ofenvironmentclearance.nic.in/writereaddata/online/tor/10...i. policy to be adopted (central/ state)...

OF

THE PROPOSED EXPANSION PROJECT

(BY ENHANCEMENT IN CAPACITY)

(Manufacturing of Dispersing Agents)

Under Activity: 5(f)

(Synthetic Chemical Manufacturing Industry)

OF

Located at:

Plot No. 1734 & 1702/B, Phase-III,

GIDC Vapi, Tal-Vapi, Dist- Valsad

Pin- 396195, Gujarat-India

Prefeasibility Report M/s. Gujarat Polysol Chemicals Pvt. Ltd.

Expansion project-Synthetic Organic Chemicals Page | i

INDEX

1. Executive Summary……………………………………………………………………………………….……………… 01

2. Introduction……………………………………………………………………………………..………….………………. 03

i. Identification of the Project and Proponent. 03

ii. Brief Description of the project 03

iii. Need of the project and its importance to the country and or region 04

iv. Demand –Supply Gap 04

v. Imports vs. Indigenous production 04

vi. Export Possibility / Domestic / export Markets 04

vii. Employment Generation (Direct and Indirect) due to the project. 04

3. Project Description………………………………………………………………………………………………………… 05

i. Type of Project including interlinked and interdependent projects, If any 05

ii. Location (map showing general location, Specific location, and project boundary & project site layout)with coordinates

05

iii. Profile of Project site 07

iv. Site Layout Plan 08

v. Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted

09

vi. Size or magnitude of operation 09

vii. Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given)

09

viii. Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product

29

ix. Resource optimization/ recycling and reuse envisaged in the project, 32

x. Availability of water its source, Energy/power requirement and source 32

xi. Quantity of waste to be generated (liquid and solid) and scheme for their Management/disposal

33

xii. Schematic representations of the feasibility drawing which give information of EIA purpose

37

4. Site Analyses………………………………………………………………………………………………………………… 38

i. Connectivity 38

ii. Land Form, land Use and Land Ownership 38

iii. Existing Infrastructure/ land use pattern 38

iv. Soil Classification and Land Use Classification 38

v. Climate Data from secondary source 38

vi. Social Infrastructure 38

5. Planning Description……………………………………………………………………………………………………… 39

i. Planning Concept (Type of industries, facilities, transportation, etc.) 39

ii. Population Projection 39

iii. Land use planning (breakup along with green belt etc. 39

Prefeasibility Report M/s. Gujarat Polysol Chemicals Pvt. Ltd.

Expansion project-Synthetic Organic Chemicals Page | ii

iv. Assessment of Infrastructure demand (Physical & Social) 39

v. Amenities/ Facilities 39

6. Proposed Infrastructure ……………………………………………………………………………………………….. 40

i. Industrial Area (Processing Area) 40

ii. Residential Area (Non Processing Area). 40

iii. Green belt 40

iv. Connectivity 40

v. Drinking Water management (Source& Supply of water) 40

vi. Sewage System 40

vii. Industrial Waste Management 40

7. Rehabilitation and Resettlement (R&R) Plan…………………………………………………………………. 40

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):

40

8. Project Schedule & Cost Estimates…………………………………………………………………….............. 40

i. Likely date of start of construction and likely date of completion 40

ii. Estimated project cost along with analysis in terms of economic viability of the project

41

9. Analysis of Proposal (Final Recommendations)…………………………………………………............. 41

i. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area

41

Prefeasibility Report M/s. Gujarat Polysol Chemicals Pvt. Ltd

Expansion project-Synthetic Organic Chemicals Page | 1

1. EXECUTIVE SUMMARY

1.0 About Project:

M/s. Gujarat Polysol Chemicals Pvt. Ltd. proposes to expand its manufacturing capacity of “Dispersing

agent, leather chemicals and construction chemicals”, in the main chemical hub of the country at

Plot No. 1734 & 1702/B, Phase – III, G.I.D.C., Vapi in the state of Gujarat. The total capacity of the

plant will be increased from 3980 MT / month to 7650 MT / month.

2.0 Highlights of the Project:

Sr. No. Particulates Description

1. Project Location M/s. Gujarat Polysol Chemicals Pvt. Ltd.

Plot No. 1734 & 1702/B, 3rd Phase, G.I.D.C., Vapi - 396 195,

Gujarat, INDIA.

2. Project Activity, Category as

per amendments

Project Activity:-5(f)- Synthetic Organic Chemicals,

Category:-A (Due to applicability of General Conditions)

3. Project Cost 2031.80 Lakhs after proposed expansion

4. Total area of Project Existing: 4696 sq.m., Proposed: 5000 Sq.m

5. Products with capacity Existing: Dispersing agent, leather chemicals and construction chemicals @ 3980 MT/ Month Proposed: Dispersing agent, leather chemicals and construction chemicals @ 4820 MT/ Month

6. Power Requirement Existing 350 KVA ,Proposed 125 KVA

7. Utilities (D.G. Sets, Boilers,

Thermopack, etc...)

Steam boiler :

Existing: 600 kg/hr 2no. and 800 kg/hr,

Proposed steam requirement : 2000 kg/hr from steam boiler

Thermic fluid heater: Existing: 4 lakh kcal /Hr

D.G. Set: Existing : 250 KVA, Proposed: 250 KVA

8. Fuel Requirements Natural Gas for Steam boiler: 200 SCM /day for each

Natural Gas for Thermic fluid heater: 200 SCM /day

Diesel: Existing :20 Lit/ Hr., Proposed:

20 Lit/ Hr

9. Man Power Total 55 persons

10. Air pollution Control

Measures

Provided Adequate stack height and vent of flue gas is connected to spray dryer for hot air.

Single stage scrubber attached to spray dryer (3 nos.)

Two stage scrubber attached to process reactor

Carbon Adsorption System attached to Formaldehyde reactor.

11. Water requirement & waste

water generation with mode

Total Fresh Water requirement will be 217.37.00 KL/day &



of disposal Water supply will be met from GIDC water supply dept.

Total industrial Waste Water Generation will be 8.00

KL/Day.

Domestic waste water (8.00 KL/day) will be disposed of

through Septic Tank.

12. Solid / Hazardous waste

Generation

Managed as per Hazardous Waste (Management, Handling

And Transboundary Movement) Rules-2016.

13. Nearest Highway NH-8: 2.5 Km W(Approx.)

14. Nearest Railway Station Vapi- 4.0 Km (Approx.)

15. Nearest Airport Daman 12.41 Km W (Approx.) and Mumbai :170 Km S

(Approx.)

16. Nearest Forest/

Sanctuary/Eco-sensitive zone.

None



2. INTRODUCTION

I. Identification of Project and Proponent:

Name of the Project Proponent: M/s. Gujarat Polysol Chemicals Pvt. Ltd.

M/s. Gujarat Polysol Chemicals Pvt. Limited is a medium scale unit is located in notified industrial estate,

GIDC Vapi, District Valsad, Gujarat, INDIA a well enthusiastic & professionally managed manufacturer &

marketer of dispersing agent especially used in disperse dyes, pigments, textile dyeing, pesticide

formulation, agro chemicals, construction chemicals & leather chemicals are as per requirement of

industries.

The company is a registered Private Limited company and is promoted by three Directors. Details

related to them are given below:

Sr.

