PFR-Unit 3 -Updated sfter ToR PPTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...1.3 Water The total water requirement after Production startup at new site has been estimated

M/S. JUBILANT LIFE SCIENCES LIMITED

Pre-feasibility Report for

Installation of Manufacturing Facility of Technical Grade Pesticides and Pesticide Specific Intermediates by Jubilant Life Sciences Limited (Unit 3) at SEZ Operated by M/s. Jubilant Infrastructure Limited, Vilayat GIDC, Taluka Vagra, District Bharuch, Gujarat

SEPTEMBER 2014

Kadam Environmental Consultants w w w . k a d a m e n v i r o . c o m

Env i ronment for Development

JUBILANT LIFE SCIENCES LIMITED

PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH QUALITY CONTROL

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 2


Pre-feasibility Report for Installation of Manufacturing Facility of Technical Grade Pesticides and Pesticide Specific Intermediates by Jubilant Life Sciences Limited (Unit 3) at SEZ Operated by M/s. Jubilant Infrastructure Limited, Vilayat GIDC, Taluka Vagra, District Bharuch, Gujarat © Kadam Environmental Consultants (‘Kadam’), September, 2014

This report is released for the use of the Jubilant Life Sciences Ltd., Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

QUALITY CONTROL

Name of Publication

Installation of Manufacturing Facility of Technical Grade Pesticides and Pesticide Specific Intermediates by Jubilant Life Sciences Limited (Unit 3)

at SEZ Operated by M/s. Jubilant Infrastructure Limited, Vilayat GIDC, Taluka Vagra, District Bharuch, Gujarat

Project Number 14187017

06 Report

No. 1

Version

1 Release

d September,

2014

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to

serve as legal advice related to the individual situation.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH TABLE OF CONTENTS


CONTENTS

1 EXECUTIVE SUMMARY .......................................................................... 9

1.1 INTRODUCTION AND BACKGROUND ................................................................ 9

1.2 PROPOSED PLANT FEATURES AND PRODUCTION CAPACITY ........................................ 9

1.3 WATER ............................................................................................ 9

1.4 EFFLUENT GENERATION, TREATMENT AND DISPOSAL .............................................. 9

1.5 POWER REQUIREMENT .......................................................................... 10

1.6 AIR EMISSIONS ................................................................................. 10

1.6.1 Flue Gas Stacks ......................................................................... 10

1.6.2 Process Vents ............................................................................ 10

1.7 SOLID/HAZARDOUS WASTE GENERATION AND DISPOSAL ........................................ 10

2 INTRODUCTION ................................................................................ 11

2.1 ABOUT THE PRE-FEASIBILITY REPORT ........................................................... 11

2.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ........................................ 11

2.2.1 Project Proponent – Jubilant Life Sciences Limited ................................. 11

2.3 BRIEF DESCRIPTION OF THE PROJECT ........................................................... 12

2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND / OR REGION ............ 12

2.4.1 Demand Supply Gap .................................................................... 13

2.5 IMPORT VS. INDIGENOUS PRODUCTION ......................................................... 14

2.6 EXPORT POSSIBILITY ............................................................................ 14

2.7 DOMESTIC / EXPORT MARKETS .................................................................. 14

2.7.1 Domestic Market ........................................................................ 14

2.7.2 Export & Import Market ................................................................ 16

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ...................... 17

3 PROJECT DESCRIPTION ...................................................................... 18

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS .................. 18

3.1.1 Type of Project .......................................................................... 18

3.1.2 Interlinked and Interdependent Project .............................................. 18

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY

AND PROJECT PLANT LAYOUT) WITH CO-ORDINATES .................................................... 18

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE . 22

3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................ 22

3.5 TECHNOLOGY AND PROCESS DESCRIPTION ...................................................... 22

3.5.1 Description of Unit Operations ........................................................ 22

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY & STORAGE DETAILS. ............ 27

3.7 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY. ........ 31

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND THEIR SOURCE ....... 31

3.8.1 Water consumption ..................................................................... 31

3.8.2 Waste Water Treatment and Disposal ................................................ 32

3.8.3 Power Requirement ..................................................................... 32

3.8.4 Steam Requirement ..................................................................... 33

3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT

/DISPOSAL .............................................................................................. 33




3.9.1 Gaseous Emission ....................................................................... 33

3.9.2 Liquid Effluent ........................................................................... 33

3.9.3 Solid / Hazardous Waste ............................................................... 34

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF

EIA PURPOSE ........................................................................................... 35

4 SITE ANALYSIS ................................................................................. 36

4.1 CONNECTIVITY .................................................................................. 36

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................. 36

4.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................... 36

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, ETC SENSITIVE AREAS, WATER

BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. ............................................... 36

4.5 EXISTING INFRASTRUCTURE ..................................................................... 37

4.6 SOIL CLASSIFICATION ........................................................................... 37

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ..................................................... 37

4.7.1 Temperature ............................................................................. 37

4.7.2 Wind ...................................................................................... 37

4.7.3 Rainfall ................................................................................... 38

4.7.4 Cloud Cover .............................................................................. 38

4.7.5 Humidity.................................................................................. 38

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ............................................................ 38

5 PLANNING BRIEF .............................................................................. 39

5.1 PLANNING CONCEPT ............................................................................. 39

5.2 POPULATION PROJECTION ....................................................................... 39

5.3 LAND USE PLANNING ............................................................................ 39

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ..................................................... 39

5.5 AMENITIES / FACILITIES ........................................................................ 40

6 PROPOSED INFRASTRUCTURE ............................................................. 41

6.1 INDUSTRIAL AREA (PROCESSING AREA) .......................................................... 41

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ................................................... 41

6.3 GREEN BELT ..................................................................................... 41

6.4 SOCIAL INFRASTRUCTURE ....................................................................... 41

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ....... 41

6.5.1 By Road .................................................................................. 41

6.5.2 By Rail .................................................................................... 41

6.5.3 By Air ..................................................................................... 42

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER) .............................. 42

6.7 SEWAGE SYSTEM ................................................................................ 42

6.8 INDUSTRIAL WASTE WATER MANAGEMENT ....................................................... 42

6.9 SOLID WASTE MANAGEMENT ..................................................................... 42

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE .................................................. 42

7 REHABILITATION AND RESETTLEMENTS (R AND R) PLAN ......................... 43

8 PROJECT SCHEDULE AND COST ESTIMATE ............................................. 44




8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR

THE PROJECT TO BE GIVEN) ............................................................................. 44

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT. ............................................................................................... 44

9 ANALYSIS OF PROPOSAL ..................................................................... 45

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA .................................................. 45




LIST OF TABLES

Table 2-1: Production Capacity ....................................................................................... 12

Table 2-2: Consumption of Pesticides in India .................................................................. 15

Table 3-1: Co-ordinates of SEZ Area ............................................................................... 19

Table 3-2: Details of Raw Material Consumption and Storage Capacity ............................... 27

Table 3-3: Water Consumption Details ............................................................................ 32

Table 3-4: Fuel Consumption ......................................................................................... 33

Table 3-5: Hazardous Waste Generation and disposal Details ............................................ 34

Table 4-1: Distance of Project site from Water Bodies ...................................................... 36

Table 4-2: Predominant Wind Direction ........................................................................... 37

Table 5-1: Land Use Breakup at Site ............................................................................... 39




LIST OF FIGURES

Figure 2-1: Per Capita Consumption of Pesticides (Kg/Ha), FY 12 ...................................... 15

Figure 2-2: Crop Protection Market Split, India, FY 12 ...................................................... 16

Figure 2-3: Export & Import of Pesticides in India ............................................................ 17

Figure 2-4: Domestic Crop Protection Market Growth Potential (USD Bn) ........................... 17

Figure 3-1: Location Map in Google Image ...................................................................... 19

Figure 3-2: Site Layout of SEZ ........................................................................................ 20

Figure 3-3: Site Layout Map of Proposed Unit 3 (Technical Grade Pesticides manufacturing Unit) ............................................................................................................................ 21

Figure 3-4: Typical Flow Diagram for Jubilant Products ..................................................... 26


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH LIST OF ANNEXURES


LIST OF ANNEXURES

Annexure 1: SEZ Notification of Government of Gujarat .................................................... 46


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

1.1 Introduction and Background

Jubilant Life Sciences Limited, an Indian multinational corporate, is a leader in Research and Manufacturing of Synthetic Organic Chemicals, Advanced Pharmaceutical Ingredients (API), Pharmaceutical manufacturing, Agri Intermediates, Drug Discovery and Contract Research Manufacturing Services Company with a wide range of products and services for global life sciences companies. The Company is one of the largest Custom Research and Manufacturing Services (CRAMS) and drug discovery services companies in India.

