PRE- FEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/.../PFR/18_Apr_2018_135100030H0QT6J…1.1 Introduction: M/s Asian Polymers is a proprietorship company

PRE- FEASIBILITY REPORT

FOR

THE EXPANSION OF SYNTHETIC RESINS MANUFACTURING

INDUSTRY

At

Plot No. 64B & 65C,

KIADB Industrial Area, Tubinakere,

Mandya District

Prepared by:

F- 4, I Floor, Swastik Manandi Arcade,

S. C. Road, Sheshadripuram,

Bangalore - 560 020

Phone: 080-23460102

Email: [email protected]/ [email protected]

Submitted to:

The Member Secretary

SEIAA, Karnataka,

Department of Forest Ecology and Environment,

Room No 709, 7th Floor 4th Gate MS Building,

Bangalore 56001.

APRIL 2018

mailto:[email protected]/

mailto:[email protected]

Asian Polymers Pre-Feasibility Report

CONTENTS

CHAPTER 1-Executive Summery .......................................................................................................... 01-02

CHAPTER 2-Introduction of the Project Background Information ........................................................... 03-06

CHAPTER 3- Project Description ........................................................................................................... 07-42

CHAPTER 4- Site Analysis..................................................................................................................... 43-47

CHAPTER 5- Planning Brief ................................................................................................................... 48-49

CHAPTER 6- Proposed Infrastructure .................................................................................................... 50-51

CHAPTER 7- Rehabilitation & Resettlement Plan .................................................................................. 52-52

CHAPTER 8- Project Schedule & Cost Estimates .................................................................................. 53-53

CHAPTER 9- Analysis of Proposal ......................................................................................................... 54-54

LIST OF TABLES

Table 2.1- Details of Existing and proposed products .................................................................................. 04

Table 3.1- Location details .......................................................................................................................... 07

Table 3.2 Details of existing, proposed & expansion products with capacity ................................................ 12

Table 3.3-Raw Material Details ................................................................................................................... 37

Table 3.4-Water Consumption Details ......................................................................................................... 38

Table 3.5-Power and Energy Requirement .................................................................................................. 39

Table 3.6--Air pollution Details .................................................................................................................... 40

Table 3.7 Hazardous waste management ................................................................................................... 41

Table 4.1-Site co-ordinates ......................................................................................................................... 44

Table 4.2-Claimatic Data ............................................................................................................................. 46

Table 5.1-Census details ............................................................................................................................. 48

Table 5.2-Land use planning ....................................................................................................................... 49

Table 8.1-Project cost ................................................................................................................................. 53

Asian Polymers Pre-Feasibility Report

LIST OF FIGURES

Figure 3.1- Location of project site on google map (5Km radius) ................................................................ 08

Figure 3.2-Location of proposed project plant on the district map ................................................................ 09

Figure 3.2-Plant Layout Plan ....................................................................................................................... 11

Figure 4.1-Shows the location of the plant on the topo-map ........................................................................ 44

Figure 4.2-Annual temperature graph of Mandya ........................................................................................ 47

Figure 4.3-Annual precipitation graph of Mandya ........................................................................................ 47

LIST OF ANNEXURES

Annexure 1 – CFO Compliance ................................................................................................................... 55

Annexure 2 – Onsite Emergency Plan ......................................................................................................... 56

Pre-feasibility Report

1

CHAPTER 1

EXECUTIVE SUMMERY

1. Executive Summery

1.1 Introduction:

M/s Asian Polymers is a proprietorship company and is into the business of manufacturing of synthetic

resins. The existing manufacturing capacity is 6218 MTPA. The industry is operating since 2010, with valid

consent from KSPCB at 64 B & 65 C, KIADB Industrial Area, Tubinakere, Mandya Taluk & District, and

Karnataka State. The land area is 4007 sq mts or 0.99 acres.

1.2 Project Details:

The industry intend for expansion in production capacity of existing products along with two new products.

Presently 6 products are manufacture with combined manufacturing capacity of 6218 MTPA. After

proposed expansion the number of products manufactured will be eight with combined capacity 27,900

MTPA.

i. Water Management:

The water source for the industry is KIADB supply. Water is used for process, softener generation

plant, cooling tower make up, boiler feed & domestic utilities.

The process effluent generated from the process will be evaporated in Forced Evaporation System.

Whereas the waste water from the process is re-cycled. The cooling tower bleed off is being

recycled back, boiler blow down & softener plant waste is being used for on land for gardening.

Domestic Sewage will be disposed to septic tank followed by soak pit.

ii. Air Pollution:

The source of emission is from boiler (i.e wood husk fired boiler-1TPH) & DG Set-62.5 KVA X 1 No.

are provided with stacks of adequate height. APC measures are adequate to control and disperse

the pollutant.


2

iii. Solid waste Management:

There is no generation of solid waste from the process, only domestic garbage is the solid waste

generation from the industry. This has being disposed through composting.

iv. Hazardous Waste Management:

The hazardous waste generation from the industry will be stored in safe and scientific manner which

will be disposed to KSPCB authorized agencies only.

Applicability of Environmental clearance:

The Asian Polymers manufactures Synthetic Resins. Synthetic Resins manufacturing activity is listed under

serial No. 5(f) of schedule to the EIA Notification, 2006.

The Asian Polymers being a very small scale industry located in KIADB Industrial Area, Tubinakere,

Mandya District has not obtained Environmental Clearance. However, the plant is following all the pollution

control measures to control water pollution and air pollution and complying with environmental norms with

adequate environmental safeguards. No damage to the environment of what so ever in nature is done due

to the operation of the Asian Polymers. The Karnataka State pollution Control Board is regularly issuing the

Consent to Operate, the present consent is valid for a period up to 30.06.2018 to manufacture 6 products

on campaign basis. The compliance statement of consent is appended as Annexure - 1.


