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1 Executive Summary 1 2 Introduction of the Project 3 2.1 Identification of the Project and Project Proponent 3 2.1.1 Identification of the Project 3 2.1.2 Project Proponent 4 2.1.3 Nature of the Project 5 2.1.4 Need of the Project & Demand-Supply Gap 5 2.1.5 Import vs. Indigenous Production 5 2.1.6 Export Possibility 6 2.1.7 Domestic/Export Markets 6 2.1.8 Employment generation due to Project 6 3 Project Description 7 3.1 Type & Location of the Project 7 3.1.1 Type 7 3.1.2 Location 7 3.2 Details of the Alternative Site 9 3.3 Size & Magnitude of Operation 10 3.4 Project Description with Process Details 10 3.4.1 Brief about the Technology – POY, FDY & PSF 10 3.4.1.1 Operating Philosophy for Process vapour
absorption Chiller 12
3.4.2 Manufacturing Process of POY & FDY 13 3.4.2.1 Chemical Reactions 13 3.4.2.2 Process flow Diagram 15 3.4.2.3 Process Description 16 3.4.2.4 Material Mass Balance 17 3.4.2.5 Filament Yarn (Partially Oriented Yarn – POY) 18 3.4.2.6 Filament Yarn (Full Drawn Yarn – FDY) 18 3.4.2.7 Polyester Staple Fiber – (PSF) 18 3.5 Raw Materials for finished Products 19 3.6 Hazardous Chemicals Storage & Handling 20 3.7 Resource Optimization & Availability 21 3.7.1 Land & Building requirement 21 3.7.2 Equipment 21 3.7.3 Power & Fuel Requirement 24
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3.7.4 Water Requirement 25 3.7.5 Man – Power Requirement 26 3.8 Quantity of Waste to be generated 26 3.8.1 Wastewater generation & Management 26 3.8.2 Wastewater characteristics 28 3.8.3 Waste water treatment & disposal 29 3.8.4 Air Emission & Control 30 3.8.4.1 Process Emission 30 3.8.4.2 Utility Emission 31 3.8.4.3 Fugitive Emission 32 3.8.5 Hazardous & Non – Hazardous waste management 32 3.8.6 Noise Control 33 3.9 Health & Safety Measures 34 3.10 Environment Health & Safety Cell 35 3.11 Post Project Monitoring Plan 35 4 Site Analysis 37 4.1 Connectivity 37 4.2 Land Form, Land use & Land ownership 37 4.2.1 Land Form 37 4.2.2 Land use Pattern 37 4.2.3 Land Ownership 37 4.3 Topography 38 4.4 Salient features 38 4.5 Existing Infrastructure 38 4.6 Soil Classification 39 4.7 Climate & Meteorology 39 4.7.1 Temperature 40 4.7.2 Humidity 40 4.7.3 Cloud Cover 40 4.7.4 Rainfall 40 4.7.5 Wind Pattern 40 4.8 Social Infrastructure 40 4.8.1 Educational Facilities 41 4.8.2 Medical Facilities 41 5 Planning Brief 42 5.1 Planning Concept 42 5.2 Population Projection 42 5.3 Area Statement 42 5.4 Assessment of Infrastructure Demand 43 5.5 Amenities/Facilities 43 5.5.1 Drinking water Facilities 43 5.5.2 Power Supply Facilities 43 5.5.3 Communication & Banking Facilities 44 5.5.4 Transport Facilities 44
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6 Proposed Infrastructure 45 6.1 Industrial Area 45 6.2 Residential Area 45 6.3 Greenbelt 45 6.4 Social Infrastructure 45 6.5 Connectivity 45 6.6 Drinking Water Management 46 6.7 Sewerage System 46 6.8 Industrial waste Management 46 6.9 Solid Waste Management 46 6.10 Power Requirement & Source of Supply 46 7 Rehabilitation & Resettlement (R&R) Plan 47 7.1 Policy to be Adopted 47 8 Project Schedule & Cost Estimates 48 8.1 Time Schedule of the project 48 8.2 Estimated Project Cost 48 9 Analysis of Proposal 50 9.1 Financial & Social Benefits 50
LIST OF TABLES Sr. No. Particulars Page No.
