m/s cytec india specialty chemicals & materials pvt....

1. Executive Summary

Name of the Project Proponent : Mr. Mathew Kavalam

Pre - feasibility Report

For

M/s Cytec India Specialty Chemicals &

Materials Pvt. Ltd.,

Plot no : G-54, MIDC Butibori, Nagpur. Pincode – 441 122

Consultant:

M/s. SADEKAR ENVIRO ENGINEERS PVT. LTD.

Accredited by QCI – NABET Lab. Recognized by MoEF, Govt. of India NABL Accredited Certificate No. T- 2190,

Certified by ISO 9001:2008 Certified by 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]

Web site:-www.sadekarenviro.com

October, 2016

mailto:[email protected]

mailto:[email protected]

http://www.sadekarenviro.com/

Sadekar Enviro Engineers Pvt. Ltd.

Address of the Industry :M/s Cytec India Specialty Chemicals & Materials

Pvt. Ltd.

:Plot no : G-54, MIDC Butibori, Nagpur.

Pincode – 441 122.

Total Plot Area : 40,500 Sq.m.

Green Belt Area : 6682 Sq .m.

Production Details (MT/M) : 305MT/m (Existing )

250MT/m (Proposed)

555 MT/M (Total)

Sr. No. in the Schedule: 5(f)

Project Category : B-1

Water Requirement

1. Existing Requirement : 245.2 CMD

2. Proposed Requirement : --

3. Total water requirement : 245.2CMD

Power Requirement

1. Connected Load : 2000 KW

2. Existing Power Demand : 1550KVA

3. Proposed Power Demand : --

Total Cost of the project : 121.61Crores

Pollution Load and Mitigation Measures

The industry takes the necessary precaution to protect the environment by implementing

efficient pollution control equipments like 2 stage condenser and chiller to control air

emissions as well as ETP for treatment of waste water & membership of Common Effluent

Treatment Plant Butibori. The company is having membership of CHWTSDF atButiborifor


disposal of hazardous waste. The other solid wastes like empty drums and paper bags etc.

are sold to recycler. The production process equipments are so efficient and modern as such

the waste generation is very minimal.

A. Quantum of Waste Water Generated : 5.9 CMD

Existing Quantity of Effluent : 5.9 CMD

Proposed Quantity of Effluent : 00CMD

Effluent Treatment Plant

Company is having Effluent Treatment Plant of 10CMD capacity whichis used to treat

blow down from boiler and cooling tower. Process will not generate any effluent because

the water is recycled to the plant. Domestic sewage is treated in 15 CMD capacity STP.

After treatment sewage and effluent will be discharged to CETP, Butibori.

Characteristics of effluent

Parameters (pH, BOD, COD, etc)

Inlet

effluent

Charact-

eristic

Outlet

effluent

Charac

teristic

Effluent Discharge

Standards (CPCB/MPCB)

pH 7.8 8.2 5.5-9.0

TDS 2076 2032 2100

BOD 66 28 100

COD 210 112 250

O & G BDL BDL 10

Chloride 278 153 600

Bioassay

test --

Sample

passes

the test

90% survival of fish after

first 96 hours in 100%

effluent.

sulphate 226 138 1000

Phenolics BDL BDL 1.0

TAN <0.1 <0.1 50

Iron 2.16 1.36 3

Zinc .38 .94 5

Sulfide 0.52 0.19 2

Chromium

hexavalent BDL BDL 0.1

cyanide BDL BDL 0.1

Note: All the parameters are expressed in mg/L except pH.

B. Quantum of Waste Generated:

1. Non Hazardous waste:


Sr. No

Particulars Existing

Proposed

Total

Method of

Disposal

1 Municipal

solid waste 0.2 MT/m - 0.2 MT/m Local facility

2 Fly ash 10.4

MT/M -

10.4

MT/M

Sale to brick

manufacturer

3

Damaged

wooden pellet/

water house

0.5 MT/m - 0.5 MT/m Sale to authorized

recycler

2. Hazardous waste

Sr.

No

Particulars Categor

y

Existin

g

MT/A

Pro

pose

d

Total

Method of Disposal

1 ETP Sludge 34.3 10 -- 10

CHWTSDF, Butibori

MIDC 2 Distillation

Residue 20.1 --

3 Used/ spent oil 5.1 0.235 -- 0.235

4 Discarded

containers

barrels/liners/

plastic bags/

PPE etc

33.3 51 -- 51

CHWTSDF, Butibori

MIDC / MPCB

authorized recycler

5 E-waste and

equipment/

instruments -- 0.2 -- 0.2

6 Used batteries

-- 0.15 -- 0.15 CHWTSDF, Butibori

MIDC

Waste Disposal:

The hazardous waste will be sent to CHWTSDF at Butibori for disposal. The other non

hazardous waste will be sold to recycler.

