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Indobaijin Chemicals Pvt Ltd Plot No: Z-7/1 & Z-8/Part, SEZ-1,

GIDC Dahej, Taluka – Vagra, Dist: Bharuch,

Gujarat

PRE- FEASIBILITY REPORT

FOR

Proposed Expansion in Existing Production Capacity within existing premises

Prepared By

Eco Chem Sales & Services Surat

(NABET Accredited consultant)

INDOBAIJIN CHEMICALS PVT LTD.

Pre – Feasibility Report for Capacity Expansion Project

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Contents EXECUTIVE SUMMARY ................................................................................................................................................. 5

1.0 PROJECT BRIEF ....................................................................................................................................................... 6

2.0 INTRODUCTION OF THE PROJECT .......................................................................................................................... 9

2.1 DETAILS OF THE PROJECT PROPONENT ............................................................................................................. 9

2.2 DESCRIPTION OF NATURE OF THE PROJECT .................................................................................................... 10

2.2.1 NEED OF PROPOSED PROJECT .................................................................................................................. 10

2.2.2 DEMAND SUPPLY GAP .............................................................................................................................. 10

3.0 PROJECT DESCRIPTION ........................................................................................................................................ 12

3.1 PROPOSED PROJECT & APPLICABILITY OF EIA ................................................................................................. 12

3.2 PROJECT LOCATION ..................................................................................................................................... 12

3.2.3 SITE SELECTION CRITERIA: ........................................................................................................................ 17

3.3 RESOURCE REQUIREMENT .............................................................................................................................. 18

3.3.1 LAND REQUIREMENT ................................................................................................................................ 18

3.3.2 MAN POWER REQUIREMENT: .................................................................................................................. 18

3.3.3 ELECTRICITY REQUIREMENT: .................................................................................................................... 19

3.3.4 WATER REQUIREMENT: ............................................................................................................................ 20

4.0 RAW MATERIAL AND PRODUCT DETAILS ............................................................................................................ 21

4.1 RAW MATERIAL DETAILS ................................................................................................................................. 21

4.2 PRODUCT DETAILS ........................................................................................................................................... 21

5.0 MANUFACTURING PROCESS: ............................................................................................................................... 22

7.0 ENVIRONMENTAL MANAGEMENT PLAN ............................................................................................................. 25

7.1 AIR ENVIRONMENT:......................................................................................................................................... 25

7.2 WATER ENVIRONMENT: ............................................................................................................................ 26

7.3 SOLID/HAZARDOUS WASTE ....................................................................................................................... 33

7.4 NOISE ENVIRONMENT ............................................................................................................................... 34

7.5 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT ................................................................................. 35



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8.0 SITE ANALYSIS ...................................................................................................................................................... 36

8.1 CONNECTIVITY ................................................................................................................................................. 36

8.2 TOPOGRAPHY .................................................................................................................................................. 37

8.3 EXISTING INFRASTRUCTURE ............................................................................................................................ 37

8.4 SOIL CLASSIFICATION ....................................................................................................................................... 37

8.5 CLIMATE DATA FROM SECONDARY SOURCE ................................................................................................... 37

9.1 PROJECT SCHEDULE & COST ESTIMATES ............................................................................................................. 38

9.1 PROJECT SCHEDULE ......................................................................................................................................... 38

9.2 PROJECT COST ESTIMATION ............................................................................................................................ 38

FINANCIAL & SOCIAL BENEFITS ................................................................................................................................. 40



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LIST OF TABLES

Table 1: Land Breakup................................................................................................................................. 18

Table 2: Water Consumption ...................................................................................................................... 20

Table 3: Raw Material Consumption .......................................................................................................... 21

Table 4: Details of Product .......................................................................................................................... 21

Table 5: Details of Air Emission ................................................................................................................... 25

Table 6: Water Consumption ...................................................................................................................... 26

Table 7: Wastewater Generation ................................................................................................................ 27

Table 8: Sizing of Sewage Treatment Plant................................................................................................. 33

Table 9: Hazardous/Solid Waste Generation .............................................................................................. 33

Table 10: Salient Features of the project site ............................................................................................. 36

Table 11: Climate Data ................................................................................................................................ 37



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LIST OF FIGURES

Figure 1: world consumption of carbon disulfide ....................................................................................... 11

Figure 2: Short view of the project site ...................................................................................................... 14

Figure 3: Site Plant Layout with nearby industries ..................................................................................... 15

Figure 4: Plant Layout ................................................................................................................................. 16

Figure 5: Manufacturing Process flow sheet .............................................................................................. 24

Figure 6: Water balance diagram, in KLD ................................................................................................... 29

Figure 7: Flow Diagram of Combination Cooling Tower ............................................................................. 30

Figure 8: Sewage Treatment Plant (STP) Flow Diagram ............................................................................. 32

LIST OF ANNEXURES

Annexure 1: Existing Environmental Clearance ......................................................................................... 41

Annexure 2: Consent to Operate (CC&A) .................................................................................................. 47

Annexure 3: Water withdrawal Permission from GIDC .............................................................................. 53

Annexure 4: Land Document ...................................................................................................................... 54

Annexure 5: Membership of BEIL ............................................................................................................... 56

Annexure 6: EC letter for Dahej SEZ ........................................................................................................... 57

Annexure 7: Watercess returns of last three years .................................................................................... 63

Annexure 8: Electricity of last two months................................................................................................. 66



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EXECUTIVE SUMMARY

India is one of the leading manufacturers and suppliers of pesticides intermediates. India has a

good engineering & research scientist pool along with long proven expertise of producing quality

products. The proposed project is an expansion project proposed by Indobaijin Chemicals Pvt. Ltd.

with a total product capacity of Carbon Disulphide of 75000 MTPA. Carbon disulfide has been an

important industrial chemical since the late nineteenth century. It is used in a variety of applications

like production of regenerated cellulose (rayon and cellophane) and the manufacture of organic

sulfur compounds including agricultural, pharmaceutical, rubber chemicals and especially as

Pesticide intermediate. The proposed project will be undertaken within the existing premises of

Indobaijin Chemicals Pvt. Ltd. located at Plot No: Z-7/1 & Z-8/Part, SEZ-1, Village: Dahej, Tehsil:

Vagra, District: Bharuch, Gujarat.

