pre-feasibility...
TRANSCRIPT
PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT
For Proposed Expansion Project
MMAANNUUFFAACCTTUURRIINNGG OOFF SSPPEECCIIAALLTTYY CCHHEEMMIICCAALL && IINNTTEERRMMEEDDIIAATTEESS
By
M/s. ODYSSEY ORGANICS PVT. LTD. Plot No, B-36, 37, 39, Birwadi M.I.D.C., Taluka: Mahad,
District: Raigad, Maharashtra, India
Conducted & Prepared By
GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers
(MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, NABL/17025:2005, OHSAS: 18001 Certified Organization & GPCB approved Environment
Auditor – Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 24.01.2013
Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India Tel: 0265-2371269.
Corp. Office & Environmental Research Laboratory:
Flat No 6 ,Ground Floor,Shakuntala Niwas, M G Road,Borivali (E),Mumbai- 400066
Mumbai office
Tel : 022-28943090 /60 www.greencircleinc.com
ALSO AT
BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA
OVERSEAS
AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
TABLE OF CONTENTS
LIST OF TABLES
Sl. No. Particulars Page No.
1 Introduction 1
2 Benefits of Project 3
3 Project Location 3
4 Cost of Project 5
5 Proposed Product Details 6
6 Raw Material Requirement 8
7 Process Details 14
8 Utility and Requirements 14
9 Stack Details & Fuel Requirement 19
10 Hazardous Waste Generation and Management 20
11 Land Requirement Details 21
12 Green Belt Development 24
13 Storm Water-Collection and Disposal 24
14 Conclusion 24
Table.
No. Particulars Page No.
1 Environment setting of the proposed project 4
2 Proposed Cost 6
3 Name of Product with its Quantity 6
4 Details of Raw Material for Nitro Amino Phenol Group 8
5 Details of Raw Material Requirement for Bulk Drug &
Intermediates 10
6 Details of Water Requirement & Waste Water
Generation 14
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
LIST OF FIGURES
7 Details of Power Consumption 18
8 Employment Details 19
9 Details of Flue gas Stack 19
10 Hazardous Waste Management 20
11 Non Hazardous Solid Waste Generation 20
12 Details of Land use Break-up 21
Fig. No. Particulars Page No.
1 Google image of propose site 5
2 Water Balance Diagram 15
3 Flow Diagram of Existing ETP 16
4 Flow Diagram of Existing MEE 18
5 Lay-out Plan of Plot no. 36 & 37 22
6 Lay-out Plan of Plot no. 39 23
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 1
1. INTRODUCTION
M/s. Odyssey Organics Pvt Ltd is situated at Birwadi M.I.D.C. area of Raigad district in
Maharashtra State. M/s Odyssey Organics Pvt Limited is engaged in the manufacturing
of Specialty Chemicals and also expansions as well as new projects to manufacture the
Organic Chemicals which include – “Dyes Intermediates” (Nitro Amino Phenol groups),
Bulk Drug & Bulk Drug Intermediates.
Odyssey Organics Pvt. Ltd is established in 2006. Basically it is a sister concern – “Apte
Organics Pvt. Ltd” – situated at Mahad industrial area –since 1989. The company was
founded by a sound technocrat – Mr. D. V. Apte (M.Sc. By Research).
The company has almost 13 years versatile experience in the field of Organic Chemical
Manufacturing. Odyssey Organics Pvt Ltd having a sound technical knowledge &
hence he provide excellent quality in the market with innovative production process.
Innovative changes in the process, company always get success to overcome from the
process challenge like – Low Yields, Inferior Product Quality, High Raw Material Costs, &
Effluent treatment.
Due to above all, Odyssey Organics Pvt. Ltd has produced the products in competitive
cost with effective reduction in energy, water, raw materials & other resources. They
operate in a responsible manner and comply with all environmental, health and safety
standards. Hence company faces minimal obligations from Government departments
as well as International bodies. This is one of greatest advantageous over our
competitors. Due to it he gives a consistent & continuous supply to customers.
