At Veraval, District - Gir Somnath (Gujarat) · At Veraval, District - Gir Somnath (Gujarat) Pre -...

Proposed Installation of Chlorinated Paraffin Wax Plant of 50 TPD Capacity in Existing Plant Prem ises

At Veraval, District - Gir Somnath (Gujarat)

Pre - feas ibility Report

Grasim Industries L imited; Unit - Indian Rayon i

CONTENTS

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

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION.............................................................. 3

(i) Identification of Project and Project Proponent .................................................................................. 3

(ii) Brief description of nature of the project .............................................................................................. 4

(iii) Need for the project and its importance to the country and or region .............................................. 4

(iv) Demand-Supply Gap ................................................................................................................................ 5

(v) Import vs. Indigenous Production.......................................................................................................... 5

(vi) Export Possibility ..................................................................................................................................... 6

(vii) Domestic Markets.................................................................................................................................... 6

(viii) Employment Generation (Direct and Indirect) due to the project ...................................................... 6

3.0 PROJECT DESCRIPTION .................................................................................................................................. 6

(i) Type of Project including interlinked and independent projects, if any. ........................................... 6

(ii) Location Map (showing general location, specific location, and project boundary & project site

layout) with coordinates ............................................................................................................................................... 8

(iii) Key Plan ...................................................................................................................................................10

(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted. ............................................................................ 11

(v) Size or magnitude of operation............................................................................................................. 11

(vi) Project description with process details (a schematic diagram/ flow chart showing the project

layout, components of the project etc. should be given) ......................................................................................... 11

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined. .................................................................................................................................................................. 15

(ix) Availability of water it’s source, energy /power requirement and source should be given. ...........16

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal .

..................................................................................................................................................................16

4.0 SITE ANALYSIS .................................................................................................................................................16

(i) Connectivity ............................................................................................................................................16

(ii) Land from Land use and Land ownership............................................................................................. 17

(iii) Topography ............................................................................................................................................. 17

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park,

wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of

notified industrial area, a copy of the Gazette notification should be given. ......................................................... 17

(v) Existing Infrastructure ...........................................................................................................................18

(vi) Soil Classification ....................................................................................................................................19

(vii) Climatic data from secondary sources ..................................................................................................19

(viii) Social Infrastructure available ...............................................................................................................19




Grasim Industries L imited; Unit - Indian Rayon ii

5.0 PLANNING BRIEF..............................................................................................................................................19

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification. ........................................................................................................................19

(ii) Population Projection ............................................................................................................................19

(iii) Land use planning (breakup along with green belt etc) .....................................................................19

(iv) Assessment of infrastructure demand (Physical & Social) .................................................................19

(v) Amenities/Facilities................................................................................................................................ 20

6.0 PROPOSED INFRASTRUCTURE..................................................................................................................... 20

(i) Industrial Area (Processing Area) ........................................................................................................ 20

(ii) Residential Area (Non-processing area) .............................................................................................. 20

(iii) Green Belt............................................................................................................................................... 20

(iv) Social Infrastructure ............................................................................................................................... 21

(v) Connectivity ............................................................................................................................................ 21

(vi) Drinking Water........................................................................................................................................ 21

(vii) Sewerage System ................................................................................................................................... 21

(viii) Industrial Waste Management .............................................................................................................. 21

(ix) Solid Waste Management ...................................................................................................................... 21

(x) Power requirement and source............................................................................................................. 21

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN ................................................................................ 22

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given). .......................................................... 22

8.0 PROJECT SCHEDULE AND COST ESTIMATES ................................................................................................ 22

(i) Likely date of start of construction and likely date of completion (time schedule for the project

to be given). 22

(ii) Estimated project cost along with analysis in term of economic viability of the project. .............. 22

9.0 ANALYSIS OF PROPOSAL (final recommendations).................................................................................... 22

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area........................................................................................................................... 22




Grasim Industries L imited; Unit - Indian Rayon iii

LIST OF ABBREVIATIONS

ABNL : Aditya Birla Nuvo Limited

APCE : Air Pollution Control Equipment

Cl : Chlorine

Cl2 : Chlorine Gas

CPCB : Central Pollution Control Board

CPP : Captive Power Plant

CPW : Chlorinated Paraffin Wax

E : East

EC : Environmental Clearance

EIA : Environmental Impact Assessment

ESE : East of South-East

GEB : Gujarat Electricity Board

GHG : Green House Gas

Ha : Hectare

HCl : Hydrochloric Acid

HNP : Heavy Normal Paraffin

KL : Kilo Litre

KLD : Kilo Litre Per Day

MoEF : Ministry of Environment and Forest

MoEFCC : Ministry of Environment, Forest & Climate Change

MTPA : Million Tonnes Per Annum

MTPM : Million Tonnes Per Month

MW : Mega Watt

N : North

NE : North-East

NH : National Highway

NNE : North of North-East

NO2 : Nitrogen Dioxide

NOx : Oxides of Nitrogen

PFR : Pre-Feasibility Report

R & R : Rehabilitation & Resettlement

S : South

SE : South-East

SH : State Highway

SO2 : Sulphur Dioxide

STP : Sewage Treatment Plant

SW : South West

TPA : Tonnes Per Annum

TPD : Tonnes Per Day

VSF : Viscose Staple Fibre

VFY : Viscose Filament Yarn

W : West

WNW : West of North-West

WSW : West of South-West

µg/m3 : Micro gram per metre cube

Ha : Hectare

km : Kilometre

m : Metre

Proposed Installation of Chlorinated Paraffin Wax Plant of 50 TPD Capacity in Existing Plant Premises



