1.0 executive summary · pre feasibilty report m/s popular chemical manufacturers & supplies...
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PRE FEASIBILTY REPORT
M/s POPULAR CHEMICAL MANUFACTURERS & SUPPLIES
PREPARED BY WOLKEM INDIA LIMITED Page 1 of 24
1.0 EXECUTIVE SUMMARY
M/s Popular Chemical Manufacturers & Supplies proposes for manufacturing of technical
grade pesticides capacity of 750 MTPA located at Site No. 380 karagada village belur taluk
district Hassan (Karnataka).
TABLE-1.1 Project Summary
S.N. Parameter Description
1. Category of
project as per EIA
notification &
Amendment
5(b)
“A” Category
2. Name of Company M/s Popular Chemical Manufacturers & Supplies
3. Existing
Production
Capacity(As per
earlier EC)
NA
4. Proposed Product
S.No. Name of the product Total Capacity (TPA)
1. Aluminium Phosphide 500
2. Zinc Phosphide 250
Total 750 TPA
5. Location Site No: 380
Village: Karagada
Tehsil: Belur
District: Hassan (Karnataka)
6. Total land area of
plot
2.03 Acres
7. Project cost for
expansion
Total Project Cost: Rs. 5 Crores
8. Electricity
requirement
Total power requirement 300 KVA to be provided by State
Electricity Board.
9. Source of State Electricity Board
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electricity
10. D.G. sets D.G Set : 62.5 KVA
11 Water
Consumption
Total Water requirement is 24 KLD
Source of water Out sources from Tankers/ground water
Waste Water
Generated
Approx. 7 KLD waste water will be generated.
Mode of Disposal After treatment waste water will be used in plantation.
12. Boiler 0.6 TPH
13. Fuel 1. Risk Husk Briquette for Boiler : 1.5 MT/Day
2.HSD for D.G Set: 82 Liters/Day
14. Solid Waste
Generation
Hazardous waste will be sent to TSDF
15 Nearest Highway Name Distance (In km) Direction
SH-57 0.49 East
NH-234 8.81 SE
SH-110 9.23 SE
16 Nearest Railway
station
Chikmaglur Railway station is about 13 KM in north direction from
the site
17 Nearest Airport Manglore airport is about 140 KM away from the site
2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of Project and Project Proponent
M/s Popular Chemical Manufactures & Supplies proposes to set up a new technical grade
pesticides plant capacity of 750 MTPA at. Plot No. 380, Village Karagada, Tehsil Belur,
district Hassan (Karnataka)
M/s Popular Chemical Manufactures & Supplies has obtained consent to establish No.CTE-
306532 dated 27.06.2018 valid up to 21.03.2023 for formulation of following product.
Aluminum Phosphide 25 MT/Month
Zinc Phosphide 10MT/Month
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H3PO4 10MT/Month
The new plant will be designed with the basic concept of green chemistry with
modifications to optimize energy utilization and with significant reduction of manual
interface. To meet the target production rate, all equipment’s capacities and their sizes will
be optimized.
An equipment list is prepared which includes the capacities and equipment sizes with
minimum other details required to finalize the overall land requirement and cost. Detail of
proposed products with capacity is given in table 1.2.
TABLE 1.2 PROPOSED PRODUCTS CAPACITY
2.2 Brief description of nature of Project
The proposed project is a technical grade pesticide manufacturing unit. This project involves
a production of new technical grade pesticides capacity of 750 MTPA. The manufacturing
process involves chemical reactions and physical process like storage, packing and
packaging and dispatch of Technical Grade Pesticides products.
As per EIA Notification dated September 14, 2006 and as amended till date, the project falls
in Category ‘A’, S. No. – 5 (b) “Pesticides industry and pesticides specific Agrochemical
intermediates (excluding formulations)” appraised in Ministry of Environment Forest &
Climate Change (MoEF.CC), New Delhi.
2.3 Need for the project and its importance to the country or region
India’s population is increasing and also the purchasing power of people is growing due to
economic development. Hence the demand for pesticides is growing rapidly. In order to
satisfy this need, more production of pesticides is needed. The pesticides production will
S.No. Name of the product Total
Capacity
(TPA)
1. Aluminum Phosphide 500
2. Zinc Phosphide 250
Total 750TPA
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bring new job opportunities for the local people & they will therefore become economically
stronger.
