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ASHA CELLULOSE (I) PVT. LTD
PRE-FEASIBILITY REPORT
FOR
PROPOSED EXPANSION PROJECT FOR MANUFACTURING OF ETHYL CHLORIDE
(FROM ETHYL ALCOHOL), ETHYL CHLORIDE (FROM MIXED SOLVENT OF EXISTING PROCESS), METHYL CHLORIDE (FROM METHYL ALCOHOL) & HYDROXY PROPYL METHYL CELLULOSE (HPMC)
[Schedule 5 (f) Category “A” as per EIA notification 2006 and its amendment thereof]
At
S. No. 303/2, 302/P, 273/2, 275/1 Near Water Works, Abrama, Valsad - 396001
Ta: Valsad, Dist- Valsad, Gujarat.
Land/Plot Area: 31874 m
2
Production Capacity: 96.54 to 1028.54 TPM (All products together)
APPLICANT CONSULTANT
ASHA CELLULOSE (I) PVT. LTD ECO CHEM SALES & SERVICES S. No. 303/2, 302/P,273/2, 275/1
Near Water Works, Abrama, Valsad, Tal./Dist: Valsad - 396001Gujarat.
E-Mail: srini@ashacel.com ashacel@ashacel.com
Tel: +919825132304 +91 2632 254299
Office Floor, Ashoka Pavilion - A New Civil Road, Surat, 395001
NABET/EIA/1720/RA 051 E-mail: eco@ecoshripad.com Tel No. +91 261 2231630
Document No.: 2019_ECSS_EIAI2_1800002
January 2019
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 2
1.0 EXECUTIVE SUMMARY
1.0.1 Name & Location
Name of the Project: Asha Cellulose (I) Pvt. Ltd.
Location: S. No. 302/P, 303/2, 273/2, 275/1, Near Water Works, Abrama, Valsad-396001 Ta: Valsad, District: Valsad, Gujarat
1.0.2 Project
M/s. Asha Cellulose (I) Pvt. Ltd is located at S. No. 302/P, 303/2, 273/2, 275/1, Near Water
Works, Abrama, Valsad-396001, Ta: Dist: Valsad, Gujarat area, falling under medium Scale
category manufacturing products as mentioned under. The company had obtained Environment
Clearance and Consent to Establish and operates from Gujarat Pollution Control Board for all
the existing products.
The company proposes to introduce new product i.e. ethyl chloride from mix solvent of existing
ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward integration, Methyl
chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC). Ethyl Chloride is
one of the main raw materials required in the production of Ethyl Cellulose and Methyl Chloride
is one of the raw materials for the manufacture of HPMC.
Total project cost (Existing: Rs. 1516.27 lakhs + Proposed: Rs. 1538 lakhs = Total: 3054.27
lakhs)
1.0.3 Applicability of EIA notification – 2006
As per the amended EIA notification - 2006: as proposed expansion products (i.e. ethyl chloride
from mix solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for
backward integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose
(HPMC) are covered under the Category 5 (f) A. Hence, Environmental Clearance is required.
1.0.4 Project Proponent
The company in India comprises of technically sound directors
Medium scale unit
1.1 LIST OF FINISHED PRODUCTS
Sr. No.
Product CAS No. Capacity, TPM
End-Use Existing Proposed Total
1. Ethyl Cellulose (Aqua Process)
9004-57-3
20.0
0
20.0
Used in the manufacture of printing
inks, solar paste, specialty paints, in
electronic applications, as a binder and coating
agent in pharma industry besides
defense purposes.
Used for coating application in
Pharmaceutical Industries
2. Ethyl Cellulose
(Solvent Process)
9004-57-3
31.72 0
31.72
3.
Ethyl Cellulose Aqueous
Dispersion- Non Plasticized
9004-57-3
20.124
0
20.124
4.
Ethyl Cellulose Aqueous
Dispersion- Plasticized
9004-57-3 24.70 0 24.70
5. Ethyl Chloride 75-00-3 0 322.0 322.0 Used as a raw material
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 3
(From Alcohol) in the manufacture of Ethyl cellulose and
other chemical synthesis.
6. Ethyl Chloride
(From existing mix solvent)
75-00-3 0 160.0 160.0
7. Methyl Chloride
74-87-3
0
250.0
250.0
Used as a raw material in the manufacture of
HPMC and other chemical synthesis.
8. Hydroxy propyl methyl cellulose
(HPMC)
9004-65-3
0
200.0
200.0
Used in pharmaceutical coating applications
Total --- 96.544 932.000 1028.544
Manufacturing process with chemical reaction & mass balance is attached as Annexure 3.
1.2 RESOURCE REQUIREMENT
Components Existing Proposed Total Resources availability
Power, KVA 650 350 1000 Dakshin
Gujarat Vij Co. Ltd.
Fresh Water, KLD 37.48 0 37.48 Own bore well
Chilling plant, TR 140 100 240 In house
Cooling Tower, TR 400 300 700 In house
Natural gas (SCM/h)/Furnace oil(kg/h) for 3 TPH
Steam boiler
230/200 0 230 /200 Gujarat Gas/ Local Traders
Solid fuel or Natural gas / Furnace oil for 3 TPH Steam
boiler.
0 Coal- 300 Kg/Hr
400 SCM/Hr 325 Kg/h-FO
Coal- 300 Kg/Hr 400 SCM/Hr 325 Kg/h-FO
In house
Furnace oil or natural gas for 6 lakh k cal/hr
Thermopak 0
115 Kg/Hr-FO 135 SCM/Hr-
NG
115 Kg/Hr-FO 135 SCM/Hr- NG
In house
LDO/Furnace oil for 0.8 TPH boiler
25 liters/hr -25 liters/hr 0 To be removed
LDO/Furnace oil for 0.8 TPH boiler
25 liters/hr -25 liters/hr 0 To be removed
LDO/Furnace oil for 0.8 TPH boiler
25 liters/hr -25 liters/hr 0 To be removed
LDO/Natural gas for 6 lakhs k cal/hr hot air
generator
40 Lts/Hr- LDO 50 SCM/Hr-NG
0 40 Lts/Hr- LDO 50 SCM/Hr-NG
From Gujarat Gas From
Local Traders
LDO/Natural gas for 6 lakhs k cal/hr hot air
generator
40 Lts/Hr-LDO 50 SCM/Hr-NG
0 40 Lts/Hr-LDO 50 SCM/Hr-NG
From Gujarat Gas
From Local Traders
LDO/Natural gas for 6 lakhs k cal/hr hot air
generator 0
40 Lts/Hr-LDO 50 SCM/Hr-NG
40 Lts/Hr-LDO 50 SCM/Hr-NG
From Gujarat Gas
From Local Traders
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 4
HSD for D G set (110 KVA)
45 kg/h 0 45 kg/h From Local
Traders
HSD for D G set (35 KVA)
15 kg/h 0 15 kg/h From Local
Traders
1.3 RAW MATERIAL CONSUMPTION
Sr. No.
Raw Material CAS No. Consumption in MT/Month
MT/MT Existing Proposed Total
1.0 For Ethyl Cellulose (Aqua Process)
Wood pulp - 0.825 16.5 0 16.5
Caustic flakes 1310-73-2 5.4 108.0 0 108.0
Ethyl Chloride 75-00-3 3.365 67.3 0 67.3
Acetic acid 64-19-7 0.001 0.1 0 0.1
2.0 For Ethyl Cellulose (Solvent Process)
Wood pulp - 0.836 26.52 0 26.52
Caustic flakes 1310-73-2 1.75 55.6 0 55.6
Ethyl Chloride 75-00-3 2.36 74.9 0 74.9
Toluene 108-88-3 0.40 13.0 0 13.0
Acetic acid 64-19-7 0.60 19.10 0 19.10
SDS 151-21-3 0.19 6.24 0 6.24
3.0 For Ethyl Cellulose Aqueous Dispersion- Non Plasticized
Ethyl cellulose 9004-57-3 0.27 5.460 0 5.460
Solvent (Ethylene Dichloride, Acetone
and Methylene Dichloride)
(Fresh) (Recovered)
Mixture
0.03 0.86
0.624 17.32
0 0
0.624 17.32
Sodium Lauryl Sulfate
– Powder 151-21-3 0.01 0.312
0 0.312
Cetyl Alcohol Powder 36653-82-4 0.03 0.624 0 0.624
4.0 For Ethyl Cellulose Aqueous Dispersion- Plasticized
Ethyl cellulose 9004-57-3 0.2 4.940 0 4.940
Plasticizer – Dibutyl
Sebacate 109-43-3 0.05 1.300 0 1.300
Oleic Acid 112-80-1 0.04 1.040 0 1.040
Ammonium Hydroxide 1336-21-6 0.05 1.300 0 1.300
5.0 For Ethyl Chloride (From Alcohol)
Calcium chloride/Zinc
Chloride 10043-52-4/ 7646-85-7 0.0003 0 0.1 0.1
Hydro Chloric acid
(30%) 7647-01-0 1.93 0 624.23 624.23
Ethanol (94%) 64-17-5 0.76 0 247.0 247.0
Caustic lye (10%) 1310-73-2 0.22 0 72.82 72.82
6.0 For Ethyl Chloride (From existing mix solvent)
Mix solvent from existing Ethyl
cellulose product by solvent process
Mixture 0.71 0 114.18 114.18
Mix solvent from
existing Ethyl Mixture 0.21 0 34.86 34.86
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 5
cellulose product process: II
Hydro Chloric acid
(30%) 7647-01-0 1.99 0 319.73 319.73
Caustic lye (10%) 1310-73-2 0.40 0 65.0 65.0
7.0 Methyl Chloride
Calcium Chloride /
Zinc Chloride 10043-52-4/ 7646-85-7
0.0003 0 0.1 0.1
Hydro Chloric Acid
(30%) 7647-01-0
2.45 0 613.6 613.6
Methanol 67-56-1 0.64 0 159.74 159.74
Caustic Lye 1310-73-2 0.21 0 52.0 52.0
8.0 Hydroxy propyl methyl cellulose
Wood Pulp - 0.67 0 134.8 134.8
Methyl Chloride 74-87-3 0.23 0 46.3 46.3
Sodium Hydroxide 1310-73-2 0.185 0 36.9 36.9
Propylene Oxide 75-56-9 0.25 0 49.76 49.76
1.4 WATER AND WASTE WATER MANAGEMENT
At existing Scenario:
Presently, total water requirement is 155.48 m3/day (Fresh: 37.48 m3/day + Recycled from
RO/MEE is 118 m3/day) which is sourced from own bore well. We have already applied to
CGWA for permission to withdrawal of ground water.
Total industrial waste water generation is 123 m3/day, which is treated in primary, secondary
and tertiary treatment plant. Treated waste water is taken to reverse osmosis plant. 102
m3/day of RO permeate is recycle in the process. Balance 18 m3/day of RO rejected is taken
to MEE. 16 m3/day of MEE condensate is recycled in the process. Thus there is no discharge
of industrial effluent on land.
Domestic waste water (1.5 m3/day) is disposed off through septic tank to ETP.
After proposed expansion:
After proposed expansion, total water requirement will be 244.9 m3/day (Fresh: 37.48 m3/day +
Recycled from RO/MEE is 207.5 m3/day) sourced from own bore well. We have already
applied to CGWA for permission to withdrawal of ground water.
Total industrial waste water generation will be 218.015 m3/day, which will be treated in primary,
secondary and tertiary treatment plant. Treated waste water will be taken to reverse osmosis
plant. 181 m3/day of RO permeate will be recycled in the process. Balance 32 m3/day of RO
reject will be taken to MEE. 26.5 m3/day of MEE condensate will be recycled in the process.
Thus there will be no discharge of industrial effluent on land.
Domestic waste water (2.0 m3/Day) will be disposed off through septic tank to ETP.
1.5 AIR EMISSION AND ITS CONTROL MEASURES
1.5.1 Flue Gas Emission and process gas emission:
At existing Scenario:
Presently, the unit has installed one number of natural gas/FO fired 3 TPH steam boiler, three
numbers of FO/LDO fired steam boiler having capacity of 800 kg/h each and two numbers of
LDO/Natural gas fired hot air generator having capacity of 6 lakhs k cal/hr each. Two numbers
of D G sets having 110 KVA and 35 KVA capacity. 30 meters height of chimney with SMF
provided to 3 TPH boiler, 15 meters common chimney provided for all three boiler and two
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 6
HAG. 11 meters chimney provided for D G Sets.
Presently two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h are used.
Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney
for each dryer is provided.
After proposed expansion:
After proposed expansion, existing one number of natural gas/FO fired 3 TPH boiler will be
continued. Existing three numbers of 800 kg/h capacity of boiler will be discontinued. Existing
two numbers of hot air generator will be continued. Additional one number of coal/natural
gas/FO fired 3 TPH boiler and one number of FO/natural gas fired 6 lakhs k cal/hr capacity of
thermopak and one number of natural gas/LDO fired hot air generator of 6 lakhs k cal/hr
capacity will be installed. Existing two numbers of D G sets having 110 KVA and 35 KVA will be
continued.
30 meters height of chimney with SMF provided to 3 TPH boiler, 15 meters common chimney
provided for three HAG. 30 meters chimney with multi cyclone separator and bag filter will be
provided to 3 TPH coal fired boiler. 11 meters height of chimney will be provided to 6 lakhs k
cal/hr capacity of thermopak. 11 meters chimney provided for D G Set.
After proposed expansion, existing two numbers of spin flash dryer having capacity of 50 kg/h
and 100 kg/h will be used. One additional spin flash dryer having a capacity of 100 kg/h will be
installed. Adequate capacity of separate cyclone separator and bag filter along with 11 meters
chimney for each spin flash dryer will be provided.
Detail of Air pollution control measures is attached as Annexure 9.
1.6 HAZARDOUS WASTES AND ITS MANAGEMENT
Sr. No.
Process waste Category Source Quantity, TPA Mode of
disposal Existing Proposed Total
1 Used oil Sch: I/5.1 Machineries/ D.G.Set
0.092 0.018 0.11 Incineration at common
incineration system of M/s
BEIL, Ankleshwar /
sold to authorized recyclers
2 Discarded containers/bags
Sch: I/33.1
Raw Material Storage area & Utility Area
50 12 62 reused for packing of solid waste or sold to
registered recyclers
3 ETP waste Sch: I/35.3
ETP 109 21 130 Disposed off into TSDF site of M/s
BEIL, Ankleshwar or
VGEL, Vapi
4 MEE waste Sch:I/35.3 MEE 234 714 948 Disposed off into TSDF site of M/s
BEIL, Ankleshwar or
VGEL, Vapi
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 7
5 Dust from air filtration system
Sch:I/26.2 air filtration system
0.22 0 0.22 Recycled in process
6 Salt from process
Sch:I/26.1 Manufacturing process
1703
0
1703
Disposed off into TSDF site of M/s
BEIL, Ankleshwar or VGEL, Vapi.
7 Mixed Solvent from the process
Sch:I/26.4 Manufacturing process
1787.44
9.98 + 51.96 (vent
condenser and
HPMC product)
1849.38
61.9
1787.44 MTPA of mix solvent from solvent process and
aqua process will be utilized
for manufacture of Ethyl chloride product within the premises and balance 61.9 MTPA of mixed solvent will be sold to
actual distillator
8 Distillation Residue / & Laboratory organic waste
Sch:I/26.1 Manufacturing process
23.0 - 18.78 4.22 Collection, storage
transportation, disposal to BEIL
incineration facility.
9 Spent carbon from ETP &
Chimney
Sch:I/36.2 ETP/Chimney 4.8 1.2 6.0 Collection, storage
transportation, disposal to BEIL
incineration facility.
