0 0 19 jul 2015 1405318531texcoretechnologies pfr report

APPLICATION

FOR ENVIRONMENT CLEARANCE

AND

FEASIBILITY REPORT

M/s Texcore Technologies Pvt Ltd. Plot No.:- 3092, Phase - III, GIDC Estate,

Vill: Chhatral, Dist: Gandhinagar

Prepared by:

EXCEL ENVIRO TECH

(NABET Accredited EIA Consultant Organization)

TF-2 , SUN HOUSE,

Near Old High Court Off Ashram Road,

Ahmedabad – 380 009

Tele-fax: 079–27542219 Cell: +91-98255 88910

Email: [email protected]

Website : www.excelenviro.com

Synthetic Organic Chemicals

Texcore Technologies Pvt Ltd. Feasibility Report

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TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION TO THE PROJECT 2

1.1 Project PROPONENTs 2

CHAPTER 2 PROJECT DESCRIPTION 3

2.1 Project Location 3

2.2 Alternate Sites Considered 3

2.3 Products & Raw Material Details 4

2.4 Manufacturing Process: 7

2.5 Utilities Requirement 7

2.6 Manpower Requirement 12

CHAPTER 3 SITE ANALYSIS 13

3.1 Connectivity 13

3.2 Existing Landuse Pattern 13

3.3 Topography 13

3.4 Social Infrastructure Available: 14

3.5 Rehabilitation & Resettlement Plan 14

3.6 Landuse Breakup 14

CHAPTER 4 PROPOSED ENVIRONMENTAL INFRASTRUCTURE 15

4.1 Management of Domestic Waste Water 15

4.2 Management of Industrial Waste Water 15

4.3 Air Quality Management: 15

4.4 Solid & Hazardous Waste Management 15

4.5 Hazardous Chemicals Details 16

4.6 Waste Minimization Measures 16

CHAPTER 5 PROJECT SCHEDULE & COST ESTIMATES 17

5.1 Proposed Schedule 17

ANNEXURE 18

CTE Copy 18


2

CHAPTER 1

INTRODUCTION TO THE PROJECT

M/s. Texcore Technologies Pvt Ltd. is a small scale unit incorporated in

2014. Having established their market in manufacturing and trading of textile auxiliaries, the unit now proposes to proceed for manufacturing

various varieties of water soluble polyester and acryl-amide resins. The company's current product range involves; formulations of textile

auxiliary & emulsions, textile sizing blends and purification of sodium sulfate powder. Now, looking at the prospective market growth in the

chemical field, the project proponent is keen to start manufacturing of

water soluble acrylamode polymer and water soluble polyester resins.

1.1 PROJECT PROPONENTS

Texcore Technologies Pvt Ltd. is a Private Limited Company governed

by Mr. Rajendrakumar K. Patel & Mr. Dibyendu Bhtacharjee. Directors are dynamic and enthusiastic to lead the task towards completeness.

The long lasting vision, marketing support and the managerial aspects of the project are rendered by technically qualified and experienced

team headed by Mr. Rajendrakumar K. Patel.

Currently, the managerial team includes 3 administrative and 6 working

staff. Same man power would be utilized to undertake proposed activity also. As the existing set up is to be utilized for manufacturing proposed

products also, there would not be requirement of additional manpower.

Detail of Directors

Name of Directors Address

Mr. Rajendrakumar K. Patel

Mob. 9824027339

31,Nirman Twin Bunglows,

Ghatlodiya, Ahmedabad-380061

Mr. Dibyendu Bhtacharjee 7/A, Shanidhya,8/A-Gordhan Park

society, B/h. Azad sweets, Ashram Road, Naranpura,

Ahmedabad.


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CHAPTER 2

PROJECT DESCRIPTION

2.1 PROJECT LOCATION

The Project is located at coordinates 23o17’28’’ N 72o26’32’’ E in Phase

-III, GIDC Estate, Chhatral, Dist: Gandhinagar. Plot No:- 3092 about 8

km far from Kalol railway station and 38 KM far from Ahmedabad

Airport. Distance from Nearest state highway (SH-41) is merely 300 m

and aerial distance from National highway (NH8C) is 20 kilometer;

which provides a convenient & competitive trade gateway to domestic

market transportation.

