APPENDIX I Form 1 S.No. Item Details Whether it is a violation case and application is being submitted under Notification No. S.O.804(E) dated 14.03.2017 ? No Name of the Project/s Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant, Sea Water Desalination Plant (RO process) for captive consumption by Veritas Polychem Private Limited. IA/MH/IND2/80916/2018 143205 1. Brief summary of project Proposal Number Project Cost (in lacs) 2. S. No. in the schedule Project Sector 5(e) Petrochemical based processing (processes other than cracking & reformation and not covered under the complexes) Industrial Projects - 2 3. Proposed capacity/area/length/tonnage to be handled/command area/lease area/number or wells to be drilled For details please refer PFR 4. New/Expansion/Modernization New 5. Existing Capacity/Area etc. 19.99 Hectare 6. Category of project i.e. 'A' or 'B' A 7. Does it attract the general condition? If yes, please specify No 8. Does it attract the specific condition? If yes, please specify No 9. Location of the project Shape of the project land Dighi Port Area. Village Dighi, Taluka Shriwardhan , Dist. Raigad, Maharashtra, 402402 Block (Polygon) Annexure-II in PFR Annexure III in PFR-Survey of Uploaded GPS file Uploaded copy of survey of India Toposheet
Transcript
APPENDIX I
Form 1
S.No. Item Details
Whether it is a violation case and application is being submitted under Notification No. S.O.804(E) dated 14.03.2017 ?
No
Name of the Project/s
Integrated Project consisting of Poly vinyl Chloride
Details of State of the project S.no State Name District Name Tehsil Name
Maharashtra Raigad Shrivardhan
10 Nearest railway station along with distance in kms Nearest airport along with distance in kms
Roha railway Station, 40 km Chhatrapati Shivaji International Airport, 200 km
11.
Nearest Town/City/District Headquarters along with distance in kms
Shrivardhan , 30 km
12. Village Panchayats, Zila Parishad, Muncipal Corporation, Local body (Complete postal address with telephone nos. to be given)
Shrivardhan Municipal Council Ravindra Narayan Raut Administrative building Shivaji Road Shriwardhan District :- Raigad State :- Maharashtra Pincode :- 402110 Tel :- 02147222378
13. Name of the Applicant Mr. Praveen Bhatnagar 14. Registered Address 701, Embassy Centre, Nariman Point, Mumbai
15. Address for correspondence: Name of the Company Name of the Applicant Designation (Owner/ Partner/ CEO)
Pin code E-mail Telephone No. Fax No.
VERITAS POLYCHEM PVT LTD Praveen Bhatnagar Head projects
ii) Whether the proposal involves approval/clearance under the wildlife (Protection) Act,1972?
iii) Whether the proposal involves approval/clearance under the C.R.Z notification, 2011?
No
Yes, Pipeline corridor from jetty to site & SWRO plant will be in CRZ III area. Annexure A
22. Whether there is any Government Order/Policy relevant/relating to the site?
No
23. Whether any Forest Land Involved? Area of Forest land Involved (hectares)
No
24. Whether there is any litigation pending against the project and/or land in which the project is proposed to be set up? (a) Name of the Court (b) Name of the Sub court (c) Case No.
No No No
II) Activity:
1. Construction, operation or decommissioning of the Project involving actions, which will cause
physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr
.No Information/Checklist confirmation Yes/No
there of (with approximate quantities/rates, sible) with source of information data
1.1
Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)
No
The proposed project will be developed and commissioned within Dighi Port limits.
1.2 Clearance of existing land, vegetation and buildings?
No The project will be developed on the vacant land within the Dighi Port limits.
1.3 Creation of new land uses? No Dighi Port land has approval of port related /Industrial use
1.4 Pre-construction investigations e.g. bore houses, soil testing?
Yes The detailed Geotechnical Investigation is being carried out.
1.5 Construction works? No Construction for setting up of Plants and Infrastructure will be carried out after NOC /
EC from MOEFCC is granted.
1.6 Demolition works? No Not Applicable
1.7 Temporary sites used for construction works or housing of construction workers?
No Not Applicable
1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations and fill or excavations
Yes Construction for setting up of Plants and Infrastructure will be carried out after NOC / EC from MOEFCC is granted.
1.9 Underground works including mining or tunnelling?
No Not Applicable
1.10 Reclamation works? No Not Applicable
1.11 Dredging? No Not Applicable
1.12 Offshore structures? Yes Steel structures for Intake and Outfall of SWRO Desalination Plant will be erected.
1.13 Production and manufacturing processes?
Yes Please Refer the PFR
1.14 Facilities for storage of goods or materials?
Yes During Construction Phase sand, cement, aggregates and steel will be stored at site. Operation Phase the proposal includes the storage of Liquefied gases, Bitumen and Chemicals at the site.
1.15 Facilities for treatment or disposal of solid waste or liquid effluents?
Yes For details please refer the PFR
1.16 Facilities for long term housing of operational workers?
No Not Applicable
1.17 New road, rail or sea traffic during construction or operation?
No Not Applicable (Site is connected by existing NH753F from Dighi to Mangaon on NH66)
1.18 New road, rail, air water borne or other transport infrastructure including new or altered routes and stations, ports, airports etc?
No Raw material will be imported via sea & will carried up to the site through pipeline corridor from dighi port to project site.
1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?
No Not Applicable
1.20 New or diverted transmission lines or pipelines?
yes Pipelines corridor will be laid from existing Dighi port Jetty to the site. Permission letter from Dighi port is Attached as Annexure B. EC of Dighi port Annexure C
1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or
No Not Applicable
aquifers?
1.22 Stream crossings? No Not Applicable
1.23 Abstraction or transfers of water from ground or surface waters?
No Not Applicable
1.24 Changes in water bodies or the land surface affecting drainage or run-off?
No Not Applicable
1.25 Transport of personnel or materials for construction, operation or decommissioning?
Yes There will be transportation of construction material and personnel in the project site during construction phase.
1.26 Long-term dismantling or
decommissioning or restoration works? No Not Applicable
1.27
Ongoing activity during decommissioning
which could have an impact on the
environment?
No
Not Applicable
1.28
Influx of people to an area in either
temporarily or permanently?
Yes During construction phase contracted
personnel will be deployed at site from nearby
places. Influx of these people will be
temporary in nature. Operation Phase: -Total
employment of the whole project will be
approx. 1000 out of which permanent staff will
be 500 nos. and contract workmen will be 500
nos.
1.29 Introduction of alien species?
No Not Applicable
1.30 Loss of native species or genetic
diversity? No Not Applicable
1.31 Any other actions?
No Not Applicable
2.0 Use of Natural resources for construction or operation of the Project (such as land, water,
materials or energy, especially any resources which are non-renewable or in short supply):
2.5 Forests and timber (source – MT) No Not Applicable
2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT),energy (MW)
Yes Captive power plant of 18MW will be installed for electricity requirement. It will be based on LNG(64-65 MT/day).
2.7 Any other natural resources (use appropriate standard units)
No Not Applicable
3.0 Use, storage, transport, handling or production of substances or materials, which could be harmful to
human health or the environment or raise concerns about actual or perceived risks to human health
S.No Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
3.2 Changes in occurrence of disease
or affect disease vectors (e.g. insect or water borne diseases)
No Not Applicable
3.3 Affect the welfare of people e.g. by changing living conditions?
No Not Applicable
3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.
No Not Applicable
3.5 Any other causes No Not Applicable
4.0 Production of solid wastes during construction or operation or decommissioning MT/month)
S.No Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
4.1 Spoil, overburden or mine wastes No Not Applicable
4.2 Municipal waste (domestic and or commercial wastes)
Yes Construction Period: Excavated Earth will be reused for backfilling. Operation Period: Solid waste / Bio waste shall be disposed off through authorized agencies. Operation phase: The estimated waste quantities are, Garbage : 10TPA, Canteen Waste: 10TPA
4.3 Hazardous wastes (as per Hazardous Waste Management Rules)
Yes The estimated hazardous waste quantities are:
spent and lube oils: 10TPA
Sludge and Filter contaminated with oil:5TPA
Discarded Containers and Barrels:5 TPA
Chemical Sludge from Waste Water Treatment Plant (WWTP):127TPA
Filter and filter material which have organic liquid in them, for example mineral oils, synthetic oil and organic chlorine compounds:2TPA
4.4 Other industrial process wastes No Not Applicable
4.5 Surplus product No Not Applicable
4.6 Sewage sludge or other sludge from effluent treatment
Yes The sludge will be treated and will be used as organic manure for gardening and agriculture, etc.
4.7
Construction or demolition wastes
Yes
There shall be no demolition, however the waste generated during construction shall be used for back filling and the waste which cannot be used shall be disposed off through authorized agencies.
4.8 Redundant machinery or equipment No Not Applicable
4.9 Contaminated soils or other materials No Not Applicable
4.10 Agricultural wastes No Not Applicable
4.11 Other solid wastes Yes Shall be disposed off through authorized agencies.
5. Release of pollutants or any hazardous, toxic or noxious substances to air(Kg/hr)
S.No Information/Checklist confirmation
Yes/No Details thereof (with approximate
quantities/rates, wherever possible) with source of information data
5.1
Emissions from combustion of fossil fuels from stationary or mobile sources
Yes
LNG will be used for captive power generation. Emission in the form of NOX are expected from power plant stack.
5.2
Emissions from production processes
Yes
Air emissions will be there from Captive power plant stack, process stacks, scrubber stacks.
It will be treated and let to atmosphere as per EP guidelines.
5.3 Emissions from materials handling including storage or transport
Yes Emission from material handling including storage and transport is expected in the form of PM,SOX & NOX
5.4 Emissions from construction activities including plant and
Yes There will be emission of dust and other gaseous material due to construction activities,
equipment construction vehicle, handling of materials.
5.5 Dust or odours from handling of materials including construction materials, sewage and waste
Yes There will be emission of dust and other gaseous material due to construction activities, construction vehicle, handling of materials. Sewage sludge / waste will be stored in close container.
5.6 Emissions from incineration of waste
No Not applicable. There will not be any incineration of waste at site.
5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)
No Not applicable
5.8 Emissions from any other sources No Not applicable
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S.No Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes DG / Gas Generator sets shall have acoustic enclosures in order to keep the noise within limits. There will not be any vibrations on these engines.
6.2
From industrial or similar processes
Yes
There will be noise generation due to operation of plant machinery, handling of materials, vehicle movement etc. during operation phase which will be addressed by: 1. Providing noise barriers in the form of Green Belt around the premises. 2. Proper maintenance of plant and machineries. 3. Proper equipment’s for loading and unloading of transport vehicles.
