CHEMPLAST SANMAR LIMITED
(UNIT 2)
Prefeasibility Report for Proposed Chloromethanes Manufacturing Plant at RS No. 28, Melavanjore, T. R. Pattinam, Karaikal Puducherry UT
MAY 2016
Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m
Envi ronment for Deve lopment
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT QUALITY CONTROL
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 2
CHEMPLAST SANMAR LIMITED (UNIT 2)
Prefeasibility Report for Proposed Chloromethanes Manufacturing Plant at RS No. 28, Melavanjore, T. R. Pattinam, Karaikal Puducherry UT © Kadam Environmental Consultants (‘Kadam’), May, 2016
This report is released for the use of the Chemplast Sanmar Limited (Unit 2), Regulators and relevant
stakeholders solely as part of the subject project’s Environmental Clearance process. Information
provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used
for any other purpose without the written consent of Kadam.
PROJECT DETAILS
Name of
Publication
Prefeasibility report for Proposed Chloromethanes Manufacturing Plant at Survey No.
28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT
Project Number 1624372106 Report No. 1 Version 1 Released May, 2016
Prepared &
Managed By Bijal Kothari &Jitixa Upadhyay Released By Sangram Kadam
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-3001000; F: +91 265 300106
Delhi / NCR
SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,
Sohna Road, Gurgaon -122 002 (Haryana)
E: [email protected];T: 0124-4242430; M:+91-98998-04300
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.
Kadam also believes that the facts presented in the report are accurate as on the date it was written. However,
it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically
disclaims any liability resulting from the use or application of the information contained in this report. The
information is not intended to serve as legal advice related to the individual situation.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT QUALITY CONTROL
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 3
CONTENTS
1 EXECUTIVE SUMMARY ................................................................................. 6
1.1 PROPOSED PLANT FEATURES AND PRODUCTION CAPACITY .............................................. 6
1.2 WATER ................................................................................................... 6
1.3 EFFLUENT GENERATION, TREATMENT AND DISPOSAL .................................................... 6
1.4 POWER REQUIREMENT ................................................................................... 6
1.5 AIR EMISSIONS ........................................................................................... 7
1.5.1 Flue Gas Stacks .................................................................................. 7
1.6 SOLID/HAZARDOUS WASTE GENERATION AND DISPOSAL................................................ 7
2 INTRODUCTION .......................................................................................... 8
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................ 8
2.2 BRIEF DESCRIPTION OF THE PROJECT .................................................................... 8
2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO REGION .............................................. 9
2.4 DEMAND SUPPLY GAP .................................................................................... 9
2.5 IMPORT VS. INDIGENOUS PRODUCTION ................................................................ 10
2.6 EXPORT POSSIBILITY ................................................................................... 10
2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. .......................... 10
3 PROJECT DESCRIPTION ............................................................................. 11
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ................ 11
3.1.1 Type of Project ................................................................................. 11
3.1.2 Interlinked and Interdependent Project .................................................... 11
3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &
PROJECT LAY OUT) WITH COORDINATES ........................................................................ 11
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,
PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 14
3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 14
3.5 PROCESS DESCRIPTION WITH PROCESS DETAILS (SCHEMATIC DIAGRAM / FLOW CHART SHOWING THE
PROJECT LAY OUT, COMPONENT OF THE PROJECT ETC. SHOULD BE GIVEN SALIENT FEATURES OF TECHNOLOGY
14
3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF
FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 17
3.6.1 Raw Materials ................................................................................... 17
3.6.2 Transportation details of Raw Materials .................................................... 18
3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 18
3.7.1 Water consumption ............................................................................ 18
3.7.2 Power Requirement ............................................................................ 19
3.8 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE
BRIEFLY OUTLINED ............................................................................................. 19
3.8.1 Gaseous Emission .............................................................................. 19
3.8.2 Solid / Hazardous Waste ...................................................................... 19
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT QUALITY CONTROL
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 4
3.9 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA
PURPOSE ....................................................................................................... 20
4 SITE ANALYSIS ......................................................................................... 21
4.1 CONNECTIVITY ......................................................................................... 21
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ........................................................ 21
4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 21
4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING
AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE
FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE
HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION
SHOULD BE GIVEN. ............................................................................................. 22
4.1 EXISTING INFRASTRUCTURE ............................................................................ 22
4.2 SOIL CLASSIFICATION .................................................................................. 22
4.3 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 22
4.3.1 Temperature .................................................................................... 23
4.3.2 Wind ............................................................................................. 23
4.3.3 Rainfall ........................................................................................... 23
4.3.4 Cloud Cover ..................................................................................... 23
4.3.5 Humidity ......................................................................................... 23
4.4 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 23
5 PLANNING BRIEF ...................................................................................... 24
5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY
PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ....................................................... 24
5.2 POPULATION PROJECTION .............................................................................. 24
5.3 LAND USE PLANNING (BREAK UP ALONG WITH GREEN BELT ETC.) ..................................... 24
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ................................ 25
5.5 AMENITIES / FACILITIES ............................................................................... 25
6 PROPOSED INFRASTRUCTURE .................................................................... 26
6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 26
6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 26
6.3 GREEN BELT ............................................................................................ 26
6.4 SOCIAL INFRASTRUCTURE .............................................................................. 26
6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ............ 26
6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...................................... 26
6.7 SEWAGE SYSTEM ....................................................................................... 26
6.8 INDUSTRIAL WASTE MANAGEMENT ..................................................................... 26
6.9 POWER REQUIREMENT & SUPPLY/ SOURCE ............................................................. 26
7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 27
7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING
HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS(A BRIEF OUTLINE TO BE GIVEN) .................. 27
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT QUALITY CONTROL
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 5
8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 28
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE
PROJECT TO BE GIVEN) ......................................................................................... 28
8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT.
