1

Prefeasibility Study Report

of

Aromatics India Pvt. Ltd.

At & Po: 334, Phase-II, GGDC-GIDC,

Village: Mithi Rohar, Taluka: Gandhidham, Dist.: Kutch

For

Proposed Project of

LABSA (Linear Alkyl Benzene Sulphonic Acid)

PREPARED BY:

PAVAN ENVITECH CONSULTANT PVT. LTD., AHMEDABAD.

OCTOBER - 2015

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INDEX

Sr. No. Content Page No.

1. Introduction 3 2. Details of Proposed Project 4

2.1 Location of the proposed Project 5 2.2 Product Details 6 2.3 Manufacturing Process 6

3. Resource Requirement 9

3.1 Raw material Requirement 9 3.2 Electricity 10 3.3 Water 10 3.4 Fuel Requirement 10 3.5 Employment 10 3.6 Reactors, Vessels, Equipments Required 10

4. Environment Pollution & Pollution load 11

4.1 Water and Waste water 11 4.2 Air Pollution 14 4.3 Solid/Hazardous Wastes Generation 15 4.4 Noise Pollution 15

5. Environment Management Plan 16

5.1 Effluent Treatment System 16 5.2 Air Pollution Control Measures 17 5.3 Noise Pollution control measures 18 5.4 Solid/Hazardous Wastes Management system 18 5.5 Environment Management Cell 19 5.6 Physical and Chemical Properties of Product & Raw

materials 20

5.7 General Safety Measures 21

6. Annexure 23 Annexure-I : Google image of plot 24 Annexure-II: Plan lay-out 25 Annexure-III: Plot Possession Documents 26

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1. Introduction :

Aromatics IndiaPvt. Ltd. is planning to set up Manufacturing unit of LAB

Sulphonic Acid (LSA) at Plot No.: 334, Phase-II, GGDC Industrial

Estate, Village: Mithi Rohar, Taluka: Gandhidham, District : Kutch. The

unit envisages manufacturing of LABSA (Linear Alkyl Benzene Sulphonic

Acid).

As the proposed manufacturing unit is covered under the New EIA

Notification, 2006, amended in December-2009, the unit has to get the

Environmental Clearance prior to commission of the plant.

It is proposed to manufacture LAB Sulphonic Acid with installed capacity of

3,000 MT/Month which is listed at 5(f)B under the EIA Notification, 2006. The

unit is located in GIDC area hence the unit has to get the Environmental

Clearance from the SEAC, Gandhinagar.

In the present report the proposed project location, about facilities,

infrastructure details, manufacturing process, water and wastewater details,

air pollution and control measures, solid and hazardous waste management

and chemical properties of the products, by-products & raw-materials.

We have purchased the said plot from Manoj Timber Traders vide Deed of

Assignment on 29-07-2015, who are engaged in processing of timber and wood

at the said premises.

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2. Details of Proposed Project:

Aromatics India Pvt. Ltd. is planning to set up the plant for manufacturing

LAB Sulphonic Acid at Plot No.: 334, Phase-II, GIDC-GGDC Industrial

Estate, Village: Mithi Rohar, Taluka: Gandhidham, District : Kutch. The

detail of the proposed project is given below;

Name of the Industry : Aromatics India Pvt. Ltd.

Location : Plot No.: 334, Phase-II, GGDC-GIDC Industrial

Estate, Village: Mithi Rohar, Taluka: Gandhidham,

District: Kutch.

Project Activity

: Manufacturing activity of Linear Alkyl Benzene

Sulphonic Acid (LABSA)

Cost of the Project

: Rs.2.95 Crore

Product

(MT/Month)

: 1. Linear Alkyl Benzene Sulphonic Acid: 3,000

2. Sulphuric Acid (75-80%): 2,436 (By-product)

Total land area acquired

for the project

: 11,050 m2

Category of proposed

project as per EIA

notification, 2006 and

subsequent

amendments.

: 5 (f) B

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2.1 Location of the Proposed Project: The industry has acquired a plot entitled as Aromatics India Pvt. Ltd., at Plot No.:

334, Phase-II, GGDC-GIDC Industrial Estate, Village: Mithi Roar, Taluka: Gandhidham,

District: Kutch. Table 2.1 The detail of the project site is as given in the following table

We have enclosed herewith Annexures: Annexure – 1 : Google Image - Proposed Project Site of Aromatics India Pvt.