As chemical companies around the world reach out to enhance their strength &
competitiveness. In past 13 years since 2000, Odyssey Organics Pvt. Ltd has entered in
existing product field then he has given tough competition to Chinese origin material.
Before 2000 all materials were imported from China. Company slowly raises our market
share and from 6 years the situation is – the Indian Industry is no more importing the
products from China. Also company has taken a major share of China from global
customers. For the same Odyssey Organics Pvt. Ltd won the “National Awards” from
central govt. H.R. Ministry.
The company upcoming project also includes the same type of products. Which at
present are only manufactured from China. Our Indian consumers are totally
dependent on China. This results in to increase in Import.
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 2
1.1. COMPANY PROFILE
Odyssey Organics Pvt. Ltd is established in 2006. Basically it is a sister concern – “Apte
Organics Pvt. Ltd” – situated at Mahad industrial area –since 1989. The company was
founded by a sound technocrat – Mr. D. V. Apte (M.Sc. By Research).
M/s Odyssey Organics Pvt Limited is engaged in the manufacturing of Specialty
Chemicals. The present product is Picric acid, Sodium Picramate and Picramic Acid.
Previously these products were only manufactured in China.
The company has pioneer of the above products in India & supplying the quality
material in Indian & global dyestuff industry. Our Indian market is mainly located at
Gujarat, Rajasthan, while company exports to Japan, Bangladesh, Germany, U.K, Russia
& U.S.A.
1.2. COMPANY MISSION & VISION.
Vision Statement
“We must always look for versatile molecules & should manufacture them with a
Quality & Quantity.”
In an upcoming future the ‘Odyssey –Group’ must be one of the genuine &
reputed group in the Chemical Industry with the diverse specialties.
We are working not only for our own growth counts in “Money” – but we are
working for “Esteem” & “Satisfaction”.
Along with our own growth we aim to contribute & strengthen the Indian
Chemical Industry by Manufacturing the Products, for which our industry
depends on other nations.
“ODYSSEY”- MUST BE ONE OF THE IPORTANT FACTOR FOR INDIAN CHEMICAL
INDUSTRY BY ITS PRODUCT RANGE.”
Mission
The excellent team building, Innovative technologies, & transparent Working
systems are our Strengths.
Follow the International standard Systems & Quality Management Systems and
also bound for the Continuous Improvements & Quality Management through
the same.
Safe Working, Zero Accidents & Green Environment are our mottos.
Complete customer satisfaction & Quality service is our trade mark in the
market.”
1.3. MARKET ANALYSIS
The project is design with the optimum market study & data collection.
The project is based to target mainly the Indian consumers.
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 3
The consumers will be the – reputed chemical industries in India as well as some
from Global MNC.
For the project of – Average share of each product varies from min. 20 MT to
Max 60 MT / month.
While the total annual turnover expected from this Project in total is up to 250 Cr.
1.4. EXPORT POSSIBILITY
Most of the bulk export through by Sea from J.N.P.T. Port Bombay.
2. BENEFITS OF PROJECT
I. Reduce Import: It ultimately aiming to enter in to Chinese dominating products - it
will directly reduce the Import of Chinese origin product (Total amount is
approximate 220 Cr/ year).
II. Increase Export: As part of our produced material will get consume globally it will
increase the Export. (Approximate amount will be 45 Cr).
III. Local Economy Rolling: The main raw material required for the above projects will
be purchased locally from Indian Manufacturers. Also the major consumer base
will be in India. Ultimately it contributes in the local rolling of the economy & local
business.
IV. Job Generation: The Project will create direct & indirect employment opportunities
within the surrounding region. The Unit will use good faith efforts to employ local
people from the nearby villages depending upon the availability of skilled & un-
skilled man-power surrounding the project site. In operation phase, the proposed
project would require significant workforce of non-technical and technical
persons. Migration of highly education and skilled experience will result in increase
of literacy in the surrounding villages.
