APPENDIX I · Capacity expansion of existing Chlor-Alkali Plant from 5,08,000 MTPA to 8,13,000 MTPA...

8/2/2019 Report Part 1(FORM - B)

environmentclearance.nic.in/state/Form_B_PDF.aspx?cat_id=SIA/GJ/IND2/30857/2019 1/15

APPENDIX I(See Paragraph-6)

CATEGORY - BNote : If space provided against any parameter is inadequate,Kindly upload supportingdocument under 'Additional Attachments if any' at the last part of the Form1. Please notethat all such Annexures must be part of single pdf document.

(I)Basic Informations

S.No. Item Details

Whether it is a violation case andapplication is being submitted underNotification No. S.O.804(E) dated14.03.2017 and read with amendmentvide notification dated 08.03.2018. ?

No

1. Name of the ProjectProposed Capacity Expansion of Existing Captive PowerPlant and Chlor Alkali Plant at Plot No. 749, GIDCJhagadia, District Bharuch, Gujarat

2. Project Sector Industrial Projects - 2

3. Location of the project Plot No. 749, GIDC Jhagadia, Dist. Bharuch, Gujarat,India

4. Shape of the project land Block (Polygon)

Uploaded GPS file Annexure-GPS file Uploaded copy of survey of IndiaToposheet Annexure-Survey of india toposheet

5. Brief summary of project Annexure-Brief summary of project

6. State of the project Gujarat

Details of State of the project

S.no State Name District Name Tehsil Name

(1.) Gujarat Bharuch Jhagadia

(2.) Haryana Gurgaon Gurgaon

(3.) Madhya Pradesh Sidhi Sihawal

7. Town / Village Jhagadia

8. Plot/Survey/Khasra No. Plot No. 749, GIDC Jhagadia

9. S. No. in the schedule 4(d) Chlor-alkali industry

10.Proposed capacity/area/length/tonnageto be handled/command area/leasearea/number or wells to be drilled

Capacity expansion of existing Chlor-Alkali Plant from5,08,000 MTPA to 8,13,000 MTPA of Caustic Soda andCaptive Thermal Power Plant from 146 MW to 242MW ha.

11. New/Expansion/Modernization ExpansionMoEF file number(Previous EC) SIA/GJ/IND2/21528/2014Existing capacity/area etc. 46.7 ha.Uploaded EC letter Annexure-Uploaded EC letter

http://environmentclearance.nic.in/auth/testmap.aspx?type=caformb&fname=24_Jan_2019_182350300A1EN7BLGShreeramAlkali.kml&proposalno=SIA/GJ/IND2/30857/2019

http://environmentclearance.nic.in/download.aspx?files=writereaddata/FormB/TOR/GPS/24_Jan_2019_182350300A1EN7BLGShreeramAlkali.kml

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Toposheet/24_Jan_2019_1823503034H65JA5VAnnexure-SurveyofIndiaToposheet.pdf

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Brief_Summary/24_Jan_2019_182350350OLZDF16ZAnnexure-BriefSummaryofProject.pdf

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Previous_EC_letter/24_Jan_2019_182350380VC9LM2ZDPreviousEC.pdf



12. Category of project B

13. Does it attract the general condition? Ifyes, please specify No

15. Does it attract the specific condition? No

16. Is there any litigation pending againstthe project? No

17. Nearest railway station along withdistance in kms. Bharuch, 24 km

18. Nearest airport along with distance inkms Surat, 93.4 km

19. Nearest Town/City/District Headquartersalong with distance in kms Bharuch , 24.6 km

20. Distance of the project from nearestHabitation 1 , 1 km

21. Details of alternative sites examinedshown on a toposheet Yes

Uploaded details Annexure-Uploaded details

22. Whether part of interlinked projects? No

23. Whether the proposal involvesapproval/clearance under the Forest(Conservation)Act,1980?

No

24. Whether the proposal involvesapproval/clearance under the wildlife(Protection)Act,1972?

No

25.Whether the proposal involvesapproval/clearance under the C.R.Znotification,2011?

No

26. Whether there is any GovernmentOrder/Policy relevent/relating to thesite?

Yes

Uploaded Order/Policy Annexure-Uploaded order/policy

27. Whether there is any litigation pendingagainst the project and/or land in whichthe project is proposed to be set up?

No

28. Project Cost(in lacs) 105000

Activity

1Construction, operation or decommissioning of the Project involving actions, which willcause physical changes in the locality (topography, land use, changes in water bodies,etc.)

S.No

Information/Checklist confirmation Yes/No

Details there of (withapproximate

quantities/rates, whereverpossible) with source of

information data

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Alternative_Sites/24_Jan_2019_183320197LELPBQ26AlternateSites.pdf

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Order_Policy/24_Jan_2019_183320230S2HPT6L2Policy-GIDCJhagadiaChemicalNotifiedZone.pdf



1.1 Permanent or temporary change in land use, land coveror topography including increase in intensity of land use(with respect to local land use plan)

No The proposed expansion will becarried out within the existingfactory premises wherein Chloralkali and Captive power plantsare already existing. The factoryis located within a notifiedindustrial estate speciallydeveloped by Government ofGujarat (through GujaratIndustrial DevelopmentCorporation – GIDC) for waterintensive chemical industries. Nochanges in land use areenvisaged. Land cover within theFactory would change at placeswhere the additional processunits would be constructed

1.2 Clearance of existing land, vegetation and buildings? Yes

Land clearance is not involved.The land is already available andearmarked for expansion withinexisting plant. A few existingstructures will be relocatedwithin the site.

1.3 Creation of new land uses? NoThe expansion is proposedwithin existing plant, hence nonew land use will be created.

1.4 Pre-construction investigations e.g. bore houses, soiltesting? Yes

Prior to commencement ofconstruction activities, essentialstudies such as soil testing willbe conducted to ensure a safebuilding design.

1.5 Construction works? YesAdditional construction work willbe carried out as per the plantrequirements.

1.6 Demolition works? Yes A few existing structures will berelocated within the site

1.7 Temporary sites used for construction works or housingof construction workers? No

The proposed site has sufficientavailability of land forconstruction related activitiessuch as storage, utilities, work &rest spaces. The constructionworkers would be residing inhouses in nearby villages whereadequate residential & otherfacilities for them are available

1.8Above ground buildings, structures or earthworksincluding linear structures,cut and fill or excavationsand fill or excavations

Yes

Above ground buildings includes,structures for cell houses, Boilerand turbine building, producttank farm etc. cut, fill orexcavation activities are part ofthe project.

1.9 Underground works including mining or tunneling? No Not Applicable

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore structures? No Not Applicable

1.13 Production and manufacturing processes? Yes Proposed expansion is for



capacity enhancement of:Membrane cell based Chlor-Alkali plant: 508000 MT to813000 MT/Year Caustic Sodaand Captive Power Plant: 146MW to 242 MW. Please refer Pre-Feasibility Report (PFR) formanufacturing process and flowdiagram.

1.14 Facilities for storage of goods or materials? Yes Additional storage facilities willbe created

1.15 Facilities for treatment or disposal of solid waste orliquid effluents? Yes

Solid waste: Brine sludge isgenerated during the brinepurification process. This will bedisposed-off at secured landfillfacility, developed inside factorypremises or CTSDF locatednearby. The design/constructionof SLF constructed in thepremises is approved by GujaratPollution Control Board (GPCB)recognized 3rd party Schedule -I Auditor. Fly ash generatedfrom Captive thermal powerplants will be disposed as per FlyAsh notification 2009 and itsamendments. Liquid effluents:Efflue

1.16 Facilities for long term housing of operational workers? No

No long term housing facility willbe provided by the company.Most of the workers are locallyemployed who reside in nearbyvillages / town.

1.17 New road, rail or sea traffic during construction oroperation? Yes

Some traffic is likely to begenerated due to additional roadtrips during construction andoperation but the same will notbe significant

1.18New road, rail, air water borne or other transportinfrastructure including new or altered routes andstations, ports, airports etc?

No

As the site is well connectedwith access to roads and statehighways of adequate carryingcapacity, no additionaltransportation infrastructure willbe required.

1.19 Closure or diversion of existing transport routes orinfrastructure leading to changes in traffic movements? No

As there is no major increase intraffic due to construction andthen operation activity, closureor existing routes in trafficmovement is not foreseen.

1.20 New or diverted transmission lines or pipelines? No No transmission lines / pipelinespass inside the plant premises

1.21Impoundment, damming, culverting, realignment orother changes to the hydrology of watercourses oraquifers?

No These activities will not becarried out.

1.22 Stream crossings? No There is no stream crossingthrough the project site.

1.23 Abstraction or transfers of water from ground or No Surface water: Water is



surface waters? available throughout year fromthe water supply system ofGujarat Industrial DevelopmentCorporation (GIDC), ultimatelysourced from Narmada river.This water is proposed to beused for the expansion project.Water consumption will increasedue to the proposed project.Please refer Sr. No. 2.2 fordetails. Ground Water: Noabstraction or transfer of waterfrom ground or surface watersdue to proposed activity isenvisaged.

1.24 Changes in water bodies or the land surface affectingdrainage or run-off? No

There would be no changes inwater bodies or land surface inthe facility. The Run-off waterwill continue to flow in theexisting pattern after theproposed expansion project iscommissioned.

1.25 Transport of personnel or materials for construction,operation or decommissioning? Yes

During the construction andimplementation of the projectperiod, transport of materialsand personnel would take placethrough existing roads.

1.26 Long-term dismantling or decommissioning orrestoration works? No Not envisaged

1.27 Ongoing activity during decommissioning which couldhave an impact on the environment? No No decommissioning work is

envisaged currently.

1.28 Influx of people to an area in either temporarily orpermanently? No

There would be movement oflabourers during constructionphase but will not cause anypermanent influx of people.

1.29 Introduction of alien species? No Not Applicable

1.30 Loss of native species or genetic diversity? No Not Applicable

1.31 Any other actions? No Not Applicable

2Use of Natural resources for construction or operation of the Project (such as land,water, materials or energy, especially any resources which are non-renewable or inshort supply):

S.No


Details thereof (withapproximate


information data

2.1 Land especially undeveloped or agricultural land (ha) No Project site is a developed landfor industrial uses in adesignated industrial area ofJhagadia GIDC, Categorized aschemical notified zone. Existingactivity at the site involves themanufacturing of Chlor –Alkali



products and captive powergeneration.

2.2 Water (expected source & competing users) unit: KLD Yes

Water requirement is to becatered from existing watersupply scheme of GIDC forexisting water intensive chemicalunits located in the GIDCindustrial estate. GIDC hasinfrastructure/capabilities tosupply additional waterrequirement. Existing waterreqmt=14491 KLD, Proposedwater reqmt=10500 KLD. Totalwater reqmt.=24991 KLD

2.3 Minerals (MT) Yes

Blended Fuel (Indigenous coal /Imported coal / Lignite / Bio-Mass / Pet coke) to be used inThermal power plant. Existingblended coalconsumption=731000 MTPA,Proposed blended coalconsumption=834000 MTPA.Total blended coalconsumption=1565000 MTPA

2.4 Construction material – stone, aggregates, sand / soil(expected source – MT) Yes

Construction materials likestones, aggregates, sand, brick,steel, cement, rubble, etc. wouldbe procured from the localmarket of the region, which areavailable locally.

