PRE-FEASIBILITY REPORT...PRE-FEASIBILITY REPORT FOR PROPOSED EXPANSION IN PRODUCTION CAPACITY OF...

PRE-FEASIBILITY REPORT

FOR

PROPOSED EXPANSION IN PRODUCTION CAPACITY OF

CARBON DI SULPHIDE (CS2) AND EXPORT OF STEAM

[Schedule 5 (b) Category “A” as per EIA notification 2006 and its

amendment thereof]

At

Z-7/1, SEZ area, SEZ-1, GIDC Dahej, PCPIR Ta: Vagra, Dist- Bharuch, Gujarat.

Land/Plot Area: 50,000 m2

Production Capacity: Carbon Di Sulphide (CS2): 75,000 to 100,000 TPA

Steam: 65,000 to 85,000 TPA

APPLICANT CONSULTANT

M/S. INDOBAIJIN CHEMICALS PVT LTD ECO CHEM SALES & SERVICES Z-7/1, SEZ area, SEZ-1, GIDC Dahej, PCPIR

Village: Dahej, Ta: Vagra, Dist- Bharuch 392130 Gujarat. E-Mail: [email protected]

Tel No: 02642-277202

Office Floor, Ashoka Pavilion - A New Civil Road, Surat, 395001

NABET/EIA/1720/RA 051 E-mail: [email protected] Tel No. +91 261 2231630

Document No.: 2018_ECSS_EIAI2_1800032 December 2018

mailto:[email protected]

INDOBAIJIN CHEMICALS PVT LTD.

Pre – Feasibility Report for Capacity Expansion Project

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EXECUTIVE SUMMARY

India is one of the leading manufacturers and suppliers of pesticides intermediates. India has good

engineering & research scientist pool along with long proven expertise of producing quality products.

The proposed project is an expansion project proposed by Indo-Baijin Chemicals Pvt. Ltd. with a total

product capacity of Carbon Di-Sulphide of 100,000 MTPA. Carbon disulfide has been an important

industrial chemical since the late nineteenth century. It is used in a variety of applications like

production of regenerated cellulose (rayon and cellophane) and the manufacture of organic sulfur

compounds including agricultural, pharmaceutical, rubber chemicals and especially as Pesticide

intermediate. The proposed project will be undertaken within the existing premises of Indo-Baijin

Chemicals Pvt. Ltd. located at Plot No: Z-7/1, SEZ area, SEZ-1, Village: Dahej, Tehsil: Vagra, District:

Bharuch, PCPIR, Gujarat.

As per the provision of the SO 1533, the proposed project falls under the item no. 5(b) -“A” and the

project is to be appraised at the MoEFCC, New Delhi. Further, the proposed project is located in the

Notified industrial estate/park (as described in Item 3(b) of notification), Hence Public hearing shall be

exempted (A copy of Gazette notification is attached as Annexure-5)

This pre-feasibility report has been prepared as a part of the ToR application, which includes a brief

introduction of the company, need and justification of the project, manufacturing process description,

required and available resources, proposed Environment Management Systems, existing land-use and

proposed infrastructure, project schedule and cost estimate, and proposed Terms of reference for

conducting the EIA studies.

The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultant to

conduct the EIA studies for obtaining EC for the proposed project. ECSS is a NABET accredited (QCI

approved) Environmental Consultant.



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1.0 PROJECT BRIEF

PROJECT BRIEF

No. Description Proposed Project Details

1 Name of project &

Address

Indo Baijin Chemicals Pvt Ltd

Plot No: Z-7/1, SEZ area, SEZ-1,

GIDC Dahej, PCPIR, Taluka – Vagra,

Dist: Bharuch,

Gujarat

2 Project Category 5 (b)-A of EIA notification – 2006

3 Project capital cost Existing cost: Rs. 193 Crores Expansion cost: Rs. 100 Crore Total Cost: 293 Crore

4 Products Enhancement of production capacity of Carbon Di-Sulphide

(CS2) from 75,000 MTPA to 100,000 MTPA and steam

export capacity from 65,000 MTPA to 85,000 MTPA

No Product Existing

capacity

(MTPA)

Proposed

Capacity

(MTPA)

Total

Capacity

(MTPA)

1 Carbon Di-

Sulphide

75,000 25,000 100,000

2 Steam Export 65,000 20,000 85,000

5 By-products No By-Product will be generated

6 Resource Requirement

Land 50,000 m2

(No additional land will be required due to proposed

expansion)

Water Source: GIDC water supply

Existing Water Consumption:

Domestic Activities: 50 KLD

Industrial Activities: 700 KLD

Total Water Consumption after Proposed Expansion:

Construction phase: 5-10 KLD

Operation phase:

Total water consumption: 1000 KLD

Domestic Activities: 50 KLD

Industrial Activities: 950 KLD

Existing Proposed Total

Domestic

Activity

50 KLD Nil 50 KLD

Industrial

Activity

700 KLD 250 KLD 950 KLD

Electricity Source: Torrent Energy Ltd



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Existing Contract Demand - 1900 KVA

Proposed additional Contract Demand – 1250 KVA

Total Contract Demand - 3150 KVA

Fuel Existing:

Natural gas: 97,469.17 SCM/day

Proposed:

Natural Gas: 21,183.3 SCM/day

Total:

Natural gas: 118,652.47 SCM/day

Manpower Existing: 104 Nos.

Proposed additional Manpower:

Construction phase –25 Nos.

Operation phase – 12 nos.

7 Source of Pollution

Waste Water Generation No industrial wastewater is discharged from the existing

unit hence the unit is a zero liquid discharged unit. After

the proposed expansion same shall be achieved.

Existing sewage is treated in STP and treated water is

partly reused gardening and partly send to cooling tower

for evaporation. After the proposed expansion additional

sewage will be treated in existing STP having spare

capacity.

