ASHA CELLULOSE (I) PVT. LTD PRE-FEASIBILITY REPORT...Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD Page 3 (From Alcohol) in the manufacture of Ethyl cellulose and other chemical

ASHA CELLULOSE (I) PVT. LTD

PRE-FEASIBILITY REPORT

FOR

PROPOSED EXPANSION PROJECT FOR MANUFACTURING OF ETHYL CHLORIDE

(FROM ETHYL ALCOHOL), ETHYL CHLORIDE (FROM MIXED SOLVENT OF EXISTING PROCESS), METHYL CHLORIDE (FROM METHYL ALCOHOL) & HYDROXY PROPYL METHYL CELLULOSE (HPMC)

[Schedule 5 (f) Category “A” as per EIA notification 2006 and its amendment thereof]

At

S. No. 303/2, 302/P, 273/2, 275/1 Near Water Works, Abrama, Valsad - 396001

Ta: Valsad, Dist- Valsad, Gujarat.

Land/Plot Area: 31874 m

2

Production Capacity: 96.54 to 1028.54 TPM (All products together)

APPLICANT CONSULTANT

ASHA CELLULOSE (I) PVT. LTD ECO CHEM SALES & SERVICES S. No. 303/2, 302/P,273/2, 275/1

Near Water Works, Abrama, Valsad, Tal./Dist: Valsad - 396001Gujarat.

E-Mail: [email protected] [email protected]

Tel: +919825132304 +91 2632 254299

Office Floor, Ashoka Pavilion - A New Civil Road, Surat, 395001

NABET/EIA/1720/RA 051 E-mail: [email protected] Tel No. +91 261 2231630

Document No.: 2019_ECSS_EIAI2_1800002

January 2019

mailto:[email protected]

mailto:[email protected]

Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD

Page 2

1.0 EXECUTIVE SUMMARY

1.0.1 Name & Location

Name of the Project: Asha Cellulose (I) Pvt. Ltd.

Location: S. No. 302/P, 303/2, 273/2, 275/1, Near Water Works, Abrama, Valsad-396001 Ta: Valsad, District: Valsad, Gujarat

1.0.2 Project

M/s. Asha Cellulose (I) Pvt. Ltd is located at S. No. 302/P, 303/2, 273/2, 275/1, Near Water

Works, Abrama, Valsad-396001, Ta: Dist: Valsad, Gujarat area, falling under medium Scale

category manufacturing products as mentioned under. The company had obtained Environment

Clearance and Consent to Establish and operates from Gujarat Pollution Control Board for all

the existing products.

The company proposes to introduce new product i.e. ethyl chloride from mix solvent of existing

ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward integration, Methyl

chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC). Ethyl Chloride is

one of the main raw materials required in the production of Ethyl Cellulose and Methyl Chloride

is one of the raw materials for the manufacture of HPMC.

Total project cost (Existing: Rs. 1516.27 lakhs + Proposed: Rs. 1538 lakhs = Total: 3054.27

lakhs)

1.0.3 Applicability of EIA notification – 2006

As per the amended EIA notification - 2006: as proposed expansion products (i.e. ethyl chloride

from mix solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for

backward integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose

(HPMC) are covered under the Category 5 (f) A. Hence, Environmental Clearance is required.

1.0.4 Project Proponent

The company in India comprises of technically sound directors

Medium scale unit

1.1 LIST OF FINISHED PRODUCTS

Sr. No.

Product CAS No. Capacity, TPM

End-Use Existing Proposed Total

1. Ethyl Cellulose (Aqua Process)

9004-57-3

20.0

0

20.0

Used in the manufacture of printing

inks, solar paste, specialty paints, in

electronic applications, as a binder and coating

agent in pharma industry besides

defense purposes.

Used for coating application in

Pharmaceutical Industries

2. Ethyl Cellulose

(Solvent Process)

9004-57-3

31.72 0

31.72

3.

Ethyl Cellulose Aqueous

Dispersion- Non Plasticized

9004-57-3

20.124

0

20.124

4.

Ethyl Cellulose Aqueous

Dispersion- Plasticized

9004-57-3 24.70 0 24.70

5. Ethyl Chloride 75-00-3 0 322.0 322.0 Used as a raw material


Page 3

(From Alcohol) in the manufacture of Ethyl cellulose and

other chemical synthesis.

6. Ethyl Chloride

(From existing mix solvent)

75-00-3 0 160.0 160.0

7. Methyl Chloride

74-87-3

0

250.0

250.0

Used as a raw material in the manufacture of

HPMC and other chemical synthesis.

8. Hydroxy propyl methyl cellulose

(HPMC)

9004-65-3

0

200.0

200.0

Used in pharmaceutical coating applications

Total --- 96.544 932.000 1028.544

Manufacturing process with chemical reaction & mass balance is attached as Annexure 3.

1.2 RESOURCE REQUIREMENT

Components Existing Proposed Total Resources availability

Power, KVA 650 350 1000 Dakshin

Gujarat Vij Co. Ltd.

Fresh Water, KLD 37.48 0 37.48 Own bore well

Chilling plant, TR 140 100 240 In house

Cooling Tower, TR 400 300 700 In house

Natural gas (SCM/h)/Furnace oil(kg/h) for 3 TPH

Steam boiler

230/200 0 230 /200 Gujarat Gas/ Local Traders

Solid fuel or Natural gas / Furnace oil for 3 TPH Steam

boiler.

0 Coal- 300 Kg/Hr

400 SCM/Hr 325 Kg/h-FO

Coal- 300 Kg/Hr 400 SCM/Hr 325 Kg/h-FO

In house

Furnace oil or natural gas for 6 lakh k cal/hr

Thermopak 0

115 Kg/Hr-FO 135 SCM/Hr-

NG

115 Kg/Hr-FO 135 SCM/Hr- NG

In house

LDO/Furnace oil for 0.8 TPH boiler

25 liters/hr -25 liters/hr 0 To be removed





LDO/Natural gas for 6 lakhs k cal/hr hot air

generator

40 Lts/Hr- LDO 50 SCM/Hr-NG

0 40 Lts/Hr- LDO 50 SCM/Hr-NG

From Gujarat Gas From

Local Traders


generator

40 Lts/Hr-LDO 50 SCM/Hr-NG

0 40 Lts/Hr-LDO 50 SCM/Hr-NG

From Gujarat Gas

From Local Traders


generator 0



From Gujarat Gas

From Local Traders


Page 4

HSD for D G set (110 KVA)

45 kg/h 0 45 kg/h From Local

Traders

HSD for D G set (35 KVA)

15 kg/h 0 15 kg/h From Local

Traders

1.3 RAW MATERIAL CONSUMPTION

Sr. No.

Raw Material CAS No. Consumption in MT/Month

MT/MT Existing Proposed Total

1.0 For Ethyl Cellulose (Aqua Process)

Wood pulp - 0.825 16.5 0 16.5

Caustic flakes 1310-73-2 5.4 108.0 0 108.0

Ethyl Chloride 75-00-3 3.365 67.3 0 67.3

Acetic acid 64-19-7 0.001 0.1 0 0.1

2.0 For Ethyl Cellulose (Solvent Process)

Wood pulp - 0.836 26.52 0 26.52

Caustic flakes 1310-73-2 1.75 55.6 0 55.6

Ethyl Chloride 75-00-3 2.36 74.9 0 74.9

Toluene 108-88-3 0.40 13.0 0 13.0

Acetic acid 64-19-7 0.60 19.10 0 19.10

SDS 151-21-3 0.19 6.24 0 6.24

3.0 For Ethyl Cellulose Aqueous Dispersion- Non Plasticized

Ethyl cellulose 9004-57-3 0.27 5.460 0 5.460

Solvent (Ethylene Dichloride, Acetone

and Methylene Dichloride)

(Fresh) (Recovered)

Mixture

0.03 0.86

0.624 17.32

0 0

0.624 17.32

Sodium Lauryl Sulfate

– Powder 151-21-3 0.01 0.312

0 0.312

Cetyl Alcohol Powder 36653-82-4 0.03 0.624 0 0.624

4.0 For Ethyl Cellulose Aqueous Dispersion- Plasticized

Ethyl cellulose 9004-57-3 0.2 4.940 0 4.940

Plasticizer – Dibutyl

Sebacate ‎109-43-3 0.05 1.300 0 1.300

Oleic Acid 112-80-1 0.04 1.040 0 1.040

Ammonium Hydroxide 1336-21-6 0.05 1.300 0 1.300

5.0 For Ethyl Chloride (From Alcohol)

Calcium chloride/Zinc

Chloride 10043-52-4/ 7646-85-7 0.0003 0 0.1 0.1

Hydro Chloric acid

(30%) 7647-01-0 1.93 0 624.23 624.23

Ethanol (94%) 64-17-5 0.76 0 247.0 247.0

Caustic lye (10%) 1310-73-2 0.22 0 72.82 72.82

6.0 For Ethyl Chloride (From existing mix solvent)

Mix solvent from existing Ethyl

cellulose product by solvent process

Mixture 0.71 0 114.18 114.18

Mix solvent from

existing Ethyl Mixture 0.21 0 34.86 34.86


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cellulose product process: II

Hydro Chloric acid

(30%) 7647-01-0 1.99 0 319.73 319.73

Caustic lye (10%) 1310-73-2 0.40 0 65.0 65.0

7.0 Methyl Chloride

Calcium Chloride /

Zinc Chloride 10043-52-4/ 7646-85-7

0.0003 0 0.1 0.1

Hydro Chloric Acid

(30%) 7647-01-0

2.45 0 613.6 613.6

Methanol 67-56-1 0.64 0 159.74 159.74

Caustic Lye 1310-73-2 0.21 0 52.0 52.0

8.0 Hydroxy propyl methyl cellulose

Wood Pulp - 0.67 0 134.8 134.8

Methyl Chloride 74-87-3 0.23 0 46.3 46.3

Sodium Hydroxide 1310-73-2 0.185 0 36.9 36.9

Propylene Oxide 75-56-9 0.25 0 49.76 49.76

1.4 WATER AND WASTE WATER MANAGEMENT

At existing Scenario:

Presently, total water requirement is 155.48 m3/day (Fresh: 37.48 m3/day + Recycled from

RO/MEE is 118 m3/day) which is sourced from own bore well. We have already applied to

CGWA for permission to withdrawal of ground water.

Total industrial waste water generation is 123 m3/day, which is treated in primary, secondary

and tertiary treatment plant. Treated waste water is taken to reverse osmosis plant. 102

m3/day of RO permeate is recycle in the process. Balance 18 m3/day of RO rejected is taken

to MEE. 16 m3/day of MEE condensate is recycled in the process. Thus there is no discharge

of industrial effluent on land.

Domestic waste water (1.5 m3/day) is disposed off through septic tank to ETP.

After proposed expansion:

After proposed expansion, total water requirement will be 244.9 m3/day (Fresh: 37.48 m3/day +

Recycled from RO/MEE is 207.5 m3/day) sourced from own bore well. We have already

applied to CGWA for permission to withdrawal of ground water.

Total industrial waste water generation will be 218.015 m3/day, which will be treated in primary,

secondary and tertiary treatment plant. Treated waste water will be taken to reverse osmosis

plant. 181 m3/day of RO permeate will be recycled in the process. Balance 32 m3/day of RO

reject will be taken to MEE. 26.5 m3/day of MEE condensate will be recycled in the process.

Thus there will be no discharge of industrial effluent on land.

Domestic waste water (2.0 m3/Day) will be disposed off through septic tank to ETP.

1.5 AIR EMISSION AND ITS CONTROL MEASURES

1.5.1 Flue Gas Emission and process gas emission:


Presently, the unit has installed one number of natural gas/FO fired 3 TPH steam boiler, three

numbers of FO/LDO fired steam boiler having capacity of 800 kg/h each and two numbers of

LDO/Natural gas fired hot air generator having capacity of 6 lakhs k cal/hr each. Two numbers

of D G sets having 110 KVA and 35 KVA capacity. 30 meters height of chimney with SMF

provided to 3 TPH boiler, 15 meters common chimney provided for all three boiler and two


Page 6

HAG. 11 meters chimney provided for D G Sets.

Presently two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h are used.

Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney

for each dryer is provided.


After proposed expansion, existing one number of natural gas/FO fired 3 TPH boiler will be

continued. Existing three numbers of 800 kg/h capacity of boiler will be discontinued. Existing

two numbers of hot air generator will be continued. Additional one number of coal/natural

gas/FO fired 3 TPH boiler and one number of FO/natural gas fired 6 lakhs k cal/hr capacity of

thermopak and one number of natural gas/LDO fired hot air generator of 6 lakhs k cal/hr

capacity will be installed. Existing two numbers of D G sets having 110 KVA and 35 KVA will be

continued.

30 meters height of chimney with SMF provided to 3 TPH boiler, 15 meters common chimney

provided for three HAG. 30 meters chimney with multi cyclone separator and bag filter will be

provided to 3 TPH coal fired boiler. 11 meters height of chimney will be provided to 6 lakhs k

cal/hr capacity of thermopak. 11 meters chimney provided for D G Set.

After proposed expansion, existing two numbers of spin flash dryer having capacity of 50 kg/h

and 100 kg/h will be used. One additional spin flash dryer having a capacity of 100 kg/h will be

installed. Adequate capacity of separate cyclone separator and bag filter along with 11 meters

chimney for each spin flash dryer will be provided.

Detail of Air pollution control measures is attached as Annexure 9.

1.6 HAZARDOUS WASTES AND ITS MANAGEMENT

Sr. No.

Process waste Category Source Quantity, TPA Mode of

disposal Existing Proposed Total

1 Used oil Sch: I/5.1 Machineries/ D.G.Set

0.092 0.018 0.11 Incineration at common

incineration system of M/s

BEIL, Ankleshwar /

sold to authorized recyclers

2 Discarded containers/bags

Sch: I/33.1

Raw Material Storage area & Utility Area

50 12 62 reused for packing of solid waste or sold to

registered recyclers

3 ETP waste Sch: I/35.3

ETP 109 21 130 Disposed off into TSDF site of M/s

BEIL, Ankleshwar or

VGEL, Vapi

4 MEE waste Sch:I/35.3 MEE 234 714 948 Disposed off into TSDF site of M/s

BEIL, Ankleshwar or

VGEL, Vapi


Page 7

5 Dust from air filtration system

Sch:I/26.2 air filtration system

0.22 0 0.22 Recycled in process

6 Salt from process

Sch:I/26.1 Manufacturing process

1703

0

1703

Disposed off into TSDF site of M/s

BEIL, Ankleshwar or VGEL, Vapi.

7 Mixed Solvent from the process


1787.44

9.98 + 51.96 (vent

condenser and

HPMC product)

1849.38

61.9

1787.44 MTPA of mix solvent from solvent process and

aqua process will be utilized

for manufacture of Ethyl chloride product within the premises and balance 61.9 MTPA of mixed solvent will be sold to

actual distillator

8 Distillation Residue / & Laboratory organic waste


23.0 - 18.78 4.22 Collection, storage

transportation, disposal to BEIL

incineration facility.

9 Spent carbon from ETP &

Chimney

Sch:I/36.2 ETP/Chimney 4.8 1.2 6.0 Collection, storage



10

Date-Expired, Discarded and off-specification Material & floor sweeping

Sch:I/28.5

Product Storage area

1.0

1.0

2.0

Collection,

storage transportation,

disposal to BEIL incineration

facility.

