1
Prefeasibility Study Report
of
Aromatics India Pvt. Ltd.
At & Po: 334, Phase-II, GGDC-GIDC,
Village: Mithi Rohar, Taluka: Gandhidham, Dist.: Kutch
For
Proposed Project of
LABSA (Linear Alkyl Benzene Sulphonic Acid)
PREPARED BY:
PAVAN ENVITECH CONSULTANT PVT. LTD., AHMEDABAD.
OCTOBER - 2015
2
INDEX
Sr. No. Content Page No.
1. Introduction 3 2. Details of Proposed Project 4
2.1 Location of the proposed Project 5 2.2 Product Details 6 2.3 Manufacturing Process 6
3. Resource Requirement 9
3.1 Raw material Requirement 9 3.2 Electricity 10 3.3 Water 10 3.4 Fuel Requirement 10 3.5 Employment 10 3.6 Reactors, Vessels, Equipments Required 10
4. Environment Pollution & Pollution load 11
4.1 Water and Waste water 11 4.2 Air Pollution 14 4.3 Solid/Hazardous Wastes Generation 15 4.4 Noise Pollution 15
5. Environment Management Plan 16
5.1 Effluent Treatment System 16 5.2 Air Pollution Control Measures 17 5.3 Noise Pollution control measures 18 5.4 Solid/Hazardous Wastes Management system 18 5.5 Environment Management Cell 19 5.6 Physical and Chemical Properties of Product & Raw
materials 20
5.7 General Safety Measures 21
6. Annexure 23 Annexure-I : Google image of plot 24 Annexure-II: Plan lay-out 25 Annexure-III: Plot Possession Documents 26
3
1. Introduction :
Aromatics IndiaPvt. Ltd. is planning to set up Manufacturing unit of LAB
Sulphonic Acid (LSA) at Plot No.: 334, Phase-II, GGDC Industrial
Estate, Village: Mithi Rohar, Taluka: Gandhidham, District : Kutch. The
unit envisages manufacturing of LABSA (Linear Alkyl Benzene Sulphonic
Acid).
As the proposed manufacturing unit is covered under the New EIA
Notification, 2006, amended in December-2009, the unit has to get the
Environmental Clearance prior to commission of the plant.
It is proposed to manufacture LAB Sulphonic Acid with installed capacity of
3,000 MT/Month which is listed at 5(f)B under the EIA Notification, 2006. The
unit is located in GIDC area hence the unit has to get the Environmental
Clearance from the SEAC, Gandhinagar.
In the present report the proposed project location, about facilities,
infrastructure details, manufacturing process, water and wastewater details,
air pollution and control measures, solid and hazardous waste management
and chemical properties of the products, by-products & raw-materials.
We have purchased the said plot from Manoj Timber Traders vide Deed of
Assignment on 29-07-2015, who are engaged in processing of timber and wood
at the said premises.
4
2. Details of Proposed Project:
Aromatics India Pvt. Ltd. is planning to set up the plant for manufacturing
LAB Sulphonic Acid at Plot No.: 334, Phase-II, GIDC-GGDC Industrial
Estate, Village: Mithi Rohar, Taluka: Gandhidham, District : Kutch. The
detail of the proposed project is given below;
Name of the Industry : Aromatics India Pvt. Ltd.
Location : Plot No.: 334, Phase-II, GGDC-GIDC Industrial
Estate, Village: Mithi Rohar, Taluka: Gandhidham,
District: Kutch.
Project Activity
: Manufacturing activity of Linear Alkyl Benzene
Sulphonic Acid (LABSA)
Cost of the Project
: Rs.2.95 Crore
Product
(MT/Month)
: 1. Linear Alkyl Benzene Sulphonic Acid: 3,000
2. Sulphuric Acid (75-80%): 2,436 (By-product)
Total land area acquired
for the project
: 11,050 m2
Category of proposed
project as per EIA
notification, 2006 and
subsequent
amendments.
: 5 (f) B
5
2.1 Location of the Proposed Project: The industry has acquired a plot entitled as Aromatics India Pvt. Ltd., at Plot No.:
334, Phase-II, GGDC-GIDC Industrial Estate, Village: Mithi Roar, Taluka: Gandhidham,
District: Kutch. Table 2.1 The detail of the project site is as given in the following table
We have enclosed herewith Annexures: Annexure – 1 : Google Image - Proposed Project Site of Aromatics India Pvt.
