PFR for 66 MW New Power Plant, DCM Kotaenvironmentclearance.nic.in/writereaddata/Online/TOR/06...Nirma Ltd. is one of the leading soda ash producing company in India. The group has

M/S. NIRMA LIMITED

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat.

NOVEMBER, 2017

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/

NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND

CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL SHEET

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 II

M/S. NIRMA LIMITED

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat. © Kadam Environmental Consultants (‘Kadam’), November, 2017

This report is released for the use of the M/s. NIRMA LIMITED., 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 for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex

at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat

Project Number 1730141406 Report No. 1 Version 1 Released November,

2017

Prepared &

Managed By

Tanu Prasad & Bhavin Jambucha, K.K

Antani Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

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

E: [email protected]; T:+91-265-6131000

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]



CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 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 ........................................................................................................... 3

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

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

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

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

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

2.1.2 Proposed Project ................................................................................................ 4

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................... 4

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION .......................................... 4

2.4 DEMAND & SUPPLY GAP ................................................................................................. 5

2.5 EXPORT POSSIBILITY .................................................................................................... 5

2.5.1 Domestic / Export Market ..................................................................................... 5

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............................................. 5

3 PROJECT DESCRIPTION .............................................................................................. 6

3.1 TYPE OF PROJECT ....................................................................................................... 6

3.2 LOCATION OF THE PROJECT ............................................................................................. 6

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

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

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

3.5.1 Soda Ash (Existing + Expansion) ............................................................................. 9

3.5.2 Caustic Soda (Existing + Expansion) ....................................................................... 10

3.5.3 Captive Power Plant (Existing + Expansion) ............................................................... 12

3.6 UTILITIES .............................................................................................................. 13

3.6.1 Power Requirement ............................................................................................ 13

3.6.2 Fuel Requirement .............................................................................................. 13

3.6.3 Water Requirement ............................................................................................ 13

3.6.4 Storage Details ................................................................................................. 13

3.7 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 13

3.7.1 Air Emissions & Control ....................................................................................... 13

3.7.2 Noise Generation ............................................................................................... 16

3.7.3 Waste Water Generation ...................................................................................... 16

3.7.4 Hazardous Waste & Other Solid Waste ..................................................................... 17

4 SITE ANALYSIS ........................................................................................................ 20

4.1 CONNECTIVITY ......................................................................................................... 20

4.1.1 By Road .......................................................................................................... 20

4.1.2 By Rail ........................................................................................................... 20

4.1.3 By Air ............................................................................................................ 20

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 20


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 IV

4.3 TOPOGRAPHY ........................................................................................................... 20

4.4 EXISTING INFRASTRUCTURE ............................................................................................ 20

4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 20

4.5.1 Soil Classification ............................................................................................... 20

4.5.2 Geology .......................................................................................................... 20

4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 21

4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 21

5 PLANNING BRIEF ..................................................................................................... 22

5.1 PLANNING CONCEPT .................................................................................................... 22

5.2 LANDUSE PLANNING .................................................................................................... 22

5.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 22

5.4 AMENITIES/FACILITIES ................................................................................................. 22

6 PROPOSED INFRASTRUCTURE ................................................................................... 23

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 23

6.2 NON- PROCESSING AREA ............................................................................................... 23

6.3 GREENBELT ............................................................................................................. 23

6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 23

6.5 CONNECTIVITY ......................................................................................................... 23

6.6 DRINKING WATER MANAGEMENT ...................................................................................... 23

6.7 SEWAGE SYSTEM ....................................................................................................... 23

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 23

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 24

7 REHABILITATION AND RESETTLEMENT (R&R) PLAN ..................................................... 25

8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................... 26

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 26

8.2 ESTIMATED PROJECT COST ............................................................................................ 26

8.2.1 Profitability ...................................................................................................... 26

9 ANALYSIS OF PROPOSAL .......................................................................................... 27

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 27


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR LIST OF ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 V

ANNEXURES

Annexure 1: Preliminary Site Layout Map ......................................................................................................... 29

Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ......................................... 30

Annexure 3: Long Term Meteorological Data for Bhavnagar City ........................................................................ 31


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR LIST OF TABLES

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 VI

LIST OF TABLES

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

Table 2-1: Products Capacity .............................................................................................................................4

Table 3-1: Co-ordinates of Site Boundary ...........................................................................................................8

Table 3-2: Area Statement* ..............................................................................................................................8

Table 3-3: Details of Stack Emissions ............................................................................................................... 14

Table 3-4: Details of Process Emissions ............................................................................................................ 14

Table 3-5: Wastewater Generation Details ........................................................................................................ 16

Table 3-6: Solid Waste Generation & Disposal................................................................................................... 17

Table 3-7: Hazardous Waste Generation and Disposal ....................................................................................... 18

Table 6-1: Identification of Other Wastes ......................................................................................................... 24

Table 8-1: Tentative Project Time Schedule ...................................................................................................... 26

Table 8-2: Breakup of Project Cost .................................................................................................................. 26

LIST OF FIGURES

Figure 3-1: General Location of Proposed Project Site .........................................................................................6

Figure 3-2: Specific Map Showing Project Boundary ............................................................................................7

Figure 3-3: Process Flow Diagram - Soda Ash Manufacturing Process ................................................................. 10

Figure 3-4: Process Flow Diagram - Caustic Soda Manufacturing Process ............................................................ 12


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 1

1 EXECUTIVE SUMMARY

Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the

production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl

Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt and consumer salt to facilitate

quality production of their consumer products.

It is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District Bhavnagar, Gujarat.

Nirma Limited, Bhavnagar now proposes for modernization with expansion of their existing production plant

capacity.

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

including Project / Activity: 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant, 1(d) - Captive Power Plant and

categorized under “A”.

1.1 Plant Features and Production Capacity

Existing cost of project is INR 3,110 crores. The expected cost of the proposed expansion project will be around

INR 1,320 crores. Details of existing and proposed products are listed in Table 1-1.

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

Sr.

