PREFEASIBILITY REPORT - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/P… · · 2016-07-30PREFEASIBILITY REPORT ... Sadolin Paints Kenya, Asian PPG,

PREFEASIBILITY REPORT

For grant of Environmental Clearance

for

Manufacture of Synthetic Resins

Schedule - 5(f)

Category B

By

Ideal Chemi Plast Pvt. Ltd.

Plot No. A1 & A2, MIDC, Kulgaon, Badlapur-421 503,

Maharashtra

Prepared by

FINE ENVIROTECH ENGINEERS 102, HIREN INDUSTRIAL ESTATEMOGUL LANE,

MAHIM (W) MUMBAI – 400 016 EMAIL: [email protected]

FINE ENVIROTECH ENGINEERS

M/S. Ideal Chemi Plast Pvt. Ltd.

INDEX

SR NO. CHAPTER

PAGE NO.

CHAPTER 1

INTRODUCTION TO THE COMPANY

1.1 Introduction 1-1

1.2 Technology 1-1

1.3 Products Manufactured 1-1

1.4 Company Vision And Strategy 1-1

1.5 Departments 1-2

1.6 Infra Structure 1-2

CHAPTER 2

PROMOTERS AND DIRECTORS OF THE COMPANY

2.1 Board Of Directors 2-1

2.2 Company Profile 2-1

2.3 Promoters Information 2-3

CHAPTER3

MAJOR COMPONENTS OF THE PROJECT

3.1 Introduction 3-1

3.2 Location 3-1

3.3 Production Capacity 3-2

3.4 Raw Materials 3-2

3.5 Manufacturing Process 3-3

3.6 Power Requirement 3-4

3.7 Fuel Requirement 3-5

3.8 Water Requirement 3-5

3.9 Effluent Generation And Treatment 3-5

3.10 Solid Waste 3-5

3.11 Man Power 3-6

3.12 Environmental Aspects 3-6

3.13 Cost Of The Project 3-6


1-1 M/S. Ideal Chemi Plast Pvt. Ltd.

CHAPTER 1

INTRODUCTION TO THE COMPANY

1.1 Introduction

M/s. Ideal Chemi Plast Pvt. Ltd. (ICPPL) is a manufacturer and exporter of Synthetic

Resins. Company has been involved in the manufacture of various types of Resins. Due to

change in economic scenario, it is time to change as per market requirements and change

the products which gives optimum results for company as well as society. We have

established in market new products for various applications like wood coatings,

automotive, coil and other industries. Prominent customers include Pidilite, Nippon,

Jubilant, Sadolin Paints Kenya, Asian PPG, E. I. Dupont, Kansai Nerolac, MRF Limited,

Sheenlac, Hibuild Coatings, Wel Coat Dubai, Sadolin Oman, etc. The industry runs by a

team of technocrats having vast experience in development and production of resin.

The EIA notification (S.O.1533) promulgated on 14th

September 2006 has covered these

types of Synthetic Chemical industries under category 5(f) in schedule I. It is stated that

synthetic organic chemical industry located in a notified industrial area/estate is classified

under Category B.

Since being a notified industrial region the land is not agricultural and is under industrial

use only. The total area of the plot is 2021 sq. meters. ICPPL proposes to increase its

annual production from 33.9 MT/day to 43.1 MT/day.

ICPPL is an ISO 9001, ISO14001 & OHSAS 18001 certified company and is located at

Plot No. A1 & A2 at Badlapur MIDC near Kulgaon village.

1.2 Technology

Esterification, Etherification, solution polymerization and polyaddition technologies are

employed to manufacture various synthetic resins.

1.3 Products Manufactured

Using aforesaid technologies, we manufacture synthetic resins such as alkyds, Polyesters,

amino resins, acrylic resins & oligomers and polyurethane disopersions. These products

are used for manufacturing automotive (refinish and OE coatings), Coil and can coatings,

Industrial coatings, decorative & wood coatings.

1.4 Company Vision and Strategy



ICPPL operates its business in a manner which actively seeks prevention of environmental

pollution. We also strive to provide the resources to educate and involve every individual

in the Company in achieving this objective

The continual improvement of quality is fundamental in every activity.

This means that each one in ICPPL is committed to:

Anticipating and exceeding external as well as internal Customer expectations.

Achieving excellence with pride in the areas of business processes, product sourcing,

manufacturing technology and safety, health & environmental compliance.

Delivering continual improvement through establishing measurable objectives at

relevant functions and levels, and a systematic review of performance and processes.