Table 1.1 Project Summary 1 Table 2.1 List of Products 4 Table 2.2 Details of Proponent 4 Table 3.1 Molecular Weight of Reactants & Products 15 Table 3.2 List of Raw Materials 20 Table 3.3 Storage, Handling & Transport of Chemicals 20 Table 3.4 Characteristics of Raw Materials 20 Table 3.5 List of Equipment & Machinery 21 Table 3.6 Detail of Power 25 Table 3.7 Fuel Requirement 25 Table 3.8 Category wise Water Requirement 26 Table 3.9 Man Power Requirement 26 Table 3.10 Category wise waste water generation 27 Table 3.11 Expected Characteristics of Waste water 28 Table 3.12 Details of Process Emission 30 Table 3.13 Details of Utility Emission 31 Table 3.14 Details of Hazardous waste generation & Disposal 33 Table 3.15 Noise level with company premises 34 Table 3.16 Post Project monitoring plan 36 Table 4.1 Salient features of the Project Site 38 Table 4.2 Summary of Meteorological Data at nearest IMD 39
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Station – Dahanu Table 5.1 Distribution of Population 42 Table 5.2 Area Statement 43 Table 8.1 Total Capital Cost Projection 48 Table 8.2 Recurring Cost provision of EHS 49
LIST OF FIGURES S.No. Particulars Page No. Figure 3.1 Project Site 8 Figure 3.2 Layout of Project Site 9 Figure 3.3 General Schematic of Vapour Absorption
Machine 13
Figure 3.4 Typical material mass balance for manufacturing of POY/ FDY/ PSF
17
Figure 3.5 (a) Water Balance Diagram – Existing Scenario (in KLD)
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Figure 3.5 (b) Water Balance Diagram – Proposed Scenario (in KLD)
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Figure 3.6 Schematic Diagram of Effluent treatment plant 30
LIST OF ANNEXURES S.No. Particulars Page No. Annexure – I (a) Copy of Existing EC A Annexure – I (a) Forwarding Letter for EC Compliance Report
Submitted to RO Bhopal F
Annexure – I (a) G Annexure – II Copy of Existing CC&A H Annexure – III Water drawl Permission L
Project Pre-feasibility Report
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Project: Debottlenecking of existing plant for increase in production capacity
CHAPTER – 1 EXECUTIVE SUMMARY The project is summarized in the below table: Table1.1: Project Summary
PARTICULARS DETAILS NAME OF THE UNIT
M/s. Wellknown Polyester Ltd.
OCCUPIER Mr. R. P. Shah PRODUCTS S. No. Product Production Capacity (TPD)
Existing Proposed Total 1. Partially Oriented Yarn (POY)/ Fully drawn
2. PSF (Polyester Staple Fiber) - 500 500 Total 900 600 1500 Note: POY & FDY manufactured through continuous polymerization process using raw materials such as PTA + MEG.
• In the existing operation, the total Domestic wastewater generated is @ 11.5 KLD, which is being diverted to the septic tank/ soak pit system. Wastewater generated from industrial activities @173 KLD which is diverted to the Cooling tower as makeup water after ETP treatment . Blow down from cooling tower generated @79 KLD from which 50 KLD is recycled as CT makeup water & 29 KLD for gardening.
• Whereas, after proposed expansion project, domestic waste water generation will be @15 KLD & from industrial activities 305 KLD will be diverted to the Cooling tower as makeup water after ETP treatment. Blow down from cooling tower generated @86 KLD from which 35 KLD is recycled as CT makeup water & 51 KLD for gardening.
Air Emissions Emission norms for Boiler, Thermic Fluid Heater & DG set • PM < 150 mg/Nm3 • SO2 <100 ppm • NOx < 50 ppm
• In existing installations, the company has 2 Nos of Thermic Fluid Heater each having capacity of 10 million K.cal/Hr. The company has also 12 Nos. of D.G. set of 625 kVA capacity. The D.G. Set acts as standby unit and is only utilized in case of power failure.
• FO is used as fuel in the Thermic Fluid Heaters & LDO is used as fuel in the D.G set.
• For proposed expansion project, 3 nos. of TFH of capacity 8 Milillion.Kcal/hr (2 working + 1 standby) & two nos. of dual fired steam boiler of 10 TPH capacity (1 working + 1 standby).
• FO will be used as fuel in TFH & imported coal or FO will be used as fuel in dual fired steam boiler.
• The Company also proposes to install 15 Nos. of D.G. set of 625 kVA capacities.
• Adequate chimney height is/ will be provided. • Raw Materials & Products is/ will be stored in properly designated storage
area and under good storage conditions to prevent any volatilities. • Regular monitoring is/ will be done of piping and fittings for checking of
any leakages. • Good housekeeping is/ will be maintained in the plant.
Hazardous & solid waste
Types of Waste
Existing Quantity
Proposed Quantity
Hazardous Waste ETP Waste
400 Kgs/Month
700 Kgs/Month
Used oil 125 lts./Month
350 lts/month
Empty bags
23200 Nos/Month
26070 Bags/Month
Empty PP Liner
24000 Nos/Month
37500 Bags/Month
Empty drums
135 Drums/Month
120 Carboys/ Month
Polymer waste
8.2 MT/Month 35 MT/Month
Non - Hazardous Waste Fly Ash -- 125
MT/Month
• The Hazardous wastes are handled, stored & transported as per CPCB/ MoEF Guidelines
• ETP sludge is/ will be disposed to GEPIL, Silvassa. • Empty bags/ PP liners is/ will be Reused/Sale after decontamination. • Empty drums is/ will be sold to authorized reconditioners • Used oil is/ will be sold to CPCB registered recyclers. • Polymer waste is/ will be sold to actual users. • Fly ash will be sold to brick manufacturers.