10
Date-Expired, Discarded and off-specification Material & floor sweeping
Sch:I/28.5
Product Storage area
1.0
1.0
2.0
Collection,
storage transportation,
disposal to BEIL incineration
facility.
11 Spent Filter cloth & filter
material
Sch:I/36.2
From process plant
1.0
0
1.0
Collection,
storage transportation,
disposal to BEIL incineration
facility.
12 Spent Resins from D M plant
Sch:I/35.2 D M plant 1.0 0.2 1.2 Collection, storage
transportation, disposal at TSDF/BEIL Collection,
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 8
storage transportation,
disposal at TSDF/BEIL
13 Used hot & cold insulation material
Schedule: X/02
Manufacturing process
0.5 0.1 0.6 Collection, storage
transportation, disposal at TSDF/BEIL
14 Weak caustic soln (18-20%
Sch: II/C2 Manufacturing process
17723 0 17723 Sell to actual/authorized
users
Solid Waste
15 Fly ash - Boiler 0 179 179 Sell to Brick manufacturer
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 9
1.7 INTRODUCTION OF THE PROJECT AND THE PROPONENT
Name of the project Proponent: M/S Asha Cellulose (I) Pvt. Ltd
ASHA GROUP OF COMPANIES were floated by three enterprising gentlemen, Mr. H. V. Shah,
Mr. C. D. Mehta and Mr. J. L. Shah in the year 1968 with main line of business being
manufacturing of Industrial Paints. ASHA NITROCHEM INDUSTRIES LTD was the flagship
Company which remained in existence for two decades till 1998, then was sold to ICI India Ltd.
in May 1998, retaining global marketing rights in the name of ASHA EXPORTS. With time the
group grown into other business activities successfully and diversified into chemical
manufacturing, import / export and real estate. Asha Group was the Pioneer in the Field of
manufacturing Nitrocellulose, Celluloid Sheets & Ethyl Cellulose.
ASHA CELLULOSE (I) PVT. LTD. was incorporated in the year 1988. The Plant is located at
Abrama, Near water Works, Valsad, Dist. Valsad, Gujarat State, which is approx. 1 km off
National Highway No. 8. The location is on the banks of river Auranga and is in the proximity of
Abrama water Works.
ASHACELLULOSE(I)PVT.LTD.hasdeveloped“ETHYLCELLULOSE“manufacturingprocess
byinhouseR&Defforts.ItisthepioneerandtheonlyCompanymanufacturing“EthylCellulose
“inIndiaandwasthethird in world after USA and China when it entered the domestic market.
Apart from the Industrial and Pharmaceutical grades, the Company is manufacturing high tech
speciality Ethyl Cellulose for Defence and Electronic sector. The product is well accepted by all
leading Pharmaceutical Companies, including multinationals. The product finds application in
paints, printing inks, adhesives, pharmaceutical, electronic industry besides defence purposes.
ASHA CELLULOSE (I) PVT. LTD. has ventured into export of Ethyl cellulose and successfully
bagged orders from Europe, USA, China, Korea, Far East and Middle east countries.
The Company is managed by Professionals supported by highly qualified technicians in the
manufacturing process. The Company has a total work force of 100 dedicated persons including
Mangers and Techno – Commercial personnel.
THE GROUP :
ASHA CELLULOID is the Company engaged in manufacturing of Cellulose Nitrate Sheets for
Defense supply. ASHA CELLULOID is the only Company manufacturing CN Sheets in India.
ASHA PENN COLOR PVT. LTD. is the Company having partnership with PENN COLOR INC.
USA and engaged in manufacturing of Pre-dispersed Pigmented Chips based on resins like
Cellulose Acetate, Cellulose Acetate Butyrate, Vinyl, Polyamide and Nitrocellulose. The
Company is the only manufacturer of this product in India. This product is also well accepted in
Indian market as well as in overseas. The Company is regularly exporting to Europe, Middle
East and Africa etc.
ASHA EXPORTS is the Company acting as global export agent for NITREX CHEMICALS INDIA
LTD. for their product Industrial Nitrocellulose. The Company has developed excellent overseas
market and contacts.
The group has always remained cohesive and concentrated on vertical (forward as well as
backward) and horizontal integration in manufacturing. It believes in taking up manufacture of
products with a long life cycle having very few manufacturers in the world. This strategy provides
the Group with a competitive edge in comparison to manufacture of conventional products.
M/S Asha Cellulose (I) Pvt. Limited is a medium scale unit is located in private industrial estate,
near water works, Abrama, Valsad, Di: Valsad having total plot area is 31874 m2 & proposed
investment will be (Existing: Rs. 1516.27 lakhs + Proposed: Rs. 1538 lakhs) 3054.27 lakhs &
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 10
wishes to introduce new product i.e ethyl chloride from mix solvent of existing ethyl cellulose
product, Ethyl chloride from ethyl alcohol for backward integration, Methyl chloride from Methyl
Alcohol and Hydroxy propyl methyl cellulose (HPMC).
The unit has experienced technocrats having more than 30 years of experience in
manufacturing & marketing of Ethyl cellulose, Ethyl Chloride, HPMC, Methyl Chloride and its
derivatives.
The company has prepared well equipped production plant which will be managed by dedicated,
qualified & skilled persons. The main equipment is as under:
S. No. Name of the equipment MOC
1. Reactors MS Glass lined
2. 30% HCl Storage Tanks PP FRP
3. Scrubber PP FRP & SS 316
4. Extraction Column Graphite
5 Heat Exchangers Graphite
6 Product receiver SS 316
7 Pumps MS PFA lined, SS 316
8 Reactors SS 316
9 Storage tanks SS 316
10 Heat Exchangers SS 316
11 Nutch Filters SS 316
12 Dryer SS 316
The proposed project area lies on 20035’38.39” N Latitude & 72057’40.59” E Longitude. M/s
ACIPL is located at S. No. 303/2, 302/P, 273/2, 275/1 near water works, Abrama, Valsad,Ta:
Valsad, Di: Valsad in Gujarat state and same western part comes under Daman union Territory.
Biggest GIDC Vapi is 30 kms away & Atul estate is 6 kms away from the project. National
Highway No. 8 connecting Mumbai and Ahmedabad is passes nearby the project site. The
western Railway Main Line is 5 kms away from the area (Double & Electrified). Valsad is the
biggest railway station in the study area; where, almost all the important mail & express trains
stop. Entire study area is well connected with the other major cities of the state and the country.
Beside the rail connectivity, the site is well connected by road transport (NH 8 less than a
kilometer). There is a good network of roads in the area and contributes for the development
and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now six
lanes, double tracked, more elevated and Jam free highway, which is developed by M/s L & T
Company. This highway has given a further boost to the economic growth of this area.
The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crossing
the NH – 8 in VAPI Town. Almost every village is now well connected to each other by well
maintained tar roads.
Nearest Vapi township has emerged as an Industrial hub on Gujarat – Maharashtra border.
Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has
gained a special status on the industrial map of the country mainly for chemical industrial units.
Over the years, it has emerged as a major cosmopolitan industrial township equipped with
hospitals. school, colleges, community centres, temples, churches, mosques, cinema house, fire
stations, blood banks, water filtration plants, police stations, post offices, banks, telephone
exchanges hotels, guesthouses etc. The town has got a major face-lift after the completion of
national highway and other links roads are of good standard. Mumbai, the economic capital of
the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms. The
district Head Quarter – Valsad is 30 km from the Vapi town.
Nearest Vapi Industrial estate, developed by Gujarat Industrial Development Corporation (GIDC)
has come into existence during 1967-1968. The entire estate, which was developed in phases,
is now spread over 1140 hectares and houses more than 1400 industries, most of which are
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 11
small-scale Industrial units although some have grown bigger units at later stages. The industrial
township isbasicallyadeclared “ChemicalEstate”whereabout705of the industrialunitsare
either Chemical or Chemical related, such as, Dyes and Dyes intermediates, pigments
pesticides, fine chemicals and pharmaceuticals etc. The remaining 30% companies of paper
mills, packing, plastics, engineering textiles, paints, food processing printing, etc. One of the
countries largest common effluent treatment plant has been setup in Vapi industrial estate.
Being a major industrial & commercial centre, it caters to other peripheral industrial estates like
Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.
1.7.1 Identification of the Project Proponent
M/S Asha Cellulose (India) Pvt. Limited is an existing medium scale unit located at Private
Industrial estate, near Water works, Abrama, Valsad, Di: Valsad, a well enthusiastic &
professionally managed manufacturer & marketer of Organic chemical i.e ethyl cellulose
especially used paints, solar panel, printing inks, adhesives, pharmaceutical, electronic industry
besides defence purposes as per requirement.
1.7.2 List of Directors:
Mr.HirubhaiVShah,theCMDofthecompany,whoisagraduatehaving50years’experience
in marketing of cellulose products. He looks after financial and commercial matter with
development of project and management. His vast experience & vision will be very much
helpful for decision making in all areas of business.
Mr. C D Mehta, the Directorofthecompany,whoisacharteredaccountanthaving40years’
experience in financial matter also he is from well establish business family & he looks after
financial matter of the company.
Mr. B B Mehta, the director of the company, looks after administration of the company.
Mr.KJDave,thedirectorofthecompany,whoisgraduatehaving35years’experienceinthe
export, import & sales of product of the company.
Mr. J KMehta, the director of the company, who is CA having 30 years’ experience in the
financial matter & local sales of the company.
Mr. K Srinivas, the technical director the company, who is a chemical engineer having 33 years
of experience in the manufacturing of organic chemicals and cellulose products.
1.7.3 Brief description of nature of the Project
M/S Asha Cellulose (I) Pvt. Limited proposes to introduce new product i.e ethyl chloride from mix
solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward
integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC) at
existing S. No. 303/2, 302/P, 273/2, 275/1 near water works, Abrama, Valsad, Ta: Valsad, Di:
Valsad in Gujarat state.
The proposed expansion project involves the production of new product i.e ethyl chloride from
mix solvent of existing ethyl cellulose product, Ethyl chloride from ethyl alcohol for backward
integration, Methyl chloride from Methyl Alcohol and Hydroxy propyl methyl cellulose (HPMC).
Apart from the Industrial and Pharmaceutical grades, the Company is manufacturing high tech
specialilty Ethyl Cellulose for Defence and Electronic sector. The product is well accepted by all
leading Pharmaceutical Companies, including multinationals. The product finds application in
paints, printing inks, adhesives, pharmaceutical, electronic industry besides defence purposes.
As per the EIA notification- 2006 as amended products are covered under category 5(f) required
Prior Environmental Clearance.
For the proposed expansion project, the company intends to procure the available latest
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 12
technology for manufacturing the products.
The industrial sector in the past 5 to 7 years has seen a drastic boom and also the keeping in
mind the globalization trend, we have identified the demand for the product and with continuous
R & D found that it is developed in-house and produce commercially for domestic market as well
as an eye more on export markets.
1.7.4 Need for the project and its importance to the country and region
The proposed expansion project provides a potential growth opportunity for the already running
business of the company. The company is already engaged in the business of manufacturing of
“Ethyl cellulose and its derivatives”. The project would increase the overall export and also
increase the foreign revenue. Product is now well established and acceptable in the international
markets like USA, Europe, China, Taiwan, Middle East, Far East, Isreal, Egypt etc.
Additional capacities of product range required over & above our existing capacities, as the
company expect strong growth of exports to the extent of 50-60%. Local market also showing
strong growth potential.
Domestic market concentrated in Western India, North India, Hyderabad, Chennai, and Bangalore.
This project will generate additional employment of 6 people
1.7.5 Demand –Supply Gap
Our products are mainly used in paints, solar panel, printing inks, adhesives, pharmaceutical,
electronic industry besides defence purposes as per requirement. We are the only company
manufacturing Ethylcellulose in India, so demand of our products is sustainable. Most of the
raw materials indigenous and are easily available in India, only one main raw material i.e. wood
pulp is imported.
1.7.6 Imports vs. Indigenous production
Existing products manufacturing in the country will be very much economical compare to
Imports of the same except from China and also the export of the same will earn extra foreign
exchange for our county. If we produce raw material (Ethyl Chloride) on our own, we can
compete with Chinese products also.
1.7.7 Export Possibility
Existing products have high export potential. Also these products have very good potential in
local market.
Additional capacities of product range required over & above our existing capacities at Abrama,
Dist: Valsad, as the company expect strong growth of exports to the extent of 50-60%. Local
market also showing strong growth potential.
1.7.8 Domestic / export Markets
The company’s product is used as raw material to manufacture various pharmaceutical
industries, chemical industries etc. as per the required applications and having very good market
in domestic and also having very good international markets.
1.7.9 Employment Generation (Direct and Indirect) due to the project
There will be an opportunity of employment generation directly and indirectly due to proposed
expansion project. At present the manpower employed in the industry is 110 numbers. Due to
proposed expansion project 50 people will be directly/indirectly employed. Thus total number of
employees after proposed expansion will be 160.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 13
1.8 PROJECT DESCRIPTION
1.8.1 Type of Project including interlinked and interdependent projects, If any
The proposed project is an interdependent project of the company.
1.8.2 Location (map showing general location, Specific location, and project
boundary & project site layout) with coordinates
The map showing general location, specific location and project boundary and project site lay
out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.
1.8.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted
Proposed expansion will be carried out in existing premises only. (Land documents are attached
as Annexure-6). The proposed activity will be accommodated in existing plant having proper
industrial infrastructure, so there is no alternate site consideration.
1.8.4 Size or magnitude of operation
As per the proposed project cost, the project is covered under medium Scale category of
manufacturing industries.
1.8.5 Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given)
Detailed project description with process details is enclosed as Annexure-3
1.8.6 Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product
Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products & characteristics of hazardous chemicals are as below:
DETAILS ON PRODUCT TRANSPORTATION
Sr. No.
Product Physical State Packing Means of
Transportation
1 Ethyl Cellulose (Aqua
Process) Solid Powder
Fibre Drums, Paper Bags, Aluminum
Bags
By Road, Sea & Air
2 Ethyl Cellulose (Solvent
Process) Solid Powder
Fibre Drums, Paper Bags, Aluminum
Bags
By Road, Sea & Air
3 Ethyl Cellulose Aqueous
Dispersion- Non Plasticized Dispersion
HDPF Jerry Can
By Road, Sea & Air
4 Ethyl Cellulose Aqueous Dispersion- Plasticized
Dispersion HDPF Jerry
Can By Road, Sea & Air
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 14
5 Ethyl Chloride (From Ethyl
Alcohol) Liquid
Through close Pipe line
Captive use /sale
Tonners By Road
6 Ethyl Chloride (From
existing mixed solvent) Liquid
Through close Pipe line
Captive use / sale
Tonners By Road
7 Methyl Chloride Liquid under
pressure
Through close Pipe line
Captive use / sale
Tonners By Road
8 Hydroxy Propyl Methyl
Cellulose Solid Bags By Road, Sea & Air
DETAILS OF RAW MATERIAL – TRANSPORTATION
Sr. No.
