techno -economic pre-feasibility...

TECHNO -ECONOMIC PRE-FEASIBILITY

REPORT

FOR EXPANSION

IN POLYESTER CHIPS & FULLY DRAWN YARN (FDY)

ADDITION OF PARTIALLY ORIENTED YARN (POY)/

TEXTURIZED YARN, NYLON CHIPS/NYLON YARN UNIT

& COAL BASED CAPTIVE POWER PLANT

AT M/S. SHREE DURGA SYNTEX PVT. LTD.

BLOCK NO.: 128,129,130 & 175, PLOT NO.: E & Z,

VILLAGE: JOLWA, TAL: PALSANA, DIST.: SURAT

Email: [email protected]

Prepared by M/s. ENVISION ENVIRONMENTAL SERVICES 201 & 301, Union Trade Center (UTC), Near Apple Hospital,

Udhna Darwaja, Surat - 395002, Gujarat. Phone: 0261-2344773, 2344774

Email: [email protected], [email protected] Visit us at www.en-vision.co.in

EXECUTIVE SUMMARY OF THE REPORT M/s. Shree Durga Syntex Pvt. Ltd. (SDSPL) is a medium scale industrial unit which is located at Block No. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, Dist.: Surat in Gujarat State. The company manufactures Polyester Chips & Fully Drawn Yarn (FDY). Now the company proposes new products viz… Partially Oriented Yarn (POY)/ Texturized Yarn, Nylon Chips/Nylon Yarn unit & 21.0 MW coal based power plant. SDSPL has decided to expand its Polyester chips manufacturing capacity 600 tons/day to 800 tons/day, Fully Drawn Yarn manufacturing capacity from 300 tons/Day to 500 tons/Day and addition of Partially Oriented Yarn or Texturized Yarn of 300 tons/day capacity, 21.0 MW coal based captive power plant is proposed while existing 3.25 MW Natural Gas based power plant and 9 MW bagasse/gas based captive power plant will be stand by for emergency use. PROJECT COST Proposed total Cost of Project is Rs. 570.0 Crore. PRODUCT LIST

S.No. Product Existing Proposed Total Product

1. Polyester Chips 600 tons/day 200 tons/day 800 tons/day 2. Fully Drawn Yarn (FDY) 300 tons/day 200 tons/day 500 tons/day

3. Partially Oriented Yarn (POY)/ Texturised Yarn -- 300 tons/day 300 tons/day

4. Nylon- 6 Chips/ Nylon Yarn -- 200 tons/day 200 tons/day

5. Power

3.25 MW* 9.0 MW#

(Bagasse/gas based Captive power plant)

21.0 MW (Coal/ Lignite Based) Captive power Plant

21.0 MW

By-Product 1. Nylon Polymer Lumps -- 1.0 tons/day 1.0 tons/day

* NG based 3.25 MW CPP will be kept as stand by after commissioning of proposed 21.0 MW coal base CPP. # Bagasse/gas based 9 MW CPP will be kept as stand by after commissioning of proposed 21.0 MW coal base CPP. RAW MATERIAL AND QUANTITY Details of material consumption are given in following table. S.No. Raw material Raw material Requirement in tons/day Mode of

Transportation Existing Proposed Total

1. Purified Terapthalic Acid (PTA) 480 160 640 By Road Through

covered Trucks

2. Mono Ethylene Glycol (MEG) 180 60 240 By Road

tankers/barrels

3. Caprolactum -- -- 201 By Road Through covered Trucks

STORAGE DETAILS

S. No. Particulars Storage

1. PTA 1100 Kg LDPE Bag in Covered Godown 2. MEG Two Nos. 300 m3 SS Tanks each 3. Caprolactum 25kg or 1000 Kg LDPE Bag in Covered Godown 4. Polyester Chips 25kg or 850 Kg LDPE Bag in Covered Godown 5. Nylon-6 Chips 25kg or 850 Kg LDPE Bag in Covered Godown

REQUIREMENTS FOR THE PROJECT Land: The proposed expansion is within the existing land of industry. No additional land will be required. Plot size is 63,730.00 sq.m. Water: Total water requirement will be 1481.0 KLD which will be sourced from existing bore wells. Electrical Energy: Total power requirement for existing plant is 13 MW, sourced from Dakshin Gujarat Vij Company Limited (DGVCL). Company proposing the 21.0 MW coal based captive power plant and have existing, 3.25 NG based Captive power plant and 9.0 MW bagasse/gas based captive power plant which will be kept as stand by after commencement of 21.0 MW CPP. Fuel: Fuel requirement for expansion and existing will be coal 530 tons/day, LDO/FO 100 m3/day and natural gas 76,875 SCM/ day, bagasse 250 tons/day. Manpower: The proposed plant will have great employment potential providing employment to approximately 100 full time persons for proposed expansion. SOURCES OF POLLUTION AND CONTROL MEASURES The Following shall be used as a Fuel. S.NO. FUEL TYPE EXISTING PROPOSED TOTAL

1. Imported Coal 80 tons/day 450 tons/day

or 500 tons/day

530 tons/day

Lignite -- 500 tons/day

2. Natural Gas 76875 scm/day -- 76875 scm/day 3. LDO/FO 100 m3/day -- 100 m3/day 4. Bagasse 250 tons/day -- 250 tons/day

FLUE GAS EMISSION AND CONTROL MEASURES ARE GIVEN IN FOLLOWING TABLE:

NO. OF STACK EMISSIONS SOURCE

STACK HEIGHT & DIAMETER

POLLUTION CONTROL

EQUIPMENT

POLLUTANTS (SPCB LIMIT)

A. EXISTING

1. Steam boiler (1 TPH)

11 Meters

Adequate Stack height

SPM < 150 mg/Nm3

SO2 < 100 ppm NOx < 50 ppm

2. Thermic Fluid Heater (Natural Gas Based) (2.0 Lakhs Kcal/Hr.) 20

Meters


SPM < 150 mg/Nm3


3.

Thermic Fluid Heater (Natural Gas Based) (2.0 Lakhs Kcal/Hr.) (Stand by)


SPM < 150 mg/Nm3


4.

Thermic Fluid Heater (Natural Gas Based) (10 Million Kcal/Hr.)

20 Meters Adequate Stack

height

SPM < 150 mg/Nm3


5.

Thermic Fluid Heater (FO/LDO) (10 Million Kcal/Hr.) (Stand by)

35 Meters

(Common)


SPM < 150 mg/Nm3

SO2 < 100 ppm Nox < 50 ppm

6. Thermic Fluid Heater (Coal based) (14 Million Kcal/Hr.)

50 Meters

Electrostatic Precipitator

SPM < 150 mg/Nm3


7. * Natural Gas Based CPP Engines (3.25 MW)

30 Meter


SPM < 150 mg/Nm3


8.

