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Prefeasibility Report Welspun Flooring Limited FOR Proposed Green filed project For manufacturing of Bulk Continuous Filament (BCF) Yarn and Partially Oriented Yarn, “MANMADE FIBER - (OTHER THAN RAYON)” Activity: 5(d), Category: B2 BY M/s. Welspun Flooring Ltd Unit proposed location : Survey No. 190, Village : Chandanvalli , Shabad (Mandal), Ranga Reddy District, State : Telangana.

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Page 1: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

FOR

Proposed Green filed project

For manufacturing of

Bulk Continuous Filament (BCF) Yarn and Partially Oriented Yarn,

“MANMADE FIBER - (OTHER THAN RAYON)” Activity: 5(d), Category: B2

BY

M/s. Welspun Flooring Ltd

Unit proposed location :

Survey No. 190, Village : Chandanvalli , Shabad (Mandal), Ranga Reddy District,

State : Telangana.

Page 2: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 1

EXECUTIVE SUMMARY

Name of the Project: M/S Welspun Flooring Limited

Location: Survey No. 190, Chandanvelli Village,

Shabad (M), Rangareddy District

Telangana

Project

M/s. Welspun Flooring limited proposed to and has set up its industrial establish Tufted

carpet & synthetic floor tiles at Survey No. 190, Village: Chandanvelli, Shabad ( Mandal),

Rangareddy District, Telangana state

The unit obtained CFE ( Consent for establishment) for manufacture of Tufted carpet and Floor

Tiles unit from Telangana State Pollution Control Board.

Now the company has planned to establish synthetic yarn unit ( Non Rayon and Non

polymerization route) to manufacture Bulk Continuous Filament ( BCF) yarn and Partially

oriented yarn (POY) . Both these materials will be raw materials for manufacture of Tufted

Carpet and Floor tiles.

Proposed Project Cost: Rs. 344.75 Crores

Applicability of EIA notification – 2006

As per the EIA notification- 2006 as amended: Activity-5(d)– “Manmade fiber other than Rayon

”.

Manufacturing of “Manmade fiber other than Rayon”falls under Category-B . As per the Office

Memorandum No. J-13012/12/2013 – IA -II (I) dated 24th December,2013, this is categorized as

B2 project as these fibres are manufactured from Chips and no polymerization reactions are

involved

Project Proponent

• Indian Limited company with diversified activities with its presence in more than 50 countries

• Large Scale Unit

LIST OF FINISHED PRODUCTS ( Proposed)

S.No Name Of the Product Capacity (MT/Annum)

(i) 1 Bulk Continuous Filament Yarn (BCF) 17,500

(ii) 2 (iii) Partially Oriented Yard (POY) 7500

Total 25,000

Note: Both Bulk continuous Filament Yarn & Partially Oriented Yarn (POY) is used as raw

material for tufted carpets and wall tiles which is downstream unit. The unit already obtained CFE

(Consent for establishment) from Telangana State Pollution Control Board for manufacture of tufted

floor carpets and tiles , as it does not attract EC Requirement.

Page 3: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 2

Resource Requirement

• Product wise Raw material Consumption

Sr. No Input material Consumption in

MT/Annum

BCF – 17,500 MT/Annum 1 Base white polymer( PP/

PET/ RPET/ PA6 Chips 17790.5

2 Chips for Colorization 700

3 Spin finish oil 175

Total 18665.5

POY – 7500 MT/Annum

1 Base white polymer Chips (PET/ RPET/ PA6)

7615.55

2 Chips for colorization 350

3 spin finish oil 35

Total 8000.15

• Utilities

Components Requirement Sourced from

Power 8.7 MW TSPDCL ( State Electricity Distribution Company)

D.G. Sets -

(As Standby Power source)

3x 1500 KVA DG sets are common for Tufted carpet plant and BCF & POY plant

Steam Boilers 90.0 TPD

2 x 10TPH coal/Rice Husk Boilers one stand by and one working. These boilers are common for both Tufted plant and BCF&POY plants

HVAC system 5,00,000 M3/hour air handling

capacity To be established for plant

Cooling tower ( with 3 units)

1x 3900 TR To be established for this plant

Water and Waste Water Management

Total fresh water requirement will be @ 688 KL/Day. The same will be sourced from

Government supply through pipeline (Surface water source).

Page 4: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 3

6.5 KLD of wastewater is generated from Monomer washer and Burnout.

Industrial waste water in the form of washings from process, will be treated in the Effluent

Treatment Plant & ZLD system and treated effluent will be re -used back

Blow downs from utilities will be treated in RO system followed by MEE

Domestic waste water will be treated in STP and will be re-used for plantation purpose

ZLD system is common for both this plant and Tufted carpet plant with the following capacities

25 KLD ETP , 50 KLD STP, 170 KLD of RO , 50 KLD MEE

Air Emission and its Control Measures

Proposed to install two nos. Of Steam boilers with 10 TPH capacity ( One stand by and one

running) with Coal/Husk as fuel. This will be established in Tufted carpet plant and steam is

taken from that plant. Bag filters will be control equipment

Three no. of D.G. Set (1500 KVA each) will be installed for proposed Tufted carpet plant and

this project as common resource . This will be only standby power supply.

Adequate stack heights will be providing to boilers and D.G.Sets.

There are no chemical reactions involved hence there are no process gas emission.

Solid & Hazardous Wastes and its Management

Types of Waste & Category

Source of Generation

Total Quantity per

Year Storage Methods Method of Disposal

MEE (28.8 of Sch.IV)

From MEE 0.9 MT/Day Will be stored at a separate storage area

Will be sent to TSDF near Hyderabad

ETP Sludge (32.1 Sch. IV)

From ETP 0.4 MT/day Will be stored in drums

Will be sent to TSDF near Hyderabad.

Empty drums Oil Drums (33.3)

Spin finish oil drums

25No/month Will be stored at a separate storage area

sold to authorized scrap vendor

Yarn waste Solid waste

From process

1710 Kg/Day

Will be packed in bags and stored at a designated area

Sold authorized Recyclers

Multi colored Yarn left outs on bobbins

From Process

2500 Kgs/day Will be stored on bobbins

Sold to secondary yarn users as bi product

Details of Hazardous Chemicals

There are no hazardous chemicals used in the manufacturing process.

