SHREE GANESH FATS (P) LTD. -...

SHREE GANESH FATS (P) LTD.

Pre-Feasibility Report for Environmental Clearance (EC) of Proposed Greenfield Chlor-Alkali Plant of 600 MTD (2×300 MTD) and Captive Power Plant of 32 MW at Landha Village, Tehsil: Saha, District: Ambala, Haryana.

OCTOBER, 2014

Consultant:

K a d a m Environmental

Consultants www.kadamenviro.com

Environment for Development

http://www.kadamenviro.com/

SHREE GANESH

FATS (P) LTD. EC FOR PROPOSED CHLOR-ALKALI PLANT AND CPP AT VILLAGE:

LANDHA, TEHSIL: SAHA, DISTRICT: AMBALA, HARYANA

PRE-FEASIBILITY

REPORT

KADAM ENVIRONMENTAL CONSULTANTS |OCTOBER 2014 1

SHREE GANESH FATS (P) LTD.

Pre-Feasibility Report for Environmental Clearance (EC) of Proposed

Greenfield Chlor-Alkali Plant of 600 MTD (2×300 MTD) and Captive

Power Plant of 32 MW at Village: Landha, Tehsil: Saha, District:

Ambala, Haryana © Kadam Environmental Consultants (‘Kadam’), October 2014

This report is released for the use of the Shree Ganesh Fats (P) Ltd. Regulators and relevant stakeholders

solely as part of the subject project’s Environmental Clearance process for Proposed Greenfield Chlor-

Alkali plant and Captive Power Plant at Village: Landha, Tehsil: Saha, District: Ambala, Haryana.

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.

QUALITY CONTROL

Name of

Publication

EC for Proposed Greenfield Chlor-Alkali plant of 600 MTD (2×300 MTD) and Captive

Power Plant of 32 MW at Village: Landha, Tehsil: Saha, District: Ambala, Haryana

Project Number 1418051306 Report No. 1 Version 1 Released October, 2014

Prepared By Ms. Nazneen Mansuri /Ms. Ishita Garg

Reviewed By Mr. Sangram Kadam/Mr. J.A Rathi

Released By Mr. Sangram A. Kadam

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.

SHREE GANESH



TABLE OF

CONTENTS


CONTENTS

1 EXECUTIVE SUMMARY ................................................................................. 6

2 INTRODUCTION OF THE PROJECT ................................................................. 7

2.1 IDENTIFICATION OF PROJECT ............................................................................. 7

2.2 PROJECT PROPONENT .................................................................................... 7

2.3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ........................................................ 7

2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION ....................... 7

2.5 DEMAND-SUPPLY GAP .................................................................................... 8

2.6 IMPORT VS. INDIGENOUS PRODUCTION .................................................................. 8

2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT............................. 8

3 PROJECT DESCRIPTION ............................................................................... 9

3.1 TYPE OF PROJECT ........................................................................................ 9

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT SITE LAYOUT) WITH COORDINATES ..................................................................... 9

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE. ....... 9

3.4 SIZE OR MAGNITUDE OF OPERATION ................................................................... 10

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC DIAGRAM/FLOW CHART SHOWING THE

PROJECT LAYOUT, COMPONENTS OF THE PROJECT ETC, SHOULD BE GIVEN) .................................... 10

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE PF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCTS. ........................ 16

SALT ............................................................................................................ 16

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, ...................... 16

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 16

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR

MANAGEMENT/DISPOSAL ....................................................................................... 16

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA

PURPOSE. 19

4 SITE ANALYSIS ......................................................................................... 20

4.1 CONNECTIVITY ......................................................................................... 20

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ....................................................... 20

4.3 TOPOGRAPHY ........................................................................................... 20

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, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM

HFL OF THE RIVER), CRZ. ..................................................................................... 20

4.5 EXISTING INFRASTRUCTURE ............................................................................ 21

4.6 SOIL CLASSIFICATION .................................................................................. 21

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 21

4.8 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................. 21

5 PLANNING BRIEF ...................................................................................... 22

SHREE GANESH



TABLE OF

CONTENTS


5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY

PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION ...................................................... 22

5.2 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC) ........................................ 22

5.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................... 22

5.4 AMENITIES/FACILITIES ................................................................................. 22

6 PROPOSED INFRASTRUCTURE .................................................................... 23

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 23

6.2 RESIDENTIAL AREA (NON- PROCESSING AREA) ........................................................ 23

6.3 GREEN BELT ............................................................................................ 23

6.4 SOCIAL INFRASTRUCTURE .............................................................................. 23

6.5 CONNECTIVITY ......................................................................................... 24

6.6 DRINKING WATER MANAGEMENT ...................................................................... 24

6.7 SEWERAGE SYSTEM .................................................................................... 24

6.8 INDUSTRIAL WASTE MANAGEMENT..................................................................... 24

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ............................................................ 24

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN .................................... 25

