Polyols EC

EXPANDED POLYMER SYSTEMS
PVT. LTD.
Amendment in Existing Environment

Clearance for Petrochemical Based
Processing Manufacturing Plant at Plot
No. CH-10, GIDC Estate Dahej, Taluka
Vagra, District Bharuch, Gujarat
OCTOBER 2023
Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development

E: [email protected]; T:+91-265-6131000
ACCREDITATION DETAILS
NABET Certificate No. NABET/EIA/1922/RA 0138 valid till 25th May, 2022 and NABET/EIA/2023/SA 0164 valid from 19.04.2022
up to 19.03.2023; Validity Extension Certificate No. QCI/NABET/ENV/ACO/23/2709 valid up to June 13, 2023 & Validity
extension Certificate No. QCI/NABET/ENV/ACO/23/2778 valid up to September 11, 2023 Validity extension Certificate No.
QCI/NABET/ENV/ACO/23/2775 Valid up to December 05, 2023
AMENDMENT IN EXISTING EC OF
PETROCHEMICAL BASED PROCESSING MFG.
EXPANDED POLYMER SYSTEMS PVT. LTD. PLANT AT GIDC ESTATE DAHEJ TABLE OF CONTENT
M/S. EXPANDED POLYMER SYSTEMS PVT LTD
Amendment in Existing Environment Clearance for

Petrochemical Based Processing Manufacturing Unit at
Plot No. CH-10, GIDC Estate Dahej, Taluka Vagra, District
Bharuch, Gujarat
© Kadam Environmental Consultants (‘Kadam’), October, 2023
This report is released for the use of the M/s. Expanded Polymer Systems Pvt Ltd, Regulators and relevant
stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided, unless
attributed to referenced third parties, is copyrighted and shall not be used for any other purpose without the
written consent of Kadam.
QUALITY CONTROL
Name of Amendment in Existing Environment Clearance for Petrochemical Based Processing Manufacturing Plant
Publication at Plot No. CH-10, GIDC Estate Dahej, Taluka Vagra, District Bharuch, Gujarat
Project Number 2356828101 Issue No. 01 Revision No. 00 Released October, 2023
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.
Description of images on the front page:
1. Main Gate 2. Security Cabin

3. Processing Block 4. Plant Area
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2023 2

TABLE OF CONTENTS
1 INTRODUCTION 7
1.1 Identification of Project and Project Proponent............................................................................7
1.2 Purpose of the Report .....................................................................................................................7
1.3 Proposed Amendment Required .....................................................................................................8
1.3.1 Justification for Amendment 9
2 PROJECT DESCRIPTION 15
2.1 Type of Project .............................................................................................................................. 15
2.2 Location ......................................................................................................................................... 15
2.3 Technology and Process Description ............................................................................................ 18
2.3.1 Polyether Polyol 18
2.3.2 Polyester Polyol 21
2.3.3 Polycarbonate Polyol 23
2.3.4 Polymer Polyol 25
2.3.5 Blended Polyol 27
2.3.6 Pre-polymer Polyol 27
2.3.7 Cross Linker 29
2.3.8 Pentane Mixture 29
2.3.9 Stabilizer 30
2.3.10 Solvent Recovery 31
2.3.11 Pollution Load Calculation 31
2.4 Raw Material Consumption ........................................................................................................... 34
2.5 Water Consumption, Wastewater Generation and Treatment Facilities .................................... 37
2.5.1 Source of water Supply 37
2.5.2 Water Consumption and Waste Water Generation for Proposed Unit 37
2.5.3 Waste Water Generation 37
2.5.4 Hazardous waste 41
2.6 Conclusion...................................................................................................................................... 43

LIST OF ANNEXURES
Annexure 1: Existing EC letter copy .......................................................................................................... 45
Annexure 2: Existing CTE ........................................................................................................................... 53
Annexure 3: Existing CTE Product Mix Received ...................................................................................... 56
Annexure 4: Existing CC&A ........................................................................................................................ 62
Annexure 5: GIDC Letter for Water Supply Permission ............................................................................ 67
Annexure 6: Agreement Letter with GIDC for Treated Wastewater Discharged into GIDC drain. ........ 68
Annexure 7: Membership Certificate of BEIL for Hazardous Waste Disposal ......................................... 69
Annexure 8: Membership Certificate of RSPL for Hazardous Waste Disposal ......................................... 72

LIST OF TABLES
Table 1-1: Permission Received Till Date ....................................................................................................7
Table 1-2: Existing Production Details (As per EC No. SEIAA/GUJ/EC/5(e)/1071/2018 dated
05/10/2018) .................................................................................................................................................7
Table 1-3: Proposed Product List .................................................................................................................8
Table 1-4: EC Conditions in which Amendment is Required .................................................................... 10
Table 1-5: Pollution Load Statement after EC Amendment ...................................................................... 13
Table 2-1: Latitude and Longitude of Project Site .................................................................................... 15
Table 2-2: Area Break up at Site ................................................................................................................ 18
Table 2-3: Mass Balance for Polyether Polyol ........................................................................................... 20
Table 2-4: Mass Balance for Polyester Polyol by Reaction of Adipic acid and DEG ................................. 22
Table 2-5: Mass Balance for Polycarbonate Polyol ................................................................................... 24
Table 2-6: Mass Balance for Polymer Polyol ............................................................................................. 26
Table 2-7: Mass Balance for Blended Polyol ............................................................................................. 27
Table 2-8: Mass Balance for Pre-polymer Polyol (PP-100) ...................................................................... 28
Table 2-9: Mass Balance for Pre-polymer Polyol (PP-100 D) ................................................................... 28
Table 2-10: Mass Balance for Cross Linker ............................................................................................... 29
Table 2-11: Mass Balance for Stabilizer .................................................................................................... 31
Table 2-12: Existing Solvent consumption and Recovery ........................................................................ 31
Table 2-13: Proposed after amendment Solvent consumption and Recovery ........................................ 31
Table 2-14: Existing Pollution Load Calculation ...................................................................................... 32
Table 2-15: Proposed Pollution Load Calculation ..................................................................................... 32
Table 2-16: Details of Raw Materials......................................................................................................... 34
Table 2-17: Details of Water consumption ................................................................................................ 37
Table 2-18: Details of Wastewater Generation ......................................................................................... 37

LIST OF FIGURES
Figure 2-1: Site Location Map .................................................................................................................... 15
Figure 2-2: Map Showing Project Boundary ............................................................................................. 16
Figure 2-3: Site Layout Map ....................................................................................................................... 17
Figure 2-4: Flow diagram for Polyether Polyol ......................................................................................... 20
Figure 2-5: Flow diagram for Polyester Polyol .......................................................................................... 22
Figure 2-6: Flow diagram for Polycarbonate Polyol ................................................................................. 23
Figure 2-7: Flow diagram for Polymer Polyol ............................................................................................ 26
Figure 2-8: Flow Diagram for Blended Polyol ........................................................................................... 27
Figure 2-9: Flow Diagram for Pre-polymer Polyol .................................................................................... 28
Figure 2-10: Flow Diagram for Cross Linker ............................................................................................. 29
Figure 2-11: Flow Diagram for Pentane Mixture ...................................................................................... 30
Figure 2-12: Flow Diagram for Stabilizer .................................................................................................. 30
Figure 2-13: Existing Water Balance ......................................................................................................... 39
Figure 2-14: Water Balance after Amendment ......................................................................................... 40

EXPANDED POLYMER SYSTEMS PVT. LTD. PLANT AT GIDC ESTATE DAHEJ INTRODUCTION
1 INTRODUCTION
1.1 Identification of Project and Project Proponent
Expanded Polymer Systems Private Limited (EPSPL) was born as Expanded Incorporation in 1983. Expanded
Incorporation started with blending Polyols at the small gala in Nand kishore Industrial Estate in Andheri. It also
complimented its PU chemicals business with the marketing of PU machinery from leading manufacturers around
the world.
In 1987, Expanded Incorporation developed in-house technology for manufacturing polyester polyols and in 1991, it
moved into the first building of its new manufacturing unit at Pawne, Navi Mumbai. Here, it develops in-house
technology for manufacturing polyether polyols.
In 2001, Expanded Incorporation introduced specialty polyether polyols in its existing products.
In 2007, Expanded Incorporation becomes Expanded Polymer Systems Pvt. Ltd. on completion of its 15 years.
In 2010, Expanded Polymer Systems Pvt. Ltd. commissioned a new plant with a much higher production capacity at
Dahej (Gujarat), with a PO bulk storage facility at the GCPTCL, Dahej Tank Farm. Expanded Polymer Systems Pvt.
Ltd is an ISO 9001:2015 company.
This proposed project is for amendment in existing Environment Clearance received to establish Petrochemical
based processing (processes other than cracking & reformation and not covered under the complexes)
manufacturing Plant at Plot No. CH-10, GIDC Estate Dahej, Taluka Vagra, District Bharuch, Gujarat State.
1.2 Purpose of the Report
M/s. Expanded Polymer Systems Pvt Ltd (EPSPL) has received Environment Clearance for petrochemical based
processing manufacturing plant located at plot no. CH-10, GIDC Estate Dahej, Taluka Vagra, District Bharuch,
Gujarat, vide letter no. SEIAA/GUJ/EC/5(e) /1071/2018 dated 05.10.2018 attached as Annexure 1. Permission
received till date for this manufacturing facility is given in Table 1-1.
Table 1-1: Permission Received Till Date

