EIA & EMP for 100 MW Thermal Power Plant at...

M/S. KUTCH CHEMICAL

INDUSTRIES LIMITED (UNIT-2)

Pre-Feasibility Report requiring Environmental Clearance for Manufacturing of Caustic Soda, Chlorine, Hydrogen Peroxide, Synthetic Organic, Inorganic, Specialty Chemicals & Coal based Captive Power Plant at Survey No. 169, 170, 175, 190, 191 of Village: Varsana, Taluka: Anjar, Distt. Kachchh, Gujarat.

MARCH, 2016

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/

M/S. KCIL (UNIT 2) PFR – EC – MANUFACTURING OF CAUSTIC SODA, SYNTHETIC ORGANIC,

INORGANIC, SPECIALTY CHEMICALS & CPP QUALITY CONTROL

SHEET

KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 II

M/S. KUTCH CHEMICAL INDUSTRIES LIMITED (UNIT-2)

Pre-Feasibility Report requiring Environmental Clearance for Manufacturing of Caustic Soda, Chlorine, Hydrogen Peroxide, Synthetic Organic, Inorganic, Specialty Chemicals & Coal based Captive Power Plant at Survey No. 169, 170, 175, 190, 191 of Village:

Varsana, Taluka: Anjar, Distt. Kachchh, Gujarat. © Kadam Environmental Consultants (‘Kadam’), March, 2016

This report is released for the use of the M/s. Kutch Chemical Industries Limited (Unit-2), 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.

PROJECT DETAILS

Name of

Publication

Pre-Feasibility Report requiring Environmental Clearance for Manufacturing of Caustic Soda,

Chlorine, Hydrogen Peroxide, Synthetic Organic, Inorganic, Specialty Chemicals & Coal based

Captive Power Plant at Survey No. 169, 170, 175, 190, 191 of Village: Varsana, Taluka:

Anjar, Distt. Kachchh, Gujarat

Project Number 1624321310 Report No. 1 Version 1 Released March, 2016

Prepared &

Managed By

Bhavin Jambucha & KCIL

Representatives Released By Jagdishchandra Rathi

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.

Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it

is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims

any liability resulting from the use or application of the information contained in this report. The information is not

intended to serve as legal advice related to the individual situation.

mailto:[email protected]



INORGANIC, SPECIALTY CHEMICALS & CPP TABLE OF CONTENT

KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 III

CONTENTS

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

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

1.2 INFRASTRUCTURE ........................................................................................ 2

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

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

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

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

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

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

2.1.1 About Proposed Project ......................................................................... 4

2.1.2 Promoters and their Background .............................................................. 4

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

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION ........................... 5

2.4 EXPORT POSSIBILITY ..................................................................................... 6

2.5 EMPLOYMENT GENERATION .............................................................................. 6

3 PROJECT DESCRIPTION ............................................................................... 7

3.1 TYPE OF PROJECT ........................................................................................ 7

3.2 LOCATION OF THE PROJECT .............................................................................. 7

3.3 DETAILS OF ALTERNATE SITES CONSIDERED ............................................................. 8

3.4 SIZE OR MAGNITUDE OF OPERATION..................................................................... 8

3.4.1 Storage Details of Finished Products.......................................................... 9

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ........................................................ 9

3.5.1 Caustic Chlorine Plant (Caustic Soda, 600 TPD & Caustic Potash – 100 TPD) ......... 9

3.5.2 Hydrogen Peroxide (100% H2O2 Basis) – 100 TPD ....................................... 15

3.5.3 Anhydrous Aluminum Chloride – 100 TPD ................................................. 17

3.5.4 Poly Aluminum Chloride – 50 TPD .......................................................... 17

3.5.5 Calcium Chloride – 175 TPD .................................................................. 19

3.5.6 Para Amino Phenol – 120 TPD ............................................................... 20

3.5.7 Hydrogenation of Hydrocarbon, Nitro & Chloro Hydrocarbon - 10,000 TPM ......... 20

3.5.8 Chlorination of Hydrocarbons – 7,500 TPM ................................................ 22

3.5.9 Chlorination of Toluene ....................................................................... 25

3.5.10 Chlorination of Acetic Acid - Mono Chloro Acetic Acid ................................. 26

3.5.11 Chlorination of Paraffins - CPW ........................................................... 28

3.5.12 Captive Power Plant – 100 MW ........................................................... 29

3.6 RAW MATERIALS ....................................................................................... 31

3.7 UTILITIES .............................................................................................. 31

3.7.1 Power Requirement ............................................................................ 31

3.7.2 Fuel Requirement .............................................................................. 32

3.7.3 Water Requirement ............................................................................ 32



KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 IV

3.8 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT ................................................ 32

3.8.1 Air Emissions & Control ....................................................................... 32

3.8.2 Fugitive Emissions & its Control ............................................................. 35

3.8.3 Line Source Emissions & Control ............................................................ 35

3.8.4 Noise Generation ............................................................................... 35

3.8.5 Waste Water Generation ...................................................................... 36

3.9 HAZARDOUS WASTE AND OTHER SOLID WASTE ....................................................... 36

4 SITE ANALYSIS ......................................................................................... 37

4.1 CONNECTIVITY OF PROPOSED SITE .................................................................... 37

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................... 37

4.3 TOPOGRAPHY ........................................................................................... 37

4.4 EXISTING LANDUSE PATTERN WITH SENSITIVITY TABLE ............................................... 37

4.5 EXISTING INFRASTRUCTURE ............................................................................ 38

4.6 SOIL CLASSIFICATION .................................................................................. 38

4.7 CLIMATIC DATA ......................................................................................... 39

4.8 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................. 39

5 PLANNING BRIEF ...................................................................................... 40

5.1 PLANNING CONCEPT .................................................................................... 40

5.2 POPULATION PROJECTION .............................................................................. 40

5.3 LAND USE PLANNING ................................................................................... 40

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................... 41

5.5 AMENITIES/FACILITIES ................................................................................. 41

6 PROPOSED INFRASTRUCTURE .................................................................... 42

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................ 42

6.2 NON-PROCESSING AREA ............................................................................... 42

6.3 GREEN BELT ............................................................................................ 42

6.4 SOCIAL INFRASTRUCTURE .............................................................................. 42

6.5 CONNECTIVITY ......................................................................................... 42

6.6 DRINKING WATER MANAGEMENT ...................................................................... 43

6.7 SEWAGE SYSTEM ....................................................................................... 43

6.8 SOLID & INDUSTRIAL WASTE MANAGEMENT ........................................................... 43

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................... 43

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 44

8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 45

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION ........................ 45

8.2 ESTIMATED PROJECT COST ............................................................................ 45

8.2.1 Profitability ...................................................................................... 45

9 ANALYSIS OF PROPOSAL ........................................................................... 46

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................... 46



KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 V

ANNEXURES

Annexure 1: General and Specific Location Map ............................................................................ 48

Annexure 2: Project Boundary Map .............................................................................................. 49

Annexure 3: Site Layout Map - Preliminary .................................................................................... 50

Annexure 4: Project Site Located on Toposheet ............................................................................. 51



KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 VI

LIST OF TABLES

Table 1-1: Product List .................................................................................................................. 1

Table 3-1: Co-ordinates of Project Boundary ................................................................................... 7

Table 3-2: List of Proposed Products and Production Capacity .......................................................... 8

Table 3-3: Mass Balance – Caustic Soda ....................................................................................... 13

Table 3-4: Mass Balance – Caustic Potash ..................................................................................... 14

Table 3-5: Mass Balance – Sodium Hypo Chloride .......................................................................... 15

Table 3-6: Mass Balance – Hydrogen Peroxide .............................................................................. 16

Table 3-7: Mass Balance – Aluminum Chloride .............................................................................. 17

Table 3-8: Mass Balance – Poly Aluminum Chloride ....................................................................... 18

Table 3-9: Mass Balance – Calcium Chloride .................................................................................. 19

Table 3-10: Mass Balance – Hydrogenated Products ...................................................................... 22

Table 3-11: Mass Balance – MCB .................................................................................................. 23

Table 3-12: Mass Balance – ODCB & PDCB ................................................................................... 25

Table 3-13: Mass Balance – Mono Chloro Acetic Acid ..................................................................... 27

Table 3-14: Mass Balance – Chlorinated Paraffin Wax (CPW) .......................................................... 28

Table 3-15: Details of Raw Material Quantity and Means of Storage ................................................ 31

Table 3-16: Fuel Details ............................................................................................................... 32

Table 3-17: Water Consumption and Waste Water Generation Details ............................................. 32

Table 3-18: Details of Stacks, Fuel Used and APCM attached to Flue Gas Stacks .............................. 34

Table 3-19: Details of Stacks, APCM attached to Process Gas Stacks / Vents ................................... 34

Table 4-1: Nearest Villages and Ponds .......................................................................................... 37

Table 4-2: Nearest Industries ....................................................................................................... 38

Table 4-3: Long term Climatic Data for New Kandla ....................................................................... 39

Table 4-4: Social Infrastructure around Project Site ....................................................................... 39

Table 5-1: Area Breakup for Proposed Plant .................................................................................. 40



KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 VII

LIST OF FIGURES

Figure 3-1: Block Diagram for Caustic Soda Manufacturing ............................................................. 12

Figure 3-2: Block Diagram for Hydrogen Peroxide Manufacturing .................................................... 16

Figure 3-3: Block Diagram for Poly Aluminum Chloride Manufacturing ............................................. 18

Figure 3-4: Block Diagram for Calcium Chloride Manufacturing ....................................................... 19

Figure 3-5: Block Diagram for Hydrogenated Product Manufacturing ............................................... 21

Figure 3-6: Block Diagram for MCB Manufacturing ......................................................................... 23

Figure 3-7: Block Diagram for ODCB & PDCB Manufacturing ........................................................... 24

Figure 3-8: Block Diagram for Chlorination of Toluene Manufacturing ............................................. 26

Figure 3-9: Block Diagram for Mono Chloro Acetic Acid Manufacturing ............................................ 27

Figure 3-10: Block Diagram for CPW Manufacturing ....................................................................... 28

Figure 3-11: PFD – Power Plant ................................................................................................... 30


INORGANIC, SPECIALTY CHEMICALS & CPP EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | MARCH, 2016 1

1 EXECUTIVE SUMMARY

Kutch Chemical Industries Limited (KCIL) proposes to set up Unit-2 for manufacturing of new Caustic

Soda, Chlorine, Hydrogen Peroxide, Synthetic Organic, Inorganic, Specialty Chemicals along with Coal

based Captive Power Plant at Survey No. 169, 170, 175, 190, 191 of Varsana Village of Anjar Taluka,

Kachchh District, Gujarat.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed products

falls under several categories including Project / Activity: 4(d) – Chlor-Alkali Industry, 5(f) – Synthetic

Organic Chemicals Industry & 1(d), Thermal Power Plants which shall be treated as Category “A”.

