Pre-Feasibility Report Vinati Organics limited, Plot No.

A-20, D-30/2, MIDC Lote Parshuram

Pre-feasibility report for

Expansion of Synthetic Organic Chemical

Manufacturing Unit
By

M/s. Vinati Organics Limited

PROJECT TERMED UNDER SCHEDULE 5 (f) (SYNTHETIC ORGANIC CHEMICALS)

CATEGORY - B

Prepared By

M/s Vinati Organics Ltd

Plot No. A 20 & D 30/2, Lote MIDC, Lote Parshuram
Dist: Ratnagiri – 415722
Maharashtra, India
Web: www.vinatiorganics.com

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 1 Executive Summary

Company Profile

Vinati Organics Limited was established in 1989 and is a specialty chemical company
producing aromatics, monomers, polymers and other specialty products.
The company started operations in its first plant in Mahad in 1992, with its focus on Isobutyl
Benzene (IBB). A decade later, in 2002, it started commercial production in its second plant in
Lote, producing 2-Acrylamido-2-methyl propane Sulphonic acid. Vinati Organics Limited (VOL)
has enhanced the scope of its facilities and now also produces organic intermediates and
aromatics.
IBB, a specialty organic intermediary, is used as a raw material for the manufacture of Ibuprofen,
an anti-inflammatory analgesic bulk drug.
2-Acrylamido-2-methylpropane Sulphonic acid, a specialty monomer finds several applications
in oil-field recovery, water treatment, acrylic fibre manufacturing, adhesives, personal care
products, medical hydrogel, mining industry, coatings and as dispersing and flocculating agents.
Vinati Organics Limited is the world’s largest manufacturer of both 2-acrylamido-2-
methylpropane Sulphonic acid and IBB.
Company also started producing Isobutylene (IB), one of the key components used to
manufacture 2-Acrylamido-2-methyl propane sulphonic acid. Apart from being used internally,
IB is also sold to agrochemical and antioxidant industry.
Vinati Organics Limited (VOL) has always strived for excellence through adopting the best and
clean route for manufacturing chemicals. VOL has R & D facilities at both of its plant locations
which deal with synthesizing new molecules and optimizing the process promoters. VOL has
always emphasized on developing green and cost effective manufacturing techniques for
specialty chemicals which have the potential of developing into large scale products in the
future. VOL has collaborations with global technology providers like Institut Francais du Petrole
(IFP) France, Saipem SpA, Italy, etc. VOL has been closely associated with National Chemical
Laboratories (NCL), Indian Institute of Technology, Hyderabad (IICT) for developing cutting
edge technologies for commercially manufacturing specialty chemicals. VOL has successfully
demonstrated technology absorption from these research organizations in the past.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Vinati Organics limited now proposes to expand by adding manufacturing unit of synthetic
organic chemical (Butyl phenols, Para Tertiary Butyl Benzaldehyde and Lili aldehyde) at its
existing facility at plot no-A 20 & D 30/2, Lote- Parshuram MIDC, Dist Ratnagiri.

The company got EC for expansion at this site vide letter SEAC – 2015/CR-236/TC-2 dated 28th
June 2016 for expansion at the site.

With this PFR, the company wish to delete “Tertiary Butanol” product and wish to include “Butyl
phenols, Para Tertiary Butyl Benzaldehyde and Lili aldehyde” products.

The google image of the plot site is at Annexure – I

Proposed Layout Plan for new establishment is attached as Annexure–II.

Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide EIA
Notification SO 1533, dated September 14, 2006 and its amendments for Synthetic Organic
chemicals manufacturing units. This project falls under category ‘B’ and schedule item no. 5(f):
Synthetic organic chemicals.

The project brief is summarized in the table below

Project summary at a glance

Sr. No. Particulars Details

1 Name of Company Vinati Organics Limited
2 Products Butyl phenols, Para Tertiary Butyl Benzaldehyde, Lili-
Aldehyde and its by products
3 Location Plot no A20 & D30/2, Lote MIDC area, Dist Ratnagiri,
Pin 415722 Maharashtra.
4 Name of the project 1) Manufacture of Butyl phenols (39,000MTPA),
PTBBAL(2,000MTPA), Lili Aldehyde (2,000MTPA)
and its by products
5 Total land area of the 96,570 sq m (~23.86 Acres)
plot
6 Total proposed built up 81,797 sq m
area
7 Major raw material Refer chapter 3
8 Water Total fresh water requirement shall be approximately
27 CMD. It will be source from MIDC.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

9 Power Total power requirement is 250 KVA. It will be

sourced from MSEDCL Or Cogen Plant as per
availability.
Proposed additional Coal consumption: 30 TPD
10 Proposed manpower 120 No (permanent 45 & Contract 75)
11 Waste water quantity Trade effluent 18 cmd
(estimate) Domestic effluent 7 cmd
Total effluent generation 25 cmd

Trade effluent and domestic sewage will be treated

and recycled.
12 Air emissions The air emissions will be from Thermic fluid heater.