Page 5: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 4

1. INTRODUCTION

(i) Identification of Project and proponent.

Name of the project Proponent: M/s. WELSPUN Flooring Limited., proposed to set up Synthetic floor

carpets and carpet floor tiles at Sy. NO 190, Chandanvelli (V), Shabad (M), Ranga Reddy District.

Telangana. Government of Telangana allotted 600 acres of land to Welspun group for all their

upcoming units in this complex.

Welspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun Group

is one of India’s fastest growing conglomerates, registered at a CAGR of more than 20% over the last

decade. Welspun is a fully integrated player within the Pipes, Plates & Coils and Home Textiles

sector, while it also has a presence in the other business verticals such as Steel and Infrastructure.

As a globally recognized leader in the fields of Line Pipes and Home Textiles, Welspun Group has

captured a strong foothold in more than 50 Countries, it employs over 26,000 people and has as

many as 100,000+ shareholders.

Welspun Flooring Limited is a new venture of Welspun Group to provide specialized Flooring

solutions for both domestic and International Market. The facility shall be manufacturing

specialized carpet tiles, wall to wall carpet solution, hard flooring, artificial grass and other products

to be used for Commercial, Residential, Hospitality and Infrastructure sector.

The Company is managed by Board of Directors. The names of the Directors and their

addresses are given below.

Table 1.0 List of Directors of the company

Sl. No. Name of Directors Designation Address

1. Mukesh Sawalani CEO & Director Boulevard I 205, The Address, LBS Marg Ghatkopar West Mumbai 400086

2. Dipali Goenka Director “Rocky Isle”, 46/C, B.Desai Road, Breach Candy Mumbai - 400 26, Maharashtra, India

3. Altaf Jiwani Director 2/1706/Tower 2, 17th Floor, Casa Grande CHS Ltd, S.B. Marg, Lower Parel (W) Mumbai 400013, Maharashtra

4. Devendra Patil Director B/13, Yojna Co-Operative Housing Society Ltd., Natwar Nagar Road No. 5,Jogeshwari (East), Mumbai-400060

5. Pradeep Poddar Independent Director

Flat No. 2, Mont Blanc, 22nd Floor, August Kranti Marg, Off Kemps Corner, Mumbai – 400036

Page 6: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 5

(ii) Brief description of nature of the Project

M/S Welspun Floorings Limited proposed to set up a manufacturing unit at Survey No190,

Village – Chandanvelli, in Rangareddy District of Telangana State, for manufacturing Bulk

Continuous Filament Yarn and Partially Oriented Yarn @ 17,500 TPA and 7,500 TPA

respectively (covered under manmade fiber)

Both Bulk continuous Filament Yarn & Partially Oriented Yarn (POY) is used as raw material

for tufted carpets and wall tiles which is downstream unit. Both these materials are proposed

to use internally. The unit already obtained CFE (Consent for establishment) from Telangana

State Pollution Control Board for manufacture of tufted floor carpets and tiles

Now the company is going for back ward integration to manufacture BCF and POY yarn for

internal consumption

For the proposed project, the company intends to procure the available latest technology for

manufacturing the products listed.

Page 7: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Business Model (Manufacturing Flow chart) Figure 1.0 Process Flow Diagram BCF

Bringing the Chips

Storage of Chips

Conveying of Chips,

conditioning of chips in case

PET/ PA6 & to metering zone

Mixing of Chips and colour chips

Extruder

Melting the Mixture

The melts pump is arrangement of spur gears in planetary

fashion with special design which acts as metering

mechanism for polymer & forces this metered polymer to

spin packs which have fine hair like capillaries for filament

formation.

Spin pack - heart of spinning.

Quenching

Spin Finish Application

Stretching

The strand of filaments is then drawn by stretching

the between pair of rollers in draw zone in tune of 1.1 to

3.5 times of their original length. Surface of rollers are

heated to facilitate drawing process as well as set

molecular orientation.

Texturizing process

Cooled strand of fibres is then lifted off from

cooling drum, Interlaced & wound on paper-tubes

under appropriate tension.

Winding on winders

Page 8: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 7

Page 9: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

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

The proposed project provides key raw materials i.e. BCF and POY for tufted Wall carpet and

carpet tiles which is final product of this company

The domestic demand for PFY stood at 10, 14,755 Tons during the year 2003. The demand for PFY

grew at CAGR of 4.21% to reach an estimated 12, 88,523 Tons by the years 2008. PFY industry, as

we know, had faced difficult market conditions during the years 1999-2002 due to excess capacity

over demand which lead to cut throat unhealthy competition causing substantial erosion in

profitability of these companies. However, as now new capacities came up during this period, the

gap between supply and demand got gradually bridged up and POY manufacturing

units/companies are doing reasonably well since beginning of 2002 and are expected to do much

better during the next few years in view of the sustained demand growth. As per detailed survey

conducted by 'CRISINFAC' the domestic Polyester industry is likely to witness robust demand

growth and higher profit margins in the next five years due to the following positive factors

favoring Polyester industry.

Demand Push:

Increase of PFY in non-appeal segments: In India, fiber is mostly used for textile applications

i.e. 93% and only 7% for non-apparel applications like home textiles, automotive an industrial

segments as against 59% worldwide. The demand of non-apparel segment is expected to grow @

20% p.a. as Polyester offers high tenacity and strength which is most suitable for such

applications.

Lower per capita consumption: The average per capita consumption (PCC) of fabric in India is

much lower than in its neighboring countries. India has a huge potential market, given that its PCC

is as low as 1.4 kg as compared China (5 kgs), Pakistan (3 kgs) and Indonesia (5 kgs). India has the

advantage of a large growing domestic market, and a good GDP growth.

Tufted carpets and wall tiles are gaining lot of market with growing infrastructure projects

such air ports and retail malls.

Manufacturing of manmade fibers globally is getting shifted mainly to China and India. As

China's domestic consumption almost matches its production, India will be able to increase its

presence in the International market. Keeping in view the strong fundamentals mentioned above,

CRISINFAC has projected the POY industry grows at a healthy 7.8% Compounded Annual Growth

Rate (CAGR).