1.1 Plant Features and Production Capacity

The plot is a vacant barren land. Plot area of the project is 74 acre. Around ~ 33 % of total plot area

will be developed as greenbelt.

The total estimated capital investment for these products would be around INR 1,000 Crore. Project

shall be implemented in phased manner.

The total design capacity of the plant for various products is tabulated in Table 1-1.

Table 1-1: Product List

S. No. Name of Product/Byproduct Production Capacity (MTPA)

1 Caustic Chlorine Plant

1(a) Caustic Soda (100%) Lye / Prills / Flakes 2,16,000

1(b) Caustic Potash (100%) Lye / Flakes 36,000

1.1 Chlorine Gas / Liquid 2,12,900

1.2 Hydrogen 6,050

1.3 Hydrochloric acid (32%) 1,80,000

1.4 Dilute Sulphuric acid (78-80%) 12,000

1.5 Sodium Hypochlorite 12,000

1.6 Gypsum 3,600

2 Hydrogen Peroxide (100% H2O2 Basis) 36,000

3 Anhydrous Aluminum Chloride 36,000

4.1 Poly Aluminum Chloride (18%) 18,000


5 Calcium Chloride (100%) 60,000

6 Para Amino Phenol 36,000

7

Hydrogenation of Hydrocarbon, Nitro Hydrocarbon & Chloro

Hydrocarbon like:

Aniline, Chloro Aniline, OA/PA, DCA / PCA / MCA, OPDA / PPDA,

Toludiene, Cumidiene, Xyldine.

1,20,000*





8 Chlorination of hydrocarbon such as MCB, DCB, ODCB, PDCB, TCB.

90,000* 9

Chlorination of toluene such as Benzyl Chloride, Benzal Chloride,

Benzo Trichloride.

10 Chlorination of Acetic Acid - MCA.

11 Chlorination of Paraffins – CPW

12 Hydrochloric Acid (30%) 1,32,000

13 Coal based Captive Power Plant 100 MW (Capacity)

* Total Overall Capacity combining all the products. Product mix will be based on market requirement

from time to time.

1.2 Infrastructure

Basic facilities of infrastructure like storage area, processing area, internal roads etc. shall be

developed on the project site. Transportation of raw material and finished goods will be carried out

through proposed internal roads and finally through existing state highway NH 8A.

Cooling towers, air compressors, various scrubbers, ETP and other utilities shall be provided as per the

process requirement. Adequate quantity of water will be stored in underground water tank for fire

hydrant system. Adequate storage facilities for coal, salt, hazardous and solid waste, ash shall be

provided. One spare tank for liquid chlorine storage will be provided.

1.3 Utility

Power: Power requirement of will be sourced from proposed 100 MW CPP having backup source of

PGVCL. Two DG Sets of 1,000 KVA each will be installed and used as standby back-up supply for

emergency conditions & safe shutdown of Chemical plants in case of main power failure only.

Steam: Steam requirement of Process plants shall be met from the Captive co-generation 100 MW

Coal based power plant.

Fuel: 1,860 MT/day of Imported Coal (Indonesian / South African, as per availability), sourced from

open market (Kandla/Mundra Port), will be used to run Boilers with total steam generation capacity of

215 TPH each. 400 LPH HSD, sourced from local depot/suppliers, will be used for running DG Sets.

Raw Water: 7.0 MLD of water requirement will be met from GWIL (Narmada Canal).

Manpower: During the construction phase around 1,000 workers will be hired. During operation

phase, project will generate direct employment for more than 500 people and indirect employment for

approx. 500 people. It will provide employment to the people of Kutch district.

1.4 Environment

Environmental issues associated with proposed units are:

Air Emissions: Likely air pollutants from proposed project shall be PM, SO2, NOx from boiler stack

and DG Sets, HC, HCl & Cl2 from various process vents, as point source. Adequate APC equipment

like scrubber, bag filters having adequate stack height will be provided. Area source is envisaged




due to storage of coal stock piles, vehicular emissions like CO & HC’s will be generated as line

source emissions. Odorous fugitive emissions are also envisaged from proposed project.

Wastewater: Waste water will be generated from the process (organic & inorganic), utilities and

domestic activities of the proposed plant. Adequate Effluent Treatment Plant having RO, MEE,

ATFD/Spray driers shall be provided. System will adhere to ZLD principle.

Solid & Hazardous Waste: Non-hazardous solid waste like Brine Sludge will be stored in in-

house SLF and disposed to authorized TSDF. Fly ash shall be disposed off as per Fly ash

notification. Hazardous waste like Used/spent oil, Distillation residue, Process waste from CaCl2

Plant, Chemical containing residue arising from decontamination, Discarded containers/ barrels/

liners contaminated with hazardous waste, Chemical sludge from waste water treatment, ATFD /

Spray Dryer Solid Waste, Inorganic acids (HCl) shall be generated. Based on the Hazardous Waste

(Management, Handling and Transboundary Movement) Rules, 2008, as amended till date,

categorization, storage and disposal of both process and non-process wastes shall be done. In-

principal approval for receiving landfilling / incineration waste from authorized TSDF operator will

be ensured.

1.5 Sensitivity

There is no forest, national park or wild life sanctuary within 10 Km (study area) from the project site.

Gandhidham is the nearest town having dense population at 12 km from project site. There are

around 12 villages & several ponds in the study area. Salt works are at 12 km from site.

Project site is well connected with National Highway (NH 8A) at an aerial distance of 500 m. Major

railway station for public transportation is Gandhidham Railway Station, located at an aerial distance of

~12 Km. Nearest airport is Gandhidham Airport, located at an aerial distance of ~ 12 Km. Nearest port

is Kandla port located at an aerial distance of ~14 Km.

1.6 Conclusion

Promoters have vast experience in the manufacturing field of industrial and specialty chemicals. Group

also have highly qualified and dedicated employees having vast experience in plant operation,

developing new technologies, implementation of projects, finance management and commercial

operations of a large chemical industries.

There is availability of barren land for putting up plant. There are no sensitive areas within 10 Km of

project site. The project is approachable to major port Kandla via NH 8A which is just 500 m away.

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

If this project comes up, it will have social & financial benefits.

Pre-feasibility study confirms viability of the project.


INORGANIC, SPECIALTY CHEMICALS & CPP INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project & Project Proponent

M/s Kutch Chemical Industries Limited (KCIL) is one of flagship companies of Goyal Group of

Industries, engaged in manufacturing and export of various Chemicals used as intermediates in

Pharma, Agro, Plasticizer & Dyes sectors. It is one of the leading & fastest growing chemical

manufacturing companies in Gujarat.

Incorporated in 2002, KCIL is an ISO 9001: 2008, ISO 14001: 2004 and an OSHAS 18001:2007

certified company.

Their global reach spreads over many countries along with local presence in Gujarat state through

multiple dedicated distribution channels.

They have established aggressive growth plans for its business with a well-defined pathway for the

next several years. Led by a strong and enthusiastic team of technocrats, the company is capable in

executing plans for organic growth in the near & medium term.

Their existing plant is situated at Village- Padana near Gandhidham in Kutch district. It is engaged in

manufacturing of chlorination, Nitration and hydrogenation of hydro carbon. Various Chlorine based

chemicals like CPW, Chloro-Benzenes, Thionyl Chloride, Chloro-Sulfonic acid etc are manufactured. It

also has a Sulfuric acid plant of 15,000 MTA capacity.

At KCIL, 225 MT (Approx.) of Chlorine & 125 MT (Approx.) of Caustic Soda are consumed on daily

basis. At present Liquid chlorine & Caustic Soda are procured from various Chlor-Alkali plants located

in different parts of Gujarat, like Bhavnagar, Vadodara, Dahej etc.

2.1.1 About Proposed Project

As a part of backward integration, it is planned to set up a Caustic-Chlorine plant of 600 TPD in

phased manner so as to meet its present & future Chlorine requirement of downstream projects. Land

admeasuring 74 Acres is already acquired for setting up proposed new unit i.e. Unit-2.

Further various down steam products based on Chlorine like AAC, PAC, calcium chloride, PAP, MCA,

CPW, OCB, MCB, DCB, TCB, Chloro-Toluenes etc. are proposed in the project.

For gainful & effective utilization of Hydrogen gas, it is planned to set up Hydrogen Peroxide plant of

100 TPD (On 100% H2O2 basis) along with downstream products involving hydrogenation of

hydrocarbon, nitro hydrocarbon & chloro hydrocarbon like Aniline, Chloro Aniline, OA/PA, DCA / PCA /

MCA, OPDA / PPDA, Toludiene, Cumidiene, Xyldine.

In order to meet the power requirement of the new complex, it is proposed to set up a Captive Coal

based co-generation 100 MW Power plant.

2.1.2 Promoters and their Background

The group is headed by Mr. Shiv Lal Goyal and other directors, namely Mr. Kailash Chandra Goyal, Mr.

Jay Prakash Goyal, Mr. Piragchand Goyal & Ms. Kanta Goyal. Promoters have vast experience in the

manufacturing field of industrial and specialty chemicals.




Group also have highly qualified and dedicated employees having vast experience in plant operation,

developing new technologies, implementation of projects, finance management and commercial

operations of a large chemical industries.

Their manufacturing units are in Jhagadia estate, Nandesari industrial estate and at Gandhidham,

Kutch. To ensure prompt and efficient service to their clientele, they have headquartered themselves

at Vadodara, within easy access to their customer of western India, one of the prime industrial centers

of Gujarat. To support and sustain flow of requisitions, they have developed a network spanning the

length and breadth of the country and have established other offices at Ahmedabad, Mumbai and New

Delhi.

