M/S. MACRO POLYMERS PVT. LTD.-Unit-3environmentclearance.nic.in/writereaddata/Online/TOR/0_0_29_Oct_2015... · Proposed Project for Manufacturing of Synthetic Organic Resins at existing

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.-Unit-3 Plot No. : 21 & 22, B. No.: 395/4 & 396/P, New Ahmedabad Industrial Estate,

Village: 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

Proposed Project for Manufacturing of Synthetic Organic Resins at existing unit of Macro Polymers Pvt. Ltd.-Unit-3, Moraiya, Ahmedabad

Form-1 for Environmental Clearance Page - 2 -

Appendix – I (See paragraph – 6)

FORM-1

(I) Basic Information Name of the project : M/s. Macro Polymers Pvt.Ltd.-Unit-3 Location / Site alternative under consideration

: Plot No. : 21 & 22, B. No.: 395/4 & 396/P, New Ahmedabad Industrial Estate, Village: Moraiya, Taluka: Sanand, District: Ahmedabad, Gujarat.

Size of the Project * : Proposed Synthetic Organic Resins Manufacturing with production capacity of 1500 MT/Month in Existing unit.

Expected cost of the project : Rs. 75 Lacs * 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.-Unit-3 2. S. No. in the schedule 5(f) 3. Proposed capacity/area/length/tonnage to be handled / command area / lease area/

number of well to be drilled.

Sr. No.

Name of Products

Production Capacity (MT/Month) Existing as per CC & A application

Proposed Total after Expansion

1 Industrial & Decorative Coating Polymers 30 Nil 30 2 Purified Butanol / Glycerin (by

rectification/ distillation / extraction only) 510 Nil 510

3 Resin Solutions (by Formulation) 1500 (-) 1000 500 4 Resin manufacturing by synthesis

Nil 1000 1000

Alkyd Resins Polyamide Resins Polyester Resins Acrylic Resins Rosin Esters and Derivatives Epoxy Derivatives

5 Resin manufacturing by synthesis

Nil 500 500 Amino Resins (Melamine resin/ Urea resin/ Phenol Resins)

Ketonic Resins By-product 1 Caustic Lye (45%) Nil 870 870



Sr. No.

Item Details

Products details and raw materials requirement is given in Annexure-1. 4. New/ Expansion/ Modernization Proposed Project of Resin manufacturing in

existing premises. 5. Existing Capacity/ Area etc. Existing products and capacity are given in

Point 3 above. Area of the existing premises is 4,770 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. Plot No. : 21 & 22, B. No.: 395/4 & 396/P Village New Ahmedabad Ind. Estate, Moraiya Tehsil Sanand District Ahmedabad State Gujarat

10. Nearest railway station/airport along with distance in kms

Nearest Railway station: Moraiya @ 1.2 Km, NE Nearest Airport: Ahmedabad @ 26 Km, NE

11. Nearest Town, city, District Headquarters along with distance in kms.

Nearest Village (Residential area): Moraiya @ 1 Km, NW 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.-Unit-3

165, Mahagujarat Industrial Estate, Opp. Nova Petrochem, Sarkhej Bavla Road, P.O. Moraiya, Taluka: Sanand, District: Ahmedabad.

15. Address for correspondence

Name Mr. Mayank Parikh Designation (Owner/ Partner/ CEO) Director Address Same as above E-mail [email protected] Telephone No. 9898079801 Fax No. --

16. Details of Alternative Sites examined, if any. Location of these sites should be shown on a topo sheet.

Proposed Project will be carried out in existing premises. No other site was examined.

17. Interlinked Projects Not Applicable



Sr. No.

Item Details

18. Whether separate application of interlinked projects has been submitted?

Not Applicable

19. If yes, date of submission Not Applicable 20. If no, reason Not Applicable 21. Whether the proposal involves approval/

clearance under: If yes, details of the same and their status to be given. (a)The Forest (Conservation) Act, 1980? (b)The Wildlife (Protection) Act, 1972? © The C.R.Z Notification, 1991?

