Plot No.: G-60, MIDC, Lote Parshuram, Tehsil: Khed, … station is Chiplun 7 km SE and Khed is about 18 Km N of the site on Konkan Railway Line and Mumbai – Goa National Highway

Prefeasibility Report – M/s. Laxmi Organic Industries Limited

1

PREFEASIBILITY REPORT

For

Proposed

Synthetic Organic Chemicals

Manufacturing Facility

By

LAXMI ORGANIC INDUSTRIES LIMITED

Plot No.: G-60,

MIDC, Lote Parshuram,

Tehsil: Khed, District: Ratnagiri

Maharashtra-415722

Synopsis

1. Introduction

2. Justification

3. Location

4. Recourses

5. Process

6. Pollution Control

7. Background Study

8. Safety

9. Benefits

10. EIA structure

11. Scoping

12. Conclusion


2

1. Introduction

M/s.LAXMI ORGANIC INDUSTRIES LIMITED (This Industry, TI) are desirous to set up

specialty chemicals industrial unit for producing specialty chemicals at Plot No. G-60, at

Government developed Maharashtra Industrial Development Corporation (MIDC)

industrial estate, Lote Parshuram, district Ratnagiri, Maharashtra.

The proposed industrial unit will cater to demand of pharmaceutical, colorant and

agrochemical industry and substitutes imports by about 70% to 80%. The industry

proposes to set up new facility to substitute imports and enhance exports.

Indianand worldwide demand for specialty chemicals is increasing steadily. The

intermediates proposed to be manufactured will be used in following industry segments.

• Pharmaceutical industry

• Colorant industry

• Agrochemical industry

• Organic synthesis industry

• Polymer and coating industry

The Notification no. S.O. 1533 promulgated on 14th September 2006 has covered this type

of industries under its entry ‘5(f)’. Synthetic organic chemicals industry located in a

notified industrial area/ estate will come under purview of SEAC/SEIAA, Maharashtra to

obtain environment clearance.

Now we are seeking addition in production capacity with addition of new products at new

location at LoteParshuram Industrial Area. This prefeasibility report is prepared for

forming a frame work for EIA study, scoping and finalizing terms of reference as may be

required.

Form - I, as is prescribed by the said notification is duly filled up. The prefeasibility report

is an accompaniment to the same.

Form - I submitted by us generally covered Justification, nearby Land Use, Resources,

Process, Pollution Control, Aesthetics, Risk Involved, Consequent Developments and

Environmental Sensitive Issues.

2. Justification

The Indian pharmaceutical industry is the world's second-largest by volume and is likely to

lead the manufacturing sector of India. Several Government and private sector projects

with huge amount of investments have been initiated but could not attend the speed of

development for the need of good quality material. Over the last decade, there has been a

sizeable growth in Pharmaceutical sector both in small, medium and large scale units. This

has given rise to many small and medium scale units to manufacture pharmaceutical

intermediate. The ever growing requirements of India, due to higher population and


3

various diseases indicated the need for the growth of this industry. Thus there is a gap in

demand and supply. Our efforts of generating products, by-products, downstream products

and recycling - reprocessing are indeed needed. With multinational pharmaceutical

companies enhancing their presence in India, the long-term prospects of the

pharmaceutical industry seem fairly bright.

Indian agro sector demand is increasing to improve productivity and to deal with attack of

various types of pests etc. The intermediates proposed will substitute imports.

The colorant industry demand for intermediates is increasing as multinational companies

are shifting manufacturing base in India.

But the impact of some factors on the industry's growth remains to be seen. For one, there

is the power supply situation. Power accounts for around 10% of the manufacturing cost

and availability could be an issue in future. Also, manufacturers need to modernize their

processes to reduce energy consumption and become more cost efficient.

Due to shortage of power in the country, the company proposes to set up a Captive Power

Plant (CPP). Power during CPP shutdown will be sourced from MSEDCL.

The fate of industrialization depends on the proper and effective conjugation of large and

medium/small scale industries each supporting each other in their requirement to bridge

the gap between demand and supply. In order to be competitive in the global market this

synergy between large & medium/small scale industries is a prerogative. Therefore

considering the above, large companies do require the help of small units to support them

by giving them quality products at lesser price.

