Expansion Project for manufacturing of Synthetic Organic Chemicals
Bharat Chemicals -Tarapur
PFR for Bharat Chemicals Tarapur Page 1
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M/s. BHARAT CHEMICALS
PFR for Environmental Clearance (EC) of proposed expansion project at
existing unit at Plot No.: L–13, L-28, L-29 & L-30, MIDC Tarapur, District:
Palghar, Maharashtra
© Goldfinch Environmental Engineering Systems Private Limited (‘Goldfinch’), February
2017
This report is released for the use of the M/s Bharat Chemicals (Bharat).Regulators and
relevant stakeholders solely as part of the subject EC of Proposed expansion at existing
manufacturing facility located at plot No-L–13, L-28, L-29 & L-30, MIDC Tarapur,
Palghar, Maharashtra. 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 Goldfinch/Bharat.
QUALITY CONTROL
Name of
Publication
Bharat ChemicalsProposedexpansion project of Manufacturing
Synthetic organic chemicals at Plot No. L–13, L-28, L-29 & L-30,
MIDC Tarapur, Palghar-410208, Maharashtra
Project
Number
GEC/BCT/201
6/12/03
Report
No. 1 Version 1 Released
February,
2017
Prepared By Mr. Kamlesh Bagul & Mr. Rakesh Suryawanshi
Reviewed By Mr. K. N. Sharma
Released By Mr. Anand Apte
DISCLAIMER
Goldfinch has taken all reasonable precautions in the preparation of this report as per
its auditable quality plan. Goldfinch also believes that the facts presented in the report
are based on information submitted by Bharat and based on the technical expertise of
Goldfinch as on the date it was written. However, it is impossible to dismiss absolutely,
the possibility of errors or omissions. Goldfinch 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.
Expansion Project for manufacturing of Synthetic Organic Chemicals
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Contents
EXECUTIVE SUMMARY .................................................................................................... 5
1.0 INTRODUCTION OF THE PROJECT ......................................................................... 6
1.1 Introduction of the Project ......................................................................................... 6
1.2 Introduction of the Project Proponent ...................................................................... 7
1.3 Brief description of nature of the project .................................................................. 7
1.4 Need for the project and its importance to the country and or region........................... 7
1.5 Demands-Supply Gap ............................................................................................ 7
1.6 Imports vs. Indigenous Production .............................................................................. 7
1.7 Domestic /Export Markets .......................................................................................... 8
1.8Employment Generation due to the project ................................................................... 8
2.0 PROJECT DESCRIPTION ........................................................................................ 9
2.1 Type of Project ..................................................................................................... 9
2.2 ProjectLocation ..................................................................................................... 9
2.3 Details of alternate sites considered and the basis of selecting the proposed site ........ 10
2.4 Size or Magnitude of Operation ........................................................................... 10
2.5 Process Description.................................................................................................... 11
2.6 Raw material required along with estimated quantity, likely source, marketing area of final
Product/s, mode of transport of raw material and finished product. .................................... 15
2.7 Resource optimization/recycling and reuse envisaged in the project .............................. 16
2.8 Availability of water its source, energy/power requirement and source ...................... 16
2.8.1 Water Requirement and Source ..................................................................... 16
2.8.2 Power Requirement ..................................................................................... 17
2.8.2.1 Emergency power .................................................................................... 17
2.8.2.2 Utility Existing ................................................................................................ 17
2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their
management/disposal ................................................................................................... 17
2.9.1 Gaseous Emissions ........................................................................................ 17
2.9.2 Effluent ......................................................................................................... 18
2.9.3 Details of Hazardous wastes ........................................................................... 24
2.10 Schematic representations of the feasibility drawing which give information of EIA
purpose. ..................................................................................................................... 26
3.0 SITE ANALYSIS ................................................................................................ 27
Expansion Project for manufacturing of Synthetic Organic Chemicals
Bharat Chemicals -Tarapur
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3.1 Connectivity ....................................................................................................... 27
3.2Land Form, Land use and Land ownership .................................................................. 27
3.3 Topography ........................................................................................................ 27
3.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including
area under
CRZ)), shortest distances from the periphery of the project to periphery of the forests, national
park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river),
CRZ. 28
3.5 Soil classification .................................................................................................... 28
3.6 Climatic data from secondary sources .................................................................... 28
3.7 Social Infrastructure Availability ........................................................................... 28
4.0 Planning In Brief .............................................................................................. 29
4.1 Planning Concept ............................................................................................... 29
