PROJECT PRE-FEASIBILITY REPORT ON …environmentclearance.nic.in/.../PFR/...feasibilityReport(PFR)file.pdfThe company’s commitment is to manufacturing of fiber. ... The unit is committed

M/s. VARDHMAN ACRYLICS LIMITED

PROJECT PRE-FEASIBILITY REPORT

ON

PROPOSED PROJECT

FOR

MANUFACTURING OF FIBERS & TOW

OF M/s. VARDHMAN ACRYLICS LIMITED

AT

PLOT NO:755

GIDC ESTATE,JHAGADIA,

DIST:BHARUCH

M/s. VARDHAMAN ACRYLICS LIMITED 1

CONTENTS

S. No. Particulars Page No.

1 SUMMARY 6

2 INTRODUCTION 7

2.1 The Project 7

2.2 Project Proponent 7

2.3 Quality Policy 8

2.4 Environmental Policy 9

2.5 Nature of project 11

2.6 Market Feasibility 11

3 PROJECT DESCRIPTION 11

3.1 Type of Project 11

3.2 Project Location 11-12

3.3 Site selection 13

3.4 Neighboring Industries 14

3.5 Size of project 14

3.6 Process Technology 15-17

3.7 Raw material 18

3.8 Resource requirement 18

3.8.1 Land 18

3.8.2 Fuel Consumption 18

3.8.3 Water 19

3.8.3.1 Water Consumption 19

3.8.4 Waste Water Management 20



3.8.4.1 Waste water characteristics 22

3.8.4.2 Waste water treatment and Disposal 22

3.9 Mitigation measures & EMP 22

3.9.1 Gaseous emission & Control 22

3.9.1.1 Flue gas emission 22

3.9.1.2 Process emission 23

3.9.2 Hazardous Waste Management 23

3.9.3 Noise control& odour 24

3.9.4 Storage ,handling and transport of Hazardous chemical 24

3.9.5 Health & Safety measures 24

4 SITE ANALYSIS 25

4.1 Connectivity 25

4.2 Land use and land ownership 25

4.3 Existing land-use 25

4.4 Existing infrastructure 26-27

4.5 Soil Classification 27

4.6 Climate Data 27

4.7 Social Infrastructure 28

5 PLANNING BRIEF 29

5.1 Planning concept 29

5.2 Population projection 29

5.3 Land use planning 29

6 PROPOSED INFRASTRUCTURE 29

6.1 Processing area 29



6.2 Non processing area 29

6.3 Green belt area 29

6.4 Social Infrastructure 30

6.5 Connectivity 30

6.6 Drinking water management 30

6.7 Industrial waste management 30

6.8 Solid waste management 30

6.9 Source of power 31

7 REHABILITATION & RESETTLEMENT (R & R) PLAN 31

8 PROJECT SCHEDULE & COST ESTIMATES 31

8.1 Project Implementation Schedule 31

8.2 Estimated project cost 31

9 ANALYSIS OF PROPOSAL 31-34

10 HONORS & ACHIEVEMENTS LIST 35-37

10.1 Honors & Achievements List(EHS) 35-36

10.2 Honors & Achievements List(Quality circle & TPM) 36-37


LIST OF TABLES

Table

No.

Topic Page No.

1. List of Products 6

2. Contact details of the Directors 10

3. Salient features of the Project Site 11

4. Nearby Industries in the vicinity 14

5. Capital cost of projection 14

6. List of Raw Materials-Product wise 18

7. Fuel requirement 18

8. Power Consumption 19

9. Water Consumption 19

10 Waste water generation 20

11 Fuel gas emission 22

12 Details of hazardous waste 23

13 Details of different verities of plants planted in green belt area 25

14 Details of meteorological condition from March 2015 to May 2015.

27

15 Name of some prominent industries. 29

16 Projection implementation schedule 31

17 CSR Activities fy 13-14 32



20 Achievements list 35

21 Achievements list 36


LIST OF FIGURES

Sr. No. Description Page No.

1. Location of the Project Site 12

2. Aerial view of the 5 km radial periphery from the Project Sites 13

3. Wind rose 28


1.0 EXECUTIVE SUMMARY

M/s.Vardhman Acrylics Limited is a fiber manufacturing unit. The promoters are well

experienced in this field. They have proposed to do debottlenecking –that will result in the

increasing the production capacity of the unit. The Vardhman Acrylics Limited is involved in the

manufacturing of fiber and tow at Plot No:755, GIDC Estate, Jhagadia Dist. Bharuch.The

production capacity of the unit is 20,000 MT/Year. Due to the debottlenecking, 10% production

capacity will be increased and reach to 22,000 MT/Year. As per EIA notification 2006, the

proposed project falls under category 5(d)-B.

The details of products are given below table 1.

TABLE: 1

List of Product

Sr. No

Name of product Existing capacity in MT/Year

Proposed capacity in MT/Year

Total capacity in MT/Year

1. Acrylic fiber & Tow

20,000 2,000 22,000

2. Captive Power Plant (Coal Based)

5.5MW -- 5.5MW

COST OF PROJECT The expected cost of project is Rs. 537 Lacs. The total plot area of the unit is 52.918 hecter. The total plantation and green belt area is 38.395 hecter. FUEL AND ELECTRICITY CONSUMPTION The Unit is using Furnace Oil, Coal and high speed diesel as a fuel. The existing consumption of

Furnace Oil, Coal, and High speed diesel is 2.25 KL/Hr and 8.0 MT/Hr and160 Ltr/Hr/DG

respectively. Unit has its own power generation facility of 5.5 MW.

