M/S. KANSAI NEROLAC PAINTS LIMITEDenvironmentclearance.nic.in/writereaddata/Online/TOR/24...M/S....

M/S. KANSAI NEROLAC PAINTS LIMITED

Pre-feasibility Report for Environmental Clearance for Proposed Expansion of Integrated Paint Manufacturing Facility at UPSIDC Industrial Estate, Village Jainpur, Tehsil Akbarpur, Dist. Kanpur Dehat, Uttar Pradesh

OCTOBER 2017

Kadam Environmental Consultants www . ka dame nv i r o . co m

Env i ronment for De vel op ment


PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING FACILITY AT

JAINPUR, KANPUR DEHAT, UP PRE-FEASIBILITY REPORT

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER 2017 2


Prefeasibility Report for Environmental Clearance for Proposed Expansion of Integrated Paint Manufacturing Facility at UPSIDC Industrial Estate, Village Jainpur, Tehsil Akbarpur, Dist. Kanpur Dehat, Uttar Pradesh © Kadam Environmental Consultants (‘Kadam’), October, 2017

This report is released for the use of the M/s. Kansai Nerolac Paints Limited, Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of Publication

Prefeasibility Report for Environmental Clearance for Proposed Expansion of Integrated Paint Manufacturing Facility at UPSIDC Industrial Estate, Village Jainpur,

Tehsil Akbarpur, Dist. Kanpur Dehat, Uttar Pradesh

Project Number 1523772310 Report No. 1 Version 1 Released October

2017

Prepared & Managed By

Jayesh Makwana & Mitali Khuman

Released By Sameer Kadam

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010. E: [email protected]; T:+91-265-3001000; F: +91 265 300106

Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,

Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected]; T: 0124-4242430; M:+91-98998-04300

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore

specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation.

.





CONTENTS

1 EXECUTIVE SUMMARY ............................................................................ 6

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ..................................................... 6 1.2 ENVIRONMENT ....................................................................................... 7 1.3 SUBMISSION ......................................................................................... 7

2 INTRODUCTION ..................................................................................... 8

2.1 BRIEF DESCRIPTION OF THE PROJECT ............................................................... 8 2.2 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION ......................................... 8 2.3 DEMAND SUPPLY GAP: .............................................................................. 8

2.3.1 Global Market. ............................................................................... 8 2.3.2 Domestic Market ............................................................................ 8

2.4 IMPORT VS. INDIGENOUS PRODUCTION ............................................................. 8 2.5 EXPORT POSSIBILITY ................................................................................ 8 2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ....................... 9

3 PROJECT DESCRIPTION .........................................................................10

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ..... 10 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT LAY OUT) WITH COORDINATES .................................................................... 10 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED. ........... 13 3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................... 13 3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ................................................... 13 3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA

OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ................. 19 3.6.1 Raw Materials ............................................................................... 19 3.6.2 Transportation details of Raw Materials ................................................ 19

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE

BRIEFLY OUTLINED ......................................................................................... 23 3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE

GIVEN 23 3.8.1 Water consumption and waste water generation ..................................... 23 3.8.2 Wastewater Generation, Treatment & Disposal Facility - Existing Unit ........... 27 3.8.3 Wastewater Generation, Treatment & Disposal Facility - After Proposed Expansion .............................................................................................. 27 3.8.4 Energy/Power Requirement .............................................................. 27 3.8.5 Fuel ........................................................................................... 27

3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT

/DISPOSAL .................................................................................................. 28 3.10 DETAILS OF STACK .............................................................................. 31

3.10.1 Details of Air Pollution Control Measures ............................................... 31

4 SITE ANALYSIS .....................................................................................38

4.1 CONNECTIVITY ..................................................................................... 38 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP .................................................... 38





4.3 TOPOGRAPHY (ALONG WITH MAP) .................................................................. 38 4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES

(INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO

PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER

BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY

OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ....................................................... 38 4.5 EXISTING INFRASTRUCTURE ........................................................................ 39

4.5.1 Land .......................................................................................... 39 4.5.2 Buildings ..................................................................................... 39 4.5.3 Plant Machinery & Utilities ................................................................ 39

4.6 SOIL CLASSIFICATION .............................................................................. 40 4.7 CLIMATIC DATA FROM SECONDARY SOURCES ...................................................... 41 4.8 SOCIAL INFRASTRUCTURE AVAILABLE .............................................................. 42

5 PLANNING BRIEF ..................................................................................44

5.1 PLANNING CONCEPT ................................................................................ 44 5.2 POPULATION PROJECTION .......................................................................... 44 5.3 LAND USE PLANNING (BREAKUP ALONGWITH GREENBELT ETC.) .................................... 44 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)............................. 45

5.4.1 Greenbelt Development ................................................................... 45 5.4.2 Fire-fighting system ....................................................................... 45 5.4.3 Storm water management plan .......................................................... 46 5.4.4 Rainwater harvesting system ............................................................ 46

6 PROPOSED INFRASTRUCTURE ................................................................47

6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................ 47 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ..................................................... 47 6.3 GREEN BELT ........................................................................................ 47 6.4 SOCIAL INFRASTRUCTURE .......................................................................... 47 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ..... 47

6.5.1 By Road...................................................................................... 47 6.5.2 By Rail ....................................................................................... 48 6.5.3 By Air ........................................................................................ 48 6.5.4 By Water .................................................................................... 48

6.6 SEWAGE SYSTEM ................................................................................... 48 6.7 INDUSTRIAL WASTE MANAGEMENT ................................................................. 48

6.7.1 Details of ETP ............................................................................... 48 6.7.2 Scheme for Sewage treatment plant ................................................... 51

6.8 POWER REQUIREMENT & SUPPLY/ SOURCE ........................................................ 51

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ...............................52

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS

INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE

GIVEN) 52

8 PROJECT SCHEDULE AND COST ESTIMATES ..............................................53

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR

THE PROJECT TO BE GIVEN). ............................................................................... 53





8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT. ................................................................................................... 53

9 ANALYSIS OF PROPOSAL .......................................................................54

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. .................................................... 54





1 EXECUTIVE SUMMARY

This Pre-feasibility report is part of documentation filed by Kansai Nerolac Paints Limited as part of the Environment Clearance (EC) Process, a mandatory regulatory clearance required from the Ministry of Environment and Forests (MoEF) prior to commencement of construction at site.

Kansai Nerolac Paints Limited (Hereafter will be referred as KNPL), incorporated on 2-09-1920, at Lower Parel in Bombay is one of the leading paint companies in India with gross sales of Rs.4936 Crores for the year 2016-17. KNPL is engaged in manufacturing/ marketing of & Architectural & Industrial coatings, Powder Coatings& High Performance Coatings. It has operations spread across the country with four strategically located factories & has 98 depots from where they service a vast base of customers both in decorative & industrial side. The plants are located at Lote Parshuram in Maharashtra, Jainpur in Kanpur Dehat of Uttar Pradesh, Bawal at Haryana and Hosur at Tamil Nadu. KNPL is a subsidiary of Kansai Paints Co., Japan’s number one coating company, who holds 74.99% equity. KNPL is targeting a growth significantly better than the expected industry growth rates, as aforesaid.

Company enjoys thorough connectivity across its branches, factories & HO through V-SATS/ leased lines and functions on SAP platform, thus bringing transparency in operations & working on live data. Our Supply Chain department uses advance IT tools like APO for Forecast, production planning & scheduling. All its operations are thus computerized & it is truly IT enabled company KNPL is committed to creating value addition to customers by way of continuous up-gradation of technology resulting in reduction in paint consumption per vehicle, increasing the utility & life span of paints, reducing energy consumption and in manufacturing of environmental friendly paints. Latest technology application knowledge, technical sales service and knowledge of entire paint system are key factors in Auto paint market. With collaboration from world leaders across various continents and with wealth of experience over the years in running various auto lines, KNPL is well equipped to maintain and consolidate its position of strength, KNPL is proud to be the first company to introduce latest environmental friendly lead free Cathodic Electro Deposition (CED) paint in India and eco-friendly water based coatings like Acrylic CED in the Industrial segment as well as lead-free paints and special Low VOC odor free paints in Decorative paints segment. All of our plants have been certified with ISO 14001, OHSAS 18001, ISO 9001 & TS 16949 certification. We are the recipients of Golden Peacock & Greentech award for Environmental Management for various plants. We have also received Sustainability award from Frost & Sullivan and from our renowned customers like Tatas, Maruti, Honda and M & M.

