pre-feasibility report for proposed establishment of...

Pre-Feasibility Report IG Petrochemicals Limited MIDC Taloja

Pre-feasibility report for

Proposed establishment of synthetic organic chemical

manufacturing unit

By

IG Petrochemicals limited

PROJECT TERMED UNDER SCHEDULE 5 (f) (SYNTHETIC ORGANIC CHEMICALS)

CATEGORY - A

Prepared By

M/s IG Petrochemicals Limited T-2, M.I.D.C Taloja,

Dist : Raigad – 410208, Maharashtra, India

Tel.: 022 - 39289102 Web site: www.igpetro.com

http://www.igpetro.com/


Table of Contents

1 . Executive Summary ........................................................................................................................... 1

2. Introduction of the Project ............................................................................................................... 4

2.1 Identification of the project and Project Proponent ....................................................... 4

2.2 Brief Description of nature of Project ................................................................................... 5

2.3 Need of project with description for region and country ............................................. 5

2.4 Demand – Supply gap .................................................................................................................. 5

2.5 Imports vs indigenous production ........................................................................................ 6

2.6 Export Possibility ......................................................................................................................... 7

2.7 Domestic / Export Markets ...................................................................................................... 7

2.8 Employment Generation due to Project (Direct and indirect) ................................... 7

3. Project Description .............................................................................................................................. 8

Type of Project ............................................................................................................................... 8

Location of the Project ................................................................................................................ 8

Details of Alternative sites ...................................................................................................... 10

Size or magnitude of operation ............................................................................................. 10

Project Description with Processes Details: .................................................................... 10

Raw Material for finished Product ....................................................................................... 13

Resource optimization.............................................................................................................. 14

Water, Energy / Power availability and source .............................................................. 14

Manpower requirement ....................................................................................................................... 15

Waste Generation, management and disposal ................................................................ 15

Manpower ................................................................................................................................. 16

Schematic of EIA Purpose ................................................................................................... 16

4. Site Analysis .......................................................................................................................................... 17

4.1 Connectivity .................................................................................................................................. 17

4.2 Land form, Land use and Land ownership ....................................................................... 17

4.3 Topography ................................................................................................................................... 17

4.4 Existing land use pattern ......................................................................................................... 17

4.5 Existing Infrastructure ............................................................................................................. 17

4.6 Soil Classification ........................................................................................................................ 17

4.7 Climate data from secondary sources ................................................................................ 18

4.8 Social infrastructure available ............................................................................................... 20

5. Planning Brief ...................................................................................................................................... 21

5.1 Planning Concept ........................................................................................................................ 21

5.2 Population Projection ............................................................................................................... 21

5.3 Land use planning ...................................................................................................................... 21

5.4 Assessment of Infrastructure Demand (Physical and Social) ................................... 22

5.5 Amenities / facilities ................................................................................................................. 22

6. Proposed Infrastructure .................................................................................................................. 23


6.1 Industrial area ............................................................................................................................. 23

6.2 Residential Area .......................................................................................................................... 23

6.3 Green Belt ...................................................................................................................................... 23

6.4 Social Infrastructure .................................................................................................................. 23

6.5 Connectivity .................................................................................................................................. 23

6.6 Water Management ................................................................................................................... 23

6.7 Sewage and waste water treatment system..................................................................... 23

6.8 Industrial waste management ............................................................................................... 24

6.9 Solid waste management ......................................................................................................... 24

6.10 Power requirement & supply /source ........................................................................... 24

7. Rehabilitation and Resettlement (R & R Plan) ........................................................................ 25

8. Project schedule and cost estimates ........................................................................................... 26

8.1 Likely date of start of construction and likely date of completion .......................... 26

8.2 Estimated project cost (Economic Viability of the Project) ....................................... 26

9. Analysis of Proposal .......................................................................................................................... 27

List of Annexures Annexure No Description Page no

I Plot possession letter / Plot allotment letter 28-31

II Google image of plant site 32

III Layout plant of the proposed plant 33-34

IV Proposed effluent treatment scheme 35


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1 . Executive Summary

Company Profile

I G Petrochemicals Ltd. (IGPL) is an established market leader in Phthalic Anhydride (PAN) with strong recognition and excellent plant facilities of international standards.

Phthalic Anhydride (PAN) is used in industries such as flexible PVC, plastics, paints, construction, transportation and marine.

IGPL commenced production in the year 1992 with a view to become one of the leading players

in the petrochemicals industry. Today, we are the largest producer of PAN in India. Our dynamic spirit to go beyond the normal realms of success and our relentless will to be the market leader has been the hallmarks of our pursuit of excellence.

IGPL is promoted by the Dhanuka Group in technical collaboration with Lurgi GmbH, Germany.

The plant is located at MIDC, Taloja in Raigad District, Maharashtra, India, 50 Km from Jawaharlal Nehru Port Trust (JNPT), Maharashtra, thus enabling us to provide unsurpassed customer service to versatile and diversified market since 1992.

