project feasibility report - welcome to...

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PRE FEASIBILITY REPORT FOR PROPOSED

EXPANSION OF RESINS, PHARMACEUTICAL

INTERMEDIATES, PERFUMERY PRODUCTS AND

SPECIALTY CHEMICALS IN EXISTING UNIT

of

M/s. Vapi Products Industries Pvt. Ltd.

Plot No. 789/3A & 791/4 & 5,

Phase-III, G.I.D.C., Vapi-396 195,

Di: Valsad, State: Gujarat

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CONTENTS

Sr. No. Description Page No.

1. Executive Summary 3

2. Introduction of the Project/Background information 7

3. Project Description 9

4. Site Analysis 15

5. Planning Brief 18

6. Proposed Infrastructure 19

7. Rehabilitation and resettlement (R & R) Plan 22

8. Project Schedule & Cost Estimates 22

9. Analysis of Proposal (Final Recommendations) 23

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1.0 EXECUTIVE SUMMARY

1.1 Company Profile

M/s. Vapi Products industries Pvt. Ltd. was established in 1988 by Mr. Hemant Shah, a

young man belongs to rural farmer family. Today, Vapi Products is key player in polymer

intermediates and Styrene Acrylic resin and emulsions. M/s. Vapi Products industries Pvt.

Ltd. has unique processes and facilities and long term relationships with companies such as

G.E. Plastics, SABIC, Ciba, BASF, Vertellus, etc. The company is engaged in the commercial

production of Styrene Acrylic Resin (Synthetic Monomer) and Emulsion Polymers, used in

Printing Ink, Coating & Adhesives Industries, at its manufacturing facility located at Plot No.

789/3A & 791-4&5, GIDC, Vapi, Gujarat.

The Company is engaged in manufacturing of (1) Styrene Acrylic Resins (Synthetic

Monomer) & (2) Emulsion Polymers. The company has obtained consolidated consents &

Authorization (CC&A) No. AWH 65392 Valid up to 10/07/2019 for manufacturing of above

said products.

1.2 Project Details

Sr. No. Name of Product

Existing

Capacity

(MT/Month)

Additional

Capacity

(MT/Month)

Total after

Proposed

Expansion

(MT/Month)

1.0 Acrylic Polymers 50 200 250

2.0 Emulsion Polymers 100 900 1000

3.0 4- Nitro N- Methyl PhthaIimide 00 250 250

4.0 3- Amino 4- Methoxy Acetanilide 00 100 100

5.0 Specialty Chemicals

5.1 2-Aminobenzene Dimethyl -1,4-Dicarboxylate / 2-

Amino Di Methyl Terephthalate

00

500

500

5.2 2,4 DCNB Nitrated Ether / OPNA (NITRATED

AROMATIC ETHER)

5.3 N-Hydroxy Methyl Benzamide

5.4 N- Hydroxymethyl Chloro Acetamide 90 % / N-

Hydroxy methyl Chloro Acetamide

5.5 Di Phenyl Sulphone

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5.6 4-4” Di Hydroxy Di Phenyl Sulfone

6.0 Pharma Intermediates

6.1 Ethyl 2-Chloro-2 -(4-Methoxy

PhenylHydrazinylidene) Ethanoate

00 500 500

6.2 5 - (4-Bromophenyl)-4,6-Di hydroxyl pyrimidine

/(BDP)

6.3 3-Acetamidophthalic Anhydride (APA)

6.4 6 - Chloro 1,3 Di hydro- 2H – Indole-2- One

6.5 Dibenzo [b.f][1,4]thiazepin-11(10H)-one ( DTO)

6.6 2,4 Dimethyl Benzene Thiol

7.0 Perfumery Products

7.1 Phenyl Ethyl Alcohol 00 300 300

7.2 Phenyl Ethyl Methyl Ether

Total 150 2750 2900

List of By-Products

Sr.

No. Name of Products

Existing Capacity

(MT/Month)

Additional Capacity

(MT/Month)

Total after Proposed

Expansion (MT/Month)

1.0 Sulphuric Acid (By-Product) -- 2248 2248

2.0 Aluminum Chloride -- 1125 1125

3.0 Phosphoric Acid -- 680 680

4.0 Acetic Acid -- 60 60

5.0 Sodium Thiosulphate -- 365 365

6.0 Sodium Sulfite -- 15 15

7.0 Aluminium Chloride (28%) -- 1642 1642

1.3 Green Belt Development

M/s. Vapi Products industries Pvt. Ltd. has develop an effective green belt within the

factory and on periphery of the factory. In addition to this, majority of the vacant land is

planted with trees, shrubs and grasses.

