dow chemical international private...

ProposedCapacity Expansion

in Existing Emulsion PlantLocated at Plot No.L-7, SIPCOT Industrial Park(Phase-II), Mambakkam Post, Sriperumbudur,

Kanchipuram District,Tamil Nadu.

August -2017

Prepared By

Dow Chemical International Private Limited

Application for Terms of Reference

Form I &

Pre Feasibility Report

Schedule : 5(f) – Category : B

PREFEASIBILITY REPORT

1 ABC/DOW/PFR/VER2.0

1.0 INTRODUCTION

1.1 IDENTIFICATION OF PROJECT

The project proponent M/s. Dow Chemical International Private Limited, Sriperumbudur,

Chennai, is engaged in the production of Emulsion. Their existing production line includes 1)

Water Based Latex Polymer and 2) Latex Polymer Cake. The unit was established prior to EIA

Notification 2006, after obtaining Consent to Establish (Annexure - I) in August 2006. The

company was established by Rohm and Haas India Pvt. Ltd. and later merged with Dow

Chemical International Private Limited, the court order regarding merger is enclosed as

(Annexure-II).

The proponent has proposed to increase the production capacity of Water Based Latex Polymer

& Latex Polymer Cake at their factory located at SIPCOT Industrial Park (Phase– II),

Sriperumbudur. This proposal has been submitted for obtaining Environmental Clearance for

increasing the production capacity of Water Based Latex Polymer & Latex Polymer Cake.

1.2 IDENTIFICATION OF PROJECT PROPONENT

M/s. Dow Chemical International Private Limited is a fully owned subsidiary of The Dow

Chemical Company, USA and The Dow Chemical Company, commonly referred to as Dow, is

an American multinational chemical corporation headquartered in Midland, Michigan, United

States.

1.3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The unit currently manufactures two products namely

1) Water Based Latex Polymer - 40000 MT/Year

2) Latex Polymer Cake – 407 MT/Year

The proponent has planned to increase the total quantity of products manufactured at the factory

to the following quantities

1) Water Based Latex Polymer - 70000 MT/Year

2) Latex Polymer Cake – 1462 MT/year



The proposed expansion will fall under Schedule 5(f) of the EIA Notification - 2006 and

Amendments thereon. As the project site is located inside a notified industrial estate this project

falls under ‘B’ category and requires clearance from SEIAA-Tamil Nadu.

1.4 NEED FOR THE PROJECT AND IMPORTANCE TO THE NATION

DCIPL Chennai plant caters to the Emulsions (which are primarily used for water based paints)

requirements of Southern, Central and Eastern Regions of India apart from south Asian countries

and the Middle East. Export earnings of over 25 crores /year in foreign exchange are achieved

due to the operation of this plant. In order to meet the increase in demand, it is very much

essential to go for the expansion activities.

2.0 SITE ANALYSIS

2.1 LOCATION

Dow Chemical International Private Limited is located at Plot No.L-7, SIPCOT Industrial Park

(Phase– II), Ponthur A B C Village, Sriperumbudur Taluk, Kancheepuram District, Tamil Nadu.

The satellite Imagery of the site is shown Figure 2.1. The location of the project site is

represented in Figure 2.2.

Figure 2.1 Satellite image of project site



Figure 2.2 Location map of project site



2.2 CONNECTIVITY

The site is well connected by the Bangalore and Chennai National Highway (NH48) at a distance

of 1.2 km. This unit is located in the Southern direction of this road. The raw material & product

is conveniently transported by this road.

Figure 2.3 Connectivity map of project site

2.3 LANDUSE CLASSIFICATION & LANDUSE BREAKUP

Tamil Nadu Government has recognized the location of this unit as “SIPCOT Industrial Area”

and encouraging entrepreneurs to come forward for setting up industries. The area is dominated

by large scale industries and other medium scale industries.

The total plot area of the facility is 61,700 sq.m. The land use breakup of the project site is given

in Table 2.1. The topo map of the project site and its surrounding area covering 10 km radius are

given in Figures 2.4 and Environmental settings are presented in Table 2.2.