No. Products/By-Products Units

Existing

Capacity Proposed

Total Capacity after

Expansion

1 Soda Ash Plant

A Light Soda Ash TPD 2,800 1,500 4,300

B Dense Soda Ash TPD 1,800 600 2,400

C Refined Sodium Bicarbonate (RBC)

(NOC) TPD 400 0 400

D Pure Water Plant M3/D 6,720 0 6,720

E Vacuum Salt TPD 2,400 0 2,400

2 Caustic Soda Plant

A Product

Caustic Soda (100%) TPD 750 250 1,000

Hydrochloric Acid (100%) TPD 280 220 500

B By-Products

Chlorine Gas (100%) TPD 665.2 220.8 886

Hydrogen (100%) TPD 18.75 6.25 25

Sodium Hypo Chlorite (100%) TPD 12 3 15

3 Captive Power Plant

Power MW 197.18 152.82 350

4 Chlorine & Hydrogen Derivatives

A Hydrogen Peroxide (100%) TPD 84 0 84

B Epichlorohydrin (ECH) TPD 150 0 150

C Glycerin TPD 160 0 160

D Mono Chloro Acetic Acid (MCAA) TPD 120 0 120

By-Products


Mother Liquor of MCAA TPD 30 0 30




Sr.

No. Products/By-Products Units

Existing

Capacity Proposed

Total Capacity after

Expansion


Product

E Tricolor Acetyl Chloride (TCAC) TPD 10 0 10

By-Product



Sodium Bisulfite Solution (100%) TPD 3 0 3

F Calcium Chloride (100%) (NOC) TPD 152 0 152

Calcium Chloride Granules TPD 160 0 160

By-Product

CO2 Gas TPD 60 0 60

Solid CO2 (Dry Ice) & / or Liquid CO2 TPD 60 0 60

G Phosphoric Acid (61.5% P2O5) (NOC) TPD 100 0 100

5 Toilet Soap Plant

Toilet Soap TPD 200 0 200

Detergent Powder TPD 414.66 0 414.66

Detergent Cake TPD 414.66 0 414.66

Fatty Acid TPD 150 0 150

Glycerin TPD 167 0 167

6 Bromine Plant

Bromine TPD 20 0 20

1.2 Infrastructure

The proposed expansion would be implemented in Nirma Ltd.’s existing manufacturing facility at Kalatalav, near

Bhavnagar, Gujarat.

Main components of the existing project which includes Captive Power Plant, Soda Ash Plant, Caustic Soda Plant,

Chlorine and Hydrogen derivatives plant, , Toilet soap plant and Bromine Plant and their associated utilities /

components like Boiler House of CFBC Boilers, Steam Turbine, Generator, Utility Area consisting of cooling tower,

ESP section Fly ash storage area. Water & wastewater infrastructure like Effluent Treatment Plant (ETP), Air

compressors & Hazardous storage facility area are being used.

1.3 Utility

Power: The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH ,

total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.

* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as

540 TPH.

Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.

Fuel: Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr

for existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

Raw Water: Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater

intake – 14 x 105 m3/day. Additional seawater intake - 3.6 x 105 m3/day.




Manpower: Existing manpower at the operational site is 1,630 nos. Manpower during Construction phase would

be 150 nos. The manpower for operation phase of Expansion plants would be 100 nos. Thus, the total manpower

during full operation phase of Nirma-Kalatalav complex will be approximately 1,730 nos.

1.4 Environment

Environmental issues associated with proposed units are:

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

Wastewater: The wastewater generated from the proposed activities would be treated in Effluent treatment

plant. The treated effluent would be discharged into the Gulf of Khambhat through existing outfall equipped

with diffuser system.

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

the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016.

1.5 Sensitivity

Project boundary is well beyond minimum distance of 500 m from CRZ boundary. About 6.5 km in North (Gundala

Creek), 6.0 km East side (Malcolm Channel), and 3.0 km in the South direction (Bhavnagar Creek). Project site falls

in Zone-III of Seismicity. Civil and Structures shall be designed according to applicable code. It is 6.0 km from

Malcolm Channel (Gulf of Khambhat) thus susceptible to natural hazards like cyclone/storm etc.

1.6 Conclusion

There is no adverse impact on the water environment due to the operation of the project. The air environment has

negligible effect due to the activities related to the operation of the project.

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

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

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

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

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

Pre-feasibility study confirms viability of the project.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project Proponent & Project

2.1.1 Project Proponent

Nirma is one of the few names - which is instantly recognized as a true Indian brand, which took on mighty

multinationals and rewrote the marketing rules to win the heart of princess, i.e. the consumer.

Nirma, the proverbial ‘Rags to Riches’ saga of Dr. Karsanbhai Patel, is a classic example of the success of Indian

entrepreneurship in the face of stiff competition. Starting as a one-man operation in 1969, today, it has about

15,000+ employee-base and annual turnover is more than 10,000 Crores INR.

Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the

production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl

Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt, Cement and consumer salt to

facilitate quality production of their consumer products.

2.1.2 Proposed Project

Proposed project is for expansion in Existing Production Capacity.

2.2 Brief Description of nature of the Project

Details of existing and proposed products for which expansion is proposed are listed in Table 2-1.

Table 2-1: Products Capacity

Sr.

No. Project or activity

Capacity (TPD)

Existing Proposed Total

Soda Ash Plant (Area = 2,61,548.33 m2)

1. Light Soda Ash Plant 2,800 1,500 4,300

2. Dense Soda Ash* 1,800 600 2,400

Ash * Dense Soda is conversion of Light Soda Ash

Caustic Soda Plant (Area = 2,88,945.55 m2)

1. Caustic Soda (100%) 750 250 1,000

2. Hydrochloric Acid (100%) 280 220 500

Caustic Soda Plant – By Products

1. Chlorine Gas (100%) 665.2 220.8 886

2. Hydrogen (100%) 18.75 6.25 25

3. Sodium Hypo Chlorite (100%) 12 3 15

Captive Thermal Power Plant (Area = 69,100 m2)

1. Captive thermal Power Plant 197.18 MW 152.82 MW 350 MW

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

There is regular use of these products and has demand in local market as well as in export. This will meet the local

demand and generate employment.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2.4 Demand & Supply Gap

Limestone requirement is approximate 5,050 TPD for existing Soda Ash Plant.

