PrefeasibilityReport–M/s.Aarav Fragrances & Flavors Pvt Ltd
PREFEASIBILITY REPORT
“Expansion Of Existing Production Capacity For
Fragrances, Flavors & Manufacturing Chemicals”
By
Aarav Fragrances & FlavorsPvt. Ltd.
Gut No 167,169,170,171,296,Vill. Lakhamapur,
Tal. Wada,District: Thane, Maharashtra
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Synopsis
1. Introduction
2. Justification
3. Location
4. Recourses
5. Process
6. Pollution Control
7. Background Study
8. Safety
9. Benefits
10. EIA structure
11. Scoping
12. Conclusion
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
1. Introduction
M/s Aarav Fragrances and Flavors Pvt Ltd are desirous to expand to manufacture new products having either
raw material synergy or superior quality and technology to meet demands in India as well as for further
producing the fragrance and flavors at Aarav Fragrances and FlavorsPvt Ltd, Gut No
167,169,170,171,296,Vill. Jamghar -Lakhamapur, Tal. Wada, District: Thane, Maharashtra
The existing industrial unit is only manufacturing facility for Fragrances and Flavors. The industry now
proposes to enhance the manufacturing capacity of the present Fragrances & Flavors, and further the it is
proposed to add additional capacity tomanufacture the chemicals that could be used in house as well as cater
to the open Market, this will reduce the costs of the fragrances and flavors and make them more competitive
in the Indian as well as export markets.
Indian and worldwide demand for fragrances, flavors, perfumery chemicals and related specialty chemicals
is increasing steadily.
2. Justification
The Indian consumer industry is one of the world’s largest by volume and is likely to lead the manufacturing
sector of India. Several private sector projects with huge amount of investments have been initiated but
could not attend the speed of development for the need of good quality material. Over the last decade,
there has been a sizeable growth in fragrances and flavors sector both in small, medium and large scale units.
This has given rise to many small and medium scale units. There is a ever growing requirements
of the consumers in India and also the world markets. Thus there is a gap in demand and supply. Our efforts
of generating products, by-products, downstream products and recycling - reprocessing are indeed needed.
With multinational fragrance and flavor companies enhancing their presence in India, the long-term
prospects of the fragrances and flavors industry seems verybright. The intermediates proposed will substitute
imports and compliment the products in terms of costs.
The fate of industrialization depends on the proper and effective conjugation of large and medium/small
scale industries each supporting each other in their requirement to bridge the gap between demand and
supply. In order to be competitive in the global market this synergy between large & medium/small scale
industries is a prerogative. Therefore considering the above, large companies do require the help of small
units to support them, the main target is to give the consumer superior quality products at a competitive
price. In addition, it is also examined whether industry had made complianceas expected in
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Consent to Operate by MPCB for existing production.
S.No. Condition Compliance
1 Addressstatus Continuousthesamenochange
2 No. &Validity Validtill30.09.2015
3 Productsize Sr.no. Product Capacity
(TPM)
1 Fragrance/Perfumes &
Flavors
70
4 Waste water
quantity
8.5m3/dpermitted.
5 Waste
waterTreatment
Foundinlimit
6 ECE Presently NA
7 LDAR Leakdetection&repairprogramwith
monitoringprotocolundertakenas consented.No–
towardincident reported.Work zoneambiancecognizes
8 Hazardouswaste MembershipofCHWTSDF to be obtained
3. Proposal:
The Industryproposedtoproduceasunder:
Sr
No
Products Prese
nt
MT
/M
Propose
d MT/M
Total
MT/M
Field Of Application
1. Fragrances/Perfumes & Flavors 70 210 280 Fragrances & Flavors
2.
Perfumery Esters by hot esterification/
addition of organic acid into olefin/ trans
esterification/ reacting alkali halide with
sodium salt of corresponding acid/Cold
Esterification -Ethyl Esters/ Esterification by
reaction of alcohols with anhydride/
Perfumery Esters by Darzen Condensation
00 300
300
Fragrances & Flavors
3
Perfumery Alcohol by Grignard reaction / by
reduction of aldehyde, or ketone by hydrogen
& Reducing Agents / by addition of water
into olefins / by saponification of
esters/Perfumery Compounds by Ring
Reduction
00 300 Fragrances & Flavors
4 Perfumery Aldehyde by ester / epoxide
rearrangement/ dehydrogenation of alcohols/
reduction of acids/ aldol condensation
00 300 Fragrances & Flavors
5 Dimerization and Trimerization of simple
olefins. 00 300 Fragrances & Flavors
6 Ketals / Acetals / substituted 1,3-propanediols
and other propylene derivatives 00 300 Fragrances & Flavors
7 AmbrettolideMacro cyclic and polycyclic
musks derived from propylene or butadiene 00 300 Fragrances & Flavors
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
8 Aldehydes & ketones by Aldol Condensation 00 300 Fragrances & Flavors
9 Nitriles / cyclo propyl acetylene and other
alkyne derivatives 00 300 Fragrances & Flavors
10
Cyclo Alkylation/Acetylation ,Diel Alders
Reactions : Cyclization Reaction,
Etherification of Alkyl Halide and Alcohol,
Epoxidation of Alkenes
00 300 Fragrances & Flavors
11 Hydrogenation 00 300 Fragrances & Flavors
12 Inorganic Salts 00 50 50 Side Stream Products
Total 630
From the list of ProductsSrNos 2 to11 only two to three products will be manufactured simultaneously. The
total quantities to produce for Products Sr No 2 to 11 willbe for any one or all cumulatively up to 300MT
Since many of the products planned are either forward integration or corollary to a known manufacturing
process. The above mentioned process based chemicals are important chemicals in the vast field of
fragrances and flavors where many such routed chemicals are required to make a fragrances and flavors.
