PRE FEASIBILITY REPORT RB POLYMERS LTD.

PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

PROPOSED EXPANSION OF RESIN MANUFACTURING UNIT

RB POLYMERS LTD.

Survey No.: 196/1, Plot No.: 103 to 108,

Mahalaxmi Industrial Estate,

Village: Iyava, Taluka: Sanand,

District: Ahmedabad, Gujarat.

Contact No.: 9724330497

Email: [email protected]

Prepared By:

T. R. ASSOCIATES

C‐605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,

S. G. Highway, Ahmedabad

Contact No.: 9825371099

Email: [email protected]

AUGUST 2018

PFR

RB Polymers Ltd. Page 1 of 13

1. Introduction

RB Polymers Ltd. is a limited company Proposed Expansion of Resin Manufacturing unit at Survey No.: 196/1, Plot No.: 103 to 108, Mahalaxmi Industrial Estate, Village: Iyava, Taluka: Sanand, District: Ahmedabad‐382110, Gujarat. Project Proponent and their back ground.

Details of Partner are as given below.

Sr. No. Name of Director Contact No. Address

1 Rakesh Roongta 9825037363 903, Pushkar Tower, Nr. Judge Bunglows

Road, Bodakdev, Ahmedabad

2 Subhash Roongta 9830096742 P‐42, C.I.T. Road, Csheme‐VIM, Kolkata

3 Chirag Sheth 9824042030 C‐605, Gurukul Park, Nr. Sterling Hospital,

Gurukul, Ahmedabad

2. Brief description of nature of the project:

M/s. RB Polymers Ltd. is manufacturing Laminated sheets , Phenol Formaldehyde Resin and

Melamine Formaldehyde Resin at Survey No.: 196/1, Plot No.: 103 to 108, Mahalaxmi Industrial

Estate, Village: Iyava, Taluka: Sanand, District: Ahmedabad‐382110, Gujarat. Now we want to

increase production capacity of Existing Product (i.e. MF Resin & PF Resin) and proposed to

manufacture a new product i.e. UF resin in their existing plant due to higher market demand as

well as Laminate sheet production.

M/s. RB Polymers Ltd. is willing for expansion to manufacture Melamine Formaldehyde Resin,

Phenol Formaldehyde Resin and proposed to manufacture Urea Formaldehyde Resin at Plot No.:

103 to 108, Mahalaxmi Industrial Estate, Village: Iyava, Taluka: Sanand, District: Ahmedabad,

Gujarat. The existing products are already used for captive consumption for Laminate sheet

production, where in the proposed products also shall be used in the Laminate sheet production

as well as for sale purpose.

The stated products falls under Category 5(f) as stated in Environment Impact Assessment

Notification Published on 14th September, 2006 and its subsequent amendments. Further, the

location of the proposed project is outside the notified industrial estate. Hence, the project

proponent has to obtain the EC from the Ministry of Environment, Forest & Climate Change, New

Delhi. M/s. T. R. Associates (NABET and NABL Accredited EIA consultants) has been appointed to

carry out EIA/EMP studies for obtaining Environmental Clearance.

The total land area of company is 10,407.46 m2 out of which 3,453.21 m2 (33.2 % of total land)

area will be used for greenbelt development. Total after proposed expansion project cost will be

approx. 550 lakh [Existing project cost ‐ 515 lakh + Proposed Expansion project cost – 35 lakh]. Total

budget allocation towards Environmental Management Facilities will be approx. 40 lakh [Existing

project cost ‐ 25 lakh + Proposed Expansion project cost – 15 lakh]. Total 30 persons [Existing persons –

14 + Proposed Expansion persons ‐ 16] will be employed including skilled persons, unskilled

persons & office staff.

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Local workers Permanent workers

Existing workers 5 Nos. 9 Nos.

After Total Proposed Expansion 12 Nos. 18 Nos.

Resins are used predominantly in the wood based product manufacturing industry as adhesives.

Growth of the resin market is strongly correlated to construction/remodeling activity (which

accounts for over 50% of consumption), and to a lesser degree, to the automotive industry.

The stated products like Resins (Melamine Formaldehyde, Urea Formaldehyde and Phenol

Formaldehyde Resins) mainly used to manufacture Laminated Sheets. These sheets have good

market demand to develop the home and office for furniture.

3. Project Description

(i) Type of project including interlinked and interdependent projects:

RB Polymers Ltd. is expanding the manufacturing of synthetic organic chemicals which are

Phenol Formaldehyde Resin, Melamine Formaldehyde Resin and addition of new product i.e.