Ltd. Annexure – 2 : Factory Plan Layout. Annexure – 3 : Plot Possession Document.

Sr. No. Particulars Details

1. Location

a) Site Plot No.: 334, Phase-II, GGDC-GIDC Industrial Estate,

b) Village Mithi Rohar

c) Taluka Gandhidham

d) District Kutch

e) State Gujarat

3 Nearest Railway Station Gandhidham

4 Reserved Forest/National Park --

5 Nearest City Gandhidham

6 Nearest Village Mithi Rohar @ 4 KM

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2.2 Product Details

The industry is planning to manufacture Linear Alkyl Benzene Sulphonic Acid.

The details of product are given in following table.

Table 2.2 Details of Proposed Product

Sr. No. Product Production

MT/Month 1. Linear Alkyl Benzene Sulphonate & 3,000

2. Sulphuric Acid (75-80 %) 2,436

2.3 Manufacturing process: 2.3.1 (A) Manufacturing process

LAB Sulphonic Acid is the economical name linear alkyl benzene sulphonic

acid which is produced by sulphonating linear alkyl benzene with sulphuric

acid. The equipment used is MS/SS reactor vessels. The required amount of

LAB is transferred into the reactor vessel and sulfuric acid is added

gradually. The mixture is continuously stirred to ensure complete mixing and

completion of reaction between LAB and sulphuric acid. Since the reaction is

exothermic, temperature is controlled by circulating water in jacket of the

vessel. The mixture now contains LABSA and Sulphuric Acid. To facilitate

the separation of LABSA and Sulphuric Acid, water has to be added to the

total mass. The mixture then stirred for 10-15 minutes and transferred to the

separator vessel and allowed to settle. The Sulphuric Acid (75-80%) forms the

bottom layer and is transferred to suitable storage tanks. LABSA forms the

upper layer and is transferred to suitable storage tanks.

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LABSA is main raw material for detergent powder & cake, liquid detergent &

scouring agent. The Sulphuric Acid (75-80%) is sold to end users like:

fertilizer and alum industries, etc.

For quality assurance, necessary standard should be followed.

Standards of Linear Alkyl Benzene

Molecular weight : 238

Bromine Number : 0.04 Max

Say Bolt Color : + 30 Max

Doctor Test : Negative

Completeness sulphonation : 98 % Min

Standards of Sulphric Acid

Total acidity as H2SO4 : 98 % min

Resistant as ignition : 0.2 % Min

Iron as Fe : 0.05% max

lead as Pb : 0.05% max

Arsenic : 0.004 % Max

Standard of LAB Sulphonic Acid

Active Matter : 90 ±1 % Min

Free LAB : 1.5 % Max

Free H2SO4 : 7 % Max

Colour on Klett : 50 Unit Avg

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Mass Balance

Raw Materials Consumption Kg/Kg of Product MT/Day

Input Linear Alkyl Benzene 0.670 80.400 Sulphuric Acid 0.992 119.040 Water 0.150 18.000

Total 1.812 217.44 Out put Linear Alkyl Benzene Sulphonic Acid (LABSA)

1.000 120.000

Sulphuric Acid (75-80%) 0.812 97.440 Total 1.812 217.44

2.3.2 Block Diagram:

Sulphonation

Agitation (30 min.)

Addition

Separation

LAB

H2SO4 (98%)

0.670

0.992

Water 0.150

Sulphuric Acid: 0.812 (75-80%)

TOTAL INPUT: 1.812 TOTAL OUTPUT: 1.812 ALL THE UNITS ARE EXPRESSED IN MT/ TON OF PRODUCT.

Product LABSA:

1.000

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3. Resource Requirement: 3.1 Raw Material Requirement:

This plant is based on slphonating of LAB with Sulphuric Acid (98%) for

production of LAB Sulphonic Acid and Sulphuric Acid (75-80%). In this

process following raw material will be require

1. Linear Alkyl Benzene

LAB is introduced in 1960 to replace the poorly biodegradable branched

alkyl benzene sulphonates. LAB produced only in 20 countries. Proposed

unit will arrange this main raw material from Reliance, IOCL, Nirma, etc.

