pre feasibility report -...
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1
PRE FEASIBILITY REPORT
for
PROPOSED PROJECT FOR MANUFACTURING DYES,
DYES INTERMEDIATES AND PIGMENTS
of
M/s. NUCHEM DYESTUFF PVT. LTD.
Plot no-C- 284,285,299,& 300
Saykha Industrial Estate
Taluka: Vagra, Dist- Bharuch
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
2
CONTENTS
Sr.
No.
Description Page No.
1. Executive Summary 3
2. Introduction of the Project/Background information 11
3. Project Description 13
4. Site Analysis 17
5. Planning Brief 19
6. Proposed Infrastructure 20
7. Rehabilitation and resettlement (R & R) Plan 21
8. Project Schedule & Cost Estimates 21
9. Analysis of Proposal (Final Recommendations) 22
3
1.0 EXECUTIVE SUMMARY
1.1 Company Profile
Introduction
Nuchem is involved in the reactive dyes trading and manufacturing since 1962, by the name
of Kishori Lall Rangwala since 1962, initially started off as a trading house in Reactive dyes
locally in Gujarat and Ludhiana area and then putting up a manufacturing unit with a single
spray dryer in 1996. With a vintage of more than 50 years, Nuchem has achieved a name in
the industry of providing value to its customers with guaranteed quality and service.
Nuchem exports more than 80% of its production to Bangladesh, Indonesia and Thailand
and rest to Ludhiana and Ahmedabad.
Nuchem had a turnover over of approximately 19.25 Crore in the last financial year.
Defying the challenges of the external market such as price competitiveness, rising raw
material prices etc, Nuchem has always had stable orders from customers in all the
locations it markets its products, even sometimes orders had to be deferred or cancelled
from export markets due to restriction in production by GPCB due to pollution related
issues in Nuchem’s older unit.
It is due to above reason, Nuchem decided to set up another large unit in the Industrial
Zone, especially set up by Gujarat Government for dyes and allied chemicals production,
with complete provisions for pollution control, utility services and port availability near
industrial zone.
1.2 Project Details
Sr. No. Name of Product Proposed Capacity (MT/Month)
ACID DYES
100 MT/Month
1 Acid Black 210
2 Acid Black 194
3 Acid Black 235
4 Acid Brown 75
5 Acid Brown 165
6 Acid Brown 161
7 Acid Brown 282
8 Acid Brown 355
9 Acid Brown 432
10 Acid Brown 434
4
11 Acid Brown 425
12 Acid Green 68
13 Acid Blue 113
14 Acid Blue 193
15 Acid Red 119
16 Acid Red 97
17 Acid Red 357
18 Acid Violet 90
19 Acid Yellow 42
20 Acid Orange 142
REACTIVE DYES
1000 MT/Month
1 Reactive Black B and Black Mixes
2 Reactive Orange M2R
3 Reactive Red M8B/H8B
4 Reactive Red ME6BL
5 Reactive Orange ME2RL (Orange - 122)
6 Reactive Red ME4BL (Red- 195)
7 Reactive Golden Yellow ME4RL (Yellow
145)