Phthalic Anhydride (PAN) is used in manufacturing plasticizers, which are most essential in making PVC products, shoe soles, cables, pipes and hoses, leather cloth, films for packaging and other products. It is also used to manufacture alkyd resins used in paints and in the production

of unsaturated polyester resins for building materials, plastic products, textile industries and printing inks. Being a "value driven" company, the values are a part of individual and collective objectives for continuous business excellence.

Equipped with one of the largest capacity at a single location, the Company has the ability to cater to local and international market.

Our growth evolution is captured in the following table

Table 1-1 Growth milestones

Year Description 1988 Incorporated as 100% EOU in technical collaboration with Lurgi

GmbH, Germany. 1992 – 1993 Started production with initial capacity of 45,000 MTPA (PA 1) 1997 – 1998 Brownfield expansion of 50,000 MTPA (PA 2) 2006 – 2007 Debottlenecking of capacity by 26100 MTPA 2008 – 2009 Converted from EOU to DTA 2013 – 2014 Brownfield expansion of 53,000 MTPA (PA 3) with recovery of

Benzoic acid 1000 TPA from residue/effluent & 2.5 MW Captive Power to grid Total PA Licensed Capacity of 169,110 MTPA


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IGPL is an environmentally conscious company. The company has incorporated technologies to recover valuable organics from its effluents and residues. Scrubber effluents from its plants and distillation residues are taken for recovery of Benzoic acid, and after recovery scrubber effluents are taken for recovery of Maleic anhydride recovery to neighbouring unit of Mysore Petrochemicals Ltd located at plot T-1, MIDC Taloja, which will be shortly taken over by IG Petrochemicals limited. Current Maleic anhydride recovered is 6500 TPA. IGPL has already made an application for increasing Phthalic anhydride capacity by 53000 TPA and also additional Maleic anhydride recovery by 1160 TPA. Consequent to this production, IGPL proposes to enter into downstream products viz Plasticizers (DEP/DMP) of capacity 12600 TPA using part of Phthalic anhydride produced. The ToR for the enhanced production has been granted by MoEFCC and EIA for the enhanced production is under finalization and will be

considered by EAC shortly for grant of Environmental clearance.

IGPL now wishes to enter into growing market segment of chemical (Malic acid) manufacture based on Maleic anhydride which is mainly used in fruit based / flavored beverages.

Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide EIA

Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic

chemicals manufacturing units. This proposed project falls under category ‘A’ and schedule item

no. 5(f): Synthetic organic chemicals.

The project brief is summarized in the table below

Project summary at a glance

Sr No Particulars Details

1 Name of Company IG Petrochemicals Limited

2 Products (Proposed) Malic acid 5,000 TPA

3 Location Plot No T-2 (part), MIDC Taloja, Tal Panvel, Dist

Raigad

4 Name of the project 1) Proposed establishment of Synthetic organic

chemical (Malic acid) manufacturing facility.

5 Total land area of the plot 17,150 sq m

6 Major raw material Maleic anhydride & Fumaric acid

7 Water requirement and source 344 cmd , MIDC

8 Power requirement and source 1500 Kw, MSEDCL

9 Proposed manpower ~ 80 Nos (Skilled and unskilled)

10 Waste water quantity (estimate) Refer section 3.9

11 Air emissions Expected emission of NOx, SO2 & Particulate

matter from coal/ FO fired boiler

12 Solid Waste Refer section 3.9

13 Project cost estimate ~ Rs. 30 Crores


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The Land shall be used as “Industrial” land thus there shall be no change in land use.

This industrial plot is allotted by MIDC.

(Plot allotment letter / plot possession letter is at Annexure I).

MIDC has provided all basic infrastructures like Electrical Power, water supply, the internal road

network, external approach road and networking with CHWSTDF (Common Hazardous Waste

Storage Treatment and Disposal Facility).

There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological

monuments, sanctuaries, etc.

The land and infrastructure is made available by MIDC and the raw material is easily available

(a) captively – in way of Maleic anhydride and (b) through the easy transport via road

connectivity by local suppliers as well as imported one.


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2. Introduction of the Project

2.1 Identification of the project and Project Proponent

It is proposed to manufacture Malic acid based on growing market demand.

Proposed products are summarized below,

S. N. Name of Product Quantity (TPA) 1 Malic acid 5,000

IGPL is promoted by the Dhanuka Group through Mysore Petro Chemicals Ltd & other group

companies in technical collaboration with Lurgi GmbH of Germany. The Management team comprises qualified & dedicated professionals. Promoters/ Directors and their background are as follows:

Mr. M M Dhanuka (Chairman): B.E. (Chem), aged 68 years, is a Promoter of the Company and is associated with the company since inception and is also a Promoter & Managing Director of Mysore Petro Chemicals Ltd, a group concern.

Mr. Nikunj Dhanuka (Managing Director): B. Com, MBA aged 48 years is a Promoter of the Company. He has vast experience in finance, banking and all major functions of the Company and is a Promoter & Director of Mysore Petro Chemicals Ltd, a group concern.

Mr J K Saboo (Executive Director): B. Com, LLB. Aged 62 years. He is associated with the company since 1991 and has more than 35 years’ experience in petrochemical

industry. He is in charge of the Taloja Plant and looks after the overall activities of the plant.

