maharashtra aldehydes & chemicals ltd. plot no: a-17,...

Pre-Feasibility Report Maharashtra Aldehydes and Chemicals limited, MIDC Mahad

Pre-feasibility report for

Expansion of synthetic organic chemical manufacturing unit

By

M/s. Maharashstra Aldehydes and Chemicals Limited

PROJECT TERMED UNDER SCHEDULE 5 (f)

(SYNTHETIC ORGANIC CHEMICALS)

CATEGORY - B

Prepared By

Maharashtra Aldehydes & Chemicals Ltd.

Plot No: A-17, MIDC, Mahad- 402309, India.

www.macl.co.in

http://www.macl.co.in/


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Chapter 1 Executive Summary

Company Profile

Maharashtra Aldehydes & Chemicals Ltd. (MACL) is manufacturer of Esters used for perfumery industry and specialty chemicals.

MACL (A group company of Laxmi Organics) is the only Indian company that is backward integrated for its raw material. MACL have Ethyl Alcohol manufacturing facilities with two distilleries within the group. The in-house sourcing as well as expertise of our group in alcohol-based chemicals gives us the leverage to use the best quality alcohol for manufacturing compared to our competitors in the market.

Considering our proficiency in Alcohol we have successfully developed new range of Ethyl Alcohol based esters, such as Tri Ethyl Citrate (TEC), Ethyl Propionate (EP) & Ethyl Butyrate (EB) and animal feed. In line with our expressed mission, MACL is backed by world class manufacturing facilities, a highly functional R&D department & stringent quality assurance systems. Our long-term relationships with multinational companies bear testimony to our strict adherence to intellectual property.

MACL’s Product range now accounts for 4 main verticals, which includes Flavors & Fragrance Ingredients, Plasticizers, and Laboratory Chemicals. We are in the process of developing new products that include for the cosmetic, Flavor and Fragrance Industries.

We are committed to the Health and Safety of our employees, the welfare of our community & environment protection.

MACL has existing plant at Plot no. A-17, MIDC Mahad, dist. Raigad.

Plot plan possession receipt / plot possession letter is at Annexure I.

The google image of the plot site is at Annexure – II.

Proposed Layout Plan for expansion is attached as Annexure–III.


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Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide

EIA Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic

chemicals manufacturing units. This project falls under category ‘B’ and schedule item no. 5(f):

Synthetic organic chemicals.

The project brief is summarized in the table below

Project summary at a glance

Sr

No

Particulars Details

1 Name of Company Maharashtra Aldehydes & Chemicals Ltd.

2 Products (existing and

proposed)

Refer Chapter 2

3 Location A-17, Mahad MIDC area, Mahad, Dist Raigad.

4 Name of the project 1) Expansion of Synthetic Organic Manufacturing facility

5 Total land area of the plot 20,000 sq. mtr.

6 Total proposed built up

area

Built up area - 5209 sq m

Proposed built up area – 2500 sq m

7 Major raw material Phthalic Anhydride, SDS, Methanol, Citric acid, Propoinic

acid/Ethyl Acrylate, Butyric Acid/Ethyl crotonate, Butanol,

Formic Acid, Heptanoic acid, valeric acid, capric acid,

caproic acid caprylic acid, benzoic acid, adipic acid, lauric

acid, Anisole, undecylenic acid, salicylic acid, pelargonic

acid, palmitic acid, myristic acid, Crotonic Acid, Cinnamic

Acid, Teraphthalic Acid, Guaiacol, Catechol, Heliotropin,

Vanillin, Vitamin E, Wet Alcohol etc.

8 Water requirement and

source

319 cmd (proposed additional requirement) from MIDC

9 Power requirement and

source

770 KVA additional from MSEDCL

10 Existing and proposed

manpower

Existing – 120, Proposed – 180, Total – 300 No.

11 Waste water quantity

(estimate)

202 cmd, shall be treated and discharged to CETP

12 Air emissions SOx, NOx, TPM from proposed boiler and Thermic fluid heater

13 Solid Waste Refer 3.7 below

14 Project cost estimate ~ 50 Crores


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The Land shall be used as “Industrial” land thus there shall be no change in land use.

This industrial plot is allotted by MIDC to Maharashtra Aldehydes and Chemicals limited.

(Plot allotment letter / plot possession letter is at Annexure I).

MIDC has provided all basic infrastructures like Electrical Power, water supply, the internal

road network, external approach road and networking with CHWSTDF (Common Hazardous

Waste Storage Treatment and Disposal Facility).

There is no sensitive establishment in the vicinity such as health resort, hospital,

archaeological monuments, sanctuaries, etc.

The land and infrastructure is made available by MIDC and the raw material is easily available

through the easy transport via road connectivity by local suppliers as well as imported one.


