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M/s Seya Industries Ltd. Proposed Greenfield project of Synthetic Organic Chemicals at Plot

No.: D-14, MIDC Tarapur, Dist: Palghar, Maharashtra Pre-Feasibility Report

PFR for M/s. Seya Industries Ltd., D-14 Prepared by Goldfinch Engineering Systems Pvt. Ltd.

M/S SEYA INDUSTRIES LTD.

PFR for Environmental Clearance (EC) of Proposed Greenfield project of Manufacturing of

Synthetic Organic Chemicals at Plot No.: D - 14, MIDC Tarapur, Taluka: Palghar, District:

Palghar, Maharashtra

© Goldfinch Environmental Engineering Systems Private Limited (‘Goldfinch’), June 2016

This report is released for the use of the M/s SEYA Industries Ltd. (SEYA). Regulators and relevant stakeholders

solely as part of the subject EC of Proposed Greenfield project of Manufacturing of Synthetic Organic Chemicals

at Plot No.: D-14, MIDC Tarapur, Taluka: Palghar, District: Palghar, Maharashtra. 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 Goldfinch/SEYA.

QUALITY CONTROL

Name of Publication Proposed Greenfield project of Manufacturing of Synthetic Organic Chemicals, at Plot

No.: D - 14, MIDC Tarapur, Taluka: Palghar, District: Palghar, Maharashtra

Project Number Report No. 1 Version 1 Released June, 2016

Prepared By Mr. Rakesh Suryawanshi

Reviewed By Mr. Anand Apte

Released By Mr. Anand Apte

DISCLAIMER

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

Goldfinch also believes that the facts presented in the report are based on information submitted by SEYA and

based on the technical expertise of Goldfinch as on the date it was written. However, it is impossible to dismiss

absolutely, the possibility of errors or omissions. Goldfinch 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.




CONTENTS

0 EXECUTIVE SUMMARY ...................................................................................................................... 5

1 INTRODUCTION OF THE PROJECT...................................................................................................... 6

1.1 IDENTIFICATION OF PROJECT ................................................................................................................... 6

1.2 PROJECT PROPONENT ............................................................................................................................ 6

1.3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ......................................................................................... 6

1.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION .............................................. 6

1.5 DEMAND-SUPPLY GAP .......................................................................................................................... 7

1.6 IMPORT VS. INDIGENOUS PRODUCTION ..................................................................................................... 7

1.7 DOMESTIC/ EXPORT MARKETS ................................................................................................................ 7

1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ...................................................... 7

2 PROJECT DESCRIPTION ..................................................................................................................... 8

2.1 TYPE OF PROJECT .................................................................................................................................. 8

2.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH

COORDINATES ................................................................................................................................................. 8

2.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE ............................. 10

2.4 SIZE OR MAGNITUDE OF OPERATION ....................................................................................................... 10

2.5 PROJECT DESCRIPTION WITH PROCESS DETAILS .......................................................................................... 11

2.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCT/S, MODE

OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ................................................................................... 18

2.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, ............................................... 18

2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN ................. 18

2.8.1 Water ..................................................................................................................................... 18

2.8.2 Power ..................................................................................................................................... 19

2.8.3 Fuel Requirement ................................................................................................................... 19

2.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT/DISPOSAL .. 19

2.9.1 Gaseous Emissions ................................................................................................................. 19

2.9.2 Liquid Effluent ........................................................................................................................ 20

2.9.3 Details of Hazardous wastes .................................................................................................. 22

2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE. ...... 23

3 SITE ANALYSIS ................................................................................................................................ 24

3.1 CONNECTIVITY ................................................................................................................................... 24

3.2 LAND FORM, LAND USE AND LAND OWNERSHIP ....................................................................................... 24

3.3 TOPOGRAPHY .................................................................................................................................... 24

3.4 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,

ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM HFL OF THE RIVER), CRZ. ...................................................... 25

3.5 SOIL CLASSIFICATION ........................................................................................................................... 25

3.6 CLIMATIC DATA FROM SECONDARY SOURCES ............................................................................................ 25




3.7 SOCIAL INFRASTRUCTURE AVAILABLE ...................................................................................................... 26

4 PLANNING BRIEF............................................................................................................................. 27

4.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY PLANNING/

DEVELOPMENT AUTHORITY CLASSIFICATION ........................................................................................................ 27

4.2 LAND USE PLANNING ........................................................................................................................... 27

4.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) .............................................................. 27

4.4 AMENITIES/FACILITIES ......................................................................................................................... 28

4.5 Population Projection .................................................................................................................... 28

5 PROPOSED INFRASTRUCTURE ......................................................................................................... 29

5.1 INDUSTRIAL AREA (PROCESSING AREA/NON- PROCESSING AREA) ................................................................ 29

5.2 RESIDENTIAL AREA .............................................................................................................................. 29

5.3 GREEN BELT ...................................................................................................................................... 29

5.4 SOCIAL INFRASTRUCTURE ..................................................................................................................... 29

5.5 CONNECTIVITY ................................................................................................................................... 29

5.6 DRINKING WATER MANAGEMENT ......................................................................................................... 29

5.7 SEWERAGE SYSTEM ............................................................................................................................. 29

5.8 INDUSTRIAL WATER MANAGEMENT ....................................................................................................... 30

5.9 SOLID WASTE MANAGEMENT ............................................................................................................... 30

5.10 POWER REQUIREMENT & SUPPLY / SOURCE ............................................................................................ 30

6 REHABILITATION AND RESETTLEMENT (R & R) PLAN ...................................................................... 31

6.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND

OUSTEES AND LANDLESS. ................................................................................................................................. 31

