PROJECT PRE FEASIBILITY...

PROJECT PRE FEASIBILITY REPORT

On

DEBOTTELNECKING OF EXISTING POLYESTER PLANT

For

INCREASE IN PRODUCTION CAPACITY

At

Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3, 183/4, 183/8A, 183/9A, 184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4, 203/1, 203/2,

203/3, 203/4, 203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6, 210/7, 211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3, 225/1, 229/1A, 229/2, Dabhel

Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).

Project proponent

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CONTENTS

LIST OF CHAPTERS Sr. No. Particulars Page No.

1 Executive Summary 1 2 Introduction of the Project 3 2.1 Identification of the Project and Project Proponent 3 2.1.1 Identification of the Project 3 2.1.2 Project Proponent 4 2.1.3 Nature of the Project 5 2.1.4 Need of the Project & Demand-Supply Gap 5 2.1.5 Import vs. Indigenous Production 5 2.1.6 Export Possibility 6 2.1.7 Domestic/Export Markets 6 2.1.8 Employment generation due to Project 6 3 Project Description 7 3.1 Type & Location of the Project 7 3.1.1 Type 7 3.1.2 Location 7 3.2 Details of the Alternative Site 9 3.3 Size & Magnitude of Operation 10 3.4 Project Description with Process Details 10 3.4.1 Brief about the Technology – POY, FDY & PSF 10 3.4.1.1 Operating Philosophy for Process vapour

absorption Chiller 12

3.4.2 Manufacturing Process of POY & FDY 13 3.4.2.1 Chemical Reactions 13 3.4.2.2 Process flow Diagram 15 3.4.2.3 Process Description 16 3.4.2.4 Material Mass Balance 17 3.4.2.5 Filament Yarn (Partially Oriented Yarn – POY) 18 3.4.2.6 Filament Yarn (Full Drawn Yarn – FDY) 18 3.4.2.7 Polyester Staple Fiber – (PSF) 18 3.5 Raw Materials for finished Products 19 3.6 Hazardous Chemicals Storage & Handling 20 3.7 Resource Optimization & Availability 21 3.7.1 Land & Building requirement 21 3.7.2 Equipment 21 3.7.3 Power & Fuel Requirement 24

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3.7.4 Water Requirement 25 3.7.5 Man – Power Requirement 26 3.8 Quantity of Waste to be generated 26 3.8.1 Wastewater generation & Management 26 3.8.2 Wastewater characteristics 28 3.8.3 Waste water treatment & disposal 29 3.8.4 Air Emission & Control 30 3.8.4.1 Process Emission 30 3.8.4.2 Utility Emission 31 3.8.4.3 Fugitive Emission 32 3.8.5 Hazardous & Non – Hazardous waste management 32 3.8.6 Noise Control 33 3.9 Health & Safety Measures 34 3.10 Environment Health & Safety Cell 35 3.11 Post Project Monitoring Plan 35 4 Site Analysis 37 4.1 Connectivity 37 4.2 Land Form, Land use & Land ownership 37 4.2.1 Land Form 37 4.2.2 Land use Pattern 37 4.2.3 Land Ownership 37 4.3 Topography 38 4.4 Salient features 38 4.5 Existing Infrastructure 38 4.6 Soil Classification 39 4.7 Climate & Meteorology 39 4.7.1 Temperature 40 4.7.2 Humidity 40 4.7.3 Cloud Cover 40 4.7.4 Rainfall 40 4.7.5 Wind Pattern 40 4.8 Social Infrastructure 40 4.8.1 Educational Facilities 41 4.8.2 Medical Facilities 41 5 Planning Brief 42 5.1 Planning Concept 42 5.2 Population Projection 42 5.3 Area Statement 42 5.4 Assessment of Infrastructure Demand 43 5.5 Amenities/Facilities 43 5.5.1 Drinking water Facilities 43 5.5.2 Power Supply Facilities 43 5.5.3 Communication & Banking Facilities 44 5.5.4 Transport Facilities 44

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6 Proposed Infrastructure 45 6.1 Industrial Area 45 6.2 Residential Area 45 6.3 Greenbelt 45 6.4 Social Infrastructure 45 6.5 Connectivity 45 6.6 Drinking Water Management 46 6.7 Sewerage System 46 6.8 Industrial waste Management 46 6.9 Solid Waste Management 46 6.10 Power Requirement & Source of Supply 46 7 Rehabilitation & Resettlement (R&R) Plan 47 7.1 Policy to be Adopted 47 8 Project Schedule & Cost Estimates 48 8.1 Time Schedule of the project 48 8.2 Estimated Project Cost 48 9 Analysis of Proposal 50 9.1 Financial & Social Benefits 50

LIST OF TABLES Sr. No. Particulars Page No.

Table 1.1 Project Summary 1 Table 2.1 List of Products 4 Table 2.2 Details of Proponent 4 Table 3.1 Molecular Weight of Reactants & Products 15 Table 3.2 List of Raw Materials 20 Table 3.3 Storage, Handling & Transport of Chemicals 20 Table 3.4 Characteristics of Raw Materials 20 Table 3.5 List of Equipment & Machinery 21 Table 3.6 Detail of Power 25 Table 3.7 Fuel Requirement 25 Table 3.8 Category wise Water Requirement 26 Table 3.9 Man Power Requirement 26 Table 3.10 Category wise waste water generation 27 Table 3.11 Expected Characteristics of Waste water 28 Table 3.12 Details of Process Emission 30 Table 3.13 Details of Utility Emission 31 Table 3.14 Details of Hazardous waste generation & Disposal 33 Table 3.15 Noise level with company premises 34 Table 3.16 Post Project monitoring plan 36 Table 4.1 Salient features of the Project Site 38 Table 4.2 Summary of Meteorological Data at nearest IMD 39

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Station – Dahanu Table 5.1 Distribution of Population 42 Table 5.2 Area Statement 43 Table 8.1 Total Capital Cost Projection 48 Table 8.2 Recurring Cost provision of EHS 49

LIST OF FIGURES S.No. Particulars Page No. Figure 3.1 Project Site 8 Figure 3.2 Layout of Project Site 9 Figure 3.3 General Schematic of Vapour Absorption

Machine 13

Figure 3.4 Typical material mass balance for manufacturing of POY/ FDY/ PSF

17

Figure 3.5 (a) Water Balance Diagram – Existing Scenario (in KLD)

27

Figure 3.5 (b) Water Balance Diagram – Proposed Scenario (in KLD)

28

Figure 3.6 Schematic Diagram of Effluent treatment plant 30

LIST OF ANNEXURES S.No. Particulars Page No. Annexure – I (a) Copy of Existing EC A Annexure – I (a) Forwarding Letter for EC Compliance Report

Submitted to RO Bhopal F

Annexure – I (a) G Annexure – II Copy of Existing CC&A H Annexure – III Water drawl Permission L

Project Pre-feasibility Report

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Project: Debottlenecking of existing plant for increase in production capacity

CHAPTER – 1 EXECUTIVE SUMMARY The project is summarized in the below table: Table1.1: Project Summary

PARTICULARS DETAILS NAME OF THE UNIT

M/s. Wellknown Polyester Ltd.

OCCUPIER Mr. R. P. Shah PRODUCTS S. No. Product Production Capacity (TPD)

Existing Proposed Total 1. Partially Oriented Yarn (POY)/ Fully drawn

Yarn (FDY)/ Draw Texturized Yarn (DTY) 900 100 1000

2. PSF (Polyester Staple Fiber) - 500 500 Total 900 600 1500 Note: POY & FDY manufactured through continuous polymerization process using raw materials such as PTA + MEG.

LOCATION Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3, 183/4, 183/8A, 183/9A, 184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4, 203/1, 203/2, 203/3, 203/4, 203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6, 210/7, 211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3, 225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).

NATURE OF PROJECT

Debottlenecking of existing plant for increase in production capacity

RESOURCES Resource type Requirement Source Land Existing Scenario: 42395 m2

Proposed Scenario: 182059 m2 Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman

Building Existing Scenario: 8045 m2 Proposed Scenario: 56438 m2

Construction material will be purchased from local market.

Raw-materials (Quantity in MT/MT)

PTA = 0.858 MEG = 0.325 Antimony Trioxide = 0.0003 Titanium Dioxide = 0.0027

PTA - Reliance, MCPI, IOCL MEG - Reliance, SABIC, India Glycol, IOCL Antimoney Trioxide - Paras, Canlong Titanium Dioxide - Hombiton, Fuji, Precheza

Power Existing Scenario: 15.95 MW Proposed Scenario: 21 MW

Electricity Board

Fuel Existing Scenario: FO – 25 KLD LDO – 100 lit/hr Proposed Scenario: FO – 103 KLD Coal – 35 TPD LDO – 125 lit/hr

FO – Reliance Industries Ltd. Coal – Imported & Indigenous LDO – Local Market

Water Existing Scenario (Fresh Water): • Domestic: 14 KLD • Industrial: 100 KLD Proposed Scenario (Fresh Water): • Domestic: 20 KLD • Industrial: 469 KLD

Dabhel Gram Panchayat Pond/ Damanganga Canal

Man-power Existing Scenario: 250 Nos. Proposed Scenario: 361 Nos.

