

4.8.2 MEDICAL FACILITIES

Details of medical facilities available in the study area are given below.

Table 4.5: Details of Medical facilities Sr. No. Particulars No of villages in UT of D&NH

1 Hospitals 1

2 Dispensaries 3

3 Primary Health Centers 9

4 Primary Health sub centre 37

5 Allopathic Hospital 1

6 Allopathic dispensary 3

7 Maternity and Child welfare Centre 3

8 Maternity Home 1

9 Child Welfare Centre 64

10 Health Centre 1

11 Registered Private Medical Practitioners 5

12 Subsidized Medical Practitioners 3

13 Community Health Workers 56 (Source: Primary Census Abstract – Census of India, 2001)


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CHAPTER – 5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The existing company is located at Survey No. 193/1/4/5 & 6, Kherdi, Khanvel, Silvassa (U.T.)

and the proposed expansion activities will be accommodated in the existing plots.

Dadra and Nagar Haveli comprising of 72 villages including Silvassa, the census town, forms a

single District and single Taluka Union Territory. The Union Territory has two towns i.e.

Silvassa, the headquater of Dadra and Nagar Haveli and Amli. Silvassa till 1971 was located as

revenue village. Now it is a non statutory town since 1981. The Silvassa is spread over an area

of 6.7sq.km showing significant growth of urban population (6%).

There are more than 1,600 S.S.I. units in the U.T., which include Cottage, Village Industries and

430 Medium Scale/Large Scale Industries in Textiles, Engineering, Plastics, Electronics,

Chemicals, Pharmaceuticals, etc., employing more than 43,100 persons.

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

supply, arrangements for power, streetlights etc.

The plots for existing project were purchased from private owners and transferred in the

company’s name. There is sufficient land available in the existing plots to accommodate the

proposed expansion project.

5.2 POPULATION PROJECTION

The average household size is around 5 persons. The Sex ratio is less compared to other

regions in surrounding states.

The demographic profile of study area within 10 km radius is presented below.

Table 5.1: Distribution of population

Sr. No.

Particulars Observed values in UT of D&NH

1 Total Population 270953

2 No. of Households 57234

3 Avg. household size (persons) 5.0

4 Male population 151500

5 Male population (in %) 55.91

6 Female population 119453

7 Female population (in %) 44.09

8 Sex ratio 788 (Source: Primary Census Abstract – Census of India, 2001)


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5.3 AREA STATEMENT

The total area of the plot is 30000 m2 out of which Greenbelt area of the plant is 10140 m2 which

is 33.8%. The bifurcation of the same is given below in table no. 5.2.

No additional construction is required for proposed expansion.

Table 5.2: Area Statement

Particular Existing Area (in m2) Proposed Area (in m

2)

Constructed Area 10716.06 10716.06

Greenbelt area 10140.00 10140.00

Open land area 9143.94 9143.94

Total plot area 30000.00 30000.00 (Source: M/s Aarti Industries Ltd.)

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

In this proposed expansion project which will be having production in the existing setup itself

and; which does not require any change in existing Physical Infrastructure; but the company will

acquire plant and machinery for the proposed expansion project so there will be some demand

of change in physical infrastructure and social infrastructure. As manpower requirement for the

proposed project shall be locally fulfilled, employment generation will lead to additional benefits

to social infrastructure.

5.5 AMENITIES/FACILITIES

5.5.1 DRINKING WATER FACILITIES

As per census 2001 following drinking facilities are available in study region.

Table 5.3: Drinking Water Facilities

Sr. No.

Particulars No of villages in UT of D&NH

1 Tap 70

2 Well water 70

3 Tank water 70

4 Tube well water 70

5 Hand pump 70

6 River water 70

7 Canal 70

8 Lakes 70

9 Spring 70

10 Other drinking water sources 70 (Source: Primary Census Abstract – Census of India, 2001)


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5.5.2 POWER SUPPLY FACILITIES

As per census 2001, following no. of villages has power supply available for various purposes.

Table 5.4: Power Supply Facilities

Sr. No.


1 Power supply facilities 69

2 Electricity for Domestic use 69

3 Electricity of agricultural use 69

4 Electricity of other purposes 69

5 Electricity for all purposes 69 (Source: Primary Census Abstract – Census of India, 2001)

5.5.3 COMMUNICATION & BANKING FACILITIES

Distribution of facilities such as post office, post & telegraph office, banks, telephone

connections in the study area are illustrated in Table below.

Table 5.5: Communication & Banking Facilities

Sr. No.


1 Post Office 34

2 Post and telegraph office 1

3 Telephone connection 33

4 Commercial Bank 4 (Source: Primary Census Abstract – Census of India, 2001)

5.5.4 TRANSPORT FACILITIES

Bus service is available in 63 villages in the study region. The villages are well connected with

the State Highways. There are also 63 Railway stations found in the study region.

5.5.5 APPROACH TO VILLAGES

As per census 2001, out of 71 villages, 69 villages have paved road, mud road and foot path.

5.5.6 RECREATIONAL FACILITIES

As per census 2001, only 1 cinema hall was in the study region. Data on the other facilities were

not available.


