IG3 INFRA LTD PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ...environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/31_Oct... · PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ASPECTS OF THE

IG3 INFRA LTD

PRE-FEASIBILITY REPORT

ON

ENVIRONMENTAL ASPECTS

OF

THE PROPOSED TEXTILE SEZ

AT

Survey No. S.F. No. 126, 129, 132, 135 - 144, 151 - 161, 165, 166, 167, 171, 178, 209, 216 - 218, 229,

232, 235, 237

Vadamugam Kangeyampalayam Village, Avinashi Taluk, Tiruppur District, Tamilnadu State.

November 2015

DPR, IG3 INFRA –TEXTILE SEZ i

CONTENTS

1.0 EXECUTIVE SUMMARY 1

2.0 INTRODUCTION / BACKGROUND INFORMATION 3

3.0 ENVIRONMENTAL SETTINGS 4

4.0 PROJECT DESCRIPTION 7

5.0 RAW WATER REQUIREMENT 9

6.0 ENERGY CONSUMPTION 9

7.0 WASTE & WASTE MANAGEMENT 9

8.0 REHABILITATION AND RESETTLEMENT 11

9.0 PROJECT SCHEDULE & COST ESTIMATION 12

10.0 ANALYSIS OF PROPOSAL 12

LIST OF FIGURES

Fig. 1.0 TOPO MAP 5

Fig. 2.0 PLANT LAYOUT 6

Fig. 3.0 PROCESS FLOWCHART 8

Fig. 4.0 WATER BALANCE 10

DPR, IG3 INFRA –TEXTILE SEZ 1

1.0 EXECUTIVE SUMMARY

IG3 Infra Ltd. proposes a textile SEZ at an area of 256 acres housing 26 industrial

sheds. Weaving, warping, sizing, dyeing and garmenting are activities which will be

carried out within the SEZ area. This area is declared as a notified SEZ by Ministry of

Commerce & Industry vide its Gazette notification. No. 785 dated 9th June, 2008.

Project Location

Survey No. 126, 129, 132, 135 - 144, 151 - 161, 165, 166, 167, 171, 178, 209, 216 -

218, 229, 232, 235, 237 at Vadamugam Kangeyampalayam Village, Avinashi Taluk,

Tiruppur District, Tamilnadu State.

Project Proponent

M/s. IG3 Infra Limited.

Land Requirement

The area under the ownership of IG3 Infra Limited is 103.60 ha (256.0) which is notified

as a sector specific SEZ by Ministry of Commerce & Industry. In the SEZ, captive power

plant and one textile shed has been allotted already. The captive power plant has been

allotted with an area of 6.1 ha (15.07) for which the environmental clearance has been

obtained (SEIAA-TN/F.No.679/2012/1d/EC/025/2014 dated 23.12.2014) and textile unit

with the build-up area of 10,000 sq.m has obtained consent from Tamilnadu Pollution

control Board. The remaining area of 97.5 ha (241.01) has been allotted for textile SEZ.

The buildup area is 2,20,000 sq.m. The existing textile shed of build-up area 10,000

sq.m has been included in this build up area.

S.No Particulars Area

(%) Hectare Acres

1 Industrial sheds 33.0 81.5 33.8

2 Open parking area 1.0 2.4 1.0

3 Road 5.0 12.4 5.1

4 Green belt area 33.2 82.0 34.0

5 OSR area 9.8 24.2 10.0

6 Open area 15.2 37.6 15.6

7 CETP, STP & Solid Waste storage area 0.4 1.0 0.4

Total 97.5 241.01 100

Production Capacity

S.No Products Production Capacity

1 Fabric 1,00,000 Meters/Day

2 Garments 3,00,000 Pieces/ Day

S.No Name of Shed Capacity Number of sheds

1 Spinning Sheds 1 x 50,000 spindles 1

2 Weaving Sheds 300 Looms 18

3 Garments Sheds 5 x 100 seats 5

4 Dyeing Sheds 0.5 MLD 2

Total -- 26


Water requirement

The total water required for the proposed textile SEZ is 1548 KLD. The fresh water will

be sourced from New Tiruppur Area Development Corporation limited (NTADCL).

Initially, the whole water will be sourced for primary consumption and then make up water of 40 KLD will be sourced from the same provider.

Waste water Generation

The sewage generated from the domestic consumption will be treated in Sewage

Treatment Plant of capacity 275 KLD. The trade effluent generated from the process will

be treated in Common Effluent Treatment Plant of capacity of 3500 KLD. The plant

operates in Zero Liquid Discharge System.

