EIA & EMP for 100 MW Thermal Power Plant at Delhi

M/S. GUJARAT ALKALIES AND

CHEMICALS LTD.

Updated Form I for Proposed New Chlor-Alkali Plant and Coal Based Captive Power Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat.

JANUARY 2017

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

M/S. GACL FORM I - PROPOSED NEW CHLOR-ALKALI PLANT, SYNTHETIC ORGANIC

CHEMICAL PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 I

M/S. GUJARAT ALKALIES AND CHEMICALS LTD.

Form I for Proposed New Chlor-Alkali Plant and Coal Based Captive Power Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat. © Kadam Environmental Consultants (‘Kadam’), January, 2017

This report is released for the use of the M/s. Gujarat Alkalies and Chemicals Ltd., Regulators and

relevant stakeholders solely as part of the subject project’s Environmental Clearance process.

Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall

not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of

Publication

Updated Form 1 for Proposed New Chlor-Alkali Plant and Coal Based Captive Power

Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D

II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat..

Project

Number 1521871310

Report

No. 1 Version 1 Released

January,

2017

Prepared &

Managed

By

Bhavin Jambucha, GACL

Representatives Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433

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.

mailto:[email protected]




KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 II

CONTENTS

1 SCOPING ................................................................................................... 1

1.1 UPDATED FORM – 1 ................................................................................... 1

2 ANNEXURES – UPDATED FORM 1 ................................................................ 16



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 III

LIST OF ANNEXURES

Annexure 1: Detailed Product List ................................................................................................ 17


CHEMICAL PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. UPDATED FORM - 1

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 1

1 SCOPING

1.1 UPDATED FORM – 1

The scoping for the project has been done based on FORM 1, as per EIA Notification, dated

September 14, 2006 amended as on date. The scoping details are as follows:

I. Basic Information

S.

No. Item Details

1 Name of the Project/s

Proposed New Chlor-Alkali Plant and Coal Based Captive

Power Plant in JV with NALCO along with Synthetic

Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej,

Taluka: Vagra, District: Bharuch, Gujarat.

2 S. No. in the Schedule

Sector

No. Project or activity Category

13 4(d), Chlor- Alkali

Industry B

21 5(f) Synthetic Organic

Chemical Industries B

4 1(d), Thermal Power

Plants B

3

Proposed capacity / area /

length / tonnage to be handled/

command area / lease area / no.

of wells to be drilled

Proposed capacity:

List of all products is attached as Annexure 1.

Proposed area: 102 Ha. (10,20,000 m2)

4 New / Expansion /

Modernization New

5 Existing Capacity / Area etc. Not Applicable.

6 Category of Project (A or B) “B”

7

Does it attract the general

conditions? If yes, please

specify.

The project does not attract any general conditions

8 Does it attract specific

condition? If yes, please specify It does not attract any specific condition.

9

Location Dahej

Plot Survey / Khasra No. Plot No. DII/9, GIDC Dahej, Taluka: Vagra, District:

Bharuch, Gujarat

Village Rahiyad

Tehsil / Taluka / Mandal Vagra

District Bharuch

State Gujarat

10 Nearest railway station / airport

/ along with distance in km.

Nearest Railway Station

Dahej : ~9.6 km towards W

Bharuch : ~31.2 km towards E

Nearest Airport




S.

No. Item Details

Surat : ~65.7 km towards SSE

Vadodara : ~85.3 km towards E

11

Nearest town, city, district

headquarters along with

distances in kms

Nearest Town:

Bharuch : ~27.7 km towards E

Nearest District Head Quarter:

Bharuch : ~27.7 km towards E.

12

Village Panchayat, Zilla Parishad,

Municipal Corporation, Local

Body (complete postal address

with telephone nos. to be given)

The appropriate local bodies governing the area are

Municipal Corporation

Bharuch Nagarpalika, Bharuch

Email : [email protected]

13 Name of the applicant M/s. Gujarat Alkalis and Chemicals Ltd.

14 Registered address

Gujarat Alkalis and Chemicals Ltd.

Registered Office and Works

P.O : Petrochemicals, -391 346,

Ranoli, District: Vadodara, Gujarat State.

15

Address for correspondence

Name Shri Amrit P. Rathod

Designation General Manager (Project and Infrastructure)

Address Dahej Complex: P.O. Dahej, Taluka: Vagra, District:

Bharuch (Gujarat) INDIA.

Pin Code 392 130

E-mail [email protected]

Telephone no.

Phone No.: +91-2641-256315/6/7, 256325/35, Ext.: 581,

Mo: 09909021822,

Residency: 02642- 231456

Fax no. +91-2641-256220

16

Details of alternative sites

examined, if any. Location of

these sites should be shown on

the Toposheet.

No

17 Interlinked Projects No, however integrated projects are covered in S. No. 2.

18

Whether separate application of

interlinked project has been

submitted?

Not Applicable

19 If yes, date of submission Not Applicable

20

If no, reason

Not Applicable

21

Whether the proposal involves

approval / clearance under: if

yes, details of the same and

their status to be given:

The Forest (Conservation) Act,

1980

The Wildlife (Protection) Act,

1972

No




S.

No. Item Details

The C.R.Z Notification, 1991

22

Whether there is any

Government order / policy,

relevant / relating to the site

No

23 Forest land involved (ha.) No

24

Whether there is any litigation

pending against the project and

/ or land in which the project is

proposed to be set up? Name of

the Court, Case No.

Order / directions of the Court,

if any and its relevance with the

proposed project

No Litigation Pending.

II. Activity

1. Construction, operation or decommissioning of the project involving actions,

which will cause physical changes in the locality (topography, land use, changes in

water bodies, etc.)

S. No. Information/Checklist

Confirmation

Yes

/No

Details thereof (with approximate

quantities / rates, wherever possible)

with source of information data

1.1

Permanent or temporary change in

land use, land cover or topography

including increase in intensity of land

use (with respect to local land use

plan)

Yes

The plot is a vacant barren plot situated in a GIDC

approved area for Chemical Zone. Permanent

change in Land Use from Barren to Industrial Use

is envisaged.

1.2 Clearance of existing land, vegetation

and buildings? Yes

Shrubs & under shrubs like Prosopis juliflora, a

rampantly growing shrub also known as ‘ganda

bawal’ will be cleared before construction phase.

1.3 Creation of new land uses? Yes The designated land use will be Industrial.

1.4 Pre-construction investigations e.g.

bore houses, soil testing? Yes

Geotechnical investigations like soil testing will

be conducted prior to construction. However,

these will not cause physical changes in the

locality.

1.5 Construction works? Yes

As part of the Industrial Project, There will be

construction of admin building, plant machinery

storage tanks and parking facilities within the

site boundary.

1.6 Demolition works? No Not Applicable

1.7

Temporary sites used for construction

works or housing of construction

workers?

No

The proposed site has sufficient availability of

land for development of construction activities

whenever required. Local workers will be hired

during construction phase. If outside Workers

will be hired then only Labors Colony will be

developed with other infrastructure.





Confirmation

Yes

/No




1.8

Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

Yes

Above ground buildings will include structures

for Turbine, Boiler, reactors, ESP, Cooling

towers, Conveyors, Silos, Cell house, Brine

section, HCl plants, Sodium Hypochlorite plants,

Caustic Concentration Unit (CCU), Liquid

chlorine storage in bullet, shed for tonner

storage, product tank farm etc. Cut, fill or

excavation activities are part of the project.

1.9 Underground works including mining

or tunneling? No Not Applicable.

1.10 Reclamation works? No Not Applicable.

1.11 Dredging? No Not Applicable.

1.13 Production and manufacturing

processes? Yes

Details of manufacturing process have been

provided in Pre-Feasibility Report, refer

Chapter 3, Section 3.5.

1.14 Facilities for storage of goods or

materials? Yes

Raw materials and Finished goods will be stored

in tanks/bags/barrels/sheds as per the

requirement and storage rules.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents? Yes

Effluent will be treated in ETP and treated

effluent will be discharged into GIDC drain line

for final disposal in deep sea.

Hazardous waste generated from proposed

plants will be handled in environmentally sound

manner, stored in adequate space and disposed

of as per HWR, 2016 to authorized recyclers

and/or TSDF or Incineration site.

1.16 Facilities for long term housing of

operational workers? No

Employees will be hired from nearby villages

and Bharuch city.

1.17 New road, rail or sea traffic during

construction or operation? Yes

Road Traffic:

Additional 300 trucks will be using SH-6 for

movement of raw material and finished goods

during operation phase.

Rail Traffic:

There will not be any additional direct rail traffic

due to proposed activities.

Sea Traffic:

There will not be any additional direct sea traffic

due to proposed activities.

1.18

New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No

Existing infrastructure developed by Dahej

Industrial Estate is sufficient for project’s need.

No additional road, Rail and waterborne

transportation infrastructure is required.

1.19 Closure or diversion of existing

transport routes or infrastructure No Not Envisaged.





Confirmation

Yes

/No




leading to changes in traffic

movements?

1.20 New or diverted transmission lines or

pipelines? Yes

Internal pipelines for the transfer of materials

will be developed.

1.21

Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No No change in hydrology of water courses /

aquifers are envisaged.

1.22 Stream crossings? No Site does not involve any stream crossing.

1.23 Abstraction or transfers of water from

ground or surface waters? No

Ground Water

No abstraction or transfers of water from

ground.

Surface Water

26.46 MLD raw water will be made available

throughout the year from GIDC, ultimately

sourced from Narmada.

1.24 Changes in water bodies or the land

surface affecting drainage or run-off? No

Surface run off from site will be channelized

through existing storm water drains hence no

change in drainage pattern is envisaged. Pre

dominant slope is towards South and South

west direction.

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes

During construction and implementation of the

project period, transport of materials and

personnel will be through the existing road.

1.26 Long-term dismantling or

decommissioning or restoration works? No

Proposed project does not involve any long term

dismantling or decommissioning or restoration

works.

1.27

Ongoing activity during

decommissioning which could have an

impact on the environment?

No Not Applicable.

1.28 Influx of people to an area either

temporarily or permanently? No

Local people will be hired as far as possible.

Construction phase

~500 persons will be hired.

Operational phase

~750 persons will be hired.

1.29 Introduction of alien species? No None Identified.

1.30 Loss of native species or genetic

diversity? No No effect on species or generic diversity.

1.31 Any other actions? No

Not visualized as required activities will not

cause any major physical changes in the

locality.




2. Use of Natural resources for construction or operation of the Project (such as land,

water, materials or energy, especially any resources which are non-renewable or

in short supply):


confirmation

Yes

/No




2.1 Land especially undeveloped or

agricultural land (ha) No

Plot area is 102 Ha. Existing land is barren and

undeveloped which will be converted for

industrial purpose. The zoning of land as of now

as per the Regional plan is Industrial Area.

There will be no significant change in the

existing land use pattern by proposed industrial

development project as it will be set up in

GIDC.

2.2 Water (expected source & competing

users) unit: KLD Yes

26.46 KLD of water requirement will be met

from GIDC water supply. Plant-wise water

requirement is given in Pre-feasibility report,

Ref. Chapter 3, Section 3.8.4.

2.3 Minerals (MT) No Not Applicable.

2.4

Construction material stone,

aggregates, sand / soil (expected

source, MT)

Yes

Construction materials like stones, aggregates,

sand, bricks, steel, cement, rubble, etc. will be

procured from the local market of the region.

2.5 Forests and timber (source, MT) No Not Applicable.

2.6

Energy including electricity and fuels

(source, competing users) unit: fuel

(MT), energy (MW)

Yes

Power:

Power requirement of ~ 130 MW will be met

through Captive power plant. In case of plant

start-up, emergency, scheduled/un-scheduled

stoppages, 3 Nos. DG set of 1,000 kVA for

Caustic Soda plant & 1 No. DG set of 225 kVA

for Chlorinated paraffin wax plant will be

provided.

Fuel:

5.5 Lac TPA Imported Coal (having high GCV &

low sulphur value) from Adani/nearby local

sources will be used.

800 Lts/Hr. HSD will be used for DG Sets.

NG will be used for incinerator, ECH Unit.

Quantification for NG will be provided in EIA

report.

2.7 Any other natural resources (use

appropriate standard units) Yes

Salt:

7,12,800 MTPA for the proposed Chlor-Alkali

project.




3. Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about

actual or perceived risks to human health.

S. No. Information / Checklist

confirmation

Yes

/No




3.1

Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes

The storage of hazardous material shall meet all

the requirement of MSIHC rules. Use, storage,

transport and handling will be done carefully by

qualified and trained persons.

3.2

Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No

Suitable OH & EMS, proper drainage and waste

management measures will be adopted in

construction and operational phase, which will

restrict the growth and reproduction of disease

vectors.

3.3 Affect the welfare of people e.g. by

changing living conditions? Yes

Due to employment generated as per S. No.

1.28, improvement in economic status of people

in nearby villages is envisaged.

3.4

Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.,

No

No vulnerable groups live near project area.

Also, since relevant emission norms, water

treatment and waste generation norms are

issued by different statutory agencies shall be

strictly followed, people shall be affected.

3.5 Any other causes No No other causes identified.

4. Production of solid wastes during construction or operation or decommissioning

(MT/month)


confirmation

Yes

/No




4.1 Soil, overburden or mine wastes No Not applicable

4.2 Municipal waste (domestic and or

commercial wastes) Yes

Municipal Waste

Waste paper from administrative buildings,

waste metals, kitchen waste etc.

Disposal method

Waste paper and metal will be given to

recyclers, and kitchen waste will be

converted into manure.

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules) Yes

Details of Hazardous waste is given in Pre-

feasibility Report, Chapter 3, Section 3.9.6.

4.4 Other industrial process wastes No

Brine sludge will be disposed off in own secured

landfill site. Inorganic waste like used paper and

waste wood shall be recycled or reused through

recyclers, Waste metal shall be sold as scrap,

Waste plastic shall be sold to recyclers.





confirmation

Yes

/No




4.5 Surplus product No Adequate storage will be provided and

inventory shall be properly managed.