1.1 Plant Features and Production Capacity

The existing manufacturing facility manufactured different type of paint , thinner and Resin as captive consumption. At present the plant is manufacturing paint 92400 KLPA and resin 28500 MTPA. However, process improvement and cycle time reduction, the plant is now capable to produce paint 155000 KLPA and Resin 50000 MTPA by using existing equipment and machinery. There will not be any additional capital investment to increase production capacity.

Production capacity is given below:





Table 1-1: Production Details Sr. No.

Name of the Product Unit Existing production

Additional Production

Total production at full capacity

1 Paints, varnish & thinner,

KL/Annum 92400 62600 155000

2 Resins MT/Annum 28500 21500 50000

1.2 Environment

In the light of the above, we would like to state that the integrated Paint manufacturing facility at Jainpur, Tehsil: Akbarpur, District: Kanpur Dehat with a production capacity of Paints 155000 KLPA and Resin: 50000 MTPA would have in place systems, procedures and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation has no adverse impact on environment.

1.3 Submission

In the light of above ,we would like to state that the integrated paints manufacturing facility at Jainpur , Tehsil: Akbarpur, District: Kanpur Dehat with a production capacity as per Table 1-1 have in place systems, procedures and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation has no adverse impact on environment.





2 INTRODUCTION

2.1 Brief Description of the Project

M/s. Kansai Nerolac Paint limited has proposed the project for expansion of integrated paint manufacturing facilities at Jainpur, District Kanpur Dehat, Uttar Pradesh. Kansai Nerolac Paints Ltd, intends to optimize & utilize its existing manufacturing facility to manufactured different type of paint, thinner and Resin as captive consumption. At present the plant is manufacturing paint 92400 MTPA and resin 28500 MTPA. However, process improvement and batch cycle time reduction, the plant is now capable to produce paint 155000 KLPA and Resin 50000 MTPA by using existing equipment and machinery. There will not be any additional capital investment to increase production capacity.

2.2 Need for the project and it’s importance to region

Indian Paint is growing at the rate of 12-14 % CAGR driven by strength growth in Industrial and Real estate sector .Growing disposable income along with growing life style aspirations of people have resulted in to increased demand for decorative coatings for homes.

Kansai Nerolac Paints Ltd, Currently hold 2nd position by sales turnover in Indian paints Industry, fueled by strong technological base , dynamic management team and aspirations to become the market leader , KNPL wants to expand its manufacturing capacity by process improvement and cycle time reduction in its existing manufacturing set up in Jainpur factory. We shall be able to cater the growing market demand in North India more effectively by improving our existing production capacities .

2.3 Demand Supply Gap:

In the last ten years, the Indian paints industry has grown at the compounded annual growth rate (CAGR) of 10-12 % .The market for paints in India is expected to grow at the 1.5 times to 2 times GDP growth rate in next five years . In order to cater its growth rates, KNP is looking to expand the current manufacturing capabilities by process improvement and cycle time reduction in its existing manufacturing set up in Jainpur factory.

2.3.1 Global Market.

All paints will be supplied in domestic market to meet the demand

2.3.2 Domestic Market

KNPL is looking to improve market share in Northern & Eastern zone

2.4 Import vs. Indigenous Production

No import of raw material is required as major raw materials required for paints manufacturing like soapstone, talc, calcium carbonate etc are available in Rajasthan

2.5 Export Possibility

There is no export possibility in the proposed project





2.6 Employment Generation (Direct and Indirect) due to the project.

This is capacity enhancement through automation and efficiency improvement so will not require additional manpower .The manpower requirement for the existing plant is based on the number of the persons required on each machine / process. The paint manufacturing requires skillful handling by expertise manpower. For operating in full capacity KNPL requires approximately 116 operators, Mangers & Officers 125, & 500 Contractual Person. It is the endeavor of the company to utilize local manpower meeting the qualifications, to the extent possible.





3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

This project is a capacity utilization of existing plant by M/S Kansai Nerolac Paints Ltd .The basic information about the project is given in below table

Location

Plot No B1-B2, G-30, 31,32, 33,34, 35 & 36 UPSIDC Industrial Estate, Village Jainpur,Taluka Akbarpur,

District Kanpur Dehat -209311

Uttar Pradesh

Present Sanction Capacity by MOEFCC & UPPCB Paints, varnish & thinners 92400 MTPA

Resins : 28500 MTPA

Proposed expansion to Paints, Varnish & Thinners: 155000 KLPA

Resins : 50000 MTPA

Total Area

Plot Area (plot area BI&B2): 60702.8m2

Existing Plot area( B1, B2, G30- G34): 87516 m2

Future total Plot area (above plot+G35 &G36): 95616 m2

Achievement of Production Five years from Environment Clearance

This plant is a modern plant requiring less of manual intervention .The broad lines of products being Manufacturer /processed are water and solvents based paints ,thinners ,powders, pretreatment chemicals and CED primers .The products of the company have various applications in the field of automobile ,white goods appliances , buildings , furniture & other industry/engineering products . There is no interlinked and independent project

3.2 Location (map showing general location, specific location and project boundary & project lay out) with coordinates

M/s. Kansai Nerolac Paint limited has proposed the project for capacity expansion of integrated paint manufacturing facilities using existing resources at Jainpur, District Kanpur Dehat, Uttar Pradesh. The site location map is given in Figure 3-1 and The project site is shown in Error! Reference source not found..





Figure 3-1: Site Location

M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING FACILITY AT JAINPUR, KANPUR DEHAT,

UP PRE-FEASIBILITY REPORT


Figure 3-2: Site Layout





3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.

Since the proposed project is for expansion, the alternate site option is not explored.

3.4 Size or Magnitude of Operation

Product details and production capacities are given in Table 3-1

Table 3-1: Details of Product and Production Capacities

Sr. No.

Name of the Product Unit Existing

production Additional Production

Total production at full capacity

1 Paints, varnish &

thinner, KL/Annum

92400 62600 155000

2 Resins MT/Annum 28500 21500 50000

3.5 Project Description with Process details

Manufacturing Processes

Following types of paints shall be manufactured in the proposed unit.

a) Water based paints

b) Solvent Based paints

c ) Thinner

The description of brief process to be used for manufacturing of each type of paint is given below.

A) WATER BASED PAINTS

There will be basically two types of processes:

Manufacture of intermediaries like acrylic resin (water based) for internal consumption

Manufacture of paints,

a) Water based resin manufacturing process …

Acrylic resin (water based) is basically manufactured through a emulsion polymerization of monomers at low temperatures in the water as media. Surfactants emulsifiers are added to maintain emulsion stability. Reaction takes place around 75-80’C at atmospheric pressure. Stainless steel reactor is used. Typical monomers are methyl Methacrylate, Butyl Acrylate,,Vinyl Acetate, styrene etc. No byproduct is generated.

The resin formed is diluted with water and filtered and stored in tanks. This is used as intermediate for manufacturing of paints.





Figure 3-3: The schematic flow diagram for water based resins

Paint Manufacturing Process

The Water Based Paints manufacturing process consists mainly of dispersion of Pigments (mainly TiO2) & extenders (e.g. Talc,CaCo3,Clay etc) in water under vigorous agitation & followed by fine grinding through Sand mill( whenever necessary). The slurry is diluted by adding Emulsion, water & thickeners to get the required physical parameters. The final paint is filled in the containers & dispatched.

The Process steps consist of

Dispersion – Pigments powders are wetted with optimum quantity of water along with wetting agents. This is done in the equipment called Twin Shaft Disperse (TSD).

Grinding: This step is required in certain premium product only. The slurry is ground in high speed sand Mills to achieve the desired particle size, which is at micron levels, to get desired finish.

Dilution- Slurry is transferred to Mixing vessel. The slurry is thinned by adding emulsion, Thickener & water as per the recipe, to get desirable physical parameters.

Filling & Packing Filling is carried out in Bulk Packs (10, 20 lt.) or Small packs (1, 4 lt.). Automatic filling machines are used for big batch sizes. Smaller batches are filled with manual machine. Small packs containers are packed in cartons.-Packed containers/Cartons are sent to BSR for storage & onward dispatch.

