PRE FEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/30_Sep... · PRE – FEASIBILITY REPORT ... Project Proponent M/s Vacmet

PRE – FEASIBILITY REPORT

for

PRIOR ENVIRONMENTAL CLEARANCE

Proposed Manufacturing of Polyester Resin-Polyethylene Terephthalate (PET) Chips -99000 MTPA and installation of

HTM heater (Pet coke as fuel) 13.5 Million KCAL

At Plot No. 1, New Industrial Area Ujjaini (MPAKVN), Lebad-Manpur Road

Village Ujjaini, P.O. Digthan, Tehsil-District Dhar -454773, (MP)

Project Proponent

M/s Vacmet India Limited

Environment Consultant

Anacon Laboratories Pvt. Ltd.

Recognized by MoEF (GOI) as per EPA and valid upto 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

SEPTEMBER, 2016

Pre-Feasibility Report


Nagpur, Maharashtra. 1

1.0 EXECUTIVE SUMMARY

1.1 Name of the Project

Proponent:

: M/s Vacmet India Limited

1.2 Location : Plot No. 1 New Industrial Area Ujjaini (MPAKVN),

Lebad-Manpur Road

Village Ujjaini, P.O. Digthan, Tehsil, Dhar, District Dhar

(MP) Pin Code – 454773 (Figures 1 & 2)

1.3 Office (Regd.) : Anant Plaza, IInd Floor, 4/117-2A, Civil Lines, Church

Road, Agra 2, Uttar Pradesh 282002

Phone:0562 4050400

1.4 Name of Promoters : Mr. Pradeep Kumar Agarwal Vice President

(Commercial)

1.5 Proposed product and their Installed Capacity

1. Resin (Polyethylene Terephthalate (PET) Chips -99000 MTPA)

2. Installation of HTM heater (Pet coke) 13.5 Million KCAL

1.6 Total Project Area : 263992.93 sq.m. (65.64 acres)

1.7 Water Requirement : Total Water Requirement - 1560 KLD

Daily water requirement after recycle – 1416 m3/day

1.8 Power Requirement : 1) Electric Power per 1000 Kg of chips from CP – 45 KW

2) Electric Power per 1000 Kg of chips from BP – 80 KW

3) DG set: 1650 KVA

4) DG set: 2500 KVA will be available in standby mode

Proposed installation Installation period

Power consumption/Kg

BOPET film plant Mar-17 0.95 kW

Metaliser Mar-17 0.8kW

PET chips plant Jul-17 0.45kW

Coating machine May-17

Phase II

BOPP Films line Jan-18 0.95 kW

BOPLA films line 2019-2020 0.9 kW

Metaliser Jan-18 0.8 kW

Phase III

BOPET film plant 2021-2022 0.95 kW

BOPPLA film plant 2021-2022 0.9 kW

Metaliser 2021-2022 0.8 kW

Coating Machines 2021-2022 1.25 Kw

1.9 Number of Shift : Three Shift Basis ( Round the clock)

1.10 No. of Working Days : 365 Days

1.11 Total Cost of Project : 110 crore – PET chips plant

Total estimated cost of complete project is 1580 crore

for all three phases.




1.12 Investment Plan

:

1.13 Means of Finance

: Total estimate cost of complete project is Rs 1580 Crores. (INR in Lakhs)

S. No.

Particulars Phase –I

Phase-II

Phase-III

Total

1 Company Contribution

8,500 10,000 18,000 36,500

2 Fresh Equity

- 25,000 - 25,000

3 Bank / institutional long Term Borrowing

36,500 25,000 35,000 96,500

4 Total 45,000 60000 53,000 158,000

1.14 Man Power Utilization : 600

1.15 Schedule of Implementation : Plant Expected plant commencing Date

Phase I

BOPET film plant March 2017

Metaliser March 2017

PET chips plant July 2017

Coating machine May 2017

Phase II

BOPP Films line January 2018

BOPLA films line 2019-2020

Metaliser January 2018

Phase III

BOPET film plant 2021-2022

BOPPLA film plant 2021-2022

Metaliser 2021-2022

Coating Machines 2021-2022

1.16 Environment Consulting

Organization

: Anacon Laboratories Pvt. Ltd.

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

mailto:[email protected]




2.0 INTRODUCTION

2.1 Identification of project and project proponent

Company Background

Vacmet India Limited is a closely held Public Limited Company engaged in the manufacturing of

packaging materials having applications in various food and non-food (Electrical, Magnetic Media,

Reprographics) sectors.

Vacmet India Limited (Vacmet / Company) was established in 1993 by Mr. Dinesh Chand Agarwal, a

graduate in plastic & polymer engineering from U. K. He is a first generation entrepreneur having 42

years of experience in the polymer Industry currently. It is one of the few companies worldwide to

manufacture products as diverse as Hot stripping foil, Holographic Films, Metalized paper and BOPP

film, Polyester Film, Metalized paper and BOPP Film, Polyester Film, Metalized film Y coated

products. Currently the Company’s products are supplied to large number of converters for

companies that make laminated like Unilever, Procter and Gamble, Calvin Care, Colgate-Palmolive

Cadbury, ITC, Shaw Wallance, Dawat Basmati Rice, Dabur etc.

Vacmet is geographically well placed vis-à-vis its competitors as it is close to the NCR (National

Capital Region) which is a key hub for Indian flexible packaging activities. Currently, the company has

four manufacturing facilities based at Kosl, Chhata, Mathura District, Uttar Pradesh spread over an

area of 1,00,000 square meters.

However, to provide end to end customer solutions and eventually move up the product supply chain,

Vacmet is expanding its current capacities. Vacmet is backward integrating its operations for cost

efficiencies by setting up a Polyester Chips Plant.

Snapshot of the Existing Operations

Unit Product Location Capacity

(MTPA)

Date of

commercial

production

Unit No. I Converted product Industrial Area

Sikandara, Agra

1200 1994

Unit No. II Metalized / coated leaguered

polyester film, hot stamping foil and

partial metalized and holographic

films

Kosi Kalan,

Mathura District

8400 1997

Unit No. III Metalized/ coated lacquered

polyester film, hot stamping foil and

holographic films

Kosi Kalan,

Mathura District

12000 2003

Unit No. IV Polyester Films Chhata, Mathura district 20,000 2007

Unit No. IV Polyester Films Chhata, Mathura district 28,000 2011

Unit No. IV BOPP Films Chhata, Mathura district 40,000 2012




MANAGEMENT: PROMOTERS PROFILE

Managing Director: MR. Dinesh Chand Agarwal

Aged 65 years, Mr. D.C. Agarwal is a man of vision and mission. He possesses 42 years of

experience in the field of polymer and plastic processing. Mr. D.C. Agarwal is a graduate in the field

of plastic and polymer engineering from UK.

Director (Product Development): Mr. Nitin Agarwal

Mr. Nitin Agarwal has 21 years of experience in the plastic processing industry. Aged 42 years, Mr.

Nitin Agrawal possesses a Master’s degree in the field of plastic and polymer engineering from UK.

Director (Operations): Mr. Rahul Agarwal

Mr. Rahul Agarwal has 20 years of experience in manufacturing and plant operations. Aged 40 years,

Mr. Rahul Agarwal is a science graduate and has attended many workshop internationally on

manufacturing.

Director (Business Strategy): Mr. Mayank Agarwal

Mr. Mayank Agarwal has 17 years of experience in the field of business development. 37 years of

age Mr. Mayank Agarwal possesses Commerce Graduate and MBA from UK. A man of great zeal

and enthusiasm, he has taken Vacmet to next level internationally.

KEY MANAGERIAL PERSONS

SR Vice president: Mr. S.C. Kapoor (Electrical Engineer)

Having 40 years of experience in Engineering he is working with Vacmet for last 7 years, prior to this

he worked with peer group companies

Vice President (Converting) – Mr. S. K. Tyagi

Mr. S. K. Tyagi has 30 years of experience in the field of plastic processing and converting

operations. He possesses a degree in Electrical Engineering and has been with Vacmet since its

inception.

Chief Financial Officer: Mr. Pradeep Kumar Gupta

Mr. Pradeep Kumar Gupta (B. Com, TCA) possess a vast experience of 25 years in the field of

finance, fund raising, taxation and strategic planning.

Vice President (Marketing): Mr. Harjeet Sing

Mr. Harjeet Sing has been in the field of marketing and strategic planning since the past 30 years. He

has been working with Vacmet since the last 3 years, prior to which he worked with peer group

companies.

General Manager (Commercial and HR): Mr. Pradeep Agarwal

Mr. Pradeep Agarwal (B. Sc. LLB) has an experience of 41 years in field of human resource, indirect

taxes and legal matter. He has been working with Vacmet since its inception.