Noise Expected levels Inside the plant: <75dB(A)
• The major sources of noise generation in plant area shall be the pumps and motors.
• Regular maintenance will be done • Accoustic enclosure will be provided to DG set.
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Project: Debottlenecking of existing plant for increase in production capacity
CHAPTER – 2
INTRODUCTION OF THE PROJECT
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT
2.1.1 IDENTIFICATION OF THE PROJECT
M/s. Wellknown Group of companies have two plants located in the near vicinity in Village-
Dabhel, Daman (U.T.) which is already manufacturing “Polyester Draw Texturised Yarn & Fully Drawn Yarn. The production started with Twisting & Texturising of POY in 1989.
Manufacturing of fancy yarn was added in 1999.
One of the existing units named “Wellknown Polyester Ltd.” located at Survey No. 178 & 185/2,
2. PSF (Polyester Staple Fiber) - 500 500Total 900 600 1500Note: POY & FDY manufactured through continuous polymerization process using raw materials such as PTA + MEG.
The copy of existing CC&A is attached as Annexure – 2.
2.1.2 PROJECT PROPONENT
Wellknown Group of companies was promoted by Gupta Family in the year 1987. The promoter
has experience of over a decade in the various fields in textile business. Under their leadership,
the Group has grown rapidly. It commands very good respect in the field of Textiles and its
stature is growing with passage of time.
1. Shri Anil Gupta Mr. Gupta is a Commerce Graduate and is in the textile business for over 40 years. He started
his career by joining the family’s textile manufacturing & trading business. He gained experience
in weaving and processing of various textile materials including suiting, shirting, sarees, dress
materials & home linen. Later, in the year 1988 he set off on his own to promote Wellknown
Polyester Ltd. In 1990, Wellknown Polyester Ltd. started operation with manufacturing of DTY at
Dabhel the UT of Daman. Under the leadership of Mr. Gupta, over the years the Company has
expanded its capacity and now the Company has two plants in close proximity to one another.
Table 2.2: Details of Proponent Sr. No. Name of Directors Residential Address 1.
Project: Debottlenecking of existing plant for increase in production capacity
2.1.3 NATURE OF THE PROJECT
The proposed expansion project involves the production of “Manmade fiber such as PSF through continuous polymerization”, which falls under item no. 5(d) i.e. manmade fibres manufacturing and under the category B as per the EIA notification, 14 September 2006 (as
amended timely). However, the project is to be considered at central level due to the
applicability of general conditions – presence of state boundary of Gujarat within 5 km radial
periphery.
2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP
Wellknown Polyester Ltd is proposing to debottleneck of its existing plant for increase in
production capacity by adding a similar category product PSF.
Presently PSF is contributing 8% annual growth in polyester market. With PSF manufacturing
facility, we will have market share in these segments. The product mix of POY, DTY, FDY and
PSF will give competitive edge to the company as it is contributed in polyester market growth.
Operation of the plant at higher capacity with PSF stream will reduce the conversion cost due to
energy efficient operation of the plant. Thus the bushiness viability will be further improved.
To improve the base line it is important to have reduction in the manufacturing cost of finished
product. The fuel cost is one of the major inputs in the manufacturing of finished goods.
WPL is also proposes to include Coal as an alternative fuel to the existing fuel viz. FO in
proposed dual fired steam boiler. The ‘addition of Fuel’ is proposed due to the following
reasons:
• Techno-commercial viability of coal vis-à-vis FO.
• Coal is economical than FO
2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION
The consumers of POY, FDY & PSF are located in and around the area of existing facility. By
doing so, it would also result in saving transportation cost.
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Project: Debottlenecking of existing plant for increase in production capacity
2.1.6 EXPORT POSSIBILITY The product has also huge international market demand to earn foreign exchange.
2.1.7 DOMESTIC / EXPORT MARKETS Market for the proposed products includes not only the domestic market but also the
international market.
2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT The proposed project will provide direct employment opportunity to additional 111 persons. The
man-power required for the project will be employed locally from the nearby areas.
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Project: Debottlenecking of existing plant for increase in production capacity
CHAPTER – 3
PROJECT DISCRIPTION
3.1 TYPE & LOCATION OF PROJECT
3.1.1 TYPE The proposed project is the type of expansion project for manufacturing of manmade fibers.
3.1.2 LOCATION The proposed project is located at Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4, 216/5,
3.6 HAZARDOUS CHEMICAL STORAGE & HANDLING Hazardous chemicals will be used as raw material in the manufacturing process. The storage,
handling & transport of Haz. chemicals is given in table 3.3 and characteristics of raw material is
given in table 3.4.
Table 3.3: Storage, Handling & Transport of Chemicals
Sr. No.
