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PrefeasibilityReport–M/s.Aarav Fragrances & Flavors Pvt Ltd

PREFEASIBILITY REPORT

“Expansion Of Existing Production Capacity For

Fragrances, Flavors & Manufacturing Chemicals”

By

Aarav Fragrances & FlavorsPvt. Ltd.

Gut No 167,169,170,171,296,Vill. Lakhamapur,

Tal. Wada,District: Thane, Maharashtra

Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.

Synopsis

1. Introduction

2. Justification

3. Location

4. Recourses

5. Process

6. Pollution Control

7. Background Study

8. Safety

9. Benefits

10. EIA structure

11. Scoping

12. Conclusion


1. Introduction

M/s Aarav Fragrances and Flavors Pvt Ltd are desirous to expand to manufacture new products having either

raw material synergy or superior quality and technology to meet demands in India as well as for further

producing the fragrance and flavors at Aarav Fragrances and FlavorsPvt Ltd, Gut No

167,169,170,171,296,Vill. Jamghar -Lakhamapur, Tal. Wada, District: Thane, Maharashtra

The existing industrial unit is only manufacturing facility for Fragrances and Flavors. The industry now

proposes to enhance the manufacturing capacity of the present Fragrances & Flavors, and further the it is

proposed to add additional capacity tomanufacture the chemicals that could be used in house as well as cater

to the open Market, this will reduce the costs of the fragrances and flavors and make them more competitive

in the Indian as well as export markets.

Indian and worldwide demand for fragrances, flavors, perfumery chemicals and related specialty chemicals

is increasing steadily.

2. Justification

The Indian consumer industry is one of the world’s largest by volume and is likely to lead the manufacturing

sector of India. Several private sector projects with huge amount of investments have been initiated but

could not attend the speed of development for the need of good quality material. Over the last decade,

there has been a sizeable growth in fragrances and flavors sector both in small, medium and large scale units.

This has given rise to many small and medium scale units. There is a ever growing requirements

of the consumers in India and also the world markets. Thus there is a gap in demand and supply. Our efforts

of generating products, by-products, downstream products and recycling - reprocessing are indeed needed.

With multinational fragrance and flavor companies enhancing their presence in India, the long-term

prospects of the fragrances and flavors industry seems verybright. The intermediates proposed will substitute

imports and compliment the products in terms of costs.

The fate of industrialization depends on the proper and effective conjugation of large and medium/small

scale industries each supporting each other in their requirement to bridge the gap between demand and

supply. In order to be competitive in the global market this synergy between large & medium/small scale

industries is a prerogative. Therefore considering the above, large companies do require the help of small

units to support them, the main target is to give the consumer superior quality products at a competitive

price. In addition, it is also examined whether industry had made complianceas expected in


Consent to Operate by MPCB for existing production.

S.No. Condition Compliance

1 Addressstatus Continuousthesamenochange

2 No. &Validity Validtill30.09.2015

3 Productsize Sr.no. Product Capacity

(TPM)

1 Fragrance/Perfumes &

Flavors

70

4 Waste water

quantity

8.5m3/dpermitted.

5 Waste

waterTreatment

Foundinlimit

6 ECE Presently NA

7 LDAR Leakdetection&repairprogramwith

monitoringprotocolundertakenas consented.No–

towardincident reported.Work zoneambiancecognizes

8 Hazardouswaste MembershipofCHWTSDF to be obtained

3. Proposal:

The Industryproposedtoproduceasunder:

Sr

No

Products Prese

nt

MT

/M

Propose

d MT/M

Total

MT/M

Field Of Application

1. Fragrances/Perfumes & Flavors 70 210 280 Fragrances & Flavors

2.

Perfumery Esters by hot esterification/

addition of organic acid into olefin/ trans

esterification/ reacting alkali halide with

sodium salt of corresponding acid/Cold

Esterification -Ethyl Esters/ Esterification by

reaction of alcohols with anhydride/

Perfumery Esters by Darzen Condensation

00 300

300

Fragrances & Flavors

3

Perfumery Alcohol by Grignard reaction / by

reduction of aldehyde, or ketone by hydrogen

& Reducing Agents / by addition of water

into olefins / by saponification of

esters/Perfumery Compounds by Ring

Reduction

00 300 Fragrances & Flavors

4 Perfumery Aldehyde by ester / epoxide

rearrangement/ dehydrogenation of alcohols/

reduction of acids/ aldol condensation


5 Dimerization and Trimerization of simple

olefins. 00 300 Fragrances & Flavors

6 Ketals / Acetals / substituted 1,3-propanediols

and other propylene derivatives 00 300 Fragrances & Flavors

7 AmbrettolideMacro cyclic and polycyclic

musks derived from propylene or butadiene 00 300 Fragrances & Flavors


8 Aldehydes & ketones by Aldol Condensation 00 300 Fragrances & Flavors

9 Nitriles / cyclo propyl acetylene and other

alkyne derivatives 00 300 Fragrances & Flavors

10

Cyclo Alkylation/Acetylation ,Diel Alders

Reactions : Cyclization Reaction,

Etherification of Alkyl Halide and Alcohol,

Epoxidation of Alkenes


11 Hydrogenation 00 300 Fragrances & Flavors

12 Inorganic Salts 00 50 50 Side Stream Products

Total 630

From the list of ProductsSrNos 2 to11 only two to three products will be manufactured simultaneously. The

total quantities to produce for Products Sr No 2 to 11 willbe for any one or all cumulatively up to 300MT

Since many of the products planned are either forward integration or corollary to a known manufacturing

process. The above mentioned process based chemicals are important chemicals in the vast field of

fragrances and flavors where many such routed chemicals are required to make a fragrances and flavors.