7 PROJECT SCHEDULE & COST ESTIMATES ......................................................................................... 32

7.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION .................................................. 32

7.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT ................. 32

Economic Viability ................................................................................................................................. 32

8 ANALYSIS OF PROPOSAL ................................................................................................................. 33

8.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE. ..................... 33




LIST OF FIGURES

Figure 2-1: Satellite Image of the Site ............................................................................................ 8

Figure 2-2: Site Photographs ......................................................................................................... 9

Figure 3-1:Topograph ................................................................................................................. 25

LIST OF TABLES

Table 1-1: List of Directors and their designations ........................................................................... 6

Table 2-1:Size/Magnitude of Proposed Production Capacity ............................................................ 10

Table 2-2: Details of Raw material Quantity, Source and Mode of Transport .................................... 18

Table 2-3: Details of Raw water consumption ............................................................................... 19

Table 2-4: Details of emissions from process and flue gas ............................................................ 19

Table 2-5: Details Stacks along with their mitigation method ......................................................... 20

Table 2-6: Details of Effluent Generation ....................................................................................... 20

Table 2-7: Design details and Performance Projection of ETP ........................................................ 22

Table 2-8: Details of Proposed Hazardous Solid waste along with the Category and disposal method 23

Table 4-1: Land Use Break Up ...................................................................................................... 27

Table 7-1: Cost Break-Up ............................................................................................................. 32

LIST OF ANNEXURES

Annexure 1: Site Layout Map ....................................................................................................... 34




EXECUTIVE SUMMARY

M/s Seya Industries Limited (Seya) an emerging leader in chemical industry is engaged in manufacturing and

exporting of Pigment Pharmaceuticals, chemicals intermediates’.Seya specializes in manufacture of chlorination

and Nitration processes, Benzene based products and aims to become the largest producer of Benzene based

chemical Intermediates in the world.

Seya has fully equipped QC labs with high tech advanced instruments and highly qualified technical personnel strict

compliance with stringent international norms to meet global challenges head on using sophisticated and

advanced equipment of very high precision.

Seya proposed green field project in the category of Synthetic Organic Chemicalsat Plot no. D - 14, MIDC Tarapur,

District Palghar, Maharashtra.

Synopsys of the Project:

Sr. No Parameters Description

1. Category as per EIA Notification ( 5 f)B

2. Proposed Production Capacity 48000 MT/A and byproducts having capacity of 4013 MT/A

3. Total Plot Area 61760 sq. m.

4. Green Belt Area 10190 sq. m.

5. Fresh Water Requirement 2559 CMD

6. Effluent Quantity (Trade + Domestic) 1252 + 45 = 1297 CMD

7. Trade Effluent Treatment

High TDS stream from paracetamol plant will be treat in

Multi effect evaporator (MEE). MEE condensate and

stream from acetic anhydride plant will be treat in full

fledge Effluent Treatment Plant (ETP), then treated

wastewater will be discharge to CETP. Blow down from

cooling tower and boiler will be passing through RO,

Permeate will be reuse.

8. Domestic Waste water Treatment Will be treated in proposed STP plant of capacity 54 CMD

9. Fuel requirement Imported Coal = 132 TPD for boiler, HSD = 500 lit/hr for DG and for ketene furnace 575 lit/hr.

10. Power Requirement 8149 KW

11. Boiler , Stack height i. 35 TPH (1 no.) and ii. 10 TPH (1 no.)

Stack height = 60 m common stack for both boilers

12. DG Sets, Stack height 01 no. 1.750MW

Stack Height : 8.5m above enclosure

13. Ketene Furnace Stack Height 4.5 Mkcal/hr. Stack height 45m above ground level

14. Work Force (Proposed) 370 nos.

15. Total Capital Cost the project (Cr) 323 Cr.




1.0INTRODUCTION OF THE PROJECT

1.1 Introduction of the Project

The objective of this pre‐feasibility study is to provide information for the synthetic organic chemicals

manufacturing unit by M/s. Seya Industries Ltd. at Plot No-D-14, MIDC Tarapur, District Palghar, Maharashtra.

As per the EIA Notification No. S. O. 1533 promulgated on 14th

September 2006, proposed project has covered

Synthetic Organic Chemical Industry as 5 (f) and need prior environmental clearance. It is stated that 5(f) industries

located in a notified industrial area are classified under category B and would be appraised by State Level Expert

appraisal committee/ impact assessment authority. Based on the OM dated 16th

May 2014 by Director MoEF,

Public Hearing is exempted for the Industrial Estates / Parks which have taken Environmental Clearance.

1.2 Introduction of the Project Proponent

M/s SEYA industries was established in the year 1990, an emerging leader in Chemical Industry engaged in

manufacturing and exporting of basic chemicals, manufacturing facilities located in MIDC Tarapur, Maharashtra.

List of directors along with their designation is given in Table 1-1

Table 1-1: List of Directors and their designations

S.No. Name Designation

1 Mr. Ashok G. Rajani Chairman and Managing Director

2 Mr. AsitKumarBhowmik Director

3 Mr. Anand Taggarsi Director

4 Ms. KalpanaNasikraoTirpude Director

5 Mr. Amrit A. Rajani Director

1.3Brief description of nature of the project

The proposed project will be on Plot No. D – 14 at MIDC Industrial area Tarapur with land admeasuring 61760Sq.

Meters.Existing production facility is located at same MIDC area at Plot NoT-13/14 which gives an edge for

managing the proposed project.Preliminary Layout Plan is attached as Annexure–I. The land is already in

demarcated as “Industrial” in a notified industrial area and is not a prime Agricultural land. Thus there is no change

in the land use status.

