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PRE FEASIBILITY REPORT
(As per MoEF Guidelines)
FOR
M/s. JBF PETROCHEMICALS LTD
PROPOSED PART CHANGE IN FUELCONFIGURATION
(100 % COAL) FOR TWOOF FOUR BOILERS IN PTA UNIT AND
ALL FOUR THERMIC FLUID HEATERS IN PET UNIT
AT
MANGALORE SEZ LIMITED
VILLAGE: BAJPE
TALUK: MANGALORE
DIST: DAKSHINA KANNADA
KARNATAKA
[Project termed under schedule 5 (e), category B project, and petrochemical
based processing]
November 2015
BY
HUBERT ENVIRO CARE SYSTEMS PVT LTD., CHENNAI
Prefeasibility Report for Change in Fuel configuration
i
TABLE OF CONTENTS
1. EXECUTIVE SUMMARY ......................................................................................................... 1
1. INTRODUCTION ....................................................................................................................... 4
1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT .................................... 4
1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ................................................. 5
1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR
REGION ............................................................................................................................................ 5
1.4 DEMAND-SUPPLY GAP ..................................................................................................... 6
1.5 IMPORTS VS. INDIGENOUS PRODUCTION ................................................................... 6
1.6 EXPORT POSSIBILITY ....................................................................................................... 7
1.7 DOMESTIC / EXPORT MARKETS .................................................................................... 7
1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 7
2. PROJECT DESCRIPTION ....................................................................................................... 8
2.1 TYPE OF PROJECT .............................................................................................................. 8
2.2 LOCATION ........................................................................................................................... 9
2.3 SALIENT FEATURES OF THE PROJECT SITE .............................................................. 10
2.4 BASIS OF CALCULATION FOR STEAM AND FUEL ................................................... 13
2.5 SIZE OR MAGNITUDE OF OPERATION ........................................................................ 14
2.6 PROJECT DESCRIPTION WITH PROCESS DETAILS .................................................. 15
2.6.1 MANUFACTURING PROCESS OF PTA .................................................................. 15
2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET .............................. 20
2.6.3 RAW MATERIALS REQUIRED ................................................................................... 24
2.6.4 RAW-MATERIALS AND ITS CONSUMPTION FOR PTA PLANT ....................... 24
2.6.5 RAW-MATERIALS AND ITS CONSUMPTION FOR POLYESTER CHIPS / PET 25
2.7 RESOURCE OPTIMIZATION ........................................................................................... 26
2.7.1 SPECIFICATION OF PROPOSED FUELS ............................................................... 26
2.7.2 COAL LINKAGE ........................................................................................................ 28
2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER REQUIREMENT .... 30
2.9 QUANTITY OF WASTE WATER GENERATED ............................................................ 31
2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH
GIVE INFORMATION OF EIA PURPOSE .................................................................................. 33
2.11 PROPOSED EMISSIONS & STACK DETAILS ........................................................... 33
3. SITE ANALYSIS....................................................................................................................... 39
3.1 CONNECTIVITY ................................................................................................................ 39
3.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................... 39
3.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................................ 40
3.4 EXISTING LAND USE PATTERN .................................................................................... 41
3.5 EXISTING INFRASTRUCTURE ....................................................................................... 43
3.6 SOIL CLASSIFICATION ................................................................................................... 43
Prefeasibility Report for Change in Fuel configuration
ii
3.7 CLIMATIC DATA FROM SECONDARY SOURCES ...................................................... 43
3.8 SOCIAL INFRASTRUCTURE ........................................................................................... 44
4. PROPOSED INFRASTRUCTURE ......................................................................................... 45
4.1 INDUSTRIAL AREA .......................................................................................................... 45
4.2 RESIDENTIAL AREA ........................................................................................................ 46
4.3 GREENBELT ...................................................................................................................... 46
4.4 SOCIAL INFRASTRUCTURE ........................................................................................... 46
4.5 CONNECTIVITY ................................................................................................................ 46
4.6 DRINKING WATER MANAGEMENT ............................................................................. 46
4.7 SEWERAGE SYSTEM ....................................................................................................... 46
4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT ........................................................ 47
4.8.1 ASH GENERATION ................................................................................................... 47
4.8.2 DUST SUPPRESSION AND TREATMENT SYSTEM FOR COAL ........................ 47
4.8.3 ELECTROSTATIC PRECIPITATOR (ESP) .............................................................. 47
4.8.4 ASH HANDLING SYSTEM ....................................................................................... 48
4.8.4.1 HAZARDOUS WASTE AND ITS MANAGEMENT ............................................ 50
4.8.5 NOISE AND ODOUR CONTROL ............................................................................. 52
4.8.6 HAZARDOUS CHEMICAL STORAGE & HANDLING .......................................... 52
4.9 POWER REQUIREMENT .................................................................................................. 54
5. PLANNING BRIEF .................................................................................................................. 55
5.1 PLANNING CONCEPT ...................................................................................................... 55
5.2 POPULATION PROJECTION ............................................................................................ 55
5.3 LAND USE PLANNING..................................................................................................... 56
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ....................................................... 57
5.4.1 PHYSICAL INFRASTRUCTURE .............................................................................. 57
5.4.2 SOCIAL INFRASTRUCTURE ................................................................................... 57
5.4.3 AMENITIES/FACILITIES .......................................................................................... 57
6. REHABILITATION AND RESETTLEMENT (R & R) PLAN ........................................... 58
6.1 BRIEF OUTLINE ON THE POLICY ADOPTED ............................................................. 58
7. PROJECT SCHEDULE & COST ESTIMATES ................................................................... 59
7.1 TIME SCHEDULE FOR THE PROJECT ........................................................................... 59
7.2 ESTIMATED PROJECT COST .......................................................................................... 59
8. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ........................................ 60
Prefeasibility Report for Change in Fuel configuration
iii
LIST OF TABLES
Table 1-1Details of the proposed project ............................................................. 5
Table 1-2 Proposed products for the Project ....................................................... 6
Table 2-1Proposed products from the Project ..................................................... 8
Table 2-2 Financial Breakup for the project ........................................................ 8
Table -2-3 Salient Features of the project site ................................................... 10
Table 2-5Raw Materials in PTA manufacturing................................................ 24
Table 2-6Raw Material in PET Manufacturing ................................................. 25
Table 2-7 Typical Properties of Natural gas ...................................................... 26
Table 3-1 Land Use classification for the Project Site ...................................... 40
Table 3-2 Land use Pattern as per Census Data (area in Hectare) .................... 41
Table 3-3Textural Class of Soil in the Study Area ............................................ 43
Table 3-4 Mangalore Climate Data.................................................................... 43
Table 4-1 Summary of proposed change ........................................................... 45
Table 4-2 Specification of ESP .......................................................................... 48
Table 4-3 Specification of ash conveying system ............................................. 49
Table 4-4 Estimated Hazardous Waste Generation & Disposal ........................ 51
Table 4-5 Details of Hazardous Chemicals and its storage ............................... 53
Table 5-1Demographic Summary ...................................................................... 55
Table 5-2 Summary of project ........................................................................... 56
Table 7-1 Project Cost Details ........................................................................... 59
Prefeasibility Report for Change in Fuel configuration
iv
LIST OF FIGURES
Figure 2-1Satellite map of 10 km radius around the project Site ............................................. 9
Figure2-2 Satellite image of Project Site .................................................................................. 9
Figure 2-3 Location drawing of proposed unit ....................................................................... 11
Figure 2-4 Recent site photo ................................................................................................... 12
Figure 2-5Process Flow Diagram of PTA Manufacturing ...................................................... 18
Figure 2-6PTA Block Diagram with Vent and Effluent streams ............................................ 19
Figure 2-7Flow Diagram for PET/Polyester chips manufacturing ......................................... 22
Figure 2-8Site Layout Plan for Manufacturing of Polyester Chips / PET .............................. 23
Figure 2-9 Movement of Coal from Port ................................................................................ 29
Figure 3-1 Project Site location at Mangalore SEZ ................................................................ 39
Figure 3-2 Topography of the Project Site ............................................................................. 40
Figure 3-3 Land use map of Study Area ................................................................................. 42
Figure 3-4 Cropping Pattern in Study Area ............................................................................ 42
Figure 4-1 Details of the integrated scrap yard ....................................................................... 52
Figure 4-2Flow Chart for Captive power plant and Heat recovery system ............................ 54
Prefeasibility Report for Change in Fuel configuration
1
1. EXECUTIVE SUMMARY
This is asummary forProposed amendment for Fuel Configuration for using
100% Coal in TWOOF FOUR Boilers in PTA Unit and all FourThermic Fluid
Heaters in PET Unit for the Proposed Manufacturing of Pure Terephthalic Acid
(PTA) & Polyester Chips / PET Chips of Various Types & Grades and Power
Generation through Captive Power Plant at Mangalore SEZ in Dakshina Kannada
District of Karnataka. This project falls under item no. 5(e) i.e. Petrochemical based
processing industry under the category ―B‖ as per the EIA notification 2006 and
amendments thereof. JBF received Environmental Clearance for Manufacture of
Purified Terephthalic Acid (PTA), Polyester chips / PET Chips of various types and
grades and Power generation through Captive Power Plant from SEIAA vide letter
no. SEIAA/26/IND/2011 dated 30 March 2012 (Annexure-1) and CFE from
Karnataka State Pollution Control Board vide letter no. KSPCB/ HPI/ 269/ JBFL/
CFE/2011-12/443 dated 13 July 2012 (Annexure-2) Subsequently, JBF signed a
licensing agreement with world-renowned BP Technology wherein for the first time,
BP would be licensing its PTA manufacturing technology to a Non-Affiliate Third
Party, which considerably reduced our Water consumption, Power consumption,
Process Emissions, Effluent generation & discharge and led to a positive change in
the overall Environmental footprint of the Plant. Thus, due to change in Process
Licensor, JBF applied for and received a Corrigendum to Environmental Clearance
from SEIAA vide letter no. SEIAA/26/IND/2011 dated 18 April 2013 (enclosed as
Annexure 3), amendments for fuel change to Environmental Clearance from SEIAA
vide letter no SEIAA/17/IND/2014 dated 06 August 2015 (enclosed Annexure 4)
and amendment to CFE from KSPCB vide letter PCB/HPI/269/2013-14/3892 dated
07 October 2013 (enclosed Annexure 5). The construction activities have
commenced and are progressing in full swing, about 80% of Overall Project is
completed.
Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with
renewable Bio-fuel becoming visible, JBF has already obtained permission to use
85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.
However, it is prudent to have a fall-back arrangement in order to ensure reliability &
Prefeasibility Report for Change in Fuel configuration
2
availability, by designing the system for firing 100% Coal. Hence, JBFwould like to
propose fuel conversion as follows.
The Present Consented fuel configuration and proposed change in fuel configuration
is as listed in the table below:
S.No. Particulars
Present EC
Proposed change
1) Thermic Fluid Heater
(3+1 Nos.) Capacity: 9.5 M K.Cal/Hr
each
(85% Biomass + 15%
Coal) Biomass-205 TPD +
Coal-30 TPD
100% Coal firing: (3W + 1 S)
: 165 TPD
2) Turbine with WHR
system (2 Nos.) Capacity: Power-12.00
MW each
Diesel 2160 KL/month or Natural Gas 60 Lacs
SCM / Month
No change
3) Steam Generator / Boiler
(4 Nos.) Total Capacity: 460 TPH
(120+120+120+100)
3 x 120 TPH Boiler: Natural Gas: 3,00,000 SCM/ day (or) Furnace oil 216 MTPD 1 x 100 TPH Boiler (85% Biomass + 15%
coal) Biomass-165 TPD +
Coal- 25 TPD
2 X 120 TPH ONG Boilers
Normal FuelConsumption:
Natural Gas: 300,000
SCM/Day
Fuel Oil– 36T/ day
PLUS
1 x 100 TPH Boiler
100% coal (Phase -1) PLUS
1 x 120 TPH Boiler
100% Coal (Phase – 2) Normal Fuel Consumption:
576 TPDof Coal
The total Coal consumption for Boilers and Thermic Fluid Heaters is 741TPD.
Reasons for change in fuel configuration are described in Annexure – 9.
Prefeasibility Report for Change in Fuel configuration
3
The reduction in SO2 emission during coal combustion will be attained by employing
desulfurization process which involves the use of Calcium – based sorbent such as limestone
powder that captures the SO2 emitted during combustion of Fuel. This measure taken is
expected to achieve a reduction of at least70 % ofSO2 emissions. The addition of sand will
ensure the removal of excess Calcium in the form of Calcium silicate.
Prefeasibility Report for Change in Fuel configuration
4
1. INTRODUCTION
1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
JBF Industries Ltd., is the parent company, conceived as a Private Ltd. company in
1982, attainted corporate status by becoming Public Ltd Company in the year 1986.
The company has its subsidiary unit as JBF RAK LLC, at Ras-Al–khaima, UAE. JBF
Group is engaged in the manufacturing operation of Polyester chips / PET chips,
Polyester Partially Oriented Yarn (POY), Fully Drawn Yarn (FDY) & Polyester Film.
At present, the group turnover is of above Rs. 7000 crores. JBF group is committed
towards the Quality, Environment and Health & Safety. JBF has also been accredited
with ISO 9001, ISO 14001 & OHSAS 18001 certificates for its manufacturing
locations. Mr. B. C. Arya is the key promoter of the company and has experience of
the various fields in textile business. Under his leadership JBF group is now planning
for further backward integration project as PTA is the key raw material for
manufacturing of Polyester chips in the chain of textile commodity. Polyester chips /
PET chips have a growing market in India as well as outside India due to its wide
applicationin the Film, Bottle /Jar, Pharmaceutical, Beverages industries etc., Thus
under the name of JBF Petrochemicals Ltd., JBF group proposes the project of PTA
& PET chips along with power generation through captive power plant in Mangalore
SEZat Mangalore to cater the needs of their parent company as well as exporting to
various countries due to its global demand. JBF Petrochemicals Limited is a Limited
Company promoted by Mr. B.C. Arya and other Directors on the board are
Mr.A.G.Pai, Mr. Rakesh Gothi, Mr B R Gupta and Mrs. Ujjwala Apte. All the Board
of Directors have over 30 years of experience in various fields of business.
Prefeasibility Report for Change in Fuel configuration
5
1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT
The proposed project from JBF Petrochemicals Ltd., is as follows,
Table 1-1Details of the proposed project
Name of the Project M/s. JBF PETROCHEMICALS LTD.
Proposed Change In Fuel Configuration for Boilers and Thermic
Fluid Heaters for the Proposed Manufacturing of Pure Terephthalic
Acid (PTA) & Polyester Chips / Pet Chips of Various Types &
Grades and Power Generation through Captive Power Plant
Proposed Capacity 2.50 million tons per Annum of PTA, 0.5 million tons per annum of
PET / Polyester Chips, 24 MW Captive Power Generation
Project Proponent JBF Petrochemicals Ltd
Location Mangalore SEZ
Total Land Area 115.3 acres
Project Cost INR 3566 Crores
EIA Consultant Hubert Enviro Care Systems Pvt. Ltd
Project termed under Schedule 5 (e), category B project, petrochemical based processing
(Processes other than cracking and reformation and not covered under the complexes) located
inside notified industrial area
1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE
COUNTRY AND OR REGION
With the proposed 2.50 million tons per Annum of PTA, 0.5 million tons per annum
of PET / Polyester Chips, 24 MW Captive Power Generation capacity, JBF
Petrochemicals Ltd is one of the largest such plants proposed in India. The company
would help to attract investment, employment opportunity for the downstream chain
of textile processing and result in accruingrevenue for Karnataka/ Indian government.
The existing production units of JBF group in India & UAE are already
manufacturing Polyester Chips & consuming PTA as key raw material and demand
on PTA based processing of Polyester chips and Polyester Yarn are increasing
internationally. At present the plant has obtained Environmental Clearance to use85%
Biomass + 15% Coal in one of four boilers and four Thermic fluid heaters vide letter
no. SEIAA 17/IND 2014 dated 06/08/2015. The same is enclosed in Annexure-3.
Prefeasibility Report for Change in Fuel configuration
6
Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with
renewable Bio-fuel becoming visible, JBF has already obtained permission to use
85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.
Due to monsoons for nearly 6 months a year in DK District, the Biomass procured
will not be able to provide adequate Heating Value to support the minor variations in
process demands leading to frequent stops in a manufacturing process which has been
designed to operate on a continual basis all year round. Therefore, it is prudent to
have a fall-back arrangement in order to ensure reliability & availability, by designing
the system for firing 100% Coal. Hence we propose the use of 100% Coal in our
Thermic Fluid Heaters and two of the four Boilers.
JBF, being on the cusp of setting up a one-of-a-kind manufacturing facility in
Mangalore SEZ, DK District, Karnataka, would like to ensure that such uncertainties
are adequately backed up by redundancy measures to ensure uninterrupted running of
the Plant without compromising on the quality of Environment.
1.4 DEMAND-SUPPLY GAP
The existing plants of JBF group in India & UAE are already manufacturing
Polyester Chips & consuming PTA as key raw material and demand on PTA based
processing of Polyester chips and Polyester Yarn are increasing internationally. The
PTA produced at Mangalore will be able to cater to JBF Group’s captive
consumption of PTA in their Plants located across the world.
1.5 IMPORTS VS. INDIGENOUS PRODUCTION
The proposed products and capacity for the project is given in Table 2-2.
Table 1-2Proposed products for the Project
Sl.
No. Description of product
Capacity per month Capacity
(MTA) Phase -1
(MT)
Phase -2
(MT)
Total
(MT)
01 Purified Terephthalic Acid (PTA) 1,04,000 1,04,000 2,08,000 25,00,000
02 Polyester / PET Chips of various
types & grades 42,000 -- 42,000 5,00,000
03 Captive Power Plant 24 MW -- 24 MW
Prefeasibility Report for Change in Fuel configuration
7
1.6 EXPORT POSSIBILITY
As PTA is the key raw material for manufacturing of Polyester chips in the chain of
textile commodity, Polyester chips / PET chips have a growing market in India as
well as outside India due to its wide application in the Film, Bottle /Jar,
Pharmaceutical, Beverages etc. Thus under the name of JBF Petrochemicals Ltd., JBF
group proposes the project of PTA & PET chips along with power generation through
captive power plants in SEZ at Mangalore SEZ. Once the PTA plant is under
continuous operation, there will be additional generation of Power of around 8 MW,
which will be exported to OSBL for running the Utilities.
1.7 DOMESTIC / EXPORT MARKETS
The PTA produced by JBF at the project location will have TWO consumers;
PET Plant of 0.5 Million Tons per Annum capacity being setup at the same
location within Mangalore SEZ (adjacent to the PTA Plant)
JBF’s PET manufacturing facilities located at Ras-Al-Khaimah (RAK), UAE,
Silvassa (Dadra & Nagar Haveli) and Sarigam, Gujarat.
The PTA and PET produced by JBF will pave way for a host of downstream
industries which use PET as raw material, bringing direct and indirect employment to
a large number of local populace.
1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE
TO THE PROJECT
The project will contribute towards improvements in the quality of life of the people
in the area. With this in view, following measures are recommended:
Scheme to increase employment opportunities for the local people would be
implemented, as a part of Rehabilitation and Resettlement measures, such as
vocational training for skilled jobs for youth and women, providing opportunities for
setting up ancillary industries/ service industries etc.
As per agreement signed with MSEZL, JBF will provide jobs to about 115
individuals from rehabilitated families.
Prefeasibility Report for Change in Fuel configuration
8
2. PROJECT DESCRIPTION
2.1 TYPE OF PROJECT
The project involves the proposed change in fuel configuration in boilers and Thermic
Fluid Heaters in the proposed production of ―PTA & Polyester chips / PET chips of
various types & grades and Power Generationthrough Captive Power Plants‖ which
falls under item no. 5(e) i.e. Petrochemical based processing under the category ―B‖
as per the EIA notification 2006 and as amended in 2009.
