PROPOSED EXPANSION OF PESTICIDE INTERMEDIATES &...

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NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat - 395002

Prepared By:











Prepared By:

PRE FEASIBILITY REPORT

for

PROPOSED EXPANSION OF PESTICIDE

INTERMEDIATES & TECHNICALS WITHIN THE

EXISTING PREMISES

of

M/s. GUJARAT AGROCHEM LTD. PLOT No. 2901 to 2906, GIDC, PANOLI,

DIST: BHARUCH-394 116, GUJARAT

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CONTENTS

Sr. No. Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 10

3. Project Description 12

4. Site Analysis 18

5. Planning Brief 19

6. Proposed Infrastructure 20

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 Gujarat Agrochem Limited is located at Plot No. 2901-2906, GIDC, Panoli, Dist: Bharuch

(Guj.) which is 230 km away from the commercial capital of India, Mumbai. The plant is

located 1.3 Km away from national highway number 8 joining Delhi and Mumbai and

railway route from Delhi to Mumbai and is about 60 km away from Surat in north.

Ankleshwar town is about 10 km north of the plant site. GIDC, Panoli is an Industrial Estate

with a number of Chemical plants, Pesticides industries, pharmaceuticals and other allied

industries. The site is about 19.2 m above mean sea level.

The plant is located in a well-developed industrial zone developed by Gujarat Industrial

Development Corporation, which has all essential facilities such as water, power, post,

telecommunication, bank, etc. Other major industries in the region are M/s Sun

Pharmaceutical Ind. Ltd., M/s. Savla Chemicals Ltd., M/s. Cheminova India Ltd., M/s. Unique

Chemicals, M/s. Gharda Chemicals Ltd., M/s. P. I. Ind. Ltd., M/s. Hikal Ltd., M/s. Isagro (Asia)

Agrochemicals Pvt. Ltd., etc. The predominant mode of transportation in the area is by

network of roads & rail.

The agriculture sector dominates the economic scenario in India and occupation of nearly

60% of the population is agriculture. M/s Gujarat Agrochem Limited is an existing pesticide

intermediates & technicals manufacturing unit. Manufacturing activities of this project

started in 2001. Growth in the pesticide market is expected to increase at the rate of 12 to

15% per annum in coming years considering the increased awareness of the benefits of

pesticide use. Keeping in mind the phenomenal growth of pesticide market both domestic

and global, M/s Gujarat Agrochem Limited proposes expansion in the existing unit of

Pesticide Intermediates & Technicals in existing premises.

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1.2 Project Details

1.2.1 Products along with Production Capacity

SR.

NO.

PRODUCT NAME EXISTING

CAPACITY

(MT/MONTH)

TOTAL

PROPOSED

CAPACITY

(MT/MONTH)

PESTICIDES INTERMEDIATES & TECHNICAL

1 DV Acid Chloride 250

2 Meta Phenoxy Benzaldehyde 250

3 Cypermethrin (Tech.) 200

4 Permethrin (Tech.) 100

5 Alphamethrin (Tech.) 50

6 Metamitron (Tech.) 150

7 MBB Forcut 45

8 Ethofumesate (Tech.)

9 Hydroxy Benzo Furan (HBF)

110

10 Lambda Cyhalothrin (Lambamethrin)

11 Diethyl Phenyl Acetamide (Tech.) (DEPA)

100

12 Pyriproxypane

13 Tefluthrin

14 TransFluthrin

50

15 Sodium Sulfite 200 487

16 Ammonium Chloride 60 217

17 Potassium Chloride 60 140

TOTAL 430 2039

BY PRODUCTS:

1 Hydrochloric Acid (30%) 180 202

2 Spent Sulphuric Acid 140.76 528

3 Aluminium Chloride (30%) 289 1031

4 NaCl Solution (18%) 600 1091

5 Cu(OH)2 Powder - 2.63

TOTAL 1209.76 2854.63

1 D.G. Sets 1,000 KVA x 1,

625 KVA x 1,

320 KVA x 1

= 1,945 KVA

1,010 KVA x 3,

725 KVA x 3,

625 KVA x 1

= 5,830 KVA

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1.3 Raw Material Requirement

SR.