Various Categories: Indian textile industry can be divided into several segments, some of which

can be listed as below:

• Partially Oriented Yarn

• Fully Drawn Yarn

Page 10: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 9

• Nylon Filament Yarn

• Bulk Continuous Filament

• Texturized Yarn, Twisted Yarn, Monofilament Yarn, Splitting Yarn, Intermingled Yarn

(iv) Demand –Supply Gap

The products have very high demand for the process of weaving and knitting carpets and wall

tiles

(v) Imports vs. Indigenous production

Existing products manufacturing in the country will be very much economical compare to Imports

of the same. The growing crude prices and pushing international price for filament yarn

(vi) Export Possibility / Domestic / export Markets

There is a huge demand of synthetic filament yarn in the export market.

Employment Generation (Direct and Indirect) due to the project

There will be very good opportunity of employment generation directly and indirectly due to

proposed expansion. Directly about 270 no. of persons. It will also generate employment in

transport and other support sectors.

Page 11: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 10

2. PROJECT DESCRIPTION

(i) Type of Project including interlinked and interdependent projects, If any :

The project is interdependent project of the company. The down stream project of Tufted wall to

wall carpets and Carpet tiles unit is under implementation in the same complex

(ii) Location (map showing general location, Specific location, and project boundary & project

site layout) with coordinates:

The map showing general location, specific location and project boundary and project site layout

of Welspun Flooring Limited Located at Survey No. 190, Chandanvelli (V), Shabad (M) ,

Rangareddy District, Telangana

Figure 2.0: Location map showing the Project site and features within 10 Kms radius

Page 12: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 11

Figure 3.0 Topo Map of The Plant and 10 KM radius

Page 13: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 12

(iii) Profile of Project Site:

Table 2.0 Salient features of Project site and surroundings

Sr. No. Nearest Infrastructure Feature Distance from Project Site (Aerial Distance)

1 Geographical Position

N 17 13 08.3 , E 78 10 30.8 N 17 13 08.7 , E 78 10 59.4 N 17 12 55.4 , E 78 10 59.1 N 17 12 55.2 , E 78 10 31.0

2 Elevation above Sea Level 520 Meters above MSL (Approx.)

3 Nearest Village

Anthareddyguda – 0.5 KM – South-West Chandanvelli – 1.45 KM - North Machanpali - 1.2 KM - South - West

4 Nearest Town Shabad– 8 Km SW (Approx.)

5 Nearest National Highway NH 8: 15.7km (Approx.) in West (Approx.)

6 Nearest State Highway SH No 5.87 Km West (Approx.)

7 Nearer Railway Station Thimmapur - 13 KM

8 Nearest Airport Samshabad - 26 KM

9 Nearest Surface water Resource/Reservoir

Polaram cheruvu 0.64(SW), Machanpalli cheruvu 1.08 Kms(SW), Nagarkunta tank2.16 Kms(SW), Musa River – about 3 KM in the North

10 Forest Land Mudimial RF-8.92 Kms(NE)

11 Location of Archaeologically /Historically important places

None

12 National Park/Sanctuary or Ecologically sensitive Area

None

13 National or State Boundary None

14 Tourist Places None

• Area Statement

Table 3.0 Area statement of the project

S.No Description Area in Sq.Mtrs

1 Tufted wall carpet & Tiles plant 53799

2 Ware house 25200 3 Utilities 5300 4 Administrative office 1800 5 Area for future expansion 570209 6 Canteen Building 150 7 Security 100

8 Waste water treatment plant 1600

9 Scrap yard 500

10 Green belt 113547 11 Parking 19056 12 BCF & POY 17939

Total area 809200

Page 14: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 13

➢ Out of 600 acres of land allotted by Telangana State Industrial Infrastructure corporation

(TSIIC), 200 acres of land is allocated for Tufted carpets and BCF & POY plant.

➢ This project will be implemented within the existing premises procured at the initial stage of

unit with required civil construction and installation of required plant and machineries.

➢ There is no requirement of additional land for the implementation of proposed change in

product profile.

Site Layout Plan:

Figure 4.0 Site Lay out plan

Page 15: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 14

Figure 5.0 Plant lay out plan

Page 16: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 15

(iv) Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted :

Proposed change in product profile will be implemented in the existing developed site only hence

alternate site consideration is not envisaged.

(v) Size or magnitude of operation :

As per the proposed project cost the project is covered under Large Scale category of

manufacturing industries.

(vi) Project description with process details :

• LIST OF FINISHED PRODUCTS

Proposed products & capacity

S.No Production Details Quantity In MT 1 Bulk Continuous Filament (BCF) 17,500 MT/Annum

2 Partially Oriented Yarn (POY) 7, 500 MT/Annum

• INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES

Within the existing premises with required civil work for manufacturing of the these

products

Within the existing premises and infrastructure the installation of required plant and

machineries will be required.

List of critical machinery involved in manufacture of Synthetic Filament yarn

Table 4.0 Critical Machinery Proposed

Sr. No. Description of Equipment Sr. No. Description of Equipment BCF Manufacturing – Key equipment For POY Line I Chips conveying system 1 Chips Silos and Conveyor system 1. Chips Crystallizer 2 Chips Crystallizers 2. Chips Dryer 3 Chips Dryer 3. Master batch metering and

mixing device 4 Metering and mixing unit

4. Extruder 5 Melting and Extruder 5. Spinning beam arrangement 6 Spinning machine 6. Spin packs 7 Quenching unit 7. Dow therm Heating system 8 Winding unit 8 Quench air unit with

humidifier 9 Process control room

9 Texturising machine 10 Chilled water system 11 Process control room

Page 17: M/s. Welspun Flooring Ltdenvironmentclearance.nic.in/writereaddata/EIA/22112018H720QETAPFR.pdfWelspun Flooring Limited is part of Welspun Group has a US$ 2.3 billion company, Welspun

Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 16

• MANUFACTURING PROCESS

The company is using the latest available process technology for the production. This chapter

Includes the manufacturing process of the product and material mass balance for the product.

