RESINS & ALLIED CHEMICALS INDUSTRIES (BOMBAY) PVT. LTD.

Transcription

1 FOR THE PROPOSED EXPANSION PROJECT FOR THE MANUFACTURING OF KETONIC RESINS Category: 5(f) OF RESINS & ALLIED CHEMICALS INDUSTRIES (BOMBAY) PVT. LTD. Located at: Plot No. C-1/46, 100 SHED AREA, GIDC, Vapi, Dist- Valsad (Gujarat). Page 1

2 Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA Notification EXECUTIVE SUMMARY: No. Description Proposed Project Details 1 Name of project & Address Resins & Allied Chemicals Industries (Bombay) Pvt. Ltd. Plot No: C-1/46, 100 shed area, G.I.D.C, VAPI. Pin Code: Dist. - Valsad (Gujarat) 2 Project Category 5 (f) of EIA notification Project capital cost Proposed : Rs.0.10 Crores 4 Products Name of product Production capacity, MT/month Existing Proposed Total after expansion Ketonic Resins By Product (Resin Cake) 5 By-products Resin cake = 21.5 MT/month 6 Resource Requirement Land 855 m 2. Water Electricity Fuel Man power 7 Source of Pollution Waste Water Generation Source: GIDC water supply Existing: KL/day Proposed: KL/day Total after expansion: KL/day Source: DGVCL Power requirement: 60 HP DG set: 82.5 KVA. (In case of power failure only) Natural Gas: 200 kg/day HSD for DG set: 15 lit/hr Operation phase 20 nos. Existing: Industrial Effluent : 8.0 KL/day Sewage : 2.0 KL/day Proposed: Industrial Effluent : KL/day Sewage : 0.5 KL/day Total after expansion: Industrial Effluent : KL/day Sewage : 2.5 KL/day Air Emission PM10, PM2.5, SOx & NOx Solid Waste Generation Hazardous waste: ETP sludge, Used Oil, Discarded containers/bags/liners 8 Mode of Treatment Waste water 1) Industrial Effluent: High COD stream shall be treated in Primary Treatment unit and then sent to CMEE of Vapi Green Enviro Limited/ Own MEE for further treatment and disposal. Page 2

3 Air Solid Waste Low COD stream shall be treated in Primary, Secondary & Tertiary Effluent Treatment Plant and finally drained to CETP drainage line. 2) Domestic effluent will be treated in septic tank/soak pit system. Chimney with adequate height has been provided to Boiler and DG set. Solid/hazardous waste will be collected, stored and disposed as per Hazardous Waste Management Rules. 2. INTRODUCTION OF THE PROJECT: 2.1. Introduction of the project and project proponent: Name of the Project Location : Resins & Allied Chemical Industries (Bombay) Pvt. Ltd. : Plot No: C-1/46, 100 shed area, G.I.D.C, VAPI. Pin Code: Dist. - Valsad (Gujarat) Introduction of the project proponent: The company is a Private limited company and is promoted by Shri R. N. Mandal. The details related to directors are given below: Sr. No. Name of Directors Residential Address 1. Shri Ramanath Mandal Geetanjali, Plot No. 582, 2. Mrs. Sandhya Mandal Khar Section, Ambernath Dist- Thane, Maharashtra Brief description of the project: Resins & Allied Chemical Industries (Bombay) Pvt. Ltd. is located in GIDC notified industrial area falling under medium Scale category The unit is manufacturing Ketonic resins with production capacity 20 MT/month at existing premises Now looking to the existing market conditions, the company proposed to enhance the production capacity of the Ketonic Resins to 100 MT/month in the same premises with the installed and additional plant machineries with required modifications Considering the Environment concerns the company proposed to manufacture the Ketonic resins with improved technology which leads to decrease the effluent Page 3

4 generation with respect to production capacity and hence there shall be no additional load on existing ETP There shall be no process gas emission in existing as well as proposed expansion The company is also having the membership of TSDF site for disposal of solid waste generated Need of the project: At present company exports 95% of its production to Europe and US Expansion is needed to meet the growing export demand MARKET FEASIBILITY: The existing unit is already engaged in the manufacturing of Ketonic Resins since Presently, the product has a very good potential in the foreign markets as well as in the domestic market hence the company proposes to increase its existing production capacity Employment Generation (Direct and Indirect) due to the project: Details of Man power requirement are as under: Existing Proposed : 11 Nos. : 9 Nos. Total after expansion : 20 Nos. 3. PROJECT DESCRIPTION: 3.1. PROPOSED PROJECT & APPLICABILITY OF EIA: Category as per the amended EIA notification-2006: The existing and proposed expansion in Ketonic Resins manufacturing is covered under the Category-5(f) Synthetic Organic Chemicals. As per the EIA Notification the proposed expansion project is covered under category A Project Location: Location: Plot No: C-1/46, 100 shed area, G.I.D.C, VAPI. Pin Code: , Dist. - Valsad (Gujarat) Page 4

