FORM – 1 With Basic Information FOR OBTAINING ENVIRONMENTAL CLEARANCE For the Proposed Synthetic Organic Resins Manufacturing in EXISTING UNIT of M/S. MACRO POLYMERS PVT. LTD. Plot No. : 133, 134, 135, 136, 164 & 165, Mahagujarat Industrial Estate, Moraiya, Taluka: Sanand, District: Ahmedabad, Gujarat. Mob No.: 09898079801 Email: [email protected]Prepared By: T. R. ASSOCIATES C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S.G.Highway, Ahmedabad. Mo. No.: 98253 71099 Email ID: [email protected]; [email protected]October 2015
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FORM – 1 With Basic Information
FOR OBTAINING ENVIRONMENTAL CLEARANCE For the Proposed Synthetic Organic Resins Manufacturing in
Size of the Project * : Proposed Synthetic Organic Resins Manufacturing with production capacity of 3500 MT/Month in Existing unit.
Expected cost of the project : Rs. 2 Crore * Capacity corresponding to second activity (such as production capacity for manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.) Sr. No.
Item Details
1. Name of the Project/s M/s. Macro Polymers Pvt.Ltd. 2. S. No. in the schedule 5(f) 3. Proposed capacity/area/length/tonnage to be handled/ command area/ lease area/
Products details and raw materials requirement is given in Annexure-1.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 3 -
Sr. No.
Item Details
4. New/ Expansion/ Modernization Proposed Project of Resin manufacturing in existing premises as well in proposed adjacent plot.
5. Existing Capacity/ Area etc. Existing products and capacity are given in Point 3 above. Area of the existing premises is 11,971 sq.m. and area of proposed adjacent plot is 1,650.53 sq.m.
6. Category of Project i.e. ‘A’ or ‘B’ A 7. Does it attract the general Condition? If
Yes, please specify. No
8. Does it attract the specific Condition? If Yes, please specify.
No
9. Location Google Map showing project site is enclosed as Annexure-2.
Plot/Survey/Khasra No. 133, 134, 135, 136, 164, 165 Village Mahagujarat Ind. Estate, Moraiya Tehsil Sanand District Ahmedabad State Gujarat
10. Nearest railway station/airport along with distance in kms
Nearest Railway station: Moraiya @ 2 Km, NW Nearest Airport: Ahmedabad @ 26 Km, NE
11. Nearest Town, city, District Headquarters along with distance in kms.
Nearest Village (Residential area): Tajpur @ 1.3 Km, ESE Nearest City: Ahmedabad @ 10 Km, NE
12. Village Panchayats, Zila Parishad, Municipal Corporation, Local body(complete postal) address with telephone nos. to be givan)
Moraiya Village Panchayat
13. Name of the applicant Mr. Mayank Parikh 14. Registered Address Macro Polymers Pvt. Ltd.
22. Whether there is any Government Order/ Policy relevant/ relating to site?
Not Applicable
23. Forest land involved (hectares) Not Applicable 24. Whether there is any litigation pending
against the project and/ or land in which the project is propose to be set up? a) Its relevance with the proposed
project.
Not Applicable
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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(II) Activity 1. Construction, operation or decommissioning of the Project involving actions,
which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr. No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities / rates, wherever) with
source of information data 1.1 Permanent or temporary change in
land use, land cover or topography including increase in intensity of land use (with respect to local and use plan)
No Construction Phase: The existing industry is located in an industrial estate. The proposed expansion will be carried out in the existing factory premises and an adjoining industrial land. Hence, there will not be any change in land use, land cover or intensity of land use during construction phase. Operation Phase: The industry is a manufacturing unit with all activities carried out in permanent structure. Hence there will not be any change in land use, land cover or intensity of land use during operation phase. Decommissioning Phase: The industry will not be decommissioned.
1.2 Clearance of existing land, vegetation and buildings?
No Construction Phase: No clearance of vegetation and building will be done as the proposed expansion will be carried out in the existing premises. Operation Phase: There will not be any clearance of existing land, vegetation and building during operational phase.
