APRIL 2016 - environmentclearance.nic.in · m/s. kansai nerolac paints limited paints & resins...

M/s. KANSAI NEROLAC PAINTS LIMITED

Prefeasibility Report for Paints & Resins Manufacturing Plant at Plot No. C/385 & C/386, Saykha Industrial Estate, Vagra Taluka, Bharuch District

APRIL 2016

Kadam Environmental Consultants

w w w . ka d am en v i r o . c o m

Env ironm ent for Deve lop ment

M/S. KANSAI NEROLAC PAINTS

LIMITED

PAINTS & RESINS MANUFACTURING

PLANT AT SAYKHA INDUSTRIAL

ESTATE QUALITY SHEET

KADAM ENVIRONMENTAL CONSULTANTS | APRIL 2016 2

M/S. KANSAI NEROLAC PAINTS LIMITED

Prefeasibility Report for Paints & Resins Manufacturing Plant at Plot No. C/385 & C/386, Saykha Industrial Estate, Vagra Taluka, Bharuch District © Kadam Environmental Consultants (‘Kadam’), April 2016

This report is released for the use of the Kansai Nerolac 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 Paints & Resins Manufacturing Plant at Plot No. C/385 &

C/386, Saykha Industrial Estate, Vagra Taluka, Bharuch District

Project Number 1521362322 Report No. 1 Version 1 Released April 2016

Prepared &

Managed By

Bijal Kothari & Jitixa

Upadhyay 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.


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ESTATE CONTENTS


CONTENTS

1 EXECUTIVE SUMMARY .......................................................................... 7

1.1 INTRODUCTION ................................................................................... 7

1.2 PROPOSED PLANT FEATURES AND PRODUCTION CAPACITY ........................................ 7

1.3 WATER ............................................................................................ 8

1.4 EFFLUENT GENERATION, TREATMENT AND DISPOSAL .............................................. 8

1.5 POWER REQUIREMENT ............................................................................ 8

1.6 AIR EMISSIONS ................................................................................... 8

1.6.1 Flue Gas Stacks ........................................................................... 8

1.6.2 Process Vents .............................................................................. 9

1.7 SOLID/HAZARDOUS WASTE GENERATION AND DISPOSAL .......................................... 9

2 INTRODUCTION ................................................................................ 10

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ........................................ 10

2.1.1 Identification of Project Proponent ................................................... 10

2.1.2 Identification of Proposed Project .................................................... 11

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ............................................... 11

2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION ...................................... 11

2.4 DEMAND SUPPLY GAP ........................................................................... 12

2.4.1 Global Market ............................................................................ 12

2.5 IMPORT VS. INDIGENOUS PRODUCTION ......................................................... 12

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ..................... 12

3 PROJECT DESCRIPTION ...................................................................... 13

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS,IF ANY ............ 13

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT LAY OUT) WITH COORDINATES ................................................................. 13

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ........... 16

3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................ 16

3.5 TECHNOLOGY AND PROCESS DESCRIPTION ...................................................... 16

3.6 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE

BRIEFLY OUTLINED ...................................................................................... 26

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN

26

3.7.1 Water consumption ..................................................................... 26

3.7.2 Fuel ....................................................................................... 27

3.7.3 Power Requirement and Source ....................................................... 27

3.7.4 Transportation details of Raw Materials .............................................. 27

3.8 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT

/DISPOSAL .............................................................................................. 28

4 SITE ANALYSIS ................................................................................. 29

4.1 CONNECTIVITY .................................................................................. 29

By Road ............................................................................................ 29


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ESTATE CONTENTS


By Rail .............................................................................................. 29

By Air ............................................................................................... 29

By Water ........................................................................................... 29

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................. 29

4.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................... 29

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. ............................................................. 29

4.5 EXISTING INFRASTRUCTURE ..................................................................... 30

4.6 SOIL CLASSIFICATION ........................................................................... 30

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ..................................................... 30

4.7.1 Temperature ............................................................................. 30

4.7.2 Wind ...................................................................................... 30

4.7.3 Rainfall ................................................................................... 31

4.7.4 Cloud Cover .............................................................................. 31

4.7.5 Humidity ................................................................................. 31

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ............................................................ 31

5 PLANNING BRIEF .............................................................................. 32

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC.) TOWN AND

COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION ...................................... 32

5.2 POPULATION PROJECTION ....................................................................... 32

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREENBELT ETC.) ................................. 32

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ........................... 33

5.5 AMENITIES/FACILITIES .......................................................................... 33

5.5.1 Greenbelt Development ................................................................ 33

5.5.2 Fire-fighting system..................................................................... 33

5.5.3 Storm water management plan ....................................................... 34

5.5.4 Rainwater harvesting system .......................................................... 34

6 PROPOSED INFRASTRUCTURE ............................................................. 35

6.1 INDUSTRIAL AREA (PROCESSING AREA) .......................................................... 35

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ................................................... 35

6.3 GREEN BELT ..................................................................................... 35

6.4 SOCIAL INFRASTRUCTURE ....................................................................... 35

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ....... 35

6.5.1 By Road .................................................................................. 35

6.5.2 By Rail .................................................................................... 35

6.5.3 By Air ..................................................................................... 35

6.5.4 By Water ................................................................................. 36

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ................................ 36

6.7 SEWAGE SYSTEM ................................................................................ 36

6.8 INDUSTRIAL WASTE MANAGEMENT ............................................................... 36

6.9 SOLID WASTE MANAGEMENT ..................................................................... 36

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE .................................................... 36


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ESTATE CONTENTS


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN .............................. 37

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) . 37

8 PROJECT SCHEDULE AND COST ESTIMATE ............................................. 38

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR

THE PROJECT TO BE GIVEN) ............................................................................. 38

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT. ............................................................................................... 38

9 ANALYSIS OF PROPOSAL..................................................................... 39

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. .................................................. 39


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ESTATE CONTENTS


List of Tables Table 1-1: Production Details ........................................................................................................ 8

Table 2-1: Production Details ...................................................................................................... 11

Table 3-1: Production details ...................................................................................................... 16

Table 3-2: Raw Material Storage Details...................................................................................... 17

Table 3-3: Water Consumption Details ........................................................................................ 26

Table 3-4: Waste Water Generation Details ................................................................................. 26

Table 3-5: Fuel consumption ...................................................................................................... 27

Table 3-6: Hazardous Waste Generation and disposal Details ...................................................... 28

Table 4-1: Distance of Project site from Water Bodies ................................................................. 30

Table 4-2: Predominant Wind Direction ....................................................................................... 31

Table 5-1: Proposed landuse at project site ................................................................................ 32

Table 5-1: The premises/ areas where various fire protection systems will be provided are listed

below: ........................................................................................................................................ 34

List of Figures Figure 3-1: Site Location Map ..................................................................................................... 14

Figure 3-2: Project site Boundary with Coordinates ..................................................................... 15


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ESTATE EXECUTIVE SUMMARY


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 (formerly known as Goodlass 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 98 depots & 4 RDC 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 Proposed Plant Features and Production Capacity

The project execution is planned in two phases visa:, Phase-I: Commissioning of Non EC product -

Paint & Thinner manufacturing facility, Phase-II: Commissioning of Resin manufacturing facility.