S. Regulatory
Permission Permission number Attached As
No. Authority
SEIAA/GUJ/EC/5(e)/1071/2018 dated
1 Environmental Clearance SEIAA Gujarat Annexure 1
05/10/2018
No. GPCB/BRCH-B/CCA-16(3)/ID.
2 CTE Amendment GPCB Annexure 2
29454/491683 dated 18/01/2019
CTE Amendment No. CTE – 124479
3 CTE Product Mix GPCB Annexure 3
dated 24/03/2023
AWH 114731 dated 20/11/21 and
4 Existing CCA GPCB Annexure 4
valid upto 23/09/2025
Details of all the products as per the permissions mentioned in table above are as follows:
Table 1-2: Existing Production Details (As per EC No. SEIAA/GUJ/EC/5(e)/1071/2018 dated 05/10/2018)
Sr. Name of the Products CAS no. Quantity MT/Month End-use of
No. Existing Proposed Total product
1 Polyether Polyol 9082-00-2/ 25791-96-2/ 2000 3950 5950 Rigid, Flexible

52625-13-5/ 9049-71-2/ polyurethane
25322-69-4 foam, Shoe
2 Polyester /Polycarbonate 9003-11-6/ 124-04-9/ 111- 0 1710 1710 sole, Coating,
Polyol 46-6/ 140936-35-2/ 26702- Adhesive,

Sr. Name of the Products CAS no. Quantity MT/Month End-use of

No. Existing Proposed Total product
65-8/ 9010-89-3/ 25103- Sealant,
87-1/ 24938-37-2/ 86713- elastomer and
72-6/ 698388-01-1 various
3 Polymer Polyol 57913-80-1 0 600 600 polyurethane
applications
4 Blended Polyol 9049-71-2/ 52625-13-5/ 0 5750 5750
3030-47-5/ 52625-13-5/
75-56-9
5 Prepolymer 57-50-1/ 101-68-8/ 86713- 0 1125 1125
72-6
6 Cross Linker 107-21-1/ 280-57-9/ 102- 0 300 300
71-6/
Pentane Mixture 287-92-3/ 78-78-4/ 109-66-
7 (Cyclopentane/ Isopentane/ 0 0 150 150
N- Pentane)
8 Stabiliser 2094-99-7 / 52625-13-5 0 30 30
1.3 Proposed Amendment Required
Details of amendment required in existing EC are mentioned as following;
Table 1-3: Proposed Product List

Sr. Name of the Quantity MT/Month End-use of
CAS no. Remarks
No. Products Existing Proposed Total product
9082-00-2/ 25791-
96-2/ 52625-13-5/
1 Polyether Polyol 5950 0 5950 No Change
9049-71-2/ 25322-
69-4
9003-11-6/124-04-
9/ 111-46-6/
Polyester 140936-35-2/
2 /Polycarbonate 26702-65-8/ 9010- 1710 -1710 0
Polyol 89-3/ 25103-87-1/
24938-37-2/ 86713- To split the
72-6/ 698388-01-1 production
Rigid, Flexible quantity as
9003-11-6/124-04-
polyurethane given in Sr. 2a &
9/ 111-46-6/
2a Polyester Polyol 0 864 864 foam, Shoe sole, 2b along with
140936-35-2/
Coating, reduction
26702-65-8
Adhesive,
9010-89-3/ 25103-
Sealant,
Polycarbonate 87-1/ 24938-37-2/
2b 0 146 146 elastomer and
Polyol 86713-72-6/
various
698388-01-1
polyurethane
applications Additional
3 Polymer Polyol 57913-80-1 600 700 1300
quantity
9049-71-2/ 52625-
4 Blended Polyol 13-5/ 3030-47-5/ 5750 0 5750 No Change
52625-13-5/75-56-9
57-50-1/ 101-68-8/
5 Prepolymer 1125 0 1125 No Change
86713-72-6
107-21-1/ 280-57-9/
6 Cross Linker 300 0 300 No Change
102-71-6/
Pentane Mixture 287-92-3/ 78-78-4/
150 0 150 No Change
7 (Cyclopentane/ 109-66-0

Sr. Name of the Quantity MT/Month End-use of

CAS no. Remarks
No. Products Existing Proposed Total product
Isopentane/N-
Pentane)
2094-99-7/ 52625-
8 Stabiliser 30 0 30 No Change
13-5
Total 15615 0 15615 No increase
1.3.1 Justification for Amendment

1. Bifurcate product i.e. “Polyester Polyol (1500 MTPM) and Polycarbonate Polyol (210MTPM)” instead of EC
quantity 1710 MTPM for Polyester polyol/polycarbonate as it was a typing mistake and all the calculations
for water, fuel, waste, emissions are based on bifurcated quantity.
2. To increase production of Polymer Polyol by 700 MTPM i.e. from 600 MTPM to 1300 MTPM, & reduction of
polyester polyol by 636 MTPM and polycarbonate polyol by 64 MTPM (total reduction by 700 MTPM).
3. Final balance of Polyester Polyol will be 864 MTPM and Polycarbonate Polyol will be 146 MTPM. Total
production of the project will remain same as per existing EC which is 15615 MTPM.
Hence, Project proponent would like to request Hon. SEIAA / SEAC for the following amendments in existing EC;
 Change in production capacity of 3 products i.e. Polyester Polyol, Polycarbonate Polyol and Polymer Polyol
without changing overall production capacity.
 Change in total water consumption from 966.25 KLD to 968.03 KLD.
 Reduction in fresh water consumption from 647.95 KLD to 640.73 KLD.
 Reduction in industrial waste water generation from 50.38 KLD to 49.92 KLD.
 Reduction of hazardous waste generation by 3 MT/Annum.
EC conditions with amendments required are given in Table 1-4.

AMENDMENT IN EXISTING EC OF PETROCHEMICAL BASED PROCESSING MFG. PLANT AT GIDC ESTATE
EXPANDED POLYMER SYSTEMS PVT. LTD. DAHEJ INTRODUCTION
Table 1-4: EC Conditions in which Amendment is Required