Air Emission Control

Sr.

No

Item Utilities Existing / Proposed to be installed

1. Air Stack attached to

various utilities with

sufficient height

Utilities Existing Proposed

Boiler

Capacity 1X 3000 kg/hr Existing capacity is

sufficient for proposed

expansion, there will be

only increased hours of

boiler operation

Fuel Baggase – 5.52

MT/DAY

Coal – 10


MT/Day

Stack

height

30 m Bag filter will be

installed to control PM

emission.

Source

of fuel

Local vendor Local vendor

Thermo pack

Capacity 1X2,00,000

kilocal/hr.

Existing capacity is


expansion

Fuel LDO - 960

Kg/day

Fuel quantity will

remain same

Stack

height

22 m Existing stack will be

used

Source

of fuel


D.G Set

Capacity 1X 180 KVA

1X 750 KVA



expansion

Fuel Diesel –0.170

MT/day (only

during power

failure)



expansion

Stack

height

5 m & 15m

ground level

No change in existing

stack

Source

of fuel


2. Introduction of the project/Background information

i) Identification of Project & Project Proponent

Identification of Project:

The proposed expansion project is for specialty chemicals production from existing capacity of

305MT/month to 555MT/month.

Project Proponent:

M/s Cytec India Specialty Chemicals & Materials Pvt. Ltd. is privately held ISO 9001:2008

certified company, which was established in 2012 primarily to manufacture specialty

chemicals.

Cytec has a team of highly qualified individuals having vast experience in various facets of

chemical process development, process scale-up, chemical technology & manufacturing

expertise, well trained in all process & safety requirements. The company provides cost

effective solutions for our customer‟s diverse requirements.


Our long-term relationships with multinational companies bear testimony to our strict

adherence to Intellectual Property. We leverage best practices and technology to ensure

confidentiality in our operations.

We are committed to the health and safety of our employees, the welfare of our community

and environment protection. We play a proactive role in creating awareness, imparting

training and minimizing pollution.

Figure 1:Google Earth Imagery depicting Location of M/s Cytec India Specialty Chemicals &

Materials Pvt. Ltd. at Butibori MIDC, Nagpur

Highlights of the proposed project are:

The proposed project for expansion with existing and new products is located in the Notified

Industrial Area of Butibori MIDC, Nagpur.

The project activity will use existing infrastructurefor the proposedproduction expansion

activity within existing premises on Plot No. G-54. Since the proposed expansion activity will

be executed within the existing premises, no new land is required.


The existing ETP of capacity 10 CMD and STP of capacity 15 CMDwill be utilized for

proposed expansion.

ii) Brief description of nature of project


305MT/month to 555 MT/month.The company will be producing specialty chemical required for

copper ore extraction from copper mines. The product will be exported to South Africa, and South

American continent.

iii)Need of the Project and its importance to the country:

Cytec is a leading supplier of chemical reagents to the copper industry, enabling its customers to

maximize the performance of their operations through optimized reagent selection, superior

application expertise, and a constant stream of innovative products and technologies. Company

offer a broad range of solvent extraction reagents, collectors (promoters), frothers, flocculants, and

depressants. Products include specialized collectors used in the separation of copper sulfide ores

and for copper containing byproduct metals, such as gold and molybdenum. Company has

developed a proprietary methodology developed in-house combining 100 years of experience in

flotation, unique chemistries and our application expertise and insights to optimize mineral

flotation. The benefits that can be experienced by following this approach are:

Optimized reagent performance

Enhanced recovery of value minerals

Increased recovery and concentrate grade

Company will export the floatation products to African and south American region. It will generate

foreign exchange for the country

iv) Employment generation (Direct & Indirect due to the project)

The current man power employed by the industry is 86people &for the proposed expansionno extra

man power is required.

Applicability for Environmental Clearance:

The proposed project of M/s Cytec India Specialty Chemicals & Materials Pvt. Ltd. comes under

the project activity 5(f) category „B1‟, as per the “EIA Notification No. S.O.1533 (E)” dated 14th

September 2006 amended on January 19, 2009.

3. Project Description

(i) Type of project including interlinked and interdependent projects, if any.


The proposed project is for specialty chemicals production with addition of new products.

Interlinked & Interdependent projects: Not Applicable

(II) Location (map showing general location, specific location and project boundary & project site

layout with co ordinates).

