PRE-FEASIBILITY REPORT
For Proposed Expansion Project
MANUFACTURING OF SPECIALTY CHEMICAL & INTERMEDIATES
By
M/s. ODYSSEY ORGANICS PVT. LTD. Plot No, B-36, 37, 39, Birwadi M.I.D.C., Taluka: Mahad, District: Raigad, Maharashtra, India
Conducted & Prepared By
GREEN CIRCLE, INC.
Integrated HSEQR Consulting Engineers, Scientists & Trainers (MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, NABL/17025:2005, OHSAS: 18001 Certified Organization & GPCB approved Environment Auditor – Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 24.01.2013
Corp. Office & Environmental Research Laboratory: Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India Tel: 0265-2371269.
Mumbai office Flat No 6 ,Ground Floor,Shakuntala Niwas, M G Road,Borivali (E),Mumbai- 400066 Tel : 022-28943090 /60 www.greencircleinc.com E: [email protected]
ALSO AT
BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA
OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
TABLE OF CONTENTS
Sl. No. Particulars Page No.
1 Introduction 1
2 Benefits of Project 3
3 Project Location 3
4 Cost of Project 5
5 Proposed Product Details 6
6 Raw Material Requirement 8
7 Process Details 14
8 Utility and Requirements 14
9 Stack Details & Fuel Requirement 19
10 Hazardous Waste Generation and Management 20
11 Land Requirement Details 21
12 Green Belt Development 24
13 Storm Water-Collection and Disposal 24
14 Conclusion 24
LIST OF TABLES
Table. Particulars Page No. No.
1 Environment setting of the proposed project 4
2 Proposed Cost 6 3 Name of Product with its Quantity 6
4 Details of Raw Material for Nitro Amino Phenol Group 8 Details of Raw Material Requirement for Bulk Drug & 5 10 Intermediates Details of Water Requirement & Waste Water 6 14 Generation
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
7 Details of Power Consumption 18
8 Employment Details 19
9 Details of Flue gas Stack 19 10 Hazardous Waste Management 20
11 Non Hazardous Solid Waste Generation 20
12 Details of Land use Break-up 21
LIST OF FIGURES
Fig. No. Particulars Page No.
1 Google image of propose site 5
2 Water Balance Diagram 15 3 Flow Diagram of Existing ETP 16 4 Flow Diagram of Existing MEE 18
5 Lay-out Plan of Plot no. 36 & 37 22
6 Lay-out Plan of Plot no. 39 23
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
1. INTRODUCTION M/s. Odyssey Organics Pvt Ltd is situated at Birwadi M.I.D.C. area of Raigad district in Maharashtra State. M/s Odyssey Organics Pvt Limited is engaged in the manufacturing of Specialty Chemicals and also expansions as well as new projects to manufacture the Organic Chemicals which include – “Dyes Intermediates” (Nitro Amino Phenol groups), Bulk Drug & Bulk Drug Intermediates.
Odyssey Organics Pvt. Ltd is established in 2006. Basically it is a sister concern – “Apte Organics Pvt. Ltd” – situated at Mahad industrial area –since 1989. The company was founded by a sound technocrat – Mr. D. V. Apte (M.Sc. By Research).
The company has almost 13 years versatile experience in the field of Organic Chemical Manufacturing. Odyssey Organics Pvt Ltd having a sound technical knowledge & hence he provide excellent quality in the market with innovative production process. Innovative changes in the process, company always get success to overcome from the process challenge like – Low Yields, Inferior Product Quality, High Raw Material Costs, & Effluent treatment.
Due to above all, Odyssey Organics Pvt. Ltd has produced the products in competitive cost with effective reduction in energy, water, raw materials & other resources. They operate in a responsible manner and comply with all environmental, health and safety standards. Hence company faces minimal obligations from Government departments as well as International bodies. This is one of greatest advantageous over our competitors. Due to it he gives a consistent & continuous supply to customers.