As per the provision of the SO 1533, the proposed project falls under the item no. 5(b) -“A” and the

project is to be appraised at the MoEFCC, New Delhi. Further, the proposed project is located in the

Notified industrial estate/park (as described in Item 3(b) of notification), Hence Public hearing shall

be exempted (A copy of Gazette notification is attached as Annexure-6)

This pre-feasibility report has been prepared as a part of the ToR application, which includes a brief

introduction of the company, need and justification of the project, manufacturing process

description, required and available resources, proposed Environment Management Systems,

existing land-use and proposed infrastructure, project schedule and cost estimate, and proposed

Terms of reference for conducting the EIA studies.

The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultant to

conduct the EIA studies for obtaining EC for the proposed project. ECSS is a NABET accredited (QCI

approved) Environmental Consultant.



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1.0 PROJECT BRIEF

PROJECT BRIEF

No. Description Proposed Project Details

1 Name of project &

Address

M/s. Indobaijin Chemicals Pvt Ltd

Plot No: Z-7/1 & Z-8/Part, SEZ-1,

GIDC Dahej, Taluka – Vagra,

Dist: Bharuch,

Gujarat

2 Project Category 5 (b)-A of EIA notification – 2006

3 Project capital cost Existing cost: Rs. 178 Crores

Expansion cost: Rs. 15 Crores

4 Products Enhancement of production capacity of Carbon Di

Sulphide (CS2) from 50,000 MTPA to 75,000 MTPA and

steam export capacity from 45,000 MTPA to 65,000

MTPA

No Product Existing

capacity

(MTPA)

Proposed

Capacity

(MTPA)

Total

Capacity

(MTPA)

1 Carbon Di-

Sulphide

50,000 25,000 75,000

2 Steam Export 45,000 20,000 65,000

5 By-products No By-Product will be generated

6 Resource Requirement

Land 50,000 m2

(No additional land will be required due to proposed

expansion)

Water Source : GIDC water supply

Existing Water Consumption:

Domestic Activities: 50 KLD

Industrial Activities: 700 KLD

Proposed Additional Water Consumption:

Construction phase: 5-10 KLD



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Operation phase:

Existing Proposed Total

Domestic

Activity

50 KLD Nil 50 KLD

Industrial

Activity

700 KLD Nil 700 KLD

No additional water will be required for domestic as well

as industrial purpose as current water consumption is

around 450 KLD only, hence no additional water will be

required for the proposed expansion.

Electricity Source: Torrent Energy Ltd

Total Connected load -5110 KW

Original Contract Demand -1920 KW

Existing Contract Demand, which is used - 1520 KW

Proposed additional Contract Demand – 30 KW

No change in existing contract demand due to proposed

expansion as only additional 30 KW of additional

connected load is required for proposed expansion,

which is already available with unit. Hence no additional

electricity will be required for proposed expansion.

Fuel Existing:

Natural gas: 29350000 Nm3

After Proposed Expansion:

Natural gas: 37500000 Nm3

Manpower Existing: 98 Nos.

Proposed additional Manpower:

Construction phase –75 Nos.

Operation phase – 12 nos.

7 Source of Pollution

Waste Water

Generation

No industrial wastewater is discharged from the

existing unit hence the unit is a zero liquid discharged

unit. After the proposed expansion same shall be

achieved.



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Existing sewage is treated in STP and treated water is

reused in gardening purpose. After the proposed

expansion same practice shall be continued.

Air Emission Flue stack Emission:

PM10 , PM2.5, SOx & NOx

Process stack Emission:

CS2, SO2, H2S

Solid/Hazardous Waste

Generation

Hazardous waste:

Furnace Slag from furnace pipe and reactor cleaning,

Used Spent Oil, Discarded Containers/liners/Barrels

contaminated with Hazardous waste/chemicals,

Evaporation salt, Sludge from Sulfur Filter

Solid Waste:

STP Sludge

8 Mode of Treatment

Wastewater 1) No Additional Industrial effluent will be generated due

to the proposed expansion.

2) Additional Domestic sewage will be treated in existing

Sewage Treatment Plant (STP) and treated water shall

be reused in toilet flashing and partially fed to

combination cooling tower.

Air No additional furnace, flare stack or D.G. Set will be

installed due to proposed expansion. Adequate Air

pollution control devices are already provided to achieve

GPCB norms.

Solid Waste Solid/hazardous waste for collection, storage and

disposal will be carried out as per Hazardous Waste

Management Rules.



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2.0 INTRODUCTION OF THE PROJECT

2.1 DETAILS OF THE PROJECT PROPONENT

Indo-Baijin Chemicals Private Limited is a Joint Venture Company of Indofil Industries Limited, India

& Shanghai Baijin Chemicals Group Co. Ltd., China. Proponent is proposing to expand its current

manufacturing plant for producing Carbon Di-sulphide using Natural Gas (NG) as raw material at its

existing plant located at Special Economy Zone (SEZ), Dahej, Gujarat, India.

Indofil Industries Limited is a company from K.K. Modi Group of India an Industrial Conglomerate

with diverse businesses in the Agro Chemicals, Fine Specialty Chemicals, Entertainments, Healthcare

etc.

Indofil Industries Limited is uniquely placed both in Agriculture chemical as well as Specialty and

Performance chemical business. In India, Indofil is successful in strategic marketing of insecticides

including IGRs, Fungicides, Bactericides, Herbicides, Acaricides, Surfactants and Plant growth

regulators. Indofil is working for betterment of farmers, operating in Indian Market for more than 4

decades. INDOFIL is an ISO-9001-2000 and ISO 14001 Company and famous for excellence in product

quality. Indofil have stringent safety regime and an ability to handle hazardous chemicals such as

carbon disulphuide.