Jubilant has five state-of-the-art manufacturing plants strategically located at Gajraula (UP, 100-km from Delhi), Nira (Maharashtra, 70-km from Pune), Ambernath (Maharashtra), Samlaya (Gujarat, 45-km from Vadodara) and Bharuch (Gujarat). Jubilant’s units at Gajraula, Nira, Samlaya, Bharuch SEZ are accredited with ISO-14001 and OHSAS-18001 certification, which shows company’s commitment towards Environment and Society.

The Bharuch SEZ operated by M/s Jubilant Infrastructure Limited (JIL) was constructed in 2008 for sector specific Synthetic Organic Chemicals (category 5(f)). Now, to cater to the market demand JIL has applied to MoEF seeking expansion for change of scope to include Technical Grade Pesticide Manufacturing in the SEZ.

M/s Jubilant Life Sciences Limited proposes to install a Technical Grade Pesticide Manufacturing facility in the SEZ for an annual capacity of 32,350 MTPA.

1.2 Proposed Plant Features and Production Capacity

The proposed project is Greenfield and will be set up to manufacture Technical Grade Pesticides and Pesticide Specific Intermediates. The estimated cost of the proposed project is INR 250 Crores. The Total Production capacity of the proposed site is 32,350 MTPA.

1.3 Water

The total water requirement after Production startup at new site has been estimated as 1860 KLD. Out of 1860 KLD 200 KLD will be recycled water and 1660 KLD will be fresh water requirement. The fresh water demand will be fulfilled through water supply from SEZ water supply line which is received through GIDC. The permission letter for water supply to SEZ has already been received from GIDC.

1.4 Effluent Generation, Treatment and Disposal

The proposed project will generate 45 KLD sewage. Total 804 KLD industrial effluent will be generated from the proposed manufacturing activity. Out of 804 KLD, 345 KLD effluent will be from process which will be sent to MEE after primary treatment and other 459 KLD comprise of utilities and washings will be sent to ETP operated by SEZ operator for treatment and final disposal.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH EXECUTIVE SUMMARY


1.5 Power Requirement

The power requirement for the proposed facility will be met through SEZ operator M/s Jubilant Infrastructure Limited, either sourced from grid or through its own captive generation. Total estimated electrical load for the proposed manufacturing unit is around 4 MW. In addition, the plant will have 4 DG sets of 500 KVA capacity each, for emergency power back-up during grid failure.

1.6 Air Emissions

1.6.1 Flue Gas Stacks

There will be 7 flue gas stacks as follows:

Four stacks attached to DG sets of capacity 500 kVA each, and Three stacks attached to Thermic Fluid Heaters of capacity 2 million kcal each.

Adequate stack height will be provided to all flue stacks, based preferably on the Environment Protection Rules, or in the absence of specific guidance in regulations, good engineering practice.

1.6.2 Process Vents

There will be 6 process vents as follows:

One common vent for all reactors at outlet of Condensation and Chilling of Common Venting system

Two at outlet of scrubber of Chlorination Reactor One at outlet of Caustic Scrubber of Sulphonation Reactor One at outlet of Caustic Scrubber of Bromination Reactor, and One at outlet of Caustic Scrubber of Flourination Reactor

1.7 Solid/Hazardous Waste Generation and Disposal

Both Municipal Solid Wastes (MSW) and Hazardous Wastes gets generated at the proposed facility. No residential facility is planned within the project site and consequently MSW will be mainly from offices and canteens.

Hazardous wastes like ETP sludge, discarded containers, used oil, process residue, off specific or obsolete raw material /products, spent solvents, used filter media and scrubber sludge gets generated during the production. These will be managed as per the Hazardous Wastes (Management, Transport and Transboundary) Rules 2008 as amended till date and will be disposed off as detailed in Table 3-5.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH INTRODUCTION


2 INTRODUCTION

2.1 About the Pre-feasibility Report

The EIA Notification 2006 requires submission of Form I (as per details provided as Annexure to the EIA Notification) along with a Pre-feasibility report as a first step for obtaining prior Environmental Clearance (EC). This report, namely the pre-feasibility report, is a companion volume to the Form I submitted by Jubilant Life Sciences Limited (‘JLSL’) to the MoEF to complete the initial documentation and secure Terms of Reference (ToR) from the Ministry of Environment and Forests (MoEF).

The contents of this report are based on the MoEF document, Guidelines for Preparation of Pre-feasibility Report for obtaining prior Environmental Clearance in terms of the Provisions of EIA Notification, 2006, vide Circular of MoEF No. J-11013/41/2006-IA.II(I) dated 30th December 2010.

2.2 Identification of Project and Project Proponent

2.2.1 Project Proponent – Jubilant Life Sciences Limited

Jubilant Life Sciences Limited, an Indian multinational corporate, is a leader in Research and Manufacturing of Synthetic Organic Chemicals, Advanced Pharmaceutical Ingredients (API), Pharmaceutical manufacturing, Agri Intermediates, Drug Discovery and Contract Research Manufacturing Services Company with a wide range of products and services for global life sciences companies. The Company is one of the largest Custom Research and Manufacturing Services (CRAMS) and drug discovery services companies in India.

The company’s business operations are organized in to pharmaceutical and life science chemicals; performance chemicals and industrial chemicals. Jubilant Life Sciences enjoys leadership in Indian market in industrial chemicals and performance polymers and is also a prominent player in the Agrovet sector.

Jubilant has established its reputation as a consistent and reliable supplier of advance intermediates for the life science industry worldwide and is now proposing to enter into manufacturing of Active Pesticides. Jubilant’s experience in CRAMS for life science companies has lead its pursuit manufacture Technical Grade Pesticides and of becoming a major force globally in Pesticide manufacturing.

Jubilant has five manufacturing plants located at Gajraula (UP, 100-km from Delhi), Nira (Maharashtra, 70-km from Pune), Ambernath (Maharashtra), Samlaya (Gujarat, 45-km from Vadodara) and Bharuch (Gujarat). Jubilant’s units at Gajraula, Nira, Samlaya, Bharuch SEZ are accredited with ISO-14001 and OHSAS-18001 certification, which shows company’s commitment towards Environment and Society.

The Bharuch SEZ operated by M/s Jubilant Infrastructure Limited (JIL) was constructed in 2008 for sector specific Synthetic Organic Chemicals (category 5(f)). Now, to cater to the market demand JIL has applied to MoEF seeking expansion for change of scope to include Technical Grade Pesticide Manufacturing in the SEZ.




M/s Jubilant Life Sciences Limited proposes to install a Technical Grade Pesticide Manufacturing facility in the SEZ for an annual capacity of 32,350 MTPA in its Unit 3.