2. Sulphuric acid

Sulphuric Acid (98%) require for this process and unit will arrange this raw

material from Hindustan zinc limited, Udaipur and other manufacturer on

regular basis. Sulphuric Acid is categorized under the Hazardous chemical

so unit will make proper arrangements for handling and storage of this

chemical. The detailed product wise raw material requirement is as given

here below Table no. 3.1;

Table 3.1 The detail of the Product & Raw materials requirement:

Raw Material Requirements:

Raw Materials Consumption Kg/Kg of Product MT/Month

Linear Alkyl Benzene 0.670 2,010 Sulphuric Acid 0.992 2,976 Water 0.150 450

Total 1.812 5,436 Product:

Sr. No. Product Production

MT/Month 1. Linear Alkyl Benzene Sulphonate 3,000

2. Sulphuric Acid (75-80%) 2,436

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3.2 Electricity: Total Power requirement : 100 KW

Source of Power supply : Pashchim Gujarat Vij Company Limited (PGVCL)

3.3 Water: The total fresh water require for the manufacturing of proposed product will

be @ 23.9 KL/day. Industrial water requirement will be @ 20.4 KL/Day, 2.0

KL/day water required for Gardening/Greenbelt and @ 1.5 KL/day will be

require for the domestic.

3.4 Fuel requirement :

HSD will be used as fuel for the D.G. set of capacity 125 KVA @ rate of 20

L/Hr.

3.5 Employment :

The proposed unit will have great employment potential providing

employment to approximately 20 full time persons. The manpower

requirement for the proposed project will be fulfilled from nearby area.

3.6 Reactors, Vessels, Equipments Required : Table:3.2 - Reactor, Vessels, Equipment Details

Sr. No. Storage Tank Quantity

MOC Capacity

1. Tank for Linear Alkyl Benzene 3 MS 300 MT

2. Tank for Sulphuric Acid (98%) 4 MS 300 MT

3. Tank for LABSA 2 MS 100 MT

4. Tank for Sulphuric Acid (75-80%)

4 1

MS 50 MT 270 MT

5. Feeding Tanks for LAB/Sulphuric Acid/Water 5 MS 15 MT

6. Closed Reactors/Vessels 3 MS 25 MT

7. Separators 3 MS 35 MT

8. Decantation Tank 2 MS 20 MT

9. Pumps 10 MS/CI

10. Diesel Generator Set 1 125 KVA

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4. Environment Pollution & Pollution Load: 4.1 Water and Waste water 4.1.1 Water Consumption

In the proposed project, water will be required for following purposes:

Domestic & Gardening purpose

Industrial Use

Table:4.1: Break up for fresh Water Consumption

Source: GGDC-GIDC or purchase through tankers from outside.

Rain water will be collected in separate tank and will be utilized in manufacturing process. Thus, fresh water requirement becomes less or recharge in ground by providing percolation/recharge well.

Sr.

No. Purpose

Water Consumption

(KL/day)

1. Domestic 1.500

2. Industrial 20.400

i) Process (16.000)

ii) Cooling (4.400)

3. Gardening/ Green Belt

Development 2.000

Total 23.900

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4.1.2 Waste Water Generation

Table:4.2: Break up for Wastewater Generation

Note: There will not be any wastewater discharge from the proposed

manufacturing process and no disposal of wastewater from the system,

hence the unit will be “THE ZERO DISCHARGE UNIT”

Sr.

No. Purpose

Waste Water Generation

(KL/day) Remarks

1. Domestic 1.500 Soak Pit

2. Industrial

i) Process -- No w/w generation

ii) Cooling 2.000 Recycle in Process

Total 3.500 --

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Water Balance Diagram (all figures are in KL/Day)

Fresh Water Consumption 23.900

Domestic 1.500

Cooling (Make-up)

4.400

Industrial 20.400

Waste Water Generation

1.500

To Soak Pit 1.500

Evaporation Loss 2.400

Waste water generation: Nil

Process 18.000

Gardening 2.000

Cooling (bleed-off) 2.000

16.000 4.400

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4.2 Air Pollution :

The Impact on the air quality is divided into two categories:

A. Impact on air quality during construction phase

B. Impact on air quality during operation phase.

A. Impact on Air Quality during Construction Phase

There will be mainly particulate matter emission due to the

transportation of vehicle and construction activity. Particulate matter

emission during construction phase will be reduced by sprinkling water

in open ground area of the site and controlling the speed of the vehicles

inside the premises. The impact is limited to the construction phase

only.