2.5 Forests and timber (source – MT) No Not Applicable

2.6 Energy including electricity and fuels (source,competing users) Unit: fuel (MT),energy (MW) Yes

Electricity Power will be suppliedfrom the existing 122 MW andProposed expansion = 120 MWthermal captive power plantTotal Electricity generation afterexpansion = 242 MW Existing 24MW DG sets (5 nos.) shall bedecommissioned and the landwill be made available forthermal power plant setup. FuelBlended Fuel (consisting of coal/ lignite / Bio mass/ Petcoke) :Existing = 7,31,000 MTPA;Proposed = 8,34,000 MTPAExisting HSD : 100 MTPA;Proposed = 98 MTPA ExistingHFO: 52700 MTPA

2.7 Any other natural resources (use appropriate standardunits)

Yes Salt is the main raw material,which is obtained from the seawater. Salt is sourced mainlyfrom Kutch, Dahej and Jamnagardistricts of Gujarat state.Existing level of saltconsumption is ~8.14 lakhMTPA, additional level of saltconsumption would be 4.89 lakhMTPA. Thus, the total saltconsumption quantity after



expansion will be 13.03 lakhMTPA.

3Use, storage, transport, handling or production of substances or materials, which couldbe harmful to human health or the environment or raise concerns about actual orperceived risks to human health

S.No




information data

3.1Use of substances or materials, which are hazardous(as per MSIHC rules) to human health or theenvironment (flora, fauna, and water supplies

Yes

Following substances / materialare presently used: • SodiumHydroxide • Chlorine •Hydrochloric Acid • SulphuricAcid • Hydrogen • HFO • HSD •NaOCl These would also be usedin the proposed expansion.Consumption details of the samewill be given in the EIA report.Please also refer Table 3.2 ofPre-Feasibility report.

3.2 Changes in occurrence of disease or affect diseasevectors (e.g. insect or water borne diseases) No

Suitable OH & EMS, properdrainage and wastemanagement measures will beadopted in construction andoperation phase, which willrestrict the growth andreproduction of disease vectors.

3.3 Affect the welfare of people e.g. by changing livingconditions? Yes

The proposed project wouldimprove the living standardsdirectly and indirectly due toemployment, transportation,marketing, etc.

3.4Vulnerable groups of people who could be affected bythe project e.g. hospital patients, children, the elderlyetc.

Yes

The site is in the ChemicalNotified GIDC, JhagadiaIndustrial Estate. Hospitals arelocated in Jhagadia andAnkleshwar. There are villages inthe vicinity which are havingpopulation of the elderly andchildren. However, looking at thepast performance of the projectwith respect to emissions andreleases, nearby populations ofsuch vulnerable groups areextremely unlikely to beaffected.

3.5 Any other causes No Not envisaged

4 Production of solid wastes during construction or operation or decommissioning(MT/month)

S.No Information/Checklist confirmation Yes/No Details thereof (withapproximate




information data

4.1 Spoil, overburden or mine wastes No Not Applicable

4.2 Municipal waste (domestic and or commercial wastes) Yes

Municipal waste: Waste paperfrom administration building,waste metals, kitchen waste etc.Disposal method: Waste paperand metal will be given torecyclers and kitchen waste willbe converted into manure.

4.3 Hazardous wastes (as per Hazardous WasteManagement Rules) Yes

Used or spent Oil (Category 5.1)(Existing=200 MTPA,Proposed=0 MTPA, Total=200MTPA); Cotton wastes / residuescontaining oil (Category 5.2)(Existing=1.5 MTPA,Proposed=1 MTPA, Total=2.5MTPA); Empty Barrels /Containers / Liners (Category33.1) (Existing=200 MTPA,Proposed=100 MTPA, Total=300MTPA); Chemical sludge fromwastewater treatment (Category35.3) (Existing=4 MTPA,Proposed=1 MTPA, Total=5MTPA); Dilute Sulphuric acid(70-78%) (Existing=11415MTPA, Proposed=6853 MTPA,Total=1826

4.4 Other industrial process wastes Yes

Brine Sludge (Existing=30000MTPA, Proposed=12861MTPA,Total=42861 MTPA); Fly Ash(Existing=146200 MTPA,Proposed=166800 MTPA,Total=313000 MTPA)

4.5 Surplus product No No Surplus product

4.6 Sewage sludge or other sludge from effluent treatment No

Currently, sewage is beingtreated in septic tanks anddisposed off in soak pits.Modular Sewage treatmentplants (STPs) are also used inpart of the site. Sludge from theSTPs generated are used asmanure within the premises.Additionally, sludge is generatedfrom existing ETP which isdisposed in SLF / nearby CTSDF.

4.7 Construction or demolition wastes Yes

Minimal quantity of debris,scrap, excavated soil, usedcement bags, iron / steel scrapand cardboard waste could begenerated during construction. Afew existing structures will berelocated within the site.

4.8 Redundant machinery or equipment Yes Existing DG sets would bedecommissioned.

4.9 Contaminated soils or other materials No Not Applicable



4.10 Agricultural wastes No Not Applicable

4.11 Other solid wastes No None

5 Release of pollutants or any hazardous, toxic or noxious substances to air(Kg/hr)

S.No




information data

5.1 Emissions from combustion of fossil fuels fromstationary or mobile sources Yes

Additional emissions due tocombustion of fossil fuels isenvisaged and will be suitablytreated to contain within theprescribed limits.

5.2 Emissions from production processes YesEmission from flue gas stacksand process vents are given inPFR (Table 3.5 & 3.6)

5.3 Emissions from materials handling including storage ortransport Yes Emissions from Truck movement

are envisaged

5.4 Emissions from construction activities including plantand equipment Yes

Emission from diesel operatedconcrete mixers and excavators.However these equipment will

be maintained properly toensure minimum emissions andvehicles with PUC certificate willbe used. Dust emission due to

earth moving machinery

5.5 Dust or odours from handling of materials includingconstruction materials, sewage and waste Yes

Dust: Dust will be generatedduring handling of constructionmaterials, this will be controlledby sprinkling of water. Sewage:Sewage is disposed throughsoak pit followed by septic tanksystem as per existing practice.Modular STPs are used in part ofthe site and will replace theexisting practice in a phasedmanner

5.6 Emissions from incineration of waste No Not Applicable

5.7 Emissions from burning of waste in open air (e.g. slashmaterials, construction debris) No Not Applicable

5.8 Emissions from any other sources No None envisaged

6 Generation of Noise and Vibration, and Emissions of Light and Heat:

S.No Information/Checklist confirmation Yes/No Details thereof (withapproximate

quantities/rates, wherever



possible) with source ofinformation data

6.1 From operation of equipment e.g. engines, ventilationplant, crushers Yes

Noise: Coal Crusher, Turbine<85dB(A)* * Noise levels aremeasured one meter away fromthe source. There will be minoradditional noise sources in theform of new Cooling towers andadditional traffic movement.Additional sources, if any, will beidentified and reported in theEIA study Vibration: There willbe minimal vibration during theoperation of machinery &equipment. Proper controlmeasures will be taken. Light &Heat: No new activity isenvisaged which could lead toemissi

6.2 From industrial or similar processes Yes

Noise: Pump, Blowers,Compressors<85 dB(A)* *Noiselevels are measured one meteraway from the source. Vibration:No such activity is envisagedwhich could lead to vibration.Light & Heat: No such activity isenvisaged which could lead toemission of abnormal light andheat

6.3 From construction or demolition Yes

Noise would be generated fromconstruction machines such ascranes, hydra, excavatorsmachines, etc. duringconstruction activity only. Thiswill be within acceptable norms.There will not be any emission ofabnormal light & heat due toproposed project. A few existingstructures will be relocatedwithin the site.

6.4 From blasting or piling No Not Applicable

6.5 From construction or operational traffic Yes

Construction: Noise fromconstruction machines such ascranes, hydra, excavatormachine, etc. duringconstruction activity only. Thiswill be within acceptable norms.There will not be any abnormalemission of light & heat due toproposed project. Demolition:Demolition activity is notenvisaged

6.6 From lighting or cooling systems Yes

Noise from cooling tower will bebetween 62 to 76 dB(A)* *Noiselevels are measured one meteraway from the source.

6.7 From any other sources Yes Noise: From Compressor area=68 to 85 dB(A) and Fans ofexisting boiler (ID + FD + PA)<85 dB(A)* *Noise levels are



measured one meter away fromthe source.

7 Risks of contamination of land or water from releases of pollutants into the ground orinto sewers, surface waters, groundwater, coastal waters or the sea:

S.No




information data

7.1 From handling, storage, use or spillage of hazardousmaterials Yes

Occasional & minor spillage ofchemicals or other material mayoccur. They will be suitablycollected and managed. Thesewill not cause any major impacton water or land due to adoptionof adequate spill controlmeasures.

7.2 From discharge of sewage or other effluents to water orthe land (expected mode and place of discharge) Yes

Treated effluent: Treated effluentfrom the proposed expansionproject, complying with theprescribed norms of GujaratPollution Control Board will bedischarged into GIDC aboveground effluent pipeline andcollected into NCT commoneffluent sump. From this sumpthe entire treated effluent isbeing discharged into deep seathrough Jhagadia Pipeline ofNarmada Clean Tech Limited(NCT). Sewage: Sewage isdisposed through septic tank /soak pit system as per existingpractice. The water from

7.3 By deposition of pollutants emitted to air into the landor into water No

Adequate stack height, goodengineering and operationalpractices will ensure that therewill be marginal increase inemission of pollutants leadingdeposition onto land or intowater.

7.4 From any other sources No None identified

7.5 Is there a risk of long term build up of pollutants in theenvironment from these sources? No

Adequate mitigation measures,monitoring and periodicmaintenance of equipment willensure that there is marginalrisk of long term buildup ofpollutants in the environment.

8 Risk of accidents during construction or operation of the Project, which could affecthuman health or the environment

S.No Information/Checklist confirmation Yes/No Details thereof (with



approximatequantities/rates, wherever

possible) with source ofinformation data

8.1 From explosions, spillages, fires etc from storage,handling, use or production of hazardous substances Yes

The hazards associated with theplant are toxic release and fire.These hazards can take placedue to process upsets, leakages,equipment and hardwarefailures, loss of containment,human failures, etc., duringoperation The proposed plantwill process chlorine,hydrochloric acid, sulphuric acid,hydrogen, storage areas of HFO,diesel and coal. Adequate safetymeasures will be provided toprevent risk of explosion,spillages, fire etc.

8.2 From any other causes No Not Applicable

8.3Could the project be affected by natural disasterscausing environmental damage (e.g. floods,earthquakes, landslides, cloudburst etc)?

Yes

Floods Heavy monsoonsoccasionally cause floods, butthe site elevation at the projectarea ensures that there is noimpact of floods in the area.Earthquakes As per thegeological map published byGeological survey of India, thearea comes under the moderaterisk zone (Zone-III) of theSeismic Zone classification. Thedesign of structures at theproject site shall be based on IS1893 to make it earthquakeresistant. Landslides Not notedto occur in the area CloudburstNot a known

9Factors which should be considered (such as consequential development) which couldlead to environmental effects or the potential for cumulative impacts with other existingor planned activities in the locality

S.No Information/Checklist confirmation Yes/No



information data

9.1 Lead to development of supporting utilities, ancillarydevelopment or development stimulated by theproject which could have impact on the environmente.g.:

Supporting infrastructure (roads, powersupply,waste or waste water treatment, etc.)housing developmentextractive industriessupply industriesOther

Yes Existing road will be utilized forfuture activities. Transportroutes & traffic movement willnot likely to be affected byfuture activities Duringconstruction and implementationof the project period, transportof materials and man by existingroad. SAC has it’s own captivepower plant which is beingexpanded as part of theproposed project. Treatedeffluent: Treated effluent will be



discharged through GIDCdrainage line to Narmada CleanTech (NCT) for ultimatedischarge into deep sea.