The estimated cost of the proposed project is INR 350 Crores (including working capital). The Total

Production capacity is given in Table 1-1.


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Table 1-1: Production Details

S. No. Name of the Product Production Capacity,

MT/Annum

A EC Products

1 Resin 40080

B Non EC Products (NOC Received)

1 Paint and varnish, Enamels, Lacquer 68280

2 Thinner 18000

Total B 86280

Total Production (A + B) 126360

1.3 Water

Total fresh water demand for the Non-EC products manufacturing facility is 375 KLD and will be

increased up to 750 KLD after the proposed expansion. Water demand will be entirely fulfilled

through piped water supply from GIDC, Gujarat, which in turn sources water from the River

Narmada.

1.4 Effluent Generation, Treatment and Disposal

The total quantity of wastewater generated from the Non-EC products manufacturing facility will be

100 KLD. Out of this, 35 KLD will be domestic waste water which will be sent to STP for treatment

and treated water will be used for gardening/toilet flushing. Further, 65 KLD industrial waste water

will be generated from the process and utilities will be sent to ETP furnished with UF/RO for

treatment and treated water (permeate) will be used for cooling tower and rejects will be sent to

MEE for evaporation. From proposed plant 15 KLD domestic waste water and 75 KLD industrial

effluent will be increased and will follow the same treatment and disposal mode as existing.

The proposed plant is designed on “Zero Liquid Discharge” basis with capability to prevent discharge

of effluent outside the premises using thermal destruction technique (namely MEE).

1.5 Power Requirement

The total estimated power requirement of the plant will be around 5000 KVA. This power

requirement will be fulfilled through the grid supply of Dakshin Gujarat Vij Company Limited

(DGVCL), the local power utility. There will be 2 nos. of DG sets (2000 KVA) for Non EC products.

For proposed EC products one DG Set of 400 KVA and two Gas Gen Set of 1400 KVA will be required.

DG sets will be operated only during power failure.

1.6 Air Emissions

1.6.1 Flue Gas Stacks

There will be 4 flue gas stacks for Non-EC products manufacturing facility and additional 10 flue gas

stacks will be there for proposed expansion as follows:

Three stacks will be attached to the Boiler.

Three stacks will be attached to each of the DG sets.

Two stacks will be attached to Gas Gen Set.


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Four stacks will be attached to Thermic Fluid Heaters

One attached to Incinerator

Adequate stack height will be provided to all flue stacks, based preferably on the Environment

Protection Rules, or in the absence of specific guidance in regulations, good engineering practice.

1.6.2 Process Vents

There will be various process vents as follows:

One at outlet of scrubber system

Sixteen at outlet of Fume Extraction System

Twenty attached to Reactors

18 attached to Mixers and

6 attached to Pre-mixers

1.7 Solid/Hazardous Waste Generation and Disposal

Both Municipal Solid Wastes (MSW) and Hazardous Wastes gets generated at the proposed facility.

No residential facility is planned within the project site and consequently MSW will be mainly from

offices and canteens.

Hazardous wastes like Process wastes, residues and sludge, Fillers Residues, Distillation Residue,

Spent Organic Solvent, Used / spent oil, Discarded containers/ barrels, ETP Sludge, Contaminated

cotton waste/liners, MEE Salt, Oil/grease scheming residue and Incinerator ash gets generated

during the production. These will be managed as per the Hazardous Wastes (Management,

Transport and Transboundary) Rules 2008 as amended till date and will be disposed off as detailed

in Table 3-6.


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ESTATE INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project and Project Proponent

Kansai Nerolac Paints Limited (formerly known as Goodlass Nerolac Paints Ltd) (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 98 depots & RDC 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.

2.1.1 Identification of Project Proponent

KNPL will set up integrated paint manufacturing with zero liquid discharge facility at Saykha

Industrial estate, Bharuch in two phases, Resin manufacturing with a total capacity of 40080 MTA

will be set up. The cost of the total project is 420 crores which include 7.35 crores for environmental

protection measures i.e. 1.75% 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.


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ESTATE INTRODUCTION


2.1.2 Identification of Proposed Project

The proposed project is expansion project. In which NOC received for non EC products i.e. Paints

and Varnish, Enamels, Lacquer and Thinner. The estimated cost of the proposed project is ~ INR

420 Crores. The Total Production capacity is given in Table 2-1.

Table 2-1: Production Details


MT/Annum

A EC Products

1 Resin 40080



2 Thinner 18000

Total B 86280


2.2 Brief Description of nature of the Project

The Kansai Nerolac Paints Ltd, intend to set up integrated paint manufacturing facility in Saykha

industrial Estate. The project site is located in an industrial area identified by the “allotment order

for plots” issued by the Gujarat Industrial Development Corporation. The said allotment is in the

Saykha 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 will be 40080 MT/month. The estimated cost of the entire project is Rs. 420 crores

approximately for the phase – I & II, which will be borne out of internal accruals.

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 demand in auto sector and performance coating in western and

northern part of India has resulted into increased demand for automotive and industrial paints.

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 western India esp. the

states of Gujarat, Madhypradesh and Rajasthan. Moreover, leading car automobile manufacturers

are setting up their manufacturing facilities in State of Gujarat. Being a sole/primary supplier they

are also demanding to set up KNPL’s manufacturing facility in Gujarat.

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. The site offers the advantage from the

supply-chain point of view as many of the raw materials esp. extenders used in the paints are

available in Gujarat & Rajasthan. Also the product shall be marketed in & nearby states. Proximity

to the national highway (Delhi Mumbai Industrial Corridor) shall provide easy access to the target

destinations for the product. Skilled labor (ITI trained) and Supervisory staff shall be sourced from

nearby areas.


