phillips carbon black limited...phillips carbon black limited proposed expansion of carbon black...

PHILLIPS CARBON

BLACK LIMITED

Pre-feasibility Report for Proposed Expansion of Carbon Black Manufacturing Plant along with Waste Gas Based Co-Generation Power Plant at Survey No. 47, SH-46, Village Mokha, Taluka Mundra, District Kutch, State Gujarat

JULY 2019

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

Envi ronment for Deve lopment

PHILLIPS CARBON BLACK LIMITED

PROPOSED EXPANSION OF CARBON BLACK

MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PROJECT DETAILS

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2019 2


Prefeasibility Report for Proposed Expansion of Carbon Black Manufacturing Plant along with Waste Gas Based Co-Generation Power Plant at Survey No. 47, SH-46, Village Mokha, Taluka Mundra, District Kutch, State Gujarat © Kadam Environmental Consultants (‘Kadam’), July, 2016

This report is released for the use of the M/s. Phillips Carbon Black Limited, Regulators and relevant stakeholders solely

as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced

third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of Publication

Prefeasibility Report for Proposed Expansion of Carbon Black Manufacturing Plant along with Waste Gas

Based Co-Generation Power Plant at Survey No. 47, SH-46, Village Mokha, Taluka Mundra, District

Kutch, State Gujarat

Project Number Report No. 1 Version 1 Released July, 2019

Prepared &

Managed By Dhara Patel & Jitixa Upadhyay Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

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

E: [email protected]; T:+91-265-3001000; F: +91 265 300106

Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,

Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected];T: 0124-4242430; M:+91-98998-04300

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes

that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss absolutely,

the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or application of the

information contained in this report. The information is not intended to serve as legal advice related to the individual situation.





CONTENTS

1 EXECUTIVE SUMMARY ..................................................................................................... 6

1.1 PLANT FEATURES AND PRODUCTION CAPACITY .............................................................................. 6

1.2 ENVIRONMENT ................................................................................................................ 6

1.2.1 Water .................................................................................................................. 6

1.2.2 Effluent Generation, Treatment and Disposal ................................................................... 6

1.2.3 Power .................................................................................................................. 6

1.2.4 Air Emission ........................................................................................................... 7

1.2.5 Hazardous Waste Generation and Disposal ...................................................................... 7

1.2.6 Submission ............................................................................................................ 7

2 INTRODUCTION .............................................................................................................. 8

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT .................................................................... 8

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ........................................................................... 8

2.3 NEED FOR THE PROJECT AND IT’S IMPORTANCE TO THE COUNTRY AND/OR REGION .......................................... 8

2.4 DEMAND SUPPLY GAP ........................................................................................................ 9

2.5 IMPORT VS. INDIGENOUS PRODUCTION .................................................................................... 11

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

2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. .............................................. 11

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

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY .................................... 12

3.1.1 Type of Project including Interlinked and Interdependent Project, if any ................................ 12

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT) WITH

COORDINATES ...................................................................................................................... 12

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ......................................................... 15

3.4 SIZE OR MAGNITUDE OF OPERATION....................................................................................... 15

3.5 PROCESS DESCRIPTION WITH PROCESS DETAILS (SCHEMATIC DIAGRAM / FLOW CHART SHOWING THE PROJECT LAY OUT,

COMPONENT OF THE PROJECT ETC. SHOULD BE GIVEN) ............................................................................ 15

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE

OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ....................................................................... 15

3.7 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED 15

3.7.1 Water consumption and waste water generation ............................................................. 16

3.7.2 Power Requirement ................................................................................................ 27

3.8 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL ........ 27

3.8.1 Gaseous Emission .................................................................................................. 28

3.8.2 Solid / Hazardous Waste .......................................................................................... 28

3.9 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE ............. 30

4 SITE ANALYSIS ............................................................................................................. 31

4.1 CONNECTIVITY ............................................................................................................. 31





4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ............................................................................ 31

4.3 TOPOGRAPHY (ALONG WITH MAP) .......................................................................................... 31

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ)),

SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE

SANCTUARY, ETC. SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED

INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ................................................... 31

4.5 EXISTING INFRASTRUCTURE ................................................................................................ 32

4.6 SOIL CLASSIFICATION ...................................................................................................... 32

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ............................................................................... 32

4.7.1 Temperature ........................................................................................................ 32

4.7.2 Wind ................................................................................................................. 33

4.7.3 Rainfall ............................................................................................................... 33

4.7.4 Cloud Cover ......................................................................................................... 33

4.7.5 Humidity ............................................................................................................. 33

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ....................................................................................... 34

5 PLANNING BRIEF .......................................................................................................... 35

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC.) TOWN AND COUNTRY

PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ........................................................................... 35

5.2 POPULATION PROJECTION .................................................................................................. 35

5.3 LAND USE PLANNING (BREAK UP ALONG WITH GREEN BELT ETC.) ......................................................... 35

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) .................................................... 36