No. Name of Directors Residential Address

1. Mr. Shailesh Desai, Managing Director, Plot no. 20,

Behind MBA Roffel Collage Chharwada Road,

GIDC, Vapi-396195

2. Mr. Umang Desai, Director,

Plot no. 20,

Behind MBA Roffel Collage Chharwada Road,

GIDC, Vapi-396195

3.

Mr. Kishor S. Gupte,

Director

7, Bank Colony

Opp. Dutt Nagar,

Civil Hospital Road

Nanakwada,

Valsad -396001

II. Brief description of nature of the Project:

M/s. Gujarat Polysol Chemicals Pvt. Ltd. is an existing Company which situated in Plot No. 1734 & 1702/B, Phase – III, G.I.D.C., Vapi in the state of Gujarat, the industrial belt of Gujarat (India) and is logistically well connected by road and rail. The company has experienced personnel and well equipped production plant with state of art machinery. Since the inception, company has carved its niche by offering a distinct value and quality proposition to its customers. Our company is dedicated to constantly expanding and updating our product range in order to stay ahead of the market. The company has been a preferred vendor for more than 100 Companies in the field of chemicals. The company also exports to countries like Bangladesh, Indonesia, Singapore & Vietnam and expanding its arm globally. Company's objective is focused on high quality products, continuous innovation, R&D & solution centric customer satisfaction. M/s. Gujarat Polysol Chemicals Pvt. Ltd. is a Small Scale Unit which proposes to increase its manufacturing capacity of various types of Dispersing Agents and Leather Chemicals. These Dispersing Agents are especially used in the manufacture of disperse dyes, pigments, textile dyeing, pesticide formulations, agro chemicals, construction chemicals whereas Leather chemicals are used in leather chemicals industries.



As per the EIA notification‐ 2006 as amended the proposed expansion project involves the production of “Dispersing agent, leather chemicals and construction chemicals” which falls under item no. “5(f) – Synthetics Organic Chemical Industries “as per the EIA notification- 2006, hence required prior Environmental Clearance.

III. Need for the project and its importance to the country and or region: The proposed expansion project will provide a potential & required growth opportunity for the already running business of the company. Moreover company has strong presence with leading locally as-well-as internationally; mainly in regulated market. The company & the products are well approved & registered with the leading regulatory authorities & the pharma customers’ in local &international markets.

IV. Demand–Supply Gap: The demand of such products is tremendous in our country and there is a huge gap in the demand

supply.

V. Imports vs. Indigenous production: Proposed products manufacturing in the country will be very much viable &acceptable compare to imports due to our grass-root technology, efficient productivity and EHS-GMP compliances. Our products approval & DMF filing for leading overseas customers gives tremendous boost to our export; which earns valued forex revenue generation for our county.

VI. Export Possibility / Domestic / export Markets: The Dispersing Agents and Leather Chemicals market has fast progressing growth and there is

ample opportunity in indigenous as well as export market.

VII. Employment Generation (Direct and Indirect) due to the project: There will be very good opportunity of employment generation of additional qualified staff

&unqualified workers directly for 15 nos. and indirectly for 5 nos.) Due to proposed expansion project.



3. PROJECT DISCRIPTION

I. Type of Project including interlinked and interdependent projects, If any :

The proposed project is not interlinked and 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 layout of

M/s. Gujarat Polysol Chemicals Pvt. Ltd. unit located at Plot no. 1734 & 1702/B_G.I.D.C, Phase-III,

Tal.-Vapi,Dist.-Valsad,Gujarat-396195.The latitude and longitude of the project site is 20.368527°N

and 72.946300°E.

Figure No- 3.1 Location Map showing the project site in satellite image (5 km radius vapi)



Figure No- 3.2: Location map showing the Project site in Notified Industrial area of GIDC Vapi



III. Profile of Project Site:

Sr. No. Nearest Infrastructure Feature Distance from Project Site

1 Geographical Position Lat.: 20.368527°N, Long.:72.9946300°E.

2 Elevation above Sea Level 29 Meters (Approx.)

3 Nearest Village Chhiri- Chharwada (0.35 kmN)

4 Nearest Town Vapi(5.0 km W)

5 Nearest National Highway NH 8 (2.5 Km W)

6 Nearest State Highway GJ SH 5 (2.6 Km W)

8 Nearer RW Station Vapi (4.0 Km)

9 Nearest Airport Daman (12.41 KmsW)

Surat (125 Kms NW)

10 Nearest Surface water Resource/Reservoir

Arabian Sea (16 Km W)

Damanganga River (7 Km SW)

Kolak river (2.65 Km N)

11 Forest Patches No patches of Reserve Forest within the study

area of project site.

12 Location of Archaeologically /Historically

important places --

13 National Park/Sanctuary or Ecologically

sensitive Area

Dadra& Nagar Haveli Wild Life Sanctuary

Approx. 24 km E

14 National or State Boundary Dadra & Nagar Haveli – 3.5 Km E

Daman – 5.1 km W

15 Tourist Places Dadra & Nagar Haveli – 3.5 Km E

Daman – 5.1 km W

16 Selection of project Site and Detail of

alternate Site.

Proposed project is in the GIDC Notified

Industrial area having proper industrial

infrastructure hence alternate site

consideration is not envisaged.

17 Size or Magnitude of Operation Small Medium Scale (SME)

Plot site Area Statement:

Area Statement Existing Proposed Area After Proposed Expansion (in m2)

Total Area 4696.00 5000.00 9696.00

Construction Area 2480.00 1764.00 4244.00

Open Land Area 558.00 2236.00 2794.00

Internal Road Area 558.00 0.00 558.00

Greenbelt Area 1100.00 1000.00 2100.00



IV. Site Layout Plan:



V. Details of alternate sites considered and the basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted:

Existing unit is acquired for the proposed project in the GIDC Notified Industrial area having an

excellent locational advantage & very good industrial infrastructure including CETP, COE, VIA, etc.

Hence alternate site consideration is not envisaged.

VI. Size or magnitude of operation:

As per the proposed project cost the project is covered under Small Medium Scale category of

manufacturing industries, it comes under SME segment of the industry

VII. Project description with process details (a schematic diagram/ flow chart showing the project

layout components of the project etc. should be given):

Detailed project & product profile details –

LIST OF FINISHED PRODUCTS

Sr. No.

Name of Product Product Capacity MT/Month

Existing Proposed Total

1. Naphthalene Based Dispersing Agent (Liquid) 2500.00 500.00 3000.00

2. Naphthalene Based Dispersing Agent (Powder) 300.00 500.00 800.00

3. Phenol Based Dispersing Agent (Liquid) 200.00 800.00 1000.00

4. Phenol Based Dispersing Agent (Powder) 200.00 100.00 300.00

5. Lather Chemicals (Powder)Syntans 200.00 100.00 300.00

6. Lather Chemicals (Liquide)Fat Liquor 100.00 100.00 200.00

7. PEG Based Polycarboxylate Ether (Liquid & Powder) 400.00 1600.00 2000.00

8. BOPP Self Adhesive 50.00 200.00 250.00

9. Sulphonated Alkyl naphthalene Formaldehyde Condensate Sodium Salt

30.00 270.00 300.00

10. Dibutyl Naphthalene sulphonated sodium salt - 350.00 350.00

11. Waterproofing polymer - 300.00 300.00

Total 3980.00 4820.00 8800.00

LIST OF FINISHED PRODUCTS

Sr. No. Name of Product Chemical Name End use of product

1. Naphthalene Based Dispersing Agent (Liquid)

Sulphonated naphthalene formaldehyde condensate, sodium salt

To manufacture Disperse dyes, construction chemicals, Lather chemicals, etc..

