m/s rspl limited -...

M/S RSPL LIMITED

Prefeasibility Report for Expansion of Optical Brightener Agent (OBA) Plant within Existing Manufacturing Facility at Sidhgawan Village of Sagar District, Madhya Pradesh

September 2017

Kadam Environmental Consultants w w w . ka d am en v i r o . c o m

Env ironm ent for Deve lop ment

RSPL LTD., SAGAR, MADHYA

PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION OF OPTICAL BRIGHTENER (OBA)

PLANT QUALITY SHEET

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2017 2

M/s RSPL Limited Prefeasibility Report for Expansion of Optical Brightener Agent (OBA) Plant within Existing Manufacturing Facility at Sidhgawan Village of Sagar District, Madhya Pradesh © Kadam Environmental Consultants (‘Kadam’), September 2017

This report is released for the use of the M/s. RSPL Limited., Regulators and relevant stakeholders solely as part of

the subject project’s Environmental Clearance process. Information provided (Unless attributed to referenced third

parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of Publication Prefeasibility Report for Expansion of Optical Brightener Plant (OBA) within Existing Manufacturing

Facility at Sidhgawan Village of Sagar District, Madhya Pradesh.

Project Number 1730542106 Report No. 1 Version 0 Released September 2017

Prepared & Managed

By Anand Kunte & Kundan Ajudiya Released By Anand Kunte, EIA Coordinator

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-6131000; F: +91 265 61300106

Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,

Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected];T: 0124-4242430; M:+91-98998-04300

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also

believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss

absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or

application of the information contained in this report. The information is not intended to serve as legal advice related to the

individual situation.

Cover Photos, from left to right:

1. Admin Building; 2. Internal Greenbelt; 3. New Site area;

4. New Site area adjacent to present operational premises



PLANT EXECUTIVE SUMMARY


CONTENTS

1 EXECUTIVE SUMMARY ............................................................................................. 6

1.1 PROJECT AND PRODUCTION CAPACITY ................................................................................6

1.2 ABOUT PROJECT ......................................................................................................6

2 INTRODUCTION ..................................................................................................... 8

2.1 BRIEF DESCRIPTION OF THE PROJECT PROPONENT ....................................................................8

2.2 ABOUT THE PROJECT .................................................................................................8

2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION ............................................................8

2.4 DEMAND SUPPLY GAP .................................................................................................9

2.4.1 Global Market .................................................................................................9

2.4.2 Import Vs. Indigenous Production ..........................................................................9

2.4.3 Export Possibility ..............................................................................................9

2.5 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ..........................................9

3 PROJECT DESCRIPTION .......................................................................................... 10

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ............................... 10

3.1.1 Type of Project .............................................................................................. 10

3.1.2 Interlinked and Interdependent Project ................................................................. 10

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT)

WITH COORDINATES ........................................................................................................ 10

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................................................... 15

3.4 SIZE OR MAGNITUDE OF OPERATIONS .............................................................................. 16

3.5 TECHNOLOGY AND PROCESS DESCRIPTION .......................................................................... 16

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS,

MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT ........................................................... 16

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN ............... 21

3.7.1 Source of Water ............................................................................................ 21

3.7.2 Water consumption ......................................................................................... 21

3.8 POWER ............................................................................................................. 26

3.8.1 Fuel Consumption .......................................................................................... 26

3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL .... 26

3.9.1 Details of Wastewater Treatment System – Existing Unit ............................................. 26

3.9.2 Details of MEE ............................................................................................... 31

3.9.3 Details of Wastewater Treatment System – After Expansion of OBA Plant ......................... 34

3.9.4 Gaseous emission ........................................................................................... 34

3.9.5 Hazardous Waste Generation ............................................................................. 35

4 SITE ANALYSIS ..................................................................................................... 37

4.1 CONNECTIVITY ...................................................................................................... 37

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ..................................................................... 37

4.3 TOPOGRAPHY ....................................................................................................... 37

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER

CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD





LIFE SANCTUARY, ETC. SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF

NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ................................... 37

4.5 EXISTING INFRASTRUCTURE ......................................................................................... 38

4.6 SOIL CLASSIFICATION............................................................................................... 38

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................ 38

4.7.1 Temperature ................................................................................................ 38

4.7.2 Wind .......................................................................................................... 39

4.7.3 Rainfall ....................................................................................................... 39

4.7.4 Cloud Cover ................................................................................................. 39

4.7.5 Humidity ..................................................................................................... 39

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................................ 39

5 PLANNING BRIEF .................................................................................................. 40

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC.) TOWN AND COUNTRY

PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ..................................................................... 40

5.2 POPULATION PROJECTION .......................................................................................... 40

5.3 LAND USE PLANNING (BREAK UP ALONG WITH GREEN BELT ETC.) ................................................... 40

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ............................................... 41

5.5 AMENITIES / FACILITIES ............................................................................................ 41

6 PROPOSED INFRASTRUCTURE ................................................................................. 42

6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................................. 42

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ....................................................................... 42

6.3 GREEN BELT ........................................................................................................ 42

6.4 SOCIAL INFRASTRUCTURE ........................................................................................... 42

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC) ........................... 42

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

6.7 SEWAGE SYSTEM .................................................................................................... 43

6.8 INDUSTRIAL WASTE MANAGEMENT .................................................................................. 43

6.9 SOLID WASTE MANAGEMENT ....................................................................................... 43

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE ........................................................................ 43

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN .................................................. 44

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME

OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) ...................................... 44

8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................. 45

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE

GIVEN) 45

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. ............. 45

8.2.1 Fixed Capital ................................................................................................. 45

8.2.2 Working Capital ............................................................................................. 45

8.2.3 Revenues .................................................................................................... 45

8.2.4 Breakeven Point ............................................................................................ 45

8.2.5 Profitability .................................................................................................. 45

9 ANALYSIS OF PROPOSAL ........................................................................................ 46





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

POPULATION, IF ANY, IN THE AREA .......................................................................................... 46

LIST OF TABLES

Table 1-1: Details of Products ................................................................................................................................. 6

Table 3-1: Area Break up at Site ........................................................................................................................... 15

Table 3-2: Details of Production (Existing + Proposed) .......................................................................................... 16

Table 3-3: Raw Material Transportation Details ..................................................................................................... 16

Table 3-4: Raw Material Storage Details ................................................................................................................ 18

Table 3-5: Details of Water consumption from Existing and Proposed Unit ............................................................ 21

Table 3-6: Details of Wastewater Generation from Existing and Proposed Unit ...................................................... 21

Table 3-7: Fuel Consumption Details ..................................................................................................................... 26

Table 3-8: Characteristics of MEE Feed Water ....................................................................................................... 27

Table 3-9: Design Inlet & Outlet Characteristics of Existing ETP ............................................................................ 27

Table 3-10: Adequacy of Existing ETP units ........................................................................................................... 30

Table 3-11: Details of Flue Gas Stacks .................................................................................................................. 34

Table 3-12: Details of Process Vents ..................................................................................................................... 34

Table 3-13: Details of Hazardous Waste Generation .............................................................................................. 35

Table 4-1: Distance of Project Site from Sensitive Areas ........................................................................................ 37

Table 4-2: Distance of Project site from Water Bodies ........................................................................................... 38

Table 4-3: Predominant Wind Direction ................................................................................................................. 39

Table 5-1: Land Breakup at Site ............................................................................................................................ 40

LIST OF FIGURES

Figure 3-1: Project Site Location Map .................................................................................................................... 11

Figure 3-2: Site Location with project boundary map showing on Google Image .................................................... 12

Figure 3-3: Site Layout Plan .................................................................................................................................. 14

Figure 3-4: Water Balance Diagram – Existing Unit ............................................................................................... 23

Figure 3-5: Water Balance Diagram –Proposed Expansion ..................................................................................... 24

Figure 3-6: Water Balance Diagram (Existing + Proposed) .................................................................................... 25

Figure 3-7: Process Block Diagram of Existing ETP ................................................................................................ 31

Figure 3-8: Process Block Diagram of MEE ............................................................................................................ 33

Figure 3-9: Existing Membership from TSDF site for Hazardous Waste Disposal ..................................................... 36





1 EXECUTIVE SUMMARY

1.1 Project and Production Capacity

RSPL LIMITED, a flagship company of GHARI Group, was incorporated on 22nd June 1988 with the name Shri.

