M/S TECHNO PLASTIMER

Transcription

1 ON PROPOSED EXPANSION PROJECT FOR MANUFACTURING OF VINYL ESTER RESIN & UNSATURATED POLYESTER RESIN Category 5 (f) of M/S TECHNO PLASTIMER Located at: Plot No. C-1-B/3, Old GIDC, GIDC Notified Industrial Area, Gundlav, Ta: Valsad, Dist- Valsad Gujarat. Expansion Project: 1 Manufacturing: Resins

2 Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification Executive Summary : Name & Location: Name of the Project : M/s. Techno Plastimer Location : Plot No.- C-1-B/3, Old GIDC Gundlav,, GIDC Notified Industrial Estate, Ta: Valsad, Dist- Valsad Gujarat. Project is located in GIDC notified industrial area, falling under small Scale category manufacturing products as mentioned under. The company had obtained Consent to Establish and operates from Gujarat Pollution Control Board for all the existing products. The company proposes to enhance the capacity of existing products under the category Resin Total project cost (Existing: Rs lacs + Proposed: Rs lacs = Total: 42.3 lacs) Applicability of EIA notification 2006 Category as per the amended EIA notification- 2006: as existing & proposed products (i.e. Resins) are covered under the Category 5 (f) B. Hence, Environmental Clearance is required. Project Proponent The company is a small scale proprietary concern unit with a sound technical back ground. The details are as under; 1) Mr. Bharatbhai A Desai Karta of Bharat Desai (HUF) (Proprietor) List of finished products & by- products LIST OF PRODUCTS AT EXISTING & AFTER PROPOSED EXPANSION Sr. No. Product Capacity, TPM Existing Proposed Total 1 Epoxy Hardener Epoxy Resin Formulation Vinyl Ester Resin Unsaturated Polyester Resin Total Note: Expansion Project: Page 2 Manufacturing: Resins

3 Product no. 1 & 2 are manufacturing by mixing, blending & formulations only. Product no. 3 & 4 are manufactured by chemical reaction. Manufacturing process with chemical reaction & mass balance is attached as Annexure-3 Resource Requirement Components Existing Total after Resources availability Proposed expansion Power, KVA Will be sourced from Dakshin Gujarat Vij Co. Ltd. Fresh Water, kl/day Will be sourced from GIDC Gundlav Chilling plant, TR 0 15 In house Cooling Tower, TR In house Imported coal for 2 lacs k cal of thermopak, MT/Month Will be sourced from local dealer HSD for D G set (60 KVA), kgs/hr 0 8 Will be sourced from local dealer Raw material Consumption Sr. No. Raw Material Consumption in MT/Month MT/MT Existing Proposed Total 1.1 FOR EPOXY HARDENER:I Tetra Hydro Phthalic Anhydride Phthalic Anhydride Crasyl Glycidiol Ether Hexa Hydro Phthalic Anhydride Total FOR EPOXY HARDENER:II Di Amino Di Phenyl Methane Di Butyl Phthalate Phenyl Glycidiol Ether Besic Epoxy Resin (BER) Total FOR EPOXY HARDNER:III Tri Methyl Hexa Methylene Di Amine Expansion Project: Page 3 Manufacturing: Resins

4 1.3.2 Basic Epoxy Resin Total FOR EPOXY RESIN FORMULATION 2.1 Epoxy resin Reactive Diluents like (Phenyl Glycidit Ether, Cresyl Glycidit ether) Non Reactive Diluents like (Di Butyl phthotate, Di Octyl Phthalate) Advancement ingredients like (Bis Phenol-A, Para Tertiary butyl Phenol) Fillers like ( Barytes, China clay micro grite, Zirconium silicate) Total FOR VINYL ESTER RESIN 3.1 Epoxy Resin Maleic Anhydride Methacrylic acid Bis phenol A Styrene monomer Total FOR UNSATURATED POLYESTER RESIN 4.1 Di Basic acids like (Phthalic Anhydride, Isophthalic Acid, Terphthalic Acid, Adipic acid, Maleic Anhydride, Fumeric acid) Glycols like (Propylene glycol,mono ethylene glycol, Di Ethylene glycol, MPdiol, Neo Phenyl Glycol, Di Propylene glycol) Vinyl Monomer like ( Styrene monomer, methacrylates, Vinyl toluene) Total Expansion Project: Page 4 Manufacturing: Resins