5 There is clustered of profuse large-scale, medium scale and small-scale industries, engaged in manufacturing of various products, Bulk drugs, Organic pigments, Organic and Inorganic Chemicals, Pharmaceuticals, Pesticides etc. The GIDC area has a Disaster management cell set up by Vapi Industrial Association. Common Effluent treatment plant and common hazardous waste disposal site is set up by Vapi Waste & Effluent Management Co. Ltd. Vapi also having the drainage system for the disposal of the treated effluent from individual industry to the CETP for further treatment and disposal into the saline region of Damanganga River. Location of project sit: Page 5

6 Location map showing the Project site and inter-state boundary within 5 km radius Page 6

7 LAYOUT OF THE PROJECT SITE: SITE SELECTION: The major reason for selection of the existing location was that the existing infrastructure & resources can be availed for the expansion activities. Secondly, it falls in the GIDC notified industrial area of Vapi and hence the required infrastructure and resources are readily available. The plot was allotted in the name of M/s. Resin & Allied Chemical Industries (Bombay) Pvt. Ltd. in the year The copy of the GIDC plot allotment letter is enclosed as Annexure I Alternative Studies No alternative site study has been done as the proposed project is located in notified industrial area of GIDC, Vapi. Page 7

8 3.4. Resource Requirement Raw Material Sr. No. Raw materials Quantity (MT/MT) 1. Formaldehyde Cyclohexanone Land Requirement The total plot area of the unit is 855 m 2 out of which 215 m 2 of area is allotted for Green Belt Area. Area break up is mentioned in below table. Particulars Area (m 2 ) Total Constructed Area 255 Total Gardening Area 215 Total Open Land Area 385 Total Plot area Man Power Details of Man power requirement are as under: Existing Proposed Total after expansion : 11 Nos. : 9 Nos. : 20 Nos POWER AND FUEL REQUIREMENT Power requirement: The main power supply is provided by Dakshin Gujarat Vij Co. Ltd. The present total connected load is 60 HP which will be sufficient for proposed expansion. Fuel Requirement: The company operates LDO fired Boiler (1 No) of 600 kg/hr capacity and uses LDO as fuel for the same. Now the company proposes to switch over the fuel Page 8

9 from LDO to Natural Gas with consumption of 100 kg/day. Hence after proposed expansion, use of LDO shall be omitted in existing boiler. Earlier the drying of finished product in Tray Dryer was carried out by steam only. Now after proposed expansion, it is proposed to carry out the drying of finished product in Tray Dryer by Flue gas of Natural Gas only, hence no steam is required. Natural gas consumption for the drying shall be 100 kg/day. D.G. set of 82.5 KVA is also installed and HSD is used as fuel. D.G Set is operated only in case of power failure. The details of fuel consumption are as under. Requirement Sr. Particulars Total after No. Existing Proposed expansion Source 1 Energy Electricity, HP Dakshin Guj. Vij Co. Ltd. 2 LDO for Existing Boiler (600 Kg/Hr.), lit/hr Local suplier 3 Natural Gas for boiler & drying, kg/day Gujarat Gas Co. Ltd 4 HSD for existing D.G. Set (82.5 KVA), lit/hr Local suplier Water Requirement: Sr. Water cons., KL/day Particular No. Existing Proposed Total after expansion 1 Domestic Industrial 2.1 Processing + Washing Boiler Cooling Subtotal Industrial Others (Gardening) Total (1+2+3) Page 9

10 3.5. Product detail: Sr. Production Capacity, MT/Month Name of the Product No. Existing Proposed Total after expansion 1 Ketonic Resin By product 1 Resin Cake MANUFACTURING PROCESS: 4.1. PROCESS TECHNOLOGY The company is using the latest available process technology for the production. This chapter includes the manufacturing process of the product, chemical reactions, and material mass balance for the product MANUFACTURING PROCESS WITH CHEMICAL REACTION Chemical Reaction: HCHO + Formaldehyde Cyclohexanone Ketonic Resin MANUFACTURING PROCESS WITH CHEMICAL REACTION A measured quantity of formaldehyde, cyclohexanone and water is taken in a closed reaction kettle and mixed properly. A little quantity of catalyst is then added to initiate the reaction and is allowed to continue until solid granules of ketonic resin are formed. The whole mass is then washed with fresh water, filtered, dried and packaged in paper/hdpe bags. Page 10

