Prefeasibility Report for Proposed Chloromethanes Manufacturing …environmentclearance.nic.in/writereaddata/Online/TOR/0… · · 2016-05-05Prefeasibility Report for Proposed Chloromethanes

CHEMPLAST SANMAR LIMITED

(UNIT 2)

Prefeasibility Report for Proposed Chloromethanes Manufacturing Plant at RS No. 28, Melavanjore, T. R. Pattinam, Karaikal Puducherry UT

MAY 2016

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

CHEMPLAST SANMAR LIMITED (UNIT 2)

PFR FOR PROPOSED CHLOROMETHANES

MFG. PLANT AT KARAIKAL, PUDUCHERRY UT QUALITY CONTROL

KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 2


Prefeasibility Report for Proposed Chloromethanes Manufacturing Plant at RS No. 28, Melavanjore, T. R. Pattinam, Karaikal Puducherry UT © Kadam Environmental Consultants (‘Kadam’), May, 2016

This report is released for the use of the Chemplast Sanmar Limited (Unit 2), Regulators and relevant

stakeholders solely as part of the subject project’s Environmental Clearance process. Information

provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used

for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of

Publication

Prefeasibility report for Proposed Chloromethanes Manufacturing Plant at Survey No.

28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT

Project Number 1624372106 Report No. 1 Version 1 Released May, 2016

Prepared &

Managed By Bijal Kothari &Jitixa Upadhyay Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

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

E: [email protected]; T:+91-265-3001000; F: +91 265 300106

Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,

Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected];T: 0124-4242430; M:+91-98998-04300

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]






CONTENTS

1 EXECUTIVE SUMMARY ................................................................................. 6

1.1 PROPOSED PLANT FEATURES AND PRODUCTION CAPACITY .............................................. 6

1.2 WATER ................................................................................................... 6

1.3 EFFLUENT GENERATION, TREATMENT AND DISPOSAL .................................................... 6

1.4 POWER REQUIREMENT ................................................................................... 6

1.5 AIR EMISSIONS ........................................................................................... 7

1.5.1 Flue Gas Stacks .................................................................................. 7

1.6 SOLID/HAZARDOUS WASTE GENERATION AND DISPOSAL................................................ 7

2 INTRODUCTION .......................................................................................... 8

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................ 8

2.2 BRIEF DESCRIPTION OF THE PROJECT .................................................................... 8

2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION .............................................. 9

2.4 DEMAND SUPPLY GAP .................................................................................... 9

2.5 IMPORT VS. INDIGENOUS PRODUCTION ................................................................ 10

2.6 EXPORT POSSIBILITY ................................................................................... 10

2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. .......................... 10

3 PROJECT DESCRIPTION ............................................................................. 11

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ................ 11

3.1.1 Type of Project ................................................................................. 11

3.1.2 Interlinked and Interdependent Project .................................................... 11

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT LAY OUT) WITH COORDINATES ........................................................................ 11

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 14

3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 14

3.5 PROCESS DESCRIPTION WITH PROCESS DETAILS (SCHEMATIC DIAGRAM / FLOW CHART SHOWING THE

PROJECT LAY OUT, COMPONENT OF THE PROJECT ETC. SHOULD BE GIVEN SALIENT FEATURES OF TECHNOLOGY

14

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 17

3.6.1 Raw Materials ................................................................................... 17

3.6.2 Transportation details of Raw Materials .................................................... 18

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 18

3.7.1 Water consumption ............................................................................ 18

3.7.2 Power Requirement ............................................................................ 19

3.8 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE

BRIEFLY OUTLINED ............................................................................................. 19

3.8.1 Gaseous Emission .............................................................................. 19

3.8.2 Solid / Hazardous Waste ...................................................................... 19





3.9 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA

PURPOSE ....................................................................................................... 20

4 SITE ANALYSIS ......................................................................................... 21

4.1 CONNECTIVITY ......................................................................................... 21

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................ 21

4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 21

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING

AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE

FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE

HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION

SHOULD BE GIVEN. ............................................................................................. 22

4.1 EXISTING INFRASTRUCTURE ............................................................................ 22

4.2 SOIL CLASSIFICATION .................................................................................. 22

4.3 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 22

4.3.1 Temperature .................................................................................... 23

4.3.2 Wind ............................................................................................. 23

4.3.3 Rainfall ........................................................................................... 23

4.3.4 Cloud Cover ..................................................................................... 23

4.3.5 Humidity ......................................................................................... 23

4.4 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 23

5 PLANNING BRIEF ...................................................................................... 24

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY

PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ....................................................... 24

5.2 POPULATION PROJECTION .............................................................................. 24

5.3 LAND USE PLANNING (BREAK UP ALONG WITH GREEN BELT ETC.) ..................................... 24

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ................................ 25