28
8.2.1 Fixed Capital .................................................................................... 28
9 ANALYSIS OF PROPOSAL ........................................................................... 29
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 6
1 EXECUTIVE SUMMARY
Chemplast Sanmar Limited is the flagship company of Sanmar Group, which is one of the largest
industrial firms in the Southern Part of the India with a Group turnover of Rs. 6,000 Crores per annum.
The Sanmar Group manages many businesses grouped under various industry segments viz., Chemicals,
Engineering, Shipping and Metals.
Chemplast Sanmar already manufactures the Chlorine that is required for the manufacture of
Chloromethanes. The plant will be located at Karaikal, where Chemplast has its Caustic Chlor facility.
Chlorine will be supplied through a pipeline and this is the main reason for choosing this location for the
project. The other main raw material is Methanol and it will be imported or domestically sourced. As
Karaikal Port is in close proximity, it would be easier to import.
1.1 Proposed Plant Features and Production Capacity
The proposed project is for installation of a manufacturing facility for producing Chloromethanes. The
proposed project will be located at S. No. 28, Village Melavanjore, Taluka: Thirumalairayan Pattinam
(TR Pattinam), Dist. Karaikal, Puducherry. The estimated cost of the proposed project is INR 220 Crores.
The Total Production capacity of the proposed site is 53,000 MTPA of Chloromethanes.
1.2 Water
The fresh water requirement after Production startup at new site has been estimated as 1210KLD. Water
source will be underground bore well water. The rejects from the RO treatment of this water will be
sent to the existing Desalination plant of Chemplast Sanmar that can handle this rejects as feed to the
desalination RO.
1.3 Effluent Generation, Treatment and Disposal
The proposed expansion project will generate 15 KLD of sewage. Total 600KLD of industrial effluent
will be generated from the proposed manufacturing activity and RO & DM Rejects.
Domestic Sewage waters will be sent to STP and treated water will be used for gardening.
Effluent will be treated in to remove suspended solids and to remove calcium and magnesium impurities.
This effluent can also be used a feed to the seawater desalination plant of Chemplast Sanmar plant.
The effluent will be used to as feed to the desalination RO reducing the seawater intake to that extent.
1.4 Power Requirement
The power requirement for the proposed expansion facility will be met through Puducherry Electricity
Board. Total estimated electrical load for the proposed manufacturing unit is around 3000 kVA. In
addition, the plant will have one DG set of 500 kVA for emergency power back up during grid failure.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 7
1.5 Air Emissions
1.5.1 Flue Gas Stacks
The Chloromethanes plant will have following sources of emission namely,
Process emission from HCl absorption unit.
Flue gas emission from the proposed Coal based boiler.
Flue gas emission from the incinerator.
Flue gas emission from stack attached to stack attached to the Emergency DG set.
The emission from stacks will be well within the stipulated norms.
Adequate stack height will be provided to all flue stacks, based preferably on the Environment Protection
Rules, or in the absence of specific guidance in regulations, good engineering practice.
1.6 Solid/Hazardous Waste Generation and Disposal
Hazardous Solid wastes generated by the unit will be maintained as per Hazardous Waste
Handling and Trans-boundary Movement) Rules, 2008 and will be disposed off as per the details given
in Schematic Representation of the Feasibility Drawing which give Information of EIA Purpose
A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break
up is attached as Figure 3-2.
.
1.7 Submission
In the light of the above, we would like to state that the proposed Chloromethanes plant will be set up
employing best available engineering practices that would enable to meet the environmental norms
specified. The complete system will be studied for its environmental impacts and the required systems
will be put up to ensure minimal environmental impact.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 8
2 INTRODUCTION
2.1 Identification of Project and project proponent
Chemplast Sanmar Limited is the flagship company of Sanmar Group, which is one of the largest
industrial firms in the Southern Part of the India with Group turnover of Rs. 6,000 Crores per annum.
The Sanmar Group manages businesses that are grouped under various industry segments viz.,
Chemicals, Engineering, Shipping and Metals.