Grasim Industries L imited; Unit - Indian Rayon 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

Grasim Industries Limited; Unit - Indian Rayon has an existing Viscose Filament Yarn Plant with

production capacity of 2400 MTPM along with CPP (54.5 MW) and associated plant of Sodium

Sulphate (2350 MTPM), Sodium Sulphite (3000 MTPM), Liquid Sulphur-Dioxide (1500 MTPM),

Sulphuric Acid (3600 MTPM), Carbon-Disulphide (1000 MTPM), Caustic Soda Lye (12000 MTPM),

Chlorine (10560 MTPM), Compressed Hydrogen (650,000 Nm3), Sodium Sulphide (100 MTPM),

Hydrochloric Acid (1800 MTPM) and Sodium Hypochlorite (3750 MTPM) at Veraval, District - Gir

Somnath (Gujarat).

Environmental Clearance the same has been obtained from MoEFCC, New Delhi vide letter no. J-

11011/343/2013-IA II (I) dated 22nd June, 2015 in the name of M/s. Indian Rayon (a unit of Aditya Birla

Nuvo Limited). Copy of the same is enclosed as Annexure - 1 along with PFR.

Aditya Birla Nuvo Limited (ABNL), the previous parent company of Indian Rayon, was amalgamated

with Grasim Industries Limited (Grasim). The Scheme of Arrangement between ABNL and Grasim

was sanctioned by the National Company Law Tribunal Bench at Ahmedabad on 01st June, 2017 for

the amalgamation of ABNL with Grasim and transfer of “ABNL Business”, including the Unit (Indian

Rayon) for which this EC is issued, from ABNL to Grasim.

Online application for change of name in the EC Letter dated 22nd June 2015 issued for existing plant

of Indian Rayon was uploaded on web portal of MoEFCC, New Delhi on 04th Jan. 2019 (Proposal No.

IA/GJ/IND2/90464/2015). Copy of the Acknowledgement Slip is enclosed as Annexure - 2 along with

PFR.

Grasim Industries Limited; Unit - Indian Rayon is now proposing installation of Chlorinated Paraffin

Wax Plant of 50 TPD Capacity in Existing Plant Premises at Veraval, District - Gir Somnath (Gujarat).

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the Project Proposed Project for installation of Chlorinated Paraffin Wax Plant

B. Size of the Project

Particulars Proposed Capacity (TPD)

Main Product

Chlorinated Paraffin Wax 50

Associated Product

HCl (100%) 29

By-Product

Sodium hypochlorite 3






C. Category of the Project

As per EIA Notification dated 14th Sept., 2006 & as amended from time

to time; this project falls under Category ‘A’, S. No. 5 (Material

Production), Project Activity ‘5 (f)’ Synthetic Organic Chemical

D. Location Details

Town Veraval

District Gir Somnath

State Gujarat

Existing Plant Proposed Plant (Within Existing Plant)

Latitude N 200 54’ 49.03’’ to N 200 55’ 32.46’’ N 200 55’ 19.82’’ to N 200 55’ 22.96’’

Longitude E 700 20’ 57.67’’ to E 700 21’ 31.19’’ E 700 21’ 13.29’’ to E 700 21’ 15.59’’

E. Area Details

Total Plant Area Existing plant area is 71.33 ha; proposed installation will be done on 1.6

ha of open land within existing plant premises

Greenbelt / Plantation Area (ha) 24 ha i.e. 33.6% of the total existing plant area has already been

developed under greenbelt/plantation and the same will be maintained.

F. Environmental Setting Details (with approximate aerial distance & direction from the plant site)

1. Nearest Town Veraval (adjoining to plant site)

2. Nearest City Junagadh (67 km in NNE direction)

3. Nearest National Highway /

State Highway

• NH - 6 (1.0 km in North direction)

• SH - 8E (Adjacent in NE direction)

• SH - 26 (2.0 km in ESE direction)

4. Nearest Railway Station Veraval Railway Station (1.5 km in ESE direction)

5. Nearest Airport Diu Airport (63 km in ESE direction)

6.

National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, Reserved/Protected

Forests within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve,

Reserve/Protected Forests exists within 10 km radius of the plant site.