Substance Physical
State Source of
Supply Means of
Transportation
Distance of supplier from
project site (km)
1 Wood pulp Solid Sheet
Imported By Sea More than 5000
2 Caustic flakes Solid Local Manufacturers By Road 200
3 Ethyl Chloride Liquid In house Pipe line 200
4 Acetic acid liquid Local Manufacturers By Road 200
5 Toluene liquid Local Manufacturers By Road 200
6 SDS liquid Local Manufacturers By Road 200
7 Ethylene
Dichloride Liquid Local Manufacturers By Road
350
8 Acetone Liquid Local Manufacturers By Road 25
9 Methylene Dichloride
Liquid Local Manufacturers
By Road
350
10 Sodium Lauryl
Sulfate Solid
Powder Local Manufacturers By Road
200
11 Cetyl Alcohol
Powder Solid
Powder Local Manufacturers By Road 200
12 Ethyl cellulose Powder in-house By road 0-1 km
13 Plasticizer –
Dibutyl Sebacate
Liquid Local Manufacturers By Road
200
14 Oleic Acid Liquid By Road 200 200
15
Ammonium Hydroxide
Liquid Local Manufacturers By Road 200
16 Calcium
chloride/Zinc Chloride
Solid Local Manufacturers By Road 200
17 Hydro Chloric
acid (30%) Liquid Local Manufacturers By Road 200
18 Ethanol (94%) liquid Local Manufacturers By Road 200
19 Caustic lye Liquid In house Internal Pipeline
--
20 Methanol (99.5%)
liquid Local Manufacturers By Road 200
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 15
DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS
S.No Name of the Raw Materials
Quantity stored,
MT/Month
BP. 0C
MP0C Place of its
Storage
State operating pressure
temperature
Possible type of hazards
Control measures provided
Max Actual
1
Wood pulp
150 100 NA NA Isolated
Store
Atmosphere & Room Temp.
Fire
Fire Extinguishers,
Hydrant system
2
Caustic flakes
125 100 NA NA Isolated
Store
Atmosphere & Room Temp.
Corrosion Corrosion resistant
paints used
3
Ethyl
Chloride 12.5 10 12 -138
Isolated Store in tonners
Atmosphere & Room Temp.
Flammable
Foam Fighting and
Fire extinguishers
4
Acetic acid 4 3.5 106 16
Storage Tank
Atmosphere & Room Temp.
Toxic & Corrosion
Fire Hydrant and Fire
Extinguishers
5
Toluene 15 10 110 -95
Isolated Storage
Tank
Atmosphere & Room Temp.
Flammable
Foam Fighting and
Fire Extinguishers
6
Ethyl
cellulose 40 35 NA 180
FG Store
Atmosphere & Room Temp.
Combustible
Fire Extinguishers
and Fire hydrant
7 Ethylene
Dichloride 1.5 1.0 80 -35 Drums
Atmosphere & Room Temp.
Flammable Foam &Fire
Extinguishers
8 Acetone 0.3 0.15 56 -95 Drums Atmosphere
& Room Temp.
Flammable Foam &Fire
Extinguishers
9 Methylene Dichloride
1.0 0.75 40 -97 Drums Atmosphere
& Room Temp.
Flammable Foam &Fire
Extinguishers
10
Sodium Lauryl
Sulfate – Powder
0.05 0.025 NA NA PP Bag Atmosphere
& Room Temp.
Combustible Fire
Extinguishers
11
Cetyl Alcohol Powder
0.03 0.015 NA NA PP Bag Atmosphere
& Room Temp.
Combustible Fire
Extinguishers
12
Plasticizer – Dibutyl
Sebacate 0.025 0.025 340 -35 Carboy
Atmosphere & Room Temp.
Combustible Fire
Extinguishers
13 Oleic Acid 0.025 0.025 286 16 Carboy Atmosphere
& Room Temp.
Combustible Fire
Extinguishers
14 Ammonium Hydroxide
0.025 0.025 NA -69 Carboy Atmosphere
& Room Temp.
Toxic Fire hydrant
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 16
15
Calcium chloride/Zinc
Chloride 100 100 NA NA
HDPE Drum
Atmosphere & Room Temp.
Toxic Fire hydrant
16
Hydro Chloric acid
(30%) 30 15 100 NA
PP FRP Tank
Atmosphere & Room Temp.
Toxic Fire hydrant
17 Ethanol (94%)
15 10 79 -114 Isolated Storage
tank
Atmosphere & Room Temp.
Flammable Fire hydrant
18 Caustic lye 30 15 NA NA Isolated Storage tanks
Atmosphere & Room Temp.
Corrosion Fire
Extinguishers
ASHA CELLULOSE (I) PVT. LTD
1.8.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outline
Entire industrial effluent will be recycled after RO/MEE treatment system to minimize the fresh
water consumption. Rain water harvesting shall be provided & utilized the rain water for
processing. Mix Solvent will be recycled to produce proposed new product:
SOLVENT MANAGEMENT PLANT
Mixed solvent received from granulator will be scrubbed / washed with water and scrubbed
mixed solvent will be reused in the next batch.
Pure solvent, crude solvent and recovered solvent shall be stored only in closed insulated
storage tanks and we shall not be using drums at any stage in the Solvent Management
System.
Wherever required, the solvents shall be directly pumped into day tanks from the storage tanks
and shall be charged into the reactors without involving manual handling.
All the pumps shall be mechanical seal type to avoid any leakage of solvent.
All necessary fire fighting systems shall be provided with alarm system. Flame proof wiring and
flame proof electrical accessories shall be provided to avoid any mishap.
All the storage tank and day tank shall be connected to a vent system through chilled
water/chilled brine condensers to prevent loss of solvents in the atmosphere.
All the vents of solvent handling systems & process vessels are connected to chill water/chilled
brine condensers and scrubbing system to avoid loss of solvent.
All the solvent storage tanks shall be provided with breather valves.
In process vessels nitrogen blanketing shall be provided
1.8.8 Availability of water source, Energy/Power requirement and source should be given
Availability of water its source, Energy/power required and its source is mentioned below.
Water will be sourced from own borewell. Water withdrawal permission is attached as
Annexure-4.
OVERALL WATER CONSUMPTION
No Particular Existing Proposed Total
1.1 Domestic 2.2 0.8 3.0
1.2 Industrial
1.2.1 Processing + washing 85.18 18.72 103.9
1.2.2 Boiler 40.5 14.5 55.0
1.2.3 DM Plant 5.0 9.0 14.0
1.2.4 Cooling 17.5 39.5 57.0
1.2.5 Container/floor/equipment washing , QC, R&D 1.6 0.4 2.0
1.2.6 Gardening 3.5 6.5 10.0
1.2 Total Industrial 149.78 82.12 231.9
1.3 Total 155.48 89.42 244.9
1.4 Recycle from RO/MEE 118 89.5 207.5
1.5 Net Fresh Water 37.48 0 37.48
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 18
At existing Scenario:
Presently, total water requirement is 155.48 m3/day (Fresh: 37.48 m3/day + Recycled from
RO/MEE is 118 m3/day) sourced from own bore well. For the withdrawal of water from ground,
we have already applied to CGWA for withdrawal of ground water.
Total industrial waste water generation is 123 m3/day, which is treated in primary, secondary
and tertiary treatment plant. Treated waste water is taken to reverse osmosis plant. 102
m3/day of RO permeate is recycle in the process. Balance 18 m3/day of RO rejected is taken
to MEE. 16 m3/day of MEE condensate is recycled in the process. Thus there is no discharge
of industrial effluent on land.
Domestic waste water (1.5 M3/Day) is disposed off through septic tank to ETP
WATER BALANCE DIAGRAM
WATER BALANCE AT EXISTING SCENARIO
TOTAL WATER CONSUMPTION: 155.48 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 118 m3/day)
Domestic: 2.2 Processing &Washing: 85.18
Boiler: 40.5 Cooling: 17.5 D M plant: 5.0 floor /containerwashing: 1.6
Gardening: 3.5
88.0 25.0 2.5 5.0 1.0
123.0
1.5
P/S/T ETP: 123.0 Loss: 3.0
REVERSE OSMOSIS: 120
RO Permeate recycle : 102RO Rejection: 18 MEE Salt : 2
Condensate recycle : 16
Water evaporated: 1.25 MT
Dry Salt to TSDF: 0.75 MT
After proposed expansion:
After proposed expansion, total water requirement will be 244.9 m3/day (Fresh: 37.48 m3/day
+ Recycled from RO/MEE is 207.5 m3/day) sourced from own bore well. For the withdrawal of
water from ground, we have already applied to CGWA.
Total industrial waste water generation will be 218.015 m3/day, which will be treated in
primary, secondary and tertiary treatment plant. Treated waste water is taken to reverse
osmosis plant. 181 m3/day of RO permeate is recycle in the process. Balance 32 m3/day of
RO rejected is taken to MEE. 26.5 m3/day of MEE condensate is recycled in the process.
Thus there is no discharge of industrial effluent on land.
Domestic waste water (2.0 m3/Day) will be disposed off through septic tank and overflow of
the septic tank will be discharged to ETP.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 19
WATER BALANCE AFTER PROPOSED EXPANSION
TOTAL WATER CONSUMPTION: 244.9 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 207.5 m3/day)
Domestic: 3.0 Processing &Washing: 103.9
Boiler: 55 Cooling: 57 D M plant: 14 Floor/containerwashing: 2.0
Gardening: 10
162.515
37.0 2.5 12.5 1.5
207.465
2.0
P/S/T ETP: 207.465 Loss: 4.465
REVERSE OSMOSIS: 203
RO Permeate recycle : 173RO Rejection: 30 MEE
Condensate recycle : 34.5
High TDS: 10.55 Normal: 151.965
Salt : 6.05
Water evaporated: 3.04 MT
Dry Salt to TSDF: 3.04 MT
ENERGY REQUIREMENTS AND ITS SOURCE
Sr. No.
Particulars Existing After proposed
expansion Source
1 Steam 3.8 5 Obtained from Steam boilers
POWER REQUIREMENTS AND ITS SOURCE
Sr. No. Particulars Existing After Proposed
expansion Source
1 Power –Electricity requirement, KVA
650
1000
Dakshin Gujarat Vij Co. Ltd.
1.8.9 Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal
Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal
is enclosed as Annexure-5.
1.8.10 Schematic representations of the feasibility drawing which give information of EIA purpose
A schematic representation of the feasibility drawing is enclosed as Annexure -8.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 20
1.9 SITE ANALYSIS
1.9.1 Connectivity
Site is very well connected by road i.e. N.H. No. 8 & Western Railway.
Availability of power evacuation facilities.
Availability of abundant water for industrial use .
Infrastructure like TSDF, CHWIF etc.
1.9.2 Land Form, Land use and Land ownership
The proposed expansion plant is in existing unit located in private industrial estate, Village:
Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner &
registered with district collector & revenue department. Possession letter is enclosed as
Annexure 6.
1.9.3 Topography (along with map)
The entire land is non-agriculture land. The overall project site is located on plain barren land devoid of any permanent and economically useful vegetation. The proposed expansion project is to be carried out in existing plant only. There will be no extra land required for the proposed expansion. Topography map is enclosed herewith as Annexure: 7.
1.9.4 Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given
The proposed expansion plant is in existing unit located in private industrial estate, near Water Works, Abrama, Valsad, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner & registered with district collector & revenue department.
The entire land is non-agriculture land. The overall project site is located on plain barren land devoid of any permanent and economically useful vegetation. The proposed expansion project is to be carried out in existing plant only. There will be no extra land required for the proposed expansion. There is no forest, national park, wild life sanctuary, eco sensitive areas within the 10 kms distances from the periphery of the proposed expansion project.
1.9.5 Existing Infrastructure
Major factors involved in the selection of site is based Existing Infrastructures facilities which are listed below:
Site is very well connected by road i.e. N. H No. 8 & western railway
Proximity to Raw Material suppliers
Availability of sufficient fresh water
Availability of un-interrupted electric power
Availability of skilled manpower,
Availability of full-fledged effluent treatment facility and Zero liquid discharge facility,
Well-developed infrastructure like internal roads, lights, under, TSDF, CHWIF etc.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 21
1.9.6 Soil classification
The proposed expansion plant is in existing unit located in private industrial estate, Village: Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner & registered with district collector & revenue department. We have constructed our existing plant as per plan approved by factory inspectorate. We will utilize existing plant for the proposed expansion. Only MS structure & minor construction work will be carried out. There will be no new major construction activities carried out. It will not have any major affect on the soil environment.
1.9.7 Climate data from secondary sources Rainfall Data:
The project site location receives annual rainfall of 2010 – 1200 to 1300 mm in 35 rainy days
with coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the
study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch
district and western parts of Banaskantha and Patan district and parts of Jamnagar, Rajkot and
Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400
mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and
Daman & Diu) are characterized as sub humid climate. The rest part of the state receives rainfall
between 500-1000 mm and generally fall under semi-arid climate.
Table 2: Rainfall projection for Project site and Gujarat
Sr. No.
Region Rainfall Projection (in mm) June – Oct
Normal Rainfall (In mm)
Rainfall Projection
(% Departure from normal)
1 Middle Gujarat 905.3 796 13.7
2 South Gujarat 696.3 575 21.0
3 Project site 2071.7 1433.7 44.5
4 Saurashtra 767.1 580.4 32.2
5 Gujarat State 1110.1 846.5 31.1 Source: AAU, Anand, Gujarat
Temperature Data:
The site location M/s. Asha Cellulose (I) Pvt. Limited is located in the southern part of Gujarat.
The secondary data was collected from Worldclim.org. The project site temperature regime for
medium to high level temperature (30-32°C) during the seasonal months (June to Sep). The
climate map for site location shows that temperature recorded over a month of (4
month).Coastal area from the inland site for 10 km distance, temperature recorded for this area
low to medium level. Figure showing project site for seasonal temperature in (June to
September).
1.9.8 Social Infrastructure available
Social infrastructure in Valsad district is as under :
Education: There are 990 primary and 161 secondary and higher secondary. List of Educational
Institutes schools in the district Educational Total With over 1,250 seats, there are 6 ITIs offering
several industrial training Institutes programs which includes, fitting, armature & motor rewinding,
Primary School 990 electrician, information technology and electronic system maintenance
Secondary School etc 166 Higher Secondary School, One Government polytechnic College is
present in the district offering courses in civil, chemical, electrical, mechanical and plastic
engineering,ITI’s6withanintakecapacityof360Polytechnic1CollegeWith120seats, there is
one Degree Engineering College present in Pharmacy College 2 Valsad offering engineering
courses in mechanical and chemical Engineering 1 branches College§ Located in Vapi, G. M.
Bilakhia Pharmacy College has an intake Management 1 College capacity of 60 students per year
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 22
Other Colleges Rofel Institute of Management studies in Valsad offers full time MBA Other
Colleges: Arts, Commerce, Science, B.Ed and Law College course and takes 120 students per
annum Source: Department of Education.
Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10
Government and 1 Municipal hospital present in the district. Valsad has several private specialized
hospitals to provide a comprehensive range of tertiary and secondary care services backed by
state-of- the- art technology and trained medicos A multi-specialty 21st Century Hospital, (branch
of Nadkarni Group of Hospitals) is present in Vapi, giving services in general and laparoscopic
surgery, trauma, orthopedic and urology etc. the hospital is one of the few centers in India offering
Uterine Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB)
patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital,
and Adarsh Hospital are also present in Valsad
Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also known Fire Temple as
Mecca for the Parsi community in India, makes the city a famous pilgrimage center throughout the
world Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town
with pleasant climate throughout the years The collection at the Lady Wilson Museum in
Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District
Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, has increased the
graph of tourist flow in the district.
1.10 PLANNING BRIEF
1.10.1 Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification
The proposed expansion plant is in existing unit located in private industrial estate, Village:
Abrama, Di: Valsad. We have purchased NA land in the year of 1999 from the land owner &
registered with district collector & revenue department. We have constructed our existing plant as
per plan approved by factory inspector. We will utilize existing plant for the proposed expansion.
Only MS structure & minor construction work will be carried out. There will be no new major
construction activities carried out.