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ESTATE INTRODUCTION


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. Industrial paints have evolved dynamically over the past decade. India has witnessed an

increase in investment in industrial sector. In order to cater to its growth rates; KNP is looking to

expand the current manufacturing capacities by setting up a Greenfield plant in Gujarat. This is

imperative to cater to the demand for automotive industries and performance coating in the state

of Gujarat, and nearby areas.

In India 30% accounts for the industrial paint segment in paint Industry while the decorative paint

segment accounts for 70 % of paints sold in India. 30% to the paint industry revenue in India is

accumulated from Industrial Paints.

2.4.1 Global Market

All paints will be supplied in domestic market to meet the demand.

2.5 Import vs. Indigenous Production

Major Raw Materials as required for paint like TiO2, Talc, Calcium carbonate etc are available in

Rajasthan. Solvents are also available in Gujarat and nearby State. However few special chemical

will be imported for paint manufacturing

Export Possibility

The export possibility is not envisaged. The product will meet the domestic requirement.

2.6 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. The selection will be through

written exams & personal interviews and mostly through campus recruitments and on the guidelines

provided by our principals, M/S Kansai Paint, Japan, who will have the final say on all appointments.

For operating at the full capacity KNPL will require approximately 165 operators & 120 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 labour laws.

In addition about 145 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.


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ESTATE PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects,if any

The proposed project is solvent based paint and thinner manufacturing facility covering area of

about 153138 m2 situated at Plot No C-385 & C-386, of Saykha Village, Vagra Taluka, Bharuch

District. Plant will have total Paint and varnish, Enamels, Lacquer Capacity: 68280 TPA, Thinner

Production Capacity: 18000 TPA and Resin: 40080 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: Gujarat

District: Bharuch

Tehsil / Taluk / Mandal: Vagra

Village: Saykha

Project site location map is shown as Figure 3-1. The project site boundary with coordinates is

shown in Figure 3-2.

M/S. KANSAI NEROLAC PAINTS LIMITED PAINTS & RESINS MANUFACTURING PLANT AT SAYKHA

INDUSTRIAL ESTATE PROJECT DESCRIPTION


Figure 3-1: Site Location Map




Figure 3-2: Project site Boundary with Coordinates

Point Latitude Longitude Point Latitude Longitude

A 21°47'57.69"N 72°53'34.96"E D 21°48'14.67"N 72°53'51.59"E

B 21°47'59.66"N 72°53'46.93"E E 21°48'22.12"N 72°53'41.71"E

C 21°48'12.82"N 72°53'43.55"E F 21°48'19.45"N 72°53'31.63"E


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3.3 Details of alternate sites considered and the basis of selecting the

proposed site, particularly the environmental considerations gone into

should be highlighted

Before zeroing down on the site at Saykha, the company went through the process of evaluating

sites in the state of Gujarat and Rajasthan as their focus area was towards western India. The

Locations like Vithlapur (Gujarat), Bhiwadi, Nimrana (Rajasthan) all are private land were initially

evaluated. The initially Vithlapur was shortlisted. The plot is private land and multiple owners which

lead to delay in acquisition of land and hence rejected.

The site at Saykha has been selected due to following reasons –

1. A develop township Bahruch is within 30 km of the site

2. Plot provided by GIDC meant for chemical industry with all infrastructure facility for

industrial set up

3. Assurance of availability of water and power.

4. It is also close proximity of National highway – Delhi Mumbai Industrial Corridor.

5. Easy availability of trained manpower

6. Proximity to our customer in Gujarat, Rajasthan & Madhypradesh

3.4 Size or Magnitude of Operation

Product details and production capacities are given in Table 3-1 .

Table 3-1: Production details


MT/Annum

A EC Products

1 Resin 40080



2 Thinner 18000

Total B 86280


3.5 Technology and Process Description

Technology and Manufacturing Process description is given in Form 1 with TOR, Annexure 6.




Table 3-2: Raw Material Storage Details

S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press

(Kg/cm2) Temp. (°C)

EC Products

1 Iso Pthalic acid Solid 12.24 Fibre drums atmospheric ambient 41 25 kg 1.2 MT

2 Bezoic acid Solid 129.30 bag atmospheric ambient 431 25 kg 11 MT

3 Maleic Anhydride Solid 3.75 bag atmospheric ambient 13 25 kg 0.5 MT

4 Phthalic Anhydride solid 1682.63 bag atmospheric ambient 5610 25 kg 140 MT

5 Pentaerythritol Powder 196.12 bag atmospheric ambient 654 25 kg 17 MT

6 Trymethylol propane Solid 319.49 bag atmospheric <25 1065 25 kg 27 MT

7 Neopentyl glycol Solid 336.67 bag atmospheric ambient 1122 25 kg 28 MT

8 1 6 Hexanediol Liquid 101.20 Barrel atmospheric ambient 42 200 Litr. 9 MT

9 Bisphenol A solid 761.96 Bag atmospheric ambient 2540 25 kg 64 MT

10 Paraformaldehyde solid 1056.26 bag atmospheric ambient 3521 25 kg 90 MT

11 Melamine crystals Powder 818.46 Fibre drum atmospheric ambient 2728 25 kg 69 MT

12 Adipic acid Solid 196.03 bag atmospheric <25 653 25 kg 17 MT

13 Hexa hydro phthalic

anhydride Liquid 275.94 Barrel atmospheric ambient 115 200 Kg 23 MT

14 AIBN (azo-bis iso-

butyronitrile) ind. powder 222.61 Fiber drum atmospheric 15-20 742 25 kg 19 MT

15 Benzoyl peroxide solid 19.37 Fiber drum atmospheric <40 65 25 kg 2 MT

16 Methyl ethyl ketoxime/mek

oxime (aska) Liquid 186.23 Barrel atmospheric ambient 78 200 Litr. 16 MT

17 Placcel m (Capralactone) Liquid 143.45 Barrel atmospheric ambient 60 200 Litr. 12 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