There is no change in the proposed production capacity. About 80% of Projecthas
been completed. The proposed products and capacity for the project is given in Table
2-1.
Table 2-1Proposed products fromthe Project
SI.
No. Description of product
Capacity per month Capacity
(MTA) Phase -1
(MT)
Phase -2
(MT)
Total
(MT)
01 Purified Terephthalic Acid (PTA) 1,04,000 1,04,000 2,08,000 25,00,000
02 Polyester / PET Chips of various
types & grades 42,000 -- 42,000 5,00,000
03 Captive Power Plant 24 MW -- 24 MW
The Capital Cost Projection and its break up for the Proposed Project are given in
Table 2.2.
Table 2-2 Financial Breakup for the project
Sr.
No. Particulars
Total Cost (Rs. In
Crores)
1. Civil Work (Steel structure) 280
2. Plant & Machinery 2824
3. Effluent Treatment System (Stripper
column) 350
4. Power Plant 100
5. Furniture & Fixture 2
6. Computer & Electronic Data System 10
TOTAL 3566
Prefeasibility Report for Change in Fuel configuration
9
2.2 LOCATION
The project is located at Mangalore SEZ, Village: Bajpe, Tehsil: Mangalore, Dist:
Dakshina Kannada, Karnataka State. The Satellite image of project site within 10 Km
radius is given in Figure 2-1.
Figure 2-1Satellite map of 10 km radius around the project Site
Figure2-2 Satellite image of Project Site
Mangalore is an industrial city with well-established infrastructure like road and rail
connectivity, maritime seaport as well as airport facilities and assumes strategic
importance to business and economic development because of its geographic
advantages. A special purpose vehicle (SPV), named Mangalore SEZ Ltd (MSEZL)
has been incorporated with (i) ONGC-MRPL, (ii) Karnataka Industrial Areas
Development Board (KIADB) representative of Government of Karnataka, (iii)
Kanara Chamber of Commerce and industries (KCCI) and (iv) Infrastructure
Prefeasibility Report for Change in Fuel configuration
10
Leasing and Financial Services Ltd (IL&FS) as joint venture partners. Mangalore
SEZ is notified as SEZ by Ministry of Commerce & Industries for setting up
Petroleum and Petrochemicals Units. The layout of Mangalore SEZ is enclosed in
Annexure-10.
The Mangalore SEZ has acquired around 1800 acres of land for Phase I project and
the project is approved by Ministry of Environment & Forests vide their approval No.
21-383/2007-IA, dated 3rd April 2008 and Consent for Establishment from Karnataka
State Pollution Control Board dated 30th April 2008 (Copies enclosed in Annexure-6
& 7). Mangalore SEZ is providing developed industrial plots for setting up Petroleum
and Petrochemicals Units in place of the previously approved Olefin Complex.
Mangalore SEZ is providing the entire infrastructure like road connectivity, graded
plots, water infrastructure, Waste water collection system, solid waste management
system, green belt, marine disposal facilities for treated waste water etc. JBF
Petrochemicals has signed MoU with Mangalore SEZ Ltd. for leasing 115.3 Acres of
land for setting up the project.
2.3 SALIENT FEATURES OF THE PROJECT SITE
The salient features of the project site are given in the following table.
Table -2-3 Salient Features of the project site
Features Description
Name of the project JBF Petrochemicals Ltd
Purpose of the report
Change In Fuel Configuration for Two of Four Boilers and
four Thermic Fluid Heaters for the Proposed Manufacturing
of Pure Terephthalic Acid (PTA) & Polyester Chips / Pet Chips
of Various Types & Grades and Power Generation through
Captive Power Plant
Land Area 115.3 Acres
Nearest Village Bajpe
Nearest Railway station Suratkal (6 km from site of west)
Highway NH-17 at about 7 km on west side.
Airport Bajpe (Mangalore) at 2 km in South East direction
Sea port NMPT, Mangalore (7 km in South West direction)
Prefeasibility Report for Change in Fuel configuration
11
Features Description
Forest/Wildlife
Sanctuary
No Sanctuaries/ National Parks or Reserved Forests. However,
Pilikula Nisarga Dhama (Zoo), located at about 15 km from the
proposed site
Historical/
Archaeological Place Nil
Project site
Total estimated land requirement for PTA & PET units is 115.3
Acres being leased from Mangalore SEZ Ltd. The land is in
possession of Mangalore SEZ which is notified by Ministry of
Commerce & Industries, Gol.
The geographical coordinates of the project is as attached as Annexure -11. The plant
layout plan has been attached as Annexure-12. The location drawing of the proposed
unit in Mangalore SEZ is shown below in Figure 2-3.
Figure 2-3 Location drawing of proposed unit
Construction activities at site are in progress and recent photographs of the site are
given in figure below.
Prefeasibility Report for Change in Fuel configuration
12
Figure 2-4 Recent site photos
JBF Site Entrance
Construction of Guard Pond
Construction of WWTP
Prefeasibility Report for Change in Fuel configuration
13
2.4 BASIS OF CALCULATION FOR STEAM AND FUEL
JBF Petrochemicals Ltd has decided to setup a Petrochemicals unit for manufacture
of 2.5 MMTPA of Purified Terephthalic Acid (PTA) in TWO Phases, each of 1.25
MTPA capacity. The project also includes a manufacturing facility for Poly Ethylene
Terephthalate (PET) of 0.5 MTPA.
The PTA Plants will require High Pressure Steam @ 330 ˚C& 90 BarG and will be
catered to by FOUR Boilers; TWO of Steam Generation capacity 120 TPH using
Natural Gas / Furnace Oil as fuel. TWO Boilers, ONE of capacity 100 TPH (Phase –
1) & ONE of 120 TPH (Phase – 2), shall operate on Coal as Fuel.
The PET Plant has FOUR (3 Working – 1 Standby) Thermic Fluid Heaters (TFH),
each of capacity 9.5 Million Kcal/h. The fuel proposed to be used isCoal (low-ash
Coals like Indonesian/ Australian) from existing 85% Biomass +15% Coal.
For PTA Plant the basis of calculation is as below
Total Coal required : 576 TPD
Calorific Value of Coal : 5000 kcal/kg
Sulfur Content in Coal : 1%
Fuel Oil firing : 36 TPD
Sulfur Content in Fuel Oil : 2 %
Total Sulfur Loading :540 kg/h SO2
Revised Sulfur Loading
(after70% Sulfur Reduction) : 204 kg/h SO2
Para Xylene Tanks
Prefeasibility Report for Change in Fuel configuration
14
Stack Height Calculation; H : 14 x (204) 0.3
Or 69m.
JBF has already designed a 90m Stack which, as per calculation, is capable of
effectively dispersing emissions.
CONFIGURATION FOR FUEL FIRING SYSTEM IN PET PLANT
THERMIC FLUID HEATERS
PET Plant has 4 nos. (3 Working & 1 Standby) of Thermic Fluid Heaters, each of
9.5MM kcal/h.
During NORMAL Plant operation, 3nos. Thermic Fluid Heaters, each of 9.5 M kcal/h
shall be in operation.
Total Heat Thermal Efficiency of 85% for Thermic Fluid Heaters, Fired Heat Load:
28.5 / 0.85 = 33.5 M kcal/h
Assuming CV of Coal as 5000 kcal/kg, Coal required: 33.5 x 106 / 5000 = 6.7
MT/h or say160.8 TPD.
Therefore, the PET Plants will require about 165 MT/day of Coal (correcting for
variations in operating conditions and efficiencies).
Total Sulfur Loading :68.75 kg/h Sulfur OR 137.5 kg/h SO2
Revised Sulfur Loading
(after70% Sulfur Reduction) : 20.63 kg/h Sulfur OR 41.25 kg/h SO2
Stack Height Calculation; H : 14 x (41.25) 0.3
Or 42.7m.
The present Stack Height of 65m is sufficient for dispersion of SO2 as per
stipulations of Environment Protection Act 1986 & amendments thereof.
JBF has made all necessary provisions for Limestone addition which will reduce
SO2 emission by at least 70%.
2.5 SIZE OR MAGNITUDE OF OPERATION
There is no change in the production capacity/ products manufactured. The
application is for Proposed Change in Fuel Configuration for TWOBoilers(from 85%
Biomass – 15% Coal to 100% Coal) and Four Thermic Fluid Heaters (from 85%
Biomass +15% Coal to 100% coal) for the Proposed ―Manufacturing of Pure
Terephthalic Acid (PTA) & Polyester Chips / Pet Chips of Various Types & Grades
and Power Generation through Captive Power Plant‖.
Prefeasibility Report for Change in Fuel configuration
15
2.6 PROJECT DESCRIPTION WITH PROCESS DETAILS
This chapter includes the manufacturing process and flow diagrams for the
manufacturing processes.
2.6.1 MANUFACTURING PROCESS OF PTA
a) AIR COMPRESSION
Atmospheric air is compressed in a Compressor, driven by combination of
electric motor, an off-gas expander and a steam turbine. In oxidation reactor,
Oxygen of air reacts with PX in a liquid phase solution containing catalyst
and acetic acid solvent, to form crude Terephthalic acid (CTA) & water.
Oxidation reaction is highly exothermic; Heat is recovered in a series of
Heat Exchangers to generate steam, which is sent to the steam turbine to
generate power.
b) OXIDATION REACTION
Crude TA slurry from the reactor enters a series of crystallizers where
additional TA crystals are formed, as the slurry is depressurized and cooled.
Additional air is added in the first of the three crystallizers to complete the
oxidation reaction. The flashed solvent from the crystallizers is sent to the
low pressure absorber in the solvent recovery area, while the resulting slurry
enters the TA solids separation section.
c) TA CRYSTALLIZATION AND SOLIDS SEPARATION
Rotary Filters separates TA crystals from mother liquor. The mother liquor,
which contains acetic acid, water, and catalyst, is recycled to reactor. TA
solids are sent to Purification. Process gases are sent to LP absorber for acid
recovery
d) VENT GAS TREATMENT
Off-gas from the oxidation reactor is sent to a catalytic oxidation (CATOX)
section, where volatile organic compounds are converted to CO2 & water.
