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Prefeasibility Report Makwell Organics Pvt. Limited

Expansion project- Epoxy Plasticizer

Project pre-feasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification – 2006

1 EXECUTIVE SUMMARY:

Name & Location

Name of the Project: Makwell Organics Pvt. Limited Location : Plot No: 57/D/A, 1st Phase, G.I.D.C,

Vapi, Pin: 396195 Dist. - Valsad (Gujarat) Project Makwell Organics Pvt. Limited is located in GIDC notified industrial area, falling under small

Scale category manufacturing products as mentioned under for which the company had obtained Consent To Establish and Operate from Gujarat pollution Control Board.

The company proposes to enhance the capacity of existing products under the category “Epoxy Plasticizer”.

Existing project cost is Rs. 97.00 Lacs. Proposed expansion Project Cost: Rs. 200.00 Lacs. Total cost after proposed expansion will be Rs. 297.00 Lacs.

Applicability of EIA notification – 2006 Category as per the amended EIA notification-2006: as existing and proposed products (i.e.

Epoxy Plasticizer) are covered under the Category-5(f). Hence, Prior Environmental clearance is required.

Project Proponent

The company in India comprises of 6 directors

Small scale unit List of finished products:

S. No Product TPM

Existing Proposed Total after proposed expansion

1. Epoxy Plasticizer 54 946 1000

Manufacturing process is attached as Annexure-3.

Resource Requirement:

Components Existing

Proposed Total after proposed expansion

Resources availability

Power, KVA 140 80 220 Sourced from Dakshin Gujarat Vij Co. Ltd.

Fresh Water, kl/day 13.36 35.78 49.14 Will be sourced from GIDC water supply Dept.

Imported coal for thermopak: I (4 lacs k cal) Kgs/Hr

0 80 80 GSPC

Imported coal for Steam boiler (3 TPH), Kgs/Hr

0 160 160 GSPC

Fuel (HSD) for D.G.Set, kgs/hr (Capacity: 500 KVA)

0 25 25 Sourced from local dealer

Cooling Tower, TR 250 150 400 In-house



Raw material Consumption:

S. No. Raw Materials Quantity in MT

Per tone per month

Existing Proposed Total

1. Soya bean oil 0.935 50.49 884.51 935

2. Hydrogen peroxide 0.299 16.146 282.854 299

3. Formic Acid 0.042 2.268 39.732 42

4. Caustic lye (100%) 0.014 0.756 13.244 14

Water and Waste Water Management At present, the water consumption is 13.36 Kl /day sourced from GIDC Vapi. After proposed expansion,

the Raw Water requirement will be 49.14 Kl/day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

At present, industrial waste water generation is 2.94 Kl/day. After proposed expansion, the industrial Waste Water Generation will be 23 KL/Day. Entire effluent will be treated in existing primary effluent treatment plant and finally treated effluent will be disposed off into CETP Vapi for further treatment and disposal into Arabian Sea.

Domestic waste water (4 KL/day) will be disposed off through Septic Tank and overflow is drained into drainage line.

Air Emission and its Control Measures Flue gas emission: At present, the unit is using steam from their sister concern unit, hence there is no flue gas emission.

After proposed expansion, unit proposed to install one number of imported coal fired 3 TPH steam boiler and imported coal fired 4 lacs k cal/hr capacity of thermopak. Also one number of HSD fired D G Set of 500 KVA capacity. Adequate height of chimney will be provided to the boiler, thermopak and D G set. (Detail of Air pollution control measures is attached as Annexure-10)

Process gas emission: At present, there is no process gas emission and after proposed expansion, there will be no process gas emission. Hazardous Wastes and its Management

S. No.

Type of Hazardous

waste

Category as H/W rules

2016

Generation, TPA

Treatment Disposal

Existing Proposed

1. Waste from ETP Sch: I, 35.3 2.5 5.0 Packed in HDE bags, stored

Dispose off into TSDF Vapi

2. Used Oil Sch:I, 5.1 0.024 0.3 Packed in HDPE drum

Sell to registered recycler

3. Discarded containers

Sch I: 33.1 5.0 15.0 Washed and stored

Utilized for packing of hazardous waste or sell to authorized

recycler



2. INTRODUCTION OF THE PROJECT AND THE PROPONENT Name of the project Proponent: Makwell Organics Pvt. Limited

Makwell Organics Pvt. limited is a small scale unit is located in notified industrial estate, GIDC, Vapi, Ta:

Pardi Di: Valsad, Gujarat having total plot area of 4576 m2 and total investment after proposed

expansion will be Rs. 297 lakhs. The proponent wishes to enhance the Production capacity of Existing

Products. The Epoxy Plasticizer is especially used in PVC compounding industries as per requirement.