Catalyst Water

Water Surfactants

Reaction Terminator+ Antifungal agent

Monomer Tank

Pre Mixing Tank

Reactor

Catalyst Sol. Tank

Let down Vessel Filter Water based resin storage

Tank





Figure 3-4: The schematic flow diagram for the Water based paints

B) SOLVENT BASED PAINTS

There will be basically two types of processes:

-Manufacture of intermediaries like resins for internal consumption

-Manufacture of paints,

Resin manufacturing process

Synthetic alkyd resins are produced through a reaction of polyhydric alcohol and polybasic acids modified with vegetable oils. Reaction takes place around 220-250’C at atmospheric pressure. Stainless steel reactor is used. Typical raw materials are various non edible vegetable oils like Dehydrated Castor Oil, linseed Oil, Soya oil, Pthalic anhydride, Penta-erythritol. Xylene is used as solvent to remove water of reaction through the formation of azeotrope. Xylene is separated and recovered and reused. Water of reaction is sent to ETP.

The resin formed is diluted with MTO and stored in tanks, to be used in manufacturing paints.

Thinning/ Tinting Mixer

Twin Shaft Disperser

Filter

Filling / Cartoning

Bonded Store

Dispatch to Depot

Batch Silo

Powder Storage Silo

Water

Additives

Pigment/ Extender

Sand mill

Water based resin Water Additive





Figure 3-5: Schematic flow diagram for the solvent based resin process

Solvent Based Paint manufacturing Process

Solvent based decorative paints, also called as enamels are made by dispersing pigments and extenders in a base of resins (acting as binders). It is diluted to the required viscosity and various physical and application properties are adjusted by specialty additives.

Basic process consists of...

Premixing: Pigments powders are wetted with optimum quantity of resin/ solvents. This is done in high speed dispersers.

Grinding: The slurry is ground in high speed sand Mills to achieve the desired particle size, which is at micron levels.

Blending: Adjustment with remaining resins, solvents, additives etc. to achieve desired physical properties like viscosity, sp. Gravity, drying properties etc. Dry film properties like elasticity, strength, scratch resistance etc also adjusted.

Tinting: Tinting is done by adding various strainers/pigment concentrates to bring the product to the desired shade

Filtration: Final product is filtered through fine filters before filling in specified containers

Veg Oi l Tank s

Solv ent Tan ks

Resin Stora geTanks

R e

T. F . In

B atch TanksC W O ut

C W In

R ef lux

T. F. o ut

RE ACT O R

B LE N DE R

For Usag e in Pain t

S parkler F ilter

Water of Reac tio n to ETP

P owd er, Catalyst

Sol vent s





Filling: Final product is filled in required pack sizes, carbonized, palletized and sent to warehouse for storage and dispatch

Figure 3-6: Process flow chart for the production of solvent based paints

c) Thinner Manufacturing process:

Basic process consist of ---

Mixing: 2 - 3 type of solvents as per formulation is mixed in mixer to make the uniform mixture.

Filtration: The mixed solvent is filtered through fine filters before filling in specified containers

Filling: Final product is filled in required pack sizes, carbonized, palletized and sent to

warehouse for storage and dispatch

Thinner is mixture of different solvent. The operation is closed loop system. There is no loss in the process.





Figure 3-7: Schematic flow diagram for thinner process





3.6 Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product.

3.6.1 Raw Materials

The raw materials required for manufacturing of paints include the followings

Rutile Pigments Other Pigments Extenders Vegetable Oils –Non Edible Pthalic Anhydride Pentaerithritol MTO Other Solvents Additive & Dryers Monomers Biocides Miscellaneous ( Water & others)

3.6.2 Transportation details of Raw Materials

Table 3-2: Details of Raw Material Consumption and Transportation Details

Raw Material Consumption

MTPM Source Mode of Transport

Additive 652 By Road

Ammonia 19 By Road

Biocide 26 By Road

Solvent 2007 By road

Monomer 715 By road

Pigment 4495 By road

Powder 669 By road

Resin 6585 In house/ purchase

Chemical 385 By road

Vegetable oils (Non edible) 752

By road

Emulsion 1561 In

house/Purchase By road

Intermediate 40

Comp. B 15 In house By road

Stainer 95 In house

Water 1126 In house Thru’ pipeline

M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR EXPANSION OF INTEGRATED PAINT MANUFACTURING

FACILITY AT JAINPUR, KANPUR DEHAT, UP

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER 2017

Table 3-3: Storage Details of Raw Material

S. No.

Chemical State Consumption (MT/Annum)

Means of Storage

Operating Condition (Storage) Nos. of vessel/

drums/bagsPress

(Kg/cm2) Temp. (°C)

1 Additives Powder &Liquid 7825 Bag, Barrel &

Carbouy atmospheric ambient

ST-15KL:1

ST-30KL:6

ST-60KL:2

Carboy: 25Kg

2 Ammonia Liquid 234 Carbouy atmospheric ambient 300

3 Biocide Powder &

liquid 308 Bag, carbouy atmospheric ambient

Bag: 400

Carbouy:300

4 Solvent Liquid 24080 Storage Tanks atmospheric ambient

ST-30KL: 14

ST-60KL: 2

ST-150 KL:2

5 Monomer Liquid 8580 Storage Tanks,

Barrels atmospheric <25 deg C

ST-60KL:3

ST-100 KL:4

6 Pigment Solid, Liquid

,Paste 53944 Bag & Carbouy atmospheric ambient

Bag: 8000

Carboy: 4267

7 Powder (TiO2,

Extender) Powder 8030 Bag, Silo atmospheric ambient

Bag: 1800

Silo: 10 Nos.

8 Resin Semi Liquid 79022 Storage Tank, atmospheric ambient

ST-13KL: 1

ST-15KL: 2

ST-30 KL:6

ST-50 KL:5

9 Chemical Solid, Liquid 4620 Bag, carboy atmospheric ambient Bag: 6000 Nos

Carbouy:4367


FACILITY AT JAINPUR, KANPUR DEHAT, UP PRE-FEASIBILITY REPORT


S. No.

Chemical State Consumption (MT/Annum)

Means of Storage

Operating Condition (Storage) Nos. of vessel/

drums/bags

Storage capacity of Bag / Drum / Tank

(MT)

Maximum Storage Capacity

(MT)

Press (Kg/cm2)

Temp. (°C)

10 Vegetable oils (Non

edible) Liquid 9019 Storage Tank atmospheric ambient

ST-10KL:2

ST-15KL:3

ST-30KL:11

ST-60KL:2

Storage Tank: 10 KL, 60KL, 30 KL, 60 KL

515 MT

11 Emulsion Liquid 18731 Storage Tank atmospheric ambient ST-15 KL:3

ST-60KL:14

Storage Tank: 7KL &10 KL

885 MT

12 Intermediate Liquid 475 Barrels atmospheric ambient 653 200 Ltr. 960 MT

13 Component B Liquid 179 Drum atmospheric ambient 550 Drum: 20Kg

10 MT

14 Stainer Liquid 1142 Drum atmospheric ambient 3000 50 kg 60 MT

15 Water Liquid 13509 Storage Tank atmospheric Ambient ST-30 KL:4

ST-1000KL:3 30 KL.1000KL 3120 KL




Table 3-4: Storage Details of Products

S.

No. Chemicals State

Production (MT/Annum)

Hazard Involved

Means of Storage

Operating Condition (Storage) Capacity of Vessel /

Bag

No. of Vessels /

bag

Storage Capacity

(m3) Press Kg/Cm2 Temp ºC

1

Paint and varnish, Enamels, Lacquer, thinner

Liquid 155000 Fire Drum & barrel Atmospheric Ambient Container:2ltr,4ltr. ,20 ltr,

200ltr. - 5600 KL

2 Resin Resin

50000 Fire

Storage tank

Atmospheric Ambient

ST- 15KL, 30KL , 50KL

ST-15KL:2nos

30KL:5 nos

50KL:5 nos

1275 KL





3.7 Resource Optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined

The Following hierarchy is followed for waste management with an ultimate aim of Zero waste

Resource Conservations Elimination of Waste Streams Minimize Waste Reuse of Waste Recycle of Waste Treatment and disposal for making waste harmless

Wash water generated from cleaning of equipments will be re used back into process/product

3.8 Availability of water its source, energy/power requirement and source should be given

3.8.1 Water consumption and waste water generation

In the existing unit the total water demand is 449 KLD and in proposed expansion the fresh water requirement will be estimated about 210 KLD. So total water demand after the expansion of paint unit will be about 620 after recycling of treated water.