Air Emission Flue stack Emission:

SPM, SO2, NOx

Process stack Emission:

SPM, SO2, NOx

Solid/Hazardous Waste

Generation

Hazardous waste:

Furnace Slag from furnace pipe and reactor cleaning, Used

Spent Oil, Discarded Containers/liners/Barrels

contaminated with Hazardous waste/chemicals,

Evaporation salt, Sludge from Sulfur Filter, , Spent Catalyst

and Molecular sieves, Residue Carbon, Wastage or

residue containing oil, Contaminated Cotton rags or other

cleaning materials

Solid Waste:

STP Sludge

8 Mode of Treatment

Wastewater 1) Due to proposed expansion additional 200 KLD Industrial

effluent will be generated.



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2) Additional Domestic sewage will be treated in existing

Sewage Treatment Plant (STP) and treated water shall

be reused in gardening and partially fed to combination

cooling tower.

Air One no. of Tail Gas Treatment Unit & heating furnace will

be installed during the proposed expansion as process gas

and one no D.G.Set with 1650 KVA will be installed for

emergency power back up.

Adequate Air pollution control device (i.e Sulphur Recovery

Unit & Tail Gas Treatment Unit) will be provided to achieve

GPCB norms.

Solid Waste Solid/hazardous waste for collection, storage and disposal

will be carried out as per Hazardous Waste Management

Rules 2016.

2.0 INTRODUCTION OF THE PROJECT

2.1 Details of Project Proponent

Indo-Baijin Chemicals Private Limited is a Joint Venture Company of Indofil Industries Limited, India &

Shanghai Baijin Chemicals Group Co. Ltd., China. Proponent is proposing to expand its current

manufacturing plant for producing Carbon Di-sulphide using Natural Gas (NG) as raw material at its

existing plant located at Special Economy Zone (SEZ), Dahej, Gujarat, India.

Indofil Industries Limited is a company from K.K. Modi Group of India an Industrial Conglomerate with

diverse businesses in the Agro Chemicals, Fine Specialty Chemicals, Entertainments, Healthcare etc.

Indofil Industries Limited is uniquely placed both in Agriculture chemical as well as Specialty and

Performance chemical business. In India, Indofil is successful in strategic marketing of insecticides

including IGRs, Fungicides, Bactericides, Herbicides, Acaricides, Surfactants and Plant growth

regulators. Indofil is working for betterment of farmers, operating in Indian Market for more than 4

decades. INDOFIL is an ISO-9001-2000 and ISO 14001 Company and famous for excellence in

product quality. Indofil have stringent safety regime and an ability to handle hazardous chemicals such

as carbon disulphuide.

Shanghai Baijin Chemicals Group Co. Ltd., China was established in 1990. With Carbon Di-sulphide

production as the major business, Baijin group, consistently extending the industrial chain of fine

chemicals, chemical fibers, coke chemicals as well as endeavoring in international trade, technical

export and R&D, is a group company with the largest production scale, the most complete technical

processes and latest technologies. Shanghai Baijin Chemical Group Co., Ltd, has a total asset of 2.6

billion Chinese yuan and 8 subordinates. The company also owns 14 proprietary patents and is



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applying 2 international patents at present. Successively, 7 carbon disulfide manufacturing plants in

Shanxi, Chongqing, Sichuan, Xinjiang, Anhui, Shandong, and Jiangsu respectively have been

established, with an annual output of 3,50,000 tons.

2.2 Description of Nature of the Project

The company is located at Plot No: Z-7/1, SEZ area, SEZ-1, GIDC Dahej, PCPIR, Taluka-Vagra,

District: Bharuch, Gujarat. The unit is involved in manufacturing of Carbon Di-Sulphide, having granted

capacity of 75,000 MT/Annum and steam export with capacity 65,000 MT/Annum.

The unit has also obtained Environmental Clearance for existing products vide letter No: J-

11011/361/2016-IA II (I), dated: 30/08/2017 (Attached as Annexure-1) & the unit holds

Consolidated Consent having Order no. AWH-64179 dated 02/04/2014, unit has also amended the

CC&A dated 11/12/1018 which is valid up to: 01/04/2019 (Attached as Annexure-2)

2.2.1 Need of Proposed Project

As India is a developing country with increasing population, pesticides‟ and pesticides intermediates‟

demand is increasing day by day. Asia is accounted for about 72% of world production and nearly 75%

of world consumption of carbon disulfide.

Carbon disulfide has been an important industrial chemical since the late nineteenth century. It is used

in a variety of applications like production of regenerated cellulose (rayon and cellophane) and the

manufacture of organic sulfur compounds including agricultural, pharmaceutical, rubber chemicals and

especially as Pesticide intermediate.

China is the dominant global player in this industry, with 49% of global consumption, followed by India

(13%). Both the countries have expanding industries, which account for the majority of carbon disulfide

consumption. The situation is similar in Western Europe, which accounted for 12% of world

consumption in 2010. In total, 98% of the world consumption of carbon disulfide was accounted for

Asia, Europe and America (74.5%, 15.8% and 7.7% of global demand, respectively). The rise of Asia

as the powerhouse where carbon disulfide is consumed (and produced) is closely related to the

changes in the global pattern of the textile, rubber, mining and agricultural chemicals industries, which

have increasingly relocated their manufacturing bases to this region. Hence, the demand of carbon Di-

Sulphide is increasingly gradually.