7. Water Bodies (within 10 km

radius)

Arabian Sea (0.7 km in SW direction)

Triveni Sangam (of rivers namely Hiran, Kapila and Saraswati) (6.5 km

in SE direction)

Devka River (non- perennial) (0.3 km in West direction)

8. Nearest Sea Port Porbandar Port (110 Km in NW direction)

Pipavav Port (120 Km in East direction)

9. Area under cultural importance/

Pilgrimage Somnath Temple (5.5 km in SE direction)

10. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]

G. Cost Details

Total Cost of the Proposed

Project Rs. 17.50 Crores

Cost for Environment

Management Plan

• Capital Cost - Rs. 5 Lacs

• Recurring Cost- Rs. 1 Lac / annum






H. Basic Requirements for the project

Water Requirement

137 KLD

Source: Umrethi Dam

Permission for withdrawal of water from Umrethi Dam will suffice the

total water requirement of Existing Plant (15938 KLD) and Proposed

CPW Plant (137 KLD)

Power Requirement 0.21 MW

Source: Captive Power Plant and GEB

Manpower Requirement

Construction Phase Operation Phase

Regular 4 14

Contractual 36 13

Total 40 27

Source: Local / Outside

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Project:

Proposed Installation of Chlorinated Paraffin Wax Plant of 50 TPD Capacity in Existing Plant

Premises at Veraval, District - Gir Somnath (Gujarat) by Grasim Industries Limited; Unit- Indian

Rayon.

Project Proponent:

Grasim Industries Limited is the flagship company of the Aditya Birla Group. The company started

as a textile manufacturer in India in 1947. At present, it is a leading global producer of Viscose Staple

Fibre (VSF), Chlor-Alkali, Cement and Diversified Financial Services.

Chemical Business was set up for manufacture of Caustic Soda, which serves as a raw material for

VSF. Over the years, the company has strengthened backward integration in Dissolving Grade Pulp,

Power & Steam which are major inputs required for the production of VSF.

The Unit - Indian Rayon of Grasim Industries Limited was established in 1963 at Veraval, Gujarat. At

present, company produces Viscose Filament Yarn, Sulphuric Acid, Carbon-Di-Sulphide, Sodium

Sulphide, Sodium Sulphate, Caustic Soda, Liquid Chlorine, Compressed Hydrogen, Hydrochloric

Acid, Sodium Hypochlorite and Captive Power.













PFR.

The Ministry of Environment, Forest and Climate Change (MoEFCC) has given many accolades to

Grasim Industries Limited (Unit-Indian Rayon) for its unrelenting endeavours towards

environmental conservation and development of clean technologies. The ministry chose Indian

Rayon for the coveted National Award for Prevention of Pollution 2008-09. Indian Rayon has been

a consistent awardee of Genentech Environment Excellence Gold Award for many years in the

chemical sector for outstanding achievement in Environment Management.

Under the Chicago Climate Exchange’s (CCX) Carbon Offset Program to reduce GHG emission as a

proactive step, Indian rayon became the first company to attempt and take measures in Energy

Conservation. The project activity has been registered with CCX and has been issued 55,700 T CO2

GHG.

(ii) Brief description of nature of the project


Wax Plant of 50 TPD capacity in existing plant premises at Veraval, District - Gir Somnath (Gujarat).

The plant will make captive use of chlorine generated in other sections of the existing plant to

produce CPW, which has various applications such as plasticiser, in plastic and rubber industry, as

flame retardant, etc. The entire manufacturing process is a closed loop and all un-reacted chemicals

are either fed back into the system or absorbed in a scrubber.

As per EIA Notification dated 14th Sept. 2006, as amended from time to time, the project falls under

Category “A” Project Activity 5 (f) of Project S. No. 5 “Synthetic Organic Chemicals Industry”.

(iii) Need for the project and its importance to the country and or region

During the manufacturing of caustic soda, one of the products produced in the existing plant, Cl2

and HCl gases are generated as by-products. Chlorine thus produced is in part utilized captive for

HCl production and the rest is compressed and filled in tonners for sale off to respective consumers.

Chlorine is a highly reactive gas that is classified as a hazardous chemical by the Manufacture,

Storage and Import of Hazardous Chemicals Rules, 1989.

The main objective of producing Chlorinated Paraffin Wax is to increase captive use of chlorine gas,

resulting in reduced risks and hazards that arise during storage, handling & transportation of Cl2.

Chlorinated paraffin a lso has a widespread range of applications, right from plastic additives to

metal working lubricants and flame retardants. The largest application of chlorinated paraffin wax,

however, is as a plasticizer, generally in conjunction with primary plasticizer such as certain

phthalates, for production of flexible PVC. CPW encompasses a host of benefits, including the likes

of chemical resistance, flame resistance, low-temperature flexibility, and plastic viscosity stability,

on the grounds of which it is being increasingly preferred over conventional plasticizers and

lubricants. Its inertness and enhancement of flame retardant properties also makes it a suitable

plasticisers in production of paint sealants and adhesives.



Pre - feasibility Report

Grasim Industries Limited; Unit - Indian Rayon 5

(iv) Demand-Supply Gap

The global demand for CPW stands at 1.6 million tonnes per annum with a growth rate in demand

of 1.5 to 2 % per annum. The growing demand for chlorinated paraffin wax for manufacturing flexible

PVC has been projected to inherently boost India chlorinated paraffin market outlook over the

coming years. Hence, chlorinated paraffin wax manufacturers in India are expected to experience

quite an affluent period, given that the product is extensively deployed across myriad end-use

domains.