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING

HOME OUSTEES, LAND OUSTEES AND LANDLESS. ............................................................... 25

8 PROJECT SCHEDULE & COST ESTIMATES ...................................................... 26

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................... 26

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT

26

9 ANALYSIS OF PROPOSAL ........................................................................... 27

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE. . 27

SHREE GANESH



TABLE OF

CONTENTS


LIST OF FIGURES

Figure 3-1: Process Flow Diagram ................................................................................................ 15

SHREE GANESH



TABLE OF

CONTENTS


LIST OF TABLES

Table 2-1: Details of Management team ......................................................................................... 7

Table 3-1: Co-ordinates of the Proposed Project Site ....................................................................... 9

Table 3-2: Size/Magnitude of Proposed Facilities ........................................................................... 10

Table 3-3: Proposed Production Capacity of Chlor-Alkali plant ........................................................ 10

Table 3-4: Details of Raw material Quantity, Source and Mode of Transport .................................... 16

Table 3-5: Details of Proposed Energy Requirement ...................................................................... 16

Table 3-6: Details of emissions from process and flue gas stacks along with their mitigation methods17

Table 3-7: Details of Hazardous Solid Waste generation from proposed project ............................... 18

Table 3-8: Details of Solid Waste Generation from proposed project ............................................... 18

Table 4-1: Connectivity of Road, Railway and Airport with the site .................................................. 20

SHREE GANESH



TABLE OF

CONTENTS


LIST OF ANNEXURES

Annexure 1: Map Showing General and Specific Location of Project Site .......................................... 29

Annexure 2: Project Boundary Map .............................................................................................. 30

Annexure 3: Site Layout Map ....................................................................................................... 31

Annexure 4: Land Documents ...................................................................................................... 32

Annexure 5: NOC from Department of Town and Country Planning, Haryana .................................. 38

SHREE GANESH

FATS (P) LTD.

EC FOR PROPOSED CHLOR-ALKALI PLANT AND CPP AT VILLAGE:


PRE-FEASIBILITY

REPORT


1 EXECUTIVE SUMMARY

Name of Company Shree Ganesh Fats (P) Ltd.

Category Category “A”

Location of Plant Village Landha, Tehsil Saha, District: Ambala, Haryana

Total Area 5.2 ha (52609.1 m2)

Production Details Chlor alkali plant and Captive Power Plant

Capacity of Proposed Plants Chlor-Alkali: 600 MTD (2×300 MTD)

Power plant: 32 MW

Raw Material Requirement

Salt

Na2CO3

Sodium Sulphite

Flocculent

H2SO4

Coal/Petcoke

Quantity: MTPA

1,60,000

770

140

1

1,500

1,21,968

Water Source Borewell

Total Power Requirement (MW) 32 MW

Total Project Cost Approx. 350 Crore

Project Time Schedule 24 Months from date of issue of EC from MoEF and CTO from SPCB.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


2 INTRODUCTION OF THE PROJECT

2.1 Identification of project

The proposed project is a new Greenfield Chlor Alkali plant and Captive power plant. The project falls

under the schedule “Materials Processing”, Project or Activity 4(d), Chlor-Alkali Industry, Category “A”.

This project attracts Public consultation/hearing as per EIA notification, 2006 amended till date.

2.2 Project proponent

Shree Ganesh Group today holds business activities in Edible and Non Edible Oils. From a wide range

of products made available to the consumers and also tailor made for specific requirements.

With present manufacturing of products ‘Distilled Fatty Acids’ ‘Stearic Acids’ ‘Soap Noodles’ ‘Soaps’

‘Hydrogenated Oils’ all from manufacturing facility in Baddi (Barotiwala), Refined rice bran oils, crude

solvent oils from Ambala (Haryana). The management team includes:

Table 2-1: Details of Management team

S. No. Name Designation

1 Mr. Madan Lal Garg Chairman

2 Mr. Parvind Kumar Garg Managing Director

3 Mr. Vinod Kumar Garg Managing Director

4 Mr. Parmod Kumar Garg Managing Director

5 Mr. Raj Kumar Garg Managing Director

6 Mr. Pragun Garg Director(Operations And Business Development)

2.3 Brief description of nature of the project

The proponent intends to establish a Greenfield Chlor-Alkali plant of 600 MTD (2×300 MTD) and Captive

Power Plant of 32 MW on total plot area of 5.2 ha. The water will be sourced from in-house Borewell.

Coal/Petcoke will be used as raw material for Captive power plant. The Chlor-Alkali process is an

industrial process for the electrolysis of sodium chloride. It is the technology used to produce chlorine

and sodium hydroxide (Caustic Soda), which are commodity chemical required by industry. Usually the

process is conducted on a brine (an aqueous solution of NaCl), in which case NaOH, Hydrogen and

Chlorine results. HCl is produced from H2 and Cl2.

2.4 Need for the project and its importance to the country and or region

The project proponent is involved in other businesses of Chlorination and Hydrogenation which requires

Chlor-Alkali products as raw material. Hence, to cater the need of this raw material and also the

increasing demand of caustic soda in the market the proponent has intended to propose Chlor-Alkali

plant.