Proposal:

The industry proposed to produce as under:

Product TPM

I. Diketene Derivatives 2850

a. Esters / Ester Derivatives 1250

b. Amides / Amide Derivatives 700

c. Aromatic derivatives 500

d. Hetrocyclic Derivatives 300

e. Halogenated Derivatives 100

II. Diketene 1350

III. Ketene derivatives 100

IV. Ethylene oxide derivatives 200

Total 4500

Captive Co-gen Power (CPP) 10 MW


4

These are important chemicals and none of them are banned for production in other

developed countries, nor is banned for use. The chemicals produced have following merits.

• Import substitute

• Export oriented

• Energy integration by setting up co-generation for steam and power requirements.

• The reaction product is water

• Clean production technology adopted by ensuring

- Minimize pollutants at source

- Maximize recycle

- Treat to PCB norms

- Use low ash and sulphur coal for boiler

• Maximize recycle of effluents for process.

Laxmi Organic Industries Limited (TI) is the only producer of Diketene derivatives &

Ketene derivatives and major producer of Ethyl acetateand have expertise in Co-gen CPP.

TI has proposed to increase production capacity at new location in the same products

range and introduce new products and has expertise in design, engineering, construction,

commissioning and operation of these products and has network of marketing these

products in domestic and export markets.

3. Location-

The plant facility is to be located at Plot No. G-60, MIDC Lote Parshuram, in Khed Tehsil,

District Ratnagiri of Maharashtra- 415722. Site is well connected by rail and road. Nearest

railway station is Chiplun 7 km SE and Khed is about 18 Km N of the site on Konkan

Railway Line and Mumbai – Goa National Highway (NH-17) is adjacent to the site. Site is at

a distance of 250 km from Mumbai. The plant facility to be located in vacant plot already

owned in well developed industrial estate. Nearest human habitation is at village Songaon,

1 Km,South-West of the plant. Major port is JNPT, about 190 Km to the North.in immediate

vicinity of the plant.

The site is in premises of MIDC estate which is meant for this type of industries. On all four

sides we are surrounded by industries and no nuisance is spread. The surrounding

neighbors are,

1. East : MIDC plot

2. West : Vacant agricultural land.

3. South : MIDC Plot

4. North :MIDC Plot

Location too is justifiable. Unit size is kept correct for ease of handling and environmental

control.


5

Government MIDC at Lote Parshuram has provided all infrastructures like assured

Electrical power, continuous water supply with purification from water works having, RSF

(Rapid Sand Filtration) and disinfection, internal road, network, external approach roads

and has networking with Common Hazardous Waste Storage Treatment and Disposal

Facility (CHWTSDF). CHWTSDF at Maharashtra Industrial Development Corporation

(MIDC), Taloja, in vicinity has been established with support of MIDC and Maharashtra

Pollution control Board (MPCB). A Common effluent Treatment Plant (CETP), is also under

expansion at MIDC, LoteParshuram and will be functional before commissioning of the

project.

Location can be thus justified. A relevant portion of index map is enclosed.

The proposed land plot admeasuring 80,000 m2 This is not a Prime Agricultural Land. The

land use is already as “Industrial”. Thus, there is no change in the status. This is a flat land

where by cutting- filling balances and there will be No Low Borrowing from Nature.

The river, city, railway line and national highway are sufficiently at safe distance. The

Industrial Area is a Chemical Process Industries belt. Hence, have public acceptability.

GEOGRAPHICAL LOCATION OF SITE :

� Latitude : Approx. 170 35’ 38.72”N

� Longitude : Approx. 730 28’ 54.58"E

� Terrain : Hilly terrain

� Climate : Semi-Arid


6

Figure 1: Location map of the project

Figure 2: Google Image of the project site

Project: Laxmi Organic

Industries Ltd.

Location : Mahad, MIDC


7

Figure 3: Project layout

4 Resources

TI is desirous to set up new specialty chemicals industrial unit for producing synthetic

organic chemicals.

It requires following resources,

• Area 80,000 m2

• Water Input Assured from MIDC

• Work force 150 Nos.

• Raw Materials commensurate with product, as also work up

Chemicals, solvents & catalysts

• Effluent Facility high COD and TDS sub stream segregated self-treatment

andto CETP later.

