Project Pre-feasibility Report Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants PROJECT PRE FEASIBILITY REPORT ON PROPOSED CAPACITY EXPANSION For MANUFACTURING OF SURFACTANTS & SPECIALITY SURFACTANTS At Survey No. 193, Khanvel- Udhwa Road, Village- Kherdi, Silvassa-396230 Submitted to Ministry of Environment & Forest By
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Project Pre-feasibility Report
0 Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
PROJECT PRE FEASIBILITY REPORT
ON
PROPOSED CAPACITY EXPANSION
For
MANUFACTURING OF SURFACTANTS &
SPECIALITY SURFACTANTS
At
Survey No. 193, Khanvel- Udhwa Road,
Village- Kherdi, Silvassa-396230
Submitted to
Ministry of Environment & Forest
By
Project Pre-feasibility Report
Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
CONTENTS S. No. Particulars Page No.
1 Executive Summary 1-3
2 Introduction Of The Project 4-6
2.1 Identification Of The Project And Project Proponent 4
2.1.1 Identification Of The Project 4
2.1.2 Project Proponent 5
2.2 Nature Of The Project 5
2.3 Need Of Project & Demand-Supply Gap 6
2.4 Imports Vs. Indigenous Production 6
2.5 Export Possibility 6
2.6 Domestic / Export Markets 6
2.7 Employment Generation Due To Project 6
3 Project Discription 7-59
3.1 Type & Location Of Project 7
3.1.1 Type 7
3.1.2 Location 7
3.2 Details Of The Alternative Site 9
3.3 Size & Magnitude Of Operation 10
3.4 Project Discription With Process Details 10
3.4.1 So3 Gas Generation 10
3.4.1.1 Manufacturing Process 10
3.4.1.2 Material Balance 11
3.4.2 Group A – Surfactants (100% Purity Basis) 11
4. Linear Alkyl Benzene Sulfonic Acid (LABSA/Acid Slurry)
650
5. Liquid Detergents 250
6. Household Cleaners 150
7. Ammonium Lauryl Sulfate (ALS) --
8. Ammonium Lauryl Ether Sulfate (ALES) --
Group B - Speciality Surfactants
1. Fatty Monoethanol Amide --
2. Fatty Diethanol Amide --
3. Cocoamidopropyl Betaine --
4. Coco betaines --
5. Amine oxides --
6. Sodium Lauryl Sulfosuccinate (LSS)
--
7. Sodium Lauryl Sulfosuccinate (LES)
8. Benzalkonium Chloride 50%
--
9. Benzalkonium Chloride 80%
10. Ether Carboxylate, Sodium Salt
11. Alcohol / Amine Ethoxylates --
12. Ethylene Glycol Mono Stearate --
13. Ethylene Glycol Di Stearate --
14. Sorbitan Mono Oleate --
Kindly note that after expansion, we propose to manufacture “Surfactants (Group-A)” & “Speciality Surfactants (Group-B)” @ 3000 MT/M for any one of the products or cumulative production capacity not exceeding more than 3000 MT/M.
Man-power Existing Scenario: Skilled – 43 No (Approx) Unskilled – 59 No (Approx) Proposed Scenario: Skilled – 75 No (Approx) Unskilled – 100 No (Approx)
To be employed from local area
POLLUTION POTENTIAL & MITIGATION MEASURES
Parameter Potential Mitigation
Wastewater Existing Scenario:
Domestic: 3.0 KLD
Industrial: 3.1 KLD Proposed Scenario:
Domestic: 14.0 KLD
Industrial: 50.0 KLD
Existing domestic wastewater is being disposed through septic tank/ soaks pit system. Now we propose to install 20 KLD Sewage Treatment Plant for treatment and recycle of domestic effluent for gardening purpose.
High TDS stream from alkali scrubber, to be converted to Na2SO4 (15%) and reused in process.
In existing streams from washings, boiler and cooling is treated in ETP and treated wastewater is used for gardening.
After proposed expansion streams from process, washings, boiler and cooling will be treated in proposed state-of-the-art ETP and treated wastewater will be sent to RO & MEE then reused in cooling tower makeup.
Air Emissions Emission norms for Boilers, S D Burner, DG set and Process
PM < 150 mg/Nm3
SOx <100 ppm
In existing scenario, the company has two Steam Boilers having capacity of 4 TPH and 2 TPH which works on 50% load capacity.
The company will replaced two D.G. Sets having capacity of 840 KVA each by installing new two D.G. Sets having
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
PARTICULARS DETAILS
NOx < 50 ppm
capacity of 1500 & 750 KVA which acts as standby unit
In proposed expansion additional one Thermic fluid heater having capacity of 2 Lakhkcal/hr will be installed and existing steam boiler of 4 TPH will be operated on 100 % load and steam boiler of 2 TPH will be act as standby facility.
