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PRE FEASIBILITY REPORT

1

INTRODUCTION

1.1 Identification of Project

The project proponent M/s Balmer Lawrie & Co Ltd is engaged in the production of synthetic

organic chemicals at its SBU Leather Chemicals, for use in the leather processing industry. Their

existing production line includes 1) Synthetic Fat Liquors and 2) Synthetic Tanning Agents

(Syntans). The unit (SBU Leather Chemicals) has obtained prior Environmental Clearance

(Annexure I) from the Ministry of Environment & Forests for the existing production capacity.

The proponent has proposed to increase the production capacity of leather chemicals at their

factory located in Manali Industrial Area, Chennai. This proposal has been submitted for obtaining

Environmental Clearance for increasing the production capacity of the leather chemicals.

1.2 Identification of Project Proponent

Balmer Lawrie & Co Ltd, a Government of India Enterprises under the Ministry of Petroleum &

Natural gas has set up an Industrial complex presently comprising of units for manufacturing a)

Leather Chemicals b) Greases & Lubricants, c) Barrels. All the three Divisions are located side by

side, each one separated by a fence and registered as a separate Factory under Factories Act, 1948.

Founded by two Scotsmen, George Stephen Balmer and Alexander Lawrie, in Kolkata, Balmer

Lawrie & Co. Ltd. started its corporate journey as a Partnership Firm on 1st February 1867.

Traversing the 150 years gone by, today Balmer Lawrie is a Mini-Ratna I Public Sector Enterprise

under the Ministry of Petroleum and Natural Gas, Govt. of India, with a turnover of Rs. 2500

crores and a profit of Rs. 240 crores. Along with its six Joint Ventures in India and abroad, today

it is a much-respected transnational diversified conglomerate with presence in both manufacturing

and service sectors. Balmer Lawrie is a market leader in Steel Barrels, Industrial Greases &

Specialty Lubricants, Corporate Travel and Logistics Services. It also has significant presence in

most other businesses, it operates, viz, Leather Chemicals, Logistics Infrastructure etc. In its 150

years of existence, Balmer Lawrie has been successfully responding to the demands of an ever

changing environment, leveraging every change as an opportunity to innovate and emerge a leader

in industry.


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1.3 Brief Description of Nature of the Project

The unit currently manufactures two products namely

1) Synthetic Tanning Agents (Syntans) - 420 MTPM

2) Synthetic Fat Liquors (SFL) - 480 MTPM

The proponent has planned to increase the total quantity of leather chemicals manufactured at the

factory to the following quantities

1) Synthetic Tanning Agents (Syntans) - 480 MTPM

2) Synthetic Fat Liquors (SFL) - 850 MTPM

3) Construction Chemicals - 100 MTPM

4) Beam House Chemicals – 100 MTPM

5) Finishing Chemicals - 250 MTPM

6) Agro and other intermediates – 300 MTPM

By products:

1) Hydrochloric Acid - 300 MTPM

2) Mixed Salts - 98 MTPM

The proposed expansion in leather chemical production will fall under Schedule 5 (f) of the

Notification. The existing facility is located in Manali Industrial Area, Chennai which is

categorized as Critically Polluted Area (CPA) & it comes under Category ‘A’ as per

Environmental Impact Assessment (EIA) Notification 2006 and its amendments. The expansion

activity requires prior Environmental Clearance from the MoEF/CC.

1.4 Need for the Project

The Leather Industry holds a prominent place in the Indian economy. This sector is known for its

consistency in high export earnings and it is among the top ten foreign exchange earners for the

country. With an annual turnover of over US$ 7.5 billion, the export of leather and leather products

increased manifold over the past decades and touched US$ 4.86 billion in 2011-12, recording a

cumulative annual growth rate of about 8.22% (5 years).

The Government of India had identified the Leather Sector as a Focus Sector in its Foreign Trade

Policy 2004-09 in view of its immense potential for export growth prospects and employment

generation. Accordingly, the Government is also implementing various Special Focus Initiatives


3

under the Foreign Trade Policy for the growth of leather sector. With the implementation of various

industrial developmental programmes as well as export promotional activities; and keeping in view

the past performance, and industry’s inherent strengths of skilled manpower, innovative

technology, increasing industry compliance to international environmental standards, and

dedicated support of the allied industries, the Indian leather industry aims to augment the

production, thereby enhance export, and resultantly create additional employment opportunities

for overall one million people. It is an indigenous industry in which the country is well endowed

with an affluence of raw materials, skilled manpower, innovative technology, increasing industry

compliance to international environment standards and the dedicated support of the allied

industries. Presence of support industries like leather chemicals and finishing auxiliaries will aid

in the continued success of the leather industry and contribute towards the growth rate of the leather

industry in India.

