PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-11-05 · M/s. Gujarat Insecticides Ltd Expansion in Existing Unit Pre-Feasibility Report

Annexure - 12

PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT((AASS PPEERR TTHHEE GGUUIIDDEELLIINNEE OOFF MMooEEFF))

FOR

PROPOSED EXPANSION AT

EXISTING MANUFACTURING UNIT

Name of the Industrial

Unit

M/s. Gujarat Insecticides LtdPlot No. 805/806,GIDC Estate, Ankleshwar,Dist.: Bharuch, Gujarat, India

Registered Office M/s. Gujarat Insecticides LtdPlot No. 805/806,GIDC Estate, Ankleshwar,Dist.: Bharuch, Gujarat, India

M/s. Gujarat Insecticides LtdExpansion in Existing Unit Pre-Feasibility Report

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1.0 EXECUTIVE SUMMARY

Gujarat Insecticides Ltd (GIL) was established as a joint sector company in 1980, with an aim tomanufacture sophisticated and modern technical grade pesticides. The promoters of theCompany were M/s Gujarat Agro Industries Corporation Ltd, Ahmedabad, a Government ofGujarat Enterprise and M/s Gharda Chemicals Ltd, Mumbai, a company engaged in Research &Development and also in manufacturing of pesticides, intermediates. In August 1996, M/sGharda Chemicals Ltd purchased the entire holdings of M/s Gujarat Agro Industries CorporationLtd. Since then Gujarat Insecticides Ltd became the subsidiary of M/s Gharda Chemicals Ltd,Mumbai.

GIL has set up new records by manufacturing technical pesticides in the Country withindigenously developed technical know-how. Formerly, such pesticides were either imported orproduced in foreign multi-national sectors.

In July 2008 the Company has obtained the IMS (Integrated Management Systems)Certification, which covers ISO 9001 Quality Management System, ISO 14001 EnvironmentalManagement System and OHSAS 18001 (Occupational Health & Safety Audit System).

GIL also actively participates in educational, social and rural development projects. AnkleshwarTaluka Educational Development programmes, Mobile Library Projects, Mobile LaboratoryProjects, Mobile Medical Van for rural areas, tree plantations in GIDC area as well as adjoiningvillages, adopting villages for their betterment and participating in State Governments GokulGram Yojna etc are covered under this projects for which the Company was awarded the SocialResponsibility award in 1998 by ICMA, Mumbai.

Applicability of EIA Notification 2006

The proposed project is to enhance production capacity of existing product and manufacturenew products in its existing unit located within Ankleshwar GIDC. Hence it falls under projecttype 5(b) and Screening Category A of the EIA notification dated 14-09-2006 and thereforerequires prior Environmental Clearance from the Ministry 0f Environment & Forest Climatechange , Delhi.

2.0 INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION

2.1 Identification of project and project proponent.

Dicamba, di-chlorophenol ,PEI,Metalaxyl,Difenthiuron,Thiomethoxam.Buprofezin are new

products & remaining are capacity enhancement

Promoter Information:M/s. Gujarat Insecticides LtdPlot No. 805/806,GIDC Estate, Ankleshwar,Dist.: Bharuch, Gujarat, India

Key Personnel(1) Mr. Dilip H Mirani - Director(2) Mr. RN Chhawsaria- Factory Manager(3) Dr. PH Nagar - General manager QA &R&D


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2.2 Brief description of nature of the project.

After the success of the chemical plants in Ankleshwar, the company now proposes to expandthe chemical production facilities at the existing site Ankleshwar by putting up one more Multi-purpose chemical plant for agrochemicals & its intermediate. Along with the productionfacilities, necessary support infra-structure like Wastewater Treatment plant and requiredUtilities will be put up.

Sr.No.

Name of Product Consentavailable for

Production ofMT/Annum

EC applied foradditionalProductionMT/Annum

TotalProduction

after ECexpansion

MT/Annum1 Fenvalerate & Cypermethrin OR

Lambda Cyhalothrin or Bifentrinor Alpha Methrin orDeltamethrin

100 1100 1200

2 Quinalphos or Triazophos orChlorpyriphos or Temephos orMethyl Chlorpyriphos orAnilophos

1200 1200 2400

3 Meta Phenoxy Benzaldehyde(MPB)

2400 2600 5000

4 Indoxacarb or Propenophos orTricyclazole or Haxaconazol orPropicanazole

130 1070 1200

5a Crude Pigment Violet-23 OrPEK or PEKK or ABPBI or ABPBO 300 200

5005b Poly Ether Imide (PEI) - 5006 N-Acetoacetyl

Aminobenzimidazadone (NAA) 50 - 50

7 Bromine Recovery 700 1800(500+1300)* 2500

8 Di Chloro phenol Nil 4500 45009 Dicamba Nil 5000 500010 Metalaxyl

Nil 1200 120011 Difenthiuron12 Thiomethoxam13 Buprofezin14 Cabendazim Nil 1200 120015 Formulation Of Technical