2.2 ALTERNATE SITES CONSIDERED The company has not considered any alternate site as they already

have set up a plant for manufacturing of textile auxiliaries at the site.

Necessary permissions from State Pollution control Board for the same

have been procured. As the unit is located in notified area of GIDC, the

site is having all required infrastructure facilities in form of; water,

electricity, Natural Gas and Road available for the proposed activities.


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Location of the project (500-m radius) with surroundings

2.3 PRODUCTS & RAW MATERIAL DETAILS Product Details

The Details of proposed products are given in following table:

SR

NO Proposed Products

Quantity

(MT/Month)

1. Textile Auxiliary 100 MT

2. Textile sizing Blends 100 MT

3. Water soluble acryl amide polymer 50 MT

4. Water Soluble polyster-1 75 MT

5. Water Soluble polyster-2 75 MT

Raw Material Details

Water Soluble Acryl amide polymer:-

Raw Materials Quantity for 01 kg.

Acrylamide 0.0791

Acrylic acid 0.014

Ammonia 0.014

Liquid glucose 0.4651

Sodium per sulphate 0.0003

Water 0.4275

Total 1.0000


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Water Soluble polyster-1:-


Di ethylene glycol 0.0404

Mono ethylene glycol 0.0323

Neo Pentyl glycol 0.0162

Pentaerythritol 0.0081

Glycerin Ethoxylate 0.0388

Catalyst 0.0005

Iso Phthalic Acid 0.0566

Tere Phthalic Acid 0.1212

Poly ethylene glycol 0.3233

Water 0.4008

Biocide 0.0004

Sub total 1.0386

Water of reaction 0.0386

Total 1.0000

Water Soluble polyster-2:-


Di ethylene glycol 0.0720

Neo Pentyl glycol 0.0107

Pentaerythritol 0.0058

Glycerin Ethoxylate 0.0223

Catalyst 0.0003

Phthalic anhydride 0.0576

Terephthalic Acid 0.0576

Maleic anhydride 0.0593

Sodium Sulphite 0.0762

Sugar 0.2879

Caustic soda 0.0012

Ammonia 0.0080

Biocide 0.0002

Water 0.3604

Sub total 1.0195

Water of reaction 0.0195

Total 1.0000

Details of Flue Gas Stack

Sr.

No

Source Fuel Stack height

Parameter Permissible Limit

1. Thermic fluid

heater

LDO 11 m PM

SO2

NOX

150 mg/Nm3

100 ppm

50 ppm


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Details of Process gas emission

Sr.

No

Stack Attached to

APCM Stack height

Parameter Permissible Limit

1. Ribbon

Blender

Ventilation

& Exhaust system &

Bag house for

prevention for dusting

-- PM

SO2

NOX

150 mg/Nm3

100 ppm

50 ppm 2. Distillation

Column --


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2.4 MANUFACTURING PROCESS:

MANUFACTURING PROCESS FOR TEXTILE AUXILIARIES

1. The process is a simple mixing of various ingredients in the tank, under stirring.

2. Various raw materials are charged in the tank under stirring listed below as per formulation.

(Materials out sourced) (Materials manufactured in house)

CO-40 Water soluble Acrylamide polymer

CO-20 Water soluble polyester resin

LA-10 Phosphate ester

LA 20

CSA-10

CSA-80

NP-9.5

NP-4.5

HEDP

Iso propyl Alcohol

Tri ethanol amine

Di ethanol amine

Phosphorous Pentoxide

Liquid Glucose

3. The stirring is continued until the final mixture is homogeneous and various properties match the required specifications.

4. Finished product is packed in various size suitable packing.


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MANUFACTURING PROCESS FOR TEXTILE SIZING BLENDS

Raw materials details

Binders like polyester resin (coarse powder), Acrylic binder in

powder form, Polyester resin and Acrylic binder in liquid form produced in house.

Humectant like Urea(Technical grade for Industrial use) Flow agent like Aerosil(Fumed silica)

Softeners like Hydrogenated Castor oil, polyethylene Glycol in flake or powder form.