KCIL’s net worth as on 31st March 2015 was INR 172 Crores. KCIL’s total revenue for 2014-15 was INR

726 Crores. Out of which INR 147 Crores was from Export. Thus 20.25% revenue was from Export.

2.2 Brief Description of nature of the Project

Proposed project is consisting of manufacturing of caustic & chlorine from chlor alkali plant and

various inorganic, specialty chemicals basically synthetic organic compounds by hydrogenation

chlorination of base chemicals. It will have its own captive power plant. Project shall be commenced in

phases.

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

Amongst the products proposed, hydrogenated products & chlorination products are already being

manufactured at the company’s current facility.

The additional products proposed are backward integration of the company’s current products and

have a great demand both global and domestic. The demand is envisaged to increase rapidly in the

domestic market.

India is net deficit of Caustic Soda / Caustic Potash and hence regular import is coming. Gujarat &

Maharashtra are leading Industrial States of India and hence regular import of Caustic Soda / Caustic

Potash is taking place at Kandla & Nahva Shava ports. Hence sell of Caustic Soda / Caustic Potash

shall be easily get absorbed as import substitute in domestic market.

Chlorine is a co-product of Caustic Soda / Caustic Potash. Being a gaseous and hazardous product, it

has to be consumed either captively or in nearby area. Presently we are consuming Chlorine @ 225

MT per day and further Chlorine based Products are also proposed as a part of expansion. Hence we

shall be able to consume total production of Chlorine in-house captively.

Hydrogen is also a co-product while making Caustic Soda / Caustic Potash. Our group company is

already manufacturing Speciality Chemicals based on hydrogenation process. Moreover India is

regularly importing products like Para Amino Phenol, Aniline, OA / PA and hence we shall be able to

sell in domestic market as Import substitute. It is therefore proposed to use hydrogen fully by setting

up downstream hydrogen process based products like Hydrogen Peroxide, Para Amino Phenol, Aniline,

Chloro Aniline, OA / PA, DCA / PCA / MCA, ODPA / PPDA, Toludiene, Cumidiene, Xyldine

Hydro Chloric Acid which is being produced as a co-product is proposed to use as a raw material for

making Calcium Chloride. The Calcium Chloride is being largely used by oil and gas exploration sector




in Middle East Asia and as De-iceing material in cold countries. We are already exporting this product

and hence have experience of global market.

Poly aluminium chloride is using as water treatment chemical for which we have large domestic

market.

With change in global economic scenario, focus is shifting from China and India is now emerging as

strong global base manufacturing hub. Our proposed location of Project is within India’s largest salt

producing belt in Kutch (Gujarat) which assure availability of main raw material at lowest price. We

also have added advantage of producing coal base power at the lowest cost. This is because of having

proximity advantage of nearest Kandla Port where large quantity of coal is being regularly imported.

More so, this proximity advantage of Kandla Port (14 Km away) & Mundra Port (55 Km away) reduce

logistic cost significantly for export of our Products in the world market. In view of this, we shall have

global competitiveness for the Products which are based on Caustic Soda, Chlorine & Hydrogen. In

view of having very good hands on experience of Chemical processes like Chlorination, Nitration &

Hydrogenation, we have proposed various downstream Products as under:

Hydrogenation of Hydrocarbon, Nitro Hydrocarbon & Chloro Hydrocarbon like Aniline, Chloro

Aniline, OA / PA, DCA / PCA / MCA, ODPA / PPDA, Toludiene, Cumidiene, Xyldine, Para Amino

Phenol

Chlorination of hydrocarbon such as MCB, DCB, ODCB, PDCB, TCB

Chlorination of toluene such as Benzyl chloride, Benzal Chloride, Benzal Trichloride, MCA, CPW

Moreover India is regularly importing products like Para Amino Phenol, Aniline, OA / PA and hence

we shall be able to sell in domestic market as Import substitute.

2.4 Export Possibility

Many of proposed products have got very good export potential which can lead to forex revenues for

the country.

2.5 Employment Generation

During the construction phase around 1,000 workers will be hired. During operation phase, project will

generate direct employment for more than 500 people and indirect employment for approx. 500

people.

Local skilled and semi-skilled workers will be engaged during construction phase. The positives impact

include enhanced direct employment for technical/administrative works and indirect employment. It

will provide employment to the people of Kutch district.

The activities under proposed project will have positive impact on the socio economic status of people

in the study area in terms of local labour employment & contract basis jobs. The proposed activity will

provide employment opportunities to the local populace, especially in business and other services like

transportation activity.


INORGANIC, SPECIALTY CHEMICALS & CPP PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed products

falls several categories including Project / Activity: 4(d) – Chlor-Alkali Industry, 5(f) – Synthetic

Organic Chemicals Industry & 1(d), Thermal Power Plants which shall be treated as Category “A”.

3.2 Location of the Project

It will be located at Survey No. 169, 170, 175, 190, 191 situated in Varsana Village, Anjar Taluka, of

Kachchh district, Gujarat state.

Location map showing general & specific location of proposed project is given in Annexure 1. Project

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

Table 3-1: Co-ordinates of Project Boundary

POINT LATITUDE LONGITUDE

A 23°10'9.99"N 70°11'30.91"E

B 23°10'7.42"N 70°11'31.59"E

C 23°10'4.21"N 70°11'26.87"E

D 23°10'8.77"N 70°11'24.52"E

E 23°10'7.05"N 70°11'21.45"E

F 23°10'8.18"N 70°11'19.94"E

G 23°10'6.31"N 70°11'16.64"E

H 23°10'7.19"N 70°11'15.99"E

I 23°10'6.38"N 70°11'14.46"E

J 23°10'8.92"N 70°11'12.01"E

K 23°10'5.95"N 70°11'6.82"E

L 23°10'7.12"N 70°11'5.70"E

M 23°10'10.84"N 70°11'10.64"E

N 23°10'18.65"N 70°11'5.20"E

O 23°10'20.80"N 70°11'9.48"E

P 23°10'21.17"N 70°11'9.29"E

Q 23°10'25.28"N 70°11'19.69"E

R 23°10'24.78"N 70°11'19.84"E

S 23°10'25.16"N 70°11'22.80"E

T 23°10'17.51"N 70°11'23.45"E

U 23°10'17.18"N 70°11'20.45"E

V 23°10'15.92"N 70°11'19.84"E

W 23°10'12.55"N 70°11'20.70"E

X 23°10'13.82"N 70°11'27.73"E

Y 23°10'15.19"N 70°11'32.65"E

Z 23°10'10.44"N 70°11'32.00"E




3.3 Details of Alternate Sites Considered

Project proponent has manufacturing units in Jhagadia estate, Nandesari industrial estate and at

Gandhidham, Kutch. Consideration was given to land availability in these areas. Required huge land

was not available at Jhagadia & Nandesari. In their Gandhidham unit, plants for manufacturing various

Chlorine based chemicals, approximately 225 MT of Chlorine is consumed on daily basis.

Location for proposed project is selected adjacent to the existing complex of KCIL. Chlorine will be

supplied through pipeline across the wall and hence transportation of Chlorine can be avoided. Further

site has proximity with Kandla port (14 Km) and Mundra port (55 Km), which will facilitate Import of

coal & export of finished products. Other major input Salt is also available in plenty within a radius of

50 Km from the proposed site. Site is very close (500 Mtrs) to the Ahmedabad-Gandhidham National

Highway- 8A.

Project site at Gandhidham, adjacent to the existing complex has been selected keeping in view the

following locational benefits:

Chlorine gas can be supplied through pipeline across the wall for the existing operation and

transportation of hazardous chemical is avoided.

Site’s proximity with Kandla port (14 Km) and Mundra Port (55 Km), which will give logistic benefit

for import of coal and also export of finished products.

Other major input common salt is also available in plenty within a radius of 50 Km from the

proposed site.

Site is very close (500 Meters) from the Ahmedabad – Gandhinagar National Highway- 8A.

At present there is no Caustic-Chlorine plant in that region.

3.4 Size or Magnitude of Operation

Plot area of the project consists of 74 acre area. Details of all the proposed products are listed in

Table 3-2.

Table 3-2: List of Proposed Products and Production Capacity


1 Caustic Chlorine Plant

1(a) Caustic Soda (100%) Lye / Prills / Flakes 2,16,000

1(b) Caustic Potash (100%) Lye / Flakes 36,000

1.1 Chlorine Gas / Liquid 2,12,900

1.2 Hydrogen 6,050

1.3 Hydrochloric acid (32%) 1,80,000

1.4 Dilute Sulphuric acid (78-80%) 12,000

1.5 Sodium Hypochlorite 12,000

1.6 Gypsum 3,600

2 Hydrogen Peroxide (100% H2O2 Basis) 36,000

3 Anhydrous Aluminum Chloride 36,000



5 Calcium Chloride (100%) 60,000





6 Para Amino Phenol 36,000

7

Hydrogenation of Hydrocarbon, Nitro Hydrocarbon & Chloro

Hydrocarbon like:

Aniline, Chloro Aniline, OA/PA, DCA / PCA / MCA, OPDA / PPDA,

Toludiene, Cumidiene, Xyldine.

1,20,000*

8 Chlorination of hydrocarbon such as MCB, DCB, ODCB, PDCB, TCB.

90,000* 9

Chlorination of toluene such as Benzyl Chloride, Benzal Chloride,

Benzo Trichloride.

10 Chlorination of Acetic Acid - MCA.

11 Chlorination of Paraffins - CPW

12 Hydrochloric Acid (30%) 1,32,000

13 Coal based Captive Power Plant 100 MW (Capacity)

* Total Overall Capacity combining all the products. Product mix will be based on market requirement

from time to time.

3.4.1 Storage Details of Finished Products

Adequate storage facilities will be provided for finished products keeping in view production rate and

market demand variation.

3.5 Project Description with Process Details

Project description with process details are described as follows:

3.5.1 Caustic Chlorine Plant (Caustic Soda, 600 TPD & Caustic Potash – 100 TPD)

Process Description:

During manufacturing of process of caustic soda, Hydrogen and Chlorine gas as co products are

generated. HCl, hypochlorite, dilute H2SO4 are by products.

Brine Preparation, Filtration and Purification

This section consists of Salt Handling system, Brine Saturator, Reactor Clarifier, Clarified Brine Tank,

Filtration and associated facilities.

