PROJECT REPORT

For

PROPOSED CHEMICAL (POLYURETHANE

FOAM) MANUFACTURING UNIT

From

M/s. USHA FOAM PVT. LTD.

LOCATED AT:

K-19, Sector-15, G.I.D.A. Gorakhpur, Uttar Pradesh

 INDEX

CHAPTER
TITLE PAGE NO.
NO.

1. Executive Summary 1

2. Introduction of Project / Background Information 2

3. Project Description 3

4. Site Analysis 8

5. Planning Brief 10

6. Proposed Infrastructure 12

7. Rehabilitation and Resettlement (R & R) Plan 13

8. Project Schedule & Cost Estimates 13

9. Analysis of Proposal 14
PROJECT REPORT M/s. Usha Foam PVT. LTD.

1. EXECUTIVE SUMMARY
M/s. Usha Foam Pvt. Ltd. has proposed to manufacture the product Polyurethane Foam
at K-19, Sector-15, G.I.D.A. Gorakhpur, Uttar Pradesh.

There is no forest/wild life sanctuary/eco sensitive area present within 10 Km area from
the project site.

The proposed unit will be developed in an industrial park. The land is already Non-
Agriculture. The Proposed project activity will be developed as per plan lay out shown in
Annexure – 2 of EC Application in industrial park.

The Proposed project activity will be carried out in existing Industrial shed. No additional
construction activity will carry out.

For, Electric power requirement: Unit will apply for electric connection of 150 KVA to DGVCL.
One D. G Set of capacity 2150 KVA will be installed which will be used in case of power
failure.

For proposed activity, water required for domestic & industrial purpose will be sourced from
Bore well. Domestic effluent will be disposed in to Septic tank/Soak pit system. No Industrial
effluent will be generated from process.

No solid hazardous waste will be generated from manufacturing process. Hazardous waste
generated from the other industrial activity will be stored in a separate hazardous waste
storage area and then it will be disposed by selling to register re-cyclers/re- refiners/reused.

Proper safety measures will be undertaken during storage, handling and use of hazardous
substance. Fire hydrants, Hose reel & Portable Fire Extinguishers will be provided at key
location.

Total area of project site is 5373.0 m2.

During operation phase 75 people (50 men + 25 women) will be required.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

2. INTRODUCTION OF PROJECT / BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
Unit is located in G.D.I.A, Gorakhpur, Uttar Pradesh

List of product to be manufactured is as under;

LIST OF PRODUCT

Sr. Quantity
No. Name of Product (MT/Month)
1. Polyurethane Foam 300

PROJECT PROPONENT
M/s. Usha Foam Pvt. Ltd. is a Private Limited Firm.
Ms. Priyanka and Ms. Parinaz are the Directors of the company.

2.2 NATURE OF THE PROJECT

M/s. Usha Foam Pvt. Ltd. is a small scale unit. It falls under the category of synthetic
organic chemical (Polyurethane Foam) industry.

2.3 NEED FOR THE PROJECT

M/s. Usha Foam Pvt. Ltd. will be supplying polyurethane foam to several industries. There
are numerous uses of polyurethane foams such as packaging, acoustic insulation,
filtration, sponges, seals, padding in sports shoes, paint rollers, medical applications,
textiles, furniture, Bedding and many other varied applications. Due to increase in both
national & local market demand, unit proposes to the production of Polyurethane foam.

2.4 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE

PROJECT
Due to the project, employment will be increased. The unit will hire local people from the
nearby villages.

People will get direct & indirect employment due to the project activity. Unit will hire 75
employees- (50 men + 25 women)

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

3. PROJECT DESCRIPTION
3.1 TYPE OF PROJECT

The unit has proposed to manufacture synthetic organic chemical – Polyurethane foam.

3.2 LOCATION
The site is located at about 26.7393° N, 83.2765° E latitude and longitude respectively.

LOCATION OF THE PROJECT

3.3 DETAILS OF ALTERNATE SITES

Proposed project is identically located in an industrial park having all adequate
infrastructure available. Therefore, no alternate site is considered for the proposed project.

3.4 SIZE / MAGNITUDE OF OPERATION

Proposed project activity will be carried out on K-19, Sector-15, G.I.D.A. Gorakhpur, Uttar
Pradesh.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

Manufacturing Process Description:

The raw materials n-Butyl Alcohol (Polyol), TDI (Toluene Di Isocyanate), Catalysts (Silicon,
SO, DMEA/MI), Filler (CaOH) and MECL (Methylene Chloride) are pumped from their own
storage tank in required proportions to a common mixing chamber where the materials are
mixed at high speed and flows as cream on to a conveyor.
While passing on the conveyor the cream expands to full height to make foam blocks.
Continuous foamed blocks are cut into required block sizes by the block cutter and the cut
blocks are left for sufficient time in open atmosphere for curing.
The blocks are further cut into sheets of required size by horizontal and/or vertical cutting
machines and are packed for dispatch or cut into rolls by peeling machine.