None of these chemicals are banned for production in developed countries nor is banned for use. The
chemicals produced have the following merits:
- Import /Cost Substitution
- Minimizepollutantsatsource
- Maximizerecycle of recovered RMs and Water
- Treatto MPCBnorms
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
General formulas limited to groups of manufacture
Sr
No Products
General Reaction(s) Field Of Application
1. Fragrances/Perfumes &
Flavors Mixing/Blending
Fragrances& Flavors.
2.
Perfumery Esters by hot
esterification/ addition of
organic acid into olefin/ trans
esterification/ reacting alkali
halide with sodium salt of
corresponding acid/Cold
Esterification -Ethyl Esters/
Esterification by reaction of
alcohols with anhydride/
Perfumery Esters by Darzen
Condensation
Fragrances & Flavors
3
Perfumery Alcohol by
Grignard reaction / by
reduction of aldehyde, or
ketone by hydrogen &
Reducing Agents / by
addition of water into olefins /
by saponification of
esters/Perfumery Compounds
by Ring Reduction
Fragrances & Flavors
4
Perfumery Aldehyde by ester
/ epoxide rearrangement/
dehydrogenation of alcohols/
reduction of acids/ aldol
condensation
Fragrances & Flavors
5
Dimerization and
Trimerization of simple
olefins.
Fragrances & Flavors
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
6
Ketals / Acetals / substituted
1,3-propanediols and other
propylene derivatives
Fragrances & Flavors
7
AmbrettolideMacrocyclic and
polycyclic musks derived
from propylene or butadiene
Fragrances & Flavors
8
Aldehydes & ketones by
Condensation with vinyl ether
Fragrances & Flavors
9 Nitriles / cyclo propyl
acetylene/ Acetylene and other
alkyne derivatives RC≡CR + R'C≡CR' 2 RC≡CR'
Fragrances & Flavors
10
Cyclo Alkylation Reactions
/Acetylation ,Diel Alders
Reactions : Cyclization
Reaction, Etherification of
Alkyl Halide and Alcohol,
Epoxidation of Alkenes
Fragrances & Flavors
11 Hydrogenation
Fragrances & Flavors
12
Inorganic Salts
NaCl, AlCl3, MgCl.HSO4, KCl, BaSO4
Side Stream Products
Total
From the list of Products Sr No 2 to11 only two to three products will be manufactured simultaneously. The
total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT
List of Raw Materials and Source:
The list of raw materials along with monthly consumption is given in table, However there will be only
2-3 products being manufactured at the same time hence the requirement of the raw materials will be
low, however the below raw material quantities are reflected based on single product manufacturing. Sr. No. Raw Material Required Consumption in
MT/Month 1. Acetic Acid 234
2. Acetic Anhydride 70.46 3. Acid Catalyst 27.45 4. Aldehyde 47.17
5. Caryophellene 4.00
6. Caustic Lye 10% 1.04
7. Citronellol 17.03
8. Benzylledene Acetone 80 9. D’limonene/Orange Terpenes 47.94
10. Di Ethanol Amine 0.43
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
11. Dicyclopentadiene 783.33
12. Ethyl Chloro Acetate 22.05
13. Benzyl chloride 27.6
14. Halide (Pentyl Bromide/Chloride) 75.47
15. HCL 45% 0.16
16. Hexyl Alcohol 112 17. Iodine 0.18
18. Iso Amyl Alcohol 12.86
19. Isobutyric Acid 72.50 20. Methyl Heptanone 98.97 21. Methanol (Fresh & Recycled) 47.94 KL
22. Methyl Magnesium Bromide / Chloride 31.61 23. Mg Turnings 12.74 24. Phase transfer catalyst 1.10
25. Pentanol mixture 77.14 26. Propionic Acid 80.23
27. Salicylic Acid 265
28. Soda Ash 12.24
29. Sodium Acetate 21.30
30. Sodium Methoxide 22.05
31. Sulphuric Acid 31.98
32. Terpineol 68.18
33. Tetra Hydro Furon (Fresh & Recycled) 235.85 KL 34. Toluene (Fresh & Recycled) 28.03
35. Sodium Salicylate 35.7 36. Zn Chloride 0.52 37. Propylene 38. Acetylene 39. Hydrogen 40. Benzaldehyde 41. N Pentanol 42. Propionaldehyde 43. Pthalic Acid 45. Vinyl Ethyl Ether 46. Sodium Hydride 47. Aluminum Trichloride 48. Di Chloro Methane 49. N Butyl Aldehyde 50. Tertiary Butyl Methyl Ether 51. N ,O Dimethyl Hydroxyl Amine Hydrochloride 52. Geraniol 53. Linalool 54. Meta Chloro Pre Benzoic Acid 55. 1 Phenyl Ethanol ( Styrallyl Alcohol) 56. Furan 57. Allyl Alcohol
Source:
Raw material will be sourced locally and also from countries like Japan, USA and Germany.