Solid Waste Generated

Sr. No Description of solid waste Quantity (TPD)

Hazardous wastes

1 CETP Sludge 1.6

Recovered salt 4.6

Non-hazardous wastes

2 Loom operations 0.3

3 Sizing units 0.4

4 Domestic waste

i) Biodegradable

ii) Non-biodegradable

0.45

0.27 (60%)

0.18 (40%)

5 STP Sludge 0.1

Man Power

About 2100 employees will be employed in the SEZ.

Project Cost

The total project cost for proposed project is 70.93 Crores.

Pollution Control Cost

The total pollution control cost is 41.07 Lakhs.


2.0 INTRODUCTION / BACKGROUND INFORMATION

ABOUT PROJECT PROPONENT

The project envisages setting up of a Textile SEZ for manufacture of fabrics on wide

width, shuttle less looms; yarn and cloth processing and manufacture of bed linen and

garments for export and domestic markets. The proposed textile SEZ will be set up on a

256 acre plot on NH-47 about 60 km from Coimbatore in Tiruppur District of Tamil Nadu.

It will comprise of integrated facilities for weaving, processing and stitching along with

ancillary activities like quilting and embroidery.

The Project is conceived by a group of leading textile entrepreneurs for years. This

Textile SEZ would have state-of-the-art modern shuttle less looms, hi-tech wide width

processing and garmenting and bed linen manufacturing Units with modern physical and

social infrastructure that would enable the entrepreneurs to produce high value added

products, enhance their productivity and meet international procurement standards.

The Textile SEZ shall be environment friendly and a self contained facility comprising of

physical and common infrastructure components that shall cater to the needs of the

Industry. The Master plan has been conceptualized considering the opportunities and

constraints of the site integrated with a sustainable and environmental friendly land use.

The guiding principle of the master plan is to incorporate the principles of an Eco-

industrial Textile SEZ by maximizing green space and open spaces, provision of green

belts around polluting locations to isolate and contain polluting effects.

THE PROPOSED PROJECT

Survey No. 126, 129, 132, 135 - 144, 151 - 161, 165, 166, 167, 171, 178, 209, 216 -

218, 229, 232, 235, 237 at Vadamugam Kangeyampalayam Village, Avinashi Taluk,

Tiruppur District, Tamilnadu State.

NEED FOR THE PROJECT

The proposed project is a textile SEZ of IG3 Infra Limited. The Textile SEZ is proposed to

be developed in 46.7 ha area in keeping with the need for developing common facilities

and also making provision for establishing individual industrial units by prospective

entrepreneurs.

WORK FORCE

There will be direct employment for 2100 people and indirect employment opportunities

for 10000. Hence, there will be positive impacts on economic and social status of the

local people.


3.0 ENVIRONMENTAL SETTINGS

The environmental setting of the project location is given below.

Sr.

No. Particulars Details

1 Site-coordinates Latitude Longitude

A 11º12’36.57” N 77º26’23.65” E

B 11º12’53.39” N 77º27’09.06” E

C 11º12’21.85” N 77º27’13.39” E

D 11º12’06.73” N 77º26’49.48” E

2 Elevation 299 m AMSL

3 Climatic conditions (IMD,

Coimbatore)

Annual Max. Temp: 380C

Annual Min. Temp: 180C

Annual Total Rainfall: 574.3 -mm

5 Land use Unclassifed land as per DTCP

6 Nearest highway NH– 47, adjacent to the site in North

direction

7 Nearest railway station Tiruppur R.S. (15.5 km, SW)

8 Nearest airport Coimbatore - 48 km, SW

9 Nearest habitations Samaiarpalayam – 2.2 km

Sengalipalayam – 2.3 km

Kasturipalayam – 3.2 km

10 Densely populated area Uthukuli – 6.2 km

11 Interstate Boundary Not applicable

11 Inland water bodies Noyyel River – 9.2 km

12 Ecologically sensitive zones

like Wild Life Sanctuaries,

National Parks and

biospheres

Nil within 10 km radius

13 Defense establishments None within 10 km radius

14 Socio-economic factors No Resettlement and Rehabilitation issues

15 Seismicity zone Zone-III as per IS: 1893 (Part-1) 2002

16 Nearest sea Port Kochi, Kerala

17 Reserve forests Kongampalayam R.F – 6.0 km, East

Vayappadi R.F. – 6.5 Km, ESE

18 Historical / archaeological

places

Nil within 10 km radius

19 Bird migratory routes Bird routes has been observed around the

area of Sarkar Periyapalayam Eri which is

located at distance of 9.7 km from the project

site. The area has not a notified bird migratory

route/ sanctuary by Tamilnadu Forest

Department

20 Nearby Industries Sakthi Autocomponents – 7.2 km

The geographical location of the project site is as shown in Fig.1.0 – Index Map

DPR, IG3 INFRA –TEXTILE SEZ

5

Fig. 1.Index Map

Project Site


6

Fig. 2.0 Plant Layout


7

Process Description

General

A fibre undergoes various transformations, before it is converted into a fabric.