We are planning to expand our business in to other areas of specialty chemicals mainly to

construction chemicals and agro & other intermediates also. The snapshot citing the growth rate

of these two industries are given below

Construction Chemicals

Construction chemicals account for a 2% –5% increase in the total construction expenses;

however, they enhance the strength of buildings by enhancing the overall life of the structure and

thus the maintenance costs. This industry has demonstrated a significant market growth with

intense competition among construction chemical companies in the past 5 years with novel

chemicals having properties that protect and enhance the quality of a structure. Over the following

5 years, the predicted growth rate for the Indian construction chemical industry is 15% p.a. Indian

construction chemicals industry is expected to double to Rs 7,000 crore by 2019-20 on the back of

demand from smart cities, said a report. The industry was valued at Rs 3,500 crore in 2014-15.

Indian Agro chemicals market

Agrochemicals can play a major role in enhancing productivity and crop protection post-harvest.

They are diluted in recommended doses and applied on seeds, soil, irrigation water and crops with

surfactants to prevent damage from pests, weeds and diseases. Insecticides are the largest sub-


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segment of agrochemicals with 60% market share, whereas herbicides with16% market share are

the fastest growing segment in India.

India is the fourth largest global producer of agrochemicals after the US, Japan and China. This

segment generated a value of USD 4.4 billion in FY15 and is expected to grow at 7.5% per annum

to reach USD 6.3 billion by FY20. Approximately 50% of the demand comes from domestic

consumers while the rest goes towards exports. While the domestic demand is expected to grow at

6.5% per annum, exports are estimated to grow at 9% per annum during the same period.


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SITE ANALYSIS 2. 1 Location

M/s Balmer Lawrie & Co Ltd commenced production in the factory in 1985. Satellite image showing

the project site is given in Figure 2.1. The location of project site is represented in the Figure 2.2.

Figure 2.1 Satellite image of project site


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Figure 2.2 Location map of project site


7

2.2 Connectivity

The site has excellent connectivity through road & railways. Tiruvottiyur railway station is the

nearest Railway Station, which is 2.5km [ENE] away from project site. Metropolitan Transport

Corporation (MTC) runs passenger buses to Manali from other major parts of the Chennai city.

Figure 2.3 Connectivity map of project site

2.3 Land Use & Land Use Breakup

Existing landuse of the project site is “Industrial Use Zone”. The total plot area of the existing

facility is 44000 sq.m. The topo & land use maps of the project site and its surrounding area

covering 10 km radius are given in Figures 2.3 & 2.4. Environmental settings are presented in

Table 2.1.


8

Figure 2.4 Topo map (5km & 10km surrounding project site)


9

\

Figure 2.5 Land use map (5km & 10km surrounding project site)


10

Table 2.1 Environmental Settings of Project Site

Sl. No. Particulars Details

1 Site Latitude 13° 9'16.55"N

2 Site Longitude 80°16'24.05"E

3 Site Elevation above MSL 5m

4 Nearest highway

SH 56 – 50m (E)

SH 1A – 2.7km (W)

SH 111 – 4.5km (W)

NH 5 – 6.6km (W)

5 Nearest railway station Tiruvottiyur Railway Station – 2.5km (ENE)

6 Nearest airport Chennai International Airport – 20km (SSW)

7 Nearest town/ city Tiruvottiyur – 2.5km (E)

8 Topography Plain

9 Archaeologically important places Fort St. George – 8.3km (SSE)

10 National parks/ Wildlife Sanctuaries Nil in 15km radius

11 Reservoir

Puzhal lake – 8.3km (W)

Korattur lake – 8.9km (SW)

Cholavaram lake – 14.7km (NW)

12 Reserved/ Protected Forests Nil in 10km radius

13 Seismicity Zone III

14 Defense Installations Nil in 15km radius

15 Nearest Port Chennai Port – 7.3km (SSE)

2.4 Site Suitability / Alternate Sites Considered

The proposed expansion in leather chemical production will take place within the existing

facility owned & operated by M/s Balmer Lawrie & Co Ltd. This site has the following

advantages:

As the factory is currently in operation all infrastructural facilities are already in place.