Majority of the gas from the CATOX is sent to turbo-expander for energy
recovery. Gas is then sent to a scrubber and subsequently discharged to
atmosphere, through process stack meeting all environmental norms. Minor
Prefeasibility Report for Change in Fuel configuration
16
portion of the Off-gas from the CATOX is used for pneumatic conveying of
PTA
e) SOLVENT AND CATALYST RECOVERY
The solvent recovery area involves several steps to recover acetic acid &
catalyst from the TA mother liquor purge stream. The purge stream is first
evaporated to vaporize the acetic acid. This vapor stream is then sent to LP
absorber, which is a two-stage scrubber using acetic acid followed by water.
Various other Oxidation process vapor streams are also scrubbed in the
LPA. The recovered acid from the LPA is recycled, while the overhead
gases VOC are treated in CATOX.
Residue generated in the solvent evaporation is treated in catalyst recovery
section to recover catalyst. This is a two-stage extraction process to recover
catalyst metals by precipitation using pH adjustment. The recovered metals
are recycled to the reactor while the purge stream is sent to waste water
treatment
f) PURIFICATION REACTION
CTA cake is first mixed with water. The CTA / Water slurry is heated in a
series of heat exchangers to the temperature required to dissolve all of the
solids in water, upstream of Purification reactor. The heated CTA / water
solution is reacted with hydrogen, in presence of a Palladium-on-carbon
catalyst, to convert the major CTA impurity (4-Carboxy Benzaldehyde) into
water soluble Para - Toluic acid
g) PTA CRYSTALLIZATION AND VENT SCRUBBER
Then PTA/water solution passes through a series of crystallizers .The
resulting slurry is sent to the solids separation section. The water vapor
evaporated in the crystallizers is used to preheat the reactor feed. Excess
vapor that cannot be condensed is sent to the PTA Vent scrubber, where
they are cooled and scrubbed with water to remove solids. The scrubbed gas
is sent to CATOX to destroy VOC.
Prefeasibility Report for Change in Fuel configuration
17
h) PTA SEPARATION, DRYING AND BAGGING
In PTA solids separation section, PTA crystals are separated from mother
liquor. Majority of mother liquor is recycled. The cake discharges to the
PTA dryer. Evaporated moisture is cooled & scrubbed in Dryer scrubber to
remove solids. The treated vapors are sent to CATOX for VOC destruction.
Dry PTA from Dryer is pneumatically conveyed to the Product handling
area for bagging & dispatch.
Prefeasibility Report for Change in Fuel configuration
18
Figure 2-5Process Flow Diagram of PTA Manufacturing
Prefeasibility Report for Change in Fuel configuration
19
Figure 2-6PTA Block Diagram with Vent and Effluent streams
20
2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET
a) PTA SLURRY MAKING
Purified Terephthalic Acid (PTA) in powder form is charged in Hopper and
conveyed to the plant under 0.5 Kg pressure to the Slurry Preparation Reactor.
Mono Ethylene Glycol (MEG) is charged under the close condition to pump
from MEG Storage Yard to PTA Slurry making Reactor. PTA and MEG are
mixed in the PTA slurry reactor and transferred through Mass Flow Meter to
esterification reaction.
b) ESTERIFICATION REACTION
Under the continuous process from one side slurry of PTA received goes under
gradual heating up to 2500C to start esterification reaction. The reacted mass is
passed through esterification stage – II having temperature of 250 to 2600C and
form Monomer during the process. During this process, water is generated as
byproduct and is transferred to Effluent Treatment System for the treatment.
During the esterification reaction, Antimony Trioxide is added as a catalyst to
accelerate the rate of reaction.
c) PREPOLYMERIZATION
During the continuous process, monomer mass from esterification stage is
passed through prepolymerization stage between 260 to 280°C and at the same
time delustering agent as Titanium Dioxide (TiO2) is added in the reaction
mass. Under this stage, mixture of Oligomer and Polymer are formed.
d) POLYCONDENSATION
Under continuous process, Oligomer in molten form is filtered through S.S.
Candle Filter and the mass is received for final condensation. The final
polycondensation reaction is carried out between 280 to 290°C and after
achieving the desired Viscosity, the molten polymer mass is passed through
Cutter to form the required size of Polyester Chips.
21
e) DRYING OF THE CHIPS
Preferred size of chips are dried in Dryer and passed through Classifier and
transferred to Intermediate Storage Vessel.
f) STORAGE & DESPATCH
The manufactured chips are checked for various physico-chemical parameter
and the approved chips are stored in Chips Silo. Finally it is packed in jumbo
bags and dispatched to the various customers & option is also kept open for
dispatching it in tanker load (if required).
22
Figure 2-7Flow Diagram for PET/Polyester chips manufacturing
23
Figure 2-8Site Layout Plan for Manufacturing of Polyester Chips / PET
24
2.6.3 RAW MATERIALS REQUIRED
The raw materials and products for the proposed project will be brought and sent to
the Mangalore Port through a dedicated road cum pipeline corridor, the layout of
which is attached as Annexure- 13.
2.6.4 RAW-MATERIALS AND ITS CONSUMPTION FOR PTA PLANT
The raw material requirement along with their specific consumption in PTA
manufacturing is as follows.
Table 2-4Raw Materials in PTA manufacturing
S.
No
Description Specific
Consumpt
ion
PTA - 1 PTA - 2 Means of Storage
kg per MT
PTA
Requireme
nt
(MT/Mont
h)
Requireme
nt
(MT/Mont
h)
1 Para Xylene 650.0 67700 67700 Floating roof Storage
tanks
2 Acetic Acid (as 100%) 30.0 3125 3125 Storage tanks
3 Cobalt (as metal) 0.015 1.6 1.6 Bag/Drum
4 Manganese (as metal) 0.008 0.8 0.8 Bag/Drum
5 Hydrogen Bromide (as
100%)
0.23 24 24 Storage tanks
6 Hydrogen 0.21 22 22 MRPL/OMPL -
Outsourcing
7 PTA Purification
Catalyst (5%
Palladium on Carbon)
0.025 2.6 2.6 Bag/Drum
8 Sodium Carbonate
(as 100%)
3.28 342 342 Bags
25
Apart from above inputs, following catalyst & chemicals will be used during manufacturing of
PTA:
a) Caustic Soda solution - for neutralization of effluent and as scrubbing media in vent scrubber
b) Aluminium oxide pellets - used as desiccant.
c) Ceramic-base CATOX catalyst for destruction of VOC.
d) Sodium Formate (40% solution) is used as Scrubbing media
2.6.5 RAW-MATERIALS AND ITS CONSUMPTION FOR POLYESTER CHIPS /
PET
The raw material requirement along with their specific consumption in PET/Polyester
chips manufacturing is as follows.
Table 2-5Raw Material in PET Manufacturing
Sr.
No.
Raw materials Consumption in
(MT/MT)
Requirement
(MT/Month)
Means of
Storage
1 PTA 0.86 36120 Bags/Silo
2 MEG 0.338 14196 Storage Tanks
3 Antimony
Acetate/Trioxide
0.0004 16.8 Bags/Drum
4 Isophthalic acid 0.022 924 Bags/Drum
5 Diethylene glycol 0.002 84 Storage Tanks
6 Titanium dioxide 0.003 126 Bags/Drum
7 Ortho phosphoric acid 0.0005 21 Carboyes
Apart from above following chemicals will be used during manufacturing PET Chips:
a) Ammonia Gas - 50 Kg/cylinder and monthly consumption will be 2500 Kgs for Nitrogen
generation plant
b) Palladium & De-oxo catalyst and carbon molecular sieve for nitrogen generation and drying
26
2.7 RESOURCE OPTIMIZATION
TwoBoilers each of capacity 120 TPH are proposed to be based onNatural gas / Furnace
Oil and TwoBoilersof capacity 100TPH & 120 TPH arebased on 100 % Coal will be
installed with a capacity considering peak load of 460 TPH at 90 BarGworking pressure
for high pressure steam generation for the PTA process.
Normally each PTA plant upon stabilization, will consume 125TPH of high pressure
steam. During process upsets, about 340 TPH of high pressure steam will be consumed.
Hence 4 nos. of Boilers withcombined steam generation capacity 460 TPH will be
installed for generation of high pressure steam to meet the peak load requirement during
start up / breakdown / upset conditions of the PTA plant.
The Coal requirements in the premises under normal operating situation will be576 TPD
for Boiler and 165 TPD for Thermic Fluid Heater. Total Coal consumption is 741 TPD
2.7.1 SPECIFICATION OF PROPOSED FUELS
i. Natural Gas
Table 2-6 Typical Properties of Natural gas
Sr. No. Component
Composition in Vol % or
Mol%
1 Methane 97.9
2 Ethane 0.1
3 Carbon Dioxide 0.5
4 Nitrogen 1.5
Total 100
Gas Properties
1 Specific Gravity of gas w.r.t air at 60°F and 14.696 psi 0.566
2 Density at 60°F and 14.696 psi in kg/m3 0.692
3 Z Factor at 60°F and 14.696 psi 0.997
4 Net Calorific value at 60°F and 14.696 psi in kcal/sm3 7973
5 Gross Calorific value at 60°F and 14.696 psi in kcal/sm3 8854
27
ii. Furnace Oil
Table 2 – 8 Typical Properties of Furnace Oil
iii. Coal
Table 2–9 Typical Properties of Coal
SL. NO. DESCRIPTION UNIT VALUE
1 Calorific value KCAL / KG 5000 – 5200
2 Bulk density KG/M3 650 – 850
3 Ash fusion point DEGREE C 1250
4 Maximum quantity to be fired MT/DAY 200
5 Hard grove index HGI 45 – 50
6 Range of particle size MM 0 – 50
PROXIMATE ANALYSIS
1 Moisture content % 15 – 20
2 Ash content % 8 – 10%
3 Volatile matter % 38 – 42
4 Fixed carbon % 25 – 35
ULTIMATE ANALYSIS
1 Carbon % 70 – 75
2 Oxygen % 15 – 20
Sr. No. Properties
Composition in Vol
% or Mol%
1 Density (Approx. g/cc at 15°C) 0.89–0.95
2 Flash Point (°C) 66
3 Pour Point (°C) 20
4 G.C.V. (kCal/kg) 10,500
5 Sediment, % Wt. Max. 0.25
6 Water Content, % Vol. Max. 1.0
7 Sulphur Total, % Wt. Max. Upto 2.0
8 Ash % Wt. Max. 0.1
28
SL. NO. DESCRIPTION UNIT VALUE
3 Hydrogen % 5 – 6
4 Nitrogen % 1.2 - 1.5
5 Sulfur % 0.1 - 0.9
2.7.2 COAL LINKAGE
Coal will be transported through trucks from New Mangalore Port to JBF plant
through dedicated MSEZ Corridor. The coal linkage drawing is shown below in
Figure 2-9.