Shanghai Baijin Chemicals Group Co. Ltd., China was established in 1990. With Carbon Di-sulphide

production as the major business, Baijin group, consistently extending the industrial chain of fine

chemicals, chemical fibers, coke chemicals as well as endeavoring in international trade, technical

export and R&D, is a group company with the largest production scale, the most complete technical

processes and latest technologies. Shanghai BaiJin Chemical Group Co., Ltd, has a total asset of 2.6

billion Chinese yuan and 8 subordinates. The company also owns 14 proprietary patents and is

applying 2 international patents at present. Successively, 7 carbon disulfide manufacturing plants in

Shanxi, Chongqing, Sichuan, Xinjiang, Anhui, Shandong, and Jiangsu respectively have been

established, with an annual output of 3,50,000 tons.



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2.2 DESCRIPTION OF NATURE OF THE PROJECT

The company is located at Plot No: Z-7/1 & Z-8/part, SEZ-1, GIDC Dahej, Taluka-Vagra, District:

Bharuch, Gujarat. The unit is involved in manufacturing of Carbon Di-sulphide, having granted

capacity of 50,000 MT/Annum and steam export with capacity 45,000 MT/Annum.

The unit has also obtained Environmental Clearance for existing products vide letter No: J-

11011/301/2011-IA II (I), dated: 24/12/2012 (Attached as Annexure-1) & the unit holds

Consolidated Consent having Order no. AWH-64179 dated 02/04/2014, which is valid up to:

01/04/2019 (Attached as Annexure-2)

2.2.1 NEED OF PROPOSED PROJECT

As India is a developing country with increasing population, pesticides’ and pesticides intermediates’

demand is increasing day by day. Asia is accounted for about 72% of world production and nearly

75% of world consumption of carbon disulfide.

Carbon disulfide has been an important industrial chemical since the late nineteenth century. It is

used in a variety of applications like production of regenerated cellulose (rayon and cellophane) and

the manufacture of organic sulfur compounds including agricultural, pharmaceutical, rubber

chemicals and especially as Pesticide intermediate.

China is the dominant global player in this industry, with 49% of global consumption, followed by

India (13%). Both the countries have expanding industries, which account for the majority of carbon

disulfide consumption. The situation is similar in Western Europe, which accounted for 12% of world

consumption in 2010. In total, 98% of the world consumption of carbon disulfide was accounted for

Asia, Europe and America (74.5%, 15.8% and 7.7% of global demand, respectively). The rise of Asia

as the powerhouse where carbon disulfide is consumed (and produced) is closely related to the

changes in the global pattern of the textile, rubber, mining and agricultural chemicals industries,

which have increasingly relocated their manufacturing bases to this region. Hence, the demand of

carbon disulphide is increasingly gradually.

2.2.2 DEMAND SUPPLY GAP

As discussed above, the consumption of carbon disulfide is consumed (and produced) is closely

related to the changes in the global pattern of the textile, rubber, mining and agricultural chemicals



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industries, which have increasingly relocated their manufacturing bases to this region. The following

pie chart shows world consumption of carbon disulfide in the past few years:

Figure 1: world consumption of carbon disulfide

The production of regenerated cellulose (in the form of rayon fibers, cellophane, sponges and

casing) is the dominant industrial application of carbon disulfide, accounting for 70% of total

demand. In the absence of new applications, the health of the overall carbon disulfide market will

depend on sustainable growth in the fibers application, which on a global scale is expected to rise in

the near future. Other important areas where carbon disulfide is being used are in the production of

rubber chemicals (predominantly as vulcanization accelerators) and agricultural chemicals (as

fumigants). With the increasing prices of basic raw materials, the use of carbon disulfide in the

manufacture of mining chemicals (as flotation agents) is gaining in importance and has the highest

forecast growth rate among the different applications.

Future growth is expected to be most significant in Asia, whereas other regions with significant

demand are expected to stagnate or to grow at only about 1–2% annually over the forecast period.

On a global level, demand has increased 4% annually on average between 2010 and 2015. Indian

demand for CS2 is around 95,000 tons/annum.



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2.2.5 EMPLOYMENT GENERATION

The proposed expansion project shall generate employment during the construction for local skilled

and semi-skilled workers. Thus no need to provide housing facility to workers. Approx. 75 nos. of

people will get direct employment during construction phase.

During the operation phase, additional 12 nos. of individuals will get direct employment during

operation phase depending on their education background and technical skills.

3.0 PROJECT DESCRIPTION

3.1 PROPOSED PROJECT & APPLICABILITY OF EIA

The existing unit of Indobaijin Chemicals Pvt Ltd is located at at Plot No: Z-7/1 & Z-8/part, SEZ-1,

GIDC Dahej, Taluka-Vagra, District: Bharuch, Gujarat. The unit is now planning to increase its

production capacity from 50,000 MT/Annum to 75,000 MT/Annum.

The applicability of the SO 1533 for the proposed expansion project was explored by considering

different possibilities & provisions made in the said EIA notification, SO 1533 amended on 14th

September 2006. Considering the products, the proposed expansion project falls under Category 5

(b) - “A”.

3.2 PROJECT LOCATION

The company is located at Dahej SEZ in Vagra Taluka in western part of the Bharuch district,

Gujarat. It is well connected with National Highway (NH-8). Road and Railway both are having the

connectivity to New Delhi, the National Capital and Mumbai, the commercial Capital of India. SEZ is

a part of Dahej Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) and is within

Delhi-Mumbai Investment Corridor (DMIC).

Connectivity:

Road: SEZ is on 4 lane State Highway connecting at Bharuch (40 km) and National Highway No. 8

Rail: 40 km from Bharuch, Main Rail Head connecting Mumbai – Delhi.

Port: Gujarat Chemical Port Terminal Company Limited for chemical cargo and Adani-Petro LNG for

solid bulk cargo handling.

Airport: Baroda-150 km and Surat-120 km (Daily flights to Mumbai & Delhi).

http://www.gcptcl.com/



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Four corners Latitudes and Longitudes of the proposed project are as under:

Project Co-ordinates

Corner Latitude Longitude

A 21°42'35.74"N 72°37’06.78"E

B 21°42'36.02"N 72°37'10.94"E

C 21°42'27.10"N 72°37'11.04"E

D 21°42'30.92"N 72°37'10.30"E



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Figure 2: Short view of the project site

Source: Google Earth Image



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Figure 3: Site Plant Layout with nearby industries



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Figure 4: Plant Layout



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3.2.2 ALTERNATIVE STUDIES:

As the proposed project is capacity enhancement project, alternative site has not been considered.