Primary use for CPW in India is as a secondary plasticizer used in manufacture of PVC Products. PVC

production levels has seen a major increase in the recent years.

Graph - 1: Production levels of PVC

Increase In production of PVC leads to an increase in demand for CPW. Considering a requirement

of 120 kg of CPW per tonne of Flexible PVC and production of 366 lakh tonnes per annum of Flexible

PVC, the annual demand of CPW is bound to increase up to 45000 tonne.

CPW is also an ideal investment in the small and medium scale sector. In recent times, the export of

the product has been increasing due to the competitive nature of India’s production Industry. The

present export level of the product is about 10000 tonnes per annum. Considering the likely growth

rate in demand, additional capacity can be created to meet the demand in local regions and exploit

the export opportunities.

(v) Import vs. Indigenous Production

The current manufacturing units for CPW largely do so only on a small scale. The established

production capacity in India is around 1,25,000 TPA. The current import levels of CPW is negligible.





(vi) Export Possibility

The current export level of chlorinated paraffin is about 10,000 TPA to countries such as Mombasa

and Djibouti. This export level is not enough to fulfil the global demand for CPW, which is around

1.6 MTPA with a growth rate of about 1.5 - 2% per annum. Hence, this global market can be an ideal

market for sale of CPW.

(vii) Domestic Markets

The proposed chlorinated paraffin wax production will cater to flexible PVC manufacturers all over

the country. Other sectors where CPW is used include lubricants, rubber products (like belts), PVC

floor tiles, cable compounds and reprocessing PVC granules.

(viii) Employment Generation (Direct and Indirect) due to the project

Grasim Industries Limited; Unit-Indian Rayon currently employs 3153 persons, directly or indirectly,

in the existing plant. The additional manpower requirement for the new CPW Plant is 27 persons;

preference will be given to local people as per their eligibility and experience.

Table - 2

Manpower Requirement

Particulars Manpower Requirement Source

Construction Operation

Local/Outside Regular 04 14

Contractual 36 13

Total 40 27

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

Grasim Industries Limited; Unit - Indian Rayon has an existing Viscose Filament Yarn Plant with

production capacity of 2400 MTPM along with CPP (54.5 MW) and associated plant of Sodium

Sulphate (2350 MTPM), Sodium Sulphite (3000 MTPM), Liquid Sulphur-Dioxide (1500 MTPM),

Sulphuric Acid (3600 MTPM), Carbon-Disulphide (1000 MTPM), Caustic Soda Lye (12000 MTPM),

Chlorine (10560 MTPM), Compressed Hydrogen (650,000 Nm3), Sodium Sulphide (100 MTPM),

Hydrochloric Acid (1800 MTPM) and Sodium Hypochlorite (3750 MTPM) at Veraval, District - Gir

Somnath (Gujarat).

Environmental Clearance the same has been obtained from MoEFCC, New Delhi vide letter no. J-

11011/343/2013-IA II (I) dated 22nd June, 2015 in the name of M/s. Indian Rayon (a unit of Aditya Birla

Nuvo Limited). Copy of the same is enclosed as Annexure - 1 along with PFR.













PFR.


Wax Plant of 50 TPD Capacity in existing plant premises for captive use of chlorine produced as a

by-product during manufacture of caustic soda.

Interlinked Project: Existing Caustic Soda Plant of Grasim Industries Limited; Unit - Indian Rayon at

Veraval (Gujarat). Environmental Clearance for the same has already been obtained from MoEFCC,

New Delhi vide their letter no. J-11011/343/2013-IA-II (I) dated 22nd June, 2015.

Independent Project: This is not an independent project.




Grasim Industries Limited; Unit - Indian Rayon 8

(ii) Location Map (showing general location, specific location, and project boundary & project site

layout) with coordinates

Figure - 1: Location Map




Grasim Industries Limited; Unit- Indian Rayon 9

Figure - 2: Plant Layout

Proposed Project Site




Grasim Industries L imited; Unit- Indian Rayon 10

(iii) Key Plan

Figure - 3: Key Plan





(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

The proposed installation will be done within the existing VFY plant premises; hence, no alternative

site has been considered.

(v) Size or magnitude of operation


Wax Plant of 50 TPD Capacity within Existing Plant Premises at Veraval, District - Gir Somnath

(Gujarat).

(vi) Project description with process details (a schematic diagram/ flow chart showing the project

layout, components of the project etc. should be given)

Project Description:

Proposed installation of Chlorinated Paraffin Wax Plant of 50 TPD capacity within existing premises

of existing plant.

Table - 3

Proposed Production Capacity

Units Proposed Capacity (TPD)

Main Product

Chlorinated Paraffin Wax 50

Associated Product

HCl (100%) 29

By-product

Sodium hypochlorite 3

Process Description:

The manufacture of CPW involves reaction of gaseous chlorine (produced as by-product in existing

caustic soda plant) with liquid heavy normal paraffin (HNP) in a batch reactor at 70-900C.

