benzochem industries pvt. ltd. · industries pvt. ltd. infrastructure is designed to carry out many...

1

Pre - Feasibility Report

of

Benzochem Industries Pvt. Ltd.

Plot No. B-26, B-27, B-14, &B-15, Dasarkhed MIDC, Tal. Malkapur,

Dist. Buldhana, Pin - 443101.

Consultant:

M/s. SADEKAR ENVIRO ENGINEERS PVT.LTD.

QCI-NABET Accredited EIA Consultancy for Schedule 5 (b) & 5 (f) - Cat ‘A’

Certificate No – NABET/EIA/1821/RA 0121 NABL Accredited Laboratory, Valid up to 29.06.2020 Lab. Recognized by MoEF& CC, GOI, Valid up to 2.01.2019

Certified by ISO 9001:2008 & BS OHSAS 18001:2007

Plot No. A-95, Road No. 16, Wagle Estate MIDC Area,

Thane (W) - 400604 Telephone: 022 -2583321/22/23/24

Email: [email protected] / [email protected] www.sadekarenviro.com

April 2019

mailto:[email protected]

mailto:[email protected]

http://www.sadekarenviro.com/

2

1. Executive Summary

Salient Features of Project

Name & Address of

Company

M/s Benzochem Industries Pvt. Ltd.

Plot No. B-26, B-27, B-14, & B-15 Dasarkhed MIDC, Tal. Malkapur, Dist.

Buldhana, Pin - 443101.

Applicant Name Mr. Pralhad Zope

Schedule of project as per

EIA Notification, 2006 5 (f) & 5 (b)

Category of Project 'A'

Total Plot Area

Particulars Existing (m2) Proposed (m

2) Total (m

2)

Total Plot Area 33350 0 33350

Built Up Area 7856.36 946.56 8747.72

Parking Area 1240 2095 3335

Green belt 3340 7665 11005.5

Production Details Particulars Existing production quantity

Production Qty. After

Expansion

Products

(Intermediate

Chemicals)

58 MT/M 227 MT/M

By-product 39.4 MT/M 129 MT/M

Water Requirement of

Project

Existing water requirement: 143 m3/day

Proposed water requirement: 77.9 m3/day

Total water requirement : 220.9 m3/day after expansion

Source of water: MIDC

Effluent Generation EXISTING

Existing Industrial Effluent Generation: 12.85 m3/day

Existing Domestic Effluent Generation: 6 m3/ day

Total Existing Effluent Generation: 18.85 m3/day

AFTER EXPANSION

Total Industrial Effluent Generation (After Expansion): 59.7 m3/day

Domestic Effluent Generation: 10 m3/ day

Total Effluent Generation After Expansion: 69.7 m3/day

Effluent Treatment

Facility

Existing:

1) Industrial Effluent: 12.85 CMD Effluent presently treated in ETP of 60

CMD capacity comprising of primary, secondary and tertiary treatment

scheme & MEE of 30 CMD capacity. Treated effluent is recycled to plant for

3

process use.

2) Domestic Effluent: Treated sewage is used for gardening.

Proposed (After Expansion):

1) Industrial Effluent: Industrial effluent after expansion i.e. 69.7 CMD will

be treated in Evaporator of 100 CMD capacity. Evaporator salt residue will

be treated in 3 stage ETP of 100 CMD capacity followed by RO 100 CMD

capacity. Along with that, 150 CMD MEE will be installed as standby unit.

RO reject will be mixed with industrial effluent for treatment in Evaporator.

2) Domestic Effluent: Total Domestic Effluent i.e. 10 CMD will be treated in

septic tank & its overflow will be mixed with industrial effluent in aeration

tank.

Power Requirement Electricity Supplied by: MSEDCL

Existing connected load: 570 KW, Existing maximum demand: 800 kVA

Proposed connected load: 180 KW, Proposed additional demand: 200 kVA

Total connected load (after expansion): 750 KW, Total demand after expansion:

1000 kVA.

Boiler Details Boilers:

Existing Steam Boiler

Capacity: 6 TPH

Fuel quantity: 20.30 MT/day

Fuel used: Coal/ Agro waste

Proposed Steam Boiler

Capacity: 10 TPH


Fuel used: Coal

Thermic Fluid Heater Existing Thermic Fluid Heater

Capacity: 6.0 Lakh Kilo Calorie/Hr



Proposed Thermic Fluid Heaters

1. Capacity: 6 Lakh Kilo Cal/Hr



2. Capacity: 2 Lakh Kilo Cal/Hr -3

4

Fuel used: Furnace Oil


D.G. set capacity Existing: 380 kVA (Existing DG set will be replaced)

Proposed: 1000 kVA

Fuel requirement D. G. Set

Existing: 60 Lit/Hr HSD

Proposed: 194 Lit/Hr HSD

Total: 254 Lit/Hr.