Presently company employing more than 300 engineers and technicians. Also company employs

several Chartered Accountant and Financial Professional, on the part of Finance Team.

AWARDS & CERTIFICATES

Over the years, Vacmet’s continuous efforts to upgrade itself in the packaging industry have largely

been recognized and awarded by the government. Some of the Company’s awards are as follows.

Awarded the “Top Exporter of Metallized Polyester Film for the year 2012-13”, by The Plastic

Export Promotion Council.

Awarded the “Second Best Exporter of BOPF film for the year 2012-13” by the Plastic Export

Promotion Council.

Awarded the “Top Exporter of Metallized Polyester film for the year 2011-12”, by the Plastic

Export Promotion council.

Awarded the “Second Best Exporter of BOPP Film for the year 2011-12”, by the Plastic Export

Promotion Council

Awarded the “Top Exporter of Metallized Polyester Film for the year 2010-11”, by the Plastic

Export Promotion council.


Export Promotion Council







Awarded the “Second Best Exporter of Metallized Polyester film for the year 2005-06”, by the

Plastic Export Promotion Council





Awarded the “First Prize for Excellence Performance in Exporter for the year 2004-05” by the

Small Scale Industries and Export Promotion Department, Government of India.

Awarded the “First Prize for Excellence Performance in Exporter for the year 2003-04” by the

Small Scale Industries and Export Promotion Department, Government of India.

2.2 Brief Description and Nature of the Project

M/s Vacmet India Limited has proposed to manufacture Resin-Polyethylene Terephthalate (PET)

Chips with capacity of 99000 MTPA and installation of HTM heater (Pet coke as fuel) 13.5 Million

KCAL.

2.3 Need for the project and its importance to the country and/or region

Due to increasing demand and the shortage of polyester products, the plant will be setup on the land

available in New Industrial Area Ujjaini (MPAKVN), P.O. Digthan, Tehsil- Dhar, Dist-Dhar (MP).

Proposed PET Chips plant of a capacity of 99,000 MTPA is necessary for running BOPET film plant

and for further supply. PET Chips plant will also enhance the profitability of the Vacmet. Main raw

material for making PET Chips is PET and MEG which will be available from Reliance, Indian Oil and

India Glycols etc. Import under OGL is also available. There is good availability of these raw materials

in India.

The company now proposed polyester chips of capacity 99000 MTPA because there is demand for




Polyester Resin which is used in sheet moulding compound, bulk moulding compound polyester

resins reinforced with fiberglass (- so-called fiberglass) reinforced plastic (FRP) are typically used in

restaurants, kitchens, restrooms and other areas that require washable low-maintenance walls.

Polyester films are made from polyester resin. Different types of films such as Metallised Film,

holographic films are made from polyester films which are used for different packaging products. In

India polyester film industries are importing raw material i.e. polyester resin.

2.4 Demand-Supply Gap

PET is the fastest growing polymer in the world. Main raw materials for making PET Chips are PTA

and MEG which will be available from Reliance, Indian Oil and India Glycols etc. Import under OGL is

also available. There is good availability of these raw materials in India.

GLOBAL SCENARIO

Major uses are fibres and yarns (about 72% of global market share), sheet applications (11%)

and blow moulding (about 11%).

In Asia, China is the largest importer of PET scrap with about 1.7m tonnes of imports in 2011,

accounting for more than one-half of Asian demand, according to China Customs.

Close to 1m tonnes of R-PET short staple fibres are produced in China, according to one major

producer. In the Chinese domestic market, close to 60% of PET fibres are used in yarn spinning,

20% for nonwovens and an estimated 10% for the filling market.

Being the world's most important polyester market, China's industry is reaching maturity, with

limited growth in recent years. Demand from downstream textile and garment sectors is stable,

but not strong enough to support another round of aggressive expansions.

PET is used in a wide variety of packaging products including those for carbonated soft drinks,

water, juice, personal care items, household cleaners, beer and food containers. PET is used in

beverage and food packaging and other applications such as custom-care and cosmetics

packaging, health care and pharmaceutical uses, household products, and industrial packaging

applications. The demand for PET chips has grown steadily over the past several years, driven

by its popularity for recyclable, single-serve containers and as a substitute for glass and

aluminium. PET chips have already made significant inroads in soft drink and water bottles, and

producers are currently targeting markets such as hot-fill soups and sauces and containers for

beer. The market for global PET Chips is expected to increase to 17.5 mn tonnes in 2010 from

11.9 mn tonnes in 2005, a 8% CAGR.

2.5 Imports vs. Indigenous production

M/s Vacmet India Limited has proposed to manufacture Resin-Polyethylene Terephthalate (PET)

Chips with capacity of 99000 MTPA and installation of HTM heater (Pet coke as fuel) 13.5 Million

KCAL. Proposed products manufacturing in the country will be very much economical compared to

Imports and export of the same will earn extra revenue generation for our county.

2.6 Export possibility

Vacmet has producing polymer and BOPP (Biaxially Oriented Polypropylene) film since 1993. The

company exports these films to about 80 countries, its Chairman and Managing Director Mr Dinesh

Chand Agrawal said.

As PTA is the key raw material for manufacturing of Polyester chips in the chain of textile commodity,

Polyester chips / PET chips have a growing market in India as well as outside India due to its wide

application in the Film, Bottle /Jar, Pharmaceutical, Beverages etc. Thus Vacmet India Limited,

proposes the project of PET chips along with Installation of HTM heater (Pet coke as a fuel) 13.5

Million KCAL plant in a New Industrial Area Ujjaini (MPAKVN).

http://en.wikipedia.org/wiki/Fiberglass_reinforced_plastic

http://english.customs.gov.cn/




2.7 Domestic/ Export Markets

There is a huge demand of the proposed products in the export market. Our products are widely used

and are in demand in the Polymer industry.

2.8 Employment Generation (Direct and Indirect) due to the project

Around 600 persons directly, which will be helping to improve quality of life of the people.

3.0 PROJECT DESCRIPTIONS

3.1 Type of project including interlinked and interdependent projects, if any.

The proposed project is a polyester resin project falling under “B” category. It will be an independent

project that will be engaged in the production of Resin-Polyethylene Terephthalate (PET) Chips with

capacity of 99000 MTPA and installation of HTM heater (Pet coke as fuel) 13.5 Million KCAL at Plot

No. 1, New Industrial Area Ujjaini (MPAKVN), Village Ujjaini, Tehsil Dhar, Dist Dhar in 263992.93

sq.m. area.

3.2 Location (map showing general location, specific location andproject boundary and

project site layout) with coordinates.

Details about the Project area are presented in Table 1.

TABLE 1

DETAILS ABOUT THE PROJECT AREA

State Madhya Pradesh

Tehsil / District Tehsil, Dhar, District Dhar

Village Ujjaini, P.O. Digthan

Plot No. Plot No. 1 New Industrial Area Ujjaini (MPAKVN), Lebad-Manpur Road

Pin Code 454773

Area 263992.93 sq.m.

Toposheet No. 46 N/6, 46 N/7, 46 N/10

Geo-coordinates

Latitude Longitude

22035’04.5’’N 75

026’34.8’’E

22034’47.0’’N 75

026’39.5’’E

22034’42.3’’N 75

026’20.1’’E

22035’01.5’’N 75

026’22.5’’E

The index map is presented in Figure 1, Location map showing 10 km radius of study area shown in

Figure 2 and layout plan is given in Figure 3.




FIGURE 1: INDEX MAP




FIGURE 2: STUDY AREA MAP

(10 KM RADIAL DISTANCE FROM THE PROJECT SITE)




FIGURE 3: LAYOUT PLAN

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

The land is allotted to project proponent by Madhya Pradesh Audyogik Kendra Vikas Nigam. The

proposed plant is falling within New Industrial Area Ujjaini (MPAKVN). Hence site is already selected

by project proponent and no alternative site is required.

3.4 Size or Magnitude of Project.

Sr. No. Description Capacity

1. PET chips 99000 MTPA

2. HTM heater ; fuel used - Pet coke/Indian coal/Imported

coal/ Rice Husk

13.5 MKCAL (17520 MTPA)




3.5 Project description with process details.

Process Description (PTA ROUTE)

Esterification

The PTA and MEG are well mixed in a slurry tank by an agitator of special design.

The paste then discharged into ESTERIFICATION reactor is equipped within internal heating coil and

special agitator, which produces very high turbulence. The reactor and glycol produced during the

reaction are withdrawn through the rectification column and condensed in the condensed in the

condenser. Part of the condensate is refluxed back into the column and the other part is collected in

spent water tank. At the end of the reaction the product is discharged through a monomer filter to pre-

poly reactor.