The proposed products range having good demand in the market & as per market survey by
the company there is a less supply of the products its demand, to overcome this shortage &
to bridge demand supply gap, the company proposed to have this expansion
Pesticides are essential input for agriculture & grain preserve at project will provide
adequate availability of required product at cheaper cost and will also be reduces the import
quantities.
2.4 Demands-Supply Gap.
Based on our informal survey of the market with our current customers and various traders,
we have found that there is a big potential for the range of the products we are planning.
These products are versatile products as far as pesticides application is concerned.
Since the requirement of Pesticides is increasing @ 10% to 15% every year, there is a huge
gap between the demand and supply. Import is also reducing every year as Indian
government is promoting Make in India.
2.5 Export Possibility
Based on the current cost of indigenous raw materials, it will make us very competitive
against imported finished products and we will be able to increase the export of our
finished products.
2.6 Employment Generation (Direct and Indirect) due to the project
S.no. Particulars No. of Employee Functional Area
1. Key managerial staff 5 Finance, Marketing
& Production
2. Administration 5 Quality Control,
R&D, Logistics,
Office Work etc
3 Skill&Semi Skilled 70 Production process,
Maintenance Store,
Safety and Unskilled
works
Total 80
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3.0 PROJECT DESCRIPTION
3.1 Type of Project
The proposed project is a technical grade pesticide manufacturing unit. This project involves
a production of new technical grade pesticides capacity of 750 MTPA. The manufacturing
process involves chemical reactions and physical process like storage, packing and
packaging and dispatch of Technical Grade Pesticides products.
As per EIA Notification dated September 14, 2006 and as amended till date, the project falls
in Category ‘A’, S. No. – 5 (b) “Pesticides industry and pesticides specific Agrochemical
intermediates (excluding formulations)” appraised in Ministry of Environment Forest &
Climate Change (MoEF.CC), New Delhi.
3.2 Location
The proposed project is a technical grade pesticide manufacturing unit located at Site No.
380 karagada village belur taluk district Hassan (Karnataka).
The latitude and longitude of proposed site is 15°30' 29.0” N and 75°54'53.75” E
There are no any archaeological and historical sites located nearby area. M/s Popular
Chemical Manufacturers & Supplies Private Ltd is well connected by road and railway line.
At present, the study area connects different types of roads, i.e. National Highway with a
length of 208.2 kilometers, State Highways 369.03 kilometers followed by Major District
roads 448.05 kilometers, Village roads with a length of 2788 kilometers and other roads
131 Kilometer sand are interrelated to each other.
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FIGURE 1 LOCATION MAP
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3.3 Detail of alternative sites considered.
The current site of pesticide manufacturing unit is satisfying the screening criteria for the
proposed activity. Therefore no alternate site was selected for proposed activity. The
screening criteria set by the company are economic & social factors. Overall, no alternative
site is examined.
3.4 Size or magnitude of operation
Pesticides will be produced in batch process. The total installed capacity of proposed plant
will be of 750 TPA. All the solvents used will be recovered and recycled for all products.
Energy efficient equipment will be installed at all location. Waste water will also be reused
after proper treatment. There will be no discharge from the site. Total plot area is 2.03
acres and 34 % Green belt is allocated for the greenbelt which already maintained.