2. Naphthalene Based Dispersing Agent (Powder)

3. Phenol Based Dispersing Agent (Liquid)

Phenol sulphonic, formaldehyde condensate, sodium salt

4. Phenol Based Dispersing Agent (Powder)

5. Lather Chemicals (Powder) Syntans

Blend of sulphonated phenol & Naphthalene formaldehyde condensate, sodium salt

For Leather processing industries.

6. Lather Chemicals (Liquid) Fat Liquor

Blend of wax sulphochloride and sulphonated paraffin wax, sodium salt

7. PEG Based Polycarboxylate Eather (Liquide & Powder)

Polycarboxylate ether Construction chemicals



8. BOPP Self Adhesive Butyl acrylate copolymer For manufacturing BOPP self-adhesive Taps

9. Sulphonated Alkylnapthaline Formaldhyde Condensate Sodium Salt

Sulphonated Alkyl napthalineFormaldhyde Condensate Sodium Salt

Used in Agro pesticide formulation and Agro Industries

10. Dibutyl Naphthalene sulphonated, sodium salt

Dibutyl Naphthalene sulphonated, sodium salt

Use in Agro pesticide formulation and Agro Industries

11. Waterproofing polymer Butyl acrylate-styrene polymer Use in Construction chemicals

INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES:

In-house technology, Installation of the plants, machineries and suitable manpower will be required

to manufacture the above additional products with proposed capacity

To get the best results in terms of quality and quantity, the company will invests in the latest available

state-of-the-art plant - machinery and leverages of grass-root technologies duly supported by

excellent marketing network will enable the project to get best of results.

MANUFACTURING PROCESS:

The company shall use the latest documented & developed green & eco-friendly non-hazardous

process technology for the production of all above products. This section includes the manufacturing

process of the product, chemical reactions, flow diagrams and mass balance of each product.

1. NAPHTHALENE BASED DISPERSING AGENT (LIQUID) :

Capacity: 3000.00 MT/Month

Manufacturing process:

Naphthalene is charged in a Sulphonator and heated to about 90°C. 23 % Oleum and 98 % Sulphuric

Acid is added slowly. The temperature is maintained for 10 hours till Sulphonation is completed. 37 %

Formaldehyde and water in 3 hours are added the entire mass is stirred at 110 °C. The mass is then

neutralized with Caustic Lye and water is added. Finally the liquid is packed in a drum as a final

product.

In this process, there is no filtration or washing, so there is no generation of any process effluent.



Process flow diagram:

No. of batches per day 4.5

Water Consumption per batch 8.25 m3

Water Consumption per day 37.125 m3

Effluent Generation Nil

Solid waste generation Nil

Chemical reaction:

SULPHONATION

+H2SO4

Oleum

SO3H

+ OH2

Napthalene: 128 98 Napthalene 2 Sulphonic Acid: 208

18

CONDENSATION

SULPHONATION at

90oC

(10 HRS ) 10450 kg

Oleum (23%): 3675 kg

Sulphuric Acid (98%): 1325 kg

Naphthalene: 5000 kg

CONDENSATION at

110oC

(20 HRS) 15850 kg

NEUTRALIZATION at

room temperature

(3 HRS) 26600 kg

PRODUCT: 11172 kgs

Real (26600 kgs as it is)

PACKAGING IN DRUM/TANKER

Water: 2500 kg

Formaldehyde: 3000 kg

Water (Steam condensed):

5750 kg

Caustic Lye: 5000 kg

Vapor loss: 50 kg Scrubber

Vapor loss: 100 kg

Condenser

Carbon

Adsorber



SO 3H

2 + HCHO

30

HO 3S CH2 SO 3H

+ OH2

18

Naphthealene 2 Sulphonic Acid-416

1methylene, Di Naphthealene Sulphonic Acid- 428

NEUTRALIZATION

CH2HO3S SO3H

428

2NaOH

80

CH2NaO3S SO3Na

472

+ 2 H2O

36

Na Salt Of B-Napthalene Sulphuric Acid Condensate

Mass Balance:

Sr.

No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Oleum(23%) 3675.00 Dispersing Agent Based On

Naphthalene (Liquid)

26600.00 Product

2. Sulphuric Acid (98%) 1325.00 Vapour loss 150.00

3. Naphthalene 5000.00

4. Water 8250.00

5. Formaldehyde 3000.00

6. Caustic Lye 5000.00

Total 26250.00 Total 26250.00

2. NAPHTHALENE BASED DISPERSING AGENT (POWDER) : Capacity: 800 MT/Month

Manufacturing process: Naphthalene is charged in a reactor and heated up to 90 °C. Sulphuric Acid is then added. Raise the

temperature till Sulphonation reaction is completed. After testing for the completion of reaction, add

37 % Formaldehyde and water is added and the mass is stirred at 110 ºC for 10 hours. Then the mass

is neutralized with Caustic Lye and Hydrated Lime to bring the pH to about 7. The mass is then filtered

and washed. The wet cake is collected and stored as a solid waste. The wash water is recycled back in

the neutralization process. The filtrate is further reacted with Soda Ash. Again the wet cake is

collected and stored as solid waste. Finally the filtrate is taken to the Spray Drier for drying. The dry

powder as a result is packed in HDPE bags for dispatch.








Solid waste generation per batch 1120 kg

Solid waste generation per month 124040 kg

SULPHONATOR at

90oC

(10 HRS) 8000kg



CONDENSATION

at 110oC

(10 HRS) 12333 kg

NEUTRALIZATION

up to 7 pH

at room temperature

(3 HRS) 18386kg

Spray Drying: 17042 kg

PRODUCT: 7218 kg

Water: 2650 kg

Formaldehyde: 1733

kg

Hydrated lime: 533 kg

Caustic Soda Lye: 3200 kg

Soda ash: 130 kg

Vapor loss: 50 kg

Carbon Adsorption

Vapor Loss: 50kg Scrubber

Water: 640 kg +

1600 recycled

Wash Water recycled: 1600 kgs

Filtrate: 17042 kg

Wash Water (Steam

condensed): 1600 kg

Filtration 17042 kg

FILTRATE AS FINAL PRODUCT: 17042 kg real (7218) kg as

it is)

Vapor Loss : 9824 kg

Wet cake : 1344 kgs (1120 kgs

+ 224 kgs Water in Solid

Waste)



Chemical reaction:

SULPHONATION SO3H

+H2SO4

Oleum + H2O

Napthalene: 128 Napthalene 2 Sulphonic Acid: 208

18

CONDENSATION

SO3H CH2HO3S SO3H

+ + H2O

Napthalene 2 Sulphonic Acid: 416

18

2

428

HCHO

30

NEUTRALIZATION

CH2HO3S SO3H

+ 2 H2O

428

2NaOH/Ca(OH) 2

CH2NaO3S SO3Na

472 36

Na Salt of B-Napthalene Sulphuric Acid Condensate

80

Mass Balance:

Sr.