The depleted brine returned from Electrolyzer is fed to the Brine Saturator and saturated and Salt is

added to make it saturated. The salt is continuously fed through a Belt Conveyor System.

In order to remove various impurities like Sulfates, Magnesium, Calcium etc, from the brine Chemicals

such as barium carbonate, sodium carbonate, caustic soda are added to Saturated brine. After

reaction, insoluble are produced which are precipitated out in precipitation tanks & Clarifier.

pH of the brine is controlled by the addition of caustic-soda to the brine.

The brine, thus clarified, flows into clarified Brine. A part of slurry from the clarifier bottom is sent to

Sludge Filter System.

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




Secondary Brine Purification Section consists of Anthracite Brine Filters, Polishing filters and Ion

Exchange Resin Columns. In this section impurities are removed to ppb level to make brine suitable

for Membrane cell electroyzers.

Purified brine is then fed to Electrolyzers.

ELECTROLYSIS

Electrolysis section consists of latest version of Membrane Cell Electrolysers and their associated

equipments. In the electrolysis the following reaction takes place.

Electrolysis

NaCl + H2O NaOH + ½ Cl2 + ½ H2

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.

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

electrolyzer. A part of the anolyte, is taken out from Anolyte Circulation Tank to Depleted Brine Tank

by overflow. 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 header. Chlorine gas is sent for drying,

Filtration, Compression & liquefaction.

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.

A part of it is taken out from Catholyte i.e. 30%~33% Caustic Soda is sent to Caustic Soda tank which

is then fed to caustic evaporation section. Demineralised water is fed to catholyte circulation system to

maintain level..

Hydrogen gas generated in Electrolyser is separated from the catholyte in the header.

DE- CHLORINATION OF RETURN BRINE

Depleted brine returning from electrolysis system contains Chlorine and chlorine is required to be

removed before feeding it to saturators. In the De-Chlorination Tower tower, chlorine is stripped

together with water vapor, and passed through De-chlorination Tower cooler. The vapor is condensed

there and the chlorine gas is sucked by the steam ejector to Ejector Cooler. Steam is condensed and

the chlorine gas is then mixed to main stream of chlorine gas product.

The remaining traces of free chlorine are removed by adding Sodium sulfite.

Return brine is then fed to Return Brine Tank & pumped to salt saturator.

Caustic Concentration

For Caustic concentration from 30% to 50%, triple effect energy efficient evaporator system will be

adopted. In the Evaporator system 30% caustic solution at 80 0C is fed to third effect evaporator.

Steam at 11 kg/cm2a pressure is used as heating media.

Caustic Soda lye of 48~50% concentration is produced.




Chlorine Drying, Compression and Liquefaction

Chlorine Gas coming out of Anolyte circulation tank contains water vapor saturated at about 900C and

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

contact scrubbing packed tower. It is further cooled to 160 C.

The cooled chlorine gas is fed to chlorine Gas Drying Tower. The moisture of chlorine gas is absorbed

into 98% Sulfuric Acid. Moisture of Chlorine gas is absorbed in Surfuric acid it gets diluted to 78%.

Dry chlorine gas from chlorine Gas Drying Section is compressed to 3.5~ 4 kg/cm2 (a) by using Acid

Ring type Compressor.

Chlorine gas from compressor is sent to chlorine Gas Liquefaction Unit. Freon 22 is used as

refrigerant. The sniff gas from Liquefier is sent to HCI Synthesis unit for burning with Hydrogen to

produce HCl.

Liquefied chlorine from liquefier is sent to Chlorine Storage Tank.

A large quantity of Liquid Chlorine will be vaporized and sent to other units through pipeline to

manufacture various Chlorinated products.

Waste Chlorine Neutralization / Sodium Hypochlorite Section

In case of plant emergency, Waste chlorine gas from various sections of the plant is diverted to

Sodium Hypochlorite Unit. This unit consists of packed tower in which caustic solution is circulated to

absorb waste chlorine.

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 Sodium Hypochlorite.

HCL Synthesis

The chlorine gas reacts with Hydrogen to form HCI gas which is cooled and absorbed in DM water.

The flow rate of DM water is adjusted to obtain 30-33% HCI Solution. Safety Interlocking provisions

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

a product tank from where is pumped to main HCI Storage Tanks.

Hydrogen Compression

Hydrogen gas is compressed and will be supplied to Hydrogen Peroxide plant & other units consuming

Hydrogen as raw material filled in hydrogen cylinders banks of the customers and also stored in

cylinder banks.

Caustic Soda Flaking Plant

Flaker plant is a double effect evaporator. 48% Caustic is feed to produce 98% Caustic Flakes. Molten

Salt (Mixture KNO3, NaNO2 & NaNO3) is used as heating media. Caustic flakes is then cooled and

packed using a polythene liner to avoid moisture pick-up as it is a hygroscopic product.




Figure 3-1: Block Diagram for Caustic Soda Manufacturing

Caustic Potash

Process Description:

Manufacturing process for Caustic Potash is similar to that for manufacture of Caustic Soda. The raw

material used for manufacture of Caustic Potash is Industrial grade Potassium Chloride (KCl) instead of

common salt used for Caustic Soda.

For manufacture of Caustic Potash, latest Membrane cell technology shall be adopted. Hydrogen and

Chlorine gas produced as the co-product, shall me mixed with those manufactured from Electrolysers

of Caustic Soda.

Brine Preparation, Filteration and Purification

This section consists of KCl Handling system, Saturator, Chemical dosing system, Clarifier, Clarified

Brine Tank, Filteration and associated facilities.

The depleted Kcl brine returned from Electrolyzer is fed to the Saturator and Kcl is added to make it

saturated.

In order to remove various impurities like Sulfates, Magnesium, Calcium etc, from the Chemicals such

as barium carbonate, sodium carbonate, caustic potash are added to Saturated brine. After reaction,

insolubles are produced which are precipitated out in precipitation tanks & Clarifier.

The brine, thus clarified, flows into clarified Kcl Brine tank. A part of slurry from the clarifier bottom is

sent to Sludge Filter System.

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




Secondary Brine Purification Section consists of Anthracite Brine Filters, Polishing filters and Ion

Exchange Resin Columns. In this section impurities are removed to ppb level to make brine suitable

for Membrane cell electroyzers.

Purified Kcl brine is then fed to Electrolyzers.

ELECTROLYSIS

Electrolysis section consists of latest version of Membrane Cell Electrolysers and their associated

equipments. In the electrolysis the following reaction takes place.

Electrolysis

KCl + H2O KOH + ½ Cl2 + ½ H2

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 etc.

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

electrolyzer. A part of the anolyte, is taken out from Anolyte Circulation Tank to Depleted Kcl Brine

Tank by overflow. The diluted Kcl 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

Header. Chlorine gas is sent for drying, Filtration, Compression & liquefaction.

Potassium Hydroxide (KOH) 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.

A part of it is taken out from Catholyte i.e. 30%~33% Caustic Potash is sent to storage tank which is

then fed to evaporation section. Demineralised water is fed to catholyte circulation system to maintain

level. Hydrogen gas & Chlorine gas generated in Electrolyser are separated from the Catholyte header

& Anolyte header. Chlorine gas is mixed with the Chlorine gas generated from Caustic soda plant for

further treatment.

Hydrogen gas generated from Caustic Potash plant is mixed with Hydrogen generated from Caustic

soda plant, for further treatment.

Mass Balance

Mass balance per ton of product and per day basis is given in Table 3-3 & Table 3-4.

Table 3-3: Mass Balance – Caustic Soda

S.

No. Raw Materials

Input/MT of

Product (MT)

Input /Day

of Product

(MT)

1 Common Salt 1.55 930

2 Water 1.45 870

Total 3.000 1,800

S.

No.

Output/MT of Product Output/

Day of

Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emissio

n

Recovery

HW /

Solid

Waste




1

Caustic Soda

Lye (as 50%

NaOH)

2 - - - - 1,200 Product

2 Chlorine 0.88 - - - - 528 Co-Product

3 Hydrogen 0.02 - - - 12 Co-Product

4 Brine Sludge - - - - 0.10 60 To TSDF

Total 2.90 - 0 0 0.10

1,800 3.000

Table 3-4: Mass Balance – Caustic Potash

S.No. Raw Materials Input/MT of Product

(MT)

Input /Day

of Product

(MT)

1 Potassium Chloride 1.36 136

2 Water 0.34 34

Total 1.70 170

S.

No.

Output/MT of Product Output/Day

of Product

MT

Remarks Material

/ Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 Caustic

Potash 1 - - - - 100 Product

2 Chlorine 0.634 - - - - 63 Co-Product

3 Hydrogen 0.016 - - - 2 Co-Product

4 Brine

Sludge - - - - 0.05 5 To TSDF

Total 1.650 - 0 0 0.05

170 1.70

Sodium Hypo Chloride

Manufacturing Process

Sodium Hypochlorite unit is Caustic Soda plant is for De-chlorination of waste air from different parts

of the plant. It is triple effect absorption system (Primary, Secondary & Finishing). Caustic Soda (18%)

is circulated continuously in all the three absorbers. Waste air enters from the bottom of the primary

tower. Top of the primary tower is fed in the bottom of the secondary tower. Top of secondary tower

is fed to final tower to remove any traces of Chlorine before discharging waste air in to atmosphere. In

these towers Chlorine reacts with Caustic Soda and Sodium Hypochlorite is manufactured.

2NaOH + Cl2 ---- NaOCl + NaCl + H2O

Sodium Hypochlorite of 150 gpl concentration is taken out to Sodium Hypochlorite tank.

Thus this unit is for Pollution Control.

Mass Balance

Mass balance per ton of product and per day basis is given in Table 3-5.




Table 3-5: Mass Balance – Sodium Hypo Chloride

Sr. No. Input Quantity

(MT) Sr. No. Input

Quantity

(MT)

1. Caustic Lye (20%) 0.53 1. Sodium Hypo Chloride 0.5

2. Chlorine 0.47 2. Sodium Chloride 0.38

3. Water 0.12

Total 1.0 Total 1.0

3.5.2 Hydrogen Peroxide (100% H2O2 Basis) – 100 TPD


For manufacture of Hydrogen Peroxide, “Auto-Oxidation” process shall be adopted.

