PREFEASIBILITY REPORT
For grant of Environmental Clearance
for
Manufacture of Synthetic Resins
Schedule - 5(f)
Category B
By
Ideal Chemi Plast Pvt. Ltd.
Plot No. A1 & A2, MIDC, Kulgaon, Badlapur-421 503,
Maharashtra
Prepared by
FINE ENVIROTECH ENGINEERS 102, HIREN INDUSTRIAL ESTATEMOGUL LANE,
MAHIM (W) MUMBAI – 400 016 EMAIL: [email protected]
FINE ENVIROTECH ENGINEERS
M/S. Ideal Chemi Plast Pvt. Ltd.
INDEX
SR NO. CHAPTER
PAGE NO.
CHAPTER 1
INTRODUCTION TO THE COMPANY
1.1 Introduction 1-1
1.2 Technology 1-1
1.3 Products Manufactured 1-1
1.4 Company Vision And Strategy 1-1
1.5 Departments 1-2
1.6 Infra Structure 1-2
CHAPTER 2
PROMOTERS AND DIRECTORS OF THE COMPANY
2.1 Board Of Directors 2-1
2.2 Company Profile 2-1
2.3 Promoters Information 2-3
CHAPTER3
MAJOR COMPONENTS OF THE PROJECT
3.1 Introduction 3-1
3.2 Location 3-1
3.3 Production Capacity 3-2
3.4 Raw Materials 3-2
3.5 Manufacturing Process 3-3
3.6 Power Requirement 3-4
3.7 Fuel Requirement 3-5
3.8 Water Requirement 3-5
3.9 Effluent Generation And Treatment 3-5
3.10 Solid Waste 3-5
3.11 Man Power 3-6
3.12 Environmental Aspects 3-6
3.13 Cost Of The Project 3-6
FINE ENVIROTECH ENGINEERS
1-1 M/S. Ideal Chemi Plast Pvt. Ltd.
CHAPTER 1
INTRODUCTION TO THE COMPANY
1.1 Introduction
M/s. Ideal Chemi Plast Pvt. Ltd. (ICPPL) is a manufacturer and exporter of Synthetic
Resins. Company has been involved in the manufacture of various types of Resins. Due to
change in economic scenario, it is time to change as per market requirements and change
the products which gives optimum results for company as well as society. We have
established in market new products for various applications like wood coatings,
automotive, coil and other industries. Prominent customers include Pidilite, Nippon,
Jubilant, Sadolin Paints Kenya, Asian PPG, E. I. Dupont, Kansai Nerolac, MRF Limited,
Sheenlac, Hibuild Coatings, Wel Coat Dubai, Sadolin Oman, etc. The industry runs by a
team of technocrats having vast experience in development and production of resin.
The EIA notification (S.O.1533) promulgated on 14th
September 2006 has covered these
types of Synthetic Chemical industries under category 5(f) in schedule I. It is stated that
synthetic organic chemical industry located in a notified industrial area/estate is classified
under Category B.
Since being a notified industrial region the land is not agricultural and is under industrial
use only. The total area of the plot is 2021 sq. meters. ICPPL proposes to increase its
annual production from 33.9 MT/day to 43.1 MT/day.
ICPPL is an ISO 9001, ISO14001 & OHSAS 18001 certified company and is located at
Plot No. A1 & A2 at Badlapur MIDC near Kulgaon village.
1.2 Technology
Esterification, Etherification, solution polymerization and polyaddition technologies are
employed to manufacture various synthetic resins.
1.3 Products Manufactured
Using aforesaid technologies, we manufacture synthetic resins such as alkyds, Polyesters,
amino resins, acrylic resins & oligomers and polyurethane disopersions. These products
are used for manufacturing automotive (refinish and OE coatings), Coil and can coatings,
Industrial coatings, decorative & wood coatings.
1.4 Company Vision and Strategy
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1-2 M/S. Ideal Chemi Plast Pvt. Ltd.
ICPPL operates its business in a manner which actively seeks prevention of environmental
pollution. We also strive to provide the resources to educate and involve every individual
in the Company in achieving this objective
The continual improvement of quality is fundamental in every activity.
This means that each one in ICPPL is committed to:
Anticipating and exceeding external as well as internal Customer expectations.
Achieving excellence with pride in the areas of business processes, product sourcing,
manufacturing technology and safety, health & environmental compliance.
Delivering continual improvement through establishing measurable objectives at
relevant functions and levels, and a systematic review of performance and processes.
