PREFEASIBILITY REPORT - Environmental Clearances

Transcription

1
PREFEASIBILITY REPORT
“Expansion
of Existing Production Capacity for Fragrances, Flavors &
Manufacturing Chemicals”
By
Aarav Fragrances & FlavorsPvt. Ltd.
Gut No 167, 169, 170, 171, 296, Village. Jamghar -Lakhamapur,
Tal. Wada, District: Thane, Maharashtra
PrefeasibilityReport–M/s.Aarav Fragrances & Flavors Pvt Ltd
2
Synopsis
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Introduction
Justification
Location
Recourses
Process
Pollution Control
Background Study
Safety
Benefits
EIA structure
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
3
1. Introduction
M/s Aarav Fragrances and Flavors Pvt Ltd are desirous to expand to manufacture new products having either raw
material synergy or superior quality and technology to meet demands in India as well as for further producing the
fragrance and flavors at Aarav Fragrances and FlavorsPvt Ltd, Gut No 167,169,170,171,296,Vill. Jamghar Lakhamapur, Tal. Wada, District: Thane, Maharashtra
The existing industrial unit is only manufacturing facility for Fragrances and Flavors. The industry now proposes
to enhance the manufacturing capacity of the present Fragrances & Flavors, and further the it is proposed to add
additional capacity to manufacture the chemicals that could be used in house as well as cater to the open Market,
this will reduce the costs of the fragrances and flavors and make them more competitive in the Indian as well as
export markets. Indian and worldwide demand for fragrances, flavors, perfumery chemicals and related specialty
chemicals is increasing steadily.
2. Justification
The Indian consumer industry is one of the world’s largest by volume and is likely to lead the manufacturing sector
of India. Several private sector projects with huge amount of investments have been initiated but could not
attend the speed of development for the need of good quality material. Over the last decade, there has been a
sizeable growth in fragrances and flavors sector both in small, medium and large scale units. This has given rise
to many small and medium scale units. There is an ever growing requirement of the consumers in India
and also the world markets. Thus there is a gap in demand and supply. Our efforts of generating products, byproducts, downstream products and recycling - reprocessing are indeed needed. With multinational fragrance and
flavor companies enhancing their presence in India, the long-term prospects of the fragrances and flavors industry
seems verybright. The intermediates proposed will substitute imports and compliment the products in terms of
costs.
The fate of industrialization depends on the proper and effective conjugation of large and medium/small scale
industries each supporting each other in their requirement to bridge the gap between demand and supply. In order
to be competitive in the global market this synergy between large & medium/small scale industries is a prerogative.
Therefore considering the above, large companies do require the help of small units to support them, the main
target is to give the consumer superior quality products at a competitive price. In addition, it is also examined
whether industry had made compliances expected in
Consent to Operate by MPCB for existing production.
S.No.
Condition
Compliance
1
Addressstatus
Continuousthesamenochange
2
No. &Validity
Validtill30.09.2015
3
Productsize
Sr.no.
1
Product
Fragrance/Perfumes
Flavors
Capacity
(TPM)
& 70
4
Waste
quantity
water 8.5m3/dpermitted.
5
Waste
waterTreatment
Foundinlimit
6
ECE
Presently NA
7
LDAR
Leakdetection&repairprogramwith
monitoringprotocolundertakenas consented.No–
towardincident reported.Work zoneambiancecognizes
8
Hazardouswaste
MembershipofCHWTSDF to be obtained
4
3. Proposal:The Industryproposedtoproduceasunder:
Sr
Products
Present
No
MT /M
1.
Fragrances/Perfumes & Flavors
70
Proposed
MT/M
Total
MT/M
Field Of Application
280
Fragrances & Flavors
210
Perfumery& Flavor Esters by hot esterification/
addition of organic acid into olefin/ trans
esterification/ reacting alkali halide with sodium
2.
salt of corresponding acid/Cold Esterification 00
Ethyl Esters/ Esterification by reaction of
alcohols with anhydride/ Perfumery Esters by
Darzen Condensation
Perfumery & Flavor Alcohol by Grignard
reaction / by reduction of aldehyde, or ketone by
hydrogen & Reducing Agents / by addition of
3
00
water into olefins / by saponification of
esters/Perfumery
Compounds
by
Ring
Reduction
Perfumery & Flavor Aldehyde by ester /
epoxide rearrangement/ dehydrogenation of
300
4
00
alcohols/
reduction
of
acids/
aldol
condensation& derivatives
300
Dimerization and Trimerization of simple
5
00
olefins.
6
Ketals / Acetals / substituted 1,3-propanediols
00
Macro cyclic and polycyclic musks derived
7
from propylene or butadiene and other
00
propylene derivatives
8
Aldehydes & Ketones by Aldol Condensation
00
9
Acetylene and other alkyne derivatives
00
Cyclo Alkylation/Acetylation ,Diel Alders
Reactions : Cyclization Reaction, Etherification
10
00
of Alkyl Halide and Alcohol, Epoxidation of
Alkenes /Friedel Craft Reactions
11
Hydrogenation
00
12
Inorganic Salts
00
50
50
Side Stream Products
Total
630
From the list of ProductsSrNos 2 to11 only two to three products will be manufactured simultaneously. The total
quantities to produce for Products Sr No 2 to 11 willbe for any one or all cumulatively up to 300MT
Since many of the products planned are either forward integration or corollary to a known manufacturing process.