4.6 Sewage sludge or other sludge from

effluent treatment Yes

ETP Sludge will be generated from Effluent

Treatment Plant. Detailed Quantification shall

be carried out in EIA.

4.7 Construction or demolition wastes Yes

Debris, Scraps, Excavated soil, Used Cement

bags, Steal inbits and pieces and cardboards

waste shall be generated and disposed

properly. Demolition activity is not envisaged.

4.8 Redundant machinery or equipment No Not applicable as project is greenfield.

4.9 Contaminated soils or other materials No Adequate precautions will be taken.

4.10 Agricultural wastes No Not Applicable.

4.11 Other solid wastes No

~ 1 Lac MTPA of Fly ash will be generated from

Coal based Captive Power Plant (CPP) which

shall be given to Brick/Cement manufacturing

Industries.

5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)


confirmation

Yes

/No




5.1

Emissions from combustion of fossil

fuels from stationary or mobile

sources

Yes

During Construction Phase:

Vehicular Emissions shall be from use of

construction machinery and vehicles.

During Operation Phase:

Emissions from Stacks are given in Pre-

Feasibility report, Chapter 3, Section 3.9.1.

ESP & Adequate stack height and proper

pollution control equipment will be provided for

all flue gas stacks & process stacks/vents.

Fugitive emissions of Cl2 is also envisaged due

to proposed project. The ambient air quality &

stack emissions will be maintained as per

GPCB/CPCB norms.

5.2 Emissions from production processes Yes Emissions from process Stacks are given in Pre-

Feasibility report, Chapter 3, Section 3.9.1.

5.3 Emissions from materials handling

including storage or transport Yes

Coal dust generation is anticipated from coal

storage and handling. Arrangements for wetting

and water spray /extraction of emission from

transfer points will be provided.

5.4 Emissions from construction activities

including plant and equipment Yes

During construction activities, emissions will be

in the form of dust. Apart from it, application of

heavy machinery and earth movers will

generate emissions. Suitable dust suppression

techniques such as waster sprinkling will be

taken at these times as relevant.





confirmation

Yes

/No




5.5

Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes Odour of raw materials & finished goods limited

to plant area is envisaged.

5.6 Emissions from incineration of waste No No incinerator is proposed.

5.7

Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No No waste will be burnt in open air.

5.8 Emissions from any other sources No No other emissions sources are identified.

6. Generation of Noise and Vibration, and Emissions of Light and Heat:


confirmation

Yes

/No




6.1 From operation of equipment e.g.

engines, ventilation plant, crushers Yes

Noise

Source Noise Level d(B)A*

1. Coal Crusher < 75

2. Turbine < 75

*Noise level – One meter away from the source

Adequate acoustic enclosures provided at

turbine.

Vibration

There will be minimal vibration during the

operation of machineries & equipment.

Proper control measures will be taken like

installation of anti-vibration pad & mass

concrete with floating foundation.

Light & Heat

No such activity is envisaged which could lead

to emission of light and heat

6.2 From industrial or similar processes Yes

Noise


1. Pump 60-75

2. Blower < 75

3. Compressor < 75

* Noise level – One meter away from the source

Vibration


to vibration.

Light & Heat


to emission of light and heat

6.3 From construction or demolition Yes

Construction

Noise from construction machineries such as

cranes, hydra, excavator machine, etc. during





confirmation

Yes

/No




construction activity only. This will be within

acceptable norms

There will not be any emission of light & heat

due to proposed project

Demolition

No such activity is envisaged

6.4 From blasting or piling No Blasting and piling are not envisaged as part of

the construction process.

6.5 From construction or operational

traffic Yes

Minimal during the transportation of raw

materials and finished goods and due to the

vehicular movement on the site and will be

maintained within acceptable norms.

6.6 From lighting or cooling systems Yes

Noise


1. Cooling tower 62 - 75

* Noise level – One meter away from the

source.

6.7 From any other sources No

Noise


1. Fans of boiler < 75

(ID+FD+PA)

* Noise level – One meter away from the

source.

7. Risks of contamination of land or water from releases of pollutants into the

ground or into sewers, surface waters, groundwater, coastal waters or the sea


confirmation

Yes

/No




7.1 From handling, storage, use or

spillage of hazardous materials Yes

Occasional & minor fuel / chemicals spills may

occur. These will not affect water or land

because of appropriate flooring & presence of

spill control procedures.

Moreover all of the Hazardous wastes will be

disposed off as per guidance of State Pollution

Control Board.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No

Treated effluent

Effluent will be treated in ETP and treated

effluent will be discharged into GIDC drain line

for final disposal in deep sea.

Sewage

Sewage will be treated in Sewage Treatment

Plant.





confirmation

Yes

/No




7.3 By deposition of pollutants emitted to

air into the land or into water No

Shall be provided with EIA report after air

dispersion modeling using site specific

meteorological data.

7.4 From any other sources No Not Identified.

7.5

Is there a risk of long term build up of

pollutants in the environment from

these sources?

No Not Identified.

8. Risk of accidents during construction or operation of the Project, which could

affect human health or the environment


confirmation

Yes

/No




8.1

From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes

The associated hazards from the plant are toxic

release and fire. These hazards can take place

due to process upsets, leakages, equipment

and hardware failures, loss of containment,

human failures etc.

The proposed plant will process chlorine,

hydrochloric acid, sulfuric acid, hydrogen and

storage areas of furnace oil, diesel and coal.

Adequate safety measures will be provided to

prevent risk of explosions, spillages, fires etc.

8.2 From any other causes Yes

Common risks in factories such as:

Electric Shock, Hit by Objects, Fall / Slips, Hot

Work such as Welding and Cutting & during

maintenance activities.

8.3

Could the project be affected by

natural disasters causing environmental

damage e.g. floods, earthquakes,

landslides, cloudburst etc)?

No

Floods

Heavy monsoons occasionally cause floods, but

the site elevation at the project area ensures

that there is no impact of floods in the area.

Earthquakes

The area comes under the moderate risk zone

(Zone-III) of the Seismic Zonation. The design

of structure at the project site shall be based

on IS 1893 to make it earthquake resistant.

Landslides

Not noted to occur in the area.

Cloudburst

Not a known feature in the study area




9. Factors which should be considered (such as consequential development) which

could lead to environmental effects or the potential for cumulative impacts with

other existing or planned activities in the locality


confirmation

Yes

/No


quantities/ rates, wherever possible) with

source of information data

9.1

Lead to development of supporting

Facilities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.: supporting

infrastructure (roads, power supply,

waste or waste water treatment, etc.)

housing development extractive

industries supply industries, (other)

Yes

Development of Supporting Facilities

Adequate supporting facilities are already

available in the factory premises and the

infrastructure (water, roads, treated effluent

disposal facilities) already existing in the area is

adequate to take care of all requirements of the

project, which will not overburden the existing

infrastructure.

9.2

Lead to after-use of the site, which

could have an impact on the

environment.

No Not Applicable.

9.3 Set a precedent for later developments No

It is expected that the proposed project will set

high standards of process safety and

environmental excellence.

9.4

Have cumulative effects due to

proximity to other existing or planned

projects with similar effects

No Very negligible cumulative effect, as adequate

mitigation measures will be provided.

III. Environmental Sensitivity

S.

No. Areas

Name /

Identity

Aerial Distance (within 15 km) of the proposed

project location boundary

1

Areas protected under

international conventions,

national or local legislation for

their ecological, landscape,

cultural or other related value

No No such area exist within 15 km.

2

Areas which are important or

sensitive for ecological

reasons - Wetlands,

watercourses or other water

bodies, coastal zone,

biospheres, mountains,

forests

Yes

Wetlands

Wetlands recognized or lying within UNESCO

World Heritage Sites: None identified.

High altitude wetlands (above elevation of

2500 m above MSL, with an area equal to or

greater than 5 hectares): None identified

Any other wetlands identified by an

authority of the central government under

provision of the Environment Protection Act,

1986: Not identified. There are many ponds within 15

Km of Project Area. Details shall be provided in EIA

report.




S.

No. Areas

Name /

Identity



Coastal Zone

Coastal area is not present.

Biosphere Reserve

Biosphere Reserve is not present.

Mountains

There are no mountain.

3

Areas used by protected,

important or sensitive species

of flora or fauna for breeding,

nesting, foraging, resting,

over wintering, migration

No No such area exist within 15 km.

4 Inland, coastal, marine or

underground waters Yes

Coastal or marine waters are located at an aerial

distance of ~3 km towards S. Underground waters in

the form of aquifers would be present at the site and

the study area and the details pertaining to these

would be studied and reported in the EIA report.

5 State, National boundaries No None identified

6

Routes or facilities used by

the public for access to

recreation or other tourist,

pilgrim areas

Yes

Site is well connected to Dahej and Bharuch via

Bharuch Dahej State Highway (SH – 6) at a distance

of 0.08 Km in north Direction.

7 Defense installations No None identified

8 Densely populated or built-up

area Yes

Details of populated/built up area is provided in Pre-

Feasibility Report, Chapter 4, Section 4.4.

9

Areas occupied by sensitive

man-made land uses

(hospitals, schools, places of

worship, community facilities)

Yes

Primary health centers, primary schools, hospitals,

worship places etc. are located within the vicinity of

the project site.

10

Areas containing important,

high quality or scarce

resources (ground water

resources, surface resources,

forestry, agriculture, fisheries,

tourism, minerals)

No None Identified.

11

Areas already subjected to

pollution or environmental

damage. (Those where

existing legal environmental

standards are exceeded)

No None Identified.

12

Areas susceptible to natural

hazard which could cause the

project to present

environmental problems

(earthquakes, subsidence,

landslides, erosion, flooding

Yes

Project area is categorized in the seismic zone III, as

per Seismic Zoning Map of Gujarat by Institute of

Seismological Research (ISR), which is classified as

having a Moderate Damage Risk Zone. Hence

environmental impacts due to the proposed

development may be ruled out however the structure




S.

No. Areas

Name /

Identity



or extreme or adverse

climatic conditions)

design shall be as per codes to negate the threat of

environmental and other damages.


CHEMICAL PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. ANNEXURES –

UPDATED FORM 1


2 ANNEXURES – UPDATED FORM 1


CHEMICAL PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. ANNEXURES –

UPDATED FORM 1


Annexure 1: Detailed Product List

S. No. Products Quantity (MTPD /

MW)

A Chlor-Alkali Plant (800 TPD)

1 Caustic Soda (100%) Lye/ Prills / Flakes 800

2 Chlorine Gas 710

3 Hydrochloric acid 186

4 Hydrogen Gas 20

5 Sodium Hypochlorite 34

6 Dilute Sulphuric acid (78-80%) 16

B Chlorotoluene Plant (205 TPD)

1 Benzyl chloride 100

2 Benzyldehyde 50

3 Benzyl Alcohol 55

Other Derivatives and Bi-products are listed below

4 Benzoyl chloride 5

5 Cinemic aldehyde 5

6 Benzyl acetate 15

7 Benzal chloride (Intermediate Product) 85

8 Sodium benzoate 4

9 Di benzyl ether 15


C Chlorinated Paraffin Wax Plant (100 TPD)

1 Chlorinated Paraffin Wax 100

2 Hydrochloric Acid (33%) 180

3 Sodium hypochlorite 43

D Epi Chloro Hydrin (ECH) Plant (84 TPD)*

1 Epi Chloro Hydrin (ECH) 84

E Chloromethanes (CLM) Plant (300 TPD)*

1 Chloromethanes (CLM) 300

F Coal Based Captive Power Plant (130 MW)**

1 CPP 130 MW

* indicates New products added;

** indicates Capacity increased from 120 MW to 130 MW.

CONTACT DETAILS




Delhi / NCR



E: [email protected]; T: +91-124-4242430 to 436; F: +91-124-4242433






M/S. GUJARAT ALKALIES AND

CHEMICALS LTD.

Revised Pre-Feasibility Report for Proposed New Chlor-Alkali Plant and Coal Based Captive Power Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat.

JANUARY, 2017




M/S. GACL PFR – PROPOSED NEW CHLOR-ALKALI PLANT, SYNTHETIC ORGANIC CHEMICAL

PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. QUALITY CONTROL

SHEET

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 II

M/S. GUJARAT ALKALIES AND CHEMICALS LTD.

Revised Pre-Feasibility Report for Proposed New Chlor-Alkali Plant and Coal Based Captive Power Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat. © Kadam Environmental Consultants (‘Kadam’), January, 2017

This report is released for the use of the M/s. Gujarat Alkalies and Chemicals Ltd, Regulators and

relevant stakeholders solely as part of the subject project’s Environmental Clearance process.

Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall

not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of

Publication

Revised Pre-Feasibility Report for Proposed New Chlor-Alkali Plant and Coal Based Captive

Power Plant in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D

II/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat..

Project

Number 1521871310 Report No. 1 Version 1 Released

January,

2017

Prepared &

Managed By

Bhavin Jambucha, GACL

Representatives Released By Sangram Kadam

CONTACT DETAILS




Delhi / NCR




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.




PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. TABLE OF CONTENT

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 III

CONTENTS

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

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ................................................ 1

1.2 INFRASTRUCTURE .................................................................................... 2

1.3 UTILITY ................................................................................................. 2

1.4 ENVIRONMENT ........................................................................................ 3

1.5 SENSITIVITY ........................................................................................... 3

1.6 CONCLUSION .......................................................................................... 3

2 INTRODUCTION .......................................................................................... 4

2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT ....................................... 4

2.1.1 Project Proponent ................................................................................ 4

2.1.2 Proposed Project ................................................................................. 6

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

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION ............ 7

2.3.1 Chlor Alkali ........................................................................................ 7

2.3.2 Chlorotoluene ..................................................................................... 7

2.3.3 Chlorinated Paraffin Wax ....................................................................... 7

2.3.4 Epi Chloro Hydrin (ECH) ........................................................................ 8

2.3.5 Chloromethanes (CLM) .......................................................................... 8

2.3.6 Power Plant ....................................................................................... 8

2.4 DEMAND & SUPPLY GAP .............................................................................. 8

2.4.1 Chlor Alkali ........................................................................................ 8

2.4.2 Chlorotoluene ..................................................................................... 9

2.4.3 Chlorinated Paraffin Wax ....................................................................... 9

2.4.4 Epi Chloro Hydrin (ECH) ........................................................................ 9

2.4.5 Chloromethanes (CLM) .......................................................................... 9

2.4.6 Power Plant ....................................................................................... 9

2.5 IMPORT VS. INDIGENOUS PRODUCTION ....................................................... 10

2.5.1 Chlor-Alkali ...................................................................................... 10

2.5.2 Chlorotoluene ................................................................................... 10

2.5.3 Chlorinated Paraffin Wax ..................................................................... 10

2.5.4 Epi Chloro Hydrin (ECH) ...................................................................... 10

2.5.5 Chloromethanes (CLM) ........................................................................ 11

2.5.6 Power Plant ..................................................................................... 11

2.6 EXPORT POSSIBILITY .............................................................................. 11

2.7 DOMESTIC / EXPORT MARKET .................................................................... 11

2.8 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............. 11

3 PROJECT DESCRIPTION ............................................................................. 12

3.1 TYPE OF PROJECT ................................................................................... 12

3.2 LOCATION OF THE PROJECT ...................................................................... 12



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 IV

3.3 DETAILS OF ALTERNATE SITES CONSIDERED ................................................. 13

3.4 SIZE OR MAGNITUDE OF OPERATION ........................................................... 14

3.4.1 Storage Details of Finished Products........................................................ 15

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ............................................ 15

3.5.1 Caustic Soda .................................................................................... 15

3.5.2 Chlorotolune .................................................................................... 20

3.5.3 Chlorinated Paraffin Wax ..................................................................... 26

3.5.4 Epi Chloro Hydrin Plant (ECH Unit).......................................................... 27

3.5.5 Chloromethanes (CLM) ........................................................................ 30

3.5.6 Power Plant ..................................................................................... 32

3.6 RAW MATERIALS .................................................................................... 32

3.7 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE ......................................... 33

3.8 UTILITIES ............................................................................................ 33

3.8.1 Power Requirement ............................................................................ 33

3.8.2 Fuel Requirement .............................................................................. 34

3.8.3 Water Requirement ............................................................................ 34

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) .......................... 35

3.9.1 Air Emissions & Control ....................................................................... 35

3.9.2 Fugitive Emissions & its Control ............................................................. 37

3.9.3 Line Source Emissions & Control ............................................................ 37

3.9.4 Noise Generation ............................................................................... 37

3.9.5 Waste Water Generation ...................................................................... 37

3.9.6 Hazardous Waste and Other Solid Waste .................................................. 38

4 SITE ANALYSIS ......................................................................................... 40

4.1 CONNECTIVITY ...................................................................................... 40

4.1.1 By Road .......................................................................................... 40

4.1.2 By Rail ........................................................................................... 40

4.1.3 By Air ............................................................................................ 40

4.1.4 By Water ........................................................................................ 40

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .................................................. 40

4.3 TOPOGRAPHY ........................................................................................ 40

4.4 EXISTING LANDUSE PATTERN WITH SENSITIVITY TABLE ................................... 40

4.5 SOIL CLASSIFICATION, GEOLOGY, DRAINAGE, TOPOGRAPHY .............................. 41

4.5.1 Soil Classification ............................................................................... 41

4.5.2 Geology .......................................................................................... 42

4.5.3 Drainage ......................................................................................... 42

4.5.4 Topography ..................................................................................... 42

4.6 CLIMATIC DATA FROM SECONDARY SOURCES................................................. 42

4.7 SOCIAL INFRASTRUCTURE AVAILABLE .......................................................... 42

4.8 EXISTING INFRASTRUCTURE ..................................................................... 42

5 PLANNING BRIEF ...................................................................................... 43

5.1 PLANNING CONCEPT ............................................................................... 43



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 V

5.2 POPULATION PROJECTION ........................................................................ 43

5.3 LAND USE PLANNING ............................................................................... 43

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ..................... 43

5.5 AMENITIES/FACILITIES ............................................................................ 44

6 PROPOSED INFRASTRUCTURE .................................................................... 45

6.1 INDUSTRIAL AREA (PROCESSING AREA) ........................................................ 45

6.2 NON-PROCESSING AREA ........................................................................... 45

6.3 GREEN BELT.......................................................................................... 45

6.4 SOCIAL INFRASTRUCTURE ........................................................................ 45

6.5 CONNECTIVITY ...................................................................................... 45

6.6 DRINKING WATER MANAGEMENT ................................................................ 45

6.7 SEWAGE SYSTEM .................................................................................... 45

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT ........................................ 45

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ................................................... 45

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 46

8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 47

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION ...... 47

8.2 ESTIMATED PROJECT COST ....................................................................... 47

8.2.1 Profitability ...................................................................................... 48

9 ANALYSIS OF PROPOSAL ........................................................................... 49

9.1 FINANCIAL AND SOCIAL BENEFITS .............................................................. 49



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 VI

ANNEXURES

Annexure 1: IMS Certification – Existing GACL Complex ................................................................. 51

Annexure 2: Land Possession Documents from GIDC ..................................................................... 53

Annexure 3: Site Layout Map – Preliminary ................................................................................... 58

Annexure 4: Project Site Located on Toposheet ............................................................................. 59

LIST OF TABLES

Table 1-1: List of Proposed Production Capacity .............................................................................. 1

Table 2-1: Details of IMS Certifications ........................................................................................... 4

Table 2-2: Awards and Achievements ............................................................................................. 5

Table 2-3: List of Directors and their Designations ........................................................................... 6

Table 2-4: Brief Description of Project ............................................................................................ 7

Table 2-5: Demand Supply Gap – Chlor Alkali (Year 2014) ............................................................... 8

Table 2-6: Demand Supply Gap – Chlorinated Paraffin Wax (Year 2014-15) ...................................... 9

Table 2-7: Demand Supply Gap – ECH (Year 2011 to 2016) ............................................................. 9

Table 2-8: Demand Supply Gap – CLM (Year 2015-16) .................................................................... 9

Table 2-9: Import and Export data – Chlor Alkali ........................................................................... 10

Table 2-10: Import Data – CPW ................................................................................................... 10

Table 2-11: Import Data – ECH .................................................................................................... 10

Table 3-1: Co-ordinates of Site Boundary ...................................................................................... 13

Table 3-2: Site Selection Criteria for Proposed Project .................................................................... 13

Table 3-3: List of Proposed Products ............................................................................................ 14

Table 3-4: Details of Main Raw Material Quantity and Means of Storage .......................................... 32

Table 3-5: Fuel Details ................................................................................................................ 34

Table 3-6: Water Requirement - Chlor-Alkali Plant ......................................................................... 34

Table 3-7: Water Requirement - Chlorotoluene Plant ..................................................................... 34

Table 3-8: Water Requirement - Chlorinated Paraffin Wax Plant ..................................................... 34

Table 3-9: Water Requirement - Epi Chloro Hydrin (ECH) Plant ...................................................... 35

Table 3-10: Water Requirement - Chloromethanes (CLM) Plant ...................................................... 35

Table 3-11: Water Requirement – Captive Power Plant .................................................................. 35

Table 3-12: Details of Stacks, Fuel Used and APCM attached to Flue Gas Stacks .............................. 36



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 VII

Table 3-13: Details of Stacks, APCM attached to Process Gas Stacks / Vents ................................... 36

Table 3-14: Waste Water Generation – Chlor Alkali Plant ............................................................... 37

Table 3-15: Waste Water Generation – Chlorotoluene Plant ........................................................... 37

Table 3-16: Waste Water Generation – Epi Chloro Hydrin (ECH) Plant ............................................. 38

Table 3-17: Waste Water Generation - Chloromethanes (CLM) Plant ............................................... 38

Table 3-18: Waste Water Generation – Captive Power Plant ........................................................... 38

Table 3-19: Hazardous & Other Solid Waste Details ....................................................................... 39

Table 4-1: Nearest Villages in Surrounding Area ............................................................................ 41

Table 5-1: Area Statement ........................................................................................................... 43

Table 8-1: Estimated Cost – Chlor Alkali Plant ............................................................................... 47

Table 8-2: Estimated Cost – Chlorotoluene Plant ........................................................................... 47

Table 8-3: Estimated Cost – Chlorinated Paraffin Wax .................................................................... 47

Table 8-4: Estimated Cost – Epi Chloro Hydrin (ECH) ..................................................................... 48

Table 8-5: Estimated Cost – Chloromethanes (CLM) ...................................................................... 48

Table 8-6: Estimated Cost – Captive Power Plant ........................................................................... 48



KADAM ENVIRONMENTAL CONSULTANTS | JANUARY, 2017 VIII

LIST OF FIGURES

Figure 3-1: General Location of Proposed Project Site .................................................................... 12

Figure 3-2: Specific Map Showing Project Boundary ....................................................................... 13

Figure 3-3: Process Flow Diagram of Caustic Soda ......................................................................... 19

Figure 3-4: Process Flow Diagram of BCL ...................................................................................... 24

Figure 3-5: Process Flow Diagram of BCHO ................................................................................... 24

Figure 3-6: Process Flow Diagram of BHO ..................................................................................... 25

Figure 3-7: Process Flow Diagram of BAC ..................................................................................... 25

Figure 3-8: Process Flow Diagram of CNMD .................................................................................. 25

Figure 3-9: Process Flow Diagram of Chlorinated Paraffin wax ........................................................ 26

Figure 3-10: Process Flow Diagram of Chloromethane ................................................................... 31


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

Gujarat Alkalies and Chemicals Limited (GACL) was incorporated on 29th March 1973 in the State of

Gujarat by Gujarat Industrial Investment Corporation Limited (GIIC), a wholly owned company of

Govt. of Gujarat, as a Core Promoter.

The proposed Project includes setting up of New Chlor-Alkali plant, Synthetic Organic Chemical Plants

like Chlorotoluene, Chlorinated Paraffin Wax, Epi Chloro Hydrin (ECH) plant & Chloromethanes (CLM)

plant along with Captive Power Plant at Plot No. DII/9, Industrial Estate, Vagra Taluka, Bharuch

district, Gujarat. It is located in notified industrial estate.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed products

falls in category including Project / Activity: “4(d), Chlor-Alkali Industry”, schedule

“Manufacturing/fabrication” and Project or Activity “5(f), Synthetic Organic Chemicals Industry”,

schedule “Mining, Extraction of Natural Resources and Power Generation, Project or Activity “1(d),

Thermal Power Plants”, which shall be treated as Category “B”.

1.1 PLANT FEATURES AND PRODUCTION CAPACITY

Plot area of the project consists of 102 Ha. The total estimated capital investment for these products

would be around INR 2,822.57 Crore.

Details of existing and proposed products are listed in Table 1-1.

Table 1-1: List of Proposed Production Capacity

S. No. Products Quantity (MTPD / MW)



2 Chlorine Gas 710


4 Hydrogen Gas 20





2 Benzyldehyde 50

3 Benzyl Alcohol 55




6 Benzyl acetate 15


8 Sodium benzoate 4
















1 CPP 130 MW



1.2 INFRASTRUCTURE

Basic facilities of infrastructure like storage area, processing area, internal roads etc. will be developed

within the project site. Transportation of raw material and finished goods will be carried out through

proposed internal roads and finally through existing state highway SH-6.

Cooling towers, air compressors, chilling systems, various scrubbers, ESP, ETP and other utilities shall

be provided as per the process requirement. Adequate quantity of water will be stored in underground

water tank for fire hydrant system. Adequate storage facilities for salt, hazardous and solid waste, etc.

shall be provided.

1.3 UTILITY

Power: Power requirement of ~ 130 MW for proposed plants will be met through Captive power

plant. In case of plant start-up, emergency, scheduled/un-scheduled stoppages, 3 Nos. DG set of

1,000 kVA for Caustic Soda plant & 1 No. DG set of 225 kVA for Chlorinated paraffin wax plant will be

provided.

Fuel: 5.5 Lac MTPA Imported Coal having high GCV & low Sulphur content will be used for the

proposed Boilers and 800 Lts/Hr. HSD will be used for DG Sets in case of plant start-up, emergency,

scheduled/un-scheduled stoppages.

Raw Water: 26.46 MLD of water requirement will be met from GIDC Reservoir.

Manpower: During the construction phase around 500 workers will be hired. During operation phase,

project will generate direct employment for more than 750 people along with indirect employment for

locals. 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. It will provide employment to the people of Bharuch district.




1.4 ENVIRONMENT

Environmental issues associated with proposed units are:

Air Emissions: Likely air pollutants from proposed project shall be PM, SO2 & NOx from boiler

and DG Sets, HCl, Cl2, SO2, NOx, HC, Dioxin from incinerator as flue gas emissions & HCl, Cl2, CO,

SO2, NOx, HC, Dioxin from process vents, as point source. Adequate APC equipment like ESP,

scrubbers with adequate stack height will be provided. Vehicular Emissions like CO & HC’s will be

generated as line source emissions. Fugitive emission of Cl2 is also envisaged from proposed

project.

Wastewater: Around 4,920 KLD waste water will be generated from the process, utilities &

domestic area. Effluent will be treated in ETP and treated effluent will be discharged into GIDC

drain line for final disposal in deep sea. Sewage will be treated in STP.

Solid & Hazardous Waste: Hazardous waste generated from proposed plants will be handled in

environmentally sound manner, stored in adequate space and disposed of as per HWR, 2016 to

authorized recyclers and/or TSDF site. Membership shall be taken from M/s. BEIL.

1.5 SENSITIVITY

Site is well connected to various cities via SH-6 (0.08 Km in N Direction). Major railway station for

public transportation is Bharuch Railway Station located at an aerial distance of ~31.2 Km in E

Direction form the project site. Nearest airport from project site is Surat Airport located at an aerial

distance of ~ 65.7 Km in SSE Direction. Nearest port is Adani port at Dahej located at an aerial

distance of ~16 Km in W direction.

