1
PRE FEASIBILITY REPORT
For
PROPOSED EXPANSION OF CARBON BLACK (10950 TPM
TO 15750 TPM ) AND CO-GENERATION POWER PLANT
(22 MW TO 32 MW) IN EXISTING PREMISES
of
M/s. PHILLIPS CARBON BLACK LTD.
Survey No. 47, SH – 46, Village: Mokha, Tal: Mundra Dist:
Kutchh-370421, Gujarat
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CONTENTS
Sr. No. Description Page No.
1. Executive Summary 3
2. Introduction of the Project/Background information 7
3. Project Description 10
4. Site Analysis 15
5. Planning Brief 16
6. Proposed Infrastructure 16
7. Rehabilitation and resettlement (R & R) Plan 18
8. Project Schedule & Cost Estimates 18
9. Analysis of Proposal (Final Recommendations) 18
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1.0 EXECUTIVE SUMMARY
1.1 Company Profile
Introduction
PCBL, a part of USD 2500 million (or 2.5 billion) RP-Sanjiv Goenka Group, has a business of USD
500 million and four strategically located state-of-the-art Carbon Black plants at Durgapur,
Palej, Cochin and Mundra. PCBL today is India's largest and globally seventh largest carbon
black producer.
Set up in collaboration with a US company Phillips Petroleum, PCBL started production in 1962
with 14,000 metric tonnes (MT) of carbon black at Durgapur. Currently, it has a production
capacity of 4,72,000 MT per annum in India, and involves a dedicated capacity of Specialty
Blacks of 40,000 MT per annum at Palej.
PCBL provides a complete portfolio of products to meet the specific end requirements across
Rubber, Plastics, Coatings, Inks and other niche industries globally. The Company has been
continuously reinventing itself in order to make the best in class products. Additionally, PCBL's
after sales service and strong technical support ensures a fiercely loyal base of customers from
around the world. PCBL has etched its global footprints and has a market presence in more than
30 nations with decanting stations, warehouses located near customer locations. A few of the
Company's prized customers are CEAT, MRF, Michellin, Yokohama, Birla Tyres, Goodyear,
Sumitomo Tires, Bridgestone, Kumho Tires, etc.
PCBL has redefined its business by establishing captive power plants at each factory from the
off-gas or waste product from the carbon black manufacturing process thus creating a
sustainable green movement. The gas, a by-product of carbon black production, is harnessed
for generating electricity at the Company's Captive Power Plants (CPP), at Palej, Durgapur,
Mundra and Kochi. That is why PCBL is the first carbon black company in the world to receive
carbon credits. The Company has heavily cut down on carbon and gas emission, and serves
green power to Large Private industrial units and State Electricity utilities.
From the pioneer plant at Durgapur in the East to Kochi plant in the south, Palej and Mundra
plants in the west - PCBL footprint spans across India. Wherever PCBL goes, the Company
becomes an integral part of the social eco-system. PCBL's more than 50 years' journey to be the
cleanest carbon black company is the result of meticulous planning and committed execution.
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1.2 Project Details
SR.
NO. PRODUCT NAME
EXISTING
CAPACITY
(MT/MONTH)
ADDITIONAL
CAPACITY
(MT/MONTH)
TOTAL CAPACITY
(MT/MONTH)
1 Carbon Black 10950
Phase – I: 2400
Phase – II: 2400
Phase – I: 13350
Phase – II: 15750
2 Co-generation Power (waste gas
base) 22 MW
Phase – I: 2 MW
Phase – II: 6 MW
Phase – I: 24 MW
Phase – II: 32 MW
1.3 Green Belt Development
Company has developed an effective green belt within the factory and on periphery of the
factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses.
1.4 Power & Fuel Requirement
Fuel
Existing:
LDO= 30 KL/Month (only for heating & cooling during startup & stops)
HSD= 4 KL/Month
After Proposed Expansion:
LDO= 40 KL/Month (only for heating & cooling during startup & stops)
HSD= 6 KL/Month
Energy :
Existing: 7 MW from own CPP
After Proposed Expansion:
Total: 9.5 MW from own CPP
Note: During start up & shut down PGVCL power will be utilized.
1.5 Water Requirement and Wastewater Generation & Treatment
Total Proposed Expansion scenario:
• Source of water will be met through GWIL water supply. Total water requirement will be
2029 m3/day (Fresh –1691 m
3/day + Recycled -338 m
3/day).
• The total wastewater generations will be 391 m3/day.
• 338 KL/Day wastewater from the Cooling and chilling, boiler, and washing will be treated in
ETP and treated effluent recycled back for cooling & chilling purpose and gardening.
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• 53 m3/day Domestic wastewater generated shall be disposed through septic tank & soak
pit.