2.2.2 Demand Supply Gap

As discussed above, the consumption of carbon disulfide is consumed (and produced) is closely related

to the changes in the global pattern of the textile, rubber, mining and agricultural chemicals industries,

which have increasingly relocated their manufacturing bases to this region. The following pie chart

shows world consumption of carbon disulfide in the past few years:



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Figure 1: world consumption of carbon disulfide

Current Production Capacity in India : 2,42,000 MTPA

Current Demand in India : 2,77,000 MTPA

Current Gap in India : 21,000 MTPA

Indian CS2 consumption is on growing path considering the growing Agro Chemicals, Rayon & Fiber,

Rubber Chemicals & Pharma Intermediate industries. The production of regenerated cellulose (in the

form of rayon fibers, cellophane, sponges and casing) is the dominant industrial application of carbon

disulfide, accounting for 70% of total demand. In the absence of new applications, the health of the

overall carbon disulfide market will depend on sustainable growth in the fibers application, which on a

global scale is expected to rise in the near future. Other important areas where carbon disulfide is

being used are in the production of rubber chemicals (predominantly as vulcanization accelerators)

and agricultural chemicals (as fumigants). With the increasing prices of basic raw materials, the use of

carbon disulfide in the manufacture of mining chemicals (as flotation agents) is gaining in importance

and has the highest forecast growth rate among the different applications.

Available Domestic Market : 2,77,000 PTPA

Average Regular Export by IBJ : 10,000 MTPA

There is export market available and Indobaijin is exporting on regular basis to countries like

Indonesia, Taiwan, Iran, Israel, Maxico, Peru, Korea etc. and export is expected to grow in the coming

years.

Future growth is expected to be most significant in Asia, whereas other regions with significant

demand are expected to stagnate or to grow at only about 1–2% annually over the forecast period.



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2.2.5 Employment Generation

The proposed expansion project shall generate employment during the construction for local skilled

and semi-skilled workers. Thus no need to provide housing facility to workers. Approx. 25 nos. of

people will get direct employment during construction phase.

During the operation phase, additional 12 nos. of individuals will get direct employment during

operation phase depending on their education background and technical skills.

3.0 PROJECT DESCRIPTION

3.1 Proposed Project & Applicability of EIA

The existing unit of Indo Baijin Chemicals Pvt Ltd is located at Plot No: Z-7/1, SEZ area, SEZ-1, GIDC

Dahej, PCPIR, Taluka-Vagra, District: Bharuch, Gujarat. The unit is now planning to increase its

production capacity from 75,000 MT/Annum to 100,000 MT/Annum.

The applicability of the SO 1533 for the proposed expansion project was explored by considering

different possibilities & provisions made in the said EIA notification, SO 1533 amended on 14th

September 2006. Considering the products, the proposed expansion project falls under Category 5 (b)

- “A”.

3.2.3 Site Selection Criteria:

The land for the proposed expansion project is already in the possession of Indo Baijin as the

proposed project is an expansion project. All the infrastructure facilities are available with the

existing unit of Indo Baijin.

The project site is in Special Economic Zone (SEZ), which has all the facility such as RCC road,

water supply, effluent disposal line, power supply from Torrent Energy Ltd, Gas supply, Fire and

Safety Services.

The existing project site is well connected by road to National Highway No. 8.

Easy availability of infrastructure facilities.

No prime agricultural land / forest land needed to be converted for industrial use.

There is enough extra land to raise required green belt / green cover.

Area where proposed site is to be located has no history of natural calamities like floods, cloud

burst etc.

Proximity to raw material suppliers.

The human resource required for the proposed project will be easily available.

In addition to the above, the following factors within the study area have also been considered:

There is no National Park or Wild Life Sanctuary.

There are no metropolitan cities.

There are no ecologically sensitive areas.



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3.2 Project Location

The company is located at Dahej SEZ in Vagra Taluka in western part of the Bharuch district, Gujarat.

It is well connected with National Highway (NH-8). Road and Railway both are having the connectivity

to New Delhi, the National Capital and Mumbai, the commercial Capital of India. SEZ is a part of Dahej

Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) and is within Delhi-Mumbai

Investment Corridor (DMIC).

Connectivity:

Road: SEZ is on 4 lane State Highway connecting at Bharuch (40 km) and National Highway No. 8

Rail: 40 km from Bharuch, Main Rail Head connecting Mumbai – Delhi.

Port: Gujarat Chemical Port Terminal Company Limited for chemical cargo and Adani-Petro LNG for

solid bulk cargo handling.

Airport: Baroda-150 km and Surat-120 km (Daily flights to Mumbai & Delhi).

Four corners Latitudes and Longitudes of the proposed project are as under:

Project Co-ordinates

Corner Latitude Longitude

A 21°42'35.74"N 72°37‟06.78"E

B 21°42'36.02"N 72°37'10.94"E

C 21°42'27.10"N 72°37'11.04"E

D 21°42'30.92"N 72°37'10.30"E

http://www.gcptcl.com/



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Figure 2: Short view of the project site

Source: Google Earth Image



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Figure 3: Site Plant Layout with nearby industries



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Figure 4: Plant Layout



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3.2.2 Alternative Studies:

As the proposed project is capacity enhancement project, alternative site has not been considered.

Since, by nature, the project is an expansion project, the existing premises of operational unit is the

most convenient site for the proposed expansion project. Moreover all the utilities & infrastructure

facilities are available in the present set up. Hence the existing premise with available infrastructure &

ease of operation is the best option available for the proposed expansion.

3.3 Resource Requirement

To carry out the proposed expansion, various resources like raw materials, power, fuel, water,

manpower, etc will be utilized.

3.3.1 Land Requirement

As mentioned above, the proposed expansion shall be developed within existing premises by using the

existing infrastructure. No additional land will be purchased/procured for the proposed expansion. Plant

layout is attached as Figure No: 4. Land document is attached as Annexure-7.

Total Plot Area - 50,000 m2

Existing spare land of 2000 m2 will be utilized for the proposed expansion.

Table 1: Land Breakup

No. Description Existing Area (m2)

Proposed Area (m2)

Total Area (m2)

Percentage %

1. Plant Area 16,219 2000 18219 36.44

2. Ground coverage Area 13,931 -- 13,931 27.86

3. Future expansion 3,349 -2000 1349 2.70

4. Greenbelt area 16,501 -- 16,501 33.00

Total Area 50,000 0.0 50,000 100

3.3.2 Man Power Requirement:

The company has already employed maximum nos. of manpower from the nearby area. Same policy of

local employment will be followed for the proposed expansion project as well.

