PROJECT PRE-FEASIBILITY REPORT
AND ENV. MANAGEMENT PLAN
ON
PROPOSED PROJECT
FOR
MANUFACTURING OF ALKYD RESINS
AT
Sr. No. 165/p2, Plot No. 3 & 4, Galaxy Industrial, B/h. Vadalia Foods,
Village. Lothada, Taluka – Rajkot,
Dist. Rajkot - 360002.
Project Proponent:
Galaxy Polymers
Galaxy Polymers
Mfg. of Alkyd Resin 2
Chapter-0 EXECUTIVE SUMMARY
The project is summarized in the below table:
Table 0.1 Project Summary
PARTICULARS DETAILS Name of the Unit M/S. Galaxy Polymers Project Proponent Maheshbhai L. Vekariya Products Long Oil Alkyd Resin OR
Medium Oil Alkyd Resin OR Rosinated Oil Alkyd Resin OR Fast Drying Chain stop Alkyd Resin
Location Sr.No.165/ p2, Plot No. 3 & 4,Galaxy Industrial, B/H. Vadalia Foods, Village : Lothada, Taluka. Rajkot, Dist. Rajkot.
Nature of Project Manufacturing Unit Resources Resource type Requirement Source Land 750 m2 Own plot .The plot is N.A. land
designated for industrial purpose Building Total Built-up area = 279 m2
The required shed, plant and machinery to be constructed at the site.
Raw-materials Linseed Oil/Soya Oil/Castor Oil Soya/DCO Fatty Acid Pentaerythritol Glycerin Phthalic Anhydride Catalyst Xylene Benzoic acid
Local traders/market
Water 200 L/D Source: Borewell Power 30 HP Elect. Dept. (PGVCL) Fuel LDO-125 L/D Local traders Man-power Construction & comissioning: 2
Nos. Operarion- Managerial/skilled: 2 Nos. Unskilled: 2 Nos.
Priority to the local people
Galaxy Polymers
Mfg. of Alkyd Resin 3
Pollution Potential & Mitigation Measures Parameter Potential Mitigation Wastewater
Domestic: 100 L/D Generation
Industrial: 90 L/D
The domestic effluent shall be disposed off through septic tank/ soak pit system.
Evaporator will be used to evaporate the effluent, there shall be zero discharge of industrial effluent.
Air Emissions Emission load from installations under continuous operation
PM: < 150 mg/Nm3 From TFH
SO2:<100 ppm NOx:< 50ppm
LDO will be used as fuel in TFH and a chimney height of 11m will be provided.
The process will be carried out in close condition; chemicals will be handled in a closed manner by pumping or by vacuum transfer to minimize chances of fugitive emissions
The loading – unloading and charging shall be done with pumps. The pump glands and piping will be checked regularly to ensure no leakage.
The manufacturing plant will be in shed which will be open from both sides and hence natural ventilation will be available.
Hazardous & solid waste Discarded bags – 500 kg/Y Empty drums -1000 Nos./Y
The Hazardous wastes will be handled, stored & transported as per CPCB/MoEF Guidelines
Discarded bags will be sold to GPCB approved recyclers.
Empty drums will be recycled/ sold to GPCB approved recyclers.
Noise Inside the plant: <80dB(A) Expected levels The major sources of noise
generation shall be the pumps and motors.
Balancing of shaft of motor and will be done during installation to reduce vibrational noise.
Regular oiling/ maintenance will be done.
Galaxy Polymers
Mfg. of Alkyd Resin 4
Chapter-1 INTRODUCTION 1.1 THE PROJECT
M/s. Galaxy Polymers has planned to manufacture the products as mentioned in Table-
1.1 at Village Lothada, Sr.No.165/p2, Plot no. 3 & 4, Galaxy Industrial, B/h. Vadalia
Foods, Taluka Rajkot, Dist. Rajkot.
The list of products is provided in the below table:
Table 1.1
List of Proposed Products
Sr. No. Name of Product Quantity (MT/Month) 1. Long Oil Alkyd Resin 40 OR 2. Medium Oil Alkyd Resin 40 OR 3. Rosinated Oil Alkyd Resin 40 OR 4. Fast Drying Chain stop Alkyd Resin 40
1.2 PROJECT PROPONENT M/s. Galaxy Polymers is a new company. It is proprietary firm promoted by Mr. Mahesh L.
Vekariya.
The Proprietor of the company is engaged in manufacturing of oil paints. Above product is
raw material of oil paint. Details of proponent are given below:
Table 1.2 Details of Proponent
Sr. No. Particulars Details 1. Full name & Address of the
Project Proponent Mr. Maheshbhai L. Vekariya “Shriji”, Om Tirupati Balaji Park,Street No.2, Nr. Tapsi Hotel, Kothariya Ring road, Rajkot.