There will be no any additional requirement of fuel due to proposed project.

WATER CONSUMPTION The total water consumption permission for industrial purpose and domestic purpose is 3105

M3/day and 95 M3/day respectively. There will be no additional requirement of fresh water due

to the proposed project.


WASTEWATER GENERATION

The total industrial waste water generation from the unit is 1325 M3/day and waste water

generation from the domestic is 21 M3/day. There will be no any extra wastewater generation

due to proposed project.

GASEOUS EMISSION

There is a flue gas emission from the Boiler and D.G.Set stacks. Unit has installed ESP as an

APCM to prevent the pollution. There is a no process gas emission from the manufacturing

process.

There will be no any change in gas emission due to proposed project.

HAZARDOUS WASTE MANAGEMENT The Hazardous wastes from the unit are ETP Sludge, Used Oil, Discarded

Containers/Bags/Liners, Spent Carbon, Polymer Waste and Filter & Filter Materials.

2. INTRODUCTION

2.1 THE PROJECT

M/s. Vardhman Acrylics Limited is involving in the manufacturing of fiber and tow at

Plot No:755,GIDC Estate,Jhagadia,Dist:Bharuch.

The list of the product is provided in table -1.

2.2 PROJECT PROPONENT M/s.Vardhman Acrylics Limited is a fiber manufacturing unit. The promoters are well

experienced in this field. Now they want to increase the production capacity of the unit by

debottlenecking. The plant boasts of contemporary infrastructure facilities with advanced

machinery and automated processes. They are conscious of environment protection measures and

from the conception stage itself necessary care has been taken.


QUALITY POLICY

The company’s commitment is to manufacturing of fiber. The company has in house testing

facility with modern testing equipments to ascertain the quality of raw materials as well as

finished products. Continued emphasis towards process and technology up gradation is being

done effectively to enrich the product quality. R & D with initiative & innovative ideas had

resulted into excellent performance in respect of quality products.


ENVIRONMENTAL POLICY

The unit is committed to execute all operations, products and services by environmental

protection activities to the extent possible.

As a means of achieving these, the unit pledge to company with the legal & other requirements

to their core and focus on continually improving products, systems & operations.


TABLE: 2

CONTACT DEAILS OF DIRECTORS

Sr. No

Name Present Residential Address

Designation Contact No.

1. Shri Paul. Oswal

Auro Mira Bhawan, H. No. 2722, Gurdev Nagar. Pakhowal Road, Ludhiana. Punjab.

Chairman & Director

Office : (0161) – 2228945

2. Shri Darshan Lal Sharma

B-xx-770/2, Gurdev Nagar, Ludhiana,141001, Punjab, India

Director Office : (0161) – 2228945

3. Shri Sachit Jain Auro Mirra Bhawan, 2722, Gurdev Nagar, Pakhowal Road, Ludhiana-141001, Punjab, India

Director Office : (0161) – 2228945

4. Shri Bal.Krishan Choudhary

1099, Sector 14, Faridabad-121007, Haryana, India

Managing Director

Office : (0124) – 4981610

5. Shri Surinder Kumar Bansal

D-7,Maharani Bagh, New Delhi- 110065, Delhi, India

Director --

6. Shri Sanjit.Paul. Singh

House No.202B, Court Greens, Lalburnum, Sector-28,Gurgaon-122001, Haryana, India

Director --

7. Shri Munish.Chandr

a.Gupta

House.No 771, sector-15,Part-11,Gurgaon-122001, Haryana, India.

Director --

8. Geeta Mathur B-1/8,Vasant Vihar, New Delhi-110057, Delhi, India

Director --


The directors of the company have good experience in handling the production management,

financial management and all the allied areas.

2.3 NATURE OF PROJECT

The proposed unit will engage in the manufacturing of Fiber & Tow. The current production

capacity of the manufacturing unit is 20000 MT/year. The proposed production capacity will be

2000 MT/year. Thus total production capacity will be 22,000 MT/Year. As per EIA notification

2006, the proposed project falls under category 5(d)-B.

2.4 MARKET FEASIBILITY

Vardhman, a leading textiles group in India ventured into manufacture of Acrylic Fiber &

Acrylic Tow in 1999. A modern plant with technology from Japan Exlan Co. Ltd, Japan, a

company in forefront of innovation in this field was set-up initially as a joint venture with Japan

Exlan Co. and Marubeni Corporation, Japan in the state of Gujarat in western India.

The main application of these products is in the Hosiery of Sweater-Shirts, Scarf, Children cloths

and Jersey, in the Weaving of Shawl, Lohi, Check shirt, Sari and Bed spread, in the Home

furnishing of Table mat, Bath mat, Curtain, Carpets and Shoe laces and for the Industrial Filter

and Non Woven.

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is not including any interlinked and interdependent project

3.2 PROJECT LOCATION

The proposed project site is located at Plot No: 755, GIDC Estate, Jhagadia, and Dist: Bharuch in

the state of Gujarat. The approximate geographical positioning of the project site is at Latitude:

21038’38.96”N Longitude: 73008’44.62”E. It has an average elevation of 44 m. The location of

the project site can be identified from the location map shown in Figure-2.

The salient features of the location of the project site are presented in Table 3.

