M/S. Roman Petrochemical - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/12_May... · M/s. Roman Petrochemical ... Project description with process

PRE FEASIBILITY REPORT

FOR

PROPOSED NEW PROJECT OF

M/s. Roman Petrochemical

Survey No. 922/P, Village-Mota Dahisara,

Navlakhi Highway, Ta-Maliya, Dist.-Morbi,

Gujarat

Mr. Ravikumar R Vansadiya Mob No.: 99043 87000

Email: [email protected]

Prepared By: T. R. Associates

[email protected]

[email protected]

Mo. No.: 98253 71099

mailto:[email protected]

mailto:[email protected]

M/S. Roman Petrochemical

Pre-Feasibility Report Page 1

Executive summary M/s. Roman Petrochemical is proposing to manufacture New Products Unsaturated Polyester Resin at Survey No. 922/P2, Village–Mota Dahisara, Navlakhi Highway, Ta- Maliya, Dist.-Morbi, Gujarat.

The total land area of company is 12950 m2 out of which 4270 m2. land will be used for greenbelt area development. The cost for proposed plant will be Rs. 3.0 Crore. Total budget allocation towards Environmental Management Facilities will be Rs. 10 Lacs. Total 30 persons will be employed including skilled persons, unskilled persons and office staff.

M/s. T. R. Associates is carried out EIA/EMP studies for Environmental Clearance from SEIAA, Gujarat. Production details are given below:

Sr. No.

Name of Product Quantity

1 Unsaturated Polyester Resin 500 MT/Month



Salient Features with in 10 km radius surroundings area as follows:

Sr. No. Important Features Description

• Location Survey No. 922/P2, Village-Mota Dahisara, Navlakhi Highway, Ta-Maliya, Dist.-Morbi, Gujarat.

• Topomap F42E8, F42E12, F42K5, F42K9 • Latitude 22°57'2.67"N • Longitude 70°35'9.15"E • MSL 8 m • Nearest power station PGVCL (Paschim Gujarat Vij Company Ltd.) • Proponent Name Mr. Ravikumar R Vansadiya • Corporate office address M/s. Roman Petrochemical

401, Avadh Appartment, Akshar Residency, Opp. Om Party Plot, Canal Chowkdi, Ravapar Road, Morbi – 363 641

• Temperature range 80 C to 400 C • Annual Rain fall 709 mm • Nearest Road SH 24 (0.17 Km) • Nearest Railway station Wankaner-Navlakhi Railway Line (0.42

Km) • Nearest city Morbi (27.2 Km) • Nearest village Khirasara (0.92 Km) • National HW No. NH 947 (8.28 Km) • Seismic Zone Zone-III • National Parks / Sanctuary None within 10 Km radius.



Introduction of the project/ Background information:

(i) Identification of project proponent

Mr. Ravikumar R Vansadiya has 1 year experience in Natural petro chemical.

(ii) Brief description of nature of the project.

It is a small scale project for production of Unsaturated Polyester Resin for sale purpose.

(iii) Need for the project and its importance to the country and or region.

Unsaturated Polyester Resins are used predominantly in making trays, shower stalls, boats, swimming pool, water tanks, etc. Growth of these resins is strongly correlated to decorative coatings and remodeling activity (which accounts for over 50% of consumption), and to a lesser degree, to the aircraft and marine industry also.

(iv) Demand-Supply Gap.

The burgeoning market demands of urban and semi-urban India are estimated at Rs 5,00,000 Crore. The demand-supply gap has already attracted foreign players to India; and the e-retailing boom offers immense business opportunities. But a mere 15% of India's polymer industry is organized. Its semi-skilled decorators, self-styled interior decorators and small-scale local manufacturers will need to be trained and organized to meet future market demands and exploit business opportunities.

(v) Imports v/s. Indigenous production.

