01.03 2016 pfr knpl punjab - environmentclearance.nic.in · spaze it park, unit no. 1124, 11th...
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M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB QUALITY SHEET
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 2
M/S. KANSAI NEROLAC PAINTS LIMITED
Prefeasibility Report for Environmental Clearance forProposed Integrated Paint Manufacturing Facility at Goindwal Sahib Village, Tarntaran District, Punjab © Kadam Environmental Consultants (‘Kadam’), March 2016
This report is released for the use of the Asian Paints Limited, Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.
PROJECT DETAILS
Name of Publication
Prefeasibility Report for Environmental Clearance forproposed Integrated Paint Manufacturing Facility at Goindwal Sahib Village, Tarntaran District, Punjab
Project Number 1523632310 Report No. 1 Version 1 Released March 2016
Prepared & Managed By
Parul Patel & Surbhi Makwana Released By Sameer Kadam
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-3001000; F: +91 265 300106
Delhi / NCR
SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,
Sohna Road, Gurgaon -122 002 (Haryana) E: [email protected];T: 0124-4242430; M:+91-98998-04300
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore
specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 3
CONTENTS
1 EXECUTIVE SUMMARY .......................................................................... 6
1.1 INTRODUCTION ................................................................................... 6 1.2 PLANT FEATURES AND PRODUCTION CAPACITY .................................................... 6 1.3 ENVIRONMENT .................................................................................... 7 1.4 SUBMISSION ...................................................................................... 7
2 INTRODUCTION .................................................................................. 8
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT .......................................... 8 2.1.1 Identification of Project Proponent ..................................................... 8 2.1.2 Identification of Proposed Project ...................................................... 8
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ................................................. 8 2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION ........................................ 9 2.4 DEMAND SUPPLY GAP ............................................................................. 9
2.4.1 Global Market .............................................................................. 9 2.5 IMPORT VS. INDIGENOUS PRODUCTION ........................................................... 9 2.6 EXPORT POSSIBILITY .............................................................................. 9 2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ....................... 9
3 PROJECT DESCRIPTION ...................................................................... 11
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS,IF ANY ............ 11 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &
PROJECT LAY OUT) WITH COORDINATES ................................................................. 11 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSEDSITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BEHIGHLIGHTED ............ 15 3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................ 15 3.5 TECHNOLOGY AND PROCESS DESCRIPTION ...................................................... 15 3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA
OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ................ 20 3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE
BRIEFLY OUTLINED ...................................................................................... 21 3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE
GIVEN 21 3.8.1 Water consumption ..................................................................... 21 3.8.2 Fuel ....................................................................................... 22 3.8.3 Power Requirement and Source ....................................................... 22 3.8.4 Transportation details of Raw Materials .............................................. 22
3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT
/DISPOSAL .............................................................................................. 23
4 SITE ANALYSIS ................................................................................. 24
4.1 CONNECTIVITY .................................................................................. 24 By Road ............................................................................................ 24 By Rail .............................................................................................. 24 By Air ............................................................................................... 24
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 4
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................. 24 4.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................... 24 4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES
(INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO
PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER
BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY
OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ..................................................... 26 4.5 EXISTING INFRASTRUCTURE ..................................................................... 26 4.6 SOIL CLASSIFICATION ........................................................................... 26 4.7 CLIMATIC DATA FROM SECONDARY SOURCES ..................................................... 26
4.7.1 Temperature ............................................................................. 26 4.7.2 Wind ...................................................................................... 27 4.7.3 Rainfall ................................................................................... 27 4.7.4 Cloud Cover .............................................................................. 27 4.7.5 Humidity ................................................................................. 27
4.8 SOCIAL INFRASTRUCTURE AVAILABLE ............................................................ 28
5 PLANNING BRIEF .............................................................................. 29
5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC.) TOWN AND
COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION ...................................... 29 5.2 POPULATION PROJECTION ....................................................................... 29 5.3 LAND USEPLANNING (BREAKUP ALONGWITH GREENBELT ETC.) ................................... 29 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ........................... 30 5.5 AMENITIES/FACILITIES .......................................................................... 30
5.5.1 Greenbelt Development ................................................................ 30 5.5.2 Fire-fighting system..................................................................... 30 5.5.3 Storm water management plan ....................................................... 31 5.5.4 Rainwater harvesting system .......................................................... 31
6 PROPOSED INFRASTRUCTURE ............................................................. 32
6.1 INDUSTRIAL AREA (PROCESSING AREA) .......................................................... 32 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ................................................... 32 6.3 GREEN BELT ..................................................................................... 32 6.4 SOCIAL INFRASTRUCTURE ....................................................................... 32 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ....... 32
6.5.1 By Road .................................................................................. 32 6.5.2 By Rail .................................................................................... 32 6.5.3 By Air ..................................................................................... 32
6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ................................ 33 6.7 SEWAGE SYSTEM ................................................................................ 33 6.8 INDUSTRIAL WASTE MANAGEMENT ............................................................... 33 6.9 SOLID WASTE MANAGEMENT ..................................................................... 33 6.10 POWER REQUIREMENT & SUPPLY/ SOURCE .................................................... 34
7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN .............................. 35
7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS
INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS(A BRIEF OUTLINE TO BE GIVEN) . 35
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 5
8 PROJECT SCHEDULE AND COST ESTIMATE ............................................. 36
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR
THE PROJECT TO BE GIVEN) ............................................................................. 36 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE
PROJECT. ............................................................................................... 36
9 ANALYSIS OF PROPOSAL..................................................................... 37
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE
INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. .................................................. 37
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 6
1 EXECUTIVE SUMMARY
1.1 Introduction
This Pre-feasibility report is part of documentation filed by Kansai Nerolac Paints Limited as part of the Environment Clearance (EC) Process, a mandatory regulatory clearance required from the Ministry of Environment and Forests (MoEF) prior to commencement of construction at site.