NO.

NAME QUANTITY

(MT/TON Production)

1. D V Acid Chloride

Acrylonitrile 0.460

Carbon Tetrachloride 1.300

CAT-1 0.001

CAT-2 0.015

Acetonitrile 0.005

Hydrochloric Acid 1.073

Liq. Ammonia 0.043

CAT-3 0.002

Thionyl Chloride 1.072

Triethyl Amine 0.065

Isobutylene 0.595

Hexane 0.349

Sodium Bicarbonate 0.153

CAT-4 0.017

Sulphuric Acid 4.800

CS Lye 2.060

CS Flakes 1.207

2. Hydroxy Benzo Furan

Isobutyl Aldehyde 0.314

Toluene 0.084

Morpholine 0.328

Para Benzoquinone 0.383

3. Cypermethrin

m-Phenoxy Benzaldehyde 0.465

D V Acid Chloride 0.562

Sodium Cyanide 0.14

Soda Ash 0.015

Catalyst 0.015

Acetic Acid 0.003

Hexane 0.061

Hypochlorite 0.420

4. Permethrin

m-Phenoxy Benzyl Alcohol 0.512

D V Acid Chloride 0.583

Hexane 0.041

Soda Ash 0.015

Acetic Acid 0.003

Catalyst 0.015

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5. Alpha Cypermethrin

Cypermethrin 1.820

Catalyst 0.273

Hexane 0.025

6. Ethofumesate

Isobutyl Aldehyde 0.451

Toluene 0.251

Morpholine 0.471

Para Benzoquinone 0.550

Methyl Sulfonyl Chloride 0.541

Triethyl Amine 0.126

Ethanol 0.545

Caustic Lye 0.697


Isopropyl Alcohol 0.031

C S Flakes 0.078

7. Metamitron

Sodium Cyanide 0.058

Toluene 0.149

Benzaldehyde 1.022


Sulphuric Acid 2.771

Methanol 0.474

TEBA 0.042

Sodium Hydrochloride 5.142

Hydrazine Hydrate 0.654

PTSA 0.049

Acetyl Hydrazine 0.079

N,N-Dimethyl Acetamide 0.018

Acetic Acid 0.014

Potassium Carbonate 0.002

8. Meta Phenoxy Benzaldehyde

Benzaldehyde 1.000

Bromine 0.771

Chlorine 0.646

EDC 7.009

AlCl3 0.796

Sodium Thiosulphate 0.022

MEG 0.533

Phenol 0.751

KOH 0.465

Toluene 1.388

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9. LAMBDA CYHALOTHRIN (TECH)

Chrysanthanic Acid 0.539


HCl 0.081

MPBD 0.441

NaCN 0.109

Water 0.370

C.S.Lye 0.015

Hexane 0.060

10. Diethyl Phenyl Acetamide (Tech) (DEPA)

HCl 0.260

Phenyl Acetic Acid 0.903

EDC 2.350


Diethyl Amine 0.625

Sodium Bi Carbonate 0.045

11 Pyriproxypane

4-Phenoxyphenol 0.351

Propylene Oxide 0.265

30% Hydrochloric Acid 0.243

Toluene 0.096

2-Chloropyridine 0.464

Potassium Hydroxide 0.342

Methanol 0.174

12 Tefluthrin

Lambda Cyclothric Acid 0.581


Soda Ash 0.050

Toluene 0.060

m TFBA 0.465

Isopropyl Alcohol 0.080

13 TransFluthrin

Trans Cypermethric Acid 0.574

Resolv-X 0.065

47% Caustic Lye 0.410

30% HCl 0.098

EDC 0.042


2,3,5,6-Tetrafluoro Benzyl Alcohol 0.485

Sodium Carbonate 0.025

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1.4 Water Requirement, Waste Water Generation and Treatment

Total water requirement will be 764.56 KL/Day (Existing: 265.7 KL/Day + Additional: 498.86

KL/Day) which shall be met through GIDC water supply. The wastewater generation will be

431.88 KL/Day (Existing: 148.98 KL/Day + Additional: 282.9 KL/Day). Effluent generated shall

be treated in ETP consisting of primary, secondary and tertiary treatment facility followed

by MEE & RO Unit. Final Treated effluent shall be sent to Common CETP of M/s. PETL,

Panoli for further treatment and ultimately will be discharged to deep sea via FETP of M/s.