Additional approximate 3,964 TPD (2,705 TPD for SA + 1,259 TPD for CPP) is required for proposed Soda Ash

Expansion and desulphurization in Captive Power Plant. Limestone requirement will be met from the limestone

mines located in Junagadh & Porbandar districts as well as imports.

2.5 Export Possibility

2.5.1 Domestic / Export Market

There is regular use of these products and has demand in local market as well as in export. This will meet the local demand, generate employment and generate revenue for government.

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

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR 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 project falls in category

including Project / Activity: 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant, 1(d) - Captive Power Plant and

categorized under “A”.

3.2 Location of the Project

Proposed project is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District

Bhavnagar, Gujarat.

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

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

Figure 3-1: General Location of Proposed Project Site

NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY

AT KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION


Figure 3-2: Specific Map Showing Project Boundary

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




Table 3-1: Co-ordinates of Site Boundary

POINT LATITUDE LONGITUDE

A 21°51'56.83"N 72° 9'30.48"E

B 21°51'46.15"N 72°10'17.76"E

C 21°51'42.81"N 72° 9'23.53"E

D 21°51'39.12"N 72° 9'28.14"E

E 21°51'33.87"N 72° 9'27.12"E

F 21°51'32.87"N 72° 9'25.35"E

G 21°51'31.17"N 72° 9'25.11"E

H 21°51'30.23"N 72° 9'20.84"E

I 21°51'24.09"N 72° 9'20.45"E

J 21°51'23.82"N 72° 9'25.64"E

K 21°51'13.96"N 72° 9'26.98"E

L 21°51'12.59"N 72° 9'17.77"E

M 21°51'7.73"N 72° 9'13.03"E

N 21°50'51.17"N 72° 9'8.71"E

O 21°50'52.41"N 72°10'8.26"E

P 21°51'16.70"N 72°10'10.47"E

Q 21°51'23.75"N 72°10'15.83"E

3.3 Details of Alternate Sites Considered

The expansion and set-up of new project is within the existing chemical complex. Hence no alternative sites were

explored.

3.4 Size or Magnitude of Operation

Total plot area is 22,49,458 m2. The details of area calculations are given in Table 3-2. Site layout is provided as

Annexure 1.

Table 3-2: Area Statement*

S. No. Particular Area (Acre) Area (m2)

1 Plant facilities 84.0 3,39,825

2 Storage (Raw Material & Finished Products) 23.0 92,930

3 Storage (Fuel) 107.2 4,33,940

4 Storage (Water) 7.5 30,400

5 Storage (Others) 22.3 90,286

6 Utilities 16.9 68,250

7 Laboratory 0.9 3,600

8 Approach Road(s) 3.2 13,000

9 Green Belt 183.4 7,42,321

10 ETP 3.1 12,500

11 Office + Parking + Security 3.6 14,500

12 Open area 100.8 4,07,906

Total 555.8 22,49,458

* Area given are tentative and are subjected to changes, which will be clearly demarcated in the EIA study report.




3.5 Project Description with Process Details

3.5.1 Soda Ash (Existing + Expansion)

The global theoretical equation for the production of soda ash, involving sodium chloride and calcium carbonate is

as follows;

2 NaCl + CaCO3 Na2CO3 + CaCl2

In practice the reaction is not possible and needs the participation of other substances and many different process

steps to get the final product. The first reaction involves absorption of ammonia in salt solution, followed by

reaction of ammoniated brine with carbon dioxide to obtain ammonium carbonate followed by ammonium

carbonate. The continuous introduction of carbon dioxide injection and cooling the solution, precipitation of sodium

bicarbonate is achieved and ammonium chloride is formed. The chemical reactions of the process are given below:

NaCl + H2O + NH3 NaCl + NH4OH

2 NH4OH + CO2 (NH4)2 CO3 + H2O

(NH4)2CO3 + CO2 + H2O 2 NH4HCO3

2 NH4HCO3 + 2 NaCl 2 NaHCO3 + 2 NH4Cl

Sodium Bicarbonate crystals are separated from the mother liquor by filtration, followed by thermal decomposition

to obtain sodium carbonate, water and carbon dioxide. Sodium carbonate, thus formed is called “light soda ash”

because its bulk density is approximately 0.5 t/m3.

2 NaHCO3 Na2CO3 + H2O + CO2

CO2 is recovered in the carbonation step. The mother liquor is treated to recover ammonia, by reacting with dry lime

followed by steam stripping to recover free gaseous ammonia, which is recycled to absorption step.

2 NH4Cl + H2O+CaO CaCl2 + 2 NH3 + 2 H2O

Carbon dioxide and Calcium oxide originate from limestone calcinations CaCO3 CaO + CO2. Calcium and

magnesium which are impurities in the brine are removed by reacting with alkali and carbon dioxide to produce

insoluble salts. Brine purification reactions are described in the following equations:

Ca2+ + CO32- CaCO3

Mg2+ + 2 OH- Mg (OH)2

The difference between Light and Dense Soda ash is bulk density & the size of particles. Dense Soda ash is produced

via the monohydrate process. The hot light soda ash discharge from Calciner is transported via chain conveyors and

bucket elevator to Hydrator. In hydrator Light Soda ash is mixed with water to form monohydrate according to the

exothermic reaction:

Na2CO3 + H2O Na2CO3.H2O

The next step is dehydration and drying of the monohydrate in Fluid Bed Dryer according to endothermic reaction:

Na2CO3.H2O Na2CO3 + H2O

The Dense Soda Ash is cooled and transported to storage to packing plant. The block diagram of the Soda Ash

Manufacturing unit is given in Figure 3-3.