3. Location-
For theproposed project the company will use its spare land from the existing plotsat Gut No 167, 169,
170, 171, 296, Vill. Lakhamapur, Tal. Wada,District: Thane, Maharashtra.
Thissiteisin onallfoursides wearesurroundedby industriesandnonuisance
isspread.Thesurroundingneighborsare,
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
To BE CHECKED BY ADITYA
East :Abhinav Pharmaceuticals Pvt Ltd, Mumbai Wada Jawahar Highway
West: Agricultural Land, Village Lakhmapur
South: A gr i c u l t u r a l L a n d , V i l l a ge L a k h m a p u r
North: AFFPL Green Belt, Village Road, Residential Building
Locationtooisjustifiable.Unit sizeiskeptcorrectfor easeofhandling andenvironmental control.
As t h e r e a r e o t h e r indus t r i es inthe neighborhoodw i t h similarn a t u r e , there is compatibility.
This isnot aPrimeAgriculturalLand.Thelanduseisalreadyas“Industrial land/Non Agriculture
Land”.Thus,thereisnochangeinthestatus.Thisisaflat landwhereby cutting- f i l l i n g balancesand
t he re will beNoLowBorrowingfromNature.
Tansa wildlife Sanctuary is about 8.3 kms North West of the site and the plot is
located in private industrial land hence requires Environment Clearance from the
Ministry Of Environment, Forest and Climate Change with Public Consultation.
To be checked by ADITYA
Geographical Location Items:
Latitude : Approx. 19° 5'9.63"N
Longitude : Approx. 73°10'9.86"E
Terrain : Flat terrain
Climate : Semi-Arid
4. Resources
Site
AFFPL is desirous to establish and it requires following resources,
• Area 48900sq. mts
• Water Input Ground Water for existing 2 No’sbore wells and 1 No Well.
New Two No’sBore wellproposed with Rain Harvesting
Facility will be put in place. • Work force 65
• Raw Materials Commensurate with product, as also work up chemicals
Solvents& catalysts
•Effluent Facility High COD and TDS sub stream segregated self-treatment
And Later CETP (membership is sought)/Gardening
• Haz. Waste Facility CSWTSDF at Taloja, Maharashtra
• Process Machinery Developed by self available locally maintained sophisticated
Laboratory Attendants, cooling tower, hot water generations,
Steam Boilers • Units Instrumentation Precision and accurate
• Total InvestmentRs.19.3408Crores (Rs 9.3408Crores Present + Rs 10.00Crores
Expansion)
• Environment Fund 2 %
• Proponents Law abiding. No litigation pending.
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Site
1. Existing industrial premises and land area: 48900sq mts
2. Climatic condition suitable for finer adjustments of control, making it fit for processing Conditions.
3. Well connected for transportationthrough Mumbai WadaJawahar Highway
4. Leveled ground and load bearing soil
Technology Selection
1. The products proposed are in the same manufacturing range for which the technology is
alreadydeveloped, and well known.
2. The process used isbased on raw materials that are available, without any bottleneck. Thus,
Excessstorage also means wastage. Here, we can follow easily the principle of JIT (Just in Time).
3. The process used is developed by AFFPL themin house and hence we are aware
aboutthesensitivepoints needing careful attention in advance.
4. The process is cost effective, safe and environmentally friendly.
5. There is no elevated pressure condition in processing.
6. Solvents used that are recoverable, and are so recovered.
7. The steam & hot water from boilers will be used for process
Instrumentation
1. Latestelectronicinstrumentationwithhighaccuracyandreliability
2. 100%redundancyforcontrolandpowersupply.
3. EmergencyShutDownSystemforensuringsafetyofplantandpersonnel.
4. Streamflow,feedwaterflowismeasurable(indicatingandrecording) 5. Waterlevelandliquidmateriallevelismeasurable(indicatingand recording)
6. Multipoint temperaturescannerwiththermocouple.Allpointsindicatingandrecording(allforsteam,fe
edwater,fluegasandair) 7. Pressuregaugesatreactors.
8. Multi-channeldataloggertoinputs
likecurrents,mv,T/Candrecordingwithcolumneddotmatrixprinter.
9. Hootersfortrips,lowlevels,highlevelsandhightemperatures.
Machinery & Hardware:
1. ModernClosed Pump transfer system isused toavoid any risks in human being handling the
production.
2. All processing equipment likereactors material of construction will be compatible to process.
3. Generally, will be of SS316/GLR quality and will be kept validated as per strict international guidelines
prescribed.
4. The condensers are in SS316.
5. Wherever water is used, will be specially purified for process and cleaning- washing.
6. Help of sophisticated configuration may be taken, if necessary.
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Project proponents
AARAV Fragrances & Flavors Pvt.Ltd. (AFFPL) was incorporated in 2007. The promoters of the company
have more than 20 years of experience and profound understanding of the fragrance & flavor industry to
provide strategic inputs into key business decisions and developing long term goals.
AFFPL have developed strategic partnership with key global & local suppliers of synthetic and Natural
ingredients to provide consistent supply of fragrances & flavors to our valued customers.
AFFPL proudly service a wide range of SME's as well as multinational companies, both global & Indian.
To experience a great fragrance is to experience magic, fragrance has the power to captivate the senses and
transport our mind to new realm of imagination. AFFPL excels in the art and science of great fragrance
creation. Guided by our principles of Balance, Clarity and Integrity, we put our expertise behind your brand
to create signature fragrances. AFFL fragrances create unique, consistent and lasting experience for all
consumers.