Pre - Polymeriser

The filtered esterification product, after addition of SiO2 slurry and poly-condensation catalyst, is poly-

condensed in the pre poly up to certain extent. The material is mixed by the agitator a vacuum is

created by ejector. During pre-poly condensation glycol is set free and the viscosity of the product

increases steadily. To avoid oligomer carrying phenomenon, the vacuum sequence control is set up.

The product is transferred to pc autoclave under vacuum.

Poly-Condensation

The PC Autoclave is equipped with special agitator the speed of which varies automatically with

varying viscosity. The PC Autoclave is heated by a liquid thermic fluid system consists of circulating

pump and cooler.

The autoclave reactor is equipped with a product circulation gear pump. This pump circulates the

product during the reaction phase & this step quickly rises-up the product temperature & the helps to

shorten the reaction time.

The pressure in the PC Autoclave is reduced to less than 0.3mm Hg by a glycol ejector system unit.

Pressure and temperature of the product are controlled by the central computer. The speed of

agitator is used to determine the end point of poly condensation process at which the agitator speed

is reduced to min. RPM. The 3 way value of the valve of the discharge pump is opened towards the

die heat for casting.

Chips Production

Vacuum in the Autoclave is regulated and the polymer pump speed is adjusted for max discharge

through die plate. The extruded polymer is fed into an underwater palletize which solidifies them, then

chops them into regular size chips.

The excess water is subsequently removed in an air driven drier. After classifying the same for over

sizing chips, chips are conveyed and stored in silos.

PTA discharge and conveying, section 01 common for CP and BP

The chosen raw materials are PTA - Pure Terephthalic Acid and MEG - Mono-Ethylene glycol. PTA is

a fine powder, normally delivered in road tankers, containers or in 1t flexible big bags.

The PTA big bags are stored in a PTA ware house. From there the big bags will be transported to the

PTA big bag discharge station located at ground floor closed to the PTA dosing silo in the poly

building. By the tube chain conveyer the PTA is conveyed into the PTA dosing silo.




IPA discharge and storage, section B03 for BP

In order to produce a modified polymer, IPA (Isophthalic acid) may be used. IPA is a fine powder, like

PTA, normally delivered in tank cars, containers or in 1t flexible big bags. The big bags are stored in

an open but covered area. From there they are carried to the IPA storage and dosing silo located in

the plant. The big bags will be transported the discharge place where they are emptied into the IPA

storage-dosing silo.

MEG unloading and tank farm, section 04 common for CP and BP

MEG, being a clear liquid is normally delivered in road tankers. After laboratory check (if any), the

MEG is pumped into the storage tanks, one unloading station is provided. From the storage tanks, it

is automatically pumped to the consumers in the poly building. The spent MEG of the process is

collected in tanks which are located in the tank farm. From the storage tanks (one tank for the CP and

one tank for the BP) the mixed/spent MEG will be pumped back to the polycondensation plant.

DEG storage and dosing, section 05 common for CP and BP

DEG, being a clear liquid is normally delivered in tank cars or barrels. It is used for modification of

polymer. It is foreseen to use DEG delivered in barrels. After laboratory check, the DEG is pumped

into the storage tank. From there it flows by gravity to the consumer in the poly building.

Hot water system, section 08 of CP

A hot water system will be installed in order to use the heat of the process steam of the CP in order to

save energy. This hot water is used for the production of chilled water

PTA-paste (slurry) preparation, section 10 for CP

The raw materials PTA, EG as well as additives must be dosed with high accuracy, at the chosen

molecular ratio, into the esterification reactor to form a uniform monomer, DGT (Diglycolterephthalat)

and uniform polymer respectively. To be able to keep the mole ratio constant and to ensure a raw

material feed without interruption, a slurry is formed first from PTA and EG and additives. From the

PTA dosing silo, the PTA is charged to the mass dosing system, from where it is continuously fed into

the paste mixer.

MEG from the mixed/spent MEG storage tank and dissolved polycondensation catalyst are directly

fed into the paste mixer. The quantities are measured and controlled by mass dosing systems. Slurry

is formed in the mixer and is fed by a slurry pump to the esterification reactor. Two special paste

pumps (one as stand-by) are provided, each inverter controlled.

PTA-slurry preparation, section B10 for BP

The principal design of the section is exactly as for the CP. In addition IPA / NPG can be dosed to the

paste mixer. The content of paste mixer is for one batch + a certain quantity of mother batch that

remains in the mixer for easy preparation of the next batch. The quantity of paste that is fed to the

batch esterification reactor is measured and controlled by a mass flow meter.

Esterification, section 11 for CP

In the esterification, the reaction takes place for the formation of monomer. As result of the under-

stoichiometric feed of glycol, a monomer is produced which consists of monomer, low molecular

weight polymer and not reacted acid.

The esterification reaction is achieved in a two chamber reactor, the so called UPR®-REACTOR. The

first chamber of the reactor has an integrated heat exchanger and is equipped with an agitator for

better mixing and heat transfer. By pressure difference the monomer is flowing from the first chamber

to the second chamber.

In the second chamber of the reactor the rate of reaction, required for the polycondensation, is

achieved. This chamber is not agitated. It has integrated heating coils and special product passes.

The esterification takes place at raised temperature, approximately 258 to 265 °C,




The heating of section 1 of the UPR®-REACTOR is done by liquid high temperature heating oil, HTM

oil. Section 2 of the UPR®-REACTOR is heated by Dowtherm (Therminol VP1) vapour. From the

second chamber of the UPR®-REACTOR the monomer is flowing by pressure difference to the pre-

poly reactor.

Pre-Polycondensation, section 11 for CP

During polycondensation, the excess MEG is evaporated to allow chain formation of the polymer. The

pre-polycondensation takes place at raised temperature and vacuum.

The pre-poly reactor has an external heat exchanger and is equipped with a special horizontal disc

ring cage agitator. The heat exchanger and reactor are heated by Dowtherm (Therminol VP1) vapour

The vacuum, required for the pre-poly reactor is generated by the vacuum group of the finisher.

The polymer transfer between pre-poly reactor and finisher is made by a polymer gear pump. A

viscometer is installed in the polymer line to indicate and control the prepolymer viscosity.

Esterification, section B11 for BP

In the esterification, the reaction takes place for the formation of monomer, DGT

(Diglycolterephthalat). As result of the under-stoichiometric feed of Glycol, a monomer is produced,

which consists of monomer, low molecular weight polymer and not reacted acid. The reaction is

achieved in a heated (jacketed) vessel, with special agitator. The volume of the reactor is

dimensioned for 2 batches.

A fixed amount of 1 batch of monomer is always kept in the esterification reactor, (mother batch)

except when the reactor itself is discharged for cleaning or maintenance. At the beginning of every

esterification batch the paste is fed on top of the already existing monomer mother batch. At the end

of every esterification batch, one batch of monomer is discharged to the pre-polycondensation

reactor, while 1 batch is left inside the reactor.

The esterification takes place at raised temperature and controlled over pressure and vacuum. During

the whole process the monomer is agitated. The heating jacket of the esterification reactor as well as

the heating coil is heated by a separate secondary HTM oil circulation.

Process- column, section 13 for CP

During the esterification reaction, water is formed which leaves the two ester-sections of the

esterification reactor together with a certain amount of MEG. The vapor is flowing to a rectification

column that separates the reaction water and other low boilers from glycol and high boilers. The

vapors are entering the column and are flowing in counter-current to an amount of reflux water that is

fed to the column at the top. The water is leaving the column at the top and the glycol at the bottom.

The bottom of the column re-boiler is equipped with a heating coil.

The separated glycol is collected in the storage tank for mixed/spent MEG and then returned into the

process.

The water vapors at the top of the column are used for pre-heating of reflux water, spent MEG,

catalyst MEG and heating of the hot water system, section 08. Remaining vapour will be condensed

in an air cooled total condenser.

Process column, section B13 for BP

During the esterification reaction, water is formed which leaves the process together with a certain

amount of MEG. The vapor is flowing to a rectification column that separates the reaction water and

other low boilers from vapor mixture. The vapors are entering the column and are flowing in counter-

current to an amount of reflux water that is fed to the column at the top. The water is leaving the

column at the top and the glycol at the bottom. The separated glycol is returned into the esterification

process or to the spent EG tank.

The water vapour at the top of the column are condensed and discharged into a vessel. The amount

of water that has been collected is measured, weighed. At the end of esterification a slight vacuum

will be applied to the reactor in order to reduce the amount of excess glycol. The glycol is condensed,

collected and the weight is measured. This glycol is returned to the spent EG tank.