Mahadoe Soap Industries Private Limited and the name was changed to Rohit Surfactants Private Limited with effect

from 17th June 2005. The name was further changed to RSPL Private Limited w.e.f. 26th August 2011 and consequent

to conversion of company from private limited to public limited the name of company stands changed to RSPL Limited

w.e.f. 29th August 2011.

Recent, the group has undergone a major corporate restructuring, whereby the Leather & Footwear Division of Rohit

Surfactants Private Limited has been transferred M/s. Leayan Global Private Limited with a view to provide focused

management orientation due to individual specialization and leadership vision; opportunities for strategic partnership

for growth of the business

Group of Companies mentioned under:-

1. RSPL Limited -Company does the manufacturing and marketing of detergents, toilet soaps, wind energy and

other FMCG products.

2. Leayan Global Private Limited - This Company is engaged in the manufacturing & marketing of Leather &

Leather Footwear.

3. Nimmi Build Tech Private Limited (formerly known as Poonam Developers & Infrastructure India

Private Limited) - This company is involved in the business of construction and real estate.

4. Namaste India Foods Private Limited – This is the latest venture of the group into the dairy business. The

Company has set up number of milk collection centers at Shivrajpur, Kanpur for collection of milk from

villagers.

All the Companies are under the supervision and control of the single management thereby making its recognition

as the “GHARI GROUP”.

RSPL is planning to expand the capacity of Optical Brightener Agent from 3000 TPA to 8400 TPA in the existing

premises at Plot no. 42 to 59, MPAKVN, Sector K, IIDC growth center, Village Sidhgawan, District Saugor, Madhya

Pradesh

Table 1-1: Details of Products

Sr. No.

Name of Product

Quantity in MTPA

Existing Proposed Expansion

Total

1 Detergent cake 19200 0 19200

2 Detergent powder 39600 0 39600

3 LABSA 24000 0 Discontinued the

product

4 Acid Slurry 27000 0 27000

5 Optical Brightener Agent 3000 5400 8400

1.2 About Project

Area of the Project

Total Plot area of the proposed project is 62,000 m2 including Existing and proposed Expansion of OBA plant.





Project Cost

The total investment for the project is INR 78.5 Crores.

Water Consumption

After the proposed expansion, total fresh water requirement will be about 293 KLD which will be met from Borewell/

Madhya Pradesh Audyogic Kendra Vikas Nigam (MPAKVN).

Wastewater Generation

For liquid waste treatment ETP, RO and MEE will be proposed at site. Stream segregation were carried out at site.

The utilities blow downs, domestic sewage and washing water will be treated in ETP followed by RO and MEE while

process effluent along with scrubbing wastewater will be directly treated in MEE along with RO reject and MEE

condensate will recycle in plant area.

After expiation of OBA plant, capacity of ETP & MEE will be increased to treat proposed effluent load as per below.

1. Existing ETP will be augmented from 40 KLD to 100 KLD. The proposed expansion of ETP will be designed

maintaining the existing flow scheme of treatment system.

2. Recycling UF and RO System will be installed of 100 KLD capacity for recycling and reuse the ETP outlet.

3. MEE System will be installed of 200 KLD capacity for OBA effluent

Air Emission

Adequate stack heights are provided to flue gas stacks of Boilers, Thermic Fluid Heater & D.G. Sets. Stack emission

quality are maintained as per the SPCB norms. Air pollution control measures like mechanical dust collector and bag

filters are proposed for flue gas stacks.

Power

The power requirement for the proposed facility will be met through Madhya Pradesh Paschim Kshetra Vidyut

Vitaran Company Ltd. (‘MPPKVVCL’). Total estimated electrical load required for the existing unit is 1305 KVA. After

proposed expansion the required power will be estimated about 2200 HP i.e. 2934 KW.

DG Sets will be installed as a backup power supply.

Green Belt

Area of ~23.6% of total plot is developed as greenbelt.


PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION OF OPTICAL BRIGHTENER

(OBA) PLANT INTRODUCTION


2 INTRODUCTION

2.1 Brief Description of the Project Proponent

RSPL LIMITED, a flagship company of GHARI Group, was incorporated on 22nd June 1988 with the name Shri.

Mahadoe Soap Industries Private Limited and the name was changed to Rohit Surfactants Private Limited with effect

from 17th June 2005. The name was further changed to RSPL Private Limited w.e.f. 26th August 2011 and consequent

to conversion of company from private limited to public limited the name of company stands changed to RSPL Limited

w.e.f. 29th August 2011.

Recent, the group has undergone a major corporate restructuring, whereby the Leather & Footwear Division of Rohit

Surfactants Private Limited has been transferred M/s. Leayan Global Private Limited with a view to provide focused

management orientation due to individual specialization and leadership vision; opportunities for strategic partnership

for growth of the business

Group of Companies mentioned under:-

1. RSPL Limited -Company does the manufacturing and marketing of detergents, toilet soaps, wind energy and

other FMCG products.

2. Leayan Global Private Limited - This Company is engaged in the manufacturing & marketing of Leather &

Leather Footwear.

3. Nimmi Build Tech Private Limited (formerly known as Poonam Developers & Infrastructure India

Private Limited) - This company is involved in the business of construction and real estate.

4. Namaste India Foods Private Limited – This is the latest venture of the group into the dairy business. The

Company has set up number of milk collection centers at Shivrajpur, Kanpur for collection of milk from

villagers.

All the Companies are under the supervision and control of the single management thereby making its recognition

as the “GHARI GROUP”.

2.2 About the Project

RSPL is planning to expand the capacity of Optical Brightener Agent from 3000 TPA to 8400 TPA in the existing

premises at Plot no. 42 to 59, MPAKVN, Sector K, IIDC growth center, Village Sidhgawan, District Sagar, Madhya

Pradesh.

2.3 Need for the project and it’s importance to region

Optical brighteners, formally known as Optical Brightening Agents (OBAs) are chemicals used for providing additional

whiteness to the substrate on which they are applied.

There are different OBAs for different substrates such as for textiles (cotton, polyester, polyamide and wool), paper

(pulp, paper and tissues), plastic (for container packaging) and for clothing (apparel and laundry).

The proposed project will manufacture OBAs used in cotton textiles and also for captive consumption in other

plants of RSPL.

Currently OBA is utilized for internal consumption by RSPL’s existing detergents plants to achieve better cost saving

and establish stronger control over final quality of the product.

Due to more requirements and market demand, RSPL’s intends to expand the capacity of OBA plant.



(OBA) PLANT INTRODUCTION


Importance to Region

Investment

An investment of ~ INR 78.5 crores will be invested in the project expansion of OBA. This investment will go into

the local economy.

Direct Jobs

Around 100 jobs will be directly created by the setting up of the project during its operational lifecycle.