Kansai Nerolac Paints Limited (Hereafter will be referred as KNPL), incorporated on 2-09-1920, at Lower Parel in Bombay is one of the leading paint companies in India with gross sales of Rs.4212 Crores for the year 2014-15. KNPL is engaged in manufacturing/ marketing of & Architectural & Industrial coatings, Powder Coatings& High Performance Coatings. It has operations spread across the country with four strategically located factories & has 94 depots from where they service a vast base of customers both in decorative & industrial side. The plants are located at Lote Parshuram in Maharashtra, Jainpur in Kanpur Dehat of Uttar Pradesh, Bawal at Haryana and Hosur at Tamil Nadu. KNPL is a subsidiary of Kansai Paints Co., Japan’s number one coating company, who holds 69.27% equity. KNPL is targeting a growth significantly better than the expected industry growth rates, as aforesaid.
Company enjoys thorough connectivity across its branches, factories & HO through V-SATS/ leased lines and functions on SAP platform, thus bringing transparency in operations & working on live data. Our Supply Chain department uses advance IT tools like APO for Forecast, production planning & scheduling. All its operations are thus computerized & it is truly IT enabled company
KNPL is committed to creating value addition to customers by way of continuous up-gradation of technology resulting in reduction in paint consumption per vehicle, increasing the utility & life span of paints, reducing energy consumption and in manufacturing of environmental friendly paints. Latest technology application knowledge, technical sales service and knowledge of entire paint system are key factors in Auto paint market. With collaboration from world leaders across various continents and with wealth of experience over the years in running various auto lines, KNPL is well equipped to maintain and consolidate its position of strength, KNPL is proud to be the first company to introduce latest environmental friendly lead free Cathodic Electro Deposition (CED) paint in India and eco-friendly water based coatings like Acrylic CED in the Industrial segment as well as lead-free paints and special Low VOC odor free paints in Decorative paints segment.
All of our plants have been certified with ISO 14001, OHSAS 18001, ISO 9001 & TS 16949 certification and the new facility too will go for such certification. We are the recipients of Golden Peacock & Greentech award for Environmental Management for various plants. We have also received Sustainability award from Frost & Sullivan and from our renowned customers like Tatas, Maruti, Honda and M & M.
1.2 Plant Features and Production Capacity
The proposed project is Greenfield and will be set up to manufacture water based paints, powder coating paints and emulsion for captive consumption. The estimated cost of the proposed project is INR 180 Crores (including working capital). The Total Production capacity is given in Table 1-1.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 7
Table 1-1: Production Details S.No. Name of Products Unit Production capacity
1 Water based paints TPA 38000
2 Powder coating paints TPA 14400
3 Emulsion TPA 24000
1.3 Environment
In the light of the above, we would like to state that the integrated Paint manufacturing facility at Goindwal sahib, Tarn Taran Taluka, tarntaran District with a production capacity of 38000 TPA water based paints, 14400 TPA of powder coating paints and 24000 TPA of Emulsion would have in place systems, procedures and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation has no adverse impact on environment.
1.4 Submission
In the light of the above, we would like to state that the integrated water based Paint & powder coating paints manufacturing facility in industrial estate at Goindwal Sahib with a production capacity as per Table 1-1 would have in place systems, procedures and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation has no adverse impact on environment.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB INTRODUCTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 8
2 INTRODUCTION
2.1 Identification of Project and Project Proponent
The Kansai Nerolac Paints Ltd, intend to set up green filed integrated paint manufacturing facility in Goindwal Sahib. The project site is located in an industrial area identified by the “allotment order for plots” issued by the Punjab Small Industries & export Corporation Ltd (PSIEC). The said allotment is in the Goindwal industrial area which is state notified industrial area.
The plant is going to be most modern, automatic facility with less manual intervention. The total capacity of paint in Phase I will be 38000 MT/Annum (emulsion 24000 MT/Annum as intermediate) which will be enhance to 52400 MT/Annum. The estimated cost of the project is Rs. 180 crores approximately for the phase – I, which will be borne out of internal accruals.
The entire product will be manufactured throughout the year. The various water based paints and powder coating paints are traded by the names of Excell, Suraksha, lotus touch, Beauty silver/Gold, Little Master, Beauty smooth, Nerocoat Powders etc.
2.1.1 Identification of Project Proponent
KNPL will set up integrated paint manufacturing with zero liquid discharge facility at Goindwal Sahib, Tarntaran in two phases. In Phase – I, KNPL will installed Water Based Paints manufacturing facility with capacity 38000 MTA & Emulsion as a intermediate with capacity 24000 MTA . In Phase -II, Powder coating paint manufacturing with a total capacity of 12000 will be set up. The cost of the total project is 180 crores which include 4.6 crores for environmental protection measures i.e. 1.5% of total project cost. The project will be commissioned within 18 – 20 months from zero date. The plant will be having most modern technology for improved quality and productivity
2.1.2 Identification of Proposed Project
The proposed project is Greenfield and will be set up to manufacture water based paints and powder coating paints. The estimated cost of the proposed project is ~ INR 180 Crores. The Total Production capacity is given in Table 2-1.
Table 2-1: Production Details S.No. Name of Products Unit Production capacity
1 Water based paints TPA 38000
2 Powder coating paints TPA 14400
3 Emulsion TPA 24000
2.2 Brief Description of nature of the Project
The Kansai Nerolac Paints Ltd, intend to set up Greenfield integrated paint manufacturing facility in Goindwal Sahib . The project site is located in an industrial area identified by the “allotment order for plots” issued by the Punjab Small Industries & export Corporation Ltd (PSIEC). The said allotment is in the Goindwal industrial area which is state notified industrial area.