The manufacturing process involves, Hydrogenation of 2-Ethyl Anthra Quinone (2-EAQ) in solvent

medium (Working Solution), to get its Quinol and subsequent oxidation of the Quinol to get parent

EAQ and crude Hydrogen Peroxide. The crude is then purified and concentrated to marketable

products.

Hydrogenation

Working solution and Hydrogen are fed to hydrogenator and in the presence of palladium catalyst, 2

EAQ will be converted to 2 Ethyl hydro anthrax quinone.

2-EAQ + H2 Pd Catalyst 2-EAQH

The working solution is filtered & then fed to Oxidizer

Oxidation

The hydrogenated working solution is oxidized with air (oxygen) in an oxidizer.

2-EAQ + O2 2-EAQ + H2O2

The depleted air from the oxidizer is passed the solvent recovery system to recover working solution &

it is discharge atmosphere after removal of Organics.

Working solution containing Hydrogen Peroxide is then fed to extraction.

Extraction

In the Extraction operation is extracted in demineralized water through counter-current operation.

Working solution flows upwards and discharges from the top of the extractors after stripping hydrogen

peroxide. The aqueous phase is discharged from the bottom of the extractor which contains 30%-35%

Hydrogen Peroxide.

Working solution is returned back to Hydrogenator through WSN storage.

Product treatment

Crude Hydrogen peroxide passes through coulesers, where traces of solvents are separated from

Hydrogen Peroxide. Purified Hydrogen Peroxide is pumped to the product day tank to the distillation.




Distillation

Hydrogen Peroxide having concentration of 30%-35% is fed to distillation wherein it is concentrated to

50%, 60% or 70% as required.

The product is drawn from the bottom of the column and pumped to the storage tanks.

Reaction and Process Flow Diagram

Reaction involved is shown below and the process flow diagram is shown in Figure 3-2.

Figure 3-2: Block Diagram for Hydrogen Peroxide Manufacturing

Mass Balance


Table 3-6: Mass Balance – Hydrogen Peroxide


(MT)

Input /Day

of Product

(MT)

1 Hydrogen 0.065 6.5

2 Air 6 600

Total 6.065 606.5

S.

No.


of Product

MT

Remarks Material

/ Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1

Hydrogen

Peroxide

(100%

basis)

1 - - - - 100 Product

2 Inert Gas - - 5.064 - - 506.43 Off Gas Vent




3 Hydrogen - - 0.001 - - 0.07 Off Gas Vent

Total 1 0 5.065 0 0

606.5 6.065

3.5.3 Anhydrous Aluminum Chloride – 100 TPD


Gaseous chlorine is reacted with molten Aluminum in specially designed reactor to form Aluminum

Chloride in gaseous phase. Heat liberated because of the exothermic reaction is removed partially in

melting solid Aluminum and balance by radiation from the molten Aluminum surface. Vapors of

Aluminum Chloride lose their heat of sublimation from the wall of the condenser and get deposited

there. This deposited solid is discharged into specially designed containers by hammering the

condenser wall from outside, periodically. After cooling, it is conveyed to a silo from where it is size

graded and packed under dry air blanketing.

Unreacted Chlorine and uncondensed gases are efficiently scrubbed in well-designed scrubbers.

Mass Balance


Table 3-7: Mass Balance – Aluminum Chloride


(MT)

Input

/Day of

Product

(MT)

1 Aluminum 0.205 20.5

2 Chlorine 0.797 79.7

Total 1.002 100.2

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1

Anhydrous

Aluminum

Chloride

1 - - - - 100 Product

2 Sodium

Hypochlorite - - - 0.002 - 0.2 Saleable

Total 1.015 0 0 0.002 0

100.2 1.002

3.5.4 Poly Aluminum Chloride – 50 TPD


Hydrochloric acid and Alumina hydrate in required quantities are fed to a glass-lined reactor.

The reactor is heated to a desired temperature & pressure in a predetermined cycle, to avoid thermal

shock. It is maintained at this temperature & pressure to complete the reaction.




It is then cooled in a manner where thermal shock to the glass lined reactor is avoided.

The cooled PAC solution is filtered and stored in product tanks. It is then sent to either liquid

formulation section or to spray drier for powder production



12 HCl + 6 Al(OH)3 ---- Al12Cl12 (OH)24

(PAC)

Figure 3-3: Block Diagram for Poly Aluminum Chloride Manufacturing

Mass Balance


Table 3-8: Mass Balance – Poly Aluminum Chloride

S. No. Raw Materials Input/MT of Product

(MT)

Input /Day of

Product (MT)

1 Aluminum Hydroxide 0.528 26.4

2 HCl 0.378 18.9

3 Water 0.094 4.7

Total 1.000 50

S.

No.


of Product

MT

Remarks Material

/ Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 PAC 1.00 - - - - 50 Product

2 Waste - - - - Negligible 0 For Recycling

Total 1.00 - - - -

50 1.000




3.5.5 Calcium Chloride – 175 TPD


Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.



CaCO3 + 2 HCl ---- CaCl2 + H2O + CO2

100 73 111 18 44

Figure 3-4: Block Diagram for Calcium Chloride Manufacturing

Mass Balance


Table 3-9: Mass Balance – Calcium Chloride


(MT)

Input /Day of

Product (MT)

1 Lime Stone 0.752 125.3

2 HCl 0.650 108.3

Lime Stone (3,600) Reactor – (6,200)

HCl (2,600)

Ventuary Scrubber (Alkali)

Unreacted Lime (1,200)

Filter Press (5,000)

Evaporator

CaCl2 Clear Liquid

Moisture Loss (1,000)

Dry CaCl2 Product (4,000)




Total 1.402 233.7

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 CaCl2 1.00 - - - - 166.7 Product

2 Moisture Loss - 0.25 - - - 41.7 Recycled

3 Soild Waste - - - - 0.15 25 Sold

4 Air Emissions - - 0.002 - - 0.3 Scrubber

Total 1.00 0.25 0.002 0 0.15

233.7 1.402

3.5.6 Para Amino Phenol – 120 TPD


PNCB is reacted with caustic soda at temperature of 160 deg C and pressure of 5 – 6 Kg/cm2 getting

PNP.Na which is further hydrogenated to get PAP.

Reaction

Reaction involved is shown below:

160oC, 5-6 Kg/Cm2

C6H4Cl.NO2 + 2 NaOH ------------- C6H4ONaNO2 + NaCl

157.5 80 161 58.5

C6H4ONaNO2 + 3 H2 ------------- C6H4OHNH2 + 2H2O

161 6 109 36

3.5.7 Hydrogenation of Hydrocarbon, Nitro & Chloro Hydrocarbon - 10,000 TPM

Products: Aniline, Chloro Aniline, OA/PA, DCA/PCA/MCA, OPDA/PPDA, Toludiene,

Cumidiene, Xyldine


The reaction involves one-step hydrogenation process on the respective raw materials. Raw Material

will be fed to the raw material preparation tank as per the batch size. Nitro/Chloro derivatives of

Hydrocarbon form homogenous slurry with metal catalyst will be pumped to High Pressure Autoclave.

In Autoclave material will be heated by means of Oil Heating to 90-95 °C. Then H2 will be supplied

through PRS. H2 pressure in autoclave maintained at 15-21.5 Kg/cm2. Through PRS, unreacted &

unresolved dispersed gas in autoclave will be passed through condenser and recirculated. As the

reaction is exothermic in nature, temperature of reaction mass shall start rising which will be




controlled and maintained at 120-130°C by applying cooling water jerk. After completion of

hydrogenation, the product mass will be cooled to 30-35°C and transferred to candle filter.

From Filtration the product will be fed to conical separation vessel, where aqueous phase will be

separated from product by providing sufficient settling time. Product from separator shall be pumped

to crude storage tank. Catalyst will be recycled back to autoclave via. Candle filters.

The crude product contains traces of water and high boiler along with the product, which will be

distilled out in High Vacuum Batch Distillation Column.



Catalyst

R-NO2 + 3H2(g) ---- R-NH2 + 2H2O

Catalyst

C6H4CH3.NO2 + 3H2(g) ---- C6H4CH3.NH2 + 2H2O

Figure 3-5: Block Diagram for Hydrogenated Product Manufacturing

Nitro/Chloro Hydro-

carbon Compound

(2,558.1)

Reactor

Catalyst (26.6)

Recycle

Filter

Distillation

Hydrogen (111.9)

2,696.6

26.6

2,670

Pure Amino Product

2,000

Water

Reuse (650)

Crude Product (20)




Mass Balance


Table 3-10: Mass Balance – Hydrogenated Products


(MT)

Input /Day of

Product (MT)

1 Nitro Compound 6.40 2,558

2 Hydrogen 0.28 112

3 Water 5.00 2,000

4 Catalyst 0.07 27

Total 11.74 4,697

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 Hydrogenated

Products 1.00 - - - - 400 Product

2 Effluent - - - 0.325 - 130 Recycled

3 Recovered

Catalyst - - - 0.067 - 27

Total 1.00 0 0 0.392 0

557 1.392

3.5.8 Chlorination of Hydrocarbons – 7,500 TPM

Mono Chloro Benzene MCB


Mono Chlorobenzene plant is continuous plant. Benzene and Chlorine continuously feed in reactor

from bottom. From overflow, product Mono Chlorobenzene will be extracted. The reaction is

exothermic so cooling water circulation will control temperature of the reactor. During the reaction

Hydrochloric Acid vapor shall be generated. This vapor will be passed through the water to produce

30% Hydrochloric Acid. Material getting from reactor will be fed into acid stripper to remove the

acidity. Material from the stripper will be sent to remove any unreacted benzene. The benzene free

material will be fed into the MCB stripper; from MCB stripper, pure mono chloro benzene will be

generated.



