m/s. beekaylon synthetics pvt....

For

THE PROPOSED NEW PROJECT

MANUFACTURING OF “MANMADE FIBER (OTHER THAN RAYON)”

Activity: 5(d), Category-B

[General Condition (Interstate Boundary) applicable; hence Category: A]

By

M/s. Beekaylon Synthetics Pvt. Ltd. Unit Located at:

Survey No.: 287/1, 284P, 289/1/3, 289/1/2, 289/2, 286/1/P, 287/2 Village: Velugam, Union Territory of Dadra & Nagar Haveli

Pre-feasibility Report M/sBeekaylon Synthetics Pvt. Ltd.,Velugam

INDEX

1 Executive Summary……………………………………………………………………………………….……………… 01

2 Introduction……………………………………………………………………………………..………….………………. 03 i. Identification of the Project and Proponent. 03 ii. Brief Description of the project 03 iii. Need of the project and its importance to the country and or region 04 iv. Demand –Supply Gap 04 v. Imports vs. Indigenous production 04 vi. Export Possibility / Domestic / export Markets 04 vii. Employment Generation (Direct and Indirect) due to the project. 04

3 Project Description………………………………………………………………………………………………………… 05 i. Type of Project including interlinked and interdependent projects, If any 05 ii. Location (map showing general location, Specific location, and project boundary

& project site layout)with coordinates 05

iii. Profile of Project site 05 iv. Site Layout Plan 06 v. Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted 06

vi. Size or magnitude of operation 06 vii. Project description with process details (a schematic diagram/ flow chart

showing the project layout components of the project etc. should be given) 06

viii. Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product

13

ix. Resource optimization/ recycling and reuse envisaged in the project, 14 x. Availability of water its source, Energy/power requirement and source 14 xi. Quantity of waste to be generated (liquid and solid) and scheme for their

Management/disposal 14

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

16

4 Site Analyses………………………………………………………………………………………………………………… 17 i. Connectivity 17 ii. Land Form, land Use and Land Ownership 17 iii. Soil Classification and Land Use Classification 17 iv. Climate Data from secondary source 17 v. Social Infrastructure 17

5 Planning Description……………………………………………………………………………………………………… 18 i. Planning Concept (Type of industries, facilities, transportation, etc.) 18 ii. Population Projection 18 iii. Land use planning (breakup along with green belt etc. 18 iv. Assessment of Infrastructure demand (Physical & Social) 18 v. Amenities/ Facilities 18

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Pre-feasibility Report M/sBeekaylon Synthetics Pvt. Ltd.,Velugam

6 Proposed Infrastructure ……………………………………………………………………………………………….. 19 i. Industrial Area (Processing Area) 19 ii. Residential Area (Non Processing Area). 19 iii. Green belt 19 iv. Connectivity 19 v. Drinking Water management (Source& Supply of water) 19 vi. Sewage System 19 vii. Industrial Waste Management 19

7 Rehabilitation and Resettlement (R&R) Plan…………………………………………………………………. 20

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):

20

8 Project Schedule & Cost Estimates…………………………………………………………………….............. 20

i. Likely date of start of construction and likely date of completion 20

ii. Estimated project cost along with analysis in terms of economic viability of the project 20

9 Analysis of Proposal (Final Recommendations)…………………………………………………............. 21 i. Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area 21

New project-Synthetic Organic Chemicals Page | ii

Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 1. EXECUTIVE SUMMARY

1.0 About Project: M/s. Beekaylon Synthetics Pvt. Ltd. is existing company engaged in manufacturing of various types of synthetic yarns since 1975. Now the company proposes to setup its additional manufacturing unit for manufacturing of “MANMADE FIBER (OTHER THAN RAYON)” located at Survey No.: 287/1, 284P, 289/1/3, 289/1/2, 289/2, 286/1/P, 287/2; Village: Velugam, Union Territory of Dadra & Nagar Haveli. The detailed product profile with production capacity is as mentioned below Table 1.0 :

Table: 1.0

Sr. No.

Product Description QUANTITY

TPA

1.

Polyester Filament Yarn (POY/FDY) / Staple Fiber/Polyester Granules

By Continuous Polymerization & melt spinning process using PTA and MEG as raw material

432000

2.

Synthetic Filament Yarn :

Bulk Continuous Filament Yarn(BCF)/Partially Oriented Yarn(POY)/Fully Drawn Yarn(FDY)/Dope Dyed Yarn(DD)/Low Oriented Yarn(LOY)/Highly Oriented Yarn(HOY)/ Nylon Yarn(N6 & N66)/ Polypropylene Yarn(PP)

By Melt Spinning Using Ready Polyester/Nylon Chip /Polyamide Chips/ Polypropylene Chips As Raw Materials.

378000

3.

Polyester Texturised Yarn/Draw Texturised Yarn/Air Texturised Yarn/ Polyester Twisted Yarn/Cable Yarn/Double Yarn/ Draw Twisted Yarn/Acrylic Yarn /Covered Yarn/Spandex Yarn

By Using Ready Yarn Of Polyester/Nylon/Acrylic

288000

4. Winding Of Yarn/Heat Setting Of Yarn/Circular Knitting/Warping / Warp Knitting/Weaving Fabrics/Carpet Weaving/ Narrow Fabrics

36000

5. Color Master Batch Chips / granules 9000

2.0 Highlights of the Project:

Sr. No.

Particulates Description

1. Project Location M/s. Beekaylon Synthetics Pvt. Ltd.

287/1, 284P, 289/1/3, 289/1/2, 289/2, 286/1/P, 287/2 Village: Velugam, Dadra & Nagar Haveli

2. Project Activity, Category as per amendments

Project Activity: 5(d)-“MANMADE FIBER (OTHER THAN RAYON)”, Category: B, but considered as cat.-A (Due to applicability of GC interstate boundary with Maharastra state)

3. Project Cost Rs. 443 Crore

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Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam

4. Total area of Project 98200 Sq. m.

5. Area for Green Belt 33612 Sq. m. (@ 33 % of the total plot area)

6. Products with capacity As mentioned in table no. 1.0

7. Power Requirement Power –Electricity requirement: 27000 KVA Source: DNH Power distribution corporation Ltd.

8. Utilities Requirement (Boilers, Thermic Fluid Heater and D.G. Sets,)

Steam Boiler: 03 nos. Thermic Fluid Heaters: 03 nos. Stand by D. G. Set: 03 Nos.

