PRE - FEASIBILITY REPORT FOR THE PROPOSED EXPANSION OF CRESOLS, AROMATIC PRODUCTS

Transcription

1 PRE - FEASIBILITY REPORT FOR THE PROPOSED EXPANSION OF CRESOLS, AROMATIC PRODUCTS BY ATUL LIMITED-A ZERO LIQUID DISCHARGE UNIT (AROMATICS DIVISION) 297, 297/1, GIDC INDUSTRIAL ESTATE, VILLAGE ANKLESHWAR, TALUKA ANKLESHWAR, DISTRICT BHARUCH, GUJARAT

2 SUMMARY M/s. Atul Limited M/s. Atul Limited (Aromatics Division) is planning for the expansion of Para Cresol in their manufacturing unit at 297, 297/1, GIDC Industrial Estate, Village Ankleshwar, Taluka Ankleshwar, District Bharuch, Gujarat PROJECT COST The total cost of the project after proposed expansion will be around Rs crores. Total capital cost of pollution control measures will be Rs crores & Recurring Cost per Annum will be 7.9 crores. DETAILS OF PRODUCTS Details of existing and proposed products are given in following table. LIST OF PRODUCTS SR. NO. PRODUCT NAME TYPE EXISTING CAPACITY (TPM) PROPOSED CAPACITY (TPM) TOTAL CAPACITY(TPM) 1 Cresols L Para Anisaldehyde L Para Anisyl Alcohol L Para Cresidine S Para Anisic Acid ( from para Anisaldehyde plant) S Anisyl Acetate L Manganese Sulphate (from para Anisaldehyde) S Manganese Sulphate (from para Anisaldehyde) L Methoxy Acetophenone S Sodium Sulphite ( from Cresol plant) S Sodium Sulphate ( from Cresol plant) S Para Toluene Sulphonic Acid S Octyl Methoxy Cinnamate L Anethole L Para Cresyl Acetate L Avobenzone L Para Cresyl Phenyl Acetae S Para Anisyl Propanal L Methoxy phenyl Acetonitrile L Para Cresyl Caprylate L Para Cresyl Isoebutyrate L Para Cresyl Formate L Para Anisyl Formate L Para Anisyl Phenyl Acetate L Methoxy Phenyl Acetic Acid S Methoxy Phenyl Methyl Amine L Perfumery ingredients L Ethanol ( from OMC plant) L HCl ( from Nitrile plant) L Total

3 REQUIREMENTS FOR THE PROJECT LAND Around 1,33,110.0 m 2 of total land area is available in Notified Industrial Area, Ankleshwar GIDC. WATER : 1,622 m 3 /Day, Proposed: 178 m 3 /Day, Total: 1,800 m 3 /Day. Total additional water requirement for the proposed expansion project would be estimated as 178 m 3 /Day, which would be sourced from GIDC Ankleshwar. ELECTRICAL ENERGY No additional Power will be needed due various energy conservation measures implemented at site. connected Power: 9500 KVA. Total connected power requirement after the proposed expansion project will be 8250 KVA. Power supply shall be full-filled by DGVCL through 66 KV express feeder line. MANPOWER At present, 190 personnel are working at the site. For proposed expansion project additional 40 personnel will be employed who will come from local area. Total manpower after expansion will be 230 personnel. SOURCES OF AIR POLLUTION AND CONTROL MEASURES EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES FLUE GAS EMISSION (EXISTING) Sr. No. Location height (mtrs) Monitoring facilities No of stacks Para Meters Prescribed Norms Emission Flue Gas (kgs /hr) Type of fuel Fuel Cons. 1 Cresol Fusion Furnace 16 Yes 20 PM 150 mg/nm³ 64 SO₂ 100 ppm 9 NO X 50 ppm / fusion pot Natural Gas 1600 M 3 /hr 2 Boiler 33 Yes (16 TPH) (4 Nos) PM 150 mg/nm³ 35 SO₂ 100 ppm 7 NO X 50 ppm (2 stack ) Natural Gas/ Furnace Oil 1800 M 3 /hr / 1.05 KL/hr 3 Cogen 22 Yes 4 0.9MW each PM 150 mg/nm³ 33 SO₂ 100 ppm 6 NO X 50 ppm / gen set Natural Gas 1183 M 3 /hr FLUE GAS EMISSION (PROPOSED) Sr Location height (mtrs) Monitoring facilities No of stacks Proposed Para Meters Prescribed Norms Proposed Emission Proposed Flue Gas (kgs /hr) Type of fuel Fuel Cons. 1 Cresol Fusion Furnace 16 yes 10 PM 150 mg/nm³ 64 SO₂ 100 ppm 9 NO X 50 ppm /fusion pot Natural Gas 2200 m 3 /hr 2 Cogen 22 yes -2 PM 150 mg/nm³ 33 SO₂ 100 ppm 6 NOx 50 ppm Natural Gas 0