Adequate stack height as per statutory norms will be

provided to TFH sets.
13 Solid Waste Refer chapter 3
14 Project cost estimate ~ 179 Crores

The Land shall be used as “Industrial” land thus there shall be no change in land use.

This industrial plot A 20 & D 30/2 is allotted by MIDC to Vinati Organics limited and existing
unit is operational at site.

MIDC has provided all basic infrastructures like Electrical Power, water supply, the internal road
network, external approach road and networking with CHWSTDF (Common Hazardous Waste
Storage Treatment and Disposal Facility).

There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological
monuments, sanctuaries, etc.

The land and infrastructure is made available by MIDC and the raw material is easily available
through the easy transport via road connectivity by local suppliers as well as imported one.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 2 Introduction of the Project

2.1 Identification of the project and Project Proponent

This is a new project for the manufacturer of Synthetic organic chemical (Butyl phenols) by well-
known business group “Vinati Organics Limited” (VOL).

Some of the recent achievements of VOL are:

 Listed consecutively in Forbes Asia’s 200 Best Under A Billion companies for 2010 and
2011
 Ranked amongst Top 10 Fastest Growing Companies in India for 2009 & 2010 by The
Economic Times.
 Ranked among the Top 30 Fastest Growing Companies by Outlook Business in 2013
 In recognition of exemplary growth VOL was awarded Inc 500 Certificate of Excellence
in 2012 & 2011 by 99 Media
 VOL was accorded SILVER by EcoVadis towards Corporate Social Responsibility Rating

Vinati Organics limited are the major manufacturer of variety of specialty chemicals,
pharmaceutical intermediates and chemicals / additives with expertise in the field of synthetic
organic chemicals.

2.2 Need of project with description for region and country

Butyl Phenols are intermediates which find applications as raw materials for products that go
into a wide variety of industries such as perfumery, inks & resins, plastics and lubricants. Butyl
phenols are not directly used for these applications, but act as building blocks for making useful
products. VOL is planning to manufacture the following for butyl phenols:

a. Para-Tertiary Butyl Phenol (PTBP)

b. Ortho-Tertiary Butyl Phenol (OTBP)
c. 2,4-Di Tertiary Butyl Phenol (2,4-DTBP)
d. 2,6-Di Tertiary Butyl Phenol (2,6-DTBP)

Almost all quantity of butyl phenols used in India is imported. Around 35-40% of the total
quantity finds application in the perfumery industry. Around 15% is used for plastic additives
and the remaining butyl phenols are used for inks/resins and lubricants.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Indian Butyl Phenols Scenario

India is a net importer of butyl phenols. By volume, PTBP is the largest product amongst the four
butyl phenols. It is mostly imported from Korea, Taiwan, Singapore and Russia. There are
majorly 2 grades of PTBP imported into India– Technical grade used for perfumery application
and Standard grade that is used in resin/ink application.

OTBP come second by volume amongst these four butyl phenols. It goes entirely into
manufacturing of perfumery products. All leading Indian perfumes manufacturing companies
are users of OTBP. This product is imported from Switzerland and Taiwan.

The use of 2,4-DTBP and 2,6-DTBP is currently smaller by volume. These two products are used
for manufacturing antioxidants which are used as additives for plastics. With increasing use of
plastics and composites in India, the use of these butyl phenol based antioxidants is expected to
grow rapidly. 2,4-DTBP and 2,6-DTBP are imported into India from Switzerland, Taiwan,
Singapore and China.

The total demand of these butyl phenols in India is currently 20,500 MTPA.

In India, currently, there are no manufacturers for butyl phenols. Previously, companies like
Herdillia (Now SI Group), Balmer Lawrie, Naik Naware Chemical Pvt Ltd tried to manufacture
these products. However, due to lack of scale, IB supply constraint, they couldn’t manufacture
products economically.

Butyl Phenol import trend in India is as follows:

Butyl Phenol India imports

25000

19903 20581
19706
20000 18729
Quantity MT

15000 12932

10000
6400
5000

0
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Q1

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

In FY 2014-15 and FY 2015-16, India spent around $ 45 million and $ 35 million respectively for
importing the butyl phenols. VOL will help save so much foreign exchange in case the plant is
operational.
In addition to this, because of the availability of raw materials like 2,4-DTBP and 2,6-DTBP, there
will be an increased manufacturing of antioxidants and UV stabilizers in India. These
antioxidants which are currently being imported into India will be manufactured in India
eventually adding to the self-sufficiency and additional foreign currency savings besides
generating employment opportunities.