9. Fuel Requirements Furnace Oil : 60 KL/DAY High Speed Diesel : 1250 liters/Hr.

10. Man Power 1500 to 2000

11. Air pollution Control Measures Adequate stack height will be provided to all the stacks

12. Water requirement • Industrial Total: 4390 KL/day (Fresh: 3640, Recycled: 750). • Domestic : 100.00 KL/Day

13. waste water generation with mode of disposal

• Industrial: 800.00 KL/Day treated in ETP/RO/MEE-reuse. • Domestic: 80.00 KL/Day treated in STP- use for plantation.

14. Solid / Hazardous waste Generation

Will be managed as per Hazardous Waste (Management, Handling And Transboundary Movement) Rules-2016.

15. Nearest Highway NH-8: 7.8 km W

16. Nearest Railway Station Sanjan - 18.90 Km W

17. Nearest Airport Daman, 36 Km NW (Approx.)

18. Nearest Forest/ Sanctuary/Eco-sensitive zone.

• Patches of Reserved forests - 2.59 km W • Vasona Lion safari - 9.37 km NW • Satmalia Deer Park - 5.3 km NE • DNH Wildlife sanctuary -1.30 km E & 2.30 W • River Daman Ganga - 8.74 km N • River Dongar Khadi (1.40 km N) • River Sakartod (3.45 km NE) • Darotha River (5.23 Km NW)


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 2. INTRODUCTION

Identification of Project and Proponent: M/s. Beekaylon Synthetics Pvt. Ltd. is existing company engaged in manufacturing of various types of synthetic yarns since 1975. Beekaylon Synthetics Pvt. Ltd is a company registered in India having its registered office at Office Nos. 15,16 & 17, Maker Chamber-3, Jamnalal Bajaj Road, Nariman Point, Mumbai – 400 021.

The company has been promoted by, well experienced Khemani family, having sound financial strength and demonstrated track record in the Textiles business. The senior members of the family have been active in textile industry for more than Three decades. Khemani family is well known amongst the textile industrialist for their commitments towards quality and customer relationship. The family is also known for philanthropic works in society.

The Company is a registered Private Limited company and is promoted by three Directors. Details related to them are given below:

Sr. No. Name of Directors Background Residential Address

1. Mr. Nand K. Khemani Industrialist 32,Elcid, 13,Ridge Road,

Malabar Hill, Mumbai – 06

2 Mr. Ashok K. Khemani Industrialist 32,Elcid, 13,Ridge Road,


3 Mr. Rahul A. Khemani Industrialist 32,Elcid, 13,Ridge Road,


4 Mr. Shahin N. Khemani Industrialist 32,Elcid, 13,Ridge Road,


5 Mr. Mahesh L. Lakhwani Industrialist Beekaylon Bungalow,

Kilwani Road, Silvasssa( D & NH)

Brief description of nature of the Project:

M/s. Beekaylon Synthetics Pvt. Ltd. proposes to setup its additional manufacturing unit for manufacturing of “MANMADE FIBER (OTHER THAN RAYON)” located at Survey No.: 284P, 289/1/3, 289/1/2, 287/1, 289/2, 286/1/P, 287/2; Village: Velugam, Union Territory of Dadra & Nagar Haveli. D&NH is logistically well connected by road and rail. The company has experienced personnel and will install state of art machinery. Company's objective is focused on high quality products, continuous innovation, R&D & solution centric customer satisfaction. For the proposed project, the company intends to procure the best available technology for manufacturing the products as listed. With the textile & garment industry's development, more and more companies have begun to pay attention to the functional fiber’s application, especially to the differential fiber. The company produces all kinds of lusters including semi-dull, full dull and cationic. The company Supplies Dope Dyed polyester yarn with fine flexibility, good colour fastness, equal diameter and usability. Company’s products include s, Semi Dull Dope Dyed Black and Dope Dyed Colours, Cationic and Full Dull (Cot look) RW Yarns and Semi-Dull RW Yarns. Any other qualities in Semi-Dull, Full-Dull (RW, Dope Dyed Black and



Dope Dyed Colours) and Micro Filaments can be manufactured as make to order requests. The detailed proposed product profile with production capacity is as mentioned in Table no. 1.0.

As per the EIA notification- 2006 as amended the proposed new project for the production of “Manmade Fiber (Other Than Rayon)” which falls under item no. “5(d) – Manmade Fiber (Other Than Rayon)“as per the EIA notification- 2006, hence required prior Environmental Clearance.

Manufacturing of “Manmade fiber other than Rayon ” is covered under Category –B, but due to the applicability of General Conditions (interstate boundary with Maharastra state is 0.3 km E which is within 5 km radius) this project is categorized as Category-A and applied to MoEF&CC for obtaining Environmental Clearance.

Need for the project and its importance to the country and or region: The proposed project provides a potential growth opportunity for the already running business of the company. The industrial sector in the past few years has seen a drastic boom and also the keeping in mind the globalization trend, we have identified the demand for the proposed products and with continuous R&D found that it can be developed in-house and produce commercially for domestic market as well as an eye more on export markets.

Demand–Supply Gap: The products have very high demand for the process of weaving and knitting of fabrics meant for

suiting, shirting, dress materials and home furnishings.

Imports vs. Indigenous production: Proposed products manufacturing in the country will be very much economical compare to Imports of the same and also the export of the same will earn extra revenue generation for our county

Export Possibility / Domestic / export Markets: There is a huge demand of synthetic filament yarn in the export market. Our products are widely used

and are in demand in the domestic Textile industry.

Employment Generation (Direct and Indirect) due to the project: There will be very good opportunity of employment generation directly and indirectly due to proposed

project. Due to proposed project there will be ~ 2000 person will be directly employed and more than

2500 will be indirectly employed.


