pre-feasibility reportfor amendment in existing ec for...

ALKYL AMINES CHEMICALS

LIMITED

Pre-feasibility Reportfor Amendment in Existing EC for Expansion of Amines, Amine Derivatives and Acetonitrile Plants at GIDC Dahej, Phase II, District Bharuch, Gujarat

MARCH 2018

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

ALKYL AMINE CHEMICALS LTD.

EXPANSION OF AMINES, AMINE

DERIVATIVES AND ACETONITRILE

PLANTS AT GIDC DAHEJ, PHASE II QUALITY CONTROL

KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2018 2

ALKYL AMINES CHEMICALS LIMITED

Pre-feasibility Reportfor Amendment in Existing EC for Expansion of Amines, Amine Derivatives and Acetonitrile Plants at GIDC Dahej, Phase II, District Bharuch, Gujarat © Kadam Environmental Consultants (‘Kadam’), March, 2018

This report is released for the use of the M/s. Alkyl Amines Chemicals Limited, Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information

provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of Publication

Pre-feasibility Report for Amendment in Existing EC for Expansion of Amines, Amine Derivatives and Acetonitrile Plants at GIDC Dahej, Phase II, District Bharuch, Gujarat

Project Number 1732022106 Report No. 1 Version 0 Released March 2018

Prepared & Managed By

Dhara Patel Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office) 871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-6131000; F: +91 265 6131006 Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall, Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected];T: 0124-4242430; M:+91-98998-04300

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims

any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation.

mailto:[email protected]

mailto:[email protected]




PLANTS AT GIDC DAHEJ, PHASE II TABLE OF CONTENTS


CONTENTS

1 EXECUTIVE SUMMARY ................................................................................. 6

1.1 INTRODUCTION AND PLANT FEATURES AND PRODUCTION CAPACITY .................................... 6

1.2 WATER ................................................................................................... 6

1.3 EFFLUENT GENERATION, TREATMENT AND DISPOSAL .................................................... 6

1.4 POWER ................................................................................................... 7

1.5 AIR EMISSION ............................................................................................ 7

1.6 HAZARDOUS WASTE GENERATION AND DISPOSAL ....................................................... 7

2 INTRODUCTION .......................................................................................... 8

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................ 8

2.1.1 Introduction of Project Proponent ............................................................. 8

2.1.2 About Proposed Project ......................................................................... 8

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION. .............................................. 8

2.3 DEMAND SUPPLY GAP .................................................................................... 9

2.3.1 Global Market ..................................................................................... 9

2.3.2 Domestic Market ................................................................................. 9

2.4 IMPORT VS.INDIGENOUS PRODUCTION ................................................................... 9

2.5 EXPORT POSSIBILITY ..................................................................................... 9

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ............................ 9

3 PROJECT DESCRIPTION ............................................................................. 10

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ................ 10

3.1.1 Type of Project ................................................................................. 10

3.1.2 Interlinked & Interdependent Project ....................................................... 10

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT LAY OUT) WITH COORDINATES ........................................................................ 10

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 15

3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 16

3.5 PROCESS DESCRIPTION WITH PROCESS DETAILS (SCHEMATIC DIAGRAM / FLOW CHART SHOWING THE

PROJECT LAY OUT, COMPONENT OF THE PROJECT ETC. SHOULD BE GIVEN) .................................... 16

3.5.1 Salient Features of Technology .............................................................. 16

3.5.2 Process Description ............................................................................ 16

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 16

3.6.1 Raw Materials Required ....................................................................... 16

3.6.2 Transportation details of Raw Materials .................................................... 17

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 19

3.7.1 Water consumption ............................................................................ 19

3.7.2 Power Requirement ............................................................................ 20

3.7.3 Fuel ............................................................................................... 20






3.8 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT

/DISPOSAL ...................................................................................................... 21

4 SITE ANALYSIS ......................................................................................... 22

4.1 CONNECTIVITY ......................................................................................... 22

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................ 22

4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 22

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING

AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE

FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE

HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION

SHOULD BE GIVEN. ............................................................................................. 22

4.5 EXISTING INFRASTRUCTURE ............................................................................ 22

4.6 SOIL CLASSIFICATION .................................................................................. 22

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 23

4.7.1 Temperature .................................................................................... 23

4.7.2 Wind ............................................................................................. 23

4.7.3 Rainfall ........................................................................................... 23

4.7.4 Cloud Cover ..................................................................................... 23

4.7.5 Humidity ......................................................................................... 24

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 24

5 PLANNING BRIEF ...................................................................................... 25

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

PLANNING /DEVELOPMENT AUTHORITY CLASSIFICATION: ..................................................... 25

5.2 POPULATION PROJECTION .............................................................................. 25

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.): ...................................... 25

