Project feasibility report -...

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PRE FEASIBILITY REPORT

For

PROPOSED SPECIALTY CHEMICALS PLANT IN EXISTING

PREMISES

of

M/s. BROMCHEM LABORATORIES PVT. LTD.

SURVEY No. 295, VILLAGE: LUNEJ, TAL: KHAMBHAT, DIST:

ANAND, GUJARAT

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CONTENTS

Sr. No. Description Page No.

1. Executive Summary 2

2. Introduction of the Project/Background information 9

3. Project Description 10

4. Site Analysis 14

5. Planning Brief 25

6. Proposed Infrastructure 27

7. Rehabilitation and resettlement (R & R) Plan 28

8. Project Schedule & Cost Estimates 28

9. Analysis of Proposal (Final Recommendations) 29

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1.0 EXECUTIVE SUMMARY

1.1 Company Profile

M/s. Bromchem Laboratories Pvt. Ltd. have proposed for expansion of Chemicals

manufacturing unit at survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat.

Proposed expansion will be carried within the existing unit having land area of 6981 m2.

Total project cost is Rs. 4.5 Crores.

1.2 Project Details

1.2.1 Products along with Production Capacity

Sr. No.

Product Existing Capacity (MT/Month)

Proposed Capacity (MT/Month)

1. Potassium chloride 400 Max. 1 product

400 Max. 1 product

2. Calcium chloride 3. Barium chloride 4. Zinc chloride 5. Potassium bromate 100

Max. 1 product 100 Max. 1 product 6. Sodium bromate

7. Potassium bromide 70 Max. 1 product

70 Max. 1 product

8. Sodium bromide 9. Calcium bromide 10. Ammonium bromide 11. Sodium carbonate 100

Max. 1 product 100 Max. 1 product 12. Potassium carbonate

13. Sodium phosphate 300 Max. 1 product

300 Max. 1 product

14. Potassium phosphate 15. Dicalcium phosphate 16. Tricalcium phosphate 17. Sodium sulphate

200 Max. 1 product

200 Max. 1 product

18. Potassium sulphate 19. Copper sulphate 20. Zinc sulphate 21. Chloroacetyl chloride ‐‐ 80 22. Benzoyl chloride ‐‐ 310 23. Pivaloyl chloride ‐‐ 40 24. Propionyl chloride ‐‐ 80 25. 2‐chloropropionyl chloride ‐‐ 40 26. Butyryl chloride ‐‐ 40

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By‐Products

27. Isobutyryl chloride ‐‐ 40 28. 4‐Chlorobenzoyl chloride ‐‐ 40 29. 2‐chlorobenzoyl chloride ‐‐ 40 30. Velaryl chloride ‐‐ 40 31. 3‐chloropropionyl chloride ‐‐ 40 32. 4‐chlorobutyryl chloride ‐‐ 40 33. 4‐methoxybenzoyl chloride ‐‐ 25 34. 3‐methoxybenzoyl chloride ‐‐ 25 35. 3‐chlorobenzoyl chloride ‐‐ 25 36. 2,3‐Dichlorobenzoyl chloride ‐‐ 25 37. 2,4‐Dichlorobenzoyl chloride ‐‐ 25 38. 3,4‐Dichlorobenzoyl chloride ‐‐ 25 39. 3,5‐Dichlorobenzoyl chloride ‐‐ 25 40. 4‐methylbenzoyl chloride ‐‐ 25 41. 2‐methylbenzoyl chloride ‐‐ 25 42. Isophthaloyl chloride ‐‐ 20 43. N‐butyl chloride ‐‐ 20 44. Isobutyl chloride ‐‐ 20 45. N‐Hexyl chloride ‐‐ 20 46. Propiophenone ‐‐ 20 47. 3‐chloropropiophenone ‐‐ 20 48. Benzophenone ‐‐ 20 49. 4‐chlorobenzophenone ‐‐ 20 50. 2,4‐dichloroacetophenone ‐‐ 20 51. Valarophenone ‐‐ 20 52. Trityl chloride ‐‐ 50 53. Acetanilide ‐‐ 20 54. Triethylamine hydrochloride ‐‐ 21 55. 2,4,6‐Trichloropyrimidine ‐‐ 20 Total 1170 2536

Sr. No.