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 3. PROJECT DISCRIPTION

I. Type of Project including interlinked and interdependent projects, If any :

The proposed new project is interdependent project for manufacturing of some the products.

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 M/s. Beekaylon Synthetics Pvt. Ltd unit located at Survey No.: 287/1, 284P, 289/1/3, 289/1/2, 289/2, 286/1/P, 287/2; Village: Velugam, U.T. of Dadra & Nagar Haveli. The latitude and longitude of the project site is 20° 8'15.46"N and 72°59'32.41"E. The Location Map showing the Project site is attached as Figure no. 3.1 and 3.2.

III. Profile of Project Site:

Sr. No. Nearest Infrastructure Feature Distance from Project Site

1 Geographical Position 20° 8'15.46"N and 72°59'32.41"E

2 Elevation above Sea Level 72 Meters (Approx.)

3 Nearest Village Velugam-1.9 km SW

4 Nearest Town Silvassa - 13.00 km N

5 Nearest National Highway NH-8- 7.8 km W

6 Nearest State Highway SH-29- 4.75 km NE

8 Nearer RW Station Sanjan- 18.90 Km W

9 Nearest Airport Daman: 37.00 Km NW (of Coast Guard only),

Surat : 112.00 Km N & Mumbai- 117.00 Km S

10 Nearest Surface water Resource/Reservoir

Arabian Sea (29.7 Km W) Damanganga Reservoir(8.41 Km N) Kurze Reservoir (6.24 km NE)

11 Forest Patches 2.59 km W

12 Location of Archaeologically /Historically important places

--

13 National Park/Sanctuary or Ecologically sensitive Area

• Madhuban Dam(8.41 km NE) • Kurze Dam (6.24 kmNE) • Damanganga River (8.22 Km NE) • Dongar Khadi River (1.40 km N) • Sakartod River (3.45 km NE) • Darotha River (5.23 Km NW)

14 National or State Boundary • Gujarat – 7.5 Km E • Maharashtra– 0.3 Km E

15 Tourist Places Gardens & monuments- within 15 Km N Madhuban Dam - 8.41 km NE



16 Selection of project Site and Detail of alternate Site.

Proposed new project is in the Industrial area having proper industrial infrastructure hence alternate site consideration is not envisaged.

17 Size or Magnitude of Operation Large Scale

18 Seismic Zone Zone- III

IV. Site Layout Plan: The proposed site layout plan is attached as Figure 3.3 V. Details of alternate sites considered and the basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted: The company has acquired plot for the proposed new manufacturing unit in village Velugam, in notified industrial zone of U.T. D&NH. The site is having good connectivity of road, power etc.to set up industrial unit.

VI. Size or magnitude of operation: As per the proposed products, the project is covered under Large Scale category of manufacturing industries.

VII. Project description with process details :

Detailed Proposed product profile along with its capacity are mentioned in Table no. 1.0.

Infrastructure, Machineries, Equipment & Technologies: In-house technology, Installation of the plants, machineries and suitable manpower will be required to

manufacture the above mentioned product with proposed capacity. To get the best results in terms of quality and quantity, the company will invests in the best available

state-of-the-art plant - machinery and leverages of grass-root technologies duly supported by excellent marketing network will enable the project to get best of results.

MANUFACTURING PROCESS: • Product: 1 : Polyester Filament Yarn (POY/FDY) / Polyester Staple Fiber/Polyester Granules by

Continuous Polymerization process using PTA and MEG @ 432000 TPA.

The manufacturing process consists of three stages, polycondensation, spinning and processing. There are

primarily two raw materials namely; Purified terephthalic acid (PTA) and Mono Ethylene Glycol (MEG). The

manufacturing process is explained in the subsequent sections.

The two main raw materials PTA (Purified Terephthalic Acid - powder form) and MEG (Mono Ethylene Glycol –

Liquid form) are fed through metering system to Paste Preparation Tank in desired mole ratio. The mixing of

PTA & MEG is a continuous process and Slurry thus formed is supplied to the Esterification reactor-ES1. The

reaction of PTA and MEG is accomplished in a set of two Esterification reactors – ES1 & ES2 under required

heating conditions. The Heat is provided through low pressure Heat Transfer Media (HTM) in closed circuit.

Excess glycol and water formed during the reaction, in vapour form, are taken from the top of the

Esterification reactors to a column for necessary separation. Water from the top is condensed in a Heat


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam Exchanger and sent to Stripping column system for further purification. From here Water is pumped for final

treatment to ETP. Separated glycol is pumped back to the Esterification reactors. Antimony Trioxide (Sb2O3), a

catalyst used for Polymerization reaction is added in EG solution to ES-1. Delustrant Agent – Titanium Dioxide

(TiO2) and Diethylene Glycol is added to ES-2.

The Oligomer or pre-polymer formed in the Esterification reactors is fed to continuous polymerization

reaction vessels consisting of Pre-polymeriser and Finisher. Here Oligomer further reacts to form Polyester of

the desired viscosity under specified and controlled temperature and vacuum conditions.

These reactors are also heated using HTM in closed circuit. The reaction links polymer chains with the

evolution of glycol. Excess glycol vapours are removed, condensed and taken to Esterification Reactors. The

polymer from the final reactor is then pumped through Gear Pump to polymer transfer lines, filtered in

Continuous Polymer Filter and distributed to Filament Yarn Spinning machines continuously.

• Filament yarn (POY):

Molten Polymer from Polycondensation is passed through polymer coolers and after pressure boosting

polymer is further processed in POY.

Molten Polymer from CP is fed to individual machines. Here the Molten Polymer is pumped through various

Gear Pumps. Polymer passes through a Filtration Pack. Polymer from the Pack of specific number of holes in

the form of Filaments is exposed to the Quenching Zone (air of specific quality) and then transported through

the inter floor tube. Spin Finish application is done on Oiling guides. This yarn is then passed through special

pre intermingling guides where with the help of air, the applied spin finish is properly migrated between all

the filaments in a uniform way. Filaments pass from Feed Roller to Let down roller. Here the post

Intermingling air is applied. The Filaments are taken on to the Paper tubes to form Bobbins. POY Bobbins are

then packed in the pallets and also on trolley to be sent to DTY department for texturising purpose.