NCT (BEAIL) pipeline.

When CETP is not in operation we have proposed MEE & RO Units from which RO Permeate

will be recycled as Boiler feed/Process Use & RO Reject will be mixed with High TDS/High

COD Tank for MEE Process.

1.5 Air Pollution Source and Control Management

There will be emission from Boiler, Thermo Pack, D.G. Set and Process Vent. To control the

emission from Boiler & Process Vent adequate scrubbers i.e. Bag Filter for Boiler & Water

Scrubber/ Alkali Scrubbers for Vent will be installed.

1.6 Hazardous Waste

Hazardous waste generation will be as follows:

TOTAL QTY. SR.

NO.

NAME OF

WASTE

WASTE

CATEGORY Existing Total Proposed

MODE OF DISPOSAL

1. Used Lube Oil 5.1 10 Ltr/M 50 Ltr/M Collection, Storage, Transportation and Sale to

GPCB Authorized Reprocessors

2. Spent

Solvents:

Toluene

20.2 4.75 MT/M 200 MT/M Collection, Storage, Transportation and reuse

within Factory Premises or co-processing in

cement industries or incineration at CHWIF.

3. Process

Distillation

Residue &

Residual

Waste (After

Effluent

29.1 7.5 MT/M

71 MT/M

150 MT/M

Collection, Storage, Transportation &

Incineration at CHWIF or Sent to Cement

Industries for Co-Processing

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1.7 Green Belt

Total 30,000 sq. meter land area is available at site; out of this area about 9,281.18 sq.

meter (30.94 %) area is covered as greenbelt and other forms of greenery.

Treatment)

4. MEE Salt 34.3 700 MT/M 1200 MT/M Collection, Storage, Transportation & disposal

to TSDF

5. Packing

Materials

(a) Empty

Bags

(b) Barrel

33.3

110 Nos/M

35 Nos/M

1100 Nos/M

1350 Nos/M

Collection, Storage, Transportation & Sale to

GPCB Authorized Reprocessor

6. ETP Sludge

34.3 4 MT/M

10 MT/M

Collection, Storage, Transportation and Final

Disposal at TSDF

7. Spent Carbon

from ETP

34.3 0.2 MT/M 0.4 MT/M Collection, Storage, Transportation and Final

Disposal at TSDF or Sent to Cement Industries

for Co-Processing

8. Aluminum

Chloride

(30%)

B-30 289 MT/M 1031 MT/M

9. Hydrochloric

Acid (30%)

- 180 MT/M 202 MT/M

10. Spent

Sulphuric

Acid

29.6 140.76 MT/M 528 MT/M

11. NaCl Solution

(18%)

- 600 MT/M 1091 MT/M

12. Cu(OH)2

Powder

- - 2.63 MT/M

Collection, Storage, Transportation & sale to

end user

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1.8 Power & Fuel Requirements

TOTAL POWER REQUIREMENT & SOURCE OF POWER

FUEL REQUIREMENT

Requirement Sr.

No.

Fuel

Existing Total Proposed

1 Coal 25 MT/Day 70 MT/day

2 Furnace Oil 1000 Lit/ Day 1000 Lit/ Day

3 Bio Mass (Briquettes) -- 3 MT/Day

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 & project

proponent

M/s. Gujarat Agrochem Ltd., proposes expansion of Pesticide Intermediates & Technicals

plant within the existing premises located at Plot No. 2901 to 2906, GIDC, Panoli, Dist:

Bharuch – 394 116, Gujarat.

2.2 Brief description of nature of the Project

Proposed expansion of Pesticide Intermediates & Technicals plant within the existing

premises.

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 international

market. By expansion of this unit, M/s. Gujarat Agrochem Ltd. will be able to meet the

demand of various products in foreign countries. The project will earn forex. This will also

Requirement Sr.

No.

Description

Existing Total

Proposed

Source

1. Power Supply 2300 KVA 5000 KVA DGVCL

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generate direct and indirect employment opportunity for various levels of people in the

state of Gujarat.