2.2 Brief Description of the Project
The proposed expansion project isfor manufacturing of Chloromethanes. The proposed project will be
located at S. No. 28, Village- Melavanjore, and Taluka: TR Pattinam, Dist. Karaikal, Puducherry UT. The
estimated cost of the proposed project is INR 220 Crores. The Total Production capacity of the proposed
site is 53,000 MTPA. Total plot area for proposed expansion is 31,485m2. The details of production
capacity given below in Error! Reference source not found..
2.2.1 Technology
Chemplast Sanmar Operates a 34000 TPA Chloromethanes Plant at its Mettur Dam facility in Tamil Nadu.
The plant is in operation from 1967. The technology for the proposed project is being sourced from
China. This technology provides for varying composition of the three products viz, Methylene Chloride,
Chloroform and Carbon tetra Chloride. The technology focuses on maximization of Methylene Chloride.
The technology has two steps -
1. Hydro Chlorination - Methanol is converted in to Methyl Chloride Catalytically. The other reactant is
Anhydrous HCl that is obtained as a byproduct from the second step.
2. Thermal Chlorination - The Methyl Chloride is then chlorinated to Methylene Chloride, Chloroform and
CTC. All the three products are formed simultaneously in the reactor. The proportion of formation
depends on the mole ratio of the reactant. More Methyl Chloride favors Methylene Chloride and less
Methyl chloride favors CTC.
After the Thermal chlorination, the Excess Methyl Chloride fed is recovered and then recycled.
Distillation is done to separate the three products into its pure form. The distillation residues (heavy
ends) will be incinerated.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
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2.3 Need for the project and it’s importance to region
Chloromethanes consist of 4 products namely - Methyl Chloride, Methylene Chloride,
Chloroform and Carbon tetrachloride.
Major demand for Chloromethanes are
Methylene is used as a solvent in Pharma industry.
Carbon tetrachloride is used for manufacturing of agro intermediates.
Chloroform is used a solvent in Pharma industry, a key raw material for manufacturing
of refrigerant gas R-22 -->TFE-->PTFE.
Methyl Chloride also finds demand in manufacturing of Pharma intermediates.
With Pharma industry growing in India at an average CAGR of 15%, the demand for Solvents
is estimated to grow at an average rate of 6%.
The total Chloromethane supply from 5 producers in India would be 260 KTPA and current
demand is around 315 KTPA, which is a gap of 55 KTPA. Considering the growth of Pharma
and agro industries, the gap for chloromethane is expected to widen and would invite imports
and loss of foreign exchange to India.
40% of Chloromethane demand is from South India would give us an regional advantage with
an added advantage of in house Chlorine, a key raw material used in manufacturing of
Chloromethane.
2.4 Demand Supply Gap
The following table provides the supply demand gap for the products in India
Table 2-1: Demand Supply Gas
Description Financial Year(Values in TPA)
2014-15 2015-16 2016-17 2017-18 2018-19 2019-20
Domestic Demand
Methylene Chloride 172 200 210 220 230 240
Chloroform 107 107 117 117 108 108
Carbon Tetrachloride 19 20 23 23 23 23
Total Demand 298 327 350 360 361 371
Domestic Supply
Methylene Chloride 112 115 135 135 135 135
Chloroform 87 88 103 103 103 103
Carbon Tetrachloride 18 19 21 21 21 21
Total Supply 217 222 259 259 259 259
Demand - Supply gap
Methylene Chloride 60 85 75 85 95 105
Chloroform 20 19 14 14 5 5
Carbon Tetrachloride 1 1 2 2 2 2
Demand - Supply gap 81 105 91 101 102 112
As the Pharmaceutical Industry is bound to grow over the years, the demand for solvents also will
grow. This phenomenon is seen globally.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 10
2.5 Import vs. Indigenous Production
The entire production will be import substitution.
2.6 Export Possibility
There is certainly possibility of exports, but as given above the domestic market demand is very high
focus will be to sell in the domestic market.
2.7 Employment Generation (Direct and Indirect) due to the project.
During construction phase: 300 – 350 persons
During Operation phase: 120 persons
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
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3 PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects, if any
3.1.1 Type of Project
The proposed project is for manufacturing of petrochemical based processing that is covered under
Category – 5 (f). As interstate boundary of Tamilnadu-Puducherry is less than 1km from project site
hence it will be considered as “A” category project as per new EIA notification vide gazette no. S.O.
1533 dated 14th September 2006.
3.1.2 Interlinked and Interdependent Project
The project is interlinked with the existing Unit of Chemplast Sanmar Limited as the treated effluent,
fresh RO rejects will be fed to the desalination unit. This will reduce the seawater intake of the
existing unit.
3.2 Location (map showing general location, specific location and project boundary
& project lay out) with coordinates
The proposed facility is located at RS. No. 28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT.
The total plot area of the proposed unit is 31,485 m2. Location map of the proposed site is attached as
Error! Reference source not found.. Site lay out map of proposed project is given as Error!