11 Spent Filter cloth & filter

material

Sch:I/36.2

From process plant

1.0

0

1.0

Collection,



facility.

12 Spent Resins from D M plant

Sch:I/35.2 D M plant 1.0 0.2 1.2 Collection, storage

transportation, disposal at TSDF/BEIL Collection,


Page 8


disposal at TSDF/BEIL

13 Used hot & cold insulation material

Schedule: X/02

Manufacturing process

0.5 0.1 0.6 Collection, storage

transportation, disposal at TSDF/BEIL

14 Weak caustic soln (18-20%

Sch: II/C2 Manufacturing process

17723 0 17723 Sell to actual/authorized

users

Solid Waste

15 Fly ash - Boiler 0 179 179 Sell to Brick manufacturer


Page 9

1.7 INTRODUCTION OF THE PROJECT AND THE PROPONENT

Name of the project Proponent: M/S Asha Cellulose (I) Pvt. Ltd

ASHA GROUP OF COMPANIES were floated by three enterprising gentlemen, Mr. H. V. Shah,

Mr. C. D. Mehta and Mr. J. L. Shah in the year 1968 with main line of business being

manufacturing of Industrial Paints. ASHA NITROCHEM INDUSTRIES LTD was the flagship

Company which remained in existence for two decades till 1998, then was sold to ICI India Ltd.

in May 1998, retaining global marketing rights in the name of ASHA EXPORTS. With time the

group grown into other business activities successfully and diversified into chemical

manufacturing, import / export and real estate. Asha Group was the Pioneer in the Field of

manufacturing Nitrocellulose, Celluloid Sheets & Ethyl Cellulose.

ASHA CELLULOSE (I) PVT. LTD. was incorporated in the year 1988. The Plant is located at

Abrama, Near water Works, Valsad, Dist. Valsad, Gujarat State, which is approx. 1 km off

National Highway No. 8. The location is on the banks of river Auranga and is in the proximity of

Abrama water Works.

ASHA‎CELLULOSE‎(I)‎PVT.‎LTD.‎has‎developed‎“ETHYL‎CELLULOSE‎“manufacturing‎process‎

by‎in‎house‎R‎&‎D‎efforts.‎It‎is‎the‎pioneer‎and‎the‎only‎Company‎manufacturing‎“Ethyl‎Cellulose‎

“in‎India‎and‎was‎the‎third in world after USA and China when it entered the domestic market.

Apart from the Industrial and Pharmaceutical grades, the Company is manufacturing high tech

speciality Ethyl Cellulose for Defence and Electronic sector. The product is well accepted by all

leading Pharmaceutical Companies, including multinationals. The product finds application in

paints, printing inks, adhesives, pharmaceutical, electronic industry besides defence purposes.

ASHA CELLULOSE (I) PVT. LTD. has ventured into export of Ethyl cellulose and successfully

bagged orders from Europe, USA, China, Korea, Far East and Middle east countries.

The Company is managed by Professionals supported by highly qualified technicians in the

manufacturing process. The Company has a total work force of 100 dedicated persons including

Mangers and Techno – Commercial personnel.

THE GROUP :

ASHA CELLULOID is the Company engaged in manufacturing of Cellulose Nitrate Sheets for

Defense supply. ASHA CELLULOID is the only Company manufacturing CN Sheets in India.

ASHA PENN COLOR PVT. LTD. is the Company having partnership with PENN COLOR INC.

USA and engaged in manufacturing of Pre-dispersed Pigmented Chips based on resins like

Cellulose Acetate, Cellulose Acetate Butyrate, Vinyl, Polyamide and Nitrocellulose. The

Company is the only manufacturer of this product in India. This product is also well accepted in

Indian market as well as in overseas. The Company is regularly exporting to Europe, Middle

East and Africa etc.

ASHA EXPORTS is the Company acting as global export agent for NITREX CHEMICALS INDIA

LTD. for their product Industrial Nitrocellulose. The Company has developed excellent overseas

market and contacts.

The group has always remained cohesive and concentrated on vertical (forward as well as

backward) and horizontal integration in manufacturing. It believes in taking up manufacture of

products with a long life cycle having very few manufacturers in the world. This strategy provides

the Group with a competitive edge in comparison to manufacture of conventional products.

M/S Asha Cellulose (I) Pvt. Limited is a medium scale unit is located in private industrial estate,

near water works, Abrama, Valsad, Di: Valsad having total plot area is 31874 m2 & proposed

investment will be (Existing: Rs. 1516.27 lakhs + Proposed: Rs. 1538 lakhs) 3054.27 lakhs &


Page 10

wishes to introduce new product i.e ethyl chloride from mix solvent of existing ethyl cellulose

product, Ethyl chloride from ethyl alcohol for backward integration, Methyl chloride from Methyl

Alcohol and Hydroxy propyl methyl cellulose (HPMC).

The unit has experienced technocrats having more than 30 years of experience in

manufacturing & marketing of Ethyl cellulose, Ethyl Chloride, HPMC, Methyl Chloride and its

derivatives.

The company has prepared well equipped production plant which will be managed by dedicated,

qualified & skilled persons. The main equipment is as under:

S. No. Name of the equipment MOC

1. Reactors MS Glass lined

2. 30% HCl Storage Tanks PP FRP

3. Scrubber PP FRP & SS 316

4. Extraction Column Graphite

5 Heat Exchangers Graphite

6 Product receiver SS 316

7 Pumps MS PFA lined, SS 316

8 Reactors SS 316

9 Storage tanks SS 316

10 Heat Exchangers SS 316

11 Nutch Filters SS 316

12 Dryer SS 316

The proposed project area lies on 20035’38.39”‎ N‎ Latitude‎ &‎ 72057’40.59”‎ E‎ Longitude.‎ M/s

ACIPL is located at S. No. 303/2, 302/P, 273/2, 275/1 near water works, Abrama, Valsad,Ta:

Valsad, Di: Valsad in Gujarat state and same western part comes under Daman union Territory.

Biggest GIDC Vapi is 30 kms away & Atul estate is 6 kms away from the project. National

Highway No. 8 connecting Mumbai and Ahmedabad is passes nearby the project site. The

western Railway Main Line is 5 kms away from the area (Double & Electrified). Valsad is the

biggest railway station in the study area; where, almost all the important mail & express trains

stop. Entire study area is well connected with the other major cities of the state and the country.

Beside the rail connectivity, the site is well connected by road transport (NH 8 less than a

kilometer). There is a good network of roads in the area and contributes for the development

and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now six

lanes, double tracked, more elevated and Jam free highway, which is developed by M/s L & T

Company. This highway has given a further boost to the economic growth of this area.

The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crossing

the NH – 8 in VAPI Town. Almost every village is now well connected to each other by well

maintained tar roads.

Nearest Vapi township has emerged as an Industrial hub on Gujarat – Maharashtra border.

Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has

gained a special status on the industrial map of the country mainly for chemical industrial units.

Over the years, it has emerged as a major cosmopolitan industrial township equipped with

hospitals. school, colleges, community centres, temples, churches, mosques, cinema house, fire

stations, blood banks, water filtration plants, police stations, post offices, banks, telephone

exchanges hotels, guesthouses etc. The town has got a major face-lift after the completion of

national highway and other links roads are of good standard. Mumbai, the economic capital of

the‎ country‎ is‎ 180‎ km‎ from‎ Vapi;‎ whereas,‎ the‎ state‎ capital‎ “Gandhinagar”‎ is‎ 370‎ kms.‎ The‎

district Head Quarter – Valsad is 30 km from the Vapi town.

Nearest Vapi Industrial estate, developed by Gujarat Industrial Development Corporation (GIDC)

has come into existence during 1967-1968. The entire estate, which was developed in phases,

is now spread over 1140 hectares and houses more than 1400 industries, most of which are


Page 11

small-scale Industrial units although some have grown bigger units at later stages. The industrial

township‎ is‎basically‎a‎declared‎ “Chemical‎Estate”‎where‎about‎705‎of‎ the‎ industrial‎units‎are‎

either Chemical or Chemical related, such as, Dyes and Dyes intermediates, pigments

pesticides, fine chemicals and pharmaceuticals etc. The remaining 30% companies of paper

mills, packing, plastics, engineering textiles, paints, food processing printing, etc. One of the

countries largest common effluent treatment plant has been setup in Vapi industrial estate.

Being a major industrial & commercial centre, it caters to other peripheral industrial estates like

Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.

1.7.1 Identification of the Project Proponent

M/S Asha Cellulose (India) Pvt. Limited is an existing medium scale unit located at Private

Industrial estate, near Water works, Abrama, Valsad, Di: Valsad, a well enthusiastic &

professionally managed manufacturer & marketer of Organic chemical i.e ethyl cellulose

especially used paints, solar panel, printing inks, adhesives, pharmaceutical, electronic industry

besides defence purposes as per requirement.

1.7.2 List of Directors:

Mr.‎Hirubhai‎V‎Shah,‎the‎CMD‎of‎the‎company,‎who‎is‎a‎graduate‎having‎50‎years’‎experience

in marketing of cellulose products. He looks after financial and commercial matter with

development of project and management. His vast experience & vision will be very much

helpful for decision making in all areas of business.

Mr. C D Mehta, the Director‎of‎the‎company,‎who‎is‎a‎chartered‎accountant‎‎having‎40‎years’‎

experience in financial matter also he is from well establish business family & he looks after

financial matter of the company.

Mr. B B Mehta, the director of the company, looks after administration of the company.

Mr.‎K‎J‎Dave,‎the‎director‎of‎the‎company,‎who‎is‎graduate‎having‎35‎years’‎experience‎‎in‎the‎

export, import & sales of product of the company.

Mr.‎ J‎ K‎Mehta,‎ the‎ director‎ of‎ the‎ company,‎ who‎ is‎ CA‎ having‎ 30‎ years’‎ experience‎ in the

financial matter & local sales of the company.

Mr. K Srinivas, the technical director the company, who is a chemical engineer having 33 years

of experience in the manufacturing of organic chemicals and cellulose products.

1.7.3 Brief description of nature of the Project

M/S Asha Cellulose (I) Pvt. Limited proposes to introduce new product i.e ethyl chloride from mix

solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward

integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC) at

existing S. No. 303/2, 302/P, 273/2, 275/1 near water works, Abrama, Valsad, Ta: Valsad, Di:

Valsad in Gujarat state.

The proposed expansion project involves the production of new product i.e ethyl chloride from

mix solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward

integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC).

Apart from the Industrial and Pharmaceutical grades, the Company is manufacturing high tech

specialilty Ethyl Cellulose for Defence and Electronic sector. The product is well accepted by all

leading Pharmaceutical Companies, including multinationals. The product finds application in

paints, printing inks, adhesives, pharmaceutical, electronic industry besides defence purposes.

As per the EIA notification- 2006 as amended products are covered under category 5(f) required

Prior Environmental Clearance.

For the proposed expansion project, the company intends to procure the available latest


Page 12

technology for manufacturing the products.

The industrial sector in the past 5 to 7 years has seen a drastic boom and also the keeping in

mind the globalization trend, we have identified the demand for the product and with continuous

R & D found that it is developed in-house and produce commercially for domestic market as well

as an eye more on export markets.

1.7.4 Need for the project and its importance to the country and region

The proposed expansion project provides a potential growth opportunity for the already running

business of the company. The company is already engaged in the business of manufacturing of

“Ethyl‎ cellulose‎ and‎ its‎ derivatives”.‎ ‎ The‎ project‎ would‎ increase‎ the‎ overall‎ export‎ and‎ also‎

increase the foreign revenue. Product is now well established and acceptable in the international

markets like USA, Europe, China, Taiwan, Middle East, Far East, Isreal, Egypt etc.

Additional capacities of product range required over & above our existing capacities, as the

company expect strong growth of exports to the extent of 50-60%. Local market also showing

strong growth potential.

Domestic market concentrated in Western India, North India, Hyderabad, Chennai, and Bangalore.

This project will generate additional employment of 6 people

1.7.5 Demand –Supply Gap

Our products are mainly used in paints, solar panel, printing inks, adhesives, pharmaceutical,

electronic industry besides defence purposes as per requirement. We are the only company

manufacturing Ethylcellulose in India, so demand of our products is sustainable. Most of the

raw materials indigenous and are easily available in India, only one main raw material i.e. wood

pulp is imported.

1.7.6 Imports vs. Indigenous production

Existing products manufacturing in the country will be very much economical compare to

Imports of the same except from China and also the export of the same will earn extra foreign

exchange for our county. If we produce raw material (Ethyl Chloride) on our own, we can

compete with Chinese products also.

1.7.7 Export Possibility

Existing products have high export potential. Also these products have very good potential in

local market.

Additional capacities of product range required over & above our existing capacities at Abrama,

Dist: Valsad, as the company expect strong growth of exports to the extent of 50-60%. Local

market also showing strong growth potential.

1.7.8 Domestic / export Markets

The‎ company’s‎ product‎ is‎ used‎ as‎ raw‎ material‎ to‎ manufacture‎ various‎ pharmaceutical‎

industries, chemical industries etc. as per the required applications and having very good market

in domestic and also having very good international markets.

1.7.9 Employment Generation (Direct and Indirect) due to the project

There will be an opportunity of employment generation directly and indirectly due to proposed

expansion project. At present the manpower employed in the industry is 110 numbers. Due to

proposed expansion project 50 people will be directly/indirectly employed. Thus total number of

employees after proposed expansion will be 160.


Page 13

1.8 PROJECT DESCRIPTION

1.8.1 Type of Project including interlinked and interdependent projects, If any

The proposed project is an interdependent project of the company.

1.8.2 Location (map showing general location, Specific location, and project

boundary & project site layout) with coordinates

The map showing general location, specific location and project boundary and project site lay

out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

1.8.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted

Proposed expansion will be carried out in existing premises only. (Land documents are attached

as Annexure-6). The proposed activity will be accommodated in existing plant having proper

industrial infrastructure, so there is no alternate site consideration.

1.8.4 Size or magnitude of operation

As per the proposed project cost, the project is covered under medium Scale category of

manufacturing industries.

1.8.5 Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given)

Detailed project description with process details is enclosed as Annexure-3

1.8.6 Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product

Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products & characteristics of hazardous chemicals are as below:

DETAILS ON PRODUCT TRANSPORTATION

Sr. No.

Product Physical State Packing Means of

Transportation

1 Ethyl Cellulose (Aqua

Process) Solid Powder

Fibre Drums, Paper Bags, Aluminum

Bags

By Road, Sea & Air

2 Ethyl Cellulose (Solvent

Process) Solid Powder

Fibre Drums, Paper Bags, Aluminum

Bags

By Road, Sea & Air

3 Ethyl Cellulose Aqueous

Dispersion- Non Plasticized Dispersion

HDPF Jerry Can

By Road, Sea & Air

4 Ethyl Cellulose Aqueous Dispersion- Plasticized

Dispersion HDPF Jerry

Can By Road, Sea & Air


Page 14

5 Ethyl Chloride (From Ethyl

Alcohol) Liquid

Through close Pipe line

Captive use /sale

Tonners By Road

6 Ethyl Chloride (From

existing mixed solvent) Liquid


Captive use / sale

Tonners By Road

7 Methyl Chloride Liquid under

pressure


Captive use / sale

Tonners By Road

8 Hydroxy Propyl Methyl

Cellulose Solid Bags By Road, Sea & Air

DETAILS OF RAW MATERIAL – TRANSPORTATION

Sr. No.