Not Applicable

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



(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. 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 required 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.

1.6 Demolition works? No There will not be any type of demolition work carried out in premises.

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 No Such structures will not be required as



Sr. No.


Yes/No


source of information data or earthworks including linear structures, cut and fill or excavations

the proposed project will be carried out within the existing premises.

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.

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 0.5 km.

1.18 New road, rail, air water borne or other transport infrastructure including new or altered routes and stations, ports, airports etc?


1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?


1.20 New or diverted transmission lines or pipelines?

No Not required

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 Estate water as well as own existing

borewells will be utilized to satisfy the water requirements after the proposed project.



Sr. No.


Yes/No


source of information data 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 0.5 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 10 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



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. Proposed Project will be carried out in existing premises having an area 4,770 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 16 KLD and same will be fulfilled by estate water / 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 200 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



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.

Sr. No.


Yes/No



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)

Sr. No.


Yes/No



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



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

(Kg/hr)

Sr. No.


Yes/No



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

Yes 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 will not be any chances of fugitive emissions.

5.4 Emissions from construction activities including plant and

No No air emissions will occur from the construction activities.



Sr. No.


Yes/No



equipment 5.5 Dust or odors from handling of

materials including construction materials, sewage and waste

No Will not occur.

5.6 Emissions from incineration of waste No Not applicable as no such activity will be carried out.

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

No Not applicable as no such activity will be carried out.

5.8 Emissions from any other sources No Not Applicable

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr. No.


Yes/No



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



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:

Sr. No.


Yes/No



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.



Sr. No.


Yes/No



7.4 From any other sources No Not Applicable 7.5 Is there a risk of long term build up

of pollutants in the environment from these sources?

No Not Applicable

8. Risk of accidents during construction or operation of the project, which could

affect human health or the environment

Sr. No.


Yes/No



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

natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?

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.

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

Sr. No.


Yes/No



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.)

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.



Sr. No.


Yes/No



Housing development Extractive industries Supply industries Other

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



(III) Environmental Sensitivity

Sr. No.


Yes/No



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 NE 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 NE 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



(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 drawn 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 16th September, 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.



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



ANNEXURE-1

List of Existing & Proposed Products

Sr. No.

Name of Products

Production Capacity (MT/Month) Existing as per

CC & A application*

Proposed Total after Expansion

1 Industrial & Decorative Coating Polymers

30 Nil 30

2 Purified Butanol /Glycerin (by rectification / distillation / extraction only)

510 Nil 510

3 Resin Solutions (by Formulation) 1500 (-) 1000 500

4

Resin manufacturing by synthesis

Nil 1000 1000

A. Alkyd Resins B. Polyamide Resins C. Polyester Resins D. Acrylic Resins E. Rosin Esters and Derivatives F. Epoxy Derivatives

5

Resin manufacturing by synthesis

Nil 500 500 A. Amino Resins (Melamine resin/

Urea resin/ Phenol Resins) B. Ketonic Resins

By-Product 1 Caustic Lye (45%) Nil 870 870

Note: *CC & A: Consolidated Consent & Authorization application to Gujarat Pollution Control Board dated.

List of Raw Materials

Sr. No.

Name of Raw Material Requirement (MT/Month)

Existing Proposed Total after Expansion

Industrial and decorative coating Polymers 1 Phenol 6 Nil 6 2 Formaldehyde 12 Nil 12 3 Methanol 6 Nil 6 4 Melamine 3 Nil 3 5 Urea 2.3 Nil 2.3 6 Ammonia 0.05 Nil 0.05 7 Filler 2.6 Nil 2.6



Sr. No.



