1

PRE FEASIBILITY REPORT

INCREASE IN THE PRODUCTION OF

PENTAERYTHRITOL FROM 560 MTM TO 730 MTM &

SODIUM FORMATE FROM 336 MTM TO 480 MTM

(PRODUCT IS IN POWDER & SOLUTION FORM)

at

SIPCOT INDUSTRIAL COMPLEX, CUDDALORE, TAMILNADU,

INDIA

ASIAN PAINTS LIMITED

Penta Division, B-5 to B-10, SIPCOT Industrial Complex,

Kudikadu Village, Cuddalore, Tamil Nadu – 607005

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CONTENTS

1 Executive Summary.................................................................................................... 5

2.0 Introduction of the Project and Background Information .......................................... 7

2.1 Identification of the Project and Project Proponent .................................................. 7

2.2 Brief Description of Nature of Project ...................................................................... 7

2.3 Need for the Project and its Importance to the Country ........................................... 8

2.4 Demand Supply Gap ............................................................................................... 8

3.0 Project Description ................................................................................................ 10

3.1 Type of Project Including Interlinked and Interdependent Projects ........................ 10

3.2 Location of the Project .......................................................................................... 10

3.3 Details of Alternate Site ........................................................................................ 10

3.4 Size or Magnitude of Operation............................................................................. 10

3.5 Project Description with Process Details ............................................................... 10

3.6 Raw Material Required along with Estimated Quantity .......................................... 12

3.7 Resource Optimization/ Recycle and Reuse ......................................................... 12

3.8 Availability of Water and its Source ....................................................................... 13

3.8.1 Power Requirement ........................................................................................... 13

3.9 Quantity of Wastes to be Generated (Liquid and Solid) and Scheme for their

Management Disposal. .................................................................................................... 13

3.9.1 Industrial Waste Management ........................................................................... 13

3.9.2 Solid Waste Management ................................................................................. 14

3.9.3 Method of Disposal of HZW ............................................................................... 14

4.0 Site Analysis ......................................................................................................... 16

4.1 Connectivity .......................................................................................................... 16

4.2 Land Form, Land Use and Land Ownership .......................................................... 16

4.3 Topography along with Map .................................................................................. 16

4.4 Existing Land Use Pattern ..................................................................................... 16

4.5 Existing Infrastructure ........................................................................................... 16

3

4.6 Soil Classification .................................................................................................. 16

4.7 Climatic Data from Secondary Sources ................................................................. 16

4.8 Social Infrastructure Available ............................................................................... 17

5.0 Planning Brief ....................................................................................................... 18

5.1 Planning Concept ................................................................................................. 18

5.2 Population Projection ............................................................................................ 18

5.3 Land Use Planning................................................................................................ 18

5.4 Assessment of Infrastructure Demand (Physical & Social) .................................... 18

5.5 Amenities/Facilities ............................................................................................... 18

6.0 Proposed Infrastructure ........................................................................................ 20

6.1 Industrial Area (Processing Area) ......................................................................... 20

6.2 Residential Area (Non – Processing Area) ............................................................ 20

6.3 Greenbelt .............................................................................................................. 20

6.4 Social Infrastructure .............................................................................................. 20

6.5 Connectivity .......................................................................................................... 21

6.6 Drinking Water Management ................................................................................ 21

6.7 Industrial Waste Management/ Solid Waste Management .................................... 21

6.8 Power Requirement Supply and Source ............................................................... 21

7.0 Rehabilitation and Resettlement Plan ................................................................... 21

8.0 Project Schedule and Cost Estimates ................................................................... 21

8.1 Likely Start Date and Completion .......................................................................... 21

8.2 Estimated Project Cost ......................................................................................... 21

4

List of Tables

Table 1 Salient Features of the Site ................................................................................... 5

Table 2 Expansion Details ................................................................................................. 7

Table 3 Production Capacity of Pentaerythritol ................................................................ 12

Table 4 Raw Material Requirment ................................................................................... 12

Table 5 Power Requirement ............................................................................................ 13