1.10.2 Population Projection:
The proposed expansion plant is in existing unit located in private industrial estate, Village:
Abrama, Di: Valsad. The composition or nature of working population near plant area are as under;
Total
Population Total
Workers Main
Workers Marginal Workers
Non Workers
Cultivators Agricultural Labours
Workers in
Household Industry
Other Worker
s
Gujarat State
Total Persons 48387270 20368797 16288598 4080199 28018473 5613185 4987657 381601 9386354
Male 25208865 13870929 12920179 950750 11337936 3804880 2404180 222579 7439290
Female 23178405 6497868 3368419 3129449 16680537 1808305 2583477 159022 1947064
Rural Persons
30160219 14341413 10590157 3751256 15818806 5491522 4816260 224102 3809529
Male 15506359 8620383 7816150 804233 6885976 3707298 2301215 141209 2470661
Female 14653860 5721030 2774007 2947023 8932830 1784224 2515045 82893 1338868
Urban Persons
18227051 6027384 5698441 328943 12199667 121663 171397 157499 5576825
Male 9702506 5250546 5104029 146517 4451960 97582 102965 81370 4968629
Female 8524545 776838 594412 182426 7747707 24081 68432 76129 608196
Valsad District
Total Persons 1410680 650604 503506 147098 760076 184837 154395 9495 301877
Male 734945 422476 381574 40902 312469 103034 66885 5204 247353
Female 675735 228128 121932 106196 447607 81803 87510 4291 54524
Rural Persons
1029294 507973 369190 138783 521321 182878 150425 7581 167089
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
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Male 526285 301309 264317 36992 224976 101610 64529 4065 131105
Female 503009 206664 104873 101791 296345 81268 85892 3516 35984
Urban Persons
381386 142631 134316 8315 238755 1959 3970 1914 134788
Male 208660 121167 117257 3910 87493 1424 2356 1139 116248
Female 172726 21464 17059 4405 151262 535 1614 775 18540
Valsad Taluka
Total Persons 385159 158263 129314 28949 226896 27911 36242 2618 91492
Male 198064 109730 100920 8810 88334 16609 16909 1512 74700
Female 187095 48533 28394 20139 138562 11302 19333 1106 16792
Rural Persons
222550 104648 78779 25869 117902 27437 35125 1908 40178
Male 113632 65465 58380 7085 48167 16225 16120 1137 31983
Female 108918 39183 20399 18784 69735 11212 19005 771 8195
Urban Persons
162609 53615 50535 3080 108994 474 1117 710 51314
Male 84432 44265 42540 1725 40167 384 789 375 42717
Female 78177 9350 7995 1355 68827 90 328 335 8597
Vapi (M)
Total Persons 71395 29655 28719 936 41740 141 161 149 29204
Male 41608 26478 26059 419 15130 115 119 78 26166
Female 29787 3177 2660 517 26610 26 42 71 3038
Vapi (INA)
Total Persons 23845 8538 8284 254 15307 2 19 86 8431
Male 13141 7648 7579 69 5493 2 10 33 7603
Female 10704 890 705 185 9814 0 9 53 828
There are 8 Talukas fall in Valsad District which is 5135 km2 in area. Pardi Taluka has an area of 425.89 km2 and has 79 villages and two towns. 75% of its population is tribal. 0.87 % of the area fails under forest category. Demographic details of Pardi Taluka are presented as follows:’
DEMOGRAPHIC DETAILS OF PARDI TALUKA
PARTICULARS RURAL URBAN TOTAL
Area in Sq, Km. 395.67 30.22 425.89
No. of Houses 37554 15146 52700
No. of Occupied Houses
36105 13429 49534
Total Population 206345 65874 272219
Male population 105722 35147 140869
Female Population 100623 30727 131350
Male Literates 71160 26672 97832
Female Literates 47630 19050 66680
Population per Sq. Km.
521.5 2179.81 639.17
Basic Information on population in villages around the plant site is presented as follows;
BASIC INFORMATION ON POPULATION
Sr.
No Village
Area in Hec
Population No. of
House
Holds
Occupied
Residential
Houses Total M F
1. Saron 308.77 951 471 480 203 203
2. Abrama 31.20 907 472 435 190 190
3. Tukwada 814.35 3832 1939 1893 763 763
4. Vashier 801.64 4046 2163 1883 736 580
5. Gundlav 402.58 34831 1774 1709 694 682
Population trend showing growth rate, sex ratio and literacy rate in Valsad district are as follows;
Prefeasibility Report ASHA CELLULOSE (I) PVT. LTD
Page 24
Total Population
1) Persons
2) Male
3) Female
1137801
566802
573999
1428742
715473
713269
1774136
895313
878823
2173672
1110632
1063040
Decimal Growth + 21.38 + 25.57 + 24.17 + 22.52
Sex Ratio
(No. of Female per 1000
Males)
1012 996 981 957
Note :
Decadal growth in population is 22.52%.
Sex ratio females to males have decreased to 957 females per 1000 men.
The population in Valsad area is cosmopolitan and education level is high.
Socio-cultural conditions are greatly influenced by literacy. Literacy rate in this region has increased. The literacy rate was 15% in 1961. It grew to 27% in-1 971, then to 42% in 1981 and to 54.3% in 1991.
Note :
1). Average Population Density : 639.20 persons /sq. km.
2). Population in Rural Areas : 75.00%
3). Population in Urban Areas : 25.00%
1.10.2 Land use Planning (breakup along with green belt etc)
Agro – climate
The study area forms part of the Agro – climaticzonedesignatedas“SouthGujaratHeavyRainfall
Zone” comprising Valsad, Dang, etc. It receives intensive rains of over 1500mm and at times
touches 2000 mm per annum. Major part is received in July and August. According to National
Bureau of Soil Survey and Land Use Planning, Nagpur, the study area forms a part of humid to per
humid ecosystem with red lateritic soils – having a growth period of (GP) 210 and more days. This
zone“19” isabbreviated“E2BA5”ontheAgro– Ecological Region Map. The study area has red
lateritic type of soil on basaltic hills but alluvium is blackish clayey derived from basalt.
Physiography, Relief, Drainage and soils
The study area formspartof“Zonea(1)“comprisinghillyareasofValsaddistrict.Thishillyarea
sub-zone consists of hilly tracts with undulating hills varying in elevation ranging form 60 to 90 in
above the mean sea level (MSL). While flatter areas are about 25-26m above msl. The soils of this
hilly tract are not typical lateritic, whereas plains have clayey soils have developed from trap. A
thick detritus material forms pediment. The general slope direction is from south-east to north-west
and the drainage pattern is linear dendrite.
Soils are slightly shallow in the hills whereas, deep black mild to slightly alkaline silty clays in the
plain, Alluvium is yellow red neutral to moderately alkaline highly calcareous clayey soils.
Geology
According to geological Map of India (1993), the study area forms part of Cretaceous –
Palaeogene: Basic(Bkpg). In general, the study area is covered by Deccan trap (Basalt) with
dykes. At places, it is covered by marine alluvium.
Land use and Agriculture
It is an agrarian ecosystem with potential impact of industrialization. It is also reflected in prepared
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land use / land Map showing 68% area under agriculture while the built up area is quite high of
22%. The double-cropped area is quite high in agriculture: while, second highest are the mango
plantation mixed with agriculture. Shallow hilly soils grow Negli (ragi Eleusine coracana), Kodra
Paspalum scrobiculatum), Banti (Echinochlo/stagnina), Wari (Panicum miliare) and Chino
(Panicum millirea). Rice is the major crop. Other important crops are sorghum, groundnut tur, other
pulses, and cotton. Fruit crops like banana, mango coconut, sapota and sugarcane are common.
Natural Vegetation
According to Champion and Seth (1968), the study is falls under the “Tropical dry (mixed)
deciduous forest”.Thereisnotionalpatchofreserveforest,howeversomescrubforestisseenin
pockets. Some of the common trees found in this area are Mango, Chiku, Casuarinas equisetifolia,
Eucalyptus hybrid, Paltophorum pterocarpum, Thuja occidentals Acacias spp. Azadirachta indica,
Gliricidia sepium, Some of the common grasses found in this area are Dicanthium annulatmm,
Vitevera, Cenchrus clitoris, etc.
Land use, land cover classification system
S.No. Level I S.No.
NNo.
No.
Level II S. No. Level III Map
Symbols 1 Built-up Land 1.1 Town/Cities 01
1.2 Villages 02
2 Agricultural Land 2.1 Agricultural
Land
2.1.1 Kharif 03 2.1.2 Rabi 04
2.1.3 Double 05
2.2 Fallow 06
2.3 Plantations 07
3 Forest 3.1 Evergreen/Semi
Evergreen
3.1.1 Dense 08 3.2 Deciduous
(Moist & Dry)
3.1.2 Open 09
3.2.1 Dense 10
3.2.2 Open 11
3.3 Scrub Forest 12
3.4 Forest Blank 13
3.5 Forest
Plantation
14
3.6 Mangrove 15
4 Wastelands 4.1 Salt affected
land
16 4.2 Waterlogged
Land
17
4.3 Marsh /
Swampy Land
18
4.4 Gullied and
Ravenous Land
19
4.5 Land with Scrub 20
4.6 Land without
Scrub
21
4.7 Sand area
(Coast and
desertic)
22
4.8 Mining and
Industrial waste
23
4.9 Barren rocky/
Stony waste /
Sheet
24
5 Water Bodies 5.1 River / Stream 5.2 Canals
5.3 Lake /
Reservoir /
Tanks
25
6. Others 6.1 Shifting
Cultivation
26 6.2 Grassland 6.2.1 Dense 27
6.2.2 Open 28
6.3
Salt Pan 29
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6.4 Mud 30
Image Characteristics of different Land Use/Land cover classes
S.No. Mapping Unit Brief Description Image Characteristics
1 Built-up area 1.1 Residential Light bluish with very faint white
brownish mottles reddish
pixels are of avenue trees.
1.2 Industrial
Smooth, blue, blackish, reddish
tone good street network
regular shape
1.3 Recreational, Parks./Green
belts etc.
Smooth red, regular shape
within city area
1.4 Vacant Under developed Smooth whitish brownish.
Regular pattern.
2.0 Villages Deep blue, irregular pattern
surrounded by agriculture lands
and small water bodies,
connected by roads with other
villages
2 Agriculture 5 Double cropped land) Smooth, red mixed with small
vacant parcels of greenish
brownish and whitish trees.
6 Fallow lands Whitish gray parcels within
smooth regular red agri, land.
7 Plantations
& Agriculture Mixed
Dark brownish red, violet
smooth & regular.
3 Forest 10 Dense forest Dark, radish brownish, smooth
13 Scrub Land Brownish/ Light, Mattled,
Pinkish
14 Forest Plantation Dark, radish brownish, smooth
Regular.
4 Waste Land 17 Water Logged Dark, blackish, red, irregular.
19 Gullied Lands Light bluish,
22 Sand Whitish or blackish
24 Stony/ rocky Bluiesh & Blakish irregular
5 Water Bodies 25 Tank/ pond Dark, black with reddish tinge of
phytoplankton’s (Water loving
Plant)
6 Others 27 Grass Land Light brownish, smooth.
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The detail description of each land use category in terms of their defilation, image characteristics
are given below:
Agricultural Land
These areas are agricultural lands used for growing at least 2 crops in a year .
Fallow land
These are agricultural lands, which are taken up for cultivation but are temporarily allowed to
remain uncropped. The texture is medium to coarse due to surface irregularities.
Mixed – Plantations
It covers plantation agriculture orchards and horticultural nurseries. They mixed with agriculture
appear as dark red, small to medium in regular size and shapes. Extension in this area:
LAND USE CATEGORY
Level I Level II
Category Name Area Sq.
K.M
% Sub Category Name Area
(Sq.Km)
%
1 Built up area 34.1 22.15 Town /Cities
1.1 Residential
1.2 Industrial
1.3 Recreational
1.4 vacant
2 villages
8.3
19.1
0.4
4.5
1.8
5.39
12.41
0.26
2.92
1.17
Sub Total 34.1 22.15 Sub Total 34.1 22.15
2 Agriculture 106.0 68.87 5 Double Crop 64.0 41.58
6 Fallow Lands 16.5 10.72
7 Agri + Plantations 25.5 16.57
Sub Total 106.0 68.87 Sub Total 106.0 68.87
3 Forest 0.6 0.38 10 dense
12 scrub lands
14 plantation
0.3
0.2
0.1
0.19
0.13
0.6
Subtotal 0.6 0.38
4 Waste lands 11.7 7.63 17 Seasonally water
logged
19 Gullied
21 undulating upland
without scrub
River (Sand)
24 Stony/Rocky
0.3
0.7
10.1
0.2
0.4
0.19
0.45
6.60
0.13
0.26
Sub Total 11.7 7.63 Sub Total 11.7 7.63
5 Water bodies 0.5 0.32 Ponds/Tank 0.5 0.32
Sub Total 0.5 0.32 Sub Total 0.5 0.32
6 Others 1.0 0.65 Grass land 1.0 0.65
Sub Total 1.0 0.65 Sub Total 1.0 0.65
Grand Total 153.9 100.0 Grand Total 153.9 100.0
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SITE PLAN WITH AREA TABLE
S.No. Area Description Area in Sq.M %
Existing Proposed Total
1 Process Plant area 2420 800 3220 10.10
2 RM Storage 500 100 600 1.88
3 ETP , RO, MEE & HW Storage 885 150 1035 3.25
4 Ethyl Chloride/ Methyl Chloride Storage 150 1050 1200 3.76
5 Office Building 602 0 602 1.89
6 Utilities 547 400 947 2.97
7 Engineering Store 455 0 455 1.43
8 Roads 3355 0 3355 10.53
9 Open Area 16635 -6300 10335 32.42
10 Green Belt 6325 3800 10125 31.77
11 Total 31874 6300 31874 100.00
1.10.3 Site map with Green Belt Development Planning
It is given as Annexure 2.
1.10.4 Assessment of Infrastructure demand (Physical & Social):
Employment would be as per prevailing norms of state government for skilled and unskilled
people for the proposed new 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
1.10.5 Amenities/ Facilities
Following gives details of amenities available in Valsad District. This is somewhat lower than
normally required. This deficit is, however, bridged by a large number of dispensaries, health care
units and secondary health centres. There are many family welfare centres. Educational facilities
are fairly good. All villages have electricity.
EXISTING CIVIL AMENITIES IN THE DISTRICT
EDUCATION MEDICAL PUBLIC
TRANSPORT
FACILITY
WATER
SUPPLY
POST &
TELEGRA-PHS
P&MS : 1656
H/HSC : 244
Colleges : 21
Total : 1921
Literacy :
Male : 62.03%
Female: 54.27%
Libraries : 323
H : 11
PHC : 60
No. of Beds :
999
Doctors : 108
Nurses : 727
No of Vehicles :
425/day (Avg)
Villages Connected
with all Weather roads :
693
OPW
BW
RIVERS
DAMS
CANALS
HAND-
PUMPS
Post
Offices :
473
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P&MS = Primary & Middle School
H/HSC = Higher School & Higher Secondary
H= Hospital
PHC= Primary Health Center
OPW= Open well
BW= Bore-well
Valsad town has good and adequate facilities. Good water is supplied by municipal water works
Abrama. Adequate power is available from Dakshin Gujarat Vij Company Ltd. (DGVCL). Good
hospitals and adequate dispensaries with well-qualified doctors are available. Good
communication systems, fire brigades etc. are available.
1.11 PROPOSED INFRASTRUCTURE
1.11.1 Processing Area
The proposed expansion plant is in existing unit located in private industrial estate, near Water
Works, Abrama, Valsad, Di: Valsad. We have purchased NA land in the year of 1999 from the land
owner & registered with district collector & revenue department. We have constructed our existing
plant as per plan approved by factory inspector. We will utilize existing plant for the proposed
expansion. Only MS structure & minor construction work will be carried out. There will be no new
major construction activities carried out.
1.11.2 Residential Area (Non Processing Area)
The proposed expansion plant is to be carried our in existing plant only. There is no residential
area nearby the plant.