As chemical companies around the world reach out to enhance their strength & competitiveness. In past 13 years since 2000, Odyssey Organics Pvt. Ltd has entered in existing product field then he has given tough competition to Chinese origin material. Before 2000 all materials were imported from China. Company slowly raises our market share and from 6 years the situation is – the Indian Industry is no more importing the products from China. Also company has taken a major share of China from global customers. For the same Odyssey Organics Pvt. Ltd won the “National Awards” from central govt. H.R. Ministry. The company upcoming project also includes the same type of products. Which at present are only manufactured from China. Our Indian consumers are totally dependent on China. This results in to increase in Import.
Pre-Feasibility Report 1
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
1.1. COMPANY PROFILE Odyssey Organics Pvt. Ltd is established in 2006. Basically it is a sister concern – “Apte Organics Pvt. Ltd” – situated at Mahad industrial area –since 1989. The company was founded by a sound technocrat – Mr. D. V. Apte (M.Sc. By Research). M/s Odyssey Organics Pvt Limited is engaged in the manufacturing of Specialty Chemicals. The present product is Picric acid, Sodium Picramate and Picramic Acid. Previously these products were only manufactured in China. The company has pioneer of the above products in India & supplying the quality material in Indian & global dyestuff industry. Our Indian market is mainly located at Gujarat, Rajasthan, while company exports to Japan, Bangladesh, Germany, U.K, Russia & U.S.A.
1.2. COMPANY MISSION & VISION. Vision Statement “We must always look for versatile molecules & should manufacture them with a Quality & Quantity.” In an upcoming future the ‘Odyssey –Group’ must be one of the genuine & reputed group in the Chemical Industry with the diverse specialties. We are working not only for our own growth counts in “Money” – but we are working for “Esteem” & “Satisfaction”. Along with our own growth we aim to contribute & strengthen the Indian Chemical Industry by Manufacturing the Products, for which our industry depends on other nations. “ODYSSEY”- MUST BE ONE OF THE IPORTANT FACTOR FOR INDIAN CHEMICAL INDUSTRY BY ITS PRODUCT RANGE.” Mission The excellent team building, Innovative technologies, & transparent Working systems are our Strengths. Follow the International standard Systems & Quality Management Systems and also bound for the Continuous Improvements & Quality Management through the same. Safe Working, Zero Accidents & Green Environment are our mottos. Complete customer satisfaction & Quality service is our trade mark in the market.”
1.3. MARKET ANALYSIS The project is design with the optimum market study & data collection. The project is based to target mainly the Indian consumers.
Pre-Feasibility Report 2
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
The consumers will be the – reputed chemical industries in India as well as some from Global MNC. For the project of – Average share of each product varies from min. 20 MT to Max 60 MT / month. While the total annual turnover expected from this Project in total is up to 250 Cr.
1.4. EXPORT POSSIBILITY Most of the bulk export through by Sea from J.N.P.T. Port Bombay.
2. BENEFITS OF PROJECT I. Reduce Import: It ultimately aiming to enter in to Chinese dominating products - it will directly reduce the Import of Chinese origin product (Total amount is approximate 220 Cr/ year). II. Increase Export: As part of our produced material will get consume globally it will increase the Export. (Approximate amount will be 45 Cr). III. Local Economy Rolling: The main raw material required for the above projects will be purchased locally from Indian Manufacturers. Also the major consumer base will be in India. Ultimately it contributes in the local rolling of the economy & local business. IV. Job Generation: The Project will create direct & indirect employment opportunities within the surrounding region. The Unit will use good faith efforts to employ local people from the nearby villages depending upon the availability of skilled & un- skilled man-power surrounding the project site. In operation phase, the proposed project would require significant workforce of non-technical and technical persons. Migration of highly education and skilled experience will result in increase of literacy in the surrounding villages.