None of these chemicals are banned for production in developed countries nor is banned for use. The

chemicals produced have the following merits:

- Import /Cost Substitution

- Minimizepollutantsatsource

- Maximizerecycle of recovered RMs and Water

- Treatto MPCBnorms


General formulas limited to groups of manufacture

Sr

No Products

General Reaction(s) Field Of Application

1. Fragrances/Perfumes &

Flavors Mixing/Blending

Fragrances& Flavors.

2.

Perfumery Esters by hot

esterification/ addition of

organic acid into olefin/ trans

esterification/ reacting alkali

halide with sodium salt of

corresponding acid/Cold

Esterification -Ethyl Esters/

Esterification by reaction of

alcohols with anhydride/

Perfumery Esters by Darzen

Condensation


3

Perfumery Alcohol by

Grignard reaction / by

reduction of aldehyde, or

ketone by hydrogen &

Reducing Agents / by

addition of water into olefins /

by saponification of

esters/Perfumery Compounds

by Ring Reduction


4

Perfumery Aldehyde by ester

/ epoxide rearrangement/

dehydrogenation of alcohols/

reduction of acids/ aldol

condensation


5

Dimerization and

Trimerization of simple

olefins.



6

Ketals / Acetals / substituted

1,3-propanediols and other

propylene derivatives


7

AmbrettolideMacrocyclic and

polycyclic musks derived

from propylene or butadiene


8

Aldehydes & ketones by

Condensation with vinyl ether


9 Nitriles / cyclo propyl

acetylene/ Acetylene and other

alkyne derivatives RC≡CR + R'C≡CR' 2 RC≡CR'


10

Cyclo Alkylation Reactions

/Acetylation ,Diel Alders

Reactions : Cyclization

Reaction, Etherification of

Alkyl Halide and Alcohol,



11 Hydrogenation


12

Inorganic Salts

NaCl, AlCl3, MgCl.HSO4, KCl, BaSO4

Side Stream Products

Total

From the list of Products Sr No 2 to11 only two to three products will be manufactured simultaneously. The

total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT

List of Raw Materials and Source:

The list of raw materials along with monthly consumption is given in table, However there will be only

2-3 products being manufactured at the same time hence the requirement of the raw materials will be

low, however the below raw material quantities are reflected based on single product manufacturing. Sr. No. Raw Material Required Consumption in

MT/Month 1. Acetic Acid 234

2. Acetic Anhydride 70.46 3. Acid Catalyst 27.45 4. Aldehyde 47.17

5. Caryophellene 4.00

6. Caustic Lye 10% 1.04

7. Citronellol 17.03

8. Benzylledene Acetone 80 9. D’limonene/Orange Terpenes 47.94

10. Di Ethanol Amine 0.43


11. Dicyclopentadiene 783.33

12. Ethyl Chloro Acetate 22.05

13. Benzyl chloride 27.6

14. Halide (Pentyl Bromide/Chloride) 75.47

15. HCL 45% 0.16

16. Hexyl Alcohol 112 17. Iodine 0.18

18. Iso Amyl Alcohol 12.86

19. Isobutyric Acid 72.50 20. Methyl Heptanone 98.97 21. Methanol (Fresh & Recycled) 47.94 KL

22. Methyl Magnesium Bromide / Chloride 31.61 23. Mg Turnings 12.74 24. Phase transfer catalyst 1.10

25. Pentanol mixture 77.14 26. Propionic Acid 80.23

27. Salicylic Acid 265

28. Soda Ash 12.24

29. Sodium Acetate 21.30

30. Sodium Methoxide 22.05

31. Sulphuric Acid 31.98

32. Terpineol 68.18

33. Tetra Hydro Furon (Fresh & Recycled) 235.85 KL 34. Toluene (Fresh & Recycled) 28.03

35. Sodium Salicylate 35.7 36. Zn Chloride 0.52 37. Propylene 38. Acetylene 39. Hydrogen 40. Benzaldehyde 41. N Pentanol 42. Propionaldehyde 43. Pthalic Acid 45. Vinyl Ethyl Ether 46. Sodium Hydride 47. Aluminum Trichloride 48. Di Chloro Methane 49. N Butyl Aldehyde 50. Tertiary Butyl Methyl Ether 51. N ,O Dimethyl Hydroxyl Amine Hydrochloride 52. Geraniol 53. Linalool 54. Meta Chloro Pre Benzoic Acid 55. 1 Phenyl Ethanol ( Styrallyl Alcohol) 56. Furan 57. Allyl Alcohol

Source:

Raw material will be sourced locally and also from countries like Japan, USA and Germany.