It is only expansion of existing operation.

There is no adverse sitting factor such as reclassification of land use and pattern, R & R as

the facility is located within Manali Industrial Area.

Hence, no alternative sites were considered.


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2.5 Brief Profile of Thiruvallur District

A. Climate

The district enjoys tropical climate.

B. Temperature

The annual mean minimum and maximum temperature are 24.3 ° and 32.9°C respectively. The

day time heat is oppressive and the temperature is as high as 41.2°C. The lowest temperature

recorded is of the order of 18.1°C.

C. Rainfall

The district receives the rain under the influence of both southwest and northeast monsoons.

Most of the precipitation occurs in the form of cyclonic storms caused due to the depressions

in Bay of Bengal chiefly during Northeast monsoon period. The southwest monsoon rainfall is

highly erratic and summer rains are negligible. The average normal rainfall of the District is

1104 mm. Out of which 52% has been received during North East Monsoon period and 41%

has been received during South West Monsoon period. Rainfall data analysis shows that the

normal annual Rainfall varies from 950mm to 1150mm.

D. Relative Humidity

The period from April to June is generally hot and dry. The weather is pleasant during the

period from November to January. Usually mornings are more humid than afternoons. The

relative humidity varies between 65 and 85% in the mornings while in the afternoon it varies

between 40 and 70%.

E. Geology

The prominent geomorphic units identified in the district through interpretation of Satellite

imagery are 1) Alluvial Plain, 2) Old River Courses 3) Coastal plains 4) Shallow & deep buried

Pediments, 5) Pediments and 6) Structural Hills. The elevation of the area ranges from 183 m

amsl in the west to sea level in the east. Four cycles of erosion gave rise to a complex

assemblage of fluvial, estuarine and marine deposits. The major part of the area is characterised

by an undulating topography with innumerable depressions which are used as irrigation tanks.

The coastal tract is marked by three beach terraces with broad inter-terrace depressions. The

coastal plains display a fairly lower level or gently rolling surface and only slightly elevated

above the local water surfaces or rivers. The straight trend of the coastal tract is resultant of

development of vast alluvial plains. There are a number of dunes in the coastal tract.


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F. Soil

Soils in the area have been classified into i) Red soil ii) Black soil iii) Alluvial soil iv) colluvial

soil. The major part is covered by Red soil of red sandy/clay loam type. Ferruginous red soils

are also seen at places. Black soils are deep to very deep and generally occur in the depressions

adjacent to hilly areas, in the western part. Alluvial soils occur along the river courses and

eastern part of the coastal areas. Sandy coastal alluvium (arenaceous soil) are seen all along the

sea coast as a narrow belt.

G. Infrastructure

Manali Industrial Area, Chennai

Chennai Petroleum Corporation Limited (CPCL) (formerly MRL) is the largest company in

Manali. Started in 1969, CPCL's Manali Refinery now has a capacity of 9.5 MMTPA and is

one of the most complex refineries in India with Fuel, Lube, Wax and Petrochemical feedstocks

production facilities. The main products of the company are LPG, Motor Spirit, Superior

Kerosene, Aviation Turbine Fuel, High Speed Diesel, Naphtha, Bitumen, Lube Base Stocks,

Paraffin Wax, Fuel Oil, Hexane and Petrochemical feed stocks

Other Industries located in Manali are given below:

Madras Fertilizers Limited (MFL)

Manali Petro Chemical Ltd(MPL)

Futura Polymers Ltd

Cetex Petro Chemicals Ltd

Tamilnadu Petroproducts Limited (TPL)

Sriram Fibres Ltd(SRF)

Madras Rubber Factory(MRF)

Kothari chemicals and pesticides

Infra tanks and polymers

The Hunstman Polyurethenes

ICI limited

SRF limited


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PROJECT DESCRIPTION

3.1 Magnitude of Operation

M/s. Balmer Lawrie & Co Ltd is currently manufacturing two varieties of leather chemicals at

the production rates detailed below,

1. Synthetic Tanning Agent (Syntans) – 480 MTPM

2. Synthetic Fat Liquors (SFL) – 850 MTPM

The unit has obtained Environmental Clearance from MoEF vide Lr.No.J.11011/33/96 –IA II

dated 14.03.1997 for manufacturing the above mentioned products & associated sub-products.