6.3 From construction or demolition No There will be no demolition during the entire project, however during construction noise will be generated due to various equipment’s running at site.
6.4 From blasting or piling Yes There will be no blasting, however noise and generation of vibration will be through Piling only during construction stage.
6.5 From construction or operational traffic
Yes Construction Phase: Cranes, Dumpers, Excavators, Dozers, Trucks and Trailers shall be used. Operation Phase: - Trucks, Tankers and trailers.
6.6 From lighting or cooling systems No There will not be any noise generation for lighting, however noise occurring due to cooling systems
shall be kept to minimum levels by having proper enclosures.
6.7 From any other sources No Not applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
S.No Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
7.1 From handling, storage, use or spillage of hazardous materials
No Precautions will be taken during transportation, loading/unloading etc. MSDS will be followed.
7.2 From discharge of sewage or other
effluents to water or the land (expected mode and place of discharge)
No
Wastewater generated during operation phase
will be treated in ETP and the treated water will be disposed off to the sea.
SWRO reject will be sent back to sea.
7.3 By deposition of pollutants emitted to air into the land or into water
No Air Pollution Control equipment will be provided at source to prevent emissions in air.
7.4 From any other sources No Not Applicable
7.5 Is there a risk of long term build up of pollutants in the environment from these sources?
No Not Applicable
8. Risk of accidents during construction or operation of the Project, which could affect
human health or the environment
S.No Information/Checklist confirmation
Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances
Yes Disaster and risk management plan will be prepared and implemented.
8.2 From any other causes No Not applicable
8.3
Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburstetc)?
Yes
The project will be designed by taking into consideration these factors as per relevant codes and standards. The proposed project site has not reported any kind of natural disasters like earthquake, floods, Tsunami etc. However, a proper DMP will be prepared and executed in case of any such eventualities.
9. Factors which should be considered (such as consequential development) which could lead to
environmental effects or the potential for cumulative impacts with other existing or planned
activities in the locality
Sr.No. Information/Checklist confirmation
Yes/No Details thereof (with approximate
quantities/rates, wherever possible) with source of information data
Lead to development of supporting utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.:
9.1 • Supporting infrastructure (roads, power supply,waste or waste water treatment, etc.)
• housing development extractive industries supply industries Other
Yes
The project will have positive impact of supply industries, due to procurement of raw materials etc. required for production.
9.2 Lead to after-use of the site, which could have an impact on the environment
No Not Applicable
9.3 Set a precedent for later developments No Not Applicable
9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects
1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other relatedvalue
Yes Phansad wildlife sanctuary located at 11 km towards the North East.
2
Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests
Yes
Proposed project is located within Dighi Port situated near Rajapuri Creek. Murud janjira Fort (ESZ as per the MoEF notification dated 6th jan 1989):~3 km toward north side of project site Kasa fort(Notified Heritage site): ~5 km towards north waste side of project site. Khokhari Tomb (Notified Heritage site): ~4km towards northeast side o project site.
3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration
No Not Applicable
4 Inland, coastal, marine or underground waters
No Not Applicable
5 State, National boundaries Yes Not Applicable
6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas
Yes Murud Janjira Fort: 3 km towards north side of project site. Murud beach: ~5 km toward north side of the project site. Ahmadganj Siddi Palace, Murud: ~7 km Towards north east side of the project site.
7 Defence installations No Not Applicable
8 Densely populated or built-up area Yes Roha: 40 km
9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)
Yes Dr. A.R. Undre English High School & Junior College, Diveagar: 13 km South. • Sir S. A. High School, Murud: 4.60 North East
10 Areas containing important, high quality or scarce resources. (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)
No Not Applicable
11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)
No Not Applicable
12
Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions) similareffects
No
The project will be designed by taking into consideration these factors as per relevant codes and standards. The proposed project site has not reported any kind of natural disasters like earthquake, floods, Tsunami etc. However, a proper DMP will be prepared and executed in case of any such eventualities.
2 INTRODUCTION OF THE PROJECT ...................................................................................... 9
IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ....................................................... 9 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ........................................................................... 9 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ..................... 9
Poly Vinyl Chloride (PVC) .......................................................................................................... 9 Polymer Modifed Bitumen (PMB) .......................................................................................... 9 Gas storage tank farm and bottling unit ......................................................................... 10
DEMAND – SUPPLY GAP .................................................................................................................... 10 Poly Vinyl Chloride (PVC) ....................................................................................................... 11 PVC India Production Demand in MMT ........................................................................... 12 Vinyl Chloride Monomer (VCM) ........................................................................................... 15 Why India for PVC plant? ....................................................................................................... 15
2.4.4.1 Water Conservation ........................................................................................................ 15 Polymer Modified Bitumen (PMB) ..................................................................................... 16 Liquefied Petroleum Gas (LPG)............................................................................................ 19
2.4.6.1 Description of the LPG Market: ................................................................................... 19 IMPORTS VS INDIGENOUS PRODUCTION ........................................................................................... 21 EXPORT POSSIBILITY ......................................................................................................................... 22 DOMESTIC / EXPORT MARKET ......................................................................................................... 22 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ............................. 22
TYPE OF PROJECT .............................................................................................................................. 23 LOCATION ........................................................................................................................................... 23 DETAILS OF ALTERNATIVE SITES ..................................................................................................... 24 SIZE OR MAGNITUDE OF OPERATION ................................................................................................ 25 PROJECT DESCRIPTION WITH PROJECT DETAILS ............................................................................. 26
PVC Plant ....................................................................................................................................... 26 3.5.1.1 Basic structure of PVC .................................................................................................... 26 3.5.1.2 PVC Process Technology Review ............................................................................... 27 3.5.1.3 Product applications of PVC ......................................................................................... 27 3.5.1.4 Product PVC ........................................................................................................................ 28 3.5.1.5 Installed production capacity ...................................................................................... 28 3.5.1.6 PVC Plant Process Description .................................................................................... 28 3.5.1.7 VCM unloading, storage and feeding system ......................................................... 28 3.5.1.8 VCM Pipeline transfer facilities ................................................................................... 29 3.5.1.9 Receipt and storage facility at Gas Storage Terminal ......................................... 30 3.5.1.10 Preparation and charging of demineralized water ......................................... 31 3.5.1.11 Preparation and feeding of additive agents ....................................................... 31 3.5.1.12 Polymerization .............................................................................................................. 31 3.5.1.13 Shortstop (Terminator) system .............................................................................. 31 3.5.1.14 Vacuum system ............................................................................................................. 31 3.5.1.15 VCM Recovery system ................................................................................................ 32 3.5.1.16 PVC slurry stripping .................................................................................................... 32
PMB Plant ..................................................................................................................................... 35 3.5.2.1 Design basis ........................................................................................................................ 35 3.5.2.2 Process Description ......................................................................................................... 35 3.5.2.3 Process Flow Diagram .................................................................................................... 38
Utilities ........................................................................................................................................... 39 Gas Storage terminal and bottling unit ........................................................................... 39
3.5.4.1 Design basis ........................................................................................................................ 39 3.5.4.2 Process Description ......................................................................................................... 40
Gas based Captive power plant ............................................................................................ 43 3.5.5.1 Waste Heat recovery Boilers ....................................................................................... 43 3.5.5.2 Fuel supply source and quantity ................................................................................ 43 3.5.5.3 Regasification of LNG ...................................................................................................... 44
Utility Plants ................................................................................................................................ 44 3.5.6.1 Cooling Water System .................................................................................................... 44 3.5.6.2 Sea Water Desalination Plant ...................................................................................... 45 3.5.6.3 Demineralization (DM) Water Plant ......................................................................... 45 3.5.6.4 Compressed Air System ................................................................................................. 45 3.5.6.5 Nitrogen generation system ......................................................................................... 45
RAW MATERIAL REQUIRED ............................................................................................................... 46 Manpower ..................................................................................................................................... 47
RESOURCE OPTIMIZATION................................................................................................................. 47 WATER, ENERGY / POWER AVAILABILITY AND SOURCE ............................................................... 47
Water .............................................................................................................................................. 47 Energy............................................................................................................................................. 48 Power .............................................................................................................................................. 48
WASTE GENERATION, MANAGEMENT AND DISPOSAL .................................................................... 48 Industrial Waste water ........................................................................................................... 48 Solid waste – const .................................................................................................................... 49 Non hazardous waste .............................................................................................................. 49 Hazardous waste ....................................................................................................................... 49
4 SITE ANALYSIS ......................................................................................................................... 50
CONNECTIVITY ................................................................................................................................... 50 LAND FORM, LAND USE AND LAND OWNERSHIP ............................................................................. 50 TOPOGRAPHY (ALONG WITH MAP) .................................................................................................. 50 EXISTING LAND USE PATTERN .......................................................................................................... 50 EXISTING INFRASTRUCTURE ............................................................................................................. 51 SOIL CLASSIFICATION......................................................................................................................... 51 CLIMATE DATA FROM SECONDARY SOURCES ................................................................................... 54 SOCIAL INFRASTRUCTURE AVAILABLE ............................................................................................. 56
LAND USE PLANNING ......................................................................................................................... 57 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ...................................... 58 AMENITIES / FACILITIES ................................................................................................................... 58
INDUSTRIAL AREA (PROCESSING AREA) ......................................................................................... 59 RESIDENTIAL AREA (NON-PROCESSING AREA) ............................................................................... 59 GREEN BELT ....................................................................................................................................... 59 SOCIAL INFRASTRUCTURE ................................................................................................................. 59 CONNECTIVITY ................................................................................................................................... 59 DRINKING WATER MANAGEMENT .................................................................................................... 59 SEWERAGE SYSTEM ........................................................................................................................... 59
POWER REQUIREMENT AND SUPPLY / SOURCE ............................................................................... 60
7 REHABILITATION & RESETTLEMENT PLAN ................................................................. 61
8 PROJECT SCHEDULE AND COST ESTIMATES ................................................................. 62
LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ......................... 62 ESTIMATED PROJECT COST ................................................................................................................ 62
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION) ................................... 63
List of Annexures Annexure No Description
I Land ownership documents II GPS location on google map. III Proposed plot layout IV Topography map of 10 km radius V Waste water treatment scheme
GROUPE VERITAS (GV), a diversified multinational business group with business interests in the following domains:
➢ International Trade, Distribution & Manufacturing ➢ Infrastructure & Logistics ➢ Alternate Fuel & Energy ➢ Agro Ventures & Biotechnology ➢ Information Technology
The various verticals under each Business Domain are depicted below:
The promoters of GV, a third-generation business family, have more than two decades of experience in International Trade and Distribution. GV, with a customer base in excess of 30,000 is the preferred customer/supply chain partner for most of the top principals and customers around the world due to:
✓ Global reach with offices across the world ✓ Extensive knowledgebase from research and experience ✓ A one-stop-shop for basket of products and services ✓ Adaptation of technology to improve transparency and efficiency ✓ Stakeholders being the #1 priority
GV, with Group-wide revenues in excess of US$ 4 Billion, is driven by its 900+ motivated associates and team members operating out of its 18 offices in India and 16 international offices and is ably supported by globally integrated systems and processes, highly evolved corporate governance, and state-of-the-art logistics infrastructure across India and the Globe. GV handles millions of tons of product across its different business verticals, with distribution in India and the Middle East being the most prominent markets. VIL, a public listed entity and a key group company of GV, is primarily engaged in the business of International Trade & Distribution and Infrastructure & Logistics with specialization in International Trade & Distribution of Chemicals, Petrochemicals,
Petroleum products, Polymers, Metals & Minerals, Paper & Paper Boards, Rubber, Fertilizers, and Agro Commodities. The Trade is supported by VIL’s Infrastructure & Logistics assets such as:
✓ Strategically located terminals with various tank size configurations and specifications, for storing Class A/B/C products, which include specialized tanks requiring heating, refrigeration, corrosion resistance, etc.