1.11.3 Green Belt
M/s. ACIPL is located in private industrial area, near Water Works, Abrama, Valsad, Di: Valsad. The unit has already developed about 6325 m2 of area as a green belt & also proposed to develop additional area i.e. 3800 m2 for green belt. In addition to this, majority of the vacant land shall be
planted with trees and grasses.
1.11.4 Social Infrastructure
Depending on the growth of the company the required social infrastructure will be provided
1.11.5 Connectivity (Traffic and Transportation Road/Rail/ Metro/ Water ways etc)
Major factors involved in the selection of site are listed below:
Site is very well connected by road N.H No. 8, western railway
Proximity to Raw Material suppliers
Developed infrastructure TSDF, CHWIF, internal road, lights, fresh water, power
Availability of power evacuation facilities
1.11.6 Drinking Water management (Source & Supply of water)
Water requirement will met through own existing bore well.
1.11.7 Sewerage System:
For the domestic effluent, we have provided adequate capacity of septic tank/soak pit to ETP. After proposed expansion, the entire treated effluent will be recycled in the process, thus there will be no
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discharge of any industrial effluent on land.
1.11.8 Industrial Waste Management:
For the domestic effluent, we have provided adequate capacity of septic tank/soak pit to ETP. After
proposed expansion, the entire treated effluent will be recycled in the process, thus there will be no
discharge of any industrial effluent on land.
1.11.9 Solid/Hazardous Waste Management:
Sr. No.
Process waste Category Source Quantity, TPA Mode of
disposal Existing Proposed Total
1 Used oil Sch: I/5.1 Machineries/ D.G.Set
0.092 0.018 0.11 Incineration at common
incineration system of M/s
BEIL, Ankleshwar /
sold to authorized recyclers
2 Discarded containers/bags
Sch: I/33.1
Raw Material Storage area & Utility Area
50 12 62 reused for packing of solid waste or sold to
registered recyclers
3 ETP waste Sch: I/35.3
ETP 109 21 130 Disposed off into TSDF site of M/s
BEIL, Ankleshwar or
VGEL, Vapi
4 MEE waste Sch:I/35.3 MEE 234 714 948 Disposed off into TSDF site of M/s
BEIL, Ankleshwar or
VGEL, Vapi
5 Dust from air filtration system
Sch:I/26.2 air filtration system
0.22 0 0.22 Recycled in process
6 Salt from process
Sch:I/26.1 Manufacturing process
1703
0
1703
Disposed off into TSDF site of M/s
BEIL, Ankleshwar or VGEL, Vapi.
7 Mixed Solvent from the process
Sch:I/26.4 Manufacturing process
1787.44
9.98 + 51.96 (vent
condenser and
HPMC product)
1849.38
61.9
1787.44 MTPA of mix solvent from solvent process and
aqua process will be utilized
for manufacture of Ethyl chloride product within the premises and balance 61.9 MTPA of
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mixed solvent will be sold to
actual distillator
8 Distillation Residue / & Laboratory organic waste
Sch:I/26.1 Manufacturing process
23.0 - 18.78 4.22 Collection, storage
transportation, disposal to BEIL
incineration facility.
9 Spent carbon from ETP &
Chimney
Sch:I/36.2 ETP/Chimney 4.8 1.2 6.0 Collection, storage
transportation, disposal to BEIL
incineration facility.
10
Date-Expired, Discarded and off-specification Material & floor sweeping
Sch:I/28.5
Product Storage area
1.0
1.0
2.0
Collection,
storage transportation,
disposal to BEIL incineration
facility.
11 Spent Filter cloth & filter
material
Sch:I/36.2
From process plant
1.0
0
1.0
Collection,
storage transportation,
disposal to BEIL incineration
facility.
12 Spent Resins from D M plant
Sch:I/35.2 D M plant 1.0 0.2 1.2 Collection, storage
transportation, disposal at TSDF/BEIL Collection,
storage transportation,
disposal at TSDF/BEIL
13 Used hot & cold insulation material
Schedule: X/02
Manufacturing process
0.5 0.1 0.6 Collection, storage
transportation, disposal at TSDF/BEIL
14 Weak caustic soln (18-20%
Sch: II/C2 Manufacturing process
17723 0 17723 Sell to actual/authorized
users
Solid Waste
15 Fly ash - Boiler 0 179 179 Sell to Brick manufacturer
1.11.10 Power Requirement & Supply / Source
Power requirement for proposed project will be taken from DGVCL.
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1.12 REHABILITATION AND RESETTLEMENT (R&R) PLAN
1.12.1 Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given)
The proposed expansion plant shall be carried out in existing plant, located at village: Abrama, Di;
Valsad. The existing plant is already developed with all infrastructure facilities in the year of 1999,
thus there will be no re-habitation and re-settlement on the proposed expansion project, so R & R
policy is not applicable to this project.
1.13 PROJECT SCHEDULE & COST ESTIMATES
1.13.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given)
After obtaining Environmental clearance, the company shall start the proposed minor construction
and provide necessary hardware. The production is likely to commence within 3 to 4 months after
obtaining EC.
1.13.2 Estimated project cost along with analysis in terms of economic viability of the project:
Estimated project cost along with the analysis in terms of economic viability of the project is given as below;
Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads considered in the Capital Cost Projection for the proposed expansion project. Environment Protection has also been considered in planning the Cost Projection, which will include Green belt development, safety systems, etc
CAPITAL COST PROJECTION
S. No. Particulars Existing,
Lakhs Proposed,
Lakhs Total, Lakhs
1.0 Land 31874 m2 76.4 0 76.4
2.0 Building 216.75 350 566.75
3.0 Plant & Machinery
3.1 Equipment & machineries 733.58 850 1583.58
3.2 Pipes, fittings, lagging, electrification
210.86 150 360.86
3.3 Laboratory equipments 44.18 20 64.18
4.0 Environmental Management System
4.1 Effluent treatment plant 205.5 35 240.5
4.2 Air pollution control measures 16 8 24
4.3 Hazardous waste management system (MEE Plant)
13.0 125 138
5.0 Total Project Cost 1516.27 1538 3054.27
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PROJECT VIABILITY
Sr. No.
Particulars Amount in Rs.Lakhs
Product Ethyl
cellulose HPMC
Ethyl Chloride
Methyl Chloride
1 Proposed Sale 4000 3500 950 484
2 Raw Material Cost* 2038 1754 670 306
3 Power & Fuel 484 425 36 28
4 Labor Cost 480 432 28 28
5 Environmental Management
System 102 90 14 8
6 Maintenance Cost 124 108 18 18
7 Selling, packing & Office
Expenses 55
48 6 6
8 Proposed Gross Profit 717 643 178 90
* Presently Ethyl chloride (one of the raw materials) is being purchased from various local
manufacturers and we are finding stiff competition in domestic as well as export market to match Ethyl cellulose price against Chinese make product. By producing Ethyl Chloride in house as backward integration we can contribute good foreign exchange revenue to the country. Also we can sell Ethyl chloride in local market to sustain current profitability in view of prevailing rise in the prices of all commodities & service sectors. HPMC is also an import substitute like Ethyl cellulose. HPMC is also widely used in pharmaceutical industry along with Ethyl cellulose. HPMC can be more competitive against imported product particularly if we produce on our own one its major raw material Methyl Chloride. The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budget.
The company will provide budgetary provision for the recurring/operating expenses for
environmental issues while planning the allocation of funds during the annual budgetary planning.
RECURRING/OPERATING COST PER ANNUM
Sr. No. Component Proposed (Rs. In
Lakhs/annum
1. Environment & Safety Management System 200
2. Greenbelt Maintenance 4
3. Solid waste Disposal 10
Total 214
1.14 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
1.14.1 Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area:
Proposed expansion will provide benefits to the local people in terms of financial and social welfare.
Local people will get direct financial benefit by way of employment.
Local people will get some contracts of supply and services to get indirect income.
Company will contribute in social upliftment programs by the way of improving
education and health facilities in nearby area.
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ANNEXURES
ASHA CELLULOSE (I) PVT. LTD
ANNEXURE 1 LOCATION MAP SHOWING THE PROJECT SITE
The map showing general location, specific location and project boundary and project site layout of
M/s Asha Cellulose (I) Pvt. Limited, is located at S. No. 302/P, 303/2, 273/2, 275/1, Near Water
Works, Abrama, Valsad-396001, Ta: Dist: Valsad, Gujarat. The location of the project site can be
viewed in following figure.
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ANNEXURE 2 PLANT LAYOUT
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ANNEXURE 3 MANUFACTURING PROCESS
Ethyl Cellulose (Aqua Process) (Existing):
The bleached Cotton Linter / Wood Pulp are fed to a shredding mill. The shredded Bleached Cotton
Linter or Wood Pulp is charged into rector containing Caustic solution, through alkali cellulose tank
and screw conveyor. The reactor is a jacketed and agitated type autoclave. The temperature, time
and concentration depend on the intrinsic viscosity desired in the product. The required amount of
diluents (crude solvent) and ethyl chloride are added to the alkali pulp and viscosity is controlled by
air as an oxidizing agent.
The reaction is carried out in jacketed and agitated autoclave. Ethyl Chloride and crude solvent are
also charged along with Caustic during the course of reaction if necessary. The reactor content is
heated by passing steam through jacket. Working pressure of about 23 Kg / cm2 is obtained
maximum and the reaction is continued till the desired Degree of Substitution of Ethyl Cellulose is
obtained. After completion of reaction, Ethyl cellulose gets separated from solvent, salt, water &
sodium hydroxide. Solvent mixture along with water is stripped off from the reactor, which is purified in
distillation column, part of it is used in the process and remaining is sold off.
As the solvent is removed, ethyl cellulose precipitates in the liquor containing caustic and salt. The
slurry is then discharged from the reactor in to a holding tank, where alkali solution along with salt is
recovered. After giving adequate water wash, the product is neutralized by the addition of acid and
centrifuged. Wet ethyl cellulose is subjected to wet grinding in hammer mill. After grinding, the
material is discharged into to washing tank for further purification. After purification, the slurry is
subjected to centrifuging for maximum water separation and wet cake is fed to a spin flash dryer.
Dried product is packed in Fibre Drum / Paper Bags.
CHEMICAL REACTION:
Main Reaction :
C6H7O2(OH)3 + C2H5Cl + NaOH -------------> C6H7O2(OH)3 + NaCl + H2O 162 64.5 40 232 58.5 18
Reaction Mole Balance :
Reaction C6H7O2(OH)3 + 2.5 C2H5Cl + 2.5NaOH --> C6H7O2(OC2H5)2.5(OH)0.5 +2.5 NaCl +2.5 H2O M. Wt. 162 161.25 100 232 146.25 45
Name Wood Pulp Ethyl Chloride Sod. Hydroxide Ethyl Cellulose Sodium Chloride Water
Side Reaction :
1 : Ether Formation :
Reaction : 2C2H5Cl + 2 NaOH --------> (C2H5)2O + 2NaCl + H2O
M. Wt. 129 80 74 117 18
Name Ethyl Chloride Sodium Hydroxide Diethyl Ether Sodium Chloride Water
Total 209 ----------> 209
2 : Ethyl Alcohol Formation :
Reaction C2H5Cl + NaOH ----------> C2H5OH + NaCl
Mol. Wt. 64.5 40 46 58.5
Name Ethyl Chloride Sodium Hydroxide Ethyl Alcohol Sodium Chloride
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MASS BALANCE WITH FLOW DIAGRAM:
FLOW DIAGRAM OF ETHYL CELLULOSE BY AQUA PROCESS
REACTION(AUTOCLAVE
FILTRATION &NEUTRALIZATION
GRINDING &CENTRIFUGE
WASHING
FINAL WASHING &CENTRIFUGING
DRYING: 424.8 kgs
ETHYL CELLULOSE : 260 KG
NaOH Prills : 1400 kg
Water : 854 kg
Wood pulp : 210 kg(Wood pulp: 185.5 kgs
Water: 24.5 kgs)
CAUSTIC SOLN.PREPARATION
SHREDDING& MIXING
Ethyl chloride : 875 kg
Diluents : 284 kg
Mixed solvent to Scrubbing : 732 kg
(EC + EA +Ether +water)
Recycle from Ethyl ChlorideIncineration :
448 kg
Water : 3600 kg
Water : 2400 kg
Water : 4500kg
Acetic acid : 1.02kg
Water : 2233.38 kg
Weak alkali (18-20%) sell : 4800 kg
Eff. To ETP : 2400 kg
Eff. To ETP : 4500 kg
Eff. To ETP : 3500 kg
Drying loss : 164.3 kg
Drying loss : 0.5 kg
Total 104.5 -------------> 104.5
3 : Residual Sodium Hydroxide neutralization with Acetic Acid
Mol.Wt. 60 40 82 18
Name Acetic Acid Sodium Hydroxide Sodium Acetate Water
Total 100 --------- > 100
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Ethyl Cellulose (Solvent Process) (Existing):
The bleached cotton linters or Wood Pulp sheet (Cellulose) is dipped in aqueous Caustic solution and
passed through squeeze rollers to remove excess Caustic solution. Then the Alkali Cellulose sheet is
fed to a shredding mill. The shredded Alkali Cellulose is charged into an autoclave containing Toluene
through a mixer and conveyor. This autoclave is jacketed & limpet coiled agitated vessel. The
temperature, time and concentration depend on the intrinsic viscosity desired in the final product. The
required amount of diluents (Toluene / Recycled Solvent mixture) and Ethyl Chloride are added to
Alkali Cellulose. The viscosity is controlled by air as an oxidizing agent.
The reactor contents are heated by passing steam through limpet coil. Ethyl Chloride, Toluene along
with Caustic Flakes / Prills is also charged during the reaction as per requirement. A working pressure
in the range of 10 to 12 Kg / cm2 is obtained and reaction is continued till the desired Degree of
Substitution of Ethyl Cellulose is achieved. After completion of reaction, the unconverted ethyl
chloride and by-products are recovered and reused in the next batch. The viscous reaction product is
discharged into settling tank.
Adequate quantity of recycled solvent mix is added and total mass is mixed thoroughly and
neutralized. The mass is allowed to settle for couple of hours. The upper layer is passed through a
filter press. The salt mass is washed with recycled solvent and washed salt is fed to an ANFD. The
solvents present in the salt are recovered and re used for dilution or sold to actual users. The dried
salts shall be sent to TSDF or partly go for sale if possible. The filtrate from filter press is fed to a
granulator containing water. Live steam is introduced to precipitate Ethyl cellulose and to strip off
organic solvents.
The organic solvents recovered from granulator are scrubbed with water and Toluene is reused in the
next batch. The precipitated Ethyl Cellulose slurry is transferred to washing tanks where the product
is given hot water washes and pH of the product is corrected in the range of 5.5 to 7.5.
The purified Ethyl cellulose is centrifuged in basket type centrifuge and the wet cake is fed to Spin
Flash Dryer. The dried product is passed through a compactor to improve bulk density if required and
packed in Paper Bags or Fibres Drums as per requirement.