4.2 Land Use Planning ............................................................................................... 29
4.3 Assessment of Infrastructure Demand (Physical & Social) ........................................ 29
4.4 Amenities/Facilities ............................................................................................. 30
4.5 Population Projection ........................................................................................... 30
5.0 Existing infrastructure .................................................................................... 31
5.1 Industrial area ....................................................................................................... 31
5.2 Residential Area .................................................................................................. 31
5.3 Green Belt......................................................................................................... 31
5.4 Social Infrastructure ........................................................................................... 31
5.6 Drinking Water Management ................................................................................ 32
5.7 Sewage System .................................................................................................. 32
5.8 Industrial Water Management ............................................................................... 32
5.9 Solid Waste Management ..................................................................................... 32
5.10 Power Requirement & Supply / source ..................................................................... 32
6.0 Rehabilitationand Resettlement (R & R) Plan ................................................ 32
6.1 Policy to be adopted (Central/State) in respect of the project affected persons including
home
oustees, land oustees and landless. ................................................................................ 32
7.0 PROJECT SCHEDULE & COST ESTIMATES ...................................................... 32
7.1 Likely date of start of construction and likely date of completion ............................... 32
The modernization/product mix activity is likely to start after getting Environmental Clearance
and
Expansion Project for manufacturing of Synthetic Organic Chemicals
Bharat Chemicals -Tarapur
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NOC/CTE from the authorized committee. .......................................................................... 32
7.2 Estimated project cost along with analysis in terms of economic viability of the project
32
Economic Viability ........................................................................................................ 33
8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ................................. 33
Expansion Project for manufacturing of Synthetic Organic Chemicals
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EXECUTIVESUMMARY
BHARAT CHEMICALS established in 1982 and is one of the leading manufacturers of
PARACETAMOL in India and has a significant global presence. They have head office
located in Mumbai, the commercial capital of India. Bharat have state of the art facility
located in TARAPUR MIDC in Maharashtra on the leading commercial hub in India.
Bharat proposed expansion project manufacturing of synthetic organic chemicals at
existing manufacturing unit at Plot No. L-13, L-28, L-29&L-30, MIDC Tarapur, Palghar,
Maharashtra. The proposed project falls under classification 5(f) of schedules listed in
EIA notification SO1533 dated 14/09/2006. Its appraisal category is B-1.
Project Synopsis:
Sr. No.
Parameters Description
1. Category as per EIA Notification 5 (f) B
2. Longitude 72.727414 N
3. Latitude 19.790480E
4. Total Production Capacity after expansion
Total = 1435 MT/Month
(Existing = 270 MT/M & Proposed = 1165 MT/M)
5. Total Plot Area 4008.00 sq. m.
6. Green Belt Area 500 sq. m.
7. Fresh Water Requirement 432 CMD
8. Effluent Quantity (Trade +
Domestic) 85 CMD +08 CMD = 93 CMD
9. Trade Effluent Treatment
Existing effluent 23 CMD will be discharged
to CETP and proposed effluent 65 CMD after
treatment will be reuse for utilities.
High TDS stream will be fed to MEE
followed by ATFD. Low TDS stream along with condensate from MEE will be treated in conventional ETP consisting of primary, two
stage secondary and tertiary treatment. This will be further treated by RO for
permeate recycled and effect zero liquid discharge (ZLD).
10. Domestic Waste water Treatment Sewage treatment plant of capacity 10CMD will be proposed.
11. Fuel requirement at full load Steam will purchased from Aarti Industries
Ltd, L-10, MIDC Tarapur
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Sr. No.
Parameters Description
Existing D G set = 125 KVA X 1 no Proposed D G Set = 800 KVA X 1 no Fuel Required = 500 lit/day
(Type Fuel: HSD)
12. Power Requirement Existing : 600KW, Proposed : 400 KW
13. Dispersion of emission for Boiler Stack Height: 20 m stack for(2 TPH) boiler and For 6 TPH boiler stack height is 55 m
14. Dispersion of emission DG Sets, Stack Height: 6m above enclosure
15. Work Force Total 175 nos.
Existing = 115 nos.& Proposed 60 nos.
16. Total Capital Cost the project
(Cr) Rs 26.19 Cr.
1.0 INTRODUCTION OF THE PROJECT
1.1 Introduction of the Project
Bharat Chemicals (Here after being referred as Bharatfor brevity in this text) intends to
expansion of existing projectsin the category of synthetic organic chemicals.
The existing manufacturing unit is in Tarapur MIDC; which is approved chemical
manufacturing zone of MIDC. Bharat is located at plot no.- L-13, L-28, L-29 & L-30.
Existing manufacturing capacity of the unit is 270 MT/M. After expansion the total
quantities of products and by-products will become 1165 MT/M and 900 MT/M
respectively .
As per the EIA Notification S.O. 1533 dated 14thSeptember 2006, proposed activity is
covered under Synthetic Organic Chemical Industry 5 (f) and needs prior environmental
clearance. Further, as the proposed industry is under category B. Since it is located in a
notified industrial area the project will not need public approval and is under category B.
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1.2 Introduction of the Project Proponent
Table No 1.1 List of Directors and their designations
Sr.No. Name Designation
1 Mr. Shantibhai Vora Partner
2 Mr. Santosh Vora Partner
3 Mr. Paresh Shah Partner
1.3 Brief description of nature of the project
Existing manufacturing capacity of the unit is 270 MT/M. After expansion the total
quantities of products and by-products will becomes 1165 MT/M and 900 MT/M
respectively.