Proposed project is a greenfield project to manufacture synthetic organic chemicals having capacity of 48000 MT/A

and byproducts having capacity of 4013 MT/A.

1.4 Need for the project and its importance to the country and or region

India's pharmaceutical industry is the third largest in the world in terms of volume. Its rank is 14th

in terms of value.

India is also one of the top five active pharmaceutical ingredients (API) producers (with a share of about 6.5%). The




ever-increasing demand for synthetic organic chemicals in India and abroad as well as changing market conditions

requisite Indian synthetic organic chemicals industries to grow further.

Seya is a global supplier of of chemical Intermediates in the world.Seya aims to expand its product portfolio further

in order to cater to Domestic & International markets by expanding its production capacities. These products will

serve to cut the supply of imports from foreign countries thus saving currency and at the same time will earn

valuable foreign currency by export of the proposed products.

1.5Demands-Supply Gap

The population of India as well as internationally is increasing at an alarming rate. This has created a huge gap

between demand & supply of API & finally the finished dosage form globally. To fulfill this gap, SEYA are proposing

to increase the range and production capacity to meet the market requirement. The products manufactured will

be sold both in domestic & Export markets. The major thrust in Export market will earn foreign currency for the

country. The foreign currency earned will be utilized to import Raw materials used to manufacture these products

and save valuable foreign exchange for the country.

1.6 Imports vs. Indigenous Production

The proposed products have high in demand in the export market. Also their demand is increasing in the domestic

market. Production of these drugs domestically reduces the need to import these in future along with significant

scope for export in these products.

1.7 Domestic /Export Markets

The finished goods will be sold in domestic market and would be largely exported to the Regulated International

Market as per demand.

1.8 Employment Generation due to the project

The activities under proposed industry would produce improvement in the socioeconomic status of people in the

study area in terms of local labor employment and contract basis jobs. The proposed activity might provide

employment opportunities to the local populace, especially in business and other services like transportation

activity.It is expected to direct or indirect employ about370 nos. people of various skills will be required during

operation phase.Peoples will work in 3 shifts of 8 hr. each




2.0 PROJECT DESCRIPTION

2.1 Type of Project

Proposed project is a greenfield to manufacture paracetamol & acetic anhydride having total capacity of 48000

MT/A and byproducts having capacity of 4013 MT/A

2.2 Project Location

Seya proposes manufacturing unit at Plot No.D – 14, MIDC Tarapur, District: Palghar, State:Maharashtra. Location

map is shown at Figure 2-1.

The proposed plant is well connected both toMumbai Ahmadabad Highway at 20 Km and Railway line at BoisarRail

Way Station is 3.5 Km. A total of about 61760 SQMs of land is acquired for the proposed project.Satelliet image of

the proposed project and site photographs are as shown below.

Figure 2-1 : Satellite Image of the Site




Figure. 2-2:Photographs of Site Location of proposed project of Seya Industries Ltd.




The project site is situated in MIDC Tarapur. It is a notified industrial area where the land is owned by Maharashtra

Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity.

Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the

Company for 99 years.

2.3 Details of alternate sites considered and the basis of selecting the proposed site

Existing synthetic organic chemicals manufacturing unit of Seya Industries Ltd is located at T-13/14 in the same

MIDC area where proposed project would be located, which gives an edge for managing the proposed project.

Only as a part of growth policy Seya wish to expand chemical production activity at proposed site to remain in a

business and retain the leadership.

Since the proposed site has sufficient land available and owned by proponent. The following points were

considered for selecting the proposed site:

Location is within the established notified industrial estate

Availability of common infrastructural facilities of the industrial estate

Availability of water supply in the industrial estate

Availability of un-interrupted power supply in the industrial estate

Nearby availability of CETP for the disposal of treated effluent

In close vicinity of sister industry for the transportation of finished goods

Hence alternate sites were not considered.

2.4 Size or Magnitude of Operation

The products manufactured and their capacities proposed are shown in below Table 2.1.

Table 2-1: Size/Magnitude of Proposed Production Capacity

S.No. Products Quantity (MTA)

1 Paracetamol 24000

2 Acetic Anhydride 24000

Total /Year 48000

By-products

S.No. Products Quantity (MTA)

1 Dil. Acetic Acid 4013

Total /Year 4013




2.5 Process Description

1. Paracetamol

Process:-

Reaction 1:- Hydrolysis

Hydrolysis of PNCB in presence of Water and Caustic lye gives Sodium Salt of Para-Nitrophenol. Reaction

temperature is maintained at 162˚C and pressure 5.5 to 6 Kg/cm2.This reaction is exothermic and controlled by

cooling in jacket.

Reaction 2:- Hydrogenation

Catalytic Hydrogenation of Sodium Salt of Para-Nitrophenol gives Sodium salt of Para Amino Phenol (Na-

PAP).Reaction temperature is maintained at 90˚C to 95˚C & pressure 5.5 to 6 Kg/cm2. This is a reduction reaction

by Catalytic Hydrogenation. This is Green Technology to reduce the reaction waste and also a Cleaner Production

technique. Giving better yield in compare to Fe-HCL reduction process.

Reaction 3:- Neutralization

Neutralization of Sodium Salts of Para Amino Phenol (Na-PAP) by 30% HCL gives Para Amino Phenol (PAP). 30%

HCL used in first 3-4 batches, then after ACML (Crude Paracetamol Mother Liquor) is used for neutralization. Then

after filtration of PAP. Filtrate is send to ETP. In first 3-4 batches PAP Slurry prepared in Dil. Glacial Acetic Acid to

generate ACML. After that ACML is used for PAP Slurry. This PAP Slurry sends for Acetylation.