C6H6 + Cl2 C6H5Cl + HCl

78 71 112.5 36.5




Figure 3-6: Block Diagram for MCB Manufacturing

Mass Balance


Table 3-11: Mass Balance – MCB


(MT)

Input /Day of

Product (MT)

1 Benzene 0.690 207

2 Chlorine 0.650 195

3 Water 0.238 198

Total 1.578 473

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Waste

1 MCB 1 - - - - 300 Product

2 Dil. HCl - - - 0.576 - 173 By Product

3 Air Emissions - - 0.002 - - 1 To Scrubber

Total 1.013 0 0.002 0.576 0

473 1.578

Benzene (690) Reactor – (1,340)

Chlorine (650)

HCl Absorber Water (238) Dil. HCl (576)

Recycle

Acid Stripper

Benzene Stripper

MCB Stripper

MCB (1,000)




Di Chloro Benzene (i.e. ODCB, Ortho Di-chloro Benzene & PDCB, Para Di-chloro Benzene) & TCB


The raw material Benzene will be fed into continuous chlorinator (Packed Column) via Benzene dryer

to remove the moisture from Benzene. Chlorine will be fed through vaporizer which will react with

Benzene in manner to produce DCB isomer and lower high boiler by controlling the process parameter,

where HCl gas coming out from top of reactor will be scrubbed with water in absorber to produce 30%

HCl as byproduct.

The reactor mass will be washed with water to remove the impurity and then it will be delivered to the

crystallizer to crystallize para isomer of DCB. After crystallizing the PDCB, it will be centrifuged and

mother liquor will be taken into distillation section. In distillation section, from the bottom of the first

column ODCB shall be obtained and top will contain high concentrate PDCB which will be recycled in

crystallization section. And from the top of the second column in distillation section, pure ODCB will be

separated as a product. At the end of distillation, a mix of TCB is collected.



C6H6 + Cl2 -- C6H5Cl + HCl

78 71 112.5 36.5

C6H6 + 2 Cl2 -- C6H4Cl2 + 2 HCl

78 142 147 73

C6H6 + 3 Cl2 -- C6H3Cl3 + 3 HCl

78 213 182.5 109.5

Figure 3-7: Block Diagram for ODCB & PDCB Manufacturing

Benzene (530) Reactor – (1,460)

Chlorine (930)


Recycle

Crystallizer

Centrifuge

Distillation

ODCB (350)

PDCB (650)




Mass Balance


Table 3-12: Mass Balance – ODCB & PDCB


(MT)

Input /Day of

Product (MT)

1 Benzene 0.53 159

2 Chlorine 0.93 279

3 Water 0.322 97

Total 1.782 535

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 ODCB 0.35 - - - - 105 Product

2 PDCB 0.65 - - - - 195 Product


Total 1.00 0 0 1.41 0

535 1.782

3.5.9 Chlorination of Toluene

Benzyl Chloride / Benzal Chloride / Benzal Trichloride


Toluene & Cl2 are reacted in a reactor to form Benzal Chloride & Benzyl Chloride. After Fractionation

and purification, it forms Benzo trichloride.



C6H5CH3 + Cl2 -- C6H5CH2Cl2 + HCl

C6H5CH3 + Cl2 -- C6H5CHCl2 + HCl

C6H5CHCl2 + Cl2 -- C6H5CCl3 + HCl




Figure 3-8: Block Diagram for Chlorination of Toluene Manufacturing

3.5.10 Chlorination of Acetic Acid - Mono Chloro Acetic Acid


Acetic Acid will be charged in the reactor and heated to 100˚C through hot water circulation. Chlorine

shall be charged in the reactor for chlorination. Acetic acid will be converted into Mono Chloro Acetic

Acid (MCA) in presence of suitable catalyst.

During the process, HCl gas will be generated, which will be scrubbed through scrubber and dissolved

in water to get 30% HCl liquor.

After completion of reaction, the mass will be transferred in buckets for crystallization where natural

followed by induced cooling takes place. After about 70 hrs, pure MCAA crystals shall be recovered.

After centrifuging, MCAA product will be ready for packing.

The Mother Liquor (ML) generated from centrifuge shall be separated out and sold as ML of MCA.



CH3COOH + Cl2 ---- Cl.CH2COOH + HCl

Acetic Acid Chlorine MCA Hydrochloric Acid

Toluene Reactor

Chlorine

HCl Absorber Water Dil. HCl

Benzyl Chloride / Benzal Chloride

Purification

Benzo Trichloride

For Sale




Figure 3-9: Block Diagram for Mono Chloro Acetic Acid Manufacturing

Mass Balance


Table 3-13: Mass Balance – Mono Chloro Acetic Acid


(MT)

Input /Day of

Product (MT)

1 Acetic Acid 0.670 201

2 Chlorine (Liq.) 0.900 270

3 Catalyst 0.0375 11

3 Water 0.051 15

Total 1.659 498

S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 MCA 1.00 - - - - 300 Product


3 Rec. Catalyst - - - 0.038 - 11 Recycle

Total 1.00 0 0 0.659 0

498 1.659

Liq. Cl2 (900) GLR

Catalyst (37.5)


Recycle Crystallizer

Centrifuge

Packing

MCA (1,000)

Mother Liquor of MCA

(200)

Acetic Acid (870)




3.5.11 Chlorination of Paraffins - CPW


Raw Heavy Normal Paraffin will be heated electrically to the required temperature in a Heavy Normal

Paraffin storage tank and measured quantity of Heavy Normal Paraffin will be charged in to reactor

(chlorinator). Then chlorine gas will be bubbled through the H.N.P in a reactor. Reaction between HNP

and chlorine shall take place. The reaction will be exothermic. During reaction liberated HCl gas will be

scrubbed in to water scrubber, where this gas will be converted to Hydrochloric Acid. Recirculation of

HCl gas shall take place in the system & bubbling tank until the desired concentration of HCl is

attained. In the final stage the left over gases mostly unreacted chlorine shall be taken to the alkali

tower, where by alkali solution will be pumped counter. In the reactor it is necessary to maintain

constant temperature so cooling water shall be circulated.

After completion of reaction, the product, chlorinated paraffin wax obtained will be aerated for

removal of any free gases. The chlorinated paraffin wax will be then filled in drums for dispatch.



R-H + Cl2 --- R-Cl + HCl, where R is the hydrocarbon.

Figure 3-10: Block Diagram for CPW Manufacturing

Mass Balance


Table 3-14: Mass Balance – Chlorinated Paraffin Wax (CPW)


(MT)

Input /Day of

Product (MT)

1 Heavy Normal Paraffin 0.45 135

2 Chlorine 1.20 360

3 Water 1.35 405

Total 3.00 900

Heavy Normal Paraffin (2,475)

Dil. HCl (11,000) HCl Absorber

Chlorination

Product – CPW (5,500 MT)

Chlorine (6,600)

Water (7,000)

HCl Gas




S.

No.


of Product

MT

Remarks Material /

Item

Product /

Byproduct

Liquid

Effluent

Air

Emission Recovery

HW /

Solid

Waste

1 CPW 1.00 - - - - 300 Product


Total 1.00 0 0 2.00 0

900 3.00

3.5.12 Captive Power Plant – 100 MW

In coal thermal power plan, the steam is produced in high pressure in the steam boiler due to burning

of fuel (coal) in boiler furnaces. This steam is further heated in a super heater. This super heated

steam then enters into the turbine and rotates the turbine blades. The turbine is mechanically coupled

with alternator that its rotor will rotate with rotation of turbine blades. After entering the turbine the

steam pressure suddenly falls and corresponding volume of the steam increase. After imparting

energy to the turbine rotor the steam passes out of the turbine blades into the condenser. In the

condenser the cold water is circulated with the help of pump, which condense the low-pressure wet

steam. This condensed water is further supplied to low-pressure water heater where the low-pressure

steam increases the temperature of feed water; it again heated in high pressure.

Major steps of coal base power plant operation:

First the coal is burnt into furnace of steam boiler.

High-pressure steam is produced in the boiler.

This steam is then passed through the super heater, where it further heated up.

This super-heated steam is then entered into a turbine at high speed.

In turbine this steam force rotates the turbine blades that means here in the turbine the stored

potential energy of the high-pressure steam is converted into mechanical energy. Turbine shaft

connected with generator in which power generates.

After rotating the turbine blades, the steam has lost its high pressure, passes out of turbine

blades and enters into a condenser.

In the condenser the cold water is circulated with help of pump, which condenses the low-

pressure wet steam.

This condensed water is then further supplied to low pressure water heater where the low

pressure steam increase the temperature of this feed water, it is then again heated in a high

pressure heater where the high pressure of steam is used for heating.

The turbine in thermal power station acts as a prime mover of the alternator.




Figure 3-11: PFD – Power Plant

Coal Handling System

Capacity of Coal Handling Plant (CHP) is envisaged 115 ton/Hr for 215 TPH Boiler, and total capacity

of CHP for both the plant is envisaged 230 TPH.

Coal will be fed to ground hopper grizzly by pay-loaders or dumper.

From ground hopper, coal shall be fed to crusher via raw coal conveyor and primary screen.

Primary screen will segregate <6 mm sized coal and it shall be fed to product conveyor and over sized

coal shall go to crusher. Crushed coal shall again segregated by secondary screen and oversized coal

shall fed to raw coal conveyor via recycle conveyor and sized coal <6 mm shall be fed to product

conveyor. Which will ultimately fed bunkers through shuttle conveyor.

Bunker capacity per boiler is designed based on 18 hours of storage considering 100% Imported Coal

as a fuel.

Crusher capacity shall be designed to operate for 8 hours considering 100% Imported Coal as a fuel.

Ash Handling System

Dense phase Ash Handling System is proposed for two boilers, operating on 100% imported coal

having max 7% of ash in imported coal. The maximum Ash generation is envisaged 130 TPD so AHP

capacity is envisaged 150 TPD.RCC Ash silo capacity is envisaged as 2x 300 m3 based on 48 hrs of min

storage. Dense phase Ash handling System is designed to handle bed ash from bottom hoppers of

boiler after Bed ash cooler and fly ash from Bottom hoppers of economizer, Air pre heater and ESP.

Separate lubricated screw type, air cooled, service air compressors (1W+1S), which can delivered air

pressure of maximum 5 kg/cm2 (g) for ash handling system. One number of suitable capacity air

receiver tank shall also be considered.




Bed Ash handling System

Dense phase Bed ash handling system along with ash cooler (air cooled) shall be provided.

Dense phase Bed ash/ fly ash handling system

Bed ash from boiler and Fly ash from economizer, air pre heater & of ESP hoppers shall be carried to

silo with the help of service air supplier.

Ash conditioning system with water spray, nozzles and telescopic chute shall be considered along with

dust extraction at top of the Silo, by the EPC Supplier.