Figure 2: Google Earth Imagery depicting Location of M/s Cytec India Specialty Chemicals

& Materials Pvt. Ltd. at Butibori MIDC, Nagpur

Latitude 20°56'38.60"N

Longitude 78°57'42.10"E

Location ButiboriMIDC,Nagpur

Elevation Above Mean

Sea Level (meters)

284 m

(iii) Details of alternate site considered and the basis of selecting the proposed site:

The proposed project is an expansion project of the unit located at plotG-54. The total plot area is

40500 sq.m. & existing built up area is9677 sq.m. For the proposed expansion activity no

additional built up will be required.total built up area will be same would be 9677 sq. m.which is

within the permissible FSI & existing plot being located in notified industrial area which serves the


purposes for proposed expansion activity hence none alternative sites were considered for the

proposed project.

(IV) Size or Magnitude of Operation:


305MT/month to 555 MT/month. The detailed existing & proposed product list along with

quantities is attached as Annexure – I.

(v) Project description with process details:

MANUFACTURING PROCESS OF IPETC

Stage-1SIPX Solution Preparation- To a batch reactor,required waterand solid SIPX (Sodium

Isopropyl Xanthate) is added under agitation to form SIPX solution.

Stage-2Catalyst solution preparation-To a batch reactor, required waterand solid Nickel sulfate

hexa-hydrate is added under agitation to form Nickel sulfate hexa-hydrate solution.

Stage-3 IPETC SYNTHESIS – To a batch reactor, SIPX solution and Nickel sulfate hexa-hydrate

solutionis added under stirring and heated to required temperature. Required quantity of

Ethylamine solution is added to this solution. Batch is maintained at required temperature till

completion of reaction. After completion of reaction stirrer is turned off and batch is allowed to

settle,separating into Mother Liquor (bottom layer) and organic phase (top layer).

The Mother Liquor (containing Sodium sulfhydrate/Nickel sulfide/Ethyl aminein it) is drained to

one receiver. Filtration is carried out to separate solid NiS for sale to Catalyst Recycler. Remaining

mother liquor is then further treated in the Stage-4 as given below.

The remaining organic layer containing crude IPETC is then washed with two washes with water.

After each wash step, phase separation is again allowed to occur and the aqueous phase is drained

away for later recycling. The recycled aqueous wash water after saturation is distilled to separate

out aq. IPA for sale to Vendor. The distilled water collected is recycled back to process.

The remaining organic phase containing IPETC product is transferred to the Stage 5 for further

treatment as given below.

Stage- 4ETHYL-AMINE RECOVERY - – In the Stage 4,mother liquor solution from stage 3 is

charged to an off-line batch distillation system. Recovered aqueous Ethylamine is recycled in next

batch and By-products –residue with mother liquorand aqueous NaSH solution is packed for sale to

Vendor.

Stage -5PACKAGING OF IPETC- The collected IPETC from stage 3 is fed to nylon cloth

filtration system. The filtered finished IPETC product is then packed directly in drums

orIntermediate Bulk containers (IBCs).

(vi) Raw material required

The detailed raw material list is attached as Annexure – II.

Source of the Raw Material: Local & Abroad


Marketing Area of the Finished Product: Local

Mode of Transport of Raw material and Finished Products: By Road, Sea &Air

(vii) Resource optimization/recycling and reused envisaged in the project, if, should be briefly

outlined

The proposed project envisages resources optimization measures such as recovery of water and

IPA from mother liquor generated from the process for reuse. Treated sewage water will be

used for gardening activity.

(viii) Availability of water, its source, Energy/Power requirement

Existing Requirement : 245.2 CMD

Proposed Requirement : --

Total water requirement : 245.2 CMD

Source: MIDCButibori

Total Water Budget:

Phase Water (CMD) Effluent

(CMD)

Consumption Losses Domestic Industrial byproduct

Domestic 4.5 0.9 3.6 --

Industrial

Processing

20.7 -- -- -- 20.7

Boiler 50

28.8 (20 CMD

condensate

recovery)

-- 1.2

Cooling Tower 150 145.3 -- 4.7

Gardening 20 20 -- --

Total 245.2 195.0 3.6 5.9

Power Requirement:

Connected Load : 2000 KW

Existing Power Demand : 1550 KVA


Proposed Power Demand : --

Source: MSEDCL

Alternate Source for Power: D.G. set

D.G. Set

Existing Proposed

D.G Sets – 180 KVA and 750

KVA.

Fuel – HSD. Qty – 0.170 MT/Day

Existing D.G set is sufficient

for proposed expansion

D.G Set will be used only during power failure.