Galaxy Polymers
Mfg. of Alkyd Resin 5
1.3 NATURE OF THE PROJECT
The proposed project involves the manufacturing of Alkyd Resins. This falls in category
5(f) of the schedule of the EIA notification 2006. As per amendment to EIA Notification,
2006 vide SO 1599 (E) dated 25/06/14, small units are defined as with water
consumption less than 25 KLPD, fuel consumption less than 25 TPD and not covered in
the category of MAH units as per the management, Storage, Import of Hazardous
chemical Rules (MSIHC rules)-1989, the proposed project is categorized as ‘B2’ category.
1.4 NEED FOR THE PROJECT
Alkyd resins have a wide usage as film forming substances with protection characteristics
at anticorrosive paints. Alkyd resins are thermoplastic polyester resins with polybasic acids
or their anhydrides. They are used in making protective coatings with good weathering
properties and are important ingredients in many synthetic paints due to their versatility
and low cost. We are manufacturing oil paints so alkyd resins are use for captive
consumption.
Galaxy Polymers
Mfg. of Alkyd Resin 6
1.5 PROJECT COST
The proposed project cost will be around Rs.43.70 Lacs. The unit is covered under the
Small Scale Industrial Sector.
Environment Protection and safety systems have also been considered in planning the
Cost Projection. Green belt development, provision of fire extinguishers etc. is also
calculated. The below given table shows the break-up of the proposed project cost.
Table 1.3 Capital Cost Projection
Sr. No. Purpose Proposed Scenario
(Rs. in Lacs) 1. Land 4.20 2. Building 20.00 3. Plant and Machinery 15.00 4. Q.A. Lab set up 1.00 5. Env. Protection & Safety b) Safety Equipment (PPE, fire ext., ventilation, etc.) 2.00 c) Green belt development outer side of the premises 1.50 Total 43.70
Galaxy Polymers
Mfg. of Alkyd Resin 7
Chapter-2 PROJECT SITE 2.1 PROJECT LOCATION
The project site is located in the village of Lothada of Rajkot district and the site is
obtained N.A. order for general Industry purpose. The certificate confirming the same is
attached as Annexure-1.
Rajkot is very well connected to all the major Indian cities by air, railway and road. A number of
flights operate via the Rajkot Airport. A good network of roads also connect most of the major
cities of Gujarat such as Vadodara, Junagadh, Amreli, Bhavnagar, Jamnagar, Ahmedabad, Surat
etc. Rajkot is a main railway junction of Saurashtra, from where trains to all the major cities of
India
The location of the project site can be identified from the location map shown in Figure-2.1. The
salient features of the location of the project site are presented in the table given below:
Table 2.1 Salient features of the Project Site
Particulars Details Village Lothada Taluka/ Tehsil Rajkot District Rajkot Approx. Geographical positioning Lat: 22°10'36.85"N, Long: 70°50'59.25” E Neighbouring industries Surounding with Foundry units & one food unit Nearest Water body Aji Dam ~9.5 Km-N Nearest Highway NH 27 ~5.5 Km W Nearest Railway line/ Railway station Railway line ~3.72 Km-W,
Kotharia Railway station ~3.72 Km- W Nearest Airport/ Airbase Rajkot ~15 km –NW Protected Areas/ Sanctuaries None within 10 km Seismicity Seismic Zone-III (Moderate)
Galaxy Polymers
Mfg. of Alkyd Resin 8
Fig- 2.1: Location of the Project Site
1 km Circle(proposed site)
10 Km radius
Galaxy Polymers
Mfg. of Alkyd Resin 9
2.2 SITE SELECTION
Following points were considered for selection of the site. • Location is well connected with highways, nearby Rajkot. • Own plot & it is suitable for proposed project. • Availability of resources like power supply, water, man power etc. • Closeness to the target market. • There are no ecological sensitive areas located within 10 km radius. • No any national park or wild life sanctuary located within 10 km radius.
2.3 SITE LAYOUT The site layout plan is attached as under:
Galaxy Polymers
Mfg. of Alkyd Resin 10
Chapter-3 PROCESS TECHNOLOGY
The proposed products details like Process description, chemical reactions and
mass balance for each grade of products are as below.
3.1 REACTION CHEMISTRY
The chemistry principles of resin synthesis are simple. First, an acid/ anhydride react with glycol
to form an ester with release of a water molecule. i.e. The acid/ anhydride group (COOH or CO-
O-CO) reacts with the OH group to form an ester and a water molecule.
Galaxy Polymers
Mfg. of Alkyd Resin 11
3.2 MANUFACTURING PROCESS
1. Manufacturing Process for Long Oil alkyd Resin
• Charge oil in reactor and start stirring.