Acid Mist & SO2 gas is generated as process emission gases from the Sulfonation plant. The gas is scrubbed out through Alkali scrubber.
In the proposed scenario, 2 Electrostatic precipitators shall be run in series to minimize the acid mist load on scrubber.
After proposed expansion Particulate matter will also be generated as process emission from the Spray Dryer Plant and Bag Filters will be provided as control measures.
Minor quantity of fugitive emissions will be lost as handling losses and some quantity is expected to be released in atmosphere during storage.
Raw Materials & Products are stored in properly designed storage area and under good storage conditions to prevent any volatilities
The fugitive emissions in terms of handling losses get reduced by proper storage and handling.
Regular monitoring will be done of piping and fittings for checking of any leakages.
Good housekeeping maintained in the plant.
Adequate stack height is provided to all the utilities.
Hazardous & solid waste
Type of waste & Category
Existing Qty
Total Qty after
proposed expansion
ETP Waste (Cat. 34.3)
4.0 MT/Annum
500.0 MT/Annum
Used Oil (Cat. 5.1)
1.0 KL/Annum
2.0 KL/Annum
Discarded drums (Cat. 33.3)
240 Nos/Annum
30000 Nos/Annum
Used Ion Exchange material
0.05 MT/Annum
0.1 MT/Annum
Spent Catalyst
1.0 MT/Annum
3.0 MT/Annum
Spent Desiccant
0.05 MT/Annum
2.0 MT/Annum
ETP waste is being regularly sent to the PCC approved TSDF (GEPIL site) at Silvassa, for final disposal and the same will be followed for additional quantity.
The used oil is collected and stored separately in closed containers and finally sold to the registered re-refiners.
The discarded drums are stored separately in company premises and are returned back to the supplier / sold to the authorized re-conditioners and same practice will be followed for addn. qty.
Used Ion exchange material generated is stored properly and finally disposed off to GEPIL site, Silvassa.
Spent catalyst generated is stored properly and finally disposed off to GEPIL site, Silvassa.
Spent Desiccant generated will be stored properly and finally disposed off to GEPIL site, Silvassa
Noise Expected levels
Inside the plant: 75 dB(A)
Sturdy foundation to all the noise generating equipments.
D.G. Set installed in closed room
Ear Plugs and Ear muffs provided to the workers in Utility Section.
Greenbelt will be further developed.
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
CHAPTER – 2
INTRODUCTION OF THE PROJECT
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT
2.1.1 IDENTIFICATION OF THE PROJECT
M/s. Aarti Industries Ltd. (Surfactants Specialities Division) located at Survey No. 193,
Khanvel-Udhwa Road, Village- Kherdi; Silvassa (U.T.) is in operation since 2002. Today we are
one of the pioneer and leading companies in the manufacturing of “Surfactants and Speciality
Surfactants”. We propose expansion of the existing unit by way of increasing the production
capacity of the existing products and introducing some new products. Existing CC&A No.
PCC/DDD/O-1594/WA/AA/UR/01-02//346 dated 09/10/2013 is attached as Annexure-1. The
4. Linear Alkyl Benzene Sulfonic Acid (LABSA/Acid Slurry)
650
5. Liquid Detergents 250
6. Household Cleaners 150
7. Ammonium Lauryl Sulfate (ALS) --
8. Ammonium Lauryl Ether Sulfate (ALES) --
Group B - Speciality Surfactants
1. Fatty Monoethanol Amide --
2. Fatty Diethanol Amide --
3. Cocoamidopropyl Betaine --
4. Coco betaines --
5. Amine oxides --
6. Sodium Lauryl Sulfosuccinate (LSS)
7. Sodium Lauryl Sulfosuccinate (LES)
8. Benzalkonium Chloride 50%
--
9. Benzalkonium Chloride 80% --
10. Ether Carboxylate, Sodium Salt --
11. Alcohol / Amine Ethoxylates --
12. Ethylene Glycol MonoStearate --
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
13. Ethylene Glycol DiStearate --
14. Sorbitan Monooleate --
Kindly note that after expansion, we propose to manufacture “Surfactants (Group-A)” & “Speciality Surfactants (Group-B)” @ 3000 MT/M for any one of the products or cumulative production capacity not exceeding more than 3000 MT/M.
2.1.2 PROJECT PROPONENT The company is a limited firm and is promoted by board of directors.
Shri. Rajendra Gogari and Shri. Parimal Desai- UDCT Graduate Engineers are associated with
this group right from the inception and setting of various operations and is having vast
experience in the field of marketing, finance and administration.