CHEMICAL REACTION: Main Reaction :
C6H7O2(OH)3 + C2H5Cl + NaOH -------------> C6H7O2(OH)3 + NaCl + H2O
162 64.5 40 232 58.5
18
Reaction Mole Balance :
Reaction C6H7O2(OH)3 + 2.5 C2H5Cl + 2.5NaOH ----> C6H7O2(OC2H5)2.5(OH)0.5 +2.5 NaCl +2.5 H2O M. Wt. 162 161.25 100 232 146.25 45
Name Wood Pulp Ethyl Chloride Sodium Hydroxide -> Ethyl Cellulose Sodium Chloride Water
Side Reaction :
1 : Ether Formation :
Reaction : 2C2H5Cl + 2 NaOH --------> (C2H5)2O + 2NaCl + H2O
M. Wt. 129 80 74 117 18
Name Ethyl Chloride Sod. Hydroxide Diethyl Ether Sodium Chloride Water
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
Page 40
Total 209 ----------> 209
2 : Ethyl Alcohol Formation :
Reaction C2H5Cl + NaOH ----------> C2H5OH + NaCl
Mol. Wt. 64.5 40 46 58.5
Name Ethyl Chloride Sodium Hydroxide Ethyl Alcohol Sodium Chloride
Total 104.5 -------------> 104.5
3 : Residual Sodium Hydroxide neutralization with Acetic Acid
Reaction : CH3COOH + NaOH ---------> CH3COONa + H2O
Mol.Wt. 60 40 82 18
Name Acetic Acid Sodium Hydroxide Sodium Acetate Water
Total 100 --------- > 100
FLOW DIAGRAM OF ETHYL CELLULOSE BY SOLVENT PROCESS
DIPPING BATH
REACTION(AUTOCLAVE)
DILUTION & NEUTRALIZATION
FILTRATION / CENTRIFUGE
NaOH : 2646 kgWater : 954 kg
NaOH Prills : 2700 kg
Ethyl Chloride : Fresh : 7200 kg
Recycled Solvent :30169.4 kgsEthyl Chloride: 2400 kgs
Toluene : 27560 kg
Di Ethyl Ether : 120 kgsEthanol : 44.7 kgWater:44.7 kgs
SDS: 600 kg
Toluene : 8000 kg
Wood pulp : 2550 kg
Vent Losses: 271.55 kgs
Mixed Solvent for Distillation: 12935.7 kgsEthyl Chloride : 2724 kg
Toluene : 7824 kgDi ethyl ether : 2096 kg
Ethanol : 182.7 kgWater : 109 kg
Wet Cake : 10881.7 kg
Toluene: 1240 kg
Cooling watercondenser
Upper layer: 7500 kgs to reactor
Bottom layer: 75 kgs to ETP
Chilled watercondenser
Mixed solvent: 2453 kgs for
ethyl chloride
Chilled Brinecondenser
Column Top : 2484.9 kgs to reactor
Bottom : 151.25 kgs residue recycle for
Ethyl Chloride
Recycled Toluene: 6000 kg
Acetic Acid: 1835 kg
Dry in ANFMixed solvent: 1785.5 kgs for
ethyl chloride
Solvent loss: 69.2 kgs
Solid waste: 9027 kgs
GRANULATION
WASHING
CENTRIFUGING: 27029 kgs
DRYING: 5029.2 kgs
ETHYL CELLULOSE : 3065 KG
Steam : 24000 kg
Water : 42000 kg
Mixed Solvent : 33154 kg
SCRUBBERWater : 22988 kgs to ETP
Fresh Water : 12000 kg
Water Evaporation : 1957.84 kg
Water : 34000 kg
Dry Powder Losses : 6.36 kg
Solvent loss: 217.3 kgs
Solvent loss: 56 kg
Toluene: 26110 kgs recycle
Hot Water : 62336 kg
Recycled Water : 18000 kg Water : 16000 kg
Water : 118032 kgs to ETP
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
Page 41
Manufacturing Process of Aqueous Ethylcellulose Dispersion- Non Plasticized
Raw Materials / Additives: Ethylcellulose, Dichloro Ethane or Dichloro Methane, Toluene, Acetone,
Water, Sodium Laurel Sulphate, Cetyl Alcohol, Defoamer, Hydrogen Peroxide
Manufacturing Operations: Mixing, Coarse Dispersion, Fine Dispersion, Solvent Recovery and
Packing & Storage of finished product.
Preparation of Par1 & Part 2 Solutions: Homogenous solution of Ethylcellulose is prepared by
dissolving Ethylcellulose and Cetyl Alcohol in Dichloro Ethane / Dichloro Methane / Toluene / Acetone.
Sodium Lauryl Sulfate solution is prepared by dissolving SLS in water.
Pre – mixing & Coarse Dispersion: Both solutions are mixed and passed through coarse disperser
to achieve homogenous dispersion. Antifoam agent is added as per requirement.
Fine Dispersion: The above dispersion is passed through a fine disperser mill to achieve desired fine
dispersion.
Recovery of solvent: The fine emulsion is charged in a stripping pot and Dichloro Ethane or Dichloro
Methane / Acetone are stripped off to achieve finished product of non plasticized Ethylcellulose
Aqueous dispersion. Hydrogen Peroxide and defoamer are added before filling the product in HDPE
carboys.
Usage of Ethylcellulose Aqueous Dispersion Non - Plasticized:
Control release of drug
As seal coat
Taste Masking agent
Moisture barrier coat
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
Page 42
MASS BALANCE FOR ETHYL CELLULOSE DISPERSION NON PLASTICIZED
PRE- MIXING VESSEL: 1(308 Kgs)
Cetyl Alcohol: 8 kgsEthylene Di Chloride (Recovered): 222 kgsEDC/MDC (Fresh): 8 kgsEthyl Cellulose: 70 kgs
PRE- MIXING VESSEL: 1(310 Kgs)
Sodium Lauryl Sulfate: 4 kgsWater (fresh): 186 kgsWater (recovered): 120 kgs
MIXING VESSEL(618 Kgs)
FINE DISPERSION(618 kgs)
EDC loss: 2 kgsWater loss: 2 kgs
FINE DISPERSION RECEIVER(Total 614 kgs) [ Ethyl cellulose: 70 kgs
+ EDC/MDC: 228 kgs + Cetyl Alcohol: 8 kgs + Sodium lauryl sulfate: 4 kgs + water: 304 kgs]
SOLVENT STRIPPING POT (614 kgs)
FINAL PRODUCT: 258 kgs(Ethyl Cellulose: 70 kgs + Cetyl Alcohol: 8 kgs
+ Sodium Lauryl sulfate: 4 kgs + Water: 176 kgs)
PRIMARY/SECONDARY CONDENSOR : (356 kgs)
EDC loss: 6 kgsWater loss: 8 kgs
SEPARATION (342 kgs)
RECOVERED EDC/MDC: 222 kgsRecovered Water: 120 kgs
Manufacturing Process of Aqueous Ethylcellulose Dispersion- Plasticized
Raw Materials / Additives: Ethylcellulose, Ammonium Hydroxide, Medium Chain Triglicerides /
Plasticizers (Dibutyl Sebacate, PEG etc), Oleic Acid and water.
Ethylcellulose is blended with Oleic Acid and plasticizers in a mixing vessel thoroughly. The mixture is
homogenized by passing through extruder and heated to the melting temperature. The molten
plasticized Ethylcellulose solution is then emulsified with ammoniated water in a high shear mixing
device under pressure to form the dispersion of plasticized Ethylcellulose particles. Additional Water
is then added to achieve the final solids content.
Usage of Ethyl cellulose Aqueous Dispersion Plasticized:
Control release of drug
As seal coat
Taste Masking agent
Moisture barrier coat
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
Page 43
Ethyl cellulose Aqueous Dispersion
Ethyl cellulose Aqueous Dispersion is being used in pharmaceutical industry for tablet coating
specifically for sustained / delayed release applications, as binder, taste masking agent, seal coat,
moisture barrier coat etc.
This product is produced by two methods.
1. Ethyl cellulose Aqueous Dispersion – Non Plasticized
2. Ethyl cellulose Aqueous Dispersion – Plasticized
Ethyl cellulose Aqueous Dispersion – Non Plasticized:
Ethyl cellulose is water insoluble product. It is soluble in almost all solvents. It is very difficult to
disperse Ethyl cellulose in aqueous medium. Hence a process was developed where in Ethyl
cellulose is dissolved in solvents and the solvent solution is dispersed in aqueous medium. After
dispersion the solvent is stripped out to achieve Ethyl cellulose aqueous dispersion. During stripping
of solvent steam is utilized. Customers have the choice of using their plasticizers as per their choice
with respect to quantity and grade.
Ethyl cellulose Aqueous Dispersion – Plasticized:
Ethyl cellulose is water in soluble material as explained above. So Ethyl cellulose is extruded and
melted and molten Ethyl cellulose is dispersed in aqueous medium along with plasticizer. In this type
customer can use the dispersion directly in their application without adding any plasticizer. But they
have no choice of using differ composition or different quantities as it was possible in the above non-
plasticized grade.
Both products are available in the market and customers are using both grades as per their
requirement.
As we are already manufacturing Ethyl cellulose powder we are going to produce both grades of
product which enable the customers the select their choice of product.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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Ethyl Chloride Through Alcohol:
Many processes are known for the manufacture of Ethyl Chloride. We have selected two processes
to manufacture Ethyl chloride as continuous process. In the first process Ethyl Alcohol is reacted with
hydrogen chloride in presence of catalyst solution prepared from Zinc Chloride or Calcium chloride. In
the second process Ethyl Chloride is produced by reacting existing bi-product (mixed solvent of
Alcohol & Diethyl ether mixture) from the Ethyl Cellulose manufacturing processes with hydrogen
chloride. This is part of backward integration.
Manufacturing of Ethyl Chloride through Ethyl Alcohol:
The catalyst solution is prepared in a glass lined reactor and the temperature of catalyst solution is
raised from ambient to 130OC with help of steam or hot oil system. Ethyl Alcohol and 30%
Hydrochloric acid as per the recipe continuously fed at constant rate to the glass lined reactor while
temperature of reactor mass is maintained at between 130OC to 135OC. Vapor mixture of Ethyl
Chloride, Ethanol, Water and hydrochloric acid are pass through a packed column. The un- reacted
Ethanol and hydrochloric acid are returned to the column with the help reflux. The catalyst solution
will remain the reactor only. The vapors are cooled in an over head cooler before feeding to Caustic
scrubber. Small amount of Hydrochloric acid is neutralized in caustic scrubber and continuously
withdrawn from the bottom of the Caustic scrubber and lined to ETP. The scrubbed Ethyl Chloride
vapors are passed through a water scrubber to ensure Ethyl Chloride free from Hydrogen Chloride
and water. Finally the pure Ethyl Chloride vapors condensed in Chilled Brine condenser and collected
in product receiver.
Reaction C2H5OH + HCl C 2H5Cl + H2O
Ethanol Ethyl Chloride Water
Mole Balance: 46 36.5 64.5 18
Mass Balance: 8832 7008 12384 3456
Side reaction C2H5Cl + C2H5OH C2H5OC2H5 + HCl
Ethyl Chloride Ethanol Di-Ethyl Ether Hydrogen Chloride
Mole Balance: 64.5 46 74 36.5
Mass Balance: 64.5 46 74 36.5
12384 kgs/day of Ethyl chloride requires 9500 kgs/day of Ethanol and 24000 kgs/day of Dil.HCl acid
Hydrogen Chloride
64.5 kgs of Ethyl Chloride requires 46 kgs of Ethanol and 36.5 kgs of Hydrogen Chloride.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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Catalyst solution Preparation vessel :4800 Kgs
Calcium Chloride/Zinc Chloride:4800 Kg
Jacketed ReactorCatalyst Solution 38300 Kg
30% HCl acid: 24000 kg94% Ethanol: 9500 kg
Caustic Scurbber : 12835.5 Kg
Ethyl Chloride: 12312 Kg, HCl: 9.5 Kg
Water: 474 KgDiethyl Ether: 40 Kg,
To ETP: 23464.5 KgCaustic: 40 Kg, Nacl: 351 KgEthanol: 52 kg, Water:22980 KgEthyl Chloride: 7.5 KgDiethyl Ether: 34 Kg
Caustic Lye: 2800 Kg (Water: 2520 + NaOH: 280 Kg)
Water Scurbber : 12400 KgEthyl Chloride: 12312 Kg,
Diethyl Ether: 40 KgWater: 48 Kg,
To ETP: 3435.5 KgHCl : 9.5 KgWater: 3426 Kg
Water: 3000 Kg
Chilled Brine Condenser12380 Kg
Vent condenser : 20 kgEthyl Chloride: 12 KgDiethyl Ether: 8 Kg
Product Receiver: 12380 KgEthyl Chloride: 12300 Kg(99.35%)
Diethyl Ether: 32 Kg (0.26%)Water: 48 Kg ( 0.39%)
Process flow Diagram of ETHYLChloride from Ethyl Alcohol
(1) Condensate from Condenser attached to reactor: 33500 kgsTo caustic scrubber(EthylChloride: 12319.5 kg, Hcl:228.5 Kg
Ethanol: 52 Kg, Water:20826 KgDiethyl Ether: 74Kg )(2) Catalyst from bottom of reactor: 4800 kgs remain in reactor for next cycle
Ethyl Chloride Through existing mix solvent: Catalyst solution is prepared in a glass lined reactor and temperature of catalyst solution is raised
from ambient to 150OC. The mixture of Ethanol and Diethyl Ether and 30% Hydrochloric acid are
continuously at constant rate fed to glass lined reactor as per the recipe. The temperature of the
reactor is maintained between 150OC and 155OC. Vapor mixture of Ethyl Chloride, Mixed Solvent,
Water and hydrochloric acid are pass through a packed column. The un- reacted mixed solvent
mixture and hydrochloric acid are returned to the column with the help reflux. The catalyst solution will
remain the reactor only. The vapors are cooled in an over head cooler before feeding to Caustic
scrubber. Small amount of Hydrochloric acid is neutralized in caustic scrubber and continuously
withdrawn from the bottom of the Caustic scrubber and lined to ETP. The scrubbed Ethyl Chloride
vapors are passed through a water scrubber to ensure Ethyl Chloride free from Hydrogen Chloride
and water. Finally the pure Ethyl Chloride vapors condensed in Chilled Brine condenser and collected
in product receiver.
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Vent Losses : 7 kgsFeed from existing EC solvent Process: 4389 KgEthyl chloride: 269 kgs, Diethyl Ether: 2065, Ethanol: 566Toluene: 1130, Water: 359
Distillation System
To re-use in existing EC solvent Process: 1415 KgEthyl Chloride: 265Diethyl Ether: 10, Toluene: 1130Ethanol: 6, Water: 4
To Ethyl Chloride Reactor: 2662 kgDiethyl Ether: 2052
Ethanol: 555, Water: 55
To ETP: 305 kgEthanol: 5, Water: 300
Jacketed Reactor with Rectification column:8500 Kg
Zinc Chloride: 6000 Water: 2500
(Catalyst solution - one time charge and remain in reactor)
Feed from existing EC aqua Process : 1340 KgDiethyl Ether: 672, Water: 130Ethanol: 538
30% HCl: 12290 Kg HCl: 3687, Water: 8603
Water:1500 kg
Catalyst Solution recycled in jacketed reactor : 8500 KgZinc Chloride: 6000 KgWater: 2500 Kg
Cooling Water Condenser: 16292 kgEthyl Chloride: 6127.5 kg, Hcl:219.5 Kg
Ethanol: 35 Kg, Water: 9850 KgDiethyl Ether: 60Kg
Caustic Scurbber : 6283 KgEthyl Chloride: 6125 kg, Water:114 Kg
Diethyl Ether: 40 Kg, NaCl: 4
To ETP: 12509 KgCaustic: 10, NaCl: 347 Ethanol: 35, Water: 12094 Ethyl Chloride: 2.5 , Hcl: 0.5Diethyl Ether: 20
10% Caustic Lye: 2500 Kg
NaOH: 250, Water: 2250
Water Scurbber : 6162 KgEthyl Chloride: 6125 Kg,
Diethyl Ether: 31 KgWater: 6 Kg
To ETP: 2121 KgDiethyl Ether: 9, NaCl: 4Water: 2108 kgs
Water:2000 Kgs
Chilled Brine Condenser: 6150 Kg
Product Receiver: 6150 KgEthyl Chloride: 6117 Kg(99.46%)
Diethyl Ether: 27 Kg (0.44%)Water: 6 Kg ( 0.1%)
Process flow Diagram of ETHYLChloride from Mix solvent of existingproduct
Vent condenser : 12 kgsEthyl chloride: 8 kgsDiethyl ether: 4 kgs
Methyl Chloride: Many processes are proposed for the manufacture of Methyl Chloride. We have selected a process to
produce Methyl chloride in continuous manner. In this process Methanol is subjected catalytic hydro
chlorination. Methyl Alcohol is reacted with hydrogen chloride in liquid phase in presence of catalyst
solution prepared from Zinc Chloride. The process is similar to Ethyl chloride process.