Product 1400 KL - 1400 KL

16 Captive Power Plant – Gas Based 0.945 MW Nil 0.945 MW17 Coal fired Boiler (Power Plant) Nil 3 MW 3 MWLIST OF BY PRODUCT1 Hydrochloric acid 0 4178 MT 4178 MT2 Potassium chloride solution

&Potassium chloride Powder

**4800 MT &864 MT

10860 MT &1955 MT

15660 MT& 2819 MT


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3 Aluminum chloride **9600 MT 15531 MT 21131 MT4 Spent Sulfuric Acid 0 20655 MT 20655 MT5 Crude Phenol 0 240 MT 240 MT6 Aqueous Ammonia

**60 MT390 MT 390 MT

7 Sodium Sulphite 1164 MT 1224 MT8 Aqueous Bromide 0 360 MT 360 MT9 Sodium bisulphate 0 6935 MT 6935 MT

2.3

*Actually bromine recovery ratio is 0.5 MT/MT of the product.** In a present this by products are cover under Hazardous waste categories.

Need for the project and its importance to the country and or region,DCP & Dicamba are new product. DCP is an intermediate of Dicamba & it can be sold directly.At present GCL is manufacture about 200 MT per month.Dicamba is 100 present export markets. This gives foreign revenue to the country. Others pareproduct enhancement

The proposed expansion is necessitated because of the following reasons: To make the facility more resource efficient. Reduce operational costs and increase productivity. Development of the infrastructure of the facility. Entry into new product segments.

Its importance to the country can be accounted by Add to foreign exchange generated by Exports. Ensure continued employment to workforce without affecting work conditions and

hence supporting their families. Lead to generation of direct and indirect employment opportunities. Reduce dependence on Imports hence reducing Forex risks.

2.4 Demand-Supply Gap.

Dicamba has 100 export market & remaining product oregano phosphors & syntheticparathyroid product has local market

2.5 Imports vs. Indigenous production.

MPB is 25% export, Dicamba 100persent export. oregano phosphors & synthetic parathyroidproduct has local market

2.6 Export Possibility.

25% MPB , Dicamba 100%

2.7 Domestic / export Markets.

Organo phosphors & synthetic parathyroid are sold to local market. Highest purity & low priseis principal of gharda chemical plant.


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2.8 Employment Generation (Direct and Indirect) due to the project.

Direct: 100Nos.Indirect: 300Nos.

3.0 PROJECT DISCRIPTION

3.1 Type of project including interlinked and interdependent projects, if any.

Independent Project. No interlinked or interdependent project.

3.2 Location (map showing general location, specific location, and project boundary & Projectsite layout) with coordinates.

Latitude: 21°36’59.99”N

Longitude: 73°1’2.48” E at ELE 26 m feet height.

Detailed site plan is attached as Annexure-1

The unit has total 73084 sq.m. Of land area. Unit will commit to maintain green belt @ 35%. The site is located within Ankleshwar GIDC and hence there is no agricultural or forest land

involved in the project site. The estate is located at sufficient distance from reserved forests and sanctuaries,

archeological sites and historical sites to ensure that there is no impact of industrialactivities.

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

It is not considered since the project is for expansion in existing unit only

3.4 Size or magnitude of operation.

M/s. Gujarat Insecticides Ltd is a Large scale industry. The total existing production capacity ofare 4880 MT/Annum. After proposed expansion also it will remain as large scale unit.(Annexure-15)

3.5 Project description with process details

Detailed manufacturing process of existing & proposed products are attached as an annexure-5

3.6 Raw material required along with estimated quantity, Likely source, marketing area of finalproduct/s, Mode of transport of raw material and Finished product

The raw materials required for the proposed production shall be either imported or procuredfrom domestic market and transported conveniently by road.Detail raw material (MT/MT & MT/Month) of the product is explained Annexure-4

The manufacturing process for the proposed products are detailed step-wise with materialbalance and calculations for product-wise waste generation w.r.t water and hazardous waste


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are made.Detailed manufacturing process of proposed products are attached as an annexure-5

As being in Ankleshwar, Mode of transport would be via road.