Since, by nature, the project is an expansion project, the existing premises of operational unit is the

most convenient site for the proposed expansion project. Moreover all the utilities & infrastructure

facilities are available in the present set up. Hence the existing premise with available infrastructure

& ease of operation is the best option available for the proposed expansion.

3.2.3 SITE SELECTION CRITERIA:

The land for the proposed expansion project is already in the possession of Indobaijin as the

proposed project is an expansion project. All the infrastructure facilities are available with the

existing unit of Indobaijin.

The project site is in Special Economic Zone (SEZ), which has all the facility such as RCC road,

water supply, effluent disposal line, power supply from Torrent Energy Ltd, Gas supply, Fire and

Safety Services.

The existing project site is well connected by road to National Highway No. 8.

Easy availability of infrastructure facilities.

No prime agricultural land / forest land needed to be converted for industrial use.

There is enough extra land to raise required green belt / green cover.

Area where proposed site is to be located has no history of natural calamities like floods, cloud

burst etc.

Proximity to raw material suppliers

The human resource required for the proposed project will be easily available

In addition to the above, the following factors within the study area have also been considered:

There is no National Park or Wild Life Sanctuary.

There are no metropolitan cities.

There are no ecologically sensitive areas.



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3.3 RESOURCE REQUIREMENT

To carry out the proposed expansion, various resources like raw materials, power, fuel, water,

manpower, etc will be utilized.

3.3.1 LAND REQUIREMENT

As mentioned above, the proposed expansion shall be developed within existing premises by using

the existing infrastructure. No additional land will be purchased/procured for the proposed

expansion. Plant layout is attached as Figure No: 3. Land document is attached as Annexure-4.

Total Plot Area – 50,000 m2

Existing spare land of 220 m2 will be utilized for the proposed expansion.

Table 1: Land Breakup

No. Description Existing Area (m2)

Proposed Area (m2)

Total Area (m2)

Percentage %

1. Plant Area 15,999 220 16,219 32.44

2. Ground coverage Area 13,931 -- 13,931 27.86

3. Future expansion 3,569 - 220 3,349 6.70

4. Greenbelt area 16,501 -- 16,501 33.00

Total Area 50,000 0.0 50,000 100

3.3.2 MAN POWER REQUIREMENT:

The company has already employed maximum nos. of manpower from the nearby area. Same policy

of local employment will be followed for the proposed expansion project as well.

The existing unit has existing manpower of 98 nos. Additional manpower shall be employed during

the construction & operation phase directly and indirectly through contracts for Civil Construction,

Piping Works and Associated Amenities. Approximately 75 nos. of people will get direct employment

during the construction phase.

Based on the unit’s organizational pattern, after proposed expansion total 110 nos. of technical staff

will be required to operate the plant after the proposed expansion.



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3.3.3 ELECTRICITY REQUIREMENT:

Source: Torrent Energy Ltd

Total Connected load -5110 KW

Original Contract Demand -1920 KW

Existing Contract Demand, which is used - 1520 KW

Proposed additional Contract Demand – 30 KW

No change in existing contract demand due to proposed expansion as only additional 30 KW of

additional connected load is required for proposed expansion, which is already available with unit.

Hence no additional electricity will be required for proposed expansion.

With all these actions, unit is able to operate plant with lesser amount of electricity. Hence no

additional power will be required for the proposed expansion. To substantiate the electricity

consumption below the consented quantity bill of last two month is attached as Annexure-8.

The proponent is energy conscious and has taken various actions to reduce the power

consumption:

Replacing higher HP pumps with lower HP pumps

Replacing various lights with LED lights

Avoiding double pumping at various locations

Replacing cooling tower fans by FRP fans

Replacing electrical driven pump & blower with steam turbine driven etc.



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3.3.4 WATER REQUIREMENT:

Source of water: GIDC Water Supply

Unit has obtained permission for 750 KLD water for the existing unit and no additional water will be

required for the proposed expansion. (Copy of the water withdrawal permission is attached as

Annexure-3)

Table 2: Water Consumption

Existing (KLD)

Actual Water consumption (KLD)

Proposed (KLD)

Total (KLD)

i) Domestic 50 45 5 50

ii) Industrial

a) Processing 17 10 7 17

b) Waste heat

recovery Boiler

595 357 238 595

b) Combination

Cooling

80 33 47 80

d) Washing 8 5 3 80

Total Requirement 750 450 300 750



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4.0 RAW MATERIAL AND PRODUCT DETAILS

4.1 RAW MATERIAL DETAILS

An estimated requirement of various raw materials for the proposed expansion is given in following

table. The basic raw materials required are given below:

Table 3: Raw Material Consumption

No. Raw Material Existing Quantity

Per annum

Proposed Quantity

Per annum

Total Quantity

Per annum

1 Sulphur 43500 MT 21750 MT 65250 MT

2 Natural Gas 29350000 Nm3 815000 Nm3 37500000 Nm3

3. Water 250000 M3 Nil 250000 M3

4. Electric Power 1900 kVA Nil 1900 kVA

4.2 PRODUCT DETAILS

The unit is engaged in manufacturing CS2 with capacity of 50,000 MT/Annum and increase the

production capacity up to 75,000 MT/Annum.