B. Impact on Air Quality during Operation Phase.

Sources of air pollution

Combustion of Fuel for DG sets.

4.2.1 Details of Stack:

The main sources of gaseous air pollution will be from operation of D. G. Set.

The details for the same are given here in Table: 4.3 (A) & Table: 4.3 (B).

Details of stack:

Table: 4.3 (A) – details of stack

Sr. No.

Stack attached to

Stack Ht & Dia

(m)

Type of Fuel &

Consumption

APC Measures

Concentration of pollutants

1. D.G. Set (125 KVA)

Height: 7 Dia.: 0.10

HSD : 20 L/Hr

Not Required

PM<150 mg/Nm3 SO2<100 ppm NOx<50 ppm

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4.3 Solid/Hazardous Wastes Generation :

There will be no any major source of hazardous waste generation due to

proposed project. However, the ancillary sources of hazardous wastes

generation are as under: Table: 4.1- Details of hazardous waste generation

Sr. No.

Type of Hazardous Waste Category No. Quantity;

per Annum

1 Used oil 5.1 0.100 MT

4.4 Noise Pollution

There are few potential sources such as Pumps, D.G. set, and other

manufacturing operations which would generate noise. However, proper

maintenance of the all equipments will be taken. Adequate protective

measures in the form of ear muffs/ earplugs shall be given to workers working

in these areas and greenbelt development shall further attenuate the noise

transmission.

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5. Environment Management Plan:

The proposed unit will provide adequate Environmental Management Plan to

assure the regular and efficient working / operation of the same. The details of

Environmental Management Plan are described here under :

Objectives:

Regular and efficient working of the Plant / Operation with acceptable

minimum Environmental Impact.

To conserve the environment.

To check and maintain the record of the environmental parameters for

furtherer improvement of the process and the environment.

To comply the Act, Rules, Notifications directly applicable to

Environmental Management.

5.1 Effluent Treatment System

A) Domestic waste water

The generated 1.500 KL/Day of domestic waste water will be drained in to the

Soak Pit.

B) Industrial Waste Water

There will not be any effluent generation from the proposed project. There will

not be any waste water discharge from the proposed manufacturing process;

hence the unit will be “THE ZERO DISCHARGE UNIT”

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5.2 Air Pollution Control Measures:

5.2.1 Air Pollution Control Measures during the Construction Phases

Sprinkling of water in open area of factory premises will be done.

All the safety measures prescribed in code for building and construction

will be followed.

Regular monitoring of construction activity.

By controlling the speed of vehicles inside the factory premises.

Personal Protective Equipments (PPEs) will be provided to all the

workers.

5.2.2 Air pollution control measures during the operation Phase

HSD will be used as fuel into the DG set. PM10, PM2.5, SO2 & NOx will be

emitted into the atmosphere due to the combustion.

The sources of gaseous air pollution and the control measure are given as

under the table:

Table: 5.1- Details for Air pollution control measures for Flue Gas Emission

Table: 5.1 – details of stack

Sr. No.

Stack attached to

Stack Ht & Dia

(m)

Type of Fuel &

Consumption

APC Measures

Concentration of pollutants

1. D.G. Set (125 KVA)

Height: 7 Dia.: 0.10

HSD : 20 L/Hr

Not Required

PM<150 mg/Nm3 SO2<100 ppm NOx<50 ppm

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5.3 Noise Pollution Control Measures:

There are few potential sources such as Pumps, D.G. set, and other

manufacturing operations which would generate noise. Proper maintenance of

the all equipments will be taken. Adequate protective measures in the form of

ear muffs/ earplugs shall be given to workers working in these areas and

greenbelt development shall further attenuate the noise transmission outside

the premises.

5.4 Solid/Hazardous Wastes Management System

There will be no any major source of hazardous waste generation due to

proposed project. However, the ancillary source of hazardous wastes

generation and its as under, and for that unit will provide designated storage

area.