1.3 Creation of new land uses? No Not Applicable 1.4 Pre-construction investigations e.g.
bore houses, soil testing? No Not Applicable as this is an existing unit.
1.5 Construction works? No There will not be any construction work
carried out in existing premises. Minor fabrication works will be carried out within the existing premises as per the requirement. In proposed plot of 1,650.53 sq.m., civil work and fabrication work will be carried out as per requirement.
1.6 Demolition works? No There will not be any type of demolition work carried out in existing premises as
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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Sr. No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities / rates, wherever) with
source of information data well in proposed plot.
1.7 Temporary sites used for construction works or housing of construction workers?
No Not required as no major construction works will be done.
1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations
No Such structures will not be required as the proposed project will be carried out within the existing premises. In adjoining plot of 1,650.53 sq.m. area, civil work and fabrication work of industrial shed will be carried out as per requirement.
1.9 Underground works including mining or tunneling?
No Not applicable as this is an existing chemical industry.
1.10 Reclamation works? No Not Applicable 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and manufacturing
processes? Yes Detailed manufacturing process is
attached as Annexure-3 1.14 Facilities for storage of goods or
materials? No Tank farm and covered sheds are
already provided for storage of goods & materials as well as fuel in existing premises. Proposed plot will be developed as per the requirement.
1.15 Facilities for treatment or disposal of solid waste or liquid effluents?
Yes Sewage and industrial wastewater will be generated from the proposed project which will be treated alongwith existing wastewater in existing ETP. Details of ETP are provided in Annexure-5. Details of hazardous waste and its management for the existing and proposed project are given in Annexure-6.
1.16 Facilities for long term housing of operational workers?
No There is an existing labor rooms in the premises. There will not be any provision of additional rooms for proposed projects.
1.17 New road, rail or sea traffic during construction or operation?
No Not required as proposed increase in traffic will be taken care by existing estate road which is well connected to the NH 8A at only about 1 km.
1.18 New road, rail, air water borne or other transport infrastructure including new or altered routes and stations, ports, airports etc?
No Not required as proposed increase in traffic will be taken care by existing estate road which is well connected to the NH 8A at only about 1 km.
1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?
No Not required as proposed increase in traffic will be taken care by existing estate road which is well connected to the NH 8A at only about 1 km.
1.20 New or diverted transmission lines No Not required
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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Sr. No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities / rates, wherever) with
source of information data or pipelines?
1.21 Impoundment, damming, culver ting, realignment or other changes to the hydrology of watercourses or aquifers?
No Not Applicable
1.22 Stream crossings? No Not Applicable 1.23 Abstraction or transfers of water
form ground or surface waters? Yes own existing borewells will be utilized to
satisfy the water requirements after the proposed project.
1.24 Changes in water bodies or the land surface affecting drainage or run-off?
No Not Applicable
1.25 Transport of personnel or materials for construction, operation or decommissioning?
No Only fabrication work will be carried out. No construction work will be required. Transportation of materials will be taken care by existing estate road which is well connected to the NH 8A at only about 1 km.
1.26 Long-term dismantling or decommissioning or restoration works?
No Not Applicable
1.27 Ongoing activity during decommissioning which could have an impact on the environment?
No For proposed project, no such decommissioning activities will be carried out.
1.28 Influx of people to an area in either temporarily or permanently?
No There will be only 25 workmen additionally required. Hence, there will not be any influx of people to the area, either temporarily or permanently.
1.29 Introduction of alien species? No Not Applicable 1.30 Loss of native species or genetic
diversity? No Not Applicable
1.31 Any other actions? No Not Applicable
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr. No.
Information/checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
2.1 Land especially undeveloped or agricultural land (ha)
No The project will be carried out in Industrial land. Area of the existing premises is 11,971 sq.m. Proposed Project will be carried out in existing premises as well in proposed adjacent plot having an area of 1,650.53 sq.m. Plant lay-out of existing premises is enclosed as Annexure-8.