Shri. Rashesh Gogri is also associated with all the group operations for more than last 18 years
and is having thorough experience in marketing, administration and technicalities.
All other directors are also having ample experience of marketing, finance and administration.
Table 2.2: Addresses of Directors
Sr. No.
Name of Director Designation Address Telephone No.
1.
Shri. Rajendra V. Gogri Chairman & Managing Director
1401,Antriksh Morar Road Mulund(W) Mumbai- 400080
022-67976666
2.
Shri. Rashesh C. Gogri Vice Chairman & Managing Director
601,Antriksh Morar Road Mulund (W) Mumbai-400080
022-67976666
3. Shri. Parimal H. Desai Whole-time Director
A/1403 14th floor, Runwal Heights, L.S.B. Uarg, Mulund (W) Mumbai-400080
022-67976666
4. Shri. Manoj M. Chheda Whole-Time Director
Dunhill Villa Co.op.HSG. SOC. Ltd., Besant Road, Santacruz (W), Mumbai-400054
Hazardous chemicals will be used as raw material in the manufacturing process. The details of
the raw materials are given below in table 3.2.
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
Table 3.2: Storage, Handling & Transport of Haz. Chemicals
Raw Material Source Means of
storage
Means of
transport
Storage conditions Max. Qty. to be
stored
(In MT) Press., Kg/m2
Temp (ºC)
Alfa Olefin Imp Storage Tank By road Atm Ambient 300
Sulfur trioxide In-house -- - 1 45 -
NaOH (48%) Ind Storage Tank By road Atm Ambient 70
Fatty Alcohol Ind / Imp Storage Tank By road Atm Ambient 200
Ethoxylated Fatty Alcohol Ind / Imp Storage Tank By road Atm Ambient 200
Surfactants In-house Storage Tank By road Atm Ambient 500
Sp. Surfactants In-house Storage Tank By road Atm Ambient 100
Linear Alkyl Benzene Ind / Imp Storage Tank By road Atm Ambient 200
Ammonium hydroxide (25%) Ind Storage Tank By road Atm Ambient 30
Fatty Acid Ind / Imp Drums By road Atm Ambient 100
Monoethanol amine (MEA) Ind / Imp Drums By road Atm Ambient 70
Diethanol amine (DEA) Ind / Imp Drums By road Atm Ambient 20
Dimethyl amine propyl amine (DMAPA)
Ind / Imp Drums By road Atm Ambient 40
Monochloro Acetic Acid (MCA)
Ind / Imp Bags By road Atm Ambient 20
Dimethyl Lauryl Amine (DMLA)
Imp Drums By road Atm Ambient 70
Hydrogen Peroxide Ind / Imp Drums By road Atm Ambient 20
Maleic Anhydride Ind / Imp Bags By road Atm Ambient 25
Sodium Sulfite Ind Bags By road Atm Ambient 20
Benzyl Chloride Ind / Imp Drums By road Atm Ambient 50
IPA Ind / Imp Drums By road Atm Ambient 5
Crude Ethoxylated Fatty Alcohol
Ind / Imp Storage Tank By road Atm Ambient 25
Chloro Acetic Acid Ind Drums By road Atm Ambient 10
Hydrochloric Acid Ind Drums By road Atm Ambient 2
Phosphoric Acid Ind / Imp Drums By road Atm Ambient 5
Sorbitol Ind / Imp Drums By road Atm Ambient 5
Glycerine Ind / Imp Drums By road Atm Ambient 2
Monoethylene Glycol (MEG) Ind / Imp Drums By road Atm Ambient 5
Project Pre-feasibility Report
41 Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
Table 3.3: Characteristics of Raw Materials
SR No.