5.5 AMENITIES / FACILITIES ............................................................................... 25

6 PROPOSED INFRASTRUCTURE .................................................................... 26

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 26

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 26

6.3 GREEN BELT ............................................................................................ 26

6.4 SOCIAL INFRASTRUCTURE .............................................................................. 26

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ............ 26

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...................................... 26

6.7 SEWAGE SYSTEM ....................................................................................... 26

6.8 INDUSTRIAL WASTE MANAGEMENT ..................................................................... 26

6.9 POWER REQUIREMENT & SUPPLY/ SOURCE ............................................................. 26

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 27

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING

HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS(A BRIEF OUTLINE TO BE GIVEN) .................. 27





8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 28

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE

PROJECT TO BE GIVEN) ......................................................................................... 28

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT.

28

8.2.1 Fixed Capital .................................................................................... 28

9 ANALYSIS OF PROPOSAL ........................................................................... 29



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

Chemplast Sanmar Limited is the flagship company of Sanmar Group, which is one of the largest

industrial firms in the Southern Part of the India with a Group turnover of Rs. 6,000 Crores per annum.

The Sanmar Group manages many businesses grouped under various industry segments viz., Chemicals,

Engineering, Shipping and Metals.

Chemplast Sanmar already manufactures the Chlorine that is required for the manufacture of

Chloromethanes. The plant will be located at Karaikal, where Chemplast has its Caustic Chlor facility.

Chlorine will be supplied through a pipeline and this is the main reason for choosing this location for the

project. The other main raw material is Methanol and it will be imported or domestically sourced. As

Karaikal Port is in close proximity, it would be easier to import.

1.1 Proposed Plant Features and Production Capacity

The proposed project is for installation of a manufacturing facility for producing Chloromethanes. The

proposed project will be located at S. No. 28, Village Melavanjore, Taluka: Thirumalairayan Pattinam

(TR Pattinam), Dist. Karaikal, Puducherry. The estimated cost of the proposed project is INR 220 Crores.

The Total Production capacity of the proposed site is 53,000 MTPA of Chloromethanes.

1.2 Water

The fresh water requirement after Production startup at new site has been estimated as 1210KLD. Water

source will be underground bore well water. The rejects from the RO treatment of this water will be

sent to the existing Desalination plant of Chemplast Sanmar that can handle this rejects as feed to the

desalination RO.

1.3 Effluent Generation, Treatment and Disposal

The proposed expansion project will generate 15 KLD of sewage. Total 600KLD of industrial effluent

will be generated from the proposed manufacturing activity and RO & DM Rejects.

Domestic Sewage waters will be sent to STP and treated water will be used for gardening.

Effluent will be treated in to remove suspended solids and to remove calcium and magnesium impurities.

This effluent can also be used a feed to the seawater desalination plant of Chemplast Sanmar plant.

The effluent will be used to as feed to the desalination RO reducing the seawater intake to that extent.

1.4 Power Requirement

The power requirement for the proposed expansion facility will be met through Puducherry Electricity

Board. Total estimated electrical load for the proposed manufacturing unit is around 3000 kVA. In

addition, the plant will have one DG set of 500 kVA for emergency power back up during grid failure.



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT EXECUTIVE SUMMARY


1.5 Air Emissions

1.5.1 Flue Gas Stacks

The Chloromethanes plant will have following sources of emission namely,

Process emission from HCl absorption unit.

Flue gas emission from the proposed Coal based boiler.

Flue gas emission from the incinerator.

Flue gas emission from stack attached to stack attached to the Emergency DG set.

The emission from stacks will be well within the stipulated norms.

Adequate stack height will be provided to all flue stacks, based preferably on the Environment Protection

Rules, or in the absence of specific guidance in regulations, good engineering practice.

1.6 Solid/Hazardous Waste Generation and Disposal

Hazardous Solid wastes generated by the unit will be maintained as per Hazardous Waste

Handling and Trans-boundary Movement) Rules, 2008 and will be disposed off as per the details given

in Schematic Representation of the Feasibility Drawing which give Information of EIA Purpose

A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break

up is attached as Figure 3-2.

.

1.7 Submission

In the light of the above, we would like to state that the proposed Chloromethanes plant will be set up

employing best available engineering practices that would enable to meet the environmental norms

specified. The complete system will be studied for its environmental impacts and the required systems

will be put up to ensure minimal environmental impact.



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION


2 INTRODUCTION

2.1 Identification of Project and project proponent

Chemplast Sanmar Limited is the flagship company of Sanmar Group, which is one of the largest

industrial firms in the Southern Part of the India with Group turnover of Rs. 6,000 Crores per annum.

The Sanmar Group manages businesses that are grouped under various industry segments viz.,

Chemicals, Engineering, Shipping and Metals.