11 Process Flow Chart with Mass Balance for Production of 1000 kg Ketonic Resin at existing scenario: MASS BALANCE: Sr. No. Input Quantity, kg Out Put Quantity, kg Remark 1 Formaldehyde 1300 Ketonic Resin 1000 PRODUCT 2 Cyclohexanone 792 Effluent water To ETP 3 Process Water 1600 Handling loss 30 4 Wash Water Evaporation loss 100 Total Page 11

12 Process Flow Chart with Mass Balance for Production of 1000 kg Ketonic Resin after proposed expansion: MASS BALANCE: Sr. No. Input Quantity, kg Out Put Quantity, kg Remark 1 Formaldehyde 1300 Ketonic Resin 1000 PRODUCT 2 Cyclohexanone 780 High COD stream 2835 MEE 3 Process Water 2520 Low COD stream Wash Water 3680 Resin cake 215 By Product 5 Handling loss 30 6 Evaporation loss 100 Total Page 12

13 5. Water Environment: 5.1. Water management system includes water balance data, wastewater characteristics and effluent treatment plant. The source of water is the GIDC Water Supply Department Water Consumption & effluent generation, KL/day: WATER CONSUMPTION: Sr. Water cons., KL/day Particular No. Existing Proposed Total after expansion 1 Domestic Industrial 2.1 Processing + Washing Boiler Cooling Subtotal Industrial Others (Gardening) Total (1+2+3) Effluent generation with segregation of effluent stream: Sr. No. Particular Effluent generation, KL/day Existing Proposed Total after expansion 1 Domestic Industrial 2.1 Processing + Washing Boiler Cooling Subtotal Industrial Others (Gardening) Total (1+2+3) Segregation effluent stream 1 High COD stream to CMEE after Primary Treatment Low COD to ETP Effluent to ETP 1 Domestic Industrial 2.1 Processing + Washing Boiler Cooling Subtotal Industrial Others (Gardening) Total (1+2+3)Effluent to ETP Page 13

14 Sr. No Expected quality of untreated & treated effluent. Parameter Unit High COD stream to CMEE Low COD stream to ETP Treated effluent to Drainage 1 ph ph units Colour Pt-Co scale <25 3 Total Dissolved Solids (TDS) ppm Chemical Oxygen Demand (COD) mg/l Suspended Solids (SS) mg/l Based on the quantity and characteristics of waste water generated as above, the existing Effluent Treatment Plant is adequate to treat the effluent after proposed expansion. The sewage generated shall be disposed into septic tank/soak pit of adequate capacity. The process effluent is proposed to segregate in High COD effluent stream and Low COD effluent stream. The High COD effluent stream shall be treated in Primary treatment and further sent to Common MEE of Vapi Green Enviro Limited, Vapi/own MEE. The membership of Vapi Green Enviro has already been obtained. Or the company also proposed to install an own MEE for the treatment of High COD effluent. The condensate from MEE shall be recycled/reuse for industrial purpose. The Low COD effluent stream shall be treated in existing Effluent Treatment Plant consists of Primary, Secondary & Tertiary Treatment Units. The treated effluent from the ETP shall be drained in CETP drainage line to CETP, Vapi. The copy of the membership letter from Vapi Green Enviro Limited (Vapi Waste Effluent Mgt. Co. Ltd.) CETP is enclosed as Annexure II. Page 14

15 5.5. Water balance Diagram at existing scenario, KL/day 5.6. Water balance Diagram after proposed expansion, KL/day Page 15

16 5.7. Details of Effluent Treatment Plant: PRIMARY TREATMENT: UNITS: Oil & Grease removal Tank Collection cum Neutralization / Reaction Tank Primary settling and sludge removal The effluent coming from the plant is initially passed through the Oil & Grease removal system. The oil free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank various chemicals like None Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added to ensure proper settling which reduces the suspended solid concentration, color and COD in the effluent. The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling tank is charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into the sludge drying beds and leached of the sludge drying beds is going back to collection tank SECONDARY TREATMENT (BIOLOGICAL TREATMENT) UNITS : Aeration Tank Secondary settling The primary treated clear effluent is passed through the aeration tank where the biodegradation of the organic matter is taken place in presence of active microorganism and required Dissolved Oxygen level. During the biological treatment BOD Value and COD Value are reduced. After the biological treatment (aeration tank) the effluent with the biomass is passed through secondary settling tank where biomass is settled and settled biomass is recycle back to aeration tank or if excess is discharged into the sludge drying beds. And clear effluent is collected into the holding tank TERTIARY TREATMENT UNIT: Sand and Carbon Filter (Mixed bed) After secondary treatment the effluent is passed through the mixed bed filter for further reduction of COD Value, BOD Value and Color. Treated water is collected into Page 16

