Prefeasibility report QAQC -...

FOR

THE PROPOSED EXPANSION PROJECT FOR THE MANUFACTURING OF BULK DRUGS/FOOD (SORBITOL/GLUCOSE/DRY STARCH/LIQUID GLUCOSE/FRUCTOSE/DEXTROSE MONO

HYDRATE)

Category: 5(f)

OF

KASYAP SWEETNERS LIMITED

Located at: Plot No. 20/C, 20/B, A‐1/5, A‐1/10, 1st Phase,

GIDC Notified Industrial Area, Vapi, Dist‐ Valsad (Gujarat).

Pre‐feasibility Report‐Annexure Kasyap Sweetners Limited

Expansion Project Page 2 Manufacturing : Bulk drug/food product

Project prefeasibility report for obtaining prior Environmental Clearance in terms of provisions of EIA

Notification - 2006

1 Executive Summary:

Name & Location Name of the Project : Kasyap Sweetners Limited Location : Plot No: 20/C, 20/B, A-1/5 & A-1/10, 1st phase, G.I.D.C, VAPI. Pin Code: 396195 Dist. - Valsad (Gujarat) Project

Kasyap Sweetners Limited is located in GIDC notified industrial area, falling under Large Scale category manufacturing products as mentioned under for which the company had obtained Consent To Establish and Operate from Gujarat pollution Control Board.

The company proposes to enhance the capacity & also introduce new similar group of products under the category “Bulk Drug/Food”

Proposed expansion Project Cost: Rs. 13223 lacs. Applicability of EIA notification – 2006

Category as per the amended EIA notification-2006: as existing and proposed products (i.e. “Bulk Drug/Food) are covered under the Category-5(f). Hence, Environmental clearance is required.

As per the EIA Notification the proposed expansion project is covered under category B but due to the applicability of General conditions the same is applied to MoEF for permission.

Submission for obtaining EC under provision of EIA notification 14 September 2006 as amended.

Project Proponent • The company in India comprises of 4 directors • Large Scale Unit

List of finished products & by- products:

Sr. No. Product Capacity, TPM

Existing Proposed Total after expansion

1 Sorbitol/Glucose 2400 -2400 0

2 Sorbitol/Glucose/Dry Starch/Liquid

Glucose/Fructose/Dextros

0 13500 13500



e mono hydrate

Total 2400 11100 13500

Note: We shall manufacture either of the products with maximum capacity of 13500 MT/Month.

List Of By- Products With Monthly Capacity

Sr. No. By-Products Quantity, TPM

Existing Proposed Total After expansion

1 Fibre 327.8 1493.3 1821.1

2 Gluten 128.9 587.2 716.11

3 Germ 152.2 693.3 845.5

4 Grit/Cattle feed 46.8 213.2 260

Manufacturing process is attached as Annexure-3.

Resource Requirement:

Components Existing Total After Proposed expansion

Resources availability

Power, KVA 1500 6000

Will be sourced from Dakshin Gujarat Vij Co. Ltd./Captive generation from steam

Fresh Water, kl/day 999.2 2659 Will be sourced from GIDC water supply dept.

Indian Coal/lignite/Imported coal for Steam Boiler (17 Tons/Hr & 50 Tons/hr)

1.25 9 local dealer

Fuel (HSD) for D.G.Set (Capacity: 1000 & 1250 KVA)

160 360 Will be sourced from

local dealer



Raw material Consumption:

Product Name of RM RM consumption in MT

Per ton of product Per month Existing After Proposed

Expansion

Sorbitol Maize 1.126 2702.4 15201Sulphur 0.00153 3.672 20.655 Enzymes 0.01366 32.784 184.41 Carbon 0.0015 3.6 20.25Filter aids 0.001 2.4 13.5

Hydro Chloric acid 0.00665 15.96 89.775 Caustic soda lye 0.0109 26.16 147.15 Nickel catalyst 0.0007 1.68 9.45

Total 1.16194 2788.656 15686.19 Glucose Maize 1.126 2702.4 15201

Sulphur 0.00153 3.672 20.655 Enzymes 0.00926 22.224 125.01 Carbon 0.0015 3.6 20.25 Filter aids 0.001 2.4 13.5

Hydro Chloric acid 0.00345 8.28 46.575 Caustic soda lye 0.00707 16.968 95.445

Total 3.47369 2759.544 15522.44 Dry Starch Maize 1.485 0 20047.5

Sulphur 0.00226 0 30.51Total 1.487 0 20078.0

Liquid Glucose Maize 1.485 0 20047.5 Sulphur 0.00226 0 30.51 Enzymes 0.01145 0 154.575 Carbon 0.00178 0 24.03

Filter aids 0.001187 0 16.0245 Hydro Chloric acid 0.00409 0 55.215 Caustic soda lye 0.00839 0 113.265

Total 1.514157 0 20441.12 Fructose Maize 1.126 0 15201

Sulphur 0.00153 0 20.655 Enzymes 0.00926 0 125.01 Carbon 0.0015 0 20.25


Total 1.15621 0 15608.84 Dextrose Mono

hydrate Maize 1.485 0 20047.5 Sulphur 0.00226 0 30.51



Enzymes 0.01145 0 154.575 Carbon 0.00178 0 24.03


Total 1.515157 0 20441.12 Water and Waste Water Management

Total Raw Water requirement is 5346 kl/day (Fresh: 2659 kl/day + Recycle from MEE/RO & ion exchange 2687 kl/day) supply will be met from GIDC water supply dept. Copy of GIDC water supply is enclosed herewith.

Total industrial Waste Water Generation is 3311 KL/Day & net waste water discharge after RO/MEE treatment will be 602.1 KL/Day.

Domestic waste water (30 KL/day) will be passed through Septic Tank and overflow will be taken to ETP.

Air Emission and its Control Measures Flue gas emission:

At present, the unit is having one number of 17 TPH steam boiler & one number of 5 TPH (Standby). The company shall install additional one number of Steam Boiler having capacity 50 TPH. Indian Coal/lignite/Imported Coal will be used as fuel. The unit has installed ESP to coal fired boiler.

At present, the unit is having one number of 1000 KVA of D G set (standby). The company shall install additional 1250 KVA capacity of D.G. Set, as stand by. It will be used only during power failure.

Adequate stack height and stack monitoring facilities will be provided.

Process gas emission: • Presently the unit has installed three numbers of two stage water scrubber followed by

alkali scrubber to scrub H2S, SO2 & PM gas generated from the process. After proposed expansion, the unit shall install additional three numbers of two stage water followed by alkali scrubbers to scrub H2S, SO2 & PM gas generated from the process. Adequate height of process vent will be provided. (Details of Air pollution control measures is attached as Annexure-10)



Hazardous Wastes and its Management

Sr. No.