3.6 Raw Materials

Raw material shall be sourced from registered supplier within India and Imported (if required) based

on the need and availability. Details of raw materials along with the quantity and means of storage are

given in Table 3-15.

Table 3-15: Details of Raw Material Quantity and Means of Storage

S.

No. Name of Raw Material

Consumption

MTPA

Physical

State Source

Means of

Transportation

1 Common Salt 3,25,550 Solid Kutch Trucks

2 Potassium Chloride 47,600 Solid Kutch Trucks

3 Hydrogen 1,13,960 Gas In-house Pipeline

4 Chlorine 3,19,795 Gas In-house Pipeline

5 Chlorine (Liq.) 94,500 Liquid In-house Pipeline

6 HCl 44,532 Liquid In-house / Local Pipeline / Trucks

7 Aluminum 7,175 Solid Local Trucks

8 Aluminium Hydroxide 9,240 Liquid Local Trucks

9 Lime Stone 43,867 Solid Local Trucks

10 ONCB / PNCB 2,14,760 Liquid Local Trucks

11 Caustic Flake 70,000 Solid Local Trucks

12 Dichloro Nitro Benzene 1,89,000 Liquid Local Trucks

13 Methanol 28,000 Liquid Local Trucks

14 Benzene 1,28,100 Liquid Local Trucks

15 Heavy Normal Paraffin 47,250 Liquid Local Trucks

16 Acetic Acid 70,350 Liquid Local Trucks

3.7 Utilities

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

3.7.1 Power Requirement

Power requirement will be sourced from proposed 100 MW CPP having backup source of PGVCL.

Two DG Sets of 1,000 KVA each will be installed and used as standby back-up supply for emergency

conditions & safe shutdown of Chemical plants in case of main power failure only.




3.7.2 Fuel Requirement

Imported Indonesian/ South African Coal having 0.5 % sulphur and 7.0% ash content will be used for

the proposed Boilers and HSD will be used for DG Sets. Details of the same are tabulated in Table

3-16.

Table 3-16: Fuel Details

S. No. Type of Fuel Used in Quantity Source

1 Imported Coal Boiler

(2 Nos, 215 TPH Capacity each) 1,860 MT/Day

Open Market - Nearest

Ports (Kandla & Mundra)

2 HSD DG Sets

(2 Nos. 1,000 kVA each) 400 Ltr/Hr. Local Depot/ Suppliers

3.7.3 Water Requirement

7.0 MLD of water requirement will be met from GWIL (Narmada Canal).

By implementing various recycle/reuse schemes water will be reused. Water consumption & Waste

water generation breakup is given in Table 3-17.

Table 3-17: Water Consumption and Waste Water Generation Details

S. No. Description Water Consumption

(KLD)

Effluent Treatment

and Disposal Facility

1 Domestic 22.5

To ETP, leading to ZLD.

2 Industrial

(Process + DM + Boiler + Cooling Tower)

2.1 Caustic Soda 2,900

2.2 Caustic Potash 500

2.3 Hydrogen Peroxide 1,000

2.4 Power Plant 1,400

2.5 Organic Plants 1,000

3 Gardening 173

Total Water Consumption 7,000

3.8 Pollution Load on Environment due to Project

Environmental issues associated with pesticides manufacturing, formulation and packaging include:

Air emissions;

Wastewater;

Hazardous Materials;

Wastes.

3.8.1 Air Emissions & Control

During construction phase, vehicular emissions will be from use of construction machinery and

vehicles. For dust suppression water sprinkling will be done from time to time.

During operation phase, likely air pollutants from proposed project will be PM, SO2 & NOx from boiler

stack and DG Sets, HCl, Cl2 & HC from various process vents, as point source. Adequate APC




equipment like scrubber, adequate height will be provided. Vehicular Emissions like CO & HC’s will be

generated as line source emissions.

Fugitive emissions from storage, handling & plant (MCB/ODCB/PDCB/TCB) area also envisaged. Area

source emission of PM from coal stock piles is also visualized. The ambient air quality & stack emission

norms will be adhered to as per GPCB/CPCB norms.

Details of proposed stacks with fuel consumption and attached Air Pollution Control Equipment details

are tabulated in Table 3-18 & Table 3-19.

M/S. KCIL (UNIT 2) PFR – EC – MANUFACTURING OF CAUSTIC SODA, SYNTHETIC ORGANIC, INORGANIC, SPECIALTY CHEMICALS &

CPP PROJECT DESCRIPTION


Table 3-18: Details of Stacks, Fuel Used and APCM attached to Flue Gas Stacks

S.

No. Stack Attached to Fuel Used

Quantity of

Fuel APCM

Expected

Pollutants

Efficiency of

APCE

Stack

Height

(m)

Stack

Top Dia.

(m)

Exit

Temp.

(°C)

Exit

Velocity

(m/s)

1 Boilers

(2 Nos.) Imported Coal 1,860 MT/Day ESP PM, SO2 & NOx > 99.5 % 105 3.5 140 18

2 DG Sets (2 Nos.) HSD 400 Ltr/Hr. Adequate

Stack Ht. PM, SO2 & NOx - 15 0.5 150 15

Table 3-19: Details of Stacks, APCM attached to Process Gas Stacks / Vents

S.

No. Stack Attached to APCM

Expected

Pollutants

Stack Height

(m)

Stack Top

Dia. (m)

Exit Temp.

(°C)

Exit Velocity

(m/s)

1 Waste air De-Chlorination Unit -1 & 2 3 Stage Caustic Scrubbing System Cl2 30 0.4 35 1.5

2 HCl synthesis Unit 1 & 2 Single Stage DM Water Scrubbing

System HCl, Cl2 30 0.15 35 1.5

3 Depleted air from solvent recovery

Unit 1 & 2 (H2O2 Plant) Activated Carbon Adsorption HC 32 0.4 40 2.5

4 Calcium Chloride Plant Alkali Ventury Scrubber HCl, Cl2 11 0.2 30 1.5

5 CPW Plant Water + Alkali Scrubber HCl, Cl2 15 0.2 30 1.5

6 Chlorinator of Chloro Benzene Plant –

MCB

Water Absorber + Glass Water

Scrubber + Caustic Scrubber HCl, Cl2 22 0.2 30 1.5

7 Chlorinator of Chloro Benzene Plant –

ODCB/PDCB/TCB

Water Absorber + Glass Water

Scrubber + Caustic Scrubber HCl, Cl2 22 0.2 30 1.5

8 Chlorinator of Toluene Plant Water Absorber + Caustic Scrubber HCl, Cl2 22 0.2 30 1.5




3.8.2 Fugitive Emissions & its Control

Fugitive emissions from storage & handling area for raw materials, solvents, finished products is

envisaged due to proposed project. Odor of raw materials & finished goods shall be limited to plant

area.

Odor shall be controlled by taking following steps:

All liquid raw materials and intermediates shall be charged into Reactors with pumps or under

gravity through closed pipes.

All vents of holding tanks and dosing vessels shall be connected to a Vent Scrubber system

comprising of a suction Blower, Acid Scrubber, Alkali Scrubber and an Activated Carbon Column

before venting through a tall stack.

Alkaline and Acidic gases present in the Vent gases shall be absorbed in the Acid & Alkali

scrubbers. VOC present in the vent gas stream shall be absorbed in the Activated Carbon tower.

Suction Hoods shall be placed near the Man-holes & Charging funnels of Reactors & Filters so that

chemical vapors and dust do not escape into the Plant & surroundings, when the man-hole covers

are opened for inspection or charging of RM.

All storage tanks of low boiling solvents / chemical shall be provided with Conservation Vents.

Vents of HCl storage tanks shall be provided with a Water filled trap to prevent Acid fumes from

escaping out.

All pumps handling hazardous chemicals shall be provided with mechanical seals to prevent

fugitive emission. Wherever possible magnetic coupled pumps will be used.

Any spillage from drums etc. will be absorbed with saw dust / soda ash and moped clean. The

contaminated absorbent will be safely disposed off along with hazardous waste.

Measuring Instruments with sound alarm and having strategically placed sensing elements will be

provided for alerting the personnel in case of any escape of gases like Chlorine, HCl vapors.

3.8.3 Line Source Emissions & Control

During construction phase, vehicular emissions will be from use of construction machinery and

vehicles. Apart from it, application of heavy machinery and earth movers will generate emissions.

Suitable dust suppression techniques such as water sprinkling will be taken at these times as relevant.

During operation phase, vehicular emissions due to transportation of raw materials, finished goods

and local travel of employees are envisaged.

Approximately, 250 trucks per day carrying raw material and finished goods shall be using the national

highway connecting Kutch and Ahmedabad.

3.8.4 Noise Generation

Sources of noise generation from proposed activities are:

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

construction phase;

Operation of boiler, compressors, chillers, DG sets, etc. will have a permanent effect;

Vehicle movement for transportation of raw material and finished goods.




3.8.5 Waste Water Generation

The waste water will be generated from the process, utilities and domestic area. The process effluent

along with utilities blowdowns and domestic sewage will be treated in ETP followed by RO. The

permeate from the RO will be reused in plant areas and reject will be treated into MEE. Advance

systems like ATFD / Spray dryers shall be equipped to achieve” Zero Liquid Discharge” concept.

3.9 Hazardous Waste and Other Solid Waste

From the proposed project, it is envisaged that different type of hazardous waste like Used/spent oil,

Distillation residue, Process waste from CaCl2 Plant, Chemical containing residue arising from

decontamination, Discarded containers/barrels/liners contaminated with hazardous waste, Chemical

sludge from waste water treatment, ATFD / Spray Dryer Solid Waste, Inorganic acids (HCl) shall be

generated.

Non-hazardous solid waste like Brine Sludge will be stored in in-house SLF and disposed to authorized

TSDF. Fly ash shall be disposed off as per Fly ash notification.

Based on the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008,

as amended till date, categorization, storage and disposal of both process and non-process wastes

shall be done.

In-principal approval for receiving landfilling / incineration waste from authorized TSDF operator will

be ensured.


INORGANIC, SPECIALTY CHEMICALS & CPP PLANNING BRIEF


4 SITE ANALYSIS

4.1 Connectivity of Proposed Site

Project site is well connected with National Highway (NH 8A) at an aerial distance of 500 m. Major

railway station for public transportation is Gandhidham Railway Station, located at an aerial distance of

~12 Km. Nearest airport is Gandhidham Airport, located at an aerial distance of ~ 12 Km. Site is well

connected by Kandla port located at an aerial distance of ~14 Km.

