HERANBA INDUSTRIES LIMITED (UNIT: II).environmentclearance.nic.in/writereaddata/Online/TOR/0_0_12_Sep_2014_0838464771Pre...Prefeasibility Report-Annexure Heranba Industries Limited

FOR

PROPOSED EXPANSION PROJECT

FOR

MANUFACTURING OF

PESTICIDE TECHNICAL & INTERMEDIATES

Category: 5(b)

of

HERANBA INDUSTRIES LIMITED(UNIT: II).

Located at:Plot No. A-2/2214 & 2215, 3rd Phase,

GIDC Notified Industrial Area, Vapi, Dist- Valsad (Gujarat).

Prefeasibility Report-Annexure Heranba Industries Limited (Unit: II).

Expansion Project Page 2 Manufacturing : Pesticides & intermediates

Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIANotification - 2006

1 Executive Summary:Name & Location

Name of the Project : Heranba Industries Limited (Unit: II).Location : Plot No: A-2/2214, 2215, 3rd phase, G.I.D.C,

VAPI. Pin Code: 396195Dist. - Valsad (Gujarat)

Project

Heranba Industries limited (Unit: II) is located in GIDC notified industrial area, fallingunder Medium Scale category manufacturing products as mentioned under for which thecompany had obtained Consent To Establish and Operate from Gujarat pollution ControlBoard.

The company proposes to enhance the capacity of existing products under the category“Pesticides & Intermediates”

Proposed Project Cost: Rs. 2900 lacs.

Applicability of EIA notification – 2006

Category as per the amended EIA notification-2006: as existing and proposed products (i.e.Pesticides & intermediates) are covered under the Category-5(b) A. Hence,Environmental clearance is required.

Project Proponent

The company in India comprises of 4 directors Medium Scale Unit

List of finished products & by- products:

No Product MT/MONTHExisting Proposed Total after

proposedexpansion

1 Cyper methric Acid Chloride 10 170 180

2 Cyper Methrin technical 5 95 100

3 Alpha Cyper Methrin technical 5 55 60

4 Permethrin technical 5 0 5

Total 25 320 345

By-products

1 Ammonium Chloride Powder(85%)

5.08 86.36 91.44

2 Sodium Sulphite Powder(80%)

22.4 380.8 403.2



3 Hydro Chloric Acid solution(30%)

18.765 290.7 309.465

4 Sodium Sulphate powder(80%)

17.22 292.74 309.96

Manufacturing process is attached as Annexure-3.

Resource Requirement:

Components ExistingTotal afterproposedexpansion

Resources availability

Power, KVA 600 1250Will be sourced fromDakshin Gujarat Vij Co.Ltd.

Fresh Water, kl/day 82.8 217.09Will be sourced fromGIDC water supply dept.

Natural Gas/FO forSteam Boiler (3Tons/Hr) x 2 Nos

2500 scm/day or2.5 kl/day

5000 scm/day or5 kl/day

GSPC & local dealer

Fuel (HSD) for D.G.Set(Capacity: 750 & 500KVA)

75 kgs/hr 125 kgs/hrWill be sourced fromlocal dealer

Raw material Consumption:

Product Name of RM RM consumption in MTPer ton of product Per month

Existing After ProposedExpansion

Cypermethric acidChloride

Forcut (Recovered) 0.380 3.8 68.4

Acrylo nitrile 0.522 5.22 93.96

CTC 1.550 15.5 279

Catalyst 0.010 0.1 1.8

DEA-HCl 0.011 0.11 1.98

HCl 30 %(Recovered)

1.71 17.1 307.8

HCl 30% (Fresh) 0.09 0.9 16.2

DMF 0.020 0.2 3.6

TC 1.067 10.67 192.06

Soda Ash 0.005 0.05 0.9

Caustic Lye 48 % 3.315 33.15 596.7

Catalyst 0.010 0.1 1.8

n-Hexane(Recovered)

8.912 89.12 1604.16

n-Hexane (Fresh) 0.228 2.28 41.04

IB (Recovered) 0.137 1.37 24.66

IB (Fresh) 0.457 4.57 82.26



TEA (Fresh) 0.01 0.1 1.8

TEA (Recovered) 0.824 8.24 148.32

Sulphuric Acid 1.199 11.99 215.82

DMF 0.010 0.1 1.8

Thionyl Chloride 0.606 6.06 109.08

Total 21.073 210.73 3793.14

Cypermethrin Sodium Cyanide 0.140 0.7 14

Catalyst 0.013 0.065 1.3

Soda Ash 0.013 0.065 1.3

CMAC 0.584 2.92 58.4

MPB 0.483 2.415 48.3

n-Hexane(Recovered)

2.037 10.185 203.7

n-Hexane (Fresh) 0.063 0.315 6.3

Sodium HypoChloride

0.830 4.15 83

Total 4.163 20.815 416.3

Permethrin Cypermethric acidchloride

0.62 3.1 3.1

m-Phenoxybenzyl alcohol

0.52 2.6 2.6

PotassiumCarbonate

0.015 0.075 0.075

Total 1.155 5.775 5.775Alpha Methrin Sodium Cyanide 0.230 1.15 13.8

Catalyst 0.020 0.1 1.2

Soda Ash 0.020 0.1 1.2

CMAC 0.900 4.5 54

MPB 0.720 3.6 43.2Sodium Hypo

Chloride1.500

7.5 90Tri-ethyl Amine

(Fresh)0.056

0.28 3.36Tri ethyl Amine

(Recovered)0.644

3.22 38.64n- Hexane

(Recovered)7.661

38.305 459.66n-Hexane (Fresh) 0.319 1.595 19.14

Total 12.07 60.35 724.2



Water and Waste Water Management

Total Raw Water requirement is 230.96 kl/day (Fresh: 217.09 kl/day + condensate fromMEE 13.87 kl/day) supply will be met from GIDC water supply dept. Copy of GIDC watersupply is enclosed herewith.

Total industrial Waste Water Generation is 89.03 KL/Day. Domestic waste water (12 KL/day) will be disposed off through Septic Tank.

Air Emission and its Control Measures

Flue gas emission: At present, the unit is having one number of 3 TPH steam boiler. The company shall install

additional one number of Steam Boiler having capacity 3 TPH. Natural Gas/furnace oil willbe used as fuel.

At present, the unit is having one number of 750 KVA of D G set (standby). The companyshall install additional 500 KVA capacity of D.G. Set, as stand by. It will be used onlyduring power failure.

Adequate stack height and stack monitoring facilities will be provided.

Process gas emission: Presently the unit has installed two numbers of two stage water scrubber followed by alkali

scrubber to scrub HCl & SO2 gas generated from the process. After proposed expansion,the unit shall install additional two numbers of two stage water followed by alkali scrubbersto scrub HCl & SO2 gas generated from the process. Adequate height of process vent willbe provided. .(Detail of Air pollution control measures is attached as Annexure-10)

Hazardous Wastes and its Management

Sr.No.

Type ofhazardous

waste

Category

Quantity, TPA Place ofStorage

Disposal

Existing Afterproposedexpansion

1 Waste from ETP 34.3 40 80 HDPEbags

Disposed offinto TSDF,

Vapi2 Used oil 5.1 0.06 1.5 Drum Sold to

registered re-refiner

3 Discardedcontainers

33.3 10.0 20.0 Pallets/drums

Sold toauthorized

recycler4 Salt from MEE 34.3 42 1116 HDPE

BagsDisposed offinto TSDF,

Vapi5 Process residue 26.1 13.56 244.08 HDPE

drumsSent for co-

processing tocement

industries orsent to SEPPL,Kutch or sent



to proposedIncinerator tobe installed at

HIL:I6 Concentrated

effluent sent toTEE of HIL

(Unit: I)

34.3 1083.6 6894 Bytanker

To MEE ofHIL Unit: I

7 AmmoniumChloride Powder

(85%)

Sch:IIB30

60.96 1097.28 HDPEbags

Sold to actualusers as a by-

product8 Sodium Sulphite

Powder (80%)Sch:

II C13268.8 4838.4 HDPE

bagsSold to actualusers as a by-

product9 Hydro Chloric

Acid solution(30%)

Sch:IID2

225.18 3713.58 Tanker Sold to actualusers as a by-

product10 Sodium

Sulphate powder(80%)

Sch:II C13

206.64 3719.5 HDPEbags


product11 Recovered

Solvent20.2 160 2479 Tanker Recycled in

process



2. Introduction of Project / Back Ground Information :(i) Introduction of the Project and the Proponent.

Name of the project Proponent: Heranba Industries Limited (Unit: II).

Heranba Industries Limited (Unit: II) is a medium scale unit is located in notifiedindustrial estate, GIDC, Vapi Di: Valsad, Gujarat having total plot area of 3584.8 m2

& total investment after proposed expansion will be Rs. 2900 lacs. The proponentwishes to expand the existing production capacity. The pesticides products areespecially used in agriculture as insecticides, fungicides & herbicides.

