1. EXECUTIVE SUMMARY 1.1 BACKGROUND M/s. Gokul Agro Resources Ltd. is an existing large ...

96 Pages·2015·2.15 MB·English

Pre-Feasibility Report for
Proposed expansion Project of Synthetic Organic Chemicals

1. E
XECUTIVE SUMMARY
1.1 BACKGROUND
M/s. Gokul Agro Resources Ltd. is an existing large scale unit located at Survey No.
76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-Borichi, Tal.: Anjar Dist.: Kutch and
engaged in the manufacturing of Refined Oil. At the time of establishment of the unit
in the year 2004, Environment Clearance was not applicable as per the EIA
notification of 1994 for manufacturing of Refined Oil. As per EIA notification of 2006,
manufacturing of existing products was not covered under categories listed in
notification, hence Environment Clearance was not applicable. Therefore, unit has
obtained Consent to Establish (CTE) and Consent to Operate (CCA) from GPCB for
manufacturing of existing products. As per current CCA of GPCB, maximum
production capacity of the unit is 2,29,690 MT/Month. Gokul Group has filed petition in
High Court of Gujarat and received court order, w.e.f. 1st July 2015, for de-merger of
their existing unit Gokul Refoils and Solvent Ltd. (GRSL) in to Gokul Agro Resources
Limited (GARL).
GRSL has been granted Consolidated Consents and Authorization by Gujarat
Pollution Control Board (GPCB) as follows
Survey Order Date of
Letter No. Validity
No. No. Issue
89 AWH- PC/CCA-KUTCH-171(4)/GPCB ID 07/08/2014 19/06/2019
63949 17855/221545
80 & AWH- PC/CCA-KUTCH-468(2)/GPCB ID 17/05/2014 13/02/2019
91 62132 33304/213613
Unit has filed an application at GPCB for amendment in above listed CCA for change
in name of the company to Gokul Agro Resources Ltd. and consolidation of two CCA
into Single one.
Now, considering the market demand, the unit proposes to manufacture various
synthetic organic chemicals derived from Castor Oil to the tune of 12,000 MT/Month.
The proposed project will be covered under Category 5(f)-B as per new EIA
Notification of Ministry of Environment & Forest (MoEF), dated 14/09/2006. Therefore,
unit requires obtaining Environmental Clearance from State Level Environmental
Impact Assessment Authority (SEIAA), Gujarat.

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Proposed expansion Project of Synthetic Organic Chemicals

1.2 SALIENT FEATURES OF THE PLANT SITE:
 The proposed project will be set up in existing premises. Existing plot size is
adequate for the proposed project requirement. Thus, no additional land will be
required.
 The project site is located in the light industrial zone declared by Gandhidham
Development Authority (GDA) having all basic facilities like availability of water
and natural gas, electricity, transport, telecommunication systems, etc.
 The proposed products will be manufactured within the existing industrial
establishment, which would facilitate existing infrastructure mainly covering utility
services.
 There is no protected area notified under the Wild Life (Protection) Act (1972) &
Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-
1986 existing within 10 Km radius areas from the Plant Site.
1.3 DETAILS OF EXISTING AND PROPOSED PRODUCTS:
Existing unit is involved in the manufacturing of Refined Castor oil. Unit proposes to
manufacture synthetic organic chemicals derived from Castor oil. The details of
existing and proposed products and by-products are given in Table 1(a), 1(b) & Table
2(a), 2(b).
Table- 1(a): Details of Existing Products
Capacity
Sr. No. Name Of The Products
(MT/Month)
Refined Oil :
1. A. Crude Palmolein (Physical) 30,000.00
B. Crude Palm Oil (Physical)
2. Refined Oil (Conventional): Degummed Soya Oil 12,000.00
Hydrogenated Vanaspati Oil
3. Hydrogenated Palm Fatty Acid 7,000.00
Bakery Shortenings
4. Crude Soya Bean Oil 8,500.00
5. Solvent Extracted Meal 36,000.00
6. Crude Rapeseed Oil 8,500.00
7. Lecithin 250.00
8. Soya Bean Gums 250.00
9. Soya Flour 6,750.00
10. Soya Vadi 3,500.00
11. Castor Commercial and its different grades 25,000.00
12. Castor Cake 32,400.00