• Haz. Waste Facility CSWTSDF at Taloja

• Process Developed by company

• Machinery Available locally

• Laboratory Maintained sophisticated

• Attendants Units Utilities like Boiler, Cooling tower, Chilled brine etc.

• Instrumentation Latest - state of art

• Total Investment Rs. 180Crores.

• Environment Fund 2 %

• Proponents Law abiding. No litigation pending.


8

Site

1. Site is in Govt. MIDC Estate, its infrastructure will be used.

2. Climatic condition suitable for finer adjustments of control, making it fit for

processing conditions.

3. Well connected for transportation.

4. Leveled ground and load bearing soil

Project proponents

Laxmi Organic Industries Ltd. is a producer of green solvents based on alcohols for

pharmaceutical and printing industry. It was established in 1988, with a focus on the

solvents for Pharmaceuticals and Printing industries.

The company has adopted following certifications for its units at MIDC, Mahd, Dist Raigad.

1. ISO 9001

2. ISO 14001

3. ISO 18001

4. ISO 50001 (Under implementation)

5. Kosher

6. Responsible Care

Today, Laxmi Organic Industries Ltd manufactures a wide range of intermediates and

solvents and has forged enduring relationships with large and small companies all over the

world. Laxmi Organic Industries Ltd. has established reputation for providing quality

products in manufacturing plants that meet global standards. The proponents are,

S. No. Name Designation

1. Ravi Goenka

Chemical Engineer

Managing Director

2. Radhesh Welling

MechanicalEngineer, MBA

Executive Director & CEO

3. Ashok Pol

M. Sc. Organic Chemistry

Sr. Vice President–Sales &Marketing

4. Vijaysing Borse

Chemical Engineer

Sr. Vice-President– (Operations & Projects)

5. Partha Roy Chowdhury

Chartered Accountant

President-Corporate &C.F.O.


9

5 Process

Products

This industry proposes to establish a plant to produce green solvents. The products serve

as green solvents for Pharmaceuticals and Printing. As season changes or as immunity

changes, demand for particular chemical changes, the industry has thus to be in readiness

to change the product suitability and be prepared to mitigate the corresponding

environmental challenges. The utilities are normally the same, but the reactors are used by

different combination and sequence.

The product mix is as given below.

Product TPM

I. Diketene Derivatives 2850

a. Esters / Ester Derivatives 1250

b. Amides / Amide Derivatives 700

c. Aromatic derivatives 500

d. Heterocyclic Derivatives 300

e. Halogenated Derivatives 100

II. Diketene 1350

III. Ketene derivatives 100

IV. Ethylene oxide derivatives 200

Total 4500

Captive Co-gen Power (CPP) 10 MW

It may be seen that,

• There is a capability of making these products

• Production process is continuous with “Cleaner Production” strategy with effluents recycle

• Machineries, utilities will be installed according to the expansion requirement.

Process – The details of manufacturing process is submitted as annexures.

Overall Environmental Significance:

Unit Operation/

process

Peculiarities Environmental significance

1.

Incoming raw material

Selected from known

vendors

Transportation in closed

tankers

Prompt use and storage in

closed containers prevent

spillages and loss of strength.

Less emissions.

2. Weighing and Load Cell based weighing Better check on mass


10

strict quality control system provided balance, purer material and

less rejections.

3. In process Solvents Recovered and reused

By products Recovered and sold to

parties, when in demand

Gaseous emissions Scrubbed and detoxified

Process waste residue To be sent on common

facility for disposal

4. Instrumentation DCS Control system for

accurate process controls

Facilitates monitoring of

quality of the product and

safety aspects.

5. Control Excellent system of

documentation and

control of critical stages in

production process

Better operation and

retrievable records for better

checks.

6. Solvent

recovery

No solvents are used in

the process

Not applicable

6 Pollution control

Clean production technology adopted by ensuring following at design and engineering

stage.

- All reactions selected are producing water as by product.

- Minimize pollutants at source

- Maximize recycle

- Treat to PCB norms

- Maximize recycle of effluents for process.

- Treatability data available from existing ETPs

- Reduction of VOC at every processing stage by vent condensers and

scrubbers.