3

CHAPTER 2

INTRODUCTION OF THE PROJECT BACKGROUND INFORMATION

2. INTRODUCTION

2(i) Identification of project & project proponent

2.1 Identification of Project

Asian Polymers is a proprietorship company and is into the business of manufacturing of synthetic resins.

The total manufacturing capacity is 6218 MTPA. The industry is operating since 2010, with valid consent

from KSPCB at 64 B & 65 C, KIADB Industrial Area, Tubinakere, Mandya Taluk & District, and Karnataka

State. The land area is 4007 sq mts or 0.99 acres. The consent for operation for manufacturing of synthetic

resins from KSPCB is valid up to 30.06.2018. The company has the Authorization under the Hazardous

Waste (Management, Handling and Transboundary Movement) Rules, 2008. With validity upto 30.06.2020.

The location of the industry is in designated industrial area, well connected between Bangalore and Mysore

by railways and road transport facility.

2.2 About the Project Proponent

Mr. Tom Mathew. BSc (Chemistry) is the proprietor of Asian Polymers. He is a young entrepreneur from

Kerala State., he is 39 years old. He is having one more unit at Kerala, in the name and style, M/s Asian

Polymers, Keeriyad, Kattampally, Kannur District, Kerala.

2(ii) Brief description of the nature of the project

Asian Polymers situated in KIADB Industrial Area of Tubinakere, Mandya is a small scale industry. As per

the market demand industry propose to change the product mix and also add on two additional resins.

The list of existing, proposed expansion product and total product after expansion are given in below said

table;


4

Table 2.1: Details of existing & expansion products

Sl

#

Product Name Production Capacity in MTPA*

Existing Total (after expansion)

1 Phenol Formaldehyde Resin powder 36 900

2 Phenol Formaldehyde Liquid Resin (73%) 12 2100



5 Urea Formaldehyde Resin 65% 120 2400


7 Phenol Formaldehyde Liquid Resin (80%) - 3000


Total 6218 27900

* The production will be based on the product demand and it will be on campaign basis. The industry

manufactures two products at a time in a day.

2(iii) Need for the project & its importance to region

The requirements of the various synthetic resins are increasing day by day in various applications such as

plywood, grinding wheel, brake lining and clutch lining in foundries in corks, in shell moulding, in lamp

camping etc. Thus, company has planned to manufacture synthetic resins as mentioned above to meet the

market requirement and demand. The present project of the company for manufacture of synthetic resins is

surly feasible. Finished products will be sold in domestic market. The present project will also contribute the

revenue of the central and state exchequer by means of payment of various taxes applicable to the similar

types of industries.

2(iv) Demand- supply gap

Demand of synthetic resins in the country is increasing day by day. Synthetic resins are also used in

various applications such as plywood, grinding wheel, brake lining and clutch lining in foundries in corks, in

shell moulding, in lamp camping etc. The growth and demand of the ply board largely play an important role

for the growth and demand of synthetic resins. Since last 2-3 years the Plywood, Laminate, Fabric items,

Steel Industries and Engineering products are growing at a remarkable pace, which in turn increased the

demand of various industrial inputs. The market demand of synthetic resins is also seeing the upward

growth tendency hence there is a scope for further investments in this sectors, especially because the


5

existing capacities may not be sufficient to meet the new demand. Moreover, the recently invented process

technology for better quality product also needs further investments and shall open new markets. Indian

plywood industry is valued at Rs. 5,000 crores. The industry is growing at rapid pace of 10-20% per annum.

Approximately 600 units are currently functioning all over the country. There is tremendous growth

potential. Panel and plywood products are the main wood products in India. Product categories include

veneer sheets, particle board (composite wood core with plastic laminate finish), panel products (fiber

board), plywood made from both hard and softwood (veneered panels and laminated woods), and medium

density fiber board. The major export destinations for Indian Plywood and Wood Products are USA (23%),

Germany (10%), UK (9%), France (7%), UAE (7%), Italy (4%), Netherlands (3%), Australia (3%), Belgium

(3%) and Spain (2%). Indian particle board and plywood industry accounts for 15% of the total production

and some 30 million sq mt of plywood and block boards.

With the above scenario our project is viable and will narrow the gap of demand and supply.

2(v) Imports vs. Indigenous production

The process of manufacture of Synthetic resins is a simple process and standardized. Asian Polymers, has

technology, experience and competence to manufacture the proposed products. Thus, the dependency on

foreign countries for import could be reduced to certain extent and will also add to the economic

improvement in India.

2(vi) Export possibility

Asian Polymers manufactures the synthetic resins for the domestic market, also they are plans to export

our products in the near future depending up on market condition.

2(viii) Employment generation (direct and indirect) due to the project

The Asian polymers is a small scale industry having only one reactor at present and has employed the local

people in the industry. At present the total manpower is 15 Nos. on direct role which include production

manager, supervisor, lab assistant etc.,

Indirectly many people will be employed as casual laborers, and there is also potential for other business

opportunities such as hired vehicles for the transportation of the finished product etc. It is estimated that

more than 50 people will be benefitted indirectly.


6

CHAPTER 3

PROJECT DESCRIPTION

3. PROJECT DESCRIPTION

3(i) Type of Project Including Interlinked and Interdependent Projects, If Any.

The project is for the synthetic resin manufacturing. The facility is located within Karnataka Industrial Area

Development Board, Tubinakere, Mandya. The company will manufacture Synthetic resin of various

combinations on campaign basis on market demand. The project aims on domestic market for the

business.