CmHn + xCl2 CmHyCl + xHCl + Heat (n=x+y)

The heat of the reaction will be removed with the help of cooling water circulating through a

cooling coil (or jacket) in the lead lined reactor. After the reaction is over the CPW liquid will be

stripped of dissolved gases and strained to remove any suspended impurities before being sent for

final packaging. The HCL gas evolved in the process will be stripped of HNP droplets and absorbed

in water to form HCL solution and un-reacted Cl2 will be sent to the sodium hypochlorite

manufacturing section of the caustic soda plant (a part of the existing unit). The last trace of the

unabsorbed HCl gas and un-reacted Cl2 will be absorbed in alkali to remove last traces of the

pollutants.

The detailed process is as given below, which comprises of the following sections:

Ξ Reaction Section

Ξ Scrubbing Section

Ξ Packing Section





Reaction Section:

• Heavy Normal Paraffin (HNP) will be fed into a MS jacketed melter, wherein steam at

pressure of 3 kg/cm2 will be passed into the jacket for providing heat input. Temperature of

65°C to 70°C will be maintained in the melter.

• The molten HNP will be transferred to a MS lead bonded chlorinator. Chlorine gas will be

kept in cylinder connected to headers. Liquid chlorine gas would be blended slowly through

MS pipe line up to the chlorinator. In the line, chlorine would be transferred as gas in a

continuous process.

• Transfer of liquid HNP to the melter will be carried out by vacuum /pump. When the transfer

process completes, chlorine gas will be charged to the chlorinator at a slow rate. The

reaction of chlorine gas reacts with HNP will be exothermic and hence will be vigorous. The

flow of Chlorine will be gradually increased, so that the reaction temperature is maintained

between 50°C-70°C. Once the chlorination process starts, due to the exothermic nature of

reaction, the contents would always remain in liquid form. The temperature will be

maintained in the reactor by allowing cooling water to flow through the jacket of the

reactor.

CnH2n+2 + mCl2 → CnH2n+2-mClm + mHCl + ∆THeat

• After the reaction, the CPW will be stripped of all dissolved gases (primarily un-reacted Cl2)

under vacuum or by bubbling a stream of dry air through the liquid. The CPW is then

strained to remove all traces of suspended impurities.

Scrubbing Section:

The HCl gas evolved in the process will be stripped of HNP droplets in a cyclone type mist

eliminator and passed through the Graphite Absorber. The HCl gas will be absorbed in

water and the proportion of acid to water will be recalculated till HCl of desired strength is

obtained. The HCl absorption system will have a proper heat removal arrangement to

control the system’s temperature.

The final traces of Cl2 will be sent to the sodium hypochlorite section of the caustic soda

plant.

The entire system will be connected with lime scrubber wherein the last trace of

unabsorbed HCl gas along with traces of un-reacted chlorine is absorbed in alkali to remove

the last traces of the pollutants and keep the environment free of pollution.

Packing Section:

The product from de-gasifier will be collected and packed in HDPE barrels with holding

capacity of 250 kg each.

The Process flow chart is given in Figure - 4.





Figure - 4: Process Flow Chart of CPW Plant





Specifications for the Chlorinated Paraffin Wax are given below:

Table - 4

Product Specifications

Chlorine Content 20-70 %

Chemical formula CnH2n+2-XClx (n = 12 to 22)

Colour (Gardner Scale) 6 max.

Fire Point None

Flash Point None

Specific gravity (25/25 ºC) 1.16

Viscosity (at 25ºC; poises) 26-39

Equipment Details

A list of equipment and storage capacities are given below. To select a particular type of equipment

or storage for the project, among others, the following issues have been considered:

• Equipment costs

• Energy consumption

• Raw material characteristics

• Sizes in which the equipment is available

• Lead times for particular types of equipment

• Operating experience with various types of equipment

• Ease of operation of equipment

• Product to be manufactured

• Site conditions

• Local skills available

• Environmental issues

Table - 5

Details of proposed machinery

S. No. Description Specification/ Capacity (Kindly Provide)

1. Air Compressors 2 Units (250 Nm3 /hr each)

2. Reactors 12 Units (12 KL each)

3. Cooling Towers 2 Units (300 m3/hr)

4. Air Blower 2 Units (850 Nm3 /hr each)

5. Storage Tanks 10 Units (4*200 m3 + 4*100 m3 + 2*60 m3)

Details of Air Pollution Control Equipment

The details of air pollution control equipment that will be installed are as given below:





Table - 1

Details of Air Pollution Control Equipment

Location of APCE Type of APCE Design Efficiency Parameter

Stack Absorption Tower 99.99% HCl and Cl2

(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

The sources of raw material and their approximate distances from the plant site are given below:

Table - 2

Raw Material Requirement, Source & Transportation

S.

No.