Polycondensation, section 20 for CP

The final polycondensation is carried out in a shaft-less horizontal DISC-RING-CAGE reactor, the

finisher (DRC® Reactor). In that reactor thin films and strings are formed mechanically by the discs,

which are presenting a large product/evaporation surface to the vacuum. The finisher is of special

design with heating jacket and drive gearbox. The vacuum sealing is of simple and reliable design.

The motor speed can be adjusted according to the required viscosity and throughput.

The polymer enters the reactor on one side and is flowing through the reactor, forced by the incoming

product and by the DISC-RING-CAGE agitator. On the opposite side of the product inlet, the product

outlet and the vacuum connection nozzle are provided. In- and outlet product levels are measured by

radiometric level sensors.

To achieve the desired viscosity the finisher operates at product temperature of about 280°C and at

vacuum between 0,6 and 2 mbar. The finisher is heated by Dowtherm (Therminol VP1) vapour.

The MEG with adhering monomers and Oligomer, evaporated during the polycondensation, is

condensed in specially designed spray condenser.

The spray condenser is of special design with automatic mechanical cleaning system. Maintenance

on spray nozzles can be made without disturbance of production. The spray glycol is circulated by a

centrifugal pump through a cooler to the spray condenser. From the spray condenser the glycol is

flowing to the hotwell. Course particles that have been scraped off in the spray condenser are

separated in a special vessel.

Polycondensation, section B20 for BP

After esterification the monomer is sent by nitrogen pressure through a monomer filter to the

polycondensation reactor that is under vacuum. During polycondensation the excess EG is

evaporated. The polycondensation takes place in a jacketed reactor, with special shaped agitator.

The polycondensation is carried out, under vacuum at raised temperatures, up to required viscosity.

The volume of the reactor and the agitator surface are gently dimensioned to obtain a careful

treatment of the polymer. During the polycondensation the polymer is continuously circulated by a

gear pump.

This gear pump is also discharging the polymer to the cutting system. The EG with adhering

monomers and oligomers, evaporated during the polycondensation, is condensed in a spray

condenser. The spray condenser is of special design with automatic mechanical cleaning system,

same as for CP. The agitator of the reactor is driven by a variable speed drive, inverter controlled.

Heating of polycondensation reactor is done by secondary high temperature heating oil, HTM oil.

Polymer transport, section 21 for CP

At the outlet of the finisher a discharge gear pump is feeding the polymer through a no-stop polymer

filter to the die head of cutting unit. An inline viscometer is installed behind the polymer filter,

measuring the viscosity of the polymer. The signal of agitator torque and viscometer are used for

vacuum (viscosity) control of the finisher.

Polymer lines, pump and filter are jacketed and heated by a separate liquid HTM secondary heating

system.

Chips production (strand cutting), section 25 for CP

One cutter type M-USG 600 H is foreseen.

In the spinneret of the die head, strands of about 3 mm diameters are formed. The strands are

solidified and cooled by water and led to the cutting equipment. From the cutter the chips are

conveyed by the cooling water to a chips-water separator. From there, the chips are falling through a

vibrating screen into a chip conveying system that conveys the chips to the chips collecting tank.

One spare cutting head is foreseen that is also spare for the BP. The water, used for cutting, is

filtered, cooled and fed back to the cutting system. The speed of the cutting systems is controlled by

the polymer pump, thus allowing producing chips with constant size at different throughput rates

automatically.

Chips production (underwater cutting), section B 25 for BP

One cutter type M-USG 600 H is foreseen. Cutter type and principle of operation are same as for CP.




Chips conveying and storage, section 31 for CP

After cutting, the chips are falling from the screen into a conveying system that conveys the chips to a

collecting tank described before. From there the chips are either conveyed to chips storage silos or

directly packed into big bags.

Chips conveying and storage, section B31 for BP

After cutting, the chips are conveyed to a collecting tank as described before. After laboratory check

the chips can be either conveyed to chips storage silos or directly packed into big bags. The system

is designed for conveying into 3 silos, app. 50 m3 each.

Catalyst preparation, section 40 common for CP and BP

A catalyst solution can be prepared with warm MEG. This catalyst solution is fed into the paste mixer.

Stabilizer preparation, section 41 common for CP and BP

For heat stabilizing of polymer a stabilizer may be used. It is diluted in MEG and fed, if required, into

the process by dosing pumps. Special injection valves have been provided.

Silica slurry preparation, section 45 common for CP and BP

For the production of special polymer with silica a suitable system for silica slurry preparation and

dosing is provided.

Pinning additive preparation, section 46 common for CP and BP

A pinning additive preparation system is foreseen. The pinning additive is diluted in MEG and fed, if

required, into the process by dosing pumps. Special injection valve has been provided.

Cleaning and drain system, section 49 common for CP and BP

At a programmed stop of the plant, the paste, monomer and polymer will be discharged during

production. Remaining products will be drained into pans before cleaning takes place.

The characteristic of fuel used for heater are presented in Table 2, and Schematic diagram for the

manufacturing of PET chips is shown in Figure 4.

TABLE 2

CHARACTERISTICS OF FUEL

Composition UOM Pet coke Rice Husk Indonesian coal Indian coal

Ash % mass 1.00 18.80 10.20 32.64

Moisture % mass 0.80 10.00 20.00 19.00

Carbon % mass 86.70 36.70 55.28 40.01

Hydrogen % mass 3.18 3.00 2.87 2.91

Oxygen % mass 1.16 31.02 10.54 4.05

Nitrogen % mass 1.22 0.40 0.92 0.91

Sulphur % mass 5.94 0.08 0.19 0.49

Mineral Matter % mass 1.00 18.80 10.20 32.64

Gross Calorific Value (GCV) kCal/kg 8230 3129 5152 4050

Fuel Size

Pet coke, Indonesian coal and Indian coal for over bed operation: Fuel size 6 to 10 mm,

Finnes less than 2 mm limited to 15%. (75% 6-10mm, 10% 2-5, 15% less than 2)

Rice husk: Standard fuel size




FIGURE 4: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING

OF POLYESTER FILM




BOPET- Product Description and Substitutes

BOPET film is specially characterized by a good strength and dimension stability, almost unaffected

by moisture. The film has very good heat stability and melts at 2250C. Its chemical and solvent

resistance is good, being similar to that of polyamides. It is also exceptionally clear. Polyester has

good barrier properties towards both water vapor and oxygen.

Polyester (PET) films are manufactured by extruding film grade PET (Poly Ethyl Terepthalate) resins

are manufactured from Mono Ethylene Glycol (MEG) and Dimethyl Terepthalate (DMT) or purified

Terepthalic acid (PTA) Various modifications are employed during the manufacturing process to

obtain various types of films to suit different applications.

One type of film may have extra high insulation properties useful in capacitors, whereas another type

may possess very high tensile strength in longitudinal direction idea for use in manufacturing

magnetic tapes. Consequently, in industry parlance, PET films are classified based on their end uses.

Some of the grades are packing grade, audio tape grade, electrical grade, photo film grade etc.

BOPET film has exceptionally high di-electric strength and high volume resistive even at high

temperature. PET film possesses excellent dimensional stability over a wide range of humidity and

temperature. It also has very low absorption characteristics. PET films have excellent clarity and

gloss.

Competitors to PET films include commercially important films like coated and coated BOPP, ordinary

PP, uncoated cellophane, coated cellophane, LDPE, Biaxially oriented PVC and HDPE. The main

applications for BOPP are food packing and capacitors. Growth of BOPP market was initially

stimulated by replacement of cellophane PVC and PS. Though it has a higher cost and has more

production difficulties. BOPET is preferred to BOPP for several of these applications including:

Packaging applications because of its higher moisture and flavor barrier properties

In magnetic media (audio/video tapes)

Photographic media (professional still films, instant films etc.) because of its higher tensile

strength

There is relationship between the thickness of the film and the intended end use, but other

parameters are also relevant according to the individual application industry. In general the

production lines are designed to cater range of BOPET films, which cater to one or more specific

applications. The thickness and the width vary according to the customer requirements. Guages and

microns are the measure of the thickness of the film with a higher guage representing a thicker film.

Applications

Due to its inherent advantages BOPET films have gained acceptance in a variety of uses. BOPET

films are used as plain film for packaging applications and also as lamination films. The applications

for BOPET films can be divided in to two categories packaging i.e. food applications and non food

applications.

Process Description for Polyester Film (BOPET) Manufacturing: Recycled Chips

Polyester Chips is received in granular Form. This chip is heated to 170°C to remove the moisture.