Figure 3-3: Process Flow Diagram - Soda Ash Manufacturing Process

3.5.2 Caustic Soda (Existing + Expansion)

The Caustic soda manufacturing technology being used i.e. membrane technology is completely environment

friendly. The by products are hydrogen, chlorine & sodium hypo chlorite. Hydrochloric acid is manufactured using

H2 and Cl2 (produced from cell house).

Manufacturing process of Caustic Soda involves the following key steps:

Brine Saturation: Desirable circulating rate of brine in saturator is attained by dissolving salt from solar salt works

and depleted brine from the process. The water loss by membrane is compensated by supply of demineralized

water.

Chemical Preparation: In precipitation tanks saturated brine is treated to remove Ca, Mg & Sulphates by adding

Na2CO3, NaOH and Barium Chloride.

Clarification: Flocculants are added to enhance the settling. Impurities are removed in clarifier. Main impurities

are solids which are pumped to sludge filtration unit. Filtrate is recycled to clarifier.

Filtration: Anthracite filters are used to remove suspended solids.

Secondary Brine Purification: Polishing candle filters and ion exchange system is used for this process. The

objective of producing ultra-pure brine required for membrane cell operation is achieved. Polished brine after

heating through brine heater is passed through two ion exchange columns connected in series. The columns have

cation exchange resin, which provides active sites for adsorption of residual calcium and magnesium salts still

present in brine. Brine is passed through heat exchanger for achieving the temperature required at cell inlet.

Electrolysis: Brine flows into the anode chamber. Cl2 is liberated at the anode surface with depleted brine left

behind. Cl2 and depleted brine overflows from the anode chambers into the anolyte header. Weak caustic flows

SALT

BRINE PREPARATION

RO / RAIN WATER LIME STONE COKE

LIME KILNS

ABSORPTION

CARBONATION

CALCINATION

DENSIFICATION

STORAGE

WASTE TREATMENT

DISTILLATION

COMPRESSION

GAS CONDENSATION

PACKING

FILTERATION

FINAL PRODUCTS

CLEAR LIQ. TO SALT WORKS

AIR

STEAM 38-40% CO2

80-90% CO2

PURIFIED BRINE CaCl2 Waste

CRUDE BICARBONATE

STEAM

LSA

DSA

LSA

LSA & DSA

MOTHER LIQUOR

NH4Cl

AMMONIA GAS

AMMONIA MAKE UP

LIME

CO2 + H2O

STEAM

ZERO

DISCHARGE




into the cathode chamber. H2 is generated at the cathode surface and OH ions combine with the Na+ ions diffusing

through the membrane. A two-phase mixture of 32% NaOH and hydrogen overflows into the catholyte header.

Anode Reaction: 2NaCl 2Na+ + Cl2 + 2 e –

Cathode Reaction: 2H2O + 2 e – 2OH– +H2

Overall Reaction: 2NaCl + 2H2O 2NaOH + Cl2 + H2

Catholyte System: In the catholyte header the two-phase mixture of NaOH and Hydrogen gets separated. This

catholyte stream is tapped as “Product” and fed to the caustic evaporation unit. Whole stream is not tapped and

some part is sent for internal consumption.

Anolyte Dechlorination: Depleted brine containing dissolved chlorine (called anolyte) is dechlorinated in two

stages: Vacuum dechlorination and chemical dechlorination. A part stream of chemically dechlorinated brine is be

purged out of the system to keep the sulphate within the desired levels.

Caustic Evaporation Unit: Here the incoming 32% Caustic is concentrated to 50%. The 50% caustic coming

from this unit can be stored in 50% storage tank.

Chlorine Treatment: The water vapor is removed, from the saturated chlorine, using series of coolers. The gas is

then passed through the moist chlorine filter to remove the entrained brine aerosol. In drying towers 98% H2SO4 is

used to dry moist chlorine.

The dried chlorine gas is compressed to the required pressure and then liquefied. Liquid chlorine from the liquefiers

is sent to liquid chlorine storage tanks. Sniff gas from the liquefier containing inlets and chlorine gas is sent to the

HCl synthesis unit. Excess sniff gas, is diverted to the waste air system.

Hydrogen Treatment: Hydrogen gas leaving the cells saturated with water vapor is cooled. The cooled gas is

passed through filters to remove the NaOH aerosols. Some amount of hydrogen is required for HCl synthesis and a

part of the gas is sent to caustic flaking unit to be used as fuel and a part is sent to hydrogen bottling through

hydrogen compressors as per requirement and the balance hydrogen is vented through with flame arrestor.

HCl Synthesis Unit

Hydrogen is burnt in Chlorine atmosphere and the combustion gases are absorbed in water to yield a 32% HCl

solution. HCl produced is pumped to HCl head tank from HCl receiver for internal consumption within plant. The

Block diagram showing the Caustic Soda Manufacturing Process is shown in Figure 3-4.




Figure 3-4: Process Flow Diagram - Caustic Soda Manufacturing Process

3.5.3 Captive Power Plant (Existing + Expansion)

In the case of lignite/coal-fired boilers, steam generation with any of following firing technology is technically

feasible:

Circulating fluidized bed combustion (CFBC)

Pressurized Fluidized Bed Combustion (PFBC)

Integrated Gasification Combined Cycle (IGCC)

Pulverized Fuel Firing (PF)

Circulating fluidized bed combustion (CFBC) technology is adopted for the proposed captive power plant. A 100 MW

captive power plant turbo-alternator and 350 TPH + 350 TPH (standby) lignite / coal / petcoke based CFBC Boilers,

along with captive power plant machineries will be installed in order to meet internal steam and power requirement

for the proposed expansion.