9.2 Lead to after-use of the site, which could have animpact on the environment No Not applicable

9.3 Set a precedent for later developments Yes

It is expected that the proposedproject will lead to further plantexpansion both within theexisting premises and in theimmediate vicinity in the comingyears.

9.4 Have cumulative effects due to proximity to otherexisting or planned projects with similar effects Yes

Due to operation of existing unitand other units surroundingSAC-Jhagadia.

(III) Environmental Sensitivity

S.No Areas Name/IdentityAerial distance (within

15km.) Proposed projectlocation boundary

1Areas protected under international conventions,national or local legislation for their ecological,landscape, cultural or other related value

No

No such areas exist within 15km radius of the proposedproject site, other than thosementioned in subsequent sub-sections of this section.

2Areas which are important or sensitive for ecologicalreasons - Wetlands, watercourses or other waterbodies, coastal zone, biospheres, mountains, forests

Yes

Wetlands: Wetland recognizedor lying within UNESCO worldHeritage sites: None identified.High altitude wetlands (aboveelevation of 2500 m aboveMSL, with an area equal to orgreater than 5 hectaresidentified by an authority of thecentral government underprovision of the EnvironmentProtection Act, 1986: notidentified. Water Bodies /Watercourses: Sardarpuravillage pond (2.75 km WSW),Narmada River (7.24 km NW),Padvaniya village pond (12.85km ENE), Ankleshwar GIDCreservoir (14.13 km

3Areas used by protected, important or sensitivespecies of flora or fauna for breeding, nesting,foraging, resting, over wintering, migration

NoNo such area exists within 15kms radius of the proposedproject site.

4 Inland, coastal, marine or underground waters YesThe Narmada river is 7.24 km(Aerial distance) towardsNorth-West (NW) to the site.

5 State, National boundaries No Not present

6 Routes or facilities used by the public for access torecreation or other tourist, pilgrim areas No None



7 Defence installations No Not identified

8 Densely populated or built-up area Yes

Densely populated or built uparea in following villages:Fulwadi (1 km NNE), Selod(1.54 km ESE), Kapalsadi (2km NW), Sardarpura (2.2 kmWSW), Navagan Mota (2.8kmE), Untia (3.3 km SW), Kharia(4.2 km NNE), Boridara (4.3km NW), Kararvel (4.7 kmSW), Kharchi (4.8km W),Jhagadia (5.2 km N), Govali(5.4 km NW), Borjai (5.5 kmESE), Dholakuva (5.5 km NE),Padal (5.9 km ENE), Rajpora(5.7 km E), Limbet (6.1 km S),Panvadi (6.6 km SE), Mandva(7 km WNW), Ankleshwar (7.2km SW), Valia (9.4 km S), B

9Areas occupied by sensitive man-made land uses(hospitals, schools, places of worship, communityfacilities)

Yes

Primary health centres, Primaryschools, hospitals, worshipplaces etc. are located inJhagadia, Bharuch andAnkleshwar

10Areas containing important, high quality or scarceresources.(ground water resources,surfaceresources,forestry,agriculture,fisheries,tourism,minerals)

Yes

Surface water and agriculturalresources located within thestudy area. Forest area islocated at 8.02 km

11Areas already subjected to pollution or environmentaldamage.(those where existing legal environmentalstandards are exceeded)

No None reported

12

Areas susceptible to natural hazard which could causethe project to present environmental problems(earthquakes, subsidence, landslides, erosion, floodingor extreme or adverse climatic conditions) similareffects

No

Floods Heavy monsoonsoccasionally cause floods, butthe site elevation at the projectarea ensures that there is noimpact of floods in the area.Earthquakes As per thegeological map published byGeological survey of India, thearea comes under themoderate risk zone (Zone-III)of the Seismic Zoneclassification. The design ofstructures at the project siteshall be based on IS 1893 tomake it earthquake resistant.Landslides Not noted to occurin the area Cloudburst Not aknown fea

(IV) PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

1 Uploaded Proposed TOR File Annexure-TOR file

2 Uploaded scanned copy of covering letter Annexure-scanned copy ofcovering letter

3 Uploaded Pre-Feasibility report(PFR) Annexure-PFR

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Proposed_TOR_File/24_Jan_2019_195435603FE2S4ZCSAnnexure-ProposedToRfile.pdf

http://environmentclearance.nic.in/writereaddata/FormB/TOR/Covering_Letter/24_Jan_2019_195435647S2R84ZCSCoveringLetter.pdf

http://environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/24_Jan_2019_195435670MEHIU2WVAnnexure-Pre-feasibilityReport(PFR)File.pdf



ADDITIONAL MULTIPLE ENTERIES

Sr.no. Remarks Uploaded Additional Attachments

1 The attached document uploaded contains thereplies to EDS raised by SEIAA Annexure-Additional Attachments

(V) Undertaking

The aforesaid application and documents furnished here with are true to my knowledge

V.(i)

Name DCM SHRIRAM LIMITEDDesignation SVPCompany DCM SHRIRAM LIMITED

Address 5th Floor, Kanchenjunga Building, 18, BarakhambaRoad, New Delhi

http://environmentclearance.nic.in/writereaddata/FormB/TOR/ConceptualPlan/11_Feb_2019_1437550679TS5OHBVEDSReply.pdf

M/S. DCM SHRIRAM LTD. (UNIT: SHRIRAM ALKALI & CHEMICALS)

Pre-Feasibility Report: Environmental Clearance for Proposed Capacity Expansion of Existing Captive Power Plant and Chlor Alkali Plant at Plot No. 749, GIDC Jhagadia, District Bharuch, Gujarat

JANUARY, 2019

(The expansion is proposed as per the MoU signed by the company in Vibrant

Gujarat 2015 summit)

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

SAC PFR – PROPOSED CAPACITY EXPANSION IN CAPTIVE POWER GENERATION & CHLOR

ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA QUALITY CONTROL SHEET

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 II

M/S. DCM Shriram Ltd. (Unit: Shriram Alkali & Chemicals)

Pre-Feasibility Report: Environmental Clearance for Proposed Capacity Expansion of Existing Captive Power Plant and Chlor Alkali Plant at Plot No. 749, GIDC Jhagadia, District Bharuch, Gujarat © Kadam Environmental Consultants (‘Kadam’), January, 2019

This report is released for the use of the M/s. DCM Shriram Ltd. (Unit: Shriram Alkali and Chemicals (SAC)),

Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process.

Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used

for any other purpose without the written consent of Kadam.

QUALITY CONTROL

Name of

Publication

DCM Shriram Ltd. (Unit: Shriram Alkali & Chemicals) : Pre-Feasibility Report: Environmental Clearance for Proposed Capacity Expansion of Existing Captive Power Plant and Chlor Alkali Plant at Plot No. 749, GIDC,

Jhagadia, District Bharuch, Gujarat.

Project

Number 1937991306 Report No. 1 Version 0 Released

CONTACT DETAILS

Vadodara Office: Address: 871/B/3, GIDC Makarpura, Vadodara, India–390 010; T:+91-265-6131000; E: [email protected];

Delhi / NCR Office: Address: Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana, INDIA – 122002; T:0124-4242430 to 436; E: [email protected];

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Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan, believes that the facts presented in the report are accurate as on the date it was written and takes full responsibility of what has been

mentioned. However, we are human: it is impossible to dismiss absolutely, the possibility of unintended errors or omissions. Kadam therefore specifically disclaims any liability resulting from third party use or application of the

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ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 III

CONTENTS

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

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 1

1.2 INFRASTRUCTURE ....................................................................................................... 1

1.3 UTILITY ................................................................................................................. 2

1.4 ENVIRONMENT ........................................................................................................... 2

1.5 SENSITIVITY ............................................................................................................. 3

1.6 CONCLUSION ............................................................................................................ 3

2 INTRODUCTION ......................................................................................................... 4

2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT ................................................................. 4

2.1.1 Project Proponent ............................................................................................... 4

2.1.2 Proposed Project ................................................................................................ 5

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................... 5

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION .......................................... 6

2.3.1 Chlor-Alkali ....................................................................................................... 6

2.4 DEMAND & SUPPLY GAP ................................................................................................. 7

2.5 EXPORT POSSIBILITY .................................................................................................... 7

2.5.1 Domestic / Export Market ..................................................................................... 7

2.6 CAPTIVE POWER PLANT ................................................................................................. 7

2.7 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............................................. 7

3 PROJECT DESCRIPTION .............................................................................................. 8

3.1 TYPE OF PROJECT ....................................................................................................... 8

3.2 LOCATION OF THE PROJECT ............................................................................................. 8

3.3 DETAILS OF ALTERNATE SITES CONSIDERED ........................................................................... 10

3.4 SIZE OR MAGNITUDE OF OPERATION................................................................................... 10

3.4.1 Chlor-Alkali and Captive Power Plant ....................................................................... 10

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ...................................................................... 10

3.5.1 Chlor Alkali Plant (Existing + Expansion) .................................................................. 10

3.5.2 Coal based Captive Power Plant ............................................................................. 14

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL

PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT ............................................... 16

3.7 UTILITIES .............................................................................................................. 16

3.7.1 Power Requirement ............................................................................................ 17

3.7.2 Fuel Requirement .............................................................................................. 17

3.7.3 Water Requirement ............................................................................................ 17

3.7.4 Storage Details ................................................................................................. 17

3.8 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 17

3.8.1 Air Emissions & Control ....................................................................................... 18

3.8.2 Noise Generation ............................................................................................... 19

3.8.3 Waste Water Generation ...................................................................................... 19

3.8.4 Hazardous Waste & Other Solid Wastes ................................................................... 20

4 SITE ANALYSIS ........................................................................................................ 23

4.1 CONNECTIVITY ......................................................................................................... 23


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 IV

4.1.1 By Road .......................................................................................................... 23

4.1.2 By Rail ........................................................................................................... 23

4.1.3 By Air ............................................................................................................ 23

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 23

4.3 TOPOGRAPHY ........................................................................................................... 23

4.4 EXISTING INFRASTRUCTURE ............................................................................................ 23

4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 23

4.5.1 Soil Classification ............................................................................................... 23

4.5.2 Geology .......................................................................................................... 24

4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 24

4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 24

5 PLANNING BRIEF ..................................................................................................... 25

5.1 PLANNING CONCEPT .................................................................................................... 25

5.2 POPULATION PROJECTION .............................................................................................. 25

5.3 LAND USE PLANNING ................................................................................................... 25

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 25

5.5 AMENITIES / FACILITIES ............................................................................................... 25

6 PROPOSED INFRASTRUCTURE ................................................................................... 26

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 26

6.2 RESIDENTIAL AND NON- PROCESSING AREA ........................................................................... 26

6.3 GREENBELT ............................................................................................................. 26

6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 26

6.5 CONNECTIVITY ......................................................................................................... 26

6.6 DRINKING WATER MANAGEMENT ...................................................................................... 27

6.7 SEWERAGE SYSTEM .................................................................................................... 27

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 27

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 27

7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .................................................... 28

8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................... 29

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 29

8.2 ESTIMATED PROJECT COST ............................................................................................ 29

8.2.1 Economic Viability .............................................................................................. 29

9 ANALYSIS OF PROPOSAL .......................................................................................... 30

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 30


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA LIST OF ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 V