3. PROJECT LOCATION
The Plant is located at plot no. B-36, 37, 39, Birwadi MIDC, Taluka- Mahad, Dist. Raigad,
State-Maharashtra. The Total Plot area of the site is 25,000 sq m. The environmental
setting around the site is given in Table-1 and the Google image of project site is shown
as Figure 1.
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 4
Table 1: Environment setting of the proposed project
Sl. No. Particulars Details
1 Latitude 18° 06.147’N
2 Longitude 73°29.369’E
3 Elevation above MSL 60.0 m above Mean Sea Level
4 Present land use at the location Existing Plant
5 Nearest Village Birwadi (3.0 km)
6 Nearest Town/City Town: Mahad (10.0 km)
7 Nearest Railway Station Veer Railway Station (19 km)
8 Nearest Hospital M.M.A Hospital M.I.D.C (3.0 km)
9 Nearest Highway NH 17 (4.0 km)
10 Nearest Airport Mumbai Airport (190.0 km)
11 Nearest Water Body Kal River (1.0 km)
12 Ecologically sensitive zones within
10-km distance
No Eco sensitive Zone present within 10
km of radius.
13 Historical/ Archaeological places Raigad Fort (16 km), Chavdar Tale (8 km)
14 National Parks/Wild Life Sanctuary NA
15 List of Major Industries (within 10 km) Sandoz, Privi, Sudarshan, Vinati,
16 Seismic Zone Zone – III
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 5
Specific location and Project Boundary (10 km)
Figure 1 : Google image of Specific location and Project boundary
4. COST OF PROJECT
Estimated Cost of proposed expansion as on date is approx 215.0 crores. Company has
planned to expend 43 crores in Effluent Treatment System include in total proposed
estimated cost. The detailed project cost proposed is as given in Table 2.
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 6
Table 2. Proposed Cost
S.No. Description Amount in Crore (INR)
1 Expansion of Current Products 30
2 Starting of 3 New Molecules 80
3 Starting of 2 – Dyes Intermediates 25
4 Starting of Bulk Intermediate 80
Total 215
5. PROPOSED PRODUCT DETAILS
At present the production capacities of M/s Odyssey Organics Pvt. Ltd. is 34.0 MT/Month
and propose to expand manufacturing capacity by 1651.0 MT/Month. The detail
products capacity is given in Table-3.
Table 3 : Name of Product with its Qty.
Sr. No Product Name Quantity, MT/Month
Existing Proposed Total
A Dyes Intermediate – Nitro Amino Phenol Group
1 2,4-Dinitrochlorobenzene Nil 220 220
2 2,4-Dinitrophenol
9.8 (Intermediate
for In-house
Consumption)
106.2 116
3 Picric Acid
12.0
(Intermediate for
In-house
Consumption)
128 140
4 Sodium Picramate 10.0 75 85
5 Picramic Acid 5.0 13.0 18
6 4 - Nap Nil 50 50
7 Dinitro – Sec. Butyl Phenol Nil 100 100
8 N-Amino Dinitro Benzene Nil 30 30
9 4-Nitro-Ortho Xylene Nil 80 80
10 2-Nitro-4-Chloro Sulfonic Nil 29 29
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 7
Sr. No Product Name Quantity, MT/Month
Existing Proposed Total
Chlorobenzene
11 2-Nitro-4-Chloro Sulfonamide