Substance Physical

State Source of

Supply Means of

Transportation

Distance of supplier from

project site (km)

1 Wood pulp Solid Sheet

Imported By Sea More than 5000

2 Caustic flakes Solid Local Manufacturers By Road 200

3 Ethyl Chloride Liquid In house Pipe line 200

4 Acetic acid liquid Local Manufacturers By Road 200

5 Toluene liquid Local Manufacturers By Road 200

6 SDS liquid Local Manufacturers By Road 200

7 Ethylene

Dichloride Liquid Local Manufacturers By Road

350

8 Acetone Liquid Local Manufacturers By Road 25

9 Methylene Dichloride

Liquid Local Manufacturers

By Road

350

10 Sodium Lauryl

Sulfate Solid

Powder Local Manufacturers By Road

200

11 Cetyl Alcohol

Powder Solid

Powder Local Manufacturers By Road 200

12 Ethyl cellulose Powder in-house By road 0-1 km

13 Plasticizer –

Dibutyl Sebacate

Liquid Local Manufacturers By Road

200

14 Oleic Acid Liquid By Road 200 200

15

Ammonium Hydroxide

Liquid Local Manufacturers By Road 200

16 Calcium

chloride/Zinc Chloride

Solid Local Manufacturers By Road 200

17 Hydro Chloric

acid (30%) Liquid Local Manufacturers By Road 200

18 Ethanol (94%) liquid Local Manufacturers By Road 200

19 Caustic lye Liquid In house Internal Pipeline

--

20 Methanol (99.5%)

liquid Local Manufacturers By Road 200


Page 15

DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS

S.No Name of the Raw Materials

Quantity stored,

MT/Month

BP. 0C

MP0C Place of its

Storage

State operating pressure

temperature

Possible type of hazards

Control measures provided

Max Actual

1

Wood pulp

150 100 NA NA Isolated

Store

Atmosphere & Room Temp.

Fire

Fire Extinguishers,

Hydrant system

2

Caustic flakes

125 100 NA NA Isolated

Store


Corrosion Corrosion resistant

paints used

3

Ethyl

Chloride 12.5 10 12 -138

Isolated Store in tonners


Flammable

Foam Fighting and

Fire extinguishers

4

Acetic acid 4 3.5 106 16

Storage Tank


Toxic & Corrosion

Fire Hydrant and Fire

Extinguishers

5

Toluene 15 10 110 -95

Isolated Storage

Tank


Flammable

Foam Fighting and

Fire Extinguishers

6

Ethyl

cellulose 40 35 NA 180

FG Store


Combustible

Fire Extinguishers

and Fire hydrant

7 Ethylene

Dichloride 1.5 1.0 80 -35 Drums


Flammable Foam &Fire

Extinguishers

8 Acetone 0.3 0.15 56 -95 Drums Atmosphere

& Room Temp.


Extinguishers

9 Methylene Dichloride

1.0 0.75 40 -97 Drums Atmosphere

& Room Temp.


Extinguishers

10

Sodium Lauryl

Sulfate – Powder

0.05 0.025 NA NA PP Bag Atmosphere

& Room Temp.

Combustible Fire

Extinguishers

11

Cetyl Alcohol Powder

0.03 0.015 NA NA PP Bag Atmosphere

& Room Temp.

Combustible Fire

Extinguishers

12

Plasticizer – Dibutyl

Sebacate 0.025 0.025 340 -35 Carboy


Combustible Fire

Extinguishers

13 Oleic Acid 0.025 0.025 286 16 Carboy Atmosphere

& Room Temp.

Combustible Fire

Extinguishers

14 Ammonium Hydroxide

0.025 0.025 NA -69 Carboy Atmosphere

& Room Temp.

Toxic Fire hydrant


Page 16

15

Calcium chloride/Zinc

Chloride 100 100 NA NA

HDPE Drum


Toxic Fire hydrant

16

Hydro Chloric acid

(30%) 30 15 100 NA

PP FRP Tank


Toxic Fire hydrant

17 Ethanol (94%)

15 10 79 -114 Isolated Storage

tank


Flammable Fire hydrant

18 Caustic lye 30 15 NA NA Isolated Storage tanks


Corrosion Fire

Extinguishers


1.8.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outline

Entire industrial effluent will be recycled after RO/MEE treatment system to minimize the fresh

water consumption. Rain water harvesting shall be provided & utilized the rain water for

processing. Mix Solvent will be recycled to produce proposed new product:

SOLVENT MANAGEMENT PLANT

Mixed solvent received from granulator will be scrubbed / washed with water and scrubbed

mixed solvent will be reused in the next batch.

Pure solvent, crude solvent and recovered solvent shall be stored only in closed insulated

storage tanks and we shall not be using drums at any stage in the Solvent Management

System.

Wherever required, the solvents shall be directly pumped into day tanks from the storage tanks

and shall be charged into the reactors without involving manual handling.

All the pumps shall be mechanical seal type to avoid any leakage of solvent.

All necessary fire fighting systems shall be provided with alarm system. Flame proof wiring and

flame proof electrical accessories shall be provided to avoid any mishap.

All the storage tank and day tank shall be connected to a vent system through chilled

water/chilled brine condensers to prevent loss of solvents in the atmosphere.

All the vents of solvent handling systems & process vessels are connected to chill water/chilled

brine condensers and scrubbing system to avoid loss of solvent.

All the solvent storage tanks shall be provided with breather valves.

In process vessels nitrogen blanketing shall be provided

1.8.8 Availability of water source, Energy/Power requirement and source should be given

Availability of water its source, Energy/power required and its source is mentioned below.

Water will be sourced from own borewell. Water withdrawal permission is attached as

Annexure-4.

OVERALL WATER CONSUMPTION

No Particular Existing Proposed Total

1.1 Domestic 2.2 0.8 3.0

1.2 Industrial

1.2.1 Processing + washing 85.18 18.72 103.9

1.2.2 Boiler 40.5 14.5 55.0

1.2.3 DM Plant 5.0 9.0 14.0

1.2.4 Cooling 17.5 39.5 57.0

1.2.5 Container/floor/equipment washing , QC, R&D 1.6 0.4 2.0

1.2.6 Gardening 3.5 6.5 10.0

1.2 Total Industrial 149.78 82.12 231.9

1.3 Total 155.48 89.42 244.9

1.4 Recycle from RO/MEE 118 89.5 207.5

1.5 Net Fresh Water 37.48 0 37.48


Page 18


Presently, total water requirement is 155.48 m3/day (Fresh: 37.48 m3/day + Recycled from

RO/MEE is 118 m3/day) sourced from own bore well. For the withdrawal of water from ground,

we have already applied to CGWA for withdrawal of ground water.

Total industrial waste water generation is 123 m3/day, which is treated in primary, secondary

and tertiary treatment plant. Treated waste water is taken to reverse osmosis plant. 102

m3/day of RO permeate is recycle in the process. Balance 18 m3/day of RO rejected is taken

to MEE. 16 m3/day of MEE condensate is recycled in the process. Thus there is no discharge

of industrial effluent on land.

Domestic waste water (1.5 M3/Day) is disposed off through septic tank to ETP

WATER BALANCE DIAGRAM

WATER BALANCE AT EXISTING SCENARIO

TOTAL WATER CONSUMPTION: 155.48 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 118 m3/day)

Domestic: 2.2 Processing &Washing: 85.18

Boiler: 40.5 Cooling: 17.5 D M plant: 5.0 floor /containerwashing: 1.6

Gardening: 3.5

88.0 25.0 2.5 5.0 1.0

123.0

1.5

P/S/T ETP: 123.0 Loss: 3.0

REVERSE OSMOSIS: 120

RO Permeate recycle : 102RO Rejection: 18 MEE Salt : 2

Condensate recycle : 16

Water evaporated: 1.25 MT

Dry Salt to TSDF: 0.75 MT


After proposed expansion, total water requirement will be 244.9 m3/day (Fresh: 37.48 m3/day

+ Recycled from RO/MEE is 207.5 m3/day) sourced from own bore well. For the withdrawal of

water from ground, we have already applied to CGWA.

Total industrial waste water generation will be 218.015 m3/day, which will be treated in

primary, secondary and tertiary treatment plant. Treated waste water is taken to reverse

osmosis plant. 181 m3/day of RO permeate is recycle in the process. Balance 32 m3/day of

RO rejected is taken to MEE. 26.5 m3/day of MEE condensate is recycled in the process.

Thus there is no discharge of industrial effluent on land.

Domestic waste water (2.0 m3/Day) will be disposed off through septic tank and overflow of

the septic tank will be discharged to ETP.


Page 19

WATER BALANCE AFTER PROPOSED EXPANSION

TOTAL WATER CONSUMPTION: 244.9 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 207.5 m3/day)


Boiler: 55 Cooling: 57 D M plant: 14 Floor/containerwashing: 2.0

Gardening: 10

162.515

37.0 2.5 12.5 1.5

207.465

2.0

P/S/T ETP: 207.465 Loss: 4.465


RO Permeate recycle : 173RO Rejection: 30 MEE

Condensate recycle : 34.5

High TDS: 10.55 Normal: 151.965

Salt : 6.05



ENERGY REQUIREMENTS AND ITS SOURCE

Sr. No.

Particulars Existing After proposed

expansion Source

1 Steam 3.8 5 Obtained from Steam boilers

POWER REQUIREMENTS AND ITS SOURCE

Sr. No. Particulars Existing After Proposed

expansion Source

1 Power –Electricity requirement, KVA

650

1000

Dakshin Gujarat Vij Co. Ltd.

1.8.9 Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal

Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal

is enclosed as Annexure-5.

1.8.10 Schematic representations of the feasibility drawing which give information of EIA purpose

A schematic representation of the feasibility drawing is enclosed as Annexure -8.


Page 20

1.9 SITE ANALYSIS

1.9.1 Connectivity

Site is very well connected by road i.e. N.H. No. 8 & Western Railway.

Availability of power evacuation facilities.

Availability of abundant water for industrial use .

Infrastructure like TSDF, CHWIF etc.

1.9.2 Land Form, Land use and Land ownership

The proposed expansion plant is in existing unit located in private industrial estate, Village:

Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner &

registered with district collector & revenue department. Possession letter is enclosed as

Annexure 6.

1.9.3 Topography (along with map)

The entire land is non-agriculture land. The overall project site is located on plain barren land devoid of any permanent and economically useful vegetation. The proposed expansion project is to be carried out in existing plant only. There will be no extra land required for the proposed expansion. Topography map is enclosed herewith as Annexure: 7.

1.9.4 Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given

The proposed expansion plant is in existing unit located in private industrial estate, near Water Works, Abrama, Valsad, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner & registered with district collector & revenue department.

The entire land is non-agriculture land. The overall project site is located on plain barren land devoid of any permanent and economically useful vegetation. The proposed expansion project is to be carried out in existing plant only. There will be no extra land required for the proposed expansion. There is no forest, national park, wild life sanctuary, eco sensitive areas within the 10 kms distances from the periphery of the proposed expansion project.

1.9.5 Existing Infrastructure

Major factors involved in the selection of site is based Existing Infrastructures facilities which are listed below:

Site is very well connected by road i.e. N. H No. 8 & western railway

Proximity to Raw Material suppliers

Availability of sufficient fresh water

Availability of un-interrupted electric power

Availability of skilled manpower,

Availability of full-fledged effluent treatment facility and Zero liquid discharge facility,

Well-developed infrastructure like internal roads, lights, under, TSDF, CHWIF etc.


Page 21

1.9.6 Soil classification

The proposed expansion plant is in existing unit located in private industrial estate, Village: Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner & registered with district collector & revenue department. We have constructed our existing plant as per plan approved by factory inspectorate. We will utilize existing plant for the proposed expansion. Only MS structure & minor construction work will be carried out. There will be no new major construction activities carried out. It will not have any major affect on the soil environment.

1.9.7 Climate data from secondary sources Rainfall Data:

The project site location receives annual rainfall of 2010 – 1200 to 1300 mm in 35 rainy days

with coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the

study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch

district and western parts of Banaskantha and Patan district and parts of Jamnagar, Rajkot and

Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400

mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and

Daman & Diu) are characterized as sub humid climate. The rest part of the state receives rainfall

between 500-1000 mm and generally fall under semi-arid climate.

Table 2: Rainfall projection for Project site and Gujarat

Sr. No.

Region Rainfall Projection (in mm) June – Oct

Normal Rainfall (In mm)

Rainfall Projection

(% Departure from normal)

1 Middle Gujarat 905.3 796 13.7

2 South Gujarat 696.3 575 21.0

3 Project site 2071.7 1433.7 44.5

4 Saurashtra 767.1 580.4 32.2

5 Gujarat State 1110.1 846.5 31.1 Source: AAU, Anand, Gujarat

Temperature Data:

The site location M/s. Asha Cellulose (I) Pvt. Limited is located in the southern part of Gujarat.

The secondary data was collected from Worldclim.org. The project site temperature regime for

medium to high level temperature (30-32°C) during the seasonal months (June to Sep). The

climate map for site location shows that temperature recorded over a month of (4

month).Coastal area from the inland site for 10 km distance, temperature recorded for this area

low to medium level. Figure showing project site for seasonal temperature in (June to

September).

1.9.8 Social Infrastructure available

Social infrastructure in Valsad district is as under :

Education: There are 990 primary and 161 secondary and higher secondary. List of Educational

Institutes schools in the district Educational Total With over 1,250 seats, there are 6 ITIs offering

several industrial training Institutes programs which includes, fitting, armature & motor rewinding,

Primary School 990 electrician, information technology and electronic system maintenance

Secondary School etc 166 Higher Secondary School, One Government polytechnic College is

present in the district offering courses in civil, chemical, electrical, mechanical and plastic

engineering,‎ITI’s‎6‎with‎an‎intake‎capacity‎of‎360‎Polytechnic‎1‎College‎With‎120‎seats,‎ there‎ is‎

one Degree Engineering College present in Pharmacy College 2 Valsad offering engineering

courses in mechanical and chemical Engineering 1 branches College§ Located in Vapi, G. M.

Bilakhia Pharmacy College has an intake Management 1 College capacity of 60 students per year


Page 22

Other Colleges Rofel Institute of Management studies in Valsad offers full time MBA Other

Colleges: Arts, Commerce, Science, B.Ed and Law College course and takes 120 students per

annum Source: Department of Education.

Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10

Government and 1 Municipal hospital present in the district. Valsad has several private specialized

hospitals to provide a comprehensive range of tertiary and secondary care services backed by

state-of- the- art technology and trained medicos A multi-specialty 21st Century Hospital, (branch

of Nadkarni Group of Hospitals) is present in Vapi, giving services in general and laparoscopic

surgery, trauma, orthopedic and urology etc. the hospital is one of the few centers in India offering

Uterine Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB)

patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital,

and Adarsh Hospital are also present in Valsad

Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also known Fire Temple as

Mecca for the Parsi community in India, makes the city a famous pilgrimage center throughout the

world Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town

with pleasant climate throughout the years The collection at the Lady Wilson Museum in

Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District

Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, has increased the

graph of tourist flow in the district.

1.10 PLANNING BRIEF

1.10.1 Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification


Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner &

registered with district collector & revenue department. We have constructed our existing plant as

per plan approved by factory inspector. We will utilize existing plant for the proposed expansion.

Only MS structure & minor construction work will be carried out. There will be no new major

construction activities carried out.