Shri Rajesh Muni: B.Com (Hons.), F.C.A. Aged 64 years he is an Independent & Non-Executive Director and associated with IGPL since 2002. He is a senior partner of M/s. R.R. Muni & Co and has more than 30 years of experience in auditing and taxation areas. He was also the President of Bombay Chartered Accountants’ Society.

Dr. A K A Rathi: M.E. (Chem), Ph.D (Chem) and Diploma in Management and Integrated Coastal Zone Management. Aged 67 years he is an Independent & Non-Executive Director associated with IGPL since 2009. He has worked in Industries Department as Chief Technical Advisor and as Director (Environment) in Forest and Environment Department in the Government of Gujarat. He was associated with Faculty of Planning

and Public Policy, CEPT University, Ahmedabad, Gujarat. He has contributed a number of articles on various aspects of industrial development, management, safety and environment in different journals, periodicals etc. and is a visiting professor to various engineering and management colleges.

Shri P H Ravikumar: B.Com., CAIIB, ACIB (Lond.), FCISI (Lond.) (Hons.)Aged 65 years is a retired Banker and is an Independent & Non-Executive Director associated with IGPL since Oct, 2012. He has vast knowledge and experience in corporate banking functions, treasury, retail, agri business verticals and also associated with Commodity and Derivatives exchanges.


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Dr. Vaijayanti Pandit: M.A. in Political Science, Diploma in Journalism and Mass Communications and Ph.D in Management Studies Aged 65 years she is an Independent & Non-Executive Director associated with IGPL since March, 2015. She has built up a vibrant organization of woman entrepreneurs, managers, professionals from 1982-99. She was Secretary of Indian Merchants Chambers for the period 1999-2006 and was also a Director of Federation of Indian Chambers of Commerce and Industry (FICCI) from 2006-12, which is India’s leading apex industry body.

2.2 Brief Description of nature of Project

It is an establishment project for manufacturing of Malic acid. The estimated capital cost of the

project is approximately Rs 30 Crores.

2.3 Need of project with description for region and country Malic acid is an organic compound with the formula HO2CCH2CHOHCO2H. This carboxylic diacid is the active ingredient in many sour or tart foods. Malic acid is found mostly in unripe fruits. Malic acid has two stereo isomeric forms (L- and D-enantiomers), though only the Lisomer exists naturally. The pleasant, refreshing experience of an apple or cherry is partly caused by Malic acid. Malic acid results into smooth, persistent sourness which allows it to be blend with multiple food acids, sugars, high intensity sweeteners, flavors, and seasonings to create unique taste experiences in foods, beverages and confections. Major applications

• Enhances flavors • Provides sourness/tartness • Controls growth of microorganisms (preservation) • unsaturated polyester resins, copolymer and alkyd resins • Paper sizing, Printing inks • Agrochemicals, Antihistamine drugs • Used to adjust pH (as an acidulant) in baking powders, beverages, confections and food,

including cereal, sports and energy bars, and sports, energy and protein drinks

(including fortified and enhanced water)

• The following pie chart shows world consumption of DL-malic acid.

2.4 Demand – Supply gap

In 2009, beverages both liquids and powders and mainly in fruit flavored beverages, accounted for approximately 53% of the world consumption of DL-malic acid; confections and food account for most of the remainder, at 39%.


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Current worldwide major manufacturers are,

Polynt Italy

Bartek Canada

Tate & Lyle USA

Fuso Japan

ISEGEN South Africa

Thirumalai Chemicals, India

2.5 Imports vs indigenous production Malic Acid manufacturers/sellers in India Thirumalai Chemicals Limited is the only large scale producer of Malic acid in India.

Import export data (2001-2010) is given below,

Year Import qty (Ton) Unit price ($/kg)

2011 190 2.32

2012 441 2.49

2013 349 2.38

Major importing countries are China, South Africa, USA


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2.6 Export Possibility

Worldwide Malic acid consumption

Malic acid consumption (world wise and India)

Growth rate 3 % (assumption)

Year 2006 2009 2011

Worldwide consumption (Ton/year) 55,000 60,100 63,760

Consumption in India (Ton/year)

(assuming 5 % share of global market)

2,750 3,005 3,188

2.7 Domestic / Export Markets

Domestic consumption of Malic Acid in India: From the figure above, it can be seen that India’s share the worldwide consumption is about 5%. This indicates that in the year 2011, the estimated malic acid consumption in India would be around 2,500-3,500 MT. Domestic production of Malic acid is led by Thirumalai Chemicals with a few other minor players. Thirumalai could be producing around 1000 -2000 tons/year.

Major use of Malic acid

Beverages (both liquids and powders and mainly in fruit flavored beverages) – 53 %

Confections and food – 39 %

As can be seen from the table above, the main use of Malic acid is in beverages and particularly, fruit based/flavored beverages. The global and Indian market processed foods/beverages have been growing steadily. Particularly in India, the demand for these products has been increasing steeply in the last few years.

2.8 Employment Generation due to Project (Direct and indirect)

IGPL expect to generate employment to about 80 personnel (skilled and non-skilled).

Besides this IGPL expect to contract security, gardening, housekeeping, painting etc. which will

lead to more employment in the region. Additionally there will also be indirect employment of

service providers such as Transportation, warehousing, maintenance, civil and mechanical, pest

control, painting etc.