Table 4: Details of Product

No. Product Existing

Quantity

Proposed

Quantity

Total

Quantity

1 Carbon Di-sulphide 50,000 MTPA 25,000 MTPA 75,000 MTPA

2 Steam Export 45,000 MTPA 20,000 MTPA 65,000 MTPA



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5.0 MANUFACTURING PROCESS:

This plant will produce liquid Carbon Di sulphide (CS2) by using natural gas and melting sulfur as raw

materials, the whole process consists various units like of Molten Sulfur Preparation Unit, Natural Gas

Purification Unit, CS2 Synthesis Unit, CS2 Refining Unit, Sulfur Recovery Unit, Tail Gas Treatment Unit, CS2

Tank Farm and Utilities to meet the requirements of process. The natural gas based proprietary

technology of CS2 production for this project has been provided by Shanghai Baijin Chemical Group

Company and same procedure will be adopted for the continued in the proposed expansion. The

synthesis process is as under:

a) Liquid Sulfur Unit

Solid sulphur powder, granular or flake sulfur is acceptable and large lump sulfur is not permissible. The

Sulphur is stored in solid sulfur storage yard. It is then fed to melting sulfur tank and then the molten

sulfur is pumped into sulfur filter for filtration. Finally this on-spec liquid sulfur is flown into the

underground molten sulfur storage pit for pumping into the reacting furnace as the raw material of CS2

synthesis. While the liquid sulfur recovered by the flash system of the CS2 production and Sulfur

Recovery Unit, shall enter directly the underground pit of the liquid sulfur, where it is also transmitted by

the liquid sulfur feed pump to the CS2 reacting furnace for reaction. Provisions for receiving molten liquid

sulfur from outsource and unloading from liquid sulfur tankers directly into molten sulfur storage tank

are provided.

b) Natural Gas Purification Unit

Natural gas received is purified by the Natural Gas Purification Unit with Pressure Swing Adsorption (PSA)

unit to desired purity for the reaction. Off gases are used for reactor heating purposes.

c) Reaction Unit

Natural Gas – Sulfur Method is adopted with natural gas as feed for CS2 production.

CH4 + 2S2 CS2 + 2H2S

After the natural gas (feed natural gas), with its pressure stabilized via PSA purified gas buffer tank, is

metered accurately, it enters the preheating section of tubular heating furnace. After mixing with the

liquid sulfur (excess sulfur) from the liquid sulfur Unit via mixer, it enters the heating section of tubular

heating furnace, where the material is fluidized severely and the liquid sulfur vaporized. The gaseous

sulfur and natural gas (mainly methane) are heated with partial chemical reaction inside furnace. The



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mixed gas coming from the tubular heating furnace enters the adiabatic reactor, while the unreacted

gaseous sulfur and natural gas continue to react inside the adiabatic reactor. Upon completion of

reaction, the reaction process gas coming from the adiabatic reactor is sent to the refining unit.

d) Refining Unit

The hot gases received from reaction section are cooled to recover Sulphur/H2S & CS2 is refined.

Recovered Sulphur is send to Sulphur tanks while H2S is send to Claus unit for further conversion to

elemental Sulphur.

e) CS2 Tank Farm

For the convenience of production management, the on-spec CS2 produced by CS2 Refinery Unit enters

the finished product intermediate tanks separately. The finished product produced in each shift, after

qualified via laboratory test, is sent by the finished product forwarding pumps, to the large CS2 tank in

the tank farm or to the pitch-arm loading station for tank truck loading.

f) Sulfur Recovery Unit

The sulfur recovery unit (SRU) comprises of one thermal reaction section and two catalytic reaction

sections. Here Sulphur is recovered from H2S based on partial oxidation of H2S, and subsequent reaction

of H2S and SO2.

g) Tail Gas Treatment Unit

In the tail gas treatment unit, the residual H2S containing gas from the Claus unit is recovered via Amine

absorption and regeneration process. The recovered gas is fed back to the Claus furnace for recovery.

The treated gas from the Amine section is then taken to a thermal oxidizer furnace, where the traces of

H2S remaining are converted to SO2, before the gases leave from the stack. This ensures a recovery

Efficiency of 99.9% in SRU.



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h) Energy Saving & Heat Recovery Plan

The proposed plant will consist of various waste heat recovery boilers /turbines to recover energy in

most economical way. The plant will be self-sufficient in Steam production and also export steam to

neighbouring company. An optimized energy saving scheme will be part of Basic Energy Package.

Figure 5: Manufacturing Process flow sheet

Salient Features of the Process/Technology adopted /to be adopted

Existing CS2 manufacturing plant in India requires 350 kg charcoal per MT CS2 production which

comes from 1000 kgs of wood which results in to deforestation of 58 km2 per year.

SBC technology is well proven and replaces charcoal by Natural gas.

Proposed plant will be zero effluent discharge plant.

SRU is based on SCOT process technology, which shall achieve recovery efficiency of 99.9%.



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7.0 ENVIRONMENTAL MANAGEMENT PLAN

7.1 AIR ENVIRONMENT:

Adequate and efficient measures shall be provided to keep the process and dust emission at a

minimum level. The particulars of most specific individual sources and their pollution control

measures are as follows:

Table 5: Details of Air Emission

Stack No: 1

Stack : 1

Stack attached to : Tail Gas Treatment Unit & Flue Gas from Reaction heating Furnace

Stack height from GL : 80 m

Temperature : 270oC

Expected Pollutants : SOx, NOx, CO2

Air Pollution Control Devices : Sulfur recovery Unit

Stack No: 2

Stack : 1 (Emergency Flare Stack)

Stack attached to : Emergency system venting


Expected Pollutants : SO2

Air Pollution Control Devices : --

Stack No: 3 & 4

Stack : 2 (Emergency back-up power Generator- DG )

Stack attached to : D G Set if capacity 1650 kVA


Expected Pollutants : SOx, NOx, CO

Air Pollution Control Devices : --



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No additional furnace, emergency flare stack or D.G.Set will be required the proposed expansion as the

existing furnace has additional capacity to take care of additional load for the proposed expansion.

7.2 WATER ENVIRONMENT:

Water Consumption

Existing water requirement for domestic and industrial purposes is 750 KLD and is obtained from

the GIDC water supply.

Table 6: Water Consumption

Existing (KLD)

Actual Water consumption (KLD)

Proposed (KLD)

Total (KLD)


ii) Industrial


b) Waste heat

recovery Boiler

595 357 238 595

b) Combination

Cooling

80 33 47 80

d) Washing 8 5 3 80


In the proposed expansion, no additional water will be required as existing water quantity shall be

sufficient to meet additional water requirement for proposed expansion. Unit has implemented

various schemes for water conservation such as –

Using treated waste water for make up in dyke wall

Steam condensate recovery system

Replacing filter press in waste water treatment plant with pressure sand filter

Providing side stream filter for cooling tower etc.

With all these actions, unit is able to operate plant with around 450 KL/day water consumption.