6 PROPOSED INFRASTRUCTURE .................................................................... 26

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 26

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 26

6.3 GREEN BELT ............................................................................................ 26

6.4 SOCIAL INFRASTRUCTURE .............................................................................. 26

6.5 CONNECTIVITY ......................................................................................... 26

6.5.1 By Road .......................................................................................... 26

6.5.2 By Rail ........................................................................................... 26

6.5.3 By Air ............................................................................................ 26

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...................................... 26

6.7 SEWAGE SYSTEM ....................................................................................... 26

6.8 INDUSTRIAL WASTE MANAGEMENT ..................................................................... 27

6.9 POWER REQUIREMENT & SUPPLY/ SOURCE ............................................................. 27

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 28






7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING

HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS(A BRIEF OUTLINE TO BE GIVEN) ................... 28

8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 29

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE

PROJECT TO BE GIVEN) ......................................................................................... 29

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

29

8.2.1 Fixed Capital .................................................................................... 29

8.2.2 Working Capital ................................................................................ 29

8.2.3 Revenues ........................................................................................ 29

8.2.4 Breakeven Point ................................................................................ 29

8.2.5 Profitability ...................................................................................... 29

8.2.6 Fixed Capital .................................................................................... 29

9 ANALYSIS OF PROPOSAL ........................................................................... 30

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFITS TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. ........................................................ 30




PLANTS AT GIDC DAHEJ, PHASE II EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

1.1 Introduction and Plant Features and Production Capacity

Alkyl Amines Chemicals Ltd. Is in the business of manufacturing and marketing various aliphatic

amines, amine derivatives and other Speciality chemicals for the last 30 years in India. It has

established a leading position in the domestic market and a presence in the international market with

a reputation for reliable service and quality products.

The unit now proposes expansion of amines, amine derivatives and acetonitrile plants at GIDC Dahej,

Phase II, District Bharuch, Gujarat. Details of Production are given in Table 1-1.

Table 1-1: Detail of Production

S.

No. Products

Quantity MT/ Annum

Existing (EC &

CTE Received

for)

CTO

Received For Proposed

Total

(Existing +

Proposed)

1 Methylamines (Mono, Di & Tri) 49500 49500 - 49500

2 Dimethylaminopropylamine

(DMAPA) 4950 - - 4950

3 Tertiaryamine 4950 - - 4950

4 N-Methyl Pyrollidone (NMP) 9900 -

-9900 9900 N- Ethyl Pyrollidone (NEP) 9900 -

5 Acetonitrile 16500 - - 16500

6 Sodium acetate 6105 - - 6105

7 Dimethylacetamide (DMAC) - - 8250 8250

8 Amine Hydrochloride - - 57750 57750

Total 101805 49500 56100 157905

Unit have proposed to reduce capacity of NMP/NEP from 19,800 MTPA to 9,900 MTPA which

compensate additional requirement of fresh water and effluent. Total existing quantity reduced by

1,01,805 MTPA to 91,905 MTPA.

1.2 Water

Water is sourced from GIDC water supply. Existing water consumption is 994 KLD and after proposed

expansion there will be no increase in water consumption. So after expansion total water consumption

will be 994 KLD.

1.3 Effluent Generation, Treatment and Disposal

Existing wastewater generation is 485 KLD. Proposed wastewater generation will be 40.5 KLD. So after

proposed expansion total wastewater generation will be remain 485 KLD as we are reducing capacity

of existing products NMP/NEP by 9900 MTPA.




PLANTS AT GIDC DAHEJ, PHASE II EXECUTIVE SUMMARY


After proposed expansion there will be no increase in water consumption and waste water generation

as Unit have proposed to reduce capacity of NEP/NMP from 19800 MTPA to 9900 MTPA which

compensate additional requirement of fresh water and effluent. Water balance remain same after

addition of DMAC and Amine Hydrochloride solution.

1.4 Power

Power is sourced from Dakshin Gujarat Vij Company Ltd. (DGVCL). Existing power requirement is

4000kW and proposed requirement will be 750 kW. During emergency existing 1 DG set of 1000 kVA

is provided & after proposed expansion no additional DG Set will be required.

1.5 Air Emission

Flue Gas Stacks

Stacks for boilers, thermic fluid heater and DG set are provided. Coal, FO and HSD are used as fuel.

ESP is provided to the boiler as pollution control measures. Adequate stack will be provided to all

stacks. After proposed expansion, no additional Flue Gas Stack required.