The proponent has planned to increase the production of the above products to the quantities

detailed below,

1. Synthetic Tanning Agent (Syntans) – 480 MTPM

2. Synthetic Fat Liquors (SFL) – 850 MTPM

3. Construction Chemicals – 100 MTPM

4. Beam House Chemicals – 100 MTPM

5. Finishing Chemicals – 250 MTPM

6. Agro and other intermediates – 300 MTPM

Individual production capacities of the products and associated sub-products for the existing

and proposed expansion have been detailed in Table 3.1.

Table 3.1 List of products & manufacturing capacities

Sl.No. Name of the product Quantity

(Existing)

Quantity

(Proposed) Unit End Use

Products

1 Synthetic Fat Liquor 480 850 MTPM Leather Industry

2 Synthetic Tanning Agent 420 480 MTPM Leather Industry

3 Construction Chemicals - 100 MTPM

Building &

construction

industry

4 Finishing Chemical - 250 MTPM Leather Industry

5 Beam House Chemical - 100 MTPM Leather Industry

6 Agro and other intermediates - 300 MTPM Agro Industry

By Products

1 Hydrochloric acid 300 MTPM Will be sold to

authorized dealers


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2 Mixed Salt 98 MTPM

Partially will be

reused & the rest

will be sold to

authorized dealers

3.2 Raw Materials Required for Production

Table 3.2 List of Raw Materials for Synthetic Fat Liquor

Sl. No.

Name of the Raw

Material

For Synthetic Fat Liquor

Existing Proposed

Addition Final

Quantity (TPA)

1 Heavy Normal Paraffin 240 -- --

2 Paraffin Wax 1200 1088 2288

3 Chlorine 1020 839 1859

4 Sulphur-Di-Oxide 420 367 787

5 Ammonia 120 95 215

6 Caustic Lye (100% Conc.) 180 263 443

7 Chlorinated Paraffin 720 -- --

8 Additives 360 1588 1948

Total 4260 4240 7540

Table 3.3 List of Raw Materials for Synthetic Tanning Agent

Sl. No.

Name of the Raw

Material

For Synthetic Tanning

Agent

Existing Proposed

Addition Final

Quantity (TPA)

1 Aluminium sulphate 1186 0 1186

2 Basic Chromium Sulphate 657 0 657

3 Sulphuric Acid 2300 0 2300

4 Pthalic Anhydride 73 0 73

5 Naphthalene 1278 0 1278

6 Phenol 456 0 456

7 Urea 274 0 274

8 Lixin 730 0 730

9 Sodium Carbonate 1825 0 1825

10 Sodium Sulphite 44 0 44

11 Formaldehyde 365 0 365

12 Formic Acid 73 0 73


15

13 Melamine 0 30 30

14 China Clay 0 120 120

15 Acrylic monomers 0 220 220

Total 9261 370 9631

Table 3.4: List of raw materials for Finishing, Construction chemicals, Agro and other

intermediates

Sl. No.

Name of the Raw

Material

For Finishing Chemicals

Existing Proposed

Addition Final

Quantity (TPA)

1. Acrylate monomers 0 70 70

2. Caprolactam 0 10 10

3. Caesin 0 5 5

4. Additives 0 10 10

Total 0 95 95

Sl. No.

Name of the Raw

Material

For Beam House

Existing Proposed

Addition Final

Quantity (TPA)

5. Magnesium oxide 0 25 25

6. Magnesium silicate 0 15 15

7. Fatty alcohol ethoxylate

with different EO contents 0 40 40

Total 0 80 80

Sl. No.

Name of the Raw

Material

For Agro& other

intermediates

Existing Proposed

Addition Final

Quantity (TPA)

8. Emusifiers like different

fatty alcohol ethoxylates 0 100 100

9. Potassium per sulphate 0 10 10

10. Branched C10 ethoxylates 0 75 75

11. Phosphorous pentoxide 0 5 5

12. Sodium bisulphite 0 10 10

13. Maleic anhydride 0 5 5


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14. Lauryl alcohol 0 10 10

15. Castor oil 0 20 20

Total 0 235 235

Sl. No.