Hence no additional water will be required for the proposed expansion. To substantiate the water

consumption below the consented quantity water cess return of last three years is attached as

Annexure-7.



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Wastewater Generation:

Indo Baijin is/will use using high cost Hydrogen Reduction Technology instead of cheaper and generally

used desulphurization technology to eliminate generation of high quantities of waste water.

The wastewater is mainly the blow down water from various waste heat recovery units (waste heat

boiler), DM plant wash water, the unrecovered steam condensate (majority of which is recovered),

moisture separated in the oxidation tower, the ground flush water, etc. They are/will be collected, mixed

and cooled inside the plant, and then sent to the wastewater treatment unit.

Table 7: Wastewater Generation

Existing wastewater

(KLD)

Actual Wastewater generation

(KLD)

Proposed Wastewater

(KLD)

Total (KLD)


ii) Industrial


b) Waste heat

recovery Boiler

460 282 178 460

b) Combination

Cooling

0 0 0 0

d) Washing 8 5 3 8


Existing wastewater Generation:

1. The evaporation losses of 585 KLD from combination cooling tower, these water is coming from 80

KLD of fresh water and 505 KLD of recycle water steams from process, waste heat recovery boiler,

washing and domestic activities.

2. The total fresh water intake of 750 KLD is the sum of evaporation losses of 585 KLD in cooling

tower + 135 KLD steam export + 30 KLD horticulture consumption.



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Actual wastewater Generation:

1. The evaporation losses of 345 KLD from combination cooling tower, these water is coming from

33 KLD of fresh water and 312 KLD of recycle water steams from process, waste heat recovery

boiler, washing and domestic activities.

2. The total fresh water intake of 450 KLD is the sum of evaporation losses of 345 KLD in cooling

tower + 75 KLD steam export + 30 KLD horticulture consumption.

Proposed additional wastewater Generation:

1. The evaporation losses of 240 KLD from combination cooling tower, these water is coming from

47 KLD of fresh water and 193 KLD of recycle water steams from process, waste heat recovery

boiler, washing and domestic activities.

2. The total additional fresh water intake of 300 KLD is the sum of evaporation losses of 240 KLD

in cooling tower + 60 KLD steam export.

Conclusion:

No additional water will be required for proposed expansion as actual water consumption will be very

much less than the granted water withdrawal permission from GIDC, hence no additional water

permission will be required due to proposed expansion.

No additional wastewater treatment facility will be required for proposed expansion as existing facility

is adequate to treat the existing as well as proposed quantity of effluent. The existing wastewater

treatment facility i. e Combination Cooling Tower has capacity to treat 585 KLD wastewater, but actual

wastewater generation of existing unit is around 345 KLD only. Hence existing treatment facility has

spare capacity to treat the additional load due to proposed expansion.

All the generated effluent is/will be evaporated in Combination Cooling Tower hence unit is/will be a

zero liquid discharge unit.



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Figure 6: Water balance diagram, in KLD



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Action Plan for Zero Discharge of Effluent

a) Wastewater Streams :

i) Water from the Boiler feed water pollutant rejects from the demineralising section, and blowdown

water from waste heat recovery boiler. The average composition of this stream is within 800 ppm

of dissolved salts. The maximum actual quantity is 282 KLD.

ii) From the tail gas treatment section of Sulphur recovery unit, the excess water condensed from the

flue gas is separated in the water removal tower. This water called Sour water and has traces of

H2S. This is treated in an oxidation tower to convert the H2S into safe salt Na2S2O3. The maximum

actual quantity is 10 KLD. The concentration of dissolved salts is within 200 ppm.

iii) The third stream is from general washing of plant and lab areas, this quantity is maximum actual 5

KLD. The concentration of dissolved salts is within 200 ppm.

Action Plan for Zero Waste Water Discharge:

As all the waste water streams are not having any COD and BOD, and only have shall quantity of dissolved

solids (salts), the design Philosophy of the plant has included the concept of ‘Zero Waste Water

Discharge”. In existing practice, Indo Baijin is using “Combination Type Cooling Towers” to achieve zero

liquid discharge and same shall be utilized after proposed expansion.

Figure 7: Flow Diagram of Combination Cooling Tower



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Inside this cooling tower, the circulating cooling water flows through the inside of the cooling tube

bundles. This tube bundle is cooled from the outside in set up similar to a conventional cooling tower.

The outside water is circulated and sprayed on top of the tube bundle, and also a draft is maintained by a

fan across the cooling tower. By evaporation of outside water, the water inside the tube bundle is cooled

and returned to the plant supply. As the outside water is not taken directly to the plant cooling duties it

can be used and circulated with high solid content.

Combination Cooling Tower Treatment Scheme

To understand the concept of this Combination type of cooling tower, we need to compare this with the

conventional cooling tower working.

Working of Conventional Cooling Tower:

In a conventional cooling tower, the cooling water return streams from the plant are cooled by direct

contact with air, and the cooling takes place by part evaporation from the circulating water. During this

process the salt concentration of the water increases, and some water is drained off as blowdown to limit

the concentration of salts in the cooling water circuit. This is required to ensure water quality fit for heat

transfer in the plant equipment. This demands that only clean good water is added for making up the

losses in the cooling water system which are based on conventional cooling towers.

The Working of Combination Cooling Tower:

In this cooling tower, the cooling operation in the cooling tower is separated & isolated from the

circulating cooling water used to remove heat from the plant equipment. This ensures a closed circuit for

cooling in the plant, and hence no contamination of this stream takes place. The hot return stream from

the plant is cooled by indirect contact in the cooling tower, by a local circulation of water which in turn is

cooled by evaporative cooling by contact with air.

The local circulation water stream in the cooling tower can be used continuously till it reaches a critical

concentration of dissolved solids, after which it is discharged to a final evaporator for separation of salts

for disposal. The design of the cooling tower ensures continuous wetting of heat transfer surface to

enable required evaporative cooling and maintaining clean surfaces without any scales formation. This

design feature is achieved by the patented co-current air-water flow technology by the supplier.



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Due to these design features it is not necessary to add clean water make up in this type of cooling tower.

Hence in our units set up we add recycle water streams as part of make up water to the cooling tower.