- Use low sulphur and ash coal for boilers for reducing emissions

The process adopted is based on esterification of organic acid and alcohol producing water

as an effluent. The recovery system will be designed in such a way that entire water is used

for process application thereby replacing fresh water input.

The boiler is provided with cyclone separator, bag filter/ESP, to control emission within

prescribed limits. The stack height is up to62 meters to control ground level clearance

within limits.

Process vents are controlled by condensers followed by water scrubber and organics are

recovered and recycled.


11

(a) Water & waste water:

The water and waste water generated in the factory will be as follows;

a. Water requirement :

Consumption m3/Day

CW makeup 1910

DM water 145

Potable water 40

Process water 313

Gardening 5

Total 2412

b. Waste Water generation:

ESTIMATED QUALITY OF RAW &TREATED EFFLUENT:

Source m3/Day

Effluent

CW & Boiler Blowdown 229

DM water 19

Potable water 34

Process water 335

Total 616

Effluent characteristics for discharge to CETP

SR.

NO.

PARAMETER RAW

EFFLUENT

TREATEDEFF.

QUALITY

(MPCB LIMITS)

UNITS

1. pH 6-7 6.5 to 8.5 --

2. B.O.D 70 Max. 100 Mg/lit.

3. C.O.D 300 Max. 250 Mg/lit.

4. T.S.S. 200 Max. 100 Mg/lit.

5. T.D.S 1800 Max. 2100 Mg/lit.

6. Oil & grease 8 Max. 10 Mg/lit.

7. Ammonical Nitrogen <50 <50 Mg/lit.


12

Proposed ETP Flow Sheet:

PROCESS FLOW DIAGRAM FOR ETP

INFLUENT

SLUDGE

BIO REACTORS

SLUDGE RECYCLE

CLARIFIER

SLUDGE DRYING BED

TO CETP

PRIMARY

SETTLER

EQUILISATION

TANK

NEUTRALISA

TION

FILTER

TREATED

EFFLUENT

TANK

CAUSTIC SODA TANK


13

(b) Air pollution:

The proposed plant will not produce any significant air pollution load. The major sources of

air pollution are:

• Boiler

• D.G. Set Emissions

• Fugitive emissions

• Process emissions

The efforts taken by the proposed plant to tackle these issues are also given below.

Emission Control Equipment:

The fuel used here is coal & electricity. Stack of 62 m shall be provided. DG set of capacity

1010 KVA will be on low sulphur diesel and will be provided stack and acoustic enclosure

as per MoEF standards.

# Source In-plant

Measures

Control Equipment

1 Proposed

Boiler

Dust Collectors,

ESP or Bag

Filters, Dust

extraction with

Bag filters,

fogging.

Tall stack of 62 m.

3 In process Closed loop

transfer

Vent condensers,

Extraction and

scrubbing

4 In process SO2 Scrubbing and

detoxification

5 ETP Covered transfer Fully aerobic

In addition, other attendant efforts like water spraying, tree plantations and covered

storage, etc shall be adopted, wherever feasible and needed.


14

Stack Details:

Stack no. 1 2 3 4 5 6

Attached to Boiler Boiler Furnace Scrubber 1 Scrubber 2 DG Set

Capacity, TPH, KVA 60 25 1050 KVA

Operating Status Operating Stand by Operating Operating Operating Stand by

Fuel Type Coal Coal

Coal

------ ------ Diesel C-9

Residue

Fuel quantity (Kg/hr) 8880 3089

1215

------ ------ Non continuous 221

200

Material of

Construction RCC RCC MS MS MS MS

Shape Round Round Round Round Round Round, 2 Nos

Height, mtrs 62 45 34 30 30 6.3 (above roof)

Diameter, mtrs 1.60 0.90 1.1 0.6 0.2 0.25 * 2 nos

Gas Quantity Nm3/hr 66178 23023 13065 3000 650 3000

Gas Temperature oC 150 150 140 35 30 160

Exit Gas Velocity

(m/sec) 14 16 6 7 6 7

Control equipment

preceding the Stack Dust collector

and ESP Dust collector

and Bag Filter

Scrubber of

diameter

1200mm

Scrubber of

diameter

600mm

As per air pollution

prevention norms for

DG

Nature of pollutants

likely to be present in

the stack gases such as

Cl2, NOx, Sox, TPM

etc

SOx, TPM SOx, TPM SOx, TPM SOx, TPM SOx, TPM

Emission Control

System provided Dust collector

and ESP Dust collector

and Bag Filter NA-Gas, liquid

fuel fired Scrubber Scrubber

As per air pollution

prevention norms for

DG


15

Dispersion:

Point Emissions are coming from two boilers, and a proper stacks are provided for the

same. Refer enclosed of stack details

The stack will be fitted with port-holes, ladder and platform for facility of taking samples.