8 Reactive Golden Yellow HER
9 Reactive Orange H2R
REACTIVE BLUE
1 Blue 3R
2 Blue F4R
3 Blue HERD
4 Blue 221
5 Blue HEGN
6 Blue LFNG
7 Blue BF
8 Blue BFN
5
9 Blue 2B
REACTIVE RED
1 Red mixes
2 Red BS
3 Red RB
4 Red HE3B
5 Red 5B
6 Red F3G
7 Red H7B
8 Red DS4B
9 Red F2B
10 Crimson XLE
11 Red DSGD CONC.
12 Blue Mixes
13 Red SGR
REACTIVE GOLDEN YELLOW
1 Golden Yellow RNL
2 Golden Yellow R
REACTIVE NAVY BLUE
1 NAVY BLUE 2G
2 NAVY RGB
3 NAVY XLE
DIRECT DYES
1 Direct Orange 26
2 Direct Red 31
3 Direct Black 22 100 MT/Month
4 DIRECT BLUE 71
5 DIRECT BLUE 281
6 DIRECT BLUE 218
7 DIRECT RED 239
8 DIRECT BLUE 80
9 DIRECT BLACK 170
6
10 DIRECT BLACK 168
11 DIRECT BLACK 179
12 DIRECT BLACK 80
13 DIRECT BLACK 22
14 DIRECT ORANGE 39
CPC BASE DYES
150 MT/Month
1 Reactive Blue 21
2 Reactive Blue 25
3 DIRECT BLUE 199
4 Reactive blue 72
5 Direct Blue 86
ACRYLIC DYES
100 MT/Month
1 Basic Yellow 28
2 Basic Yellow 13 ( Yellow 8 GL)
3 Basic Blue 54. ( Blue GL).
4 Basic Blue 41( Blue GRL)
5 Basic Blue 3. ( Blue BG).
6 Basic Violate 16. ( Red 2B).
7 Basic Red 18. ( Red GTL).
8 Basic Red 13. ( Pink FG).
9 BASIC RED 14
PIGMENTS 1 Azo Pigments
2 Quinacridone Pigment
200 MT/Month
3 Carbazole Dioxane Violet Pigment
4 CPC Base Pigments
5 Pigment Emulsions
DYES INTERMEDIATES
900 MT/Month
NAPTHANLENE BASE DERIVATIVES
1 H-Acid
2 Vinyl Sulphone
BETA BASE DERIVATIVES
7
1 K-acid
2 Sulfo Tobia Acid
3 Gamma Acid
4 Tobias Acid (SCHAEFFER’S ACID)
5 N Methyl J Acid
CPC BASE DERIVATIVES
1 Amine Base
2 Phthalimide Based
BLUE BASE
Tripheno Dioxazine
Total 2550
LIST OF BY-PRODUCTS WITH THEIR PRODUCTION CAPACITY
Sr. No. Name of By-Product Proposed Capacity (MT/Month)
1 Sodium Sulfite salt 130
2 Rec. Acetic Acid 45
1.3 Green Belt Development
Company has developed an effective green belt within the factory and on periphery of the
factory. Total Plot Area is 79603.62 m2, out of which 23873.62 m
2 is Green Belt Area. In
addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.
1.4 Power & Fuel Requirement
Fuel:
Natural Gas 2200 scm / Hr
LDO / FO 560 Liter / Hr
HSD for DG Sets
(for emergency
only.) 80 Liter / Hr
F.O. for lncinerators 40 Liter / Hr
Energy:
4500 KVA from MGVCL
8
DG set - 2500 KVA (In case of Emergency only)
1.5 Water Requirement and Wastewater Generation & Treatment
Source of water requirement will be met through GIDC water supply. Total water
requirement will be 2295 KL/Day. Total 863 KL/Day (835 KL/Day Industrial + 28.0 KL/Day
domestic) of effluent shall be generated; out of which 835 KL/Day will be treated in ETP and
finally Distillate water is reused in to Process & Distillation Residue shall be sent to Captive
Incinerator.
1.6 Air Pollution Source and Control Management
FLUE GAS EMISSION
Sr.
No. Stack Attached to
Height &
Diameter
Fuel
Consumption APCM
A PROPOSED
1. Steam Boiler
Cap. 6 MT/Hr
Height –
30 Meter
Dia.- 800 mm
LDO/FO – 12
MT/Day
Scrubber System
2. Thermic Fluid Heater
Cap. 2.5 MT/hour or 6 Lac
Kcal
Height –
30 Meter
Dia.- 800 mm
Natural Gas -
2200 SCM/Hr
As Natural Gas is used a fuel,
adequate stack height is
provided
3. Incinerator
Height –
35 Meter
Dia.- 1000
mm
FO – 40 Lit/Hr Scrubber System
4. D. G. Set – Stand By
Cap. : 2500 KVA
Height –
11 Meter
Dia.- 150 mm
HSD – 1.6 KL/Day As LDO / HSD are used as a
fuel, adequate stack height is
provided.