Local Area

POLLUTION POTENTIAL & MITIGATION MEASURES Parameter Potential Mitigation


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PARTICULARS DETAILS Wastewater Existing Scenario:

• Domestic: 11.5 KLD • Industrial: 252 KLD Proposed Scenario: • Domestic: 15 KLD Industrial: 391 KLD

• In the existing operation, the total Domestic wastewater generated is @ 11.5 KLD, which is being diverted to the septic tank/ soak pit system. Wastewater generated from industrial activities @173 KLD which is diverted to the Cooling tower as makeup water after ETP treatment . Blow down from cooling tower generated @79 KLD from which 50 KLD is recycled as CT makeup water & 29 KLD for gardening.

• Whereas, after proposed expansion project, domestic waste water generation will be @15 KLD & from industrial activities 305 KLD will be diverted to the Cooling tower as makeup water after ETP treatment. Blow down from cooling tower generated @86 KLD from which 35 KLD is recycled as CT makeup water & 51 KLD for gardening.

Air Emissions Emission norms for Boiler, Thermic Fluid Heater & DG set • PM < 150 mg/Nm3 • SO2 <100 ppm • NOx < 50 ppm

• In existing installations, the company has 2 Nos of Thermic Fluid Heater each having capacity of 10 million K.cal/Hr. The company has also 12 Nos. of D.G. set of 625 kVA capacity. The D.G. Set acts as standby unit and is only utilized in case of power failure.

• FO is used as fuel in the Thermic Fluid Heaters & LDO is used as fuel in the D.G set.

• For proposed expansion project, 3 nos. of TFH of capacity 8 Milillion.Kcal/hr (2 working + 1 standby) & two nos. of dual fired steam boiler of 10 TPH capacity (1 working + 1 standby).

• FO will be used as fuel in TFH & imported coal or FO will be used as fuel in dual fired steam boiler.

• The Company also proposes to install 15 Nos. of D.G. set of 625 kVA capacities.

• Adequate chimney height is/ will be provided. • Raw Materials & Products is/ will be stored in properly designated storage

area and under good storage conditions to prevent any volatilities. • Regular monitoring is/ will be done of piping and fittings for checking of

any leakages. • Good housekeeping is/ will be maintained in the plant.

Hazardous & solid waste

Types of Waste

Existing Quantity

Proposed Quantity

Hazardous Waste ETP Waste

400 Kgs/Month

700 Kgs/Month

Used oil 125 lts./Month

350 lts/month

Empty bags

23200 Nos/Month

26070 Bags/Month

Empty PP Liner

24000 Nos/Month

37500 Bags/Month

Empty drums

135 Drums/Month

120 Carboys/ Month

Polymer waste

8.2 MT/Month 35 MT/Month

Non - Hazardous Waste Fly Ash -- 125

MT/Month

• The Hazardous wastes are handled, stored & transported as per CPCB/ MoEF Guidelines

• ETP sludge is/ will be disposed to GEPIL, Silvassa. • Empty bags/ PP liners is/ will be Reused/Sale after decontamination. • Empty drums is/ will be sold to authorized reconditioners • Used oil is/ will be sold to CPCB registered recyclers. • Polymer waste is/ will be sold to actual users. • Fly ash will be sold to brick manufacturers.

Noise Expected levels Inside the plant: <75dB(A)

• The major sources of noise generation in plant area shall be the pumps and motors.

• Regular maintenance will be done • Accoustic enclosure will be provided to DG set.


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CHAPTER – 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT

M/s. Wellknown Group of companies have two plants located in the near vicinity in Village-

Dabhel, Daman (U.T.) which is already manufacturing “Polyester Draw Texturised Yarn & Fully Drawn Yarn. The production started with Twisting & Texturising of POY in 1989.

Manufacturing of fancy yarn was added in 1999.

One of the existing units named “Wellknown Polyester Ltd.” located at Survey No. 178 & 185/2,

216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6,

216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel,

Daman-396 210 (U.T.) has obtained EC for manufacturing of POY the primary raw material for

the production of Polyester Drawn Texturised Yarn (DTY) through continuous polymerization

process using raw materials such as PTA and MEG as a part of its backward integration

program in 2008. It is a continuous polymerization unit where POY (Partially oriented yarn) and

FDY (Fully drawn yarn) are produced. POY is used for captive consumption of DTY and the

excess is sold in the open market while FDY is final product. The copy of EC & its Forwarding

Letter with Register AD Post Slip for EC Compliance Report Submitted to RO Bhopal is

attached as Annexure – 1 (a), 1 (b) & 1 (c) respectively.

Now the company plans for debottlenecking of existing plant for increase in production capacity

by adding a similar category product PSF (Polyester Staple Fiber) from 900 TPD to 1500 TPD

at existing site as well as plots closer to existing plots located at Survey No. 178, 185/2, 216/1,

216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7,

219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3,

183/4, 183/8A, 183/9A, 184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4,

203/1, 203/2, 203/3, 203/4, 203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6, 210/7,

211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3, 225/1,

229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).


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Through debottlenecking of existing continuous polymerization process additional melt will be

produced and it will be used to make PSF similar to the POY and FDY. Debottlenecking will be

done by adding vessels in cascade/ series to the existing process stream. The reactors capacity

and reliability will be augmented by adding conveying unit, enhancing pump capacity, doing

modification for reactors level indication, Improving agitation and vapour line profile of reactors

and separation columns. The list wise product expansion is as given below:

Table 2.1: List of Products

S. No. Product Production Capacity (TPD)Existing Proposed Total

1. Partially Oriented Yarn (POY)/ Fully drawn Yarn (FDY)/ Draw Texturized Yarn (DTY)

900 100 1000

2. PSF (Polyester Staple Fiber) - 500 500Total 900 600 1500Note: POY & FDY manufactured through continuous polymerization process using raw materials such as PTA + MEG.

The copy of existing CC&A is attached as Annexure – 2.

2.1.2 PROJECT PROPONENT

Wellknown Group of companies was promoted by Gupta Family in the year 1987. The promoter

has experience of over a decade in the various fields in textile business. Under their leadership,

the Group has grown rapidly. It commands very good respect in the field of Textiles and its

stature is growing with passage of time.

1. Shri Anil Gupta Mr. Gupta is a Commerce Graduate and is in the textile business for over 40 years. He started

his career by joining the family’s textile manufacturing & trading business. He gained experience

in weaving and processing of various textile materials including suiting, shirting, sarees, dress

materials & home linen. Later, in the year 1988 he set off on his own to promote Wellknown

Polyester Ltd. In 1990, Wellknown Polyester Ltd. started operation with manufacturing of DTY at

Dabhel the UT of Daman. Under the leadership of Mr. Gupta, over the years the Company has

expanded its capacity and now the Company has two plants in close proximity to one another.

Table 2.2: Details of Proponent Sr. No. Name of Directors Residential Address 1.

Mr. Anil Gupta

28, SWDESHI Market, Dr. Viegas Street, Kalbadevi Road, Mumbai - 400002


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2.1.3 NATURE OF THE PROJECT

The proposed expansion project involves the production of “Manmade fiber such as PSF through continuous polymerization”, which falls under item no. 5(d) i.e. manmade fibres manufacturing and under the category B as per the EIA notification, 14 September 2006 (as

amended timely). However, the project is to be considered at central level due to the

applicability of general conditions – presence of state boundary of Gujarat within 5 km radial

periphery.

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP

Wellknown Polyester Ltd is proposing to debottleneck of its existing plant for increase in

production capacity by adding a similar category product PSF.

Presently PSF is contributing 8% annual growth in polyester market. With PSF manufacturing

facility, we will have market share in these segments. The product mix of POY, DTY, FDY and

PSF will give competitive edge to the company as it is contributed in polyester market growth.

Operation of the plant at higher capacity with PSF stream will reduce the conversion cost due to

energy efficient operation of the plant. Thus the bushiness viability will be further improved.

To improve the base line it is important to have reduction in the manufacturing cost of finished

product. The fuel cost is one of the major inputs in the manufacturing of finished goods.

WPL is also proposes to include Coal as an alternative fuel to the existing fuel viz. FO in

proposed dual fired steam boiler. The ‘addition of Fuel’ is proposed due to the following

reasons:

• Techno-commercial viability of coal vis-à-vis FO.

• Coal is economical than FO

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION

The consumers of POY, FDY & PSF are located in and around the area of existing facility. By

doing so, it would also result in saving transportation cost.


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2.1.6 EXPORT POSSIBILITY The product has also huge international market demand to earn foreign exchange.

2.1.7 DOMESTIC / EXPORT MARKETS Market for the proposed products includes not only the domestic market but also the

international market.

2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT The proposed project will provide direct employment opportunity to additional 111 persons. The

man-power required for the project will be employed locally from the nearby areas.


