PROPOSED EXPANSION PROJECT OF PHOSPHORIC ACID PLANT, HYDROGEN

PEROXIDE PLANT AND NEW CHLOROMETHANE PLANT OF GACL AT PLOT NO.:3,

DAHEJ, GUJARAT

DECEMBER 2015 1

AT PLOT NO.:3 (Existing Plot)

Project Name and Location: Proposed Expansion Phosphoric Acid Plant, Hydrogen Peroxide plant and New Chloromethane Plant at Plot No. 3 (99.386 ha), GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat.

S. No. in the Schedule as per EIA notification amended till date

Sector No. Project or activity Category

16 5(a), Chemical Fertilizers

Phosphoric Acid Plant, H2O2 A

21 5(f), (Synthetic Organic), Chloromethane Plant A

Cost of the Project: 1611.5 INR Crores

Production Capacity

Details of Existing and Proposed Production capacities at Plot No.:3

S.

No. Products

Existing capacity

(MTPM)

Additional

Proposed

(MTPM)

Total after

expansion

(MTPA)

A Phosphoric Acid Plant

1 Phosphoric Acid

(100% P2O5 basis) 1725 2783 4508

2 Phosphoric Acid

(85% H3PO4 basis) 2790 4500 7290

3 High Boiling Material 6 9.67 15.67

4 Calcium Chloride 17400 0 17400

B Hydrogen Peroxide (100%) 2493 1200 3693

C Chloromethane Plant

1 Total Chloromethane 0 18000 18000

2 Methylene Chloride 0 14400 14400

3 Chloroform 0 2700 2700

4 Carbon Tetra Chloride 0 900 900

D Poly Aluminum Chloride Plant

1 Poly Aluminum Chloride (18%) 3750 0 3750

2 Poly Aluminum Chloride (30%) 1080 0 1080

E Anhydrous Aluminum Chloride Plant

1 A.A.C (Granules/Powder) 1890 0 1890

2 Sodium hypochlorite (10-13% Cl2 basis) 755 0 755

3 Non- Ferrous Alum 6 0 6

F Stable Bleaching Powder 1250 0 1250

PROPOSED EXPANSION PROJECT OF PHOSPHORIC ACID PLANT, HYDROGEN

PEROXIDE PLANT AND NEW CHLOROMETHANE PLANT OF GACL AT PLOT NO.:3,

DAHEJ, GUJARAT

DECEMBER 2015 2

S.

No. Products

Existing capacity

(MTPM)

Additional

Proposed

(MTPM)

Total after

expansion

(MTPA)

G Sodium Chlorate Plant

1 Sodium Chlorate Solid (MT) 1860 0 1860

2 Sodium Chlorate Solution (M3) 3400 0 3400

Details of Existing capacity of Natural Gas Based Captive Power Plant at Plot No.:3

S.

No. Plant

Existing capacity

(MW)

A Power 70,560 MWH/M

B Steam 120 TPH HP

24 TPH IP

Resources Requirement

The power requirement for the proposed project will be met from 120 MW Captive Power Plant , 29

MW from DGVCL/Wind, 30 MW from GUVNL and 25 MW from GSEC PP. For emergency the demand

will be met from existing 5 nos. D.G sets of 1 MW.

The water is supplied by Gujarat Industrial Development Corporation (GIDC) reservoir. The proposed water requirement is:

1. Phosphoric Acid Plant: 3850 KLD

2. Hydrogen Peroxide Plant: 1500 KLD

3. Chloromethane Plant: 900 KLD

Gaseous emission, liquid effluent and solid and hazardous waste and their mitigation measures:

The anticipated air emissions from the proposed project are HC, HCl and HF, for which

APCM’s like Caustic scrubbers, water scrubbers, Chilled water Circulation and Activated

Carbon Adsorption will be provided.

About 2149 KLD of treated effluent generated shall be disposed off into the present

disposal line up to sub sea.

The hazardous waste generated will be carbon waste, Tar pot heavies, Chemical Sludge,

Spent Activated Carbon, Contaminated Alumina, Spent Catalysts and Waste drums. Non-

Hazardous waste includes Spent alumina catalyst, uncontaminated rubble waste and

other inorganic solid waste. The solid and hazardous waste will be disposed off into

owned landfill or will be sent to common landfill sites and Incineration facilities as per the

requirement.

PROPOSED EXPANSION PROJECT OF PHOSPHORIC ACID PLANT, HYDROGEN PEROXIDE PLANT AND NEW CHLOROMETHANE

PLANT OF GACL AT PLOT NO.:3, DAHEJ, GUJARAT

DECEMBER 2015 3

Site Boundary Map: Plot No.:3 GACL proposed

PROPOSED EXPANSION PROJECT OF PHOSPHORIC ACID PLANT, HYDROGEN PEROXIDE PLANT AND NEW CHLOROMETHANE PLANT OF GACL AT PLOT NO.:3, DAHEJ, GUJARAT

DECEMBER 2015 4

Site layout Plan

PROPOSED EXPANSION PROJECT OF CHLOR-ALKALI AND COAL BASED POWER PLANT OF

GACL AT PLOT NO.: CH-17, GIDC DAHEJ, GUJARAT

December 2015 1

AT PLOT NO.: CH-17 (New Plot)

Project Name and Location: Proposed Expansion of Chlor-Alkali Plant and Coal based Power Plant at Plot No. CH-17 (28.78 ha), GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat.

