PROPOSED EXPANSION OF ORGANIC CHEMICALS …

1

PRE FEASIBILITY REPORT

For

PROPOSED EXPANSION OF ORGANIC CHEMICALS

MANUFACTURING IN EXISTING INORGANIC CHEMICALS

MANUFACTURING UNIT

of

M/s. D Y INDUSTRIES

PLOT NO. 3003, PHASE-III, GIDC ESTATE,

PANOLI-394116, TALUKA: ANKLESHWAR,

DIST: BHARUCH, GUJARAT

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CONTENTS

Sr. No. Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 9

3. Project Description 10

4. Site Analysis 16

5. Planning Brief 18

6. Proposed Infrastructure 19

7. Rehabilitation and resettlement (R & R) Plan 21

8. Project Schedule & Cost Estimates 21

9. Analysis of Proposal (Final Recommendations) 22

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1.0 EXECUTIVE SUMMARY

1.1 Company Profile

M/s. D Y Industries proposes organic chemicals manufacturing in the existing inorganic

chemicals manufacturing unit located at Plot no. 3003, GIDC Panoli-394116, Taluka:

Ankleshwar, Dist: Bharuch, Gujarat by expansion.

1.2 Project Details

1.2.1 Products along with Production Capacity Sr.

No.

Product Existing

Quantity

(TPM)

Additional

Quantity

(TPM)

Total

Quantity

(TPM)

Inorganic Products

1 Copper Sulphate

850

0

850 2 Potassium Sulphate

3 Mono Ammonium Phosphate

4 Sodium Nitrate

Organic Products

1 Theobromine 0 10 10

2 MetaBromo Anisol

0

25

25

3 Chlorhexidine Base

4 Chlorhexidine Digluconate

5 Chlorhexidine Diacetate

6 Chlorhexidine Hydrochloride

7 3-Chloropropiophenone

8 Tetra Butyl Ammonium Bromide

9 Tetra Butyl Ammonium Chloride

10 Tetra Butyl Ammonium Hydrogen Sulphate

11 Tetra Butyl Ammonium Iodide

12 Tetra Butyl Ammonium Fluoride Trihydrate

13 N-Butyl Bromide

14 N-Propyl Bromide

15 Bis-2-chloro ethyl amine hydrochloride

16 2-Nitro 4-Thiocyno Aniline

By Products

1 Acetic Acid 0 19 19

2 Spent Sulphuric Acid 0 173 173

3 Dilute HCl 0 82 82

4 AlCl3 Solution 0 81 81

5 Potassium Bromide Solution 0 152 152

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6 Sodium Bromide Solution 0 15 15

7 Sodium Sulphite Solution 0 156 156

1.3 Raw Material Requirement

List of Raw Materials and Their Capacity

SR. NO. Name of Raw Materials CAPACITY (MT/Tonne of Product)