01. Product: Bulk Continuous Filament Yarn (BCF)

a. Manufacturing Process:

BCF process is combination of two processes of drawing and texturising combined together at

high speed of manufacturing. This process is used to make coarser denier (single strand) directly

between 1000 denier to 4000. Primarily three Raw material i.e. Polyester, Nylon, PP are used in

the form of Chips. Majority of yarns will be coloured at melt stage involving no use of water in

coloration.

Step wise process is as follows:

Chips drying and crystallizing

• Chips are stored in silo as per fibres, grades, supplier, lustres etc. Special storage conditions of

dry air / nitrogen purging are required for PA6. This is required for preventing hydrolysis of

PA6 polymer

• For PET as mentioned crystallizing and drying is required. This is done using hot air circuit and desiccant dryers. In this process PET chip moisture content is reduced to less than 30 PPM.

Extrusion process

• Dried chips are fed into extruder for melting, compression and mixing (homogenization by a

moving spiral barrier type screw. Screw barrel is treated in five different constant

temperature zones.

• From outlet of extruder, melt is transferred to spin beam via melt transfer line Spin which is

electrically heated

Spin Beam Process

• Spin beam is a jacket sump which includes static mixtures, manifold and melt pump. Here

melts is further homogenize due to presence of static mixtures in polymer lines. Spin beam is

heated using thermic fluid vapor

Metering

Positive displacement pump of different capacity speed controlled by inverter, decides.

Melt comes to pack contains various filters and spinneret which decides number of filament in

yarn.

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 17

Quenching:

These hot melt steam projecting out of spinneret capillaries are greeted by conditioned air in

quench zone. The temperature of quench zone is positively controlled for temperature as well as

humidity.

Typical quench temp range between 14-21 deg. Velocity of air for quench ranges from 0.2 m/s to

0.8 m/s. Relative humidity is also a critical parameter along with temp in Pa6 as Shrinkage values

Spin finish application:

• Cooled strands of fibers is applied spin finish oil in metered quantity to overcome friction in

next process & keep fibrous bundle in cohesive form.

• Unlike POY / FDY process here we apply neat oil. Oil application is done in two stages and has

migration nozzles which blow air a low pressure to evenly spread oil applied.

Stretching:

• The strand of filaments is then drawn by stretching them between pair of rollers in draw zone

in tune of 1.1 to 3.5 times of their original length. This value varies for fiber to fiber. DPF has

important role in deciding the stretch.( D.R). This is important parameter which resilience of

yarn to an extend.

• We have series of 5 rollers in drawing arrangements. Surface of rollers are heated to facilitate

drawing process as well as set molecular orientation. Temperatures are different for fibres

spun. PP needs temp of 130-140 deg, Pa6 up to 180 & PET up to 190 deg

Texturizing

• The strand of filaments is then subjected to texturizing process. This is heart of BCF process

were flat drawn filaments are processed to apply bulk using hot compressed air and then

cooled off on cooling drum.

• As seen in photo yarn moves straight in nozzle grove at steady tension and jet of hot air at

high pressure hits the yarn at angle, creates vortex .This creates yarn to loose it straight form

and gains bulk

• Further yarn enters lamella chamber which form a conical space used for pluck formation.

Geometry of nozzle & lamella dimensions are demonstrated in next step

Winding :

• The Yarn is ready. It will be wound on the tubes using a very accurate winding speed.

• It’s a complex robotic mechanism yet very accurate & precise in terms of speed and length. We

need to set length of yarn to be wound on package. This is automatic machine which

automatically changes and doffs bobbin once set length is achieved

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 18

Inspection, packing and Dispatch

Inspection & Testing and Grading will be done and material is ready for Packing and dispatch.

Material will be send to downstream plant of the unit i.e., Tufted carpet plant, located in the

same premises

b. Process Flow Diagram

Packing and dispatch to Tufted carpet division

Spinning of Yarn as per required denier and QUENCHING

Spin finish oil application to Yarn

Texturising

Winding of Yarn by high speed spindle driven auto turret winder

Filtration through C.P.F and METERING

Dried chips melting, compression and mixing in extruder

Drying in Fluidized bed crystallizer cum dryer

Polyester/Nylon chips / colour master batches conveying pneumatically

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 19

c. Material mass balance :

Table 5.0 Typical Material Balance of BCF

Sr. No Input material

Consumption in MTPA Output material

Quantity in MTPA

1 Base white polymer( PP/ PET/ RPET/ PA6 Chips

17790.5 BCF Fibre 17500

2 Colour pigments compounded with base polymer

700 2nd quality of Fibre ( Bi- product)

612.50

3 Spin finish oil 175 Yarn waste 416.50

Hard Flushing waste 49.00

Moisture and other system losses

87.50

Total 18665.5 18665.5

02. Product: Partially Oriented Yarn ( POY )

a. Manufacturing Process:

The process is very similar to BCF manufacturing except that PET ( Poly Ehylene Tetra ) chips are

first crystallised and dried as chips need to be modified from amorphous to Crystallised form

amorphous form to crystallised form and to avoid shrinkage of chips in the extruder. The moisture

need to be removed from chips then they will go to extruder.

Another major difference in POY is, it is process where fibre is manufactured material which neither

drawn nor texturized . material is drawn and textured on different machine which is called as Draw

texturizing process. So its using two stage process. Here due to process speeds we can make a finer

DPF product ranging between 0.5 to 2.5

Poy is dimensionally unstable product with higher % elongation ranging between 120-150 % and

characterised by low strength and high shrinkage making it unsuitable to use in direct tufting/ heat

setting or tufting process.

The poy yarn is drawn and texturized on friction texturising machines and then Bundled together ( On

parallel winding machines or texturising machine itself) to form a coarser denier to be used in

Twisting/ heat setting or direct tufting.

Feel of yarn manufactured By Poy route are much softer as compare to BCF yarns and hence poy route

process is applied to manufacture carpet yarn suitable for certain applications of carpets like bath mats

or area rugs.

Carpet manufactured out of POY route yarn may have lower resilience and high wear under high traffic

areas and hence BCF yarns are preferred in areas of high traffic.