3.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should be brieflyoutline

Proponent commit that they shall be optimize resource and reuse envisaged in the project atthe time of commissioning.

3.8 Availability of water & its sources, Energy power requirement

Water : Supplied from GIDC reservoirExisting:1011 KL/dayAfter Proposed expansion:3263 KL/Day (Detail attached as Annexure - 6)

Electricity Power is supplied from DGVCLExisting requirement of electricity @ 30000 KWHProposed additional requirement of Electricity @ 70000 KWHTotal after proposed expansion will be @ 100000 KWH

Natural gas consumption after proposed expansion shall be 710 NM3/hr

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for theirmanagement/disposal

Wastewater Generation, Treatment and Disposal There shall be additional effluent generation after proposed expansion.

Existing: 820 KL/dayAdditional effluent: 1569 KL/dayTotal effluent After proposed expansion: 2389 KL/day

Existing 820 KL/day Industrial effluent is treated in ETP (By chemical & biological treatment).Treated effluent from ETP discharged into u/g pipeline connected to FETP of M/s. NCTL(formerly known as BEAIL).

Additional effluent after proposed expansion i.e 1569 KL/day will send to RO for treatment.Permit will be reuse in cooling and reject send for MEE (i.e. 314 KL/day).276 KL distillate ofMEE sent to cooling. And 38 MT MEE salt send to TSDF side.(Detail attached as annexure-6)

Proposed products are also from the same category as existing; hence quality of industrialeffluent will not be changed. The industrial effluent will be treated in own ETP aftermodification.

Existing effluent treatment plant (capacity 960 KL/day) shall be modified to treat 2389KL/day (capacity 3000 KL/day) total effluent load after proposed expansion.

Air pollution and Control Measures

Flue gas Emission: The flue gas emission from operation of boilers & Incinerator shall be increase after

proposed EC expansion. All stacks are provided with sampling point and access ladder.Annexure-7


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Process Emissions : There shall be increase in process emission after proposed expansion for which new

scrubber system shall be provided. Scrubbing solution shall be sale as by product. Detail of air pollution control measure taken for existing process emission and after

proposed expansion is given in annexure-7

Solid / Hazardous wastes The hazardous / solid wastes generated from existing production are identified and

authorization has been obtained under the Hazardous Wastes Authorization Rules.Adequate arrangements are made for the storage, treatment and disposal of these wastes.

The quantity of existing Hazardous wastes shall increased after proposed EC expansion Detailed of all waste category with quantity and their storage and disposal are given in

Annexure-8.

Environmental Monitoring Plan The unit has established an EHS cell and prepare an Environmental Monitoring plan for

carrying out the following activities :1. To follow the trend of parameters those have been identified as critical;2. To comply with the conditions of consent order of GPCB3. To check / assess / maintain the efficiency of controlling measures;

In-house facilities and infrastructure for monitoring of certain parameters has beendeveloped. Where it is not feasible to establish such facilities, the same has been doneby appointing external recognized/ approved agencies.

The monitoring of environmental parameters is carried out time to time and the reportsof all the monitoring / analysis / assessment studies shall be well-documented.

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

It will be submitted later up on the requirement.

4.0 SITE ANALYSIS

4.1 Connectivity

Nearest towns / cities : Ankleshwar – 1.11 kms towards NNWBharuch – 10.08 kms towards NNWVadodara – 78.34 kms towards NNESurat – 52.97 kms towards SSW

Transport by roadNH-8 is connected with the surrounding districts. Transport by RailNearest City Ankleshwar has a railway junction which is approximately 1.89 km away fromAnkleshwar. Transport by AirSurat domestic is 61.86 KM towards SSW and Mumbai international airport is 280.17 KMtowards NNE away from the project site.


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4.2 Land form, Land use and land ownership

Since the project is for expansion within existing unit located in Ankleshwar, GIDC and noadditional land will be acquired for proposed expansion.Existing Project is located at Ankleshwar GIDC and land possession document is attachedherewith as annexure:14

4.3 Topography(along with map)

The following are the main features of this estate, which make it suitable for industrial activitiesof all types. The entire GIDC estate area is located at sufficient height from sea level and assessed for

suitability with respect to topographical and geological requirement for industrial activities. District map and area map from googlemaps.com and googleearth.com are as under,


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(Source: Google earth imagery date 8/2/2014).