17 the treated water tank above the roof. Finally the treated effluent confirming the treated water discharge norms laid down by board is discharged into the underground drainage to CETP for final treatment and disposal SCHEMATIC DIAGRAM OF EFFLUENT TREATMENT PLANT Page 17

18 6. AIR ENVIRONMENT 6.1. The company operates LDO fired Boiler (1 No) of 600 kg/hr capacity and uses LDO as fuel for the same. Now the company proposes to switch over the fuel from LDO to Natural Gas with consumption of 100 kg/day. Hence after proposed expansion, use of LDO shall be omitted in existing boiler Earlier the drying of finished product in Tray Dryer was carried out by steam only. Now after proposed expansion, it is proposed to carry out the drying of finished product in Tray Dryer by Flue gas of Natural Gas only, hence no steam is required. Natural gas consumption for the drying shall be 100 kg/day D.G. set of 82.5 KVA is also installed and HSD is used as fuel. D.G Set is operated only in case of power failure There shall be no process gas emission The details of fuel consumption are as under. Page 18

19 6.6. Details of proposed flue gases stack, nature of emitted pollutants and system provided for air pollution control are mentioned in the following table. Sr. No. Stack attached to Type of fuel Fuel cons. Existing Proposed Total after expansion Stack Ht., m Emission Parameter Permissible limit Unit 1 Boiler Capacity: LDO, lit/hr or kg/hr Natural gas, kg/day PM 150 mg/nm 3 2 DG set KVA HSD, lit/hr SO2 100 ppm 3 Tray dryer Natural gas, kg/day NOx 50 ppm Page 19

20 7. Solid/Hazardous Waste 7.1. Hazardous waste will be generated from the Effluent treatment plant, D.G. Set and raw material consumption. The company has adequate storage facility for the storage of waste The details of Hazardous waste generation and management are as under. Sr. No Types of Waste ETP Waste, MT/month Discarded containers, Nos/month Used lit/year Oil, Category Source of Generation Quantity Existing Proposed Total after expansion 34.4 From ETP Raw material cons D.G. Set Method of Disposal Sent to TSDF Site of M/s. VWEMCL through Vapi Waste & Effluent Mgt. Co. Ltd. for final disposal Returned back to the supplier / Sold to authorized scrap vendor. Sold to registered refiners. Page 20

21 8. WASTE MINIMIZATION AND CLEANER PRODUCTION 8.1. Waste minimization and Cleaner production after proposed expansion at overall scenario shall be as under. Sr. No. Particulars Existing After proposed expansion Diff. % Diff. Remarks 1 Ketonic Resin production, MT/month Resin Cake as by product, MT/month Waste minimization - By product recovery 3 Water consumption, KL/day Cleaner production by reducing water requirement 4 Effluent generation, KL/day Cleaner production by reducing effluent generation 5 Effluent stream segregation, KL/day 5.1 High COD Cleaner production by segregation and treatment of 5.2 Low COD effluent streams at source 6 Water conservation by recycle/reuse, KL/day Fuel Consumption 7.1 LDO, lit/hr Natural gas, kg/day HSD, lit/hr Cleaner production by switching over to cleaner fuel and omitting LDO Page 21

22 Sr. No Waste minimization and Cleaner production after proposed expansion per MT of Ketonic Resin manufactured shall be as under. Particulars Existing After proposed expansion Diff. % Diff. Remarks 1 Resin Cake as by product, MT/month Waste minimization - By product recovery 2 Water consumption, KL/day Cleaner production by reducing water requirement 3 Effluent generation, KL/day Cleaner production by reducing effluent generation 4 Effluent stream segregation, KL/day 4..1 High COD Cleaner production by segregation and treatment of 4.2 Low COD effluent streams at source 5 Water conservation by recycle/reuse, KL/day Fuel Consumption 6.1 LDO, lit/hr Natural gas, kg/day HSD, lit/hr Cleaner production by switching over to cleaner fuel and omitting LDO Page 22