Product Existing Capacity (MT/Month)

Proposed Capacity (MT/Month)

1. HCL (30 % ) ‐‐ 872

2. Sodium Bisulfite ‐‐ 1772

3. Aluminum Chloride Solution ‐‐ 396

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1.3 Raw Material Requirement

Sr. No.

Raw Material Required

Existing Consumption (MT/Month)

Proposed Consumption (MT/Month)

1. Potassium hydroxide 818 818 2. 30% Hydrochloric acid 1570 1570 3. Calcium oxide 222 222 4. Calcium hydroxide 743 743 5. Barium oxide 294 294 6. Zinc oxide 339 339 7. Bromine 202 202 8. Sodium hydroxide 460 460 9. 50% Hydrobromic acid 226 226 10. Ammonium carbonate 25 25 11. 30% Phosphoric acid 2262 2262 12. 50% sulfuric acid 990 990 13. Copper oxide 100 100 14. Monochloroacetic acid (MCA) ‐‐ 84 15. Benzotrichloride ‐‐ 509 16. Pivalic acid ‐‐ 34 17. Thionyl chloride ‐‐ 640 18. Sodium hydroxide ‐‐ 1434 (15%) 19. Propionic acid ‐‐ 64 20. 2‐Chloropropionic acid ‐‐ 34 21. Butyric acid ‐‐ 33 22. Isobutyric acid ‐‐ 33 23. 4‐Chlorobenzoic acid ‐‐ 36 24. 2‐Chlorobenzoic acid ‐‐ 36 25. Valeric acid ‐‐ 34 26. Acrylic acid ‐‐ 23 27. Gamma‐butyrolactone ‐‐ 25 28. 4‐Methoxybenzoic acid ‐‐ 22 29. 2‐Methoxybenzoic acid ‐‐ 22 30. 3‐Chlorobenzoic acid ‐‐ 22 31. 2,3‐Dichlorobenzoic acid ‐‐ 23 32. 2,4‐Dichlorobenzoic acid ‐‐ 23 33. 3,4‐Dichlorobenzoic acid ‐‐ 23 34. 3,5‐Dichlorobenzoic acid ‐‐ 23 35. 4‐Methylbenzoic acid ‐‐ 18 36. 2‐Methylbenzoic acid ‐‐ 18 37. Isophthalic acid ‐‐ 16 38. N‐Butanol ‐‐ 16

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39. Isobutanol ‐‐ 16 40. N‐Hexanol ‐‐ 17 41 Aluminium chloride ‐‐ 104 42. Benzene ‐‐ 65 43. Propionyl chloride ‐‐ 14 44. 3‐Chloropropionyl chloride ‐‐ 15 45. Benzoyl chloride ‐‐ 28 46. 1,3‐Dichlorobenzene ‐‐ 16 47. Acetyl chloride ‐‐ 21 48. Valeryl chloride ‐‐ 15 49. Aniline ‐‐ 14 50. Triethylamine ‐‐ 15 51. Barbituric acid ‐‐ 14

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1.4 Water Requirement, Waste Water Generation and Treatment

Total water requirement will be 45 m3/day which will be met through Ground Water. Total

wastewater generation will be 8.8 m3/day. The industrial effluent (6.3 m3/day) will be

treated in proposed ETP consists of primary & tertiary treatment facility & then it will go to

CETP for further treatment.

Domestic Waste water (2.5 m3/day) will be disposed by septic tank & soak pit.

1.5 Air Pollution Source and Control Management

There will be emission from Thermopack & Steam Boiler, D.G. Sets and Process Vents. To

control the emission from process vents, adequate scrubbers will be installed.