Indian market is open and big that is why every kind of import is booming. Indian polymer resin trade has become global place as the consumption of different imported plastics or fibre plastics are on the rise. Unlike before Indians are now welcomed by polymer resin manufacturer of china. Earlier India was a self dependent country for commercial or high quality polymer resins, but sharp drop in domestic manufacturing output has resulted in material sourcing from countries like Burma, Malaysia,



Indonesia, China, Vietnam etc. Now Indian polymer market is somehow curtailed or competed by incoming polymer products from China. Be it film face, decorative, Laminate or everything is now being imported partially or more and is sold. Indian industrialist must understand the fact that it’s no more a regional shift, it is a global shift. Indian technology should be upgraded an updated at par with international standards.

The working environment in India has changed tremendously. Earlier the trade fairs were hardly participated by foreign plastics, thermoset plastics and reinforced plastic manufacturing companies where as now it is flooded with global suppliers.

(vi) Export Possibility.

We are manufacturing Resin for sale purpose. Resin is an intermediate product for manufacturing of decorative coatings, reinforce plastics, etc. Liquid resins are quite expensive for export. So we have only local sale market for distribution.

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

This project will provide direct employment to 30 people in proposed resin unit whereas it will provide employment to many others indirectly.



Project Description 1. Type of project including interlinked and interdependent projects.

Mainly Polymer Resins are used to produce trays, shower stalls, boats, swimming pool, water tanks, etc. Industry will utilize resins for sale purpose only.

2. Location (map) & coordinates

1)

A Latitude: 22°56'58.84"N

3) C Latitude: 22°57'6.34"N

Longitude: 70°35'9.97"E Longitude: 70°35'7.82"E

2) B Latitude: 22°57'5.52"N

4) D Latitude: 22°56'59.94"N

Longitude: 70°35'6.19"E Longitude: 70°35'11.85"E

Satellite Image of project site.



Key Plan of project site

3. Alternate site considered No other sites were selected, as the project is proposed.

4. Size or magnitude of operation

NOTE: Resin will be manufactured for sale purpose.

Sr. No. Name of Product Quantity


Project Location



5. Project description with process details (a schematic diagram/ flow chart Showing the project layout should be given)

Manufacturing Process

Unsaturated Polyester Resin: Manufacturing Process (Using Poly Ethylene Terephthalate as main raw material):

A mixture of 1 mole Poly Ethylene Terephthalate (PET), 1.5 moles Glycol (Di/ Mono Ethylene Glycol or Propylene Glycol) is fed to a reactor equipped with stirrer, thermometer, Nitrogen gas introducing tube and with condenser.

The mixture is mechanically stirred and heated to 150 oC to 170 oC under nitrogen gas stream. When reaction mass become a clear, it is allowed to cool at room temperature and then add 0.6 mole Maleic Anhydride (MA) and continuous heated up to 200 oC – 210 oC until an acid number reaches below 10.

During esterification reaction water formed as a part of reaction, which is continuously removed from the reaction mass as it inhibit the reaction rate.

Then the produced unsaturated polyester resin is cooled to 160 oC. Then add 50 mg of Hydroquinone as inhibitor. When resin temperature dropped below the boiling point of reactive diluent (i.e. Styrene), the polyester resins were mixed with Styrene by 35 weight plastic resin. This mixture is ready for packing.

Chemical Reaction:



Process Flow Diagram:

Poly Ethylene Tere-phthalate Monoethylene or Di Ethylene or Propylene Glycol

Reaction Vessel

Stirring and heating up to 150 °C

When mixture become clear Cool up to room temperature

Reaction Mass

Stirring and heating up to 200 °C – 210 °C until Acid number reaches

below 10

Unsaturated Polyester Resin cooled to 160 °C

Maleic Anhydride

Aquous water

Viscous Unsaturated Polyester Resin

Styrene as a solvent by 35 % of resin for dilution

Product: Unsaturated Polyester Resin



Mass Balance for Unsaturated Polyester Resin:

Raw Material Input Quantity(Kg) Product Output

Quantity(Kg) Poly Ethylene Terephthalate

4468 Unsaturated Polyester Resin

10236

Mono Ethylene Glycol 2164 Aqueous 417 Maleic Anhydride 1368 Styrene 2653

Total 10653 Total 10653 Or




10268

Di Ethylene Glycol 2500 Aqueous 393 Maleic Anhydride 1289 Styrene 2662

Total 10661 Total 10661

Or




10327

Propylene Glycol 3104 Aqueous 350 Maleic Anhydride 1148 Styrene 2677


Manufacturing Process (Using Phthalic Anhydride/Iso phthalic acid as main raw material):

A mixture of 2 mole Mono ethylene Glycol (MEG), 1.0 mole Phthalic Anhydride (PA) will be fed to a reactor equipped with stirrer, thermometer, nitrogen gas indtroducing tube and water condenser.