The above mentioned process based chemicals are important chemicals in the vast field of fragrances and flavors
where many such routed chemicals are required to make a fragrances and flavors. None of these chemicals are
banned for production in developed countries nor is banned for use. The chemicals produced have the following
merits:
- Import /Cost Substitution
- Minimizepollutantsatsource
- Maximizerecycle of recovered RMs and Water
- Treatto MPCBnorms
5
General formulas limited to groups of manufacture
Sr
Products
No
General Reaction(s)
Formulation
1.
2.
3
4
Perfumery& Flavors Esters by
hot esterification/ addition of
organic acid into olefin/ trans
esterification/ reacting alkali
halide with sodium salt of
corresponding acid/Cold
Esterification -Ethyl Esters/
Esterification by reaction of
alcohols with anhydride/
Perfumery Esters by Darzen
Condensation
Perfumery& Flavors Alcohol
by Grignard reaction / by
reduction of aldehyde, or
ketone by hydrogen &
Reducing Agents / by addition
of water into olefins / by
saponification of
esters/Perfumery Compounds
by Ring Reduction
Field Of Application
Fragrances& Flavors.
Perfumery &FlavorsAldehyde
by ester / epoxide
rearrangement/
dehydrogenation of alcohols/
reduction of acids/ aldol
condensation and Derivatives
Dimerization and Trimerization
of simple olefins.
5
6
7
8
Ketals / Acetals / substituted
1,3-propanediols
Macrocyclic and polycyclic
musks derived from propylene
or butadiene/and other
propylene Derivatives
Aldehydes & ketones by
Condensation with vinyl ether
Acetylene and other alkyne
derivatives
9
RC≡CR + R'C≡CR'
2 RC≡CR'
6
10
Cyclo Alkylation Reactions
/Acetylation ,Diel Alders
Reactions : Cyclization
Reaction, Etherification of
Alkyl Halide and Alcohol,
Epoxidation of Alkenes/Friedel
Craft Reactions
3.
Hydrogenation
11
NaCl, AlCl3, MgCl.HSO4, KCl, BaSO4
12
Inorganic Salts
Side Stream Products
Inorganic Salts
Total
From the list of Products SrNo 2 to11 only two to three products will be manufactured simultaneously. The total
quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT
List of Raw Materials and Source:
The list of raw materials along with monthly consumption is given in table, However there will be only 2-3 products
being manufactured at the same time hence the requirement of the raw materials will be low, however the below
raw material quantities are reflected based on single product manufacturing.
Sr.
Raw Material Required
Consumption
No.
in MT /M
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Acetic Acid Glacial
Acetic Anhydride
Acid Catalyst
Aldehyde
Caryophellene
Phase transfer Catalyst
Caustic lye
Citronellol
Benzylledene Acetone
D’limonene/Orange Terpenes
Di Ethanol Amine
Dicyclopentadiene
Ethyl Chloro Acetate
Benzyl chloride
Halide (Pentyl Bromide/ Chloride)
HCL 45%
Iodine
Iso Amyl Alcohol
Isobutyric Acid
Methanol
Methyl Heptanone
Methyl Magnesium Bromide /
Chloride
Hexyl Alcohol
Mg Turnings
Pentanol mixture
Propionic Acid
182.00
53.00
17.00
85.00
4.00
1.10
1.04
17.03
105.00
98.00
1.00
240.00
22.05
27.60
106.00
1.00
0.05
10.00
60.00
15.00
69.00
31.61
52.00
12.74
77.14
46.00
7
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Salicylic Acid
Soda Ash
Sodium Acetate
Sodium Methoxide
Sulphuric Acid
Terpineol
Tetra hydro Furon
Toluene
Sodium salicylate
Zn Chloride
Propylene
Acetylene
Hydrogen
Benzaldehyde
N Pentanol
Propionaldehyde
Pthalic Acid
Vinyl Ethyl Ether
Sodium Hydride
Aluminum Trichloride
Di Chloro Methane
N Butyl Aldehyde
Tertiary Butyl Methyl Ether
N ,O Dimethyl Hydroxyl Amine
Hydrochloride
160.00
12.24
21.30
15.00
10.00
68.18
200.00
28.03
35.70
0.52
5.00
5.00
6.00
100.00
96.00
142.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
Geraniol
Linalool
Meta Chloro Pre Benzoic Acid
1 Phenyl Ethanol ( Styrallyl
Alcohol)
55 Furan
56 Allyl Alcohol
57 Aroma & Flavor Ingredients For
Formulation
5.00
5.00
5.00
5.00
51
52
53
54
5.00
5.00
80.00
Source:
Raw material will be sourced locally and also from countries like Japan, USA and Germany.