The existing unit has existing manpower of 104 nos. Additional manpower shall be employed during the

construction & operation phase directly and indirectly through contracts for Civil Construction, Piping

Works and Associated Amenities. Approximately 25 nos. of people will get direct employment during

the construction phase.

Based on the unit‟s organizational pattern, 12 nos. of additional technical staff will be required to

operate the plant for the proposed expansion.



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3.3.3 Electricity Requirement:

Source: Torrent Energy Ltd

Existing Contract Demand - 1900 KVA

Proposed additional Contract Demand – 1250 KVA

Total Contract Demand - 3150 KVA

Permission letter for the additional 1250 KVA load from Torrent Power is attached as Annexure-3.

The proponent is energy conscious and has taken various actions to reduce the power

consumption:

Replacing higher HP pumps with lower HP pumps

Replacing various lights with LED lights

Avoiding double pumping at various locations

Replacing cooling tower fans by FRP fans

Replacing electrical driven pump & blower with steam turbine driven etc.

3.3.4 Water Requirement:

Source of water: GIDC Water Supply

Total water requirement after proposed expansion will be 1000 KLD which will be supplied from GIDC

water supply. (Copy of the water withdrawal permission is attached as Annexure-4)

Table 2: Water Consumption

Existing (KLD)

Proposed (KLD)

Total (KLD)

i) Domestic Horticultural 50 00 50

ii) Industrial

a) Processing 17 06 23

b) Waste heat recovery

Boiler

595 201 796

c) Combination Cooling 80 35 115

d) Washing 8 8 16

Total Requirement 750 250 1000



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4.0 RAW MATERIAL AND PRODUCT DETAILS

4.1 Raw Material Details

An estimated requirement of various raw materials for the proposed expansion is given in following

table. The basic raw materials required are given below:

Table 3: Raw Material Consumption

No. Raw Material Existing Quantity

Per annum

Proposed Quantity

Per annum

Total Quantity Per annum

Mode of transportatio

n

1 Sulphur 65,250 MT 21,750 MT 87000 MT By Road

2 Natural Gas 97,469.17 SCM/Day 21,183.3 SCM/Day 118,652.47

SCM/Day Pipe line from

GSPC

3. Water 750 KLD 250 KLD 1000 KLD GIDC water supply Pipe

Line

4. Electric Power 1900 kVA 1250 KVA 3150 KVA -

4.2 Product Details

The unit is engaged in manufacturing CS2 with capacity of 75,000 MT/Annum and increase the

production capacity up to 100,000 MT/Annum.

Table 4: Details of Product

No. Product Existing

Quantity

Proposed

Quantity

Total

Quantity

1 Carbon Di-sulphide 75,000 MTPA 25,000 MTPA 100,000 MTPA

2 Steam Export 65,000 MTPA 20,000 MTPA 85,000 MTPA

5.0 MANUFACTURING PROCESS:

This plant will produce liquid Carbon Di sulphide (CS2) by using natural gas and melting sulfur as raw

materials, the whole process consists various units like of Molten Sulfur Preparation Unit, Natural Gas

Purification Unit, CS2 Synthesis Unit, CS2 Refining Unit, Sulfur Recovery Unit, Tail Gas Treatment Unit,

CS2 Tank Farm and Utilities to meet the requirements of process. The natural gas based proprietary

technology of CS2 production for this project has been provided by Shanghai Baijin Chemical Group

Company and same procedure will be adopted for the continued in the proposed expansion. The

synthesis process is as under:



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a) Liquid Sulfur Unit

Solid sulphur powder, granular or flake sulfur is acceptable and large lump sulfur is not permissible.

The Sulphur is stored in solid sulfur storage yard. It is then fed to melting sulfur tank and then the

molten sulfur is pumped into sulfur filter for filtration. Finally this on-spec liquid sulfur is flown into the

underground molten sulfur storage pit for pumping into the reacting furnace as the raw material of CS2

synthesis. While the liquid sulfur recovered by the flash system of the CS2 production and Sulfur

Recovery Unit, shall enter directly the underground pit of the liquid sulfur, where it is also transmitted by

the liquid sulfur feed pump to the CS2 reacting furnace for reaction. Provisions for receiving molten

liquid sulfur from outsource and unloading from liquid sulfur tankers directly into molten sulfur storage

tank are provided.

b) Natural Gas Purification Unit

Natural gas received is purified by the Natural Gas Purification Unit with Pressure Swing Adsorption

(PSA) unit to desired purity for the reaction. Off gases are used for reactor heating purposes.

c) Reaction Unit

Natural Gas – Sulfur Method is adopted with natural gas as feed for CS2 production.

CH4 + 2S2 CS2 + 2H2S

After the natural gas (feed natural gas), with its pressure stabilized via PSA purified gas buffer tank, is

metered accurately, it enters the preheating section of tubular heating furnace. After mixing with the

liquid sulfur (excess sulfur) from the liquid sulfur Unit via mixer, it enters the heating section of tubular

heating furnace, where the material is fluidized severely and the liquid sulfur vaporized. The gaseous

sulfur and natural gas (mainly methane) are heated with partial chemical reaction inside furnace. The

mixed gas coming from the tubular heating furnace enters the adiabatic reactor, while the unreacted

gaseous sulfur and natural gas continue to react inside the adiabatic reactor. Upon completion of

reaction, the reaction process gas coming from the adiabatic reactor is sent to the refining unit.

d) Refining Unit

The hot gases received from reaction section are cooled to recover Sulphur/H2S & CS2 is refined.