ANNEXURES

Annexure 1: Preliminary Site Layout Map 32

Annexure 2: Project Site Located on Top sheet showing 3, 5, 7 & 10 km Radii Circles 33

Annexure 3: GIDC Appreciation letters for Green Belt developed by DCM-SAC 34


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA LIST OF TABLES

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 VI

LIST OF TABLES

Table 1-1: Products Capacity (Existing & Proposed) ............................................................................................1

Table 1-2: Capacities of Power plants.................................................................................................................2

Table 1-3: Fuel Requirements ............................................................................................................................2

Table 2-1: List of Directors ................................................................................................................................5

Table 2-2: Products Capacity (Existing & Proposed) – Chlor Alkali Plant ................................................................5

Table 2-3: Power Generation Capacity (Existing & Proposed) ...............................................................................6

Table 3-1: Co-ordinates of Site Boundary ......................................................................................................... 10

Table 3-2: Details of Raw material Quantity, Source and Mode of Transport ....................................................... 16

Table 3-3: Power Generation Capacity (Existing & Proposed) ............................................................................. 17

Table 3-4: Fuel Requirements .......................................................................................................................... 17

Table 3-5: Details of Flue Stack Emissions ........................................................................................................ 18

Table 3-6: Details of Process Vent Emissions .................................................................................................... 19

Table 3-7: Wastewater Generation Details ........................................................................................................ 20

Table 3-8: Solid Waste Generation & Disposal................................................................................................... 20

Table 3-9: Hazardous Waste Generation and Disposal ....................................................................................... 21

Table 3-10: Side and Bottom Liner System of Secured Landfill Facility ................................................................ 21

Table 6-1: Existing and Proposed units within DCM-SAC, Jhagadia ..................................................................... 26

LIST OF FIGURES

Figure 3-1: General Location of Proposed Project Site .........................................................................................8

Figure 3-2: Specific Map Showing Project Boundary and site neighbours ...............................................................9

Figure 3-3: Process Flow Diagram .................................................................................................................... 14

Figure 3-4: Flow diagram of Captive power plant .............................................................................................. 16

Figure 3-5: Secured Landfill Facility (SLF) ......................................................................................................... 22


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2019 1

1 EXECUTIVE SUMMARY

DCM Shriram Ltd. is a leading business conglomerate with a legacy of more than 130 years. The group turnover for

FY. 2017-18 was Rs. 7007 crores.

DCM Shriram has manufacturing facilities in Kota (Rajasthan) and in Bharuch (Gujarat). The business portfolio of

DCM Shriram comprises primarily of:

Agri-Rural Business: Urea & SSP fertilizers, Sugar, Farm inputs marketing such as DAP, Crop care Chemicals, Hybrid

Seeds

Chlor-Vinyl Business: Caustic Soda, Chlorine, Calcium Carbide, PVC resins, PVC Compounds, Power and Cement.

Value added business: Fenesta Building Systems- UPVC Windows & Door

The Chlor-Alkali facility at Plot No. 749, GIDC, Jhagadia, Gujarat is operated by DCM Shriram Ltd. (Unit: Shriram

Alkali and Chemicals (SAC) proposing expansion in its existing Chlor alkali and Captive thermal power plants.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category

including Project / Activity: 4(d) Chlor-Alkali Industries & 1(d) Thermal Power plant and categorized under “B”.

1.1 Plant Features and Production Capacity

Cost of existing project is Rs. 1327 crores. The expected cost of the proposed expansion project will be around Rs.

1050 crores.

Details of existing and proposed products are listed in Table 1-1.

Table 1-1: Products Capacity (Existing & Proposed)

Sr. No. Product Capacity (MTPA)

Existing Additional Proposed Total after expansion

1 Caustic Soda (Lye & Flakes) 5,08,000 305000 813000

2 Chlorine 4,47,200 268496 715696

3 Hydrochloric Acid (100 %) –

on 33% basis

1,20,000 =

3,63,636

36500

1,10,600

156500

4,74,236

4 Hydrogen 13,541 8130 21671

5 Sodium Hypochlorite 24,360 14626 38986

6 Aluminium Chloride (Non EC-

able product) 36500 0 36500

7 Steam 1,05,120 105120 210240

1.2 Infrastructure

The proposed expansion would be implemented in DCM-SAC’s existing manufacturing facility at Plot No. 749, GIDC,

Jhagadia, Bharuch, Gujarat.

Main components of the existing project which includes Captive Power Plant, Chlor Alkali Plant, Chlorine,

Hydrogen plant and their associated utilities / components like Boiler House of CFBC Boilers, Steam Turbine,

Generator, Utility Area consisting of cooling tower, ESP section Fly ash storage area. Water & wastewater

infrastructure like Effluent Treatment Plant (ETP), Air compressors, Hazardous storage facility area and Secured

Landfill are being used. Details of additional infrastructure are in Table 6-1.




1.3 Utility

Power: The capacity of existing coal based captive power plant is 122 MW. The capacity of existing FO based

captive Diesel Generator (DG) sets of 24 MW capacity. The expansion of Captive power plant project would entail

the following Table 1-2:

Table 1-2: Capacities of Power plants

Sr. No. Description Capacity (MW)


1 Captive Power Plant 122 120 242

2 DG sets 24 -24 0

Blended Fuel is being used for the power generation. In Gujarat, imported coal is available from Dahej, Bhavnagar,

Mundra, Surat etc. The coal is transported by road through dumpers / trucks.

Fuel: The additional fuel requirement are as per Table 1-3:

Table 1-3: Fuel Requirements

Sr. No. Description Consumption (MTPA)


1 Blended fuel

7,31,000

(blended coal-

(Indigenous/

Imported/ Lignite /

Bio-Mass)

834000

(Indigenous coal/

Imported coal/ Lignite /

Bio-Mass/Pet coke)

1565000

2 HSD 100 98 198

3 HFO 52700 -23700 29000

Raw Water: The water is supplied by Gujarat Industrial Development Corporation (GIDC), sourced from Narmada

and supplied from intake point at Rundh. The existing water consumption for the facility is 14491 KLD. The water

required for proposed expansion will be 10500 KLD. Thus, total water consumption after expansion will be 24991

KLD.

Manpower: During the construction phase approximately 500 persons and during operational phase approximately

additional 50 personnel will be hired. Local skilled and semi-skilled workers will be preferentially hired for the

purpose.

1.4 Environment

Environmental issues associated with proposed units are:

Air Emissions: These would be due to presence of various Flue Gas stacks and process vents

Wastewater: The Treated effluent, complying with the prescribed norms of Gujarat Pollution Control Board

will be discharged into GIDC above ground effluent pipeline and collected into GIDC common effluent sump.

From GIDC sump the entire treated effluent is being discharged into deep sea through Jhagadia Pipeline of

Narmada Clean Tech (NCT).

Solid & Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per

the Hazardous and Other Wastes (Management and Trans boundary Movement) Rules, 2016 and its

amendments.




1.5 Sensitivity

The proposed expansion of SAC’s Chlor-Alkali and Thermal power project would take place in it’s existing

manufacturing facility in GIDC Jhagadia which is a Notified Industrial Area of the Gujarat Industrial Development

Corporation (GIDC) Ltd. Several large scale multi-product facilities are operating in this estate. The Project site falls

in Zone-III of Seismicity. Civil works and Structures shall be designed according to applicable codes.

1.6 Conclusion

There is no significant adverse impact envisaged on the water environment due to the proposed project. The air

environment has negligible effect due to the activities related to the proposed project.

After implementation of pollution control measures there will be no emission from the plant which are beyond the

norms specified by Gujarat Pollution Control Board (GPCB). The project is not contributing to any adverse impact on

the surrounding soil, as the pollutants emitted are of negligible amount.

Project intends to generate employment preferentially for local people and unskilled / semiskilled workers during

construction phase. If this project comes up, it will have social, financial benefits and will be environmentally

sustainable.

Pre-feasibility study confirms viability of the project.


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project Proponent & Project

2.1.1 Project Proponent

DCM Shriram Ltd. is a leading business conglomerate with a group turnover of Rs. 7,007 crores for FY 2017-18. The

business portfolio of DCM Shriram comprises primarily of:

Agri-Rural Business: Urea & SSP fertilizers, Sugar, Farm inputs marketing such as DAP, Crop care Chemicals, Hybrid

Seeds

Chlor-Vinyl Business: Caustic Soda, Chlorine, Calcium Carbide, PVC resins, PVC Compounds, Power and Cement.

Value added business: Fenesta Building Systems- UPVC Windows & Door

DCM Shriram, a spin-off from trifurcation of the reputed erstwhile DCM Group in 1990, is managed by Mr. Ajay S.

Shriram, Chairman & Senior Managing Director, Mr. Vikram S. Shriram, Vice Chairman & Managing Director and Mr

Ajit S. Shriram, Joint Managing Director along with a highly professional executive team.

DCM Shriram has manufacturing facilities of Fertiliser & Cement in Kota (Rajasthan) and of Chlor- Alkali in Bharuch

(Gujarat). The company operates coal-based captive power facilities in Kota, rated at 133 MW and in Bharuch

(Gujarat), at 122 MW. The Urea plant in Kota has a Production capacity of 379,000 TPA & Chlor- Alkali capacity of

6, 80,000 TPA in both Kota & Bharuch.

DCM Shriram Sugar factories are located in Ajbapur, Rupapur, Hariawan and Loni in Uttar Pradesh with

cogeneration of power from bagasse and distilleries. The Hybrid seed operations- ‘Bioseed’ started in Hyderabad

(India) and now has a global footprint with presence in Vietnam, Philippines and Indonesia.

Fenesta windows fabrication units are located in Bhiwadi, Hyderabad and Chennai. All manufacturing units have

implemented the all test requirements of international standards of ISO 9001 & 14001 (Quality & Environment

Systems) and OHSAS 18001/ISO45001 (Occupational Health and Safety Standards) for its facilities/products.

DCM Shriram has well defined processes in all its manufacturing facilities. Continuous improvements are made

through global benchmarking, TQM, TPM, etc.

There is a strong and proactive focus on safety, health and environment. Some of the facilities (including SAC-

Jhagadia) have received international recognitions such as Sword of Honour from British Safety Council, Energy

Efficiency Award from Bureau of Energy Efficiency (BEE) and many more recognitions from ICC, FICCI, CII etc. in

the fields of Environment, Safety, Water and Energy conservation.

DCM Shriram, across its various businesses, is strategically diversified yet operationally integrated at a high level.

Some of the businesses feed others, thereby lowering operation costs and making DCM Shriram a highly

competitive player. DCM Shriram is amongst the most cost efficient producers of products and services in all its

businesses and has been continuously striving to lower costs and increasing efficiency. It also has the unique

advantage of low-cost captive power for all the major operations.

The Chlor-Alkali facility at Jhagadia is operated by the name, Shriram Alkali and Chemicals Ltd. (A Unit of DCM

Shriram Ltd.).




The List of Directors of the Company along with their designation is given in Table 2-1 below:

Table 2-1: List of Directors

Sr. No. Name Designation Address

1. Mr. Ajay S. Shriram

S/o Late Shri Shridharji

Chairman & Senior

Managing Director

Shivam, A-37, Vasant Marg,

Vasant Vihar, New Delhi-110057

2. Mr. Vikram S. Shriram


Vice Chairman &

Managing Director

5/16, Shanti Niketan,

New Delhi-110021

3. Mr. Ajit S. Shriram


Jt. Managing Director 5/20, Shanti Niketan,

New Delhi-110021

4. Mr. K K. Kaul

S/o Late Shri P.N. Kaul

Whole Time Director 6-A, Vallabh Nagar,

Kota — 324007, Rajasthan

5. Mr. Krishan Kumar Sharma

S/o. Shri Hari Dutt Sharma

Whole Time Director

(EHS)

Flat No.806, Tower-3,

Purvanchal Royal Park, Sector — 137,

Noida - 201301, U.P.