The unit is operated by technocrats having more than 25 years of experience in manufacturing and

marketing of various Plasticizers. The company has established well equipped production plant which is

being managed by dedicated, qualified and skilled persons. The proposed expansion project is to

enhance the capacity of Plasticizer to 1000 TPM and process capabilities to manufacture plasticizer.

The proposed expansion project site lies on 20021’21.58” N Latitude & 72055’11.59” E Longitude.

Makwell Organics Pvt. limited is located at Plot. No. 57/D/A, 1st phase, GIDC Vapi, Ta: Pardi, Di: Valsad in

Gujarat state. GIDC Vapi is centrally located in the both sides of National Highway No. 8 connecting

Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and

Dadra & Nagar Haveli on the eastern side.

Vapi is the biggest railway station in the study area. Beside the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is a six lane and double tracked. This highway has given a further boost to the economic growth of this area. The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected to each other by a Pucca road. Vapi Township has emerged as an Industrial hub on the Gujarat- Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for chemical manufacturing industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals, school and colleges, community centres, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchange, hotels, guesthouses etc. The town has got a major face-lift after the completion of national highway. Other links roads are also of good standard. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms away. The district Head Quarter – Valsad is 30 km from Vapi town. VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968. The entire estate, which was developed in phases, is now spread over 1140 hectares and houses more than 1400 industries, most of which are small-scale industrial units although some of them have grown into bigger units at later stage. The industrial township is basically a declared “Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related, such as Dyes and Dyes intermediates, pigments, pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s largest common effluent treatment plants has been setup in Vapi industrial estate. Being a major industrial and commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon and Dadra and Nagar Haveli, etc.



Makwell Organics Pvt. Limited was started in the year of 1993. The product has been developed through strong in-house R&D. The Group’s turnover is about 80 Crores for the year 2015-16. The management is concerned about Environment and Safety issues and gives utmost importance to these aspects by continuous training and improvement followed by various external Audits. We have a strong in-house R&D team. We have a small Pilot plant at this site to support the R & D activities.

(i) Identification of the project proponent :

Makwell Organics Pvt. limited is a small scale unit is located at notified industrial estate, GIDC Vapi, Ta: Pardi, Di: Valsad, a well enthusiastic and professionally managed manufacturer. List of Directors:

(1) MR. SHASHIKANT N THAKKER (DIRECTOR) (2) MR. KISHOR N THAKKER (DIRECTOR) (3) MR. HIREN S THAKKER (DIRECTOR) (4) MR. AMRISH K THAKKER (DIRECOR) (5) MR. VISHAL S THAKKER (DIRECTOR) (6) MR. ZUBIN K THAKKER (DIRECTOR)

Most of the members are qualified in engineering, management, safety, accounts, operations and marketing field and human relation.

Apart from these there are Expert from Field- Industries to achieve and perform better and better.

ii) Brief description of nature of the Project : Makwell Organics Pvt. Limited proposes to enhance the production capacity (54 TPM to 1000 TPM) at Plot No. 57/D/A, 1st phase, GIDC, Vapi-396195, Dist.- Valsad (Gujarat).

The proposed expansion project involves the capacity enhancement of existing Products. As per the amended EIA notification- 2006, the proposed products are covered under category 5(f)- B, but due to applicability of general condition i.e. within the 5 kms radius of interstate boundary of union territory of D N & H and Daman & Diu it is falls under category A and hence require Prior Environmental Clearance.

iii) Need for the project and its importance to the country and region:

The proposed project provides a potential growth opportunity for the ongoing business of the company. The company is engaged in the business of manufacturing of Epoxy Plasticizer and Chlorinated Paraffin wax. The project would also help the company to support the Indian economy in the following way:

Growth in Export Revenue and thereby increasing the inflow of foreign currency which is much needed by our country.