1.5 Departments

ICPPL manages their business with following departments

1. Manufacturing & Logistic

2. Procurement & Distribution

3. Engineering

4. Finance & IT

5. Human Resources & Administration

6. Finance

7. Research & Technology Development

8. Quality Control

9. Customer & Technical services.

1.6 Infrastructure

ICPPL has fully developed infrastructure to support its manufacturing activity

1. Transformer and electrical substation

2. Boiler fired with Furnace Oil

3. Thrmopacks and DG set

4. Water storage and distribution facility

5. Fire fighting with sprinklers

6. Fire alarm system



7. Workers amenity block

8. Manufacturing plant

9. Warehousing

10. Roads and drains

11. Effluent treatment plant

12. QC laboratory


2-1 M/S. Ideal Chemi Plast Pvt Ltd

CHAPTER 2

PROMOTERS AND DIRECTORS OF THE COMPANY

2.1 Board of Directors

ICPPL is managed by its group of directors. Names of the Board Members given below

Designation Name

Directors : Raghuram Kavu Rao,

Vishwas Vishnu Puranik,

Arvindkumar Chimanlal Bhatt,

Raghavendra Govind Joshi

2.2 Company Profile

Ideal Chemi Plast Private Limited India was set up in 2004 for the manufacturing,

marketing and sales of various resins products in India.

Ideal Chemi Plast Private Limited India is a key manufacturer of synthetic resins

being used into automotive coating (OEM & refinishes), wood coating, coil coating

and general industrial coating purpose. The company manufacturers different grades

of resins as per the customer specifications and have following major product lines;

Acrylic resins

Alkyd resins

Amino resins

Polyester resins (Saturates and Modified Polyester resins)

Modified Epoxy resins

Modified Polyimide reins



Today, Ideal Chemi Plast Pvt Ltd is a supplier of choice for leading companies in a

wide range of industries, employing 72 people. Company has its Corporate office &

manufacturing site at Badlapur.

Ideal Chemi Plast Private Limited offers its customers a unique combination of

various technology platforms, product development skills and market knowledge.

Company has developed an underlying diversified portfolio of products that cut across

virtually all needs of the customer. Supported by 24x7 in house research &

development lab and manufacturing facilities, the business has established an image of

quality supplier and is the market leader in the above segments.

Ideal Chemi Plast Private Limited manufactures approximately 120 finished products

(excluding intermediates) to a customer base of 100 (including distributors).

Some of the key strengths of Ideal Chemi Plast Private Limited are-

o Strong brand image of Ideal Chemi Plast Private Limited in the resins industry

o Strong position with industry leaders

o Consistently superior product quality and product performances

o Ability to customize products to market needs with well-resourced R&D function

o Diversified portfolio

o Versatile & flexible manufacturing

o Strong distribution network

o Preferred choice of customer

The business has demonstrated resilience and consistent growth across business cycles.

With Ideal Chemi Plast Private Limited’s focus on the high-growth Indian market, the

business is well-poised to make significant progress in coming years.



2.3 Promoter’s Information

Raghuram Kavu Rao is a bachelor of engineering in electrical. He has 10 years of

experience with state electricity board and 26 years of experience into resins

manufacturing business. He is instrument in developing new client relationship and

nurturing the existing customers. At present, he is a Director, Technical Sales at Ideal

Chemi Plast Private Limited.

Vishwas Vishnu Puranik holds B.Sc. Tech degree and has 40 years of experience of

resins manufacturing and development experience across leading paint companies in

India. He is instrumental in developing new resins product range and making it

commercially viable. At present, he is a Director, Production and R&D

Arvindkumar Chimanlal Bhatt is a B.Sc. Chemical engineering. At present he is

serving as a Director and managing engineering and maintenance division at Ideal

Chemi Plast Private Limited. He has 43 years of resins manufacturing and

petrochemical plant operation experience.

Raghavendra Govind Joshi holds bachelor of engineering in Electrical with 20

years of experience at state electricity board and 26 years into resins manufacturing.

At present, he is managing the commercial, finance and administration functions at

Ideal Chemi Plast Private Limited.



CHAPTER 3

MAJOR COMPONENTS OF THE PROJECT

3.1 Introduction

M/s. Ideal Chemi Plast Pvt. Ltd. is involved in manufacturing of synthetic resins since 2004.

The company works with a strategy to satisfy its customers by striving to understand the

needs of the customer and providing satisfactory services by exceeding the customer

requirement. Keeping this vision the company is proposing to expand its manufacturing

capacity from 33.9 Mt/day to 43.1 Mt/day. Proposed expansion will be carried out at existing

plot only as sufficient place and infrastructure is available.

3.2 Location

The plant is located at Plot No A1 & A2, MIDC, Kulgaon, Badlapur, Dist. Thane, 421503.

Figure 3.1: Google Image of the Site Location

19°09'35.5"N 73°14'31.0"E



3.3 Production Capacity

The proponent proposes to expand the manufacturing capacity of the plant. Production

capacity will be enhanced by reducing in cycle time of the batches of Alkyds and

polyesters. Reduction in cycle time (time required till reactor is engaged) of alkyd and

polyester batches will be achieved by addition/ modification of accessories in plant without

enhancing the capacity of the reactor. The existing manufacturing capacity and proposed

capacity are shown in the table below:

Table 3.1: Existing and proposed manufacturing capacity of the plant.

Sr.

No.