5 Water and Waste Water Management Total raw water requirement is 1.9 M 3 /day supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith. Total Industrial Waste water generation is 760 liters/day, which will be collected in collection tank and directly send to M/S BEIL, Ankleshwar for incineration. Thus there will be no discharge on land. Domestic waste water (0.5 M 3 /Day) will be disposed off through septic tank. Air Emission and its Control Measures Flue gas emission: At existing unit there is a imported coal fired thermopak which uses coal of 2 lacs k cal/hr. Multi cyclone separator and 11 meters height of chimney is provided. After proposed expansion, existing thermopak will be utilized. The coal consumption will increase up to by 20 MT/month. There will be no addition of any new boiler/thermopak. 60 KVA capacity of D G set will be installed in power failure. The stack of 11 meter height will be provided with D G set. Process gas emission: At existing scenario, there is no process gas emission and also after proposed expansion, there will be no process gas emission. Hazardous Wastes and its Management Sr. No. Type of waste Category Qty. MT/ Year Existing After Proposed expansion 1 Used Oil Discarded containers Treatment Packed in carboys Decontaminated, stored Disposal Sell to registered recycler Sell to authorized recycler Expansion Project: Page 5 Manufacturing: Resins

6 2. Introduction of Project / Back Ground Information : (i) Identification of Project. Name of the project Proponent: is an existing small scale unit and is located in notified industrial estate, GIDC, Gundlav, Di: Valsad having total plot area 742 m2 & total investment after proposed expansion will be Rs Lacs. The unit is engaged in synthetic resins for varied application in the composite industry. The proponent wishes to enhance the existing production capacity of Vinyl Ester resin and Unsaturated Polyester resin. The Resin products are especially used in Fiber Glass Reinforced Plastics industry, Artificial quartz stone, FRP boats, Chemical tanks, Amusement rides, Putties, Roofing sheets, Wind mills and many more as per requirement. The production unit is located at C1/B3 old G.I.D.C Gundlav, Dist.- Valsad, Gujarat. Current total manufacturing capacity of the unit is 115 TPM. To further penetrate into the market & serve the market demands, the Unit now proposes to enhance its manufacture capacity from 115 TPM to 405 TPM, which will help the company to expand its horizon & grab more business domestically as well internationally. The total plot area of Techno Plastimer is 742 sq. m. The proposed expansion will be carried out within the same premises. No new land will be acquired for the expansion project. Details of the Project proponent: The founder of the company Mr. Bharat A. Desai by education is a Chartered Account and has a rich experience in this field of more than 30 years. His son Mr. Nirmal Desai who currently looks after production & sales is a Chemical Engineer and Master in Business Administration. The company is managed by Mr. Bharat Amrutlal Desai- Karta of Bharat Desai HUF (Proprietor) and Mr. Nirmal Desai & their team members having experience for several years in this field. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. was established in 2001 and managed by a professional technocrat. It manufactures and markets a wide range of Resins. Personnel are available for providing support to the manufacturing unit in the areas of technology, R&D, manufacturing, quality control and quality assurance. Various resins & its formulations manufactured at this location are for sale in local & international market. Firm s strength is commitment, best quality, timely delivery at best prices. Expansion Project: Page 6 Manufacturing: Resins

7 The proposed expansion project site lies on N Latitude & E Longitude. is located at plot. No. C-1-B/3, Old GIDC Gundlav, Ta: Valsad, Di: Valsad in Gujarat state. GIDC Gundlav is located nearby National Highway No. 8 connecting Mumbai and Ahmedabad. The western Railway Main Line is passing through the area (Double & Electrified). Valsad is the nearest town having a railway station. Entire study area is well connected with the other major cities of the state and the country. Nearest private industrial estate M/S Atul limited at a distance of 8.5 kms and biggest industrial estate GIDC Vapi at a distance of 28 kms from the project site. Beside the rail connectivity, and also well connected by road transport. Almost every village is now well connected to each other by a Pucca road. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat Mumbai) is now six lanes, double track. This highway has given a further boost to the economic growth of this area. (ii) Brief description of nature of the Project : Proposes to expand their product manufacturing capacity of existing product at existing plot No. C-1-B/3, old GIDC Gundlav, Ta: Valsad, Di: Valsad, Gujarat. The proposed expansion project involves the production of Various resins & its Formulation which are used in application In Fiber Glass Reinforced Plastics industry, Artificial quartz stone, FRP boats, Chemical tanks, Amusement rides, Putties, Roofing sheets, Wind mills and many more. As per the EIA notification as amended products are covered under any category 5(f) required Prior Environmental Clearance. For the proposed expansion project, the company intends to procure the available latest technology for manufacturing the products. The industrial sector in the past 5 to 7 years has seen a drastic boom and also the keeping in mind the globalization trend, we have identified the demand for the product and with continuous R & D found that it can be developed in-house and produce commercially for domestic market as well as an eye more on export markets. (iii) Need for the project and its importance to the country and or region : The proposed expansion project provides a potential growth opportunity for the already running business of the company. The company is already engaged in the business of manufacturing of Various Resins & Its formulation. The project would increase the overall export and also increase the foreign revenue. Product is now well established and acceptable in the international markets. Poland, Italy, Germany, Canada, Egypt, Spain, Pakistan, Nepal etc. Expansion Project: Page 7 Manufacturing: Resins