After heating, it is extruded in extrusion process at a temperature of approximately 290°C and then

filtered. After Filtration it is casted through die and cooled to give the form of solid sheet. This cast

sheet is then stretched longitudinally at a temp in the range of 70-90°C in MDO (Machine Direction

Orienter). After MDO film can be coated in line with chemicals. Transverse Direction Orienter (TDO)

then stretches the film with moving chain. Heat setting is also done inside the TDO. Temperature

inside the TDO is in the range of 90-240°C. Edge trim is removed at Take-up transfer unit and




Jumbo roll of BOPET (Bi-axially Oriented Poly Ethylene Terepthalate) film is formed. This jumbo roll

finally slitted in customer required sizes. Finally the film is packed and dispatched.

The recyclable waste from different points of the process is recycled in a recycling unit and recycled

chips out of this unit can be reused along with the normal vergin PET Chips.

End use Application of PET films

Sr. No. End use application Form

1. Instant foods Laminated

2. Metallic Yarn Laminated

3. Magnetic Tapes Coated

4. Cable Insulation Plain

5. Electric Motor Laminated

6. Capacitors Plain, Metallised

7. Insulation Tape Coated

8. Tracing/Drafting film Coated

9. Photographic films Coated

10. Greeting cards Coated

11. Solar applications Laminated

12. Stamping foils Metallized

13. Other miscellaneous uses- Rakhees, decorative etc. Metallized

Packaging is the largest end use for BOPET films. Besides packaging, the other sectors include use

in magnetic media, photographic films, electrical/ electronics, reprography etc.

The process flow diagram for the manufacturing of BOPET is shown in Figure 5.




FIGURE 5: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF BOPET FILMS




BOPET –Film Substitutes

As mentioned above a wide range of packaging material are available for use depending on the

requirements. Options available for flexible packaging are as diverse and include a range of polymer

plastic materials including poly vinyl chloride, poly styrene, poly ethylene, poly propylene and

polyester etc.

Biaxially oriented films are a sub sector of the broader sector of flexible packaging films. The world

market for bi-axially oriented films today represents a volume of about 5 million tones per annum

Biaxially oriented poly propylene (BOPP) and BOPET are two main segments accounting for about

58% and 31% respectively of the global bi-axially oriented films market. Thus BOPP is the main

substitute / competitor to BOPET films.

Selection of a packaging film depends on the requirements of the products to be packed. Both BOPP

and BOPET require to be used in combination with material like polyethylene to provide optimum

heat sealability features. BOPET provides a number of comparative advantages in term of good

barrier properties and better quality of printability, it is preferred in packaging of items were these are

an important criterion to ensure increased product shelf life and visibility.

BOPP FILM – BIAXIALLY ORIENTED POLYPROPLYENE FILM

Introduction

BOPP is made from polypropylene Homopolymer (PPHP) and its copolymer. BOPP film is one of the

most versatile packaging material among all the flexible packaging substrates, it offer a very high

yield on account of very low density compared to other biaxially oriented flexible packaging

substrates makes it economically most preferred packaging material

Further very low moisture vapor transmission rate (MVTR) compared to all commonly used packaging

substrates make it a necessary packaging substrate for moisture sensitive products.

Because of this property BOPP is used for cigarette carton over wrapping and many other moisture

sensitive products. BOPP surface is chemically inert to most of chemical used in food industry and

hence it is a preferred flexible packaging material for the food processing industry too

Process Description for BOPP Film Manufacturing

Polypropylene Chips (PP chips) is received in granular Form. It is extruded in extrusion process at a

temperature of approximately 250°C and then filtered. After Filtration it is casted through die and

cooled to give the form of solid sheet. This cast sheet is then stretched longitudinally at a temp in the

range of 90-140°C in MDO (Machine Direction Orienter). Transverse Direction Orienter (TDO) then

stretches the film with moving chain. Heat setting is also done inside the TDO. Temperature inside

the TDO is in the range of 150-215°C. Edge trim is removed at Take-up transfer unit and Jumbo roll

of BOPP (Bi-axially Oriented Poly Propylene) film is formed. This jumbo roll finally slitted in customer

required sizes. Finally the film is packed and dispatched. The process flow diagram of BOPP film

manufacturing is shown in Figure 6.

The recyclable waste from different points of the process is recycled in a recycling unit and recycled

chips out of this unit can be reused along with the normal vergin Polypropylene (PP) Chips.




BOPP: Production Flow Chart:

FIGURE 6: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF BOPP




BOPP: Application

Following are the main applications of BOPP:

FOOD PACKAGING

Bakery & snacks

Ice Creams candies

Noodles pasta

Cereal food gain legumes Flours

Confectionery

Vegetables

INDUSTRIAL

Adhesive tape

Textile over-warp

Label

Capacitor

Cable over – warp

OVER WRAPPING

Cigarette cartoon wrapping

Cassettes CDs, DVDs and other carton over wrapping

General over wrapping

Global BOPP Film Market: Strong Gains in Emerging Regions

BOPP films a part of the flexible packaging industry emerged as one of the most popular highly

growth films in the world lower cost and convince has added to the growth off BOPP in the past few

years along with other flexible packaging materials. More over the growth in demand for this film has

been sustain both in developed as well as emerging markets on account of its recyclable nature and

application in a variety of non food and food products.

The BOPP films are categorized into two different segment commodity and specialty films. Among the

two category the commodity films comprises of around 80% of the market as this is category, the

commodity films comprises of around 80% of the market, as this category by low margin and price

competitiveness, while the specialty films which are mainly consumed in the developed market

account for the remaining 20%. Recent year has been the consumption of BOPP in different markets

such as food industry, tape/adhesives, and certain industrial products, among others, the world wide

demand for BOPP film has been growing rapidly and since 2002, the global BOPP films industry has

expanded by 72% with China accounting for the major production and consumption. Geographically,

Asia as the target market for BOPP, followed by Europe and North America region. In last few years,

the emerging economics have witnessed an improved standard of living, urbanization and increased

per capital consumption, and this has led to an increase in demand in BOPP films.

BOPP is a bi-axially oriented polypropylene film designed for flexible packaging and label

applications. The global demand for BOPP films is estimated at 6.8 millions tonnes 2013 as growing

at rate of 40 % globally, driven by increasing consumerism rising income levels young population and

rapid urbanization

In 2008, while Asia saw demand grows by 7% BOPP volume demand in Western Europe shrunk by

3.1% due to the economic downturn. Global Bopp Films capacity will increase by 2.3 millions tones

over the same period. The global BOPP industry is dominated by China which accounts for nearly

40% of the global capacity and the consumption. The capacity utilization in China has been around

70% for the last few years. The Chinese market itself is growing at an average rate of around 8% p.a.




Global growth will be driven primarily by Asia Pacific markets. With robust economic activity expected

in China and India packaged food processing industries are likely to accelerate further and the market

could experience growth rates of up to 8.3%, according to PCI. Both China and India enjoy significant

cost advantages over competitors in developed markets and most of the new capacity expected to

come online will come up in this region

Types of BOPP Film Used in Indian Market

Printing & lamination grade, from 9 Mic to 12 Mic

Packing or converting grade, from 10 mic to 20 mic in following types

Transparent BOPP film

Pearlised film

White opaque film

Heat selable plain and metallised film

Tape & textile grade, from 23 mic to 38 mic

Electrical grade heatselable and white opaque

Cigarette /casatte/cd cover wrap 20 mic to & 25 mic

Strength of Indian Market

Rise in organized retailing in urban areas consisting of hypermarket and super markets.

Rising income levels.

Growing middle class.

Young population.

Increased media penetration.

BIO-DEGRADABLE – BOPLA FILMS (Bi-axially oriented Poly-Lactic Acid Film)

BOPLA in an innovative bio-based film made from plants instead of crude oil. Vacmet is going to

introduce this product first time in India. No other players / competitor are producing this film at

present.

It is a responsible and contemporary innovation film that gives consumers alternative choices for

natural products and possibility to give their contribution to the preservation of our environment. The

packaging performance of BOPLA is at least equivalent, if not better, to that of traditional oil-based

films for many applications matching a growing demand for eco-sensible products. On top of that,

BOPLA Film offers a significant reduction in greenhouse gas emissions which contribute to global

warming and climate change and offers the potential for significant waste reduction

From an environmental perspective, the Green House Gas (GHG) emissions and the non-renewable

energy usage of a bioplastic are very important key indicators. PLA offers significant improvements

versus other plastics and this is without taking into consideration the “credit” in CO2, coming from the

amount of carbon dioxide absorbed by the plant during its growth (3.3 kg of CO2 for each kg of corn

produced – Cemcorp, 1992). If we include this, PLA is actually reducing the amount of CO2 in the

atmosphere. Furthermore, new technologies are being developed in PLA production, which will bring

a further process optimization and GHG reduction.