The transformations are carried out under dry process that includes weaving,

warping, sizing and looms etc.,

Manufacturing Process

In a cotton textile mill, the carded, combed and spun raw cotton is warped and

sized (slashed) into a mono colour and multi-colour fabrics. All these processes

are dry processes except sizing.

Yarn

Yarn is a long continuous length of interlocked fibres, suitable for use in the

production of textiles, sewing, crocheting, knitting, weaving, embroidery and

ropemaking.

Dyed yarn / Grey yarn received in the form of Cone or Cheese package received

from outside Mills with below specified quantity.

Yarn quality specification (Raw materials)

Particulars Single Yarn Double Yarn

Count CV% 3.0 2.5

Strength CV% 4.0 5.0

CSP 2100 2600

U% 9 9

Thin 1 1

Thick 25 28

Neps 25 28

Total ims/km 51 57

Warping

It is a commonly known fact that fabrics are constructed through two major

techniques – weaving and knitting apart from other minor techniques. In these

processes, two distinct sets of yarns called the warp and the weft are interlaced

with each other to form a fabric.

The fabric is separated in two steps of warping, direct warping is mono colour or

Grey fabrics and Sectional warping is Multi colour pattern.

Sectional Warping

In put material received from stores, this machine application only for

multicolouir pattern. Machine having Creel, leasing/ denting head, warping head,

waxing head and weavers beam head with downing / doffing arrangement. Input

dyed yarn packages mounting in creel against fabric pattern, Leasing / denting

devices will helps to separating the yarn, Waxing device will helps to coating

lubrication, Section Head will helps to groping the yarn against pattern, Finally

beaming Head produce required warp sheet and wound on weavers beam for

weaving, 4 Nos of Direct warping machine launching for feeding 420 Looms


8

Direct Warping

In put material received from stores, this application only for Mono colour or Grey

fabrics. Machine having Creel, leasing/denting head, warping head with

downing/doffing arrangement. Input grey yarn packages mounting in creel

against fabric width, Leasing / denting devices will helps to separating the yarn,

Beam Head will helps to groping the yarn against width of fabric, beaming Head

produce required warp sheet and wound on wrappers beam for sizing, 2 Nos of

Direct warping machine launching for feeding 420 Looms

Sizing

Sizing of the warp yarn is essential to reduce breakage of the yarn and thus

production stops on the weaving machine. The yarn is seized with starch and Poly

Vinyl Alcohol (PVA) or Carboxy Methyl Cellulose (CMC) to give necessary tensile

strength and smoothness required for weaving.

Looms

A loom is a device used to weave cloth. The basic purposes of any loom are to

hold the warp threads under tension to facilitate the interweaving of the weft

threads. Warp yarn & weft yarn interlacement process done in Dobby/Jacquard

looms

Inspections

The cloth Roll is received from looms and the grade is inspected and the

inspected cloth bundles are sending to processing unit.

Garments

Processed cloth bundles received from processing unit and confection process

done in Garment section.

Final Inspection and dispatch

Finally the quality and quantity is inspected and the finished goods are packed

and dispatched


9

Fig. 3.0 Plant Layout


10

5.0 WATER REQUIREMENT

The one time water required for the proposed textile SEZ is 1548 KLD. Then

make up water of 40 KLD will used. The one time requirement and make up

water of both will be sourced from New Tiruppur Area Development Corporation limited (NTADCL).

Sr. No Description Requirement in KLD

1 Processing (Dyeing & Bleaching) 1500

2 Weaving & warping (humidification) 15

3 Sizing 20

4 Cleaning & Sanitation 2.5

5 Spinning (humidification) 10

6 Restrooms 3

7 Industrial Sheds 60

Total 1548

*For weaving & warping, 97% water loss is considered

*For Spinning, 100% water loss is considered

6.0 ENERGY CONSUMPTION

The power required for the proposed Textile SEZ will be sourced from captive

power plant of 48 MW which has received Environmental clearance (EC) vide its

SEIAA Letter - SEIAA-TN/F.No.679/2012/1d/EC/025/2014 dated 23.12.2014. In

case of power failure, 3 DG sets of 185 KVA capacities will be used. The fuel for

DG Sets will be LS-Diesel with 37 L/hr/DG as requirement.