3(ii) Location (Map Showing General Location, Specific Location, Project Boundary and Project Site Layout

with Coordinates)

The project site is located at Plot No.64 B and 65 C, KIADB Industrial area, Tubinakere, Mandya Taluk &

District. The plant facilities are spread over 4007 Sq mt (0.99 Acres) in KIADB land. The project site falls in

the Latitude 12029’40.90” N and Longitude 76048’21.81” E at a distance of about 150 mts from the

Bengaluru to Mysore SH 17.

The location details of the project is given below table.

Table 3.1: Location Details

Description Details

Location Plot No. 64B & 65C, KIADB Industrial Area, Tubinakere, Mandya

Taluk & District, Karnataka.

Co-ordinates points Latitude Longitude

A 12029’41.97” N 76048’21.17” E

B 12029’40.17” N 76048’21.40” E

C 12029’42.40” N 76048’23.29” E

D 12029’40.55” N 76048’23.69” E

Village & Plot No. Plot No. 64 B & 65 C, KIADB Industrial Area, Tubinakere,

Mandya Taluk & District, Karnataka.

Total Area 4007 Sq mt ( 0.99 Acres)

Across road Bengaluru to Mysore SH 17 – 150 Mts towards N


7

District Headquarters Mandya District Headquarters – 10.6 Kms towards NE

Nearest Town Mandya District- 10.6 Kms towards NE

Nearest Railway Station Mandya Railway Station- 10.6 Kms towards NE

Nearest Airport Mysore Airport- 33.5Kms towards SW

Figure 3.1: Location of project site on Google Map- 5Km radius


8

Figure 3.2: Location of the proposed plant on the district map

SITE PHOTOS


9


10

Figure 3.3: PLANT LAYOUT PLAN


11

3(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the

environmental considerations gone into.

No alternative site is considered as the proposed expansion activity is within the existing premises. The

existing infrastructure (Plant machinery, factory building, office, stores/cold room, security shed, toilet etc.,)

are in the existing facility. Only one new reactor/kettle will be installed adjacent to the existing one within

the process area.

3(iv) Size or magnitude of operation

The list of existing, proposed and expansion product are given in below said table;

Table 3.2: Details of existing, proposed & Expansion products and capacity

Sl

#

Product Name Production Capacity in MTPA*

Existing Total (after expansion)

1 Phenol Formaldehyde Resin powder 36 900








Total 6218 27900

* The production will be based on the product demand and it will be on campaign basis. The industry

manufactures two products at a time in a day.

3(v) Project description with process details (a schematic diagram/flow chart showing the project layout,

components of the project etc.)

Out of eight products two products will be manufactured in a day, as there is only one reactor/kettle. Now

the company is going to put up one additional reactor/kettle for proposed expansion. The product will be

manufactured based on the market/customer’s requirement on campaign basis.


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Process Description:

The manufacturing process details for each products are explained below.

1. PHENOL FORMALDEHYDE RESIN POWDER:

Process in brief:

1. Phenol + Formaldehyde + Para formaldehyde and oxalic acid is charged in the reaction kettle and

reaction carried out under reflex till the reaction is complete.

2. It is then dehydrated and discharged in to M.S trays.

3. The lumps are broken and packed in bags.

4. The batch time is 24 hours.

Reaction chemistry:

Phenol + + + + H2O

Para formaldehyde water

Phenol Formaldehyde Resin Powder


13

Process Description (per Day):

INPUT REACTION OUTPUT

Phenol 100% + Formaldehyde 37% +

Para formaldehyde + Oxalic acid + water.

Charged to kettle 4545 Kg reaction mixture

The reaction mixture heating through

indirect steam.

Refluxed till reaction

completed.

4545 Kg refluxed reaction mixture.

The refluxed reaction mixture is vacuum

distilled.

Dehydration. 3000 Kg Phenol Formaldehyde

Resin Powder. Water from

dehydration 1455 kg.


14

Process Flow Diagram (Per day):

Water-30Kg Emission

(Recycled of waste water)

90 Kg Evaporation loss

Steam

Vapours to Scrubber

Cooling tower

3000 Kg

Phenol + Formaldehyde + Para Formaldehyde

= 4545 Kg

Charging into kettle

Boil and Reflux

Dehydration

Vacuum Distillation

Discharge

Cooling in trays

Solidification

Broken into Lumps & Stored in

Gunny Bags

Dispatched

Acid Catalyst

1455 Kg -Wastewater

1425 Kg to Forced

Evaporation System

1385 Kg -

Condensate

Water

40 Kg Residue to

Hazardous Waste

incinerator

APC

Scrubber


15

2. PHENOL FORMALDEHYDE RESIN LIQUID-73%:

Process in brief:

1. Phenol + Formaldehyde + Para formaldehyde + catalyst caustic soda and water charged in the kettle.

2. It is then heated by steam and refluxed.

3. Vacuum distilled will be started.

4. Water will be removed from the vessel as per batch size.

5. Cooling down to 300C.


Reaction chemistry

Phenol + + + NaOH + H2O

Para formaldehyde caustic soda water

Phenol Formaldehyde Resin Liquid


16


NPUT REACTION OUTPUT

Phenol 100% + Formaldehyde 37% +

Para formaldehyde + Caustic soda + water

Charged to

kettle

4224.5 Kg reaction mixture


indirect steam.

Refluxed till

reaction mixture.

4224.5 Kg refluxed reaction mixture.


distilled

Dehydration. 3500 Kg of 73% of Phenol

Formaldehyde Resin Liquid. Water

from dehydration 724.5 kg.