The Chlor-alkali industry in India is approximately 65 yrs old. It forms an important component of basic

chemicals industry, comprising around 74% of the basic chemicals production in India. Caustic soda,

chlorine alongside hydrogen and hydrochloric acid comprise the Chlor-alkali industry’s components.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


These chemicals find their applications in a number of industries such as textiles, chemicals, paper, PVC,

water treatment, alumina, soaps & detergents, glass, chlorinated paraffin wax, among others. The

demand for the two sub-segments – caustic soda & soda ash, has increased significantly registering a

CAGR of 5.6% and 4.7% respectively, over the past five years.

CARE Research’s report on ‘Indian Chlor-Alkali Industry’ throws light on key aspects that govern the

industry’s present market dynamics, while commenting on the future demand and supply growth in

industry for the next five years, by offering an individual focus on its prime sub-segments.

2.5 Demand-Supply Gap

The Chlor-alkali industry mainly consists of the production of three key products – caustic soda, soda

ash, and chlorine. Together, the alkali chemicals comprised 74% of the total chemicals production in

FY10. According to Alkali Manufacturers’ Association of India (AMAI), the Indian Chlor-alkali market was

estimated at around USD 1.9 billion in FY2010, vis-à-vis global market size of USD 48 billion. Caustic

soda and chlorine are produced together in the ratio of 1:0.89 (also known as Electrochemical Unit or

ECU) through electrolysis of salt. On account of their co-production, the market dynamics for caustic

soda and chlorine are heavily influenced by each other. Internationally, it is chlorine based, whereas, in

India, it is influenced by caustic soda.

Caustic soda finds its application mainly in alumina, textiles, paper, organics, inorganics, soaps &

detergents, etc. The supply of caustic soda can be influenced by the chlorine derivatives markets. If

caustic soda is in surplus, it can be stored safely. Chlorine find its way in market as its uses is in many

industrial sectors. The global demand for caustic soda grows by an average of 3% a year, for chlorine

by an average of 2.2% a year.

2.6 Import vs. Indigenous production

The global caustic soda, chlorine, and soda ash market volume is expected to reach 79.8, 74.2, and

58.1 million tons respectively translating into total revenue of over $60 billion by the year 2017. As of

year 2012, Asia consumes almost half of the combined volume of all the aforesaid products followed by

North America and Europe. The major application segments for chlorine are PVC and organic chemicals,

for caustic soda major applications are pulp and paper and organic and inorganic chemicals. Chlorine

and caustic soda are mainly produced using membrane and diaphragm technology with mercury cell

process in phasing out mode.

The major players in the market are The DOW Chemical Company (U.S.), Occidental Chemical

Corporation (U.S.), Bayer AG (Germany), PPG Industries (U.S.), Tata Chemicals Ltd (India), Shin-Etsu

Chemical Co. Ltd (Japan), Formosa Plastics Corp. (Taiwan), Solvay Chemicals (Belgium), Ineos Chlor

Ltd (U.K.), FMC Corporation (U.S.), Shangdong Haihua Group Co. Ltd (China), and Ciech S.A. (Poland).

2.7 Employment Generation (Direct and Indirect) due to the Project

During the construction phase around 200 workers and during the operational phase around 50 workers

will be required. Local skilled and semi-skilled workers will be engaged during construction phase. The

positives impact include enhanced direct employment for technical/administrative works and indirect

employment opportunities for transporters of raw material like salt, coal/petcoke etc. and finished goods.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


3 PROJECT DESCRIPTION

3.1 Type of project

The project is a Greenfield Chlor-Alkali Plant of 600 MTD (2×300 MTD) and Captive Power Plant of 32

MW. The project does not include any interlinked or interdependent projects.

3.2 Location (map showing general location, specific location and project boundary

& project site layout) with coordinates

The project site is located at Khasra No.: 15//11, 12,13,18/3,19,20,16//7/2,12/2,13,14,15,16,17,18/1,24

/2,25/1 at Village Landha, Tehsil Saha, and District: Ambala, Haryana. The total plot area is 5.2 ha.

Location map showing general location, specific location of proposed project is given in Annexure 1 Project boundary map is given in Annexure 2. Project site layout map is given in Annexure 3. The

co-ordinates of the project site is given in Table 3-1.

Table 3-1: Co-ordinates of the Proposed Project Site

Code Latitude Longitude

A 30°14'11.38"N 76°51'59.30"E

B 30°14'11.45"N 76°52'2.50"E

C 30°14'13.31"N 76°52'2.67"E

D 30°14'13.29"N 76°52'4.78"E

E 30°14'11.55"N 76°52'4.81"E

F 30°14'11.23"N 76°52'14.98"E

G 30°14'9.10"N 76°52'14.89"E

H 30°14'9.18"N 76°52'12.61"E

I 30°14'7.27"N 76°52'12.45"E

J 30°14'7.29"N 76°52'7.50"E

K 30°14'6.72"N 76°52'7.46"E

L 30°14'6.61"N 76°52'4.90"E

M 30°14'6.00"N 76°52'4.88"E

3.3 Details of alternate sites considered and the basis of selecting the proposed

site.

