PRE FEASIBILITY REPORT - …environmentclearance.nic.in/writereaddata/FormB/TOR/...100___Coal.pdfPRE...

PRE FEASIBILITY REPORT

(As per MoEF Guidelines)

FOR

M/s. JBF PETROCHEMICALS LTD

PROPOSED PART CHANGE IN FUELCONFIGURATION

(100 % COAL) FOR TWOOF FOUR BOILERS IN PTA UNIT AND

ALL FOUR THERMIC FLUID HEATERS IN PET UNIT

AT

MANGALORE SEZ LIMITED

VILLAGE: BAJPE

TALUK: MANGALORE

DIST: DAKSHINA KANNADA

KARNATAKA

[Project termed under schedule 5 (e), category B project, and petrochemical

based processing]

November 2015

BY

HUBERT ENVIRO CARE SYSTEMS PVT LTD., CHENNAI

Prefeasibility Report for Change in Fuel configuration

i

TABLE OF CONTENTS

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

1. INTRODUCTION ....................................................................................................................... 4

1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT .................................... 4

1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ................................................. 5

1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGION ............................................................................................................................................ 5

1.4 DEMAND-SUPPLY GAP ..................................................................................................... 6

1.5 IMPORTS VS. INDIGENOUS PRODUCTION ................................................................... 6

1.6 EXPORT POSSIBILITY ....................................................................................................... 7

1.7 DOMESTIC / EXPORT MARKETS .................................................................................... 7

1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 7

2. PROJECT DESCRIPTION ....................................................................................................... 8

2.1 TYPE OF PROJECT .............................................................................................................. 8

2.2 LOCATION ........................................................................................................................... 9

2.3 SALIENT FEATURES OF THE PROJECT SITE .............................................................. 10

2.4 BASIS OF CALCULATION FOR STEAM AND FUEL ................................................... 13

2.5 SIZE OR MAGNITUDE OF OPERATION ........................................................................ 14

2.6 PROJECT DESCRIPTION WITH PROCESS DETAILS .................................................. 15

2.6.1 MANUFACTURING PROCESS OF PTA .................................................................. 15

2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET .............................. 20

2.6.3 RAW MATERIALS REQUIRED ................................................................................... 24

2.6.4 RAW-MATERIALS AND ITS CONSUMPTION FOR PTA PLANT ....................... 24

2.6.5 RAW-MATERIALS AND ITS CONSUMPTION FOR POLYESTER CHIPS / PET 25

2.7 RESOURCE OPTIMIZATION ........................................................................................... 26

2.7.1 SPECIFICATION OF PROPOSED FUELS ............................................................... 26

2.7.2 COAL LINKAGE ........................................................................................................ 28

2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER REQUIREMENT .... 30

2.9 QUANTITY OF WASTE WATER GENERATED ............................................................ 31

2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH

GIVE INFORMATION OF EIA PURPOSE .................................................................................. 33

2.11 PROPOSED EMISSIONS & STACK DETAILS ........................................................... 33

3. SITE ANALYSIS....................................................................................................................... 39

3.1 CONNECTIVITY ................................................................................................................ 39

3.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................... 39

3.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................................ 40

3.4 EXISTING LAND USE PATTERN .................................................................................... 41

3.5 EXISTING INFRASTRUCTURE ....................................................................................... 43

3.6 SOIL CLASSIFICATION ................................................................................................... 43


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3.7 CLIMATIC DATA FROM SECONDARY SOURCES ...................................................... 43

3.8 SOCIAL INFRASTRUCTURE ........................................................................................... 44

4. PROPOSED INFRASTRUCTURE ......................................................................................... 45

4.1 INDUSTRIAL AREA .......................................................................................................... 45

4.2 RESIDENTIAL AREA ........................................................................................................ 46

4.3 GREENBELT ...................................................................................................................... 46

4.4 SOCIAL INFRASTRUCTURE ........................................................................................... 46

4.5 CONNECTIVITY ................................................................................................................ 46

4.6 DRINKING WATER MANAGEMENT ............................................................................. 46

4.7 SEWERAGE SYSTEM ....................................................................................................... 46

4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT ........................................................ 47

4.8.1 ASH GENERATION ................................................................................................... 47

4.8.2 DUST SUPPRESSION AND TREATMENT SYSTEM FOR COAL ........................ 47

4.8.3 ELECTROSTATIC PRECIPITATOR (ESP) .............................................................. 47

4.8.4 ASH HANDLING SYSTEM ....................................................................................... 48

4.8.4.1 HAZARDOUS WASTE AND ITS MANAGEMENT ............................................ 50

4.8.5 NOISE AND ODOUR CONTROL ............................................................................. 52

4.8.6 HAZARDOUS CHEMICAL STORAGE & HANDLING .......................................... 52

4.9 POWER REQUIREMENT .................................................................................................. 54

5. PLANNING BRIEF .................................................................................................................. 55

5.1 PLANNING CONCEPT ...................................................................................................... 55

5.2 POPULATION PROJECTION ............................................................................................ 55

5.3 LAND USE PLANNING..................................................................................................... 56

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ....................................................... 57

5.4.1 PHYSICAL INFRASTRUCTURE .............................................................................. 57

5.4.2 SOCIAL INFRASTRUCTURE ................................................................................... 57

5.4.3 AMENITIES/FACILITIES .......................................................................................... 57

6. REHABILITATION AND RESETTLEMENT (R & R) PLAN ........................................... 58

6.1 BRIEF OUTLINE ON THE POLICY ADOPTED ............................................................. 58

7. PROJECT SCHEDULE & COST ESTIMATES ................................................................... 59

7.1 TIME SCHEDULE FOR THE PROJECT ........................................................................... 59

7.2 ESTIMATED PROJECT COST .......................................................................................... 59

8. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ........................................ 60


iii

LIST OF TABLES

Table 1-1Details of the proposed project ............................................................. 5

Table 1-2 Proposed products for the Project ....................................................... 6

Table 2-1Proposed products from the Project ..................................................... 8

Table 2-2 Financial Breakup for the project ........................................................ 8

Table -2-3 Salient Features of the project site ................................................... 10

Table 2-5Raw Materials in PTA manufacturing................................................ 24

Table 2-6Raw Material in PET Manufacturing ................................................. 25

Table 2-7 Typical Properties of Natural gas ...................................................... 26

Table 3-1 Land Use classification for the Project Site ...................................... 40

Table 3-2 Land use Pattern as per Census Data (area in Hectare) .................... 41

Table 3-3Textural Class of Soil in the Study Area ............................................ 43

Table 3-4 Mangalore Climate Data.................................................................... 43

Table 4-1 Summary of proposed change ........................................................... 45

Table 4-2 Specification of ESP .......................................................................... 48

Table 4-3 Specification of ash conveying system ............................................. 49

Table 4-4 Estimated Hazardous Waste Generation & Disposal ........................ 51

Table 4-5 Details of Hazardous Chemicals and its storage ............................... 53

Table 5-1Demographic Summary ...................................................................... 55

Table 5-2 Summary of project ........................................................................... 56

Table 7-1 Project Cost Details ........................................................................... 59


iv

LIST OF FIGURES

Figure 2-1Satellite map of 10 km radius around the project Site ............................................. 9

Figure2-2 Satellite image of Project Site .................................................................................. 9

Figure 2-3 Location drawing of proposed unit ....................................................................... 11

Figure 2-4 Recent site photo ................................................................................................... 12

Figure 2-5Process Flow Diagram of PTA Manufacturing ...................................................... 18

Figure 2-6PTA Block Diagram with Vent and Effluent streams ............................................ 19

Figure 2-7Flow Diagram for PET/Polyester chips manufacturing ......................................... 22

Figure 2-8Site Layout Plan for Manufacturing of Polyester Chips / PET .............................. 23

Figure 2-9 Movement of Coal from Port ................................................................................ 29

Figure 3-1 Project Site location at Mangalore SEZ ................................................................ 39

Figure 3-2 Topography of the Project Site ............................................................................. 40

Figure 3-3 Land use map of Study Area ................................................................................. 42

Figure 3-4 Cropping Pattern in Study Area ............................................................................ 42

Figure 4-1 Details of the integrated scrap yard ....................................................................... 52

Figure 4-2Flow Chart for Captive power plant and Heat recovery system ............................ 54


1

1. EXECUTIVE SUMMARY

This is asummary forProposed amendment for Fuel Configuration for using

100% Coal in TWOOF FOUR Boilers in PTA Unit and all FourThermic Fluid

Heaters in PET Unit for the Proposed Manufacturing of Pure Terephthalic Acid

(PTA) & Polyester Chips / PET Chips of Various Types & Grades and Power

Generation through Captive Power Plant at Mangalore SEZ in Dakshina Kannada

District of Karnataka. This project falls under item no. 5(e) i.e. Petrochemical based

processing industry under the category ―B‖ as per the EIA notification 2006 and

amendments thereof. JBF received Environmental Clearance for Manufacture of

Purified Terephthalic Acid (PTA), Polyester chips / PET Chips of various types and

grades and Power generation through Captive Power Plant from SEIAA vide letter

no. SEIAA/26/IND/2011 dated 30 March 2012 (Annexure-1) and CFE from

Karnataka State Pollution Control Board vide letter no. KSPCB/ HPI/ 269/ JBFL/

CFE/2011-12/443 dated 13 July 2012 (Annexure-2) Subsequently, JBF signed a

licensing agreement with world-renowned BP Technology wherein for the first time,

BP would be licensing its PTA manufacturing technology to a Non-Affiliate Third

Party, which considerably reduced our Water consumption, Power consumption,

Process Emissions, Effluent generation & discharge and led to a positive change in

the overall Environmental footprint of the Plant. Thus, due to change in Process

Licensor, JBF applied for and received a Corrigendum to Environmental Clearance

from SEIAA vide letter no. SEIAA/26/IND/2011 dated 18 April 2013 (enclosed as

Annexure 3), amendments for fuel change to Environmental Clearance from SEIAA

vide letter no SEIAA/17/IND/2014 dated 06 August 2015 (enclosed Annexure 4)

and amendment to CFE from KSPCB vide letter PCB/HPI/269/2013-14/3892 dated

07 October 2013 (enclosed Annexure 5). The construction activities have

commenced and are progressing in full swing, about 80% of Overall Project is

completed.

Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with

renewable Bio-fuel becoming visible, JBF has already obtained permission to use

85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.

However, it is prudent to have a fall-back arrangement in order to ensure reliability &


2

availability, by designing the system for firing 100% Coal. Hence, JBFwould like to

propose fuel conversion as follows.

The Present Consented fuel configuration and proposed change in fuel configuration

is as listed in the table below:

S.No. Particulars

Present EC

Proposed change

1) Thermic Fluid Heater

(3+1 Nos.) Capacity: 9.5 M K.Cal/Hr

each

(85% Biomass + 15%

Coal) Biomass-205 TPD +

Coal-30 TPD

100% Coal firing: (3W + 1 S)

: 165 TPD

2) Turbine with WHR

system (2 Nos.) Capacity: Power-12.00

MW each

Diesel 2160 KL/month or Natural Gas 60 Lacs

SCM / Month

No change

3) Steam Generator / Boiler

(4 Nos.) Total Capacity: 460 TPH

(120+120+120+100)

3 x 120 TPH Boiler: Natural Gas: 3,00,000 SCM/ day (or) Furnace oil 216 MTPD 1 x 100 TPH Boiler (85% Biomass + 15%

coal) Biomass-165 TPD +

Coal- 25 TPD

2 X 120 TPH ONG Boilers

Normal FuelConsumption:

Natural Gas: 300,000

SCM/Day

Fuel Oil– 36T/ day

PLUS

1 x 100 TPH Boiler

100% coal (Phase -1) PLUS

1 x 120 TPH Boiler

100% Coal (Phase – 2) Normal Fuel Consumption:

576 TPDof Coal

The total Coal consumption for Boilers and Thermic Fluid Heaters is 741TPD.

Reasons for change in fuel configuration are described in Annexure – 9.


3

The reduction in SO2 emission during coal combustion will be attained by employing

desulfurization process which involves the use of Calcium – based sorbent such as limestone

powder that captures the SO2 emitted during combustion of Fuel. This measure taken is

expected to achieve a reduction of at least70 % ofSO2 emissions. The addition of sand will

ensure the removal of excess Calcium in the form of Calcium silicate.


4

1. INTRODUCTION

1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

JBF Industries Ltd., is the parent company, conceived as a Private Ltd. company in

1982, attainted corporate status by becoming Public Ltd Company in the year 1986.

The company has its subsidiary unit as JBF RAK LLC, at Ras-Al–khaima, UAE. JBF

Group is engaged in the manufacturing operation of Polyester chips / PET chips,

Polyester Partially Oriented Yarn (POY), Fully Drawn Yarn (FDY) & Polyester Film.

At present, the group turnover is of above Rs. 7000 crores. JBF group is committed

towards the Quality, Environment and Health & Safety. JBF has also been accredited

with ISO 9001, ISO 14001 & OHSAS 18001 certificates for its manufacturing

locations. Mr. B. C. Arya is the key promoter of the company and has experience of

the various fields in textile business. Under his leadership JBF group is now planning

for further backward integration project as PTA is the key raw material for

manufacturing of Polyester chips in the chain of textile commodity. Polyester chips /

PET chips have a growing market in India as well as outside India due to its wide

applicationin the Film, Bottle /Jar, Pharmaceutical, Beverages industries etc., Thus

under the name of JBF Petrochemicals Ltd., JBF group proposes the project of PTA

& PET chips along with power generation through captive power plant in Mangalore

SEZat Mangalore to cater the needs of their parent company as well as exporting to

various countries due to its global demand. JBF Petrochemicals Limited is a Limited

Company promoted by Mr. B.C. Arya and other Directors on the board are

Mr.A.G.Pai, Mr. Rakesh Gothi, Mr B R Gupta and Mrs. Ujjwala Apte. All the Board

of Directors have over 30 years of experience in various fields of business.


5

1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project from JBF Petrochemicals Ltd., is as follows,

Table 1-1Details of the proposed project

Name of the Project M/s. JBF PETROCHEMICALS LTD.

Proposed Change In Fuel Configuration for Boilers and Thermic

Fluid Heaters for the Proposed Manufacturing of Pure Terephthalic

Acid (PTA) & Polyester Chips / Pet Chips of Various Types &

Grades and Power Generation through Captive Power Plant

Proposed Capacity 2.50 million tons per Annum of PTA, 0.5 million tons per annum of

PET / Polyester Chips, 24 MW Captive Power Generation

Project Proponent JBF Petrochemicals Ltd

Location Mangalore SEZ

Total Land Area 115.3 acres

Project Cost INR 3566 Crores

EIA Consultant Hubert Enviro Care Systems Pvt. Ltd

Project termed under Schedule 5 (e), category B project, petrochemical based processing

(Processes other than cracking and reformation and not covered under the complexes) located

inside notified industrial area

1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE

COUNTRY AND OR REGION

With the proposed 2.50 million tons per Annum of PTA, 0.5 million tons per annum

of PET / Polyester Chips, 24 MW Captive Power Generation capacity, JBF

Petrochemicals Ltd is one of the largest such plants proposed in India. The company

would help to attract investment, employment opportunity for the downstream chain

of textile processing and result in accruingrevenue for Karnataka/ Indian government.

The existing production units of JBF group in India & UAE are already

manufacturing Polyester Chips & consuming PTA as key raw material and demand

on PTA based processing of Polyester chips and Polyester Yarn are increasing

internationally. At present the plant has obtained Environmental Clearance to use85%

Biomass + 15% Coal in one of four boilers and four Thermic fluid heaters vide letter

no. SEIAA 17/IND 2014 dated 06/08/2015. The same is enclosed in Annexure-3.


6

Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with

renewable Bio-fuel becoming visible, JBF has already obtained permission to use

85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.

Due to monsoons for nearly 6 months a year in DK District, the Biomass procured

will not be able to provide adequate Heating Value to support the minor variations in

process demands leading to frequent stops in a manufacturing process which has been

designed to operate on a continual basis all year round. Therefore, it is prudent to

have a fall-back arrangement in order to ensure reliability & availability, by designing

the system for firing 100% Coal. Hence we propose the use of 100% Coal in our

Thermic Fluid Heaters and two of the four Boilers.

JBF, being on the cusp of setting up a one-of-a-kind manufacturing facility in

Mangalore SEZ, DK District, Karnataka, would like to ensure that such uncertainties

are adequately backed up by redundancy measures to ensure uninterrupted running of

the Plant without compromising on the quality of Environment.

1.4 DEMAND-SUPPLY GAP

The existing plants of JBF group in India & UAE are already manufacturing

Polyester Chips & consuming PTA as key raw material and demand on PTA based

processing of Polyester chips and Polyester Yarn are increasing internationally. The

PTA produced at Mangalore will be able to cater to JBF Group’s captive

consumption of PTA in their Plants located across the world.

1.5 IMPORTS VS. INDIGENOUS PRODUCTION

The proposed products and capacity for the project is given in Table 2-2.

Table 1-2Proposed products for the Project

Sl.

No. Description of product

Capacity per month Capacity

(MTA) Phase -1

(MT)

Phase -2

(MT)

Total

(MT)

01 Purified Terephthalic Acid (PTA) 1,04,000 1,04,000 2,08,000 25,00,000

02 Polyester / PET Chips of various

types & grades 42,000 -- 42,000 5,00,000

03 Captive Power Plant 24 MW -- 24 MW


7

1.6 EXPORT POSSIBILITY

As PTA is the key raw material for manufacturing of Polyester chips in the chain of

textile commodity, Polyester chips / PET chips have a growing market in India as

well as outside India due to its wide application in the Film, Bottle /Jar,

Pharmaceutical, Beverages etc. Thus under the name of JBF Petrochemicals Ltd., JBF

group proposes the project of PTA & PET chips along with power generation through

captive power plants in SEZ at Mangalore SEZ. Once the PTA plant is under

continuous operation, there will be additional generation of Power of around 8 MW,

which will be exported to OSBL for running the Utilities.

1.7 DOMESTIC / EXPORT MARKETS

The PTA produced by JBF at the project location will have TWO consumers;

PET Plant of 0.5 Million Tons per Annum capacity being setup at the same

location within Mangalore SEZ (adjacent to the PTA Plant)

JBF’s PET manufacturing facilities located at Ras-Al-Khaimah (RAK), UAE,

Silvassa (Dadra & Nagar Haveli) and Sarigam, Gujarat.

The PTA and PET produced by JBF will pave way for a host of downstream

industries which use PET as raw material, bringing direct and indirect employment to

a large number of local populace.

1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE

TO THE PROJECT

The project will contribute towards improvements in the quality of life of the people

in the area. With this in view, following measures are recommended:

Scheme to increase employment opportunities for the local people would be

implemented, as a part of Rehabilitation and Resettlement measures, such as

vocational training for skilled jobs for youth and women, providing opportunities for

setting up ancillary industries/ service industries etc.

As per agreement signed with MSEZL, JBF will provide jobs to about 115

individuals from rehabilitated families.


8

2. PROJECT DESCRIPTION

2.1 TYPE OF PROJECT

The project involves the proposed change in fuel configuration in boilers and Thermic

Fluid Heaters in the proposed production of ―PTA & Polyester chips / PET chips of

various types & grades and Power Generationthrough Captive Power Plants‖ which

falls under item no. 5(e) i.e. Petrochemical based processing under the category ―B‖

as per the EIA notification 2006 and as amended in 2009.

There is no change in the proposed production capacity. About 80% of Projecthas

been completed. The proposed products and capacity for the project is given in Table

2-1.