Indirect Jobs

Approx. 150 jobs will be indirectly created by the setting up of the project during its operational lifecycle.

Taxes and Levies

The project will add to the local and state tax collection, enlarging the base of the state exchequer. Also State and

National exchequer.

Skills Creation

Local persons will be given to upgrade their skills in chemical manufacturing sector.

2.4 Demand Supply Gap

2.4.1 Global Market

Market of OBA is increasing day by day in various usages and products. M/s RSPL intends to increase OBA production

in order to cater their internal production needs as well as other customers in India and abroad.

2.4.2 Import Vs. Indigenous Production

The expansion of OBA plant is a backward integration for utilization in detergent manufacturing products of Power

and Cake.

2.4.3 Export Possibility

The product of OBA is used for indigenous consumption in products of Detergent Power and Cake.

2.5 Employment Generation (Direct and Indirect) due to the project.

During construction phase ~100 people will be employed on contract basis for construction activities. Presently we

have strength of 700 people in totality in plant out of which 100 people are employed in OBA Plant. This new

expansion of OBA could generate additional employment of 150 people at the completion of the project.



(OBA) PLANT PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

3.1.1 Type of Project

RSPL intends to expand the capacity of production for Optical Brightener manufacturing plant at an existing unit at

site premises by acquiring additional land. The total plot Nos after expansion will cover No. from 42 to 59, Sector K,

IIDC growth center, Village Sidhgawan, District Sagar, Madhya Pradesh totaling to 62,000 sq.m (44,000 + 18000

sq.m)

The proposed project is covered under Category – 5 (f) “B” as per new EIA notification vide gazette no. S.O. 1533

dated 14th September 2006.

3.1.2 Interlinked and Interdependent Project

There is no project interlinked or interdependent with the proposed project

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

lay out) with coordinates

General location map of project site is presented in Figure 3-1. Map showing the specific location of the proposed

project with project boundary Figure 3-2 and Site layout map is presented in Figure 3-3.

RSPL LTD., SAGAR, MADHYA PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION OF OPTICAL BRIGHTENER (OBA) PLANT PROJECT DESCRIPTION


Figure 3-1: Project Site Location Map

RSPL LTD., SAGAR, MADHYA PRADESH PFR FOR EXPANSION OF OPTICAL BRIGHTENER PLANT, SIDHGAWAN, SAGAR DISTRICT,

MP PROJECT DESCRIPTION


Figure 3-2: Site Location with project boundary map showing on Google Image




Project Site showing Study Area and Villages in the Study Area




Figure 3-3: Site Layout Plan

RSPL LTD., SAGAR, MADHYA PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION OF OPTICAL

BRIGHTENER (OBA) PLANT PROJECT DESCRIPTION


Table 3-1: Area Break up at Site

S. No. Title Existing Area, m2

Proposed Area, m2

Total Area m2 % of total

Area

Existing Plant Area

1 Administrative Building 279 0 279 0.5

2 BSR + Packing Area 3826 0 3826 6.2

3 Powder Plant 490 0 490 0.8

4 Cake Plant 364 0 364 0.6

5 Raw Material Storage Area 3589 0 3589 5.8

6 Tank Farm 1148 0 1148 1.9

7 Electrical Room 811 0 811 1.3

8 ETP 279 0 279 0.5

9 Tank Yard 186 0 186 0.3

10 Rain Water Harvesting Tank 95 0 95 0.2

11 Clarification area Waste Water Tank 70 0 70 0.1

12 Effluent Collection Sump 70 0 70 0.1

13 Clarified Water Storage 70 0 70 0.1

14 Multiple Effect Evaporator 70 0 70 0.1

15 Water Tank 292 0 292 0.5

16 Toilet Block 140 0 140 0.2

17 Septic Tank 103 0 103 0.2

18 Boiler and Coal Storage 1200 0 1200 1.9

19 Master Green Plant 1500 0 1500 2.4

20 OBA Plant (Existing) 2667 0 2667 4.3

21 Green Area 8397 0 8397 13.5

22 H2SO4 Tank area 102 0 102 0.2

23 LABSA Plant 1289 0 1289 2.1

24 SO2 Absorber 11 0 11 0.0

25 Steam Manifold 4 0 4 0.0

26 Sulphur Melter 15 0 15 0.0

27 Boiler and Softening Plant 38 0 38 0.1

28 Soft Water Tank 17 0 17 0.0

29 Transfer Pump 11 0 11 0.0

30 Cooling Tower 34 0 34 0.1

31 Hot/Cold Well 5 0 5 0.0

32 Road and Open Space 16572 0 16572 26.7

33 Acid Slurry Plant 256 0 256 0.4

Total 44000

Proposed Expansion Area

34 OBA Plant 2 0 2323 2323 3.7

35 MEE Plant 0 1904 1904 3.1

36 Boiler House with Cold Storage 0 2364 2364 3.8

37 Road / Open Space 0 5124 5124 8.3

38 Green Area / Green Belt 0 6285 6285 10.1

Total 44000 18000 62000

Total Green Belt / Green Area 8397.0 6285.0 14682.0 23.6

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

particularly the environmental considerations gone into should be highlighted

Not Applicable as it is an expansion project in existing premises.




3.4 Size or Magnitude of Operations

Table 3-2: Details of Production (Existing + Proposed)

Sr. No.

Name of Product Quantity in MTPA

Existing Proposed Expansion

Total

1 Detergent cake 19200 0 19200

2 Detergent powder 39600 0 39600

3 LABSA 24000 0 Discontinued the

product

4 Acid Slurry 27000 0 27000

5 Optical Brightener Agent 3000 5400 8400

3.5 Technology and Process Description

Technology and process description is presented in Annexure 10 of Form-1.

3.6 Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product

Table 3-3: Raw Material Transportation Details

Sr.

No. Name

Transportation Details

Source

State Means of

Transportation

Max. Qty.

Transported per

Day

1 Linear Alkyl Benzene Liquid Road tanker 200 MT/day Reliance Gujarat

2 Sulfur Powder Open trucks 50 MT/day -

3 Soda Ash Powder Truck load 100 MT/day Gujarat

4 LABSA Liquid Road tanker 100 MT/day -

5 AOS Thick slurry Road tanker 50 MT/day Self

6 Salt Powder Truck load 100 MT/day Gujarat

7 Dolomite Powder Truck load 100 MT/day Jabalpur MP

8 OBA Powder Truck load 20 MT/day Self

9 Colour (Master Green) Powder Truck 1 MT/day Self

10 Acosol liquid Road tanker 20 MT/day Gujarat

11 China clay Powder Truck load 100 MT/day Rajasthan

12 S.T.P.P. Powder. Truck load 100 MT/day Gandhidham

Gujarat

13 Sodium silicate Liquid Road tanker 20 MT/day Jabalpur MP

14 Perfumes Liquid Truck 1 MT/day Uttarakhand

15 Caustic Lye 48% Liquid Road tanker 100 MT/day MP

16 DASDA 96% Powder Truck 100 MT/day Gujarat

17 Cyanuric Chloride Powder Containerized cargo 100 MT/day Import

18 Aniline Liquid Road tanker 20 MT/day GNFC Gujarat

19 Monoethanol Amine Liquid HDPE drums 10 MT/day Mumbai

20 HIS liquid Liquid HDPE carboys 5 MT/day Ahmedabad

21 Perro flight Powder Bags 10 MT/day Rajasthan




Sr.

No. Name

Transportation Details

Source

State Means of

Transportation

Max. Qty.