Type of hazardous

waste

Category

Quantity, TPA Place of Storage

Disposal

Existing After proposed expansion

1 Waste from ETP 34.3 216 1212 HDPE bags

TSDF, Vapi

2 Used oil 5.1 0.5 1.5 Drum Sell to registered re-

refiner 3 Discarded

containers 33.3 2.4 12.0 Pallets/dr

ums Sell to

authorized recycler

4 Salt from MEE 34.3 0 4896 HDPE Bags

TSDF, Vapi

5 Spent catalyst 28.2 20.16 113.0 HDPE drums

Sent to actual re-processor

for manufacture of

Nickel salts 6 Spent Resin 34.2 1.2 3.6 HDPE

bags TSDF, Vapi

7 Spent Carbon 35.3 178.2 1693 HDPE bags

TSDF, Vapi or sent to cement industries for co-processing

8 Sludge from wet scrubber

36.1 30 75 HDPE bags

TSDF, Vapi



2. Introduction of Project / Back Ground Information : (i) Introduction of the Project and the Proponent.

Name of the project Proponent: Kasyap Sweetners Limited. Kasyap Sweetners Limited is a large scale unit & is located in notified industrial estate, GIDC, Vapi Dist: Valsad, Gujarat having total plot area of 40626 m2 & total investment after proposed expansion will be Rs. 17747 lacs. The proponent wishes to enhance the existing production capacity as well as introduce similar group of new products. The Bulk drug / Food products are especially used in Oral care & Cosmetics, Food & Beverages and Pharmaceutical industries. The unit is operated by technocrats having more than 30 years of experience in manufacturing and marketing of various Bulk drug/food products worldwide. The company has established well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proposed expansion proposes to expand the capacity of bulk drug /food with total capacity of 13500 MT per month and process capabilities to manufacture all types of bulk drug/food.

The proposed expansion project site lies on 20021’09.26” N Latitude & 72054’46.50” E Longitude. Kasyap Sweetners Limited is located at Plot. No. 20/B, 20/C, A-1/5 & A-1/10, 1st phase area, GIDC Vapi, Dist: Valsad in Gujarat state. GIDC Vapi is centrally located in both sides of National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and Dadra & Nagar Haveli on the eastern side. The western Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with other major cities of the state and the country. Beside the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now a six laned, double tracked, more elevated and Jam free highway, developed by L&T Company. This highway has given a further boost to the economic growth of this area.

The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected to each other by a Pucca road.

About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat – Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for chemical industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals. school, colleges, community centers, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchanges hotels, guesthouses etc. The town has got a major face-lift after the completion of national highway and other links roads are of good standard. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms. The district Head Quarter – Valsad is 30 km from Vapi town.



VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-1968. The entire estate, which was developed in phases, is now spread over 1140 hectares and houses more than 1400 industries, most of which are small-scale industrial units although some have grown bigger units at later stages. The industrial township is basically a declared “Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related, such as, Dyes and Dyes intermediates, pigments pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s largest common effluent treatment plants has been setup in Vapi industrial estate. Being a major industrial & commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.

KASYAP SWEETNERS LIMITED, (KSL) was incorporated in 1986 and is engaged in the business of manufacturing and marketing Bulk Drugs/Food products like Sorbitol, Glucose & Starch since 1988. The company has its corporate office at Marthanda, 84, Dr. A.B. Road, Worli, Mumbai – 400 018 and Manufacturing unit at Plot No. 20B &C, A1/5 & A1/10, 1st phase, GIDC, Vapi Dist: Valsad, Gujarat.

eIdentification of the project proponent

The Company is managed by the promoters and whole time Directors, Shri Siddharth Kasyap , Chairman and Managing Director and Shri Rajiv Gorwara, Executive Director who are ably assisted by Directors Shri V.C.Kothari and Shri Sushil Farabada.

BACKGROUND OF PROMOTERS

Shri Siddharth Kasyap

Graduate in Chemical Engineering and a technocrat with over 12 Years of experience and expertise in operating chemical plant and effectively running the Industry, now leading the team of KSL , Shri Rajiv Gorwara , Executive Director supports him.

Shri Rajiv Gorwara

Graduate in Chemical Engineering is a technocrat with over 25 Years of experience and expertise in operating chemical plant and effectively running the Industry,

Shri V.C.Kothari

Post Graduate in Commerce , LL.B with professional degree in CWA ( Institute of Cost and Works and Accountant) and Diploma Company Secretary Ship.

Shri Sushil Farabada.

Post Graduate in Psychology. Own Large Agricultural Farms and having expertise in farming and Agricultural activities.



(ii) Brief description of nature of the Project :

Kasyap Sweetners Limited proposes the expansion of their production capacity at Plot No. 20/B, 20/C, A-1/5 & A-1/10, 1st phase, GIDC, Vapi-396195, Dist.- Valsad (Gujarat).

The proposed expansion project involves in the production of “Bulk drugs /Food”. As per the amended EIA notification- 2006, the proposed products are covered under category 5(f)- A and hence require Prior Environmental Clearance.

For the proposed project, the company intends to procure the latest technology for manufacturing the products.

(iii) Need for the project and its importance to the country and region :

The proposed project provides a potential growth opportunity for the already running business of the company. The company is engaged in the business of manufacturing of Bulk drug/food. The project would increase the overall export and also increase the foreign revenue. Products are now well established and acceptable in the international markets.

Additional capacities of product range required over & above our existing capacities, as the company expects growth of exports to the extent of 60-70%. Local market is also showing strong growth potential.

(iv) Demand –Supply Gap :

The products have very high specific demand as they are especially used in Oral Care & Cosmetics, Food & Beverage industry & Pharmaceutical industries as a Bulking agent, Humectants & Low Calorie Sweetner.

(v) Imports vs. Indigenous production :

Existing products manufactured in the country will be very much economical compared to imports of the same and also the export of the same will earn extra revenue generation for our county.

(vi) Export Possibility :

Existing products have high export potential. Also these products have very good potential in the local market.

Additional capacities of product range required over & above the unit’s existing capacities, as the company expects strong growth of exports to the extent of 60-70%. Local market also shows strong growth potential.

(vii) Domestic / export Markets :

The company’s products are used in Oral Care & Cosmetics, Food & Beverage industry & Pharmaceutical industries as a Bulking agent, Humectants & Low Calorie Sweetner. These are having very good demand in domestic as well as international markets.



(viii) Employment Generation (Direct and Indirect) due to the project :

There will be very good opportunity of employment generation directly and indirectly due to proposed expansion project. Due to proposed project there will be requirement of manager, supervisor, operator and semi-skilled workers. For this, the company will employ about additional 80 people to fulfill its need to handle the plant. So that 80 people will be directly employed and more than 50 will be indirectly employed.



3 Project Description :

(i) Type of Project including interlinked and interdependent projects, If any :

The proposed expansion project is an interdependent project of the company.