Table 6 Hazardous Waste Generation ............................................................................. 14

Table 7 Details of Solid Waste which are not listed in the current consent ....................... 14

Table 8 Climatic Data ...................................................................................................... 17

Table 9 Land Breakup Details ......................................................................................... 18

Table 10 Existing Infrastructure ....................................................................................... 20

Table 11 Project Cost Estimation ..................................................................................... 22

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1 Executive Summary

Asian Paints is India’s leading paint company with a consolidated turnover of `

15,841.70 crores (158.4 billion). Asian Paints along with its subsidiaries have

operations in 19 countries across the world with 26 paint manufacturing facilities,

servicing consumers in over 65 countries through Berger International, SCIB Paints –

Egypt, Asian Paints, Apco Coatings, Taubmans and Kadisco. Asian Paints has also

marked its foray into the Home Improvement and Décor space in India with the

acquisition of Sleek group – a kitchen solutions provider and Ess Bathroom Products

- a prominent player in the bath and wash segment in India. Asian Paints Limited is

headquartered in Mumbai, Maharashtra. Asian Paints is India's largest and Asia's

fourth largest paints company (mentioned in Coatings world – 2016 top companies

report (July 2016). As of 2016, it is the leading paint company in India (mentioned in

Cyber Media Research Limited).

Asian Paints Limited, Penta Division intends to increase the production of

Pentaerythritol and Sodium Formate within the existing plant in an existing plant

encompassing an area of 29.20 Acres situated in SIPCOT Industrial Complex,

Kudikadu Village, Cuddalore District, Tamil Nadu.

The proposed expansion is the production of Pentaerythritol from 560 MTM to 730

MTM, and Sodium Formate from 336 MTM to 480 MTM in solid and solution form. The

prominent features of the proposed expansion project is given in Table 1.

Table 1 Salient Features of the Site

Sl.no Description Details

1 Name of the Project production of Pentaerythritol from 560 MTM to 730 MTM, and Sodium Formate from 336 MTM to 480 MTM, by Asian Paints Limited, Penta Division

2 Schedule as per EIA Notification, 14th September 2006.

5(f), Synthetic Organic Chemicals

3 Area required 29.20 Acres, Establishing within the Existing facility, hence no further land required for expansion.

4 Location Located in SIPCOT Industrial Complex, Cuddalore, Tamil Nadu.

5 Plot No Plot no B5 – B10

6 Site Elevation Ranging from 5 to 8 meters above MSL

7 Cost of the Project Rs 4.8 Crores

8 Total water requirement 695 KLD will be sourced from SIPCOT supply(no change)

9 Nearest Railway Station Capper Quarry Railway Station 400 meters West

10 Nearest Highway NH 45A Chennai to Nagapattinam 20 meters West

6

11 Nearest City Nearest city- Cuddalore Old Town – 4 Km N District Headquarters – Cuddalore – 7 KM NW

12 Mean Maximum Temperature 35.6 0C

13 Mean Minimum Temperature 20.8 0C

14 Seaport Connectivity Cuddalore 3.5 km North

15 Water Bodies Uppanar River – 0.5 km Perumal Lake – 5.0 Km Bay of Bengal – 3.0 Km

16 Forest Area None in Study Area

17 Archaeological Places None in Study Area

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2.0 Introduction of the Project and Background Information

2.1 Identification of the Project and Project Proponent

M/s Asian Paints limited, Penta Division located at plot no B5 – B10 SIPCOT Industrial

Complex, Kudikadu Village, Cuddalore is engaged in manufacturing of Pentaerythritol

and Sodium Formate. The proposed expansion project is establishing at a capital cost

of Rs 4.8 Crores. Asian paints limited is the India’s largest paint company and is

amongst the top 10 decorative paint manufacturing companies in the world with

operations across 22 countries and 30 manufacturing plants. The company has an

enviable reputation for world class EHS practices with corporate philosophy to much

beyond environmental compliance. Penta division of Asian Paints at Cuddalore has

been accredited with ISO 9001, 14001 and OHSAS 18001 certifications. The

expansion details is given in Table 2.