Transported per

Day

22 EDTA Powder Bags in truck 10 MT/day Mumbai

23 OBA Powder Bags 40 MT/day Self / Gujarat /

Mumbai

24 Detergent cake Cake Carton in truck 200 MT/day Self

25 Detergent powder Powder Bags in truck 200 MT/day Self



Table 3-4: Raw Material Storage Details

S.

No. Chemical State

Consumption

(MT/Annum)

Hazard

Involved

Means of

Storage

Operating

Condition

Nos. of Tanks Capacity of

each Tank, m3

Safe Tank

Volume, KL Press

Kg

/Cm2

Temp,

°C

1 LABSA– Existing Product (24000 MTPA)

1.1 Linear Alkyl Benzene Liquid 18360 Fire Storage tank Normal 20-40 2 100 80

1.2 Sulphur Solid 2760 fire Closed area normal 20-40 - - -

1.3 Water Liquid 2880 Non

hazardous Water tank. Normal 20-40 1 - -

2 Detergent Powder– Existing Product (39600 MTPA)

2.1 Soda Ash Solid 14572 Non

hazardous bags normal 20-40 - - -

2.2 LABSA Viscous Liquid

3960 Non

hazardous Storage tank normal 20-40 - 2 100

2.3 AOS Slurry 2296 Non

hazardous Storage tanks normal 20-40 - 2 100

2.4 Salt Powder 3603 Non

hazardous bags Normal. 20-40 - - -

2.5 Dolomite Solid 14533 Non


2.6 Optical Brightener Powder 110 Non

hazardous bags Normal 20-40 - - -

2.7 Perfume Liquid 21 Non hardous carboys Normal. 20-40 - - -

2.8 Color Powder 15 Non

hazardous drums normal 20-40 - - -

2.9 Acosol Liquid 435 Non

hazardous Storage tank. normal 20-40 1 100 80

2.1 Water (Approx) Liquid 475 Non

hazardous Water tank. Normal 20-40 1 60 50

3 Detergent Cake – Existing Product (19200 MTPA)

3.1 Soda Ash Solid 1401 Non-




S.

No. Chemical State

Consumption

(MT/Annum)

Hazard

Involved

Means of

Storage

Operating

Condition


each Tank, m3

Safe Tank

Volume, KL Press

Kg

/Cm2

Temp,

°C

3.2 LABSA Viscous Liquid

2362 Non

hazardous Storage tank Normal 20-40 - - -

3.3 AOS Slurry 884 Non


3.4 SLS Viscous Liquid

364 Non


3.5 Dolomite Solid 6970 Non


3.6 China Clay Powder 2765 Non-


3.7 S.T.P.P. Powder 1382 Non


3.8 Sodium Silicate Liquid 1382 Handling Storage tanks Normal 20-40 - - -

3.9 Perfume Liquid 13 Fire. arboys Normal 20-40 - - -

3.1 Color & OBA Powder 67 Non

hazardous bags Normal. 20-40 - - -

3.11 Perro flight Powder 1382 Non

hazardous. normal 20-40 - - -

3.12 Acosol Liquid 230 Non

hazardous. Storage tank normal 20-40 1 100 80

3.13 Water (Approx) Liquid 768 Non

hazardous Water tank. Normal 20-40 1 60 50

4 Optical Brightening Agent – (8400 MTPA)

4.1 Ice - 22400 Non

hazardous. Ice room Normal

-5 to 0 deg.

1 40 mt 40 mt

4.2 Caustic Lye 48% Liquid 3360 corrosive Storage tank. Normal 20-40 1 30 mt 20 mt.

4.3 Vac. Salt - 2619 Non


4.4 DASDA 96% Powder 2314 Non

hazardous. bags Normal 20-40 - - -



S.

No. Chemical State

Consumption

(MT/Annum)

Hazard

Involved

Means of

Storage

Operating

Condition


each Tank, m3

Safe Tank

Volume, KL Press

Kg

/Cm2

Temp,

°C

4.5 Cyanuric chloride Solid 2240 lachrimetric Bags/drums Normal 20-30 - - -

4.6 Aniline Oily

Liquid 1120

Non-hazardous.

Storage tank Normal 20-40 1 30 20

4.7 Mono Ethanol Amine Liquid 896 Non

hazardous. drums normal 20-40 - - -

4.8 Soda Ash Powder 980 Non

hazardous. bags normal 20-40 - - -

4.9 HSI liquid Liquid 28 Non

hazardous. carboys Normal. 20-40 - - -

4.1 EDTA Powder 9.3 Non

hazardous. bags Normal. 20-40 - - -

4.11 HCl 30% Liquid 466 Corrosive carboys Normal 20-40 - - -




3.7 Availability of water its source, energy/power requirement and source should be given

3.7.1 Source of Water

The main source of water will be met from Bore well / MPAKVN government Assurance. Permission letter for water supply from

MPAKVN is given form 1 as Annexure 15.

3.7.2 Water consumption

In the proposed API manufacturing unit, the water will be mainly used for following areas:

Process

Utilities

Domestic Usage

Washing

Gardening

The total fresh water consumption after the proposed expansion will be estimated about 293 KLD. The breakup of

water consumption and wastewater generation from the existing and proposed unit is described in below table and

the water balance diagram is given in below figure.

Table 3-5: Details of Water consumption from Existing and Proposed Unit

S. No. Area of Consumption Existing, KLD Proposed, KLD Total, KLD

1 Domestic 10.7 9 19.7

2 DM Plant 2.5 2.5 5

3 Process 105 149 254

4 Boiler 17 49 66

5 Softener 0 3 3

6 Cooling Tower 96 164 260

7 Scrubber 6 10 16

8 Other/Floor Washings 1 2 3

9 Gardening 30 0 30

10 Total 268 389 657

11 Recycled water from ETP & MEE 125 225 350

12 Fresh Water Requirement 143 164 307

Table 3-6: Details of Wastewater Generation from Existing and Proposed Unit

S. No. Area of Consumption Existing, KLD Proposed, KLD Total, KLD Treatment and

Disposal Facility

1 Domestic 8 8 16 To ETP followed by RO & MEE

2 DM Plant 2.5 2.5 5

3 Process 95 170 265 To MEE

4 Boiler 2.5 3.5 6

To ETP followed by RO & MEE

5 Softener 0 3 3

6 Cooling Tower 16 30 46

7 Scrubber 4 8 12

8 Other/Floor Washings 1 2 3

9 Total 129 227 356

277 KLD from process to MEE,

79 KLD to ETP and then RO reject to

MEE




Mode of Wastewater Disposal

Existing Unit:

The wastewater generated from the existing unit is segregated at source. The process and scrubbing wastewater is

directly treated in MEE and condensate from the MEE is reused in plant.

Other wastewater like domestic sewage, utilities blow downs and washing effluents is treated in EPP and treated

water from the ETP is used for gardening.

After Expansion of Project:

After the proposed expansion the utilities blow downs along with washing and domestic effluent will be treated in

proposed ETP followed by RO & MEE. The process wastewater along with scrubbing water will be directly treated in

proposed MEE.

Treated water from the RO & MEE will be reused plant premises.



Figure 3-4: Water Balance Diagram – Existing Unit



Figure 3-5: Water Balance Diagram –Proposed Expansion



Figure 3-6: Water Balance Diagram (Existing + Proposed)




3.8 Power

The power requirement for the proposed facility will be met through Madhya Pradesh Paschim Kshetra Vidyut

Vitaran Company Ltd. (‘MPPKVVCL’). Total estimated electrical load required for the existing unit is 1305 KVA. After

proposed expansion the required power will be estimated about 2200 HP i.e. 2934 KW.