Name of the Raw

Material

For Construction

Chemicals

Existing Proposed

Addition Final

Quantity (TPA)

16. Allyl ether polyethylene

glycol 0 7 7

17. Methoxy polyethylene

glycol 0 3 3

18. Formaldehyde 0 8 8

19. Naphthalene 0 8 8

20. Sulphuric acid 0 3 3

21. Sodium hydroxide 0 16 16

22. Acrylic acid 0 3 3

23. Methacrylic acid 0 3 3

24. Sodium ligno sulphate 0 3 3

Total 0 54 54

3.3 Manufacturing Process

3.3.1 Synthetic Fat Liquors

Two main reactions are involved in the manufacturing of fatliquors

a. Sulphochlorination process

b. Sulphitaion of vegetable oils

Sulphochlorination process results in 92 % of synthetic fatliquor products (SFL).

a) Sulphochlorination process:

This process involves conversion of paraffin wax/wax substitutes into intermediary products

through photo-sulpho-chlorination and subsequent blending to obtain various finished products

of differing properties. The process starts with addition of paraffin wax into primary reactor

and melted. It is sulpho-chlorinated in a photo reactor.


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Scrubbing of unreacted gases

HCl gas is released on reaction. Unreacted Cl2, SO2 along with HCl are contacted with water

in an HCl absorber. The unabsorbed gases are further scrubbed in caustic soda/soda ash

solution to form sodium sulphate. The scrubbed liquor (pH of 7 to 7.5) is sent to MEE & ATFD.

The sulphonyl chlorides from primary reactor treated with ammonia, ethanol-amines, caustic

soda/potash etc., depending on various intermediate products and sent to settlers. The brine

layers after separation are sent to MEE & ATFD and the resultant products free from inorganic

salt, are sent to intermediate storage tanks. These are blended with various bought out products

such as vegetable, mineral and marine oils, and non-ionic emulsifiers etc., to produce various

types of Synthetic Fat Liquors. The % of main product, neutralized paraffin sulfonyl chloride,

by products namely hydrochloric acid, sodium sulphate and ammonium chloride are given in

the Table below. The mixture of inorganic salts include sodium sulphite /sulphate, sodium

chloride and ammonium chloride.

Table 3.5: Products and by products in sulphochloribation process

Products and by products in sulphochlorination Percentage

Neutralized parrafin sulfonyl chloride 68

HCl gas (By product) 14.7

Off gases scrubbed as Inorganic salts and sent to ZLD

Inorganic salts (Sodium sulphite , sulphate & ammonium

chloride) 7.6

Water 9.7

Total 100.0

Sulphochlorination reaction

RH + SO2 + Cl2 RSO2Cl + RCl

UV/Visible Cl2 2 Cl Initiation

RH + Cl R + HCL

R + SO2 RSO2

RSO 2 + Cl2 RSO2CL + Cl

R + Cl2 RCL + Cl

R (H;Cl ) + R (H;Cl ) stable compound termination


18

Reactions in scrubber

Figure 3.1 Process Flow for Manufacturing Operations – Sulphochlorination

HCl (g) H

2

O(l) HCl (l)

SO2 + 2NaOH Na2SO3

Cl2 + Na2SO3 + 2NaOH Na2SO4 + H2O


19

Table 3.6 Mass balance in sulphochlorination process for one batch of 4400 Kg input

Product

Raw material

quantity in Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material

loss

through

scrubber

(kg/Batch)

Material

loss

through

vessel

washing

(kg/month)

For

reaction Scrubbing Products

By

products

Neutralized

paraffin

sulfonyl

chloride

4400 1375 3000

(68.2%)

650

(14.7%) 0

750 (SO2,

NH4Cl &

water)

(17.0%)

0

b) Sulphitation of vegetable oils:

The process involves two stages namely:

1. Oxidation

2. Sulphitation

Different vegetable oils like palm, ground nut oils are oxidized with air and peroxides

as catalyst. The oxidized oil is then reacted with bi sulphite solution to form sulphited /

sulphonated oils. These sulphonated oils are used as fatliquuroing agents. The reaction

scheme is given below.

Sulphitaion of oils

Different fatty acids ranging 12 to 20 Carbon atoms are present. Majorly sulphitaion

happens at 18:2 and 18:3 fatty acids

--CH = CH-CH2-CH=CH-+O2+ NaHSO3 -CH2-CH-CH2-CH=CH-

SO3Na


20

Figure 3.2 Process Flow for Manufacturing Operations – Sulphitaion vegetable oils

Table 3.7 Mass balance in sulphitation process for one batch of 2500 Kgs input

Product

Raw material

quantity in

Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material

loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month) 2500

Products By

products

Sulphited

vegetable oil

2085

(83.4) -- --

415 – water

(16.6%) --

Mass Balance for Synthetic Fat Liquor (SFL)

The Synthetic fat liquors are made blending the intermediates from the above two

reactions with suitable additives.