Table 2-1Proposed products fromthe Project

SI.

No. Description of product

Capacity per month Capacity

(MTA) Phase -1

(MT)

Phase -2

(MT)

Total

(MT)

01 Purified Terephthalic Acid (PTA) 1,04,000 1,04,000 2,08,000 25,00,000

02 Polyester / PET Chips of various

types & grades 42,000 -- 42,000 5,00,000

03 Captive Power Plant 24 MW -- 24 MW

The Capital Cost Projection and its break up for the Proposed Project are given in

Table 2.2.

Table 2-2 Financial Breakup for the project

Sr.

No. Particulars

Total Cost (Rs. In

Crores)

1. Civil Work (Steel structure) 280

2. Plant & Machinery 2824

3. Effluent Treatment System (Stripper

column) 350

4. Power Plant 100

5. Furniture & Fixture 2

6. Computer & Electronic Data System 10

TOTAL 3566


9

2.2 LOCATION

The project is located at Mangalore SEZ, Village: Bajpe, Tehsil: Mangalore, Dist:

Dakshina Kannada, Karnataka State. The Satellite image of project site within 10 Km

radius is given in Figure 2-1.

Figure 2-1Satellite map of 10 km radius around the project Site

Figure2-2 Satellite image of Project Site

Mangalore is an industrial city with well-established infrastructure like road and rail

connectivity, maritime seaport as well as airport facilities and assumes strategic

importance to business and economic development because of its geographic

advantages. A special purpose vehicle (SPV), named Mangalore SEZ Ltd (MSEZL)

has been incorporated with (i) ONGC-MRPL, (ii) Karnataka Industrial Areas

Development Board (KIADB) representative of Government of Karnataka, (iii)

Kanara Chamber of Commerce and industries (KCCI) and (iv) Infrastructure


10

Leasing and Financial Services Ltd (IL&FS) as joint venture partners. Mangalore

SEZ is notified as SEZ by Ministry of Commerce & Industries for setting up

Petroleum and Petrochemicals Units. The layout of Mangalore SEZ is enclosed in

Annexure-10.

The Mangalore SEZ has acquired around 1800 acres of land for Phase I project and

the project is approved by Ministry of Environment & Forests vide their approval No.

21-383/2007-IA, dated 3rd April 2008 and Consent for Establishment from Karnataka

State Pollution Control Board dated 30th April 2008 (Copies enclosed in Annexure-6

& 7). Mangalore SEZ is providing developed industrial plots for setting up Petroleum

and Petrochemicals Units in place of the previously approved Olefin Complex.

Mangalore SEZ is providing the entire infrastructure like road connectivity, graded

plots, water infrastructure, Waste water collection system, solid waste management

system, green belt, marine disposal facilities for treated waste water etc. JBF

Petrochemicals has signed MoU with Mangalore SEZ Ltd. for leasing 115.3 Acres of

land for setting up the project.

2.3 SALIENT FEATURES OF THE PROJECT SITE

The salient features of the project site are given in the following table.

Table -2-3 Salient Features of the project site

Features Description

Name of the project JBF Petrochemicals Ltd

Purpose of the report

Change In Fuel Configuration for Two of Four Boilers and

four Thermic Fluid Heaters for the Proposed Manufacturing

of Pure Terephthalic Acid (PTA) & Polyester Chips / Pet Chips

of Various Types & Grades and Power Generation through

Captive Power Plant

Land Area 115.3 Acres

Nearest Village Bajpe

Nearest Railway station Suratkal (6 km from site of west)

Highway NH-17 at about 7 km on west side.

Airport Bajpe (Mangalore) at 2 km in South East direction

Sea port NMPT, Mangalore (7 km in South West direction)


11

Features Description

Forest/Wildlife

Sanctuary

No Sanctuaries/ National Parks or Reserved Forests. However,

Pilikula Nisarga Dhama (Zoo), located at about 15 km from the

proposed site

Historical/

Archaeological Place Nil

Project site

Total estimated land requirement for PTA & PET units is 115.3

Acres being leased from Mangalore SEZ Ltd. The land is in

possession of Mangalore SEZ which is notified by Ministry of

Commerce & Industries, Gol.

The geographical coordinates of the project is as attached as Annexure -11. The plant

layout plan has been attached as Annexure-12. The location drawing of the proposed

unit in Mangalore SEZ is shown below in Figure 2-3.

Figure 2-3 Location drawing of proposed unit

Construction activities at site are in progress and recent photographs of the site are

given in figure below.


12

Figure 2-4 Recent site photos

JBF Site Entrance

Construction of Guard Pond

Construction of WWTP


13

2.4 BASIS OF CALCULATION FOR STEAM AND FUEL

JBF Petrochemicals Ltd has decided to setup a Petrochemicals unit for manufacture

of 2.5 MMTPA of Purified Terephthalic Acid (PTA) in TWO Phases, each of 1.25

MTPA capacity. The project also includes a manufacturing facility for Poly Ethylene

Terephthalate (PET) of 0.5 MTPA.

The PTA Plants will require High Pressure Steam @ 330 ˚C& 90 BarG and will be

catered to by FOUR Boilers; TWO of Steam Generation capacity 120 TPH using

Natural Gas / Furnace Oil as fuel. TWO Boilers, ONE of capacity 100 TPH (Phase –

1) & ONE of 120 TPH (Phase – 2), shall operate on Coal as Fuel.

The PET Plant has FOUR (3 Working – 1 Standby) Thermic Fluid Heaters (TFH),

each of capacity 9.5 Million Kcal/h. The fuel proposed to be used isCoal (low-ash

Coals like Indonesian/ Australian) from existing 85% Biomass +15% Coal.

For PTA Plant the basis of calculation is as below

Total Coal required : 576 TPD

Calorific Value of Coal : 5000 kcal/kg

Sulfur Content in Coal : 1%

Fuel Oil firing : 36 TPD

Sulfur Content in Fuel Oil : 2 %

Total Sulfur Loading :540 kg/h SO2

Revised Sulfur Loading

(after70% Sulfur Reduction) : 204 kg/h SO2

Para Xylene Tanks


14

Stack Height Calculation; H : 14 x (204) 0.3

Or 69m.

JBF has already designed a 90m Stack which, as per calculation, is capable of

effectively dispersing emissions.

CONFIGURATION FOR FUEL FIRING SYSTEM IN PET PLANT

THERMIC FLUID HEATERS

PET Plant has 4 nos. (3 Working & 1 Standby) of Thermic Fluid Heaters, each of

9.5MM kcal/h.

During NORMAL Plant operation, 3nos. Thermic Fluid Heaters, each of 9.5 M kcal/h

shall be in operation.

Total Heat Thermal Efficiency of 85% for Thermic Fluid Heaters, Fired Heat Load:

28.5 / 0.85 = 33.5 M kcal/h

Assuming CV of Coal as 5000 kcal/kg, Coal required: 33.5 x 106 / 5000 = 6.7

MT/h or say160.8 TPD.

Therefore, the PET Plants will require about 165 MT/day of Coal (correcting for

variations in operating conditions and efficiencies).

Total Sulfur Loading :68.75 kg/h Sulfur OR 137.5 kg/h SO2

Revised Sulfur Loading

(after70% Sulfur Reduction) : 20.63 kg/h Sulfur OR 41.25 kg/h SO2

Stack Height Calculation; H : 14 x (41.25) 0.3

Or 42.7m.

The present Stack Height of 65m is sufficient for dispersion of SO2 as per

stipulations of Environment Protection Act 1986 & amendments thereof.

JBF has made all necessary provisions for Limestone addition which will reduce

SO2 emission by at least 70%.

2.5 SIZE OR MAGNITUDE OF OPERATION

There is no change in the production capacity/ products manufactured. The

application is for Proposed Change in Fuel Configuration for TWOBoilers(from 85%

Biomass – 15% Coal to 100% Coal) and Four Thermic Fluid Heaters (from 85%

Biomass +15% Coal to 100% coal) for the Proposed ―Manufacturing of Pure

Terephthalic Acid (PTA) & Polyester Chips / Pet Chips of Various Types & Grades

and Power Generation through Captive Power Plant‖.


15

2.6 PROJECT DESCRIPTION WITH PROCESS DETAILS

This chapter includes the manufacturing process and flow diagrams for the

manufacturing processes.

2.6.1 MANUFACTURING PROCESS OF PTA

a) AIR COMPRESSION

Atmospheric air is compressed in a Compressor, driven by combination of

electric motor, an off-gas expander and a steam turbine. In oxidation reactor,

Oxygen of air reacts with PX in a liquid phase solution containing catalyst

and acetic acid solvent, to form crude Terephthalic acid (CTA) & water.

Oxidation reaction is highly exothermic; Heat is recovered in a series of

Heat Exchangers to generate steam, which is sent to the steam turbine to

generate power.

b) OXIDATION REACTION

Crude TA slurry from the reactor enters a series of crystallizers where

additional TA crystals are formed, as the slurry is depressurized and cooled.

Additional air is added in the first of the three crystallizers to complete the

oxidation reaction. The flashed solvent from the crystallizers is sent to the

low pressure absorber in the solvent recovery area, while the resulting slurry

enters the TA solids separation section.

c) TA CRYSTALLIZATION AND SOLIDS SEPARATION

Rotary Filters separates TA crystals from mother liquor. The mother liquor,

which contains acetic acid, water, and catalyst, is recycled to reactor. TA

solids are sent to Purification. Process gases are sent to LP absorber for acid

recovery

d) VENT GAS TREATMENT

Off-gas from the oxidation reactor is sent to a catalytic oxidation (CATOX)

section, where volatile organic compounds are converted to CO2 & water.