Table 2 Expansion Details

Details Existing (MTM) Proposed (MTM)

Pentaerythritol 560 730

Sodium Formate 336 480

This Pre-feasibility Report is based on proven production technology, market demand,

site suitability with respect to environmental norms, available infrastructure and

economic viability of the project.

2.2 Brief Description of Nature of Project

Pentaerythritols are speciality chemicals finding application in manufacturing of resins

used in protective coatings, as an additive in synthetic lubricants used in aviation

industry apart from other numerous applications. Sodium Formate finds application in

the chrome tanning process for the processing of leather and onshore drilling process.

Penta plant is going to be made modern with field level automations and effective

utilisation of manpower. The raw material requirement for the production of

Pentaerythritol consists of Acetaldehyde, Formaldehyde, Caustic and Water. Quantity

may vary based on the final grades/product mix of Pentaerythritols.

Pentaerythritol is a speciality chemical finding application in manufacturing of resins

used in protective coatings, as an additive in synthetic lubricants used in aviation apart

from other numerous applications. Sodium formate finds application in the chrome

tanning process for the processing of leather and onshore drilling process.

8

Asian Paints Limited, Penta Division intends to increase the production of

Pentaerythritol and Sodium Formate within the existing plant in an existing plant

encompasses an area of 29.20 Acres situated in SIPCOT Industrial Complex,

Kudikadu Village, Cuddalore District, Tamil Nadu. The proposed expansion is the

production of Pentaerythritol from 560 MTM to 730 MTM, and Sodium Formate from

336 MTM to 480 MTM in solid and in solution form.

2.3 Need for the Project and its Importance to the Country

Requirement of Pentaerythritols in India is growing at the rate of 6.5 %. CAGR is driven

by strong growth in Industrial and Automobile sector. Growing disposable income

along with growing life style aspirations of people have resulted into increased demand

for paints which use Pentaerythritol as one of the input Raw Material.

Looking at the Indian markets and availability of appropriate technology, it is proposed

to increase production of Pentaerythritol & Sodium Formate since the market is well

developed in many parts of India.

2.4 Demand Supply Gap

At present the consent limit of Pentaerythritol by Asian Paints is 6720 MTPA while the

market demand for Pentaerythritol in India in FY 2017 is 31,000 MTPA with a growth

rate of 6.5%. The main key consumers for the pentaerythritol in India are Asian Paints

Limited, Berger Paints and Kansai Nerolac. Consumption of Pentaerythritol by Asian

Paints itself is approximately. 31% (9610 MTPA). India imports 19,000 MTPA from the

global markets. Import of Penta come from Perstrop (Saudi & Sweden) about 13000

MTPA followed by Japan, Taiwan and China.

This expansion will help country save on valuable foreign exchange while increasing

revenue from exports.

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2.5 Export Possibility Domestic/Export Markets

The finished products will be sold in domestic market and in export markets in USA,

Colombia and Netherlands.

2.6 Employment Generation

The plant will be modernized with field level automation & it will further reduce manual

intervention. Therefore, requirement for additional manpower is not required for the

project.

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3.0 Project Description

3.1 Type of Project Including Interlinked and Interdependent Projects

There are no interlinked or inter dependent projects on this Plant.

3.2 Location of the Project

The activity will be carried out within the existing plant located in SIPCOT industrial

complex, Kudikadu Village, Cuddalore District, Tamil Nadu. The site is at a distance of

about 0.5 Km from National highway 45A. The coordinates of the site is 110 38’ 49.67’’

N and 790 44’ 22.50’’ E, the mean average of the site is ranging from 5 to 8 meters

above MSL.

3.3 Details of Alternate Site

Since the proposed project is expansion of production of Pentaerythritol from 560 MTM

to 730 MTM, and Sodium Formate from 336 MTM to 480 MTM, by Asian Paints

Limited, Penta Division within the existing plant premises located at SIPCOT,

Cuddalore. No additional land is required for the proposed capacity expansion. Hence,

alternate sites were not considered.