18 Mono ethanol amine Liquid 55.45 barrel atmospheric ambient 23 200 Litr. 5 MT

19 Diethanol amine Liquid 227.19 barrel atmospheric ambient 95 200 Litr. 20 MT

20 Alkali refined linseed oil Liquid 62.86 Storage Tank atmospheric ambient 1 30 KL 30 KL

21 Dehydrated castor oil/

commercial castoroil Liquid 191.5 Storage tank atmospheric ambient 1 30 KL 30 KL

22 Refined Soyabean oil

(indl.grade) Liquid 1038.67 Storage Tank atmospheric ambient 1 60 KL 60 KL

23 Refined coconut oil Liquid 116.02 Storage Tank atmospheric ambient 1 30 KL 30 KL

24 Cardura e 10 p Liquid 53.54 Barrel atmospheric ambient 12 200 Ltr. 5 MT

25 D C O Fatty acid Liquid 27.95 Barrel atmospheric ambient 12 200 Ltr. 3 MT

26 Soya Fatty acid Waxy solid 31.84 Drum atmospheric ambient 27 50 Kg 2.6 MT

27 Castor oil fatty acid Liquid 26.52 Barrel atmospheric ambient 11 200 Ltr. 2.2 MT

28 Mineral turpentine oil Liquid 693.65 Storage Tank atmospheric ambient 1 100 KL 100 KL

29 Dist. C IX Solvent Liquid 1653.75 Storage Tank atmospheric ambient 1 100 KL 100 KL

30 Toluene Liquid 204.82 Storage Tank atmospheric ambient 1 50 KL 50 KL

31 Mixed Xylene Liquid 5056.97 Storage tank atmospheric ambient 1 150 KL 150 KL

32 Methanol Liquid 182.60 Storage tank atmospheric ambient 1 50 KL 50 KL

33 Butanol Liquid 2259.14 Storage tank atmospheric ambient 1 100 KL 100 KL

34 Octonal (2 ethyl hexanol) Liquid 32.29 Barrel atmospheric ambient 13 200 Ltr. 3 MT

35 Butyl cellosolve Liquid 768.45 Storage Tank atmospheric ambient 1 50 KL 50 KL

36 Ethyl acetate Liquid 5.84 Storage Tank atmospheric ambient 1 50 KL 50 KL




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


37 Butyl acetate Liquid 901.87 Storage Tank atmospheric ambient 1 50 KL 50KL

38 Cellosolve acetate (hiso solve

acetate) Liquid 87.39 Storage Tank atmospheric ambient 1 50 KL 50 KL

39 Methyl ethyl ketone (MEK) Liquid 51.45 Barrel atmospheric ambient 21 200 Litr. 14 KL

40 Methyl iso butyl ketone

(MIBK) Liquid 984.85 Storage Tank atmospheric ambient 1 50 KL 50 KL

41 Iso butanol Liquid 290.03 Storage Tank atmospheric ambient 1 50 KL 50 KL

42 Dowanol P M Liquid 79.54 Barrel atmospheric ambient 33 200 Litr. 7 MT

43 Lactic acid Liquid 54.30 Barrel atmospheric ambient 23 200 Litr. 5 MT

44 Sorbitol 70 %.paint grade Liquid 25.40 Barrel atmospheric ambient 11 200 Litr. 2.5 MT

45 Ethylene glycol Liquid 75.12 Barrel atmospheric ambient 31 200 Litr. 6 MT

46 Glycerine water white Liquid 449.42 Storage Tank atmospheric ambient 1 40 KL 40 KL

47 A (DI-Ethylene Triamine) Liquid 16.37 Barrel atmospheric ambient 7 200 Litr. 1.5 MT

48 Styrene Liquid 1624.21 Storage Tank atmospheric <22 1 50 KL 50 KL

49 Methyl methacrylate Liquid 1148.28 Storage Tank atmospheric <25 1 60 KL 60 KL

50 Glycidyl methacrylate Liquid 32.36 Barrel atmospheric <25 14 200 Litr. 3 MT

51 Hydroxy ethyl acrylate (HEA) Liquid 45.30 Storage Tank atmospheric <25 1 30 KL. 30 KL

52 Butyl acrylate monomer Liquid 1113.08 Storage Tank atmospheric <25 1 60 KL. 60 KL

53 2 ethyl hexyl acrylate

monomer Liquid 70.51 Barrel atmospheric <25 29 200 Litr 6 MT

54 Ethyl acrylate Liquid 160.61 Barrel atmospheric <25 67 200 Litr. 15 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


55 2 ethyl hexyl methacrylate

monomer Liquid 97.14 Barrel atmospheric ambient 40 200 Litr. 10 MT

56 Butyl methacrylate monomer Liquid 927.34 Storage Tank atmospheric <25 1 60 KL 60 KL

57 Iso-butyl methacrylate Liquid 15.68 Barrel atmospheric ambient 7 200 Litr. 1.5 MT

58 Hydroxy propyl acrylate Liquid 160.14 Storage tank atmospheric <30 1 30 KL. 30 KL

59 Acrylic acid Liquid 73.77 Barrel atmospheric ambient 31 200 Litr. 8 MT

60 Lauryl methacrylate Liquid 91.19 Barrel atmospheric <25 38 200 Litr. 8 MT

61 Isobutyl acrylate Liquid 13.50 Barrel atmospheric ambient 6 200 Litr. 1.5 MT

62 2 Hydroxy ethyl methacrylate Liquid 1010.84 Storage Tank atmospheric ambient 1 60 KL 60 KL

63 HMDI (Hexa methylene di-

isocyanate) Liquid 196.28 Barrel atmospheric ambient 82 200 Litr. 17 MT

64 IPDI Monomer Liquid 104.37 Barrel atmospheric ambient 44 200 Litr. 9 MT

65 Diethylene glycol mono ethyl

ether Liquid 312.04 Drum /Barrel atmospheric ambient 130 50/ 200 Kg 30 MT

66 Distill fatty Acid Liquid 41.38 Drum atmospheric <35 69 50 kg 3.5 MT

67 Duranate-TPA-100 Liquid 70.04 Barrel atmospheric ambient 29 200 Litr. 6 MT

68 Diethylamine Liquid 13.35 Drum atmospheric ambient 267 50 Litr. 14 MT

69 Dimethyl Ethanol Amine (

Indigenous) Liquid 47.34 Barrel atmospheric ambient 20 200 Litr. 4 MT

70 Placcel FM-3 Liquid 113.06 Barrel atmospheric ambient 47 200 Litr. 10 MT

71 N heptane Liquid 45.63 Barrel atmospheric ambient 19 200 Ltrs. 4 MT

72 LA Solvent Liquid 38.67 Barrel atmospheric ambient 16 200 Litrs. 7 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