23 9. HAZARDOUS CHEMICAL STORAGE & HANDLING: Sr. No. Hazardous chemicals Place of storage Storage facility 1. Formaldehyde Within the Storage tank 2. Cyclohexanone premises Storage tank Mode of Transport By road 10. NOISE AND ODOUR CONTROL There is no major activity due to which noise is generated. The industry has provided acoustic enclosure to the D.G. Set in order to minimize the noise level. There is no major generation of bad odor as process is carried out in closed reactors. 11. HEALTH AND SAFETY The Industry has to be concerned about occupational health and safety among its work force as the man power is the biggest assert to the industry. Some key safety measures implemented in the plant and will be followed after proposed expansion. Safety Training is provided to the employees. Manual call bells for use in case of emergency are provided. Emergency Control Room with emergency sirens is established. Assembly point is provided. Fire Extinguishers are provided. First Aid Facility and training is provided. Personal protective equipment are provided to employees. Health checkup is organized at regular intervals. Safety / Health records and MSDS are maintained. 12. RAIN WATER HARVESTING The industry has decided to implement Rain Water Harvesting to prevent runoff and help in ground water restoration. It is proposed to collect roof top water in pipes and drain and which shall be used for recharging of ground water. Page 23

24 A dedicated Storm water drain shall be provided throughout the site and divert all rain water to water harvesting ponds without any contamination. During rainy season, the rain water will be collected from roofs in underground tank and the collected water will be used for process. 13. GREENBELT DEVELOPMENT The company has allotted 25 % area for the greenbelt and proposes to utilize maximum open land for green belt development. The industry proposes to plant different species and variety of plants in the green belt area. 14. SITE ANALYSIS CONNECTIVITY The project location is well connected with road, rail and air route to transport raw materials, machineries etc. and hence, it exhibits good potential for industrial growth. The salient features mentioned below, indicate favorable conditions for industrial development at the project location. Particulars Town Nearest City River/Streams Nearest Highway Nearest Railway Station Nearest Airport Tourist places Protected areas (National parks/ sanctuaries) Nearest state boundary Defense installations Sites of Historical/ Archaeological Importance Densely Populated or built up Area School/College Hospital Details Vapi 4 km Valsad - 30 km River Damanganga - 2 km NH km Vapi Railway Station - 4 km Surat Airpot km None None within 10 km radial periphery State boundary of Gujarat & Maharashtra No defense Installation. No Sites of Historical/ Archaeological Importance Vapi town Vapi town has primary, secondary, higher and CBSC schools as well as Engineering, Medical, Arts, and Commerce & Science colleges. Hariya Hospital and private experts of every medicine are available in the area. Page 24

25 15. CLIMATE DATA FROM THE SECONDARY SOURCE: Climate Seismic Zone Semi-Arid II Maximum temperature, 0 C 42 C Minimum temperature, C 8.5 C Relative Humidity Max.:- 89%; Min.:- 56% Max Rain Period June to October 16. BUDGETARY PROVISION & PROJECT COST The company has budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning. The existing shed is sufficient for the proposed expansion. Plant and machinery for the proposed expansion will be acquired and installed. Environment Protection has also been considered in planning the Cost Projection. It includes the installation of ETP for treatment of effluent. Green belt development is also calculated. Capital Cost for proposed expansion: The proposed expansion is in existing premises only. Cost of the proposed expansion shall be Rs. 10 lac only. Recurring Cost for Environment Management per month Sr. No. Purpose Total Cost, Rs. lacs 1 ETP (Operations and Maintenance) Environment & Safety Mgt. System Greenbelt Maintenance Expenses for CETP & CSWP facilities 2.25 TOTAL : 2.75 Page 25

26 Conclusion: As summarized in the above sections, it has been noticed that the proposed expansion project of Ketonic Resins will not have any major impacts, which can lead to serious issues of environmental pollution or any other hazards. Considering the probability of impacts, Resins & Allied Chemicals Industries (Bombay) Pvt. Ltd. shall plan adequate mitigation measures and EMP. Further, Resins & Allied Chemicals Industries (Bombay) Pvt. Ltd. has also been planned to organize CSR programs, rainwater harvesting, energy conservation, which will have considerable beneficial impacts. Looking to the employment potentials and other allied development potentials, it has been noticed that the proposed project will significantly help in improving social status of the region. Page 26

27 Annexure I GIDC plot allotment letter Page 27

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29 Annexure II Membership letter from Vapi Green Enviro Limited Page 29

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