Process Vents

There are existing 4 process vents provided and 1 proposed. All process vent will adequate with water

scrubber to control pollutants like ammonia, HCL and total amines.

1.6 Hazardous Waste Generation and Disposal

Hazardous waste generated from the plant operations will be disposed in nearby waste management

landfill facility. The unit has membership of M/s. Bharuch Enviro Infrastructure Ltd. (BEIL),

Ankleshwar.




PLANTS AT GIDC DAHEJ, PHASE II INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project and Project Proponent

2.1.1 Introduction of Project Proponent

Alkyl Amines Chemicals Ltd. is in the business of manufacturing and marketing various

aliphaticamines, amine derivatives and other specialty chemicals for the last 30 years in India. It

hasestablished a leading position in the domestic market and a presence in the international market

witha reputation for reliable service and quality products. Currently, it has two manufacturing sites

with 9production plants and related utilities at Patalganga and Kurkumbh in MIDC, Maharashtra.

Diaminesand Chemicals Limited, Vadodara is an associate company manufacturing a range of Ethyl

amines.With the growing demand for its products, the company has set up a new manufacturing base

in Dahej, Gujarat where it has Methylamines plant is in commissioning stage in the new industrial zone

to expand its business.

2.1.2 About Proposed Project

Details of existing and proposed production are given in Table 2-1.

Table 2-1: Detail of Production

S.

No. Products

Quantity MT/ Annum

Existing (EC &

CTE Received

for)

CTO

Received For Proposed

Total

(Existing +

Proposed)

1 Methylamines (Mono, Di & Tri) 49500 49500 - 49500

2 Dimethylaminopropylamine

(DMAPA) 4950 - - 4950

3 Tertiaryamine 4950 - - 4950

4 N-Methyl Pyrollidone (NMP) 9900 -

-9900 9900 N- Ethyl Pyrollidone (NEP) 9900 -

5 Acetonitrile 16500 - - 16500

6 Sodium acetate 6105 - - 6105

7 Dimethylacetamide (DMAC) - - 8250 8250

8 Amine Hydrochloride - - 57750 57750

Total 101805 49500 56100 157905

2.2 Need for the project and its importance to region.

Industrialization in India is increasing at rapid pace and is leading to growth and expansion of

variousindustries like Pharmaceuticals, agrochemicals etc. Alkyl Amines Chemicals Limited is a global

supplierof amines and amine-based chemicals to the pharmaceutical, agrochemical, rubber chemicals

& watertreatment industries, among others. M/s AACL aims to expand its horizons further in India and

abroadby expanding its capacities. These products will serve to cut the supply of imports from foreign

products.




PLANTS AT GIDC DAHEJ, PHASE II INTRODUCTION


2.3 Demand Supply Gap

DMAHCL It is mainly used in Metformin which is growing @ of 10% per annum. Although the current

combined capacities (AACL + Bal+ Shraibs) are meeting the demand but from the growth rate it is

evident that the demand will overshoot the capacities in coming years.

DMAC majorly used as solvent in pharma. It also used in textile industry as spandex (fiber). There is

no growth in demand but the current capacity in India (4500 MTPA). Considering 7000 MT demand of

India there is a gap of 2500 MTPA which is currently fulfilled by imports from other countries.

2.3.1 Global Market

Globally the Dmahcl market is around 40,000 MTPA. It is a combined requirement of India, Spain,

Iran, Taiwan, Bangladesh etc.

Globally the Dmac market is around 17000 MTPA. It is a combined requirement of India, Oman, China

Vietnam, Turkey etc.

2.3.2 Domestic Market

Currently Indian market for DMAHCL is around 28000 MTPA and for DMAC demand of India is around

7000 MTPA.

2.4 Import vs.Indigenous Production

Currently there is no import of DMAHCL and our indigenous capacity is 17000 MTPA.

At present 3500 MTPA of DMAC is being imported in India from countries like China, Turkey, Japan,

and Belgium.

2.5 Export Possibility

DMAHCL is exported in various countries i.e. Spain, Taiwan, Bangladesh, Iran etc.

DMAC is exported in various countries i.e. Oman, China, Veitnam etc.

Applicator areas DMAHCL- It is used as key starting material mainly in pharmaceutical industry.

End use molecules are Metformin, Ranitidine, Tremedol.

Applicator areas DMAC- It is used mainly in pharmaceutical and agro industry. It is used as solvent.

It also used in textile industry as spandex (fiber).

2.6 Employment Generation (Direct and Indirect) due to the project.

Direct: ~25

Indirect: ~20




PLANTS AT GIDC DAHEJ, PHASE II PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

3.1.1 Type of Project

The proposed project is for Amendment in existing EC for expansion of Amines, Amine Derivatives &

Acetonitrile plants that is covered under Category – 5 (f) “B” as per new EIA notification vide gazette

no. S.O. 1533 dated 14th September 2006.