8 Additional capacities of product range required over & above our existing capacities, as the company expect strong growth of exports to the extent of 50-60%. Local market also showing strong growth potential. Domestic market concentrated in Western India, Hyderabad, Chennai, and Banglore. This project will generate employment of 6 people. (Existing: 9 Nos. + Additional 6 nos.) Total 15 numbers of employees. (iv) Demand Supply Gap : The products have very high specific demand as they are especially used in Fiber Glass Reinforced Plastics industry, Artificial quartz stone, FRP boats, Chemical tanks, Amusement rides, Putties, Roofing sheets, Wind mills and many more. (v) Imports vs. Indigenous production : Existing products manufacturing in the country will be very much economical compare to Imports of the same and also the export of the same will earn extra revenue generation for our county. (vi) Export Possibility : Existing products have high export potential. Also there products have very good potential in local market. Additional capacities of product range required over & above our existing capacities at Gundlav GIDC, Dist: Valsad, as the company expect strong growth of exports to the extent of 50-60%. Local market also showing strong growth potential. (vii) Domestic / export Markets : The company s product is used as raw material to manufacture various plastic industries, chemical industries etc. as per the required applications and having very good market in domestic and also having very good international markets. (viii) Employment Generation (Direct and Indirect) due to the project : There will be an opportunity of employment generation directly and indirectly due to proposed expansion project. At present the manpower employed in the industry is 9 numbers. Due to proposed expansion project 5 people will be directly/indirectly employed. Thus total 15 numbers of employees after proposed expansion. Expansion Project: Page 8 Manufacturing: Resins

9 3. Project Description : (i) Type of Project including interlinked and interdependent projects, If any : The proposed project is an interdependent project of the company. (ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates : The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1.Plant layout is attached as Annexure-2. (iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted : Proposed expansion will be carried out in existing premises only. (Land allotment letter & rent agreement is attached as Annexure-7). The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration (iv) Size or magnitude of operation : As per the proposed project cost the project is covered under small Scale category of manufacturing industries. (v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) : Detailed project description with process details is enclosed as Annexure-3 (vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product : Raw material requirement along with estimated quantity, likely source, marketing are of final products mode of transport of raw material and finish product & characteristics of hazardous chemicals are as below: DETAILS ON PRODUCT/BY-PRODUCTS TRANSPORTATION Sr. Means of Product Physical State Packing No. Transportation 1 Epoxy Hardener Liquid Drums/Carboys Truck/Tempo 2 Epoxy Resin Formulation Liquid Drums/Carboys Truck/Tempo 3 Vinyl Ester Resin 4 Liquid Drums/Carboys Truck/Tempo Unsaturated Polyester Resin Liquid Drums/Carboys Truck/Tempo Expansion Project: Page 9 Manufacturing: Resins

10 Sr. No. Substance DETAILS ON RAW MATERIAL TRANSPORTATION Physical State Source of Supply Means of Transportation Expansion Project: Page 10 Manufacturing: Resins Distance of supplier from project site (km) Tetra Hydro Solid Phthalic Domestic Truck/Tempo Anhydride Phthalic Solid Anhydride Domestic Truck/Tempo Crasyl Glycidiol Ether Liquid Domestic Truck/Tempo Hexa Hydro Domestic Solid Phthalic Truck/Tempo Anhydride Di Amino Di Phenyl Methane Liquid Domestic Truck/Tempo Di Butyl Phthalate Liquid Domestic Truck/Tempo Phenyl Glycidiol Ether Liquid Domestic Truck/Tempo Basic Epoxy Resin (BER) Liquid Domestic Truck/Tempo Tri Methyl Hexa Domestic Liquid Methylene Di Truck/Tempo Amine Cresyl Glycidyl ether Liquid Domestic Truck/Tempo/Tank Di Butyl Phthalate Liquid Domestic Truck/Tempo/Tank Di Octyl Liquid Domestic Domestic Domestic Phthalate Bis Phenol-A Solid Domestic Truck/Tempo Para Tertiary Solid Domestic butyl Phenol Barytes Solid Domestic China clay Solid Domestic Zirconium Solid Domestic silicate Methacrylic acid Liquid Domestic 19 Isophthalic Acid 20 Terphthalic Acid 21 Adipic acid Solid Solid Solid Domestic Domestic Domestic Maleic Solid Domestic Anhydride Fumeric acid Solid Domestic Propylene glycol Liquid Domestic Mono ethylene glycol Di Ethylene glycol Liquid Liquid Domestic Domestic Truck/Tempo Truck/Tempo Truck/Tempo Truck/Tempo Truck/Tempo/Tank Truck/Tempo Truck/Tempo Truck/Tempo Truck/Tempo Truck/Tempo Truck/Tempo/Tank Truck/Tempo/Tank Truck/Tempo/Tank