Steam Boiler (40 TPH) for Bagasse/gas based Power Plant (9 MW) #

80 Meter

Economizer, Air Pre-heater,


SPM < 150 mg/Nm3


B. PROPOSED

1. Steam Boiler (93 TPH) for Coal based Power Plant (21 MW)

80 Meter

Economizer, Air Pre-heater,


SPM < 150 mg/Nm3


* NG based 3.25 MW CPP will be kept as standby after commencement of 21.0 MW coal base CPP. # Bagasse/gas based 9.0 MW CPP will be kept as stand by after commissioning of proposed 21.0 MW coal base CPP. WASTE WATER GENERATION AND ITS TREATMENT: Industrial waste water of 550.0 KL/day will be generated from the project will be treated in in-house ETP and will be discharged in to CETP of M/s. PEPL, Palsana for further treatment. Domestic waste water i.e. 26.0 KL/Day will be generated which will be treated through septic tank and disposed through soak pit/well. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project: 1. Encasement of noise generating equipment. 2. A thick greenbelt will be developed all around the plant boundary to act as noise attenuator. 3. In addition personnel working near high noise level generating sources will be provided with ear muffs. 4. Proper and suitable acoustic barrier will also be provided around areas generating high noise. 5. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the

improvement of plant life and also noise reduction. SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes generation and its management are given in the following table.

CAT.NO.

TYPE OF HAZARDOUS

WASTE

QUANTITY MODE OF STORAGE

METHOD OF

DISPOSAL EXISTING ADDITIONAL PROPOSED TOTAL

5.1 Used oil 1.0 KL/Year

2.0 KL/Year

3.0 KL/Year

Collected in barrels & stored

in sludge storage area

Sent to GPCB Approved

recycler for Suitable

Treatment

33.1

Discarded Containers/barrels/liners/Carboys/bags

10 tons /year

15 tons/year

25 tons/year

Stored in sludge storage area

Sent back to supplier/ to

GPCB approved recycler

35.3 Chemical Sludge from ETP

25.0 tons/year 50.0 tons/year 75.0

tons/year

Stored in Sludge

Storage area

Sent to TSDF Site for suitable

Treatment.

-- Fly Ash from Boiler Nil 24000.0

tons/year 24000.0 tons/year

Stored in Sludge

Sent to brick manufacturer

Storage area

24.1 Process Waste (Oligomer) Nil 300 tons/year 300.0

tons/year

Stored in Sludge

Storage area

Sent to TSDF Site for suitable Treatment/sale

to co-processing unit

GREEN BELT DEVELOPMENT Unit has already developed about 5462.0 sq.m; of green belt for the existing production facilities and will develop another 3152.0 sq.m; of green belt considering proposed expansion which require about 10577.0 sq.m; land area. The total green belt area will be 8614.0 sq.m; Green belt will be developed at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 6.0 Lacs approx.

INDEX

CHAPTER CONTENT PAGE NO.

1. INTRODUCTION OF THE PROJECT 1

2. PROJECT DESCRIPTION 3

3. SITE ANALYSIS 10

4. PLANNING BRIEF 13

5. PROPOSED INFRASTRUCTURE 14

6. REHABILITATION AND RESETTLEMENT (R & R) PLAN 15

7. PROJECT SCHEDULE & COST ESTIMATES 16

8. ANALYSIS OF PROPOSAL 18

LIST OF TABLES

TABLE PARTICULAR PAGE NO. 1 DETAILS OF THE DIRECTORS 1 2 DETAILS OF EMPLOYMENT REQUIREMENT 2 3 DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) 4 4 DETAILS OF FUEL REQUIREMENT 4 5 WATER CONSUMPTION AND WASTE WATER GENERATION 5 6 ETP DIMENSIONS (PROPOSED) 7 7 INLET & OUTLET CHERECTRISTIC OF EFFLUENT 7 8 DETAILS OF SOLID WASTE 8 9 DETAILS OF EXISTING LAND USE 10

10 DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE 10 11 TEMPERATURE DATA 11 12 RAINFALL DATA 12 13 PROJECT IMPLEMENTATION SCHEDULE 16 14 TOTAL PROJECT COST AND IT’S BREAK UP 17

LIST OF FIGURES

FIGURE PARTICULAR PAGE NO.

1 MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC

1

2 WATER BALANCE DIAGRAM (BASIS KL/DAY) 9 3 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 16

LIST OF ANNEXURE

ANNEXURE PARTICULAR

1 SITE LAYOUT PLAN 2 MANUFACUTING PROCESS

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CHAPTER – 1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. Shree Durga Syntex Pvt. Ltd. is a large scale industrial unit which is located at Block no. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, dist.: Surat in Gujarat State. The company manufactures Polyester Chips & Fully Drawn Yarn (FDY). Now the company proposes new products Viz… partially oriented yarn (poy)/ Texturized yarn, nylon chips/nylon yarn unit & coal based captive power plant. SDSPL has decided to expand its Polyester chips manufacturing capacity 600 tons/day to 800 tons/day, Fully Drawn Yarn manufacturing capacity from 300 tons/Day to 500 tons/Day and addition of Partially Oriented Yarn or Texturized Yarn of 300 tons/day capacity, 21.0 MW coal based captive power plant while existing 3.25 MW Natural Gas based power plant & 9.0 Bagasse/gas based power plant will be stand by for emergency use.

TABLE 1: DETAILS OF THE DIRECTORS S. No. Name of The Director Age Qualification Experience

1. Mr. Bachharaj Begani 62 12th Pass 35 years exp. polyester chips and yarn manufacturing industry.

2. Mr. Pawankumar Begani 30 B.Com 7 years exp. polyester chips and yarn manufacturing industry.

The Company, which was started with a concept from raw to finish, Shree Durga Syntex is the extract of it. In the year 2006 Shree Durga was established and progress tremendously and is one of the leading firm in the yarn industry. Hard work of team Member, dedication to work and non compromising attitude towards quality of the product are attributes which are synonymous to the company and have been the main constitute of this success story. It is because of these factors company has always exceeded the expectations of its customers and consistently meet international standard and diversified its product range. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT PET Chips, also known as Polyester Chips or Polyethylene Terephthalate Chips is the base of any type of plastics & polymer. Depending on the processing, PET may exist both as an amorphous (transparent) commonly known as Bright or Super Bright Chips and as a semi-crystalline material commonly known as PET Semi-Dull Chips. Polyester Partially Oriented Yarn, commonly known as Polyester POY is the primary form of Polyester yarn. It is also known as Polyester Pre-Oriented Yarn. It is the first form of yarn made directly from PTA & MEG or by spinning Polyester PET Chips. POY is mainly used in texturizing to make textured yarn, also known as Polyester Drawn Textured Yarn (DTY). POY can also be used in draw warping for weaving and warp knitting of fabrics. POY yarn is available in different luster like Semi-Dull POY and Bright POY. The Bright POY has the shine in it due to the cross-sections in the filaments. The fabric made from Bright POY also has the bright luster. Polyester POY yarn is mainly available in Raw White color & is also available in various different colors. POY is usually colored by the Dope Dyed technology as it is more efficient & the yarn gets evenly colored at each & every part. Color master-batch is mixed with the raw material to make the dope dyed POY. Dope dyed POY yarn can be used to make the Dope Dyed DTY yarn. Polyester FDY is the abbreviation for Polyester Fully Drawn Yarn. It is also know as Polyester Filament Yarn (PFY) or Spin Draw Yarn (SDY). FDY is mainly used as weft or weaves in making fabrics. FDY can be knitted or woven with any other filament yarn to get fabric of various different varieties. It is mainly used in Home Furnishing Fabrics, Fashion Fabrics, Denim, Terry Towel and others. FDY yarn is mainly available in 3 lustre - Semi-dull (SD), Bright (BR) having circular section & Trilobal Bright (TBR) having triangular cross-sections. Filament yarn having trilobal bright lustre is widely used in