The existing project site is having following infrastructure amenities:

Availability of utilities – electricity and Process Water

Availability of land, approach roads& accessibility to highway.

Topography of land & geological aspects

Nearness to rail head, transport logistics.

3.4 Size or Magnitude of Operation

Asian Paints Limited, Penta Division has proposed to increase the production of

Pentaerythritol from 560 to 730 MTPM and sodium formate from 336 MTPA to 480

MTPM through process automation, reliability improvement projects, de-bottlenecking

and process optimization at SIPCOT industrial complex.

3.5 Project Description with Process Details

Proposed increase in the production capacity from 560 MTM to 730 MTM of

Pentaerythritol and from 336 MTM to 480 MTM of Sodium Formate. The production

rates of proposed expansion is given in Table 3. The increase in production capacity

is envisaged through

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Process Modification.

Process Automation

Reliability improvement

Debottlenecking activities

Process Automation

It is proposed to do field level automation and online conductivity measurement for

Deioniser section for operations. It is proposed to do field level automation in Mono

Pentaerythritol section for avoiding chocks and quality consistency.

Process Modification proposed for improvement in Quality

Currently we are able to cater few grades of Pentaerythritols only. Demand from

market for higher purity Pentaerythritols is proposed to be met by way of the following

activities:

1) Maintaining the Formaldehyde concentration from 10% to 11.5 % in the reaction

stage.

2) Better purification through additional washings in the filtration and centrifuge

operations.

3) Reducing the operating cycle of Deionizer resin columns by frequent

regenerations.

De - bottlenecking Activities proposed for increase in capacity

The following number of debottlenecking activities are proposed to enhance the

production capacity of the plant:

Pre-cooling of formaldehyde solution - To cool the formaldehyde solution prior

to reaction start up in a tank and then start the reaction process to reduce batch

cycle time.

Reducing cycle time – To increase pumping capacities in Reactor and

Evaporator section to increase the process throughput.

Augmentation of Heat exchangers to improve heat recovery.

Improved cooling tower performance to cater to the additional heat load on

account of increased throughput.

Modification in piping around reactor - Reduction of reaction cycle time by

providing faster draining of residual hold up material from the reactor.

Elimination of Transfer delays by automation in the specific batch processes

such as reaction and mono pentaerythritol section.

To replace in process tanks with higher capacity and crystallising facility to

cater to the increased production requirement.

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Table 3 Production Capacity of Pentaerythritol

Number of Reactions /day MT

per Reaction for avg 30 operating days in a

month

Details of proposed Debottlenecking

Activity

Proposed Reduction in Batch cycle time (minutes)

Reaction Batches per day for avg 30 operating days in a month

Increase in reaction nos. per day due to the proposed changes

Proposed increase in Production (including

Penta solution)

MTS/Day

Proposed increase in Production MTS/Month

% Contribution to proposed increase in

capacity

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Pre Cooling of Formaldehyde Solutions.

9 20.17 2.17 2.31 67.48 39.76

Elimination of Transfer delays by automation.

4 21.36 1.20 1.28 37.25 21.95

Modification of piping around reactor:

5 23.08 1.71 1.83 53.28 31.40

Revamping of pumping facilities in Reaction.

1 23.45 0.38 0.40 11.70 6.89

Total savings 18.6 5.45 5.82 170.00 100.00 Existing

Production

MTS per

month

(including

Penta

solution )

560 Total Proposed increase in Production from current level in MTM 730

Total no. of reactions after modification/ day 23.45

Production per month of Pentaerythritol in Metric Tonne per month including Pentaeythritol solution

730

Production per month of Sodium Formate in Metric Tonne Production per month including Sodium Formate solution

480

Maximum operating days considered is 30 in a month.

3.6 Raw Material Required along with Estimated Quantity

Methanol, acetaldehyde and Caustic Soda are the main raw materials required for the

production. The details are given in Table 4.