The steam generator units proposed for the plant will be compact, semi-outdoor, natural/assisted circulation,

balanced draft, single drum, water tube type provided with Circulating Fluidized Bed Combustion system using pan-

leg furnace configuration. In a typical Circulating Fluidized Bed furnace, the lignite fed on a bed of suitable inert

material with addition of a sorbent material (such as lime stone) is burnt in suspension through the action of

primary air distributed below the combustor floor. In addition, secondary air is introduced at suitable points in the

combustion zone to ensure controlled and complete combustion of the fuel. Suitable lignite feeding and limestone

feeding arrangements are provided in the typical Circulating Fluidized Bed Combustion systems and is commonly

used as bed material for initial start-up of the boiler. The steam generators will be designed for satisfactory

continuous operation with the range of lignite/coal expected for this plant without any need for auxiliary fuel oil for

fire stabilization etc. Lignite and Coal are used as fuel after mixing in appropriate ratio.

VENT

CAUSTIC TO STORAGE AND

FILLINGSALT SATURATION

BRINE PRECIPITATION

CHLORATE DESTRUCTION

CATHOLYTE SYSTEM

DM WATER/CONDENSATE

CHEMICALS Na2CO3,NaOH SALT

FLOCCULANT

NaHSO3, NaOH 32% SOLUTION

DM WATER

FLAKES STORAGEAND BAGGING

HYDROGEN BOTTLING

FLAKING UNIT

CAUSTIC EVAPORATION

CHLORINE LIQUEFICATION

HYDROGEN TREATMENT

LIQUID CHLORINE STORAGE

CHLORINE FILLING

48.5 / 50%NaOH SOLUTION

BRINE PURIFICATION

(ION EXCHANGE)

BRINE FILTRATION

SLUDGE FILTRATION

BRINE CLARIFICATION

ANOLYTE DECHLORINATION

SLUDGE

CHLORINE COOLING &

DRYING

98% H2SO4

CHLORINE COMPRESSION

ANODE CATHODE+ -

78% H2SO4

H2 TO STACK

HCL FILLING

HCL STORAGE

HCL SYNTHESIS UNIT

HYPO FILLING

HYPOCHLORITE STORAGE

WASTE GAS DECHLORINATION

VENT

SALT SATURATION

BRINE PRECIPITATION

CATHOLYTE SYSTEM




Steam generating unit would be provided with electrostatic precipitator in the flue gas path. The overall efficiency

of ESP will be around 99.70% with one field remaining as operational standby. The ESP would have adequate

number of ash hoppers provided with electric heaters. The design of ESP will be such that the dust burden at the

outlet of chimney with one field out of service doesn’t exceed 50 mg/Nm3 at 100 % BMCR with worst fuel.

Common chimney for boiler G and H will be constructed. The NOx emission from the steam generator is least in

case of CFBC steam generator design in view of low combustion temperature maintained in the furnace. The steam

generator and auxiliaries will perform continuously within noise limits as per relevant standard specification but not

more than 85 dB (A) at 1.0 meter from any equipment or sub equipment. The steam from the boiler will go to back

pressure turbo generators. The extracted back pressure steam will be used in process.

3.6 Utilities

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

3.6.1 Power Requirement

The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH,

total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.


540 TPH.

Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.

3.6.2 Fuel Requirement

Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr for

existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

3.6.3 Water Requirement

Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater intake – 14 x 105

m3/day. Additional seawater intake - 3.6 x 105 m3/day.

3.6.4 Storage Details

Unit will create additional storage facilities for products, raw materials as per the MSIHC rules.

3.7 Pollution Load on Environment due to project

Environmental issues include:

Air emissions;

Wastewater;

Solid Wastes.

3.7.1 Air Emissions & Control

Point Source

Likely air pollutants from proposed project shall be PM, SOx & NOx from flue gas stack, HCl, Cl2 & NH3 from process

stacks/vents as point source.




Volume Source

PM emission from coal storage yard is envisaged as volume source emissions.

Fugitive Emissions

Line Source Emissions

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

with fuel consumption and attached Air Pollution Control Equipment details are tabulated in Table 3-3 & Table

3-4.

Table 3-3: Details of Stack Emissions

S. No. Stack Attached to Stack Height

(m)

Stack Top

Dia. (m) APCM

Expected

Pollutants*

Existing

Soda Ash Division

1 Boiler - A, B, C & D (100 TPH Each) 100 (Common

Stack) 5.04

ESP to Each

Boiler PM, SO2 & NOx

2 DG Set (1000 KVA)

2 No. 24 each 0.2 -- PM, SO2 & NOx

Caustic Soda & CPP Division

2 Boiler - E (200 TPH) 121 (Common

Stack) 4.5

ESP PM, SO2 & NOx

3 As per EC 2014 Boiler - F (200 TPH) –

Not Installed Yet ESP PM, SO2 & NOx

4

As per EC 2017 Boiler - G & H (350 TPH

each ) – Installed One boiler having

capacity 410 TPH

121 (Common

Stack) 4.5 ESP PM, SO2 & NOx

5 DG Set (1000 KVA) 30 0.32 - PM, SO2 & NOx

6 DG Set (1500 KVA) 30

0.32

-

PM, SO2 & NOx

7 DG Set (1500 KVA)

Toilet Soap plant

8 Thermic Fluid Heater

(3 No.) 45 0.4 PM, SO2 & NOx

Proposed

Soda Ash Division

1. DG Set (2000 KVA) 30 0.32 -- PM, SO2 & NOx

Caustic Soda & CPP Division

1 Boiler - I & J (410 TPH + 130 TPH) * 121 (Common

Stack) 4.5 ESP PM, SO2 & NOx

2 DG Set (1850 KVA) 30 0.32 -- PM, SO2 & NOx


540 TPH.

Table 3-4: Details of Process Emissions

Sr.

No. Vent Attached to

Stack

Height (m)

Stack Dia.

(m)

Air Pollution Control

System Pollutant

1

Soda Ash Plant – Existing & Proposed

Lime Kilns (A to H) – 8 nos. 68 (Common

Stack) 0.8

4 scrubbers and 3 ESP in

Series PM, SO2, NOx

Ammonia Recovery System (A

to E) 5 No.

56 (Common

Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia




Sr.


Stack

Height (m)

Stack Dia.

(m)


System Pollutant

Lime Grinding System A to E

(5 nos.)