The unit is operated by technocrats having more than 30 years of experience inmanufacturing and marketing of various pesticides worldwide.The company has established well equipped production plant which is being managedby dedicated, qualified & skilled persons.

The proposed expansion proposes to expand the capacity of pesticides with totalcapacity of 345.0 MT per month and process capabilities to manufacture all types ofPesticides.

The proposed expansion project site lies on 20022’20.77” N Latitude & 72056’55.16” ELongitude. Heranba Industries Limited (Unit: II) is located at Plot. No. A2/2214 &2215 ,3rd phase area, GIDC Vapi, Di: Valsad district in Gujarat state. GIDC Vapi iscentrally located in the both sides of National Highway No. 8 connecting Mumbai andAhmedabad and is surrounded by Union territories of Daman on the western side andDadra & Nagar Haveli on the eastern side. The western Railway Main Line passesthrough the area (Double & Electrified). Vapi is the biggest railway station in the studyarea; where, almost all the important mail & express trains stop. Entire study area iswell connected with other major cities of the state and the country.

Beside the rail connectivity, the site is also well connected by road transport. There is agood network of roads in the area and contributes for the development and economicgrowth of the area. The National Highway No. 8 (Surat – Mumbai) is now a six laned,double tracked, more elevated and Jam free highway, developed by 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) whichis crosses the NH – 8 in Vapi town. Almost every village in the district is now wellconnected to each other by a Pucca road.

About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat –Maharashtra border. Administratively, it is a part of Valsad district. After theestablishment of GIDC estate, Vapi has gained a special status on the industrial map ofthe country mainly for chemical industrial units. Over the years, it has emerged as amajor cosmopolitan industrial township equipped with hospitals. school, colleges,community centers, temples, churches, mosques, cinema house, fire stations, bloodbanks, water filtration plants, police stations, post offices, banks, telephone exchangeshotels, guesthouses etc. The town has got a major face-lift after the completion ofnational highway and other links roads are of good standard. Mumbai, the economiccapital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is370 kms. The district Head Quarter – Valsad is 30 km from Vapi town.



VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during1967-1968. The entire estate, which was developed in phases, is now spread over 1140hectares and houses more than 1400 industries, most of which are small-scale industrialunits although some have grown bigger units at later stages. The industrial township isbasically a declared “Chemical Estate” where about 705 of the industrial units are eitherChemical or Chemical related, such as, Dyes and Dyes intermediates, pigmentspesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of papermills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. Oneof the country’s largest common effluent treatment plants has been setup in Vapiindustrial estate. Being a major industrial & commercial centre, it caters to otherperipheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra andNagar Haveli, etc.

HERANBA INDUSTRIES LIMITED, (HIL) was incorporated in 1992 and isengaged in the business of manufacturing and marketing agrochemicals especiallypesticides and their intermediates since 1995. The company has its corporate office at101/102, Kanchanganga, Factory Lane, Borivali (West), Mumbai – 400 092 andManufacturing unit at Plot No. 1505/1506 & A2/2214 & 2215, 3rd phase, GIDC, VapiDist, Valsad, Gujarat.

(i)(i) IdeIdentification of the project proponent(ii)

The Company is managed by the promoters and whole time Directors Mr. Sadashiv K.Shetty and Mr. Raghuram K. Shetty who are ably assisted by Directors Ms. Sujata S.Shetty – Post Graduate in Commerce with diploma in Finance Management and Ms.Vanita R. Shetty – Graduate in Science with specialization in Chemistry.

BACKGROUND OF PROMOTERS

Mr. SadashivK. Shetty

Post Graduate in Chemistry, is a technocrat with over twodecades of experience and expertise in operating chemicalplant and effectively running chemical business, now leadingthe team of HIL Mr. Raghuram K. Shetty ably supports him.

He had built up his career in renowned companies likeHoechst India Ltd., Gharda Chemicals Ltd and SudharshanChemical Ltd at various levels of operation of chemical plant.

Mr. RaghuramK. Shetty

Graduate in Economics with post graduation in Commerce, aprofessional with over two decades of experience in theadministrative and financial matters is the Executive Directorof the company.

Mrs. Sujata S.Shetty

Post Graduate in Commerce with Diploma in FinanceManagement.

Mrs. Vanita R.Shetty

Graduate in Science with Specialization in Chemistry.



(ii) Brief description of nature of the Project :

Heranba Industries Limited (Unit: II) proposes the expansion of their productioncapacity at Plot No. A-2/2214 & 2215, 3rd phase, GIDC, Vapi-396195, Dist.- Valsad(Gujarat).

The proposed expansion project involves in the production of “pesticide &intermediates”. As per the amended EIA notification- 2006, the proposed products arecovered under category 5(b)- A and hence require Prior Environmental Clearance.

For the proposed project, the company intends to procure the latest technology formanufacturing the products.

(iii) Need for the project and its importance to the country and region :

The proposed project provides a potential growth opportunity for the already runningbusiness of the company. The company is engaged in the business of manufacturing ofPesticides & intermediates. The project would increase the overall export and alsoincrease the foreign revenue. Products are now well established and acceptable in theinternational markets.

Additional capacities of product range required over & above our existing capacities, asthe company expects growth of exports to the extent of 40-50%. Local market is alsoshowing strong growth potential.

(iv) Demand –Supply Gap :

The products have very high specific demand as they are especially used in agricultureas insecticides, fungicides & herbicides.

(v) Imports vs. Indigenous production :

Existing products manufactured in the country will be very much economical comparedto imports of the same and also the export of the same will earn extra revenue generationfor our county.

(vi) Export Possibility :

Existing products have high export potential. Also these products have very goodpotential in the local market.

Additional capacities of product range required over & above the unit’s existingcapacities, as the company expects strong growth of exports to the extent of 40-50%.Local market also shows strong growth potential.

(vii) Domestic / export Markets :

The company’s products are used in agriculture as an insecticides, fungicides &herbicides. These are having very good demand in domestic as well as internationalmarkets.



(viii) Employment Generation (Direct and Indirect) due to the project :

There will be very good opportunity of employment generation directly and indirectlydue to proposed expansion project. Due to proposed project there will be requirement ofmanager, supervisor, operator and semi-skilled workers. For this, the company willemploy about additional 30 people to fulfill it’s need to handle the plant. So that 30people will be directly employed and more than 50 will be indirectly employed.



3 Project Description :

(i) Type of Project including interlinked and interdependent projects, If any :

The proposed project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary & projectsite layout) with coordinates :

The map showing general location, specific location and project boundary and projectsite lay out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularlythe environmental considerations gone into should be highlighted :

The proposed activity will be accommodated in the notified industrial area havingproper industrial infrastructure so; there is no alternate site consideration. Proposedexpansion will be carried out in exiting premises only. (Land allotment letter isattached as Annexure-8)

(iv) Size or magnitude of operation :

As per the proposed project cost, the project is covered under Medium Scale category ofmanufacturing industries.

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

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

(vi) Raw material required along with estimated quantity, likely source, marketing area of finalproducts/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 Dispatch Means ofTransportation

1 Cyper methric AcidChloride

Liquid In MS HDPEdrums

Truck orContainer

2 Alpha Methrin Powder( solid)

25 kg fibre boarddrum

Truck orContainer

3 Cyper Methrin Viscours liquid 200 kg ms drum Truck orContainer

4 Permethrin Viscours liquid 200 kg ms drum Truck

By-product

1 Ammonium ChloridePowder (85%)

Solid 25 kg or 50 kgbags

Truck



2 Sodium Sulphite Powder(80%)

Solid 50 kg bags Truck

3 Hydro Chloric Acidsolution (30%)

Liquid Captive use Truck

4 Sodium Sulphate powder(80%)

Solid 25 kg or 50 kgbags

Truck

DETAILS ON RAW MATERIAL TRANSPORTATION

Sr.No.