Product Proposed Capacity

MT/Day

Existing Proposed

1. MF/UF Resins 4.5 5.4

2. Alkyl Resins 12.5 14.4

3. Polyester Resins 12.5 14.4

4. Acrylic Resins 4.4 8.9

Total 33.9 43.1

3.3 Raw Materials

The raw materials are available through network of dealers and distributors both in the

domestic as well as overseas markets. As the company is already in the segment and has

established contacts with suppliers and therefore the availability of raw material shall be

smooth.

Table 3.2: List of raw materials with quantity (Kg /day).

Name of Raw Material Amino Resins

Polyester Resins

Alkyd Resins

Acrylic Resins

Total

Paraform 1519 0 0 0 1519

Fatty Acids/Fatty oils 0 0 3269 0 3269

Polyols/Glycols/Amines 1360 3490 2203 0 4788

Organic Acids/Anhydride 20 6015 3859 0 9894

Acrylic Monomer(MMA,BA,NBMA etc) 0 0 0 6223 6223

Solvents (Xylene, MTO, C-IX, C-X, BA.BuOH etc.) 3695 5775 5761 2660 16117

Catalysts 38 19 22 124 203

Water in process 213 0 0 0 213



Water for product washing 0 0 0 0 416

3.4 Manufacturing process

1. Alkyd, Amino and Polyester Resins

Raw Materials with reflux solvent are charged to reactor. Material is continuously stirred

under heating to required temperature. Reflux starts after reaching required temperature, water

of reaction is removed and solvent is recirculated. After desired water removal and desired

viscosity is achieved. The products are partially cooled and thinned with solvent to desired

solid content, after testing the sample batch is discharged in drums or tank with or without

filtration as required.

2. Acrylic Resins

Solvent is first charged to the vessel small quantity of monomer mix is also added. The

contents are heated till reflux. After getting desired reflux rate monomer mixture is added at

desired constant rate after complete addition products are checked for Desired Properties.

Finally the material is filtered and filled in drums. No water of reaction is evolved during the

process. No spent solvents are generated in this process.



Flow Diagram for manufacturing process for Acrylic, Alkyd, Amino and Polyester Resins

3.5 Power Requirement

The power requirement is acquired and fulfilled through MSEDCL. The power requirement for

proposed expansion is 105 HP. It is also proposed to install a DG set having a capacity of 125

KVA.

Condenser

Receiver

Water of reaction

storage drum

Raw Materials

Monomer Tank

Reaction

vessel

Stirred at

45-50 rpm

Blender / Dilution

Tank Filter

To Drum Filling

or Storage Tank



3.6 Fuel Requirement

Fuel

Daily consumption

(Lit/Day)

Existing Proposed Total

Furnace oil 1200 60 1260

HSD 25 2.5 27.5

3.7 Water Requirement

The water source is from MIDC. The water requirement for expansion shall be 25 m3/day. The

break of water requirement is as

Table 3.3: Water Requirement

Usage category

Water

Requirement

(m3/day)

Process water 0.7

Cooling tower makeup 10

Boiler feed water 7.3

Water for vessel cleaning 0

Domestic 5

Gardening 2

Total 25

3.8 Effluent Generation and Treatment

Effluent will be treated in existing ETP prior to release to CETP. Effluent generated in process

is collected in collection tank and further subjected to oil separation. It is passed further for

primary treatment where effluent is neutralized and equalized. Equalized neutral pH effluent is

subjected to sedimentation. Sludge generated by sedimentation is sent for disposal at

CHWTSDF. Clear treated effluent is collected in holding tank which is then disposed to CETP.

Total effluent generated from process will not exceed 5 CMD.

3.9 Solid waste

Hazardous waste generated will be disposed to CHWTSDF.

Table 3.4: Solid Waste

Sr.

No.

Category

No. Type of Waste

Quantity (Kg/Day) Form (Sludge

dry/ slurry) Disposal Existing Proposed



1 23.1 Wastes/Residues 3 3 Slurry CHWTSDF

2 34.3 Chemical sludge from

waste water treatment

8.3 10 Sludge CHWTSDF

3.10 Man Power

The existing facility manpower strength is 64. Additional 16 persons are envisaged. Since the

location is in the industrially developed town with many small units operating in the locality

the availability of workmen is considered to be smooth.

3.11 Environmental Aspects

3.11.1 Air

No air pollution is envisaged from the project site as mechanical dust collectors are installed.

Fuel used for boiler and thermopacks is furnace oil which produces less SO2 and particulate

emissions upon burning, which makes the process more environment friendly.

3.11.2 Water

The effluent from the manufacturing process shall be treated in effluent treatment plant

provided in the unit. No waste water treated or untreated shall be discharged on ground.

3.12 Cost of the Project

Sr.

No.

Description Cost in Crores

1 Land 0.0121320

2 Building 0.4007167

3 Plant & Machinery 2.0027262

4 Other assets 1.3040226

5 Capital work in progress 0.8450430

Total cost 4.5646405

Documents

PREFEASIBILITY REPORT - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/P… · · 2016-07-30PREFEASIBILITY REPORT ... Sadolin Paints Kenya, Asian PPG,