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CHAPTER – 3

PROJECT DISCRIPTION

3.1 TYPE & LOCATION OF PROJECT

3.1.1 TYPE The proposed project is the type of expansion project for manufacturing of manmade fibers.

3.1.2 LOCATION The proposed project is located at Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4, 216/5,

210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7, 219, 223/1, 223/2, 223/4,

223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3, 183/4, 183/8A, 183/9A, 184,

185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4, 203/1, 203/2, 203/3, 203/4,

203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6, 210/7, 211/1, 212, 212/B, 213/5 to

213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3, 225/1, 229/1A, 229/2, Dabhel Ind.

Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).

There are some more than 600 small scale industries present in Daman and Diu. The main

industries are located at Somnath, Dabhel, Bhimpore and Kadaiya.

The Union Territory of Daman and Diu has an industrial development corporation known as the

Omnibus Industrial Development Corporation (OIDC).

It is a multipurpose organization performing diverse activities like housing, industrial estates,

promoting tourism, quality liquor, branded computers and providing raw material to the industrial

units. The region is well planned with all the basic infrastructural facilities like internal roads,

water supply, arrangements for power, streetlights & other common facilities like Hospitals,

Hotels, Banks, Meeting Halls, etc.

Location of project site is shown in figures 3.1 and Layout is shown in figure 3.2.


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Figure 3.1: Project Site


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Figure 3.2: Layout Project Site

3.2 DETAILS OF THE ALTERNATIVE SITE

The factors involved in the selection of existing site for expansions are:

• New plots are purchased for proposed expansion that is closer to the existing unit which is

already engaged in manufacturing activity.


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• Secondly, it is surrounded by cluster of industries and hence the basic infrastructure is

readily available.

• There is no Octroi Duty and power is available at subsidized rates in the region.

• Government Tax holidays for promoting the manufacturing units.

• The further integrated set-up for utilizing the product of this plant is already planned. This

reduces intermediate transports and packing which help in reducing the manufacturing cost

of further product.

• Water is available from nearby canal/Panchayat Pond.

• The territory’s vicinity to well-developed industrial estate in Vapi, Silvassa & Sarigam also

plays an important role in the site selection.

Based on the above reasons, this location is most suitable for the proposed expansion project

and hence no other alternative site is selected.

3.3 SIZE & MAGNITUDE OF OPERATION The total magnitude of operation will be 1500 TPD.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS The proposed products process details like Process Description, Material Balance and

Chemical Reaction are as below –

3.4.1 BRIEF ABOUT THE TECHNOLOGY – POY, FDY & PSF

Continuous Polymerisation process for POY manufacturing is in vogue for many years now. In

the initial years, continuous polymerisation technology and plant were supplied by few

renowned suppliers like Du Pont-Chemtex & Zimmer. However, over the years the technology

has been well absorbed and now there are number of technology suppliers offering Continuous

Polymerisation technology and plants. Most of these suppliers procure critical components like

finishers and polymer pumps from sources considered by original proponents of technology like

Zimmer and Du Pont-Chemtex.

WPL has decided to source technology and plant from BARMAG.


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BARMAG is able to supply process technology, engineering design and complete equipment,

and performance test in accordance with international practice. BARMAG is an ISO 9001

certified company. It has also achieved Class A certificate for the design of textile, finishing,

chemical fibre, petrochemical and civil and also other project engineering related certificates.

The factors favouring BARMAG Technology includes:

• Proven track record of BARMAG has supplied Continuous Polymerisation technology

and plant to more than 20 units in China, some of which are large and important players

in PFY/ PSF market.

• The process for reduction of Polyethylene Terephthalate (PET) with PTA and MEG as

developed by BARMAG is characterized with up to date technology having more

operational flexibility, high automation and less pollution/waste emissions.

• Lesser number of reactors would lead to lower residence time, which would mean more

flexibility. This would enable Wellknown Polyester Ltd. to ensure higher returns.

• Total EG recovery and recycle is achieved by using the efficient process column.

• Various consumption indexes of raw materials and utilities are comparable to the

stipulation of other leading polyester companies in the world and the design can be

suitably tailor-made to suit the requirement of the customers.

• The overall cost economics (i.e. Capital and Operating Cost) based on BARMAG

technology is very favorable.

BARMAG, the technology supplier, has given due consideration to Safety & Health,

Environment and Energy conservation while designing the plant. The key features are as

follows:

• For generating vacuum in the reactors, BARMAG has considered Mono Ethylene Glycol

Ejectors instead of Steam Ejectors. This system enables total recycling of MEG from

jets.

• Reaction water from the Esterification Reactor is separated in a Separation column from

Ethylene Glycol. The separated reaction water is contaminated with Ethylene Glycol and

low boiling organic compounds. This water is sent to Stripping Column. Where air is

used as a stripping media. The air strips off low boiling organic compounds and is

passed through condenser to get recovery of Alcohol. The condensate water & low


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boiling organic compounds are separated in separator & the clean water is then

transferred to ETP for further treatment.

• The complete plant is designed with sophisticated safety Interlock for the safety of

Equipment as well as of Process, and in turn Human safety. Complete instrumentation is

through a centrally located Distributed Control System.

• The waste heat generated in Separation Column shall be used for Chilled water

generation. Thus the waste heat is used and in turn saves energy. Due to this, lot of

Electricity (Power) would be saved. The detailed description of this process is given

below.

3.4.1.1 OPERATING PHILOSOPHY FOR PROCES VAPOR ABSORPTION CHILLER

Process vapors from process column enter in the generator of Vapor Absorption Chiller.

Lithium Bromide solution is heated with process vapors and water gets evaporated. Due to

water removal of water, lithium bromide solution gets concentrated.

Water vapor from generator enters the condenser where cooling water is circulated in tubes.

Water vapor gets condensed in condenser and enters the evaporator. Concentrated lithium

bromide enters the absorber where 0.8 Kpa vacuum is maintained.

Concentrated lithium bromide absorbs moisture from evaporator which results into low temp

in evaporator.

Due to low temp the water takes heat from chilled water which is circulated in evaporator

tubes and chilled water temp comes down.

The chilled water from chiller outlet goes to plant for cooling purpose and comes back to

chiller after taking heat from process.

The process has been made very environmental friendly with following steps:

Off gases generation is reduced due to usage of glycol ejectors.

The balance off - gas is scrubbed in water which is further treated.

The waste heat generated in Process column is being used for chilled water generation

which has reduced cooling water requirement in process compared to other technology

supplier.

At most of places at higher heat loading points air cooled heat exchanger are planned to

install, which will help in cooling water loading drastically compared to other technology

supplier.

The schematic diagram for Process column/ VAM is shown below.


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Figure 3.1: General Schematic of Vapor Absorption Machine (VAM)

3.4.2 MANUFACTURING PROCESS OF POY & FDY

3.4.2.1 CHEMICAL REACTIONS

The first reaction of the process is the esterification reaction. The esterification is a reaction

between acid and alcohol resulting in ester and water.

The esterification reaction, which mainly takes place in the first two reactors, converts Pure

Terephthalic Acid (PTA) with Mono Ethylene Glycol (MEG) to diethylene glycol terephthalate

(DGT) by splitting off water molecules. The reaction is acid catalysed and requires no additional

acid + alcohol ester water saponification

esterification +

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PurifieMono Di-hydPolyetWater

PROCESS

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existing plan

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16


3.4.2.3 PROCESS DESCRIPTION

The manufacturing process consists of three stages, polycondensation, spinning and

processing. There are primarily two raw materials namely; Purified Terephthalic acid (PTA) and

Mono Ethylene Glycol (MEG). The manufacturing process is explained in the subsequent

sections.

The manufacture of polyester basically takes place in two stages.

1. Esterification of Purified terepthalic acid with Mono ethylene glycol to form a monomer -

dihydroxy ethylene terepthalate and water.

2. Polycondensation - This compound is polymersied through polycondensation to form

Polyester, liberating glycol.

These basic processes are carried in 4 vessels where first two stages complete the

esterification and next two stages complete the polycondensation in minimum possible

residence time at lowest possible temperatures. The complete process briefs are as below.

Slurry Preparation:

To obtain a pumpable and homogeneous suspension, PTA and MEG are fed together with

catalyst into slurry preparation vessel, At this stage there is only physical mixing and no

chemical reaction takes place.

Esterification:

The esterification is carried out in two reactors. The PTA slurry is transferred from the slurry

preparation vessel into the first esterification reactor wherein the reaction proceeds and reaches

to 90% conversion. In the second reactor, the conversion reaches to more than 96%

conversion. A complete esterification in the esterification stage is not required. The remaining

esterification proceeds in Prepolycondensation and Polycondensation section.

Prepolycondensation:

The prepolycondensation is carried out in the prepolycondensation reactor. The construction of

Prepoly reactor enhances removal of the excess glycol after the monomer conversion. The

temperature in the prepolycondensation reactor is raised and the pressure is reduced to support

the MEG evaporation. The vacuum of the reactor is produced by the glycol vapour jet. A


17


differential pressure is maintained in two compartments of Pre poly condensor reactor for

avoiding the solid carry overs. The esterification degree increases during the pre poly

condensation to more than 99%.