• Filament yarn (FDY):

Molten polymer from CP is fed to the individual machines in the same way as described for POY. Here the yarn

is taken over a set of Hot godets with 6-7 wraps on the godets and then over another set of hot godets with 6-

7 wraps. This set of hot godets and separator roll runs at speeds of 4500 to 5200 mpm (so called the yarn is

hot drawn) and then it is intermingled with high pressure air so as to impart intermingling knots @ 25 to 35

per meters in the FDY yarn. This FDY yarn is then wound on the special designed paper tubes at speeds of

4500 to 5200 mpm depending on the FDY yarn and FDY packages are formed of approx 7 kgs net wt. of yarn.

• Staple Fiber:

In making polyester staple fiber, polymerization, drying, and melt spinning are the same as in the manufacture

of filament yarn. However, in the melt spinning process, the spinneret has many more holes when the product

is staple fiber. The rope-like bundles of polyester that emerge are called tow.

Drawing tow: Newly-formed tow is quickly cooled in cans that gather the thick fibers. Several lengths of tow

are gathered and then drawn on heated rollers to three or four times their original length.


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam Crimping: Drawn tow is then fed into compression boxes, which force the fibers to fold like an accordion, at a

rate of 9-15 crimps per inch (3-6 per cm). This process helps the fiber hold together during the later

manufacturing stages.

Setting: After the tow is crimped, it is heated at 212-302°F (100-150°C) to completely dry the fibers and set

the crimp. Some of the crimp will unavoidably be pulled out of the fibers during the following processes.

Cutting: Following heat setting, tow is cut into shorter lengths. Polyester that will be blended with cotton is

cut in 1.25-1.50 inch (3.2-3.8 cm) pieces; for rayon blends, 2 inch (5 cm) lengths are cut. For heavier fabrics,

such as carpet, polyester filaments are cut into 6 inch (15 cm) lengths.

Chemical Reaction:

The proposed project is of manufacturing of manmade fibers through continuous polymerization involving

following two main reactions.

i) Esterification Process

1n HOOC-C6H4-COOH +2n HO-C2H4-OH--------1nHO-C2H4-OH-OOC-C6H4-COO-C2H4-OH + 2n H2O

(PTA) (MEG) BHET WATER

Using PTA, MEG and the catalyst, the first reaction takes place via the production of Bis-(Beta hydroxyethyl)-

terephthalate (BHET). More than 96% of the -COOH end groups react with EG in this first step; water as side

product of this reaction has to be removed via the process column to shift the equilibrium to the right side.

The water removed from the Esterification cannot interfere with this process and complete Esterification can

take place.

ii) Polycondensation Process

1nHO-C2H4-OH-OOC-C6H4-COO-C2H4-OH + 1nHO-C2H4-OH-OOC-C6H4-COO-C2H4-OH

(BHET) (BHET)

HO-C2H4-(OOC-C6H4-COO-C2H4)n-OH + (n-1) HO-C2H4-OH

(PET) (MEG)

During the Polycondensation reaction, BHET is reacted further leading to polyester (Polyethylene

Terephthalate-PET) with MEG being split off. In these steps MEG has to be continuously removed by different

vacuum steps to shift the equilibrium to the polymer side. The final product is an amorphous polyester melt

which goes for spinning to POY and FDY products. The degree of polymerisation is of the order of 80 to 100.


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam Materials Balance:

The complete representation of material balance with respect to the above chemistry has been illustrated in

the following figure as diagrammatic presentation of process & material balance.

Process flow diagram with Material Mass Balance



B. Product: 2 - Synthetic Filament Yarn : Bulk Continuous Filament Yarn(BCF)/Partially Oriented Yarn(POY) /Fully Drawn Yarn(FDY)/Dope Dyed Yarn(DD)/Low Oriented Yarn(LOY)/Highly Oriented Yarn(HOY)/ Nylon Yarn(N6 & N66)/ Polypropylene Yarn(PP) By Melt Spinning @ 378000 TPA.

C. Product: 3- Polyester Texturised Yarn/Draw Texturised Yarn/Air Texturised Yarn/ Polyester Twisted Yarn/Cable Yarn/Double Yarn/ Draw Twisted Yarn/Acrylic Yarn /Covered Yarn/Spandex Yarn @ 288000 TPA.

Manufacturing process for all the products are similar, physical properties are varies as per requirement of the product. Unloading and storage of polyester/Nylon/PP chips & Granules and Conveying pneumatically by dense phase conveying system. In Fluidized bed crystallizer cum dryer Moisture level of chips is brought to 0.003%. 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. Melt is filtered up to 20 micron through C.P.F (Continuous Polymer Filter) and fed to various pumps. 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. QUENCHING: Melt in yarn shape is quenched in cold air(23oC) in quench chamber were air is equally distributed by honey combs. Spin finish oil is applied to the yarn for better binding & reduction& static charge generation by positive displacement pump. Speed controlled by inverter. Yarn is given "S" wrap by two Godet rollers for controlling tension. Driven by inverter. Additional three HOT godet are used for FDY in same process. WINDING: Yarn is wrapped on paper tube by high speed spindle driven auto turret winder 2800-3400 meter / min for FDY4500 to 5200M/Min. Inspection & Testing and Grading (POY/FDY/NFY/PPFY) can be sale directly or further. Bobbins are sent for further processing i. e. Texturising to get texturized yarn Texturized Yarn is sent to Twisting to get twisted Yarn. Packing and dispatch for further processing to make fabrics.



