PRE FEASIBILITY REPORT

Transcription

1 PRE FEASIBILITY REPORT For PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO TPM ) AND CO-GENERATION POWER PLANT (22 MW TO 32 MW) IN EXISTING PREMISES of M/s. PHILLIPS CARBON BLACK LTD. Survey No. 47, SH 46, Village: Mokha, Tal: Mundra Dist: Kutchh , Gujarat 1

2 CONTENTS Sr. No. Description Page No. 1. Executive Summary 3 2. Introduction of the Project/Background information 7 3. Project Description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation and resettlement (R& R) Plan Project Schedule & Cost Estimates Analysis of Proposal (Final Recommendations) 18 2

3 1.0 EXECUTIVE SUMMARY 1.1 Company Profile Introduction PCBL, a part of USD 2500 million (or 2.5 billion) RP-Sanjiv Goenka Group, has a business of USD 500 million and four strategically located state-of-the-art Carbon Black plants at Durgapur, Palej, Cochin and Mundra. PCBL today is India's largest and globally seventh largest carbon black producer. Set up in collaboration with a US company Phillips Petroleum, PCBL started production in 1962 with 14,000 metric tonnes (MT) of carbon black at Durgapur. Currently, it has a production capacity of 4,72,000 MT per annum in India, and involves a dedicated capacity of Specialty Blacks of 40,000 MT per annum at Palej. PCBL provides a complete portfolio of products to meet the specific end requirements across Rubber, Plastics, Coatings, Inks and other niche industries globally. The Company has been continuously reinventing itself in order to make the best in class products. Additionally, PCBL's after sales service and strong technical support ensures a fiercely loyal base of customers from around the world. PCBL has etched its global footprints and has a market presence in more than 30 nations with decanting stations, warehouses located near customer locations. A few of the Company's prized customers are CEAT, MRF, Michellin, Yokohama, Birla Tyres, Goodyear, Sumitomo Tires, Bridgestone, Kumho Tires, etc. PCBL has redefined its business by establishing captive power plants at each factory from the off-gas or waste product from the carbon black manufacturing process thus creating a sustainable green movement. The gas, a by-product of carbon black production, is harnessed for generating electricity at the Company's Captive Power Plants (CPP), at Palej, Durgapur, Mundra and Kochi. That is why PCBL is the first carbon black company in the world to receive carbon credits. The Company has heavily cut down on carbon and gas emission, and serves green power to Large Private industrial units and State Electricity utilities. From the pioneer plant at Durgapur in the East to Kochi plant in the south, Palej and Mundra plants in the west - PCBL footprint spans across India. Wherever PCBL goes, the Company becomes an integral part of the social eco-system. PCBL's more than 50 years' journey to be the cleanest carbon black company is the result of meticulous planning and committed execution. 3

4 1.2 Project Details SR. NO. PRODUCT NAME EXISTING CAPACITY (MT/MONTH) 1 Carbon Black ADDITIONAL CAPACITY (MT/MONTH) Phase I: 2400 Phase II: 2400 TOTAL CAPACITY (MT/MONTH) Phase I: Phase II: Co-generation Power (waste gas base) 22 MW Phase I: 2 MW Phase II: 6 MW Phase I: 24 MW Phase II: 32 MW 1.3 Green Belt Development Company has developed an effective green belt within the factory and on periphery of the factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses. 1.4 Power & Fuel Requirement Fuel Existing: LDO= 30 KL/Month (only for heating & cooling during startup & stops) HSD= 4 KL/Month After Proposed Expansion: LDO= 40 KL/Month (only for heating & cooling during startup & stops) HSD= 6 KL/Month Energy : Existing: 7 MW from own CPP After Proposed Expansion: Total: 9.5 MW from own CPP Note: During start up & shut down PGVCL power will be utilized. 1.5 Water Requirement and Wastewater Generation & Treatment Total Proposed Expansion scenario: Source of water will be met through GWIL water supply. Total water requirement will be 2029 m 3 /day (Fresh 1691 m 3 /day + Recycled -338 m 3 /day). The total wastewater generations will be 391 m 3 /day. 338 KL/Day wastewater from the Cooling and chilling, boiler, and washing will be treated in ETP and treated effluent recycled back for cooling & chilling purpose and gardening. 4