2.2 Water (expected source & competing users) unit: KLD
Yes Construction Phase: There is no major construction required for the project. During construction phase, water requirement will be meet from existing source of water supply. Existing sanitary facilities will also be used by construction workmen. Operational phase: Water requirement for operation after proposed project for industrial & domestic use will be 24 KLD and same will be fulfilled by own existing borewell. Water balance diagram is attached as Annexure-4.
2.3 Minerals (MT) No Not required 2.4 Construction material – stone,
aggregates, and /soil (expected source – MT)
No No construction activities will require to be carried out.
2.5 Forests and timber (source – MT) No Not applicable 2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel (MT), energy (MW)
Yes Total contract load is 275 KW from Uttar Gujarat Vij Company Limited. Imported Steam Coal/ Briquettes and HSD will be utilized as fuel in Thermic fluid heaters and D. G. Sets respectively. Fuel requirements and flue gas generation details are given in Annexure-7.
2.7 Any other natural resources (use appropriate standard units)
No Not required
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)
Yes Hazardous chemicals as per MSIHC rules are already handled in existing set up. Some additional hazardous chemicals will be handled during proposed project. However, all the necessary measures are being taken for storage and handling of these chemicals. If any additional measure is required, it will be taken care of before commissioning of the proposed expansion.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)
No Not Applicable
3.3 Affect the welfare of people e.g. by changing living conditions?
No Not Applicable
3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.
No Not Applicable
3.5 Any other causes No Not Applicable
4. Production of solid wastes during construction or operation or decommissioning (MT/Month)
4.1 Spoil, Over burden or mine wastes No Not applicable as this is a chemical industry.
4.2 Municipal Waste (domestic and or commercial wastes)
Yes There will not be any demolition activity carried out. Civil / Fabrication work will be done as per requirement. Construction work will not require much man power. Hence, there will not be any municipal waste.
4.3 Hazardous wastes (as per Hazardous Waste Management Rules)
Yes From civil / fabrication work, there will not be any type of hazardous waste generation. Details of hazardous waste to be generated from operation are attached as Annexure-6.
4.4 Other industrial process wastes Yes During manufacturing process some process waste will be generated. Details
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
of such hazardous waste with its management are attached as Annexure-6.
4.5 Surplus product No Not Applicable 4.6 Sewage sludge or other sludge from
effluent treatment. Yes At present, sewage is treated alongwith
industrial effluent in effluent treatment plant. There is no physic-chemical treatment and no chemical sludge is generated from ETP. Excess biomass from effluent treatment plant is utilized as manure.
4.7 Construction or demolition waste No Not generated as no such activities will be carried out.
4.8 Redundant machinery or equipment No No such waste will be generated 4.9 Contaminated soils or other
materials No Not Applicable
4.10 Agricultural wastes No Not applicable as this is an existing chemical industry.
4.11 Other solid wastes No Not Applicable
5. Release of pollutants or any hazardous, toxic or noxious substances to air
5.1 Emissions from combustion of fossil fuels from stationery or mobile sources
Yes Details of flue gas stack are given in Annexure-7
5.2 Emissions from production processes
No All processes are / will be carried out in closed vessel and no process gas is / will be generated. Hence, there will not be any process gas emission occurred from the proposed project.
5.3 Emissions from materials handling including storage or transport
No Liquid materials are / will be storage in closed tanks and handled in closed loop pipelines with mechanical seal pumps to prevent spillages and emissions. Solid materials are / will be stored in bags with adequate liners to prevent any spillage / fugitive emissions during handling. All solid materials are / will be stored in covered sheds with impervious flooring. The best handling practices are / will be followed for material handling. So there
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
6.1 From operation of equipment e.g. engines, ventilation plant, crushers
Yes Noise is / will be generated due to operation of DG sets. However, DG sets are for stand-by power supply in case of power cut. DG sets are installed with acoustic enclosures to keep noise level below prescribed limits. No ventilation plant, crushers and other noise generating equipment / plant / operations are / will be carried out
6.2 From industrial or similar processes Yes Noise is / will be generated due to operation of machineries like pumps, compressors and utilities. However, all measures are / will be taken to maintain noise level within prescribed norms in working area as well as in surroundings.