4 PROCESS GAS EMISSION (EXISTING) Sr. No. attached To polluta nt Ht (mtrs) Dia. mts monitoring facilities Air pollution control system Scrubber inlet Scrubber outlet Prescribed norms 1 PCD PLANT -Nitration Process NO X Available Caustic scrubber 300 ppm 20 mg/nm³ 25 mg/nm³ 2 CRESOL PLANT -Sulphonation Process SO Available Caustic ventury scrubber ( With auto caustic addition system) 150 kgs /hr 30 mg/nm³ 40 mg/nm³ WASTE WATER GENERATION AND IT S TREATMENT: Industrial waste water will be generated from existing and proposed expansion of manufacturing production. Generation of waste water will be restricted to 755 KLD and treated in the existing 1000 m3/day cap ETP fully equipped with OTTO Germany diffused aeration system for biological oxidation followed by tertiary treatment to meet the prescribed norms. Treated waste water will be fully recycled back in the process using RO Technology as boiler feed water for steam generation which is well established and being currently practiced for last two years in our operation and No discharge of treated waste water from the site. In case of RO plant maintenance, treated waste water will be disposed off in U/G pipeline of BEAIL for further treatment in FETP and final discharge to Arabian Sea. NOISE POLLUTION AND CONTROL MEASURES: From the existing and proposed expansion manufacturing unit noise pollution will generate which will be controlled by adopting different types of noise pollution control measures. Main sources of the noise pollution are machineries, Electric motors, dryers and heaters, etc. Following noise control measures to be adopted in the existing and proposed manufacturing project, Encasement of noise generating equipment. Greenbelt will be developed all around the plant boundary to act as noise attenuator. In addition personnel, working near high noise level generating sources, will be provided with ear muffs. Proper and suitable acoustic barrier will also be provided around, areas generating high noise. Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also noise reduction. SOLID WASTE GENERATION AND ITS DISPOSAL METHOD The sources of solid wastes, generation and its management are as given in the following table. Sr. No. WASTE Quantity (MT/M) Proposed Quantity (MT/M) Total Quantity (MT/M) Disposal 1 ETP Sludge At TSDF of BEIL /SEPPL 2 Salt From MEE Collection, Storage within factory premises and transportation and final disposal at common TSDF by BEIL/SEPPL. 3 Tarry Waste Incineration at common incinerator of BEIL /GSPL 4 Gypsum Sludge ( Cresol & MnSO4 Plant) At TSDF of BEIL/GSPL

5 5 Spent Nickel Catalyst Sold to Registered recycler 6 Used/Spent Oil Sell to Registered re-refiners 7 Discarded Containers/ Liners/barrels/glass At TSDF of BEIL /SEPPL wool packing material 8 Spent Carbon Incineration at BEIL/SEPPL 9 Filter & Filter material Incineration at BEIL /SEPPL 10 Sludge & Filter Incineration at BEIL /SEPPL 11 Spent Ion Exchange Resin from DM Plant Incineration at BEIL /SEPPL 12 Oil & grease skimming residue Incineration at BEIL /GSPL 13 Evaporated Mother Liquor generated from To BEIL/RSPL/GSPL MEE Note : MEE salt generation has been radically reduced from 2000 to 600 TPM by change in the technology and converting waste to wealth as 99% Sodium Sulphate Powder as a saleable Product. This is directly used by paper glass & textile industries. Generation of Gypsum is also reduced by continuous process optimization. Generation of ETP sludge has also been restricted by installation of innovative Volute Press Filter Technology. GREEN BELT DEVELOPMENT Company is having total 1,33,110.0 m 2 land area is available. Around 30% out of total plot area will be developed as green belt.

6 INDEX CHAPTER NO. CONTENT 1 INTRODUCTION OF THE PROJECT 2 PROJECT DESCRIPTION 3 SITE ANALYSIS 4 PLANNING BRIEF 5 PROPOSED INFRASTRUCTURE 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN 7 PROJECT SCHEDULE & COST ESTIMATES 8 ANALYSIS OF PROPOSAL

7 INTDOUCTION OF THE PROJECT CHAPTER IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Atul Limited (Aromatics Division) is an ISO , ISO 14001, FAMI-QS certified Company, Incorporated in 1976 as a Joint Sector Company, Known As Gujarat Aromatics Limited. Main Products are Cresols, Para Anisaldhyde, Para Anisyl Alcohol, Para Cresidine & Manganese Sulphate. Atul's marketing edge comes from its direct and close contact with consumers and dealers / retailers. Atul has a very strong marketing team. 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. Atul Limited (Aromatics Division) is planning for the expansion of Para Cresol in their manufacturing unit at 297, 297/1, GIDC Industrial Estate, Village Ankleshwar, Taluka Ankleshwar, District Bharuch, Gujarat. LIST OF PRODUCTS SR. NO. PRODUCT NAME TYPE EXISTING CAPACITY (TPM) PROPOSED CAPACITY (TPM) TOTAL CAPACITY(TPM) 1 Cresols L Para Anisaldehyde L Para Anisyl Alcohol L Para Cresidine S Para Anisic Acid ( from para Anisaldehyde plant) S Anisyl Acetate L Manganese Sulphate (from para Anisaldehyde) S Manganese Sulphate (from para Anisaldehyde) L Methoxy Acetophenone S Sodium Sulphite ( from Cresol plant) S Sodium Sulphate ( from Cresol plant) S Para Toluene Sulphonic Acid S Octyl Methoxy Cinnamate L Anethole L Para Cresyl Acetate L Avobenzone L Para Cresyl Phenyl Acetae S Para Anisyl Propanal L Methoxy phenyl Acetonitrile L Para Cresyl Caprylate L Para Cresyl Isoebutyrate L Para Cresyl Formate L Para Anisyl Formate L Para Anisyl Phenyl Acetate L Methoxy Phenyl Acetic Acid S Methoxy Phenyl Methyl Amine L Perfumery ingredients L Ethanol ( from OMC plant) L HCl ( from Nitrile plant) L Total