Majority of the gas from the CATOX is sent to turbo-expander for energy

recovery. Gas is then sent to a scrubber and subsequently discharged to

atmosphere, through process stack meeting all environmental norms. Minor


16

portion of the Off-gas from the CATOX is used for pneumatic conveying of

PTA

e) SOLVENT AND CATALYST RECOVERY

The solvent recovery area involves several steps to recover acetic acid &

catalyst from the TA mother liquor purge stream. The purge stream is first

evaporated to vaporize the acetic acid. This vapor stream is then sent to LP

absorber, which is a two-stage scrubber using acetic acid followed by water.

Various other Oxidation process vapor streams are also scrubbed in the

LPA. The recovered acid from the LPA is recycled, while the overhead

gases VOC are treated in CATOX.

Residue generated in the solvent evaporation is treated in catalyst recovery

section to recover catalyst. This is a two-stage extraction process to recover

catalyst metals by precipitation using pH adjustment. The recovered metals

are recycled to the reactor while the purge stream is sent to waste water

treatment

f) PURIFICATION REACTION

CTA cake is first mixed with water. The CTA / Water slurry is heated in a

series of heat exchangers to the temperature required to dissolve all of the

solids in water, upstream of Purification reactor. The heated CTA / water

solution is reacted with hydrogen, in presence of a Palladium-on-carbon

catalyst, to convert the major CTA impurity (4-Carboxy Benzaldehyde) into

water soluble Para - Toluic acid

g) PTA CRYSTALLIZATION AND VENT SCRUBBER

Then PTA/water solution passes through a series of crystallizers .The

resulting slurry is sent to the solids separation section. The water vapor

evaporated in the crystallizers is used to preheat the reactor feed. Excess

vapor that cannot be condensed is sent to the PTA Vent scrubber, where

they are cooled and scrubbed with water to remove solids. The scrubbed gas

is sent to CATOX to destroy VOC.


17

h) PTA SEPARATION, DRYING AND BAGGING

In PTA solids separation section, PTA crystals are separated from mother

liquor. Majority of mother liquor is recycled. The cake discharges to the

PTA dryer. Evaporated moisture is cooled & scrubbed in Dryer scrubber to

remove solids. The treated vapors are sent to CATOX for VOC destruction.

Dry PTA from Dryer is pneumatically conveyed to the Product handling

area for bagging & dispatch.


18

Figure 2-5Process Flow Diagram of PTA Manufacturing


19

Figure 2-6PTA Block Diagram with Vent and Effluent streams

20

2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET

a) PTA SLURRY MAKING

Purified Terephthalic Acid (PTA) in powder form is charged in Hopper and

conveyed to the plant under 0.5 Kg pressure to the Slurry Preparation Reactor.

Mono Ethylene Glycol (MEG) is charged under the close condition to pump

from MEG Storage Yard to PTA Slurry making Reactor. PTA and MEG are

mixed in the PTA slurry reactor and transferred through Mass Flow Meter to

esterification reaction.

b) ESTERIFICATION REACTION

Under the continuous process from one side slurry of PTA received goes under

gradual heating up to 2500C to start esterification reaction. The reacted mass is

passed through esterification stage – II having temperature of 250 to 2600C and

form Monomer during the process. During this process, water is generated as

byproduct and is transferred to Effluent Treatment System for the treatment.

During the esterification reaction, Antimony Trioxide is added as a catalyst to

accelerate the rate of reaction.

c) PREPOLYMERIZATION

During the continuous process, monomer mass from esterification stage is

passed through prepolymerization stage between 260 to 280°C and at the same

time delustering agent as Titanium Dioxide (TiO2) is added in the reaction

mass. Under this stage, mixture of Oligomer and Polymer are formed.

d) POLYCONDENSATION

Under continuous process, Oligomer in molten form is filtered through S.S.

Candle Filter and the mass is received for final condensation. The final

polycondensation reaction is carried out between 280 to 290°C and after

achieving the desired Viscosity, the molten polymer mass is passed through

Cutter to form the required size of Polyester Chips.

21

e) DRYING OF THE CHIPS

Preferred size of chips are dried in Dryer and passed through Classifier and

transferred to Intermediate Storage Vessel.

f) STORAGE & DESPATCH

The manufactured chips are checked for various physico-chemical parameter

and the approved chips are stored in Chips Silo. Finally it is packed in jumbo

bags and dispatched to the various customers & option is also kept open for

dispatching it in tanker load (if required).

22

Figure 2-7Flow Diagram for PET/Polyester chips manufacturing

23

Figure 2-8Site Layout Plan for Manufacturing of Polyester Chips / PET

24

2.6.3 RAW MATERIALS REQUIRED

The raw materials and products for the proposed project will be brought and sent to

the Mangalore Port through a dedicated road cum pipeline corridor, the layout of

which is attached as Annexure- 13.

2.6.4 RAW-MATERIALS AND ITS CONSUMPTION FOR PTA PLANT

The raw material requirement along with their specific consumption in PTA

manufacturing is as follows.

Table 2-4Raw Materials in PTA manufacturing

S.

No

Description Specific

Consumpt

ion

PTA - 1 PTA - 2 Means of Storage

kg per MT

PTA

Requireme

nt

(MT/Mont

h)

Requireme

nt

(MT/Mont

h)

1 Para Xylene 650.0 67700 67700 Floating roof Storage

tanks

2 Acetic Acid (as 100%) 30.0 3125 3125 Storage tanks

3 Cobalt (as metal) 0.015 1.6 1.6 Bag/Drum

4 Manganese (as metal) 0.008 0.8 0.8 Bag/Drum

5 Hydrogen Bromide (as

100%)

0.23 24 24 Storage tanks

6 Hydrogen 0.21 22 22 MRPL/OMPL -

Outsourcing

7 PTA Purification

Catalyst (5%

Palladium on Carbon)

0.025 2.6 2.6 Bag/Drum

8 Sodium Carbonate

(as 100%)

3.28 342 342 Bags

25

Apart from above inputs, following catalyst & chemicals will be used during manufacturing of

PTA:

a) Caustic Soda solution - for neutralization of effluent and as scrubbing media in vent scrubber

b) Aluminium oxide pellets - used as desiccant.

c) Ceramic-base CATOX catalyst for destruction of VOC.

d) Sodium Formate (40% solution) is used as Scrubbing media

2.6.5 RAW-MATERIALS AND ITS CONSUMPTION FOR POLYESTER CHIPS /

PET

The raw material requirement along with their specific consumption in PET/Polyester

chips manufacturing is as follows.

Table 2-5Raw Material in PET Manufacturing

Sr.

No.

Raw materials Consumption in

(MT/MT)

Requirement

(MT/Month)

Means of

Storage

1 PTA 0.86 36120 Bags/Silo

2 MEG 0.338 14196 Storage Tanks

3 Antimony

Acetate/Trioxide

0.0004 16.8 Bags/Drum

4 Isophthalic acid 0.022 924 Bags/Drum

5 Diethylene glycol 0.002 84 Storage Tanks

6 Titanium dioxide 0.003 126 Bags/Drum

7 Ortho phosphoric acid 0.0005 21 Carboyes

Apart from above following chemicals will be used during manufacturing PET Chips:

a) Ammonia Gas - 50 Kg/cylinder and monthly consumption will be 2500 Kgs for Nitrogen

generation plant

b) Palladium & De-oxo catalyst and carbon molecular sieve for nitrogen generation and drying

26

2.7 RESOURCE OPTIMIZATION

TwoBoilers each of capacity 120 TPH are proposed to be based onNatural gas / Furnace

Oil and TwoBoilersof capacity 100TPH & 120 TPH arebased on 100 % Coal will be

installed with a capacity considering peak load of 460 TPH at 90 BarGworking pressure

for high pressure steam generation for the PTA process.

Normally each PTA plant upon stabilization, will consume 125TPH of high pressure

steam. During process upsets, about 340 TPH of high pressure steam will be consumed.

Hence 4 nos. of Boilers withcombined steam generation capacity 460 TPH will be

installed for generation of high pressure steam to meet the peak load requirement during

start up / breakdown / upset conditions of the PTA plant.

The Coal requirements in the premises under normal operating situation will be576 TPD

for Boiler and 165 TPD for Thermic Fluid Heater. Total Coal consumption is 741 TPD

2.7.1 SPECIFICATION OF PROPOSED FUELS

i. Natural Gas

Table 2-6 Typical Properties of Natural gas

Sr. No. Component

Composition in Vol % or

Mol%

1 Methane 97.9

2 Ethane 0.1

3 Carbon Dioxide 0.5

4 Nitrogen 1.5

Total 100

Gas Properties

1 Specific Gravity of gas w.r.t air at 60°F and 14.696 psi 0.566

2 Density at 60°F and 14.696 psi in kg/m3 0.692

3 Z Factor at 60°F and 14.696 psi 0.997

4 Net Calorific value at 60°F and 14.696 psi in kcal/sm3 7973

5 Gross Calorific value at 60°F and 14.696 psi in kcal/sm3 8854

27

ii. Furnace Oil

Table 2 – 8 Typical Properties of Furnace Oil

iii. Coal

Table 2–9 Typical Properties of Coal

SL. NO. DESCRIPTION UNIT VALUE

1 Calorific value KCAL / KG 5000 – 5200

2 Bulk density KG/M3 650 – 850

3 Ash fusion point DEGREE C 1250

4 Maximum quantity to be fired MT/DAY 200

5 Hard grove index HGI 45 – 50

6 Range of particle size MM 0 – 50

PROXIMATE ANALYSIS

1 Moisture content % 15 – 20

2 Ash content % 8 – 10%

3 Volatile matter % 38 – 42

4 Fixed carbon % 25 – 35

ULTIMATE ANALYSIS

1 Carbon % 70 – 75

2 Oxygen % 15 – 20

Sr. No. Properties

Composition in Vol

% or Mol%

1 Density (Approx. g/cc at 15°C) 0.89–0.95

2 Flash Point (°C) 66

3 Pour Point (°C) 20

4 G.C.V. (kCal/kg) 10,500

5 Sediment, % Wt. Max. 0.25

6 Water Content, % Vol. Max. 1.0

7 Sulphur Total, % Wt. Max. Upto 2.0

8 Ash % Wt. Max. 0.1

28

SL. NO. DESCRIPTION UNIT VALUE

3 Hydrogen % 5 – 6

4 Nitrogen % 1.2 - 1.5

5 Sulfur % 0.1 - 0.9

2.7.2 COAL LINKAGE

Coal will be transported through trucks from New Mangalore Port to JBF plant

through dedicated MSEZ Corridor. The coal linkage drawing is shown below in

Figure 2-9.