Reference source not found..
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 12
Figure 3-1: Site Location on Google Image with Latitude-Longitude
CHEMPLAST SANMAR LIMITED (UNIT 2) PFR FOR PROPOSED CHLOROMETHANES MFG. PLANT AT
KARAIKAL, PUDUCHERRY UT PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 13
Figure 3-2: Site Layout Map
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PLANNING BRIEF
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 14
3.3 Details of alternate sites considered and the basis of selecting the proposed
site, particularly the environmental considerations gone into should be
highlighted
The main raw material for the project is Chlorine. Chemplast Sanmar Limited manufactures Chlorine in
its existing Chlor Alkali facility at Karaikal. The Chlorine can be supplied through pipeline. In locating
the project adjacent to the existing Chlor Alkali, plant avoids road transport of Chlorine that is risky.
Hence, it is ideal to locate the plant at Karaikal.
3.4 Size or Magnitude of Operation
Chemplast Sanmar Limited (Unit 2) plans to install production plant of Chloromethanes: 53,000 MTPA
Methyl Chloride: 3000 TPA
Chloroform, Methylene Chloride, Carbon Tetra Chloride: 50,000 MTPA
Total plot area for proposed plant is ~ 31,485 m2. 31.29% of the land will be used for green cover
(9853 m2). The estimated cost of the proposed facility is INR 220 Crores.
3.5 Process Description with Process Details (Schematic Diagram / Flow Chart
showing the project lay out, component of the project etc. should be given
Salient Features of Technology
Chemplast Sanmar Operates a 34000 TPA Chloromethanes Plant at its Mettur Dam facility in Tamil Nadu.
The plant is in operation from 1967. The technology for the proposed project is being sourced from
China. This technology provides for varying composition of the three products viz, Methylene Chloride,
Chloroform and Carbon tetra Chloride. The technology focuses on maximization of Methylene Chloride.
This process is based on the methanol as raw material to generate Chloromethanes (CMS), by two
steps:
Hydrochloride reaction: Methanol reacts with HCl to general CH3Cl (hereinafter as C1); and
Chlorination reaction: CH3Cl reacts with Cl2 to generate CH2Cl2, CHCl3 and CCl4 (hereinafter as C2,
C3 and C4 respectively)
Process of CMS plant is very complicate, with very strict operation and control, so need many testing
and controlling points.
System composition
The plant composes of
Hydrochloride reaction unit;
Chlorination reaction unit;
Rectifying unit;
HCl absorbing and cleaning unit;
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PLANNING BRIEF
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 15
Effluent gas washing unit; and
Auxiliary unit like interim tank, steam / condensate recovery system
System Characteristics
The system will fulfill the following main requirements;
The system will be the Best Available Technology (BAT).
The system will be of proven design and safe in operation
The system will be designed for optimum low energy consumption and low effluent.
Basis of Design
Capacity: This project is for manufacturing 100,00 TPA of Chloromethanes (CMS), in which, C2:
30%~70%; C3: 60%~20%; C4: 5%~10%
Operating Time: 8000h
Description of Process
Hydrochloride reaction and chlorination reaction are core units of the plant and process. The
principles are:
Hydrochloride reaction
CH3OH and HCl react in gas phase under Al2O3 as catalyst, to generate C1 and water, the formula is
CH3OH+HCl CH3Cl+H2O
It is an exothermic reaction, and heat is transferred by heat transfer oil. This reaction is happened
withy by reaction as below:
2CH3OH CH3OCH3+ H2O
Dimethyl ether (CH3OCH3) by-product depends on the ratio of HCl and CH3OH in the reactor. If
CH3OH exceeds, then more CH3OCH3 is generated. To increase the conversion and selectivity of
CH3OH to C1, HCl is controlled excessively.
Chlorination reaction
C1 and Cl2 are reacted under ~430°C to generate other CMS mixture, the formula is:
It is a strong exothermic reaction, so to control the temperature of reaction, C1 shall far exceed, and
at same time, most products in this reaction shall be circulated for quenching.
CH3Cl + Cl2 CH2Cl2 + HCl
CH3Cl + 2Cl2 CHCl3 + 2HCl
CH3Cl + 3Cl2 CHCl4 + 3HCl
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PLANNING BRIEF
KADAM ENVIRONMENTAL CONSULTANTS | MAY 2016 16
Units Description
The process composes of
Hydrochloride reaction unit;
Chlorination reaction unit;
Rectifying Unit;
HCl absorbing and cleaning unit;
Effluent gas washing unit; and
Auxiliary unit like interim tank, steam / condensate recovery system.
Hydrochloride Reaction Unit
Raw material CH3OH is evaporated and over-heated, then mixed with evaporated and over-heated HCl
gas. The two materials are reacted in the tubular fixed bed hydrochloride reactor under Al2O3
catalyst. The reaction generates C1 and H2o.