1.5 Departments
ICPPL manages their business with following departments
1. Manufacturing & Logistic
2. Procurement & Distribution
3. Engineering
4. Finance & IT
5. Human Resources & Administration
6. Finance
7. Research & Technology Development
8. Quality Control
9. Customer & Technical services.
1.6 Infrastructure
ICPPL has fully developed infrastructure to support its manufacturing activity
1. Transformer and electrical substation
2. Boiler fired with Furnace Oil
3. Thrmopacks and DG set
4. Water storage and distribution facility
5. Fire fighting with sprinklers
6. Fire alarm system
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7. Workers amenity block
8. Manufacturing plant
9. Warehousing
10. Roads and drains
11. Effluent treatment plant
12. QC laboratory
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2-1 M/S. Ideal Chemi Plast Pvt Ltd
CHAPTER 2
PROMOTERS AND DIRECTORS OF THE COMPANY
2.1 Board of Directors
ICPPL is managed by its group of directors. Names of the Board Members given below
Designation Name
Directors : Raghuram Kavu Rao,
Vishwas Vishnu Puranik,
Arvindkumar Chimanlal Bhatt,
Raghavendra Govind Joshi
2.2 Company Profile
Ideal Chemi Plast Private Limited India was set up in 2004 for the manufacturing,
marketing and sales of various resins products in India.
Ideal Chemi Plast Private Limited India is a key manufacturer of synthetic resins
being used into automotive coating (OEM & refinishes), wood coating, coil coating
and general industrial coating purpose. The company manufacturers different grades
of resins as per the customer specifications and have following major product lines;
Acrylic resins
Alkyd resins
Amino resins
Polyester resins (Saturates and Modified Polyester resins)
Modified Epoxy resins
Modified Polyimide reins
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2-2 M/S. Ideal Chemi Plast Pvt Ltd
Today, Ideal Chemi Plast Pvt Ltd is a supplier of choice for leading companies in a
wide range of industries, employing 72 people. Company has its Corporate office &
manufacturing site at Badlapur.
Ideal Chemi Plast Private Limited offers its customers a unique combination of
various technology platforms, product development skills and market knowledge.
Company has developed an underlying diversified portfolio of products that cut across
virtually all needs of the customer. Supported by 24x7 in house research &
development lab and manufacturing facilities, the business has established an image of
quality supplier and is the market leader in the above segments.
Ideal Chemi Plast Private Limited manufactures approximately 120 finished products
(excluding intermediates) to a customer base of 100 (including distributors).
Some of the key strengths of Ideal Chemi Plast Private Limited are-
o Strong brand image of Ideal Chemi Plast Private Limited in the resins industry
o Strong position with industry leaders
o Consistently superior product quality and product performances
o Ability to customize products to market needs with well-resourced R&D function
o Diversified portfolio
o Versatile & flexible manufacturing
o Strong distribution network
o Preferred choice of customer
The business has demonstrated resilience and consistent growth across business cycles.
With Ideal Chemi Plast Private Limited’s focus on the high-growth Indian market, the
business is well-poised to make significant progress in coming years.
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2-3 M/S. Ideal Chemi Plast Pvt Ltd
2.3 Promoter’s Information
Raghuram Kavu Rao is a bachelor of engineering in electrical. He has 10 years of
experience with state electricity board and 26 years of experience into resins
manufacturing business. He is instrument in developing new client relationship and
nurturing the existing customers. At present, he is a Director, Technical Sales at Ideal
Chemi Plast Private Limited.
Vishwas Vishnu Puranik holds B.Sc. Tech degree and has 40 years of experience of
resins manufacturing and development experience across leading paint companies in
India. He is instrumental in developing new resins product range and making it
commercially viable. At present, he is a Director, Production and R&D
Arvindkumar Chimanlal Bhatt is a B.Sc. Chemical engineering. At present he is
serving as a Director and managing engineering and maintenance division at Ideal
Chemi Plast Private Limited. He has 43 years of resins manufacturing and
petrochemical plant operation experience.
Raghavendra Govind Joshi holds bachelor of engineering in Electrical with 20
years of experience at state electricity board and 26 years into resins manufacturing.
At present, he is managing the commercial, finance and administration functions at
Ideal Chemi Plast Private Limited.
FINE ENVIROTECH ENGINEERS
3-1 M/S. Ideal Chemi Plast Pvt. Ltd.
CHAPTER 3
MAJOR COMPONENTS OF THE PROJECT
3.1 Introduction
M/s. Ideal Chemi Plast Pvt. Ltd. is involved in manufacturing of synthetic resins since 2004.
The company works with a strategy to satisfy its customers by striving to understand the
needs of the customer and providing satisfactory services by exceeding the customer
requirement. Keeping this vision the company is proposing to expand its manufacturing
capacity from 33.9 Mt/day to 43.1 Mt/day. Proposed expansion will be carried out at existing
plot only as sufficient place and infrastructure is available.
3.2 Location
The plant is located at Plot No A1 & A2, MIDC, Kulgaon, Badlapur, Dist. Thane, 421503.
Figure 3.1: Google Image of the Site Location
19°09'35.5"N 73°14'31.0"E
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3-2 M/S. Ideal Chemi Plast Pvt. Ltd.
3.3 Production Capacity
The proponent proposes to expand the manufacturing capacity of the plant. Production
capacity will be enhanced by reducing in cycle time of the batches of Alkyds and
polyesters. Reduction in cycle time (time required till reactor is engaged) of alkyd and
polyester batches will be achieved by addition/ modification of accessories in plant without
enhancing the capacity of the reactor. The existing manufacturing capacity and proposed
capacity are shown in the table below:
Table 3.1: Existing and proposed manufacturing capacity of the plant.