29
Figure 2-9 Movement of Coal from Port
JBF Project
Site
MSEZL’s 60m
Wide Road-
cum-Pipeline
Corridor
30
2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER
REQUIREMENT
Table 2–10 Availability of Energy and water as per EC
S.NO PROJECT DETAILS EXISTING AS PER EC PROPOSED
1. Power requirement Peak load (MW) 87 No change
Normal operation
(MW)
24 No change
2. Water consumption
(KLD)
43,100 No change
3. Domestic effluent
(KLD)
200 No change
4. Effluent generation
(KLD)
21600 No change
Table 2–11Water Requirement
SI
No
Details For PTA plant
(KLD)
For Polyester chips
plant (KLD)
Total
requirement
(KLD)
1 Water
consumption for
industrial purpose
9840 220 10,060
2 Water
consumption for
cooling tower
32,200 590 32,790
3 Water
consumption for
domestic
200 50 250
Grand Total 42,240 860 43,100
31
2.9 QUANTITY OF WASTE WATER GENERATED
The proposed project will have effluent treatment plant consisting of Physico-chemical
treatment, primary treatment & secondary treatment. After micro filtration and RO
(tertiary treatment), 70% of the treated effluent is recycled to the plant. The remaining
30% of the treated effluent meeting Environmental norms will be discharged to the final
outlet as approved to Mangalore SEZ.
Table 2–12 Phase wise effluent generation
SL.NO. SOURCE PHASE - 1 (IN
KLD)
PHASE - 2 (IN
KLD)
1 Waste water generated during the
process PTA – 1 plant 4456 -
2 Waste water generated during the
process PTA – 2 plant - 4456
3 Waste water generated during the
process pet plant 525 -
4 Water generated from process 910 910
5 Condensate recovery (DM regeneration
waste & boiler blow down) 615 615
6 Other services (floor washes & solution
preparation) 460 460
7 Cooling tower blowdown 4196 3996
Total quantity (industrial) 11,162 10438
Total quantity (domestic) 200
Total (for the respective phase) 11 362 10438
Grand total 21800
32
Table 2–13 Waste Water Generation – Total
SI. No. Details Proposed Qty KL/day Avg. COD mg/ltr. Avg. COD
mg/ltr.
1. Domestic 200 - -
2. Process 13,408 14,000 6000-7500
3. Cooling Tower & Utilities 8,192 100 -
Total 21,800
JBF will have designed capacity of effluent treatment plant to take care of normal, peak,
routine & non-routine operations. Condensate water generated due to high pressure steam
supply to the process plant will be recycled to boiler, and the Blow-down will be routed to
ETP. Domestic waste as overflow of soak pit will be connected to biological treatment
section of the Sewage treatment plant for final treatment.
The average COD level in the generated effluent will be about 14000 mg/l, BOD 6000 to
7500 mg/l. 70 % of the treated effluent will be recycled back to cooling tower. Effluent will
be treated up to a Statutory Board Standard prior to its final discharge. There will be a
Methane gas generation during the anaerobic treatment of effluent which will be utilized
for making HP Steam (90BarG) for Process. The ETP Process Flow Diagrams are
enclosed in Annexure-14.
Table 2–14 Components for operation and treatment of waste water
SI.
NO.
DESCRIPTION USAGE
1 Various size of collection sump ETP
2 Oil & grease separator ETP
3 Neutralization sump ETP
4 Caustic solution / lime solution tank ETP
5 Polyelectrolyte solution tank ETP
6 Anaerobic digesters ETP
7 Aeration tank ETP
8 Clarifier ETP
33
SI.
NO.
DESCRIPTION USAGE
9 Thickener and belt filter press ETP
10 Sludge drying bed ETP sludge removal
11 Aerator ETP
12 Diffuser ETP
13 Pressure sand and activated carbon filter ETP
14 Ultra filtration unit ETP
15 Reverse osmosis plant ETP
16 Treated water, permeate and rejected water tank ETP
17 Gas compression system with blower & tank Biogas utilization
18 Flare Burning of low pressure gas
19 TOC meter Online water monitoring
20 De-mineralize water polishing system ETP
21 Quality control laboratories with instruments to
analyze major parameters of effluent
Water analysis
2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY
DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE
The plot plan for the proposed project indicating the location of project components is
enclosed in Anexure-13.
2.11 PROPOSED EMISSIONS & STACK DETAILS
Among the four Boilers, 2 nos. of boilers using Oil & Natural Gas and 2nos Solid fuel
Coal have a combined stack height of 90 m and the 4 Thermic Fluid Heaters have a
separate stack of 65 m height, based on the prescribed empirical formula of Sulfur
loading rate as per the EP Act, 1986.
34
Table 2–15 Stack and Emission Details
SI.
No.
Description/Parameter Value Remarks
1 SO2 245.25 kg/hr
Total Emissions from JBF PTA
(Phase 1 & 2) and PET Plants.
2 Boiler vent stack H – 90m
Common Stack for all 4 Boilers
Stack height designed for effective
dispersion Of SOx emissions using
The formula:
H = 14x(Q)0.3
;
H – Height of stack(M)
Q – Mass flow rate of SOX(kg/h)
3 Thermic fluid heater
vent stack
H – 65m Remains unchanged
4 Particulate matter 50 Mg/Nm3
As Per existing CFE issued by
KSPCB
5 Ash generation 80 TPD Shall be disposed as per
MOEF/KSPCB guidelines
6 DG Stack 30 m Common stack for DGs
7 ETP Flare (Closed-
type)
12 m As per API – 527 Guidelines
35
Table 2–16 Details of Air pollution control Equipment as approved in EC & CFE
S.
NO
DESCRIPTION OF
EQUIPMENT QTY. MOC CAPACITY / SPECIFICATION
DESIGN
TEMP
(⁰ C)
DESIGN
PRESS.
(BAR G)
01 Catalytic oxidation reactor ONE SS 316 L H-4.2 M,Φ-3.1 M 19.5 M3
Catalyst 430 10.6/-0.18
02 Recuperative heater ONE Shell- SS 316
Tube – SS 316
A-2382 M2
Q-17.6 M KCAL/H
Shell-430
Tube-430
Shell 10.6/-
0.18
Tube 10.6/-
0.18
03 Catox start-up heater ONE Shell-CS
Tube – Titanium
A-91 M2
Q-3.8 M KCAL/H
Shell-320
Tube-430
Shell-103/ FV
Tube- 10.6/-
0.18
04 Process vent scrubber ONE Shell-FRP. glass filled PP
packing H-15.5 Φ-6.0 M packedbed 5 M 81 0.15 /-0.18
05 Vent scrubber circulation
pumps TWO SS 316 L V-656 M3/H,∆P-2.4 Bar,P-75 KW 81 4.5
06 Process vent stack ONE SS 304 L H- 13.0 / 32.8 M Φ- 2.4 / 1.9 M 196 0.15 /-0.18
07 High pressure bromine
scrubber ONE
ShelL-TIT. cladon CS PP
packing H-9.2 M Φ-1.4 M Packedbed 5 M 220 10.6/-0.18
08 Bromine scrubber quench
pumps TWO SS 316 L V-62.5 M3/H,∆P-3.6 Bar,P-15 KW 92 16
09 Quench cooler ONE Shell-CS
Tube – DSS 2205
A-45 M2
Q-1.0 MKCAL/H
Shell -65
Tube-92
Shell-10.6/-
0.18
Tube- 16 /-
36
S.
NO
DESCRIPTION OF
EQUIPMENT QTY. MOC CAPACITY / SPECIFICATION
DESIGN
TEMP
(⁰ C)
DESIGN
PRESS.
(BAR G)
0.18
10 Conveying gas chiller
package ONE SS 316 L Chills 16 T/H GAS TO DEW PT. 5 ⁰ C 50 10.6/-0.18
11 PTA drier vent scrubber ONE SS 304 L H- 8.5 M
Φ – 2.8 M 129 1.1 /-0.18
12 Drier vent scrubber
circulation pumps TWO SS 304 L V-110 M3/H, ∆P-9.6 BAR,P-75 KW 129 14
13 PTA drier vent scrubber hot
cond. ONE
Shell-CS
Tube – SS 304 L
A-164 M2
Q- 3.0 MKCAL/H
Shell -123
Tube-129
Shell-17.2/FV
Tube- 1.1/-
0.18
14 PTA drier vent scrubber 2
nd
cond. ONE
Shell-CS
Tube – DSS 2205
A-384 M2
Q- 10.6 MKCAL/H
Shell – 65
Tube-129
Shell-10.3
Tube- 1.1 /-
0.18
15 PTAday silo vent dust
collector TWO SS 304 L Filters 3100 NM
3/H OF GAS 149 0.35 /-0.133
16 PTA product silo dust
collector ONE SS 304 L Filters 13200 NM3/H OF GAS 149 0.35 /-0.133
17 PTA vent ko drum ONE SS 304 L H- 6 M Φ- 3.6 M 195 4.0 /-0.18
18 PTA vent ko drum condenser ONE Shell-CS
Tube – DSS 2205
A-156 M2
Q- 4.6 MKCAL/H
SHELL – 65
TUBE-195
Shell-10.3/-
0.18
Tube- 4.0 /-
0.18
19 PTA vent ko drum circulation TWO SS 304 L V-166 M3/H, ∆P-4.9 BAR, P-37 KW 195 10.7
37
S.