The heat from the reaction is transferred by heat transfer oil. The liquid hot transfer oil is transferred
to CH3OH and HCl over-heater; some evaporated transfer oil from the reactor top shall return to
hydrochloride reactor after transfer oil condenser.
The mater discharged from hydrochloride reactor contents C1, H2O and excess HCl, small amount un-
reacted CH3OH, by-product CH3OCH3. After quenching tower and water cooling, C1 is separated in
gas phase. Then it is transferred in to H2SO4 drying tower, to remove the H2O and CH3OCH3. The
dried C1 is compressed, most part is fed into Chlorination reaction unit, balance part condensed and
stored in crude C1 interim tank, as the buffer material for chlorination unit.
The quenching liquid from quenching tank is 22% HCl (content few CH3OH). It is transferred to acid
stripping tower. CH3OH is recovered at the tower top, condensed, then re-evaporated and transferred
into hydrochloride reactor. 22% HCl is discharged from tower bottom, transferred to HCl absorbing
and cleaning unit.
Chlorination Reaction Unit
C1 from hydrochloride reaction is first mixed with the circulated gas phase CMS for pre-heating, then
reacted with over-heat Cl2 in reactor, to generate polychlorinated methane.
Material from reactor is quenched by liquid from recirculation tower feeding tank, then top gas is
stepwise condensed, cooled and separated by circulation water, -28°C 3rd stage condensed liquid, -
35°C R22 condenser. The condensed liquid is transferred into recirculation tower feeding tank, part of
which is as quenching liquid, while balance is transferred into recirculation tower to recover C1.
Incondensable gas from 3rd stage condenser is HCl mainly, part of which is back to hydrochloride
reaction unit as raw material, while part of which is transferred to HCl absorbing and cleaning unit.
C1 and HCl is the main component of recirculation tower top gas. Part of it is condensed as reflux
liquid for recirculation tower, and balance is back to chlorination reactor. Material discharged from
recirculation tower is mixture of C2, C3 and C4, which is transferred to crude CMS storage tank after
cooling.
CHEMPLAST SANMAR LIMITED (UNIT 2)
PFR FOR PROPOSED CHLOROMETHANES
MFG. PLANT AT KARAIKAL, PUDUCHERRY UT PLANNING BRIEF
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Rectifying Unit C2 rectifying system
Crude CMS is transferred by pump to C2 tower. C3 and C4 are discharged from bottom to crude C3
tank after cooling. Material from C2 tower top is C2 with slight acid, which is transferred into caustic
washing system after cooling. Then it is neutralized by diluted NaOH and phases separated. Top
phase is diluted alkali, and bottom phase is wet neutral C2, which is pumped to azeotrope tower.
Water and C2 azeotropic gas from tower top is condensed and back to phases separator and C2
product is discharged from bottom and transferred into the C2 product-testing tank.
C3 rectifying system
Crude C3 is pumped to C3 tower. Crude C4 is discharged from tower bottom and transferred to C4
storage tank after cooling. Material from C3 tower top is C3 with slight acid, which is transferred in to
caustic washing system after cooling. Then it is neutralized by diluted NaOH and phases separated.
Top phase is diluted alkali, and bottom phase is wet neutral C3, which is pumped to azeotrope tower.
Water and C3 azeotropic gas from tower top is condensed and back to phases separator, and C3
product is discharged from bottom and transferred into the C3 product testing tank.
HCl Absorbing and Cleaning Unit
Part of HCl generated from Chlorination unit, is back to hydrochloride reaction, and balance is
absorbed by process water and 22% HCl (by production in hydrochloride reaction) in falling film
absorber and tail gas tower, to generate 31% HCl. The 31% HCl which content few organics (mainly
C1) is transferred into organics stripping tower. Organics is resolved and mixed with tail gas, back to
chlorination unit after H2SO4 drying, compressing and condensing. 31% HCl after organic removal is
cooled and transferred into storage tank, as by-product. Table 3-1: Input of Chloromethanes
S. No. Input/MT of Product
Raw Materials Quantity (MT/MT)
1 Chlorine 1.2
2 Methanol 0.34
3 Sulphuric Acid 0.024
4 Caustic 0.025
3.6 Raw material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of raw material and finished product.
3.6.1 Raw Materials
Detail of raw material is given in Table 3-2.
Table 3-2: Details of Raw Material
S. No.
Chemical State Consumption (MT/Month)
Means of Storage
Mean Storage Capacity, MT
No. of Storage
Total Storage, MT
1 Methanol Liquid 1500 MS Tank 500 KL 2 1000 KL
2 Sulphuric
Acid (98%) Liquid 210
MS RL Tank
50 KL 1 50 KL
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S. No.
Chemical State Consumption (MT/Month)
Means of Storage
Mean Storage Capacity, MT
No. of Storage
Total Storage, MT
3 Sodium
Hydroxide (32%)
Liquid 225 MS Tank 20 KL 1 20 KL
3.6.2 Transportation details of Raw Materials
Transportation details of raw materials are given in Table 3-3.