9
1.7 Hazardous Waste Management
CAT.
NO.
HAZARDOUS
WASTE
PROPOSED
TOTAL
(MT/Month)
MODE OF
STORAGE METHOD OF DISPOSAL
5.1 Used Oil 0.2 Collected in barrels
& stored in sludge
storage area
Sent to GPCB approved
recycler
33.3 Discarded
barrels/
containers/
liners
5 Stored in sludge
storage area
Sent back to supplier / to
GPCB approved recycler
34.3 ETP Sludge 50 Collected in plastic
/ HDPE bags &
stored in sludge
storage area
Sent to TSDF site for
secured land filling
- MEE Salt * 315 Collected in plastic
/ HDPE bags &
stored in sludge
storage area
Sent to TSDF site for
secured land filling
26.1 Iron Sludge 300 Collected in plastic
/ HDPE bags &
stored in sludge
storage area
Collection, Storage,
Transportation and
Disposal at Nearest TSDF
or sell to Cement Industry
PROCESS GAS EMISSION
Sr.
No. Vent Attached to
Height &
Diameter Pollutants APCM
PROPOSED
1. Process Vent Height –
11 Meters
Dia – 200 mm
HCl, SO2, Cl2 Two stage Scrubber
10
-- Gypsum 650 Collected in plastic
/ HDPE bags &
stored in sludge
storage area
Collection, Storage,
Transportation and
Disposal at Nearest TSDF
or sell to Cement Industry
36.4 Distillation
Residue
55 Collected in barrels
& stored in haz.
waste
storage area
Collection, Storage,
Transportation and sell to
Cement Industry for Co-
processing or Disposal at
Common Incineration Site
D2 Dilute
Sulphuric Acid
880 Collected in tank &
stored in haz.
waste
storage area
To sell manufacturer
Ferrous Sulphate, Copper
Sulphate and Single Super
Phosphate
-- Sodium Sulfite
salt
130 Collected in plastic
/ HDPE bags &
stored in sludge
storage area
Collection, Storage,
Transportation and Sell to
end user
-- Recovered
Acetic Acid
45 Collected in barrels
& stored in haz.
waste
storage area
Collection, Storage,
Transportation and Sell to
end user
D2 Dilute HCl 1200 Collected in tank &
stored in haz.
waste
storage area
To sell manufacturer of
Calcium Chloride and
Dicalcium phosphate
11
2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of the project and project proponent. In case of mining project, a copy
of mining lease/letter of intent should be given.
Identification of the project
Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.
Identification of the project proponent
Presently following are the Directors of the company:-
(1) Mr. Pawan Kumar Goyal
Managing Director
(2) Mr. Rajendra Chandulal Patel
Whole Time Director
(3) Mr. Shravan Goyal
Director
2.2 Brief description of nature of the Project
Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.
2.3 Need for the project and its importance to the country and or region
The objective is to be achieved by:
• Consolidating Business.
• By constantly upgrading the product range.
• Continuously reducing the Costs & improving Quality.
• To generate local employment.
2.4 Demands-Supply Gap
Based on our informal survey of the market with our current customers and various traders,
we have found that there is a big potential for the range of the products we are planning.
These products will be an addition to the current range of our products.
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2.5 Imports vs. Indigenous production
Based on the current cost of indigenous raw materials will make us very competitive against
imported finished products and we will be able to increase the export of our finished
products.
2.6 Export possibility
Depending on the international demand of products we shall explore the more possibility of
exporting the products.
2.7 Domestic/Export Markets
Majority of the products will be used for International market and rest will be used for
domestic market.
2.8 Employment Generation (Direct and Indirect) due to project
Employment would be as per prevailing norms of state government for skilled and unskilled
people for the proposed expansion project for manufacturing specialty chemical.
13
3.0 Project Description
3.1 Type of Project including interlinked and interdependent projects, if any.
Proposed Project For Manufacturing Dyes, Dyes Intermediates And Pigments.