The breakup of water consumption for existing and proposed unit is presented in below table..

Table 3-5: Water Consumption from Existing and Proposed Unit

Sr. No. Description

Water Consumption

in Exiting Unit in KLD

Water Consumption in Proposed Unit

in KLD

Total Water Consumption

after Expansion in

KLD

1 Domestic 37.5 10 48

2 RO 27 19 46

3 Process 111 70 181

4 Boiler 72 24 96

5 Cooling Tower 161 52 213

6 Washings (Vessel,Drum, floor & Lab

equipment's etc) 60 30 90

7 Firefighting 10 5 15

8 Gardening 115 8 139

9 Total Water Consumption 593 218 827

10 Recycled water from ETP, RO & STP 145 8 207

11 Total Fresh Water Demand 449 210 620





Table 3-6: Waste Water Generation from existing and Proposed Unit

Sr. No. Description

Wastewater Generation in Existing Unit in KLD

Wastewater Generation in Proposed Unit in KLD

Total Wastewater Generation

After Expansion in

KLD

Treatment & Disposal Facility

1 Domestic 35 8 43 To STP

2 RO 27 19 46 To Gardening

3 Process 0 0 0

4 Boiler 1 1 2

To ETP 5 Cooling Tower 24 8 31

6 Washings (Vessel,Drum, floor & Lab equipment's

etc) 58 30 88

7 Total Wastewater

Generation (Industrial + Domestic)

145 66 210

131 KLD to ETP followed by RO &

MEE 36 KLD RO reject

to Gardening 43 KLD sewage to

STP




Figure 3-8: Existing Water Balance




Figure 3-9: Total Water Balance (Existing + Proposed)





3.8.2 Wastewater Generation, Treatment & Disposal Facility - Existing Unit

In the existing unit the wastewater generated from the various areas such as

1. Domestic 2. Utilities blow downs and 3. Washings

Domestic sewage is separately treated in STP and treated water is used for gardening.

Other wastewater from utilities blow downs along with washing effluents will be treated in existing ETP and treated water from ETP is reused in cooling tower and other process areas.

3.8.3 Wastewater Generation, Treatment & Disposal Facility - After Proposed Expansion

After the proposed expansion the effluent generated from the various areas such as

1. Domestic 2. Washings 3. Utilities Blow Downs etc.

Domestic sewage generated will be treated in existing sewage treatment plant and treated sewage will be reused for gardening.

For industrial effluent Zero Liquid Discharge facility will be proposed by installing ETP, RO & MEE. Suitable modification will be carried out in the existing ETP to take care the proposed effluent load. ETP capacity will be augmented from 115 KLD to 140 KLD. Recycling RO and MEE will be installed with capacity of 140 KLD & 30 KLD respectively.

Sludge generated from the ETP and MEE salts will be disposed at approved TSDF facility while STP sludge will be used as manure for greenbelt development.

3.8.4 Energy/Power Requirement Power supply from Grid: Total power requirement is around 5000 KVA & are sourced from Uttar Pradesh Power Corporation Ltd. (UPPCL). Standby Emergency DG Sets: The DG sets (1500 KVA -2 nos, 520 KVA-3 nos, 500 KVA- 1, and 320 KVA-2 nos) are available in plant as a backup source in case of power failure.

3.8.5 Fuel

The fuel consumption data is given below

Table 3-7: Fuel Consumption

Sr. No.

Stack Attached to Capacity Stack Nos.

Type of Fuel used

Fuel consumption

(litr/hr)

1 Boiler 650 Kg/hr 3 HSD 35

2 Boiler 850 kg/hr 3 HSD 45

3 Thermic fluid heater 4 lac Kcal 2 HSD 45



6 Thermic fluid heater 10 Lac Kcal 2 HSD 75

7 DG set 520 KVA 3 HSD 70





Sr. No.

Stack Attached to Capacity Stack Nos.

Type of Fuel used

Fuel consumption

(litr/hr)

8 DG Set 500 KVA 1 HSD 70

9 DG set 320 KVA 2 HSD 40

10 DG set 1500 KVA 2 HSD 200

11 Solid fuel boiler 15 Lac K cal 1 Rice husk 400

*Note: Dg Sets will be used only during Power failure.

Note: 1 Boiler and stack with capacity of 350 kg/hr will be added after proposed expansion

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal




Table 3-8: Hazardous waste generation (Existing + proposed)

Sr. No. Type of Waste

Hazardous Waste

Category

Existing Quantity

(MT/Ann-um)

Proposed Quantity

(MT/Ann-um

Total Quantity after expansion in (MT/Annum)

Source Method of Collection

Handling and Storage

Treatment / Disposal

1

ETP Waste Water sludge 35.3 7.39 15 22.39 ETP

Dried sludge from SDB / Filter press will be packed in

bags

Storage in Hazardous

Waste Storage Room

Landfilling

2 Incineration ash 37.2 2.6 22 24.6 In-house Incinerator Packed in Bags

Stored in Hazardous

Waste Storage Room

Landfilling

3 Used Oil/Spent oil 5.1 3.7 2 5.7

DG, compressor, Gear Box, drives etc

UPPCB approved recycler

Stored in Hazardous

Waste Storage Area in Drums

Sale to authorized recycler

4 Oil & grease scheming

residue 34.4 - 2 2 ETP Packed in Bags Sent for

Incineration In house

In-house Incineration

5 Spent Solvent 20.2 3.26 423 426.26 Paint

manufact-uring

In-house Distillation Stored in Drums

Recycle back in plant by

distillation

6 Distillation sludge 20.3 - 265 265 Distillation Process

Sent for Incineration

In-house Incinerator

Ash for Disposal to Landfilling

6 Process waste, residue, sludge

21.1 2 37 39 Paint

manufact-uring process

Sent for Incineration

In-house Incinerator


7 Discarded container/drum/liner

33.1 - 125 125 Paint

manufact-uring process

UPPCB Authorized vendor

Stored in Hazardous

Waste Storage Area

Sale to Authorized

vendor

8 Conta-minated cotton waste/liner 33.2 - 7.5 7.5

Paint manufact-

uring process Sent for Incineration

In-house

Incinerator





Sr. No. Type of Waste

Hazardous Waste

Category

Existing Quantity

(MT/Ann-um)

Proposed Quantity

(MT/Ann-um

Total Quantity after expansion in (MT/Annum)

Source Method of Collection

Handling and Storage

Treatment / Disposal

9 MEE salt 35.3 - 105 105 ETP Packed in Bags

Stored in Hazardous

Waste Storage Room

Landfilling

Note : Categorized as per Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016.





3.10 Details of Stack

Table 3-9: Details of Flue Gas Stack

Stack Attached to Sources Capacity Nos. of Stacks

Stack Height, m

Stack Top Dia, m

Boiler 650 Kg/hr 3 30 0.3

Boiler 850 kg/hr 3 30 0.3

Thermic fuid heater 4 lac Kcal 2 30 0.3

Thermic fluid heater 2 lac Kcal 4 30 0.3

Thermic fluid heater 6 lac Kcal 1 30 0.3

Thermic fluid heater 10 Lac Kcal 2 30 0.3

DG set 520 KVA 3 15 0.3

DG set 500 KVA 1 15 0.3

DG set

320 KVA 2

15 0.3

DG set 1500 KVA 2 15 0.3

Solid fuel boiler 15 Lac K cal 1 30 0.3

Note: Dg Sets will be used only during Power failure.

Table 3-10: Details of Process Vents

Stack Attached to Nos. of Stacks

Stack Height in m

Pollutants Emitted

Air Pollution Control Measures

Attached

Premixer 5 13.9 dust Dust collector (bag filter)

Resin scrubber Stack 1 20 Particulate matter Wet scrubber

Fume extractor system attached to mixer

1 11 Traces of fumes

Adequate stack height

Reactor vent 11 11 Traces of fumes

Open to air

3.10.1 Details of Air Pollution Control Measures

Stack emission from generators, boilers and thermopacs

The control of air pollution from stacks of diesel generators, steam boilers, thermic fluid heaters is proposed by providing adequate stack height to attain maximum dispersion of flue gases





containing SPM, SO2, NOx and CO. additional boiler for multiple effect evaporator will be installed with Stack. Gas and dust emission from process reactor vessels, mixers, condensers, blenders, chargers etc. During charging, dust collection and fine particle filtration systems will be installed to trap the particulate matter thus allowing only clean air to be discharged into the atmosphere.