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Chapter 2 Introduction of the Project

2.1 Identification of the project and Project Proponent

The project is expansion of synthetic Organic chemicals manufacturing facility at the current

location of the plant site.

Project proponents are,

Directors

No Name Address 1 Vasudeo Nathmal Goenka 242-C, Grand Paradi Apartment, August Kranti Marg,

Mumbai - 400 036. 2 Ravi Vasudeo Goenka 221-C, Grand Paradi Apartment, August Kranti Marg,

Mumbai - 400 036. 3 Rajeev Vasueo Goenka 241-C, 24th Floor, Grand Paradi Apartment, August Kranti

Marg, Mumbai - 400 036. 4 Sunil Kumar Gupta E-102, Shanti Nagar - E, Dattamandir Road, Malad (East),

Mumbai - 400 097. 5 Aditi Rajeev Goenka 241-C, 24th Floor, Grand Paradi Apartment, August Kranti

Marg, Mumbai - 400 036. 6 Anilkumar Govindprasad

Lohia 404/A, Meghdoot New D.P.Road, Lokhandwala Complex, Andheri (West), Mumbai - 400 053.

2.2 Need of project with description for region and country

Project is required to products having high export potential & export substitute. Site is situated

in the proximity of port. Raw materials are easily available. Job generation in local surrounding

area. Easy availability of skilled and unskilled labor. Site is situated in a dedicated chemical

zone.

2.3 Brief Description of Project

Size : It is proposed to produce following products at the site.

The existing products (as per CTO) and proposed products are summarized below,


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Sr. No

Product / By product Existing as per CTO MT/M

Proposed Add. production capacity (expansion)(MT/M)

Total

(MT/M) Product

1 Syrindaldehydes 1.5 0 1.5 2 Di ethyl Phthalate 750

2170

3000

3 Di methyl Phthalate 50 4 Ethyl Benzoate 30 5 Esters (Ethyl Formate, Ethyl Butyrate,

Triethyl Citrate, Ethyl Propionate, Acetyl Tributyl Citrate, Ethyl Aceto Acetate, Ethyl Caprate, Ethyl Caproate, Ethyl Caprylate, Ethyl Heptanoate, Ethyl Isovalerate)

0

Di Octyl Adipate 0 Di Octyl Phthalate 0 Ethyl Laurate 0 Di Butyl Phthalate 0 Di-iso nonyl Phthalate 0 Di Octyl Terephthalate 0 Ethyl 2-Methyl Pentanoate 0 Ethyl 2-Methyl Butyrate 0 Ethyl Acetate 0 Ethyl Valerate 0 Ethyl Cinnamate 0 Ethyl Crotonate 0 Ethyl Myristate 0 Ethyl Palmitate 0 Ethyl Pelargonate 0 Ethyl Salicylate 0 Ethyl Undecylenate 0

6 Sodium Pyrithione 75 0 75 7 Cyclopentanone & its derivative 100 0 100 8 Trimethyl Hydroquinone & it's

formulation 20 0 20

9 Anisole 0 1000 1000 10 4-Methoxy Acetophenone 0 100 100 11 Anethol 0 100 100 12 Mono Methyl Ether of Hydroquinone 0 300 300 13 Guaiacol 0 150 150 14 Vanillin 0 50 50 15 Heliotropin 0 30 30 16 Helional 0 30 30 17 Absolute Alcohol 0 50 KLPD 50 KLPD 18 Distillation of Methanol 30 135 300 19 Distillation of Acetonitrile 30 20 Distillation of Ethyl Acetate 30 21 Distillation of Toluene 15


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Sr. No

Product / By product Existing as per CTO MT/M

Proposed Add. production capacity (expansion)(MT/M)

Total

(MT/M) 22 Distillation of Acetic Acid 30 23 Distillation of Hexane 15 24 Distillation of Butanol 15 25 Distillation of Ethyl Aceto Acetate 0

Formulation Product 1 Vitamin E Blend (MAXVIT) 0 100 100 By Products

1 Sodium sulphate Solution 0 1500 1500 2 Acetic Acid 0 40 40 3 2-methoxy Acetophenone 0 7 7 4 2,4-Diacetyl toluene 0 1.8 1.8 5 Propionic Acid 0 50 50 6 1-Methoxy-4-Propylbenzene 0 7.1 7.1 7 Cis Anethole 0 7 7

2.4 Export Possibility 70 % - 80 % of the products manufactured, specifically, Esters will be for Export’s to Major Global Flavor Houses. Internationally the Flavor market is more developed and advanced and so is the demand. India can compete with the Global manufacturers mainly from Europe and China for these products.

2.5 Domestic / Export Markets Plasticizers: In view of the economic growth of India being projected at 7% to 7.5% PA, the domestic

demand for Consumer & Industrial Products viz. All Plastic Products, Vinyl Products,

Medical & Surgical Aids, etc. is increasing. We foresee a surge in the demand of close to

12% - 15% annually of such products. This demand translates to an increase in the

consumption of Plasticizers in all these segments of Industry.