The proposed project is intended to be establish at Village: Landha, Taluka: Saha, District: Ambala

considering the following points:

Proximity to NH-1 catering 3 states- New Delhi, Himachal Pradesh, and Punjab which are

major market.

Close Proximity of local region like Rohtak, Bahadurgarh, Rewari for chlorine derived products.

Hence need of alternative site identification is not felt.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


3.4 Size or magnitude of operation

Capacity of proposed facility is given in Table 3-2

Table 3-2: Size/Magnitude of Proposed Facilities

S. No. Proposed Facility Capacity

1 Chlor Alkali Plant 600 MTD

2 Captive Power Plant 32 MW

3.5 Project description with process details (a schematic diagram/flow chart

showing the project layout, components of the project etc, should be given)

Details of proposed production capacity of Chlor-Alkali plant is given in Table 3-3

Table 3-3: Proposed Production Capacity of Chlor-Alkali plant

S.

No. Products Additional Proposed (MTPA)

1 Caustic Soda (Lye) 1,04,400

2 Chlorine 90,000

3 Hydrochloric Acid (100%) 3,600

4 Hydrogen 3,000

5 Sodium hypochlorite 900

Project Description:

Chlor-Alkali Plant

The process is based on Membrane Cell technology. The main steps in the process to manufacture

caustic soda are

Purification of brine.

Electrolysis.

Concentration and flaking of caustic soda solution.

In the process Hydrogen and Chlorine gas are produced as the co-product.

Brine Purification

General: Brine for ion exchange membrane Chlor-Alkali process is prepared by dissolving salt in the

return brine from the electrolysis plant, and purified in two stages. Primary purification removes

impurities like calcium, magnesium, sulphate, iron, silica etc. to ppm level. Secondary purification is

required to make brine suitable for the ion exchange membrane Chlor-alkali process.

1. Primary Brine Purification

Primary Brine Purification section consists of Salt Handling system, Brine Saturator, Reactor Clarifier,

Clarified Brine Tank and associated facilities.

This process includes Brine saturation, chemicals dosage, reaction and sedimentation. The purpose of

this process is to re-saturate the return brine with raw salt and to remove impurities from the

saturated raw brine.

The return brine is fed from the top of the Brine Saturator and saturated with salt. The salt is

continuously supplied to the top of the saturator by a Belt Conveyor System.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


The saturated raw brine overflows from the Brine Saturator and flows into Reactor. Chemicals such as,

sodium carbonate, caustic soda are fed to Reactor.

Calcium, magnesium and other multivalent cations and sulphate anions in the raw brine react with these

chemicals and are changed to suspend solids while the brine is held in the reactor.

pH of the brine is controlled by the addition of caustic-soda to the brine. Then the brine overflows from

the reactor into the Brine Clarifier. Flocculent is fed to the brine line entering the clarifier.

Suspended solids in the brine are removed by settling in the Clarifier provided with water seal & insulated

from the sides. The brine, thus clarified, flows into clarified Brine tank over the weir of Clarifier & is

pumped out and recirculated to the brine system before reactor for better clarification. Slurry is

periodically measured for better control.

A part of slurry is sent to Sludge Filter System. The clarified brine is sent to Secondary Brine purification

section by clarified brine pump.

2. Secondary Brine Purification

Secondary Brine Purification Section consists of Brine Filter and Ion Exchange Resin Column.

The clarified brine is filtered through the filter and flows into filtered Brine tank. Suspended solids

caught on the filter element surface are blown down to Filter Slurry Pit. Filter Slurry in the pit is sent

to centrifuge where most of the brine is recovered and fed back to Return Brine Tank.

Ion Exchange Resin Column packed with special Ion Exchange resin is operated and controlled

automatically from control room.

This specially developed Ion exchange resin can remove multivalent cations harmful to the Ion

exchange membrane. The brine thus purified is fed to Electrolyser and electrolysis is conducted.

ELECTROLYSIS

Electrolysis section consists of bipolar Electrolysers and their associated equipment’s.

1. Electrolyser

Electrolyser consists of number of bipolar type cell frames with the metal anode and the activated

cathode, the Ion exchange membrane, press unit for mounting cell frames, sub-headers for feeding

anolyte and catholyte, sub-headers, and oil pressure unit which supplies oil to oil cylinders.

Cell frames holding the Ion Exchange membrane in between are fixed by the oil cylinder installed at

the end of the press unit. This structure ensures no leakage of electrolytes because uniform pressure

can be applied to gasket surface and cell frame of metal structure ensures no electrolyte leakage

caused by deformation even after a long period of operation.

2. Anolyte Circulation

Anolyte circulation system is composed of Anolyte Circulation Tank and anolyte circulation pump.

Anolyte is fed into each of anode compartment of cell frames through subheaders and hoses, and

recirculated to Anolyte circulation Tank. Purified brine is fed to maintain anolyte concentration within a

designed level. A part of the anolyte, is taken out from Anolyte Circulation Tank to Depleted Brine

Tank by overflow.