• Heat till 1750 – 1800 C.
• Add catalyst and Glycerine and increase temperature up to 2650 – 2700 C.
• Check for clear monoglyceride.
• Cool to 1600 C and add pentaerythritol, xylene and Phthalic Anhydride.
• Start reflux and increase temperature slowly step by step up to 2250 C.
• Check reaction viscosity and acid value.
• Cool to 1300 C and unload the batch in blander.
• Thin down to required solids with mineral turpentine oil (MTO).
• Check for final QC parameters, filter and pack to barrels.
• Reflux water is send to ETP Collection tank.
2. Manufacturing Process for Medium Oil alkyd Resin
• Charge oil in reactor and start stirring.
• Heat till 1750 – 1800 C.
• Add catalyst and Glycerine , increase temperature up to 2650 – 2700 C.
• Check for clear monoglyceride.
• Cool to 1600 C and add pentaerythritol, xylene and Phthalic Anhydride.
• Start reflux and increase temperature slowly step by step up to 2250 C.
• Check reaction viscosity and acid value.
• Cool to 1300 C and unload the batch in blander.
• Thin down to required solids with mineral turpentine oil (MTO).
• Check for final QC parameters, filter and pack to barrels.
• Reflux water is send to ETP Collection tank.
Galaxy Polymers
Mfg. of Alkyd Resin 12
3. Manufacturing Process for Rosinated Oil alkyd Resin
• Charge oil in reactor and start stirring.
• Heat till 1250 – 1300 C.
• Add xylene for reflux, pentaerythritol, xylene and Phthalic Anhydride.
• Start reflux and increase temperature up to 2750 C.
• Check reaction viscosity.
• Cool to 1400 C and unload the batch in blander.
• Thin down to required solids with mineral turpentine oil (MTO).
• Check for final QC parameters, filter and pack to barrels.
• Reflux water is send to ETP Collection tank.
4. Manufacturing Process for Fast Drying Chain Stop Alkyd Resin
• Charge Fatty acid in reactor and start stirring.
• Heat till 800– 900 C.
• Add Phthalic Anhydride, pentaerythritol, Benzoic Acid, xylene and catalyst.
• Raise the temperature slowly to 2250 C.
• Check reaction viscosity and acid value.
• Cool to 1300 C and unload the batch in blander.
• Thin down to required solids with xylene.
• Check for final QC parameters, filter and pack to barrels.
• Reflux water is send to ETP Collection tank.
Galaxy Polymers
Mfg. of Alkyd Resin 13
3.3 MATERIAL BALANCE
Fig – 3.1
Material Balance
1. Long oil alkyd resin Input Kg
Output Kg
Linseed Oil/Soya Oil/Castor Oil
68 Long oil alkyd resin
96
Pentaerythritol 10 Reflux water 04 Glycerine 02 Total 100 Phthalic Anhydride 17 Catalyst 01 Xylene 02 Total 100
2. Medium oil alkyd resin
Input Kg
Output Kg
Linseed Oil/Soya Oil/Castor Oil
58 Medium oil alkyd resin
96
Pentaerythritol 15 Reflux water 04 Glycerine 04 Total 100 Phthalic Anhydride 20 Catalyst 01 Xylene 02 Total 100
Galaxy Polymers
Mfg. of Alkyd Resin 14
3. Rosinated oil Alkyd resin Input Kg
Output Kg
Linseed Oil/Soya Oil/Castor Oil
50 Rosinated oil alkyd resin
96
Pentaerythritol 10 Reflux water 04 Glycerine 17 Total 100 Phthalic Anhydride 20 Catalyst 01 Xylene 02 Total 100
4. Fast Drying Chain Stop Alkyd Resin Input Kg
Output Kg Soya/DCO fatty acid 40 Fast Drying
Chain stop alkyd resin
96 Pentaerythritol 19 Benzoic acid 18 Phthalic Anhydride 20 Reflux water 04 Catalyst 01 Total 100 Xylene 02 Total 100
Galaxy Polymers
Mfg. of Alkyd Resin 15
Chapter-4 RESOURCE REQUIREMENTS
The major resources for the project are land, raw-materials, power, fuel and man-power
etc.
4.1 LAND The total plot area is 750 Sq. m. The plot is presently non-agriculture Industrial plot. The break-up of area is provided in Table 4.1.
Table 4.1: Breakup of land
S. No. Description Approximate Area (m2) Approximate Area (%) 1. Buildup area 279.44 37.00 2. Greenbelt 125.00 17.00 3. Open land 346.00 46.00
TOTAL 750.44 100.00
4.2 BUILDING Building will have to be constructed for accommodating the plant & machinery, administrative office. The approximate requirement of construction material for the same is given below:
Table 4.2: Details of Construction Materials
Sr. No.