Reaction 4:- Acetylation

Acetylation of PAP Slurry with Acetic Anhydride gives Crude Paracetamol. Reaction carried out at 75˚C to

80˚C.Then after cool, chill & filter. Filtrate is ACML. This is reused for neutralization and PAP Slurry. This will reduce

load on recovery plant. Crude Paracetamol slurry prepared in CR ML (Final Paracetamol Centrifuged Mother

Liquor).Slurry is sends for Activated Charcoal treatment.

Reaction 5:- Purification

Crude Paracetamol Purified with Activated Charcoal and after filtration of Activated Carbon Crystallization filtrate

gives Pure Paracetamol. Then centrifuging, drying, pulverizing, sampling & packing of PARACETAMOL. Centrifuged

Filtrate is reuse in Crude Paracetamol Slurry Preparation for carbon treatment. This will save water consumption.

As per pollution load Reaction 1 and 2 having no major ETP Load, just normal load of vent vessels liquid. In

Reaction 3 after neutralization filtrate goes to ETP. And Reaction 4 and 5 having Zero Loads on ETP.




Reaction:-

1. Stage I Hydrolysis

PNCB to Para Nitro phenol-Na salt (Na-PNP)

2. Stage II Hydrogenation

Na-PNP to Na-PAP

3. Stage III Neutralization

Na-PAP to PAP

4. Stage IV Acetylation

PAP to PARACETAMOL




Material Balance

Stage – I Hydrolysis of PNCB

Sr. No. INPUT MATERIAL OUTPUT MATERIAL

Name Quantity (Kg) Name Quantity (Kg)

1. PNCB 10781 NaPNP 11024

2. Water 26635.7 Water generated in reaction 1230

3. 100% Caustic solution 5914

NaCl 4003

Un reacted water & NaOH 25451

Water vapour (out) 1623

Total 43331 Total 43331

Stage – II Hydrogenation of Sodium salt of P-nitrophenol



1. Stage – I output 41708 NaPAP 8971

2. Hydrogen 415 NaCl 4003

3. Catalyst (on dry basis) 57 Water carried over 26242

4. Water for catalyst 57

Catalyst + water 114

Water generated in reaction 2400

Unreacted NaOH 439

H2Vent (out) 5

Water vent (out) 63


Stage – III Catalyst filtration



1. Stage – II output 42169 NaPAP 8971

2. Acetic acid (glacial) – 1st

wash 241 NaCl 4003

3. Water fresh 951 Water generated in reaction 2400

4. Water fresh – 2nd

wash 1903

Water unreacted 29096

Water generated in sodium acetate formation

72

Unreacted NaOH 279

Sodium acetate 329

Catalyst + water 114





Stage – IV Neutralization



1. Stage – III output 45150 PAP 7459

2. Water for washing 1585 NaCl carried over 4003

3. Paracetamol 549 Paracetamol 549

4. Acetic acid 4170 Sodium hydro 60

5. Sodium hydro 60 Unreacted PAP 58

6. Unreacted PAP 58 Water 10823

7. Water 10982

Sodium acetate generated in reaction

6253

Water carried over 31496

Water for washing 1585

Water formation due neutralization of free alkalinity

125

Water along with hydro 143


Stage – IV Acetylation



1. PAP (Dry basis) 7334 Paracetamol 9963

2. Acetic acid 6075 Unreacted PAP 142.242

3. Sodium hydro 26 Water 7775

4. water 4683.6 Acetic acid 4062

5. Paracetamol 388.3 Acetic acid from recycle 6075

6. Water as moisture in PAP cake (30%)

3107 Paracetamol carried over 388

7. Sodium hydro sulphite 17 Sodium hydro sulphite 43.4

8. Acetic anhydride 6817


Stage – V filtration



1. Stage – IV output 28448

Paracetamol 9679

Filtrate 17061

Moisture in product 1708


After washing – 1, 2, 3






1. Paracetamol 11387 Paracetamol 9451

2. water 17519

ML (Recycle) 19737.6 3. hydro 11

4. Acetic acid 271.6

Total 29188.6 Total 29188.6

Carbon treatment, filtration and drying



1. Paracetamol 9451 Paracetamol (Dry basis) 9073

2. Water 35758 Spent carbon and other impurities

150

3. Hydro 19.6 Filtrate 36486

4. Acetic acid 406 Hydro solution 20

5. Carbon dry basis 95


2. Acetic Anhydride

Process

The glacial acetic acid is first mixed with recovered acid from concentration section and diluted with adequate quantity of process water to make a feed concentration of about 98% strength acetic acid. The feed acetic acid as prepared above is then vaporized and fed along with the catalyst (Tri Ethyl Phosphate) to the high temperature cracking furnace, maintained under vacuum, where it passes through coils made of heat resistant material. Ammonia is injected into the gases exiting the furnace and the gaseous products are then rapidly cooled/quenched to avoid the reverse reaction and the unreacted acetic acid along with water formed in the reaction are condensed and separated as dilute acetic acid. The separated gases then pass through a series of two absorption towers in which they are scrubbed by acetic acid/acetic anhydride mixtures of various concentrations. The glacial acetic acid is added to the scrubbing liquid of 2nd absorption tower.The gases are further scrubbed in two washing towers in series to prevent any acetic anhydride to escape along with other gases through vacuum pump discharge. In the first washing tower the gases are scrubbed with crude acetic anhydride and in the second one the gases are scrubbed with diluted recovered acetic acid from the reaction. The remaining gases are vented through a vacuum pump. The absorber/washing tower train, as well as the furnace and evaporators are under vacuum. The crude acetic anhydride obtained from the absorption step is distilled in a distillation column where acetic anhydride is obtained as a bottom product and sent to storage. The top product from this column is acetic acid which is recycled back to the process. The dilute acid obtained from the reaction is preheated and fed to the distillation column where an entrainer (Butyl Acetate) is used to carry water to the top in an azeotropic mixture. Concentrated acetic acid is taken from the bottom of the column and recycled back to the process. The slime (primarily acetic acid/ acetic anhydride along with high boiling polymeric compounds and phosphates) collected in the reboilers is periodically withdrawn and vacuum distilled in a stirred vessel to recover acetic