11 MPdiol Liquid Domestic Neo Phenyl Glycol Solid Domestic Di Propylene Liquid Domestic glycol Styrene Liquid Domestic monomer Methyl Methacrylate Liquid Domestic Monomer Vinyl toluene Liquid Domestic Truck/Tempo/Tank Truck/Tempo Truck/Tempo/Tank Truck/Tempo/Tank Truck/Tempo/Tank Truck/Tempo/Tank DETAILS ON STORAGE & HANDLING OF HAZARDOUS CHEMICALS Sr. No. Name of the Raw Materials Quantity stored, MT/Month Max Actual BP. 0 C MP 0 C Place of its Storage State operating pressure temperat ure Possible type of hazards Control measures provided 1 Tetra Hydro Phthalic Anhydride 2 Phthalic Anhydride 3 Crasyl Glycidiol Ether 4 Hexa Hydro Phthalic Anhydride 5 Di Amino Di Phenyl Methane 6 Di Butyl Phthalate 7 Phenyl Glycidiol Ether 8 Basic Epoxy Resin (BER) 9 Tri Methyl Hexa Methylene Di Amine 10 Cresyl Glycidyl ether 11 Di Butyl phthotate 12 Di Octyl Phthalate Bag Normal at Bag Normal at Drum Normal at Bag Normal at Drum Normal at Drum Normal at Drum Normal at Drum Normal at Drum Normal at Drum Normal at Drum Normal at Drum Normal at Expansion Project: Page 11 Manufacturing: Resins

12 13 Bis Phenol-A Bag Normal at 14 Para Tertiary butyl Phenol Bag Normal at 15 Barite Bag Normal at 16 China clay Bag Normal at 17 Zirconium silicate 18 Methacrylic acid 19 Isophthalic Acid 20 Terphthalic Acid Expansion Project: Page 12 Manufacturing: Resins Bag Normal at Drum Normal at Bag Normal at Bag Normal at 21 Adipic acid Bag Normal at 22 Maleic Anhydride Bag Normal at 23 Fumeric acid Bag Normal at 34 Propylene glycol 25 Mono ethylene glycol 26 Di Ethylene glycol Drum Normal at Drum Normal at Drum Normal at 27 MPdiol Drum Normal at 28 Neo Phenyl Glycol 29 Di Propylene glycol 30 Styrene monomer 31 Methyl Methacrylate Bag Normal at Drum Normal at Drum Normal at Drum Normal at

13 Monomer 32 Vinyl toluene Drum Normal at (vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outlined : All the materials are used as a reactant. There will be no recovery of any raw materials. There will be 99.9% of product yield, hence no by-products or any materials comes out. Cooling water will be recycled. (viii) Availability of water its source, Energy/power requirement and source should be given: Availability of water its source, Energy/power required and its source is below. Water withdrawal permission is attached as Annexure-4. Sr. No. Particulars WATER CONSUMPTION (M 3 /DAY) Water Consumption Existing After Proposed expansion Effluent Generation Existing After Proposed expansion 1 Domestic Processing Cooling Floor/contain er/equipment washing 5 Gardening Total Total Industrial Note: Domestic effluent shall be passed through adequate capacity of septic tank. After proposed expansion, total water consumption will be 1.9 m 3 /day. There will be no use of water in process. Water of reaction generated from the process as waste water. After proposed expansion, total 0.76 m3/day of waste water will be generated. As the process water having pungent smell of Maleic anhydride, hence it is collected and directly sent for incineration of M/S BEIL, Ankleshwar. Thus there will be no discharge of any industrial effluent on land. Expansion Project: Page 13 Manufacturing: Resins

14 Water Balance Diagram At Existing Scenario Total Water consumption, 0.7 M 3 /Day sourced from GIDC Gundlav Domestic: 0.5 Processing: 0 Cooling make up water: 0.2 Septic tank Water of Reaction: Collection tank m3/day of waste water Sent to CHWIF of M/S BEIL, Ankleshwar Water Balance Diagram After Proposed expansion Total Water consumption, 1.9 M 3 /Day sourced from GIDC Gundlav Domestic: 1.0 Processing: 0 Floor/container Cooling make Gardening: 0.1 washing: 0.1 up water: 0.7 Septic tank Water of Reaction: Collection tank: m3/day of waste water Sent to CHWIF of M/S BEIL, Ankleshwar Expansion Project: Page 14 Manufacturing: Resins

15 ENERGY REQUIREMENT AND ITS SOURCE Sr. No. Particulars Existing After proposed expansion Source 1 Heat requirement 2 lacs k cal/hr 2 lacs k cal/hr Obtained from 2 lacs k cal of thermopack POWER REQUIREMENT AND ITS SOURCE (ix) Sr. No. 1 Particulars Power Electricity requirement, KVA Existing After Proposed Source expansion Will be sourced from Dakshin Gujarat Vij Co. Ltd. Quantity of waste to be generated ( liquid and solid) and scheme for their Management/disposal : Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Anneuxure-5. (x) Schematic representations of the feasibility drawing which give information of EIA purpose: A schematic representations of the feasibility drawing is attached in PFR report. 4. Site Analysis (i) Connectivity : The project is located in notified Industrial Estate of Gundlav which is very well connected to National Highway no.8, Western Railway. The nearest airport (Mumbai) and port are 150 KM away from the project site by road. (ii) Land Form, Land use and Land ownership : The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation. (iii) Topography (along with map) : The proposed expansion project is in existing unit located in notified industrial estate, GIDC Gundlav, Di: Valsad. We have started our unit in the year of The entire land is non-agriculture land. The overall project site is located on plain barren land devoid of any permanent vegetation. The proposed expansion project is to be carried out in existing plant only. There will be no extra land required for the proposed expansion. The Landuse map is enclosed as Annexure-6. Expansion Project: Page 15 Manufacturing: Resins