3. Location-

For theproposed project the company will use its spare land from the existing plotsat Gut No 167, 169,

170, 171, 296, Vill. Lakhamapur, Tal. Wada,District: Thane, Maharashtra.

Thissiteisin onallfoursides wearesurroundedby industriesandnonuisance

isspread.Thesurroundingneighborsare,


To BE CHECKED BY ADITYA

East :Abhinav Pharmaceuticals Pvt Ltd, Mumbai Wada Jawahar Highway

West: Agricultural Land, Village Lakhmapur

South: A gr i c u l t u r a l L a n d , V i l l a ge L a k h m a p u r

North: AFFPL Green Belt, Village Road, Residential Building

Locationtooisjustifiable.Unit sizeiskeptcorrectfor easeofhandling andenvironmental control.

As t h e r e a r e o t h e r indus t r i es inthe neighborhoodw i t h similarn a t u r e , there is compatibility.

This isnot aPrimeAgriculturalLand.Thelanduseisalreadyas“Industrial land/Non Agriculture

Land”.Thus,thereisnochangeinthestatus.Thisisaflat landwhereby cutting- f i l l i n g balancesand

t he re will beNoLowBorrowingfromNature.

Tansa wildlife Sanctuary is about 8.3 kms North West of the site and the plot is

located in private industrial land hence requires Environment Clearance from the

Ministry Of Environment, Forest and Climate Change with Public Consultation.

To be checked by ADITYA

Geographical Location Items:

Latitude : Approx. 19° 5'9.63"N

Longitude : Approx. 73°10'9.86"E

Terrain : Flat terrain

Climate : Semi-Arid

4. Resources

Site

AFFPL is desirous to establish and it requires following resources,

• Area 48900sq. mts

• Water Input Ground Water for existing 2 No’sbore wells and 1 No Well.

New Two No’sBore wellproposed with Rain Harvesting

Facility will be put in place. • Work force 65

• Raw Materials Commensurate with product, as also work up chemicals

Solvents& catalysts

•Effluent Facility High COD and TDS sub stream segregated self-treatment

And Later CETP (membership is sought)/Gardening

• Haz. Waste Facility CSWTSDF at Taloja, Maharashtra

• Process Machinery Developed by self available locally maintained sophisticated

Laboratory Attendants, cooling tower, hot water generations,

Steam Boilers • Units Instrumentation Precision and accurate

• Total InvestmentRs.19.3408Crores (Rs 9.3408Crores Present + Rs 10.00Crores

Expansion)

• Environment Fund 2 %

• Proponents Law abiding. No litigation pending.


Site

1. Existing industrial premises and land area: 48900sq mts

2. Climatic condition suitable for finer adjustments of control, making it fit for processing Conditions.

3. Well connected for transportationthrough Mumbai WadaJawahar Highway

4. Leveled ground and load bearing soil

Technology Selection

1. The products proposed are in the same manufacturing range for which the technology is

alreadydeveloped, and well known.

2. The process used isbased on raw materials that are available, without any bottleneck. Thus,

Excessstorage also means wastage. Here, we can follow easily the principle of JIT (Just in Time).

3. The process used is developed by AFFPL themin house and hence we are aware

aboutthesensitivepoints needing careful attention in advance.

4. The process is cost effective, safe and environmentally friendly.

5. There is no elevated pressure condition in processing.

6. Solvents used that are recoverable, and are so recovered.

7. The steam & hot water from boilers will be used for process

Instrumentation

1. Latestelectronicinstrumentationwithhighaccuracyandreliability

2. 100%redundancyforcontrolandpowersupply.

3. EmergencyShutDownSystemforensuringsafetyofplantandpersonnel.

4. Streamflow,feedwaterflowismeasurable(indicatingandrecording) 5. Waterlevelandliquidmateriallevelismeasurable(indicatingand recording)

6. Multipoint temperaturescannerwiththermocouple.Allpointsindicatingandrecording(allforsteam,fe

edwater,fluegasandair) 7. Pressuregaugesatreactors.

8. Multi-channeldataloggertoinputs

likecurrents,mv,T/Candrecordingwithcolumneddotmatrixprinter.

9. Hootersfortrips,lowlevels,highlevelsandhightemperatures.

Machinery & Hardware:

1. ModernClosed Pump transfer system isused toavoid any risks in human being handling the

production.

2. All processing equipment likereactors material of construction will be compatible to process.

3. Generally, will be of SS316/GLR quality and will be kept validated as per strict international guidelines

prescribed.

4. The condensers are in SS316.

5. Wherever water is used, will be specially purified for process and cleaning- washing.

6. Help of sophisticated configuration may be taken, if necessary.


Project proponents

AARAV Fragrances & Flavors Pvt.Ltd. (AFFPL) was incorporated in 2007. The promoters of the company

have more than 20 years of experience and profound understanding of the fragrance & flavor industry to

provide strategic inputs into key business decisions and developing long term goals.

AFFPL have developed strategic partnership with key global & local suppliers of synthetic and Natural

ingredients to provide consistent supply of fragrances & flavors to our valued customers.

AFFPL proudly service a wide range of SME's as well as multinational companies, both global & Indian.