7.0 WASTE & WASTE MANAGEMENT

7.1 Air Pollution

DG sets will be provided with stack height of 3m above the roof top of the

building.

7.2 WASTEWATER MANAGEMENT

Sr.

No Description

Raw water

requirement in

KLD

Wastewater

generation in

KLD

Treatment

1 Processing (Dyeing &

Bleaching)

1500 1500

CETP

2 Weaving & warping

(humidification)

15.0 0.4

3 Sizing 20.0 20.0

4 Cleaning & Sanitation 2.5 2.5

5 Spinning

(humidification)

10.0 --

6 Restrooms 3.0 2.4 STP

7 Industrial Sheds 60.0 51.0

Total 1548 1523

*For weaving & warping, 97% water loss is considered

*For Spinning, 100% water loss is considered


11

All values are in KLD

Fig. 4.0 Water Balance

One time water requirement1548

New Tiruppur Area Development Corporation (NTADCL)

Weaving & Warping(Humidification)

Rest rooms

STP (275 KLD)

Greenbelt

Unit employeesProcessing(dye & Bleaching)

CETP (1750 KLD)

MEE Salt Recovery System

40

1500

1508 (99% efficiency)

Spinning(Humidification

Sizing Cleaning & Sanitation

603

51

51 (100% efficiency)

102.515 201500

0.4 20 2.5

Water Loss

Water Loss14.6

10

1523

1508

Treated water for reuse

Make up water 40

New Tiruppur Area Development Corporation (NTADCL)

1.6 TPD

Solar Beds


12

The wastewater generated from industrial processes shall be treated in Common

Effluent Treatment Plant of 1700 KLD. Another 1700 KLD will be erected as a

another module based upon requirement. Whereas the domestic wastewater

generated from industrial sheds, restrooms shall be treated in STP of 276 KLD.

The treated water from CETP shall be re-used in process and from STP shall be

used for nourishing greenbelt respectively.

7.3 SOLID WASTE MANAGEMENT

Non-hazardous waste

The solid wastes generated from the process are non-hazardous waste generated

from weaving and sizing process. This waste will be sold to recyclers. The organic

waste will be decomposed and converted into manure. The non-organic waste will

be disposed to authorized recyclers.

The quantity of waste generated is as follows

Sr.

No

Description of solid waste Quantity (TPD) Treatment &

disposal

Hazardous wastes

1 CETP Sludge 1.6 TSDF, Gummidipoondi

Recovered salt 4.6 TSDF, Gummidipoondi

Non-hazardous wastes

2 Loom operations 0.3 Re-used in process

3 Sizing units 0.4 Re-used in process

4 Domestic waste

i) Biodegradable

ii) Non-biodegradable

0.45

0.27 (60%)

0.18 (40%)

Composting

5 STP Sludge 0.1 Dried and used as

manure for greenbelt

Hazardous waste

The sludge generated from CETP and recovered salts are the hazardous waste

generated. The biological sludge from CETP will be dried in sludge drying beds

and disposed in authorized landfills. The recovered salts can be reused in the

process.

8.0 REHABILITATION AND RESETTLEMENT

The proposed project site is located in a SEZ notified area. There are no

settlements in and around the project site and hence there are no R & R issues.


13

9.0 PROJECT COST ESTIMATION

The construction of proposed textile SEZ will be be carried out after obtaining EC.

S.No Description

Capital Cost

Rs. in Lakhs

1 Land 230.00

2 Common Infrastructure

Site Development 325.9

Roads 364.2

Storm Water Drains 127.1

Water Supply Network 522.1

Sewage Distribution and Treatment Plant 40.5

Fire and Irrigation System 64.4

Effluent Treatment Plant 0.6

Electrical Generation & Distribution 528.6

Telecommunication 76.7

Landscaping 24.2

3 Common Facilities 1086.8

4 Factory Buildings 3702.0

Total Cost 7093.1

The total project cost will be Rs.70.93 crores, which is inclusive of pollution

control activities.

10.0 ANALYSIS OF PROPOSAL

There will be direct employment for 2100 people and indirect employment

opportunities for 10000. Hence, there will be positive impacts on economic and

social status of the local people.

Documents

IG3 INFRA LTD PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ...environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/31_Oct... · PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ASPECTS OF THE