Urea Formaldehyde Resin.

(ii) Location

Survey No.: 196/1, Plot No.: 103 to 108, Mahalaxmi Industrial Estate, Village: Iyava, Taluka:

Sanand, District: Ahmedabad‐382110, Gujarat.

Geographic Coordinates

Latitude: 23° 1'27.03"N Longitude: 72°18'29.85"E

Google image showing proposed project site is given below;

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Salient features in the surroundings area of the proposed site within 10 km radius are as follows:

Sr. No. Important Features Description

1 Location Survey No.: 196/1, Plot No.: 103 to 108, Mahalaxmi

Industrial Estate, Village: Iyava, Taluka: Sanand,

District: Ahmedabad‐382110, Gujarat.

2 GPS Coordinates Latitude: 23°1'27.03"N Longitude: 72°18'29.85"E

3 Temperature Range 11.7 °C – 41.8 °C

4 Mean Sea Level 34 m

5 Annual Rain Fall 630 mm

6 Nearest Railway Station Chharodi Railway Station – 3.70 km in WNW

direction

7 Nearest Airport Ahmedabad Airport – 32.50 km in East direction

8 Nearest Taluka Sanand – 7.1 km in ESE direction

9 Nearest Village Iyava – 1.45 km in East direction

10 Nearest State Highway State Highway 17 – 0.24 km in NNE direction

11 Nearest National Highway National Highway 947 – 0.24 km in NNE direction

12 Nearest River/Water body Khoda pond‐ 1.47 km in West direction

Chharodi pond – 5.51 km in WSW direction

Iyava pond‐1.35 km in NE direction

13 Nearest National Parks /

Sanctuary

None Within 10 km radius circle.

(iii) Alternative Sites considered

No other sites were selected.

(iv) Size or magnitude of operation

List of Proposed Products

Sr.

No. Name of Product

Existing capacity

MT/ month

Proposed capacity

MT/ month

Total capacity

MT/ month

1 Phenol Formaldehyde Resin 60 325 385

2 Melamine Formaldehyde Resin 14 81 95

3 Urea Formaldehyde Resin ‐‐ 550 550

Please refer Annexure 4 & Annexure – 10 for more details

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List of Raw Materials

Sr. No. Name of Raw Materials Existing Quantity

(MT/Month)

Proposed

Quantity

(MT/Month)

Total Quantity

(MT/Month)

1 Phenol 23.00 125.00 148.00

2 Melamine 4.90 28.35 33.25

3 Urea ‐‐ 137.50 137.50

4 Formaldehyde (37%) 38.30 621.34 659.64

5 Methanol 14.30 77.20 91.50

6 Caustic Flakes 0.21 1.94 2.15

7 Acetic Acid ‐‐ 0.55 0.55

(v) Project description with process details

Details of manufacturing process are given in Annexure‐ 5 of Form‐ 1.

(vi) Raw material required along with estimated quantity

Details of raw material and its consumption are given in Annexure‐ 4 of Form‐ 1.

(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Latest process technology will be adopted as available in market with optimum resources

requirement with highest yield and less waste and pollution generation. In addition to this,

all the feasible cleaner production technologies will be adopted.

(viii) Availability of water its source, Energy/ power requirement and source should be given.

Energy/power requirement after total expansion will be 350 KVA [275 KVA Existing

+ 75 KVA Proposed] which will be procured through Uttar Gujarat Vij Company Limited.

The total after expansion fresh water requirement will be 27.3 KL/day [Existing‐11.26 KL/day

+ Proposed‐ 17.20 KL/day] which will be fulfilled by own Borewell.

(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal

Hazardous Waste Generation and Disposal

Details of hazardous waste generation and its disposal are given in Annexure‐ 6 of Form‐ 1.

Wastewater Generation and Disposal Facility

Details of domestic as well as industrial wastewater generation and its disposal are given in

Annexure‐ 8 of Form‐ 1.

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(x) Schematic representations of the feasibility drawing which give information of EIA purpose

1. Site Analysis

(i) Connectivity

Nearest railway station Chharodi Railway Station 3.70 Km

Nearest state highway State Highway 17 0.24 Km

Nearest airport Ahmedabad Airport 32.50 Km

(ii) Land Form, Land use and Land ownership.

Proposed Expansion project site will be carried out within the existing project site where presently

existing products are manufactured according to the NOC/CCA issued by Gujarat Pollution Control

Board.