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making curtains, bed-sheets and carpets. FDY is available in Raw-white as well dope dyed. Dope Dyed FDY yarn can be used to make the colored fabric directly instead of making the fabric with FDY Raw-white first & then dyeing it. Catonic FDY is another variation of Filament yarn. Catonic FDY yarn is made from Catonic PET Chips. Nylon 6 chips is obtainable by hydrolytic polymerization of caprolactam in the presence of dicarboxylic acids as chain regulators, subsequent processing of the polymer melt into chip, extraction of the low molecular weight portions from the chips with water and subsequent drying of the chips. The Yarn grade or Textile grade chips are available in Super Bright (BR Chips), Semi Dull (SD Chips), 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The Gujarat region is expected to continue with increased focus on development and infrastructure activity. The current growth trends are expected to continue. Nylon Industry in India, nylon is mainly used in textile, tyre cord and engineering plastics. Use of nylon as staple fibres or in carpets is as yet negligible. The total size of the nylon industry in India is approximately 160,000-tpa. Mainly nylon-6 is used. Globally, textiles are the largest application for nylons, but in India it is the industrial segment that is the largest. Markets like hosiery, swimwear etc. is almost non-existent in India. The market for carpets, especially with synthetics, is very small. Of the total nylon consumption, 42 percent is used for industrial purposes, 35 percent in textiles and 23 percent in engineering plastics. Globally, textile consumes 39 percent, industrial purposes 24 per cent, carpets 25 percent and staple fibre 12 percent. In many parts of Asia, including India, nylon consumption is very low compared to the rest of the world. This shows high potential for growth. Total market for nylons in Asia Pacific during 2005 was 5.60-mt. Of this, 2.50-mt (45%) was for nylon 6, 6, 2.60- mt (46%) for nylon 6, and 50,000-tons for other polyamides (nylon 11, 12 etc.). Of the total polyamide consumption in Asia-Pacific, 30% was consumed by the automotive sector, 25% by the industrial and consumer industries and 45% by the electrical and electronics industries. Major international and regional players like DuPont, BASF, DSM, Rhodia, Lanxess, Solutia, Toray and others command 80-90 percent of the total market. ADVANTAGES 1. Expansion can be undertaken in existing land. 2. Captive Power plant 3. Existing proven technical team. 4. Employment generation of additional 100 people will help the society at large.

1.4 DEMAND-SUPPLY GAP PRODUCT PROFILE Our products are backed by unique technology and or process, and are not readily available with the

competitor. These products play an important role in the production process of the user and hence user do not

compromise or shift from tested products and user industry TECHNOLOGY Technology is typically developed in-house with the critical equipment being out-sourced. 1.5 EMPLOYMENT GENERATION DUE TO THE PROJECT The manpower requirement for the project is estimated at about 100. The managerial, supervisory and skilled personal shall be sourced from nearby area. The break-up of the manpower requirement is as under: TABLE 2: DETAILS OF EMPLOYMENT REQUIREMENT

S. NO. DESCRIPTION EXISTING PROPOSED TOTAL 1 Administration Department 10 5 15 2 Managers 15 10 25 3 Plant Operators 100 20 120 4 Technical staff 100 10 110 5 Skilled workers 150 25 175 6 Unskilled workers 175 30 205

TOTAL 550 100 650

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CHAPTER – 2

PROJECT DESCRIPTION 2.1 TYPE OF PROJECT M/s. Shree Durga Syntex Pvt. Ltd. is a large scale industrial unit which is located at Block no. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, dist.: Surat in Gujarat State. The company manufactures Polyester Chips & Fully Drawn Yarn (FDY). Now the company proposes new products Viz… partially oriented yarn (poy)/ Texturized yarn, nylon chips/nylon yarn unit & coal based captive power plant. SDSPL has decided to expand its Polyester chips manufacturing capacity 600 tons/day to 800 tons/day, Fully Drawn Yarn manufacturing capacity from 300 tons/Day to 500 tons/Day and addition of Partially Oriented Yarn or Texturized Yarn of 300 tons/day capacity, 21.0 MW coal based captive power plant while existing 3.25 MW Natural Gas based power plant & 9.0 Bagasse/gas based power plant will be stand by for emergency use.

2.2 LOCATION WITH COORDINATES A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure –1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE

HIGHWAYS, RAILWAY LINES, ROADS ETC.

PROJECT SITE

COORDINATES AT THE PROJECT SITE: At the project site, latitude and longitude are as per the mentioned below: Latitude: 21°09'52.5"N Longitude: 73°00'13.2"E

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2.3 DETAILS OF ALTERNATE SITES The proposed project site is situated Block No. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, Dist.: Surat in Gujarat State. The site is about 19 km West Direction from Surat. The access road around the proposed project site has already been developed. The proposed project site is located on an Industrial land. The site would need to be suitably developed to suit plant layout requirements. Transportation facilities to access various markets are readily available. Both skilled and unskilled labours are easily available in the area. The choice of the site is appropriate from the point of view of raw materials availability and market access. No alternate site was considered as proposed site is well connected with the existing infrastructure and requirement of the project like raw material, construction material, etc. 2.4 SIZE OR MAGNITUDE OF OPERATION M/s. Shree Durga Syntex Pvt. Ltd. is planning expansion in existing Polyester Chips & Fully Drawn Yarn (FDY), POY/ Texturizing yarn and addition of new products like Nylon Chips/ Nylon yarn and Captive coal based power plant at Block No. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, Dist.: Surat in Gujarat State.

2.4.1 Process: Manufacturing process is attached as Annexure-2 2.6 RAW MATERIAL REQUIREMENT TABLE 3: DETAILS OF RAW MATERIAL REQUIREMENTS (MONTHLY) S.No. Raw material Raw material Requirement in tons/day Mode of

Transportation Existing Proposed Total

1. PTA 480 160 640 By Road Through covered Trucks

2. MEG 180 60 240 By Road tankers/barrels

3. Caprolactum -- -- 201 By Road Through covered Trucks

2.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE We will be provided rain water harvesting for the resource optimization. The used oil i.e. 3.0 KLD/year will be generated from prime movers which will be reused in plant machinery. 2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND

SOURCE 2.8.1 WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed expansion and existing activity will be 1481.0 KLD which mainly for Boiler and Cooling (make up water), Washing, Domestic and for gardening. Total water requirement shall be met from existing 3 nos; of bore wells.

2.8.2 POWER REQUIREMENT AND ITS SOURCE Total power requirement is 13 MW that is fulfill by DGVCL electricity connection. In case of emergency or power failure, 3.25 MW NG based captive power plant and additional 21.0 MW coal based power plant and 9.0 MW bagasse based power plant is proposed., TABLE 4: DETAILS OF FUEL REQUIREMENT S.NO. FUEL TYPE EXISTING PROPOSED TOTAL

1. Imported Coal 80 tons/day 450 tons/day

or 500 tons/day

530 tons/day

Lignite -- 500 tons/day

2. Natural Gas 76875 scm/day -- 76875 scm/day 3. LDO/FO 100 m3/day -- 100 m3/day 4. Bagasse 250 tons/day -- 250 tons/day

5

2.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND ITS

MANAGEMENT / DISPOSAL 2.9.1 WASTEWATER GENERATION Water requirement will be mainly for process, Boiler and cooling (Make up water), Domestic and gardening. Industrial waste water approximately 550.0 KL/day will be generated which will be treated through proposed ETP and will be sent to CETP finally. Details of water requirement and waste water generation are given in following tables.