2.2 Brief Description of the Project

The proposed expansion project isfor manufacturing of Chloromethanes. The proposed project will be

located at S. No. 28, Village- Melavanjore, and Taluka: TR Pattinam, Dist. Karaikal, Puducherry UT. The

estimated cost of the proposed project is INR 220 Crores. The Total Production capacity of the proposed

site is 53,000 MTPA. Total plot area for proposed expansion is 31,485m2. The details of production

capacity given below in Error! Reference source not found..

2.2.1 Technology

Chemplast Sanmar Operates a 34000 TPA Chloromethanes Plant at its Mettur Dam facility in Tamil Nadu.

The plant is in operation from 1967. The technology for the proposed project is being sourced from

China. This technology provides for varying composition of the three products viz, Methylene Chloride,

Chloroform and Carbon tetra Chloride. The technology focuses on maximization of Methylene Chloride.

The technology has two steps -

1. Hydro Chlorination - Methanol is converted in to Methyl Chloride Catalytically. The other reactant is

Anhydrous HCl that is obtained as a byproduct from the second step.

2. Thermal Chlorination - The Methyl Chloride is then chlorinated to Methylene Chloride, Chloroform and

CTC. All the three products are formed simultaneously in the reactor. The proportion of formation

depends on the mole ratio of the reactant. More Methyl Chloride favors Methylene Chloride and less

Methyl chloride favors CTC.

After the Thermal chlorination, the Excess Methyl Chloride fed is recovered and then recycled.

Distillation is done to separate the three products into its pure form. The distillation residues (heavy

ends) will be incinerated.





2.3 Need for the project and it’s importance to region

Chloromethanes consist of 4 products namely - Methyl Chloride, Methylene Chloride,

Chloroform and Carbon tetrachloride.

Major demand for Chloromethanes are

Methylene is used as a solvent in Pharma industry.

Carbon tetrachloride is used for manufacturing of agro intermediates.

Chloroform is used a solvent in Pharma industry, a key raw material for manufacturing

of refrigerant gas R-22 -->TFE-->PTFE.

Methyl Chloride also finds demand in manufacturing of Pharma intermediates.

With Pharma industry growing in India at an average CAGR of 15%, the demand for Solvents

is estimated to grow at an average rate of 6%.

The total Chloromethane supply from 5 producers in India would be 260 KTPA and current

demand is around 315 KTPA, which is a gap of 55 KTPA. Considering the growth of Pharma

and agro industries, the gap for chloromethane is expected to widen and would invite imports

and loss of foreign exchange to India.

40% of Chloromethane demand is from South India would give us an regional advantage with

an added advantage of in house Chlorine, a key raw material used in manufacturing of

Chloromethane.

2.4 Demand Supply Gap

The following table provides the supply demand gap for the products in India

Table 2-1: Demand Supply Gas

Description Financial Year(Values in TPA)

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Domestic Demand

Methylene Chloride 172 200 210 220 230 240

Chloroform 107 107 117 117 108 108

Carbon Tetrachloride 19 20 23 23 23 23

Total Demand 298 327 350 360 361 371

Domestic Supply


Chloroform 87 88 103 103 103 103


Total Supply 217 222 259 259 259 259

Demand - Supply gap


Chloroform 20 19 14 14 5 5


Demand - Supply gap 81 105 91 101 102 112

As the Pharmaceutical Industry is bound to grow over the years, the demand for solvents also will

grow. This phenomenon is seen globally.





2.5 Import vs. Indigenous Production

The entire production will be import substitution.

2.6 Export Possibility

There is certainly possibility of exports, but as given above the domestic market demand is very high

focus will be to sell in the domestic market.

2.7 Employment Generation (Direct and Indirect) due to the project.

During construction phase: 300 – 350 persons

During Operation phase: 120 persons





3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

3.1.1 Type of Project

The proposed project is for manufacturing of petrochemical based processing that is covered under

Category – 5 (f). As interstate boundary of Tamilnadu-Puducherry is less than 1km from project site

hence it will be considered as “A” category project as per new EIA notification vide gazette no. S.O.

1533 dated 14th September 2006.

3.1.2 Interlinked and Interdependent Project

The project is interlinked with the existing Unit of Chemplast Sanmar Limited as the treated effluent,

fresh RO rejects will be fed to the desalination unit. This will reduce the seawater intake of the

existing unit.

3.2 Location (map showing general location, specific location and project boundary

& project lay out) with coordinates

The proposed facility is located at RS. No. 28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT.

The total plot area of the proposed unit is 31,485 m2. Location map of the proposed site is attached as

Error! Reference source not found.. Site lay out map of proposed project is given as Error!

Reference source not found..