Process Flow Diagram:

Inspection & Testing and Grading (POY/FDY/NFY/BCFY) Can Be Sale Directly Or Further processing

Texturising of Yran to get texturized yarn/monofilament yarn/ twisted yarn/ Splitting Yarn/ Intermingled Yarn

Required operation to get required properties of yarn and application of antistatic conning oil

Packing and dispatch for further processing to make fabrics

Spinning of Yarn as per required denier and QUENCHING (-5 kgs)

Spin finish oil application to Yarn (+8 kgs)

Physical Property control by tension and temperature

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 (1005 kgs)

Drying in Fluidized bed crystallizer cum dryer (-45kgs)

Polyester/Nylon chips / colour master batches conveying pneumatically (1050 Kgs)



D. Product: 4- Winding Of Yarn/Heat Setting Of Yarn/Circular Knitting/Warping / Warp Knitting/ Weaving Fabrics/Carpet Weaving/ Narrow Fabrics @36000 TPA.

Manufacturing of Winding Of Yarn/Heat Setting Of Yarn/Circular Knitting/Warping / Warp Knitting/ Weaving Fabrics/Carpet Weaving/ Narrow Fabrics will be carried out on required automatic machines as pre required properties of products..


E. Product: 4- Color Master Batch Chips @ 9000 TPA

Manufacturing Process

Manufacturing of color master batches is a simple mixing of pigment, polymer (polyester) and waxes. Mixture of all the ingredients is passed through twin screw extruder, melt mixing extruder and cooling of stand in water bath and pelletizing of master batches, packing and dispatch for further utilization.


Cooling of stand in water bath & Pelletizing

Charging of premix in Twin screw extruder and melt mixing extruder

Pre-mixing in mixer

Colour Pigment + Polymer (polyester) + waxes

Packing and dispatch

Quality Control/Assurance

Winding/Heat Setting/Cir. Knitting/Warping/Knitting/Weaving/ Carpet Weaving/Narrowing on applicable machines as per requirement

Yarn of required product

Packing and dispatch



VIII. Raw material required along with estimated quantity, likely source, marketing area of final product(s), mode of transport of raw material and finished product: • Detailed raw material requirement along with estimated quantity, likely source, marketing area of

final products, mode of transport of raw material and finish product is as under. Sr. No.

Name of the product Raw Materials

Consumption Quantity MT/MT MT/Year

1. Polyester Filament Yarn (POY/FDY) / Staple Fiber/Polyester Granules By Continuous Polymerization process using PTA and MEG @ 432000 TPA

Purified Terepthalic Acid 0.858 370656 Mono Ethylene glycol 0.334 144288 Antimony trioxide 0.003 1296 Titanium Dioxide 0.030 12960 Spin Finish oil 0.008 3456

2. Synthetic Filament Yarn : Bulk Continuous Filament Yarn(BCF)/Partially Yarn(POY)/Fully Drawn Yarn(FDY)/Dope Dyed Yarn(DD)/Low Oriented Yarn(LOY)/Highly Oriented Yarn(HOY)/ Nylon Yarn(N6 & N66)/ Polypropylene Yarn(PP) @ 378000 TPA

Polyester/Nylon/Polyamide/ Polypropylene/Color master batch Chips/Granules

1.050 396900

Spin Finish oil 0.008 3024

3. Polyester Texturised Yarn/Draw Texturised Yarn/Air Texturised Yarn/ Polyester Twisted Yarn/Cable Yarn/Double Yarn/ Draw Twisted Yarn/Acrylic Yarn /Covered Yarn/Spandex Yarn @ 288000 TPA

Yarn of Polyester / Nylon / Acrylic

0.960 276480

Antistatic oil 0.004 1152

4. Winding Of Yarn/Heat Setting Of Yarn/Circular Knitting/Warping / Warp Knitting/Weaving Fabrics/Carpet Weaving/ Narrow Fabrics @ 36000 TPA

Texturized Yarn/BCF/FDY

1.00 36000

5. Color Master Batch Chips @ 9000 TPA Colour Pigment 0.30 2700 Waxes 0.10 900 Polypropylene/Polyamide 6/ Polyethelene terephthalate (PET) / Polybutylene Terepthalate

0.60 5400

• Transport and storage details of Raw materials: Sr. No.

Raw Material

Storage Quantity

State of RM

Means of storage

Storage condition

Source of supply

Mode of transportation

• PTA 5000 MT Powder Warehouse/Silo

Covered Local/Imported Truck/Container

• MEG 4000 MT Liquid Tank Covered Local/Imported Container/Tanker

• Spin Finish Oil

200 MT Liquid Tank Covered Local/Imported Truck/Container

• Antistatic oil 25 MT Liquid Drum Covered Manufactrr. By Road

• Antimony trioxide

20 MT Solid Bags Covered Manufactrr. By Road


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam • Titanium

Dioxide 40 MT Solid Bags Covered Manufactrr. By Road

• Polyester/PP/Nylon Chips

500 MT Granules In Jumbo Bag/Warehouse

Covered Local/Imported Truck/Container

The Detail of Hazardous Chemical and its Properties - attached as table-3.1 Marketing area of final products: The product which is used in the process of weaving and knitting of fabrics meant for suiting, shirting, dress materials Carpet weaving and home furnishings. The company has a wider customer base and to cater to the increased market demand.

IX. Resource optimization/ recycling and reuse envisaged in the project, if any, should briefly outlined: By adoption continuous improvement in technology and process the desired reduction in process

waste generation will be achieved. By proper and efficient handling of raw materials, wastages of raw materials will be reduced.

X. Availability of water its source, energy/power requirement and source :

• Water Requirement:

Sr. No.

Particulars Water requirement - KLD

Total Recycled Fresh

1. Domestic 100.00 0.00 100.00

2. Industrial 4390.00 750.00 3640.00

Total 4490.00 750.00 3740.00

• Source of water: Fresh water requirement will be catered from River/canal.

• Power Requirements and its source: Total Power – Electricity Requirement will be 27 MW and the same will be obtained from DNHPDCL, Silvassa.