73 Methyl Acrylate Liquid 5.24 Barrel atmospheric <21 2 200 Litrs. 0.5 MT

74 Acrylonitrile Liquid 4.70 Barrel atmospheric ambient 2 200 Litrs. 0.5 MT

75 THEIC Powder 39.13 bag atmospheric ambient 16 25 kg 3.5 MT

76 Mostanol -120 Liquid 43.84 Barrel atmospheric ambient 18 200 Litrs. 4 MT

77 Monomer 60 S Liquid 52.39 Barrel atmospheric ambient 22 200 Litrs. 4.5 MT

78 Diethyl malonate Liquid 11.11 Barrel atmospheric ambient 5 200 Ltrs. 1 MT

79 PG Monopropyl ether Liquid 33.55 Barrel atmospheric ambient 14 200 Ltrs. 3 MT

80 Palm kernel oil Liquid 100.72 Barrel atmospheric ambient 42 200 Ltrs. 8.5 MT

81 Noigen EA 142B Liquid 7.29 Carbouy atmospheric ambient 25 25 kg 0.7 MT

82 Triphenyl phosphite Liquid 3.68 Carbouy atmospheric ambient 10 30 Ltr. 0.5 MT

83 t-Butyl Peroxy 2-ethyl

hexanoate Liquid 13.11 Carbouy atmospheric <10 37 30 Litr. 1.2 MT

84 Z-6018 Intermediate Liquid 6.12 Barrel atmospheric ambient 3 200 Ltr. 0.5

85 Thermosetting acrl resin

55%kh 730 Liquid 43.51 bag atmospheric ambient 18 200 Ltr. 3.8 MT

86 Rosin W G grade Solid 11.39 Bag atmospheric ambient 38 25 kg 1 MT

87 Araldite Liquid 142.49 Barrel atmospheric ambient 59 200 Ltr. 12 MT

88 Epikote Liquid 1933.41 Barrel atmospheric ambient 805 200 Ltr. 162 MT

89 Hartol-M-33 Liquid 54.48 Barrel atmospheric ambient 23 200 Ltr. 4.5 MT

90 Cosmonet M-200 / Desmodur

44 V 20 L Liquid 661.44 Barrel atmospheric <50 276 200 Ltr. 55 MT

91 Resin 15 E Liquid 10.20 Barrel atmospheric ambient 5 200 Ltr. 1 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


92 SUMI EPOXY ESCN-195 LB Liquid 7.45 Barrel atmospheric ambient 3 200 Ltr. 0.8 MT

93 Resin 16 D Liquid 143.11 Barrel atmospheric ambient 60 200 Ltr. 12 MT

94 FUJICURE FXK # 930 Liquid 123.51 Barrel atmospheric ambient 51 200 Ltr. 11 MT

95 70 % DFA base alkyd Liquid 20.39 Barrel atmospheric ambient 9 200 Ltr. 2 MT

96 Base for Epoxy silicone

Resin Liquid 47.82 Barrel atmospheric ambient 20 200 Ltr 4 MT

97 DOW CORNING 3074 Liquid 12.30 Barrel atmospheric <25 5 230 Kg 1.5 MT

98 SUMIDUR N 3300 Liquid 17.67 Barrel atmospheric ambient 8 200Ltr. 1.5 MT

99 60% KH-940 Intermediate

for NB-014_KPJ Liquid 33.47 Barrel atmospheric ambient 14 200 Ltr. 3 MT

100 58%FTB-433 Intermediate

for NAD Rsn_KPJ Liquid 32.57 Barrel atmospheric ambient 14 200 Ltr. 3 MT

101 43% KU-921 Liquid 9.91 Drum atmospheric ambient 42 20 Ltr 1 MT

102 60% KHB - 981 Liquid 6.46 Drum atmospheric ambient 27 20 Ltr. 1 MT

Non EC Products (NOC Received)

1 Mixed xylene Liquid 488 Storage tank atmospheric ambient 1 150 KL 150 KL

2 Butanol Liquid 147 Storage Tank atmospheric ambient 1 100 KL 100 KL

3 Butyl Cellosolve Liquid 121 Storage Tank atmospheric ambient 1 50 KL 50 KL

4 Toluene Liquid 121 Storage Tank atmospheric ambient 1 50 KL 50 KL

5 Distilled C9solvent Liquid 117 Storage Tank atmospheric ambient 1 100 KL 100 KL

6 Mostanol 120 Liquid 112 Storage Tank atmospheric ambient 1 50 KL 50 KL

7 Mineral Turpentine oil Liquid 110 Storage Tank atmospheric ambient 1 100 KL 100 KL




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


8 Methyl Iso butyl ketone

(MIBK)

Liquid 72 Storage Tank atmospheric ambient 1 50 KL 50 KL

9 Butyl Acetate Liquid 66 Storage Tank atmospheric ambient 1 50 KL 50 KL

10 Cellosolve Acetate (Hiso

Solve acetate)

Liquid 55 Storage Tank atmospheric ambient 1 50 KL 50 KL

11 Iso Propyl Alcohol Liquid 50 Storage Tank atmospheric ambient 1 50 KL 50 KL

12 Ethyl Acetate Liquid 50 Storage Tank atmospheric ambient 1 50 KL 50 KL

13 Methanol Liquid 44 Storage Tank atmospheric ambient 1 50 KL 50 KL

14 Di ethylene glycol mono ethyl

ether Liquid 31 Drum atmospheric ambient 13 50/200 kg 30 MT

15 Cellosolve (Indigenous) Liquid 22 Storage Tank atmospheric ambient 1 50 KL 50 KL

16 Iso Butanol Liquid 22 Storage Tank atmospheric ambient 1 50 KL 50 KL

17 Methyl Ethyl Ketone (MEK) Liquid 20 Barrel atmospheric ambient 8 200 Ltr. 14 KL

18 HMDI (Hexa methylene di-

isocyanate)

Liquid 17 Barrel atmospheric ambient 7 200 Litr. 2 MT

19 Butyl glycol acetate Liquid 15 Barrel atmospheric ambient 7 200 Ltr. 8.4 MT

20 DBE Solvent Liquid 9 Barrel atmospheric ambient 4 200 Ltr. 7 MT

21 Acetic Acid ( Glacial) Liquid 7 Carbouy atmospheric ambient 3 30 Kg 1 MT

22 2- Octanate ( Methyl Hexyl

Ketone)