Process Description for BOPLA Film Manufacturing

Poly Lactic Acid Chips (PLA chips) is received in granular Form. It is extruded in extrusion process at

a temperature of approximately 250°C and then filtered. After Filtration it is casted through die and

cooled to give the form of solid sheet. This cast sheet is then stretched longitudinally at a temp in the

range of 90-140°C in MDO (Machine Direction Orienter). Transverse Direction Orienter (TDO) then

stretches the film with moving chain. Temperature inside the TDO is in the range of 150-215°C. Edge

trim is removed at Take-up transfer unit and Jumbo roll of BOPLA (Bi-axially Oriented Poly Lactic

Acid) film is formed. This jumbo roll finally slitted in customer required sizes. Finally the film is packed

and dispatched. The process flow diagram for the manufacturing of BOPLA film is shown in Figure 7.

FIGURE 7: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF BOPLA FILM

Specific characteristics of BOPLA

Specific PLA grade combined with adequate extrusion and orientation processes given BOPLA a

wide range of specific characteristics which make it suitable for various different applications:

High mechanical strength

Very strong seals (welding )

Good transparency and Gloss

Consistence surface energy

Good oxygen barrier

High Moisture Transmission Rate

Excellent Aroma Barrier

Anti-Fog properties

Paper like dead fold

Excellent twist

Fat and oil resistance

Alcohol resistant




Segment and Application of BOPLA Film




COATED FILM

Process Description for Coated Film Manufacturing

Bare or metallised BOPP or BOPET film is loaded on unwinder unit of coating machine, this film can

be corona treated if required and then coated with required type of chemical coating. Coating is done

with the process of kiss coating or gravure roll coating. After coating on the surface of the film it is

passed through heated oven for drying operation where temperature is in the range of 100-190 °C.

After passing through the oven it is rewound and rolls finally slitted in customer required sizes. Finally

the film is packed and dispatched. The process flow diagram for the manufacturing of coated film is

shown in Figure 8.

FIGURE 8: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF COATED FILM

HOLOGRAPHIC FILM

Process Description for Holographic Film Manufacturing

Bare or metallised BOPP or BOPET film is loaded on unwinder unit of holographic machine, this film

can be corona treated if required and then coated with special holographic coating. After coating on

the surface of the film it is passed through heating oven for drying operation at a temperature of 100-

110°C then it is passed through an embossing head where temperature is in the range of 120-130 °C.

After passing through the embossing head it is rewound and metallised. These rolls finally slitted in

customer required sizes. Finally the film is packed and dispatched. The process flow diagram for the

manufacturing of Holographic Film is shown in Figure 9.




FIGURE 9: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF HOLOGRAPHIC FILM

3.6 Raw material required along with estimated quantity, likely source, marketing area of

final product/s, Mode of transport of raw Material and Finished Product.

Estimated raw materials quantity likely to be sourced from outside, mode of transportation is given in

Table 4.

TABLE 4

ESTIMATED RAW MATERIAL QUANTITY

Sr. No. RAW MATERIAL

SPECIFICATION

1. PTA

Chemical formula HOOC-C6H4-COOH (C8H604)

ash max % b.w. 0,0015

water max % b.w. 0,2

iron max % b.w. 0,0002

Medium particle size μm 90-110

2. IPA

Chemical formula C8H6O4

ash max % b.w. 0,005


iron max % b.w. 0,0002

3. MEG

Chemical formula HO-CH2-CH2-OH (CH602)

boiling range min °C 196.0

ash max % b.w. 0.005

water max % b.w. 0.06

diethylene glycol max % b.w. 0.2

4. DEG

Chemical formula C4H10O3

purity min % b.w. 99,5





All given figures for raw material consumption refer for synthesis to 1000 kg polyester chips

of guaranteed quality.

CP BP

Terepthalic acid (PTA) Kg 857+2 860

Monoethylene glycol (MEG) Kg 334+2 337

Catalyst as Sb Kg 0.400 Kg/MT

Heat stabilizers ad additives Kg 0.200 Kg/MT

Source: Reliance, Indian Oil and India Glycols etc.

Mode of Transportation: By road

3.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

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

waste generation will be achieved.

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

3.8 Environmental and Infrastructural Aspects

Availability of water its source, Energy/ Power requirement and source:

3.8.1 Availability of water and its source:

Water will be sourced from Madhya Pradesh Audyogik Kendra Vikas Nigam (Indore) ~ 1560 m3/day

water will be required for plant activities. Total water after DMF treatment will be 1530 m3/day.

TABLE 5

WATER REQUIREMENT

Total water requirement for the plant 1560 m3/day

Total water after DMF treatment 1530 m3/day

A.

Softening 1112 m3/day

Cooling 1086 m3/day

B. Potable 110 m3/day

C. Ultrafiltration 308 m3/day

RO feed 286 m3/day

RO water 220 m3/day

Chiller 172 m3/day (make up)

MB feed 48 m3/day

Total A+B+C 1530 m3/day

3.8.2 Energy/ Power requirement and source:

Electric Power per 1000 Kg of chips from CP – 45 KW

Electric Power per 1000 Kg of chips from BP – 80 KW

One DG capacity 1650 KVA, One DG 2500 KVA will be available in standby mode

For proposed plant installation of HTM heater (Pet coke ) 13.5 Million KCAL, pet coke requirement

would be around 710 kg/hr X 3 heaters X 24 hours =52 MT/Day.

Proposed installation Installation period Power consumption/Kg

BOPET film plant Mar-17 0.95 kW

Metaliser Mar-17 0.8kW

PET chips plant Jul-17 0.45kW




Proposed installation Installation period Power consumption/Kg

Coating machine May-17

Phase II

BOPP Films line Jan-18 0.95 kW

BOPLA films line 2019-2020 0.9 kW

Metaliser Jan-18 0.8 kW

Phase III

BOPET film plant 2021-2022 0.95 kW

BOPPLA film plant 2021-2022 0.9 kW

Metaliser 2021-2022 0.8 kW

Coating Machines 2021-2022 1.25 Kw

ANNULAL CONSUMPTION OF FUEL

ANNUAL CAPACITY MT

PET Coke MT Rice Husk MT

Indonesian coal MT

Indian coal MT

BOPET film plant 30500 3050 7320 4575 5795

Metaliser 7200 No fuel consumption

No fuel consumption

No fuel consumption

No fuel consumption

PET chips plant 99000 6930 18810 11880 14850

Coating machine 4500 1260 3330 2025 2520

Phase II

BOPP Films line 45000 2050 5400 3600 4500

BOPLA films line 12000 2080 5880 3600 4560

Metaliser 7200

Phase III

BOPET film plant 30500 3050 7320 4575 5795

BOPPLA film plant 12000 2080 5880 3600 4560

Metaliser 7200 No fuel consumption

No fuel consumption

No fuel consumption

No fuel consumption

Coating Machines 4500 1260 3330 2025 2520

Note – Only one or mix of fuel will be used at a time, details will be provided in EIA.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal:

3.9.1 Waste water generation & management plan

Domestic wastewater (88m3/day) will be treated in STP and used for plantation/gardening. Total

quantity of wastewater in the form of rejects from various treatment systems will be (192 m3/d) as

shown in Table 6. These rejects will be collected and treated in RO, 75 % of treated RO i.e.144

M3/day will be recycled and intake will be reduced to 1416 M3/day.




TABLE 6

WASTE WATER GENERATION

Total water requirement for the plant 1560 m3/day Wastewater generation

Total water after DMF treatment 1530 m3/day 30 m3/day

A.

Softening 1112 m3/day 26 m3/day

Cooling 1086 m3/day 44 m3/day (Blow down)

B. Potable 110 m3/day 88 m3/day (Domestic waste)

C. Ultrafiltration 308 m3/day 22 m3/day

RO feed 286 m3/day -

RO water 220 m3/day 66 m3/day


-

MB feed 48 m3/day 4 m3/day

Total A+B+C 1530 m3/day 280 m3/day

Note:

1. DMF - Dual media filtration

2. STP with capacity of 125 m3/day will be installed to treat domestic wastewater (88 m3/d). Treated

domestic wastewater from STP will be used for irrigation & road sprinkling within the plant area

and thus zero discharge will be complied.

280 - 88 =192 m3/day wastewater with TDS 1100-1200 mg/l will be treated in RO. 75% of 192

m3/day water i.e. is 144 m3/day will be recycled. Hence– 1560 - 144 = 1416 m3/day) will be daily

water intake. RO back wash 48 M3/day will be evaporated in oxygen pond and cakes will be

disposed off at TSDF.