Sr. EC Condition no. in Details mentioned in existing EC issued vide letter no. SEIAA/GUJ/EC/5(e) Proposed Amendment required in existing EC Reason for Amendment in
No which changes /1071/2018 dated 05.10.2018 EC
proposed
1 Detail of Products Sr. Name of CAS No. Quantity (MT/Month) End use of Sr. Name of the Quantity (MT/Month) End-use of To split the production
No Products product CAS no. Remarks quantity as given in Sr. 2a &
Existing Proposed Total No. Products Existing Proposed Total product
2b along with reduction and
1 Polyether 9082-00-2/ 2000 3950 5950 Rigid, 9082-00-2/ Rigid, Flexible to increase the production of
Polyol 25791-96-2/ flexible 25791-96-2/ polyurethane Polymer Polyol
52625-13-5/ polyurethane 1 Polyether Polyol 52625-13-5/ 5950 0 5950 foam, Shoe No Change
9049-71-2/ foam shoe 9049-71-2/ sole, Coating,
25322-69-4 sole coating 25322-69-4 Adhesive,
adhesive 9003-11-6/124- Sealant,
2 Polyester 9003-1 1 -6/ 0 1710 1710 sealant elastomer and
Polyol/ 124-04- 04-9/ 111-46-6/
elastomer 140936-35-2/ various
Polycarbonate 9/111- 46-6/ and various polyurethane
Polyol 140936-35-2/ Polyester 26702-65-8/
polyurethane 2 /Polycarbonate 9010-89-3/ 1710 -1710 0 applications
26702-65-8/ applications
9010-89-3/ Polyol 25103-87-1/
25103-87-1/ 24938-37-2/ To split the
24938-37-2/ 86713-72-6/ production
86713-72-6/ 698388-01-1 quantity as
698388-01-1 given in Sr.
9003-11-6/124-
2a & 2b
3 Polymer Polyol 57913-80-1 0 600 600 04-9/ 111-46-6/
2a Polyester Polyol 0 864 864 along with
140936-35-2/
4 Blended Polyol 9049-71-2/ 0 5750 5750 reduction
26702-65-8
52625-13-5/
3030-47-5/ 9010-89-3/
52625-13-5/ 25103-87-1/
Polycarbonate
75-56-9 2b 24938-37-2/ 0 146 146
Polyol
86713-72-6/
5 Pre-polymer 57-50-1/101- 0 1125 1125 698388-01-1
68-8/
86713-72-6 Additional
3 Polymer Polyol 57913-80-1 600 700 1300
quantity
6 Cross Linker 107-21-1/ 0 300 300
280- 57-9 9049-71-2/
102-71-6 52625-13-5/
4 Blended Polyol 3030-47-5/ 5750 0 5750 No Change
7 Pentane 287-92-3/ 0 150 150 52625-13-5/75-
Mixture 78-78-4t 56-9
(Cyclopentane/ 109-66-0
Iso-pentane/ 57-50-1/ 101-
N-Pentane) 5 Prepolymer 68-8/ 86713-72- 1125 0 1125 No Change
6
8 Stabiliser 2094-99-7 0 30 30
52625-13-5 107-21-1/ 280-
6 Cross Linker 300 0 300 No Change
57-9/ 102-71-6/
Pentane Mixture
(Cyclopentane/ 287-92-3/ 78-
150 0 150 No Change
7 Isopentane/N- 78-4/ 109-66-0
Pentane)
2094-99-7 /
8 Stabiliser 30 0 30 No Change
52625-13-5
No
Total 15615 0 15615
increase
2 A.1 Specific Condition Spent solvent as methanol (636 MT/year) shall be disposed off by Incineration at CHWIF or co- Spent solvent as methanol (444 MT/year) shall be disposed off by Incineration at CHWIF or co-processing or by selling Decrease due to reduction of
1 processing or by selling to authorize recyclers having rule 9 permission under HW Rules 2016. to authorize recyclers having rule 9 permission under HW Rules 2016. production capacity of
Polycarbonate Polyol
3 A.1 Specific Condition Spent solvent as isopropyl alcohol (120 MT/ Year) shall be disposed off by Incineration at Spent solvent as isopropyl alcohol (260 MT/ Year) shall be disposed off by Incineration at CHWIF or co-processing or by Increase due to increase in
2 CHWIF or co-processing or by selling to authorize recyclers having rule 9 permission under HW selling to authorize recyclers having rule 9 permission under HW Rules 2016. production capacity of
Rules 2016. Polymer Polyol
4 A.1 Specific Condition Spent solvent as Methylene Chloride (42 MT/ Year) shall be disposed off by Incineration at Spent solvent as Methylene Chloride (91 MT/ Year) shall be disposed off by Incineration at CHWIF or co-processing or Increase due to increase in
3 CHWIF or co-processing or by selling to authorize recyclers having rule 9 permission under HW by selling to authorize recyclers having rule 9 permission under HW Rules 2016. production capacity of
Rules 2016. Polymer Polyol

proposed
5 A.2 Water 12 Total water requirement for the project shall not exceed 966.252 KL/day. Unit shall reuse Total water requirement for the project shall not exceed 968.03 KL/day. Unit shall reuse 327.3 KLD waste water (177.4 Reduction in fresh water due
318.30 KLD waste water (177.4 KLD steam condensate & 140.9 KLD from RO permeate of KLD steam condensate, 140.9 KLD from RO permeate of cooling tower bleed off & 9 KLD treated sewage) for Boiler, to increase of reused water
cooling tower bleed off) for Boiler, cooling tower, Domestic & gardening purposes within cooling tower, Domestic & gardening purposes within premises. Hence, fresh water conscription shall not exceed of treated sewage.
premises. Hence, fresh water conscription shall not exceed 647.952 KLD and it shall be met 640.73 KLD and it shall be met through GIDC water supply only. Prior permission from the concerned authority shall be
through GIDC water supply only. Prior permission from the concerned authority shall be obtained for withdrawal of water
obtained for withdrawal of water
6 A.2 Water 14 The industrial effluent generation from the project shall not exceed 13.66 KLD (Concentrated The industrial effluent generation from the project shall not exceed 8.0 KLD (Concentrated stream A from polyester Decrease due to reduction of
stream A from polyester polyol) and 36.81 Kl/day (Dilute Stream B) after proposed expansion polyol) and 36.36 Kl/day (Dilute Stream B) after proposed expansion production capacity of
polyester Polyol
7 A.2 Water 15 Steam A effluent shall be subjected to in-house distillation unit Distillate (6.9 KLD) shall be sent Steam A effluent shall be subjected to in-house distillation unit Distillate (3.92 KLD) shall be sent to ETP with dilute Decrease due to reduction of
to ETP with dilute stream & distillation residue (6.76 KLD) shall be sent to authorized co- stream & distillation residue (6.76 KLD) shall be sent to authorized co-processing unit or CHWIF or incinerate in thermal production capacity of
processing unit or CHWIF or incinerate in thermal oxidizer at onsite oxidizer at onsite polyester Polyol
8 A.2 Water 17 Total 43.7 kl/day of treated waste water shall be discharged through GIDC underground Total 34.16 kl/day of treated waste water shall be discharged through GIDC underground drainage system after Reduction in treated water
drainage system after conforming GPCB norm conforming GPCB norm discharge due to increase in
reused water and reduction
in production capacity.
9 A.2 Water 19 The domestic wastewater generation shall not exceed 9 KL/day and it shall be treated in ETP The domestic wastewater generation shall not exceed 9 KL/day and it shall be treated in STP and treated water will be Change in treatment and
with industrial effluent.' used for gardening purposes in industrial premises disposal mode
10 A.4 Solid /Hazardous Category Quantity in MTPA Category as Quantity in MTPA Spent Solvent as Methanol
Waste 34 as per per decreases due to reduction
S. Types of Hazardous Method of S. Types of Hazardous Method of of production capacity of
No. waste Waste as Disposal Remark Polycarbonate Polyol.
Existing Proposed Total No. waste Waste as Existing Proposed Total Disposal
per Rule per Rule
2016 2016 Spent Solvent as Isopropyl
Collection, Collection, Storage, Alcohol and Spent Solvent as
Storage, Transportation, Methylene Chloride increase
Transportation, 1. ETP Sludge 34.2 48.504 0 48.504 No Change Disposal at TSDF- due to increase in production
1. ETP Sludge 34.2 6 42.504 48.504
Disposal at TSDF- BEIL, Dahej/ capacity of Polymer Polyol.
BEIL, Dahej/ Ankleshwar.
Ankleshwar.
Collection, Storage,
Collection, Transportation,
Storage, Waste /Spent
2. 5.1 7836 L 0 7836 L No Change Disposal by selling to
Waste Transportation, Oil
2. 5.1 960 Lit 6876 Lit 7836 L Registered
/Spent Oil Disposal by selling Recyclers.
to Registered
Recyclers. Discarded
Collection, Storage,
Containers/
Discarded Collection, Detoxification,
barrels used
Containers/ Storage, 3. 33.1 260 0 260 No Change Transportation,
for hazardous
barrels used Detoxification, Disposal by selling to
waste/
3. for 33.1 30 230 260 Transportation, authorized recycler.
chemicals
hazardous Disposal by selling
waste/ to authorized Collection, Storage,
chemicals recycler. Transportation,
Collection, Disposal by
Process
Storage, 4. 20.4 523.08 0 523.08 No Change incineration at
Sludge
Transportation, CHWIF/Co-
Process Disposal by processing/Cement
4. 20.4 30 493.08 523.08 Industry.
Sludge incineration at
CHWIF/Co- Cotton waste Collection, storage,
processing/Cement Containing oil Transportation,
Industry. 5. i.e. waste 5.2 1.944 0 1.944 No Change Disposal by
Cotton residue incineration at
Collection, containing oil CHWIF.
waste
storage,
Containing Collection, storage,
Transportation,
5. oil i.e. waste 5.2 0.24 1.704 1.944 Transportation,
Disposal by Waste Schedule VI-
residue 6. 0.24 0 0.24 No Change Disposal by
incineration at membrane B3- B3010
containing incineration at
CHWIF.
oil CHWIF.

proposed
Collection, Decrease due Collection, storage,
storage, to reduction of Transportation,
Schedule
Waste Transportation, Spent Solvent production Disposal by
6. VI- B3- 0.03 0.21 0.24 7 20.2 636 -192 444
membrane Disposal by as Methanol capacity of incineration at
B3010
incineration at Polycarbonate CHWIF/ Co-
CHWIF. Polyol processing/ Sale.
Collection, Collection, storage,
storage, Transportation,
Spent Transportation, Spent Solvent
Disposal by
7 Solvent as 20.2 - 636 636 Disposal by 8 as Isopropyl 20.2 120 140 260
incineration at
Methanol incineration at Alcohol Increase due CHWIF/ Co-
CHWIF/ Co- to increase in processing/ Sale.
processing/ Sale. production
capacity of Collection, storage,
Collection, Transportation,
storage, Spent Solvent Polymer Polyol
Spent Disposal by
Transportation, 9 as Methylene 20.2 42 49 91
Solvent as incineration at
8 20.2 - 120 120 Disposal by Chloride
Isopropyl CHWIF/ Co-
incineration at processing/ Sale.
Alcohol
CHWIF/ Co-
processing/ Sale. Polyurethane Schedule VI-
10 12 0 12 No change Sale or Incineration
Foam B3- B3010
Collection,
storage, Collection, storage,
Spent
Transportation, Transportation,
Solvent as
9 20.2 - 42 42 Disposal by Distillation Disposal by
Methylene 11 20.3 2433.6 0 2433.6 No Change
incineration at residue incineration at
Chloride
CHWIF/ Co- CHWIF/ Co-
processing/ Sale. processing/ Sale.
Schedule
Polyurethane Sale or
10 VI- B3- - 12 12
Foam Incineration
B3010
Collection,
storage,
Transportation,
Distillation
11 20.3 - 2433.6 2433.6 Disposal by
residue
incineration at
CHWIF/ Co-
processing/ Sale.