1.4 Need for the project and its importance to the country and or region
India's pharmaceutical industry is the third largest in the world in terms of volume. Its
rank is 14th in terms of value. India is also one of the top five active pharmaceutical
ingredients (API) producers (with a share of about 6.5%). The ever-increasing demand
for Bulk Drugs and Intermediated in India and abroad as well as changing market
conditions requisite Indian pharmaceutical industries to grow further.
Bharat aims to maximize their existing project in order to cater to Domestic &
International markets. These products will serve to cut the supply of imports from
foreign countries thus saving currency and at the same time will earn valuable foreign
currency by export of the proposed products.
1.5 Demands-Supply Gap
The population of India as well as internationally is increasing at an alarming rate. This
has created a huge gap between demand & supply of API & finally the finished dosage
form globally. To fulfill this gap, Bharat is proposing to increase the range and
production capacity to meet the market requirement. The products manufactured will be
sold both in domestic & Export markets. The major thrust in Export market will earn
foreign currency for the country. The foreign currency earned will be utilized to import
Expansion Project for manufacturing of Synthetic Organic Chemicals
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Raw materials used to manufacture these products and save valuable foreign exchange
for the country.
1.6Imports vs. Indigenous Production
The proposed products have high in demand in the export market. Also their demand is
increasing in the domestic market. Production of these chemicals domestically reduces
the need to import these in future along with significant scope for export in these
products.
1.7 Domestic /Export Markets
The finished goods will be sold in domestic market and would be largely exported to the
Regulated International Market as per demand all over the world.
1.8 Employment Generation due to the project
Existing employees are 115 nos. and additionally 60 nos. required, so total 175 nos.of
employees will be required for this expansion.
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2.0 PROJECT DESCRIPTION
2.1 Type of Project
Proposed project is expansion of existing products in the category of synthetic organic
chemicals in existing manufacturing facility located at MIDC Tarapur. It is included in
category 5(f) B of EIA notification 2006.
2.2 ProjectLocation
Existing manufacturing unit is located at Plot No.L-13, L-28, L-29 & L-30 MIDC Tarapur,
District- Palghar, State-Maharashtra.Major factories adjacent to the manufacturing unit
are open plot located on west side and Bright star textile on south side, Surchem
polymers Pvt Ltd.is located on east side&Nutraplus India ltd. on north side. The site is
well connected by road to Mumbai Ahmadabad Highway at 20 Km. The nearest railway
station is Boisar3.5 km.The nearest airport is at Mumbai 110 km.
Figure 1 Google image of the site
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The project site is situated in MIDC Tarapur. It is a notified industrial area where the
land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to
the Company. The land is meant for industrial activity.The detailed plant lay out is
attched as Annexure-I
Land Ownership: Land is owned by Maharashtra Industrial Development Corporation
(MIDC) and leased to the Company for 99 years.
2.3 Details of alternate sites considered and the basis of selecting the
proposed site
The proposal is for expansion of existing products in the same manufacturing unit using
existing infrastructure only hence consideration of alternate site is not required.
2.4 Size or Magnitude of Operation
The products manufactured and their capacities proposed are shown in below:
Table 2.2. Size/Magnitude of Proposed Production & By-product
List of Proposed By-Products
Sr.
No. List of Products
Capacity Tons / Month
Existing Proposed Total
1 Dil. Acetic Acid 70 830 900
Total 70 830 900
Sr. No. List of Products Capacity Tons / Month
Existing Proposed Total
1 Paracetamol 125 1000 1125
2 Para Nitro Phenol and salt 10 00 10
3 Caffeine 90 210 300
4 Mefanamic Acid 10 -10 00
5 Chlorozoxasone
Hydrochloride 25 -25 00
6 Albendazole 5 -5 00
7 Other Bulk Drug Product Mix 5 -5 00
Total 270 1165 1435
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2.5 PROCESS DESCRIPTION
1. Paracetamol
Chemical Reaction:
Process:
Para Amino Phenol is reacted with acetic anhydride to give Crude Paracetamol.
This Crude Paracetamol is purified with water or mother liquor to give Paracetamol. This
is dried, pulverized & packed.
Material Balance:
PRODUCT : PARACETAMOL (1MT)
Sr.