Anolyte Circulation system is designed to ensure steady and uniform distribution of anolyte to each

cell and to cope-up with any change in electrolysis conditions such as production rate change.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


The diluted brine collected in Depleted Brine Tank is sent to De-chlorination Tower for removal of

Chlorine gas. Chlorine gas generated in electrolyser is separated in Anolyte Circulation Tank and sent

to Chlorine gas cooling, drying and compression section.

3. Catholyte Circulation

Catholyte Circulation System is composed of Catholyte Circulation Tank, Catholyte Circulation Pump

and Catholyte Cooler.

Catholyte is circulated through cathode compartment of cell frames to Catholyte Circulation Tank by

Catholyte Circulation Pump, and a part of it is taken out from Catholyte Circulation Tank to Caustic

Soda Tank and sent out to caustic evaporation section. To keep the concentration of caustic soda at

designed level, demineralised water is fed to catholyte inlet sub-header. Hydrogen gas generated in

Electrolyser is separated from the catholyte in catholyte Circulation Tank and sent to Hydrogen Gas

Cooling and Compression Section. Heat generated in electrolyser is removed by cooling water in

Catholyte Cooler.

DE- CHLORINATION OF RETURN BRINE

De-chlorination section is composed of De-Chlorination Tower, De-Chlorination Tower Cooler, Ejector,

Ejector Cooler and associated facilities. Return brine, (depleted brine) from Electrolysis Section is

saturated with chlorine.

In the tower, chlorine is stripped together with water vapor, and passed through De-chlorination

Tower cooler. The vapor are condensed there and the chlorine gas is sucked by the steam ejector to

Ejector Cooler.

Steam is condensed there and the chlorine gas is then introduced to chlorine gas product main line.

The depleted brine dechlorinated through De-chlorination tower, still contains small amount of free

chlorine which can cause damage to the filter elements in Brine Filters and damage ion exchange resin

in Ion Exchange Resin Columns. Sodium sulfite is added to kill free chlorine. Return brine is then fed

to Return Brine Tank & pumped to salt saturator.

Caustic Concentration

The caustic soda concentration system consists of triple effect falling film evaporators operating on

backward feed flow scheme. 30% caustic solution 80 0C is fed to third effect evaporator. Vapors are

separated from solution and concentrated solution of third effect evaporator is pumped to second

effect evaporator after passing through two heat exchangers in series. In the second effect

evaporator, flash evaporation of liquor takes place and liquor is further heated by steam and vapors

are separated in second effect evaporator to concentrate liquor.

The concentrate from the second effect evaporator is pumped through first effect evaporator after

passing through two heat exchangers in series. Steam at 11 kg/cm2a pressure is used to attain

required concentration of caustic.

Chlorine Liquefaction & Bottling

1. Chlorine Gas Washing and Cooling

Chlorine Gas coming out of Anolyte circulation tank contains water vapor saturated at about 900C

and has little amount of Sodium Chloride as entrainment. Gas is first washed by process water in a

direct contact scrubbing packed tower. Condensate is sent to dechlorination tower. The process water

is in turn cooled by cooling tower.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


Cooled gas is then passed through a packed tower having chilled process water circulation at 160 C so

as to cool the gas to reduce water vapors load.

Chlorine gas temperature is generally around 15-20 deg C as cooling below 9-10 0C will result into

formation of Chlorine hydrate. Cooled gas is then dried with direct spray of sulfuric acid in packed

towers.

2. Chlorine Gas Drying

The cooled chlorine gas is led to chlorine Gas Drying Tower. The moisture of chlorine gas is absorbed

into sulfuric Acid of 98% concentration fed into the two stage chlorine gas drying tower, and gets

diluted to 70% by absorption of moisture from chlorine gas. Chlorine Gas Drying Tower has a

cooler to cool circulating sulfuric Acid. The Dry Chlorine gas is sent for compression.

3. Chlorine Gas Compression

Dry chlorine gas from chlorine Gas Drying Section is compressed to 4 kg/cm2 (a) by using Acid Ring

type Compressor.

4. Chlorine Gas Liquefaction and Filling

Chlorine gas from compressor is sent to chlorine Gas Liquefaction Unit to be condensed by the Freon

22 refrigerant. The unliquefied gases along with inert gas from Liquefier are sent to HCI Synthesis unit

for burning with Hydrogen to produce HCl.

Liquefied chlorine enters Chlorine Storage Tank from where it is transferred by means of compressed

dry air to chlorine bottling section. Part of liquid Chlorine is vaporised and sent to nearby customers

through pipeline.

5. Waste Chlorine Neutralization / Sodium Hypochlorite Section

Waste chlorine gas, only in case of plant emergency is led to the Sodium Hypochlorite Unit. Chlorine

Gas during start up and plant tripping is fed to the absorption tower. This unit consists of packed

tower in which caustic solution is circulated to absorb waste chlorine. Temperature of the liquid is

controlled by heat transfer through plate type heat exchanger with chilled water.

After a desired strength of sodium hypochlorite is reached, the solution is sent to a Hypo Reactor.

Here it is reacted with fresh chlorine to produce marketable quality Sodium Hypochlorite.