In the International Market, the consumption of such Plasticizers is projected to grow at of

10% - 12% annually as Plastics are replacing traditional metals across the Consumer &

Industrial goods spectrum. In India, we have the advantage of availability of local Raw

Materials, skilled labour & technology to compete with the best in the world.

Esters: India is a major importer of these products except for few manufacturers who may or may

not be manufacturing the products in small volumes mainly due to the stricter norms of

obtaining Licenses for Ethyl Alcohol. We will be manufacturing the entire range of esters

and cater to all the domestic customers and discourage customers to import these

materials from China. The Domestic Market is around 20 % to 30% and Export market


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around 70% to 80%. Over a period of time we would try to capture 45 % to 50 % of the

market share.

Distilled Solvents:

India is emerging on the world map as a major producer of High Value Chemicals & the

demand for Distilled Solvents is increasing by the day as these are used in the R & D

Facilities of all such Industrial Units. We plan to cater to the rising demand. Acceptance by

MNCs in India opens up the doors for us to venture into the International Market.

2.6 Employment Generation due to Project (Direct and indirect)

Once the project is fully operational we expect to create approx. 80 – 100 new job

opportunities for Technical, Clerical, and Skilled & Semi Skilled Labor.

With the expansion in capacities of our Plant, we would also be upgrading our

Infrastructure thereby creating a demand for Industrial Equipment & raw Materials. This

will create a ripple effect & help in employment generation at our suppliers’ side as well.


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Chapter 3 Project Description

3.1 Type of Project:

Expansion of existing products with new products

3.2 Location of the Project

Details of Nearest Infrastructure Facilities

Sr. No Destination App. Distance of Project

Site 01 Nearest Town

Mahad 7 km 02 Nearest National Highway (Mumbai Goa)

NH-66 7 km 03 Nearest Airport

Mumbai 177 km 04 Nearest Railway Station

Karanjadi 17 km 05 Nearest Port

JNPT 190 km

The project expansion is proposed at Plot No A - 17, Mahad MIDC, Dist. Raigad Maharashtra.

The Geographical Location of this plot is at 18.104259 N Latitude and 73.481089 E Longitude

with an elevation of 20 meter above sea level MSL.

Site coordinates are as follows:

Direction Latitude Longitude

North east corner 18.105698 73.481034

North west corner 18.105635 73.480143

South east corner 18.103913 73.481200

South west corner 18.103826 73.480261

This site is in premises of MIDC Estate which is meant for these types of Industries.

GPS Location on Google Imagery of the proposed site is attached as Annexure II.

Land Form: Land is on plain contour, it is flat terrain.


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Land Ownership: Land ownership is with project proponents (Maharashtra Aldehydes and

Chemicals limited)

Existing Land use Pattern: The Land is reserved for Industrial use & the proposed project

shall be at the same plot.

Existing Infrastructure: Presently there is an existing Infrastructure around the site.

Infrastructure like water, electricity, telephone facility, roads already available. Other

Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at

Mahad Town (Which is at distance of about 7 km)

Mahad MIDC provides many basic facilities like uninterrupted water supply, power and Road

Network. When various sites were seen, this site appeared to be environmentally best as also

from the business angle and therefore this option was finally adopted. This site is inside the

campus of the MIDC and means safe transportation, less need of Utilities, less constructing

buildings and roads, less fuel, less water with optimization of infrastructure.

There is no sensitive establishment in the vicinity such as health resort, hospital,

archaeological monuments.

The location justification for the project is as under

a. Availability of required land and infrastructure for locating the establishment for the

synthetic organic chemical manufacturing.

b. Suitability of land from topography & geological aspects, synergy and business point of

view

c. Proximity to rail / road to facilitate transport of equipment / materials/ product

d. Availability of adequate quantity of water to meet water requirements.

Lay-Out

Refer Annexure III for the proposed plant site layout plan.

3.3 Project Description with Processes Details:

The project is expansion project for manufacture of Synthetic Organic chemicals

Refer Annexure IV for product description with process details.


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3.4 Raw Material for finished Product:

Raw Materials:

The basic raw material for the proposed production capacity is submitted herein below.

Source for Raw Material Procurement: Raw Material is easily available in the local market.

Mode of Transport of Raw Materials: Mode of transport to site is by road truck/tankers.