AMENDMENT IN EXISTING EC OF PETROCHEMICAL BASED PROCESSING
EXPANDED POLYMER SYSTEMS PVT. LTD. MFG. PLANT AT GIDC ESTATE DAHEJ INTRODUCTION
Table 1-5: Pollution Load Statement after EC Amendment

S.
Parameter Unit Existing Amendment in EC Remarks
No.
1 Land Area m2 49,996 49,996 No change
2 Cost of the Project, INR in Crores 82.5 82.5 No change in project cost
Reduction in Fresh water consumption by 7.22 KLD due to
3 Fresh Water Requirement m3/day 647.95 640.73
proposed change
Recycle water (RO Permeate/ steam Increase in recycled water consumption by 9 KLD due to proposed
4 m3/day 318.3 327.3
Condensate/ STP) change
Increase in total water consumption by 1.78 KLD due to proposed
5 Total Water Requirement m3/day 966.25 968.03
change
6 Domestic Waste Water Generation m3/day 12 12 No change
7 Industrial Waste Water Generation m3/day 41.38 40.92 Reduction of 0.46 KLD due to proposed change
Process water sent to authorized co-
8 m3/day 6.76 6.76 No change
processing unit or CHWIF
9 KLD Sewage will be sent to STP and 0.55 KLD industrial water
9 Waste water to ETP m3/day 43.71 34.16 will be reduced. Reduction in treated water disposal to GIDC drain
by 9.55 KLD
10 Industrial Effluent Disposal Mode -- To GIDC Drain To GIDC Drain No Change
Treatment in ETP
Treatment in STP and
Domestic Waste Water Treatment and along with industrial
11 -- treated water will be Change as explained
Disposal waste water and
reused for Gardening
disposal to GIDC Drain
12 Flue Gas Stacks Nos. 19 19 No Change
13 Process Vents Nos. 0 0 No Change
14 Fuel Consumption
LDO: LDO:
8603.2 Lit/Day 8603.2 Lit/Day
14.1 Boilers, Thermopacks and thermal Oxidiser No Change
or or
NG: 7969 SM3/Day NG: 7969 SM3/Day
14.2 D.G. sets HSD: 842 Lit/day HSD: 842 Lit/day No Change
15 Hazardous Waste
15.1 ETP Sludge MTPA 48.504 48.504 No Change

EXPANDED POLYMER SYSTEMS PVT. LTD. MFG. PLANT AT GIDC ESTATE DAHEJ INTRODUCTION
S.
Parameter Unit Existing Amendment in EC Remarks
No.
15.2 Waste /Spent Oil MTPA 7836 L 7836 L No Change
Discarded Containers/ barrels used for
15.3 MTPA 260 260 No Change
hazardous waste/ chemicals
15.4 Process Sludge MTPA 523.08 523.08 No Change
Cotton waste Containing oil i.e. waste
15.5 MTPA 1.944 1.944 No Change
residue containing oil
15.6 Waste membrane MTPA 0.24 0.24 No Change
Decrease due to reduction of production capacity of
15.7 Spent Solvent as Methanol MTPA 636 444
Polycarbonate Polyol
15.8 Spent Solvent as Isopropyl Alcohol MTPA 120 260
Increase due to increase in production capacity of Polymer Polyol
15.9 Spent Solvent as Methylene Chloride MTPA 42 91
15.10 Polyurethane Foam MTPA 12 12 No change
15.11 Distillation residue MTPA 2433.6 2433.6 No Change
Total MTPA 11913.37 11910.37 Reduction of 3 MT/Annum of hazardous waste

EXPANDED POLYMER SYSTEMS PVT. LTD. PLANT AT GIDC ESTATE DAHEJ PROJECT DESCRIPTION
2 PROJECT DESCRIPTION
2.1 Type of Project
The proposed project is for amendment in existing environmental clearance of petrochemical based processing
manufacturing plant at plot no. CH-10, GIDC Estate Dahej, Taluka Vagra, District Bharuch, Gujarat, covered under
Category 5 (e) “B” (since project is located in a notified Industrial area of GIDC Dahej) as per EIA notification vide
gazette no. S.O. 1533 dated 14th September 2006.
2.2 Location
Proposed project is located at Plot No. CH-10 of GIDC Dahej in District Bharuch of Gujarat State. The general
location of the proposed project in India is presented in Figure 2-1.
Map showing the project boundary on Google image is shown as Figure 2-2 whereas the site co-ordinates are
shown in Table 2-1. Similarly the site layout map is presented as Figure 2-3 and area breakup at site is given in
Table 2-2. There will be no change in site lay out map and in area breakup after proposed
amendment.
Table 2-1: Latitude and Longitude of Project Site
S. No. Latitude Longitude S. No. Latitude Longitude
A 21°43’0.59” N 72°36’14.06” E C 21°43’8.17” N 72°36’21.72” E
B 21°43’8.71” N 72°36’14.86” E D 21°42’59.99” N 72°36’20.91” E
Figure 2-1: Site Location Map

EXPANDED POLYMER SYSTEMS PVT. LTD. MFG. PLANT AT GIDC ESTATE DAHEJ PROJECT DESCRIPTION
Figure 2-2: Map Showing Project Boundary

EXPANDED POLYMER SYSTEMS PVT. LTD. DAHEJ PROJECT DESCRIPTION
Figure 2-3: Site Layout Map

Table 2-2: Area Break up at Site

S. No. Title Area in m2 % of Total Area
1 Plant Facilities 5864 11.73
2 Future plant building area 3297 6.6
3 Fuel Storage 213.5 0.43
4 Water Storage 227.5 0.46
5 Hazardous waste Storage 87.5 0.17
6 Hazardous chemicals Storage 4316 8.63
7 Raw material and finished good storage area 2467.5 4.94
8 Green belt 13980 27.96
9 Utilities 1155 2.31
10 Environmental facilities (Including Proposed) 175 0.35
11 Others including Administration building 1542 3.08
12 Non Built-up area (Including road facilities) 16671 33.34
Total 49996 100%
2.3 Technology and Process Description
Process technology of the production will remain same as per existing EC/ EIA. We are proposing for bifurcation of
the given production capacity which is 1710 MTPM of Polyester /Polycarbonate Polyol (Polyester Polyol 1500 MTPM
and Polycarbonate Polyol 210 MTPM) and to increase production of Polymer Polyol by 700 MTPM i.e. from 600
MTPM to 1300 MTPM, reduction of polyester polyol by 636 MTPM and polycarbonate polyol by 64 MTPM (total
reduction by 700 MTPM). Final balance of Polyester Polyol will be 864 MTPM and Polycarbonate Polyol will be 146
MTPM (total reduction by 700 MTPM) and, total production of the project will remain same as per existing EC which
is 15615 MTPM.
Mass Balance will be same as per existing EC/ EIA for the product there is only change in production quantity.
Details of the production capacity is given in Table 1-3.
Fuel and water requirement, hazardous waste, waste water, emission were calculated based on 1500 MT/M of
Polyester Polyol and 210 MT/M of Polycarbonate Polyol while submission of application at SEIAA and hence no
changes are expected in any of above with bifurcation of products.
Due to amendment, there will be no increase in water consumption, wastewater generation, fuel consumption-
emission, hazardous waste generation in the project. Due to amendment, there will be no increase in water
consumption, wastewater generation, fuel consumption-emission, hazardous waste generation from the project.
2.3.1 Polyether Polyol
Process Description
Stage 1: Raw Material Charging Liquid and solid starter (Polyhydric Alcohol: Glycerine, DEG, Sorbitol, TMP and
Sucrose) are charged with catalyst solution to alcoholation vessel or melter for anhydration.
Stage 2: Anhydration Anhydration takes place at 110°c to 140°c by using agitation, steam heating and vacuum.
For anhydration, melter and alcoholation vessel will be used for rigid and flexible polyol respectively.
Stage 3: Pre-polymerisation after anhydration starter material is transferred to pre-polymerisation vessel where
initial polymerization reaction takes place at 100° c to 120° c and pressure (14 to 100 PSI) with alkylene oxide
which is added from batch tank. After desired polymerization is achieved reaction mass is transferred to main
polymerization vessel.