TABLE: 3

SALIENT FEATURES OF THE PROJECT SITE

Particulars Details Distance from Site

Villages Selod

Dadheda

4KM

4 KM


Particulars Details Distance from Site

Talodara

Fulwari

2 KM

4 KM

Approx. Geographical positioning Latitude:

Longitude:

21038’38.96”N

73008’44.62”E

Nearest City Ankleshwar

Bharuch

14.5 Km

24.7 Km

Nearest Railway line/ Railway station

Ankleshwar 15.4 KM

Nearest Airport/ Airbase Baroda 99.7 KM

FIGURE -1

LOCATION OF THE PROJECT SITE

Ankleshwar Industrial area Panoli Industrial area Jhagadia industrial area Priaman CETP Canal Piraman to Katiyajal Effluent Pipe Jhagadia to Piraman CETP

PROJECT


Figure-2

Aerial view of the 5km radial periphery from the project Site

3.3 SITE SELECTION

The project proponent did not consider any other alternative site for proposed project.


3.4 NEIGHBORING INDUSTRIES

The industry is located in an area, which is already industrialized. The industries in the vicinity

of the proposed project are given in the table-4 below:

TABLE: 4

NEARBY INDUSTRIES IN THE VICINITY

Sr. No. Plot No Industries Name

1 754 HUBER CHEM LTD.

2 750 UNITED PHOSP LTD.

3. 892 GALAXY LTD

4. 772 NITREX LTD

5. 797 MTZ LTD

3.5 SIZE OF PROJECT

The proposed unit is involving in the manufacturing of Acrylic Fiber and Tow. The exiting

production capacity of the unit is 20000 MT/year. The proposed additional production capacity

will be 2000 MT/Year. Thus total production capacity will be 22,000 MT/Year. The expected

cost of proposed project is Rs.537 lacs. New Plant and machinery installations will also have to

be acquired and installed. Environment Protection and safety systems have also been considered

in planning the Cost Projection. The break-up of the proposed project cost is given in below table

no:-5.

TABLE: 5

CAPITAL COST PROJECTION

Sr. No. Purpose Total (Rs. In Lacs)

1. Land NIL 2. Building NIL 3. Plant and Machinery 510 4. Environment Protection & Safety a) Effluent treatment Plant 20.0 b) Safety Equipment (PPE, fire

extinguishers, Ventilation, etc.) 2.0

c) Green belt development 5.0 Total 537


3.6 PROCESS TECHNOLOGY

Unit is involving in the manufacturing of Acrylics fiber & Tow. Process details like Process

description, chemical reactions and mass balance for each product are as below:

MANUFACTURING PROCESS AND MATERIAL BALANCE Japan Exlan’s acrylic fiber process is divided into 2 areas, namely CHEMICAL AREA & FIBER

AREA.

A. Chemical Area:

Chemical Area consists of Polymerisation, dope making & solvent recovery.

1. Polymerisation:

Polymerisation is prepared by the continuous aqueous suspension polymerization of the reactive

ingredients (Acrylonitrile + VAM) in a precisely controlled reactor system to provide a raw

polymer characterised by constant composition and close control of molecular weight. The

unique catalyst system (Sodium chlorate & Sodium metabisulphite) results in close control of

molecular weight and high percent conversion.

Untreated monomer is stripped under vacuum then condensed and reused. Polymer in slurry

form is continuously overflowed from reactor and it is washed in polymer washing machine to

remove contaminated materials. Washed polymer now stored in polymer holding tank.

2. Dope Making:

Polymer in slurry form dissolved with highly concentrated solvent (Sodium thio-cyanate) by

continuous dissolver. The dissolved spinning solution (dope) with good uniformity is fed to a

flash deaerator, then to a dope heater and then transferred to spinning.

3. Solvent Recovery:

As the solvent (Sodium thio-cyanate) in the coagulation bath of spinning machine is diluted, the

diluted coagulant is transferred to a solvent recovery. The grain form active carbon is used for

purification of the recovered solvent. Highly efficient 5-effect evaporator is applied for

concentration of solvent. The recovered condensed water which is vaporized in the evaporator is

used in tow washing as wash water. Concentrated solvent is adjusted for pH and to the

concentration required and send to dope making.


B. Fiber Area:

Fiber Area is divided in two process, namely spinning and After Treatment.

1. Spinning:

Spinning dope is extruded in the diluted coagulant through the spinnerets and gel fiber is fed to a

tow washing process. Uniformly coagulated gel tow is completely washed out from solvent and

then processed in hot stretching machine. For purpose of getting dense and solid fiber without

void structure tow from Hot stretching machine is fed to apron dryer (Ist heat treatment).

2. After Treatment:

Conditioned tow from dryer is immersed in finishing bath and fed to Crimper. The crimped tow

is fed to 2nd heat treatment at steamer for permanent setting of fiber properties. In these way

physical properties such as stress-strain, toughness, uniformity in fiber structure, durability of

crimp is attained. Finally tow is transferred to a final dryer for being dried to certain moisture

content and then to a tow baler or to staple baler after cutting.