3.1.2 Interlinked & Interdependent Project

There is no project interlinked or interdependent with the proposed project.

3.2 Location (map showing general location, specific location and project boundary

& project lay out) with coordinates

The proposed facility is located at Dahej, GIDC. The total plot area of the unit is 98,680 m2. Location

map of the proposed site is attached as Figure 3-1. Site location on Google image is attached as

Figure 3-2. Site layout map of proposed project is given as Figure 3-3.

ALKYL AMINE CHEMICALS LTD. EXPANSION OF AMINES, AMINE DERIVATIVES AND

ACETONITRILE PLANTS AT GIDC DAHEJ, PHASE II PROJECT DESCRIPTION


Figure 3-1: Site Location Map

ALKYL AMINE CHEMICALS LTD. EXPANSION OF AMINES, AMINE DERIVATIVES AND

ACETONITRILE PLANTS AT GIDC DAHEJ, PHASE II PROJECT DESCRIPTION


Figure 3-2: Site Location on Google Image

ALKYL AMINE CHEMICALS LTD. EXPANSION OF AMINES, AMINE DERIVATIVES AND ACETONITRILE PLANTS AT GIDC DAHEJ, PHASE II PROJECT DESCRIPTION


Figure 3-3: Site Layout Map






Table 3-1: Area Break up at Site

S. No. Unit

No. Area Designation

Area in m2 % of Total

Area Existing Proposed Total

A. Plant

1 1 Methyl Amine Plant 1120.5 1120.5 1.1

2 30 Acetonitrile Plant 1320 1320 1.3

3 31 DMA HCL Solution Plant 933.85 933.85 0.9

4 32 DMAC Plant 543.4 543.4 0.6

5 33 NMP Process Plant 800 800 0.8

6 49 MPP Plant I (DMAPA / TA) 760 760 0.8

B. Raw Materials & Finished Products Storage

1 2 Drum Filling Storage 638 638 0.6

2 3

Finished Goods Storage (70% MEA Tank)