Ltd. Annexure – 2 : Factory Plan Layout. Annexure – 3 : Plot Possession Document.
Sr. No. Particulars Details
1. Location
a) Site Plot No.: 334, Phase-II, GGDC-GIDC Industrial Estate,
b) Village Mithi Rohar
c) Taluka Gandhidham
d) District Kutch
e) State Gujarat
3 Nearest Railway Station Gandhidham
4 Reserved Forest/National Park --
5 Nearest City Gandhidham
6 Nearest Village Mithi Rohar @ 4 KM
6
2.2 Product Details
The industry is planning to manufacture Linear Alkyl Benzene Sulphonic Acid.
The details of product are given in following table.
Table 2.2 Details of Proposed Product
Sr. No. Product Production
MT/Month 1. Linear Alkyl Benzene Sulphonate & 3,000
2. Sulphuric Acid (75-80 %) 2,436
2.3 Manufacturing process: 2.3.1 (A) Manufacturing process
LAB Sulphonic Acid is the economical name linear alkyl benzene sulphonic
acid which is produced by sulphonating linear alkyl benzene with sulphuric
acid. The equipment used is MS/SS reactor vessels. The required amount of
LAB is transferred into the reactor vessel and sulfuric acid is added
gradually. The mixture is continuously stirred to ensure complete mixing and
completion of reaction between LAB and sulphuric acid. Since the reaction is
exothermic, temperature is controlled by circulating water in jacket of the
vessel. The mixture now contains LABSA and Sulphuric Acid. To facilitate
the separation of LABSA and Sulphuric Acid, water has to be added to the
total mass. The mixture then stirred for 10-15 minutes and transferred to the
separator vessel and allowed to settle. The Sulphuric Acid (75-80%) forms the
bottom layer and is transferred to suitable storage tanks. LABSA forms the
upper layer and is transferred to suitable storage tanks.
7
LABSA is main raw material for detergent powder & cake, liquid detergent &
scouring agent. The Sulphuric Acid (75-80%) is sold to end users like:
fertilizer and alum industries, etc.
For quality assurance, necessary standard should be followed.
Standards of Linear Alkyl Benzene
Molecular weight : 238
Bromine Number : 0.04 Max
Say Bolt Color : + 30 Max
Doctor Test : Negative
Completeness sulphonation : 98 % Min
Standards of Sulphric Acid
Total acidity as H2SO4 : 98 % min
Resistant as ignition : 0.2 % Min
Iron as Fe : 0.05% max
lead as Pb : 0.05% max
Arsenic : 0.004 % Max
Standard of LAB Sulphonic Acid
Active Matter : 90 ±1 % Min
Free LAB : 1.5 % Max
Free H2SO4 : 7 % Max
Colour on Klett : 50 Unit Avg
8
Mass Balance
Raw Materials Consumption Kg/Kg of Product MT/Day
Input Linear Alkyl Benzene 0.670 80.400 Sulphuric Acid 0.992 119.040 Water 0.150 18.000
Total 1.812 217.44 Out put Linear Alkyl Benzene Sulphonic Acid (LABSA)
1.000 120.000
Sulphuric Acid (75-80%) 0.812 97.440 Total 1.812 217.44
2.3.2 Block Diagram:
Sulphonation
Agitation (30 min.)
Addition
Separation
LAB
H2SO4 (98%)
0.670
0.992
Water 0.150
Sulphuric Acid: 0.812 (75-80%)
TOTAL INPUT: 1.812 TOTAL OUTPUT: 1.812 ALL THE UNITS ARE EXPRESSED IN MT/ TON OF PRODUCT.
Product LABSA:
1.000
9
3. Resource Requirement: 3.1 Raw Material Requirement:
This plant is based on slphonating of LAB with Sulphuric Acid (98%) for
production of LAB Sulphonic Acid and Sulphuric Acid (75-80%). In this
process following raw material will be require
1. Linear Alkyl Benzene
LAB is introduced in 1960 to replace the poorly biodegradable branched
alkyl benzene sulphonates. LAB produced only in 20 countries. Proposed
unit will arrange this main raw material from Reliance, IOCL, Nirma, etc.