Dust collection system

Pulse jet filters are continuous self-cleaning units. A high-pressure blast of clean, dry compressed air is injected into each filter element at periodic intervals. This air is stored in a reservoir called a header. Several purge pipes are attached to the header and extend into the clean air plenum above rows of filter bags or cartridges. Holes are drilled in the purge pipes directly above each of the filter elements. Several elements are cleaned by one purge pipe. A solid state timer controls a solenoid that opens a diaphragm valve allowing air to flow from the reservoir into the purge pipe and filter element. The element experiences a shock wave while air is forced through it in a direction opposite to the dirty air flow. A portion of the dust cake will fall away from the bag into the filter’s hopper.

Figure 3-10: Process Flow Diagram of Dust Collection/Filtration system

Process Flow Diagram of Dust Collection/Filtration system

Clean air

Collected dust recycled

Particle laden gas emitted from handling of pigments and extenders

Dust Collector Filtration Mechanism





Fume Extraction System with Dry scrubber

Fume Extraction will be provided to all the solvent handling process equipments and vents are connected with dry scrubbing (activated carbon) mechanism to control the emissions.

Air Emission control from Resin reactor: Air emission streams from resin reactor vessels during resin making is passed through a condenser where the solvent vapours and steam (azeotrope) condensate and is collected in a separator. Thereafter, the separation of immiscible liquids is done and the solvent reused. Hence, emission to the atmosphere contains almost clean air, as the design efficiency of condensers is almost 100%. Prior to the reaction emissions, there is emission of pthalic dust during charging (while manufacturing alkyd resin only). Pthalic is odorous. Emission during charging is sucked into scrubber, where most of the pthalic removed before venting. The scrub air is then passed through charcoal bed which absorb all the odour and clean air is released into the atmosphere.

Figure 3-11: Scrubbing system (Process flow diagram)

Scrubber

Scrubbing Liquid (Water/caustic solutions)

Volatile organic compound (VOC) emitted during mixing and dispersion

Clean Air stream

Effluent to ETP





Figure 3-12: Resin reactor scrubbing system

The scrubber system is designed as the gas transfers using the vacuum created by the centrifugal corrosion resistance blower. First the oil drain box attracts the oil transferring to the ducts, where the heavy oil is trapped. The hot fumes generated from the reactors are exhausted through the header duct line connecting all the reactors transfers to the oil separation column for complete separation of oil and manually collected in a pot by gravity and centrifugal action created by the column.

The hot gas (2500C) transfers to the Venturi to bring down the temperature and drastically absorb the acidic fumes of Phathalic, Penta and Maleic generated by the hot Phtalic anhydradide solution by the chemical mixer with water solution. When it passes through the venturi chamber, the maximum quantity of fumes get wet due to jet spray of liquid placed inside the venture throat.

Subsequently, the gas pass through the PP/FRP ceramic pall rings packed jet flashed distributor built in second column for scrubbing the left out acidic fumes of Phathalic , Penta, Maleic fume absorbed by Lime solution. The circular spray nozzles to trap the left out oil and then it passes through the ceramic bed column having one more circular spray nozzle which sprays the neutralizing solution to scrub the phthalic, penta, ma;eic fumes. Now the gas temperature is 900C . Then it passes through charcoal bed tower where the odour is elimination takes place and then passes through the demister pad to trap any traces of escapes at this charcoal tower. Finally, the clean air let out through stack to the atmosphere.





Incinerator Existing Incineration system has a firing rate 20 kg/hr. incineration system comprising of primary chamber, post combustion chamber, ventury scrubber, packed column, ID fan, Stack, Control panel, BMS panel for burner having waste firing rate 20 kg/hr at overall calorific value 2977 Kcal/kg and HSD as fuel. The system is designed for destruction of the solid waste generated from a paint processing plant consists of the following:

Waste feeding system Incineration system Flue gas cleaning system

Waste Preparation & Feeding System The incinerable waste (solid waste, slurry & Viscous streams) are collected near incinerator waste storage area. The same is weighed on a weighing scale & mixed together in desire proportion. The waste in mixed condition is packed together in polythene bags and charged through DFDV (Double flap dump valve) into the primary chamber. DFDV is located on the primary chamber and works on 2flaps manual mechanism. The flap of DFDV opens one by one (to be opened manually with help of hand lever) & drops the waste into the primary chamber. It also ensures safety of operation as well as not allowing any gases to escape out.

Waste water Waste water waste is unloaded into a waste water tank & is then pumped to primary chamber via metering pump through waste water injector using compressed air as atomizing media. This ensures even distribution of the waste on the hearth thus ensuring compete destruction. Waste water injector specially developed for this kind of application.

Incineration System The incineration system consists of

- Primary furnace

- Post combustion chamber

Primary furnace The primary chamber is cylindrical furnace duly lined with refractory material of adequate thickness. An hearth is located inside the furnace on which the waste burns continuously. The hearth is provided by the combustion air. The air is admitted through manifold located at the bottom of the furnace. All the waste is fed manually at a regular interval through the burner. The main function of the chamber is burning the waste under starved air conditions. All the volatiles are liberated and other carbonaxeous matter is totally burned in the primary chamber.

Prior to waste firing, chamber is heated up initially by firing HSD through burner. The temperature of furnace is raised upto around 800 ± 500C . The ignition is automatic through UV cell and flame relay (burner programmer). Once the flue gas temperature has reached around 800 ± 500C, solid waste is charged through the feeding mechanism.

Ash Handling System Ash pit is provided at the end of the deashing chamber and the ash is dragged out at the end of the shift and quenched in the pit. The pit has a capacity of 3 days and can be transferred to the landfill at one stretch.

Post combustion chamber This is horizontal, cylindrical side fired furnace lined with refractory and insulating material. The chamber is initially heated up to the operating temperature using burner. The function of this





chamber is compete combustion of volatiles/ smoke coming from primary chamber. Temperature in this chamber is maintained at 1050 ± 500C. Under controlled conditions of temperature, time and turbulence the unburnt in the flue gas get completely oxidized to harmless products. The function of the PCC is to complete the gas phase reactions initiated in the primary Chamber. The incinerator is provided with controls to ensure smooth operation. The temperature at the outlet of PCC is sensed by a temperature element located at the outlet of the furnace in the path of the flue gas. The fuel firing is controlled by the solenoid valve on ON/OFF basis per signal from temperature indicator controller.

Flue gas cleaning system The flue gas cleaning system consists of

a. Venturi Scrubber and packed column b. Induced draft fan & stack

Venturi scrubber The flue gas @ 2800C is cooled in venture scrubber by spraying water through tangentially placed nozzles. The temperature of the flue gas is reduced to the adiabatic saturation temperature i.e. around 65 – 700C. The saturated flue gas also facilitates higher removal of particulate matter by initiating particle agglomeration. The VS is designed to serve as a control device for applications requiring very high collection efficiencies for fine particulate matter. It employs gradually converging and then diverging sections to clean the flue gases. As the re-circulating scrubber solution is atomized, it begins to collect particle s from the gas impacting into the liquid as result of the difference in velocity of gas streams and atomized droplets. As the mixture decelerates in the expanding section, further impaction occurs causing the droplets to agglomerate. Once the liquid has trapped the particles, separation of the same can be done easily the pressure drop is provided in the venturi to ensure trapping of the particulate and is decided while sizing the throat. The venture scrubber is designed for a maximum pressure drop of 1000 mmWC. Partial SO2 removal also takes place in the VS. Caustic solution (5%) is re-circulated in packed column to achieve the desired results.

Packed column The gas enters into packed column wherein the gases pass through a packed section. Caustic solution is circulated across counter currently for the removal of pollutants to bring it down to PCB norms. A separate pump is provided for the circulation of the liquid in packed column.

Demister The flue gases then further passes through demister for removal of water mist. A separate spray is provided to clean the demistor periodically.

ID Fan & stack The flue gas is drawn through an ID fan before being let out to the atmosphere via a 30 mtr. High stack. The pressure in the furnace is maintained below the atmospheric pressure within certain limits by controlling the suction damper manually at inlet of the ID fan.

