1 PREFEASIBILITY REPORT “Expansion of Existing Production Capacity for Fragrances, Flavors & Manufacturing Chemicals” By Aarav Fragrances & FlavorsPvt. Ltd. Gut No 167, 169, 170, 171, 296, Village. Jamghar -Lakhamapur, Tal. Wada, District: Thane, Maharashtra PrefeasibilityReport–M/s.Aarav Fragrances & Flavors Pvt Ltd 2 Synopsis 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Introduction Justification Location Recourses Process Pollution Control Background Study Safety Benefits EIA structure Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 3 1. Introduction M/s Aarav Fragrances and Flavors Pvt Ltd are desirous to expand to manufacture new products having either raw material synergy or superior quality and technology to meet demands in India as well as for further producing the fragrance and flavors at Aarav Fragrances and FlavorsPvt Ltd, Gut No 167,169,170,171,296,Vill. Jamghar Lakhamapur, Tal. Wada, District: Thane, Maharashtra The existing industrial unit is only manufacturing facility for Fragrances and Flavors. The industry now proposes to enhance the manufacturing capacity of the present Fragrances & Flavors, and further the it is proposed to add additional capacity to manufacture the chemicals that could be used in house as well as cater to the open Market, this will reduce the costs of the fragrances and flavors and make them more competitive in the Indian as well as export markets. Indian and worldwide demand for fragrances, flavors, perfumery chemicals and related specialty chemicals is increasing steadily. 2. Justification The Indian consumer industry is one of the world’s largest by volume and is likely to lead the manufacturing sector of India. Several private sector projects with huge amount of investments have been initiated but could not attend the speed of development for the need of good quality material. Over the last decade, there has been a sizeable growth in fragrances and flavors sector both in small, medium and large scale units. This has given rise to many small and medium scale units. There is an ever growing requirement of the consumers in India and also the world markets. Thus there is a gap in demand and supply. Our efforts of generating products, byproducts, downstream products and recycling - reprocessing are indeed needed. With multinational fragrance and flavor companies enhancing their presence in India, the long-term prospects of the fragrances and flavors industry seems verybright. The intermediates proposed will substitute imports and compliment the products in terms of costs. The fate of industrialization depends on the proper and effective conjugation of large and medium/small scale industries each supporting each other in their requirement to bridge the gap between demand and supply. In order to be competitive in the global market this synergy between large & medium/small scale industries is a prerogative. Therefore considering the above, large companies do require the help of small units to support them, the main target is to give the consumer superior quality products at a competitive price. In addition, it is also examined whether industry had made compliances expected in Consent to Operate by MPCB for existing production. S.No. Condition Compliance 1 Addressstatus Continuousthesamenochange 2 No. &Validity Validtill30.09.2015 3 Productsize Sr.no. 1 Product Fragrance/Perfumes Flavors Capacity (TPM) & 70 4 Waste quantity water 8.5m3/dpermitted. 5 Waste waterTreatment Foundinlimit 6 ECE Presently NA 7 LDAR Leakdetection&repairprogramwith monitoringprotocolundertakenas consented.No– towardincident reported.Work zoneambiancecognizes 8 Hazardouswaste MembershipofCHWTSDF to be obtained Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 4 3. Proposal:The Industryproposedtoproduceasunder: Sr Products Present No MT /M 1. Fragrances/Perfumes & Flavors 70 Proposed MT/M Total MT/M Field Of Application 280 Fragrances & Flavors 210 Perfumery& Flavor Esters by hot esterification/ addition of organic acid into olefin/ trans esterification/ reacting alkali halide with sodium 2. salt of corresponding acid/Cold Esterification 00 Fragrances & Flavors Ethyl Esters/ Esterification by reaction of alcohols with anhydride/ Perfumery Esters by Darzen Condensation Perfumery & Flavor Alcohol by Grignard reaction / by reduction of aldehyde, or ketone by hydrogen & Reducing Agents / by addition of 3 00 Fragrances & Flavors water into olefins / by saponification of esters/Perfumery Compounds by Ring Reduction Perfumery & Flavor Aldehyde by ester / epoxide rearrangement/ dehydrogenation of 300 4 00 Fragrances & Flavors alcohols/ reduction of acids/ aldol condensation& derivatives 300 Dimerization and Trimerization of simple 5 00 Fragrances & Flavors olefins. 