No. INPUT

QTY

(Kgs) OUTPUT QTY (Kgs) REMARK

1. Sulphuric Acid (98%) 4000.00 Dispersing Agent Based On

Naphthalene (Powder) 7218.00

Product

2. Naphthalene 4000.00 Vapour loss 9924.00

3. Water 4890.00 Wet cake 1344.00 Solid waste

4. Hydrated Lime 533.00

5. Caustic soda Lye 3200.00


7. Soda Ash 130.00

Total 18486.00 Total 18486.00

3. PHENOL BASED DISPERSING AGENT (LIQUID) :

Capacity: 1000 MT/Month


Phenol is first reacted with Caustic Soda Lye to form Sodium Phenolate. This is condensed with

Formaldehyde and Sodium Sulphite at 120 °C and 1.5 – 2 kg / cm2 pressure. After the reaction is over,

the liquid product in solution form is directly filled in drums as a final product.





No. of batches per day 8





Chemical reaction:

OH

Phenol

+ NaOH + HCHO + Na2SO3

+ H2O

CH3CH2

CH2H2C-

SO3Na

NaO SO3Na

ONa

ONa

SO3Na

Sodium

Mass Balance:

Sr.


1. Phenol 1080.00 Dispersing Agent Based

On Phenol (Liquid) 4755.00

Product

2. Water 1200.00


4. Caustic Soda Lye 570.00

5. Sodium Sulphite 600.00

Total 4755.00 Total 4755.00

REACTOR at 120oC

(6 Hrs)

Phenol: 1080 kg

HCHO: 1305 kg

Sodium sulphite: 600 kg

Water: 1200 kg

Caustic Lye: 570 kg

PACKING

4755 kg As is

DISPERSING AGENT BASED ON PHENOL (LIQUID)



4. PHENOL BASED DISPERSING AGENT (POWDER): Capacity: 300 MT/Month

Manufacturing process: Phenol is first reacted with Sulphuric Acid in a Sulphonator Reactor at 90 ºC for 10 hours. This is condensed with Formaldehyde and Sodium Sulphite at 110 °C and maintained for 10 hours. After the reaction is over, the liquid product is neutralized to pH 7 with Caustic Soda lye. The liquid mass is then spray dried in a Spary Drier. Finally the dry powder is packed in bags as a final product.




Water Consumption per batch 4 m3




Chemical reaction:

SULPHONATION

SULPHONATOR

at 90oC

(10 HRS ) 4100 kg


Phenol: 2300 kg

CONDENSATION

at 110oC

(10 HRS ) 10850 kg

NEUTRALIZATION

up to 7 pH

at room temperature

(3 HRS) 12950 kg

SPRAY DRYING

12950 kg

PRODUCT: 5439 kg

Water: 2000 kg

EDTA: 100 kg

Caustic Soda Lye: 2000 kg

Vapor loss: 7511 kg

Vapor loss: 50 kg

Carbon Adsorption

Water (Steam condensed):

2000 kg

Formaldehyde: 2800 kg



OH

+ H2SO4

OH

SO3H

+ OH2

Phenol: 94 98 174 18

CONDENSATION

OH

SO3H

CH2

OH

OH

SO3H

SO3H

2

174

+ HCHO

30

+ H2O

NEUTRALIZATION

+OH CH2

SO3HSO3H

OH 2 NaOH

OH CH2

SO3NaSO3Na

OH + 2H2O

Mass Balance:

Sr.


1. Sulphuric Acid(98%) 1800.00 Dispersing Agent Based

On Phenol (Powder)

5439.00 Product

2. Phenol 2300.00 Vapour loss 7561.00

3. Water 4000.00


5. EDTA 100.00

6. Caustic Soda Lye 2000.00

Total 13000.00 Total 13000.00



5. LEATHER CHEMICALS (POWDER) SYNTAN :



PAK Liquid, Adipic Acid, Fumeric Acid, Phthalic Anhydried, EDTA, Sodium Lingo, Glaubbers Salt and H S

Liquid are mixed in a reactor as per the required quantity. After proper mixing, the liquid mass is

taken into the Spray Drier. The drier powder is packed in bags for dispatch.



Water Consumption per batch nil

Water Consumption per day Nil


Solid waste generation per batch Nil

Solid waste generation per month Nil

Chemical reaction: No Chemical reaction only mixing and spray drying process

Mass Balance:

Sr.

No. INPUT

QTY


1. PAK liquid 2750.00 Leather Chemicals (Powder) 5262.50 Product

2. Adipic Acid 100.00 Vapour loss 1525.00

3. Fumeric Acid 50.00

4. Phthalic Anhydride 50.00

5. EDTA 12.50

6. Sodium Lingo 500.00

7. Glauber’s Salt 3025.00

8. H.S. liquid 300.00

Total 6787.50 Total 6787.50

Reactor

PAK Liquid:2750kg

Adipic Acid: 100 kg

Fumeric Acid: 50

kg

Spray Dying: 6787.5 kg

Product: 5262.5 kg

Vapor loss: 1525 kg

Phthalic Anhydride:

50 kg

EDTA: 12.5 kg

Sodium Lingo: 500 kg

Glaubber’s Salt: 3025

kg

H S Liquid: 300 kg



6. LEATHER CHEMICALS (LIQUID) FAT LIQUOR

Capacity: 200 MT/ Month


Wax Sulpho Chloride, CPW, SPN, Caustic Soda, Sodium Hypochlorite, Acetic Acid, Sodium

Sulphate and water are mixed in a reactor as per the required quantity. The reactor is fitted with

a stirrer for proper mixing. The mass is heated upto 60 – 70 °C. Finally the mixture is packed into

drums as a final product.





Effluent Generation nil

Solid waste generation per batch nil

Solid waste generation per month nil

Chemical reaction: no Chemical reaction only mixing and blending process

Mass Balance:

Sr. No. INPUT QTY (Kgs) OUTPUT QTY (Kgs) REMARK

1. Wax Sulpho Chloride

1600.00 Leather Chemicals

(Liquid) Fat Liquor

5200.00 Product

2. CPW 800.00

3. SPN 240.00

4. Caustic Soda 280.00

5. Hypo chlorite 50.00

6. Acetic Acid 90.00

7. Sodium Sulphate 650.00

8. Water 1490.00

Total 5200.00 Total 5200.00

Reactor Heat

Wax Sulpho Chloride: 1600

kg

CPW: 800 kg

SPN: 240 kg

Product: 5200 kg

Caustic Soda: 280 kg

Hypo chlorite: 50 kg

Acetic Acid: 90 kg

Sodium Sulphate: 650

kg

Water: 1490kg



7. PEG Based Polycarboxylate Ether (Liq. & Powder)



After charge raw materials, heat the reactor to 70oC & start addition of emulsion & potassium persulphate solution.

Charge both solutions simultaneously in 3 hours at 90oC to 95oC.

After complete addition, maintain further 1 hour at 90oC to 95oC.

After that cool to 50oC& charge 1.) CAUSTIC SODA LYE 41 kg.

Further mix 20 min. & sample send to QC lab for quality evaluation. If sample okay, then pack in drums.