Chlorobenzene Nil 23 23
12 2-Amino-4-Chlorosulfonamide
Phenol Nil 17.0 17
13 Monochlorobenzene Nil 150 150
B Bulk Drugs & Intermediates
1 2-Methoxy Naphthalene Nil 80 80
2 2-Acetyl-6-Methoxy
Naphthalene Nil 86 86
3 3-Nitro Acetophenone Nil 32 32
4 3-Amino Acetophenone Nil 26 26
5 3-Hydroxy Acetophenone Nil 20 20
6 3-Acetoxy Acetophenone Nil 10 10
7 4-Amino-Salicyclic Acid Nil 44 44
8 Sodium Pas Nil 40 40
9 3-Amino Pyrazole 4-
Carboxamide Hemisulphate Nil 36 36
10 Allopurinol Nil 10 10
11 C.P.A. Derivative Of Q Acid Nil 174 174
12 Ciprofloxacin –Q Acid Nil 126 126
13 Ciprofloxacin Base Nil 30 30
14 Ciprofloxacin Hydrochloride Nil 29 29
C By-Products
1 80% Spent Sulfuric Acid 10 1820 1830
2 Water White 30% Spent Sulfuric
Acid 100 100 200
3 Dil Acetic Acid Nil 65 65
4 30% Hydrochloric Acid Nil 166 166
5 Ethanol Nil 36 36
6 Copper Oxide Nil 40 40
7 Ammonium Sulfate Nil 80 80
8 Sodium Methyl Sulfate Nil 87 87
9 2-Nitro Acetophenone Nil 22 22
10 Sodium Acetate Nil 6 6
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 8
Sr. No Product Name Quantity, MT/Month
Existing Proposed Total
11 Dichlorobenzene Nill 36 36
12 1-Acetyl-2-Methoxy
Naphthalene Nil 10 10
13 Coal Ash Nil 200 200
6. RAW MATERIAL REQUIREMENT
Raw materials is purchased from indigenous and abroad market by roads/sea way.
Details of raw material required for enhancement of existing Products and Proposed
Products given in Table-4 & Table-5.
Table 4 : Details of Raw Material Requirement for Nitro Amino Phenol Group
S.No. Name of Raw
Material
Quantity /
Month Source Transportation Storage Condition
A Basic Raw Material
1 Sulfuric Acid (98%) 1080 Mt Domestic (DMC
Roha) Road Tank
2 Sulfuric Acid (30%) 90 Kl Self Made (Bi-
product) Road Tank
3 Fuming Nitric Acid 185 Mt Domestic (RCF) Road Tank
4 Nitric Acid 70% 175 Mt Domestic Road Tank
5 Caustic Lye (50%) 290 Mt
Domestic &
Imported
(Trader)
Road Tank
6
Sodium Hydrogen
Sulphide 30%
Aqueous Solution
140 Kl Domestic Road Tank
7 Sodium Sulfate
(Na2s) 26 Mt Domestic Road Bag
8 Lime Powder 32 Mt Domestic Road Bag
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 9
S.No. Name of Raw
Material
Quantity /
Month Source Transportation Storage Condition
9 Sulphur Powder 20 Mt
10 Urea Only 220
Kg Domestic Road Bag
11 Sodium Chloride
Salt 8.0 Mt Domestic Road Bag
12 Hydrogen
Peroxide 3 Mt Domestic Road Cans
13 Organic Amines 6.0 Mt Domestic Road Tanks
14 20% Aqueous
Ammonia Solution 25 Kl Domestic Road Cans
15 Chloro Sulfonic
Acid 35 Mt Domestic Road Tank
16 Dil. Hydrochloric
Acd 12 Kl Domestic Road Tank
17 Ice 230 Mt Self Produce +
domestic Road Containar
18 Acetic Anhydride 54 Mt Domestic Road Tank
19 Chlorine Gas 120 Mt Domestic Road Cylinders
20 Ferric Chloride 30 Mt Domestic Road Bag
B Solvents - Raw Material
1 Iso Propyl Alcohol 6.0 Mt Domestic Road Tank
2 Methylene Di
Chloridee 10 Mt Domestic Road Tank