Construction Material
Quantity
1. Cement 15 MT 2. Bricks/Bela Stone 100 MT 3. Steel, Both Mild & TMT, Sections ISI 10 MT 4. Sand 20 MT 5. Kapachi 25 MT 6. Black Stones 20 MT 7. Gates & grilling (iron) 1 MT
Galaxy Polymers
Mfg. of Alkyd Resin 16
4.3 EQUIPMENTS
Based on process necessity list of the proposed machinery is shown in the table given
below:
Table 4.3: Details of Equipments
Sr. No. Equipment Capacity Nos. 1. Reactor S.S 1200 Kg 1 2. Blender S.S. 2200 kg 1 3. Cooling Tower 40 lpm 1 4. Thermic Fluid Heater 1 Lakh Kcal/Hr 1
4.4 RAW-MATERIALS
The proposed products are organic chemicals and the required raw materials will be
purchased from the local/ Indian market. Details of raw-material consumption are as
shown in the table given below:
Table 4.4
1. List of Raw Materials-for Long oil Alkyd Resin
Sr. No. Name of Raw material Source MT/Month 1 Linseed Oil/Soya Oil/Castor Oil Local Trader 28 2 Pentaerythritol Local Trader 04 3 Glycerine Local Trader 0.8 4 Phthalic Anhydride Local Trader 6.8 5 Catalyst Local Trader 0.4 6 Xylene Local Trader 0.8
2. List of Raw Materials-for Medium Oil Alkyd Resin
Sr. No. Name of Raw material Source MT/Month 1 Linseed Oil/Soya Oil/Castor Oil Local Trader 24 2 Pentaerythritol Local Trader 06 3 Glycerine Local Trader 1.6 4 Phthalic Anhydride Local Trader 8.0 5 Catalyst Local Trader 0.4 6 Xylene Local Trader 0.8
Galaxy Polymers
Mfg. of Alkyd Resin 17
3. List of Raw Materials-for Rosinated Oil Alkyd Resin
Sr. No. Name of Raw material Source MT/Month 1 Linseed Oil/Soya Oil/Castor Oil Local Trader 21 2 Pentaerythritol Local Trader 04 3 Glycerine Local Trader 6.8 4 Phthalic Anhydride Local Trader 8.0 5 Catalyst Local Trader 0.4 6 Xylene Local Trader 0.8
4. List of Raw Materials-for Fast Drying Chain Stop Alkyd Resin
Sr. No. Name of Raw material Source MT/Month 1 Soya/DCO fatty acid Local Trader 16 2 Pentaerythritol Local Trader 7.9 3 Benzoic Acid Local Trader 08 4 Phthalic Anhydride Local Trader 7.8 5 Catalyst Local Trader 0.4 6 Xylene Local Trader 0.8
4.5 POWER AND FUEL Electric power will be sourced from State Electricity Board. LDO will be used as fuel in
Thermic Fluid Heater. The details of the power and fuel requirement are in the table given
below:
Table 4.5 Power and Fuel Requirement
Sr. No. Name Requirement Source 1 LDO 125 L/D Local Traders 2 Energy - Electricity 20 HP PGVCL
4.6 MANPOWER
The manpower required for the project commissioning and operational activities will be
employed from the local area.
Table 4.6 Man Power Requirement
Phase of project Type of labor No. of workers
During operations Managerial/Skilled 2 Un-skilled 2
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4.7 WATER
The category wise bifurcation of the water requirement is given in the table below. There
will be no requirement of water in process. The water requirement will be only for cooling
purpose and domestic use. Moreover, the water of reaction to be generated in process
will be evaporated in the evaporator.
Table 4.7 Category-wise Water Requirement
Particulars L/D Ind. Cooling 100 Process Nil Domestic use 100 TOTAL 200
• For the proposed manufacturing activity the total water consumption will be 200 L/D • From that the domestic water consumption will be 100 L/D • Industrial water consumption for cooling makeup will be 100 L/D.
Rain water Harvesting The source water will be from bore-well. The unit has also proposed to carry rainwater
harvesting in their plant. The total rooftop catchment area will be 279 sq. mt. Hence,
considering the seasonal rainfall in Rajkot District at 800 mm, the groundwater recharge
through rainwater harvesting is estimated as below:
Total rainwater harvested = Catchment area (m2) x Avg.rainfall (m) x efficiency
= 279 x 0.8 x 0.8
= 178 m3 per annum.
The total water requirement per annum will be:
Maximum requirement per annum = Requirement per day (m3) x working days
= 0.2 x 315
= approx. 63 m3 per annum
Galaxy Polymers
Mfg. of Alkyd Resin 19
Chapter-5 MITIGATION MEASURES & EMP
Based on overall manufacturing & operation activities, the mitigation measures have been
proposed by the company for the control of the anticipated pollution load.