Global Butyl Phenol market and past trends:

Globally, Butyl Phenols are well known compounds widely used in numerous applications.
While, in India PTBP and OTBP are large volume products, globally, 2,6-DTBP and 2,4-DTBP are
large volume products. Globally, these di-tertiary butyl phenols are widely used in lubricants,
plastic additives and fuel additives The use of 2,6-DTBP as a jet fuel additive is a large volume
application globally. Globally, PTBP is also used in poly carbonate manufacturing.

Some companies that are large volume manufacturers of butyl phenols are SI Group, BASF,
Songwon, Oxiris, Chemtura/ Addivant, Eutec, Kaoching, Tasco, DIC. Almost all these butyl phenol
manufacturers are forward integrated and they also manufacture antioxidants for plastics and
lubricants from di tertiary butyl phenols.

The estimated capacity of butyl phenols globally is close to 400000 TPA. However, since a large
quantity of butyl phenols are captively consumed, estimating the exact production of butyl
phenols globally is not possible.

Market Scenario for Lili aldehyde:

Lily Aldehyde

Lilial is a chemical compound commonly used as a perfume in cosmetic preparations and

laundry powders. The name of the compound is p-tert-Butyl-alpha-methylhydrocinnamic
aldehdye (BMHCA) or (2-(4-tert-butylbenzyl) propionaldehyde).[CAS no. 80-54-6]
The product is known based on brand names of global manufacturers like Lysmeral [BASF],
Lilestralis [Kalama] and Lilial [Kuraray].
The R enantiomer of the compound has a strongly diffusive fresh, light, green floral, reminiscent
of lily (Also called Lily of the valley)
Applications:

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Its strong diffusivity makes it invaluable for use in soaps and detergents. Leading FMCG soaps
and detergent manufacturers are the users of formulated lily aldehyde. Other than soaps and
detergents, the product is also used in cleaning agents, fine fragrances, cosmetics and air
fresheners. It may also be used as a perfumery ingredient is various coatings and paints,
fillers/plasters, ink/toners, polishes/wax blends and scented articles (clothes, eraser, toys,
paper articles, CD).
While most of the applications of lily aldehyde are related to personal care and perfume
applications, there is a small demand of this product in agrochemical industry as an intermediate
to make weedicide.
Indian market and global market
At present, there is no manufacturer of lily aldehyde in India and current imports of this product
in India are close to 800 metric tons per annum. In India, all the lily aldehyde that is imported is
used in the personal care industry in the form of perfume/ fragrance. In India, the product is not
currently used in agrochemical industry.
The global market for this product is close to 20000 metric ton per annum. The global demand
of this product is estimated to remain stable or slightly decline. The Indian market of this
product is expected to remain constant or grow moderately.
The raw materials for this product are p-tertiary butyl benzaldehyde, propionaldehyde and
hydrogen. Propionaldehyde is a widely traded product in India and is readily available. VOL is
going to establish a plant to make p-tertiary butyl benzaldehyde and hydrogen plant is also
proposed to be established by VOL. VOL is proposing to establish a plant of close to 2000 Ton
per annum of which half will be used for import substitution and other half will be for exports.

2.3 Brief Description of Project

Size: It is proposed to produce following products at the existing site at lote after removal of
plan to produce Tertiary Butyl Alcohol due to place constraints which was considered in recently
issued EC letter to this site Ref. SEAC-2015/CR-236/TC-2 dated 28.06.2016.

The proposed products are summarized below

Sr. No Product / By product Proposed production capacity (TPA)

Product
1 Butyl Phenols 39,000
2 Para tertiary Butyl Benzaldehyde 2,000
3 Lili-Aldehyde 2,000
Total 43,000
By Products
1 Aluminum Sulphate (Solution) 1980

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

2.4 Export Possibility

VOL would like to install a capacity of 39,000 MTPA for the 4 butyl phenols put together. Out of
these around 20,500 MTPA is the current Indian demand while the remaining 18,500 MTPA will
be for exports. Since 2,4-DTBP and 2,6-DTBP have huge demand globally, it will be possible to
export these products. Some of the target customers for di tertiary butyl phenols could be Cytec,
Everspring, Omnova, Adeka, etc.

Due to the availability of butyl phenols in India, eventually, there will be an increased production
of downstream derivatives of butyl phenol which will lead to more export possibilities.

2.5 Employment Generation due to Project (Direct and indirect)

The proposed establishment of plant at plot A-20 MIDC, Lote will certainly lead to increase in
employment generation. We will have employment generation for operation, maintenance,
Packaging, Dispatch, administration etc. We estimate that there will be a net generation of
around 120 jobs on account of this project. Also there is great potential for employment in the
downstream industries.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 3 Project Description

3.1 Type of Project:

The project is for manufacture of Synthetic organic chemical (Butyl Phenols) as follows:

Sr. No Product / By product Proposed production capacity (TPA)

Product
1 Butyl Phenols 39,000
2 Para Tertiary Butyl Benzaldehyde 2,000
3 Lili-Aldehyde 2,000
Total 43,000
By Products
1 Aluminum Sulphate (25% Solution) 1,980

3.2 Location of the Project

Details of Nearest Infrastructure Facilities

Sr. No Destination App. Distance of Project Site
01 Nearest Town Chiplun: 10 km
02 Nearest National Highway NH-66: 1 km
(Mumbai Goa)
03 Nearest Airport Mumbai International Airport: 257 km
04 Nearest Railway Station Chiplun Railway Station: 10 km
05 Nearest Port JNPT: 270 km

The project is proposed at Plot No A20 & D 30/2, Lote MIDC, Dist. Ratnagiri, Maharashtra.