8 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION. Atul serves about 4,000 customers belonging to diverse industries, namely, Aerospace, Adhesives, Agriculture, Animal Feed, Automobile, Composites, Construction, Cosmetic, Defence, Dyestuff, Electrical and Electronics, Flavour and Fragrance, Glass, Home Care, Paint and Coatings, Paper, Personal Care, Pharmaceutical, Plastic, Polymer, Rubber, Soap and Detergent, Textile and Tyre, in 80 countries. Atul has gained truly leadership position in Para Cresol in the world by doing continuous improvement and increasing atom efficiency over Chinese manufacturers. We had also made the site zero liquid discharge for last 2 years and made the overall operation very efficient. This gave us the opportunity to expand further as there is a demand supply gap in the world market for Para Cresol. Decision of expansion was taken by the Honorable Board to capture almost 40% of the total volume in the world. 1.4 DEMANDS-SUPPLY GAP Atul manufactures 1,350 products. These products are divided into two Segments, namely, Life Science Chemicals and Performance and Other Chemicals. These products are placed under 6 Businesses, namely, Aromatics, Bulk Chemicals, Colors, Crop Protection, Floras, Pharmaceuticals and Polymers, depending upon the industries serviced. There is a demand supply gap of p-cresol in the world market and product is also very competitive. Due to our increased atom efficiency & efficient operation, customers are favoring us a preferred supplier for p- Cresol over Chinese in all aspect of the business and therefore giving us an opportunity for further expansion. 1.5 EMPLOYMENT GENERATION: For the proposed expansion project additional 40 nos. of personnel (existing 190 nos.) will be employed. 2

9 PROJECT DESCRIPTION CHAPTER TYPE OF PROJECT M/s Atul Limited (Aromatics Division) is planning for the expansion of Para Cresol in their manufacturing unit at 297, 297/1, GIDC Industrial Estate, Village Ankleshwar, Taluka Ankleshwar, District Bharuch, Gujarat Atul Limited (Aromatics Division) is an ISO , ISO 14001, FAMI-QS certified Company, Incorporated In 1976 As A Joint Sector Company, Known As Gujarat Aromatics Limited. Main Products are Cresols, Para Anisaldhyde, Para Anisyl Alcohol, Para Cresidine & Manganese Sulphate. Atul's marketing edge comes from its direct and close contact with consumers and dealers / retailers. Atul has a very strong marketing team. 2.2 LOCATION M/s Atul Limited (Aromatics Division) located at 297, 297/1, GIDC Industrial Estate, Village Ankleshwar, Taluka Ankleshwar, District Bharuch, Gujarat. Total plot area of 1,33,110.0 m 2 is sufficient for proposes expansion. It is situated at 21 37'.37.57" North latitude and 73 01'16.20" East longitude. A map showing project site is given in following figure-1 & a detailed map of the project site & surrounding is showing in following figure. LOCATION MAP 3

10 2.3 SIZE OR MAGNITUDE OF OPERATION M/s Atul Limited (Aromatics Division) is planning for the expansion of Para Cresol in their manufacturing unit at 297, 297/1, GIDC Industrial Estate, Village Ankleshwar, Taluka Ankleshwar, District Bharuch, Gujarat 2.4 PROCESS DESCRIPTION MANUFACTURING PROCESS: 1. CRESOLS Toluene is sulphonated with liquid Sulphur trioxide to give Toluene Sulphonic Acid. Sulfonated mass is neutralized with Sodium Sulphite Slurry partially. Sodium Toluene Sulphonate and Caustic soda Lye are concentrated separately and then fused together at high temperature. Fused mass is then quenched in water and Sodium Sulphite (By-product) is separated by centrifuging. The solution from centrifuge is neutralized with SO 2 to yield crude Cresols and 99% Sodium Sulphate Powder. Crude Cresols is distilled further under vacuum to give purified Para Cresol. Some Cresol dimer and Tarry waste is obtained as distillation residue. 2. PARA ANISALDEHYDE Methylation: Para Cresol (99%) is methylated by dimethyl sulphate in presence of Caustic soda to give Para Cresyl methyl ether. Oxidation: Para Cresyl Methyl Ether is oxidized by Natural Manganese Dioxide and Sulphuric Acid to give crude para Anisaldehyde. Extraction: Crude Para Anisaldehyde is extracted by using toluene as a solvent. Aqueous phase, Manganese sulphate solution is separated out and processed further to recover 99% MnsO4 powder as a feed grade Product for Chicken application which is 100% exported. Organic Toluene Layer is separated and stored. Washing: Extracted toluene layer is washed with water to remove p-anisic acid. Toluene layer and wash water are separated. Wash water is neutralized and sent to ETP for treatment. Organic Toluene layer is sent to distillation. Distillation: For separation of toluene, unreacted Para Cresyl Methyl Ether and Para Anisaldehyde fractional distillation is carried out. Para Anisaldehyde fraction is separated as a main product. Toluene and Para Cresyl methyl Ether are collected in storage & recycled back. 3. PARA ANISYL ALCOHOL Hydrogenation: Para Anisaldehyde is hydrogenated by using Hydrogen gas in the presence of Nickel Catalyst. Para Anisyl Alcohol is formed. Filtration: Para Anisyl Alcohol formed, which contain Nickel Catalyst is filtered to separate the spent catalyst cake and it is taken for reuse in next batch. Distillation: For the separation of Para Anisyl Alcohol, fraction distillation is carried out under high vacuum. Para Anisyl Alcohol is collected as a final product. Small amount of PCME is recovered and recycled back. 4