Category: B-5(f)
No interlinked project has been submitted.
3.2 Location (map showing general location, specific location and project boundary &
project site layout) with coordinates.
Map showing general location
14
Project Site Layout
15
3.3 Details of alternate sites considered and the basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
Major factors involved in the selection of site are listed below:
• Site is very well connected by road
• Proximity to Raw Material suppliers
• Availability of sufficient land free from cultivation
• Availability of power evacuation facilities
• Availability of water for industrial use
• Availability of common effluent treatment & disposal facility
Modern infrastructure support and amenities at par with industrial estates in other global
markets, including:
� Efficient transport facilities within the industrial estate and to & fro the city area.
� Environment-friendly zone.
� Uninterrupted power supply.
3.4 Size or Magnitude of Operation
Please refer Section-1.2, Page No. 3
3.5 Project Description with process details (a schematic diagram/flow chart showing the
project layout, components of the project etc. should be given)
Please refer Annexure-III in Form-I.
3.6 Raw material required along with estimated quantity, likely source, marketing area of
final products. Mode of transport of raw materials and finished products.
Raw material requirement is referred as Annexure-I in Form-I.
Raw materials and finished products will be transported by road only.
3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be
briefly outlined.
Every possible effort will be made to reduce fresh water requirement.
N
16
3.8 Availability of water its source, energy/power requirement and source should be
given.
Fuel:
Proposed
Natural Gas 2200 scm / Hr
LDO / FO 560 Liter / Hr
HSD for DG Sets
(for emergency
only.) 80 Liter / Hr
F.O. for lncinerators 40 Liter / Hr
Energy:
4500 KVA from MGVCL
DG set - 2500 KVA (In case of Emergency only)
Water Source
Water requirement will be met through GIDC water supply.
3.9 Schematic representations of the feasibility drawing which give information of EIA
purpose.
RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT
MARKET ASSESSMENT
FINANCIAL REPORT
PROJECT REPORT
INTRODUCTION
MONITORING OF AIR, WATER & SOIL QUALITY & NOISE
LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC
STATUS & BASIC AMENITIES. SITE VISITS BY AND
INTERVIEWS WITH LOCALS
BASELINE
ENVIRONMENTAL
STATUS
ENVIRONMENTAL INFORMATION CENTRE
CENTRAL GROUND WATER BOARD
GUJARAT POLLUTION CONTROL BOARD (GPCB)
PUBLIC HEALTH ENGINEERING DEPT.
AGRICULTURE DEPARTMENT
FOREST DEPARTMENT
IRRIGATION DEPARTMENT
EMPLOYMENT EXCHANGE
HEALTH CENTER
CENSUS DEPT.
INDIAN METEOROLOGICAL DEPT.
SOCIOECONOMIC
STATUS &
INFRASTRUCTURE
PROPOSED
EXPANSION PLANT
FACILITY DESCRIPTION
IMPACTS
METHODOLOGY OF
IMPACT
ASSESSMENT
IDENTIFICATION & ASSESSMENT OF IMPACTS
EVALUATION OF IMPACTS BY MATRIX METHOD
SOURCE OF INFORMATION OVERVIEW OF
E. I. A. STUDIES
ACTIVITIES
ENVIRONMENTAL
MANAGEMENT PLAN
DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR
POLLUTION CONTROL, HAZARDOUS WASTE
MANAGEMENT, GREEN BELT DEVELOPMENT
MONITORING PROGRAM
RISK ANALYSIS
STUDIES &
DISASTER
MANAGEMENT PLAN
SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY
DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS
PREPARATION OF DISASTER MANAGEMENT PLAN
17
4.0 Site Analysis
4.1 Connectivity
• Site is very well connected by road & rail
• Availability of power evacuation facilities
• Availability of water for industrial use
4.2 Land Form, Land Use and Land Ownership
It will be incorporated in EIA Studies.
4.3 Topography (along with map)
We will be incorporated topography in EIA Studies.