There are around 30 villages within 10 km from the project site.

1.6 CONCLUSION

Promoters have vast experience in the manufacturing field of Chlor-alkali industry and other

chemicals. Group also have highly qualified and dedicated employees having vast experience in plant

operation, developing new technologies, implementation of projects, finance management and

commercial operations of a large chemical industries.

There is availability of land for putting up proposed plants. Project intends to generate employment for

local people and unskilled / semiskilled workers during construction phase.

If this project comes up, it will have social, financial and environmental benefits.

Pre-feasibility study confirms viability of the project.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. INTRODUCTION


2 INTRODUCTION

2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT

2.1.1 Project Proponent

Gujarat Alkalies and Chemicals Limited (GACL) was incorporated on 29th March 1973 in the State of

Gujarat by Gujarat Industrial Investment Corporation Limited (GIIC), a wholly owned company of

Govt. of Gujarat, as a Core Promoter.

GACL has two units located at Vadodara and Dahej, both in the State of Gujarat. GACL sells 24

products today, maintaining it's leadership in Caustic-Chlorine industry with 16% market share and

has emerged as a major player in the segment of value added products like Sodium Cyanide,

Chloromethanes, Hydrogen Peroxide, Caustic Potash, Potassium Carbonate, Phosphoric Acid,

Aluminium Chloride, Polyaluminium chloride Potassium Hydroxide, Sodium Chlorate etc. The Dahej

unit also has 90 MW Captive Power Plant (CPP) for regular and economical power supply.

Company exports its products to USA, Europe, Australia, Africa, Far & Middle East countries, China &

South Asian Markets.

The total turnover of the company at Vadodara unit is 1,05,924.63 Lacs and at Dahej unit is

1,09,792.4 Lacs for the year 2014-15.

The location of both the plants 'Vadodara' and 'Dahej' has dual advantage of proximity to the raw

material suppliers and the end users and both plants are connected by VSAT and lease lines. This

provides on-line information at any given point of time.

The Company commenced its operations in 1976 with 37,425 MTPA Caustic Soda Plant based on the

then, state-of-the-art Mercury Cell process at its Vadodara unit. Converted to Membrane Cell

Technology from Mercury Cell Technology way back in 1989 and since 1994 all the plants are running

on Mercury free Membrane Cell Technology.

Certification

Integrated Management System (IMS) certification for GACL, Dahej is given in

Table 2-1: Details of IMS Certifications

Systems Certification

Integrated Management System for :

Quality Management System

Environmental Management System

Occupational Health & Safety Management

System

ISO 9001:2008

ISO 14001: 2004

OHSAS 18001: 2007

The ISOQAR certificate are attached as Annexure 1.




Awards and Achievements

Details of Awards along with the year achieved in is given in Table 2-2.

Table 2-2: Awards and Achievements

S. No. Date Awards & Achievements

1 2013 Winner in category of Scheme-II (Accident Free Man Hours)- for the

performance year-2011

2 2013 Winner in category of Scheme-I (Based on Lowest Frequency)- for the


3 23/02/2013

“Letter of Appreciation” given to GACL by Directorate of Industrial Safety and

Health, Gujarat State-as Fire crew deployed to control fire incident in the

Hydrocarbon Storage installation of IOCL, Hazira which occurred on

05/01/2013

4 2012 Runner-up in category of Schem-II (Accident Free Man Hours)- for the


5 2012 Runner-up in category of Scheme-I (Based on Lowest Frequency)- for the


6 2012 Won I-Runner Up Prestigious Award for the year-2010 from Labor and

Employment Government of India for “Accident-Free Man Hour”


Employment Government of India for “Lowest Frequency Rate”


Employment Government of India for “Lowest Frequency Rate”

9 2011

Received Awards-2011 Certificate of Appreciation in recognition of

appreciable achievement in “Occupational Safety and Health’ during the

assessment period of Three years-2007-2009 Awarded by National Safety

Council of India

10 2010

Received Award Certificate of “Honour” for the Safety Performance Year-

2009 from Gujarat Safety Council working more than 3 million Accident Free

Hours

11 2010 “Winner of Rotating Shield’ for achieving lowest “Disabled Injury Index’ by

Gujarat Safety Council-year-2009

12 2010

Received Awards-2009 “Certificate of Appreciation” in recognition of

appreciable achievement in “Occupational Safety and Health’ during the

assessment period of Three years-2006-2008 Awarded by National Safety

Council of India

13 2009 GACL received Appreciation letter for maintaining excellent Safety, Healthy &

Environment Standards in Year-2008

14 September 2009 National Safety Award for the year 2008

15 2009 Certificate of Honour for the year-2008 and Certificate of Appreciation for the

year-2008 for Safety Performance from Gujarat Safety Council

16 14/12/2008 National Energy Conservation Award 2007: National Level (Chlor-Alkali

Sector) Merit Certificate (Dahej Unit)

17 14/12/2007

National Energy Conservation Award 2007: National Level (Chlor-Alkali

Sector) 2nd Prize (Dahej Unit), by Hon’ble president of India, Smt. Pratibha

Patil

18 2006 Rotary Safety Shield “Rotary Club Ankleshwar” & Factory Inspectorate Office,

Bharuch for the year-2005




S. No. Date Awards & Achievements

19 15/12/2006 Gujarat Safety Council-Certificate of Honour for Dahej Complex

20 31/08/2006 Greentech Silver Award for Environment Excellence 2006 for Dahej unit-

National Level

21 08/04/2006 Greentech Silver Award 2006 in Chemical Sector for Dahej Unit received at

Hyderabad

22 16/12/2005 Certificate of Honour for Dahej Unit from Gujarat Safety Council for the year

2004

23 14/12/2005 National Energy Conservation Award 2007: National Level (Chlor-Alkali

Sector) Merit Certificate Awarded (Dahej Unit), by Hon’ble president of India

24 22/09/2005 Greentech Environment Excellence Gold Award-2005 for Dahej Unit

25 18/01/2005 Certificate of Honour for Safety Performance-2003 from Gujarat Safety

Council

26 14/12/2004 National Energy Conservation Award 2004: (Chlor-Alkali Sector) Dahej Unit

27 04/11/2004 Greentech Gold Award for Environment Excellence 2003-04 for Dahej Unit

28 21/06/2004 Greentech Safety Silver Award 2003-04, Dahej Unit-National Award

About Directors of Gujarat Alkalies and Chemicals

The company is headed by Chairman, vice-chairman, managing director, and directors. List of their

top management is tabulated in Table 2-3.

Table 2-3: List of Directors and their Designations

S. No. Name Designation

1 Dr. J.N Singh I.A.S Chairman

2 Shri J.N Godbole Independent Director

3 Ms. Pallavi S. Shroff Independent Director

4 Dr. Rajiv I. Modi Independent Director

5 Shri Rajeev Lochan Jain Independent Director

6 Shri P. K. Gera I.A.S Managing Director

2.1.2 Proposed Project

The proposed Project includes setting up of New Chlor-Alkali Plant and Coal Based Captive Power Plant

in JV with NALCO along with Synthetic Organic Chemical Plants at Plot No.: D II/9, GIDC Dahej,

Taluka: Vagra, District: Bharuch, Gujarat.

Synthetic Organic Chemical Plants shall include chemicals like Chlorotoluene, Chlorinated Paraffin Wax,

Epi Chloro Hydrin (ECH) plant & Chloromethanes (CLM) plant.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed products

falls in category including Project / Activity: “4(d), Chlor-Alkali Industry”, schedule

“Manufacturing/fabrication” and Project or Activity “5(f), Synthetic Organic Chemicals Industry”,

schedule “Mining, Extraction of Natural Resources and Power Generation, Project or Activity “1(d),

Thermal Power Plants”, which shall be treated as Category “B”.




2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

Brief description of the project is given in Table 2-4.

Table 2-4: Brief Description of Project

S.

No. Details Description

1 Nature New Chlor Alkali plant, Synthetic Organic Chemicals plant and Coal based Power

Plant.

2 Size Plot Area: 102 ha. Product and their capacities are shown in Table 3-3,

3 Location Plot No.: DII/9, GIDC Dahej, Taluka: Vagra, District: Bharuch, Gujarat

4 Cost of the project ~ INR 3,980.9 Crores

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION

2.3.1 Chlor Alkali

The size of the Indian Chlor-Alkali sector at 7 million tones is 4% of world market. The Chlor-Alkali

industry is the oldest and largest segment of the inorganic chemical industry. It comprises of caustic

soda, liquid chlorine and soda ash.

Caustic soda is used in various applications such as finishing operations in textiles, manufacture of

soaps and detergents, alumina, paper and pulp, control of pH (softening) of water, general Cleansing

and bleaching. The aluminum industry is the biggest demand driver for Caustic soda.

Chlorine is used in multiple sectors such as manufacture of polymers like PVC, bleaching applications,

paper and pulp and textile industry. Alumina processing is expected to drive the caustic soda demand

in the country. Textile and chemical sectors are expected to further push the caustic soda demand in

India.

Indian Chlor Alkali industry is driven by caustic soda demand which stood at 2.95 million metric tones

in year 2014.

2.3.2 Chlorotoluene

Such plants have lower environmental risk. The demand in the market for Chlorotoluene is 450 KT but

the supply is only 400 KT. 3,000 MT of domestic market is envisaged. Domestic growth rate in year

2015 – 2020 is expected to be 4 – 5 %.

Export potential is low. Europe and China are the largest producers and consumers for the product.

There is no manufacturer available in India for the production of Chlorotoluene and presently, India is

net importer of Chlorotoluene products.

2.3.3 Chlorinated Paraffin Wax

This product is major consumer of chlorine and about 12% of chlorine produced in India is consumed

by these units.

Major use of CPW is as secondary plasticizer in the manufacturing of PVC products. About 72% of

Chlorinated paraffin produced is consumed in manufacturing of PVC, which has Compounded Annual

Growth Rate (CAGR) of 5.4%.




2.3.4 Epi Chloro Hydrin (ECH)

The import of ECH has been steadily going up in the last few years, as additional production capacity

for ECH has not been built in the country in tune with growth of demand.

The demand for ECH would go up in tune with the growth in capacity creation for epoxy resin in the

country. While the demand of epoxy resin would go up, additional capacities are likely to be created

by new projects and expansion of existing one.

CAGR of ECH (projected up to 2022) is ~ 9 % per year.

Hence, by looking above factors for increasing demands of Epoxy Resin and ECH as a key raw material

in production of Epoxy Resins, ECH plant is proposed to reduce net import of country.

2.3.5 Chloromethanes (CLM)

For manufacturing of Chloromethane either methane or methanol is use as a major raw material,

whereas second major raw material is hydrochloric acid or chlorine. And in methanol base route,

methanol and hydrochloric acid will be major raw material to produce Chloromethane in our process.

To utilize huge quantity of hydrochloric acid generated by chlor-alkali industry due to compulsion of its

production by process defaults, CLM plant is proposed.

There are huge demand and supply gap for chloromethane in India. In India there are no enough

plant capacities for fulfilling demand of Chloromethane so India needs to import chloromethane from

other country for fulfilling its huge total demand.

Around 42 % of total demand is fulfill by import only. To reduce import quantity of Chloromethane

from other country and full filling the huge gap between demands and supply this new plant is

necessary.

2.3.6 Power Plant

As caustic soda is a power intensive product in which 70% of its production cost is due to power, so to

sustain in highly competitive market low rate power is required. So captive power plant is required for

supplying low cost power to proposed caustic soda plant.

2.4 DEMAND & SUPPLY GAP

2.4.1 Chlor Alkali

Domestic consumption of caustic soda was 33.6 Lac Tons during 2015-16. Out of this, 5.7 Lac tons

was met through imports, which is nearly 17% of total demand. Furthermore Hydrogen is the cleanest

fuel available. Demand- supply gap for year 2014 is shown in Table 2-5.

Table 2-5: Demand Supply Gap – Chlor Alkali (Year 2014)

Particulars Qty. (million T)

Capacity 3.30

Production 2.61

Demand 2.95

Gap 0.34




2.4.2 Chlorotoluene

For year 2014-15, supply was noted as 400 KT against 450 KT.


The demand Supply gap for year 2014-15 is shown in Table 2-6.

Table 2-6: Demand Supply Gap – Chlorinated Paraffin Wax (Year 2014-15)

Description Quantity in MT

Indian Installed Capacity 1,95,000

Indian demand including export market 1,45,000

Import capacity 2,489

Domestic Market 1,37,608

Demand Supply gap 52,489


The demand of ECH would increase in tune with the growth of the important applications sectors such

as epoxy resin as well as Indian GDP. The demand Supply gap is shown in Table 2-7.

Table 2-7: Demand Supply Gap – ECH (Year 2011 to 2016)

Period

Installed

Capacity

(MT)

Domestic

Production

(MT)

Domestic

Demand

(MT)

Gap in Supply

(MT)

2011 – 12 10,000 8,500 27,568 19,068

2012 – 13 10,000 8,500 31,600 23,100

2013 – 14 10,000 8,500 34,455 25,955

2014 – 15 46,500 39,525 37,555 ---

2015 – 16 46,500 39,525 40,935 1,410


India is major importer of Chloromethane in FY 2014 data. There are huge gap between total demand

and total supply. Total demand and supply gap for year 2015-16 is shown in Table 2-8.

Table 2-8: Demand Supply Gap – CLM (Year 2015-16)

Total demand 271 KT/A

Domestic Supply 160 KT/A

Import from Other Country 111 KT/A

Demand – Supply Gap 111 KT/A

2.4.6 Power Plant

Power plant is for captive use; generated power is not for selling in market.




2.5 IMPORT VS. INDIGENOUS PRODUCTION

2.5.1 Chlor-Alkali

Imports have increased from 0.14 million tones in 2006 – 07 to 0.186 million tones in 200 – 11. About

0.27 million tones of caustic soda was imported in 2009 – 10. Exports increased from 52,000 tons to

84,000 tons during the same period. Import and Export data are shown in Table 2-9.