Substance PhysicalState

Source ofSupply

Means ofTransport

ation

Distance ofsupplier

fromproject site

(km)1 Acrylo nitrile Liquid RIL Baroda) Tanker 2502 Carbon Tetra

chlorideLiquid GACL (Baroda) Tanker 250

3 Catalyst Solid Sahajanand chemindustries

( Ahmedabad)

Truck 400

4 DEA-HCl Solid Alkyl amines(Pune)

Truck 300

5 HCl 30 % Liquid Shree omchemicals (Vapi)

Tanker 07

6 DMF Liquid Khodiyarchemicals( mumbai)

Truck 150

7 ThionylChloride

Liquid Transpek ind(baroda)

Tanker 250

8 Soda Ash Solid Smp chemicals,(vapi)

Truck 07

9 Caustic Lye48 %

Liquid GFCL ( Dahej) Tanker 180

10 n-Hexane Liquid BPCL( mumbai) Tanker 15011 IB Gas & liquid

underpaessure

Savla chemicals( ankleshwar)

Tanker isotank

150

12 TEA Liquid Alkyl amines(Pune)

Truck 300

13 SulphuricAcid

Liquid Shree omchemicals (vapi

Tanker 07

14 SodiumCyanide

Liquid GACL (Baroda) Truck 250

15 MPB Liquid BRL( Dahej) Drum intruck

180

16 Sodium HypoChloride

Liquid Shree omchemicals (Vapi

Tanker 07

17 m-Phenoxybenzylalcohol

Liquid Kanoria chemicalAnkleshwar

Drum intruck

200



18 PotassiumCarbonate

Solid M.J.Croporation(Vapi)

Truck 10

19 Tri-ethylAmine

Liquid Alkyl amines(Pune)

Drums 300

(vii) Resource optimization/ recycling and reuse envisaged in the project , if any , should brieflyoutlined :

Resource optimization/recycling and reuse envisaged in the project (solvent recoverysystem) in detail are as mentioned below.

The raw materials will be stored in closed containers and will be handled throughclosed system to avoid the handling losses.

The solvents are reused in the manufacturing of pesticides. Details of solvent use &recovery are as under.

PRODUCT WISE SOLVENT USED/RECOVERED PER TONE OF PRODUCTFOR EXISTING & PROPOSED EXPANSION

Product Afterproposed

ExpansionTPM

Name of RM RM consumption in MTPer ton ofproduct

Per monthExisting After

ProposedExpansion

Cypermethricacid Chloride

180.0 n-Hexane(Recovered)

8.912 89.12 1604.16

n-Hexane(Fresh)

0.228 2.28 41.04

IB (Recovered) 0.137 1.37 24.66IB (Fresh) 0.457 4.57 82.26

TEA (Fresh) 0.01 0.1 1.8TEA

(Recovered)0.824 8.24 148.32

Cypermethrin 100.0 n-Hexane(Recovered)

2.037 10.185 203.7

n-Hexane(Fresh)

0.063 0.315 6.3

Alphamethrin 60.0 Tri-ethylAmine (Fresh)

0.056 0.28 5.6

Tri ethylAmine

(Recovered)

0.644 3.22 38.64

n- Hexane(Recovered)

7.661 38.305 459.66

n-Hexane(Fresh)

0.319 1.595 19.14



OVERALL SOLVENT BALANCE AFTER PROPOSED EXPANSION

Sr.No.

Solventused

TotalSolvent

used, MT/M

SolventRecovery &

reuse, MT/M

Solventloss/with

residue/asreactant,MT/M

%recove

ry

Remarks

1 n- Hexane 2334.0 2267.52 66.48 97.152 Iso

Butylene106.92 24.66 82.26 23.06 As

reactant

3 TEA 194.36 186.96 7.4 96.192635.28 2479.14 156.14

(viii) Availability of water its source, Energy/power requirement and source should be given :

Availability of water its source, Energy/power required and its source is below. Waterwithdrawal Permission is attached as Annexure: 4

WATER CONSUMPTION (m3/DAY)

Sr.No.

Particulars Existing Proposed AfterProposedexpansion

1 Domestic 5.0 10.0 15.02 Processing , washing &

scrubber20.6 85.36 105.96

3 Cooling 15.0 25.0 40.04 Boiler 30.0 20.0 50.05 Floor/equipment/container

washing10.0 4.0 14.0

6 Gardening 4.0 2.0 6.07 Total 84.6 146.36 230.968 Total industrial 75.6 133.46 209.069 Condensate from MEE

recycle1.8 12.07 13.87

10 Net fresh water 82.8 134.29 217.09



WATER BALANCE DIAGRAM AFTER PROPOSED EXPANSION)

TOTAL WATER CONSUMPTION: 230.96 3M3/Day (Fresh: 217.09+ Recycle from MEE: 13.87 M3/Day

DOMESTIC:15 M3/Day

PROCESS, WASHING& SCRUBBER :105.96 M3/Day

COOLING:40 M3/Day

SEPTIC TANK/SOAK PIT

61.18 M3/Day

PRIMARY, SECONDARY & TERTIARY TREATMENT UNITS

CETP, VAPI

BOILER:50 M3/Day

FLOOR &CONTAINERWASHING: 14 M3/Day

GARDENING& OTHERS:6 M3/Day

10 M3/Day 20 M3/Day 14 M3/Day

Norma stream:42.03M3/Day 89.03 M3/Day

MEE

TIDAL ZONE OF RIVER DAMANGANGA TO ARABIAN SEA

High TDSStream: 19.15

Salt: 3.44 MTTSDF

13.87 M3/dayCondensate recycle

3 M3/Day

Loss:1.84

ENERGY REQUIREMENTS AND ITS SOURCE

Sr.No.

Particulars Existing Proposed Source

1 Steamrequirement

3000kg/Hr

6000 Kg/Hr. Will be obtained by installation ofBoiler havingsteam generation capacity of 3 TPH

x 2 nos

POWER REQUIREMENTS AND ITS SOURCE

Sr.No.

Particulars Existing Proposed Source

1 Power – Electricity requirement 600 KVA 1250 KVA Will besourced from

DakshinGujarat Vij

Co. Ltd.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for theirManagement/disposal :

(x)

Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal is enclosed as Annexure-5.Schematic representations of the feasibility drawing which give information of EIApurpose:

A schematic representation of the feasibility drawing is enclosed as Annexure -9.



4. Site Analysis(i) Connectivity :

The project is located in notified Industrial Estate of Vapi which is very well connectedto National Highway no.8 and Western Railways. The nearest airport is Mumbai whichis 150 KM away from the project site by road.

(ii) Land Form, Land use and Land ownership :

The land is in the form of industrial shed owned by Gujarat Industrial DevelopmentCorporation.

(iii) Topography (along with map) :

Topography map showing the elevation of the study area below. The topographical mapis enclosed as Annexure-7.

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

The existing land is located in the notified industrial area and a copy of gazettenotification is enclosed as Annexure-8

(v) Existing Infrastructure :

GIDC notified industrial area of Vapi has available infrastructure like water, electricity,roads, rail, transportation, availability of raw material and drainage system.

(vi) Soil classification :

General soil classification of the area is as under :

Soil Characteristics & Land use classification: The study area is located atouter part of Dadra. Northern part of the site is fully developed for settlementwith cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.

The project site around 10 km radius has mixed soil type of Basalt soil and Claysoil. This type of soil is not suitable for cultivation purpose.

The land is suitable for industrial development.

Damanganga River is located at 3 km distance from the site location; both side of theriver has mixed soil type (Sand, clay & Basaltic soil).

(vii) Climate data from secondary sources :

Rainfall Data :

The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy dayshaving coefficient of variation of 65 %. There is large spatial and temporal variation inrainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall arecomprised of Kutch district and western parts of Banaskantha and Patan districts and



parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized byarid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad,Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as subhumid climate. The remaining part of the state receives rainfall between 500-1000 mmand generally falls under semi-arid climate. Considering the abnormality of weatherparticularly rainfall during the monsoon period, the observed and predicted rainfall wasthen analyzed for its validity.

Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

Sr.

No

Region RainfallProjection

(in mm) June -Oct

Normal Rainfall(In mm)

Rainfall Projection

(% Departure fromnormal)

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 is located in the southern part of Gujarat. The secondary data was collected fromfree data of Worldclim.org for the year 2010. The project site temperature regime formedium to high level temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available :

Social Infrastructure in Valsad district is as under :

Education: There are 990 primary, 161 secondary and higher secondary schools.

There are 6 ITIs offering several industrial training Institutes programs which includes,fitting, armature & motor rewinding, electrician, information technology and electronicsystem maintenance etc., 166 Higher Secondary School, One Government polytechnicCollege is present in the district offering courses in civil, chemical, electrical,mechanical and plastic engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nosof Polytechnic College With 120 seats, there is one Engineering College, PharmacyCollege, Arts, Commerce, Science, B. Ed and Law College. Valsad district also hasinstitutes which offers management studies with fulltime MBA.

Source: Department of Education, 2007

1. Health: There are 43 primary healthcare centres, 10 community healthcarecentres, 10 Government and 1 Municipal hospital present in the district. Valsad hasseveral private specialized hospitals to provide a comprehensive range of tertiary andsecondary care services backed by state-of-the-art technology and trained medicos. A



multi-specialty Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi,providing services in general and laproscopic surgery, trauma, orthopedic and urologyetc. The hospital is one of the few centers in India offering Uterine ThermochoiceThermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Besidethis, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital andAdarsh Hospital are also present in Valsad.

2.