16 (iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In notified industrial area, a copy of Gazette notification should be given : The existing land is located in the notified industrial area. A copy of gazette notification is enclosed as Annexure-7. (v) Existing Infrastructure : GIDC notified industrial area of Gundlav has the entire available infrastructure like water, electricity, roads, rail, transportation, availability of raw material etc. (vi) Soil classification : General soil classification of the area is as under : The area, being of basaltic formation, falls under the broad soil group of red loams and black clay soils. The transmission of water through similar parent material seems to have influenced the development of different physiographic characteristics of the soils in the area. The area in between the hills with sloping lands contains dark yellowish brown to very dark grayish brown gravelly clay loam to clayey soils of shallow to moderate thickness. The dissected hill and steep slopes suffer from severe erosion hazards. The steep hill slopes are almost devoid of soil. (vii) Climate data from secondary sources : Rainfall Data : The project site location receives annual rainfall of to 1300 mm in 35 rainy days with coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan district and parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The rest part of the state receives rainfall between mm and generally fall under semi-arid climate. Expansion Project: Page 16 Manufacturing: Resins

17 Table 2. Rainfall projection for Project site and Gujarat Sr. No. Region Rainfall Projection (in mm) June Oct Normal Rainfall (In mm) Rainfall Projection (% Departure from normal) 1 Middle Gujarat South Gujarat Project site Saurashtra Gujarat State Source: AAU, Anand, Gujarat Temperature Data: The site location M/s. Techno Plastimer is located in the southern part of Gujarat. The secondary data was collected from Worldclim.org. The project site temperature regime for medium to high level temperature (30-32 C) during the seasonal months (June to Sep). The climate map for site location shows that temperature recorded over a month of (4 month).coastal area from the inland site for 10 km distance, temperature recorded for this area low to medium level. Figure showing project site for seasonal temperature in (June to September). Expansion Project: Page 17 Manufacturing: Resins

18 (viii) Social Infrastructure available : Social Infrastructure in Valsad district is as under : Education : There are 990 primary and 161 secondary and higher secondary Table 5: List of Educational Institutes schools in the district Educational Total With over 1,250 seats, there are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature & motor rewinding, Primary School 990 electrician, information technology and electronic system maintenance Secondary School etc 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical, mechanical and plastic engineering, ITI s 6 with an intake capacity of 360 Polytechnic 1 College With 120 seats, there is one Degree Engineering College present in Pharmacy College 2 Valsad offering engineering courses in mechanical and chemical Engineering 1 branches College Located in Vapi, G. M. Bilakhia Pharmacy College has an intake Management 1 College capacity of 60 students per year Other Colleges Rofel Institute of Management studies in Valsad offers full time MBA Other Colleges: Arts, Commerce, Science, B.Ed and Law College course and takes 120 students per annum Source: Department of Education. Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of- the- art technology and trained medicos A multi-specialty 21 st Century Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, giving services in general and laparoscopic surgery, trauma, orthopedic and urology etc. the hospital is one of the few centers in India offering Uterine Thermochoice thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital, and Adarsh Hospital are also present in Valsad Tourism: Tourism Built in 1742, the Fire Temple at Udawada, which is also known Fire Temple as Mecca for the Parsi community in India, makes the city a famous pilgrimage center throughout the world Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the years The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, has increased the graph of tourist flow in the district. 5. Planning Brief : (i) Planning Concept ( Type of industries, facilities, transportation etc) Town and Country Planning /Development authority Classification : There is a cluster of numerous medium-scale and small-scale industries, engaged in manufacture of variety of products, for example pharmaceuticals, paints, plastics, packaging, textiles, specialilty chemicals and electroplating and engineering in the Gujarat Industrial Development Corporation (GIDC) notified area of Gundlav. (ii) Population Projection: The proposed expansion to be carried out in existing plant located at notified industrial estate. This project will generate employment for 6 people. (Existing 9 no + Additional 6 no = 15 no) Expansion Project: Page 18 Manufacturing: Resins

19 (iii) Land use Planning (breakup along with green belt etc) : The existing as well as proposed expansion project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below. For Green Belt Development, the company proposes 23.0% green belt of the total land, i.e. 742 sq. meter. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises. Plants with thick foliage leaf and trees having large canopy will be selected. Site plan with Area table at Existing after proposed expansion Sr. No Area in m 2 Particulars Existing Proposed Total Total Plot area, m Production Plant Office &laboratory RM & FG storage Boiler shed ETP Green belt Open land Expansion Project: Page 19 Manufacturing: Resins