Fugitive:

A number of mitigation measures are taken to control fugitive emissions

• Engineering the plant layout in such a way so as to virtually eliminate need of

using heavy equipment for material handling in the main plant

• Internal roads paved, leveled, no undulations, no sharp curves, slow speed

• No open storage of materials involved

• Fumes extraction and scrubbing system provided for extraction of fumes

from the reactors and the process plant areas.

SOLID WASTE

Introduction:

Following mitigation practice is the policy for future:

• Minimization at all levels will be attempted for discarded products, empty

containers, packing surpluses, incoming raw material unloading spillages and

fugitives.

• The plant will produce very less amount of scrap materials. All these, however, be

carefully stored on raised platform with dwarf toe walls all around, and a roof over-

head. The contents will not be held in the premises for more than a fortnight.

• The main solid waste from factory will be in form of and residues form catalyst

recovery. This waste will be transported to the Common Hazardous Waste

Treatment and Disposal site for proper treatment and disposal.

• We buy raw materials in tankers and chemicals in bags. The bags are recycled.

• The ETP sludge will be sent to CHWTSDF.


16

(A) Non Hazardous solid waste:

Based on above working, the summary of Non Hazardous solid waste is given below

Non hazardous solid

waste generation

Type of

waste

Total

Quantity

Management

From Domestic Activities Dry garbage 34.00 Kg/day Handed over

to the authorised recyclers

Wet

garbage

49.00 Kg/day Composing

From Process Coal Ash 19 MT/day To Brick Manufacturers

Plastic

Drums /

Containers

75 Nos./ Day Handed over

to the authorised

recyclers

(B) Hazardous Waste:

The unit is member of CHWTSDFTaloja the copy of membership is attached

The relevant summary is given below:

Sr. No. Schedule I

Category No. Type

Qty (kg/day) Method of Disposal

1 34.3 (ETP Sludge) Chemical

sludge from waste water

treatment

5 MT/month (Total) CHWTSDF

2 26.1 Process waste sludge /

residue containing acid or

other toxic metals or organic

complexes. D-7 Organic

nitrogen containing

compounds expressed as

nitrogen

200 MT/month (Total) Used as fuel in

furnace along with

other fuels, after

reprocessing

Aesthetics:

There will be no nuisance from noise. DG set only run occasionally during power failures to

keep plant under safe conditions. There are crushing and pulverizing operations for coal

handling. Dust suppression system is provided. Dust extraction with dust collection is

provided. Labor strength is also limited in this MSI unit.

Odor however can be of some sensitivity in chemical industries. However, in this case

majority input is odorless and only few with mild or characteristic odor. This will be

handled carefully. No nuisance will go to surrounding chemical industries.


17

7. Background Study:

This is important part of study.

(A)Natural Environment: We propose to do sampling as –

• Surface Water: 8 Locations, 11 Parameters.

• Ground Water: 9 Locations, 9 Parameters. Includes 1 up gradient and 2 down

gradient source.

• Air Quality: 3 Months, For PM10, PM2.5, SO2 and NOx.

• Noise: 9 Locations.

• Soil: 9 locations

The stations will be selected in all the eight directions from the factory and in 10 km radius.

(B) Manmade Environment

This includes existing land-use, demography, employment, socio-economic aspects and

community development needed and proposed. This is for entire area both rural and urban

in this study zone.

• Socio-Economic Status in Influence Zone explained in the study of Non-Workers

percentage whether high, from the percentage employed population on

Agricultural, how far is the scope for other avenues of livelihood like Live Stock,

Forestry, Fishing, Hunting, Orchards, Mining, Trade Commerce.