TABLE 3.1 Machineries required for Proposed Unit
S. No. Machine Description Capacity – No.
1 S.S. REACTOR 2KL-2
2 S.S. REACTOR 3KL-2
3 S.S. REACTOR 4KL-2
4 S.S. REACTOR 5KL-2
5 S.S. REACTOR 6KL-2
6 S.S. REACTOR 8KL-1
7 FILTER PRESS 23*18-2
8 FILTER PRESS 46 x 36-1
9 ROTATORY VACCUM DRIER 760 Kg.-2
10 NOTCH FILTER 1200 LT-2
11 NOTCH FILTER 2000 LT-1
12 CENTRIFUGE 24-25 Kg.-2
13 CENTRIFUGE 36-150 Kg.-2
14 CENTRIFUGE 250-300 Kg.-1
15 FLUID BED DRIER 60 Kg.-2
16 RIBBON BLENDER 600 Kg.-2
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17 LATHE MACHINE 14’ 14’-2
18 DRILL MACHINE Normal-1
19 GRINDER MACHINE Normal-1
20 COOLING TOWER 25 TR-2
21 COOLING TOWER 35 TR-2
22 HOT WATER BATH 1 KL-2
23 CHILLING COMP. 17 TR-2
24 HOT WATER BATH 3 KL
25 CHILLING COMP. 17 TR
26 OIL BOILER (THERMAL) 850 kg/hr-2
27 VACCUM EJECTOR 730 mm/hg-2
28 STEAM EJECTOR 740 mm/hg-2
29 OXYGEN FEEDER 10 cylinder-2
30 OPIL VACCUM PUMP 730 mm/hg-3
31 SCRUBBER SYSTEM 1500 rpm-2
32 SUBMERSIBLE BOREWELL-1 Size 4”-3
TABLE 3.2 LIST OF UTILITIES
S.NO. MACHINE DESCRIPTION MAKE CAPACITY
1 TUBEWELL PUMP ROCKWELL 700 LTR/MIN
2 FIRE PUMP KIRLOSKAR 18LPS/90M/30HP
RPM2830
3 BLOWER (AIR POLLUTION) AIR TECH 1000CFM
4 BLOWER (AIR POLLUTION) AIR TECH 100 CFM
5 GEN-SET CIMINS 250 KVA
6 AIR COMPRESSOR IONGERSOL RAND 12 CFM
7 FIRE SIREN EXPRESS 50 KM
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8 SOLVENT PUMP-1 KIRLOSKAR 6.0 KL/HR
9 SOLVENT PUMP-2 KIRLOSKAR 6.0 KL/HR
10 SOLVENT STORAGE TANK SAIFA ENGG. 100 KL
11 SOLVENT STORAGE TANK SAIFA ENGG. 100 KL
12 WATER COOLER SHRI RAM 80 LTR/Hrs/60/120
13 Boiler 0.6TPH -
14 DG 62.5 KVA -
TABLE 3.3 LIST OF LABORATORY EQUIPMENT
S. No. Machinery Description Make Model No. No.
1 HPLC (Chemistration) Agilent 1100 2
2 HPLC with Software Thermo-separation P100 2
3 Gas Chromatograph with
Software
Nucon 5765 2
4 U.V. Spectrophotometer Perkin Ekmer -- 1
5 Ph. meter Lab India Effem
Technology
0006NBS DBK
Digital
Instruments
2
6 Polarimeter Rajdhani Scientific
Instrument Co.
12 SPI 1
7 Oven Elcon -- 1
8 Vaccum Oven -- -- 1
9 Analytical Balance Sartrius BP121S 2
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10 Analytical Metler Toledo AB1045 2
11 Wrist Action Shaker PR Scientific -- 1
12 Vaccum Pump Farcov -- 2
13 Vaccum Pump Local -- 1
14 Water Bath SM Industries -- 1
15 Magnetic Sttirer Local -- 2
16 Flash Point Apparatus Ashain Scientific -- 1
17 Refrigerator BPL, Godrej -- 2
18 Bod Incubator Calton -- 2
19 Melting Point Apparatus Local -- 1
3.4.1 Name of Raw Material and consumption per annum
S. No Name of Raw Material Consumption
MTPA
Aluminium Phosphide
1 Aluminium Powder 35
2 White Phosphorus 38.9
3 Groundnut Oil 0.5
4 Paraffin Wax 2.9
5 Urea 4.20
6 Ammonium Carbamate 19.50
7 Zinc Stearate 4.5
8 Graphite Powder 5.80
Zinc Phosphide
White Phosphorus 11.35
Zinc Dust 39.90
4.0 Process Description and Process Details
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4.1 Aluminum Phosphide
Process Description
Aluminium Powder is mixed with White (Yellow) Phosphorus in presence of Groundnut oil
to give Technical Aluminium Phosphide (87%), P2O5 generated during the reaction, is
scrubbed with water to give H3PO4 acid as a byproduct. Technical aluminum phosphide is
then diluted with ingredients like Paraffin Wax, Ammonium Carbamate (MR-17), T.G.Urea,
Zinc Stearate, Graphiteto give required Aluminium Phosphide with 56% to 60% and 15%.