3. PROJECT LOCATION The Plant is located at plot no. B-36, 37, 39, Birwadi MIDC, Taluka- Mahad, Dist. Raigad, State-Maharashtra. The Total Plot area of the site is 25,000 sq m. The environmental setting around the site is given in Table-1 and the Google image of project site is shown as Figure 1.
Pre-Feasibility Report 3
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Table 1: Environment setting of the proposed project
Sl. Particulars Details No. 1 Latitude 18° 06.147’N 2 Longitude 73°29.369’E 3 Elevation above MSL 60.0 m above Mean Sea Level 4 Present land use at the location Existing Plant 5 Nearest Village Birwadi (3.0 km) 6 Nearest Town/City Town: Mahad (10.0 km) 7 Nearest Railway Station Veer Railway Station (19 km) 8 Nearest Hospital M.M.A Hospital M.I.D.C (3.0 km) 9 Nearest Highway NH 17 (4.0 km) 10 Nearest Airport Mumbai Airport (190.0 km) 11 Nearest Water Body Kal River (1.0 km) Ecologically sensitive zones within No Eco sensitive Zone present within 10 12 10-km distance km of radius. 13 Historical/ Archaeological places Raigad Fort (16 km), Chavdar Tale (8 km) 14 National Parks/Wild Life Sanctuary NA 15 List of Major Industries (within 10 km) Sandoz, Privi, Sudarshan, Vinati, 16 Seismic Zone Zone – III
Pre-Feasibility Report 4
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Specific location and Project Boundary (10 km)
Figure 1 : Google image of Specific location and Project boundary
4. COST OF PROJECT Estimated Cost of proposed expansion as on date is approx 215.0 crores. Company has planned to expend 43 crores in Effluent Treatment System include in total proposed estimated cost. The detailed project cost proposed is as given in Table 2.
Pre-Feasibility Report 5
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Table 2. Proposed Cost
S.No. Description Amount in Crore (INR) Expansion of Current Products 30 1
Starting of 3 New Molecules 80 2
Starting of 2 – Dyes Intermediates 25 3
80 4 Starting of Bulk Intermediate
Total 215
5. PROPOSED PRODUCT DETAILS At present the production capacities of M/s Odyssey Organics Pvt. Ltd. is 34.0 MT/Month and propose to expand manufacturing capacity by 1651.0 MT/Month. The detail products capacity is given in Table-3.
Table 3 : Name of Product with its Qty.
Quantity, MT/Month Sr. No Product Name Existing Proposed Total A Dyes Intermediate – Nitro Amino Phenol Group 1 2,4-Dinitrochlorobenzene Nil 220 220 9.8 (Intermediate 2 2,4-Dinitrophenol for In-house 106.2 116 Consumption) 12.0 (Intermediate for 3 Picric Acid 128 140 In-house Consumption) 4 Sodium Picramate 10.0 75 85 5 Picramic Acid 5.0 13.0 18 6 4 - Nap Nil 50 50 7 Dinitro – Sec. Butyl Phenol Nil 100 100 8 N-Amino Dinitro Benzene Nil 30 30 9 4-Nitro-Ortho Xylene Nil 80 80 10 2-Nitro-4-Chloro Sulfonic Nil 29 29
Pre-Feasibility Report 6