Our products are well accepted by international users and can substitute the international speciality Grades. Thus the Domestic Industry can replace the imported Plasticizer used by them with ours and there by curtail the outflow of foreign currency spent on Plasticizer imported by them.

Potential increase in Job opportunities for the Local surroundings.

Boost to the Local service providers and the overall improvement in the economic activities like



Local raw materials Suppliers, Transporters, contractors, clearing and forwarding agents and other allied suppliers.

The Company Objective is to achieve:

Consolidation of Epoxy Plasticizers and Chlorinated paraffin wax business. The Proposed expansion will help the company to move towards more specialized products and there by focus on value addition which will improve the shareholder’s worth.

The Proposed increase in capacity will also assist the company to reduce the costs due to increase in the sale of manufacturing and intern make the company’s products more competitive in the market.

Considering the nature of speciality chemicals business, the proposed increase in capacity will also help the company to standardize and produce the speciality chemicals with more consistency because higher volumes will help to achieve better control over Physico-chemical conditions while manufacturing.

To generate Local Employment

iv) Demand –Supply Gap :

Our product is mainly used in PVC compounding industries as per requirement. Since our products

are approved by quality conscious users which are multinational companies. We can cater to the

ever increasing demand in India as well as in the Export Market.

v) Imports vs. Indigenous production:

Existing products manufactured in the country will be very much economical compared to Imports of the same and also the export of the same will earn extra revenue generation for our county.

vi) Export Possibility:

Existing products have high export potential. Also these products have very good potential in the

local market. Additional capacities of product range required over and above the unit’s existing

capacities, as the company expects strong growth of exports to the extent of 40-50%. Local market

also shows strong growth potential.

vii) Domestic / export Markets:

The company’s products are used in PVC compounding industries as per requirement. These are

having very good demand in domestic as well as international markets.

viii) Employment Generation (Direct and Indirect) due to the project:

There will be very good opportunity of employment generation directly and indirectly due to

proposed expansion project. Due to proposed project there will be requirement of manager,

supervisor, operator and semi-skilled workers. For this, the company will employ about additional

30 people to fulfil it’s need to handle the plant.

Presently there are 25 numbers of employees. There will be additional 30 numbers of employees,

thus total 55 numbers of employees after proposed expansion.



3 PROJECT DESCRIPTION :

(i) Type of Project including interlinked and interdependent projects, If any :

The proposed project is an interdependent project of the company.

(ii)

Location (map showing general location, Specific location, and project boundary and project site layout) with coordinates :

The map showing general location, specific location and project boundary and project site is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii)

Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted :

The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in exiting premises only. (Land allotment letter is attached as Annexure-8)

(iv)

Size or magnitude of operation :

As per the proposed project cost, the project is covered under small scale category of manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. Should be given) :

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products and characteristics of hazardous chemicals are as below:

DETAILS ON PRODUCT TRANSPORTATION

S. No. Product Physical State Dispatch Packing and Means of transportation

1 Epoxy plasticizer liquid Local/Export Drums and transport through truck/container



DETAILS OF SAFE STORAGE and HANDLING OF HAZARDOUS CHEMICAL

S.No. Name of Finish

Products

Quantity stored (MT)

Place of Storage

Standard operating

Pressure and temperature

Possible Type of Hazards

Control Measures Provided

Max. Actual

1 Soya Bean Oil

200.0 100.0 Storage tank

Liquid at room

temperature

Eye: Irritant, Animal

tests indicate lowest

rating for corneal injury

Move affected person to fresh air. In case of

respiratory system or mucous membranes, or if you feel unwell or in case

of prolonged exposure, get medical attention

2 Hydrogen peroxide

100.0 50.0 HDPE carboys

Liquid, Ambient

temperature

Corrosive and irritant

to respiratory

tract

Self contained breathing apparatus , protective

clothing to prevent contact with eye & skin

3 Formic acid


Liquid, Ambient

temperature

Corrosive and Irritant

Use water spray

4 Caustic lye


liquid , Ambient

Temperature

Corrosive and Irritant

Use water spray

vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outline:

• The raw materials will be stored in closed containers and will be handled through closed

system to avoid the handling losses. • Condensate from boiler will recycled to minimize the water consumption. • There will be no use of any solvent. • PLC system provided for reactor. • Control of Raw materials by QC monitoring.

viii) Availability of water its source, Energy/power requirement and source should be given: Availability of water its source, Energy/power required and its source is below. Water will be sourced from GIDC Notified industrial estate, Vapi. Water withdrawal Permission is attached as Annexure: 4

OVERALL WATER CONSUMPTION AT EXISTING AND AFTER EXPANSION, M3/DAY

S.No. Particulars Water Consumption, M3/Day

Existing Proposed Total after expansion

1. Domestic 1.0 3.0 4.0

2. Processing and Product washing 0.358 6.29 6.648

3. Cooling 10.0 10.0 20.0

4. Boiler 0 15.0 15.0

5. Reactor/floor/container washing

1.0 1.0 2.0

6. Gardening 1.0 0.5 1.5

Total 13.358 35.79 49.148



Total Water Consumption: 13.358 m3/day, Sourced from GIDC Vapi

Domestic: 1.0

Septic tank

/soak pit

Processing &

Product washing: 0.358

Boiler: 0 Cooling: 10.0 Floor/

container

Washing: 1.0

Gardening: 1.0

Water Balance Diagram at Existing Scenario

0.914 1.0 1.0

2.914

Primary Effluent Treatment plant

CETP, Vapi

Arabian Sea

Total Water Consumption: 49.14 m3/day, Source from GIDC Vapi

Domestic: 4.0

Septic tank

/soak pit

Processing &



container

Washing: 2.0

Gardening: 1.5

Water Balance Diagram After Proposed Expansion

16.99 2.0 2.0

22.99 M3/Day


CETP, Vapi

Arabian Sea

2.0



ENERGY REQUIREMENTS AND ITS SOURCE

S. No

Particulars Existing Kgs/hr

After Proposed expansion

Kgs/Hr

Source

1 Steam requirement

1000 3000 At present steam obtained from sister concern unit. After proposed expansion steam will be obtained from proposed 3 TPH boiler

POWER REQUIREMENTS AND ITS SOURCE

S. No.

Particulars Existing After Proposed expansion

Source

1 Power – Electricity requirement 140 KVA 220 KVA Sourced from Dakshin Gujarat Vij

Co. Ltd.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal:

Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure-5.



(x) Schematic representations of the feasibility drawing which give information of EIA purpose:

A schematic representation of the feasibility drawing is enclosed as Annexure -9.

4 SITE ANALYSIS

(i) Connectivity :

Vapi Railway Station- 2.37 km approx., NW direction.

Surat Airport – 86.60 km approx., NNW direction

National Highway- NH:8, 0.51 Km. approx., West direction

(ii) Land Form, Land use and Land ownership :

The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation.

(iii) Topography (along with map) :

Topography map showing the elevation of the study area below. The topographical map is enclosed as Annexure-7.

(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given :

The existing land is located in the notified industrial area and a copy of which is enclosed as Annexure-8

(v) Existing Infrastructure :

GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.

(vi) Soil classification :

General soil classification of the area is as under :

Soil Characteristics and Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.

The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose.

The land is suitable for industrial development.

Damanganga River is located at 3 km distance from the site location; both side of the river has mixed soil type (Sand, clay and Basaltic soil).

(vii) Climate data from secondary sources :

Rainfall Data :

The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and Surendranagar



districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives rainfall between 500-1000 mm and generally falls under semi-arid climate. Considering the abnormality of weather particularly rainfall during the monsoon period, the observed and predicted rainfall was then analyzed for its validity.

Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

S.