5 53 m 3 /day Domestic wastewater generated shall be disposed through septic tank & soak pit. 1.6 Air Pollution Source and Control Management The source of air pollution due to the expansion project will be Flue gas emission and process gas emission. The source of flue gas emission will be from the stack attached to Flare stack-1, Flare stack-2, CPP-1, CPP-2, CPP-3, D.G. Set. The source of process gas emission will be from the vent attached to VBC- 1, VBC- 2, VBC- 3, Dryer -1, Dryer -2& Dryer -3 etc. Total: 1) Flue Gas Stacks SR. NO. STACKS ATTACHED TO 1 Process Plant Flare stack (Existing) 2 Process Plant Flare stack (Proposed) 3 CPP 16MW Boiler Chimney (Existing) 4 CPP 6MW Boiler Chimney (Existing) 5 CPP 8MW Boiler Chimney (Proposed) HEIGHT FROM GROUND LEVEL (m) CONSUMPTION OF FUEL (KL/hr) DIAMETER (m) EXPECTED POLLUTANTS 50 Nil 1.0 SPM, SOx, NOx 50 Nil 1.8 SPM, SOx, NOx 80 Nil 2.5 SPM, SOx, Nox 80 Nil 1.8 SPM, SOx, Nox 80 Nil 1.8 SPM, SOx, Nox 5

6 2) Process Stacks SR. NO. PROCESS STACK ATTACHED TO HEIGHT FROM GROUND (m) 1.7 Hazardous Waste Management DIAMETER (m) AIR POLLUTION CONTROL SYSTEM EXPECTED POLLUTANTS 1 VBC- 1 (Existing) Bag Filter SPM, NOx 2 VBC- 2 (Existing) Bag Filter SPM, NOx 3 Dryer -1(Existing) Bag Filter SPM, NOx 4 Dryer -2(Existing) Bag Filter SPM, Nox 5 VBC- 3 (Proposed) Bag Filter SPM, NOx 6 Dryer -3(Proposed) Bag Filter SPM, NOx SR. NAME OF WASTE EXISTING QTY. ADDITIONAL TOTAL MODE OF DISPOSAL NO. WASTE CATEGORY MT/YEAR QTY. MT/YEAR 1 Used Oil I Collection, Storage, Transportation, reuse in process/sent to GPCB registered recycler 2 Spent Acid from Batteries 3 Chemical Sludge from Waste water treatment 4 Oily Sludge Emulsion I Collection, Storage, Transportation, Disposal by Authorized way I Collection, Storage, Transportation, Disposal at TSDF site of SEPPL. I Collection, Storage, Transportation, Disposal at Common Incineration site of SEPPL Bhachau 5 Used Batteries (CCA Amendm Collection, Storage, Transportation, and Disposal as per lead batteries rules. 6

7 ent Applied) 6 Discarded Drum / Barrels/ Containers / Bags/ Liners (CCA Amendment Applied) 7 Plastic Waste X (CCA Amendment Applied) 8 Spent Ion Exchange Resin (CCA Amendment Applied) 9 Oily Cotton Waste /Leather Hand (CCA Gloves / Cotton Amendment Hand Gloves Applied) 10 E-Waste (CCA Amendment Applied) 11 Waste Insulation - 1 Material (CCA Amendment Applied) 4 12 Collection, Storage, Transportation, sent to GPCB Approved recycler Collection, Storage, Transportation, sent to GPCB Approved recycler Collection, Storage, Transportation, Disposal at TSDF site Collection, Storage, Transportation, and Disposal by incineration at SEPPL Bhachau Collection, Storage, Transportation, sent to GPCB Approved Recycler Collection, Storage, Transportation, and Disposal by incineration at SEPPL Bhachau 2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 2.1 Identification of the project and project proponent. In case of mining project, a copy of mining lease/letter of intent should be given. Identification of the project 7