Boilers & Thermo pack

Existing: 23.9 MT/D (995.83 Kg/Hr) Coal/Agro Waste

Proposed: a. 30 MT/D (1250 Kg/Hr) Coal/Agro Waste

b. 0.55 MT/D (22.7 Kg/Hr) Furnace Oil

After expansion: 53.9 MT/D (2245.83 Kg/Hr.) Coal/Agro Waste

Scrubber Existing: 2 Nos. (HCL/Cl2 & NH3) Scrubber

Proposed: 1 No. CN Scrubber

Plant Section & Units Height form

ground level Existing/Proposed

Process Scrubbers:

1. HCl/ Cl2 Scrubber 12.0 m Existing

2. Ammonia Scrubber 12.0 m Existing

3. CN Scrubber 12.0 m Proposed

Stack details Details of Existing:

Common stack for Boiler & TFH = 30.5 Meter

DG stack height = 3 m above roof

Scrubber stack = 12 m from ground

Proposed Stacks :

Common stack for Boiler & TFH = 30 Meter

DG stack height =3 m above roof

Scrubber stack= 12 m above roof

TFH proposed stack = 17.2 Meter

Hazardous Waste

Generation

Type of

waste

Category

of HW * UOM

Quantity Mode of

Disposal Existing Proposed Total

Distillation

Residue 20.3 MT/M 0.5 1.2 1.7 CHWTSDF

Chemical

Sludge

from waste

water

35.3 MT/M 0.5 0.8 1.3 CHWTSDF

5

Treatment

Evaporatio

n residue 37.3 Kg/M - 364 364

CHWTSD

F

Waste oil 5.1 Kg/M - 20 20

CHWTSDF/

authorised

recycler

Empty

containers 33.1 No./M - 52 52

CHWTSDF/

authorised

recycler

Empty

barrels 33.1 No./M - 8 8

CHWTSDF/

authorised

recycler

Spent

solvent 20.2 Kg/M - 52 52

CHWTSDF/

authorised

recycler

Contaminat

ed cotton

rags or

other

cleaning

material

33.2 No./M - 3 3 CHWTSDF

* As per Schedule-I of the Hazardous and Other Wastes (Management and

Trans-boundary Movement) Rules, 2016

E waste

Particulars E Waste

Category Existing

Propose

d

Kg/A

Total Method of

Disposal

Personal Computers

(Central Processing

Unit with input and

output devices)

ITEW2 -- 40 40

Sale to

MPCB

authorised

recycler/retu

rned to

manufacture

r/supplier

Personal

Computing: Laptop

Computers

(Central Processing

Unit with input and

output devices)

ITEW3 -- 20 20

Printers including

cartridges ITEW6 -- 20 20

Telephones ITEW12 -- 5 5

Bio medical waste Particulars

BMW

Category

Existing

Propose

d, kg/A Total

Method of

Disposal

Soiled waste

(Items

contaminated with

blood, body fluids

like dressings,

plaster casts,

cotton swabs and

Yellow -- 8 8

Disposal to

CBMWTF/

MPCB

authorised

processor

for Buldana

region

6

bags containing

residual or

discarded blood

and blood

components)

Expired medicines

(Pharmaceutical

waste like

antibiotics,

cytotoxic drugs

including all items

contaminated with

cytotoxic drugs or

plastic ampoules)

Yellow -- 6 6

Battery waste

Lead batteries

from D.G. Sets,

UPS system

-- 30

Nos./A

30

Nos./A

Sale to

supplier/MP

CB

authorised

party

Non Hazardous Waste

Generation

Coal ash: Existing quantity : 3.34 MT/D

After expansion: 7.54 MT/D

Man power Existing: Skilled – 67 Nos., Unskilled –125 Nos. Total: 192 Nos.

Proposed: Skilled – 8 Nos., Unskilled –25 Nos. Total: 33 Nos.

After Expansion Total Manpower : 225 Nos.

Project cost Project Cost Rs. 4.0 Cr.

EMP cost Capital Cost (Rs.) – 4.96 Cr

Recurring Cost (Rs.)–182.65 Lakhs

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2. Introduction of the Project

2.1 Identification of Project Proponent

Benzochem Industries Pvt Ltd. is an ISO 9001:2015, ISO 14001:2015 & OHSAS 18001: 2007

certified privately held firm established in the year 1997 primarily for manufacturing of

Intermediate Chemicals for Pharmaceutical, Agro chemicals and specialty Chemicals.

Company has a versatile plant with glass lined & stainless steel reactors, pressure reactors etc.

capable of carrying out various different kinds of reactions under different conditions. Benzochem

Industries Pvt. Ltd. infrastructure is designed to carry out many types of processes in a safe

manner.

Benzochem Industries Pvt. Ltd. has a successful track record in manufacturing non-infringing

processes and scaling them up from laboratory to kilo scale to commercial scale production.

Benzochem Industries Pvt. Ltd. expertise enables to successfully manage and develop a wide

range of processes that conform to stringent quality and safety guidelines.

The Company has quality assurance & quality control department staffed with competent

individuals & is highly equipped with latest instrument.

The Company play’s a proactive role in creating awareness, imparting training and minimizing

pollution & is also committed to the health & safety of employees, the welfare of community and

environment protection.

Benzochem Industries Pvt. Ltd. maintains long-term relationships with customers bear testimony

to our strict adherence to intellectual property. We leverage best practices and technology to

ensure confidentiality in our operations.