3. Tourism: The Tourism department built the Fire Temple at Udawada in 1742,which is also known Fire Temple for the Parsi community in India, makes the city afamous pilgrimage center throughout the world. Dharampur is surrounded on three sidesby the Sahyadri Mountains which grace the town with pleasant climate throughout theyear. The collection at the Lady Wilson Museum in Dharampur includes tribal art and artcrafts that highlights the local culture. Besides this, District Science Centre is alsopresent in Valsad Proximity of Valsad with Daman & Diu, which has increased thegraph of tourist flow in the district.



5. Planning Brief :

(i) Planning Concept (Type of industries, facilities, transportation, etc.) Town and CountryPlanning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries,engaged in the manufacture of variety of products like pharmaceuticals, dyes andchemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals,pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notifiedarea of Vapi.

(ii) Population Projection :

Not applicable

(iii) Land use Planning (breakup along with green belt etc) :

The existing as well as proposed expansion project is located within the NotifiedIndustrial Area by Government of Gujarat and due to the proposed project there will notbe any change in the land use pattern of the region. Proposed Green belt planning in theproject area is as below.

For Green Belt Development as per the revised layout plan, the company proposes 33%green belt of the total land, i.e. 3584.8 sq. meter. The company shall develop green beltalong the periphery of the proposed site and in common premises available outside thecompany premises.

While selecting the plants species to be grown in the green belt zone, following pointswill be taken into account:

1. Climatic condition and soil characteristics of the region.2. The air pollution emitted by the industry – gaseous and particulate matter. Plant

interaction with both gaseous and particulate pollutants and to a great extentabsorbs them and thus, removes them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary foreffective absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal.5. For absorbance of gases, the duration of the foliage should be longer.6. Vegetation controls soil erosion rates significantly. The decrease of water erosion

rates with increasing vegetation cover is exponential. This review reveals that thedecrease in water erosion rates with increasing root mass is also exponential.Plant species having good root system are selected, so that soil erosion can bechecked.



Site Plan with Area Table at Existing & After proposed expansion

Sr. No Particulars Area in m2

Existing Proposed Total afterexpansion

1.0 Total plot Area 3584.8 0 3584.8

1.1 Production Plant 120.54 361.62 482.161.2 Office & lab area 197 0 197

1.3 OHC Area 6.45 0 6.45

1.4 Green Belt 800 385 11851.5 Raw materials & other Storage 96.95 0 96.951.6 Solvent storage area 40.0 35.55 75.551.7 Utility 250 267 5171.8 Boiler shed area 83.20 0 83.201.9 ETP & solid waste storage area 150 100 250

1.10 Toilet block 17.70 0 17.701.11 Open space 1822.96 -1149.17 673.79



Site map with Green Belt Development Planning



(iv) Assessment of Infrastructure demand ( Physical & Social) :

There is no need for any infrastructure demand in terms of physical or social needs forthe proposed expansion.

(v) Amenities/ Facilities :

GIDC notified industrial area of Vapi has the available infrastructure like water,electricity, roads, rail, transportation, availability of raw material and drainage system.



6. Proposed Infrastructure :

(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standardengineering design considering all the relevant parameters related to environment, healthand safety.

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project

(iii) Green Belt :

Green belt will be provided and maintained at the tune of 33% of the total land area.

(iv) Social Infrastructure :

Not applicable

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

The project site is very well connected by road through National Highway no. 8, westernrailways.

(vi) Drinking Water management ( Source & Supply of water ) :

Source of water is from GIDC water supply services.

(vii) Sewerage System :

GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management :

Industrial liquid effluent generated during the manufacturing of proposed productswill be segregated, concentrated effluent will be treated in MEE & normal effluentwill be treated in the primary, secondary & tertiary ETP and will be dischargedthrough GIDC underground drainage to CETP.(Membership certificate is attached asAnnexure-6)

Generated domestic liquid waste is being disposed off through soak pit system todrainage.

(ix) Solid/Hazardous Waste Management :

Sr.No.

Type ofhazardous

waste

Category Quantity, TPA Place ofStorage

Disposal








Sold toauthorized

recycler



4 Salt from MEE 34.3 42 1116 HDPEBags



drumsSent for co-

processing tocement

industries orsent to

SEPPL, Kutchor sent to

incinerator tobe installed at

HIL:I6 Concentrated


(Unit: I)

34.3 1083.6 6894 By tanker To MEE ofHIL Unit: I

7 AmmoniumChloride

Powder (85%)

Sch:IIB30

60.96 1097.28 HDPEbags



Powder (80%)Sch: II

C13268.8 4838.4 HDPE



Acid solution(30%)

Sch:II D2 225.18 3713.58 Tanker Sold to actualusers as a by-

product10 Sodium


Sch: IIC13

206.64 3719.5 HDPEbags


product11 Recovered


process(Membership certificate is attached as Annexure-6)

(x) Power Requirement & Supply / Source :

Power requirement for proposed project will be taken from DGVCL.

7. Rehabilitation and Resettlement (R&R) Plan:(i) Policy to be adopted (Central/ State) in respect of the project affected persons including

home oustees, land oustees and landless laborers (a brief outline to be given):

There will be no rehabilitation and resettlement undertaken as labours and workers fromlocal & nearby areas for the proposed construction activity which will be minor as theproposed expansion activity is to be undertaken at the existing site.

8. Project Schedule & Cost Estimates :

(i) Likely date of start of construction and likely date of completion ( Time schedule for theproject to be given ) :

After obtaining Environmental clearance and Consent to Establish from GPCB, thecompany shall start the proposed construction and commissioning of the project.



(ii) 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 theproject is given as below.

CAPITAL COST PROJECTION

Cost in INR (Crore)Sr.No.

Particulars Existing Proposed Total

1.0 Land 3584.8 m2 4.0 0 4.0

2.0 Building 2.0 2.0 4.03.0 Plant & Machinery3.1 Equipment & machineries 2.0 4.0 6.03.2 Pipes & fittings 1.0 2.0 3.03.3 Utilities 1.0 5.0 6.04.0 Environmental Management

System2.0 4.0 6.0

5.0 Total Project Cost 12.0 17.0 29.06.0 Utilities6.1 Boiler, TPH 3 3 3 + 36.2 Cooling Tower, TR 100 300 4006.3 D.G. Set (Standby) 750 500 750+ 5007.0 Power from DGVCL, KVA 600 650 12508.0 Fuel8.1 FO, kl/d or Natural gas, SCM/day 2.5 or 2500 2.5 or 2500 5.0 OR

50008.2 HSD, kgs/hr 75 50 1259.0 Water from GIDC Vapi 84.6 146.36 230.9610.0 Waste Water (Industrial) 42.99 46.04 89.03

PROJECT VIABILITY

Sr.No.

PARTICULARS AMOUNT (INR Crore)

1 Proposed Sale 2352 Raw Material Cost 1403 Power & Fuel 204 Labor Cost 105 Environmental Management System 206 Maintenance Cost 107 Selling, packing & Office Expenses 108 Proposed Profit 25

The company will provide budgetary provision for the recurring expenses forenvironmental issues while planning the allocation of funds during the annual budgetaryplanning.



RECURRING COST PER ANNUM

Sr. No. ComponentProposed(Rs. in Lacs/annum)

1. Environment & Safety Management System 30

2. Greenbelt Maintenance 2.5

3. Solid waste Disposal 55

Total 87.5

9. Analysis of Proposal ( Final Recommendations):

(i) Financial and social benefits with special emphasis on the befit to the local people includingtribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms offinancial 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 improving education and health facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius



Prefeasibility Report-Annexure Heranba Industries Limited (Unit; II).

Expansion Project: 30 Manufacturing : Pesticides & intermediates

ANNEXURE: 2

Plant Layout



ANNEXURE: 3

Detailed project description with process details - MANUFACTURING PROCESSThe company is using the latest available process technology for the production. This chapter includes themanufacturing process of the product, chemical reactions, and material mass balance & mole balance for theproduct.

(1.0) Process of Cyper methric Acid Chloride:

Stage -1:- Preparation of tetra Chloro Butyro Nitrite (TBN)

Reaction of Carbon Tetra Chloride with Acrylonitrile at 100°Cto 125°C in present of cupric chloride catalyst,DEA HCI as a buffer and Acetonitrile as solvent gives Tetra Chloro Butyro Nitrile (TBN (.Excess CTC andAcetonitrile is removed by distillation. In water wash cupric chloride DEA HCI is removed.

Stage - 2:- Preparation of tetra Chloro jiutvic Acid. (TBA)

Acid hydrolysis of crude TBN using 30 % HCI solution gives tetra Chloro Butyic Acid (TBA). Afterreaction TBA is separated from bottom and dehydrated up to moisture contain level of 0.1 %.