2.3 Brief Description of the Project

The Proposed Project is a green field project for installation of facilities for manufacturing of varieties of Pesticides and pesticide specific intermediates to cater to domestic and international market. India is expected to become a major consumer of Pesticide in improving its agricultural yield and also India is growing to become a manufacturing hub of Pesticides for international market, thus boosting exports. The project is also envisaging a remarked growth in Contract Manufacturing of Pesticides in India for international brands and JLSL looks into catering to this demand.

The proposed project will be located within the SEZ operated by M/s Jubilant Infrastructure Limited at GIDC-Vilayat, Bharuch, Gujarat. M/s. Jubilant Life Sciences Limited proposes to manufacture Technical Grade Pesticide and pesticide specific intermediates (Category 5 (b)) within the SEZ.

The proposed project is Greenfield and will be set up to manufacture Technical Grade Pesticides and pesticide specific intermediates. The estimated cost of the proposed project is INR 250 crores. The detailed production capacities are given as below in Table 2-1.

Table 2-1: Production Capacity

S. No. Name of Product Quantity in MT/Annum

1 Mepiquat Chloride 160

2 Chlormequat Chloride 2000

3 Chlorpyrifos & its derivatives 10000

4 Imidacloprid 1000

5 Acetamiprid 500

6 Thiamethoxam 500

7 Thiacloprid 200

8 Chlorfluazuron 100

9 Chlorantraniliprole 1000

10 Cyantraniliprole 1000

11 Triclopyr 220

12 Triclopyr butoxy ethyl ester 220

13 Fluroxypyr-meptyl 1000

14 Clodinafop Propargyl 200

15 Diquat dibromide 1500

16 Haloxyfop‐P‐methyl 100

17 Fluazifop-P-butyl 50

18 Diflufenican 100

19 Nicosulfuron 150

20 Picloram 300




S. No. Name of Product Quantity in MT/Annum

21 Clopyralid 300

22 Paraquat & its derivatives 5000

23 Trifloxystrobin 400

24 Imazethapyr 100

25 Pyroxsulam 150

26 Picoxystrobin 2000

27 Boscalid 100

28 Azoxystrobin 1000

29 Intermediates of all above (#1 to #28)

30 2-Chloro-6-(trichloromethyl)pyridine 3000

TOTAL 32350

2.4 Need for the Project and Its Importance to the Country and / or Region

Agrochemicals are used to improve crop performance, yield or control pests. As per Indian Journal of Ecology report, major crop losses due to non-usage of pesticides were about 17.5% of the yield valued at ~INR 90,000 Cr per annum (FY12 estimated). It is estimated that the present food grain production can increase from 3 Trillion Ton to 4 Trillion Ton by using appropriate crop protection. Therefore, right usage of crop protection chemicals is essential in increasing agricultural production by preventing crop losses before and after harvesting.

Crop losses in the country due to various pests range from 10 to 30 percent each year depending upon the severity of pest attack. Pesticides play an important role in sustaining agricultural production of the country by protecting crops from pest attacks and by keeping the pest population under control. Availability of safe and efficacious pesticides and their judicious use by the farming community is critical to a sustained increase in agricultural production and productivity. Pesticides are also useful in health programmes for controlling vectors responsible for diseases like malaria.

Pesticides proposed to be manufactured by the project proponent are widely used all over the world including India. At present, there are only few industries in India manufacturing these particular products, which have good market potential and will help farmers for better crop yield. By using appropriate pesticides, up to 90% crop loss can be avoided in various crops. Benefit in terms of saving of crop output is multifold compared to expenses for buying Agrochemicals.

It is thus, very much justified to manufacture these Pesticides not only to increase the market availability but also to reduce import burdens of the country.

2.4.1 Demand Supply Gap

Over the years, the production of Agrochemicals has made significant progress. The crop protection chemicals accounts for ~2% of the total chemicals market in India. The Indian pesticides industry has been growing at 8-9% p.a. over the past five years (FY07-FY11). Industry size is estimated to be USD 3.8 billion (INR 21,000 CR) in FY12 with exports




accounting for 50%. Over the 12th plan period, the segment is expected to grow at 12-13% p.a. to reach ~USD 7 Bn (INR 39,000 Cr) by FY17 with domestic demand growing at 8-9% p.a. and export demand at 15-16% p.a.

With increasing population, demand for food grains is increasing at a faster pace as compared to its production. In addition to that, every year, significant amount of crop yield is lost due to non-usage of crop protection products. At the present rate food grain requirement will not able to meet the projected demand and would result in a large deficit in food supply. To mitigate the gap between demands and supply of Food it is necessary to increase yield of crops, for that controlled use of different Pesticide is necessary.

2.5 Import vs. Indigenous Production

More than 60 technical grade pesticides are being manufactured indigenously by 125 Producers. Large & medium scale enterprises (including about 10 Multinational companies) and more than 500 pesticide formulator spread over the country. India is the 4th largest producers of Agrochemicals after USA, Japan & China. The per hectare consumption of pesticides is low in India when compared with world. The production of Indian pesticide industry is 85,000 MT during 2008-09. India has imported approx. 11,500 Cr. of pesticides during 2009-10.

2.6 Export Possibility

Indian exports of pesticides have been witnessing a strong growth in recent times. Exports now account for ~40% of the industry. Last few years have witnessed sharp growth rates in exports as India is attractive destination for low cost manufacturing with ample talent pool in complex chemistry.

It is projected that the export demand will grow faster than the domestic consumption, as existing players leverage their relationships with clients and more players are expected to enter into attractive Contract Research and Manufacturing Services (CRAMS) opportunities. India has emerged as the thirteenth largest exporter of pesticides in the world. However, most of the exports are off-patent products. Currently, the total export value of crop protection chemicals amounts to USD 1.9Bn (INR 11,000 Cr) with America, Asia (excluding Middle East) and Europe are the major exporting destinations.

Exports are expected to grow at a higher rate of 15% p.a. to reach ~ USD 5.8 Bn (INR 32,000 Cr) by FY20.

2.7 Domestic / Export Markets

2.7.1 Domestic Market

Consumption of crop protection products in India is among the lowest in the world. Consumption of pesticides in India is close to 0.57 kg/ha while in countries like Taiwan it is 17 kg/ha; in the US it is 7 kg/ha, in the EU it is 3 kg/ha and in Japan it is 12 kg/ha. Some of the reasons for low consumption in India are low purchasing power of farmers, lack of awareness among farmers, limited reach and lower accessibility of products. This presents an immense opportunity for growth of the crop protection industry in India.




Table 2-2: Consumption of Pesticides in India

Year 1991-92 1995-96 2000-01 2005-06 2009-10 2010-11

Consumption of Pesticides, Thousand

Tonnes 72.13 61.26 43.58 39.77 41.82 55.54

Source: Directorate of Economics and Statistics, DAC

Figure 2-1: Per Capita Consumption of Pesticides (Kg/Ha), FY 12

Insecticides form the largest segment of the domestic crop protection chemicals market accounting for 65% of the total market. It is mostly dependent on rice and cotton crops. Herbicides are the largest growing segment and currently account for 16% of the total crop protection chemicals market. Sales are seasonal, owing to the fact that weeds flourish in damp, warm weather and die in cold spells. Rice and wheat crops consume the major share of herbicides. Increasing cost of farm labor will drive sales of herbicides going forward.

Fungicides, accounting for 15% of the total crop protection market, are used for fruits and vegetables and rice. With farmers moving from cash crops to fruits and vegetables and government support for exports are increasing the fungicides usage.