Modified and Unmodified Starched(Maize and Tapioca)

1. The process is a simple mixing of various ingredients in the Ribbon blender.

2. Various Starches, Softeners, Humectants, Flow agents and Binders are charged under blender on condition.

3. The Mixing is continued in the Ribbon Blender until the final mixture is homogeneous and properties match the required specifications.

4. Finished product is packed in suitable packing like HDPE woven sack/paper bags or drums.


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MANUFACTURING PROCESS FOR WATER SOLUBLE ACRYLAMIDE POLYMER

(POLYMERIZATION OF ACRYLAMIDE IN WATER )

1 ] The general chemical reaction can be represented as under Free

radical chain polymerization:

Chain polymerization is the process by which a polymer chain grows by

addition of monomers – single units – only; growth does not occur by addition of oligomers –multiunit segments. Free radical polymerization

is one type of chain polymerization. Free radical polymerization produces "linear" strings of monomer units by a chain reaction started

by free radical initiators. Reaction below shows the key reaction of propagation, that a chain initiated by a radical R already having n vinyl

units (i) adds another monomer (ii) to its active radical end, thereby making the added monomer the new active end.

H H H R-(CH2CHX)n-1- CH2C• + H2C=C ------- R-(CH2CHX)n - CH2C •

X X X

2] To polymerize acrylamide in water to polyacrylamide (polymer)

by free radical polymerization using a initiator.

3] The polymerization progress is monitored by the variation of

temperature and viscosity with time.

4] Water is used as diluents.

5] No solvent is used or recovered during process.


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MANUFACTURING PROCESS FOR SOLUBLE POLYESTER-1

1] Diethylene glycol, Mono ethylene glycol, Neopentyl glycol,

pentaerythritol, Glycerine ethoxylate, Iso phthalic acid, pure terephthalic acid and catalyst are charged into reactor and

heated.

2] Water of reaction is removed and progress of the reaction is

monitored by checking acid value and viscosity.

3] When acid value and viscosity are within specifications the mass is cooled down and PEG is added and heating is restarted.

4] Again the progress of the reaction is monitored by checking acid

value and viscosity and when they are as per specifications it is cooled down.

5] After cooling the material is dispersed into water.

6] Q.C parameters are adjusted as per specifications.

7] Material is filtered and packed into clean drums


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MANUFACTURING PROCESS FOR SOLUBLE POLYESTER-2

1] Di ethylene glycol, Neopentyl glycol, Pentaerythritol, Glycerine

ethoxylate, Phthalic anhydride, pure terephthalic acid and

catalyst are charged into reactor and heated.

2] Water of reaction is removed and progress of the reaction is

monitored by checking acid value and viscosity.

3] When acid value and viscosity are within specifications the mass

is cooled down.

4] After cooling maleic anhydride is added and reacted to required

acid value. When acid value is within specification the batch is

cooled.

5] Material is dispersed into sodium sulfite solution along with

caustic soda and liquor ammonia.

5] Then sugar is added and dissolved.

6] Q.C parameters are adjusted as per specifications.

7] Material is filtered and packed into clean drums.


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2.5 Utilities Requirement

All utilities required for the project would be developed in the existing

facility and the utility requirements are as under.

Sr. No.

Particulars Details

1 Power Consumption 100 HP

2 Fresh Water Requirement 4.0 m3/day

3 Thermic Fluid Heater LDO

o Power: Required power would be taken from UGVCL

o Water: Water would be available from GIDC pipeline.

o Fuel: Piped Natural Gas easily available.

2.6 Manpower Requirement

Required specialized man power & talent would be recruited / hired

locally and supporting services would be made available from nearest

village. Approximately 15 people will be employed.


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CHAPTER 3

SITE ANALYSIS

3.1 Connectivity

Gandhinagar is well connected by rail, road & air.

Road:

Linked to State highway 41; which is a Highway Network through

an extension of NH 8 from Gandhinagar NH-8, an offshoot of NH 8

connects Delhi, Ahmadabad to Mumbai.

Rail

Nearest major Railway station is 8 Km away from factory site to

connect the National Railway Network

Air

Ahmadabad has a fully functional, long airstrip for servicing the needs of

private commercial jets which is proposed to be developed as an air

cargo hub.

Ahmadabad airport is 38 km from GIDC Chhatral.