5.1 WASTE WATER MANAGEMENT
5.1.1 Wastewater Generation
The category-wise bifurcation of the anticipated wastewater generation details is given in
Table no. 5.1.
Table 5.1 Category-wise Wastewater Generation
Particulars L/day Industrial Process 80 Industrial Cooling 10 Domestic 100 TOTAL 190
• Total wastewater generation will be 190 L/D • From that 100 L/D Domestic wastewater will goes to soak pit via septic tank. • Industrial wastewater 90 L/D will be evaporated in Evaporator to achieve Zero discharge.
Fig-5.2: Water Balance Diagram (in L/day)
(90 L/D) Evaporator
Fresh Water
(200 L/D)
Domestic (100 L/D)
Cooling
(Fresh-100 L/D)
Process requirement
(Nil)
Septic tank/ soak pit
(100 L/D)
Water of reaction collected by
distillation (80 L/D)
Cooling + Process (10 + 80)=90 L/D
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Mfg. of Alkyd Resin 20
5.1.2 Wastewater Characteristics
The water of reaction to be generated shall be collected by reflux. The characteristics of
wastewater & final outlet would be as follows:
Parameter pH SS TDS COD Value 6.8-7.5 200 mg/lit. 1500 mg/lit. 700 mg/lit.
5.1.3 Wastewater treatment & disposal
Sr. No. Source Quantity and mode of disposal 1. Domestic sewage 100 L/D of sewage will be discharged to a septic tank and
soak‐pit system. 2. Industrial wastewater 1. Process effluent will be treated in proposed Effluent
Treatment Plant and Finally it will be evaporated. 2. Cooling tower blow down will be treated with process effluent and finally it will be evaporated.
Effluent Treatment Detail For process reflux water we will provide collection cum equalization tank of capacity 200 lit. We will provide Thermic Fluid Evaporator of capacity 50 it./Hr. As we will generate 90 lit./day effluent so evaporator will be sufficient for completely evaporate. Hence there shall be zero discharge of industrial effluent.
Fig-5.3: ETP Diagram
Collection tank Tank 200lit.
Evaporator 50 lit./hr.
Galaxy Polymers
Mfg. of Alkyd Resin 21
5.2 AIR EMISSIONS & CONTROL
5.2.1 Flue gas emissions
The company will install Thermic Fluid Heater (1 Lakh KCal/ Hr) for the heat requirement in the
process. The details of utility emissions and control measures are in the table given below:
Table no. 5.2
Utility Emissions and Control Measures
Installation Fuel Fuel Cons. Pollution Parameters
Emission rate/ Norms
Air Pollution Control System
TFH (1 Lakh KCal/
Hr)
LDO 125 Lit/day PM < 150 mg/Nm3 Stack Ht.: 11 m
SO2 < 100 ppm NOx < 50 ppm
5.2.2 Process gas emissions There shall be no process gas emissions from the proposed manufacturing activities.
5.2.3 Fugitive emissions
No low boiling materials or fine dust generating materials to be used in the process.
Hence, chances of fugitive emissions are less. Moreover, the process will be carried out in
close condition; chemicals will be handled in a closed manner by pumping or by vacuum
transfer to minimize chances of fugitive emissions. The loading – unloading and charging
shall be done with pumps. The pump glands and piping will be checked regularly to
ensure no leakage.
Work place monitoring will be carried out regularly for work place exposure level
measurement in Form No-37. The manufacturing plant will be in shed which will be open
from both sides and hence natural ventilation will be available.
Galaxy Polymers
Mfg. of Alkyd Resin 22
5.3 HAZARDOUS/ NON-HAZARDOUS WASTE MANAGEMENT
The following type of hazardous waste will be generated from the operational activities.
All the waste will be stored separately in a designated storage area.
Table 5.3 :Details of Hazardous Waste
Name of the
Waste Physical Prop.
Catg. Quantity Mode of Disposal
Discarded bags/ drums
HDPE/ LDPE 33.3 500 kg/year, 1000 Drums/year
Sale of bags to Reg. Recy. and Drums will be used for
filing of products
In addition to the above, proper management for hazardous waste as below:
Records of waste generation reuse and disposal will be maintained in log book as per the format
of Form-3 as per Hazardous and other Waste (Management and Transboundary Movement)
Rules, 2016.
• Transportation of hazardous waste to the reg. recycler will be governed as per the
guidelines and accompanied with Form-9.
• Annual returns of the disposal of wastes in Form-4 and Form-13 will be submitted
regularly to the local office of the GPCB.