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 20

b. Process Flow Diagram

c. Material mass balance :

Table 6.0 Typical Material Balance for POY Fibre – Production capacity of 7500 MT

Sr. No Input material

Consumption in MTPA Output material

Quantity in MTPA

1 Base white polymer Chips (PET/ RPET/ PA6)

7615.55 POY Fiber 7500

2 Colored Chips for (colored chips made in our RM plant . It uses color pigments compounded with base polymers)

350 Un useable fiber on bobbins ( Bi- product)

262.50

3 spin finish oil 35 Yarn waste 179.55

Hard Flushing waste 21.00

Moisture and other system losses

37.50

Total 8000.55

8000.55

Quenching

Spinning

Extrusion

Crystalliser & Dryer

Base White Polymer Chips ( PET, RPET, PA6) , Master Batch & other

Additives

Winding

Inspection and Dispatch

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(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source, marketing are of

final products mode of transport of raw material and finish product

• Raw material requirements:

Table 7.0

List of Raw-materials

S.No Raw material Per Ton of BCF

production in Tons

Quantity required for in TPA ( Tons per annum)

For BCF Production 1 Base white polymer( PP/

PET/ RPET/ PA6 Chips 1.0166 17790.5

2 Color pigments 0.04 700 3 Spin finish Oil 0.01 175 FOR POY Production 1 Base white polymer Chips

(PET/ RPET/ PA6) 1.0154 7615.55

2 Colored Chips with Additives

0.0467 350

3 Spin Finish Oil 0.00467 35

• Marketing area of final products:

Company is manufacturing Bulk Continuous Filament yarn and Partially Oriented Yarn (FDY)” which is used in the process of manufacture of Tufted wall to wall carpet and floor tiles unit established in house

• Transport of Raw material and Finish products:

Table 8.0 Storage and Transportation of Raw materials

Sr. No.

Name Storage Capacity

Means of Storage

Mode Of transport

Source

1. Chips for POY / FDY 500 MT Ware house By road in truck Manufacturer

2. Spin finish oil 50 MT Storage Tank By road in tanker

Manufacturer

3. Pigments 10 MT Ware house By road in truck Manufacturer

4. Waxes 5 MT Ware house By road in truck Manufacturer

(viii) Resource optimization/ recycling and reuse envisaged in the project , if any , should briefly

outlined :

By adoption continuous improvement in technology and process the reduction in process

waste generation will be achieved.

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Efficient handling of raw materials the wastages of raw materials will be reduced.

(ix) Availability of water its source, Energy/power requirement and source should be given:

Availability of water its source, Energy/power required and its source.

• Water Requirement

Table 9.0 Water requirement

S.No. Stream Fresh Water requirement in

KLD

Recycled KLD

Total KLD

1 Process

Monomer washer (BCF)

3.5 0 3.5

Spin Finish Preparation (POY)

1.5 0 1.5

Burn out (BCF & POY)

4 0 4

2 Cooling tower make up

445 27.5 472.5

2 (a) HVAC Make up 120 34 154

3 Boiler * 99 0 99

4 Domestic 24 0 24

5 Gardening & Landscaping

0 19 66

Total 688 80.5 768.5

* Steam requirement is met from common boiler for both plants. Quantity given here for steam

requirement of this plant

Source of water : Supplied through TSIIC Pipeline

• Energy Requirements and its source:

Table 10.0 Energy Requirement

Sr. No. Particulars Existing Proposed Source

1 Steam requirement

Nil 3750 Kgs/Hr (max)

Two nos. of Steam Boiler having steam generation. capacity of 10 T/hour will be established as common resource for this plant and Tufted carpet plant One will be stand by. Fuel will be either coal or Rice Husk

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• Power Requirements and its source:

Table 11.0 Power requirement

Sr. No.

Particulars Requirement Source

1 Power –Electricity

requirement 8.7 MW TS PDCL

(x) Quantity of waste to be generated (liquid and solid) and scheme for their

Management/disposal:

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

• Quantity of Waste Water (liquid waste) generation and its management :

Table 12.0 Waster water generation & Management

S.No. Stream Waste water generation in KLD

Treatment & Point of Disposal

1 Process

Monomer washer (BCF) 2.5 Will be treated in ETP, RO and MEE and re-used for cooling tower

Spin Finish Preparation (POY)

0

Burn out (BCF & POY) 4.0

2 Cooling tower blow down 50.0 Blow down water Will be treated in RO and re-used

2 (a) HVAC system blow down 3.0

3 Boiler blow down 2.0 Will treated in RO and re-used

4 Domestic 19 Treated in STP and re-used for plantations

Total 80.5

• The Domestic waste water generated will be treated in STP and reused for plantation purpose

• Industrial waste water in the form of washing are treated in ETP and then send to RO. RO rejects

will be send to MEE and RO Permeat will be used back for utilities

• Blow downs from utilities will be treated in RO and rejects will be sent to MEE and permeate will

be re-used

• Hence, there is no discharge of treated effluent

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Water Balance Diagram: considering proposed

Figure 6.0 Water Balance diagram

Detailed of Effluent Treatment Plant

• Design Criteria:

• Product : Synthetic Filament Yarn

• Source of Effluent : Process Washings & Process effluents from Tufted carpet plant

• Design Flow of Effluent : 25 KL/day Max.

• Design Parameter : As under

Table 13.0

Effluent Characteristics

Sr. No.

Test Parameters Untreated effluent Treated Effluent

1. pH 6 to 8 6.5 to 8.5

2. Suspended Solids (mg/lit) 250 to 350 <100 3. Total Dissolved Solids (mg/lit) 1500 to 2000 <2100 4. COD Value (mg/lit) 2000 to 3000 <100

5. BOD Value ( 3 days at 27o c) (mg/lit) 900 to 1300 <30

6. Oil & Grease (mg/lit) 10 to 25 <10

Domestic

15.00 KL/day Process

9.00 KL/day

Boiler, Cooling Tower & HVAC

655KL/day

STP Total Effluent (61.5 KL/day) (

Process effluents will be treated in ETP followed by RO and MEE

Utility blow downs will be directly

send to RO

Fresh water (688 KL/day)

24.00 KL/day 9.00 KL/day 301.5 KL/day

19.00 KL/day 6.5 KL/day 55 KL/day

Condensate

from MEE

Reused for utilities

Gardening

19.0 KL/day

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EFFLUENT TREATMENT SCHEME

1. PRIMARY TREATMENT

UNITS : Oil & Grease removal Tank

Collection Cum Neutralization / Reaction Tank

Primary settling and sludge removal

The effluent coming from the plant is initially passed through the Oil & Grease removal system. The oil

free effluent is then collected into the collection cum reaction tank. In the collection cum reaction tank

various chemicals like None Ferric Alum, Caustic soda/acid and polyelectrolyte (coagulant) are added

to ensure proper settling which reduces the suspended solid concentration, colour and COD in the

effluent. The treated effluent is then fed into the primary clarifier. Clear effluent from primary settling

tank is charged into the secondary treatment tank (Aeration tank) and settled sludge is discharged into

the sludge drying beds and leached of the sludge drying beds is going back to collection tank.