6. Mr. Pradep Dinodia

S/o Late Shri S.R. Dinodia

Director A-9A, Maharan Bagh,

New Delhi-11 0 065

7 Mr. Vimal Bhandari

S/o Late Shri Ranjeet Mal Bhandari

Director Flat No 164, 16” Floor,

Tower "A", Kalpataru Horizon,

S.K Ahire Marg, Worli Mumbai - 400 018

8. Mr. Sunil Kant Munjal

S/o Late Shri Brij Mohan Lal Munjal

Director 1-A, Friends Colony (West),

New Delhi — 110 065

9. Mrs. Ramni Nirula

W/o. Mr. Deepak Nirula

Director A-14, Anand Niketan,

New Delhi — 110 021

10. Justice (Retd.) Vikramajit Sen

S/o. Late Shri E.H.K. Sen

Director 34A, First Floor,

Friends Colony (East), New Delhi — 110

065

11. Mr. Pravesh Sharma

S/o. Late Shri Chiranjiv Lal Sharma

Director Flat C-2/303,

Asian Games Village Complex, New Delhi

— 110 049

12. Mr. Sharad Shrivastva

S/o Shri Ramesh Chandra Srivastava

Director

(LIC Nominee)

C-G-Jeevan Jyot, Setalvad Lane, Nepean

Sea Road, Mumbai - 400 036

2.1.2 Proposed Project

Proposed project is for expansion in Existing Production Capacity of the Chlor-Alkali plant located in GIDC, Jhagadia,

Gujarat, India. As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project

falls in category including Project / Activity: 4(d) – Chlor Alkali industry and 1(d) – Thermal power plant and both

are categorized under “B”.

2.2 Brief Description of nature of the Project

Details of existing and proposed products are listed in Table 2-2.

Table 2-2: Products Capacity (Existing & Proposed) – Chlor Alkali Plant



1 Caustic Soda (Lye & Flakes) 5,08,000 305000 813000

2 Chlorine 4,47,200 268496 715696






3 Hydrochloric Acid (100 %) –

on 33% basis

1,20,000 =

3,63,636

36,500

1,10,606

1,56,500

4,74,242

4 Hydrogen 13,541 8,130 21,671

5 Sodium Hypochlorite 24,360 14,626 38,986

6 Aluminium Chloride (Non EC-

able Product) 36,500 - 36,500

7 Steam 1,05,120 1,05,120 2,10,240

The power generation capacities of existing coal based captive power plant & FO based DG set would be expanded

as per Table 2-3:

Table 2-3: Power Generation Capacity (Existing & Proposed)

Sr.

No. Product

Existing Capacity

(MW)

Additional Proposed

Capacity (MW) Total after expansion

(MW)

1 Coal based Captive Co

Generation Power Plant (CPP) 122 120 242

2 FO based DG sets 24 -24 0

2.3 Need for the Project and its Importance to the Country & Region

The expansion is proposed in fulfilment of the MoU signed by the company in Vibrant Gujarat 2015 summit. Based

on the current market scenario of Caustic soda the existing production is increased from 508000 to 813000 MTPA

as well as Captive power plant from 146 MW to 242 MW and also due to the availability of infrastructure at the

existing facility the need for the proposed expansion of the project is decided to be carried out.

2.3.1 Chlor-Alkali

The size of the Indian Chlor-Alkali sector at 4.1 million tonnes1 (~5% of world market). The Chlor-Alkali industry is

the oldest and largest segment of the inorganic chemical industry. It comprises of caustic soda, liquid chlorine and

soda ash.

Caustic soda is used in various applications such as finishing operations in textiles, manufacture of soaps and

detergents, alumina, paper and pulp, control of pH (softening) of water, general cleansing and bleaching. The

aluminium industry is the biggest demand driver for caustic soda.

Chlorine is used in multiple sectors such as manufacture of polymers like PVC, bleaching applications, paper and

pulp and textile industry. Alumina processing is expected to drive the caustic soda demand in the country. Textile

and chemical sectors are expected to further push the caustic soda demand in India.

Indian Chlor Alkali industry is driven by caustic soda demand which stood at ~7 million metric tonnes in FY 20172.

This project aims to satisfy pending Caustic Soda demand in the Country and will help in import substitution to a

great extent.

1

1 Source: Alkali Manufacturers Association of India (AMAI) Bulletin, June 2018

2 Reference: Indian Chemical Industry 12th Five Year Plan 2012-2017




2.4 Demand & Supply Gap

Chlor-alkali is an industrial process for the electrolysis of sodium chloride. It is the technology used to produce

chlorine and sodium hydroxide (lye/caustic soda), which are commodity chemicals required by industry. The global

Chlor-Alkali market is valued at 97000 million US$ in 2017 and will reach 147800 million US$ by the end of 2025,

growing at a CAGR of 5.4% during 2018-2025. Caustic soda and chlorine are produced together in the ratio of

1:0.89 (also known as Electrochemical Unit or ECU) through electrolysis of salt. On account of their co-production,

the market dynamics for caustic soda and chlorine are heavily influenced by each other. Internationally, it is

chlorine based, whereas, in India, it is influenced by caustic soda.

Domestic demand has been stable and market is expected to grow @ 5% in next 3-5 years. According to Alkali

Manufacturers’ Association of India (AMAI), the Indian Chlor-alkali market was estimated at around USD 1.9 billion

in FY2010, vis-à-vis global market size of USD 48 billion. The consuming Industries such as alumina, paper and

textile are growing faster than GDP and expected to add more capacities

Chlorine demand has also been matching up caustic growth due to growth in downstream industry. It is further

expected to grow at @ 5-6% in next 2-3 year.

Driven by above positive sentiments, we propose the expansion of our existing chlor alkali facility along with a

captive power to support the production

2.5 Export Possibility

2.5.1 Domestic / Export Market

DCM Shriram Ltd., Unit: Shriram Alkali & Chemicals (SAC) is pioneer in the market having more than 50 years

expertise in manufacturing. The finished products are conforming to Indian Standard /as per the customer

requirement. The customers are located mainly within Gujarat. Some customers are located outside Gujarat also.

Sale is made to direct customers and through traders. SAC also supplies their product to adjacent factories through

pipeline.

2.6 Captive Power Plant

Power is one of the main input for the production of Caustic Soda and constitutes about 70% of cost of production.

The existing captive power plant capacity of SAC is 122 MW thermal and 24 MW DG based. The thermal power

generation is proposed to be expanded by 120 MW and FO based DG sets are to be decommissioned. After

expansion the total Power generation will increase to 242 MW (thermal).

2.7 Employment Generation (Direct & Indirect) due to the project

During the construction phase around 500 workers and during the operational phase around 50 workers will be

required. Local skilled and semi-skilled workers will preferentially be engaged during construction phase. The

positive impact includes enhanced direct employment for technical / administrative works and indirect employment

opportunities for transporters of raw material like salt, coal etc. and finished goods.


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project

The project is an expansion project to increase the capacity of existing Chlor-Alkali plant from 508000 MTPA to

813000 MTPA caustic as well as increasing Captive thermal power plant capacity from 122 MW to 242 MW within

the existing factory premises. The project does not include any interlinked or interdependent projects.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category

including Project / Activity: 4(d) – Chlor Alkali industry and 1(d) – Thermal Power Plants and categorized under “B”.

3.2 Location of the Project

Shriram Alkali & Chemicals is located on Plot No.: 749, Industrial Estate of Jhagadia, developed by the Gujarat

Industrial Development Corporation (GIDC), categorized as chemical notified zone for setting up chemical industries

in District Bharuch, Gujarat. The total plot area is 46.7 ha.

Location map showing general location of proposed project is given in Figure 3-1. Specific Map showing project

boundary is given in Figure 3-2. The co-ordinates of the project site are given in Table 3-1.

Figure 3-1: General Location of Proposed Project Site




Figure 3-2: Specific Map Showing Project Boundary and site neighbours

Red highlighted boundary shows boundary of Plant. No extra land is required.




Table 3-1: Co-ordinates of Site Boundary

Code Latitude Longitude

A 21°39'13.71 N 73° 8'22.73" E

B 21°39'47.53"N 73° 8'30.64"E

C 21°39'53.83"N 73° 7'58.96"E

D 21°39'20.07"N 73° 7'50.41"E

3.3 Details of Alternate Sites Considered

The proposed expansion will be carried out within the existing factory premises considering the following points:

1) Less investment per MT of installed plant capacity.

2) Availability of required infrastructure.

3) Reduction in per MT of manufacturing cost.

4) Proximity to market.

5) Availability of Raw material in close proximity.

6) The existing plant is located in GIDC Jhagadia Industrial Estate which is categorized as chemical notified

zone / notified Industrial Area, developed specifically for chemical / water intensive industries.

7) Waste water and solid / hazardous waste treatment / disposal infrastructure is readily available

Hence need of alternative site identification is not felt.

3.4 Size or Magnitude of Operation

3.4.1 Chlor-Alkali and Captive Power Plant

Total plot area is 4,67,500 m2. Out of this, the area of the existing Chlor Alkali plant and captive power plant

comprises 2,67,600 m2. The area of proposed expansion project will be 43000 m2. This area given is tentative and

is subject to changes as detailed engineering takes place. This will be demarcated in the EIA study report.

3.5 Project Description with Process Details

3.5.1 Chlor Alkali Plant (Existing + Expansion)

The process is based on Membrane Cell technology. The main steps in the process to manufacture caustic soda

are:

Purification of brine.

Electrolysis.

Concentration and flaking of caustic soda solution.

In the process Hydrogen and Chlorine gas are produced as the co-product.

Brine Purification

General

Brine for ion exchange membrane Chlor-Alkali process is prepared by dissolving salt in the return brine from the

electrolysis plant, and purified in two stages. Primary purification removes impurities like calcium, magnesium,

sulphate, iron, silica etc. to ppm level.

Secondary purification is required to make brine suitable for the ion exchange membrane Chlor-alkali process.




Primary Brine Purification

Primary Brine Purification section consists of Salt Handling system, Brine Saturator, Reactors, Clarifiers, Clarified

Brine Tank and associated facilities.

This process includes Brine saturation, chemicals dosage, reaction and sedimentation. The purpose of this process

is to re-saturate the return brine with raw salt and to remove impurities from the saturated raw brine.

The return brine is fed from the top of the Brine Saturator and saturated with salt. The salt is continuously supplied

to the top of the saturator by a Belt Conveyor System.

The saturated raw brine overflows from the Brine Saturator and flows into Reactor. Chemicals such as barium

carbonate, sodium carbonate, caustic soda are fed to Reactors. Calcium, magnesium and other multivalent cations

and sulphate anions in the raw brine react with these chemicals and are changed to suspend solids while the brine

is held in the reactor.

pH of the brine is controlled by the addition of caustic-soda to the brine. Then the brine overflows from the reactor

into the Brine Clarifier. Flocculent is fed to the brine line entering the clarifier.

Suspended solids in the brine are removed by settling in the Clarifier provided with water seal & insulated from the

sides. The brine, thus clarified, flows into clarified Brine Tank over the weir of Clarifier & is pumped out and

recirculated to the brine system before Reactor for better clarification. Slurry from clarifier is periodically pumped to

vaccum drum filter (VDF). The brine from is sucked into the system and the residual brine sludge is disposed in

captive SLF or nearby CTSDF.