The company has a team of highly qualified work force having vast experience in various facets of

chemical technology & manufacturing expertise, well trained in all process & safety requirements.

Benzochem Industries Pvt. Ltd. provides cost effective solutions for customer’s diverse

requirements.

Highlights of the expansion project are:

The proposed production capacity enhancement project with existing &new products is located

in the existing unit at MIDC Dasarkhed, Malkapur.

The project activity will involve creation of new infrastructure for the proposed expansion

activity within existing premises on Plot No. B-26, 27 & B-14, 15. Since the proposed

expansion activity will be executed within the existing premises.

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Company is having 60 CMD capacity ETP in wake of proposed expansion the ETP treatment

scheme will be upgraded by installing new bioreactors (aeration tank), MEE, ATFD & RO.

The unit is at Dasarkhed MIDC (Existing unit) area which provides a good infrastructure for

the supply of water, power and transportation facility.

2.2 Nature of project

The project is for enhanced production capacity of intermediates chemicals from existing 58 MT/M

(39.4 MT/month of by-products) to 227 MT/M with By-products quantity will be 129 MT/M. The

expansion will be done by changing existing production quantity and introduction of new products.

2.3. Need for the project and its importance to the country and or region:

The main products of the company are intermediates for Agro Chemicals, Specialty Chemicals &

Pharma. With the increasing demands in India as well as abroad for manufacturing of most effective

Agrochemicals for cost effective & more yielded better cropping & for manufacturing most effective

API’s products has become a necessity. The demand for intermediates for Agrochemicals, Specialty

Chemicals & Pharma is increasing and therefore the need for agro-chemicals to increase food yield.

Most effective API’s for betterment of many dieses & Speciality Chemicals for different other uses.

The company also plans to expand its range of products in the category of intermediates of Agro

Chemicals, Speciality Chemicals & Pharma to cater to domestic and export needs.

Exports are a key focus area to support the vision of Hon’ble Prime Minister “Make in India”

program. Some of the products will help reduce imports and develop indigenous production.

2.4 History of the Project

Benzochem Industries Private Limited is wholly owned company of Mohatta Group.

The company is incorporated in 1st December, 1986 and started Malkapur based intermediate

chemicals manufacturing unit in 1997; Benzochem Industries Pvt. Limited was first incepted with the

production of intermediate Chemicals. Soon the company has developed substantial competencies in

the areas of Specialty chemicals & Pharmaceuticals Intermediates as performance chemicals.

Innovative products with the environmentally greener processes and fast system solutions enabled us to

expand further to incorporate Benzochem Industries Pvt. Limited in 1986 at Jalgaon and 1997 at

Malkapur in Maharashtra, about 400 kms from Mumbai.

In 2009 a new 100% Export Oriented Unit has been in operation at Malkapur. The company also has

local FDA approved c-GMP plant.

The company earned ISO 9001-2015, ISO 14001-2015 and OHSAS 18001-2007 recognition from

IQCS. India.

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The average turnover is 75 Cr. and it will be expected to reach around 110 Cr. for next year because of

which company is going for plant expansion at Malkapur.

Events & Status

Dasarkhed MIDC, Taluka Malkapur, District Buldhana, State Maharashtra was selected for set

up of manufacturing unit since the area is connected to NH & hence transportation of raw

material & finished product is easier.

The Dasarkhed MIDC, Taluka Malkapur, District Buldhana, State Maharashtra handed over the

plot possession to M/s Benzochem Industries Pvt Ltd, plot no B-26 & 27 admeasuring 24800

sqmt dated on 14.2.994.

The Dasarkhed MIDC, Taluka Malkapur, District Buldhana, State Maharashtra handed over the

plot possession to M/s Benzochem Industries Pvt Ltd, plot no B-14 &15 admeasuring 8550

sq.mt dated on 16.3.1998.

The Lease Agreement was executed between Dasarkhed MIDC & M/s Benzochem Industries

Pvt Ltd of plot no B-26 & 27 dated on 19th September 1999.

The Company M/s Benzochem Industries Pvt Ltd has purchased the Plot No. B-14 & 15, MIDC

Dasarkhed, Malkapur, Dist Buldhana from M/s Lakshumi Agro Development Corporation,

Malkapur for expansion purpose (Area 8550 sq. m).

The commencement of production on 04.11.1999 as per DIC Certificate (i.e. Udyog Aadhaar

Memorandum).

The plots B-26, 27 & B-14, 15 were amalgamated dated 05/05/2016.

2.5 Demand Supply Gap:

Import Vs. Indigenous production

Innovative products with the environmentally greener processes and fast system solutions

enabled us to expand further to occupy domestic & international market. The products list

widened with domestic & international requirement and company became market leader in the

manufacturing products based on chlorination and cyanation. With the passage of time the

company diversified its production expertise and started producing derivatives based on Para

Chloro Toluene, 2,4-Dichloro Toluene, Meta Chloro Toluene, Ortho Chloro Toluene, 3,4-

Dichloro Toluene and specialty products.

Export & Economic Feasibility

The company has established a global presence through the export of its range of products to

USA, Brazil, Europe, Japan, Korea, Taiwan etc.