6 Ketals / Acetals / substituted 1,3-propanediols 00 Fragrances & Flavors Macro cyclic and polycyclic musks derived 7 from propylene or butadiene and other 00 Fragrances & Flavors propylene derivatives 8 Aldehydes & Ketones by Aldol Condensation 00 Fragrances & Flavors 9 Acetylene and other alkyne derivatives 00 Fragrances & Flavors Cyclo Alkylation/Acetylation ,Diel Alders Reactions : Cyclization Reaction, Etherification 10 00 Fragrances & Flavors of Alkyl Halide and Alcohol, Epoxidation of Alkenes /Friedel Craft Reactions 11 Hydrogenation 00 Fragrances & Flavors 12 Inorganic Salts 00 50 50 Side Stream Products Total 630 From the list of ProductsSrNos 2 to11 only two to three products will be manufactured simultaneously. The total quantities to produce for Products Sr No 2 to 11 willbe for any one or all cumulatively up to 300MT Since many of the products planned are either forward integration or corollary to a known manufacturing process. The above mentioned process based chemicals are important chemicals in the vast field of fragrances and flavors where many such routed chemicals are required to make a fragrances and flavors. None of these chemicals are banned for production in developed countries nor is banned for use. The chemicals produced have the following merits: - Import /Cost Substitution - Minimizepollutantsatsource - Maximizerecycle of recovered RMs and Water - Treatto MPCBnorms Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 5 General formulas limited to groups of manufacture Sr Products No General Reaction(s) Fragrances/Perfumes & Flavors Formulation 1. 2. 3 4 Perfumery& Flavors Esters by hot esterification/ addition of organic acid into olefin/ trans esterification/ reacting alkali halide with sodium salt of corresponding acid/Cold Esterification -Ethyl Esters/ Esterification by reaction of alcohols with anhydride/ Perfumery Esters by Darzen Condensation Perfumery& Flavors Alcohol by Grignard reaction / by reduction of aldehyde, or ketone by hydrogen & Reducing Agents / by addition of water into olefins / by saponification of esters/Perfumery Compounds by Ring Reduction Field Of Application Fragrances& Flavors. Fragrances & Flavors Fragrances & Flavors Perfumery &FlavorsAldehyde by ester / epoxide rearrangement/ dehydrogenation of alcohols/ reduction of acids/ aldol condensation and Derivatives Fragrances & Flavors Dimerization and Trimerization of simple olefins. Fragrances & Flavors 5 6 7 8 Ketals / Acetals / substituted 1,3-propanediols Fragrances & Flavors Macrocyclic and polycyclic musks derived from propylene or butadiene/and other propylene Derivatives Fragrances & Flavors Aldehydes & ketones by Condensation with vinyl ether Acetylene and other alkyne derivatives Fragrances & Flavors 9 Fragrances & Flavors RC≡CR + R'C≡CR' 2 RC≡CR' Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 6 10 Cyclo Alkylation Reactions /Acetylation ,Diel Alders Reactions : Cyclization Reaction, Etherification of Alkyl Halide and Alcohol, Epoxidation of Alkenes/Friedel Craft Reactions Fragrances & Flavors 3. Hydrogenation 11 Fragrances & Flavors NaCl, AlCl3, MgCl.HSO4, KCl, BaSO4 12 Inorganic Salts Side Stream Products Inorganic Salts Total From the list of Products SrNo 2 to11 only two to three products will be manufactured simultaneously. The total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT List of Raw Materials and Source: The list of raw materials along with monthly consumption is given in table, However there will be only 2-3 products being manufactured at the same time hence the requirement of the raw materials will be low, however the below raw material quantities are reflected based on single product manufacturing. Sr. Raw Material Required Consumption No. in MT /M 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Acetic Acid Glacial Acetic Anhydride Acid Catalyst Aldehyde Caryophellene Phase transfer Catalyst Caustic lye Citronellol Benzylledene Acetone D’limonene/Orange Terpenes Di Ethanol Amine Dicyclopentadiene Ethyl Chloro Acetate Benzyl chloride Halide (Pentyl Bromide/ Chloride) HCL 45% Iodine Iso Amyl Alcohol Isobutyric Acid Methanol Methyl Heptanone Methyl Magnesium Bromide / Chloride Hexyl Alcohol Mg Turnings Pentanol mixture Propionic Acid 182.00 53.00 17.00 85.00 4.00 1.10 1.04 17.03 105.00 98.00 1.00 240.00 22.05 27.60 106.00 1.00 0.05 10.00 60.00 15.00 69.00 31.61 52.00 12.74 77.14 46.00 Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 7 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Salicylic Acid Soda Ash Sodium Acetate Sodium Methoxide Sulphuric Acid Terpineol Tetra hydro Furon Toluene Sodium salicylate Zn Chloride Propylene Acetylene Hydrogen Benzaldehyde N Pentanol Propionaldehyde Pthalic Acid Vinyl Ethyl Ether Sodium Hydride Aluminum Trichloride Di Chloro Methane N Butyl Aldehyde Tertiary Butyl Methyl Ether N ,O Dimethyl Hydroxyl Amine Hydrochloride 160.00 12.24 21.30 15.00 10.00 68.18 200.00 28.03 35.70 0.52 5.00 5.00 6.00 100.00 96.00 142.