Figure 2-2: Crop Protection Market Split, India, FY 12

Source: Ministry of Chemicals & Petrochemicals

Contract manufacturing is also an emerging opportunity for agro-chemical companies. Some of the factors which make contract manufacturing an attractive opportunity for Indian players are as follows:

Strong presence of MNCs in Indian markets who have the ability and know-how to develop and launch innovative products. For small Indian players, developing capability for contract manufacturing would be easier than capability to invent new chemicals.

High investment requirement in R&D for new molecule development and long gestation period of 3-5 years for registration of new chemicals, is a major deterrent for Indian players to developing new molecules and have instead led to increased focus on generics.

Large pool of technically skilled manpower enables Indian players to develop custom products at low cost. This gives an opportunity to Indian players to tie-up with large MNCs.

2.7.2 Export & Import Market

Since the Indian agricultural sector is highly dependent on monsoons, the market for agrochemicals is expected to grow at a conservative growth rate of 8% p.a. to reach ~ USD 3.2Bn (INR 18,000 Cr) by FY18. Exports are expected to grow at a higher rate of 15% p.a. to reach ~ USD 5.8 Bn (INR 32,000 Cr) by FY20.




Figure 2-3: Export & Import of Pesticides in India

Source: http://chemicals.nic.in/chem1.htm

Figure 2-4: Domestic Crop Protection Market Growth Potential (USD Bn)

Source: FICCI – 3rd National Agrochemicals Conclave 2013

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

During construction period the requirement of man power will be about 600 persons. During construction Phase, majority of the employees will be either locally employed or will come from nearby villages. In the operation phase, 400 persons will get employment in various services.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked and Interdependent Projects

3.1.1 Type of Project

The proposed project is for manufacturing Technical Grade Pesticide and pesticide specific intermediate that is covered under Category- 5 (b) “A” projects of MoEF as per the new EIA notification vide gazette no. S.O. 1533 dated 14th September, 2006.

3.1.2 Interlinked and Interdependent Project

The project is interlinked with SEZ operator JIL. JIL has applied for Amendment in its EC to include 5(b) category projects in addition to its existing 5(f) category projects. Further, JIL facilities such as water, steam, power, ETP, Incinerator etc. shall be utilized for this project.

3.2 Location (Map Showing General Location, Specific Location and Project Boundary and Project Plant Layout) with co-ordinates

The proposed facility is located at GIDC-Vilayat, in SEZ operated by Jubilant Infrastructure Limited. The total plot area of the unit is about 20 ha (2,00,000 m2). Location map proposed site is attached as Figure 3-1. Site lay out map of SEZ is given in Figure 3-2. Site lay out map of proposed Unit 3 is attached as Figure 3-3.




Figure 3-1: Location Map in Google Image

Table 3-1: Co-ordinates of SEZ Area

Point Latitude Longitude

A 21°46'57.57"N 72°53'32.47"E

B 21°47'16.48"N 72°53'26.66"E

C 21°47'15.74"N 72°53'24.42"E

D 21°47'32.08"N 72°53'18.85"E

E 21°47'27.27"N 72°52'47.49"E

F 21°47'2.77"N 72°52'49.23"E

G 21°46'46.42"N 72°52'52.89"E

JUBILANT LIFE SCIENCES LIMITED PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ),

BHARUCH PROJECT DESCRIPTION


Figure 3-2: Site Layout of SEZ




Figure 3-3: Site Layout Map of Proposed Unit 3 (Technical Grade Pesticides manufacturing Unit)




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

No alternate sites were evaluated as the proposed site is an operating SEZ with all infrastructure including land, water, power supply, common treatment facility and other infrastructure is readily available.

3.4 Size or Magnitude of Operation

JLSL plans to produce Technical Grade Pesticides and it’s intermediates at 32,350 MTPA capacity.

The proposed facility will occupy an area of 20 ha. 8% of the land will be used for green cover (1.6 ha.) in addition to common green belt developed by SEZ operator. The estimated cost of the proposed facility is INR 250 crores. Details pertaining to the production capacity have already been provided in Table 2-1.

3.5 Technology and Process Description

Attached below is the general process flow diagram and description for the manufacturing process. Depending on the type of product produced suitable operation will be employed.

3.5.1 Description of Unit Operations

Reactors

The most common type of reactor vessel is the kettle-type reactor. These reactors typically range in capacity from 50-litre to several thousand liters. The vessels are made of either stainless steel or glass-lined carbon steel. Reactors are equipped to provide a range of capabilities that may be required during the batch reaction step. This equipment may include: A jacket for heating and cooling, hook-ups for charging raw materials and for discharging the contents of the reactor, an agitation and recycle line for mixing, control systems for temperature and pressure, a condenser system for controlling vent losses, return line for refluxing condensable, a steam ejector for vacuum operation, a nitrogen supply for padding and purging the reactor, and a man way for taking samples and adding solid catalysts, reactants, and other solid materials to the reactor.

Raw materials or ingredients, including solvents, used to produce the intermediate or bulk substances are charged into the reactor vessel. Liquid ingredients are drawn into the reactor either by pumping or through vacuum from drums and storage tanks. Solids may be charged manually or via mechanical means such as through a vacuum system.

Once the reactor vessels are charged with the raw materials, the reaction takes place. The reactor can be operated at atmospheric pressure, elevated pressure, or under vacuum. Because of their flexibility, reactors may be used in a variety of ways. Besides hosting chemical reactions, they can act as mixers, heaters, holding tanks, crystallizers, and evaporators. Typical reactions performed include alkylations, hydrogenations, brominations etc. Temperature, pressure and the degree of mixing are carefully monitored to achieve the desired product and to ensure worker safety.




Reaction

A chemical compound is a pure chemical substance consisting of two or more different chemical elements that can be separated into simpler substances by chemical reactions. Chemical reaction is a process that leads to the transformation of one set of chemical substances to another. Classically, chemical reactions encompass changes that only involve the positions of electrons in the forming and breaking of chemical bonds between atoms, with no change to the nuclei (no change to the elements present), and can often be described by a chemical equation.

Neutralization

Neutralization is a chemical reaction in which an acid and a base react to form a salt. Water is frequently, but not necessarily, produced as well. Neutralizations with Arrhenius acids and bases always produce water where acid–alkali reactions produce water and a metal salt.

Separation

Several separation mechanisms are employed by the pharmaceutical industry including extraction, decanting, centrifugation and filtration. These mechanisms may be employed jointly or individually, in multiple stages, to separate the intermediate or bulk substance from the reaction solution and to remove impurities.

Extraction

Extraction is used to separate liquid mixtures by taking advantage of differences in the solubility of the mixture components. Absolvent that preferentially combines with only one of the components is added to the mixture.

Decanting

Decanting is a simple process used to separate mixtures of liquid and insoluble solid that has settled to the bottom of a reactor or settling vessel. The liquid over the solid is either pumped out of the vessel or poured from the vessel leaving behind the insoluble solid and a certain amount of liquid.

Scrubber

Scrubber systems are a diverse group of air pollution control devices that can be used to remove some particulates and/or gases from industrial exhaust streams. Traditionally, the term "scrubber" has referred to pollution control devices that use liquid to wash unwanted pollutants from a gas stream. Scrubbers are one of the primary devices that control gaseous emissions, especially acid gases. Scrubbers can also be used for heat recovery from hot gases by flue-gas condensation.

Condensation

Condensation is the change of the physical state of matter from gas phase into liquid phase, and is the reverse of vaporization. It can also be defined as the change in the state of water vapor to liquid water when in contact with any surface.




Absorption

Absorption is a physical or chemical phenomenon or a process in which atoms, molecules, or ions enter some bulk phase – gas, liquid or solid material. This is a different process from adsorption, since molecules undergoing absorption are taken up by the volume, not by the surface (as in the case for adsorption). A more general term is sorption, which covers absorption, adsorption, and ion exchange. Absorption is a condition in which something takes in another substance.