Name of the Chemical
Maximum Storage Capacity
Means of Storage Source of Supply
1. MEG 4500 KL Tank 1- 3000 KL Tank 2- 750 KL Tank 3- 750 KL
Reliance, Sabic, Indian Glycol
2. Antimony trioxide 14 MT Bags – 30 kg Drums- 60 kg
Paras, CanLong
3. Titianium Dioxide 216 MT Bags - 25 kg Bags – 500 kg
Hombitton, Fuji, Precheza
4. Purified Terephthalic Acid
9610 MT Silo – 400 MT+ bags - _1100 Kg & 1200 kg
Reliance, MCPI, IOCL
Table 3.4: Characteristics of Raw Materials
Sr. No.
Name of the Chemical
HAZARD FP (oC)
BP (oC)
MP (oC)
LFL %
UFL %
SP. GR.
VD
1 2 3 4 5 6 7 8 9 10 1. MEG H & F 111 197 -13 3.2 -- 1.12 2.14 2. Antimony trioxide H & F NA* 1425 655 NA* NA* 5.67 NA 3. Titianium Dioxide H NA* 2750 1855 NA* NA* 4.26 NA 4. Purified Terepthalic
Acid H & F 260 NA 300 NA NA NA 5.74
Note: NA = Not available, NA* = Not Applicable, M.P.=Melting Point, B.P.=Boiling Point, F.P.=Flash Point, UEL= Upper flammable limit, LEL= Lower flammable limit, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million
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Project: Debottlenecking of existing plant for increase in production capacity
Table 3.4 (cont..): Characteristics of Raw Materials Sr. No.
Name of the Chemical
Solubility With water at 25 oC
NFPA TLV PPM TWA
IDLH LC50 Carcinogenic Characteristics H F R
1 2 11 12 13 14 15 16 1. MEG soluble 1 1 0 NA NA >200 NO 2. Antimony
trioxide Insoluble 2 0 0 0.5 NA NA YES
3. Titianium Dioxide
Insoluble 1 0 0 10 NA NA NO
4. Purified Terephthalic Acid
Insoluble 0 1 0 10 NA NA NO
Note: NA = Not available, NA* = Not Applicable, TLV=Threshold Limit Value, LC50= Median Lethal Concentration, H= Health, F= Fire, R= Reactivity, ppm= Parts Per Million,
3.7 RESOURCE OPTIMIZATION & AVAILABILITY The major resources for the proposed project will be plant & machinery, raw-materials, power,
fuel, water, man-power, etc.
3.7.1 LAND & BUILDING REQUIREMENT The existing set up is not sufficient to accommodate the proposed expansion project hence the
plots for the existing project has been purchased from private owners and transferred in the
company’s name. The total plot area of the unit is 182059 M2.
3.7.2 EQUIPMENTS Based on process necessity, list of the equipment’s and machinery used in existing operation &
additional equipment’s used for proposed project is provided in table 3.5.
Table 3.5: List of Equipment & Machinery S. No. Equipment’s Quantity Existing Operations 1. Reactors and columns 20 2. Vessels and tanks 55 3. Pumps, 125 4. Vapour Absorption Chillers 4 5. Heat Exchangers 25 6. Filters 8 7. Conveyors, 3
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Project: Debottlenecking of existing plant for increase in production capacity
S. No. Equipment’s Quantity 8. Ejectors 4
9. Polymer booster pumps 17
10. Evaporators 16
11. Pearl 2
12. Centrifuge 2
13. HTM heaters 2
14. DG sets 12
15. ETP 1
16. POY 24
17. FDY 19
18. DTY (DTex) 132
Proposed Additional
1. Reactors and columns 1
2. Vessels and tanks 10 3. Pumps, 8
4. Vapour Absorption Chillers 1
5. Heat Exchangers 2
6. Filters 2
7. Conveyors, 1
8. Polymer booster pumps 2
9. Evaporators 2
10. HTM heaters (FO fired) 1
11. Steam Boilers (FO/ Coal fired)
12. Pearl 1
13. Centrifuge 1
14. HTM heaters 1
15. Polymer valves 2
16. Polymer Booster pumps 2
17. Polymer cooler & static mixers 2
18. DG sets 4
19. ETP 1
Spinning Equipment’s
20. Polymer Distribution pipeline for 48 positions 1 set
21. Spinning beam arrangement 6 x 8 positions 1 sets
22. Spin Packs diameter 410 mm 72
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Project: Debottlenecking of existing plant for increase in production capacity
S. No. Equipment’s Quantity 23. Spinnerets 680 Holes of round profile 72
24. HTM Vapor generator 3
25. Set of quench air chambers for 48 position 1
38. Air supply/exhaust system 1
35. Spin finish unit 1
36. Quench air unit 1
38. Spin pack mounting and transporting device 1
Fiber Draw-off System
39. Fiber draw-off wall 1
40. Feed roller assembly 1
41. Sunflower unit 1
42. Tow cut off device 1
43. Can traversing unit 1
44. Set of roller tracks 1
45. Can transport trucks 2
46. Set of electrical equipment for spinning & fiber draw-off 1
47. Set of power /control cables and cable trays 1
48. Set of data BUS cables 1
Fiber drawing Equipment’s
49. Can creel 1
50. Thread guides and breaking devices 1
51. Knot detectors for can creel01
52. Set of tow cans 1
53. Inlet thread guide 1
54. Tow guide stand 1
55. Immersion bath 1
56. Secondry circulating system 1
57. 7 roller draw stand 1 1
58. Draw bath heated and cooled 1
59. Secondary circulating system 1