No

Region Rainfall Projection

(in mm) June - Oct

Normal Rainfall (In mm)

Rainfall Projection

(% Departure from normal)

1 Middle Gujarat 905.3 796 13.7

2 South Gujarat 696.3 575 21.0

3 Project site 2071.7 1433.7 44.5

4 Saurashtra 767.1 580.4 32.2

5 Gujarat State 1110.1 846.5 31.1

Source: AAU, Anand, Gujarat

Temperature Data:

The site is located in the southern part of Gujarat. The secondary data was collected from free data of Worldclim.org for the year 2010. The project site temperature regime for medium to high level temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available :

Usha Shalby Hospital, Vapi- 1.05 km approx., ESE direction.

21st Century Hospital,Vapi- 1.66 km approx., NNE direction.

Union Bank of India, Vapi- 1.77 km approx., North direction.

UCO bank, Vapi- 1.99 km approx., North direction.

Vidhya Vikas Hindi School, Vapi- 1.15 km approx., NNW direction.

Sanskar Bharti, Vapi- 1.74 km approx., NW direction.

Rofel College, Vapi- 3.05 km approx.,NW direction.

Natraj Professional Science College, Vapi- 1.74 km approx.,SE direction.

1. Planning Brief :

Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi.

Land use Planning (breakup along with green belt etc) :

The existing as well as proposed expansion project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below.



For Green Belt Development as per the revised layout plan, the company proposes 770 m2 (17% ) of green belt of the total land, i.e. 4576 sq. meter. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises.

While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

1. Climatic condition and soil characteristics of the region. 2. The air pollution emitted by the industry – gaseous and particulate matter. Plant interaction with

both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal. 5. For absorbance of gases, the duration of the foliage should be longer. 6. Vegetation controls soil erosion rates significantly. The decrease of water erosion rates with

increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.

Site Plan with Area Table at Existing & After proposed expansion

S. No Particulars Area in m2


1. Production Plant 1700 0 1700

2. Office and lab area 90 0 90

3. Green Belt 770 0 770

4. Raw materials and & other Storage 300 100 400

5. Utility 50 50 100

6. ETP and solid waste storage area 44 20 64

7. Toilet block 9 0 9

8. Open space 913 -170 743

9. Finish product storage area 700 0 700

Total plot Area 4576 0 4576

Note: Proposed expansion will be carried out in existing plant by installing bigger capacity of

machineries. Plant layout along with greenbelt area is attached as Annexure-2

(iv) Assessment of Infrastructure demand ( Physical and Social) :

There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion.

(v) Amenities/ Facilities :

GIDC notified industrial area of Vapi has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.



6 PROPOSED INFRASTRUCTURE:

(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety.

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project

(iii) Green Belt :

Green belt will be provided and maintained at the tune of 17% of the total land area.

(iv) Social Infrastructure :

• Usha Shalby Hospital, Vapi- 1.05 km approx., ESE direction.

• 21st Century Hospital,Vapi- 1.66 km approx., NNE direction.

• Union Bank of India, Vapi- 1.77 km approx., North direction.

• UCO bank, Vapi- 1.99 km approx., North direction.

• Vidhya Vikas Hindi School, Vapi- 1.15 km approx., NNW direction.

• Sanskar Bharti, Vapi- 1.74 km approx., NW direction.

• Rofel College, Vapi- 3.05 km approx.,NW direction.

• Natraj Professional Science College, Vapi- 1.74 km approx.,SE direction.

(v) Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc):

Vapi Railway Station- 2.37 km approx., NW direction.

Surat Airport – 86.60 km approx., NNW direction

National Highway- NH:8, 0.51 Km. approx., West direction

(vi) Drinking Water management ( Source & Supply of water ) :

Source of water is from GIDC water supply services.

(vii) Sewerage System :

GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management :

Entire Industrial liquid effluent generated after proposed expansion will be treated in the primary, ETP and will be discharged through GIDC underground drainage to CETP Vapi (CETP Membership certificate is attached as Annexure-6)

Generated domestic liquid waste is being disposed off through soak pit system to drainage.