5.5 AMENITIES / FACILITIES ................................................................................................... 36

6 PROPOSED INFRASTRUCTURE ........................................................................................ 37

6.1 INDUSTRIAL AREA (PROCESSING AREA) .................................................................................... 37

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ............................................................................. 37

6.3 GREEN BELT ................................................................................................................ 37

6.4 SOCIAL INFRASTRUCTURE .................................................................................................. 37

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC.) ................................ 37

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) .......................................................... 37

6.7 SEWAGE SYSTEM ........................................................................................................... 37

6.8 INDUSTRIAL WASTE MANAGEMENT ......................................................................................... 37

6.9 POWER REQUIREMENT & SUPPLY/ SOURCE ................................................................................. 37

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ....................................................... 38

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES,

LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) ...................................................... 38

8 PROJECT SCHEDULE AND COST ESTIMATE ........................................................................ 39

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE

GIVEN) 39

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. ................. 39

9 ANALYSIS OF PROPOSAL ............................................................................................... 40





9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL

POPULATION, IF ANY, IN THE AREA ................................................................................................. 40



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

1.1 Plant Features and Production Capacity

PCBL, a part of RP-Sanjiv Goenka Group, has a business of USD 500 million and four strategically located state-of-the-

art Carbon Black plants at Durgapur, Palej, Cochin and Mundra. PCBL today is India's largest and globally seventh largest

carbon black producer.

Set up in collaboration with a US company Phillips Petroleum, PCBL started production in 1962 with 14,000 metric tonnes

(MT) of carbon black at Durgapur. Currently, it has a production capacity of 5,71,000 MT per annum in India, and involves

a dedicated capacity of Specialty Blacks of 40,000 MT per annum at Palej.

Details of proposed project is provided in Table 1-1.

Table 1-1: Details of product

S. No. Product Production Capacity in MT/Month

Existing Proposed Total

1 Carbon Black, MTPM 16500 15900 32400

2 Co-generation Power (waste gas base), MW 32 32 64

1.2 Environment

1.2.1 Water

Water is sourced from Gujarat Water Infrastructure Ltd. (GWIL) & Bore well.

Total Water Consumption:

Existing: 2021 KLD; Proposed 2407 KLD; after proposed expansion: 4428 KLD

Recycle Water from RO:

Existing: 338 KLD; Proposed 292 KLD; after proposed expansion: 630 KLD

Fresh water consumption:

Existing: 1683 KLD; Proposed 2115 KLD; after proposed expansion: 3798 KLD.

1.2.2 Effluent Generation, Treatment and Disposal

Wastewater generation:

Existing: 394 KLD; Proposed: 297 KLD; Total: 691 KLD

There is ZLD facility as described below;

1. 42 KLD sent to Soak pit

2. 120 KLD use for Gardening

3. 408 KLD utility blow downs from boiler and cooling tower will send to WTP/ZLD and further reuse in process, boiler

and cooling tower make up water.

4. 115 KLD treated water from washing reuse in cooling tower make up

5. 6 KLD salts with moisture from WTP/ZLD will send to TSDF for disposal

1.2.3 Power

During Construction Phase 200 kVA power will be sourced from existing co-generation power plant.

During Operation Phase:



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT EXECUTIVE SUMMARY


Existing: 8.3 MW

Proposed: 9.5 MW

In case of emergency power will be sourced from Grid of Pashchim Gujarat Vij Company Limited (PGVCL).

1.2.4 Air Emission

Bag filter is attached to existing boilers and process vents as air pollution control measures.

1.2.5 Hazardous Waste Generation and Disposal

There will be slight increase in quantity of hazardous waste generation due to proposed project. The hazardous waste

will be disposed at TSDF site or sent to authorized recycler as per consent.

1.2.6 Submission

In the light of the above, we would like to state that the proposed expansion would have in place systems, procedures

and hardware to ensure that all guidelines for protecting the environmental emission norms are followed and its operation

has no adverse impact on environment.



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project and Project Proponent

PCBL, a part of RP-Sanjiv Goenka Group, has a business of USD 500 million and four strategically located state-of-the-

art Carbon Black plants at Durgapur, Palej, Cochin and Mundra. PCBL today is India's largest and globally seventh largest

carbon black producer.

Set up in collaboration with a US company Phillips Petroleum, PCBL started production in 1962 with 14,000 metric tonnes

(MT) of carbon black at Durgapur. Currently, it has a production capacity of 4,72,000 MT per annum in India, and involves

a dedicated capacity of Specialty Blacks of 40,000 MT per annum at Palej.

PCBL provides a complete portfolio of products to meet the specific end requirements across Rubber, Plastics, Coatings,

Inks and other niche industries globally. The Company has been continuously reinventing itself in order to make the best

in class products. Additionally, PCBL's after sales service and strong technical support ensures a fiercely loyal base of

customers from around the world. PCBL has etched its global footprints and has a market presence in more than 30

nations with decanting stations, warehouses located near customer locations. A few of the Company's prized customers

are CEAT, MRF, Michellin, Yokohama, Birla Tyres, Goodyear, Sumitomo Tires, Bridgestone, Kumho Tires, etc.