Recovered Sulphur is send to Sulphur tanks while H2S is send to Claus unit for further conversion to

elemental Sulphur.

e) CS2 Tank Farm

For the convenience of production management, the on-spec CS2 produced by CS2 Refinery Unit

enters the finished product intermediate tanks separately. The finished product produced in each shift,

after qualified via laboratory test, is sent by the finished product forwarding pumps, to the large CS2

tank in the tank farm or to the pitch-arm loading station for tank truck loading.



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f) Sulfur Recovery Unit

The sulfur recovery unit (SRU) comprises of one thermal reaction section and two catalytic reaction

sections. Here Sulphur is recovered from H2S based on partial oxidation of H2S, and subsequent

reaction of H2S and SO2.

g) Tail Gas Treatment Unit

In the tail gas treatment unit, the residual H2S containing gas from the Claus unit is recovered via

Amine absorption and regeneration process. The recovered gas is fed back to the Claus furnace for

recovery. The treated gas from the Amine section is then taken to a thermal oxidizer furnace, where

the traces of H2S remaining are converted to SO2, before the gases leave from the stack. This ensures

a recovery Efficiency of 99.9% in SRU.

h) Energy Saving & Heat Recovery Plan

The proposed plant will consist of various waste heat recovery boilers /turbines to recover energy in

most economical way. The plant will be self-sufficient in Steam production and also export steam to

neighboring company. An optimized energy saving scheme will be part of Basic Energy

Package.

Figure 5: Manufacturing Process flow sheet



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Salient Features of the Process/Technology adopted /to be adopted from old PFR

Existing CS2 manufacturing plant in India requires 350 kg charcoal per MT CS2 production

which comes from 1000 kgs of wood which results in to deforestation of 58 km2 per year.

SBC technology is well proven and replaces charcoal by Natural gas.

Proposed plant will be zero effluent discharge plant.

SRU is based on SCOT process technology, which shall achieve recovery efficiency of 99.9%.

6.0 ENVIRONMENTAL MANAGEMENT PLAN

6.1 Air Environment:

Adequate and efficient measures shall be provided to keep the process and dust emission at a minimum

level. The particulars of most specific individual sources and their pollution control measures are as

follows:

Table 5: Details of Air Emission

Sr. No.

Stack attached to Type of

Boiler/Furnace

Height of stack

(m)

Expected pollutants

APC

Existing

1. Tail Gas Treatment Unit & Flue Gas from Reaction heating Furnace

Incinerator

80 SPM, SO2,

NOx, Sulphur

recovery unit

2. Emergency System Venting (Emergency Flare Stack)

Flare

30 SPM, SO2,

NOx, --

3. D G Set of capacity 1650 kVA

Emergency Backup DG Set 11

SPM, SO2, NOx,

--

4. D G Set of capacity 1650 kVA

Emergency Backup DG Set 11

SPM, SO2, NOx,

--

Proposed

1. Tail Gas Treatment

Unit & Flue Gas

from Reaction

heating Furnace

Incinerator

Common Stack

with the

existing Unit

shall be used.

--

SPM, SO2,

NOx,

Tail Gas

Treatment

Unit, SRU

2. D G Set of capacity

1650 kVA Emergency

Backup DG

Set

11

SPM, SO2,

NOx, --



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Water Environment:

Water Consumption

Existing water requirement for domestic and industrial purposes is 750 KLD and is obtained from the

GIDC water supply.

Table 6: Water Consumption

Existing (KLD)

Proposed (KLD)

Total (KLD)

iii) Domestic Horticultural 50 00 50

iv) Industrial

e) Processing 17 06 23

f) Waste heat recovery

Boiler

595 201 796

g) Combination Cooling 80 35 115

h) Washing 8 8 16

Total Requirement 750 250 1000

Unit has implemented various schemes for water conservation such as –

Using treated waste water for make up in dyke wall

Steam condensate recovery system

Replacing filter press in waste water treatment plant with pressure sand filter

Providing side stream filter for cooling tower etc.

With all these actions, unit is able to operate plant with around 750 KL/day water consumption.

Additional 250 KLD water will be required for the proposed expansion.

Wastewater Generation:

Indo Baijin is/will be using high cost Hydrogen Reduction Technology instead of cheaper and generally

used desulphurization technology to eliminate generation of high quantities of waste water.

The wastewater is mainly the blow down water from various waste heat recovery units (waste heat

boiler), DM plant wash water, the unrecovered steam condensate (majority of which is recovered),

moisture separated in the oxidation tower, the ground flush water, etc. They are/will be collected, mixed

and cooled inside the plant, and then sent to the wastewater treatment unit.



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Table 7: Wastewater Generation

Existing wastewater

(KLD)

Proposed Wastewater

(KLD)

Total (KLD)

i) Domestic/ Horticultural 20 - 20

ii) Industrial

a) Processing 17 6 23

b) Waste heat recovery

Boiler 460 154 614

c) Combination Cooling 0 0 0

d) Washing 8 8 16

Total 505 168 673

Existing wastewater Generation:

1. The evaporation losses of 585 KLD from combination cooling tower, these water is coming from

80 KLD of fresh water and 505 KLD of recycle water steams from process, waste heat recovery

boiler, washing and domestic activities.

2. The total fresh water intake of 750 KLD is the sum of evaporation losses of 585 KLD in cooling

tower + 135 KLD steam export + 30 KLD horticulture consumption.

Proposed additional wastewater Generation:

1. The evaporation losses of 203 KLD from combination cooling tower, these water will coming

from 35 KLD of fresh water and 168 KLD of recycle water steams from process, waste heat

recovery boiler, washing and domestic activities.

2. The total additional fresh water intake of 250 KLD will the sum of evaporation losses of 203

KLD in cooling tower + 47 KLD steam export.