Table 3-3: Transportation Details of Raw Material
S. No. Name State Source Mode of Transport
1 Methanol Liquid Imported/local Trucks
2 Chlorine Gaseous Sourced from adjacent
Plant Pipeline
3 Sulphuric acid Liquid Indigenous Trucks
4 Caustic Soda Liquid Adjacent plant Trucks
3.7 Availability of water its source, energy/power requirement and source should
be given
In the proposed project, resource conservation of chemicals and water conservation are inherently
designed for effluent re-use/recycle and hence consumption is optimized. Availability of water its
source, energy/power requirement and source are given below,
3.7.1 Water consumption
Water will be sourced from Bore well. Fresh water consumption will be 1210 KLD. The below Table 3-4 shows the
water consumption and waste water generation figures.
Table 3-4: Water Consumption Details
S. No. Area Water
Consumption in KLD
Effluent Generation in
KLD Treated Effluent Disposal mode
A RO Plant 1210 300 To desalination plant of Existing
Chemplast Sanmar Plant
1 Domestic 20 15 To be treated in STP and then treated
water will be used for Gardening
2 Cooling Tower 700 175
To desalination plant of Existing Chemplast Sanmar Plant after pH
neutralization
3 Floor Washing
& Pump Seal 50 50
4 DM Plant 60 10
a Boiler Make up 50 50
5 HCl Absorption 50 0 To be sold as Byproduct
6 Gardening 30 0
Total 910 600
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3.7.2 Power Requirement
Power will be supplied by Puducherry Electricity Department (PED). During construction phase1000 kVA power will
be required and during operation phase 3000 kVA will be required. In addition, the plant will have DG set of 500
kVA for emergency power back up.
Table 3-5: Fuel Consumption
S.
No.
Stack
Attached
to
Capacity Stack
Nos.
Stack
Height in
meter
Type of
Fuel used
Fuel
consumption
Air Pollution
Control
Measure
1 DG Set 500 kVA 1 11 HSD 125 L/hr Not Required
2 Boiler 360 TPD 1 54 Imported
Coal 100 TPD ESP
3 Incinerator 10 TPD 1 25 HSD
Supplemental
fuel - as and
when required
to get 1200 °C
Water scrubber
3.8 Resource Optimization / recycling and reuse envisaged in the project, if any,
should be briefly outlined
The generation of pollutants associated with the proposed expansion will be in the form of Gaseous
emissions, Liquid effluent, solid waste, and Hazardous waste.
3.8.1 Gaseous Emission
The expansion unit will have following sources of emission namely,
Process emission from HCl synthesis process and Tail Gas Absorption Tower.
Flue gas emission from stack attached to Boiler, Incinerator and DG Set
The emission from stacks will be well within the stipulated norms.
3.8.2 Solid / Hazardous Waste
Hazardous Solid wastes generated will be maintained as per Hazardous Waste (Management, Handling
and Transboundary Movement) Rules, 2008 and will be disposed off as per the details given in
Schematic Representation of the Feasibility Drawing which give Information of EIA Purpose
A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break
up is attached as Figure 3-2.
. Solid wastes like e-waste and bio medical waste will be generated. Details are provided in Table
3-7.
Table 3-6: Hazardous Waste Generation and disposal Details
S. No. Type of Waste Hazardous
Waste Category
Quantity per Year
Source Treatment / Disposal
1 Used Oil & Waste
Oil 5.1 2 KL
Compressors, blowers etc.
to registered recyclers
2 Distillation Residues
20.3 150 MT Manufacturing
Process Incineration
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3 ETP Sludge 34.3 50 MT Filtration and pH
correction
To be disposed off at TSDF operated by Ramky at
Gummidipondi, TN
Table 3-7: Solid Wastes
S. No.
Type of Waste Quantity MT per
Year Source
Collection, Treatment / Disposal
1 STP Sludge 2 Sewage treatment
plant Will be used as manure for
gardening
3.9 Schematic Representation of the Feasibility Drawing which give Information of
EIA Purpose
A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break
up is attached as Figure 3-2.
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4 SITE ANALYSIS
4.1 Connectivity
By Road
The Project site is well connected with Major District Road and easily accessible through National
Highway 45A which is at a distance of 0.3 km Chidambaram at North and Nagapattinam in the South
via Karaikal.
Karaikal connected to various places in neighboring Tamilnadu state by state highways.
SH 147 and SH 200 Connected to Kumbakonam.
SH148 connected to Thiruvarur.