4.4 Existing land use pattern, nearby water bodies, forest, eco sensitive zones, CRZ.etc.

Sr.No. Particulars Details1 City Ankleshwar2 District Bharuch3 Latitude 21°36’59.99”N

4 Longitude 73°1’2.48” E at ELE 26 m5 Nearest water bodies Narmada river- 7.38 km towards NNW6 Nearest Highway NH-8 1.41 Km towards NWW7 Nearest Railway station Ankleshwar -1.89 km towards NNW

Bharuch- 9.77km NNW

8 Nearest Airport/ Airbase Surat- 61.86 KM towards SSWVadodara- 78.86 km towards NNEMumbai international airport- 280.17 KMtowards NNE

Existing land use is already allotted for industrial use by Ankleshwar GIDC No eco sensitive zone. The project is not covered under CRZ. The estate is located at sufficient distance from reserved forests and sanctuaries,

archeological sites and historical sites to ensure that there is no impact of industrialactivities.

4.5 Existing infrastructure:

The Ankleshwar GIDC is establishment since 40 years. There are 1000 industries of all scale VizSSIs, MSIs, LISs. Established in the GIDC, manufacturing almost all categories of chemical and


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allied product namely organic chemical, inorganic chemical, dyes and dyes intermediates, drugand drugs intermediates, paints and varnishes, engineering units etc.

Many international companies have established their main as well as supportive units in thisestate.

The following are the main features of this estate, which make it suitable for industrial activitiesof all types.

The entire estate area is located at sufficient height from sea level and assessed forsuitability with respect to topographical and geological requirement for industrialactivities.

The estate is located at sufficient distance from reserved forest and sanctuaries,archeological sites and historical sites to ensure that there is no impact of industrialactivities.

4.6 Soil classification

The project is for expansion in existing unit only. The soil classification of Gujarat state is asunder,

The quality of Bharuch district area soil had been identified as deep black coastal alluvial type.

4.7 Climate data from secondary sources


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Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.January 11 36.7 54 98 18 56 0 12 0 12 0 6 0 6 0 0February 13.5 38.5 49 90 22 63 0 8 4 12 0 6 0 4 0 0March 16.4 39.3 21 89 17 64 0 8 4 12 0 6 0 6 0 0April 21.2 41 44 85 16 77 0 12 4 18 0 5 0 7 0 0May 26 40.6 48 82 40 74 0 12 6 20 0 5 0 4 0 0June 23.8 35.3 69 98 50 97 0 12 0 14 0 8 2 8 760.4 19July 23.5 32.4 82 98 73 98 0 18 0 18 4 8 5 8 641.1 25August 23.8 31.4 78 98 75 98 0 12 4 18 4 8 3 8 302 22

September 23.6 35.1 80 97 54 96 0 22 0 14 2 8 1 8 85.5 10October 20.5 36.4 51 95 29 90 0 10 0 10 0 7 0 7 12.1 6November 16.5 36.6 49 84 22 59 0 12 0 10 0 4 0 3 0 0December 12.8 34.5 48 91 25 67 0 8 0 10 0 5 0 6 0 0

Month(2013)

Temperature in °C Relative humidity in % Wind speed in kmph Cloud Cover in oktasRainydaysMin. Max.

0830 hrs 1730 hrs 0830 hrs 1730 hrs 0830 hrs 1730 hrsTotal

Rainfallin mm

(Courtesy: Indian Meteorological Department, Surat)

4.8 Social infrastructure available

Educational facilities in project area are quite good because all nearby villages haveprimary schools. There are secondary and higher secondary schools in Bharuch city. Thereare collages having different streams of education.

The town has private dispensaries and hospitals in all major branches of medicines andsurgery.

Drinking water quality is good. All small villages have postal and telephone connection facilities. Electricity for all purpose (agriculture, industrial and residential) is available. All small villages are connected with pucca roads.

5.0 PLANNING BRIEF

5.1 Planning concept(type of industries, facilities, transportation etc)

M/s. Gujarat Insecticides Ltd is Large scale industry. Existing plant is at Ankleshwar GIDC

5.2 Population projection

It will be submitted later up on the requirement.

5.3 Land use planning, break up along with green belt etc.)

Existing and proposed breakup of land. As per annexure-1

5.4 Assessment of infrastructure demand (physical & social)

Well developed Infrastructure since project site is located in Ankleshwar GIDC


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5.5 Amenities/Facilities

The existing amenities/facilities of project area are explained as earlier.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area)

Explained in CA certificate. Attached as Annexure-13.