Table: 5.5- Details for hazardous waste management

Sr. No

Type of Hazardous Waste & Quantity

Category No.

Methods of Handling Disposal

1 Used oil : 0.100 MT/Annum 5.1 Stored in drum

Collection, Storage, Re-use as lubricant or Transportation & Disposed-off to authorized refiners.

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5.5 Environment Management Cell :

The proposed unit will provide/prepare an adequate Environmental

Management Cell to assure the regular and efficient working /operation as

given here below;

Managing Director

Factory Manager

Chemist

Helpers

Operator

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5.6 Physical and Chemical Properties of Product & Raw materials:

Linear Alkyl benzene

Physical State Liquid Color White Bulk Density 0.855 Solubility in water Insoluble Boiling Point 300 0C Molecular Weight (G/Mol) 238

Sulphuric Acid(98%)

Physical State Liquid Color colorless Odor Odorless Specific Gravity 1.844 Solubility in water soluble pH 0.3 (1N) Boiling Point 327 0C Melting Point -2 0C Vapor Density 3.4 Molecular Weight (G/Mol) 98.07 Molecular Formula H2SO4

LAB Sulphonate

Physical State Liquid Color Brown Specific Gravity 1.08 Solubility in water Water Soluble Boiling Point 315 oC Molecular Weight (G/Mol) 320

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5.7 General Safety Measures: All the personnel at the plant will be made aware about the hazardous

substance stored at the plant and risk associated with them. Personnel engaged in handling of hazardous chemicals will be trained to

respond in an unlikely event of emergencies. Safe work practices will be developed to provide for the control of hazards

during operation and maintenance. The workers will be made aware about the hazards associated with manual

handling of chemicals. Adequate fire fighting facilities will be provided at the plant, including, dry

chemical powder type, water CO2 type, mechanical foam type, CO2 type of Fire Extinguishers and sand buckets. Personnel will be trained to combat the fire in various hazardous chemicals.

The fire fighting system and equipment will be tested and maintained as per

relevant standards. Safety measures in the form of DO and Don’t DO will be displayed at strategic

locations especially in local language. Good house keeping will be maintained in the plant. The required PPEs for each area/operation should be identified and the

necessary PPEs, like, helmets, goggles, hand gloves, mask, PVC suit, Self Containing Breathing Apparatus, safety belts, ear muff and plug, etc. will be provided to the personnel.

The plant will check and ensure that all instruments provided in the plant are

in good condition and documented. Adequate ventilation will be provided. Local exhaust ventilation will be

effective in controlling the dust and fumes in the work environment. All equipment and storage tanks/containers of flammable chemicals should be

bounded and earthed. First aid box will be provided within the plant. List of important telephone numbers will be displayed at each and every

location in the plant.

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All the accidents and incidents will be recorded, investigated and analysed in the proposed plant.

Safety awareness programme and training of the worker will be carried out to

motivate the workers to increase the safety level at personal level. Occupational Health Aspect: As per govt. standard all facilities will be

provided. Safety Precautions for Storage & Handling of Acids: The unit will provide special precautions for storage & handling of Sulphuric Acid

within the premises.

Acids storage tanks will be placed in to the separate storage area within the

premises.

The proper collection system will be provided for the leakage & spillage collection

of both the acids by preparing dyke wall and Acid Proof flooring with spillage

collection tank and will be transferred to the emergency storage tank.

Proper vent will also be provided to each storage tank. Moreover, Weather shed

and water sprinkling system will be provided.

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6. ANNEXURES

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ANNEXURE – I Google Image - Proposed Project Site of Aromatics India Pvt. Ltd.

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ANNEXURE – II FACTORY PLAN LAYOUT

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5 5

Sr. No.

Area Marking No.

1 Production Plant

1& 1a

2 Storage yard 2 &3 3 Utilities/ADM 4 4 Roads 5 5 Open/Un-

developed 6

6 Green belt 7

3

4

4

2

GATE NO 1 GATE NO 2 N

S

EW

SCHEMATIC LAYOUT OF AROMATICS INDIA PVT.LTD.

1

7

1A

6

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ANNEXURE – III PLOT POSSESSION DOCUMENTS

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29

30

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