222 222 0.2

3 4 Emergency Storage Tank 195 195 0.2

4 5 Methanol Storage 3250 3250 3.3

5 6

Amine Tanker Filling Station Area

225 225 0.2

6 7 Liquid N2 Storage Tank 185.5 185.5 0.2

7 8 SMPV Vent Scrubbing Area 120.6 120.6 0.1

8 9

Ammonia / Methylamine Storage

6249 6249 6.3

9 34 Process Storage Tank 192.64 192.64 0.2

10 35 Process Storage Tank 90.9 90.9 0.1

11 36 F.G.I. Storage 317.12 317.12 0.3

12 37 DMAC Storage 208 208 0.2

13 38 Acetic Acid storage 616 616 0.6

14 39 FO Storage 349.16 349.16 0.4

15 40 Caustic & R.M. II Storage 275 275 0.3

16 41 HCL/DMAHCL Storage 886 886 0.9

17 42 Drum Filling Storage 910 910 0.9

C. Utilities

1 10 Boiler House 2898 2898 2.9

2 11 Ash Handling System 54 54 0.1

3 12A Coal Conveyor System 780 780 0.8

4 12B Coal Storage 504 504 0.5

5 13 Air Compressor Shed 100 100 0.1

6 14A ETP + STP 1110.66 1110.66 1.1

7 14B DM Plant 96 96 0.1

8 14C

DM Tank + Safety Shower Tank + MCC Room

148 148 0.1






S. No. Unit

No. Area Designation

Area in m2 % of Total

Area Existing Proposed Total

9 15 Cooling Tower I & II 165 165 0.2

10 16A

Air Cooled Heat Exchangers I 463 463 0.5

11 16B

Tempered Water Storage I 143 143 0.1

12 17 RW/FW Storage & Pump Hose 1150 1150 1.2

13 43 Cooling Tower III & IV 167.7 167.7 0.2

14 44 Cooling Tower for DMAC Plant 61.15 61.15 0.1

16 45 Tempered Water Storage II 140 140 0.1

17 46 Air Cooled Heat Exchangers II 179 179 0.2

18 47 Chilling Plant 110.25 110.25 0.1

19 48 Thermic Fluid Heater 232.65 232.65 0.2

D. Non Plant

1 18 Administrative Building 767.25 767.25 0.8

2 19 Control Room Building 787.52 787.52 0.8

3 20 Sub Station – 1 607 607 0.6

4 21 Sub Station – 2 624 624 0.6

5 22 Engineering Store & Workshop 363.81 363.81 0.4

6 23 Main Gate security Cabin 77.28 77.28 0.1

7 24 Material Gate Security Cabin 35.98 35.98 0.0

8 25 Weigh Bridge 108.75 108.75 0.1

9 26 GOD Power & Transformer 45 45 0.0

10 27 Meter Room 20 20 0.0

11 28 Car Parking 2790 2790 2.8

12 29 Truck Parking 684.6 684.6 0.7

13 50 Contactor Shed 215.6 215.6 0.2

14 51 Scrap Yard 400 400 0.4

15 52 Open Store 132 132 0.1

16 53 Green Belt 23633 23633 23.9

17 54 Roads and Other area 38478.02 38478.02 39.0

Total 96108.64 2571.25 98679.89 100.0

3.3 Details of alternate sites considered and the basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted

Land is acquired for the proposed expansion project in the GIDC Notified Industrial area having proper

industrial infrastructure hence alternate site consideration is not envisaged.






3.4 Size or Magnitude of Operation

The production detail is given in Table 1-1.

3.5 Process Description with Process Details (Schematic Diagram / Flow Chart

showing the project lay out, component of the project etc. should be given)

3.5.1 Salient Features of Technology

Both the technologies have been developed in-house. DMAHCL solution technology is being practiced

at our Kurkumbh plant since last 20 years and well established.

The DMAC technology is relatively new but we are producing number of amines at our Kurkumbh

plant and this technology is having slight variation of the existing processes.

3.5.2 Process Description

Details of manufacturing process is given in the Annexure 6 of additional document in Form-1.

3.6 Raw material required along with estimated quantity, likely source, marketing

area of final products, mode of transport of raw material and finished product.

3.6.1 Raw Materials Required

The consumption figures and mode of storage for the major raw materials are presented Annexure 7

of additional document in Form -1.






3.6.2 Transportation details of Raw Materials

Table 3-2: Transportation details of Raw Materials

S.No. Chemical Name Consumption

(kg)

Mode

ofTransport Source

Existing

1 Methanol 1.35 Road Tanker GNFC/Import

2 Ammonia 0.45 Road Tanker GSFC/Kribhco

3 Acrylonitrile 0.552 Road Tanker RIL/Import

DMA 0.469 Pipe line In house

4 Hydrogen Gas (Nm3) 0.044 Gas Cylinders GFL/GACL/Grasim

5 GBL 0.914 Road Tanker Import

MMA 45% Solution 0.696 Pipe line In house

GBL 0.801 Road Tanker Import

6 MEA 70% 0.569 Road Tanker Own Plant

7 Acetic Acid 1.21 Road Tanker Local Importers

Ammonia 0.34 Road Tanker GSFC/Kribhco

8 Caustic Lye 46% (as lye) 0.2 Road Tanker RIL/

GFL/GACL/Grasim

9 Fatty Alcohol 0.970 Road Tanker Local / VVF

DMA 0.235 Pipe line In house

Proposed

1 Anhydrous Dimethylamine 0.550 Pipe line In house

2 Acetic acid 0.733 Road Tanker Local Importers

3

Anhydrous amine like

Dimethylamine,Trimethylamine,

Monomethylamineetc

0.407 Pipe line In house

4 Hydrochloric acid -30 % solution 1.053 Road Tanker GFL/GACL/Grasim

Table 3-3: Transportation details of Products

S.No. Chemical Name Quantity in

MT/Annum Mode ofTransport

Existing

1 Monomethylamine

49500 Road Tanker 2 Dimethylamine

3 Trimethylamine

4 Dimethyl amino propylamine 4950 Road Tanker/Truck

5 N-methyl pyrollidone / n-ethyl pyrollidone 19800 Road Tanker/Truck

6 Acetonitrile 16500 Road Tanker/Truck

7 Sodium acetate solution 6105 Road Tanker

8 Tertiary Amines 4950 Road Tanker/Truck

By-Products

1 Spent Ammonia Solution 3345 Road Tanker

2 Spent Caustic Solution 4770 Road Tanker

3 Spent Catalyst 60 Truck

4 Spent Organic Solvent 746 Road Tanker/Truck






S.No. Chemical Name Quantity in

MT/Annum Mode ofTransport

Proposed

1 Dimethylacetamide 8250 Road Tanker/truck

2 Amine Hydrochloride 70% soln 57750 Road Tanker






3.7 Availability of water its source, energy/power requirement and source should

be given

3.7.1 Water consumption

Existing Water consumption is 994 KLD which is being sourced from GIDC water supply. Existing

industrial Waste water generation is 468 KLD which sent to ETP for treatment and finally disposed

through GIDC effluent drain. Existing sewage generation is 17 KLD is being treated in STP and

recycled for Gardening purpose.