Particular Evaporation (m3/day)

Cooling 1086

Domestic waste 22

Chiller 172

1280

1280+280 (Evaporation+ Reject)= 1560




3.9.2 Effluent Treatment scheme

Not applicable

Total water balance

The fresh water requirement for the plant is estimated to be 1560 m3/d. This raw water will be treated

in water treatment plant having softening, D.M. and RO treatment systems and soft water generated

will be used in the plant activities. Total water balance is shown in below Table 7.

TABLE 7 TOTAL WATER BALANCE

Total water requirement for the plant

1560 m3/day Wastewater generation

Evaporation (m3/day)

Total water after DMF treatment 1530 m3/day 30 m3/day

A.

Softening 1112 m3/day 26 m3/day

Cooling 1086 m3/day 44 m3/day (Blow down)

1086

B. Potable 110 m3/day 88 m3/day (Domestic waste)

C. Ultrafiltration 308 m3/day 22 m3/day 22

RO feed 286 m3/day -

RO water 220 m3/day 66 m3/day


- 172

MB feed 48 m3/day 4 m3/day

Total A+B+C 1530 m3/day 280 m3/day 1280

280 - 88 =192 m3/day wastewater with TDS 1100-1200 mg/l will be treated in RO. 75% of 192

m3/day water i.e. is 144 m3/day will be recycled. Hence– 1560 - 144 = 1416 m3/day) will be daily

water intake. RO back wash 48 M3/day will be evaporated in oxygen pond and cakes will be

disposed off at TSDF.

3.9.3 Solid/hazardous waste generation and Management plan

1.5 Mt/Year Approx. solid waste and Used oil – 1000 Ltrs /Year will be generated from the plant

TABLE 8

DETAILS OF SOLID/HAZARDOUS WASTE GENERATION

Sr. No. Type of waste Quantity Disposal Plan

1 Solid (ETP sludge) 1.5 MTPA Nearest TSDF site

2 Used oil 1000 liters/year To be sold to authorized reprocessors/

recycler

3.9.4 Stack details and air pollution measures

Two DG sets one each of 2500 kVA and 1650 kVA will be required for power supply in case of power failure. The expected pollutants emitted from the DG sets will be PM, SO2, NOx and CO. There will not be any impact on surrounding area as this will be the occasional activities. 4.0 SITE ANALYSIS

4.1 Connectivity.




The proposed project area falls under Notified Industrial Zone, Plot No. 1, New Industrial Area Ujjaini

(MPAKVN), Lebad-Manpur Road, Village Ujjaini, P.O. Digthan, Tehsil, Dhar, District Dhar (MP).

The site is well connected with Road/Rail. The details are as follows:

Nearest Road: Lebad-Dhar By pass road ~6.0 Km, NNW

Nearest airport- Devi Ahilyabai Holkar (Indore) Airport ~40.43 Km, ENE

4.2 Land Form, Land use and Land ownership.

The proposed activities will be within the new industrial area Ujjaini (MPAKVN). The total land

identified for the proposed project is 263992.93 sq/m (65.64 acres). It is under notified industrial zone.

Plot No. 1.

The details regarding the breakup of the land for the various activities of the proposed project is as

follows (Tables 9, 10, 11).

TABLE 9

AREA STATEMENT Sr. No. Description Area in Sq. M.

1 Total Plot Area 263992.93

2 Deductions NIL

3 NET plot area 263992.93

4 FAR 1.0

5 Permissible built up Area 263992.93

6 Proposed built up area 20852.97

7 Future expansion area 46022.40

8 Permissible Ground coverage (60% of 5) 158395.80

9 Proposed Ground coverage 16152.68

10 Future Ground coverage 46046.40

11 Permissible green belt (10% of 3) 26399.29

12 Proposed green belt area 26806.01

13 Permissible Ambient space (5% of 3) 13199.65

14 Proposed Ambient space 13721.24

15 Permissible open space (10% 3) 26399.29

16 Proposed open space 26484.13

17 Proposed parking area 2304.12

18 FAR consumed {(6 + 7) / 4} 0.25

TABLE 10

PROPOSED BUILT UP AREA CALCULATIONS

Unit No.

Description Basement Area Sq. M.

Ground floor Area Sq. M.

First Floor Area Sq. M.

Mzzanine Floor Area Sq. M.

Second Floor Area Sq. M.

Third Floor Area Sq. M.

Total area Area Sq. M.

1 Main Plant Building (Bopet line - 4)

1007.995 11582.037 601.800 1910.900 601.800 601.800 16306.332

2 RMS – 1 (Chips storage Area) – 1

2431.290 2431.290

3 Utility Building

1520.960 1520.960

4 Main Receiving Station

202.860 202.860

5 Firefighting pump house / Raw water

213.668 213.668




Unit No.

Description Basement Area Sq. M.

Ground floor Area Sq. M.

First Floor Area Sq. M.

Mzzanine Floor Area Sq. M.

Second Floor Area Sq. M.

Third Floor Area Sq. M.

Total area Area Sq. M.

storage tank

6 Security cabin - 1

80.325 80.325

7 Weigh Bridge (2 Nos)

36.980 36.980

8 MCC Room 60.562 60.562

Total Ground Coverage

16152.682 Total area

20852.977

TABLE 11

OPEN SPACE CALCULATION

Unit No. Total open space area Sq. M.

A. 11226.779

B. 3253.385

C. 750.000

D. 5024.282

E. 6229.684

Total Area 26484.130

4.3 Topography of the project area

The project area proposed in the Plot No. 1, New Industrial Area Ujjaini (MPAKVN). Flat terrain,

under Industrial Area, Ujjani, Barren land. The project site lies at the 22°34'42.30"N to 22°35'4.50"N

Latitude and 75°26'19.01"E to 75°26'39.50"E longitude on the Topo sheet No. 46 N/6, 46 N/7, 46

N/10. The site specific Topography map is given in Figure 10.




FIGURE 10: SITE SPECIFIC TOPOGRAPHY MAP (10 KM Radius)

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(distance from HFL to the river), CRZ. In case of notified industrial area, a copy of Gazette

Notification should be given:-

The proposed project is located within new industrial area Ujjaini (MPAKVN). Proposed land use is

notified industrial zone. The land is being used for Industrial Purpose. Land allotment letter is

enclosed as Appendix – I.

There is no forest, national park, wild life sanctuary, eco sensitive areas in surrounding 10 Km from

the plant boundary. CRZ is not applicable to the project.

Existing infrastructure

Proposed project site is clear, barren land. Photographs are attached in following Figure 11.

FIGURE 11: PROPOSED PROJECT SITE PHOTOGRAPHS

5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities transportation Townand Country

Planning Development authority Classification.

Type of Industry

Polymer Industry (PET Chips plant)

Town and Country Planning Development authority Classification

The proposed project falls under new industrial area Ujjaini (MPAKVN). Town and country planning

department has already classified land as Notified Industrial Zone. Adequate road facilities are

already available for transportation of raw materials as well as finished products.

5.2 Population Projection

The proposed industry will be providing employment to about 600 people directly and indirectly. Since

the proposed plant is located in the Dhar district in which trained manpower are readily available,

therefore the employment will be given mostly to local people, so there will not be any substantial

increase in the population of local villages. However, due to increase economic growth, the local

youth will be benefited with respect to employment.

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




Plantation will be done in 10% area, green belt in approx. 20% area. Total plot area is 263992.93

sq.m., proposed greenbelt area will be around 26806.01 sq.m.

The breakup of the land for the proposed project is given in Table 12.

TABLE 12

LANDUSE BREAKUP ALONG WITH GREENBELT

Sr. No. Description Area in Sq. M.

1 Total Plot Area 263992.93

2 Deductions NIL

3 NET plot area 263992.93

4 FAR 1.0

5 Permissible built up Area 263992.93

6 Proposed built up area 20852.97

7 Future expansion area 46022.40

8 Permissible Ground coverage (60% of 5) 158395.80

9 Proposed Ground coverage 16152.68

10 Future Ground coverage 46046.40

11 Permissible green belt (10% of 3) 26399.29

12 Proposed green belt area 26806.01

13 Permissible Ambient space (5% of 3) 13199.65

14 Proposed Ambient space 13721.24

15 Permissible open space (10% 3) 26399.29

16 Proposed open space 26484.13

17 Proposed parking area 2304.12

18 FAR consumed {(6 + 7) / 4} 0.25

5.4 Assessment of Infrastructure Demand

The basic infrastructure (Connective roads, Water resource vicinity) is required for the proposed

project is available at the project site as the proposed project is within Notified Industrial Zone. Apart

from that the additional infrastructure will be developed by the company as per the requirement.