TABLE 5: WATER CONSUMPTION AND WASTE WATER GENERATION (LITRES/DAY)

TABLE 5A: WATER CONSUMPTION Description Existing Proposed Total

(A) Domestic 25 05 30 (B) Industrial

Boiler 26 222 248 Cooling 683 366 1049 Washing 40 80 120

(C) Gardening 25 9 34 Total Water Consumption

(A)+(B)+ (C) 799.0 682.0 1481.0

TABLE 5B: WASTER WATER GENERATION

Description Existing Proposed Total (A) Domestic

(Sewage Generation) 22.0 4.0 26.0

(B) Industrial Boiler 26.0 178.0 204.0 Cooling 114.0 112.0 226.0 Washing 40.0 80.0 120.0

Industrial Effluent Generation 180.0 370.0 550.0

Domestic sewage 26.0 KLD will be disposed off through septic tank/soak pits. Generated industrial effluents will be treated in in-house primary ETP and additional effluent will be treated in proposed primary ETP, treated effluents will be sent to CETP of M/s. Palsana Enviro Protection Ltd; for further treatment and disposal. We already have membership certificate of PEPL Palsana for discharge effluent with book load 420 KLD. We have applied for the additional load of 140 KLD.

6

FIGURE 2: WATER BALANCE DIAGRAM (BASIS KL/DAY)

120

FRESH WATER REQUIREMENT 1481

BOILER

COOLING TOWER

CONDENSATE RECOVERY SYSTEM

DOMESTIC

WASHING

GARDENING

1049

226 BLOWDOWN

204 BLOWDOWN

26

2010

TO ETP (PRIMARY)

LOSSES 44

823 DRIFT &

EVAPORATION LOSS

TO CETP OF PEPL

248

SEPTIC TANK/ SOAK PIT

120

34 30

550

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2.10 FACILITIES FOR TREATMENT OF LIQUID EFFLUENTS (ETP) PROPOSED FACILITIES FOR TREATMENT OF LIQUID EFFLUENT:

DESCRIPTION OF PROPOSED EFFLUENT TREATMENT PLANT INTRODUCTION: - Design Effluent Flow = 550 Kl/Day (max.) Type of Production = Nylon-6 Chips Source of W/w generation = Chips washing, cooling & boiler blow down Table No. 6 DESIGN CHARACTERISTICS:

SR. NO. PARAMETERS ETP INLET CETP NORMS

(mg/l, except pH) 1.0 pH 5.5 – 6.0 6.5 – 8.5 2.0 Chemical Oxygen Demand 1,600 – 1,800 ≤ 1,000 3.0 Biochemical Oxygen Demand (BOD5

@ 20 °C) 500 – 600 ≤ 400

4.0 Total Dissolved Solids 1,600 – 1,800 ≤ 2,100 5.0 Oil & Grease 10 – 15 ≤ 10 6.0 Temperature 70 ⁰C 40 ⁰C

2.00 PHILOSOPHY OF TREATMENT: -

Physical Treatment: The Effluent shall be first collected in a Collection cum Equalization Tank after screening of floatable materials. For mixing, and to avoid solids from settling, air shall be bubbled in the Equalization Tank through a grid placed at the b ase of the tank. The equalized Effluent is pumped at a uniform and constant rate for further treatment. Primary Treatment: Equalized Effluent water shall be subjected to Coagulation process in Mixing Channel. The Clogs/flocs so formed in the process will be settled in the Primary Settling Tank (PST) OR Clearifier. Sludge treatment: The sludge collected in the hopper bottom of the Primary Tank shall be withdrawn to Sludge Storage Area. Overflow from the PST will be subjected to Tertiary Treatment. Tertiary treatment: Overflow from the PST shall be taken for Filtration process through a Dual Media Filter for removal of SS/particulate matter, color, odour, trace organics etc. Polishing Treatment: Thenafter, the treated effluent will be subjected to Ozonation System to remove excess colour and COD.

Table No. 7 SPECIFICATION OF PROPOSED WORK: - (A) PROPOSED ETP WORK:

SR. NO.

NAME OF UNIT SIZE IN METERS NOS. MOC

1. Screen Chamber 2.50 x 1.00 x (0.70SWD+0.50 FB) 01 RCC M20 2. Equalization Tank 8.00 x 6.00 x (3.50LD + 0.50 FB) 01 RCC M20 3. Mixing Tank 2.50 x 2.50 x (2.00+1.1 HB+ 0.30FB) 01 MSEP 4. Dosing Tanks

(Lime, Alum/Ferrous & Poly-electrolytes)

500 Liters 03 Sintex

5. Primary Clarifier 5.00 Dia x (2.50SWD+0.30FB) 01 RCC M20 6. Intermediate Sump 5.00 x 4.00 x (3.50 LD + 0.50 FB) 01 RCC M20 7. Treated Effluent Sump 5.00 x 4.00 x (3.50 LD + 0.50 FB) 01 RCC M20

8. Sludge Sumps 2.00 x 2.00 x (2.50 + 0.50 FB) 01 RCC M20

8

9. Sludge Storage Room As per requirement 01 RCC M20 10. MCC Panel Room 3.00 x 2.00 01 RCC M20

* Size may vary at the time of detail engineering works., FB: Free board, SWD: Side Water Depth, LD: Liquid depth

Table No. 7 SPECIFICATION OF PROPOSED WORK: - (B) PROPOSED MECHANICAL UNITS & EQUIPMENTS:

SR. NO.

NAME OF UNIT SIZE IN METERS NOS. MOC

1. Fine Screen 8 – 10 mm opening (Make: En-vision/Standard)

01 MSEP/SS

2. Grid Mechanism for Equalization Tank and Air lining for Dosing

Tanks

As per Eq. Tank Size (Make: En-vision/Standard) LOT HDPE

3. Raw Effluent Transfer Pumps 25 m3/hr @ 12m head (Make: Kirlosker/Equivalent)

1+1 CI

4. Paddle type Impeller based Agitator Size: 1.5 HP 01 MS 5. Dosing Pumps

(Lime, Alum & Floccsure-1164) Dose: 0–60 LPH

(Make: Fivebro/Standard) 03 CI

6. Twin Lobe Blowers for Equalization Tank

100 CMH @ 0.45 kg/cm2

(Make: Usha/Everest/Kulkarni) 1+1 CI

7. Primary Clarifier Mechanism 5.00 Dia x (2.50 SWD+0.30 FB) (Make: Kunal/Equivalent)

02 MSEP

8. Duel Media Filter Flow: 25 m3/hr. 01 MSEP 9. Filter feed Pumps 25.0m3/hr @ 32-35 m head

(Make: Kirlosker/Equivalent) 1+1 CI

10. Electro-magnetic Type Flow meter Flow: 28 m3/Hr. (Make: Unitech/MTS/Toushbro)

01 ELE

11. Online pH meter 0 – 14 range (digital) (Make: Optima/Equivalent)

01 ELE

12. Ozonation System (with pumps) Dosage: 70 gm/Hr. 01 MS NOTE: 1+1 = Working & Stand by

2.11 SOLID WASTE GENERATION Solid waste generated will be Ash from boilers and Sludge from ETP, used/spent oil and discarded bags. The sources of solid wastes, generation and its management are as given in the following table. TABLE 8: DETAILS OF SOLID WASTE

CAT.NO.