Liquid 13 Barrel atmospheric ambient 6 200 Ltr. 1.2 MT

23 Butyl Carbitol Liquid 7 Barrel atmospheric ambient 3 200 Ltr 5.4 MT

24 Solvent GR Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr 4 MT

25 3 Methoxy Butyl Acetate Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr 4 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


26 Acrylic Acid Liquid 5.5 Carbouy atmospheric ambient 3 200 Ltr 8 MT

27 Lecithin (Alcolec) Powder 13 Bag atmospheric <25 44 25 Kg 1.2 MT

28 Formic Acid 85% Liquid 7 Carbouy atmospheric ambient 24 25 Ltr 0.7 MT

29 Titanium di oxide Powder 216 Bag atmospheric ambient 720 25 Kg 20 MT

30 China Clay Powder 70 Bag atmospheric ambient 233 25 Kg 6 MT

31 Calcite powder 244 Bag atmospheric ambient 813 25 Kg 22 MT

32 Red oxide powder 345 Bag atmospheric ambient 1150 25 Kg 29 MT

33 Dolomite solid 103 Bag atmospheric ambient 343 25 Kg 9 MT

34 Soap stone solid 61 Bag atmospheric ambient 203 25 Kg 6 MT

35 Aluminium paste Solid 28 Bucket atmospheric <25 94 25 kg 3 MT

36 Cyclohexanone Liquid 2.4 Barrel atmospheric ambient 1 200 Ltr. 1 MT

37 Dipentene Liquid 2.4 Barrel atmospheric ambient 1 200 Ltr. 2 MT

38 Tetra ethyl ortho silicate Liquid 3.7 Barrel atmospheric ambient 2 200 Ltr. 1 MT

39 Monomer 60S Liquid 5.5 Barrel atmospheric ambient 3 200 Ltr. 1 MT

40 Hydrocarbon Resin Liquid 4.6 Barrel atmospheric ambient 2 200 Ltr. 1 MT

41 DOTO Powder Solid 5.5 Drum atmospheric ambient 19 25 Kg 1 MT

42 M.F.Resin Liquid 191 Storage Tank atmospheric ambient 1 30 KL 30 KL

43 Acrylic resin Liquid 391 Storage Tank atmospheric ambient 1 30 KL 30 KL

44 CED Resin Liquid 121 Storage Tank atmospheric ambient 1 30 KL 30 KL

45 Alkyd resin Liquid 110 Storage Tank atmospheric ambient 1 30 KL 30 KL

46 Zinc dust Powder 6.7 Drum atmospheric <23 23 25 kg 1 MT




S.

No. Chemical State

Consumption

(MT/Annum)

Means of

Storage

Operating Condition

(Storage) Nos. of

vessel/

drums/bags

Storage

capacity of

Bag / Drum

/ Tank (MT)

Maximum

Storage

Capacity

(MT) Press


47 Yellow oxide of iron Powder 3.3 Bag atmospheric ambient 11 25 kg 1 MT

48 Carbon black Powder 2.0 Bag atmospheric ambient 7 25 kg 0.5 MT

49 Lemon chrome Powder 2.0 Bag atmospheric ambient 7 25 kg 0.5 MT

50 Matting agent TSA 270L Liquid 2.0 Drum atmospheric ambient 9 20 kg 0.5 MT

51 Mapico yellow oxide XLO Powder 1.7 Bag atmospheric ambient 7 25 kg 0.5 MT

52 Scarlet chrome BS Powder 1.3 Drum atmospheric ambient 5 25 kg 0.5 MT

53 Blue ESP Powder 0.7 bag atmospheric ambient 6 10 kg 0.1 MT

54 Signal red Powder 0.6 bag atmospheric ambient 3 20 kg 0.1 Mt

55 K- White- 140 E Powder 2.9 bag atmospheric ambient 2 20 kg 0.5 MT

56 Bismuth hydroxide Solid 6.1 Bag atmospheric ambient 21 25 kg 1 MT


LIMITED





3.6 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.

3.7 Availability of water its source, energy/power requirement and source

should be given

3.7.1 Water consumption

Water supply: GIDC

Table 3-3: Water Consumption Details

S. No. Area of Consumption

Fresh Water Quantity, KLD

For Non EC

Products For EC Products Total

1 Domestic 40 15 55

2 Industrial

2.1 Manufacturing Process 60 0 60

2.2 Cooling Tower/Chiller/FDV 150 235 385

2.3 Boiler Make up 50 50 100

2.4 Washing 30 50 80

3 Gardening 30 20 50

4 Misc. e.g. Fire Hydrant 15 5 20

Total Water Consumption 375 375 750

Table 3-4: Waste Water Generation Details


Waste Water Generation

Quantity, KLD Treatment and Disposal

Mode For Non EC

Products

For EC

Products Total

1 Domestic 35 15 50

To STP for treatment and

treated water will be used

for gardening/toilet flushing

2 Industrial To ETP furnished with

UF/RO for treatment and

treated water (permeate)

will be used for cooling

2.1 Manufacturing Process 20 0 20

2.2 Cooling Tower/Chiller/FDV 15 33 48

2.3 Boiler Make up 5 3 8


LIMITED






Waste Water Generation

Quantity, KLD Treatment and Disposal

Mode For Non EC

Products

For EC

Products Total

2.4 Washing 25 39 64 tower and rejects will be

sent to MEE for evaporation 3 Gardening 0 0 0

4 Misc. e.g. Fire Hydrant 0 0 0

Total Waste Water Generation 100 90 190

3.7.2 Fuel

The fuel consumption data is given in Table 3-5.

Table 3-5: Fuel consumption

Sr.

No. Stack Attached to Nos. Type of Fuel used Fuel consumption

For EC Products

1 Boiler (5000 kg/hr) 2 Dual fired – HSD/PNG 275.2 Kg/hr

2 D G Set (400 KVA) 1 Dual Fired – HSD/PNG 75.7 Kg/hr

3 Gas Genset (1400 KVA) 2 PNG 335 SCM/hr each

4 Thermic fluid heater (15 lac

Kcal) 2 Dual fired- HSD/PNG 142 Kg/Hr.