No. INPUT OUTPUT
Stage –I : ACETYLATION
RAW MATERIAL Quantity
(Kgs) FINISHED PRODUCT
Quantity
(Kgs)
1 Para Amino Phenol 800 Wet Crude Paracetamol 1120
2 Acetic Anhydride 775 Dilute Acetic Acid 900
3 Soda Ash 100 Air Emission 100
4 Water /ML 700 Recovery Paracetamol 50
5 Washing Water 200
Solid Waste ( Sodium Acetate) 155
Recycle water 150
Evaporation 100
Total 2575 Total 2575
Stage –II : PURIFICATION, CENTRIFUGING,DRYING & PACKING
1. Wet Crude
Paracetamol 1120 Paracetamol Dry 1000
2. ML/WATER 2500 ML (to be recycle) 2400
3. Activated Carbon 05 Losses (Evaporation) 215
Wet Carbon Sludge 10
Total 3625 Total 3625
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2. Para Nitro Phenol and salt
Chemical Reaction:
Process Description:
Para Nitro Chloro Benzene is hydrolyzed with caustic soda lye & Water at the
temperature of about 155°C – 160°C and to get sodium salt of Para Nitro phenol. After
acidification with sulphuric acid gives Para Nitro phenol.
Material Balance:
PRODUCT : PARANITRO PHENOL & SALT (1MT)
Para Nitro Chloro Benzene
1150 Para Nitro Phenol 1000
Caustic Soda 750 Waste Water 4700
Sulphuric Acid 500 Air Emission 200
Water 3500 Waste Water
Total 5900 Total 5900
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3. Caffeine
Chemical Reaction:
Stage I:
Stage II:
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Process Description:
Step No. I:
Theophylline Crude reacts with Sodium Hydroxide which results in in-situ formation
of Sodium Theophyllinate / Sodium Theophyllinate which further reacts with Di
methyl Sulphate [(CH3)2SO4] at controlled pH 8.0 to 8.5 results in formation of
Caffeine Crude.
Step No. II:
Caffeine Crude dissolved in water and charcoalised with Activated charcoal then
filtered crystallized and Slurry filtered in Agitated nutsche filter to get Caffeine
Pure. Drying of caffeine pure done in SFD and mixing done in Homonizer and
further packed as per party requirements.
Material Balance:
PRODUCT : CAFFEINE (1MT)
STAGE-I REACTION
1. Theophylline Crude/
Soda salt of Theophylline 1500 Reaction Mass 3990
2. Recycle ML/Water 1380
Spent Carbon 60 3. Di- methyl Sulfate 1130
4. Activated Carbon 40
Total 4050 Total 4050
STAGE-II :CRUDE FILTERATION
1. Reaction Mass 3990 Wet Caffeine Crude 1340
2. Chloroform ML 2650
Total 3990 Total 3990
STAGE-III :PURIFICATION
1. Caffeine Crude 1340 Caffeine Wet Cake 1176
2. Water 1056 ML Recycle 1319
3. Activated Carbon 50 Spent Carbon 75
4. Washing Water 124
Total 2570 Total 2570
STAGE-IV :DRYING
1. Caffeine Wet Cake 1176 Caffeine Pure 1050
Losses 126
Total 1176 Total 1176
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2.6 Raw material required along with estimated quantity, likely source,
marketing area of final Product/s, mode of transport of raw material and
finished product.
Raw Materials:
The detailed raw material list for product mixed products as per selected capacity is
detailed below for all reactants, solvents and support chemicals.
Source for Raw Material Procurement:
Raw Materials are easily available in the local market, from Mumbai and Gujarat. Part of
the raw materials are generated In-house and used internally and some raw material
will be imported.
Mode of Transport of Raw Materials:
Raw Materials will be transported through Trucks/ Tankers from suppliers factories or
traders go-downs. Those which are in house will be transported through internal
pipelines as per the requirements.
Storage at the site:
Raw Materials are stored in storage yard at the project site. Location of storage yard is
demarcated in Layout Plan.
Table 2-2: List of Raw material
Sr. No. Name of the product Existing Qty.
(MT/Month)
Proposed Qty.
(MT/Month)
Total Qty.
(MT/Month)
Para Nitro Phenol & Salt
1 Para nitro Chloro benzene 11.50 00.00 11.50
2 Caustic soda 100% basis 07.50 00.00 07.50
3 Sulphuric acid 05.00 00.00 05.00
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Paracetamol
4 Para amino phenol 110.00 812.00 900.00
5 Acetic Anhydride / Acetic acid 97.00 765.00 850.00
6 Soda ash 20.00 240.00 270.00
7 Activated carbon 01.00 11.00 12.00
Caffeine
8 Theophylline Crude/Soda salt
of Theophylline 90.00 210.00 300.00
9 Caustic soda 100% basis 10.50 24.05 34.55
10 Dimethyl sulphate 77.00 180.00 257.00
11 Hydrochloric acid 77.00 180.00 257.00
12 Activated carbon 9.00 21.00 30.00
2.7 Resource optimization/recycling and reuse envisaged in the project
To conserve the water, various recycle/ reuse schemes will be implemented. Most energy
efficient technology is selected.
