VEDANT CHLORO CHEM
Prefeasibility Report of Proposed Hydrogenation, Hydrolysis and Chlorination products at Plot No.D-2/CH/77, GIDC Dahej, Vagra Taluka, Bharuch District, Gujarat State
DECEMBER 2 0 1 6
Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m
Envi ronment f or Deve lopment
VEDANT CHLORO CHEM EXPANSION PROJECT OF EXISTING PLANTS
AT GIDC DAHEJ, PHASE II EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | DECEMBER 2016 2
VEDANT CHLORO CHEM
Prefeasibility Report for Proposed Hydrogenation, Hydrolysis and Chlorination products at Plot No. D-2/CH/77, GIDC Dahej, Vagra Taluka, Bharuch District, Gujarat State © Kadam Environmental Consultants (‘Kadam’), December, 2016
This report is released for the use of the Client Name, 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 Hydrogenation, Hydrolysis and Chlorination products at Plot No. D-2/CH/77, GIDC Dahej, Vagra Taluka, Bharuch District, Gujarat State
Project Number 1522722122 Report No. 1 Version 1 Released December, 2016
Prepared & Managed By
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.
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AT GIDC DAHEJ, PHASE II EXECUTIVE SUMMARY
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CONTENTS
1 EXECUTIVE SUMMARY ................................................................................. 6
1.1 PLANT FEATURES AND PRODUCTION CAPACITY .......................................................... 6 1.2 ENVIRONMENT ............................................................................................ 8
1.2.1 Water .............................................................................................. 8 1.2.2 Effluent Generation, Treatment and Disposal ............................................... 8 1.2.3 Power .............................................................................................. 8 1.2.4 Air Emission ....................................................................................... 8 1.2.5 Hazardous Water Generation and Disposal .................................................. 8
1.3 SUBMISSION .............................................................................................. 8
2 INTRODUCTION .......................................................................................... 9
2.1 BRIEF DESCRIPTION OF THE PROJECT .................................................................... 9 2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION .............................................. 9 2.3 DEMAND SUPPLY GAP. ................................................................................... 9
2.3.1 Global Market ..................................................................................... 9 2.3.2 Domestic Market ................................................................................. 9 Presently the domestic markets of the above products are approximately 150000 MT/YEAR . 9
2.4 IMPORT VS. INDIGENOUS PRODUCTION .................................................................. 9 2.5 EXPORT POSSIBILITY ..................................................................................... 9 2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ............................. 9
3 PROJECT DESCRIPTION ............................................................................. 10
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ......... 10 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &
PROJECT LAY OUT) WITH COORDINATES ........................................................................ 10 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 10 3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 11 3.5 TECHNOLOGY AND PROCESS DESCRIPTION ............................................................ 11
3.5.1 Salient Features of Technology .............................................................. 11 3.6 RAW MATERIALS ....................................................................................... 13 3.7 PROCESS DESCRIPTION ................................................................................ 13 3.8 ADDITIVES AND CHEMICALS ............................................................................ 13 3.9 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF
FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 13 3.9.1 Transportation details of Raw Materials .................................................... 13
RRM-2*, RM-3** AND RM – 4*** .......................................................................... 14 3.10 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN
14 3.10.1 Water consumption ............................................................................ 14 3.10.2 Power Requirement ............................................................................ 14
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3.11 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT
/DISPOSAL ...................................................................................................... 14
4 SITE ANALYSIS ......................................................................................... 17