TYPE OF HAZARDOUS

WASTE

QUANTITY MODE OF STORAGE

METHOD OF

DISPOSAL EXISTING ADDITIONAL PROPOSED TOTAL

5.1 Used oil 1.0 KL/Year

2.0 KL/Year

3.0 KL/Year

Collected in barrels & stored in sludge storage

area

Sent to GPCB Approved

recycler for Suitable

Treatment 33.1 Discarded

Containers/barrels/liners/Carboys/bags

10 tons /year

15 tons/year

25 tons/year

Stored in sludge storage area

Sent back to supplier/ to

GPCB approved recycler

35.3 Chemical Sludge from ETP

25.0 tons/year

50.0 tons/year 75.0 tons/year

Stored in Sludge

Storage area


Treatment.

9

Fly Ash from Boiler

Nil 24000.0 tons/year

24000.0 tons/year

Stored in Sludge

Storage area

Sent to brick manufacturer

24.1 Process Waste (Oligomer)

Nil 300.0 tons/year

300.0 tons/year

Stored in Sludge

Storage area


Treatment/sale to co-

processing unit

10

CHAPTER – 3 SITE ANALYSIS 3.1 CONNECTIVITY 3.1.1 Road Connectivity The plant location is about 0.8 km from Surat-Bardoli State Highway in South direction and 4.2 Km from Mumbai-Ahmedabad Highway on NH – 8 in West direction. 3.1.2 Rail The Area is well connected by Railway. Bagumra, approx 1.8 km in SSW direction, however major railway station-Surat approx 19.0 km in West direction. 3.1.3 Airport The nearest airport to the project will be Surat at a distance of 27 Km in SSW direction. 3.1.4 Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP About 63730.0 sq.m; of land at Plot No. Z & E, Block No. 128, 129, 130 & 175, Vill- Jolwa, Tal. Palsana, Dist. Surat, Gujarat, is already acquired.

3.3 TOPOGRAPHY Topography of the area is almost plain.

3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table: TABLE 9: DETAILS OF SITE LOCATION

S.NO. PARTICULAR NAME & ITS DISTANCE 1. Nearest National Highway NH-8 at around 4.2 Km 2. Nearest State Highway Surat-Bardoli at around 0.8 Km 3. Nearest city Surat at around 17.0 Km 4. Nearest River Tapi at around 13.8 Km 5. Nearest Railway station Bagumra at around 1.8 Km 6. National park/Reserve Forest, Biosphere, etc. None within a radius of 10 Km 6. Seismicity Zone III

3.5 EXISTING SOCIAL INFRASTRUCTURE The following are the existing infrastructure facilities availability and distance from site are given in the following table: TABLE 10: DETAILS OF EXISITNG SOCIAL INFRASTRUCTURE

S. NO. PARTICULAR DISTANCE 1. Civil Hospital Within 15 km 2. Colleges Within 15 km 3. Govt & Pvt Schools Within 15 km 4. Temple Within 15 km

3.6 CLIMATIC DATA The climate of the area is humid and tropical. A hot and humid pre-monsoon from March to mid May, a prolonged southwest monsoon or rainy season from mid May to September, a pleasant post-monsoon or retreating monsoon from October to November and a cold pleasant winter from

11

December to February are the characteristics of the general climate. Summer runs concurrently with the later part of the pre-monsoon season and continues throughout the monsoon season. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months:

Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February

Sometimes, the monsoon commences in mid-June and ends in mid-September. Therefore, the boundaries between the seasons are not very rigid. Surat is the meteorological observatory, to whom the meteorological data (Temperature, Relative Humidity, Rainfall, Wind speed and Wind direction) for the year 1980 to 2010, Climatological Normals data collected from Indian Meteorological Department (IMD) Pune. 3.6.1 TEMPERATURE DETAILS The hottest months were March to June. The coldest months were December, January and February when temperature drops to 15ºC. The months, November and March, can also be quite cold in some years. During the other months, temperature was more or less moderate in nature and pleasant to bear. Monthly mean Minimum and Maximum Temperatures of Surat station for the period of 1981-2010 are given in following table. TABLE 11: TEMPERATURE DATA

S. NO. MONTHS MONTHLY MEAN MINIMUM (0C)

MONTHLY MEAN MAXIMUM (0C)

1. January 30.8 15.2 2. February 32.3 16.7 3. March 35.4 20.7 4. April 36.7 24.0 5. May 35.8 26.8 6. June 34.0 27.0 7. July 31.2 25.9 8. August 30.8 25.5 9. September 32.3 25.4

10. October 35.1 23.3 11. November 34.1 19.6 12. December 31.9 16.5

Annual 33.4 22.2 (Courtesy: Indian Meteorological Department) 3.6.2 RELATIVE HUMIDITY (RH) The mean monthly of Relative Humidity values for Surat station was recorded for 08:30 hrs and 17:30 hrs. Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period. 3.6.3 WIND SPEED AND WIND DIRECTION The April – Sept Month, have winds from South West to North East. From October-March is a period mixed with calm conditions and winds mainly from North East to South East. The winter months, November to February, experience frequent calm conditions. The maximum number of calm periods observed is in the month of December and February. 3.6.4 RAINFALL Monthly total rainfall data for Surat station is presented in following table.

12

TABLE 12: RAINFALL DATA

(Courtesy: Indian Meteorological Department)

S. No. Months Mean Total Rainfall

(mm) 1. January 1.5 2. February 0.3 3. March 0.4 4. April 0.2 5. May 3.9 6. June 245.2 7. July 466.3 8. August 283.8 9. September 151.8

10. October 41.8 11. November 7.1 12. December 0.6

TOTAL 1202.8

13

CHAPTER – 4

PLANNING BRIEF 4.1 PLANNING CONCEPT M/s. Shree Durga Syntex Pvt. Ltd. is planning for expansion in Polyester Chips & Fully Drawn Yarn (FDY) manufacturing unit & addition of partially oriented yarn (poy)/ texturized yarn, nylon chips/nylon yarn unit & coal based captive power plant at Block no. 128,129,130 & 175, Plot No.: E & Z, Village: Jolwa, Tal: Palsana, dist.: Surat in Gujarat State. Proposed expansion is envisaged as existing manmade fibers facilities in Gujarat are not adequate to handle new development activities as well for the industries in Surat, Ankleshwar, Jhagadia, Panoli, Vapi, Navsari, Vadodara, and others cities. 4.2 LAND USE PLANNING Total 63730.0 sq m. area has been already acquired, refer layout attached in Annexure-1. . 4.3 AMENITIES / FACILITIES At the project site first aid centre will be set up. Company will provide drinking water and other sanitary facilities to the workers.

14

CHAPTER – 5

PROPOSED INFRASTRUCTURE 5.1 INDUSTRIAL AREA Total 63730.0 sq m. area has been already acquired, refer layout. Annexure – I. Proposed expansion will be done in existing premises.