Solid/Hazardous Waste Management :

S. No.

Type of Hazardous waste

Category as H/W rules

2016

Generation, TPA

Treatment Disposal

Existing Proposed

1 Waste from ETP Sch: I, 35.3 2.5 5.0 Packed in HDE bags, stored

Dispose off into TSDF Vapi

2 Used Oil Sch:I, 5.1 0.024 0.3 Packed in HDPE drum

Sell to registered recycler

3 Discarded containers

Sch I: 33.1 5.0 15.0 Washed and stored

Utilized for packing of hazardous waste

or sell to authorized recycler

(Membership certificate is attached as Annexure-6)

(x) Power Requirement and Supply / Source :

Power requirement for proposed project will be taken from DGVCL.

7. REHABILITATION AND RESETTLEMENT (R&R) PLAN:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given):

There will be no rehabilitation and resettlement undertaken as labours and workers from local and nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site.

8. PROJECT SCHEDULE AND COST ESTIMATES :

(i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) : After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed minor construction and commissioning of the project. (ii) Estimated project cost along with analysis in terms of economic viability of the project : Estimated project cost along with the analysis in terms of economic viability of the project is given as below.



CAPITAL COST PROJECTION

S. No. Items Existing Rs. In lakhs

Proposed, Rs. In lakhs

Total, Rs. In Lakhs

1. Land 4576 m2 45 0 45

2. Building 25 30 55

3. Plant and Machinery 25 150 175

4. Environmental Management System 2 20 22

Total 97 200 297

Details of Utilities

S. No. Particulars Details

Existing Proposed Total

1 Boiler, kgs/hr 0 3000 3000

2 Thermopak, lac k cal/hr 0 4 l 4

3 Cooling Tower, TR 250 150 400

4 D.G. Set (Standby), KVA 0 500 500

5 Power from DGVCL, KVA 140 80 220

6 Fuel

I. Imported Coal, kgs/hr 0 240 240

II. HSD, kgs/hr 0 25 25

7 Water From GIDC, m3 / day

13.36 35.78 49.14

8 Waste Water, m3 / day (industrial)

2.914 20.076 22.99

9 Treatment Scheme Primary Primary Primary

10 Disposal CETP CETP CETP

PROJECT VIABILITY

S. No.

PARTICULARS AMOUNT (INR Lakhs)

1 Proposed Sale 800

2 Raw Material Cost 600

3 Power and Fuel 60

4 Labour Cost 20

5 Environmental Management System 10

6 Maintenance Cost 5

7 Selling, packing and Office Expenses 4

8 Proposed Profit 101

The company will provide budgetary provision for the recurring/operating expenses for environmental issues while planning the allocation of funds during the annual budgetary planning.



RECURRING/OPERATING COST PER ANNUM

S. No. Component Proposed (Rs. in Lacs/annum)

1. Environment and Safety Management System 5.0

2. Greenbelt Maintenance 2.0

Total 7.0

8. Analysis of Proposal and Final Recommendations:

(i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare.

Local people will get direct financial benefit by way of employment.

Local people will get some contracts of supply and services to get indirect income.

Company will contribute in improving education and health facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius

Prefeasibility Report Makwell Organics Pvt. limited


ANNEXURE: 2

Plant Layout



ANNEXURE: 3

Detailed project description with process details - MANUFACTURING PROCESS The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance & mole balance for the product.

MANUFACTURING PROCESS , CHEMICAL REACTION AND MASS BALANCE

In a jacketed vessel fitted with stirrer, add Soya bean oil, heat it up to 45 0C. Then add slowly hydrogen peroxide & formic acid. Exothermic reaction takes place above 40 0C. Then start cooling through jacket. The total reaction time is 24 hrs. After that, keep for a layer separation. Bottom layer is taken into collection tank of ETP for treatment. Upper layer is neutralized with caustic lye. Then given wash of hot water. Further keep for a layer separation. Bottom layer mainly water is taken into collection tank of ETP for treatment. Steam is given to the upper layer for moisture removal. After removal of steam; mass is directly packed in a drum as a finished product.