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(iii) Existing Land Use Pattern

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(iv) Topography Map

Project Site

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(v) Existing Infrastructure

(1) Nearest railway station: Chharodi railway station is 3.70 km away from the project site

(2) Nearest highway: State Highway 17 is 0.24 km away from the project site.

(3) Nearest airport: Ahmedabad Airport is 32.50 km from the project site.

(4) Power: 350 KVA from Uttar Gujarat Vij Company Limited.

(5) Water: Source of the water will be a borewell.

(6) Basic amenities: Telephone, Bus Stop & Road facilities are available in nearby Village

Iyava and Sanand Taluka

(vi) Soil classification of Ahmedabad District

The soils found in the district are mostly of Black soil, Goradu soil, Kyari and Rocky soil.

Goradu Soils

Goradu soils vary from fertile brown to sandy loam and are found in City, Daskroi and parts

of Sanand, Dholka and Viramgam talukas. This soil is mostly fertile and responds very well

to irrigation and manuring. Practically all kinds of crops can grow on this soil.

Kyari

Kyari soils are found in several parts of City, Daskroi, Sanand, Dholka and Viramgam taluka.

It is the most fertile soil with very good moisture and retentive capacity. Well known

varieties of paddy such as Pankali, kamod, Jirasar, Sukhvel, Sutarsal and Basumati are

grown on this soil.

(vii) Climate data from secondary source

The district has extreme climate and wide variation in temperature is observed.

Seasons:

The climate of the district is characterised by hot summer and general dryness except

during the southwest monsoon seasons. The year can be divided into four seasons. The

period from March to May is the hot season (summer) followed by southwest monsoon

from June to September. October and November constitute the post‐monsoon or

retreating monsoon season. The cold season (winter) starts from December and ends in

February.

Temperature:

The mean maximum temperature ranges between 28.4 0C during January to 41.8 0C during

May and the mean minimum temperatures vary between 11.7ºC during January and 27ºC

during June.

Winds:

Winds are generally light with some strengthening in force in summer and in the south‐

west monsoon season. During South west monsoon winds are generally SW to W. during

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end of monsoon NW winds also starts. Wind direction is between NW & NE in morning;

between SW & NW in afternoon in February & March. Rest of summer wind direction is

between SW & NW.

Rainfall:

The annual rainfall is received during SW monsoon season from June‐September, with July

being the highest rainfall month. Average annual rainfall is 500‐1000 mm.

(viii) Social Infrastructure available.

Ahmedabad city is near to project site. The social infrastructure of district has good

education, health and other facilties.

Education

There are 2373 primary, 1293 secondary and higher secondary schools in the district along

with major colleges such as

Indian Institute of Management (IIM)

National Institute of Design (NID)

Nirma education & Research Foundation (NERF)

National Institute of Fashion Technology (NIFT)

Indian Institute of Packaging

Mundra Institute of Communications, Ahmedabad (MICA)

Center for Environment Planning & Technology (CEPT)

Gujarat National Law University (GNLU)

Applications Center of the Indian Space Research Organisation (ISRO)

Apparel Export Promotion Council (AEPC)

Various Industrial Training Institutes provide training in areas like electronics, instrument

and motor mechanic, wielding, dress making, tailoring and cutting, painting, stenography,

carpentry and Wood working, oil engine and tractor repairing and others.

Health

The district has 43 primary healthcare centres, 9 community healthcare centres, 18

government, 8 municipal and 6 government aided hospitals.

Ahmedabad hosts some of the best private hospitals in the State such as Apollo Hospital,

Sterling Hospital, Krishna Heart Centre and Gujarat Cancer Society which have the facility

and the expertise to provide the best health services

Apollo hospital in Ahmedabad specialises in cardiology, orthopaedics, urology, oncology,

nephrology, gastroenterology and has the largest Dialysis Unit with in‐house Reverse

Osmosis Plant.

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Sterling is a multi‐super specialty corporate hospital situated in Ahmedabad. With a net

worth of over INR 100 crores (USD 23.8 million), Sterling has state of the art infrastructure

to provide high quality services across a range of specialties.

Krishna Heart Centre, one of the leading medical service providers, is the multi‐specialty

hospital present in the district.

2. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and Country

Planning/Development authority Classification.