By Rail
There are two nearest railway stations almost at an equal distance from Project site. Thirumalairayan
Pattinam a small railway station at an aerial distance of 3.0 km towards north direction from project
site and Nagore railway station at an aerial distance of 3.0 km towards South direction from project
site. Karaikal port railway yard is just 0.6 km from project side in the Eastern direction having enough
Railway Siding. Karaikal in main railway station in the area located at an aerial distance of 8.0 km
towards North direction from project site. Karaikal has railway connectivity with major cities like
Mumbai, Chennai, Bangalore, Ernakulum and Trichy
By Air
Airport at Trichy is the nearest domestic as well as international airport in the region, located at an
aerial distance of 125 km towards west direction from project site. Trichy has connectivity with Dubai.
Singapore, Kualalampur, Colombo.
Chennai, a very important domestic and International Airport located at an aerial distance of 240 km
towards north direction from project site.
By Water
Karaikal port located in the east direction from project site handled cargoes such as Coal, Pet coke,
raw sugar, and Fertilizer, Cement, Project Cargo and construction materials.
4.2 Land Form, Land Use and Land ownership
The total plot area of the proposed project will be 31,485 m2.The land is already an industrial area.
4.3 Topography (along with map)
Karaikal is on the east coast about 140 kms south of Pondicherry and 300 kms south of Chennai
(Madras) located on the Coromandel Coast of the Bay of Bengal.
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Karaikal is bounded on the North and South by Nagapattinam district of Tamil Nadu state, on the west
by Tiruvarur district (also belonging to Tamil Nadu), and on the East by the Bay of Bengal.
Forming part of the fertile Cauvery delta the region is completely covered by the distributaries of
Cauvery. Covered completely by a thick mantle of alluvium of variable thickness, the lie of the region
is flat having a gentle slope towards the Bay of Bengal in the east. It is limited on the north by the
Nandalar and on the south-east by the Vettar. The group of rocks known as Cuddalore formations is
met with in the area contiguous to Karaikal region in Nagapattinam District.
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ)), shortest distances from the periphery of the
project to periphery of the forests, national park, wild life sanctuary, etc
sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case
of notified industrial area, a copy of the Gazette notification should be given.
Existing Land use pattern: Industrial Area
Distance of Project site from Water Bodies are given in following table.
Table 4-1: Distance of Project Site from Sensitive Areas
Area Distance in km Direction
Bay of Bengal ~ 1.89 E
Puravadaiyanar River ~ 0.4 N
Table 4-2: Distance of Project site from Water Bodies
Water Body Distance in km Direction
Bay of Bengal ~ 1.89 E
Puravadaiyanar River ~ 0.4 N
4.1 Existing Infrastructure
Not Applicable
4.2 Soil classification
Not done.
4.3 Climatic data from secondary sources
The general agro-climate zone of the study area is Semi-Arid.
Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD),
Long Term Climatological Tables, 1961-1990, Karaikal. These tables give useful information about a
region’s weather, since they are collected over a 30-year period.
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4.3.1 Temperature
Mean daily maximum temperature is recorded in the month of May at 39.8°C. January is generally the
coldest month, with minimum morning temperature at 22.0°C. During the post-monsoon months of
October and November, day temperatures remain between 23.6-24.7ºC. In winters, i.e. December,
January and February, average day temperatures remain between 22.0-22.8ºC.
4.3.2 Wind
Table 4-3: Predominant Wind Direction
Predominant First Second Third
Month Morning Evening Morning Evening Morning Evening
January NE NE N N NW E
February NE NE N E NW SE
March E SE NE E SW NE
April SW SE S S SE E
May SW S W SW S SE
June W SW SW S S,NW W
July W SW SW S NW W
August W SW SW S NW W
September SW S W SW S,NW SE
October SW NE W s NW SW
November N NE NE N NW E
December NE NE N N NW E
4.3.3 Rainfall
The total rainfall in year is observed to be 1369.2 mm. Distribution of rainfall by season is 335.1 mm
in winter (December, January, February), 72.7 mm in summer (March, April, May), 261.9 mm in pre-
monsoons (June, July, August, September) and 699.5mm in monsoons (October - November).
4.3.4 Cloud Cover
The area remains cloudy between the months of June – September, which is the active period of the
monsoon season. Cloud cover is 5.4 – 5.8oktas during monsoon season.
4.3.5 Humidity
Most humid conditions are found in the Post monsoons, followed by winter, summer and monsoons in
that order. Mornings are more humid than evenings and humidity ranges from a high of 83 – 86% in
Post monsoon mornings. During monsoon season, in morning humidity remains between 69 – 78%
and in the evening it remains between 66 – 75%.
4.4 Social infrastructure available
The project site is locates about 7 kms from the city of Karaikal where major social infrastructure is
available.
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5 PLANNING BRIEF
5.1 Planning Concept (type of industries, facilities, transportation etc) Town and
Country Planning/Development authority Classification
The entire area is a notified industrial area
5.2 Population Projection
During the Construction and Execution phase of the Project, it is estimated that about 300 - 350
workers will be involved.
Thereafter during the operation phase at the new plant around 100 positions will be created and
employed.
5.3 Land Use planning (Break up along with green belt etc.)
The Proposed Plant is located S. No. 28, Melavanjore, T.R. Pattinam, Karaikal, Puducherry UT, M/s.