PCBL has redefined its business by establishing captive power plants at each factory from the off-gas or waste product

from the carbon black manufacturing process thus creating a sustainable green movement. The gas, a by-product of

carbon black production, is harnessed for generating electricity at the Company's Captive Power Plants (CPP), at Palej,

Durgapur, Mundra and Kochi. That is why PCBL is the first carbon black company in the world to receive carbon credits.

The Company has heavily cut down on carbon and gas emission, and serves green power to Large Private industrial units

and State Electricity utilities.

From the pioneer plant at Durgapur in the East to Kochi plant in the south, Palej and Mundra plants in the west - PCBL

footprint spans across India. Wherever PCBL goes, the Company becomes an integral part of the social eco-system.

PCBL's more than 50 years' journey to be the cleanest carbon black company is the result of meticulous planning and

committed execution.

Table 2-1: Production Capacity per Month in all Plants of Phillips Carbon Black Limited

Mundra Palej Durgapur Kochi Total

CB Capacity (MT/ Month) 16500 10083 10910 8250 45743

Power Capacity (MW) 32 12 30 12 86

2.2 Brief Description of nature of the Project

The proposed project is for expansion of Carbon black manufacturing from 16500 MT/month to 32400 MT/Month along

with increase in Co-generation power from 32 MW to 64 MW in phases. The estimated cost of the proposed project is

INR 710 Crores. Total plot area for the project is 2,91,456 m2.

2.3 Need for the project and it’s importance to the country and/or region

The objective is to;

Consolidate Business.





Constantly upgrade the product range.

Continuously reduce the Costs & improving Quality.

Generate local employment

Increase Govt. revenue in form of taxes and duties

2.4 Demand Supply Gap

Currently approx. 30 % of carbon black production is exported into international market and the balance is sold in India.

In domestic market, the company is a regular supplier to all the major tyre manufacturers and has an overall domestic

market share of around 37 - 40 %.

The global demand supply situation in world Carbon Black market is as under

2017 2021 CAGR % 2021

Over 2017

2026

Demand Mln MT Capacity Mln MT Demand Mln MT Demand Mln MT

North America 1.84 2.10 1.99 1.97 2.13

Western Europe 1.67 1.11 1.75 1.17 1.86

Asia 8.13 9.84 9.38 3.64 10.99

Latin America 0.64 0.74 0.72 2.98 0.79

Eastern Europe 0.43 1.10 0.47 2.25 0.55

Africa & M. East 0.39 0.58 0.45 3.64 0.54

Overall 13.1 15.47 14.76 3.2 16.86

Worldwide demand growth is being driven by Asia followed by North America and Western Europe. However, new capacity

for Carbon Black manufacturing being added globally is not at commensurate pace with the growth in demand. Therefore,

there is going to be demand supply imbalance with demand outpacing the supply in future. .

Asia has 60% of the world’s population and with continuing economic development of more than 5% in most of the Asian

countries, the region is expected to grow economically faster than other regions leading to higher motor vehicles and

tyre production. This would also result in substantial increase in Carbon Black requirement. Details of Tyre Capacity

investment during 2016 – 21 and production are as under

Global Tyre Capacity Investment

Region USD Bn

World 21.82

North America 6.32

South America 0.15

Europe 3.56

Asia 9.87

China 4.15

India 1.3

Other Asia 4.42

Africa / ME 1.93





Asia Tyre Production

Key Indicators World Asia % Asia CAGR 2016-21

Population (Million) 7500 4500 60.0 0.9

Motor Vehicles – Production (Million) 97.9 51.9 53.0 3.3

Motor Vehicles in circulation (Million) 1355 425 31.3 3.2

Tyre Production (Million) 1849 1097 59.3 3.6

From above it would be observed that Tyre production in Asia is going to increase by 3.6% p.a in coming years leading

to similar increase in Carbon Black requirement.

The scenario with respect to Demand and Capacity of Carbon Black and the expected growth for various countries in the

Asia Region is as under;

Country Capacity Demand

MMT % of World total MMT % of Asia total

China 6.75 45 4.65 56.7

Japan 0.71 17 0.67 8.2

India 1.02 12 0.90 10.7

South Korea 0.62 11 0.43 5.2

Thailand 0.47 7 0.51 6.2

Indonesia 0.09 2 0.37 4.5

Taiwan 0.12 2 0.15 1.8

Malaysia 0 2 0.17 2.0

Vietnam 0 0 0.1 1.2

Other Asia/Pacific 0.06 2 0.24 2.92

Total 9.84 8.12

The above data shows that while there is high surplus capacity in China, and marginal surplus in India, South Korea and

Japan there is shortfall in other Asian countries. South East Asian countries are meeting the shortfall by importing it from

China, South Korea, Japan & India.