NAME OF CHEMICAL
CAS No. HAZARD
FLASH POINT0 C (CC)
BP 0 C
MP 0 C
LEL %
UEL %
SP.GR. 20 0 C
VD SOLUBILITY WITH WATER at 25 0 C
NFPA
TLV ppm/ mg/m3 TWA
IDLH LC50 mg/m3
CARCINOGENIC CHARACTERISTIC
H F R
1. Alfa Olefin 1120-36-1
F >107 251 -13.9 0.5 5.4 0.77 (15.60
C)
6.8 In Soluble 0 1 0 NA NA 9900 NA
2. Sulfur trioxide 7446-11-9
H & R NA* 45 16.8 NA NA 1.92 2.8 Very Soluble 3 0 2 NA NA NA YES
3. NaOH 48% 1310-73-2
H & R NA 1390 318 NA NA 2.13 >1.0 Soluble 3 0 1 2 NA NA NA
4. Lauryl Alcohol 112-53-8 H & F 129 254-259
23 0.6 5.1 NA 6.4 In Soluble 2 2 0 NA NA 1.01 NA
5. Ethoxylated Fatty Alcohol
68439-45-2
H & F NA 100 9.9-10.8
NA NA 0.902 NA Soluble 1 1 0 1 ppm NA 1-10 YES
6. Surfactants Mixture H NA 100 10.36 NA NA 1.03 3.4 Easily Soluble 3 0 0 1 TWA NA NA YES
7. Sp. Surfactants 9003-11-6
H & F NA NA NA NA NA 0.99-1.03
NA Soluble 1 1 0 NA NA NA NA
8. Linear Alkyl Benzene
6774-74-7
F 140 278-314
NA NA NA 0.858 8.4 Slightly Soluble 0 1 0 NA* NA* NA* NO
9. Ammonia 7664-41-7
H & F -- -33.3 NA 16 25 NA 0.62 Very Soluble 3 1 0 25 NA 2000 --
10. Fatty Acid 67701-05-7
--- 100 239.7-365.2
20-28 NA NA NA NA In Soluble --- NA NA NA NA
11. Monoethanol amine
141-43-5 H & F 86 170.8 10.3 3 23.5 1.018 2.1 Soluble 3 2 0 6 ppm NA NA NA
12. Diethanol amine
111-42-2 H & F 165.6 268 28 NA NA 1.1 3.6 Soluble 1 1 0 0.46 ppm
NA NA NA
13. Dimethyl amine propyl amine
109-55-7 H & F 32 133 60 2-3 12-35
8120 3.5 Soluble 3 3 0 NA NA 4 ppm (Rats)
NO
14. MCA 79-11-8 H & F 150 189 63 8 --- 1.4043 NA Soluble 3 1 0 NA NA 254.6 ppm (Rats)
NA
15. DMLA 112-18-5/112-75-4
H & F 118 110-112
-20 NA NA 7870 7.36 NA 3 1 0 NA NA 1.1 g/kg (Rats)
NO
16. Hydrogen Peroxide
7732-18-5
H & R NA 108 -33 NA NA 1.2 1.1 Easily Soluble 3 0 1 1.42 TWA
NA NA YES
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
SR No.
NAME OF CHEMICAL
CAS No. HAZARD
FLASH POINT0 C (CC)
BP 0 C
MP 0 C
LEL %
UEL %
SP.GR. 20 0 C
VD SOLUBILITY WITH WATER at 25 0 C
NFPA
TLV ppm/ mg/m3 TWA
IDLH LC50 mg/m3
CARCINOGENIC CHARACTERISTIC
17. Maleic Anhydride
108-31-6 F T R 103.3 202 NA 1.4 7.1 1.48 3.4 Soluble 3 1 2 0.25 ppm
10 NA* NO
18. Sodium Sulfide 1313-82-2
H & F NA NA 1180 NA NA 1.86 NA Soluble 3 1 1 NA NA NA NA
19. Benzyl Chloride
100-44-7 H & F 67.2 179 -43 1.1 14 1.1 4.36 Partially soluble 3 2 1 --- NA 1231 (Rat)
YES
20. IPA 67-63-0 H & F 11.667 82.5 -88.5 2 12.7 0.78 2.07 Easily Soluble 1 3 0 400 ppm
NA 3600 (Mouse)
NO
21. Phosphoric Acid
7664-38-2
H NA 158 21 NA NA 1.685 3.4 Easily Soluble 1 0 0 1 TWA NA NA NA
22. Acetic Acid 64-19-7 H &F 39 118.1 16.7 NA NA 1.049 2.07 Soluble 3 2 0 10 ppm NA 5620 NA
23. Hydrochloric Acid
7647-01-0
H & R NA 108.5 -62.25
NA NA 1.1 -1.19
1.267 Soluble 3 0 1 NA NA 1108 NA
24. Sorbitol 50-70-4 H & F 100 296 NA NA NA 1.489 NA Soluble 2 1 0 NA NA NA NA
25. Glycerine 56- 81 -5 H & F 189 290 20 NA NA 1.26 NA Soluble 1 1 0 NA NA NA NA
26. Monoethylene Glycol (MEG)
107 -21 -1
H & F 111 197 NA NA NA 1.115 NA Soluble 1 1 0 NA NA NA NA
Note: NA = Not available, NA* = Not Applicable, M.P.=Melting Point, B.P.=Boiling Point, F.P.=Flash Point, TLV=Threshold Limit Value, LC50= Median Lethal Concentration, UEL= Upper flammable limit, LEL= Lower flammable limit, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million, ND = Not Detectabl
Project Pre-feasibility Report
43 Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
3.6 RESOURCE OPTIMIZATION & AVAILABILITY
The major resources for the proposed project will be plant & machinery, raw-materials, power,
fuel, water, man-power, etc.