This Aluminium Phosphide is then sent for either tableting or directly for Pouch Packing. In
tableting, basically there are three types of tablets: Flat (3gm wt), Round (3gm wt) and
Pellet (0.6 gm wt). Tablets are packed either in aluminium flasks & then in boxes Or in
tubes-tins & then CFB boxes. In pouch packing, aluminium phosphide powder is packed in
pouches, single or interlinked with each other called as chains or blanket. Such single or
interlinked pouches are then packed in secondary packing of aluminium foil, which is
vacuumed to remove air. This vacuumed aluminium foil is then packed in tins & then in CFB
boxes. After CFB packing of pouches & tablets, boxes are strapped individually or on
wooden pallets for dispatch.
Reaction Chemistry
Formula
4Al + P4 4 AlP
P2O5 + 3H2O 2H3PO4
ALP + 3H2O PH + AL(OH)3
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Process Flow Diagram
Input In kg In kg Output
Ground nut Oil 5
Water 2824
2774
Urea 42
Zn. Stearate
Graphite Powder
Aluminium Phosphide
Al. Hydroxide
195
29
Effluent
Aluminium Phosphide
Aluminium Powder 350
White Phosphorus389 150 Phosphoric Acid
1000 kg
Ammonium
Paraffin Wax
45
58
13
Reaction and
Scrubber
Formualtion
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Material Balance Aluminium Phosphide
4.2 Zinc Phosphide
Process Description
Zinc Dust coarse and fine grade both are mixed with White (Yellow) Phosphorus to give
Technical Zinc Phosphide (84%). This zinc Phosphide powder is then packed into drums /
tin / Pouches.
Reaction Chemistry
6Zn + P4 2ZN3P2
1 350
2 389
3 5
4 29
5 42
6 195
7 45
8 58
9 2824
Kg/MT
Graphite Powder
3937Total
Paraffin Wax
Urea
Ammonium Carbamate
Zinc Stearate
Water
Groundnut Oil
S.No. INPUT
Aluminium Powder
White Phosphorus
Liquid Air EmIssi Solid
Effluent on/Loss Waste
2 Phosphoric Acid 0 0 150 0
3 Al (OH)3 Aluminum Hydroxide Waste 0 0 0 13
4 Effluent 2774 0 0 0
3937Total
2774 0 1150 13
0 Product
By Product
TSDF
ETP
1 Al. Phosphide 0 0 1000
S.No.
OUT-PUT (KG/MT)
Product Recovery Remarks
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Process Flow Diagram
Material Balance Zink Phosphide
4.3 Resource optimization- Utilize & Recycling
The plant working will be hard to optimize the resource utilization. The industrial waste
water will be recycled and reused after proper treatment through ETP and thereafter RO
process which will reduce water requirement significantly.
Input In kg In kg Output
19 Solid Wate
Zinc Phosphide
White
Phosphorus227
Zinc Dust792
Zinc Phosphide
1000 KG
Reactor
1 792
2 227
Liquid Air EmIssion Solid
Effluent on/Loss Waste
2 Solid Waste 0 0 0 19
1019
Product
Solid Waste
Total
0 0 1000 19
1 Zn. Phosphide 0 0 1000 0
Total 1019
S.No.
OUT-PUT (KG/MT)
Product Recovery Remarks
S.No. INPUT
Zinc Dust
White Phosphorus
KG/MT
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Rain water harvesting structure will be developed at the site that will help in recharging
the ground water.
5.0 Availability of Water and its source, Energy/Power requirement
5.1 Water
Proposed project Popular Chemical Manufacturing and Supplies will require 9 KLD fresh
water which will be sourced through Tankers.
TABLE 3.3 WATER CONSUPTION DETAIL
S.No. Process Proposed water consumption
KLD
1 Boiler 14
2 Cooling Tower 4
3 Domestic 1.0
4 Industrial Process 7.0
5 Miscellaneous (Laboratory) 2.5
6 Scrubber 1.0
Total 29.5
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Figure-2 Water Balance of M/s Popular Chemical Manufacturers & Supplies
Total Water Requirement
29.5 KL
5 KLD
Plantation
ETP
12.5 KL
Boiler Blow
Down
1.5 KL
Process
7
Acid
Scrubbing
1 KL
Utility
18 KL Process
8 KL
Boiler
14KL
Cooling
Tower
4 KL
Domestic
1 KL
Drinking
0.5 KL
Toilet
0.5 KL
Lab
2.5 KL
1.50 KL Soak Pit
2.5 KL
Biological
treatment
Process
w/w
7 KL
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5.2 Power requirement
Total power requirement will be 300 KVA which will be sourced from State electricity
board. DG 62.5 KVA set to be installed for power backup.