The mixture will be mechanically stirred and heated to 150 oC under nitrogen gas stream. When reactor mass become clear, it will be allowed to cool below 60 oC or room temperature and then 0.9 mole Maleic Anhydride (MA) will be fed and continuously heated to 200 oC – 210 oC until an acid number reaches below 10.



During esterification reaction, water formed as a part of reaction and is continuously removed from the reaction mass as it inhibits the reaction rate.

Then the produced unsaturated polyester resin is cooled to 160 oC. Then add 150 mg of Hydroquinone as inhibitor. When resin temperature dropped below the boiling point of reactive diluent (i.e. Styrene), the polyester resins were mixed with Styrene by 30 to 35 weight percent of resin. This mixture is ready for packing.

Chemical Reaction:

Or



Process Flow Diagram:

Mass Balance for Unsaturated Polyester Resin:


Quantity(Kg) Phthalic Anhydride 3287

Unsaturated Polyester Resin

10716

Mone Ethylene Glycol 2754 Aqueous 760 Maleic Anhydride 1960 Styrene (as diluent solvent) 3476

Total 11476 Total 11476 Or

Product: Unsaturated Polyester Resin

Phthalic Anhdride Monoethylene Glycol Or Iso Phthalic acid Propylene Glycol

Reaction Vessel

Stirring and heating up to 150 °C

Reaction Mass

Stirring and heating up to 200 °C –210 °C until

Acid number reaches 16

Unsaturated Polyester Resin cooled to 160 °C

Maleic Anhydride

Aquous water

Viscous Unsaturated Polyester Resin

Styrene as solvent by 35 % of resin for dilution

When mixture become clear cool up to 60 °C




Quantity(Kg) Iso Phthalic Acid 3269

Unsaturated Polyester Resin

10843

Propylene Glycol 2993 Aqueous 673 Maleic Anhydride 1738 Styrene (as diluent solvent) 3516


LIST OF PRODUCTS & RAW MATERIAL USED FOR PRODUCTION

Sr. No. Name Of The Product Quantity


LIST OF RAW MATERIALS REQUIRED FOR PRODUCTION

Sr. No. Name Of The Raw Material Quantity MT/Month

Raw Materials for Unsaturated Polyester Resin : 500 MT/Month (If we use Polyethylene Terephthalate as main raw material)

1 2 3

Polyethylene Terephthalate Mono Ethylene Glycol

Maleic Ahydride

281.2 105.7 66.8

OR 1 2 3

Polyethylene Terephthalate Di Ethylene Glycol Maleic Anhydride

205.0 121.7 62.8

OR 1 2 3

Polyethylene Terephthalate Propylene Glycol Maleic Anhydride

181.5 150.3 55.6

4 Styrene(for resin dilution) 129.6 Raw Materials for Unsaturated Polyester Resin : 500 MT/Month

If we use Iso Phthalic Acid/ Phthalic Anhydried as main raw material) 1 2 3

Phthalic Anhydride Mono Ethylene Glycol

Maleic Anhydride

153.4 128.5 91.5

OR



Sr. No. Name Of The Raw Material Quantity MT/Month

1 2 3

Iso Phthalic Acid Propylene Glycol Maleic Anhydride

150.7 138.0 80.1

4 Styrene(for resin dilution) 162.2 Note: When PET is not available then Phthalic Anhydride or Iso Phthalic acid is

used as raw material.

6. Resource optimization/ recycling and reuse envisaged in the project, if any, Should be briefly outlined. No.

7. Availability of water its source, Energy/ power requirement and source should be given. (i) Water source: Road Tanker. (ii) Proposed Water Requirement: 16.9 KL/day. (iii) Energy/power requirement: 200 HP from PGVCL.