1.6 Air Pollution Source and Control Management
The source of air pollution due to the expansion project will be Flue gas emission and process
gas emission. The source of flue gas emission will be from the stack attached to Flare stack-1,
Flare stack-2, CPP-1, CPP-2, CPP-3, D.G. Set. The source of process gas emission will be from
the vent attached to VBC- 1, VBC- 2, VBC- 3, Dryer -1, Dryer -2 & Dryer -3 etc.
Total:
1) Flue Gas Stacks
SR.
NO. STACKS ATTACHED TO
HEIGHT FROM
GROUND
LEVEL (m)
CONSUMPTION
OF FUEL (KL/hr)
DIAMETER
(m)
EXPECTED
POLLUTANTS
1 Process Plant –Flare stack
(Existing)
50 Nil 1.0 SPM, SOx, NOx
2 Process Plant –Flare stack
(Proposed)
50 Nil 1.8 SPM, SOx, NOx
3 CPP 16MW–Boiler Chimney
(Existing)
80 Nil 2.5 SPM, SOx, Nox
4 CPP 6MW–Boiler Chimney
(Existing)
80 Nil 1.8 SPM, SOx, Nox
5 CPP 8MW–Boiler Chimney
(Proposed)
80 Nil 1.8 SPM, SOx, Nox
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2) Process Stacks
1.7 Hazardous Waste Management
SR.
NO
.
PROCESS STACK
ATTACHED TO
HEIGHT FROM
GROUND (m)
DIAMETER
(m)
AIR POLLUTION
CONTROL SYSTEM
EXPECTED
POLLUTANTS
1 VBC- 1 (Existing) 50 1.0 Bag Filter SPM, NOx
2 VBC- 2 (Existing) 50 1.0 Bag Filter SPM, NOx
3 Dryer -1 (Existing) 50 1.1 Bag Filter SPM, NOx
4 Dryer -2 (Existing) 50 1.1 Bag Filter SPM, Nox
5 VBC- 3 (Proposed) 50 1.0 Bag Filter SPM, NOx
6 Dryer -3 (Proposed) 50 1.1 Bag Filter SPM, NOx
SR.
NO.
NAME OF
WASTE
WASTE
CATEGORY
EXISTING QTY.
MT/YEAR
ADDITIONAL
QTY. MT/YEAR
TOTAL MODE OF DISPOSAL
1 Used Oil I-5.1 1.56 0.64 2.20 Collection, Storage,
Transportation, reuse in
process/sent to GPCB registered
recycler
2 Spent Acid from
Batteries
I-36.3 0.024 0.00 0.024 Collection, Storage,
Transportation, Disposal by
Authorized way
3 Chemical Sludge
from Waste water
treatment
I-34.3 27.00 8 35 Collection, Storage,
Transportation, Disposal at TSDF
site of SEPPL.
4 Oily Sludge
Emulsion
I-4.1 6.0 0 6 Collection, Storage,
Transportation, Disposal at
Common Incineration site of
SEPPL – Bhachau
5 Used Batteries 17 0.1
(CCA
Amendm
0 0.1 Collection, Storage,
Transportation, and Disposal as
per lead batteries rules.
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2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of the project and project proponent. In case of mining project, a copy of
mining lease/letter of intent should be given.
Identification of the project
ent
Applied)
6 Discarded Drum /
Barrels/
Containers / Bags/
Liners
33.3 8
(CCA
Amendment
Applied)
4 12 Collection, Storage,
Transportation, sent to GPCB
Approved recycler
7 Plastic Waste X-9 0.5
(CCA
Amendment
Applied)
0.5 1 Collection, Storage,
Transportation, sent to GPCB
Approved recycler.
8 Spent Ion
Exchange Resin
34.2 0.4
(CCA
Amendment
Applied)
0.2 0.6 Collection, Storage,
Transportation, Disposal at TSDF
site.
9 Oily Cotton Waste
/Leather Hand
Gloves / Cotton
Hand Gloves
33.2 0.4
(CCA
Amendment
Applied)
0.1 0.5 Collection, Storage,
Transportation, and Disposal by
incineration at SEPPL – Bhachau.
10 E-Waste 18.5 0.5
(CCA
Amendment
Applied)
0.2 0.7 Collection, Storage,
Transportation, sent to GPCB
Approved Recycler
11 Waste Insulation
Material
- 1
(CCA
Amendment
Applied)
0.5 1.5 Collection, Storage,
Transportation, and Disposal by
incineration at SEPPL – Bhachau
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PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO 15750 TPM ) AND CO-GENERATION
POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES
Identification of the project proponent
Presently following are the directors of the company:-
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2.2 Brief description of nature of the Project
PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO 15750 TPM ) AND CO-GENERATION
POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES
2.3 Need for the project and its importance to the country and or region
The objective is to
• Consolidate Business.