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Pre-Feasibility Report for
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Capacity
Sr. No. Name Of The Products
(MT/Month)
13. Rapeseed / Mustard Seed / Canola Seed Cake 9,540.00
Rapeseed / Mustard Seed / Canola Seed Extraction
14. 25,000.00
Meal
15. Castor Extraction Meal 25,000.00
Total 2,29,690.00
1. Captive Power Plant 1.3 MW
2. Filling Plant for Consumer Packing
2.1 Soft Oil Pouch Filling: 200 ML to 1 Liter (Unit I) 2,500.00
2.2 Soft Oil Pouch Filling: 200 ML to 1 Liter (Unit II) 5,000.00
Soft Oil PET Bottle Filling: 500 ML, 1 Liter & 5 Liters – 2 Lines
2.3 3,500.00
(Unit I)
2.4 Soft Oil HDPE Jar Filling: 2 Liters to 15 Liters (Unit I) 3,500.00
2.5 Soft Oil Tin Filling: 15 Liters & 15 Kg. (Unit II) 10,500.00
2.6 Vanaspati Pouch Filling: 200 ML to 1 Liter (Unit I) 3,000.00
2.7 Vanaspati Jar Filling: 2 Liters to 15 Liters / KG (Unit I) 10,500.00
2.8 Vanaspati Tin Filling: 15 Liter and 15 Kg (Unit I) 10,500.00
2.9 Bakery Shortening Filling: 15 Kg. Poly Bag 500.00
3. Empty Tin Container: 15 Liters 6,00,000.00
4. HDPE Jar: 2 Liters and 5 Liters 90,000.00
5. HDPE Jar: 15 Liters and 15 Kg. 60,000.00
6. PET Bottles: 200 ML to 1 Liter 7,50,000.00
Table- 1(b): Details of Proposed Products
Total
Sr. Batch
Name of Product Capacity
No. Size (Kg)
(MT/Month)
a. Hydrogenated Castor Oil 15,000.00
1. 3,000.00
b. Hydrogenated Palm Strarine 15,000.00
a. 12 Hydroxy Stearic Acid (HSA) 3,500.00
2. b. Ricinoleic Acid (RA) 3,500.00 2,000.00
c. Hydrogenated Methyl Ricinoleate 5,000.00
a. Polymerized RA 3,500.00
3. b. Blown Castor Oil 4,000.00 500.00
c. Bisamide 4,000.00
a. De-Hydradted Castor Oil (DCO) 4,000.00
4. 500.00
b. DCO Fatty Acid 4,000.00
5. Undecylenic Acid (UDA) 1,000.00 30.00
6. Zinc UDA 1,000.00 30.00
7. Sebacic Acid 8,000.00 240.00
8. Sebacodiamine (C-10 Diamine) 8,000.00 240.00
9. Polyol 115 8,000.00 240.00

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Pre-Feasibility Report for

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10. Ethoxylated Castor oil 8,000.00 240.00
11. Glycerol Monosterate 8,000.00 240.00
12. Zinc Ricinoleate 5,000.00 150.00
13. DCO Stand Oil 5,000.00 360.00
14. Sulphonated Castor Oil 8,000.00 240.00
15. Distilled Fatty Acid 25,000.00 2,250.00
16. Dimer Acid 7,500.00 750.00
17. Iso Stearic Acid 5,000.00 300.00
18. Euracic Acid 5,000.00 450.00
19. Glycerine 8,000.00 240.00
Total 12,000.00

Table- 2(a): Details of existing By-Products:
Sr. Capacity
By-Products
No. (MT/Month)
1 Acid Oil 225.00
2 Deodistilate
1200.00
3 Palm Fatty Acid Distillate
4 Spent Earth 650.00
Table- 2(b): Details of proposed By-Products:
Sr. Capacity
By-Products Source
No. (MT/Month)
1 C18,C24,C18 270.00 Product 18
2 Distilled Monomer 615.00 Product 16
Product 4(b)
Product 7
Product 15
3 Glycerin 800.00 Product 2(a)
Product 2(b)
Product 2(c)
Product 18
4 Heptaldehyde 24.00 Product 5
5 Light Fatty Acid 25.00 Product 4(b)
Product 5
6 Mixed Fatty Acid 95.00
Product 7
7 2-Octanol (85%) 155.00 Product 7
Pitch
8 Product 8
(C-10 diamine/sebeconitrile) 28.00

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Pre-Feasibility Report for
Proposed expansion Project of Synthetic Organic Chemicals