Sr. Raw Material
Quantity
Storage Physical Stored In
MOC
No
in MT/M
At a
Form
time
during
the
month
1 Acetic Acid Glacial
182.00
10.00
Liquid
Tank
SS304
2 Acetic Anhydride
53.00
4.00
Liquid
Drums
HDPE
3 Acid Catalyst
17.00
2.00
Liquid
Carboy/
Drums
HDPE
4 Aldehyde
5 Caryophellene
6 Phase transfer
Catalyst
7 Caustic lye
85.00
4.00
1.10
6.00
1.00
0.10
Liquid
Liquid
Liquid
Drums
Drums
Drum
HDPE
GI
HDPE
1.04
1.00
Liquid
Carboy
HDPE
8
8 Citronellol
9 Benzylledene
Acetone
10 D’limonene/Orange
Terpenes
11 Di Ethanol Amine
12 Dicyclopentadiene
13 Ethyl Chloro Acetate
14 Benzyl chloride
15 Halide (Pentyl
Bromide/ Chloride)
17.03
105.00
2.00
10.00
Liquid
Liquid
Drums
Drums
MS Epoxy
GI
98.00
10.00
Liquid
Drums
MS Epoxy
1.00
240.00
22.05
27.60
106.00
1.00
20.00
5.00
2.50
10.00
Liquid
Liquid
Liquid
Liquid
Liquid
Drums
Tank
Drums
Drums
Drums
MS Epoxy
SS304
HDPE
HDPE
HDPE
16
17
18
19
20
21
22
HCL 45%
Iodine
Iso Amyl Alcohol
Isobutyric Acid
Methanol
Methyl Heptanone
Methyl Magnesium
Bromide / Chloride
1.00
0.05
10.00
60.00
15.00
69.00
31.61
1.00
0.05
2.00
10.00
3.00
10.00
2.50
Liquid
Solid
Liquid
Liquid
Liquid
Liquid
Liquid
Carboys
Can
Drums
Drums
Drums
Drums
Drums
HDPE
GI
HDPE
HDPE
MS
HDPE
MS
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Hexyl Alcohol
Mg Turnings
Pentanol mixture
Propionic Acid
Salicylic Acid
Soda Ash
Sodium Acetate
Sodium Methoxide
Sulphuric Acid
Terpineol
Tetra hydro Furon
Toluene
Sodium salicylate
Zn Chloride
Propylene
Acetylene
Hydrogen
Benzaldehyde
N Pentanol
Propionaldehyde
Pthalic Acid
Vinyl Ethyl Ether
Sodium Hydride
Aluminum
Trichloride
Di Chloro Methane
N Butyl Aldehyde
Tertiary Butyl Methyl
Ether
N ,O
Dimethylhydroxylam
ine Hydrochloride
Geraniol
52.00
12.74
77.14
46.00
160.00
12.24
21.30
15.00
10.00
68.18
200.00
28.03
35.70
0.52
5.00
5.00
6.00
100.00
96.00
142.00
5.00
5.00
5.00
5.00
2.80
2.00
20.00
5.00
16.00
2.00
2.20
2.00
1.20
5.00
6.00
3.00
3.50
0.05
1.00
1.00
1.00
10.00
10.00
10.00
1.00
1.00
1.00
1.00
Liquid
Solid
Liquid
Liquid
Solid
Solid
Solid
Solid
Liquid
Liquid
Liquid
Liquid
Solid
Solid
Gas
Gas
Gas
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Drums
Bags
Tanks
Drums
Bags
Bags
Bags
Can
Carboys
Drums
Drums
Drums
Containers
Can
Capsules
Capsules
Capsules
Drums
Drums
Tank
Drums
Drums
Drums
Drums
MS Epoxy
PP
MS
HDPE
PP
PP
PP
GI
HDPE
GI
MS
MS
HDPE
GI
SS304
SS304
SS304
MS
MS
SS304
MS
MS
MS
MS
5.00
5.00
5.00
1.00
1.00
1.00
Liquid
Liquid
Liquid
Drums
Drums
Drums
MS
MS
MS
5.00
1.00
Liquid
Drums
MS
5.00
1.00
Liquid
Drums
MS
47
48
49
50
51
9
52 Linalool
53 Meta Chloro Pre
Benzoic Acid
54 1 Phenyl Ethanol (
Styrallyl Alcohol)
5.00
5.00
1.00
1.00
Liquid
Liquid
Drums
Drums
MS
MS
5.00
1.00
Liquid
Drums
MS
55 Furan
56 Allyl Alcohol
57 Aroma & Flavor
Ingredients
5.00
5.00
80.00
1.00
1.00
50.00
Liquid
Liquid
Liquid &
Solids
Drums
Drums
Drums/Cans/Boxes
/Containers
MS
MS
MS/HDPE
/Aluminu
m
LocationFor theproposed project the company will use its spare land from the existing plotsat Gut No 167, 169, 170,
171, 296, Village. Jamghar Lakhamapur, Tal. Wada, District: Thane, Maharashtra.
Thissiteisin onallfoursides wearesurroundedby industriesandnonuisance isspread.The immediate
surroundingneighborsare:
 East :Abhinav Pharmaceuticals Pvt Ltd, Mumbai Wada Jawahar Highway
 West: Agricultural Land, Village Lakhmapur
 South: A g r i c u l t u r a l L a n d , V i l l a g e L a k h m a p u r
 North: AFFPL Green Belt, Village Road, Residential Building
Locationtooisjustifiable.Unitsizeiskeptcorrectfor easeofhandling andenvironmentalcontrol.
Astherea r e o t h e r i n d u s t r i e s inthe neighborhoodw i t h similarn a t u r e , there is compatibility.