The plant is going to be most modern, automatic facility with less manual intervention. The total capacity in Phase I will be - Paint :38000 MT/month & Emulsion - 24000 The Powder coating
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB INTRODUCTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 9
paints 14400 MTA will be added in 2nd phase. The estimated cost of the project is Rs. 180 crores approximately for the phase – I, which will be borne out of internal accruals.
The entire product will be manufactured throughout the year. The various water based paints and powder coating paints are traded by the names of Excell, Suraksha, lotus touch, Beauty silver/Gold, Little Master, Beauty smooth, Nerocoat Powders etc.
2.3 Need for the project and it’s importance to region
Indian Paint Industry is growing at the rate of 12-14% CAGR driven by strong growth in Industrial and Real estate sector. Growing disposable income along with growing life style aspirations of people have resulted into increased demand for decorative coatings for homes.
Kansai Nerolac Paints Ltd. currently holds 2nd position by sales turnover in Indian paints Industry. Fueled by strong technological base, dynamic Management team, and aspirations to become the market leader, KNPL wants to expand its manufacturing capacity by installing a new production plant. This production plant shall cater to the growing market demand in North India esp. the states of J&K, Punjab, Haryana, and Rajasthan.
The location has been shortlisted based upon various internal criteria to strike an optimum balance of availability of resources and supply chain ease and cost. Major raw material required for paint like Soapstone, Talc, Calcium carbonate etc is available in Rajasthan. Proximity to the national highway shall provide easy access to the target destinations for the product. Skilled labor (ITI trained) and Supervisory staff shall be sourced from nearby areas.
2.4 Demand Supply Gap
In the last ten years, the Indian Paint Industry has grown at a compounded annual growth rate (CAGR) of 12-13%. The market for paints in India is expected to grow at 1.5 times to 2 times GDP growth rate in the next five years. The paint industry is dominated by decorative paints. Emulsion, which constitutes the majority share of decorative paints, is the fastest growing segment in the paint industry. In order to cater to its growth rates, KNP is looking to expand the current manufacturing capacities by setting up a Greenfield plant in Punjab. This is imperative to cater to the demand for the state of Punjab, and nearby areas.
2.4.1 Global Market All paints will be supplied in domestic market to meet the demand.
2.5 Import vs. Indigenous Production No import has been proposed for Raw Materials as Major raw material required for paint like Soapstone, Talc, Calcium carbonate etc are available in Rajasthan.
2.6 Export Possibility There will not be any export. The product will meet the domestic requirement.
2.7 Employment Generation (Direct and Indirect) due to the project.
The manpower requirement for the new plant is based on the number of persons required on each machine/ process. The paint manufacturing requires skillful handling thus it has been decided to have all apprentices/ workers who have a minimum qualification of ITI.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB INTRODUCTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 10
For operating at the full capacity KNPL will require approximately 45 operators & 80 indirect workers. It will be the endeavor of the Company to utilize local manpower meeting the requirements of qualifications, to the extent possible. Fresh ITI passed outs shall be taken as apprentices for two years. People completing the apprenticeship successfully shall be absorbed as regular employees. Stipend/salary shall be keeping in mind prevailing labor laws.
In addition about 20 numbers of Supervisory/Managerial staff will be required. The qualification requirement for these staff will be degree in Paint Technology or BSc/ MSc Chemistry for production /QC related work or Graduation in Engineering for Maintenance or Process engineering work.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 11
3 PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects,if any
The proposed project is water based paint and powder coating paint manufacturing facility covering area of about 1,42,179 m2 situated at Plot No 1 (Zone – 1) of Goindwal Sahib Village, Tarn Taran Taluka, Tarntaran District. Plant will have total water based paint Production Capacity: 38000TPA,powder coating Production Capacity: 14400 TPA and Emulsion: 24000 TPA. There is no interlinked and interdependent project.
3.2 Location (map showing general location, specific location and project boundary & project lay out) with coordinates
Location:
State: Punjab
District: Tarn taran
Tehsil / Taluk / Mandal: Tarn Taran
Village: Goindwal Sahib
The entire project area isabout 35 Acres.
Project site location map is shown as Figure 3-1. The project site boundary with coordinates is shown inFigure 3-2.
M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY
IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 12
Figure 3-1: Site Location Map
M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY
IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 13
Figure 3-2: Project site Boundary with Coordinates
M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY
IN GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 14
Figure 3-3: Satellite Imagery of 10 Km Radius
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 15
3.3 Details of alternate sites considered and the basis of selecting the proposedsite, particularly the environmental considerations gone into should behighlighted
Beside Goindwal Saihib site, 2 more sites at Rajasthan and Uttarakhand were shortlisted for setting up integrated paint Manufacturing Plant. However, Goindwal Sahib Site has been selected based on notified Zone for industrial set up and also availability of water and power and close proximity of state highway.
3.4 Size or Magnitude of Operation
Product details and production capacities are given in Table 3-1 .
Table 3-1: Production details S.No. Name of Products Unit Production capacity
1 Water based paints TPA 38000
2 Powder coating paints TPA 14400
3 Emulsion TPA 24000
3.5 Technology and Process Description
1. Manufacturing Paints
1. Water based Paint Manufacturing process:
Water Based Paints manufacturing process consists mainly of dispersion of Pigments (mainly TiO2) & extenders (e.g. Talc,CaCO3,Clay, etc.) in water under vigorous agitation & followed by fine grinding through Sand mill(whenever necessary). The slurry is diluted by adding Emulsion, water & thickeners to get the required physical parameters. The final paint is filled in the containers & dispatched.
The Process Steps consist of:
1. Dispersion – Pigments powders are wetted with optimum quantity of water along with wetting agents. This is done in the equipment called Twin Shaft Disperse (TSD).