Sr.
No.
Product Proposed Capacity
MT/Day
Existing Proposed
1. MF/UF Resins 4.5 5.4
2. Alkyl Resins 12.5 14.4
3. Polyester Resins 12.5 14.4
4. Acrylic Resins 4.4 8.9
Total 33.9 43.1
3.3 Raw Materials
The raw materials are available through network of dealers and distributors both in the
domestic as well as overseas markets. As the company is already in the segment and has
established contacts with suppliers and therefore the availability of raw material shall be
smooth.
Table 3.2: List of raw materials with quantity (Kg /day).
Name of Raw Material Amino Resins
Polyester Resins
Alkyd Resins
Acrylic Resins
Total
Paraform 1519 0 0 0 1519
Fatty Acids/Fatty oils 0 0 3269 0 3269
Polyols/Glycols/Amines 1360 3490 2203 0 4788
Organic Acids/Anhydride 20 6015 3859 0 9894
Acrylic Monomer(MMA,BA,NBMA etc) 0 0 0 6223 6223
Solvents (Xylene, MTO, C-IX, C-X, BA.BuOH etc.) 3695 5775 5761 2660 16117
Catalysts 38 19 22 124 203
Water in process 213 0 0 0 213
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Water for product washing 0 0 0 0 416
3.4 Manufacturing process
1. Alkyd, Amino and Polyester Resins
Raw Materials with reflux solvent are charged to reactor. Material is continuously stirred
under heating to required temperature. Reflux starts after reaching required temperature, water
of reaction is removed and solvent is recirculated. After desired water removal and desired
viscosity is achieved. The products are partially cooled and thinned with solvent to desired
solid content, after testing the sample batch is discharged in drums or tank with or without
filtration as required.
2. Acrylic Resins
Solvent is first charged to the vessel small quantity of monomer mix is also added. The
contents are heated till reflux. After getting desired reflux rate monomer mixture is added at
desired constant rate after complete addition products are checked for Desired Properties.
Finally the material is filtered and filled in drums. No water of reaction is evolved during the
process. No spent solvents are generated in this process.
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Flow Diagram for manufacturing process for Acrylic, Alkyd, Amino and Polyester Resins
3.5 Power Requirement
The power requirement is acquired and fulfilled through MSEDCL. The power requirement for
proposed expansion is 105 HP. It is also proposed to install a DG set having a capacity of 125
KVA.
Condenser
Receiver
Water of reaction
storage drum
Raw Materials
Monomer Tank
Reaction
vessel
Stirred at
45-50 rpm
Blender / Dilution
Tank Filter
To Drum Filling
or Storage Tank
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3-5 M/S. Ideal Chemi Plast Pvt. Ltd.
3.6 Fuel Requirement
Fuel
Daily consumption
(Lit/Day)
Existing Proposed Total
Furnace oil 1200 60 1260
HSD 25 2.5 27.5
3.7 Water Requirement
The water source is from MIDC. The water requirement for expansion shall be 25 m3/day. The
break of water requirement is as
Table 3.3: Water Requirement
Usage category
Water
Requirement
(m3/day)
Process water 0.7
Cooling tower makeup 10
Boiler feed water 7.3
Water for vessel cleaning 0
Domestic 5
Gardening 2
Total 25
3.8 Effluent Generation and Treatment
Effluent will be treated in existing ETP prior to release to CETP. Effluent generated in process
is collected in collection tank and further subjected to oil separation. It is passed further for
primary treatment where effluent is neutralized and equalized. Equalized neutral pH effluent is
subjected to sedimentation. Sludge generated by sedimentation is sent for disposal at
CHWTSDF. Clear treated effluent is collected in holding tank which is then disposed to CETP.
Total effluent generated from process will not exceed 5 CMD.
3.9 Solid waste
Hazardous waste generated will be disposed to CHWTSDF.
Table 3.4: Solid Waste
Sr.
No.
Category
No. Type of Waste
Quantity (Kg/Day) Form (Sludge
dry/ slurry) Disposal Existing Proposed
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1 23.1 Wastes/Residues 3 3 Slurry CHWTSDF
2 34.3 Chemical sludge from
waste water treatment
8.3 10 Sludge CHWTSDF
3.10 Man Power
The existing facility manpower strength is 64. Additional 16 persons are envisaged. Since the
location is in the industrially developed town with many small units operating in the locality
the availability of workmen is considered to be smooth.
3.11 Environmental Aspects
3.11.1 Air
No air pollution is envisaged from the project site as mechanical dust collectors are installed.
Fuel used for boiler and thermopacks is furnace oil which produces less SO2 and particulate
emissions upon burning, which makes the process more environment friendly.
3.11.2 Water
The effluent from the manufacturing process shall be treated in effluent treatment plant
provided in the unit. No waste water treated or untreated shall be discharged on ground.
3.12 Cost of the Project
Sr.
No.
Description Cost in Crores
1 Land 0.0121320
2 Building 0.4007167
3 Plant & Machinery 2.0027262
4 Other assets 1.3040226
5 Capital work in progress 0.8450430
Total cost 4.5646405