10

The company have new export order in hands, thereof it will help to the Government to

generate foreign currency. As per new export order, we will Import raw materials and also buy

some raw materials from local manufacturer / Traders.

Owing to the plant expansion, the company will recruit more workers and people will get the

employment, who are belongs to the below poverty line. Also the company is starting CSR

activity for needy people.

2.6 Employment Generation

The current man power employed by the industry is 192 people (skilled 67 & unskilled 125) & for the

proposed expansion additional man power requirement will be 33 people off which 8 will be skilled

and 25 will be unskilled. In the present unit majority of the skilled and unskilled workers are hired

from nearby locality. Semi-skilled workers are trained as per the requirement to efficiently execute the

responsibility.

2.7 Applicability for Environmental Clearance:

The expansion project of Benzochem Industries Pvt. Ltd. comes under the project activity 5(f) & 5(b)

category ‘A’, as per the “EIA Notification No. S.O.1533 (E)” dated 14th

September, 2006

3. Project Description

3.1 Project Type:

It is a brown field (Expansion) project. Industrial unit have existing manufacturing capacity of

synthetic organic chemicals of intermediate chemicals nature is 58 MT/month. It will be increased to

227 MT/month by changing capacity of existing products and introduction of new products. The

expansion will be done at existing site i.e. plot no. B-26,27 & B-14,15 located in Dasarkhed MIDC.

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

site layout with coordinates).

Plot No. B-26, 27 & B-14, 15, Dasarkhed MIDC, Taluka Malkapur, District - Buldhana, Maharashtra,

India. Company has valid consent to operate (format 1.0/BO/AST/EIC. No.- AM-6693-

15/Amravati/R/CC-05404) from Maharashtra Pollution Control Board for manufacturing of existing

products dated 26/04/2016. It is valid from 01/01/2015 till 30/09/2021.

Table 1: Latitude & Longitude of Boundary Corners of the project plot

Boundary Corner Latitude Longitude

A 20°58'25.93"N 76°11'13.76"E

B 20°58'25.07"N 76°11'16.88"E

C 20°58'26.63"N 76°11'17.30"E

D 20°58'25.09"N 76°11'22.53"E

E 20°58'20.44"N 76°11'21.12"E

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Boundary Corner Latitude Longitude

F 20°58'21.94"N 76°11'15.69"E

G 20°58'22.19"N 76°11'15.79"E

H 20°58'23.09"N 76°11'12.93"E

Figure 1: Plot Layout of Benzochem Industries Pvt. Ltd. at Dasarkhed MIDC, Malkapur

12

Table 2: Nearby Industries

Sr. No Direction Industry

1 North Gajanan Paper industries 2 South BenzoChem Industries Pvt. Ltd. –(EOU Unit)

3 East Balaji Oil Mill

4 West Anant Krupa Paper Industries

Table 3: Area statement of M/s Benzochem Industries Pvt. Ltd

Particulars Existing (m2) Proposed (m

2) Total (m

2)

Total Plot area 33350 0 33350

Built Up Area 7856.36 891.36 8747.72

Parking Area 1240 2095 3335

Green belt 3340 7665 11,005.5

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

The proposed activity is an expansion of the unit located at plot no. B-26, 27, B-14 & 15. The total plot

area is 33350 sq. m out of which existing built up area is 7801.16 sq. m also 55.20 sq. m. area for

existing structure will be demolished. For the proposed expansion activity additional built up area of

946.56 sq. m would be required hence the total built up area would be 8747.72 sq. m. for which

adequate open area is present in the existing premises serving the purposes for proposed expansion

activity hence none alternative sites were considered for the proposed expansion project.

3.4 Size or Magnitude of Operation:

The project is for enhanced production capacity from existing 58 MT/M (at any given point of time) to