✓ Vessels that are owned and time chartered; as well as arrangements with several shipping agents and shipping lines.
✓ Exclusive management of Tank Terminals, Logistics Parks and Dry warehouses in UAE / INDIA with specific thrust on major port cities.
✓ A mini petroleum refinery associated with our own tank storage terminal which is one of the largest in Hamriyah, UAE.
✓ Drumming facilities for liquid bulk. ✓ Surface transportation ✓ Hazel International FZE (HIF), a wholly owned subsidiary company of VIL, which
has constructed a tank terminal for storage of petrochemicals with a capacity of ~200,000 m3 at Hamriyah Free Zone, Sharjah, UAE with an asset value of ~$220 Million. The terminal is ~340 meters away from the jetty with direct pipeline connectivity. It has 30 tanks spread across 30,000 square meters, which are used to store Class A, B, and C petrochemicals, Base Oils, Bitumen, Ethanol, etc. In addition to storage, the terminal offers value-added manufacturing facilities such as Blending, Sparging, Fractionating and Distillation, Drumming and other services as may be required by our customers.
Synergising two primary Business Domains, i.e International Trade & Distribution and Infrastructure & Logistics, the group is able to deal in large volumes of various products annually, for example GV’s Bitumen storage and trade business alone is over 1 million tonnes per annum. Across business domains and geographies, GV trades in almost 6 million tonnes of various petrochemicals annually. GV now proposes to set up an Integrated industrial complex at Dighi Port, Maharashtra, which shall, inter-alia, comprise of:
1. PVC plant 2,00,000 MTPA 2. PMB plant 3,60,000 MTPA 3. 16 mounded bullets of capacity 2500 m3 each (6 for VCM, 6 for LPG 4 for
Propylene) 4. LPG Bottling plant 5. Captive gas-based power plant (18MW) 6. Sea Water Desalination Plant (RO process)
The above facilities (collectively called as “Project”) would be natural backward integration for the Group GV given its existing business facilities & operations and trade relationship. The Project will be implemented, financed and operated by Veritas Polychem Private Limited, a 100% subsidiary of Veritas (India) Limited. An overview of the Company is given under: Table 1-1: Overview of the Company
Promoter Veritas India Limited Constitution Private Limited Company Listing Unlisted Sector Oil & Gas (Petrochemicals)
A brief about the Board of Directors of VPPL is mentioned below: Table 1-2: Brief Profile of Board of Directors of VPPL
Name Description Nitinkumar Didwania
Mr. Nitinkumar Didwania, is an M.Com and Masters in Economics from Mumbai University. Mr. Didwania is the promoter, shareholder and the group Chairman. He has over 20 years of experience in the petrochemical and other trading business. He is supported by a team of well qualified and professional people.
Mr. Praveen Bhatnagar
Mr. Bhatnagar, is a Chemical Engineer from Delhi University and a post graduate from Indian Institute of Foreign Trade. Mr. Bhatnagar has three decades of experience in the polymer and petrochemical industry. Having worked with LG Chem Ltd, Hi Tech Carbon, Oriental Carbon and Chemicals Ltd and Godrej Industries etc., and he has expertise to set up the manufacturing facilities
The Company would be broad basing its Board of Directors as per its business plan. The project brief is summarized in the table below Project summary at a glance
Brief Project summary
Sr No Particulars Details 1 Name of Company Veritas Polychem Private Limited 2 Products PVC, PMB, LPG, Propylene 3 Location Gat No 52,53,54,56,61,63,57,66 & adjacent
reclaimed land, Dighi Port Area. Village Nanavali, Taluka Shrivardhan , Dist. Raigad, Maharashtra
4 Name of the project Establishment of Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant, Sea Water Desalination Plant (RO process) for captive consumption by Veritas Polychem Private Limited
7 Main raw material Vinyl chloride monomer (VCM), Bitumen, Polymers, LPG, Propylene, LNG
8 Water Water requirement at site will be met by Sea water desalination Plant.
9 Power Captive power plant of 18 MW will be installed based on LNG.
10 Expected Manpower Total ~ 1000 Nos (Permanent 500 Nos, Contract 500 Nos).
11 Waste water generation, treatment and disposal
Trade effluent will be treated and discharged to sea. Domestic sewage - Sewage will be treated in independent STP and treated water will be used onsite for green belt maintenance.
12 Air emissions Air emissions will be there from Captive power plant stack, process stacks, scrubber stacks. It will be treated and let to atmosphere as per EP guidelines.
13 Waste generation and disposal
Waste generation in the form of solid and liquid will be stored and disposed as per rules.
Identification of the Project and Project Proponent
Proposed Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant, Sea Water Desalination Plant (RO process) along with associated utilities will be executed by Veritas Polychem Private Limited (wholly subsidiary of Veritas (India) Limited).
Brief Description of nature of the Project
It is an integrated petrochemical complex consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant, Sea Water Desalination Plant (RO process) for captive consumption and associated utilities and infrastructure.
Need of the Project and Its Importance to the country and/or Region
Poly Vinyl Chloride (PVC)
PVC is third most used plastic in the world. Globally the PVC supply outstrips the demand. However, prospering Indian market for PVC historically in short supply and in 2016 demand supply gas has reached about 1.4 million MT. The gap is solely catered to by imports. Hence in order to fulfill the demand VPPL decided India as location for the PVC plant. GV further foresees clear demand supply gas in the Indian market during the life of PVC plant as
o No additional capacity is being added in India. o Steady and assured growth of domestic demand.
PVC enjoy huge market in India (2.8 million Ton for 2016) and is expected to cross 4 Million MT by 2020. India’s per capita consumption of PVC is 2.5 kg as compared to global average of 6 kg. India’s PVC import demand is met by South Korea, Taiwan, USA, Japan and China.
Polymer Modified Bitumen (PMB)
India is witnessing tremendous boom in infrastructure development. In keeping with plan to develop modern and efficient highways, National highway authority of India (NHIA) has planned to increase length of road across the country. This is apart from plans of many smaller authorities. Bitumen, product of refineries is mainly used for road construction. VPPL plans to manufacture polymer modified bitumen (PMB), a formulation of bitumen with suitable polymer. In India, its application in road construction and maintenance is a recent
phenomenon and the usage is stated to pick up for PMB as it is advantageous over bitumen in following aspects
o Greater rigidity and water resistance o Resistance to permanent deformation and crack formation o Higher durability
PMB scores over standard bitumen especially under conditions of heavy load traffic and in extreme climate conditions. GV this foresees an opportunity to serve the nation with a superior product that lead to durable and robust road infrastructure.
Gas storage tank farm and bottling unit
India is net importer of Liquified petroleum gas (LPG). VPPL intend to utilize available space for storage and bottling of LPG. The facility will cater for domestic and industrial demand of the gas in the proximate market. VPPL intends to use liquefied gas facility for storage and supply of propylene. Propylene is raw material for the second most consumed polymer viz. polypropylene, which India is net imported off. The gas will also cater to few other end applications including propylene oxide, propylene glycols, acetone, phenol and polyols.
Demand – Supply gap
PVC Industry in India is more than 50 years old. The production plant of 60,000 TPA capacity was commissioned in 1961 by M/s Calico Industries. In India, PVC production is having strong support in the form of backward integration to chloro alkali plants, which are essentially promoted by textile, paper and soda ash for want of sodium hydroxide in their process. Earlier PVC was produced from calcium carbide through acetylene route, which was energy intensive and involved heavy usage of mercury in the process. It proved to be uneconomical. Hence manufacturing shifted to economical ethylene-based PVC manufacture. Till date, there are 5 PVC manufacturers in India having capacity of 1.4 million MT with a capacity utilization of around 100 %. Reliance being leader having plant capacity of 735,000 TPA, Finolex with capacity of 270,000 TPA, Chemplast Sanmar with a capacity of 250,000 TPA, DCW with a capacity fo 90,000 TPA and Shriram Chemicals with a capacity of 70,000 TPA. With a total annual consumption of PVC around more than 2.8 Million MT, 1.4 million MT PVC is being currently imported. The committee of Perspective Planning of Petrochemical Industries estimates PVC demand to be around 4 million MT by 2020 and over 5 million MT by 2025.
Globally, plastics industry is one of the leading contributors to economic growth Globally, plastics industry is one of the leading contributors to economic growth. In spite of recession and long-term consolidation trend, the plastics industry has been one of the largest and fastest-growing industry. In the second half of the 20th century, plastics emerged as one of the most globally-utilized and multipurpose materials. The plastics industry is the third largest manufacturing industry contributing significantly to the world economy. Competition in the industry is constantly growing. Plastic manufacturing is increasingly shifting towards Asia, especially to China and India. Global plastic demand in 2015-16 was observed to be close to 170 million metric tonnes (MMT). Asia's current 43% share is expected to grow to 47% by 2021, by which timeline global plastic consumption is estimated to reach 250 MMT. Globally, PVC is the third largest consumed polymer. The world demand for PVC grew from 35 _MMT in 2010 to 41 MMT in 2016 as depicted in the following diagram. For the said period, the supply has invariably been in excess to the demand. The global consumption of PVC is slated to reach 46 MMT by 2020, which will be met by excessive capacities.