6.2 Non processing area

Explained in CA certificate. Attached as Annexure-13.

6.3 GreenbeltPresently 25579 sq.m. has been covered for green belt. Unit is committed to maintain greenbelt @ 35%. No additional green belt is required after proposed expansion.

6.4 Social infrastructure:

The project is a large scale and total investment approximately 181.27 CRORE. The projectproponent is planning towards the social and economic development of small villages aroundAnkleshwar.

6.5 Connectivity(Transportation)

The existing connectivity is convenient for future also.

6.6 Drinking water management(Source and supply)

The existing source of drinking water is GIDC & will be continuing for future expansion.

6.7 Sewage system

There will be 25 KL/day rise (Total-95 KL/day) in the domestic effluent quantity. However,Domestic effluent is discharge with industrial effluent

6.8 Industrial waste management

After proposed expansion, total Industrial wastewater will be generated 2389 KL/Day.Proposed products are also from the same category as existing hence quality of industrialeffluent will not be changed. The industrial effluent will be treated in own ETP aftermodification.Detail water balance diagram of Existing & proposed expansion is attached as annexure:6Detail of schematic diagram of ETP is attached as annexure:9

6.9 Solid waste management

There shall be Twenty Three (23) numbers of Hazardous / solid waste categories identified tobe generated.

The unit has obtained membership of TSDF & incineration Site


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Detail of solid waste is explained in annexure-8

6.10 Power requirement and supply source.

Electricity Power shall be supplied by DGVCLExisting requirement of electricity @ 30000KWHProposed additional requirement of Electricity @ 70000KWHTotal after proposed expansion will be @100000

7.0 REHABILITATION AND RESETTLEMENT (R&R)Plan

7.1 Policy to be adopted(central/state) in respect of the project affected persons including homeoutees, land outees and landless laborers (a brief outline to be given)

Not applicable because the unit is in Ankleshwar GIDC

8.0 PROJECT SCHDULE& COST ESTIMATION

8.1

8.2

Likely date of start of construction and likely date of completion(Time schedule)

Construction/modification is planned to be started after having an Environmental clearancefrom MoEFLikely completion time is considered approximately two years of projectconstruction/commission.

Estimated project cost along with analysis in terms of economic viability of the projectThe estimated approx. cost of the project shall be Rs. 181.27 Crore out of which approximatelyRs. 74.27 Crore shall be invested in Environmental Management System (EMS) constitutingproposed ETP, solid / hazardous waste management and disposal facilities, Air pollution controlmeasuresTable given as under,


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Group Particulars Nos. Cost Rs (In lac)Reactors 70 1200Condenser 21 150Hydrogenated reactor 2 20Filter press 2 20Cone blender 1 25Rotary drum flaker 2 60Fluidized bed dryers 1 50Thermic fluid heater 1 25D.G set 2 40Demineralizer 1 20Chilling plant 2 50Cooling tower 6 70Water Storage Tank 3 30Raw material storage tank 30 300Preoperative expenses 100Contingencies 1000Piping 1000Installation 2000Electrical installation 2500Misc expenses? Lab, office, plant building, ware house, furniture & fixtures,office & lab requirementEffluent treatment plant 1 3302Green Belt Development 1 25APCM 1 25Haz. storage facilities 1 253 MW Power Plant 1 4000DM Plant 1 50

TOTAL 18127181.27 Crore

2040

Enviro

Process Plant

Storage Tanks

Civil

Utilities

9.0 ANALYSIS OF PROPOSAL(FINAL RECOMMANDATIONS)

9.1 Financial and social benefits with special emphasis on the benefit to the local peopleincluding tribal population any in the area

From the proposed production, there shall be increase to foreign exchange generated byExports.

Reduce dependence on Imports hence reducing forex risks. There shall be direct or indirectly increase in employment generation for the local people

hence supporting their families. Company shall increase its contribution for community welfare of the local connected area. The proposed new project shall not have any adverse environmental impacts because

adequate protection measures will be provided to achieve permissible norms of GPCB.

Conclusion:

The proposed project is feasible w.r.t environmental impact since there is no major POLLUTIONLOAD as well as adequate environmental protection measures are proposed by the unit.

Documents

PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-11-05 · M/s. Gujarat Insecticides Ltd Expansion in Existing Unit Pre-Feasibility Report