To experience a great fragrance is to experience magic, fragrance has the power to captivate the senses and

transport our mind to new realm of imagination. AFFPL excels in the art and science of great fragrance

creation. Guided by our principles of Balance, Clarity and Integrity, we put our expertise behind your brand

to create signature fragrances. AFFL fragrances create unique, consistent and lasting experience for all

consumers.

AFFL takes pride in partnering with their customers to ensure that when a product is picked off the self,

customer brand promise is fulfilled to the utmost satisfaction of the consumers from various categories

Some of the most profound memories are attached with food customer’s taste. We develop unique flavor

experiences that deliver your brand promise to consumers.

AFFL experts are constantly researching trends and focusing on the magic that consumers are looking for in

the market. AFFL development team works closely with the clients on specific briefs to deliver unique

flavours within stipulated deadlines for various categories.

Thecompany hasadoptedfollowingcertifications

1. ISO 9001

2. ISO 22000

3. ISO27001( Under Implementation)

4. Food Safety Standards Authority Certification.

The Board of Directors represents an optimum mix of knowledge, experience and expertise to guide the

long-term success of the company.Theproponentsare,

Sr.No. Name Designation

1. Mr. Ajit Suresh Vaze

Master Of Science Organic

ChemistryEngineer

CEO/Managing

Director

2. Ms. AnuradhaAjitVaze Director

3. Mr. AjitDeshmukh Director

4. Mr. Jean Louis Matthey Director

5. Mr. HolgerHauenschild Director


5. Process

Products

AFFPL proposes to establish a plant to produce synthetic organic chemicals catering to the perfumery &

Flavor industry. These products serve as raw material to the fragrance and flavors industries. As season

changes the demand for a fragrance /flavor changes, hence the demand for particular chemical

ingredients also changes, the industry has thus to be in readiness to change the product suitability as

well as the application and be preparedto mitigatethe corresponding customer requirement challenges.

The utilitiesrequired will be steam which will be provided by the existing steamer and a new IBR Boiler

will be installed. Other will be provided by newer fresh technologies for cooling, vacuum etc. The

multi-product facility will be operated as normal chemical industry but the reactorswill be used by

different combination and sequence.

The product mix is as given below why repeating??????????????If not required please remove the same

Sr

No

Products Present

MT /M

Proposed

MT/M

Total

MT/

M

Field Of Application

1. Fragrances/Perfumes & Flavors 70 210 280 Fragrances &Flavors

2.





Esterification -Ethyl Esters/ Esterification by

reaction of alcohols with anhydride/


00 300

300

Fragrances &Flavors

3

Perfumery Alcohol by Grignard reaction / by

reduction of aldehyde, or ketone by hydrogen

& Reducing Agents / by addition of water

into olefins / by saponification of

esters/Perfumery Compounds by Ring

Reduction

00 300


4

Perfumery Aldehyde by ester / epoxide

rearrangement/ dehydrogenation of alcohols/

reduction of acids/ Aldol condensation.

00 300



olefins. 00 300


6 Ketals / Acetals / substituted 1,3-propanediols

and other propylene derivatives 00 300


7 Ambrettolide,Macrocyclic and polycyclic

musks derived from propylene or butadiene 00 300



8 Aldehydes & ketones by Aldol Condensation 00 300 Fragrances & Flavors

9 Nitriles / cyclo propyl acetylene lenend other

alkyne derivatives 00 300


10


Reactions:Cyclization,Reaction,



00 300


11 Hydrogenation 00 300 Fragrances & Flavors

12 Inorganic Salts 00 50 50 Side Stream Products

Total 630

From the list of Products SrNos 2 to11 only two to three products will be manufactured simultaneously. The

total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT

It may be seen that,

There is a capability of making these products

Production process is batch process with “Cleaner Production” strategy with effluents recycles

Machineries, utilities will be installed according to the requirement of the plantand products.

Schematic Process Flow for Proposed Products


COMPLIANCE TO MSIHC RULES:

According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical Rules, 1989),

data on the toxicity and flammable characteristics for the chemicals involved is as presented below in

the form of tables.

Storage details for Raw Materials to be used in manufacturing activities:

Sr.

No.

Raw Material Quantity in

MT/Month

Storage At a

time in

MT/Month

Physical

form

Stored In MOC

1. Acetic Acid Fragrances/Perfumes & Flavors

234 10 Liquid Tank SS304

2. Acetic Anhydride 70.46 8 Liquid Drums HDPE

3. Acid Catalyst 27.45 2 Liquid Carboy HDPE

4. Aldehyde 47.17 2.5 Liquid Drums HDPE

5. Caryophellene 4.00 1 Liquid Drums GI

6. Phase transfer Catalyst 1.10 0.1 Liquid Drum HDPE

7. Caustic lye 1.04 1 Liquid Carboy HDPE

8. Citronellol 17.03 2 Liquid Drums MS Epoxy

9. Benzylledene Acetone 80 6 Liquid Drums GI

10. D’limonene/Orange

Terpenes

47.94 4

Liquid

Drums

MS Epoxy

11. Di Ethanol Amine 0.43 0.22 Liquid Drums MS Epoxy

12. Dicyclopentadiene

(underground)