2. Grinding: This step is required in certain premium product only. The slurry is ground in high speed sand Mills to achieve the desired particle size, which is at micron levels, to get desired finish.
3. Dilution- Slurry is transferred to Mixing vessel. The slurry is thinned by adding emulsion, Thickener & water as per the recipe, to get desirable physical parameters.
4. Filling & Packing Filling is carried out in Bulk Packs (10, 20 lt.) or Small packs (1, 4 lt.).Automatic filling machines are used for big batch sizes. Smaller batches are filled with manual machine. Small packs containers are packed in cartons. Packed containers/Cartons are sent to BSR for storage & onward dispatch.
The process flow diagram is given in Figure 3-4.
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 16
Figure 3-4: Process Flow Diagram – Water Based Paints
B AT CH SI LO
T W I N S HA FT D ISP E RSE R
TH IN N I N G /TI N T IN G
M I X E R
FI LT ER
FI LL I N G / C A RT ON I N G
SAN D M IL L
P RO CES S FL OW CHAR T WAT E R BAS ED P AINT S
FRO M PO W D ER ST O RA G E S ILO
A D DIT IV ES
W A TER
PIG M EN T/E XT EN DE R
A D DIT IV E
W AT ER
E M UL SIO N
B ON D E D S T OR E
D I S PA T C H TO D E POT S
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 17
2. Powder Coating Paint
The production process consists of following stages.
Premixing - The raw materials are in powder / flake form. These are weighed and added in a pre-mixer. The pre-mixer blends these materials mechanically
Extrusion/ Melt Mixing- The ' Premix ' is fed into an extruder. The Extruder ensures uniform dispersion of the material at temperature of 100’ -1400C) and converts it into paste form. The paste coming out of the Extruder is squeezed between two rollers. Rollers are cooled using chilled water circulation inside the rollers. The paste on squeezing forms a thin uniform film. The film formed by squeezing is laid on a conveyor belt for cooling.
Pre-breaking -The cooled film is crushed into small flakes of size approximately 1 sq.cm, by the pre-breaker.
Blending - These flakes are charged into DCM (Double cone blender), small quantity of additive is added to the flakes, blending is done for proper mixing of additive.
Micronizing -Blended flakes are then fed into a micro pulverizer (also known as air classifying mill). The micro pulverizer grinds the flakes into fine powder. The powder is then sieved and packed for dispatch. These micro-pulverizer are provided with dust collector & blowers to prevent dust pollution.
Figure 3-5: Process Flow Chart - Powder Coating Paints
Note: The flow diagram may change based on actual design considerations.
3. Emulsion manufacturing process
Production process consists of following steps:
Pre Emulsion Stage: De-ionised water, surfactants and Monomers are mixed at Room temperature in Pre Emulsion Vessel. Initiators and chain terminators solutions prepared in De mineralized water will be charged after thorough Emulsification of Monomers in Water.
Reactor Charge Stage: De mineralized water and Surfactants are charged into reactor at 35-40 deg C followed by Initiator and buffer solution. Raise the Temperature to 50 deg C and charge 3% of Pre Emulsion from Pre Emulsion tank. Start Heating and after attaining 78 deg C take out
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 18
the sample and check for wetting. If wetting is good continue Pre Emulsion addition for Four hours by means of metering pump.
Digestion Stage: After Pre Emulsion addition add chaser catalyst and digest for one hour at 80 deg C to remove Free Monomers if any
Additive Stage: After digestion, cool the batch to 40 deg C and add Additives such as defoamers and Preservatives. This is followed by pH adjustment using Neutralizers. After Neutralization the batch is filtered using 80 mesh Filter cloth and transfer to Emulsion Storage Tank.
Figure 3-6: Process Flow Chart – Water Based Emulsion
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 19
Table 3-2: Material Balance
S. No. Input/MT of Product
Raw Materials Quantity (MT/MT)
Product: Water Based Paint
1 Additives 0.0218
2 Biocides 0.0113
3 Driers 0.0002
4 Emulsion 0.2006
5 Extenders 0.2868
6 Pigments 0.0270
7 Liquor Ammonia 0.0018
8 Chemicals 0.0078
9 TiO2 0.0509
10 Water 0.3978
Total 1.006
Product: Powder coating paint
1. Additive 0.0180
2 Catalyst 0.0004
3 Extender 0.3698
4 Hardener 0.0056
5 Metallic Pigment 0.0002
6 Pigment 0.0826
7 Resin 0.5416
8 Wax 0.0023
Total 1.0205
Product: Emulsion
1 Additives 0.0015
2 Biocides 0.0013
3 Monomer 0.4621
4 Chemicals 0.0466
5 Liquor Ammonia 0.0082
6 De-ionized water 0.4904
Total 1.0101
S. No.
Output/MT of Product
Remark Product Liquid
Effluent Air
Emission Recovery/
Product Solid
Waste
1
Water based paints ( with traces of
biocide/fungicide as preservative)
0.0035 0.0005 1 0.002
1. Effluent after separation of solid is sent to ETP 2. Dust collected in dust collector is recycled. 3. Solid waste is sent to TSDF
2 Powder coating paints 0 0.0110 1 0.0095
1. Powder fines are collected and recycled
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2. Solid waste is sent to TSDF
3 Emulsion 0.0037 0 1 0.0064
1. Effluent sent to ETP for treatment 2. Solid waste sent to TSDF for disposal
Total 0.0072 0.0115 3 0.0179
3.0366
3.6 Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product.
The major raw materials required for manufacture of Paint include the following:
Additives
Biocides
Driers
Emulsions
Extenders
Pigments
Solvents
Miscellaneous (Water &Others)
The project shall provide all necessary aspects in design, to support safe and environment friendly handling of all hazardous chemicals.
