M/s. SRF - environmentclearance.nic.in€¦ · 2.3 Selection of Site (Alternate site) 9 2.4 Topography and land use 9 2.5 Project Description 9 3. Infrastructure Facility 3 ... M/s

PRE-FEASIBILITY REPORT For

PRIOR ENVIRONMENTAL CLEARANCE

Environmental Impact Assessment for increasing

production volume through debottlenecking of existing

Machineries and fuel change for SRF Ltd

at

Village-Malanpur, District- Bhind,

Madhya Pradesh

Project Proponent:

M/s. SRF

Environmental Consultant:

Recognized by MoEF (GOI) as per EPA and valid up to Jan’2019

Accredited by NABL for Chemical &Biological), valid up to 03.10.2016

Accredited under the QCI-NABET Scheme for EIA Consultant Certified by ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007

Head Office: 60, Bajiprabhu Nagar, Nagpur-440 033, MS

Lab. : FP-34, 35, Food Park, MIDC, Butibori, Nagpur – 441122

Ph.: (0712) 2242077, 9373287475 Fax: (0712) 2242077

Email: [email protected], [email protected]

Website: www.anaconlaboratories.com

March 2016

http://www.anaconlaboratories.com/

1

INDEX

S. No. Contents Page. No.

1. Introduction

1.1 Company Profile 1

1.2 Need and justification of the project 1

1.3 Market scenario 1

1.4 Land allocation 2

1.5 The Project 2

1.6 Project Proponent 2

1.7 Project Schedule 3

2. Project Descriptions

2.1 Type of Project 4

2.2 Location of Plant site 4

2.3 Selection of Site (Alternate site) 9

2.4 Topography and land use 9

2.5 Project Description 9

3. Infrastructure Facility

3.1 Raw material 13

3.2 Transportation and route connectivity 13

3.3 Amenities / Facilities 13

3.4 Manpower 13

3.5 Greenbelt and plantation 13

3.6 Effluent treatment plant 13

3.7 Solid & Hazardous waste management 14

3.8 Rain water harvesting 14

4. Resource Availability

4.1 Raw materials 14

4.2 Water availability 15

4.3 Power requirement and supply 15

5. Environmental Aspects

5.1 Environmental setting 15

5.2 Water Requirement wastewater generation and treatment 16

5.3 Power requirement 23

5.4 Solid and Hazardous waste generation 23

5.5 Noise Generation 23

5.6 Air emission 24

5.7 Plantation 24

5.8 Waste Disposal (Liquid & Solid) 24

6. Project Schedule and cost Estimates

6.1 Project Schedule 24

6.2 Cost estimates 25

6.3 Economic viability 25

7. Corporate Social responsibility (CSR) Policy

2

Figures

S. No. Figure Name Page. No.

1 Location Map of the Project site 5

2 10 Km Radius map from project site on toposheet 6

3 Existing Layout Plant of SRF 7

4 Google View with Coordinate of the Plant Site 8

5 Process flow diagram 12

6 ETP flow Diagram 18

7 RO system in the treatment plant 19

8 Designing for use of treated wastewater for plantation 20

9 Installation of ozone generation in the treatment system 21

Tables

S. No. Table name Page. No.

1 Land Use Breakup 9

2 Existing Water Balance 17

3 Diffused aeration system for aeration tank 1 technical Specification 21

4 Diffused aeration system for aeration tank 2 technical Specification 22

5 Water Pollution Load, water sample: treated effluent characteristics

(Year 2009-2015)

22

Annexure

S. No. Annexure Page. No.

1. Land Documents 26

Pre-Feasibility Report

Anacon Laboratories Pvt. Ltd. Nagpur, Maharashtra. 1

Appendix- B

Pre Feasibility Report

1.0 INDRODUCTION

1.1 Company Profile

M/s SRF Ltd. the multi-business corporate group with headquarters in Gurgaon, India, has over the

years expanded its footprints beyond the national boundaries. Today it enjoys the status of a global

entity with operations in three countries; nine manufacturing plant locations in India and one each in

Thailand and South Africa. The market leader in most of its businesses in its home market in India.

M/s. SRF Ltd. is the world's 2nd largest manufacturer of both the Nylon 6 tyre cord as well as the

belting fabrics. M/s. SRF Ltd. strives to ensure faster integration of people, procedures and practices

across global entities to build synergies and create value for its stakeholders.

With a wide range of products M/s SRF Pvt. Ltd. is not only the largest manufacturer of technical

textiles in India, but also enjoys a global leadership for most of the products under this business.

Apart from India, its manufacturing plants for technical textiles are present in Thailand and South

Africa. SRF's product basket for technical textiles contains nylon tyre cord fabrics, polyester tyre cord

fabrics, belting fabrics, coated fabrics, laminated fabrics, fishnet twines and industrial yarns.

1.2 Need and justification of the project

The existing plant having three major processes known as Polymerization, Spinning and

Textile. At present, product of polymerization (nylon Chips) is used in spinning and spinning

product (Nylon Yarn/cord) used in Textile. As per market requirement industry can sell

Spinning (Nylon Yarn/cord) and Textile products (Nylon Fabric) in market, hence, consent

from MPPCB has taken for two products (Nylon Yarn/cord and fabric). Now as per current

market scenario, polymerization product (Nylon Chips) can also sell in market, hence,

modification is required in production process to take out chips as product.