Chemplast Sanmar Limited (Unit 2). It is already developed according to Chemical Industrial Use. The
Land use breakup at site is given in Table 5-1.
Table 5-1: Land Use Breakup at Site
S. No. Title Area, m2 % of total Area
1 Processing Area 1850 5.88
2 Storage Area
a Hazardous Chemicals 2400 7.62
b Water Storage 525 1.67
c Fuel Storage 300 0.95
3 Effluent Treatment Plant 600 1.90
4 Boiler 750 2.38
5 Cooling tower 375 1.19
6 DG Sets 200 0.64
7 Roads 3887 12.35
8 Administrative Building 100 0.32
9 Open Space 8570 27.22
10 Greenbelt Area 9853 31.29
11 Warehouse 1500 4.76
12 Utility and Maintenance Section 375 1.19
13 11 KV Yard and Switchgear 200 0.64
Total 31485 100
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5.4 Assessment of Infrastructure Demand (Physical and Social)
The proposed project is located S. No. 28, Melavanjore, TR Pattinam, Karaikal, Puducherry UT. This
site is ~7 km to Karaikal.
Physical Demand:
Water: Water demand will be met from new bore wells.
Electricity: The electricity will be sourced from grid of Puducherry
Machinery: Reactors, Storage tanks, holding vessel, columns, condensers, Chilled Water unit,
scrubbers, and other equipment
Materials and Others: The Raw Material supply will be met by local and other markets. Other
general utilities facilities are available in the area.
5.5 Amenities / Facilities
Following facilities will be made available at site:
First Aid Facility
Hygienic Drinking Water Facility
Green Area
Regular Worker Medical Checkup Facility
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6 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (processing area)
The proposed project is located S. No. 28, Melavanjore, TR Pattinam, Karaikal, Puducherry UT. Total
Plot Area will be of 31,485 m2for proposed project. Appropriate infrastructures are already in place
including approach roads, drainages etc.
6.2 Residential Area (non-processing area)
No residential facility will be provided.
6.3 Green belt
Around 31.29% of total plot area will be developed as greenbelt.
6.4 Social Infrastructure
Canteen, Rest shelter / room, Recreation Room shall be provided.
6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)
Already covered in Section Error! Reference source not found..
6.6 Drinking water management (source & supply of water)
Ground water treated will be used as drinking water.
6.7 Sewage system
Sewage generated will be sent to STP for treatment and treated water will be used for Gardening
within the premises.
6.8 Industrial waste management
Industrial effluent from utilities will be sent to desalination plant of Existing Chemplast Sanmar Plant
for treatment and effluent from reactor washing will be sent to Existing Chemplast Sanmar Plant after
filtration and pH neutralization.
6.9 Power requirement & supply/ source
The power requirement for the proposed expansion will be met through Puducherry Electricity
Department (PED). Total estimated electrical load for the proposed manufacturing unit is around 2000
kVA. In addition, the plant will have DG sets of 500 kVA for emergency power back up during grid
failure.
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7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN
7.1 Policy to be adopted (central/state) in respect of the project affected persons
including home oustees, land oustees and landless labourers (a brief outline to
be given)
Not applicable as rehabilitation and resettlement will not be required.
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8 PROJECT SCHEDULE AND COST ESTIMATE
8.1 Likely date of start of construction and likely data of completion (time schedule
for the project to be given)
24 months from the date of receipt of consent to establish.
8.2 Estimated project cost along with analysis in terms of economic viability of the
project.
8.2.1 Fixed Capital
Below is a brief summary of capital investment at site to develop necessary infrastructure and install
manufacturing capabilities.
Description Value Rs in Crs
Major Equipment cost including utilities 140
Civil, Steel structures and Buildings 20
Piping 15
Electrical 8
Instrumentation 15
Painting and Insulation 2
Detailed Engineering 10
Contingency 10
Total Project Cost 220
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9 ANALYSIS OF PROPOSAL
The project will improve the socio-economic status of the society in the region by generating direct
and indirect employment opportunities. The project will contribute additional revenue to the State &
Central exchequers in the form of taxes, cess, etc.
The anticipated impacts of the project are explained below:
The project related construction activities will benefit the local populace in a number of ways such
as supply of construction laborers – skilled, semi-skilled and un-skilled, tertiary sector employment
and provision of goods and services for daily needs including transport.
The proposed project will provide employment to the skilled as well as un-skilled persons.
The local population will be given preference depending upon their suitability to the job requirement.
Besides direct employment, indirect employment opportunities will also open up.
Social investment in the form of CSR would help improve the healthcare, education, sanitation,
infrastructure and other areas wherein the project proponent would be actively involved as part of
its CSR commitments.
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-3001000; F: +91-265-3001069
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India – 122 002
E: [email protected]; T/F : 0124-424 2430-436
Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m
Envi ronment for Deve lopment