29

Figure 2-9 Movement of Coal from Port

JBF Project

Site

MSEZL’s 60m

Wide Road-

cum-Pipeline

Corridor

30

2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER

REQUIREMENT

Table 2–10 Availability of Energy and water as per EC

S.NO PROJECT DETAILS EXISTING AS PER EC PROPOSED

1. Power requirement Peak load (MW) 87 No change

Normal operation

(MW)

24 No change

2. Water consumption

(KLD)

43,100 No change

3. Domestic effluent

(KLD)

200 No change

4. Effluent generation

(KLD)

21600 No change

Table 2–11Water Requirement

SI

No

Details For PTA plant

(KLD)

For Polyester chips

plant (KLD)

Total

requirement

(KLD)

1 Water

consumption for

industrial purpose

9840 220 10,060

2 Water

consumption for

cooling tower

32,200 590 32,790

3 Water

consumption for

domestic

200 50 250

Grand Total 42,240 860 43,100

31

2.9 QUANTITY OF WASTE WATER GENERATED

The proposed project will have effluent treatment plant consisting of Physico-chemical

treatment, primary treatment & secondary treatment. After micro filtration and RO

(tertiary treatment), 70% of the treated effluent is recycled to the plant. The remaining

30% of the treated effluent meeting Environmental norms will be discharged to the final

outlet as approved to Mangalore SEZ.

Table 2–12 Phase wise effluent generation

SL.NO. SOURCE PHASE - 1 (IN

KLD)

PHASE - 2 (IN

KLD)

1 Waste water generated during the

process PTA – 1 plant 4456 -


process PTA – 2 plant - 4456


process pet plant 525 -

4 Water generated from process 910 910

5 Condensate recovery (DM regeneration

waste & boiler blow down) 615 615

6 Other services (floor washes & solution

preparation) 460 460

7 Cooling tower blowdown 4196 3996

Total quantity (industrial) 11,162 10438

Total quantity (domestic) 200

Total (for the respective phase) 11 362 10438

Grand total 21800

32

Table 2–13 Waste Water Generation – Total

SI. No. Details Proposed Qty KL/day Avg. COD mg/ltr. Avg. COD

mg/ltr.

1. Domestic 200 - -

2. Process 13,408 14,000 6000-7500

3. Cooling Tower & Utilities 8,192 100 -

Total 21,800

JBF will have designed capacity of effluent treatment plant to take care of normal, peak,

routine & non-routine operations. Condensate water generated due to high pressure steam

supply to the process plant will be recycled to boiler, and the Blow-down will be routed to

ETP. Domestic waste as overflow of soak pit will be connected to biological treatment

section of the Sewage treatment plant for final treatment.

The average COD level in the generated effluent will be about 14000 mg/l, BOD 6000 to

7500 mg/l. 70 % of the treated effluent will be recycled back to cooling tower. Effluent will

be treated up to a Statutory Board Standard prior to its final discharge. There will be a

Methane gas generation during the anaerobic treatment of effluent which will be utilized

for making HP Steam (90BarG) for Process. The ETP Process Flow Diagrams are

enclosed in Annexure-14.

Table 2–14 Components for operation and treatment of waste water

SI.

NO.

DESCRIPTION USAGE

1 Various size of collection sump ETP

2 Oil & grease separator ETP

3 Neutralization sump ETP

4 Caustic solution / lime solution tank ETP

5 Polyelectrolyte solution tank ETP

6 Anaerobic digesters ETP

7 Aeration tank ETP

8 Clarifier ETP

33

SI.

NO.

DESCRIPTION USAGE

9 Thickener and belt filter press ETP

10 Sludge drying bed ETP sludge removal

11 Aerator ETP

12 Diffuser ETP

13 Pressure sand and activated carbon filter ETP

14 Ultra filtration unit ETP

15 Reverse osmosis plant ETP

16 Treated water, permeate and rejected water tank ETP

17 Gas compression system with blower & tank Biogas utilization

18 Flare Burning of low pressure gas

19 TOC meter Online water monitoring

20 De-mineralize water polishing system ETP

21 Quality control laboratories with instruments to

analyze major parameters of effluent

Water analysis

2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY

DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE

The plot plan for the proposed project indicating the location of project components is

enclosed in Anexure-13.

2.11 PROPOSED EMISSIONS & STACK DETAILS

Among the four Boilers, 2 nos. of boilers using Oil & Natural Gas and 2nos Solid fuel

Coal have a combined stack height of 90 m and the 4 Thermic Fluid Heaters have a

separate stack of 65 m height, based on the prescribed empirical formula of Sulfur

loading rate as per the EP Act, 1986.

34

Table 2–15 Stack and Emission Details

SI.

No.

Description/Parameter Value Remarks

1 SO2 245.25 kg/hr

Total Emissions from JBF PTA

(Phase 1 & 2) and PET Plants.

2 Boiler vent stack H – 90m

Common Stack for all 4 Boilers

Stack height designed for effective

dispersion Of SOx emissions using

The formula:

H = 14x(Q)0.3

;

H – Height of stack(M)

Q – Mass flow rate of SOX(kg/h)

3 Thermic fluid heater

vent stack

H – 65m Remains unchanged

4 Particulate matter 50 Mg/Nm3

As Per existing CFE issued by

KSPCB

5 Ash generation 80 TPD Shall be disposed as per

MOEF/KSPCB guidelines

6 DG Stack 30 m Common stack for DGs

7 ETP Flare (Closed-

type)

12 m As per API – 527 Guidelines

35

Table 2–16 Details of Air pollution control Equipment as approved in EC & CFE

S.

NO

DESCRIPTION OF

EQUIPMENT QTY. MOC CAPACITY / SPECIFICATION

DESIGN

TEMP

(⁰ C)

DESIGN

PRESS.

(BAR G)

01 Catalytic oxidation reactor ONE SS 316 L H-4.2 M,Φ-3.1 M 19.5 M3

Catalyst 430 10.6/-0.18

02 Recuperative heater ONE Shell- SS 316

Tube – SS 316

A-2382 M2

Q-17.6 M KCAL/H

Shell-430

Tube-430

Shell 10.6/-

0.18

Tube 10.6/-

0.18

03 Catox start-up heater ONE Shell-CS

Tube – Titanium

A-91 M2

Q-3.8 M KCAL/H

Shell-320

Tube-430

Shell-103/ FV

Tube- 10.6/-

0.18

04 Process vent scrubber ONE Shell-FRP. glass filled PP

packing H-15.5 Φ-6.0 M packedbed 5 M 81 0.15 /-0.18

05 Vent scrubber circulation

pumps TWO SS 316 L V-656 M3/H,∆P-2.4 Bar,P-75 KW 81 4.5

06 Process vent stack ONE SS 304 L H- 13.0 / 32.8 M Φ- 2.4 / 1.9 M 196 0.15 /-0.18

07 High pressure bromine

scrubber ONE

ShelL-TIT. cladon CS PP

packing H-9.2 M Φ-1.4 M Packedbed 5 M 220 10.6/-0.18

08 Bromine scrubber quench

pumps TWO SS 316 L V-62.5 M3/H,∆P-3.6 Bar,P-15 KW 92 16

09 Quench cooler ONE Shell-CS

Tube – DSS 2205

A-45 M2

Q-1.0 MKCAL/H

Shell -65

Tube-92

Shell-10.6/-

0.18

Tube- 16 /-

36

S.

NO

DESCRIPTION OF


DESIGN

TEMP

(⁰ C)

DESIGN

PRESS.

(BAR G)

0.18

10 Conveying gas chiller

package ONE SS 316 L Chills 16 T/H GAS TO DEW PT. 5 ⁰ C 50 10.6/-0.18

11 PTA drier vent scrubber ONE SS 304 L H- 8.5 M

Φ – 2.8 M 129 1.1 /-0.18

12 Drier vent scrubber

circulation pumps TWO SS 304 L V-110 M3/H, ∆P-9.6 BAR,P-75 KW 129 14

13 PTA drier vent scrubber hot

cond. ONE

Shell-CS

Tube – SS 304 L

A-164 M2

Q- 3.0 MKCAL/H

Shell -123

Tube-129

Shell-17.2/FV

Tube- 1.1/-

0.18

14 PTA drier vent scrubber 2

nd

cond. ONE

Shell-CS

Tube – DSS 2205

A-384 M2

Q- 10.6 MKCAL/H

Shell – 65

Tube-129

Shell-10.3

Tube- 1.1 /-

0.18

15 PTAday silo vent dust

collector TWO SS 304 L Filters 3100 NM

3/H OF GAS 149 0.35 /-0.133

16 PTA product silo dust

collector ONE SS 304 L Filters 13200 NM3/H OF GAS 149 0.35 /-0.133

17 PTA vent ko drum ONE SS 304 L H- 6 M Φ- 3.6 M 195 4.0 /-0.18

18 PTA vent ko drum condenser ONE Shell-CS

Tube – DSS 2205

A-156 M2

Q- 4.6 MKCAL/H

SHELL – 65

TUBE-195

Shell-10.3/-

0.18

Tube- 4.0 /-

0.18

19 PTA vent ko drum circulation TWO SS 304 L V-166 M3/H, ∆P-4.9 BAR, P-37 KW 195 10.7

37

S.

NO

DESCRIPTION OF


DESIGN

TEMP

(⁰ C)

DESIGN

PRESS.