AFFL takes pride in partnering with their customers to ensure that when a product is picked off the self,
customer brand promise is fulfilled to the utmost satisfaction of the consumers from various categories
Some of the most profound memories are attached with food customer’s taste. We develop unique flavor
experiences that deliver your brand promise to consumers.
AFFL experts are constantly researching trends and focusing on the magic that consumers are looking for in
the market. AFFL development team works closely with the clients on specific briefs to deliver unique
flavours within stipulated deadlines for various categories.
Thecompany hasadoptedfollowingcertifications
1. ISO 9001
2. ISO 22000
3. ISO27001( Under Implementation)
4. Food Safety Standards Authority Certification.
The Board of Directors represents an optimum mix of knowledge, experience and expertise to guide the
long-term success of the company.Theproponentsare,
Sr.No. Name Designation
1. Mr. Ajit Suresh Vaze
Master Of Science Organic
ChemistryEngineer
CEO/Managing
Director
2. Ms. AnuradhaAjitVaze Director
3. Mr. AjitDeshmukh Director
4. Mr. Jean Louis Matthey Director
5. Mr. HolgerHauenschild Director
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
5. Process
Products
AFFPL proposes to establish a plant to produce synthetic organic chemicals catering to the perfumery &
Flavor industry. These products serve as raw material to the fragrance and flavors industries. As season
changes the demand for a fragrance /flavor changes, hence the demand for particular chemical
ingredients also changes, the industry has thus to be in readiness to change the product suitability as
well as the application and be preparedto mitigatethe corresponding customer requirement challenges.
The utilitiesrequired will be steam which will be provided by the existing steamer and a new IBR Boiler
will be installed. Other will be provided by newer fresh technologies for cooling, vacuum etc. The
multi-product facility will be operated as normal chemical industry but the reactorswill be used by
different combination and sequence.
The product mix is as given below why repeating??????????????If not required please remove the same
Sr
No
Products Present
MT /M
Proposed
MT/M
Total
MT/
M
Field Of Application
1. Fragrances/Perfumes & Flavors 70 210 280 Fragrances &Flavors
2.
Perfumery Esters by hot esterification/
addition of organic acid into olefin/ trans
esterification/ reacting alkali halide with
sodium salt of corresponding acid/Cold
Esterification -Ethyl Esters/ Esterification by
reaction of alcohols with anhydride/
Perfumery Esters by Darzen Condensation
00 300
300
Fragrances &Flavors
3
Perfumery Alcohol by Grignard reaction / by
reduction of aldehyde, or ketone by hydrogen
& Reducing Agents / by addition of water
into olefins / by saponification of
esters/Perfumery Compounds by Ring
Reduction
00 300
Fragrances & Flavors
4
Perfumery Aldehyde by ester / epoxide
rearrangement/ dehydrogenation of alcohols/
reduction of acids/ Aldol condensation.
00 300
Fragrances & Flavors
5 Dimerization and Trimerization of simple
olefins. 00 300
Fragrances & Flavors
6 Ketals / Acetals / substituted 1,3-propanediols
and other propylene derivatives 00 300
Fragrances & Flavors
7 Ambrettolide,Macrocyclic and polycyclic
musks derived from propylene or butadiene 00 300
Fragrances & Flavors
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
8 Aldehydes & ketones by Aldol Condensation 00 300 Fragrances & Flavors
9 Nitriles / cyclo propyl acetylene lenend other
alkyne derivatives 00 300
Fragrances & Flavors
10
Cyclo Alkylation/Acetylation ,Diel Alders
Reactions:Cyclization,Reaction,
Etherification of Alkyl Halide and Alcohol,
Epoxidation of Alkenes
00 300
Fragrances & Flavors
11 Hydrogenation 00 300 Fragrances & Flavors
12 Inorganic Salts 00 50 50 Side Stream Products
Total 630
From the list of Products SrNos 2 to11 only two to three products will be manufactured simultaneously. The
total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT
It may be seen that,
There is a capability of making these products
Production process is batch process with “Cleaner Production” strategy with effluents recycles
Machineries, utilities will be installed according to the requirement of the plantand products.
Schematic Process Flow for Proposed Products
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
COMPLIANCE TO MSIHC RULES:
According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical Rules, 1989),
data on the toxicity and flammable characteristics for the chemicals involved is as presented below in
the form of tables.
Storage details for Raw Materials to be used in manufacturing activities:
Sr.
No.