Thelanduseisalreadyas“Industrial land/Non Agriculture Land”.Thus,thereisnochangeinthestatus.Thisisaflat
landw h e r e by cutting- f i l l i n g balancesand t h e r e willbeNoLowBorrowingfromNature.
Tansa wildlife Sanctuary is about 8.3 kms North West of the site and the plot is located in
private industrial land hence requires Environment Clearance from the Ministry Of
Environment, Forest and Climate Change with Public Consultation.
Geographical Location Items:
Latitude
: Approx. 19° 5'9.63"N
Longitude
: Approx. 73°10'9.86"E
Terrain
:: Flat
terrain
Climate
Semi-Arid
4. Resources
Site
AFFPL is desirous to establish and it requires following resources,
• Area
48900sq. mts
• Water Input
Ground Water for existing 2 No’s bore wells and 1 No Well.
New Two No’s Borewell proposed with Rain Harvesting
Facility will be put in place.
• Work force
65
• Raw Materials
Commensurate with product, as also work up chemicals
Solvents& catalysts
•Effluent Facility
High COD and TDS sub stream segregated self-treatment
And Later CETP (membership is sought)/Gardening
• Haz. Waste Facility CSWTSDF at Taloja, Maharashtra
• Process Machinery
Developed by self available locally maintained sophisticated
Laboratory Attendants, cooling tower, hot water generations,
Steam Boilers
• Units Instrumentation Precision and accurate
• Total InvestmentRs.19.3408Crores (Rs 9.3408Crores Present + Rs 10.00Crores Expansion)
• Environment Fund
2%
• Proponents
Law abiding. No litigation pending.
Site
1.
Existing industrial premises and land area: 48900sq mts
10
2.
3.
4.
Climatic condition suitable for finer adjustments of control, making it fit for processing Conditions.
Well connected for transportation through Mumbai Wada-Jawahar Highway
Leveled ground and load bearing soil
Technology Selection
1.
The products proposed are in the same manufacturing range for which the technology is already developed,
and well known.
2.
The process used is based on raw materials that are available, without any bottleneck. Thus, Excess storage
also means wastage. Here, we can follow easily the principle of JIT (Just in Time).
3.
The process used is developed by AFFPL them in house and hence we are aware aboutthesensitivepoints
needing careful attention in advance.
4.
The process is cost effective, safe and environmentally friendly.
5.
There is no elevated pressure condition in processing.
6.
Solvents used that are recoverable, and are so recovered.
7.
The steam & hot water from boilers will be used for process
Instrumentation
1.
Latestelectronicinstrumentationwithhighaccuracyandreliability
2.
100% redundancy forcontrolandpowersupply.
3.
EmergencyShutdownSystemforensuringsafetyofplantandpersonnel.
4.
Streamflow,feedwaterflowismeasurable(indicatingandrecording)
5.
Waterlevelandliquidmateriallevelismeasurable(indicatingand recording)
6.
Multipointtemperaturescannerwiththermocouple.Allpointsindicatingandrecordingallforsteam,feedwater
,fluegasandair)
7.
Pressuregaugesatreactors.
8.
Multi-channeldataloggertoinputs likecurrents,mv,T/Cam recordingwith columneddotmatrixprinter.
9.
Hootersfortrips,lowlevels,highlevelsandhightemperatures.
Machinery & Hardware:
1.
ModernClosed Pump transfer system isused toavoid any risks in human being
handling the production.
2.
All processing equipment likereactors material of construction will be compatible to process.
3.
Generally, will be of SS316/GLR quality and will be kept validated as per strict international guidelines
prescribed.
4.
The condensers are in SS316.
5.
Wherever water is used, will be specially purified for process and cleaning- washing.
6.
Help of sophisticated configuration may be taken, if necessary.
Project proponents
AARAV Fragrances & Flavors Pvt.Ltd. (AFFPL) was incorporated in 2007. The promoters of the company have
more than 20 years of experience and profound understanding of the fragrance & flavor industry to provide
strategic inputs into key business decisions and developing long term goals.
AFFPL have developed strategic partnership with key global & local suppliers of synthetic and Natural ingredients
to provide consistent supply of fragrances & flavors to our valued customers.
AFFPL proudly service a wide range of SME's as well as multinational companies, both global & Indian.
To experience a great fragrance is to experience magic, fragrance has the power to captivate the senses and
transport our mind to new realm of imagination. AFFPL excels in the art and science of great fragrance creation.
Guided by our principles of Balance, Clarity and Integrity, we put our expertise behind your brand to create
signature fragrances. AFFL fragrances create unique, consistent and lasting experience for all consumers.
AFFL takes pride in partnering with their customers to ensure that when a product is picked off the self, customer
brand promise is fulfilled to the utmost satisfaction of the consumers from various categories
Some of the most profound memories are attached with food customer’s taste. We develop unique flavor
experiences that deliver your brand promise to consumers.
AFFL experts are constantly researching trends and focusing on the magic that consumers are looking for in the
market. AFFL development team works closely with the clients on specific briefs to deliver unique flavours within
stipulated deadlines for various categories.
Thecompany hasadoptedfollowingcertifications
1.
ISO 9001
2.
ISO 22000
3.