Polycarboxylate Ether (LIQUID& POWDER)

Emulsion

polymerization

DM Water: 5000 kg

Acrylic Acid: 240 kg

PEG: 4500 kg

Meth Acrylic Acid: 110 kg

Caustic Lye: 82 kg

Poly Carboxylate Ether:

10000 Kg (Liquid)

Soda ash: 4 kg

Potassium per sulphate: 24 kg

Sulphuric Acid: 40 kg


Poly Carboxylate Ether: 5000 Kg (Powder)

Vapour loss: 5000 kg



Chemical reaction:

CH2 CH

Rx

CH2

CH2

O

CH2

CH2

O

CH2

CH CH3

O

Hn

m

+ CH2 CH

COOH

+ CH2 C

CH3

C O

O

CH2

N+

CH3CH3

CH3

Cl-

H2O2

-Vc

70 C

n

m

CH2C

CH3

C O

O

CH2

CH2

CH2 CH

Rx

CH2

CH2

O

CH2

CH2

O

CH2

CH CH3

O

H

CH2 CH

COOH

*

N+

CH3

CH3

CH3

a b c

Cl-

Polycarboxylate ether

Mass Balance:

Sr.

No. INPUT

QTY


1. Acrylic acid 240.00 Poly carboxylate ether 5000.00 Product

2. PEG 4500.00 Vapour Loss 5000.00

3. Meth acrylic acid 110.00

4. Caustic Lye 82.00

5. Soda ash 4.00

6. Potassium per sulphate 24.00

7. Sulphuric acid 40.00

8. DM water 5000.00

Total 10000.00 Total

8. BOPP Self Adhesive



After charge raw materials, heat the reactor to 70oC & start addition of emulsion & potassium persulphate solution.

Charge both solution simultaneously in 2 hours at 70oC to 75oC.


After that cool to 50oC& charge 1.) AMMONIA 28 kg.











Chemical reaction:

O

O

Bu

H

OBu

O

O O

Bu

Bu

C

O

radical

PolymerizationO O

Bu

Long-chain branch from intermolecular CTP

Short-chain branch from intermolecular CTP

Emulsion

Polymerisation

DM Water: 5328 kg

Dainol : 60.28 kg

Butyl acrylate: 6328.52

kg

Meth Acrylic Acid: 132 kg

Noigen DKX-405: 4.8 kg

Self Adhesive:

12000 Kg

Soda ash: 4.8 kg

Potassium per sulphate: 28.8 kg

Ammonia: 67.2

kg

TBHP: 2.4

Kg

Safolite: 4.8 Kg

Nonyl Phenol 9.5 mole: 26.4 Kg

Formaldehyde: 12 Kg



Mass Balance:

Sr.


1. Dainol 25 60.28.00 BOPP Self Adhesive 12000.00 Product

2. Butyl acryl ate 6328.52

3. Meth acrylic acid 132.00

4. Noigen DKX-405 4.80

5. Soda ash 4.80

6. Potassium per sulphate 28.80

7. Ammonia 67.20

8. TBHP 2.40

9. Safolite 4.80

10. Nonyl phenol 9.5 mole 26.40


12. DM Water 5328.00

Total 12000.00 Total 12000.00

9. Sulphonated alkyl naphthalene formaldehyde condensate sodium salt



After charge raw materials, slowly heat to 120o temperature.

After that maintain 4 hours at 120-125oC to get complete sulphonation.

First charge water in lead bonding reactor, than slowly charge sulphonatedmaas under cooling.

Temperature should be below 80o during drowning of acidic mass.

After that charge formaldehyde in 3 hours at 70-80o.

After addition of formaldehyde, slowly heat to 100-105o& maintain 8 hours at same temperature to get complete condensation.

After condensation charge water & slowly add caustic lye under fast cooling.

Temperature should not go above 80o during neutralization.

After complete neutralization (PH 7.0 – 7.5), mix further 1 hour to get homogeneous solution. Sample send to QC lab for quality evaluation.

If sample okay, then material hand over to spray dryer unit.

Run SANFC liquid 50% into spray dryer through feed pump & keep inlet/outlet temperature.

Power sample send to QC lab for quality evaluation. If sample okay, then pack in 25 kg bags.










Mass Balance:

Sr.


1. Alkyl Naphthalene 2250.00 Sulphonated alkyl

naphthalene formaldehyde condensate sodium salt

5000.00 Product

2. Suphuric Acid 2400.00 Vapor loss 5000.00 Due to Spray

drying


4. Caustic Lye (48 %) 2208.00

5. DM Water 2042.00

Total 10000.00 Total 10000.00

Sulphonation

+

Condensation

DM Water: 2042 kg

Alkyl Naphthalene: 2250

kg

Sulphuric Acid: 2400 Kg

Formaldehyde: 1100 Kg

Caustic Lye( 48%):2208 kg

SANFC: 10000 Kg (50%)


SANFC POWDER: 5000 Kg (Powder)




Chemical reaction:

H

Alkyl Napthalene

Sulphuric Acid

R

SO3M

Alkyl NapthaleneSulphuric Acid

CH2CH3

RRSO3X SO3X

n

Final Product

10. Di butyl Naphthalene Sulphonated, sodium salt Capacity: 350 MT/Month


After charge raw materials, cool to 12-16°C temperature.

After that maintain 20 hours at 12-16oC to get complete sulphonation.

After sulphonation charge water & slowly add caustic lye under fast cooling.

Temperature should not go above 90o during neutralization.

After complete neutralization (PH 7.0 – 7.5), mix further 1 hour to get homogeneous solution. Sample send to QC lab for quality evaluation.

If sample okay, then material hand over to spray dryer unit.

Run DNS (Dibutyl Naphthalene sulphonate) liquid 50% into spray dryer through feed pump & keep inlet/outlet temperature.

Power sample send to QC lab for quality evaluation. If sample okay, then pack in 25 kg bags.


Sulphonation

+

Neutralisation

N-Butanol: 2400 kg


Water: 1500 Kg

Caustic Lye: 5100 kg

Sulphuric Acid: 3000 Kg

DNS: 14000 Kg (50%)


DNS POWDER: 7000 Kg (Powder)










Mass Balance:

Sr.


1 Naphthalene 2000.00 Di butyl Naphthalene

Sulphonated, sodium salt 7000.00

Product

2 Suphuric Acid 3000.00 Vapor loss 7000.00 Due to Spray drying

3 N-Butanol 2400.00

4 Caustic Lye (48 %) 5100.00

5 DM Water 1500.00

Total 14000.00 Total 14000.00

Chemical reaction:

+ H2SO4 + C4H10O

Napthalene Sulphuric Acid Butanol

C4H9

C4H9

SO3Na

Dibutyl Napthalene Sulphonate, Sodium Salt



11. Waterproofing polymer



After charge raw materials, heat the reactor to 70°C & start addition of emulsion & potassium persulphate solution.

Charge both solution simultaneously in 2 hours at 70oC to 75oC.


After that cool to 50oC& charge AMMONIA 28 kg.









Emulsion

Polymerisation

DM Water: 4711 kg

Noigen DKX-405: 80 kg

Butyl acrylate: 4100 kg

Styrene: 2700 kg

Meth Acrylic Acid: 105

kg

kg

Waterproofing

polymer: 12000 Kg

Soda ash: 10 kg

Potassium per sulphate: 40 kg

Ammonia: 120 kg

TBHP: 3.5 Kg

Safolite: 5.5 Kg

Dainol: 75 Kg

Formaldehyde: 50 Kg



Chemical reaction:

+ BuO2C

CH CH2

F.R.

Wateremulsion

CH CH2 CH CH2

BuO2C

n

m

Waterproofing Polymer

Mass Balance:

Sr.