(ii) Location (map showing general location, Specific location, and project boundary & project site layout) with coordinates :

The map showing general location, specific location and project boundary and project site lay out is enclosed as Annexure-1. Plant layout is attached as Annexure-2.

(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted :

• The proposed activity will be accommodated in the notified industrial area having proper industrial infrastructure so; there is no alternate site consideration. Proposed expansion will be carried out in exiting premises only. (Land allotment letter is attached as Annexure-8)

(iv) Size or magnitude of operation :

As per the proposed project cost, the project is covered under Large Scale category of manufacturing industries.

(v) Project description with process details (a schematic diagram/ flow chart showing the project layout components of the project etc. should be given) :

Detailed project description with process details is enclosed as Annexure-3

(vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw Material and finished product :

Detailed raw material requirement along with estimated quantity, likely source, marketing of final products, mode of transport of raw materials and finished products & characteristics of hazardous chemicals are as below:

Details On Product Transportation

Sr. No.

Product Physical State

Dispatch Means of Transportation

1 Sorbitol Liquid Local /export tanker/container

2 Glucose Liquid Local/export tanker/container

3 Dry Starch Solid Powder Local/export Bags/container

4 Liquid Glucose Liquid Local/export tanker/container

5 Fructose Liquid Local/export tanker/container



6 Dextrose mono hydrate

Solid Powder Local/export Bags/container

Details On Raw Material Transportation

Sr.

No.

Substance Physical State

Source of

Supply

Means of Transporta

tion

Distance of supplier

from project site

(km)

1 Maize Solid Gunny bags Road/Rail 300 - 400

2 Sulphur Solid Plastic bags Road 250

3 Enzymes Liquid Plastic Carboys Road 180

4 Carbon Powder Plastic bags Road 1200

5 Filter aids Powder Plastic bags Road 1200

6 Hydro Chloric acid

Liquid Tankers Road 200 -250

7 Caustic soda lye

Liquid Tankers Road 200-250

8 Nickel catalyst

Solid suspension

Plastic Carboys Road 600-700

Safe Storage & Handling Of Hazardous Chemicals

Sr. No.

Raw materials

Qty. Stored maximum MT/M

Storage BP 0C

MP0C

Standard operating Pressure & temperature

Possible Type of Hazards

Control Measures Provided

Maximum

Actual

1 Hydrochloric Acid

333 80 HDPE TANKS

53 ‐74 Atmosphere pressure & Room temperature

SKIN & EYE IRRITATION

EYE WASH WITH SHOWER

2 Caustic Soda

200 50 MILD STEEL

141 ‐ Atmosphere pressure

SKIN & EYE

EYE WASH



Lye STORAGE TANKS

& Room temperature

IRRITATION

WITH SHOWER

3 Hydrogen gas

1350000 NM3

nil CYLINDERS

‐252 ‐259

35 ‐ 40 Kg/cm2 & 130‐140 'C

INHALATION HAZARD AFFECTING LUNGS & CNS

EYE WASH/ PROTECTIVE CLOTHING

(vii) Resource optimization/ recycling and reuse envisaged in the project , if any , should briefly outlined :

Resource optimization/recycling and reuse envisaged in the project (Methane gas recovery system) in detail are as mentioned below;

• Maize is our major raw material & the leachate that comes out after the steeping process is called Corn Steep Liquor (CSL). This CSL is highly bio-degradable & Methane Gas is generated by passing this effluent through an Anaerobic Bio-Digester. This Methane Gas is utilized as a fuel in our driers thus resulting in good savings in terms of oil.

• Reverse osmosis plant will be installed in lieu of DM plant (to reduce reject water generation) for boiler feed and ion exchange resin washing. This will also reduce overall TDS in the system.

• Reject water from RO will be used in floor washing and toilet flushing. • Treated effluent will be used for gardening, thus reducing fresh water

consumption. • Efficient cooling towers are being planned to reduce evaporation losses. • Generated biogas duly sulphur scrubbed will be used for replacing coal in boiler

or power generation. • State of art sludge dewatering system will be installed and no additional sludge

drying bed will be constructed. • RO and MEE/WHE will be installed to reuse the treated effluent and no

additional treated effluent generated will be discharged to CETP after proposed expansion

(viii) Availability of water its source, Energy/power requirement and source should be given :

Availability of water its source, Energy/power required and its source is below. Water withdrawal Permission is attached as Annexure: 4



Water Consumption (M3/Day)

Sr. No.

Particulars Existing Proposed After Proposed expansion

Remarks (Recycle water)

1 Domestic 12.0 28.0 40.0 2 Processing &

washing 700.8 3187.2 3888.0 Recycled

(1269) 3 Cooling 183.4 386.6 570.0 Recycled

(570)4 Boiler 50.0 470 520.0 Recycled

(520) 5 Scrubber 50.0 228 278.0 Recycled

(278) 6 Floor/equipment/co

ntainer washing 3.0 17.0 20.0 Recycled

(20) 7 Gardening &

fire/safety 0 30.0 30.0 Recycled

(30) 8 Total 999.2 4346.8 5346.0 9 Condensate from

MEE/Permeate from RO recycle

0 2687.0 2687.0

10 Net fresh water 999.2 1659.8 2659.0 Note: Water consumption is calculated for the product which requires maximum water (i.e. Sorbitol)



WATER BALANCE DIAGRAM AFTER PROPOSED EXPANSION

Energy Requirements And Its Source

Sr. No.

Particulars Existing Proposed Source

1 Steam requirement

17000 kg/Hr

67000 Kg/Hr. Will be obtained by installation of Boiler having steam generation capacity of 17 TPH & 50 TPH

Power Requirements And Its Source

Sr. No.

Particulars Existing After proposed expansion

Source

1 Power – Electricity requirement 1500 KVA 6000 KVA Will be sourced from

Dakshin Gujarat Vij Co. Ltd./ Captive

generation from Steam

& gas



(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

Management/disposal :

Quantity of waste to be generated (liquid and solid) and scheme for their Management/ disposal is enclosed as Annexure-5.

(x) Schematic representation of the feasibility drawing which give information of EIA purpose: A Schematic representation of the feasibility drawing is enclosed as Annexure: 9

4. Site Analysis (i) Connectivity :

The project is located in notified Industrial Estate of Vapi which is very well connected to National Highway no.8 and Western Railways. The nearest airport is Mumbai which is 150 KM away from the project site by road.

(ii) Land Form, Land use and Land ownership :

The land is in the form of industrial shed owned by Gujarat Industrial Development Corporation.

(iii) Topography (along with map) :

Topography map showing the elevation of the study area below. The topographical map is enclosed as Annexure-7.