1.10.2 Population Projection:


Abrama, Di: Valsad. The composition or nature of working population near plant area are as under;

Total

Population Total

Workers Main

Workers Marginal Workers

Non Workers

Cultivators Agricultural Labours

Workers in

Household Industry

Other Worker

s

Gujarat State

Total Persons 48387270 20368797 16288598 4080199 28018473 5613185 4987657 381601 9386354

Male 25208865 13870929 12920179 950750 11337936 3804880 2404180 222579 7439290

Female 23178405 6497868 3368419 3129449 16680537 1808305 2583477 159022 1947064

Rural Persons

30160219 14341413 10590157 3751256 15818806 5491522 4816260 224102 3809529

Male 15506359 8620383 7816150 804233 6885976 3707298 2301215 141209 2470661

Female 14653860 5721030 2774007 2947023 8932830 1784224 2515045 82893 1338868

Urban Persons

18227051 6027384 5698441 328943 12199667 121663 171397 157499 5576825

Male 9702506 5250546 5104029 146517 4451960 97582 102965 81370 4968629

Female 8524545 776838 594412 182426 7747707 24081 68432 76129 608196

Valsad District

Total Persons 1410680 650604 503506 147098 760076 184837 154395 9495 301877

Male 734945 422476 381574 40902 312469 103034 66885 5204 247353

Female 675735 228128 121932 106196 447607 81803 87510 4291 54524

Rural Persons

1029294 507973 369190 138783 521321 182878 150425 7581 167089


Page 23

Male 526285 301309 264317 36992 224976 101610 64529 4065 131105

Female 503009 206664 104873 101791 296345 81268 85892 3516 35984

Urban Persons

381386 142631 134316 8315 238755 1959 3970 1914 134788

Male 208660 121167 117257 3910 87493 1424 2356 1139 116248

Female 172726 21464 17059 4405 151262 535 1614 775 18540

Valsad Taluka

Total Persons 385159 158263 129314 28949 226896 27911 36242 2618 91492

Male 198064 109730 100920 8810 88334 16609 16909 1512 74700

Female 187095 48533 28394 20139 138562 11302 19333 1106 16792

Rural Persons

222550 104648 78779 25869 117902 27437 35125 1908 40178

Male 113632 65465 58380 7085 48167 16225 16120 1137 31983

Female 108918 39183 20399 18784 69735 11212 19005 771 8195

Urban Persons

162609 53615 50535 3080 108994 474 1117 710 51314

Male 84432 44265 42540 1725 40167 384 789 375 42717

Female 78177 9350 7995 1355 68827 90 328 335 8597

Vapi (M)

Total Persons 71395 29655 28719 936 41740 141 161 149 29204

Male 41608 26478 26059 419 15130 115 119 78 26166

Female 29787 3177 2660 517 26610 26 42 71 3038

Vapi (INA)

Total Persons 23845 8538 8284 254 15307 2 19 86 8431

Male 13141 7648 7579 69 5493 2 10 33 7603

Female 10704 890 705 185 9814 0 9 53 828

There are 8 Talukas fall in Valsad District which is 5135 km2 in area. Pardi Taluka has an area of 425.89 km2 and has 79 villages and two towns. 75% of its population is tribal. 0.87 % of the area fails under forest category. Demographic details of Pardi Taluka are presented as follows:’

DEMOGRAPHIC DETAILS OF PARDI TALUKA

PARTICULARS RURAL URBAN TOTAL

Area in Sq, Km. 395.67 30.22 425.89

No. of Houses 37554 15146 52700

No. of Occupied Houses

36105 13429 49534

Total Population 206345 65874 272219

Male population 105722 35147 140869

Female Population 100623 30727 131350

Male Literates 71160 26672 97832

Female Literates 47630 19050 66680

Population per Sq. Km.

521.5 2179.81 639.17

Basic Information on population in villages around the plant site is presented as follows;

BASIC INFORMATION ON POPULATION

Sr.

No Village

Area in Hec

Population No. of

House

Holds

Occupied

Residential

Houses Total M F

1. Saron 308.77 951 471 480 203 203

2. Abrama 31.20 907 472 435 190 190

3. Tukwada 814.35 3832 1939 1893 763 763

4. Vashier 801.64 4046 2163 1883 736 580

5. Gundlav 402.58 34831 1774 1709 694 682

Population trend showing growth rate, sex ratio and literacy rate in Valsad district are as follows;


Page 24

Total Population

1) Persons

2) Male

3) Female

1137801

566802

573999

1428742

715473

713269

1774136

895313

878823

2173672

1110632

1063040

Decimal Growth + 21.38 + 25.57 + 24.17 + 22.52

Sex Ratio

(No. of Female per 1000

Males)

1012 996 981 957

Note :

Decadal growth in population is 22.52%.

Sex ratio females to males have decreased to 957 females per 1000 men.

The population in Valsad area is cosmopolitan and education level is high.

Socio-cultural conditions are greatly influenced by literacy. Literacy rate in this region has increased. The literacy rate was 15% in 1961. It grew to 27% in-1 971, then to 42% in 1981 and to 54.3% in 1991.

Note :

1). Average Population Density : 639.20 persons /sq. km.

2). Population in Rural Areas : 75.00%

3). Population in Urban Areas : 25.00%

1.10.2 Land use Planning (breakup along with green belt etc)

Agro – climate

The study area forms part of the Agro – climatic‎zone‎‎designated‎as‎“South‎Gujarat‎Heavy‎Rainfall‎

Zone”‎ comprising‎ Valsad,‎ Dang,‎ etc.‎ It‎ receives‎ intensive‎ rains‎ of‎ over‎ 1500‎mm‎ and‎ at‎ times‎

touches 2000 mm per annum. Major part is received in July and August. According to National

Bureau of Soil Survey and Land Use Planning, Nagpur, the study area forms a part of humid to per

humid ecosystem with red lateritic soils – having a growth period of (GP) 210 and more days. This

zone‎“19”‎ is‎abbreviated‎“E2BA5”‎on‎the‎Agro‎– Ecological Region Map. The study area has red

lateritic type of soil on basaltic hills but alluvium is blackish clayey derived from basalt.

Physiography, Relief, Drainage and soils

The study area forms‎part‎of‎“Zone‎a‎(1)‎“comprising‎hilly‎areas‎of‎Valsad‎district.‎This‎hilly‎area‎

sub-zone consists of hilly tracts with undulating hills varying in elevation ranging form 60 to 90 in

above the mean sea level (MSL). While flatter areas are about 25-26m above msl. The soils of this

hilly tract are not typical lateritic, whereas plains have clayey soils have developed from trap. A

thick detritus material forms pediment. The general slope direction is from south-east to north-west

and the drainage pattern is linear dendrite.

Soils are slightly shallow in the hills whereas, deep black mild to slightly alkaline silty clays in the

plain, Alluvium is yellow red neutral to moderately alkaline highly calcareous clayey soils.

Geology

According to geological Map of India (1993), the study area forms part of Cretaceous –

Palaeogene: Basic(Bkpg). In general, the study area is covered by Deccan trap (Basalt) with

dykes. At places, it is covered by marine alluvium.

Land use and Agriculture

It is an agrarian ecosystem with potential impact of industrialization. It is also reflected in prepared


Page 25

land use / land Map showing 68% area under agriculture while the built up area is quite high of

22%. The double-cropped area is quite high in agriculture: while, second highest are the mango

plantation mixed with agriculture. Shallow hilly soils grow Negli (ragi Eleusine coracana), Kodra

Paspalum scrobiculatum), Banti (Echinochlo/stagnina), Wari (Panicum miliare) and Chino

(Panicum millirea). Rice is the major crop. Other important crops are sorghum, groundnut tur, other

pulses, and cotton. Fruit crops like banana, mango coconut, sapota and sugarcane are common.

Natural Vegetation

According‎ to‎ Champion‎ and‎ Seth‎ (1968),‎ the‎ study‎ is‎ falls‎ under‎ the‎ “Tropical‎ dry‎ (mixed)‎

deciduous forest”.‎There‎is‎notional‎patch‎of‎reserve‎forest,‎however‎some‎scrub‎forest‎is‎seen‎in‎

pockets. Some of the common trees found in this area are Mango, Chiku, Casuarinas equisetifolia,

Eucalyptus hybrid, Paltophorum pterocarpum, Thuja occidentals Acacias spp. Azadirachta indica,

Gliricidia sepium, Some of the common grasses found in this area are Dicanthium annulatmm,

Vitevera, Cenchrus clitoris, etc.

Land use, land cover classification system

S.No. Level I S.No.

NNo.

No.

Level II S. No. Level III Map

Symbols 1 Built-up Land 1.1 Town/Cities 01

1.2 Villages 02

2 Agricultural Land 2.1 Agricultural

Land

2.1.1 Kharif 03 2.1.2 Rabi 04

2.1.3 Double 05

2.2 Fallow 06

2.3 Plantations 07

3 Forest 3.1 Evergreen/Semi

Evergreen

3.1.1 Dense 08 3.2 Deciduous

(Moist & Dry)

3.1.2 Open 09

3.2.1 Dense 10

3.2.2 Open 11

3.3 Scrub Forest 12

3.4 Forest Blank 13

3.5 Forest

Plantation

14

3.6 Mangrove 15

4 Wastelands 4.1 Salt affected

land

16 4.2 Waterlogged

Land

17

4.3 Marsh /

Swampy Land

18

4.4 Gullied and

Ravenous Land

19

4.5 Land with Scrub 20

4.6 Land without

Scrub

21

4.7 Sand area

(Coast and

desertic)

22

4.8 Mining and

Industrial waste

23

4.9 Barren rocky/

Stony waste /

Sheet

24

5 Water Bodies 5.1 River / Stream 5.2 Canals

5.3 Lake /

Reservoir /

Tanks

25

6. Others 6.1 Shifting

Cultivation

26 6.2 Grassland 6.2.1 Dense 27

6.2.2 Open 28

6.3

Salt Pan 29


Page 26

6.4 Mud 30

Image Characteristics of different Land Use/Land cover classes

S.No. Mapping Unit Brief Description Image Characteristics

1 Built-up area 1.1 Residential Light bluish with very faint white

brownish mottles reddish

pixels are of avenue trees.

1.2 Industrial

Smooth, blue, blackish, reddish

tone good street network

regular shape

1.3 Recreational, Parks./Green

belts etc.

Smooth red, regular shape

within city area

1.4 Vacant Under developed Smooth whitish brownish.

Regular pattern.

2.0 Villages Deep blue, irregular pattern

surrounded by agriculture lands

and small water bodies,

connected by roads with other

villages

2 Agriculture 5 Double cropped land) Smooth, red mixed with small

vacant parcels of greenish

brownish and whitish trees.

6 Fallow lands Whitish gray parcels within

smooth regular red agri, land.

7 Plantations

& Agriculture Mixed

Dark brownish red, violet

smooth & regular.

3 Forest 10 Dense forest Dark, radish brownish, smooth

13 Scrub Land Brownish/ Light, Mattled,

Pinkish

14 Forest Plantation Dark, radish brownish, smooth

Regular.

4 Waste Land 17 Water Logged Dark, blackish, red, irregular.

19 Gullied Lands Light bluish,

22 Sand Whitish or blackish

24 Stony/ rocky Bluiesh & Blakish irregular

5 Water Bodies 25 Tank/ pond Dark, black with reddish tinge of

phytoplankton’s‎ (Water‎ loving‎

Plant)

6 Others 27 Grass Land Light brownish, smooth.


Page 27

The detail description of each land use category in terms of their defilation, image characteristics

are given below:

Agricultural Land

These areas are agricultural lands used for growing at least 2 crops in a year .

Fallow land

These are agricultural lands, which are taken up for cultivation but are temporarily allowed to

remain uncropped. The texture is medium to coarse due to surface irregularities.

Mixed – Plantations

It covers plantation agriculture orchards and horticultural nurseries. They mixed with agriculture

appear as dark red, small to medium in regular size and shapes. Extension in this area:

LAND USE CATEGORY

Level I Level II

Category Name Area Sq.

K.M

% Sub Category Name Area

(Sq.Km)

%

1 Built up area 34.1 22.15 Town /Cities

1.1 Residential

1.2 Industrial

1.3 Recreational

1.4 vacant

2 villages

8.3

19.1

0.4

4.5

1.8

5.39

12.41

0.26

2.92

1.17

Sub Total 34.1 22.15 Sub Total 34.1 22.15

2 Agriculture 106.0 68.87 5 Double Crop 64.0 41.58

6 Fallow Lands 16.5 10.72

7 Agri + Plantations 25.5 16.57


3 Forest 0.6 0.38 10 dense

12 scrub lands

14 plantation

0.3

0.2

0.1

0.19

0.13

0.6

Subtotal 0.6 0.38

4 Waste lands 11.7 7.63 17 Seasonally water

logged

19 Gullied

21 undulating upland

without scrub

River (Sand)

24 Stony/Rocky

0.3

0.7

10.1

0.2

0.4

0.19

0.45

6.60

0.13

0.26


5 Water bodies 0.5 0.32 Ponds/Tank 0.5 0.32


6 Others 1.0 0.65 Grass land 1.0 0.65


Grand Total 153.9 100.0 Grand Total 153.9 100.0


Page 28

SITE PLAN WITH AREA TABLE

S.No. Area Description Area in Sq.M %

Existing Proposed Total

1 Process Plant area 2420 800 3220 10.10

2 RM Storage 500 100 600 1.88

3 ETP , RO, MEE & HW Storage 885 150 1035 3.25

4 Ethyl Chloride/ Methyl Chloride Storage 150 1050 1200 3.76

5 Office Building 602 0 602 1.89

6 Utilities 547 400 947 2.97

7 Engineering Store 455 0 455 1.43

8 Roads 3355 0 3355 10.53

9 Open Area 16635 -6300 10335 32.42

10 Green Belt 6325 3800 10125 31.77

11 Total 31874 6300 31874 100.00

1.10.3 Site map with Green Belt Development Planning

It is given as Annexure 2.

1.10.4 Assessment of Infrastructure demand (Physical & Social):

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

people for the proposed new project.

Social Welfare

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

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

1.10.5 Amenities/ Facilities

Following gives details of amenities available in Valsad District. This is somewhat lower than

normally required. This deficit is, however, bridged by a large number of dispensaries, health care

units and secondary health centres. There are many family welfare centres. Educational facilities

are fairly good. All villages have electricity.

EXISTING CIVIL AMENITIES IN THE DISTRICT

EDUCATION MEDICAL PUBLIC

TRANSPORT

FACILITY

WATER

SUPPLY

POST &

TELEGRA-PHS

P&MS : 1656

H/HSC : 244

Colleges : 21

Total : 1921

Literacy :

Male : 62.03%

Female: 54.27%

Libraries : 323

H : 11

PHC : 60

No. of Beds :

999

Doctors : 108

Nurses : 727

No of Vehicles :

425/day (Avg)

Villages Connected

with all Weather roads :

693

OPW

BW

RIVERS

DAMS

CANALS

HAND-

PUMPS

Post

Offices :

473


Page 29

P&MS = Primary & Middle School

H/HSC = Higher School & Higher Secondary

H= Hospital

PHC= Primary Health Center

OPW= Open well

BW= Bore-well

Valsad town has good and adequate facilities. Good water is supplied by municipal water works

Abrama. Adequate power is available from Dakshin Gujarat Vij Company Ltd. (DGVCL). Good

hospitals and adequate dispensaries with well-qualified doctors are available. Good

communication systems, fire brigades etc. are available.