Manufacturing Process Flow Diagram

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

REACTION CHEMISTRY

MATERIAL BALANCE

3.6 RAW MATERIAL WITH REQUIRED QUANTITY, SOURCE, MARKETING

AREA OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND
FINISHED PRODUCT
For Product and Raw material with required quantity, please refer Annexure – 4 of EC
application. For source of raw materials, supply of final product, their handling- management
& mode of transportation, please refer Annexure – 7 of EC application.

3.7 RESOURCE OPTIMIZATION / RECYCLING AND REUSE

Used oil generates from operation of DG Set will be reused as lubricant for the machinery.

3.8 AVAILABILITY OF WATER, ITS SOURCE, ENERGY / POWER

REQUIREMENT AND SOURCE

Energy / Power Requirement & Its Source

Electric power requirement for proposed project is 150 KVA, which will be procured from
Dakshin Gujarat Vidyut Company Ltd. (DGVCL).
One D. G Set of capacity 250 KVA will be installed which will be used in case of power failure.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

Water Availability & Its Source

Source of Water: Bore well (Water Depth: 20 – 25 Mtr.)

WATER CONSUMPTION

Water
Sr.
Category Consumption
No.
(KL/day)

1. Domestic 11.0
2. Gardening 12.0
i. TOTAL 23.0
1. Process 3.0
2. Chilling Plant 0.3
ii. TOTAL 3.3
GRAND TOTAL (i + ii) 26.3

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND

SCHEME FOR THEIR MANAGEMENT / DISPOSAL

(A) Quantity of Liquid Waste to be Generated & Its Management / Disposal:

WASTEWATER GENERATION
Water
Sr.
Category Generation
No.
(KL/day)
1. Domestic 10.0
2. Gardening NIL
i. TOTAL 10.0
1. Process NIL
2. Chilling Plant NIL
ii. TOTAL NIL
GRAND TOTAL (i + ii) 10.0

Disposal of Wastewater:

1. Domestic effluent will be disposed in to Septic tank / Soak pit system.

2. The quantity of trade effluent generated will be NIL

(B) Quantity of Solid Waste to be Generated & Its Management / Disposal:

 No Hazardous waste will be generated from the process. Hazardous waste generated
from other industrial activity will be stored in a separate hazardous waste storage area
and it will be disposed by selling to the register re-cyclers/re-finer/reused.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

Sr. Source of Quantity

Type of Waste Category Facility
No. Generation Total
Collection, Storage, Transportation,
0.045 Disposal by selling to Registered
01. Used Oil 5.1 D. G Set MT/Year Re-refiners, approved by
GPCB/CPCB or reused as lubricant
for machinery within the factory.
Collection, Storage, Transportation,
Discarded 60
02. 33.3 -- Disposal by selling to Registered
Containers/Bags Nos./Year
recycler approved by GPCB/CPCB
Waste Foam
03. (Product cutting -- Process -- Collection & reuse again in process
waste)
Collection, Storage, Transportation,
2
04. Carbon Waste 35.3 APCM Disposal by selling to Registered
Kg/Month
recycler approved by GPCB/CPCB

 The municipal solid wastes generated during operation phase will be disposed to bin of
Industrial park.

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING

WHICH GIVE INFORMATION OF EIA PURPOSE

SCHEMATIC REPRESENTATIONS OF PROJECT

Location of Activity
Project

Outside GIDC/Notified Production of

area Polyurethane Foam –
Synthetic Organic
Chemical activity

Thus, overall project

require EIAas
per MoEF

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

4. SITE ANALYSIS
4.1 CONNECTIVITY
 The project site is well connected with all infrastructures like National Highway, Railway,
Airport, telephone, internet, fax, post, etc.
 Nearest town Gorakhpur is located 2 6 K M from the project site.
 Nearest railway station Gorakhpur Junction.
 Nearest airport Kushinagar 30 KM from the project site.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The Proposed project activity will be carried out in existing Industrial shed. No additional construction
activity will carry out. The proposed project will not cause any permanent or temporary change to
land use.

LAND AREA BIFURCATION

Sr.
Title Area (m2)
No.
GROUND FLOOR
Finished product section (Cutting, Packing &
1. 932.4
Storage)
2. Raw Material Storage Area 337.0
3. D. G Set 5.0
4. Hazardous Waste Storage Area 10.0
5. Office 30.0
6. Parking Area 97.5
7. Open Space 1386.1
8. Product Curing Area 932.0
9. Process Area 189.0
10. Chilling Plant 4.0
11. Road area within premises 1450
TOTAL AREA 5373.0

4.3 TOPOGRAPHY

The project area is plain and flat surface with elevation 21 m above MSL. However, in the
NE part, the elevation is in the range of 21 – 24 m above MSL & in the SW part, the elevation
is in the range of 18 – 25 m above MSL. The general slope of the area is from

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

NE to SW. In the buffer zone towards NE, E & SE, the elevation rises to 24 m and above
MSL & towards S, SW & W the elevation descend to 18 m above MSL.