Polycondensation:

For final polymerization, a Cage type finisher is used, which ensures the shorter residence time

of the product. The cage is designed for high surface renewal of polymer for enhancing the

glycol release from polymer, along with proper heat distribution along polymer with agitation.

This process helps in achieving the desired molecular weight of polymer. Molten Polymer from

Polycondensation enters booster pump where pressure is increased then it goes to spinning

through polymer coolers to produce POY, FDY & PSF.

The results of this process are excellent properties of the product such as low COOH- group,

less viscosity variation, excellent color and high uniformity in the PET- polymer properties which

is desired part for further processing in textile units.

3.4.2.4 MATERIAL MASS BALANCE

The typical material mass balance for manufacturing of POY/ FDY is given below as figure 3.4.

Figure 3.4: Typical material mass balance for manufacturing of POY/ FDY/ PSF


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3.4.2.5 FILAMENT YARN (PARTIALLY ORIENTED YARN - POY)

Molten polymer from CP is fed to individual machines. Here the Molten polymer is pumped

through various Gear Pumps. Polymer passes through a filtration Pack in spinning. Polymer

from the pack of specific number of holes in the form of filaments is exposed to the quenching

zone (air of specific quality) in the Inter flow tube. Spin finish application is done on oiling

guides. Filaments pass from feed roller to lead down roller. Here the Intermingling air is applied.

The filaments are taken on to the paper tubes to form bobbins. POY bobbins are then packed in

the packing boxes.

3.4.2.6 FILAMENT YARN (FULLY DRAWN YARN - FDY)

Molten polymer from CP is fed to individual machines of FDY, which operates comparatively

higher speed than the POY machines. Here the molten polymer is pumped through various gear

pumps. Polymer passes through a filtration pack at spinning. Polymer from the pack of specific

number of holes in the form of filaments is exposed to the quenching zone (air of specific

quality) in the inter flow tube. Spin finish application is done on oiling guides. Filaments pass

from feed roller to led down roller. Here the intermingling air is applied. The winder speed of

FDY machines is high than the POY machines which in term means more production and FDY

do not need further texturising. The filaments are taken on to the paper tubes to form bobbins.

FDY bobbins are the packed in the packing boxes.

3.4.2.7 POLYESTER STAPLE FIBER (PSF)

Polyester Staple Fibers (PSF) is produced from molten polymer by the main conversion steps:

1) Spinning system comprising of extrusion/pumping, melt spinning, spun tow collection

2) Fiber Line consists of drawing, crimping, drier/relaxer

3) cutting and

4) Bailing.

The PSF Fibers produced will go for applications in high tenacity (HT) and modulus such as

“cotton type”, “sewing thread” or as wool-like yarn, in carpets or soft fiberfill etc.


produced in existing CP and will be pumped to make PSF similar to the POY and FDY.

Debottlenecking will be done by adding vessels in cascade/series to the existing process


19


stream. The reactors capacity and reliability will be augmented by adding conveying unit,

enhancing pump capacity, doing improvements for level indication, agitation and vapour line of

reactors and separation columns.

The polymer booster pumps with cooler will be installed for polymer melt transferring to the

newly installed PFS processing Unit (technology collaborator Barmag -Oerlikon-Neumag).

Molten polymer from CP is fed to individual spinning machines through spinning beam for

making spun tow to produce PSF at downstream (fiber line); Here the Molten polymer is

pumped through various Gear Pumps (Polymer booster pumps, spinning metering pumps).

Polymer passes through a filtration Pack. Polymer from the pack of specific number of holes in

the form of filaments is exposed to the quenching zone (air of specific quality) in the Inter floor

spinning duct. Spin finish application is done on oiling cum tow guides. Filaments (as tow) pass

from Fiber draw off wall with reversing rolls to feed roller assembly and lead down from

Sunflower wheels through Tow cutting device into can creel placed on Can Traversing unit.

The spun tow collected in Cans together forms a creel and loaded on fiber line for downstream

processing. In fiber line, the tow from can creel travels through inlet thread guide & tow guide

stand and inters on moisturizing unit followed by draw stand – Draw chest, calendar drier,

spraying device, cooling stand, tow stacker, dance roller then through steam chest into crimper.

By this time tow is imparted with all the textile properties such as denier, tenacity, crimps etc. At

crimper outlet the tow feeding unit is there and processed tow inters to the plate belt drier,

where tow relaxed and stable moisture content is maintained.

Now it enters to draw off frame and through tow tension stand it is fed to the cutter unit where

staple length fiber is cut in desired length.

The generated fiber from cutter directly goes into baler (baling press unit). At baler constant

weight PSF bales are produced and packed in bale cover. A PSF bale from baler through

conveyor goes to storage area and dispatched to the customers.

3.5 RAW MATERIAL FOR FINISHED PRODUCTS The raw materials for the proposed range of products will be indigenously available and will be

also imported. The product-wise raw-material consumption is given in Table 3.2.


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Table 3.2: List of Raw Materials

Name Requirement (MT/MT)

Purified Terephthalic Acid 0.858 Mono Ethylene glycol 0.325 Titanium Dioxide 0.00272 Catalyst 0.0003 Modifier 0.00015

3.6 HAZARDOUS CHEMICAL STORAGE & HANDLING Hazardous chemicals will be used as raw material in the manufacturing process. The storage,

handling & transport of Haz. chemicals is given in table 3.3 and characteristics of raw material is

given in table 3.4.

Table 3.3: Storage, Handling & Transport of Chemicals

Sr. No.

Name of the Chemical

Maximum Storage Capacity

Means of Storage Source of Supply

1. MEG 4500 KL Tank 1- 3000 KL Tank 2- 750 KL Tank 3- 750 KL

Reliance, Sabic, Indian Glycol

2. Antimony trioxide 14 MT Bags – 30 kg Drums- 60 kg

Paras, CanLong

3. Titianium Dioxide 216 MT Bags - 25 kg Bags – 500 kg

Hombitton, Fuji, Precheza

4. Purified Terephthalic Acid

9610 MT Silo – 400 MT+ bags - _1100 Kg & 1200 kg

Reliance, MCPI, IOCL

Table 3.4: Characteristics of Raw Materials

Sr. No.


HAZARD FP (oC)

BP (oC)

MP (oC)

LFL %

UFL %

SP. GR.

VD

1 2 3 4 5 6 7 8 9 10 1. MEG H & F 111 197 -13 3.2 -- 1.12 2.14 2. Antimony trioxide H & F NA* 1425 655 NA* NA* 5.67 NA 3. Titianium Dioxide H NA* 2750 1855 NA* NA* 4.26 NA 4. Purified Terepthalic

Acid H & F 260 NA 300 NA NA NA 5.74

Note: NA = Not available, NA* = Not Applicable, M.P.=Melting Point, B.P.=Boiling Point, F.P.=Flash Point, UEL= Upper flammable limit, LEL= Lower flammable limit, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million


21


Table 3.4 (cont..): Characteristics of Raw Materials Sr. No.


Solubility With water at 25 oC

NFPA TLV PPM TWA

IDLH LC50 Carcinogenic Characteristics H F R

1 2 11 12 13 14 15 16 1. MEG soluble 1 1 0 NA NA >200 NO 2. Antimony

trioxide Insoluble 2 0 0 0.5 NA NA YES

3. Titianium Dioxide

Insoluble 1 0 0 10 NA NA NO

4. Purified Terephthalic Acid

Insoluble 0 1 0 10 NA NA NO

Note: NA = Not available, NA* = Not Applicable, TLV=Threshold Limit Value, LC50= Median Lethal Concentration, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million,

3.7 RESOURCE OPTIMIZATION & AVAILABILITY The major resources for the proposed project will be plant & machinery, raw-materials, power,

fuel, water, man-power, etc.

3.7.1 LAND & BUILDING REQUIREMENT The existing set up is not sufficient to accommodate the proposed expansion project hence the

plots for the existing project has been purchased from private owners and transferred in the

company’s name. The total plot area of the unit is 182059 M2.

3.7.2 EQUIPMENTS Based on process necessity, list of the equipment’s and machinery used in existing operation &

additional equipment’s used for proposed project is provided in table 3.5.