8 Drier 0.8 Nil 0.8 9 Solvent 0.5 Nil 0.5

Purified Butanol /Glycerin (by rectification / distillation / extraction only) 1 Crude Butanol (5%) 200 Nil 200 2 Crude Glycerin (50%) 1000 Nil 1000

Resin Solutions 1 Base resins 900 (-) 600 300 2 solvents 600 (-) 400 200

For Alkyd Resins And/Or Polyamide Resins And/Or Polyester Resins And/Or Acrylic Resins And/Or Rosin Esters and Derivatives And/Or Epoxy Derivatives: 1000 MT/Month Alkyd Resins

1 Vegetable Oils or Fatty acids

Nil 400 400

2 Phthalic Anhydride or di or poly acid

Nil 200 200

3 Benzoic Acid or mono acid Nil 47 47 4 Glycerin/penta or any polyol Nil 120 120

5 Toluene/Xylene/ MTO (Mineral Turpentine oil) or other solvent

Nil 350 350

Polyamide Resins 1 Dimer Acid Nil 600 600

2 Polyamines (EDA, DETA, TETA, TEPA, etc.)

Nil 360 360

3 Veg. Fatty acid Nil 100 100 Polyester Resins

1 Phthalic Anhydride/ iso phthalic acid/maleic anhydried or any other di or poly acid

Nil 520 520

2 Mono/Di/Poly glycol Nil 200 200 3 Benzoic Acid or other mono acid Nil 40 40

4 Styrene/CIX/Butyl Cellosolve or any other solvent

Nil 300 300

Acrylic Resins

1 Monomer (Acrylates, MMA, BAM, NBMA, 2HEMA, EA, Methacrylates, Styrene etc.)

Nil 590 590

2 Solvents like Xylene / Toluene/ cellosolve acetates/Butyl Acetate

Nil 400 400



Sr. No.



etc. 3 Initiators Nil 10 10

Rosin Esters and Derivatives 1 Rosin Nil 400 400 2 Glycerin/penta or other polyols Nil 100 100

3 Maleic Anhydried or mono/di or poly acids

Nil 50 50

Epoxy Derivatives 1 Epoxy resin Nil 500 500 2 Fatty acid Nil 200 200 3 Xylene / Toluene / MTO Nil 400 400

For Amino Resins And/Or Ketonic Resins: 500 MT/Month Amino Resins

1 Butanol/octanol/methanol Nil 300 300 2 Formaldehyde 37%/ Paraform Nil 437.5 437.5 3 Melamine/urea Nil 250 250 4 Phenol Nil 25 25 5 Caustic Soda Flakes Nil 412.5 412.5

Ketonic Resins 1 Cyclohexane Nil 125 125 2 Formaldehyde 37%/ Paraform Nil 250 250



ANNEXURE-2

Google Image showing location of Proposed Project Site

Proposed Project Site

NH 8A



ANNEXURE-3

Manufacturing Process Details Industrial & Decorative Coating Polymers:

Industrial & decorative coating polymers are prepared from phenol formaldehyde

resin and melamine formaldehyde resin. Melamine Formaldehyde Resin: Formaldehyde is taken in a jacketed reaction vessel

to which melamine powder is added slowly and the mixture is then stirred well. After about 15 minutes a solution of caustic soda (NaOH) is added to the mixture to make it alkaline. The mixture is then heated by hot Thermic fluid to raise its temperature gradually up to 85°C. The process is continued till the solution becomes clear. Vacuum distillation is then started and water is removed. After removal of water, entire product mass is cooled at 40°C. Resin is now ready for use.

Phenol Formaldehyde Resin: liquid phenol, formaldehyde and ammonia/caustic are taken in a vessel in desired quantity. It is stirred and heat upto 60°C. When it reaches upto 90°C, the temperature is maintained upto 1 hr. reflux is done upto 30 min upto 98°C. Vacuum distillation is then started and water is removed. After removal of water, entire product mass is cooled at 40°C. Resin is now ready for use.

The above resins are prepared and solvents, fillers and driers are added to it and whole mass is mixed in closed vessel at 70° C to form uniform mixture. This mixture is the final product which is then packed for sale.