Figure 3-1: Site Location on Google Image with Latitude-Longitude

CHEMPLAST SANMAR LIMITED (UNIT 2) PFR FOR PROPOSED CHLOROMETHANES MFG. PLANT AT

KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION


Figure 3-2: Site Layout Map



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PLANNING BRIEF


3.3 Details of alternate sites considered and the basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted

The main raw material for the project is Chlorine. Chemplast Sanmar Limited manufactures Chlorine in

its existing Chlor Alkali facility at Karaikal. The Chlorine can be supplied through pipeline. In locating

the project adjacent to the existing Chlor Alkali, plant avoids road transport of Chlorine that is risky.

Hence, it is ideal to locate the plant at Karaikal.

3.4 Size or Magnitude of Operation

Chemplast Sanmar Limited (Unit 2) plans to install production plant of Chloromethanes: 53,000 MTPA

Methyl Chloride: 3000 TPA

Chloroform, Methylene Chloride, Carbon Tetra Chloride: 50,000 MTPA

Total plot area for proposed plant is ~ 31,485 m2. 31.29% of the land will be used for green cover

(9853 m2). The estimated cost of the proposed facility is INR 220 Crores.

3.5 Process Description with Process Details (Schematic Diagram / Flow Chart

showing the project lay out, component of the project etc. should be given

Salient Features of Technology

Chemplast Sanmar Operates a 34000 TPA Chloromethanes Plant at its Mettur Dam facility in Tamil Nadu.

The plant is in operation from 1967. The technology for the proposed project is being sourced from

China. This technology provides for varying composition of the three products viz, Methylene Chloride,

Chloroform and Carbon tetra Chloride. The technology focuses on maximization of Methylene Chloride.

This process is based on the methanol as raw material to generate Chloromethanes (CMS), by two

steps:

Hydrochloride reaction: Methanol reacts with HCl to general CH3Cl (hereinafter as C1); and

Chlorination reaction: CH3Cl reacts with Cl2 to generate CH2Cl2, CHCl3 and CCl4 (hereinafter as C2,

C3 and C4 respectively)

Process of CMS plant is very complicate, with very strict operation and control, so need many testing

and controlling points.

System composition

The plant composes of

Hydrochloride reaction unit;

Chlorination reaction unit;

Rectifying unit;

HCl absorbing and cleaning unit;





Effluent gas washing unit; and

Auxiliary unit like interim tank, steam / condensate recovery system

System Characteristics

The system will fulfill the following main requirements;

The system will be the Best Available Technology (BAT).

The system will be of proven design and safe in operation

The system will be designed for optimum low energy consumption and low effluent.

Basis of Design

Capacity: This project is for manufacturing 100,00 TPA of Chloromethanes (CMS), in which, C2:

30%~70%; C3: 60%~20%; C4: 5%~10%

Operating Time: 8000h

Description of Process

Hydrochloride reaction and chlorination reaction are core units of the plant and process. The

principles are:

Hydrochloride reaction

CH3OH and HCl react in gas phase under Al2O3 as catalyst, to generate C1 and water, the formula is

CH3OH+HCl CH3Cl+H2O

It is an exothermic reaction, and heat is transferred by heat transfer oil. This reaction is happened

withy by reaction as below:

2CH3OH CH3OCH3+ H2O

Dimethyl ether (CH3OCH3) by-product depends on the ratio of HCl and CH3OH in the reactor. If

CH3OH exceeds, then more CH3OCH3 is generated. To increase the conversion and selectivity of

CH3OH to C1, HCl is controlled excessively.

Chlorination reaction

C1 and Cl2 are reacted under ~430°C to generate other CMS mixture, the formula is:

It is a strong exothermic reaction, so to control the temperature of reaction, C1 shall far exceed, and

at same time, most products in this reaction shall be circulated for quenching.

CH3Cl + Cl2 CH2Cl2 + HCl

CH3Cl + 2Cl2 CHCl3 + 2HCl

CH3Cl + 3Cl2 CHCl4 + 3HCl





Units Description

The process composes of

Hydrochloride reaction unit;

Chlorination reaction unit;

Rectifying Unit;

HCl absorbing and cleaning unit;

Effluent gas washing unit; and

Auxiliary unit like interim tank, steam / condensate recovery system.

Hydrochloride Reaction Unit

Raw material CH3OH is evaporated and over-heated, then mixed with evaporated and over-heated HCl

gas. The two materials are reacted in the tubular fixed bed hydrochloride reactor under Al2O3

catalyst. The reaction generates C1 and H2o.

The heat from the reaction is transferred by heat transfer oil. The liquid hot transfer oil is transferred

to CH3OH and HCl over-heater; some evaporated transfer oil from the reactor top shall return to

hydrochloride reactor after transfer oil condenser.