As per current market scenario, production capacity of Textile section needs to be increased,

Along with above activities, Dipping section need to be added in production process to

complete the entire value chain of Nylon Tyre cord fabric from Lactum to Dipped fabric.

In view of above, it is decided by the Management of M/s SRF Ltd. to carry out above activities for better

costumer services and quality products. Hence, there is requirement for getting environmental clearance

from SEAC for above activities for better catering market demand, mentioning that the pollution load with

respect to Air, Water and generation of Solid / Hazardous wastes due to proposed activities will marginally

increase.

1.3 Market Scenario

With a wide range of products M/s SRF Ltd. is not only the largest manufacturer of technical textiles

in India, but also enjoys a global leadership for most of the products under this business.

M/s SRF Ltd. supplies tyrecord fabrics to all major tyre companies in India and abroad. The company

boasts of having state-of-the-art technology from the world famous Industries for manufacturing High

Modulous Low Shrinkage (HMLS) polyester yarn for tyrecord fabric. The company has four tyrecord

fabric plants in India and one in Thailand. The Indian plants are located at Manali, Malanpur (Madhya

Pradesh), Gummidipoondi (Tamil Nadu) and Viralimali (Tamil Nadu). Three of M/s SRF Ltd plants

have fully integrated facility from polymerization to dipped fabric and one from polymerization to

greige fabric



1.4 Land allocation

The land was allotted to M/s. SRF Ltd. by Madhya Pradesh Audyogik Kendra Vikas Nigam (Gwalior)

for an area of 293389.50 Sq. mts. The project falls under Madhya Pradesh Audhyogik Kendra Vikas

Nigam (Gwalior), D-1 to 4 and E-1 to 24, Industrial Growth Centre, Malanpur, Dist-Bhind – 477116

(M.P)(Annexure-I)

1.5 The project

M/s SRF Ltd is a Technical textile plant with captive power generation located in AKVN existing plot

area 67 acres (293389.50sq.m). Planning for increasing production volume through debottlenecking

of existing machineries and fuel change. The plant is operating since 1992, having valid consent. No

violation notice is issued so far. The details of the products and production capacities (existing and

proposed) are as under:

Existing and proposed products capacity

Sr.

No.

Name of products Existing capacity Proposed Additions Total Capacity after

Expansion

1. Nylon chips 33000 MTPA

((currently being

produced, but not taken

out as a separate product

, it is directly sent to next

process i.e. spinning)

Nil 33000 MTPA

(proposed to take out as a

separate product,)

2. Nylon industrial

yarn

33,000 MTPA Nil 33,000 MTPA

3. Nylon tyre cord

fabrics

23,300 MTPA 4700 MTPA 28,000 MTPA

4. Nylon tyre cord

dipped fabric

Nil 14500 MTPA 14500 MTPA

5. Power generation 10 MW Nil 10 MW

6. Steam boiler and

thermic fluid heater

(TFH)

Coal based:

-Steam-Boiler:10.TPH.

TFH: 1.5 Million KCAL/Hr

Pet Coke based:


-TFH: 1.5 Million

KCAL/Hr

Coal and Pet Coke based:


-TFH: 1.5 Million KCAL/Hr

M/s SRF Ltd. has decided to do changes in their production capacity and adding Dipped unit,

accordingly applying for the environmental clearance from SEAC for the same and thereby for better

production capacity mentioning that the pollution load due to proposed activities will marginally

increase. Hence in this context, M/s SRF Ltd. retained Anacon Laboratories Pvt. Ltd. for carrying

out Environmental Impact Assessment studies with respect to environmental components i.e.

Air, noise, water, land, biological and socio-economic along with the quantification and

assessment of pollution load exerted due to existing and proposed activities. The impacts will

be predicted and evaluated and accordingly management plan with respect to activities will be

suggested.

1.6 Project proponent

M/s SRF Ltd. started as Shri Ram Fibres in 1970, Currently it is engaged in the field of Technical

textiles which include tyre cord, belting fabrics, coated fabrics, industrial yarns, laminated fabrics;

Chemicals which include fluro chemicals, speciality chemicals; packaging films and engineering

plastics. Mr. Sanjiv Tipnis is the Sr. vice president of operation.



1.7 Project schedule

M/s SRF Ltd. manufactures tyre cord fabrics which are being used as reinforcement for all categories

of tyres i.e. cycle, passenger car, light commercial vehicles, heavy commercial vehicles, tractor and

off-the-road (OTR) tyres. It has the entire range of textile reinforcement including wicking and non-

wicking chafer for heavy-duty tyres and tubeless radial tyres. Today SRF is the second largest Nylon

6 tyre cord fabrics manufacturer in the world. M/s SRF Ltd also boasts of India's first and only plant

having capacity to produce new generation High Modulus Low Shrinkage (HMLS) yarn used for

reinforcement of passenger radial tyres and transmission belts and rubberised hoses.