4.1 CONNECTIVITY ......................................................................................... 17 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................ 17 4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 17 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. ............................................................................................. 17 4.5 EXISTING INFRASTRUCTURE ............................................................................ 18 4.6 SOIL CLASSIFICATION .................................................................................. 18 4.7 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 18
4.7.1 Temperature .................................................................................... 18 4.7.2 Wind ............................................................................................. 19 4.7.3 Rainfall ........................................................................................... 19 4.7.4 Cloud Cover ..................................................................................... 19 4.7.5 Humidity ......................................................................................... 19
4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 19
5 PLANNING BRIEF ...................................................................................... 20
6 PROPOSED INFRASTRUCTURE .................................................................... 21
6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 21 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 21 6.3 GREEN BELT ............................................................................................ 21 6.4 SOCIAL INFRASTRUCTURE .............................................................................. 21 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC) ............. 21
6.5.1 By Road .......................................................................................... 21 6.5.2 By Rail ........................................................................................... 21 6.5.3 By Air ............................................................................................ 22 6.5.4 By Water ........................................................................................ 22
6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...................................... 22 6.7 SEWAGE SYSTEM ....................................................................................... 22 6.8 INDUSTRIAL WASTE MANAGEMENT ..................................................................... 22 6.9 SOLID WASTE MANAGEMENT ............................................................................ 22 6.10 POWER REQUIREMENT & SUPPLY/ SOURCE .......................................................... 22
7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 23
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) ......... 23
8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 24
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8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE
PROJECT TO BE GIVEN) ......................................................................................... 24 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. 24
8.2.1 Fixed Capital .................................................................................... 24 8.2.2 Working Capital ................................................................................ 24 8.2.3 Revenues ........................................................................................ 24 8.2.4 Breakeven Point ................................................................................ 24 8.2.5 Profitability ...................................................................................... 24
9 ANALYSIS OF PROPOSAL ........................................................................... 25
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE
INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA ......................................................... 25
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AT GIDC DAHEJ, PHASE II EXECUTIVE SUMMARY
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1 EXECUTIVE SUMMARY
1.1 Plant Features and Production Capacity
Vedant Chloro Chem, an ISO 9001:2008 certified company is one of the leading precipitated silica manufacturer in India. With use of latest technology, Company provides the best quality precipitated silica for various industrial applications.
Precipitated Silica is pure white synthetic amorphous material which is inert, non-toxic, chemically balanced and suited for diverse applications. Precipitated silica use in many filed like Tyre/rubber, food/feed, pesticides, toothpaste, plastics, detergents, paints coating and several other application.
Our plant is located at Dahej GIDC of Vagra Taluka in Bharuch District, Gujarat. The unit is assisted by highly dedicated and experienced team of technical as well as commercial the company has successfully met the demand of several key customers across in India as well as in abroad.
We have a world class research & development center equipped with sophisticated equipment as per international standards for safe, secure and efficient running of plant. We have the potential land & utilities for expanding our production capacity at top most.