3 Ethylene Di
Chloride 10 Mt Domestic Road Tank
4 Ethyl Benzene 50 Mt Domestic Road Tank
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 10
S.No. Name of Raw
Material
Quantity /
Month Source Transportation Storage Condition
C Main Organic Raw Material as –
Starting Material
1 Mono Chloro
Benzene 117 Mt Domestic Road Tank
2 2,4- Dinitrochloro
Benzene 226 Mt
Domestic + Self
Made Road Bags
3 2,4- Dinitro Phenol 116 Mt Self Made Road Carboys
4 Picric Acid 104 Mt Self Made Road Carboys
5 Sodium Picramate 22 Mt Self Made Road Carboys
6 2- Secondary Butyl
Phenol 66 Mt Domestic Road Tank
7 Ortho Xylene 60 Mt Domestic +
Import Road / Sea Tank
8 O –Nitro
Chlorobenzene 18 Mt Domestic Road Bags
9
2-Chloro-4-
Chlorosulfon
Chlorobenzene
29 Mt Self Made Road Carboys
10
2-Nitro-4-
Sulfonamide
Chlorobenzene
23 Mt Self Made Road Carboys
11 Benzene 130 Mt Domestic Road Drum
Table 5 : Details of Raw Material Requirement for Bulk Drug & Intermediates
No Particulars Quantity
/ Month Source Transportation Storage Condition
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 11
No Particulars Quantity
/ Month Source Transportation Storage Condition
A Basic Raw Materials
1 Sulfuric Acid 584 Mt Domestic Road Tank
2 Caustic Lye 50% 60 Mt Domestic Road Tank
3 Dil Sulfuric Acid 105 Mt Self Made Road Tank
4 Caustic Flex 46 Mt Imported Sea / Road Tank
5 Ice 94 Mt Self Made Road Container
6 Acetic Anhydride 60 Mt Domestic Road Tank
7 Zinc Chloride
Anhydrous 110 Mt Domestic Road Bags
8 Dimethyl Sulfate 164 Mt Domestic Road Tank
9 Sodium Methoxide 35 Mt Import Sea & Road Drums
10 Cyclopropyl Amine 32 Mt Import Sea & Road Drums
11 Sodium Sulfate
Anhydrous 1 Mt Domestic Road Bags
12 Potassium Carbonate 33 Mt Domestic Road Bags
13 Tri Ethyl Ortho
Formate 180 Mt Import Sea & Road Drums
14 Morpholine 110 Mt Import Sea & Road Drums
15 Hydrazine Hydrate 45 Mt Import Sea & Road Drums
16 Formamide 19 Mt Import Sea & Road Drums
17 20% Aqueous
Ammonia 100 Kl Domestic Road Tanks
18 Nitric Acid (72%) 35 Mt Domestic Road Tanks
19 Sodium Nitrate 14 Mt Domestic Road Tanks
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 12
No Particulars Quantity
/ Month Source Transportation Storage Condition
20 Sodium Hydrogen
Sulphide 30% 80 Mt Domestic Road Tanks
21 Glacial Acetic Acide 60 Mt Domestic Road Tanks
22 Anhydrous Piperazine 21 Mt Import Sea & Road Bags
23 Carbon Di Oxide Gas 18 Mt Domestic Road Tank / Cylinders
24 Hydrochloric Acid
30% 117 Kl Domestic Road Tanks
25 Dimethyl Sulfoxide 30 Mt Domestic Road Tanks
26 Activated Charcoal 20 Mt Domestic Road Bags
27 H-Flow Supercell 10 Mt Domestic Road Bags
B Solvent – Raw Materials
1 Methanol 30 Kl Domestic Road Tanks
2 Ethanol 5 Kl Domestic Road Tanks
3 Methylene Di
Chloride 30 Kl Domestic Road Tanks
4 Toluene 50 Kl Domestic Road Tanks
5 Dimethyl Carbonate 200 Kl Imported Sea & Road Drums