The Geographical Location of this plot is at 17°35'44.43 "N Latitude and 73°29'14.697"E
Longitude with an elevation of 16 meter above sea level MSL.

This site is in premises of MIDC Estate which is meant for these types of Industries.

GPS Location on Google Imagery of the proposed site is attached as Annexure I.

Land Form: Land is on plain contour; it is flat terrain.

Land Ownership: Land ownership is with project proponents (Vinati Organics limited)

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Existing Land use Pattern: The Land is reserved for Industrial use & the proposed project shall
be at the same plot.

Existing Infrastructure: Presently there is an existing Infrastructure around the site.

Infrastructure like water, electricity, telephone facility, roads already available. Other
Infrastructure like, hospital, school, housing, entertainment, daily needs are available easily at
Chiplun Town (Which is at distance of about 10 km)

Lote MIDC provides many basic facilities like uninterrupted water supply, power and Road
Network. When various sites were seen, this site appeared to be environmentally best as also
from the business angle and therefore this option was finally adopted. This site is inside the
campus of the MIDC and means safe transportation, less need of Utilities, less constructing
buildings and roads, less fuel, less water with optimization of infrastructure.

There is no sensitive establishment in the vicinity such as health resort, hospital, and
archaeological monuments.

The location justification for the project is as under

a. Existing well established plant of Vinati organics is already running successfully at said
location, also one of the raw materials for Butyl phenols i.e IB is available here.
b. Availability of required land and infrastructure for locating the establishment for the
synthetic organic chemical manufacturing.
c. Suitability of land from topography & geological aspects, synergy and business point of
view
d. Proximity to rail / road to facilitate transport of equipment / materials/ product
e. Availability of adequate quantity of water to meet water requirements.

Lay-Out

Refer Annexure II for the proposed plant site layout plan.

3.3 Project Description with Processes Details:

For Butyl Phenols:-

Manufacturing Process: Broad manufacturing process of the chemical (Butyl Phenols) is

described and depicted below.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Ortho tertiary Butyl Phenol & 2, 6 Di tertiary butyl phenols:- Phenol dehydration followed by
Aluminum phenoxide preparation & Alkylation of phenol with Iso-butylene to form maximum
of OTBP (Ortho tertiary butyl phenol) & 2,6 DTBP( 2,6 di tertiary butyl phenol). In this process
there is release of H2 gas & formation of Aluminum sulphate as by product during reactive
extraction with dilute sulphuric acid.

Para tertiary Butyl Phenol:- In this process catalytic alkylation of phenol with Isobutylene in
continuous vertical catalytic reactor to form maximum of PTBP(Para Tertiary Butyl Phenol).
There is no downstream process for this reaction; product mixture will be sent directly to
separation section.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

2,4 di Butyl Phenol:- In this process catalytic alkylation of Phenol with Iso butylene followed by
extraction of liquid catalyst with DM water & product stream will go to distillation / Separation
section.

Downstream separation:-
Product mix from PTBP will be directly go to separation section where unreacted Phenol &
heavies will be separated to get pure PTBP as liquid form. This molten PTBP will be further send
to flakers & packing section.

Product mix generated from OTBP/2,6 DTBP reaction scheme & 2, 4, DTBP scheme will be mixed
together & then separation of desired product from product mix will be done with removal of
unreacted phenol & heavies to get pure OTBP,2,6DTBP & 2,4DTBP as pure product which will
be stored in respective storage tanks. All the 3 products will be stored & supply in liquid form
only.

For PTBBAL:-
VOL has already received EC for Manufacturing of p-tert Butyl Toluene (PTBT) from Isobutylene
and Toluene and also manufacturing of p-tert Butyl Benzoic Acid (PTBBA) by Air Oxidation of
PTBT.

VOL subsequently worked out with IICT Hyderabad (who have developed the PTBT & PTBBA
process) for partial oxidation process of PTBT.
Partial Oxidation process results in formation of p-tert Butyl Benzaldehyde also along with p-
tert Butyl Benzoic Acid. The brief process description is as follows

Desired quantity of PTBT/Acetic Acid / Catalysts and co-catalysts is charged in the reactor. The
mix is heated to desired temperature and then air is introduced for oxidation purpose. Partial
oxidation is achieved by reducing the reaction time.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

After the reaction is over the mixture is splashed in crystallizer where PTBBA is crystallized out
and purified by washing/filtration and drying. The mother liquor after PTBBA removal contains
unreacted PTBT, acetic acid, dissolved PTBBA and catalysts, p-tert Butyl Benzaldehyde
(PTBBAL) formed. This is subject to distillation to recover and recycle acetic acid and soluble
PTBBA + Catalyst, PTBT and PTBBAL in last column.