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, eco sensitive areas, water bodies (distance from
HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette
notification should be given.
It will be incorporated in EIA Studies.
18
4.5 Existing Infrastructure
Existing Infrastructures facilities are listed below:
Site is very well connected by road
Proximity to Raw Material suppliers
Availability of sufficient land free form cultivation
Availability of power evacuation facilities
Availability of common effluent treatment & disposal facility
4.6 Soil Classification
It will be incorporated in EIA Studies.
4.7 Climatic data from secondary sources
Secondary Sources – Indian Meteorological Department, Ahmedabad and our own weather
station.
4.8 Social infrastructure available
Depending on the growth of the company the required social infrastructure will be
provided.
19
5.0 Planning Brief
5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country
planning/Development authority classification.
Type of Industry: Proposed Project For Manufacturing Dyes, Dyes Intermediates And
Pigments
Facility: Canteen, Administration, Transportation
5.2 Population Projection
It will be incorporated in EIA Studies.
5.3 Land use planning (breakup along with green belt etc.)
Total Area – 79603.62 m2
Plant Area – 21300 m2
Open Area – 6700 m2
Green Belt Area – 23873.62 m2
5.4 Assessment of Infrastructure Demand (Physical & Social)
It will be incorporated in EIA Studies.
5.5 Amenities/Facilities
It will be incorporated in EIA Studies.
20
6.0 Proposed Infrastructure
Sr.
NO.
PARTICULARS LAND AREA (Sq. m) % OF LAND AREA
USE
1 Plant Area 21300 26.76
2 Storage Area (Raw material & finish
goods) & Administration, Lab &
Other Buildings
22600 28.39
3 Utilities 3000 3.77
4 ETP Area 1130 1.42
5 HW Storage Area 1000 1.26
6 Open Area 6700 8.42
7 Green Belt Area 23873.62 29.99
Total 79603.62 100.00
6.3 Green Belt
Company has developed an effective green belt within the factory and on periphery of the
factory. Total Plot Area is 79603.2 m2, out of which 23873.62 m
2 (30%) is Green Belt Area. In
addition to this, majority of the vacant land shall be planted with trees, shrubs and grasses.
6.4 Social Infrastructure
Depending on the growth of the company the required social infrastructure will be
provided.
6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc)
Site is very well connected by road & railway.
6.6 Drinking water Management (Source & Supply of water)
Water requirement will be met through GIDC water supply.
21
6.7 Sewerage System
Sewage pipes would be laid in entire company for the removal and disposal of mainly non-
harmful liquid wastes from the offices, canteen and domestic waste coming from different
sections. These liquid wastes would be treated and disposed by septic tank and soak pit.
6.8 Solid Waste Management
Please refer Section 1.7, Page No. 8.
7.0 Rehabilitation and Resettlement (R & R) Plan
7.1 Policy to be adopted (central/state) in respect of the project affected including home
ousters, land ousters and landless laborers (a brief outline to be given)
There is no habitation on the proposed expansion project area and it is industrial land which
is purchased by company for development of Company, so that R & R policy is not
applicable to this project.
There shall be no displacement of any population in project area.
8. Project Schedule & Cost Estimates
8.1 Likely date of start of construction and likely date of completion (Time schedule for
the project to be given).
We shall start construction after getting environmental clearance and consent to establish.
We shall start production upon making application for CCA.
8.2 Estimated Project cost along with analysis in terms of economic viability of the
project.
Total costs of the project will Rs. 140 Crore. Capital cost of air & water pollution control
system and environmental monitoring equipments will be Rs. 8 Crore.
22
9. Analysis of Proposal (Final Recommendations)
9.1 Financial and social benefits with special emphasis on the benefit to be local people
including tribal population, if any, in the area.
• Employment would be as per prevailing norms of state government for skilled and
unskilled people for the proposed expansion project.
• Social Welfare shall be done.
• Cordial relation with the industry shall be established and representation shall be made
to villagers for help for creation of facilities related to health, education, etc.