Planned Tyre Capacity Addition in India

Location Tyre manufacturer Segment Expected date of commissioning

Chennai Apollo Tyres Ltd. truck, bus 2016 to 2018

Kalamassery Apollo Tyres Ltd. specialty, industrial 2016 to 2017

Sri City, Andhra Pradesh Apollo Tyres Ltd. motorcycle 2018 to 2019

Pune Bridgestone PC 2013 to 2020

Pune Bridgestone truck, bus 2013 to 2020

Pune & Indore Bridgestone PC 2017 to 2022

Butibori, Nagpur Ceat Ltd. 2- & 3-wheeler 2016 to 2018

Ahmedabad, Gujarat Cheng Shin Rubber Maxxis Int'l 2-wheeler tires & tubes 2017 to 2018

Aurangabad Goodyear PC, LT (large HVA) 2017 to 2019

Jalandahar Speedways Rubber ATV tires 2016 to 2017





The Carbon Black market in India is estimated at, 10, 00,000 MT and is expected to grow y at 4-5 % CAGR higher than

the global average of 3.3 % during the next 5 years. This growth is driven by growth in Indian economy of over 7% as

well as capacity expansion plans by major tyre companies such as Apollo tyres, MRF, CEAT, Bridgestone etc.

The growth in Carbon Black market in India is also driven by demand for other rubber manufactured goods and specialized

applications in non-rubber goods derived from growth in construction, automobile industry activities.

2.5 Import vs. Indigenous Production

Based on the current cost of indigenous raw materials and the non-availability of some materials, we will have to import

some of the key raw materials as they are not available indigenously. This will make us very competitive against imported

finished products and we will be able to increase the export of our finished products.

2.6 Export Possibility

Approx. 30% of the production will be exported.

2.7 Employment Generation (Direct and Indirect) due to the project.

Construction Phase – 500 (for a few months only when construction takes place)

Operation Phase – Total 320; Permanent = 80, Contractual = 240



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any

3.1.1 Type of Project including Interlinked and Interdependent Project, if any

The proposed project is for manufacturing of petrochemical based processing that is covered under Category – 5 (e). As

the project is not located within Notified Industrial Area it will be considered as “A” category project as per new EIA

notification vide gazette no. S.O. 1533 dated 14th September 2006.

3.2 Location (map showing general location, specific location and project boundary & project lay

out) with coordinates

The project facility is located at Survey No. 47, SH-46, Village Mokha, Talulka Mundra, District Kutch, State Gujarat. The

total plot area of the proposed unit is 2,92,456 m2. Location map of the site is attached as Figure 3-1. Site lay out map

of project is given as Figure 3-2.

PHILLIPS CARBON BLACK LIMITED PROPOSED EXPANSION OF CARBON BLACK MFG. PLANT AT MUNDRA,

DISTRICT KUTCH, STATE GUJARAT PROJECT DESCRIPTION


Figure 3-1: Site Location Map

PHILLIPS CARBON BLACK LIMITED PROPOSED EXPANSION OF CARBON BLACK MFG. PLANT AT MUNDRA,

DISTRICT KUTCH, STATE GUJARAT PROJECT DESCRIPTION


Figure 3-2: Site Lay Out Map


FORM-1 FOR PROPOSED EXPANSION OF

CARBON BLACK MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT FORM I


3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted

Major factors involved in the selection of site are listed below:

Existing operational industry

Site is very well connected by road

Proximity to Mundra & Kandala Ports

Availability of sufficient land free from cultivation

Availability of power evacuation facilities

Availability of water for industrial use

Environment-friendly zone

Uninterrupted power supply

3.4 Size or Magnitude of Operation

The proposed project is for expansion of Carbon black manufacturing from 16500 MT/month to 32400

MT/Month along with increase in Co-generation power from 32 MW to 64 MW in phases.

Table 3-1: Production Details

S. No. Product Production Capacity in MT/Month


1 Carbon Black, MTPM 16500 15900 32400

2 Co-generation Power (waste gas base), MW 32 32 64

The proposed facility will occupy an area of 77361 m2. 32.67% of the land is used for green cover (95,219

m2). The estimated cost of the proposed facility is INR 710 Crores.

3.5 Process Description with Process Details (Schematic Diagram / Flow Chart showing

the project lay out, component of the project etc. should be given)

Process description along with flow diagram, material balance and chemical reaction is given in Annexure

7 of Form I.

3.6 Raw material required along with estimated quantity, likely source, marketing area

of final products, mode of transport of raw material and finished product.

Storage and transportation details of raw material are given in Annexure 8 & 9 of Form I.