60. 7 roller draw stand 2 1
61. Steam draw chest 1
62. Steam controlling device for calander drier 1
63. Spin finish spraying device 1
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Project: Debottlenecking of existing plant for increase in production capacity
S. No. Equipment’s Quantity 64. 7 Roller draw stand 3 1
65. Tow stacker 1
66. Dancer roller unit 1
67. Steam Chest 1
68. Steam regulating device for steam chest 1
69. Crimper 1
70. Water circulating unit for crimper 1
71. Outlet chute 1
72. Spare crimper head 1
73. Feeding device 1
74. Plate belt drier 1
75. Tow guide roller 1
76. Tension stand 1
77. Cutting machine 1
78. Baling system 1
79. Bale transport trucks 2
80. Set of mechanical devices 1
81. Set of electrical devices 1
82. Set of electrical equipment for drawing line 1
83. Low voltage distribution system 1
84. Battery pack 1
85. Set of power / control cables and cable trays 1
86. Set of data BUS cables 1
87. Process control system 1
88. Set of consumables for first start up 1
89. Set of tools 1
3.7.3 POWER AND FUEL REQUIREMENT The main power supply will be provided by Electricity Department, Daman. The existing power
requirement is 15.95 MW. After proposed project it will be 21 MW. D.G. set will be used for the
power generation in case of power failure from the Electricity Board. The statement showing
bifurcation of power is given below in Table no. 3.6.
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Project: Debottlenecking of existing plant for increase in production capacity
Table 3.6: Details of Power Sr. No.
Particulars ExistingRequirement
(in KW)
Proposed Requirement
(in KW)
Source of Supply
1. CP + POY a) Domestic 100 150 • Electricity department
• 12 nos. of D.G. set of 625 kVA acts as stand by for existing unit.
• 15 nos. of D.G. set of 625 kVA acts as standby for proposed
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b) Plant 15850 178503. PSF -- 3000
GRAND TOTAL 15950 21000
Furnace Oil is used as fuel in TFH (3 Nos.) and LDO is used as fuel in DG Set to in the existing
project. After proposed project FO will be used as fuel. The fuel requirement is as given below in
Table 3.7.
Table 3.7: Fuel Requirement
Sr. No.
Type of fuel Existing Requirement
Proposed Requirement
Source of supply
1. Furnace Oil (in Thermopack boilers)
25 KLD 115 KLD Reliance IndustriesLtd.
2. Coal -- 35 TPD Imported & Indigenous 3. LDO (in D.G. Set) 100 L/Hr. 100 L/hr Local Market
3.7.4 WATER REQUIREMENT Necessary water requirement for the existing expansion project is catered from the Dabhel
Gram Panchayat Pond/ Canal Water. The company has permission for the usage of Dabhel
Gram Panchayat Pond. The proposed water requirement will be fulfilled from the Dabhel Gram
Panchayat Pond/ Canal Water. The copy of the letter is enclosed as Annexure – III.
In existing operation, water is required for domestic, washing, utility and gardening purpose.
Total water consumption for the existing project is 374 KLD in which 122 KLD fresh water is
used. Total water consumption after proposed expansion will be 883 KLD in which 492 KLD
fresh water will be used. Remaining 391 KLD will be recycled water. The category wise
bifurcation of the water requirement is given in the table 3.8.
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Project: Debottlenecking of existing plant for increase in production capacity
Table 3.8: Category-wise Water Requirement (in KLD)
S. No. Particulars Requirement (KLD)Existing Scenario Proposed Scenario
The category wise bifurcation of the waste water generation is given in Table 3.10.
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Project: Debottlenecking of existing plant for increase in production capacity
Table 3.10: Category-wise Wastewater Generation (in KLD) Sr.No.
Particulars Waste Water generation (KLD)
Existing Scenario Proposed Scenario1 Domestic 11.5 15.02 Industrial 3 Process Washing 5.0 8.04 Process (Water of Reaction) 168.0 279.05 Cooling tower blow down 79.0 86.06 Softener regeneration 0.0 10.07 Boiler Blowdown 0.0 8.08 Sub-Total: Industrial 252.0 391.09 Grand Total 263.5 406.0
Figure 3.5 (a): Water Balance Diagram – Existing Scenario (in KLD)
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Project: Debottlenecking of existing plant for increase in production capacity
Figure 3.5 (b): Water Balance Diagram – Proposed Scenario (in KLD)
3.8.2 WASTE WATER CHARACTERISTICS The expected wastewater characteristic of effluent before treatment in ETP is given below in
Table No. 3.11.
Table 3.11: Expected Characteristics of Wastewater Sr. No.