Table 3-3: Raw Material Storage Details
S. No.
Chemical State Storage means
Size of storage means
Consumption (MT/Month)
Product: Water based paint
1. Additives Powder & liquid Bag, barrel &
Carbouy Bag: 25 kg
Barrel: 200 litrs Carbouy: 25 Litrs.
105
2 Biocides Powder & liquid Bag, barrel &
Carbouy Bag: 25 kg
Barrel: 200 litrs Carbouy: 25 Litrs.
55
3 Driers Liquid Barrel 200 Litrs 1
4 Emulsion Liquid Barrel,
Carbouy, Storage Tank
Barrel: 200 Litrs. Carbouy: 25 Litrs
Storage Tank: 30 KL 967
5 Extenders Powder Bag 25 Kg 1382
6 Pigments Solid, Liquid,Paste Bag , Carbouy Bag:25 KgCarbouy: 25 Kg 130
7 Liquor ammonia Liquid Carbouy Carbouy: 25 Litr 9
8 Chemicals Powder, Solid Bag 25 Kg 38
9 TiO2 Powder Bag 25 Kg 246
10 Water Liquid Storage Tank 60 KL 1917
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S. No.
Chemical State Storage means
Size of storage means
Consumption (MT/Month)
Product: Powder coating paint
11 Additive Solid Bag 25 kg 22
12 Catalyst Solid Bag 25 kg 0.5
13 Extender Solid Bag 25 kg 444
14 Hardner Solid Bag 25 kg 7
15 Metallic Pigment Solid Bag 25 kg 0.2
16 Pigment Solid Bag 25 kg 99
17 Resin Liquid, Solid Barrel, Bag 200 Litr, 25 Kg 650
18 Wax Solid Bag 25 kg 3
Product : Emulsion
19 Additives Powder Bag 20 kg 3.1
20 Chemicals Powder, Liquid Bag, Carbouy, Barrel
Bag- 25 kgCarbouy: 25 litr Barrel: 200 litr.
93.2
21 Monomer Liquid Storage Tank Styrene :60 KL
Other Monomers– 100 kl
924.3
22 Liquor ammonia Liquid Carbouy 25 litrs 16.3
23 De-ionised water Liquid Storage tank 60 KL 981
24 Biocides Liquid Carbouy 25 litrs. 2.5
3.7 Resource Optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined
The following hierarchy is followed for waste management with an ultimate aim of “Zero Waste”.
1. Resource Conservation 2. Elimination of Waste Streams 3. Minimizing Waste 4. Reuse of Wastes 5. Recycle of Wastes 6. Treatment and Disposal for making wastes harmless
Wash water generated from cleaning of equipments will be re-used back into the process/product.
3.8 Availability of water its source, energy/power requirement and source should be given
3.8.1 Water consumption
Water supply: borewell / tubewell from PSIEC
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Table 3-4: Water Consumption and Waste Water Generation Details
S. No. Area of Consumption Fresh Water Quantity, KLD
Waste Water Generation, KLD Treatment / Disposal
1 Processing
(including product water) 137 0
2 Washing
(Reactor and Floor) 70 63 Sent to ETP furnished with
UF/RO for treatment and treated water and permeate will be used for cooling tower and rejects will be sent to MEE for evaporation
3 Boiler 26 1
4 Cooling Tower 60 24
5 Gardening 35 0
6 Others
(Fire-fighting, etc.) 15 0
7 Domestic 27 25 Sent to STP for treatment and treated water will be used for
gardening/toilet flushing
Total 370 113
3.8.2 Fuel
The fuel consumption data is given in Table 3-5.
Table 3-5: Fuel consumption
Sr. No.
Stack Attached to Capacity Stack Nos.
Type of Fuel used
Fuel consumption
1 Boiler 300 kg/hr 1 HSD 18 kg/hr
2 Boiler 900 kg/hr 1 HSD 43 kg/hr
3 DG set 2000 KVA 1 HSD 344 kg/hr
Note: DG Sets will be used only during Power failure.
3.8.3 Power Requirement and Source
Punjab State Power Corporation Ltd ( PSPCL)will supply power. The peak power demand will be 4200 KVA. The DG set(1 nos. x 2000KVA) will be installed and will be used in case of power failure. The details are given in above Table 3-5.
3.8.4 Transportation details of Raw Materials
There shall be movement of approximately 20 trucks per day (of 9 T) for the finished goods and almost equal number of raw materials. The total movement is approximately 4680 MT/Month or 180 MT/day. This translates to 20 trucks of 9T each. And equal number will be bringing in the raw material into the plant. The loading /unloading shall mostly be done at the RM Godown and warehouse which is surrounded by loading and unloading bays of for the trucks. Additionally, a truck parking area has been provided adjacent to the warehouse. The third place where trucks shall be moving in would be the RDC (Regional distribution centre), which has its own separate entry and segregated from the main plant. Beside above, the internal movement of raw material or finished goods shall be done through Forklift.
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3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal
Table 3-6: Hazardous Waste Generation and disposal Details
S. No. Type of Waste Hazardous Waste
Category Quantity per
Year Source Method of Collection Treatment / Disposal
1 ETP sludge 34.3 50 Tons ETP TSDF Land filling
2 Used/spent oil 5.1 5 Tons DG set, Compressor, gear box PPCB approved authorized recycler Recycle
3 Oil/grease scheming residue 34.4 2 Tons ETP PPCB approved authorized
recycler Recycle
4 Process waste/residue/sludge 21.1 36 Tons Paint Manufacturing process TSDF Land filling
5 Contaminated cotton waste/liner 21.2 10 Tons Paint manufacturing process TSDF Incineration
6 Filler residue 21.2 15 Tons Paint manufacturing process
TSDF Land filling
7 Discarded
containers/Bags, barrel liners
33.3 97920 nos Paint manufacturing process PPCB approved party Sold
8 MEE Salt 34.3 34 Tons ETP
TSDF
Land filling
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4 SITE ANALYSIS
4.1 Connectivity
By Road
NH 15 is the main approach road from Amritsar to Project site. It is four lane state highway, lies at an aerial distance of 2.66 km towards S direction.