11 4. PARA CRESIDINE Nitration: The solution of P-Cresol in Mono Chloro Benzene is nitrated with diluted nitric acid at low temperature by controlling temperature by indirect cooling. After nitration is over, 3-Nitro-P-Cresol organic layer is separated and collected in separate vessel and neutralized with Caustic soda Solution. Then the solvent M.C.B. recovered. The solution of 3-Nitro-P-Cresol is transferred to Methylator vessel. Methylation: The alkaline solution of 3-Nitro-P-Cresol is methylated with dimethyl sulphate. During methylation, the temperature is controlled by indirect cooling. After methylation is over, the reaction mixture is diluted with water. The organic phase is separated from the aquous phase and collected in a separate vessel. The organic phase oil transferred for reduction. Reduction: Methylated 3-Nitro-P-Cresol (oil) is reduced to p-cresidine by hydrogenation using Ni cat. added in very controlled manner. Reduction mass is cooled, filtered and extracted with Toluene. Organic layer is transferred to distillation. Distillation: From the extracted reduction mass, P-Cresidine is recovered by vacuum distillation in a vessel with provision for indirect heating with steam. Initially toluene cut is separated in toluene day tank and then inter cut is removed.pcd main cut is collected separately. Flaking of Liquid PCD is carried out in Flakers. 5. PARA ANISIC ACID The alkaline wash of Para anisaldehyde is acidified under acidic ph.the crude para anisic acid is filtered, centrifuged and dried. The dried crude paraanisic acid is esterified with methanol in acidic medium. After desirable conversion methanol is recovered by distillation. The esterified mass is extracted with toluene in alkaline ph. The separated organic layer is subjected to distillation. The ester is hydrolyzed in presence of alkali and Hydrogen Peroxide. Pure Para anisic acid is recovered in acidic medium. It is centrifuged and dried in Tray Dryer. The aqueous layer after neutralization is treated thereafter. 6. ANISYL ACETATE P-anisyl alcohol is reacted with acetic anhydride at high temperature under agitation and reflux. The reaction mass is washed with water and then with dilute sodium bicarbonate solution to remove the acetic acid formed. The organic layer is separated out. The aqueous effluent is discharged after neutralization to ETP for treatment. The crude product is taken for distillation. 7. MANGANESE SULPHATE (SOLID) Manganese sulphate solution is neutralized by MnO natural ore & filtered. The filtrate is then concentrated in a suitable evaporator / MEE and sent for spin flash drying unit to give white 99% MnSO 4 Powder as by-product, which is 100% exported. The MnSO4 powder is completely recovered and sold. 8. MANGANESE SULPHATE (LIQUID) Manganese Sulphate liquid will be recoverd from the para anisaldehyde,depending on the requirement further process of magnansese sulphate is carried out. 5

12 9. 4-METHOXY ACETOPHENONE (4-MAP) M/s. Atul Limited Acylation of anisole is carried out by using acetic anhydride as an acetylating agent in the presence of zeolite catalyst. After filtration, followed by fractional distillation to get pure 4-Methoxy acetophenone. 10 & 11. SODIUM SULPHATE AND SODIUM SULPHITE Sodium Sulphate and sodium sulphite will be generated from the cresol plant. Which is sold as and when demand. 12. P-TOLUENE SULPHONIC ACID MONOHYDRATE Sulphonation of toluene is carried out by using SO 3.The sulphomass is crystallized by using water as a solvent to get pure p-toluene sulphonic acid Crystal. Liquid TSA is sent for Cresols manufacture. 13. OCTYL METHOXY CINNAMATE Para Anisaldehyde is reacted with Ethyl acetate in presence of sodium methoxide to give Ethyl Methoxy cinnamate & water. Ethyl Methoxy cinnamate reacts with 2-Ethyl Hexanol to give Octyl Methoxy cinnamate. 14. ANETHOLE Anisole is condensed with propionyl chloride in presence of AlCl3 to give 4-Methoxy Propiophenone (4- MPP). 4-MPP is again hydrogenated in presence of Ni Catalys t and Methanol Solvent to get 4-Methoxy Propiophenone Alcohol. Thereafter post Methanol Recovery 4-Methoxy Propiophenone Alcohol is dehydrated to make crude Anethole in presence of suitable catalyst. Crude Anethole is further purified by high vaccum distillation to get the desired final product having perfumery value. 15. P-CRESYL ACETATE Para Cresol and acetic anhydride are mixed under agitated condition. After reaction is completed, cool the reaction mass. Extract the product with toluene. Wash toluene layer with water and sodium carbonate solution. Organic layer is taken for distillation. 16. AVOBENZENE Tertiary benzoic acid is esterified with methanol in acidic media to get methyl-4-t-butylebenzoate. Methyl-4-t-butylebenzoate is then condensed with 4-Methoxi acetophenone in presence of methanol solvent and catalyst to get crude Avobenzone. Crude Avobenzone is further purified by high vaccum distillation to get the desired final product having perfumery value. 17. PARA CRESYL PHENYL ACETATE Para cresol is esterified with phenyl acetic acid using catalyst and toluene as solvent. After esterification the product is washed with sodium carbonate followed by water. The crude product is distilled and then crystallized. 18. P-ANISYL PROPANAL Para Anisaldehyde is condensed with propanaldehyde in presence of sodium hydroxide solution. Methanol is recovered and the condensed product is extracted with toluene. Toluene layer is washed with sodium carbonate and water. The organic layer is taken for distillation. The condensed product is 6