ISO27001( Under Implementation)
4.
Food Safety Standards Authority Certification.
The Board of Directors represents an optimum mix of knowledge, experience and expertise to guide the longterm success of the company.Theproponentsare
11
Sr.No.
1.
2.
Name
Designation
Mr. Ajit Suresh Vaze
CEO/ManagingDirector
Master Of Science Organic Chemistry
Engineer
Ms. AnuradhaAjitVaze
Director
3.
Mr. AjitDeshmukh
Director
4.
Mr. Jean Louis Matthey
Director
5.
Mr. HolgerHauenschild
Director
5. Process
Products
AFFPL proposes to establish a plant to produce synthetic organic chemicals catering to the perfumery & Flavor
industry. These products serve as raw material to the fragrance and flavors industries. As season changes the
demand for a fragrance /flavor changes, hence the demand for particular chemical ingredients also changes, the
industry has thus to be in readiness to change the product suitability as well as the application and be prepared to
mitigate the corresponding customer requirement challenges.
The utilities required will be steam which will be provided by the existing steamer and a new IBR Boiler will be
installed. Other will be provided by newer fresh technologies for cooling, vacuum etc. The multi-product facility
will be operated as normal chemical industry but the reactors will be used by different combination and sequence.
From the list of Products Sr Nos 2 to11 only two to three products will be manufactured simultaneously. The total
quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT
It may be seen that,
 There is a capability of making these products
 Production process is batch process with “Cleaner Production” strategy with effluents recycles
Machineries, utilities will be installed according to the requirement of the plant and products.
Schematic Process Flow for Proposed Products
COMPLIANCE TO MSIHC RULES:
According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical Rules, 1989), data on the
toxicity and flammable characteristics for the chemicals involved is as presented below in the form of tables.
12
Storage details for Raw Materials to be used in manufacturing activities:
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Raw Material
Quantity in
MT/M
Acetic Acid Glacial
Acetic Anhydride
Acid Catalyst
Aldehyde
Caryophellene
Phase transfer Catalyst
Caustic lye
Citronellol
Benzylledene Acetone
D’limonene/Orange Terpenes
Di Ethanol Amine
Dicyclopentadiene
Ethyl Chloro Acetate
Benzyl chloride
Halide (Pentyl Bromide/
Chloride)
HCl 45%
Iodine
Iso Amyl Alcohol
Isobutyric Acid
Methanol
Methyl Heptanone
Methyl Magnesium Bromide
/ Chloride
Hexyl Alcohol
Mg Turnings
Pentanol mixture
Propionic Acid
Salicylic Acid
Soda Ash
Sodium Acetate
Sodium Methoxide
Sulphuric Acid
Terpineol
Tetra hydro Furon
Toluene
Sodium salicylate
Zn Chloride
Propylene
Acetylene
Hydrogen
Benzaldehyde
N Pentanol
Propionaldehyde
Pthalic Acid
Vinyl Ethyl Ether
Physical
Form
182.00
53.00
17.00
85.00
4.00
1.10
1.04
17.03
105.00
98.00
1.00
240.00
22.05
27.60
106.00
Storage At
a time
during the
month
10.00
4.00
2.00
6.00
1.00
0.10
1.00
2.00
10.00
10.00
1.00
20.00
5.00
2.50
10.00
Stored In
MOC
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Tank
Drums
Carboy/Drums
Drums
Drums
Drum
Carboy
Drums
Drums
Drums
Drums
Tank
Drums
Drums
Drums
SS304
HDPE
HDPE
HDPE
GI
HDPE
HDPE
MS Epoxy
GI
MS Epoxy
MS Epoxy
SS304
HDPE
HDPE
HDPE
1.00
0.05
10.00
60.00
15.00
69.00
31.61
1.00
0.05
2.00
10.00
3.00
10.00
2.50
Liquid
Solid
Liquid
Liquid
Liquid
Liquid
Liquid
Carboys
Can
Drums
Drums
Drums
Drums
Drums
HDPE
GI
HDPE
HDPE
MS
HDPE
MS
52.00
12.74
77.14
46.00
160.00
12.24
21.30
15.00
10.00
68.18
200.00
28.03
35.70
0.52
5.00
5.00
6.00
100.00
96.00
142.00
5.00
5.00
2.80
2.00
20.00
5.00
16.00
2.00
2.20
2.00
1.20
5.00
6.00
3.00
3.50
0.05
1.00
1.00
1.00
10.00
10.00
10.00
1.00
1.00
Liquid
Solid
Liquid
Liquid
Solid
Solid
Solid
Solid
Liquid
Liquid
Liquid
Liquid
Solid
Solid
Gas
Gas
Gas
Liquid
Liquid
Liquid
Liquid
Liquid
Drums
Bags
Tanks
Drums
Bags
Bags
Bags
Can
Carboys
Drums
Drums
Drums
Containers
Can
Capsules
Capsules
Capsules
Drums
Drums
Tank
Drums
Drums
MS Epoxy
PP
MSEpoxy
HDPE
PP
PP
PP
GI
HDPE
GI
MSEpoxy
MSEpoxy
HDPE
GI
SS304
SS304
SS304
MS
MSEpoxy
SS304
MSEpoxy
MS Epoxy
13
45
46
47
48
49
50
51
52
53
54
Sodium Hydride
Aluminum Trichloride
Di Chloro Methane
N Butyl Aldehyde
Tertiary Butyl Methyl Ether
N ,O Dimethylhydroxylamine
Hydrochloride
Geraniol
Linalool
Meta Chloro Pre Benzoic
Acid
1 Phenyl Ethanol ( Styrallyl
Alcohol)
55 Furan
56 Allyl Alcohol
57 Aroma & Flavor Ingredients
5.00
5.00
5.00
5.00
5.00
5.00
1.00
1.00
1.00
1.00
1.00
1.00
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
Drums
Drums
Drums
Drums
Drums
Drums
MS Epoxy
MSEpoxy
MSEpoxy
MSEpoxy
MS
MS
5.00
5.00
5.00
1.00
1.00
1.00
Liquid
Liquid
Liquid
Drums
Drums
Drums
MS
MS
MS
5.00
1.00
Liquid
Drums
MS
5.00
5.00
80.00
1.00
1.00
50.00
Liquid
Liquid
Liquid &
Solids
Drums
MS
Drums
MS
Drums/Cans/
MS/HDPE/
Boxes/Contain Aluminum
ers
Storage Details For Products Proposed to be Manufactured
Sr.