Stage - 3:- Preparation of tetra Chloro Butyric Acid Chloride (TBAC)

Reaction of TBA with Thionyl Chloride in presence of Dimethyl Formamide at 60°C gives tetraChloroButyric Acid Chloride (TBAC), During reaction SO2 and HCI gas is evolved which is scrubbed inscrubber. Crude TBAC is further distilled under high vacuum. The purity of Distilled TBAC is 98 %.

Stage-4:- Preparation of 2 - ChlorqCycIo Butanone Derivative ( 2 CB )

TBAC is reacted with Jsobutylene in presence of Tri Ethyl Amine (TEA) at 70°C under 5.0 Kg/cm2 pressure,n-Hexane is used as solvent. After reaction excess Isobutylene is recovered. The whole mass is washed withwater to remove TEA. The organic mass is neutralized with Sodium bi carbonate and organic mass istransferred for further process.

Stage - 5:- Preparation of Sodium Salt of Cypermerhric Acid (Na-CMA)

2 CB is isomerised to 4 CB in presence of catalyst and then directly reacted with caustic lye solution whichgives Na-CMA.

Stage - 6:- Preparation of Cypermerhric Acid (CMA)

Na- CMA is acidified with dilute Sulphuric Acid at room temperature. CMA is extracted in n-Hexane.Aqueous layer (sodium sulphate + sodium chloride + organic impurities) is drain to ETP

Stage - 7:- Preparation of Cypenmerhric Acid Chloride (CMAC)

Reaction of CMA with Thionyl Chloride in presence of Dimethyl Formamide at 60X gives CypermethricAcid Chloride (CMAC). During reaction SO,, and HCI gas is evolved which is scrubbed in scrubber. CrudeCMAC is further distilled under high vacuum. The purity of Distilled CMAC is 98 %.



Chemical reaction of Cyper methric Acid Chloride:

Stage - 1 Cl

CCl4 CH2 CH CN CCl3 CH2 CH CN154 53 207CTC Acrylonitrile Tetra Chloro Butyronitrile

Stage - 2

Cl Cl

CCl3 CH2 CH CN 2H2O + HCl CCl3 CH2 CH COOH NH4Cl207 18 36.5 226 53.5

Tetra Chloro Butyronitrile Water HydrochloricAcid

Tetra Chloro Butyric Acid Ammonium Chloride

Stage - 3

Cl Cl

CCl3 CH2 CH COOH SOCl2 CCl3 CH2 CH COCl SO2 + HCl226 119 244.5 64 36.5

Tetra Chloro Butyric Acid Thyonil Chloride Tetra Chloro Butyric Acid Chloride Sulphur Dioxide

Hydrochloric Acid

Stage - 4

Cl ClH3C

CCl3 CH2 CH COCl C CH2 CCl3 CH2 C C O + HClH3C

H3C C CH2

H3C244.5 56

264 36.5Tetra Chloro Butyric Acid Chloride Isobutylene 2 - Chloro Cyclobutanone Derivat ive Hydrochloric

Acid

Preperation of Tetra Chloro Butyronitrile TBN

Preperation of Tetra Chloro Butyric Acid

Preperation of Tetra Chloro Butyric Acid Chloride

Preperation of 2 - Chloro Cyclobutanone Derivative



Stage - 5

Cl

CCl3 CH2 C C O CCl3 CH2 CH C O

H3C C CH2 H3C C CH Cl

H3C H3C264 264

2 - Chloro Cyclobutanone Derivat ive 4 - Chloro Cyclobutanone Derivat ive

Stage -6

CCl3 CH2 CH C O + 2 NaO H CCl3 CH2 CH CH C OONa + NaClC

H3C C CH Cl H3C CH3

H3C264 80 267.5 58.5

4 - Chloro Cyclobutanone Derivat ive Sodium Hydroxide Sodium Salt of Saturated Cypermethric Acid Sodium Chloride

Stage -7

CCl3 CH2 CH CH C OONa + NaOH CCl2 CH CH CH C OONa + NaClC C

H3C CH3 H3C CH3

267.5 40 231 58.5

Sodium Salt of Saturated Cypermethric Acid Sodium Hydroxide Sodium Salt of Cypermethric Acid Sodium Chloride

Preperation of Sodium Salt of Saturated Cypermethric Acid

Preperation of Sodium Salt of Cypermethric Acid

Preperation of 4 - Chloro Cyclobutanone Derivative

Stage - 8

CCl2 CH CH CH C OONa + 1/2 H2SO4 CCl2 CH CH CH C OOH 1/2 Na2SO4C C

H3C CH3 H3C CH371

231 49 209Sodium Sulphate

Sodium Salt of Cypermethric AcidSulphuric Acid

Sodium Salt of Cypermethric Acid

Stage - 9

CCl2 CH CH CH C OOH + SOCl2 CCl2 CH CH CH C OCl + SO2 + HClC C

H3C CH3 H3C CH3

209 119 227.5 64 36.5Sodium Salt of Cypermethric Acid Thyonil Chloride Cypermethric Acid chloride Sulphur Di oxide

HydrochloricAcid

Preperation of Cypermethric Acid

Preperation of Cypermethric Acid Chloride



Mass Balance of Cyper methric Acid Chloride:

Forcut 380Acrylonytrile 500CTC 1550 22 Evaporattion LossAcetonytrile 22 380 Forcut recoveryCatalyst 10 328 Waste Water to ETPDEA-HCl 11Water 230 730

27031973

30 % HCl 1800 1753 29 % AmmoniumWater 333 Chloride Solution

4106

2353Water 281 837 Waste WaterWater from 2 CB 610 To ETP

32442407

DMF 20 286 Distilled Water recycle stage 2ATC 1067 174 Evaporation LossWater for HCl 763 5058 22.3 % Na2SO3Caustic Lye 48 % 1495 1090 30 % HCl recycle in stage 2Water for Scrubber 2989 68 Organic Residue

8741 66762065

n- Hexane 5140IB 594 137 IB Recivered 824 TEA recoveredTEA 824 300 Evaporation LossWater for TEA HCl 500 1622 TEA-HCl +764 C.S. lye Soda Ash 5 4840 n-Hexane RecoveryWater for Soda Ash 505 610 Soda Wash Aq.

9633 7509 1562 aq. Mass to MEE

Catalyst 10 2124TEA 10n-Hexane 1000 1405 n-HexaneCaustic 100 % 971Water 5141

92567851

Sulphuric Acid 1199Water 514 8519 (6889 (20%) Sodium Sulphate soln.)n-Hexane 3000 (1630 sent to MEE)

125644045

DMF 10 2667 n- Hexane RecoveryTC 606 2976 22.3 % Na2SO3 Soln.Ct. Lye 48% 849 620 30 % HCl recycle in stage 2Water for scrubber 1697 333 Evaporation LossWater for HCl 434

7641 1045 6596

45 Organic Residue

Process Flow Diagram of (Cypermethric Acid Chloride)

Stage : 1TBN

Stage : 2

CMA

1000 KG CMAC

2 CB

CMAC

CMAC Distillation

Stage : 7

TBA Washing

Stage : 3TBAC

Stage : 4

TBA

Stage : 2A

Na-CMAStage : 5

Stage : 6



(2.0) Process of Cyper Methrin technical:

Solution of CMAC (in – house manufacture as well as procured from the market) and Meta PhenoxyBenzaldehyde ( MPBD) reacts with solution of Sodium Cyanide in water in presence of phasetransfer catalyst at 20°C to 30°C to give Cypermethrin. After reaction, water and Cyanide layer isseparated. This layer is treated with Sodium Hypo chloride to destroy Sodium Cyanide .The organicmass is washed with water to remove impurities. The obtain purity of Cypermethrin is minimum 92%.

Chemical reaction of Cyper Methrin technical

O

CCl2 CH2 CH CH COCl OHC NaCN

CH3C CH3

227.5 198 49 Cypermethric Acid chloride

M eta Phenoxy Benzaldehyde Sodium Cyanide

Catalyst

O CN O

CCl2 CH2 CH CH C O CH NaCl

CH3C CH3

416 58.5

Cypermethrin Sodium Chloride

Detoxification of Cyanide by Hypo

NaCN NaOCl NaOCN NaCl49 74.5 65 58.5

Sodium Cyanide Sodium Hypo Chloride Sodium Cynate Sodium Chloride

2 NaOCN 3 NaOCl NaCl N2 NaHCO3

65 74.5 58.5 28 84

Sodium Cynate Sodium Hypo Chloride Sodium Chloride Nitrogen Sodium Bicarbonate



Mass balance of Cypermethrin technical

Hypo ChlorideSodium Cyanide 140 830 KgsWater 600Catalyst 13 1654 KgsSoda Ash 13 824 Waste WaterCMAC 584 Cyanide LayerMPB 483n-Hexane 2100

39333109 Organic mass ( N-Hexane + Cyper)

Water 600 5 Evaporation Loss618 Waste Water


Water 10005 Evaporation Loss

1030 Waste Water


14 Evaporation Loss2037 R . N-Hexane

1000 KgsCypermethrin

Stage - 1Cyper Reaction

Stage - 4n-Hexaqne recovery &

Final Packing

All quantities are in Kgs

Stage - 2Washing

Stage - 3Washing

Cyanide LayerTreatment



(3.0) Process of Per Methrin technical :

Cypermethric Acid Chloride (CMAC) reacts with Meta Phenoxy Benzyl Alcohol (MPBAL) at 70°Cto 80°C to give Permethrin. The evolved HCL gas during reaction is scrubbed in water. The reactionmass is washed with Potassium Carbonate solution to remove the dissolve HCl gas. Permethrin isdehydrated under high vacuum to remove traces of water. The purity of the Technical productPermethrin obtained will be minimum 92 %.