60

(each) 0.65 Bag Filter PM

Calcinations Vessel (A to D 4

nos) 29 (each) 0.7 Water Scrubber PM

Densification 1 40 1.37 Water Scrubber PM



Lime Kilns (I to L) – 4 nos.

(Proposed)

68 (Common

Stack) 0.8

Two scrubbers and two

ESP in Series PM, SO2, NOx

Ammonia Recovery System (F

& G) 2 nos. (Proposed)

56 (Common

Stack) 0.75 Brine Scrubbers (2 nos.) Ammonia

Lime Grinding System (F 1

nos.) (Proposed) 60 0.65 Bag Filter PM

Calcinations Vessel (E & F 2

nos) (Proposed)

29 (Common

vent) 0.7 Water Scrubber PM

Densification 4 (Proposed) 51 1.37 Water Scrubber PM

2

Caustic Soda and CPP - Existing & Proposed

HCl Synthesis Unit – 1 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit - 2 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit – 3 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit - 4 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit – 5

(Proposed) 30 0.1 Water Scrubbers HCl & Cl2

Waste Gas Dechlorination

System - 1 30 0.3 18% NaOH Scrubber Cl2


System - 2 30 0.3 18% NaOH Scrubber Cl2


System – 3 30 0.3 18% NaOH Scrubber Cl2

Hydrogen unit with Flame arrestor and steam snuffing –

1 30 -- -- --

Hydrogen unit with Flame

arrestor and steam snuffing –

2

30 -- -- --

Hydrogen unit with Flame

arrestor and steam snuffing –

3

30 -- -- --

3. Bromine Plant

De-bromination System 30 0.3 Alkali Scrubber Bromine

4.

Chlorine & Hydrogen Derivatives

Solvent Recovery 30 0.3 Ceramic + Activated

Carbon Filter Aromatic Solvent

Hydrogenation Plant (purge

gas) 30 0.3

Ceramic + Activated

Carbon Filter

H2 + Aromatic

Solvent

Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,

HCl, TOC

HCl Synthesis Unit 30 0.1 Water Scrubbers HCl




Sr.


Stack

Height (m)

Stack Dia.

(m)


System Pollutant

Chlorination Plant 30 0.3 Acidic/Water Scrubber (3

nos.) SO2, HCl, Cl2

Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2

Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2

Hydrogenation Plant (purge

gas) 30 0.3 ---- H2

3.7.2 Noise Generation

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

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

phase;

Operation of plant machinery and diesel generator set;

Vehicle movement for transportation of raw material.

3.7.3 Waste Water Generation

The main source of the industrial wastewater generation will be from domestic, process, utilities, washing and

others. The total quantity of effluent will be increased from 5,86,445.2 KLD to 9,06,634.7 KLD. Entire quantity of

wastewater will be treated in existing treatment facilities. In existing scenario Treated effluent is partly reused /

recirculated in salt works and around 12000 m3/day of Soda Ash effluent and 6000 m3/day of Bittern is being

disposed off in to the sea at a discharge point suggested by National Institute of Oceanography (NIO).

In proposed expansion, Additional soda ash effluent, additional bittern & cooling water will be disposed in sea along

with existing effluent and bittern at point suggested by NIO. Return cooling water of 3,00,000 m3/day will be

disposed into deep sea at a discharge Point suggested by NIO on permanent basis and during emergency purpose /

monsoon 8,60,000 m3/day will be disposed into sea.

Details of Waste water generation is given in

Table 3-5: Wastewater Generation Details

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


Soda Ash plant

1. Domestic 184 99 283

2. Process 32,547 17,436 49,983

3. Boiler 216 0 216

4. Cooling 4,73,571 2,86,840 7,60,411

5. Others 0 0 0

Total (I) 5,06,518 3,04,375 8,10,893

Toilet Soap plant

1. Domestic 48 0 48

2. Process 0 0 0

3. Washing 25 0 25

4. Cooling 275 0 275

Total (II) 348 0 348

Caustic Soda Plant & CPP

1. Domestic 11 3.5 14.5

2. Process 750 250 1,000




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


3. Boiler 1,340 447 1,787

4. Cooling 4,03,842 14,614 58,456

Total (III) 45,943 15,314.5 61,257.5

Salt works

1. Salt works 11,000 500 11,500

Total (IV) 11,000 500 11,500

Bromine plant

1. Cooling tower 1,000 0 1,000

2. Process 12,500 0 12,500

Total (V) 13,500 0 13,500


1. Domestic 6.6 0 6.6

2. Process + DM 1,595 0 1,595

3. Cooling + Chilling 2,977 0 2,977

4. Boiler 0 0 0

5. Washing/Others 41 0 41

Total (VI) 4,619.6 0 4,619.6

RBC Plant, Calcium Chloride plant & Phosphoric acid plant

1 Domestic 8.6 0 8.6

2 Process 4,250 0 4,250

3 Cooling 258 0 0

Total (VII) 4,516.6 0 4,516.6

Grand Total (I to VI) 5,86,445.2 3,20,189.5 9,06,634.7

3.7.4 Hazardous Waste & Other Solid Waste

The main source of hazardous waste generation will increase after proposed expansion. ETP sludge will be dispose

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

registered recyclers.

The details of Solid & hazardous waste are given in Table 3-6 & Table 3-7.

Table 3-6: Solid Waste Generation & Disposal

Sr.

No. Solid Waste

Quantity (TPD) Mode of Disposal

Existing Proposed After Expansion

1 Settling Pond Sludge 880 482 1,362 Shall be used in road construction,

salt works bund preparation

2 Lime stone rejects /under

size 700 375 1,075

Shall be used in boilers for

desulphurization in boilers

3 Brine Sludge 19 10 29 Non-hazardous; Shall be used

dumped in identified area

4 Fly ash/ Bottom ash 2,185 1,693 3,878 Brick manufacturing, bund

preparation, road making etc…

5 Incineration Ash --- 15 15 Brick manufacturing, bund

preparation, road making etc…

6 Saponification

Solid Waste 3 0 3

Non-hazardous; Shall be

dumped in identified area




Table 3-7: Hazardous Waste Generation and Disposal

S No Hazardous Waste Category

Quantity (MTPA)

Mode of Disposal Existing Proposed

Total After

Expansion

1

Soda Ash Plant

Waste Oil/ Lub. Oil

from 5.1 10 5 15

Collection, Storage, Transportation &

disposal by selling to Registered

Recyclers

Spent ion exchange

resins 34.2

1,830

lt/year

980

lt/year 2,810 lt/year

Collection, Storage, Transportation,

Disposal by selling to authorized

recyclers or sent to NECL Nandesari

for Incineration.