It is chemical manufacturing industry located in Ahmedabad district. Total available area is

10,407.46 m2 out of it 3,453.21 m2 area has been provided as a greenbelt area. Industry

proposed expansion to manufacture Phenol Formaldehyde Resin, Melamine Formaldehyde

Resin and Urea Formaldehyde Resin.

Further the proposed activities will take care of all the rules and regulation of statutory

authority and provide the control measures and devices to achieve the standard norms.

(ii) Population

Description No.

Population Total : 72,14,225 Person

Male : 37,88,051 Person

Female: : 34,26,174 Person

Population density 308 persons per sq. km.

Village Population Total: 11,11,178 Person

Urbanised Population Total: 60,64,047 Person

Population increase rate N.A

Male‐ Female ratio 1000 : 904

Scheduled Caste population 7,59,483 Persons

Scheduled Tribe population 89,138 Persons

(iii) Land use planning (breakup along with green belt etc).

Sr.

No. Particular Area (m2)

1 Built Up Area 4,447.87

2 Green belt area 3,453.21

3 Open/ Road area 2,506.38

Total 10,407.46

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(iv) Assessment of Infrastructure Demand (Physical & Social).

Surrounded villages in 10 km area from the project site are having all the necessary physical

and social infrastructure facilities due to agricultural activities, animal husbandry and

industrial development within the area as well the nearby Sanand Taluka.

(v) Amenities/Facilities.

All the basic amenities/facilities such as power connection & power back‐up, drinking water,

internal roads, water & wastewater treatment plant etc. will be provided.

3. Proposed Infrastructure

a. Industrial Area

Industry has provided 4,447.87m2 built up area for industrial process/manufacturing activity

which provides all needed facility including proper ventilation, safe handling system, etc.

b. Residential Area

Industry has provided labor quarter for their labors and provides all basic facilities to them.

c. Green Belt.

3,453.21 m2 areas have developed for greenbelt development. In addition to this, project

proponent will participate in greenbelt development programs in nearby areas under their

CER.

d. Social Infrastructure

The proponent will provide social infrastructure facilities within 10 km radius of the proposed

project.

Education Facilities: ‐ Many Facilities for village schools like game kits, drawing kits, table‐

chairs; school construction (classroom/toilet/school boundary), ceiling fans/ coolers or books

for school library are proposed.

Health Facilities: ‐ Assistance to existing health facilities in nearest Hospital, for improvement

in health facilities or services.

e. Connectivity (Traffic and Transportation Road / Rail / Metro / Water ways

Proposed project site is located adjacent to State Highway 17 and well connected to the

internal roads and highways. The site is well connected to all major cities through State

highways and National highways.

f. Drinking Water Management

After total expansion of project, domestic water approx. 3.3 KL/day [Existing‐1.6 KL/day +

Proposed‐ 1.7 KL/day] will be consumed for domestic purpose.

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g. Sewerage System.

Domestic wastewater 2.7 kl/day [Existing‐1.3 KL/day + Proposed‐ 1.4 KL/day] will be treated in

Sewage Treatment Plant (STP).

h. Industrial Wastewater Management.

Waste water from Boiler blow down, cooling tower blow down, Process waste water and

Washing water will be collected in Collection cum Neutralization Tank. Then wastewater will

be given Chemical Oxidation treatment. Then Effluent will be taken to Nutch filter/Filter Press

for sludge separation. Separated dried sludge will be collected, stored and disposed of at

approved TSDF site. Filtrate water from Filter press will be taken in the holding tank and then

Effluent will be evaporate in the Steam based Evaporator. We will use simple Steam based

evaporator. Heat will be given by Steam boiler. The capacity of evaporator will be around 350

L/Hr considering worst scenario of effluent quantity. Hence we shall maintain Zero Discharge.

i. Solid/Hazardous Waste Management

Details of hazardous waste generation and its disposal are given in Annexure‐ 6 of Form‐ 1.

j. Power Requirement & Supply / source

Power requirement for the existing project is approx. 275 KVA and after expansion it will be

350 KVA, which will be obtained from UGVCL.

4. Rehabilitation and Resettlement (R & R) Plan

Not applicable.

5. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion

(Time schedule for the project to be given)

Existing project has already been constructed and is in operation phase. Construction work

related to proposed expansion of Resin manufacturing plant will be only started after

obtaining EC.

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

Total after proposed expansion project cost will be approx. 550 lakh [Existing project cost

‐ 515 lakh + Proposed Expansion project cost – 35 lakh].

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PRE FEASIBILITY REPORT RB POLYMERS LTD.

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