CH2 - O - C – (CH2) x - CH CH – (CH2)y – CH3

O

CH - O - C – (CH2) x - CH CH – (CH2)y – CH3

O


O+ 6 H2O2 + HCOOH

CH2 - O - C – (CH2) x - CH CH – (CH2)y – CH3

O


O


O

O

O

O

+ 6 H2O + HCOOH + 3/2 O2

Soya bean Oil

CHEMICAL REACTION OF EPOXYDISED SOYA BEAN OIL ( EPOXY PLASTICIZER)

Epoxy Plasticizer



Soya bean Oil:1000 kgs

Hydrogen peroxide: 320 kgs

Formic Acid: 43 kgs Heat it upto 450C, takes place exothermic reaction,

then cool it by jacket. Total reaction time is 24 hrs.

LAYER SEPARATION

BOTTOM LAYER : 373 kgs

ETP : 373 kgs

1363 kgs

Caustic lye: 15 kgs

Water: 85 kgs

1090 kgs

UPPER LAYER : 990 kgs

LAYER SEPARATION

Hot water wash: 100 kgs

BOTTOM LAYER : 100 kgs ETP : 100 kgs

UPPER LAYER : 1090 kgs STEAMING FOR MOISTURE REMOVAL : 1090 kgs PACKING : 1070 kgs

LOSS: 20 KGS

MASS BALANCE OF EPOXY PLASTICIZER



ANNEXURE: 4 Water requirement letter from Notified industrial estate:



ANNEXURE: 5

Quantity of Waste Water (liquid waste) generation and its management :

S. No. Particulars Effluent generation, M3/Day


1 Domestic 1.0 3.0 4.0

2 Processing & product washing 0.914 16.08 16.99

3 Cooling 1 1 2

4 Boiler 0 2 2

5 Reactor/floor/container washing 1 1 2

Total 3.914 23.08 26.99

Total Industrial 2.914 20.08 22.99

Note:

Domestic effluent is passes through adequate capacity of septic tank/soak pit.

At present, there is no boiler. Steam is obtained from sister concern unit.

At present, there is a generation of 2.914 m3/day of industrial effluent, which is treated in primary effluent treatment plant and discharge into under ground effluent drainage line to CETP for further treatment.

After proposed expansion, there will be generation of total 22.99 m3/day of industrial effluent, which is treated in primary effluent treatment plant and discharge into under ground effluent drainage line to CETP for further treatment.

Total Water Consumption: 13.358 m3/day, Sourced from GIDC Vapi

Domestic: 1.0

Septic tank

/soak pit

Processing &



container

Washing: 1.0

Gardening: 1.0

Water Balance Diagram at Existing Scenario

0.914 1.0 1.0

2.914


CETP, Vapi

Arabian Sea



Details of Effluent Treatment Plant

Design Criteria : Product : Plasticizer Source of Effluent : Process, washing & Utilities. Design Flow of Effluent : 22.99 KL/day Max. Design Parameters : As under Effluent Characteristics:

S.No Effluent parameters Domestic Process + washing

Boiler + cooling

Equip + floor + cont. wash

1 pH 6.8 4.0 8.1 6.5

2 Color, pt.Co 80 50 60 100

3 TDS, mg/L 800 4000 2400 2000

4 S/S, mg/L 255 564 121 456

5 Oil/grease, mg/L 12.5 1.2 3.6 1.8

6 BOD, mg/L - 1634 10 150

7 COD, mg/L - 4783 124 603

8 Ammonical nitrogen, mg/L 25 ND 8 ND

9 Phenolic compound, mg/L ND ND ND ND

Based on the above criteria Effluent Treatment Plant having under mentioned specification is required to install: Details of effluent treatment plant for normal industrial effluent stream:

S. No.

Name of Equipment Capacity in (KL) MOC

1. Oil & Grease tank 0.5 RCC

2. Collection Tank 5.0 HDPE

3. Fenton Reactor 15 SS 316

4. FeSO4 dosing tank 0.2 HDPE

5. Holding tank 5 RCC/TL

6. Settling tank x 2 Nos 15 each HDPE

7. Filter nutsch 2 m2 MSRL

8. Final Treated effluent holding tank 5 HDPE

Treatment Scheme:

From the manufacturing process, there is a generation of effluent from two stages. (1) from 1st stage as

water of reaction having COD in the range of 4000-4500 mg/l containing Hydrogen peroxide (2) from