(iv) Existing land use pattern (agriculture, non-agriculture, forest , water bodied ( including area under CRZ)), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary , eco sensitive areas, water bodies (distance from the HFL of the river), CRZ . In case of notified industrial area, a copy of Gazette notification should be given :

The existing land is located in the notified industrial area and a copy of gazette notification is enclosed as Annexure-8

(v) Existing Infrastructure :

GIDC notified industrial area of Vapi has available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.

(vi) Soil classification :

General soil classification of the area is as under :

• Soil Characteristics & Land use classification: The study area is located at outer part of Dadra. Northern part of the site is fully developed for settlement with cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.

• The project site around 10 km radius has mixed soil type of Basalt soil and Clay soil. This type of soil is not suitable for cultivation purpose.

• The land is suitable for industrial development.



Damanganga River is located at 3 km distance from the site location, both side of the river has mixed soil type (Sand, clay & Basaltic soil).

(vii) Climate data from secondary sources :

Rainfall Data : The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days having coefficient of variation of 65 %. There is large spatial and temporal variation in rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are comprised of Kutch district and western parts of Banaskantha and Patan districts and parts of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid climate. The remaining part of the state receives rainfall between 500-1000 mm and generally falls under semi-arid climate. Considering the abnormality of weather particularly rainfall during the monsoon period, the observed and predicted rainfall was then analyzed for its validity.

Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)

Sr.

No

Region Rainfall Projection

(in mm) June – Oct

Normal Rainfall (In mm)

Rainfall Projection

(% Departure from normal)

1 Middle Gujarat 905.3 796 13.7

2 South Gujarat 696.3 575 21.0

3 Project site 2071.7 1433.7 44.5

4 Saurashtra 767.1 580.4 32.2

5 Gujarat State 1110.1 846.5 31.1

Source: AAU, Anand, Gujarat

Temperature Data: The site is located in the southern part of Gujarat. The secondary data was collected from free data of Worldclim.org for the year 2010. The project site temperature regime for medium to high level temperature (30-32 °C) during the seasonal months (June to Sep).

(viii) Social Infrastructure available :

Social Infrastructure in Valsad district is as under :

Education: There are 990 primary, 161 secondary and higher secondary schools.

There are 6 ITIs offering several industrial training Institutes programs which includes, fitting, armature & motor rewinding, electrician, information technology and electronic system maintenance etc., 166 Higher Secondary School, One Government polytechnic College is present in the district offering courses in civil, chemical, electrical,



mechanical and plastic engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nos of Polytechnic College With 120 seats, there is one Engineering College, Pharmacy College, Arts, Commerce, Science, B. Ed and Law College. Valsad district also has institutes which offers management studies with fulltime MBA.

Source: Department of Education, 2007

Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10 Government and 1 Municipal hospital present in the district. Valsad has several private specialized hospitals to provide a comprehensive range of tertiary and secondary care services backed by state-of-the-art technology and trained medicos. A multi-specialty Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, providing services in general and laproscopic surgery, trauma, orthopedic and urology etc. The hospital is one of the few centers in India offering Uterine Thermochoice Thermal Balloon Therapy for Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such as, Kasturba Hospital, Bhatia General Hospital and Adarsh Hospital are also present in Valsad.

Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage center throughout the world. Dharampur is surrounded on three sides by the Sahyadri Mountains which grace the town with pleasant climate throughout the year. The collection at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights the local culture. Besides this, District Science Centre is also present in Valsad Proximity of Valsad with Daman & Diu, which has increased the graph of tourist flow in the district.



5. Planning Brief :

(i) Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification :

There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like pharmaceuticals, dyes and chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi.

(ii) Population Projection :

• Not applicable

(iii) Land use Planning (breakup along with green belt etc) :

The existing as well as proposed expansion project is located within the Notified Industrial Area by Government of Gujarat and due to the proposed project there will not be any change in the land use pattern of the region. Proposed Green belt planning in the project area is as below.

For Green Belt Development as per the revised layout plan, the company proposes 33.2 % green belt of the total land, i.e. 40626 sq. meter. The company shall develop green belt along the periphery of the proposed site and in common premises available outside the company premises. While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

1. Climatic condition and soil characteristics of the region. 2. The air pollution emitted by the industry – gaseous and particulate matter. Plant

interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.

3. Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.

4. Height of the plants should not be too high to be lethal. 5. For absorbance of gases, the duration of the foliage should be longer. 6. Vegetation controls soil erosion rates significantly. The decrease of water erosion

rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.



Site Plan with Area Table at Existing & after proposed expansion

Sr. No Particulars Area in m2

Existing Proposed Total

1.0 Total Plot Area 40626 0 40626

1.1 Production Plant 6119 4000 10119

1.2 Green Belt 1000 12500 13500

1.3 Raw Materials Storage 200 200 400 1.4 Building Go Down 432 518 950 1.5 ETP 1800 3200 5000 1.6 Utility 810 1190 2000 1.7 Roads 3000 2000 5000 1.8 Solid Waste Storage 250 500 750 1.9 Canteen 0 150 150 1.10 Admin Building/ R&D/Toilets 200 425 625 1.11 Security / Weighbridge Cabin 10 10 20 1.12 Open Space 26805 -24693 2112



Site map with Green Belt Development Planning

(iv) Assessment of Infrastructure demand ( Physical & Social) :

There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion.

(v) Amenities/ Facilities :

GIDC notified industrial area of Vapi has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.



6. Proposed Infrastructure :

(i) Industrial Area (Processing Area).

The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety.

(ii) Residential Area (Non Processing Area) :

No residential area is involved in the proposed expansion project

(iii) Green Belt :

Green belt will be provided and maintained at the tune of 33.2% of the total land area.

(iv) Social Infrastructure :

Not applicable

(v) Connectivity (Traffic and Transportation Road/ Rail/ Metro/ Water ways etc) :

The project site is very well connected by road through National Highway no. 8, western railways.

(vi) Drinking Water management ( Source & Supply of water ) :

Source of water is from GIDC water supply services.

(vii) Sewerage System :

GIDC has provided sewerage system to dispose the sewage effluent.

(viii) Industrial Waste Management :

• Industrial liquid effluent generated during the manufacturing of proposed products will be treated in the primary, Anaerobic, aerobic & tertiary ETP. Out of which partially treated in RO followed by MEE in proposed RO & MEE system & partially treated effluent will be discharged through GIDC underground drainage to CETP.(Membership certificate is attached as Annexure-6)

• Generated domestic liquid waste is being disposed off through septic tank to ETP.

(ix) Solid/Hazardous Waste Management :

Sr. No.