13 selectively hydrogenated to form crude Para anisyl propanal. The Crude product is vacuum distilled to get pure Para anisyl propanal METHOXY PHENYL ACETONITRILE Paraanisyl alcohol is reacted with dilute hydrochloric acid under agitation. The reaction mass is allowed to settle and the organic layer of para anisyl chloride, after addition of a stabilizer is reacted with sodium Cyanide in presence of a catalyst, water & toluene. This reaction mixture is then phase separated whereby the aqueous layer is generated. The organic layer is given further washes. The washed organic layer is taken for distillation. The combined aqueous layers after cynation containing traces of NaCN are treated with dilute sodium hypochlorite solution to bring the free cyanide content within the permissible limits. 20. PARA CRESYL CAPRYLATE p-cresol is reacted with Caprylic acid and refluxed to remove water azeotropicaly. After completion of the reaction cool the reaction mass, wash toluene layer with sodium bicarbonate solution & water. Organic layer is taken for distillation. 21. PARA CRESYL ISOBUTYRATE p-cresol is reacted with Isobutyric acid and refluxed to remove water azeotropicaly. After completion of the reaction cool the reaction mass, wash toluene layer with sodium bicarbonate solution & Water. Organic layer is taken for distillation. 22. PARA CRESYL FORMATE p-cresol is reacted with formic acid to produce Para Cresyl formate 23. PARA ANISYL FORMATE Para Anisyl Alcohol is reacted with formic acid to produce Para Anisyl formate 24. PARA ANISYL PHENYL ACETATE Esterification of p-anisyl alcohol is carried out with phenyl acetic acid by using a catalyst, triethylamine and toluene as a solvent. After esterification reaction mass is washed with 5% sodium bicarbonate solution followed by water. Finally the organic layer is distilled and to get pure p-anisyl phenyl acetate METHOXY PHENYL ACETIC ACID The process involves Hydrolysis of p-anisyl nitrile with NaOH solution. The reaction mass diluted with water and acidified with HCl to give p-methoxy phenyl acetic acid METHOXY PHENYL ETHYL AMINE Hydrogenation of P-Anisylnitrile in presence of Ruthenium catalyst gives 4-Methoxy Phenyl Ethyl Amine. 27. PERFUMERY INGREDIENTS (ESTERS) Ester manufacture is carried out by heating the alcohol and an acid are heated together in the presence of a sulfuric acid catalyst, and the reaction is driven to completion by removing the products as formed. 7

14 28. ETHANOL (FROM OMC PLANT) M/s. Atul Limited Ethanol will be generated from the Octyl Methoxy Cinnamate products will be sold as by-product 29. HCL (FROM NITRILE PLANT) HCL will be generated as by-products from the 4- methoxy phenyl Acetonirile plant. 2.5 RAW MATERIALS REQUIREMENT WITH THEIR SOURCE AND TRANSPORATATION Details of Raw material consumption and Mode of Transportation are given in following table. LIST OF RAW MATERIALS Sr. No Raw Material Name Consumption TPM Proposed Consumption TPM Total Consumption TPM Type of storage Mode of Transport 1 Caustic Soda Lye (100%) MS Tank By Road 2 Toluene MS Tank By Road 3 Sulphur Dioxide MS Tank By Road 4 Sulphur Trioxide MS Tank By Road 5 Acetic Acid SS Tank By Road 6 Sulfuric acid MS Tank By Road 7 Calcium carbonate Bags By Road 8 Dimethyl sulfate MS Tank By Road 9 Manganese dioxide Bags By Road 10 Hydrogen Gas (m3) In Cylinder Bank By Road 11 Raney Nickel Catalyst Carboys By Road 12 Nitric acid SS Tank By Road 13 Monochloro Benzene MS tank By Road 14 Tartaric acid Carboys By Road 15 Methanol Drums in closed room By Road 16 Hydrogen peroxide Carboys By Road 17 Acetic Anhydride drums By Road 18 Sodium bicarbonate Bags By Road 19 Manganese Oxide Bags By Road 20 Zeolite Catalyst Bags By Road 21 Ethyl Acetate drums By Road 22 Sodium Methoxide drums By Road 23 2-Ethyl Hexanol drums By Road 24 Acetic Anhydride tankers By Road 25 Sodium Carbonate Bags By Road 26 Phenyl Acetic Acid Drum By Road 27 Propanaldehyde drums By Road 28 Hydrochloric Acid FRP Tank By Road 29 Sodium Cyanide bags By Road 30 Phase transfer Catalyst bags By Road Sodium Hypochlorite 31 Solution drums By Road 32 Caprylic Acid drums By Road 33 Isobutyric Acid drums By Road 34 Formic Acid drums By Road 8