Mixing

Mixing is a unit operation that involves manipulation of a heterogeneous physical system with the intent to make it more homogeneous. Mixing is performed to allow heat and/or mass transfer to occur between one or more steams, components or phases. Modern industrial processing almost always involves some form of mixing. Some classes of chemical reactors are also mixers. With the right equipment, it is possible to mix a solid, liquid or gas into another solid, liquid or gas.

Distillation

Distillation is a process of separating component substances from liquid mixtures through vaporization and condensation, based on different volatility point of components in the mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction.

Centrifugation

Centrifuges are used to remove the intermediate or product solids from a liquid stream. Centrifuges work on the principle of centrifugal force, in which an outward force is exerted on rotating object. Centrifuges are cylinders with rotating baskets within them. The sides of the basket are perforated and covered with filter medium such as woven fabric or metal.

Filtration

Filtration is the separation of fluid-solids mixture-involving passage of most of the fluid through a porous barrier (the filter medium), which retains most of the solid particulates, contained in the mixture. In the pharmaceutical industry, filtration is used to remove solids from a liquid, whether these solids be product, process intermediates, catalysts or carbon particulates (e.g., from a discoloring step).

Crystallization

After the reaction takes place, the intermediate or final bulk substance (which is usually in solid form) can be separated from the reaction solution by crystallization. Crystallization is one of the most common separation techniques and is often used alone or in combination with one or more of the separation techniques described above. In crystallization, a supersaturated solution is created in which crystals of the desired compound are formed. Super saturation depends on the solubility of the desired compound.

Purification

Once the intermediate or the bulk substance has been separated, it may need to be purified. Depending on the intermediate or the bulk substance produced, there may be several




purification steps involved to produce the desired active ingredient. In vitamin production, for example, there are at least three to four purification steps. Purification typically is achieved through additional separation steps such as those described above. Purification is often achieved through re-crystallization. Washing with additional solvents and filtration may also be used.

Vacuum System

Vacuum system has a wide range of applications like evacuation, evaporation and pumping of gases and vapors in chemical, biological and pharmaceutical Molecules. Vacuum System is ideal for high boiling solvents. Typical applications are High Boiler distillation or Heat sensitive Product Drying.

Drying

The final step in the chemical synthesis process is drying of the intermediate or final bulk substance. Drying is done by evaporating the solvents from the solids. Solvents released from drying operations may be condensed for reuse or disposal. There are various types of dryers used by the pharmaceutical industry including tray dryers, rotary dryers, drum or tumble dryers, or pressure filter dryers. The selection of the dryer type depends primarily on the characteristics of the solid.

Bulk Manufacturing

Wide variation in bulk manufacturing makes prediction of typical or annual average emissions difficult. This is because emissions generated are predicated based on type of bulk substance or intermediate manufactured, duration of manufacturing time, type of equipment used and raw materials used.

Dryers are one of the largest sources of VOC emissions in bulk manufacturing. In addition to the loss of solvent during drying, manual loading and unloading of dryers can release solvent vapors into ambient air, especially when tray dryers are used. VOCs are also emitted from reaction and separation steps via reactor vents and man ways. Centrifuges may be source of VOC emissions, especially in top loading types, where solids are manually scooped out.

Typical controls for these emission sources, excluding storage and transfer operations, include condensers, scrubbers, carbon absorbers and occasionally incinerators. Storage and transfer emissions can be controlled by vapor return lines, vent condensers, conservation vents, vent scrubbers, pressure tanks and carbon absorbers. Floating roofs may be feasible controls for large vertical storage tanks.

JUBILANT LIFE SCIENCES LIMITED PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT

AT GIDC VILAYAT (SEZ), BHARUCH PROJECT DESCRIPTION


Figure 3-4: Typical Flow Diagram for Jubilant Products




3.6 Raw material required along with estimated quantity & Storage details.

Many raw materials are required for the chemical synthesis processes used by the industry. These include organic and inorganic compounds and are used in gas, liquid, and solid forms. The consumption figures and mode of storage for the major raw materials are presented in Table 3-2. The required quantity of raw materials will be obtained from different suppliers across the country. Raw materials and products will be transported by primarily through road. Important raw materials and their proposed storage capacities are as listed below.

Table 3-2: Details of Raw Material Consumption and Storage Capacity

S. No.

Name of the Raw Materials State Quantity,

MT/Annum Storage

Capacity, MT

1 (R)-(+)-2-(4-Hydroxyphenoxy)

propionic acid Solid 130 20

2 1,2,3-Trichloro-5-nitrobenzene Solid 82 15

3 1-Chloro-2-nitro benzene Solid 184 20

4 2- chloro -5 (methylaminomethyl)

pyridine Liquid 420 25

5 2,3,4,5,6 - Penta chloropyridine Solid 1330 25

6 2,3,5,6-Tetrachloropyridine Solid 7564 50

7 2,3-dichloro-5-trifluoromethyl pyridine Liquid 40.5 5

8 2,3-Dichlorpyridine Solid 2440 25

9 2,4-Difluoroaniline Liquid 47 8

10 2,6-diflurobenzamide Solid 112.5 15

11 25% Sodium hydroxide soln. Liquid 270 20

12 2-amino-2,3-dimethyl butyronitrile Liquid 53 5

13 2-Amino-3-methyl benzoate Solid 680 5

14 2-amino-4,6-dimethoxy pyrimidine Solid 277.5 10

15 2-aminoethanethiol hydrochloride Solid 196 15

16 2-butoxy ethanol Liquid 88 10

17 2-Chloro nicotinic acid Solid 418 15

18 2-chloro Pyridine Liquid 1575 25

19 2-Chloro-5-(Trifluoromethyl) Pyridine Liquid 30 6

20 2-chloro-5chloromethyl pyridine Liquid 992 25

21 2-chloro-5-nitro-phenol Solid 32 5

22 2-Chloro nicotinic acid Solid 68 10

23 2-Coumaranone Solid 315 15

24 2-cyanophenol Solid 485 25

25 2-fluoro-3-Chloro-5-(Trifluoromethyl)