Type of hazardous

waste

Category

Quantity, TPA Place of Storage

Disposal

Existing After proposed expansion

1 Waste from ETP 34.3 216 1212 HDPE bags

TSDF, Vapi

2 Used oil 5.1 0.5 1.5 Drum Sell to registered re-refiner



3 Discarded containers

33.3 2.4 12.0 Pallets/ drums

Sell to authorized recycler

4 Salt from MEE 34.3 0 4896 HDPE Bags

TSDF, Vapi

5 Spent catalyst 28.2 20.16 113.0 HDPE drums

Sent to actual re-processor

for manufacture of Nickel

salts 6 Spent Resin 34.2 1.2 3.6 HDPE

bags TSDF, Vapi

7 Spent Carbon 28.2 178.2 1693 HDPE bags

TSDF, Vapi or sent to cement

industries for co-

processing 8 Sludge from wet

scrubber 36.1 30 75 HDPE

bags TSDF, Vapi

(Membership certificate is attached as Annexure-6)

(x) Power Requirement & Supply / Source :

Power requirement for proposed project will be taken from DGVCL/Captive generation from Steam.

7. Rehabilitation and Resettlement (R&R) Plan: (i) Policy to be adopted (Central/ State) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be given):

There will be no rehabilitation and resettlement undertaken as labours and workers from local & nearby areas for the proposed construction activity which will be minor as the proposed expansion activity is to be undertaken at the existing site.

8. Project Schedule & Cost Estimates :

(i) Likely date of start of construction and likely date of completion ( Time schedule for the project to be given ) :

After obtaining Environmental clearance and Consent to Establish from GPCB, the company shall start the proposed construction and commissioning of the project.



(ii) Estimated project cost along with analysis in terms of economic viability of the project :

Estimated project cost along with the analysis in terms of economic viability of the project is given as below.

Capital Cost Projection

S.NO. PARTICULARS COST IN Rs.(Lacs) Existing Proposed Total 1.0 Land 732 0 732

2.0 Building 797 2495 3292

3.0 Plant & Machinery 2610 8448 11058 3.1 Equipment & Machineries 1738 5738 7476

3.2 Pipes & fittings 259 710 969

3.3 Utilities 613 2000 2613

Total 4139 10943 15082

4.0 Environmental Management System

4.1 Effluent Treatment Plant 250 1780 2030

4.2 Air Pollution Control 125 400 525

4.3 Hazardous waste 10 100 110

5.0 Total Project Cost 4524 13223 17747 6.0 Utilities

6.1 Steam Boiler, TPH 17 50 67

6.2 Cooling Tower, TR 1500 6000 7500

6.3 Chilling Plant, TR 0 50 50

6.4 D.G. Set (Standby), KVA 1000 1250 2250

7.0 Power from DGVCL, KVA 1500 4500 6000

8.0 Fuel

8.1 Lignite/Steam Coal/Imp. Coal MT/day 30 200 230

8.2 HSD, Kgs/hr 160 200 3609.0 Fresh Water from GIDC, Vapi,

M3/day 999.2 1659.8 2659

10.0 Waste water ,M3/day 602.1 0 602.1



Project Viability

Sr .No. PARTICULARS AMOUNT (INR LACS)

1st YEAR 2nd YEAR

3rd YEAR

90% 95% 100%1 Proposed Sale 51840 58320 61560

2 Raw Material Cost 30812 34664 37160

3 Power & Fuel 5054 5686 6002

4 Labour Cost 900 990 1089

5 Environmental System 244 254 264

6 Maintenance Cost 480 540 570

7 Selling, Packing & Office Expenses

4642 5214 5516

8 Proposed Profit 5206 6062 6465

The company will provide budgetary provision for the recurring expenses for environmental issues while planning the allocation of funds during the annual budgetary planning.

Recurring Cost Per Annum

Sr. No. Component Proposed (Rs. in Lacs/annum)

1. Environment & Safety Management System 120

2. Greenbelt Maintenance 6

3. Solid waste Disposal 118

Total 244



9. Analysis of Proposal ( Final Recommendations): (i) Financial and social benefits with special emphasis on the befit to the local people

including tribal population, if any, in the area:

Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare.

• Local people will get direct financial benefit by way of employment.

• Local people will get some contracts of supply and services to get indirect income.

• Company will contribute in improving education and health facilities in nearby area.



ANNEXURES



ANNEXURE: 1

Location map showing the Project site and inter-state boundary within 10 kms radius



Prefeasibility Report‐Annexure Kasyap Sweetners Limited.

Expansion Project: 30 Manufacturing : Bulk drug/Food product

ANNEXURE: 2

Plant Layout



ANNEXURE: 3

Detailed project description with process details ‐ MANUFACTURING PROCESS

(1) SORBITOL

Maize is processed by wet milling process under which maize first undergoes cleaning and steeping by controlling temperature of SO2 water wherein maize gets softened up to the required condition.

This steeped maize is first grinded in a series of grinders to get maize germ. Germ gets separated from the slurry by density difference and maize slurry is then fine grinded to get fine particles of starch, gluten and fiber. Fiber is then separated by high pressure filtration through special screens. Later the Grit content in Fiber is also separated as a separated cattle feed product.

Starch gluten slurry mixture is then passed through a primary centrifuge, where starch gets separated from gluten. Gluten is collected through filter press. Starch slurry is then passed through Hydro-cyclone system where counter water is given to the starch slurry to remove remaining protein impurities and produce final starch slurry.

This starch slurry (on alternate starch powder) is subject to liquefaction by adding Enzymes and chemicals under certain process conditions.

This slurry is passed through jet Cooker with steam and converter pipe where liquefaction takes place.

The liquefied slurry is given certain retention time in Dextrination vessels where starch start getting converted to dextrin.

This Dextrinated slurry is allowed to age and saccharify in Tanks by adding another enzyme. After complete saccharifcation activated charcoal and filter aids are added in solution and filter through filter press. Filter liquid is then allowed to pass through Ion Exchange Columns. In Ion Exchange Columns, different types of resins work according to their nature.

Ion Exchange Resins are regenerated by acid & alkali i.e. by HCL & NaOH. During regeneration they absorb acid impurities from S. H. solution. Due to friction and handling some percentage of Resin becomes fine and gets loss. This is to be made up from time to time by new resin.

The ion Exchanged material is then stored in holding tanks and concentrated to the desired concentration in evaporator. The concentrated starch Hydrolysis solution is hydrogenated in Sorbitol plant. For this purpose SH solution (or alternate DMH) is mixed with catalyst and promoter and feed into Autoclave where S. H. solution or DMH solution reacts with Hydrogen at high pressure & temperature and Sorbitol is formed.

During Hydrogenation some catalyst becomes fine & goes along with Sorbitol

Therefore some quantity of fresh catalyst is added in every batch.

After double settler, material is taken for carbon treatment where activated carbon or earth & filter aid are added and the material is filtered through filter press. Filtrate is collected in



holding tank. This carbon treated material is passed through Ion Exchange for the removal of ionic impurities.

This impurity free dilute Sorbitol is concentrated up to 70 % w/w The concentrated material is taken into holding tank to enable it to get homogenized and for final adjustment.