2. Sulphuric acid
Sulphuric Acid (98%) require for this process and unit will arrange this raw
material from Hindustan zinc limited, Udaipur and other manufacturer on
regular basis. Sulphuric Acid is categorized under the Hazardous chemical
so unit will make proper arrangements for handling and storage of this
chemical. The detailed product wise raw material requirement is as given
here below Table no. 3.1;
Table 3.1 The detail of the Product & Raw materials requirement:
Raw Material Requirements:
Raw Materials Consumption Kg/Kg of Product MT/Month
Linear Alkyl Benzene 0.670 2,010 Sulphuric Acid 0.992 2,976 Water 0.150 450
Total 1.812 5,436 Product:
Sr. No. Product Production
MT/Month 1. Linear Alkyl Benzene Sulphonate 3,000
2. Sulphuric Acid (75-80%) 2,436
10
3.2 Electricity: Total Power requirement : 100 KW
Source of Power supply : Pashchim Gujarat Vij Company Limited (PGVCL)
3.3 Water: The total fresh water require for the manufacturing of proposed product will
be @ 23.9 KL/day. Industrial water requirement will be @ 20.4 KL/Day, 2.0
KL/day water required for Gardening/Greenbelt and @ 1.5 KL/day will be
require for the domestic.
3.4 Fuel requirement :
HSD will be used as fuel for the D.G. set of capacity 125 KVA @ rate of 20
L/Hr.
3.5 Employment :
The proposed unit will have great employment potential providing
employment to approximately 20 full time persons. The manpower
requirement for the proposed project will be fulfilled from nearby area.
3.6 Reactors, Vessels, Equipments Required : Table:3.2 - Reactor, Vessels, Equipment Details
Sr. No. Storage Tank Quantity
MOC Capacity
1. Tank for Linear Alkyl Benzene 3 MS 300 MT
2. Tank for Sulphuric Acid (98%) 4 MS 300 MT
3. Tank for LABSA 2 MS 100 MT
4. Tank for Sulphuric Acid (75-80%)
4 1
MS 50 MT 270 MT
5. Feeding Tanks for LAB/Sulphuric Acid/Water 5 MS 15 MT
6. Closed Reactors/Vessels 3 MS 25 MT
7. Separators 3 MS 35 MT
8. Decantation Tank 2 MS 20 MT
9. Pumps 10 MS/CI
10. Diesel Generator Set 1 125 KVA
11
4. Environment Pollution & Pollution Load: 4.1 Water and Waste water 4.1.1 Water Consumption
In the proposed project, water will be required for following purposes:
Domestic & Gardening purpose
Industrial Use
Table:4.1: Break up for fresh Water Consumption
Source: GGDC-GIDC or purchase through tankers from outside.
Rain water will be collected in separate tank and will be utilized in manufacturing process. Thus, fresh water requirement becomes less or recharge in ground by providing percolation/recharge well.
Sr.
No. Purpose
Water Consumption
(KL/day)
1. Domestic 1.500
2. Industrial 20.400
i) Process (16.000)
ii) Cooling (4.400)
3. Gardening/ Green Belt
Development 2.000
Total 23.900
12
4.1.2 Waste Water Generation
Table:4.2: Break up for Wastewater Generation
Note: There will not be any wastewater discharge from the proposed
manufacturing process and no disposal of wastewater from the system,
hence the unit will be “THE ZERO DISCHARGE UNIT”
Sr.
No. Purpose
Waste Water Generation
(KL/day) Remarks
1. Domestic 1.500 Soak Pit
2. Industrial
i) Process -- No w/w generation
ii) Cooling 2.000 Recycle in Process
Total 3.500 --
13
Water Balance Diagram (all figures are in KL/Day)
Fresh Water Consumption 23.900
Domestic 1.500
Cooling (Make-up)
4.400
Industrial 20.400
Waste Water Generation
1.500
To Soak Pit 1.500
Evaporation Loss 2.400
Waste water generation: Nil
Process 18.000
Gardening 2.000
Cooling (bleed-off) 2.000
16.000 4.400
14
4.2 Air Pollution :
The Impact on the air quality is divided into two categories:
A. Impact on air quality during construction phase
B. Impact on air quality during operation phase.
A. Impact on Air Quality during Construction Phase
There will be mainly particulate matter emission due to the
transportation of vehicle and construction activity. Particulate matter
emission during construction phase will be reduced by sprinkling water
in open ground area of the site and controlling the speed of the vehicles
inside the premises. The impact is limited to the construction phase
only.