17

Process Flow Diagram (per day):

Water-35Kg Emission


98 Kg Process loss

3500 Kg

Cooling Tower

Charging to reaction kettle by vacuum

Catalyst Added

Stirring

Heated by steam

Refluxed

Dehydrated by vacuum to get

viscosity

Cooled to 300C

Finished good to barrel/carbouys

626.5 Kg -

Wastewater

591.5 Kg - Forced

Evaporation System

563.5 Kg -

Condensate

water

28 Kg -Residue

to Hazardous

Waste

Incinerator

APC

Scrubber

Phenol + Formaldehyde + Para Formaldehyde + Caustic Soda

= 4224.5 Kg


18

3. PHENOL FORMALDEHYDE LIQUID RESIN -80%:

Process in brief:

1. First all raw material like Phenol + Formaldehyde + Para Formaldehyde + Caustic soda + Water will be

added into closed vessel.


3. Vacuum distillation will be started.

4. Water will be removed from the vessel as per batch size.



Reaction Chemistry:

Phenol + + + NaOH + H2O

Para formaldehyde caustic soda water

Phenol Formaldehyde Liquid Resin


19



Phenol 100% + Formaldehyde

37% + Para Formaldehyde +

Caustic Soda + Water


The reaction mixture heating

through indirect steam.


completed.

5075Kg refluxed reaction mixture.

5075Kg refluxed mixture is

vacuum distilled.

Dehydration is done to get

viscosity and solid content.

3500 Kg 70-80% Phenol

Formaldehyde Liquid Resin. Water

from dehydration 1473.5 Kg.


20


Water-35Kg Emission


101.5 Kg process

loss

3500 Kg

Cooling tower


Catalyst Added

Stirring

Heated by steam

Refluxed

Dehydrated by vacuum to get

viscosity

Cooled to 300C


1473.5 Kg -

Wastewater

1438.5 Kg - Forced

Evaporation System

1398.5 Kg

Condensate

water

40 Kg - Residue

to Hazardous

Waste

Incinerator

APC

Scrubber

Phenol + Formaldehyde + Para Formaldehyde + Caustic Soda

= 5075 Kg


21

4. PHENOL FORMALDEHYDE LIQUID RESIN-50%:

Process in brief:

1. First all raw materials viz., Phenol + Formaldehyde + Caustic soda + Water will be added into closed

vessel.


3. Vacuum distillation will be started.



Reaction Chemistry:

Phenol + + NaOH + H2O

Caustic soda water

Phenol formaldehyde Liquid Resin


22



Phenol 100% + Formaldehyde 37% Charged to kettle 5586 Kg reaction mixture

5586 Kg of the reaction mixture is

added with caustic soda + Water

The reaction is exothermic the

temperature is maintained at 80-

900C till reaction completed to get

viscosity, solid contented and is

cooled 350C.

6000 Kg 50% of Phenol

formaldehyde Liquid

Resin.

NOTE: Entire process condensate is recycled in the process.


23


Emission

6000 Kg


Catalyst Added

Stirring

Reaction to get required viscosity

Cooling


APC

Scrubber

Phenol + Formaldehyde + Caustic Soda

= 5586 Kg

Caustic soda &

Water


24

5. UREA FORMALDEHYDE RESIN LIQUID - 65%:

Process in brief:

1. First all raw materials like Urea + Formaldehyde + Para formaldehyde charged into the kettle.

2. To dissolve everything catalyst caustic soda solution is added to get pH 8.

3. Stirring and heating will done.

4. Dehydrate with steam heating remove water.

5. The citric acid solution is added to get pH 5.5-6.

6. The batch at 800C – 900C to get the required viscosity and pH 8- 8.5.

7. Then cooled till 350C.

8. The batch time is 12 hrs.

Reaction Chemistry:

+ HCHO + + NaOH + H2O

Urea formaldehyde Para formaldehyde caustic soda water

Urea Formaldehyde Liquid Resin 65%.


25



Urea + Formaldehyde 37% + Para

formaldehyde + Caustic soda + water


4636Kg reaction mixture heating


Heated to 900C with steam

and dehydrated.

3992 Kg dehydrated mixture

and 564 Kg wastewater.

3992 Kg of dehydrated mixture is

acidified with citric acid solution and pH

is adjusted with caustic soda solution.

Keep at temperature 800C –

900C to get the required

viscosity and solid content

and cooled to 350C.

4000Kg of Urea Formaldehyde

Liquid Resin 65%.


26


Emission

80 Kg Process loss

4 Kg

Cooling Tower


Catalyst Added

Stirring

Heated by steam

Refluxed

Dehydration with vacuum

Cooling Finished good to

barrel/carbouys

APC

Scrubber

Urea + Formaldehyde + Para Formaldehyde + Caustic Soda

= 4636 kg

pH adjusted


pH adjusted

564 Kg -

Wastewater

560 Kg - Forced

evaporation system

530Kg -

Condensate

water

30 Kg - Residue

to Hazardous

Waste

Incinerator

Citric acid

Caustic soda


27

6. UREA FORMALDEHYDE RESIN- 50%:

Process in brief:

1. First all raw materials like Urea + Formaldehyde + Caustic soda and water is charged in to the reactor.

2. Stirring and heating will done.

3. Refluxed at 900C till the reaction is completed.

4. Then cooled till 350C.

5. No effluent is generated in this method.

6. The batch time is 6hrs.

Reaction Chemistry:

+ HCHO + NaOH + H2O

Urea formaldehyde caustic soda water

Citric acid H2O

NaCl

Urea Formaldehyde Liquid Resin 50%.


28



Urea + Formaldehyde 37% +

Caustic Soda + water


The reaction mixture heating


Heated to 900C with steam and

refluxed till the reaction is

completed.

4094 Kg of refluxed reaction

mixture & 17Kg evaporation

loss.

4094Kg of refluxed reaction mixture

is acidified with citric acid + sodium

chloride salt+ water + pH is then

adjusted with caustic soda.

Keep at temperature 80 -900C to

get the required viscosity and

solid content. Then cool the

mixture to 350C.