15 Sr. No Raw Material Name Consumption TPM Proposed Consumption TPM Total Consumption TPM M/s. Atul Limited Type of storage Mode of Transport 35 Activated Carbon bags By Road 36 Propionyl Chloride drums By Road 37 AlCl bags By Road 38 Tert Butyl Benzoic Acid bags By Road 39 Anisole drums By Road 2.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE IN THE PROJECT Treated waste water will be completely recycled back in the process using RO Technology leading conservation of water and therefore no major increased in fresh water intake. Treated waste water will also be directly used /recycled in appropriate location of the operation. 2.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE WATER : 1,622 m 3 /Day, Proposed: 178 m 3 /Day, Total: 1,800 m 3 /Day. Total additional water requirement for the proposed expansion project would be estimated as 178 m 3 /Day, which would be sourced from GIDC Ankleshwar. ELECTRICAL ENERGY No additional Power will be needed due various energy conservation measures implemented at site. connected Power: 9500 KVA. Total connected power requirement after the proposed expansion project will be 8250 KVA. Power supply shall be full-filled by DGVCL through 66 KV express feeder line WATER REQUIREMENT AND WASTE WATER GENERATION : 1,622 m 3 /Day, Proposed: 178 m 3 /Day, Total: 1,800 m 3 /Day. Total additional water requirement for the proposed expansion project would be estimated as 178 m 3 /Day, which would be sourced from GIDC Ankleshwar. Generation of waste water will be restricted to 755 KLD and treated in the existing 1000 m 3 /day cap ETP fully equipped with OTTO Germany diffused aeration system for biological oxidation followed by tertiary treatment to meet the prescribed norms. Treated waste water will be fully recycled back in the process using RO Technology as boiler feed water for steam generation which is well established and being currently practiced for last two years in our operation and No discharge of treated waste water from the site. In case of RO plant maintenance, treated waste water will be disposed off in U/G pipeline of BEAIL (NCTL) for further treatment in FETP and final discharge to Arabian Sea POWER REQUIREMENT Scenario Project (KVA) Source 9500 KVA Total power requirement is/will source from Daxin Gujarat Vij Company Limited (DGVCL). Proposed No additional Power will be needed due various energy conservation measures implemented 9

16 Scenario Project (KVA) Source FUEL REQUIREMENT M/s. Atul Limited at site. connected Power: 9500 KVA. Total connected power requirement after the proposed expansion project will be 8250 KVA. Power supply shall be full-filled by DGVCL through 66 KV express feeder line. Sr. Daily Fuel Consumption Fuel No. Proposed Total 1. HSD 8 KL/Month 0 8 KL/Month 2. FO 756 KL/Month KL/Month 3. Natural Gas 4583 m 3 /hr m 3 /hr Source & Mode of Transportation From GGCL through direct pipe line AIR POLLUTION EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES FLUE GAS EMISSION (EXISTING) Sr Location Cresol Fusion Furnace Boiler Cogen height (mtrs) Monitoring facilities No of stacks 16 Yes Yes 22 Yes FLUE GAS EMISSION (PROPOSED) (16 TPH) (4 Nos) 4 0.9MW Each Para Meters Prescribed Norms Emission PM 150 mg/nm³ 64 SO₂ 100 ppm 9 NOx 50 ppm 0.04 PM 150 mg/nm³ 35 SO₂ 100 ppm 7 NOx 50 ppm 0.04 PM 150 mg/nm³ 33 SO₂ 100 ppm 6 NOx 50 ppm 0.03 Flue Gas (kgs /hr) 937 / fusion pot (2 stack ) 2999 / gen set Type of fuel Natural Gas Fuel Cons M 3 /hr Natural 1800 Gas/ M 3 /hr Furnace / 1.05 Oil KL/hr Natural Gas 1183 M 3 /hr Sr. No. 1 Location Cresol Fusion Furnace height (mtrs) Monitoring facilities No of stacks Proposed 16 yes 10 Para Meters Prescribed Norms Proposed Emission PM 150 mg/nm³ 64 SO₂ 100 ppm 9 NOx 50 ppm 0.04 Proposed Flue Gas (kgs /hr) 850 /fusion pot Type of fuel Natural Gas Fuel Cons m 3 /hr 2 Cogen 22 yes -2 PM 150 mg/nm³ 33 SO₂ 100 ppm 6 NOx 50 ppm Natural Gas 0 10

17 PROCESS GAS EMISSION (EXISTING) Sr. No. 1 2 attached To PCD PLANT -Nitration Process CRESOL PLANT -Sulphonation Process pollutant height (mtrs) Dia. mts monitoring facilities NO X Available SO Available APCM Caustic scrubber Caustic ventury scrubber ( With auto caustic addition system) Note : In the proposed scenario no addition process is proposed. Scrubber inlet 300 Ppm 150 kgs /hr Scrubber outlet 20 mg/nm³ 30 mg/nm³ Prescribed norms 25 mg/nm³ 40 mg/nm³ 11