For Lili Aldehyde:-

The major use of PTBBAL formed by partial oxidation is in manufacturing of Lilialdehyde (lilial)
which has main application in perfumery industry.

Lilial is manufactured from PTBBAL in two stage synthesis. In first step PTBBAL is reacted with
Propionaldehyde to form an intermediate aldehyde which on hydrogenation gets converted to
Lilial / Lili aldehyde. The reaction mixture is separated/purified by Distillation to get pure
Liliakdehyde.

Process block diagram for the manufacturing of:-

Butyl Phenols:-

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

For PTBBAL :-

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

For Lilialdehyde:-

3.4 Raw Material for finished Product:

Raw Materials:
The basic raw material for the proposed production capacity is submitted herein below.

Source for Raw Material Procurement: Raw Material is easily available in the local market.

Mode of Transport of Raw Materials: Few of the raw materials will be transported locally and
few will be imported from the International Market. Mode of transport to site is by road
truck/tankers.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

List of Major Raw Material & Storage

Total consumption Qty. per
Sr. No. Raw Material Unit
year (proposed)
1 Phenol Tons 23304
2 Isobutylene Tons 20560
3 Liquid catalyst Tons 163
4 Sulphuric acid Tons 2696
5 Aluminum turnings (Igots) Tons 424

Proposed major bulk storages at site are as follow:

Sr. No Raw material/ Physical No. of Proposed Proposed
Products state tanks liquid storage liquid
(Liquid/ capacity of storage (KL)
solid) tank (KL) at site
1 Phenol 1 1000 800
2 Liquid catalyst 1 10 8
3 Ortho tertiary Butyl 1 360 288
Phenol
4 2,4 di-tertiory butyl 1 360 288
phenol Liquid
5 2,4 di-tertiory butyl 1 360 288
phenol
6 Al2(SO4)3, solution 1 360 288
7 PTBBAL 1 30 24
8 Lili aldhyde 1 30 24

3.5 Resource Optimization:

Vinati Organics limited are desirous to establish the manufacturing facilities for the product
indicated above. The resource optimization shall be carried out at the site and with other plants
within the site and other VOL sites in order to reduce wastage and minimum transport needs.

3.6 Availability of Resources (Water, Energy/Power Requirement):

Power: The proposed power requirement for the facility is 250 KVA which will be source from
Our Existing power inputs to site & newly installed Cogen plant.

Heating utility: - Heating utility like steam about 2 Tons/hr will be made available from Co-gen
plant & TFH plant of capacity 30LacKcal/hr of plant to be installed additionally for this project.

Water: The total water requirement is about 27 cmd for domestic, process, and Boiler /cooling
purpose. It will be source from MIDC water works.
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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Fresh water requirement and waste water generation for proposed establishment shall be as
follows:

Water requirement
No. Description Existing water Proposed Total
input* (cmd) water input requirement
(cmd) (cmd)
1 Domestic 28 9
2 Industrial cooling/boilers 1663 0
3. Processing whereby water 164 18
gets polluted and pollutants
are easily biodegradable
4. Gardening 23 0 23
Total 1662 +216 = 1878 27
* - As per EC SEAC – 2015 / CR – 236/TC – 2 dated 28th June 2016 … 1662 cmd is fresh water from
MIDC and 216 cmd is recycled water (after treatment).

Waste water
No. Description Existing Proposed Total Disposal
generation# generation
(cmd) (cmd)

1. Trade 230 18 248 Proposed trade effluent shall

effluent be treated (primary,
secondary and tertiary
treatment) and will be
recycled.
2. Domestic 23 7 30 Proposed domestic effluent
effluent shall be treated at STP and
treated effluent shall be
recycled.
Total 253 25 278 --
# - As per EC SEAC – 2015 / CR – 236/TC – 2 dated 28th June 2016

Existing discharge to CETP is 23 cmd which will be maintained (ZLD for proposed
expansion)

Manpower: Expected manpower requirement for the establishment shall be as follows:

Description Proposed, No (approx.)
Permanent 45
Contract 75
Total 120

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 Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Heating utility: - Heating utility like steam about 2 Tons/hr will be made available from Co-gen
plant so no need for additional boiler.

Thermic Fluid Heater (TFH) of capacity 30 LacKcal/hr is proposed be installed additionally for
this expansion project.

Coal will be fuel for the proposed Thermic fluid heater (30 Lac Kcal/hr duty)

Type of Fuel Quantity

Coal 30 MTPD

DG Set:
There is no DG set required for this proposed Expansion.