5 Thermic fluid heater (10 lac

Kcal) 2 Dual fired – HSD/PNG 94.6 kg/hr

6 Incinerator 1 HSD 69 kg/hr

For Non – EC Products (NOC Received)

1 D. G. Set (2000 KVA) 1 HSD 344 kg/Hr

2 D. G. Set (2000 KVA) 1 HSD 344 kg/Hr

3 Boiler (850 kg/Hr) 1 HSD 43 kg/Hr

4 Boiler (850 kg/Hr) 1 HSD 43 kg/Hr

Note: DG Sets will be used only during Power failure.

3.7.3 Power Requirement and Source

Dakshin Gujarat Vij Company Limited (DGVCL) will supply power. The peak power demand will be

5000 KVA. The DG set (2 nos. x 2000KVA + 1 no. x 400KVA) and 1400 Gas Gen set will be installed

and will be used in case of power failure. The details are given in above Table 3-5.

3.7.4 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 7190 MT/Month or 277

MT/day. This translates to 31 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. Beside above, the internal movement

of raw material or finished goods shall be done through Forklift.




3.8 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

Hazardous Waste Generation in MT/Year Source

Treatment / Disposal For EC

Products

For Non-EC

Products Total

1 Process wastes, residues and

sludge 21.1 73 T 267 340

Paint manufacturing

process

To Incinerator plant for disposal

by incineration

2 Fillers Residues 21.2 3.0 T 0 3.0 Paint manufacturing

process


by incineration

3 Distillation Residue 20.3 270 T 132 402 Solvent recovery plant To Incinerator plant for disposal

by incineration

4 Spent Organic Solvent 20.2 899 T 441 1340 Vessel washing,

storage washing

To Solvent recovery plant for

distillation

5 Used / spent oil 5.1 3 T 3 6 DG set, Compressor,

gear box GPCB approved authorized recycler

6 Discarded containers/ barrels 33.3 135 T 260 395 Paint manufacturing

process Sold to GPCB approved party

7 ETP Sludge 34.3 40T 20 60 ETP To Incinerator plant for disposal

by incineration

8 Contaminated cotton waste/liners 33.3 18 T 7 25 Paint manufacturing

process


by incineration

9 MEE Salt 34.3 36 T 14 50 ETP To TSDF for disposal by landfill

10 Oil/grease scheming residue 34.4 0 4 4 ETP oil trap To incinerator plant for disposal

by incineration

11 Incinerator ash 36.2 0 180 180 Incinerator To TSDF for disposal by landfill


LIMITED



ESTATE SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

By Road

NH 228 is the main approach road from Jambusar to Bharuch. SH 161 connect NH 228 to

project site. It is two lane state highway, lies at an aerial distance of 0.6 km towards E direction.

By Rail

Site is also approachable by railway which connected Bharuch and Dahej via Samni & Vagra.

District Head Quarter Bharuch is a Major railway station lies on Mumbai-Vadodara mainline is

nearest railway station at an aerial distance of about 15 km towards SSE direction from project

site. Bharuch is well connected with various parts of the country.

By Air

Nearest domestic airport from proposed project site is located at Vadodara, at an aerial distance

of about 67 km towards NE direction. Vadodara is well connected with Mumbai and Delhi with

daily multiple flights.

Ahmedabad Airport (Domestic as well as international) is located at about 142 km towards N

direction from project site. Regular flights to all aver India and abroad are available from here.

By Water

Dahej is a port Village lies on the Bay of Cambay, having a small jetty under maritime board.

It is situated 35 km towards W direction from project site. There are several other private

jetties developed by industries.

4.2 Land Form, Land Use and Land ownership

4.3 Topography (along with map)

Topographical survey of project site is shown in below figure.

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.


LIMITED





Land allotment letter from GIDC vide letter no.: GIDC/DM/CG/ANK/231 dated 06/02/2015.

(Land Possession letter from GIDC vide letter no.: GIDC/DM/CG/ANK/1139 dated 03/07/2015

Table 4-1: Distance of Project site from Water Bodies

Water body Distance in km Direction

Narmada River 12.63 S

Bhukhi River 1.5 SE

Minor Canal 0.21 W

Argama 0.8 ESE

Saladra 1.04 NNE

Vorasamni 1.38 W

Ankot 1.88 NW

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 GIDC.

4.6 Soil classification

Survey & Soil Investigation work for Nerolac Paints Ltd at Sayka Village is found to consist of stiff to

very stiff silty clay having medium to high plasticity followed by hard silty clay having medium

plasticity upto termination depth below existing ground level (EGL). The Ground water table was

encountered in the borehole at 5.90m to 6.0m depth below EGL at time of investigation. (September

- 2015).

(Source: Annexure 15 of Form I (Soil Testing Report))

4.7 Climatic data from secondary sources

The general agro-climate zone of the study area is Semi-Arid.

Information presented in subsequent paragraphs is from the Indian Meteorological Department

(IMD), Long Term Climatological Tables, 1961-1990, Bharuch. These tables give useful information

about a region’s weather, since they are collected over a 30-year period.

4.7.1 Temperature

Mean daily maximum temperature is recorded in the month of May at 43.8°C. From October to

December, both day and night temperatures begin to decrease rapidly. January is generally the

coldest month, with minimum morning temperature at 11.3°C. During the post-monsoon months of

October and November, day temperatures remain between 16.7-35.9ºC. In winters, i.e. December,

January and February, average day temperatures remain between 11.3-33.5ºC.

4.7.2 Wind

Long- term wind direction data is presented inTable 4-2.


LIMITED





Table 4-2: Predominant Wind Direction

Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening

January NE NE SW SW SE SE

February NE NE NW NW SW SW

March SW SW NE NE SE SE

April SW SW NW NW SE SE

May SW SW NW NW SE SE

June SW SW SE SE NW NW

July SW SW S S W W

August SW SW W W NW NW

September SW SW NW NW W W

October SW SW NE NE SE SE

November NE NE SE SE SW SW

December NE NE SE SE SW SW

4.7.3 Rainfall

The total rainfall in year is observed to be 912.1 mm. Distribution of rainfall by season is 2.8 mm in

winter (December, January, February), 9.9 mm in summer (March, April, May), 860.7 mm in

monsoons (June, July, August, September) and 38.7mm in post-monsoons (October - November).

4.7.4 Cloud Cover

The area remains cloudy between the months of June – September, which is the active period of

the monsoon season.