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1.4 Power & Fuel Requirement

Power requirement:

Existing: 80 KVA from DGVCL

After Proposed Expansion: 500 KVA

1 DG Set – 250 KVA (In case of Emergency)

Fuel requirement:

Existing: Natural gas @ 150 SCM/day

After Proposed Expansion: Natural gas @ 4750 SCM/day

Diesel @ 83 lit/hr.

1.5 Water Requirement and Wastewater Generation & Treatment

• After Proposed Expansion, fresh water requirement will be met through GIDC, Vapi.

Total water requirement after proposed expansion will 261 m3/day. Total wastewater

generation after proposed expansion will be 127.1 m3/day. The Low COD -effluent (67.1

m3/day) shall be treated in proposed effluent treatment plant consisting of primary

treatment and secondary treatment & send it to CETP for treatment and disposal.

• The High COD & High TDS-effluent (60.0 m3/day) shall be treated in proposed effluent

treatment plant consisting of primary treatment and evaporator & send it to CETP for

treatment and disposal.

• Domestic Effluent (12.0 m3/day) is disposed through septic tank & soak pit.

1.6 Air Pollution Source and Control Management

In existing operations, the company has one steam boiler of 800 kg/hr. For the proposed

expansion project existing steam boiler will be replaced by installing new boiler of 3000

kg/hr. and also one thermic fluid heater of 2 lakh kcal/hr. and one D.G. Set of 250 KVA

(Stand-by) will be installed.

Natural Gas is/will be used as fuel in existing as well as proposed utilities. Diesel will be used

as fuel in D.G.Set.

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1.7 Hazardous Waste Management

Hazardous wastes generated are in the form of ETP sludge, spent solvent, iron sludge,

organic residue, process waste, inorganic salts, spent carbon and discarded containers.

Company has provided adequate storage area for proper storage of wastes.

Type of waste &

Category

Source Existing Additional

Total Disposal Method

ETP Sludge

(Cat. 34.3)

ETP -- 30

MT/Month

30

MT/Month

Collection. Storage,

Transportation and

dispose to TSDF

Spent solvent

(Cat. 20.2)

Process 0.0

MT/Month

110.5

MT/Month

110.5

MT/Month

Collection, Storage,

& Reprocess/Reuse

back in process.

Discarded Drums

/Containers

(Cat. 33.3)

Process 16

Nos/Month

464

Nos/Month

480

Nos/Month


Transportation,

Disposal by selling to

registered recycler

Iron Sludge Process -- 1227

MT/Month

1227

MT/Month


Transportation and

dispose to TSDF or

send to cement

industries

Organic Residue Distillation -- 100

MT/Month

100

MT/Month


Transportation and

dispose to common

incineration Site or co-

processing in cement

industries

Inorganic Salt Process -- 3000

MT/Month

3000

MT/Month


Transportation and

dispose to TSDF

Spent HCl Process -- 272

MT/Month

272

MT/Month


Transportation and sell

to end user

Sulphuric Acid Process -- 2248

MT/Month

2248

MT/Month


Transportation and sell

to end user

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Process Sludge Process -- 180

MT/Month

180

MT/Month


Transportation and

dispose to common



industries

Spent Carbon Process -- 12

MT/Month

12

MT/Month


Transportation and

dispose to common



industries

INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project and project proponent. In case of mining project, a copy

of mining lease/letter of intent should be given.

Identification of the project

Proposed expansion of Resins, Specialty Chemicals, Pharma Intermediates and Perfumery

products is in Existing Unit.

Identification of the project proponent

The company is managed by Directors. Name of the directors are given below:

The company is a small scale manufacturing unit and directors of the company are well

educated and professionally qualified; they take every step to ensure that all safety

measure to Plant and Environment are fully complied with.

Mr. Hemant M. Shah (Director)

Mr. Hemant M. Shah has done his B.Com. from south Gujarat University, he has around 25

years of experience in the Chemicals industry. He has an exclusive distributorship of GACL,

India’s leading Chemicals Company working for more than 25 years. He mainly looks after

Technical and Marketing aspects in the company.