After proposed expansion there will be no increase in water consumption and waste water generation

as Unit have proposed to reduce capacity of NEP/NMP from 19800 MTPA to 9900 MTPA which

compensate additional requirement of fresh water and effluent. Water balance remain same after

addition of DMAC and Amine Hydrochloride solution.

The below Table 3-4 shows the water consumption details and Table 3-5 shows the waste water

generation details.

Table 3-4: Water Consumption Details

S.

No.

De

scri

pti

on

Water Consumption, KLD

Ex

isti

ng

(E

C a

nd

CT

E R

ece

ive

d f

or)

CT

O R

ece

ive

d f

or

De

leti

on

du

e t

o

Re

du

cti

on

in

th

e

ex

isti

ng

Ca

pa

cit

y

Aft

er

De

leti

on

of

ex

isti

ng

pro

du

cti

on

Ca

pa

cit

y (

C-E

)

Pro

po

sed

To

tal

(Aft

er

De

leti

on

of

ex

isti

ng

pro

du

cti

on

Ca

pa

cit

y +

Pro

po

sed

) (F

+G

)

A B C D E F G H

1 DM Plant 282 230 27 255 25 280

a Process 180 171 2 178 4 182

b Boiler 86 43 23 63 19 82

3 Cooling

Tower 653 440 190 463 186 649

4 Washings 20 5 0 20 3 23

5 Fire Hydrant 5 0 0 5 0 5

6 Domestic 20 8 0 20 3 23

7 Gardening 14 0 0 14 0 14

Total 994 683 217 777 217 994






Table 3-5: Wastewater Generation Details

S.

No

.

De

scri

pti

on

Wastewater Generation, KLD

Tre

atm

en

t Fa

cil

ity

Ex

isti

ng

(E

C a

nd

CT

E

Re

ce

ive

d f

or)

CT

O R

ece

ive

d f

or

De

leti

on

du

e t

o

Re

du

cti

on

in

th

e

ex

isti

ng

Ca

pa

cit

y

Aft

er

De

leti

on

of

ex

isti

ng

pro

du

cti

on

Ca

pa

cit

y (

C-E

)

Pro

po

sed

To

tal

(Aft

er

De

leti

on

of

ex

isti

ng

pro

du

cti

on

Ca

pa

cit

y +

Pro

po

se

d)

(F+

G)

A B C D E F G H I

1 DM Plant 16 16 2 14 2 16 To ETP

a Process 335 170 19 316 16 332 To ETP

b Boiler 15 7 0.5 14.5 0.5 15 To ETP

3 Cooling Tower 82 55 19 63 19 82 To ETP

4 Washings 20 5 0 20 3 23 To ETP

5 Fire Hydrant 0 0 0 0 0 0

6 Domestic 17 8 0 17 0 17 To STP

7 Gardening 0 0 0 0 0 0

Total 485 261 40.5 444.5 40.5 485

468 KLD Industrial

effluent to ETP and Domestic

Sewage 17 KLD will be treated

in STP and recycled for Gardening purpose.

3.7.2 Power Requirement

Source: Dakshin Gujarat Vij Company Ltd. (DGVCL).

Existing Power Requirement: 4000kW

Proposed Power Requirement: 750kW

Total Power Requirement: 4750kW

3.7.3 Fuel

Table 3-6: Fuel Consumption

Sr.

No. Stack Attached to Capacity

Stack

Nos.

Type of Fuel

used

Fuel

consumption

Existing

1 Boiler-1 30 MT/Hr 1 Coal 5450 kg/Hr

2 Boiler -2 30 MT / Hr 1 Coal 5450 kg/Hr






3 Thermic Fluid Heater -1 20 Lacs Kcal / Hr 1 Furnace Oil 260 Kgs/ Hr

4 Thermic Fluid Heater -2 20 Lacs Kcal / Hr 1 Furnace Oil 260 Kgs/ Hr

5 D. G. Set 1000 KVA 1 HSD 208 Ltr/Hr

Proposed

No additional fuel consumption

*Note: DG Set will be used only during Power failure.

3.8 Quantity of waste to be generated (liquid and solid) and scheme for their

management /disposal

Table 3-7: Hazardous Waste Generation and disposal Details

S.

No.