• Constantly upgrade the product range.
• Continuously reduce the Costs & improving Quality.
• Generate local employment
• Increase Govt. revenue in form of taxes and duties
2.4 Demands-Supply Gap
Based on our informal survey of the market with our current customers and various traders, we
have found that there is a big potential for the range of the products we are planning. This is
expansion of existing product's manufacturing capacity.
2.5 Imports vs. Indigenous production
Based on the current cost of indigenous raw materials and the non availability of some
materials, we will have to import some of the key raw materials as they are not available
indigenously. This will make us very competitive against imported finished products and we will
be able to increase the export of our finished products.
2.6 Export Possibility
There is export potential of our proposed products. At present, we are exporting approx 30 % of
product to countries all over the world.
2.7 Domestic/Export Markets
There is export potential as well as demand in local market. At present with operation at
approx. 100 % capacity utilization, we are not able to meet the demand of the market.
2.8 Employment Generation (Direct and Indirect) due to project.
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Employment would be as per prevailing norms of state government for skilled and unskilled
people for the proposed expansion project.
3.1 Project Description
3.2 Type of Project including interlinked and interdependent projects, if any.
PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO 15750 TPM ) AND CO-GENERATION
POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES
- Category: A-5(c)
3.3 Location (map showing general location, specific location and project boundary & project
site layout) with coordinates.
Map showing general location
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Layout
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3.3 Details of alternate sites considered and the basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
Major factors involved in the selection of site are listed below:
• Existing operational industry
• Site is very well connected by road
• Proximity to Mundra & Kandala Ports
• Availability of sufficient land free from cultivation
• Availability of power evacuation facilities
• Availability of water for industrial use
• Environment-friendly zone
• Uninterrupted power supply.
3.4 Size or Magnitude of Operation
Please refer Section 1.2 (Page No. 4) of Pre-Feasibility Report.
3.5 Project Description with process details (a schematic diagram/flow chart showing the
project layout, components of the project etc. should be given)
Please refer Annexure-III in Form-I (Page No. 14)
3.6 Raw material required along with estimated quantity, likely source, marketing area of
final products. Mode of transport of raw materials and finished products.
Please refer Annexure-1 in Form-I (Page No. 14)
3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be
briefly outlined.
There will not resource optimization/recycling and reuse envisaged in the project.
3.8 Availability of water its source, energy/power requirement and source should be given.
Power & Fuel Requirement
Fuel
Existing:
LDO= 30 KL/Month (only for heating & cooling during startup & stops)
HSD= 4 KL/Month
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After Proposed Expansion:
LDO= 40 KL/Month (only for heating & cooling during startup & stops)
HSD= 6 KL/Month
Energy :
Existing: 7 MW from own CPP
After Proposed Expansion:
Total: 9.5 MW from own CPP
Note: During start up & shut down PGVCL power will be utilized.
Water Source
The entire water requirement will be met through GWIL water Supply.
3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their
management/disposal.
Liquid Waste:
• Source of water will be met through GWIL water supply. Total water requirement will be
2029 m3/day (Fresh –1691 m
3/day + Recycled -338 m
3/day).
• The total wastewater generations will be 391 m3/day.
• 338 KL/Day wastewater from the Cooling and chilling, boiler, and washing will be treated in
ETP and treated effluent recycled back for cooling & chilling purpose and gardening.
• 53 m3/day Domestic wastewater generated shall be disposed through septic tank & soak
pit.
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3.10 Schematic representations of the feasibility drawing which give information of EIA
purpose.
RECONNAISSANCE SURVEY OF EXISTING PLANT ANNUAL REPORT
MARKET ASSESSMENT
FINANCIAL REPORT
PROJECT REPORT
INTRODUCTION
MONITORING OF AIR, WATER & SOIL QUALITY & NOISE
LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS
& BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH
LOCALS
BASELINE
ENVIRONMENTAL
STATUS
ENVIRONMENTAL INFORMATION CENTRE
CENTRAL GROUND WATER BOARD
GUJARAT POLLUTION CONTROL BOARD (GPCB)
PUBLIC HEALTH ENGINEERING DEPT.
AGRICULTURE DEPARTMENT
FOREST DEPARTMENT
IRRIGATION DEPARTMENT
EMPLOYMENT EXCHANGE
HEALTH CENTER
CENSUS DEPT.
INDIAN METEOROLOGICAL DEPT.