Addresses of Directors

Sr. No. Name of Directors Addresses

1. Mr. Hemant M. Shah Ajit Nagar, Vapi-Daman Road, Chala, Vapi-396191,

Gujarat. 2. Mrs. Parul H. Shah

Ajit Nagar, Vapi-Daman Road, Chala, Vapi-396191,

Gujarat.

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3. Mr. Siddharth H. Shah Ajit Nagar, Vapi-Daman Road, Chala, Vapi-396191,

Gujarat.

2.2 Brief description of nature of the Project

The proposed expansion project involves the production of Resins which falls under item no

5(f) i.e. synthetic organic chemicals as per the EIA notification, Sept. 14, 2006 (as amended

time to time), Since The project is located in Vapi, GIDC and due to located within 5 km

distance of interstate-UT boundary, it is to be treated as Category 'A', and needs to obtain

the prior Environmental Clearance from MoEFCC, New Delhi.

2.3 Need for the project and its importance to the country and or region

The products are widely used in Printing Inks, Coatings & Adhesives Industries. 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 against its demand, to overcome this

shortage & to bridge demand-supply gap, the company proposed to have this expansion.

2.4 Demand-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 will be an addition to the current range of our products.

2.5 Imports vs. Indigenous production

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 Export possibility

As per market survey by the company, these proposed products are having a domestic as

well as export market due to its application in various types of Printing Inks, Coatings &

Adhesives Industries.

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2.7 Domestic/Export Markets

According to our principal customer, there is very good possibility of export of the products.

2.8 Employment Generation (Direct and Indirect) due to project.

Employment would be as per prevailing norms of state government for skilled and unskilled

people (25 Nos.) for the proposed expansion project.

3.0 Project Description

3.1 Type of Project including interlinked and interdependent projects, if any.

Proposed expansion of Resins, Specialty Chemicals, Pharma intermediates & Perfumery

products is in Existing Unit. Category: 'A'-5(f).

3.2 Location (map showing general location, specific location and project boundary &

project site layout) with coordinates.

Map showing general location

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Project Site:

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Plant Layout

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3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Major factors involved in the selection of site are listed below:

• Site is very well connected by road

• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation

• Availability of power evacuation facilities

• Availability of abundant water for industrial use

Modern infrastructure support and amenities at par with industrial estates in other global

markets, including:

� Efficient transport facilities within the industrial estate.

� Environment-friendly zone.

� Uninterrupted power supply.

3.4 Size or Magnitude of Operation

Please refer section 1.2 of PFR.

3.5 Project Description with process details (a schematic diagram/flow chart showing the

project layout, components of the project etc. should be given)

Please refer Annexure-III in Form-I.

3.6 Raw material required along with estimated quantity, likely source, marketing area of

final products. Mode of transport of raw materials and finished products.

Please refer Annexure-II in Form-I.

3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be

briefly outlined.

There will not resource optimization/recycling and reuse envisaged in the proposed

expansion project.

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3.8 Availability of water its source, energy/power requirement and source should be

given.

Water Source

After proposed expansion, quantity of water consumption will be 261 KL/Day. The entire

water requirement will be met through GIDC Water Supply.

Power & Fuel Requirement

Power requirement:

Existing: 80 KVA from DGVCL

After Proposed Expansion: 500 KVA


Fuel requirement:



Diesel @ 83 lit/hr.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/disposal.

• After Proposed Expansion, fresh water requirement will be met through GIDC, Vapi.

Total water requirement after proposed expansion will 261 m3/day. Total wastewater

generation after proposed expansion will be 127.1 m3/day. The Low COD -effluent (67.1

m3/day) shall be treated in proposed effluent treatment plant consisting of primary

treatment and secondary treatment & send it to CETP for treatment and disposal.

• The High COD & High TDS-effluent (60.0 m3/day) shall be treated in proposed effluent

treatment plant consisting of primary treatment and evaporator & sent to CETP for

treatment and disposal.

• Domestic Effluent (12.0 m3/day) is disposed through septic tank & soak pit.

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3.10 Schematic representations of the feasibility drawing which give information of EIA

purpose.

RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT

MARKET ASSESSMENT

FINANCIAL REPORT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS

& BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH

LOCALS

BASELINE

ENVIRONMENTAL

STATUS

ENVIRONMENTAL INFORMATION CENTRE

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT.

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS DEPT.

INDIAN METEOROLOGICAL DEPT.