5.2 RESIDENTIAL AREA There will be no residential area proposed for the project.

5.3 GREEN BELT Unit has already developed about 5462.0 sq.m; of green belt for the existing production facilities and will develop another 3152.0 sq.m; of green belt considering proposed expansion which require about 10577.0 sq.m; land area. The total green belt area will be 8614.0 sq.m; Green belt will be developed at plant boundary, road side, around offices and buildings and Stretch of open land. Total investment in green belt development shall be Rs. 6.0 Lacs approx. 5.4 SOCIAL INFRASTRUCTURE No new social infrastructure facility will be developed as the plot is located in industrial area having well developed infrastructure. 5.5 CONNECTIVITY 5.5.1 ROAD CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation. 5.6 DRINKING WATER MANAGEMENT For the proposed project water will be sourced from the existing bore wells located within premises. 5.7 WASTE WATER MANAGEMENT 5.7.1 STORM WATER DRAINAGE Storm water drainage system shall consist of well-designed open surface drains network so that all the storm water is efficiently drained of without any water logging. Based on the rainfall intensity of the proposed area drainage system shall be design on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow. Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations. For crossing roads, culverts shall be provided.

5.7.2 SEWERAGE WATER SYSTEM The sanitary sewerage system shall be designed to cater the sanitary sewerage from plant premises. The facial sewerage system shall be designed based on no. of person to be served and average daily consumption of water. Only 26.0 KL/day will be generated which will be treated through septic tank and disposed through soak pit/well. For inspection, cleaning and maintenance of sewer lines, manholes of reinforced concrete constructions shall be provided at every bend, junction point of change in slope or diameter and on straight sections of pipes at interval not exceeding 30 meters. 5.7.3 INDUSTRIAL WASTE WATER MANAGEMENT Water will be required for Boiler and Cooling purpose, washing, Domestic and Green belt development. Maximum industrial waste water will be 550.0 KL/day generated from process and utilities of the proposed project. Same will be treated in proposed ETP and treated effluents are finally discharged in to CETP for further treatment and disposal and 26.0 KLD domestic sewage water will be disposed off in septic tank/soak pit. 5.8 SOLID WASTE MANAGEMENT The sources of solid wastes, generation and its management are as given in the table no. 8 in chapter no. 2

15

CHAPTER – 6

REHABILITATION AND RESETTLEMENT (R & R) PLAN The proposed plant will be installed in the existing premises. No additional land will be required. Therefore, it is not applicable.

16

CHAPTER – 7 PROJECT SCHEDULE & COST ESTIMATES 7.1 PROJECT IMPLEMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. We are giving here under the details of the Project Implementation. From the date of start, the implementation schedule envisages completion of project in 15 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows: TABLE 13: PROJECT IMPLEMENTATION SCHEDULE

S.NO. WORK IMPLEMENTATION TIME 1. Construction work 8 Months 2. Machinery installation 4 Months 3. Recruitment process 1 Month 4. Commissioning 1 Month 5. Operation and functions 1 Month

Total 15 months 7.1.1 PROPOSED ORGANISATION CHART In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to ensure its effective implementation. Hence, company will create a team consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level etc. either permanently or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried - out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in figure – 2.

FIGURE 3: AN ORGANOGRAM OF SDSPL AND EMC 7.2 ESTIMATED PROJECT COST Cost of the proposed project would be approx Rs. 570.0 Crores. Break up of proposed project cost is given in following table:

DIRECTORS

TECHNICAL MANAGER (PRODUCTION)

LABORATORY MANAGER / TECHNICAL WORKS MANAGER

ACCOUNTANT

SUPERVISORS CHEMIST

LAB ATTENDANT

GENERAL MANAGER QUALITY CONTROL

HEALTH, SAFETY & ENVIRONMENT OFFICER

MANAGER SUPERVISORS

WORKERS

OPERATORS

UNSKILLED WORKERS

FIELD ASSISTANT

17

TABLE 14: TOTAL PROJECT COST AND IT’S BREAK UP S. NO. COST OF PROJECT COST (RS. CRORES)

1.

Plant & Machineries FDY 100.0 Polyester Chips 55.0 Poy 40.0 Nylon Chips 75.0 Texurizer 15.0

2. Duty & Transportation 85.0 3. Civil / Utility / Piping / Wiring 120.0 4. Contingencies 15.0

Total Capital Cost 5. Margin Money for Working Capital 65.0

Total Cost of Project 570.0 7.3 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. Capital cost of Rs. 120 Lakhs and recurring (Rs 35 Lakhs per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance.

18

CHAPTER - 8

ANALYSIS OF PROPOSAL 8.1 FINANCIAL AND SOCIAL BENEFITS The industrial activity of the proposed project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region.

8.2 DIRECT BENEFITS TO THE NATIONAL AND STATE EXCHEQUER Employment generation, Income tax from individual as well as corporate taxes from company and ancillary units, Transportation reduction.

8.3 OTHER BENEFITS Most of the work force required for construction and operation of the proposed project will be drawn from the surrounding villages. During the construction phase, no family is required to rehabilitate from the core zone. The economic growth of the area in terms of employment generation, consumption of goods and market-growth are expected outcome of the project. The project has an employment generation prospect on skilled manpower. The direct employment potential of the project is estimated as 100 persons, the share of local people in this is expected to be significant. It is assumed that the generation of indirect employment would be multiple of direct employment. The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. This will have impact on the current literacy level, primary and middle level education and on existing health facilities. A new awareness generated will have positive impact on the social pattern, which at this stage, is caste and community oriented. The long-term implications of this change are definitely progressive.

8.4 EMPLOYMENT Due to proposed project, there will be development of communication facilities in the area. The total manpower requirement will be 100. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities etc. During operation, plant will generate direct employment as explained in the previous paragraph. The preference will be given for local population for employment in the semi-skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods. Moreover, permanent supply of electricity in the area will support to improve other type of industries.

8.5 HEALTH AND SAFETY MEASURES The workers engaged in high pollution generation area will be equipped with appropriate protective equipment. Following measures will be adopted in the plant to keep check on the safety measures and health:

- Inspection and maintenance of pollution control systems regularly - All safety measures such as provision of safety appliances, training, and giving-of safety

awards. - The workers exposed to noisy sources will be provided with ear muffs/plugs - Adequate facilities for drinking water and sufficient toilets will be provided to the employees

8.6 SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY The firm shall earmark funds for social development and welfare measures in the surrounding villages. These measures will include funding for:

1) Education Facilities 2) Health Care and Family Welfare 3) Infrastructure Developments 4) Social Causes

The details of peripheral development plan including development in infrastructure, health, education and socio cultural aspects which will be carried out are as follows under the Corporate Responsibility:

1 The firm will organize free medical camps at least twice in a year for the benefit of the villagers.

2 The firm will organize cultural programmes in connection for the sake of local villagers every year.

3 The firm will provide chairs and cooking vessels on returnable basis to all the villagers for marriages.

19

BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control/monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance will be as given in following table:

S. NO. ITEM RS. IN LACS 1 Capital Expenditure 120.00

2 Recurring expenditure on environmental management cell and on pollution control systems per annum 35.00

20

ANNEXURE – I SITE LAYOUT PLAN

21

ANNEXURE - 2

MANUFACTURING PROCESS 1. (Polyester Chips): PROCESS DESCIRPTION: PTA Unloading & Conveying Conveying system will convey PTA delivered in bags into PTA storage silo of the poly plant. From PTA silo PTA is continuously metered into paste preparation tank byloss in weight feeder. Paste Preparation: PTA, MEG & Poly condensation catalyst are mixed in a defined ratio to form a paste. Esterification Reactor: Esterification comprises two reactors equipped with agitators. The esterification rate in first reactor is achieved up to 91 %. The esterification continues in second reactor & it is controlled up to 96.5 %. The temp is controlled between 250-2700 c temp, pressure level in reactor are regulated so as to control esterification reaction for smooth and stable reaction. Water is liberated as by product in this reaction, which is taken out through distillation column connected with two esterification reactors. Water is taken out through this column to its pure form. Heavy component (EG) flows back to reactor. Water vapors are condensed by air cooler and collected in tank. The internal heat exchanger coils of the first esterification reactor are heated by primary heat transfer medium. The internal heat exchanger coils of the second esterification reactor & process column are heated with liquid head transfer medium from the secondary heating circuit, supplied directly with liquid HTM from the primary heating circuit. All the vapor lines & heating jackets of the reactors are heated by Dowtherm system. TiO2 is feed to the second esterification reactor by a screw pump. Pre Poly-condensation: The diglycol terephthalate (DGT) leaving the esterification stage is fed into pre-poly condensation reactor, equipped with agitator. The poly condensation process initiated in the esterification is further continued in the pre poly condensation reactor & a low molecular PET is obtained. The degree of poly condensation (DP) is set by maintaining pressure, temp & residence time. The EG split off during pre poly condensation is withdrawn in the form of vapor, condensed in the spray scrapper condenser with a cold EG cycle & feed back into the process column. The required vacuum is generated by a central vapor MEG vacuum ejector (Common for pre poly condensation & poly condensation reactor). Pre polymer melt is conveyed through pre polymer filter by gear pump & sent to the final poly condensation reactor (Finisher). The internal heat exchanger coils of pre- poly condensation reactor are heated by liquid heat transfer medium from the secondary heating circuit. All the vapor lines & heating jackets of the reactors are heated by dowtherm system.

Finisher: The product leaving the pre poly condensation system is fed continuously into the finisher, where under agitation & high vacuum the final product quality is achieved. The degree of poly condensation (DP) measured as viscosity is set to the desired final valve by maintaining pressure, temp & residence time. The EG split off during poly condensation in the spray scrapper condenser with a cold EG cycle & feed back into the paste preparation tank. Vapour EG vacuum ejector removes the inert gases. The polymer melt is feed to the chips production/ POY production unit system through polymer filter by the special design polymer discharge pump. The

22

C C

C C

C CC

H H

H H

C C CO

HH

H H

C OCHO

HH

H H

O OOH

POLYMER n

melt is filtered & feed to the melt pumps through precisely designed polymer conduit. The minimum degradation of the polymer with constant uniform residence time is key design of the conduit. The melt pumps are kept rotating at a constant rpm through the inverters in the spinning beam. The rpm of melt pump depends upon denier of the yarn to be produced. The pre calculated quantity of a polymer is delivered to spin pack. The spin pack suspended at the bottom of spin beam, contains the distributors, filters & spinnerets the polymer is maintained at the constant temperature with the down that vapors inside the spin beam. The polymer temperature of 2800C- 2900 is maintained from the outlet of the finisher unit it is being extruder in from of the spinneret. The spinneret is having nos. of capillary holes to produce equal nos. of filaments. The extruded bunch of filaments is cooled down in the quenching chamber with the controlled flow of the quench air blowing across the filaments from backside of a quench chamber. Pre calculated quantity of spin finish oil is applied through nozzle on the filaments at the bottom of quench chamber. The filaments are fully/partially drawn due to the drag of High/Normal speed and heated godets/Cold godets of the take up machine at down The take up machine contains a pair of hot godets/ Cold godets, interlacing jets and high-speed winder. the POY/FDY thus produced is set between godets by marinating uniform tension across each yam before it is wound at high speed of 4800-5000 m/Min. (FDY) & 3200-3400 m/Min (POY) are being produced in such a way that the unwinding can be done at customer end. Feeding to all the reactors is continuous and close. All this is controlled by DCS system connected to process. This helps in on line monitoring of process for achieving smooth and stable production, CHEMICAL REACTION

C C

C C

C CC

H H

H H

C C + 2 H OCO

H

H H

C OCHO

H

H H

O O

2OH

INTERMEDIATE COMPOUND

H H

C C

C C

C C C HO

H H

H H

HO C + C OH C 2 HO

H H

H H

TPA EG

O O

23

2.1 Polymerization Process: The Polymerization Process has the following Steps

(1) Caprolactam pre - heater (2) Pre - poly (3) V. K. Tube

Melting, Storage and Mixing of Caprolactam Caprolactam is delivered in solid form. Solid Caprolactam in bags is stored according to the prescription of the producer.

Solid Caprolactam, the required bags are sent to the Caprolactam melting station where they are opened and empty in to the charging station.

The charging station has a crusher and a suitable ventilation and filter system. Crushing is required, because the flakes, due to storage, are compressed and have formed lumps.

From the crusher the Caprolactam falls into the melter where solid Caprolactam get melted into liquid form. The molten material is circulated by pumps through course filters, that eliminates coarse particles or packing substances that may have fallen into the charging station; a heat exchanger; and back to the melter.

The melter is a steam jacketed tank where Caprolactam is melted & its melting point of caprolactam is 69ºC, all pipes and pumps are heated by hot water. The heat exchanger is heated by medium pressure steam.

From the melter tank, the Caprolactam is pumped to intermediate storage tank & then into the Caprolactam mixing tank passing a mass flow meter. Catalyst, additives as well as concentrated Caprolactam water from recovery plant and / or water are added in to tank. The components are mixed homogenously as per programme in DCS.

Sample is collected from tank & once it is checked by laboratory it is transferred to Caprolactam feeding tank.

2.2 Continuous Polymerization:

Mixed Caprolactam is pumped from the storage tank, through a heat exchanger of special design, to the pre-polymerization reactor. In the heat exchanger the mixture, under pressure, is heated to reaction temperature.

The Caprolactam is fed to the Pre-poly reactor which is operated under pressure.

The Pre heated Caprolactam enters pre-poly which is under pressure. There is a sudden adiabatic expansion of the reaction mixture as it enters the pre-poly reactor. Pre-poly reactor is a vertical jacketed vessel, heated with Thermic fluid, chemical reaction starts at temperature 240 deg. C. The special design of the pre-poly reactor secures a piston flow of product that is required throughout the plant to ensure an equal product.

Heat exchanger, reactor and product lines are heated by HTM liquid and Dowtherm vapour.

By means of gear pump & as per level of the next reactor i.e. VK-tube, the material in pre-polymer is fed into a VK-tube, where the requested final viscosity is achieved. The VK-tube, a vertical jacketed vessel, is operating at atmospheric pressure/vacuum and temperature. Special inserts of the VK-tube ensures an equal product flow.

During the reaction in the pre-poly reactor, as well as in the VK-tube, water and some Caprolactam is evaporated. The vapours are condensed in condensing systems. The condensed water is send to a Caprolactam concentration plant for Caprolactam recovery.

At the bottom of the VK-tube, the polymer is discharged by gear pumps. Pump feed the polymer through heated polymer lines to the die head.