783.33 40

Liquid

Tank

SS304

13. Ethyl Chloro Acetate 22.05 1.5 Liquid Drums HDPE

14. Benzyl chloride 27.6 2.5 Liquid Drums HDPE

15. Halide (Pentyl

Bromide/Chloride)

75.47 5

Liquid

Drums

HDPE

16. HCL 45% 0.16 0.5 Liquid Carboys HDPE

17. Iodine 0.18 0.09 Solid Can GI

18. Iso Amyl Alcohol 12.86 3 Liquid Drums HDPE

19. Isobutyric Acid 72.50 2 Liquid Drums HDPE

20. Methanol 47.94 KL 3 Liquid Drums MS

21. Methyl Heptanone 98.97 3.5 Liquid Drums HDPE

22. Methyl Magnesium

Bromide / Chloride

31.61

2.5

Liquid

Drums

MS

23. Hexyl Alcohol 112 2.8 Liquid Drums MS Epoxy

24. Mg Turnings 12.74 1 Solid Bags PP

25. Pentanol mixture

(Under Ground

Storage)

77.14

20

Liquid

Tanks

MS

26. Propionic Acid 80.23 3 Liquid Drums HDPE

27. Salicylic Acid 265 8 Solid Bags PP

28. Soda Ash 12.24 1 Solid Bags PP

29. Sodium Acetate 21.30 1.2 Solid Bags PP

30. Sodium Methoxide 22.05 2 Solid Can GI

31. Sulphuric Acid 31.98 1.2 Liquid Carboys HDPE

32. Terpineol 68.18 5 Liquid Drums GI

33. Tetra hydro Furon 235.85 KL 6 Liquid Drums MS

34. Toluene 28.03 3 Liquid Drums MS

35. Sodium salicylate 35.7 3.5 Solid Containers HDPE

36. Zn Chloride 0.52 0.1 Solid Can GI


Sr

No

Products Quantity

In MT/M

Max

Storage

MT/M

Physical

Form

Stored In MOC

1. Fragrances/Perfumes & Flavors 280 20 Liquid Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

2.





Esterification -Ethyl Esters/ Esterification

by reaction of alcohols with anhydride/


300

20 Liquid Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

3

Perfumery Alcohol by Grignard reaction /

by reduction of aldehyde, or ketone by

hydrogen & Reducing Agents / by

addition of water into olefins / by

saponification of esters/Perfumery

Compounds by Ring Reduction


Drums

SS316/304/

HDPE/

Aluminum

4

Perfumery Aldehyde by ester / epoxide

rearrangement/ dehydrogenation of

alcohols/ reduction of acids/ Aldol

condensation.


Drums

SS316/304/

HDPE/

Aluminum


olefins. 20 Liquid

Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

6 Ketals / Acetals / substituted 1,3-

propanediols and other propylene

derivatives


Drums

SS316/304/

HDPE/

Aluminum

7 Ambrettolide,Macrocyclic and polycyclic

musks derived from propylene or

butadiene


Drums

SS316/304/

HDPE/

Aluminum

8 Aldehydes & ketones by Aldol

Condensation 20 Liquid Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

9 Nitriles / cyclo propyl acetylene and other

alkyne derivatives 20 Liquid Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

10


Reactions:Cyclization,Reaction,




Drums

SS316/304/

HDPE/

Aluminum

11 Hydrogenation 20 Liquid Storage Tanks/

Drums

SS316/304/

HDPE/

Aluminum

12 Inorganic Salts 50 Solids Bags

Leak Proof

HDPE


Overall Environmental Significance:

UnitOperation/

Process

Peculiarities Environmentalsignificance

1.IncomingRaw Materials Selectedfromknown vendors

transportationinclosed

tankers/Drums in limited low

volumes.

Promptuseandstoragein

closedcontainersprevent

spillagesandlossofstrength.

LessHCemissions.

2.Weighingand strict

qualitycontrol

LoadCellbasedweighing

system provided

Bettercheckonmass balance,purer

materialand lessrejections.

3.Inprocess Solvents Recoveredandreused

Byproducts Recoveredandsoldto

parties,whenindemand

Gaseousemissions Scrubbedanddetoxified

Processwasteresidue Tobesentoncommon

facilityfordisposal by

incineration. 4.Instrumentation Controlsystemfor

accurateprocesscontrols

Facilitatesmonitoringof

qualityoftheproductand

safetyaspects.

5.Control Excellentsystem of

documentationand

controlofcriticalstagesin

productionprocess

Betteroperationand retrievable

records forbetter checks.

6.Solvent Recovery Proper recovery systems

with vapor condenser and

chilled unit.

Vapor and Product Condensers with Step

down chilling and cooling systems

6. Pollution control

Clean productiontechnologyadopted byensuringfollowing a tdesigna n d e n g i n e e r i n g stage.

- All Products & their reactions selected after considering the friendliness of these products on the

environment

- Minimize pollutants at source

- Recovering and recycle of the RM

- Maximize recycle of water resources.

- Tertiary ETP System will be erected and operated

- Treat to PCB norms

- 100% recycle of increased effluents for process for defined cycles.

- Procure CEPT Membership when available

- Use with Priority Environment Friendly Fuels Like Ground Shells Briquettes, Agricultural Waste.

- Reduction of VOC at every processing stageby vent condensers and scrubbers.