anhydride/acetic acid. The small amount of waste remaining after vacuum distillation is discharged and collected as semi solid sludge which needs to be incinerated/sent to landfill site for hazardous chemicals. Reaction

Acetic Acid decomposes mainly into ketene and water as per the following endothermic reaction:

CH3COOH CH2CO+ H2O Some other side reactions also occur simultaneously. The main side reactions are as follows:

CH3COOH 2CO+2H2 CH3COOH CH4 + CO2 2CH2OH CH4 + C + 2CO 2CH2CO C2H4 + 2CO Ketene reacts with acetic acid to form acetic anhydride

CH2CO + CH3COOH (CH3CO) 2O

Overall Material Balance

Ketene Formation and Condensation

INPUT MATERIAL OUTPUT MATERIAL

Sr. No. Name Quantity (Kg) Name Quantity (Kg)

1 Fresh Glacial acetic acid 702 Unreacted Acid(condensed) 113

2 Water 18 Feed Water (condensed) 18

3 Triethyl phosphate 4 Reaction Water (condensed) 188

4 Fuel oil / LDO (For cracking) 135 Ketene (gas)+Process Off Gases

521

5 Air (for cracking process) 2125 Combustion gases 2260

6 Ammonia 3

7 Recycled Glacial Acetic Acid 113


Absorption



1 Fresh Glacial acetic acid 598 Acetic Anhydride 1052

2 Ketene (gas)+Process Off Gases

521 Process Off gases 67

3 Recovered Glacial Acetic Acid 114 Excess Glacial Acetic Acid 114


Anhydride Distillation



1 Glacial acetic acid 114 Acetic Anhydride 1000

2 Acetic Anhydride 1052 Semisolid Waste 52




Glacial Acetic Acid Recovered

114


Dilute Acid Concentration



1 Glacial acetic acid 113 Recovered Acetic acid 113

2 Water 201 Total water 201

3 Fresh Butyl acetate 2 Butyl Acetate 5

4 Recycled Butyl acetate 3

Total 319 Total 319

Solvent Recovery



1 Water 201 Effluent Waste water 235

2 Live Steam 32 Butyl Acetate Lost with Effluent

2

3 Butyl Acetate 5 Butyl Acetate Recovered 3

Total 238 Total 238

Acetic Acid Recovery from Paracetamol Plant




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

Product/s, mode of transport of raw material and finished product

Raw Materials:

The basic raw material for this key products capacity are submitted herein below and for the details are given for

all reactants, solvents and work up support chemicals.

Source for Raw Material Procurement: Raw Material is easily available in the local market; some of the raw

materials are In-house.

Mode of Transport of Raw Materials: Raw Material and finished goods will be transported through Trucks/

Tankers or which are in house will be transported through pipelines as per the requirements.

Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of storage yard is

demarcated in Layout Plan.

Table 2-2: Details of Raw material

Sr. No. Name of the Product Raw Material

1 Paracetamol

Para-nitro Chloro Benzene

32% Caustic lye

Hydrogen

Acetic acid (glacial)

Sodium hydro sulphide solution

Acetic anhydride

Activated Carbon

Dil hydrochloric acid

2 Acetic Anhydride

Glacial and Dilute acetic acid

Triethyl Phosphate (Catalyst) Butyl Acetate

Ammonia

Butyl Acetate

Dil. caustic soda for DM Water

Dil hydrochloric acid for DM Water

2.7 Resource optimization/recycling and reuse envisaged in the project

To conserve the water, various recycle/ reuse schemes will be implemented. Most energy efficient technology is

selected.




2.8 Availability of water its source, energy/power requirement and source

2.8.1 Water Requirement and Source

Proposed fresh water requirement of the project for domestic and industrial activity during operation phase will be

2559CMD. The water requirement will be sourced from MIDC. The details of water requirement are given in Table

2-3

Table 2-3: Details of Raw water consumption

S. No. Units Raw Water Qty.(KLD)

A Process

1 Paracetamol 367


B Utilities

1 Cooling water 1648

2 Boiler 418

C Domestic 56

D Gardening 51

Total 2559

2.8.2 Power Requirement

Power requirement of proposed project will be made available through State Electricity Board. Power requirement

of proposed plant is as below:

Power requirement: 8149 KW

01 nos. of D. G. sets of capacity 1750 KVA are proposed to meet emergency power requirement of the plant.

2.8.3 Fuel Requirement

It is proposed to install 02 nos. of 35 TPH & 10TPH boilers. Fuel required for proposed project will be around 132

T/day of coal. Only imported coal will use as a fuel for boiler. HSD will be used as fuel to runone DG set having

capacity 1750 KVA. Requirement of HSD will be around 500lit/hr. (as and when the power shortage occurs due to

power failures). DG will be operated in case of emergency only. HSD is also used for energy requirements of

Ketene furnace. Requirement of HSD for this purpose would be around 575 lit/hr on continuous basis.