SOCIOECONOMIC
STATUS &
INFRASTRUCTURE
PROPOSED Expansion
PLANT
FACILITY DESCRIPTION
IMPACTS
METHODOLOGY OF
IMPACT
ASSESSMENT
IDENTIFICATION & ASSESSMENT OF IMPACTS
EVALUATION OF IMPACTS BY MATRIX METHOD
SOURCE OF INFORMATION OVERVIEW OF
E. I. A. STUDIES
ACTIVITIES
ENVIRONMENTAL
MANAGEMENT PLAN
DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR
POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT,
GREEN BELT DEVELOPMENT MONITORING PROGRAM
RISK ANALYSIS
STUDIES &
DISASTER
MANAGEMENT PLAN
SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY
DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS
PREPARATION OF DISASTER MANAGEMENT PLAN
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4.0 Site Analysis
4.1 Connectivity
• Site is very well connected by road
• Availability of power evacuation facilities
• Availability of water for industrial use
4.2 Land Form, Land Use and Land Ownership
It will be incorporated in EIA Studies.
4.3 Topography (along with map)
It is attached separately.
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. In case of the notified industrial area, a copy of the Gazette notification should be
given.
It will be incorporated in EIA Studies. CRZ Clearance is not applicable to us.
4.5 Existing Infrastructure
Existing Infrastructures facilities are listed in Topic no. 1.6 on Page no. 5.
4.6 Soil Classification
It will be incorporated in EIA Studies.
4.7 Climatic data from secondary sources.
Primary source: our own weather station & Secondary sources: Indian Meteorological
Department, Ahmedabad.
4.8 Social infrastructure available.
Depending on the requirement of the region, social infrastructure will be provided.
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5.0 Planning Brief
5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country
planning/Development authority classification.
PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO 15750 TPM ) AND CO-GENERATION
POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES
5.2 Population Projection
No major effect on population in the surrounding region.
5.3 Land use planning (breakup along with green belt etc.)
5.4 Assessment of Infrastructure Demand (Physical & Social)
• Employment would be as per prevailing norms of state government for skilled and unskilled
people for the proposed expansion project.
• Social Welfare
• Cordial industrial relation in the industry shall be established and representation shall be
made to villagers for help for creation of facilities related to health, education, etc.
5.5 Amenities/Facilities
It will be incorporated in the EIA Studies.
6.0 Proposed Infrastructure
6.1 Industrial Area (Processing Area)
Processing Area (Processing Zone, ETP Area and Utility Area): 112647 m2
6.2 Residential Area (Non Processing Area)
Non Processing Area (Green belt, road, Open Area): 181076 m2
Sr. no. Particular Area in M2
1 Rooftop & building shade 20262
2 Road/Paved Area (Plant) 112647
3 Green Belt Area 119210
4 Open Area 39337
Total Area 291456
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6.3 Green Belt
Company has developed an effective green belt within the factory and on periphery of the
factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses.
6.4 Social Infrastructure
Depending on the requirement of the region, social infrastructure will be provided.
6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc.)
Site is very well connected by road & railway.
6.6 Drinking water Management (Source & Supply of water)
Water requirement will meet through the GWIL Water Supply.
6.7 Sewerage System
Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful
liquid wastes from the offices, canteen and domestic waste coming from different sections.
These liquid wastes are treated and disposed by septic tank and soak pit.
6.8 Solid Waste Management
Please refer Section 1.6 in Pre-Feasibility Report.
6.9 Power Requirement & Supply/Source
Energy :
Existing: 7 MW from own CPP
After Proposed Expansion:
Total: 9.5 MW from own CPP
Note: During start up & shut down PGVCL power will be utilized.
7.0 Rehabilitation and Resettlement (R & R ) Plan
7.1 Policy to be adopted (central/state) in respect of the project affected including home
oustees, land ouatees and landless laborers (a brief outline to be given)
There is no habitation on the existing project area and it is industrial land which is purchased by
company for development of Company, so that R & R policy is not applicable to this project.
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There shall be no displacement of any population in project area.
8. Project Schedule & Cost Estimates
8.1 Likely date of start of construction and likely date of completion (Time schedule for the
project to be given).
We shall start construction after getting environmental clearance and consent to establish. We
shall start production upon making application for CCA.
(Tentative Date for Construction Start: 01.11.2016)
(Tentative Project Completion Date: 31.10.2017)
8.2 Estimated Project cost along with analysis in terms of economic viability of the project.
Total costs of the existing project is Rs. 369 Crore. Total costs of the Proposed Expansion project
will be Rs. 210.00 Crore.
9. Analysis of Proposal (Final Recommendations)
9.1 Financial and social benefits with special emphasis on the benefit to be local people
including tribal population, if any, in the area.
• Employment would be as per prevailing norms of state government for skilled and unskilled
people for the proposed project.
• Social Welfare shall be done.
• Cordial industrial relation in the industry shall be established and representation shall be
made to villagers for help for creation of facilities related to health, education, etc.