This enables recycling of all waste water streams (after suitable pre-treatment) of the plant as make up to

this cooling tower. Therefore the plant facility does not discharge any waste water from the premises.

The addition of recycle streams also enable saving of fresh water consumption of over 200 KLD for our

unit. Elimination of blowdown from the cooling tower saves another 80 KLD considering a concentration

cycle of 7. Therefore this system saves about 300 KLD or 100,000 m3/annum for our unit.

In our existing project these is served as the Heat Sink and also Zero Discharge Unit, by combining the

functions of the cooling tower and also a water evaporator. Adequate overdesign has been built into this

system to ensure sufficient spare capacity.

Domestic Waste Water:

The domestic waste water streams shall be treated in a modern packaged sewage treatment unit with

capacity of 50 KLD, and the treated water shall be available for reuse in toilets, and feeding to the Zero

Discharge cooling tower unit.

Figure 8: Sewage Treatment Plant (STP) Flow Diagram



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Table 8: Sizing of Sewage Treatment Plant

7.3 SOLID/HAZARDOUS WASTE

The entire quantity of hazardous waste is handled and disposed as per Hazardous Waste (Management,

Handling and Trans-boundary Movement) Rules - 2016. Furnace slag from furnace pipe and reactor

cleaning, Used spent Oil, Discarded Container/Barrels/Liners, Evaporation salt and Sludge from sulfur

filter are generated from existing unit. Unit has obtained membership for BEIL (Attached as Annexure-5).

After expansion, no additional quantity of Hazardous waste will be generated except Sludge from sulfur

filter. As a solid waste STP sludge is generated, which is used as manure in the premises.

Table 9: Hazardous/Solid Waste Generation

No. Name of Waste Waste category

Existing Total after Proposed expansion

Solid waste Disposal / Management

1 Furnace slag from furnace pipe and reactor cleaning

1.1 55 MTPA 55 MTPA Collection, Storage, Transportation & Disposal at common incineration facility.

2 Used spent Oil 5.1 1.0002 MTPA

1.0002 MTPA

Collection, Storage, Transportation & Disposal by selling to register refiners

3 Discarded Container/Barrels/Liners

33.1 100 MTPA 100 MTPA Collection, Storage, Transportation & Disposal by GPCB approved scrap dealer

4 Evaporation salt 37.3 144 MTPA 144 MTPA Collection, Storage, Transportation & Disposal at TSDF, BEIL.

5 Sludge from sulfur filter -- 55 MTPA 78 MTPA

Collection, Storage, Transportation & Disposal at at common incineration facility.

S No Unit Size

1 Collection tank 3 m X 1 m X 3 m

2 Aeration tank 3 m X 3 m X 3 m

3 Treated water tank 2 m X 2 m X 3 m

4 Filtered water tank 2 m X 2 m X 3 m

5 Sand filter cum solid collection tank 2 m X 2 m X 3 m



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No. Name of Waste Waste category

Existing Total after Proposed expansion

Solid waste Disposal / Management

Solid waste

1 STP Sludge 30 kg/day -- Used as manure

7.4 NOISE ENVIRONMENT

The industry is in the SEZ area and located 8-km away from the nearest settlement. There are two

categories of noise generated due to the unit.

Noise due to plant operation

Noise due to transportation of vehicles.

Noise Control Measures:

All the vibrating parts are checked periodically and serviced to reduce the noise generation. The

equipment, which is prone to generate excessive noise, is already provided with enclosures. To

minimize the adverse effect on the health, ear muffs/ earplugs is provided to the workers working

under high noise area.

The industry has already developed 16500 m2 area for green belt around the periphery of the plant. This

will help in reducing the adverse effect of noise pollution in general. All the equipment in the complex is

designed/operated in such away that the noise level shall not exceed 85 dB (A).

All rotating equipment in the plant would be designed/operated to have a total noise level not

exceeding 85 to 90 dB (A) as per the requirement of OSHA (Occupational Safety and Health

Administration) standard and the Environment (Protection) Rules.

However, if during operation, the noise level exceeds the above norms then the protective measures

given in Environmental Management Plan will be followed. Hence, no impact due to proposed plant on

ambient noise is anticipated.



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7.5 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT

The company is very much concerned in terms of health, safety and environment protection. Indo Baijin

commitment towards safety can be reflected from its ‘Health, Safety & Environment Policy’ prepared

for the existing project.

No major accident has taken place in the factory so far in the existing project. From their previous

performance, same dedication is to be continued for the proposed expansion. To maintain high

standards in Health, Safety and Environment, various activities are undertaken at the site.

The following key safety measures are implemented in the existing plant and the same shall be a part of

proposed expansion project:

1. Safety Training is provided to the employees.

2. Safety Sirens with Alarm System in case of emergency are provided.

3. Emergency Control Room is established.

4. Assembly point is provided.

5. Sprinkler Systems will be provided as needed

6. Fire Hydrant System is installed.

7. Fire Extinguishers are provided.

8. Mock drills are periodically conducted and factors like response time are evaluated.

9. Fire squad team is formed for handling any emergency situation.

10. First Aid Facility and training are provided.

11. Personal protective gears and equipments are provided to employees.

12. Health check-ups are organized at regular intervals.

13. Safety / Health records are maintained.

14. MSDS for all the chemicals are easily available.

Fire Fighting Details:

3217 m3 dedicated water storage for firefighting.

46 hydrant point with hose boxes nearby.

2 Electrical operated water Monitor, can be operated from remote location.

10 Manual Water monitors.

160 Different size of ABC pressurised Extinguishers.

16 Different size of CO2 Extinguishers.



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8.0 SITE ANALYSIS

8.1 CONNECTIVITY

The project location is well connected with road, rail and air route to transport raw materials,

machineries, etc. and hence it exhibits good potential for industrial growth. The salient features

mentioned below, indicate favorable conditions for industrial development at the project location.