Figure 2.4 Topo map (10km around project site)



Table 2.1 Land Use Break up of Project Site

S. No Land Use Breakup Details Area (Sq.m.) 1. Process Building Area 515 2. Non-Process Building Area 3293 3. Storage Area 3600 4. Parking Area 600 5. Driveway & Pathway Area 5500

6. Future Expansion Area 1000

7. Green Belt Development Area 21500 8. Open Area ( Including lawns) 25692

Total Area 61700

Table 2.2 Environmental Settings of Project Site

S. NO. PARTICULARS DETAILS 1 Site Latitude 12°55'32.12"N 2 Site Longitude 79°54'40.24" E 3 Site Elevation 60 m

4 Nearest highway Bangalore and Chennai National Highway (NH48) – 1.2 km (N)

5 Nearest railway station Tambaram Railway Station- 22 Km [E] 6 Nearest airport Chennai International Airport - 28 km (ENE) 7 Nearest town/ city Sriperumbudur Town – 5.5 KM [NE] 8 Topography Plain 9 Archaeologically important places Nil within 10 km radius

10 National parks/ Wildlife Sanctuaries

Nil within 10 km radius

11 Reservoir Sriperumbudur Lake - 4.3 KM ( NE) Thenneri Lake - 7.1 KM (SE)

12 Reserved/ Protected Forests Vattambakkam R.F. - 8.5 km (S) 13 Seismicity Zone III 14 Defence Installations Nil within 10 km radius 15 Nearest Port Chennai Port – 45 km (NE)

2.4 SITE SUITABILITY / ALTERNATE SITES CONSIDERED

The proposed expansion will take place within the existing facility leased from SIPCOT. This

site has the following advantages:

• As the factory is currently in operation, all infrastructural facilities are already in place.

• It is an only expansion of existing operation.

Hence, no alternative sites were considered.



3.0 PROJECT DESCRIPTION

3.1 MAGNITUDE OF OPERATION

Production capacities of the products, existing and after expansion have been detailed in

Table 3.1.

Table 3.1 Production Capacity before and after expansion

Water Based Latex polymer

(MT/Year)

Latex Polymer Cake

(MT/Year)

Existing 40000 407

After expansion 70000 1462

3.2 RAW MATERIALS REQUIRED FOR PRODUCTION

Table 3.2 List of Raw Materials

Raw-Material

Name

Raw-Material

Quantity(MT/Day)

[Existing - 40000T/Year]

Raw-Material

Quantity(MT/Day) [After

Expansion - 70000T/Year]

Mode of

Transport

Butyl Acrylate 12 21 Ship

Methyl

Methacrylate 5.5 9.625 Ship

Ethyl Acrylate 1.7 2.975 Road

Vinyl Acetate 3 5.25 Road

Styrene 12 21 Road

2 Ethyl hexyl

Acrylate 5 8.75 Ship

Acrylonitrile 1 1.75 Road

Additives 2 3.5 Ship/Road

Water 77 134.75 In House



3.3 PROCESS DESCRIPTION

This plant produces a wide range of acrylic, vinyl acetate, vinyl acrylic and other water based

latex polymers. Bulk monomers stored in storage tanks and other monomers from

drums/totes are pumped in measured quantities to Emulsion feed tank and water and

additives are added to disperse the monomer to form monomer emulsion using gentle

agitation. The reactor is cleaned and hot RO water is added to preset quantity along with

other additives. The preset quantity of monomer emulsion and additives from feed tank

(catalyst) are added to the reactor in a controlled manner so as to maintain the temperature

80-95.C by means of external cooling water circulation in the reactor. The polymerization of

monomers to desired product is completed with the final reactor level. The product emulsion

is transferred to drain the tank and final cooling and other additives addition effected to adjust

desired parameters in the product like pH, viscosity etc. The product after quality testing is

transferred to product storage tanks. The product from the storage tank is also packed in

drums/totes as per the requirement and mainly transported in tankers to customers.

The reaction has following steps:

1. Initiation

2. Propagation

3. Termination

1) INITIATION: Under the influence of heat and/or chemical activators, the persulphate

bond breaks, giving a free radical. The radical then attacks the double bond of the monomer.

R-O-O-R 2 R-O

2) PROPAGATION: The radial reacts with one of the carbon atoms of the monomer with a

double bond. This leaves the second carbon with a free radical at other end to react with

another monomer unit.

R-O + M R-O-M

R-O-M + nM R-O-M-(M)n

3) TERMINATION: The reaction ends when two propagating units join, or when a radical

reacts with the propagating chain.

Coupling

R-O-(M)n + (M)m-O-R R-O-(M)m + n-O-R



These latex products are a mixture of polymers are used in applications for Textile

processing, Water based Latex Coatings, Paper Coatings, etc., as a low VOC replacement for

solvent based polymers. The special features of our Latex Polymers are an improvement of

properties of many of the products made in India. This makes these products more cost and

quality competitive in both domestic and international markets.