Table 4 Raw Material Requirment

Sl. No Raw Material Existing

Requirement, MT/Month

Expected Requirement,

MT/Month

Mode of Transport

1 Methanol 800 800 Tanker

2 Acetadehyde 224 292 Tanker

3 Caustic Soda 465 640 Tanker

3.7 Resource Optimization/ Recycle and Reuse

The following hierarchy is followed for waste management with an ultimate aim of “Zero

Waste”.

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Resource Conservation

Elimination of Waste Streams

Minimizing Waste

Reuse of Wastes

Recycle of Wastes

Treatment and Disposal for making wastes harmless

Wash water generated from cleaning of equipment’s will be re-used back into the

process/product.

3.8 Availability of Water and its Source

Make up water for the expansion of the plant is estimated to be 695 KLD which will be

supplied by the SIPCOT. There is no change in water consumption envisaged.

3.8.1 Power Requirement

The plant has a captive power generation, a steam generation of 30 TPH boiler will be

used and coal as a primary fuel. The power required is given in Table 5.

Table 5 Power Requirement

Captive power plant Existing Proposed Expansion

Power 1.5 MW 1.5 MW

Steam generation 16 TPH 30 TPH**

** Spare Boiler of 14 TPH capacity will be used to increase the required steam generation

Additional standby boiler of (8-10 TPH) capacity will be procured to cater for the startup operations.

3.9 Quantity of Wastes to be Generated (Liquid and Solid) and Scheme for their

Management Disposal.

3.9.1 Industrial Waste Management

Hazardous waste from process (ETP Sludge and Spent Carbon) is being sent to TSDF

facility IWMA Gummidipoondi. The amount of HZW anticipated to generate is given in

Table 6. Handling and disposal of HZW shall comply with TNPCB norms.

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Table 6 Hazardous Waste Generation

Solid Waste Type Existing Quantity

Expected Quantity

Mode of Disposal

Spent Carbon (Kg) 200 7780 To authorised waste processing agency

Used Spent Oil (Lts)

900 900 To authorised waste processing agency

Waste Oil (Lts) 300 300 To authorised waste processing agency

Sludge (Tons) 128 172* TSDF Gummidipoondi, Chennai

* In order to obtain the desired purity level in the products, regeneration rate of

deioniser column will increase from every 1.5 days to every day due to faster saturation

of resin column.

3.9.2 Solid Waste Management

There are two types of solid wastes generated – process wastes and non-process

wastes, which may or may not be hazardous in nature. The waste water from

manufacturing process, washings, etc. will get treated in the effluent treatment plant

and that will give rise to sludge. The other type of solid wastes generated will include

the dust collected from dust collectors, empty barrels (metal and plastic), bags,

sweepings and other biodegradable waste from canteen. Solid waste of organic nature

such as canteen wastes, STP sludge, sweepings etc. will be composted or vermin

composted for use as manure in the greenbelt and lawns. Other non-hazardous waste

like empty container, bags, paper/cardboard, metal, wooden waste etc. will be sold to

external agency. The hazardous waste will be disposed of through authorized TSDF

as land filling. The following solid waste is expected during the implementation of the

proposed project, details given in Table 7.

Table 7 Details of Solid Waste which are not listed in the current consent

Waste type Kgs Expected Quantity( Kgs)

Ion Exchange Resins 9600

Used Insulation Material 4100

Use HDPE bags 5200

Used Filter Clothes 3000

3.9.3 Method of Disposal of HZW

The hazardous waste will be sent for disposal into hazardous waste landfill site

authorized by the State Government.

Mitigation Measures to be adopted

15

Hazardous waste will be sent to an authorized TSDF site. All hazardous wastes shall

be securely stored, under a shed for eventual transportation to the authorized TSDF,

the solid domestic waste shall be stored within the premises temporarily and then

sent to common solid waste disposal facility

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4.0 Site Analysis

4.1 Connectivity

The site is at a distance of about 0.5 km from National Highway NH45A. The nearest

railway station is Cuddalore at a distance of 5 Km, site is at a distance of 200 km from

Chennai International Airport, and 5 km from sea port.