2.8 Availability of water its source, energy/power requirement and source
2.8.1 Water Requirement and Source
Fresh water requirement of the project for domestic and industrial activity during
operation phase will be 432 CMD. The water supply is from MIDC. The details of water
requirement are given below
Table 2-3: Details of Raw water consumption
Sr. No. Units Raw Water Qty.(CMD)
1 Domestic 11
2 Industrial Process 150
3 Cooling tower & Boiler 266
4 Gardening 5
Total 432
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2.8.2 Power Requirement
Existing power requirement is 600 KW and additionally 400 KW will be required for
expansion. Total power requirement will be 1000 KW. Source is State Electricity Board.
2.8.2.1 Emergency power
Existing 1 no. of D. G. set having capacity125 KVA (1 no.) & additionally 800 KVA (1 no.)
are required to meet emergency power requirement.
2.8.2.2 Utility Existing& Proposed
Sr. No. Item Quantity Capacity Type Fuel Quantity
1 D G Set
(Existing) 1 125 KVA HSD 0.10 TPD
2 D G Set
(Proposed) 1 800 KVA HSD 0.30 TPD
Note: Steam will purchased from Aarti Industries Ltd, L-10, MIDC Tarapur
2.9 Quantity of wastes to be generated (liquid and solid) and scheme for
their management/disposal
2.9.1 GaseousEmissions
Details of gaseous emissions from Process and Flue gas are given in Table 2-4
Table 2-4: Details of emissions from process and flue gas
Sr. No.
Pollutant Source of Emission
Concentration in flue gas
1. SPM No emission <150 mg/Nm3
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Details of stack are given in Table 2-5
Table 2-5: Details stacks along with their mitigation methods
Stack Attached to
D. G. Set
Existing Proposed
Capacity 125 KVA 800 KVA
Fuel type Diesel Diesel
Fuel qty. 100 lit/day 400 lit/day
MOC/Make Kirloskar Cummins
Shape Round Round
Diameter 6” 6”
Height (m) (above ground
level)
5 6
Control
equipments Adequate Stack Adequate Stack
2.9.2 Effluent Generation:
The quantity of effluent generated proposed project is given in Table 2.6
Table 2-6: Details of Effluent Generation
Sr. No. Units Effluent generation
(CMD)
A Process 28
B Utilities 57
Trade effluent Total 85
C Domestic 08
Trade effluent generated from the expansion project will be 85 CMD. High TDS will be
treat in MEE followed by ATFD and Low TDS will be treat in ETP plant consisting primary,
secondary and tertiary treatment with RO unit for permeate will be recycled and effect
Zero Liquid Discharge (ZLD). The sewage generated due to domestic activities will be
treated in STP of 10 CMD capacity and treated water will be reused for gardening.
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Table 6.1: Design Data & Performance projection
High TDS Stream : To MEE
Sr.
No. Parameters Unit
RO
Reject Inlet to MEE Condensate of MEE
1. Flow m3 /
d 20 85
85 + 17 Steam
condensate
2. pH --- 6.5 -8.0 7.0 – 8.0 7.0 – 7.5
3. TSS mg/l < 100 Nil Nil
4. TDS mg/l 10100 150000 -
200000 < 150
Low TDS Stream (including condensate of Multiple Effect Evaporator) : To
ETP
Sr. No. Parameters Inlet Effluent
Characteristics
Characteristics of
Effluent to CETP
Characteristics
of Effluent to RO
1 Flow 125 23 102
2 pH 4-5 7 to 8.5 7 to 8.5
3 TDS 3000 - 4000 mg/l 1800-2000 mg/l 1800-2000 mg/l
4 BOD 2500 - 3000 mg/l 60-80 mg/l 60-80 mg/l
5 COD 5000 - 6000 mg/l 180-200 mg/l 180-200 mg/l
6 TSS 300 - 400 mg/l 70-90 mg/l 70-90 mg/l
All values are in mg/L except pH and Flow
To RO
Sr.No. Parameters Unit Inlet Permeate Reject
1 Quantity m3/day 102 82 20
2 pH ---- 7 to 7.5 7 to 7.5 7 to 7.5
3 TDS mg/L 1800 – 2000
< 100 10100
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The ETP Process Details:
ETP shall be installed to treat 125 CMD of waste water. The capacity of the ETP will be
150 CMD and it will treat effluent till tertiary level with RO unit to achieve Zero Liquid
Discharge (ZLD).
Schematic Flow Diagram of ETP has been presented in below diagram
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Standard Operating Procedure of Effluent Treatment Plant
Source of effluent generation:
High TDS Effluent: The treatment to the high TDS effluent is given the following
sequence.
1. Multiple Effect Evaporator
2. Agitated Thin Film Dryer
The high TDS effluent arising from the production activities will be collected in separate
collection sump tank near the individual plants. The effluent from collection tank shall
be collected in collection tank.
The effluent will be fed to MEE (capacity 125 CMD) where the effluent will be
concentrated up to 50 % w/w by evaporating the water with the high pressure steam.