The company has got CTE and CTO for the manufacturing of required products and it is regularly

renewed. Now it is proposed to increase fabric production capacity, adding Dipping Unit for

producing dipped fabric and modification for takeout nylon chips as separate product, so that

change market requirement can be fulfilled. Since the company is increasing the production

capacity in fabric section, it is expected that there will not be any additional impacts on environmental

components as well as pollution load with respect to air, water and hazardous waste generation,

however, there will be marginal impact due to adding Dipping Unit.

Background of the project:

The industry is having following existing activities with production capacity as follows:

Nylon industrial yarn(33,000 MTPA )

Nylon tyre cord fabrics (23,300 MTPA )

Power generation through DG set (10 MW )

Coal based steam boiler and thermic fluid heater (10 TPH, 1.5 Million KCAL)

The existing consent for air and water has already been granted from Madhya Pradesh Pollution

Control Board (MPPCB) and validity is from Dec-2015 to Dec-2016. The authorization for hazardous

waste is granted and valid upto March-2019. The chronological activities starting from its inception is

as follows:

Year of Activity Activity

October1990 Laying of Foundation Stone

March 1992 Start- up of Tyre cord Fabric production

December 1992 Start- up of Chip and Yarn production

September 1995 Achieved ISO 9002 Certification

February 1996 Acquisition by SRF Limited from CEAT

March 1997 Introduction of TQM

April 1999 Achieved ISO 14001 Certification

October 2004 Winning the coveted Deming Application Prize

September 2005 Yarn capacity expansion completed

December 2006 Capacity Expansion in fabric

February 2007 Become Partner in MCPL Power Project(Operation of FO

based DG sets and Boilers were stopped and kept as stand

by)

February 2008 Achieved 18001 Certification

October 2008 Installation of Plate and tube type RO plant (Recycling of ETP

water started for re-use in process)

Now it is proposed to increase fabric production capacity, adding Dipping Unit for producing

dipped fabric and modification for takeout nylon chips as separate product, so that change

market requirement can be fulfilled. It is also proposed to use Pet-Coke along with coal for



steam generation. Since the company is increasing the production capacity in fabric section, it is

expected that there will not be any additional impacts on environmental components as well as

pollution load with respect to air, water and hazardous waste generation, however, there will be

marginal impact due to adding Dipping Unit.

2.0 PROJECT DESCRIPTION

2.1 Type of project

It is an independent project engaged in the production of Nylon Chips (33000MT/annum) Industrial

Nylon Yarn (33000 MT/annum), Nylon Tyre Cord (28,000 MTPA), Nylon dipped fabric (14500 MTPA)

and Power Generation (10MW) along with installation of coal/Pet coke based steam boiler and

thermic fluid heater of 10 TPH and 1.5 million KCAL at its existing plant site, D-1 to 4 and E-1 to 24,

Industrial Growth Centre, Malanpur, Dist-Bhind, 47716(M.P

2.2 Location of plant site.

The existing plant is located at Latitude 26021”09.59”N and Longitude 78017”04.83”E in an area of

293389.50 sq.m. in D-1 to 4 and E-1 to 24 , Industrial Growth Centre, Malanpur, Dist-

Bhind,47716(M.P). The plant is connected with pacca road upto the factory. The nearest railway

station is Rithora and the nearest major railway station is Gwalior. The surface water source is from

Kotwal dam. There are other industries in the vicinity of existing plant namely Supreme, Surya Roshni

and Atlas etc. The details regarding plant location is shown in Figures 1-2. The plant layout is also

shown in Figure 3.

.



FIGURE 1: LOCATION MAP OF THE PROJECT SITE



FIGURE 2: 10 KM RADIUS MAP FROM PROJECT SITE ON TOPOSHEET



FIGURE 3: EXISTING LAYOUT PLANT OF SRF



Plant Layout

FIGURE 4: GOOGLE VIEW WITH COORDINATES OF THE PLANT SITE

Sr. No. Latitude Longitude

1. 26°21'10.82"N 78°16'51.09"E

2. 26°21'22.00"N 78°16'57.17"E

3. 26°21'23.15"N 78°17'0.34"E

4. 26°21'19.46"N 78°17'8.04"E

5. 26°21'12.96"N 78°17'7.93"E

6. 26°21'08.15"N 78°17'19.37"E

7. 26°20'57.04"N 78°17'14.39"E

8. 26°21'05.47"N 78°16'53.64"E

9 26°21'09.74"N 78°16'54.05"E



2.3 Selection of site (Alternate site)

The existing plant is in Industrial area, Malanpur, Dist Bhind. Hence site is already selected and no

alternative site is required.

2.4 Topography and land use.

The land (Plant site) is flat, and owned by Madhya Pradesh Adhyogic Vikas Nigam (Gwalior) and

allotted to M/s. SRF vide letter no.13/AKVN: IND: INFRA: 2004:546 and 93/AKVN/INFRA/2014/13755

dated 20.01.2005 and 19.11.2014 respectively in an area 272109.5sq. m. The land use breakup for

the plant is presented in Table 1.

TABLE 1

LAND USE BREAKUP

Sr.No Particular Unit-Sq. mt

1 Total Area 272109.5

2 Constructed Area Built up- 67476.4 sq.mt

Pipe rack- 2705.9459 sq.mt

Road-19225.3 sq.mt

3 Area of Plantation 182701.8 sq.mt

2.5 Project Description

Manufacturing process of Nylon Yarn:

The company is engaged in manufacturing of Nylon yarn of which the process is given below:

1) Lactan Storage Tank:

The virgin caprolactam flakes, received in bags, is charged in the caprolcatammelter

through crusher.