Table 2-9: Import and Export data – Chlor Alkali

Year Import Exports

2006 – 2007 140 52

2007 – 2008 172 56

2008 – 2009 185 66

2009 – 2010 270 36

2010 – 2011 186 84

All quantities are in thousands tonnes.

2.5.2 Chlorotoluene

3,000 MT of domestic market having Domestic growth rate (2015 – 20): CAGR 4 – 5 % is expected.


Import data for CPW are shown in Table 2-10.

Table 2-10: Import Data – CPW

Year (April- March) Quantity in tones

2008-09 3,869

2009-10 5,591

2010-11 1,992

2011-12 94

2012-13 900


No Export market of ECH in India is envisaged. Imports and domestic demand is tabulated in Table

2-11.

Table 2-11: Import Data – ECH

Period Imports

(MT)

Production

(MT)

Domestic Demand

(MT)

2011 – 12 19,068 8,500 27,568

2012 – 13 23,100 8,500 31,600

2013 – 14 25,955 8,500 34,455

2014 – 15 --- 39,525 37,555

2015 – 16 1,410 39,525 40,935





For fulfilling a total demand of Chloromethane in India, it is necessary to import Chloromethane from

other country because there is no enough plant capacity installed in India to fulfill this huge total

demand. Around 42 % of total demand is fulfilling by Import only.

Total Import of 111 KT/A & Export of 3 3KT/A for Chloromethane was seen for year 2015-16.

2.5.6 Power Plant

Power plant is for captive use only.

2.6 EXPORT POSSIBILITY

The company is also exploring marketing with its own brand name in various overseas countries in

addition to the domestic market.

2.7 DOMESTIC / EXPORT MARKET

GACL is pioneer in the market. The finished products are conforming to Indian Standard /as per the

customer requirement. The customers are located mainly within Gujarat. Some customers are located

outside Gujarat also. Sale will be made to direct customers and through traders.

Power plant is for captive use. Generated power is not for selling in market.

2.8 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT

During the construction phase around 500 workers will be hired. During operation phase, project will

generate direct employment for more than 750 people along with indirect employment for locals.

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. It

will provide employment to the people of Bharuch district.

The positives impacts include enhanced direct employment for technical/administrative works and

indirect employment opportunities to the local populace, especially in business and other services like

transportation activity.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is for setting up New Chlor-Alkali plant, Coal Based Power Plant (CPP) and

Synthetic Organic Chemical Plants.

3.2 LOCATION OF THE PROJECT

Proposed project is located at Plot No.: DII/9, Industrial Estate, situated in Vagra Taluka of Bharuch

district, Gujarat state. It is in a notified Industrial Estate developed by the Gujarat Industrial

Development Corporation (GIDC), categorized as chemical zone for setting up chemical industries.

Land possession documents from GIDC for plot are attached as Annexure 2.

Location map showing general location of proposed project is given in Figure 3-1. Specific Map

showing project boundary is given in Figure 3-2. The co-ordinates of the project site are given in

Table 3-1.

Figure 3-1: General Location of Proposed Project Site




Figure 3-2: Specific Map Showing Project Boundary

Red highlighted boundary represents the proposed site.

Table 3-1: Co-ordinates of Site Boundary

Code Latitude Longitude

A 21°43'4.30"N 72°41'33.62"E

B 21°42'34.95"N 72°41'36.51"E

C 21°42'15.06"N 72°41'5.15"E

D 21°42'56.06"N 72°35'19.88"E

3.3 DETAILS OF ALTERNATE SITES CONSIDERED

Since the end users of the proposed products are in Western part of India and also due to the location

and infrastructure benefit, the most preferred site is in Dahej.

Site selection was based on the various criteria as mentioned in Table 3-2.

Table 3-2: Site Selection Criteria for Proposed Project

Criteria Locations

Dahej Bhavnagar Vadodara Kota Kutch

Land Availability

(High rates)

(Low rates)

(V.High rates)

(V.High rates)

(Moderate)

Water Availability ×




Criteria Locations

Dahej Bhavnagar Vadodara Kota Kutch

Raw Material

Availability (Mainly

Salt)

(~ 5 Km)

(~ 8 Km)

×

(~ 350 Km)

×

(~850 Km)

(~15 Km)

Infrastructure

available ×

TSDF Site in Vicinity

(BEIL & SEPPL) ×

(NECL)

(UCCI,

Udaipur)

(SEPPL)

Industries with Similar

Products

(GACL Existing,

MFL, GFL)

(Nirma)

(GACL) × ×

Population within 3

Km

Low

(~ 1,350)

Low

(~ 800)

High

(~12,500)

High

(~24,694)

Medium

(~3,000)

Existing Pollution

Levels (CEPI Scores) NA

70.99

(13.01.10)

66.91

(13.01.10) NA NA

3.4 SIZE OR MAGNITUDE OF OPERATION

Plot area of the project consists of 102 Hectare. Details of all the proposed products are listed in

Table 3-3.

Table 3-3: List of Proposed Products




2 Chlorine Gas 710


4 Hydrogen Gas 20





2 Benzyldehyde 50

3 Benzyl Alcohol 55




6 Benzyl acetate 15






8 Sodium benzoate 4












1 CPP 130 MW



3.4.1 Storage Details of Finished Products

Adequate storage facilities will be provided for finished products keeping in view production rate and

market demand variation.

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

Project description with process details are described as follows:

3.5.1 Caustic Soda

Process Description

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

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.

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.

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

barium carbonate, 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.

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 9 Nos. bipolar Electrolysers and their associated equipment’s.

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.




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 sub headers 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.

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.

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, demineralized 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

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.

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.

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.

Chlorine Gas Compression

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

type Compressor.

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 vaporized and sent to nearby customers

through pipeline.

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.




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.

Hydrogen Bottling and Storage

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

in cylinder banks.

Caustic Soda and Flaking Plant

Flaker plant is a double effect evaporator. 48% Caustic is feed to produce 98% Caustic Flakes. Salt

mixture (KNO3, NaNO2 & NaNO3) which is heated by burning Hydrogen is a heating media to increase

Caustic lye temperature in final concentrator. 98 % Caustic flakes is then cooled and packed using a

polythene liner to avoid moisture pick-up as it is a hygroscopic product.

Chemical Reaction:

CaCl2 + Na2CO3 -----> CaCO3 + 2 NaCl

MgCl2 + 2 NaOH -----> Mg(OH)2 + 2 NaCl

Ca++ + Na2 [resin] Ca [Resin] + 2Na+

Cl2 + 2NaOH -----> NaOCl + NaCl + H2O

Process Flow Diagram of Caustic Soda is given in Figure 3-3.

Figure 3-3: Process Flow Diagram of Caustic Soda




3.5.2 Chlorotolune

Process Description:

Chlorination of Toluene

Chlorination of toluene in presence of ultra violet lights will produce chlorinated mass of BCL, OPCT,

BCL2 and BTC. Chlorinator is a set of three glass columns connected in series with overflow of first

going to second and the overflow of the second is going to third. Each chlorinator is fitted with UV

lights. Chlorination is a highly exothermic reaction, generating hydrogen chloride gas as a by-product.

The vapours generated due to the exothermic of the reaction are condensed in series of condensers

and condensate is refluxed into chlorinators. The hydrogen chloride coming from the vent of the

condenser is scrubbed with chilled toluene in toluene scrubber to absorb any residual chlorine coming

from the chlorinators. Hydrogen chloride coming from scrubber condenser is absorbed in water in HCl

absorber to produce 30 % HCl.

Generated chlorinated mass is pumped to degasser to remove any dissolved gas from the chlorinated

mass. Degassed chlorinated mass is fed to toluene recovery column. Where at elevated temperature

and reduced pressure toluene is recovered from chlorinated mass along with OPCT & BCL are recycled

to the Chlorinator. After distillation of toluene, remaining chlorinated mass containing mixture of BCL,

BCL2 & BTC is pumped to BCL recovery column. The recovered BCL is stored in holding tank. The

remaining mass is fed to intermediate distillation column. In this column BCL2 fraction containing

BCL2, BTC, higher and some BCL is distilled to remove BCL which is recycled back to toluene recovery

column. After the removal of BCL the BCL 2 fraction along with heavy is fed to BCL2 fraction

purification column BCL2 fraction is distilled in this column and stored in intermediate holding tank for

further processing at hydrolyser. Bottom of BCL2 purification column is fed to residue distillation

column, in this column distilled BCL2 residual recycle back to BCL2 purification column. The bottom

residue column is pumped to incinerator for disposal.

Chemical Reaction:

Hydrolysis of BCL2 / BTC:

Hydrolysis of mixture of BCL2 fraction containing BCL2 and BTC separated from chlorinated mass with

10 % dilute solution of ferrous chloride in agitated hydrolyser at an elevated temperature and




atmospheric pressure will produce hydrolyzed mass of BCHO and BCOOH mixture and HCl vapours as

a by-product. The vapours generated during the reaction are condensed during the reaction

condensed in series of condenser and condensate is refluxed back to respective hydrolysers. The HCl

coming from vent of the condensers are scrubbed from chilled toluene in toluene scrubber to absorb

any residual organic vapour coming from the hydrolyser. Uncondensed HCl vapours escape from the

vent of the scrubber condenser is absorbed in water in HCL absorber to produce 30 % HCl.

To make organic free, cool down the hydrolyzed mass containing BCHO and BCOOH to 40 – 45 deg.C.

Give 10 % wash to cooled hydrolyze mass and allow separation in gravity separator. Separate light

phase of mixture of Fe2Cl3 and water recycle back to the hydrolysis process and heavy phase of

mixture of BCHO and BCOOH pumped to neutralization section for further purification.

Chemical Reaction:

Neutralization

BCOOH and BCHO mixture have limitation for separation due to similarly in their physical properties at

some extent. So soda ash solution into mixture of BCOOH and BCHO in the agitated neutralizer

reactor. Neutralization of BCOOH with soda ash solution will produce NaB solution. Produced

neutralized mass of sodium benzoate and BCHO fed to gravity separator and allow separation of NaB

and BCHO in gravity separator. Separate light phase of BCHO send for further purification at treatment

section and heavy phase of NAB is fed to jacketed kettle to heat up and remove water. Evaporated

water is condensed in condensers. After water removal concentrated NaB solution pass through

activated carbon bed to make it free from organic material. Prepare flakes and powders of organic

free, pure sodium benzoate solution through drum dryer and send for packing.

Chemical Reaction:

Treatment and Purification

Separate light phase of BCHO treat with soda ash and NaB in batch operation for 4 – 5 hrs at elevated

temperature and nil the traces of BCL content from BCHO. After treatment separate out low purity

NaB solution from the treatment reactor and send for the storage. Remained BCL free BCHO separate

from the treatment reactor and fed to BCHO purification column and at elevated temperature and

reduce pressure pure BCHO distillate collect into receiver tank and pumped for storage. The bottom

residue of column recycles back to crude BCHO purification column.




Hydrolysis of BCL

Hydrolysis of BCL with fresh process water in agitated hydrolyser at temperature of 135 – 137 deg. C

and at elevated pressure will produce hydrolyzed mass of BOH and vapours of hydrogen chloride as a

by-product/ Flash out produced hydrolyzed mass at elevated temperature and reduced pressure to

separate dissolved gases, un-reacted BCL vapours and water from hydrolyzed mass. Flashed vapours

then condense in series of condensers and condensate collect into gravity separator through

barometric seal pot. Separated organic layer of BCL recycle back to hydrolyser and aquas layer recycle

back to fresh process water tank.

Separation & Purification

Separate light phase of aqueous layer pumped to extractor and extract out low percentage (3.5 %)

HCl produced during hydrolysis of BCL solvent. Extract low percentage HCL then transfer to HCl

absorber through tail gas scrubber to recover HCl from 20 % HCl absorber. After extraction used BCL

solvent from underflow of extractor recycle back to the hydrolysis process.

Separate heavy phase organic layer from gravity separator fed to water and BCL fraction removal

column. At elevated temperature and an under vacuum recovered distillate BCL fraction recycle back

to hydrolyser to produce BCO. At certain temperature BCL reacts with benzyl alcohol and formed DBE

ad some heavier. The left over bottom residue containing crude benzyl alcohol and high boiling

fraction fed to high boiling fraction removal column where at elevated temperature and reduce

pressure distillate of low boiling fraction separate out and left over high boiling fraction containing

DBE. Separate distillate of low boiling fraction fed to further recovery column and distilled out LBF at

temperature 123 deg. C from top and BOH at temperature 134 deg. C from bottom of the column and

transfer to storage tanks.

Chemical Reaction:

30 % HCl Absorption

HCL vapour generated during toluene chlorination, hydrolysis of BCL2 fraction and hydrolysis of BCL.

HCl vapour generated in toluene chlorination and hydrolysis of BCHO section pass through series of

condensers. Uncondensed vapours escape from the vent of the condensers is scrubbed with chilled

toluene in toluene scrubber to dissolve any residual chlorine. HCl vaoprs coming from scrubber

condenser is passed through adiabatic absorber.

Dilute solution of HCl (2.4%) from extractor outlet is concentrated to solution strength of 8 & by

evaporating excess water. This evaporated water is then recycled back to hydrolyser, vaporizing this

water helps to remove any organic contamination in the dilute HCL the dilute 8 % HCl solution is fed




to adiabatic absorber through tail gas scrubber. Counter current flow of hydrogen chloride vapour and

water in contact with each other will release adsorption energy and HCl vapours will absorbs in water.

Vapours generated during absorption are passed through series of condensers. Collect condensed

during absorption. Separate light phase of organic layer send to distillation kettle to recover organic

material at elevated temperature and vacuum and aqueous layer recycle. Redirect back to absorber as

a reflux. Uncondensed vapours escape after secondary condenser of 30 % HCl absorber pass through

tail gas scrubber and scrubber vapours fed to 30 % HCl absorber at the top. Any acidic fumes /

vapours exhaust after tail gas scrubber will get sucked by venture scrubber due to partial vacuum

generated at the suction of venture scrubber by circulation of dilute caustic to neutralize acidic fumes.