3.3.2 Synthetic Tanning Agents (SYNTANS)

These are produced in solid or liquid forms. In each type there are several grades.

a) Phenol formaldehyde Syntan

The solid Syntan process involves reacting Naphthalene / Phenol with Sulphuric acid at 100-140

Deg C. The sulphonic acids obtained are condensed with Formaldehyde/Urea straight away,

complexed with metal salts such as Basic Chromium Sulphate / Aluminum Sulphate, Melamine

etc and then neutralized. The neutralized mass is spray dried to obtain product and bagged.

Oxidation of vegetable

Oil/ Palm Oil/

Groundnut Oil/ other

Oil

Sulphitation of Oils with

bisulphite

Product


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Reactions of Phenol formaldehyde Syntan

Figure 3.3 Process Flow for Manufacturing Operation – Synthetic Tanning Agents

(Syntans)

OH OH OH

H2SO4 NaOH

SO3Na

SO3Na

NH2-CO-NH2

n HCHO OH OH

n

SO3Na

CH2-NH-CO-NH-H2-C CH2

SO3Na


22

Table 3.8- Mass balance in Phenol formaldehyde condensate intermediate for one batch

of 10000 Kgs input

Product

Raw

material

quantity in

Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month)

10000

Products By

products

Phenol

formaldehyde

condensate –

intermediate

9800

(98) 0 0

200 –

formaldehyde

(2%)

0

b) Liquid Acrylic Syntans

The liquid Syntan involves solution polymerization of the acrylic acid, methacrylic acid,

gluteraldehyde, etc. These are polymerized in liquid form.

Reaction of acrylics:

Table 3.9- Mass balance in acrylic Syntan for one batch of 3000 Kgs input

Product

Raw material

quantity in Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material

loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month) 3000

Products By

products

Acrylic syntan 2940

(98%) 0 0

60 –

monomer

(2%)

0

3.3.3 Construction Chemicals

The Construction chemicals manufacturing activities will be carried out in the existing

production facility of Synthetic Tanning Agents.

m n m CH2 = CH + n CH2 = CH-C-NH2 CH2-CH CH2-CH

= O COOH COOH CONH2


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In this process, naphthalene is melted and sulphonated with concentrated sulphuric acid to give

2 – naphthalene sulphonic acid. It is then reacted with formaldehyde to undergo condensation

reactions to from naphthalene formaldehyde condensate.

Figure 3.4 Process Flow for Manufacturing Operation of super plasticizer –

Naphthalene formaldehyde condensate

Table 3.10- Mass balance in Naphthalene formaldehyde condensate intermediate for

one batch of 10000 Kgs input

Product

Raw material

quantity in Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month)

10000

Products By

products

Naphthalene

formaldehyde

condensate –

intermediate

9800

(98) 0 0

200 –

formaldehyde

(2%)

0

3.3.4 FINISHING CHEMICALS

Copolymerization of different acrylic monomers with various glass transition temperatures are

prepared by emulsion polymerization of their monomers. These polymers are used as binders, as

part of finishing of leathers.

Melter for molten Naphthalene

Reactor – 1 Sulphonation of naphthalene

Neutralization tank

Reactor – 2 Formaldehyde condensation

Scrubber

Holding Tank

Alkali

Recycle for

process


24

Polymerization of ethyl acrylate

Figure 3.5 Process Flow for Manufacturing Operation of Acrylic binders in finishing

chemicals

Table 3.11- Mass balance in acrylic binders for one batch of 2000 Kgs input

Product

Raw material

quantity in Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material

loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month) 2000

Products By

products

Acrylic binders 1960

(98%) 0 0

40 –

monomer

(2%)

0

3.3.5 AGRO AND OTHER INTERMEDIATES

Process for making lauryl ethoxylate phosphate, sulfosuccinate – wetting agent /dispersing

agent

m m CH2 = CH CH2-CH

COOC2H5 COOC2H5

Initiator Tank

Pre-emulsion tank with

Monomers

Reactor Polymerization

Scrubber

Alkali

Recycle for

process

Filtration

Packing


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+ R-OH Mono ester sulfosuccinate

o

R

o

oH

o

o

R SO3 Na

o

oH

o

o

o

o

SBS / SMBS aqueous sol.