3.7 Resource Optimization / recycling and reuse envisaged in the project, if any, should

be briefly outlined

In the proposed project, resource conservation of water is inherently designed for effluent re-use/recycle

and hence consumption is optimized. Availability of water its source, energy/power requirement and source

are given below,


FORM-1 FOR PROPOSED EXPANSION OF

CARBON BLACK MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT FORM I


3.7.1 Water consumption and waste water generation

Existing source of water is Gujarat Water Infrastructure Limited (GWIL) and Borewell. The same source will

be utilized for proposed water demand. The below Table 3-2 shows the water consumption and wastewater

generation figures.

Table 3-2: Water Consumption Details

S. No. Description Water Consumption in KLD


1 Domestic 60 50 110

2 Cooling Tower 377 348 725

3 WTP Plant (UF/RO/ZLD) 1394 1679 3073

5 Process 1104 1278 2382

220 220

6 Boiler 298 400 698

7 Washing 120 60 180

8 Gardening 70 50 120

9 Total Water Consumption 2021 2407 4428

10 Recycle water from RO 338 292 630

11 Fresh Water Consumption 1683 2115 3798

Table 3-3: Waste Water Generation

S. No. Description Wastewater Generation in KLD

Treatment and Disposal Facility Existing Proposed Total

1 Domestic 53 44 97 42 KLD sent to Soak pit

55 KLD use for gardening

2 Cooling Tower 124 87 211 Send to WTP plant

3 WTP Plant

(UF/RO/ZLD) 3 3 6 Salt with moisture send to TSDF

4 Process 0 0 0

5 Boiler 94 103 197 Send to WTP plant

6 Washing 120 60 180

115 KLD to reuse in cooling tower as a

make-up water

65 KLD use for gardening

7 Total wastewater

Generation 394 297 691

There is ZLD facility as described

below;

1. 42 KLD sent to Soak pit

2. 120 KLD use for Gardening

3. 408 KLD utility blow downs from

boiler and cooling tower will send to

WTP/ZLD and further reuse in process,

boiler and cooling tower make up water.

4. 115 KLD treated water from washing

reuse in cooling tower make up

5. 6 KLD salts with moisture from

WTP/ZLD will send to TSDF for disposal

PHILLIPS CARBON BLACK LIMITED FORM-1 FOR PROPOSED EXPANSION OF CARBON BLACK MFG. PLANT

AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT FORM I


Figure 3-3: Existing Water Balance




Figure 3-4: Proposed Water Balance




Figure 3-5: After Proposed Expansion Water Balance





Figure 3-6: Agreement for Water Supply with GWIL





Figure 3-7: CGWA Permission for Water Withdrawal





3.7.2 Power Requirement

During Operation Phase 10 MW will be sourced from Captive Co-generation power plant. PGVCL Power will be used during

start up and shut down.

Table 3-4: Fuel Consumption

S.

No. Stack Attached to Capacity No. of working hrs Type of Fuel used

Fuel consumption

in Lit/day

Existing

1 Process Plant - Flare

Stack

65000 NM3/hr of

Tail Gas

Intermittent i.e. during

startup / shut down /

break down

Tail Gas from Carbon

Black Process Plant -


Stack

123000 NM3/hr

of Tail Gas



break down



3 CPP 16 MW–Boiler

Chimney

To handle 16

MW boiler flue

gas

Continuous except during


break down

Tail Gas: During

Normal Operation

64760 NM3/hr of Tail

Gas

4 CPP 8 MW–Boiler

Chimney

To handle 8 MW

boiler flue gas



break down

Tail Gas: During

Normal Operation


Gas

5 CPP 8 MW–Boiler

Chimney

To handle 8 MW

boiler flue gas



break down

Tail Gas: During

Normal Operation


Gas

6 DG Set 1250 kVA In case of power failure HSD 6 KL/ Month

Proposed


Stack

123000 NM3/hr

of Tail Gas



break down



2 CPP 12 MW–Boiler

Chimney

To handle 12

MW boiler flue

gas



break down

Tail Gas: During

Normal Operation


Gas

3 CPP 9 MW–Boiler

Chimney

To handle 9 MW

boiler flue gas



break down

Tail Gas: During

Normal Operation


Gas

4 CPP 9 MW–Boiler

Chimney

To handle 9 MW

boiler flue gas



break down

Tail Gas: During

Normal Operation


Gas

5 DG Set 1250 kVA In case of power failure HSD 6 KL/ Month

3.8 Quantity of waste to be generated (liquid and solid) and scheme for their management

/disposal

The generation of pollutants associated with the proposed expansion will be in the form of Gaseous emissions, Liquid

effluent, Solid waste, and Hazardous waste.





3.8.1 Gaseous Emission

The expansion unit will have following sources of emission namely,

Process emission from VBC and dryers.

Flue gas emission from stack attached to CPP Boilers (3 Nos. Existing and 3 Nos. Proposed) and Flare Stacks (2 Nos.

Existing and 1 No. Proposed)

The emission from stacks will be well within the stipulated norms.