Stage 4: Polymerization
Polymerization is carried out with Alkylene Oxide which are added from batch tank. This reaction carries out at
elevated temperature (100 to 120oc), pressure (14 to 100 PSI) and under inert atmosphere (Nitrogen blanketing).
After achieving the desired degree of polymerization unreacted PO and EO vapours will be vented out (degassing)
to scrub out with water.
Stage 5: Neutralization, Crystallization and Filtration
Acid and water are added to neutralize. Anhydration is carried out for removal of water. After removing water,
Magnesium silicate will be added as adsorbent for purification. Filtration is carried out for removing added
adsorbent and salts. Filter cake is sent for incineration.
Stage 6: Stabilisation
Stabilizers are added to improve properties (self-life, colour etc.) of the Polyether Polyol
Stage 7: Quality Check
After quality check finished polyol is either transferred to storage tank or in drums/bulk tanker for dispatch.
Reaction Chemistry

Figure 2-4: Flow diagram for Polyether Polyol
PO & EO D STARTER: SOLID B STARTER: LIQUID A CATALYST: BASE CATALYST C STAGE 2

Storage Tank Polyhydric Alcohol Polyhydric Alcohol SOLUTION OR OTHER CATALYST
STAGE 2
ALCHOLATION OR MELTER Receiver
(FOR RIGID) ANHYDRATION Water ETP
removal
PO B PREPOLYMERISATION A
(FOR FLEXIBLE POLYOL) STAGE 3
PO
POLYMERIZATION A
EO
PO/EO ETP STAGE 4
DEGASSING B SCRUBBING
Landfill
ACID/WATER/MA NEUTRALISATION CAKE
GNASIUM CRYSTALISATION &
ETP
OILICATE FILTERAION WATER STAGE 5
STABILISERS STABILIZATION STAGE 6
POLYETHER POLYOL STAGE 7
Table 2-3: Mass Balance for Polyether Polyol
S. INPUT/MT of Product
No. Raw Materials Quantity (MT)
1 Glycerine 0.071
2 Sucrose 0.0769
3 Propylene oxide 0.533

4 Ethylene oxide 0.2
5 Fullers earth 0.004
6 Catalyst solution 0.005
7 Neutralizer and stabilizer 0.005
8 Water 0.072
9 Diethylene Glycol 0.113
10 Double metal catalyst 0.00005
Total 1.080
OUTPUT/MT of Product
S.
Liquid Air Recovery/ Solid Remark
No. Components
Effluent Emission Product Waste
1 Polyether Polyol R 1 Product
2 Liquid Effluent 0.007
3 Process Effluent 0.035
To ETP for Treatment
Liquid Effluent from
4 0.030
Vacuum Pump
5 Solid Waste 0.0073 To CHWIF for Incineration
0.072 0 1 0.0073
Total
1.080
Note: Solid waste generation optimized to 0.007325 MT/MT.
2.3.2 Polyester Polyol
Process Description
 Polyester polyol is manufactured by the reaction of Liquid raw material i.e. polyhydric alcohol with solid raw
material like adipic acid and phthalic anhydride which is in powder and flakes form respectively.
 All the required raw materials are added at the beginning of the reaction or in some cases step wise.
 This reaction is condensation polymerization where the by-product produced i.e. water is continuously removed
by distillation method. This is a reversible reaction so water need to be removed immediately to let the reaction
proceed in forward direction.
 This is an endothermic reaction as removal of water needs a lot of heat.
 Raw Materials are slowly heated up to 230 °C with nitrogen on for fast removal of water. Total vacuum is also
applied when water removal slows down.
Types of Polyester polyol
 Aromatic Polyester Polyol,

 Aliphatic Polyester Polyol.

Chemical Reaction
Figure 2-5: Flow diagram for Polyester Polyol
RAW MATERIAL: RAW MATERIAL:

SOLID Glycol
dbasic acid
Catalyst amine solution
catalyst or other catalyst
Polymerization at elevated Water

temperature Receiver
Cooling & Drying
Discharge into storage tank or drums
Table 2-4: Mass Balance for Polyester Polyol by Reaction of Adipic acid and DEG
1 Adipic Acid 0.739
2 Diethylene Glycol 0.251
3 Mono Ethylene Glycol 0.214
4 Water 0.034
Total 1.238
S.
Liquid Air Recovery/ Remark
No. Components Solid Waste
Effluent Emission Product
1 Polyester Polyol 1 Product
2 Liquid Effluent 0.121 To ETP for Treatment
3 Liquid Effluent 0.117 Sent for Incineration
0.238 0 1 0
Total
1.238

2.3.3 Polycarbonate Polyol
Process Description
 Polycarbonate polyol is manufactured by the reaction of liquid raw material i.e. polyhydric alcohol
/polyether polyol and dimethyl carbonate (DMC).
 All the required raw materials are added are at the beginning of the reaction or in some cases step wise.
 This reaction is a condensation polymerization where the by-product produced is methanol. DMC and
methanol/DMC mixture which is continuously removed by the distillation method. This is a reversible
reaction so by-product need to be removed immediately to let the reaction proceed in forward direction.
This is an endothermic reaction.
 Raw materials are slowly heated up to 230°C with nitrogen purging on for fast removal of the by-product.
Total vacuum is also applied when by-product removal slows down.
Types of Polycarbonate polyol.
 Aromatic polycarbonate polyol

 Aliphatic polycarbonate polyol
Chemical Reactions
Figure 2-6: Flow diagram for Polycarbonate Polyol
Raw Material: Polyether

Raw Material : DMC
Polyol/Glycols
Catalyst: Tin Based Catalyst
Methanol Polymerization At
(99.99%) Elevated Temperature
Sale Cooling & Drying
Discharge into Storage

Tank Or Drums

Table 2-5: Mass Balance for Polycarbonate Polyol
1 Polyether Polyol 0.90
2 Dimethyl carbonate 0.35
Total 1.25
S.
No. Components
1 Polycarbonate Polyol 1 Product
2 Methanol 0.25 To solvent recovery System
0.25 0 1 0
Total
1.25
Recovery of Methanol
A mixture of dimethyl carbonate and methanol is continuously fed to a first column A and also a solution of
dimethyl oxalate is fed continuously. The mixture is refluxed by heating the bottom of the column to effect
continuous distillation and methanol is taken out from the top of the First column as a distilled solution 3. A first
column bottom draw i.e. solution 2 is a mixture of dimethyl carbonate and dimethyl oxalate and it is fed to a
second column B and refluxed to effect continuous distillation whereby dimethyl carbonate is taken out from the
top thereof as a second column distilled solution 5. A second tower draw, solution 4 at the bottom thereof is
dimethyl oxalate as a distillation residue and it is returned to the first column A to use again by circulation whereby
continuous operation can be done. By this way we can separate the DMC/methanol mixture
Block Diagram of Methanol Recovery
DMC 30%
Methanol 70%
From Process
REFLUX
Distillation
DMC reuse in
Methanol for Sale
Process

Process Flow Diagram of Methanol Recovery
2.3.4 Polymer Polyol
Process Description
Partial quantity of Polyol is charged into the reactor. Then styrene, acrylonitrile, IPA, stabilizer, catalyst and polyol
are charged simultaneously at elevated temperature and at inert atmosphere. After the addition is over catalyst is
added further to ensure complete conversion. Isopropyl Alcohol is then recovered by condensing the vapours. IPA
is collected in receiver and 90% IPA is recycled in next batch. PMPO is then cooled and drummed or pumped into
tanker as per the requirement. Once in three months’ reactor is to be washed with methyl chloride to dissolve any
solid polymer deposited on the inside surface of the reactor.
Chemical Reaction

Figure 2-7: Flow diagram for Polymer Polyol
Raw Material: Styrene, Raw Material: Polyol,

Accrylonitrile Stabiliser, IPA
Catalyst Solution in Polyol
Polymerization at elevated
temp.
IPA recovery &
Recycle to Batch
Cooling & Drying
Tank
Discharge into storage tank

or drums
Table 2-6: Mass Balance for Polymer Polyol
1 Polyol 0.582
2 Iso Propyl Alcohol 0.061
3 Catalyst 0.001
4 Styrene 0.233
5 Acrylonitrile 0.155
6 Stabilizer 0.034
7 Water 0.103
Total 1.169
S.
No. Components
1 Polymer Polyol 1 Product
2 Iso Propyl Alcohol 0.055 Recycled
3 Spent Iso Propyl Alcohol 0.006 Sale / Incineration*
4 Liquid Effluent 0.005
5 Process Effluent 0.088
To ETP for Treatment
Liquid Effluent from Vacuum
6 0.015
Pump
0.108 0 1.061 0
Total
1.169
*Note: Entire quantity of IPA is required to be disposed off at defined interval. Overall spent IPA comes out as
0.01663 Mt/Mt of product. MDC is required to clean the reactor. Overall MDC need to be disposed off is quantified
as 0.00583 Mt/Mt.
Water and waste water optimized to 0.103 Mt/Mt and 0.1085 Mt/Mt respectively.