2. SECONDARY TREATMENT (BIOLOGICAL TREATMENT)

UNITS: Aeration Tank & Secondary clarifier

The primary treated clear effluent is passed through the aeration tank where the biodegradation of the

organic matter is taken place in presence of active microorganism and required Dissolved Oxygen level.

During the biological treatment BOD Value and COD Value are reduced. After the biological treatment

(aeration tank) the effluent with the biomass is passed through secondary settling tank where biomass

is settled and settled biomass is recycle back to aeration tank or if excess is discharged into the sludge

drying beds. And clear effluent is collected into the holding tank.

3. TERTIARY TREATMENT

UNIT: Sand Filter & Ultra Filtration

After secondary treatment the effluent is passed through sand filtration and ultra filtration along with

utilities blow downs . Treated water sent to RO System. The Rejects from RO will be sent to MEE for

evaporation. Concentrate from MEE will be send to dryer and Dried salts are disposed to TSDF facility.

The condensate from MEE will be send back to units for utilization in utilities.

The company will monitor the characteristics of the effluent and as required by state pollution Control

Board

The Process flow sheet of proposed ETP is given hereunder

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Figure 7.0 ETP Flow Diagram

19KLD

Blow downs from utilities From BCF plant ( 55KLD)

Blow downs from tufted carpet plant (84 KLD)

45 KLD

Condensate Condensate

42 KLD 3 KLD ( concentrate

Salts

• Utility Emission & Control Measures :

❖ Utility Emissions & Control Measures as per existing permissions and proposed project:

Effluent Treatment Plant

Collection Tank Waste Water Tufted Carpets

Plant 10 KLD

BCF & POI Plant

9.0 KLD

Preliminary Treatment

Oil & Grease trap, Flocculation, Clarifier,

Biological Treatment

Aeration system and secondary clarifier

Tertiary treatment

Sand & Ultra Filtration & RO

MEE

Dryer TSDF

Recycled back

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Table 14.0 Emission sources and controls

Details Fuel & its consumption

Probable Pollutants

Emission Rate

Control Measures

Remark

Stand by D.G. Sets: 3 x1500 KVA

HSD = 12 KL/Month

PM SO2

NOx

<100mg/Nm3

< 100 ppm < 50 ppm

Stack Ht: 20 meters. With Acoustic enclosure

Will be common resource for both this plant Tufted carpet plant

Steam Boiler: 2 Nos. Capacity: 2x 10 TPH Capacity

Coal /Hsuk If Coal – 20

TPD If Husk – 35

TPD

PM SO2

NOx

<115 mg/Nm3

< 100 ppm < 50 ppm

Stack Ht: 30 meters With Bag filter as control equipment

Will be common resource for both this plant Tufted carpet plant .

Monomer washer Nil

PM <100 mg/Nm3

Stack Ht: 15 meters.

Water trap

The company is installing 3 D.G. Sets of 1500 KVA capacity each. The D.G. Sets will act as standby

unit and will be only utilized in case of power failure. The company has valid consent to operate

under the air act to operate D.G. Sets. Flue gas stack monitoring reports are enclosed for the same.

The company will provide adequate chimney height to the utilities in order to control the utility

emissions. Apart from the above mentioned utilities, there will be Cooling Tower, DM Water Plant

and Chillers. The company will use Coal/Husk for boiler as fuel and HSD for DG sets.

• Quantity of Solid Waste generation and its management :

The hazardous waste will be generated from process, ETP, machinery and raw material

consumption. All the wastes will be stored separately in a designated storage area safely and

properly. The company will send its ETP waste to Ramkey TSDF facilities near Hyderabad

for final disposal.

Yarn waste from process will be sold to other users. Used oil from machinery will be sold to

registered recycler/re-processor. Empty drums and bags will be sold to authorized re-

conditioner & authorized scrap vendor. The following wastes will be generated from the

operational activities.

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Table 15.0 Hazardous and Non hazardous waste generation and Disposal

Types of Waste & Category

Source of Generation

Total Quantity per Year

Storage Methods Method of Disposal

ETP Waste (32.1)

From ETP 1 MT/Day Will be stored at a separate storage area

Will be sent to TSDF Site of Ramkey near Hyderabad.

MEE Salts From MEE 0.9 T/day Will be stored at a separate storage area

Will be sent to TSDF Site of Ramkey near Hyderabad.

Used oil (5.1) From process

1.5 TPA Will be stored in drums

Will be sold to registered recycler/ re-processor.

Empty drums/ bags/Liners (33.3)

Raw material cons.

10000 Nos./Year

Will be stored at a separate storage area

Will be reused internally and sold to authorized scrap vendor or reused.

Left over yarn on bobbins

From process

2500 Kgs/day

Will be packed in bags and stored at a designated area

Will be recycled back /sold to other users

Yarn soft waste

From process

1710 Kgs/day Will be packed in bags and stored at a designated area

Will be sold to other users/Authorised re-processors

Hard Flush Waste ( Generated when there are power failures )

From process

200 Kgs/day Will be packed in bags and stored at a designated area

Will be sold to other users/Authorised re-processors

Other packaging Waste

From Stores

7000 Kg/day Will be stored in designated area

Will be given to scrap dealer

Coal/Husk Ash

From Boiler section

10 T/Day Will be stored in closed shed

Will be sold to brick manufacturers

Details of Hazardous Chemicals

There are no hazardous chemicals used in the existing manufacturing process. Also, there will be no hazardous chemicals involved in the process in the proposed expansion project.