6000 Kg Urea Formaldehyde

Liquid Resin 50%.

NOTE: The entire condensate water from the process is recycled.


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Emission


Catalyst Added

Stirring

Heated by steam

Refluxed


barrel/carbouys

APC

Scrubber

Urea + Formaldehyde + Caustic Soda

= 4196 Kg

pH adjusted


pH adjusted


30

ADDITIONAL PRODUCTS:

7. PHENOL PARA-FORMALDEHYDE LIQUID RESIN-80%:

Process in brief:

1. Phenol + Formaldehyde + Para formaldehyde were charged to reactor and caustic soda was added in

15 intervals for a period of 2 hours.

2. The content will be refluxed in the mean while.

3. The water formed in the reaction was vacuum distilled to get semi solid product.

4. After the contents of the reactor attain the temperature of 300C.

5. Rescorcinol was added and stirred for an hour.

6. Product formed was cooled and tested for quality.


Reaction Chemistry:

Phenol +HCHO+ +NaOH ………STEP I

Formaldehyde Para formaldehyde caustic soda

Reaction Mixture 1

+H2O ………… STEP 2

Resorcinol water Reaction mixture 2

Reaction Mixture 1+ Reaction Mixture 2


31



Phenol + Formaldehyde +Para

formaldehyde + Caustic soda +

Resorcinol + water

Charged to kettle 5473.2 Kg reaction mixture


indirect steam.


completed.

5473.2 Kg reaction mixture.


distilled

Dehydration. 5000 Kg 80% of Phenol Para-


from dehydration 442.2 kg.


32


Water-211Kg Emission


31 Kg process loss

Cooling Tower


Catalyst Added

Stirring

Heated by steam

Refluxed



barrel/carbouys

APC

Scrubber

Phenol + Formaldehyde + Para Formaldehyde + Caustic Soda +

Resorcinol + 5473.2 Kg

pH adjusted


pH adjusted

442.2 Kg

Waste water

262.2 Kg - Forced

Evaporation System

200.2 Kg -

Condensate

water

31 Kg -

Residue to

Hazardous

Waste

Incinerator


33

8. PHENOL PARA-FORMALDEHYDE LIQUID RESIN-76%:

Process in brief:

1. Phenol + Para formaldehyde + Formaldehyde were charged to reactor and caustic soda was added in

15 intervals for a period of 2Hrs.

2. The content will be refluxed in the mean while.

3. The water formed in the reaction was vacuum distilled to get semi solid product.

4. After contents of the reactor attain the temperature of 300C.

5. Urea and melamine was added and stirred for an hour.

6. Product formed was cooled and tested for quality.


Reaction Chemistry:

Phenol +HCHO+ + NaOH ……………STEP I

Formaldehyde Para formaldehyde caustic soda

Reaction Mixture 1

NH2 CONH2+ + H2O ……………. STEP 2

Urea Melamine Water

Reaction Mixture 2

Reaction Mixture 1+ Reaction Mixture 2


34

Phenol Para-Formaldehyde Liquid Resin-76%



Phenol + Formaldehyde + Para

formaldehyde + Caustic soda + urea +

Melamin + water



indirect steam.


completed.

5346 Kg reaction mixture.

The reaction mixture is vacuum distilled. Dehydration. 5000 Kg of 76% Phenol Para-


from dehydration 324 kg.


35


Water-182.5 Kg Emission


22 kg Process loss

Cooling Tower

Phenol + Formaldehyde + Para Formaldehyde + Caustic Soda + Urea + Melamine

= 5346 Kg


Catalyst Added

Stirring

Heated by steam

Refluxed



barrel/carbouys

APC

Scrubber

pH adjusted


pH adjusted

324 Kg

Waste water

141.5 Kg - Forced

Evaporation System

126.5 Kg -

Condensate

water

15 Kg -

Residue to

Hazardous

Waste

Incinerator


36

Sl.

No.

Product Name Batch

time in

Hours

No. of

Batch/d

ay

Capacity/

batch

Existing

capacity/ann

um in MT

Capacity after

expansion (per

annum in MT) in Kg In MT

1 Phenol Formaldehyde Resin Powder 24 1 3000 3 36 900

2 Phenol Formaldehyde Resin Liquid 73% 12 2 3500 3.5 12 2100

3 Phenol Formaldehyde Liquid Resin 80%. 12 2 3500 3.5 1150 2100

4 Phenol Formaldehyde Liquid Resin 50% 6 4 6000 6 900 7200

5 Urea Formaldehyde Resin 65% 12 2 4000 4 120 2400

6 Urea Formaldehyde Resin 50%. 6 4 6000 6 4000 7200

ADITIONAL PRODUCTS

7 Phenol Para formaldehyde Liquid Resin 80% 12 2 5000 5 - 3000

8 Phenol Paraformaldehyde Liquid Resin 76% 12 2 5000 5 - 3000

Total 6218 27900

NOTE: The above production capacity is arrived considering 300 working days.

3 (vi) Raw material required along with estimated quantity likely source, marketing area of final products,

mode of transport of raw material and finished product:

The raw materials required for all products are given below. The availability of these materials is ever

assured. All raw materials are available in the Indian market. Hence the promoter never expects any

storage in the supply of raw materials.

Table 3.3: Raw Material required for manufacturing of 8 products

Sl No Raw Materials Total required per batch Transportation

Kg/batch T/batch

1 Phenol 12708.5 12.7085 Tankers

2 Formaldehyde 15085.2 15.0852 Tankers

3 Para formaldehyde resin 5437.5 2.4375 Truck

4 Urea 2861.7 2.8617 Truck

5 Caustic soda 358.9 0.3289 Truck

6 Citric acid 10 0.001 Truck

7 Oxalic acid 30 0.003 Truck

8 Sodium Chloride (Salt) 728 0.728 Truck

9 Resorcimol 92.8 0.0928 Truck

10 Melamin 63.5 0.0635 Truck


37

3 (vii) Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.