• Fuel Requirement :

Sr. No. Particulars Requirement Source

1. Furnace Oil for proposed Steam Boilers and Thermic Fluid Heaters

60.00 KLD Registered Dealers

2. Diesel for proposed stand by D.G. Sets 3750 Lit/Hr.

XI. Quantity of Waste Water (liquid waste) generation and its management / Disposal :

Sr. No. Particulars Quantity – KDL Treatment Disposal

1. Domestic 80.00 STP Reuse for plantation within the

premises

2. Industrial 800.00 ETP-RO-MEE Reuse for cooling


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam • Water Balance Diagram – Attached as Figure no. 3.3 • The detail of proposed effluent treatment plan with design criterial - Attached as Figure no. 3.4 • Utility Emission & Control Measures :

Sr. No.

Item Capacity & no. of units

Fuel & Fuel consumption

Stack Ht.& Dia. Emission

1. Steam Boiler 1 nos. -10 TPH 2 nos. 1 TPH

Furnace Oil : 60.00 KDL

30 m Ht. & 500 m Dia.

PM<150 mg/Nm3

SO2< 100 ppm NOx < 50 ppm

2. Thermic Fluid Heater

3 Nos of 10 M. Kcal./Hr

30 m Ht. & 500 m Dia. (Common chimney)

PM<150 mg/Nm3


3. D. G. Set 1 no. of 1000 KVA and 2 nos. of 2500 KVA

Diesel 1250 lit/hr. each

11 m Ht. & 150 m Dia. Common chimney)

PM<150 mg/Nm3


• Process and Fugitive Emission & Control Measures: There will not be any process emission during

proposed product manufacturing, fugitive emission will be control by installation of adequate plant and machineries.

Hazardous Waste Management:

During our proposed production activities hazardous wastes will be generated as per HW (M, H & TM) Rules 2016 and will be managed as follows.

Types of Waste Source of Generation

Total Qty Storage Method Method of Disposal

ETP Waste Including MEE residue

From ETP & Multi effect Evaporator

60 MT/Month Will be stored at a separate storage area

Will be sent to GEPIL Site, Silvassa for final disposal.

Process waste (polymer)

From process 15 MT/Month Will be packed in bags and stored at a designated area

Will be sold to actual users.

Yarn waste From process 750 MT/Month

Will be packed in bags and stored at a designated area

Will be recycled back /sold to actual users.

Used oil From process 1.0 KL/Month Will be stored in drums

Will be sold to registered recycler/re-processor

Empty drums/ bags/Liners

Raw material cons.

50000 Nos./Month

Will be stored at a separate storage area

Will be sold to authorized scrap vendor or reused



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

Resource requirements • Raw Material: Sourced from Manufacturer / Traders of the same. • Land: Manufacturing unit will be located at village Velugam • Water: will be sourced through River. Canal. • Power: power will be sourced through DNH Electricity Department • Fuel : Local dealer

Environment Management Plan (EMP) • Air Pollution Control Measures: Air Pollution control system will be provided due to

process emissions • Water Pollution : ETP • Greenbelt Area: About 33 % (33611.76 sq.m.) • Health & Safety measures will be followed properly

• Industrial waste: No Industrial waste water will be generated. • Domestic Waste water: Soak pit/ Septic Tank. • Flue Gas emissions: Adequate chimney height will be provided. • Fugitive emission: There is no generation of fugitive emissions.

Type of Activities as per EIA Notification Proposed new manufacturing unitto manufacture

“Manmade Fiber (other than Rayon)” is covered under activities Activity 5(d)

Site Location: Survey No.: 287/1; Village Velugam,

Dadra & Nagar Haveli

Public consultation: Not required as the project is located in notified

Industrial Zone

Submission of Form-1 and Pre-Feasibility Report & Draft TOR

Proposed Activity: The proposed new project involves the production of "Manmade Fiber

(other than Rayon)"

Type of category as per EIA notification: Manmade fiber other than Rayon

(Activity -5(d)-“A” due to GC applicability

Presentation before the EAC for TOR


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 4. SITE ANALYSIS

4.0 Site Analysis I. Connectivity:

The project is located in Village Velugam, Dadra Nagar Haveli, which is very well connected to National Highway no.8 and Western Railways. And the nearest Daman airport and port are 36.34 KM away from the project site by road.

II. Land Form, Land use and Land ownership: • The land is owned by M/s. Beekaylon Synthetics Pvt. Ltd. The land is within the notified industrial zone of U.T. D&NH.

III. Soilclassification and Land use classification: General soil classification of the area is as under: • Soil Characteristics & Land use classification: Most of the area cultivated, some area non

cultivated under sallow and past forest. • Surface color: Reddish brown to dark brown, in hilly area very dark, grayish to dark brown and

dark Yellowish brown • Depth of the soil: 0 to 25 cm (shallow to mod deep) in hilly forest 45 to 150 cms. (Deep to very

deep) in predominant slope & flood plain alluvial area. • Predominant Texture: Heavy Texture, predominantly clay.

IV. Climate data from secondary sources:

Rainfall Data: The northern part has comparatively poor rainfall. Rainfall data was taken fromworldclim.org

indicates that the long term mean spanning the period 1965 -2020 is medium to high226 to 259 cm rainfall for the Dadra & Nagar Haveli (DNH Spinners)region as compared to 197 to 242 cm rainfall for the central Gujarat. The isohyetal map for that period shows a high variation in rainfall from the Gujarat, Rajasthan towards the north and south part.

Rainfall data is important in the planning strategy for industry development. The Rainfall map for Dadra &Nagar Haveli shows that Precipitation recorded over a long-term period (1 year) attains a yearly mean maximum of 200- 250 cm for the year 2015.

V. Social Infrastructure available:

Silvassa infrastructure owes itself largely to the initiatives of Administration, in building the Industrial infrastructure and in attracting young entrepreneurs from Dadra & Nagar Haveli (U.T) Equally, the growth of the social infrastructure – Residential facility, Drinking water, Health-care Facilities , Education Facilities , Socio-Cultural Facilities , Other Public-Semi-Public Facilities ,Police, Fire &Emergency Services ,Communication (Postal Facility) , Recreational Facilities & Open Spaces, Distributive Services, Miscellaneous Facilities, Banking facility Garden etc. - There are good residential and commercial areas Daman and Silvassa (the capital of Dadra and Nagar Haveli) attract both Indian and international tourists. The nearest Railway station is Vapi and Bhilad. All major Mail/Express trains are available at Vapi. The UT of Dadra & Nagar Haveli is almost touching Mumbai - Baroda - Delhi National Highway No. 8 (Western Express Highway). Silvassa is about 14 Kms from Bhilad & 18 Kms from Vapi. Mumbai 180 Kms, Surat 140 Kms, Nasik 140 Kms and Daman 30 Kms.