Raw Material Quantity in
MT/Month
Storage At a
time in
MT/Month
Physical
form
Stored In MOC
1. Acetic Acid Fragrances/Perfumes & Flavors
234 10 Liquid Tank SS304
2. Acetic Anhydride 70.46 8 Liquid Drums HDPE
3. Acid Catalyst 27.45 2 Liquid Carboy HDPE
4. Aldehyde 47.17 2.5 Liquid Drums HDPE
5. Caryophellene 4.00 1 Liquid Drums GI
6. Phase transfer Catalyst 1.10 0.1 Liquid Drum HDPE
7. Caustic lye 1.04 1 Liquid Carboy HDPE
8. Citronellol 17.03 2 Liquid Drums MS Epoxy
9. Benzylledene Acetone 80 6 Liquid Drums GI
10. D’limonene/Orange
Terpenes
47.94 4
Liquid
Drums
MS Epoxy
11. Di Ethanol Amine 0.43 0.22 Liquid Drums MS Epoxy
12. Dicyclopentadiene
(underground)
783.33 40
Liquid
Tank
SS304
13. Ethyl Chloro Acetate 22.05 1.5 Liquid Drums HDPE
14. Benzyl chloride 27.6 2.5 Liquid Drums HDPE
15. Halide (Pentyl
Bromide/Chloride)
75.47 5
Liquid
Drums
HDPE
16. HCL 45% 0.16 0.5 Liquid Carboys HDPE
17. Iodine 0.18 0.09 Solid Can GI
18. Iso Amyl Alcohol 12.86 3 Liquid Drums HDPE
19. Isobutyric Acid 72.50 2 Liquid Drums HDPE
20. Methanol 47.94 KL 3 Liquid Drums MS
21. Methyl Heptanone 98.97 3.5 Liquid Drums HDPE
22. Methyl Magnesium
Bromide / Chloride
31.61
2.5
Liquid
Drums
MS
23. Hexyl Alcohol 112 2.8 Liquid Drums MS Epoxy
24. Mg Turnings 12.74 1 Solid Bags PP
25. Pentanol mixture
(Under Ground
Storage)
77.14
20
Liquid
Tanks
MS
26. Propionic Acid 80.23 3 Liquid Drums HDPE
27. Salicylic Acid 265 8 Solid Bags PP
28. Soda Ash 12.24 1 Solid Bags PP
29. Sodium Acetate 21.30 1.2 Solid Bags PP
30. Sodium Methoxide 22.05 2 Solid Can GI
31. Sulphuric Acid 31.98 1.2 Liquid Carboys HDPE
32. Terpineol 68.18 5 Liquid Drums GI
33. Tetra hydro Furon 235.85 KL 6 Liquid Drums MS
34. Toluene 28.03 3 Liquid Drums MS
35. Sodium salicylate 35.7 3.5 Solid Containers HDPE
36. Zn Chloride 0.52 0.1 Solid Can GI
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Sr
No
Products Quantity
In MT/M
Max
Storage
MT/M
Physical
Form
Stored In MOC
1. Fragrances/Perfumes & Flavors 280 20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
2.
Perfumery Esters by hot esterification/
addition of organic acid into olefin/ trans
esterification/ reacting alkali halide with
sodium salt of corresponding acid/Cold
Esterification -Ethyl Esters/ Esterification
by reaction of alcohols with anhydride/
Perfumery Esters by Darzen Condensation
300
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
3
Perfumery Alcohol by Grignard reaction /
by reduction of aldehyde, or ketone by
hydrogen & Reducing Agents / by
addition of water into olefins / by
saponification of esters/Perfumery
Compounds by Ring Reduction
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
4
Perfumery Aldehyde by ester / epoxide
rearrangement/ dehydrogenation of
alcohols/ reduction of acids/ Aldol
condensation.
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
5 Dimerization and Trimerization of simple
olefins. 20 Liquid
Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
6 Ketals / Acetals / substituted 1,3-
propanediols and other propylene
derivatives
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
7 Ambrettolide,Macrocyclic and polycyclic
musks derived from propylene or
butadiene
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
8 Aldehydes & ketones by Aldol
Condensation 20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
9 Nitriles / cyclo propyl acetylene and other
alkyne derivatives 20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
10
Cyclo Alkylation/Acetylation ,Diel Alders
Reactions:Cyclization,Reaction,
Etherification of Alkyl Halide and Alcohol,
Epoxidation of Alkenes
20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
11 Hydrogenation 20 Liquid Storage Tanks/
Drums
SS316/304/
HDPE/
Aluminum
12 Inorganic Salts 50 Solids Bags
Leak Proof
HDPE
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Overall Environmental Significance:
UnitOperation/
Process
Peculiarities Environmentalsignificance
1.IncomingRaw Materials Selectedfromknown vendors
transportationinclosed
tankers/Drums in limited low
volumes.
Promptuseandstoragein
closedcontainersprevent
spillagesandlossofstrength.
LessHCemissions.
2.Weighingand strict
qualitycontrol
LoadCellbasedweighing
system provided
Bettercheckonmass balance,purer
materialand lessrejections.
3.Inprocess Solvents Recoveredandreused
Byproducts Recoveredandsoldto
parties,whenindemand
Gaseousemissions Scrubbedanddetoxified
Processwasteresidue Tobesentoncommon
facilityfordisposal by
incineration. 4.Instrumentation Controlsystemfor
accurateprocesscontrols
Facilitatesmonitoringof
qualityoftheproductand
safetyaspects.
5.Control Excellentsystem of
documentationand
controlofcriticalstagesin
productionprocess
Betteroperationand retrievable
records forbetter checks.
6.Solvent Recovery Proper recovery systems
with vapor condenser and
chilled unit.
Vapor and Product Condensers with Step
down chilling and cooling systems
6. Pollution control
Clean productiontechnologyadopted byensuringfollowing a tdesigna n d e n g i n e e r i n g stage.
- All Products & their reactions selected after considering the friendliness of these products on the
environment
- Minimize pollutants at source
- Recovering and recycle of the RM
- Maximize recycle of water resources.
- Tertiary ETP System will be erected and operated
- Treat to PCB norms
- 100% recycle of increased effluents for process for defined cycles.