The wastewater generated from manufacturing process is subjected to evaporation in a Forced Evaporator.

The condensate is collected and recycled back to the process. The concentrate is dried and disposed as

Hazardous Waste.

3 (viii) Availability of water its source, energy/power requirement and source.

Resource requirement:

i. Water Requirement

The source of water for the industry is KIADB Supply- 4750 LPD. Water is used for manufacturing

process, cooling tower, boiler feed, softener regeneration and domestic purpose of about 2050 LPD,

1000 LPD, 1000 LPD, 50 LPD and 700 LPD, respectively.

Table 3.4: Water consumption details

Sl. No. Description Quantity in LPD

1 Domestic 700

2 Process* 2050

3 Softener regeneration plant 50

4 Cooling Tower 1000

5 Boiler feed 1000

Total 4800

*water requirement when two products are manufactured, where the water requirement is maximum.

ii. Energy Requirement

There is no additional power required for proposed expansion activity. The total connected load of the

unit is 100 HP from BESCOM. DG Set will act as a backup facility in case of power failure. The details of

power requirement given in below table;


38

Table 3.5: Power & Energy Requirement

Details Capacity

Existing Proposed

Power requirement 100 HP No change

Power backup 62.5 KVA DG Set-1No. No change

Wood husk fired Boiler 1 TPH No change

iii. Manpower Requirement

The Asian polymers is a small scale industry and has employed the local people in the industry. At

present the total manpower is 15 Nos. on direct role which include production manager, supervisor, lab

assistant etc.,

Indirectly many people will be employed as casual laborers, and there is also potential for other

business opportunities such as hired vehicles for the transportation of the finished product etc. It is

estimated that more than 50 people will be benefitted indirectly.

3 (ix) Quantity of wastes to be generated (liquid and solid) and scheme for their management/ disposal.

i. Water Environment & Management:

The wastewater generation per day varies with the type of product manufactured on the particular day.

The quantity of wastewater generation for each product per day considering the number of batches a

day is given in the table below. The cooling tower bleed off is being recycled back, boiler blow down &

softener plant wastewater is being used for gardening. The process effluent is being evaporated in

Forced Evaporation System (FES) of capacity 2000 Ltrs/day. The remaining residues from the FES

which is Hazardous Waste is being disposed to KSPCB Authorized agencies for treatment and

disposal. The sewage is being disposed to septic tank followed by soak pit.


39

KIADB- 4800LPD

Domestic Process* Cooling Tower Boiler Feed Softener Plant Regenerator 700 LPD 2050 LPD 1000 LPD 1000 LPD 50 LPD

Sewage Effluent** Blow down Bleed off Softener plant effluent

560 LPD 1500 LPD 100% recycle 100LPD 20 LPD

1300 LPD Septic tank ETP followed by FES, Blowdown water storage& nutralization

& soak pit Condensate for cooling 120 LPD tower makeup- 1300 LPD. (150 LPD to 200 LPD will be the evaporation loss)

Residues of adhesives & resins– 50-40 Kg/day Handed over to KSPCB authorized agencies

On land for gardening

NOTE: *Depends on the product manufactured on the particular day

**Varies with the product manufactured (Maximum will be 1500 LPD).

ii. Air Environment & Management:

Existing: The major source of emission is from boiler & DG stack. APC measures are adequate to

control and disperse the pollutant. Adequate green belt is already developed. The air pollution source

and control measures are given below;

Table 3.6: Air Pollution Details

Stack No

Stack attached to Stack height

Emission Limits Air pollution control measures

1 Wood husk fired boiler

(1 TPH)

18m AGL SPM 150 Cyclone dust collector

& chimney.

2 62.5 KVA DG Set 3m AGL So2 - Acoustic enclosure

3 Kettle outlet 3m ARL ---- ----- Alkali Scrubber


40

After Expansion: There is no additional air pollution source for proposed expansion activity. The existing

facility will be enough for additional products and proposed expansion activity.

iii. Solid waste Management:



iv. Hazardous waste Management:

The Hazardous Waste generation quantity and disposal details are given below;

Sl

No

Product Name Batch

time in

Hours

No. of

Batch/

day

Residue to Hazardous

Waste incinerator

In Kg/batch In Kg/day

1 Phenol Formaldehyde Resin Powder. 24 1 40 40

2 Phenol Formaldehyde Resin Liquid 73%. 12 2 28 56

3 Phenol Formaldehyde Liquid Resin 80%. 12 2 40 80

4 Phenol Formaldehyde Liquid Resin 50%. 6 4 - -

5 Urea Formaldehyde Resin 65%. 12 2 30 60

6 Urea Formaldehyde Resin 50%. 6 4 - -

7 Phenol Para formaldehyde Liquid Resin 80%. 12 2 31 62

8 Phenol Para formaldehyde Liquid Resin 76%. 12 2 15 30

Total 184 328

Table 3.7: Hazardous waste management

Waste

category

Hazardous waste

generated

Quantity Method of handling

Existing After Expansion

23.1 Waste residues of

adhesives and resins

6 MTPA

98.4 MTPA*

Stored in secure manner and

dispose to KSPCB

authorized incinerator.

20.3 Distillation residue (from

forced evaporator

concentrate)

30 MTPA Stored in secure manner and

dispose to KSPCB

authorized incinerator.

33.3 Discarded containers 1.25 MTPA - Stored in secure manner and

dispose to supplier.


41

NOTE: * The quantity calculated is for eight products, however two products will be manufactured at a time

on campaign basis on market demand and the waste residues of adhesives and resins generated from

manufacture of that product will be disposed regularly.