Table 3.5: List of Equipment & Machinery S. No. Equipment’s Quantity Existing Operations 1. Reactors and columns 20 2. Vessels and tanks 55 3. Pumps, 125 4. Vapour Absorption Chillers 4 5. Heat Exchangers 25 6. Filters 8 7. Conveyors, 3


22


S. No. Equipment’s Quantity 8. Ejectors 4

9. Polymer booster pumps 17

10. Evaporators 16

11. Pearl 2

12. Centrifuge 2

13. HTM heaters 2

14. DG sets 12

15. ETP 1

16. POY 24

17. FDY 19

18. DTY (DTex) 132

Proposed Additional

1. Reactors and columns 1

2. Vessels and tanks 10 3. Pumps, 8

4. Vapour Absorption Chillers 1

5. Heat Exchangers 2

6. Filters 2

7. Conveyors, 1

8. Polymer booster pumps 2

9. Evaporators 2

10. HTM heaters (FO fired) 1

11. Steam Boilers (FO/ Coal fired)

12. Pearl 1

13. Centrifuge 1

14. HTM heaters 1

15. Polymer valves 2

16. Polymer Booster pumps 2

17. Polymer cooler & static mixers 2

18. DG sets 4

19. ETP 1

Spinning Equipment’s

20. Polymer Distribution pipeline for 48 positions 1 set

21. Spinning beam arrangement 6 x 8 positions 1 sets

22. Spin Packs diameter 410 mm 72


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S. No. Equipment’s Quantity 23. Spinnerets 680 Holes of round profile 72

24. HTM Vapor generator 3

25. Set of quench air chambers for 48 position 1

38. Air supply/exhaust system 1

35. Spin finish unit 1

36. Quench air unit 1

38. Spin pack mounting and transporting device 1

Fiber Draw-off System

39. Fiber draw-off wall 1

40. Feed roller assembly 1

41. Sunflower unit 1

42. Tow cut off device 1

43. Can traversing unit 1

44. Set of roller tracks 1

45. Can transport trucks 2

46. Set of electrical equipment for spinning & fiber draw-off 1

47. Set of power /control cables and cable trays 1

48. Set of data BUS cables 1

Fiber drawing Equipment’s

49. Can creel 1

50. Thread guides and breaking devices 1

51. Knot detectors for can creel01

52. Set of tow cans 1

53. Inlet thread guide 1

54. Tow guide stand 1

55. Immersion bath 1

56. Secondry circulating system 1

57. 7 roller draw stand 1 1

58. Draw bath heated and cooled 1

59. Secondary circulating system 1

60. 7 roller draw stand 2 1

61. Steam draw chest 1

62. Steam controlling device for calander drier 1

63. Spin finish spraying device 1


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S. No. Equipment’s Quantity 64. 7 Roller draw stand 3 1

65. Tow stacker 1

66. Dancer roller unit 1

67. Steam Chest 1

68. Steam regulating device for steam chest 1

69. Crimper 1

70. Water circulating unit for crimper 1

71. Outlet chute 1

72. Spare crimper head 1

73. Feeding device 1

74. Plate belt drier 1

75. Tow guide roller 1

76. Tension stand 1

77. Cutting machine 1

78. Baling system 1

79. Bale transport trucks 2

80. Set of mechanical devices 1

81. Set of electrical devices 1

82. Set of electrical equipment for drawing line 1

83. Low voltage distribution system 1

84. Battery pack 1

85. Set of power / control cables and cable trays 1

86. Set of data BUS cables 1

87. Process control system 1

88. Set of consumables for first start up 1

89. Set of tools 1

3.7.3 POWER AND FUEL REQUIREMENT The main power supply will be provided by Electricity Department, Daman. The existing power

requirement is 15.95 MW. After proposed project it will be 21 MW. D.G. set will be used for the

power generation in case of power failure from the Electricity Board. The statement showing

bifurcation of power is given below in Table no. 3.6.


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Table 3.6: Details of Power Sr. No.

Particulars ExistingRequirement

(in KW)

Proposed Requirement

(in KW)

Source of Supply

1. CP + POY a) Domestic 100 150 • Electricity department

• 12 nos. of D.G. set of 625 kVA acts as stand by for existing unit.

• 15 nos. of D.G. set of 625 kVA acts as standby for proposed

i

b) Plant 15850 178503. PSF -- 3000

GRAND TOTAL 15950 21000

Furnace Oil is used as fuel in TFH (3 Nos.) and LDO is used as fuel in DG Set to in the existing

project. After proposed project FO will be used as fuel. The fuel requirement is as given below in

Table 3.7.

Table 3.7: Fuel Requirement

Sr. No.

Type of fuel Existing Requirement

Proposed Requirement

Source of supply

1. Furnace Oil (in Thermopack boilers)

25 KLD 115 KLD Reliance IndustriesLtd.

2. Coal -- 35 TPD Imported & Indigenous 3. LDO (in D.G. Set) 100 L/Hr. 100 L/hr Local Market

3.7.4 WATER REQUIREMENT Necessary water requirement for the existing expansion project is catered from the Dabhel

Gram Panchayat Pond/ Canal Water. The company has permission for the usage of Dabhel

Gram Panchayat Pond. The proposed water requirement will be fulfilled from the Dabhel Gram

Panchayat Pond/ Canal Water. The copy of the letter is enclosed as Annexure – III.

In existing operation, water is required for domestic, washing, utility and gardening purpose.

Total water consumption for the existing project is 374 KLD in which 122 KLD fresh water is

used. Total water consumption after proposed expansion will be 883 KLD in which 492 KLD

fresh water will be used. Remaining 391 KLD will be recycled water. The category wise

bifurcation of the water requirement is given in the table 3.8.


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Table 3.8: Category-wise Water Requirement (in KLD)

S. No. Particulars Requirement (KLD)Existing Scenario Proposed Scenario

1. Domestic 14 202. Gardening 8 543. Industrial 4. Process Washing 5 85. Cooling Tower (Make-up) 318 7756. Softener Regeneration 0 107. Boiler (Make-up) 0 168. Sub-Total: Industrial 323 8099. Grand Total 374 883

3.7.5 MAN-POWER REQUIREMENT

There are currently 250 persons employed in the existing unit. The man-power required for the

project will be employed locally from the nearby areas. Skilled as well as unskilled labor will be

employed for the project.

Table 3.9: Man Power Requirement Phase of project Type of Labour No. of Workers

Existing scenario

Manager 15Chemist 20Workers Skilled 100Workers Semi Skilled 115

Proposed Scenario Manager 25Chemist 30Workers Skilled 150Workers Semi Skilled 156

3.8 QUANTITY OF WASTE TO BE GENERATED

3.8.1 WASTE WATER GENERATION & MANAGEMENT

The category wise bifurcation of the waste water generation is given in Table 3.10.


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Table 3.10: Category-wise Wastewater Generation (in KLD) Sr.No.

Particulars Waste Water generation (KLD)

Existing Scenario Proposed Scenario1 Domestic 11.5 15.02 Industrial 3 Process Washing 5.0 8.04 Process (Water of Reaction) 168.0 279.05 Cooling tower blow down 79.0 86.06 Softener regeneration 0.0 10.07 Boiler Blowdown 0.0 8.08 Sub-Total: Industrial 252.0 391.09 Grand Total 263.5 406.0

Figure 3.5 (a): Water Balance Diagram – Existing Scenario (in KLD)


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Figure 3.5 (b): Water Balance Diagram – Proposed Scenario (in KLD)

3.8.2 WASTE WATER CHARACTERISTICS The expected wastewater characteristic of effluent before treatment in ETP is given below in

Table No. 3.11.

Table 3.11: Expected Characteristics of Wastewater Sr. No.

Parameter

CharacteristicsUntreated Range Treated Permissible

limits1. pH 5-6 4 to 8 7.19 6.5 to 9.02. TSS 600 70 to 90 80 <1003. TDS 500 250 to 400 840 <21004. COD 5000 5000 to 7000 185 < 2505. BOD 1500 1500 to 3000 54 < 100Note: All above values in mg/ lit except pH or where specified


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3.8.3 WASTE WATER TREATMENT & DISPOSAL

In the existing operation, the total Domestic wastewater generated is @ 11.5 KLD, which is

being diverted to the septic tank/ soak pit system. Wastewater generated from industrial

activities @173 KLD is treated in ETP and the treated wastewater is diverted to the Cooling

tower as makeup water. Blow down from cooling tower generated @79 KLD from which 50 KLD

is recycled as CT makeup water & 29 KLD for gardening.

Whereas, after proposed expansion project, domestic waste water generation will be @15 KLD

& from industrial activities 305 KLD will be treated in ETP and the treated wastewater will be

diverted to the Cooling tower as makeup water. Blow down from cooling tower generated @86

KLD from which 35 KLD is recycled as CT makeup water & 51 KLD for gardening.

Modification in ETP will be done after proposed expansion project. Existing ETP Scheme is as

below:

Effluent Treatment Scheme: The effluent generated from the process plant shall be initially collected into the collection tank.

Now, the effluent in the collection tank shall be neutralized by adding some chemicals. The

neutralized effluent from this tank shall be pumped to the aeration tank - 1 for biological

treatment. The biodegradation of the effluent in the aeration tank takes place in the presence of

active biomass and dissolved oxygen which is provided by the surface aerator. The overflow of

the aeration tank - 1 is diverted into the secondary clariflocculator -1 for biomass sludge

separation. The clear overflow of the secondary clariflocculator - 1 is pumped to the aeration

tank -2 where remaining biodegradation of effluent takes place. The settled biomass from the

bottom of the secondary clariflocculator - 1 shall be recycled back to the aeration tank -1 and

excess biomass shall be diverted into the sludge pit - 1. Similarly the overflow of aeration tank –

2 is diverted to secondary clariflocculator – 2. The settled biomass from the bottom of the

secondary clariflocculator - 2 shall be recycled back to the aeration tank -2 and excess biomass

shall be diverted into the sludge pit – 2. The total sludge from sludge pit – 1 & sludge pit – 2 is

diverted to sludge drying bed.