Source: Platts
On the contrary, for the similar period, the Indian demand growth out-spaced the supply. The demand supply gap remained negative throughout the period under consideration. This is evident from the following graph:
The deficit is slated to increase further till 2020. It will reach 2.6 MMT by the year, whereby in-land supply and demand figures will be 1.4 MMT and 4.0 MMTY, respectively. The widened gap occurs as no capacity additions are planned, whether by existing or new manufacturers, for the period 2016-2020. It is schematically shown below:
Source: Platts
It is to seen from the above diagram that capacities built up in North America, Asia (largely China and North East Asia), and to small extent, in the rest of the world. As far as future capacity built-up is concerned, one can see these emerging only on North America. It leads to conclusion that in India no new capacities are planned until 2020, though market reports, as recent as April 2017, reveal a 0.6 MMT new capacities planned by Chemplast Sanmar. It will overcome the 2020 projected deficit only by 23%, the balance yet being managed by progressive imports till that year.
In the global PVC trade that occurred from 2010 and its projection till 2020, as represented by the following graph, North America and Rest of Asia (after exclusion of India and China) continue to export its excess PVC capacity. Europe became net exporter in 2015. China is likely to join this club by 2020. For the decade under consideration,
India remained NET IMPORTER and will continue to do so.
The diagram clearly depicts India's increasing import from 0.6 MMT in 2010 to 1.3 MMT in 2015 with projections of close to 3 MMT by 2020. This is where GV sees its opportunity to overcome a fraction of the deficit by manufacturing PVC. As the planned capacity amounts to 150,000 MTpa, it will be about 11% of the imports registered in 2015 and, at constant capacity, will be about 5% of the projected imports in 2020. PVC holds a significant share among polymers. PVC consumption in India is about 50 years old and is flourishing since last couple of decades. Indian PVC industry is currently valued at >US$4b. The following pie-charts would explain the anticipated upsurge in PVC demand growth.
Source: Platts It can be seen that there is a clear distinction in the global and India usage patterns. In either cases, the application pipes & fittings takes the biggest pie, however, in India 73% of the PVC is used in making pipes and fittings, courtesy to agricultural revolution. In this segment, Indian PVC is widely used in making pipes and hoses that are extensively used in irrigation. In Agriculture Segment, the double digit growth is persistent. In depth market research indicates that, the pie belonging to profiles (current 3% usage) will increase substantially post 2016 owing to various upcoming infrastructure projects declared by Government of India coupled with booming real estate market. It is noteworthy that PVC actually replaces wood as well as metals consumed by these industries on large scale. Thus, the PVC market in India in Infrastructure segment will be driven by:
1. Smart City Projects covering 100 cities 2. Atal Mission for Rejuvenation & Urban Transformation (AMRUT) 3. 50 million new dwellings for housing to all Indians by 2020
Further consumption drivers have been pipes & fittings towards water management and water conservation. PVC industry is one of the major contributors to the economy of the country. With huge investments in infrastructure development, India will be the growth center of the global PVC industry. PVC products have huge potential to curb the challenges faced by the country. Introduction of innovative technologies and products based on PVC will certainly make difference in the sustainable management of country's infrastructure and economy.
VCM is the key raw material for the manufacture of PVC. As a measure of profitability of the plant, Delta (A) PVC is considered as a crucial figure. A represents the price differential between the product PVC and the raw material VCM. The long-term average A value (i.e. for the period 2011-2016) is approximately US$205. The history of the individual prices (in US$/MT) and the A values is represented by the following diagram:
Source: Platts One can observe from the above diagram that A is continuously increasing from and is >205 during latter half of 2016, the above published data indicates the South East prices of VCM, while prices of VCM imports in India indicate lower levels. The Suspension grade PVC price in India considered in the financials in fact, includes the customs duty @ 7.5% which is charged to importers after adding 1% landing charges on the C & F price. With the clearing and forwarding charges, insurance, loading and unloading of containers and the logistics cost comes to approximately Rs 4,000 PMT, to bring parity with the import pricing of Suspension grade PVC by importers. However, in the financials we have conservatively considered the above charges of Rs 2,000 per MT. This prompts GV to safely assess that the envisaged PVC manufacturing plant will run with healthy bottom-lines.
Why India for PVC plant?
2.4.4.1 Water Conservation
It is observed that about 40% water is wasted during transportation due to leaks and breakages in ageing metal pipelines. Products like weld-able PVC pipes, expandable PVC
pipe have the capacity to reduce the wastage by replacement of these aging pipelines. Advantage of these products is that they can be used with trenchless installations without disturbing the existing pipeline. On the other hand, damaged leaking sewer pipelines are contaminating ground water resources leading to the severe health hazards. PVC products like spiral wound pipe renewal system, fold and form PVC pipes can be used for replacement of these old damaged pipes to increase the life of the sewer system.
A. PVC to control Deforestation and Ultimately Reduce it:
PVC windows and wood PVC composites are taking care of ecology and environment by reducing the demand for wood and wood-based products. Use of PVC in construction is practiced in developed countries for more than 2 decades and India is following suit. Forest cover in the country has reduced to 19% of total geographical area from 30% at the beginning of 20th century. Wood PVC composites are considered as an option for wood and wood-based products like plywood or particle boards for furniture applications as well as construction boards, tiles etc due to the superior water resistance. This segment is growing very fast in the country at the rate of 30%. There are many more applications yet to be emerged for wood PVC composites including decorative profiles, decking, outdoor furniture, etc.
B. Benefits to Agriculture and Food Preservation:
India is an agriculture-based country and is continuously improving the food grain production after Green Revolution. Food grain production increased to 253 MMT in 2013 from 241 MMT in 2011. Unfortunately, available storage facilities of food grain cannot manage with this kind of production which is leading to food grain wastage to the tune of 20 MMT. PVC based food grain storage structures are beneficial in terms of handling and installation. The structures are made up of gas tight through zip-lock type joint which gives perfect conditions for hermetic storage of food grains. Adoption of these structures can save precious resource — food grains with economical storage for long duration. PVC industry is one of the major contributors to the economy of the country. With massive investments in infrastructure development, India will be the growth centre of the global PVC industry. PVC products have huge potential to curb the challenges faced by the country. Introduction of innovative technologies and products based on PVC will certainly make difference in the sustainable management of country's infrastructure and economy.
Polymer Modified Bitumen (PMB)
PMB is one of the specially designed and engineered bitumen grades that is used in making pavement, roads for heavy duty traffic and home roofing solutions to withstand extreme weather conditions. PMB with added polymer, which gives it extra strength, high cohesiveness and resistance to fatigue, stripping and deformations, makes it a favorable material for infrastructure.
When a polymer is added to regular bitumen, it becomes more elastomeric, which provides it with additional elasticity. The polymer that is added is Styrene Butadiene Styrene (SBS), which acts as a binder modification agent. The primary objective of SBS polymer modified bitumen is to provide extra life to pavement, roads and construction designs. Some of the qualities exhibited by PMB are:
• Higher rigidity • Increased resistance to deformations • Increased resistance to cracks and stripping • Better water resistance properties • High durability
PMB is used for:
• Construction of hilly terrain road and in heavy rainfall areas • Roads for high and heavy traffic. • High loading . • High temperature amplitude. • More durable pavement. • Draining pavements. To meet the demands of technological and demographic changes, the use of polymer modified bitumen has become increasingly important. Increased stress on highways due to heavier loads, higher tire pressures, and ever rising traffic counts are causing premature failures. Severe climates, always a source of concern, and an increased emphasis on safety have prompted research towards the amelioration of highway paving materials. As the network of highways ages, the demand for quality maintenance and recycling products is becoming more important than that for new construction. To address these problems, the highway engineer has turned to polymer modification for custom design of pavement materials. It is possible to construct roads which require overlay not before 8 to 12 years as well as save on huge quantities of fuel. PMB can enhance the service life of roads by 50% to 150%. PMB can be used as binder in Bituminous Macadam, Bituminous concrete in construction of road. Use of PMB increases the rut, creep and fatigue resistance of the pavement, enhancing its performance and service life. Use of PMB in 'wearing course' enhances its overlay period where as its use in the binder course can enhance the design life of the road or reduce thickness of pavement resulting saving in initial cost of road. Wearing course of a road costs around 10 percent of the cost of the road. Bitumen contributes around 50 percent to this cost. Use of PMB costs around 25 to 50 percent more than convention bitumen, depending on the type of PMB. Thus, use of SBS PMB in wearing course, increases the cost of wearing course by 12.5 percent to 25 percent and that of the road by 1.25 to 2.5 percent. But the life of wearing course increases by 50 to 150 percent.
Period of overlay of a road, ordinarily being overlaid at five years, will increase to eight (or even 12) years if PMB is used as binder in place of conventional bitumen. Thus saving costs in the long run.
There are guidelines and specifications on modified bitumen issued by BIS (IS 15462:2002), by IRC (SP 53 2002, 2010) and the Ministry of Surface Transport And Highways (MORT&H) specs 2001 Clause 521.
The global modified bitumen market is projected to reach USD 19.29 billion by 2021, at a CAGR of 6.5% from 2016 to 2021. The growth of the market is attributed to the growing construction industry in emerging nations, cost-effectiveness of modified bitumen, and increasing demand for modified bitumen in regions such as Asia-Pacific and the Middle East & Africa. Modified bitumen is largely used in road construction. In addition, rising awareness about the benefits of modified bitumen is also fueling the demand. In 2015 — 2016 it is estimated that the demand for PMB in India was 430,000 MT. India is expected to lead the growth in the PMB market owing to its increasing consumption over the years for existing as well as new infrastructure projects. India has the second largest road network globally; in FY16 it was estimated to be over 5.23 Million Km and, over 64.5% of all goods in the country are transported through roads, while, 85.9% of the total passenger traffic use the road network to commute. In FY16 the length of national highways was 100,475 km and as part of infrastructure reforms, the government plans to double the length of national highways to km. The Indian roads and bridge infrastructure industry will be worth USD19.2 billion by the end FYI 7 (Source: IBEF). Modified Bitumen Market, by Region, 2021 (USD Million)
Market size in 2021
Source: Markets and Markets Analysis
As of May 2017 the price differential between Imported Bitumen and PMB is Rs
11,358.45. The cost of Imported Bitumen being USD 262 PMT CIF + 5% duty is Rs. 17,631.55 and the current price of PMB ex warehouse of one of the largest manufactures like Hincol is Rs 28,990/MT. We understand from the market sources, there are discounts being offered on PMB as well as on bitumen privately, by PSU's to their trade partners. The discounts may vary from 8% to as high as 10% as per market conditions. If discounts are considered as a regular practice, the price differential may reduce to below Rs 8500 / MT.