Vedant Chloro Chem is known as one of the fastest growing industry in India. Recognized as a reliable manufacturer of the specialty chemicals, the company has achieved high level recognition in competitive market.
Our highly futuristic infrastructure facility is equipped with all require machinery and equipment for attainment of the firm’s goals and objectives. We engage in regular up gradation helps in maintaining quality product as per customer’s satisfaction.
It has committed work force as well as all the required facilities to manufacture tailor made products to suit customer’s requirement.
Our vision is to be as the best quality base specialty chemical company in the world.
We satisfy our customer by delivery result through quality chemical product & service. We tap new markets via product and process innovations for tomorrow’s world.
Details of proposed project is provided in Table 1-1
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Table 1-1: Details of Product S.No. Product Capacity in MTPM
Existing
1 Activated Silica 825
Proposed
1 Hydrolysis products such as Benzyl Alcohol, Benzaldehyde, Benzoyl Chloride, Chlorobenzaldehyde, 4-Chloro benzoyl Chloride, Nitro benzoyl chloride, Propargyl Chloride, Pivaloyl Chloride, N-Valeroyl Chloride, 2,4 Dichloro benzoyl Chloride, 4-chloro butyryl Chloride, Phthaloyl Chloride, 2-methoxy 5-bromo 6-methyl benzoyl chloride, Terephthaloyl Chloride, IsoPhthaloyl Chloride, O-Chloro Benzyl Alcohol, Para-Chloro Benzyl Alcohol, 4-methyl benzoyl chloride etc
1500
2 Chlorination products such as Chloro Benzene, Chloro Toluene, Chlorinated PVC, Poly aluminum chloride, Mono chloro acetic acid, Chloro acetic acid, 2,6 Dichloro phenol, sulphurMonichloride, Ferric chloride, Aluminium chloride, Cuprous chloride, Calcium chloride, Cyanauric Chloride, Trichloro Acetyl Chloride, paracetamol, Epichlorohydrin, 4-Chloro 2-Hydroxy Aniline, Para Amino Phenol, Nitro Chloro Benzene, Benzyl Chloride, Sodium Hypo Chloride, Benzo Trichloride, 2,4 D Esters, 2,4 D Amine, Chlorinated Paraffin Wax, Phosphorous Penta Chloride, Phosphorous Trichloride, Caboxy Methyl Cellulose Sodium Salt, Mono Chloro Benzene, 5,Chloro Ortho hydroxy benzoic Acid, 2,4 Dichloro Phenol, Dichloro Benzene, ParaChloroToluene/OrthoChloroTol, 2,4-Dichloro Phenoxy Acetic Acid, P-Chlorobenzyl Chloride, O-Chloro Benzyl Chloride, O-ChloroBenzal Chloride and O-Chloro Benzo Trichloride
1500
3 Hydrogenation products
such as Xylidine, Anisidine, 2-Methyl Cyclohexyl Acetate, Para Hydroxy Aniline, Aniline, 3,4 Diamine Toluene, 3,4 Di chloro Aniline, 2,4,5-Trichloroaniline, O-M-P Toluidine, 2-Chloro, 5 Methyl, 1,4 Phenylene Diamine, 3-Amino Benzotrifloride, 3- Amino 4-Chloro Benzotrifloride, Silane- Hydrogenation Of Precipated Silica, 3 Amino 4-Methyl Benzoic, 3-Amino 4-Chloro Benzoic acid, 3 Amino 4-Methyl Benzoic, IsoPhoronDia Amine, 2 Chloro 1,4 Phenylene Diamine, 2,5 Dichloro 1,4 Phenylene Diamine, 3-Iso Propoxy Aniline, . 2 Chloro 5-Methyl, 1,4 Phenylene Diamine, 6-Methyl 5-Amino Benzimidazolone, 2,5 Dimethyl 1,4 Phenylene Diamine, 5-Amino Benzimidazolone, 3-5 Dichloro Aniline, 2-5 Dichloro Aniline, 2,3 Dichloro Aniline
1500
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1.2 Environment
1.2.1 Water
Source of water is GIDC water supply. Existing water demand is 50 KLD and proposed water demand will be 35 KLD. So after expansion total water consumption will be 85 KLD.
1.2.2 Effluent Generation, Treatment and Disposal
Existing wastewater generation is 21 KLD. Proposed wastewater generation will be 8 KLD. So after proposed expansion total wastewater generation will be 29 KLD. After proposed expansion, treated effluent will be discharge to GIDC drain for final disposal.
1.2.3 Power
Proposed power requirement during Construction Phase is 15 kVA and during Operation Phase is 75 kVA which will be supplied by Dakshin Gujarat Vij Company Limited (DGVCL).
1.2.4 Air Emission
Cyclone & Bag filter are attached to existing Spray Dryer and Activator. Packed Column will be attached to proposed Scrubber. Adequate stack height is provided to flue gas stacks of boiler, hot air generator, Spray Dryer and Activator. Stack will be attached to proposed scrubber in proposed expansion. LDO/ NG will be used as fuel.
1.2.5 Hazardous Water Generation and Disposal
Due to proposed expansion hazardous waste generation will not increase. Hazardous waste generated from the existing plant operation will be disposed in nearby Waste Management landfill facility. The unit has membership of M/s. Saurastra Enviro Projects Pvt. Ltd. (SEPPL), Kutch for Integrated Common Hazardous Waste Management Facility.
1.3 Submission
In the light of the above, we would like to state that the proposed expansion at Dahej would have in place systems, procedures and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation has no adverse impact on environment
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2 INTRODUCTION
2.1 Brief Description of the Project
Vedant Chloro Chem (VCC) is the manufacturing of Activated Silica by using spent acid from the nearby unit. VCC has planned for expansion of their project for chlorination, Hydrogenation and Hydrolysis of Organic and Inorganic Chemical to reduce the environment load in this area by consuming by product of spent acid in their present unit.