This product is analyzed in Laboratory. After getting quality approval from lab., this final product is filled either in tanker or in drum (HDPE OR MS epoxy) and weighed.

(2) GLUCOSE





This slurry is passed through jet Cooker with steam and converter pipe where liquefaction take place.




The Ion-Exchanged material is then stored in holding tanks and concentrated to the desired concentration in evaporator.

This product is analyzed in Laboratory. After getting quality approval from lab., this final product is filled either in tanker or in drum (HDPE OR MS epoxy) and weighed.



(3) DRY STARCH


This steeped maize first grinded in a series of grinders to get maize germ. Germ gets separated from the slurry by density difference and maize slurry is then fine grinded to get fine particles of starch, gluten and fiber. Fiber is then separated by high pressure filtration through special screens. Later the Grit content in Fiber is also separated as a separated cattle feed product.


This starch slurry is centrifuged and the cake is dried in a flash dryer. The starch powder is sieved and then bagged and weighed.

(4) LIQUID GLUCOSE




Starch slurry obtained from the starch plant is adjusted to the required pH value by addition of either Hydrochloric acid or Caustic Soda lye, as the case may be and dozed with adequate quantity of Liquefaction enzyme (Alpha Amylase enzyme).

If Starch (dry powder) is used then a suspension of it is formed in water to make starch slurry. The enzyme mixed starch slurry is processed through a Jet cooker in presence of high pressure steam at a temperature of 105 to 108 degree Celsius. The liquefied starch is allowed a resident time of about 100 minutes before it is taken into pH adjustment tanks.

Here it is ensured that there is no starch present and when this is done then little quantity of hydrochloric acid is mixed in the liquor and it is cooled to 60 degree Celsius temperature.

Then another Enzyme called Saccharification enzyme (Gluco Amylase enzyme) is added and the dextrose equivalent of the liquor is allowed to increase to the desired level. This is usually in the range of 30% to 50% wt/wt.

After achieving the desired percentage of dextrose equivalent, this dilute liquor is subjected to the purification operations. First it is treated with activated carbon at 80 degree celsius



temperature and filtered through press using filter aid to facilitate the filtration. The colour and the insoluble impurities are thus removed here. The liquor is then subjected to the Ion exchange operation where it is passed through a series of Cation, Anion and a resin Mixed bed column. The soluble impurities are removed here. The reins of the cation, anion and mixed bed columns are regenerated after every cycle by means of hydrochloric acid and caustic soda lye.

The clear, but dilute liquor is then subjected to the concentration operation which is done in triple effect evaporators (using Steam) where-in the excess water is removed (and re-used) and the concentration of glucose is set as per the requirement. In order to make Liquid glucose the solution is further concentrated in a single effect evaporator to the desired level and then packed either in HMHDPE drums or in stainless steel tankers.

(5) FRUCTOSE:









The Exchanged material is then stored in holding tanks and concentrated to the desired concentration in evaporator.



This Concentrated glucose is passed through a Resin bed to obtain Fructose. The Crude Fructose so obtained is once again ion exchanged and evaporated to desired concentration and is packed in drums/tankers as final product.

(6) DEXTROSE MONO HYDRATE:









The Exchanged material is then stored in holding tanks and concentrated to the desired concentration in evaporator.

This concentrated glucose is subjected to crystallization in a crystallizer using chilled water as cooling medium. The crystals are then centrifuged, dried in a drier & then packed in HDPE bags as final product.



PROCESS FLOW CHART FOR SORBITOL AND OTHER INTERMEDIATES

HYDROGENATION

THROUGH RESIN BED

CRYSTALLIZATION

DRYING

CONCENTRATION

JET COOKING SACCHRIFICATION

DRYING

MAIZE PROCESSING

STARCH SLURRY

GLUCOSE

SORBITOL

DRY STARCH POWDER

DEXTROSE MONO-HYDRATE

LIQUID GLUCOSE

FRUCTOSEE



MASS BALANCE

1.0 MASS BALANCE DIAGRAM FOR MAIZE TO SORBITOL/1

MAIZE 1115.2, MOISTURE 119.49, D.S 995.74

MAIZE CLEANING SYSTEMMAIZE 1126 HANDLING LOSS 11.26

SO2 WATER SO2 3.06 KG WATER 1137

SO2 GAS 3.06 KG

SULPHUR FURNACE

SULPHUR 1.53 AIR

PROCESS WATER 1723 FOR GLUTEN SEPARATION

STARCH PLANT

STARCH SLURRY WATER 1592.5 D.S 677.1 TOTAL 2269.6

STEEPING VATS

GLUTEN WATER 6.57 + D.S 54.8

GERM: WATER 7.77 + D.S 64.7

FIBER: WATER 481.39 + D.S 139.4

CATTLE FEED/GRIT: WATER 2.39 + D.S 19.9

CORN STEEP LIQUOR TO ANAEROBIC DIGESTOR D.S 39.83COD 39.83BOD 13.14WATER 593

WATER LOSS DUE TO EVAPORATION/DRYING OF 295.69

Steam 201

Steam Loss 11

Steam Condensate 106

Dryer

Steam 111.5

Steam condensate 190



STARCH HYDROLYSATE / GLUCOSE/DEXTROSE

1.1 MASS BALANCE DIAGRAM FOR MAIZE TO SORBITOL/2

ENZYME MIXINGENZYMES 4.4

VENT STEAM LOSS 119.4LIVE STEAM 269

ENZYMES 4.86

CARBON 1.5

FILTER AIDS 1.0

FRESH WATER 3766

CARBON TREATMENT

JET COOKER

SPENT CARBON + FILTER AID + PROTEIN + WATER 1.5 +1 + 4.4 + 1.97 + 10.84

WATER 4371 + 26.46 KG DS = 4397.5 TO ETP

EVAPORATION LOSS 303

SACCHRIFICATION

ION EXCHANGE

19.71 SOLID WASTE WET BASIS

NaOH 7.07 HCL 3.45 WATER 4371 CONCENTRATION

IN TEE D.S 716.04 WATER 762.56 TOTAL 1478.6

VAPOR CONDENSATE 605

DS 716 WATER 1670.8 TOTAL 2386.9

Steam condensate 410Steam 432

Steam 100

Steam condensate 95



























ANNEXURE: 4

Water requirement letter from Notified industrial estate:



ANNEXURE: 5

Quantity of Waste water (liquid waste) generated and its management:

Sr. No.

Particulars Existing Proposed After Proposed expansion

1 Domestic 7.0 23 30.0 2 Processing &

washing 577.3 2356.7 2934.0

3 Cooling 8.2 117.8 126.0 4 Boiler 13.6 76.4 90.0 5 Scrubber 0 111 111.0 6 Floor/equipment/co

ntainer washing 3 17 20.0

7 Gardening & fire/safety

0 0 0

8 Total 609.1 2701.9 3311 9 Net discharge to

CETP 602.1 0 602.1

10 Recycle RO/MEE treated water

0 2687 2687

Note: Waste water generation worked out based on maximum pollution load of product i.e. Sorbitol.



