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
Anacon Laboratories Pvt. Ltd.
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.
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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
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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
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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.
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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.
Awarded the “Top Exporter of Metallized Polyester film for the year 2009-10”, by the Plastic
Export Promotion Council
Awarded the “Top Exporter of Metallized Polyester film for the year 2008-09”, by the Plastic
Export Promotion Council
Awarded the “Top Exporter of Metallized Polyester film for the year 2007-08”, by the Plastic
Export Promotion Council
Awarded the “Top Exporter of Metallized Polyester film for the year 2006-07”, by the Plastic
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 “Second Best Exporter of Metallized Polyester film for the year 2004-05”, by the
Plastic Export Promotion Council
Awarded the “Second Best Exporter of Metallized Polyester film for the year 2003-04”, 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
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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).
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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.
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FIGURE 1: INDEX MAP
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FIGURE 2: STUDY AREA MAP
(10 KM RADIAL DISTANCE FROM THE PROJECT SITE)
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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)
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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.
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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,
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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.
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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.
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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
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FIGURE 4: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING
OF POLYESTER FILM
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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
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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.
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FIGURE 5: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF BOPET FILMS
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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.
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BOPP: Production Flow Chart:
FIGURE 6: PROCESS FLOW DIAGRAM FOR THE MANUFACTURING OF BOPP
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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.
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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.
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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
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Segment and Application of BOPLA Film
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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.
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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
water max % b.w. 0,1
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
water max % b.w. 0,05
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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
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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.
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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
Chiller 172 m3/day (make up)
-
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
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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
Chiller 172 m3/day (make up)
- 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.
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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
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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.
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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.)
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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
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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.
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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
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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
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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.
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Appendix I
LEASE DEED FROM MPAKVN
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