5.4 NOISE CONTROL
No major sources of noise generation other than pumps and motors. Balancing of shaft of
motor and will be done during installation to reduce vibration noise. Regular oiling/
maintenance will be done.
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Mfg. of Alkyd Resin 23
5.5 STORAGE, HANDLING & TRANSPORT OF HAZ. CHEMICALS
The details of storage and mode of transport of chemicals to be used are provided in the
Table 5.4 and their characteristics are provided in Table no 5.5.
Table 5.4
Storage facility of Raw Materials Sr. No.
Name of Raw Material Container Type
Physical form
At a time storage in MT
Max. Storage Capacity in MT
1. Fatty Acid Drums Liquid 10 15 2. Xylene Drums Liquid 1 2 3. Soya Oil/castor oil Drums Liquid 10 15 4. Glycerin Drums Liquid 3 5 5. Penta(Pentaerythritol) Bags Solid 7 10 6. Benzoic Acid Bags Solid 5 7 7. Phthalic Anhydride Bags Solid 10 15
Following steps will be adopted.
• SOP will be prepared and implemented.
• Proper storage area will be made for separation of incompatible chemicals and material
handling equipments will be used for safe material handling.
• Material issuing procedure will be prepared and implemented as per batch requirement.
• Flame-proof area.
• Flame-proof equipments.
• Proper ventilation.
• Fire fighting equipment.
• PPEs.
• Safety shower, eye wash.
• Drum handling trolley.
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Mfg. of Alkyd Resin 24
Table 5.5 Characteristics of Raw Materials
1. Fatty Acid
Sr. No. Properties Description 1. Chemical Name : Fatty acid 2. Molecular Weight : ----- 3. Appearance : Liquid Yellow wish brown 4. Flash Point : 185 0C 5. Fire Point : No data available 6. Boiling Point : >300 0C 7. Melting Point : >25 0C 8. Solubility : In Soluble in Cold water 9. Specific Gravity : No data available 10. CAS. No. : 68308-53-2 11. Protective Equipment : Eye Protection-Safety Goggles Hand Protection-
Compatible resistance Gloves Respiratory Protection- Non Required
12. Toxicological Information : 4640 mg/kg 13. Fire Extinguishing Measures : Not Flammable 14. First Aid Measures : Eye contact- check for & removal any contact
lenses immediately flush eye with Plenty of water for at least 15 minute. Occasionally lifting upper & lower eyelids. Get medial attention if symptoms occur. Skin contact-if in case of contact flush skin plenty of water at least 15 minute. While removing contaminated clothes. Wash clothing before reuse. Clean shoes before reuse get medical attention if symptoms occur. Inhalation- move exposed person to fresh air, if not breathing is irregular give artificial respiration or oxygen by trained person. Never give anything by mouth. Loosen tight Clothing such as collar ,tie, belt, get medical attention if symptoms is occur Ingestion-Wash out mouth with fresh water Do not inducing vomiting unless directed to do by medical person. Never give anything by mouth to unconscious person. Get medical attention if symptoms occurs
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Mfg. of Alkyd Resin 25
2. Xylene
Sr. No. Properties Description 1. Chemical Name : Dimethylbenzene 2. Molecular Weight : 106gm/mole 3. Appearance : Colourless 4. Flash Point : 37.7 °C 5. Fire Point : No data available 6. Boiling Point : 137-140 °C 7. Melting Point : No data available 8. Solubility : Not Soluble 9. Specific Gravity : 0.864 at 20/4 °C (water=1) 10. CAS. No. : 1330-20-7 11. Protective Equipment : Provide approved canister or air supplied mask,
face shield, plastic gloves, boots& apron 12. Toxicological Information : 4300 mg/kg 13. Fire Extinguishing Measures : Co2,Form,Dry chemical Powder 14. First Aid Measures : Inhalation removes the victim to fresh,
Administer artificial respiration or oxygen if necessary. Ingestion- Do not induce vomiting, Skin-Wash the affected area with plenty of water and soap Eyes-Irrigate with plenty of water for 15 mins. Seek medical aid treatment
3. Glycerin
Sr. No. Properties Description 1. Chemical Name : Glycerin 2. Molecular Weight : 92 gm/mole 3. Appearance : Colourless or Yellow 4. Flash Point : 166.5 °C 5. Fire Point : No data available 6. Boiling Point : 290 °C 7. Melting Point : 17.9 °C 8. Solubility : Miscible 9. Specific Gravity : 1.261 at 20 0C 10. CAS. No. : 56-81-5 11. Protective Equipment : Provide rubber gloves and goggles 12. Toxicological Information : 12600 mg/kg 13. Fire Extinguishing Measures : Alcohol Form,Co2,Dry Chemical Powder Water or
form may causes frothing. 14. First Aid Measures : Non-Hazardous
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Mfg. of Alkyd Resin 26
4. Pentaerythritol
Sr. No. Properties Description 1. Chemical Name : 2,2-bis(hydroxymethayle),1,3 propanediol 2. Molecular Weight : 136.15gm/mole 3. Appearance : Solid 4. Flash Point : No data available 5. Fire Point : No data available 6. Boiling Point : Decomposes 7. Melting Point : 260°C 8. Solubility : Partially Soluble in cold water 9. Specific Gravity : 1.396 ( water=1) 10. CAS. No. : 115-77-5 11. Protective Equipment : Gloves, Lab coat, dust respirator be sure to use
approved or certified respirator or euaivalent, wear appropriate respirator ventilation in adequate, wear safety glasses.