3.7 Waste Generation and its treatment, disposal

I. Solid Waste

(a) Non Hazardous Solid Waste:

Sr Type of Waste Quantity UOM Mode of Disposal

No
1 Fly Ash 9 TPD Sale to offsite recycling brick
making or for landfill
2 Rubber, Hand gloves, PVC 0.15 TPA Sale for offsite recycling/
shoes, Tarpaulin, Hose pipes CHWTSDF
3 Insulating material 0.25 TPA Sale to authorized vendor/
CHWTSDF
4 Iron scrap, Glass, Paper, Plastic 0.15 TPA Sold to scrap dealer for recycle
bottles etc

(b) Hazardous Waste:

The quantification of hazardous solid waste generated from present activity and proposed
activities is presented as follows:
Sr Category Type of Waste Quantity* UOM Mode of Disposal
No
1 5.1 Used/ Spent Oil 0.25 KLPA CHWTSDF/ Sale to
Authorized party approved
by MOEF/CPCB/MPCB

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

2 15.2 Discarded 0.25 MTPA CHWTSDF

Asbestos (AC
sheets) (one time
generation)
3 33.3 Discarded 25 Nos/annum Authorized MPCB Drum
Drums, carbuoys Recycler
etc
4 21.1 Paint cans, brush 0.5 MTPA CHWTSDF
etc
* Estimate, Quantity shall be worked out during EIA stage.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 4 Site Analysis

Proposed projects are planned in existing spare land of company. The nearest town / cities are
Khed (21kms)/ Chiplun (about 10 kms)/Pune approx. 250 kms and Panvel/Mumbai 210/250
kms respectively. Company has already taken adjacent plot D-30/2 admeasuring almost 9000
Sq M. This project will be accommodated at the site. The industrial area are provided with good
infrastructure like road connectivity to National Highways (NH-66, old NH-17), railways
(nearest station is Khed/Chiplun about 18/10 kms) / un-interrupted power supply as well
water supply.
The land in possession with the company is lease hold land & the lease with MIDC is for 99 years
with nominal lease charges.
The land doesn’t fall under CRZ.

Location of MIDC Lote

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Existing land use pattern, Forest, water bodies details are as follows

Sr. No. Particulars Details

1. Town Lote MIDC
2. Taluka Khed
3. District Ratnagiri
4. Latitude Latitude: 170 35’ 44.43” N
5. Longitude Longitude: 730 29’ 24.69” E
6. Nearest water bodies River Vashishti (about 4 km in southwest direction)
7. Nearest Highway NH – 66 = 1 km towards West
8. Nearest Railway Khed / Chiplun on Konkan railway which is
station approximately 18/10 km
9. Nearest Airport/ Mumbai International Airport – 250 KM towards NW
Airbase Pune Lohegaon Airport / Airbase– 134.5 KM towards NE

 Proposed land use is allotted for industrial use by MIDC, Lote.

 The project site does not come in range of Eco sensitive Area by MoEF
 The project is not covered under CRZ.
 The estate is located at sufficient distance from reserved forests and sanctuaries,
archeological sites and historical sites to ensure that there is no impact of industrial activities.

The land is in notified industrial area MIDC which is developed by Govt of Maharashtra. Hence
it has fully developed infrastructure required for running the chemical manufacturing units.
Company’s existing unit is running since 2001-02 in same MIDC area. The site/land/location is
well connected by Rail/Road and also has all possible communication networks. Manpower
(technical/ non-technical) is easily available. Social infrastructures like
schools/markets/residential areas/entertainment/medical facilities are well developed.

4.1 Climate:
Lote comes in Ratnagiri district of Maharashtra. The location climate is similar to that on the
west coast of India, with plentiful and regular seasonable rainfall, oppressive weather in the hot
months and high humidities throughout the year. The summer season from March to May is
followed by the south-west monsoon season from June to September. October and November
form the post-monsoon or the retreating monsoon season. The period from December to
February is the cold season.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

4.2 Rainfall:

The regional distribution of rainfall is mainly explained by the relief of the land and the direction
of the rain bearing winds. The supply of rain to the inland areas is considerably more than to the
coastal areas. It becomes heavier or lighter, according to the nearness or otherwise of the station
to the great Sahyadri range which powerfully attracts the rain clouds. Mandangad is, however,
an exception though its distance from the sea-is just about 14 miles. The average rainfall
recorded by this station appears to be quite high as compared to the averages of Deorukh,
Chiplun, Rajapur and Khed which are so near the Sahyadri hills.
Ante-monsoon or "mango" showers occur in April-May. Although the amount of precipitation is
small, these showers have great value in so far as the preliminary kharif operations are
concerned. The south-west monsoon is the main rainy season, commencing by about the middle
of June and lasting till the end of September. Winter fall, resulting from the retreating monsoon,
is almost negligible, which explains why rabi cultivation is practiced on an insignificant scale.
Most of the rabi crops are brought to maturity mainly by irrigation.
The length of the rainy season has an important bearing on the agricultural operations and
output of the district. In a normal rainy season, there are about 100 rainy days. A substantial
portion of which runs to waste because of its extreme concentration during a certain part of the
season which reduces the effectiveness of the rainfall commensurately. From the point of view
of agriculture, effectiveness of rainfall depends on many factors such as, the normal rainfall,
length of the rainy season, occurrence of rain at the right time during the agricultural season, its
spacing during the season, nature of the soil, rate of evaporation, etc.
4.3 Temperature:

Meteorological data are available for four stations in the district, viz., Harnai, Ratnagiri, Deogad
and Vengurla. Being a coastal district the variation of temperature during the day and through
the seasons is not large.
In the hot season temperature rises slowly from March, and May is the hottest month. With the
onset of the monsoon, temperature drops by three to four degrees. Day temperatures during the
monsoon are lower than those in the cold season. In the post monsoon months of October and
November, day temperatures increase and days in November are as hot as in May. Night
temperatures are the lowest in January. Areas within 20 to 25 kilometres of the coast are the
most pleasant particularly in the hot months with the sea breeze blowing, nearly throughout the
day. Further inland during the hot months both days and nights can be oppressive and more so
in the tract at the foot of the Western Ghats. Along the coast the maximum temperature rarely
goes beyond 38°C (100.4°F) but in the interior may reach 40° or 41°C (104°0 or 106°0 F).
Winds:

Winds are very strong and are mainly westerly or south westerly during the monsoon. In the
rest of the year winds blow from directions between north and east in the mornings and
between west and north-west in the afternoons.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

4.4 SOILS
The most predominant rock formation of the district is the Konkan laterite, formed from the
original trap. It is an argillo-ferrugenous deposit and covers the major portion of the land surface
forming undulating plateaus with a general elevation of 200 to 300 feet Laterisation has taken
place under the hot humid conditions. Due to heavy rainfall, the bases have been leached away
along with the silicic acid and hence the resulting rock is acidic in reaction and rich in iron and
aluminium oxides with a silica-sesquioxide ratio of less than two. The hydrated iron oxides
impart the red colour to the soils. Due to these geological formations the soils of the district are
mostly lateritic which are found mixed with trapping soils in the north and shallow soils in the
south. Along the coast are the alluviums. There are small patches of salt lands developed near
the creeks.
Lateritic Soils
Lateritic soils which are predominant in the district, vary in color from bright red to brownish
red owing to the preponderance of hydrated iron oxides. They are always acidic, the pH value
ranging from 4.5 to 6.5. Lime is deficient or almost absent. Usually they have very low
phosphorus and potash content, but are fairly well supplied with nitrogen and organic matter.
Their texture is loamy and depth varies from one foot to three feet. They are porous and not
retentive of moisture and are found all over the district except in Mandangad taluka which
consists mainly of forests. These soils, however, are found in several grades, which depend upon
their (soils) location and the extent of admixture of different rocks. The following of these grades
are of special significance.

Rice Soil
These soils have various names which are identified with their location. Those situated at higher
levels are usually known as mal, while those at slightly lower levels are called kuryat soils. Near
the water courses, which have a fair supply of water during the rabi season, are the panthal or
vaingan soils. All these soils benefit by liming and give high response to the application of
phosphatic and potassic fertilisers. Only a kharif crop of paddy can be taken on these soils. On
the panthal soils, however, a crop of rabi pulse (wal) or summer (vaingan) paddy can also be
taken.
Varkas Soil
These soils are situated on the slopes of the hills and are partly eroded, yellowish red and poor
in fertility. Further, they are shallow in depth and coarse in texture. Ragi (nagli) is the principal
crop in these soils and it responds well to supplies of nitrogen and phosphate. Cashewnut grows
in plenty in this area. It is on these soils that the world renowned Alphonso mangoes are grown.
On the mountain tops are the perennial forests, where the soils are rich in humus because of
their being protected from erosion. They are reddish-brown in colour.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Coastal Alluvium
The coastal strips in Dapoli, Guhagar, Ratnagiri and Rajapur talukas are covered with soils of
recent deposits and are locally known as pulanwat. They are deep sandy loams and cocoanut
gardens and arecanut gardens thrive well in them. Paddy is also taken here to some extent.

Salt Land

Due to the inundation of the sea, a part of the coastal soils has "become salty. They are locally
known by several names like khar, khajan, kharvat, etc. In Deogad, Malvan and Vengurla talukas,
the entire western strips are salty while in other coastal talukas only salt patches which are
suited to the coarser types of paddy are to be noticed.

4.5 Planning in Brief

The expansion is planned at existing plot of the company, so no new specific / additional
planning is envisaged. The Green Belt area statement is attached herewith.