Catalyst solution is prepared in a glass lined reactor and the temperature of catalyst solution is raised
from ambient to 150OC with help of steam or hot oil system. Methanol and 30% Hydrochloric acid
continuously mixed as per recipe and fed at constant rate to the glass lined reactor while temperature
of reactor mass is maintained at between 155OC to 160OC. Vapor mixture of Methyl Chloride,
Methanol, Water and hydrochloric acid are pass through a packed column attached to reactor. The
un- reacted Methanol and hydrochloric acid are returned to the column with the help internal reflux.
The catalyst solution will remain the reactor only. The vapors are cooled in an over head cooler prior
to feeding to Caustic scrubber. Small amount of entrained Hydrochloric acid is neutralized in caustic
scrubber and continuously withdrawn from the Caustic scrubber and lined to ETP for further
treatment. The scrubbed Methyl Chloride vapours are fed to a water scrubber to ensure Methyl
Chloride free from impurities. Finally the pure Methyl Chloride vapours condensed in Chilled Brine
condenser or compressed to receive in liquid phase before filling in cylinders.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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Production basis: 9.61 MT/Day Reaction: CH3OH + HCl CH3Cl + H2O 32 36.5 50.5 18 Methanol Hydrochloric Acid Methyl Chloride Water NaOH + HCl NaCl + H2O 40 36.5 58.5 18 Sodium Hydroxide Hydrochloric Acid Sodium Chloride Water
Catalyst solution Preparation vessel :4800 Kgs
Calcium Chloride/Zinc Chloride:3600 KgWater: 1200 kgs
Jacketed ReactorCatalyst Solution 34544 Kg
30% HCl acid: 23600 kg99.5% Methanol: 6144 kg
Caustic Scrubber: 9651.3 KgMethyl Chloride: 9593 Kg,
HCl: 6.3 KgWater: 48 Kg
Methanol: 4 kgs
To ETP: 22092.7 KgCaustic: 48 Kg, NaCl: 222.3 KgMethanol: 60 kg, Water: 21760.4 KgMethyl Chloride: 2 Kg
10% NaOH Soln: 2000 Kg (Water: 1800+ NaOH: 200 Kg)
Water Scurbber : 9615 KgMethyl Chloride: 9593 Kg,
Water: 22 Kg,
To ETP: 1036.3 KgHCl : 6.3 KgWater: 1026 KgMethanol: 4 kgs
Water: 1000 Kg
Chilled Brine Condenser9615 Kg
Vent condenser: 5 kg
Product : Methyl Chloride: 9610 Kg
Process flow Diagram of METHYLChloride from Methyl Alcohol
(1) Product vapour from reactor is cooled in a cooler and fed to a caustic scrubber: 29744 kgs(2) (MethylChloride: 9595 kg, HCl:145 Kg
Methanol: 64 Kg, Water:19940 Kg(2) Catalyst from bottom of reactor: 4800 kgs remain in reactor for next cycle
Hydroxy Propyl Methyl Cellulose (HPMC)
Hydroxy Propyl Methyl Cellulose also known as HPMC or Hypromellose is one of cellulose
derivatives widely used in various applications. HPMC is inert visco elastic polymer used in
pharmaceutical and food additive applications. The manufacturing process is a batch type one and
consists of the following stages.
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
Page 48
Preparation of alkali cellulose.
Etherification reaction
Recovery solvents
Purification
Drying
Blending and Packing.
Wood Pulp / Cotton linters pulp sheets are fed to a shredder machine and conveyed to reactor. 50%
Caustic solution is prepared and charged into rector to prepare alkali cellulose and allowed for aging
for different durations depend on final viscosity of the product.
The reactants Methyl Chloride and Propylene oxide are charged as per the formulation and the
reactor mass is heated with the help of low pressure steam. The reactor temperature is maintained at
different temperatures as for the formulation to achieve desired degree of substitution. The operating
temperature range is from 50OC to 80OC. The reaction is exothermic in nature and temperature is
controlled precisely with help of cooling water.
After completion of reaction the solvents and by-products formed during reaction are recovered from
the reactor. The reactor product is discharged into a neutch filter unit to separate salt water. The
reaction product is subjected hot water washes to receive salt free product.
The wet cake from neutch filter is discharged into the feed hopper of spin flash dryer. Dry product
from different batches will be blended to achieve designated viscosity product in blender and packed.
C6H7O2(OH)3 + CH3Cl + NaOH + C3H6O 162 50.5 40 58 Wood Pulp Methyl Sodium Propylene Chloride Hydroxide Oxide
C6H7O2(OH)(OCH3)(OCH2CHOHCH3 ) + NaCl + H2O 234 58.5 18 Hydroxy Propyl Methyl Cellulose (HPMC) Sodium Water Chloride Side Reactions: CH3Cl + NaOH CH3OH + NaCl 50.5 40 32 58.5 Methyl Chloride Sodium Hydroxide Methanol Sodium Chloride
2CH3Cl + 2NaOH H2O + CH3OCH3 + 2NaCl 101 80 18 46 117 Methyl Chloride Sodium Hydroxide Water Di-Methylether Sodium Chloride C3H6O + H2O C3H8O2 Propylene Oxide Water Propylene Glycol 58 18 76
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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REACTOR: 11718 kgs(HPMC: 7488 kgsNaCl: 2047.5 kgs
NaOH: 20 kgsWater: 1996 kgs
Methanol: 32 kgsDi methyl ether: 46 kgs
Propylene glycol: 76 kgs), methyl chloride: 12.5 kgs
Wood pulp: 5184 kgs50% Caustic soln. : 2840 kgsMethyl Chloride: 1780 kgsPropylene o0xide: 1914 kgs
To ETP: 10551.5 kgs ( NaCl: 2047.5 kgs + HPMC: 8 kgs + NaOH: 20 kgs + Methanol: 4 kgs + Water: 8472 kgs)
Hot water: 8000 kgs
Wet Cake Receiver: 9000 kgs
Water Evaporated: 1310 kgs
Product : HPMC: 7690 Kg
PROCESS FLOW DIAGRAM FOR HYDROXY PROPYL METHYL CELLULOSE (HPMC)
Crude Product: 11551. 5 kgs
Mix solvent: 166.5 kgs (Di methyl Ether + Propylene glycol + Methanol) sell to
authorized distillator
Washing
Spin Flash Dryer
Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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ANNEXURE: 5 WASTE WATER MANAGEMENT
Quantity of Waste Water (liquid waste) generation and its management :
No Particular Existing Proposed Total
2.1 Domestic 1.5 0.5 2.0
2.2 Industrial
2.2.1 Processing + washing 88.0 74.515 162.515
2.2.2 Boiler 25.0 12.0 37.0
2.2.3 DM Plant 5.0 7.5 12.5
2.2.4 Cooling 2.5 0 2.5
2.2.5 Container/floor washing, QC, R&D 1.0 0.5 1.5
2.2 Total Industrial 121.5 94.515 216.015
2.3 Total effluent 123.0 95.015 218.015
Domestic effluent is/will be passes through septic tank/soak pit of adequate capacity & finally
mixed with industrial effluent.
Entire quantity of effluent is/will be treated in primary, secondary & tertiary effluent treatment plant
followed by RO & MEE system. Thus after RO & MEE, entire treated water is/will be recycled. RO
Permeate & MEE condensate is/will be recycled. RO rejected is/will be taken into MEE. Salt from
MEE is/will be dispose off into TSDF.
Water is/will be used in the process to dissolve the raw materials only.
Steam is/will be required to for stripping and recovery of solvent is/will be obtained from existing
boiler only.
WATER BALANCE AFTER PROPOSED EXPANSION
TOTAL WATER CONSUMPTION: 244.9 M3/DAY ( Fresh: 37.48 m3/day + Recycled: 207.5 m3/day)
Domestic: 3.0 Processing &Washing: 103.9
Boiler: 55 Cooling: 57 D M plant: 14 Floor/containerwashing: 2.0
Gardening: 10
162.515
37.0 2.5 12.5 1.5
207.465
2.0
P/S/T ETP: 207.465 Loss: 4.465
REVERSE OSMOSIS: 203
RO Permeate recycle : 173RO Rejection: 30 MEE
Condensate recycle : 34.5
High TDS: 10.55 Normal: 151.965
Salt : 6.05
Water evaporated: 3.04 MT
Dry Salt to TSDF: 3.04 MT
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CHARACTERISTICS OF UNTREATED & TREATED EFFLUENT
Sr. No. Parameters Untreated
combined effluent
from existing
plant
Untreated
combined effluent
from proposed
plant
Untreated
combined effluent
after proposed
expansion
1 pH 9.39 8.02 9.02
2 Colour, pt.Co 180 150 140
3 Temperature 32 32 32
4 Suspended
solids, mg/l
304 286 276
5 Oil & grease,
mg/l
7.20 2.8 4.2
6 Phenolic
compound, mg/l
0.2 0.21 0.19
7 Cyanides, mg/l ND ND ND
8 Ammonical
nitrogen, mg/l
24.2 16.0 18.5
9 TDS, mg/l 4600 3200 3420
10 Chloride, mg/l 800 1020 985
11 Sulphate, mg/l 650 740 725
12 Phosphates, mg/l 1.2 0.8 0.62
13 COD, mg/l 3150 3780 3670
14 BOD, mg/l 1117 1486 1615
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CHARACTERISTICS OF TREATED EFFLUENT
Sr. No. Parameters Treated combined
effluent after proposed
expansion plant
GPCB disposal
norms
1 pH 8.02 6.5 to 8.5
2 Colour, Pt.Co 80 <100
3 Temperature 30 <40
4 Suspended solids, mg/l 46 <100
5 Oil & grease, mg/l 0.86 <10
6 Phenolic compound, mg/l 0.08 <1
7 Cyanides, mg/l ND <0.1
8 Ammonical nitrogen, mg/l 16.0 <50
9 TDS, mg/l 2050 <2100
10 Chloride, mg/l 550 <600
11 Sulphate, mg/l 580 <1000
12 Phosphates, mg/l 0.18 <2
13 COD, mg/l 79.9 <250
14 BOD, mg/l 26 <30
Remarks:
After proposed expansion, we will treat our entire effluent into our modified full-fledge
effluent treatment plant consisting of primary, secondary & tertiary treatment units
followed by Reverse osmosis & MEE.
RO permeate & MEE condensate shall be recycled in the process, hence after RO/MEE
treatment, there will be no discharge of any industrial effluent on land.
CHARACTERISTICS OF RO TREATED & MEE CONDENSATE
Sr. No. Parameters RO Permeate MEE
Condensate
1 pH 7.0 7.0
2 TDS, mg/l 150 -
3 COD, mg/l < 20.0 < 50.0
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Details of Effluent Treatment Plant , RO plant and MEE with proposed modification
Sr. No. Particulars Capacity, m3 MOC
Existing Proposed Total
1 Collection Tank 205 0 205 RCC
2 Neutralization Tank 40 0 40 RCC
3 Floculator 7 7 14 MSRL
4 Primary lamella separator
with tube deck
26 26 52 MSRL
5 Sludge drying bed 30 30 60 Brick
Masonry
6 Aeration tank with tube
deck packing
526 0 526 RCC
7 Secondary Lamella
separator with tube deck
26 26 52 MSRL
8 Holding tank 30 30 60 RCC
9 Activated carbon bed 6 m3 6 m3 12 m3 MSRL
10 Sand bed filter 6 m3 6 m3 12 m3 MSRL
11 Final treated water
holding tank
111 99 211 RCC
12 RO System 12 m3/hr 12 m3/hr 24 m3/hr PP
13 RO Rejection collection
tank
30 0 30 RCC
14 MEE followed by
centrifuge and ANFD
system
1.75
m3/hr
0 1.75
m3/hr
Titanium/SS
15 Final RO permeate &
MEE condensate
collection tank
50 160 210 RCC
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FLOW DIAGRAM OF ETP FOLLOWED BY RO PLANT AND MEE
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Details of RO Plant
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Prefeasibility Report ASHA CELLULOSE (I) PVT. LIMITED
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Flow Diagram of MEE
TRIPPLE EFFECT EVAPORATOR PLANT
Steam 6 Kgs/cm2
Barometric Leg
Conenser Vent
M
Vacuum Pump
Seal Water Circulation
Cooling Tower
Cooling Tower
Feed Pump CW Pump
Transfer Product Condensate
Transfer Transfer Pump Pump Product Pump
FF
Evaporator
FCE
vaporator
PreH
eater
FCE
vaporator
Pre
Heater
Pre
Heater
VLS VLS
VLS
TVR
CondensateReceiver
FeedVessel
Barometric receiver
PHE
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ANNEXURE 6 COPY OF LAND DOCUMENT
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ANNEXURE 7 LAND USE MAP
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ANNEXURE 8 TSDF MEMBERSHIP
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ANNEXURE 9 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES
At existing Scenario:
Presently, the unit has installed one number of natural gas/FO fired 3 TPH steam boiler, three
numbers of FO/LDO fired steam boiler having capacity of 800 kg/h each and two numbers of
LDO/Natural gas fired hot air generator having capacity of 6 lakhs k cal/hr each. Two numbers of
D G sets having 110 KVA and 35 KVA capacity. 30 meters height of chimney with SMF provided to
3 TPH boiler, 15 meters common chimney provided for all three boiler and two HAG. 11 meters
chimney provided for D G Sets.
Presently two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h are used.
Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney for
each dryer is provided.
After proposed expansion:
After proposed expansion, existing one number of natural gas/FO fired 3 TPH boiler will be
continued. Existing three numbers of 800 kg/h capacity of boiler will be discontinued. Existing two
numbers of hot air generator will be continued. Additional one number of coal/natural gas/FO fired
3 TPH boiler and one number of FO/natural gas fired 6 lakhs k cal/hr capacity of thermopak and
one number of natural gas/LDO fired hot air generator of 6 lakhs k cal/hr capacity will be
installed. Existing two numbers of D G sets having 110 KVA and 35 KVA will be continued.
30 meters height of chimney with SMF provided to 3 TPH boiler, 15 meters common chimney
provided for three HAG. 30 meters chimney with multi cyclone separator and bag filter will be
provided to 3 TPH coal fired boiler. 11 meters height of chimney will be provided to 6 lakhs k cal/hr
capacity of thermopak. 11 meters chimney provided for D G Set.
After proposed expansion, existing two numbers of spin flash dryer having capacity of 50 kg/h and 100 kg/h will be used. One additional spin flash dryer having a capacity of 100 kg/h will be installed. Adequate capacity of separate cyclone separator and bag filter along with 11 meters chimney for each spin flash dryer will be provided.
There will be no process gas emission from the reaction.