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Quantity, MT/Month Sr. No Product Name Existing Proposed Total Chlorobenzene 2-Nitro-4-Chloro Sulfonamide 11 Nil 23 23 Chlorobenzene 2-Amino-4-Chlorosulfonamide 12 Nil 17.0 17 Phenol 13 Monochlorobenzene Nil 150 150 B Bulk Drugs & Intermediates 1 2-Methoxy Naphthalene Nil 80 80 2-Acetyl-6-Methoxy 2 Nil 86 86 Naphthalene 3 3-Nitro Acetophenone Nil 32 32 4 3-Amino Acetophenone Nil 26 26 5 3-Hydroxy Acetophenone Nil 20 20 6 3-Acetoxy Acetophenone Nil 10 10 7 4-Amino-Salicyclic Acid Nil 44 44 8 Sodium Pas Nil 40 40 3-Amino Pyrazole 4- 9 Nil 36 36 Carboxamide Hemisulphate 10 Allopurinol Nil 10 10 11 C.P.A. Derivative Of Q Acid Nil 174 174 12 Ciprofloxacin –Q Acid Nil 126 126 13 Ciprofloxacin Base Nil 30 30 14 Ciprofloxacin Hydrochloride Nil 29 29 C By-Products 1 80% Spent Sulfuric Acid 10 1820 1830 Water White 30% Spent Sulfuric 2 100 100 200 Acid 3 Dil Acetic Acid Nil 65 65 4 30% Hydrochloric Acid Nil 166 166 5 Ethanol Nil 36 36 6 Copper Oxide Nil 40 40 7 Ammonium Sulfate Nil 80 80 8 Sodium Methyl Sulfate Nil 87 87 9 2-Nitro Acetophenone Nil 22 22 10 Sodium Acetate Nil 6 6
Pre-Feasibility Report 7
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Quantity, MT/Month Sr. No Product Name Existing Proposed Total 11 Dichlorobenzene Nill 36 36 1-Acetyl-2-Methoxy 12 Nil 10 10 Naphthalene 13 Coal Ash Nil 200 200
6. RAW MATERIAL REQUIREMENT Raw materials is purchased from indigenous and abroad market by roads/sea way. Details of raw material required for enhancement of existing Products and Proposed Products given in Table-4 & Table-5.
Table 4 : Details of Raw Material Requirement for Nitro Amino Phenol Group
Name of Raw Quantity / S.No. Source Transportation Storage Condition Material Month
A Basic Raw Material
Domestic (DMC 1 Sulfuric Acid (98%) 1080 Mt Road Tank Roha)
Self Made (Bi- 2 Sulfuric Acid (30%) 90 Kl Road Tank product)
3 Fuming Nitric Acid 185 Mt Domestic (RCF) Road Tank
4 Nitric Acid 70% 175 Mt Domestic Road Tank
Domestic & 5 Caustic Lye (50%) 290 Mt Imported Road Tank (Trader)
Sodium Hydrogen 6 Sulphide 30% 140 Kl Domestic Road Tank Aqueous Solution
Sodium Sulfate 7 26 Mt Domestic Road Bag (Na2s)
8 Lime Powder 32 Mt Domestic Road Bag
Pre-Feasibility Report 8
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Name of Raw Quantity / S.No. Source Transportation Storage Condition Material Month
9 Sulphur Powder 20 Mt
Only 220 10 Urea Domestic Road Bag Kg
Sodium Chloride 11 8.0 Mt Domestic Road Bag Salt
Hydrogen 12 3 Mt Domestic Road Cans Peroxide
13 Organic Amines 6.0 Mt Domestic Road Tanks
20% Aqueous 14 25 Kl Domestic Road Cans Ammonia Solution
Chloro Sulfonic 15 35 Mt Domestic Road Tank Acid
Dil. Hydrochloric 16 12 Kl Domestic Road Tank Acd
Self Produce + 17 Ice 230 Mt Road Containar domestic
18 Acetic Anhydride 54 Mt Domestic Road Tank
19 Chlorine Gas 120 Mt Domestic Road Cylinders
20 Ferric Chloride 30 Mt Domestic Road Bag
B Solvents - Raw Material
1 Iso Propyl Alcohol 6.0 Mt Domestic Road Tank
Methylene Di 2 10 Mt Domestic Road Tank Chloridee
Ethylene Di 3 10 Mt Domestic Road Tank Chloride
4 Ethyl Benzene 50 Mt Domestic Road Tank
Pre-Feasibility Report 9
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Name of Raw Quantity / S.No. Source Transportation Storage Condition Material Month
Main Organic Raw Material as – C Starting Material
Mono Chloro 1 117 Mt Domestic Road Tank Benzene
2,4- Dinitrochloro Domestic + Self 2 226 Mt Road Bags Benzene Made
3 2,4- Dinitro Phenol 116 Mt Self Made Road Carboys
4 Picric Acid 104 Mt Self Made Road Carboys