4.6 Proposed Infrastructure

There is no specific additional infrastructure required for the proposed expansion.
Power / Water required for existing as well new proposed plants will be supplied by
MSEB/MIDC respectively. Company already has uninterrupted and stable power supply through
Express Feeder Lines however power will also be generated & utilized as per the need from
proposed Co-gen plant. For solid waste disposal Company is already member of Hazardous
Waste disposal center run by agencies authorized by local state government / pollution control
board.
4.7 Rehabilitation and Resettlement Plan

Since expansion doesn’t involve relocation/shifting of any existing settlements on land, the
rehabilitation and resettlement is not applicable for this expansion.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 5 Planning Brief

5.1 Planning Concept:

 Plot is at well-established MIDC Lote Parshuram industrial area
 Purified Water supply from MIDC
 Well-developed roads and connectivity.
 Infrastructure facilities available established MIDC site
 Utilities Integration with existing unit

5.2 Population Projection

An official Census 2011 detail of Ratnagiri, a district of Maharashtra has been released by
Directorate of Census Operations in Maharashtra. Enumeration of key persons was also done
by census officials in Ratnagiri District of Maharashtra.

In 2011, Ratnagiri had population of 1,615,069 of which male and female were 761,121 and
853,948 respectively. In 2001 census, Ratnagiri had a population of 1,696,777 of which males
were 794,498 and remaining 902,279 were females. Ratnagiri District population constituted
1.44 percent of total Maharashtra population. In 2001 census, this figure for Ratnagiri District
was at 1.75 percent of Maharashtra population.

There was change of -4.82 percent in the population compared to population as per 2001. In
the previous census of India 2001, Ratnagiri District recorded increase of 9.89 percent to its
population compared to 1991.

5.3 Assessment of Infrastructure Demand (Physical and Social)

No major infrastructure demand is envisaged as the proposed site is in well-developed MIDC

area.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 6 Proposed Infrastructure

Since the expansion is planned at existing site in developed MIDC industrial area, no
special/specific development is anticipated. Company has not planned any additional
residential area at the proposed site as MIDC has already existing Residential areas earmarked
for housing colonies. For additional essential manpower company may decide at later date about
building additional colony building.
6.1 Industrial area:
Vinati Organic Ltd., Plot no A20 & D 30/2, Lote MIDC proposes to expand existing plant for
manufacture of synthetic organic chemical (Butyl Phenols) based on demand and market
projection.

6.2 Residential Area:

No Residential area has been proposed within the plant site.

6.3 Green Belt:

Green belt of adequate area within and around the project site shall be carried out as per
industries norms and requirement.

6.4 Social Infrastructure:

Local people will be given preference wherever found suitable for all the jobs in the plant, direct
as well as indirect. Thus the project shall have a positive impact on the employment pattern of
the region. Economic status of the local population will improve due to increased
ancillary/business opportunities, thereby making positive impact. Educational, medical &
housing facilities will improve due to the proposed project.

6.5 Water Management:

The total water requirement is about 27cmd for Domestic, boiler/cooling, Greenery and process.
The source of water shall be from MIDC. The water supply will be through the good offices of
MIDC. VOL will not be encroaching on anybody’s water source.

6.7 Sewage and waste water treatment system:

Existing Vinati organics plot (A20) is well developed & has existing ETP facility to cater the waste
water treatment generated from this plant.

Detailed ETP & STP process description for treatment will be submitted in EIA report of
subjected expansion plans.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 7 Rehabilitation and Resettlement Plan

Since expansion doesn’t involve relocation/shifting of any existing settlements on land, the
rehabilitation and resettlement is not applicable for this expansion.

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Chapter 8 Project Schedule & Cost Estimate

Project Schedule is given below and Cost estimate/feasibility is given in tabulated form below
The following schedule is based on assumption that Company gets Environmental Clearance by
Sep, 2016. Time frame is to be considered
Project Likely Start Likely Completion
Butyl Phenols Oct, 2016 Oct, 2017
(PTBP, OTBP, 2, 4 DTBP, 2,6DTBP)
PTBBAL Oct, 2016 Apr, 2017
Lili Aldehyde Apr, 2017 Oct, 2017

The approximate Project Costs (Figures in Lacs)

Sr. No. Description BUTYL PHENOLS PTBBAL Total

1 Civil Cost 1,396 750 2,146
Plant & Machineries including
2 11,660 2,340 14,000
Utilities
1,580
3 Margin Money 162 1,742

4 Total Project Cost 14,636 3,252 17,888

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Annexure I
Site google image

Site & surrounding study area of 1 km

Site & surrounding study area of 10 km

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Annexure II

Proposed Layout Plan

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Pre-Feasibility Report Vinati Organics limited, Plot No. A-20, D-30/2, MIDC Lote Parshuram

Proposed area statement for Plot no A20 & D 30/2

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