S. No. in the Schedule as per EIA notification amended till date

Sector No. Project or activity Category

13 4(d), Chlor- Alkali Industry B

4 1(d), Thermal Power Plants B

The project is considered in Category “A”:

Since the proposed project of Chlor-Alkali and Power Plant is interlinked with the expansion project of Phosphoric acid, Hydrogen Peroxide and New Chloromethane plant at Plot No.:3 which is Category “A”

Since the proposed project is located in GIDC Estate which is a non-notified Industrial Estate.

Cost of the Project: 1839.321 INR Crores

Production Capacity

Details of Existing and Proposed Production capacity of Chlor-Alkali Plant

S.

No. Products

Existing capacity

(MTPM)

(At Plot No.:3)

Additional

Proposed (MTPM)

(At Plot No.:CH-

17)

Total after

expansion

(MTPA)

Caustic Soda Plant

1 Caustic Soda (100%) Lye/Prills/Flakes 23550 24000 47550

2 Chlorine Gas 20784 21264 42048

3 Hydrochloric acid 7260 5580 12840

4 Hydrogen Gas 695.1 523 1218.1

5 Sodium Hypochlorite 1019 1019 2038

6 Dilute Sulphuric acid

(78-80%) 589 461 1050

7 Gypsum 780 0 780

Details of Proposed capacity of Coal based Captive Power Plant

S.

No. Plant

Proposed

(MW)

a Power 120

b Steam 60 TPH

PROPOSED EXPANSION PROJECT OF CHLOR-ALKALI AND COAL BASED POWER PLANT OF

GACL AT PLOT NO.: CH-17, GIDC DAHEJ, GUJARAT

December 2015 2

Resources Requirement

The power requirement for the proposed project will be met from 120 MW Captive Power Plant. For emergency

the demand will be met from existing 5 nos. D.G sets of 1 MW available at Plot No.:3.

The water is supplied by Gujarat Industrial Development Corporation (GIDC) reservoir. The proposed water

requirement is:

1. Chlor-Alkali Plant:11200 KLD

2. Coal based Thermal power plant: 11000 KLD

Gaseous emission, liquid effluent and solid and hazardous waste and their mitigation

measures:

The anticipated air emissions from the proposed project are PM, SO2, NOx, HCl and Cl2. For which

APCM’s like Caustic scrubbers, water scrubbers, ESP and adequate height to the stack will be

provided.

About 4,171 KLD of treated effluent shall be disposed off into new disposal line up to sub sea.

The Non Hazardous waste generated is Brine Sludge which will be disposed into owned TSDF site

located at Plot No.:3 and Fly Ash which will be given to cement industries as per Fly Ash

notification.

PROPOSED EXPANSION PROJECT OF CHLOR-ALKALI AND COAL BASED POWER PLANT OF GACL AT PLOT NO.: CH-17, GIDC

DAHEJ, GUJARAT

December 2015 3

Site Boundary Map:

Plot No: CH-17 is located on the opposite side of existing plant of GACL at Plot No.:3

PROPOSED EXPANSION PROJECT OF CHLOR-ALKALI AND COAL BASED POWER PLANT OF GACL AT PLOT NO.: CH-17, GIDC DAHEJ, GUJARAT

December 2015 4

Site layout Plan

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 1

1 ANNEXURES (ADDITIONAL ATTACHMENTS)

Annexure 1: Proposed Production capacity of Chlor-Alkali Plant and Captive power Plant (CPP) .......... 2

Annexure 2: Details of Hazardous wastes........................................................................................ 3

Annexure 3: Details of Water Consumption and Effluent Generation ................................................. 4

Annexure 4: Stack and Emission Details .......................................................................................... 5

Annexure 5: Flood Map of Gujarat .................................................................................................. 6

Annexure 6: Seismic Map of Gujarat ............................................................................................... 7

Annexure 7: Water bodies and Water Courses of the region within 15 kms radius .............................. 8

Annexure 8: Populated or built up area of the region within 15 km radius ......................................... 9

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 2

Annexure 1: Proposed Production capacity of Chlor-Alkali Plant and Captive power Plant (CPP)

Details of Proposed Production capacity of Chlor-Alkali Plant

S.

No. Products

Existing capacity

(MTPM)

(At Plot No.:3)

Additional

Proposed

(MTPM)

(At Plot

No.:CH-

17)

Total

after

expansion

(MTPA)

Caustic Soda Plant

1 Caustic Soda (100%) Lye/Prills/Flakes 23550 24000 47550

2 Chlorine Gas 20784 21264 42048

3 Hydrochloric acid 7260 5580 12840

4 Hydrogen Gas 695.1 523 1218.1

5 Sodium Hypochlorite 1019 1019 2038

6 Dilute Sulphuric acid

(78-80%) 589 461 1050

7 Gypsum 780 0 780

Details of Existing and Proposed capacity of Captive power Plant (CPP)

S.