8. Quantity of wastes to be generated (liquid and solid) and scheme for

their Management/disposal.

a. Solid waste generation and disposal

Sr. No. Description Category Total Quantity Mode of Disposal

1 Used oil/Spent Oil

5.1 50 Lit/ Month Collection, storage and Use within premises as a lubricant/ sell to registered recycler

2 Discarded Plastic Bags/ Drums

33.3 9.09 MT/month Collection, storage and reuse within premises/ sell to approve scrap vendor.

3 ETP Sludge 34.3 6.0 MT/Annum Collection, storage and disposal at authorized TSDF site.



b. Waste water generation and Disposal facility 1900 liter/day waste water will be generated from the process, washing & cooling.

Effluent treatment plant:

9. Schematic representations of the feasibility drawing which give information of EIA purpose.

The acceptability of the S.O.1533 for the proposed project was explored by considering different possibilities & provision made in the said notification. Considering the products & project’s location of the proposed project, It is notified that the proposed project falls under Category 5(f)”B” of the schedule of EIA notification and its amendments.

As per the provisions of the notification, it is necessary to get Environmental Clearance by applying to MoEF or SPCB, along with the Environmental Impact Assessment report for the proposed project. Therefore the EIA is not required to conduct.

Collection Tank cum

Neutralization Tank

Nutch Filter /Filter Press

Holding Tank

Evaporation system

ETP Sludge to be sent to TSDF site

Waste water from floor washing,

process and cooling tower

blow down



Site Analysis (i) Connectivity.

Nearest Railway line Wankaner-Navlakhi Railway Line

0.42 Km

Nearest Railway station

Morbi Maliya

28.7 km 24.2 km

Nearest National highway

NH 947 8.28 Km

Nearest State highway SH 24 0.17 km Nearest Airport Rajkot 73.68 Km Nearest Seaport Navlakhi Port 12.92 km

(ii) Land Form, Land use and Land ownership.

Industry is proposed unit manufacturing unsaturated polyester resin.

Fig: 1 Land use pattern



There would not be any change in Land use/Land cover activity or Topography due to construction activity after implementation of the project, 32.97% area will be provided for greenbelt development.

(iii) Topography (along with map).

Fig: 2 legendry map of Morbi District

(iv) Existing land use pattern.

Existing land use pattern shown in fig no: 1

(v) Existing Infrastructure. Nearest railway station: Wankaner-Navlakhi Railway Line is 0.42 km in

North direction from the project site. Morbi railway station is 28.7 km in ESE direction and maliya railway station is 24.2 km in NE direction.

Nearest Highway: State highway 24 is 0.17 km away in North from the project site.

Nearest Airport: Rajkot is 73.6 km away in SSE direction from the project site.

Power: 200 HP from PGVCL, Mota Dahisara. Water: Source of the water is Road Tanker. Basic amenities:

Project site



c. Educational facility: Lukhdhirji Engineering Collage, Morbi is 29.9 km away in ESE direction from the project site.

d. Masjid: Kothawala peer, Zinzuda is 4.7 km away in SSW direction from the project site.

e. Post Office: Mota Dahisara is 3.22 km away in ENE direction from the project site.

f. Hospital: Vedant hospital Sanala Road, Morbi is 29.1 km ESE away from the project site.

Land / Soil Characteristic:

The soils are generally developed from Alluvium and basalt formation and are coarse in texture with satisfactory internal drainage. The sub soil conditions below the existing ground level are almost uniform in nature. Sub soil is composed of Clay mixed with little fine grained silty sand, moram and Kankar with low resistivity due to clay and soil moisture. The area is covered with recent to sub recent alluvial deposits comprising of brownish clay mixed with little fine grained sand, silty sand. The Soil below ground level consists of top silty low plastic soil layer having no swelling nature. Blackish brown to yellowish brown clayey silt or sand silt layer extends to the depth of 2 to 3 mt.

Rain fall:-

The average annual rainfall is 551 mm. (30 years). Dependable Rainfall is 660 mm.

(vi) Climatic data from secondary sources.

Location of IMD station: Rajkot

Month

Air Temperature,

°C Humidity, % Mean Wind

Speed,

Km/hr.