Inorganic Products

1. Copper Sulphate

1. Copper Metal 0.473

2. Sulphuric Acid 0.684

2. Potassium Sulphate

1. Potassium Hydroxide 0.653


3.Mono Ammonium Phosphate

1. Phosphoric Acid 1.010

2. Anhydrous Ammonia 0.151

4. Sodium Nitrate

1. Sodium Carbonate 0.637

2. Nitric Acid 1.070

Organic Products

1. Theobromine

1. Cyno Acetic Acid 1.80

2. Mono Methyl Urea 1.19

3. Acetic Anhydride 1.87

4. Caustic Lye 48% 1.97

5. HCl 1.83

6. Sodium Nitrite 0.79

7. Acetic Acid 0.60

8. Pd on Carbon 0.00

9. Formic Acid 1.58

10. DiMethyl Sulphate 1.32

11. Activated Carbon 0.10

12. Water 1.60

2. Meta Bromo Anisol

1. Nitrobenzene 1.11

2. Oleum 23% 3.93

3. Bromine 0.59

4. Iodine 0.01

5. Soda Ash 0.06

6. Methanol 0.28

7. Toluene 6.11


9. Sodium Methoxide 0.28

10. Salt 0.72

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11. HCl 1.94

12. Tetra Butyl Ammonium Bromide 0.19

13. Water 4.03

3.Chlorohexidine

1. Sodium dicynamide 0.36

2. N-Butanol 0.69

3. Hexamethyl Diammine 0.23

4. TEA 0.02

5. Caaustic Lye 48% 0.10

6. PCA HCl 0.64

7. Methanol 0.66

8. Water 0.69

4. Chlorhexidine Digluconate

1. Chlorhexidine 0.57

2. Gluconic Acid 0.44

3. Water 4.02

4. Carbon 0.01

5.Chlorhexidine Diacetate


2. Acetic Acid 0.20

3. Recycle Water 0.37

4. Water 0.17

5. Carbon 0.02

6. Chlorhexidine Dihydrochloride


2. HCl 30% 0.12

3. Water 1.62

7. 3-Chloropropiophenone

1. MDC 3.29

2. AlCl3 1.96

3. Propiophenone 1.64

4. Chlorine Gas 1.30

5. NaoH 0.03

6. Water 5.47

7. Hexane 1.64

8. HCl 0.59

8. Tetra Butyl Ammonium Bromide

1. Tri N-Butyl Amine 0.55

2. Butyl Bromide 0.45

3. Acetonitrile 0.30

4. Ethyl Acetate 0.40

5. Soda Ash 0.10

9. Tetra Butyl Ammonium Chloride



3. Toluene 2.24

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4. HCl 0.48

5. Methanol 2.64

6. Water 2.00

10. Tetra Butyl Ammonium Hydrogen Sulphate


2. Butanol 1.20


4. Sodium Hydrogen Sulphate 0.12

5. Soda Ash 0.12

6. Methyl Ethyl Ketone 0.80

7. Methyl Isobutyl Ketone 0.80

8. Methylene Dichloride 0.80

11. Tetra Butyl Ammonium Iodide


2. Potassium Iodide 0.50

3. Ethyl Acetate 1.00

4. Methanol 2.00


6. Sodium Hydroxide 0.25

7. Water 5.00

12. Tetra Butyl Ammonium Fluoride Trihydrate



3. Methanol 2.00

4. Hydrofloric Acid 0.25

5. Charcoal 0.08

13. N-Butyl Bromide

1. N-Butanol 0.57

2. Sulphure Powder 0.05

3. Bromine 0.67

4. Soda Ash 0.02

5. Water 0.23

14. N-Propyl Bromide

1. N-Propanol 0.57

2. Sulphure Powder 0.06

3. Bromine 0.76

4. Soda Ash 0.01

5. Water 0.23

15. Bis-2-chloro ethyl amine hydrochloride

1. Diethanol amine 0.63

2. Thionyl Chloride 1.56

3. Toluene 1.88

4. Caustic Lye(48%) 2.00

5. Soda Ash 0.05

6. Water 4.03

16.2-Nitro 4-ThiocynoAniline

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1.4 Water Requirement, Waste Water Generation and Treatment

Total water requirement will be 17.21 m3/day which will be met through GIDC water supply.

The total waste water generation will 5.6 m3/day. The Industrial effluent 3.3 m3/day will be

treated in ETP consists of primary treatment and after primary treatment the effluent will be

sent to CETP for further treatment and disposal.

Domestic Waste water 2.3 m3/day will be disposed of through the specific tank & Soak Pit

System.

1.5 Air Pollution Source and Control Management

There will be flue gas emission from Boiler, THF and process gas emission from stack attached

to reactor. Company will install water Scrubber to reduce air pollution.

1.6 Hazardous Waste

CAT. NO.

HAZARDOUS WASTE

Existing Quantity

Additional Quantity

Total Quantity METHOD OF DISPOSAL

33.3 Discarded / containers/ barrels /liners

3 MT/Month

5 MT/Month 8 MT/Month Collection, Storage, Decontamination & Reuse or given GPCB registered vendors.

5.1 Used Oil 1 Lit/Month 2 Lit/Month 3 Lit/Month Collection, Storage and Reuse as Lubricant Within Premises/given to GPCB registered Recycler/Reprocessors.

33.1 ETP Sludge 0 5 MT/Month 5 MT/Month Collection, Storage, Transportation & disposal at TSDF.

28.1 Process Residue 0 4 MT/Month 4 MT/Month Collection, Storage, Transportation & sent for

1. Orthonitroaniline 0.74

2. Ammonium Thiocynate 0.88

3. Methanol 2.82

4. Chlorine Gas 0.51

5. Soda Ash 0.33

6. Water 4.03

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co-processing or incineration.

28.2 Spent charcoal 0 0.2 MT/Month 0.2 MT/Month Collection, Storage, Transportation & sent for co-processing or disposal in TSDF.

28.5 Spent Solvent 0 0.1 MT/Month

0.1 MT/Month Collection, Storage, Transportation & sent for co-processing or incineration.

20.3 Distillation Residue

0 3.5 MT/Month

3.5 MT/Month

1.7 Green Belt

Total 1,000 sq. meter land area is available at site; out of this area around 300 sq. meter (30 %)

area will be developed as greenbelt.

1.8 Power & Fuel Requirements

Power Requirements: Power required : 71 HP (Existing) : 125 HP (Proposed) Source: DGVCL Fuel Requirements: LDO/Diesel: 360 Lit/Day (Existing capacity) Natural Gas: 800 SCM/Day (Proposed capacity)

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project and project proponent. In case of mining project, a copy of

mining lease/letter of intent should be given.