Parameter
CharacteristicsUntreated Range Treated Permissible
limits1. pH 5-6 4 to 8 7.19 6.5 to 9.02. TSS 600 70 to 90 80 <1003. TDS 500 250 to 400 840 <21004. COD 5000 5000 to 7000 185 < 2505. BOD 1500 1500 to 3000 54 < 100Note: All above values in mg/ lit except pH or where specified
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Project: Debottlenecking of existing plant for increase in production capacity
3.8.3 WASTE WATER TREATMENT & DISPOSAL
In the existing operation, the total Domestic wastewater generated is @ 11.5 KLD, which is
being diverted to the septic tank/ soak pit system. Wastewater generated from industrial
activities @173 KLD is treated in ETP and the treated wastewater is diverted to the Cooling
tower as makeup water. Blow down from cooling tower generated @79 KLD from which 50 KLD
is recycled as CT makeup water & 29 KLD for gardening.
Whereas, after proposed expansion project, domestic waste water generation will be @15 KLD
& from industrial activities 305 KLD will be treated in ETP and the treated wastewater will be
diverted to the Cooling tower as makeup water. Blow down from cooling tower generated @86
KLD from which 35 KLD is recycled as CT makeup water & 51 KLD for gardening.
Modification in ETP will be done after proposed expansion project. Existing ETP Scheme is as
below:
Effluent Treatment Scheme: The effluent generated from the process plant shall be initially collected into the collection tank.
Now, the effluent in the collection tank shall be neutralized by adding some chemicals. The
neutralized effluent from this tank shall be pumped to the aeration tank - 1 for biological
treatment. The biodegradation of the effluent in the aeration tank takes place in the presence of
active biomass and dissolved oxygen which is provided by the surface aerator. The overflow of
the aeration tank - 1 is diverted into the secondary clariflocculator -1 for biomass sludge
separation. The clear overflow of the secondary clariflocculator - 1 is pumped to the aeration
tank -2 where remaining biodegradation of effluent takes place. The settled biomass from the
bottom of the secondary clariflocculator - 1 shall be recycled back to the aeration tank -1 and
excess biomass shall be diverted into the sludge pit - 1. Similarly the overflow of aeration tank –
2 is diverted to secondary clariflocculator – 2. The settled biomass from the bottom of the
secondary clariflocculator - 2 shall be recycled back to the aeration tank -2 and excess biomass
shall be diverted into the sludge pit – 2. The total sludge from sludge pit – 1 & sludge pit – 2 is
diverted to sludge drying bed.
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Project: Debottlenecking of existing plant for increase in production capacity
The dried sludge from the sludge drying beds shall be collected and packed into the plastic
bags properly and shall be stored into the solid waste storage area as per norms. The dried
ETP sludge is finally handover to GEPIL for landfill disposal.
The clarified effluent from clariflocculator - 2 is switched to the stabilization pond from where it is
pumped to the pressure sand filter and activated carbon filter for tertiary treatment. The outlet
of the filters is sent to the softener plant. The treated effluent from the softener is recycled back
for using the treated effluent for cooling tower make-up purpose.Schematic of Effluent Treatment Plant: The flow diagram of the ETP is shown in figure 3.6.
Figure 3.6: Schematic Diagram of Effluent Treatment Plant
3.8.4 AIR EMISSIONS & CONTROL
3.8.4.1 Process Emission Process gas emission details from CP process are as below:
225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).. The Site
is 1.04 km from Village Dabhel. The site is 2.37km from National Highway. The land and
infrastructure is already available and the raw material is easily available through the easy
transport via road connectivity. The nearest Railway station is Vapi railway station which is 4.73
km from the project site.
4.2 LAND FORM, LAND USE & LAND OWNERSHIP
4.2.1 LAND FORM The proposed project to be located at new plots, closer to the existing unit which is already
engaged in manufacturing activity. Currently it is a vacant land.
4.2.2 LAND USE PATTERN Currently it is a vacant land.
4.2.3 LAND OWNERSHIP The plot is located in the industrial Zone –I of Dabhel Industrial Co. Op. Society Ltd.. The plots
for the proposed project has been purchased from private owners and transferred in the
company’s name.
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Project: Debottlenecking of existing plant for increase in production capacity
4.3 TOPOGRAPHY Daman is situated on the western coast of India and bordered by the clear, blue waters of the
Arabian Sea. The entire district of Daman is covered by Deccan trap belong to the type called
“plateau Basalt”. The area is characterized by hilly terrain. Daman is bisected by two rivers viz.
Kolak River which flows towards the north & Damanganga River which flows through the centre.
The river divides the district of Daman in the two parts known as Nani-Daman and Moti-Daman,
which lie opposite each other across the Damanganga.
The project site is at a slightly elevated terrain. It is at an altitude of 16 m above MSL.