B. Impact on Air Quality during Operation Phase.
Sources of air pollution
Combustion of Fuel for DG sets.
4.2.1 Details of Stack:
The main sources of gaseous air pollution will be from operation of D. G. Set.
The details for the same are given here in Table: 4.3 (A) & Table: 4.3 (B).
Details of stack:
Table: 4.3 (A) – details of stack
Sr. No.
Stack attached to
Stack Ht & Dia
(m)
Type of Fuel &
Consumption
APC Measures
Concentration of pollutants
1. D.G. Set (125 KVA)
Height: 7 Dia.: 0.10
HSD : 20 L/Hr
Not Required
PM<150 mg/Nm3 SO2<100 ppm NOx<50 ppm
15
4.3 Solid/Hazardous Wastes Generation :
There will be no any major source of hazardous waste generation due to
proposed project. However, the ancillary sources of hazardous wastes
generation are as under: Table: 4.1- Details of hazardous waste generation
Sr. No.
Type of Hazardous Waste Category No. Quantity;
per Annum
1 Used oil 5.1 0.100 MT
4.4 Noise Pollution
There are few potential sources such as Pumps, D.G. set, and other
manufacturing operations which would generate noise. However, proper
maintenance of the all equipments will be taken. Adequate protective
measures in the form of ear muffs/ earplugs shall be given to workers working
in these areas and greenbelt development shall further attenuate the noise
transmission.
16
5. Environment Management Plan:
The proposed unit will provide adequate Environmental Management Plan to
assure the regular and efficient working / operation of the same. The details of
Environmental Management Plan are described here under :
Objectives:
Regular and efficient working of the Plant / Operation with acceptable
minimum Environmental Impact.
To conserve the environment.
To check and maintain the record of the environmental parameters for
furtherer improvement of the process and the environment.
To comply the Act, Rules, Notifications directly applicable to
Environmental Management.
5.1 Effluent Treatment System
A) Domestic waste water
The generated 1.500 KL/Day of domestic waste water will be drained in to the
Soak Pit.
B) Industrial Waste Water
There will not be any effluent generation from the proposed project. There will
not be any waste water discharge from the proposed manufacturing process;
hence the unit will be “THE ZERO DISCHARGE UNIT”
17
5.2 Air Pollution Control Measures:
5.2.1 Air Pollution Control Measures during the Construction Phases
Sprinkling of water in open area of factory premises will be done.
All the safety measures prescribed in code for building and construction
will be followed.
Regular monitoring of construction activity.
By controlling the speed of vehicles inside the factory premises.
Personal Protective Equipments (PPEs) will be provided to all the
workers.
5.2.2 Air pollution control measures during the operation Phase
HSD will be used as fuel into the DG set. PM10, PM2.5, SO2 & NOx will be
emitted into the atmosphere due to the combustion.
The sources of gaseous air pollution and the control measure are given as
under the table:
Table: 5.1- Details for Air pollution control measures for Flue Gas Emission
Table: 5.1 – details of stack
Sr. No.
Stack attached to
Stack Ht & Dia
(m)
Type of Fuel &
Consumption
APC Measures
Concentration of pollutants
1. D.G. Set (125 KVA)
Height: 7 Dia.: 0.10
HSD : 20 L/Hr
Not Required
PM<150 mg/Nm3 SO2<100 ppm NOx<50 ppm
18
5.3 Noise Pollution Control Measures:
There are few potential sources such as Pumps, D.G. set, and other
manufacturing operations which would generate noise. Proper maintenance of
the all equipments will be taken. Adequate protective measures in the form of
ear muffs/ earplugs shall be given to workers working in these areas and
greenbelt development shall further attenuate the noise transmission outside
the premises.