4.2 Land Form, Land Use and Land Ownership

Asian Paints Limited, Penta Division intends to increase the production of

Pentaerythritol and Sodium Formate within the existing plant in an existing plant

encompasses an area of 29.20 Acres situated in SIPCOT Industrial Complex,

Kudikadu Village, Cuddalore District, Tamil Nadu. The proposed expansion is located

in the notified industrial area.

4.3 Topography along with Map

The topography of the site is flat and less undulated. The slope gradually tends to lean

from SW to NE, the elevations are ranging from 5 – 8 meters above MSL.

4.4 Existing Land Use Pattern

The project location is established in notified Industrial Area.

4.5 Existing Infrastructure

Required infrastructure facility are prevailing in the proximity of existing project site.

4.6 Soil Classification

The texture of the soil investigated and found out to be a sandy soil.

4.7 Climatic Data from Secondary Sources

Cuddalore experiences a Tropical wet and dry climate, the yearly meteorological

data of the Cuddalore is taken from IMD data 1961-1990. IMD data is given in

Table 8.

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Table 8 Climatic Data

IMD Station Cuddalore – 110 46’ N, 790 46’ E

Month Temperature 0C

Humidity % Rainfall mm Wind speed kmph

Predominant wind

direction Min Max 8.30 Hrs

17.30 Hrs

Monthly mm

No of rainy days

Jan 20.2 28.4 85 70 42.9 1.9 3 NE

Feb 20.8 29.7 84 69 17.1 0.8 5 NE

Mar 22.7 31.5 81 70 17.2 0.9 7 SE

Apr 25.5 33.5 75 73 6.5 0.5 6 SE

May 26.8 36.4 68 72 36.4 1.7 3 SE

June 26.6 36.9 64 62 36.5 2.7 2 SW

July 25.5 35.4 70 65 89.1 5.9 3 SW

Aug 25.0 34.6 74 68 143.9 7.6 4 SW

Sep 24.6 33.6 76 73 136.6 6.7 5 SE

Oct 24.0 31.7 83 73 261.4 9.7 5 SE

Nov 22.4 29.4 85 76 374.0 10.9 4 NE

Dec 21.2 28.3 86 75 196.6 7.1 2 N Source : GoI, Ministry of Earth Sciences, IMD, Climatological Norms 1961-1990

4.8 Social Infrastructure Available

All infrastructure facilities such as education, health facilities and other social facilities

are adequate at district headquarter.

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5.0 Planning Brief

5.1 Planning Concept

Asian Paints Limited, Penta Division has proposed to increase the production of

Pentaerythritol from 560 to 730 MTPM and sodium formate from 336 MTPA to 480

MTPM through process automation, reliability improvement projects, de bottlenecking

and process optimization at SIPCOT industrial complex.

5.2 Population Projection

The study area of 10 Km has been studied for projected population, it’s observed that

46 villages are present near the study area with a total literacy population of 49,976

out of total population 83,839.

5.3 Land Use Planning

The proposed activity will be carried out within the existing plant located in SIPCOT

industrial complex, the identified plot has an area of 29.20 Acres. The land breakup

details of the site is given in Table 9.

Table 9 Land Breakup Details

Sl. No Description Area in Acres % Allocation

1 Plotted Industrial Area 5.6 19.17

2 Greenbelt 15.7 53.76

3 Roads 2.6 8.9

4 Lawn and garden 5.3 18.15

Total Area 29.2 100

5.4 Assessment of Infrastructure Demand (Physical & Social)

The proposed expansion is within the well-established industrial area notified by

Government of Tamil Nadu. The demand for infrastructure physical and social may not

be required for the expansion project. The SIPCOT industrial area is well developed to

cater the needs of the industries.

5.5 Amenities/Facilities

The amenities/ facilities are already existing in the plant, hence no new facilities are

as such required.

Potable drinking water

Firefighting/ alarm system and ambulance is available in case of emergency

19

Drinking water, canteen and electricity facilities is provided

Separate sanitation facilities is provided for men and women.