(ix) Quantity of wastes to be generated (liquid & solid)

Liquid (Effluent)

Existing Quantity of Effluent : 5.9 CMD

Proposed Quantity of Effluent : --CMD

Hazardous waste generation

1. Non Hazardous waste:

Sr. No

Particulars Existing

Proposed

Total

Method of

Disposal

1 Municipal

solid waste 0.2 MT/m - 0.2 MT/m Local facility

2 Fly ash 10.4

MT/M -

10.4

MT/M

Sale to brick

manufacturer

3

Damaged

wooden pellet/

water house

0.5 MT/m - 0.5 MT/m Sale to authorized

recycler

2. Hazardous waste

Sr.

No

Particulars Categor

y

Existin

g

MT/A

Pro

pose

d

Total

Method of Disposal

1 ETP Sludge 34.3 10 -- 10

CHWTSDF, Butibori

MIDC 2 Distillation

Residue 20.1 --

3 Used/ spent oil 5.1 0.235 -- 0.235

4 Discarded

containers

barrels/liners/

plastic bags/

PPE etc

33.3 51 -- 51

CHWTSDF, Butibori

MIDC / MPCB

authorized recycler


5 E-waste and

equipment/

instruments -- 0.2 -- 0.2

6 Used batteries

-- 0.15 -- 0.15 CHWTSDF, Butibori

MIDC


(x) Schematic Representation of the Feasibility Drawing of EIA

PRODUCTION ACTIVITY

RESOURCE CONSUMPTION

(WATER)

POWER CONSUMPTION

WASTE

GENERATION FINISHED PRODUCTS

MARKET

ECONOMY

EMPLOYMENT

RAW MATERIAL

POLLUTION

ABATEMENT

CLEAN

ENVIRONMENT


4. Site Analysis

(i) Connectivity:The project is located in Butibori industrial area which is easily accessible by

NH7 from Nagpur further connecting to the project site by internal access roads developed by

MIDC.

Nearest Railway Station: Butibori, approximately at a distance of 10 km (aerial distance).

Nearest Airport: Nagpur Airport approximately at a distance of30km.

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: Nagpur- Chandrapur highway plies at a distance of approximately

4 km from the project site.

(ii) 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.

(iii) Topography:

The study area forms part of Deccan Plateau having flat topped and terraced features. It is a plain

area with the general topography some areas and its vicinity have higher elevation. Lineaments are

also observed in the study area. Dendrtic to sub dendritic of drainage pattern is observed in study

area. Lithologically, the area comprises formations of Deccan Basalt of Cretaceous age. Drainage

pattern Dendritic to sub dendritic of drainage pattern is observed in study area. BashimarNala flows

from NNW to ENE and joins to Wenna River. Krishna Nala flows from NW to SE region.

KanholiNala flows in Southern Region of the study area. Soil types There are three types of soils

found in Nagpur district. The details are as follows: 1) Kali soils: These are black cotton soils

which are fine grained clayey in texture and varies in depth from 1 m to 6 m or more and retain

moisture. 2) Morand soils: These are predominant in the district. They are black cotton soils with

higher percentage of lime than the Kali soils. They are black, grey or light to dark brown in colour,

clayey in texture and have a depth of about 1 to 3 m. 3) Bardi soils: They are red gravel covered

with boulders found on summits and slopes of trap hills and are less fertile in nature

(iv) 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,


quarryingland use classes.

(v) Existing Infrastructure

Sr.

No.

Description Status

Existing Infrastructure

Proposed Infrastructure for

Expansion

1. Location Plot no : G-54, MIDC

Butibori, Nagpur. Pincode –

441 122

Proposed expansion activity will be

carried out within the existing

premises

2. Power demand

Connected Load 2000 KW

As per existing requirement

Maximum demand 1550 KVA

3. Water Requirement 245.2 CMD

4. ETP Capacity

10 CMD

5. D.G. Set 1X180 KVA

1X750 KVA

6. Fuel Requirement HSD. Qty – 0.170 MT/Day

Baggase – 5.52 MT/DAY

Coal – 10 MT/Day

LDO: 960 Kg/DAY

7 Boiler Capacity: 1 X 3000 kg/hr

Thermic Fuid Heater: 1 X

2,00,000 kilocal/hr

(vi) Soil Classification

The main type of soils found in the district are forest soils, varkas soils, rice soils, coastal alluvium

& laterite soils.

(vii) Climatic data

Generally the district experiences dry climate. The climate of the district is typical as that of central

region of India with seasonal monsoon pattern.. The year may be divided into four seasons; the

summer - March to May, the rainy - June to September, the post monsoon - October to November

& the winter - December to February.