List of Major Raw Material & Storage

Sr. No. Raw Material Unit

Total consumption Qty. per year

(existing)

Total consumption Qty. per year (proposed)

Total

1 Phthalic Anhydride Ton 6650 18368 25018 2 Citric acid Ton 0 2087 2087 3 2-Methyl Butyric acid Ton 0 1982 1982 4 2-Methyl Pentanoic acid Ton 0 2036 2036 5 Benzoic Acid Ton 305 1729 2034 6 Butyric Acid Ton 0 2023 2023

7 Capric acid Ton 0 2294 2294

8 Caproic acid Ton 0 2149 2149

9 caprylic acid Ton 0 2233 2233

10 Formic Acid Ton 0 1658 1658

11 Heptanoic Acid Ton 0 2194 2194

12 Iso Butyric Acid Ton 0 2023 2023

13 Iso Valeric Acid Ton 0 2092 2092

14 Lauric Acid Ton 0 2339 2339

15 Propionic Acid Ton 0 1935 1935

16 Valeric Acid Ton 0 2092 2092

17 Adipic Acid Ton 0 8004 8004

18 Teraphthalic Acid Ton 0 1135 1135

19 Cinnamic Acid Ton 0 2242 2242

20 Crotonic Acid Ton 0 2012 2012

21 Myristic acid Ton 0 2375 2375

22 Palmitic acid Ton 0 2404 2404

23 Pelargonic acid Ton 0 2265 2265

24 Salicylic acid Ton 0 2217 2217

25 undecylenic acid Ton 0 2314 2314

26 Phenol Ton 0 11605 11605

27 Anisole Ton 0 7159 7159


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Sr. No. Raw Material Unit

Total consumption Qty. per year

(existing)

Total consumption Qty. per year (proposed)

Total

28 Guaiacol Ton 0 544 544

29 Catechol Ton 0 293 293

30 Heliotropin Ton 0 313 313

31 Wet Alcohol(SDS) KL 5400 13852 19252 32 methanol KL 400 3913 4313 33 Acetonitrile Ton 400 3600 4000 34 Ethyl Acetate Ton 400 3600 4000 35 Ethyl Aceto Acetate Ton 0 4000 4000 36 Acetic Acid Ton 400 3600 4000 37 Hexane Ton 502 4102 4604 38 Butanol Ton 200 6692 6892 39 Toluene Ton 200 3800 4000 40 2 Chloro Pyridene Ton 1138 0 1138 41 Vitamin E Ton 0 642 642 42 Trimethyl Phenol Ton 267 0 267 43 Vanillin Ton 0 21 21 44 2 Ethyl Hexanol Ton 0 1874 1874 45 Iso Nonyl Alcohol Ton 0 1837 1837

46 Acetic Anhydride Ton 0 1583 1583

47 Prop ionic Anhydride Ton 0 1171 1171

48 50% Glyoxylic acid Ton 0 522 522

49 Silicon Dioxide Ton 0 570 570

Existing and Proposed major bulk liquid storages at site are as follow:

Sr. No Raw material Number of

tanks (existing)

Number of

tanks (proposed)

Liquid storage capacity

(existing)(KL)

Liquid storage capacity

(proposed)(KL)

1 SDS 3 3 300 600 2 Methanol 1 1 46 50 3 Acetic Anhydride 0 1 0 20 4 Hexane 3 0 36 20 5 2 Ethyl Hexanol 0 1 0 20 6 Iso Nonyl Alcohol 0 1 0 20 7 Propionic

Anhydride 0 1 0 20

8 Acetonitrile 0 1 0 20 9 Ethyl Acetate 0 1 0 20

10 Ethyl 0 1 0 20


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3.5 Resource Optimization:

Maharashtra Aldehyde and Chemicals limited are desirous to expand the manufacturing

facilities for the product indicated above. The resource optimization shall be carried out at the

site in order to reduce wastage and minimum transport needs.

3.6 Availability of Resources (Water, Energy/Power Requirement):

Power: Existing power requirement of the site is 370 KVA.

The proposed power requirement for the expansion is 770 KVA which will be source from

MSEDCL grid.

It is proposed to install 1 Nos of DG sets of 250 KVA capacity based on HSD as fuel as

emergency backup in case of power outage.

Water: The total water requirement for the expansion is about 319 cmd mainly for domestic,

process, Boiler/cooling purpose. It will be source from MIDC water works.

Fresh water requirement and waste water generation for proposed establishment shall be as

follows:

Fresh water intake

No. Description Existing as per CTO (cmd)

Proposed water input (cmd) for

expansion

Total (cmd)

1 Domestic 10.5 9 19.5

2 Industrial cooling/boilers

67 135

202

3. Processing whereby water gets polluted and pollutants are easily biodegradable

79 175 254

4. Gardening 0 0 0

Total 156.5 319 475.5

Acetoacetate 11 Acetic acid 0 1 0 20 12 Butanol 0 1 0 20 13 Toluene 0 1 0 20


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Waste water

No. Description Existing as per CTO

Proposed generation

(cmd)

Disposal

1. Trade effluent 67.5 190 281.5

2. Domestic effluent 8 7

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Total 75.5 197 296.5

Manpower: Expected additional manpower requirement for the expansion shall be as

follows:

Description Existing Proposed, No (approx.)