Details Of Effluent Treatment Plant With Proposed Modification

Product : Bulk Drug/Food Source of effluent : Process, washing & utilizes Design flow of effluent : 3311 kl/day Design parameter : As under

Sr. No.

Parameters Combined untreated effluent

1 pH 8.32

2 Colour, pt. Co. 300

3 Temperature, 0C 32

4 SS, Mg/L 638

5 BOD, Mg/L 7180

6 COD, Mg/L 12390

7 NH3 N, Mg/L 19.8

8 Sulphide, Mg/L 0.78

9 Oil/grease, Mg/L 7.20

10 Nickel, Mg/L 1.92

Based on the above criteria effluent treatment plant having under mentioned specification is required to install: Details Of Effluent Treatment Plant With Specification: Sr. No.

Name of the unit

Dimension in meters

Capacity, M3 MOC

Existing Proposed Total after modification

1 Collection tank 8 x 7 x 2 + 8 x 6 x 2

212 900 1112 RCC

2 Equalisation tank

8 x 8 x 3.5 224 0 224 RCC

3 NaoH Dozing Tank

- 0.1 0.1 0.2 HDPE

4 HCL Dozing Tank

- 0.1 0.1 0.2 HDPE



5 Polyelectrolyte Dozing Tank

- 0.1 0.1 0.2 HDPE

6 Flocculator 1.8m dia x 2m.ht

6 24 30 MS

7 Primary Clarifier 8m dia x 3.5m.ht

175 500 675 RCC

8 Buffer Tank 5m dia x 2.5 m.ht

50 400 450 RCC

9 Digester 16m dia x 7.5 m.ht & 19.5 diax 10 m ht

4400 3000 7400 RCC

10 Methane Gas Holder

5m dia x 3.0 ht 50 100 150

11 Sludge Drying Beds

8 x3m x7nos 168 0 168 Bricks

12 Filter press - 0 36 x 36 36 x 36 PP

13 Aeration Tank-1 with diffused aeration system

9 x 9 x(4.0+1.5) 567 3500 4067 RCC

14 Secondary Clarifier-1

19m dia x 3.5 m.ht

175 800 975 RCC

15 Aeration Tank-2 with diffused aeration system

9 x 9 x(4.0+1.5) 405 0 405 RCC

16 Secondary Clarifier-2

8m dia x 3.5m.ht

175 0 175 RCC

17 Final Polishing Aeration Tank

421 1000 1421 RCC

18 Carbon Bed 1.6m dia x 2.5m.ht

10 20 30 MS

19 Sand Bed 1.6m dia x 2.5m.ht

10 20 30 MS

20 Holding tank 10 x 10 x5 0 500 500 RCC

21 RO - - 2739 Kl/day

2739 Kl/day PP/FRP

22 MEE - - 274 Kl/day

274 Kl/day SS



Brief process of ETP:

1. PRIMARY TREATMENT: All the effluent generated from plant is collected in underground Collection Pits. It is then pumped into equalization where the pH becomes homogeneous. This effluent is taken into a Primary Clarifier for removal of suspended solids. The clear effluent then travels to Buffer Tank which is the feed tank to the anaerobic Bio-Digester.

2. ANAEROBIC TREATMENT: The raw effluent having high COD/BOD values enters the Bio-Digester. The Anaerobic microorganisms degrade the effluent & thereby Bio-gas is generated. The generated bio-gas is collected thru hoods at the top of Digester & is taken thru Foam Trap & Sediment Trap into a Gas holder.

3. SECONDARY TREATMENT (BIOLOGICAL TREATMENT): The partially treated

effluent travels to the Aeration tanks. Due to biological action of the aerobic microorganisms,

the effluent gets further treated & is taken into a collection tank thru Secondary Clarifiers.

The clarifiers do the job of settling the sludge that has got carried over from the Aeration

Tanks.

4. TERTIARY TREATMENT: The effluent from the Secondary Treatment plant is further

treated in the Tertiary treatment plant to reduce COD/BOD levels to as low as 250 / 30 mg/l.

In this tertiary treatment the TSS gets reduced to less than 100 ppm.



Flow Diagram Of Effluent Treatment Plant



Process Flow Diagram Of Proposed Revesrse Osmosis Plant



Details Of Proposed Reverse Osmosis Plant

Average Flow: 2709 M3/Day





Process Of Proposed Multi Effect Evaporator



Details Of Proposed Multi Effect Evaporation System

Average Flow: 270.9 M3/Day





ANNEXURE: 6

Membership Certificate of CETP, Vapi



Membership Certificate of TSDF Vapi & CHWIF, Kutch







ANNEXURE: 7



ANNEXURE: 8

Copy of plot allotment letter issued by GIDC











ANNEXURE: 9

Copy Of Notification Regarding The Unit Is Located In Notified Industrial Area



ANNEXURE: 9

A Schematic Representation Of The Feasibility Drawing



ANNEXURE: 10

Details Of Air Pollution & Its Control Measures For Existing & Proposed Expansion The utility emissions will be from the Steam Boiler of 17 Tons/Hr & 40 Tons/Hr. Imported coal/lignite as fuel will be used in the Steam Boiler. Also we have installed a D.G. Set of 1000 KVA & 1250 KVA capacities to use in case of power failure and HSD shall be used as a fuel. From the existing plant SO2, H2S & Particulate matter gases are generated. For the scrubbing of these process gases, two stage water followed by alkali scrubber are provided to recover the valuable by products. After proposed expansion additional, three numbers are scrubbing system will be provided. Details of which are as under;

Sr. No. Particulars Existing After Proposed Expansion

Remarks

1.0 Capacity of Steam boiler

17 TPH 17 TPH + 50 TPH One additional

1.1 Fuel Used Indian Coal/Imported

coal/lignite

Indian Coal/Imported coal/lignite

1.2 Fuel Consumption 1.25 Tones/Hr 9 Tone/Hr 1.3 APC provided Electro static

PrecipitatorElectro static Precipitator One additional

1.4 Height/dia of chimney

54 meters 54 meters x 2 One additional

2.0 Capacity of D G set

1000 KVA (Standby)

1000 KVA + 1250 KVA Standby

2.1 Fuel Used HSD HSD 2.2 Fuel Consumption 160 liters/hr 360 lits/hr 2.3 APC provided Exhaust Exhaust 2.4 Height/dia of

Exhaust 11 meters 11 meters

3.0 Stack attached to Sulphur burning chamber

Sulphur burning chamber Total Two numbers

3.1 APC provided ventury scrubber followed by alkali

scrubber

ventury scrubber followed by alkali

scrubber

3.2 Height of vent 11 meters 11 meters 3.3 Expected emission SO2: < 40 mg/Nm3

SO2: < 40 mg/Nm3

4.0 Stack attached to Anaerobic Digester

of ETP Anaerobic Digester of

ETP Total Two

numbers 4.1 APC provided ventury scrubber

followed by alkali scrubber

ventury scrubber followed by alkali

scrubber

4.2 Height of vent 11 meters 11 meters 4.3 Expected emission H2S:< 45 mg/Nm3 H2S:< 45 mg/Nm3 5.0 Stack attached to Gluten Dryer Gluten Dryer Total