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3. Project Description

Type of Project

The project is Synthetic organic chemical product manufacturing which are of organic type.

There is no interlinked or interdependent project.

Location of the Project

The plot is located at Taloja MIDC, in Raigad district.

Location of MIDC in the Raigad district map is shown below.

Plot No. T-2 (part) in MIDC Taloja located in Panvel Tehsil and district of Raigad in Maharashtra.

Details of Nearest Infrastructure Facilities


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Sr. No Destination App. Distance of Project Site

1 Nearest National Highway NH-4 4 km 2 Nearest Airport Mumbai 28 km 3 Nearest Railway Station Taloje Panchnand 4.5 km 4 Nearest Port JNPT sea port 30 km

The Geographical Location of this plot is at 190 05’16.62” N Latitude and 730 07’ 31.87” E

Longitude with an elevation of 10 meter above sea level MSL.

Site coordinates are as follows:

Direction Longitude Latitude

North east corner 190 05’20.94” N 730 07’ 32.33” E

North west corner 190 05’20.52” N 730 07’ 30.18” E

South east corner 190 05’13.25” N 730 07’ 35.00” E

South west corner 190 05’12.59” N 730 07’ 30.46” E

This site is in premises of MIDC area which is meant for these types of Industries.

Google Image of the proposed site is attached as Annexure II.

Land Form: Land is on plain contour, it is flat terrain and is fallow land.

Land Ownership: Land ownership is with project proponents (IG Petrochemicals Limited)

Existing Land use Pattern: The Land is reserved for Industrial use & the proposed project shall be at the same plot. MIDC Taloja is a multi-product industrial estate Existing Infrastructure: Presently there is an existing Infrastructure around the site.

Infrastructure like water, electricity, telephone facility, roads already available. Other

Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at

Panvel Town (which is at distance of about 7 km)

MIDC Taloja provides many basic facilities like uninterrupted water supply, power and Road

Network. This site appeared to be environmentally best as also from the business angle and

therefore this option was finally adopted. This site is inside MIDC and means safe transportation,

less need of Utilities, less constructing buildings and roads, less fuel, less water with

optimization of infrastructure.


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There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological

monuments.

The location justification for the project is as under

Availability of required land and infrastructure for locating the establishment for the

organic chemical manufacturing.

Suitability of land from topography & geological aspects, synergy and business point of

view

Proximity to raw material source (Maleic anhydride from existing IGPL/MPCL unit) and

manufacturing facility so gives advantage of existing facility, technical manpower etc

Proximity to rail / road to facilitate transport of equipment /materials/ product

Availability of adequate quantity of water to meet water requirements.

Lay-Out

Refer Annexure III for the proposed plant site layout plan.

Details of Alternative sites Considering that Maleic anhydride a major raw material is available at existing plot T-1, IGPL

sought a land from MIDC near existing site to make this and other downstream products. No

alternative sites were examined

Size or magnitude of operation

The project is for the manufacture of Malic acid 5000 Tons per year.

Project Description with Processes Details:

Malic acid is an organic compound with the molecular formula C4H6O5. It is a Dicarboxylic

acid that is made by all living organisms, contributes to the pleasantly sour taste of fruits, and is

used as a food additive. Malic acid has two stereoisomeric forms (L- and D-enantiomers), though

only the L-isomer exists naturally. The Salts and Esters of Malic acid are known as malates. The

Malate anion is an intermediate in the Citric acid cycle.

Manufacturing Process

The process and technology for the manufacture of Malic Acid from Maleic Anhydride is

proposed to be supplied by ISGEN South Africa.

Maleic Anhydride is dissolved in water to get solution of Maleic Acid. The solution of Maleic Acid

is fed to reactor with catalyst and the reaction is carried out under pressure. Maleic acid gets

partly converted first to Fumaric acid simultaneously Fumaric Acid gets partially converted to

https://en.wikipedia.org/wiki/Organic_compound

https://en.wikipedia.org/wiki/Molecular_formula

https://en.wikipedia.org/wiki/Dicarboxylic_acid

https://en.wikipedia.org/wiki/Dicarboxylic_acid

https://en.wikipedia.org/wiki/Stereoisomeric

https://en.wikipedia.org/wiki/Salt_(chemistry)

https://en.wikipedia.org/wiki/Ester

https://en.wikipedia.org/wiki/Anion

https://en.wikipedia.org/wiki/Citric_acid_cycle


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Malic Acid in the reactor. The reactor product is solution of Malic acid and Fumaric Acid and

small quantity of unreacted Maleic acid in water.

The reactor product mixture is evaporated to crystallize out Fumaric Acid while Malic Acid and

unreacted Maleic acid remains in solution. It is filtered, Fumaric Acid is recycled back to reactor

while filtrate is crude Malic Acid & unreacted Maleic acid in solution.

Crude Malic Acid solution is evaporated to crystallize crude Malic Acid. It is filtered off and

filtrate is recycled back to evaporation and partly to reactor.

Crude Malic Acid crystals dissolved in water, filtered to remove insolubles (residual fumaric

acid) which is recycled back to reactor. The solution of Malic Acid is then given color removal

treatment to obtain pure Malic Acid solution.