2.3.5 Blended Polyol
Process Description
Polyether polyol and polyester are added to blender, temperature is brought to ambient if it is high then additives,
surfactant, blowing agent are added to Blender. Agitation is done to mix it well. It is sampled and then drummed.
Figure 2-8: Flow Diagram for Blended Polyol
Polyether Polyol Polyester Polyol
Catalyst Surfactant
Blowing
Agent
Blended Polyol
Drumming
Table 2-7: Mass Balance for Blended Polyol

1 Polyether Polyol 50- 88.6
2 Polyester Polyol 20.27- 7
3 Blowing agent/ 141B 22- 0
4 Tertiary Amine Catalyst 0.97- 2.4
5 Surfactant 1.5- 2
6 Fire Retardant 5.26- 0
Total 100
S.
No. Components
1 Blended Polyol 100 Product
0 0 100 0
Total
100
2.3.6 Pre-polymer Polyol
Process Description
Pre-polymer polyol is manufactured by reacting Methyl di-isocyanate (MDI) with polyol
Types of Pre-polymer polyol
 Polyester Prepolymer Polyol,

 Polyether Prepolymer Polyol.
Pure MDI drums which are stored in cold storage are heated up to 90 °C for 6 hrs. in a water bath to melt. Molten
MDI is charged into the reactor. Required amount of polyol mixture is charged into the batch tank. Polyol is fed at a
controlled rate into the reactor. Temperature and pressure of reactor is maintained. It is an exothermic reaction so

cooling is done to maintain the temperature at 90 °C. After feeding is over, digestion is to be done for three hrs.
Analyze for NCO content, if found ok, cool down to less than 60 °C and drum it.
Chemical Reaction
Figure 2-9: Flow Diagram for Pre-polymer Polyol
Raw Material: Raw Material:

MDI Polyol
POLYMERIZATION
At 85-90 c
Cooling
Discharge in drums
Table 2-8: Mass Balance for Pre-polymer Polyol (PP-100)

1 Polyol Mix 0.154
2 MDI (Methyl Di-Isocyanate) 0.346
Total 0.500
S.
Liquid Air Recovery/ Remark
No. Components Solid Waste
Effluent Emission Product
1 Prepolymer Polyol(PP 100) 0 0 0.5 0 Product
0 0 0.5 0
Total
0.500
Table 2-9: Mass Balance for Pre-polymer Polyol (PP-100 D)
1 Polyol Mix 0.153
2 Methyl di-isocyanate 0.347
Total 0.500

S.
No. Components
1 Pre-polymer Polyol (PP 100 D) 0.500 Product
0 0 0.500 0
Total
0.500
2.3.7 Cross Linker
Process Description
Glycols, catalyst and surfactant are added to Blender. Agitation is done to mix it well. Then drummed.
Figure 2-10: Flow Diagram for Cross Linker
Glycols
Catalyst
Surfactant
Cross Linker
Drumming
Table 2-10: Mass Balance for Cross Linker
1 Glycol 89.3
2 Tertiary Amine Catalyst 4.3
3 Silicon Surfactant 6.4
Total 100
S.
No. Components
1 Cross Linker 100 Product
0 0 100 0
Total
100
2.3.8 Pentane Mixture
Process Description
Cyclo-pentane, Iso-pentane and N-pentane are pumped from respective storage tank in a fixed ration as per the
requirement of customer through a static mixer and directly drummed or filled in a tanker.

Figure 2-11: Flow Diagram for Pentane Mixture
Isopentane
Cyclopentane N-Pentane
Static Mixture
Drumming
2.3.9 Stabilizer
Process Description
Stabilizer is manufactured by reacting Isocyanate (TMI) with polyol
Isocyanate TMI is charged into the batch Tank. Required amount of catalyst is added to batch tank and stirred well.
Required amount of polyol is charged into the reactor. Isocyanate is fed at a controlled rate into the reactor.
Temperature and pressure of reactor is maintained. It is an exothermic reaction so cooling is done to maintain the
temperature at 90 Deg C. After feeding is over, digestion is to be done for two hrs. Analyse for NCO content, if
found ok, cool down to less than 60 Deg C and drum it.
Figure 2-12: Flow Diagram for Stabilizer
Raw Material: Raw Material:

TMI Polyol
POLYMERIZATION
At 85-90 c
Cooling
Discharge in drums

Table 2-11: Mass Balance for Stabilizer
1 Polyether Polyol 0.098
2 TMI isocyanate 0.002
3 Catalyst T-12 0.000037
Total 0.1
S.
No. Components
1 Stabilizer 0.1 Product
0 0 0.1 0
Total
0.1
2.3.10 Solvent Recovery
Details of Solvent recovery is given as below;
Table 2-12: Existing Solvent consumption and Recovery

Quantity of
Spent Solvent Disposal/sell
S. Name of Solvent Used in Solvent %
Generated in Quantity Remark
No. Solvent MTPA recovered in Recovery
MTPA MTPA
MTPA
Generated in
Spent
Process as By
Solvent
1 product of 636 0 636 0
as
polycarbonate
methanol
polyol Sold to
authorized
2 IPA 439.2 439.2 319.2 120 ~73% under Rule-9
3 MDC 42 42 0 42 0
Table 2-13: Proposed after amendment Solvent consumption and Recovery

Spent Quantity of
S. Name of Solvent used in Solvent Solvent Disposal/ %
Remark
No. Solvent MTPA generated in recovered in Sell MTPA recovery
MTPA MTPA
Spent By Product of
1 Solvent as Polycarbonate 444 0 444 0
Methonol Polyol Will be sold
to authorized
2 IPA 955 955 695 260 ~72% under Rule-9
3 MDC 91 91 0 91 0
2.3.11 Pollution Load Calculation
Existing as well as proposed Pollution Load Calculation is given in Table 2-14 and Table 2-15 respectively.

Table 2-14: Existing Pollution Load Calculation

Nos. of Waste Water to Process Waste to
Sr. Name of the Quantity Water Consumption Waste Water to ETP
Working Incineration Incineration
No. Products
MT/Month MT/Year MT/Day Day MT/MT MT/Day MT/MT MT/Day MT/MT MT/Day MT/MT MT/Year
1 Polyether Polyol 5950 71400 198.3 30 0.072 14.28 0.072 14.4 0 0 0.0073 521.2
2a Polyester Polyol 1500 18000 57.7 26 0.035 2.02 0.122 7.0 0.117 6.76 0.000
2b Polycarbonate Polyol 210 2520 8.1 26 0 0 0 0 0 0 0 0
3 Polymer Polyol 600 7200 20.0 30 0.103 2.06 0.108 2.2 0 0 0 0
4 Blended Polyol 5750 69000 221.2 26 0 0 0 0 0 0 0 0
5 Prepolymer 1125 13500 43.3 26 0 0 0 0 0 0 0 0
6 Cross Linker 300 3600 11.5 26 0 0 0 0 0 0 0 0
Pentane Mixture
(Cyclopentane/
7 150 1800 5.8 26 0 0 0 0 0 0 0 0
Isopentane/ N-
Pentane)
8 Stabiliser 30 360 1.2 26 0 0 0 0 0 0 0 0
Total 15615 187380 566.9 18.36 23.6 6.76 521.2
Table 2-15: Proposed Pollution Load Calculation

No. Products
1 Polyether Polyol 5950 71400 198.3 30 0.072 14.28 0.072 14.4 0.0073 521.2
2a Polyester Polyol 864 10368 33.2 26 0.035 1.16 0.122 4.1 0.117 3.9* 0.000
2b Polycarbonate Polyol 146 1752 5.6 26 0.000 0.000 0.000
3 Polymer Polyol 1300 15600 43.3 30 0.103 4.46 0.108 4.7 0.000
4 Blended Polyol 5750 69000 221.2 26 0 0 0 0
5 Prepolymer 1125 13500 43.3 26 0 0 0 0
6 Cross Linker 300 3600 11.5 26 0 0 0 0
7 Pentane Mixture 150 1800 5.8 26 0 0 0 0

(Cyclopentane/


No. Products
Isopentane/ N-
Pentane)
8 Stabiliser 30 360 1.2 26 0 0 0 0
Total 15615 187380 563.4 19.91 23.2 3.9 521.2
Note: Existing 6.76 KLD is not reduced considering emergency situations in distillation for compliance.