6. HCL Synthesis

The HCI Synthesis unit consists of combustion furnace fitted with absorbers. The chlorine gas reacts

with Hydrogen to form HCI gas which is cooled and absorbed in DM water. The flow rate of DM water

is adjusted to obtain 30-33% HCI Solution. The flow rates of Chlorine and Hydrogen are controlled by

flow controllers. Safety Interlocking provisions are made which get actuated by flame protection

device. The Hydrochloric Acid Solution is collected in a product tank from where is pumped to HCI

Storage Tanks.

7. Hydrogen Bottling and Storage

Hydrogen gas is compressed and filled in hydrogen cylinders banks of the customers and also stored

in cylinder banks.

Chemical Reaction:

2 NaCl(aq) + 2 H2O(l) H2(g) + Cl2(g) + 2NaOH(aq)

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


Power Plant

Process Description

Coal/Petcoke will be used as a fuel source for the Power plant. Basic process involves steam

generation by combustion of coal in boiler. Steam is used to run turbine for power generation.

The process flow diagram is given in Figure 3-1.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


Figure 3-1: Process Flow Diagram

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


3.6 Raw material required along with estimated quantity, likely source, marketing

area of final products, mode pf transport of raw material and finished products.

The major raw materials are industrial salt and power. Details of raw material along with the Quantity,

Source and Mode of Transport is given in Table 3-4

Table 3-4: Details of Raw material Quantity, Source and Mode of Transport

S.

No. Raw Material

Proposed

Quantity

(MTPA)

Source Mode of

Transport

1 Salt 1,60,000 Ambala storage areas originally

from Rajasthan and Gujarat Damper/trucks

2 Na2CO3 770 Local Market Trucks

3 Sodium Sulphite 140 Local Market Trucks

4 Flocculent 1 Local Market Trucks

5 H2SO4 1,500 Local Market Tanker

6 Coal/Petcoke 1,21,968 Imported/Indigenous Trucks

3.7 Resource optimization/recycling and reuse envisaged in the project,

The process waste water will be treated with R.O technology and will be recycle back into the process.

Most energy efficient technology will be selected.

3.8 Availability of water its source, energy/power requirement and source should

be given

Water: The water will be extracted from inhouse borewell with prior permission from CGWA.

Power: The details of energy requirement is given in Table 3-5

Table 3-5: Details of Proposed Energy Requirement

S. No. Unit Proposed Quantity (MW)

1 Coal/Petcoke based Power Plant 32

Emergency Power:

D.G set of 3 Nos. will be used for back-up or emergency usage of 600 KVA.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/disposal

Gaseous Emissions

The main sources of Gaseous Emission from proposed project will be:

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


Stack attached to power plant

Waste Chlorine absorption system (Hypo Plant)

HCl plant

Details of anticipated air emissions from Process and Flue gas are given in Table 3-6.

Table 3-6: Details of emissions from process and flue gas stacks along with their mitigation methods

S.

No.

Stack

Attached to

Stack

Height

(m)

Stack

Diameter

(m)

Exit

Velocity

(m/s)

Pollutants Mitigation

measures

Process Stacks

1. HCl plant 30 0.15 1 HCl Water/Caustic

scrubber

2.

Sodium

Hypo

chlorite

plant

30 0.3 1.2 Cl2 Caustic

scrubber

Flue Gas Stack

1 Boiler of

CPP 60 3 12

SO2 Adequate

Stack height NOx

PM ESP

3 D.G Set

30 1 20.6 SO2, NOx,

PM

Adequate

Stack height 4 D.G Set

5 D.G Set

Liquid Effluent

The waste water generated from the process will be treated using R.O technology and the permeate

of R.O will be recycle back into the process while if required MEE will be used to treat R.O reject,

hence the plant will be a Zero liquid discharge unit.

Solid Waste Generation

Brine sludge is generating during brine purification process in membrane based pollution free Chlor

alkali plant. It contains Inorganic solids of Calcium carbonate, Magnesium hydroxide. Natural sea salt

(produced in Gujarat), our basic raw material, contains impurities like calcium. Magnesium & Sulfate.

We precipitate out these impurities as Calcium carbonate, Magnesium hydroxide and Barium sulfate as

per standard brine purification process followed worldwide. None of these impurities are hazardous.

Brine sludge is not Hazardous in nature.

Details of solid waste generated is given in Table 3-7

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


Table 3-7: Details of Hazardous Solid Waste generation from proposed project

S. No Waste Name Category Proposed Quantity

Per Annum Disposal Method

1 Discarded

Bags 33.3

1,02,000

(Nos.)

To authorized

vendors

2 Used Oil 5.1 250 Lt To authorized re-

refiners.

Table 3-8: Details of Solid Waste Generation from proposed project

S. No Waste Name Proposed

Quantity MTPA Disposal Method

1 Brine Sludge 3,630 To Secured landfill site

2 Fly ash 6,566.4 As per Fly ash notification will be given to brick

making units

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


3.10 Schematic representations of the feasibility drawing which give information of

EIA purpose.