NO
DESCRIPTION OF
EQUIPMENT QTY. MOC CAPACITY / SPECIFICATION
DESIGN
TEMP
(⁰ C)
DESIGN
PRESS.
(BAR G)
pumps
20 PTA crystallizer overflow ko
drum ONE SS 304 L H-2.7 M Φ- 2 M 131 1.1
21 Blowdown drum ONE CS H-4.2 M Φ-2.1 M 131 1.1/-0.18
22 Liq. catalyst tank vent
scrubber ONE SS 316 L H-6 M Φ-0.4 M 50 0.50 / -0.18
23 Acetic acid tank vent
scrubber ONE SS 316 L H-6 M Φ-0.4 M 100 0.50 / -0.18
24 Oxid. unit psv sump ONE CS Epoxy coated L-7.4 M- Φ 5.0 M 210 1.0 / -0.18
25 Low pressure absorber ONE
Shell- SS 316 L
Packing’s moc poly
Propylene
H-11 M Φ-0.8 M2
PACKED BEDS OF
HT. 1.9 & 1.3 M 115 3.5 /-0.18
26 Low pressure absorber drum ONE SS 316 L L-10 M- Φ 4 M 115 3.5 /-0.18
27 LP absorber circulation pump TWO SS 316 L V 163 M3/H, ∆P-15 BAR,P 160 KW 115 24
28 DH tower overhead final
condenser ONE
Shell-CS
Tube – DSS 2205
A-1587 M2
Q-40 MKCAL/H
Shell – 65
Tube-146
Shell-10.3/-
0.18
Tube- 12.4/-
0.18
29 High pressure absorber ONE
SHELL- SS 317 L CLAD
ON CS
TRAYS –SS 316 L
H-25 M- Φ 3.4 M PACKED BED OF 8.4
M & 10 TRAYS 154 12.4 /-0.18
30 HP absorber reflux cooler ONE SHELL-CS
TUBE – DSS 2205
A-280 M2
Q-3.6 MKCAL/H
SHELL – 65
Tube-115
Shell-10.3/-
0.18
38
S.
NO
DESCRIPTION OF
EQUIPMENT QTY. MOC CAPACITY / SPECIFICATION
DESIGN
TEMP
(⁰ C)
DESIGN
PRESS.
(BAR G)
Tube- 24 /-
0.18
31 HP absorber vent gas heater ONE SHELL-CS
TUBE – SS 316 L
A-275 M2
Q-6.5 MKCAL/H
Shell –200
Tube-145
Shell-7.8 / FV
Tube- 12.4 /-
0.18
32 ESP ONE STEEL Flue gas handling volume- 156000M
3/H
Dust removal efficiency-99.5 % 190°C -
33 Bag Filters ONE SHELL-MS ELEMENT-
POLY PROPYLENE
To Control Particulate Matter
Total No Of Filter-48
Filter Area-36 m2
Filtration Air Volume-1080 m3-8640 m
3
< 120ᵒC 0.5-0.7 MPa
39
3. SITE ANALYSIS
3.1 CONNECTIVITY
The project site is located within Mangalore SEZ and is well connected by Road. The
location of the site is given in Figure 4-1 below and the Port Road corridor is enclosed in
Annexure-13.
Figure 3-1 Project Site location at Mangalore SEZ
3.2 LAND FORM, LAND USE AND LAND OWNERSHIP
The proposed project site is within Mangalore SEZ area. The land use classification for
the study area is given in table below
40
Table 3-1 Land Use classification for the Project Site
SR. NO. LAND USE/LAND COVER CLASSES AREA IN (KM2) AREA IN
(%)
1. Vegetation 122.05 38.87
2. Land with shrub 17.64 5.62
3. Waste land 82.64 26.32
4. Bare soil/sand 12.99 4.14
5. Built-up area 26.18 8.34
6. Water body 52.46 16.71
Total 314 100.0
3.3 TOPOGRAPHY (ALONG WITH MAP)
The Topography of the project site is given in the figure below.
Figure 3-2 Topography of the Project Site
41
3.4 EXISTING LAND USE PATTERN
Table 3-2Land use Pattern as per Census Data (area in Hectare)
SI.
No.
Name Of
Village
Total
Area
Forest Irrigated Unirrigated Cultivable
Waste Land
Area Not
Available For
Cultivation
1. Bajpe 722.70 - - 150.19 162.26 410.20
2. Paduperara 822.97 - 7.10 455.13 252.17 108.57
3. Badagayekkar 1011.26 - 0.81 629.09 145.73 253.63
4. Permude 742.43 - - 264.48 44.75 431.20
5. Kalavar 330.35 - - 381.01 3.79 311.02
6. Haleangadi 198.65 - 48.58 16.12 55.22 78.73
7. Kolambe 915.03 - - 268.96 90.11 555.96
8. Muduperar 896.06 - - 308.61 332.53 254.92
9. Kilanjar 525.29 - - 395.28 6.50 123.51
10. Chellairu 317.01 - - 174.36 66.08 76.57
11. Delanthabettu 320.43 - 24.57 84.45 37.15 174.56
12. Badagayekkar 1011.26 - 0.81 629.09 145.73 235.63
13. Tenkayekkar 640.64 - 5.82 169.27 77.85 387.70
14. Kuthethur 695.82 - - 381.01 3.79 311.02
15. Bala 567.21 - - 284.94 28.13 254.14
16. Kenjaru 667.56 - - 95.41 163.56 408.59
17. Mudashedde `594.06 - - 123.08 242.92 228.06
18. Padushedde 145.58 - - 65.99 40.49 39.10
19. Mennabettu 551.90 - - 166.43 101.43 284.04
20. Kilanjur 136.59 - 31.57 33.35 50.72 20.95
21. Attur 106.70 - - 67.61 2.14 36.95
22. Koikude 278.82 - 23.40 129.31 48.72 77.31
23. Bellairu 293.65 - - 208.57 63.45 21.63
Total 22350.42 0 142.66 5481.74 2165.22 5083.99
42
Figure 3-3Land use map of Study Area
Figure 3-4Cropping Pattern in Study Area
PADDY
53%
COCONUT
15%
ARECANUT
6%
BANANA
1%
MANGO
4%
CASHEWNUT
21%
PADDY
COCONUT
ARECANUT
BANANA
MANGO
CASHEWNUT
43
3.5 EXISTING INFRASTRUCTURE
Erection and construction of proposed project is completed up to80%. This is a proposal
for Change in Fuel Configuration for Two of Four Boilers and all Thermic Fluid Heaters
(from 85% Biomass-15%Coal)to100% Coal for the Proposed ―Manufacturing of Pure
Terephthalic Acid (PTA) & Polyester Chips / Pet Chips of Various Types & Grades and
Power Generation through Captive Power Plant‖. The construction activities have
commenced and are progressing in full swing.
3.6 SOIL CLASSIFICATION
Table 3-3Textural Class of Soil in the Study Area
SI.
NO
SAMPLING
LOCATIONS
PARTICLE SIZE DISTRIBUTION (%) TEXTURAL
CLASS FINE SAND CORE SAND SILT CLAY
1. JBF PROJECT SITE 38.2 19.6 19.4 22.8 SANDY CLAY
LOAM
3.7 CLIMATIC DATA FROM SECONDARY SOURCES
Table 3-4 Meteorological Data for Dakshina Kannada District
(Source- IMD, 2014)
44
3.8 SOCIAL INFRASTRUCTURE
The project will provide employment to local youth, thus increasing their standard of
living and helping strengthen the social infrastructures of the region.
45
4. PROPOSED INFRASTRUCTURE
4.1 INDUSTRIAL AREA
Table 4-1 Summary of proposed change
S.NO Project details Existing EC amendment Changes Proposed
1. Land area 115.3 Acres No change in existing
2. Project cost 3566 Crores No change in existing
3. Proposed
capacity
2.50 million tons per annum
of PTA, 0.5 million tons per
annum of pet / polyester
chips, 24 mw captive power
generation
No change in existing EC
4. Power
requirement
Peak load
(MW)
87 No change in existing EC
Normal
operation
(MW)
24 No change in existing EC
5. Thermic fluid
heaters
Thermic fluid heater
(4 Nos.) capacity: 9.5 M
K.Cal/Hr each
85% Biomass + 15% coal
(205 TPD Biomass + 30 TPD
Coal)
Thermic fluid heater (4 nos.)
capacity: 9.5 MMkcal/h each
100%Coal 165T/day
6. Turbine with
WHR system
Turbine with WHR system (2
nos.) Capacity: Power-12.00
MW each
Diesel
2160 KL/month
No changes
7. Steam generators
/ boilers
Steam generator / Boiler
3x 120 TPH
Natural gas/Furnace Oil
1x100 TPH boiler
85% biomass+ 15% coal
(165 TPD Biomass + 25 TPD
Coal)
Steam generator / Boiler
(4 Nos.)
Total capacity: 460 TPH
(120+120+120+100 )
2 x 120 TPH Boiler
(no fuel change)
Natural gas/ Furnace Oil
1 x100 TPH (Phase – 1) &
1x120 TPH(Phase –
2)Boilers Coal 576T/DAY
46
4.2 RESIDENTIAL AREA
Adequate infrastructure facilities, viz., housing, medical, education, transportation,
communication, playground, library, canteen, market for the township would be
developed within MSEZ Non Processing area by MSEZL so as to avoid strain on the
existing infrastructure resources base.
4.3 GREENBELT
The proposed project site is situated within the Mangalore SEZ and they have provided
33% area of open land as greenbelt as a developer of SEZ which is also covered in their
environment clearance.
A green belt of required width (3m) will be provided all around the plant boundary limits.
In addition, avenue trees will be planted along the roads.
4.4 SOCIAL INFRASTRUCTURE
The project will provide employment to local youth, thus increasing their standard of
living and thus helping strengthen the social infrastructures of the region
4.5 CONNECTIVITY
Connectivity between Mangalore Port and JBF site has been shown in Annexure-13.
