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Expansion Project for manufacturing of Synthetic Organic Chemicals Bharat Chemicals -Tarapur PFR for Bharat Chemicals Tarapur Page 1 Prepared by Goldfinch Engineering Systems Pvt. Ltd. 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.
Transcript

Expansion Project for manufacturing of Synthetic Organic Chemicals

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 1

Prepared by Goldfinch Engineering Systems Pvt. Ltd.

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

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 2

Prepared by Goldfinch Engineering Systems Pvt. Ltd.

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

PFR for Bharat Chemicals Tarapur Page 3

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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

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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

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 5

Prepared by Goldfinch Engineering Systems Pvt. Ltd.

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.

Expansion Project for manufacturing of Synthetic Organic Chemicals

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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

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 8

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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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Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 9

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 10

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 13

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3. Caffeine

Chemical Reaction:

Stage I:

Stage II:

Expansion Project for manufacturing of Synthetic Organic Chemicals

Bharat Chemicals -Tarapur

PFR for Bharat Chemicals Tarapur Page 14

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

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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

Expansion Project for manufacturing of Synthetic Organic Chemicals

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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


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