Standby Power (through DG Sets) – Existing Unit

1. Detergents (Cake and Powder) Plant: 750 KVA

2. LABSA Plant: One, 1010 kVA

3. Optical Brightening Agent Plant: 1250 kVA

Standby Power (through DG Sets) – Proposed Unit

1. Optical Brightening Agent Plant: one 1050 kVA DG set

3.8.1 Fuel Consumption

Detail of Fuel is given in the following table:

Table 3-7: Fuel Consumption Details

Sr. No. Stack Attached to Capacity Stack Nos. Type of Fuel

used Fuel consumption

A Existing

1 DG Set 1010 KVA 1 HSD 150 lit/hr


3 DG set 1250 KVA 1 HSD 200 lit/hr

4 Boiler 5 TPH 1 Coal 200 Kgs / hr

5 Boiler (Thermic Fluid Heater) 15 Lac Kilo

Calorie 1 Coal 180 Kgs / hr

B Proposed


2 Boiler 5 TPH 1 Coal 200 Kgs / hr

3 Boiler (Thermic Fluid Heater) 15 Lac Kilo

Calorie 1 Coal 180 Kgs / hr

Note: DG Sets will be used only during Power failure.

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

/disposal

Waste water generation details are presented in Table 3-5 as above.

3.9.1 Details of Wastewater Treatment System – Existing Unit

Effluent Generation & Segregation

The effluent generated from the existing plant is segregated at site based on pollution load as below.

1. High TDS high COD Stream: The high TDS high COD stream coming from the OBA plant and scrubbing

wastewater is directly treated in MEE and condensate from the MEE is reused in plant




2. Low TDS Low COD Stream: The low TDS low COD streams consists utilities blow downs, wastewater from

washings and domestic sewage is treated in ETP of capacity 40 KLD and treated water from the ETP is used for

gardening. There is a zero liquid discharge facility. No wastewater disposed into the outside of plant premises

Characteristics of Wastewater

High TDS and High COD Wastewater

The effluent generated from the process consists high TDS and high COD which is treated in MEE as discussed

above. The characteristics for MEE feed is presented in table as below:

Table 3-8: Characteristics of MEE Feed Water

Sr. No. Parameters Unit Expected Characteristics of Effluent

from OBA plant/MEE Feed Water

1 Design Flow KLD 110

2 pH pH Scale 9.5

3 COD mg/lit 5000

4 BOD mg/lit 2500

5 Suspended Solids mg/lit 500

6 Total Dissolved Solids mg/lit 14000

7 Colour - Yellow

Low TDS and Low COD Wastewater

The low TDS and low COD streams from the Utilities, Washings and domestic sewage is treated in ETP at site. The

design base inlet and outlet characteristics of wastewater for ETP is given in below table.

Table 3-9: Design Inlet & Outlet Characteristics of Existing ETP

Sr. No. Parameters Unit Inlet Characteristics

of ETP

Outlet Characteristics

of ETP

1 Design Flow KLD 40 40

2 pH pH Scale 6.0 to 9.0 7.2

3 COD mg/lit 600-700 <250

4 BOD mg/lit 200-250 <30

5 Suspended Solids mg/lit 500-600 <100

6 Total Dissolved Solids mg/lit 1500-2000 <2100

7 Oil & Grease ppm 20 <5.0

Process Description of Wastewater Treatment Units

The treatment plant comprises of different treatment stages as described below.

Screen Chamber - 1 no.

Effluents emanating from the various process sections of the sulphonation plant and washing from other sections

are segregated and arrive at the screen chamber. Screen chamber is equipped with fine bar screen. Floating SS

particles will be removed manually in the Screen. The effluent will go to Equalization Tank.




Equalization Tank -1 no.

One no. of Equalization tank is provided to maintain pH & to ensure constant load on further treatment units.

Blower with course bubble aeration will be provided in the equalization tanks for mixing and equalization. From

these tanks the effluents will be further transferred to flash mixer by pumping.

Flash Mixer - 1 no.

From the equalization tank the homogeneous effluent is pumped in to the flash mixer. The pH of incoming effluent

is checked and hydrated Lime, Alum and polyelectrolyte solutions are added to maintain pH from 7 to 8. The flash

mixing vessel is provided with a stirrer.

Flocculator - 1 no.

Wastewater from Flash mixer overflows to a flocculator for agglomeration of flocs formed. Slow speed paddle type

flocculator mechanism will be provided in this tank for gentle mixing and floc- formation. Flocculated effluent will go

to primary settling tank under gravity.

Primary Settling Tank - 1 no.

Overflow from Flocculator system will pass through the Primary Settling Tank under gravity. Separation of flock

formed will take place in Primary Settling Tank. The settling tank is equipped with Tube Settler Media bed in order

to have enhanced settling characteristics. The chemical sludge is settled by gravity to the hopper portion of the

settling tank and the primary treated clear water overflow into the aeration tank by the gravity for further biological

treatment. The chemical sludge is then taken into the sludge drying beds for dewatering purpose.

Aeration Tank -1 no.

Aeration Tank will be provided for biological treatment of combined effluent. Overflow from primary settling tank

will go to Aeration Tank. Surface aerator will be provided to suffice oxygen requirement of biomass. The treated

water overflows to the secondary settling tank under gravity for sludge settlement.

Secondary Settling Tank - 1 no.

A Secondary settling tank is provided for settlement of the biomass as generated from the aeration tank. The

sludge from the bottom shall be wasted to sludge drying bed or recirculated to the aeration tank using recirculation

pump. Overflow from the secondary settling tank will go to treated water tank.

Treated Water Tank/Holding Tank – 1 no.

Treated water tank/holding tank will be provided for collection of supernatant from final settling tank. The effluent

from the treated water tank passed through Pressure Sand Filter & Activated Carbon Filter for polishing of

biologically treated effluent.

Pressure Sand Filter- 1 no.

Pressure Sand Filter will be provided as a form of tertiary treatment for removal of residual suspended solids. The

filter consists of different gradations of gravel & sand bed. The filter will be provided with necessary valve

arrangements for inflow and outflow and backwashing of the system. The backwash water of the system shall be

taken to the Equalization tank / Primary Settling Tank for re treatment.

Activated Carbon Filter - 1 no.

Activated Carbon Filter will be provided as a form of tertiary treatment for removal of residual organics, odour and

colour. The filter consists of gradations of gravel & sand sub bed and over which is provided activated carbon of

high iodine value. The filter will be provided with necessary valve arrangements for inflow and outflow and




backwashing of the system. The backwash water of the system shall be taken to the Equalization tank / Primary

Settling Tank for re treatment.

Sludge Drying Bed - 6 nos.

Sludge drying beds are provided for collection of primary sludge and secondary biological sludge. The primary

sludge from PST and secondary waste sludge from the secondary tank will be taken into the sludge drying beds for

dewatering purpose. The dried sludge is periodically cleaned from the top of the sludge drying beds and will be

suitably disposed.

Adequacy of Existing ETP

The adequacy of the effluent treatment units is presented in below below. The Treated effluents will be recycled

and reused back within the plant premises for on land irrigation to reduce fresh water consumption. The total water

requirement for the green belt development is 30 KLD.



Table 3-10: Adequacy of Existing ETP units

S.

No. Units Nos.