30


The dried sludge from the sludge drying beds shall be collected and packed into the plastic

bags properly and shall be stored into the solid waste storage area as per norms. The dried

ETP sludge is finally handover to GEPIL for landfill disposal.

The clarified effluent from clariflocculator - 2 is switched to the stabilization pond from where it is

pumped to the pressure sand filter and activated carbon filter for tertiary treatment. The outlet

of the filters is sent to the softener plant. The treated effluent from the softener is recycled back

for using the treated effluent for cooling tower make-up purpose.Schematic of Effluent Treatment Plant: The flow diagram of the ETP is shown in figure 3.6.

Figure 3.6: Schematic Diagram of Effluent Treatment Plant

3.8.4 AIR EMISSIONS & CONTROL

3.8.4.1 Process Emission Process gas emission details from CP process are as below:

Table 3.13: Details of Process Emission

Section Emission Details Remarks Stripping Column EG – < 0.01 gm/m3

Acetaldehyde/methyl dioxalane – < 19 gm/m3 1,4 Dioxane – < 0.4 gm/m3

Mixed with moisture from column to dilute its impact.

Glycol Ejector EG – nil Acetaldehyde - < 10 ppm

It is being got mixed with moisture to dilute its impact.


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3.8.4.2 Utility Emission In existing installations, the company has 2 Nos of Thermic Fluid Heater each having capacity of

10 million K.cal/Hr. The company has also 12 Nos. of D.G. set of 625 kVA capacity. The D.G.

Set acts as standby unit and is only utilized in case of power failure.

FO is used as fuel in the Thermic Fluid Heaters & LDO is used as fuel in the D.G set.

For proposed expansion project, there will be addition of 3 nos. of TFH of capacity 8

Milillion.Kcal/hr (2 working + 1 standby) & two nos. of dual fired steam boiler of 10 TPH capacity

(1 working + 1 standby). The Company also proposes to install 15 Nos. of D.G. set of 625 kVA

capacities.

FO will be used as fuel in TFH. Whereas, FO or coal both can be used in dual fired steam

boiler.

The details regarding utility emissions and control measures are mentioned in the below table

no. 3.13.

Table 3.13: Details of Utility Emission

Utilities Operation Time

Fuel Stack details (m)

APCD to be Installed

Emission Parameter

Existing installations Thermic Fluid Heater – 2 Nos. Capacity: 10 Million KCal/hr each

24 hrs FO = 0.52 KL/hr

H: 52 D: 1.3

-- PM, SO2, NOx

D.G. Set Capacity: 625 kVA – 12 Nos.

Standby LDO = 100 Lits/Hr.

H: 6 D: 0.23

--- PM, SO2, NOx

Proposed additional installations Thermic Fluid Heater: 3 Nos (one standby) Capacity: 8 Million K.Cal/hr each

24 hrs FO = 1.25 KL/hr

H: 51 D:1.3

-- PM, SO2, NOx

Dual Fired Steam Boiler: 2 Nos. (one standby) Capacity: 10 TPH

24 hrs FO = 0.75 KL/hr OR Coal = 1.45 TPH

H: 60 D: 1.2

ESP, Lime dosing with coal

PM, SO2, NOx


32


Utilities Operation Time

Fuel Stack details (m)

APCD to be Installed

Emission Parameter

D.G. Set Capacity: 625 kVA – 15 Nos.

Standby LDO = 125 Lits/Hr.

H: 6 D: 0.23

-- PM, SO2, NOx

3.8.4.3 Fugitive Emission Minor quantities of oil mist and particulate matter are released as fugitive emissions from the

texturising machine.

Following measures are adopted for control of fugitive emissions:

• All production activities are carried out in closed conditions to minimize possibility of fugitive

emission.

• Air handling unit of sufficient capacity is provided in the entire production plant

• Any leak will also be attended to immediately.

• Raw Materials & Products are stored in closed containers

• Raw Materials & Products is stored in properly designed storage are and under good

storage conditions to prevent any volatilities

• Raw Materials & Products are stored in closed containers

• Raw Materials & Products is stored in properly designed storage are and under good

storage conditions to prevent any volatilities

3.8.5 HAZARDOUS / NON-HAZARDOUS. WASTES MANAGEMENT In the existing operation, the hazardous waste is generated from process, ETP, machinery and

raw material consumption. All the wastes are stored separately in a designated storage area

safely and properly. The company sends its ETP waste to the GEPIL Site, Silvassa for final

disposal.

Polymer waste from process is sold to actual users. Used oil from machinery is sold to

registered recycler/re-processor. Empty drums and bags are sold to authorized re-conditioner &

authorized scrap vendor. Same practice will be followed for additional quantity of waste after

proposed expansion project. The following wastes are generated from the operational activities.


33


Table 3.14: Details of Hazardous Waste Generation & Disposal

Types of Waste

Cat. Source of Generation

Existing Qty Proposed Qty

Storage Method

Method of Disposal

Hazardous Waste ETP Waste

34.3 ETP 400 Kgs/Month

700 Kgs/Month

Stored at a separate storage area

Send to GEPIL Site, Silvassa for final disposal.

Used oil 5.1 Maintenance 125 lts./Month

350 lts/month Stored in drums

Sell to registered recycle/ re-processor

Empty bags

33.3 RM cons. 23200 Nos/Month

26070 Bags/Month

Stored at a separate storage area

Sell to authorized scrap vendor

Empty PP Liner

33.3 RM cons. 24000 Nos/Month

37500 Bags/Month

-- do -- Sell to authorized scrap vendor

Empty drums

33.3 RM cons. 135 Drums/Month

120 Carboys/ Month

-- do -- Sell to authorized reconditioner

Polymer waste

-- From process 8.2 MT/Month

35 MT/Month Packed in bags and stored at a designated area

Sell to actual users.

Non - Hazardous Waste Fly Ash -- From Boiler -- 125 MT/Month Stored at a

designated area

Sell to brick manufacturers.

3.8.6 NOISE CONTROL There is/ will be no major noise generating activities due to existing operation as well as

proposed project. The company has to provide acoustic enclosure for D.G. Set along with

regular maintenance of other equipments to minimize the noise generated by the equipments.

There is no generation of bad odour and the process is carried out in closed reactors. The noise

level within company premises as below


34


Table 3.15: Noise Level within Company Premises

Location Direction Noise Level dB(A)

CPCB Permissible Limit dB(A)

Within Company Premises

East 60 <75 West 62 <75 South 68 <75 North 65 <75

(Source: Wellknown Polyesters Ltd.)

3.9 HEALTH AND SAFETY MEASURES The company is concerned about occupational health and safety among its

work force as the man power is the biggest asset to the company. As an existing company, we

have implemented the following safety measures for the employees and work force employed

on contract basis -

FOR OUR EMPLOYEES:

• Working safely is a condition of employment.

• We have well experienced persons for safety and health and they give training to our

employees on regular basis.

• We have provided Fire Hydrant system and fire extinguishers.

• We have provided First Aid facility at all the necessary locations.

• Personal protective gears and equipments are provided to the employees.

• Health check ups are organized at regular intervals.

WORK FORCE ON CONTRACT BASIS:

• Third party including contractor, sub-contractor and other cargo operators working at the

premises will be made aware of Company Safety Policy and all relevant "Permit to

Work" systems that may be in force. It will be obligatory on their part to comply with the

same.

• During finalization of the contract, the line managers will ensure, as far as possible the

method of working, usage of plant and equipment, lighting, fire and any other known

hazards, allocation of responsibilities with contractors/sub-contractors and others and

provide facilities for welfare and sanitation.

• All contractors must provide adequate supervision over their workers at all time.


35


We propose to implement all the measures related to health and safety in the proposed plant.

The measures include the following.

• Safety Training will be provided to the employees.

• Manual call bells in case of emergency will be provided.

• Emergency Control Room with emergency sirens will be established.

• Assembly point will be provided.

• Fire Hydrant System will be installed.

• Fire Extinguishers will be provided at all the required points.

• Mock drills will be periodically conducted and factors like response time will be

evaluated.

• Fire squad team is formed for handling any emergency situation & regular training of

squad team will be conducted.

• First Aid Facility and training will be provided.

• Personal protective gears and equipments will be provided to employees.

• Health check up will be organized at regular intervals.

• Safety / Health records and MSDS will be maintained.

3.10 ENVIRONMENTAL HEALTH & SAFETY CELL The company will have a separate environment cell in order to keep a close watch on the

performance of the pollution control equipment, emissions from the sources and the quality of

surrounding environment in accordance with the monitoring program. The cell will also entrust

with the responsibilities of regulating the safety measures inside the plant campus. The cell will

be also responsible for maintaining the records of all data, documents and information in line

within the legislative requirement.