4.4 SALIENT FEATURES Table 4.1: Salient Features of the Project Site Particulars Details Co-ordinates 72° 53’ 48.78” E, 20° 24’ 46.86” N Village Dabhel Taluka/ Tehsil Daman District Daman Elevation 16 m above Mean Sea Level Nearest Settlement Village Dabhel @1.04 km SW Nearest Reservoir River Kolak @2.34 km -NE
River Damanganga @3.68 km -SW River Kalu @ 6.37 km in -SW
Nearest Railway station Vapi Railway station @4.73 km- SE Nearest Airport/ Airbase Daman Airport @5.79 km -NW Tourist places Daman fort and beaches Sites of Historical/ Archaeological importance
Daman fort constructed during portugese rule
Protected Area/ Sanctuaries None within 10 km from project site CRZ applicability Coastline @6.74 km from project site but CRZ not
applicable
4.5 EXISTING INFRASTRUCTURE The proposed project to be located at new plots, closer to the existing unit which is already
engaged in manufacturing activity. The plot is located in the notified industrial estate. Hence,
necessary infrastructure is already developed by OIDC.
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4.6 SOIL CLASSIFICATION The site is located in rocky area. The water storage capacity is very low and hence, it can be
considered that the entire rainwater penetrates into the groundwater table.
4.7 CLIMATE & METEROLOGY Daman is having a pleasant climate all over the year. In summers, Daman is blessed with cool
breeze coming from over the Arabian Sea. The summary of yearly meteorological data for a
period of 10 years recorded at the nearest observatory of IMD at Dahanu has been taken from
the climatological tables (1951-1980).
The entire data has been summarized in Table 4.2.
Table 4.2: Summary of Meteorological Data at nearest IMD Station - Dahanu
Location: In the compound of the old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o 58’, Long: E 72o 43’) Height of installation: 11m above MSL Month PDW
Direction Avg. W. Speed (kmph)
Temperature (oC)
Relative Humidity (%)
Cloud Cover (Oktas) Rainfall (mm)
Max. Min. Morn. Even. Morn. Even. JAN N 1-19 27.7 16.5 67 69 1.3 1.1 0.2 FEB N 1-19 28.3 17.4 66 69 1.1 0.8 0.2 MAR N 1-19 30.3 20.7 68 67 1.4 1.1 0.1 APRIL W 1-19 32.2 24.0 74 69 2.1 1.4 0.1 MAY W 1-19 33.1 26.8 77 73 3.8 2.3 5.2 JUNE SW 1-19 32.2 26.3 85 80 6.1 5.6 522.1 JULY SW 1-19 30.1 25.0 89 84 7.1 6.8 771.7 AUG W 1-19 29.5 24.7 88 83 6.9 6.7 502.3 SEP W 1-19 30.0 24.0 87 79 5.4 4.9 319.1 OCT E 1-19 32.1 23.1 77 72 2.8 2.4 44.4 NOV N 1-19 32.1 20.5 67 71 1.9 1.9 17.1 DEC N 1-19 29.8 18.0 67 71 1.6 1.5 0.3 Seasonal Average Values Period Avg. PDW
Dabhel, Daman-396 210 (U.T.).The nearest city is Vapi which is a big hub for chemical &
Pharmaceutical Products. Major raw materials will be sourced locally.
The region is well planned with all the basic infrastructural facilities like internal roads, water
supply, arrangements for power, streetlights, solid waste disposal sites etc.
5.2 POPULATION PROJECTION The average household size is around 4 to 5. The Sex ratio is very less.
Table 5.1: Distribution of population
Sr. No.
Particulars Observed values in 10 km Radius
Total Population 1977662 No. of Households 449923 Avg. household size (persons) 4-54 Male population 1169925 Male population (in %) 59.26 Female population 807747 Female population (in %) 40.88 Sex ratio 690
(Source: Primary Census Abstract – Census of India, 2001)
5.3 AREA STATEMENT The total area of the plot is 182059 m2 out of which Greenbelt area of the plant is 48942 m2
which is 26.88%. The bifurcation of the same is given below in table no. 5.2.
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Table 5.2: Area Statement
S. No.
Particulars Area (m2)
Existing Proposed Total 10. Construction Area 8045 48393 56438 11. Greenbelt area 12958 48942 61900 12. Open area 21392 42329 63721 13. Total Area 42395 139664 182059
5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) For proposed expansion project the company will acquire some plant and machinery so there
will be some demand of change in physical infrastructure and social infrastructure. As
manpower requirement for the proposed project shall be locally fulfilled, employment generation
will lead to additional benefits to social infrastructure.
5.5 AMENITIES/FACILITIES
5.5.1 DRINKING WATER FACILITIES Tap water is available in 35 villages as per the Census 2001. 56 had Wells, 16 villages had
tanks and all 57 had hand pumps. 11 Villages had River passing. Power supply was also
available in all the villages.
5.5.2 POWER SUPPLY FACILITIES As per census 2001, all the villages have power supply facilities in the study region.
5.5.3 COMMUNICATION & BANKING FACILITIES Communication facilities like Post and telegraph, telephones exist in almost all the villages as
per the 2001 census.