Existing: 1. Details of Flue Gas Stack; Stack Attached To Furnace

SOURCES OF GASESOUS EMISSION STACK

Fuel Used Agro Waste/Coal

Type of Emissions SO2 NOx SPM

Permissible Limits 262 mg/Nm3 94 mg/Nm3 150 mg/Nm3

Stack Height 10 meters

Proposed ‐ Flue Gas Emission 2. Details of Flue Gas Stack; Stack Attached To Thermopack Boiler


Capacity 6 Lack KCal /Hr





Stack Diameter at the Top 600 mm Control Measures Cyclone Separator with dust collector

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3. Details of Flue Gas Stack; Stack Attached To Steam Boiler


Capacity 1 TPH





Stack Diameter at the Top 600 mm

Control Measures Cyclone Separator with dust collector

4. Details of Process Vent ; Vent Attached To Process Sr. No. Stack attached to Stack Height Air Pollution

Control System Parameter Permissible Limit

Proposed 1 Process Vent

(Chlorination Plant) 11 m Three Stage

Scrubber HCl SO2

20 mg/Nm3 40 mg/Nm3

2 Process Vent

11 m HCl

20 mg/Nm3

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1.6 Hazardous Waste

TYPE OF WASTE SCHEDULE

CATEGORY

SOURCE QUANTITY DISPOSAL METHOD

ETP Waste

34.3

ETP 17 MT/ Month Collection, Storage, Transportation & Disposal to TSDF Site

Used Oil

5.1 Plant & Machinery

5 LITERS/ Month Collection, Storage, Transportation & Sale to GPCB Authorized Recycler

Discarded Containers/

Bags/ Carboys

33.3 Process 500 NOS. Decontamination, Storage & Given to GPCB Registered Vendor

Distillation Residue

20.3 Process 12 MT/ Month Collection, Storage, Transportation, Disposal by Incineration at CHWI of NECL OR CO‐Processing in Cement

Industries Fly Ash ‐‐ Boiler 17 MT/ Month Will be sold to Brick Manufacturers

HCL (30 % ) ‐‐ Process 872 MT/Month Captive Consumption

Sodium Bisulfite ‐‐ Process 1772 MT/Month Will be sold to end user.

Aluminum Chloride Solution

‐‐ Process 396 MT/Month Will be sold to end user.

1.7 Green Belt Maximum open land will be provided for green belt development. Total green belt area will be 2303 m2 (approx. 33%) of total land area.

1.8 Power & Fuel Requirements

S. No. Particulars Requirement Power 1 Power Requirement 150 KVA 2 Source of Supply MGVCL Fuel 1 Fuel & IT’S Consumption Agro Waste ‐ 5 MT/Month OR Coal ‐ 4 MT/Month

Diesel ‐ 150 Liter/Day (Emergency) 2 Source of Supply Nearest Supplier

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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 Proposed Specialty Chemicals plant in Existing Premises Identification of the project proponent The detail of project proponent is as below: 1. Mr. Raman A. Patel: He is B.Sc. (Chemistry). He has experience of 30 years as analytical

chemist & Production Support. 2. Mr. Mayaben R. Patel

2.2 Brief description of nature of the Project

Proposed Specialty Chemicals plant in Existing Premises 2.3 Need for the project and its importance to the country and or region

There is a good potential for us to fulfill the need of domestic market as well as contribute

in earning foreign Exchange.

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.

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 our finished products in the international market.

2.6 Export possibility

We shall explore the possibility of export (100%) the products.

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2.7 Domestic/Export Markets

Our products have good demand in international market. We shall explore the possibility of

export (100%) the products.

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

M/s. Bromchem Laboratories Pvt. Ltd. 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.