Name of Raw

Material Quantity Source

Distance & Mode of

Transportation

1. Heavy Normal

Paraffin 8640 TPA

Local Market/

Import

- 230 Km. (Reliance Industries

Limited, Jamnagar to Plant)

- Tankers (By Road)

2. Chlorine 20,000-22,500

(Depending on product mix) In house

In house through pipe line within

Plant premises

3. Epoxidized Soya

Oil 180 TPA Local Market Tankers (By Road)

4.

Sodium

Hydroxide

(NaOH) – 48%

1260 TPA In house In house through pipe line within

Plant premises

No fuel is required for the proposed project as the electricity demands will be fulfilled from the

Captive Power Plant (CPP) and Gujarat Electricity Board (GEB).

(b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for Grasim Industries Limited; Unit - Indian Rayon are local as well

as export to global markets.

Mode of transportation for final product will be by road / railway for the local markets and via

road/sea for export to global markets.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

• The proposed CPW plant is a closed system wherein Cl2, which is a by-product of manufacture of

caustic soda, will be used to manufacture CPW. All unreacted chlorine is fed back into the plant

or, at the end of the reaction, is sent to the sodium hypo section of the caustic soda plant for

production of sodium hypochlorite. Hence, the project utilizes the by-product of caustic soda

section of the plant for production of a far more stable and non-hazardous material in CPW.





• Domestic waste water generated from the plant and colony will be treated in the installed STP

(500 KLD) and the treated water will be used as make-up water for cooling systems and in

greenbelt/plantation.

(ix) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

The water requirement for the proposed project is 137 KLD, which will be sourced from Umrethi

Dam. Permission for withdrawal of water from Umrethi Dam will suffice the total water requirement

of Existing Plant (15938 KLD) and Proposed CPW Plant (137 KLD).

Break - up of water requirement is given below:

Table - 3

Water Break-Up

Purpose Requirement (KLD) Source

HCl Process 65

Umrethi Dam Cooling Tower Water 70

Domestic Use 2

TOTAL 137

(b) Power Requirement and Source

The total power requirement for the proposed project is 0.21 MW, which will be fulfilled from the

CPP and GEB.

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal

Waste water (~8.0 KLD) generated from cooling tower blowdown and floor washing will be

neutralized in existing Effluent Treatment Plant (12,000 KLD) and treated water will be disposed

through the existing Marine Pipeline.

Domestic waste water generated from the plant and colony will be treated in the installed STP

(500 KLD) and the treated water will be used as make-up water for cooling systems and in


Sludge generated from STP will be used as manure in greenbelt development/ plantation.

Sludge generated from Effluent Treatment Plant will be disposed of scientifically.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to SH - 8E (Adjacent in NE direction), NH-6 (~1.0 km in North direction)

and SH - 26 (~2.0 km in ESE direction). Nearest town is Veraval as the plant is located within the town

itself and the nearest city to the plant site is Junagadh (~67 km in NNE direction). Nearest railway

station is Veraval Railway Station (~1.5 km in ESE direction) and nearest airport from plant site is Diu





Airport (~63 km in ESE direction).

The site is well connected with communication facilities like telephone, fax and wireless and no

constraints are envisaged in this aspect as the tehsil and district headquarters are near to the site.

(ii) Land from Land use and Land ownership

The existing plant area is 71.33 ha; proposed installation of chlorinated paraffin wax plant will be

done on open area within the existing plant premises.

The plant area breakup is given below:

Table - 4

Plant Area Break - Up

S. No. Unit Area (ha)

1. Rayon Plant Area

16.37 2. Power Plant Land Area

3. Caustic Plant Land Area

4. Proposed CPW Plant 1.6

5. Colony 0.99

6. Greenbelt/Plantation 23.91

7. Open Area 27.28

8. Others (ETP, STP, WTP, Adm. Block, Canteen) 1.18

Total Plant Area 71.33

(iii) Topography

The terrain of the selected location for proposed project is flat.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under

CRZ), shortest distances from the periphery of the project to periphery of the forests, national park,

wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In

case of notified industrial area, a copy of the Gazette notification should be given.

Table - 5

Environmental Settings of the Area


(with approximate aerial distance & direction from the plant site)

1. Nearest Town Veraval (adjoining to plant site)

2. Nearest City Junagadh (67 km in NNE direction)

3. Nearest National Highway / State

Highway

• NH - 6 (1.0 km in North direction)

• SH - 8E (Adjacent in NE direction)

• SH - 26 (2.0 km in ESE direction)

4. Nearest Railway Station Veraval Railway Station (1.5 km in ESE direction)

5. Nearest Airport Diu Airport (63 km in ESE direction)






(with approximate aerial distance & direction from the plant site)

6.

National Parks, Wildlife

Sanctuaries, Biosphere Reserves,

Reserved/Protected Forests within

10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserve/Protected

Forests exists within 10 km radius of the plant site.