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CHAPTER – 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA

The total area of the plot is 30000 m2 located notified industrial zone of DN & H out of which

Greenbelt area of the plant is 10140 m2 which is 33.8%.The total production capacity will be

3000 MT/M for a single product or the cumulative product, but will not exceed 3000 MT/M.

6.2 RESIDENTIAL AREA

In the said proposal no Residential area has been proposed for workers and/or for staff.

6.3 GREENBELT

Maximum open land will be allotted for green belt development. If required, experts will also be

consulted for selection of species for the development of the greenbelt. Total greenbelt area will

be 33.8%.

6.4 SOCIAL INFRASTUCURE

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

project which is very low.

6.5 CONNECTIVITY

This proposed project is located at survey no.193 in village-Kherdi, Silvassa. The Site is 9.18

km from Dadra and Nagar Haveli .The site is 12.3 km from National highway and 6.3 km from

state highway. The land and infrastructure is already available. And the raw material is easily

available through the easy transport via road connectivity. The nearest Railway station is Sanjan

railway station which is 22.75 km and Daman Coast Guard Airbase is 41.92 km from the project

site.

6.6 DRINKING WATER MANAGEMENT

Mini Industrial Reverse Osmosis Plant followed by filters are provided for supplying drinking

water.


70


6.7 SEWERAGE SYSTEM

After proposed expansion, @14 KLD, Domestic waste water generated from the project will be

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

6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained

in Chapter 03, Section 3.7.

6.9 SOLID WASTE MANAGEMENT

Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,

salt from MEE, Used oil from gear boxes of the machineries & D.G. Set, discarded drums, Used

Ion exchange resin, spent desiccant and catalyst. Company has provided adequate storage

area for proper storage of wastes. Details of solid waste generation are given in table 3.11.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY

The power requirement after the proposed expansion will be 2250 KVA which will be sourced

from State Electricity Board Grid. The company has Existing D.G. Sets of 840 KVA (2 Nos)

Existing D.G. sets will be replaced by 2 Nos. of D.G. sets of 1500 kVA and 750 kVA capacities

which will act as standby unit and will be used only in case of power failure.


71


CHAPTER – 7

REHABILITATION & RESETTLEMENT (R &R) PLAN

7.1 POLICY TO BE ADOPTED

The proposed expansion project is to be developed in the non-agricultural land designated for

industrial use. Hence, no displacement of any population is proposed for the project. Therefore,

detailed Social Impact Assessment studies or R&R action study has not been conducted for the

proposed project.


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CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE OF THE PROJECT

At present we are not proposing any construction at the site. It will start only after getting all the

statutory permission from respective authorities.

8.2 ESTIMATED PROJECT COST

The company has made budgetary provision for the recurring expenses for the environmental

issues while planning for the allocation of funds during the annual budgetary planning.

As we are an existing unit, the existing shed will be utilized for the proposed expansion and

hence there will be no construction activity.

Environment Protection has also been considered in planning the cost projection. Green belt

development is also considered.

The estimated project cost will be approximately 1070 Lakhs.

Table 8.1: Total Capital Cost Projection

Sr. No. Purpose Existing Cost (Rs. in Lakhs)

Proposed additional Cost (Rs. in Lakhs)

1. Plant & Machinery, Land & Building 2332 868

2. Electrical Installations 858 19

3. Project Management/Misc. 20 12

4. Green belt development 2 3

5. Storage tanks 40 25

6. Effluent Treatment Plant 16 125

7. Safety Systems/ Misc. 3 18

Total 3280 1070 (Source: M/s Aarti Industries Ltd.)

Table 8.2: Recurring cost provision for EHS (per annum)

Sr. No. Purpose Existing Cost

(Rs. in Lakhs) Proposed additional Cost

(Rs. in Lakhs)

1. ETP (Operation & maintenance) 24 125

2. Greenbelt maintenance 1.5 2.5

3. Environment & Safety Management System

1.5 2.5

4. Expenses for disposal at TSDF site 1 30

Total 28 160 (Source: M/s Aarti Industries Ltd.)


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CHAPTER – 9

ANALYSIS OF PROPOSAL

9.1 FINANCIAL & SOCIAL BENEFITS

M/s. Aarti Industries Ltd. (Surfactants Specialities Division) located at Survey No. 193,

Khanvel-Udhwa Road, Village- Kherdi, Silvassa (U.T.) is in operation since 2002.

Today we are one of the pioneer and leading companies in the manufacturing of “Surfactants

and Speciality Surfactants”. In a developing nation like our’s, surfactants plays an important

role in providing hygienic conditions by virtue of its cleaning and disinfectant properties.

Surfactants are used in the manufacturing of various household products like shampoos, hand

wash, face wash, liquid detergents, laundry detergents, etc.

For this proposed expansion project, the industry intends to procure the latest available

technology. The company will plan to install full fledged Effluent Treatment Plant, RO, MEE,

ESP, & Scrubber as Air pollution control device.

Total project cost for proposed expansion will be aprox 1070 lakhs. For the proposed project,

the company intends to donate 2% of the capital cost for the social benefit as Corporate Social

Responsibility.


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Annexure


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Annexure-1 Existing CC&A


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Annexure-2 Drawing of APCD with Sulfonation Plant


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Annexure-3 drawing of proposed spray dryer


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Annexure-4: 7 and 12 document of existing land


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Annexure-5: Documents in Support of the project site being in industrial zone


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85