Chemical reaction of permethrin:

Cl2C=CH-CH-C(CH3)2

CHCOCl

2,2,Dichloro vinyl-2,2-dimethyl cyclopropanecarboxylic acid chlorideM.F.=C8H9OCl3M.wt.=227.5

+ O CH2OH

O CH2OOC-CH-C(CH3)2

CH-CH=CCl2

PermethrinM.F.=C21H20O3Cl2M.wt.=391

m-Phenoxy BenzalalcoholM.F.=C13H12O2M.wt.=200

+ HCl

Mass Balance of Permethrin:

233 Water

CMAC 620MPBAL 520Water 1250PotassiumCarbonate 15

2638

333 HCl 30 %1260 Waste Water

1045 Crude Permethrin

45 Distilled Water

1000 Kg Permethrin

Stage - 2Dehydration

Stage - 1Reaction &

Washing

Scrubber30 % HCl




(4.0) Process of Alpha Methrin:

Solution of CMAC (in – house manufacture as well as procured from the market) and Meta PhenoxyBenzaldehyde ( MPBD) reacts with solution of Sodium Cyanide in water in presence of phase transfercatalyst at 20°C to 30°C to give Cypermethrin. After reaction, water and Cyanide layer is separated. Thislayer is treated with Sodium Hypochlorite to destroy Sodium Cyanide .The organic mass is washed with waterto remove impurities. The obtain Cypermethrin is subjected to Epimerization at 25°C in presence of Tri EthylAmine (TEA) in solvent n- Hexane to obtain Alphamethrin. Then it is filtered and dried under vacuum. N-Hexane and Tri Ethyl Amine (TEA) is recovered and recycled. The purity of Alphamethrin obtain will beminimum 95 %.

Stage - 1O

CCl2 CH2 CH CH COCl OHC NaCN

CH3C CH3

227.5 198 49 Cypermethric Acid chloride

M eta Phenoxy Benzaldehyde Sodium Cyanide

Catalyst

O CN O

CCl2 CH2 CH CH C O CH NaCl

CH3C CH3

416 58.5

Cypermethrin Sodium Chloride

Stage - 2

O CN O

CCl2 CH2 CH CH C O CH

CH3C CH3

416

Cypermethrin

Epimerisation

O

CCl2 CH2 CH CH C O CH CN

CH3C CH3

416

Alphamethrin

O

Detoxification of Cyanide by Hypo

NaCN NaOCl NaOCN NaCl49 74.5 65 58.5

Sodium Cyanide Sodium Hypo Chloride Sodium Cynate Sodium Chloride

2 NaOCN 3 NaOCl NaCl N2 NaHCO3

65 74.5 58.5 28 84

Sodium Cynate Sodium Hypo Chloride Sodium Chloride Nitrogen Sodium Bicarbonate



Mass Balance of Alpha Methrin:

Hypo ChlorideSodium Cyanide 230 1500Water 1065Catalyst 20 2943Soda Ash 20 1443 Waste WaterCMAC 900 Cyanide LayerMPB 720n-Hexane 2780


Water 1500 20 Evaporation Loss1512 Waste Water


Water 200020 Evaporation Loss

2000 Waste Water


71 Evaporation Loss2669 R . N-Hexane

1500 Organic mass

644 Tri-ethyl AmineTri-ethyl Amine 700 4992 n- Hexanen- Hexane 5200 228 Evoperation LossWater 2630 2766 Water

10030

1400 Organic mass

400 ML Cyper

1000 KgAlphamethrin

Cyanide LayerTreatment


Stage - 5Epimerisation

Stage - 6Filteration

Stage - 7Drying

Stage - 2Washing

Stage - 3Washing

Stage - 4n-Hexaqne recovery

Stage - 1Cyper Reaction



ANNEXURE: 4

Water requirement letter from Notified industrial estate:



ANNEXURE: 5 Quantity of Waste Water (liquid waste) generation and its management :

Sr.No.

Particulars Existing Proposed After Proposedexpansion

1 Domestic 4.0 8.0 12.0

2 Processing , washing & scrubber 20.0 41.18 61.18

3 Cooling 5.0 5.0 10.0

4 Boiler 10.0 10.0 20.0

5 Floor/equipment/containerwashing

8.0 6.0 14.0

6 Others (Fire/safety) 3.0 0 3.0

7 Total 50.0 70.18 120.18

Mode of Disposal 0

9 Septic tank/soak pit 4.0 8.0 12.0

10 ETP to CETP 42.99 46.04 89.03

11 MEE 3.01 16.14 19.15

The generated waste water will be segregated; concentrated effluent will be treated in solvent stripperfollowed by MEE & normal effluent will be treated in adequate effluent treatment plant (ETP). Thedetails of the same is as given below :



Details of Effluent Treatment Plant Design Criteria : Product : Pesticides & intermediates Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 89 KL/day Max. Design Parameters : As under Effluent Characteristics:

No Parameters Concentratedeffluent

(High TDS)

CombinedNormaleffluent

Treatedeffluent

CETP inletnorms

EPAnorms

1 pH 7-8 6.0-7.0 7.5 6.5-8.5 6.5-8.52 Color pt. Co 200 600 50 <100 <1003 TDS mgl 20% 4000-5000 4000-5000 <2100 -4 S/S mgl 300-400 300-400 70-80 <100 <1005 Oil/grease mgl 2-3 5.6 1-2 <10 <106 BOD mgl 3000 3000 70-80 <400 <1007 COD mgl 15000-20000 9500 200-250 <1000 <2508 NH3-N mgl 70-80 50-60 10-12 <50 <509 Phenolic

compoundmgl

2-3 1.2 0.16 <1 <1

10 Sulphide mgl 3-4 1-2 ND <2 <211 Hydraulic

load, m3/day19.15 89.03 -

12 Mode oftreatment

MEE PST ETP

Based on the above criteria Effluent Treatment Plant having under mentioned specification is required toinstall:

Sr.No.

Name of the Unit Dimensions inmeters

Nos. Capacity in m3

1 Oil & grease trap 1 x 1.5 x 1.2 1 10.82 Collection Tank 5 x 5 x (3+0.5) 2 1503 Effluent transfer pump 5 HP 2 3.75 m3/hr

each4 Neutralization Tank 1.4 x 1.4 x 1.2 Nos. 4 9.55 Flash mixer / Floculator 1.25 x 1.25 2 3.06 Primary lamella type settling tank with tube deck

packing1.2 x 1.5. 2.5 3 13.5

7 Filter press 28 x 28 2 -8 Aeration tank with diffuser system 6 x11 x (5+0.5) 1 3809 Primary lamella type settling tank with tube deck

packing1.2 x 1.5. 2.5 3 13.5

10 Aeration sludge recirculation pump 3.0 HP 2 3 m3/hr11 Treated effluent collection tank 4 x 4 x 3.5 2 11212 pump - 2 7.5 m3/hr13 Pressure sand filter 1.6 x 2.5 2 1014 Activated carbon filter 1.6 x 2.5 2 1015 FACCO & Ferrate Treatment - 1 100 KL/day



EFFLUENT TREATMENT SCHEME FOR NORMAL EFFLUENT

1. PRIMARY TREATMENT:

UNITS: Oil & Grease removal Tank

Collection cum Neutralization Tank

Primary settling and sludge removal

The effluent generated from the plant is initially passed through the Oil & Grease removal system. The oil

free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank

various chemicals like Non Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added to

ensure proper settling which reduces the suspended solid concentration, colour and COD in the effluent.

The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling tank is

charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into the sludge

drying beds and leachate of the sludge drying beds is sent back to collection tank.

2. FACCO TREATMENT:The pH of the effluent is first checked and pH correction is made upto pH 3.5 by addition of Dilute acid.

H2O2 and FeSO4 solutions are prepared in two sintex tanks of 1 KL capacity. Air purging is started in the

column. The effluent is fed in the column at the rate of 5000 lit/hr. Thereafter, H2O2 solution is fed at the

the rate of 208 ml / hr by dozing pump. Thereafter, FeSO4 solution is fed at the rate of 2 lts / hr by dozing

pump. After dosing, the effluent from the column is collected in 5 KL sintex tank. The effluent is

thereafter transferred to the second neutralizer and normal pH-7 is attained by addition of Lime.