Purified Butanol /Glycerin

Distillation Crude glycerin will be taken in a closed vessel, heated at 200° C and vacuum will be

applied up to 750 mm Hg. Excess Moisture / Water will be removed and taken to ETP. Concentrated crude glycerin will be distilled out under vacuum of 1- 2. Distilled finished glycerin will be packed in barrel.

Extraction: Dilute solution of Butanol (approx. 5% in water) will be taken in to vessel. Solvent will be added in vessel to extract out Butanol from water. Total mass will be agitated in vessel is allow to settled down. Extracted solvent layer will be taken out from top. Bottom water layer will be taken it to ETP.

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.

Alkyd Resins Distilled glycerin is taken for alkyd resin manufacturing along with vegetable Oils or

their Fatty Acid & 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 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/Polyacid Acid 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. 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 to 700C 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.



ANNEXURE-4

Water balance diagram

Source of Water Supply: Borewell Existing: 23 KL/day

Proposed: (-) 7 KL/day Total: 16 KL/day

Domestic Existing: 3 KL/day

Proposed: 3 KL/day Total: 6 KL/day

Treated water

Sewage to septic tank Existing: 2 KL/day

Proposed: 2.5 KL/day Total: 4.5 KL/day Cooling

Existing: 46.2 KL/day Proposed: 5.3 KL/day Total: 51.5 KL/day

Floor Washing Existing: Nil

Proposed: 0.5 KL/day Total: 0.5 KL/day

Wastewater E: 2 KL/day P: Nil T: 2.0 KL/day

Effluent Treatment Plant 44 KL/day

Sludge used as Manure

Industrial Existing: 20 KL/day

Proposed: (-) 10 KL/day Total: 10 KL/day

Process Existing: Nil

Proposed: Nil Total: Nil

Wastewater E: 25.2 KL/day P: 11.8 KL/day T: 37.0 KL/day

Wastewater E: Nil P: 0.5 KL/day T: 0.5 KL/day

Treated water for Cooling E: 26.2 KL/day P: 15.3 KL/day T: 41.5 KL/day

Treated water for on campus horticulture

E: 1.0 KL/day P: 1.0 KL/day

T: 2.0 KL/day

Treated water for Floor washing E: Nil P: 0.5 KL/day T: 0.5 KL/day



ANNEXURE-5

Details of Effluent Treatment Plants The resin manufacturing wastewater shall be treated with H2O2 to decompose Phenol at source and then transferred to ETP through pipe line. Other streams like from Glycerin / Butanol purification and cooling activities and sewage will be transferred to ETP without any pre-treatment. The ETP contains following unit processes / operations: 1. Equalization tank: For reception, storage and homogenization of raw effluent. 2. Anaerobic Reactor system: For degradation of waste and generation of biogas. 3. Primary clarifier: For polishing anaerobically treated effluent 4. Biogas Holder: For intermediate storage of biogas. 5. Biogas Compressors: For pumping of biogas to biogas burner in boiler. 6. Aeration Tank: For further treatment of anaerobically treated effluent. 7. Secondary Clarifier: For settling of secondary solids. 8. Filter feed tank: For collection of secondary treated effluent and pumping it to

Micro-filtration system 9. Micro-filtration system: For filtration of treated effluent through micron filters of

various porosity. 10. Treated Effluent Storage Tank: For storage of treated effluent. Effluent Treatment Process: Raw effluent from different trade activities will be transferred to ETP and get

collected in equalization tank for homogenization of quantity and quality. Equalized effluent will be transferred to Anaerobic UASB reactor from the bottom to

distribute uniformly through the inlet distribution system. It will pass upwards through the dense anaerobic sludge bed. Organic matter will

be rapidly utilized by biomass and converted to methane rich biogas. Upward motion of effluent and biogas generated at the bottom of the reactor will keep the biomass in suspension and break any scum formation.