8 PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO TPM ) AND CO-GENERATION POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES Identification of the project proponent Presently following are the directors of the company:- 8

9 2.2 Brief description of nature of the Project PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO TPM ) AND CO-GENERATION POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES 2.3 Need for the project and its importance to the country and or region The objective is to Consolidate Business. Constantly upgrade the product range. Continuously reduce the Costs & improving Quality. Generate local employment Increase Govt. revenue in form of taxes and duties 2.4 Demands-Supply Gap Based on our informal survey of the market with our current customers and various traders, we have found that there is a big potential for the range of the products we are planning. This is expansion of existing product's manufacturing capacity. 2.5 Imports vs. Indigenous production Based on the current cost of indigenous raw materials and the non availability of some materials, we will have to import some of the key raw materials as they are not available indigenously. This will make us very competitive against imported finished products and we will be able to increase the export of our finished products. 2.6 Export Possibility There is export potential of our proposed products. At present, we are exporting approx 30 % of product to countries all over the world. 2.7 Domestic/Export Markets There is export potential as well as demand in local market. At present with operation at approx. 100 % capacity utilization, we are not able to meet the demand of the market. 2.8 Employment Generation (Direct and Indirect) due to project. 9

10 Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed expansion project. 3.1 Project Description 3.2 Type of Project including interlinked and interdependent projects, if any. PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO TPM ) AND CO-GENERATION POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES - Category: A-5(c) 3.3 Location (map showing general location, specific location and project boundary & project site layout) with coordinates. Map showing general location 10

11 Layout 11

12 3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Major factors involved in the selection of site are listed below: Existing operational industry Site is very well connected by road Proximity to Mundra & Kandala Ports Availability of sufficient land free from cultivation Availability of power evacuation facilities Availability of water for industrial use Environment-friendly zone Uninterrupted power supply. 3.4 Size or Magnitude of Operation Please refer Section 1.2 (Page No. 4) of Pre-Feasibility Report. 3.5 Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project etc. should be given) Please refer Annexure-III in Form-I (Page No. 14) 3.6 Raw material required along with estimated quantity, likely source, marketing area of final products. Mode of transport of raw materials and finished products. Please refer Annexure-1 in Form-I (Page No. 14) 3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. There will not resource optimization/recycling and reuse envisaged in the project. 3.8 Availability of water its source, energy/power requirement and source should be given. Power & Fuel Requirement Fuel Existing: LDO= 30 KL/Month (only for heating & cooling during startup & stops) HSD= 4 KL/Month 12

13 After Proposed Expansion: LDO= 40 KL/Month (only for heating & cooling during startup & stops) HSD= 6 KL/Month Energy : Existing: 7 MW from own CPP After Proposed Expansion: Total: 9.5 MW from own CPP Note: During start up & shut down PGVCL power will be utilized. Water Source The entire water requirement will be met through GWIL water Supply. 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal. Liquid Waste: Source of water will be met through GWIL water supply. Total water requirement will be 2029 m 3 /day (Fresh 1691 m 3 /day + Recycled -338 m 3 /day). The total wastewater generations will be 391 m 3 /day. 338 KL/Day wastewater from the Cooling and chilling, boiler, and washing will be treated in ETP and treated effluent recycled back for cooling & chilling purpose and gardening. 53 m 3 /day Domestic wastewater generated shall be disposed through septic tank & soak pit. 13