1 Dainol 25 75.00 Waterproofing polymer 12000.00 Product

2 Butyl acrylate 4100.00

3 Meth acrylic acid 105.00

4 Noigen DKX-405 80.00

5 Soda ash 10.00

6 Potassium per sulphate 40.00

7 Ammonia 120.00

8 TBHP 3.50

9 Safolite 5.50

10 Styrene 2700.00

11 Formaldehyde 50.00

12 DM Water 4711.00

Total 12000.00 Total 12000.00



VIII. Raw material required along with estimated quantity, likely source, marketing area of final

product(s), mode of transport of raw material and finished product:

Detailed raw material requirement along with estimated quantity, likely source, marketing area of

final products, mode of transport of raw material and finish product

Marketing area of final products:

The products are used in the manufacture of disperse dyes, pigments, textile dyeing, pesticide formulations, agro chemicals, construction chemicals whereas Leather chemicals are used in leather chemicals industries. and the product has very good potential in local market as well as the overseas market for export of the same. The product is meant to be exported to the most regulated countries. Company has a very wide customer base; From MNC to large Generic cos.

Sr. no.

Product Raw Material Quantity MT/Month


1 Napthalene Based Dispersing Agent (Liquid)

Napthalene 490.12 98.02 588.14 Oleum (23%) 360.25 72.05 432.3 Sulphuric Acid (98%) 129.87 25.97 155.84 Formaldehyde 294.00 58.8 352.8 Caustic Lye 490.12 98.02 588.14

2 Phenol Based Dispersing Agent (Liquid)

Phenol 45.42 181.68 227.1 Formaldehyde 54.88 219.52 274.4 Sodium Sulphite 30.23 120.92 151.15 Caustic Soda Lye 23.97 95.88 119.85

3 Phenol Based Dispersing Agent (Powder)

Sulphuric Acid(98%) 69.23 34.61 103.84 Phenol 88.46 44.23 132.69 Formaldehyde 107.69 53.84 161.53 EDTA 3.84 1.92 5.76 Caustic Soda Lye 76.92 38.46 115.38

4 Napthalene Based Dispersing Agent (Powder)

Napthalene 174.41 290.68 465.09 Sulphuric Acid (98%) 174.41 290.68 465.09 Formaldehyde 75.58 125.96 201.54 Hydrated Lime 23.25 38.75 62.00 Caustic Soda 139.53 232.55 372.08 Soda Ash 5.81 9.68 15.49

5 Leather Chemicals (Powder) Syntan

PAK liquid 104.51 52.25 156.76

Adipic Acid 3.80 1.9 5.7

Fumeric Acid 1.90 0.95 2.85

Pthalic Anhydride 1.90 0.95 2.85

EDTA 0.47 0.235 0.705

Sodium LignoSulphonate

19.00 9.5 28.5

Glauber’s Salt 114.96 57.48 172.44

HS Liquid 11.40 5.7 17.1

6 Leather Chemicals (Liquid) Fat Liquor

Wax Sulpho Chloride 30.76 30.76 61.52 CPW 15.38 15.38 30.76 SPN 4.61 4.61 9.22 Caustic Soda 5.38 5.38 10.76 Hypo chlorite 0.97 0.97 1.94 Acetic Acid 1.73 1.73 3.46



Sodium Sulphate 12.49 12.49 24.98

7 PEG Based Polycarboxylate Ether Liquid &Powder

Acrylic Acid 19.20 76.8 96.00 PEG 360.00 1440.00 1800.00 Meth acrylic Acid 8.80 35.20 44.00 Caustic Lye 6.56 26.24 32.80 Soda Ash 0.32 1.28 1.60 Potassium per sulphate

1.92 7.68 9.60

Sulphuric Acid 3.20 12.8 16.00

8 BOPP Self Adhesive

Dainol 25 0.25 1.00 1.25 Butyl acryl ate 26.36 105.44 131.80 Meth acrylic acid 0.55 2.20 2.75 Noigen DKX-405 0.02 0.08 0.10 Soda ash 0.02 0.08 0.10 Potassium per sulphate

0.12 0.48 0.60

Ammonia 0.28 1.12 1.10 TBHP(Tent Butyl Hydro Peroxide)

0.01 0.04 0.05

Safolite 0.02 0.08 0.10 Nonyl phenol 9.5 mole

0.11 0.44 0.55

Formaldehyde 0.05 0.20 0.25

9 Sulphonated Alkylnapthalene Formaldehyde Condensate, Sodium Salt

Alkyl Napthalene 13.50 121.5 135.00 Sulphuric Acid 14.40 129.6 144.00 Formaldehyde 6.60 59.4 66.00 Caustic Lye 13.28 119.52 132.8

10 Di butyl Naphthalene Sulphonated, sodium salt

Naphthalene -- 100.00 100.00 Suphuric Acid -- 150.00 150.00 N-Butanol -- 120.00 120.00 Caustic Lye (48 %) -- 75.00 75.00

11 Waterproofing polymer

Dainol 25 -- 1.87 1.87 Butyl acrylate -- 102.50 102.50

Meth acrylic acid -- 2.62 2.62

Noigen DKX-405 -- 2.00 2.00

Soda ash -- 0.25 0.25 Potassium per sulphate

-- 1.00 1.00

Ammonia -- 3.00 3.00

TBHP -- 0.08 0.08 Safolite -- 0.13 0.13 Styrene 0.75 0.75

Formaldehyde 1.25 1.25



Transport and storage details of Raw materials:

Sr. No.

Name of Raw Material Storage Cap. In MT

State of raw material

Mode of Transport

Place of storage

1 Naphthalene based Dispersing agent (liquid)

400 Liquid Tanker Ms storage tank

2 Naphthalene 200 Solid truck Warehouse

3 Oleum (23%) 30 Liquid Tanker MS storage tank with scrubber

4 Sulphuric Acid (98%) 20 Liquid Tanker MS storage tank

5 Formaldehyde 40 Liquid Tanker PP storage tank

6 Caustic lye 50 Liquid Tanker MS Storage tank

7 Phenol 30 Liquid Tanker MS storage with jacketed

9 Sodium sulphite 10 Solid Truck Warehouse

10 EDTA 1 Solid Tempo warehouse

11 Hydrated lime 15 Solid Truck Ware house

13 Soda ash 5 Solid Tempo warehouse

14 Adipic Acid 2 Solid Tempo warehouse

15 Fumeric acid 1 Solid Tempo warehouse

16 Phthalic anhydride 1 Solid Tempo warehouse

17 Sodium ligno suphonate 20 Solid Truck Warehouse

18 Glaubber’s salt 10 Solid Truck Warehouse

20 Wax Sulpho Chloride 10 Liquid Truck Drum storage in warehouse

21 Chlorinated Paraffin Wax 10 Liquid Truck Drum storage

25 Acetic acid 5 Liquid Tempo Drum storage in ware house

Unit is manufacturing campaign based products as per market demand.



IX. Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly

outlined:

The raw materials packed in drums and stored in the warehouse.

By adoption continuous improvement in technology and process the desired reduction in

process waste generation will be achieved.

By proper and efficient handling of raw materials, wastages of raw materials will be reduced.

X. Availability of water its source, energy/power requirement and source should be given:

Availability of water its source energy/power required and its source.

Water Requirement:

Sr. No.