3.6.1 LAND & BUILDING REQUIREMENT
Total plot area of existing unit is 30000 m2. No additional land will be required for proposed
expansion. The existing built-up area is 10716.06 m2 .
3.6.2 EQUIPMENTS
Based on process necessity, list of the proposed machinery is shown in the table given below:
Table 3.4: Details of Equipments
S. No. Equipment Existing (Nos.) Proposed (Nos.) Total (Nos.)
1. Sulfur melter 1 1
2. Sulfur Burner 1 1
3. Catalyst tower 1 1
4. Cascade cooler 1 1
5. Mist Eliminator 1 1
6. Acid Absorber 1 1
7. ESP 1 1 2
8. Alkali Scrubber 1 1
9. Falling Film Reactor 2 2
10. Neutralizer pump 2 2
11. Hydrolyser 2 2
12. Digester 2 2
13. Turbo tube dryer 2 2
14. Stripper 1 1
15. Steam Boiler 2 2
16. Air Compressor 1 1 2
17. Regeneration Air Blower 2 2
18. ADP Cooling air blower 2 2
19. ADP Drying Bed 2 2 4
20. Air Chiller 1 1 2
21. Cooling Tower 2 2 4
22. Product Adjustment tank 20KL 3 3
23. Product Adjustment tank 10KL 3 3
24. Bucket Filter 2 2 4
25. Spray Drying Tower 0 1 1
26. Stirred Reactors 3 3 6
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
3.6.3 POWER AND FUEL REQUIREMENT
The total existing power requirement is 1120 KVA which is sourced from State Electricity Board
Grid. After the proposed expansion total power required will be 1600 KVA which will be sourced
from State Electricity Board Grid.
In existing, the company has 2 Nos of D.G. Sets of 840 KVA capacity which acts as standby
facility and is used only in case of power failure. For proposed scenario, existing D.G. sets will
be replaced by 2 Nos. of D.G. sets of 1500 kVA and 750 kVA capacities which will act as
standby facility and will be used only in case of power failure.
Agro Based Fuel (Baggase, Husk Briquette) ,Furnace oil (FO) ,Light Diesel Oil (LDO) are used
as fuel for existing operations which are obtained from authorized dealers.
Coal/Lignite, Furnace oil (FO),Light Diesel Oil (LDO) will be used as fuel for proposed
operations which will be obtained from authorized dealers.
Table 3.5: Details of Power & Fuel
Sr. No. Particulars Existing Requirement Requirement after Proposed
Expansion
Power
1. Power Requirement 1120 kVA 1600 kVA
2. Source of supply State Electricity Board Grid and D.G. Set – 2 no. (840 KVA) – Standby facility
State Electricity Board Grid and D.G. Set – 2 no. (1500 &750 KVA) – Standby facility
In existing scenario, the company has two Steam Boilers having capacity of 4 TPH and 2 TPH
which works on 50% load capacity. The company has two D.G. Sets having capacity of 840
KVA each which acts as standby unit and is used only in case of power failure. Adequate
chimney height is provided to the existing utilities.
In proposed expansion additional one Thermic fluid heater having capacity of 2 lakhkcal/hr will
be installed and will be operated on 100% load and existing steam boiler of 4 TPH will be
operated on 100 % load and steam boiler of 2 TPH will act as standby facility. Existing D.G. sets
will be replaced by 2 Nos. of D.G. sets of 1500 kVA and 750 kVA capacities which will act as
standby unit and will be used only in case of power failure.
Project Pre-feasibility Report
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
Table 3.10: Details of Utility Emission
Particulars Details Fuel & its Qty Stack
Details(m) Emission Norms
Existing Scenario
Steam Boiler 1 No.
Capacity: 4.0 TPH (50 % load)
Agro Based Fuel ( Baggase, Husk Briquette) –250 kg/hour
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
Steam Boiler 1 No.
Capacity: 2.0 TPH (50 % load)
Furnace oil (FO) – 102 LPH (Stand by)
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
D.G.Set- 2 No.
840 kVA
Light Diesel Oil (LDO) – 600 LPH
H: 12 m D: 200 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
Proposed Scenario
Steam Boiler 1 No.
Capacity: 4.0 TPH (100 % load)
Coal/Lignite –1000 kg/hour
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
Steam Boiler 1 No.
Capacity: 2.0 TPH (100 % load) (Standby)
Furnace oil (FO) – 205 LPH (Stand by)
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
D.G.Set- 2 No.