2.2 Need for the project and its importance to region
The project is desired to be set up keeping in mind of the availability of spent, Chlorine and Hydrogen from nearby Chlor Alkali unit
2.3 Demand Supply Gap.
The demand of the product from nearby unit will be maximum as Dahej PCPIR will be the one of the biggest Chemical Hub of the India.
2.3.1 Global Market
Global market of the above product is increasing with the trend of 10 % in the world.
2.3.2 Domestic Market
Presently the domestic markets of the above products are approximately 150000 MT/YEAR
2.4 Import vs. Indigenous Production
Indigenous production is desired to have local source of the same as also to conserve valuable foreign exchange.
2.5 Export Possibility
There is no plan or requirement of exporting since there is enough demand in India itself.
2.6 Employment Generation (Direct and Indirect) due to the project
During construction phase ~100 people will be employed on contract basis for construction activities. Existing employment in operation phase is 20 on permanent basis and 20 on contractual basis. After proposed expansion, there will be addition of 25 on permanent basis and 35 on Contractual basis.
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3 PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects, if any
Not applicable
3.2 Location (map showing general location, specific location and project boundary & project lay out) with coordinates
Proposed expansion is located at Plot No. D-2/CH/77, GIDC Dahej, Industrial Estate.
3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted
In Gujarat, there are very few places available as on date that are fit for setting up of a synthetic organic chemical plant from enviro-legal angle. This is essentially because most of the other industrial clusters (such as Ankleshwar, Nandesari, Panolietc.) have been designated as critically or severely polluted by the MoEF.
The main choices available are either:
• Setting up a unit at an area where Non-Agricultural (‘NA’) land can be used for setting up of a chemical unit, or using an existing industrial estate for setting up the same, provided the said industrial estate is permitted to allow additional chemical industries
• The proposed project is a Greenfield project and its location is within an industrial area, namely GIDC, Dahej.
Thus the location has the following advantages:
• It is not located in a critically / severely polluted area • Easy availability of infrastructure such as roads and also raw water and power • Suitable environmental infrastructure in the form of TSDF and a diffuser for deep sea disposal of
effluent.
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3.4 Size or Magnitude of Operation
Table 3-1: Production capacity
S.No. Product Capacity in MTPM
Existing
1 Activated Silica 825
Proposed
1 Hydrolysis products
such as Benzyl Alcohol, Benzaldehyde, Benzoyl Chloride, Chlorobenzaldehyde, 4-Chloro benzoyl Chloride, Nitro benzoyl chloride, Propargyl Chloride, Pivaloyl Chloride, N-Valeroyl Chloride, 2,4 Dichloro benzoyl Chloride, 4-chloro butyryl Chloride, Phthaloyl Chloride, 2-methoxy 5-bromo 6-methyl benzoyl chloride, Terephthaloyl Chloride, IsoPhthaloyl Chloride, O-Chloro Benzyl Alcohol, Para-Chloro Benzyl Alcohol, 4-methyl benzoyl chloride etc
1500
2 Chlorination products
such as Chloro Benzene, Chloro Toluene, Chlorinated PVC, Poly aluminum chloride, Mono chloro acetic acid, Chloro acetic acid, 2,6 Dichloro phenol, sulphurMonichloride, Ferric chloride, Aluminium chloride, Cuprous chloride, Calcium chloride, Cyanauric Chloride, Trichloro Acetyl Chloride, paracetamol, Epichlorohydrin, 4-Chloro 2-Hydroxy Aniline, Para Amino Phenol, Nitro Chloro Benzene, Benzyl Chloride, Sodium Hypo Chloride, Benzo Trichloride, 2,4 D Esters, 2,4 D Amine, Chlorinated Paraffin Wax, Phosphorous Penta Chloride, Phosphorous Trichloride, Caboxy Methyl Cellulose Sodium Salt, Mono Chloro Benzene, 5,Chloro Ortho hydroxy benzoic Acid, 2,4 Dichloro Phenol, Dichloro Benzene, ParaChloroToluene/OrthoChloroTol, 2,4-Dichloro Phenoxy Acetic Acid, P-Chlorobenzyl Chloride, O-Chloro Benzyl Chloride, O-ChloroBenzal Chloride and O-Chloro Benzo Trichloride
1500