The solution is then fed to evaporative crystallizer to get crystals of pure Malic Acid. It is

subjected to drying to get finished product.

1) Hydrolysis of Maleic Anhydride to Maleic Acid

2) Isomerisation of Maleic acid to Fumaric acid

Hydrolysis of Maleic Anhydride to Maleic Acid

O O

CH C CH C OH

O + H2O

CH C CH C OH

O O

WATER MALEIC

MALEIC ACID

ANHYDRIDE

(MAN) (MAC)

O O

CH C OH OH C CH

HEAT

CH C OH CH C OH

O O

MALEIC ACID FUMARIC ACID

(MAC) (FAC)


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3) Hydration of Fumaric acid to Malic acid

PROCESS FLOW DIAGRAM OF MALIC ACID MANUFACTURE FROM MALEIC ANHYDRIDE

The process is a high pressure reaction; adequate safety measures are required. Major pieces of equipment includes: -

Agitated vessels Reactor Belt Filter Leaf Filter Centrifuges Forced circulation evaporators/crystallizers

O O

OH C CH + H2O HEAT OH C C OH

CH C OH HO C CH2

O O

FUMARIC ACID WATER MALIC ACID

(FAC) (MAL)

DISSOLUTIO

N&HYDROL

YSIS MAN

WATER REACTION(isomerizat

ion & hydrolysis)

EVAPORATIVE

CRYSTALLIZATION

MAL + FA

FILTRATION

EVAPORATIVE

CRYSTALLIZATION

FILTRATION

DISSOLUTION

EVAPORATIVE

CRYSTALLIZATION

FILTRATION

DISSOLUTION

DISSOLUTION

COLOR REMOVAL

DRYING SCREENING

FAC CAKE

FILTRATE CRUDE MAL

CRUDE MAL CRYSTALS

MAL SOLUTION

CAKE RESIDUAL FAC

FILTRATE MAL SOLUTION

PURE MAL

SLURRY

PURE MAL CAKE

PURE MALIC ACID

FILTRATE


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Vacuum evaporator/crystallizers. Centrifugal/canned pumps Steam jet ejectors Dryer Siefter Bagging machine Intermediate storage tanks for process liquid Intermediate storage tanks for condensate/filter washings

Raw Material for finished Product

Raw Materials:

The basic raw material for the proposed production capacity is submitted herein below.

Source for Raw Material Procurement: The major raw materials are imported. Other

materials are easily available in the local market.

Mode of Transport of Raw Materials: Mode of transport to site is by road truck/tankers.

List of Major Raw Material

Sr. No. Raw Material Nature Estimated total quantity in TPA 1 Maleic anhydride Solid 3850

2 Caustic lye (48%) (for DM Plant) Liquid 20

3 HCl acid (30%)(for DM Plant) Liquid 35

4 Furnace oil Liquid 3300

Proposed major bulk liquid storages at site shall be as follows:

Details of Bulk Liquid Storages

Sr. No. Raw Material No. of tanks MOC Capacity (KL)

1 Caustic lye 1 CS 20

2 30% HCl (for DM plant) 1 HDPE 20

3 Recycle water tank 1 SS316 40

4 Fumaric acid mother liquor tank 1 SS316 40

5 Maleic anhydride mother liquor tank 1 SS316 40

6 Malic acid solution tank 1 SS316 40

7 Pure malic acid solution tank 1 SS316 40

8 Furnace oil 1 CS 50


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Resource optimization IGPL intend to establish the manufacturing capacity of Malic acid product as mentioned above.

The resource optimization shall be carried out at the site and with other IGPL unit (which is

across the road) in order to reduce wastage and minimum transport needs.

Water, Energy / Power availability and source Power: The proposed power requirement for the establishment is 1500 KW which will be

source from MSEDCL grid.

It is proposed to install 1 DG set of 200 KVA capacity based on HSD as fuel as emergency backup

in case of power outage (mainly for Plant illumination and UPS back up). Diesel requirement for

DG set (in case of emergency) shall be 50 lit/hr at rated capacity.

Water: The total estimated water requirement for the establishment shall be ~ 344 cmd mainly

for domestic, process, Boiler & cooling purpose. It will be source from MIDC water works.

Fresh water requirement and waste water generation for proposed establishment shall be as

follows:

Proposed Fresh water requirement

No. Description Proposed water requirement (cmd)

1 Domestic 8 2 Industrial cooling/boilers 192 3. Processing whereby water gets polluted and

pollutants are easily biodegradable 134

4. Gardening 10 Total 344

Waste water generation & Disposal

No. Description Expected Generation (cmd)

Disposal

1. Domestic effluent 6 Treated effluent shall be disposed to common effluent treatment plant

(CETP) and partly used for gardening within site.

2. Trade effluent 137

Total 143

Steam / Process heat Requirement:

It is proposed to install one Boiler (based on coal / Briquette/ FO as fuel) of capacity 10 ton per

hour steam. This will take care of steam/process heat requirement of the project.