3 (x) Schematic representations of the feasibility drawing which give information of EIA purpose.

Project – Manufacturing of Synthetic Resin

S

Applicability of EIA Notification 2006,

Activity-5(f) “Synthetic Organic Chemicals” in Category “B1” and attracts

MoEF Notification No: Date: S.O. 804(E) 14th

March 2017 (Existing unit

going do expansion and do not have prior EC for the existing operation)

Scoping by EAC

Determine the Terms of Reference

for preparation of EIA

Preparation of EIA as per TOR

Submission to MoEF for

appraisal by EAC

Preparation of Pre-feasibility report

Apply to MoEF along with Form-1

Grant/ Reject of EC

Screening before EAC

Appraisable by EAC


42

CHAPTER 4

SITE ANALYSIS

4. SITE ANALYSIS

4(i) CONNECTIVITY

The unit is located at Plot No. 64 B & 65 C, KIADB Industrial Area, Tubinakere, Mandya Taluk & District,

Karnataka State. The unit is well connected by road and rail transportation. The project is located in the

Notified KIADB Industrial Area.

Road Connectivity:

The industry is located off (150 mts on south direction) Bengaluru – Mysore Highway (SH - 17).

Rail connectivity

The nearest railway station is Mandya Railway station which is located at distance of 10.6 Kms in NE

direction from the project site.

Airport connectivity

The nearest Airport is Mysore Airport at approximately 33.5 Kms from the site towards SW direction

from the project site.

Communication

The site has access of telephone, internet and mobile connectivity.

4(ii) LAND FORM, LAND USE AND LAND OWNERSHIP

Land is owned by M/s Asian Polymers. This has been allotted by KIADB in the Industrial Area. The plant

facilities are spread over 4007 Sq mt (0.99 Acres) KIADB Land which is completely fortified and protected

on all four sides by boundary walls. The surrounding area of the project site is Industrial land.

4(iii) TOPOGRAPHY (ALONG WITH MAP)

The site is a flat land and the average elevation is 738 m above MSL. The Latitude and Longitude of project

site is given below table.


43

Table 4.1: Site Co-ordinates

Points Latitude Longitude

A 12029’41.97” N 76048’21.17” E

B 12029’40.17” N 76048’21.40” E

C 12029’42.40” N 76048’23.29” E

D 12029’40.55” N 76048’23.69” E

Figure 4.1: Shows the location of the plant on the topo map

Project site


44

4(iv) Existing Land Use Pattern (Agriculture, Non-Agriculture, Forest, Water Bodies (Including Area Under

CRZ)), Shortest Distance From The Periphery of The Project To Periphery of The Forests, National Park,

Wildlife Sanctuary, Eco Sensitive Areas, Water Bodies (Distance From The HFL of The River), CRZ. In

Case of Notified Industrial Area, a Copy of the Gazette Notification Should be given.

Industry is located in Industrial area developed by KIADB. The existing plot is non-agricultural land and

industrial activity is carried out for manufacturing of synthetic resin. There are no eco sensitive areas such

as Forest, National Park, Wildlife Sanctuary, Biosphere Reserves and Wildlife Corridors etc. located within

15 Kms radius of project area.

4(v) Existing Infrastructure

Total area of the project site is 4007 Sq mt (0.99 Acres), the existing unit has raw material storage facility,

production area, office etc., One No. of new reactor/kettle will be come up for proposed expansion activity

within the existing production area adjacent to existing reactor/kettle.

4(vi) Soil Classification

The soil of Mandya district is derived from granites and gneisses interdependent with occasional patches of

schist. The soils range from red sandy loams to red clay loam very thin in ridges and higher elevations and

comparatively thick in valley portion. The soil in Mandya District is thin gravelly and underlain with a

murrum zone containing weathered rock. The soil is highly leached and poor in bases. The infiltration rate

of red loamy and red soils is 2 to 12 cm/hr and 1 to 3 cm/hr.

4(vii) Climatic data from secondary sources

During the year, there is little rainfall in Mandya. The minimum temperature is about 100C and maximum

temperature is about 39 °C. The rainfall in the year is 957 mm.

The classification of months according to the seasons is given in the following table;

Season Period

Summer March to May

Monsoon June to September

Post monsoon October to November

Winter December to February


45

The driest month is January, with no rain fall. Most precipitation falls in September, with a rainfall of 188

mm.

April and May is the warmest month of the year. The maximum temperature will be 99°C. In January, the

minimum temperature is 15°C. It is the lowest average temperature of the whole year.

The annual temperature graph and precipitation graph are given below said table.

Table 4.2: Climatic Data

Month Min. Temperature

(°C)

Max. Temperature

(°C)

Humidity % Precipitation

/Rainfall (mm)

Wind Speed

Km/hr

January 10 33 60 0 5

February 11 37 52 9 5

March 10 38 46 18 4

April 18 39 54 81 4

May 15 38 64 90 6

June 14 38 74 112 10

July 11 37 77 134 10

August 11 38 79 99 8

September 11 33 76 188 5

October 12 33 78 149 4

November 12 33 73 62 5

December 12 32 68 15 5


46

Figure 4.2: Annual Temperature Graph of Mandya

Figure 4.3: Annual Precipitation Graph of Mandya

4(viii) Social infrastructure available

Social infrastructure facilities such as schools, hospitals, community halls, markets, collages, railway station

and religious building are located with 10 Km radius from the site.


47

CHAPTER-5

PLANNING BRIEF

5. PLANNING BRIEF

5(i) Planning concept:

Asian polymers is located in designated Industrial Area (KIADB, Tubinakere, Mandya). All infrastructure

facilities viz, water, electricity, road, skilled & unskilled manpower etc., are available.