1500 KVA 750 KVA
Light Diesel Oil (LDO) =700 LPH
H: 12 m D: 200 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
Thermo pack Boiler
Capacity: 2 Lakh K.Cal/Hr (100% load)
LDO = 21 LPH
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
S.D. Burner (Spray dryer plant)
800 K.Cal/Hr FO = 50 LPH.
H: 30 m D: 500 mm
SPM<150mg/Nm3
SOX< 100 ppm NOx< 50 ppm
*Common chimney will be provided for Steam Boiler and Thermo pack Boiler.
3.7.4.3 Fugitive Emission
Minor quantity of fugitive emissions will occur during handling of the raw materials. Fugitive
emissions are also likely to occur from storage drums.
Following measures will be practiced to reduce the fugitive emissions:
Raw Materials & Products are stored in properly designated storage area and under
good storage conditions to prevent any volatilities
Raw Materials & Products are stored in closed containers
The fugitive emissions in terms of handling losses get reduced by proper storage and
handling.
Regular monitoring will be done of piping and fittings for checking of any leakages.
Good housekeeping maintained in the plant.
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
3.7.5 HAZARDOUS / NON-HAZARDOUS WASTES MANAGEMENT
Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,
Used oil from gear boxes of the machineries & D.G. Set, discarded drums, Used Ion exchange
& resin, spent desiccant and catalyst. Company has provided adequate storage area for proper
storage of wastes.
Table 3.11: Details of Hazardous/Non-Hazardous Waste Generation & Disposal
Type of waste & Category
Existing Qty Total Qty after proposed expansion
Disposal Method
Hazardous waste
ETP Waste (Cat. 34.3)
4.0 MT/Annum 500.0 MT/Annum
Company has provided adequate storage area. The ETP waste generated is stored properly and finally disposed off to GEPIL site, Silvassa and same practice will be followed for addn. qty.
Used Oil (Cat. 5.1)
1.0 KL/Annum 2.0 KL/Annum The used oil is collected and stored separately in closed containers and finally sold to the registered re-refiners. and same practice will be followed for addn. qty.
Discarded drums (Cat. 33.3)
240 Nos/Annum
30000 Nos/Annum
The discarded drums are stored separately in company premises and are returned back to the supplier / sold to the authorized reconditioners and same practice will be followed for addn. qty.
Used Ion Exchange material
0.05 MT/Annum
0.1 MT/Annum
Used Ion exchange material generated is stored properly and finally disposed off to GEPIL site, Silvassa. and same practice will be followed for addn. qty.
Spent Catalyst 1.0 MT/Annum 3.0 MT/Annum Spent catalyst generated is stored properly and finally disposed off to GEPIL site, Silvassa. and same practice will be followed for addn. qty.
Spent Desiccant
0.05 MT/Annum
2.0 MT/Annum
Spent Desiccant generated will be stored properly and finally disposed off to GEPIL site, Silvassa.
Non-Hazardous waste
Fly ash 60.0 MT/Annum
2700.0 MT/ Annum
Fly ash will be collected, stored and sold off to brick manufacturers.
Insulation waste
NIL 24.0 MT/Annum
Insulation waste will be collected, stored and sold off to scrape dealer.
3.7.6 NOISE AND ODOUR CONTROL
There are no major activities due to which noise would be generated other than compressors &
gear boxes. There is no major generation of bad odour as process will be carried out in closed
reactors. The control measures to be taken for reduction in noise & odour levels are as below:
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Project: Proposed Expansion of Manufacturing of Surfactants & Speciality Surfactants
Sturdy foundation to all the noise generating equipments.
D.G. Set installed in closed room
Ear Plugs and Ear muffs provided to the workers in Utility Section.
Closed reactors and vessels for odour control.
Greenbelt will be further developed.
3.7.7 HEALTH AND SAFETY MEASURES
The company is concerned about occupational health and safety among its
work force as the man power is the biggest asset to the company. The Off-site Emergency Plan
is available with the Collectorate Office, Silvassa.
The following key safety measures are implemented in the existing plant and the same shall be
a part of proposed expansion project:
Safety Training is provided to the employees.
Safety Sirens & Hooter Alarm System is provided for use, in case of emergency.
Fire Extinguishers are installed at identified locations in the premises.
Assembly point is provided in the plant.
First Aid Facility and training is provided to the workers.
Personal protective equipments are provided to employees.
Health check up is organized at regular intervals.
Safety / Health records and MSDS are maintained.
3.7.8 ENVIRONMENTAL HEALTH & SAFETY CELL
The company has a separate environment cell in order to keep a close watch on the
performance of the pollution control equipment, emissions from the sources and the quality of
surrounding environment in accordance with the monitoring program. The cell is also entrusted
with the responsibilities of regulating the safety measures inside the plant campus. The cell is
also responsible for maintaining the records of all data, documents and information in line within
the legislative requirement. The organogram of the EHS cell is given below in Figure 3.6.