6.3 From construction or demolition No No such construction works will be involved
6.4 From blasting or piling No Not Applicable
6.5 From construction or operational traffic
Yes Minor increase in noise level due to operational traffic
6.6 From lighting or cooling systems No Not Applicable 6.7 From any other sources No Not Applicable
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, ground water, coastal waters or the sea:
7.1 From handling, storage, use or spillage of hazardous materials
No Liquid materials are / will be stored in closed tanks and handled in closed loop pipelines by pumps with mechanical seal to prevent spillages and emissions. Solid materials are / will be stored in bags with adequate liners to prevent any spillage / fugitive emissions during handling. All solid materials are / will be stored in covered sheds with impervious flooring. The best handling practices are / will be followed for material handling. So there will not be any chances of contamination of land or water. There is no water body in the vicinity and there is no chance of contamination.
7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)
No No sewage or other effluents are / will be discharged in to water bodies or on land Sewage is / will be discharged into septic tank from where it will be mixed with industrial effluent and treated in ETP. Industrial effluent is / will be treated in Effluent treatment plant. Treated effluent quality is / will be within prescribed norms. Treated effluent is / will be reused in cooling tower make up and for horticulture within the premises.
7.3 By deposition of pollutants emitted to air into the land or into water
No Air emissions include / will include only flue gases from Thermic heater / DG set. Adequate air pollution control measures are / will be provided to maintain the emissions within prescribed limits. No process and fugitive emissions are / will be occurring. Hence, there is / will be no possibility of deposition of pollutants emitted to air into the land or into water.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
8.1 From explosions, spillages, fires etc. from storage, handling, use or production of hazardous substance
Yes There will not be any construction activity carried out which has potential for explosions, spillages, fires etc. During operation, the same risk is / will be involved while storage, handling, use or production of hazardous chemicals but all the necessary preventive and control measures are / will be taken.
8.2 From any other causes No Not Applicable 8.3 Could the project be affected by
No All the constructions are / will be as per relevant IS codes and earthquake resistant. The project site is above the high flood level and no water body is in the vicinity of the site. Hence, there is / will not be any effect of flood. The project site is in plain area, hence there is no chance for land slide.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
9.1 Lead to development of supporting, facilities, ancillary development or development stimulated by the project which could have impact on the environment e.g. Supporting infrastructure (roads,
power supply, waste or waste water treatment, etc.)
Housing development Extractive industries Supply industries Other
No The project site is already in a well developed industrial area in vicinity of Ahmedabad. The project size is very small that can lead such development.
9.2 Lead to after use of the site, which could have an impact on the environment
No The project is on an industrial land and there will not be any after use of the site.
9.3 Set a precedent for later developments
No Not Applicable
9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects
No Not Applicable
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
1 Areas protected under international conventions, national or local legislation for their ecological landscape, cultural or other related value
No Not Applicable
2 Areas with are important or sensitive for ecological reasons – Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests
No Not Applicable
3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration
No Not Applicable
4 Inland, coastal, marine or underground waters
No Not Applicable
5 State, National boundaries No Not Applicable 6 Routes or facilities used by the
public for access to recreation or other tourist, pilgrim areas
No Not Applicable
7 Defense installations No Not Applicable
8 Densely populated or built-up area No Ahmedabad city is about 10 km far from project site in NNE direction and Bavla Town is at same distance but in SSW direction.
9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)
No Ahmedabad city is about 10 km far from project site in NNE direction and Bavla Town is at same distance but in SSW direction.