Figure 3.1 Process Flow Chart [Existing – 40000 MT/Year]



Figure 3.2 Process Flow Chart [After Expansion – 70000 MT/Year]



3.4 MATERIAL BALANCE CHART [EXISTING – 40000 MT/YEAR]



MATERIAL BALANCE CHART [AFTER EXPANSION – 70000 MT/YEAR]

Basis: Per Day

3.5 INFRASTRUCTURE REQUIREMENTS

A. PROCESS EQUIPMENTS:

i. Monomer Storage Tanks:

These are the tanks where the monomers will be stored. They will be transferred from

conventional road tankers or iso containers. Monomer Unloading will be done with vapour

return to the truck to eliminate emissions and odour during operations.

ii. Additive Tanks:

Various additive solutions, catalyst, activator solutions are made in these tanks in cold water.

There is no reaction or heat generation in these vessels.

iii. Monomer Emulsion Tanks:



These are the tanks where monomer emulsion is prepared. Water is initially charged from

storage tank surfactants are charged to these tanks. Monomers are charged through a mass

meter from the monomer storage tanks. The contents are mixed until a stable mixture is

formed.

iv. Reactor:

The reaction is carried out in the reactor. A charge of water is initially added to the reactor. A

proportion of monomer emulsion is then transferred to the reactor from the monomer

emulsion tanks Catalyst, the activator is added from the additive tanks. The reaction

commences with some exotherm immediately the monomer emulsion, catalyst activator

solution feed is started and continued over the time prescribed in the Standard Operating

Procedure. The reaction is considered complete once the feeds are completed. The Heart of

reaction is removed from the reactor with cooling water running on limper coil of the reactor.

v. Drain Tank:

This is the vessel where the processing is finished. Once the reaction is completed in the

reactor the batch is transferred to the blend tank. Additives are added to this tank. Biocides

are added to the product in this vessel. Samples are taken from this vessel and analyzed.

Cooling is applied with cooling water in the limper coil of the vessel. For proposed

expansion activity, one additional drain tank will be installed.

vi. Latex Cake Separation:

The latex wash water from the process is collected and is coagulated in coagulation pits. The

Latex cake thus generated is separated in a separation process using filter press and the

separated water is sent to the effluent treatment plant. The latex cake is packed into

containers.

B. UTILITIES AND OTHERS

1. Boiler / Cooling Tower

2. Effluent Treatment Plant

3. Empty Raw Material container handling area

4. Electric Sub Station

5. MCC Room

6. R.O. Units ( Raw water and Recycle)

7. Fire Water Area

8. Administration Building & Security Area



Table 3.3 List of Equipments

S. No Description Capacity

40000 MT/Annum (Existing)

70000 MT/ Annum (Future)

1 Storage tanks for Monomers 3 No change 2 Transfer Pumps 6 No change

3 Reactor feed tanks with agitator

2 No change

4 Additives tanks with agitator 6 No change

5 Additives Pumps 6 No change

6 Heat exchangers & pumps (lot)

4 6

7 Reactor with agitator 1 No change 8 Drain tank with agitator 1 2

9 DCS and Instrumentation(lot)

1 No change

10 Scrubber system-lot 1 No change

11 Product storage tanks 6 No change

12 Drumming Tank 1 No change

13 Cooling Tower /Pumps 1 No change

14 Water Storages/pumps 2 No change

15 RO Water system 2 3 16 Waste RO System 1 No change

15 Fire water storage/pumps 1 No change

16 Air compressor 2 No change

17 Air Receivers 2 No change

18 Boiler/stack 1 No change

19 ETP system- lot 1 No change

20 Triple effect Evaporator system

1 No change



Figure 3.3 Site layout



3.5.1 MANPOWER

The existing manpower is of about 31 Nos. Additionally, 3 Nos. will be deployed for the

expansion activity. After expansion, the totaling manpower will be 34 Nos. Currently 85

contract labours are working, additionally, 15 contract labours will be employed for the

expansion activity.

3.5.2 POWER

The Power requirement is 900 KVA sourced through TANGEDCO. DG set details are given

below. For the expansion activity, no additional power will be required.

Table 3.4 Details of DG sets

SL.NO. Equipment Capacity (KVA)

1 DG Set - 1 320

2 DG Set - 2 500

3.5.3 WATER REQUIREMENT

The unit proposes to consume 236 KLD of Fresh water. The entire quantity of raw water will

be supplied by SIPCOT. Water balance table for the operation of the existing & proposed

plant is as follows.