Flue Gas Emission:
Sr. No. Particulars Details
Existing Proposed Total
1.0 Capacity of Steam boiler 3 TPH 0 3 TPH
Fuel used NG/FO 0 NG/FO
Consumption 230 SCM/hr/200 kgs/hr
0 230 SCM/hr/200
kgs/hr
APC provided Chimney 0 Chimney
Height of chimney 11 meters 0 11 meters
2.0 Capacity of Steam boiler 0 3 TPH 3 TPH
Fuel used 0 Coal/NG/FO Coal/NG/FO
Consumption 0 300 kgs/hr/400
SCM/hr/325 kgs/hr
300 kgs/hr/400
SCM/hr/325 kgs/hr
APC provided 0 MDC and bag filter
MDC and bag filter
Height of chimney 0 15 meters 15 meters
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3.0 Capacity of Thermopak 0 6 lakhs k cal/hr
6 lakhs k cal/hr
Fuel used 0 NG/FO NG/FO
Consumption 0 135 SCM/hr/115
kgs/hr
135 SCM/hr/115
kgs/hr
APC provided 0 Chimney Chimney
Height of chimney 0 15 meters 15 meters
4.0 Capacity of Steam boiler 0.8 TPH - 0.8 TPH to be
discontinued
- 0.8 TPH to be
discontinued Fuel used LDO/FO
Consumption 25 kgs/hr
APC provided Chimney
Height of chimney 11 meters
5.0 Capacity of Steam boiler 0.8 TPH - 0.8 TPH to be
discontinued
- 0.8 TPH to be
discontinued
Fuel used LDO/FO
Consumption 25 kgs/hr
APC provided Chimney
Height of chimney 11 meters
6.0 Capacity of Steam boiler 0.8 TPH - 0.8 TPH to be
discontinued
- 0.8 TPH to be
discontinued Fuel used LDO/FO
Consumption 25 kgs/hr
APC provided Chimney
Height of chimney 11 meters
7.0 Capacity of Steam boiler 0.8 TPH - 0.8 TPH to be
discontinued
- 0.8 TPH to be
discontinued Fuel used LDO/FO
Consumption 25 kgs/hr
APC provided Chimney
Height of chimney 11 meters
8.0 Capacity of Hot air generator 6 lakhs k cal/hr 0 6 lakhs k cal/hr
Fuel used NG/LDO 0 NG/LDO
Consumption 50 SCM/hr/40 kgs/hr
0 50 SCM/hr/40 kgs/hr
APC provided Chimney 0 Chimney
Height of chimney 11 meters 0 11 meters
9.0 Capacity of Hot air generator 6 lakhs k cal/hr 0 6 lakhs k cal/hr
Fuel used NG/LDO 0 NG/LDO
Consumption 50 SCM/hr/40 kgs/hr
0 50 SCM/hr/40 kgs/hr
APC provided Chimney 0 Chimney
Height of chimney 11 meters 0 11 meters
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10 Capacity of Hot air generator 0 6 lakhs k cal/hr
6 lakhs k cal/hr
Fuel used 0 NG/LDO NG/LDO
Consumption 0 50 SCM/hr/40 kgs/hr
50 SCM/hr/40 kgs/hr
APC provided 0 Chimney Chimney
Height of chimney 0 11 meters 11 meters
11 Capacity of D G set 110 KVA 0 110 KVA
Fuel used HSD 0 HSD
Consumption 45 kgs/hr 0 45 kgs/hr
APC provided Chimney 0 Chimney
Height of chimney 11 meters 0 11 meters
12 Capacity of D G set 35 KVA 0 35 KVA
Fuel used HSD 0 HSD
Consumption 15 kgs/hr 0 15 kgs/hr
APC provided Chimney 0 Chimney
Height of chimney 11 meters 0 11 meters
Expected Pollutants PM: < 150 mg/Nm3 SOX: < 100 ppm NOx: < 50 ppm
Process Gas Emission:
There will be no process gas emission from the reaction. Vent attached to spin flash dryer is considered as process gas emission.
Sr. No. Particulars Details
Existing Proposed Total
13 Capacity of Spin flash dryer 50 kgs/hr 0 50 kgs/hr
Hot air supplied by HAG 0 HAG
APC provided Cyclone separator followed by bag
filter
0 Cyclone separator
followed by bag filter
Height of chimney 11 meters 0 11 meters
14 Capacity of Spin flash dryer 100 kgs/hr 0 100 kgs/hr
Hot air supplied by HAG 0 HAG
APC provided Cyclone separator followed by bag
filter
0 Cyclone separator
followed by bag filter
Height of chimney 11 meters 0 11 meters
14 Capacity of Spin flash dryer 0 100 kgs/hr 100 kgs/hr
Hot air supplied by 0 HAG HAG
APC provided 0 Cyclone Cyclone
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separator followed by
bag filter
separator followed by
bag filter
Height of chimney 0 11 meters 11 meters
Expected Pollutants PM: < 150 mg/Nm3
Details of MDC and Bag filter attached to Spin Flash Dryer
MAKE ACMEFIL
Type Reverse pulse air jet
Air volume 17500m3/hr
Air temperature 70 oC
Dust load 12 kg/hr
Actual filtration area 34.55 m2
Air to cloth ratio 1:5
Bag size 150mm * 3000 mm long
Total no. of bags 121
Total no. of rolls 11
Cage size 150mm * 2990 mm long
Overall size of bag filter 2200 * 2200 * 5250mm
MOC of casing SS 304
MOC of bag Polyester needle felt,
Cage SS 304
PULSING PIPES SS 304
Details of Bag filter attached to Coal fired Boiler
Size of Bag filter 2.475 x 2.3 x 8.61 meters
MOC Mild steel
Size of Gas inlet 0.81 x 0.64 mm
Size of gas out let 2.716 x 0.346 mm
Designed gas volume 12750 Am3/hr
Maximum designed temp. 180 0C
Number of filter bags 120 Nos ( 500 gms/m2 filter glass)
Size of filter bags 149 mm dia x 3.65 m length
Pressure drop 150 mm
Total unit weight 7.6 MT
Hopper volume 9.72 m3
No. of cages 120
Air to cloth ratio 1.03 m3/min/m2
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ANNEXURE 10 COPY OF /CTE CC&A
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COMPLIANCE FOR EXISTING CCA
Sr.
No
CONDITIONS COMPLIANCE
1 Consent Order No.: AWH-87084, Date of issue:
12/07/2017.
We have obtained CCA of the
Board vide No. AWH-87084
which is valid up to 31/03/2022.
2 The consents shall be valid up to 31/03/2022 for use of
outlet for the discharge of trade effluent & emission due
to operation of industrial plant for manufacture of the
following items/products:
We are manufacturing products
as per consented quantity only
SUBJECT TO THE FOLLOWING CONDITIONS:
Management of Solid Waste generated from industrial
activities shall be as per Solid Waste Management
Rules 2016, (Solid waste as defined in Rule -3 (46).
We are generating hazardous
waste as per authorization
issued by the board and dispose
off as per hazardous waste rules
2016
As per provision of Rule-18 of Solid Waste
Management Rules-2016 all Industrial units using fuel
and located within 100 Km from the refused derived
fuel (RDF) plant shall made an arrangement to replace
at least five percent of their fuel requirement by refused
derived fuel so produced.
Will be implemented
3 CONDITIONS UNDER THE WATER ACT :
3.1 The quantity of total water consumption shall not
exceed 155.48 KLD as per below break up. Source of
fresh water shall be only from Borewell. Unit shall
submit NOC from central ground Authority (CGWA)
for use of Borewell water.
a) Domestic : 2.2 KLD
b) Industrial : 149.48 KLD
We are using water
consumption @ 11.48 m3/day.
We are using fresh water from
our own Bore well. We will
apply for permission for central
ground Authority (CGWA) for
use of Bore well water.
3.2 The quantity of the trade effluent discharge from the
industry shall not exceed 121.5 KLD.
Entire effluent shall be treated in ETP, followed by RO
and MEE and achieve zero liquid discharge condition.
We are generating maximum
121.5 KLD of industrial waste
water.
We have provided adequate
capacity of primary, secondary
and tertiary ETP followed by
RO and MEE to achieve zero
liquid discharge.
3.3 The quantity of Sewage effluent from the industry shall
not exceed 1.5 KLD.
We are generating maximum
1.5 KLD of domestic effluent.
3.4 Domestic effluent shall be disposed off through septic
tank/soak pit system.
We have provided adequate
capacity of septic tank/soak pit
for the disposal of domestic
effluent.
4 CONDITIONS UNDER THE AIR ACT:
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4.1 The following shall be used as fuel in the boilers, Hot
Air Generation & D.G. Sets.
We have installed utilities for
process heat requirement as per
CCA only. Also we are using
fuel in utilities as per CCA.
4..2 The flue gas emission through existing stack shall
conform to the following standards:
We are operating our air
pollution control system and
maintain the norms of flue gas
emission as specified by the
board.
4.3 The process emission through various stacks / Vent of
reactors, process, vessel shall conform to the following
standards.
We are maintaining the norms
of process gas emission.
4.4 The concentration of the following substances in the
ambient air within the premises of the industry and at a
distance of 10 meters from the source (other than the
stack/ vent with height of more than 9 meters from the
ground level)Shall not exceed the following levels:
We are maintaining the ambient
air quality within the premises
and analyze regularly to ensure
the quality within the premises
as per norms.
4.5 The applicant shall provide portholes, ladder, platform
etc at chimney(s) for monitoring the air emissions and
the same shall be open for inspection to/and for use of
Board’s staff. The chimney(s) vents attached to various
sources of emission shall be designed by numbers such
as S-1, S-2, etc. and these shall be painted / displayed to
facilitate identification.
We have provided adequate
stack monitoring facility like
portholes, ladder, platform etc
at chimney(s) for monitoring.
4.6 The industry shall take adequate measures for control of
noise levels from its own sources within the premises
so as to maintain ambient air quality standards in
respect of noise to less than 75 dB (a) during day time
and 70 dB (A) during night time. Daytime is reckoned
in between 6 a.m. and 10 p.m. and nighttime is
reckoned between 10 p.m. and 6 a.m.
Controlling noise level by
regular maintenance and close
acoustic enclose to DG set.
5 GENERAL CONDITIONS:
5.1 Any change in personnel, equipment or working
conditions as mentioned in the consents form/order
should immediately be intimated to this Board.
Agreed
6 AUTHORISATION UNDER HAZARDOUS WASTE AND OTHER WASTE
(MANAGEMTN AND TRANSBOUNDARY MOVEMENT) RULES-2016, FORM-2
(SEE RULE 6(2))
6.1 Number of authorization: AWH-87084, Date of issue:
12/07/2017.
Agreed
6.2 Reference of authorization: AWH-122307 and Date:
23/05/2017.
Agreed
6.3 M/s. ASHA CELLULOSE (I) PVT. LTD is hereby
granted an authorization based on the enclosed signed
inspection report for generation, collection, reception,
storage, transport, reuse, recycling, recovery, pre-
processing, co-processing, utilization, treatment,
disposal or any other use of hazardous or other waste or
Agreed
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both on the premises situated at Plot No. Shed No.
303/2,302/P, Village: Abrama, Abrama-369001, Dist:
Valsad.
6.4 The authorization shall be valid for a period of
31/03/2022.
Agreed
6.5 The authorization is subject to the following general
and specific conditions:
Agreed
A GENERAL CONDITIONS UNDER HAZARDOUS AND OTHER WASTES
(M&TM) RULES-2016.
1 The Authorised person shall comply with the
provisions of the Environment (Protection) Act-
1986 and rules made there under.
Complied with
2 The Authorization or its renewal shall be produced for
inspection at the request of an officer Authorized by the
State Pollution Control Board.
We will not rent, land, sell,
transfer or otherwise transport
the hazardous and other
wastes except what is permitted
through authorization.
3. The persons authorized shall not rent, lend, sell, transfer
or otherwise transport the hazardous and other
wastes except what is permitted through this
authorization.
Complied with
4. Any unauthorized change in personnel, equipment or
working conditions as mentioned in the application by
the persons authorized shall constitute a breach of this
authorization.
Complied with
5. The person authorized shall implement Emergency
Response Procedure (ERP) for which this authorization
is being granted considering all site specific possible
scenarios such as spillages, leakages, fire etc. and their
possible impacts and also carry out mock drill in this
regard at regular interval of time.
We have already made
emergency response plan and
implemented the same. We have
also carried out mock drill for
possible scenarios such as
spillages, leakages, fire etc
6. The person authorize shall comply with the provisions
outlined in the Central Pollution Control Board
guidelines on “ implementing Liabilities for
Environmental Damages due to Handling and Disposal
of Hazardous Wastes and penalty”.
We are complying with the
guide line of CPCB for
implementing Liabilities for
Environmental Damages due to
Handling and Disposal of
Hazardous Wastes and penalty”.
7. It is the duty of the authorized person to take prior
permission of the State Pollution Control Board to close
down the facility.
Agreed
8. The imported hazardous and other wastes shall be fully
insured for transit as well as for any accidental
occurrence and its clean- up operation.
Complied with
9. The record of consumption and fate of the imported
hazardous and other wastes shall be maintained.
Complied with
10. The hazardous and other waste which gets generated
during recycling or reuse or recovery or pre-processing
or utilization of imported hazardous or other wastes
shall be treated and disposed of as per specific
Not applicable, as we are not
importing any hazardous waste
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conditions of authorization.
11. The importer or exporter shall bear the cost of import or
export and mitigation of damages if any.
Agreed
12. An application for the renewal of an authorization shall
be made as laid down under these rules.
Complied with
13. Any other conditions for compliance as per the
guidelines issued by the Ministry of Environment,
Forest and Climate Change or Central Pollution Control
Board from time to time.
We are regularly submitting
return filed by June 30th for the
period ensuring 31st March of
the year.
14. Annual return shall be filed by June 30th for the period
ensuring 31st March of the year.
Complied with
B. SPECIFIC CONDITIONS (WHICHEVER IS
APPLICABLE)
1. The authorized actual of hazardous and other waste
shall maintain records of hazardous and other wastes
purchased in a passbook issued by the State Pollution
Control Board along with the authorization.
We are maintaining the records
for the hazardous and other
waste as per authorization
2. Handling over the hazardous and other wastes to the
authorized actual user shall be only after making the
entry into the passbook of the actual user.
Complied with
3. In case of renewal of authorization, a self-certified
compliance report in respect of effluent, emission
standards and the conditions specified in the
authorization for hazardous and other wastes shall be
submitted to SPCB.
Agreed
4. The occupier of the facility shall comply standards
operating procedure/guidelines published by
MoEF&CC or CPCB or GPCB from time to time.
We are complying with
standards operating
procedure/guidelines published
by MoEF&CC or CPCB or
GPCB from time to time.
5. Unit shall comply provisions of E-Waste (Management)
Rules, 2016.
Complied with
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ANNEXURE 11 COPY OF ENVIRONMENTAL CLEARANCE FOR EXISTING PLANT
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CERTIFIED COMPLIANCE REPORT EXISTING EC
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ANNEXURE 12 A SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING
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SHOW CAUSE NOTICE/CLOSURE NOTICE ISSUED BY GPCB/CPCB & ITS COMPLIANCE
Sr.
No
Date Reason For Show Cause Notice Compliance
1 05.05.2015 You have stored ETP sludge on
open land.
Complied with by shifting entire ETP
waste into secured storage area
within the premises and finally
disposed off into TSDF.
2 28.07.2016 Written instructions were given
during the visit, you are directed
to submit detailed action taken
report with supporting documents
(if not submitted).
We have already uploaded on xgn
and submitted copy of compliance
of written instruction given during
the inspection of our unit by the
officers from GPCB
3 20.04.2017 Unit is not operated MEE on
regular basis.
We have installed our MEE for full
production capacity, but our
production plant was operated on 60-
70% production capacity and hence
there was no sufficient effluent to
meet the capacity of MEE and we
were operating our MEE thrice a
week.
4 23.03.2018 The recent past result of inlet and
outlet of CETP are not as per
prescribed limits.
This is not applicable to us, as we are
a ZLD unit and we are not
discharging our treated effluent into
CETP.
Recommended