3. SECONDARY TREATMENT (BIOLOGICAL TREATMENT):

UNITS: Aeration Tank

Secondary settling

The primary treated clear effluent is passed through the aeration tank where the biodegradation of the

organic matter takes place in presence of active microorganism and required Dissolved Oxygen level.

During the biological treatment, BOD & COD are reduced. After biological treatment (aeration tank), the

effluent with the biomass is passed through secondary settling tank where biomass is settled and settled

biomass is recycled back to the aeration tank or if excess is discharged into the sludge drying beds and

clear effluent is collected into the holding tank.

3. TERTIARY TREATMENT:

UNIT: Sand and Carbon Filter (Mixed bed)

After secondary treatment, the effluent is passed through the mixed bed filter for further reduction of

COD, BOD and Colour. Treated water is collected into the treated water tank above the roof. Finally, the

treated effluent confirming the treated water discharge norms laid down by the GPCB will be discharged

for plantation or into the drainage to CETP as and when permitted.



FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT FOR NORMAL EFFLUENT

STREAM

COLLECTION TANK

NEUTRALIZATION TANK

FLOCULATOR

SETTLING TANK [LAMELLA]

COLLECTION TANK

FACCO REACTOR

SETTLING TANK [LAMELLA]

AERATION TANK

SETTLING TANK

CANDLE FILTER

SAND FILTER

CARBON FILTER

NEUTRALIZATION TANK

DOSING TANK

DOSING TANK

FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT

FERRIC HYDRATE + HYPO

DOSING TANK

AERATION TANK

FINAL HOLDING TANK



PROCESS OF SOLVENT STRIPPER & MULTI EFFECT EVAPORATOR FOR HIGH TDS EFFLUENTSTREAM INSTALLED AT OUR GROUP OF COMPANY M/S HERANBA INDUSTRIES LIMITED (UNIT: I)

LOCATED AT A DISTANCE OF 500 METERS FROM THE UNIT: II

Plant Configuration

Part – A: Stripper Unit with Flash Condenser, Re‐boiler and Recirculation Pump

Part – B: Forced Circulation Evaporation Plant with Thermo Compressor

Part – C: Agitated Thin Film Dryer

PROCESS DESCRIPTION (Part – A)

• Feed will enter a series of Pre-heaters of Evaporator: P4, P3, P2 and then P1 using Feed Pump.From discharge of feed pump, feed will be heated through series of preheater using vapour fromjacket of respective Calandria. Feed will be heated to the boiling point and will enter to therecirculation loop of Stripper.

• Recirculation Loop of Stripper will comprise of Flash Vessel, Recirculation Pump and Reboiler.• Feed coming out from Preheater of Evaporation Plant will be recirculated through reboiler and

heated up using Steam.• Heated Feed will be allowed to flash in Flash Vessel and by flashing high volatiles and water will

convert in vapour. Vapour will travel from bottom to top of Stripping column where feed liquidwill flow from top to bottom. Random packing inside the stripping column shall provide masstransfer surface to vapor liquid interface.

• Rich organic vapour with some water vapour will come out from the top of Stripper column. Thisvapour will be condensed in Flash Condenser at the top of Stripper column.

• Condensed organic rich liquid will be collected in Reflux pot from condenser. From Reflux potpartly it will be withdrawn according to the desired Water Vapour/ Organic ratio and remainingwill enter to the column as reflux.

PROCESS DESCRIPTION (Part ‐ B)

Feed will enter to the Evaporation Plant from Discharge of recirculation pump of stripper.

First Effect is a Forced Circulation Type comprising of Calandria‐1, Vapour Separator‐1 andRecirculation Pump – 1. Liquid will recirculate continuously through Calandria Tubes at highvelocity and will get heated using Heat of Condensation of First Effect Jacket. This Heated Masswill be allowed to flash in Vapour Separator and Water Vapour will be generated.

This Flash Vapour will be partly recompressed to the Jacket of FirstEffect using Thermo compressor which will convert high pressure motive steam to low pressureand will create suction and take a part of the generated water vapour from Vapour Separator ‐1.

Condensate from Jacket of First Effect will travel to 2nd Effect using pressuredifference available between these two Jackets.

Concentrate coming out from 1st Effect will be sent to Balance Tank‐2 whichwill be placed between 1st and 2nd Effect.

Second Effect also is a Forced Circulation Type comprising ofCalandria‐2, Vapour Separator‐2 and Recirculation Pump – 2. Liquid will recirculatecontinuously through Calandria Tubes at high velocity and will get heated using Heat ofCondensation of Second Effect Jacket. This Heated Mass will be allowed to flash in VapourSeparator and Water Vapour will be generated.



Flash Vapour will come out from Vapour Separator ‐2 and will be utilize asheating media for 3rd Effect.

Condensate from Jacket of 2nd Effect will travel to 3rd Effect using pressuredifference available between these two Jackets. Condensate will be taken out from plant usingcondensate outlet pump and send for storage.

Concentrate coming out from 2nd Effect will be below saturation level andthere will not be any crystallization taking place in 2nd effect.

Concentrate from Evaporation will be taken out from the Plant usingConcentrate Outlet Pump and send to Settler.

Water Vapor from Last Effect will be condensed in surface type condenser using Cooling Wateras condensing media. Steam Jet Ejectors/ Water ring Vacuum Pump will maintain vacuum in theplant back to the condenser.

Process Description (Part – C)

Treated Feed will enter the Storage Tank. Feed will not be required to preheat as it will come from the tank. Feed will enter the Vertical ATFD first for initial evaporation and then it will be

splashed to the Heat Transfer Surface of ATFD using liquid distributor. V‐ATFD will be a hollow cylindrical Jacketed Vessel having Agitator

and specially designed Scrapper blades to wipe out the Surface of ATFD to keep it clean. Thiswill maintain consistent performance of ATFD for a long time.

ATFD Scrapper will rotate at medium RPM using Gear Box for reduction ofRPM which will be govern by Variable Frequency Drive.

ATFD Heat Transfer Surface will be heated through Steam in Jacket. Vapouroutlet will be connected with Entrainment Separator to avoid product contamination inCondensate.

Vapour will be condensed in Condenser and Negative draft will be maintainedby Water Ring Vacuum Pump.

Product will come out from bottom of Vertical ATFD. Steam will be applied inJacket of same to allow the product dry.

Conclusion :‐

In general when Dried Feed comes out from the entire system, it shall be a cumulative mixture of allSolid Separated Mass, with content of moisture level less than 4%. The Solid Mass achieved will bein Lumps and Powdered form after the gelling and binding of the Solids.



DETAILS OF SOLVENT STRIPPER & MEE INSTALLED AT UNIT: I

Average hydraulic load, m3/day : 58.0 (38.0 from Unit: I + 20.0 from Unit: II)

Design hydraulic load, m3/day : 75.0

Sr. No. Particulars Size in meters Capacity in M3 MOC

1 Oil/Grease trap 1 x 1 X 0.2 0.2 m3 MS/Epoxy

2 Collection cum pHcorrection tank with air

diffuser

5 x 5 x 4.0 100 m3 RCC

3 Di. Acid/alkali dosing tank - 200 lits HDPE

4 Solvent stripper 0.3 Ø x 2.0 ht. 75 KLD SS 316

5 MEE Calndria:I 0.356 Ø x 0.844 Ht. 75 KLD SS 316

6 MEE Calndria:II 0.273 Ø x 0.836 Ht.

7 MEE Calndria:III 0.273 Ø x 0.836 Ht.

8 Agitated Thin Film Dryer(ATFD)

0.3 Ø x 2.7 ht. 7 TPD SS 316

9 Final holding tank forwater from MEE

condensate & ATFD

5 x 5 x 4.0 100 m3 RCC

FLOW DIAGRAM OF MULTI EFFECT EVAPORATOR



Hazardous Wastes and its Management

Sr.No.