- Procure CEPT Membership when available
- Use with Priority Environment Friendly Fuels Like Ground Shells Briquettes, Agricultural Waste.
- Reduction of VOC at every processing stageby vent condensers and scrubbers.
- Use of mainlyclean fuels like agricultural waste/FO/LDO.
- All Process Transfers will be conducted in enclosed systems by pumps.
Theprocesswhereverisbasedonesterificationoforganicacidandalcoholproducingwater.Therecoverys
ystem willbedesignedinsuchawaythatentirewaterisusedforprocessapplicationtherebyreplacingfresh
waterinput.
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Theboilerisprovidedwith cyclone separator, bagfilter/ESPtocontrolemissionwithin
prescribedlimits.The stack height will be up to 30 meterstocontrolgroundlevel
clearancewithinlimits.
Processvents arecontrolledbycondensersfollowed bywater cooling and chilling systemsand
organicsare recoveredandrecycled.
(a) Water & waste water:
The water and waste water generated in the factory will be as follows;
i. Water Requirements:
Details Of Fresh Water Consumption
Sr
No
Water Break Up Existing Water
Consumption
( KL/Day)
Proposed Water
Consumption
(KL/Day)
Total Water
Consumption
(KL/Day)
I Domestic 5.00 5.00 10.00
II Gardening 0.00 80.00 80.00
III Industrial
1)Process 0.00 5.00 5.00
2)Cooling Water Make up 0.00 9.00 9.00
3) Boiler Make Up 3.50 13.50 16.00
4) Washings 0.00 3.00 3.00
Total Industrial 8.50 115.50 124.00
Details Of Waste Water
Waste Water Break Up Existing Waste
Water
Generation
(KL/Day)
Proposed Waste
Water
Generation
(KL/Day)
Total Waste
Water
Generation
(KL/Day)
I Domestic 3.60 3.60 7.20
II Industrial
1)Process 0.00 5.00 5.00
2)Cooling Water 0.00 9.00 9.00
3) Boiler Blow Down &
Cooling
2.70 12.00 12.00
4) Washings 0.00 3.00 3.00
Total Industrial 7.30 32.6 36.20
The industry will obtain membership of CETP.
:MARKED IN RED O BE DECIDED AFTER DISCUSSIONS WITH ADITYA
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
ESTIMATED QUALITY OF RAW & TREATED EFFLUENT:
Characteristics of untreated waste water:
Characterisation of treated effluent:
Sr. No. Parameters Concentration
1 pH 7.82
2 COD 186 mg/L
3 BOD 80 mg/L
4 Phenolic Compounds 0.18 mg/L
5 Ammoniacal Nitrogen 14.2 mg/L
6 Suspended Solids 68.5 mg/L
7 Oil & Grease 5.2 mg/L
Sr. No. Parameters Concentration
1 pH 6.8
2 COD 3250 mg/L
3 BOD 1560 mg/L
4 Phenolic Compounds 1.12 mg/L
5 Ammoniacal Nitrogen 18.9 mg/L
6 Total Dissolved Solids 4200 mg/L
7 Suspended Solids 244 mg/L
8 Oil & Grease 21.2 mg/L
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Water Balance Diagram:
Fresh Water From Borewells/Well 124 kl/Day
Gardening Domestic Cooling
Tower
RO
Fresh 80kl/Day 10kl/Day 9kl/Day 28kl/day
Recycled 3kl/Day
Recycled 12.8kl/Day
Recycled 8kl/Day
Total 103.8kl/Day
Sewage
Treatment
Plant
Cooling
Tower
Blow
Down
RO Reject RO Water
to Boiler
Feed
3kl/day 9kl/Day 11.2kl/Day 16.8kl/Day
Process Washings
5kl/Day 3kl/Day
8KL Recovered to ETP
Boiler
Blow
Down
12.8kl/Day
Recylce back to garden/
Or CEPT Effluent Treatment Plant
Schematic Diagram for Fresh Water Requirement and Waste Water Flow
Proposed ETP Flow Sheet:
Oil & Grease Trap
Equalisation and
Neutral ization Tank
Primary Settl ing Tank
1st Stage
Aeration Tank
1st Stage
Secondary
Settl ing Tank
2nd Stage
Aeration Tank
2nd Stage
Secondary Settl ing Tank
Intermediate
Collection
Tank
Inlet
Outlet
Pressure Sand
Fil ter
Final Dishcarge
Tank
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
(b) Air Pollution:
The existing plant comprises of 1 small industrial boiler (Steamer). The fuel used in the existing boiler is
furnace oil. Two DG Sets a.63kva for emergency and power failures & b. 160kva exclusively for fire
alarms & firefighting hydrant systems is already installed, which is used only during power failures.
Proposed Scenario:
For the proposed expansion unit, the existing steam boiler will be kept as stand by. A new 5 MT IBR Boiler
and a new thermic fluid heater will be installed. The details of the boiler and thermic Fluid heater are given
below:
Details of Boiler and Thermic Fluid heaterCapacity???????????
Details of Air Pollution Control unit:
The proposed plant will not produce any significant air pollution load. The major sources of air pollution
will be:
Boiler
Thermic Fluid Heater
D.G. Set Emissions
Fugitive emissions
Processemissions
To control the fly ash particles / particulate emissions from the boiler, cyclone will be installed in the
proposed project. There are no process emissions from the proposed project.