The condensate of the Evaporator will be fed to ETP for removal of volatile organics that
will get carried away in the condensate. The concentrated liquor will be pumped to the
Agitated Thin Film Dryer for the removal of solids again by evaporation of the water
with the help of high pressure steam. Thus the dissolved solids will be completely
removed from the liquor and it will also reduce the concentration of other polluting
parameters.
The solids recovered from ATFD will be sent for disposal to CHWTSDF. The condensate
of Multiple Effect Evaporator and ATFD will be pumped to the Effluent Treatment Plant
for the removal of organics.
Low TDS Stream:
ETP is designed to treat 125 m3 / day of effluent. The treatment to the stream is in the
following sequence.
Physico-Chemical Treatment:
The treatment include the following
1) Oil and Grease trap
2) Equalization cum neutralization tank
3) Acid/Alkali dosing
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4) Effluent transfer pump
5) Flash mixture
6) Primary Settling tank
7) Bioreactor –I
8) Secondary settling Tank –I
9) Bioreactor –II
10) Secondary Settling Tank –II
11) Sludge Drying bed
The low TDS effluent generated from the utility area will be collected in separate
collection tanks near individual plants. The effluent from collection tank will be
transferred to screening sump for trapping coarse solids. The coarse solids will be
manually removed and collected in a drum for disposal. The effluent will be then
pumped to the oil and grease trap for trapping oils by virtue of its immiscibility. The oil
floats at the surface which will be skimmed out by using oil skimmer and will get
collected in drums for disposal. The effluent devoid of oils will flow to the equalization
and neutralization tank for equalizing the organic and hydraulic load. Provision of acid /
alkali dosing for neutralization of effluent will be made near the tank. The neutralizing
agents will be dosed from the respective dosing tanks. The content of equalization tank
will be mixed with help of coarse diffused aeration system. The pH will be checked with
the help of pH indicator till the pH value of 7.5 to 8 is achieved. The equalized and
neutralized effluent will be then pumped to flash mixer for primary clarification.
The dosing tanks containing alum will be used for coagulant dosing. The flash mixer will
be provided for mixing the coagulants with effluent. The coagulated mass will flow to
primary settling tank for settlement of solids. The primary settling tank will be
constructed with the hopper bottom for effective removal of solids. The clarifier
mechanisms will be fitted on the primary clarifier for effective scraping of the solids
from the walls and bottom. The settled sludge will be pumped to the sludge drying pits.
The filtrate will be collected in collection tank and pumped back to equalization tank.
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BIOLOGICAL TREATMENT
The biological treatment, (Activated Sludge Treatment) consists of following units;
1) Secondary clarifier tank-1
2) Secondary clarifier tank-2
The supernatant from the Carifloculator overflows to bio reactor - I for the aerobic
treatment. Activated sludge treatment works on the principle of development of
microbial culture in the aeration tank. Each bacterium is constituted of C, H, N, O and
P. The bacteria assimilate all carbonaceous matter. The oxygen required for the
bacterial growth will be supplied through the silicon membrane diffuser. Air will be
supplied to the diffuser through air blowers. This system is energy saving and effective
as compared to surface aerator.
The carbon and hydrogen will be present in the effluent. The microbial culture that will
be developed in the aeration tank is called Mixer Liquor Suspended Solids (M.L.S.S),
which will be in the range of 3000 to 3500 mg/lit. Mixed Liquor from the aeration tank
will flow by gravity to the settling tank-1. The sludge is settled at the hopper bottom of
the Secondary Settling tank – This sludge will be pumped back to aeration tank-1 for
marinating M.L.S.S in the tank with the help of Sludge Recycle pump. Excess Sludge
from the settling tank will be pumped to the Sludge drying Beds.The overflow of
secondary settling tank-1 will flow to aeration tank-2 and overflow of aeration tank-2
will flow to secondary settling tank-2. The organics which will not be degraded in the
1st stage bio-reactor will be degraded in the 2nd stage bio-reactor. The sludge will be
settled at the hopper bottom of the Secondary Settling tank – 2. This sludge will be
pumped back to aeration tank-2 for marinating M.L.S.S in the tank with the help of
Sludge Recycle pump. Excess Sludge from the settling tank will be pumped to the
Sludge drying Beds. The recycling of Biomass will be done in both the Bio-reactors from
the respective settling tank to maintain MLSS. The biodegradable organics which will be
not degraded in Bio-I are degraded in Bio-II.
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TERTIARY TREATMENT
Tertiary treatment includes following units;
1. Holding tank
2. Pressure Sand Filter
3. Activated Carbon filter
The biologically treated effluent flows to effluent holding sump from where will be
pumped to pressure sand filter for tertiary treatment. Tertiary treatment consists of
pressure Sand Filter and Activated Carbon Filter, which will remove traced suspended
solids which have escaped settlement and dissolved organics, color and odor. The
treated water will be collected in the final treated water tank from where it is pumped
to RO System.