3.11 POST PROJECT MONITORING PLAN The company will develop in-house facilities for monitoring certain components. Where it is not

possible to establish such facilities, the same will be done by appointing external

recognized/approved agencies. The proposed post-project monitoring plan is given below:


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Table 3.16: Post Project Monitoring Plan Component Parameter Frequency of in

house monitoring Frequency of third party monitoring

Waste water BOD, COD, pH, SS, TDS Daily (At all stages of ETP)

Quarterly in a month (treated and untreated)

Air-ambient SPM, SOx, NOx, RSPM, CO, etc.

- Quarterly

Stack monitoring SPM, SO2, NOx

- Quarterly

Noise monitoring dB(A) - Once in a month Workplace monitoring VOC -- Half Yearly


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CHAPTER – 4

SITE ANALYSIS

4.1 CONNECTIVITY This proposed project for debottlenecking of existing plant is located Survey No. 178, 185/2,

216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6,

216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2,

183/3, 183/4, 183/8A, 183/9A, 184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2,

193/4, 203/1, 203/2, 203/3, 203/4, 203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6,

210/7, 211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3,

225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).. The Site

is 1.04 km from Village Dabhel. The site is 2.37km from National Highway. The land and

infrastructure is already available and the raw material is easily available through the easy

transport via road connectivity. The nearest Railway station is Vapi railway station which is 4.73

km from the project site.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP

4.2.1 LAND FORM The proposed project to be located at new plots, closer to the existing unit which is already

engaged in manufacturing activity. Currently it is a vacant land.

4.2.2 LAND USE PATTERN Currently it is a vacant land.

4.2.3 LAND OWNERSHIP The plot is located in the industrial Zone –I of Dabhel Industrial Co. Op. Society Ltd.. The plots

for the proposed project has been purchased from private owners and transferred in the

company’s name.


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4.3 TOPOGRAPHY Daman is situated on the western coast of India and bordered by the clear, blue waters of the

Arabian Sea. The entire district of Daman is covered by Deccan trap belong to the type called

“plateau Basalt”. The area is characterized by hilly terrain. Daman is bisected by two rivers viz.

Kolak River which flows towards the north & Damanganga River which flows through the centre.

The river divides the district of Daman in the two parts known as Nani-Daman and Moti-Daman,

which lie opposite each other across the Damanganga.

The project site is at a slightly elevated terrain. It is at an altitude of 16 m above MSL.

4.4 SALIENT FEATURES Table 4.1: Salient Features of the Project Site Particulars Details Co-ordinates 72° 53’ 48.78” E, 20° 24’ 46.86” N Village Dabhel Taluka/ Tehsil Daman District Daman Elevation 16 m above Mean Sea Level Nearest Settlement Village Dabhel @1.04 km SW Nearest Reservoir River Kolak @2.34 km -NE

River Damanganga @3.68 km -SW River Kalu @ 6.37 km in -SW

Nearest Highway SH185 @1.34 km – SW NH 8B @2.37 - SW

Nearest Railway station Vapi Railway station @4.73 km- SE Nearest Airport/ Airbase Daman Airport @5.79 km -NW Tourist places Daman fort and beaches Sites of Historical/ Archaeological importance

Daman fort constructed during portugese rule

Protected Area/ Sanctuaries None within 10 km from project site CRZ applicability Coastline @6.74 km from project site but CRZ not

applicable

4.5 EXISTING INFRASTRUCTURE The proposed project to be located at new plots, closer to the existing unit which is already

engaged in manufacturing activity. The plot is located in the notified industrial estate. Hence,

necessary infrastructure is already developed by OIDC.


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4.6 SOIL CLASSIFICATION The site is located in rocky area. The water storage capacity is very low and hence, it can be

considered that the entire rainwater penetrates into the groundwater table.

4.7 CLIMATE & METEROLOGY Daman is having a pleasant climate all over the year. In summers, Daman is blessed with cool

breeze coming from over the Arabian Sea. The summary of yearly meteorological data for a

period of 10 years recorded at the nearest observatory of IMD at Dahanu has been taken from

the climatological tables (1951-1980).

The entire data has been summarized in Table 4.2.

Table 4.2: Summary of Meteorological Data at nearest IMD Station - Dahanu

Location: In the compound of the old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o 58’, Long: E 72o 43’) Height of installation: 11m above MSL Month PDW

Direction Avg. W. Speed (kmph)

Temperature (oC)

Relative Humidity (%)

Cloud Cover (Oktas) Rainfall (mm)

Max. Min. Morn. Even. Morn. Even. JAN N 1-19 27.7 16.5 67 69 1.3 1.1 0.2 FEB N 1-19 28.3 17.4 66 69 1.1 0.8 0.2 MAR N 1-19 30.3 20.7 68 67 1.4 1.1 0.1 APRIL W 1-19 32.2 24.0 74 69 2.1 1.4 0.1 MAY W 1-19 33.1 26.8 77 73 3.8 2.3 5.2 JUNE SW 1-19 32.2 26.3 85 80 6.1 5.6 522.1 JULY SW 1-19 30.1 25.0 89 84 7.1 6.8 771.7 AUG W 1-19 29.5 24.7 88 83 6.9 6.7 502.3 SEP W 1-19 30.0 24.0 87 79 5.4 4.9 319.1 OCT E 1-19 32.1 23.1 77 72 2.8 2.4 44.4 NOV N 1-19 32.1 20.5 67 71 1.9 1.9 17.1 DEC N 1-19 29.8 18.0 67 71 1.6 1.5 0.3 Seasonal Average Values Period Avg. PDW

Direction Avg WS

Avg. Max.

Avg. Min. Avg. Morn.

Avg. Even.

Avg. Morn.

Avg. Even.

Total

Summer W 1-19 31.9 23.8 73.0 69.7 2.4 1.6 5.4 Winter N 1-19 28.6 17.3 66.7 69.7 1.3 1.1 0.7 Monsoon SW 1-19 30.45 25.0 87.3 81.5 6.4 6.0 2115.2 Post monsoon

W/E 1-19 32.1 21.8 72 71.5 2.35 2.15 61.5

Annual W 1-19 30.8 22.0 74.7 73.1 3.1 2.7 2182.8 (Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)


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4.7.1 TEMPERATURE The climate of Daman is characterized by humid summer because of the coastline. The period

from March to May is one of continuous increase in temperatures. May is generally the hottest

month with the mean daily maximum temperature recorded at 33.1 oC and mean daily minimum

temperature recorded at 26.8 oC. January is the coldest month with the mean daily maximum

temperature as 27.7 oC and mean daily minimum temperature observed as 16.5 oC.

4.7.2 HUMIDITY Humidity is usually high during the monsoon months, generally exceeding 80%. Humidity

decreases during the post-monsoon months. For rest of the year i.e. the period of December to

April, the relative humidity ranges around 60-70%.

4.7.3 CLOUD COVER During the South-west monsoon months, the skies are usually heavily clouded or overcast.

Cloud cover decreases during the post monsoon months. During rest of the year the skies are

mostly clear.

4.7.4 RAINFALL About 95% of the annual rainfall is received during the southwest monsoon season i.e. from

June to September, July being the month with highest rainfall.

The average annual rainfall observed from the data is 2182.8 mm.

4.7.5 WIND PATTERN The annual predominant wind direction comes to West, followed by North and South-west.

Winds blows mostly from the West/North-West during summers and Monsoons are usually

South-west. The post-monsoon & winter seasons experience a change in the wind blowing from

North and North-east. The wind speed is high during summer and monsoon seasons, slightly

moderate during winter and low during post-monsoon phase.

4.8 SOCIAL INFRASTRUCTURE The infrastructure available in the study area denotes the economic well being of the region.

There are about 57 villages and 1 Town in the 10 km radial periphery of the project site.


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4.8.1 EDUCATIONAL FACILITIES As per census of India, 57 Primary school, 15 Middle School, 18 Secondary School, 4 senior

secondary school and 2 Training institute were found in 10 km radial periphery. One college

was found in Daman district. The female literacy rate is above 50%.

4.8.2 MEDICAL FACILITIES Out of the 57 villages, hospitals were available in 4 villages, Dispensary in 7 villages, Primary

health centers in 5 villages, Primary health sub center in 33 villages and Nursing home in 3

villages.


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CHAPTER – 5

PLANNING BRIEF

5.1 PLANNING CONCEPT The site is located at Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1,

213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2,

225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3, 183/4, 183/8A, 183/9A, 184, 185/1, 186/A,

190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4, 203/1, 203/2, 203/3, 203/4, 203/5, 203/6, 210/1,

210/2, 210/4, 210/5, 210/5A, 210/6, 210/7, 211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B,

216/8, 216/8A, 224/1, 224/2, 224/3, 225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd.,

Dabhel, Daman-396 210 (U.T.).The nearest city is Vapi which is a big hub for chemical &

Pharmaceutical Products. Major raw materials will be sourced locally.

The region is well planned with all the basic infrastructural facilities like internal roads, water

supply, arrangements for power, streetlights, solid waste disposal sites etc.