Discarded

bags/drums/containers

etc…

33.3 3.5 2 5.5



recyclers

2

Caustic Soda Plant

Waste Oil/ Lub. Oil

from 5.1 30 kl 10 kl 40 kl



Recyclers

Spent ion exchange

resins 34.2 2.56 1 3.56



recyclers or sent to NECL Nandesari

for Incineration.

Discarded

Bags / drums /

containers etc…

33.3 4.5 1.5 6



recyclers

Residue/ Sludge &

Filter sludge 16.2 6,526 2,175 8,701


Disposal at TSDF

ETP sludge 34.3 150 50 200 Collection, Storage, Transportation,

Disposal at TSDF

Spent Sulphuric Acid

(80%) D2 6,520 2,173 8,693


reuse as raw material for Nirma Ltd.

Moraiya and other end users.

3

Toilet Soap Plant

Waste Oil/ Lub. Oil

from 5.1 0.45 0 0.45



Recyclers


Disposal at TSDF

Glycerin foot D6-II 72 0 72


disposal by selling to M/s. Ultratech

Cement for Co- incineration in cement

kiln/NECL for Incineration.

Spent Sulphuric Acid

(80%) D2 24,000 0 24,000


reuse as raw material for Nirma Ltd.

Moraiya and other end users.




S No Hazardous Waste Category

Quantity (MTPA)

Mode of Disposal Existing Proposed

Total After

Expansion

4


Waste Oil/ Lub. Oil 5.1 10 0 10



Recyclers

Discarded containers/

Barrels/empty

drums/empty bags

33.3 10 0 10 Collection, Storage and disposal by

selling to authorized recyclers.


Disposal at TSDF

Glycerin foot D6-II 5,356 0 5,356 Collection, Storage & incineration in

plant incinerator.

Catalyst from

regeneration 35.2 1.2 0 1.2


Disposal at Common Haz. Waste

incineration facility

Spent Carbon from

solvent recovery 35.3 3 0 3



incineration facility

Spent Carbon from

ETP 34.3 3 0 3


Disposal at TSDF

Distillation Residue 36.4 550 0 550



incineration facility.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

4.1.1 By Road

The nearest highway (Bhavnagar-Ahmedabad SH-6 Coastal highway) is about 14.0 kms away from the plant in the

West direction.

4.1.2 By Rail

Major railway station for public transportation is Bhavnagar Railway Station located at an aerial distance of ~10 Km

from the project site in the South-South West Direction.

4.1.3 By Air

Bhavnagar has its own airport, Bhavnagar Airport, which is at ~10 Km from project site.

4.2 Land Form, Land use & Land Ownership

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

Limited. Land Cover will be as per the Site Layout Map as shown in Annexure 1.

4.3 Topography

Project site is shown on Toposheet in Annexure 2.

4.4 Existing Infrastructure

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

4.5 Soil Classification, Geology & Drainage

4.5.1 Soil Classification

Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. The soil type is a mixture

of sand & gravel with intermediate golden colour laterites with clay as binder. The subsoil strata of the study area

consist of a mixture of sandy gravel with clay as binder in the top 10 m. Thereafter the strata of about 50 m is a

thick layer of Grayish-blue clay having very hard to stiff consistency tending to rock like formation. The topsoil

around Kalatalav is made up of coarse saline soil poor in nutrients.

Most of the 10 km radial zone around Kalatalav has alluvial deposits and consists of sandy soil, tidal mudflats,

raised beaches and freshwater alluvium. Clay (size < 0.002mm) amount in the soil samples ranges from 17% to

22%; Silt (size 0.002 to 0.075 mm) in the soil samples is 14% to 18% Sand (size 0.075 to 0.475mm) in the soil

samples is 50% to 58% and gravel (size > 4.75 mm) in soil samples is 10% to 14%.

4.5.2 Geology

The Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. It falls in the seismic

zone-III as per IS 1893 (part -1) 2003. Peninsula is bounded by sea on all sides except northeast side where it is

flanked by alluvium plains of main land.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS


Bhavnagar district shows diverse features like uneven, rocky (basaltic) land surface traversed by mountain

ranges/ridges and trappean dykes. Most of the district is composed of Weathered to Hard & massive Deccan Trap

formation, which is impervious with low yield. Rocks with cracks, fractures and fissures provide some discharge and

potable water quality.

4.6 Climatic data from secondary sources

Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term

Climatological Tables, 1981-2010, Bhavnagar (A). These tables give useful information about a region’s weather,

since they are collected over a 29-year period. Copy of the same is attached as Annexure 3.

Mean daily maximum temperature is recorded in the month of May at 40.0°C. From October to December, both day

and night temperatures begin to decrease rapidly. January is generally the coldest month, having minimum

morning temperature at 13.9°C. During the post-monsoon months of October, November, December day

temperatures remain between 17.8ºC - 26.7ºC. In winters, i.e. December, January and February, average day

temperatures remain between 16.2 – 18.8ºC.

The total rainfall in year is observed to be 655.9 mm. Distribution of rainfall by season is 2.4 mm in winter

(December, January, February), 5.2 mm in summer (March, April, May), 612.4 mm in monsoons (June, July,

August, September) and 35.9 mm in post-monsoons (October, November, December). Annual total heaviest rainfall

recorded in 24 hrs is observed to be 434.4 mm on 20th July, 1996.

An online weather logger was set up at Plant site. The co-ordinates for the same are 21051’14.1”N; 72010’32.8”E.