Total

Permanent 55 70 125 Contract 65 110 175

Total 120 180 300

Steam / Process heat Requirement:

Existing steam and thermic fluid heater details are as follows,

Sr. No. Equipment Capacity Status Fuel name & Quantity

1 Boiler 2 TPH Existing Coal & 7 TPD

2 Thermic Fluid Heater

4 lakh Kcal/hour Existing FO 1.2 KL/day (FO) & 2.8 TPD(coal)

3 DG 62 KVA Existing HSD & 0.5KL/day

For expansion requirement following utility boiler and TFH are proposed to be added,

Sr. No. Equipment Capacity Status Fuel name & Quantity

1 Boiler 6TPH New Coal , 30 TPD

2 Thermic Fluid Heater 8 lakh Kcal/hour New Coal , 5.6 TPD

3 DG 250 KVA New HSD , 1.5 KL/hour

3.7 Waste Generation and its treatment, disposal

I. Solid Waste

(a) Non Hazardous Solid Waste:

Sr No

Type of Waste Quantity UOM Mode of Disposal

Existing as per CTO

1 Coal Ash 0.7 MT /D Sale to Bricks manufacture

Additional Proposed for the expansion


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1 Coal Ash 2.8 MT /D Sale to Bricks manufacture

2 Metal scrap 200 Kg/ M Sale to Authorized party

3 Insulating waste 100 Kg/M Sale to Authorized party

4 Canteen waste 900 Kg/Y Composting

5 Rubber hand gloves, PVC shoes, tarpoline, paper waste

300 Kg/Y Recycle/sale after decontamination

6 Broken discarded glass 200 Kg/Y sale after decontamination

(b) Hazardous Waste:

The quantification of hazardous solid waste generated from present activity and proposed

activities is presented as follows:

Sr No

Type of Waste Category Quantity UOM Mode of Disposal

Existing as per CTO

1 Chemical sludge form waste water treatment

35.3 10 MT/M CHWTSDF

2 Residue And wastes

28.1 120 KL/M Sale to Authorized party

3 Spent Organic solvent


4 Process sludge / residue


Additional Proposed for the expansion 1 Chemical sludge

form waste water treatment

35.3 30 MT/M MWML, Taloja

2 Residue And wastes


3 Spent Organic solvent


4 Process sludge / residue


5 Discarded barrels/liners

33.3 2200 No’s/Y Sale to Authorized party

6 Discarded Asbestos

15.2 250 Kg/Y Sale to Authorized party

7 Spent oil(waste/used oil)

5.1 230 Kg/M Sale to Authorized party

8 Oil soaked gaskets and cotton waste

5.2 5 Kg/M Sale to Authorized party


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9 Filter &filter material

35.1 1 MT/Y MWML, Taloja

Note: additional proposed quantities are estimate, Quantity shall be worked out during EIA

stage.


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Chapter 4 Site Analysis

4.1 Connectivity:

This proposed expansion of Maharashtra Aldehydes and Chemicals limited shall be located at

Plot A-17, Mahad MIDC in Raigad district, Maharashtra. The Site is 7 km from Mahad.

The land and infrastructure is made available by MIDC and the raw material is easily available

through the easy transport via road connectivity.

4.2 Land form, Land use and Land ownership:

Land Form: Land is on plain contour, it is flat terrain.

Land Ownership: Land ownership is with project proponents (Maharashtra Aldehyde and

Chemicals limited)

4.3 Topography:

The district has three physiographic divisions i.e. (i) Coastal zone in west covers about 20% percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting of fertile

land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude and covered with forest. This hill range is characterized by ruggedness and uneven topography, with crestline of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three main rivers in northern part. Kundalika River is the main river in central part whereas in the southern part Savitri River is the main river.

The soils in the district are formed from the Deccan Trap which is predominating rock formation with small out crops of Laterite at a few places in the Poladpur taluka and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation.

4.4 Existing land use pattern:

Industrial use

4.5 Existing Infrastructure:

Infrastructure is provided by additional Mahad MIDC.

4.6 Soil Classification:


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SOILS:

The soils of the district are formed from the Deccan trap which is the predominating rock

formation of this district with small out-crops of laterite at a few places in the Poladpur

taluka and in the Matheran hills. Various types of these soils are marked out as per

topographical situation and location. They ' are generally grouped as

forest, varkas, rice, khar or salt, coastal alluvial and laterite soils.

Forest soils:

These soils are not used for agricultural purposes but yield valuable forest products such as

teak-wood, hirda (myrobalan), beheda, pepper, etc. However, these soils are heavily eroded

due to grazing and cutting of the forest trees.