Pyridine Liquid 58 5

26 2-Fluro-6-trifluro methyl pyridine Liquid 1400 5

27 2-hydroxy phenyl acetic acid Solid 390 15




S. No.


MT/Annum Storage

Capacity, MT

28 2-methoxy-4-(Trifluoromethyl) pyridine-

3-sulfonyl chloride Solid 132 10

29 2-Octanol Liquid 410 20

30 3-(Trifluoromethyl) phenol Liquid 70 10

31 3,4,5,6-Tetra choropyridine-2-carboxylic

acid Solid 603 20

32 3-Chloro-5-(trifluoromethyl) pyridin-2-ol Solid 72 5

33 3-Isochromanone Solid 1700 5

34 3-trifluoroacetophenone Liquid 340 15

35 4,6-dichloropyrimidine Solid 835 25

36 40% ethanol Liquid 2260 15

37 4-Chloro phenyl boronic acid Solid 27 5

38 5-Chloro-2 3-difluoropyridine Liquid 124 10

39 5-ethyl-pyridine dicarboxylic acid Solid 83 5

40 Acetic acid Liquid 1440 15

41 Acetic Anhydride Liquid 317 20

42 Acetone Liquid 1941.8 50

43 Acetonitrile Liquid 2406.5 50

44 Activated charcoal Solid 18 5

45 Cat- CS-I Solid 24 5

46 Alfa picoline Liquid 3381 100

47 Ammonium hydroxide Liquid 550 50

48 Anhydrous potassium fluoride Solid 880 50

49 N,N-dimethyl formamide Solid 33 7

50 Aq. sodium hydroxide Liquid 392 30

51 Benzyl chloride Liquid 556 50

52 Butyl (R)-(+)-2-(4-hydroxyphenoxy)

propionate Solid 37 5

53 Catalyst-CS-E Solid 20 4

54 Chlorine gas Gas 485 50

55 Conc. Sulphuric acid Liquid 4533 50

56 Conc. HCl (30-35%) Liquid 246 20

57 Conc. HCl (30%) Liquid 1127 40

58 Conc. HCl (30-35%) Liquid 1785 40

59 Water Liquid 6634.6 20

60 Cu(I)CN Solid 350 70

61 Catalyst-F Solid 11.5 2

62 Methylene dichloride Liquid 690 30

63 Diethyl meleate Liquid 2200 20




S. No.


MT/Annum Storage

Capacity, MT

64 Diisopropyl ether Liquid 1396 40

65 Diisopropylethylamine Liquid 147 10

66 Dimethyl amine Liquid 79.5 10

67 Dimethyl carbonate Liquid 10 2

68 Dimethyl sulphate Liquid 1340 8

69 Diphenyl carbonate Solid 124.5 10

70 Dipotassium salt of N-

cyanodithioiminocarbonate Solid 386 30

71 Dimethyl sulphate Liquid 485 30

72 Dry HCl gas Gas 3346 15

73 Ethanol Liquid 1140 20

74 Ethoxycarbonyl isothiocyanate Oily

Liquid 121.5 10

75 Ethyl acetate Liquid 713 20

76 Ethylene diamine Liquid 290 20

77 Ethylene dibromide Liquid 1665 30

78 Formic acid Liquid 204.8 20

79 H2O2 (30%) Liquid 500 100

80 HBr (48%) Liquid 710 142

81 Conc. HCl (30-35%) Liquid 231 100

82 Hydrazine (95%) Liquid 84 15

83 Hydrazine hydrate (85%) Liquid 1700 40

84 Hydrochloric acid Liquid 200 20

85 Hydrochloric acid (12%) Liquid 153 20

86 Hydrogen peroxide (25%) Liquid 84 10

87 Hydroxylamine hydrochloride Solid 40.5 5

88 K2S2O8 Solid 2380 20

89 Potassium hydroxide Solid 1560 10

90 Liq. Ammonia (12%) Liquid 1950 20

91 Liquid Ammonia Liquid 273 25

92 Methylene dichloride Liquid 661.5 30

93 Methane sulfonyl chloride Liquid 730 10

94 Methanol Liquid 10781 50

95 Methy 2-amino-3-methyl benzoate Solid 550 15

96 Methyl (R)-(+)-2-(4-hydroxyphenoxy)

propionate Solid 63 10

97 Methyl amine (40%) Liquid 390 10

98 Methyl amine (40%) in methanol Liquid 730 10

99 Methyl chloride gas Gas 1892.4 30




S. No.


MT/Annum Storage

Capacity, MT

100 Methyl chloroacetate Liquid 547.6 30

101 Methyl Formate Liquid 2195 40

102 Methyl isobutyl ketone Liquid 1088 30

103 Methylene chloride Liquid 780 30

104 Methylene dichloride Liquid 4426 40

105 Methyl isobutyl ketone Liquid 900 2

106 N,N’-Dimethyl formamide Liquid 583.2 20

107 Sodium carbonate Solid 955 20

108 Sodium bicarbonate Solid 40 5

109 10% Sodium hypochlorite soln. Liquid 2990 15

110 Sodium hydroxide soln. (30%) Liquid 219 15

111 N-bromosuccinamide Solid 524 15

112 N-cynomethyl acetamidate

Liquid 290 15

113 Ammonia gas Gas 30 5

114 N-Hydroxyamine hydrochloride Solid 124 10

115 Nitroguanadine Solid 490 15

116 N-Methoxyamine hydrochloride Solid 344 15

117 N-methyl-2-Pyrrolidone Liquid 1190 40

118 N-methyl pyrrolidone Liquid 100 1

119 O,O-Di ethyl thiophosphorous chloride Liquid 6300 50

120 O-Xylene Liquid 580 1

121 O-Toluic acid Solid 772 20

122 Oxalyl chloride Liquid 68 10

123 O-Xylene Liquid 853 30

124 Para formaldehyde Solid 68.8 10

125 Piperidine Liquid 142.4 15

126 POBr3 Solid 1160 10

127 Potassium hydroxide Solid 1396 20

128 Potassium carbonate Solid 2649.5 20

129 Propargyl chloride Liquid 76 5

130 Pyridine Liquid 4870 40

131 Sodium Amide Solid 1950 15

132 Sodium bicarbonate Solid 2696 30

133 Sodium carbonate Solid 1035 15

134 Sodium cyanide Solid 356 10

135 Sodium ethoxide soln. (21% in ethanol) Liquid 1180 5

136 Sodium hydride Solid 120.5 10




S. No.


MT/Annum Storage

Capacity, MT

137 Sodium hydroxide Solid 6222.3 30

138 Sodium hydroxide soln. 20% Liquid 717 10

139 20% sulphuric acid soln. Liquid 283.8 20

140 Sodium methoxide Powder Solid 660 5

141 Sodium methoxide(28%) Liquid 105 10

142 S-phenyl Solid 835 20

143 Sulfur Solid 45 5

144 Triethyl amine Liquid 247 15

145 Catalyst-CS-D Liquid 3.3 1

146 Tetrachloroethylene [TCE ] Liquid 180 1

147 Tetrahydrofuran Liquid 102 1

148 Tetramethylene sulfone Liquid 300 15

149 Tetrahyrofuran Liquid 135 15

150 Thionyl Chloride Liquid 3588 25

151 Titanium tetrachloride Liquid 945 15

152 Toluene Liquid 799 20

153 Triclopyr Solid 193.6 15

154 Trimethyl ortho formate Liquid 615 30

155 Triphosgene Solid 23 5

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

In the proposed project, Resource conservation of Chemicals and water conservation are inherently designed for effluent re-use/recycle and hence consumption is optimised. Solvents of different varieties are used in the manufacturing process and exit the process in diluted / contaminated form as effluents. Different effluent streams shall be processed appropriately in-house through multiple stage distillation or through a 3rd party Reprocessor to recover the valuable resource and thus optimise the raw material consumption.

The final effluent for disposal shall be transferred to CETP operated by the SEZ operator for final treatment and disposal to deep sea through GIDC line or sent to 3rd party for processing/treatment.

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

3.8.1 Water consumption

The total water requirement after Production startup at new site has been estimated as 1860 KLD. Out of 1860 KLD 200 KLD will be recycled water and 1660 KLD will be fresh water requirement. GIDC Vilayat is sourcing water from Narmada River and supplying water to SEZ operated by JIL. JIL will supply required quantity of water to JLSL with mutual agreement.




The breakup of water consumption as well as wastewater generation for the proposed Project is given in Table 3-3.

Table 3-3: Water Consumption Details

S. No.

Description Water Consumption

in KLD

Wastewater generation in

KLD

Treatment & Disposal

1 DM Plant 275 9 To ETP

i Process 266 345 To MEE after primary treatment. Then contaminated condensate to ETP and clear condensate will recycle and reuse in plant area

2 Cooling Tower 1150 100 To ETP

3 Washing 150 150 To ETP

4 Others (Safety showers, fire

fighting, Laundry & Bathing)

200 200 To ETP

5 Domestic 50 45 To STP

6 Gardening 35 0

Total Water Consumption

1860 849 599 KLD to ETP including Utilities effluent and

Contaminated water from MEE, 200 KLD clear

condensate from MEE will recycle in plant premises

and 45 KLD sewage to STP

Total Recycled

water from MEE

200 - -

Total Fresh Water

Consumption

1660 - -

3.8.2 Waste Water Treatment and Disposal


3.8.3 Power Requirement

The power requirement for the proposed facility will be met either through captive generation by SEZ operator M/s Jubilant Infrastructure Limited, or sourced from grid of Dakshin Gujarat




Vij Company Limited. Total estimated electrical load for the proposed manufacturing unit is around 4 MW. In addition, the plant will have 4 DG sets of 500 KVA capacity each, for emergency power back-up during grid failure.