18 2.7.5 SOLID WASTE GENERATION AND THEIR DISPOSAL M/s. Atul Limited The sources of solid wastes, generation and its management are as given in the following table. Proposed Total Sr. WASTE Quantity Quantity Quantity No. (MT/M) (MT/M) (MT/M) Disposal 1 ETP Sludge At TSDF of BEIL /SEPPL 2 Salt From MEE Collection, Storage within factory premises and transportation and final disposal at common TSDF by BEIL/SEPPL. 3 Tarry Waste Incineration at common incinerator of BEIL /GSPL 4 Gypsum Sludge ( Cresol & MnSO4 Plant) At TSDF of BEIL/GSPL 5 Spent Nickel Catalyst Sold to Registered recycler 6 Used/Spent Oil Sell to Registered re-refiners 7 Discarded Containers/ Liners/barrels/glass At TSDF of BEIL /SEPPL wool packing material 8 Spent Carbon Incineration at BEIL/SEPPL 9 Filter & Filter material Incineration at BEIL /SEPPL 10 Sludge & Filter Incineration at BEIL /SEPPL 11 Spent Ion Exchange Resin from DM Plant Incineration at BEIL /SEPPL 12 Oil & grease skimming residue Incineration at BEIL /GSPL 13 Evaporated Mother Liquor generated from To BEIL/RSPL/GSPL MEE Note : MEE salt generation has been radically reduced from 2000 to 600 TPM by change in the technology and converting waste to wealth as 99% Sodium Sulphate Powder as a saleable Product. This is directly used by paper glass & textile industries. Generation of Gypsum is also reduced by continuous process optimization. Generation of ETP sludge has also been restricted by installation of innovative Volute Press Filter Technology. 12

19 SITE ANALYSIS M/s. Atul Limited CHAPTER CONNECTIVITY RAIL The nearest railway station is Ankleshwar Railway station, which is around 2.00 km in west direction from the project site ROAD The site is well connected by road network to all the key places. The major highway passing near the project site is NH - 8 which is around 1.00 km west direction from the project site AIR The nearest airport from the project site is Surat Airport. The distance of airport from project site is around 60 km in South West COMMUNICATION Ankleshwar GIDC is well connected with telephone, telefax etc. all the communications facilities are well developed in the district. 3.2 TOPOGRAPHY Topography of the land is plane. 3.3 EXISTING LAND USE PATTERN There is no Forest, National park; Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table: DETAILS OF EXISTING LAND USE SR.NO. PARTICULAR NAME & ITS DISTANCE 1. Nearest National Highway NH- 8 at around 0.5 km 2. Nearest city Ankleshwar at around 1.00 km 3. Nearest River Narmada river at around 6.5 km 4. Nearest Railway station Ankleshwar Railway Station 2.00 km 5. National park/reserve Forest, Biosphere, etc. None within 20 km 3.4 EXISTING SOCIAL STRUCTURE Project site is located at a distance of around 1.00 km from Ankleshwar city. All the infrastructures are available within city like Schools, Hospitals & community facilities. 13

20 PLANNING BRIEF CHAPTER PLANNING CONCEPT Type of industries: Atul Limited (Aromatics Division) is an ISO , ISO 14001, FAMI-QS certified Company, Incorporated In 1976 as a Joint Sector Company, Known As Gujarat Aromatics Limited. Main Products are Cresols, Para Anisaldhyde, Para Anisyl Alcohol, Para Cresidine & Manganese Sulphate. Atul's marketing edge comes from its direct and close contact with consumers and dealers / retailers. Atul has a very strong marketing team. Atul serves about 4,000 customers belonging to diverse industries, namely, Aerospace, Adhesives, Agriculture, Animal Feed, Automobile, Composites, Construction, Cosmetic, Defence, Dyestuff, Electrical and Electronics, Flavour and Fragrance, Glass, Home Care, Paint and Coatings, Paper, Personal Care, Pharmaceutical, Plastic, Polymer, Rubber, Soap and Detergent, Textile and Tyre, in 80 countries. 4.2 LAND USE PLANNING The Plant General Layout has been planned considering production facilities, auxiliary and ancillary facilities and plant utilities & services. The total plot area is 1,33,110.0 m AMENTIES / FACILITIES Adequate storage facility for Chemicals, machinery spares and consumables shall be provided. A small mechanical and electrical/ instrument workshop facilities for repairs and maintenance shall be provided. Time and security offices shall be provided in the plant. To avoid fire hazard, internal fire hydrants system in all major plant unit will be provided. 14