10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agricultures, fisheries, tourism, minerals)
No Not applicable
11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)
No Not applicable
12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
No Not applicable
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 16 -
(IV)Proposed Terms of Reference for EIA studies: 1. Executive summary & Justification of the project and Promoters and their back ground. 2. Regulatory framework. 3. A map indicating location of the project and distance from severely polluted area. 4. Project location and plant layout. 5. Infrastructure facilities including power sources. 6. Total cost of the project along with total capital cost and recurring cost/annum for
environmental pollution control measures. 7. Impact of ground water drawl on other users/ surroundings. Hydro-geological study of the
area for availability of ground water should also be included. 8. Project site location along with site map of 10 km area and site details providing various
industries, surface water bodies, forests etc. 9. Present land use based on satellite imagery for the study area of 10 km radius. 10. Location of National Park/Wild life sanctuary/Reserve Forest within 10 km radius of the
project. 11. Details of the total land and break-up of the land use for green belt and other uses. 12. List of existing & proposed products along with the production capacities and list of
solvents and its recovery plan, if any. 13. Detailed list of raw material required and source, mode of storage and transportation. 14. Manufacturing process details along with the chemical reactions and process flow chart. 15. Action plan for the transportation of raw material and products. 16. Site-specific micro-meteorological data using temperature, relative humidity, hourly wind
speed and direction and rainfall. 17. The details of solid and hazardous wastes generation, storage, utilization and disposal
particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler to be included.
18. Ambient air quality monitoring at 8 locations within the study area of 5 km., aerial coverage from project site as per NAAQES notified on 16thSeptember, 2009. Location of one AAQMS in downwind direction.
19. Baseline data collection will be started in November 2015. 20. Detailed Environment management Plan (EMP) with specific reference to details of air
pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.
21. Details of water and air pollution and its mitigation plan 22. Determination of atmospheric inversion level at the project site and assessment of ground
level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modelling for proposed plant.
23. Water balance chart including quantity of effluent generated, treated and evaporated. 24. Details of effluent treatment plant (ETP). Characteristics of inlet effluent and treated
effluent. 25. Ground water monitoring minimum at 8 locations to be carried out. Geological features
and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic).
26. Authorization/ Membership for the disposal of solid/hazardous waste at common facility of TSDF and incineration.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 18 -
ANNEXURES
Annexure No. Description
1 List of Existing & Proposed Products and Raw Materials
2 Google image showing project site
3 Manufacturing process details
4 Water Balance Diagram
5 Details of Effluent Treatment Plant
6 Details of hazardous waste management
7 Details of fuel and flue gas stacks
8 Plant Lay-Out
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 22 -
ANNEXURE-2
Google Image showing location of Proposed Project Site
Proposed Project Site
NH 8A
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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ANNEXURE-3
Manufacturing Process Details Industrial Polymers (Existing product): Crude Glycerin is taken to a vacuum distillation system and 95% Glycerin is
recovered. Residual water is discharged to ETP. Vegetable oil and poly-ol (Glycerin or pentaerithritol) is taken in reaction vessel The mass is heated to 250° C under slight alkaline condition and maintained the
temperature for 2-3 hours. Then Mono/Di basic Anhydried/Acid is added and polymerization reaction takes
place and polymer is formed. By varying ratio of vegetable oil and polyol, monoglycerides of various physical
properties are produced. When compatibility of total mass with ethanol is achieved, material is cooled. Being reversible action, prepared poly-glyceride is stabilized by fixing it with addition
of benzoic acid / phthalic anhydride. Solvent is added as per requirement to achieve desired specifications and to prevent
crystallization. Alkyd Resins Distilled glycerin is taken for alkyd resin manufacturing along with vegetable Oils or
their Fatty Acid & Poly functional Alcohol reacted at2500C under constant stirring alcoholysis or Acidolysis.
It is further with dibasic acid with the aid of catalyst under constant stirring till required specifications are achieved. The material thin down with required solvent filtered & packed.
Polyamide Resins Dimer Acid, Fatty Acid & polyamines are reacted with the aid of Catalyst at
elevated temperature under constant stirring till required specifications achieved. Material discharged in trays, broken in small pieces, grinded & packed or filtered and
packed in barrels.