12. Toxicological Information : 18500 mg/kg 13. Fire Extinguishing Measures : Small Fire- Use Dry Chemical Powder. Large Fire-
Use water spary,fog or foam Do not use water jet
14. First Aid Measures : Eye immediately flush eye with running water at least 15 minute, keep eyelids open Cold water may be used. Skin Contact -After contact with skin Immediately wash with plenty of water thoroughly wash contaminated skin with running water and non abrasive soap, cold Water may be used, Cover the irritated with An emollient.if irritation persists, seek medical attention. Inhalation-allow to victim rest at well ventilated area. seek immediately medical attention Ingestion-Do Not Inducing Vomiting, Loosen tight clothing Such as Cooler,tight,belt or waistband, if the victim is not breathing Perform mouth to mouth Resuscitation, Seek immediately medical Attention.
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Mfg. of Alkyd Resin 27
5. Benzoic Acid
Sr. No. Properties Description 1. Chemical Name : Benzoic acid 2. Molecular Weight : 120 gm/mole 3. Appearance : Colour less to white 4. Flash Point : Data Not available 5. Fire Point : Data Not available 6. Boiling Point : 249 °C 7. Melting Point : 121.7 °C 8. Solubility : Soluble in water at 30 °C 9. Specific Gravity : 1.316at 28 0C(Water=1) 10. CAS. No. : 65-85-0 11. Protective Equipment : Provide dust respirator, Safety goggles, Organic
respirator for fume, hand gloves, body overclothing and shoes.
12. Toxicological Information : 2530 mg/kg 13. Fire Extinguishing Measures : Carbon Dioxide, Dry Chemical Powder, water
Spary mist, 14. First Aid Measures : Inhalation: Remove the victim to fresh air area.
Skin: wash with plenty of water and soap. Eyes: wash with plenty of water for 15 mins. seek medical aid
6. Phthalic Anhydride
Sr. No. Properties Description 1. Chemical Name : Phthalic Anhydride 2. Molecular Weight : 148gm/mole 3. Appearance : White needles 4. Flash Point : 1650C 5. Fire Point : Data Not available 6. Boiling Point : 295 (Sublimes) °C 7. Melting Point : 131.2°C 8. Solubility : Soluble in water at 30 °C 9. Specific Gravity : 1.53 at 20 /4 0C 10. CAS. No. : 85-44-9 11. Protective Equipment : Provide rubber apron, rubber shoes, face shield,
approved vapour respirator, leather or rubber hand gloves
12. Toxicological Information : 4020 mg/kg 13. Fire Extinguishing Measures : CO2, Dry chemical powder. 14. First Aid Measures : Inhalation gargle with water and give sedatives
cough mixure.ingestion- induce Vomiting, give water or milk, skin & eyes-If affected, wash with plenty of water. Seek medical aid
5.6 HEALTH AND SAFETY MEASURES
The likely physical hazards due to handling of hazardous chemicals are identified and
MSDS is uploaded.
Moreover transport activity will be through drums, so there will be manual loading and
unloading and no unloading through pipe at the site. Hence, the risk of static charge
generation during transfer of such chemicals is not significant.
Below mentioned is the summary proposed safety measures to be taken at site for control
of anticipated hazards.
Table 5.6 Summary of Hazards & Proposed Safety Measures
Sr. No.
Activity/ Hazard Mitigation Measures
1. Fire and Toxic hazard during storage and handling of chemicals
• Nearest fire station is at Rajkot @~15Km. • Adequate nos. of fire extinguishers will be installed in the
entire plant area and storage area. • Flame-proof fittings will be provided. • Use of non-sparking tools will be ensured. • De-matching will be practised in the plant and store area. • Proper grounding will be provided to all the reactors/ vessels
and piping to avoid accumulation of a static charge. • PPE like face mask, safety gloves, safety goggles, apron etc.
will be provided to avoid contact with chemicals and their use will be ensured during handling of chemicals.