1.11 PROPOSED INFRASTRUCTURE

1.11.1 Processing Area

The proposed expansion plant is in existing unit located in private industrial estate, near Water

Works, Abrama, Valsad, Di: Valsad. We have purchased NA land in the year of 1999 from the land

owner & registered with district collector & revenue department. We have constructed our existing

plant as per plan approved by factory inspector. We will utilize existing plant for the proposed

expansion. Only MS structure & minor construction work will be carried out. There will be no new

major construction activities carried out.

1.11.2 Residential Area (Non Processing Area)

The proposed expansion plant is to be carried our in existing plant only. There is no residential

area nearby the plant.

1.11.3 Green Belt

M/s. ACIPL is located in private industrial area, near Water Works, Abrama, Valsad, Di: Valsad. The unit has already developed about 6325 m2 of area as a green belt & also proposed to develop additional area i.e. 3800 m2 for green belt. In addition to this, majority of the vacant land shall be

planted with trees and grasses.

1.11.4 Social Infrastructure

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

1.11.5 Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc)

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

Site is very well connected by road N.H No. 8, western railway

Proximity to Raw Material suppliers

Developed infrastructure TSDF, CHWIF, internal road, lights, fresh water, power

Availability of power evacuation facilities

1.11.6 Drinking Water management (Source & Supply of water)

Water requirement will met through own existing bore well.

1.11.7 Sewerage System:

For the domestic effluent, we have provided adequate capacity of septic tank/soak pit to ETP. After proposed expansion, the entire treated effluent will be recycled in the process, thus there will be no


Page 30

discharge of any industrial effluent on land.

1.11.8 Industrial Waste Management:

For the domestic effluent, we have provided adequate capacity of septic tank/soak pit to ETP. After

proposed expansion, the entire treated effluent will be recycled in the process, thus there will be no

discharge of any industrial effluent on land.

1.11.9 Solid/Hazardous Waste Management:

Sr. No.

Process waste Category Source Quantity, TPA Mode of

disposal Existing Proposed Total

1 Used oil Sch: I/5.1 Machineries/ D.G.Set

0.092 0.018 0.11 Incineration at common

incineration system of M/s

BEIL, Ankleshwar /

sold to authorized recyclers

2 Discarded containers/bags

Sch: I/33.1

Raw Material Storage area & Utility Area

50 12 62 reused for packing of solid waste or sold to

registered recyclers

3 ETP waste Sch: I/35.3

ETP 109 21 130 Disposed off into TSDF site of M/s

BEIL, Ankleshwar or

VGEL, Vapi

4 MEE waste Sch:I/35.3 MEE 234 714 948 Disposed off into TSDF site of M/s

BEIL, Ankleshwar or

VGEL, Vapi

5 Dust from air filtration system

Sch:I/26.2 air filtration system

0.22 0 0.22 Recycled in process

6 Salt from process


1703

0

1703

Disposed off into TSDF site of M/s

BEIL, Ankleshwar or VGEL, Vapi.

7 Mixed Solvent from the process


1787.44

9.98 + 51.96 (vent

condenser and

HPMC product)

1849.38

61.9

1787.44 MTPA of mix solvent from solvent process and

aqua process will be utilized

for manufacture of Ethyl chloride product within the premises and balance 61.9 MTPA of


Page 31

mixed solvent will be sold to

actual distillator

8 Distillation Residue / & Laboratory organic waste


23.0 - 18.78 4.22 Collection, storage



9 Spent carbon from ETP &

Chimney

Sch:I/36.2 ETP/Chimney 4.8 1.2 6.0 Collection, storage



10

Date-Expired, Discarded and off-specification Material & floor sweeping

Sch:I/28.5

Product Storage area

1.0

1.0

2.0

Collection,



facility.

11 Spent Filter cloth & filter

material

Sch:I/36.2

From process plant

1.0

0

1.0

Collection,



facility.

12 Spent Resins from D M plant

Sch:I/35.2 D M plant 1.0 0.2 1.2 Collection, storage

transportation, disposal at TSDF/BEIL Collection,


disposal at TSDF/BEIL

13 Used hot & cold insulation material

Schedule: X/02

Manufacturing process

0.5 0.1 0.6 Collection, storage

transportation, disposal at TSDF/BEIL

14 Weak caustic soln (18-20%

Sch: II/C2 Manufacturing process

17723 0 17723 Sell to actual/authorized

users

Solid Waste

15 Fly ash - Boiler 0 179 179 Sell to Brick manufacturer

1.11.10 Power Requirement & Supply / Source

Power requirement for proposed project will be taken from DGVCL.


Page 32

1.12 REHABILITATION AND RESETTLEMENT (R&R) PLAN

1.12.1 Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given)

The proposed expansion plant shall be carried out in existing plant, located at village: Abrama, Di;

Valsad. The existing plant is already developed with all infrastructure facilities in the year of 1999,

thus there will be no re-habitation and re-settlement on the proposed expansion project, so R & R

policy is not applicable to this project.

1.13 PROJECT SCHEDULE & COST ESTIMATES

1.13.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given)

After obtaining Environmental clearance, the company shall start the proposed minor construction

and provide necessary hardware. The production is likely to commence within 3 to 4 months after

obtaining EC.

1.13.2 Estimated project cost along with analysis in terms of economic viability of the project:

Estimated project cost along with the analysis in terms of economic viability of the project is given as below;

Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads considered in the Capital Cost Projection for the proposed expansion project. Environment Protection has also been considered in planning the Cost Projection, which will include Green belt development, safety systems, etc

CAPITAL COST PROJECTION

S. No. Particulars Existing,

Lakhs Proposed,

Lakhs Total, Lakhs

1.0 Land 31874 m2 76.4 0 76.4

2.0 Building 216.75 350 566.75

3.0 Plant & Machinery

3.1 Equipment & machineries 733.58 850 1583.58

3.2 Pipes, fittings, lagging, electrification

210.86 150 360.86

3.3 Laboratory equipments 44.18 20 64.18

4.0 Environmental Management System

4.1 Effluent treatment plant 205.5 35 240.5

4.2 Air pollution control measures 16 8 24

4.3 Hazardous waste management system (MEE Plant)

13.0 125 138

5.0 Total Project Cost 1516.27 1538 3054.27


Page 33

PROJECT VIABILITY

Sr. No.

Particulars Amount in Rs.Lakhs

Product Ethyl

cellulose HPMC

Ethyl Chloride

Methyl Chloride

1 Proposed Sale 4000 3500 950 484

2 Raw Material Cost* 2038 1754 670 306

3 Power & Fuel 484 425 36 28

4 Labor Cost 480 432 28 28

5 Environmental Management

System 102 90 14 8

6 Maintenance Cost 124 108 18 18

7 Selling, packing & Office

Expenses 55

48 6 6

8 Proposed Gross Profit 717 643 178 90

* Presently Ethyl chloride (one of the raw materials) is being purchased from various local

manufacturers and we are finding stiff competition in domestic as well as export market to match Ethyl cellulose price against Chinese make product. By producing Ethyl Chloride in house as backward integration we can contribute good foreign exchange revenue to the country. Also we can sell Ethyl chloride in local market to sustain current profitability in view of prevailing rise in the prices of all commodities & service sectors. HPMC is also an import substitute like Ethyl cellulose. HPMC is also widely used in pharmaceutical industry along with Ethyl cellulose. HPMC can be more competitive against imported product particularly if we produce on our own one its major raw material Methyl Chloride. The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budget.

The company will provide budgetary provision for the recurring/operating expenses for

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

RECURRING/OPERATING COST PER ANNUM

Sr. No. Component Proposed (Rs. In

Lakhs/annum

1. Environment & Safety Management System 200

2. Greenbelt Maintenance 4

3. Solid waste Disposal 10

Total 214

1.14 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

1.14.1 Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area:

Proposed expansion will provide benefits to the local people in terms of financial and social welfare.

Local people will get direct financial benefit by way of employment.

Local people will get some contracts of supply and services to get indirect income.

Company will contribute in social upliftment programs by the way of improving

education and health facilities in nearby area.


Page 34

ANNEXURES


ANNEXURE 1 LOCATION MAP SHOWING THE PROJECT SITE

The map showing general location, specific location and project boundary and project site layout of

M/s Asha Cellulose (I) Pvt. Limited, is located at S. No. 302/P, 303/2, 273/2, 275/1, Near Water

Works, Abrama, Valsad-396001, Ta: Dist: Valsad, Gujarat. The location of the project site can be

viewed in following figure.

Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED

Page 36

ANNEXURE 2 PLANT LAYOUT


Page 37

ANNEXURE 3 MANUFACTURING PROCESS

Ethyl Cellulose (Aqua Process) (Existing):

The bleached Cotton Linter / Wood Pulp are fed to a shredding mill. The shredded Bleached Cotton

Linter or Wood Pulp is charged into rector containing Caustic solution, through alkali cellulose tank

and screw conveyor. The reactor is a jacketed and agitated type autoclave. The temperature, time

and concentration depend on the intrinsic viscosity desired in the product. The required amount of

diluents (crude solvent) and ethyl chloride are added to the alkali pulp and viscosity is controlled by

air as an oxidizing agent.

The reaction is carried out in jacketed and agitated autoclave. Ethyl Chloride and crude solvent are

also charged along with Caustic during the course of reaction if necessary. The reactor content is

heated by passing steam through jacket. Working pressure of about 23 Kg / cm2 is obtained

maximum and the reaction is continued till the desired Degree of Substitution of Ethyl Cellulose is

obtained. After completion of reaction, Ethyl cellulose gets separated from solvent, salt, water &

sodium hydroxide. Solvent mixture along with water is stripped off from the reactor, which is purified in

distillation column, part of it is used in the process and remaining is sold off.

As the solvent is removed, ethyl cellulose precipitates in the liquor containing caustic and salt. The

slurry is then discharged from the reactor in to a holding tank, where alkali solution along with salt is

recovered. After giving adequate water wash, the product is neutralized by the addition of acid and

centrifuged. Wet ethyl cellulose is subjected to wet grinding in hammer mill. After grinding, the

material is discharged into to washing tank for further purification. After purification, the slurry is

subjected to centrifuging for maximum water separation and wet cake is fed to a spin flash dryer.

Dried product is packed in Fibre Drum / Paper Bags.

CHEMICAL REACTION:

Main Reaction :

C6H7O2(OH)3 + C2H5Cl + NaOH -------------> C6H7O2(OH)3 + NaCl + H2O 162 64.5 40 232 58.5 18

Reaction Mole Balance :

Reaction C6H7O2(OH)3 + 2.5 C2H5Cl + 2.5NaOH --> C6H7O2(OC2H5)2.5(OH)0.5 +2.5 NaCl +2.5 H2O M. Wt. 162 161.25 100 232 146.25 45

Name Wood Pulp Ethyl Chloride Sod. Hydroxide Ethyl Cellulose Sodium Chloride Water

Side Reaction :

1 : Ether Formation :

Reaction : 2C2H5Cl + 2 NaOH --------> (C2H5)2O + 2NaCl + H2O

M. Wt. 129 80 74 117 18

Name Ethyl Chloride Sodium Hydroxide Diethyl Ether Sodium Chloride Water

Total 209 ----------> 209

2 : Ethyl Alcohol Formation :

Reaction C2H5Cl + NaOH ----------> C2H5OH + NaCl

Mol. Wt. 64.5 40 46 58.5

Name Ethyl Chloride Sodium Hydroxide Ethyl Alcohol Sodium Chloride


Page 38

MASS BALANCE WITH FLOW DIAGRAM:

FLOW DIAGRAM OF ETHYL CELLULOSE BY AQUA PROCESS

REACTION(AUTOCLAVE

FILTRATION &NEUTRALIZATION

GRINDING &CENTRIFUGE

WASHING

FINAL WASHING &CENTRIFUGING

DRYING: 424.8 kgs

ETHYL CELLULOSE : 260 KG

NaOH Prills : 1400 kg

Water : 854 kg

Wood pulp : 210 kg(Wood pulp: 185.5 kgs

Water: 24.5 kgs)

CAUSTIC SOLN.PREPARATION

SHREDDING& MIXING

Ethyl chloride : 875 kg

Diluents : 284 kg

Mixed solvent to Scrubbing : 732 kg

(EC + EA +Ether +water)

Recycle from Ethyl ChlorideIncineration :

448 kg

Water : 3600 kg

Water : 2400 kg

Water : 4500kg

Acetic acid : 1.02kg

Water : 2233.38 kg

Weak alkali (18-20%) sell : 4800 kg

Eff. To ETP : 2400 kg



Drying loss : 164.3 kg

Drying loss : 0.5 kg

Total 104.5 -------------> 104.5

3 : Residual Sodium Hydroxide neutralization with Acetic Acid

Mol.Wt. 60 40 82 18

Name Acetic Acid Sodium Hydroxide Sodium Acetate Water

Total 100 --------- > 100


Page 39

Ethyl Cellulose (Solvent Process) (Existing):

The bleached cotton linters or Wood Pulp sheet (Cellulose) is dipped in aqueous Caustic solution and

passed through squeeze rollers to remove excess Caustic solution. Then the Alkali Cellulose sheet is

fed to a shredding mill. The shredded Alkali Cellulose is charged into an autoclave containing Toluene

through a mixer and conveyor. This autoclave is jacketed & limpet coiled agitated vessel. The

temperature, time and concentration depend on the intrinsic viscosity desired in the final product. The

required amount of diluents (Toluene / Recycled Solvent mixture) and Ethyl Chloride are added to

Alkali Cellulose. The viscosity is controlled by air as an oxidizing agent.

The reactor contents are heated by passing steam through limpet coil. Ethyl Chloride, Toluene along

with Caustic Flakes / Prills is also charged during the reaction as per requirement. A working pressure

in the range of 10 to 12 Kg / cm2 is obtained and reaction is continued till the desired Degree of

Substitution of Ethyl Cellulose is achieved. After completion of reaction, the unconverted ethyl

chloride and by-products are recovered and reused in the next batch. The viscous reaction product is

discharged into settling tank.

Adequate quantity of recycled solvent mix is added and total mass is mixed thoroughly and

neutralized. The mass is allowed to settle for couple of hours. The upper layer is passed through a

filter press. The salt mass is washed with recycled solvent and washed salt is fed to an ANFD. The

solvents present in the salt are recovered and re used for dilution or sold to actual users. The dried

salts shall be sent to TSDF or partly go for sale if possible. The filtrate from filter press is fed to a

granulator containing water. Live steam is introduced to precipitate Ethyl cellulose and to strip off

organic solvents.

The organic solvents recovered from granulator are scrubbed with water and Toluene is reused in the

next batch. The precipitated Ethyl Cellulose slurry is transferred to washing tanks where the product

is given hot water washes and pH of the product is corrected in the range of 5.5 to 7.5.

The purified Ethyl cellulose is centrifuged in basket type centrifuge and the wet cake is fed to Spin

Flash Dryer. The dried product is passed through a compactor to improve bulk density if required and

packed in Paper Bags or Fibres Drums as per requirement.