4.2 Land Form, Land use & Land Ownership

The plot is a vacant barren land. Permanent change in Land Use from Barren to Industrial Use is

envisaged. Land Cover will be as per the Site Layout Map as shown in Annexure 3. Land ownership is

of KCIL, acquired from various land owners.

4.3 Topography

The terrain of the project site is categorized as a coastal terrain, which is almost flat and with

extremely low gradient towards East and Southeast. The entire is saline mudflat, of marine and fluvial

origin, composed of clay, silt and very fine sand. Project site shown on Toposheet No. F42E4

(Gandhinagar, Gujarat) is provided in Annexure 4.

4.4 Existing Landuse pattern with Sensitivity Table

No forests, national park, wild life sanctuary, etc. are envisaged in 15 Km from the nearest boundary

of the project site. Nearest villages with village names, ponds in the study area of 10 km are

presented in Table 4-1.

Table 4-1: Nearest Villages and Ponds

Sr.

No. Nearest Villages & Pond

Distance from the Proposed Site

(in Km)

Direction wrt Project

Site

1 Padana 1.2 S

2 Varsana 1.5 NE

3 Bhimasar 2.6 NW

4 Modvadar 3.8 SW

5 Nandgam 3.9 NE

6 Cherai Nani 5.0 NE

7 Pasuda 6.1 N

9 Mithi Rohar 6.8 SW

10 Ajapar 8.0 W

11 Varshamedi 9.0 WWS

12 Tappar 9.5 NNW

There are few industries within 5 km of the project area as indicated in Table 4-2. There are many

timber based small scale industries in study area.




Table 4-2: Nearest Industries

Sr. No. Name of Industry Distance from the Proposed Site (in Km)

1 Lakme Lever India Pvt. Ltd. 0.9

2 Indian Steel Corporation Ltd. 2.4

3 Cargill India Pvt. Ltd. 0.9

4 JMD Oils Pvt. Ltd. 2.3

5 Ratnamani Metals & Tubes Limited 3.3

4.5 Existing Infrastructure

There is no infrastructure available at site except “kuchha” road connecting project site to highway.

Photographs of existing site are shown in Photograph 1.

Project Site which is a barren land Shrubs & under shrubs like Prosopis juliflora at site

EIA Coordinator with KCIL’s representatives and EIA Team members at Project Site

Photograph 1: Photographs of Proposed Site

4.6 Soil Classification

The soils belongs to the greater group Ustipsamments and in the great group Ustifluvents of order

Entisols. The area is having sandy to sandy loam texture, poor in organic carbon, available nutrients,

saline, depth > 100 cm, having high porosity and permeability, but water holding capacity is very low.




4.7 Climatic data

The climate of Gujarat is varied, as it is moist in the southern districts and dry in the northern region.

The Arabian Sea and the Gulf of Kutch in the west and the forest-covered hills in the east soften the

rigours of climatic extremes, consequently reducing the temperature and render the climate more

pleasant and healthy.

The climate of the study area is based on information from the most recent published long-term

climatological tables (1961 – 1990) by Indian Meteorological Department (IMD), for New Kandla

(Station ID: 42841). The observatory was situated at Harbour area of New Kandla.

Summary of the climatic data for the study area is given in Table 4-3.

Table 4-3: Long term Climatic Data for New Kandla

Month Mean Daily Temperature

Rainfall (mm)

Monthly Total

No. of Rainy days

Relative Humidity (%),

(Morning)

Relative Humidity (%),

(Evening) Max Min

January 25.3 13.8 1.4 0.1 55 37

February 27.7 16.1 2 0.2 60 35

March 31.7 19.9 2.8 0.2 63 37

April 34.5 23.3 0.3 0 70 43

May 35.4 26.1 1.8 0.2 75 55

June 34.9 27.7 57.9 2.5 76 59

July 32.7 26.9 162.4 6.7 80 67

August 31.6 26 119.7 5.8 82 69

September 32.8 25.3 37.8 2.4 79 60

October 34.4 24 13.2 0.5 67 42

November 30.9 20 16.6 0.5 60 39

December 26.6 15.4 6.3 0.2 56 40

Total -- -- 422.2 19.3 -- --

Average 31.5 22 -- -- 69 49

Average wind speed is 17.2 km/hr blowing predominantly from SW direction to NE direction annually.

4.8 Social Infrastructure Available

Housing facilities, general hospital and other hospitals for treatment of ailments are available in

Gandhidham. Basic infrastructure available at the vicinity of the project site is provided in Table 4-4.

Table 4-4: Social Infrastructure around Project Site

Sr.

No. Name of Place / Infrastructure

Distance from the

Proposed Site (in Km)

Direction wrt

Project Site

1 Government High School, Bhimasar Village 2.5 NW

2 Fire Station 16.5 SW

3 Gandhidham General Hospital 12.7 SW

4 Mosque 1.6 E


INORGANIC, SPECIALTY CHEMICALS & CPP PROPOSED

INFRASTRUCTURE


5 PLANNING BRIEF

5.1 Planning Concept

Site falls under the seismic intensity Zone V, which is classified as Very High Risk zone (Area liable to

shaking Intensity IX (and above)). Thus, suitable seismic coefficients accordingly shall be adopted while

designing the structures to make it earthquake resistant.

Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc.

shall be developed on the project site. Transportation of raw material and finished goods will be

carried out through proposed internal roads and finally through existing NH – 8A.

5.2 Population Projection



people. It will provide employment to the people of Kutch district.

5.3 Land Use Planning

Site layout of the proposed project is shown in Annexure 3. Area statement of the project is

tabulated in Table 5-1.

Table 5-1: Area Breakup for Proposed Plant

S. No. Type of Land Use Area in m2 % of Total Plot Area

1 Caustic Soda & Caustic Potash Plant 65,700 21.94%

2 H2O2 Plant 12,085 4.04%

3 Water Reservoir 5,000 1.67%

4 SLF area 5,000 1.67%

5 ETP 305 0.10%

6 Organic Units 27,445 9.16%

7 AAC 4,810 1.61%

8 Power Plant 23,370 7.80%

9 Coal Yard 20,750 6.93%

10 Admin Building 320 0.11%

11 Security Office 50 0.02%

12 Green area 1,00,000 33.39%

13 Road Area 14,300 4.78%

14 Ash Dyke 4,400 1.47%

15 Area for Expansion 10,520 3.51%

16 Truck Parking 5,420 1.82%

Total Plot Area 2,99,475



INFRASTRUCTURE


5.4 Assessment of Infrastructure Demand (Physical & Social)

The main infrastructure demand is of approach to the project site from national highway.

5.5 Amenities/Facilities

Within the study area (i.e. 10 kms) basic amenities/ facilities like Primary school, is available in all the

nearby villages and for further education students go to Gandhidham which is approximately 12 Km

from the project site. While there are 4 Primary Health sub centers for medication. These villages are

well connected with public bus services. Basic amenities like tap water supply and power supply are

also available in the nearby villages. Other facilities like communication services i.e. telephone and

mobile etc., are also available in the nearby villages.



INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The industrial area shall comprise of following sections:

1. Manufacturing process area;

2. Coal & Ash storage area;

3. Salt and other raw material storage;

4. Finished product storage;

5. Utility Area;

6. Packing material storage;

7. ETP area;

8. SLF area;

9. Hazardous waste storage area.

Adequate storage space for salt storage, coal, raw material, solvents, finished products, ash,

hazardous and other solid waste shall be provided.

6.2 Non-Processing Area

Requirement of non processing area will be developed as shown below:

1. Weighbridge;

2. Administrative Building;

3. Laboratory;

4. Security cabins;

5. Workers restroom;

6. Vehicle Shed;

7. Water reservoirs for raw water and fire hydrant system;

8. Temporary storage sites;

9. Worksblock etc.

6.3 Green Belt

Around 33% of total plot area will be developed as greenbelt as shown in Annexure 3.

6.4 Social Infrastructure

Refer Chapter 4, Section 4.8.

6.5 Connectivity

Refer Chapter 4, Section 4.1 .



INFRASTRUCTURE


6.6 Drinking Water Management

Domestic water shall be met from GWIL.

6.7 Sewage System

Domestic waste water shall be treated and reused in gardening.

6.8 Solid & Industrial Waste Management

Solid and hazardous waste as mentioned in Chapter 3, Section 3.9 shall be collected, stored,

disposed to authorized vendors and sold to local suppliers as per it’s characterization and based on the

prescribed Hazardous Waste Rules, 2008 amended till date.

6.9 Power Requirement & Supply / Source

Refer Chapter 3, Section 3.7.1.


INORGANIC, SPECIALTY CHEMICALS & CPP R & R PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

Project proponent has procured the land from various land owners. NA has been done for the same.

Currently the site is barren and boundary wall has been made. Hence, R&R issues are not envisaged.


INORGANIC, SPECIALTY CHEMICALS & CPP PROJECT SCHEDULE &

COST ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

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

The construction is likely to start after getting Environmental Clearance from MoEFCC and NOC/CTE

from GPCB. Project will be completed in phased manner. Caustic Soda plant will be completed after 24

months.

8.2 Estimated Project Cost

The project cost is estimated to be approximately INR 1,000 Crore.

8.2.1 Profitability

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’.


INORGANIC, SPECIALTY CHEMICALS & CPP ANALYSIS OF

PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits



people. It will provide employment to the people of Kutch district.

The positives impact include enhanced direct employment for technical / administrative works and

indirect employment opportunities for transporters of raw material and finished goods.

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


INORGANIC, SPECIALTY CHEMICALS & CPP ANNEXURES


ANNEXURES


CPP ANNEXURES


Annexure 1: General and Specific Location Map


CPP ANNEXURES


Annexure 2: Project Boundary Map


CPP ANNEXURES


Annexure 3: Site Layout Map - Preliminary

Predominant Wind Direction

(Annual) is from SW to NE.


CPP ANNEXURES


Annexure 4: Project Site Located on Toposheet

Map showing Project Site on TopoSheet No. F42E4 (Gandhidham, Gujarat) – 5 Km Radius Circle

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA – 122 002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433

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/

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