227 MT/M with By-products quantity will be 129 MT/M.

Table 4: The Existing and Proposed Capacities of Products

Sr. No. Existing Production Quantity

MT/M

1 Para Chloro Benzyl Chloride,

58

2 Para Chloro Benzyl Cyanide,

3 Para Fluro Benzaldehyde,

4 Para Chloro Benzaldehyde,

5 Para Chloro Phenyl Acetic Acid,

6 Para Chloro Methyl Ether,

7 Para Chloro Benzo Tri Chloride,

8 Ortho Chloro Benzyl Chloride,

9 Ortho Chloro Cyanide,

10 Ortho Chloro Phenyl Acetic Acid,

11 Ortho Chloro Benzaldehyde,

13

12 2,4,6 Tri Methyl Phenyl Acetic Acid,

13 2,4,6 Tri Methyl Phenyl Acetyl Chloride,

14 Methyl 2-Chloro Phenyl Acetate,

15 2,4 Di Chloro Benzaldehyde,

16 2,4 Di Chloro Benzyl Chloride,

17 2,4 Di Chloro Benzyl Cyanide,

18 2,4 Di Chloro Phenyl Acetic Acid,

19 2,4 Di Chloro Phenyl Acetyl Chloride,

20 2,4 Di Chloro Toluene,

21 Meta Chloro Benzyl Chloride,

22 Meta Chloro Benzyl Cyanide,

23 Meta Chloro Phenyl Acetic Acid,

24 Meta Chloro Benzaldehyde,

25 2,5 Di Methyl Phenyl Acetic Acid,

26 2,5 Di Methyl Phenyl Acetyl Chloride,

27 Di Chloro Ortho Xylene,

28 Tetra Chloro Ortho Xylene,

29 Ortho Methyl Benzyl Chloride,

30 Ortho Methyl Benzyl Cyanide,

31 Ortho Methyl Phenyl Acetic Acid,

32 2 Chloro 4,6 Di Methoxy 1,3,5 Triazine,

33 Benzaldehyde 2, 4- Disulphonic Acid Di Sodium Salt

Sr. No. Proposed Production after expansion Quantity

MT/M

Agro Intermediates:

137

1 Isopropyl (4-Chlorophenyl) acetyl chloride (CPIC),

2 2,5 Di Methyl Phenyl Acetyl Chloride,

3 2,4 Di Chloro Benzaldehyde,

4 Ortho Chloro Phenyl Acetic Acid,

5 2,4,6 Tri Methyl Phenyl Acetyl Chloride,

6 Para Chloro Phenyl Acetic Acid,

7 2,4 Di Chloro Phenyl Acetic Acid,

8 1-Napthyl Acetonitrile,

9 Para Chloro Benzyl Cyanide,

10 2,4 Di Chloro Phenyl Acetyl Chloride,

11 Para Chloro Benzo Tri Chloride,

12 Para Chloro Benzyl Chloride,

13 α,α,α,α Tetra Chloro Ortho Xylene

14 Ortho Methyl Benzyl Chloride,

15 2,5 Di Methyl Phenyl Acetic Acid,

16 Para Chloro α-isopropyl Phenyl Acetic Acid (CPIA)

17 Para Chloro Benzyl Cyanide 75% Solution in N-Butyl Acetate,

14

Specialty Chemicals Intermediates:

10

1 Ortho Anisoyl Chloride 75% Solution in Ethylene Dichloride,

2 αα Di Chloro Para Xylene,

3 Benzaldehyde 2,4 Di Sulphonic Acid Di Sodium Salt (Powder),

4 Benzaldehyde 2,4 Di Sulphonic Acid Di Sodium Salt (Liquid),

5 Benzaldehyde Ortho Sulphonic Acid Sodium Salt.

Pharmaceutical Intermediates:

80

1 Para Chloro Benzaldehyde,

2 Meta Chloro Benzyl Chloride;

3 Meta Chloro Benzyl Cyanide,

4 Meta Chloro Phenyl Acetic Acid,

5 Meta Chloro Benzaldehyde,

6 2,4 Di Chloro Benzyl Cyanide;

7 2,4 Di Chloro Benzyl Chloride,

8 Ortho Methyl Benzyl Cyanide,

9 Ortho Methyl Phenyl Acetic Acid,

10 Ortho Chloro Benzyl Chloride,

11 Ortho Chloro Cyanide,

12 Ortho Chloro Benzaldehyde,

13 Methyl 2-Chloro Phenyl Acetate,

14 2-Phenyl Acetyl Chloride,

15 2-Bromo Benzyl Cyanide,

16 4-Bromo Benzyl Cyanide

17 3,4 Di chloro benzyl Cyanide

18 Para Methyl Benzyl Chloride

19 Para Methyl Benzyl Cyanide

20 Para Methyl Phenyl Acetic Acid

Total Production 227 MT/M

Table 5: List of By-products

Sr. No. Name of By Product

Existing Proposed After

Expansion

MT

/Month MT /Month MT /Month

1 Hydrochloric Acid 30 20 50

2 Sodium Chloride 9.4 2.6 12

3 Hydro bromic Acid 0 3 3

4 Sodium Sulphite 0 20 20

5 Ammonium Sulphate 0 5 5

6 Sodium Bromide 0 3 3

7 Mixed Solvent 0 1 1

15

Sr. No. Name of By Product

Existing Proposed After

Expansion

MT

/Month MT /Month MT /Month

8 Ammonia solution 0 35 35

Total 39.4 89.6 129

3.5 Project description with process details:

Production Details are given in previous section. The brief reaction scheme and material balance

chart of Para Chloro Benzyl Chloride (PCBC) is given below.

Brief Manufacturing Process:

1. Para Chloro Benzyl Chloride (PCBC) CAS No.:- (104-83-6)

Reaction Scheme:

Chlorination: - Charge PCT add AIBN applied heating & start Cl2 gas till desire conversion.

Distillation: - Charge Chloromass applied heating & vacuum and distilled out PCBC.

Material Balance: Flow Chart:

Input

Component M.W.

Amt

in Kg Moles

Molar

Ratio Remark

Existing

Consumption

MT/Day

Proposed

Consumption

MT/Day

Total

Consumptio

n MT/Day

PCT 126.5 2640 20.86 1.00 Starting

Material --- 2.030 2.030

Chlorine 71 650 9.15 0.438 Reagent --- 0.500 0.500

AIBN 164.21 5 0.03 0.001 Catalyst --- 0.004 0.004

Total 3295

CH3

Cl

+ Cl2AIBN

CH2Cl

Cl

PCTM.W. = 126.5

+ HCl

PCBCM.W. = 161

ChlorineM.W. = 71

Hydrochloric AcidM.W. = 36.5

16

Output

Component M.W.