RO System:
Reverse Osmosis is at present a proven technology used to recover good quality water
for process use. The treated effluent from ETP containing TDS is passed through RO
where the dissolved solids are separated in the form of Reject & treated effluent free
from dissolved solids (Permeate - 82 CMD) is utilized for cooling tower and boiler feed.
Reject of RO (20 CMD) shall be feed to the MEE.
Treatment Scheme for Domestic Wastewater
The sewage generated due to domestic activities will be treated in proposed sewage
treatment plant of capacity 10 CMD.
2.9.3 Details of Hazardous wastes
The types of Hazardous wastes generated from the project, method of disposal is shown
in below table below:
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Table 2-7: Details of Proposed Hazardous Solid waste along with the Category
and disposal method
Sr. No. Waste Name Cat. Quantity TPA Disposal
Method Existing Proposed Total
Hazardous Waste
1 Activated carbon
sludge 28.2 120 MT/A 384 MT /A 504 MT/A
Disposal to
MWML
2 ETP Sludge 34.3 2.4 MT/A 2.4 MT/A 4.8 MT/A Disposal to
MWML
Non- Hazardous Waste
Sr. No. Waste Name Unit Existing Proposed Total Disposal
Method
1 Plastic Bags Nos. 100 900 1000
Sale to
authorized recycler
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2.10 Schematic representations of the feasibility drawing which give information of
EIA purpose.
Project Identification
what environmental impacts are normally associated with such type of projects being
proposed?
Pre-feasibility Analysis
Is the Project feasible from an environment point of view?
Project Appraisal
Have all the environmental concerns associated with the project been eliminated?
Project Implementation
what environmental concerns might arise at the implementation phase of the project?
Preparation of an Environment Monitoring and Evaluation Plan
(a) What environment monitoring indicators are required to ensure that the implementation of components of the project will be executed within
environmentally sound limits?
(b) What is required to ensure that the recommended environmental control
Measures will be implemented and enforced? (c)
(Prepare a comprehensive environment monitoring and
management plan)
Project Design
(a) What negative environmental impacts could arise if the proposed project is implemented with proposed design?
(b) Is there alternative design with less environmental impacts?
Post EIA Monitoring and Environment Audit
(a) Is the implementation of components of the project being executed in an
environmentally sound manner?
(b) Are all the recommended environmental control measures being implemented and
enforced?
(a) Are there any environmental impacts that were earlier not anticipated when EIA was done?
( Identify gaps and corrective action )
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3.0 SITE ANALYSIS
3.1 Connectivity
This unit is at Plot No. L–13, L-28, L-29&L-30, MIDC Tarapur, Palghar,Maharashtra.
The nearest city from the site is Boisar at distance of 3.5 Km
The nearest railway station is Boisar at distance of 3.5 Km from the site
The nearest airport is at Mumbai 110 km.
National Highway Mumbai Ahmadabad highway is at 20 Km from project side.
3.2 Land Form, Land use and Land ownership
The proposed land is situated in approved chemical zone of MIDC where land use is
industrial. Land is owned by MIDC and is leased for 99 years.
3.3 Topography
The proposed industry is located at Latitude -19.790480N and Longitude- 72.727414 E.
Elevation above mean sea level is: 15m. Toposheet of the site is shown below. The
study area (10 km radius) around the project site exhibits flat terrain in the east and
relatively elevated terrain in the west side.
Figure 3.1: Toposheet Showing Project site
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3.4 Existing land use pattern (agriculture, non-agriculture, forest, water
bodies (including area under CRZ)), shortest distances from the periphery of
the project to periphery of the forests, national park, wild life sanctuary, eco
sensitive areas, water bodies (distance from HFL of the river), CRZ.
Proposed site falls under the Industrial MIDC. The land is reserved for Industrial use.
3.5 Soil classification
The basic type of soil found in the area varies from brown & black. The black type of
soil is found in the eastern part. The fertility of the soil increases as it goes from red
to black.
3.6 Climatic data from secondary sources
The climate in proposed area is characterized by hot summer and general dryness
throughout the year except the south west monsoon season.
Climate Classification: Project site features a semiarid climate.
Temperature: Annual maximum and minimum temperature in Tarapur range from
max. 38°C and min.11°C.
Rainfall: Most of the rainfall occurs in the monsoon season from June to September.
Average annual rainfall is 2488 mm.
Humidity: Annually relative humidity ranged from 64% – 88% and during summer
season the humidity ranged from 64% – 75%.
3.7 Social Infrastructure Availability
Key infrastructure such as hospitals, schools, bank, places of worship and social/
community facilities such as park, market, playground etc. education, health care,
community development, income distribution, employment and social welfare are
available in nearby area of Maharashtra Industrial Estate.
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4.0 Planning In Brief
4.1 Planning Concept
MIDC Industrial area, Tarapur provides many basic facilities like uninterrupted water
supply, power and road network & solids disposal facility if feasible. When various
sites were seen, this site appeared to be environmentally best as also from the
business angle and therefore this option was finally adopted. This site is inside the
campus of the MIDC and means safe transportation, less need of Utilities, less
constructing buildings and roads, less fuel, less water with optimization of
infrastructure.