3.8.2 Solid / Hazardous Waste

Hazardous Solid wastes generated will be maintained as per Hazardous Waste (Management, Handling and

Transboundary Movement) Rules, 2016 and will be disposed off as per the details given in Table 3-5. Solid wastes details

are provided in Table 3-6.

Table 3-5: Hazardous Waste Generation and disposal Details

S.

No.

Type of

Waste

Hazardous

Waste Category

as per HWMR

2016

Quantity (MT/ Year)

Source Method of

Collection

Treatment /

Disposal Existing Proposed Total

1 Used Oil 5.1 2.2 2.082 4.282 Equipment

Lubrications

Manually in

cans from

equipments

Collection, Storage,

Transportation,

reuse in process/

sent to GPCB

registered recycler

2 Spent Acid

from Batteries - 0.024 0 0.024

From

Batteries Manual


Transportation,

Disposal by

Authorized way

3

Chemical

Sludge from

Waste water

Treatment

35.3 1735 1710 3445 ETP

Packed in

Plastic

Bags


Transportation,

Disposal at TSDF

site of SEPPL.

4 Oily Sludge

Emulsion 4.1 15 14 29

Strainers

Cleaning

Manually in

cans


Transportation,

Disposal at

Common

Incineration site of

SEPPL – Bhachau

5 Used Batteries IV-17 0.1 0.1 0.2 UPS / Fork

Lifts Manual


Transportation, and

Disposal as per lead

batteries rules.

6

Discarded

Drum / Barrels/

Containers /

Bags/ Liners/

Bag filter

33.1 20 19.4 39.4

Lubricating

Oil Drums /

Chemicals /

Packing

Bags

/Wagon

Liners

Manual


Transportation,

sent to GPCB

Approved recycler

or Disposal by

incineration at

SEPPL – Bhachau





S.

No.

Type of

Waste

Hazardous

Waste Category

as per HWMR

2016

Quantity (MT/ Year)

Source Method of

Collection

Treatment /

Disposal Existing Proposed Total

7

Spent Ion

Exchange Resin

Containing

Toxic Metal

35.2 1 0.2 1.2 DM Plant Manual


Transportation,

Disposal at TSDF

site of SEPPL.

8

Oily Cotton

Waste /Leather

Hand Gloves /

Cotton Hand

Gloves

33.2 3 3 6

Equipments

cleaning /

PPEs etc.

Manual


Transportation, and

Disposal by

incineration at

SEPPL – Bhachau

Table 3-6: Solid Wastes

S.

No. Type of Waste

Quantity (MT/ Year)

Source

Method

of

Collection

Treatment / Disposal


1 E-Waste 1 1 2

Replacement of

cards of control

instruments /

Used Computers

etc.

Manual


Transportation, sent to

GPCB Approved Recycler

2 Waste Insulation Material 15 14 29

Replacement of

insulation

materials for

maintenance of

pipe lines and

equipments

Manual


Transportation, and

Disposal by incineration

at SEPPL – Bhachau

3 Salt from Raw Water

Treatment Plant 1440 1440 2880

Raw Water

Treatment Plant

Packed in

Plastic

Bags from

Centrifuge


Transportation, Disposal

at TSDF site of SEPPL/

sell to authorized

vendor.

4 Plastic Waste 10 9 19 Wrappers of new

items procured Manual


Transportation, sent to

GPCB Approved recycler.

Willingness certificate for disposal of hazardous waste of Saurastra Enviro Projects Pvt. Ltd., is given as below;





Figure 3-8: Willingness Letter of SEPPL for Hazardous Waste Disposal

3.9 Schematic Representation of the Feasibility Drawing which give Information of EIA Purpose

A drawing (i.e. Site Layout Plan) explaining the salient project features with an index giving area break up is attached as

Figure 3-2.



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

By Road

The study area is well connected by adjacent road by Kandoria -Vadadla

The nearest Village from the current project site is: Mokha ~ 1.48 km.

The study area is well connected of NH-41 Highway at an aerial distance ~1.80 km in NW Direction.

By Rail

Bhadreshwar Railway station, located at an aerial distance of 5 Km in S.

Main Railway Gandhidham Junction, located at an aerial distance ~36.82 km in ENE.

By Air

Bhuj Airport, located at an aerial distance ~43.03 km in NNW direction.

By Water

Mundra port located at an aerial distance of 23.52 km in SW

Kandala port Located at an aerial distance of 40.44 Km in ENE

4.2 Land Form, Land Use and Land ownership

The total plot area of the proposed project will 2,91,456 m2. The land is already an industrial area.

4.3 Topography (along with map)

As per District Planning Map of Kutch,-Key Statistics of Kutch district (1991) by National Atlas and Thematic Mapping

Organization, the area has a distinguished rock formations made of Sandstone and Limestone with relief of 150 meters

(Elevation in meters) and Land slope of 20 to 83 meters per km. The area has fertile land with Red loamy soil type. The

hydrological character of the area shows suitable zone for shallow tube-well. The average rain fall received by the area

is within range of 300 to 400 mm (Source: NATMO). According to the present zoning map, Zone 5 expects the highest

level of seismicity. The project area falls in Zone V. This is referred very severe damage risk zone.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, etc. sensitive areas, water bodies (distance from the HFL of

the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be

given.