5.2 POPULATION PROJECTION The average household size is around 4 to 5. The Sex ratio is very less.

Table 5.1: Distribution of population

Sr. No.

Particulars Observed values in 10 km Radius

Total Population 1977662 No. of Households 449923 Avg. household size (persons) 4-54 Male population 1169925 Male population (in %) 59.26 Female population 807747 Female population (in %) 40.88 Sex ratio 690

(Source: Primary Census Abstract – Census of India, 2001)

5.3 AREA STATEMENT The total area of the plot is 182059 m2 out of which Greenbelt area of the plant is 48942 m2

which is 26.88%. The bifurcation of the same is given below in table no. 5.2.


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Table 5.2: Area Statement

S. No.

Particulars Area (m2)

Existing Proposed Total 10. Construction Area 8045 48393 56438 11. Greenbelt area 12958 48942 61900 12. Open area 21392 42329 63721 13. Total Area 42395 139664 182059

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) For proposed expansion project the company will acquire some plant and machinery so there

will be some demand of change in physical infrastructure and social infrastructure. As

manpower requirement for the proposed project shall be locally fulfilled, employment generation

will lead to additional benefits to social infrastructure.

5.5 AMENITIES/FACILITIES

5.5.1 DRINKING WATER FACILITIES Tap water is available in 35 villages as per the Census 2001. 56 had Wells, 16 villages had

tanks and all 57 had hand pumps. 11 Villages had River passing. Power supply was also

available in all the villages.

5.5.2 POWER SUPPLY FACILITIES As per census 2001, all the villages have power supply facilities in the study region.

5.5.3 COMMUNICATION & BANKING FACILITIES Communication facilities like Post and telegraph, telephones exist in almost all the villages as

per the 2001 census.

5.5.4 TRANSPORT FACILITIES Bus service is available in the study region and is the most preferable mode of transport in the

region. The villages are well connected with the State Highways. National Highway-8 also


44


passes from Vapi. The Western railway line between Bombay to Ahmedabad passes from the

study region and Vapi Town has a railway station on the same.


45


CHAPTER – 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA The total area of the plot will be 182059 m2 out of which Greenbelt area of the plant is 48942 m2

which will be 21.96%.The total production capacity will be 1500 TPD.

6.2 RESIDENTIAL AREA In the said proposal no Residential area has been proposed for workers and/or for staff.

6.3 GREENBELT Maximum open land will be allotted for green belt development. If required, experts will also be

consulted for selection of species for the development of the greenbelt. Total greenbelt area will

be 26.88% of total plot area.

6.4 SOCIAL INFRASTUCURE Existing infrastructure will be sufficient to accommodate the existing load from the proposed

project which is very low.

6.5 CONNECTIVITY

This proposed project for debottlenecking of existing plant is located at Survey No. 178, 185/2,

216/1, 216/2, 216/3, 216/4, 216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6,

216/7, 219, 223/1, 223/2, 223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2,

183/3, 183/4, 183/8A, 183/9A, 184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2,

193/4, 203/1, 203/2, 203/3, 203/4, 203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6,

210/7, 211/1, 212, 212/B, 213/5 to 213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3,

225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).. The Site

is 1.04 km from Village Dabhel. The site is 2.37km from National Highway. The land and

infrastructure is already available and the raw material is easily available through the easy

transport via road connectivity. The nearest Railway station is Vapi railway station which is 4.73

km from the project site.


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6.6 DRINKING WATER MANAGEMENT Drinking water is/ will be sourced from Canal water supply for the existing operations as well as

proposed project.

6.7 SEWERAGE SYSTEM Domestic waste water generated from the existing operations @11.5 KLD is disposed off

through soak pit / septic tank. Same practice will be followed for proposed quantity @ 15 KLD of

sewage after proposed expansion project.

6.8 INDUSTRIAL WASTE MANAGEMENT Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained

in Chapter 03, Section 3.8.3.

6.9 SOLID WASTE MANAGEMENT Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,

Used oil from gear boxes of the machineries, polymer waste from manufacturing process,

discarded drums & bags from storage of raw materials. Company will provide adequate storage

area for proper storage of wastes. Details of solid waste generation are given in table 3.9.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY The power requirements for existing operations is 15.95 MW & after after proposed expansion

project, it will be 21 MW which will be sourced from Electricity Board.


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CHAPTER – 7

REHABILITATION & RESETTLEMENT (R &R) PLAN 7.1 POLICY TO BE ADOPTED The proposed project is debottlenecking of existing plant for increase in production capacity

hence, it is to be deveolped in the existing plots as well as plots closer to the existing site.

Moreover, all plots are designated for industrial use. Hence, no displacement of any population

is proposed for the project. Therefore, detailed Social Impact Assessment studies or R&R action

study has not been proposed.


48


CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE OF THE PROJECT Any activity related to proposed debottlenecking of project will start only after getting all the

statutory permission from respective authorities.

8.2 ESTIMATED PROJECT COST The company has made budgetary provision for the recurring expenses for the environmental

issues while planning for the allocation of funds during the annual budgetary planning.

Environment Protection has also been considered in planning the cost projection. Green belt

development is also considered. The capital cost for existing project is 48 crores & estimated

project cost for proposed project will be approximately 167.75 Crores.

Table 8.1: Total Capital Cost Projection

Sr. No.

Purpose Capital Cost (Rs. In Crores)Existing Cost Proposed

Additional Cost

Total Cost

1 Land and Land Development 1.20 7.0 8.22 Building and Civil Works 6.00 15.0 213 Plant & Machinery 30.00 75.0 1054 Effluent Treatment Plant 1.10 2.5 3.65 Air Pollution Control Measures 0.00 06 Green Belt Development 0.25 0.50 0.757 Safety Systems 0.50 0.75 1.258 Pipeline & Fittings 3.80 7.5 11.39 Electrical Installation 1.75 4.0 5.7510 Preliminary and Preoperative

Expenses 3.407.5

10.9 TOTAL 48.00 119.75 167.75


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Table 8.2: Recurring cost provision for EHS Sr. No.

Purpose Recurring Cost (Lakhs)Existing

Scenario Proposed Scenario

1. ETP operations (chemicals/electricity/manpower) 9.6 16.02. Air pollution control device 2.0 3.33. Fees for Common disposal facilities 5.0 8.54. Env. Monitoring expenses 3.6 6.05. Safety instruments maintenance 12.0 20.06. Environment & safety training 5.0 7.57. Green belt maintenance 6.8 11.58. Social development (CSR) 12.0 18.0 TOTAL 56.0 90.8


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CHAPTER – 9

ANALYSIS OF PROPOSAL 9.1 FINANCIAL & SOCIAL BENEFITS M/S. Wellknown Polyester Ltd. is located at Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4,

216/5, 210/3, 213/1, 213/2, 213/3, 213/4, 214/1, 214/2, 215, 216/6, 216/7, 219, 223/1, 223/2,

223/4, 223/5, 225/2, 225/5, 180/6, 180/7, 181, 182, 183/1, 183/2, 183/3, 183/4, 183/8A, 183/9A,

184, 185/1, 186/A, 190/5, 191/1, 191/2, 191/4, 193/1, 193/2, 193/4, 203/1, 203/2, 203/3, 203/4,

203/5, 203/6, 210/1, 210/2, 210/4, 210/5, 210/5A, 210/6, 210/7, 211/1, 212, 212/B, 213/5 to

213/14, 214/3, 216/4B, 216/8, 216/8A, 224/1, 224/2, 224/3, 225/1, 229/1A, 229/2, Dabhel Ind.

Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).

Company is already manufacturing POY the primary raw material for the production of Polyester

Drawn Texturised Yarn (DTY) through continuous polymerization process as a part of its

backward integration program. It is a continuous polymerization unit where POY (Partially

oriented yarn) and FDY (Fully drawn yarn) are produced. POY is used for captive consumption

of DTY and the excess is sold in the open market while FDY is final product.

Now the company plans for debottlenecking of existing plant for increase in production capacity

by adding a similar category product PSF (Polyester Staple Fiber).


produced and it will be used to produce PSF similar to the POY and FDY.

As capacity of molten polymer is available in CP plant, thus its operation at higher capacity with

PSF stream will reduce the conversion cost due to energy efficient operation of the plant.

Presently PSF is contributing 8% annual growth in polyester market. With PSF manufacturing

facility, we will have market share in these segments. It has also good share in export market.

The product mix of POY, DTY, FDY and PSF will give competitive edge to the company with

addition of PSF in our product basket. Thus our bushiness viability will be further improved.

For the proposed project, the company intends to donate Rs. 18 Lakhs per year for the social

benefit as Corporate Social Responsibility.

A

Annexure – 1(a): Copy of Existing EC

F

Annexure – 1 (b): Forwarding Letter for EC Compliance Report Submitted to

RO Bhopal

G

Annexure – 1 (c): Copy of Register AD Post Slip for EC Compliance Report

Submitted to RO Bhopal

H

Annexure - 2: Copy of Existing CC&A

L

Annexure - 3: Permission letter for water

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