Table 3-4: Fuel Consumption

Sr. No.

Stack Attached to

Capacity Stack Nos.

Type of Fuel used

Fuel consumption

1 DG Sets 500 kVA 4 Diesel 500 Lit/Hr.

2 Thermic Fluid

Heater 2 million kcal 3 Coal 16 MT/Day

Note:

1. Steam will be supplied by SEZ operator M/s. Jubilant Infrastructure Limited.

2. Solid waste and liquid waste incinerator shall be installed by SEZ operator M/s. Jubilant Infrastructure Limited

3. DG Sets will be used only during Power failure.

3.8.4 Steam Requirement

The peak steam supply for the project is about 600 TPD and shall be sourced from the SEZ operator M/s Jubilant Infrastructure Limited.

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

The generation of pollutants associated with the proposed New Plant will be in the form of Gaseous emissions, Liquid effluent, Solid waste, and Hazardous waste.

3.9.1 Gaseous Emission

The JLSL plant will have following sources of emission namely,

Process emission from outlet of scrubbers attached to reactors. Flue gas emission from stack attached to Thermic Fluid Heaters (3 Nos. of capacity 2

million kcal each). Diesel Generator sets (4 nos. of capacity 500 KVA each) attached with individual stack.

The emission from stacks will be well within the stipulated norms.

3.9.2 Liquid Effluent





3.9.3 Solid / Hazardous Waste

JLSL being an environmentally conscious Organization has always emphasized on pollution prevention rather than pollution Control. To strengthen the waste management system, different types of wastes are identified along with proper disposal / recycling / reuse mechanisms.

Basically the following types of solid wastes are generated at JLSL:

Municipal wastes Hazardous wastes

Municipal waste (Non-Hazardous waste) in the plant will be very limited as no residential facility is planned in the project site. Municipal waste generation will be mainly from office area, canteens waste and will be composted and manure generated will be used for greenbelt development.

Hazardous Solid wastes generated at JLSL new site will be maintained as per Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008 and will be disposed off as per the details given in Table 3-5.

Table 3-5: Hazardous Waste Generation and disposal Details

S. No.

Type of Waste Hazardous

Waste Category

Quantity in

MT/Month

Method of

Collection

Treatment / Disposal

1 ETP Sludge 34.4 40 Poly bags To TSDF for

Landfill

2

Discarded containers / barrels/ liners

contaminated with hazardous waste /

chemicals

33.3 400 Nos. As is

Decontamination and Sold to authorized

vendor

3 Used/Spent Oil from D.G

sets, machineries 5.1 5 Drums

Sold to CPCB/GPCB authorize

Reprocessor

4 Process Residue 20.3 575 Drums To incinerator

operated by SEZ / 3rd party

5 Process Residue 20.3 170 Drums To TSDF for

Landfill

6 Spent Catalyst 28.2 24 Poly Bag To TSDF for

Landfill

7 MEE Salt 34.3 1800 Loose To TSDF for

Landfill

8 Off-spec or obsolete raw

materials or products 29.3 10

Poly Bag / Drums

Incineration

9 Spent Solvents 20.2 20 KL Drums Sold to

CPCB/GPCB




S. No.

Type of Waste Hazardous

Waste Category

Quantity in

MT/Month

Method of

Collection

Treatment / Disposal

authorize Reprocessor

10 Used Filter Media 35.1 30 Poly Bags Solid Incinerator

11 Scrubber Sludge 29.2 2 Drums Landfill

3.10 Schematic Representations of the Feasibility Drawing which give Information of EIA Purpose

A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break up is attached as Figure 3-3.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

The plant site is well connected by road to the major national and state highway network. The approach road to the site is suitable for movement of heavy loads involved including the construction materials.

The Project site is located adjacent to NH-8 and the nearest railway station is Bharuch at 15 km. The site is well connected to the Mumbai-Ahmedabad highway. The nearest airport is located in Vadodara at a distance of 103 km.

Site is located at an aerial distance of 35.5 towards E direction from costal region of Bay of cambay. The nearest sea port is located at Dahej at an aerial distance of 35.5 km towards W direction from project site.

4.2 Land Form, Land Use and Land Ownership

The total plot area of the proposed unit will be 20 ha. The land will be a part of the 106 ha SEZ operated by M/s Jubilant Infrastructure Limited which is already an industrial land.

4.3 Topography (along with map)

Topographically, the entire area is almost flat with gentle dipping toward west. Geomorphologic ally, coastal area is covered by tidal and mud flats. Drainages have acquired a pattern of deltaic condition.

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, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ.

Existing Land use pattern: Industrial Distance of Project site from Water Bodies are given in Table 4-1.

Table 4-1: Distance of Project site from Water Bodies

Water body Distance in km Direction

Bhukhi River near Vilayat Village 2.94 S Vilayat Village Pond 2.63 S Vorasamani Village Pond 1.02 N Bhersam Village Pond 2.71 WSW Argama Village Pond 2.89 E Narmada River near Vadva Village 11.1 S Minor Canal near Vorasamani Village 0.55 N

The proposed project site is situated SEZ operated by M/s. Jubilant Infrastructure Limited.




4.5 Existing Infrastructure

The plant site is proposed in an SEZ that is operational since 2009 in GIDC Vilayat, District Bharuch Gujarat. The infrastructure required is already present for Road, Electricity, Water supply, Waste disposal, Waste incinerator etc. Nearest Railway station at Bharuch is about 15 kms away on the mail line from Mumbai to Ahmedabad. Nearest Airport is at Vadodara, about 103 Kms from the site. Communication facilities such as telephone, tele-fax and Internet are available in vicinity of the proposed plant site location.

4.6 Soil classification

The top layer of the soil is of very high swelling characteristic which is not suitable for structural back filling. Below this layer soil type is very stiff clay with gravel.

4.7 Climatic data from secondary sources

The general agro-climate zone of the study area is Semi-Arid.

Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term Climatological Tables, 1961-1990, Bharuch. These tables give useful information about a region’s weather, since they are collected over a 30-year period.

4.7.1 Temperature

Mean daily maximum temperature is recorded in the month of May at 43.8°C. From October to December, both day and night temperatures begin to decrease rapidly. January is generally the coldest month, with minimum morning temperature at 11.3°C. During the post-monsoon months of October and November, day temperatures remain between 16.7-35.9ºC. In winters, i.e. December, January and February, average day temperatures remain between 11.3-33.5ºC.

4.7.2 Wind

Table 4-2: Predominant Wind Direction

Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening

January NE NE SW SW SE SE

February NE NE NW NW SW SW

March SW SW NE NE SE SE

April SW SW NW NW SE SE

May SW SW NW NW SE SE

June SW SW SE SE NW NW

July SW SW S S W W

August SW SW W W NW NW

September SW SW NW NW W W

October SW SW NE NE SE SE

November NE NE SE SE SW SW




Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening

December NE NE SE SE SW SW

4.7.3 Rainfall

The total rainfall in year is observed to be 912.1 mm. Distribution of rainfall by season is 2.8 mm in winter (December, January, February), 9.9 mm in summer (March, April, May), 860.7 mm in monsoons (June, July, August, September) and 38.7mm in post-monsoons (October - November).