Table 3.5 Water Balance

S. NO. PARTICULARS

WATER REQUIREMENT (KLD)

EXISTING AFTER EXPANSION

1 Process 77 218 2 Cleaning & Vessel Washing 79 105 3 Cooling 64 112 4 Domestic 10 16

ACTUAL REQUIREMENT 235 451 FRESH WATER REQUIREMENT 114 236 COMBINED TREATED EFFLUENT I (ETP WITH RO) 101 173.5

COMBINED TREATED EFFLUENT II (MEE CONDENSATE) 20 41.5

TOTAL WATER REQUIREMENT 235 451



Figure 3.4 Water balance chart (After Expansion)



Initiatives for water reduction:

• The plant had implemented a scheme for source reduction of water coming from

washings by articulating a recycle scheme. The washings containing product are

collected hygienically directly from vessels and recycled appropriately to respective

products resulting in savings in water and reducing the load on effluent treatment

thereby accruing water, energy and treatment chemicals savings.

• The plant uses a cooling Air Handling unit for circulating temperature controlled air

to control room, Cold Storage room, panel room and in laboratories to keep a near

sterile atmosphere and pressurization. The cooling condensate water which was going

to drain is now collected in a tank and recycled to boiler feed after ensuring the

quality through checks.

• Steam is used to heat the water for direct use in the process in a heat exchanger and

the condensate is now collected and pumped back to boiler feed.

• The plant is having a zero discharge and is successfully recycling the entire water

back to plant use since inception.

• The plant has a rain water collection pit (1000 KL) and the water collected is tested

and put back into the water system. This collection pit is also connected to storm

drains from various locations.

• A close control is kept and a task force from the plant team is working on many

schemes on internal water recycles which will be implemented in due course.



3.5.4 POLLUTION CONTROL MEASURES

3.5.4.1 AIR (EMISSIONS)

For existing plant, the following measures are taken up for control of gaseous emissions:

• The existing emission sources i.e., Polymer plant, Boiler, D.G sets are designed with

adequate stack heights and air pollution control measures to meet the standards set by the

TNPCB / CPCB.

Table 3.6 Details of air pollution control measures

S. No. Stack No Source Contro1

Measures Top

dimension

Height above

GL

Material of Construction

Exit Gas

Velocity (m/s)

Exit Gas

Temp

Max Discharge

(Cubic meter/min)

1. 1

Stack Attached to

Polymer Plant

Wet scrubber with a stack

0.4 35 Mild Steel 21.4 40 453

2. 2 Stack Attached

to Boiler 2 tons/hr capacity

Stack 0.3 45 Mild Steel & Stainless Steel 6.6 135 2090

3. 3 Stack Attached

to DG Set 320KVA

Stack 0.15 16 Mild Steel 7.2 170 850

4. 4 Stack Attached to DG Set 500

KVA Stack 0.15 16 Mild Steel 7.8 170 1090

The proposed air emissions generated from the above process will be treated in the existing

Air Pollution Control (APCS) System. The adequacy of the existing APC is sufficient for the

proposed activities

3.5.4.2 POSSIBLE FUGITIVE EMISSION SOURCES:

- Chemical storages

- Chemical transfer/charging from drums

- Process reactor vent

- Laboratory testing

Fugitive emissions control Measures:

• All monomer storage tanks are equipped with breather valves and intake and transfer

are in closed system adhering to highest safety standards.



• For all chemicals charging through drums or other chemical containers chemical

charging booths connected to a caustic scrubber. VOC is monitored continuously in

the area and hooked up to Tamil Nadu Pollution control board Control room.

• Local exhaust ventilation system has been provided for chemicals/ powders

transferring to control fugitive emissions.

• The main Reactor equipped with a condenser for vapors and pressure relief system to

prevent any emissions from the process. Also, intermediate vessels handling raw

materials are equipped with breather valves (VPRV) to prevent emissions.

• In laboratories, lab hoods have been provided for all chemical analysis.

• Performance and face velocities for all LEVs, charging booths and lab hood is

periodically monitored.

3.5.5 WASTE GENERATION

3.5.5.1 WASTE WATER GENERATION DETAILS & MANAGEMENT

S. No. Particulars Water Generated

(KLD) Existing After Expansion

1. Process Effluent 79 138 2. Sewage 8.0 12.8

3. Utilities a. Boiler Blow down 2 3.0 b. Cooling tower bleed 13.0 19.8

These are three waste water streams generated namely, Process, Utility and Sewage

streams. These streams are collected separately and fed into the Effluent treatment plant

appropriately. The treated effluent is further processed in Reverse Osmosis plant.