• Further Out of Total Land what percentage is already under Cultivation and Out

of Total Land what percentage is already under Irrigation.

• If the land is not likely to support more people, then whether Industrialization is

necessary to improve the situation.

• All this will be studied as cost benefit ratio.

8. Safety

Safety and Occupational Health will be dealt carefully. A disciplined approach is natural to

this industry. Safety policy will be in place. The unit is registered under Factory Act and is

bound by State Factory Rules.

A complete exercise of risk assessment & characterization is scientifically done. Mitigation

plan is drawn as follows:

• Mitigation measures

• Sprinkling on excavation

• Scrubbers on process vents

• Bag filters for steam boilers

• Stack height per MPCB

• Trees


18

• Barrier walls as shielding technology to suppress blast pressures, fragments, fire-

balls

• Chemical storage area – ventilation, store-rooms, fuel dyked

• For Hazardous chemicals – Flame-proof motors, “No smoking’, Thermal insulations.

First aid trained and Fire-fighting trained person will be available in every shift. Safety

Officer will be appointed, as also the competent person retained. Where necessary,

provisions of other Acts, where required like Petroleum act, Explosive Act, etc. will be

obeyed. Fire fighting system is kept as per norms of Insurance Company.

DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly,

Personal protection equipment will be given and use will be insisted. Consulting Physician

is available to attain the factory.

9. Benefits

The expanded capacity will meet the growing demand for green solvents – locally and

internationally. 40% of the products will be exported to EU and other countries.

10. EIA study report:

This will be finally prepared and submitted as per guidelines given by MoEF as –

Chapters Contents

I Proponents, ToR, Purpose

II Project explained. Why this, Why needed, Why here, What priorities, What options

III Environment Setting Natural & Man-made

Material, Method,

Approach

Delphi technique

IV High Significant Impact � Low Insignificant Impact & Shield

Proper Site � Prevention � Abatement � Treatment � Mitigation � Smooth

Disposal

V Alternate Analysis

Selection of Raw Materials, Site, Process, Machinery- Hardware, Collaborators, Staff

& Team

VI Monitoring = Stations, Parameters, Frequency, Statistics, Rectify

VII Risk = To Environment, To Health, To Bankers

Public Consultation Reporting

Community = Other Assistance

VIII Benefits = Physical, Social, Employment, Other Tangible. Sustainable considerations

IX Cost-Benefit.

X EMP = Plan, Cell, Schedule, Watch-dog, Monitoring, Documentation, Reporting.

XI Summary, Conclusion, Justification, Mitigation.

XII EIA Team = Proponent, Consultant, Associates, Future


19

11. Scoping

We shall propose in “Scoping” the details of all above, as also the following;

# Attribute ToR

1 Land Land use pattern, break up. Photographs, sensitivity, forest, heritage.

2 Environment Fuel, Mathematical model, fugitive control, effluent generation&

ETP, zero discharge, solid waste handling, SPCB compliance

3 Production Other sugar units around, working days, environmental funds, raw

material & linkages, flow sheet, boiler, water source

4 Monitoring AAQ 10 km, micro met, surface water, ground water, hydro

geological study, flora-fauna, noise.

5 Management EMP. RWH, traffic, litigation, six monthly to Bhopal, resource

conservation, pollution control, environmental protection.

6 Safety Risk assessment, fire fighting, chemical storage, occupational health,

Factory Act compliances

Some of them will be covered under MIS rules. However there use in process is small below

regulatory quantity. Risk assessment will be done and submitted.

12. Conclusion

This project is very necessary to supply green solvents for printing industry and meet

solvent demand of pharmaceutical industry both domestic and worldwide and also in view

of :

• The local people desire that this industry will be welcome in their area.

• The candidate site is suitable from general MoEF expectations.

• Water, power, raw material, Filler Material and Market is assured and found

available with ease.

• Full precautions will be taken for Pollution Control, Resource Conservation and Environmental Protection.

• This is cost effective and Sustainable Development.

Documents

Plot No.: G-60, MIDC, Lote Parshuram, Tehsil: Khed, … station is Chiplun 7 km SE and Khed is about 18 Km N of the site on Konkan Railway Line and Mumbai – Goa National Highway