5 Sodium Picramate 22 Mt Self Made Road Carboys
2- Secondary Butyl 6 66 Mt Domestic Road Tank Phenol
Domestic + 7 Ortho Xylene 60 Mt Road / Sea Tank Import
O –Nitro 8 18 Mt Domestic Road Bags Chlorobenzene
2-Chloro-4- 9 Chlorosulfon 29 Mt Self Made Road Carboys Chlorobenzene
2-Nitro-4- 10 Sulfonamide 23 Mt Self Made Road Carboys Chlorobenzene
11 Benzene 130 Mt Domestic Road Drum
Table 5 : Details of Raw Material Requirement for Bulk Drug & Intermediates
Quantity No Particulars Source Transportation Storage Condition / Month
Pre-Feasibility Report 10
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Quantity No Particulars Source Transportation Storage Condition / Month
A Basic Raw Materials
1 Sulfuric Acid 584 Mt Domestic Road Tank
2 Caustic Lye 50% 60 Mt Domestic Road Tank
3 Dil Sulfuric Acid 105 Mt Self Made Road Tank
4 Caustic Flex 46 Mt Imported Sea / Road Tank
5 Ice 94 Mt Self Made Road Container
6 Acetic Anhydride 60 Mt Domestic Road Tank
Zinc Chloride 7 110 Mt Domestic Road Bags Anhydrous
8 Dimethyl Sulfate 164 Mt Domestic Road Tank
9 Sodium Methoxide 35 Mt Import Sea & Road Drums
10 Cyclopropyl Amine 32 Mt Import Sea & Road Drums
Sodium Sulfate 11 1 Mt Domestic Road Bags Anhydrous
12 Potassium Carbonate 33 Mt Domestic Road Bags
Tri Ethyl Ortho 13 180 Mt Import Sea & Road Drums Formate
14 Morpholine 110 Mt Import Sea & Road Drums
15 Hydrazine Hydrate 45 Mt Import Sea & Road Drums
16 Formamide 19 Mt Import Sea & Road Drums
20% Aqueous 17 100 Kl Domestic Road Tanks Ammonia
18 Nitric Acid (72%) 35 Mt Domestic Road Tanks
19 Sodium Nitrate 14 Mt Domestic Road Tanks
Pre-Feasibility Report 11
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Quantity No Particulars Source Transportation Storage Condition / Month
Sodium Hydrogen 20 80 Mt Domestic Road Tanks Sulphide 30%
21 Glacial Acetic Acide 60 Mt Domestic Road Tanks
22 Anhydrous Piperazine 21 Mt Import Sea & Road Bags
23 Carbon Di Oxide Gas 18 Mt Domestic Road Tank / Cylinders
Hydrochloric Acid 24 117 Kl Domestic Road Tanks 30%
25 Dimethyl Sulfoxide 30 Mt Domestic Road Tanks
26 Activated Charcoal 20 Mt Domestic Road Bags
27 H-Flow Supercell 10 Mt Domestic Road Bags
B Solvent – Raw Materials
1 Methanol 30 Kl Domestic Road Tanks
2 Ethanol 5 Kl Domestic Road Tanks
Methylene Di 3 30 Kl Domestic Road Tanks Chloride
4 Toluene 50 Kl Domestic Road Tanks
5 Dimethyl Carbonate 200 Kl Imported Sea & Road Drums
6 Dimethyl Formamide 80 Kl Domestic Road Tanks
7 Ethyl Acetate 10 Kl Domestic Road Tank
8 Nitrobenzene 20 Mt Domestic Road Tank
9 Butanol 10 Kl Domestic Road Tank
10 Iso Propyl Alcohol 40 Mt Domestic Road Tank
Main Organic Raw Material as - C Starting Materials
Pre-Feasibility Report 12
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Quantity No Particulars Source Transportation Storage Condition / Month
Imported + 1 Beta Naphthol 77 MT Sea & Road Bags Domestic
2-Methoxy 2 80 MT Self Made Road Carboys Naphthalene
Domestic + 3 Acetophenone 40 MT Sea & Road Tanks Imported
3-Nitro 4 32 MT Self Made Road Drums Acetophenone
3-Amino 5 26 MT Self Made Road Drums Acetophenone
3- Hydroxy 6 8 MT Self Made Road Drums Acetophenone
7 3- Amino Phenol 41 MT Imported Sea & Road Drums