No
1
2
3
4
5
6
7
8
9
10
11
12
Raw Material
Quantity
in MT/M
(formulation)
Perfumery & Flavors Esters
Perfumery & Flavors Alcohol
Perfumery & Flavors Aldehyde &
Aldehyde Derivatives
Dimerization and Trimerization of
simple olefins.
Ketals / Acetals / substituted 1,3propanediols
Macrocyclic and polycyclic musks
derived
from
propylene
or
butadiene/ and other propylene
derivatives
Aldehydes & Ketones by Aldol
Condensation
Acetylene and other alkyne
derivatives
Cyclo Alkylation/Acetylation, Diel
Alders Reactions ,Friedel Craft
Reactions
Hydrogenation Compounds
Inorganic Salts
Overall Environmental Significance:
Unit Operation/
Process
1.IncomingRaw Materials
210.00
300.00
Storage
At a time
in MT/M
50.00
35.00
Physical
Form
Stored In
MOC
Liquid
Cans/Drums Aluminum/MS
Liquid
Liquid
Liquid
Liquid
Liquid
Liquid
50.00
560.00
Peculiarities
20.00
105.00
Liquid
Liquid
Liquid
Solids
Bags
HDPE/PP
Environmental significance
Selected from known vendor’s Prompt use and storage in closed
transportation enclosed
containers prevent spillages and loss of
tankers/Drums in limited low strength. Fewer emissions.
volumes.
14
2.Weighingand strict
Quality control
Load Cell based weighing system Better check on mass balance, purer
provided
material and less rejections.
3.Inprocess
Solvents
Byproducts
Recovered and reused
Recovered and sold to parties, when in
demand
Process waste residue
To be sent on common facility for
disposal by incineration.
4.Instrumentation
Control system for accurate
process controls
Facilitates monitoring of quality of the
product and safety aspects.
5.Control
Excellent system of
documentation and control of
critical stages in production
process
Better operation and retrievable records
for better checks.
6.Solvent Recovery
Proper recovery systems with
Vapor and Product Condensers with Step
vapor condenser and chilled unit. down chilling and cooling systems
6. Pollution control
Clean production technology adopted byensuringfollowing a t design a n d e n g i n e e r i n g stage.
All Products & their reactions selected after considering the friendliness of these products on the
environment
Minimize pollutants at source
Recovering and recycle of the RM
Maximize recycle of water resources.
Tertiary ETP System will be erected and operated
Treat to PCB norms
100% recycle of increased effluents for process for defined cycles.
Procure CEPT Membership when available
Use with Priority Environment Friendly Fuels Like Ground Shells Briquettes, Agricultural Waste.
Reduction of VOC at every processing stage by providing vents condensers and scrubbers.
Use of mainly clean fuels like agricultural waste/FO/LDO.
All Process Transfers will be conducted in enclosed systems by pumps.
The process where varies based on Esterification of organic acid and alcohol producing water. The
recovery system will be designed in such a way that entire water is used for process application there by
replacing fresh water input.
The boiler is provided with cyclone separator, bag filter/ ESP to control emission within prescribed limits.
The stack hei ght will be up to 30 meters to control ground level clearance within limits.
Process vents are controlled by condensers followed by water cooling and chilling systems and with
which the organics are recovered and recycled.
(a)
Water & waste water:
The water and waste water generated in the factory will be as follows;
i.
Water Requirements:
Details Of Fresh Water Consumption
Sr
Water Break Up
Existing Water
Proposed Water
Total Water
No
Consumption
Consumption
Consumption
( KL/Day)
(KL/Day)
(KL/Day)
I
5.00
5.00
10.00
Domestic
II
0.00
80.00
80.00
Gardening
III
Industrial
1)Process
0.00
5.00
5.00
2)Cooling Water Make up
0.00
9.00
9.00
3) Boiler Make Up
3.50
13.50
16.00
4) Washings
0.00
3.00
3.00
Total Industrial
8.50
115.50
124.00
Details Of Waste Water
Sr
Waste Water Break Up
Existing Waste
Proposed Waste
Total Waste
15
No.