3 Hydrogenation products such as Xylidine, Anisidine, 2-Methyl Cyclohexyl Acetate, Para Hydroxy Aniline, Aniline, 3,4 Diamine Toluene, 3,4 Di chloro Aniline, 2,4,5-Trichloroaniline, O-M-P Toluidine, 2-Chloro, 5 Methyl, 1,4 Phenylene Diamine, 3-Amino Benzotrifloride, 3- Amino 4-Chloro Benzotrifloride, Silane- Hydrogenation Of Precipated Silica, 3 Amino 4-Methyl Benzoic, 3-Amino 4-Chloro Benzoic acid, 3 Amino 4-Methyl Benzoic, IsoPhoronDia Amine, 2 Chloro 1,4 Phenylene Diamine, 2,5 Dichloro 1,4 Phenylene Diamine, 3-Iso Propoxy Aniline, . 2 Chloro 5-Methyl, 1,4 Phenylene Diamine, 6-Methyl 5-Amino Benzimidazolone, 2,5 Dimethyl 1,4 Phenylene Diamine, 5-Amino Benzimidazolone, 3-5 Dichloro Aniline, 2-5 Dichloro Aniline, 2,3 Dichloro Aniline
1500
3.5 Technology and Process Description
3.5.1 Salient Features of Technology
Chlorination: The organic and inorganic solvents are being received on tankers and are being charged to specially designed chlorinator reactors having provision of agitator reflux condenser, oil heating system with variable pressure monitoring systems. Gases chlorine received from nearby Chlor
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Alkali industries through pipe line are being charged in a close control monitoring system with DCS/PLC programming system for suitable degree of chlorination desired by process vendors. The vent is being connected with scrubber system and removed spent acid is being consumed for existing unit of PPT Silica. The product is being transferred to vendor’s tankers to carry out their other process at their unit.
Hydrogenation: The organic and inorganic solvents received through tankers and will be charged to specially design hydrogenates reactors having provision of agitator reflux condenser, heating system with variable pressure monitoring systems. Hydrogen gas received from nearby Chlor Alkali industries through pipe line are being charged in a close control monitoring system with DCS/PLC programmed system for suitable degree of hydrogenation desired by process vendors. The vent is being connected with condenser and condensed water is being consumed for existing unit of PPT Silica reactor. The product is being transferred to vendor’s tankers to carry out their other process at their unit.
Hydrolysis: The organic and inorganic solvents are received through tankers and will be charged to specially designed hydrolysis reactors-202 having provision of agitator reflux condenser, heating system with variable pressure monitoring systems. Spent Acid generated from Chlorination process are being charged in a close control monitoring system with DCS/PLC programmed system for suitable degree of hydrolysis desired by process vendors. The vent is being connected with scrubber and condensed acidic water is being consumed for existing unit of PPT Silica reactor. The hydrolysis product –is being transferred to vendor’s tankers to carry out their other process at their unit.
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3.6 Raw Materials
Details of existing and proposed raw material is provided in Table 3-2.
Table 3-2: Raw Material
S. No.
Raw Material Existing Quantity
Proposed Quantity Total Quantity after
expansion
1 Sodium Silicate 2393 - 2393
2 Spent Acid 1790 - 1790
3 Bleached Clay 41 - 41
4 Chlorine - 3000 3000
5 Hydrogen - 75 75
6 RM-2* - 1100 1100
7 RM-3** - 1000 1000
8 RM-4*** - 1300 1300
3.7 Process Description
Process description is given in Annexure 5 of Form-1
3.8 Additives and Chemicals
List of Raw materials are given in Annexure 6 of Form-1.
3.9 Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product.
3.9.1 Transportation details of Raw Materials
Table 3-3: Details of Raw Material Consumption and Transportation Details Raw Material Consumption(MTPM) Source Mode of Transport
Existing
Sodium Silicate 2393 Ankleshwar Tanker
Spent Acid 1790 Dahej Tanker
Bleached Clay 41 Bhavnagar Truck
Proposed
Chlorine 3000 Dahej PIPE LINE
Hydrogen 75 Dahej PIPE LINE
RM-2* 1100 Dahej/Ankleshwar Tanker
RM-3** 1000 Dahej/Ankleshwar Tanker
RM-4*** 1300 Dahej/Ankleshwar Tanker
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RRM-2*, RM-3** and RM – 4***
3.10 Availability of water its source, energy/power requirement and source should be given
3.10.1 Water consumption
Water will be sourced from GIDC water supply. Existing water consumption is 50 KLD and proposed water consumption will be 35 KLD. So after proposed expansion total water consumption will be 85 KLD.