Size of Units/Capacity Volume

Total

Volume

Design

Flow HRT PROVIDED

L B H

m m m m3 m3 m3/d min h day

1 SCREEN CHAMBER 1 1 1 1 1.00 1.00 40 36.00 - -

2 EQUALIZATION TANK 1 4 4 2.5 40.00 40.00 40 - - 1.00

3 FLASH MIXER 1 0.75 0.75 1 0.56 0.56 40 20.25 - -

4 FLOCCULATOR 1 1 1 2.5 2.50 2.50 40 - 1.50 -

5 PRIMARY SETTLING TANK 1 2.5 2 1.5 7.50 7.50 40 - 4.50 -

6 SLUDGE DRYING BEDS 6 2 2 1.2 4.80 28.80 40 - - -

7 AERATION TANK 1 8 4 2.5 80.00 80.00 40 - - 2.00

8 SECONDARY SETTLING TANK 1 2.5 2.5 1.5 9.38 9.38 40 - 5.63 -

9 HOLDING TANK 1 4 4 2.5 40.00 40.00 40 - - 1.00

10 LIME SOLUTION TANK 1 1 1 1 1.00 1.00 40 - - -

11 POLYELECTROLYTE TANK 1 200 Liter - - - - - -

12 DAP/UREA TANK 1 200 Liter - - - - - -




Figure 3-7: Process Block Diagram of Existing ETP

3.9.2 Details of MEE

The evaporator supplied is a hybrid evaporator having the first stage as falling film and rest three stages as forced

circulation. The capacity of existing MEE is 100 KLD.

Falling Film Evaporator

In a falling film evaporator, the liquid under concentration is fed to the calanderia (heat exchanger) via a specially

designed liquid distributor. This distributor ensures the liquid to pour at the circumference of the tubes and there by

the liquid would subsequently travel on the inner face of the tubes, in its path downwards, forming a thin film of

liquid on the inner face of the tubes.

The heating media, vapor or steam is on the shell side. Vapors being at a higher temperature, heat the down

coming liquid in the tubes. In the process condensation of the vapors take place and the heat liberated is

transferred to the liquid. The pressure / vacuum conditions maintained are such that the condensation temperature

on the shell side is higher than the vaporizing temperature in the tube side.

This ensures that the heating of the liquid is easily achieved for its boiling temperature and the tube side liquid

would boil as it reaches the bottom of the calanderia and the liquid and vapors are transferred to the vapor

separator, where the vapors are separated from the boiling liquid. This vapor is transferred to the shell side of the

next calanderia and acts as the heating media for the next stage. Variation in the vacuum brings about reduction in

the boiling temperatures and hence the vapor from the previous stage is always at a higher temperature.




The first stage is the one in which fresh steam is injected. In the first stage, part of the vapor of the first stage is

recycled using the thermo compressor, back to the shell side of the first stage. This recycle results in energy recycle

and provides for higher water evaporation per unit of steam used. The rest three stages offered are Forced

circulation calanderia or heat exchanger.

Forced Circulation Evaporator

In a forced circulation evaporator the liquid is pumped through the tubes at high velocities to ensure that no

precipitation of the salts takes place.

The effluent is introduced in the first stage of the evaporator where partial evaporation takes place and the partially

concentrated liquid is transferred to the second stage where further concentration takes place in the forced

circulation calanderia. The effluent by now has been concentrated to near its solubility limit and hence the third and

fourth stage is designed as forced circulation having Oslo Separator so that as the solubility is exceeded due to

further evaporation, the precipitated salts do not stick to the tube walls. The high velocity of the liquid ensures that

the salt formation and separation take place in the specially designed Oslo vapor separator. The vapor separator

has been specially designed so as to allow the vapor separation in the upper side, and the resulting concentrated

effluent along with the precipitating salts is brought to the lower section, where the salts would settle at the bottom

and the clear supernatant is recycled back to the inlet of the calanderia. The settled salt slurry is pumped to the

centrifuge, where the salts are separated and the mother liquor if recycled back to the inlet of the heat exchanger/

calanderia. In this manner, the entire liquid is evaporated and the salts from the centrifuge are reused in process.

The condensed steam and vapors from all the stages and from the condenser, where the vapors from the last stage

after preheating the feed are condensed are collected and pumped out from the system. This in absence of

impurities can work as good hot process water and therefore this is planned accordingly for reducing the fresh

water consumption. The process block diagram of the proposed MEE is given in below figure.



Figure 3-8: Process Block Diagram of MEE




3.9.3 Details of Wastewater Treatment System – After Expansion of OBA Plant

After proposed expansion, required modification will be carried out in existing treatment units as given below.

1. Existing ETP will be augmented from 40 KLD to 100 KLD. The proposed expansion of ETP will be designed

maintaining the existing flow scheme of treatment system.

2. Recycling UF and RO System will be installed of 100 KLD capacity for recycling and reuse the ETP outlet.

3. MEE System will be installed of 200 KLD capacity for OBA effluent

3.9.4 Gaseous emission

Table 3-11: Details of Flue Gas Stacks

Flue Gas Stacks

Sr. No.

Stack Attached to

Capacity Stack Nos. Stack

Height, m Stack Top

Dia, m Pollutant Emitted

Air Pollution Control

Measures

A Existing Stacks

1 DG Set 1010 KVA 1 10 m 0.3

PM, SOx, NOx, HCl, CO, HC, Cl2, VOC,

NH3

Adequate Stack Height

2 DG Set 750 KVA 1 10 m 0.3

3 Boiler 5 TPH 1 30 m

6.5 m diameter

bottom - 3 m at top

Mechanical Dust Collector and

Bag Filter

4 DG set 1250 KVA 1 10 m 0.3 Adequate Stack

Height

5 Boiler (Thermic Fluid Heater)

15 Lacs Kcal 1 30

6.5 m diameter

bottom - 3 m at top


Bag Filter

B Proposed Stacks

1 DG Set 1050 KVA 1 10 m 0.3

PM, SOx, NOx, HCl, CO, HC, Cl2, VOC,

NH3

Adequate Stack Height

2 Boiler 5TPH 1 30 m

6.5 m diameter

bottom - 3 m at top


Bag Filter

3 Hot Oil (Thermic

Fluid Heater) 15 Lacs Kcal


Bag Filter

Table 3-12: Details of Process Vents

S. No. Stack Attached to Nos. of Stacks Stack Height in m Pollutants Emitted

Existing Unit

1 Spin Flash Dryer 1 11 PM

2 OBA Scrubber for Process Reactor, Aniline Day Tank

and MEA Day Tank 1 10

HCl

Aniline

Mono ethanol amine

Proposed Unit

1 1 10 HCl




OBA Scrubber for Process Reactor, Aniline Day Tank

and MEA Day Tank

Aniline

Mono ethanol amine

2 Spin Flash Dryer 1 11 PM

3.9.5 Hazardous Waste Generation

Table 3-13: Details of Hazardous Waste Generation

Sr. No.

Type of Waste Hazardous

Waste Category

Existing Quantity

Proposed Quantity

Total Quantity

Disposal Method

1 Discarded Bags /

Containers, Drums and Liners

33.1 50 MT per

annum 30 MT per

annum 80 MT per

annum Sent to authorized vendors

2 ETP Sludge 35.3 5000 kg per

annum 7500 kgs per

annum 12500 kgs per annum

Sent to TSDF site – Ramky Pithampur

3 Used / Spent Oil 5.1 2000 lit per

annum 700 Litres per annum

2700 Litres per annum

Sent to authorized vendors

4 Salt Residue from

MEE - 1.2 TPD 2.1 TPD 3.4 TPD

Reused in powder manufacturing process / TSDF

site – Ramky Pithampur

5 Spent Acid 26.3 22761 MT per

annum 0

22761 MT per annum

Sold to authorized vendor B Roshanlal Chemicals Pvt,

Indore.