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 Geraniol Linalool Meta Chloro Pre Benzoic Acid 1 Phenyl Ethanol ( Styrallyl Alcohol) 55 Furan 56 Allyl Alcohol 57 Aroma & Flavor Ingredients For Formulation 5.00 5.00 5.00 5.00 51 52 53 54 5.00 5.00 80.00 Source: Raw material will be sourced locally and also from countries like Japan, USA and Germany. Sr. Raw Material Quantity Storage Physical Stored In MOC No in MT/M At a Form time during the month 1 Acetic Acid Glacial 182.00 10.00 Liquid Tank SS304 2 Acetic Anhydride 53.00 4.00 Liquid Drums HDPE 3 Acid Catalyst 17.00 2.00 Liquid Carboy/ Drums HDPE 4 Aldehyde 5 Caryophellene 6 Phase transfer Catalyst 7 Caustic lye 85.00 4.00 1.10 6.00 1.00 0.10 Liquid Liquid Liquid Drums Drums Drum HDPE GI HDPE 1.04 1.00 Liquid Carboy HDPE Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 8 8 Citronellol 9 Benzylledene Acetone 10 D’limonene/Orange Terpenes 11 Di Ethanol Amine 12 Dicyclopentadiene 13 Ethyl Chloro Acetate 14 Benzyl chloride 15 Halide (Pentyl Bromide/ Chloride) 17.03 105.00 2.00 10.00 Liquid Liquid Drums Drums MS Epoxy GI 98.00 10.00 Liquid Drums MS Epoxy 1.00 240.00 22.05 27.60 106.00 1.00 20.00 5.00 2.50 10.00 Liquid Liquid Liquid Liquid Liquid Drums Tank Drums Drums Drums MS Epoxy SS304 HDPE HDPE HDPE 16 17 18 19 20 21 22 HCL 45% Iodine Iso Amyl Alcohol Isobutyric Acid Methanol Methyl Heptanone Methyl Magnesium Bromide / Chloride 1.00 0.05 10.00 60.00 15.00 69.00 31.61 1.00 0.05 2.00 10.00 3.00 10.00 2.50 Liquid Solid Liquid Liquid Liquid Liquid Liquid Carboys Can Drums Drums Drums Drums Drums HDPE GI HDPE HDPE MS HDPE MS 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Hexyl Alcohol Mg Turnings Pentanol mixture Propionic Acid Salicylic Acid Soda Ash Sodium Acetate Sodium Methoxide Sulphuric Acid Terpineol Tetra hydro Furon Toluene Sodium salicylate Zn Chloride Propylene Acetylene Hydrogen Benzaldehyde N Pentanol Propionaldehyde Pthalic Acid Vinyl Ethyl Ether Sodium Hydride Aluminum Trichloride Di Chloro Methane N Butyl Aldehyde Tertiary Butyl Methyl Ether N ,O Dimethylhydroxylam ine Hydrochloride Geraniol 52.00 12.74 77.14 46.00 160.00 12.24 21.30 15.00 10.00 68.18 200.00 28.03 35.70 0.52 5.00 5.00 6.00 100.00 96.00 142.00 5.00 5.00 5.00 5.00 2.80 2.00 20.00 5.00 16.00 2.00 2.20 2.00 1.20 5.00 6.00 3.00 3.50 0.05 1.00 1.00 1.00 10.00 10.00 10.00 1.00 1.00 1.00 1.00 Liquid Solid Liquid Liquid Solid Solid Solid Solid Liquid Liquid Liquid Liquid Solid Solid Gas Gas Gas Liquid Liquid Liquid Liquid Liquid Liquid Liquid Drums Bags Tanks Drums Bags Bags Bags Can Carboys Drums Drums Drums Containers Can Capsules Capsules Capsules Drums Drums Tank Drums Drums Drums Drums MS Epoxy PP MS HDPE PP PP PP GI HDPE GI MS MS HDPE GI SS304 SS304 SS304 MS MS SS304 MS MS MS MS 5.00 5.00 5.00 1.00 1.00 1.00 Liquid Liquid Liquid Drums Drums Drums MS MS MS 5.00 1.00 Liquid Drums MS 5.00 1.00 Liquid Drums MS 47 48 49 50 51 Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 9 52 Linalool 53 Meta Chloro Pre Benzoic Acid 54 1 Phenyl Ethanol ( Styrallyl Alcohol) 5.00 5.00 1.00 1.00 Liquid Liquid Drums Drums MS MS 5.00 1.00 Liquid Drums MS 55 Furan 56 Allyl Alcohol 57 Aroma & Flavor Ingredients 5.00 5.00 80.00 1.00 1.00 50.00 Liquid Liquid Liquid & Solids Drums Drums Drums/Cans/Boxes /Containers MS MS MS/HDPE /Aluminu m LocationFor theproposed project the company will use its spare land from the existing plotsat Gut No 167, 169, 170, 171, 296, Village. Jamghar Lakhamapur, Tal. Wada, District: Thane, Maharashtra. Thissiteisin onallfoursides wearesurroundedby industriesandnonuisance isspread.The immediate surroundingneighborsare: East :Abhinav Pharmaceuticals Pvt Ltd, Mumbai Wada Jawahar Highway West: Agricultural Land, Village Lakhmapur South: A g r i c u l t u r a l L a n d , V i l l a g e L a k h m a p u r North: AFFPL Green Belt, Village Road, Residential Building Locationtooisjustifiable.Unitsizeiskeptcorrectfor easeofhandling andenvironmentalcontrol. Astherea r e o t h e r i n d u s t r i e s inthe neighborhoodw i t h similarn a t u r e , there is compatibility. Thelanduseisalreadyas“Industrial land/Non Agriculture Land”.Thus,thereisnochangeinthestatus.Thisisaflat landw h e r e by cutting- f i l l i n g balancesand t h e r e willbeNoLowBorrowingfromNature. Tansa wildlife Sanctuary is about 8.3 kms North West of the site and the plot is located in private industrial land hence requires Environment Clearance from the Ministry Of Environment, Forest and Climate Change with Public Consultation. Geographical Location Items: Latitude : Approx. 19° 5'9.63"N Longitude : Approx. 