2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal

2.9.1 Gaseous Emissions

Details of gaseous emissions from Process and Flue gasare given in Table 2-4

Table 2-4: Details of emissions from process and flue gas

S. No. Pollutant Source of

Emission

Emission

rate Concentration

in flue gas Proposed

1. SPM Boiler/DG <150 mg/m3 <150 mg/m

3

2. SO2 Boiler/DG <135 kg/d <135 kg/d




Details of stack mitigation measures are given in Table 2-5.

Table 2-5: Details stacks along with their mitigation methods

Attached to Ketene furnace Boiler TPH Boiler TPH DG KVA

Capacity 4.5 Mkcal/hr 35 10 1750

Fuel type HSD Coal Coal HSD

Fuel qty kg / hr 575 lit/hr 103 TPD 29 TPD 500 lit/hr

MOC MS MS MS MS

Shape Round Round Round Rectangular

Height m (above ground level) 45 m 60 m 8.5 m

Mitigation Measures Stack Stack& Cyclone dust collector followed by

Bag filter

Stack& Cyclone dust collector followed by

Bag filter

Stack, Acoustic enclosure

2.9.2 Liquid Effluent

The quantity of effluent generated proposed project is given in Table 2.5

Table 2-6: Details of Effluent Generation

S. No. Units Effluent generation

Qty.(KLD)

A Process

1 Paracetamol 522


B Utilities

1 Cooling water 636

2 Boiler 75

C Domestic 45

Total 1297

Trade effluent generated will be 1252CMD will be treat in MEE & ETP, Domestic effluent of 45 CMD will be treated

separately in STP of capacity 54 CMD, cooling tower and boiler blow down will be treat in RO and reuse.

Proposed Treatment Scheme for Trade Effluent

High TDS Effluent: The treatment to the high TDS effluent from paracetamol plant has given the following

sequence.

1. Multiple Effect Evaporator

2. Agitated Thin Film Dryer

The high TDS effluent arising from the Paracetamol plant will be collected in separate collection tank.




The effluent will be fed to MEE (capacity 950 CMD) where the effluent will be concentrated up to 50 % w/w (TDS basis)

by evaporating the water with the high pressure steam. The condensate of the Evaporator will be fed to ETP for

removal of volatile organics that will get carried away in the condensate. The concentrated liquor will be pumped to

the Agitated Thin Film Dryer for the removal of solids again by evaporation of the water with the help of high pressure

steam. Thus the dissolved solids will be completely removed from the liquor and it will also reduce the concentration of

other polluting parameters.

The solids recovered from ATFD will be sent for disposal to CHWTSDF. The condensate of Multiple Effect Evaporator

and ATFD will be pumped to the Effluent Treatment Plant for the removal of organics.

Low TDS Stream:

ETP is designed to treat 980 m3 / day of effluent coming from acetic anhydride plant and MEE condensate. Cooling

tower and boiler blow down will be separately treated in RO. The treatment to the stream is in the following sequence.

Primary Treatment

The system will be designed to treat 980 m3/day of waste water. Wastewaters from acetic anhydride plant will be

collected in the collection tank, MEE condensate will be collected in the equalization tank and air stripped. This

effluent will then be pumped to the Flash Mixer where it will be dosed with alum for coagulation.This effluent will

overflow into the settling tank where the solids will settle down and will be removed.

Secondary (Aerobic) Treatment:

The system will be designed to treat 980m3/day of waste water. The neutralized effluent will enter the bioreactor @

40.83m3 / hr. In the bio reactor, dissolved organic material is degraded by the micro–organisms present in the bio

reactor. Oxygen required for the oxidation of organic matter will be provided by means of proposed diffuser aeration

system which will mix the contents of the bioreactor also. The mixed liquor will overflow into Secondary Settling Tank

(SST). In the secondary settling tank, solid-liquid separation takes place and solids i.e. biomass will settle at the bottom

of the tank. Settled biomass will be recycled to the bio reactor for maintaining the MLVSS concentration by using

proposed sludge recycle pumps and excess biomass will be wasted periodically to the sludge sump. Two stage

treatments are proposed where the overflow from the 1st stage clarifier will enter the 2

nd stage bioreactor where the

non-degraded organics from the 1st stage bioreactor will be treated. The clear overflow from the 2

nd stage Secondary

Settling Tank will be collected in the intermediate tank.

Tertiary Treatment:

The system will be designed to treat 980 m3/day of waste water. The clear effluent from the intermediate tank will be

pumped by tertiary Feed pumps through the pressure sand filter (PSF) & activated carbon filters. The final treated

effluent will be collected in the final collection tank from where it will be discharge to proposed upgraded CETP.




Sludge Handling:

Primary sludge and excess biomass from the secondary treatment will be collected in the sludge drying bed (SBD). The

solid cake from the SDB will be sent for disposal to Hazardous waste disposal site. The filtrate from the SDB will be

drained to the equalization tank.

For cooling tower and boiler blow down: from paracetamol and acetic anhydride plant

RO System

Reverse Osmosis is at present a proven technology used to recover good quality water for process use. The blow down

from cooling tower and boiler will be passed through RO where the dissolved solids are separated in the form of Reject

& treated water free from dissolved solids (Permeate - 568 CMD) is utilized for cooling tower and boiler feed. Reject of

RO (143 CMD) shall be feed to the MEE.