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Utilities:

Following utilities shall be established at site in addition to boiler,

No. Unit Estimated requirement Capacity of unit

1 DM water plant 6 CMH 10 CMH

2 Cooling tower 670 CMH 800 CMH

3 Air compressor 200 NCMH 250NCMH

4 Chilling unit 50 TR 60 TR

Fuel Requirement: (for boiler)

Fuel requirement for

10 TPH Boiler

Coal: 45 TPD

OR

Briquette: 45 TPD

OR

FO: 10 TPD

Manpower requirement

The project will have major employment generation in terms of direct and contract employment (~ 80 nos).

Waste Generation, management and disposal

(a) Non-Hazardous Solid Waste:

Sr No

Type of waste Category Quantity Mt/day Disposal

1 Ash from boiler - 13 (estimate) (for coal

as fuel) Brick manufacturer / landfill.

(b) Hazardous Waste:

The quantification of hazardous solid waste generated from proposed activities is presented as

follows:

Sr No

Type of waste Category Quantity Disposal

1 Solids from tank cleaning 3.2 10 TPA Sent to CHWTSDF 2 Discarded

containers/Barrels/liners 33.1 50 Nos/A Washed & reuse

3 Discarded bags used for hazardous chemicals

33.2 30 TPA Sent to CHWTSDF

4 Chemical sludge from water treatment

35.3 5 TPA Sent to CHWTSDF

5 Spent Carbon from ETP 35.3 8 TPA Sent to CHWTSDF Note: Above quantities are estimates, Quantity shall be worked out during EIA stage.


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Manpower

Manpower: Expected manpower requirement for the establishment shall be as follows:

Description Proposed, No (approx.) Skilled 36

Unskilled / Contract 44 Total 80

Schematic of EIA Purpose

Figure: Schematic representation of the feasibility drawing which gives EIA purpose

-


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4. Site Analysis

4.1 Connectivity

This proposed IG Petrochemicals establishment facility shall be located at Plot T-2 (part) which is acquired adjacent plot at MIDC Taloja in Raigad district, Maharashtra.

4.2 Land form, Land use and Land ownership

Land Form: Land is on plain contour, it is flat terrain.

Land Ownership: Land ownership is with project proponents (IG Petrochemicals limited)

4.3 Topography

The project site is located on a relatively level terrain at an average elevation of 15 m above MSL and forms part of catchment area of Kasardi/Kalundri river. Mountain ranges in the area run in the North – South direction. The Malang gadh is located to the North east (having height of 437m) which stretches down south (612m high- 5-6km to the east) and to the South east (medium sized peaks about 400m high, 6-7 km away). There is another range (Parsik hill) located about 6-7km to the west also running in North-South direction and separating the MIDC

Taloja from Navi Mumbai/MIDC, TTC.

The area has a coastal climate with monsoon occurring between June to September. Like any other coastal area, wind speed, relative humidity is moderate to high and temperature variation is minimal.

Micrometeorological information for IGPL, Taloja was collected by installing a mechanical weather station at project site. Data was collected for wind speed, wind direction, temperature, relative humidity and rainfall. Whereas the first two parameters viz. wind speed and direction play a vital role in dispersion of pollutants the later ones i.e. humidity and precipitation are important to find amount of deposition for the region.

4.4 Existing land use pattern Industrial use

4.5 Existing Infrastructure Infrastructure is provided by MIDC Taloja.

4.6 Soil Classification

District Raigad is one of the coastal districts of Konkan region of Maharashtra, spread over an area of 7152 km2. It shows variation in topography from high altitudinal Sahyadri hill ranges to


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coastal plains. The soils of the district are formed from the predominating rock formation i.e. Deccan Trap. According to the topographical situation and location, soils in Raigad district are grouped as Forest, Varkas, Rice, Khar or Salt, Coastal Alluvial and Laterite soils. District receives average 3029mm annual rainfall mostly contributed by southwesterly monsoon. These climatic and edaphic conditions support different types of forests.

4.7 Climate data from secondary sources Climate:

MIDC Taloja comes in Raigad district of Maharashtra. The climate of this district is typical of that on the west coast of India, with plentiful and regular seasonable rainfall, oppressive weather in

the hot months and high humidities throughout the year. The summer season from March to May is followed by the south-west monsoon season from June to September. October and November form the post-monsoon or the retreating monsoon season. The period from December to February is the cold season.

Rainfall:

The district has a network of eleven rain gauge stations with records extending to 82 years for most of the stations. The south-west monsoon commences by about the first week of June and the rains continue till about the beginning of October. The average annual rainfall for the district as a whole is 3,028.9 mm. (119.25"). The rainfall increases rapidly from the coast Howards the Western Ghats on the eastern border of the district. In the coastal strip the

annual rainfall decreases from south to north. Uran and Alibag at the northern end of the coast get annually 2,072.3 mm. (81.58") and 2,080.8 mm. (81.92") of rain, respectively, Matheran gets as much as 5,167.5 mm. (203.45") of rain annually. Nearly 95 per cent, of the annual rainfall is received during the south-west monsoon months, and the rainfall in October forms the major portion of the rest. July is the month with the heaviest rainfall, the same being 38 per cent of the annual rainfall.