PPE’s and facilities related to safety will be provided.

Occupational Health Centre with qualified doctor is available for periodical health

check-up of employees.

Greenbelt is developed in and around plant.

20

6.0 Proposed Infrastructure

6.1 Industrial Area (Processing Area)

The typical equipment list of the whole operations for existing and expansion of the

plant is given in Table 10.

Table 10 Existing Infrastructure

Sl.No Description

1 Equipment’s

2 Raw Material Handling and Storage System

3 Weighbridge

4 Mixing Equipment

5 Pneumatic Diaphragm Pumps

6 Centrifugal Pumps

7 Automation system

8 Area Lighting

9 Air compressors / Instrument Air system 10 Emulsion & Water storage tanks

11 Filling Machine and packing system

12 Storage & retrieval system

13 Soft Water Plant

14 Electricals, Automation & Controls

15 Firefighting & Safety Equipment

16 Pollution Control System 17 DG Set

18 Boiler

19 Turbine 20 Cooling tower

21 Effluent Treatment Plant, Reverse Osmosis Plant, Zero Liquid Discharge unit.

22 Diesel and fuel oil storage area

23 Methanol storage

6.2 Residential Area (Non – Processing Area)

The proposed expansion is in notified industrial area. Residential development is not

allowed.

6.3 Greenbelt

Asian Paints Limited will continue to develop greenbelt in the plant premises. We

maintain the existing greenbelt in an area of 15.7 Acres and its the survival rate is 75-

80%.Green belt within our campus not only add up as an aesthetic feature but also act

as pollution sink.

6.4 Social Infrastructure

Social infrastructures like hospitals, schools, universities are present in vicinity of plant

area.

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6.5 Connectivity

The site is at a distance of about 0.5 km from National Highway NH45A. The nearest

railway station is Cuddalore at a distance of 5 Km, site is at a distance of 200 km from

Chennai International Airport, and 5 km from sea port.

6.6 Drinking Water Management

The source of water will be provided by SIPCOT.

6.7 Industrial Waste Management/ Solid Waste Management

All hazardous wastes shall be securely stored, under a shed for eventual transportation

to the authorized TSDF, the solid domestic waste shall be stored within the premises

temporarily and then sent to common solid waste disposal facility.

6.8 Power Requirement Supply and Source

The plant has a captive power generation of 1.5 MW. Available steam generation

capacity of upto 30 Tonnes per Hour (TPH) will be used and coal is the primary fuel.

New additional standby boiler of 8-10 TPH capacity will be sourced in 2018-19.

7.0 Rehabilitation and Resettlement Plan

There is no existence of displaced habitant in the proposed area. The proposed

expansion is already establishing in notified industrial area.

8.0 Project Schedule and Cost Estimates

8.1 Likely Start Date and Completion

Major Construction activities are not envisaged. Since, the changes involve the

following:

Process Modification.

Process Automation

Reliability improvement

Debottlenecking activities

8.2 Estimated Project Cost

Total estimated cost of the project is Rs 4.8 Crores, the detailed breakup of the cost

estimation is given in Table 11.

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Table 11 Project Cost Estimation

SL.No. Facility details for expansion from 560 to 730 MTM Cost In Rs

Lakhs

1 Pultruded Cooling tower 35

2 Field automation & online conductivity measurement in Deioniser section 6

3 Revamp of Reverse Osmosis plant & provision of Solar Drying facility 81

4 Pneumatic conveying and storage system for products 35

5 Silo system for fly ash handling & Filter press for sludge handling

70

6 Fixed Life line system for all RM & overhead pipeline in fire protection system

30

7 Revamp pumping facilities in Evaporator & flash steam recovery system provision

8

8 Revamp of Water Treatment Plant 30

9 Process Tanks, PHEs and related equipment to increase production capacity.

55

10 Boiler (8-10 ) TPH (will be planned in 2018-19) 80

11 Modern coal handling system (completed) 50

Total 480