4.4 SOIL CLASSIFICATION

Soil in the study area is primarily black & Silty clay in nature.

4.5 SOCIAL INFRASTRUCTURE AVAILABLE

The proposed project is located in an industrial park. Industrial Park authority will provide
power supply, water supply, pucca road, telephone & other communication network &
drainage network in the area.

Skilled & unskilled manpower are available within area. Ambulance and emergency fire &
medical service available round the clock.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

5. PLANING BRIEF
5.1 PLANNING CONCEPT
The unit has proposed to manufacture Polyurethane Foam. Proposed project activity will be
carried out at K-19, Sector-15, G.I.D.A. Gorakhpur, Uttar Pradesh. The Proposed project
activity will be carried out in existing Industrial shed. No additional construction activity will
carry out.

All the basic facilities like tap water, sanitation & drinking water, canteen & First aid box
will be provided within premises.
The project site is well connected with the road, railway and airport. Finished products and
raw materials will be transported through road. There is no requirement for the development
of other road or railway.

5.2 POPULATION PROJECTION

During operation phase 75 people-Direct (50 men + 25 women), 75 employees

5.3 LAND USE PLANNING

The breakup of the land area is mentioned in the below table:

LAND AREA BIFURCATION

Sr.
Title Area (m2)
No.
GROUND FLOOR
Finished product section (Cutting, Packing &
1. 932.4
Storage)
2. Raw Material Storage Area 337.0
3. D. G Set 5.0
4. Hazardous Waste Storage Area 10.0
5. Office 30.0
6. Parking Area 97.5
7. Open Space 1386.1
8. Product Curing Area 932.0
9. Process Area 189.0
10. Chilling Plant 4.0
11. Road area within premises 1450
TOTAL AREA 5373.0

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

The project is located in an industrial Park. Industrial park Authority will provide power
supply, water supply, pucca road, telephone & other communication network & drainage
network in the area.

Skilled & unskilled manpower are available within area. Ambulance and emergency fire &
medical service available round the clock.

Local people will be hired for new products and they will be trained within unit. Thus, no
social infrastructure will require.

5.5 AMENITIES / FACILITIES

All the basic facilities like tap water, sanitation & drinking water, canteen will be provided
within premises.

First aid box, free medicines & doctor service (on call basis) will be provided.

Adequate PPE’s will be provided to all workers.

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

6. PROPOSED INFRASTRUCTURE

1. Industrial Area Total Area – 5373 m2

2. Residential Area Residential area is located 700 m in NE direction.
3. Social Infrastructure Social infrastructure available within 10-15 km from project
site.
4. Drinking Water Management Source of water for domestic & industrial purpose is from
Bore Well.
5. Sewerage System Domestic effluent will be disposed in to existing Septic
tank / Soak pit system.

No Industrial effluent will be generated/ discharged.

6. Industrial Waste Management Discarded Containers/Bags – Collection, Storage,
Decontamination and Disposal by selling to registered re-
cyclers approved by GPCB/CPCB
Used Oil – Collection, Storage, Transportation, Disposal by
selling to Registered Re-refiners approved by GPCB/CPCB.
Waste Foam (Product cutting waste) – Collection & Reuse
in Manufacturing process again.

7. Solid Waste Management MSW disposed to bin of nearby GIDA Nagarpalika.

8. Power Requirement & Supply / Source: Purvanchal Vidyut Vitran Nigam Ltd.
Source Proposed power requirement: 150 KVA

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 PROJECT REPORT M/s. Usha Foam PVT. LTD.

7. REHABILITATION AND RESETTLEMENT (R & R) PLAN

The project is located within an Industrial park therefore no Rehabilitation & Resettlement
(R & R) plan is involved in proposed project.

8. PROJECT SCHEDULE & COST ESTIMATES

8.1 LIKELY DATE TO START OF CONSTRUCTION AND LIKELY DATE OF

COMPLETION

Production of proposed product will be started after getting Environment Clearance

(SEAC) and CTE/CC&A from the GPCB.

8.2 PROJECT COST ESTIMATION

Estimated cost for the proposed project is as under;

Details ApproximateCapital Cost(Rs. in Lacs)

Land 300.00
Building 500.00
Plant & Machinery 400.00
Misc. Fixed Asset 50.00
Vehicles 30.00
Furniture &Fixtures 10.00
CSR Activities 10.00
Working Capital 350.00
TOTAL 1650.00

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PROJECT REPORT M/s. Usha Foam PVT. LTD.

9. ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE

BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF
ANY, IN THE AREA

Project is located in an industrial park. Therefore, No R & R plan involved in proposed

project.

Due to proposed project it is expected that employment will increase for people who reside
nearby project area. Approx. 50 men & 25 women will get employment directly.

Due to increase in raw material and product transportation activity, indirect employment
will generate.

As local people will get job, quality of living will be increase.

Due to green belt development, aesthetic value of local environment will improve.

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