4-Amino Salicyclic 8 44 MT Self Made Road Drums Acid
9 Cyanoacetamide 22 MT Imported Sea & Road Bags
Pyrazole 4-Hydroxy 10 16 MT Self Made Road Carboys Hemisulphate
Ciprofloxacin “Q – 11 26 MT Self Made Road Carboys Acid”
12 Ciprofloxacin Base 26 MT Self Made Road Carboys
2,4-Dichloro-5-Fluoro 13 120 MT Imported Sea & Road Drums Acetophenone
Cyclopropyl Amine Derivative Of 2,4- 14 174 MT Self Made Road Carboys Dichloro- Acetophenone
Pre-Feasibility Report 13
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
7. PROCESS DETAILS Please refer Exhibit – 2, Manufacturing process of Specialty chemical & Intermediates along with Process Flow diagram with chemical reaction.
8. UTILITY AND REQUIREMENTS Company has acquired adequate land and other resources to expand the production capacity. Other requirements are Power, Water and manpower.
8.1 WATER CONSUMPTION AND WASTE WATER GENERATION The source of water for the existing as well as proposed expansion meets through MIDC. Total water requirement for the existing as well as proposed production is 468 KLD (52+ 416). 5.4 KLD Domestic effluents shall be disposed through septic tank & soak pit. Existing Trade effluent generation 26 KLD and proposed additional Trade effluent generation will be 229 KLD. From existing effluent 16 KLD is recycled through MEE and 10 KLD is send to CETP. Proposed 229 KLD effluents will be recycled using MEE. Details of water consumption and waste water generation are tabulated in Table No. 6.
Table 6: Details of Water Requirement & Waste Water Generation
Water Consumption Waste Water Generation Sr. No. Particulars KL/Day KL/Day E P T E P T 1 Domestic 2.5 6.5 9.0 1.5 3.9 5.4 2 Process 23.0 249 272.0 Gas 14.0 156 170 3 0.4 11.6 12.0 Quenching 4 Boiler 15.6 97.4 113.0 12.0 73 85 5 Cooling 2.0 25 27.0 0.0 0.0 0.0 6 Acid Dilution 8.0 22 30.0 0.0 0.0 0.0 7 Green Belt 0.5 4.5 5.0 ------Total 52 416 468 27.5 232.9 260.4
Note: E: Existing, P: Proposed, T: Total after proposed expansion
Pre-Feasibility Report 14
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd. Total Water Requirement 8.1.1 Water Balance Diagram : 468 KLD [Existing 52 KLD+ Proposed 416 KLD
Industrial Use Gardening Domestic Use 454 KLD 5.0 KLD 9.0 KLD (49+405) KLD (0.5 + 4.5) KLD (2.5 + 6.5) KLD
170 5.4 KLD
Process 272 KLD Sock Pit & Septic Tank
Gas Quenching 12 KLD
85 Boiler
113 KLD
Evaporation Loss 7.5 KLD ETP Multiple Effect Condensed Activated 255 KLD Evaporator Water (90%) Charcoal 250 KLD 225 KLD Bed
Cooling Tower 25 KLD 17.5. Recycle & Reuse for Inorganic salts as Disposal at Process Sludge from MEE MSWL Acid Dilution 30 KLD
Sell to other Industries as dilute Acid Pre-Feasibility Report 15
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
8.1.2 Effluent Treatment plant : Effluent is coming from process, boiler feed and gas quenching to be collected separately in the collection tank. It is to be neutralized, and send to Multiple Effect Evaporator (MEE). The condensed water obtained from the MEE system is to be send to Activated Charcoal Bed to remove any traces of Color & Volatile Organic Matter. Thus this Industrial water can be totally re-cycled & reused. Existing ETP and MEE is shown in Figure 3 and Figure 4.