Conclusion:

Additional 250 KLD water will be required for proposed expansion as quantity of total proposed water

consumption will be greater than the granted water withdrawal permission from GIDC, Additional

water permission will be required due to proposed expansion. Permission has been obtained for the

additional 250 KLD water, which will be supplied from GIDC.

All the generated effluent is/will be evaporated in Combination Cooling Tower hence unit is/will be a

zero liquid discharge unit. Water permission letter has been attached as Annexure 4.



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Figure 6: Water balance diagram after proposed expansion, in KLD



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Action Plan for Zero Discharge of Effluent

a) Wastewater Streams :

i) Water from the Boiler feed water treatment plant comprising rejects from the demineralizing

section, and blow down water from boilers. The average composition of this stream is within 800

ppm of dissolved salts. The maximum quantity is 134 m3/day.

ii) From the tail gas treatment section of Sulphur recovery unit, the excess water condensed from

the flue gas is separated in the water removal tower. This water called Sour water has traces of

H2S. This is treated in an oxidation tower to convert the H2S into safe salt Na2S2O3. The maximum

quantity is 24 m3/day. The concentration of dissolved salts is within 200 ppm.

iii) The third stream is from general washing of plant and lab areas, this quantity is maximum

46m3/day. The concentration of dissolved salts is within 200 ppm.

Action Plan for Zero Waste Water Discharge:

As all the waste water streams are not having any COD and BOD, and only have shall quantity of

dissolved solids (salts), the design Philosophy of the plant has included the concept of „Zero Waste

Water Discharge”. In existing practice, Indo Baijin is using “Combination Type Cooling Towers” to

achieve zero liquid discharge and same shall be utilized after proposed expansion.

Figure 7: Flow Diagram of Combination Cooling Tower

Inside this cooling tower, the circulating cooling water flows through the inside of the cooling tube

bundles. This tube bundle is cooled from the outside in set up similar to a conventional cooling tower.



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The outside water is circulated and sprayed on top of the tube bundle, and also a draft is maintained by

a fan across the cooling tower. By evaporation of outside water, the water inside the tube bundle is

cooled and returned to the plant supply. As the outside water is not taken directly to the plant cooling

duties it can be used and circulated with high solid content.

Combination Cooling Tower Treatment Scheme

To understand the concept of this Combination type of cooling tower, we need to compare this with the

conventional cooling tower working.

Working of Conventional Cooling Tower:

In a conventional cooling tower, the cooling water return streams from the plant are cooled by direct

contact with air, and the cooling takes place by part evaporation from the circulating water. During this

process the salt concentration of the water increases, and some water is drained off as blowdown to

limit the concentration of salts in the cooling water circuit. This is required to ensure water quality fit for

heat transfer in the plant equipment. This demands that only clean good water is added for making up

the losses in the cooling water system which are based on conventional cooling towers.

The Working of Combination Cooling Tower:

In this cooling tower, the cooling operation in the cooling tower is separated & isolated from the

circulating cooling water used to remove heat from the plant equipment. This ensures a closed circuit for

cooling in the plant, and hence no contamination of this stream takes place. The hot return stream from

the plant is cooled by indirect contact in the cooling tower, by a local circulation of water which in turn is

cooled by evaporative cooling by contact with air.

The local circulation water stream in the cooling tower can be used continuously till it reaches a critical

concentration of dissolved solids, after which it is discharged to a final evaporator for separation of salts

for disposal. The design of the cooling tower ensures continuous wetting of heat transfer surface to

enable required evaporative cooling and maintaining clean surfaces without any scales formation. This

design feature is achieved by the patented co-current air-water flow technology by the supplier.

Due to these design features it is not necessary to add clean water make up in this type of cooling

tower. Hence in our units set up we add recycle water streams as part of makeup water to the cooling

tower. This enables recycling of all waste water streams (after suitable pre-treatment) of the plant as

make up to this cooling tower. Therefore the plant facility does not discharge any waste water from the

premises.



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The addition of recycle streams also enable saving of fresh water consumption of over 200 KLD for our

unit. Elimination of blowdown from the cooling tower saves another 80 KLD considering a concentration

cycle of 7. Therefore this system saves about 300 KLD or 100,000 m3/Annum for our unit.

In our existing project these is served as the Heat Sink and also Zero Discharge Unit, by combining the

functions of the cooling tower and also a water evaporator. Adequate overdesign has been built into this

system to ensure sufficient spare capacity. After proposed expansion there will be additional 3 nos. of

Combination cooling tower.

Domestic Waste Water:

The domestic waste water streams shall be treated in a modern packaged sewage treatment unit with

capacity of 50 KLD, and the treated water shall be available for reuse in toilets, and feeding to the Zero

Discharge cooling tower unit. After proposed expansion,12 nos. of additional workers will be employed

for process work. Thus existing STP will be sufficient for the domestic wastewater generation after

proposed expansion.

Figure 8: Sewage Treatment Plant (STP) Flow Diagram



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Table 8: Sizing of Sewage Treatment Plant

S. No Unit Size

1. Collection tank 3 m X 1 m X 3 m

2. Aeration tank 3 m X 3 m X 3 m

3. Clarifier 1 m X 1 m X 2 m

4. Treated water tank 2 m X 2 m X 3 m

5. Filtered water tank 2 m X 2 m X 3 m

6. Sand filter cum solid collection tank 2 m X 2 m X 3 m

7. Sludge Drying Bed, 3 nos. 3 (1 m X 1 m X 2 m)

6.2 Solid/Hazardous Waste

The entire quantity of hazardous waste is handled and disposed as per Hazardous Waste

(Management, Handling and Trans-boundary Movement) Rules - 2016. Furnace slag from furnace pipe

and reactor cleaning, Used spent Oil, Discarded Container/Barrels/Liners, Evaporation salt and Sludge

from sulfur filter are generated from existing unit. Unit has obtained membership for BEIL (Attached as

Annexure-6). After expansion, no additional quantity of Hazardous waste will be generated except

Sludge from sulfur filter. As a solid waste STP sludge is generated, this is used as manure in the

premises.