4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer

in that order. Mornings are more humid than evenings and humidity ranges from a high of 81 –

90% in monsoon mornings to a low of 29 – 39% in summer evenings. During post-monsoon season,

in morning humidity remains between 73 – 76% and in the evening it remains between 42 – 46%.

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.


LIMITED



ESTATE PLANNING BRIEF


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 Non EC product - Paint & Thinner manufacturing facility

Phase-II: Commissioning of Resin manufacturing facility

Phase- I execution is planned for commissioned by August, 2017. The tentative Gantt chart for the

EC product execution (Phase –II) is as follows:

Activity Planned Completion Date

Land acquisition February, 2015

Completion of Environmental formalities January, 2017

Completion of Civil works November , 2018

Plant & Machinery January, 2019

Commissioning March, 2019

5.2 Population Projection

Man power requirement for manufacturing facility is approx. 430 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 Use Planning (breakup along with 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 12524.63 8.23

2 Storage Area

a Hazardous Chemicals 12642.89 8.31

b Other Non-hazardous chemicals - -

c Hazardous Waste 521.98 0.34

d Water Storage 420 0.28

e Fuel & solvent Storage 5752.66 3.78

3 Effluent Treatment Plant 2439 1.60

4 Boiler 244 0.16

5 Cooling tower 28.72 0.02

6 DG & LT room 286.91 0.19

7 Roads 40213.60 26.43

8 Administrative Building 241.05 0.16

9 Open Space 4915.60 3.23

10 Greenbelt Area 50209.87 33.0


LIMITED





S. No. Title Area, m2 % of total Area

11 Area for proposed Expansion 6314.62 4.15

12 Others - Parking area, weigh house,

driver rest room etc 15395.58 10.12

Total 152151.11 100

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 firefighting 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)


LIMITED





Table 5-2: The premises/ areas where various fire protection systems will be provided are listed below:

Sr. No

Firefighting 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 firefighting 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 best suitable rain water harvesting technique would be shallow pebble filled trenches to help

increase the filtration rate without increasing the risk of water logging. A Typical rain water

harvesting structure would be as follows:

- Recharge pits (w/o bores) are suitable for buildings having roof run off and where

permeable strata are available at shallow depths. Hence, this is suitable to the present

plant.

- Pit will be approximately 2 m wide, 1.5 - 3 m deep and 2 m long depending upon availability

of water to recharge.

- These will be backfilled with boulders (5-20 cm), gravel (5 -10 cm) and remaining with

coarse sand in graded form – boulders at the bottom, gravel in between and coarse sand

at the top so that the slit content that will come with runoff will be coarse sand at the top

of the sand layer and can easily be removed

- The Top layer of sand will be cleaned periodically to maintain the recharge rate.

- The total quantity of water will be collected (m3)= Roof Top area (m2) X Average monsoon

rainfall (m) x 0.8

The ground charging will improve the water level in the vicinity.


LIMITED



ESTATE PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

Total Plot area is 1,53138 m2. Out of it, approx. 12524.63 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 228 is the main approach road from Jambusar to Bharuch. SH 161 connect NH 228 to project

site. It is two lane state highway, lies at an aerial distance of 0.6 km towards E direction.

6.5.2 By Rail

Site is also approachable by railway which connected Bharuch and Dahej via Samni& Vagra. District

Head Quarter Bharuch is a Major railway station lies on Mumbai-Vadodara mainline is nearest railway

station at an aerial distance of about 15 km towards SSE direction from project site. Bharuch is well

connected with various parts of the country.

6.5.3 By Air

Nearest domestic airport from proposed project site is located at Vadodara, at an aerial distance of

about 67 km towards NE direction. Vadodara is well connected with Mumbai and Delhi with daily

multiple flights.

Ahmedabad Airport (Domestic as well as international) is located at about 142 km towards N

direction from project site. Regular flights to all aver India and abroad are available from here.


LIMITED



ESTATE PROPOSED INFRASTRUCTURE


6.5.4 By Water

Dahej is a port Village lies on the Bay of Cambay, having a small jetty under maritime board. It is

situated 35 km towards W direction from project site. There are several other private jetties

developed by industries.

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.

6.6 Drinking water management (source & supply of water)

Drinking water will be sourced from GIDC water supply system.

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 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

The solid wastes generated from the plant operations will be disposed off in nearby Waste

Management landfill facility.

6.10 Power requirement & supply/ source

Gujarat State Electricity Board will supply power through DGVCL Grid in the area. The peak demand

of power is 5000 KVA. DG sets (2 nos. x 2000 KVA, 1 no 450 KVA) and Gas Gen Sets (1 nos. x 1400

KVA) will be installed as a backup arrangement.


LIMITED



ESTATE R & R PLAN


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)

Not applicable as rehabilitation and resettlement will not be required, since the project lies in a

Industrial Area, with land acquisition procedures completed by the GIDC.


LIMITED



ESTATE PROJECT SCHEDULE AND COST

ESTIMATE


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)

The Construction activities of Non EC products have been started and will be completed by April

2017.

The construction work for the plant for EC product 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 April 2017 and commissioning of the project is

expected in March 2019.

8.2 Estimated project cost along with analysis in terms of economic viability of

the project.

Total Cost of the proposed project is 420 Cr Rs.

Non EC product: 317 crore

EC Product: 103 Crore


LIMITED



ESTATE ANALYSIS OF PROPOSAL


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, the skilled/semi-skilled employees and the managerial supervisory personnel will

stay.

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 PAINTS & RESINS MANUFACTURING

PLANT AT SAYKHA INDUSTRIAL ESTATE ANNEXURE


ANNEXURE

M/S. KANSAI NEROLAC PAINTS LIMITED PAINTS & RESINS MANUFACTURING

PLANT AT SAYKHA INDUSTRIAL ESTATE ANNEXURE


Annexure 1: Plot Allotment Letter

M/S. KANSAI NEROLAC PAINTS LIMITED PAINTS & RESINS MANUFACTURING PLANT AT SAYKHA INDUSTRIAL ESTATE ANNEXURE


Annexure 2: Long-term climatological Table, Bharuch

M/S. KANSAI NEROLAC PAINTS LIMITED PAINTS & RESINS MANUFACTURING PLANT AT SAYKHA INDUSTRIAL ESTATE ANNEXURE


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 . ka d a m en v i r o . c o m

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