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 5. Planning Description

5.0 Planning Brief. I. Planning Concept (Type of industries, facilities, transportation etc) Town and Country Planning

/Development authority Classification: There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in

manufacture of variety of products in the notified industrial zone of U.T. D&NH. The notified industrial zone of U.T. D&NH has the entire available infrastructure like water, electricity, roads, rail, and transportation, availability of raw material, TSDF Site and drainage system.

II. Population Projection:

The proposed new project will be the requirement of around 300 employees approx. in the beginning.

III. Land use planning (breakup along with green belt etc.): The proposed project is located within the notified industrial zone of U.T. D&NH and due to the proposed project there will not be any change in the land use pattern of the region. Plot Area Statement:

Area Statement Area (in m2)

Total Area 98200.00

Construction Area 39280.00

Open Land / Internal Road Area 25308.24

Greenbelt Area 33611.76

IV. Assessment of Infrastructure demand (Physical & Social):

The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. Facilities like road and communication are good. Banks, ATM's and medical facilities are also adequate.

V. Amenities/ Facilities: The industrial zone has the entire available infrastructure like water, electricity, roads, transportation, availability of raw material and drainage system. Education- schools including middle, secondary and higher secondary schools, Colleges, social welfare hostels. Medical and Health- Community Health Centre, & Primary Health center are available nearby area. Power and water- All the villages are electrified and drinking water facilities are extended to all villages. Rail and Road- The project site is very well connected by road through State Highway no. 8, Western railways.


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 6. Infrastructure Details

6.0 Proposed Infrastructure: I. Industrial Area (Processing Area):

Basic infrastructure developed already and the required additional plant and machineries will be installed after getting statutory clearance.

II. Residential Area (Non Processing Area): No residential area is involved in the proposed project. The employs are accommodated in nearby Residential areas

III. Green Belt: Green belt area will be provided and maintain at the tune of 33% (33611.76 sq.m.) of the total land area as the project site is within the developed industrial area.

IV. Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc): The project site is very well connected by road through National Highway No. 8, western railways. V. Drinking Water management (Source& Supply of water):

Water requirement will be fulfilled through River/ Canal. VI. Sewerage System:

There will be no discharge of industrial effluent (Zero Discharge). Sewerage water is disposed off through STP to plantation.

VII. Industrial Waste Management: As mentioned in sr. no. xi of Chap.3 (project Description)


Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 7. 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): The proposed new Industry does not envisage any disturbance to local community or the village since the land is acquired and fully owned by M/s. Beekaylon Synthetics Pvt. Ltd., as Notified industrial zone. The proposed new project will not affect the home oustees, land oustees and landless laborers. Hence there is no R & R plan required.

8. Project Schedule & Cost Estimates: I. Likely date of start of construction and likely date of completion (Time schedule for the project to be

given): The proposed project will be implemented in three phase and first phase will be completed within one year after obtaining required permissions. Remaining two phases will be implemented within five year of span.

II. Estimated project cost along with 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 new proposed project. Environment Protection has also been considered in planning the Cost Projection, which will include Green belt development, safety systems, etc.

Capital Cost Projection:

Sr. No.

Purpose Cost (Rs. in

Crore) 1. Land 18.00 2. Building and Civil Works 50.00 3. Plant & Machinery and other fittings 360.00 4. Environmental protection measures 10.00 5. Green Belt Development 5.00 TOTAL : 443.00

The company will provide budgetary provision for the recurring expenses for environmental issues While planning the allocation of funds during the annual budgetary planning.

Recurring Cost per annum:

Sr. No.

Component Proposed

(Rs. in Lacs/annum) 1. Environment & Safety Management System 50.00 2. Greenbelt Maintenance 10.00 3. Enterprise social contribution 106.00

Total 166.00 New project-Manmade Fiber Industry Page | 20

Pre-feasibility Report M/s.Beekaylon Synthetics Pvt. Ltd., Velugam 9. 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 new project 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.


Table- 3.1 Details of Hazardous Chemicals CHEMICAL/ MATERIAL PARTICULARS

MEG (Monoethylene Glycol), CAS# 107-21-1

Max. Storage Quantity

Transportation Storage Mode Probable Hazards

6030 tons By Road Tankers (20 T Capacity)

Storage Tanks: 500 m3 X 3 Nos

Health Hazards, Pollution, Secondary Fire,

Physical Properties Desnity

BP MP Flash Point

Auto Igni. Point

LEL/UEL Vapour Pressure

1.115 g/cm³@20°C

197°C -12.4°C 111°C 410°C 3.2%/53% 0.08 hPa @20°C

Chemical Properties Formula

MW Stability Reactive Solubility

HOCH2CH2OH

62.07 Stable Not Pertinent, No Dangerous reaction

100g/l @20°C

Terephthalic /Pthalic Acid (PTA) CAS# 100-21-0



7785 Tons

By Road Bulk Carrier in Sp. 1 Ton Bags

Sp. Storage Facility with N2 Blanketing: In 1 Ton bags & Silo

Health Hazards, Pollution, Secondary Fire, Dust Explosion

Physical Properties Desnity/Sp. Gravity

BP MP Flash Point

Auto Igni. Point


1.51 @20°C

300°C

Sublimes at BP

Not Available

Not Available

Not Available Not Available



C8H6O4 166.14 Stable Not Pertinent, Insoluble DOWTHERM, CAS# 8004-13-5



5 tons Through Road truck in Barrels Barrels in ware house

Minor Health, Water & Soil Pollution, Secondary Fire,

Physical Properties Desnity BP MP Flash

Point Auto Igni. Point


1.118 g/cm³@20°C

257°C 12°C 124°C 428.8°C 1.6% /10.8% <.001 mm Hg. @20°C



(C6H5-O-C6H5)- (C6H5-C6H5)