Figure 3: Flow Diagram of Existing ETP
At Present Odyssey Organics handles 3 Main Effluent Streams –
NITRATION SPENT SULFURIC STORAGE TANKS
PROCESS ACID
100 % SALE AS BI-
PRODUCT
Second is Reduction Stream as below:
REDUCTION STREAM NEUTRALIZATION STORAGE TANKS
MULTIPLE EFFECT CONDENSE WATER EVAPORATOR STORAGE (1000 KG / HR)
RECYCLE SLUDGE
M.S.W.L
Pre-Feasibility Report 16
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
The Third - Hydrolysis Stream Is As Below.
In the below diagram:
A & B– Collection & Primary Treatment Tanks (Neutralization & Hydrogen Peroxide Mixing).
C - Primary Clarifier to settle the Solids,
D – Secondary Tank (aeration)
E – Secondary Clarifier,
V- “V” – Shaped Notch for Sample collection & Discharge to C.E.T.P
HYDROLYSIS STORAGE TANKS 1
STREAM A B
E D C
V TO C.E.T.P.
Pre-Feasibility Report 17
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Figure 4 : Flow Diagram of Existing MEE of capacity 1000 Kg/Hour
8.2 POWER CONSUMPTION The Source of Electricity obtained from M.S.E.B. The power demand for the existing manufacturing activity is 146 KVA and 3431 KVA will be required for proposed expansion.
Table 7 : Details of Power Consumption
Power Consumption (KVA) Sr. No. Particulars Source Existing Proposed Total 1 Operations M.S.E.B 89 2236 2325 2 Effluent Treatment M.S.E.B 55 839 894 3 Other General M.S.E.B 2 356 358 D.G. Set 4 DG Set 125 125*3 125*4 (Stand By)
Pre-Feasibility Report 18
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
8.3 MANPOWER REQUIREMENT The Project will create direct & indirect employment opportunities within the surrounding region. The Unit will use good faith efforts to employ local people from the nearby villages depending upon the availability of skilled & un-skilled man-power surrounding the project site. In operation phase, the proposed project would require significant workforce of non-technical and technical persons. Migration of highly education and skilled experience will result in increase of literacy in the surrounding villages.
Table 8: Employment Details
Nos. Sr. Descriptions No. Total after proposed Existing Proposed expansion
1 Direct 55 65 120 employment
9. STACK DETAILS AND FUEL REQUIREMENT : In the existing unit Briquetes is used as a fuel for Boiler and Diesel is used as a fuel for D.G set. Details of stacks and D.G. set is given in Table 9.
Table 9: Details of Flue gas Stack
Stack Air Sr. Stack Stack Stack Capacit Fuel name Gas Pollution No Status Height Dia. attached to y & Quantity Temp Control . (m) (mm) (°C) Measure
Briquetes, Boiler (Non 500 kg 1 Existing 18 400 60 130 Stack IBR) 1 /hr Mt/Month 12,000 Coal, 250 2 IBR Boiler Proposed 22 600 180 Stack kg/ hr MT/Month
Existing Diesel, 500 3 D.G Set 125 KVA 10 400 80 Stack lit/Month
125*3 Proposed Diesel, 1500 4 DG Set 10 400 80 Stack KVA lit/Month
Pre-Feasibility Report 19
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
10. HAZARDOUS WASTE GENERATION AND MANAGEMENT
Hazardous waste generated from the process & maintenance. The Management of Hazardous waste will be done as per Hazardous Waste Management Rules 2008. The Hazardous waste generation and management are shown in Table 10.