(BAR G)

pumps

20 PTA crystallizer overflow ko

drum ONE SS 304 L H-2.7 M Φ- 2 M 131 1.1

21 Blowdown drum ONE CS H-4.2 M Φ-2.1 M 131 1.1/-0.18

22 Liq. catalyst tank vent

scrubber ONE SS 316 L H-6 M Φ-0.4 M 50 0.50 / -0.18

23 Acetic acid tank vent

scrubber ONE SS 316 L H-6 M Φ-0.4 M 100 0.50 / -0.18

24 Oxid. unit psv sump ONE CS Epoxy coated L-7.4 M- Φ 5.0 M 210 1.0 / -0.18

25 Low pressure absorber ONE

Shell- SS 316 L

Packing’s moc poly

Propylene

H-11 M Φ-0.8 M2

PACKED BEDS OF

HT. 1.9 & 1.3 M 115 3.5 /-0.18

26 Low pressure absorber drum ONE SS 316 L L-10 M- Φ 4 M 115 3.5 /-0.18

27 LP absorber circulation pump TWO SS 316 L V 163 M3/H, ∆P-15 BAR,P 160 KW 115 24

28 DH tower overhead final

condenser ONE

Shell-CS

Tube – DSS 2205

A-1587 M2

Q-40 MKCAL/H

Shell – 65

Tube-146

Shell-10.3/-

0.18

Tube- 12.4/-

0.18

29 High pressure absorber ONE

SHELL- SS 317 L CLAD

ON CS

TRAYS –SS 316 L

H-25 M- Φ 3.4 M PACKED BED OF 8.4

M & 10 TRAYS 154 12.4 /-0.18

30 HP absorber reflux cooler ONE SHELL-CS

TUBE – DSS 2205

A-280 M2

Q-3.6 MKCAL/H

SHELL – 65

Tube-115

Shell-10.3/-

0.18

38

S.

NO

DESCRIPTION OF


DESIGN

TEMP

(⁰ C)

DESIGN

PRESS.

(BAR G)

Tube- 24 /-

0.18

31 HP absorber vent gas heater ONE SHELL-CS

TUBE – SS 316 L

A-275 M2

Q-6.5 MKCAL/H

Shell –200

Tube-145

Shell-7.8 / FV

Tube- 12.4 /-

0.18

32 ESP ONE STEEL Flue gas handling volume- 156000M

3/H

Dust removal efficiency-99.5 % 190°C -

33 Bag Filters ONE SHELL-MS ELEMENT-

POLY PROPYLENE

To Control Particulate Matter

Total No Of Filter-48

Filter Area-36 m2

Filtration Air Volume-1080 m3-8640 m

3

< 120ᵒC 0.5-0.7 MPa

39

3. SITE ANALYSIS

3.1 CONNECTIVITY

The project site is located within Mangalore SEZ and is well connected by Road. The

location of the site is given in Figure 4-1 below and the Port Road corridor is enclosed in

Annexure-13.

Figure 3-1 Project Site location at Mangalore SEZ

3.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project site is within Mangalore SEZ area. The land use classification for

the study area is given in table below

40

Table 3-1 Land Use classification for the Project Site

SR. NO. LAND USE/LAND COVER CLASSES AREA IN (KM2) AREA IN

(%)

1. Vegetation 122.05 38.87

2. Land with shrub 17.64 5.62

3. Waste land 82.64 26.32

4. Bare soil/sand 12.99 4.14

5. Built-up area 26.18 8.34

6. Water body 52.46 16.71

Total 314 100.0

3.3 TOPOGRAPHY (ALONG WITH MAP)

The Topography of the project site is given in the figure below.

Figure 3-2 Topography of the Project Site

41

3.4 EXISTING LAND USE PATTERN

Table 3-2Land use Pattern as per Census Data (area in Hectare)

SI.

No.

Name Of

Village

Total

Area

Forest Irrigated Unirrigated Cultivable

Waste Land

Area Not

Available For

Cultivation

1. Bajpe 722.70 - - 150.19 162.26 410.20

2. Paduperara 822.97 - 7.10 455.13 252.17 108.57

3. Badagayekkar 1011.26 - 0.81 629.09 145.73 253.63

4. Permude 742.43 - - 264.48 44.75 431.20

5. Kalavar 330.35 - - 381.01 3.79 311.02

6. Haleangadi 198.65 - 48.58 16.12 55.22 78.73

7. Kolambe 915.03 - - 268.96 90.11 555.96

8. Muduperar 896.06 - - 308.61 332.53 254.92

9. Kilanjar 525.29 - - 395.28 6.50 123.51

10. Chellairu 317.01 - - 174.36 66.08 76.57

11. Delanthabettu 320.43 - 24.57 84.45 37.15 174.56

12. Badagayekkar 1011.26 - 0.81 629.09 145.73 235.63

13. Tenkayekkar 640.64 - 5.82 169.27 77.85 387.70

14. Kuthethur 695.82 - - 381.01 3.79 311.02

15. Bala 567.21 - - 284.94 28.13 254.14

16. Kenjaru 667.56 - - 95.41 163.56 408.59

17. Mudashedde `594.06 - - 123.08 242.92 228.06

18. Padushedde 145.58 - - 65.99 40.49 39.10

19. Mennabettu 551.90 - - 166.43 101.43 284.04

20. Kilanjur 136.59 - 31.57 33.35 50.72 20.95

21. Attur 106.70 - - 67.61 2.14 36.95

22. Koikude 278.82 - 23.40 129.31 48.72 77.31

23. Bellairu 293.65 - - 208.57 63.45 21.63

Total 22350.42 0 142.66 5481.74 2165.22 5083.99

42

Figure 3-3Land use map of Study Area

Figure 3-4Cropping Pattern in Study Area

PADDY

53%

COCONUT

15%

ARECANUT

6%

BANANA

1%

MANGO

4%

CASHEWNUT

21%

PADDY

COCONUT

ARECANUT

BANANA

MANGO

CASHEWNUT

43

3.5 EXISTING INFRASTRUCTURE

Erection and construction of proposed project is completed up to80%. This is a proposal

for Change in Fuel Configuration for Two of Four Boilers and all Thermic Fluid Heaters

(from 85% Biomass-15%Coal)to100% Coal for the Proposed ―Manufacturing of Pure

Terephthalic Acid (PTA) & Polyester Chips / Pet Chips of Various Types & Grades and

Power Generation through Captive Power Plant‖. The construction activities have

commenced and are progressing in full swing.

3.6 SOIL CLASSIFICATION

Table 3-3Textural Class of Soil in the Study Area

SI.

NO

SAMPLING

LOCATIONS

PARTICLE SIZE DISTRIBUTION (%) TEXTURAL

CLASS FINE SAND CORE SAND SILT CLAY

1. JBF PROJECT SITE 38.2 19.6 19.4 22.8 SANDY CLAY

LOAM

3.7 CLIMATIC DATA FROM SECONDARY SOURCES

Table 3-4 Meteorological Data for Dakshina Kannada District

(Source- IMD, 2014)

44

3.8 SOCIAL INFRASTRUCTURE

The project will provide employment to local youth, thus increasing their standard of

living and helping strengthen the social infrastructures of the region.

45

4. PROPOSED INFRASTRUCTURE

4.1 INDUSTRIAL AREA

Table 4-1 Summary of proposed change

S.NO Project details Existing EC amendment Changes Proposed

1. Land area 115.3 Acres No change in existing

2. Project cost 3566 Crores No change in existing

3. Proposed

capacity

2.50 million tons per annum

of PTA, 0.5 million tons per

annum of pet / polyester

chips, 24 mw captive power

generation

No change in existing EC

4. Power

requirement

Peak load

(MW)

87 No change in existing EC

Normal

operation

(MW)

24 No change in existing EC

5. Thermic fluid

heaters

Thermic fluid heater

(4 Nos.) capacity: 9.5 M

K.Cal/Hr each

85% Biomass + 15% coal

(205 TPD Biomass + 30 TPD

Coal)

Thermic fluid heater (4 nos.)

capacity: 9.5 MMkcal/h each

100%Coal 165T/day

6. Turbine with

WHR system

Turbine with WHR system (2

nos.) Capacity: Power-12.00

MW each

Diesel

2160 KL/month

No changes

7. Steam generators

/ boilers

Steam generator / Boiler

3x 120 TPH

Natural gas/Furnace Oil

1x100 TPH boiler

85% biomass+ 15% coal

(165 TPD Biomass + 25 TPD

Coal)

Steam generator / Boiler

(4 Nos.)

Total capacity: 460 TPH

(120+120+120+100 )

2 x 120 TPH Boiler

(no fuel change)

Natural gas/ Furnace Oil

1 x100 TPH (Phase – 1) &

1x120 TPH(Phase –

2)Boilers Coal 576T/DAY

46

4.2 RESIDENTIAL AREA

Adequate infrastructure facilities, viz., housing, medical, education, transportation,

communication, playground, library, canteen, market for the township would be

developed within MSEZ Non Processing area by MSEZL so as to avoid strain on the

existing infrastructure resources base.

4.3 GREENBELT

The proposed project site is situated within the Mangalore SEZ and they have provided

33% area of open land as greenbelt as a developer of SEZ which is also covered in their

environment clearance.

A green belt of required width (3m) will be provided all around the plant boundary limits.

In addition, avenue trees will be planted along the roads.

4.4 SOCIAL INFRASTRUCTURE

The project will provide employment to local youth, thus increasing their standard of

living and thus helping strengthen the social infrastructures of the region

4.5 CONNECTIVITY

Connectivity between Mangalore Port and JBF site has been shown in Annexure-13.

4.6 DRINKING WATER MANAGEMENT

The water supply in the study area is through wells, tap water, hand pumps Tube well,

river and canal allied sources. Bore wells are the main source of drinking water supply.

Potability also appears to be good. Water for the proposed Project will be provided by

Mangalore SEZ Ltd.