I
II
Domestic
Industrial
1)Process
2)Cooling Water
3) Boiler Blow Down & Cooling
4) Washings
Total Industrial
The industry will obtain membership of CETP.
Water Balance Diagram:
Water
Generation
(KL/Day)
3.60
Water Generation
(KL/Day)
WaterGeneration
(KL/Day)
3.60
7.20
0.00
0.00
2.70
0.00
7.30
5.00
9.00
12.00
3.00
32.6
5.00
9.00
12.00
3.00
36.20
Schematic Diagram for Fresh Water Requirement and Waste Water Flow
Fresh Water From Borewells/Well 124 kl/Day
Fre sh
Re cycle d
Re cycle d
Re cycle d
Total
Gardening
Domestic
80kl/Day
3kl/Day
12.8kl/Day
8kl/Day
103.8kl/Day
10kl/Day
Se wage
Tre atme nt
Plant
3kl/day
Cooling
Tower
9kl/Day
RO
28kl/day
Cooling
Tower
Blow
Down
9kl/Day
RO Reject
RO Water
to Boiler
Feed
11.2kl/Day
16.8kl/Day
Process
Washings
5kl/Day
3kl/Day
8KL Recovered to ETP
Boiler
Blow
Down
12.8kl/Day
Recylce back to garden/
Or CEPT
Efflue nt Tre atme nt Plant
Proposed ETP Flow Sheet:
Inlet
Outlet
Oil & Grease
Trap
Equalisation
and
Neutralization
Tank
Primary
Settling Tank
1st Stage
Aeration Tank
Final
Dishcarge
Tank
Pressure Sand
Filter
Intermediate
Collection
Tank
2nd Stage
Secondary
Settling Tank
1st Stage
Secondary
Settling Tank
2nd Stage
Aeration Tank
16
(b)
Air Pollution:
The existing plant comprises of 1 small industrial boiler (Steamer). The fuel used in the existing boiler is
furnace oil. Two DG Sets a.63kva for emergency and power failures & b. 160kva exclusively for fire
alarms & firefighting hydrant systems is already installed, which is used only during power failures.
Proposed Scenario:
For the proposed expansion unit, the existing steam boiler will be kept as stand by. A new 5 MT IBR
Boiler and a new thermic fluid heater will be installed. The details of the boiler and thermic Fluid heater
are given below:
Details of Boiler and Thermic Fluid heater Capacity
Details of Air Pollution Control unit:
The proposed plant will not produce any significant air pollution load. The major sources of air pollution
will be:


Boiler
Thermic Fluid Heater
Sources
of
Emissions
Fuel used
Quantity of fuel
Gaseous Boiler (1x 5MT/Hr)
Thermic Fluid Heater (1x 3Lac kcals/
hr)
Agricultural Waste /Bio Coal/ Furnace Agricultural Waste /Bio Coal/ Furnace Oil
oil/Coal / NG
/Coal /NG
22 mt/Day / 22mt/day/10 mt/day 5mt/Day/5mt/day/2.5mt/day/5mt/day/
/22mt/day/8500 m3/Day
2500m3/day
SO2, NOX, PM
SO2, NOX, PM
30 mts
13 mts
0.505 mts
0.505 mts
Type of emissions
Stack height
Stack dia. at the top

D.G. Set Emissions

Fugitive emissions

Process emissions

To control the fly ash particles / particulate emissions from the boiler, cyclone will be installed in the
proposed project. There are no process emissions from the proposed project.
Schematic diagram of cyclone
The existing D.G. Set shall be used only in case of emergencies / Power failure & Fire Related
emergencies. A New DG will be installed replacing the 63KVA
Details of D.G. Set
Existing D.G.Set
Existing D.G.Set
Proposed D.G.Set
Sources of gaseous emissions
(63 KVA)
(160 KVA)
(500 KVA)
Fuel used
Diesel
Diesel
Diesel
17
Quantity of fuel (Will depend on 11lits/Hr
Power Failure & Emergencies)
Type of emissions
PM, SO2& NOX
Stack height
3 meters
Capacity of D.G.Set
63 KVA
35lits/Hr
105 lts/hr
PM, SO2& NOX
3 meters
160 KVA
PM, SO2& NOX
3 meters
300 KVA
Sr Source
No
1 Proposed 5MTBoiler.
Pollutant
Measures
SPM, CO,SO2,
NOx
2
VOC
Dust Collectors,, ESP, Tall stack of 30 m.
Dust extraction with Bag
filters, fogging.
Closed loop transfer
Vent condensers,
Extraction and scrubbing
Segregation of Streams
Fully aerobic
3
In process
Control Equipment
ETP
COD, TDS
Noise :
There is no major noise generating sources. Only those Vehicles with PUC's and spark arresters will be
allowed inside the premises. Green belt facilities have also been provided in the plant premises.
Details of Hazardous Waste Generation and Disposal:
The plant will have the maximum solid waste generation from the ETP, which will be sent to CHWTSDF,
Taloja, Maharashtra for its disposal applied for membership.
Details of Hazardous waste generation and disposal:
Sr. Type of Waste Category Existing
Proposed
Mode of disposal
No.