5.3 Fuel Consumption
For Power backup, HSD used as a fuel for D.G sets DG set of adequate capacity will be
provided for emergency power supply.
5.4 Quantity of wastes to be generated (liquid and solid)
5.4.1 Waste Water Generation and Utilization
Waste water generation:-
The sources of waste water from the proposed plant will be process, boiler, cooling tower
and laboratory. The waste water will be treated in effluent treatment plant and will be
reused for gardening and other activities like toilet flushing and cleaning purposes.
M/s Popular Chemical Manufacturers & Supplies proposes Zero Liquid Discharge (ZLD)
Hence impact on water quality from the proposed project is insignificant
5.4.2 Solid /Hazardous waste generation and Disposal
Solid hazardous wastes will be sent to TSDF site while other solid wastes will be
segregated in salable and non-salable waste. Salable waste will be sold off. Non salable
waste will be sent to land fill.
6.0 Schematic representations of the feasibility drawing which give information of
EIA purpose.
The applicability of the S.O 1533 for the proposed project was explored by
considering different possibilities & provision made in the said notification.
Considering the products & project location of the proposed project it is noticed that the
proposed project falls under Category 5 (b) "A” of the Schedule-1of EIA Notification SO
1533 and its amendments.
As per the provision of the SO 1533, it is necessary to get Environmental Clearance by
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applying to SEAC along with the Environmental Impacts Assessment Study Report for
the proposed project prior to commissioning of the project activities. Therefore, the EIA
is required to conduct to comply with provisions of SO 1533 made for Category 5(b) "A “of
schedule -1 of the notification.
7.0 Site Analysis
7.1 Connectivity
� The nearest habitation is Karagada village at a distance of 2.5 Km in SW direction
from site.
� The nearest railway station is Chikmaglur Railway station which about 13 KM in
north direction from the site
� The nearest Airport is Manglore air port which is about 140 KM away from the site
� Details of the Highways connected with the project site is given below:
Name Distance (In km) Direction
SH-57 0.49 East
NH-234 8.81 SE
SH-110 9.23 SE
7.2 Topography
Topographically the area is flat terrain and the elevation of the plant site is between 690 -
713m above Mean Sea Level. The District lies approximately about 800 mts above the sea
level, which is why it enjoys a moderate and healthy climate. The District may be divided
into 3 natural regions, viz.,
7.3 Existing land use pattern
The project area is flat terrain, located inside notified Industrial area of Belur . CRZ is not
applicable to the proposed project.
7.4 Existing Infrastructure
The proposed site is to come inside the Belur Industrial area which is very well connected
to NH-234 and is also having very well developed internal road and other required
infrastructure. The proposed project site is to come inside the non operational Formulation
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& R& D technical unit with existing building and other infrastructure which will be utilized
according to the requirement.
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Figure-3 Plant Layout
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7.5 Soil Classification Soil investigation will be done during construction of the
proposed technical unit of pesticide
General Characteristics of the Soil in the District
Soil is closely associated with vegetation, climate, parent rock and slope. It is essential for
geographers to study the soil because all kinds of life forms entirely depend on the soil.
The soil of Hassan district may be generally classified into black soil, red soil, and laterite
soils. The great part of Hassan district is covered by black soil. Black soil is found in the
Maidan areas eastern portion and Belur taluka. The medium black soil is formed by the
Deccan volcanic rock, schist, limestone. The deep black soil is formed by the Deccan
volcanic rock schist limestone etc. Normally, this soil is made of natural erosion and mostly
found in river valleys. These soils are found with brown mixed black colour, black and
brown mixed gery colour, pure black color.
7.6 Climatic data from secondary sources
The mean annual rainfall for the period 2001-2010 in the Dharwad district is 735mm. The
mean pre monsoon rainfall is 146 mm, mean South West monsoon rainfall is around 468
mm and North East monsoon season is around 122 mm. Annual rainfall during 2011 is
734mm in which 112 mm during premonsoon, 447mm during monsoon and 175mm
during post monsoon. Maximum annual rainfall of highest 1497mm is recorded during
2005 in Hubli taluk. Minimun annual rainfall of lowest 340mm is recorded during
2003.Overall rainfall distribution shows that northeast part is receiving lowest rainfall.