The molten lactam from the lactam melter is transferred to lactam storage vessel. Molten

recovered lactam from the monomer recovery and depolymerisation process is also

transferred to the lactam storage vessel.

2) Polymeriser:

The lactam solution from the lactam storage vessel is pumped continuously to the reactor

where it gets converted to prepolymer.

The prepolymer is then pumped to the polymeriser where it gets polymerized.

3) Chips Cutter:

Polymer transfer to the extrusion unit where the polymer is extruded in the form of strands.

The strands are solidified in the quench bath and are pulled by draw off rolls and fed to the

cutters where these are palletized

4) Extraction Process:

The chips from the cutter are conveyed to the extractor with the help of water. (The

purpose of extraction process is to remove monomers and oligomors from the chips).

The chips flow downward in the extraction tower whereas the hot water flows upwards.

The water chips slurry from the extractor is conveyed to the centrifuge, where water is

separated and then the chips are charged into a hopper.

The water containing monomer and oligomers flows out from extractor top and is sent to

the monomer recovery plant for recovery of caprolactam.

5) Solid state Poymeriser/ Drying Process:

The wet nylon chips from the hopper are charged into a dryer



The chips move from top to bottom in drying tower

Continuous circulation of conditioned nitrogen is maintained in it to evaporate the moisture

from chips. In the dryer, the chips are polymerized under solid state.

6) Chips silo:

After drying, the chips are transported to silo

From silo, dried chips transported to spinning process.

7) Monomer Recovery Process:

It has two sections:

a) Concentration

Water coming out of the extractor, contains monomer and oligomers

It is concentrated at an elevated temperature under reduced pressure

b) Purification

The concentrated solution of monomer and oligomers is transferred to the distillation

In distillation, it is chemically treated for purification.

After this, it is distilled under reduced pressure and elevated temperature

The lactam thus recovered is transferred to the polymerization process.

8) Spin Draw and Take up Process:

Dryed Nylon-6 chips from silo are transferred to inter-mediate hopper system with blender

where these are blended with heat stabilizer.

After blending, these are fed to an extruder for melting and conveying to the spinning

pumps.

The spinning pumps deliver the measured quantity of polymer to the spinneret where the

polymer is extruded through many holes to form filaments.

The filaments from the spinneret are cooled by regulated flow of conditioned air and then

given a special finish by spin finish applying rolls.

The yarn is now fed to the feed rolls and then to draw rolls

9) De-Polymerization Process

The waste polymer, in the form of chips, yarn and cord, is charged in the melter for

melting.

The molten polymer and the residue formed in the monomer recovery process are

transferred to the depolymerizer

Superheated steam is fed into the molten polymer from the bottom of the depolymerizer

The polymer gets depolymerized and resulting monomer vapors along with steam are fed

to a concentration tower where they are concentrated to lactam solution.

The solution is collected in a tank and from there it is transferred batch wise to the

distillation

Distillation is done under reduced pressure and elevated temperature

The lactam thus recovered is transferred to the lactam storage tank and blended with

virgin caprolactam.

The process flow diagram is shown in Figure 5.



Pollution Load Assessment

M/s SRF Ltd. is planned for debottlenecking of existing plant to increase production capacity and

modification to takeout nylon chips as separate product, so that the quality of the product with

production capacity and product mix will be achieved. It is also planned to use Pet-coke along with

coal for steam generation. All storages of the raw materials and products are keeping in a safe

manner to avoid any spillages, contamination and emissions. Some of the activities/facilities

are dismantled during the expansion of the project. All the solvents storages are stored in a

safe manner to avoid any fugitive emission with respect to volatile organic compounds. Some

of the facilities like change in fuel, installation of RO plant, diffuse aeration system in

treatment plant and disposal pattern are already in place. The unit was using FO/HSD as a fuel

for DG sets (Total no-7), now fully switched over to MPEB to promote efficient running of the

production. . Hazardous wastes generations are disposed to TSDF facility/ recyclers as per

authorization condition.



FIGURE 5: PROCESS FLOW DIAGRAM

Proposed Dipped fabric

Proposed expansion

in production

capacity

Proposed to take

out Chips as

separate product



3.0 INFRASTRUCTURE FACILITY

3.1 Raw material

The raw materials required for the plant are as follows:

Sr.

No. Raw Material Quantity

Before Project (existing)

After Project

(Incremental Quantity)

Total Quantity after

project

1 Caprolactam

(MT/Month) 34617

1049 35666

2 Spin Finish Oil

(MT/Month) 750

23 773

The raw materials as well as finished products are being transported with the help of water and road

ways.

3.2 Transportation and route connectivity

The company has developed transportation facility for import of raw materials required for the plant

and also for the export of the finished products. The site has very good connectivity with Road, Rail,

and Air which is being used for the transportation of raw materials and finished products.