Polyester Resins Mono/di/PolyacidAcid and Polyols/Glycols reacted at 2400C till desired specifications
in Acid Value & Viscosity parameters are attained. The material thin down with required solvent to desired non-volatile contents and
cooled filtered & packed. Acrylic Resins Methacrylate Monomers like M.M.A., Acrylate monomers like Ethyl Acrylate, and
Styrene are charged into reactor along with solvents like Xylene/Toluene and Polymerized at temperature of 1000C in presence of peroxide initiators till required degree of polymerization is attained.
Then cooled, filtered and packed into barrels.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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Rosin Esters and Derivatives Rosin & Poly functional Alcohol reacted at 2500C under constant stirring alcoholysis
or Acidolysis. It is further with dibasic acid with the aid of catalyst under constant stirring till required specifications are achieved.
The material thin down & packed. Epoxy Derivatives Epoxy resin and fatty acid are reacted in vessel at 2500C. When acid value and
viscosity is achieved, it is cooled and solution made in given solvents. The material is then packed. Amino Resins (Melamine resin or Urea resin or Phenolic resin) Formaldehyde is made alkaline with caustic solution and then Butanol is added. Then Urea and Melamine is added and temperature is raised to700C and maintained
for certain time. And finally again raised to 1200C during which catalyst and Butanol is added
stepwise till final specification is achieved. Material is filtered and packed in barrels. Caustic flakes will be added in water of reaction. Resulting caustic lye will be again heated at 1250C to recover 4 to 5% of Alcohol
(Butanol etc.) from the reaction water. Resultant Lye will be sold as by-product. Ketonic Resin Formaldehyde is made alkaline with Caustic Solution and then cyclohexanone is
added. Then temperature is raised to 700C and maintained for certain time. And finally again raised to 1200C during which condensation polymerization takes
place. Material is applied vacuum to remove water and packed in bags after drying. Resin Solutions Base resin is taken in a vessel for heating. After heating, solvent/modifiers are
added to prepare the resin solution. When compatibility of total mass with solvent/modifier is achieved, material is cooled.
Prepared resin solution is packed in drums/barrels (raw material barrels) and dispatched.
Solvent is added as per requirement to achieve desired specifications and to prevent crystallization.
This manufacturing process will not involve any chemical reaction or synthesis. The product will be manufactured only by adding solvents to readymade/brought out base resins to get desired properties.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 25 -
ANNEXURE-4
Water balance diagram
Source of Water Supply: Borewell Existing: 26 KL/day
Treated water for Cooling E: 8 KL/day P: 32 KL/day T: 40 KL/day
Treated water for on campus horticulture
E: 3 KL/day P: 1.5 KL/day
T: 4.5 KL/day
Treated water for Floor washing E: Nil P: 0.5 KL/day T: 0.5 KL/day
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
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ANNEXURE-5
Details of Effluent Treatment Plants Existing ETP is designed to treat 50 m3/day effluent and therefore it has sufficient
capacity to treat proposed effluent efficiently. Raw effluent from plant (i.e. process effluent and cooling tower blow down) flows
to ETP and gets collected in Eq. Tank. Sewage is treated in septic tank for removal of sewage solids and collected in
sewage collection sump. Then it is pumped to Equalization tank for further treatment and mixed with other streams.
Unit has provided a collection cum equalization tank of 9 m3 volume. An aeration grid is provided in it for mixing of the content. The mixed effluent (sewage, blow down and process effluent) is than pumped to two anaerobic reactors, operating in parallel regime.
In anaerobic reactor, raw effluent is fed from the bottom of the reactor to distribute uniformly through the inlet distribution system. It is passed upwards through the dense anaerobic sludge bed. Organic matter is rapidly utilized by biomass and converted to methane rich biogas. Upward movement of water and keep the biomass in suspension and break any scum formation. The three-phase separator allows effective degasification to occur. The dense, granular sludge particles, devoid of attached gas bubbles, sink back to the bottom establishing a return downwards circulation. The treated effluent flows into collection channel at the top of the settlers, while the directly combustible biogas is recovered from the collection pockets.