M/s. VARDHMAN ACRYLICS LIMITED

NOTE *ACN=ACRYLONITRILE, VAM=VENYL ACETATE MONOMER, SC=SODIUM CHLORATE, SMBS=SODIUM METABI SULPHITE TG=2-MERCAPTO ETHANOL **TIO2=TITANIUM DIOXIDE, PRS=SODIUM THIOCYANATE, TDDM=TITANEUM DIOXIDE DISPERSING MACHINE

Solvent Filtration

Evaporator (Concentrate or of solvent)

Solvent Recover

TDR (TOW

DRIER)

FAT (FINISH APPLICATION TROUGH)

CRIMPER

ADR (APPRON DRIER) (Drying)

Tow Washin

Polymerization Reactor

Polymer Washing Machine

Polymer Storage

Dope (Polymer Solution

Making)

Deairation & Filtration

**TDDM

SPM (SPINNING MACHINE)

Monomer

RECYCLED TO REACTOR

**TIO2

(For Dull Fiber production l )

Finish Oil

Baling (Finished Product) Staple & Tow

**PRS

ACN, VAM, SC, SMBS,TG


MANUFACTURING PROCESS

Basis: (Poly prod.)2.471 MT/hr

RM & Additives 2.711 MT/hr

DM water 19.328 MT/hrRO water 10.000 MT/hr

Soft water 3.1 MT/hr To RO: 15.500 MT/hr

Raw water 0.05 MT/hrTo ETP: 14.218 MT/hr

Steam: 1.65 MT/hr

36.839 MT/hr 29.718 MT/ hr7.121 MT/hr

Basis: (Fibre prod.) 2.5 MT/hr

To Textile: 20.833 MT/hr

DM water 0.025 MT/hr To CT: 0.229 MT/hr

Steam: 0.275 MT/hr Losses: 0.023 MT/hr

21.09 MT/hr 21.09 MT/hr13.664 MT/hr

Strong PRSFrom Text: 46.62 MT/hrWeak PRS

Sodiumthiocyanate

0.005 MT/hr

To Text (ED): 37.0 MT/hrDM water 6.25 MT/hr To ETP: 3.672 MT/hr

Raw water 0.042 MT/hr To CT: 6.747 MT/hr


62.083 MT/hr 48.419 MT/hr

Basis: (Fibre prod.) Dope 20.83 MT/hr 2.5 MT/hr

ED water 37.000 MT/hr WPRS to Solv 46.62 MT/hr

DM Water 4.815 MT/hrRaw Water 1 MT/hr Evoperation loss 5.31 RO Water 4.16 MT/hr

Effluent to ETP 15.700 MT/hrSteam 5.725 MT/hr losses 3.4

73.530 MT/hr 71.030 MT/hr2.500 MT/hr

Raw Water 1.000 MT/hr To ETP: 4.050 MT/hrDM water 3.950 MT/hr Evoperation: 2.570 MT/hr


8.18 MT/hr 8.18 MT/hr

2.5

Final product MT/hr

POLYMERIZATION

SPG

DOPE MAKING

SOLVENTRECOVERY

AFT


3.7 RAW MATERIAL

Unit is involving in the manufacturing of Acrylics fibers & TOW and purchasing required raw

material from local/Indian market. Details of raw-material consumption are as shown in table

no.6.

TABLE: 6

LIST OF RAW MATERIALS-PRODUCT WISE

Sr. no

Name of product Production capacity MT/Year

Sr. No.

Name of Raw Material

Consumption quantity kg/kg of product

1. Acrylics fibers & TOW

22,000 1. Acrylonitrile 0.909 2. VAM 0.090 3. Sodium thiocyanate 0.002 4. Sodium

Metabisulphite 0.024 5. Sodium Chlorate 0.009 6. Thioglycol 0.002

2. Captive Power Plant (Coal Based)

5.5MW 1. Coal 8.0 MT/Hr

3.8 RESOURCE REQUIREMENTS

3.8.1 LAND

The total plot area of the unit is 52.918 Hect.

3.8.2 FUEL

For production activity, fuel requirement is as per below table 7.

TABLE: 7

FUEL CONSUMPTION

SR.

NO

FUEL QUANTITY

(As per current CCA

No:-AWH-49945)

QUANTITY

(As per Proposed

Expansion)

TOTAL

1. Furnace Oil 2.25 KL/Hr NIL 2.25KL/Hr

2. Coal 8.0 Mt/Hr NIL 8.0Mt/Hr

3. High Speed Diesel 160 Ltr/Hr/DG NIL 160Ltr/Hr/DG


TABLE: 8

POWER CONSUMPTION

3.8.3 WATER

3.8.3.1 WATER CONSUMPTION

In existing condition, Unit is consuming 3105 M3/day water for industrial purpose and 95 M3/day

for domestic purpose. The total water consumption will remain same after proposed project.

TABLE: 9

WATER CONSUMPTION

Sr. No. Section Water Consumption Existing

KL/Day as per current

CCA NO:AWH-

49945

Proposed KL/Day

Total KL/Day

1 Domestic 95 NIL 95

2 Industrial 2.1 Process 1420 NIL 1420 2.2 Soft water + CT 910 NIL 910 2.3 Boiler 450 NIL 450 2.4 Others 325 NIL 325

Total (Industrial) 3105 NIL 3105 TOTAL

(Domestic + Industrial) 3200 NIL 3200

SR. NO

POWER QUANTITY (As per current CCA

No:-AWH-49945)

QUANTITY (As per proposed

expansion)

TOTAL QUANTITY

1. Electricity 5.5MW NIL 5.5MW


3.8.4 WASTEWATER MANAGEMENT

The total industrial waste water generation from the unit is 1325 M3/day and from the domestic is

21 M3/day. There will be no any change in waste water generation due to proposed project. The

category-wise bifurcation of the waste water generation is given in Table 10.