Nearest Railway Station : Gwalior Railway Station ~19 Km, ESE

Gwalior Airport , 19.3 Km, SW

Nearest Air Port : Rajma Vijayraje Scindia Air Terminal 16.1 km ,SW

Nearest highway : NH-92

3.3 Amenities/ Facilities

The company has developed local transport, canteen, first aid center, recreational centre and sport

centre for its employee and workers.

3.4 Manpower

The project is having overall positive impact. It is currently generating direct employment to around

567 persons. All infrastructural facilities related to roads, power supply, water and wastewater

treatment are already developed by the company.

3.5 Green belt and plantation

A dense green belt is developed with a plantation of 17642 No of trees/shrubs. Four big lawns are

also developed in this premises which are infront of Admin building, reception area, ETP and RO

plant.

3.6 Effluent treatment plant

The company has set up an effluent treatment plant of 300 m3/d capacity with necessary units for the

treatment of effluent generated from the process unit and the STP capacity is 100 m3 /d. The treated

effluent is being used for plantation and horticultural purposes. The treated effluent is under the

prescribed limit of MPPCB norms.

Facility Before replacement After replacement Total

ETP Capacity (m3/day) 300 Remain same 300

STP Capacity (m3/day) 100 Remain same 100

RO Plant (m3/day) 400 Remain same 400

RO Reject (m3/day) 50 Remain same 50



3.7 Solid & Hazardous waste management

3.7.1 Raw material and Fuel consumption before and after:

The raw materials consumption is shown in subsection 3.1 and fuel consumption is described

below:

Name Before replacement After replacement Total

FUEL

Coal / Pet Coke (MT/hr) 2.7 Remain Same 2.7

FO for Boiler

(KL/hr)

0.695 Remain Same 0.695

FO/HSD for DG (KL/hr)

3.6 Remain Same 3.6

M/s SRF Ltd has provided proper storage of above materials in safety manner.

3.7.2 Solid / Hazardous Wastes Generation before and projcet

The solid and hazardous wastes generation before and after project and their management is given

below:

Waste Quantity Disposal

Existing

Sludge and filter contaminated with

oil

8.0 MTPA Send to common TSDF for safe disposal

Discarded container / Barel 10 Mt Send to common TSDF for safe disposal

ETP Sludge 30 MTPA Send to common TSDF for safe disposal

Ion Exchange Resin 1 Mt Send to common TSDF for safe disposal

Used Spent Oil 12 MTPA Send to authorized recyclers

Poly residue 270 MTPA Being sent to cement plan for co-processing

Fly ash 9000 MTPA Being sent to Brick Manufacturers

All waste and their quantity will remain same as explained above proposed activity

M/s SRF Ltd has made provision for the collection system and disposal. The sludge and the filter

contaminated with oil is sent to TSDF for safe disposal. The discarded containers/barrels are also

sent to TSDF site for disposal. Similarly ETP sludge and ion exchange resin are sent to TSDF site for

disposal. Used spent oil is sent to authorized recyclers whereas poly residue (solid waste) is sent to

cement plant for co-processing. The fly ash generated from the boilers is sent to brick manufacturer.

The solid and hazardous wastes are properly quantified yearly and analyzed for their physico-

chemical characteristics including heavy metals specially incinerator ash and ETP sludge before

sending it to disposal.

3.8 Rain water harvesting

The company has made provision for rain water harvesting by creating rain water harvesting points of

150 ft. The rain water collected from the building roof is sent to these points for further maintaining

level of ground water.

4.0 RESOURCES AVAILABILITY

4.1 Raw materials

The raw materials required for the plant is available from local market.



4.2 Water availability

Water is being sourced from AKVN supply. ~ 3170 KLD water is required for plant activities and

domestic use. Permission regarding supply of water has been accorded. 1800 KLD water is taken

from AKVN and remaining is generated through recycling process of water.

4.3 Power requirement and supply

Energy supply of 10 MW through MPEB. Since the Company has switched over to 100% MPEB

power, hence, electric supply through DG sets are stopped. However, DG sets are kept on standby

mode. 2 Nos UPS DG sets having capacity of 2750 KVA (2.5 MW) each and 5 nos FO/HSD DG sets

of 2270 KVA each are kept on standby mode in case of emergency.

5.0 ENVIRONMENTAL ASPECTS

5.1 Environmental setting

DETAILS OF ENVIRONMENTAL SETTING

Sr. No. Particulars Details

1. Project Location M/s SRF Ltd. D- 1 to 4, E-1 to 24 Industrial Growth Centre, Malanpur Dist-Bhind-477116 , Madhya Pradesh

2. Latitude/Longitude Sr. No. Latitude Longitude

1. 26°21'10.82"N 78°16'51.09"E

2. 26°21'22.00"N 78°16'57.17"E

3. 26°21'23.15"N 78°17'0.34"E

4. 26°21'19.46"N 78°17'8.04"E

5. 26°21'12.96"N 78°17'7.93"E

6. 26°21'08.15"N 78°17'19.37"E

7. 26°20'57.04"N 78°17'14.39"E

8. 26°21'05.47"N 78°16'53.64"E

9 26°21'09.74"N 78°16'54.05"E

3. Location covered in

Toposheet No.