7. Water Bodies (within 10 km radius)

Arabian Sea (0.7 km in SW direction)

Triveni Sangam (of rivers namely Hiran, Kapila and Saraswati) (6.5 km in SE

direction)

Devka River (non- perennial) (0.3 km in West direction)

8. Nearest Sea Port Porbandar Port (110 Km in NW direction)

Pipavav Port (120 Km in East direction)

9. Area under cultural importance/

Pilgrimage Somnath Temple (5.5 km in SE direction)

10. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

The Indian Rayon plant has existing manufacturing units for various products and by-products, such

as viscose filament yarn, caustic soda, sulphuric acid, carbon disulphide, hydrochloric acid, sodium

sulphate, sodium sulphide, chlorine, sodium hypochlorite and compressed hydrogen. The plant also

has a captive power plant.

o Workshop

Separate Mechanical and electrical workshops exist to take care of the regular maintenance/ repair

jobs in the plant.

o Machinery stores

A store building needed for storing tools, spare parts, consumables, etc. is available.

o Time and Security office

At the entrance of the main plant, a time office and a security office has been constructed.

o Hospital

The Aditya Birla Hospital has been built adjacent to the existing plant of Indian Rayon is a

multispecialty Hospital equipped with 24X7 Emergency facilities, Pathology, Pharmacy and

Radiology with Doctor's & well Trained Staff.

o Packaging medium storage

Space has been provided in the packing plant area for the storage.

o Parking

Adequate parking space has been provided in the unit premises for the parking of vehicles.

o Storage facilities

Adequate storage facilities have been provided for the storage of raw materials & finished product.





(vi) Soil Classification

Soil around the study area is moderately alkaline in nature with sufficient amount of nitrogen but

low phosphorous content.

(vii) Climatic data from secondary sources

The climate represents a wide variability, ranging from arid, through semi-arid to sub-humid

tropical monsoon type. The mean annual temperature ranges from 260C to 280C, with maximum

temperatures ranging from 370-420C (summer season) and minimum temperatures from 100-180C

(winter season). The average annual rainfall of the region is around 799 mm with relative humidity

ranging from 15-80%. The coastal areas enjoy a maritime climate.

(viii) Social Infrastructure available

Aditya Birla Hospital, set-up by the industry, is a multispecialty Hospital equipped with round the

clock emergency facilities, pathology, pharmacy and radiology with doctors & a well trained staff.

Facilities such as telephone and electricity are available in the nearby towns. Almost all the villages

in the buffer zone are electrified. Grasim Industries Limited; Unit- Indian Rayon is also working

actively in nearby villages for socio-economic development.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification.

The existing industry is man-made fibre industry (Red Category) and proposed project will be

established within the existing plant area. Facilities required for the proposed project will be

provided as per requirement. Transportation of raw material and final product will be done by

existing road / rail.

(ii) Population Projection

Direct and indirect employment will be created due to project. No influx of people is envisaged as

the manpower will be hired locally.

(iii) Land use planning (breakup along with green belt etc.)

The total area of the existing plant is 71.33 ha, of which 24 ha (i.e. 33.6%) area has already been

developed as greenbelt/plantation and the same will be further maintained to increase the aesthetic

beauty of the area.

Proposed installation of CPW plant of 50 TPD capacity will be done within existing premises of

existing plant.

(iv) Assessment of infrastructure demand (Physical & Social)

Grasim Industries Limited; Unit - Indian has assessed the demand of infrastructure (Physical &

Social) in nearby area of the plant site and development activities are being undertaken under

corporate social responsibilities program for rural development initiatives for the betterment of

the nearby communities from time to time.





(v) Amenities / Facilities

Grasim Industries Limited; Unit- Indian Rayon has a multispecialty hospital with Doctors and well-

trained staff, staff bus, canteen, dhabha for truck drivers etc. at the site.

It is proposed to continue development and maintenance activities for the amenities / facilities in

nearby area of the plant site as per requirement of local people of the nearby area under corporate

social responsibilities program.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

The total area of existing plant is 71.33 ha; the proposed installation will be done on 1.6 ha of open

land within the premises of existing plant.

o Workshop

Separate Mechanical and electrical workshops will be made to take care of the regular maintenance/

repair jobs in the plant.

o Machinery stores

A store building needed for storing tools, spare parts, consumables, etc. will be made available.

o Storage facilities

Adequate storage facilities will be provided for the storage of raw materials & finished product. The

details of storage of raw materials and finished product are given below:

Table - 6

Storage Details

Type of Material Type of Storage Capacity No. of days of

Storage

Paraffin MS/epoxy lined 200 * 2 = 400 KL

25 days Cylindrical-vertical 100 * 2 = 200 KL

Chlorinated Paraffin

Wax

MS/epoxy lined 100 * 3 = 300 KL 12 days

Cylindrical-vertical 50 * 4 = 200 KL

HCl Storage Tank Vertical 150 * 2=300 KL 4 Days

Sodium Hypo Vertical 50 * 2=100 KL 4 Days

(ii) Residential Area (Non-processing area)

Existing workers reside in the residential colony in and around the plant and in the near-by town of

Veraval. Since the additional manpower required will be accommodated within the same no new

residential facility is envisaged.

(iii) Green Belt

The total area of the existing plant is 71.33 ha, of which 24 ha (33.6%) area has already been

developed as greenbelt/plantation and the same will be maintained to increase the aesthetic beauty

of the area.