Cool down 30 % HCl generated at bottom of 30 % HCL absorber product cooler and send for storage

tank.

Incineration for Residue

Residue generated in the process of burned in Incinerator. Additional fuel is not required for this

operation. Additional fuel will only be required during startup of the system. The vent gases generated

in the incinerator are passes through a waste heat recovery boiler; this is done so that the

temperature of the gases leaving the boiler is above 300 deg. C. it is necessary to keep flue gases

temperature higher because of 180 deg. C there is formation of dioxane.

In order to avoid this flue gas coming from the waste heat recovery boiler is quenched to below 100

deg. C by spraying water. During the burning of residue hydrogen chloride and chlorine is formed. HCl

formed is also scrubbed with water and water is continuously fled from quencher. HCl in the bleed

stream is send to ETP to neutralizer and further treated to reduce TDS.

Vent gas from the quencher is scrubber with sodium sulphide solution to scrub chlorine from the flue

gas. The scrubbed flue gas is vented to atmosphere via chimney. The liquid effluent generated from

chlorine scrubbing is send to ETP. The effluent generated from quenched and scrubber will have TDS

of 1500 – 2000 PPM.

The process flow diagram of Toluene compounds are given in Figure 3-4, Figure 3-5, Figure 3-6,

Figure 3-7, Figure 3-8.




Figure 3-4: Process Flow Diagram of BCL

Figure 3-5: Process Flow Diagram of BCHO




Figure 3-6: Process Flow Diagram of BHO

Figure 3-7: Process Flow Diagram of BAC

Figure 3-8: Process Flow Diagram of CNMD





Process Description

Normal/ Heavy Normal Paraffin (HNP), being straight- chain saturated hydrocarbons (alkanes) react

with Chlorine readily, replacing Hydrogen atoms to produce Chlorinated Paraffin & Hydrochloric Acid.

The reaction is exothermic:

CnH2n+2 + mCI2 (CnH2n+2-m) Clm + mHCI

Mass Balance of Chlorine Utilization

The stoichiometric Mass Balance of Chlorine utilization in CPW manufacturing is presented here under:

CnH2n+2 +XCI2 CnH2n+2 + XHCI

Chlorine reacts with Paraffin to produce Chlorinated Paraffin & HCI

C14H30 +6CI2 C14H24CI6 + 6HCI

198 426 405 219

1MT CPW (50 - 51% Chlorine content CP- 52 grade) will require 488 kg. HNP (carbon chain length

C14 only) and 1.10 MT Chlorine (considering the process loss of 0.055 MT equivalent Chlorine,

theoretically 1.05 MT Chlorine will be required).

HCI released will be = 1.593 say 1.60 MT (30- 32%).

With HNP composition of C13- C16, the theoretical consumption will come to 489 kg/MT of CPW.

As the Chlorine concentration will go up, the consumption of Paraffin will come down and vice - versa

will be applicable for low Chlorine concentration in the product like CP- 45.

In our case CP- 52 is the major product where we have fixed the following norms:

HNP -490 kg.

Chlorine- 1100 Kg.

HCI - 1600 kg. (30- 32%)

Process flow Diagram of Chlorinated Paraffin Wax is given in Figure 3-9.

Figure 3-9: Process Flow Diagram of Chlorinated Paraffin wax




3.5.4 Epi Chloro Hydrin Plant (ECH Unit)

Glycerin Distillation (GLY Unit)

Neutralization and Drying of Crude-Glycerin

The Crude-Glycerin is neutralized in a vessel with about 32 % NaOH solution. In the first drying

column the main content of water is evaporated together with traces of Methanol. In the second

drying column the water content is reduced to less than 1 wt. % under vacuum.

Rectification

The condensed methanol streams are forwarded to a Methanol rectification column for separation of

water and methanol. The methanol stream is forwarded to a storage tank; the water is collected at a

waste water tank and used for dissolving of the salt streams. After the dryer section the dried crude

Glycerin comes into a column on the bottom and is evaporated in a forced circulation evaporator and

rectified in 3 packing sections, where the middle one is the product condenser and the top packing is

the by-product condenser. The by-product is Glycerin which is recycled into the column and only in

case of bad Crude glycerin quality approx. 5% of the total produced Glycerin has to be recycled back

into the vessel.

Purification of bottom product

Depending on the salt concentration in the crude Glycerin a certain quantity of bottom product from

the rectification has to be pumped into a salt separation decanter / centrifuge where the salt contend

is reduced below 10 %. After the decanter, one part of the centrifuged stream is recycled to the

bottom of the distillation column and another part is fed into a thin film evaporator where the main

part of the Glycerin is separated and the remaining part goes back into a lock hopper vessels. The

bottom product consisting of approx. 60 % MONG and 40 % Glycerin and polymers is removed from

the lock hopper and is fed into the desalination reactor.

Salt utilization

The removed salt from the bottom of the column is transferred into a mixing vessel where the salt

(75-80% of total salt content of Crude Glycerin) is mixed with brine from the saponification (ECH)

before the stream goes into the BPP plant for treatment.

Activated carbon bed

In the activated carbon bed filter the Esther content is going to be reduced in order to light up the

product and reduce the smell.

MONG Desalination Unit

The bottom product of the thin film evaporator, consisting of about 60 – 70% MONG/Salt and 30 –

40% Glycerin is fed into a Desalination Reactor where the stream is heated up to about 400°C. The

desalination reactor is a horizontal reactor consisting of a cylindrical, horizontal shell with heating

jacket and a rotor in the shell. Due to the required high service media temperatures, the desalination

reactor will be heated by molten salt. The molten salt system is included within the WIP system. The

vapor stream of the reactor is discharged to the incinerator at the WIP. The dry product stream is

cooled in a downstream cooling screw and via the Rotary Feeder routed to a Mixing Tank where waste




water is added for dissolving. The overflow of this tank is routed to another mixing vessel, where

hydrogen chloride is added for neutralization and then the solution is pumped through a filter to

remove solid particles towards the Brine Purification Plant.

Epi Chloro Hydrin Plant (ECH Unit)

Chlorination of Glycerin

The Glycerin is heated in a heat exchanger up to 100°C and is absorbing the excess of HCl Gas in a

scrubber and is reacting with the excess of HCl from the Chlorination reactors. The main Chlorination

step is taking place in the chlorination reactors, where the feed of the preheated Glycerin, HCl gas and

the catalyst oxalic acid together with the bottom product from the vacuum distillation Columns is

entering on the bottom.

The reactions happens in two steps;

Step one:

C3H8O3 + HCl C3H7ClO2 + H2O

Step two:

C3H7ClO2 + HCl C3H6Cl20 + H2O

Step one is much faster than step two.

Separation of Reaction Products: Dichlorhydrine and Water

The overflows of the reactors are collected in a vessel and pumped into the vacuum distillation column

where water and Dichlorhydrine is separated from the Glycerin and Monochlorhydrine as a bottom

product.

Separation of By-Products

A small purge is continuous separated from the reactor circuit and is partly evaporated in a heat

exchanger to recover most of the remaining Monochlorhydrine to reduce the product losses to the

waste.

Saponification into Epichlorhydrine

Saponification works according to the following reactions;

C3H6Cl20 + NaOH C3H5ClO + H2O + NaCl

To avoid polymerization as side reaction the NaOH is feeded as a 20 wt % solution, which is prepared

ISBL.

Separation of Epichlorhydrine from Brine

After each saponification step the brine is treated in a stripper column and an azeotropic mixture of

water and Epichlorhydrine is recovered on the top of the strippers. After condensing the vapors water

rich phase and a Epichlorhydrine-rich phase is obtained. The water-rich phase is recycled into the

stripper and the Epichlorhydrine rich phase is the feed to the Epichlorhydrine purification units.




Purification of Epichlorhydrine (99.8 ~ 99.9 wt.%)

To obtain high quality Epichlorhydrine two rectification columns are necessary. In the first column the

water content is separated and in the second column the Epichlorhydrine is recovered as a top product

and as bottom product some polymers and equilibrium products are separated.

Brine Purification Unit (BPP Unit)

This Unit is designed to handle the brine of the Glycerin, Epichlorhydrine and the Epoxy Resin Units.

After adjustment of the pH value, the brine is mixed with the catalyst and feed into a high pressure

reactor and afterwards treated by an ion exchange unit. In the process the TOC value of the brine is

decreased by more than 99.5% by high pressure oxidation. After the process the TOC value of the

brine is lower than 10 ppm. The Catalyst and Oxygen are recovered within the process.

Raw material input

The Brine is delivered to a surge tank where the catalyst, delivered as salt solution in water, is

dissolved. Oxygen, NaOH 32 wt% and liquid HCl 30 wt% are obtained from outside Battery Limit. The

purified brine is retained to the battery limit.

Feeding of input materials

The raw brine is stored in a surge drum and the pH is adjusted. A pump is mixing the tank content

and pumps the brine to the mixer where the catalyst is added. A high pressure pump pumps the brine

through the high pressure oxidation unit.

Waste Incineration Unit (WIP Unit)

The WIP Plant burns all liquid and gaseous residuals. In the MONG treatment unit the solid salt is

separated and the remaining system gas together with the other waste gases are fed into the

incinerator of the WIP plant to provide full oxidation of the combustible compounds. Recovered heat

from the hot gas is used for preheating the process gas required for the MONG Desalination Unit and

steam production.

Incinerator

The process gases from the MONG desalination unit together with the off-gas from the Glycerine plant

and the Epichlorhydrine plant is fed into the Incinerator. The incinerator is operated at about 900 –

1,000 °C which is required for the oxidation of the chlorinated combustible compounds. Natural gas is

used as fuel and to maintain a certain minimum oxygen concentration for the combustion ambient air

is added. The organic compounds are converted to H2O and CO2.

Steam System

The process gas from the incinerator is cooled in two steps, comprising preheating of the MONG

desalination process gas and the evaporator, which is a tube heat exchanger. The steam system

consist of the boiler feed water pumps, boiler water circulation pumps and the steam drum, where

separation of liquid and gas phase takes place.

Dioxin Filter

The dioxin filter is installed inline of the exhaust gas line from the heat exchangers towards the HCl-

Scrubber. Honeycomb shaped titanium oxide catalyst blocks are used for decomposition of the dioxin.




Tail Gas Scrubber

The tail gas scrubber removes the HCl from the process gas. It is a packed tower which uses a NaOH

– solution as washing fluid. In the recirculation pipe the washing fluid passes over plate type heat

exchangers to cool it to the required temperature. Cooling water is used as cooling media. NaOH

solution and DM water is added to the scrubber depending on the HCl load and liquid level in the

bottom of the scrubber.


Methanol Chlorination System

Methanol is reacted with concentrated hydrochloric acid which is recovered from hydrochloric acid

treatment section under the designated temperature and pressure. Less chlorinated methane product

(mainly methyl chloride) is produced in this section.

Thermal Chlorination Section

As the name implies, methyl chloride which is produced in Methanol Chlorination Section is reacted

with chlorine in this section under high temperature conditions. The reaction being exothermic, only a

part of heat has to be supplied. Before entering the reactors, recycle gas, methyl chloride and chlorine

are thoroughly mixed in the specially designed mixer to avoid risk of explosion. They are mixed and

fed into thermal reactors and reacts with chlorine in order to form methylene chloride, chloroform,

carbon tetrachloride and hydrochloric acid as gaseous products and they are further taken to

Hydrochloric acid treatment section.

Photo-chlorination Section

This unit is installed to enhance the production capacity for C3 and C4. The reaction is carried out in

presence of Ultra Violet light in glass lined reactor in liquid phase. HCl formed during the reaction is

stripped off by distillation.

Residual Chlorine/Hydrochloric acid in chloromethane is neutralized and washed in specially designed

‘U’ columns. Moisture is removed with the help of azeotropic distillation and chloromethane are fed to

distillation section for separation.

Hydrochloric acid Treatment Section

The hydrochloric acid in component mixture formed in thermal chlorination section is absorbed by

circulating weak hydrochloric acid(diluted hydrochloric acid) to form concentrated hydrochloric acid,

and the other gaseous product are transferred to the following section, reaction gas treatment section.

The weak hydrochloric acid produced in the methanol chlorination section is utilized as the circulating

weak hydrochloric acid as mentioned above.

Reaction Gas Treatment Section

Reactor discharge gas after HCl absorption is passed through a series of six columns. In first column

residual HCl gas is removed by absorption in dilute HCl. In second column traces of HCl/ Chlorine are

neutralized with NaOH solution. The gas is dehumidified in third column with NaOH solution. The gas

is dried in remaining three column with 98%H2SO4 flowing in counter current direction.




Liquefaction Section

The gaseous products after being dried is compressed and liquefied. Most of the uncondensed gas is

recycled back the reactors and a part of it is withdrawn as purge gas to maintain inert gas/ oxygen

concentration in recycle gas.

Purge Gas Treatment Section

Uncondensed chloromethane are removed from the gas in this section by scrubbing and

chloromethane are recovered after the gas has been scrubbed.

Crude Product Treatment Section

The crude chloromethane products containing small amount of hydrochloric acid and chlorine come

from Photo-chlorination section and fluids coming from other processes as drain are neutralized by

chemical and then, the crude chloromethane products are send to the following distillation section.

Distillation Section

Mixed chloromethane in liquid form from thermal chlorination section and photo-chlorination section

are separated with the help of distillation in bubble cap type columns. Some portions of the above

distilled chloromethane products are sent to thermal chlorination section and photo-chlorination

section and then, for further chlorination.

Product Handling Section

Each of the above distilled chloromethane products are treated in a series of equipment to be further

purified for better application of products. Products and co-products hydrochloric acid are finally

packed in the form of drums cylinders and/or tank lorry for shipment according to the customer’s

requirement.