Table 3-4: Details of Water Consumption
S. No. Area of Consumption Fresh Water Quantity, KLD Existing Proposed Total
1 Domestic 7 3 10
2 Industrial
i Process 35 10 45
ii Cooling Tower 0 10 10
iii Boiler 0 5 5
iv Washing 2 3 5
3 Gardening 6 4 10
Total 50 35 85
3.10.2 Power Requirement
Existing power requirement is 75 kVA.
Proposed power requirement during Construction Phase is 15 kVA and during Operation Phase is 75 kVA which will be supplied by Dakshin Gujarat Vij Company Limited (DGVCL).
Table 3-5: Fuel Consumption
S. No. Stack Attached to Capacity Type of Fuel used Fuel consumption
1 Baby Boiler 2 T/hr NG or LDO
124m3/hr or 500 Lit/hr.
2 Hot Air Generator 5 Lac Kcal/hr 124m3/hr or 500 Lit/hr.
3.11 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal
Waste water generation details are given in the following table;
Table 3-6: Wastewater Generation Details
S. No. Area of Consumption Wastewater Generation, KLD
Disposal Mode Existing Proposed Total
1 Domestic 5 2 7 To Soak Pit & Septic Tank
2 Industrial
i Process 14 0 14 GIDC disposal drainage
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S. No. Area of Consumption Wastewater Generation, KLD
Disposal Mode Existing Proposed Total
ii Cooling Tower 0 2 2 GIDC disposal drainage
iii Boiler 0 1 1 GIDC disposal drainage
iv Washing 2 3 5 GIDC disposal drainage
3 Gardening 0 0 0 GIDC disposal drainage
Total 21 8 29
There will be no any hazardous waste generation due to proposed expansion. Detail of hazardous waste generation is given in Table 3-7. Hazardous waste will be disposed to M/s. Saurastra Enviro Projects Pvt. Ltd. (SEPPL), Kutch. Willingness letter of SEPPL is given as Figure 3-1.
Table 3-7: Hazardous Waste Generation and disposal Details
S. No.
Waste Category
as per HW Rules
Quantity in MT/Year
Treatment / Disposal Method Existing Proposed Total
1 Discarded Containers
33.3 25 0 25
Collection, Storage, Decontamination, Transportation, Disposal by either reuse or selling
to vendors.
2 Used Oil 5.1 0.02 0 0.02 Collection, Storage, Transportation,
Disposal by selling to registered rerefiners.
3 Inorganic Process Waste containing Silica Graduals
34.4 26.4 0 26.4 Collection, Storage, Transportation,
Disposal at approved common TSDF site.
4 ETP Sludge 34.3 3.6 0 3.6 Collection, Storage, Transportation,
Disposal at approved common TSDF site.
5 Activated Earth - 3.6 0 3.6 Collection, Storage, Transportation,
Disposal at approved common TSDF site.
6 Sodium Sulphate - 25 0 25 Collection, Storage, Transportation,
Disposal at approved common TSDF site.
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Figure 3-1: Willingness Letter of TSDF for Waste Disposal
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4 SITE ANALYSIS
4.1 Connectivity
Most of the industries in Dahej are located in GIDC Industrial Area 1 & 2. The study area is well connected by roads to Bharuch. All the areas in the study area linked either by 4 lane roads.
Two nearest Railway stations are available from the proposed site. Dahej Railway Station is located at an aerial distance of 3.8 km in SW and Bharuch Railway Station is located at an aerial distance of 38.7 km in E
4.2 Land Form, Land Use and Land ownership
The total plot area of the unit is 10000 m2.As the project is located in notified industrial estate, the landuse of the project site is industrial.