The clarified brine is sent to Secondary Brine purification section by clarified brine pump.

Secondary Brine Purification

Secondary Brine Purification Section consists of Brine Filters and Ion Exchange Resin Columns.

The clarified brine is filtered through the filter and flows into filtered Brine tank. Suspended solids caught on the

filter element surface are blown down to Filter Slurry Pit. Filter Slurry in the pit is sent to VDF where most of the

brine is recovered and fed back to Return Brine Tank.

Ion Exchange Resin Column packed with special Ion Exchange resin is operated and controlled automatically from

control room. This specially developed Ion exchange resin can remove multivalent cations harmful to the Ion

exchange membrane. The brine thus purified is fed to Electrolyser and electrolysis is conducted.

Electrolysis

Electrolysis section consists of bipolar Electrolysers and their associated equipment.

Electrolyser

Electrolyser consists of number of bipolar type cell frames with the metal anode and the activated cathode, the

Ion exchange membrane, press unit for mounting cell frames, sub-headers for feeding anolyte and catholyte, sub-

headers, and oil pressure unit which supplies oil to oil cylinders.

Cell frames holding the Ion Exchange membrane in between are fixed by the oil cylinder installed at the end of the

press unit. This structure ensures no leakage of electrolytes because uniform pressure can be applied to gasket

surface and cell frame of metal structure ensures no electrolyte leakage caused by deformation even after a long

period of operation.

Anolyte Circulation

Anolyte circulation system is composed of Anolyte Circulation Tank and anolyte circulation pump. Anolyte is fed into

each of anode compartment of cell frames through sub-headers and hoses, and recirculated to Anolyte circulation




Tank. Purified brine is fed to maintain anolyte concentration within a designed level. A part of the anolyte after

electrolysis, is taken out from Anolyte Circulation Tank to Depleted Brine Tank by overflow.

Anolyte Circulation system is designed to ensure steady and uniform distribution of anolyte to each cell and to

cope-up with any change in electrolysis conditions such as production rate change.

The diluted brine collected in Depleted Brine Tank is sent to De-chlorination Tower for removal of Chlorine gas.

Chlorine gas generated in electrolyser is separated in Anolyte Circulation Tank and sent to Chlorine gas cooling,

drying and compression section.

Catholyte Circulation

Catholyte Circulation System is composed of Catholyte Circulation Tank, Catholyte Circulation Pump and Catholyte

Cooler. Catholyte is circulated through cathode compartment of cell frames to Catholyte Circulation Tank by

Catholyte Circulation Pump, and a part of it is taken out from Catholyte Circulation Tank to Caustic Soda Tank and

sent out to caustic evaporation section. To keep the concentration of caustic soda at designed level, demineralised

water is fed to catholyte inlet sub-header.

Hydrogen gas is generated in Electrolyser is separated from the catholyte in catholyte Circulation Tank and sent to

Hydrogen Gas Cooling and Compression Section. Heat generated in electrolyser is removed by cooling water in

Catholyte Cooler.

De-Chlorination of Return Brine

De-chlorination section is composed of De-Chlorination Tower, De-Chlorination Tower Cooler, Ejector, Ejector

Cooler and associated facilities. Return brine (depleted brine) from Electrolysis Section is saturated with chlorine.

In the tower, chlorine is stripped together with water vapour, and passed through De-chlorination Tower cooler.

The vapours are condensed there and the chlorine gas is sucked by the steam ejector to Ejector Cooler.

Steam is condensed there and the chlorine gas is then introduced to chlorine gas product main line.

The depleted brine, dechlorinated through De-chlorination Tower, still contains small amount of free chlorine which

can cause damage to the filter elements in Brine Filters and damage ion exchange resin in Ion Exchange Resin

Columns. Sodium sulphite is added to kill free chlorine. Return brine is then fed to Return Brine Tank & pumped to

salt saturator.

Caustic Concentration

The caustic soda concentration system consists of triple effect falling film evaporators operating on backward feed

flow scheme. 30% caustic solution at 80°C is fed to third effect evaporator. Vapours are separated from solution

and concentrated solution of third effect evaporator is pumped to second effect evaporator after passing through

two heat exchangers in series. In the second effect evaporator, flash evaporation of liquor takes place and liquor is

further heated by steam and vapours are separated in second effect evaporator to concentrate liquor.

The concentrate from the second effect evaporator is pumped through first effect evaporator after passing through

two heat exchangers in series. Steam at 11 kg/cm2(a) pressure is used to attain required concentration of caustic.

Chlorine Liquefaction & Bottling

Chlorine Gas Washing and Cooling

Chlorine Gas coming out of Anolyte circulation tank contains water vapour saturated at about 90°C and has little

amount of Sodium Chloride as entrainment. Gas is first washed by process water in a direct contact scrubbing

packed tower. Condensate is sent to dechlorination tower. The process water is in turn cooled by cooling tower.

Cooled gas is then passed through a packed tower having chilled process water circulation at 16 °C so as to cool

the gas to reduce water vapor load.




Chlorine gas temperature is generally around 15-20°C as cooling below 9-10°C will result into formation of Chlorine

hydrate. Cooled gas is then dried with direct spray of sulphuric acid in packed towers.

Chlorine Gas Drying

The cooled chlorine gas is led to chlorine Gas Drying Tower. The moisture of chlorine gas is absorbed in 98%

sulphuric Acid in two stage chlorine gas drying tower, and the acid gets diluted to 78% by absorption of

moisture from chlorine gas. Chlorine Gas Drying Tower has a cooler to cool circulating sulphuric Acid. The Dry

Chlorine gas is sent for compression.

Chlorine Gas Compression

Dry chlorine gas from chlorine Gas Drying Section is compressed to 4 kg/cm2 (a) by using Acid Ring type

Compressor.

Chlorine Gas Liquefaction and Filling

Chlorine gas from compressor is sent to chlorine Gas Liquefaction Unit to be condensed by the Freon 22 refrigerant.

The unliquefied gases along with inert gas from Liquefier are sent to HCl Synthesis unit for burning with Hydrogen

to produce HCl.

Liquefied chlorine enters Chlorine Storage Tank from where it is transferred by means of compressed dry air to

chlorine bottling section. Part of liquid Chlorine is vaporised and sent to nearby customers through pipeline.

Chlorine Neutralization / Sodium Hypochlorite Section

Chlorine gas, only in case of plant emergency, during start up and plant tripping is led to the Sodium Hypochlorite

Unit. This unit consists of packed tower in which caustic solution is circulated to absorb waste chlorine.

Temperature of the liquid is controlled by heat transfer through plate type heat exchanger with chilled water.

After a desired strength of sodium hypochlorite is reached, the solution is sent to a Hypo Reactor. Here it is reacted

with fresh chlorine to produce marketable quality of Sodium Hypochlorite.

HCl Synthesis

The HCl Synthesis unit consists of combustion furnace fitted with absorbers. The chlorine gas reacts with Hydrogen

to form HCl gas which is cooled and absorbed in DM water. The flow rate of DM water is adjusted to obtain 30-33%

HCl Solution. The flow rates of Chlorine and Hydrogen are controlled by flow controllers. Safety Interlocking

provisions are made which get actuated by flame protection device. The Hydrochloric Acid Solution is collected in a

product tank from where it is pumped to HCl Storage Tanks.

Hydrogen Bottling and Storage

Hydrogen gas is compressed and filled in hydrogen cylinder banks of the customers and also stored in cylinder

banks. Part of Hydrogen gas is used as alternate fuel in boilers and Caustic flaking units as per the requirement.

Hydrogen is also sold t nearby customers through pipeline.

Caustic Soda and Flaking Plant

Flaker plant is a double effect evaporator, where 48% Caustic is fed to produce 98% Caustic Flakes. Salt mixture

(KNO3, NaNO2 & NaNO3) is heated by burning Hydrogen and used as a heating media to increase Caustic lye

temperature in final concentrator. 98 % Caustic flakes is then cooled and packed using a polythene liner to avoid

moisture pick-up as it is a hygroscopic product.




Aluminium Chloride production:

Aluminium chloride is produced in reactors by first melting the pure aluminium ingots and injecting chlorine gas into

the molten aluminium. The aluminium chloride vapors produced during the process is cooled to get anhydrous

Aluminium chloride by sublimation process. The product is hygroscopic in nature and packed in LDPE bags for

despatch.

The process flow diagram is given in Figure 3-3.

Figure 3-3: Process Flow Diagram

3.5.2 Coal based Captive Power Plant

Coal based Captive Power Plant (CPP) consists of 67.5 MVA and 82.5 MVA Condensing type steam turbine with 105

Kg/cm2 boilers at operating steam temperature 540+/- 5 °C

Basic process involves steam generation by combustion of coal in boiler. Steam is used to run turbine for power

generation.

Electricity is generated at 11kv and distributed to process plant.

Power plant is mainly divided in following sections.

1. Coal yard and coal handling plant

2. Boiler and auxiliaries

3. Steam turbine and alternator.

4 .Condensers

5. Utility

6. Ash disposal system




Coal yard and Coal handling plant

Coal unloading activity involves unloading of coal from dumpers and truck by JCBs in coal yard. Coal is fed to coal

bunker with the help of conveyor belt, screen and crusher.

Boiler and auxiliaries

There is one pulverized fuel boiler and one Circulating Fluidised Bed Combustion Boiler (CFBC) for generation of

steam. They consist of steam drum, water wall & economizer. Heat generated due to coal combustion in the form

of flue gas is used at various levels in boiler to maximize thermal efficiency. Steam is passed through super heaters

to achieve final temperature

Steam turbine and alternator

High temperature, high pressure steam enters in turbine where heat energy is converted into kinetic energy.

Turbine is directly coupled to alternator where electricity is generated by electro motive force produced. Steam is

extracted for process and for heating water before feeding in boiler from various extraction points in turbine. Power

is generated at 11KV through and fed to different areas of chlor alkali plant through double bus bar system to cater

high reliability of electrical system.

Condenser system

Exhaust steam is condensed and recycled in boiler with pumping devices at various stages with minimum make up

of D.M. water.

Utility

Utilities comprise Instrument air compressors for meeting requirement of air at various control valves, Cooling

tower with well-designed water distribution system for removing heat from condenser, alternator, oil coolers and at

various fan bearing locations. There are two nos. of raw water reservoirs @ 20000 m3 and 30000 m3, respectively,

for catering raw water requirement.

Ash disposal system

The ash from bottom is trapped in ESP & stored in an ash silo. The ash is given for cement manufacturing, road

construction and road backfilling inside and outside the factory premises, wherever required.

The flow diagram of Captive power plant is shown in Figure 3-4.




Figure 3-4: Flow diagram of Captive power plant

3.6 Raw material required along with estimated quantity, likely source, marketing area of final

product/s, mode of transport of raw material and finished product

The major raw materials are industrial salt and power. Details of raw material along with the Quantity, Source and

Mode of Transport is given in

Table 3-2: Details of Raw material Quantity, Source and Mode of Transport

S.