• Full covered clothing will be ensured to avoid contact with skin • Workers will be advised to remove clothing that has
accidentally become wet or significantly contaminated. • Eyewash fountains and/or quick drench facilities will be
provided near plant area. • Shed will be open on both sides for proper natural ventilation • RM Stores will be covered to avoid contact with direct heat/
sunlight • Storage of chemicals will only be in drums / bags. • At least 10% of the volume of the Container will be left as
vapor space for adequate protection. • Mechanical seals and high quality pressure and temperature
gauges and safety valves to be provided to all reactors. • Transfer/ charging of liquid chemicals will be done by pumps,
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Sr. No.
Activity/ Hazard Mitigation Measures
wherever possible. • Provision of necessary hoppers will be made for Transfer/
charging of solid material. • In case of accidental spillage of chemical, it will be controlled
with reference to respective MSDS document. • Availability of MSDS will be ensured. • The layout will include provisions for more than one escape
route in the event of an emergency. 2. Reactivity hazard • The process needs temperature upto 2750C. Hence, a provision
of Limpted Coil oil circulation will be made to initiate the reaction, which will then be stopped after a certain time period.
3. Injury hazard during mechanical operations
• All rotary parts viz. motors of pumps, agitators etc. shall be provided proper guarding.
• Use of PPE like safety shoes and helmets will be ensured. • First-aid box will be provided in plant area.
4. Transportation • The hazardous material will be transported only in drums. • Ensure with the suppliers of RM that the drivers are licensed
and trained for safe transportation, spill control and emergency actions.
• Ensure that all containers are pasted with the precaution and indication signs of the material stored within.
5. Maintaining of Health records
• All records shall be maintained as per Factory Act. • Regular Health Check ups shall be done as per Factory Act.
6. Training and competence issues
• Establishing of the Standard operating procedures to ensure safe operations.
• Selected personnel will be identified and trained for fire fighting and providing first aid.
• Regular training will be provided to all employees for first aid and handling of emergency situations.
7. Communication of hazards/ accidents
• Adequate no. of sign boards will be provided in local language. • Emergency telephone nos. will be displayed. • Manual call bells will be provided for communication of
emergency. • Assembly point will be designated.
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5.7 ENVIRONMENT, HEALTH & SAFETY MANAGEMENT CELL
The company being a small unit, with only 4 nos. of people a small cell will be set up for
fire fighting and safety. Proprietor or Site incharge will be responsible for maintaining
records of all the data, documents and information in line with the statutory
requirements.
5.8 POST PROJECT ENVIRONMENT MONITORING PLAN
The proposed post-project monitoring plan is given below:
Table 5.7
Environmental Monitoring Plan
Component Parameter Frequency Air – Ambient PM2.5, PM10, SO2, NOx Quarterly-Third party
monitoring Stack monitoring TFH stack: PM, SO2, NOx Quarterly-Third party
monitoring Noise monitoring Noise levels in decibels Quarterly-Third party
monitoring Haz. Waste management
Maintaining records of generation, receipt & disposal in Form-3
Daily
Filing of annual returns in Form-4 for haz. Waste handling
Every year by 31st Jan
Maintaining records of transportation in Form-9
While sending for disposal
Submission of returns of used oil in Form-13
Every year by 31st Jan
CC&A Obtaining consent to operate (and renewal) under Air & Water Acts and authorization under HW rules.
Every 5 years or before expiry of validity
Water cess Filing of annual returns for cess incurred on water consumption
Every year by 30th Sept
Environmental Statement
Submission of audit statement in form-V Every year by 30th Sept
Compliance of EC conditions
Submission of compliance reports Half yearly on 1st June & 1st Dec
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5.9 GREENBELT DEVELOPMENT
We shall develop greenbelt inside & outside the plant. The proposed plantation of species
like Baval, Saptaparni, Limbdo , Silk cotton, Boganvilla , Akhdo, Garmalo, Saru, Coconut
tree , Gulmohar , Eucalyptus, Vad, Umber, Pipal, Pipli ,Gandharaj, Conical & Spherical
Asopalav, Karanj, etc will be undertaken. We shall allocate a budget of Rs. 5000/- per
annum for the development of greenbelt.
5.10 SOCIAL DEVELOPMENT PROGRAMS
The size of the project is small; therefore manpower requirement will also be lesser. The
project will employ 2 numbers of unskilled workers and 2 numbers of
supervisory/managerial personnel. All the manpower will be utilized from local Area.
The company intends to donate 2% of the profit to agencies like NGOs or social welfare
societies for projects carried out in nearby village for their welfare and upliftment.
5.11 BUDGETARY PROVISIONS FOR EHS
The capital cost for EHS system is estimated to be around Rs. 3.5 Lakhs and the provision
of recurring expenditure is Rs. 0.50 Lakhs per annum.