4.7 Social Infrastructure Available

Educational Facilities

As per 2001 census in all 5 villages, there are 4 primary schools & other educational facilities are in 10 km radius of

the study area.

Medical Facilities

Out of 4 villages in the study area, one has Primary Health Sub-Centers & other medical facilities are within 10 km

of the study area. Almost all medical facilities are available there.

Drinking Water Supply

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility.

Communication & Transport

The main mode of public transport available in the study area is by bus service. All villages are near Bhavnagar, so

almost all villages have approach to railway station as western railway meter gauge line is passing through nearby.

Post & Telegraph

There are 5 villages in study area, 2 villages have post office facility at doorstep & almost all have phone facility.

Power Supply

All the villages are getting power supply for domestic purposes.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept

Site falls under the seismic Zone III, which is classified as Low Risk zone (Area liable to shaking Intensity VI (and

lower). 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. are already

developed in the project site.

5.2 Landuse Planning

There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma Ltd.

5.3 Assessment of Infrastructure Demand (Physical & Social)

No additional infrastructure demand is required.

5.4 Amenities/Facilities

Within the study area (i.e. 10 kms) basic amenities/ facilities like there are 4 primary schools & other educational

facilities, is available in all the nearby villages. Out of 4 villages in the study area, one has Primary Health Sub-

Centres & other medical facilities are within 10 km of the study area. Bhavnagar is nearest city to the study area,

which is around 10 km away from project site. Almost all medical facilities are available there.

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility. The main mode of public

transport available in the study area is by bus service. All villages are near Bhavnagar, so almost all villages have

approach to railway station as western railway meter gauge line is passing through nearby. Majority of villages in

the study area is connected with pucca road. Out of 5 villages in study area, 2 villages have post office facility at

doorstep & almost all have phone facility. All the villages are getting power supply for domestic purposes.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing unit comprises of following sections:

Boiler House consisting of CFBC Boilers – 2 Nos., Steam Turbine, Alternator / Generator;

Fuel storage area;

Utility Area consisting of cooling tower, compressors, ESP section, ETP area;

Fly Ash & Hazardous waste storage area.

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

space will be provided as per the requirement.

6.2 Non- Processing Area

Existing non processing area includes Weighbridge, Administrative Building, Laboratory, Security cabins, Workers

restroom, Vehicle Shed, Water reservoirs for raw water and fire hydrant system, Temporary storage sites, Works

block etc.

6.3 Greenbelt

Nirma has done extensive plantation in around 110 acres and spared total 183.4 acres for greenbelt development.

Unit is also taking interest to develop greenbelt peripheral outside of the factory premises

6.4 Social Infrastructure

Refer Chapter 4, Section 4.7.

6.5 Connectivity

Refer Chapter 4, Section 4.1.

6.6 Drinking Water Management

Drinking water source for the existing Nirma plant at Kalatalav is from RO plant.

6.7 Sewage System

Sewage would be generated from the various units within the manufacturing facility. The existing sewage quantity

generated is 258.2 m3/day. The sewage expected to be generated for proposed expansion would be 102.5 m3/day.

Thus, the total sewage generation would be 360.7 m3/day. The sewage would be disposed off in soak pits of

individual plants and the same is being used in greenbelt development.

6.8 Industrial Waste & Solid Waste Management

Solid and hazardous waste as mentioned in Chapter 3, Section 3.7.4 shall be collected, stored, disposed to

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


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


Notification, 2015 & Hazardous Waste Rules, 2016 amended till date. Other wastes to be generated from the

project are tabulated in Table 6-1. Details will be provided in EIA report.

Table 6-1: Identification of Other Wastes

S. No. Type of Waste Constituents

1 Municipal Solid Waste Kitchen waste, cardboard, paper and garden wastes

2 Inorganic Waste Scraps, paper bags, cardboards and glassware’s etc.

3 Plastic Waste Plastic bags, plastic scraps etc.

4 E-waste CD’s, LAN Cables, Fuses, Data cables, circuit boards, etc.

5 Biomedical Waste Syringe, Bandages, used cotton, medicine etc.

6 Construction & Demolition waste Debris

6.9 Power Requirement & Supply / Source

Refer Chapter 3, Section 3.6.1.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR R&R PLAN


7 REHABILITATION AND RESETTLEMENT (R&R) PLAN

Since no additional land is acquired for the proposed expansion project, and all the proposed units will be inside the

existing plant premises, R & R issues are not envisaged.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROJECT SCHEDULE & COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

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

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

committee. Tentative schedule for the project to be completed is given in Table 8-1.

Table 8-1: Tentative Project Time Schedule

S. No. Activities Start Finish

1 EC Approval November, 2017 August, 2018

2 Detailed Engineering January, 2019 April, 2019

3 Procurement and Delivery June, 2019 Delivery start from

December, 2019

4 Construction at Site (Buildings, Mech., Piping, Elec., Inst etc.) June, 2019 December, 2020

5 Pre Commissioning January, 2021 June, 2021

6 CTO Approval July, 2021 January, 2022

7 Process Startup and Stabilization September, 2021 March, 2022

8.2 Estimated Project Cost

The proposed project cost is estimated to be INR 1,320 crores. The breakup of project cost is given in Table 8-2.

Table 8-2: Breakup of Project Cost

S. No. Particulars Amount (INR in Crores)

1 Soda Ash Plant 570

2 Caustic Soda and CPP 750

Total Project Cost 1,320

8.2.1 Profitability

The project has been conceived upgrading old inefficient sets with new efficient sets, hence increasing profitability.

Further capacity enhancement leads to a reasonable ROI, based on consuming plant expansion.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


ANNEXURES

NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 1: Preliminary Site Layout Map


AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


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




Annexure 3: Long Term Meteorological Data for Bhavnagar City




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

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/

Documents

PFR for 66 MW New Power Plant, DCM Kotaenvironmentclearance.nic.in/writereaddata/Online/TOR/06...Nirma Ltd. is one of the leading soda ash producing company in India. The group has