The three-phase separator will allow effective degasification to occur. The dense, granular sludge particles, devoid of attached gas bubbles, will sink back to the bottom establishing a return downwards circulation. The treated effluent will flow into collection channels at the top of the settlers for discharge and transferred to the clarifier-1. Washed out anaerobic biomass will be recovered as underflow from clarifier-1 and recycled to the reactor. Excess biomass from Anaerobic Process will be wasted to sludge decanter, if required.

Biogas will be collected in gas collection portion of three phase separator at the top of the reactor and transferred to biogas holder for intermediate storage. Then the gas will be pumped through a compressor / receiver system and will be used in the Thermic fluid heater / LPG burner system.

Aerobically treated effluent will be transferred to Aeration Tank. A culture of aerobic bacteria will decompose organic impurities in to CO2. A fine bubble aeration grid will be provided to supply O2 to aerobic bacterial culture. Air will be supplied by the twin lobe air compressor system.

Treated effluent will flow through the clarifier-2 to retain bacterial culture. The settled biomass will sink at the bottom and recycled to the aeration tank. The treated effluent will flow into outlet channel at the top of the tube settlers for discharge.



Aerobically treated effluent will be collected in a treated effluent collection sump and pumped to Micron Filtration system for polishing.

This treated effluent will be free from odor and most suitable for watering gardens by drip irrigation or sprinkler system or feed to cooling tower.

The entire system will be fully automatic and operated by timer and water level controller.

ETP Units:

Sr. No. Unit Volume/Capacity 1. Equalization tank 45 m3 2. Anaerobic Reactor 200 m3 3. Clarifier-1 20 m3 4. Aeration tank 83 m3 5. Clarifier-2 20 m3 6. Filter feed tank 11 m3 7. Dual Media Filter 0.3m dia x 1.5m ht. 8. Activated Carbon Filter 0.3m dia x 1.5m ht. 9. Treated effluent storage tank 40 m3 10. Sludge decanter 1.5 m3/d capacity

ETP Flow Diagram

Equalization

Tank

Anaerobic Reactor

Clarifier-1

Dual Media Filter

Sludge Decanter

Sludge used as manure

Treated water reused in on campus horticulture and cooling

activity

Aeration

Tank

Clarifier-2

Filter Feed

Tank

Activated Carbon Filter

Treated Effluent Tank



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

36.4 5 11 16 Collection, storage

and reused in process

2 Used Oil 5.1 0.115 19.885 20

Collection, storage and used within premises as a

lubricant / sold to registered recycler.

3 Discarded Containers/bags 33.3 3 45 48

Collection, storage & sell to authorized

vendor

4

Waste and residue (Formed during formulation)

21.1 4.5 (-) 3.0 1.5

Collection, storage and disposal at

approved TSDF Site

5

Waste and residue (Formed during Synthesis)

21.1 Nil 13 13

6 Fillers residues (Formed during formulation)

21.2 4.5 (-) 3.0 1.5

7 Inorganic process Sludge 34.3 Nil 30 30

Note: E: Existing; P: Proposed; T: Total after expansion



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 (15 Lac Kcal/hr)

33 Working

Imported Steam Coal/Briquettes

Existing: 7 MT/Day

Proposed: 8 MT/Day Total: 15 MT/Day

Multicyclone Separator

followed by bag filter SPM 150

mg/Nm3 SO2 100 ppmNOX 50 ppm

2 D.G. set (200 KVA)

7 Standby

HSD Existing: 40 L/Hr

Proposed: 30 L/Hr

Total: 70 L/Hr

Adequate stack height 3

D.G. set (160 KVA) (Proposed)



ANNEXURE-8

Area Break-up and Existing Plant Lay-out

Sr. No. Particular Area (Sq.mt.) % of Total Area

1 Built–up area 1950.00 40.90 2 Open Area 2620.00 54.90 3 Green belt area 200.00 4.20

Total 4770.00 100.00

Documents

M/S. MACRO POLYMERS PVT. LTD.-Unit-3environmentclearance.nic.in/writereaddata/Online/TOR/0_0_29_Oct_2015... · Proposed Project for Manufacturing of Synthetic Organic Resins at existing