4.3 Topography (along with map)
The project site generally flat with average level difference of 2.0m. There are isolated pockets of 1.0 – 2.0 m above or below the average ground well. Shallow depressions are observed on the site and a large area in the middle of the plot towards eastern boundary is elevated.
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.
Land use pattern: Industrial
Table 4-1: Distance of Project Site from Sensitive Areas Area Distance in km Direction
Reserved Forest 8.57 WSW
Mangroves 9.55 W
Table 4-2: Distance of Project site from Water Bodies
Water Body Distance in km Direction
Vadadla Pond 1.24 NNE
Jolwa Pond 2.7 ESE
Dahej Port Coastal Area 9.4 W
Ambheta Narmada Estuary 4.18 S
Dahej Pond 4.12 WSW
Ambheta Pond 5.18 SW
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4.5 Existing Infrastructure
Proposed expansion of the project will be done on existing land. Land is used for Industrial purpose. During expansion additional facility will be develop as pre the requirement for production of new products.
4.6 Soil classification
Not required
4.7 Climatic data from secondary sources
The general agro-climatic zone of the study area is Semi-arid. Information presented in subsequent paragraphs is from the most recently published Long Term Climatological Tables for the nearest observatory, Bharuch by the Indian Meteorological Department (IMD).
4.7.1 Temperature
Mean daily maximum temperature is recorded in the month of April at 40 °C. From October to December, both day and night temperatures begin to decrease rapidly. January is generally the coldest month, with a minimum temperature of 11.9 °C. During the post-monsoon months of October and November, day temperatures remain between 16.9-22.0 ºC. In winters, i.e. December, January and February, average day temperatures remain between 11.9-14.4 ºC.
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4.7.2 Wind
Table 4-3: Predominant Wind Direction
Month Predominant Wind
First Second Third
Morning Evening Morning Evening Morning Evening
January NE NE SE SW SW NW
February NE NE NW SW SW NW
March SW SW NE NW NW NE
April SW SW NW NW SE W
May SW SW NW NW S S
June SW SW S S W S
July SW SW S S W W
August SW SW W W NW NW
September SW SW NW NW S S
October SW SW NE NE SE SE
November NE NE SE SE SW SW
December NE NE SE NW NW NW
4.7.3 Rainfall
The total rainfall in year is observed to be 924.8 mm. Distribution of rainfall by season is 2.3 mm in winter (December, January, February), 14.3 mm in summer (March, April, May), 869.3 mm in monsoons (June, July, August, September) and 38.9 mm in post-monsoon (October - November).
4.7.4 Cloud Cover
The area remains cloudy between June - September, which is the active period of the monsoon season. Cloud cover is 6-8 oktas during monsoon season, while it is 0-2 oktas in post monsoon, winter and summer season.
4.7.5 Humidity
Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer in that order. Mornings are more humid than evenings and humidity ranges from a high of 80-90% in monsoon mornings to a low of 26-38% in summer evenings. During post-monsoon season, in morning humidity remains between 68-75% and in the evening it remains between 37-44%.
4.8 Social infrastructure available
Not applicable
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5 PLANNING BRIEF
Project activity chart for Chlorination-Hydrogenation-Hydrolysis is provided below
Table 5-1: Project Activity Chart
SN ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 PDP
2 BED
3 P.E.PO
3.1 P.E.Fabrication
3.2 P.E.Fabrication Testing
4 DED
4.1 CIVIL
4.1.1 PILING WORK
4.1.2 ROADS & DRAINS
4.1.3 TANK FOUNDATIONS
4.1.4 RCC Building & Pipe Rack work
4.1.5 Structural Bulding& Pipe Rack work
4.2 PROCUREMENT
4.2.1 ENQUIRY Floating
4.2.2 Reciept of Offers
4.2.3 Technical/ Commercial Comparatives
4.2.4 PO
4.2.5 Reciept of material at Site
4.3 SITE ERECTION
4.3.1 SITE TANKS
4.3.2 COOLING TOWER
4.3.3 EQUIPMENT ERECTION
4.3.4 PIPING ON PIPE RACK
4.3.5 AREA PIPING
4.3.6 ELECTRICAL ERECTION
4.3.7 INSTRUMENT ERECTION
4.4 MECHANICAL COMPLETION
5 Pre commissioning
6 Commissioning
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6 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (processing area)
The total plot area of the unit is 10000 m2.