Health & safety

The company is concerned about the occupational health and safety among its work force as the

man power is the biggest asset to the industry. The On-site Emergency Plan is prepared and

implemented for existing activities and will be modified as per proposed change in product mix and

will be implemented. The Off-site Emergency Plan is available with the District Collector Office, RR

district.

The following safety measures are implemented and will be followed:

➢ Safety Training will be provided to the employees.

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➢ Safety Alarm Systems are installed for use, in case of emergency.

➢ Emergency Control Room with emergency sirens is established.

➢ Assembly point is provided.

➢ Fire Hydrant System proposed .

➢ Fire Extinguishers are provided.

➢ Mock drills are periodically conducted and factors like response time are evaluated.

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

team will be conducted.

➢ First Aid Facility and training is provided.

➢ Personal protective gears and equipment’s is provided to the employees.

➢ Health checkups are organized at regular intervals.

➢ Safety / Health records and MSDS will be maintained.

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(xi) Schematic representations of the feasibility drawing which give information of EIA

purpose:

Resource requirements • Raw Material: Sourced from Manufacturer / Traders of the same. • Land: Expansion within existing premises. • Water: Will be sourced from TSIIC from surface water source • Power: power will be sourced through TS PDCL • Fuel : Local dealer

Env. Mgt. Plan (EMP)

• Air Pollution Control Measures: Air Pollution control system will be

provided.

• About 33% of the Total Area will be developed as Greenbelt.

• Health & Safety measures will be followed properly

• STP for domestic water and treated water to go for plantation

• ETP will be provided for Industrial waste water with ZLD concept

• Flue Gas emissions: Bag filters for boilers Adequate chimney height will be provided.

• Fugitive emission: There is no generation of fugitive emissions.

Public consultation: Not required it is B2 project as per As per the Office Memorandum No. J-13012/12/2013 – IA -II (I) dated 24th

December,2013

Submission of Form-1, Pre-Feasibility Report as it is category B2 as per the OM

Presentation before the EAC for TOR

Type of Industry Proposed mfg. unit of “Man Made fiber-other than Rayon”

Site Location: The company proposed this unit at SY. No 190,

Chandanvalle (V), Shabad (M), Ranga Reddy District of Telangana

Proposed Activity: The proposed project involves the production of "Synthetic Filaments Yarn- Manmade fibers" manufactured from Chips

Type of category as per EIA notification:Man Made fiber (Activity -5(d)-

Category-B)

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3. SITE ANALYSES

3.0 Site Analysis

(i) Connectivity:

The project is located in Chandanvalle (V) which is very well connected to National Highway no.7

which is about 14.3 KM from the site. And the nearest air port Hyderabad Air port which is about

26 KM from site.

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

1. The land is owned by M/s. Welspun Flooring Limited , allotted by TSIIC

2. The land is near Chandanvalle(V) and not in notified industrial area

(iii) Topography (along with map) :

Base map showing the study area below

Figure 8.0 Base map of the study area

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(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from

the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification

should be given:

Current land use is agricultural land and same is allotted by Telangana State Industrial

Infrastructural Corporation . Copy of letter from TSIIC is enclosed at Annexure. It does not come

under CRZ. No National parks, wild life sanctuaries, eco sensitive zones within 10 KM radius. The

site does not come under HFL of any river.

(v) Existing Infrastructure:

Total 600 acres of land is allotted to the company by TSIIC for various units to be established by

company. Out of this, 200 acres are allotted to Tufted carpet plant. Tufted carpet plant already

obtained CFE from state Pollution Control Board of Telangana and plant is under

implementation. This unit is back ward integration plant. Industrial infrastructure will be

developed as a part of this project

(vi) Soil classification:

General soil classification of the area is as under:

• Soil Characteristics & Land use classification: Most of the area cultivated depending on rain fed

and bore wells

• Surface color: black soils

• Depth of the soil: 0 - 25 cm (shallow to mod deep)

• Predominant Texture: Heavy Texture, predominantly clay.

(vii) Climate data from secondary sources:

Rainfall Data:

Rainfall data was taken from central Ground water board data , indicates that the mean spanning

the period 1999 -2011 is medium to high 51.6 to 110.13 cm rainfall

Climate data:

Rangareddy District is in Deccan Plato the mean temperature of the area is about 30 Deg C. Peak

summer temperature reaches up to 43 Deg C and winter lows will be around 12-13 deg C

(viii) Social Infrastructure available:

Social Infrastructure in RR District is here under

Education:

The educational quality of the local people is fairly good as the literacy rate of the area is

recorded to be 75.87%. Male literacy rate is 82.11 and female literacy rate is 69.4%

Health:

The region is served by 4 medical college hospitals, 4 General hospitals , 39 Primary Health

centers, another 30 dispencerties. The crude birth rate is 17.4 and infant mortality rate is 39 for

1000 live births

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Education:

Basic educational facilities are well developed RR District. There are 126 degree colleges, 563

Junior colleges, 134 Engineering colleges, 4 medical colleges, 5263 Schools.

Tourism:

Rangareddy District is very close to Hyderabad City. Many mandals of the District are suburbs of

Hyderabad. There are many tourist destinations in Ranga reddy District which include old siva

temple in Maheswaram, Lord Venkateswara temple near Chilukur, Anantagiri Hills which is

having resorts, Ramoji Film City which is well known film city complex in the country, Sanghi

Temple complex in Sanghi nagar, Himayat sagar, Shamirpet lakes are few to mention. However

there are no tourist spots within 10 KM radius of the current project site

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4. Planning Description

4.0 Planning Brief.

(i) Planning Concept (Type of industries, facilities, transportation etc) Town and Country

Planning /Development authority Classification:

There are few small scale units, primary agro based units are there within the vicinity.

(ii) Population Projection:

Rangareddy District is having total population of 52,96,741 people with population density of

707 people for square KM. The compound annual growth rate is 4.01 as per 2011 census data

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

Area Statement

Table 16.0 Area statement

Sr. No. Area Area Statement (Sq. mt.)

1. Total Plot Area 8,09,200

2. Total build up area for Tufted wall carpet plant 53.799

3 Total build up area for BCF& POY plant 17,939

4 Other utilities, ware house, parking etc. 53,706

3. Total Green belt Area 1,13,547

4. Open Plot Area for future expansion 5,70,209

Site Layout Plan

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(iv) Assessment of Infrastructure demand (Physical & Social) :

There is no need for any additional infrastructure demand in terms of physical or social needs.