Amount

in Kg Moles Remark

Existing

Production

MT/Day

Proposed

Production

MT/Day

Total

Production

MT/Day

HCl Vapors 36.5 334 9.15 To Scrubber --- 0.257 0.257

PCT

Recovered 126.5 1726 13.64 --- --- 1.328 1.328

Inter Cut --- 80 --- --- --- 0.061 0.061

Dist. PCBC 161 1000 6.21 Finished

Product --- 0.769 0.769

Pitch --- 6 --- Dist. Residue --- 0.005 0.005

Vapors To

Ejector --- 74 --- To ETP --- 0.057 0.057

PCBC+DC

(Last Fraction) --- 75 --- --- --- 0.057 0.057

Total 3295

3.6 Raw Materials Details

The detailed Raw Material list is attached as Annexure – I.

Source of the Raw Material: Import and Domestic Market

Marketing Area of the Finished Product: All over world (USA, Brazil, Japan, Korea, Taiwan)

Mode of Transport of Raw material and Finished Products: By Road, By Ship and By Air.

3.7 Resource optimization/recycling and reused envisaged in the project, if, should be briefly

outlined

The proposed expansion will be ZLD system wherein the entire effluent will be recycled/ reused

within the plant. Thus, the fresh water requirement will be significantly reduced.

The proposed project envisages resources optimization measures such as recovery of mother liquor

from the process for reuse and the treated effluent will be used as recycled water for Cooling Tower

make up water (63.93 m3/day).

Organic solvents will be recycled from process streams and recovered solvents will be reused for

respective products.

3.8 Availability of water, its source, Energy/Power requirement

Sr. Particular Existing After Expansion

(Total)

1 Water

Supply from : MIDC

143 CMD

(as per valid CTO) 221 CMD

17

Sr. Particular Existing After Expansion

(Total)

2

Energy

Electricity Supplied by:

MSEDCL

Connected Load:

570 KW

Power Requirement:

800 KVA

Connected Load:

750 KW

Power Requirement:

1000 KVA

3

Fuel

HSD for D.G. set

Coal/Agro Waste for

Boiler &Thermic Fluid

Heater

Furnace Oil

60 L/ hour

23.9 MT/D

--

194 L/ hour

53.9 MT/D

0.55 MT/D

Alternate Source for Power: D.G. set

Existing Proposed

350 kVA 1000 kVA

Fuel – Diesel Fuel - High Speed Diesel

Consumption -Diesel - 60 Lit/Hr

(D.G Set will be operated only during power

failure)

Note: We are replacing existing DG Set

Consumption -Proposed: 194 Lit/Hr

(D.G Set will be operated only during

power failure)

Hazardous Waste Generation

The hazardous waste generation details are as shown in the table below:

Table 6 : Solid Hazardous waste which will be generated from the manufacturing activity

Type of

waste

Category

of HW * UOM

Quantity Mode of


Distillation

Residue 20.3 MT/M 0.5 1.2 1.7 CHWTSDF

Chemical

Sludge

from waste

water

Treatment

35.3 MT/M 0.5 0.8 1.3 CHWTSDF

Evaporatio

n residue 37.3 Kg/M - 364 364

CHWTSD

F

Waste oil 5.1 Kg/M - 20 20

CHWTSDF/

authorised

recycler

Empty

containers 33.1 No./M - 52 52

CHWTSDF/

authorised

recycler

Empty

barrels 33.1 No./M - 8 8

CHWTSDF/

authorised

recycler

18

Type of

waste

Category

of HW * UOM

Quantity Mode of


Spent

solvent 20.2 Kg/M - 52 52

CHWTSDF/

authorised

recycler

Contaminat

ed cotton

rags or

other

cleaning

material

33.2 No./M - 3 3 CHWTSDF

1. Non Hazardous Waste:

Coal ash: Existing quantity: 3.34 MT/day

After expansion: 7.54 MT/day (@ 13.99 % ash content in coal)

Coal ash is sold to local brick manufacturers. In expansion project the feasibility of recycling coal ash by mixing

with cement will be explored.

19

3.9 Schematic Representation of the Feasibility Drawing of Expansion project:

PRODUCTION

ACTIVITY

RESOURCE CONSUMPTION

(WATER)

POWER CONSUMPTION

WASTE

GENERATION FINISHED

PRODUCTS

MARKET

ECONOMY

EMPLOYMENT

RAW MATERIAL

POLLUTION

ABATEMENT

CLEAN

ENVIRONMENT

20

4. Site Analysis

Land Form, Land use and Land Ownership: The Project location & the surrounding environs being

located in the notified industrial area prevails industrial land use form.

4.1 Connectivity

The project is located in MIDC Dasarkhed industrial area which is easily accessible by State Highway

further connecting to the project site by internal access roads developed by MIDC.