In the die heads the polymer passes distributor plates and a spinneret to form strands. Below die head under water cutter is placed which cuts strand into chips form.

Water of the cooling bath is continuously circulated by pumps and cooled in plate heat exchanger.

2.3 Continuous Extraction, Drying and Chips Conveying.

24

From the cutter outlet chips fall into a vibration screen, that separates uncut parts if any and from there, to a tank, called chips-water tank, which is filled with hot water.

A pump is continuously conveying water and chips from that tank to the top of the extraction tower where the chips are separated from the water. The water flows back to the chips-water tank.

The extraction tower is a cylindrical, vertical vessel with special inner design which ensures a piston flow of the chips and prevents the chips from mixing inside the tower. Un-reacted caproCaprolactam is removed in the extraction tower. Chips flow from top to bottom while hot water flows in the opposite direction. By the special design, a high concentration of Caprolactam is achieved at the overflow to the concentration plant as well as a nearly equal residence time of the chips inside the tower.

As feeding water to the extraction tower water from the Caprolactam water concentration plant is used, thus closing the water circuit. Steam heats the water just before entering the extraction tower. Additional heating of water and chips takes place inside the extraction tower by a special heating element.

At the bottom of the extraction tower, chips are continuously discharged by a roto-cell of special design. The speed of the rotor-cell is adjusted by the level instrument of the extraction tower. From there a pump sends water and chips to the chips-water separator centrifuge installed above the chip’s dryer. In the chips-water separator the chip’s separates from water. The water flows back to the rotor-cell in extraction column and the chips fall into the dryer. The chips-water separation and dryer are operating under nitrogen.

The dryer is a cylindrical, vertical vessel with special inner design, to ensure a piston flow of chips. By gravity chips travels from top to bottom. A cooler is provided at the bottom of the dryer which reduces the chip’s temperature before storage. The drying of chips is achieved by hot nitrogen in closed circulation flowing in the opposite direction to the chips.

The dryer has three nitrogen circuits & is divided into two sections. In top section two circuits of hot Nitrogen & in third cold Nitrogen is circulated. Special designed blowers circulate the nitrogen through the system. The Nitrogen absorbs the chip’s moisture and finally dried chips from dryer are continuously discharged into storage tank through Rotary valve fixed at bottom outlet of dryer.

Dried chips are then conveyed to main chips storage tank with help of Nitrogen conveying system.

2.4 Continuous Caprolactam Water Concentration and Water Storage

The monomer water from the extraction section contains about 10% monomer. It overflows into extraction water tank, and is fed into the three-stage evaporation system. The monomer water is concentrated to a certain concentration. The concentrated liquid flows from the system into the re-Caprolactam intermediate tank, & then it is concentrated further at fourth stage and treated in an automatic de-dreg filter system, stored in the re-caprolactam storage tank, and then pumped quantitatively to the mixing tank of the existing line or back to the mixing tank in the “Raw material melting and mixing” system and directly used for polymerization.

FIGURE 02: MASS BALANCE OF NYLON CHIPS

0.502 Kg

Nylon Chips 99.94 Kg

Polymer Lumps By- Product

Polymerization Process

0.446 Kg Catalyst + Additives

100 Kg Caprolactam

25

FIGURE 03: FLOW DIAGRAM FOR MANUFACTURING OF NYLON CHIPS

SHEET - 1

CRUSHER 01M01

LACTAM – MELTER 01V01

CPL INTERMEDIATE STORAGE TANK 11V06

CPL PRE- HEATER 12E01

PC TUBE 12R01

MELT FILTER 12F02

GRANULATION DEVICE 13M01

CAPROLACTAM

TO 13V11 SHEET 2

LIQUID LACTAM TANK 01V03

MIXING TANK 11V05

MIXING TANK 21V05

TO EXISTING POLY PLANT

LACTAM RECOVERY SHEET 3

PC PACKED COLUMN 12T01

12E01 PC CONDENSER

TO RECOVERY

12R01 PC TUBE

12R02 VK TUBE

12 T02

12 E10

VK CONDENSER 12E05

TO RECOVERY

26

SHEET 2

WATER/ CHIPS

RECEIVER 13V11

EXTRACTION COLUMN

13T11

DRYING COLUMN

14T01

CENTRFUGE 13M11 A/B

OVER FLOW

TO 06V01 SHEET 3

FROM GRANULATIONDEVICE 13M01

SHEET 1

13 S11

14 V01

CHIPS TO STORAGE

27

SHEET - 3

06T01 1st

EVAPORA-TOR

06E01 1ST HEATER

06T02 2ND EVAPORA-TOR

06E02 2ND HEATER

06T03 3RD EVAPORA-TOR

06E03 3RD HEATER

EXTRACTION WATER TANK 06V01

FROM 12E01 & 12E05 SHEET1 FROM 13V11 SHEET2

RECOVERED WATER TANK

06V02

RE CPL

INTERMEDIATE TANK 06V03

TO 11V05 & 21V05 SHEET 1

LOW PRESSURE STEAM

AUTOMATIC DE – DRAG

FILTER 06F03

28

3. Captive power Plant (Coal Based) We M/s. Shree Durga Syntex Pvt. Ltd. shall adopt Atmospheric fluidized bed Combustion (AFBC) technology for Captive Power Plant which promises to provide a viable alternative to conventional coal fired boilers for utility and industrial application. The total capacity of the plant is 21 MW. Coal/Lignite Fired AFBC boiler capable of generating 93TPH of steam at 88 kg/cm2 and 515OC and one extraction cum condensing Steam Turbine Generator of 21 MW. Production process includes steam generation and running the turbine. The steam shall be further used in the process for heating and other applications. For power generation, Coal would be used as fuel in the boiler. From the boiler bunker coal will be fed by gravity to furnace through rotary lock feeder here coal will be burn and heat up the boiler. DM water fed in the boiler to generate steam, it would be supplyed by DM water plant. The DM water system designed to cater the DM water requirement of the power plant. Generated steam would be send to steam turbine generator. The steam turbine Generator (STG) set will be of extration – condensing type for condensate and feed water heating .The STG will be rated for 21 MW. Maximum Continuous Rating (MCR)and will be coupled to an AC electric generator ofmatching capacity. Steam conditions at turbine inlet will be 87 ATM pressure and temperature 515oC. The extraction will be for steam supply to Deaerator, HP heater,LP heater and steam jet air ejection and also for process heating. Two motor driven, Centrifugal Condensate Extraction Pumps (CEP) will be provided for fed condensate to dearetor where the condensate along with make up DM water is heated and deaerated at 145oC. The deaerator tank is the reservoir for the boiler feed pump and is sized to provide twenty minutes reserve for the feed water system at rated load. Two no. 100% capacity, single suction, multistage centrifugal type high pressure Boiler Feed Water pumps (BFP) are provided for power generating groups consisting of one deaerator, a boiler and one STG.

29

PROCESS FLOW DIAGRAM

Steam Flue gas

Air Pollution Control

Equipment

Coal

Process Application

De-aerator Condenser

DM Water

B F Pump

Boiler

Steam Turbine Generator Power 21 MW

Internal Use

HP Heater

Fly ash

CEP

Stored in the Silo and finally sold to

end-user.

techno -economic pre-feasibility...

Documents