(v) Amenities/ Facilities:

TSIIC is providing all necessary infrastructure like power, water supply and road connectively to site etc.

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5. Infrastructure Details

5.0 Proposed Infrastructure:

(i) Industrial Area (Processing Area).

The proposed BCF and POY plant require shed and other support facilities which will be built.

Steam generation, ware house, stand by power generation , ETP , STP , parking facilities are

common to both Tufted carpet plant and this plant which are under development

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project.

(iii) Green Belt:

Green belt area will be provided and maintain at the tune of 33% of the total land area.

(iv) Social Infrastructure:

Facilities like road and communication are good. One can be sure of the uninterrupted power

supply and adequate water. There are plenty of hotels, Banks, ATM's and medical facilities are

also adequate within 10 KM radius of the plant

Amenities: Education- 30 schools including middle, secondary and higher secondary schools, 6

social welfare hostels, 2 libraries, 3 engineering colleges , 2 degree colleges are accessible to site .

Medical and Health- There is a Civil Hospital in Samshabad, Primary health center in Shabad and

other private dispenceries near by

Power and water- All the villages are electrified and drinking water facilities are extended to all

villages.

Rail and Road- The nearest railway station is Vikarabad which is 30 KM from the site. From there

the site is well connected through Shabad road which District road. NH 7 is at about 14.06 KM

(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) :

The project site is very well connected by road through National Highway no. 7 and South Central

Railway

(vi) Drinking Water management (Source& Supply of water) :

Water requirement will be fulfilled through TSIIC water supply line sourced from surface water

sources

(vii) Sewerage System:

There will be no discharge of industrial effluent (Zero Liquid Discharge). The treated effluent will

be utilized for utilities

Domestic waste water will be treated and re-used for plantation purpose

(viii) Industrial Waste Management:

Washings from process and blow downs from utilities will be treated in ZLD treatment plant and re-ued

(ix) Solid Waste Management:

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 37

Table 17.0 Details of Solid Waste Management

Types of Waste & Category

Source of Generation

Total Quantity per Year

Storage Methods Method of Disposal

ETP Waste (32.1)

From ETP 1 MT/Day Will be stored at a separate storage area

Will be sent to TSDF Site of Ramkey near Hyderabad.

MEE Salts From MEE 0.9 T/day Will be stored at a separate storage area

Will be sent to TSDF Site of Ramkey near Hyderabad.

Used oil (5.1) From process

1.5 TPA Will be stored in drums

Will be sold to registered recycler/ re-processor.

Empty drums/ bags/Liners (33.3)

Raw material cons.

10000 Nos./Year

Will be stored at a separate storage area

Will be reused internally and sold to authorized scrap vendor or reused.

Left over yarn on bobbins

From process

2500 Kgs/day

Will be packed in bags and stored at a designated area

Will be recycled back /sold to other users

Yarn soft waste

From process

1710 Kgs/day Will be packed in bags and stored at a designated area

Will be sold to other users/Authorised re-processors

Hard Flush Waste ( Generated when there are power failures )

From process

200 Kgs/day Will be packed in bags and stored at a designated area

Will be sold to other users/Authorised re-processors

Other packaging Waste

From Stores

7000 Kg/day Will be stored in designated area

Will be given to scrap dealer

Coal/Husk Ash

From Boiler section

10 T/Day Will be stored in closed shed

Will be sold to brick manufacturers

(x) Power Requirement & Supply / Source:

Power requirement for proposed project will be taken from TSPDCL and stand by DG sets are

proposed in case of any power outage

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 38

6. Rehabilitation and Resettlement (R&R) Plan:

(i) Policy to be adopted (Central/ State) in respect of the project affected persons including

home oustees, land oustees and landless laborers (a brief outline to be given):

There will be no rehabilitation and resettlement undertaken as labours and workers from local &

nearby areas for the proposed construction activity, which will be minor as the proposed plant

activity. The land is purchased from TSIIC

7. Project Schedule & Cost Estimates:

(i) Likely date of start of construction and likely date of completion (Time schedule for the

project to be given):

After obtaining Environmental clearance and Consent to Establish from PCC, the company shall

implement the proposed project.

(ii) Estimated project cost along with analysis in terms of economic viability of the project:

Estimated project cost along with the analysis in terms of economic viability of the project Plant &

Machinery, Pipeline & Fittings, Electrical Installation, Safety systems, etc. are the major heads

considered in the Capital Cost Projection for the proposed expansion project. Environment

Protection has also been considered in planning the Cost Projection, which will include Green belt

development, safety systems, etc.

Table 18.0

Capital Cost Projection

Project cost Rs. In lakhs

Civil 5450

Contingency 1546

Imported Machinery 16939

Indigenous Machinery 954

Misc. Fixed Assets 7411

Preoperative 2175

Project cost 34475

The company will provide budgetary provision for the recurring expenses for environmental

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

Table 19.0

Budget for Environment & Safety

S.No Area Budget in Lakhs

1 Effluent Treatment Plant 250

2 Bag filters for boilers 40

3 Acoustic enclosures to DG sets 15

4 Greenbelt 25

5 Fire hydrant system and other safety provisions

85

6 Rain water harvesting 50

Total 465

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Prefeasibility Report Welspun Flooring Limited

Manufacturing : Manmade Fiber Industry 39

Table 20.0

Recurring costs

Sr. No.

Component Proposed

(Rs. in Lacs/annum)

1. Environment & Safety Management System and environmental monitoring.

50.00

2. Greenbelt Maintenance 10.00

3. Enterprise Social Contribution for @ 1.5% for 10 years

51.70

Total 111.0

8. Analysis of Proposal (Final Recommendations):

(i) Financial and social benefits with special emphasis on the befit to the local people

including tribal population, if any, in the area:

Proposed activity will provide benefits to the local people in terms of financial and social welfare.

• Local people will get direct financial benefit by way of employment.

• Local people will get some contracts of supply and services to get indirect income.

• Company will contribute in improving education and health facilities in nearby area.