(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased indirect employment

opportunities in the region including ancillary development and supporting infrastructure.

(v) Connectivity

The site is well connected to SH - 8E (Adjacent in NE direction), NH-6 (~1.0 km in North direction)

and SH - 26 (~2.0 km in ESE direction). Nearest town is Veraval as the plant is located within the town

itself and the nearest city to the plant site is Junagadh (~67 km in NNE direction). Nearest railway

station is Veraval Railway Station (~1.5 km in ESE direction) and nearest airport from plant site is Diu

Airport (~63 km in ESE direction).

The site is well connected with communication facilities like telephone, fax and wireless. No

constraints are envisaged in this aspect as the Tehsil and District headquarters are near to the site.

(vi) Drinking Water

The additional drinking water requirement for the proposed project of CPW plant will be 2.0 KLD.

Source: Umrethi Dam

(vii) Sewerage System

Domestic waste water generated from the plant and colony will be treated in the installed STP (500

KLD) and the treated water will be used as make-up water for cooling systems and in


(viii) Industrial Waste Management

Waste water (~8.0 KLD) generated from cooling tower blowdown and floor washing will be

neutralized in existing Effluent Treatment Plant (12,000 KLD) and treated water will be disposed

through the existing Marine Pipeline.

Environmental Clearance for the marine pipeline was granted by MoEFCC vide letter no. 11-80/2008-

IA-III dated 20th Oct., 2008, amended vide letter no. 11-80/2008-IA-III (Part-II) dated 07th Dec., 2009.

(ix) Solid Waste Management

The solid/hazardous waste (used oil) generated from the plant will be sent for incineration at

Saurashtra Enviro Projects Private Limited (SEPPL), Bhachau or will be given to GPCB authorized

vendors depending on the quantity and nature of waste generated. Municipal Solid Waste

(domestic) generated from plant and colony will be collected, segregated and disposed of

scientifically. No commercial waste will be generated from the proposed manufacturing project.

Sludge generated from ETP will be disposed of scientifically and sludge from the STP will be used as

manure in greenbelt development/ plantation.

(x) Power requirement and source

The power requirement for the proposed plant will be around 0.21 MW.

Source: Captive Power Plant and GEB.





7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given).

R & R Plan is not applicable as the proposed installation will be done within the existing plant

premises.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project to

be given).

The project will start only after obtaining Environmental Clearance and other clearances from

statutory authority.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

Capital Cost of the project: Rs. 17.50 Crores

Environment Management Protection Cost:

o Capital Cost of the project: Rs. 5.0 Lacs

o Recurring Cost/annum: Rs. 1.0 Lac / annum.

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people including tribal

population, if any, in the area.

The proposed installation will result in growth and development of the surrounding areas by

increasing direct and indirect employment opportunities in the region which will not only improve

the socio-economic condition but will a lso raise the living standard of the local population.

The in-house utilization of Cl2 obtained from the sodium hypo plant will help counter the risks

involved with its storage and transportation. Moreover, the CPW thus produced will act as a useful

precursor for many industries such as plastic, rubber, paint and foundry. Thus the conversion of

harmful by-product into useful, easy-to- store and transport products will ultimately be useful in

improving socio-economic conditions while simultaneously reducing environmental risk.

Special emphasis on financial and social benefits will be given to the local people including tribal

population, if any, in the area. Development of social amenities will be in the form of medical

facilities, education to underprivileged and creation of self-help groups.

Also, Gujarat state will get revenues in terms of taxes and local people will get opportunities in terms

of indirect employment. Business opportunities for the local people will be enhanced like transport

of materials in the market, maintenance & housekeeping contract work etc.

No adverse effect on environment is envisaged as proper mitigation measure will be taken up for

the same.

Admin

Typewritten text

Annexure 1

Acknowledgement Slip for Transfer of EC application

This is to acknowledge that the proposal has been successfully uploaded on the portal of the Ministry. The proposalshall be examined in the Ministry to ensure that required information has been submitted. An email will be sentseeking additional information , if any, within 20 working days. Once verified, an acceptance letter shall be issuedto the project proponent .

Following should be mentioned in further correspondence

1. Proposal No. : IA/GJ/IND2/90464/2015

2. Category of theProposal : IND2

3. Name of theProposal : Expansion of Viscose Filament Yarn at Veraval, District Gir Somnath, Gujarat

by M/s Indian Rayon

4. Date of Submissionfor EC : 04 Jan 2019

5. Name of the Project Proponent along with Contact Details

a) Name of the proponent : GRASIM INDUSTRIES LIMITED UNIT INDIAN RAYON

b) State : Gujarat

c) District : Gir Somnath

d) Pincode : 362266

Admin

Typewritten text

Annexure 2

At Veraval, District - Gir Somnath (Gujarat) · At Veraval, District - Gir Somnath (Gujarat) Pre -...

Documents

Transcript of At Veraval, District - Gir Somnath (Gujarat) · At Veraval, District - Gir Somnath (Gujarat) Pre -...