Pre-Feasibility Report Fibrol Non-Ionics Private Limited Pre-Feasibility Report for Synthetic Organic Chemical Manufacturing Unit PROJECT TERMED UNDER SCHEDULE 5 (f) (SYNTHETIC ORGANIC CHEMICALS INDUSTRY) CATEGORY - A Prepared By Fibrol Non-Ionics Pvt.Ltd Survey No. 131, Rasal village, Khopoli-Pali Road Tal.: Sudhagad Pali, Dist.: Raigad, Maharashtra, Pin 410205 www.fibrol.com
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Synthetic Organic Chemical Manufacturing Unitenvironmentclearance.nic.in/writereaddata/Online/TOR/08...synthetic organic chemical manufacturing. b. Suitability of land from topography
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3.1 Type of Project: ........................................................................................................................................... 5
Chapter 4 Site Analysis ...................................................................................................................................... 14
Fibrol Non-Ionics Pvt. Ltd. is a manufacturer of Non- Ionics Surfactants & Industrial detergents and Emulsifier.
Fibrol Non-Ionics Pvt. Ltd. is a small-scale manufacturing company. Promoted by first generation entrepreneurs, who have had gained useful experience & knowledge about the process products safely aspects of the manufacturing unit, the procurement of raw materials & market potential & demands in their earlier jobs by the directors.
Being from middle class background & having limited personal financial ability to invest, most of the investment is sourced from financial institution & private borrowing. The project was erected & commissioned after understanding the growing demand for the Industrial detergent & surface active agents & with an aim to cater the same by generating some gainful employment to the local younger unskilled youth, with an aim to create maximum greenery on the available land & fulfilling social responsibility.
Health & safety of our employee & the surrounding population is our prime objective throughout our operations of last five years. We are committed to it & for welfare of community & environmental protection as long as we are in operation in future also.
We are committed to the Health and Safety of our employees, the welfare of our community & environment protection.
The google image of the plot site is enclosed in report at Annexure-I
Layout Plan for under operation is attached as Annexure-II
Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide
EIA Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic
chemicals manufacturing units. This project falls under category ‘A’ and schedule item no. 5(f):
The unit was established about 4 year ago. This PFR is made for the Environmental Clearance As per the EC notification. The project brief is summarized in the table below
Project summary at a glance
Sr No Particulars Details
1 Name of Company Fibrol Non-Ionics Pvt. Ltd.
2 Products (existing and proposed) 1. Non- Ionics Surfactants
2. Industrial detergents
3 Location Survey no.131, Rasal village, Tal-Sudhagad-Pali,
Dist. Raigad.
4 Name of the project 1) Fibrol Non-Ionics Pvt. Ltd.
5 Total land area of the plot 7460 sq. mtr.
6 Total built up area 1680 sq. mtr.
7 Major raw material Refer section 3.4
8 Water requirement and source 3.4 CMD (as per CTO) sourced by water tankers
9 Power requirement and source 106 HP sanctioned and connected by MSEDCL
10 Existing and proposed manpower 4 +13=17 existing (Admin+Labour)
11 Waste water quantity (as per
CTO)
Trade effluent- 0.25 CMD
Domestic effluent- 0.2 CMD
12 Air emissions Within the limits of CTO
13 Solid Waste No generation of solid waste
14 Project cost estimate 373 Lakhs as per certified by CA Annexure-IV
The Land is used as “Industrial” land thus there shall be no change in land use.
Land was purchased for establishing the factory for which due N.A. permission obtained from
District from Collector Raigad.
Fibrol has constructed facility such as the internal road network, external approach road etc.
There is no sensitive establishment in the vicinity such as health resort, hospital,
archaeological monuments, sanctuaries, etc.
The land and infrastructure is made available and the raw material is easily available through
the easy transport via road connectivity by local suppliers as well as imported one.
All the products are wider soluble emulsifiers being packed directly from reaction vessel and
daily production of one batch per shift is scheduled.
Change of product is mainly by change in molar ratio of reactant chemicals. Whenever change
of raw material is necessary, all the resultant products being emulsifier, they do not
contaminate or alter drastically each other at the users end.
Hence reactor washing is avoided to save time, to save energy and to save cost.
The reaction being carried out under Nitrogen blanketing and at elevated pressure.
The storage of main raw material is also at chilled temperature and under pressure.
Boiler used for raising the initial temperature to 130 deg to 150 deg C and thus for initial 90 to
120 minutes only. There onwards being exothermic the reaction mass needs to be cooled by
circulation water around vessel.
• Process Description
In a Clean & Dry reactor, the raw material (viz. Nonyl Phenol, Para Octyl Phenol, Castor Oil, Stearic and allied fatty acids, fatty alcohols like Ceto Stearyl Alcohol, Lauryl Alcohol, Oleyl Alcohol) & amines such as Stearyl, coco etc are charged, either by vacuum or manually. Reactor is closed alkaline catalyst added (NaOH/KOH/Na2CO3/K2CO3 or any such) to level of 0.02% and steam heating started by circulating steam through the limpet coil. During heating full vacuum is maintained inside the vessel, and at 130 deg to 140 deg C, reactor is purged with N2 is repeated to ensure total absence of air, oxygen. Along with heating & stirring Ethylene Oxide is introduced in the reactor through the sparger Line, below the raw material column inside the vessel, very slowly, & keeping constant watch on pressure of the vessel & temperature of the raw material inside the reactor. Pressure rises initially & temperature rise starts slowly, simultaneously, decrease in pressure is also observed, indicating the initialization of the reaction between raw material & Ethylene Oxide. Steam supply is stopped & reaction progress is continuously monitored & kept undercontrol by regulating the flow of ethylene Oxide & cooling water circulation, always maintaining positive pressure inside the reactor.
After complete addition of Ethylene oxide quantity the product is cooled to room temperature, thereactor is purged with nitrogen to remove out all unreacted (if any) gaseous Ethylene oxide & product isdischarged & packed.
This site of Fibrol Non-Ionics Pvt. Ltd. Is located at Survey no.131, Village-Rasal, Tal Sudhagad,
Pali, Dist. Raigad. The Site is 5 km from Pali town in Raigad district.
The land and infrastructure is made available by Government of Maharashtra and the raw
material is easily available through the easy transport via road connectivity.
4.2 Land form, Land use and Land ownership:
Land Form: Land is on plain contour, it is flat terrain.
Land Ownership: Land ownership is with project proponents (Fibrol Non-Ionics Pvt. Ltd.)
4.3 Topography:
The district has three physiographic divisions i.e. (i) Coastal zone in west covers about 20%
percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting of fertile land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude and covered with forest. This hill range is characterized by ruggedness and uneven topography, with crestline of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three main rivers in northern part.
The soils in the district are formed from the Deccan Trap which is predominating rock
formation with small out crops of Laterite at a few places in the Poladpur taluka and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation.
• Infrastructure facilities such as roads, communications etc.
5.2 Population Projection:
In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345
and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which
males were 1,117,628 and remaining 1,090,301 were females. Raigad District population
constituted 2.34 percent of total Maharashtra population.
In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population.
There was change of 19.31 percent in the population compared to population as per 2001. In
the previous census of India 2001, Raigad District recorded increase of 20.99 percent to its
population compared to 1991.
The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas. 5.3 Assessment of Infrastructure Demand (Physical and Social):
No major infrastructure demand is envisaged as the site is already established.