20 (iv) Assessment of Infrastructure demand ( Physical & Social) : There is no need for any infrastructure demand in terms of physical or social needs for proposed expansion. (v) Amenities/ Facilities : GIDC notified industrial area of Gundlav has the entire available infrastructure like water, electricity, roads, rail, transportation, availability of raw material etc. 6. Proposed Infrastructure : (i) Industrial Area (Processing Area). The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. (ii) Residential Area (Non Processing Area) : No residential area is involved in the proposed expansion project. (iii) Green Belt : Green belt is provided and maintained at the tune of 23% of the total land area. Additional green belt shall also be developed on the periphery of outer road of GIDC or at any other suitable location in GIDC. (iv) Social Infrastructure : Not applicable (v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) : The project site is very well connected by road through National Highway no. 8, railways. (vi) Drinking Water management ( Source & Supply of water ) : Source of water is from GIDC water supply services. (vii) Sewerage System: Adequate septic tank is provided. Overflow from septic tank will be utilized for plantation. (viii) Industrial Waste Management : Industrial liquid effluent generation during the manufacturing of proposed expansion will be collected and sent to CHWIF of M/S BEIL, Ankleshwar for incineration. Domestic liquid waste is being disposed off through septic tank. (ix) Solid Waste Management : Expansion Project: Page 20 Manufacturing: Resins

21 Sr. No. Type of waste Category Qty. MT/ Year Existing After Proposed expansion 1 Used Oil Discarded containers Treatment Packed in carboys Decontamina ted, stored Disposa l Sell to register ed recycler Sell to authori zed recycler (x) Power Requirement & Supply / Source : Power requirement for proposed expansion project will be taken from DGVCL. 7. Rehabilitation and Resettlement (R&R) Plan: (i) Policy to be adopted (Central/ State) in respect of the project affected persons including home oustees, land oustees and landless laborers (a brief outline to be given): The proposed expansion project will come up in the existing plot of GIDC hence, no local person will be affected. Infact employment opportunities will be generated for local population in construction and operation phase. 8. Project Schedule & Cost Estimates : (i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) : After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed minor construction and replacement of smaller reactors to bigger reactors. The production is likely to commence after 4-6 months after obtaining EC/CTE of GPCB. (ii) Estimated project cost along with analysis in terms of economic viability of the project: Estimated project cost along with the analysis in terms of economic viability of the project is given as below; Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads considered in the Capital Cost Projection for the proposed expansion Expansion Project: Page 21 Manufacturing: Resins

22 project. Environment Protection has also been considered in planning the Cost Projection, which will include Green belt development, safety systems, etc. Capital Cost Contribution Sr. No. Particulars Cost in Rs.(Lacs) for Existing Proposed Total 1.0 Land 742 Sq. meters Plant & Machinery Electrical installation Laboratory & furniture Security system Environmental Management System Total Project Cost Cooling Tower, TR Chilling plant, TR 9.0 Power from DGVCL, KVA Water from GIDC Waste Water (Industrial) Project Viability Sr. No. PARTICULARS AMOUNT IN Lacs 1 Proposed Sale Raw Material Cost Power & Fuel 25 4 Labor Cost 30 5 Environmental Management System 50 6 Maintenance Cost 15 7 Selling, packing & Office Expenses 85 8 Proposed Profit 130 The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning. Sr. No. Recurring/operating Cost per annum Component Proposed (Rs. In Lacs/annum 1. Environment & Safety Management System Greenbelt Maintenance Solid waste Disposal 2.5 Total 50.0 Expansion Project: Page 22 Manufacturing: Resins

23 9. Analysis of Proposal ( Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people including tribal population, if any, in the area: Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Local people will get direct financial benefit by way of employment. Local people will get some contracts of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby area. Expansion Project: Page 23 Manufacturing: Resins

24 ANNEXURES Expansion Project: Page 24 Manufacturing: Resins

25 ANNEXURE-1 The map showing general location, specific location and project boundary and project site layout of, located at Plot No. C-1-B/3, old GIDC Gundlav, Di: Valsad The location of the project site can be viewed in Figure 1.1 Fig. 1.1: Location map showing the Project site Project Site Expansion Project: Page 25 Manufacturing: Resins

26 Google Map showing project Site Expansion Project: Page 26 Manufacturing: Resins

27 ANNEXURE-2 Site Layout Plan Sr. No Area in m 2 Particulars Existing Proposed Total Total Plot area, m Production Plant Office &laboratory RM & FG storage Boiler shed ETP Green belt Open land Expansion Project: Page 27 Manufacturing: Resins