CHEMICAL REACTION: Main Reaction :

C6H7O2(OH)3 + C2H5Cl + NaOH -------------> C6H7O2(OH)3 + NaCl + H2O

162 64.5 40 232 58.5

18

Reaction Mole Balance :

Reaction C6H7O2(OH)3 + 2.5 C2H5Cl + 2.5NaOH ----> C6H7O2(OC2H5)2.5(OH)0.5 +2.5 NaCl +2.5 H2O M. Wt. 162 161.25 100 232 146.25 45

Name Wood Pulp Ethyl Chloride Sodium Hydroxide -> Ethyl Cellulose Sodium Chloride Water

Side Reaction :

1 : Ether Formation :

Reaction : 2C2H5Cl + 2 NaOH --------> (C2H5)2O + 2NaCl + H2O

M. Wt. 129 80 74 117 18

Name Ethyl Chloride Sod. Hydroxide Diethyl Ether Sodium Chloride Water


Page 40

Total 209 ----------> 209

2 : Ethyl Alcohol Formation :

Reaction C2H5Cl + NaOH ----------> C2H5OH + NaCl

Mol. Wt. 64.5 40 46 58.5

Name Ethyl Chloride Sodium Hydroxide Ethyl Alcohol Sodium Chloride

Total 104.5 -------------> 104.5

3 : Residual Sodium Hydroxide neutralization with Acetic Acid

Reaction : CH3COOH + NaOH ---------> CH3COONa + H2O

Mol.Wt. 60 40 82 18

Name Acetic Acid Sodium Hydroxide Sodium Acetate Water

Total 100 --------- > 100

FLOW DIAGRAM OF ETHYL CELLULOSE BY SOLVENT PROCESS

DIPPING BATH

REACTION(AUTOCLAVE)

DILUTION & NEUTRALIZATION

FILTRATION / CENTRIFUGE

NaOH : 2646 kgWater : 954 kg

NaOH Prills : 2700 kg

Ethyl Chloride : Fresh : 7200 kg

Recycled Solvent :30169.4 kgsEthyl Chloride: 2400 kgs

Toluene : 27560 kg

Di Ethyl Ether : 120 kgsEthanol : 44.7 kgWater:44.7 kgs

SDS: 600 kg

Toluene : 8000 kg

Wood pulp : 2550 kg

Vent Losses: 271.55 kgs

Mixed Solvent for Distillation: 12935.7 kgsEthyl Chloride : 2724 kg

Toluene : 7824 kgDi ethyl ether : 2096 kg

Ethanol : 182.7 kgWater : 109 kg

Wet Cake : 10881.7 kg

Toluene: 1240 kg

Cooling watercondenser

Upper layer: 7500 kgs to reactor

Bottom layer: 75 kgs to ETP

Chilled watercondenser

Mixed solvent: 2453 kgs for

ethyl chloride

Chilled Brinecondenser

Column Top : 2484.9 kgs to reactor

Bottom : 151.25 kgs residue recycle for

Ethyl Chloride

Recycled Toluene: 6000 kg

Acetic Acid: 1835 kg

Dry in ANFMixed solvent: 1785.5 kgs for

ethyl chloride

Solvent loss: 69.2 kgs

Solid waste: 9027 kgs

GRANULATION

WASHING

CENTRIFUGING: 27029 kgs

DRYING: 5029.2 kgs

ETHYL CELLULOSE : 3065 KG

Steam : 24000 kg

Water : 42000 kg

Mixed Solvent : 33154 kg

SCRUBBERWater : 22988 kgs to ETP

Fresh Water : 12000 kg

Water Evaporation : 1957.84 kg

Water : 34000 kg

Dry Powder Losses : 6.36 kg

Solvent loss: 217.3 kgs

Solvent loss: 56 kg

Toluene: 26110 kgs recycle

Hot Water : 62336 kg

Recycled Water : 18000 kg Water : 16000 kg

Water : 118032 kgs to ETP


Page 41

Manufacturing Process of Aqueous Ethylcellulose Dispersion- Non Plasticized

Raw Materials / Additives: Ethylcellulose, Dichloro Ethane or Dichloro Methane, Toluene, Acetone,

Water, Sodium Laurel Sulphate, Cetyl Alcohol, Defoamer, Hydrogen Peroxide

Manufacturing Operations: Mixing, Coarse Dispersion, Fine Dispersion, Solvent Recovery and

Packing & Storage of finished product.

Preparation of Par1 & Part 2 Solutions: Homogenous solution of Ethylcellulose is prepared by

dissolving Ethylcellulose and Cetyl Alcohol in Dichloro Ethane / Dichloro Methane / Toluene / Acetone.

Sodium Lauryl Sulfate solution is prepared by dissolving SLS in water.

Pre – mixing & Coarse Dispersion: Both solutions are mixed and passed through coarse disperser

to achieve homogenous dispersion. Antifoam agent is added as per requirement.

Fine Dispersion: The above dispersion is passed through a fine disperser mill to achieve desired fine

dispersion.

Recovery of solvent: The fine emulsion is charged in a stripping pot and Dichloro Ethane or Dichloro

Methane / Acetone are stripped off to achieve finished product of non plasticized Ethylcellulose

Aqueous dispersion. Hydrogen Peroxide and defoamer are added before filling the product in HDPE

carboys.

Usage of Ethylcellulose Aqueous Dispersion Non - Plasticized:

Control release of drug

As seal coat

Taste Masking agent

Moisture barrier coat


Page 42

MASS BALANCE FOR ETHYL CELLULOSE DISPERSION NON PLASTICIZED

PRE- MIXING VESSEL: 1(308 Kgs)

Cetyl Alcohol: 8 kgsEthylene Di Chloride (Recovered): 222 kgsEDC/MDC (Fresh): 8 kgsEthyl Cellulose: 70 kgs

PRE- MIXING VESSEL: 1(310 Kgs)

Sodium Lauryl Sulfate: 4 kgsWater (fresh): 186 kgsWater (recovered): 120 kgs

MIXING VESSEL(618 Kgs)

FINE DISPERSION(618 kgs)

EDC loss: 2 kgsWater loss: 2 kgs

FINE DISPERSION RECEIVER(Total 614 kgs) [ Ethyl cellulose: 70 kgs

+ EDC/MDC: 228 kgs + Cetyl Alcohol: 8 kgs + Sodium lauryl sulfate: 4 kgs + water: 304 kgs]

SOLVENT STRIPPING POT (614 kgs)

FINAL PRODUCT: 258 kgs(Ethyl Cellulose: 70 kgs + Cetyl Alcohol: 8 kgs

+ Sodium Lauryl sulfate: 4 kgs + Water: 176 kgs)

PRIMARY/SECONDARY CONDENSOR : (356 kgs)

EDC loss: 6 kgsWater loss: 8 kgs

SEPARATION (342 kgs)

RECOVERED EDC/MDC: 222 kgsRecovered Water: 120 kgs

Manufacturing Process of Aqueous Ethylcellulose Dispersion- Plasticized

Raw Materials / Additives: Ethylcellulose, Ammonium Hydroxide, Medium Chain Triglicerides /

Plasticizers (Dibutyl Sebacate, PEG etc), Oleic Acid and water.

Ethylcellulose is blended with Oleic Acid and plasticizers in a mixing vessel thoroughly. The mixture is

homogenized by passing through extruder and heated to the melting temperature. The molten

plasticized Ethylcellulose solution is then emulsified with ammoniated water in a high shear mixing

device under pressure to form the dispersion of plasticized Ethylcellulose particles. Additional Water

is then added to achieve the final solids content.

Usage of Ethyl cellulose Aqueous Dispersion Plasticized:

Control release of drug

As seal coat

Taste Masking agent

Moisture barrier coat


Page 43

Ethyl cellulose Aqueous Dispersion

Ethyl cellulose Aqueous Dispersion is being used in pharmaceutical industry for tablet coating

specifically for sustained / delayed release applications, as binder, taste masking agent, seal coat,

moisture barrier coat etc.

This product is produced by two methods.

1. Ethyl cellulose Aqueous Dispersion – Non Plasticized

2. Ethyl cellulose Aqueous Dispersion – Plasticized

Ethyl cellulose Aqueous Dispersion – Non Plasticized:

Ethyl cellulose is water insoluble product. It is soluble in almost all solvents. It is very difficult to

disperse Ethyl cellulose in aqueous medium. Hence a process was developed where in Ethyl

cellulose is dissolved in solvents and the solvent solution is dispersed in aqueous medium. After

dispersion the solvent is stripped out to achieve Ethyl cellulose aqueous dispersion. During stripping

of solvent steam is utilized. Customers have the choice of using their plasticizers as per their choice

with respect to quantity and grade.

Ethyl cellulose Aqueous Dispersion – Plasticized:

Ethyl cellulose is water in soluble material as explained above. So Ethyl cellulose is extruded and

melted and molten Ethyl cellulose is dispersed in aqueous medium along with plasticizer. In this type

customer can use the dispersion directly in their application without adding any plasticizer. But they

have no choice of using differ composition or different quantities as it was possible in the above non-

plasticized grade.

Both products are available in the market and customers are using both grades as per their

requirement.

As we are already manufacturing Ethyl cellulose powder we are going to produce both grades of

product which enable the customers the select their choice of product.


Page 44

Ethyl Chloride Through Alcohol:

Many processes are known for the manufacture of Ethyl Chloride. We have selected two processes

to manufacture Ethyl chloride as continuous process. In the first process Ethyl Alcohol is reacted with

hydrogen chloride in presence of catalyst solution prepared from Zinc Chloride or Calcium chloride. In

the second process Ethyl Chloride is produced by reacting existing bi-product (mixed solvent of

Alcohol & Diethyl ether mixture) from the Ethyl Cellulose manufacturing processes with hydrogen

chloride. This is part of backward integration.

Manufacturing of Ethyl Chloride through Ethyl Alcohol:

The catalyst solution is prepared in a glass lined reactor and the temperature of catalyst solution is

raised from ambient to 130OC with help of steam or hot oil system. Ethyl Alcohol and 30%

Hydrochloric acid as per the recipe continuously fed at constant rate to the glass lined reactor while

temperature of reactor mass is maintained at between 130OC to 135OC. Vapor mixture of Ethyl

Chloride, Ethanol, Water and hydrochloric acid are pass through a packed column. The un- reacted

Ethanol and hydrochloric acid are returned to the column with the help reflux. The catalyst solution

will remain the reactor only. The vapors are cooled in an over head cooler before feeding to Caustic

scrubber. Small amount of Hydrochloric acid is neutralized in caustic scrubber and continuously

withdrawn from the bottom of the Caustic scrubber and lined to ETP. The scrubbed Ethyl Chloride

vapors are passed through a water scrubber to ensure Ethyl Chloride free from Hydrogen Chloride

and water. Finally the pure Ethyl Chloride vapors condensed in Chilled Brine condenser and collected

in product receiver.

Reaction C2H5OH + HCl C 2H5Cl + H2O

Ethanol Ethyl Chloride Water

Mole Balance: 46 36.5 64.5 18

Mass Balance: 8832 7008 12384 3456

Side reaction C2H5Cl + C2H5OH C2H5OC2H5 + HCl

Ethyl Chloride Ethanol Di-Ethyl Ether Hydrogen Chloride

Mole Balance: 64.5 46 74 36.5

Mass Balance: 64.5 46 74 36.5

12384 kgs/day of Ethyl chloride requires 9500 kgs/day of Ethanol and 24000 kgs/day of Dil.HCl acid

Hydrogen Chloride

64.5 kgs of Ethyl Chloride requires 46 kgs of Ethanol and 36.5 kgs of Hydrogen Chloride.


Page 45

Catalyst solution Preparation vessel :4800 Kgs

Calcium Chloride/Zinc Chloride:4800 Kg

Jacketed ReactorCatalyst Solution 38300 Kg

30% HCl acid: 24000 kg94% Ethanol: 9500 kg

Caustic Scurbber : 12835.5 Kg

Ethyl Chloride: 12312 Kg, HCl: 9.5 Kg

Water: 474 KgDiethyl Ether: 40 Kg,

To ETP: 23464.5 KgCaustic: 40 Kg, Nacl: 351 KgEthanol: 52 kg, Water:22980 KgEthyl Chloride: 7.5 KgDiethyl Ether: 34 Kg

Caustic Lye: 2800 Kg (Water: 2520 + NaOH: 280 Kg)

Water Scurbber : 12400 KgEthyl Chloride: 12312 Kg,

Diethyl Ether: 40 KgWater: 48 Kg,

To ETP: 3435.5 KgHCl : 9.5 KgWater: 3426 Kg

Water: 3000 Kg

Chilled Brine Condenser12380 Kg

Vent condenser : 20 kgEthyl Chloride: 12 KgDiethyl Ether: 8 Kg

Product Receiver: 12380 KgEthyl Chloride: 12300 Kg(99.35%)

Diethyl Ether: 32 Kg (0.26%)Water: 48 Kg ( 0.39%)

Process flow Diagram of ETHYLChloride from Ethyl Alcohol

(1) Condensate from Condenser attached to reactor: 33500 kgsTo caustic scrubber(EthylChloride: 12319.5 kg, Hcl:228.5 Kg

Ethanol: 52 Kg, Water:20826 KgDiethyl Ether: 74Kg )(2) Catalyst from bottom of reactor: 4800 kgs remain in reactor for next cycle

Ethyl Chloride Through existing mix solvent: Catalyst solution is prepared in a glass lined reactor and temperature of catalyst solution is raised

from ambient to 150OC. The mixture of Ethanol and Diethyl Ether and 30% Hydrochloric acid are

continuously at constant rate fed to glass lined reactor as per the recipe. The temperature of the

reactor is maintained between 150OC and 155OC. Vapor mixture of Ethyl Chloride, Mixed Solvent,

Water and hydrochloric acid are pass through a packed column. The un- reacted mixed solvent

mixture and hydrochloric acid are returned to the column with the help reflux. The catalyst solution will

remain the reactor only. The vapors are cooled in an over head cooler before feeding to Caustic

scrubber. Small amount of Hydrochloric acid is neutralized in caustic scrubber and continuously

withdrawn from the bottom of the Caustic scrubber and lined to ETP. The scrubbed Ethyl Chloride

vapors are passed through a water scrubber to ensure Ethyl Chloride free from Hydrogen Chloride

and water. Finally the pure Ethyl Chloride vapors condensed in Chilled Brine condenser and collected

in product receiver.