73°10'9.86"E Terrain :: Flat terrain Climate Semi-Arid 4. Resources Site AFFPL is desirous to establish and it requires following resources, • Area 48900sq. mts • Water Input Ground Water for existing 2 No’s bore wells and 1 No Well. New Two No’s Borewell proposed with Rain Harvesting Facility will be put in place. • Work force 65 • Raw Materials Commensurate with product, as also work up chemicals Solvents& catalysts •Effluent Facility High COD and TDS sub stream segregated self-treatment And Later CETP (membership is sought)/Gardening • Haz. Waste Facility CSWTSDF at Taloja, Maharashtra • Process Machinery Developed by self available locally maintained sophisticated Laboratory Attendants, cooling tower, hot water generations, Steam Boilers • Units Instrumentation Precision and accurate • Total InvestmentRs.19.3408Crores (Rs 9.3408Crores Present + Rs 10.00Crores Expansion) • Environment Fund 2% • Proponents Law abiding. No litigation pending. Site 1. Existing industrial premises and land area: 48900sq mts Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 10 2. 3. 4. Climatic condition suitable for finer adjustments of control, making it fit for processing Conditions. Well connected for transportation through Mumbai Wada-Jawahar Highway Leveled ground and load bearing soil Technology Selection 1. The products proposed are in the same manufacturing range for which the technology is already developed, and well known. 2. The process used is based on raw materials that are available, without any bottleneck. Thus, Excess storage also means wastage. Here, we can follow easily the principle of JIT (Just in Time). 3. The process used is developed by AFFPL them in house and hence we are aware aboutthesensitivepoints needing careful attention in advance. 4. The process is cost effective, safe and environmentally friendly. 5. There is no elevated pressure condition in processing. 6. Solvents used that are recoverable, and are so recovered. 7. The steam & hot water from boilers will be used for process Instrumentation 1. Latestelectronicinstrumentationwithhighaccuracyandreliability 2. 100% redundancy forcontrolandpowersupply. 3. EmergencyShutdownSystemforensuringsafetyofplantandpersonnel. 4. Streamflow,feedwaterflowismeasurable(indicatingandrecording) 5. Waterlevelandliquidmateriallevelismeasurable(indicatingand recording) 6. Multipointtemperaturescannerwiththermocouple.Allpointsindicatingandrecordingallforsteam,feedwater ,fluegasandair) 7. Pressuregaugesatreactors. 8. Multi-channeldataloggertoinputs likecurrents,mv,T/Cam recordingwith columneddotmatrixprinter. 9. Hootersfortrips,lowlevels,highlevelsandhightemperatures. Machinery & Hardware: 1. ModernClosed Pump transfer system isused toavoid any risks in human being handling the production. 2. All processing equipment likereactors material of construction will be compatible to process. 3. Generally, will be of SS316/GLR quality and will be kept validated as per strict international guidelines prescribed. 4. The condensers are in SS316. 5. Wherever water is used, will be specially purified for process and cleaning- washing. 6. Help of sophisticated configuration may be taken, if necessary. Project proponents AARAV Fragrances & Flavors Pvt.Ltd. (AFFPL) was incorporated in 2007. The promoters of the company have more than 20 years of experience and profound understanding of the fragrance & flavor industry to provide strategic inputs into key business decisions and developing long term goals. AFFPL have developed strategic partnership with key global & local suppliers of synthetic and Natural ingredients to provide consistent supply of fragrances & flavors to our valued customers. AFFPL proudly service a wide range of SME's as well as multinational companies, both global & Indian. To experience a great fragrance is to experience magic, fragrance has the power to captivate the senses and transport our mind to new realm of imagination. AFFPL excels in the art and science of great fragrance creation. Guided by our principles of Balance, Clarity and Integrity, we put our expertise behind your brand to create signature fragrances. AFFL fragrances create unique, consistent and lasting experience for all consumers. AFFL takes pride in partnering with their customers to ensure that when a product is picked off the self, customer brand promise is fulfilled to the utmost satisfaction of the consumers from various categories Some of the most profound memories are attached with food customer’s taste. We develop unique flavor experiences that deliver your brand promise to consumers. AFFL experts are constantly researching trends and focusing on the magic that consumers are looking for in the market. AFFL development team works closely with the clients on specific briefs to deliver unique flavours within stipulated deadlines for various categories. Thecompany hasadoptedfollowingcertifications 1. ISO 9001 2. ISO 22000 3. ISO27001( Under Implementation) 4. Food Safety Standards Authority Certification. The Board of Directors represents an optimum mix of knowledge, experience and expertise to guide the longterm success of the company.Theproponentsare Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 11 Sr.No. 1. 