Existing Land use pattern: Industrial Area

Distance of Project site from Water Bodies are given in following table.





No Forest land is involved in the subject Project

No clearance under Forest, CRZ and agriculture and Non- agriculture and water bodies are required

Table 4-1: Distance of Project Site from Sensitive Areas

Area Distance in km Direction

Bhadreshwar Reserved Forest ~8.16 SE

Luni Reserved Forest ~7.37 S

Table 4-2: Distance of Project site from Water Bodies

Water Body Distance in km Direction

Mitti River ~0.77 ENE

Babia River ~3.74 NNW

Ruparel River ~7.44 NE

Bhukhi River ~9.79 W

Sakara River ~7.24 E

Wadala Pond ~2.95 ESE

Kandoria Pond ~4.80 NW

Bagda Pond ~6.93 NNW

Nr. Vovar Reservoir ~5.04 NE

Bhadreswar Pond ~7.67 ESE

Nr. Bharudia Reservoir ~8.16 ENE

Nr. Ratadia Reservoir ~8.37 WNW

Gulf Of Kuchh ~6.91 SSE

4.5 Existing Infrastructure

Not Applicable

4.6 Soil classification

Not done

4.7 Climatic data from secondary sources

The general agro-climatic zone of the study area is Semi-Arid. Regional meteorological data was collected from the

nearest Indian Meteorological Department (IMD) station located at New Kandal Port. The latest available chronological

data for 30 years (1981-2010) has been collected and analyzed to interpret the climatological conditions prevailing in the

region.

4.7.1 Temperature

Summer season comprises March, April and May months. Mean daily maximum temperature during season remain

between 37.8 to 40.1 °C, while mean daily minimum temperature remain between 17.0 to 24.0 °C. May is the hottest

month of the season with Maximum temperature 40.1°C. Temperature remains normal during monsoon and post

monsoon. It ranges Mean maximum between 31.4 to 38.8 °C and Mean minimum temperature between 12.1 to 25.4 °C.

Winter season comprises December, January and February months. January is generally the coldest month, with minimum





temperature recorded 11.2 °C. During the season mean maximum temperature remains between 30.2 to 33.4 °C and

Mean minimum temperatures remain between 11.2 to 13.1 °C.

4.7.2 Wind

Long- term wind direction data is presented in Error! Reference source not found.. During June to September that is

during the monsoon season wind blows mostly from southwest - West. During the period from October to February, both

the morning and evening winds are mostly from north to North east. During March to May wind mostly blows from SW-

W predominantly.

Table 4-3: Predominant Wind Direction

Month

Predominant Wind

First Second Third

Morning Evening Morning Evening Morning Evening

January N N NW NE NE SW/NW

February N N/SW NW S NE/W NE

March W SW NW S SW/N N

April SW SW W S NW W

May SW SW W W S S

June SW SW W W S S

July SW SW W W S S

August SW SW W W S S

September W SW SW W NW S

October N SW NW S W N

November N N NW NE NE NE

December N N NW NE NE NW

4.7.3 Rainfall

Average rainfall in the region is 407.4 mm. Distribution of rainfall by season is 1.6 mm in winter (December, January,

February), 4 mm in summer (March, April, May), 384.4 mm in monsoons (June, July, August, September) and 17.3 mm

in post-monsoons (October - November). Maximum rainfall in any one month was recorded in the month of July in year

1950 which was about 899.9 mm. July is having maximum number of rainy days i.e. 12.5.

4.7.4 Cloud Cover

The area remains cloudy between June - September, which is the active period of the monsoon season. During this time

all clouds cover is between 2.8 to 5.4 Oktas during day time and 1.9 to 4.5 Oktas during night time.

4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer in that order.

Mornings are more humid than evenings and humidity ranges from a high of 60 - 83% in monsoon mornings to a low of

40-76% in summer evenings. During post-monsoon season, in morning humidity remains between 41-70% and in the

evening it remains between 36-63%.





4.8 Social infrastructure available

Provision of additional social infrastructure such as schools, health centres, drinking water facilities etc. is not envisaged,

these facilities are adequately available in the Region. However, where feasible and required, such infrastructure will be

augmented.



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc.) Town and Country

Planning/Development authority Classification

The entire area is a notified industrial area

5.2 Population Projection

During the Construction and Execution phase of the Project, it is estimated that about 500 workers will be involved.

Thereafter during the operation phase ~350 Direct and ~300 Indirect in phases jobs will be generated.

5.3 Land Use planning (Break up along with green belt etc.)

The project facility is located at Survey No. 47, SH-46, Village Mokha, Talulka Mundra, District Kutch, State Gujarat. The

total plot area of the proposed unit is 2,92,456 m2. The Land use breakup at site is given in Table 5-1.