Government of India, as per its policy has given emphasis on Sustainable Development. While it is

supporting the industrial growth, the environmental protection has been made the integrated criteria

for this support. In line with this policy, Ministry of Environment & Forests has defined elaborated

‘Environmental Clearance (EC)’ framework under The Environment (Protection) Act, 1986

(Environmental Impact Assessment Notification, 2006) for establishing/expanding an

industry/development project. The EC process takes into consideration local conditions, public concerns,

effectiveness of impact assessment and proposed mitigation measures in sustaining environmental

equilibrium. The base documentation/study report, called Environmental Impact Assessment (EIA)

detailing baseline conditions, environmental impacts, mitigation measures and management plan is

required to be prepared for start of EC process. Prior Environmental Clearance is required from

concerned authorities for all projects detailed in the ‘Schedule’ as given in the ‘Notification date 14th

September, 2006’. The projects listed as category A or B under EIA notification require submission of

EIA report as per approved TOR for appraisal by expert committee for EC.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


4 SITE ANALYSIS

4.1 Connectivity

Table 4-1: Connectivity of Road, Railway and Airport with the site

S. No Routes Distance in ~km

Direction

Roads

1 NH -1 1.5 WSW

2 NH -73 12 NE

3 SH -31 3.9 S

4 SH -4 5.9 SSW

5 SH -7 7.9 SSW

6 SH -5 8 SSW

Railway

1 Mohri 2.7 NNW

2 Dukheri 6.7 NE

3 Kesari 7.0 ENE

4 Shahabad 7.7 SSW

5 Tandwal 11.5 ESE

6 Ambala Cantonment R.S 11.3 NW

Airport

1 Chandigarh 49.1 NNW

2 Patiala 49.4 NNW

4.2 Land Form, Land Use and Land Ownership

The total plot area of the plant is 5.2 ha. The proposed project is to be carried out at village Landha,

Tehsil Saha, District Ambala, Haryana. The site is an undeveloped land and is owned by Shree Ganesh

Fats (P) Ltd. The land documents are attached as Annexure 4. No Objection certificate is obtained

from the department of Town and Country Planning, Haryana for setting up of Industrial unit on the

given Khasra Nos. which is attached as Annexure 5

4.3 Topography

The district area is occupied by Indo-Gangetic alluvium, the area is traversed and drained by seasonal

streams namely Tangri, Beghna and Markanda. Physiographically the area is flat terrain. However a

little part in the extreme northeastern area of the district is occupied by Siwalik hills, and falls in the

zone of “Dissected Rolling Plain”. The area slopes towards southwest with an average gradient of

1.5m/km. The general elevation in the district varies between 245m to 300m above MSL.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


project to periphery of the forests, national park, wild life sanctuary, eco

sensitive areas, water bodies (distance from HFL of the river), CRZ.

The existing land is an undeveloped land which does not include agricultural, forestry, water bodies

(including CRZ) and there are no forests, national parks, wild life sanctuary, eco sensitive areas, water

bodies (distance from HFL of the river), CRZ within the study area.Error! Reference source not

found.

4.5 Existing Infrastructure

The proposed project is a new Greenfield project and there are no existing infrastructures on the site.

4.6 Soil Classification

The soils are non-calcareous and sandy loam on the surface, and loam to clayey loam at depth, and

placed under the classification of soil as Udipsamments/Udorthents.

4.7 Climatic data from secondary sources

The climate of Ambala district can be classified as subtropical monsoon, mild & dry winter, hot

summer and sub-humid. The hot weather season starts from mid-March to last week of the June

followed by the south west monsoon which lasts upto September. The transition period from

September to November forms the post monsoon season. The winter season starts late in November

and remains upto first week of March. The normal annual rainfall of the district is 1076 mm. The mean

maximum temperature is 40.8°C (May & June) and mean minimum is 6.8°C (January).

4.8 Social Infrastructure available

Key infrastructure such as primary health centers, schools, bank, places of worship and social/

community facilities such as market, playground etc are available in nearby area of proposed site.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


5 PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and

Country Planning/ Development Authority Classification

The proposed is Chlor-Alkali Plant. This will be the first chemical industry in this area. Within a radius of

1 km storage godowns/sheds, poultry farm etc are located. The project area does not falls within any

controlled area declared by Department of Town and Country Planning, but falls within Urban area

Ambala. No Objection certificate is obtained from the department of Town and Country Planning,

Haryana for setting up of Industrial unit on the given Khasra Nos. which is attached as Annexure 5.

5.2 Land use planning (breakup along with green belt etc)

The green belt area of 1.7 ha (17,360 sqm) i.e 33% of total plot area. Processing area includes:

Storage area, plant area, administrative buildings, parking area, canteen etc.

5.3 Assessment of Infrastructure Demand (Physical & Social)

Key infrastructure such as primary health centers, schools, bank, places of worship and social/

community facilities such as market, playground etc are available in nearby area of proposed site.