Table 2-7: Design details and Performance Projection of MEE &ETP

High TDS Stream : To MEE

S.No. Parameters Unit RO Reject Inlet Effluent Characteristics Condensate of MEE

1 Flow m3/day 143 522 665 +133 steam condensate

2 pH ---- 7.0 – 8.0 7.0 – 8.0 7.0 - 8.0

3 COD mg/L -- 5000 - 5500 4500 - 5000

4 TDS mg/L 9547 200000 <150

5 TSS mg/L <100 Nil Nil

Low TDS Stream :To ETP

(Including condensate of Multiple Effect Evaporator and effluent from acetic anhydride plant)

S.No. Parameters Unit Inlet Effluent

Characteristics Outlet Effluent Characteristics

Effluent discharge standards (MPCB)

1 Flow m3/day 817 817 --

2 pH ---- 4 to 5 7 to 8.5 6.5 -9.0

3 BOD3,270C mg/L 2000 – 2500 60 – 80 <100

4 COD mg/L 4000 – 5000 180 – 200 <250

5 TDS mg/L 250 - 300 250 - 300 <150

6 TSS mg/L 300 – 400 70 – 90 <100

Cooling tower & boiler blow down: To RO

S.No. Parameters Unit Inlet Permeate Reject

1 Quantity m3/day 711 568 143

2 pH ---- 7 to 7.5 7 to 7.5 7 to 7.5

3 TDS mg/L 1800 – 2000 < 100 9547




Treatment Scheme for Domestic Wastewater

The sewage generated due to domestic activities will be treated in STP of 54CMD capacity and treated water will

be reused for gardening.

2.9.3 Details of Hazardous wastes

The types of Hazardous wastes generated from the project, method of disposal is shown in below table below

Table 2-8: Details of Proposed Hazardous Solid waste along with the Category and disposal method

S. No. Waste Name Unit Category Quantity Disposal Method

Hazardous Waste

1 Distillation Residue T/day 20.3 4.56 CHWTSDF

2 Spent carbon from

Process T/day 35.3 1.2 CHWTSDF

3 ETP Sludge T/day 34.3 3.14 CHWTSDF

4 Spent carbon from

ETP T/day 34.3 0.74 CHWTSDF

5 MEE Solids T/day 34.3 105 CHWTSDF

2.10 Schematic representations of the feasibility drawing which give information of EIA purpose.

The applicability of the S.01533 for the proposedproject was exploredby considering different possibilities

& provision made in the said notification. Considering the products & project location of the proposed

project it is noticed that the proposed project falls under Category 5 (f) "B" of the Schedule -I of EIA

Notification SO 1533.

As per the provision of the SO 1533 it is necessary to get Environmental Clearance by applying to MoEF along

with the Environmental Impacts Assessment Study Report for the proposed project prior to commissioning

of the project activities. Therefore the EIA is required to conduct to comply with provisions of SO 1533 made for

Category 5(f) "B" of schedule —I of the notification.




3.0 SITE ANALYSIS

3.1Connectivity

M/s Seya Industries Ltd. is located at Plot No Plot no. D – 14, MIDC Tarapur, District Palghar, Maharashtra.

The nearest city from the site is Boiser at a distance of 3.5 Km.

The nearest railway station is Boiser at a distance of 3.5 Km from the site.

The nearest airport is at Mumbai 110 km.

National Highway is Mumbai Ahmadabad Highway at a distance of 20 km.

3.2Land Form, Land use and Land ownership

The proposed land for setting benzene based chemical intermediates. Proposed unit is located in Notified

Industrial Estate havingplot area 61760SQM. The land is acquired by Seya for establishing new manufacturing

facility.

3.3 Topography

The Geographical location of this industry is: Latitude -19.802694 N and Longitude- 72.726381 E

Location: Tarapur, MIDC. Elevation above mean sea level meters: 12m.Toposheet of the site is shown below. The

study area (10 km radius) around the project site exhibits flat terrain in the east and relatively elevated terrain in

the west side. The minimum and maximum elevation of the study area is 1 and 492m amsl (above mean sea level)

respectively. The maximum elevation is noticed in the western side of the study area. The highest elevation of 492

m is at SE side of the study area near Kalampedi.

The project site is flat terrain. Mean sea level of the project site is 11-14 m. Two third of the study area falls under

terrestrial and one third falls under marine environment.




Figure 3.1: Toposheet Showing Project site and 10Km of area

3.4 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, eco sensitive areas, water bodies (distance from HFL of the river), CRZ.

The proposed land for setting new unit is located in Notified Industrial Estate. The land is acquired by Seya

Industries.The proposed site is an undeveloped land which does not include agricultural, forestry, water bodies

(including CRZ) etc.

3.5 Soil classification

The basic type of soil found in the area varies from brown & black. The black type of soil is found in the eastern part.

The fertility of the soil increases as it goes from red to black.

3.6 Climatic data from secondary sources

The climate in proposed area is characterized by hot summer and general dryness throughout the year except the

south west monsoon season.

Climate Classification: Project site features a semiarid climate.

Temperature: Annual maximum and minimum temperature in Tarapur range from max. 380C mini.11

0C.




Rainfall: Most of the rainfall occurs in the monsoon season from June to September. Average annual rainfall is 2488

mm.

Humidity: Annually relative humidity ranged from 64% – 88% and during summer season the humidity ranged from

64% – 75%.

3.7 Social Infrastructure Availability

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park,

market, playground etc. education, health care, community development, income distribution, employment and

social welfare are available in nearby area of Maharashtra Industrial Estate.