Pyroletic Mass of
9 3.00 Product 5
Methyl Ricinoleate
Product 2(a)
10 Sodium Sulphate 985.00 Product 2(b)
Product 7
Product 8
11 Ammonium Sulphate 15.00
(APCM)
1.4 RESOURCE REQUIREMENT
 Land: The total land available with the existing unit is 2,12,362.12 sq. m.
additional land of 1,53,173.88 sq. m. would be required for proposed
expansion.
 Water: Presently the water requirement of the unit is met by bore well water
supply and same source will be utilized after proposed expansion. The total
fresh water requirement for the existing unit is 951.0 KL/day which will be
increased up to 1105.0 KL/day.
 Power: At present, the total connected load of power is 6500 KVA and Captive
Power of 1.23 MW. The power required is procured from Paschim Gujarat Vij
Company Limited (PGVCL) and the same source will be utilized after proposed
expansion. DG Sets (3 Nos. of 500 KVA and one 125 KVA) are installed as a
power backup in case of power failure from PGVCL. There is no additional
requirement of power for proposed expansion.
 Fuel: Presently the unit uses; coal @ 8.5 MT/hour + 150 MT/day, LDO @65 lit/h,
HSD @ 416.5 lit/h, and Furnace Oil 6000 kg/day as a fuel. Additional
requirement of the fuel for proposed expansion will be coal @ 30 MT/day,
FO/LDO @ 48 lit/h.
 Manpower: Total 613 personnel are working in the existing plant and for
proposed expansion, the unit has planned to employ about 68 additional
personnel comprising of Management, Supervisory and Workers.
 Finance: The unit is a Large Scale Unit and has made capital investment of Rs.
14,479.80 lacs in the existing plant. Capital cost towards Environmental
protection measures for existing project is Rs. 400.00 Lacs. The estimated cost
for the proposed expansion will be about Rs. 3950.00 Lacs. Out of which,
capital cost towards Environmental protection measures will be Rs. 250.00 Lacs.

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Pre-Feasibility Report for

Proposed expansion Project of Synthetic Organic Chemicals

1.5 POLLUTION POTENTIAL AND MITIGATION MEASURES:
 Water Pollution: At Present the total industrial waste water generation from
existing unit is 271 KL/day. Effluent from Process @14 KL/Day is reused for
cooling. Remaining 257 KL/Day, after treatment in ETP, is reused for cooling @
57 KL/day and gardening @ 200 KL/Day purpose.
The industrial effluent generation after the proposed expansion will increase
from 271 KL/day to 382 KL/day. Wastewater generated from proposed
expansion is 111 KL/day. Out of which 103 KL/Day will be treated in Multi Effect
Evaporator (MEE) and reused in process again and 8 KL/Day will be reused for
gardening purpose. Treated effluent will be reused in process again. Thus,
existing ETP along with an additional Evaporator will be adequate to treat and
handle the total pollution load.
 Air Pollution: There will be some flue gas emission from proposed Thermo pack
installation. Adequate APCM will be installed for proposed Thermo pack. There
will be process gas emission from the proposed expansion in the form of NH
3
Gas. Adequate scrubbing system of water scrubber followed by acidic
scrubber will be installed as an APCM. There will be very negligible chances of
fugitive emissions due to process, material handling and Transportation from
proposed expansion.
 Hazardous Waste: The main sources of hazardous waste generation from
proposed manufacturing activity will be Process Waste viz. Spent Catalyst,
Spent Carbon, Spent Acid, Distillation residue and dry ETP sludge. The ancillary
source of hazardous waste generation will be discarded containers, barrels,
bottles from storage and handling of raw materials and used/spent oil
generation from plant machinery. The unit has provided an adequate
designated storage area for the hazardous waste storage and has obtained
membership of TSDF.
 Greenbelt Development: The unit has developed green belt area in 8,466.00
sq. m. within the industrial premises. Additional greenbelt area will be
developed in 1,02,213.46 sq. m. At present, unit has planted around 1500 Nos.
of trees of various types within premises, Unit proposed to plant additional 1500
Nos. of tress for the proposed expansion.