Varkas soils:

These soils are located just below the forest soils all along the steeper slopes. They are

shallow in depth, which varies only between a foot and a foot and a half, heavily eroded and

sandy in texture and yellowish red to yellowish grey in colour with acidic reaction. They are

poor in organic matter and nitrogen and possess very little retentivity of moisture. They

yieldkharif millets but the production thereof could be increased with the addition of bulky

manures, lime and nitrogenous and phosphatic fertilisers.

Rice soils.

The district is the second largest producer of rice in the Maharashtra State. The region is

peculiarly terraced and, though the small strips in between the two terraces are levelled, it

is difficult to get even a few gunthas of land in one piece in a levelled condition. The depth

varies between two and six feet. They are loamy in texture, yellowish or reddish grey in

colour, neutral in reaction and almost devoid of lime. They are formed from the trap rock

from the Sahyadri ranges under heavy rainfall and humid climatic conditions. The linear

response of rice to the application of nitrogenous, phosphatic and potassic fertilisers is

observed in these soils. Addition of bulky manures in these soils is also found to be

advantageous from the point of view of yield. There are some patches of manat soils in

Mangaon taluka which are rich in clay and silt and which become stiff and hard when dry.


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Khar soils.

These soils are situated on the flat, levelled land near the sea at the point of creeks formed

due to the rivers. They are flat clay to clay loam in texture and reddish or yellowish grey in

colour. These soils contain hardly more than one per cent of soluble salts. These soils are

formed due to the deposition of salts by the sea or from lands reclaimed from the sea. Large

tracts of land are going out of cultivation due to the ingress of the sea and, in order to

reclaim these lands, the Government have formed the Khar Land Development Board which

has undertaken ambitious projects of the reclamation of khar lands.

Coastal alluvium soils.

These soils are found all along the coast and at places where there are no creeks. They are

deep soils developed on flat land and loamy in texture with reddish grey colour. They are

devoid of clay fraction or humus and are open in nature. The profile is difficult to

differentiate and is excessively drained. Calcium carbonate is found in abundance

throughout the profile but calcium has not entered the clay complex. The sub-soil water

level is only from ten to fifteen feet deep. The salt contents of the well water are higher in

the proximity of the sea; but due to excellent drainage, its use has not produced any

deleterious effects. The soils are almost neutral or slightly on the alkaline side of neutrality.

Good garden crops like coconut, areca-nut, plantain, etc., are grown in these soils, depending

upon the availability of water.

Laterite soils.

Out-crops of laterite rock are observed amongst the Sahyadri ranges amidst the trap rock

mainly at Matheran and in the Poladpur taluka. These soils mostly occur on the mountain

peaks. They are coarser in texture, wherever there are no forests. They are yellowish-red in

colour and shallow in depth and yield coarse millets and niger. The heavy rains in the

mountainous regions thoroughly leach the soils turning them acidic in reaction and devoid of

calcium carbonate. They are rich in sesquioxides, the ratio of silica to sesquioxides being less

than two. But they are generally poor in exchangeable bases or in fertility constituents.

However, the soils from the forest region are well-supplied with nitrogen and organic matter.


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4.7 Climate data from secondary sources:

Climate:

Mahad comes in Raigad district of Maharashtra. The climate of this district is typical of that on

the west coast of India, with plentiful and regular seasonable rainfall, oppressive weather in

the hot months and high humidities throughout the year. The summer season from March to

May is followed by the south-west monsoon season from June to September. October and

November form the post-monsoon or the retreating monsoon season. The period from

December to February is the cold season.

Rainfall:

The district has a network of eleven rain gauge stations with records extending to 82 years

for most of the stations. The south-west monsoon commences by about the first week of

June and the rains continue till about the beginning of October. The average annual rainfall

for the district as a whole is 3,028.9 mm. (119.25"). The rainfall increases rapidly from the

coast Howards the Western Ghats on the eastern border of the district. In the coastal strip

the annual rainfall decreases from south to north. Uran and Alibag at the northern end of the

coast get annually 2,072.3 mm. (81.58") and 2,080.8 mm. (81.92") of rain, respectively,

Matheran gets as much as 5,167.5 mm. (203.45") of rain annually. Nearly 95 per cent, of the

annual rainfall is received during the south-west monsoon months, and the rainfall in

October forms the major portion of the rest. July is the month with the heaviest rainfall, the

same being 38 per cent of the annual rainfall.

Temperature:

Being a coastal district the diurnal (daily) and seasonal variations of temperature are not

large. The period from March to May is one of increasing temperatures. May is the hottest

month with a mean daily maximum temperature at 31.7°C (89.1°F) and the mean daily

minimum temperature at 26.4°C (79.5°F). Fresh breezes from the sea relieve the oppressive

heat particularly in the coastal regions in the afternoons. The onset of the south-west

monsoon early in June brings down the temperatures slightly. After the withdrawal of the

south-west monsoon by the end of September the day temperatures increase slightly and

the weather in October and November is almost like the summer months. In the period from

December to February the weather is cooler than in the post-monsoon months.