6 Dimethyl Formamide 80 Kl Domestic Road Tanks
7 Ethyl Acetate 10 Kl Domestic Road Tank
8 Nitrobenzene 20 Mt Domestic Road Tank
9 Butanol 10 Kl Domestic Road Tank
10 Iso Propyl Alcohol 40 Mt Domestic Road Tank
C Main Organic Raw Material as -
Starting Materials
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 13
No Particulars Quantity
/ Month Source Transportation Storage Condition
1 Beta Naphthol 77 MT Imported +
Domestic Sea & Road Bags
2 2-Methoxy
Naphthalene 80 MT Self Made Road Carboys
3 Acetophenone 40 MT Domestic +
Imported Sea & Road Tanks
4 3-Nitro
Acetophenone 32 MT Self Made Road Drums
5 3-Amino
Acetophenone 26 MT Self Made Road Drums
6 3- Hydroxy
Acetophenone 8 MT Self Made Road Drums
7 3- Amino Phenol 41 MT Imported Sea & Road Drums
8 4-Amino Salicyclic
Acid 44 MT Self Made Road Drums
9 Cyanoacetamide 22 MT Imported Sea & Road Bags
10 Pyrazole 4-Hydroxy
Hemisulphate 16 MT Self Made Road Carboys
11 Ciprofloxacin “Q –
Acid” 26 MT Self Made Road Carboys
12 Ciprofloxacin Base 26 MT Self Made Road Carboys
13 2,4-Dichloro-5-Fluoro
Acetophenone 120 MT Imported Sea & Road Drums
14
Cyclopropyl Amine
Derivative Of 2,4-
Dichloro-
Acetophenone
174 MT Self Made Road Carboys
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 14
7. PROCESS DETAILS
Please refer Exhibit – 2, Manufacturing process of Specialty chemical & Intermediates
along with Process Flow diagram with chemical reaction.
8. UTILITY AND REQUIREMENTS
Company has acquired adequate land and other resources to expand the production
capacity. Other requirements are Power, Water and manpower.
8.1 WATER CONSUMPTION AND WASTE WATER GENERATION
The source of water for the existing as well as proposed expansion meets through MIDC.
Total water requirement for the existing as well as proposed production is 468 KLD (52+
416). 5.4 KLD Domestic effluents shall be disposed through septic tank & soak pit. Existing
Trade effluent generation 26 KLD and proposed additional Trade effluent generation will
be 229 KLD. From existing effluent 16 KLD is recycled through MEE and 10 KLD is send to
CETP. Proposed 229 KLD effluents will be recycled using MEE. Details of water
consumption and waste water generation are tabulated in Table No. 6.
Table 6: Details of Water Requirement & Waste Water Generation
Note: E: Existing, P: Proposed, T: Total after proposed expansion
Sr. No. Particulars
Water Consumption
KL/Day
Waste Water Generation
KL/Day
E P T E P T
1 Domestic 2.5 6.5 9.0 1.5 3.9 5.4
2 Process 23.0 249 272.0
14.0 156 170 3
Gas
Quenching 0.4 11.6 12.0
4 Boiler 15.6 97.4 113.0 12.0 73 85
5 Cooling 2.0 25 27.0 0.0 0.0 0.0
6 Acid Dilution 8.0 22 30.0 0.0 0.0 0.0
7 Green Belt 0.5 4.5 5.0 -- -- --
Total 52 416 468 27.5 232.9 260.4
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 15
8.1.1 Water Balance Diagram :
Sock Pit & Septic Tank
Domestic Use 9.0 KLD
(2.5 + 6.5) KLD
17.5.