14 3.10 Schematic representations of the feasibility drawing which give information of EIA purpose. ACTIVITIES OVERVIEW OF E. I. A. STUDIES SOURCE OF INFORMATION RECONNAISSANCE SURVEY OF EXISTING PLANT MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO-ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS INTRODUCTION BASELINE ENVIRONMENTAL STATUS SOCIOECONOMIC STATUS & INFRASTRUCTURE PROPOSED Expansion PLANT ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. INDIAN METEOROLOGICAL DEPT. IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX METHOD DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM IMPACTS METHODOLOGY OF IMPACT ASSESSMENT ENVIRONMENTAL MANAGEMENT PLAN FACILITY DESCRIPTION CONSEQUENCE ANALYSIS PREPARATION OF DISASTER MANAGEMENT PLAN RISK ANALYSIS STUDIES & DISASTER MANAGEMENT PLAN SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. 14

15 4.0 Site Analysis 4.1 Connectivity Site is very well connected by road Availability of power evacuation facilities Availability of water for industrial use 4.2 Land Form, Land Use and Land Ownership It will be incorporated in EIA Studies. 4.3 Topography (along with map) It is attached separately. 4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given. It will be incorporated in EIA Studies. CRZ Clearance is not applicable to us. 4.5 Existing Infrastructure Existing Infrastructures facilities are listed in Topic no. 1.6 on Page no Soil Classification It will be incorporated in EIA Studies. 4.7 Climatic data from secondary sources. Primary source: our own weather station & Secondary sources: Indian Meteorological Department, Ahmedabad. 4.8 Social infrastructure available. Depending on the requirement of the region, social infrastructure will be provided. 15

16 5.0 Planning Brief 5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country planning/development authority classification. PROPOSED EXPANSION OF CARBON BLACK (10950 TPM TO TPM ) AND CO-GENERATION POWER PLANT (22 MW TO 32 MW) IN TWO PHASES IN EXISTING PREMISES 5.2 Population Projection No major effect on population in the surrounding region. 5.3 Land use planning (breakup along with green belt etc.) Sr. no. Particular Area in M 2 1 Rooftop & building shade Road/Paved Area (Plant) Green Belt Area Open Area Total Area Assessment of Infrastructure Demand (Physical & Social) Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed expansion project. Social Welfare Cordial industrial relation in the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 5.5 Amenities/Facilities It will be incorporated in the EIA Studies. 6.0 Proposed Infrastructure 6.1 Industrial Area (Processing Area) Processing Area (Processing Zone, ETP Area and Utility Area): m Residential Area (Non Processing Area) Non Processing Area (Green belt, road, Open Area): m 2 16

17 6.3 Green Belt Company has developed an effective green belt within the factory and on periphery of the factory. In addition to this, majority of the vacant land is planted with trees, shrubs and grasses. 6.4 Social Infrastructure Depending on the requirement of the region, social infrastructure will be provided. 6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc.) Site is very well connected by road & railway. 6.6 Drinking water Management (Source & Supply of water) Water requirement will meet through the GWIL Water Supply. 6.7 Sewerage System Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful liquid wastes from the offices, canteen and domestic waste coming from different sections. These liquid wastes are treated and disposed by septic tank and soak pit. 6.8 Solid Waste Management Please refer Section 1.6 in Pre-Feasibility Report. 6.9 Power Requirement & Supply/Source Energy : Existing: 7 MW from own CPP After Proposed Expansion: Total: 9.5 MW from own CPP Note: During start up & shut down PGVCL power will be utilized. 7.0 Rehabilitation and Resettlement (R& R ) Plan 7.1 Policy to be adopted (central/state) in respect of the project affected including home oustees, land ouatees and landless laborers (a brief outline to be given) There is no habitation on the existing project area and it is industrial land which is purchased by company for development of Company, so that R & R policy is not applicable to this project. 17

18 There shall be no displacement of any population in project area. 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given). We shall start construction after getting environmental clearance and consent to establish. We shall start production upon making application for CCA. (Tentative Date for Construction Start: ) (Tentative Project Completion Date: ) 8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total costs of the existing project is Rs. 369 Crore. Total costs of the Proposed Expansion project will be Rs Crore. 9. Analysis of Proposal (Final Recommendations) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project. Social Welfare shall be done. Cordial industrial relation in the industry shall be established and representation shall be made to villagers for help for creation of facilities related to health, education, etc. 18