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Humidity:

The air is humid throughout the year. Relative humidity is on an average over 80 per cent

during the south-west monsoon season. In the rest of the year the relative humidity is

between 65 per cent and 75 per cent.

Cloudiness:

During the south-west monsoon season skies are heavily clouded to overcast. In May and

October the clouding is moderate. Clear or very lightly clouded skies are common in the rest

of the year.

Winds:

Winds are very strong and blow from west or south-west during monsoon season. During

the period from October to December winds are generally moderate but sometimes strong

in October and blow from directions between north-east and south-east. In the three

months from January to March the winds continue to be moderate and are predominantly

from directions between north and east. In April while there is a slight strengthening of

wind, the direction is variable. In May there is a further strengthening of winds and the

directions are between south-west and north-west.

Special weather phenomena:

In association with cyclonic storms in the Arabian sea in the post-monsoon months and to a

lesser extent in May, the district experiences very strong winds, sometimes reaching gale

force, particularly very near the coast and also heavy widespread rain. Occasionally these

storms may cross the coast in the northern part of the district and cause heavy damage.

Thunderstorms occur in April and May and just before the onset of the monsoon and in the

late September to the middle of November.


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Chapter 5 Planning Brief

5.1 Planning Concept:

Plot is at well-established Mahad MIDC area

Purified Water supply from MIDC

Well-developed roads and connectivity.

Infrastructure facilities available established MIDC site

Integration with the existing plant of MACL manufacturing facility

5.2 Population Projection:

In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345

and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which

males were 1,117,628 and remaining 1,090,301 were females. Raigad District population

constituted 2.34 percent of total Maharashtra population.

In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population.

There was change of 19.31 percent in the population compared to population as per 2001. In

the previous census of India 2001, Raigad District recorded increase of 20.99 percent to its

population compared to 1991.

The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas. 5.3 Assessment of Infrastructure Demand (Physical and Social):

No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC

area.


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Chapter 6 Proposed Infrastructure

Since the establishment is planned at existing plant site in developed industrial area, no

special/specific development is anticipated. Company will have to do internal site

development only. Company has not planned any residential area at the proposed site as MIDC

has already existing Residential areas earmarked for housing colonies.

6.1 Industrial area:

Maharashtra Aldehydes and Chemicals Limited Plot no A – 17, MIDC Mahad proposes to

expand manufacture of synthetic organic chemicals based on demand and market projection.

6.2 Residential Area:

No Residential area has been proposed within the plant site.

6.3 Green Belt:

Green belt of adequate area within and around the project site shall be carried out as per

industries norms and requirement.

6.4 Social Infrastructure:

Local people will be given preference wherever found suitable for all the jobs in the plant,

direct as well as indirect. Thus the project shall have a positive impact on the employment

pattern of the region. Economic status of the local population will improve due to

increased ancillary/business opportunities, thereby making positive impact. Educational,

medical & housing facilities will improve due to the proposed project.

6.5 Connectivity:

This proposed expansion project facility shall be located at Mahad MIDC area, in Raigad

district, Maharashtra. The Site is 7 km from Mahad town and 17 km from nearest railway

Station. The land and infrastructure is made available by MIDC and the raw material is easily

available through the easy transport via road connectivity.

6.6 Water Management:


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The total water requirement is about 481.5cmd for Domestic, boiler/cooling, and process.

The source of water shall be from MIDC. The water supply will be through the good offices of

MIDC. We will not be encroaching on anybody’s water source.

6.7 Sewage and waste water treatment system:

Existing Effluent treatment scheme:

The treatment of effluent arising from plant is achieved through multiple stages as follows,

A. Primary treatment

B. Secondary Treatment

C. Tertiary Treatment

Total 91.5 m3/day effluent will undergo three stages of treatment involving following steps.

A. Primary Treatment:-

This step includes neutralization and physical separation incorporating the following:

Neutralization Tank

Equalization Tank

Chemical dosing system(Lime/Alum)

Primary Clarifier

The effluent will collected in neutralization tank. Provision is made for alkali dosing as

required for neutralization. Uniform mixing will be achieved by providing aeration grid (air

sparing) in the tank. After completion of neutralization, the effluent will be pumped to

equalization tank. Effluent from equalization tank feed to primary clarifier tank for solid liquid

separation in primary treatment. Overflow from primary clarifier will be gravitate to

Evaporation Pond & then it pumped to Aeration tank for further Biological treatment.

B.Secondary Treatment:

Secondary treatment includes single stage degradation of effluent.