2.4 Demand-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 range of our products.

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 to the international markets.

2.6 Domestic/Export Markets

Our products have good demand in international markets. We shall export substantial out

put from the plant.

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

M/s. Gujarat Agrochem Ltd. has given direct employment to approx. 420 Nos. (370 + 50

(Contract)) of people based on qualification and requirement. In addition to direct

employment, indirect employment shall generate additional business to some extent for

the local population.

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3.0 Project Description

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

No interlinked project has been submitted.

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

project site layout) with coordinates.

• Map showing general location

Project Site

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• Specific location and project boundary

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Project Site (Google Map)

•

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Plot Layout

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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. Gujarat

Agrochem Ltd., to expand within the existing premises at GIDC Panoli. As GIDC Panoli is

centrally located activities can be easily handled. Over and above Gujarat has been chemical

industry friendly, Skilled/ un-skilled persons are easily available so it was finally decided for

expansion in GIDC, Panoli, Dist: Bharuch, Gujarat.

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

• Proposed expansion site is within the GIDC Panoli.

• 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 sea, road, air and railway.

• Availability of NG, Power, Water, etc.

• Availability of Skilled, Un-skilled persons.

• Availability of Good Housing for Staffs

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. 4.

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-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 export substantial out put from the

plant.

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

briefly outlined.

Recycle/Reuse shall be explored and incorporated.

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

given.

Water Source

Total water requirement shall meet through GIDC water supply.

Power & Fuel Requirement

Total Power Requirement & Source of Power

TOTAL POWER REQUIREMENT & SOURCE OF POWER

FUEL REQUIREMENT

Requirement Sr.

No.

Fuel

Existing Total Proposed

1 Coal 25 MT/Day 70 MT/day

2 Furnace Oil 1000 Ltr/ Day 1000 Ltr/ Day

3 Bio Mass (Briquettes) --------- 3 MT/Day

Requirement Sr.

No.

Description

Existing Total

Proposed

Source

1. Power Supply 2300 KVA 5000 KVA DGVCL

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

management/disposal

Please refer Section-1.6, Page No. 8.

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 sea, road, air & railway.

• 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

It will be incorporated in EIA Study.

4.3 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

Please refer Plot Layout at Page No 15.

4.6 Soil Classification


4.7 Climatic data from secondary sources.

Climatic data from primary & secondary sources will be incorporated in EIA Study.

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 Pesticide Intermediates & Technicals plant within

the existing premises.

5.2 Population Projection


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

Total 30,000 sq. meter land area is available at site; out of this area about 9,281.18 sq.

meter (30.94 %) area is covered as greenbelt and other forms of greenery.

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 project.

• Social Welfare

• Cordial relation with the nearby villagers shall be established and representation shall

be made to villages for help for creation of facilities related to health, education, etc.

5.5 Amenities/Facilities


6.0 Proposed Infrastructure

Total Plot Area: 30,000 m2

Total Built-up Area: 20,718.82 m2

Total Green Belt Area: 9,281.18 m2

6.3 Green Belt

Total 30,000 sq. meter land area is available at site; out of this area about 9281.18 sq. meter

(30.94 %) area is covered as greenbelt and other forms of greenery.

6.4 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 sea, road, air & railways.

• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation

• Availability of power evacuation facilities

• Availability of water for industrial use

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6.5 Drinking water Management (Source & Supply of water)

Total water requirement shall meet through GIDC supply.

6.6 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

sections. These liquid wastes is sent to ETP.

6.7 Solid Waste Management

Please refer Section 1.6, Page No. 8 of this report.

6.8 Power Requirement & Supply/Source

Please refer Section 1.8, Page No. 9 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 expansion 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 after getting EC & CTE. We shall start production after applying

for CCA.

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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. 1612 Lacs.

Sr.

No. Description

Project Cost

(Rs in Lacs)

1 Land Cost 25

2 Building 30

3 Plant & Machinery 50

4 Environment Management System 1507

Total Project Cost 1612

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 nearby villagers shall be established and representation shall

be made to villages for help for creation of facilities related to health, education, etc.

PROPOSED EXPANSION OF PESTICIDE INTERMEDIATES &...

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