- Use of mainlyclean fuels like agricultural waste/FO/LDO.

- All Process Transfers will be conducted in enclosed systems by pumps.

Theprocesswhereverisbasedonesterificationoforganicacidandalcoholproducingwater.Therecoverys

ystem willbedesignedinsuchawaythatentirewaterisusedforprocessapplicationtherebyreplacingfresh

waterinput.


Theboilerisprovidedwith cyclone separator, bagfilter/ESPtocontrolemissionwithin

prescribedlimits.The stack height will be up to 30 meterstocontrolgroundlevel

clearancewithinlimits.

Processvents arecontrolledbycondensersfollowed bywater cooling and chilling systemsand

organicsare recoveredandrecycled.

(a) Water & waste water:

The water and waste water generated in the factory will be as follows;

i. Water Requirements:

Details Of Fresh Water Consumption

Sr

No

Water Break Up Existing Water

Consumption

( KL/Day)

Proposed Water

Consumption

(KL/Day)

Total Water

Consumption

(KL/Day)

I Domestic 5.00 5.00 10.00

II Gardening 0.00 80.00 80.00

III Industrial

1)Process 0.00 5.00 5.00

2)Cooling Water Make up 0.00 9.00 9.00

3) Boiler Make Up 3.50 13.50 16.00

4) Washings 0.00 3.00 3.00

Total Industrial 8.50 115.50 124.00

Details Of Waste Water

Waste Water Break Up Existing Waste

Water

Generation

(KL/Day)

Proposed Waste

Water

Generation

(KL/Day)

Total Waste

Water

Generation

(KL/Day)

I Domestic 3.60 3.60 7.20

II Industrial

1)Process 0.00 5.00 5.00

2)Cooling Water 0.00 9.00 9.00

3) Boiler Blow Down &

Cooling

2.70 12.00 12.00

4) Washings 0.00 3.00 3.00

Total Industrial 7.30 32.6 36.20

The industry will obtain membership of CETP.

:MARKED IN RED O BE DECIDED AFTER DISCUSSIONS WITH ADITYA


ESTIMATED QUALITY OF RAW & TREATED EFFLUENT:

Characteristics of untreated waste water:

Characterisation of treated effluent:

Sr. No. Parameters Concentration

1 pH 7.82

2 COD 186 mg/L

3 BOD 80 mg/L

4 Phenolic Compounds 0.18 mg/L

5 Ammoniacal Nitrogen 14.2 mg/L

6 Suspended Solids 68.5 mg/L

7 Oil & Grease 5.2 mg/L

Sr. No. Parameters Concentration

1 pH 6.8

2 COD 3250 mg/L

3 BOD 1560 mg/L

4 Phenolic Compounds 1.12 mg/L

5 Ammoniacal Nitrogen 18.9 mg/L

6 Total Dissolved Solids 4200 mg/L

7 Suspended Solids 244 mg/L

8 Oil & Grease 21.2 mg/L


Water Balance Diagram:

Fresh Water From Borewells/Well 124 kl/Day

Gardening Domestic Cooling

Tower

RO

Fresh 80kl/Day 10kl/Day 9kl/Day 28kl/day

Recycled 3kl/Day

Recycled 12.8kl/Day

Recycled 8kl/Day

Total 103.8kl/Day

Sewage

Treatment

Plant

Cooling

Tower

Blow

Down

RO Reject RO Water

to Boiler

Feed

3kl/day 9kl/Day 11.2kl/Day 16.8kl/Day

Process Washings

5kl/Day 3kl/Day

8KL Recovered to ETP

Boiler

Blow

Down

12.8kl/Day

Recylce back to garden/

Or CEPT Effluent Treatment Plant

Schematic Diagram for Fresh Water Requirement and Waste Water Flow

Proposed ETP Flow Sheet:

Oil & Grease Trap

Equalisation and

Neutral ization Tank

Primary Settl ing Tank

1st Stage

Aeration Tank

1st Stage

Secondary

Settl ing Tank

2nd Stage

Aeration Tank

2nd Stage

Secondary Settl ing Tank

Intermediate

Collection

Tank

Inlet

Outlet

Pressure Sand

Fil ter

Final Dishcarge

Tank


(b) Air Pollution:

The existing plant comprises of 1 small industrial boiler (Steamer). The fuel used in the existing boiler is

furnace oil. Two DG Sets a.63kva for emergency and power failures & b. 160kva exclusively for fire

alarms & firefighting hydrant systems is already installed, which is used only during power failures.

Proposed Scenario:

For the proposed expansion unit, the existing steam boiler will be kept as stand by. A new 5 MT IBR Boiler

and a new thermic fluid heater will be installed. The details of the boiler and thermic Fluid heater are given

below:

Details of Boiler and Thermic Fluid heaterCapacity???????????

Details of Air Pollution Control unit:

The proposed plant will not produce any significant air pollution load. The major sources of air pollution

will be:

Boiler

Thermic Fluid Heater

D.G. Set Emissions

Fugitive emissions

Processemissions

To control the fly ash particles / particulate emissions from the boiler, cyclone will be installed in the

proposed project. There are no process emissions from the proposed project.