Aeration Tank

Secondary Clarifier

Sludge dewatering system

The effluent will be uniformly gravity to Aeration tank to biologically degrade the organic

matter. The Oxygen required for the biological growth was supplied through Surface Aerator

System. The overflow from Aeration tank will gravities to Secondary Clarifier. The settled

sludge will be pumped back to the Aeration Tank to maintain the bacterial concentration in the

tank. The excess sludge in the system will be sent to Sludge Drying Beds for sludge dewatering.

The dried sludge will be sent to Hazardous Waste Facility.

Overflow from Secondary Clarifier will be send to tertiary treatment.


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C .Tertiary Treatment.

The treated effluent of 91.5 m3 after primary and secondary treatment will undergo tertiary

treatment.

Overflow from Secondary Clarifier will be collected to intermediate tank and effluent will be

pumped to Sand Filter and Activated Carbon Filter.

After Tertiary Treatment effluent collected in HDPE tank and from this tank 24 m3 effluents

recycle to cooling tower makeup remaining send to CETP through flow meter to Lock & Key

tank, as per MPCB guideline and then effluent disposed off to MIDC common drainage system

for further treatment to CETP.

Expected Effluent Characteristics

Sr. No. Parameter Before Treatment After Treatment 1 pH 2-4 6.5-9 2 BOD 2750 mg/L Less than 100 mg/L 3 COD 4950 mg/L Less than 250 mg/L 4 TDS 3400 mg/L Less than 2100 mg/L 5 SS 250 mg/L Less than 100 mg/L 6 Oil & Grease 8 mg/L BDL i.e. less than

10mg/L 7 Sulphate 2450 mg/L Less than 1000 mg/L 8 Total Ammonical nitrogen 31 mg / l Less than 50 mg /l

9 Chlorides 885 mg/l Less than 600 mg/l


25

Chapter 7 Rehabilitation and Resettlement (R & R Plan)

The proposed expansion facility shall be at plot of the company which is located in Mahad

MIDC area. It does not require acquisition of Land and the Infrastructure so there is no any

kind of activity of Rehabilitation and Resettlement carried out.


26

Chapter 8 Project schedule and cost estimates

8.1 Time schedule of the Project

It is expected that the project shall be completed within 18 months from date of grant of

Environmental clearance.

8.2 Estimated project cost (Economic Viability of the Project)

Total estimated project cost is Approx. 50 Crores


27

Chapter 9 Analysis of Proposal

9.1 Financial and Social Benefits

With an increased capacity, we shall be creating new jobs thereby empowering the local

population with additional spending power. As industries grow in a hub, the social structure of

the area improves with additional facilities such as schools, technical training centers,

hospitals, etc being made available in the smaller towns. This has a long term impact on the

financial & social improvement thereby reducing the migration of population to urban centers

in search of livelihood & better living conditions.


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Annexure I

Land allotment letter


29

Annexure II

Site & surrounding study area of 1 km


30

Site & surrounding study area of 10 km


31

Annexure III

Proposed Layout Plan


32

Area statement

Details of Existing built up area

Structure no in Layout

Structure name Existing Area in sq.meter

1 Main Plant Building 922.5

1A Column Area 196.2

1b DEP extended area 123

1C Dryer room 58.55

1D DEP extended area 80

2 Raw material Store 451.9

3 Explosive tank farm 316.8

4 Effluent Treatment plant 480.7

5 Monoester Plant 123

5A Monoester Plant expansion 188.7

6 Meter room 11.9

6A PCC room 42

7 Transformer yard 50

8 Admin building &QC lab 71

9 400TR cooling tower 18.33

9A 40TR cooling tower 4

9B 75 TR cooling tower 6

9c 120TR cooling tower 8

10 Water storage tank 75.7

10A Process Water storage tank 37

11 Utility Building 116.7

11A Extended utility building 188.7

12 PAN store area 91.6

13 Acid storage tank farm 187.01

14 collection sump 3.7

17 ETP Tank 65.9

18 DEP finish product tank farm 129.2

21 DEP process storage tank farm 313.52

22 finish product Packing shed 165

24 Security cabin 39.9

25 old security cabin 10.63

26 Alcohol storage tank farm 64

25 old security cabin 10.63

26 Alcohol storage tank farm 64

27 Condensed collection tank 4

27A Condensed collection tank 4

28 Boiler 160


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Pipe rack 400.49

Total Existing Built-up area 5209.63

Total Permissible Area in (Sq.Meter) 20,000

1 Total Existing built up area(Sq.Meter) 5209.63

2 Total proposed built up area(Sq.m) 2500

Parking area (Sq.meter)

1 Near Main security gate 55

2 Near store Loading unloading area 110

3 Near Old security cabin 70

4 Near Alcohol unloading point 56

5 Near ETP area 70

6 Near PAN store area 105

Total Parking area (Sq.meter) 466

maharashtra aldehydes & chemicals ltd. plot no: a-17,...

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