5(ii) Population Projection:

An official Census 2011 detail of Mandya, it had population of 1,805,769 of which male and female were

905,085 and 900,684 respectively.

Table 5.1: Census Data

Description 2011

Actual Population 1,805,769

Male 905,085

Female 900,684

Population Growth 2.38%

Area Sq. Km 4,962

Average Literacy 70.40

Male Literacy 78.27

Female Literacy 62.54

Total Child Population (0-6 Age) 172,685

Male Population (0-6 Age) 89,063

Female Population (0-6 Age) 83,622

Literates 1,149,649

Male Literates 638,668

Female Literates 510,981

Child Proportion (0-6 Age) 9.56%

Boys Proportion (0-6 Age) 9.84%

Girls Proportion (0-6 Age) 9.28%


48

5(iii) Land use planning (breakup along with green belt etc)

The plant is located at 64 D & 65 C, KIADB Industrial Area, Tubinakere, Mandya Taluk and District. The

land use pattern is as shown in the table.

Table 5.2: Land Used Planning

Sl. No. Particulars Area (m2) In %

1 Total Plot Area 4007 -

2 Ground coverage area (total built up area) 2404 60

3 Green belt 1603 40

5(iv) Assessment of infrastructure demand (physical & social)

The infrastructure facility is already available which shall be used and properly maintained. Two Nos. of

new reactor/kettle will be installed adjacent to the existing one within the process area.

5(v) Amenities/Facilities

Basic amenities/facilities is available as road, power supply, communication, water supply, medical and

health checkup of workers and staff of the facility will be provided with the necessary Personal Protective

Equipments and periodical medical checkups will be provided to the employees.


49

CHAPTER 6

PROPOSED INFRASTRUCTURE

6. PROPOSED INFRASTRUCTURE

6(i) Industrial area (processing area)

The existing infrastructure (Plant machinery, factory building, office, stores/cold room, security shed, toilet

etc.,) are in the existing facility. Only one new reactor/kettle will be installed adjacent to the existing one

within the process area.

6(ii) Residential area (Non- processing area)

No residential area is proposed.

6(iii) Green Belt

Green belt is already developed. Trees and Plants of the various species predominant in the district are

being planted in the peripheral area.

The fruit bearing species such as coconut tree, Pomegranate, Sapota, Neem, Drum Stick, Teak etc., are

planted.

6(iv) Social Infrastructure

Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers, etc. are all

available in nearby Mandya town. The workers and employees will be residing either at Mandya or

Srirangapattana.

6(v) Connectivity (traffic and transportation/road/rail/metro/water ways etc.)

The unit is located at Plot No. 64 B & 65 C, KIADB Industrial Area, Tubinakere, Mandya Taluk & District,

Karnataka State. The unit is well connected by road and rail mode of transportation. The project is located

in the Notified KIADB Industrial Area.

Road Connectivity:

The industry is located off (150 mts on south direction) Bengaluru – Mysore Highway (SH - 17).


50

Rail connectivity:

The nearest railway station is Mandya Railway station which is located at distance of 10.6 Kms in

NE direction from the project site.

Airport connectivity:

The nearest Airport is Mysore Airport at approximately 33.5 Kms from the site towards SW

direction from the project site.

Communication:

The site has access of telephone, internet and mobile connectivity

6(vi) Drinking water management (source and supply of water)

Drinking water will be sourced from the bore well & KIADB supply which is located within industry premises.

6(vii) Sewerage Management.

The domestic sewage is being treated in septic tank and discharged to soak pits.

6(viii) Industrial Waste Management

The trade effluent generated from the process will be evaporated in Forced Evaporation System (FES). The

condensate is recycled back. The boiler blow down and softener plant effluent is used for gardening after

treatment.

6(ix) Solid Waste Management



6(x) Power requirement & supply/source

Average Power requirement for the unit is 100 HP. The Supply source of power is BESCOM in case of

power failure D.G. Set (62.5 KVA capacity) will be used as back up.


51

CHAPTER 7

REHABILITATION & RESETTLEMENT PLAN(R&R)

7. REHABILITATION & RESETTLEMENT PLAN (R&R)

7(i) Policy to adopted (central/state) in respect of the project affected person including home oustees, Land

oustee and landless labour (a brief outline to be given).

Rehabilitation and Resettlement (R & R) Plan is not applicable since the project is in KIADB Industrial Area

Tubinakere, Mandya Taluk & District, Karnataka State.


52

CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

8(i) Likely date to start of construction and likely date of completion (Time schedule for the project to be

given)

This is a small scale operating unit. Already infrastructure is in place. The production will be taken up once

the EC from SEIAA, Karnataka and Consent from KSPCB is granted.

8(ii) Estimated project cost along with analysis on terms of Economic Viability of the Project

Table 8.1: Project Cost

Sl No Description Amount in Lakhs

1 Land and Development 30.87

2 Building 94.27

3 Plant and Machinery (Additional one Kettle,

Vaccum pump and cooling tower)

168.25

4 Other Assets 17.49

TOTAL 310.88


53

CHAPTER 9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9(i) Financial and Social benefits with special emphases on the benefit to the local people including tribal

population, if any, in the area.

Ours is a very small scale operating unit. It is a proprietary concern. The local people around 50 of them will

be directly or indirectly employed and benefited. There is a growing demand for resins in the India and

State in particular. The present project will also contribute to the revenue of the central and state exchequer

by means of payment of various taxes applicable.


54

Annexure-1

CFO Compliance


55

Annexure-2

Onsite Emergency Plan

Documents

PRE- FEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/.../PFR/18_Apr_2018_135100030H0QT6J…1.1 Introduction: M/s Asian Polymers is a proprietorship company