6.2 Residential Area (non-processing area)
No Residential area
6.3 Green belt
10.46% of total plot area will be developed as greenbelt.
6.4 Social Infrastructure
Not applicable
6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc)
Proposed Project Site is located at GIDC- Dahej, Taluka Vagra, and District Bharuch in south Gujarat. Dahej, know a days is well known industrial region and developing very fast, it has also a PCPIR region. Bharuch, is a district Headquarter as well as major Town and proposed site is located at an aerial distance of 35 km towards E direction.
6.5.1 By Road
SH 6 is the main approach road from Bharuch to Project site. It is six lane state highway from Bharuch up to Dahej, lies at an aerial distance of 0.7 km towards S direction. Dahej Village is main center of this industrial region, at an aerial distance of about 3.8 km towards SW direction from site. Vagra is a Taluka HQ village at an aerial distance of about 26.14 km towards NE direction from site. Dahej is well connected to Bharuch by State Transport Buses and Private vehicles.
6.5.2 By Rail
Site is also approachable by railway which connected Bharuch and Dahej via Samni & Vagra. This railway line passing through NW to SW direction from project site. Dahej is nearest railway station at an aerial distance of about 3.8 km towards SW direction from project site. District Head Quarter Bharuch is a Major railway station lies on Mumbai-Vadodara mainline, at an aerial distance of about 38.7 km towards E direction from projects site. Bharuch is well connected with various parts of the country.
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6.5.3 By Air
Nearest domestic airport from proposed project site is located at Vadodara, at an aerial distance of about 91 km towards NE direction. Vadodara is well connected with Mumbai and Delhi with daily multiple flights.
Ahmedabad Airport (Domestic as well as international) is located at about 147.8 km towards N direction from project site. Regular flights to all aver India and abroad are available from here.
6.5.4 By Water
Dahej is a port Village lies on the Bay of Cambay, having a small jetty under maritime board. It is situated 8.6 km towards W direction from project site. There are several other private jetties developed by industries.
6.6 Drinking water management (source & supply of water)
GIDC water facilities will be used.
6.7 Sewage system
Domestic Sewage waters will be disposed in to soak pit.
6.8 Industrial waste management
The wastewater generated from the industrial unit will be disposed in GIDC drain after treatment. The hazardous waste will be transferred to Hazardous waste will be disposed to M/s. Saurastra Enviro Projects Pvt. Ltd. (SEPPL), Kutch.
6.9 Solid waste management
The solid wastes generated from the plant operations will be disposed in nearby Waste Management landfill facility. The unit has membership of M/s. Saurashtra Enviro Projects, Kutch for Integrated Common Hazardous Waste Management Facility.
6.10 Power requirement & supply/ source
Proposed power requirement during Construction Phase is 15 kVA and during Operation Phase is 75 kVA which will be supplied by Dakshin Gujarat Vij Company Limited (DGVCL).
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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, since the project lies in Industrial Area, with land acquisition procedures completed by the GIDC.
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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)
April 2017 - March 2018
8.2 Estimated project cost along with analysis in terms of economic viability of the project.
Rs. 1500 lacs
8.2.1 Fixed Capital
Rs. 1200 lacs
8.2.2 Working Capital
Rs.300 lacs
8.2.3 Revenues
Rs. 3000 lacs
8.2.4 Breakeven Point
Rs. 70 lacs
8.2.5 Profitability
Rs. 300 Lacs
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9 ANALYSIS OF PROPOSAL
9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area
• The new location will add around 20 on permanent basis and 35 on Contractual basis to its existing rolls plus some contractual employees. It is expected that all central support functions viz. Marketing, Purchase, Human resources, Legal, Finance and Accounting will continue to be handled by the existing staff with minor additions.
• Employment will get generated in market by sales and service for providing products to the industry. Also the increased capacity will increase the raw material consumption as well as the supporting services and will give further business to the vendor industry.
• During construction phase ~100 personnel will be engaged by contractors. • Many people will get indirect benefits due to coming up Industries in local market. • Transporters will be engaged to bring raw materials and supply finished goods.
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