By Rail
Site is also approachable by railway. Goindwal Sahib is nearest railway station at an aerial distance of about 2.6 km towards W direction from project site. District Head Quarter Amritsar is a Major railway station, at an aerial distance of about 37.0 km towards NW direction from projects site. Amritsar is well connected with various parts of the country.
By Air
Nearest International as well as domestic airport from proposed project site is located at Amritsar, at an aerial distance of about 48 km towards NNW direction. Amritsar is well connected with daily multiple flights.
4.2 Land Form, Land Use and Land ownership
The total plot area of the proposed unit will be 1,42,179 m2. Land use of the proposed site is industrial which is given by investment Punjab to Kansai Nerolac Paints for their proposed paint manufacturing unit.
4.3 Topography (along with map)
Topographical survey of project site is shown in below figure.
Figure 4-1: Topographical survey plan of Project site
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4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.
Land use pattern: Industrial
site lies in an industrial area No Forest land is involved in the subject Project No clearance under Forest, CRZ and agriculture and Non- agriculture and water bodies are
required. Land allotment letter from Investment Punjab vide letter no.: PSIEC/ Estate/ 1214 dated
28/08/2015 and PSIEC/ Estate/ 1201 dated 25/08/2015.
Table 4-1: Distance of Project site from Water Bodies Water body Distance in km Direction
Bias river ~2 Km East
Sobraon Branch (UPPER BARI DOAB CANAL)
~4.69 Km NW direction
4.5 Existing Infrastructure
There are no existing infrastructure facilities available at project site. It has to be created for the new manufacturing plant, however, roads and electric poles are available up to doorstep of new proposed plant by Investment Punjab.
4.6 Soil classification
Saline and alkaline soils occur in the district. Soils with salt content exceeding 0.2% are considered to be high salt soils and this concentration is injurious for plant growth. Soils whose pH values exceed 9.0 have been classified as high alkali soils.The alkalinity render the soil impervious. The alkali soils present in the area has low fertility as compared to normal soils.The Soils of the district are categorized as tropical arid brown (weakly SOLONIZED),and arid brown soil (SOLONIZED).These soils are deficient in NPK. (Source:District Tarn Taran, website: http://tarntaran.gov.in/history.html#sl)
4.7 Climatic data from secondary sources
The State of Punjab has been classified into five agro-climatic zones on the basis of homogeneity, rainfall pattern, distribution, soil texture, cropping patterns etc. the project site falls under Central plain zone (Source: website: http://punjabrevenue.nic.in/for%20website/agro-climatic%20zone.htm )
Information presented in subsequent paragraphs is from the most recently published Long Term Climatological Tables for the nearest observatory, Kapurthala by the Indian Meteorological Department (IMD). A copy of the long-term climatological data is enclosed as Annexure 2.
4.7.1 Temperature
Mean daily maximum temperature is recorded in the month of June at 40.4 °C.
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January is generally the coldest month, with a mean daily minimum temperature of 5.0 °C.
During the post-monsoon month of November, daily maximum temperature remains 26.7 °C. In winters, i.e. December, January and February, mean daily maximum temperatures remain between 18.8 – 21.0 ºC.
4.7.2 Wind
Long- term wind direction data is presented in Table 4-2 and indicates that the predominant wind direction is from East during daytime whereas at evenings the prominent wind direction is from West.
Table 4-2: Predominant Wind Direction
Month
Predominant Wind
First Second Third
Morning Evening Morning Evening Morning Evening
January E W W E N N
February N W E E SE,W N
March N, W N E E SE,NW W
April E W N E SE NW
May SE W E E N SE
June SE W E SE N E
July E W S SE,S SE N
August E N, E SE SE N W
September SE W N N,E,SE E,S,NW NW
October E W N N SE E
November E W N E S N
December W W N, NE NW SE N
4.7.3 Rainfall
The total rainfall in year is observed to be 2358.2 mm. Distribution of rainfall by season is 233.6 mm in winter (December, January, February) 485.3mm in summer (March, April, May, June), 1585.8 mm in monsoons (July, August, September, October) and 53.5 mm in post-monsoon (November).
4.7.4 Cloud Cover
The area remains cloudy between May - October, which is the active period of the monsoon season. Cloud cover is 3-4.oktas during monsoon season, while it is 2-3 oktas in post monsoon, winter and summer season.
4.7.5 Humidity
Most humid conditions are found in the winter, followed by monsoons, Post Monsoon and summer in that order. Mornings are more humid than evenings and humidity ranges from a high 87 % inwinter mornings to a low of 55% in summer evenings. During monsoon season, in morning humidity is ~82% and in the evening it is ~79%.
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4.8 Social infrastructure available
Provision of additional social infrastructure such as schools, health centers, drinking water facilities, etc. is not envisaged. However, these facilities are adequately available in the Region. Where feasible and required, such infrastructure will be augmented, if required.
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5 PLANNING BRIEF
5.1 Planning Concept (type of industries, facilities, transportation etc.) Town and Country Planning/ Development authority Classification
The project execution is planned in two phases visa:
Phase-I: Commissioning of water base Paint manufacturing facility
Phase-II: Commissioning of Powder coating manufacturing facility
Phase- I execution is planned for commissioned by August, 2017. The tentative Gantt chart for the execution is as follows:
Activity Planned Completion Date
Land acquisition Oct, 2015
Completion of Environmental formalities May, 2016
Completion of Civil works 31stMarch, 2017
Plant & Machinery 31stJuly, 2017
Commissioning 31stAugust, 2017
5.2 Population Projection
Man power requirement for manufacturing facility is approx. 145 nos. (Permanent and contract basis). Most of the employment will be generated from local people from nearby villages depending upon the availability of skilled and semi-skilled people. So there may not be any permanent migration of people. Hence, there should be no population projection.