4.6 DRINKING WATER MANAGEMENT
The water supply in the study area is through wells, tap water, hand pumps Tube well,
river and canal allied sources. Bore wells are the main source of drinking water supply.
Potability also appears to be good. Water for the proposed Project will be provided by
Mangalore SEZ Ltd.
4.7 SEWERAGE SYSTEM
Sewage from the plant would be disposed to the sewage pits/network from where it is
pumped to the main STP for treatment and the treated water is used for horticulture.
8. Total Coal
consumption
741 TPD
47
4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT
4.8.1 ASH GENERATION
From PTA Boilers
Assuming 8 - 10% Ash content in Coal (Indonesian Coal), , the Ash generation per day
shall be about 60MT/day which is trapped using a high efficiency ESP (> 99.5% Dust
removal efficiency), and pneumatically conveyed to Ash Silo thus avoiding the problems
associated with wet ash handling.
From PET Plant
Assuming 8 - 10% Ash content in Coal (Indonesian Coal), the Ash generation per day
shall be about 20MT/day. A high efficiency ESP (> 99.5% Dust removal efficiency) may
be proposed if suitable, and ash pneumatically conveyed to Ash Silo, in a similar manner
as envisaged for PTA Plant Boilers, thereby avoiding the problems associated with wet
ash handling.
Total ash generation from both PTA and PET Plants will be 80 MT/day.
4.8.2 DUST SUPPRESSION AND TREATMENT SYSTEM FOR COAL
When coal is used as fuel, water sprinkling is proposed for dust suppression at the rate of
2.5 Kg/ Sq.cm of the area incase of track hopper and 4.5 Kg/ Sq.cm in case of wagon
tipper coal stock. Of the water used, 10 % will be absorbed by Coal and 20 % will be lost
in evaporation. The treatment system proposed will be Settling Pond. The water after
treatment can be recirculated for dust suppression.
4.8.3 ELECTROSTATIC PRECIPITATOR (ESP)
Collection efficiencies of 99.5% or greater for coarse and fine particulates at
relatively low energy consumption
Dry collection and disposal of dust
Low pressure drop—typically less than 10–20 mm (0.5 inch) water column
Continuous operation with minimum maintenance
48
Relatively low operation costs
Operation capability at high temperatures up to 700oC,or (1,300
oF) and high
pressure (up to 10 atmospheres or 150 pounds per square inch, psi) or under
vacuum
Capability to handle relatively large gas-flow rates (on the order of 50,000
m3/min)
Table 4-2 Specification of ESP
S.No Parameters Specification
1 Handling flue gas volume 156000m3/h
2 Flue gas temperature 190°C
3 Dust concentration of inlet flue
gas
10 g/Nm3
4 Dust concentration of outlet flue
gas
≤50 mg/Nm3
5 Dust removal efficiency 99.5%min.
4.8.4 ASH HANDLING SYSTEM
a) Fly Ash
The ash removal system consists of three stages ESP, dust hoppers & pneumatic
ash conveying system. One cone pump (0.6 m3) will be installed under each
hopper and the dry ash shall be sent into ash silo of capacity 150 m3, which will
handle the ash discharging capacity of3.5days. The conveying distance is 50m.
Adequate dust collector or bag filters will be provided at the Ashsilo for dust
suppression & venting clean (Filtered) air from conveying system. The dry ash
can be loaded and transported for integrated utilization. Fluidization device will
be equipped to ensure smooth ash discharge into the ash silo. The fluidization air
can be provided by gasification fan, and the electric heater at the outlet of fan.
The layout showing the Ash handling system is enclosed in Annexure-15.
49
Table 4-3 Specification of ash conveying system
S.No Item Unit Parameter
1 Designed output T/H 3
2 Average ash-gas ratio kg/kg 35
3 Average conveying pressure MPa 0.1
4 Speed at the front part of ash-pipe m/s 2 ~4
5 Speed at the end part of ash pipe m/s 8 ~9
6 Air consumption for conveying m3/min 7.0
7 Airconsumption for instrument m3/min 0.5
b) Bottom ash
When burning Coal, the slag shall be discharged, and this discharged slag after
cooling can be used as bed material within the Boiler to ensure better fluidized
combustion. Bed material shall be added into boiler by coal feeder at the feed-end
of the boiler when starting and operating the boiler.
PLC shall be used for the control of ash handling system. Automatic control
consists of PLC, local control station and sensors.
c) Desulfurization Arrangement
The reduction in SO2 emission during coal combustion will be attained by utilizing
low-sulfur coal (Indonesian coal) as well as by employing desulfurization process
which involves the use of Ca-based sorbent such as limestone powder that captures
the SO2 emitted.
JBF has made all the required provision for feeding Limestone along with coal into
the boiler in the mole ratio of Ca:S = 2 for the removal of SO2 emitted. This measure
taken is expected to achieve a reduction of MINIMUM70 % in SO2 emissions. The
addition of sand will ensure the removal of excess calcium in the form of Calcium
silicate. A brief description of the system is as follows:
Limestone is stored in a Steel Bin and discharged through a Screw Conveyorfirst and
then through two conveyors before entering the Boiler Furnace through Rotary
50
Feeders, whose function is to regulate flow of Fuel, Sand and Limestone entering the
Furnace. The Limestone Bin has a storage inventory of 20m3. A rotary valve operated
by a variable frequency drive linked to the control systemis mounted at the hopper
discharge and serves as the material metering device.This valvedischarges material
through a small, vented chute directly into a blow-through rotary airlock runningat a
constant speed. The blow-through rotary airlock is the primary seal between the
metering system and the pneumatic conveying line; the metering rotary valve is the
secondary seal. Each feeder hopper is equipped with its own reverse jet pulse dust
filter system, which traps nuisance dust generated during feeder refill and returns it to
the process. The dust filter also facilitates air displacement in the hopper as material
is metered out or replenished, as well as air leakage from the blow-through rotary
airlock. Every precaution is taken to assure that the conveying lines do not become
plugged with material.
The SO2 emitted during the operation of PTA plant and PET Plant will be 204 kg/h
and 41.25 kg/h, respectively.
The detailed calculations regarding SO2 emissions will be furnished in the EIA report.
4.8.4.1 HAZARDOUS WASTE AND ITS MANAGEMENT
All the hazardous and non-hazardous waste will be stored in an integrated scrap yard
in a segregated manner. Some of the wastes, like contaminated packing material,
sweeping material and other non-hazardous waste will be disposed through registered
recycler and re-processor having KSPCB/CPCB approval.
51
Table 4-4 Estimated Hazardous Waste Generation & Disposal
Description Qty. in MT/ year Type of handling &
disposal
Future use
Spent catox
catalyst
13.4MTin 4years collected and packed in
liner containing drums
and stored in integrated
scrap yard
Send to approved TSDF site for
final disposal
Used aluminium
oxide, carbon
with palladium
catalyst
40 collected and packed in
liner containing drums
and stored in integrated
scrap yard
Sent to approved Recyclers/
TSDF site for final disposal
Scrap PTA from
various
handling points
& storage tanks
900 collected and packed in
liner containing drums
and stored in integrated
scrap yard and leach ate
systems will be provided
Sent to approved recycler / actual
user.
ETP waste 3000 packed in bags and stored
at a designated area.
Sent to TSDF site for final
disposal.
process waste
(lump waste)
1500 packed in bags and stored
at a designated area.
Sold to actual users / recycler
duly approved by KPCB/CPCB.
Used oil /
waste oil
600 kl stored in drums Sold to registered recycler/re-
processor duly approved by
KPCB/CPCB.
Empty
bags/liners
1000 stored at a separate
storage area
Sold to authorized scrap vendor.
Empty
containers/
barrels / carboys
28,500 nos stored at a separate
storage area
sold to authorized scrap vendor.
Waste resin,
used carbon,
catalyst &
expired
chemicals
100 stored in drums & bags Sent to TSDF site for final
disposal.
Residual sludge
of fuel oil
1500 stored in drums Sold to registered recycler or
actual user duly approved by
KPCB/CPCB.
Oil and
chemical soaked
cotton waste
50 Packed in bags and stored
at a designated area.
Sent to TSDF site for final
disposal/as per KSPCB norms
Flyash 30,000 Stored in Ash Silos. Will be sent to fly ash brick
manufacturers/ cement
manufacturers approved by
KSPCB.
Enclosed integrated storage yard for Hazardous &Non-hazardous waste generated in
52
the premises.
Guidelines approved by MoEF / KSPCB for notified area as Mangalore SEZ Ltd. will
be executed in ref. to disposal of hazardous &non-hazardous waste.
Integrated scrap yard will have segregation of hazardous &non-hazardous area in a
close covered shed with a separate entry for hazardous &non-hazardous storage area.
Figure 4-1 Details of the integrated scrap yard
4.8.5 NOISE AND ODOUR CONTROL
All equipment in the power plant would be designed/operated to have a noise level
not exceeding 85 dB as per the requirement of Occupational Safety and Health
Administration Standard (OSHA). In addition, since most of the noise generating
equipment would be in closed structures, the noise transmitted outside would be still
lower.
There will be no generation of bad odour as process will be carried out in closed
reactor with auto-operations in the plant.
4.8.6 HAZARDOUS CHEMICAL STORAGE & HANDLING
The raw materials consumed falls under Hazardous chemicals as per the MSIHC
rules, 2000. The details pertaining to the hazardous chemicals in terms of health,
100
m
55
m
Residual sludge of FO
15x25
ETP Waste 40x20
Used & Waste Oil 30x7.50
Process waste (L.W.) & Scrap PTA
30x15
55
m 45 m
Paper waste &
Insulation 15x25
Empty bags/liners 30x20
Empty containers / barrels /
carboys 20x15
INTEGRATED SCRAP
YARD
Gate
01
Gate
02
Spent Catox
15x12.50
Oil & Chemical soak cotton waste
30x7.50
Waste resin, used carbon
catalyst, Mol. Sieve, exp. Chemical & Lead acid battery
15x12.50
Leach
ate Pit
Iron scrap 20x15
PVC material &
Glass 15x12.50
Wooden scrap
15x12.50
53
explosion and fire hazards and measures for storage, handling & transportation will
be considered complying with statutory regulations under the various acts & rules.