Identification of the project and project proponent

M/s. D Y Industries proposes expansion of organic chemicals manufacturing in the existing

inorganic chemicals manufacturing unit located at Plot no. 3003, GIDC, Panoli-394116, Taluka:

Ankleshwar, Dist: Bharuch, Gujarat.

List of Directors:

Sr. No.

Name of Directors

Residential. Address Phone No. Qualification Experience

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1. Mr. Manharbhai M. Malaviya

B. No. 17, Vaikunth Society, GIDC, Ankleshwar-393002

+919998016156

Graduate 25 years

2. Mr. Rasikbhai M. Malaviya

B. 14, Amber Vilash Society, GIDC, Ankleshwar-393002

- Graduate 25 years

2.2 Brief description of nature of the Project

Proposed Expansion of Organic chemicals manufacturing in the existing inorganic chemicals

manufacturing unit.

2.3 Need for the project and its importance to the country and or region

The demand for products intended to be manufacture is increasing in the country by expanding

this unit, M/s. DYI will be able to meet the demand of various products locally. The project will

save forex as certain products import will be reduced. This will also generate direct and indirect

employment opportunity for various levels of people.

2.4 Demands-Supply Gap

Based on our informal survey of the market with our current customers and various traders, we

have found that there is a big potential for the range of the products we are planning. These

products will be an addition to the current product.

2.5 Imports vs. Indigenous production

Based on the current cost of indigenous raw materials and the non availability of some

materials, we will have to import some of the key raw materials as they are not available

indigenously. This will make us very competitive against imported finished products and we will

export of our finished products in the international market.

2.6 Export possibility

We shall explore the possibility of export the products.

2.7 Domestic/Export Markets

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Our products have good demand in domestic & international markets. We shall explore the

possibility of export the products.

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

M/s. D Y Industries will give direct employment to local people based on qualification and

requirement. In addition to direct employment, indirect employment shall generate ancillary

business to some extent for the local population.

3.0 Project Description

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

No interlinked project has been submitted.

Location (map showing general location, specific location and project boundary & project

site layout) with coordinates.

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Map showing general

location.

Project

Site

12

Specific location and project boundary

Project Site (Google Map)

10

Plot Layout

25.00 MTR. X 40.00 MTR.

GATE

OFFICE & Q.C, Q.A LABORATORY

PLANT

RAW MATERIAL STORAGE

UTILITY

G R E E N

B E L T

ETP

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3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Looking to the international market demand of the products it was decided by M/s. D Y

Industries to expand existing facility.

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

Existing operational facility

Minor site clearance activities shall be carried out.

The project site is located on level ground, which does not require any major land filling

for area grading work.

Proximity to Raw Material suppliers.

Site is very well connected by road and railway.

Availability of Fuel, Power, TSDF, CETP, etc.

Modern infrastructure support and amenities at par in other global markets, including:

Efficient transport facilities.

Environment-friendly zone.

Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer Section-1.2.1, Page No. 3.

3.5 Project Description with process details (a schematic diagram/flow chart showing the

project layout, components of the project, etc. should be given)

Please refer Form-I, Annexure-III.

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3.6 Raw Material required along with estimated quantity, likely source, marketing area of

final product/s, mode of transport of raw material and Finished product.

For raw material required along with quantity; Please refer Section-1.3, Page No. 4. We shall

procure the raw material as much as possible from domestic market and if there is no

availability of any raw material we will import. We shall explore the possibility of export the

finished products.

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

briefly outlined.

After expansion of the unit, possibility for reuse and recycle will be explored.

3.8 Availability of water its source, energy/power requirement and source should be

given.

Water Source

Total water requirement shall be met through GIDC Water Supply.

Power Requirements: Power required : 71 HP (Existing) : 125 HP (Proposed) Source: DGVCL Fuel Requirements: LDO/Diesel: 360 Lit/Day (Existing) Natural Gas: 800 SCM/Day (Additional)

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/disposal.

Please refer Please refer Form-I, Annexure-IV & VI.

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

purpose.

4.0 Site Analysis

4.1 Connectivity

Site is very well connected by road

Availability of fuel, power, TSDF, CETP, etc.

4.2 Land Form, Land Use and Land Ownership

Land Use will be incorporated in the EIA Study.

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC STATUS &

INFRASTRUCTURE

PROPOSED

PLANT

FACILITY DESCRIPTION

IMPACTS METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM

RISK ANALYSIS STUDIES & DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

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4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from

HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette

notification should be given.

Existing land use pattern will be incorporated in the EIA Study. CRZ is not applicable.

4.5 Existing Infrastructure

Existing operating industry having Manufacturing plant, Adm. Bldg., Godown, etc.