Emergency system It is important that the downstream equipment do not get heated up by the flue gases hence in case of any emergency (e.g. power failure) the emergency stack opens pneumatically & vents the gases to the atmosphere. An emergency overhead tank is also provided which on power failure





will flood in the Venturi Scrubber to reduce the temperature and thus protect the downstream equipment.

Bleed transfer system The system is designed for transfer of bleed coming out of scrubbing system to ETP. The system consists of

- Bleed collection sump/seal tank - Bleed pumping system

The bleed coming out of the scrubbers is sent by gravity to a underground sump/seal tank (RCC) with baffle for bleed to overflow. The tank shall act as intermittent holding tank. The first part of the tank shall be used for collection of bleed. This bleed is then pumped to ETP. The stack height of incinerator will also be provided as per CPCB/GPCB standards. The proposed height of the stack is 30 mtr heights. The flue gas generated will then be passed through a venture scrubber and packed column for complete cleaning of the pollutants. The emission of this incineration and flue treatment system will conform to the following:

S. No.

Parameter Emission (mg/Nm3)

CPCB Norms Anticipated Emissions

1 Suspended Particulate Matter (SPM) 50 50

2 HCL 50 NA

3 SO2 200 7.76 mg/m3

4 CO 100 11.45

5 TOC 20 NA

6 HF 4 NA

7 NOx 400 20.96

Hydrocarbon shall be 10 ppm over an hourly rolling average dry basis, measured as propane. Dioxins/Furans will not exceed 0.1 Ng TEC/Nm3. To reduce levels of pollutant emission, fuel with low sulphur content will be used. Also the pollutants in the plant vicinity will be abated by greenbelt plantation





4 SITE ANALYSIS

4.1 Connectivity

The Proposed project is located at Plot No. B1-B2, G-30, 31,32, 33,34, 35 & 36 UPSIDC Industrial Estate, village Jainpur, Taluka Akbarpur, District kanpu Dehat, Uttar Pradesh. Site is located at the distance of 6.6 KM in SSW direction from Lalpur railway station and approx.. 9 km in east direction from Paman railway station. The nearest airport is Kanpur which is 42 km from the proposed site

4.2 Land Form, Land Use and Land ownership

The Plant is located at Plot No. B1-B2, G-30, 31,32, 33,34, 35 & 36 UPSIDC Industrial Estate, village

Jainpur, Taluka Akbarpur, District kanpu Dehat, Uttar Pradesh. The land use is industrial.

4.3 Topography (along with map)

Detail topography of the proposed site and study area will be studied in EIA report.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.

The present land use is in industrial zone. The details of sensitive areas from the site boundary are given in Table 4-1. The site does not fall within the CRZ area.

Table 4-1: Distance of Project Site from Sensitive Areas Area Distance in km Direction

Human settlement more than 1000 population

Nearest railway station:

Lalpur railway station: ~6.6 Km

Paman Railway station:~ 9 Km Nearest airport:

Chakeri Airport, Kanpur, Kanpur,- 42 Km

Lucknow Airport, Amausi: 98 Km

Kanpur City: ~ 25.0 km in

SSW direction

East direction

East direction

NE direction

NW direction

Sanctuary- National Park-Hills- Mountains- Mangroves,

backwaters of Reservoir etc.,

NO Sanctuary- National Park-Hills- Mountains- Mangroves, backwaters of Reservoir etc in 10 Km. radius of

the factory

-





4.5 Existing Infrastructure

4.5.1 Land

The Plant facilities are spread over 243834.8 m2 UPSIDC Land which is completely fortified and protected on all four sides by boundary walls.

4.5.2 Buildings

Total built up area is divided into various sections like Production Blocks, Engineering, Warehouses, Administration, Canteen, Toilets etc. There is adequate space & provision for operations.

4.5.3 Plant Machinery & Utilities

The Plant Facilities have been designed and set up with the objective to carry out almost all chemical reactions and processes. Details of plant and machinery and utility equipments used for the production are as below:

Table 4-2: list of Equipment and Machineries List of Equipments & Machineries

Sl No EQUIPMENTS CAPACITY QUANTITY

A For Paint Manufacturing

HSD 1.5KL X 3, 3KL X 4, 2.5 KL X 4,2KL X 1 12

Pre- Mixer 3 KL X 4 4

Ball Mills 5kl X 4,3KL X 1,4.5KL X 2, 2.5KL X 1, 1KLX

1,200L X 1,100L X 1, 50L X 1 12

Bead- Mill 900L X 1,500L X 3 4

Processing

Sand Mills 60L X 1,50L X 1 2

Dyno Mills 25 L X 4, 05L X 2, 10L X 1 8

LMEs 60L X 4,30L X 2 6

IEC Mill 30L X 5 5

TSDs 3KL X 3, 12 KL X 2 3

Mixers 20KL X 4, 12KL X 20, 10KL X 4, 5KL X 14,

3KL X7, 2KL X 6, 1.5KL X 8, 6KL X 5 68

Filling

Manual Filling

Machine(Cadetronics) 10-20 L 13

Manual Filling

Machine(Cadetronics) 0.5-04 L 7

Retial Pack Fully Auto Filling

Machine (Cadetronics) 0.5 - 04 L 1

Bulk Pack Fully Auto Filling

Machine (Cadetronics) 10-20 L 1

Semi Auto Filling Machine 0.5- 04 L 2

Retail Pack Filling Machine(Mount)

0.5- 04 L 2





List of Equipments & Machineries

Sl No EQUIPMENTS CAPACITY QUANTITY

Lid Press 10-20 L 6

Lid Press 0.5 L-4 L 7

B Resin Manufacturing

Reactors 10 Ton X 2, 7.5 ton x 1,05 Ton X 2, 03 TON

X 5, 02 TON X 1,01 TON X 1, 875L X 1, 400L x 1

15

Blenders 30 Ton X 2, 22.5 Ton x 1, 10 Ton X 1,05

Ton X 2 6

Sparkler Filter 15 Plate & 24 Plate 6

C Material Handling Equipments

HOPT 02 TON 27

BOPT 02 TON 21

Diesel Forklift Trucks 02 TON 9

Barrel Movers(Semi -auto

Stacker) 0.5 TON 3

D D.G.SETS 520 KVA x 3, 500 KVAx 1, 320 KVA X2,

1500 KVA X 2 8

E Thermopac / Boiler TFH- 10 NOS. ,Steam Boiler -06 16

F Chilling Plant

20 TRX2,75TRX1,85TRX2,18TRX2,104TRX1,100

TRX2 10

G Air Compressor 360 CFMx1,500CFMX1,100CFMX1,300CFMX1 4

4.6 Soil Classification1

In spite of a relatively high proportion of arable and irrigated cropped area, land productivity in the southwestern plains of Uttar Pradesh is low. This is largely on account of cultivation of low value crops principally wheat and bajra. The region covers the districts of Badaun, Aligarh, Mathura, Agra, Etah, Farrukhabad, Kannauj, Mainpuri, Firozabad, Etawah, Kanpur Dehat and Kanpur. The climate is semi-arid and the soil type is alluvium calcareous clay. The region receives about 721 mm of rainfall. More than 74% of the net sown area is irrigated and over 69% land is cultivated.

1

1 Link: http://farmech.dac.gov.in/FarmerGuide/UP/UI.htm





4.7 Climatic Data from Secondary Sources

The climate in the region is characterized by a hot summer and general dryness except in the southwest monsoon season. The year may be divided into four seasons. The cold season from December to February is followed by the hot season from March to May. The period from June to September is the Southwest monsoon season. October and November constitute the post-monsoon or retreating monsoon season

Temperature2

The period from March to june is of continuous increase in temperatures. May and June are generally the hottest month with a mean daily maximum temperature of 44.5˚C and mean daily minimum of about 25.6˚C and 28. 6˚C respectively. The weather is intensely hot in summer and on some days the day temperature may reach up to 40.8˚C.

From November, both day and night temperatures begin to decrease rapidly. January is generally the coldest month with the mean daily maximum temperature at about 22.8˚C and mean daily minimum at about 8.0˚C.