TABLE: 10

WASTE WATER GENERATION

Sr. No. Section Waste Water Generation

Existing KL/Day as per

current CCA

NO:AWH-

49945

Proposed

KL/Day

Total

KL/Day

1. Domestic 21 NIL 21 INDUSTRIAL

2. Process 970 NIL 970 3. Soft Water+ CT 295 NIL 295 4. Boiler 60 NIL 60 5. Others 0 NIL 0

Total (Industrial) 1325 NIL 1325

TOTAL

(Domestic + Industrial)

1346 NIL 1346


WATER BALANCE DIA-GRAM

DOMESTIC95 M3

WATER CONSUMPTION

(3105M3/day) + (95 M3/Day)

PROCESS 1420 M3

BOILER 450M3

OTHERS 325 M3

COOLING WATER 910 M3

EVAPORATION LOSS 615 M3

COOLING WATER 295 M3

BLOW DOWN 60 M3

EVAPORATION LOSS 840 M3

TOTAL EFFLUENT (1346 M3)

(1325 M3 (Industrial) +

21 M3 (Domestic)

450 M3 390 M3

970 M3

21 M3

SOAK PIT

LOSSES-325

60 M3 295 M3

1325 M3


3.8.4.1 WASTEWATER CHARACTERISTICS

Existing & proposed effluent characteristic before treatment and after treatment in ETP is covered

in Annexure-10 of FORM - I.

3.8.4.2 WASTEWATER TREATMENT & DISPOSAL

A detail of existing & proposed effluent treatment plant (ETP) is covered in Annexure-10 of

FORM - I. The effluent conforming the specified standard is utilized on land for

gardening/plantation within the industrial premises and excess waste water, if any or in case of

accident/emergency,& in monsoon season it is discharged into GIDC underground drainage

leading FETP and for further disposal into deep sea, through BEAIL pipeline project.

3.9 MITIGATION MEASURES & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been

proposed by the company for the control of the anticipated pollution load.

3.9.1 GASEOUS EMISSIONS & CONTROL

3.9.1.1 FLUE GAS EMISSION

In existing condition, Unit has installed 2 Boilers and 6 D.G.Sets as mentioned in below table no:-

11.

TABLE: 11

FLUE GAS EMISSION

Stack No.

Source of emission

Stack height

(m)

Air Pollution Control System

Type of emission

Permissible Limit

EXISTING 1. Boiler- I

(Low Pressure GT-4013)

67 --

PM SO2 NOx

150 mg/Nm3 100 ppm 50 ppm

2. Boiler-II (High Pressure

GT- 4069)

62 ESP

3. D.G.Set (6 Nos)

16 each (2stack/ D.G.Set)

--

Proposed: There will not be any changed in Flue gas emission due to proposed project.


3.9.1.2 PROCESS EMISSIONS In existing process as well as after proposed expansion, there is no process gas emission during

the production of Fiber & Tow.

3.9.2 HAZARDOUS WASTE MANAGEMENT The following types of hazardous wastes are being generated during the operational activities.

All the wastes are being stored separately in a designated storage area. The details of hazardous

waste are below given Table 12.

TABLE 12

DETAILS OF HAZARDOUS WASTE

Sr. No.

Waste Category Quantity/ Year

(As per current CCA)

Quantity/ Year

(As per Proposed

Expansion)

Total Facility

1 ETP 35.3 600 MT 0 MT 600 MT

Collection, storage,

Transportation and Disposal at TSDF at

BEIL. 2 Used Oil 5.1 12 MT 0 MT 12 MT Collection,

Storage, Transportation, Disposal by

selling to Registered Re-

refiners. 3 Discarded

Containers/ Bags/Liners

33.1 200 MT 0 MT 200 MT

Collection, Storage,

Decontamination

4. Spent Carbon

35.3 0.5 MT 0 MT 0.5 MT Collection, Storage,

Transportation, Disposal by incineration at

CHWIF-BEIL.

5. Polymer Waste

21.1 1.1 MT 0 MT 1.1 MT Collection, Storage,


Due to this project there will be no extra hazardous waste generation.

3.9.3 NOISE CONTROL & ODOUR

The major noise generating installation is the D.G. Set. Unit has installed it in a closed room and

provided acoustic enclosure around it. Unit has also provided ear plugs to the operating person of

Boiler room.

Unit is following below steps to Noise control and Odour.

• Raw-material feeding is being carried out by pumps.

• All reactions are being taken in closed reactor system.

• Roof top ventilation is installed in the entire plant area.

• Regular monitoring of piping and fittings is carried out to prevent the leakages.

3.9.4 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS

The storage and mode of transport of chemicals are being done as per detailed MSDS and

chemical hazards guide (NIOSH) for the hazardous chemicals.

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

3.9.5 HEALTH AND SAFETY MEASURES

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of large

volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of MSIHC

Rules,


CHWIF-BEIL.

6. Filter & Filter

material

36.2 24 MT 0 MT 24 MT Collection, Storage,


CHWIF-BEIL.


Moreover transport activity is being done through drums, so there is a manual loading and

unloading and no unloading through pipe at the site. Hence, the risk of static charge generation

during transfer of such chemicals is not significant.

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

Jhagadia estate is connected with Ankleshwar. Ankleshwar is known for Pigment and

Pharmaceutical Industry. Ankleshwar is connected by Indian National Highway

8 (Mumbai to New Delhi) and by the Western Railway Division of Indian Railways. The railway

division runs the broad gauge train services to Rajpipla. The 133-year-old Golden

Bridge connects Ankleshwar to Bharuch across the Narmada on the station front while a new

bridge connects the highway, the other bridge on the highway is now ready to use.

Ankleshwar railway station is centrally located at the intersection of NH8 & Station Road.

Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western

section).Development projects of Ankleshwar Airport & City Bus are in last stage.

4.2 LAND USE AND LAND OWNERSHIP

The proposed project site is located at plot No: 755, GIDC Estate, Jhagadia, and Dist: Bharuch.

The total plot area of the unit is 52.918 hect in which 14.523 is total construction area and 38.395

is total green belt area.