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Fig-3.7: Organogram of EHS Cell
3.7.9 POST PROJECT MONITORING PLAN
As an existing company, the company gets monitored the components like bore well water,
waste water, flue gas and process emissions, ambient air and noise monitoring.
The company is also developing in-house facilities for monitoring certain components. Where it
is not possible to establish such facilities, the same is done by appointing external
recognized/approved agencies. The proposed post-project monitoring plan is given below:
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Table 3.12: Post Project Monitoring Plan
Components Parameters Frequency of in house monitoring
Frequency of third party monitoring
No. of sample
Drinking water IS-10500:1991 -- Quarterly One sample
Waste water BOD, COD, pH, TSS, TDS
Daily Once in a month At all stage
Air-ambient SPM, SOx, NOx, RSPM, CO, etc.
-- Quarterly 2 stations within premises
Stack monitoring SPM, SO2, NOx
-- Quarterly 3 stacks
Process stack monitoring
Acid Mist & SO2 -- Quarterly 1 stack
Noise monitoring
dB (A) -- Once in a month Main plant, utility area & boundaries
Workplace monitoring
RSPM, SPM, SOx & Lux Level
-- Half Yearly Factory Building
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CHAPTER – 4
SITE ANALYSIS
4.1 CONNECTIVITY
This proposed project is located at survey no.193 in village-Kherdi, Silvassa. The Site is 9.18
km from Dadra and Nagar Haveli .The site is 12.3 km from National highway and 6.3 km from
state highway. The land and infrastructure is already available. And the raw material is easily
available through the easy transport via road connectivity. The nearest Railway station is Sanjan
railway station which is 22.75 km and Daman Coast Guard Airbase is 41.92 km from the project
site.
4.2 LAND FORM, LAND USE & LAND OWNERSHIP
The Region of Dadra and Nagar Haveli is located on the western coast of India between the
parallels of 20 o - 0’ to 20 o - 22’ of North latitude and between the meridian 72o - 50’ and 73 o -
15’ of East longitude of Greenwich.
4.2.1 LAND FORM
The proposed expansion will be carried out in existing premises. No additional land will be
required for proposed expansion project. The land is owned by the company located at
industrial zone of DN & H. land documents is attached as Annexure-4. And Documents in
Support of the Project Site being in Industrial Zone is attached as Annexure-5.
4.2.2 LAND USE PATTERN
The existing land-use as per the State of Environment Report -2005, for all the 70 villages and 2
urban centers namely Silvassa and Amli in the Region. Land use categories are as follows:
a) Built-up area which includes urban and rural areas
b) Industry
c) Mixed uses such as commercial, mixed urban built-up
d) Agriculture
e) Irrigation command area
f) Tourism
g) Forest
h) Roads and Water body
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Forest and agriculture are the predominant land-uses, which are followed by the industrial use
and built-up structures. The share of the forest is the largest amounting to 39.85% of the total
area followed by 32.17% under agriculture use; Irrigation command area together with water
bodies covers 20.63% of the total area of the region. The predominance of rural activities in the
region is reflected by the land-use pattern. Gaunthan and urban built-up constitutes 1.69% of
the region. The area under industries is 3.73% of the gross total area and 6.90% of the net
available area i.e. excluding the reserved forest area and water bodies.
Table 4.1: Land use Distribution of Dadra & Nagar Haveli (DNH)
Major Land-use Classification
Gross Total Area in Sq. Km.
Percent to Gross Total Area
Net Developable Area
Percent to Net Developable
Area
Built-up 8.08 2% 8.08 3%
Industries 17.82 4% 17.82 7%
Agriculture 153.64 32% 153.64 59%
Irr. Command Area 69.48 15% 69.48 27%
Res. Forest 190.35 40% -- --
Roads 9.19 2% 9.19 4%
Water bodies 29.04 6% -- --
Total 477.61 100% 258.22 100% (Source: State of Environment Report, 2005 for DNH)
4.2.3 LAND OWNERSHIP
The proposed project will be sited on the existing plot located notified industrial zone of Dadra &
Nagar Havili.
4.3 TOPOGRAPHY
The topography is undulating and rolling. The territory has a hilly terrain, especially in the
northeast part, which is surrounded by the ranges of Sahyadri Mountains (Western Ghats). The
central and remaining part of the Region is fairly plain. The highest point in the Region is 423
mtrs. above the sea level.