28 ANNEXURE-3 Detailed project description with process details - MANUFACTURING PROCESS EPOXY RESIN FORMULATIONS:- The basic epoxy resin is cooked with various reactive diluents like Phenyl or cresyl glycidyl ethers at temperatures varying 45 o C. To C. Depending upon the targeted end properties along with other plasticizers like di butyl or di octyl phthalates and fillers. Since the basic reaction involved in addition reaction which propagated through free radial mechanism, no bi-products of any kind is liberated. The mass of the total charging is completely converted into the fished product. Hence there is no effluent released and the process is based on zero discharge. FLOW DIAGRAM OF EPOXY RESIN FORMULATION Basic Epoxy Liquid Resin: 4000 kgs REACTOR Additives: 1000 kgs HEATING EPOXY RESIN: 5000 Kgs EPOXY HARDENERS:- These are basically meant for curing of the epoxy systems and mainly involves mechanical mixing at slightly elevated temperatures. Here the di basic are mixed with reactive diluents and certain diamines to the required consistency at 50 0 C C and discharged through filter bags. Since this involves only a simple blending and addition reaction to a very slight extent no effluent is released and hence based on zero liquid effluent discharge. Expansion Project: Page 28 Manufacturing: Resins

29 FLOW DIAGRAM OF EPOXY HARDENER Hexa Hydro Phthalic Anhydride (HHPA): 3500 kgs Tetra Hydro Phthalic Anhydride (THPA): 500 kgs Phthalic Anhydride: 400 kgs C G E : 600 kgs REACTOR HEATING HARDNER:I : 5000 KGS Di Amino Di Phenyl Methane (DDM): 1800 kgs Di Butyl Phthalate (DBP): 800 kgs Basic Epoxy resin (BER): 2000 kgs P G E : 400 kgs REACTOR HEATING HARDNER:II : 5000 KGS Tri Methyl Hexa Methylene Di amine (TMD): 3000 kgs Basic Epoxy resin (BER): 2000 kgs REACTOR HEATING HARDNER:III : 5000 KGS VENYL ESTER RESINS:- The basic epoxy resin liquid is advanced to the required molecular weight by reacting with diphenylol propanes in the presence of traces of amine catalyst at C C. The mass is further reacted with methacrylic acid till the all reactive sites are more or less saturated to give tough resinous product at temperature ranging from 80 0 C. To C. This is further thinned down to workable consistency like polyester resin with styrene monomer. The reaction mechanism involved in addition reaction in which the epoxy group claves into primary or secondary hydroxyl sites to get reacted with pendent methacrylic acid giving rise to on effluent. Hence, this process also in on zero liquid effluent discharge basis. Expansion Project: Page 29 Manufacturing: Resins

30 Expansion Project: Page 30 Manufacturing: Resins

31 FLOW DIAGRAM OF VINYL ESTER RESIN Epoxy Resin : 1450 Kgs Maleic Anhydride : 50 Kgs Methacrylic Acid : 300 kgs Bisphenol A : 350 Kgs Styrene Monomer : 1700 Kgs REACTOR DILUTION VINYL ESTEWR RESIN : 3850 Kgs UNSATURTED POLYESTER RESINS:- Dibasic acids like Phthalic anhydride, Isophthalic acid, Terphthalic acid and Maleic anhydride or Fumeric acid are co-reacted with a combination of glycols like propylene glycol, Monoethlene glycol, diethlene glycol or Neophetyle glycol in the stoichiometric ratio at around C to the required degree of polymerization by gradually removing the water of reaction. The molten resin is transferred to the blender and subsequently thinned down with styrene monomer a copolymer to adjust the viscosity and gel time. The resin is filtered through filter bags and packed into drums. The reaction water is collected separately and sent to M/S BEIL, Ankleshwar for incineration. Thus there is no discharge of any industrial effluent on land. Expansion Project: Page 31 Manufacturing: Resins

32 Expansion Project: Page 32 Manufacturing: Resins

33 FLOW DIAGRAM OF UNSATURATED POLYESTER RESIN DIBASIC ACIDS Phthalic Anhydride, Isophthalic Acid, Terphthalic Acid, Adipic Acid, Maleic Anhydride, Fumeric Acid : 2000 Kgs ADDITIVES GLYCOLS Propylene, Mono Ethylene Glycol, Diethylene Glycol, MPDIOL, NeoPentyle Glycol, Dipropylene Glycol : 2000 Kgs REACTOR (ESTERIFICATION) Steam Condensation Reacted Water : Kgs Vinyl Monomer Styrene Monomer, Methacrylates, Vinyl Toluene : 1800 Kgs BLENDER (DILUTION) Unsaturated polyester Resin: Yield Kgs/batch Expansion Project: Page 33 Manufacturing: Resins

34 ANNEXURE-4 Water withdrawal permission from SSI Valsad Expansion Project: Page 34 Manufacturing: Resins

35 ANNEXURE-5 Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal. Quantity of Waste Water (liquid waste) generation and its management : Sr. No. Particulars Effluent Generation, M3/Day Existing After Proposed expansion 1 Domestic Processing Cooling Floor/container/e quipment washing 5 Gardening Total Total Industrial Note: Domestic effluent shall be passed through adequate capacity of septic tank. After proposed expansion, total water consumption will be 1.9 m 3 /day. There will be no use of water in process. Water of reaction generated from the process as waste water. After proposed expansion, total 0.76 m3/day of waste water will be generated. As the process water having pungent smell of Maleic anhydride, hence it is collected and directly sent for incineration of M/S BEIL, Ankleshwar. Thus there will be no discharge of any industrial effluent on land. Expansion Project: Page 35 Manufacturing: Resins