(viii) Social Infrastructure

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

railway station are available around the project location.

5. Planning Brief

The existing infrastructure of the industry will be used for manufacturing of specialty chemicals.

No additional power supply & water requirement will be required for the proposed expansion. In


the industry all necessary safety and fire fightingequipments like Hydrant, Sprinkler, Detector

System, Fire Extinguishers are available in case of emergency.

6. Proposed Infrastructure

(i) Industrial Area: Butibori MIDC,District Nagpur, Maharashtra.

(ii) Residential Area: Not applicable.

(iii) Green Belt:Thearea will be under green belt development is 6682sq.m.

(IV) Social Infrastructure and

(V) Connectivity

Road:MIDC has provided asphalt roads with varying widths; these are mainly two lane

roads and raised footpaths on either side of the roads.

Water: Water consumption of unit will be around245.2 CMD.

Electricity: Connected load - 2000 KW & Working load –1550 KVA.

Streetlights: MIDC has provided street lighting facility in the area.

Telecommunication Facility / Connectivity: Fax, telex, email and Internet facilities are

available in the vicinity of project area.

Fire Station: A fire station was deemed necessary keeping in mind the planned

development of the MIDC Area. MIDC has constructed a fire station at Butibori MIDC.

Common Effluent Disposal Facility: MIDC has constructed a common effluent

treatment plant of capacity 5 MLD.

(VI) Source of the Water will be MIDC. The daily water requirement will be around245.2CMD.

(VII) Domestic Waste water will be treated in STP.

(VIII) The Industrial Waste will be disposed off toCHWTSDF at Butibori.

(IX) The non hazardous Solid Waste generated will be soldto recycler.

7. Rehabilitation & Resettlement (R & R) Plan: Not Applicable

8. Project Schedule & Cost Estimates

1. The proposed schedule for approval and implementation.

Sr.

No.

Description Time Cost in

%

1. Obtaining all statutory permission with 8 Months 0.85 %


respect to industry

2. Design and Engineering Plan 1 Months 4.0 %

3. Factory Set Up 1 Months 92.15 %

4. Testing and Commissioning 1 Months 1.0 %

5. Actual Starting 11 Months 2.0 %

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

Please find attached copy of CA Certificate. (Refer Annexure -III)

3. For the proposed products the new infrastructure to be constructed

The necessary required infrastructure will be constructed/erected within the premises on the

existing plot.

9. Analysis of proposal (Final Recommendations)

The project may provide employment opportunities to local people and it will increase the

living standard. As the industry has the export market it will add to the net foreign exchange

earning of the country. The industry takes pride in maintaining healthy relationship with the

environment by further improvised technology of effluent treatment plant. The industry is

committed to manufacture and supply of finished products to achieve enhance customer satisfaction

by establishing and maintaining quality management system. Industry trust on employee‟s strength

so management of the industry always promotes and maintains the safety conditions in and around

the workers. The regular medical checkups, safety training program‟s, mock drill are being

conducted in the industry.

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.


ANNEXXURE – I

(Existing &Proposed products list)

Sr. No. Name of Products Maximum Quantity (MT/Month)

Existing Proposed Total

1 Oxime 305 -- 305

2 Isopropyl ethyl

thiocarbamate

(IPETC)

-- 250 250

Total 305 250 555


ANNEXXURE – II

(Raw Material List)

List of raw

materials to be used

Physical and

chemical nature

of raw material

Quantity (tones /

month) full

production

capacity

Source of

materials

Means of

transportation

(Source to storage

site) with

justification

Magnesium Metal solid 13 Local Road

Nonyl Phenol (89 -

94%)

Liquid 203 Local Road

Para Formaldehyde

(96%)

Solid 85 Local Road

Hydroxylamine

Sulphate (98%)

Solid 61 Local Road

Toluene Liquid 54 Local Road

Sulphuric Acid (98%) Liquid 72 Local Road

Methanol Liquid 2 Local Road

Caustic Lye (20%) Liquid 6 Local Road

Sodium Carbonate

(98%)

Solid 41 Local Road

Escaid -D80 Liquid 20 Local Road

Solvent –TXIB Liquid 124 Local Road

MgO (80%) Solid 26 Local Road

Demineralized water

(DM water)

Liquid 630 Local Road

Sodium iso propyl

xanthate (SIPX)

solid 462 Local Road

Nickel sulfate

hexahydrate

solid 13.16 Local Road

Ethylamine liquid 212.58 Local Road


ANNEXXURE-III

(CA - Certificate)

m/s cytec india specialty chemicals & materials pvt....

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