Nearest Railway Station: Malkapur, approximately at an aerial distance of 9.8 km from the project

site.

Nearest Airport: Jalgaon Airport approximately at an aerial distance of 59 km from the project site.

Location and Access: The industrial area is centrally located and easily accessible through all

modes of transport.

Road: The entire industrial area is well connected by internal roads.

Available Road Network: State Highway (SH-6) lies at a distance of approximately 13.80 km from

the project site in west direction & National Highway (NH-6)lies at a distance of approximately

0.77 km from the project site in west direction.

4.2 Land Form, Land use and Land Ownership: The Project location & the surrounding

environs being located in the notified industrial area prevails industrial land use form.

4.3 Topography:

The district consists of 13 tehsils of which Buldhana, Chikli, Deulgaon Raja, Mehkar, Sindhkhed Raja

and Lonar lie on the Balaghat Plateau, while rest seven tahsils viz. Khamgaon, Shegaon, Sangrampur,

Jalgaon Jamod, Nandura, Malkapur and Motala are in the great planning below known as the

panchayat.

These are the two natural sub-divisional setup of the district. The edge of the plateau where it falls

abruptly into the valley is intercepted by numerous deep ravines. The landscape is of varied character

fertile villages iterating with barren hill sides and deep ravines. Below the ghat the land is flat except

where it is broken by spurs of hills putting out into a plain, the general slope of the district above the

ghat is from north to south.

Benzochem Industries Pvt. Ltd. 2018

4.4 Existing land use pattern

The proposed project is located in the notified industrial area which has been developed for

industrial development. The existing land use pattern in the 10 km radial distance of the project site

comprises of Industrial, human habitations/settlements, small agricultural/ crop lands land use

classes.

4.5 Existing Infrastructure

Sr.

No. Description

Status

Existing Infrastructure Proposed Infrastructure for

Expansion

1. Location MIDC, Dasarkhed Proposed expansion activity will be carried

out within the existing premises

2. Power demand Total Demand 800 kVA Total Demand (after expansion):

1000 kVA

3. Water

Requirement 143 CMD 221 CMD

4. ETP Capacity

Company is having 60 CMD

capacity ETP in wake of proposed

expansion the ETP treatment

scheme will be upgraded by

installing new bioreactors(aeration

tank) , MEE, ATFD & RO.

Industrial Effluent: Total liquid effluent

after expansion i.e. 69.7 CMD will be

treated in MEE of 100 CMD capacity. MEE

condensate will be treated in 3 stage ETP of

100 CMD capacity followed by 100 CMD

capacity RO. RO reject will be mixed with

industrial effluent for treatment in MEE.

Domestic Effluent: The domestic effluent

i.e. 10 CMD will be treated in septic tank &

its overflow will be mixed with industrial

effluent in aeration tank.

5. D.G. Set 380 KVA (will be replaced) 1000 kVA

6 Boiler Existing: 20.30 MT/D Coal/Agro

Waste Proposed: 26.4 MT/day Coal/Agro Waste

Thermic Fluid

Heater

Existing: 3.60 MT/D (150 Kg/Hr)

Coal/Agro Waste

Proposed: 3.60 MT/D Coal/Agro Waste &

0.55 MT/D Furnace oil

4.6 Soil Classification

There are three major soil types in this district, locally called as Bharkali, Morand and Barad.

Morand soils are silt and lime mixed heavy in texture and blackish one suitable for cotton growing.

From the physical properties of the soil in the district it can be divided into 1) Coarse shallow soil

2) Medium black soil and 3) Deep black soil.

Coarse shallow soil covers the high lands in district. The depth of such soil remains very lese. The

infiltration is much less in these type of soils and run off is more. This type covers an area of

4564.72 Sq. Km.

Benzochem Industries Pvt. Ltd. June -2018

22

Medium black soil is developed comparatively in the plains along the tributaries of main rivers and

small plateau of the district. This type of soil area generally low in 63 clayey material.

The area covered by the type of soil in the district is 3574.68 sq. km and remains at 37 percentage

of the total soil.

4.7 Climatic data

It can influence the choice of farming system either indirectly through its impact on soil formation

or directly through such as the length of the growing season, the occurrence of Frost and the

availability of water for crop growth.

The climate of Buldhana district is on the whole dry except during the monsoon season. The year

may be divided into four seasons. The cold season from December to about the middle of February,

followed by the summer season lasting upto the end of May the south-west monsoon season from

June to September and the post-monsoon or retreating monsoon season in October and November.

4.8 Rainfall

Precipitation includes rainfall, snow, hail, fog, dew etc. Out of these, rainfall is the major one. It is

the single weather element influencing the intensity and location of farming system and farmers’

choice of enterprises. Rainfall in the greater parts of the region is highly uncertain and unevenly

distributed. Failures of rains or excessive rainfall in a short period have brought repeated crop

failures.

The average annual rainfall in the district is about 700 mm which is unevenly distributed. About 84

percentage of annual rainfall in the district is received during the south-west monsoon season. The

monsoon rain covers the region from mid June to the end of September.

There are two peaks of rainfall in the region. The first peak is in July and the second in September.