Figure 3-9: Existing Membership from TSDF site for Hazardous Waste Disposal


BRIGHTENER (OBA) PLANT SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

By Road

SH – 14 connects Sagar – Damoh, is about 0.35 km towards S direction from main approach to site.

North South Corridor NH-26 connects Gwalior-Sagar- Naringhpur stretch, sagar bypass, which is about 2.25 km

towards W direction from site.

NH – 86 connects Sagar –Banda stretch, near Russala village which is about 1.98 km towards W direction from

site.

By Rail

Makronia Railway station, Bina-Sagar –Katni section which is about 4.9 km towards SW direction from site.

Sagar railway station is about 12.5 km towards SW direction from site.

By Air

Rajabhoj Airport, Bhopal is about 168 km towards W direction from site. Daily multiple flights for Mumbai &

Delhi are available from here.

Jabalpur Airport is around 145 km towards SE direction from the project site.

Dhana (Sagar) Airport is about 15 km away from the project site which is currently not in operational phase for

commercial flights.

4.2 Land Form, Land Use and Land ownership

The total plot area of the site is 62,000 m2 including existing and proposed expansion area. As the project is located

in notified industrial estate, the land use of the project site is industrial.

4.3 Topography

The area is characterized by flat mounds of basalt flows, the height ranging from 5 to 40 m, with very thin cover of

soil, Debris is found in the form of rounded rock pieces and it is the result of spheroidal weathering. The literature

and site conditions reveal that there are number of lava flows and intrusive bodies. Impressions of subsequent lava

intrusions are observed, in the form of differential weathering, alteration of joint pattern indicating forces.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, etc. sensitive areas, water bodies (distance from the HFL

of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should

be given.

Land use pattern: Industrial

Table 4-1: Distance of Project Site from Sensitive Areas

Area Distance in km Direction

Hilly Area

Near Badkuwa 7.19 WNW




Near Guda 2.29 SW

National / State Highways

SH-14 0.35 S

NH-26 2.25 W

NH-86 1.98 W

Table 4-2: Distance of Project site from Water Bodies

Area Distance in km Direction

Lakha Banjara Lake at Sagar 11.92 SW

Dam near Khadera Khurd 10.3 NW

Bewas Rive near Dungasara 7.24 ESE

Dam nr. Bachhlon Village 7.72 W

4.5 Existing Infrastructure

Well-developed infrastructure is available around the site. Proposed expansion of the project will be done on an

additional land added to the existing premises. Land Use is for Industrial purpose.

4.6 Soil Classification

Soil Investigations have been done in past which will be used for the design of foundations for the proposed expansion

buildings and structures.

4.7 Climatic data from secondary sources

The general agro-climatic zone of the study area is Semi-arid.

Information presented in subsequent paragraphs is from the most recently published Long Term Climatological

Tables for the nearest observatory, Sagar (42671) by the Indian Meteorological Department (IMD) for year 1981 -

2010.

4.7.1 Temperature

In winter season mean daily temperature is ranges minimum between 11.4 -13.8 °C and maximum between 24.7-

27.6 °C. Extreme minimum and maximum temperature was recorded in the month of February. Minimum 1.1 °C

(1929) and maximum 37.6 °C (2006).

In Summer Season mean daily temperature is ranges minimum between 18.9-26.3 °C and maximum between 33.3-

41.0 °C. Extreme minimum was recorded 7.2 °C in March 1898 while extreme maximum was recorded 46.4 °C in

May 1994.

In Monsoon mean daily temperature is ranges minimum between 22.2-25.6 ºC and maximum between 29-37.6 ºC.

Extreme minimum temperature was recorded 8.8 ºC in June 2008 and maximum 46.4 ºC in June 1994 ºC.

In Post monsoon mean daily temperature is ranges minimum between 12.8-20.0 ºC and maximum between 26.0-

32.2 ºC. Extreme minimum for this season was recorded 2.1 ºC in December 1963 and maximum was 39.9 ºC in

Oct 1969.




4.7.2 Wind

Table 4-3: Predominant Wind Direction

Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening

January NE NE E NW SW/SE N/E

February NE NE E W SW NW

March NE W E NW SW NE

April W W SW NW NE SW

May W W SW NW NW NE

June W W SW SW NW NW

July W W SW SW NW NW

August W W SW SW NW NW

September W W SW NE NW N/NW

October NE NE SW/W N E E

November NE NE E N SW E

December NE NE E N SW/SE E

4.7.3 Rainfall

The total rainfall in year is observed to be 1148 mm. Distribution of rainfall by season is 26.4 mm in winter (January,

February), 32.3 mm in summer (March, April, May), 1043.3 mm in monsoons (June, July, August, September) and

46.0 mm in post-monsoons (October, November, December).

4.7.4 Cloud Cover

In winter cloud cover ranges between 1.3-2.0 Oktas, summer ranges between 1.3 – 3.4. The area remains cloudy

between June - September, which is the active period of the monsoon season. Cloud cover is 4.0 to 6.6 Oktas, while

in Post monsoon it is 1.2-2.4 Oktas.

4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer in

that order. Mornings are more humid than evenings and humidity ranges from a high of 61-92% in

monsoon mornings to a low of 18-24% in summer evenings. During post-monsoon season, in morning

humidity remains between 51-60% and in the evening it remains between 40-45%..

4.8 Social infrastructure available

Social investment in the form of CSR would help to improve the healthcare, education, sanitation, infrastructure and

other areas in nearby villages wherein the project proponent will try to be suitably involved as part of its CSR

commitments.

RSPL LTD., SAGAR, MADHYA PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION OF

OPTICAL BRIGHTENER (OBA) PLANT PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept (Type of industries, facilities, transportation etc.) Town and Country

Planning/Development authority Classification

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

5.2 Population Projection

It is estimated that the company will have approximately 175 employees in the beginning.

5.3 Land Use planning (Break up along with green belt etc.)

The Proposed Plant is located in MPAKVN by M/s. RSPL Limited. Limited. It is already developed according to

Chemical Industrial Use. The Land use breakup at site is given in below table.

Table 5-1: Land Breakup at Site


Proposed Area, m2


Area

Existing Plant Area

1 Administrative Building 279 0 279 0.5

2 BSR + Packing Area 3826 0 3826 6.2

3 Powder Plant 490 0 490 0.8

4 Cake Plant 364 0 364 0.6

5 Raw Material Storage Area 3589 0 3589 5.8

6 Tank Farm 1148 0 1148 1.9

7 Electrical Room 811 0 811 1.3

8 ETP 279 0 279 0.5

9 Tank Yard 186 0 186 0.3

10 Rain Water Harvesting Tank 95 0 95 0.2

11 Clarification area Waste Water Tank 70 0 70 0.1

12 Effluent Collection Sump 70 0 70 0.1

13 Clarified Water Storage 70 0 70 0.1

14 Multiple Effect Evaporator 70 0 70 0.1

15 Water Tank 292 0 292 0.5

16 Toilet Block 140 0 140 0.2

17 Septic Tank 103 0 103 0.2

18 Boiler and Coal Storage 1200 0 1200 1.9

19 Master Green Plant 1500 0 1500 2.4

20 OBA Plant (Existing) 2667 0 2667 4.3

21 Green Area 8397 0 8397 13.5

22 H2SO4 Tank area 102 0 102 0.2

23 LABSA Plant 1289 0 1289 2.1

24 SO2 Absorber 11 0 11 0.0

25 Steam Manifold 4 0 4 0.0

26 Sulphur Melter 15 0 15 0.0

27 Boiler and Softening Plant 38 0 38 0.1

28 Soft Water Tank 17 0 17 0.0

29 Transfer Pump 11 0 11 0.0

30 Cooling Tower 34 0 34 0.1

31 Hot/Cold Well 5 0 5 0.0


OPTICAL BRIGHTENER (OBA) PLANT PLANNING BRIEF



Proposed Area, m2


Area

32 Road and Open Space 16572 0 16572 26.7

33 Acid Slurry Plant 256 0 256 0.4

Total 44000

Proposed Expansion Area

34 OBA Plant 2 0 2323 2323 3.7

35 MEE Plant 0 1904 1904 3.1

36 Boiler House with Cold Storage 0 2364 2364 3.8

37 Road / Open Space 0 5124 5124 8.3

38 Green Area / Green Belt 0 6285 6285 10.1

Total 44000 18000 62000

Total Green Belt / Green Area 8397.0 6285.0 14682.0 23.6

5.4 Assessment of Infrastructure Demand (Physical and Social)

The proposed project is located in MPAKVN, District Sagar, MP. This site is 12 km to Sagar city in SW directions.