2nd stage having very low COD in the range of 1000-1200 mg/l. and other effluent from boiler, cooling

tower and floor/container washing having negligible COD. Effluent generated from the 1st stage of the

reaction having pH is 4.0 collected in a collection tank, from where it is taken to Fenton treatment

reactor, where ferrous sulphate solution is added. The Fenton reaction is as under;

After addition of the iron and the hydrogen peroxide, they are going to react together to generate some hydroxyl radicals as it shows in the following equations:

Fe2+ + H2O2 ----> Fe3+ + .OH + OH-

Fe3+ + H2O2 ----> Fe2+ + .OOH + H+



The typical range for the iron dose is 1 part of Fe per 5-25 parts of H2O2.

After that the hydroxyl radicals are going to react with the pollutants to oxidize and reduce the COD. After Fenton treatment, the waste water is collected in a holding tank, where other low COD effluent stream are added, finally it is taken to a settling tank to remove sludge. Clear treated effluent is finally discharge into underground effluent drainage line to CETP.

Collection tank

FeSO4 Dosing tank

Fenton Rector

Holding tank

Filter nutsch

Settling tank

Treated effluent holding tank

U/G drainage line

Influent

Flow Diagram of Effluent Treatment plant

Characteristics of Final Treated Effluent

No Effluent parameters Final treated effluent

CETP inlet norms

1 pH 7.5 6.5-8.5

2 Color, pt.Co 50 <100

3 TDS, mg/L 2000 <2100

4 S/S, mg/L 50-60 <300

5 Oil/grease, mg/L 0.12 <10

6 BOD, mg/L 80-100 <400

7 COD, mg/L 300-400 <1000

8 Ammonical nitrogen, mg/L ND <50

9 Phenolic compound, mg/L ND <1



ANNEXURE: 6

MEMBERSHIP CERTIFICATE OF CETP, VAPI



ANNEXURE: 7



ANNEXURE: 8 Copy of plot allotment letter issued by GIDC



COPY OF NOTIFICATION REGARDING THE UNIT IS LOCATED IN NOTIFIED INDUSTRIAL AREA



ANNEXURE: 9 A schematic representation of the feasibility drawing



ANNEXURE: 10

DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES FOR EXISTING & PROPOSED EXPANSION Flue gas emission: At present, there is no boiler or thermopak. Required steam is obtained from sister concern unit M/S

Makwell plasticizers Pvt. Limited. Thus there is no flue gas emission. After proposed expansion, there will be installation of one number imported coal fired 3 TPH capacity of

steam boiler and 4 lacs k cal/hr capacity of thermopak having 30 meters height of chimney. Also 500 KVA capacity of D G set will be installed as a standby.

Process gas emission: At present there is no process gas emission. After proposed expansion, there will be no process gas

emission. The details of air pollution & its control measures at existing & after proposed expansion are as under;

S. No. Particulars Details Remarks


FLUE GAS EMISSION

1.0 Steam Boiler, TPH 0 3 3 Proposed

1.1 Fuel used 0 Imported coal Imported coal

1.2 Fuel Consumption 0 160 kgs/hr 160 kgs/hr

1.3 Stack Height 0 30 meter 30 meter

1.4 Pollutant to be emitted 0 PM: 100mg/NM3 SO2: 100 ppm NOx: 50 ppm

PM: 100mg/NM3 SO2: 100 ppm NOx: 50 ppm

1.5 APC 0 MDC & Bag filter MDC & Bag filter

2.0 Thermopak 0 4 lacs k cal 4 lacs k cal Proposed

2.1 Fuel used 0 Imported coal Imported coal


2.3 APC 0 MDC & Bag filter MDC & Bag filter

2.4 Stack Height 0 30 meter 30 meter

3.0 D G Set 0 500 KVA 500 KVA Proposed

3.1 Fuel used 0 HSD HSD


3.3 APC 0 Exhaust Exhaust

3.4 Height of exhaust 0 11 meters 11 meters



COPY OF EXISTING CCA



COPY OF ENVIRONMENTAL CLEARANCE FOR PROPOSED EXPANSION

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