5.3 Land usePlanning (breakup alongwith greenbelt etc.)
The proposed Landuse at project site will be as given in Table 5-1.
Table 5-1: Proposed landuse at project site
S. No. Title Area, m2 % of total Area
1 Processing Area 7,750 5.45%
2 Storage Area
a Hazardous Chemicals 2056 1.45%
b Other Non-hazardous chemicals 13,568 9.54%
c Hazardous Waste 455 0.32%
d Water Storage 450 0.32%
e Fuel Storage 100 0.07%
3 Effluent Treatment Plant 1,655 1.16%
4 Boiler 375 0.26%
5 Cooling tower 400 0.28%
6 DG Sets 7,100 4.99%
7 Roads 16495 11.60%
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8 Administrative Building 4,585 3.22%
9 Open Space 13996 9.84%
10 Greenbelt Area 46920 33.00%
11 Area for proposed Expansion 26,274 18.48%
Total 142179 100%
5.4 Assessment of Infrastructure Demand (Physical and Social)
Temporary site office and stores will be provided during construction phase. Specified first-aid box with all necessary facilities will be maintained at site office. Medical facilities, primary health centers are available in nearby villages for advance medical facilities. Communication services like post office, telephone, mobiles are available in nearby villages.
5.5 Amenities/Facilities
5.5.1 Greenbelt Development
Adequate land will be available for open spaces and other non-building purposes. 33% area of total plot area will be reserved for green cover / lawn development in the proposed facility. Suitable plant species of local varieties will be planted with adequate spacing and density for their fast growth and survival shall be ensured by taking due care.
5.5.2 Fire-fighting system
The fire fighting systems have been categorised into the following types:
a) Fire Fighting systems – consisting of hydrant system, sprinkler system, foam system and water spray system.
b) Portable Fire Extinguishers c) Fire extinguishing system. d) Fire Detection and Alarm System
The hydrant system which will be provided throughout the plant may be operated to control and extinguish fires in incipient or advanced stages. Automatic sprinkler systems have been provided at locations with potential fire risks to detect and control spread of fire.
The portable fire extinguishers which shall be located all over the premises can be used for extinguishing small fires.
Sufficient number of fire hydrant valves and riser valves will be arranged to fulfill fire extinguishing need of the plant. The hydrant points are in synchronization with the number of floors. Water spray system and foam system is required for the monomer storage tanks. Apart from this, fire extinguishers will be kept at various locations inside plant and those will be hydrostatically tested and refilled at intervals as specified by statutory body.
e) ABC type – for class A,B.C type fire ( 4 kg , 6 kg) f) DCP type – for class B& C type fire ( cap:6 kg, 10 kg) g) Mechanical foam type – for Class B type fire ( 9 lts,) h) Mechanical foam trolley – for Class B type (50 lit) i) Carbon di oxide – for Class C ( cap: 4.5 kg, 6.5 kg) j) Water mist ( cap: 10 kg) for spray booth k) Cleaning agent – for server, UPS l) Fire bucket (sand) – ( cap 9 lits)
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Table 5-2: The premises/ areas where various fire protection systems will be provided are listed below:
Sr. No
Fire fighting system Area coverage
1 Fire Hydrant network Cover all area, Outside building and riser to emergency exit of the each building, Storage yard, scrap yard etc
2 Fire Extinguishers Inside buildings, storage yard, transformer area, utilities, ETP etc.
3 Water spray Packaging godown, Monomer Solvent storage,
4 Water cum foam monitor Fixed monitor from two side of monomer storage tank yard
5 Fire alarm, MCP & with hooter, siren and repeater
panel
Addressable fire alarm system covering all building. Manual call points to be provided in each entry & exit point, scrap yard, storage
tank yard, ETP, utility etc
6 Detection system ( smoke, heat & multi detector)
Smoke detectors for office building
Fire drill will be carried out by all the security guards apart from safety persons to keep them ready fortnightly. Sufficient amount of fire fighting water will always be stored in storage tank for firefighting works. In case of power failure, diesel driven fire engine pump has arranged to generate the power for emergency lighting and to run water pump.
5.5.3 Storm water management plan
Storm water drains will be provided and Storm water from the entire plot will be collected through network of storm drains. Most of storm water from plot area will be collected in the rainwater harvesting structures/recharge wells provided for better utilization of available rainwater. The excess storm water will be discharged through the storm water drainage facility provided in the industrial complex.
5.5.4 Rainwater harvesting system
The roof top rain water will be collected in the recharge through channel & storm water drain. Recharge wells of 100 to 300 mm. diameter will be constructed for recharging the deeper aquifers and water will pass through filter media to avoid choking of recharge wells. The ground charging will improve the water level in the vicinity.
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6 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (processing area)
Total Plot area is 1,42,179 m2. Out of it, approx. 7750 m2 will be processing zone.
6.2 Residential Area (non-processing area)
No residential facilities will be proposed.
6.3 Green belt
33 % of total plot area will be developed as greenbelt with three layers of tree in the periphery of the proposed Plant.
6.4 Social Infrastructure
The impacts by M/s. Kansai Nerolac Paints Ltd. will be assessed and an appropriate plan of Corporate Social Responsibility (CSR) activity will be planned. Some activities which were noted and will contribute in the social activities of nearby villages are as follows:
a) Repair and expansion of school building b) Providing study material to school children c) Repair of roads d) Tree plantation e) Free medical camp f) Free eye check-up camp g) Funds for social and cultural programs in village
6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)
6.5.1 By Road
NH 15 is the main approach road from Amritsar to Project site. It is four lane state highway, lies at an aerial distance of 2.66 km towards S direction.