The mater discharged from hydrochloride reactor contents C1, H2O and excess HCl, small amount un-

reacted CH3OH, by-product CH3OCH3. After quenching tower and water cooling, C1 is separated in

gas phase. Then it is transferred in to H2SO4 drying tower, to remove the H2O and CH3OCH3. The

dried C1 is compressed, most part is fed into Chlorination reaction unit, balance part condensed and

stored in crude C1 interim tank, as the buffer material for chlorination unit.

The quenching liquid from quenching tank is 22% HCl (content few CH3OH). It is transferred to acid

stripping tower. CH3OH is recovered at the tower top, condensed, then re-evaporated and transferred

into hydrochloride reactor. 22% HCl is discharged from tower bottom, transferred to HCl absorbing

and cleaning unit.

Chlorination Reaction Unit

C1 from hydrochloride reaction is first mixed with the circulated gas phase CMS for pre-heating, then

reacted with over-heat Cl2 in reactor, to generate polychlorinated methane.

Material from reactor is quenched by liquid from recirculation tower feeding tank, then top gas is

stepwise condensed, cooled and separated by circulation water, -28°C 3rd stage condensed liquid, -

35°C R22 condenser. The condensed liquid is transferred into recirculation tower feeding tank, part of

which is as quenching liquid, while balance is transferred into recirculation tower to recover C1.

Incondensable gas from 3rd stage condenser is HCl mainly, part of which is back to hydrochloride

reaction unit as raw material, while part of which is transferred to HCl absorbing and cleaning unit.

C1 and HCl is the main component of recirculation tower top gas. Part of it is condensed as reflux

liquid for recirculation tower, and balance is back to chlorination reactor. Material discharged from

recirculation tower is mixture of C2, C3 and C4, which is transferred to crude CMS storage tank after

cooling.





Rectifying Unit C2 rectifying system

Crude CMS is transferred by pump to C2 tower. C3 and C4 are discharged from bottom to crude C3

tank after cooling. Material from C2 tower top is C2 with slight acid, which is transferred into caustic

washing system after cooling. Then it is neutralized by diluted NaOH and phases separated. Top

phase is diluted alkali, and bottom phase is wet neutral C2, which is pumped to azeotrope tower.

Water and C2 azeotropic gas from tower top is condensed and back to phases separator and C2

product is discharged from bottom and transferred into the C2 product-testing tank.

C3 rectifying system

Crude C3 is pumped to C3 tower. Crude C4 is discharged from tower bottom and transferred to C4

storage tank after cooling. Material from C3 tower top is C3 with slight acid, which is transferred in to

caustic washing system after cooling. Then it is neutralized by diluted NaOH and phases separated.

Top phase is diluted alkali, and bottom phase is wet neutral C3, which is pumped to azeotrope tower.

Water and C3 azeotropic gas from tower top is condensed and back to phases separator, and C3

product is discharged from bottom and transferred into the C3 product testing tank.

HCl Absorbing and Cleaning Unit

Part of HCl generated from Chlorination unit, is back to hydrochloride reaction, and balance is

absorbed by process water and 22% HCl (by production in hydrochloride reaction) in falling film

absorber and tail gas tower, to generate 31% HCl. The 31% HCl which content few organics (mainly

C1) is transferred into organics stripping tower. Organics is resolved and mixed with tail gas, back to

chlorination unit after H2SO4 drying, compressing and condensing. 31% HCl after organic removal is

cooled and transferred into storage tank, as by-product. Table 3-1: Input of Chloromethanes

S. No. Input/MT of Product

Raw Materials Quantity (MT/MT)

1 Chlorine 1.2

2 Methanol 0.34

3 Sulphuric Acid 0.024

4 Caustic 0.025

3.6 Raw material required along with estimated quantity, likely source, marketing

area of final products, mode of transport of raw material and finished product.

3.6.1 Raw Materials

Detail of raw material is given in Table 3-2.

Table 3-2: Details of Raw Material

S. No.

Chemical State Consumption (MT/Month)

Means of Storage

Mean Storage Capacity, MT

No. of Storage

Total Storage, MT

1 Methanol Liquid 1500 MS Tank 500 KL 2 1000 KL

2 Sulphuric

Acid (98%) Liquid 210

MS RL Tank

50 KL 1 50 KL





S. No.

Chemical State Consumption (MT/Month)

Means of Storage

Mean Storage Capacity, MT

No. of Storage

Total Storage, MT

3 Sodium

Hydroxide (32%)

Liquid 225 MS Tank 20 KL 1 20 KL

3.6.2 Transportation details of Raw Materials

Transportation details of raw materials are given in Table 3-3.