Particulars Quantity KL /day


1 Domestic 4.00 5.00 9.00

2 Industrial

Process 54.00 137.37 191.37

Floor/container/Equipment Washing

1.00 1.00 2.00

Scrubbing 0.50 0.50 1.00

Boiler & Cooling 4.00 2.00 6.00

Sub-Total Industrial Use 59.50 140.87 200.37

3 Gardening& Misc. 1.00 2.00 3.00

Total Requirement 64.50 150.87 217.37

Source: Fresh water requirement will be catered from GIDC water supply dept.,

Power Requirements and its source:

Sr. No. Particulars Existing Proposed Total Source

1. Power –Electricity

requirement 300 HP 175 HP 475 HP DGVCL / DG set



XI. 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 :

Waste water generation:

Sr. No.

Particulars Quantity KL /day


1 Domestic 4.00 4.00 8.00

2 Industrial

3 Process 0.00 0.00 0.00

4 Floor/container/Equipment Washing 1.00 1.00 2.00

5 Scrubbing 0.50 0.50 1.00

6 Boiler & Cooling 4.00 1.00 5.00

Sub Total Industrial 5.50 2.50 8.00

Total 9.50 6.50 16.00

Domestic waste water – 8.00 KL/day disposed off through adequate soak pit and septic tank

The industrial waste water – 9.00 KL/day will be generated from floor washing, scrubbing,

boiler and cooling only which will be treated using adequate in-house ETP then, will be

disposed of through underground drainage to CETP, Vapi.

The company will discharge the additional treated waste water to CETP, when CETP permit

for additional waste water intake.

Design Criteria of ETP

Source of Effluent: process, washing and utility etc.

Effluent Generation: 8.00 KL /Day Max.

Capacity of ETP: 10 KL /Day Max

Details of Effluent Treatment Plant:

SR NO. ITEM MOC CAPACITY NOS

1 Oil/ Grease Trap RCC 0.5 KL 1

2 Collection Tank RCC 10 KL 1

4 Flocculator MS 2.0 KL 1

5 P.E. Dosing Tank HDPE 0.5 KL 1

6 Primary Lambella separator with tube deck packing RCC 3.0 KL 1

8 Holding Tank RCC 5 KL 1

9 Activated Carbon bed MS 0.5 m3/hr 1

10 Activated Carbon Filter MS 0.5 m3/hr 1

11 Sludge Drying Bed BM 1.0 x 1.0 x 1.0 1



DETAILS OF ETP PROCESS AND HYDROULIC FLOW DIAGRAM (EXISTING)

Note:- the existing ETP is adequate to treat the additional waste water from the proposed expansion

Water Balance Diagram after proposed expansion:

Domestic Process Scrubbing Washing Boiler & Cooling Gardening

9.00 KL/Day

5.00 KL/Day

180.57 KL/Day 2.00 KL/Day 6.00 KL/Day 3 KL/Day

Septic Tank

& Soak Pit

8.00 KL/Day 2.00 KL/Day Evap. Loss

1.00

KL/Day

1.00 KL/Day

Underground

Drainage to

CETP

1.00 KL/Day

Total Water Requirement 217.37 KLD

To Proposed Effluent Treatment Plant

8.00 KL/Day

Consumed in

process

Waste water:

nil



DETAILS OF AIR POLLUTION CONTROL MEASURES AFTER PROPOSED CHANGE:

Sr.

No.

Stack

Attached

Type of fuel

and consumption

Air Pollution

Control Measures Parameter

Existing

1. Non IBR Boilers (2 No.)

600 kgs/hr

Natural Gas: 200

SCM/Day

Adequate stack height 11 mt and

vent of flue gas is connected to

spray dryer for hot air

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

2. Non IBR Boilers

800 kgs/hr

Natural Gas: 200

SCM/Day


vent of flue gas is connected to

spray dryer for hot air

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

3.

Thermic pack

(4 Lakh K.cal)

Natural Gas: 200

SCM/Day


acoustic enclosure is provided.

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

4. D.G. Set 250 KVA Diesel: 20 Lit/hr


acoustic enclosure is provided and

operated only during power break

down.

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

5. Hot Air Generator

I, II & II

Natural Gas: 2000

SCM/Day



PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

Proposed

6. steam boiler

2000 Kg/hr

Natural Gas : 500

SCM/day



PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

7. D.G. Set 250 KVA Diesel: 20 Lit/hr


acoustic enclosure is provided and

operated only during power break

down.

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

8. Hot Air Generator

25 lakh k. cal/hr

Coal/agro

briquettes

2000 kgs/hr.

Bag Filter and stack Adequate stack

height 15 mt and acoustic

enclosure is provided.

PM <150 mg/Nm3

SO2 < 100 ppm

NOx< 50 ppm

Note: Hot Air Generator I, II & III will be replaced by one common Hot Air Generator with above mentioned specification.

Process Emission

Sr.

No. Stack attached to

Stack Ht.

(in mtr)

Probable pollutants

& Limits

Air Pollution

Control System

Existing

1. Spray dyer -1 (Cap.- 600 kgs/hr) 15 PM<150 mg/Nm3 Scrubber

Spray dyer-2 (Cap.- 200 kgs/hr) 15 PM<150 mg/Nm3 Scrubber

Spray dyer-3 (Cap.- 200 kgs/hr) 15 PM<150 mg/Nm3 Scrubber

2. Process Vent (Sulphonator & Oleum Storage Tank)

11 SO2< 40 mg/Nm3 Two stage Scrubber



3. Formaldehyde reactor 11 HCHO< 40 mg/Nm3 Carbon Adsorption System

Proposed

4. Spray dyer-3 (Cap.- 900 kgs/hr) 15 PM<150 mg/Nm3 Scrubber

Note: Exiting one Spray dryer having capacity of 200 kgs/hr will be replaced by a spray dryer having capacity of 900 kgs/Hr.

Hazardous Waste Management:

During our proposed production activities hazardous wastes will be generated as per HW (M, H & TM) Rules 2008 and will be managed as follows.

Sr. No.

Name of the Waste

Source

HW Sch. Category

Quantity per Year Method of Disposal Existing Proposed Total

1. ETP Waste

Effluent

Treatment

Plant

35.3 3 MT 4 MT 7 MT Collection, Storage, Transportation, Disposal at TSDF, Vapi

2. Spent/Used Oil

Machinery 5.1 40 Lit 35 Lit

75 Lit Collection, Storage, Transportation, disposal by selling to registered recyclers.

3. Discarded

materials

Drum,Liners/

Bags/ Carboys

Raw

Materials

33.1 30 Nos 80 Nos. 110 Nos. Collection, Storage, Decontamination, Disposal on sale to actual users.

4. Sludge from

wet scrubber

Mfg.

Process

26.1 0.024

MT

0.020

MT

0.044

MT Collection, Storage, transportation, Disposal at TSDF-VGEL, Vapi.

5. Used Filter

Cloths

Mfg.

Process

33.2 1.0 MT - 1.00 MT Receptions, recover, storage, reuse in premises orsale to registered distillation facilities

6. Process Waste

Mfg.

Process

26.1 1428 MT 100 MT 1528 MT Collection, storage, transportation, disposal at SEPPL-Kutch and disposal by selling to registered end users.

7. Used Carbon Mfg.

Process

36.2 0.1 MT 0.1 MT 0.1 MT Collection, storage, transportation, disposal at SEPPL-Kutch and disposal by selling to registered end users.