Sources of Gaseous
Emissions
Boiler (1 No.) Thermic Fluid Heater
Fuel used Agricultural Waste /Bio Coal/ Furnace
oil/Coal / NG
5MT/Hr
Agricultural Waste /Bio Coal/ Furnace
Oil /Coal /NG
3Lac kcals
Quantity of fuel 22 mt/Day / 22mt/day/10 mt/day
/22mt/day/8500 m3/Day
5mt/Day/5mt/day/2.5mt/day/5mt/day/
2500m3/day
Type of emissions SO2, NOX, PM SO2, NOX, PM
Stack height 30 mts 13 mts
Stack dia. at the top 0.505 mts 0.505 mts
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
Schematic diagram of cyclone
The existing D.G. Set shall be used only in case of emergencies / Power failure & Fire Related
emergencies. A New DG will be installed replacing the 63KVA
Details of D.G. Set
Sources of gaseous emissions
Existing D.G.Set
(63 KVA)
Existing D.G.Set
(160 KVA)
Proposed D.G.Set
(500 KVA)
Fuel used Diesel Diesel Diesel
Quantity of fuel (Will depend on
Power Failure & Emergencies)
11lits/Hr 35lits/Hr 105 lts/hr
Type of emissions PM, SO2& NOX PM, SO2& NOX PM, SO2& NOX
Stack height 3 meters 3 meters 3 meters
Capacity of D.G.Set 63 KVA 160 KVA 300 KVA
Sr
No
Source Pollutant Measures Control Equipment
1 Proposed 5MT
Boiler.
SPM, CO,SO2,
NOx
Dust Collectors,, ESP,
Dust extraction with Bag
filters, fogging.
Tall stack of 30 m.
2 In process VOC Closed loop transfer Vent condensers,
Extraction and
scrubbing
3 ETP COD, TDS Segregation of Streams Fully aerobic
Noise :
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
There is no major noise generating sources. Only those Vehicles with PUC's and spark arresters will be
allowed inside the premises. Green belt facilities have also been provided in the plant premises.
Details Of Hazardous Waste Generation And Disposal:
The plant will have the maximum solid waste generation from the ETP, which will be sent to CHWTSDF,
Taloja, Maharashtra for its disposal applied for membership.
Details of Hazardous waste generation and disposal:
Sr.
No.
Type of
Waste
Category Existing
QuantityMT/Annum
Proposed
Quantity
MT/month
Mode of disposal
1 ETP Sludge 34.3 0.060 100.00 Collection, storage,
transportation and disposal
to TSDF.
2 Used Oil 5.1 0.00 2.40 Collection, storage,
transportation and disposal
by sale to registered
recyclers.
3 Discarded
Containers
33.3 0.00 12.25 Collection, storage,
decontamination,
transportation and disposal
by sale to authorized
recycler
4 FO / LDO &
Oil Bottoms
Sludge
--
0.00
3.36
Collection, storage,
transportation and disposal
by sale to authorized
recycler
5 Distillation
Residue
20.3 0.00 16.200
Collection, storage,
transportation and disposal
to CHWI.
6 Grease 5.2 0.00 0.012
Collection, storage,
transportation and disposal
by sale to authorized
recycler
7 Fly ash (Boiler
& TF Ash)
- 0.00 482.00 Will be sold to brick
manufacturers.
8 Low purity
fractions
C8 0.00 72.00
Will be sold.
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
9 Spent acid -- 0.00 16.00
Will be sold.
Hazardous Waste Storage Room:
A hazardous waste storage room measuring 100sqmts will be provided with impervious RCC flooring and
leachate collection pit. The distillation residue will be stored in carboys in Hazardous waste storage room
and will be finally disposed of to CHWTDFS, Taloja, Maharashtra. The Fly ash will be stored in a defined
area and precautionary measure will take for avoid carryover of the ash by wind/breeze/water etc.
Dispersion:
Point Emissions are coming from one boiler, thermic fluid heater &3 DG hence proper stacks will be
provided for the same. Please note DG 3 Nos will be used only in emergency & during power failures.
The stacks will be fitted with port-holes, ladder and platform for facility of taking samples.
Fugitive:
A number of mitigation measures will be taken to control fugitive emissions
Engineering, the plant layout will be in such a way so as to virtually eliminate need of using heavy
equipment for material handling in the main plant
Internal roads paved, leveled, no undulations, no sharp curves, slow speed.
No open storage of materials involved
Fumes extraction and vacuum system will provided for extraction of fumes
from the reactors and the process plant areas.
Fugitive Emissions and its control:
There are no emissions from the manufacturing process. For control of fugitive emissions, chilled
water traps will be installed on the vent of the unit to arrest any escape of vapors from the reaction
and distillation unit. Fugitive emission could occur from the storage yard of raw materials and
finished products. The storage quantity is very low and proper handling methods will be adopted.
Emissions from transport of vehicles would occur to a certain extent. The emissions from traffic
movements is controlled by proper planning of the transport of raw materials and finished
products to and fro from the factory premises. Since the quantities involved are very less,
movement of vehicles will be occasional. All the roads inside the plant will be concreted to reduce
any dust emissions.
Details of Solvent recovery Plan and monitoring of vents:
The solvent recovery system for the proposed expansion project is shown in the figure below.