Page 46

Vent Losses : 7 kgsFeed from existing EC solvent Process: 4389 KgEthyl chloride: 269 kgs, Diethyl Ether: 2065, Ethanol: 566Toluene: 1130, Water: 359

Distillation System

To re-use in existing EC solvent Process: 1415 KgEthyl Chloride: 265Diethyl Ether: 10, Toluene: 1130Ethanol: 6, Water: 4

To Ethyl Chloride Reactor: 2662 kgDiethyl Ether: 2052

Ethanol: 555, Water: 55

To ETP: 305 kgEthanol: 5, Water: 300

Jacketed Reactor with Rectification column:8500 Kg

Zinc Chloride: 6000 Water: 2500

(Catalyst solution - one time charge and remain in reactor)

Feed from existing EC aqua Process : 1340 KgDiethyl Ether: 672, Water: 130Ethanol: 538

30% HCl: 12290 Kg HCl: 3687, Water: 8603

Water:1500 kg

Catalyst Solution recycled in jacketed reactor : 8500 KgZinc Chloride: 6000 KgWater: 2500 Kg

Cooling Water Condenser: 16292 kgEthyl Chloride: 6127.5 kg, Hcl:219.5 Kg

Ethanol: 35 Kg, Water: 9850 KgDiethyl Ether: 60Kg

Caustic Scurbber : 6283 KgEthyl Chloride: 6125 kg, Water:114 Kg

Diethyl Ether: 40 Kg, NaCl: 4

To ETP: 12509 KgCaustic: 10, NaCl: 347 Ethanol: 35, Water: 12094 Ethyl Chloride: 2.5 , Hcl: 0.5Diethyl Ether: 20

10% Caustic Lye: 2500 Kg

NaOH: 250, Water: 2250

Water Scurbber : 6162 KgEthyl Chloride: 6125 Kg,

Diethyl Ether: 31 KgWater: 6 Kg

To ETP: 2121 KgDiethyl Ether: 9, NaCl: 4Water: 2108 kgs

Water:2000 Kgs

Chilled Brine Condenser: 6150 Kg

Product Receiver: 6150 KgEthyl Chloride: 6117 Kg(99.46%)

Diethyl Ether: 27 Kg (0.44%)Water: 6 Kg ( 0.1%)

Process flow Diagram of ETHYLChloride from Mix solvent of existingproduct

Vent condenser : 12 kgsEthyl chloride: 8 kgsDiethyl ether: 4 kgs

Methyl Chloride: Many processes are proposed for the manufacture of Methyl Chloride. We have selected a process to

produce Methyl chloride in continuous manner. In this process Methanol is subjected catalytic hydro

chlorination. Methyl Alcohol is reacted with hydrogen chloride in liquid phase in presence of catalyst

solution prepared from Zinc Chloride. The process is similar to Ethyl chloride process.

Catalyst solution is prepared in a glass lined reactor and the temperature of catalyst solution is raised

from ambient to 150OC with help of steam or hot oil system. Methanol and 30% Hydrochloric acid

continuously mixed as per recipe and fed at constant rate to the glass lined reactor while temperature

of reactor mass is maintained at between 155OC to 160OC. Vapor mixture of Methyl Chloride,

Methanol, Water and hydrochloric acid are pass through a packed column attached to reactor. The

un- reacted Methanol and hydrochloric acid are returned to the column with the help internal reflux.

The catalyst solution will remain the reactor only. The vapors are cooled in an over head cooler prior

to feeding to Caustic scrubber. Small amount of entrained Hydrochloric acid is neutralized in caustic

scrubber and continuously withdrawn from the Caustic scrubber and lined to ETP for further

treatment. The scrubbed Methyl Chloride vapours are fed to a water scrubber to ensure Methyl

Chloride free from impurities. Finally the pure Methyl Chloride vapours condensed in Chilled Brine

condenser or compressed to receive in liquid phase before filling in cylinders.


Page 47

Production basis: 9.61 MT/Day Reaction: CH3OH + HCl CH3Cl + H2O 32 36.5 50.5 18 Methanol Hydrochloric Acid Methyl Chloride Water NaOH + HCl NaCl + H2O 40 36.5 58.5 18 Sodium Hydroxide Hydrochloric Acid Sodium Chloride Water

Catalyst solution Preparation vessel :4800 Kgs

Calcium Chloride/Zinc Chloride:3600 KgWater: 1200 kgs

Jacketed ReactorCatalyst Solution 34544 Kg

30% HCl acid: 23600 kg99.5% Methanol: 6144 kg

Caustic Scrubber: 9651.3 KgMethyl Chloride: 9593 Kg,

HCl: 6.3 KgWater: 48 Kg

Methanol: 4 kgs

To ETP: 22092.7 KgCaustic: 48 Kg, NaCl: 222.3 KgMethanol: 60 kg, Water: 21760.4 KgMethyl Chloride: 2 Kg

10% NaOH Soln: 2000 Kg (Water: 1800+ NaOH: 200 Kg)

Water Scurbber : 9615 KgMethyl Chloride: 9593 Kg,

Water: 22 Kg,

To ETP: 1036.3 KgHCl : 6.3 KgWater: 1026 KgMethanol: 4 kgs

Water: 1000 Kg

Chilled Brine Condenser9615 Kg

Vent condenser: 5 kg

Product : Methyl Chloride: 9610 Kg

Process flow Diagram of METHYLChloride from Methyl Alcohol

(1) Product vapour from reactor is cooled in a cooler and fed to a caustic scrubber: 29744 kgs(2) (MethylChloride: 9595 kg, HCl:145 Kg

Methanol: 64 Kg, Water:19940 Kg(2) Catalyst from bottom of reactor: 4800 kgs remain in reactor for next cycle

Hydroxy Propyl Methyl Cellulose (HPMC)

Hydroxy Propyl Methyl Cellulose also known as HPMC or Hypromellose is one of cellulose

derivatives widely used in various applications. HPMC is inert visco elastic polymer used in

pharmaceutical and food additive applications. The manufacturing process is a batch type one and

consists of the following stages.


Page 48

Preparation of alkali cellulose.

Etherification reaction

Recovery solvents

Purification

Drying

Blending and Packing.

Wood Pulp / Cotton linters pulp sheets are fed to a shredder machine and conveyed to reactor. 50%

Caustic solution is prepared and charged into rector to prepare alkali cellulose and allowed for aging

for different durations depend on final viscosity of the product.

The reactants Methyl Chloride and Propylene oxide are charged as per the formulation and the

reactor mass is heated with the help of low pressure steam. The reactor temperature is maintained at

different temperatures as for the formulation to achieve desired degree of substitution. The operating

temperature range is from 50OC to 80OC. The reaction is exothermic in nature and temperature is

controlled precisely with help of cooling water.

After completion of reaction the solvents and by-products formed during reaction are recovered from

the reactor. The reactor product is discharged into a neutch filter unit to separate salt water. The

reaction product is subjected hot water washes to receive salt free product.

The wet cake from neutch filter is discharged into the feed hopper of spin flash dryer. Dry product

from different batches will be blended to achieve designated viscosity product in blender and packed.

C6H7O2(OH)3 + CH3Cl + NaOH + C3H6O 162 50.5 40 58 Wood Pulp Methyl Sodium Propylene Chloride Hydroxide Oxide

C6H7O2(OH)(OCH3)(OCH2CHOHCH3 ) + NaCl + H2O 234 58.5 18 Hydroxy Propyl Methyl Cellulose (HPMC) Sodium Water Chloride Side Reactions: CH3Cl + NaOH CH3OH + NaCl 50.5 40 32 58.5 Methyl Chloride Sodium Hydroxide Methanol Sodium Chloride

2CH3Cl + 2NaOH H2O + CH3OCH3 + 2NaCl 101 80 18 46 117 Methyl Chloride Sodium Hydroxide Water Di-Methylether Sodium Chloride C3H6O + H2O C3H8O2 Propylene Oxide Water Propylene Glycol 58 18 76


Page 49

REACTOR: 11718 kgs(HPMC: 7488 kgsNaCl: 2047.5 kgs

NaOH: 20 kgsWater: 1996 kgs

Methanol: 32 kgsDi methyl ether: 46 kgs

Propylene glycol: 76 kgs), methyl chloride: 12.5 kgs

Wood pulp: 5184 kgs50% Caustic soln. : 2840 kgsMethyl Chloride: 1780 kgsPropylene o0xide: 1914 kgs

To ETP: 10551.5 kgs ( NaCl: 2047.5 kgs + HPMC: 8 kgs + NaOH: 20 kgs + Methanol: 4 kgs + Water: 8472 kgs)

Hot water: 8000 kgs

Wet Cake Receiver: 9000 kgs

Water Evaporated: 1310 kgs

Product : HPMC: 7690 Kg

PROCESS FLOW DIAGRAM FOR HYDROXY PROPYL METHYL CELLULOSE (HPMC)

Crude Product: 11551. 5 kgs

Mix solvent: 166.5 kgs (Di methyl Ether + Propylene glycol + Methanol) sell to

authorized distillator

Washing

Spin Flash Dryer


Page 50


Page 51

ANNEXURE: 5 WASTE WATER MANAGEMENT

Quantity of Waste Water (liquid waste) generation and its management :

No Particular Existing Proposed Total

2.1 Domestic 1.5 0.5 2.0

2.2 Industrial

2.2.1 Processing + washing 88.0 74.515 162.515

2.2.2 Boiler 25.0 12.0 37.0

2.2.3 DM Plant 5.0 7.5 12.5

2.2.4 Cooling 2.5 0 2.5

2.2.5 Container/floor washing, QC, R&D 1.0 0.5 1.5

2.2 Total Industrial 121.5 94.515 216.015

2.3 Total effluent 123.0 95.015 218.015

Domestic effluent is/will be passes through septic tank/soak pit of adequate capacity & finally

mixed with industrial effluent.

Entire quantity of effluent is/will be treated in primary, secondary & tertiary effluent treatment plant

followed by RO & MEE system. Thus after RO & MEE, entire treated water is/will be recycled. RO

Permeate & MEE condensate is/will be recycled. RO rejected is/will be taken into MEE. Salt from

MEE is/will be dispose off into TSDF.

Water is/will be used in the process to dissolve the raw materials only.

Steam is/will be required to for stripping and recovery of solvent is/will be obtained from existing

boiler only.

WATER BALANCE AFTER PROPOSED EXPANSION

TOTAL WATER CONSUMPTION: 244.9 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 207.5 m3/day)


Boiler: 55 Cooling: 57 D M plant: 14 Floor/containerwashing: 2.0

Gardening: 10

162.515

37.0 2.5 12.5 1.5

207.465

2.0

P/S/T ETP: 207.465 Loss: 4.465


RO Permeate recycle : 173RO Rejection: 30 MEE

Condensate recycle : 34.5

High TDS: 10.55 Normal: 151.965

Salt : 6.05




Page 52

CHARACTERISTICS OF UNTREATED & TREATED EFFLUENT

Sr. No. Parameters Untreated

combined effluent

from existing

plant

Untreated

combined effluent

from proposed

plant

Untreated

combined effluent

after proposed

expansion

1 pH 9.39 8.02 9.02

2 Colour, pt.Co 180 150 140

3 Temperature 32 32 32

4 Suspended

solids, mg/l

304 286 276

5 Oil & grease,

mg/l

7.20 2.8 4.2

6 Phenolic

compound, mg/l

0.2 0.21 0.19

7 Cyanides, mg/l ND ND ND

8 Ammonical

nitrogen, mg/l

24.2 16.0 18.5

9 TDS, mg/l 4600 3200 3420

10 Chloride, mg/l 800 1020 985

11 Sulphate, mg/l 650 740 725

12 Phosphates, mg/l 1.2 0.8 0.62

13 COD, mg/l 3150 3780 3670

14 BOD, mg/l 1117 1486 1615


Page 53

CHARACTERISTICS OF TREATED EFFLUENT

Sr. No. Parameters Treated combined

effluent after proposed

expansion plant

GPCB disposal

norms

1 pH 8.02 6.5 to 8.5

2 Colour, Pt.Co 80 <100

3 Temperature 30 <40

4 Suspended solids, mg/l 46 <100

5 Oil & grease, mg/l 0.86 <10

6 Phenolic compound, mg/l 0.08 <1

7 Cyanides, mg/l ND <0.1

8 Ammonical nitrogen, mg/l 16.0 <50

9 TDS, mg/l 2050 <2100

10 Chloride, mg/l 550 <600

11 Sulphate, mg/l 580 <1000

12 Phosphates, mg/l 0.18 <2

13 COD, mg/l 79.9 <250

14 BOD, mg/l 26 <30

Remarks:

After proposed expansion, we will treat our entire effluent into our modified full-fledge

effluent treatment plant consisting of primary, secondary & tertiary treatment units

followed by Reverse osmosis & MEE.

RO permeate & MEE condensate shall be recycled in the process, hence after RO/MEE

treatment, there will be no discharge of any industrial effluent on land.

CHARACTERISTICS OF RO TREATED & MEE CONDENSATE

Sr. No. Parameters RO Permeate MEE

Condensate

1 pH 7.0 7.0

2 TDS, mg/l 150 -

3 COD, mg/l < 20.0 < 50.0


Page 54

Details of Effluent Treatment Plant , RO plant and MEE with proposed modification

Sr. No. Particulars Capacity, m3 MOC


1 Collection Tank 205 0 205 RCC

2 Neutralization Tank 40 0 40 RCC

3 Floculator 7 7 14 MSRL

4 Primary lamella separator

with tube deck

26 26 52 MSRL

5 Sludge drying bed 30 30 60 Brick

Masonry

6 Aeration tank with tube

deck packing

526 0 526 RCC

7 Secondary Lamella

separator with tube deck

26 26 52 MSRL

8 Holding tank 30 30 60 RCC

9 Activated carbon bed 6 m3 6 m3 12 m3 MSRL

10 Sand bed filter 6 m3 6 m3 12 m3 MSRL

11 Final treated water

holding tank

111 99 211 RCC

12 RO System 12 m3/hr 12 m3/hr 24 m3/hr PP

13 RO Rejection collection

tank

30 0 30 RCC

14 MEE followed by

centrifuge and ANFD

system

1.75

m3/hr

0 1.75

m3/hr

Titanium/SS

15 Final RO permeate &

MEE condensate

collection tank

50 160 210 RCC


Page 55

FLOW DIAGRAM OF ETP FOLLOWED BY RO PLANT AND MEE


Page 56

Details of RO Plant


Page 57


Page 58

Flow Diagram of MEE

TRIPPLE EFFECT EVAPORATOR PLANT

Steam 6 Kgs/cm2

Barometric Leg

Conenser Vent

M

Vacuum Pump

Seal Water Circulation

Cooling Tower

Cooling Tower

Feed Pump CW Pump

Transfer Product Condensate

Transfer Transfer Pump Pump Product Pump

FF

Evaporator

FCE

vaporator

PreH

eater

FCE

vaporator

Pre

Heater

Pre

Heater

VLS VLS

VLS

TVR

CondensateReceiver

FeedVessel

Barometric receiver

PHE


Page 59

ANNEXURE 6 COPY OF LAND DOCUMENT


Page 60


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Page 70


Page 71

ANNEXURE 7 LAND USE MAP


Page 72

ANNEXURE 8 TSDF MEMBERSHIP


Page 73


Page 74

ANNEXURE 9 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES


Presently, the unit has installed one number of natural gas/FO fired 3 TPH steam boiler, three

numbers of FO/LDO fired steam boiler having capacity of 800 kg/h each and two numbers of

LDO/Natural gas fired hot air generator having capacity of 6 lakhs k cal/hr each. Two numbers of

D G sets having 110 KVA and 35 KVA capacity. 30 meters height of chimney with SMF provided to

3 TPH boiler, 15 meters common chimney provided for all three boiler and two HAG. 11 meters

chimney provided for D G Sets.

Presently two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h are used.

Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney for

each dryer is provided.


After proposed expansion, existing one number of natural gas/FO fired 3 TPH boiler will be

continued. Existing three numbers of 800 kg/h capacity of boiler will be discontinued. Existing two

numbers of hot air generator will be continued. Additional one number of coal/natural gas/FO fired

3 TPH boiler and one number of FO/natural gas fired 6 lakhs k cal/hr capacity of thermopak and

one number of natural gas/LDO fired hot air generator of 6 lakhs k cal/hr capacity will be

installed. Existing two numbers of D G sets having 110 KVA and 35 KVA will be continued.