4.7 SEWERAGE SYSTEM

Sewage from the plant would be disposed to the sewage pits/network from where it is

pumped to the main STP for treatment and the treated water is used for horticulture.

8. Total Coal

consumption

741 TPD

47

4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT

4.8.1 ASH GENERATION

From PTA Boilers

Assuming 8 - 10% Ash content in Coal (Indonesian Coal), , the Ash generation per day

shall be about 60MT/day which is trapped using a high efficiency ESP (> 99.5% Dust

removal efficiency), and pneumatically conveyed to Ash Silo thus avoiding the problems

associated with wet ash handling.

From PET Plant

Assuming 8 - 10% Ash content in Coal (Indonesian Coal), the Ash generation per day

shall be about 20MT/day. A high efficiency ESP (> 99.5% Dust removal efficiency) may

be proposed if suitable, and ash pneumatically conveyed to Ash Silo, in a similar manner

as envisaged for PTA Plant Boilers, thereby avoiding the problems associated with wet

ash handling.

Total ash generation from both PTA and PET Plants will be 80 MT/day.

4.8.2 DUST SUPPRESSION AND TREATMENT SYSTEM FOR COAL

When coal is used as fuel, water sprinkling is proposed for dust suppression at the rate of

2.5 Kg/ Sq.cm of the area incase of track hopper and 4.5 Kg/ Sq.cm in case of wagon

tipper coal stock. Of the water used, 10 % will be absorbed by Coal and 20 % will be lost

in evaporation. The treatment system proposed will be Settling Pond. The water after

treatment can be recirculated for dust suppression.

4.8.3 ELECTROSTATIC PRECIPITATOR (ESP)

Collection efficiencies of 99.5% or greater for coarse and fine particulates at

relatively low energy consumption

Dry collection and disposal of dust

Low pressure drop—typically less than 10–20 mm (0.5 inch) water column

Continuous operation with minimum maintenance

48

Relatively low operation costs

Operation capability at high temperatures up to 700oC,or (1,300

oF) and high

pressure (up to 10 atmospheres or 150 pounds per square inch, psi) or under

vacuum

Capability to handle relatively large gas-flow rates (on the order of 50,000

m3/min)

Table 4-2 Specification of ESP

S.No Parameters Specification

1 Handling flue gas volume 156000m3/h

2 Flue gas temperature 190°C

3 Dust concentration of inlet flue

gas

10 g/Nm3

4 Dust concentration of outlet flue

gas

≤50 mg/Nm3

5 Dust removal efficiency 99.5%min.

4.8.4 ASH HANDLING SYSTEM

a) Fly Ash

The ash removal system consists of three stages ESP, dust hoppers & pneumatic

ash conveying system. One cone pump (0.6 m3) will be installed under each

hopper and the dry ash shall be sent into ash silo of capacity 150 m3, which will

handle the ash discharging capacity of3.5days. The conveying distance is 50m.

Adequate dust collector or bag filters will be provided at the Ashsilo for dust

suppression & venting clean (Filtered) air from conveying system. The dry ash

can be loaded and transported for integrated utilization. Fluidization device will

be equipped to ensure smooth ash discharge into the ash silo. The fluidization air

can be provided by gasification fan, and the electric heater at the outlet of fan.

The layout showing the Ash handling system is enclosed in Annexure-15.

49

Table 4-3 Specification of ash conveying system

S.No Item Unit Parameter

1 Designed output T/H 3

2 Average ash-gas ratio kg/kg 35

3 Average conveying pressure MPa 0.1

4 Speed at the front part of ash-pipe m/s 2 ～4

5 Speed at the end part of ash pipe m/s 8 ～9

6 Air consumption for conveying m3/min 7.0

7 Airconsumption for instrument m3/min 0.5

b) Bottom ash

When burning Coal, the slag shall be discharged, and this discharged slag after

cooling can be used as bed material within the Boiler to ensure better fluidized

combustion. Bed material shall be added into boiler by coal feeder at the feed-end

of the boiler when starting and operating the boiler.

PLC shall be used for the control of ash handling system. Automatic control

consists of PLC, local control station and sensors.

c) Desulfurization Arrangement

The reduction in SO2 emission during coal combustion will be attained by utilizing

low-sulfur coal (Indonesian coal) as well as by employing desulfurization process

which involves the use of Ca-based sorbent such as limestone powder that captures

the SO2 emitted.

JBF has made all the required provision for feeding Limestone along with coal into

the boiler in the mole ratio of Ca:S = 2 for the removal of SO2 emitted. This measure

taken is expected to achieve a reduction of MINIMUM70 % in SO2 emissions. The

addition of sand will ensure the removal of excess calcium in the form of Calcium

silicate. A brief description of the system is as follows:

Limestone is stored in a Steel Bin and discharged through a Screw Conveyorfirst and

then through two conveyors before entering the Boiler Furnace through Rotary

50

Feeders, whose function is to regulate flow of Fuel, Sand and Limestone entering the

Furnace. The Limestone Bin has a storage inventory of 20m3. A rotary valve operated

by a variable frequency drive linked to the control systemis mounted at the hopper

discharge and serves as the material metering device.This valvedischarges material

through a small, vented chute directly into a blow-through rotary airlock runningat a

constant speed. The blow-through rotary airlock is the primary seal between the

metering system and the pneumatic conveying line; the metering rotary valve is the

secondary seal. Each feeder hopper is equipped with its own reverse jet pulse dust

filter system, which traps nuisance dust generated during feeder refill and returns it to

the process. The dust filter also facilitates air displacement in the hopper as material

is metered out or replenished, as well as air leakage from the blow-through rotary

airlock. Every precaution is taken to assure that the conveying lines do not become

plugged with material.

The SO2 emitted during the operation of PTA plant and PET Plant will be 204 kg/h

and 41.25 kg/h, respectively.

The detailed calculations regarding SO2 emissions will be furnished in the EIA report.

4.8.4.1 HAZARDOUS WASTE AND ITS MANAGEMENT

All the hazardous and non-hazardous waste will be stored in an integrated scrap yard

in a segregated manner. Some of the wastes, like contaminated packing material,

sweeping material and other non-hazardous waste will be disposed through registered

recycler and re-processor having KSPCB/CPCB approval.

51

Table 4-4 Estimated Hazardous Waste Generation & Disposal

Description Qty. in MT/ year Type of handling &

disposal

Future use

Spent catox

catalyst

13.4MTin 4years collected and packed in

liner containing drums

and stored in integrated

scrap yard

Send to approved TSDF site for

final disposal

Used aluminium

oxide, carbon

with palladium

catalyst

40 collected and packed in



scrap yard

Sent to approved Recyclers/

TSDF site for final disposal

Scrap PTA from

various

handling points

& storage tanks

900 collected and packed in



scrap yard and leach ate

systems will be provided

Sent to approved recycler / actual

user.

ETP waste 3000 packed in bags and stored

at a designated area.

Sent to TSDF site for final

disposal.

process waste

(lump waste)

1500 packed in bags and stored


Sold to actual users / recycler

duly approved by KPCB/CPCB.

Used oil /

waste oil

600 kl stored in drums Sold to registered recycler/re-

processor duly approved by

KPCB/CPCB.

Empty

bags/liners

1000 stored at a separate

storage area

Sold to authorized scrap vendor.

Empty

containers/

barrels / carboys

28,500 nos stored at a separate

storage area

sold to authorized scrap vendor.

Waste resin,

used carbon,

catalyst &

expired

chemicals

100 stored in drums & bags Sent to TSDF site for final

disposal.

Residual sludge

of fuel oil

1500 stored in drums Sold to registered recycler or

actual user duly approved by

KPCB/CPCB.

Oil and

chemical soaked

cotton waste

50 Packed in bags and stored


Sent to TSDF site for final

disposal/as per KSPCB norms

Flyash 30,000 Stored in Ash Silos. Will be sent to fly ash brick

manufacturers/ cement

manufacturers approved by

KSPCB.

Enclosed integrated storage yard for Hazardous &Non-hazardous waste generated in

52

the premises.

Guidelines approved by MoEF / KSPCB for notified area as Mangalore SEZ Ltd. will

be executed in ref. to disposal of hazardous &non-hazardous waste.

Integrated scrap yard will have segregation of hazardous &non-hazardous area in a

close covered shed with a separate entry for hazardous &non-hazardous storage area.

Figure 4-1 Details of the integrated scrap yard

4.8.5 NOISE AND ODOUR CONTROL

All equipment in the power plant would be designed/operated to have a noise level

not exceeding 85 dB as per the requirement of Occupational Safety and Health

Administration Standard (OSHA). In addition, since most of the noise generating

equipment would be in closed structures, the noise transmitted outside would be still

lower.

There will be no generation of bad odour as process will be carried out in closed

reactor with auto-operations in the plant.

4.8.6 HAZARDOUS CHEMICAL STORAGE & HANDLING

The raw materials consumed falls under Hazardous chemicals as per the MSIHC

rules, 2000. The details pertaining to the hazardous chemicals in terms of health,

100

m

55

m

Residual sludge of FO

15x25

ETP Waste 40x20

Used & Waste Oil 30x7.50

Process waste (L.W.) & Scrap PTA

30x15

55

m 45 m

Paper waste &

Insulation 15x25

Empty bags/liners 30x20

Empty containers / barrels /

carboys 20x15

INTEGRATED SCRAP

YARD

Gate

01

Gate

02

Spent Catox

15x12.50

Oil & Chemical soak cotton waste

30x7.50

Waste resin, used carbon

catalyst, Mol. Sieve, exp. Chemical & Lead acid battery

15x12.50

Leach

ate Pit

Iron scrap 20x15

PVC material &

Glass 15x12.50

Wooden scrap

15x12.50

53

explosion and fire hazards and measures for storage, handling & transportation will

be considered complying with statutory regulations under the various acts & rules.

All measures shall be taken to minimize the environmental impact during the process.