Liquefied Petroleum Gas (LPG)
2.4.6.1 Description of the LPG Market:
Liquefied Petroleum Gas (LPG) is primarily a mixture of Propane and Butane. The LPG Market is divided in two parts:
1. LPG for domestic (predominantly cooking gas)/ small consumers use 2. Commercial / Industry Use
LPG can be used in many applications in the industrial sector namely: any process-heating, powering industrial ovens, production of food, kilns, furnaces, metal finishing, textiles, production of packing material as well as in powering forklift trucks in warehouses. The graph below illustrates the Indian LPG — Sector wise demand:
Indian LPG demand
Source: Poten & Partners
LPG market is a lucrative, fast-growing, with current Indian market size being as high as over 21.1 million tons in 2016— 17 with annualized growth of 9%.
However, India is and will remain net imported of LPG and constituent gases, viz propane and butane. Domestic LPG production is at the hands of the PSU's, capacity of which is not able to reach the demand as elaborated by the following figure.
Source: Petroleum Planning & Analysis Cell (Ministry of Petroleum & Natural Gas, Government of India) As can be seen from this data, there is sufficient scope for import of LPG and constituent gases. It is estimated that, by 2020, when the demand would reach 24 MMT LPG, the deficit could be yet 12 MMT that will be overcome by imports. Projections: GV plans to have a capacity of 12,750 MT of LPG / Propylene. The proposed LPG storage capacities at gas terminal are as follows: -
Product Capacity in m3/ Bullet
Number of Bullets
Capacity in MT (at 300C)
LPG / Propylene
2,500 m3 10 12,750
Total Capacity of LPG/Propylene will be 25,000 cubic meters. With the storage of 25,000 Cubic meter of LPG, Veritas will be the second largest private operator in India. Groupe Veritas plans to serve the local distribution companies (LDCs), end-users and even the PSU — LPG producers. As per our assessment, the current private LPG static capacities are as follows: -
Company Location LPG Static Capacity IMC Kandla Port 5,600 CBM Aegis Logistics Limited Mumbai 20,000 MT
As observed, with Aegis's current combined Static capacity for LPG as of FYI 17 stands at 28,100 MT, the total LPG throughput volumes for two Aegis's terminals (located at Mumbai and Pipavav) was 1,350,000 metric tons in FY 2016-17, amounting to a growth of over 38% compared to the previous year’s numbers With subsidies on the LPG coming down the growth in the private operators would be phenomenal. The major private LPG importers who are actively marketing and importing LPG into India are as follows: 1. Adani Gas 2. Shiv Vani Universal 3. India LPG 4. Oil Gas India 5. Gujarat Oleo Chem Ltd 6. Geo Global Resources 7. Niko Resources Ltd 8. Pankaj Petrochem Private Ltd
Employment Generation (Direct and indirect) due to the project
The facility will generate direct and indirect employment. Direct employment at site will be ~ 1000 persons (Permanent 500 and Contract workmen 500) from this proposed project during operation phase. There will be at least an indirect employment generation of 5000 personnel in the transport sector, and, associated businesses like packaging, drums manufacturing, etc.
(including interlinked and interdependent projects, if any)
It is an Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant, Sea Water Desalination Plant (RO process) for captive consumption. There is no interlinking and interdependent project.
Location
(Map showing general location, specific location, and project boundary and project site layout) with co ordinates
The proposed project is establishment of integrated complex at Dighi Port. Brief location details are as follows:
Sr. No. Particulars Details 1 Taluka, District, State Taluka Shrivardhan, Dist. Raigad, Maharashtra 2 Location Dighi Port
3 Latitude & Longitude Latitude: 18016’50.00” N Longitude 73027’20.00” E
Sr. No. Location Name Approx. distance (km) 1 Nearest National Highway NH 753F 3 2 National Highway NH 66 50 3 Nearest Air port Mumbai 100 4 Nearest Railway station Mangaon 50 5 Nearest Port Dighi 2.2
The Geographical Location of this site is at 18016’50.00” N Latitude and 73027’20.00” E Longitude with an elevation of 3 meter above sea level MSL. Site coordinates are as follows:
Please refer Annexure II for Google map. GPS Location on Google Imagery of the proposed site is attached as Annexure II. Land Form: Land is reclaimed land and contour plan showing slight variation in elevation. Land Ownership: Land ownership is with project proponents (Group Veritas). Existing Land use Pattern: The Land is vacant and meant for industrial use. Existing Infrastructure: Dighi port is adjacent to site. There are tankages of M/s IMC, and other companies. Lay-Out Refer Annexure II for the plant site layout plan.
Details of Alternative sites
(Sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be given)
Dighi port site is selected based on following considerations.
Major raw materials such as VCM, Bitumen, LPG, Propylene will be transported by sea route.
Dighi port situated in Raigad District in the state of Maharashtra is a multipurpose, Multi cargo, all weather port which has direct berthing port with a state-of-the-art cargo handling equipment's. It has ample land bank approximately 1,200 acres. It is a natural harbor and an exclusive channel offering a depth of 9.5 m, making it one of the deepest channels in Maharashtra. The total waterfront of approximately 5 km is available for development of port related activities. The port is capable of handling bulk, break bulk, liquid, RORO & container cargo. The port is well connected to national highway 753F & NH 66. It is also part of the Delhi Mumbai industrial corridor. The strategic location would facilitate fast turnarounds of vessels due to high levels of efficiencies.
Being in Konkan i.e. western side of the country, its proximity to the Middle Eastern region for sourcing of VCM. The central government has already sanctioned and started the construction of the Railway line connecting the Central Railway station at Roha to the Dighi port which is about 35 Km from the port. This will enhance the connectivity with the central and northern parts of the country where in there is a huge potential for revenue to be generated from the sale of the PVC so manufactured from the region. The nearest airports are Mumbai and Pune. The nearest sea port is JNPT, which is about 70 km from the Dighi port. Dighi, as a strategic location for this Complex, carries many advantages:
1. Part of Delhi Mumbai Industrial Corridor 2. One of the seven Mega National Investment & Manufacturing Zone 3. West Coast Sagarmala Economic Cluster 4. MOU signed with Maharashtra Maritime Board for constructing and upgrading 100
km of the proximate road net-work 5. MSRDC approval for 44 km road development upto Indapur on Mumbai Goa
National Highway 6. MOU signed with Rail Vikas Nigam to construct 35 km rail link to the nearest
station Roha on Konkan Railway. 7. Dighi has 2 operational berths, 2 more will be operational by the time this project
is commissioned. 8. Road tender by MSRDC has been awarded and concrete road about 80 % is
completed. 9. Proper two lane 7 meters wide concrete road with 1.5 m side shoulders from
Mangaon to Dighi port. 10. From the junction NH 753F & NH 66 located in Mangaon the four cities can easily
be connected i.e Mumbai, Pune, Ratnagiri & Goa. MSRDC have already given the road construction contract to J.M. Mhatre & Co. With the construction of 2 lane road between Dighi and Mangaon the current capacity to receive and dispatch 500 trucks and trailers per day at Dighi, will go up to 1200 trucks and trailers per day. Therefore, with a maximum number of 200 trucks to be dispatched every day from VPPL's site, we do _not anticipate any evacuations problems. The break up for the same would be at the very most 130 trucks per day for PVC, PMB and 60 trucks for the Gas Storage outflows.
Size or magnitude of operation
It is an integrated petrochemicals complex consisting of,
1. PVC plant 2,00,000 MTPA 2. PMB plant 3,60,000 MTPA 3. 16 mounded bullets of capacity 2500 m3 each (6 for VCM, 6 for LPG, 4 for Propylene) 4. Captive gas-based power plant (18MW) 5. LPG Bottling Plant
o All other associated utilities such as DM Plants, Effluent treatment plants, Sewage treatment plant, Compressed air & Nitrogen generation plant and infrastructure facility.
Project description with Project details
(A schematic diagram / flow chart showing the project layout, components of the project etc should be given).
PVC Plant
VPPL will relocate the PVC plant of Petronas presently situated in Malaysia. The plant is capable of producing suspension grade PVC (Grades K57-K72). It is backed by a technology by world largest PVC technology provider namely Ineos Technologies, UK. The plant will be polymerization plant which will convert imported VCM (vinyl chloride monomer) to PVC. Ineos technologies will provide all the technology upgrades and developments as well as tailored support on Environment. The plant design meets and exceeds European Union standards and safety and environment norms, which are among highest in the world. The proposed plant capacity of PVC will be 200,000 TPA. The basic raw materials required is VCM, which will be imported from Qatar, China, Japan, Europe etc. It will be stored under pressure in mounded bullets with ASME specifications and as per PESO guidelines. The other component will be water. Especially for India, Ineos’s condenser process allows fast reactions without use of chilled water for reactor cooling. This is specially advantage in India, where cooling water temperatures are high, hence it saves the high energy consumption.
3.5.1.1 Basic structure of PVC
PVC is most versatile thermoplastic forming on one extreme, highly rigid products such as pipes and profiles and on the other, highly flexible products such as soft leather cloth and flexible footwear. The basic structure of this polymer is (C2H3Cl)n The degree of polymerization varies from 300 to 1500. The chlorine content in PVC is about 57% by weight which makes it less dependent on hydrocarbon content. Reaction:
There are many polymerization routes for manufacture of PVC. They are as follows,
Process Route % of world production Suspension polymerization 80 Emulsion polymerization 10 Bulk or mass polymerization 8 – 10 Copolymer PVC Not known
It can be seen from above that suspension polymerization is the most prevalent technology in the world today. The leading licensors for this technology are Ineos Technologies (UK) and Oxy Vinyl corporation (USA). In this process, Vinyl chloride monomer droplets are dispersed in water medium aided with suspending agents and agitation in the reactors/Polymerizes. Polymerization for VCM to PVC takes place in this medium initiated by peroxide catalyst. Multiple batch reactors discharge into a continuous polymer separation and finishing line. The polymer slurry from reactors is first separated from unconverted VCM by degassing and steam stripping. Water is separated from the polymer by means of centrifuging followed by drying. PVC produced by emulsion polymerization process is mainly used as latex or paste in specialty applications. In Europe, manufacture of PVC started with the emulsion process. The process is similar to suspension process except that large amount of emulsifying agents are used which result in very fine PVC particles. Consequently, separation of these fine PVC particles from water cannot be done by centrifuging action. Hence this technology employs spray driers to separate water from the fine PVC particles.