Wind2

Long term wind direction is presented in Table 4-3. During July to September, that is during the monsoon season wind blows mostly from East. During the period from October to February, wind mostly blows from west. During March to May wind mostly blows from west direction

Table 4-3: Month wise Predominant Wind Direction-Kanpur Predominant

Wind Direction

First Predominant Wind Direction

Second Predominant wind Direction

Third Predominant wind Direction

Month Mor Eve Mor Eve Mor Eve

January W W E NW NW E/W

February W W E NW NW E

March W W NW NW SW E

April W W NW NW E N

May W W E NW NW E

June W NW E W NW E

July E E W W SW NW

August E E W W SE SE

September E E W W SE N

October W E E W N/NE/S/SW N

November W W E N N/NW NE

December W W NW N N/NE NW

Rainfall2

The distribution of rainfall in the Kanpur region, which includes the study area, is uneven. Annual rainfall in the region is 802.1 mm. About 91% of the annual rainfall in the region is received during the southwest monsoon months i.e. June to September.

1

2 Indian Meteorological Department (IMD), Long Term Climatological Tables (1961-1990), Kanpur (A)





Humidity2

Most humid conditions are found in the monsoons. Mornings are more humid than evenings and humidity ranges from a high of 78-87% in monsoon mornings to a low of 37-40% in winter evenings. During post-monsoon season, in morning humidity remains between 67-77 % and in the evening it remains between 42-49%.

Table 4-4: Average Meteorological Conditions at IMD Kanpur

Month

Mean Daily Temperature Rainfall (mm)

Monthly Total

No. of Rainy days

Relative Humidity

(%), Morning

Relative Humidity

(%), Evening

Max Min

January 22.8 8 12.8 0.9 79 51

February 26 11.1 16.9 1.5 70 42

March 32 15.8 3.9 0.4 55 31

April 38.1 21.4 5.2 0.5 41 26

May 40.8 25.6 13.1 0.9 42 26

June 40.1 28.4 60.5 3.2 56 41

July 34.5 26.6 233 10.9 80 67

August 32.6 25.9 284 12 86 75

September 33 24.8 118 5.9 81 69

October 32.7 19.3 44.1 1.6 69 55

November 29.1 12.9 1.1 0.2 67 50

December 24 8.3 9.5 0.9 76 53

Total / Mean

32.1 19.0 802.1 38.9 67 49

4.8 Social Infrastructure Available

KNPL Jainpur team is totally committed towards our Corporate Social Responsibility Programs & various projects are being taken accordingly.

KNPL Jainpur is focusing on

Ensuring Environmental Sustainability

We have developed Green Belt, off the highway and approach road near KNPL Jainpur Plant.

Rural Development / Community Development

We have installed Bore wells (Hand Pumps) - 02 nos under community development programs & RO system along with water coolers l in SMD Kanpur Dehat office for the benefits of visitors coming to Akabarpur Telshil from neighbouring villages.

Road repaired in nearby vicinity under rural development program.

Preventive Health Care & Sanitation

Organized Health Camp for local villagers under preventive health care and sanitation program.

Apart from this we have proper medical plan for all employees

Pre-Employment Medical Check-up Bi annually medical examination





We provide group Medi-claim policy coverage to our employees and their family members.





5 PLANNING BRIEF

5.1 Planning Concept

M/s. Kansai Nerolac Paints Limited is the project for capacity expansion of integrated paint manufacturing facility at Jainpur, District Kanpur Dehat, Uttar Pradesh. Site is located at the distance of 6.6 KM in SSW direction from Lalpur railway station and approx.9 km in east direction from Paman railway station. The nearest airport is Kanpur which is 42 km from the proposed site

5.2 Population Projection

There will not be any permanent migration of people. Hence there should be no population projection.

5.3 Land use planning (breakup alongwith greenbelt etc.)

Area Break up at Site

S. No. Title Area, m2 % of total Area

1 Process area 26432.7 27.6

2 Storage area 0 0.0

a) Hazardous chemical storage area 4318.1 4.5

b) Non-hazardous chemical storage area 7143.12 7.5

c) Hazardous waste 560 0.6

d) Water storage 3000 3.1

e) Fuel , solvent & other liquid chemical storage 1775.1 1.9

3 Waste water treatment plant (ETP & STP) 3000 3.1

4 Boiler 1576.6 1.6

5 Utilities 200 0.2

6 DG & LT room 563.2 0.6

7 Admin Building, security cabin 506.4 0.5

8 Greenbelt area 31533.28 33.0

9 Road 11490 12.0

10 Open space 3497.5 3.7

11 Area of proposed expansion - -

12 Others – parking area, weigh bridge

-

Total 95596 100





5.4 Assessment of Infrastructure Demand (Physical and Social)

The facility is within the UPSIDC industrial area and the proposed project is only an expansion of the existing facility.

Amenities/Facilities

The existing site is having Canteen facility for employees, Occupational Health Center (OHC) and emergency assembly points etc.

5.4.1 Greenbelt Development

Green belt shall be developed in 31533.28 square meter area out of total 95596 square meter area .Development of green belt shall be as per Central Pollution Control Board Plan to ensure at least 33% of coverage.

5.4.2 Fire-fighting system

The fire fighting systems have been categorized into the following types

A) Fire Fighting System –consisting of hydrant system, sprinkler system, foam system and water spray system

B) Portable Fire Extinguishers

C) Fire Extinguishing System

D) Fire Detection and Alarm System

FIRE PROTECTION SYSTEM AT KNPL JAINPUR KANPUR DEHAT

Portable Fire Extinguishers

Extinguisher Type Numbers

DCP –5KG 101

DCP 10 KG 16

DCP 25 KG 1

DCP 75KG 1

CO 2 4.5 KG 85

CO 2 9 KG 5

CO2 22.5 KG 4

MECHANICAL FOAM-9 liter 187



ABC2KG 11

ABC 5 KG 95

TOTAL 524

Other Measures

SAND BUCKETS 200

Fixed Fire Fighting Arrangements

HYDRANT POINTS 107 (Foam Monitor-04 ,Water Monitoring-05,

Hose Reel-04 )

FIRE HOSE BOX With All Hydrant Outlets





FIRE PROTECTION SYSTEM AT KNPL JAINPUR KANPUR DEHAT

Portable Fire Extinguishers

Extinguisher Type Numbers

MONITORS 3

WATER TANK 1200 KL Underground & 1800 KL above ground

Two no fire pump station

PUMPS DIESEL (02)

273M3/Hr (primary feeding to hydrant & secondary to sprinkler if required) & 410M3/Hr

(primary feeding to sprinkler & secondary to fire hydrant if required) auto control

ELECTRICAL PUMP (02)

273M3/Hr(primary feeding to hydrant & secondary to sprinkler if required) & 410 M3/Hr (primary feeding to sprinkler & secondary to fire

hydrant if required) auto control

JOCKEY PUMP (02) 23.4 & 25 METER CUBE PER HOUR auto control

as per pressure set

Line pressure 7 kg/cm2

HOSES With All Hydrant Outlets

Hose Reel 04

Trolly Amounted Foam Monitor(CAP-100 Litre) 1

Foam Making Branch, fog & jet & auto control pressure nozzle

2 +2 +2

Auto foam making branch 08

FIRE SUIT 1

NOZZLE 110

SCBA Set 02

Online Respirator 01

Public Address System 24

Portable Alarm System 01

AFFF Foam Making Agent 1700 Liter & 1000 Liter in foam tank

5.4.3 Storm water management plan

Storms water drains have been provided and storm water from the entire plot is collected through network of storm drains .Most of the storm water from the plot is collected in the rainwater harvesting structure /recharge well provided for better utilization of rainwater .The excess storm water is discharged through storm water drainage facility provided in the industrial complex

5.4.4 Rainwater harvesting system

The roof top water is collected in the recharge well through channels & storm water drains. Recharge well of 100-300 mm diameter is constructed for recharging the deeper aquifers and water will pass through filter media to avoid choking of recharge wells. The ground charging will improve the water level in the vicinity.





6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

Overall plot area is 95596 m2.

6.2 Residential Area (non-processing area)

Not applicable

6.3 Green belt

Green belt will be developed in 31533.28 square meter area out of total 95596 square meter area. .Development of green belt shall be as per Central Pollution Control Board Plan to ensure at least 33% of coverage

6.4 Social Infrastructure

KNPL Jainpur team is totally committed towards our Corporate Social Responsibility Programs & various projects are being taken accordingly.

KNPL Jainpur is focusing on

Ensuring Environmental Sustainability

We have developed Green Belt, off the highway and approach road near KNPL Jainpur Plant.