Physical Demand:

Water:

Fresh Water demand will be met from borewell waters from tankers as well as Madhya Pradesh Audyogik Kendra

Vikas Nigam (MPAKVN) assured by Govt. of MP.

Electricity:

The electricity will be sourced from grid of Madhya Pradesh Poorva kshetra Vidhyut Vitaran Co. Ltd.

Machinery:

Reactors, Storage tanks, holding vessel, condensers, scrubbers, evaporators, spray dryers, pumps, piping, electrical

instruments etc. are available in state or nearby states.

Materials and Others:

The raw material supply will be met by local and other markets. Other utilities facilities are generated in plant

/available in plant area.

5.5 Amenities / Facilities

Following facilities will be made available at site:

First Aid Facility

Hygienic Drinking Water Facility

Green Area

Regular Worker Medical Checkup Facility


OPTICAL BRIGHTENER (OBA) PLANT PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The proposed project is located in MPAKVN, Sagar district, MP. Total Plot Area is 62,000 m2 including existing and

proposed expansion of OBA plant. Appropriate infrastructure is already in place at the MPAKVN Notified Industrial

Area including approach roads, drainages, lighting etc.

6.2 Residential Area (non-processing area)

No Residential Area

6.3 Green belt

Area of ~23.6% of total plot is developed as greenbelt.

6.4 Social Infrastructure

CSR Activities will be carried out as per the CSR Plan.

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

Proposed Project Site is located at MPAKVN, Saugor District, M.P. Saugor city is 12 km away from the project

site towards SW direction.

By Road

SH – 14 connects Sagar – Damoh, is about 0.35 km towards S direction from main approach to site.

North South Corridor NH-26 connects Gwalior-Sagar- Naringhpur stretch, sagar bypass, which is about 2.25 km

towards W direction from site.

NH – 86 connects Sagar –Banda stretch, near Russala village which is about 1.98 km towards W direction from

site.

By Rail

Makronia Railway station, Bina-Sagar –Katni section which is about 4.9 km towards SW direction from site.

Sagar railway station is about 12.5 km towards SW direction from site.

By Air

Rajabhoj Airport, Bhopal is about 168 km towards W direction from site. Daily multiple flights for Mumbai &

Delhi are available from here.

Jabalpur Airport is around 145 km towards SE direction from the project site.

Dhana (Sagar) Airport is about 15 km away from the project site which is currently not in operational phase for

commercial flights.

6.6 Drinking water management (source & supply of water)

Fresh Water demand will be met from borewell waters from tankers as well as Madhya Pradesh Audyogik Kendra

Vikas Nigam (MPAKVN) assured by Govt. of MP.


OPTICAL BRIGHTENER (OBA) PLANT PROPOSED INFRASTRUCTURE


6.7 Sewage system

Sewage will be treated in ETP and combined treated water will be reused in plant.

6.8 Industrial waste management

For liquid waste treatment ETP, RO and MEE are proposed at site. Stream segregation were carried out at site.

Proposed Scheme:

The utilities blow downs, domestic sewage and washing water will be treated in ETP followed by RO and MEE while

process effluent along with scrubbing effluent will be directly treated in MEE along with RO reject and MEE condensate

will recycle in plant area.

After expansion of OBA plant, capacity of ETP & MEE will be increased to treat proposed effluent load. Recycling RO

is proposed to be set up during expansion in order to recycle and reuse the Permeates for industrial use leading to

water conservation to more than 50%.

6.9 Solid Waste Management

The solid cum hazardous waste generated from the plant operations will be disposed to Waste Management / landfill

facility.

ETP sludge and MEE salts will be disposed at approved TSDF facility i.e. Ramky Enviro Engineers Ltd. The unit has

membership of M/s. RAMKY, Pithampur

Used oil and spent acid will be handed over to authorized vendors

6.10 Power requirement & supply/ source

Power supply from Grid:

The power requirement for the proposed facility will be met through Madhya Pradesh Paschim Kshetra Vidyut Vitaran

Company Ltd. (‘MPPKVVCL’). Total estimated electrical load required for the existing unit is 1305 KVA. After proposed

expansion the required power will be estimated about 2200 HP i.e. 2934 KW.

Standby Power (through DG Sets) – Existing Unit

1. Detergents (Cake and Powder) Plant: 750 KVA

2. LABSA Plant: One, 1010 kVA

3. Optical Brightening Agent Plant: 1250 kVA

Standby Power (through DG Sets) – Proposed Unit

4. Optical Brightening Agent Plant: one 1050 kVA DG set


OPTICAL BRIGHTENER (OBA) PLANT REHABILITATION & RESETTLEMENTS (R & R)

PLAN


7 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected persons including

home oustees, land oustees and landless labourers (a brief outline to be given)

Not applicable as rehabilitation and resettlement will not be required, since the project lies in an Industrial Area,

with land acquisition procedures completed by the MPAKVN.


PRADESH PRE-FEASIBILITY REPORT FOR EXPANSION

OF OPTICAL BRIGHTENER (OBA) PLANT PROJECT SCHEDULE & COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time

schedule for the project to be given)

It is depending upto availability of EC approval, but the planning is being made to start work

within 3 months of EC approval and start commissioning in phases by 21 months thereafter.

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

the project.

8.2.1 Fixed Capital

The fixed capital investment for the project is INR 78.5 Crores.

8.2.2 Working Capital

The working capital is around 10% of the capital investment which is INR 7.85 Crores.

8.2.3 Revenues

The overall revenues expected are around INR 11 Crores per year when full production of 5400

MT of additional OBA is achieved.

8.2.4 Breakeven Point

Expected break-even will be after 7 years of operation.

8.2.5 Profitability

Expected profitability is 10% Net Margin.


OPTICAL BRIGHTENER (OBA) PLANT ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area

The project will improve the socio-economic status of the society in the region by generating direct and indirect

employment opportunities. The project will contribute additional revenue to the State & Central exchequers in the

form of taxes, Cess, etc

The anticipated impacts of the project are explained below:

The project related construction activities will benefit the local populace in a number of ways such as supply of

construction laborers – skilled, semi-skilled and un-skilled, tertiary sector employment and provision of goods

and services for daily needs including transport.

The proposed project will provide employment to the skilled as well as un-skilled persons.

The local population will be given preference depending upon their suitability to the job requirement.

Besides direct employment, indirect employment opportunities will also open up.

Transporters will be engaged to bring raw materials and supply finished goods

Social investment in the form of CSR would help improve the healthcare, education, sanitation, infrastructure and

other areas.

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

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

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

Kadam Environmental Consultants w w w . ka d am en v i r o . c o m

E nv ironment for Deve lopm ent

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