5.5.4 TRANSPORT FACILITIES Bus service is available in the study region and is the most preferable mode of transport in the
region. The villages are well connected with the State Highways. National Highway-8 also
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Project: Debottlenecking of existing plant for increase in production capacity
passes from Vapi. The Western railway line between Bombay to Ahmedabad passes from the
study region and Vapi Town has a railway station on the same.
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CHAPTER – 6
PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA The total area of the plot will be 182059 m2 out of which Greenbelt area of the plant is 48942 m2
which will be 21.96%.The total production capacity will be 1500 TPD.
6.2 RESIDENTIAL AREA In the said proposal no Residential area has been proposed for workers and/or for staff.
6.3 GREENBELT Maximum open land will be allotted for green belt development. If required, experts will also be
consulted for selection of species for the development of the greenbelt. Total greenbelt area will
be 26.88% of total plot area.
6.4 SOCIAL INFRASTUCURE Existing infrastructure will be sufficient to accommodate the existing load from the proposed
project which is very low.
6.5 CONNECTIVITY
This proposed project for debottlenecking of existing plant is located at Survey No. 178, 185/2,
225/1, 229/1A, 229/2, Dabhel Ind. Co. Op. Soc. Ltd., Dabhel, Daman-396 210 (U.T.).. The Site
is 1.04 km from Village Dabhel. The site is 2.37km from National Highway. The land and
infrastructure is already available and the raw material is easily available through the easy
transport via road connectivity. The nearest Railway station is Vapi railway station which is 4.73
km from the project site.
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6.6 DRINKING WATER MANAGEMENT Drinking water is/ will be sourced from Canal water supply for the existing operations as well as
proposed project.
6.7 SEWERAGE SYSTEM Domestic waste water generated from the existing operations @11.5 KLD is disposed off
through soak pit / septic tank. Same practice will be followed for proposed quantity @ 15 KLD of
sewage after proposed expansion project.
6.8 INDUSTRIAL WASTE MANAGEMENT Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained
in Chapter 03, Section 3.8.3.
6.9 SOLID WASTE MANAGEMENT Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant,
Used oil from gear boxes of the machineries, polymer waste from manufacturing process,
discarded drums & bags from storage of raw materials. Company will provide adequate storage
area for proper storage of wastes. Details of solid waste generation are given in table 3.9.
6.10 POWER REQUIREMENT & SOURCE OF SUPPLY The power requirements for existing operations is 15.95 MW & after after proposed expansion
project, it will be 21 MW which will be sourced from Electricity Board.
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Project: Debottlenecking of existing plant for increase in production capacity
CHAPTER – 7
REHABILITATION & RESETTLEMENT (R &R) PLAN 7.1 POLICY TO BE ADOPTED The proposed project is debottlenecking of existing plant for increase in production capacity
hence, it is to be deveolped in the existing plots as well as plots closer to the existing site.
Moreover, all plots are designated for industrial use. Hence, no displacement of any population
is proposed for the project. Therefore, detailed Social Impact Assessment studies or R&R action
study has not been proposed.
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CHAPTER – 8
PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE OF THE PROJECT Any activity related to proposed debottlenecking of project will start only after getting all the
statutory permission from respective authorities.
8.2 ESTIMATED PROJECT COST The company has made budgetary provision for the recurring expenses for the environmental
issues while planning for the allocation of funds during the annual budgetary planning.
Environment Protection has also been considered in planning the cost projection. Green belt
development is also considered. The capital cost for existing project is 48 crores & estimated
project cost for proposed project will be approximately 167.75 Crores.
Table 8.1: Total Capital Cost Projection
Sr. No.
Purpose Capital Cost (Rs. In Crores)Existing Cost Proposed
Additional Cost
Total Cost
1 Land and Land Development 1.20 7.0 8.22 Building and Civil Works 6.00 15.0 213 Plant & Machinery 30.00 75.0 1054 Effluent Treatment Plant 1.10 2.5 3.65 Air Pollution Control Measures 0.00 06 Green Belt Development 0.25 0.50 0.757 Safety Systems 0.50 0.75 1.258 Pipeline & Fittings 3.80 7.5 11.39 Electrical Installation 1.75 4.0 5.7510 Preliminary and Preoperative
Expenses 3.407.5
10.9 TOTAL 48.00 119.75 167.75
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Table 8.2: Recurring cost provision for EHS Sr. No.
Purpose Recurring Cost (Lakhs)Existing
Scenario Proposed Scenario
1. ETP operations (chemicals/electricity/manpower) 9.6 16.02. Air pollution control device 2.0 3.33. Fees for Common disposal facilities 5.0 8.54. Env. Monitoring expenses 3.6 6.05. Safety instruments maintenance 12.0 20.06. Environment & safety training 5.0 7.57. Green belt maintenance 6.8 11.58. Social development (CSR) 12.0 18.0 TOTAL 56.0 90.8
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CHAPTER – 9
ANALYSIS OF PROPOSAL 9.1 FINANCIAL & SOCIAL BENEFITS M/S. Wellknown Polyester Ltd. is located at Survey No. 178, 185/2, 216/1, 216/2, 216/3, 216/4,