Sources of Gaseous

Emissions

Boiler (1 No.) Thermic Fluid Heater

Fuel used Agricultural Waste /Bio Coal/ Furnace

oil/Coal / NG

5MT/Hr

Agricultural Waste /Bio Coal/ Furnace

Oil /Coal /NG

3Lac kcals

Quantity of fuel 22 mt/Day / 22mt/day/10 mt/day

/22mt/day/8500 m3/Day

5mt/Day/5mt/day/2.5mt/day/5mt/day/

2500m3/day

Type of emissions SO2, NOX, PM SO2, NOX, PM

Stack height 30 mts 13 mts

Stack dia. at the top 0.505 mts 0.505 mts


Schematic diagram of cyclone

The existing D.G. Set shall be used only in case of emergencies / Power failure & Fire Related

emergencies. A New DG will be installed replacing the 63KVA

Details of D.G. Set

Sources of gaseous emissions

Existing D.G.Set

(63 KVA)

Existing D.G.Set

(160 KVA)

Proposed D.G.Set

(500 KVA)

Fuel used Diesel Diesel Diesel

Quantity of fuel (Will depend on

Power Failure & Emergencies)

11lits/Hr 35lits/Hr 105 lts/hr

Type of emissions PM, SO2& NOX PM, SO2& NOX PM, SO2& NOX

Stack height 3 meters 3 meters 3 meters

Capacity of D.G.Set 63 KVA 160 KVA 300 KVA

Sr

No

Source Pollutant Measures Control Equipment

1 Proposed 5MT

Boiler.

SPM, CO,SO2,

NOx

Dust Collectors,, ESP,

Dust extraction with Bag

filters, fogging.

Tall stack of 30 m.

2 In process VOC Closed loop transfer Vent condensers,

Extraction and

scrubbing

3 ETP COD, TDS Segregation of Streams Fully aerobic

Noise :


There is no major noise generating sources. Only those Vehicles with PUC's and spark arresters will be

allowed inside the premises. Green belt facilities have also been provided in the plant premises.

Details Of Hazardous Waste Generation And Disposal:

The plant will have the maximum solid waste generation from the ETP, which will be sent to CHWTSDF,

Taloja, Maharashtra for its disposal applied for membership.

Details of Hazardous waste generation and disposal:

Sr.

No.

Type of

Waste

Category Existing

QuantityMT/Annum

Proposed

Quantity

MT/month

Mode of disposal

1 ETP Sludge 34.3 0.060 100.00 Collection, storage,

transportation and disposal

to TSDF.

2 Used Oil 5.1 0.00 2.40 Collection, storage,


by sale to registered

recyclers.

3 Discarded

Containers

33.3 0.00 12.25 Collection, storage,

decontamination,


by sale to authorized

recycler

4 FO / LDO &

Oil Bottoms

Sludge

--

0.00

3.36

Collection, storage,



recycler

5 Distillation

Residue

20.3 0.00 16.200



to CHWI.

6 Grease 5.2 0.00 0.012




recycler

7 Fly ash (Boiler

& TF Ash)

- 0.00 482.00 Will be sold to brick

manufacturers.

8 Low purity

fractions

C8 0.00 72.00

Will be sold.


9 Spent acid -- 0.00 16.00

Will be sold.

Hazardous Waste Storage Room:

A hazardous waste storage room measuring 100sqmts will be provided with impervious RCC flooring and

leachate collection pit. The distillation residue will be stored in carboys in Hazardous waste storage room

and will be finally disposed of to CHWTDFS, Taloja, Maharashtra. The Fly ash will be stored in a defined

area and precautionary measure will take for avoid carryover of the ash by wind/breeze/water etc.

Dispersion:

Point Emissions are coming from one boiler, thermic fluid heater &3 DG hence proper stacks will be

provided for the same. Please note DG 3 Nos will be used only in emergency & during power failures.

The stacks will be fitted with port-holes, ladder and platform for facility of taking samples.

Fugitive:

A number of mitigation measures will be taken to control fugitive emissions

Engineering, the plant layout will be in such a way so as to virtually eliminate need of using heavy

equipment for material handling in the main plant

Internal roads paved, leveled, no undulations, no sharp curves, slow speed.

No open storage of materials involved

Fumes extraction and vacuum system will provided for extraction of fumes

from the reactors and the process plant areas.

Fugitive Emissions and its control:

There are no emissions from the manufacturing process. For control of fugitive emissions, chilled

water traps will be installed on the vent of the unit to arrest any escape of vapors from the reaction

and distillation unit. Fugitive emission could occur from the storage yard of raw materials and

finished products. The storage quantity is very low and proper handling methods will be adopted.

Emissions from transport of vehicles would occur to a certain extent. The emissions from traffic

movements is controlled by proper planning of the transport of raw materials and finished

products to and fro from the factory premises. Since the quantities involved are very less,

movement of vehicles will be occasional. All the roads inside the plant will be concreted to reduce

any dust emissions.

Details of Solvent recovery Plan and monitoring of vents:

The solvent recovery system for the proposed expansion project is shown in the figure below.