The permeate from the R.O plant will be recycled and rejection will be evaporated by the

Mechanical Evaporator and Solar Evaporation Pan. The current effluent treatment

system is sufficient enough to handle the expansion activities.



3.5.5.2 SOLID WASTE (HAZARDOUS & NON-HAZARDOUS WASTES)

The solid waste generated from existing & proposed expansion is as follows: Hazardous Waste Generation

S.N

Name of Process Waste(Category No)

Quantity Waste Type Waste

Storage Waste Disposal Source of

generation of waste

Physical status Existing After

Expansion

1 5.1-Used or spent oil 2 T/Annum

3.5 T /Annum Recyclable MS Drums Recovery and Reuse- Authorized recyclers

Pump Seal Oil

Transformer Oil

Oily

2

20.1-Contaminated aromatic, aliphatic or

naphthenic solvents may or may not be fit for

reuse

40 T/Annum

70 T /Annum Incinerable MS Drums

Incineration- TSDF,

Gummidipoondi

Expired Raw Materials Liquid

3

33,1-Empty barrels/containers/liners

contaminated with hazardous

chemicals /wastes

250 T/Annum

437.5 T /Annum Recyclable

Concrete Surface with Impervious

Layer

Recovery and Reuse- Authorized recyclers

Empty Raw material

Drums Solid

4

33,1-Empty barrels/containers/liners

contaminated with hazardous

chemicals /wastes

2 T/Annum

3.5 T /Annum Incinerable MS Drums Incineration-

TSDF, Gummidipoondi

Bag liners which are

contaminated with

chemical powders

Solid

5 35.3-Chemical sludge from

waste water treatment

1 T/Annum

1.75 T /Annum Landfillable Plastic Drums Common Landfill-

TSDF, Gummidipoondi

Effluent Treatment

Plant sludge Solid

6 35.3-Chemical sludge from

waste water treatment

1 T/Annum

1.75 T /Annum Landfillable Plastic Drums Common Landfill-

TSDF, Gummidipoondi

ETP - Evaporator

Residue Solid



Non Hazardous Waste Generation

Description of Non- Hazardous Waste

Qty of waste Generated (Kgs)

(Existing)

Qty of Waste Generated (kgs)

(After Expansion)

Discharged from

Accumulated Qty. (Kgs)

Disposal Method

Equipment/ facility used

Wooden & Card board / Paper scraps

1,000 1800 Logistics & office

Nil Recycled Approved Vendor

Metal scraps 930 1700 - Nil Recycled Approved

vendor



3.6 RAINWATER HARVESTING & STORMWATER MANAGEMENT

The existing rainwater collection system & storm water management will be continued

effectively.

o Storm water drains have been provided along the factory to ensure that this is

totally separated from process effluent. This will minimize runoff of the

contaminated water to the land surrounding the site.

o Runoff from roof top area is collected by means of down take pipes and diverted

to rain water collection pit (1000 KL), the water collected is tested for its quality

and reused accordingly.

o The surface runoff is diverted to the channel provided along the site boundary and

discharged in the external storm water drain.

3.7 FUEL REQUIREMENT

S. No Name of fuel points of use Quantity (T/d)

Existing proposed

1 Diesel Diesel Generators 0.250 0.437

2 Furnace Oil Boiler Fuel 0.7 1.2

3 GREENBELT DEVELOPMENT

Well-developed greenbelt totaling 35% of plot area is maintained. This will be further

strengthened during the expansion activity.

4 ENVIRONMENTAL MANAGEMENT PLAN

Table 5.1 EMP budget

S. No. Infrastructure Capital cost* ( lakhs)

Recurring cost (Lakhs)

1. Air Pollution Control 100 5

2. Effluent Treatment Plant (ETP) & Rain water harvesting measures

350 15

3. Environment Monitoring and

Management 20 2

4. Solid and Hazardous Waste

Management 15 5

5. Occupational Health & Safety 25 7.5 6. Green belt Development 20 5

Total 530 39.5 * Existing and no changes for proposed



5 PROJECT COST & IMPLEMENTATION SCHEDULE

The cost for the proposed expansion is estimated at 6 Crores. After obtaining Environmental

Clearance (EC) and Consent to Establish for the proposed expansion, construction activity

will be commenced.

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