Table 5-1: Land Use Breakup at Site

S.

No. Title

Area, m2 % of total

Area Existing Proposed Total

1 Production 16,171 19,187 35,358 12.1

2 Storage - 0.0

a Product storage 10,875 14,000 24,875 8.5

b Raw Material 8,281 8,000 16,281 5.6

c Water 10,656 10,000 20,656 7.1

d Hazardous waste storage 25 25 50 0.0

3 Boiler 4,185 5,000 9,185 3.2

4 Utility 3,850 4,000 7,850 2.7

5 Electrical room 3,556 4,000 7,556 2.6

6 DG room 24 24 48 0.0

7 Security room 25 25 50 0.0

8 Cooling tower & Air Cooled Condenser 5,328 6,000 11,328 3.9

9 Office 336 100 436 0.1

10 Effluent Treatment Plant / Water Treatment Plant 4,794 5,000 9,794 3.4

11 Green belt area 1,19,219 -24,000 95,219 32.7

12 Total Road 21,000 15,000 36,000 12.4

13 Miscellaneous 5,770 11,000 16,770 5.8

Total 2,14,095 77,361 2,91,456 100



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PLANNING BRIEF


5.4 Assessment of Infrastructure Demand (Physical and Social)

The project facility is located at Survey No. 47, SH-46, Village Mokha, Talulka Mundra, District Kutch, State Gujarat.

Physical Demand:

Water: Water demand will be met through GWIL.

Electricity: The electricity will be sourced from Captive Co-Generation Power Plant. PGVCL Power will be used during


Machinery: Storage Tanks, Reactors, Bag Collectors, Fans & Blowers, Compressors, Pumps, Rotary Dryers, Pelletisers,

Material Handling Equipment, Silos, Packing Machines, Boilers, Turbo generators, Air Cooled Condensers, Cooling Towers,

Water Treatment Plant etc.

Materials and Others: The Raw Material supply will be met by local and other markets. Other general utilities facilities

are available in the area.

5.5 Amenities / Facilities

Following facilities will be made available at site:

First Aid Facility

Hygienic Drinking Water Facility

Green Area

Regular Worker Medical Checkup Facility



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The project facility is located at survey No. 47, SH-46, Village Mokha, Talulka Mundra, District Kutch, State Gujarat. The

total plot area of the proposed unit is 2,92,456 m2. Appropriate infrastructures are already in place including approach

roads, drainages etc.

6.2 Residential Area (non-processing area)

No residential facility will be provided.

6.3 Green belt

Around 32.67% of total plot area is developed as greenbelt.

6.4 Social Infrastructure

Canteen, Rest shelter / room, Recreation Room shall be provided.

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)

Already covered in Section 4.1.

6.6 Drinking water management (source & supply of water)

Water requirement will meet through the GWIL Water Supply.

6.7 Sewage system

Sewage water is treated in the STP. After proposed expansion 42 KLD will be discharged to soak pit and rest 55 KLD will

used for gardening.

6.8 Industrial waste management

Industrial wastewater will be used as make-up water and used for gardening after treatment.

6.9 Power requirement & supply/ source

During Operation Phase 10 MW will be sourced from Captive Co-generation power plant. PGVCL Power will be used during




MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT

REHABILITATION AND RESETTLEMENTS (R&R) PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given)

Not applicable as rehabilitation and resettlement will not be required.



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT PROJECT SCHEDULE AND COST ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule for the project

to be given)

Tentative schedule for start of construction – March 2020; Tentative schedule for completion (considering all 3 phases)

– March 2023.

8.2 Estimated project cost along with analysis in terms of economic viability of the project.

Capital cost of the project is INR 710 Crore.



MFG. PLANT AT MUNDRA, DISTRICT KUTCH, STATE GUJARAT ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area

The project will improve the socio-economic status of the society in the region by generating direct and indirect

employment opportunities. The project will contribute additional revenue to the State & Central exchequers in the form

of taxes, cess etc.

The anticipated impacts of the project are explained below:

The project related construction activities will benefit the local populace in a number of ways such as supply of

construction laborers – skilled, semi-skilled and un-skilled, tertiary sector employment and provision of goods and

services for daily needs including transport.

The proposed project will provide employment to the skilled as well as un-skilled persons.

The local population will be given preference depending upon their suitability to the job requirement.

Besides direct employment, indirect employment opportunities will also open up.

Social investment in the form of CSR would help improve the healthcare, education, sanitation, infrastructure and

other areas wherein the project proponent would be actively involved as part of its CSR commitments.

CONTACT DETAILS

Vadodara (Head Office)

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

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

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Sohna Road, Gurgaon, India – 122 002

E: [email protected]; T/F : 0124-424 2430-436

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

Envi ronment for Deve lopment

phillips carbon black limited...phillips carbon black limited proposed expansion of carbon black...

Documents