The vents of the reactors will be connected to 2 stage condenser system, where chilled
water will be recirculated. The receiver will also be jacketed with circulation of chilled water. The
recovered solvents will then be stored and reused. All the units will be under nitrogen blanketing
Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
through cylinders. Proper planning and maintenance will control the extent of fugitive
emissions.During the production, the industry will carry out regular monitoring of fugitive
emissions as per the factories act.
Details of Solvent Recovery Plan
Prefeasibility Report–M/s.Aarav Fragrances & Flavors Pvt Ltd
Aesthetics:
There will be no nuisance from noise. DG 3 Nos will be used only in emergency & during power
failures tokeep plant under safe conditions. If Coal is used as fuel for boiler therewill crushing and
pulverizing operations for coal handling. Dust suppressionsystem is provided. Dust extractionwith
dust collection will be provided. Labor strength will also be limited.
7. Background Study:MARKED IN RED O BE DECIDED AFTER DISCUSSIONS WITH
ADITYA
This is important part of study.
(A)Natural Environment : We propose to do sampling as –
• Surface Water: 2 Locations, 11 Parameters.
• Ground Water: 5 Locations, 9 Parameters. Includes 1 up gradient and 2 down gradient source.
• Air Quality: 3 Months, For PM10, PM2.5, SO2 and NOx.
• Noise: 5 Locations.
• Soil: 5 locations
The stations will be selected in all the eight directions from the factory and in 10 km radius.
(B) Manmade Environment
This includes existing land-use, demography, employment, socio-economic aspects and
community development needed and proposed. This is for entire area both rural and urban in this
study zone.
• Socio-Economic Status in Influence Zone explained in the study of Non-Workers
percentage whether high, from the percentage employed population on Agricultural, how far is the
scope for other avenues of livelihood like Live Stock, Forestry, Fishing, Hunting, Orchards, Mining,
Trade Commerce.
• Further Out of Total Land what percentage is already under Cultivation and Out of
Total Land what percentage is already under Irrigation.
• If the land is not likely to support more people, then whether Industrialization is necessary to
improve the situation.
• All this will be studied as cost benefit ratio.
Prefeasibility Report–M/s.Aarav Fragrances & Flavors Pvt Ltd
Chapters Contents
I Proponents,ToR,Purpose
II Project
explained.Whythis,Whyneeded,Whyhere,Whatpriorities,Whatoption
s III EnvironmentSetting Natural&Man-made
Material,Method,
Approach
Delphitechnique
IV HighSignificantImpactLowInsignificantImpact&Shield
ProperSitePreventionAbatementTreatment
MitigationSmoothDisposal
V AlternateAnalysis
Selection ofRawMaterials,Site,Process,Machinery-Hardware,
Collaborators,Staff&Team
8. Safety
Safety and Occupational Health will be dealt carefully. A disciplined approach is natural to this
industry. Safety policy will be in place. The unit is registered under Factory Act and is bound by
State Factory Rules.
A complete exercise of risk assessment & characterization is scientifically done. Mitigation plan is
drawn as follows:
• Mitigation measures
• Sprinkling on excavation
• Bag filters for steam boilers
• Stack height per MPCB
• Trees
• Barrier walls as shielding technology to suppress blast pressures, fragments, fire- balls.
• Chemical storage area – ventilation, store-rooms, fueldyked
• For Hazardous chemicals – Flame-proof motors, “No smoking’, Thermal insulations.
First aid trained and Fire-fighting trained person will be available in every shift. Safety Officer will
be appointed, as also the competent person retained. Where necessary, provisions of other Acts,
where required like Petroleum act, Explosive Act, etc. will be obeyed. Firefighting system is kept as
per norms of Insurance Company.
DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly,
Personal protection equipment will be given and use will be insisted. Consulting Physician is
available to attain the factory.
9.Benefits
The expanded capacity will meet the growing demand for fragrances and flavors. This will make the
final products more cost effective to consumers.
10. EIA study report:
This will be finally prepared and submitted as per guidelines given by MoEF as --
Prefeasibility Report–M/s.Aarav Fragrances & Flavors Pvt Ltd
11. Scoping
We shall propose in “Scoping” the details of all above, as also the following;
•The study area of 51125 sq. km, the land under the unit. Thus, there will not be change in land use
pattern. The present land is already nonagricultural and under the industrial use.
• Raw material requirement, water requirement, water balance, process details, technology,
productdetails etc.
•Ambient Air Quality monitoring, for3 monthsexcept monsoon covering 10 km radius around
industry and its impact.
• Ground water quality around plant 10 km radius.
• Treatment scheme to achieve low discharged from premises.
• Scheme of treatment, mode of treatment
•Many other medium and large scale industries are present within 10 km radius in general.
• Information of solid waste, number of working days, CO2 emission from stack and process, etc.
• Employment generation, benefits of project
• The raw materials used are enlisted and their MSDS will be presented.
Some of them will be covered under MIS rules. However there use in process is small below
regulatory quantity. Risk assessment will be done and submitted.
12. Conclusion
This project is very necessary to supply cost effective fragrances, flavours and perfumery chemicals
with in- house technologies and expertise to both domestic and worldwide and also in view of :
• The local people desire that this industry will be welcome in their area.
• The candidate site is suitable from general MoEF expectations.
•Water, Power, Maw Material, Filler Material and Market is assured and found available with
ease.
• Full precautions will be taken for Pollution Control, Resource Conservation and
Environmental Protection.
• This is cost effective and Sustainable Development.