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED

EXPANSION PLANT

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES

ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT,

GREEN BELT DEVELOPMENT MONITORING PROGRAM

RISK ANALYSIS

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

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4.0 Site Analysis

4.1 Connectivity




4.2 Land Form, Land Use and Land Ownership

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4.3 Topography (along with map)

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4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from

HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette

notification should be given.

CRZ Clearance is not applicable to our industry.

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4.5 Existing Infrastructure


Site is very well connected by road

Proximity to Raw Material suppliers

Availability of sufficient land free form cultivation

Availability of power evacuation facilities

4.6 Soil Classification

It will be incorporated in EIA Studies.

4.7 Climatic data from secondary sources.

Primary source: our own weather station & Secondary Source: Indian Meteorological

Department.

4.8 Social infrastructure available.

Depending on the growth of the company the required social infrastructure will be

provided.

5.0 Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

planning/Development authority classification.

Type of Industry: Proposed expansion of Resins, Specialty Chemicals, Pharma intermediates

& Perfumery products in Existing Unit.

5.2 Population Projection


5.3 Land use planning (breakup along with green belt etc.)

Total Plot Area : 9757 m2

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S. No. Description Area (m2)

1. Proposed process plant 2439.63

2. R.M. Store 274.60

3. Existing Process Plant 136.57

4. Utility shed 87.55

5. Store room 17.33

6. Watchman cabin 9.00

7. Greenbelt area 1924.00

8. Open/road area 4868.32

Total plot area 9757.00

5.4 Assessment of Infrastructure Demand (Physical & Social)

• Employment would be as per prevailing norms of state government for skilled and

unskilled people for the proposed expansion project.

• Social Welfare

• Cordial relation with the industry shall be established and representation shall be made

to villagers for help for creation of facilities related to health, education, etc.

5.5 Amenities/Facilities


6.0 Proposed Infrastructure

6.1 Industrial Area (Processing Area)

Processing Area (Processing Zone, ETP Area and Utility Area): 2600 m2

6.2 Residential Area (Non Processing Area)

Non Processing Area (Green belt, Raw material storage area, finished storage area and open

area): 7157 m2

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6.3 Green Belt

M/s. Vapi Products Industries Pvt. Ltd. has developed an effective green belt within the

factory and on periphery of the factory. In addition to this, majority of the vacant land is

planted with trees, shrubs and grasses.

6.4 Social Infrastructure

Depending on the growth of the company the required social infrastructure will be

provided.

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



• Proximity to Raw Material suppliers

• Availability of sufficient land free from cultivation



6.6 Drinking water Management (Source & Supply of water)

Water requirement will meet through GIDC Water Supply.

6.7 Sewerage System

Sewage pipes are laid in entire company for the removal and disposal of mainly non-

harmful liquid wastes from the offices, canteen and domestic waste coming from different

sections. These liquid wastes are treated and disposed of by septic tank & soak pit.

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6.8 Solid Waste Management

Details of Hazardous Waste Generation & Disposal

Please refer Topic No. 1.7 on Page no. 6.

6.9 Power Requirement & Supply/Source

Power requirement:

Existing: 80 KVA

After Proposed Expansion: 500 KVA from DGVCL


Fuel requirement:



Diesel @ 83 lit/hr.

7.0 Rehabilitation and Resettlement (R & R) Plan

7.1 Policy to be adopted (central/state) in respect of the project affected including home

oustees, land ouatees and landless laborers (a brief outline to be given)

There is no habitation on the proposed expansion project area and it is within existing

industry, so that R & R policy is not applicable to this project.

There shall be no displacement of any population in the project area. Any major activity that

may lead to resettlement of the people is considered as permanent impact. Hence, there is

no permanent impact on this account. The increasing industrial activity will boost the

commercial and economical status of the locality up to some extent.

8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for

the project to be given).

We hereby state that the existing plant is operating as per present CC&A and will seek

revised CC&A only after obtaining the environmental clearance & CTE as per this

application.

Project can be implemented in 8 months after obtaining EC & CTE.

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8.2 Estimated Project cost along with analysis in terms of economic viability of the

project.

Total costs of the project will Rs. 7.00 Crore (Proposed Expansion). Capital cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 1.5 Crore

(Proposed Expansion).

9. Analysis of Proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to be local people

including tribal population, if any, in the area.

• Employment would be as per prevailing norms of state government for skilled and

unskilled people for the proposed project.

• Social Welfare shall be done.

• Cordial relation with the industry shall be established and representation shall be made

to villagers for help for creation of facilities related to health, education, etc.

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