21 PROPOSED INFRASTRUCTURE CHAPTER INDUSTRIAL AREA The company already has land of 1,33,110.0 m 2 in which land company will expand their production capacity. 5.2 RESIDENTIAL AREA There is no provision of housing for the employees at site. 5.3 GREEN BELT The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. The company has green belt area with Lawn, plants and flowers spread across about 34% of the total area. Green belt shall be developed at plant boundary, road side, around offices & buildings and Stretch of open land. The selection of tree species suitable for plantation at the industry are governed by guiding factors as stated below: The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in primary and secondary attenuation zone. The trees should posses extensive foliar area to provide maximum impinging surface for continued efficient adsorption and absorption of pollutants. The trees should be fast growing and indigenous and should maintain ecological, land and hydrological balance of the region. It is also recommended to plant few trees, which are sensitive to air pollution, as air pollution indicator. It is also recommended to carry out extensive plantation within premises. Keeping in view the climatic conditions, status of soils and vegetation types in and around the project area the species shall be selected for proposed green belt development. 5.4 SOCIAL INFRASTRUCTURE Drinking water facility, Canteen, proper sanitation, etc. will be provided to the workers working in plant. 5.5 CONNECTIVITY As discussed earlier, proposed location of the plant is already well connected with the network of road & rail. So there is no need to construct any new road or rail for the transportation. 15

22 5.6 WASTE WATER MANGAMENT Presently complete Recycle of treated waste water using a RO plant (No treated Water Discharge at Present, Fully Recycled in the process). In case of RO plant maintenance, treated waste water will be disposed off in U/G pipeline of BEAIL (NCTL) for further treatment in FETP and final discharge to Arabian Sea. 5.8 INDUSTRIAL SOLID WASTE MANAGEMENT From the proposed expansion project activity there shall be mainly Spent/Used Oil, ETP Sludge, Salt From MEE, Tarry Waste, Gypsum Sludge, Spent Nickel Catalyst, Discarded containers, Spent Carbon, Filter & Filter material, Sludge & Filter, Spent Ion Exchange, Resin from DM Plant, Oil & grease skimming residue, Evaporated Mother Liquor generated from MEE. DETAILS OF SOLID & HAZARDOUS WASTE GENERATION DURING OPERATION Sr. No. WASTE Quantity (MT/M) Proposed Quantity (MT/M) Total Quantity (MT/M) Disposal 1 ETP Sludge At TSDF of BEIL /SEPPL 2 Salt From MEE Collection, Storage within factory premises and transportation and final disposal at common TSDF by BEIL/SEPPL. 3 Tarry Waste Incineration at common incinerator of BEIL /GSPL 4 Gypsum Sludge ( Cresol & MnSO4 Plant) At TSDF of BEIL/GSPL 5 Spent Nickel Catalyst Sold to Registered recycler 6 Used/Spent Oil Sell to Registered re-refiners 7 Discarded Containers/ Liners/barrels/glass At TSDF of BEIL /SEPPL wool packing material 8 Spent Carbon Incineration at BEIL/SEPPL 9 Filter & Filter material Incineration at BEIL /SEPPL 10 Sludge & Filter Incineration at BEIL /SEPPL 11 Spent Ion Exchange Resin from DM Plant Incineration at BEIL /SEPPL 12 Oil & grease skimming residue Incineration at BEIL /GSPL 13 Evaporated Mother Liquor generated from To BEIL/RSPL/GSPL MEE Note : MEE salt generation has been radically reduced from 2000 to 600 TPM by change in the technology and converting waste to wealth as 99% Sodium Sulphate Powder as a saleable Product. This is directly used by paper glass & textile industries. Generation of Gypsum is also reduced by continuous process optimization. Generation of ETP sludge has also been restricted by installation of innovative Volute Press Filter Technology. 16

23 CHAPTER 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN The project is located on notified industrial land, which is already acquired and there is no habitat. So the project proposal does not involve any Rehabilitation & Resettlement. 17

24 CHAPTER 7 PROJECT SCHEDULE & COST ESTIMATES 7.1 TIME SCHEDULE FOR THE PROJECT The implementation of the project will involve major activities like preparation of specification / drawings, issue of tenders, receipt of quotations, scrutiny of tenders, placing of orders, civil & structural construction, delivery & erection of equipment, test trial runs of various items of equipment and commissioning of the plant & equipment and completion of the project will take about 6 months after the necessary clearances are available, and the funding for the project has been tied up. 7.2 ESTIMATED PROJECT COST The total cost of the project after proposed expansion will be around Rs crores. Total capital cost of pollution control measures will be Rs Crore. 7.3 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by the management for execution of environmental management plans. The details of capital and recurring (per annum) budget earmarked for pollution control / monitoring equipment; operation and maintenance of pollution control facilities, for greenbelt development and maintenance. COST OF ENVIRONMENTAL PROTECTION MEASURES SR. NO. PARTICULATES RS. IN LACS 1. Capital Expenditure Recurring expenditure on environmental management cell and on pollution control systems per annum

25 CHAPTER 8 ANALYSIS OF PROPOSAL 8.1 FINANCIAL AND SOCIAL BENEFITS The capital cost of the expansion Cresol Aromatics products in existing premises is estimated at about Rs.58.5crore for the installation of plants & machinery along with required auxiliary and balancing facilities for the production. The Project is evaluated fully from the financial point of view and found to be viable in long run. IRR and ROCE are estimated to be 33% and 39 % respectively. Simple pay back is about 36 months. Since 90% of the volume of p-cresol is exported in the world market. By further expansion, it will help the Country to accumulate foreign currency and will contribute in reduction in fiscal deficit a bit.. For the coming of this project surrounding area will get developed due to this project and through the Corporate Social Responsibility (CSR) activities, socio-economic status of the region will also get developed. It will also create employment helping the Society at large. 19