54 J/7 and 54 J/3

4. Climatic Conditions The average rainfall is about 1,370 mm (53.9 inch). In Summer (March

to June) temperature rises to 47°C and has a minimum of

16°C. Monsoon rainy season during July to October is humid and

temperature within 25°C to 32°C. Winter (December to February) is chilly

and can drop down to subzero. In winter day time temperature is up to

27°C. The temperature ranged from 46°C in summer & 2°C in winter.

5. Site elevation above

Mean Sea Level

Highest Observed: 220 m

Lowest Observed: 212 m

6. Land use at the

proposed project site

Flat terrain, under Industrial Area, Malanpur, Barren land

7. Site topography Flat

8. Nearest roadway NH-92 adjacent to E

9. Nearest Railway Station Rethorakalan railway Station 5 km, WNW and Nonera railway station

8.7 km, W, are nearby of Malanpur, Gwalior Railway Station ~19 Km, W

10. Nearest Air Port Gwalior Airport , 9.8 Km, SW

11. Nearest village/major

town

Nearest town- Gohad ~17Km, ESE



Sr. No. Particulars Details

12. Nearest Port NA

13. Nearest lake NA

14. District Headquarters Bhind, ~64Km, W

15. Nearest city Nearest major City- Gwalior~22Km, W

16. Nearest state/National

Boundaries

Rajasthan

17. Nearest major city with

2,00,000 population

Nearest major City- Gwalior~22Km, W

18. Distance for sea coast NA

19. Hills/valleys

20. Ecologically sensitive

zone

No ecologically sensitive zone

21. Nearest

Reserved/Protected

forests

No protected forest, sensitive species of flora and fauna

22. Historical/tourist places Nil

23. Nearest Industries Surya Ltd. Incandescent and CFL Lamp Plant, 1.3 km

VRS FOODS LTD. ABC -2 Malanpur , 1.4 km

AkzoNobel , 1.9 km

Godrej consumer product ltd., 2.2 km

TEVA API INDIA LTD, 2.8 km

Sterling Agro (NOVA) , 2.9 km

CROMPTON GREAVES LTD (T-2 Div.), Malanpur, Gwalior

(M.P.) 3.3 km

Cadbury Factory 3.7 km

24. Nearest water bodies Gurikha Resevior 5.2 km NNE

25. Seismic zone Seismic zone II as per IS-1893 (part-I)-2002

5.2 Water Requirement, wastewater generation and treatment

Water Requirement

The total water requirement for the existing plant is estimated to be 3170 m3/d. The water is being

sourced from AKVN and used for plant activities and domestic use. The permission for water supply

has been granted from AKVN. 1800 KLD water is taken from AKVN and remaining is generated

through recycling process of water.

Wastewater Generation and Pollution Load

The existing wastewater generation is estimated to be 410m3/d. Out of this 238 m3/d is used for wet

drill and gardening and remaining 122m3/d is used for dilution and 50 m3/d is used in hydrant. The

wastewater generated is treated in the effluent treatment plant (ETP) having capacity 300 m3/d and

STP 100m3/d and for RO rejects with a capacity of 50 m3/d. Provision has been made & for better

operation and maintenance of wastewater treatment system regularly to avoid any discrepancy in the

treatment units. In the production process, RO rejects after treatment are used for wet drill,

gardening, for dilution and hydrant. So zero discharge norms are adopted by the industry. The water

balance is presented in Table 2.

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TABLE 2

EXISTING WATER BALANCE

Sr.No. Particulars Water Consumption (m

3/d)

Waste Water Generation (m

3/d)

1. Domestic 50 48

2 Process 240 240

3. WTP 100 52

4. Others 250 Nil

5. Boiler 158 02

6. Cooling 2372 68

Total 3170 410

238 (m3/d) for wet drill and gardening, remaining 122 (m

3/d) is used for dilution

50(m3/d) water is used in hydrant

Effluent Treatment Facilities

There are different measures adopted by the unit to reduce the generation of effluent so that the load on the treatment system will be less. The treatment system is incorporated by putting different process units and the maintenance and operation of these units are regularly checked so as to reduce the pollution load with respect to organics and suspended loads to produce better quality of water as per the consent prescribed by MP Pollution Control Board. The treatment system is incorporated by primary, secondary and tertiary treatment. They have incorporated segregation of various stream to reduce the effluent load on treatment plant. The facilities provided for the effluent treatment are:

Equalization cum neutralization

Aeration

Stage I Stage II

Advanced Oxidation

RO

Fish Pond for toxicity

Utilization of treated waste water for plantation

The line diagram for whole treatment system as well as the RO plant is shown in Figure 6 and 7

respectively. The diffuse aeration system for aeration tank 1 and 2 and their technical specification

with respect to designing as per consent is shown in Table 3 and 4. Similarly the designing of use of

treated waste water for plantation is presented in Figure 8

Advanced Oxidation Treatment (Ozone Treatment Plant)

Textile industries are using different kinds of chemicals as coloring agents which are coming out

through process in the waste water stream contributing high organic load in the form of COD and

BOD. Because of complex nature of waste water, some of the chemicals are non-biodegradable in

nature. These compounds exerting high organic load and therefore to have a better treatment and to

convert them in biodegradable form, pre advanced oxidation process in the form of ozone is applied

to decompose the non-biodegradable organic matter into simple organic biodegradable form. M/s

SRF Ltd has adopted this type of treatment and installed ozone treatment plant for providing

support in treatment processes as to reduce the load on the respective treatment units after

having ozone treatment.