Table 3-3: Transportation Details of Raw Material

S. No. Name State Source Mode of Transport

1 Methanol Liquid Imported/local Trucks

2 Chlorine Gaseous Sourced from adjacent

Plant Pipeline

3 Sulphuric acid Liquid Indigenous Trucks

4 Caustic Soda Liquid Adjacent plant Trucks

3.7 Availability of water its source, energy/power requirement and source should

be given

In the proposed project, resource conservation of chemicals and water conservation are inherently

designed for effluent re-use/recycle and hence consumption is optimized. Availability of water its

source, energy/power requirement and source are given below,

3.7.1 Water consumption

Water will be sourced from Bore well. Fresh water consumption will be 1210 KLD. The below Table 3-4 shows the

water consumption and waste water generation figures.

Table 3-4: Water Consumption Details

S. No. Area Water

Consumption in KLD

Effluent Generation in

KLD Treated Effluent Disposal mode

A RO Plant 1210 300 To desalination plant of Existing

Chemplast Sanmar Plant

1 Domestic 20 15 To be treated in STP and then treated

water will be used for Gardening

2 Cooling Tower 700 175

To desalination plant of Existing Chemplast Sanmar Plant after pH

neutralization

3 Floor Washing

& Pump Seal 50 50

4 DM Plant 60 10

a Boiler Make up 50 50

5 HCl Absorption 50 0 To be sold as Byproduct

6 Gardening 30 0

Total 910 600





3.7.2 Power Requirement

Power will be supplied by Puducherry Electricity Department (PED). During construction phase1000 kVA power will

be required and during operation phase 3000 kVA will be required. In addition, the plant will have DG set of 500

kVA for emergency power back up.

Table 3-5: Fuel Consumption

S.

No.

Stack

Attached

to

Capacity Stack

Nos.

Stack

Height in

meter

Type of

Fuel used

Fuel

consumption

Air Pollution

Control

Measure

1 DG Set 500 kVA 1 11 HSD 125 L/hr Not Required

2 Boiler 360 TPD 1 54 Imported

Coal 100 TPD ESP

3 Incinerator 10 TPD 1 25 HSD

Supplemental

fuel - as and

when required

to get 1200 °C

Water scrubber

3.8 Resource Optimization / recycling and reuse envisaged in the project, if any,

should be briefly outlined

The generation of pollutants associated with the proposed expansion will be in the form of Gaseous

emissions, Liquid effluent, solid waste, and Hazardous waste.

3.8.1 Gaseous Emission

The expansion unit will have following sources of emission namely,

Process emission from HCl synthesis process and Tail Gas Absorption Tower.

Flue gas emission from stack attached to Boiler, Incinerator and DG Set

The emission from stacks will be well within the stipulated norms.

3.8.2 Solid / Hazardous Waste

Hazardous Solid wastes generated will be maintained as per Hazardous Waste (Management, Handling

and Transboundary Movement) Rules, 2008 and will be disposed off as per the details given in

Schematic Representation of the Feasibility Drawing which give Information of EIA Purpose



. Solid wastes like e-waste and bio medical waste will be generated. Details are provided in Table

3-7.

Table 3-6: Hazardous Waste Generation and disposal Details

S. No. Type of Waste Hazardous

Waste Category

Quantity per Year

Source Treatment / Disposal

1 Used Oil & Waste

Oil 5.1 2 KL

Compressors, blowers etc.

to registered recyclers

2 Distillation Residues

20.3 150 MT Manufacturing

Process Incineration





3 ETP Sludge 34.3 50 MT Filtration and pH

correction

To be disposed off at TSDF operated by Ramky at

Gummidipondi, TN

Table 3-7: Solid Wastes

S. No.

Type of Waste Quantity MT per

Year Source

Collection, Treatment / Disposal

1 STP Sludge 2 Sewage treatment

plant Will be used as manure for

gardening

3.9 Schematic Representation of the Feasibility Drawing which give Information of

EIA Purpose







4 SITE ANALYSIS

4.1 Connectivity

By Road

The Project site is well connected with Major District Road and easily accessible through National

Highway 45A which is at a distance of 0.3 km Chidambaram at North and Nagapattinam in the South

via Karaikal.

Karaikal connected to various places in neighboring Tamilnadu state by state highways.

SH 147 and SH 200 Connected to Kumbakonam.

SH148 connected to Thiruvarur.

By Rail

There are two nearest railway stations almost at an equal distance from Project site. Thirumalairayan

Pattinam a small railway station at an aerial distance of 3.0 km towards north direction from project

site and Nagore railway station at an aerial distance of 3.0 km towards South direction from project

site. Karaikal port railway yard is just 0.6 km from project side in the Eastern direction having enough

Railway Siding. Karaikal in main railway station in the area located at an aerial distance of 8.0 km

towards North direction from project site. Karaikal has railway connectivity with major cities like

Mumbai, Chennai, Bangalore, Ernakulum and Trichy

By Air

Airport at Trichy is the nearest domestic as well as international airport in the region, located at an

aerial distance of 125 km towards west direction from project site. Trichy has connectivity with Dubai.