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Pre-Feasibility Report for
Proposed expansion Project of Synthetic Organic Chemicals

2. I
NTRODUCTION
2.1. BACKGROUND
M/s. Gokul Agro Resources Ltd. is an existing large scale unit located at Survey No.
76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-Borichi, Tal.: Anjar Dist.: Kutch.
Presently, the unit is involved in the manufacturing of Refined Oil. Now, the unit
proposes to expand its manufacturing activity and intend to manufacture various
Castor Oil derivatives. As a part of application for obtaining Environmental
Clearance, the unit requires to submit Form-1 and Pre-Feasibility Report of the
proposed project.
The objectives of the report are,
a) To assess the feasibility of the proposed project.
b) To identify various sources of pollution and anticipate the impact of the
proposed project on the environment.
c) To evaluate Environmental Management Plan, to prevent and mitigate the
adverse impact on environment caused due to proposed project.
d) Propose the Terms of Reference to carry out EIA Study for the proposed project
2.2. NATURE OF THE PROJECT:
The unit is an existing large scale unit involved in the manufacturing of Refined Oil and
now proposes to expand its manufacturing activity. Unit intends to add new products
covered under Category 5 (f)-B as per new EIA notification.
The unit believes in sustainable development and is equally concerned about
environment preservation and pollution control. The unit has provided an adequate
Environmental Management System to meet desired norms of effluent discharge
(Water + Air + Solid) as per the statutory recruitments for their existing unit and also
proposes to expand its continuous endeavor for the pollution prevention and
betterment of environment.

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2.3. PROJECT PROPONENT:
Details about the promoters are given below:
Table-3: Details of promoters & Directors of the Company
Sr.
Name of Director Designation Address
No.
Shri Kanubhai J. 12, Ambica Nagar Society,
1 Director
Thakkar Opp. PGVCL, Sidhpur – 384 151
Shri Balwantsinh Additional 29, Ambica Nagar Society,
2
C. Rajput Director Opp. PGVCL, Sidhpur – 384 151
Shri Piyush Additional “Hari Om”, 29/B, Vasuki Society,
3
Chanra R. Vyas Director Vasna, Ahmedabad – 38 007
Smt. Dipooba H. Additional 35/3, Adyapak Niwas, Gujarat
4
Devada Director Vidyapith, Ahmedabad - 14
Shri Karansinhji D. Additional 1759/B, Sector 2-D,
5
Mahida Director Gandhinagar – 382 002
B-33, Upasana Co-op. Hsg. Soc.,
Shri Bipinkumar J. Additional
6 Survey No. 315, Maninagar,
Thakkar Director
Ahmedabad – 380 008

2.4. NEED FOR THE PROJECT & PROJECT BENEFITS:
Need for the project and its importance to the country and /or region
Castor is bio de-gradable and sustainable. Now-a-days, trend is to replace petroleum
product by the agricultural product. This is one of the commodities which can replace
one to one uses of petroleum products. Hydrogenated Castor Oil and Castor Oil
Derivatives are Agro based Organic Synthetics Chemicals having wide application in
polishes, pharmaceuticals, cosmetics, lubrication and coating & greases where
resistance to moisture, oils & other petrochemical products are required.
Demand-Supply Gap
Based on our informal survey of the market with our current customers and various
traders, we have found that there is a big potential for the range of the products we
are planning. These products will be an addition to the current range of our products.
Imports vs. Indigenous production
The latest trend exhibits the demand within Nationals and International levels. The raw
material for manufacturing the proposed products is easily available in local Indian
market, especially in the proposed area, at competitive rates, which is ultimately
benefit to finish products to enter in Global market at competitive position.

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Pre-Feasibility Report for
Proposed expansion Project of Synthetic Organic Chemicals

Export possibility
Depending on the international demand of products, the unit has explored the
possibility of exporting the products.
Domestic/Export Markets
Considering the market volatility of castor seeds and the market demand for the
Hydrogenated Castor Oil and Castor Oil Derivative products and advantage of the
location for the project; M/s. Gokul Agro Recourses Ltd. proposes to venture into
Export Oriented Unit.
Employment Generation (Direct and Indirect) due to project.
M/s. Gokul Agro Resources Ltd. will give direct employment to local people based on
their qualification and requirement. In addition to direct employment, indirect
employment will generate ancillary business to some extent for the local population.

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Proposed expansion Project of Synthetic Organic Chemicals

3. P
ROJECT LOCATION AND SITE ANALYSIS
3.1 LOCATION:
The unit is located at Survey No. 76/1, 80, 89 & 91 Near Sharma Resort, Meghpar-
Borichi, Tal.: Anjar Dist.: Kutch, Gujarat. The location map of project site is shown in
Plate-1 and the area covering 5 km radial distance from the project site is given as
Plate-2.
Plate1: Location Map of the Project Site:

Location of Kutch District in Gujarat
Location of Project Site in Kutch District

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