4.7.4 Cloud Cover

The area remains cloudy between the months of June – September, which is the active period of the monsoon season.

4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer in that order. Mornings are more humid than evenings and humidity ranges from a high of 81 – 90% in monsoon mornings to a low of 29 – 39% in summer evenings. During post-monsoon season, in morning humidity remains between 73 – 76% and in the evening it remains between 42 – 46%.

4.8 Social infrastructure available

The project site is locates about 17 kms from the city of Bharuch where major social infrastructure is available.

Social investment in the form of CSR would help to improve the healthcare, education, sanitation, infrastructure and other areas wherein the project proponent is actively involved as part of its CSR commitments.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept

The entire area is a well-developed industrial area with numerous industrial units.

5.2 Population Projection

During the Construction and Execution phase of the Project, it is estimated that about 600 workers will be involved for a period of about 72 months.

Thereafter during the operation phase at the new plant around 400 persons (90 persons - direct and 310 persons - contract) positions will be created and employed.

5.3 Land use Planning

The Proposed Plant is located in SEZ operated by M/s. Jubilant Infrastructure Limited. It is already developed according to Chemical Industrial Use. The Land use breakup at site is given in Table 5-1.

Table 5-1: Land Use Breakup at Site

S. No. Title Area, m2 % of total

Area

1 Industrial Buildings 45000 22.50

2 Raw Material, Finished Goods, Waste Storage Yard

55000 27.50

3 Utility Infrastructure 20000 10.00

4 Roads and Infrastructure 30000 15.00

5 Green Belt 16000 8.00

6 Open Spaces 34000 17.00

Total 200000 100.00

5.4 Assessment of Infrastructure Demand

The proposed project is located in an SEZ which is a part of the GIDC at Village Vilayat, Bharuch District, Gujarat. This site is 17 km to Bharuch.

Physical Demand:

Water: Water demand will be met from GIDC Vilayat through SEZ from the Narmada Project.

Electricity: The electricity will be supplied either through captive generation by SEZ operator M/s Jubilant Infrastructure Limited, or sourced from grid of Dakshin Gujarat Vij Company Ltd, Bharuch.

Machinery: Reactors, Storage tanks, holding vessel, distillation columns, condensers, Chilled Water unit, scrubbers, evaporators, spray dryers and other equipment


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH PLANNING BRIEF


Materials and Others: The Raw Material supply will be met by local and other markets. Other general utilities facilities are available in the area.

5.5 Amenities / Facilities

Following facilities will be made available at site:

First Aid Facility Hygienic Drinking Water Facility Green Area Regular Worker Medical Checkup Facility Change Room for Workers


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The Project is located at Vilayat SEZ operated by M/s. Jubilant Infrastructure Limited, Bharuch, Gujarat. Total Plot Area will be of 20 ha. Appropriate infrastructures are already in place at the SEZ including approach roads, drainages, lighting, effluent treatment plant, incinerator, steam generation, raw material storage yard, finished goods storage yard, Firefighting, Canteen, etc. All these facilities shall be extended to the proposed project also.

6.2 Residential Area (non-processing area)

No residential facility will be provided.

6.3 Green belt

The Proposed Project Plant will have 8 % Green Belt besides the greenbelt area of the SEZ.

6.4 Social Infrastructure

Canteen, Rest shelter / room, Recreation Room shall be provided and augmented.

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)

Project Site is located in SEZ near village Vilayat in Taluka Vagra, district Bharuch in Southern region of Gujarat state. It is rapidly developing industrial area and located at an aerial distance of about 12.0 km towards NW direction from district headquarter Bharuch and easily approachable.

6.5.1 By Road

State Highway, SH – 161 this is main approach road to site. It connects Bharuch with Costal Village Gandhar, via Vagra. This is double lane road passing at a distance of about 2.1 km towards E direction from proposed site. This road is also serve as a link between NH228 and costal highway SH06.

NH – 228 is a historical Dandi March route declared as national highway connects Ahmedabad and Dandi which is near Navsari, in south Gujarat. This highway is passing through study area at an aerial distance about 5.21 km towards E direction from proposed site.

National Highway, NH – 8 connects Mumbai – Ahmedabad - Delhi, is passing at an aerial distance of about 15.0 km towards E direction from proposed project site. This is busiest highway in western India having six lanes. SITE IS ALSO APPROCHABLE FROM THIS HIGHWAY THROUGH Nabipur-Dayadara road.

6.5.2 By Rail

Bharuch – Samni - Dahej broad gauge railway line passing at an aerial distance of about 5.2 km towards E direction from proposed site. Nearest railway station is at Dayadra.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH PROPOSED INFRASTRUCTURE


Bharuch is a major railway station in the area on Mumbai – Vadodara section of the western railway. It is busiest railway route passing through the region, which is about 14.51 km towards E direction from project site.

6.5.3 By Air

Vadodara Domestic Airport is about 70 km towards N direction from proposed site. Daily multiple flights for Mumbai and Delhi are available from here.

Surat Domestic Airport is about 75 km towards SSW direction from proposed site. Daily flight to Delhi available from here.

Ahmedabad Domestic and International Airport is about 144 km towards NNW direction from project site.

6.6 Drinking water management (source and supply of water)

The Drinking water will be supplied by SEZ operator JIL.

6.7 Sewage system

Sewage generated will be sent to ETP operated by SEZ operator.

6.8 Industrial waste water management


6.9 Solid waste management

Solid wastes generated will be maintained as per Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008 and will be disposed off as per the details given in Table 3-4.

6.10 Power requirement and supply/ source

The estimated power requirement of the New Plant is around 4 MW. This power requirement will be fulfilled through SEZ operator M/s Jubilant Infrastructure Limited, either through captive generation by SEZ operator M/S. Jubilant Infrastructure Limited or sourced from grid of Dakshin Gujarat Vij Company Limited, Bharuch.

The Plant will have 04 nos. Diesel Generator (DG) set of capacity 500 KVA each for providing the power back up during grid failure.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH

PROJECT SCHEDULE AND COST ESTIMATION


7 REHABILITATION AND RESETTLEMENTS (R AND R) PLAN

Not applicable as rehabilitation and resettlement will not be required, since the project lies in an Industrial Area, with land acquisition procedures completed by the SEZ.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH

PROJECT SCHEDULE AND COST ESTIMATION


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given)

Total project implementation is scheduled in phases over next 72 months, as per the market demand from the zero date.

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

The estimated capitalized cost of the project has been worked out to be Rs.250.00 Crores.


PROPOSED TECHNICAL GRADE PESTICIDES MANUFACTURING PLANT AT GIDC VILAYAT (SEZ), BHARUCH ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area

The project will improve the socio-economic status of the society in the region by generating direct and indirect employment opportunities. The project will contribute additional revenue to the State & Central exchequers in the form of taxes, cess, etc.

The anticipated impacts of the project are explained below:

The project related construction activities will benefit the local populace in a number of ways such as supply of construction laborers – skilled, semi-skilled and un-skilled, tertiary sector employment and provision of goods and services for daily needs including transport.

The proposed project will provide employment to the skilled as well as un-skilled persons. The local population will be given preference depending upon their suitability to the job

requirement. Besides direct employment, indirect employment opportunities will also open up. Social investment in the form of CSR would help improve the healthcare, education,

sanitation, infrastructure and other areas wherein the project proponent would be actively involved as part of its CSR commitments.




Annexure 1: SEZ Notification of Government of Gujarat










CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010. E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India – 122 002

E: [email protected]; T/F : 0124-424 2430-436

Kadam Environmental Consultants w w w . k a d a m e n v i r o . c o m

Env ironment for Development

PFR-Unit 3 -Updated sfter ToR PPTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...1.3 Water The total water requirement after Production startup at new site has been estimated

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