4.9 Social Infrastructure

Social infrastructures like hotels, petrol pump, hospital is available in the MIDC, Dasarkhed.

Hotels, motels, sports ground, public ground, public garden, petrol pumps, school, hospital, roads,

railway station are available in the Malkapur town near the MIDC.

5. Planning Brief

Planning concept:

Benzochem Industries Pvt. Ltd. is located in MIDC Dasarkhed, Tal. Malkapur. The total plot area

is 33350 sq. m. Since, this a production capacity enhancement project existing plot &

infrastructures with modifications and realignment will be used. Additional power supply & water

requirement will be availed from MSEDCL & MIDC respectively. In the industry all necessary

safety and fire fighting equipment’s like Hydrant, Sprinkler, Detector System, Fire Extinguishers

are available in case of emergency.


23

5.1 Land use planning:

The expansion will be carried out at existing site at Dasarkhed MIDC. The land is acquired by

MIDC and the land use will be industrial type. No cultivated land or forest land will be utilized for

the proposed unit.

5.2 Assessment of Infrastructure demand

The major physical infrastructure like road, water supply is provided by Dasarkhed MIDC. The

electricity will be supplied by MSEDCL.

The industrial infrastructure will be constructed after grant of EC. Additionally new canteen and

restrooms will be constructed for employees as s part of social infrastructure.

5.3 Amenities:

Basic amenities like road, electricity, process water will be available at site. The drinking water will

be provided by further purification of process water by RO purification unit. In the plant personal

hygiene facilities will be provided to workers as per the rule.

6. Proposed Infrastructure

6.1 Industrial area

The proposed expansion unit will be carried out at existing manufacturing site at Plot B- 26,27 &

14,15 Dasarkhed MIDC, Taluka Malkapur, district Buldhana, State Maharashtra.

6.2 Residential area

The project is manufacturing unit of intermediates & specialty chemicals which is situated at

notified Dasarkhed MIDC area. Hence, there will be no need of residential infrastructure.

6.3 Green belt

For the proposed unit the green belt area of 11,005.5 sq. m. around the boundary and inside of the

plot will be provided.

6.4 Social infrastructure

The project site is approximately at an aerial distance of 8.61 km from the Malkapur town. All

basic social infrastructure facilities are available in the study area.

6.5 Connectivity

The site can be accessed by national highway and connecting state highway. The Dasarkhed

MIDC have excellent internal and connecting road network therefore no additional connectivity

infrastructure will be constructed.

6.6 Sewerage system

The internal storm water drains are provided in the plant which is connected to MIDC sewer

network. Storm water drains provided for manufacturing area, raw material storage, product

storage, ETP and hazardous waste storage area are connected to collection tank of ETP.


24

6.7 Industrial waste management

The expansion project will be zero liquid discharge unit. The effluent will be treated and

recycled within plant to reduce fresh water consumption. The hazardous waste is disposed to

CHWTSDF, Butibori or recycled by selling to authorize processing agencies. Coal ash is

recycled by selling to brick manufactures.

6.8 Solid waste management

The hazardous waste is presently segregated as per category in schedule I of “Hazardous and

Other Wastes (Management and Transboundary Movement) Rules, 2016” and it is stored in the

demarcated area. The hazardous waste is disposed through CHWTSDF or it is sold to MPCB

authorized re-processing vendors.

6.9 Power requirement/supply/source

Electricity Supplied by: MSEDCL

Existing connected load: 570 KW, Existing maximum demand: 800 kVA

Proposed connected load: 180 KW, Proposed additional demand: 200 kVA

Total connected load (after expansion): 750 KW, Total demand after expansion: 1000 kVA

7. Rehabilitation & Resettlement (R & R) Plan:

The unit will be established in notified industrial area of Dasarkhed MIDC. No rehabilitation

and resettlement will be envisaged.

8. Project Schedule & Cost Estimates

1. The proposed schedule for approval and implementation.

Sr. No. Description Time Cost %

1. Obtaining all statutory permission with respect to industry 22 Months 0.85 %

2. Design and Engineering Plan 2 Months 4.0 %

3. Factory Set Up 20 Months 92.15 %

4. Testing and Commissioning 6 Months 1.0 %

5. Actual Starting 26 Months 2.0 %

2. Estimated project cost along with analysis of economic viability of the project.

Sr.

No Particulars

Existing

(Cost in Rs.) Lakhs

Proposed for

expansion

(Cost in Rs.)

Lakhs

1 Land 9.31 0

2 Factory building 416.49 200

3 Plant & Machinery /

Equipment 707.75

117

4 Furniture & Fixture 10

5 Office Equipment 2

6 Miscellanies machinery &

equipment 488.67 70

Total 1622.22 400


25

9. Analysis of proposal (Final Recommendations)

Proposed production activity will provide employment to the local residents, resulting financial

and social benefits of the nearby people.

Indirect employment will be generated by the proposed unit like canteen, transportation

facilities to workers.

The export will result in generation of foreign exchange to the country.

In view of the above points it is concluded that the project proposal will not have any negative

impact on the environment and people on the other hand will have positive impact by improving

the socio economic aspects with employment generation.

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