Prefeasibility Report For 30,000 KLPY Anhydrous (Absolute) Alcohol Manufacturing Plant at Patalganga MIDC of Alkyl Amines Chemicals Limited 401-407 Nirman Vyapar Kendra, Plot No. 10, Sector 17, Vashi, Navi-Mumbai 400703. Prepared by Ultra-Tech Environmental Consultancy and Laboratory NABET Accredited EIA Consulting Organization Saudamini Commercial Complex, 2nd Floor, Building C3, Right Bhusari Colony, Paud Road, Kothrud, Pune - 411038 2016
1.Executive Summary M/s. Alkyl Amines Chemicals Limited (AACL) is desirous to expand the capacity of the existing industrial unit producing anhydrous alcohol by Azeotropic Distillation or Molecular Sieves, at Plot No. A-7 & 25, MIDC Industrial Area, Patalganga Village Kaire, Taluka Khalapur, Dist Raigad of Maharashtra. The proposed product size will be 30,000 KL/Annum. Proposed expansion will be confined within existing manufacturing unit and no additional land will be procured. The Notification No. S. O. 1533 promulgated on 14 th September 2006 has covered this type of industries under its schedule 5(f) Synthetic Organic Chemical Industries located within notified industrial estate will come under Cat B. Hence AACL intend to approach SEAC and SEIAA for environment clearance for proposed expansion. The prefeasibility report is prepared for forming a frame work for EIA study, scoping and finalizing terms of reference as may be required. Form I, as is prescribed by the said notification is duly filled up and submitted. The Prefeasibility Report is an accompaniment to the same and prepared as per MoEF guideline dated 27/02/2012. It generally covers, Introduction, Justification, Location, Resources, Process, Pollution Control, Background Study, Safety, Benefits, EIA Structure, Scoping & Conclusion. 2. Justification of Project Ethanol is the commonly used word to describe alcohol or specifically ethyl alcohol with a purity of more than 99 % and a moisture content of less than 0.4 %. The government of India has been following a policy of ethanol blending in petrol for the past several years. This is with the purpose of achieving multiple targets - reducing the dependency on imported crude for producing petrol and shifting to a green source for energy being the major objectives. The government had mandated the use of 5 % Ethanol in petrol for the past several years. In the second half of 2015 it announced that the blending rate would be enhanced to 10 % thus requiring a larger quantity of ethanol. It is estimated that the total requirement for the country would be in the range of 2300 ML/Annum. It is also reported that at present the availability of ethanol is only sufficient for 2 % blending. Proposed total capacity of 30,000 KL/Annum would easily be marketed to the oil companies for the purpose of blending in petrol.
3. Manufacturing Process Anhydrous (Absolute) alcohol is an important product required by industry. As per IS Specification it is nearly 100% pure/water free alcohol. Alcohol as manufactured by Indian distilleries is rectified spirit, which is 94.68 % alcohol and rest is water. It is not possible to remove remaining water from rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with water at this concentration and is known as an azeotrope. Therefore, a special process for removal of water is required for manufacture of anhydrous alcohol. In order to extract water from alcohol it is necessary to use some dehydrant or entrainer, which is capable of separating, water from alcohol. A Simple dehydrant is unslaked lime. Industrial alcohol is taken in a reactor and quick lime is added to that and the mixture is left over night for complete reaction. It is then distilled in fractionating column to get anhydrous alcohol. Water is retained by quick lime. This process is used for small-scale production of anhydrous alcohol by batch process. AACL propose to use either the Aeotropic distillation method or the Moleular Sieve method for the dehydration. Facilities will be set up for both the systems. The salient features of these two processes are given herewith: 3.1. Dehydration with Entrainer Process (Azeotropic Distillation) For manufacturing anhydrous alcohol on large scale, Cyclohexane is used as entrainer. When 94.68 % alcohol is mixed with Cyclohexane and distilled a ternary azeotrope is formed. e.g. If a mixture of ethanol, water and cyclohexane as given below is distilled and condensed then the condensate forms two layers. The system consists of two columns i.e. first is a dehydration column followed by recovery column. The Spirit is fed into the dehydration column. Cyclohexane is also introduced in this column. Vapour of ethanol, water & cyclohexane close to its azeotropic concentration is collected from the top whereas anhydrous alcohol is collected from the bottom of the column.