3.5.1.3 Product applications of PVC
PVC products are generally classified in the industry in terms of K-values. Higher the K value, higher is the molecular weight. A, low molecular weight PVC with a K value of 57 finds main application in rigid films and sheets; blow molded bottles and other injection molded articles. PVC, if used in food application, should have a residual VCM content less than 1 ppm. Higher molecular weight PVC with a K value of 66-67 finds major application in extrusion of pipes and profiles. This constitutes one of the major PVC consumption. PVC with still higher K value of 70-72 along with high porosity finds typical application in wires and
cables and other flexible applications such as shoe lasts, flexible films etc. Emulsion PVC is used in form of plastisols or latex typically for PVC coating, multilayer films, battery separators and such specialty applications.
3.5.1.4 Product PVC
The plant is capable of manufacturing suspension PVC grades K-57 to K-73. Low K value and high K value grades can also be produced. The plant is capable to produce the full range of PVC grades for fulfilling most market requirements.
3.5.1.5 Installed production capacity
The installed capacity of the PVC plant is 200,000 MTPA. Institute of Chemical Engineers (UK) has been appointed for carefully evaluating/examining the plant in the month of March 2017, before the process of dismantling of the plant started at site.
3.5.1.6 PVC Plant Process Description
The plant section shall comprise of the following sections
o VCM unloading, storage and feeding system o Preparation and charging of DM water o Preparation and feeding of additives o Polymerization reaction o PVC slurry stripping o VCM Recovery system o PVC drying o PVC packaging and product warehousing o PVC dispatch
3.5.1.7 VCM unloading, storage and feeding system
VCM is colorless liquid with a characteristic’s sweet odor. It is highly reactive, though not with water, and may polymerize in presence of oxygen, heat and light. Its vapor are both toxic and flammable.
Vinyl chloride monomer 99.5 to 100 % CAS No 75-01-4 Molecular weight 62.5 Molecular formula C2H3Cl i.e. CH2-CHCl Boiling point (-)14 deg C Vapor pressure 2660 mm Hg @ 25 Deg C Vapor density (Air=1) 2.15 Specific gravity (water =1) 0.91 @ 25/25 deg C Water solubility 2.7 g / Lit pH Not applicable VOC content (%) 100 % Volatility 100 % Evaporation rate (ether = 1) >15
Flash point (-) 78 Deg C Each consignment in the range of 5500 – 11000 m3 of pressurized VCM shall be unloaded from ship with the help of unloading pumps through one no of 8-inch marine unloading arm and shall be transferred to proposed VCM storage bullets at VPPL’s gas storage terminal + bottling unit.
No Parameter VCM Unloading condition
1 Unloading at Dighi port 2 Unloaded by Marine unloading arm 3 Pressure at ship pump flange kg/cm2g 30 (minimum) 4 Unloading carrier Approx. 7500 MT
Marine unloading arm
3.5.1.8 VCM Pipeline transfer facilities
8 inch pipeline will be employed for transfer of VCM from ship. Two mas flow meters one at Jetty end one at tank end will be provided for mass measurement and input to leak detection system. The motorized operated valve shall be provided at jetty for emergency shut down operation in case of leak. Alternate facilities for unloading of VCM and other gases Ship to shore transfer system will be used as an alternative for unloading of the cargo from ship to shore. Dighi port is located on the Rajapuri creek. The port being at the interior of the creek, the sea is calm all around the year, therefore, vessel offloading is possible through the floating hose assembly without any hinderance. Ship to shore transfer systems are in use for the transfer of VCM and other gases between tankers and shore facilities. A ship to shore transfer system provides a safe solution to tanker loading/unloading requirements in shallow water, offering a more reliable, efficient and cost-effective alternative to jetty systems. Ship to shore transfer systems are ideally suited for shallow water applications. The life of the system is approximately 25 years.
The ship to shore transfer system allows the tankers to safely maintain position for the period required to load or offload the cargo. Typically, flexible pipes of predetermined sizes are used for station keeping of the tanker. When berthed, the tanker remains on the location using its own anchor. On the tanker side, the ship ropes are connected on either side to the bow and the stern and on the to the quick release hooks. After the tanker is positioned and anchored, picking up a submerged hose string and connecting this hose to its mid ship manifold, loading / offloading operation shall start. The other end of the hose string is connected to a pipeline end manifold (PLEM), which in turn is fixed to a subsea pipeline, transferring the product to or from any installation located onshore. On completion of loading operation, the hose string is laid down on the seabed, ready for being picked up again when the next tanker arrives.
3.5.1.9 Receipt and storage facility at Gas Storage Terminal
The VCM from ship will be transferred and stored in 6 no of pressurized VCM bullets at 10 kg/cm2g. The mounded vessels will be fabricated and installed as per OISD – 150.
The mechanical design of storage vessel shall be based on following considerations.
I. Design code – ASME SEC VIII or PD – 5500 or equivalent duly approved by CCOE. A single code shall be adopted for design, fabrication, inspection and testing. Specific consideration shall be given to
a) Internal vapor and hydraulic pressure b) External loading on the vessel c) Internal vacuum
II. Material – The Material of construction for bullets is SA 537 CL.II the selected
material conforms to the design code. III. Design temperature (-)27 to 55 deg C IV. Design pressure is 25 kg.cm2g V. Other considerations
a) Internal corrosive allowance: 1.5 mm b) Radiography – full c) Stress relieving – 100 % irrespective of thickness d) Earthquake resistance as per IS:1893:2000 e) Hydrotest pressure as per design code
The cathodic protection shall be provided to protect the external surface of the bullet from corrosion. Fire Safe Remote Operated valves (ROV’s) shall be provided on first flange on liquid lines at a minimum distance of 3 m from the vessel. Each vessel has two safety relief valves. Each storage vessel shall have minimum two different type of level indicators and one independent high-level switch. Each vessel is provided with one pressure and temperature measuring instrument. The pressure gauge shall be provided with isolation valves.
3.5.1.10 Preparation and charging of demineralized water
Part of Demin water from Demin water tank is used in polymerization charging, bearing seal priming, sealing, agitator/pump seal flushing, reactor rinsing etc. Part of cold demineralized water is stored in clod DM water tank and used for buffer preparation, catalyst preparation and additive preparation.
3.5.1.11 Preparation and feeding of additive agents
All the chemical agents for polymerization, such as initiators, dispersants, buffering agents, defoaming agents, shortstops (terminators) are prepared and stored in their own vessels. When the polymerization reaction occurs, chemical agents are sent to polymerizes by pumps as per specified quantity in the recipe and specified procedure.
3.5.1.12 Polymerization
DM water, Dispersants, buffers and initiators are automatically added into the polymerization reactor in a closed state according to PVC production process recipe for the type and amount of raw materials and the feeding program of DCS setting. Polymerization starts when the initiators are automatically added. By automatically adjusting the level of cooling water, the reaction temperature is maintained. Polymerization reaction takes place in accordance with the required temperature curves, the polymerization heat is measured by a microcomputer to calculate the monomer conversion rate. When the conversion rate is met, the terminators are automatically added into polymerization reactor to terminate the reaction, PVD slurries are automatically discharged to the vessel. After PVC is blown down, the reactor wall shall be rinsed with water of appropriate pressure.
3.5.1.13 Shortstop (Terminator) system
This process adopts two short stop systems for two different purposes and adopts different short stops. One is for normal production stop of each batch operation, the other is for emergency, during mechanical or power failure.
3.5.1.14 Vacuum system
Vacuum system shall be adopted to draw out air from all equipment of the unit containing VCM to ensure safety of the unit after maintenance.
Unreacted VCM from polymerization reactor and stripping outlet trough shall pass through the VCM recovery unit in order to be used for utilization in the polymerizer.
3.5.1.16 PVC slurry stripping
PVC slurry stripping process shall be provided to remove efficiently and recover residual vinyl chloride monomer from PVC resin. The PVC from blow down vessel enters the stripping tower. In the stripping tower PVC slurry shall make heat exchange with cooling water in counter current flow. After stripping, PVC slurry shall be stored in bin and sent to PVC drying section. The VCM after stripping passes through the top stripping tower condenser then to gas liquid separator and finally sent to VCM recovery section.
3.5.1.17 PVC centrifuge and drying
The section comprises of dewatering, finished product drying, screening and gas conveyance. PVC slurry after stripping enters centrifuge. After dewatering in centrifuge, wet PVC resin is fed in dryer. Warm air shall be used to dry the PVC resin. Then after PVC enters the vortex type cyclone dryer for drying of critical moisture content. The dried PVC powder shall be separated with the air flow by the cyclone separator set. Finished PVC product after screening shall be delivered to PVC intermediate silo and it goes into packaging process by mixing pump. Part of mother liquor from the PVC centrifuge goes to stripping tower for flushing the tower, and part of it goes to PVC mother liquor treatment and recycle system.
3.5.1.18 PVC Packaging and product warehouse
PVC material from finished product silo is measured and bagged into 25 kg /bag by quantitative semi-automatic packaging machine. After packaging, the packed PVC will be transported to PVC warehouse by forklift.
3.5.1.19 PVC dispatch
Currently the site is connected via state highway 97 to national highway 66. SH97 connects the national highway at Mangaon, approximately 40 km from plant site. It is foreseen that in first couple of years of plant operation, PVC shall be dispatched using this connectivity. The state highway is already in use for dispatch of products of other companies. The 43 km road and construction and widening tender from Indapur to Dighi port on NH66 has been allotted to M/s JM Mhatre Infrastructure limited by MSRDC. MOU is also signed between Maharashtra Maritime Board and Rail Vikas Nigam to construct 35 km rail link from Dighi port to the nearest station Roha on Konkan Railway, the link to permit speed up to 100 kmph which will further boost movement of goods.
3.5.1.20 Process Flow Diagram
Brief PVC process flow diagram is indicated below,
a) INEOS is leading technology licenser by virtue of following strengths
o High quality and low-cost production facilities o Well invested plants across the globe o Large plant that benefit from economies of scale o Favorable locations o Experienced technical management
➢ Leading market position ➢ Operating diversity – product, customers, geographic regions, applications
and end use markets
b) INEOS Technologies key values are
o Excellence in safety, health and environmental performance o Focus on customer satisfaction, total quality and reliability o Continuous improvement to reduce costs o Encouragement of innovation and reward of achievement
c) Ineos Technologies (VINYL)
Leveraging INEOS’s position as the largest PVC producer in Europe; INEOS Technologies Vinyls delivers a wide range of technologies, product know-how, and expertise that helps customers all over the world to maximize operational performance. INEOS Technologies (Vinyl) services are tailored to meet VPPL’s requirements from assistance during engineering design and construction through to plant commissioning and from research and development support to reliable supply of PVC additives and catalysts.