The vents of the reactors will be connected to 2 stage condenser system, where chilled

water will be recirculated. The receiver will also be jacketed with circulation of chilled water. The

recovered solvents will then be stored and reused. All the units will be under nitrogen blanketing


through cylinders. Proper planning and maintenance will control the extent of fugitive

emissions.During the production, the industry will carry out regular monitoring of fugitive

emissions as per the factories act.

Details of Solvent Recovery Plan

Prefeasibility Report–M/s.Aarav Fragrances & Flavors Pvt Ltd

Aesthetics:

There will be no nuisance from noise. DG 3 Nos will be used only in emergency & during power

failures tokeep plant under safe conditions. If Coal is used as fuel for boiler therewill crushing and

pulverizing operations for coal handling. Dust suppressionsystem is provided. Dust extractionwith

dust collection will be provided. Labor strength will also be limited.

7. Background Study:MARKED IN RED O BE DECIDED AFTER DISCUSSIONS WITH

ADITYA

This is important part of study.

(A)Natural Environment : We propose to do sampling as –

• Surface Water: 2 Locations, 11 Parameters.

• Ground Water: 5 Locations, 9 Parameters. Includes 1 up gradient and 2 down gradient source.

• Air Quality: 3 Months, For PM10, PM2.5, SO2 and NOx.

• Noise: 5 Locations.

• Soil: 5 locations

The stations will be selected in all the eight directions from the factory and in 10 km radius.

(B) Manmade Environment

This includes existing land-use, demography, employment, socio-economic aspects and

community development needed and proposed. This is for entire area both rural and urban in this

study zone.

• Socio-Economic Status in Influence Zone explained in the study of Non-Workers

percentage whether high, from the percentage employed population on Agricultural, how far is the

scope for other avenues of livelihood like Live Stock, Forestry, Fishing, Hunting, Orchards, Mining,

Trade Commerce.

• Further Out of Total Land what percentage is already under Cultivation and Out of

Total Land what percentage is already under Irrigation.

• If the land is not likely to support more people, then whether Industrialization is necessary to

improve the situation.

• All this will be studied as cost benefit ratio.


Chapters Contents

I Proponents,ToR,Purpose

II Project

explained.Whythis,Whyneeded,Whyhere,Whatpriorities,Whatoption

s III EnvironmentSetting Natural&Man-made

Material,Method,

Approach

Delphitechnique

IV HighSignificantImpactLowInsignificantImpact&Shield

ProperSitePreventionAbatementTreatment

MitigationSmoothDisposal

V AlternateAnalysis

Selection ofRawMaterials,Site,Process,Machinery-Hardware,

Collaborators,Staff&Team

8. Safety

Safety and Occupational Health will be dealt carefully. A disciplined approach is natural to this

industry. Safety policy will be in place. The unit is registered under Factory Act and is bound by

State Factory Rules.

A complete exercise of risk assessment & characterization is scientifically done. Mitigation plan is

drawn as follows:

• Mitigation measures

• Sprinkling on excavation

• Bag filters for steam boilers

• Stack height per MPCB

• Trees

• Barrier walls as shielding technology to suppress blast pressures, fragments, fire- balls.

• Chemical storage area – ventilation, store-rooms, fueldyked

• For Hazardous chemicals – Flame-proof motors, “No smoking’, Thermal insulations.

First aid trained and Fire-fighting trained person will be available in every shift. Safety Officer will

be appointed, as also the competent person retained. Where necessary, provisions of other Acts,

where required like Petroleum act, Explosive Act, etc. will be obeyed. Firefighting system is kept as

per norms of Insurance Company.

DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly,

Personal protection equipment will be given and use will be insisted. Consulting Physician is

available to attain the factory.

9.Benefits

The expanded capacity will meet the growing demand for fragrances and flavors. This will make the

final products more cost effective to consumers.

10. EIA study report:

This will be finally prepared and submitted as per guidelines given by MoEF as --


11. Scoping

We shall propose in “Scoping” the details of all above, as also the following;

•The study area of 51125 sq. km, the land under the unit. Thus, there will not be change in land use

pattern. The present land is already nonagricultural and under the industrial use.

• Raw material requirement, water requirement, water balance, process details, technology,

productdetails etc.

•Ambient Air Quality monitoring, for3 monthsexcept monsoon covering 10 km radius around

industry and its impact.

• Ground water quality around plant 10 km radius.

• Treatment scheme to achieve low discharged from premises.

• Scheme of treatment, mode of treatment

•Many other medium and large scale industries are present within 10 km radius in general.

• Information of solid waste, number of working days, CO2 emission from stack and process, etc.

• Employment generation, benefits of project

• The raw materials used are enlisted and their MSDS will be presented.

Some of them will be covered under MIS rules. However there use in process is small below

regulatory quantity. Risk assessment will be done and submitted.

12. Conclusion

This project is very necessary to supply cost effective fragrances, flavours and perfumery chemicals

with in- house technologies and expertise to both domestic and worldwide and also in view of :

• The local people desire that this industry will be welcome in their area.

• The candidate site is suitable from general MoEF expectations.

•Water, Power, Maw Material, Filler Material and Market is assured and found available with

ease.

• Full precautions will be taken for Pollution Control, Resource Conservation and

Environmental Protection.

• This is cost effective and Sustainable Development.

prefeasibility report - welcome to...

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