No. Raw Material

Quantity (MTPA) Source

Mode of

Transport Existing Proposed Total

1 Salt 8,14,008 4,88,725 13,02,733

Jambusar / Dahej /

Bhavnagar / Jamnagar

/ Kharaghoda etc

Dumper /

trucks

2 Na2CO3 5,844 3,509 9,353 Local Market Trucks

3 BaCO3 10,248 0 10,248 Local Market Trucks

4 Sodium Sulphite 1,782 1,070 2,852 Local Market Trucks

5 Alpha cellulose 211 127 338 Local Market Trucks

6 Flocculent 13 8 21 Local Market Trucks

7 H2SO4 7,308 4,388 11,696 Local Market Tanker

8 Fuel for boilers

7,31,000

Blended coal

(Imported/Indigenous

Lignite/ Bio-mass )

8,34,000

Blended Fuel (coal -

Imported/Indigenous

Lignite/ Bio-mass

/Petcoke)

15,65,000 Imported/Indigenous Trucks

3.7 Utilities

The estimated list of utilities required for the new project is as given below:




3.7.1 Power Requirement

The power generation capacities of existing coal based captive power plant would be expanded as per Table 3-3:

Table 3-3: Power Generation Capacity (Existing & Proposed)

Sr.

No. Product

Existing Capacity

(MW)

Additional Proposed

Capacity (MW) Total after expansion

(MW)

1 Coal based Captive Power Plant

(CPP) 122 120 242

2 FO based DG sets 24 -24 0

Coal is being used for the power generation. In Gujarat imported coal is available from Dahej, Bhavnagar, Mundra,

Surat etc. The coal is transported by road through dampers / trucks. The FO based DG sets will be

decommissioned.

3.7.2 Fuel Requirement

The additional fuel requirement are as per Table 3-4:

Table 3-4: Fuel Requirements

Sr. No. Description Consumption (MTPA)


1 Fuel for boilers

7,31,000

Blended coal

(Imported/Indigenous

Lignite/ Bio-mass )

834000

Blended Fuel (coal -

Imported/Indigenous

Lignite/ Bio-mass

/Petcoke)

1565000

2 HSD 100 98 198

3 FO 52700 -23700 29000

3.7.3 Water Requirement

The water is supplied by Gujarat Industrial Development Corporation (GIDC), sourced from Narmada and supplied

from intake point at Rundh. The existing water consumption is 14491 KLD. The expected proposed water

consumption will be 10500 KLD. Thus the total water consumption (existing + proposed) will be 24991 KLD.

3.7.4 Storage Details

The Unit will create additional storage facilities for the proposed project for products, raw materials as per the

MSIHC rules.

3.8 Pollution Load on Environment due to project

Environmental issues include:

Air emissions;

Wastewater generation;

Hazardous waste generation

Solid Waste generation.




3.8.1 Air Emissions & Control

Point Source

Likely air pollutants from proposed project shall be HCl and Cl from process vents and PM, SOX, NOx from proposed

Flue gas stack, as point sources. These are in addition to the existing Flue Gas stacks & Process Vents.

Volume Source

Particulate Matter (PM) emission from coal storage yard is envisaged as volume source emission as the Captive

Power plant would undergo expansion.

Fugitive Emissions

Line Source Emissions

The ambient air quality & stack emissions will be maintained as per GPCB / CPCB norms.

Details of proposed stacks with attached Air Pollution Control Equipment details are tabulated in Table 3-5 &

Table 3-6.

Table 3-5: Details of Flue Stack Emissions

Sr.

No. Stack Attached to

Stack

Height

(m)

Stack

Diameter

(M)

Exit

Velocity Pollutants

Air Pollution Control

measures

Flue Gas Stacks (Existing)

1. Stack attached to CPP (PF

Boiler) 85 3.5 10

PM Adequate size of ESP

with one additional field

SOX Adequate stack height

NOX -

2. Auxiliary Boiler 58 0.6 12.8 PM, SOX, NOX Adequate stack height

3. Stack Attached to CPP

(CFBC Boiler) 115 3.9 10

PM Adequate size of ESP

with one additional field

SO2 Adequate stack height

NOX -

4. Flaker plant – Molten salt

heater # 1 40 0.6 9 PM, SOX, NOX Adequate stack height





Existing flue gas stacks being decommissioned

1. D G Set (I) 58 1.05 20.6 PM, SOX, NOX Adequate stack height

2. D G Set (II) 58 1.05 20.6 PM, SOX, NOX Adequate stack height

3. D G Set (III) 58 1.05 20.6 PM, SOX, NOX Adequate stack height

4. D G Set (IV) 58 1.05 20.6 PM, SOX, NOX Adequate stack height

5. D G Set (V) 58 1.05 20.6 PM, SOX, NOX Adequate stack height

Flue Gas Stacks (Proposed)

1 Flaker plant – Molten salt


2 Stack Attached to CPP 140 4.3 10 PM Adequate size of ESP




Sr.


Stack

Height

(m)

Stack

Diameter

(M)

Exit

Velocity Pollutants

Air Pollution Control

measures

(Boiler) with one additional field

SO2 Adequate stack height

NOX -

Table 3-6: Details of Process Vent Emissions

Sr.


Stack

Height

(m)

Stack

Diameter

(M)

Exit

Velocity Pollutants

Air Pollution

Control measures

Process Vents (Existing)

1 HCl plant#1 30 0.15 1 HCl, Cl Water / Caustic

scrubber


scrubber


scrubber


scrubber


scrubber

6 Sodium Hypo chlorite plant

# 1 30 0.3 1.2 Cl Caustic scrubber





Process Vents (Proposed)


scrubber



3.8.2 Noise Generation

From the proposed project, noise shall be generated from the various activities. Source of noise generation are:

The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during construction

phase;

Operation of plant machinery and diesel generator set;

Vehicle movement for transportation of raw material.

3.8.3 Waste Water Generation

The main source of the industrial wastewater generation will be from cooling water blow down, R.O. Reject water,

Sulphate removal system rejects and plant washings. The total quantity of effluent will increase from 1080 KLD to

1730 KLD. Entire quantity of wastewater will be collected in final effluent discharge tank and will be treated in

existing treatment facilities. The Treated effluent, complying with the prescribed norms of Gujarat Pollution Control

Board will be discharged into above ground Jhagadia pipeline of Narmada Clean Tech Ltd. (NCT) to deep sea.

In proposed expansion, Additional effluent generated will follow the same methodology as described above.

Effluent quantity shall be contained within 1730 KL / day by recycling of treated waste water through Reverse




Osmosis (RO) system and other water conservation projects. It will increase by 650 KL/day (1080 KL/day to 1730

KL/day) due to cooling water blow down, R.O. Reject water, Sulphate removal system rejects and plant washings.

The booked capacity with NCT is of 1800 KL.

Details of Waste water generation is given in Table 3-7 below:

Table 3-7: Wastewater Generation Details

Sr. No. Source Wastewater Generation (m3/day)

Disposal method Existing Proposed Total

Process: Chlor-Alkali plant

1.

Cooling water blow down,

R.O. reject water,

Sulphate removal system

reject and plant washings

1080 650 1730

Through above ground Jhagadia

pipeline of Narmada Clean Tech

(NCT) to deep sea.

Domestic

2. Domestic 13 6 19 Into Soak Pit via Septic Tank

Total 1093 656 1749

3.8.4 Hazardous Waste & Other Solid Wastes

The hazardous wastes generated would be Used Oil, Empty Barrels / Containers / Liners and Chemical sludge from

wastewater treatment will increase after proposed expansion and dilute sulphuric acid. ETP sludge will be disposed

to TSDF site. Used oil will be sold to authorized recycler and discarded containers & plastic liners will be sold to

registered recyclers and sulphuric acid will be given to the units registered for use of the chemical.

The details of Solid & hazardous waste are given in Table 3-8 & Table 3-9.

Table 3-8: Solid Waste Generation & Disposal

Sr. No. Solid Waste Quantity (MTPA)

Mode of Disposal Existing Proposed Total

1 Brine Sludge 30000 12861 42861

Although Brine sludge is not

hazardous waste, the same is

disposed off to secured landfill facility

developed inside the factory

premises. Membership of nearby

CTSDF taken for disposal.

2 Fly Ash 146200 166800 313000 Fly Ash is given to Cement & Brick

manufacturers




Table 3-9: Hazardous Waste Generation and Disposal

Sr. No Waste Category3 Quantities Generated (MTPA) Mode of Disposal

Existing Proposed Total

1. Used or spent Oil 5.1 200 0 200

Sold to GPCB Authorised

Preprocessors

2. Cotton wastes/ residues

containing oil 5.2 1.5 1.0 2.5 Used internally in boilers

3. Empty Barrels /

Containers / Liners 33.1 200 100 300

Reused / Sold to Authorised

vendors

4. Chemical sludge from

wastewater treatment 35.3 4 1 5

Disposed in captive SLF or

common TSDF

5 Dilute Sulphuric acid

(70-78%) 11,415 6853 18268

Sold to the units for

manufacturing of chemicals and

water treatment

Secured Landfill Facility Disposal System for Brine Sludge:

To dispose off brine sludge generated, SAC has developed Secured landfill facility inside the factory premises as

recommended by National Productivity Council of India and tied up with nearby CTSDF. The design/construction of

SLF constructed in the premises is approved by Gujarat Pollution control Board (GPCB) recognized 3rd party

Schedule - I Auditor. The secured landfill has side liner and bottom liner systems as given in Table 3-10.

Table 3-10: Side and Bottom Liner System of Secured Landfill Facility

Side layers Base / bottom Drainage / Leachate collection system

900 mm thk. Compacted clay layer

900 mm thk. Compacted clay layer HDPE pipe laying

1.5 mm thk HDPE Geomembrane

1.5 mm thk HDPE Geomembrane Drainage layer of sand, 300 mm thick

6mm thk. Geonet (HDPE Material)

200 GSM Geotextile Protection Layer Finishing, epoxy paint of leachate collection

chamber

200 GSM Geotextile Protection Layer

300 mm Thk. Leachate Collection Layer

75 mm thk. Cast in situ Slab 200 GSM Geotextile Protection Layer

RCC Kerb (300mmw. * 450mm Ht.)

The layers in Secured Landfill facility (SLF) are described as under:

Bottom Liner System

As the ground water table is located at a depth of 10 m from the bottom of the cell, the industry has provided

single liner system at the base to avoid ground water contamination. The primary (Top) layer of liner consists of 1.5

mm thick Geo Membrane liner laid over 900 mm thick compacted clay layer. Over the Geo Membrane liner, 200

GSM Geo Textile (Non-woven) layer has been provided. Over Geo Textile layer, 300 mm thick drainage layer of

sand & pebbles (20 cm thick gravel of size 4.75 mm to 3 mm and 10 cm thick sand of size 3 mm to 2 mm) with

perforated HDPE pipeline network (250 mm dia. 4 kg/cm2 rating HDPE pipe having 10 mm dia. Holes) has been

provided for Leachate collection. Over the drainage layer 200 GSM Geo Textile (Non-woven) layer has been

provided. Leachate contribution is mainly due to the release of entrapped liquid in the solid waste and any

unseasonal rainfall.

1

3 As per the Hazardous and other wastes (Management and Trans boundary Movement) Rules, 2016.




Side Liner System

The Side layer of 1.5 mm thick HDPE geo –membrane liner has been laid over 900 mm thick compacted clay liner

resting on subsoil (well compacted base). Over the Geo Membrane liner, 6 mm thick HDPE Geonet (5 * 10-4 m2/sec.

Hydraulic Transmissibility Drainage Net) has been provided with perforated HDPE pipeline network (600 mm dia. 4

kg/cm2 rating HDPE pipe on side slope) for Leachate collection. Over the drainage layer 200 GSM Geo Textile (Non

woven) layer has been provided. A 75 mm thick precast concrete slab of 300 * 450 mm size has been provided to

serve as a cover of the side liner system.