36 Details of Effluent Treatment Plant Design Criteria : Product : Resin Source of Effluent : Water of reaction from the process. Design Flow of Effluent : 0.76 KL/day Max. Design Parameters : As under Effluent Characteristics: Sr No. Parameters unit Result Method Ref. 1 Physical state - Liquid 2 Sample Appearance - Colourless Liquid 3 *PH (10% Soln) APHA 4500+B 4 *Calorific Value Cal/gm 964 Is:1448(Part-6): Carbon % 8.65 CHNS ANALYZER 6 Hydrogen % CHNS ANALYZER 7 Nitrogen % 0.43 CHNS ANALYZER 8 Total Sulphur % 1.78 CHNS ANALYZER 9 Total Halogens % 0.25 APHA 4500CL-B 10 Cyanide ppm 0.23 APHS 4500-CN 11 *Moisture Content % IS:2362: Annealing Loss At 550 C % 38.0 STD. Methods of Chemical Analysis By N H Surman 13 *Ash Content At 550 C % 0.49 IS:1448(Part-4): Flash Point dc 45.1 IS:1448 (P-21): Compatibility Test - Ok 16 Flammability Test - Not Flammable Qualitative Organic Analysis 17 Reactivity Air/Water - No Reactive ASTM D Expansion Project: Page 36 Manufacturing: Resins

37 18 Reactivity with Lime - No Reactive ASTM D Reactivity With Triethyl Amine - No Reactive ASTM D *Fluoride Mg/Ltr APHA 4500-F-C As the entire effluent will be sent to M/S BEIL, Ankleshwar for incineration, hence only collection tank (HDPE) of 10 KL is provided for the collection of waste water. Membership Certificate of M/S BEIL, Ankleshwar is enclosed herewith. Expansion Project: Page 37 Manufacturing: Resins

38 Expansion Project: Page 38 Manufacturing: Resins

39 Quantity of Solid Waste generation and its management Sr. No. Type of waste Category Qty. MT/ Year Existing After Proposed expansion 1 Used Oil Discarded containers Treatment Packed in carboys Decontaminated, stored Disposal Sell to registered recycler Sell to authorized recycler Expansion Project: Page 39 Manufacturing: Resins

40 ANNEXURE-6 Land Use map Expansion Project: Page 40 Manufacturing: Resins

41 ANNEXURE-7 Plot Allotment Letter Issued By The GIDC & Copy of Lease Agreement Expansion Project: Page 41 Manufacturing: Resins

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43 Expansion Project: Page 43 Manufacturing: Resins

44 Expansion Project: Page 44 Manufacturing: Resins

45 Expansion Project: Page 45 Manufacturing: Resins

46 Notification for Valsad Notified industrial estate Expansion Project: Page 46 Manufacturing: Resins

47 Expansion Project: Page 47 Manufacturing: Resins

48 A schematic representation of the feasibility drawing Expansion Project: Page 48 Manufacturing: Resins

49 Annexure-8 COPY OF CCA Expansion Project: Page 49 Manufacturing: Resins

50 Expansion Project: Page 50 Manufacturing: Resins

51 Expansion Project: Page 51 Manufacturing: Resins

52 Expansion Project: Page 52 Manufacturing: Resins

53 ANNEXURE: 9 DETAILS OF AIR POLLUTION & ITS CONTROL MEASURES Presently, 2 lacs k cal/hr capacity of thermopack is used for requirement of heating and 10 MT/month of imported coal is used and also multi cyclone separator and 11 meters height of chimney is provided. For the proposed expansion, there is a spare capacity in existing thermopack; hence only coal consumption will be increased from 10 MT/Month to 20 MT/Month. Also we will install a D.G. Set of 60 KVA capacity to use in power failure and HSD shall be used as a fuel. There will be no process gas emission after proposed expansion. Sr. No. Particulars Details Existing Proposed Total 1.0 Capacity of Thermopak 2 lacs k cal 0 2 lacs k cal 1.1 Fuel Used Imported coal Imported coal Imported coal 1.2 Fuel Consumption 10 MT/M 10 MT/M 20 MT/M 1.3 APC provided Multi cyclone Separator 0 Multi cyclone Separator 1.4 Height/dia of chimney 11 meters 0 11 meters 2.0 Capacity of D G set 0 60 KVA (Standby) 60 KVA (Standby) 2.1 Fuel Used 0 HSD HSD 2.2 Fuel Consumption 0 8 liters/hr 8 liters/hr 2.3 APC provided 0 Exhaust Exhaust 2.4 Height/dia of Exhaust 0 11 meters 11 meters Expansion Project: Page 53 Manufacturing: Resins