Table 10 : Hazardous Waste Management
Sr. Quantity (MT/Month) Hazardous Category Source of Stora No Disposal Waste No. E P T Generation ge . Plant Selling to 1 Used Oil 5.1 30 150 180 Maintenan Drum registered ce Refiner M.S.W.L. for 2 ETP Sludge 26.2 2 13 15 ETP Bag Land Fill or Incineration M.S.W.L. for Solid Land Fill or 3 Sludge 34.4 10 1720 1730 MEE Bag Incineration from MEE
Organic M.S.W.L. 4 28.1 Nil 25 25 Process Bag Residue M.S.W.L. for Process 5 26.1 12 1738 1750 Process Bag Land Fill or Waste Incineration Selling to Discarded Store Production registered 6 Bags & 33.3 1200 6000 7200 into Section reuser/recyc Container SWSA lers
10.1 NON-HAZARDOUS SOLID WASTE GENERATION AND MANAGEMENT.
Table 11 : Non Hazardous Solid Waste Generation
Quantity (Mt/month) Sr. No Name of solid waste Management E P T Send to Municipal 1 Canteen Waste 1 3 4 Corporation, Mahad Paper, cardboard, Selling to registered 2 3 7 10 Metal scrap etc reuser/recyclers
Pre-Feasibility Report 20
Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Total Salt Content As : 3 Sodium Sulfate & Nil 1360 1360 Send to M.S.W.L Sodium Chloride Mixture Total Salt Content As : Nil 360 360 Send to M.S.W.L 4 Sodium Thiosulfate
Total Salts As Nil Send to M.S.W.L 5 120 120 Ammonium Chloride
11. LAND REQUIREMENT DETAILS
The existing unit of M/s. Odyssey Organics Pvt. Ltd. is located at plot no. B-36, 37, 39, Birwadi MIDC, Taluka: Mahad, District: Raigad, Maharashtra. Total Plot area of the plant is 25000 m2. The break-up area detail is given in Table 12 and the Plant Layout of the unit is given in Figure 5 & Figure 6.
Table 12: Details of Land use Break-up
Land Area in Sq.m S. No. Particulars Existing Proposed
1 Plant Facilities 798 10,399
Administrative Building and 2 2,490 500 Canteen
Effluent treatment plant – 3 multiple effect evaporator 586 2,475 & other systeems 4 Internal Approach roads 1,515 838
5 Green belt /plantation 1847 3552
6 TOTAL PLANT AREA 7,236 17,764 Open space to be use for 7 17,764 NIL Future expansion
Total AREA 25,000
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Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Figure 5. Layout Plan of Plot no. 36 & 37
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Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
Figure 6. Layout Plan of Plot no.39
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Project: Manufacturing of Specialty chemical & Intermediates Developer: M/s. Odyssey Organics Pvt. Ltd.
12. GREEN BELT DEVELOPMENT
Unit has already developed greenbelt area in 5399 Sq m within plant premises. There are shrubs and trees developed in the greenbelt area. 21.6 % of the total plot area is earmarked for green cover and open space development in the existing facility. Suitable plant species of local varieties will be planted with adequate spacing and density for their fast growth and survival.
13. STROM WATER MANAGEMENT Surface drainage has designed based on the maximum rainfall intensity prevalent in the area. All the building has been provided with a plinth protection all round, sloped towards the side drain. The storm water collection system has designed in such a manner so that clean storm water from garden, parking areas, roadways and lawns.
14. Conclusion
Looking at the present market scenario, it is concluded that the project is not only feasible and viable, but it will also increase the employment Opportunity in future.
Pre-Feasibility Report 24