Type of

Waste

Hazardous

Waste

Category

Quantity per Year Source

Collection,

Treatment /

Disposal Existing Proposed Total

1 Spent Carbon

36.2 2.0 MT 0 2.0 MT ETP Carbon

bed Sent to TSDF for

Landfill

2 Distillation Residue

20.3 1532 MT 625 MT 2157 MT Various process plants

Sent for incineration

3 Spent

Organic Solvent

20.2 760 MT 0 760 MT Various process plants

Sold to Vendor

4 Used / spent

oil 5.1 5 MT 0 5 MT

Various process plants

Sent to Authorized recyclers

5

Discarded containers/

barrels/ liners

33.1 100 MT 0 100 MT Various process plants

Sent to AuthorizedVendor

6 ETP Sludge 35.3 50 MT 0 50 MT ETP Sent to TSDF for

Landfill

Unit has Membership from M/s. Bharuch Enviro Infrastructure Ltd., Ankleshwar.


EXPANSION OF AMINES, AMINE DERIVATIVES

AND ACETONITRILE PLANTS AT GIDC DAHEJ, PHASE II SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

Most of the industries in Dahej area located in GIDC Industrial area 1 & 2. The study area is well connected by

roads to Bharuch. All the areas in the study area linked either by 4 lane roads.

Two nearest railway station are available from the proposed site.

Dahej railway station is located at an aerial distance of 6.47 km in SW.

Bharuch railway station is located at an aerial distance of 37 km in E.

4.2 Land Form, Land Use and Land ownership

The total plot area of the unit is 98680 m2. As the project is located in notified industrial estate, the landuse of the

project site is industrial.

4.3 Topography (along with map)

The project site generally flat with average level difference 2.0 m. there are isolated pockets of 1.0 m – 2.0 m

above or below the average ground well.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from

the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette

notification should be given.

Existing Land use pattern: Industrial

Distance of Project site from Water Bodies are given in Table 4-1.

Table 4-1: Distance of Project site from Water Bodies

Area ~ Distance in km Direction

Bay of Cambay 10.32 W

Narmada Estuary 6.54 S

VadadalaPond 1.19 SW

VavPond 1.60 N

Jolva Pond 2.71 SSE

Galenda Pond 2.85 E

4.5 Existing Infrastructure

Proposed Expansion of the project will be done on existing land. Land is used for Industrial purpose. During

expansion additional facility will be develop as per the requirement for production of new products.

4.6 Soil classification

Not required


EXPANSION OF AMINES, AMINE DERIVATIVES

AND ACETONITRILE PLANTS AT GIDC DAHEJ, PHASE II SITE ANALYSIS


4.7 Climatic data from secondary sources

The general agro-climatic zone of the study area is Semi-Arid.

Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term

Climatological Tables, 1981-2010, Surat. These tables give useful information about a region’s weather, since they

are collected over a 30-year period.

4.7.1 Temperature

Mean daily maximum temperature is recorded in the month of April at 36.7°C.

January is generally the coldest month, with a minimum temperature of 15.2 °C.

During the post-monsoon months of October and November, day temperatures remain between 18.9 - 23.2 ºC.

In winters, i.e. December, January and February, average day temperatures remain between 14.3- 15.6 ºC.

4.7.2 Wind

Table 4-2: Predominant Wind Direction

Month

Predominant Wind

First Second Third

Morning Evening Morning Evening Morning Evening

January CALM NW N N NE NE

February CALM NW N N NE W

March CALM NW N W NE N

April CALM SW SW W S NW

May SW SW CALM W W S

June SW SW W S S W

July SW SW W W S S

August SW SW CALM W W S

September CALM SW SW W W CALM

October CALM CALM SE NW NE SW

November CALM CALM NE NW E NE

December CALM NW NE N N CALM

4.7.3 Rainfall

The total rainfall in year is observed to be 1202.8 mm. Distribution of rainfall by season is 2.4 mm in winter

(December, January, February), 4.5 mm in summer (March, April, May), 1147.1 mm in monsoons (June, July,

August, September) and 49.5mm in post-monsoons (October, November, December).

4.7.4 Cloud Cover

The area remains cloudy between July-August, which is the active period of the monsoon season. Generally cloud

cover ranges up-to 6-7 OKTAS during this monsoon season. During post-monsoon season, cloud cover almost

becomes 0 OKTAS. In the summer season cloud cover is predominantly 0 OKTAS occasionally going to 3-5 OKTAS.




PLANTS AT GIDC DAHEJ, PHASE II SITE ANALYSIS


4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by summer, post-monsoons, and

winter in that order. Mornings are more humid than evenings and humidity ranges from a high of

78-86% in monsoon mornings to a low of 34-43% in winter evenings. During post-monsoon

season, in morning humidity remains between 65-73 % and in the evening it remains between 43-

52%.