166 Stable Not Pertinent, No Dangerous reaction

Insoluble @20°C

Titanium Dioxide CAS# 13463-67-7



36 tons

By Road Truck Bags/Drum of 50 Kg

Storage Area in supply packing

Minor Health, Pollution

Physical Properties

CHEMICAL/ MATERIAL PARTICULARS

Desnity/Sp. Gravity

BP MP Flash Point

Auto Igni. Point

LEL/ UEL Vapour Pressure

4.2 2500-3000°C

1860°C Not Available

Not Available

Not Available Not Available



TiO2 79.9 Stable Not reactive Insoluble @20°C

Antimony Trioxide, CAS# 1309-64-4



16 tons

By Road Truck Bags/Drum of 50

Storage Area in supply packing

Toxic, Pollution, Reactive

Physical Properties Density / Specific Gravity

BP MP Flash Point

Auto Igni. Point


5.2 @25°C

1425°C

655°C NA NA NA 1mm Hg @547°C



Sb2O3 291.5 Stable With PTA – Toxic gas Air: Heat Generation

Insoluble @20°C

Natural Gas (as Methane), CAS# 74-82-8



Not to Store, Direct Use @

By Pipeline of GSPL No Storage: direct use after PRV Station

Fire, Explosion, Toxic, Pollution

Physical Properties Density / Specific Gravity

BP MP Flash Point

Auto Igni. Point

LEL / UEL Vapour Pressure

0.422 @-160°C

-161.5°C

655°C -171°C 540°C 5% / 15% 6.858 psi @-170°C



CH4 16.04 Stable Not Known in normal condition 35 ml/Lit @17.2°C

Details of Proposed Effluent Treatment Scheme:

Design Criteria of ETP:

• Product : Continuous Polymerization • Source of Effluent : Process effluent, Washing & Utilities. • Design Flow of Effluent : 300 KL/day Max. • Design Parameters : as under

Table 3.2 Characteristics of Wastewater

Sr. No. Parameter Unit Raw Effluent Quality/Value

Treated effluent Quality/Value

1. Flow M3/ Day 300 Max. 300 Max. 2. pH -- 4.0 to 8.0 6.5 to 7.5 3. Suspended Solids mg/lit 250 to 350 <100 mg/lit 4. Biochemical Oxygen Demand mg/lit 1500 to 2000 <100 mg/lit 5. Chemical Oxygen Demand mg/lit 5000 to 7000 <250 mg/lit 6. Oil & Grease mg/lit 40 to 50 <10 mg/lit 7. Total Dissolved Solids mg/lit 1500 to 2000 <2100 mg/lit Based on the above criteria you have to install Effluent Treatment Plant as mentioned in the proposal with required capacity. • The details of various unit & components of the proposed ETP units with MOC to be

design are as below.

Table 3.3, Details of ETP

Sr. No.

Particulates MOC Sr. No.

Particulates MOC

1. Oil & Grease Removal Tanks RCC 14. Activated Carbon Filter MS Epoxy 2. Collection/ Reaction Tank RCC 15. Treated Water Tank RCC 3. Flash Mixer RCC 16. Sludge Drying Beds Brick Masonry 4. Primary Clarifier RCC 17. Sludge Storage Area Brick Masonry 5. 1 st Stage Aeration Tank RCC 18. Transfer Pumps C.I. 6. 1 st Stage Secondary Clarifier RCC 19. Filter feed Pumps C.I. 7. 2 nd Stage Aeration Tank RCC 20. Treated Water Pumps C.I. 8. 2 nd Stage Secondary Clarifier RCC 21. Air Blower for Collection

tank C.I.

9. Holding Tank RCC 22. Air Blower for Aeration tanks

C.I.

10. Flash Mixer MS FRP 23. Course diffuser for Equalization tank

HDPE / PVC

11. Primary Clarifier Mechanism MS FRP 24. Fine diffuser for Aeration tanks

EPDM

12. Secondary Clarifier Mechanism

MS FRP 25. Piping, Valves Fittings & fabrication

Standard

13. Pressure Sand Filter MS Epoxy

26. Electrical Panel with Energy Meter

Standard

EFFLUENT TREATMENT SCHEME

1. PRIMARY TREATMENT

UNITS: Oil & Grease removal Tank Collection cum Neutralization 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 –I &II Secondary settling

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 and Carbon Filter, R.O. and MEE

After secondary treatment the effluent is passed through the mixed bed filter for further reduction

of COD Value, BOD Value and Colour. Treated water is collected into the treated water tank above

the roof. Finally the treated effluent confirming the treated water discharge norms laid down by

board will be treated in R.O. to get water for reuse, further the R.O. reject water will be treated in

MEE to get further water for reuse and remaining residue will be sent to TSDF for final disposal.

Figure 3.3

Schematic of Proposed ETP

Figure-3.3 Water Balance Diagram

Total water requirement for proposed project – 4490 KLD (Total Fresh water- 3740 KLD + Recycle water- 750 KLD)

Cooling tower – 4215 KLD (Fresh-3465+ Recycle-750)

Industrial through RWT (4390 KLD) (Fresh-3640 KLD + Recycle-750 KLD)

Manufacturing Processes –0.00(Nil)

Ro Plant + MEE 795 KLD

Steam Boiler – 100 KLD

Floor/Equip. Washing – 75 KLD

To ETP 300 m3/day

Waste Water Generation during @

polymerization condensation – 224 KLD

Boiler Blow down – 6 KLD

Cooling tower Blow down - 500 KLD

Domestic – 100

Sewage -80 KLD

STP

Plantation - 80 KLD

Waste water 70 KLD

Permeate -750 KLD to

Reuse

Evaporation – 44.50 KLD Residue – 0.5 TPD to

Solid Waste – 1.5 TPD to TSDF

m/s. beekaylon synthetics pvt....

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