Type ofhazardous

waste

Category

Quantity, TPA Place ofStorage

Disposal








Sold toauthorized

recycler4 Salt from MEE 34.3 42 1116 HDPE

BagsDisposed offinto TSDF,


drumsSent for co-

processing tocement

industries orsent to SEPPL,Kutch or sentto proposed

Incinerator tobe installed at

HIL:I6 Concentrated


(Unit: I)

34.3 1083.6 6894 Bytanker

To MEE ofHIL Unit: I

7 AmmoniumChloride Powder

(85%)

Sch:IIB30

60.96 1097.28 HDPEbags



Powder (80%)Sch:

II C13268.8 4838.4 HDPE



Acid solution(30%)

Sch:IID2

225.18 3713.58 Tanker Sold to actualusers as a by-

product10 Sodium


Sch:II C13

206.64 3719.5 HDPEbags


product11 Recovered


process



ANNEXURE: 6

MEMBERSHIP CERTIFICATE OF CETP, VAPI



ACCEPTANCE LETTER OF CETP VAPI FOR ADDITIONAL EFFLUENT



MEMBERSHIP CERTIFICATE OF TSDF, VAPI & CHWIF, SEPPL, KUTCH



ANNEXURE: 7



ANNEXURE: 8Copy of plot allotment letter issued by GIDC





COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIEDINDUSTRIAL AREA



ANNEXURE: 9

A schematic representation of the feasibility drawing



ANNEXURE: 10DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED

EXPANSION

The utility emissions will be from the Steam Boiler (2 No.) of 3 Tons/Hr. Natural gas (green fuel)/FO as fuelwill be used in the Steam Boiler. Also we have installed a D.G. Set of 750 KVA & 500 KVA capacities to usein case of power failure and HSD shall be used as a fuel.

From the existing plant SO2 & HCl gases are generated. For the scrubbing of these process gases, two stagewater followed by alkali scrubber are provided to recover the valuable by products. After proposed expansionadditional, two numbers are scrubbing system will be provided. Details of which are as under;

Sr. No. Particulars Existing After ProposedExpansion

Remarks

1.0 Capacity of Steam boiler 3 TPH 3 TPH + 3 TPH

1.1 Fuel Used Furnaceoil/Natural gas

Furnace oil/Naturalgas

1.2 Fuel Consumption 2.5 kl/day/2500 SCM/day

5.0 kl/day/5000 SCM/day

1.3 APC provided Chimney Chimney

1.4 Height/dia of chimney 30 meters 30 meters x 2

2.0 Capacity of D G set 750 KVA(Standby)

750 KVA + 500KVA (Standby)

2.1 Fuel Used HSD HSD

2.2 Fuel Consumption 75 liters/hr 75 lits/hr + 50lits/hr

2.3 APC provided Exhaust Exhaust

2.4 Height/dia of Exhaust 11 meters 11 meters

3.0 Stack attached to Reactor ofCMAC

( Chlorination ofTBA with SOCl

2)

Reactor( Chlorination of

TBA with SOCl2)

Existingone

scrubber &additional

onescrubber

3.1 APC provided Water followedby alkali &

ventury scrubber

Water followed byalkali & ventury

scrubber3.2 Height of vent 11 meters 11 meters

3.3 Expected emission SO2: < 40

mg/Nm3

HCl:<20 mg/Nm3

SO2: < 40 mg/Nm3

HCl:<20 mg/Nm3

4.0 Stack attached to Reactor ofCMAC

( Chlorination ofCMA with

Reactor of CMAC( Chlorination of

CMA with SOCl2)

& reactor of

Existingone &

additionalone



SOCl2) Permethrin scrubber

4.1 APC provided Water followedby alkali &

ventury scrubber

Water followed byalkali & ventury

scrubber4.2 Height of vent 11 meters 11 meters

4.3 Expected emission SO2: < 40

mg/Nm3

HCl:<20 mg/Nm3

SO2: < 40 mg/Nm3

HCl:<20 mg/Nm3

DETAILS OF AIR POLLUTION CONTROL EQUIPMENTS

Sr. No. Name of the unit Size Nos.1 Height of Scrubber (Packed column) 3 meter 22 Size of Scrubber 600 mm dia 23 MOC of Scrubber MS Graphite 24 Type of Packing Paul /ring 1

5 Height of Packing 2.5 meters

6 Height of Scrubber (Falling Film) 2.5 meters 67 Size of Scrubber 400 mm dia

8 MOC of Scrubber MS graphite lined

9 Size of Vacuum catch pot 630 lits 210 MOC of Scrubber MS graphite lined 211 Capacity of water circulation tank 15 KL 212 MOC Tank MS FRP 413 Capacity of water circulation Pump 6 m3/hr 414 Size of ventury 200 kgs/hr 215 MOC of condenser PP/FRP 216 Size of condenser 20 m2 217 MOC of condenser MS

18 Size of caustic circulation tank 15 KL 119 Capacity of circulation pump 54 m3/hr 220 Size of nutsch to filter sodium sulphite 2x2x1.5 meter 221 MOC of filter nutsch MS 2



FLOW DIAGRAM OF SCRUBBING SYSTEM

HCl, SO2

From Plant

Final vent Catch

Pot

Ventury Chll out

Ventury

SO2

Scrubber

Cooling HE Chll in

Cooling HE

Tank Vent

Tank Vent

Filter Filter HCl G.HCl

Tank A S/T

ML recycle

COPY OF CONSOLIDATED CONSENT &AUTHORIZATION OF THE SPCB FOR EXISTING

PRODUCTS & ITS COMPLIANCE

For

HERANBA INDUSTRIES LIMITED (UNIT: II)

Located at:

Plot No. A-2/2214, 2215, 3rd phase,

GIDC Notified Industrial Area,

GIDC Vapi, Ta: Vapi, Dist-Valsad 396 195

Gujarat.

COPY OF CCA

COMPLIANCE OF CCA

We have obtained CCA vide order No. AWH-42066 dated 25/05/2011, which is validup to 04/03/2016.

We are manufacturing only those products with specific capacity, which arementioned in the CCA issued by the board.

We are generating domestic effluent @4 kl/day. We have provided adequate capacity of septic tank/soak pit for the disposal of

domestic effluent. We are generating maximum 46 m3/day of industrial effluent from the unit as

mentioned in the CCA. We have provided separate collection tank for concentrated & non concentrated

stream within the premises. For normal effluent stream i.e. 43 m3/day, we have provided adequate capacity of

effluent treatment plant consisting of primary, secondary & tertiary treatment units. For concentrated effluent stream @3.1 m3/day, we have provided separate collection,

neutralization & filtration system within the premises. We are sending our concentrated stream by tanker for MEE treatment to our mother

unit i.e. Heranba Industries limited (Unit: I) located at distance of 500 meter. At our HIL (Unit: I) ; we have provided adequate solvent stripper followed by multi

effect evaporation system. We are regularly operating our effluent treatment plant & MEE. We are a member of common effluent treatment plant of VWEMCL, Vapi. We are maintaining the norms of treated effluent as specified by the board. We are discharging our treated effluent into under ground effluent drainage line to

CETP Vapi for further treatment & for ultimate disposal into tidal zone of riverDamanganga to the Arabian Sea.

We have provided separate flow meter at the inlet & outlet of ETP & inlet of MEE. We have provided separate energy meter for ETP. We are maintaining the printed log-book for the operation of effluent treatment plant

& MEE on daily basis. We have provided steam boiler for process steam requirement as mentioned in CCA. We are using natural gas in our boiler. We have provided adequate height of chimney for the dispersion of flue gas emission. We are using 750 KVA capacity of D.G. set as a standby unit in case of power failure. We are using diesel as a fuel in the D.G. set at a rate of 75 kgs/hr. We have provided adequate capacity of exhaust to the D.G. set. We have provided acoustic enclosures to control noise pollution.

We have provided stack monitoring facilities like port hole, ladder & platform to thechimney.

We are generating process gas emission like SO2 & HCL gas from the reaction asmentioned in CCA.

For the scrubbing of said gases; we have provided adequate capacity of waterscrubber followed by alkali scrubber to recover valuable by-products like HCl (30%) &sodium bi sulphite.

We have provided adequate height of vent attached to the scrubbing system. We are operating our air pollution control system regularly & maintaining the norms

of process gas emission as specified by the board in CCA order. We are maintaining the fugitive emissions within the premises by adopting cleaner

production technology. We are maintaining the ambient air emissions within the premises. We are regularly carrying out monitoring of ambient, fugitive & process gas emissions

through private agency. We have provided in-house laboratory for the analysis of waste water sample. We have taken adequate steps to control noise levels within the premises. We are generating by-products as mentioned in CCA. We are selling our by-products to actual users only through xgn manifest system. We are generating hazardous wastes as mentioned in CCA. We have provided adequate storage area for hazardous waste. We are the member of common TSDF of VWEMCL, Vapi for the disposal of hazardous

waste & CHWIF of SEPPL, Kutch for the incineration of process residue. We are regularly disposing of waste into TSDF & CHWIF through xgn manifest system

only. We have developed green belt within the premises & maintain the same regularly. We are regularly paying water cess returns through xgn online system. We are regularly submitted environmental statement to the board. We have provided adequate fire & safety equipments within the premises. We are covered under ESIC scheme. We are regularly carrying out mock drill within the premises. We are complying all the conditions motioned in CCA.

Documents

HERANBA INDUSTRIES LIMITED (UNIT: II).environmentclearance.nic.in/writereaddata/Online/TOR/0_0_12_Sep_2014_0838464771Pre...Prefeasibility Report-Annexure Heranba Industries Limited