5.4 Amenities/Facilities

Approach road from highway is adequate to take load of transportation. State Electrical transmission

lines are available in the near vicinity Basic amenities like public transport, water supply,

telecommunications, educational institutions, hospitals etc. are available in nearby area. Facilities for

water requirement will be met through existing Borewell.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing area)

Salt storage area

Brine sections

Cell house

Utilities

Cooling towers

Chlorine bottling area

Liquid Chlorine storage area

Caustic soda evaporation and storage area

HCl plant, Hypo plant

Hydrogen compression and Bottling area

Hydrogen holder

Hypo, HCL storage

Chemical storage

Boilers

ESP

Effluent treatment plant

DM water plant

D.G House

Transformers and Rectifiers

6.2 Residential Area (Non- Processing Area)

Water reservoir

Weighbridge

Security cabins

Workers restroom,

Parking/Vehicle Shed

Canteen

Administrative Block

Workshop

6.3 Green Belt

The green belt area of 1.7 ha (17,360 sqm) i.e 33% of plot area will be provided.

6.4 Social Infrastructure

Civic/infrastructural facilities like public transport, water supply, telecommunications, educational

institutions, hospitals etc. are available in nearby areas.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


6.5 Connectivity

Adequately described in point 4.1.

6.6 Drinking Water Management

The water will be abstracted from in-house Borewell with prior permission from CGWA. The domestic

water requirement is ~3 KLD. Drinking water for workmen will be procured locally.

6.7 Sewerage System

The domestic effluent will be disposed off in soak pit via septic tank.

6.8 Industrial Waste Management

The process waste water generated will be treated using R.O technology and the permeate of R.O will

be recycle back into the process and MEE will be used to treat R.O reject, hence the plant will be a

Zero liquid discharge unit.

The industrial Hazardous solid waste like discarded bags will be given to authorized vendors and used

oil to authorized refineries. The other process solid waste like brine sludge will be sent to secured

landfill site. The solid waste of MEE will also be sent to secured landfill facility. Fly ash will be given to

brick making units.

6.9 Power Requirement & Supply / source

The power requirement for proposed project will be 32 MW which will be procured from Captive Power

Plant. D.G sets (3 Nos.) of 600 KVA will be installed as backup.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


7 REHABILITATION AND RESETTLEMENT (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.

Rehabilitation and Resettlement (R&R) plan is not applicable for the proposed project.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


8 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion

The construction is likely to start after getting Environmental Clearance from regulating authority. This

process may take 12-14 months. Then after NOC from pollution Control Board is required.

Construction work will start, technology selection and detailed engineering will be simultaneously done

with EC process. Construction and execution work will be completed in 12-14 months.

8.2 Estimated project cost along with analysis in terms of economic viability of the

project

The total investment is envisaged to INR 350 crores. The project is economically viable as Cl2 and

Caustic are in high demand with chemical and other process industries. There is huge demand of

these chemicals with good returns.

SHREE GANESH

FATS (P) LTD.



PRE-FEASIBILITY

REPORT


9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits with special emphasis on the benefit to the local

people.

Project process technology is well established and supplied on turnkey basis by international

process houses.

The project is being established by well-known technology having industrial background and

has financial support from parent industry. Bank loans are also available.

This will generate employment opportunity for skilled and semi-skilled work force.

Local people around 200, non-skilled or semi-skilled will get daily work during construction

phase.

During operational phase, around 50 skilled persons (Engineers, technicians, Arts and

commerce graduates) will get opportunity to work in administration process and safety or

maintenance sections.

SHREE GANESH


LANDHA, TEHSIL: SAHA, DISTRICT: AMBALA, HARYANA ANNEXURES


ANNEXURES

SHREE GANESH


LANDHA, TEHSIL: SAHA, DISTRICT: AMBALA, HARYANA ANNEXURES


Annexure 1: Map Showing General and Specific Location of Project Site

SHREE GANESH

FATS (P) LTD.

EC FOR PROPOSED CHLOR-ALKALI PLANT AND CPP AT VILLAGE: LANDHA,

TEHSIL: SAHA, DISTRICT: AMBALA, HARYANA ANNEXURES


Annexure 2: Project Boundary Map

SHREE GANESH

FATS (P) LTD.

EC FOR PROPOSED CHLOR-ALKALI PLANT AND CPP AT VILLAGE: LANDHA,

TEHSIL: SAHA, DISTRICT: AMBALA, HARYANA ANNEXURES


Annexure 3: Site Layout Map

SHREE GANESH



OTHER

DOCUMENTS

KADAM ENVIRONMENTAL CONSULTANTS |OCTOBER 2014

Annexure 4: Land Documents

SHREE GANESH



OTHER

DOCUMENTS


SHREE GANESH



OTHER

DOCUMENTS


SHREE GANESH



OTHER

DOCUMENTS


SHREE GANESH



OTHER

DOCUMENTS


SHREE GANESH



OTHER

DOCUMENTS


SHREE GANESH



OTHER

DOCUMENTS


Annexure 5: NOC from Department of Town and Country Planning, Haryana

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

K a d a m Environmental

Consultants www.kadamenviro.com

Environment for Development

mailto:[email protected]

mailto:[email protected]

http://www.kadamenviro.com/

Date post:	11-Jun-2020
Category:	Documents
Upload:	others
View:	7 times
Download:	0 times