6.5.2 By Rail
Site is also approachable by railway. Goindwal Sahib is nearest railway station at an aerial distance of about 2.6 km towards W direction from project site. District Head Quarter Amritsar is a Major railway station, at an aerial distance of about 37.0 km towards NW direction from projects site. Amritsar is well connected with various parts of the country.
6.5.3 By Air
Nearest International as well as domestic airport from proposed project site is located at Amritsar, at an aerial distance of about 48 km towards NNW direction. Amritsar is well connected with daily multiple flights.
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6.6 Drinking water management (source & supply of water)
Water supply: borewell / tubewell
Table 6-1: Water Consumption and Waste Water Generation Details
S. No. Area of Consumption Fresh Water
Quantity, KLD Waste Water
Generation, KLD Treatment / Disposal
1 Processing (including
product water) 137 0
2 Washing (Reactor and
Floor) 70 63 Sent to ETP furnished with
UF/RO for treatment and treated water and permeate will be used for cooling tower and rejects will be sent to MEE for evaporation
3 Boiler 26 1
4 Cooling Tower 60 24
5 Gardening 35 0
6 Others ( Fire fightingetc) 15 0
7 Domestic 27 25
Sent to STP for treatment and treated water will be used for
gardening/toilet flushing
Total 370 113
6.7 Sewage system
Domestic wastewater will be treated into STP and will be reuse after treatment for toilet flushing/gardening.
6.8 Industrial waste management
During paint manufacturing process, various effluent streams will be generated at various sources due to carry out manufacturing activities. Effluent streams will be generated from paint manufacturing process during activities such as cleaning of mixers, equipment cleaning, calibration of vessels, cleaning of barrels and containers etc. In addition to above, the utility waste water streams viz. cooling tower blow down, boiler blow down, backwash of DM plant will also be generated. There will not be any effluent generated during reaction.
The liquid effluent will be treated in full-fledged Effluent treatment plant comprised of Primary, secondary and tertiary treatment. The treated effluent will be further treated in UF/RO and the permeate will be used for cooling tower & boiler make –up. The reject will be treated in multiple effect evaporator ( MEE) . The dry salt from will be disposed off as a land filling through TSDF.
Other industrial wastes like process waste/ residue/ paint sludge will be stored in designated place in factory premises and disposed off through TSDF as a land filling. Packaging material such as bags and container free of hazardous content will be reused after washing. In case the contents of the packages are hazardous, their disposal will be done carefully through TSDF or through authorized recycler.
6.9 Solid waste management
There are two types of solid wastes generated – process wastes and non process wastes, which may or may not be hazardous in nature. There is no solid waste generation during manufacturing process itself. The waste water from manufacturing process, washings, etc will get treated in the
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effluent treatment plant and that will give rise to sludge. The other type of solid wastes generated will include the dust collected from dust collectors, empty barrels (metal and plastic), bags, sweepings and other biodegradable waste from canteen.
Solid waste of organic nature such as canteen wastes, STP sludge, sweepings etc will be composted or vermin composted for use as manure in the greenbelt and lawns. Other non hazardous waste like empty container, bags, paper/cardboard, metal , wooden waste etc will be sold to external agency.
The hazardous waste will be disposed off through TSDF as a land filling.
6.10 Power requirement & supply/ source
Punjab State Power Corporation Ltd (PSPCL) will supply power in the area. The peak demand of power is 4200 KVA. DG sets (1 nos. x 2000 KVA) will be installed as a backup arrangement.
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7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN
7.1 Policy to be adopted (central/state) in respect of the project affected persons including home oustees, land oustees and landless labourers(a brief outline to be given)
The plot is in Goindwal sahib industrial area and allotted by Punjab Small Industries & Export Corporation Ltd. Hence, this point is not applicable. However, preference will be given to local people for employment.
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8 PROJECT SCHEDULE AND COST ESTIMATE
8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given)
Construction work for the plant would start subsequent to receipt of Environmental Clearance (E.C) and Consent to Establish (CTE) from State Pollution Control Board. Tentatively, construction work is expected to start in 1st April 2016 and commissioning of the project is expected in 30th April 2017.
8.2 Estimated project cost along with analysis in terms of economic viability of the project.
Total estimated cost for proposed project is INR ~180Crore.
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9 ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.
Due to proposed project, there will be development of communication facilities in the area. In the nearby plant area, accommodation has been planned for the skilled/semi skilled employees and the managerial supervisory personnel.
The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities, health centers etc.
During operation, plant will generate direct and indirect employment. 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, loading/unloading operations etc.
From the above analysis it would be clear that the project is attractive and would bring in high value addition to the feedstock thereby benefiting the industry and the nation. Project has excellent connectivity through Road and Railway.
M/S. KANSAI NEROLAC PAINTS LIMITED
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ANNEXURE
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 39
Annexure 1: Plot Allotment Letter
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 40
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 41
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 42
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 43
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 44
M/S. KANSAI NEROLAC PAINTS LIMITED
PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN
GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 45
M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN GOINDWAL SAHIB, PUNJAB ANNEXURE
KADAM ENVIRONMENTAL CONSULTANTS | MARCH 2016 46
Annexure 2: Long-term climatological Table, Kapurthala
M/S. KANSAI NEROLAC PAINTS LIMITED PFR FOR PROPOSED INTEGRATED PAINT MANUFACTURING FACILITY IN GOINDWAL SAHIB, PUNJAB ANNEXURE
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CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-3001000; F: +91-265-3001069
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11thFloor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana, INDIA - 122002.
E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433
Kadam Environmental Consultants w w w . k a d a m e n v i r o . c o m
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