Rural Development / Community Development

We have installed Bore wells (Hand Pumps) - 02 nos under community development programs & RO system along with water coolers l in SMD Kanpur Dehat office for the benefits of visitors coming to Akabarpur Tehsil from neighbouring villages.

Road repaired in nearby vicinity under rural development program.

Preventive Health Care & Sanitation

Organized Health Camp for local villagers under preventive health care and sanitation program.

Apart from this we have proper medical plan for all employees

Pre-employment Medical Check-up Bi annually medical examination

We provide group Medi-claim policy coverage to our employees and their family members.

6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/Water Ways etc.)

6.5.1 By Road

The UPSIDC’s industrial area near village Jainpur in Distrct Kanpur Dehat, is located along the National Highway No-2 (Kolkata to New Delhi Highway)





6.5.2 By Rail

Tilauchi railway station is the nearest station on the broad gauge rail line of Northen Railways at the distance of 3.7 Km south of the industry.

6.5.3 By Air

Kanpur airport is the nearest from the site but there is no regular air service for all part of country. It is approx. 38 Km from the Industrial site. Chaudhary Charan Singh International Airport in Lucknow is the alternative choice of having regular air service for all the part of the country is approx. 139 KM from the Industrial site

6.5.4 By Water

Not applicable

6.6 Sewage system

Domestic waste water will be treated in to STP and will be reused for gardening purpose

6.7 Industrial Waste Management

During paints manufacturing process ,various industrial streams will be generated from various sources due to manufacturing activities .Effluent steam will be generated from paint manufacturing process during activities such as cleaning of mixers ,equipments cleaning etc .In addition to this he utility waste water stream viz cooling tower blow down, boiler blow down ,backwash of DM plant will also be generated .The liquid effluent will be treated full-fledged Effluent treatment plant comprised of primary ,secondary and tertiary treatment .The treated effluent will be further processed in UF/RO and the permeate will be used for cooling tower and boiler makeup .The reject will be treated in multiple effect evaporator (MEE) .The dirty salt form will be disposed off as land filling through TSDF.

Other industrial wastes like process waste /paints sludge/residue etc will be stored in designated place in factory premises disposed-off through TSDF. Discarded containers/drums etc will be disposed through authorized recycler.

There are two type of waste generated process waste and non-process waste which may or may not be hazardous in nature .There is no solid waste generation during manufacturing process itself .The waste water from manufacturing process, washing etc. will be treated in the ETP .The other type of solid wastes generated will include the dust collected from dust collectors, empty barrels (metal & plastic) bags, and other biodegradable waste from canteen.

Solid waste of organic in nature such as canteen waste, sweeping etc. will be composed or vermin composed for use as manure in the green belt and lawn. Other non-hazardous type of waste like empty containers, bags, paper bags, metal, wooden waste etc. will be sold to external agency.

The hazardous waste will be disposed-off through TSDF and approved recycler.

6.7.1 Details of ETP During paint manufacturing process, various effluent streams are generated at various sources due to carry out manufacturing activities. Effluent streams are generated from paint and resin manufacturing block during activities such as reaction water, cleaning of reactor/mixers, equipment cleaning, calibration of vessels, cleaning of barrels and containers etc. In addition to above, the utility waste water streams viz. cooling tower blow down, boiler blow down, backwash of DM plant are also discharged from the manufacturing plant to ETP. The domestic waste water





i.e. sewage are discharged to STP from various blocks such as administration building, canteens, toilets & washrooms for truck drivers & cleaners. The domestic effluent and trade effluents will be treated separately in STP and ETP respectively. Present treatment process The following treatment steps are adopted in KNPL to treat its waste water to meet UPPCB permissible standard for final discharge.

Equalization cum neutralization tank: The industrial waste water containing wash water and domestic water is collected in two different equalization tanks through drains. In Equalization cum neutralization tank the effluent is equalized / neutralized and also homogenized. The mixing within equalization tanks is done by air diffusion through coarse bubble aeration

Primary treatment The homogenized effluent then passes through the flash mixer provided with alum dosing to enhance the formation of flocks. The effluent then flows to primary clarifier provided with hopper bottom to enhance the settling of sludge in the form of flocks.

Secondary treatment: The secondary Treatment is based on the principal of aerobic biological oxidation. Bio-reactors contain biological mass kept in suspension. The mixing and oxygen transfer within the bio-reactors is done by diffusing air from air blowers through high efficiency fine bubble diffusers. The MLVSS from the Bio-Reactors over-flow to respective secondary clarifiers for settling. Settled bio-mass is recycled back to bio-reactor to maintain the MLVSS concentration and excess bio-mass wasted periodically.

Tertiary treatment: The effluent from Secondary clarifier flows to the intermediate tank and then pumped to PSF for removing any fine TSS and then to Activated carbon filters for adsorption of refractory COD and the treated water will be collected in the final treated water tank for disposal.





Figure 6-1: PROCESS FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT It is ensured that the treated waste water meets the standards specified for paints industry waste water discharge under the environmental (Protection) Act 1986 and Environmental (Protection) Rules, 1986.

Industrial Effluent

Equalization Tank

Oil & grease Removal

Flash Mixing/ Coagulation/ Flocculation

Primary Clarification

Bio Reactor Secondary clarifier

Filter press

Sludge drying bed

Pressure Sand Filter

Activated Carbon Filter

Gardening/ Fire service

To UPSIDC common drain





6.7.2 Scheme for Sewage treatment plant

The sewage water generated at various locations is screened & centrally collected in a sewage collection cum equalization tank wherein, the surges of flow are contained. The screened sewage is pumped out from the equalization tank to the Digester which consists of a MBBR reactor and a Tube Deck Clarifier. The water enters the top of the reactor & flows through the media in the reactor. A continuous stream of air in counter current mode aerates the sewage which flows down the reactor. The aeration of the sewage is done by fine pore sub – surface diffusers which provide the oxygen for organic digestion.

Continuous aeration ensures aerobic activity on the surface of the media. Micro – organisms attach themselves on the media & grow into dense films of a viscous jelly like nature. From the MBBR reactor the digested sewage overflows into a tube deck clarifier operating on a low hydraulic loading. Before it enters the tube deck clarifier the water is dosed with a dilute solution of alum & lime. As the water comes up through the media the suspended particles & sludge are retained & clear water overflows into the overflow chamber. The sludge collects in the tapered bottom of the settler & is periodically drained out. The clarified water from the overflow chamber of the digester is pumped through a sand filter & an activated carbon filter for removal of suspended impurities & traces of organic matter respectively. The filtered water is then dosed on-line with a dilute solution of chlorine. This water will be used for gardening & toilet flushing purposes.

Figure 6-2: Schematic Diagram of STP

6.8 Power Requirement & Supply/ Source

The manufacturing facility is located in the designated industrial area of UPSIDC in Jainpur .The Power is supplied by Electricity Distribution Division Kanpur Dehat ,State Electricity Board .the present average consumption of power 1926 KVA ,stand by DGS with total capacities (320 KVA x 2,520 KVAx3, 500KVA x1,1500KVA x2 ) KVA will be present .





7 REHABILITATION AND RESETTLEMENTS (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 labourers (a brief outline to be given)

The plot is in Jainpur industrial area and allotted by UPSIDC. Hence, this point is not applicable.





8 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given).

Not applicable.

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

The project is to optimum utilization of existing facility to enhance production capacity. The investment will be of 15 crores only.





9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.

The plant is in operation and it generates both direct and indirect employment in nearby plant area. The preference are given for local population for employment in semi-skilled and unskilled category. The indirect employment is created by the plant for supply of daily domestic goods, loading/ unloading operations etc.

The plant site area is equipped with sufficient infrastructural facilities including drinking water toilets, sanitation facilities, health centers etc.

From the above analysis it would be clear that the project is attractive and already brought high value addition to the feedstock thereby benefiting the industry and the nation. Project has excellent connectivity through Road and Railway

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F: +91-124-4242433

Kadam Environmental Consultants www . ka dame nv i r o . c o m

Envi r onment for D eve l opme nt

M/S. KANSAI NEROLAC PAINTS LIMITEDenvironmentclearance.nic.in/writereaddata/Online/TOR/24...M/S....

Documents

Transcript of M/S. KANSAI NEROLAC PAINTS LIMITEDenvironmentclearance.nic.in/writereaddata/Online/TOR/24...M/S....