Quantity
Quantity
MT/Annum
MT/month
1
ETP Sludge
34.3
0.060
100.00
Collection, storage,
transportation and disposal to
TSDF.
2
Used Oil
5.1
0.00
2.40
transportation and disposal by
sale to registered recyclers.
3
Discarded
33.3
0.00
12.25
Containers
decontamination,
sale to authorized recycler
4
FO / LDO &
-3.36
Oil
Bottoms
0.00
Sludge
5
Distillation
20.3
0.00
16.200
Residue
transportation and disposal to
CHWI.
6
Grease
5.2
0.00
0.012
7
Fly ash (Boiler
0.00
482.00
Will be sold to brick
& TF Ash)
manufacturers.
8
Low
purity
C8
0.00
72.00
Will be sold.
fractions
9
Spent acid
-0.00
16.00
Will be sold.
Hazardous Waste Storage Room:
A hazardous waste storage room measuring 100sqmts will be provided with impervious RCC flooring and
leachate collection pit. The distillation residue will be stored in carboys in Hazardous waste storage room
and will be finally disposed of to CHWTDFS, Taloja, Maharashtra. The Fly ash will be stored in a defined
area and precautionary measure will take for avoid carryover of the ash by wind/breeze/water etc.
Dispersion:
18
Point Emissions are coming from one boiler, thermic fluid heater &3 DG hence proper stacks will be
provided for the same. Please note DG 3 Nos will be used only in emergency & during power failures.
The stacks will be fitted with port-holes, ladder and platform for facility of taking samples.
Fugitive:
A number of mitigation measures will be taken to control fugitive emissions

Engineering, the plant layout will be in such a way so as to virtually eliminate need of using heavy
Equipment for material handling in the main plant

Internal roads paved, leveled, no undulations, no sharp curves, slow speed.

No open storage of materials involved

Fumes extraction and vacuum system will provided for extraction of fumes
from the reactors and the process plant areas.
Fugitive Emissions and its control:
There are no emissions from the manufacturing process. For control of fugitive emissions, chilled
water traps will be installed on the vent of the unit to arrest any escape of vapors from the reaction
and distillation unit. Fugitive emission could occur from the storage yard of raw materials and
finished products. The storage quantity is very low and proper handling methods will be adopted.
Emissions from transport of vehicles would occur to a certain extent. The emissions from traffic
movements is controlled by proper planning of the transport of raw materials and finished
products to and fro from the factory premises. Since the quantities involved are very less,
movement of vehicles will be occasional. All the roads inside the plant will be concreted to reduce
any dust emissions.
Details of Solvent recovery Plan and monitoring of vents:
The solvent recovery system for the proposed expansion project is shown in the figure below.
The vents of the reactors will be connected to 2 stage condenser system, where chilled water will be
recalculated. The receiver will also be jacketed with circulation of chilled water. The recovered solvents
will then be stored and reused. All the units will be under nitrogen blanketing through cylinders. Proper
planning and maintenance will control the extent of fugitive emissions. During the production, the
industry will carry out regular monitoring of fugitive emissions as per the factories act.
Details of Solvent Recovery Plan
Aesthetics:
There will be no nuisance from noise. DG 3 Nos will be used only in emergency & during power failures
to keep plant under safe conditions. If Coal is used as fuel for boiler there will crushing and pulverizing
19
operations for coal handling. Dust suppression system is provided. Dust extraction with dust collection
will be provided. Labor strength will also be limited.
7. Background Study:
1.a)
1.b)
1.c)
1.e)
1.f)
LAND ENVIRONMENT:
Area
: Study area (10km)
Topography of the area indicating gradients, aspects and altitude.
Details:
Establishment of Land Use Pattern. Locations of National Park/
Sanctuary/Biosphere Reserve/ Monument /Heritage site/Reserve
Forests.
Soil Samples
: Soil Analysis to cover 7 locations in the project area.
Parameters
: pH, EC (mhos/cm2), Organic Carbon, Phosphorous as P (kg/Ha),
Potassium as K (kg/Ha), Sulphate as SO4 (%), Textural
classification, Available nitrogen (kg/Ha).
AIR ENVIRONMENT:
BASELINE AAQ:
Number of stations
: 6 in study area
Frequency
: 2 days per week
Duration
: One season.
Parameters
: PM10, NOx, SO2, NMHC, CO, Primary Meteorological data,
(WS/WD/DB Temp. / RH), Review frequency of inversion,
Frequency of cyclones/ tornadoes/ cloud burst from Climatological
Tables & other available secondary data.
NOISE ENVIRONMENT:
Number of station
: Same as AAQ locations
locations
Frequency
: Hourly measurements to determine day time / night time Leq. as per
Environment Protection Act.
Duration
: Once in the season
Method of sampling
: Continuous sound level meter
and analysis
WATER ENVIRONMENT:
Number of locations
: 7 locations for Ground/ Surface water within study area.
Frequency
: One sample per location.
Duration
: One season.
Parameters
: As per ISO 10500-2012
SOCIOECONOMIC DATA:
Area
: study area
Details
: Demographic Pattern (literacy Rate, Male to Female Ratio),
Occupational Pattern, Socioeconomic Status etc.

PREFEASIBILITY REPORT - Environmental Clearances

Transcription

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