2.4 Raw Material Consumption

Raw material consumption details along with storage details is given in Table 2-16. There will be no any additional storage is required. Existing storage is adequate after
proposed amendment.
Table 2-16: Details of Raw Materials

Consumption (MTPM) Operating Condition Capacity Max qty of
S. Means of No. of
Chemical State Hazard Involved Pressure Kg Temp, Of Vessel / storage
No. Existing Proposed Total Storage Packing
/Cm2 °C Bag (m3) (MT)
1 Castor Oil Liquid 550 0 550 - Storage Tank Ambient Atm 100 1 100
Di Ethylene
2 Liquid 1048.25 -159.0 889.2 Combustible Storage Tank Ambient Atm 100 1 100
Glycol
Ethylene Di
3 Liquid 60 0 60 Flammable Drums Ambient Atm 20 1 20
Amine
4 Ethylene Oxide Liquid 1190 0 1190 Flammable Bullet 10 4 20 2 40
5 Glycerine Liquid 500 0 500 Combustible Storage Tank Ambient Atm 100 1 100
6 Np Manich Liquid 1.2 0 1.2 Drums Ambient Atm 0 1 0
Ortho Phosphoric
7 Liquid 88 0 88 Non combustible Cans Ambient Atm 50 kg 200 10
Acid
Orthotolune Di
8 Solid 104 0 104 Non Flammable Drums Ambient Atm 250 kg 200 50
Amine
9 Penta Erithritol Solid 35 0 35 Combustible Bags Ambient Atm 50 kg 200 10
10 Phenol Manich Solid 1.2 0 1.2 Drums Ambient Atm 200 kg 6 1.2
11 Propylene Oxide Liquid 3171.35 0 3171.35 Flammable Bullet 30 1.2 100 2 200
12 Sorbitol Liquid 298 0 298 Combustible Storage tank Ambient Atm 100 1 100
13 Sucrose Solid 700 0 700 Non combustible 50 kg Bags Ambient Atm 50 kg 5000 250
Potassium
14 Solid 9 0 9 Non combustible Bags Ambient Atm 50 kg 80 4
Hydroxide
15 Novolac Solid 2.8 0 2.8 Drums Ambient Atm 2.8 14 2.8


S. Means of No. of
Trimethylol
16 Solid 90 0 90 Combustible Bags Ambient Atm 25 kg 800 20
Propane
Di Methyl
17 Liquid 73.29 -22.3 50.95 Highly flammable Drums Ambient Atm 250 kg 40 10
Carbonate
Diphenyl
Methane
18 Solid/Liquid 850 0 850 Combustible Drums Ambient/ -20 Atm 250 kg 1600 400
Diisocynate
(MDI)
19 Adipic Acid Solid 1108.5 -470.0 638.5 Combustible Jumbo Bags Ambient Atm 400 400 400
Phthalic
20 Solid 400 0 400 Combustible Jumbo Bags Ambient Atm 200 1 200
Anhydride
21 Stearic Acid Solid 20 0 20 Combustible Bags Ambient Atm 25 kg 400 10
22 Triethylamine Liquid 10 0 10 Flammable Drums Ambient Atm 200 kg 25 5

23 Diethylamine Liquid 10 0 10 Flammable Drums Ambient Atm 250 kg 800 200
24 Formaldehyde Liquid 10 0 10 Flammable gas Drums Ambient Atm 250 20 5
Silicon
25 Liquid 60 0 60 - Drums Ambient Atm 250 kg 120 30
Surfactants
26 Fire Retardants Liquid 360 0 360 - Drums Ambient Atm 250 720 180
27 Trigonox 21s Liquid 1 0 1 - Cylinder ambient 1 10 1 10
Trimethanol
28 Liquid 50 0 50 Combustible Drums Ambient Atm 250 kg 100 25
Amine
29 Nonyl Phenol Liquid 200 0 200 - Drums Ambient Atm 250 kg 400 100
30 M P Diol Liquid 25 0 25 - Drums Ambient Atm 10 40 10
31 Styrene Liquid 139.8 163.1 302.9 Flammable Storage tank Ambient Atm 30 1 30
32 Acrylonitrile Liquid 93 108.5 201.5 Flammable Storage tank Ambient Atm 30 1 30
33 141 B /Methalal Liquid 900 0 900 Drums Ambient Atm 250 kg 1600 400


S. Means of No. of
Methylene
34 Liquid 3.5 0 3.5 Flammable Drums Ambient Atm 10 40 10
chloride/DMF
35 Iso Propyl Alcohol Liquid 815.1 42.7 857.8 Flammable Drums Ambient Atm 75 300 75
Toluene Di
36 Liquid 100 0 100 Combustible Drums Ambient Atm 250 kg 200 50
Isocynate (Tdi)
37 Tmi Isocynate Liquid 0.6 0 0.6 - Drums Ambient Atm 200 kg 2 0.4
Tertiary Amine
38 Liquid 60 0 60 - Drums Ambient Atm 250 kg 120 30
Catalyst
Monoethylene
39 Liquid 321 -136.1 184.9 Flammable Storage tank Ambient Atm 30 2 60
Glycol
40 Cyclopentane Liquid 900 0 900 Flammable Storage tank 0.5 Atm 30 2 60
41 Fullers Earth Solid 36 0 36 - Bags Ambient Atm 25 250 6

2.5 Water Consumption, Wastewater Generation and Treatment Facilities
2.5.1 Source of water Supply
Water will be sourced from GIDC water supply.
Existing fresh water consumption is 648 KLD which will be reduced to 647.87 KLD after proposed change in product
mix. Water supply permission Letter from GIDC is attached as Annexure 5.
2.5.2 Water Consumption and Waste Water Generation for Proposed Unit
Existing total water consumption is 966.25 KLD which will be increased up to 968.03 KLD after proposed change in
product mix. Fresh water consumption will be reduced from 647.95 KLD to 640.73 KLD due to reuse of treated
sewage for gardening within the premises. Breakup of water consumption is given in Table 2-17.
Table 2-17: Details of Water consumption

Water Consumption (KLD)
S. No. Particulars Existing Proposed Total after amendment
Fresh Recycled Fresh Recycled Fresh Recycled
1 Domestic 12 0 0 0 12 0
2 Gardening 25 0 -9 9 16 9
3 Industrial
3.1 Process 18.22 0 1.78 0 20 0
3.2 Boiler 13 177.4 0 0 13 177.4
3.3 Cooling water 573.8 140.9 0 0 573.8 140.9
3.4 Washing 5.93 0 0 5.93
Total industrial 610.95 318.3 1.78 0 612.73 318.3
Total Water Consumption 966.25 1.78 968.03
Recycled Water 318.3 9 327.3
Fresh Water Consumption 647.95 -7.22 640.73
2.5.3 Waste Water Generation
Existing waste water generation is 50.38 KLD which will be reduced to 49.92 KLD after proposed change in product
mix. From that, 34.16 KLD will be sent to ETP, 9 KLD will be sent to STP and 6.76 KLD to Incineration facility/thermal
oxidiser/external common treatment facility for further treatment (ACPTCL Ankleshwar). 34.16 KLD treated water
from ETP will be sent to GIDC drain for disposal and 9 KLD treated sewage will be reused for gardening within the
premises.
Permission letter from GIDC for disposal of treated water in GIDC drain is attached as Annexure 6 and membership
letter of authorized incineration/ co processing facility of BEIL & RSPL are attached as Annexure 7 & Annexure 8
respectively.
Table 2-18: Details of Wastewater Generation
S. Wastewater Generation (KLD)

Particulars Remark
No. Existing Proposed Total
Existing: to ETP for treatment along with
Industrial waste water
1 Domestic 9 0 9
Proposed: To STP for treatment and treated
water will be used for gardening

S. Wastewater Generation (KLD)

Particulars Remark
2 Industrial
22.98 KLD to ETP, final discharge GIDC

a Processing 30.20 -0.46 29.74 6.76 KLD Send to authorized incineration/ co
processing for further treatment
b Boiler 3.55 0 3.55
c Cooling 1.8 0 1.8 To ETP, final discharge to GIDC
d Washing 5.83 0 5.83
34.16 KLD industrial water will be sent to ETP
Total Industrial 41.38 -0.46 40.92 for treatment and treated water will be sent to
GIDC drain for disposal
Grand Total (Industry
50.38 -0.46 49.92
+Domestic)
For Domestic sewage disposal mode: In Existing EC disposal mode of domestic sewage in sent to ETP along
with industrial effluent and final disposal to GIDC drainage but in existing valid CTO disposal mode of sewage is
received as to STP and treated water shall be reused for gardening within the premises. Hence here we are
applying to change the disposal mode to regularise in EC and CTO.