Process Flow diagram of Chloromethane is given in Figure 3-10.

Figure 3-10: Process Flow Diagram of Chloromethane




3.5.6 Power Plant

In coal thermal power plan, the steam is produced in high pressure in the steam boiler due to burning

of fuel (coal) in boiler furnaces. This steam is further heated in a super heater. This super-heated

steam then enters into the turbine and rotates the turbine blades. The turbine is mechanically coupled

with alternator that its rotor will rotate with rotation of turbine blades. After entering the turbine the

steam pressure suddenly falls and corresponding volume of the steam increase. After imparting

energy to the turbine rotor the steam passes out of the turbine blades into the condenser. In the

condenser the cold water is circulated with the help of pump, which condense the low-pressure wet

steam. This condensed water is further supplied to low-pressure water heater where the low-pressure

steam increases the temperature of feed water; it again heated in high pressure.

Major steps of coal base power plant operation:

First the pulverized coal is burnt into furnace of steam boiler.

High-pressure steam is produced in the boiler.

This steam is then passed through the super heater, where it further heated up.

This super-heated steam is then entered into a turbine at high speed.

In turbine this steam force rotates the turbine blades that means here in the turbine the stored

potential energy of the high-pressure steam is converted into mechanical energy. Turbine shaft

connected with generator in which power generates.

After rotating the turbine blades, the steam has lost its high pressure, passes out of turbine

blades and enters into a condenser.

In the condenser the cold water is circulated with help of pump, which condenses the low-

pressure wet steam.

This condensed water is then further supplied to low pressure water heater where the low

pressure steam increase the temperature of this feed water, it is then again heated in a high

pressure heater where the high pressure of steam is used for heating.

The turbine in thermal power station acts as a prime mover of the alternator.

3.6 RAW MATERIALS

Raw material shall be sourced from registered supplier within India and Imported (if required) based

on the need and availability. Details of raw material along with the Quantity, Source and Mode of

Transport is given in Table 3-4.

Table 3-4: Details of Main Raw Material Quantity and Means of Storage

S.

No. Raw Material

Proposed

Quantity (MTPA) Source

Mode of

Transport

A) Chlor-Alkali Plant

1 Salt 7,12,800 Dahej, Jambuser and Bhavnagar Trucks

2 Sodium Carbonate 5,400 Local Market

3 Sulphuric acid 5,040 In-House Pipeline

4 Sodium Bisulphate 172 Local Market

Trucks 5 Alpha cellulose 1,150

6 Caustic soda (internal) 432 In-House

7 Hydrochloric acid (internal) 2,160 Pipeline

8 Flocculent 5.76 Local Market Trucks




S.

No. Raw Material

Proposed

Quantity (MTPA) Source

Mode of

Transport

B) Chlorotoluene

1 Toluene 48,180 Open market Truck

2 Chlorine 58,400 In-house Pipeline

3 Soda ash 638.75 Local market Truck

4 Caustic soda lye 182.5 In-house Pipeline

5 Stabilizer 109.5 Local market Truck

6 Ferric chloride 91.25 Local market Truck

C) Chlorinated Paraffin Wax

1 Heavy Normal Paraffins 17,885 Local market Truck

2 Chlorine 43,800 In-house Pipeline

3 Stabilizer (Soya Epoxy ) 109.5 Local market Truck

4 Sodium Hydroxide (48%) 8,318.3 In-house Bags

D) Epi Chloro Hydrin (ECH)

1 Crude Glycerin 42,210 Local Market Tanker

2 Caustic Soda 17,755 In House Pipeline

3 Hydrochloric Acid 27,805 In House Pipeline

4 Catalyst for ECH unit 201 Local Market Drum

5 Catalyst for BPP unit 50.25 Local Market Drum

6 Oxygen for BPP unit 1,35,675 (m3/A) In House Compressor Pipeline

E) Chloromethanes (CLM)

1 Methane gas 1,206 Authorized Gas Supplier Pipeline

2 Methanol 33,466.5 Local Market Tanker

3 Chlorine 97,183.5 In House Pipeline

4 Caustic soda 1,507.5 In House Pipeline

5 Sulphuric acid 9,045 Local Market Tanker

F) Coal Based Power Plant

1 Coal 5.5 Lac Imported Coal having high GCV &

low Sulphur content Trucks

3.7 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE

To conserve the water, various recycle/ reuse schemes will be implemented in proposed project. Most

energy efficient technology will be selected.

3.8 UTILITIES

The estimated list of utilities required for the project is as given below:

3.8.1 Power Requirement

Power requirement of ~ 130 MW for proposed plants will be met through Captive power plant. In case

of plant start-up, emergency, scheduled / un-scheduled stoppages, 3 Nos. DG set of 1,000 kVA for

Caustic Soda plant & 1 No. DG set of 225 kVA for Chlorinated paraffin wax plant will be provided.




3.8.2 Fuel Requirement

Imported Indonesian/ South African Coal having ~ 0.58 % Sulphur and ~ 7.0 % ash content will be

used for the proposed Boilers and HSD will be used for DG Sets. Details of the same are tabulated in

Table 3-5.

Table 3-5: Fuel Details

S. No. Type of Fuel Used in Quantity Source

1 Imported Coal Boiler

(2 Nos, 280 TPH Capacity each)

1,500

MT/Day

Open Market / Nearest

Port

2 HSD DG Sets –

4 Nos. (3 x 1,000 kVA & 1 x 225 kVA) 800 Ltr/Hr. Local Depot/ Suppliers

Note: Fuel used for DG sets is not in continuous basis. It will be used only in case of plant start-up,

emergency, scheduled / un-scheduled stoppages.

3.8.3 Water Requirement

26.46 MLD of water requirement will be met from GIDC Reservoir. Plant-wise breakup of water

requirement is given in Table 3-6 - Table 3-11.

Table 3-6: Water Requirement - Chlor-Alkali Plant

S. No. Description Quantity (KLD)

1 Process 4,135

2 Cooling tower makeup 5,328

3 Safety shower 10

4 Floor washing 10

5 Domestic 20

Total 9,503

With taking contingency and margin for fire water 11,200

Table 3-7: Water Requirement - Chlorotoluene Plant


1 Process 1,120

2 Cooling tower make up 530

3 Safety shower 10

4 Floor washing 10

5 Domestic 10

Total 1,680

Table 3-8: Water Requirement - Chlorinated Paraffin Wax Plant


1 Process 130

2 Cooling tower makeup 50

3 Safety shower 10

4 Floor washing 10

5 Domestic 20

Total 210




Table 3-9: Water Requirement - Epi Chloro Hydrin (ECH) Plant


1 Process 220


3 Safety shower 10

4 Washing 10

5 Domestic 20

Total 940

Table 3-10: Water Requirement - Chloromethanes (CLM) Plant


1 Process 90


3 Safety shower 10

4 Washing 10

5 Domestic 20

Total 930

Table 3-11: Water Requirement – Captive Power Plant


1 Process (mainly boilers) 4,000

2 Cooling tower makeup 6,800

3 Safety showers 20

4 Floor washing 20

5 Domestic 50

Total water 10,890

Contingency @ 5 % 610

Total 11,500

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

Environmental issues associated with Chlor-Alkali & synthetic organic manufacturing units include:

Air emissions;

Wastewater;

Solid Wastes.

3.9.1 Air Emissions & Control

Details of gaseous emissions from Process and Flue gas and attached Air Pollution Control Equipment

are given in Table 3-12 & Table 3-13.

M/S. GACL

PFR – PROPOSED NEW CHLOR-ALKALI PLANT, SYNTHETIC ORGANIC CHEMICAL PLANTS AND COAL BASED CPP AT

PLOT NO: D II/9, GIDC, DAHEJ. PROJECT DESCRIPTION


Table 3-12: Details of Stacks, Fuel Used and APCM attached to Flue Gas Stacks

S.

No. Stack Attached to Fuel Used

Quantity of

Fuel APCM

Expected

Pollutants

Efficiency of

APCE

Stack

Height

(m)

Stack

Top Dia.

(m)

Exit

Temp.

(°C)

Exit

Velocity

(m/s)

1 Boilers

(2 Nos.) Imported Coal 1,500 MT/Day ESP PM, SO2 & NOx > 99.5 % 80 3.25 140 15

2 DG Sets (3 Nos. 1,000

kVA each) HSD 750 Ltr/Hr.

Adequate

Stack Ht. PM, SO2 & NOx - 15 0.5 150 10

3 DG Set (225 kVA) HSD 50 Ltr/Hr. Adequate

Stack Ht. PM, SO2 & NOx - 9 0.25 150 10

4 Incinerator of ECH

Plant NG

Shall be

calculated

Caustic

Scrubber

HCl, Cl2, SO2,

NOx, HC,

Dioxin

- 25 0.5 70 10

Table 3-13: Details of Stacks, APCM attached to Process Gas Stacks / Vents

S.

No. Stack Attached to Area / Section APCM

Expected

Pollutants

Stack

Height

(m)

Stack

Top Dia.

(m)

Exit

Temp.

(°C)

Exit

Velocity

(m/s)

1 Waste air De-Chlorination Unit Caustic Soda Plant 3 Stage Caustic Scrubbing System Cl2 30 0.4 45 3.0

2 HCl synthesis Unit Caustic Soda Plant Single Stage DM Water Scrubbing

System HCl, Cl2 30 0.15 45 3.0

3 Scrubbing unit Chlorotoluene Plant Caustic Soda Scrubber HCl, Cl2, 33 0.4 45 3.0

4 Scrubbing unit CLM Plant Water + Alkali Scrubber

HCl, Cl2,

CO, SO2,

NOx, HC,

Dioxin

30 0.15 50 3.0




3.9.2 Fugitive Emissions & its Control

The processes (reactions) in caustic soda plant are in closed system. To detect and control the fugitive

emissions of Cl2 (only pollutant of fugitive nature) in the workplace environment, online sensors with

alarm will be provided at different locations in Caustic Soda plant. Immediate actions / process safety

measures may be initiated from control room in case of Cl2 level beyond TLV of 3 mg/m3 as specified

under Factories Act.

3.9.3 Line Source Emissions & Control

During construction phase, vehicular emissions will be from use of construction machinery and

vehicles. Apart from it, application of heavy machinery and earth movers will generate emissions.

Suitable dust suppression techniques such as water sprinkling will be taken at these times as relevant.

During operation phase, vehicular emissions due to transportation of raw materials, finished goods

and local travel of employees are envisaged.

Approximately, 300 trucks per day carrying raw material and finished goods shall be using the state

highway connecting Site with Bharuch & then after, NH-8, which connects site to Mumbai-Delhi and

others major cities.

3.9.4 Noise Generation

From the proposed project, noise shall be generated from the various activities. Source of noise

generation are:

The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during

construction phase;

Operation of boilers, blowers, compressors, chillers, DG sets, etc.;

Vehicle movement for transportation of raw material and finished goods.

3.9.5 Waste Water Generation

Around 4,920 KLD waste water will be generated. Effluent will be treated in ETP and treated effluent

will be discharged into GIDC drain line for final disposal in deep sea. Sewage will be treated in STP.

Plant-wise effluent generated quantity is given in Table 3-14 - Table 3-18.

Table 3-14: Waste Water Generation – Chlor Alkali Plant


1 Process 540

2 Cooling tower blow down 1,100

3 Safety shower 5

4 Floor washing 10

5 Domestic 15

Total 1,670

Table 3-15: Waste Water Generation – Chlorotoluene Plant


1 Process 140

2 Cooling tower blow down 110

3 Safety shower 10





4 Floor washing 10

5 Domestic 5

Total 275

Waste Water Generation – Chlorinated Paraffin Wax Plant

No process effluent generation in plant, only waste water from CT blow down and floor washing is

neutralized in ETP (sizing given below) and neutralized water will be used for gardening purpose.

Table 3-16: Waste Water Generation – Epi Chloro Hydrin (ECH) Plant


1 Process 180


3 Safety shower 10

4 Washing 10

5 Domestic 10

Total 330

Table 3-17: Waste Water Generation - Chloromethanes (CLM) Plant


1 Process 0


3 Safety shower 10

4 Washing 10

5 Domestic 15

Total 85

Table 3-18: Waste Water Generation – Captive Power Plant


1 Process 490

2 Cooling tower blow down 2,000

3 Safety shower 20

4 Washing 20

5 Domestic 30

Total 2,560

3.9.6 Hazardous Waste and Other Solid Waste

Brine Sludge will be generated from Chlor Alkali plant. It is a non-hazardous waste as per OM No. 23-

206/2014-HSMD dated 02-05-2016 shall be disposed off in Captive Landfill site.

Hazardous waste generated from proposed plants will be handled in environmentally sound manner,

stored in adequate space and disposed of as per HWR, 2016 to authorized recyclers and/or TSDF or

incineration site. Membership shall be taken from M/s. BEIL. Other inorganic waste like used paper

and waste wood shall be recycled or reused through recyclers, Waste metal shall be sold as scrap,

Waste plastic shall be sold to recyclers.

Summary of Hazardous & other solid waste from the proposed unit is tabulated in Table 3-19.

M/S. GACL


PLOT NO: D II/9, GIDC, DAHEJ. PROJECT DESCRIPTION


Table 3-19: Hazardous & Other Solid Waste Details

S. No Waste Name Category MT/Year Source Means of storage Disposal Method

Hazardous Waste

1 High M.P Liquid Impurities 26.1 548 Chlorotoluene Plant Drums Incineration (In-house / BEIL)

2 Used/spent oil 5.1 100 DG Sets Drums Sold to authorized Recyclers

3 Discarded drums and containers 33.1 6,000 Nos. Process As it is Collection, decontamination & sold

to authorized vendor

4 Contaminated cotton rags or other

cleaning materials 33.2 1 Handling Poly Bag / Drums Incineration

5 ETP waste 35.3 50 – 100 ETP HDPE Bags TSDF

Non-Hazardous Waste

1 Brine Sludge -- 28,800 Caustic Soda Inhouse SLF As per rules.

2 Fly Ash -- 1,00,000 Power plant Silos Shall be given to Brick/Cement

manufacturing Industries


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. SITE ANALYSIS


4 SITE ANALYSIS

4.1 CONNECTIVITY

4.1.1 By Road

Site is well connected to Dahej and Bharuch via Bharuch Dahej State Highway (SH – 6) at an aerial

distance of 0.08 Km in North Direction.