Table 10: Salient Features of the project site

Particulars Details

Approx. Geographical Co-ordinates

Latitude Longitude

A 21°42'35.74"N 72°37’06.78"E

B 21°42'36.02"N 72°37'10.94"E

C 21°42'27.10"N 72°37'11.04"E

D 21°42'30.92"N 72°37'10.30"E

Village Vadadla(@ 2.4 km in NE direction)

Nearest Town Bharuch (@ 40.0 km in E direction)

Nearest City Bharuch (@ 40.0 km in E direction)

River/Streams Narmada Estuary (@3.00 km in S direction)

Sea Arabian Sea (@ 11.0 km in W direction)

Nearest Highway

N. H. No – 228 (@ 36 km in E direction)

N. H. No –8 (@ 36 km in E direction)

S. H. No – 6 (@ 42 km in EEN direction)

Nearest Railway Station Dahej Railway Line (@ 2.50 km in WWN direction)

Bharuch (@ 40 km in E direction)

Nearest Airport Surat Airport (@ 66 km in SSE direction)

National parks/ sanctuaries None within 10 km radial area

Defense installations None within 10 km radial area

Note: All the above – mentioned distances are aerial distances from the project site.



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8.2 TOPOGRAPHY

Proposed expansion is between 20007” to 21005” North Latitude and 72043” to 73000” East

Longitude having elevation of 25 meters above sea level. The topography of the proposed site for

the project is plain terrain.

No forests, national park or wild life sanctuary is located within 10 km periphery of the project site.

No change in Land use/Topography is envisaged as the proposed project is expansion project and is

established in SEZ-1, Dahej.

8.3 EXISTING INFRASTRUCTURE

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 the study area of project site.

8.4 SOIL CLASSIFICATION

Proposed expansion will be carried out in existing premises located in SEZ, where land is already

developed for industrial purpose. Quality of soil is not considerably fertile for agriculture activities

and no evidence of any influence of soil contaminant has been noticed.

8.5 CLIMATE DATA FROM SECONDARY SOURCE

Table 11: Climate Data

Climate Type and Details

Climate Temperate climate-Semi Arid

Seismic Zone Zone III

Maximum temperature, °C 44 °C

Minimum temperature, °C 12°C

Relative Humidity Max.:- 97 %; Min.:- 20%

Max Rainfall 1500 – 2200 mm

Climate Temperate climate



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9.1 PROJECT SCHEDULE & COST ESTIMATES

9.1 PROJECT SCHEDULE

Proposed expansion activities will be started after getting statutory clearance from related authorities.

9.2 PROJECT COST ESTIMATION

No. Project Estimate cost

1 Proposed expansion cost Rs. 15 Crores

9.3 CSR ACTIVITIES

Indobaijin which is a part of Indofil group company, has always engaged in social welfare activities &

programs. It directly organizes various programs for social welfare & upliftment or indirectly contributes in

such activities conducted by other organizations by providing financial & other aid. Indobaijin is committed

to contribute in social welfare & upliftment activities on a regular basis. Indobaijin will continue such

activities to fulfill the requirements of its social responsibility under CSR Programs. With development of

community services like medical services, blood donation camp, donation for schools etc will also be

developed as a part of corporate social responsibility. Medical camps and education programmes would be

conducted for the welfare of employees and their families.

Indobaijin Chemicals Pvt Ltd. in collaboration with a non-government organisation (NGO) Ballygunge

Society for Environment & Development undertakes CSR activities in the village Purba Gopinathpur. The

following activities are evident of the fact that Indobaijin is a promoter of CSR Programs:

Donation given to JCI - Bharuch for Election Awareness Campaign organized by them at Dahej.

Donation given to CM of Gujarat (Mrs. Anandiben Patel) under Clean India Campaign.

Food Packets distributed to poor villagers of Vagra Taluka who attended “Garib Kalyan Mela” at

Jambusar.

Houses for Poor Villagers of Dahej: Given approval to construct 3 (Three) houses for poors of

Dahej village. This will be sample houses. Based on the success of this; new project will be

assigned.

Development of Digital Classroom: Given approval to Primary Girls School of Dahej to develop 1

(One) class room of the school as Digital Room.

Organised various seed to seed demonstrations, soil testing and training on safe and judicious

use of pesticides



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Operated Agril Library having more than 200 books on agriculture thrice a week at the local club

premises

Provided computer training through two trainers to 80 students thrice a week

Trained 65 young people, mostly girls, for athletics and 40 youths for football, twice every week,

under eminent coaches.

Organised health camps once in every fortnight to provide treatment for ailment and health

counseling.

Constructed sanitary facilities, especially for girls and women, at the village club premises.

Planted around 250 saplings throughout the village.

Organised cultural programmes, rally and competitions to increase awareness about the

environment.



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FINANCIAL & SOCIAL BENEFITS

The proposed activities will be carried out in the existing unit itself. Hence, no additional land is

to be purchased.

This project utilizes natural gas as one of the raw materials for the synthesis of the product.

Currently all the existing CS2 manufacturing units in India use wood charcoal for this purpose.

Considering 350 kilograms of charcoal consumption per ton of CS2, one ton of wood is used per

ton of CS2. Thus at 50,000 tons of CS2 production per annum, this project will reduce

deforestation to the extent of 58 km2 per year in the country. Thus, the project entails financial

benefits in terms of energy saving.

The company has also allocated some budget for CSR activities, which can lead to improved

social infrastructure, if planned properly.

Temporary employment of 75 people during the construction phase of the proposed

expansion. Employment to approx. 12 people is a direct benefit.

Conclusion:

As summarized in the above sections, it has been noticed that the proposed project for expansion

in capacity will not have any major impacts, which can lead to serious issue of environmental

pollution or any other hazards.

Considering the probability of impacts, proponent has planned adequate mitigation measures and

EMP. Further, it is also planned by proponent to organize CSR programs, rainwater harvesting,

energy conservation, which will have considerable beneficial impacts. Looking to the employment

potentials and other allied developmental potentials, it is noticed that the proposed project will

significantly help in improving social status of the region.



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Annexure 1: Existing Environmental Clearance



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Annexure 2: Consent to Operate (CC&A)



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Annexure 3: Water withdrawal Permission from GIDC



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Annexure 4: Land Document



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Annexure 5: Membership of BEIL



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Annexure 6: EC letter for Dahej SEZ



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Annexure 7: Watercess returns of last three years



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Annexure 8: Electricity of last two months



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