4.8 Social infrastructure available

Not Applicable




PLANTS AT GIDC DAHEJ, PHASE II PROPOSED INFRASTRUCTURE


5 PLANNING BRIEF

5.1 Planning Concept (Type of industries, facilities, transportation etc) Town

and Country Planning /Development authority Classification:

AACL has selected GIDC Dahej for its expansion based on merit. i.e. available infrastructure,

communication networks, close proximity of raw materials and finished goods etc.

A technology center was set up in Pune in the year 2002 which houses the R&D group (25

Scientist), the scale up group (5 to 7 engineers) and the implementation group (5 to 7

engineers). This center implemented all the projects and would also be executing the

proposed expansion at Dahej.

AACL may engage detailed engineering consultant and various contractors for construction

and erection.

5.2 Population Projection

Not applicable

5.3 Land use planning (breakup along with green belt etc.):

The Land use breakup at site is given in Table 3-1. Greenbelt is around 23.9 % of total area of

the plot area.






6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The proposed project is located in GIDC Dahej, Gujarat. Total Plot Area will be of 98,680 m2.

6.2 Residential Area (non-processing area)

No residential area

6.3 Green belt

Around 24% of total plot area will be developed as greenbelt.

6.4 Social Infrastructure

Not Applicable

6.5 Connectivity

6.5.1 By Road

SH-6 is the main approach road from Bharuch to project site. It is six lane state highway from

Bharuch up to Dahej, lies at an aerial distance 2.67 km towards S direction.

6.5.2 By Rail

Site is also approachable by railway which connected Bharuch and Dahej via Samani & Vagra. This

railway line passing through NW to SW direction from project site. Dahej is nearest railway station

at an aerial distance of about 6.47 km in SW direction from project site. District Head Quarter

Bharuch is a Major railway station lies on Mumbai-Vadodara mainline, at an aerial distance of

about 37 km in E direction from project site.

6.5.3 By Air

The nearest domestic airport from proposed project site is located at Vadodara, at an aerial

distance of about 88.33 km in E direction.

6.6 Drinking water management (source & supply of water)

GIDC water facilities will be used.

6.7 Sewage system

Sewage is treated in Sewage Treatment Plant (STP) of 20 KLD which already installed at existing

site and treated sewage is used for on land irrigation. Same practice will be continued after

proposed expansion.






6.8 Industrial waste management

GIDC water facilities will be used.

Company has Membership Certificate from M/s. Bharuch Enviro Infrastructure Ltd. (BEIL),

Ankleshwar for their Hazardous Waste Management.

6.9 Power requirement & supply/ source

Source: Dakshin Gujarat Vij Company Ltd. (DGVCL).

Existing Power Requirement: 4000 kW

Proposed Power Requirement: 750 kW

Total Power Requirement: 4750kW




PLANTS AT GIDC DAHEJ, PHASE II REHABILITATION & RESETTLEMENTS (R

& R) PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected persons

including home oustees, land oustees and landless laborers(a brief outline to be

given)

Not applicable as rehabilitation and resettlement will not be required, since the project lies in industrial area, with land acquisition procedures completed by GIDC.




PLANTS AT GIDC DAHEJ, PHASE II PROJECT SCHEDULE AND COST ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule

for the project to be given)

Start of construction will be immediate after getting Environment Clearance (EC) and completion of

the project will be one year from the start.

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

project.

8.2.1 Fixed Capital

INR 45Cr.

8.2.2 Working Capital

INR 10Cr.

8.2.3 Revenues

INR 240 Cr.

8.2.4 Breakeven Point

50 %

8.2.5 Profitability

20 %

8.2.6 Fixed Capital

As per following table.

Sr. No. Purpose Proposed Cost (Rs. In Lakhs)

1. Land & Building 1000

2. Plant & Machinery and other fittings 3250

3. Environmental protection measures 250

TOTAL 4500

The proposed investment will be made by company only.




PLANTS AT GIDC DAHEJ, PHASE II ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social benefits with special emphasis on the benefits to the local

people including tribal population, if any, in the area.

The new location will add around ~ 25 people to its existing rolls plus some contractual

employees. It is expected that all central support functions viz. Marketing, Purchase, Human

resources, Legal, Finance and Accounting will continue to be handled by the existing staff with

minor addition.

Employment will get generated in market by sales and service for providing products to the

industry. Also the increased capacity will increase the raw material consumption as well as the

supporting services and will give further business to the vendor industry.

During construction phase ~200 personnel will be engaged by contractors.

Many people will get indirect benefits due to coming up Industry in local market.

Transporters will be engaged to bring raw materials and supply finished goods.

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

pre-feasibility reportfor amendment in existing ec for...

Documents