4.3 EXISTING LAND USE

The proposed project site is located at plot No: 755, GIDC Estate, Jhagadia, and Dist: Bharuch.

The plot is notified by GIDC for industrial purpose. The total plot area of the unit is 52.918 ha.

Unit has allotted 38.395 ha area for green belt development. A detail of different varieties of plant

planted in green area is mentioned in below table no:-13.

TABLE 13

DETAILS OF DIFFERENT VARITIES OF PLANTS PLANTED IN GREENBELT AREA

SR. NO

Local Name English Name Scientific Name

Family TOTAL NO. OF PLANTS

1 Nilgiri Eucalyptus Eucalyptus tereticornis

Myrtaceae 43000

2 Sharu Beefwood Casuarina equisetifolia

Casuarinaceae 39000

3 Sonmahor Copper pod tree Peltophorum Caesalpiniaceae 10000


pterocarpum 4 Jambu Black plum Syzygium

cumini Myrtaceae 1887

5 Kashid Yellow cassia Cassia siamea Caesalpiniaceae 2219 6 Deshi

badam Indian almond Terminalia

catappa Combretaceae 1755

7 Katis vans Thorny bamboo Bambusa arundinacea

Gramineae 1638

8 Royal (Bottle) palm

Mountain glory Roystonea regia

Palmae 1100

9 Limdo Margosa tree Azadirachta indica

Meliaceae 2700

10 Bengali babul

Australian babul Acacia auriculiformis

Mimosaceae 1864

11 Sissoo Indian redwood Dalbergia sissoo

Papilionaceae 3625

12 Goras ambli ManilaTamarind Pithocellebium dulce

Mimosaceae 5000

13 Bottle brush Bottle brush tree Callistemon lanceolatus

Myrtaceae 174

14 Safed Shimdo

Kapok Ceiba pentandra

Bombacaceae 50

15 Ambli Tamarind Tamarindus indica

Caesalpiniaceae 35

16 Gulmahor Royal poinciana Delonix regia Caesalpiniaceae 1000 17 Khair Cutch tree Acacia

catechu Mimosaceae 112

18 Rayan Rayan Manilkera hexandra

Sapotaceae 60

19 Ambo Mango tree Mangifera indica

Anacardiaceae 150

20 Bakan limdo Persian lilac Melia azedarach

Meliaceae 200

21 Subabul subabul leuceina leucocephela

6500

22 Others spp. 23017

TOTAL TREES 145086

4.4 EXISTING INFRASTRUCTURE

The plant is located in a well-developed industrial zone, which has all essential facilities such as

internal roads, arrangement for supply of water and power to industries, effluent disposal

facilities, gas etc.


The proposed project is relatively small in size and will be employing some skilled and unskilled

people. First preference will be given to local people, so there will be no change in population

pattern due to the proposed project.

4.5 SOIL CLASSIFICATION

The soil of the district can be classified as light, medium and heavy according to depth, texture

and location. There is sandy loam to loamy in texture, brownish black in color.

4.6 CLIMATE DATA

Based on the meteorological data, wind rose is prepared for the summer season period between

the March 2015 to May 2015. The wind rose diagram prepared from same data is shown in

Figure 3.

TABLE: 14

METEOROLOGICAL DATA

(Data from Indian Meteorological Department, Ahmadabad, Station:-Baroda)

Month Temperature(oC) Humidity (%) Rain fall (mm)Maximum Minimum Maximum Minimum Maximum Minimum

March-15 41 17 57 32 012.1 00 April-15 41.4 22.4 67 30 006.9 00 May-15 42.7 27.0 75 29 0.0 00


FIGURE: 4

WIND ROSE DIAGRAM FOR PERIOD OF MARCH-2015 TO MAY-2015

Observation: It was observed that wind is blowing mainly towards the NE direction from SW.

Average wind speed was 3.26 m/s with calm winds recorded to be 5.57%.

4.7 SOCIAL INFRASTRUCTURE

There are 41 villages in Jhagadia Taluka. Population density and sex ratio of Jhagadia Taluka was

reported 212 persons/sq.km. And 937 females per 1000 males respectively in 2001 census report.

Total literacy of Jhagadia Taluka was found 65.92 %.The basic amenities like primary and

secondary education schools, community health workers, primary health sub centre, private

practitioners, primary health centre, maternity and child welfare, dispensaries, T.B clinic, family

welfare centre, hospital, drinking water, transportation facilities, electricity , telephone etc. are

available.


5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT:

Jhagadia is largely an industrial area dominated by large scale industries, especially chemical

Plants. Government agencies provide many basic facilities like uninterrupted water supply, power

and road network.

5.2 POPULATION PROJECTION.

As of 2011 India census, Ankleshwar had a population of 140,839. Males constitute 53% of the

population and females 47%. 13% of the population is under 6 years of age.

5.3 LAND USE PLANNING

The names of prominent industries are shown in table no: 14

Table: 15

NAME OF SOME PROMINENT INDUSTRIES

Sr. No. Name of industry 1 DCM SHRI RAM LTD 2 UNITED PHOSPHOROUS LTD 3 MTZ TRIBUTON ESXPORTS LTD 4 HUBER CHEM LTD 5 LANXESS INDIA PVT LTD 6 KOHLER INDIA CORPORATION. PVT. LTD.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

The process area is covered plant area, raw material storage area, hazardous waste storage area,

workshop and utilities.

6.2 NON PROCESSING AREA

The non process area is covered Admin Building, toilet blocks, change room and security cabin.