Similarly southwest part receiving highest rainfall
Rainfall
The average rainfall of the district is recorded as 734.5 millimeter in the year 2011. The
annual rainfall occurs between June to September. Maximum rainfall occurs in the month
of July. Sometimes, heavy rainfall accompanied thunder occurs during later half of summer
and northeast monsoon months. Northeast Monsoon winds contribute about 22 percent of
rainfall of the district.
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7.7 Social Infrastructure available
Well- developed social infrastructure facilities are available at nearby habitations.
8.0 Planning brief
Proposed plant activities will start after getting statuary clearance from related authorities.
Further proposed project activities will take care of all the rules and regulation of statuary
authority and provide the control measure and devise to achieve the standard norms..
Type of Industry: Technical grade pesticide plant with proposed capacity 750 TPA
Transport network:
Transport and communication plays an imperative role in not only the growth of rapid
socio-economic development of region but also enhance the comfortable life of the people
in any geographical region improved and effective transportation is indispensable to
economic progress. Transportation is a service by which persons, goods etc. are moved
from different location from producer to consumer. In this regard, the study area is
favorable placed at it has a good network of roads, railways and airways. At present, the
study area connects different types of roads, i.e. National Highway with a length of 208.2
kilometers, State Highways 369.03 kilometers followed by Major District roads 448.05
kilometers, Village roads with a length of 2788 kilometers and other roads 131 Kilometer
sand are interrelated to each other.
Population Projection
Population characteristic plays a very imperative role in any economic activity of the
region. the fact that the total population of the Hassan district is 1847023, out of which
797484 rural populations, i.e. 43.17 percent among them 409416 male (51.33) percent
and 388068 female population (48.66) percent has been registered. The urban population
of the district is 1049539 which is 56.82 percent out of which 527790(50.28) percent male
population and the share of female population is 521749(49.71) percent respectively.
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Assessment of Infrastructure Demand (Physical & Social)
On the basis of the preliminary site visit, the infrastructure demand in the villages was
assessed on the basis of need and priority. Employment would be as per prevailing norms
of state government for skilled and unskilled people for the proposed project activity.
Amenities/Facilities
Proper site services such as First Aid, Canteen, Drinking Water, etc. will be provided to the
workers.
9.0 Proposed Infrastructure
Industrial Area (processing area)
The project is fall at village Karagada, Tehsil Belur, District Hassan. No additional land will
be required.
Residential Area (non-processing area)
No residential area proposed in upcoming project
Green belt
34 % Green belt is allocated for the greenbelt which already maintained in the
nonoperational unit.
Drinking water management (source & supply of water)
Drinking water will be taken from Borewel/Tankers.
Sewage system
Domestic waste water will be send to soak pit
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Industrial waste management
Solid hazardous wastes after incineration will be sent to TSDF site while other solid wastes
will be segregated in salable and non salable waste. Salable waste will be sold off. Non
salable waste will be sent to land fill.
Power requirement & supply/ source
Total power requirement 300 KVA to be provided by State electricity board. Also for Power
backup, HSD used as a fuel for D.G sets. DG set of adequate capacity will be provided for
emergency power supply
10.0 Rehabilitation and Restoration (R&R) Plan
As there is no human settlement within notified industrial area so R& R plan is not
required.
11.0 Project Schedule & Cost estimates
11.1 Likely date of start of construction and likely date of completion
Proposed project activities will be start after getting statuary clearance from related
authorities.
11.2 Estimates project cost along with in terms of economic viability of project
Proposed activity will provide benefit to the local people in terms of financial and social
welfare. Project cost for the proposed projects is Rs 5 Crores which includes the cost of
new plant machinery.
12.0 Analysis of proposal (Final recommendations)
The project will be beneficial to people as the company progress and expands its activity
gradually. Through CSR activity company management will be committed to improve
infrastructural facilities for the local people in fields of Environmental, Medical, and
Transportation etc. The local people will be benefited by way of indirect employment
opportunities which will improve the socioeconomic environment of the area.