Predominating

Wind Direction Max. Min. Max. Min.

Mar-15 42.9 12.2 100 11 10 W

Apr-15 44.3 22 92 6 14 NW

May-15 44.4 24.7 93 7 18 WNW



Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and Country Planning/Development authority Classification.

It is Unsaturated Polyester Resin manufacturing industry located at Morbi district. Total available area is 12950 m2 out of it 4270 m2 (32.97%) area will be provided as a greenbelt area. Industry proposes to manufacture Unsaturated Polyester Resin, used for trays, shower stalls, boats, swimming pool, water tanks, reinforce plastic, etc. manufacturing plant. Further the proposed activities will take care of all the rules and regulation of statutory authority and provide the control measures and devices to achieve the standard norms.

(ii) Population Projection

As per provisional reports of Census India, population of Morbi in 2011 is 194,947; of which male and female are 101,322 and 93,625 respectively. Although Morbi city has population of 194,947; its urban / metropolitan population is 251,859 of which 131,188 are males and 120,671 are females.

Average literacy rate of Morbi in 2011 were 83.64 %. If things are looked out at gender wise, male and female literacy were 89.20% and 77.68% respectively. With regards to Sex Ratio in Morbi, it stood at 924 per 1000 male .

(iii) Land use planning (breakup along with green belt etc).

1 Built Up Area 2497 m2

2 Green belt area 4270 m2 3 Open/ Road area 6183 m2

Total Area 12950.00 m2

(iv) Assessment of Infrastructure Demand (Physical & Social).

Super Specialty and modern health facilities and medical stores are needed around.

(v) Amenities/Facilities.

Industry will provide 2.5 % of total profit for CSR activity.



Proposed Infrastructure Industrial Area

Industry will provide 2497 m2 built up area for industrial process activity. Which provide all needed facility including proper ventilation, safe handling system, etc.

Residential Area

Industry will provide labor quarter for their labors and provide all basic facilities to them.

Green Belt

4270 m2 area will be proposed for greenbelt development.

Social Infrastructure: (i) The PP proposes the following social infrastructure facilities within

10.0 km periphery of the proposed project. (ii) Education Facilities: Many Facilities for village schools like game

kits, drawing kits, table-chairs; school construction (classroom/ toilet/ school boundary), ceiling fans/ coolers or books for school library are proposed.

(iii) Health Facilities: The PP proposes to provide assistance to existing health facilities in Nearest Hospital, for improvement in health facilities or services.

Connectivity (Traffic and Transportation Road / Rail / Metro / Water

ways etc.)

The nearest city is Morbi. Approaching road State highway 24 is 0.17 km away from the project site.

Drinking Water Management

In Proposed unit, Out of 16.9 KL/day water out of which 3.2 KL water will consumed for domestic purpose; 6.2 KL/ day water will be used for industrial purpose and 7.5 KL/day water will be consume for green belt development.

Sewerage System. Domestic waste water 0.15 KL/day will be disposed through soak pit system.



Industrial Waste Management.

In proposed project 1.9 KL/day Waste water will be generated from the washing, cooling tower blow down and process. It will be treated in effluent treatment plant and evaporate after treatment.

Solid Waste Management

Used oil, ETP Sludge, discarded bags & containers are the main solid hazardous waste generated from the proposed unit. Used oil will be send to reused within the factory premises, ETP sludge will collected, stored into solid waste storage area and disposed to authorized TSDF site. Discarded bags and containers will be sold to approve vendor.

Power Requirement & Supply / source

Proposed: 200 HP from PGVCL, Mota Dahisara

Rehabilitation and Resettlement (R & R) Plan Not applicable, as ours is a very small project.

Project schedule & cost Estimates Likely date of start of construction and likely date of completion

(Time schedule for the project to be given) Start construction work: January, 2017 Completion of construction work: June, 2017

Estimated project cost along with analysis in terms of economic viability of the project. (i) Proposed cost for plant: Rs. 3.0 Crores

Documents

M/S. Roman Petrochemical - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/12_May... · M/s. Roman Petrochemical ... Project description with process