5.4 Solid/Hazardous Wastes Management System
There will be no any major source of hazardous waste generation due to
proposed project. However, the ancillary source of hazardous wastes
generation and its as under, and for that unit will provide designated storage
area.
Table: 5.5- Details for hazardous waste management
Sr. No
Type of Hazardous Waste & Quantity
Category No.
Methods of Handling Disposal
1 Used oil : 0.100 MT/Annum 5.1 Stored in drum
Collection, Storage, Re-use as lubricant or Transportation & Disposed-off to authorized refiners.
19
5.5 Environment Management Cell :
The proposed unit will provide/prepare an adequate Environmental
Management Cell to assure the regular and efficient working /operation as
given here below;
Managing Director
Factory Manager
Chemist
Helpers
Operator
20
5.6 Physical and Chemical Properties of Product & Raw materials:
Linear Alkyl benzene
Physical State Liquid Color White Bulk Density 0.855 Solubility in water Insoluble Boiling Point 300 0C Molecular Weight (G/Mol) 238
Sulphuric Acid(98%)
Physical State Liquid Color colorless Odor Odorless Specific Gravity 1.844 Solubility in water soluble pH 0.3 (1N) Boiling Point 327 0C Melting Point -2 0C Vapor Density 3.4 Molecular Weight (G/Mol) 98.07 Molecular Formula H2SO4
LAB Sulphonate
Physical State Liquid Color Brown Specific Gravity 1.08 Solubility in water Water Soluble Boiling Point 315 oC Molecular Weight (G/Mol) 320
21
5.7 General Safety Measures: All the personnel at the plant will be made aware about the hazardous
substance stored at the plant and risk associated with them. Personnel engaged in handling of hazardous chemicals will be trained to
respond in an unlikely event of emergencies. Safe work practices will be developed to provide for the control of hazards
during operation and maintenance. The workers will be made aware about the hazards associated with manual
handling of chemicals. Adequate fire fighting facilities will be provided at the plant, including, dry
chemical powder type, water CO2 type, mechanical foam type, CO2 type of Fire Extinguishers and sand buckets. Personnel will be trained to combat the fire in various hazardous chemicals.
The fire fighting system and equipment will be tested and maintained as per
relevant standards. Safety measures in the form of DO and Don’t DO will be displayed at strategic
locations especially in local language. Good house keeping will be maintained in the plant. The required PPEs for each area/operation should be identified and the
necessary PPEs, like, helmets, goggles, hand gloves, mask, PVC suit, Self Containing Breathing Apparatus, safety belts, ear muff and plug, etc. will be provided to the personnel.
The plant will check and ensure that all instruments provided in the plant are
in good condition and documented. Adequate ventilation will be provided. Local exhaust ventilation will be
effective in controlling the dust and fumes in the work environment. All equipment and storage tanks/containers of flammable chemicals should be
bounded and earthed. First aid box will be provided within the plant. List of important telephone numbers will be displayed at each and every
location in the plant.
22
All the accidents and incidents will be recorded, investigated and analysed in the proposed plant.
Safety awareness programme and training of the worker will be carried out to
motivate the workers to increase the safety level at personal level. Occupational Health Aspect: As per govt. standard all facilities will be
provided. Safety Precautions for Storage & Handling of Acids: The unit will provide special precautions for storage & handling of Sulphuric Acid
within the premises.
Acids storage tanks will be placed in to the separate storage area within the
premises.
The proper collection system will be provided for the leakage & spillage collection
of both the acids by preparing dyke wall and Acid Proof flooring with spillage
collection tank and will be transferred to the emergency storage tank.
Proper vent will also be provided to each storage tank. Moreover, Weather shed
and water sprinkling system will be provided.
26
5 5
Sr. No.
Area Marking No.
1 Production Plant
1& 1a
2 Storage yard 2 &3 3 Utilities/ADM 4 4 Roads 5 5 Open/Un-
developed 6
6 Green belt 7
3
4
4
2
GATE NO 1 GATE NO 2 N
S
EW
SCHEMATIC LAYOUT OF AROMATICS INDIA PVT.LTD.
1
7
1A
6