4.1.2 By Rail

Major railway station for public transportation is Bharuch Railway Station located at an aerial distance

of ~31.2 Km in E Direction form the project site. Also, Dahej Railway Station an aerial distance of

~10.6 Km in W Direction of project site is operational for goods transportation.

4.1.3 By Air

Nearest airport from project site is Surat Airport located at an aerial distance of ~ 65.7 Km in SSE

Direction. And Vadodara Airport is located at an aerial distance of ~ 85.3 Km in NE Direction

4.1.4 By Water

Nearest port is Adani port at Dahej located at an aerial distance of ~16 Km in W direction.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP

The total plot area is 102 ha. The land is owned by Gujarat Alkalies and Chemicals Ltd. The land

ownership document for Plot No. DII/9 is attached as Annexure 2.

The zoning of land as of now as per the Regional plan is Industrial Area (Dahej – II). The plot is a

vacant barren plot situated in a GIDC approved area for Chemical Zone. Permanent change in Land

Use from Barren to Industrial Use is envisaged. Land Cover will be as per the Site Layout Map as given

Annexure 3.

4.3 TOPOGRAPHY

Dahej GIDC is located on west of Bharuch district at Gulf of Khambhat. Topographically, the area

is almost flat with gentle slope toward south and southwest i.e. toward Gulf.

Geologically, entire area is covered with recent age deposits of fluvial and marine origin. Major part of

it is covered with dark gray to brown Stiff clayey soil.

Project site is shown on Toposheet No. NF-43-09 and the same is provided in Annexure 4.

4.4 EXISTING LANDUSE PATTERN WITH SENSITIVITY TABLE

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

(including CRZ) etc. List of villages in surrounding area is given in Table 4-1.




Table 4-1: Nearest Villages in Surrounding Area

S. No Pond Distance Direction

1 Atali 0.74 NE

2 Rahiyad 1.28 SW

3 Jolwa 3.13 W

4 Koliyad 1.23 SSE

5 Vengni 3.18 SE

6 Kaladra 5.37 SE

7 Mehegam 7.79 SE

8 Atali 0.84 ENE

9 Kesrol 9.37 E

10 Bhensli 6.42 E

11 Khojbal 6.6 ENE

12 Ahkod 3.77 NE

13 Nandirda 5.62 NE

14 Nandarkha 7.14 NE

15 Pankhajan 9.56 NNE

16 Galenda 3.12 NW

17 Samatpur 3.93 NNW

18 Sambheti 5.4 NNW

19 Janiyadra 6.66 NNW

20 Vwav 5.7 NW

21 Kadodara 6.77 NE

22 Namavi 9.36 NNW

23 Padnya 8.76 NE

24 Wardla 5.56 WNW

25 Vajapur 8.87 NE

26 Vadiya 9.76 W

27 Ambheta 9.7 WSW

28 Suva 4.18 SW

29 Manad 9.65 ESE

30 Sadathala 9.98 SE

4.5 SOIL CLASSIFICATION, GEOLOGY, DRAINAGE, TOPOGRAPHY

4.5.1 Soil Classification

The project area falls under South Gujarat Agro-climatic Zone II and Agro-ecological region-21. The

soils are predominantly of trap origin deep black soils (63%), however coastal black (14%) and loam

soils (23%) are also present. Taxonomically these soils are classified as Vertisols. The soils at the

GIDC site are also clayey having very high water holding capacity and porosity, but permeability is

very low. The soil depth is > 100 cm and soil slope is 1-3 %. As the area is in the proximity of sea,

waters and soils are likely to be saline/alkaline. The soil salinity is < 2.0 dS/m but due to ingress of

sea water soils are highly saline especially in Lakhigam. At and around project are soils are barren and




Prosopis julifera (Gandobaval) is seen. The crops of the surrounding areas are paddy, cotton and

sugarcane and in winter sorghum and wal are grown. The cropping intensity of the area is 117%.

4.5.2 Geology

Geologically, entire area is covered with recent age deposits of fluvial and marine origin. Major part of

the study area is covered with gray to yellow colored silty loam.

As per discussion with local people and well owners, depth to water level, within study area is 8 – 10

m and total depth of wells ranging from 15 – 20 m. At some places, post monsoon water, shows slight

improvement in terms of quality. However with passage of time it turns saline

4.5.3 Drainage

Geomorphologically, coastal area is covered by tidal and mud flats. Drainages have acquired a pattern

of deltaic condition.

4.5.4 Topography

Topographically, the entire area is more or less flat with gentle dipping toward west to southwest i.e.

toward Gulf.

4.6 CLIMATIC DATA FROM SECONDARY SOURCES

Based on the available long-term climatological tables (1961 – 1976) published by India Meteorological

Department (IMD) of Broach (Bharuch) District, average temperature, relative humidity and wind

speed for summer season were 31.2°C, 50.7 % and 10.0 Km/Hr respectively. Pre-dominant wind

direction recorded is from South West to North East (44.8 %).

Site specific meteorological data was collected from Bharuch town (35.0 Km ESE from the proposed

site). Average temperature, relative humidity and wind speed was recorded to be 30.2°C, 48.8 % and

3.7 m/s (13.3 Km/Hr) respectively. First pre-dominant wind direction recorded is from South South

West to North North East (21%) and second pre-dominant is from South West to North East (18%).

Above mentioned climatic conditions will be considered during designing stage.

4.7 SOCIAL INFRASTRUCTURE AVAILABLE

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities

such as park, market, playground etc. education, health care, community development, income

distribution, employment and social welfare are available in nearby area of Dahej Industrial Estate.

4.8 EXISTING INFRASTRUCTURE

Since, proposed project is Greenfield, there is no infrastructure available at site except GIDC’s

connecting road. It was observed that layout of storm water line was under progress.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PLANNING BRIEF


5 PLANNING BRIEF

5.1 PLANNING CONCEPT

Gujarat is categorized in the seismic zone III1, which is classified as having a fairly high probability of

earthquake shocks measuring 5 or 6 on the Richter scale, low probability of shocks of 6 or 7 on the

Richter scale. Thus, suitable seismic coefficients accordingly shall be adopted while designing the

structures to make it earthquake resistant.

Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc.

will be developed in the project site. Transportation of raw material and finished goods will be carried

out through proposed internal roads and finally through existing SH-6.

5.2 POPULATION PROJECTION

Refer Chapter 2, Section 2.8, Pg 11.

5.3 LAND USE PLANNING

The total plot area of Plot No. D II/9 is 102 ha. Details of Land use and green belt will be as per site

layout map. Tentative area statement is given in Table 5-1.

Table 5-1: Area Statement

S. No. Area Statement Area (m2)

1 Captive Power Plant 90,951.98

2 Chlorine Park 1,50,918.69

3 Area for common utilities 67,726.55

4 Caustic Soda Plant 85,340.22

5 Switch yard 5011.0

6 Future Expansion 22,706.35

7 Open Space 2,83,912.1

8 Truck Parking 55,620.3

9 Roads 36,952.1

10 Green Belt 1,49,932.73

11 Others 71,827.86

Total 10,20,900.00

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities

such as park, market, playground etc. education, health care, community development, income

1

1 Source: www.gujarat.earthquake.gov.in


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PLANNING BRIEF


distribution, employment and social welfare are available in nearby area of Rahiyad Village and

Bharuch Town.

5.5 AMENITIES/FACILITIES

Basic Amenities like public transport, water supply, telecommunications, hospitals etc. are available in

nearby area of Dahej Industrial Estate. Within the study area (i.e. 10 kms) basic amenities/ facilities

like Primary school, is available in all the nearby villages and for further education students goes to

Bharuch which is approximately 35.0 Km from the project site. There are number of Primary Health

sub centers for medication. These villages are well connected with public bus services. Basic amenities

like tap water supply and power supply are also available in the nearby villages. Other facilities like

communication services i.e. telephone and mobile etc., are also available in the nearby villages.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PROPOSED

INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The industrial area shall comprise of Manufacturing process area, Coal & Ash storage area, Salt and

other raw material storage, Finished product storage, Utility Area, Packing material storage, ETP area,

SLF area, Hazardous waste storage area.

Adequate storage space for salt storage, coal, raw material, solvents, finished products, ash,

hazardous and other solid waste shall be provided.

6.2 NON-PROCESSING AREA

Requirement of non processing area will comprise of Weighbridge, Administrative Building, Laboratory,

Security cabins, Workers restroom, Vehicle Shed, Water reservoirs for raw water and fire hydrant

system, Temporary storage sites, Worksblock etc.

6.3 GREEN BELT

At least 15% Green belt will be developed at proposed project site Annexure 3.

6.4 SOCIAL INFRASTRUCTURE

Refer Chapter 4, Section 4.7.

6.5 CONNECTIVITY

Refer Chapter 4, Section 4.1.

6.6 DRINKING WATER MANAGEMENT

The water will be supplied by Gujarat Industrial development Corporation (GIDC).

6.7 SEWAGE SYSTEM

Domestic waste water shall be treated in STP.

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT

Solid and hazardous waste as mentioned in Chapter 3, Section 3.9.6.

6.9 POWER REQUIREMENT & SUPPLY / SOURCE

Refer Chapter 3, Section 3.8.1.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. R & R PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

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


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PROJECT SCHEDULE &

COST ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF

COMPLETION

The construction is likely to start after getting Environmental Clearance and NOC/CTE from the

authorized committee. The EIA studies are likely to get completed in 9-24 months after the receipt of

NOC.

8.2 ESTIMATED PROJECT COST

The project cost is estimated to be INR 2,822.57 Crore. Plant-wise cost break up is given in Table 8-1

- Table 8-6.

Table 8-1: Estimated Cost – Chlor Alkali Plant

S. No. Particulars Cost (INR - Crore)

1 Land Cost + Land Development 25.0

2 Civil and Structures 167.1

3 Imported items including proprietary items 256.8

4 Indigenous items (without ED, which is moveable) 385.1

5 Erection/Insulation/Painting 61.7

6 EPCM charges 50.0

7 Startup Expenses 11.46

8 Pre-operative Expenses 62.09

9 Contingency Non-Firm 23.64

10 Finance charges 10.43

Total Project Cost 1,053.32

Table 8-2: Estimated Cost – Chlorotoluene Plant

S. No. Items Cost (INR - Crore)

1 Plant and Machinery 184

2 Civil and Buildings 42

3 Technology and Engineering fee 20

4 Pre-operative expanses 25

5 Contingency @ 5 % 13.55

Total Project Cost 284.55

Table 8-3: Estimated Cost – Chlorinated Paraffin Wax



2 Civil and Buildings 3

3 Electrical cost 3

4 Other infrastructure cost 2

5 Contingency 5

Total Project Cost 20.0


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. PROJECT SCHEDULE &

COST ESTIMATE


Table 8-4: Estimated Cost – Epi Chloro Hydrin (ECH)

S. No. Items Cost (INR - Lakhs)

1 Land and Site Development 20

2 Civil and Structural 500

3 Engineering 50


5 Erection and Commissioning 20

6 Startup Expenses 10

7 Misc. Expenses 10

Project Cost 1,110

8 Contingency @ 5% 60

Total Project Cost (in Lacs) 1,170

Table 8-5: Estimated Cost – Chloromethanes (CLM)


1 Land and Site Development 3.63

2 Civil and Structural 77.22

3 Engineering 97.29

4 Plant and Machinery 348.75

5 Erection and Commissioning 65.78

6 Startup Expenses 5.85

7 Misc. Expenses 1.07

Project Cost 599.59

8 Contingency @ 5% 30

Total Project Cost 630

Table 8-6: Estimated Cost – Captive Power Plant


1 Land and Site Development 19

2 Plant and Machinery coast including taxes/duties, initial spares etc. 605

3 Civil works 121

4 Construction and Pre-commissioning, Overheads etc. 25

5 IDC + FC 44

6 Margin money 9

Total Project Cost 823

8.2.1 Profitability

Since the project will cater to industries in the region by providing a suitable source for import, export

and coastal movement of pesticides, it will encourage industrial growth in the region and result in

additional revenue for government.

The project has been conceived assuming that there will be a growth in demand for the proposed

products, leading to a reasonable rate of return in the medium term. The project is considered

‘bankable’.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS

There shall be employment generation for the local people during the construction and operational

phase of the proposed facility. During the construction phase around 500 workers will be hired. During

operation phase, project will generate direct employment for more than 750 people along with indirect

employment for locals.

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. It

will provide employment to the people of Bharuch district.

The positives impacts include enhanced direct employment for technical/administrative works and

indirect employment opportunities to the local populace, especially in business and other services like

transportation activity.

There will be indirect development of small market for various aspects around the site.


PLANTS AND COAL BASED CPP AT PLOT NO: D II/9, GIDC, DAHEJ. ANNEXURES


ANNEXURES




Annexure 1: IMS Certification – Existing GACL Complex

ISO 9001:2008




ISO 14001:2004




Annexure 2: Land Possession Documents from GIDC

M/S. GACL


PLOT NO: D II/9, GIDC, DAHEJ. ANNEXURES


Annexure 3: Site Layout Map – Preliminary

M/S. GACL


PLOT NO: D II/9, GIDC, DAHEJ. ANNEXURES


Annexure 4: Project Site Located on Toposheet

Map showing Project Site on Toposheet No. NF-43-09 – 10 Km Radius Circle

CONTACT DETAILS




Delhi / NCR









EIA & EMP for 100 MW Thermal Power Plant at Delhi

Documents

Transcript of EIA & EMP for 100 MW Thermal Power Plant at Delhi