The anaerobically treated effluent flows to aeration tank. The aerobically treated effluent is passed through secondary settling tank. The finally treated effluent is collected in treated collection tank.
The treated effluent finally used for cooling purpose after giving polishing treated by pressure media filter & Activated carbon filter and ultra filtration.
ETP Units:
Sr. No. Unit Volume/Capacity 1. Equalization tank 9 m3 2. Anaerobic Reactor 1 80 m3 3. Anaerobic Reactor 2 120 m3 4. Aeration tank 21 m3 5. Secondary settling tank 7 m3 6. Treated effluent collection tank 3 m3 7. Dual Media Filter 0.3m dia x 1.5m ht. 8. Activated Carbon Filter 0.3m dia x 1.5m ht. 9. Sludge decanter 100 kg/d capacity
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 27 -
ETP Flow Diagram
Sewage & Effluent from process
Collection cum Neutralization tank
Pumped to Anaerobic Reactor 1 & 2
Treated Effluent Collection Tank
Secondary Settling Tank
Aeration Tank
Pressure Sand Filter Activated Carbon FilterPumped for reuse like
cooling purpose
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 28 -
ANNEXURE-6
Details of Hazardous Waste Management
Sr. No. Description Category Quantity (MT/Year) Management E P T
1
Waste/Resin Generated by Resin manufacturing
23.1 6 14 20 Collection, storage
and reused in process
2 Used Oil 5.1 0.12 29.88 30
Collection, storage and used within premises as a
lubricant / sold to registered recycler.
3 Discarded Containers/bags 33.3 0.3 149.7 150
Collection, storage & sell to authorized
vendor
4
Waste and residue (Formed during formulation)
21.1 6 (-) 4.5 1.5
Collection, storage and disposal at
approved TSDF Site
5
Waste and residue (Formed during Synthesis)
21.1 Nil 30 30
6 Fillers residues (Formed during formulation)
21.2 6 (-) 4.5 1.5
7 Inorganic process Sludge 34.3 Nil 60 60
Note: E: Existing; P: Proposed; T: Total after expansion
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 29 -
ANNEXURE-7
Details of Flue Gas Stacks
Sr. No.
Stack attached to
Stack Height
(m)
Status after
expansion
Fuel Requirement
APC System
Expected Pollutant
1 Thermic Fluid Heater (10 Lac Kcal/hr)
35 Working Imported Steam
Coal/BriquettesExisting: 6 MT/Day
Proposed: 19 MT/Day Total: 25 MT/Day
Multicyclone Separator
SPM 150 mg/Nm3
SO2 100 ppmNOX 50 ppm
2
Thermic Fluid Heater (10 Lac Kcal/hr)* 35
Upgraded to 20 Lac Kcal/hr
Cyclone Separator & Bag filter will
be after proposed expansion 3
Thermic Fluid Heater (1 Lac Kcal/hr)
Working
4 D.G.set-2 Nos. (30 KVA) 9 Standby HSD
Existing: 35 L/Hr
Proposed: 0 L/Hr
Total: 35 L/Hr
Adequate stack height 5 D.G. set
(125 KVA) 9 Standby
6 D.G. set (180 KVA) Standby
Note: * This Thermic fluid heater will be upgraded to 20 Lac Kcal/hr after proposed expansion and bag filter will be installed as air pollution control unit followed by existing cyclone separator.
Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd., Moraiya, Ahmedabad
Form-1 for Environmental Clearance Page - 30 -
ANNEXURE-8
Area Break-up and Existing Plant Lay-out
Sr. No. Particular Area (Sq m) % of Total Area
Existing Proposed Total 1 Built–up area 4390.00 730.00 5120.00 37.60 2 Open Area 6520.00 180.53 6700.53 49.20 3 Green belt area 1061.00 740.00 1801.00 13.20