4.6 Soil Classification

Soil Classification will be incorporated in the EIA Study.

4.7 Climatic data from secondary sources.

Climatic data will be incorporated in the EIA Study.

4.8 Social infrastructure available.

Various Programs/ Projects related to Social & Economic development of surrounded area

has been planned, which are as follows.

A) Natural Resource Management – The main focus of this program will be to maximize the

yield returns of the farmers through efficient management of existing resources &

extension of new agricultural practices.

1) Integrated Agricultural Growth Project – For improvement and use of the modern

techniques and thereby would certainly contribute to prosperity in the agriculture

sector and reduce the rural poverty by programs like Farmers Training, Nursery

Growing Trainings, Modern agriculture equipment distribution programs etc.

2) Animal Husbandry Projects – Various programs like health checkups & treatment,

vaccination program, Anti sterility camps, breed improvement etc. will be carried

out.

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B) Income Generation Program -

1) Establishment of Self help groups.

2) Rural Entrepreneurship Development Program

3) Handcrafts Development Program

4) Vocational Training

5) Business process outsourcing

C) Health, Education & Infrastructure

1) Aids Awareness Program

2) General Health Camps

3) Innovative Teaching Methods

4) Adult Education

5) Sanitation

6) Infrastructure Development Projects

5.0 Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

planning/Development authority classification.

Type of Industry: Proposed expansion of organic chemicals manufacturing in existing

inorganic chemicals manufacturing unit.

5.2 Population Projection

Population Projection will be incorporated in the EIA Study

5.3 Land use planning (breakup along with green belt etc.)

SR.

NO.

PARTICULAR AREA (m2) % OF TOTAL LAND

1 Process Plant 320 32

2 Raw Material & Product Storage 150 15

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3 Utility 20 2

4 Storage (Hazardous Chemicals) 20 2

5 Hazardous Waste Storage Area 20 2

6 Effluent Treatment Plant 20 2

7 Green Belt 300 30

8 Roads 40 4

9 Parking Area 20 2

10 Administrative Building 30 3

11 Undeveloped Open Area 60 6

Total 1,000 100

5.4 Assessment of Infrastructure Demand (Physical & Social)

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

unskilled people for the proposed expansion activity.

Social Welfare

Cordial relation with the villages shall be established and representation shall be made

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

5.5 Amenities/Facilities

Details of amenities available in study area

Population Projection will be incorporated in the EIA Study.

6.0 Proposed Infrastructure

6.1 Industrial Area (Processing Area)

Processing Area (Process Plant, Utility , ETP Area, Administrative Buliding) = 390 m2

6.2 Residential Area (Non Processing Area)

Non Processing Area (Raw material & product storage area, storage (Hazardous Chemicals)

area, Hazardous waste storage Area, Road ,Parking Area ,green belt and Undeveloped open

area) = 630 m2

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Green Belt: 300 m2

6.3 Green Belt

Total 1,000 sq.meter land area is available at site; out of this area around 300 sq. meter

(30%) area will be developed as greenbelt.

6.4 Social Infrastructure

Water requirement will be met through GIDC Water Supply.

Power supply by DGVCL.

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

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

Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free from cultivation

Availability of power facilities

Availability of fuel

6.6 Drinking water Management (Source & Supply of water)

Total water requirement shall be met through GIDC Water Supply.

6.7 Sewerage System

Sewage pipes are laid in entire company for the removal and disposal of mainly non-

harmful liquid wastes from the offices, canteen and domestic waste coming from different

section of industry. These liquid wastes are sent to septic tank & soak pit.

6.8 Solid Waste Management

Please refer Form-I, Annexure-VI. 6.9 Power Requirement & Supply/Source

Please refer Section 1.8, Page No. 8 of this report.

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7.0 Rehabilitation and Resettlement (R & R) Plan

7.1 Policy to be adopted (central/state) in respect of the project affected including home

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

There is no habitation on the proposed expansion project activity area and it is open

industrial land, so R & R policy is not applicable to this project.

There shall not be displacement of any population in project area. Any major activity that

may lead to resettlement of the people is considered as permanent impact. Hence, there is

no permanent impact on this account. The increasing industrial activity will boost the

commercial and economical status of the locality up to some extent.

8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for

the project to be given).

We shall start construction of expansion project after getting EC & CTE and we shall start

production after applying for CCA.

8.2 Estimated Project cost along with analysis in terms of economic viability of the

project.

The total cost of the project after proposed expansion will be around Rs. 2.0 Crores.

9. Analysis of Proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to be local people

including tribal population, if any, in the area.

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

unskilled people for the proposed expansion project.

Social Welfare shall be done.

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

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

Documents

PROPOSED EXPANSION OF ORGANIC CHEMICALS …