Arrangement of Leachate Collection:

For leachate collection 300 mm thick drainage layer of sand & pebbles (20 cm thick gravel of size 4.75 mm to 3 mm

and 10 cm thick sand of size 3 mm to 2 mm ) with perforated HDPE pipeline network (250 mm dia. 4 kg/cm2 rating

HDPE pipe having 10 mm dia.) has been provided in the bottom liner system.

Also, 6mm thick HDPE Geonet (5 * 10-4 m2/sec. Hydraulic Transmissibility Drainage Net) has been provided on the

side slope with perforated HDPE pipeline network (600 mm dia. 4 kg/ cm2 Rating HDPE pipe on side slope) for

leachate collection.

The collected leachate is stored in a leachate collection well and recycled again to the process for effective disposal.

The diagram of SLF Landfill system is given in Figure 3-5.

Figure 3-5: Secured Landfill Facility (SLF)


ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA PROPOSED INFRASTRUCTURE


4 SITE ANALYSIS

4.1 Connectivity

4.1.1 By Road

The site is well connected with the roads connecting NH-8 which in turn is located at an approximate road distance

of 13.1 km towards W (approximate aerial distance of 8 km towards W).

4.1.2 By Rail

Nearest railway station is located at Ankleshwar at an approximate road distance of 19.7 km towards WSW

(approximate aerial distance of 14.3 km towards WSW). The next nearest railway station is located at Bharuch at

an approximate road distance of 24 km towards NW (approximate aerial distance of 15 km towards NW).

4.1.3 By Air

The nearest airports are located at Surat at an approximate road distance of 93.4 km towards SW (approximate

aerial distance of 71.93 km towards SW) and Vadodara at an approximate road distance of 102 km towards N

(approximate aerial distance of 75.1 kms towards N).

4.2 Land Form, Land use & Land Ownership

The proposed expansion will be carried out within the existing factory premises of DCM-SAC-Jhagadia wherein Chlor

alkali products are already being manufactured. The factory is located within a notified industrial estate specially

developed by Government of Gujarat (through Gujarat Industrial Development Corporation – GIDC) for water

intensive chemical industries. No changes in land use are envisaged. Land cover within the Factory would change

nominally at places where the additional process units would be constructed for the proposed expansion. Land

Cover will be as per the Site Layout Map as shown in Annexure 1. SAC has the ownership of the Plot at No. 749,

GIDC, Jhagadia.

4.3 Topography

The Project site is shown on OSM sheet in Annexure 2.

4.4 Existing Infrastructure

Existing infrastructure like roads, power supply, water supply line, etc. are readily available at the site.

4.5 Soil Classification, Geology & Drainage

4.5.1 Soil Classification

At the surface, soil is light brown in colour due to presence of organic matter and due to its clayey nature, but sub-

surface soil is yellowish in colour. Soils in the area in general vary from fine to medium textured (Clayey to loamy

clay) and Soil drainage is well to moderate in nature. Soil is slight to moderately saline in nature.




4.5.2 Geology

Geology of the District

The oldest rocks found in the district are Bagh beds of middle to upper cretaceous age. They comprise of limestone

and sandstone occurring in small pockets within small pockets with the younger traps.

Deccan traps occupy quite large area forming the entire high relief zone. Several flows of varying nature occur in

thick piles. They are criss-crossed intrusive of trap and dioritic dykes. The Deccan traps fall within the age group of

upper cretaceous to lower Eocene.

Geology of the project site

The site area is mostly covered by older alluvium which is greyish in color suggestive of genetic relation to mostly

underlying trap formation. Thickness of soil noticed 15 cm to 20 cm.

Geomorphology

Geo-morphologically, the project area is located on the southern flood plain region of the Narmada River which is

about 10 km from site. The landscape is flat with ravines and comprising of unconsolidated alluvium.

Seismicity of the study area

As per the geological map published by Geological Survey of India, the Bouger Gravity anomaly varies between -30

to 10 MGal. The area comes under the moderate risk zone (Zone-III) of the Seismic Zonation of Gujarat State.

4.6 Climatic data from secondary sources

Based on the long-term climatological tables (1961 – 1976) published by Indian Meteorological Department (IMD)

of Broach (Bharuch) District for October-December, the maximum and minimum temperatures recorded are 41.7°C

and 6.3°C respectively. The maximum and minimum mean hourly relative humidity recorded are 76% and 42%

respectively. Average wind speed for post monsoon season is 5.43 km/hr. Pre-dominant wind direction is from NE.

Site specific meteorological data will be collected during the Baseline Environmental Monitoring for summer season

for the year 2019.

4.7 Social Infrastructure Available

Key infrastructure such as hospitals, schools, bank, places of worship and social / community facilities such as park,

market, playground etc. education, health care, community development, income distribution, employment and

social welfare are available in nearby areas of GIDC-Jhagadia i.e. Jhagadia Village / Ankleshwar / Bharuch.




5 PLANNING BRIEF

5.1 Planning Concept

The project is for the expansion of the Chlor-Alkali Plant and thermal power plant at existing factory premises. Basic

facilities of infrastructure like storage area, processing area, internal roads, etc., are available at existing site.

Transportation of raw material and finished goods will be carried out through existing road.

5.2 Population Projection

During the construction phase around 500 workers and during the operational phase around 50 workers will be

required. Thus, there would be minor increase in population of the site after the expansion operational activities

commissioned.

5.3 Land use Planning

There will be no change in landuse as the necessary expansion will be within the integrated complex of Shriram

Alkali and Chemicals Ltd. (SAC). The green belt area of 10.36 ha has already been developed as per the latest CCA

order of GPCB for the existing Unit. SAC has also carried out plantation in GIDC land outside adjacent to the site.

The copy of the Appreciation Letter of GIDC is attached vide Annexure 3 and relevant photos are attached vide

Photograph 9-1. GIDC has further allotted 6.5 hectares of land for doing plantation in GIDC area. Letter of land

allotment for plantation is attached as Annexure 4.

5.4 Assessment of Infrastructure Demand (Physical & Social)

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park,

market, playground etc. education, health care, community development, income distribution, employment and

social welfare are available in nearby areas of GIDC - Jhagadia.

5.5 Amenities / Facilities

Basic Amenities like public transport, water supply, telecommunications, educational institutions, hospitals etc. are

available in the areas neighbouring GIDC - Jhagadia.




6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing and proposed units comprises of following Table 6-1 below :

Table 6-1: Existing and Proposed units within DCM-SAC, Jhagadia

S. No. Description Number of Units

Existing Proposed Total

1 Brine sections (Clarifier) 4 1 5

2 Cell house 1 1 2

3 Utilities (DM Plant) 4 1 5

4 Cooling towers 4 3 7

5 Chlorine processing / filling / storage 2 0 2

6 Chlorine refrigeration unit 3 1 4

7 Caustic concentration unit (CCU) 3 1 4

8 Hypo plant 3 1 4

9 Secured Landfill facility. 5 3 8

10 Captive Power plant 2 1 3

11 Coal storage 2 0 2

Adequate storage space for fuel storage, hazardous and other solid waste is already available. Additional storage

space will be provided as per the requirement.

6.2 Residential and Non- Processing Area

No residential units / areas are planned in the facility for the proposed project. During Construction phase,

temporary storage areas would be created within the site for storage of construction materials like Bricks, cement,

steel etc.. Further, during construction phase, no residential space for construction workers would be created within

the site.

6.3 Greenbelt

The green belt area of 10.36 ha has already been developed as per the latest CCA order of GPCB. Plantation has also been carried out in GIDC land adjacent to the boundary. The copy of the certificate of GIDC is attached vide

Annexure 3 and relevant photos are attached as Photograph 9-1. GIDC has further allotted 6.5 hectares of land for doing plantation in GIDC area. Letter of land allotment for plantation is attached as Annexure 4.

6.4 Social Infrastructure

Civic/infrastructural facilities like public transport, water supply, telecommunications, educational institutions, hospitals etc. are available in nearby area of GIDC - Jhagadia.

6.5 Connectivity

Please Refer Chapter 4, Section 4.11.




6.6 Drinking Water Management

The water will be supplied by Gujarat Industrial development Corporation (GIDC) located at Rundh which sources

water from Narmada River. This water is further treated at site and supplied to various working areas.

6.7 Sewerage System

The domestic effluent will be disposed of in soak pit via septic tank. This is a tried and tested workable

arrangement, however, SAC has installed modular STPs in 2 important locations to treat and reuse the sewage

water in plantation. The same will be gradually implemented at other areas of the site also.

6.8 Industrial Waste & Solid Waste Management

Solid and hazardous waste are mentioned in Chapter 3, Section 3.8.4.

6.9 Power Requirement & Supply / Source

Refer Chapter 3, Section 3.7.1.

SAC PFR – PROPOSED CAPACITY EXPANSION IN CAPTIVE POWER GENERATION &

CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA REHABILITATION AND

RESETTLEMENTS


7 REHABILITATION AND RESETTLEMENT (R& R) PLAN

Since the proposed expansion is taking place in the existing facility, no additional land is acquired for the proposed

expansion project. Thus, all the proposed units will be inside the existing plant premises. Consequently, R & R

issues are not envisaged.


CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA PROJECT SCHEDULE & COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely date of completion

The construction is likely to start after getting Environmental Clearance from SEAC / SEIAA from GPCB. This is likely

to occur in the month of October / November 2019.

8.2 Estimated Project Cost

The total investment consisting of Plant and Machinery is envisaged to be Rs. 1050 crores.

8.2.1 Economic Viability

The project has been conceived assuming that there will be a growth in demand for the proposed products, leading

to a reasonable rate of return in the medium term. The project is considered ‘bankable’.


CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

There shall be employment generation for the local people during the construction and operational phase of the

proposed facility.

During the constructional phase ~500 workers and during operational phase ~50 additional personnel will be hired.

Additionally, local skilled and semi-skilled workers will be hired with preference given to local people.

The positive impacts include enhanced direct employment for technical / administrative works and indirect

employment opportunities for transporters of raw material like salt, etc. and finished goods.

There will be indirect development of small businesses for various aspects around the site.


CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA ANNEXURES


ANNEXURES

SAC PFR – PROPOSED CAPACITY EXPANSION IN CAPTIVE POWER GENERATION & CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA ANNEXURES


Annexure 1: Preliminary Site Layout Map

SAC PFR – PROPOSED CAPACITY EXPANSION IN CAPTIVE POWER GENERATION & CHLOR ALKALI PRODUCTION IN EXISTING

FACILITY AT GIDC JHAGADIA ANNEXURES


Annexure 2: Project Site Located on Top sheet showing 3, 5, 7 & 10 km Radii Circles

SAC PFR – PROPOSED CAPACITY EXPANSION IN CAPTIVE POWER GENERATION

& CHLOR ALKALI PRODUCTION IN EXISTING FACILITY AT GIDC JHAGADIA ANNEXURES


Annexure 3: GIDC Appreciation letters for Green Belt developed by DCM-SAC




Photograph 9-1: Photographs of Green Belt developed by DCM-SAC on GIDC land

View of Plantation in 2017

Status of above plantation as on date

APPENDIX I · Capacity expansion of existing Chlor-Alkali Plant from 5,08,000 MTPA to 8,13,000 MTPA...

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Transcript of APPENDIX I · Capacity expansion of existing Chlor-Alkali Plant from 5,08,000 MTPA to 8,13,000 MTPA...