No. Plant

Existing capacity

(MW)

Additional

Proposed

(MW)

Total after

expansion

(MW)

1 Coal based Captive Power Plant

a Power 0 120 120

b Steam 0 60 TPH 60 TPH

2 Natural Gas Based Captive Power Plant

a Power 70,560 MWH/M

--

b Steam 120 TPH HP

24 TPH IP

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 3

Annexure 2: Details of Hazardous wastes

Details of Proposed Hazardous Solid waste along with the Category and disposal method

S.

No Waste Name Category

Quantity

MTPA Source Disposal Method

Non-Hazardous Waste

1 Brine Sludge - 28800

Caustic

Soda

Plant

Disposed to owned

TSDF site

2 Fly ash - 60000

Coal

Based

Power

Plant

As per Fly ash notification.

Shall be used in

cement manufacturing

plant.

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 4

Annexure 3: Details of Water Consumption and Effluent Generation

Details of Raw water consumption for Chlor-Alkali Plant

S.

No. Plants

Quantity

(KLD) Remarks

1 Caustic Soda Plant 11200 Source of water: GIDC Dahej-

Bharuch.

Already applied to GIDC

2 Power Plant 11000

Total 22200

Details of Effluent Generation from Chlor-Alkali Plant

S. No. Plants Quantity

(KLD) Remarks

1 Caustic Soda Plant 1676 GACL will apply for the new

disposal line up to sub sea 2 Power Plant 2495

Total 4171

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 5

Annexure 4: Stack and Emission Details

Details of emissions from proposed process and flue gas stacks along with their mitigation methods

S.

No. Stack Attached to

Stack

Height

(m)

Stack

Diameter

(m)

Pollutants Mitigation

measures

Process Stacks

1 Waste air De-Chlorination

Unit 30 0.4 Cl2

3 Stage

Caustic

Scrubbing

System

2 HCl synthesis Unit 30 0.15 HCl, Cl2

Single Stage

DM Water

Scrubbing

System

Flue Gas Stacks

1 Flue Gas Stack attached to

Power Plant (2 Nos.) 90+ 3.24

PM ESP

SO2 Adequate

Stack height

NOx -

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 6

Annexure 5: Flood Map of Gujarat

Source: Gujarat State Disaster Management Authority

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 7

Annexure 6: Seismic Map of Gujarat

Source: Seismic Map of Gujarat (Institute of Seismological Research, Govt. of Gujarat)

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 8

Annexure 7: Water bodies and Water Courses of the region within 15 kms radius

Rivers/Pond Distance in km Direction

Vadadla Pond 4.5 ENE

Dahej Pond 1.5 WSW

Jolva Pond 5.8 SSE

Vav Pond 6.3 NE

Ambetha Pond 1.79 SW

Kadodara Pond 7.3 NNE

Galenda Pond 7.7 ENE

Suva Pond 6.0 SSE

Sambethi Pond 7.9 ENE

Samatpor Pond 8.4 ENE

Rahiyad Pond 7.4 SE

Padariya Pond 8.2 NNE

Jageshwar Pond 3.3 SW

Lakhigam Pond 4.0 WSW

Janiadara Pond 9.9 NE

Paniadara Pond 10.3 NNE

Koliyad Pond 9.6 SE

Luvara Pond 4.6 WSW

Atali Pond 10.4 ESE

Akhod Pond 111.36 ENE

Nadarkha Pond 12.1 ENE

Goladara Pond 13.14 NNE

Vegni Pond 11.7 SE

Aladar Pond 13.1 NE

Nandida Pond 14.2 ENE

Kaladara Pond 14.6 SE

Creek 2.04 S

GUJARAT ALKALIES AND

CHEMICALS LTD.

PROPOSED EXPANSION OF CHLOR-ALKALI PLANT AND COAL BASED POWER

PLANT AT PLOT NO.: CH-17, GIDC DAHEJ, DIST: BHARUCH, GUJARAT

ADDITIONAL

ATTACHMENTS

KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2015 9

Annexure 8: Populated or built up area of the region within 15 km radius

Villages/Towns Distance in ~km Direction

Vadadla 4.4 ENE

Dahej 0.8 WSW

Jolva 5.6 SSE

Vav 6.1 NE

Ambetha 1.3 SW

Kadodara 7.0 NNE

Galenda 7.6 ENE

Suva 6.0 SSE

Sambethi 8.3 ENE

Samatpor 8.1 ENE

Rahiyad 7.2 SE

Padariya 8.4 NNE

Jageshwar 3.0 SW

Lakhigam 3.6 WSW

Janiadara 9.7 NE

Paniadara 10.2 NNE

Koliyad 9.8 SE

Luvara 4.5 WSW

Atali 10.4 ESE

Akhod 11.4 ENE

Nadarkha 12.7 ENE

Goladara 12.7 NNE

Vegni 11.8 SE

Aladar 13.7 NE

Nandida 14.1 ENE

Kaladara 14.6 SE