30 meters height of chimney with SMF provided to 3 TPH boiler, 15 meters common chimney

provided for three HAG. 30 meters chimney with multi cyclone separator and bag filter will be

provided to 3 TPH coal fired boiler. 11 meters height of chimney will be provided to 6 lakhs k cal/hr

capacity of thermopak. 11 meters chimney provided for D G Set.

After proposed expansion, existing two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h will be used. One additional spin flash dryer having a capacity of 100 kg/h will be installed. Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney for each spin flash dryer will be provided.

There will be no process gas emission from the reaction.

Flue Gas Emission:

Sr. No. Particulars Details


1.0 Capacity of Steam boiler 3 TPH 0 3 TPH

Fuel used NG/FO 0 NG/FO

Consumption 230 SCM/hr/200 kgs/hr

0 230 SCM/hr/200

kgs/hr

APC provided Chimney 0 Chimney

Height of chimney 11 meters 0 11 meters

2.0 Capacity of Steam boiler 0 3 TPH 3 TPH

Fuel used 0 Coal/NG/FO Coal/NG/FO

Consumption 0 300 kgs/hr/400

SCM/hr/325 kgs/hr

300 kgs/hr/400

SCM/hr/325 kgs/hr

APC provided 0 MDC and bag filter

MDC and bag filter

Height of chimney 0 15 meters 15 meters


Page 75

3.0 Capacity of Thermopak 0 6 lakhs k cal/hr

6 lakhs k cal/hr

Fuel used 0 NG/FO NG/FO

Consumption 0 135 SCM/hr/115

kgs/hr

135 SCM/hr/115

kgs/hr

APC provided 0 Chimney Chimney


4.0 Capacity of Steam boiler 0.8 TPH - 0.8 TPH to be

discontinued

- 0.8 TPH to be

discontinued Fuel used LDO/FO

Consumption 25 kgs/hr

APC provided Chimney

Height of chimney 11 meters


discontinued

- 0.8 TPH to be

discontinued

Fuel used LDO/FO





discontinued

- 0.8 TPH to be






discontinued

- 0.8 TPH to be





8.0 Capacity of Hot air generator 6 lakhs k cal/hr 0 6 lakhs k cal/hr

Fuel used NG/LDO 0 NG/LDO


0 50 SCM/hr/40 kgs/hr



9.0 Capacity of Hot air generator 6 lakhs k cal/hr 0 6 lakhs k cal/hr

Fuel used NG/LDO 0 NG/LDO


0 50 SCM/hr/40 kgs/hr




Page 76

10 Capacity of Hot air generator 0 6 lakhs k cal/hr

6 lakhs k cal/hr

Fuel used 0 NG/LDO NG/LDO

Consumption 0 50 SCM/hr/40 kgs/hr

50 SCM/hr/40 kgs/hr

APC provided 0 Chimney Chimney


11 Capacity of D G set 110 KVA 0 110 KVA

Fuel used HSD 0 HSD

Consumption 45 kgs/hr 0 45 kgs/hr



12 Capacity of D G set 35 KVA 0 35 KVA

Fuel used HSD 0 HSD

Consumption 15 kgs/hr 0 15 kgs/hr



Expected Pollutants PM: < 150 mg/Nm3 SOX: < 100 ppm NOx: < 50 ppm

Process Gas Emission:

There will be no process gas emission from the reaction. Vent attached to spin flash dryer is considered as process gas emission.

Sr. No. Particulars Details


13 Capacity of Spin flash dryer 50 kgs/hr 0 50 kgs/hr

Hot air supplied by HAG 0 HAG

APC provided Cyclone separator followed by bag

filter

0 Cyclone separator

followed by bag filter


14 Capacity of Spin flash dryer 100 kgs/hr 0 100 kgs/hr

Hot air supplied by HAG 0 HAG

APC provided Cyclone separator followed by bag

filter

0 Cyclone separator

followed by bag filter


14 Capacity of Spin flash dryer 0 100 kgs/hr 100 kgs/hr

Hot air supplied by 0 HAG HAG

APC provided 0 Cyclone Cyclone


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separator followed by

bag filter

separator followed by

bag filter


Expected Pollutants PM: < 150 mg/Nm3

Details of MDC and Bag filter attached to Spin Flash Dryer

MAKE ACMEFIL

Type Reverse pulse air jet

Air volume 17500m3/hr

Air temperature 70 oC

Dust load 12 kg/hr

Actual filtration area 34.55 m2

Air to cloth ratio 1:5

Bag size 150mm * 3000 mm long

Total no. of bags 121

Total no. of rolls 11

Cage size 150mm * 2990 mm long

Overall size of bag filter 2200 * 2200 * 5250mm

MOC of casing SS 304

MOC of bag Polyester needle felt,

Cage SS 304

PULSING PIPES SS 304

Details of Bag filter attached to Coal fired Boiler

Size of Bag filter 2.475 x 2.3 x 8.61 meters

MOC Mild steel

Size of Gas inlet 0.81 x 0.64 mm

Size of gas out let 2.716 x 0.346 mm

Designed gas volume 12750 Am3/hr

Maximum designed temp. 180 0C

Number of filter bags 120 Nos ( 500 gms/m2 filter glass)

Size of filter bags 149 mm dia x 3.65 m length

Pressure drop 150 mm

Total unit weight 7.6 MT

Hopper volume 9.72 m3

No. of cages 120

Air to cloth ratio 1.03 m3/min/m2


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ANNEXURE 10 COPY OF /CTE CC&A


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COMPLIANCE FOR EXISTING CCA

Sr.

No

CONDITIONS COMPLIANCE

1 Consent Order No.: AWH-87084, Date of issue:

12/07/2017.

We have obtained CCA of the

Board vide No. AWH-87084

which is valid up to 31/03/2022.

2 The consents shall be valid up to 31/03/2022 for use of

outlet for the discharge of trade effluent & emission due

to operation of industrial plant for manufacture of the

following items/products:

We are manufacturing products

as per consented quantity only

SUBJECT TO THE FOLLOWING CONDITIONS:

Management of Solid Waste generated from industrial

activities shall be as per Solid Waste Management

Rules 2016, (Solid waste as defined in Rule -3 (46).

We are generating hazardous

waste as per authorization

issued by the board and dispose

off as per hazardous waste rules

2016

As per provision of Rule-18 of Solid Waste

Management Rules-2016 all Industrial units using fuel

and located within 100 Km from the refused derived

fuel (RDF) plant shall made an arrangement to replace

at least five percent of their fuel requirement by refused

derived fuel so produced.

Will be implemented

3 CONDITIONS UNDER THE WATER ACT :

3.1 The quantity of total water consumption shall not

exceed 155.48 KLD as per below break up. Source of

fresh water shall be only from Borewell. Unit shall

submit NOC from central ground Authority (CGWA)

for use of Borewell water.

a) Domestic : 2.2 KLD

b) Industrial : 149.48 KLD

We are using water

consumption @ 11.48 m3/day.

We are using fresh water from

our own Bore well. We will

apply for permission for central

ground Authority (CGWA) for

use of Bore well water.

3.2 The quantity of the trade effluent discharge from the

industry shall not exceed 121.5 KLD.

Entire effluent shall be treated in ETP, followed by RO

and MEE and achieve zero liquid discharge condition.

We are generating maximum

121.5 KLD of industrial waste

water.

We have provided adequate

capacity of primary, secondary

and tertiary ETP followed by

RO and MEE to achieve zero

liquid discharge.

3.3 The quantity of Sewage effluent from the industry shall

not exceed 1.5 KLD.

We are generating maximum

1.5 KLD of domestic effluent.

3.4 Domestic effluent shall be disposed off through septic

tank/soak pit system.


capacity of septic tank/soak pit

for the disposal of domestic

effluent.

4 CONDITIONS UNDER THE AIR ACT:


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4.1 The following shall be used as fuel in the boilers, Hot

Air Generation & D.G. Sets.

We have installed utilities for

process heat requirement as per

CCA only. Also we are using

fuel in utilities as per CCA.

4..2 The flue gas emission through existing stack shall

conform to the following standards:

We are operating our air

pollution control system and

maintain the norms of flue gas

emission as specified by the

board.

4.3 The process emission through various stacks / Vent of

reactors, process, vessel shall conform to the following

standards.

We are maintaining the norms

of process gas emission.

4.4 The concentration of the following substances in the

ambient air within the premises of the industry and at a

distance of 10 meters from the source (other than the

stack/ vent with height of more than 9 meters from the

ground level)Shall not exceed the following levels:

We are maintaining the ambient

air quality within the premises

and analyze regularly to ensure

the quality within the premises

as per norms.

4.5 The applicant shall provide portholes, ladder, platform

etc at chimney(s) for monitoring the air emissions and

the same shall be open for inspection to/and for use of

Board’s staff. The chimney(s) vents attached to various

sources of emission shall be designed by numbers such

as S-1, S-2, etc. and these shall be painted / displayed to

facilitate identification.


stack monitoring facility like

portholes, ladder, platform etc

at chimney(s) for monitoring.

4.6 The industry shall take adequate measures for control of

noise levels from its own sources within the premises

so as to maintain ambient air quality standards in

respect of noise to less than 75 dB (a) during day time

and 70 dB (A) during night time. Daytime is reckoned

in between 6 a.m. and 10 p.m. and nighttime is

reckoned between 10 p.m. and 6 a.m.

Controlling noise level by

regular maintenance and close

acoustic enclose to DG set.

5 GENERAL CONDITIONS:

5.1 Any change in personnel, equipment or working

conditions as mentioned in the consents form/order

should immediately be intimated to this Board.

Agreed

6 AUTHORISATION UNDER HAZARDOUS WASTE AND OTHER WASTE

(MANAGEMTN AND TRANSBOUNDARY MOVEMENT) RULES-2016, FORM-2

(SEE RULE 6(2))

6.1 Number of authorization: AWH-87084, Date of issue:

12/07/2017.

Agreed

6.2 Reference of authorization: AWH-122307 and Date:

23/05/2017.

Agreed

6.3 M/s. ASHA CELLULOSE (I) PVT. LTD is hereby

granted an authorization based on the enclosed signed

inspection report for generation, collection, reception,

storage, transport, reuse, recycling, recovery, pre-

processing, co-processing, utilization, treatment,

disposal or any other use of hazardous or other waste or

Agreed


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both on the premises situated at Plot No. Shed No.

303/2,302/P, Village: Abrama, Abrama-369001, Dist:

Valsad.

6.4 The authorization shall be valid for a period of

31/03/2022.

Agreed

6.5 The authorization is subject to the following general

and specific conditions:

Agreed

A GENERAL CONDITIONS UNDER HAZARDOUS AND OTHER WASTES

(M&TM) RULES-2016.

1 The Authorised person shall comply with the

provisions of the Environment (Protection) Act-

1986 and rules made there under.

Complied with

2 The Authorization or its renewal shall be produced for

inspection at the request of an officer Authorized by the

State Pollution Control Board.

We will not rent, land, sell,

transfer or otherwise transport

the hazardous and other

wastes except what is permitted

through authorization.

3. The persons authorized shall not rent, lend, sell, transfer

or otherwise transport the hazardous and other

wastes except what is permitted through this

authorization.

Complied with

4. Any unauthorized change in personnel, equipment or

working conditions as mentioned in the application by

the persons authorized shall constitute a breach of this

authorization.

Complied with

5. The person authorized shall implement Emergency

Response Procedure (ERP) for which this authorization

is being granted considering all site specific possible

scenarios such as spillages, leakages, fire etc. and their

possible impacts and also carry out mock drill in this

regard at regular interval of time.

We have already made

emergency response plan and

implemented the same. We have

also carried out mock drill for

possible scenarios such as

spillages, leakages, fire etc

6. The person authorize shall comply with the provisions

outlined in the Central Pollution Control Board

guidelines on “ implementing Liabilities for

Environmental Damages due to Handling and Disposal

of Hazardous Wastes and penalty”.

We are complying with the

guide line of CPCB for

implementing Liabilities for

Environmental Damages due to

Handling and Disposal of

Hazardous Wastes and penalty”.

7. It is the duty of the authorized person to take prior

permission of the State Pollution Control Board to close

down the facility.

Agreed

8. The imported hazardous and other wastes shall be fully

insured for transit as well as for any accidental

occurrence and its clean- up operation.

Complied with

9. The record of consumption and fate of the imported

hazardous and other wastes shall be maintained.

Complied with

10. The hazardous and other waste which gets generated

during recycling or reuse or recovery or pre-processing

or utilization of imported hazardous or other wastes

shall be treated and disposed of as per specific

Not applicable, as we are not

importing any hazardous waste


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conditions of authorization.

11. The importer or exporter shall bear the cost of import or

export and mitigation of damages if any.

Agreed

12. An application for the renewal of an authorization shall

be made as laid down under these rules.

Complied with

13. Any other conditions for compliance as per the

guidelines issued by the Ministry of Environment,

Forest and Climate Change or Central Pollution Control

Board from time to time.

We are regularly submitting

return filed by June 30th for the

period ensuring 31st March of

the year.

14. Annual return shall be filed by June 30th for the period

ensuring 31st March of the year.

Complied with

B. SPECIFIC CONDITIONS (WHICHEVER IS

APPLICABLE)

1. The authorized actual of hazardous and other waste

shall maintain records of hazardous and other wastes

purchased in a passbook issued by the State Pollution

Control Board along with the authorization.

We are maintaining the records

for the hazardous and other

waste as per authorization

2. Handling over the hazardous and other wastes to the

authorized actual user shall be only after making the

entry into the passbook of the actual user.

Complied with

3. In case of renewal of authorization, a self-certified

compliance report in respect of effluent, emission

standards and the conditions specified in the

authorization for hazardous and other wastes shall be

submitted to SPCB.

Agreed

4. The occupier of the facility shall comply standards

operating procedure/guidelines published by

MoEF&CC or CPCB or GPCB from time to time.

We are complying with

standards operating

procedure/guidelines published

by MoEF&CC or CPCB or

GPCB from time to time.

5. Unit shall comply provisions of E-Waste (Management)

Rules, 2016.

Complied with


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ANNEXURE 11 COPY OF ENVIRONMENTAL CLEARANCE FOR EXISTING PLANT


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CERTIFIED COMPLIANCE REPORT EXISTING EC


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ANNEXURE 12 A SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING


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SHOW CAUSE NOTICE/CLOSURE NOTICE ISSUED BY GPCB/CPCB & ITS COMPLIANCE

Sr.

No

Date Reason For Show Cause Notice Compliance

1 05.05.2015 You have stored ETP sludge on

open land.

Complied with by shifting entire ETP

waste into secured storage area

within the premises and finally

disposed off into TSDF.

2 28.07.2016 Written instructions were given

during the visit, you are directed

to submit detailed action taken

report with supporting documents

(if not submitted).

We have already uploaded on xgn

and submitted copy of compliance

of written instruction given during

the inspection of our unit by the

officers from GPCB

3 20.04.2017 Unit is not operated MEE on

regular basis.

We have installed our MEE for full

production capacity, but our

production plant was operated on 60-

70% production capacity and hence

there was no sufficient effluent to

meet the capacity of MEE and we

were operating our MEE thrice a

week.

4 23.03.2018 The recent past result of inlet and

outlet of CETP are not as per

prescribed limits.

This is not applicable to us, as we are

a ZLD unit and we are not

discharging our treated effluent into

CETP.

Documents

ASHA CELLULOSE (I) PVT. LTD PRE-FEASIBILITY REPORT...Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD Page 3 (From Alcohol) in the manufacture of Ethyl cellulose and other chemical