All measures shall be taken to minimize the environmental impact during the process.
Table 4-5 Details of Hazardous Chemicals and its storage
Hazardous
chemical
Max.
Storage
Capacity
Place of
storage
Storage
facility
Mode of Transport
Mono Ethylene
Glycol
10000 MT Raw Material
Storage Tank
yard
Tank By road
Titanium Dioxide 120 MT Raw Material
Storage
Bags By road
Antimony trioxide
or Antimony
triacetate
12 MT Raw Material
Storage
Bags/
Container
By road
Paraxylene
(2 tanks)
15000 MT
each
Raw Material
Storage Tank
yard
Tank By road/ Through
pipeline by OMPL
Acetic Acid 1500 m3 Raw Material
Storage Tank
yard
Tank By road
Hydrogen Bromide 20 MT. Raw Material
Storage Tank
Tank By road
Caustic Soda
solution
600 MT Raw Material
Storage Tank
Tank By road
Hydrogen -- -- -- From neighboring
Refinery/ Aromatic plant,
through pipeline
54
4.9 POWER REQUIREMENT
Power plant consisting of 2 nos. of 15 MW each rated capacity which can be able to
generate net 12MW per turbine during performance running at around 35°C. Initially
diesel will be used as main fuel for power generation and changeover to natural gas will
be made as and when gas will be available.
Figure 4-2Flow Chart for Captive power plant and Heat recovery system
55
5. PLANNING BRIEF
5.1 PLANNING CONCEPT
The existing plants of JBF group in India & UAE already manufacture Polyester Chips &
consume PTA as key raw material and demand on PTA based processing of Polyester
chips and Polyester Yarn are increasing internationally. Paraxylene (Px) is a basic raw
material for PTA manufacturing which may be sourced from the aromatic complex being
developed by ONGC Mangalore Petrochemicals in Mangalore SEZ or can be imported,
as the PTA plant is being developed in SEZ. The Mangalore SEZ Ltd. is providing all the
required infrastructure like road connectivity, graded plots, water infrastructure, waste
water collection system, solid waste management system, marine disposal facility for
treated waste water and green belt development. Apart of PTA produced will be used for
PET manufacturing plant being situated adjacent to the PTA plant in Mangalore, the rest
being exported to JBF RAK, UAE.
5.2 POPULATION PROJECTION
The demographic details of the study area are given in subsequent sections while the
summarized information is presented below which highlights information on household,
population, employment, literacy and community structure. The salient features of the
study area are given in table below.
Table 5-1Demographic Summary
S.No Demographic Parameters Details
1. No. of Taluk 1
2. No. Of villages 44
3. no. of urban areas (part of Mangalore) 4
4. Total no. of households 27647
5. Total population 137850
6. Population density 491.02
7. Scheduled castes (%) 8810(6.39%)
8. Scheduled tribes (%) 3325(2.41%)
56
S.No Demographic Parameters Details
9. Literate (%) 102647(74.46%)
10. Main workers (%) 58883(42.71%)
11. Marginal workers (%) 7902(5.73%)
12. Non- workers (%) 71065(51.55%)
5.3 LAND USE PLANNING
Table 5-2 Summary of project
S.NO PROJECT DETAILS EXISTING AS PER EC PROPOSED
1. Land Area 115.3 Acres No change
2. Project Cost Rs. 3566 Crores No Change
3. Proposed Capacity 2.50 million tons per Annum of
PTA, 0.5 million tons per annum
of PET / Polyester Chips, 24 MW
Captive Power Generation
No change
4. Power Requirement Peak Load (MW) 87 No change
Normal Operation
(MW)
24 No change
5. Water Consumption
(KLD)
43,100 No change
6. Domestic Effluent
(KLD)
200 No change
7. Effluent Generation
(KLD)
21600 No change
8. Green belt area 33% area of open land as greenbelt developed by Mangalore
SEZ Ltd.
57
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
5.4.1 PHYSICAL INFRASTRUCTURE
The project with an investment of more than Rs. 3500 crores will bring improvement
in physical infrastructure like roads, electricity, water infrastructure along with
various other developmental activities as per its Corporate Social Benefit strategies.
5.4.2 SOCIAL INFRASTRUCTURE
The project wills provide employment to local youth, thus increasing their standard of
living and thus helping strengthen the social infrastructures of the region.
5.4.3 AMENITIES/FACILITIES
The major facilities provided by MSEZL are
Proper First Aid centre and medical facilities will be provided
Mangalore SEZ is providing the entire infrastructure like road connectivity,
graded plots, water infrastructure, Waste water collection system, solid waste
management system, green belt development, marine disposal facilities for
treated waste water etc.
A dedicated and pressurized fire fighting ring-header along the periphery of
the Units with adequate number of fire hydrants, fixed position monitors,
water curtains, foam nozzles located strategically.
JBF & MSEZL have a mutual aid tie-up in order to contain any hazard
emanating from the Industry.
A number of fire fighting pumps with diesel prime movers backed by
adequate supply of raw water.
Dedicated fire alarm networks with adequate number of fire alarm call points
and emergency telephone handsets throughout the site.
A two-way Public Address (PA) system installed independently in all
production units and also in important service areas.
Adequate supply protective clothing & breathing apparatus will be made
available to all personnel of emergency team.
On-site first aid and treatment centre with round the clock medical attendance.
58
6. REHABILITATION AND RESETTLEMENT (R & R) PLAN
6.1 BRIEF OUTLINE ON THE POLICY ADOPTED
As a part of Rehabilitation and Resettlement measures, MSEZL has provided Project
Displaced Families (PDF) with means for livelihood generation such as sponsoring
Diploma courses in various disciplines such as Electrical& Electronics, Mechanical &
Chemical Engineering, Monetary benefits and allotment of land to re-build their houses,
vocational training for youth and women, providing opportunities for setting up ancillary
industries/ service industries etc.
As part of the Agreement signed with MSEZL , JBF shall provide jobs to about
115Project Displaced Persons nominated by their respective families and certified
by R&R Committee of Mangalore SEZ Ltd. Adequate infrastructure facilities,
viz., housing, medical, education, transportation, communication, playground,
library, canteen, market for the township would be developed (in MSEZ Non
Processing area), so as to avoid strain on the existing infrastructure resources
base, by Mangalore SEZ Ltd.
Social forestry would be encouraged as an income avenue for the local people and
helpful in maintaining the ecological balance.
Awareness programmes for likely hazards viz., fire, explosion and gas leakage
etc. and protection measures of these hazards would be conducted.
Regular safety and environmental awareness programmes would be conducted in
the nearby villages to promote awareness. Periodic health check programmes for
the nearby villages would also be taken up.
59
7. PROJECT SCHEDULE & COST ESTIMATES
7.1 TIME SCHEDULE FOR THE PROJECT
The project was commenced after being accorded with Environmental Clearance from
Karnataka SEIAA and Consent for Establishment (CFE) from Karnataka State Pollution
Control Board. The mechanical completion of the project is forecast for MARCH 2016
and the Pre-commissioning and Commissioning will be complete by JUNE2016.
7.2 ESTIMATED PROJECT COST
Table 7-1 Project Cost Details
Sr. No. Particulars Total Cost (Rs. In
Crores)
1. Civil work 280
2. Plant & machinery 2824
3. Effluent treatment system and stripper column 350
4. Power plant 100
5. Furniture & fixture 2
6. Computer & electronic data system 10
Total 3566
The proposed change converts the idea of turning waste into energy, and also reduce
emission load on the environment
60
8. ANALYSIS OF PROPOSAL (FINAL
RECOMMENDATIONS)
The project will bring in the following benefits for the proposed manufacturing plant
The proposed fuel viz., coal will provide support for uninterrupted Production
with lower down-time and is not likely to be affected by monsoons as compared
to Biomass.
The ash content is lower at about 10% as compared to Indian coal which contains
40% Ash.
The following environmental and societal benefits are expected from the given industry:
This process utilizes a Catalyst based Oxidation process for destruction of
organics and organic halides, CATOX, which eliminates the requirement for the
use of an incinerator.
Local production of PTA/PET/Polyester chips means reduction of import of the
same. Thus saving millions of gallons of fuel used up in shipping every year.
33% green belt being provided by the MSEZ, along with extra green belt
proposed by JBF will help keep the air clean..
Project using raw material from nearby OMPL, decreases the need of transport
and thus fuel usage.
500 people, mostly from the neighboring areas will benefit directly or indirectly
from the proposed Project.
About 115 persons from the rehabilitated families will be recruited by JBF, thus
improving their standards of life.
JBFs will be maximizing its utilization, recycling and reuse of wastes, even
producing energy form the off gas, which will be a highly pro environmental
benefit from the project.
Around 70% of the effluent water will be treated and reused, so it will use lesser
amount of raw water thus making it an additional environmental benefit.
Flexibility of the using Butane-rich Natural Gas as when available, in place of
Furnace Oil, as Fuel. GAIL is laying a pipeline from Kochi.
61
Low NOx burners are used throughout the plant.
Comprehensive effluent treatment plant using both conventional & tertiary
treatment technology to achieve over 70% recycle and improved quality treated
wastewater discharge.
Water consumption is reduced right at the design phase by recycling over 15000
KLD of Condensate, Process and treated water back into the process, which helps
reduce the overall water requirement.
ETP is designed in a way, so as to use the natural gradient of site for flow to
reduce the total no. of pumps required.
Mangalore City’s sewage treated and reused for Industrial purpose.
Advanced British Petroleum technology from Process Licensor to optimize the
overall energy efficiency of the plant reducing total fuel consumption and water
consumption, thereby reducing products’ environmental footprint.
Online analyzers are being proposed for real time stack monitoring.
Variable speed drives are being used.
Methane Gas, generated from Anaerobic Digester, is used to generate about 14
tons per hour of High Pressure Steam (90BarG) to meet about 20% of Process
steam requirements.
Boiler chimney height is proposed for 90meters.
Vapor Absorption machines (VAM) are being used for refrigeration and air
conditioning purposes.