Singapore, Kualalampur, Colombo.

Chennai, a very important domestic and International Airport located at an aerial distance of 240 km

towards north direction from project site.

By Water

Karaikal port located in the east direction from project site handled cargoes such as Coal, Pet coke,

raw sugar, and Fertilizer, Cement, Project Cargo and construction materials.

4.2 Land Form, Land Use and Land ownership

The total plot area of the proposed project will be 31,485 m2.The land is already an industrial area.

4.3 Topography (along with map)

Karaikal is on the east coast about 140 kms south of Pondicherry and 300 kms south of Chennai

(Madras) located on the Coromandel Coast of the Bay of Bengal.





Karaikal is bounded on the North and South by Nagapattinam district of Tamil Nadu state, on the west

by Tiruvarur district (also belonging to Tamil Nadu), and on the East by the Bay of Bengal.

Forming part of the fertile Cauvery delta the region is completely covered by the distributaries of

Cauvery. Covered completely by a thick mantle of alluvium of variable thickness, the lie of the region

is flat having a gentle slope towards the Bay of Bengal in the east. It is limited on the north by the

Nandalar and on the south-east by the Vettar. The group of rocks known as Cuddalore formations is

met with in the area contiguous to Karaikal region in Nagapattinam District.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the

project to periphery of the forests, national park, wild life sanctuary, etc

sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case

of notified industrial area, a copy of the Gazette notification should be given.

Existing Land use pattern: Industrial Area

Distance of Project site from Water Bodies are given in following table.

Table 4-1: Distance of Project Site from Sensitive Areas

Area Distance in km Direction

Bay of Bengal ~ 1.89 E

Puravadaiyanar River ~ 0.4 N

Table 4-2: Distance of Project site from Water Bodies

Water Body Distance in km Direction

Bay of Bengal ~ 1.89 E

Puravadaiyanar River ~ 0.4 N

4.1 Existing Infrastructure

Not Applicable

4.2 Soil classification

Not done.

4.3 Climatic data from secondary sources

The general agro-climate zone of the study area is Semi-Arid.

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

Long Term Climatological Tables, 1961-1990, Karaikal. These tables give useful information about a

region’s weather, since they are collected over a 30-year period.





4.3.1 Temperature

Mean daily maximum temperature is recorded in the month of May at 39.8°C. January is generally the

coldest month, with minimum morning temperature at 22.0°C. During the post-monsoon months of

October and November, day temperatures remain between 23.6-24.7ºC. In winters, i.e. December,

January and February, average day temperatures remain between 22.0-22.8ºC.

4.3.2 Wind

Table 4-3: Predominant Wind Direction

Predominant First Second Third

Month Morning Evening Morning Evening Morning Evening

January NE NE N N NW E

February NE NE N E NW SE

March E SE NE E SW NE

April SW SE S S SE E

May SW S W SW S SE

June W SW SW S S,NW W

July W SW SW S NW W

August W SW SW S NW W

September SW S W SW S,NW SE

October SW NE W s NW SW

November N NE NE N NW E

December NE NE N N NW E

4.3.3 Rainfall

The total rainfall in year is observed to be 1369.2 mm. Distribution of rainfall by season is 335.1 mm

in winter (December, January, February), 72.7 mm in summer (March, April, May), 261.9 mm in pre-

monsoons (June, July, August, September) and 699.5mm in monsoons (October - November).

4.3.4 Cloud Cover

The area remains cloudy between the months of June – September, which is the active period of the

monsoon season. Cloud cover is 5.4 – 5.8oktas during monsoon season.

4.3.5 Humidity

Most humid conditions are found in the Post monsoons, followed by winter, summer and monsoons in

that order. Mornings are more humid than evenings and humidity ranges from a high of 83 – 86% in

Post monsoon mornings. During monsoon season, in morning humidity remains between 69 – 78%

and in the evening it remains between 66 – 75%.

4.4 Social infrastructure available

The project site is locates about 7 kms from the city of Karaikal where major social infrastructure is

available.





5 PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and

Country Planning/Development authority Classification

The entire area is a notified industrial area

5.2 Population Projection

During the Construction and Execution phase of the Project, it is estimated that about 300 - 350

workers will be involved.

Thereafter during the operation phase at the new plant around 100 positions will be created and

employed.

5.3 Land Use planning (Break up along with green belt etc.)

The Proposed Plant is located S. No. 28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT, M/s.

Chemplast Sanmar Limited (Unit 2). It is already developed according to Chemical Industrial Use. The

Land use breakup at site is given in Table 5-1.