Two



numbers 5.1 APC provided Two stage wet

ventury scrubber Two stage wet ventury

scrubber 5.2 Height of vent 11 meters 11 meters 5.3 Expected emission PM: <150 mg/Nm3 PM: <150 mg/Nm3



DETAILS OF ELECTRO STATIC PRECIPITATOR ATTACHED TO COAL FIRED BOILER

ESP 1 ESP 2 ESP 3

COMPRESSEDAIR ASH SILO

FLY ASH UNLOADING TROLLY

FLUE GAS FROMTHE BOILER

CHIMNEY

FLY ASH

ID FAN

AIR POLLUTION CONTROL SYSTEM (ELECTROSTATIC PRECIPITATOR)WITH FLY ASH HANDLING SYSTEM

SAMPLINGPOINT WITHPLATFORM

ELECTROSTATIC PRECIPITATORS



DETAILS OF SCRUBBING SYSTEM WITH FLOW DIAGRAM

1. Sulfur burning chamber

No Particular APC Before Expansion APC After Expansion Remarks

1 Process gas SO2 kg/day to reactor

244.8 1132.2

2 % conversion 99 99 Consumed in the process

3 SO2 to scrubbing system 2.384 11.322

4 Scrubbing System provided

Absorption tower + Alkali scrubber

Absorption tower + Alkali scrubber

5 Scrubbing media Water in ventury ,5 % NaOH in second stage

scrubber

Water in ventury ,5 % NaOH in second stage

scrubber

Water from first stage recycled to SO2 water

system

6 Absorption tower 300 dia x 2000 mm 750 dia x 3000 mm

7 Packed tower 450 dia x 3000 mm 1000 dia x 3000 mm

8 MOC PP/FRP PP/FRP

9 Scrubbing media tank 10000 lit/2000 lit HDPE 10000 lit/5000 lit HDPE

10 Chimney height 11 meters 11 meters

11 Chimney dia 150 mm 400 mm

12 Emission rate, nm3/hr 90 410

13 SO2 mgm/nm3 10 10 40 mg/nm3

Notes:

SO2 gas generated in sulfur burning chamber is mixed with water in a tank fitted with ventury for the absorption of SO2 gas in water as 0.5 % SO2 water.

Some unabsorbed gas comes out, which is taken to another ventury scrubber which is operated on water. The water is recycled to the process ventury system and the unabsorbed gases are taken to the second stage packed tower alkali absorption system, wherein it is absorbed in dilute alkali and SO2 free air meeting emission norms of GPCB is vented through a vent pipe.



2. Scrubbing of Biogas from Anaerobic Digester of ETP

No Particular APC Before Expansion

APC After Expansion Emission norms

1 Air Pollution Control systems

2 Qty of biogas nm3/day 3600 16400

3 Qty of biogas Nm3/hr 150 683

4 Process gas, H2S 0.5% 0.5% 45 mg/nm3

5 H2S kg/day to Scrubber System

18 82

6 H2S kg/hr to Scrubber System

0.75 3.42

7 Ventury dia 200 dia x 1200 500 dia x 1200 1st Stage

8 Additional packed tower 300 dia x 2000 600 dia x 2000 2nd Stage

9 Scrubbing Media 5 % NaOH 5 % NaOH

10 Outlet of scrubber Flare /boiler/ gluten dryer

Flare /boiler/ gluten dryer

11 Flare diameter 100 mm 200 mm

12 Height of flare 11 meters 11 meters


14 Chimney dia 400 mm 900 mm

Notes:

There is generation of biogas in the anaerobic digester, which contains some hydrogen sulfide, giving odor problem. This gas is utilized fully in gluten dryer and partially in boiler as a fuel having calorific value of 5200 kcal/nm3. A flare system has been provided wherein biogas is burnt in the event of non utilization of biogas in either boiler or Gluten Dryer.

Expected H2S emission after scrubber : 25 mgm/nm3



3.0 Gluten Dryer

No Particular APC Before Expansion APC After Expansion Emission norms

1 Gluten Dryer Wet ventury scrubber750 dia x 5000

Wet ventury scrubber 1500 dia x 8000

1st stage

2 Packed tower

1250 x 1500

Packed tower

2500 x 2500

2nd stage

3 Pollutant SPM SPM 150 mg/nm3

4 Scrubbing media Alkaline water Alkaline water


6 Chimney dia 450 1000

7 Gluten from starch, MT/month

0 0

8 Gluten from Maize MT/month

144.3 657.3

9 Total MT/month 144.3 657.3

10 Avg gluten MT/day 4.81 21.91

11 Gluten to dryer kg/hr 200 913

12 Hourly Capacity of gluten dryer

400 kg/hr 1600 kg/hr

13 Daily running hr 12 13.7

14 Design of ventury 11000 m3/hr 44000 m3/hr

Explanatory notes:

The gluten dryer is operated fully on biogas. In this dryer, biogas is burnt under controlled conditions in a rotary dryer and the flue gases generated takes part in the drying operation. The flue gas along with some gluten is passed through a cyclone for the recovery of dry gluten. The flue gas from cyclone contains some gluten particles and this is taken to a two stage scrubbing system including a ventury and a packed absorption tower through which alkaline water is circulated. The gluten slurry is separated from the water and recycled in the process.

The scrubbed flue gas is vented through a chimney.



Digester

5 Kl CausticCirculation tank

Ventury Scrubber

11 meters ht. of vent

VENTURY SCRUBBING SYSTEM FOR H2S GAS GENERATED FROM DIGESTER OF ETPLANT

0.5 KL Trap

Gas Holder/Flare



10 M3Dil. NaOH

1250

400 NB P

85 m3/hr40 m headCI/SS working parts

NRV

80600 NB

GLUTEN CONTROL VENTURY SCRUBBER SYSTEM



Sulphur Burning Chamber2 Kl Water

circulation tank

Ventury Scrubber

200 litsCaustic soln. tank

11 meters ht. of vent

VENTURY SCRUBBING SYSTEM WITH ALKALI SCRUBBER FOR SO2GAS GENERATED FROM SULPHUR BURNING CHAMBER

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