3.2. Molecular Sieve Method Molecular sieves are synthetic adsorbents and for vapour phase ethanol dehydration the sieve developed is metal aluminosilcates with effective pore size opening 3 angstrom (3x10-8 cm). Molecular sieves of type 3A has chemical formula (K 2 O, Na 2 O). Al 2 O 3. 23iO 2. XH 2 O During dehydration of ethanol, the water of hydrolysis fills the cavities or pores in the molecular sieves. The potassium form of molecular sieves has pore size of 3 angstrom. The diameter of water molecule is 2.8 angstrom and the diameter of ethanol molecule is 4.4 angstrom. The water vapour molecules are having strong dipoles and elastic. They are drawn into the pores and condensed at the wall of the pores, Ethanol vapour bigger in size passes through the bed without getting in to the pores of the molecular sieves. 3.3. Resource Require ment and Othe r Specifications Cooling water recirculation rate 200 m 3 /hr for Molecular Sieve plant only @ 30 C maximum and 4 kg/cm 2 (g) pressure at cooling water header, Δ T=6 C. Steam requirement at full capacity operation is 5 kg/cm 2 (g) pressure in steam header. Electricity will Be 440 V, 3 ph, 50 Hz, AC Electric supply. The power requirement will be for Molecular sieve plant and cooling tower, which excludes utilities like boiler. Approx 150 kwh/h is required. The ethanol project will be designed and constructed in strict compliance with the international standards and brands of equipment. Design codes: The following are the design standards used for the equipment for design. Pressure Vessels and distillation columns as per ASME Storage tanks as per API Heat Exchangers as per TEMA Piping and valve as per DIN/JIS Instruments as per ISA
4. Project Location The existing manufacturing unit of AACL is located at at Plot No. A-7 & 25, MIDC Industrial Area, Patalganga Village Kaire, Taluka Khalapur, Dist Raigad of Maharashtra. Map showing project location is presented in Figure 1. Geographical Co-ordinates of project site are latitude 18 52' 52.95" N and longitude 73 10' 45.82" E. Figure 1: Project Location Map Patalganga is a well developed industrial area of the MIDC near Karjat and Panvel. It has got its name from the Patalganga River. The Patalganga industrial area, adjacent to the Mohopada village, is one of the 13 chemical industrial areas developed by MIDC. A historical temple of god Raseshwar is situated on the right bank of river Patalganga. The Patalganga Industrial area is under the jurisdiction of Khalapur taluka (about 22 km) and under Dist. Raigad (about 60 km). The area is surrounded by ranges of high mountains. Patalganga area has well developed road network, which is connected to Mumbai-Pune National Highway 4 (on10 km), Mumbai Pune Expressway (on 7 km) and Mumbai-Goa National Highway 66 (on 12 km). Karnala Bird Sanctuary is located at 5.8 km on East direction whereas Matheran an ecologically sensitive area is located at 12.9 km on Northeast direction. However, propose project being situated within notified industrial area, general conditions of EIA notification, 2006 are not applicable for this project.
5. Project Planning The proposed manufacturing facility will be located within existing plant area of 3.148 ha. Project layout is shown in Figure 2. Existing boiler capacity is adequate to cater need of proposed products. No additional stack is proposed. Waste water generated from new process will be recycled and utilized for process, boiler and cooling purpose. No waste water from new products will be released in CETP. Domestic waste water will be treated in STP and utilized in greenbelt. The water requirement and waste water generated in the factory will be as follows Sr. No. Particular Proposed Input KLD Proposed Effluent KLD 1 Domestic 30 20 2 Industrial 2.1 Processing 30 95 2.2 Boiler 95 20 2.3 Cooling 705 147 2.4 DM Water 55 35 2 Total Industrial 885 297 3 Gardening 2 Total (1+2+3) 917 317 Alkyl Amines Chemicals Limited Patalganga has its own Occupational Health Center near the main gate in the Plant having one room with floor area of 20.78 sq m as per Factory Act for management of medical & accidental casualty. Occupational Health Center is having established infrastructural and in-house facilities as per factory Act to ensure services to the company and contract employees in Plant. The aims and objectives of the department is to provide a preventive, curative and supportive services to all employees. Occupational Health Center is having two number of part time Factory Medical Officer, and Medical Assistants & ambulance facility round the clock. In and around the industry green plantation already exists. The area for green belt is approx. 1840 m 2. There are already about 183 trees existing inside the premises. In addition there are trees planted outside the boundary wall.
Figure 2: Site Layout of Patalganga Plant
6. Proposed Infrastructure The existing infrastructure for manufacturing, ancillary operations, transport of raw material and final products are adequate. 7. R&R Plan Proposed expansion will be within existing manufacturing unit, hence, R&R plan is not applicable. 8. Project Schedule and Cost Estimates M/s AACL has ability to complete proposed construction within 4 6 months and likely to be commission the project for operation purpose. Total estimated cost of project will be 4.28 crore. Capital Cost for environment management will be 99.45 lakhs while recurring cost will be 27.11 lakhs