2. Name Designation Mr. Ajit Suresh Vaze CEO/ManagingDirector Master Of Science Organic Chemistry Engineer Ms. AnuradhaAjitVaze Director 3. Mr. AjitDeshmukh Director 4. Mr. Jean Louis Matthey Director 5. Mr. HolgerHauenschild Director 5. Process Products AFFPL proposes to establish a plant to produce synthetic organic chemicals catering to the perfumery & Flavor industry. These products serve as raw material to the fragrance and flavors industries. As season changes the demand for a fragrance /flavor changes, hence the demand for particular chemical ingredients also changes, the industry has thus to be in readiness to change the product suitability as well as the application and be prepared to mitigate the corresponding customer requirement challenges. The utilities required will be steam which will be provided by the existing steamer and a new IBR Boiler will be installed. Other will be provided by newer fresh technologies for cooling, vacuum etc. The multi-product facility will be operated as normal chemical industry but the reactors will be used by different combination and sequence. From the list of Products Sr Nos 2 to11 only two to three products will be manufactured simultaneously. The total quantities to produce for Products Sr No 2 to 11 will be for any one or all cumulatively up to 300MT It may be seen that, There is a capability of making these products Production process is batch process with “Cleaner Production” strategy with effluents recycles Machineries, utilities will be installed according to the requirement of the plant and products. Schematic Process Flow for Proposed Products COMPLIANCE TO MSIHC RULES: According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical Rules, 1989), data on the toxicity and flammable characteristics for the chemicals involved is as presented below in the form of tables. Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 12 Storage details for Raw Materials to be used in manufacturing activities: Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Raw Material Quantity in MT/M Acetic Acid Glacial Acetic Anhydride Acid Catalyst Aldehyde Caryophellene Phase transfer Catalyst Caustic lye Citronellol Benzylledene Acetone D’limonene/Orange Terpenes Di Ethanol Amine Dicyclopentadiene Ethyl Chloro Acetate Benzyl chloride Halide (Pentyl Bromide/ Chloride) HCl 45% Iodine Iso Amyl Alcohol Isobutyric Acid Methanol Methyl Heptanone Methyl Magnesium Bromide / Chloride Hexyl Alcohol Mg Turnings Pentanol mixture Propionic Acid Salicylic Acid Soda Ash Sodium Acetate Sodium Methoxide Sulphuric Acid Terpineol Tetra hydro Furon Toluene Sodium salicylate Zn Chloride Propylene Acetylene Hydrogen Benzaldehyde N Pentanol Propionaldehyde Pthalic Acid Vinyl Ethyl Ether Physical Form 182.00 53.00 17.00 85.00 4.00 1.10 1.04 17.03 105.00 98.00 1.00 240.00 22.05 27.60 106.00 Storage At a time during the month 10.00 4.00 2.00 6.00 1.00 0.10 1.00 2.00 10.00 10.00 1.00 20.00 5.00 2.50 10.00 Stored In MOC Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Tank Drums Carboy/Drums Drums Drums Drum Carboy Drums Drums Drums Drums Tank Drums Drums Drums SS304 HDPE HDPE HDPE GI HDPE HDPE MS Epoxy GI MS Epoxy MS Epoxy SS304 HDPE HDPE HDPE 1.00 0.05 10.00 60.00 15.00 69.00 31.61 1.00 0.05 2.00 10.00 3.00 10.00 2.50 Liquid Solid Liquid Liquid Liquid Liquid Liquid Carboys Can Drums Drums Drums Drums Drums HDPE GI HDPE HDPE MS HDPE MS 52.00 12.74 77.14 46.00 160.00 12.24 21.30 15.00 10.00 68.18 200.00 28.03 35.70 0.52 5.00 5.00 6.00 100.00 96.00 142.00 5.00 5.00 2.80 2.00 20.00 5.00 16.00 2.00 2.20 2.00 1.20 5.00 6.00 3.00 3.50 0.05 1.00 1.00 1.00 10.00 10.00 10.00 1.00 1.00 Liquid Solid Liquid Liquid Solid Solid Solid Solid Liquid Liquid Liquid Liquid Solid Solid Gas Gas Gas Liquid Liquid Liquid Liquid Liquid Drums Bags Tanks Drums Bags Bags Bags Can Carboys Drums Drums Drums Containers Can Capsules Capsules Capsules Drums Drums Tank Drums Drums Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. MS Epoxy PP MSEpoxy HDPE PP PP PP GI HDPE GI MSEpoxy MSEpoxy HDPE GI SS304 SS304 SS304 MS MSEpoxy SS304 MSEpoxy MS Epoxy 13 45 46 47 48 49 50 51 52 53 54 Sodium Hydride Aluminum Trichloride Di Chloro Methane N Butyl Aldehyde Tertiary Butyl Methyl Ether N ,O Dimethylhydroxylamine Hydrochloride Geraniol Linalool Meta Chloro Pre Benzoic Acid 1 Phenyl Ethanol ( Styrallyl Alcohol) 55 Furan 56 Allyl Alcohol 57 Aroma & Flavor Ingredients 5.00 5.00 5.00 5.00 5.00 5.00 1.00 1.00 1.00 1.00 1.00 1.00 Liquid Liquid Liquid Liquid Liquid Liquid Drums Drums Drums Drums Drums Drums MS Epoxy