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4.4 SALIENT FEATURES
Table 4.2: Salient Features of the Project Site
Particulars Details
Co-ordinates 73° 1' 03.1” E, 20° 05' 52.9" N
Village Kherdi
Taluka/ Tehsil Dadra and Nagar Haveli
District Dadra and Nagar Haveli
Nearest Settlement Village - Kherdi
Nearest Reservoir River Damanganga @ 16.8 km
Nearest Highway State Highway @ 6.3 km National Highway 8 @ 12.3 km
Nearest Railway station & Railway line Sanjan Railway station @ 22.75 km Railway line @ 22.3 km
Nearest Airport/ Airbase Daman Coast Guard Airbase @ 41.92 km
State/ National borders Maharashtra border within 1 km
Tourist places Gardens in Khanvel and Dadra
Sites of Historical/ Archaeological importance Structures constructed during Portuguese rule.
Protected Area/ Sanctuaries None within 10km radius
CRZ applicability Not applicable
4.5 EXISTING INFRASTRUCTURE
The existing infrastructure is sufficient to accommodate the proposed expansion project and
also our major purchasers are located in the vicinity of the region. Secondly; there is no Octroi
Duty and power is available at subsidized rates in the region. The territory’s vicinity to well
developed industrial estate in Vapi, Daman & Sarigam also plays an important role in the site
selection.
The major factors involved in the selection of site are:
Availability of well connected roads to the plant site for movement of equipments, raw
material, finished products etc.
Availability of the resources like water, fuel, power etc.
Suitability of land and topographical and geological considerations.
Environmental and ecological impacts.
4.6 SOIL CLASSIFICATION
Shallow Black Cotton Soil: The soils of subdued hillocks and undulated valley plains are either
having no diagnostic horizon or have tendency of alteration to give rise to cambric horizon.
These are subjected to high erosion menace and have lost the top soil fully or partially. These
are medium textured soils with gravels and pebbles and hard rock is met early below the soil
restricted free movement of water and air. Through the soil are permeable enough but low
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moisture holding capacity of the soil calls for specific moisture management for sustainable land
use under cultivation. These soils need permanent vegetation to protect them from further
deterioration. These soils are medium to low in fertility and are placed either in entisol or
inceptisol order. These soils call for specific conservation measures for their protection and are
advised for no tilling or occasional tilling for their sustainability. Mostly these soils developed
over basaltic basic parent material occur in the central part of the territory extending in N-S
direction.
(Courtesy: Environmental Information Centre, New Delhi)
4.7 CLIMATE & METEROLOGY
The climate is characterized by oppressive summer dampness in the atmosphere nearly
throughout the year, heavy south–west monsoon rainfall and a mild winter. The year can be
divided into four seasons. The cold season from December to February is followed by the
summer season from March to May. The south-west monsoon season is from June to
September. The post-monsoon season constitutes the months of October and November.
The summary of yearly meteorological data for a period of 10 years recorded at the nearest
observatory of IMD at Dahanu has been taken from the National Data Centre of Indian
Meteorological Department at Pune.
Table 4.3: Summary of Meteorological Data at nearest IMD Station - Dahanu
Location: In the compound of the old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o 58’, Long: E 72o 43’) Height of installation: 11m above MSL
Month PDW Direction
Avg. W. Speed (kmph)
Temperature (oC)
Relative Humidity (%)
Cloud Cover (Oktas)
Rainfall (mm)
Max. Min. Morn. Even. Morn. Even.
JANUARY N 1-19 27.7 16.5 67 69 1.3 1.1 0.2
FEBRUARY N 1-19 28.3 17.4 66 69 1.1 0.8 0.2
MARCH N 1-19 30.3 20.7 68 67 1.4 1.1 0.1
APRIL W 1-19 32.2 24.0 74 69 2.1 1.4 0.1
MAY W 1-19 33.1 26.8 77 73 3.8 2.3 5.2
JUNE SW 1-19 32.2 26.3 85 80 6.1 5.6 522.1
JULY SW 1-19 30.1 25.0 89 84 7.1 6.8 771.7
AUGUST W 1-19 29.5 24.7 88 83 6.9 6.7 502.3
SEP W 1-19 30.0 24.0 87 79 5.4 4.9 319.1
OCT E 1-19 32.1 23.1 77 72 2.8 2.4 44.4
NOV N 1-19 32.1 20.5 67 71 1.9 1.9 17.1
DEC N 1-19 29.8 18.0 67 71 1.6 1.5 0.3
Seasonal Average Values
Period Avg. PDW Direction
Avg. WS
Avg. Max.
Avg. Min.
Avg. Morn.
Avg. Even.
Avg. Morn.
Avg. Even.
Total
Summer W 1-19 31.9 23.8 73.0 69.7 2.4 1.6 5.4
Winter N 1-19 28.6 17.3 66.7 69.7 1.3 1.1 0.7
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