4.0 PLANNING IN BRIEF

4.1 Planning Concept

Proposed plant activities will be started after getting statutory clearance form related authorities. The p roject

will be completed within two years. Further proposed project activities will take care of all the rules and

regulation of statutory authority and provide the control measure and devices to achieve the standard norms

Tarapur MIDC has provided all infrastructure like assured electrical power, continuous water supply with

purification from water works like disinfection, the internal road network, external approach road, and networking

with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility), MWML at Taloja in vicinity

established with support of MIDC and MPCB.All nearby villages are provided with drinking water from wells or

Government Water Supply Schemes. Hence we do not encroach upon their supply.

4.2 Land Use Planning

Existing land is barren and undeveloped which will be converted for industrial purpose. The land is located in a

designated industrial area. The total plot area is 61760m2.

Table 4-1: Land Use Break Up

S. No. Description Area in m2 Area (%)

1 Paracetamol Plant 2000 3.23

2 Acetic Anhydride Plant 1600 2.59

3 Boiler and cooling tower 5000 8.09

4 MEE, ETP, RO and STP 3200 5.18

5 Utilities 5000 8.09

6 Admin Building 2000 3.23

7 Lab 1350 2.18

8 Storages 5695 9.22

9 Workshop 0525 0.85

10 Raw / Fire water system 1500 2.42

11 Coal yard 1800 2.91

12 Acetic acid recovery plant 1210 1.95

13 Parking 7411 12.00

14 Open Space including roads and green belt 23469 38.00

Total 61760 100

Green belt (33% of open space) 10190 16.49

4.3 Assessment of Infrastructure Demand (Physical & Social)

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park,

market, playground etc. education, health care, community development, income distribution, employment and

social welfare are available in nearby area of Maharashtra Industrial Estate.




4.4 Amenities/Facilities

In proposed site many basic facilities like uninterrupted water supply, Power and Road Network & solids disposal

facility if feasible are available. This site is inside the campus of the MIDC and means safe transportation, less need

of utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure and

networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal facility), MWML, Taloja in

vicinity established with support of MIDC and MPCB.

4.5 Population Projection

Palghar District has a population of 454,635 as per census 2011. It has more than 99,652 households of Maratha,

Aagri, Koli, Muslim, Buddhist, and also includes SC, ST, OBC and open categories community. The village has

basically an agrarian economy and industrial workers and farming is the main occupation of the villagers. The local

self-Government vests with a Grampanchayat having an elected body of headed by a Sarpanch.

Population growth is being increased at alarming rate with their basic requirements. Amongst, Medicine is one of

the basic needs, which is very essential for everyone to live happy life. So to fulfil their future basic need of

Medicine for social community there is a necessity to promote R & D Centre in each industrial sector. There will be

in ratio of population increase in similar way their need also increases so to fulfil their needs we are going to set

up a proposed unit which again generates employment.




5.0 PROPOSED INFRASTRUCTURE

5.1 Industrial area

Industrial Area (Processing area)

Utilities

Cooling towers

HSD unloading/storage area

Boilers

Non- Processing Area

Administrative Buildings

Security cabins

Workers restroom

Vehicle Shed

Water reservoirs

Temporary storage sites

Works block etc

5.2 Residential Area

In M/s. Seya Industries Ltd. there is no any residential area has been proposed.

5.3 Green Belt

The project is built on an MIDC plot with plot area of 61760sq. m. and green belt area 10,190 sq. m.Green belt will

be developed at proposed project site and details will be provided in EIA report.

5.4 Social Infrastructure

The basic amenities within the study area include primary schools, dispensaries, water supply, electric supply,

public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training institute and

entertainment etc.

5.5 Connectivity

The proposed site is well connected with the roads connecting NH-8 (Mumbai-Ahmadabad)at an aerial distance of

17 kms towards East. Nearest railway station is located at Boisar at an aerial distance of 4 kms towards

East.Nearest airport is located at Mumbai at an aerial distance of 110 kms towards South.

5.6 Drinking Water Management

The source of water supply is from MIDC.

5.7 Sewage System

The domestic effluent will be treated in STP. Treated sewage water will further be used for gardening and spraying

on the coal.




5.8 Industrial Water Management

Treated Industrial effluent will be sent to CETP for final disposal.

5.9 Solid Waste Management

Hazardous solid waste generated from the process will be collected, stored, transported and send to MWML,

Taloja CHWTSDF as per Hazardous waste (Management, Handling and Transboundry Movement) Rules 2008.

5.10 Power Requirement & Supply / source

The Total Power required for the proposed project is 8149 KW.




6.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

6.1 Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless.

Rehabilitation and Resettlement (R&R) plan is not applicable for the proposed project.




7.0 PROJECT SCHEDULE & COST ESTIMATES

7.1 Likely date of start of construction and likely date of completion The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized

committee.

7.2 Estimated project cost along with analysis in terms of economic viability of the project

The total investment envisaged is Rs. 323Crore with the break-up as given in table no 7.1 below

Table 7-2: Cost Break Up

S. No Item Cost (Rs in Crore)

1 Land Cost 19.10

2 Plant & Machinery, ETP and Building infrastructure 303.9

Total – Approx. 323

Economic Viability

The project has been conceived assuming that there will be a growth in demand for the proposed products,

leading to a reasonable rate of return in the medium term. The project is considered ‘bankable’.




8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Proposed activity will provide benefits to the local people in terms of financial and social welfare.

Local people will get direct financial benefit by way of employment.

Local people will get some contract of supply and services to get indirect income.

Company will contribute in improving education and health facilities in nearby area.




Annexure –I

Plot lay Out of Proposed Project of M/s Seya Industries Ltd at Plot no D – 14, M.I.D.C. Boiser Tarapur

m/s seya industries ltd. - environmentclearance.nic.in · m/s seya industries ltd. proposed...

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