3.2 Existing Land Use Pattern

Currently the land is occupied by GIDC and private owners. No

agricultural activities are done on this. The particular plot: 3092 is under

the possession of the company.

3.3 Topography

The area is flat in nature. It is a build up plot. The average elevation

above mean sea level is 74 m.


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3.4 Social Infrastructure Available:

The social infrastructure available at Kalol; hardly 8 km from site is

listed below.

• Housing colonies

• Public School

ITI center

• Healthcare Centre

• Children’s Park

• Community Centers

• Pharmacy

• Market

3.5 Rehabilitation & Resettlement Plan

The land is already in the possession of the project proponent. The NA

permission for the land is obtained by GIDC. Therefore, resettlement

and rehabilitation is not involved.

3.6 Land use Breakup

This plant will be located in plot no-3092 having an area of 1500 sqm.

The breakup of area into different uses is summarized in following table:

Sr

No Description of Area Area (m2)

1 Storage of raw material 250

2 Plant and machineries 500

3 Storage of product 300

4 Roads 50

5 Green belt 100

6 Office Building 200

7 Open Area 100

Total 1500


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CHAPTER 4

PROPOSED ENVIRONMENTAL INFRASTRUCTURE

Company has got the consent to establish for unit of manufacturing of Textile auxiliaries from Gujarat Pollution Control Board. The proposed

products are Polyester resins. The company will take into account all

environmental aspects so that no pollution hazard is ever created in and around the plant. Every effort is being made to keep zero air

pollution as well as water pollution. In addition to the above, care has been taken to provide green belt around the plant.

4.1 Management of Domestic Waste Water

The domestic effluent (1 m3/d) shall be disposed through septic tank/

soak pit.

4.2 Management of Industrial Waste Water

There is no industrial wastewater generation proposed. Hence, there is

no ETP Proposed. Whatever wash water is generated, will be recycled

completely as the raw materials and products are 100 % water soluble.

4.3 Air Quality Management:

The source of Flue gas air pollution is Thermic Fluid Heater, which

consumes LDO and hence can be treated as non-polluting. In process

gas air pollution are Ribbon Blender and Distillation Column. APCM

System like Ventilation & Exhaust system & Bag house for prevention

for dusting. Plant area has well ventilated, cross air flow and exhaust

fans have been provided for extra air flow.

4.4 Solid & Hazardous Waste Management

The details of hazardous wastes generation from the proposed project

& its management & Handling are listed in the following tables. All the

requirements of hazardous waste as per 2008 rules shall be complied

with.


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SR

No

Detail of

Hazardous

Waste

Category Schedule Quantity Management

of Waste

1 Used Oil 5.1 I 50

Lit/year

Collection,

Storage and reuse for

lubrication purpose.

2 Discarded drums/containe

rs/bags

33.3 I 24 MT/Year

Collection, Storage and

reuse within

premises.

4.5 Hazardous Chemicals Details

The use and storage of hazardous chemicals is below the specified

threshold quantities. as per Schedule 3 under Rule 68-J of the Gujarat

Factories Rules 1963 (2004) and hence the industry is classified as Non

Major Accident Hazard (NMAH) unit.

4.6 Waste Minimization Measures

Metering and control of quantities of active ingredients to

minimize waste.

Reuse of by-products from the process as raw materials or as

raw material substitutes in other processes.

Use of automated filling to minimize spillage.

Use of Close Feed system into batch reactors.

Venting equipment through vapor recovery system.

Use of high pressure hoses for equipment clearing to reduce

wastewater generation for reuse.


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CHAPTER 5

PROJECT SCHEDULE & COST ESTIMATES

5.1 Proposed Schedule

The industry seeks Environmental Clearance (EC) and intends to start

production activities from July 2015 and final production activities from December 2015.

Sr No.

Activity Schedule

1 Application for Environmental Clearance

July 2015

2 TOR finalization Meeting Sept 2015

4 Avail Environmental Clearance Nov 2015

5 Final Project Activities Dec 2015

6 Start Production Activities Dec 2015


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ANNEXURE

CONSENT TO ESTABLLISH COPY


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0 0 19 jul 2015 1405318531texcoretechnologies pfr report

Documents

project description

project location

water soluble polyester

table of contents chapter

proposed schedule

manufacturing process

manpower requirement

proposed activity