MSEpoxy MSEpoxy MSEpoxy MS MS 5.00 5.00 5.00 1.00 1.00 1.00 Liquid Liquid Liquid Drums Drums Drums MS MS MS 5.00 1.00 Liquid Drums MS 5.00 5.00 80.00 1.00 1.00 50.00 Liquid Liquid Liquid & Solids Drums MS Drums MS Drums/Cans/ MS/HDPE/ Boxes/Contain Aluminum ers Storage Details For Products Proposed to be Manufactured Sr. No 1 2 3 4 5 6 7 8 9 10 11 12 Raw Material Quantity in MT/M Fragrances/Perfumes & Flavors (formulation) Perfumery & Flavors Esters Perfumery & Flavors Alcohol Perfumery & Flavors Aldehyde & Aldehyde Derivatives Dimerization and Trimerization of simple olefins. Ketals / Acetals / substituted 1,3propanediols Macrocyclic and polycyclic musks derived from propylene or butadiene/ and other propylene derivatives Aldehydes & Ketones by Aldol Condensation Acetylene and other alkyne derivatives Cyclo Alkylation/Acetylation, Diel Alders Reactions ,Friedel Craft Reactions Hydrogenation Compounds Inorganic Salts Overall Environmental Significance: Unit Operation/ Process 1.IncomingRaw Materials 210.00 300.00 Storage At a time in MT/M 50.00 35.00 Physical Form Stored In MOC Liquid Cans/Drums Aluminum/MS Liquid Liquid Cans/Drums Aluminum/MS Cans/Drums Aluminum/MS Liquid Cans/Drums Aluminum/MS Liquid Cans/Drums Aluminum/MS Liquid Cans/Drums Aluminum/MS Liquid Cans/Drums Aluminum/MS Cans/Drums Aluminum/MS 50.00 560.00 Peculiarities 20.00 105.00 Liquid Cans/Drums Aluminum/MS Liquid Cans/Drums Aluminum/MS Liquid Solids Cans/Drums Aluminum/MS Bags HDPE/PP Environmental significance Selected from known vendor’s Prompt use and storage in closed transportation enclosed containers prevent spillages and loss of tankers/Drums in limited low strength. Fewer emissions. volumes. Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 14 2.Weighingand strict Quality control Load Cell based weighing system Better check on mass balance, purer provided material and less rejections. 3.Inprocess Solvents Byproducts Recovered and reused Recovered and sold to parties, when in demand Process waste residue To be sent on common facility for disposal by incineration. 4.Instrumentation Control system for accurate process controls Facilitates monitoring of quality of the product and safety aspects. 5.Control Excellent system of documentation and control of critical stages in production process Better operation and retrievable records for better checks. 6.Solvent Recovery Proper recovery systems with Vapor and Product Condensers with Step vapor condenser and chilled unit. down chilling and cooling systems 6. Pollution control Clean production technology adopted byensuringfollowing a t design a n d e n g i n e e r i n g stage. All Products & their reactions selected after considering the friendliness of these products on the environment Minimize pollutants at source Recovering and recycle of the RM Maximize recycle of water resources. Tertiary ETP System will be erected and operated Treat to PCB norms 100% recycle of increased effluents for process for defined cycles. Procure CEPT Membership when available Use with Priority Environment Friendly Fuels Like Ground Shells Briquettes, Agricultural Waste. Reduction of VOC at every processing stage by providing vents condensers and scrubbers. Use of mainly clean fuels like agricultural waste/FO/LDO. All Process Transfers will be conducted in enclosed systems by pumps. The process where varies based on Esterification of organic acid and alcohol producing water. The recovery system will be designed in such a way that entire water is used for process application there by replacing fresh water input. The boiler is provided with cyclone separator, bag filter/ ESP to control emission within prescribed limits. The stack hei ght will be up to 30 meters to control ground level clearance within limits. Process vents are controlled by condensers followed by water cooling and chilling systems and with which the organics are recovered and recycled. (a) Water & waste water: The water and waste water generated in the factory will be as follows; i. Water Requirements: Details Of Fresh Water Consumption Sr Water Break Up Existing Water Proposed Water Total Water No Consumption Consumption Consumption ( KL/Day) (KL/Day) (KL/Day) I 5.00 5.00 10.00 Domestic II 0.00 80.00 80.00 Gardening III Industrial 1)Process 0.00 5.00 5.00 2)Cooling Water Make up 0.00 9.00 9.00 3) Boiler Make Up 3.50 13.50 16.00 4) Washings 0.00 3.00 3.00 Total Industrial 8.50 115.50 124.00 Details Of Waste Water Sr Waste Water Break Up Existing Waste Proposed Waste Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. Total Waste 15 No. I II Domestic Industrial 1)Process 2)Cooling Water 3) Boiler Blow Down & Cooling 4) Washings Total Industrial The industry will obtain membership of CETP. Water Balance Diagram: Water Generation (KL/Day) 3.60 Water Generation (KL/Day) WaterGeneration (KL/Day) 3.60 7.20 0.00 0.00 2.70 0.00 7.30 5.00 9.00 12.00 3.00 32.6 5.00 9.00 12.00 3.00 36.20 Schematic Diagram for Fresh Water Requirement and Waste Water Flow Fresh Water From Borewells/Well 124 kl/Day Fre sh Re cycle d Re cycle d Re cycle d Total Gardening Domestic 80kl/Day 3kl/Day 12.8kl/Day 8kl/Day 103.8kl/Day 10kl/Day Se wage Tre atme nt Plant 3kl/day Cooling Tower 9kl/Day RO 28kl/day Cooling Tower Blow Down 9kl/Day RO Reject RO Water to Boiler Feed 11.2kl/Day 16.8kl/Day Process Washings 5kl/Day 3kl/Day 8KL Recovered to ETP Boiler Blow Down 12.8kl/Day Recylce back to garden/ Or CEPT Efflue nt Tre atme nt Plant Proposed ETP Flow Sheet: Inlet Outlet Oil & Grease Trap Equalisation and Neutralization Tank Primary Settling Tank 1st Stage Aeration Tank Final Dishcarge Tank Pressure Sand Filter Intermediate Collection Tank 2nd Stage Secondary Settling Tank Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 1st Stage Secondary Settling Tank 2nd Stage Aeration Tank 16 (b) Air Pollution: The existing plant comprises of 1 small industrial boiler (Steamer). The fuel used in the existing boiler is furnace oil. Two DG Sets a.63kva for emergency and power failures & b. 160kva exclusively for fire alarms & firefighting hydrant systems is already installed, which is used only during power failures. Proposed Scenario: For the proposed expansion unit, the existing steam boiler will be kept as stand by. A new 5 MT IBR Boiler and a new thermic fluid heater will be installed. The details of the boiler and thermic Fluid heater are given below: Details of Boiler and Thermic Fluid heater Capacity Details of Air Pollution Control unit: The proposed plant will not produce any significant air pollution load. The major sources of air pollution will be: Boiler Thermic Fluid Heater Sources of Emissions Fuel used Quantity of fuel Gaseous Boiler (1x 5MT/Hr) Thermic Fluid Heater (1x 3Lac kcals/ hr) Agricultural Waste /Bio Coal/ Furnace Agricultural Waste /Bio Coal/ Furnace Oil oil/Coal / NG /Coal /NG 22 mt/Day / 22mt/day/10 mt/day 5mt/Day/5mt/day/2.5mt/day/5mt/day/ /22mt/day/8500 m3/Day 2500m3/day SO2, NOX, PM SO2, NOX, PM 30 mts 13 mts 0.505 mts 0.505 mts Type of emissions Stack height Stack dia. at the top D.G. Set Emissions Fugitive emissions Process emissions To control the fly ash particles / particulate emissions from the boiler, cyclone will be installed in the proposed project. There are no process emissions from the proposed project. Schematic diagram of cyclone The existing D.G. Set shall be used only in case of emergencies / Power failure & Fire Related emergencies. A New DG will be installed replacing the 63KVA Details of D.G. Set Existing D.G.Set Existing D.G.Set Proposed D.G.Set Sources of gaseous emissions (63 KVA) (160 KVA) (500 KVA) Fuel used Diesel Diesel Diesel Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 17 Quantity of fuel (Will depend on 11lits/Hr Power Failure & Emergencies) Type of emissions PM, SO2& NOX Stack height 3 meters Capacity of D.G.Set 63 KVA 35lits/Hr 105 lts/hr PM, SO2& NOX 3 meters 160 KVA PM, SO2& NOX 3 meters 300 KVA Sr Source No 1 Proposed 5MTBoiler. Pollutant Measures SPM, CO,SO2, NOx 2 VOC Dust Collectors,, ESP, Tall stack of 30 m. Dust extraction with Bag filters, fogging. Closed loop transfer Vent condensers, Extraction and scrubbing Segregation of Streams Fully aerobic 3 In process Control Equipment ETP COD, TDS Noise : There is no major noise generating sources. Only those Vehicles with PUC's and spark arresters will be allowed inside the premises. Green belt facilities have also been provided in the plant premises. Details of Hazardous Waste Generation and Disposal: The plant will have the maximum solid waste generation from the ETP, which will be sent to CHWTSDF, Taloja, Maharashtra for its disposal applied for membership. Details of Hazardous waste generation and disposal: Sr. Type of Waste Category Existing Proposed Mode of disposal No. Quantity Quantity MT/Annum MT/month 1 ETP Sludge 34.3 0.060 100.00 Collection, storage, transportation and disposal to TSDF. 2 Used Oil 5.1 0.00 2.40 Collection, storage, transportation and disposal by sale to registered recyclers. 3 Discarded 33.3 0.00 12.25 Collection, storage, Containers decontamination, transportation and disposal by sale to authorized recycler 4 FO / LDO & -3.36 Collection, storage, Oil Bottoms 0.00 transportation and disposal by Sludge sale to authorized recycler 5 Distillation 20.3 0.00 16.200 Collection, storage, Residue transportation and disposal to CHWI. 6 Grease 5.2 0.00 0.012 Collection, storage, transportation and disposal by sale to authorized recycler 7 Fly ash (Boiler 0.00 482.00 Will be sold to brick & TF Ash) manufacturers. 