XII. Schematic representations of the feasibility drawing which give information of EIA purpose:

A schematic representation of the feasibility drawing

Resource requirements • Raw Material: Sourced from Manufacturer / Traders of the same. • Land: Acquired land for proposed project, at existing land • Water: Will be sourced through GIDC water supply. • Power: Power will be sourced through Dakshin Gujarat Vij Co.

Ltd. • Fuel : Local dealer

Env. Mgt. Plan (EMP)

Air Pollution Control Measures: Air Pollution control system will be

provided.

Greenbelt area 22% of the total area is within company premises

Health & Safety measures will be followed properly

Soak pit/ Septic Tank and ETP for Industrial waste water.

Flue Gas emissions: Adequate chimney height will be provided.

Fugitive emission: There is no generation of fugitive emissions.

Type of Industry Proposed to expand its manufacturing capacity of Dispersing agent, leather

chemicals and construction chemicals

Site Location: Plot No. 1734 & 1702/B, Phase-III, G.I.D.C.,Vapi-

396195 Gujarat-India

Public consultation: Not required as the project is

located in notified Industrial Zone

Submission of Form-1 and Pre-Feasibility Report & Draft TOR

Proposed Activity: The proposed expansion project

involves the production of "Synthetic Organic Compounds"

Type of category as per EIA notification: Synthetic Organic Chemicals (Activity -5(f)- Category-B)

Presentation before the EAC for TOR



4. SITE ANALYSIS

4.0 Site Analysis

I. Connectivity:

The project is located in notified Industrial Estate of Vapi, Gujarat which is very well connected to National Highway no.8 and Western Railways. And the nearest Mumbai airport and port are 180 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. The total plot area (9696 sq.m.) is belonging to M/s. Gujarat Polysol Chemicals Pvt. Ltd.The existing land is located in the notified industrial area of GIDC,Vapi (Notification no.xGHU/75-45,GID:1974/4084/(10), dated : 6th May 1975)

III. Existing Infrastructure/ land use pattern Proposed project will be located within the GIDC notified industrial area of Vapi which has available infrastructure like water, electricity, roads, rail, transportation and drainage system, CETP and TSDF Site. Surrounding area is consisting with agriculture, other industrial units.

IV. Soil classification and Land use 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.

V. Climate data from secondary sources:

Rainfall Data:

The climate here is tropical. The winter months are much rainier than the summer months in Valsad. This climate is considered to be as according to the Köppen-Geiger climate classification. The temperature here averages 26.9 °C. Rain fall about 1500 mm approximately of precipitation falls annually during 2015.

VI. Social Infrastructure available:

M/s. Gujarat Polysol Chemicals Pvt. Ltd. Infrastructure owes itself largely to the initiatives of G.I.D.C., in building the Industrial infrastructure and in attracting young entrepreneurs from Gujarat and other neighboring states. Equally, the growth of the social infrastructure - School, Colleges, Hospital, vocational train ing - stems from the bold initiatives of the Gyandham School, Ashadham School, etc. Haria Hospital, other private hospitals. .National Highway No. 8 passes through Vapi. It is connected to all major cities. Vapi railway stations on the Mumbai-Ahmedabad rail link of Western Railway (India) has become the direct beneficiary in terms of revenues due to daily commuters. The Union territories as well as Vapi town, Bhilad, Umbergaon, and Pardi, only 5–40 km from Vapi, There are good residential and commercial areas. Daman and Silvassa (the capital of Dadra and Nagar Haveli) attract both Indian and international tourists.



5. Planning Description

5.0 Planning Brief.

I. Planning Concept (Type of industries, facilities, transportation etc) Town and Country Planning

/Development authority Classification:

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in

manufacture of variety of products in the Gujarat Industrial Development Corporation (GIDC)

notified area of Vapi. GIDC notified industrial area of Vapihas the entire available infrastructure like

water, electricity, roads, rail, and transportation, availability of raw material, CETP, TSDF Site and

drainage system.

II. Population Projection:

Not applicable

III. Land use planning (breakup along with green belt etc.):

The 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.

Plot Area Statement:

Area Statement Existing Proposed Area After Proposed Expansion

(in m2)

Total Area 4696.00 5000.00 9696.00

Construction Area 2480.00 1764.00 4244.00

Open Land Area 558.00 2236.00 2794.00

Internal Road Area 558.00 0.00 558.00

Greenbelt Area 1100.00 1000.00 2100.00

IV. Assessment of Infrastructure demand (Physical & Social):

The proposed infrastructure to manufacture products will be built with standard engineering design

considering all the relevant parameters related to environment, health and safety.

Facilities like road and communication are good. Banks, ATM's and medical facilitiesare also

adequate.

V. Amenities/ Facilities:

Education- schools including middle, secondary and higher secondary schools, Colleges, social

welfare hostels.

Medical and Health- Community Health Centre, & Primary Health center are available nearby area.

Power and water- All the villages are electrified and drinking water facilities are extended to all

villages.

Rail and Road- The project site is very well connected by road through State Highway no. 8,

Western railways.



6. Infrastructure Details

6.0 Proposed Infrastructure:

I. Industrial Area (Processing Area):

Basic infrastructure developed already and the required additional plant and machineries will be

installed after getting statutory clearance.

II. Residential Area (Non Processing Area):

No residential area is involved in the proposed project. The employs are accommodated in nearby

Residential areas

III. Green Belt:

Green belt area will be provided and maintain at the tune of about 22% of the total land area as the

project site is within the developed industrial area.

IV. Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc):

The project site is very well connected by road through National Highway no. 8 and western

railways.

V. Drinking Water management (Source& Supply of water):

Water requirement will be fulfilled through GIDC water supply.

VI. Sewerage System:

Sewerage water is disposed off to soak pit through septic tank.

VII. Industrial Waste Management:

Industrial waste water 8.0 KL/day generated mainly from the washing, Scrubbing, Boiler & Cooling. Generated waste water will be treated by adequate effluent treatment plant and treated water will be send to CETP, Vapi.

7. Rehabilitation and Resettlement (R&R) Plan:

II. 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 Industry does not envisage any disturbance to local community or the village since

the land is acquired and fully owned by GIDC –Vapi Notified industrial Area. The proposed project

will not affect the home oustees, land oustees and landless laborers. Hence there is no R & R plan

required.

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 construction and commissioning of the project.



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

Plant & Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major

heads considered in the Capital Cost Projection for the proposed expansion project. Environment

Protection has also been considered in planning the Cost Projection, which will include Green belt

development, safety systems, etc.

Capital Cost Projection

Sr.

No. Purpose

Cost

(Rs. in lakh)

Existing

Cost

(Rs. in lakh)

Proposed

Cost

(Rs. in lakh)

Total after

expansion

1. Land 742.00 300.00 1042.00

2. Building and Civil Works 80.82 50.00 130.82

3. Plant & Machinery and

other fittings 404.00 400.00

804.00

4. Environmental protection

measures 30.00 25.00

55.00

TOTAL : 1256.82 775.00 2031.82

The company will provide budgetary provision for the recurring expenses for environmental issues while

planning the allocation of funds during the annual budgetary planning.

Recurring Cost per annum

Sr.

No. Component

Proposed

(Rs. in Lacs/annum)

1. Environment & Safety Management System 23.00

2. Greenbelt Maintenance 2.00

3. Enterprise social contribution 5.00

Total 30.00

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.

ofenvironmentclearance.nic.in/writereaddata/online/tor/10...i. policy to be adopted (central/ state)...

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