6.3 GREEN BELT AREA

Total plot area of the unit is 52.918 Hect. Total Construction area of the unit is 14.523 Hect. Unit

has allotted 38.395 hect area for green belt.There will be provision of budget of 5 lakh rupees for

green belt development. . A detail of different varieties of plant planted in green area is mentioned

in below table no:-13.


6.4 SOCIAL INFRASTRUCTURE

The availability of basic amenities is covered as under:

• Training & Education: All the employees are being trained and educated periodically about

the hazardous nature of chemicals used in the process. Also, training for fire fighting, work

permits system, first aid, safe handling of hazardous chemicals and integrating safety, in all

activities.

• Medical facility: Pre-employment medical checkup at the time of employment. In order to

safe guard the health of the employees, all the employees undergo periodic health checkup.

• Drinking water: Unit has provided Aqua Guard/R.O at different places to provide purified

water for drinking purpose.

• Transportation: The unit is providing basic transportation facility to workers.

• Telegraph & Post: Unit has all the facilities like telephone, fax and internet for the employees.

6.5 CONNECTIVITY

This industrial estate is well connected to Ahmadabad/Mumbai/Vadodara through the

Ankleshwar. Rail services and Road services are available in Ankleshwar.

6.6 DRINKING WATER MANAGEMENT

Average daily water consumption of unit is 95KL/day for domestic purpose. GIDC water is a

source of domestic water.

6.7 INDUSTRIAL WASTE MANAGEMENT

The hazardous waste like discarded bag /containers and used oil, spent carbon, polymer waste and

filter & filter material is generating during the manufacturing process. The hazardous waste

management and disposal is shown in table 12.

6.8 SOLID WASTE MANAGEMENT

The record of hazardous waste and non hazardous solid waste like plastic waste, discarded bag &

containers and spent oil etc is being maintained by the unit.

6.9 SOURCE OF POWER

Unit has its own power generation facility. (5.5 MW)


7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

The proposed project is located in GIDC Estate, Jhagadia. There will be no any human settlement

affected by proposed project. So, there is no requirement of any R & R Plan.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

The details of project Implementation Schedule is given in below table.

TABLE: 16

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule after getting NOC from GPCB Sr. No. Activity Required Period1. Civil work Immediately after getting NOC 2. Procurement of machinery 1 month after getting NOC

3. Eraction & installation of machinery

Immediately after competition of activity no.2

4. Trial of machinery & equipment

Within 1 months after competition of activity no.3

5. Commercial activity 1 months after competition of activity no.4 8.2 ESTIMATED PROJECT COST

The details of Capital cost projection are given in table no. 5.

9.0 ANALYSIS OF PROPOSAL First preference will be given to local people for employment and Company will also try to

provide indirect employment opportunities by availing local contract services during

transportation and operational phase.

The company intends to donate 0.5 % of the profit to agencies like NGOs or social welfare

societies for projects carried out in nearby villages for their welfare and upliftment. In past years,

company has performed many CSR activities. List of activities is mentioned in below table No

17, 18 & 19.


TABLE: 17

CSR ACTIVITY IS PERFORMED BY VAL-J DURING THE YEAR 2013-2014.

Sr. No

Location Activity Activity

performed in month

Actual Amount incurred

1 Talodara Village

Organizing the Navaratri Mahotsav with the support of village seniors & Distributed Gifts (kitchen appliances) to girls , children & youth for

participation & to inspire them for cultural activities

Oct-13 20,000

2 Talodara Village

Donation given to Talodara Yuvak Mandal for celebration of Ganesh Mahotsav. Amount utilize for mandap decoration, statue of Lord Ganesha, pooja

samagri & Prasad

Aug-13 2,101

3 Dadheda Village

Donation given to Dadheda Yuvak Mandal for celebration of Ganesh Mahotsav. Amount utilize for mandap decoration, statue of Lord Ganesha, pooja

samagri & Prasad

Aug-13 2,100

4 Dadheda Village

Major community of village is Muslims & having mosque for ibadat & other holy activities.

They don't have sufficient sitting arrangements. Hence

we have provided plastic chairs - 90 nos. to enhance the

sitting facilities.

Dec-13 30,780

5 Talodara Village

Fabricated MS grilled windows & doors have been installed in class rooms & offices of Amar Vidyalaya

(Higher Secondary School) to protect school properties

i.e.computers , stationaries , sports equipments

Aug-13 15,365

6

Talodara , Dadheda & Vakhatpura

villages

Celebration of Independent Day - Distribution of Gifts

(Stationary kit) to all students & small children of

neighbouring villages to motivate them & to interact

Aug-13 25,937


TABLE: 18


with them. (Talodara - 400 , Dadheda -

375 , Vakhatpura - 50 = Total 825 sets)

7


villages

Celebration of Republic Day - Distribution of Gifts


neighbouring villages to motivate them & to interact

with them. (Talodara - 400 , Dadheda -

375 , Vakhatpura - 50 = Total 825 sets)

Jan-14 25,987

8 Kapalsadi Village

Celebration of Ursh Festival in neighbouring village , donation given for organizing festival & for increase the moral support

of local villagers

Mar-14 3,000

Total Amount used for CSR

125,270

Sr. No

Location Activity Activity

performed in month

Actual Amount incurred

1 Dadheda PCC work of compound area

of primary school May-14 66263

2 Talodara Village Main gate of primary school -

Fabrication job Jul-14 12260

3


Village

Celebration of Independent Day - Distribution of Gifts


neighbouring villages to motivate them & to interact with them. (Talodara - 400 ,