4.2 Land Use Planning
Existing land is converted for industrial purpose. The land is located in a designated
industrial area. No change in land use.
Table 4-1: Land Use Break Up
Sr.No. Particular Area in Sq.m
1 Plant area 1267
2 RM & Product storages area 486
3 ETP & STP 70
4 Office Building 293
5 Parking 480
6 Internal road 1412
Total 4008
Green belt 500
4.3 Assessment of Infrastructure Demand (Physical & Social)
Key infrastructure such as hospitals, schools, bank, places of worship and social/
community facilities such as park, market, playground etc. education, health care,
community development, income distribution, employment and social welfare are
available in nearby area of Maharashtra Industrial Estate.
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4.4 Amenities/Facilities
In proposed site many basic facilities like uninterrupted water supply, Power and Road
Network & solids disposal facility if feasible are available. This site is inside the campus
of the MIDC and means safe transportation, less need of utilities, less constructing
buildings and roads, less fuel, less water with optimization of infrastructure and
networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal
facility), MWML, Taloja in vicinity established with support of MIDC and MPCB.
All nearby villages are provided with drinking water from wells or Government Water
Supply Schemes RWS. Hence we do not encroach upon their supply.
4.5 Population Projection
Palghar District has a population of 454,635 as per census 2011. It has more than
99,652 households of Maratha, Aagri, Koli, Muslim, Buddhist, and also includes SC, ST,
OBC and open categories community. The village has basically an agrarian economy and
industrial workers and farming is the main occupation of the villagers. The local self-
Government vests with a Grampanchayat having an elected body of headed by a
Sarpanch.
Population growth is being increased at alarming rate with their basic requirements.
Amongst, Medicine is one of the basic needs, which is very essential for everyone to live
happy life. So to fulfil their future basic need of Medicine for social community there is a
necessity to promote R & D Centre in each industrial sector. There will be in ratio of
population increase in similar way their need also increases so to fulfil their needs we
are going to set up a proposed unit which again generates employment.
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5.0 Existing Infrastructure
5.1 Industrial area
Industrial Area (Processing area)
Utilities
Cooling towers
HSD unloading/storage area
DM water plant
Cooling towers
Chilling Plants
Non- Processing Area
Weighbridge
Administrative Buildings
Security cabins
Workers restroom
Vehicle Shed
Water reservoirs
Temporary storage sites
Works block etc.
For proposed expansion existing infrastructure will be utilized and is sufficient for
the proposed activity
5.2 Residential Area
There is no any residential area has been proposed.
5.3 Green Belt
The project is built on an MIDC plot with plot area of 4008 sq. m. and green belt area -
500 sq. m. Green belt is already developed at project site and details will be provided in
EIA report.
5.4 Social Infrastructure
The basic amenities within the study area include primary schools, dispensaries, water
supply, electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus
services, technical training institute and entertainment etc.
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5.6 Drinking Water Management
The source of water supply is from MIDC Tarapur.
5.7 Sewage System
The domestic effluent will be treated in proposed sewage treatment plant.
5.8 Industrial Water Management
Existing effluent 23 CMD will be discharged to CETP and propose effluent 85CMD after treatment will be reuse for utilities.
High TDS stream will be fed to MEE followed by ATFD. Low TDS stream along with condensate from MEE will be treated in conventional ETP consisting of primary, two
stage secondary and tertiary treatment. This will be further treated by RO for permeate recycled and give effect zero liquid discharge (ZLD).
5.9 Solid Waste Management
Hazardous solid waste generated from the process will be collected, stored, transported
Transboundry Movement) Rules 2008.
5.10 Power Requirement& Supply / source
The Total Power required for the proposed expansion project is 1000 KW.
6.0 Rehabilitationand Resettlement (R & R) Plan
6.1 Policy to be adopted (Central/State) in respect of the project affected
persons including home oustees, land oustees and landless.
Proposed activity will be at existing manufacturing unit located at MIDC area. Hence,
there is no any kindof activity of Rehabilitationand resettlement carried out over it.
7.0 PROJECT SCHEDULE & COST ESTIMATES
7.1 Likely date of start of construction and likely date of completion
The expansionactivity is likely to start after getting Environmental Clearance and
NOC/CTE from the authorized committee.
7.2 Estimated project cost along with analysis in terms of economic viability
of the project
The total investment envisaged is Rs. 26.19 Crore.
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Economic Viability
The project has been conceived assuming that there will be a growth in demand for the
proposed products, leading to a reasonable rate of return in the medium term. The
project is considered ‘bankable’.
8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
Proposed expansion activity will provide benefits to the local people in terms of
financial and social welfare.
Company will contribute in improving education and health facilities in nearby
area.
Annexure –I
Plant Lay out