Total Water Requirement 468 KLD
[Existing 52 KLD+ Proposed 416 KLD
Industrial Use 454 KLD
(49+405) KLD
Gardening 5.0 KLD
(0.5 + 4.5) KLD
Boiler 113 KLD
Disposal at MSWL
Inorganic salts as Sludge from MEE
Process 272 KLD
Acid Dilution 30 KLD
Multiple Effect Evaporator
250 KLD
ETP 255 KLD
170
Evaporation Loss 7.5 KLD
Cooling Tower 25 KLD
Gas Quenching 12 KLD
Sell to other Industries as dilute Acid
5.4 KLD
Condensed Water (90%)
225 KLD
Activated Charcoal
Bed
Recycle & Reuse for Process
85
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 16
8.1.2 Effluent Treatment plant :
Effluent is coming from process, boiler feed and gas quenching to be collected
separately in the collection tank. It is to be neutralized, and send to Multiple Effect
Evaporator (MEE). The condensed water obtained from the MEE system is to be send to
Activated Charcoal Bed to remove any traces of Color & Volatile Organic Matter. Thus
this Industrial water can be totally re-cycled & reused. Existing ETP and MEE is shown in
Figure 3 and Figure 4.
Figure 3: Flow Diagram of Existing ETP
At Present Odyssey Organics handles 3 Main Effluent Streams –
Second is Reduction Stream as below:
SPENT SULFURIC ACID
NITRATION PROCESS
STORAGE TANKS
100 % SALE AS BI-PRODUCT
NEUTRALIZATION STORAGE TANKS
MULTIPLE EFFECT EVAPORATOR
(1000 KG / HR)
CONDENSE WATER STORAGE
RECYCLE SLUDGE
M.S.W.L
REDUCTION STREAM
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 17
The Third - Hydrolysis Stream Is As Below.
In the below diagram:
A & B– Collection & Primary Treatment Tanks (Neutralization & Hydrogen Peroxide Mixing).
C - Primary Clarifier to settle the Solids,
D – Secondary Tank (aeration)
E – Secondary Clarifier,
V- “V” – Shaped Notch for Sample collection & Discharge to C.E.T.P
HYDROLYSIS STREAM
STORAGE TANKS 1
A B
C
D E
TO C.E.T.P. V
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 18
Figure 4 : Flow Diagram of Existing MEE of capacity 1000 Kg/Hour
8.2 POWER CONSUMPTION
The Source of Electricity obtained from M.S.E.B. The power demand for the existing
manufacturing activity is 146 KVA and 3431 KVA will be required for proposed
expansion.
Table 7 : Details of Power Consumption
Sr. No. Particulars Power Consumption (KVA)
Source Existing Proposed Total
1 Operations M.S.E.B 89 2236 2325
2 Effluent Treatment M.S.E.B 55 839 894
3 Other General M.S.E.B 2 356 358
4 DG Set D.G. Set
(Stand By) 125 125*3 125*4
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 19
8.3 MANPOWER REQUIREMENT
The Project will create direct & indirect employment opportunities within the surrounding
region. The Unit will use good faith efforts to employ local people from the nearby
villages depending upon the availability of skilled & un-skilled man-power surrounding
the project site. In operation phase, the proposed project would require significant
workforce of non-technical and technical persons. Migration of highly education and
skilled experience will result in increase of literacy in the surrounding villages.
Table 8: Employment Details
Sr.
No. Descriptions
Nos.
Existing Proposed Total after proposed
expansion
1 Direct
employment
55 65 120
9. STACK DETAILS AND FUEL REQUIREMENT :
In the existing unit Briquetes is used as a fuel for Boiler and Diesel is used as a fuel for D.G
set. Details of stacks and D.G. set is given in Table 9. Table 9: Details of Flue gas Stack
Sr.
No
.
Stack
attached to
Capacit
y Status
Stack
Height
(m)
Stack
Dia.
(mm)
Fuel name
& Quantity
Stack
Gas
Temp
(°C)
Air
Pollution
Control
Measure
1 Boiler (Non
IBR) 1
500 kg
/hr Existing 18 400
Briquetes,
60
Mt/Month
130 Stack
2 IBR Boiler 12,000
kg/ hr Proposed 22 600
Coal, 250
MT/Month 180 Stack
3 D.G Set 125 KVA Existing 10 400 Diesel, 500
lit/Month 80 Stack
4 DG Set 125*3
KVA Proposed 10 400
Diesel, 1500
lit/Month 80 Stack
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 20
10. HAZARDOUS WASTE GENERATION AND MANAGEMENT
Hazardous waste generated from the process & maintenance. The Management of
Hazardous waste will be done as per Hazardous Waste Management Rules 2008. The
Hazardous waste generation and management are shown in Table 10.