Dadheda - 375 , Vakhatpura - 50 = Total 825 sets)

Aug-14 25988

4 Talodara Village

Organizing the Navaratri Mahotsav with the support of village seniors & Distributed Gifts (kitchen appliances) to girls , children & youth for

Oct-14 25000


TABLE: 19


Sr. Project Brief Description Cost (Rs. in Lacs)

1 Talodara Village, Jhagadia GIDC area Construction of New Aaganwadi at Talodara village

1.62

2 Dadheda Village, Jhagadia GIDC area Extention of Primary School at Dadheda village with addition of computer room

6.16

3 Talodara Village, Jhagadia GIDC area Addition of a new class room at Amar Vidyalaya (Secondary School)

13.58

4 Toilets Project under Swachh Bharat Abhiyan, in GIDC Villages through Jhagadia Industries Association (Under Construction)

8.00

5 Construction of computer lab at Talodara primary school (Under Construction)

11.00

6 New building, Anganwadi , Sardarpura (Under Construction)

7.91

Grand Total 48.27

participation & to inspire them for cultural activities

5 Talodara Village Sports Equipment to Amar

Vidhyalaya Jan-15 6546

6 Utiya Village Repairing of floor of Gram Panchayat Building - Tiles

work (Massonary work) Mar-15 30000

7 Kapalsadi Village Celebration of Ursh Festival

(03.04.15/04.04.15) Mar-15 5000

8


Village

Celebration of Republic Day - Distribution of Gifts


neighbouring villages to motivate them & to interact with them. (Talodara - 400 ,

Dadheda - 375 , Vakhatpura - 50 = Total 825 sets)

Jan-15 27826

Total Amount used for CSR

198883


10. HONOURS & ACHIEVEMENTS LIST 10.1 HONOURS & ACHIEVEMENTS LIST (EHS)

We have participated in National Safety Council of India Awards for the year- 2013, 2014 &2015. Received certificate of Appreciation for the year 2013 & 2015 & Won 3rd Level award (Suraksha Puraskar) for the year-2014. For the year-2016, Result is awaited.

We have participated in Gujarat State Safety Award for the year- 2011, 2012, 2013& 2014. And won the 1staward as winner at state level 04 times in a row. For the Year-2015, Result is awaited.

Awards details are as under; TABLE: 20

ACHIEVEMENT LIST

Sr. No.

Type of Competition

Organized By

Level of Companies Participated

Prize(s) Awarded / won

1

National Safety Council of India Awards - 2013 (Manufacturing Sector)

National Safety Council of India

National level (companies)

Certificate of Appreciation

2




3rd Level (SURAKSHA PURASKAR) Bronze Trophy & Certificate

3




Certificate of Appreciation




Result yet to declare by Awarding Agency

4

Gujarat State Safety Award - 2011

Gujarat Safety Council & Directorate Industrial Safety & Health, Gujarat State

State Level (companies)

Winner (1st)

5

Gujarat State Safety

Gujarat Safety

State Level

Winner (1st)


Award - 2012 Council & Directorate Industrial Safety & Health, Gujarat State

(companies)

6


Gujarat Safety Council & Directorate Industrial Safety &Health, Gujarat State


Winner (1st)

7




Winner (1st)

8 Gujarat State Safety Award - 2015



Result yet to declare by Awarding Agency

Company has applied for ISO 14001: 2015 &OHSAS 18001:2007 Certification .Final audit completed successfully. Recommended for certification of ISO 14001 & OHSAS 18001: 2007. 10.2 HONOURS & ACHIEVEMENTS (QUALITY CIRCLE & TPM) TABLE: 21

ACHIEVEMENT LIST

Sr.No.

Category of Award

Name of Award

Organizer Date Venue AWARDS

1 State Level Gujarat State Level Safety Competition

Directorate of Industrial Safety & Health

2011 Vadodara First Prize

2 State Level QCFI Annual Case study presentation

QCFI 9/24/2011 Vadodara Bronze award


QCFI 9/16/2012 Vadodara Bronze award

4 State Level Gujarat State Directorate of 2012 Vadodara First Prize


Level Safety Competition

Industrial Safety & Health

5 National Level

India Excellence Manufacturing Awards

Frost & Sullivan

9/15/2012 On site Audit

Significant progress towards reliable process Category (Silver Certificate of Merit)

6 State Level Gujarat State Level Safety Competition

Directorate of Industrial Safety & Health

2013 Vadodara First Prize

7 National Level

KAIZEN Conference

TPM Club of India

2/27/2013 Gurgaon Certificate of Appreciation

8 National Level

Suraksha Puraskar

National Safety Council

of India 2014 New Delhi

Bronze Trophy

9 National Level

KAIZEN Conference

CII New Delhi 2/26/2015 New Delhi Certificate of Appreciation


QCFI, Vadodara Chapter

9/13/2015 Vadodara

Gold Medal (Two Teams) (Nishtha & Sankalp)

11 District Level

QCFI Annual Case study presentation

QCFI, Ankleshwar

Chapter 9/26/2015 Ankleshwar

Gold Medal (Two Teams) (Samadhan & Manthan)


QCFI 9/12/2016 Vadodara

Gold Category award (Two Teams (Nishtha & Chintan)


QCFI 9/23/2016 Ankleshwar

Gold Category award (Two Teams - Samadhan & Sankalp)


Documents

PROJECT PRE-FEASIBILITY REPORT ON …environmentclearance.nic.in/.../PFR/...feasibilityReport(PFR)file.pdfThe company’s commitment is to manufacturing of fiber. ... The unit is committed