Table 9: Hazardous/Solid Waste Generation

No. Name of Waste Waste category

Existing Total after Proposed expansion

Solid waste Disposal / Management

1 Furnace slag from furnace pipe and reactor cleaning

1.1 55 MTPA 85 MTPA Collection, Storage, Transportation & Disposal at common incineration facility.

2 Used spent Oil 5.1 1.0002 MTPA

1.5002 MTPA

Collection, Storage, Transportation & Disposal by selling to register refiners

3 Discarded Container/Barrels/Liners

33.3 100 MTPA 100 MTPA Collection, Storage, Transportation & Disposal by GPCB approved scrap dealer

4 Evaporation salt Sch: I/35.3 144 MTPA 144 MTPA Collection, Storage, Transportation & Disposal at TSDF, BEIL.

5 Sludge from sulfur filter -- 78 MT/Year

78 MTPA

Collection, Storage, Transportation & Disposal at common incineration facility.

6 STP Sludge -- 30 kg/day -- Used as manure



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No. Name of Waste Waste category

Existing Total after Proposed expansion

Solid waste Disposal / Management

7 Spent Catalyst and Molecular sieves

1.6 -- 67 MT Collection, Storage,

Transportation &

Disposal at common

incineration facility.

8 Residue Carbon 18.2 - 2 MT Collection, Storage,

Transportation &

Disposal at common


9 Spent Ion Exchange Resin

35.2 - 2 MT Collection, Storage,

Transportation &

Disposal at common


10 Wastage or residue containing oil,


Transportation &

Disposal at common


11 Contaminated Cotton rags or other cleaning materials


Transportation &

Disposal at common


6.3 Noise Environment

The industry is in the SEZ area and located 8-km away from the nearest settlement. There are two

categories of noise generated due to the unit.

Noise due to plant operation

Noise due to transportation of vehicles.

Noise Control Measures:

All the vibrating parts are checked periodically and serviced to reduce the noise generation. The

equipment, which is prone to generate excessive noise, is already provided with enclosures. To

minimize the adverse effect on the health, ear muffs/ earplugs is provided to the workers working

under high noise area.

The industry has already developed 16500 m2 area for green belt around the periphery of the plant.

This will help in reducing the adverse effect of noise pollution in general. All the equipment in the

complex is designed/operated in such a way that the noise level shall not exceed 85 dB (A).



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All rotating equipment in the plant would be designed/operated to have a total noise level not

exceeding 85 to 90 dB (A) as per the requirement of OSHA (Occupational Safety and Health

Administration) standard and the Environment (Protection) Rules.

However, if during operation, the noise level exceeds the above norms then the protective measures

given in Environmental Management Plan will be followed. Hence, no impact due to proposed plant on

ambient noise is anticipated.

6.4 Occupational Health & Safety Management

The company is very much concerned in terms of health, safety and environment protection. Indo

Baijin commitment towards safety can be reflected from its „Health, Safety & Environment Policy‟

prepared for the existing project.

No major accident has taken place in the factory so far in the existing project. From their previous

performance, same dedication is to be continued for the proposed expansion. To maintain high

standards in Health, Safety and Environment, various activities are undertaken at the site.

The following key safety measures are implemented in the existing plant and the same shall be a part

of proposed expansion project:

1. Safety Training is provided to the employees.

2. Safety Sirens with Alarm System in case of emergency are provided.

3. Emergency Control Room is established.

4. Assembly point is provided.

5. Sprinkler Systems will be provided as needed.

6. Fire Hydrant System is installed.

7. Fire Extinguishers are provided.

8. Mock drills are periodically conducted and factors like response time are evaluated.

9. Fire squad team is formed for handling any emergency situation.

10. First Aid Facility and training are provided.

11. Personal protective gears and equipments are provided to employees.

12. Health check-ups are organized at regular intervals.

13. Safety / Health records are maintained.

14. MSDS for all the chemicals are easily available.

Details of Fire Protection System:

Outdoor Fire Hydrant 20

Indoor Fire Hydrants 36

Fire Hose – Size – 15 mtr. 120

Water Monitor – Manual 10

Water Monitor – Electrically Remote Operated 02

Water Spray Cooling System at CS2 Tank Farm 01



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Water spray system at CS2 loading area 01

Dedicated storage of water for firefighting in lit 3218 M3

Manual Call Points 48

Continuous Gas Detectors CS2 14

Continuous Gas Detectors H2S 26

Continuous Gas Detectors CH4 16

Heat Detectors 04

Breathing Sets 17

Fixed Air-line system 10

7.0 SITE ANALYSIS

7.1 Connectivity

The project location is well connected with road, rail and air route to transport raw materials,

machineries, etc. and hence it exhibits good potential for industrial growth. The salient features

mentioned below, indicate favorable conditions for industrial development at the project location.

Table 10: Salient Features of the project site

Particulars Details

Approx. Geographical Co-ordinates

Latitude Longitude

A 21°42'35.74"N 72°37‟06.78"E

B 21°42'36.02"N 72°37'10.94"E

C 21°42'27.10"N 72°37'11.04"E

D 21°42'30.92"N 72°37'10.30"E

Village Vadadla(@ 2.4 km in NE direction)

Nearest Town Bharuch (@ 40.0 km in E direction)

Nearest City Bharuch (@ 40.0 km in E direction)

River/Streams Narmada Estuary (@3.00 km in S direction)

Sea Arabian Sea (@ 11.0 km in W direction)

Nearest Highway

N. H. No – 228 (@ 36 km in E direction)

N. H. No –8 (@ 36 km in E direction)

S. H. No – 6 (@ 42 km in EEN direction)

Nearest Railway Station Dahej Railway Line (@ 2.50 km in WWN direction)

Bharuch (@ 40 km in E direction)

Nearest Airport Surat Airport (@ 66 km in SSE direction)

National parks/ sanctuaries None within 10 km radial area



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Defense installations None within 10 km radial area

Note: All the above – mentioned distances are aerial distances from the project site.