Table 5-1: Land Use Breakup at Site

S. No. Title Area, m2 % of total Area

1 Processing Area 1850 5.88

2 Storage Area

a Hazardous Chemicals 2400 7.62

b Water Storage 525 1.67

c Fuel Storage 300 0.95

3 Effluent Treatment Plant 600 1.90

4 Boiler 750 2.38

5 Cooling tower 375 1.19

6 DG Sets 200 0.64

7 Roads 3887 12.35

8 Administrative Building 100 0.32

9 Open Space 8570 27.22

10 Greenbelt Area 9853 31.29

11 Warehouse 1500 4.76

12 Utility and Maintenance Section 375 1.19

13 11 KV Yard and Switchgear 200 0.64

Total 31485 100





5.4 Assessment of Infrastructure Demand (Physical and Social)

The proposed project is located S. No. 28, Melavanjore, TR Pattinam, Karaikal, Puducherry UT. This

site is ~7 km to Karaikal.

Physical Demand:

Water: Water demand will be met from new bore wells.

Electricity: The electricity will be sourced from grid of Puducherry

Machinery: Reactors, Storage tanks, holding vessel, columns, condensers, Chilled Water unit,

scrubbers, and other equipment

Materials and Others: The Raw Material supply will be met by local and other markets. Other

general utilities facilities are available in the area.

5.5 Amenities / Facilities

Following facilities will be made available at site:

First Aid Facility

Hygienic Drinking Water Facility

Green Area

Regular Worker Medical Checkup Facility



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The proposed project is located S. No. 28, Melavanjore, TR Pattinam, Karaikal, Puducherry UT. Total

Plot Area will be of 31,485 m2for proposed project. Appropriate infrastructures are already in place

including approach roads, drainages etc.

6.2 Residential Area (non-processing area)

No residential facility will be provided.

6.3 Green belt

Around 31.29% of total plot area will be developed as greenbelt.

6.4 Social Infrastructure

Canteen, Rest shelter / room, Recreation Room shall be provided.

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)

Already covered in Section Error! Reference source not found..

6.6 Drinking water management (source & supply of water)

Ground water treated will be used as drinking water.

6.7 Sewage system

Sewage generated will be sent to STP for treatment and treated water will be used for Gardening

within the premises.

6.8 Industrial waste management

Industrial effluent from utilities will be sent to desalination plant of Existing Chemplast Sanmar Plant

for treatment and effluent from reactor washing will be sent to Existing Chemplast Sanmar Plant after

filtration and pH neutralization.

6.9 Power requirement & supply/ source

The power requirement for the proposed expansion will be met through Puducherry Electricity

Department (PED). Total estimated electrical load for the proposed manufacturing unit is around 2000

kVA. In addition, the plant will have DG sets of 500 kVA for emergency power back up during grid

failure.



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT R & R PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected persons

including home oustees, land oustees and landless labourers (a brief outline to

be given)

Not applicable as rehabilitation and resettlement will not be required.



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT ANALYSIS OF PROPOSAL


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule

for the project to be given)

24 months from the date of receipt of consent to establish.

8.2 Estimated project cost along with analysis in terms of economic viability of the

project.

8.2.1 Fixed Capital

Below is a brief summary of capital investment at site to develop necessary infrastructure and install

manufacturing capabilities.

Description Value Rs in Crs

Major Equipment cost including utilities 140

Civil, Steel structures and Buildings 20

Piping 15

Electrical 8

Instrumentation 15

Painting and Insulation 2

Detailed Engineering 10

Contingency 10

Total Project Cost 220



MFG. PLANT AT KARAIKAL, PUDUCHERRY UT ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

The project will improve the socio-economic status of the society in the region by generating direct

and indirect employment opportunities. The project will contribute additional revenue to the State &

Central exchequers in the form of taxes, cess, etc.

The anticipated impacts of the project are explained below:

The project related construction activities will benefit the local populace in a number of ways such

as supply of construction laborers – skilled, semi-skilled and un-skilled, tertiary sector employment

and provision of goods and services for daily needs including transport.

The proposed project will provide employment to the skilled as well as un-skilled persons.

The local population will be given preference depending upon their suitability to the job requirement.

Besides direct employment, indirect employment opportunities will also open up.

Social investment in the form of CSR would help improve the healthcare, education, sanitation,

infrastructure and other areas wherein the project proponent would be actively involved as part of

its CSR commitments.

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, 11th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India – 122 002

E: [email protected]; T/F : 0124-424 2430-436

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment



http://www.kadamenviro.com/

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Prefeasibility Report for Proposed Chloromethanes Manufacturing …environmentclearance.nic.in/writereaddata/Online/TOR/0… · · 2016-05-05Prefeasibility Report for Proposed Chloromethanes