Temperature:

Being a coastal district the diurnal (daily) and seasonal variations of temperature are not

large. The period from March to May is one of increasing temperatures. May is the hottest month with a mean daily maximum temperature at 31.7°C (89.1°F) and the mean daily minimum temperature at 26.4°C (79.5°F). Fresh breezes from the sea relieve the oppressive

heat particularly in the coastal regions in the afternoons. The onset of the south-west monsoon early in June brings down the temperatures slightly. After the withdrawal of the south-west monsoon by the end of September the day temperatures increase slightly and the weather in October and November is almost like the summer months. In the period from December to February the weather is cooler than in the post-monsoon months.

Humidity:


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The air is humid throughout the year. Relative humidity is on an average over 80 per cent during the south-west monsoon season. In the rest of the year the relative humidity is between 65 per cent and 75 per cent.

Cloudiness:

During the south-west monsoon season skies are heavily clouded to overcast. In May and October the clouding is moderate. Clear or very lightly clouded skies are common in the rest of the year.

Winds:

Winds are very strong and blow from west or south-west during monsoon season. During the period from October to December winds are generally moderate but sometimes strong in

October and blow from directions between north-east and south-east. In the three months from January to March the winds continue to be moderate and are predominantly from directions between north and east. In April while there is a slight strengthening of wind, the direction is variable. In May there is a further strengthening of winds and the directions are between south-west and north-west.

The data on wind patterns are pictorially represented by means of wind rose for Winter Jan-Feb 2014 in figure below. The winds were moderate and are predominantly from directions between north and east. Macro level wind patterns seem to be affected by the presence of Arabian sea to the South west and the mountain ranges which deflect the winds. Calm conditions were recorded during the monitoring period. Overall meteorological and topographical condition indicates good dispersion characteristics at Taloja.

Wind Rose Winter 2014 (Jan-Feb 2014)

Special weather phenomena:


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In association with cyclonic storms in the Arabian sea in the post-monsoon months and to a lesser extent in May, the district experiences very strong winds, sometimes reaching gale force, particularly very near the coast and also heavy widespread rain. Occasionally these storms may cross the coast in the northern part of the district and cause heavy damage. Thunderstorms occur in April and May and just before the onset of the monsoon and in the late September to the middle of November.

4.8 Social infrastructure available

Nearest town is Panvel which is about 8 km from site. Social infrastructure such as schools,

Hospitals, market place and other amenities are easily available. Transport facilities by rail and

road are available.


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5. Planning Brief

5.1 Planning Concept

Plot is at well-established MIDC Taloja area Purified Water supply from MIDC Road facility with illumination. Infrastructure facilities available established MIDC site Integration with the existing manufacturing facility

5.2 Population Projection

Raigad District is a district in the state of Maharashtra, India. It is located in the Konkan region. The district was renamed after Raigad, the fort that was the former capital of the Maratha leader Shivaji Maharaj, and is located in the interior regions of the district, in dense forests on a west-facing spur of the Western Ghats of Sahyadri range. In 2011 the district had a population of 2,635,394, compared to 2,207,929 in 2001. In 2011 urban dwellers had increased to 36.91% from 24.22% in 2001. The district is bounded by Mumbai Harbour to the northwest, Thane District to the north, Pune District to the east, Ratnagiri district to the south, and the Arabian Sea to the west. It includes the large natural harbor of Pen-Mandwa, which is immediately south of Mumbai harbour, and forming a single landform with it. The northern part

of the district is included in the planned metropolis of Navi Mumbai, and its port, the Jawaharlal Nehru Port. The district includes towns / cities of Panvel Alibag, Mangaon, Roha, Pen, Khopoli, Kharghar, Taloja, Khalapur, Uran, Patalganga, Rasayani, Nagothana, Poladpur, Alibag, Karjat and Mahad. The largest city both in area and population is Panvel. The district also includes the isle of Gharapuri or Elephanta, located in Uran which has ancient Hindu and Buddhist caves.

In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345

and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which

males were 1,117,628 and remaining 1,090,301 were females. Raigad District population

constituted 2.34 percent of total Maharashtra population.

In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population.

There was change of 19.31 percent in the population compared to population as per 2001. In

the previous census of India 2001, Raigad District recorded increase of 20.99 percent to its

population compared to 1991.

The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas.

5.3 Land use planning

Refer area statement.

https://en.wikipedia.org/wiki/Districts_of_Maharashtra

https://en.wikipedia.org/wiki/Maharashtra

https://en.wikipedia.org/wiki/India

https://en.wikipedia.org/wiki/Konkan

https://en.wikipedia.org/wiki/Raigad_fort

https://en.wikipedia.org/wiki/Maratha

https://en.wikipedia.org/wiki/Shivaji_Maharaj

https://en.wikipedia.org/wiki/Western_Ghats

https://en.wikipedia.org/wiki/Mumbai_Harbour

https://en.wikipedia.org/wiki/Thane_District

https://en.wikipedia.org/wiki/Pune_District

https://en.wikipedia.org/wiki/Ratnagiri_district

https://en.wikipedia.org/wiki/Arabian_Sea

https://en.wikipedia.org/wiki/Mumbai_harbour

https://en.wikipedia.org/wiki/Navi_Mumbai

https://en.wikipedia.org/wiki/Nhava_Sheva

https://en.wikipedia.org/wiki/Nhava_Sheva


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5.4 Assessment of Infrastructure Demand (Physical and Social) No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC

area.