Figure 2-13: Existing Water Balance
All units are in KLD
Fresh Water Recycled Water
Waste Water Losses

Figure 2-14: Water Balance after Amendment
All units are in KLD
Fresh Water Recycled Water
Waste Water Losses

2.5.4 Hazardous waste
Hazardous waste generated from the plant operations will be handled as per existing proposal and disposed in nearby Waste Management landfill co-processing, cement
industry and incineration facility. The unit has membership of M/s. BEIL, Ankleshwar & Dahej and RSPL, Panoli for Solid Waste Disposal and Incineration Facility which is
attached as Annexure 7 & Annexure 8 respectively.
Table 2-21: Hazardous Waste Generation and Disposal Details

Category as per Quantity in MTPA
S.
Types of waste Hazardous Waste Remark Method of Disposal
as per Rule 2016
Collection, Storage, Transportation, Disposal at TSDF-BEIL,
1. ETP Sludge 34.2 48.504 0 48.504 No Change
Dahej/Ankleshwar.
Collection, Storage, Transportation, Disposal by selling to
2. Waste /Spent Oil 5.1 7836 L 0 7836 L No Change
Registered Recyclers.
Discarded Containers/ barrels used Collection, Storage, Detoxification, Transportation, Disposal by
3. 33.1 260 0 260 No Change
for hazardous waste/ chemicals selling to authorized recycler.
Collection, Storage, Transportation, Disposal by incineration at
4. Process Sludge 20.4 523.08 0 523.08 No Change
CHWIF/Co-processing/Cement Industry.
Cotton waste Containing oil i.e. Collection, storage, Transportation, Disposal by incineration at
5. 5.2 1.944 0 1.944 No Change
waste residue containing oil CHWIF.
Schedule VI- B3- Collection, storage, Transportation, Disposal by incineration at
6. Waste membrane 0.24 0 0.24 No Change
B3010 CHWIF.
Decrease due
to reduction of
production Collection, storage, Transportation, Disposal by incineration at
7 Spent Solvent as Methanol 20.2 636 -192 444
capacity of CHWIF/ Co-processing/ Sale.
Polycarbonate
Polyol
Increase due Collection, storage, Transportation, Disposal by incineration at
8 Spent Solvent as Isopropyl Alcohol 20.2 120 140 260
to increase in CHWIF/ Co-processing/ Sale.
production
Spent Solvent as Methylene capacity of Collection, storage, Transportation, Disposal by incineration at
9 20.2 42 49 91
Chloride Polymer Polyol CHWIF/ Co-processing/ Sale.
Schedule VI- B3-

10 Polyurethane Foam 12 0 12 No change Sale or Incineration
B3010

Category as per Quantity in MTPA

S.
Types of waste Hazardous Waste Remark Method of Disposal
as per Rule 2016
Collection, storage, Transportation, Disposal by incineration at
11 Distillation residue 20.3 2433.6 0 2433.6 No Change
CHWIF/ Co-processing/ Sale.
Note: There will be reduction of 3 MTPA in total quantity of Hazardous waste generation due to proposed amendment

2.6 Conclusion
 There will be bifurcation of the existing production capacity of Polyester /Polycarbonate Polyol which is 1710
MTPM to Polyester Polyol 1500 MTPM and Polycarbonate Polyol 210 MTPM.
 There will be increase in production of Polymer Polyol by 700 MTPM i.e. from 600 MTPM to 1300 MTPM and
reduction of polyester polyol by 636 MTPM and polycarbonate polyol by 64 MTPM (total reduction by 700
MTPM). Final balance of Polyester Polyol will be 864 MTPM and Polycarbonate Polyol will be 146 MTPM (total
reduction by 700 MTPM).
 After proposed amendment, the production quantity as per EC no SEIAA/GUJ/EC/5(e) /1071/2018 dated
05.10.2018 will not change from 15615 MTPM.
 There will be no additional fuel and power required for proposed Amendment.
 There will be no change in Plant and Machinery due to proposed amendment it will be manufacture in the
existing infrastructure only.
 There will be minor decrease fresh water consumption along with waste water generation and increase in
recycled water consumption after proposed amendment.
 There will be marginal reduction in hazardous waste generation.
 Existing waste water treatment plant, air pollution control system and hazardous waste management system
area adequate for proposed amendment.

EXPANDED POLYMER SYSTEMS PVT. LTD. PLANT AT GIDC ESTATE DAHEJ ANNEXURES
ANNEXURES

Annexure 1: Existing EC letter copy








Annexure 2: Existing CTE



Annexure 3: Existing CTE Product Mix Received






Annexure 4: Existing CC&A





Annexure 5: GIDC Letter for Water Supply Permission

Annexure 6: Agreement Letter with GIDC for Treated Wastewater Discharged into GIDC drain.

Annexure 7: Membership Certificate of BEIL for Hazardous Waste Disposal



Annexure 8: Membership Certificate of RSPL for Hazardous Waste Disposal


Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91 265 6131000
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Near
Omaxe City Center Mall, Sohna Road, Gurgaon, India – 122 002
E: [email protected]; T: +91 124 4242430 to 2436
Prepared using Kadam EIA Report Template, I01R11.Dotm 27-09-2017 1:23 PM

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EXPANDED POLYMER SYSTEMS

Amendment in Existing Environment

Environment for Development

M/S. EXPANDED POLYMER SYSTEMS PVT LTD

Amendment in Existing Environment Clearance for

Description of images on the front page:

1. Main Gate 2. Security Cabin

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2023 2

1.1 Identification of Project and Project Proponent............................................................................7

1.2 Purpose of the Report .....................................................................................................................7

1.3 Proposed Amendment Required .....................................................................................................8

1.3.1 Justification for Amendment 9

2.1 Type of Project .............................................................................................................................. 15

2.2 Location ......................................................................................................................................... 15

2.3 Technology and Process Description ............................................................................................ 18

2.3.1 Polyether Polyol 18

2.3.2 Polyester Polyol 21

2.3.3 Polycarbonate Polyol 23

2.3.4 Polymer Polyol 25

2.3.5 Blended Polyol 27

2.3.6 Pre-polymer Polyol 27

2.3.7 Cross Linker 29

2.3.8 Pentane Mixture 29

2.3.10 Solvent Recovery 31

2.3.11 Pollution Load Calculation 31

2.4 Raw Material Consumption ........................................................................................................... 34

2.5 Water Consumption, Wastewater Generation and Treatment Facilities .................................... 37

2.5.1 Source of water Supply 37

2.5.3 Waste Water Generation 37

2.5.4 Hazardous waste 41

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2023 3

Annexure 2: Existing CTE ........................................................................................................................... 53

Annexure 3: Existing CTE Product Mix Received ...................................................................................... 56

Annexure 4: Existing CC&A ........................................................................................................................ 62

Annexure 5: GIDC Letter for Water Supply Permission ............................................................................ 67

Annexure 7: Membership Certificate of BEIL for Hazardous Waste Disposal ......................................... 69

Annexure 8: Membership Certificate of RSPL for Hazardous Waste Disposal ......................................... 72

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2023 4

Table 1-3: Proposed Product List .................................................................................................................8

Table 1-4: EC Conditions in which Amendment is Required .................................................................... 10

Table 1-5: Pollution Load Statement after EC Amendment ...................................................................... 13

Table 2-1: Latitude and Longitude of Project Site .................................................................................... 15

Table 2-2: Area Break up at Site ................................................................................................................ 18

Table 2-3: Mass Balance for Polyether Polyol ........................................................................................... 20

Table 2-5: Mass Balance for Polycarbonate Polyol ................................................................................... 24

Table 2-6: Mass Balance for Polymer Polyol ............................................................................................. 26

Table 2-7: Mass Balance for Blended Polyol ............................................................................................. 27

Table 2-8: Mass Balance for Pre-polymer Polyol (PP-100) ...................................................................... 28

Table 2-9: Mass Balance for Pre-polymer Polyol (PP-100 D) ................................................................... 28

Table 2-10: Mass Balance for Cross Linker ............................................................................................... 29

Table 2-11: Mass Balance for Stabilizer .................................................................................................... 31

Table 2-12: Existing Solvent consumption and Recovery ........................................................................ 31

Table 2-14: Existing Pollution Load Calculation ...................................................................................... 32

Table 2-15: Proposed Pollution Load Calculation ..................................................................................... 32

Table 2-16: Details of Raw Materials......................................................................................................... 34

Table 2-17: Details of Water consumption ................................................................................................ 37

Table 2-18: Details of Wastewater Generation ......................................................................................... 37

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2023 5

Figure 2-2: Map Showing Project Boundary ............................................................................................. 16

Figure 2-3: Site Layout Map ....................................................................................................................... 17