Table 10 : Hazardous Waste Management
Sr.
No
.
Hazardous
Waste
Category
No.
Quantity (MT/Month) Source of
Generation
Stora
ge Disposal
E P T
1 Used Oil 5.1 30 150 180
Plant
Maintenan
ce
Drum
Selling to
registered
Refiner
2 ETP Sludge 26.2 2 13 15 ETP Bag
M.S.W.L. for
Land Fill or
Incineration
3
Solid
Sludge
from MEE
34.4 10 1720 1730 MEE Bag
M.S.W.L. for
Land Fill or
Incineration
4 Organic
Residue 28.1 Nil 25 25 Process Bag M.S.W.L.
5 Process
Waste 26.1 12 1738 1750 Process Bag
M.S.W.L. for
Land Fill or
Incineration
6
Discarded
Bags &
Container
33.3 1200 6000 7200 Production
Section
Store
into
SWSA
Selling to
registered
reuser/recyc
lers
10.1 NON-HAZARDOUS SOLID WASTE GENERATION AND MANAGEMENT.
Table 11 : Non Hazardous Solid Waste Generation
Sr. No Name of solid waste Quantity (Mt/month)
Management E P T
1 Canteen Waste 1 3 4 Send to Municipal
Corporation, Mahad
2 Paper, cardboard,
Metal scrap etc 3 7 10
Selling to registered
reuser/recyclers
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 21
3
Total Salt Content As :
Sodium Sulfate &
Sodium Chloride Mixture
Nil 1360 1360 Send to M.S.W.L
4
Total Salt Content As :
Sodium Thiosulfate Nil 360 360 Send to M.S.W.L
5 Total Salts As
Ammonium Chloride Nil 120 120 Send to M.S.W.L
11. LAND REQUIREMENT DETAILS
The existing unit of M/s. Odyssey Organics Pvt. Ltd. is located at plot no. B-36, 37, 39,
Birwadi MIDC, Taluka: Mahad, District: Raigad, Maharashtra. Total Plot area of the plant
is 25000 m2. The break-up area detail is given in Table 12 and the Plant Layout of the unit
is given in Figure 5 & Figure 6.
Table 12: Details of Land use Break-up
S. No. Particulars
Land Area in Sq.m
Existing
Proposed
1 Plant Facilities 798 10,399
2 Administrative Building and
Canteen 2,490 500
3
Effluent treatment plant –
multiple effect evaporator
& other systeems
586 2,475
4 Internal Approach roads 1,515 838
5 Green belt /plantation 1847 3552
6 TOTAL PLANT AREA 7,236 17,764
7 Open space to be use for
Future expansion 17,764 NIL
Total AREA 25,000
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 22
Figure 5. Layout Plan of Plot no. 36 & 37
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 23
Figure 6. Layout Plan of Plot no.39
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Pre-Feasibility Report 24
12. GREEN BELT DEVELOPMENT
Unit has already developed greenbelt area in 5399 Sq m within plant premises. There
are shrubs and trees developed in the greenbelt area. 21.6 % of the total plot area is
earmarked for green cover and open space development in the existing facility.
Suitable plant species of local varieties will be planted with adequate spacing and
density for their fast growth and survival.
13. STROM WATER MANAGEMENT
Surface drainage has designed based on the maximum rainfall intensity prevalent in the
area. All the building has been provided with a plinth protection all round, sloped
towards the side drain. The storm water collection system has designed in such a
manner so that clean storm water from garden, parking areas, roadways and lawns.
14. Conclusion
Looking at the present market scenario, it is concluded that the project is not only feasible and viable, but it will also increase the employment Opportunity in future.