INEOS Technologies (Vinyl)is the leading licensor of Poly Vinyl Chloride (PVC), Ethylene Di Chloride (EDC) and Vinyl chloride monomer (VCM) technologies for the PVC and Vinyl industries worldwide. With long experience of over 60years through its founder companies, INEOS Technologies Vinyl’s technical expertise is recognized as being the industry leader. Their S-PVC licensing technology brings together feature from all of INEOS Chlor-Vinyl’s plants and which has been continuously developed to keep INEOS Chlor-Vinyls plants competitive in the challenging European and Asian markets in terms of cost, quality and environmental performance.
e) Vinyls catalysts and additives Based on over 70 years of Chlor-Vinyl’s experience, INEOS Technologies Vinyl’s range PVC additives brings real value to PVC plants. Process economics are improved by using INEOS Technologies Vinyl’s high quality and well proven additives to reduce wastage, increased output reduce downtime and improve quality. INEOS Technologies Vinyls supports the entire range of Vinyls additives with technical support across the INEOS group, drawing on dedicated people with many years of experience in chemistry, engineering, Vinyls technology and Vinyls production.
f) Safety, Health and Environmental Benefits INEOS plant design meets and exceed European Union standards of safety and environmental performance, which are among the highest in the world. INEOS process complies fully with all the European Council of Vinyls Manufacturer (ECVM) environmental standards. The closed process design minimizes reactor opening loss, with associated operator hygiene and environmental benefits. The expected opening frequency is once in 500 batches, although frequencies of once per 2000 batches have been achieved on several licensee plants. The continuous stripping column reduces the residual VCM in finished product to less 1 ppm. The stripping also reduces the loss of VCM to atmosphere from the slurry Tank and Drier. The reactor protection systems major hazard releases are of very high integrity and include a reaction short stop system of extremely high reliability and effectiveness. INEOS has > 400 reactor years operating experience on large reactor plants without experiencing a release of VCM to atmosphere. The INEOS Technologies process for initiator synthesis external to reactor is intrinsically safe in that it is very difficult to overcharge initiator. Overcharging one of the initiator components does not increase the yield of product but rather reduces the yield.
Initiator is not stored for any significant length of time but is made up as required and used immediately. The inventory of initiator on the plant is very low and is in dilute solution. It therefore does not constitute a significant hazard. INEOS initiator does not require sub zero refrigerated storage. Hence VPPL does not have to create cold storage for initiators. The VCM recovery system does not use a gas holder, this gives obvious environmental benefits. All VCM contaminated water is stripped before final discharge ot levels > 1 ppm VCM.
g) Process economics INEOS Technologies low cost initiator reduces initiator cost to those of the precursors, all of which are easily available chemicals. This gives a significant saving in additives cost per MT of PVC. INEOS Technologies condenser process allows fast reactions without the need to use chilled water for cooling the reactors. This is especially advantage where cooling water temperatures are high because it saves the capital expenses of a large refrigeration system and high electricity costs.
PMB Plant
3.5.2.1 Design basis
Plant Capacity: - 360,000 MTPA (1200 Tons Day).
Bitumen Grade: - Grade 60 — 70 and Grade 80 - 100
Bitumen Property Table: -
Properties Class 80 - 100 Class 60 - 70
Penetration at 25°C, 0.1mm 80 100 60 70
Softening point, °C 45.0 52.0 45.0 52.0
Flash point, °C 276 - 276 -
Viscosity at 60°C (Poise) 140 - 260 -
Viscosity at 170°C (Poise) 0.45 - 0.65 -
3.5.2.2 Process Description
• Unloading & Handling facilities at Dighi jetty
Bitumen shall be unloaded from ship with the help of ship unloading through one number of 12”
marine unloading arm/electrically heat traced pipeline & shall be transferred to proposed
Sr. No Parameter LPG Propylene A Unloading Condition 1 Unloading at Dighi Port Dighi Port 2 Unloading by Marine Unloading arm Marine Unloading arm 3 Pressure at ship pump
No. of loading Station 4 bay Tanker Loading Facility Pumping Rate, MT/hr 100
Gas based Captive power plant
For operation of integrated petrochemical complex, captive power plant of 18 MW has been envisaged. Captive power plant producing 18 MW at 11 KV 50 Hz shall be installed. There will be gas fired generators in multiple units (4 x 4.5 MW) which will be designed taking into consideration, availability of 100 % operating power during maintenance downtime of any one of the generating units. Total expected connected load at site will be around 18 MW and operating load will be 12 MW at site.
3.5.5.1 Waste Heat recovery Boilers
Heat energy of the 18 MW gas turbines exhaust shall be utilized in the waste heat recovery boilers for generating steam required at site. Parameters of WHRB will be as follows
o Inlet gas temperature 450 ~ 500 deg C o Inlet gas source: Gas engine exhaust o Outlet gas temperature: 120 ~ 150 deg C o Outlet “superheated” steam parameter – 10 barg @ 250 deg C o Outlet “superheated” steam flow: 3 x 4 = 12 TPH
3.5.5.2 Fuel supply source and quantity
LNG will be used as fuel for gas turbines. Total requirement of fuel LNG for the 18 MW power plant and PVC plant will be approximately 82,000 to 85,000 SCM per day which will be approximately 64 – 65 Ton a day if whole plant is running at its fill capacity. LNG will be procured from IOC by way of a long-term agreement. IOC currently has a system of “LNG at doorstep”. The natural gas is presently being supplied in the country to its consumers through a network of pipelines or through road transportation to customers. Indian Oil has pioneered and commenced reliable supply of liquefied natural gas from to its end user since 2007. The supply of LNG is done using cryogenic road transportation, transfer to cryogenic storage tank at various customers premises and then using ambient air vaporizers for onsite regasification of LNG for the cleanest natural gas supply to the end use for power generation. This system is named by IOC as “LNG at Doorstep” and has been offered to VPPL for a contract of 5 years. The gas specification being offered top veritas by IOC are as follows.
Chemical name Methane Chemical family Complex mixture of saturated hydrocarbons
Gross Calorific value 51500 Btu/kg or 12978 Kcal/kg Molecular weight 16.042 Melting point @ 1 atm -182.2 deg C Boiling point @ 1 atm -161.0 deg C Auto ignition temperature 537.2 Deg C Expansion ratio of liquid at boiling point to gas at 15.6 deg C
1 to 627
Liquid density at boiling point 425.61 kg/m3 (26.56 lb/ft3) Appearance, odor and state Colorless, odorless, cryogenic liquid
3.5.5.3 Regasification of LNG
LNG vaporizers (re gasifiers) are heat exchangers used for degasifying liquified natural gas which is stored as a liquid under cryogenic temperature. Varitas has been recommended to use ambient air heated vaporizers with capacity of 90,000 scmd. The regasification cost for LNG using ambient air heated vaporizers is minimum. The ambient air vaporizers are basically the heat exchangers using fans and blowers. The storage capacity of LNG would be 3 x 110 KL cryogenic tanks. The quantity stored will be sufficient for 4 to 5 days subject to plant operating at rated capacity.
Utility Plants
3.5.6.1 Cooling Water System
Open loop induced draft cooling tower of capacity 4000 m3/hr circulation (8 x 500 m3/hr) shall be installed for process and utility requirement with supply and return temperature of 35 and 45 Deg C respectively. Cooling towers shall be of FRP construction with hot dip galvanized structural members. Cold water basin shall be of RCC type. Cooling tower basin capacity shall be cooling water pumped in five to six minutes by circulation pump.
No Description Capacity Quantity Power consumption, kw
The scheme proposed is to treat Sea water (to remove dissolved solids) and to convert it to produce potable water required at site for various purposes, 4.5 MLD capacity. The proposed scheme is broadly as per following treatment steps
o Sea water intake pump house o Electro chlorination system for sea water intake o Pretreatment scheme for SWRO o Chemical dosing for pretreatment system o Reverse osmosis system o Carbonation system o Chlorination system for Potable water o Remineralization system for potable water
3.5.6.3 Demineralization (DM) Water Plant
The scheme is proposed to generate Demin water of capacity 120 m3/hr required for power plant. The proposed scheme is broadly as per following treatment steps
o Reverse osmosis system o Degassing tower o Mixed bed (MB) unit o DM water storage tank o Chemical handling system o Effluent collection system
3.5.6.4 Compressed Air System
2 Nos of (1 working + 1 standby) of oil lubricated centrifugal compressors of capacity 1950 cubic meter/hr each shall be installed for process and utility requirement. Considering the requirement (dew point at a line pressure shall be 15 Deg C below ambient air). 2 Nos of (1 working + 1 standby) of heatless desiccant dryer each of capacity 1950 m3/hr shall be installed. VFD will be used for capacity control, It will contribute for power saving.
3.5.6.5 Nitrogen generation system
The Nitrogen generation system shall be for pipe line purging and blanketing. Pressure swing absorption (PSA) – Nitrogen generation plant is proposed to generated nitrogen gas of capacity 300 Nm3/hr. It will consist of
o Nitrogen surge vessel o Oxygen analyzer o Nitrogen storage tank
Raw material required
(Raw materials along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finish products.)
Following Major Raw materials will be required at site for the manufacturing activities.
No Raw
Material CAS No Unit State Consumption
per year (for rated plant capacity)
Likely source
Mode of transport to site
1 Vinyl Chloride Monomer
75-01-4 MT Liquid 200,800
Imported Ship/pipeline
2 LNG 74-82-8 MT Liquid 19,700 Local Road tanker 3
Bitumen 64742-
93-4 MT Liquid 360,000
Imported Ship/pipeline
4 SBS (Polymer)
9003-55-8
MT Solid 15,000 Local Paper
bags/Road 5 EVA
(Polymer) 24937-
78-8 MT Solid 15,000
Local Paper bags/Road
6 LPG
68476-85-7
MT Liquid 300,000 Imported Ship/pipeline
Following finished products will be manufactured at site, its marketing area, mode of transport is as below,
No Products CAS No Unit State Production per year (as per rated plant capacity)
Marketing area
Mode of transport from site
1 S-PVC (Sus. Poly Vinyl Chloride)
9002-86-2
MT Solid 150,000
Local Truck
2 Polymer Modified Bitumen
64742-93-4
MT Solid 360,000 Local Truck/Tanker
3 LPG (Bottles) & Bulk
68476-85-7
MT Liquid 300,000 Local Truck/Tanker
4 Propylene Bulk
74-98-6
MT Liquid 120,000 Local Tanker
Following major bulk storages are proposed at site.