The main features of the plant are as follows:

Ozone is a compound of oxygen, which consists of three ozone atoms

It is highly reactive due to its unstable nature

It is easily generated through ozone generating unit.



It attacks various micro-organisms killing them almost instantly

It removes taste, odor and color from wastewater This eliminates addition of any chemical to water

Moreover, it reduces the pollution load on the subsequent treatment system

Pre-oxidation is preferable for decreasing initial pollution load in the wastewater

The ozone generator installed by M/s SRF Ltd as a part of treatment system is shown in Figure 9

FIGURE 6: ETP FLOW DIAGRAM



FIGURE 7: RO SYSTEM IN THE TREATMENT PLANT



FIGURE 8: DESIGNING FOR USE OF TREATED WASTE WATER FOR PLANTATION



FIGURE 9: INSTALLATION OF OZONE GENERATOR IN THE TREATMENT SYSTEM

TABLE 3

DIFFUSED AERATION SYSTEM FOR AERATION TANK-1

TECHNICAL SPECIFICATION

BOD load (in effluent) 588 Kg/day (Flow – 300 m3/day and BOD 1960 Mg/Liter)

MLSS 3500 PPM

Design Basis 2 Kg 02/Kg BOD to be removed.

Oxygen required 1176Kg 02/day

Aeration stage 1 Tank Size 24 mm X 12 m X 3.4 mSWD

Blower Capacity 1200 m3/hr @ 0.45 kg/cm

2

BOD outlet <30 ppm

COD outlet <250 ppm

Blower stage 30 HP (1 W + 1 S)



TABLE 4

DIFFUSED AERATION SYSTEM FOR AERATION TANK-2

TECHNICAL SPECIFICATION

BOD load 10 kg/day

Flow 50 m3/day

BOD in 200 mg/Liter

BOD out <30 mg/liter

MLSS 3500 PPM

Design Basis removed 2 kg O2/Kg BOD to be

Aeration stage 1 Tank size 11.2 m X 5.6 m X 2.75 m SWO

Blower capacity 180 m3/hr @ 0.38 Kg/cm

2

BOD out < 30 PPM

Blower Stage 5 HP (1 W + 1S)

Wastewater pollution load

The wastewater generated (from 2009-2015) is characterized and pollution load is estimated as

presented in Table 5. It is observed that during 2009 to 2015 the pollution load exerted in the form of

suspended load and organic load in the form of BOD and COD exerted was 17.07 kg/day, 4.25

kg/day and 38.35 kg/day respectively with a pH ranged from 7.1 to 8.3. The overall pollution load

after treatment is well within the permissible load given by MPPCB as per consent. The

company is adopting zero discharged norms and not discharging anywhere in the surface

stream or ground water. Hence no impact is envisaged as surface and ground water.

TABLE 5

WATER POLLUTION LOAD

WATER SAMPLE: TREATED EFFLUENT CHARACTERISTICS

(Year 2009-2015)

Date SS BOD COD pH Waste water generation

(kg/day) (m3/day)

June 2009 5.11 1.75 8.29 8.3 72

July 2009 6.52 2.10 13.76 7.4 89

Aug 2009 6.20 2.19 13.22 7.1 87

May 2010 25.94 8.95 45.61 7.3 362

June 2010 21.01 7.21 38.64 7.3 322

July 2010 22.71 8.28 44.99 7.1 370

May 2011 19.12 4.84 27.17 7.53 209

June 2011 19.45 6.45 38.90 7.22 367

July 2011 19.36 2.04 36.42 7.17 301

May 2012 25.31 5.72 45.76 7.5 286

June 2012 9.18 2.24 14.78 7.9 112

July 2012 10.49 2.08 27.02 8.2 163

May 2013 24.12 5.37 40.32 7.6 336

June 2013 29.02 5.41 41.98 7.6 366

July 2013 7.63 4.82 57.93 7.4 355

May 2014 28.19 5.48 77.72 7.6 381

June 2014 31.9 5.06 84.2 7.8 384

July 2014 25.43 4.40 67.39 7.8 324

May 2015 10.32 2.88 42.2 7.6 240

June 2015 9.72 1.56 22.76 7.7 118.56

July 2015 7.43 1.9 18.4 7.5 100

Aug 2015 11.42 2.87 36.4 7.7 175

Average 17.07 4.25 38.35 Range 7.1-8.3 250.88



5.3 Power requirement

Energy supply of 10 MW through MPEB. 2 Nos UPS DG sets having capacity of 2.5 MW each. Both

DG sets are equipped with acoustic enclosures. 5 nos DG of 2270 KVS each are also installed and

kept as stand by.