5.5 Facilities Availability

Major basic facilities are available for the proposed project. Road, electricity, water, transportation

facility etc. are well developed in the surrounding area. The major new facilities required to be set for

the proposed project will be installation of process equipment at site within the premises along with all

the necessary infrastructures like storage house, internal access roads, office buildings, equipment

sheds etc.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The proposed project activities will be within the new industrial area Ujjaini (MPAKVN). The total land

identified for the proposed project is 263992.93 sq.m. Proposed built-up area is 20852.97 sq.m.

Remaining open area will be for future development as well as green belt development, parking bay,

etc. as given in land use statement (Table 9).

6.2 Residential Area (Non Processing Area)

There is no residential area proposed in for the project, as the existing villages have adequate

facilities to accommodate the additional manpower for residential requirements. Most of the local

people will only be employed so the need of the additional residential colony in the plant will not

require.

6.3 Green Belt




Plantation to be done in 10% area, green belt in approx. 20% area. Total plot area is 263992.93

sq.m., proposed greenbelt area will be around 26806.01 sq.m.

6.4 Social Infrastructure:

The project area lies within the district of Dhar. There is no requirement to build any social

infrastructure within the proposed plant area, however, the infrastructure for amenities to the workers

such as kitchen, canteen, rest room etc. will be provided.

6.5 Connectivity (Traffic and Transportation Road, Rail/Metro/Waterways etc.).

The proposed project is situated at Ujjaini village, Dhar district and Tehsil, State of Madhya Pradesh.

The project is located within the New Industrial Area Ujjaini (MPAKVN). The site is well connected

with Road/Rail. The details are as follows:

Nearest Road: Lebad-Dhar By pass road ~6.0 Km, NNW

Nearest airport- Devi Ahilyabai Holkar (Indore) Airport ~40.43 Km, ENE

6.6 Drinking Water Management (Source & Supply of water)

The total water requirement for the existing plant is estimated to be 1560 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.

6.7 Sewerage system

Infra-structural services including water supply, sewage, drainage facilities and electrification will be

made. Domestic wastewater generated will be treated in STP to conform to the discharge Norms.

Waste water drainage system for the proposed plant will be well connected to the sewerage channel

facilities of New Industrial Area Ujjaini (MPAKVN) to ensure minimum impact on the environment.

6.8 Industrial Waste/ Solid Waste Management

The industrial wastes generated in the form of solid wastes, and hazardous wastes will be collected,

segregated and disposed off as per CPCB guideline.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

7.1 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 project does not have any directly displaced persons, due to acquisition of land. There

are also no land oustees or project affected persons or home oustees, thus R&R plan is not

applicable here. However, the priority for employment will be given to local persons living in the

adjoining villages. In addition to this, promoter will also contribute for the welfare of the people of local

surrounding under company’s CSR policy.

DETAILS OF CORPORATE SOCIAL RESPONSIBILITY BY VACMET INDIA LIMITED:

CSR Programs

Company will be giving preference for spending the amount earmarked for CSR activities for the local

area where it operates. CSR activities will be either implemented by the company on its own or

through specialized agencies. Only such agencies will be assigned responsibility that carry a good

track record of undertaking and implementing such activities successfully.




Recent Works

Moksha DHAM (Cremation Centre) at Gohari, Chhata, Mathura (U.P).

Vacmet India Ltd had approached to help arranging a permanent covered crematorium at Gohari,

Chatta. The local people agreed to provide an open area for preparation of crematorium. The

Company constructed cremation station by doing the followings:-

Leveling the allocated plot

Construction of brick boundary wall around the plot

Steel gate installation at entry point of the plot

Making the crematorium base station

Construction of RCC columns

Covering the crematorium station with shed

Bricked entry road to cremation station

Building up the walk around the crematorium station

Installation water hand pump.

Monitoring

CSR committee authorized by board of directors will monitor CSR activities and proper utilization of

funds. The CSR committee is fully authorized to delegate appropriate authority to any employee of

the company for properly carrying out CSR activities.

Environment Impacts and Measures

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

S. No. Particulars Impacts Remediation Proposed

1. Change in

land use.

There will be change in land use

on permanent basis due to

installation of machineries and

equipment’s.

The proposed project is already in a new

Industrial area, devoid of vegetative tree

cover and the grass cover, barren land.

The land is allotted to project proponent by

Madhya Pradesh Audyogik Kendra Vikas

Nigam. The plant is falling within New

Industrial Area Ujjaini (MPAKVN)

Water will be sourced from AKVN, no

groundwater will be abstracted for the

project activities hence, and natural

recharge of groundwater level will not be

affected through proposed project

activities.

2. Transportation

of material

The existing network of transport

gets

pressurized

The proposed activity will marginally increase

in Traffic density. The project lies within New

Industrial Area Ujjaini, (MPAKVN) thus,

infrastructural facilities/road accessibility are

already developed. However, will maintain the

existing road.

3. Gaseous and

Particulate

Emission to

The atmosphere

Air quality All necessary steps will be followed to

minimize the emission from point sources as

well as line sources. Thus the standards of

Stack Emission and Ambient Air quality will be

maintained as per prescribed limits.

4. Discharge of

effluent

Impact of water quality. Zero discharge is proposed.

5. Withdrawal of Availability of ground/surface Water will be sourced from AKVN, no ground




S. No. Particulars Impacts Remediation Proposed

ground /

surface water

water is affected. water will be abstracted for the project

activities hence, natural recharge of ground

water level is not affected through project

activities. Permission regarding drawl of river

water is granted from water resource

department.

6. Operation of

equipment

and vehicles

likely to

generate

noise.

Impact on human health due to

excess noise level beyond

permissible level.

All the process equipment will be installed on

anti-vibration pad with sufficient provisions to

minimize generation of noise. The high noise

generating equipment like generator will be

enclosed with noise suppressing enclosures.

The buildings as well as boundary wall and

green belt will ensure the attenuation of noise

outside the boundary within the prescribed

limits.

7. Fire Hazard

due to storage

of fuel etc.

Risk to the surrounding

habitation.

Necessary precautions to prevent fire and all

the provisions to control fire shall be provided.

8. Employment

to outsiders

Socio-economic disparity with

local community

Priority of employment will be given to local

people, as already sufficient qualified and

trained local youth area available.

9. Cultural impact Local population feels isolated The promoters proposed to employ local

masses in the project hence no such impact

on cultural diversity is likely to take place.

10. Disposal of solid

and hazardous

wastes

Create odorous problem,

nuisance condition related to the

disposal of solid wastes.

Deterioration of soil, productivity

pollution in ground water/surface

water due to leaching and

surface runoff.

Domestic wastes will be segregated for

organics and Inorganics. Organic wastes will

be used for composting and inorganics for

approved vendors. Disposal of hazardous

wastes will be done as per hazardous wastes

handling and disposal rule.

8.0 PROJECT SCHEDULE & COST ESTIMATES

SCHEDULE FOR APPROVAL AND IMPLEMENTATION

Proposed Project

Activities at the site will be carried out after grant of Environmental clearance from Ministry of

Environment & Forests. The schedule for implementing the proposed project is given in Table 13.

TABLE 13

PROJECT IMPLEMENTATION SCHEDULE

Particulars Implementation Date/Time Period

Start of Construction After Receipt of Environmental Clearance And NOC

Construction Period

Proposed product and their Installed Capacity

1. Resin (Polyethylene Terephthalate (PET)

Chips -99000 MTPA)

2. Installation of HTM heater (Pet coke) 13.5

Million KCAL

6-9 Months

Commercial Production Period

Commercial Production will be started 6-9 Months




Schedule of Implementation

Plant Expected plant commencing Date

Phase I

BOPET film plant March 2017

Metaliser March 2017

PET chips plant July 2017

Coating machine May 2017

Phase II

BOPP Films line January 2018

BOPLA films line 2019-2020

Metaliser January 2018

Phase III

BOPET film plant 2021-2022

BOPPLA film plant 2021-2022

Metaliser 2021-2022

Coating Machines 2021-2022

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

The project cost is estimated to be Rs. 110 Crore. Total estimated cost of complete project is 1580

crore.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and social benefits with special emphasis on the benefit to the local People

Including Tribal Population, If Any, in the Area.

On overall assessment of the project with consideration of technical and financial aspects, it is

concluded that the proposed resin plant is technically highly feasible and financially highly profitable.




Appendix I

LEASE DEED FROM MPAKVN
































































Documents

PRE FEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/30_Sep... · PRE – FEASIBILITY REPORT ... Project Proponent M/s Vacmet