8 Low purity C8 0.00 72.00 Will be sold. fractions 9 Spent acid -0.00 16.00 Will be sold. Hazardous Waste Storage Room: A hazardous waste storage room measuring 100sqmts will be provided with impervious RCC flooring and leachate collection pit. The distillation residue will be stored in carboys in Hazardous waste storage room and will be finally disposed of to CHWTDFS, Taloja, Maharashtra. The Fly ash will be stored in a defined area and precautionary measure will take for avoid carryover of the ash by wind/breeze/water etc. Dispersion: Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 18 Point Emissions are coming from one boiler, thermic fluid heater &3 DG hence proper stacks will be provided for the same. Please note DG 3 Nos will be used only in emergency & during power failures. The stacks will be fitted with port-holes, ladder and platform for facility of taking samples. Fugitive: A number of mitigation measures will be taken to control fugitive emissions Engineering, the plant layout will be in such a way so as to virtually eliminate need of using heavy Equipment for material handling in the main plant Internal roads paved, leveled, no undulations, no sharp curves, slow speed. No open storage of materials involved Fumes extraction and vacuum system will provided for extraction of fumes from the reactors and the process plant areas. Fugitive Emissions and its control: There are no emissions from the manufacturing process. For control of fugitive emissions, chilled water traps will be installed on the vent of the unit to arrest any escape of vapors from the reaction and distillation unit. Fugitive emission could occur from the storage yard of raw materials and finished products. The storage quantity is very low and proper handling methods will be adopted. Emissions from transport of vehicles would occur to a certain extent. The emissions from traffic movements is controlled by proper planning of the transport of raw materials and finished products to and fro from the factory premises. Since the quantities involved are very less, movement of vehicles will be occasional. All the roads inside the plant will be concreted to reduce any dust emissions. Details of Solvent recovery Plan and monitoring of vents: The solvent recovery system for the proposed expansion project is shown in the figure below. The vents of the reactors will be connected to 2 stage condenser system, where chilled water will be recalculated. The receiver will also be jacketed with circulation of chilled water. The recovered solvents will then be stored and reused. All the units will be under nitrogen blanketing through cylinders. Proper planning and maintenance will control the extent of fugitive emissions. During the production, the industry will carry out regular monitoring of fugitive emissions as per the factories act. Details of Solvent Recovery Plan Aesthetics: There will be no nuisance from noise. DG 3 Nos will be used only in emergency & during power failures to keep plant under safe conditions. If Coal is used as fuel for boiler there will crushing and pulverizing Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd. 19 operations for coal handling. Dust suppression system is provided. Dust extraction with dust collection will be provided. Labor strength will also be limited. 7. Background Study: 1.a) 1.b) 1.c) 1.e) 1.f) LAND ENVIRONMENT: Area : Study area (10km) Topography of the area indicating gradients, aspects and altitude. Details: Establishment of Land Use Pattern. Locations of National Park/ Sanctuary/Biosphere Reserve/ Monument /Heritage site/Reserve Forests. Soil Samples : Soil Analysis to cover 7 locations in the project area. Parameters : pH, EC (mhos/cm2), Organic Carbon, Phosphorous as P (kg/Ha), Potassium as K (kg/Ha), Sulphate as SO4 (%), Textural classification, Available nitrogen (kg/Ha). AIR ENVIRONMENT: BASELINE AAQ: Number of stations : 6 in study area Frequency : 2 days per week Duration : One season. Parameters : PM10, NOx, SO2, NMHC, CO, Primary Meteorological data, (WS/WD/DB Temp. / RH), Review frequency of inversion, Frequency of cyclones/ tornadoes/ cloud burst from Climatological Tables & other available secondary data. NOISE ENVIRONMENT: Number of station : Same as AAQ locations locations Frequency : Hourly measurements to determine day time / night time Leq. as per Environment Protection Act. Duration : Once in the season Method of sampling : Continuous sound level meter and analysis WATER ENVIRONMENT: Number of locations : 7 locations for Ground/ Surface water within study area. Frequency : One sample per location. Duration : One season. Parameters : As per ISO 10500-2012 SOCIOECONOMIC DATA: Area : study area Details : Demographic Pattern (literacy Rate, Male to Female Ratio), Occupational Pattern, Socioeconomic Status etc. Prefeasibility Report–M/s Aarav Fragrances & Flavors Pvt. Ltd.
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