7.2 Topography

Proposed expansion is between 20007” to 21005” North Latitude and 72043” to 73000” East Longitude

having elevation of 25 meters above sea level. The topography of the proposed site for the project is

plain terrain.

No forests, national park or wild life sanctuary is located within 10 km periphery of the project site. No

change in Land use/Topography is envisaged as the proposed project is expansion project and is

established in SEZ-1, Dahej.

7.3 Existing Infrastructure

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

such as park, market, playground etc. education, health care, community development, income

distribution, employment and social welfare are available in the study area of project site.

7.4 Soil Classification

Proposed expansion will be carried out in existing premises located in SEZ, where land is already

developed for industrial purpose. Quality of soil is not considerably fertile for agriculture activities and

no evidence of any influence of soil contaminant has been noticed.

7.5 Climate Data From Secondary Source

Table 11: Climate Data

Climate Type and Details

Climate Temperate climate-Semi Arid

Seismic Zone Zone III

Maximum temperature, °C 44 °C

Minimum temperature, °C 12°C

Relative Humidity Max.:- 97 %; Min.:- 20%

Max Rainfall 1500 – 2200 mm

Climate Temperate climate

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

Proposed expansion activities will be started after getting statutory clearance from related authorities.



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8.2 Project Cost Estimation

No. Project Estimate cost

1 Proposed expansion cost 100 crore

8.3 Activities

Indobaijin which is a part of Indofil Group Company has always engaged in social welfare activities &

programs. It directly organizes various programs for social welfare & upliftment or indirectly contributes in

such activities conducted by other organizations by providing financial & other aid. Indobaijin is

committed to contribute in social welfare & upliftment activities on a regular basis. Indobaijin will continue

such activities to fulfill the requirements of its social responsibility under CER Programs. With

development of community services like medical services, blood donation camp, donation for schools etc

will also be developed as a part of corporate social responsibility. Medical camps and education

programmes would be conducted for the welfare of employees and their families.

Indo Baijin Chemicals Pvt Ltd. in collaboration with a non-government organization (NGO) Ballygunge

Society for Environment & Development undertakes CER activities in the village Purba Gopinathpur. The

following activities are evident of the fact that Indo Baijin is a promoter of CER Programs:

Donation given to JCI - Bharuch for Election Awareness Campaign organized by them at

Dahej.

Donation given to former CM of Gujarat (Mrs. Anandiben Patel) under Clean India Campaign.

Food Packets distributed to poor villagers of Vagra Taluka who attended “Garib Kalyan Mela”

at Jambusar.

Organised various seed to seed demonstrations, soil testing and training on safe and judicious

use of pesticides.

Operated Agril Library having more than 200 books on agriculture thrice a week at the local

club premises.

Provided computer training through two trainers to 80 students thrice a week.

Trained 65 young people, mostly girls, for athletics and 40 youths for football, twice every

week, under eminent coaches.

Organised health camps once in every fortnight to provide treatment for ailment and health

counseling.

Constructed sanitary facilities, especially for girls and women, at the village club premises.

Planted around 250 saplings throughout the village.

Organised cultural programmes, rally and competitions to increase awareness about the

environment.

Provided Shoe stand for Dahej School and Hostel for the students in tribal Area.

Houses for Poor Villagers of Dahej: Construct 5 (five) houses for poors of Dahej village. This

will be sample houses. Based on the success of this; new project will be assigned.

Development of Digital Classroom: Two digital class rooms have been constructed at Dahej

Girls‟ School by The Industry.



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Blood donation camp has been organized by the industry at Indofil industries Ltd.(Unit-2) on

October 2018.

About 30 students have been visited Unit 1 & 2 on 18 January 2019 to get Industrial exposure

of latest lab instruments.

Donation of Rs. 50,000 to the Bhootnath Trust of Dahej for “Samooh Lagan” (marriage of 48

couples from needy family) at Dahej.

Donation of computer set to the school of Dahej.

Financial & Social Benefits

The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to

be purchased.

This project utilizes natural gas as one of the raw materials for the synthesis of the product.

Currently all the existing CS2 manufacturing units in India use wood charcoal for this purpose.

Considering 350 kilograms of charcoal consumption per ton of CS2, one ton of wood is used per

ton of CS2. Thus at 100,000 tons of CS2 production per annum, this project will reduce

deforestation to the extent of 58 km2 per year in the country. Thus, the project entails financial

benefits in terms of energy saving.

The company has also allocated some budget for CER activities, which can lead to improved

social infrastructure, if planned properly.

Temporary employment of 25 people during the construction phase of the proposed expansion.

Employment to approx. 12 people is a direct benefit.

Conclusion:

As summarized in the above sections, it has been noticed that the proposed project for expansion in

capacity will not have any major impacts, which can lead to serious issue of environmental pollution

or any other hazards.

Considering the probability of impacts, proponent has planned adequate mitigation measures and

EMP. Further, it is also planned by proponent to organize CER programs, rainwater harvesting,

energy conservation, which will have considerable beneficial impacts. Looking to the employment

potentials and other allied developmental potentials, it is noticed that the proposed project will

significantly help in improving social status of the region.



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Annexure 1: Existing Environmental Clearance



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Annexure 2: Consent to Operate (CC&A)



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CC&A



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Amended CC&A



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Annexure 3: Electricity Permission Letter



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Annexure 4: Water withdrawal Permission from GIDC



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Annexure 5: EC letter for Dahej SEZ



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Annexure 6: BEIL Membership Letter



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BEIL Application for Catalyst/Resin



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BEIL NOC for receiving Incinerable/co-process waste



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Annexure 7: Land Documents



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