5.4 Solid and Hazardous waste Generation

The major hazardous wastes generation from the plant is in the form of ETP sludge, Oil soaked

cotton waste and solid wastes are Fly ash and Poly-residue. The quantification of hazardous wastes

generated from the plant has been estimated. During the year 2009-2014 the generation of used oil

was estimated to be 2.31 KL to 5.88 KL/yr and it is also given to approved recyclers or vendors. The

quantity of empty containers is in the range of 118 to 1009 Nos/yr. There is tremendous decrease in

quantity of empty containers in the subsequent years. However all these empty containers are sent

back to suppliers. The ETP sludge generated from the wastewater treatment system is

estimated to be 4.32 to 21.36 MT/Yr and sent to TSDF facility. It is observed that the other

hazardous wastes like oil sludge from storage tank, residue containing oil and residue of

contaminated organic solvent are not generated from the year 2009-2015. At present all the

hazardous wastes generated are properly quantified, analyzed for their physico-chemical

characteristics and heavy metals contamination and then disposed of in TSDF facility as well as

recycled to the approved vendors.

5.4.1 Measures taken by the company for handling, Transportation and Disposal of

Hazardous solid / liquid wastes

M/s SRF Ltd is already handling various Hazardous waste and chemicals. The employees are well trained about handling, transportation/ disposal of solid/ hazardous waste/ chemicals. The various precautionary measures are being taken up for handling, transportation/ disposal of solid/ hazardous waste/ chemicals which are as follows:

Depending on the properties of chemical storage facilities are provided. Some of the chemicals / solvents which are hazardous in nature are stored at a refrigerated condition

The chemicals are transported in a dedicated vehicles with proper measures

The chemicals are transported in drums. The drums are properly labeled and stored properly in a raw material godown and protected for direct sunlight and rain.

Transport emergency card is used for transportation of solid, hazardous waste and chemicals.

All employees are given regular/ (periodical) training in uses and handling of chemicals as well as Hazardous waste generated from the plant.

Material Safety data sheets (MSDS) are available with the plant.

All employees are given personal protective equipment (PPE)

Closed transport system is provided for hazardous / toxic chemicals

Specific instructions are displayed at various points of Do’s and Don’ts

Safety guidelines are prepared and given to all employees

Onsite emergency plan is prepared and being adopted regularly

Mock drill are conducted regularly

Occupational Health Centre is also available at the unit

Pre-employment and routine medical examination is done for all the employees

Annual medical examination is done through experts.

5.5 Noise Generation

Noise generation from the plant is only due to DG sets. However these are occasionally required to

be run in case of power failure. Proper provision has been made with enclosures to restrict noise

levels up to permissible levels. All employees and workers are provided with ear muffs / plugs as a



safety measures. There is massive plantation in and around the plant site which is also helping to

attenuate the noise levels. The noise level was monitored for DG sets are found to be within 75 dB

(A) at 1 meter from the enclosure surface.

5.6 Air emission

The air emission i.e. particulate matter (PM) is through stack only which is monitored regularly. The

particulate matter emission is estimated as 96 mg/ Nm3 which is under the prescribed limit of MPPCB

norms. Ambient air quality is also monitored regularly and levels are as follows:

PM10 - 96 mg/Nm3

SO2 - 23.28 µg/m3

NOx - 31.58 µg/m3

These are well within the AAQMS.

It is to be mentioned here that there is tremendous reduction in Air pollution load. The

reduction in pollution load is leading to the appropriate measures taken by the company by

installation of vapour absorption machines, installation of gas operated engine and use of

natural gas for electricity generation and closure of DG sets and putting up in stand by

position.

5.7 Plantation

M/s SRF has developed green belt and plantation within the plant premises. Around 17632

trees/shrubs are planted and it is maintained properly. Four big lawns are also developed in this

premises which are infront of Admin building, reception area, ETP and RO. Under EMP- around 500

trees/year are planted

Area: 272109.5 sq.mt.

5.8 Waste Disposal (Liquid & Solid)

Most of the liquid effluent is recycled in the process. The rest is treated in ETP and treated waste is

used for plantation and horticulture purposes. The company is following zero discharge norms. Solid

wastes from the process are mostly recycled or reutilized within the unit. Hazardous wastes are

collected properly and sent to common TSDF.

Domestic Solid wastes are segregated within the plant for its organics and Inorganics. Organics are

sent for composting whereas Inorganics are disposed through selling to the approved vendors or

recyclers.

6.0 PROJECT SCHEDULE AND COST ESTIMATES

6.1 Project schedule

The project is fully developed for the production of 33000 MT/Annum of Nylon Industrial Yarn and

23,300 MT/Annum of Nylon Tyre Cord Fabric, Power generation (10 MW), Coal based steam boiler

and thermic Fluid Heater (10 TPH, 1.5 Million KCAL). The plant is running and engaged in

production. The company is proposed for debottleneck the plant to increase production capacity

and modification for takeout nylon chips as separate product



6.2 Cost estimates

Proposed: 130 crores, Existing 529 Crores,

6.3 Economic viability

Considering the demand of the product in market, and the production rate, the company is yielding

profit. With a wide range of products M/s SRF Pvt. Ltd. is not only the largest manufacturer of

technical textiles in India but also enjoys a global leadership for most of the products under this

business.

7.0 CORPORATE SOCIAL RESPONSIBILITY (CSR) POLICY

The company is actively involved in CSR related activities, thorough SRF foundation run by M/s SRF

limited. Budgetary provision has been made in the financial year to spent about 7 crores as a

corporate social responsibility.



Annexure -I

Land Documents

