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

• Map showing general location

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• Specific location and project boundary

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Plot Layout

N

Parking

D.G. Set

2.5 m

73 m

12 m

100.5 m

13.5 m

37.2 m

78.18 m

40.79 m

Office

Cooling Tower

Tank Farm Area Raw Materials

& Products ‐ Storage Area

Boiler

Coal/Agro Waste Storage

Proposed Manufacturing Unit

Existing Manufacturing Unit

Proposed Manufacturing Unit

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.

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 evacuation facilities

• Availability of water for industrial use Modern infrastructure support and amenities at par with industrial estates in other global markets, including: Efficient transport facilities within the industrial estate and to & fro the city area. Environment‐friendly zone. Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer Section‐1.2.1, Page No. 2.

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 Please refer Form‐I, Annexure‐2A.

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. 3.

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

(100%) the finished products.

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

briefly outlined.

It will be incorporated in EIA Study.

3.8 Availability of water its source, energy/power requirement and source should be given. Water Source

Total water requirement shall meet through Ground Water.

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Power & Fuel Requirement Power required from MGVCL is 150 KVA. Fuel Requirement: Fuel for proposed boiler: Agro Waste ‐ 5 MT/Month or Coal ‐ 4 MT/Month

Diesel ‐ 150 Liter/Day (Emergency)

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. Please refer Form‐I, Annexure‐IV & V.

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

4.0 Site Analysis

4.1 Connectivity


• Availability of water, power, etc.

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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4.2 Land Form, Land Use and Land Ownership


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.


4.5 Existing Infrastructure

This is proposed project activity in existing premises so now there is only open land.

4.6 Soil Classification


4.7 Climatic data from secondary sources.

Climatic data from primary as well as secondary sources will be incorporated in 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.

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

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

out.

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

7)

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 Specialty Chemicals plant in Existing Premises

5.2 Population Projection


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

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 project activity.

• Social Welfare

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

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

Sr. No. Details Dimesion (m x m) Area (m2)

1 Parking 5 x 6 30

2 Office 10 x8 80

3 D.G.Set 5 x 5 25

4 Cooling Tower 10 x 10 100

5 Tank Farm Area 10 x 12 120

6 Raw Materials & Products Storage

Area

18 x 12 216

7 Boiler 5 x 5 25

8 Coal/Agro Waste Storage Area 5 x 5 25

9 Existing Manufacturing Unit 18 x 9 162

10 Proposed Manufacturing Unit‐1 29 x 15 435

11 Proposed Manufacturing Unit‐2 40 x 30 1200

12 Green Belt 45 x 51.17 2303

13 ETP 10 x 10 100

14 Road & Open Area 2160

Total 6981

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5.5 Amenities/Facilities


6.0 Proposed Infrastructure

6.1 Industrial Area (Processing Area)

Processing Area (Plant facilities, ETP Area and Engineering / Utility Services)

Developed Area: 2047 m2

6.2 Residential Area (Non Processing Area)

Non Processing Area (Green belt, Raw material storage area, finished storage area,

Administration Building, Parking, road and open area)

Area: 4934 m2

6.3 Green Belt

Total 6981 m2 land area is available at site; out of this area about 2303 sq. meter (33 %) area

is covered as greenbelt and other forms of greenery.

6.4 Social Infrastructure

• Power supply by MGVCL

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

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


• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation and will have single crop pattern

• Availability of power facilities

• Availability of water for industrial use

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6.6 Drinking water Management (Source & Supply of water)

Total water requirement shall meet through ground water.

6.7 Sewerage System

Sewage pipes would be 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

sections of industry. These liquid wastes would be sent to septic tank & soak pit.

6.8 Solid Waste Management

Please refer Form‐I, Annexure‐V. 6.9 Power Requirement & Supply/Source

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

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 project activity area and it is open non‐agricultural

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 the project after getting EC & CTE. We shall start

manufacturing after applying for CC&A.

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

project.

Total Project Cost for proposed project activity is Rs. 4.5 Crores. Capital cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 0.4 Crore.

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.

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