2 LNG Liquid KL Cryogenic Tanks 3 x 110 = 330 3 Bitumen Liquid M3 Heated Tanks 2 x 5000 = 10,000 4 PMB Liquid M3 Heated Tanks 2 x 5000 = 10000 5 SBS (Polymer) Solid MT Paper Bags 200 6 EVA (Polymer) Solid MT Paper Bags 200 7 LPG* Liquid M3
Mounded Bullets 10 x 2500 = 25,000
8 Propylene* Liquid M3 Note : *LPG/Propylene will be stored.
Manpower
Expected manpower requirement for operation phase at site for the projects shall be as follows,
Description Number Permanent 500 Contract workmen 500 Total 1000
Resource optimization
(Recycling and reuse envisaged in the project, if any, should be briefly outlined)
Following are some of the recycle options proposed by the industry.
o Improvement of yield of the products so as to reduce the waste generation during manufacturing.
o Waste / Used oil will be sent to Authorized Waste / Used oil Reprocessing units. o Container & container liners of chemicals, Polythene / HDPE Bags, broken plastic
drums shall be disposed of to outside agencies after decontamination. o Used Lead acid batteries will be sent back to suppliers on buy back basis.
Water, Energy / Power availability and source
(Availability of water, its source, Energy/power and requirement and source should be given)
Water
Sea water will be the source of water requirement for the integrated petrochemical complex.
The fresh water requirement for entire integrated complex is as follows.
Unit Capacity UOM Make up Quantity per day Domestic - M3/day 100 DM Plant (For Boilers, reactor and seal, processing)
120 m3/hr
M3/day 2880
Cooling Towers 4000 m3/hr
circulation flow
M3/day 1095
Gardening/green belt maintenance
- M3/day 230
Total - M3/day 4305
It is proposed to treat sea water to remove TDS and to produce 4,455 m3/day potable water required for domestic, Process, Boilers & Cooling towers and for green belt maintenance purpose.
Energy
Energy in the form of steam will be generated in waste heat recovery section of gas fired power generator. There will be 4 x 4.5 mw gas fired power generators. Waste heat recovery section capacity of each generator will be 12 TPH steam (at pressure 10 kg/cm2g and temperature 250 deg C).
Power
For the operation of the integrated petrochemical complex, captive power generation has been envisaged. The captive power of 18 MW (4 x 4.5 MW natural gas fired generators) will be produced at 11 KV, 50 Hz frequency. The system will be designed taking into consideration, availability of 100 % operating power during maintenance downtime of any one of the generating units. Fuel natural gas shall be procured from IOC, which will be received at site via road tankers.
Waste generation, Management and disposal
Quantity of waste to be generated (liquid and solid) and scheme of their management/disposal
Industrial Waste water
Industrial waste water (Process water) shall be treated in the ETP and the treated effluent shall be disposed off in deep sea using pipelines and diffuser.
The project site is at Dighi port. Dighi port situated in Raigad District in the state of Maharashtra is a multipurpose, Multi cargo, all weather port which has direct berthing port with a state-of-the-art cargo handling equipment's. It has ample land bank approximately 1,200 acres. It is a natural harbor and an exclusive channel offering a depth of 9.5 m, making if one of the deepest channels in Maharashtra. The port is well connected to national highway NH 753F and NH66. It is also part of the Delhi Mumbai industrial corridor. The central government has already sanctioned and started the construction of the Railway line connecting the Central Railway station at Roha to the Dighi port which is about 35 Km from the port. This will enhance the connectivity with the central and northern parts of the country where in there is a huge potential for revenue to be generated from the sale of the PVC so manufactured from the region. The nearest airports are Mumbai and Pune. The nearest sea port is JNPT, which is about 70 km from the Dighi port.
Proper two lane 7 meters wide concrete road with 1.5-meter side shoulders connectivity is available from Mangaon to Dighi Port. From the junction NH 753F and NH66 located in Mangaon the four cities can easily be connected i.e Mumbai, Pune, Ratnagiri & Goa. MSRDC have already given the road construction contract to J.M. Mhatre & Co. With the construction of 4 lane road between Dighi and Mangaon the current capacity to receive and dispatch 500 trucks and trailers per day at Dighi, will go up to 1200 trucks and trailers per day. Therefore, with a maximum number of 200 trucks to be dispatched every day from VPPL's site, we do not anticipate any evacuations problems. The break up for the same would be at the very most 130 trucks per day for PVC, PMB and 60 trucks for the Gas Storage outflows.
Land form, Land use and land ownership
Total land is 49.415 Acres. And is in is in possession of Project Proponent.
Topography (along with map)
The Topography map with a 10 km radius is enclosed as Annexure- III.
Existing land use pattern
The land use pattern of project area (core area) 49.415 Acres. Shortest distance of environmental components in buffer area from the project periphery is given in table below.
Type of Industry: Integrated Petrochemical complex. Facilities: Facilities required for Petrochemical complex will be provided as per requirement. Transportation: Transportation of raw material and final products is done via roads and sea. Town and Country Planning Classification: Industry land is private land converted to industrial use and is in possession of project proponent.
Population Projection
In 2011, Raigad district had population of 2,634,200 of which male and female were 1,344,345 and 1,289,855 respectively. In 2001 census, Raigad had a population of 2,207,929 of which males were 1,117,628 and remaining 1,090,301 were females. Raigad District population constituted 2.34 percent of total Maharashtra population. In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra population. There was change of 19.31 percent in the population compared to population as per 2001. In the previous census of India 2001, Raigad District recorded increase of 20.99 percent to its population compared to 1991. The initial provisional data released by census India 2011, shows that density of Raigad district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309 people per sq. km. Raigad district administers 7,152 square kilometers of areas. There is a scope for increase in the population from the proposed project. Skilled workers prefer to stay in the nearby locations to avoid travelling from long distances. Local non-technical villagers will be preferred for the unskilled jobs such as gardening, material movement etc. Local educated youth will be employed as semi-skilled workers and training will be provided. Hence, there is a possibility of increase in population of the skilled and semi-skilled. However, on the whole there is a possibility of little increase in population of the area.
Land use planning
The unit has been proposed in the existing land. Land use pattern of the project area is given in table below,
No Description/Purpose Area in Acres % of Total area 1 Total project land area 49.415 100 % 2 Total Built-up Area 18.54 37.52 % 3 Green Area 16.57 33.53 % 4 Parking Area 5.67 11.47 % 5 Area for road & Open space 8.455 17.11 %
Assessment of Infrastructure Demand (Physical and social)
Infrastructure such as residence, transport, health center, hospitals, amenities etc around the project will be required.
Amenities / Facilities
Industry will provide the following amenities / facilities in the proposed project. o Canteen o Potable drinking water o Training block o Concrete/tarred internal roads o Emergency and firefighting facilities o Occupational health center & Emergency services. o Rest Room for employees/Drivers o Pre-employment and routine medical examinations and the necessary
follow up actions o Transport facilities for commuting employees o Communication systems like Phone, Internet etc. o Security systems.
Production Plants, administration facilities, warehousing/storages, loading/unloading, utility area, Utility plants is proposed at the site.
Residential area (non-processing area)
There is no any residential area proposed at site.
Green Belt
Green belt of adequate area within and around the project site shall be carried out as per industries norms and requirement.
Social Infrastructure
As a part of Entrepreneur Social Commitment (ESC), Industry will contribute for development of social infrastructure around site.
Connectivity
The site is connected by road and sea.
Drinking water management
Sea water will be used for converting to potable water at desalination plant. Domestic water requirement is ~ 100 cmd at site.
Sewerage System
Sewage Treatment Plant (STP)
Sewage is proposed to be treated in independent STP of installed capacity of 80 cubic meter per day and treated sewage water will be used for gardening/green belt maintenance at the site. Sewage for entire site will be collected by gravity sewers leading to sewage collection pit at STP. Proposed scheme has following broad steps.
o Screening o Oil and grease trap o Equalization tank o Bioreactor o Secondary settling unit o Disinfection system o Multigrade filter o Activated carbon filter o Sludge handling system
Manufacturing facility generally contributes to all types of waste such as liquid, solid and gaseous. The management of these wastes is to be handled carefully and by adopting proper segregation techniques. Refer 3.9 above for details.
7 R E H A B I L I T A T I O N & R E S E T T L E M E N T P L A N
(Policy to be adopted (center/state) in respect of project affected persons including home oustees, land oustees and landless labors (a brief outline to be given) The proposed new facility shall be at plot owned by the company which is located at Dighi port. It does not require acquisition of Land and the Infrastructure so there is no any kind of activity of Rehabilitation and Resettlement required to be carried out.
9 A N A L Y S I S O F T H E P R O P O S A L ( F I N A L R E C O M M E N D A T I O N )
Benefits of the Project ➢ Socio-Economic Project: Substantial state interest and welfare of the people. ➢ Employment: Project will generate direct and indirect employment ➢ Low Cost Housing: Promotion and Development of low income and cost housing approximately
500 crores of saving annually in terms of the capital outlay with PVC Profiles. ➢ Pradhan Mantri Ujjwala Yojana: LPG bottling plant will support the PMUY. The LPG bottling
plant will upsurge the usage of LPG in the deep villages of the state. ➢ Delhi Mumbai Industrial Corridor (DMIC): Visibility and Momentum enhancement of DMIC. ➢ Skill development and economic upliftment: Location of the whole project being remote village-
Dighi, will bring in employment and skill up-gradation of the work-force and in turn prosperity to the villages nearby.
➢ Development of Port: The project will bring in over 2 – 3 MMT of captive cargo to the port presently under stress and enhance prominence of the port.
➢ Domestic Production: Boosting domestic (State) manufacturing capacities will directly bring in prosperity to the State, more so in this underdeveloped area.
➢ Import Substitution: (Over 1.8 MMTA of PVC is being imported into India)- will save foreign exchange exchequer. Aprox Rs 1,250 Cr annually.
➢ Decrease Life Cycle cost of Road: PMB is especially beneficial for coastal roads and increases the durability & safety of roads upto 8 times compared to normal bitumen roads. If the durability of roads goes up by 8 times the cost of new development, operations and maintenance of the roads will decrease substantially, on a most conservative basis we estimate it will go down by half in effect translating to a savings of atleast Rs 1500 crores annually.
➢ Green Power: Power generation though NG instead of Coal based which is highly polluting but cheaper. The Power Plant is for Captive use however, extra power will be supplied to the existing port, as it does not have the grid connectivity which will benefit the port.