Table 4-5 Details of Hazardous Chemicals and its storage

Hazardous

chemical

Max.

Storage

Capacity

Place of

storage

Storage

facility

Mode of Transport

Mono Ethylene

Glycol

10000 MT Raw Material

Storage Tank

yard

Tank By road

Titanium Dioxide 120 MT Raw Material

Storage

Bags By road

Antimony trioxide

or Antimony

triacetate

12 MT Raw Material

Storage

Bags/

Container

By road

Paraxylene

(2 tanks)

15000 MT

each

Raw Material

Storage Tank

yard

Tank By road/ Through

pipeline by OMPL

Acetic Acid 1500 m3 Raw Material

Storage Tank

yard

Tank By road

Hydrogen Bromide 20 MT. Raw Material

Storage Tank

Tank By road

Caustic Soda

solution

600 MT Raw Material

Storage Tank

Tank By road

Hydrogen -- -- -- From neighboring

Refinery/ Aromatic plant,

through pipeline

54

4.9 POWER REQUIREMENT

Power plant consisting of 2 nos. of 15 MW each rated capacity which can be able to

generate net 12MW per turbine during performance running at around 35°C. Initially

diesel will be used as main fuel for power generation and changeover to natural gas will

be made as and when gas will be available.

Figure 4-2Flow Chart for Captive power plant and Heat recovery system

55

5. PLANNING BRIEF

5.1 PLANNING CONCEPT

The existing plants of JBF group in India & UAE already manufacture Polyester Chips &

consume PTA as key raw material and demand on PTA based processing of Polyester

chips and Polyester Yarn are increasing internationally. Paraxylene (Px) is a basic raw

material for PTA manufacturing which may be sourced from the aromatic complex being

developed by ONGC Mangalore Petrochemicals in Mangalore SEZ or can be imported,

as the PTA plant is being developed in SEZ. The Mangalore SEZ Ltd. is providing all the

required infrastructure like road connectivity, graded plots, water infrastructure, waste

water collection system, solid waste management system, marine disposal facility for

treated waste water and green belt development. Apart of PTA produced will be used for

PET manufacturing plant being situated adjacent to the PTA plant in Mangalore, the rest

being exported to JBF RAK, UAE.

5.2 POPULATION PROJECTION

The demographic details of the study area are given in subsequent sections while the

summarized information is presented below which highlights information on household,

population, employment, literacy and community structure. The salient features of the

study area are given in table below.

Table 5-1Demographic Summary

S.No Demographic Parameters Details

1. No. of Taluk 1

2. No. Of villages 44

3. no. of urban areas (part of Mangalore) 4

4. Total no. of households 27647

5. Total population 137850

6. Population density 491.02

7. Scheduled castes (%) 8810(6.39%)

8. Scheduled tribes (%) 3325(2.41%)

56

S.No Demographic Parameters Details

9. Literate (%) 102647(74.46%)

10. Main workers (%) 58883(42.71%)

11. Marginal workers (%) 7902(5.73%)

12. Non- workers (%) 71065(51.55%)

5.3 LAND USE PLANNING

Table 5-2 Summary of project

S.NO PROJECT DETAILS EXISTING AS PER EC PROPOSED

1. Land Area 115.3 Acres No change

2. Project Cost Rs. 3566 Crores No Change

3. Proposed Capacity 2.50 million tons per Annum of

PTA, 0.5 million tons per annum

of PET / Polyester Chips, 24 MW

Captive Power Generation

No change

4. Power Requirement Peak Load (MW) 87 No change

Normal Operation

(MW)

24 No change

5. Water Consumption

(KLD)

43,100 No change

6. Domestic Effluent

(KLD)

200 No change

7. Effluent Generation

(KLD)

21600 No change

8. Green belt area 33% area of open land as greenbelt developed by Mangalore

SEZ Ltd.

57

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

5.4.1 PHYSICAL INFRASTRUCTURE

The project with an investment of more than Rs. 3500 crores will bring improvement

in physical infrastructure like roads, electricity, water infrastructure along with

various other developmental activities as per its Corporate Social Benefit strategies.

5.4.2 SOCIAL INFRASTRUCTURE

The project wills provide employment to local youth, thus increasing their standard of

living and thus helping strengthen the social infrastructures of the region.

5.4.3 AMENITIES/FACILITIES

The major facilities provided by MSEZL are

Proper First Aid centre and medical facilities will be provided

Mangalore SEZ is providing the entire infrastructure like road connectivity,

graded plots, water infrastructure, Waste water collection system, solid waste

management system, green belt development, marine disposal facilities for

treated waste water etc.

A dedicated and pressurized fire fighting ring-header along the periphery of

the Units with adequate number of fire hydrants, fixed position monitors,

water curtains, foam nozzles located strategically.

JBF & MSEZL have a mutual aid tie-up in order to contain any hazard

emanating from the Industry.

A number of fire fighting pumps with diesel prime movers backed by

adequate supply of raw water.

Dedicated fire alarm networks with adequate number of fire alarm call points

and emergency telephone handsets throughout the site.

A two-way Public Address (PA) system installed independently in all

production units and also in important service areas.

Adequate supply protective clothing & breathing apparatus will be made

available to all personnel of emergency team.

On-site first aid and treatment centre with round the clock medical attendance.

58

6. REHABILITATION AND RESETTLEMENT (R & R) PLAN

6.1 BRIEF OUTLINE ON THE POLICY ADOPTED

As a part of Rehabilitation and Resettlement measures, MSEZL has provided Project

Displaced Families (PDF) with means for livelihood generation such as sponsoring

Diploma courses in various disciplines such as Electrical& Electronics, Mechanical &

Chemical Engineering, Monetary benefits and allotment of land to re-build their houses,

vocational training for youth and women, providing opportunities for setting up ancillary

industries/ service industries etc.

As part of the Agreement signed with MSEZL , JBF shall provide jobs to about

115Project Displaced Persons nominated by their respective families and certified

by R&R Committee of Mangalore SEZ Ltd. Adequate infrastructure facilities,

viz., housing, medical, education, transportation, communication, playground,

library, canteen, market for the township would be developed (in MSEZ Non

Processing area), so as to avoid strain on the existing infrastructure resources

base, by Mangalore SEZ Ltd.

Social forestry would be encouraged as an income avenue for the local people and

helpful in maintaining the ecological balance.

Awareness programmes for likely hazards viz., fire, explosion and gas leakage

etc. and protection measures of these hazards would be conducted.

Regular safety and environmental awareness programmes would be conducted in

the nearby villages to promote awareness. Periodic health check programmes for

the nearby villages would also be taken up.

59

7. PROJECT SCHEDULE & COST ESTIMATES

7.1 TIME SCHEDULE FOR THE PROJECT

The project was commenced after being accorded with Environmental Clearance from

Karnataka SEIAA and Consent for Establishment (CFE) from Karnataka State Pollution

Control Board. The mechanical completion of the project is forecast for MARCH 2016

and the Pre-commissioning and Commissioning will be complete by JUNE2016.

7.2 ESTIMATED PROJECT COST

Table 7-1 Project Cost Details

Sr. No. Particulars Total Cost (Rs. In

Crores)

1. Civil work 280

2. Plant & machinery 2824

3. Effluent treatment system and stripper column 350

4. Power plant 100

5. Furniture & fixture 2

6. Computer & electronic data system 10

Total 3566

The proposed change converts the idea of turning waste into energy, and also reduce

emission load on the environment

60

8. ANALYSIS OF PROPOSAL (FINAL

RECOMMENDATIONS)

The project will bring in the following benefits for the proposed manufacturing plant

The proposed fuel viz., coal will provide support for uninterrupted Production

with lower down-time and is not likely to be affected by monsoons as compared

to Biomass.

The ash content is lower at about 10% as compared to Indian coal which contains

40% Ash.

The following environmental and societal benefits are expected from the given industry:

This process utilizes a Catalyst based Oxidation process for destruction of

organics and organic halides, CATOX, which eliminates the requirement for the

use of an incinerator.

Local production of PTA/PET/Polyester chips means reduction of import of the

same. Thus saving millions of gallons of fuel used up in shipping every year.

33% green belt being provided by the MSEZ, along with extra green belt

proposed by JBF will help keep the air clean..

Project using raw material from nearby OMPL, decreases the need of transport

and thus fuel usage.

500 people, mostly from the neighboring areas will benefit directly or indirectly

from the proposed Project.

About 115 persons from the rehabilitated families will be recruited by JBF, thus

improving their standards of life.

JBFs will be maximizing its utilization, recycling and reuse of wastes, even

producing energy form the off gas, which will be a highly pro environmental

benefit from the project.

Around 70% of the effluent water will be treated and reused, so it will use lesser

amount of raw water thus making it an additional environmental benefit.

Flexibility of the using Butane-rich Natural Gas as when available, in place of

Furnace Oil, as Fuel. GAIL is laying a pipeline from Kochi.

61

Low NOx burners are used throughout the plant.

Comprehensive effluent treatment plant using both conventional & tertiary

treatment technology to achieve over 70% recycle and improved quality treated

wastewater discharge.

Water consumption is reduced right at the design phase by recycling over 15000

KLD of Condensate, Process and treated water back into the process, which helps

reduce the overall water requirement.

ETP is designed in a way, so as to use the natural gradient of site for flow to

reduce the total no. of pumps required.

Mangalore City’s sewage treated and reused for Industrial purpose.

Advanced British Petroleum technology from Process Licensor to optimize the

overall energy efficiency of the plant reducing total fuel consumption and water

consumption, thereby reducing products’ environmental footprint.

Online analyzers are being proposed for real time stack monitoring.

Variable speed drives are being used.

Methane Gas, generated from Anaerobic Digester, is used to generate about 14

tons per hour of High Pressure Steam (90BarG) to meet about 20% of Process

steam requirements.

Boiler chimney height is proposed for 90meters.

Vapor Absorption machines (VAM) are being used for refrigeration and air

conditioning purposes.

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