5.5 Amenities / facilities Amenities and facilities are available in nearby city Panvel. The plot is located in well-developed

MIDC Taloja.


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6. Proposed Infrastructure

Since the establishment is planned at new site in developed industrial area, no special/specific

development is anticipated. Company will have to do internal site development only. Company

has not planned any residential area at the proposed site.

6.1 Industrial area The plot is located in MIDC Area at MIDC Taloja, Tal Panvel, Dist. Raigad.

6.2 Residential Area No Residential area has been proposed within the plant site.

6.3 Green Belt Green belt of adequate area within and around the project site shall be carried out as per

industries norms and requirement.

6.4 Social Infrastructure Local people will be given preference wherever found suitable for all the jobs in the plant, direct

as well as indirect. Thus, the project shall have a positive impact on the employment pattern of

the region. Economic status of the local population will improve due to increased

ancillary/business opportunities, thereby making positive impact. Educational, medical &

housing facilities will improve due to the proposed project.

6.5 Connectivity This proposed establishment project facility shall be located at Taloja MIDC area, in Raigad

district, Maharashtra. The Site is 8 km from Panvel town and 4 km from nearest railway Station.

The land and infrastructure is made available by MIDC and the raw material is easily available

through the easy transport via road / sea connectivity.

6.6 Water Management The total water requirement is about 344 cmd for Domestic, boiler/cooling, and process. The

source of water shall be from MIDC. The water supply will be through the good offices of MIDC.

We will not be encroaching on anybody’s water source.

6.7 Sewage and waste water treatment system Sewage from domestic waste water and waste water from processes shall be treated in proposed

combined effluent treatment plant.


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Expected influent quality parameters of domestic sewage and trade effluent to combined

effluent treatment plant, and treated effluent from combined effluent shall be as follows,

Sr

No

Description Unit Expected domestic

waste water quality

parameters

Expected trade

effluent quality

parameters

Expected treated

effluent quality

parameters

1 pH - 5 - 7 3 - 4 5.5 – 9

2 Oil & Grease mg/lit 100 - 150 - < 10

3 BOD mg/lit 300 - 500 300 - 400 <100

4 Suspended

solids

mg/lit 400 - 600 200 - 300 <100

5 COD mg/lit 300 - 500 800 - 1200 <250

6 Chloride (as Cl) mg/lit 100 300 - 400 <600

8 TDS mg/lit 400 - 600 ~ 800 <2100

The combined ETP shall constitute of primary (Equalization, pH correction, settling), secondary

(biological treatment followed by sludge settling) and tertiary treatment (filtration and

activated carbon treatment).

The treated effluent shall be partially used within the plant site for gardening/green belt

maintenance and balance shall be discharged to CETP.

Schematic block diagram of proposed effluent treatment scheme is given at Annexure IV.

6.8 Industrial waste management Refer above 3.9

6.9 Solid waste management Refer above 3.9

6.10 Power requirement & supply /source Power requirement is 1500 kw shall be sourced from MSEDCL.


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7. Rehabilitation and Resettlement (R & R Plan)

The proposed activities are in the acquired neighboring plot of the company which is located in

Taloja MIDC area. It does not require acquisition of Land and the Infrastructure so there will be

no any kind of activity of Rehabilitation and Resettlement carried out.


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8. Project schedule and cost estimates

8.1 Likely date of start of construction and likely date of completion

It is expected that the project shall be completed within 24 months from date of grant of

Environmental clearance.

8.2 Estimated project cost (Economic Viability of the Project)

Total estimated project cost is Approximately Rs. 30 Crores.


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9. Analysis of Proposal

Financial and Social Benefits

Since the product is niche product there is huge export potential. We expect to cater

international market with 80 % of our finished products. Besides profit to the organization this

will earn valuable and much needed foreign exchange to our Country.

Besides this the project will give direct employment to about 80 personnel apart from service

providers such as Transporters, Local suppliers, Painters, Plumbers etc.


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Annexure I

Land allotment / Possession letter


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30


31


32

Annexure II

Site & surrounding study area of 10 km radius

Site and surrounding area 1 km radius


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Annexure III

Proposed Layout Plan


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Proposed area statement

No Description Proposed area, sq m

1 Proposed security cabin 40

2 Proposed weighbridge 125

3 Proposed MSEB receiving station 660

4 Proposed DG shed 96

5 Proposed workshop, store, changing room and

canteen (Ground + 1) (Area 300 x 2)

600

6 Proposed admiration building (G +1) (100 x 2 ) 200

7 Proposed warehouse 1500

8 Proposed control room ( G + 1) (150 x 2) 300

9 Proposed Plant building ( G + 2) ( 1431 x 3) 7293

10 Proposed utility area 673.6

11 Proposed Boiler area 3026

12 Proposed hazardous waste room 80

13 Proposed ETP ( 30 x 30 ) 900


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Annexure IV

pre-feasibility report for proposed establishment of...

Documents