H

O

Nu : S

O

O

This process involves phosphation of ethoxylate to form preferably high yields of

monophosphate. For sulfouccinate an ester is prepared by reacting fatty alcohol ethoxylates

with maleic anhydride and then sulphonated. These anionic surfactants are good wetting and

dispersing agents used in agro and other formulations

Phosphation

Sulphosuccinate

Figure 3.6 Process Flow for Manufacturing Operation of phosphate surfactant used as

wetting agent in Agro formulations

4ROH + P4O10 + 2H2 4 RO-P-OH

= O

OH

Scrubber

Alkali

Phosphating agent

through screw feeder

Reactor Phosphation of fatty alcohol, fatty alcohol

ethoxylates

Holding tank

Recycle for

process


26

Table 3.12- Mass balance in agro intermediates for one batch of 6000 Kgs input

Product

Raw

material

quantity in

Kgs

Product quantity in

Kgs Material

loss

(Kg/Kg

Product)

Material

loss

through

scrubber

(kg/batch)

Material

loss

through

vessel

washing

(kg/month) 6000

Products By

products

Acrylic syntan 5880

(98%) 0 0

120 – water

(2%) 0

3.4 Infrastructure Requirements

3.4.1 Land Use Breakup

The existing land use breakup of the site is given below,

Table 3.13 Land use breakup

Sl. No Landuse parameter Existing Area

(sq.m)

Proposed Area

(sq.m)

Final Area

(sq.m)

1 Plant and R&D area 4300 - 4300 *

2 Storage area 40 - 2424 *

3 Greenbelt 10000 - 10000

4 Open area 26200 - 23816

5 Road area 8000 - 8000

Total plot area 48540 - 48540

* Shown pertaining to SBU: Leather Chemicals Unit.


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Figure 3.7 Site layout


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3.4.2 Equipments

The utility requirements for the above manufacturing process is given as follows,

Table 3.14 List of Equipments (Synthetic Fat Liquors unit)

S.No Name of the

Equipment

Capacity

(existing) Nos. (existing)

Capacity

(proposed) Nos. (proposed)

Total

Nos.

For Synthetic Fat Liquors (SFL)

1. MSGL Reactor 3 kl 4 3 kl 2 6

2. MSGL Reactor 4 kl 3 4 kl 1 4

3. SS Reactor - 0 10 kl 1 1

4. SS Reactor 4 kl 1 5 kl 1 2

5. Blender 10 kl 1 10 kl 1 2

6. Blender 5 kl 1 6 kl 1 2

7. Settler 6 kl 5 6 kl 2 7

Table 3.15 List of Equipments (Synthetic Tanning Agents unit)

S.No Name of the

Equipment

Capacity

(existing) Nos. (existing)

Capacity

(proposed)

Nos.

(proposed)

Total

Nos.

For Synthetic Tanning Agents (Syntans)

1. MSGL Reactor 10 kl 3 - 0 3



4. SS Reactor 2 kl 1 0 1

5. SS Reactor - 0 5 kl 1 1

6. Spray dryer 1500 Kg/hr 1 0 0 1

7. Ribbon blender 2000 litrs 1 6000 litrs 1 2

8. Settler 15 kl 4 10 kl 1 5

Table 3.16 List of Equipment’s (Ancillary)

S.No Name of the

Equipment

Capacity

(existing)

Nos.

(existing)

Capacity

(proposed)

Nos.

(proposed)

Total

Nos.

1 Wax Melter - SFL 5 kl 3 3 kl 1 4

2 SO2 – Evaporator - SFL 200 kg/hr 4 200 kg/hr 2 6

3 Chlorine evaporator - SFL 300 kg/hr 4 300 kg/hr 2 6

4 Emergency Scrubber -SFL 3000 CFM 1 - 0 1

5 HCL – Absorption column

- SFL 4 3 7

6 Scrubber -SFL - 2 - 2 4


29

Homogeniser- SFL 250 1 250 1 2

Scrubber - SYNTAN - 1 - 1 2

7 DG Set- Common 1000 KVA 1 - 0 1

8 DG Set-Common 500 KVA 1 - 0 1

Compressor- Common 100 CFM 2 50 CFM 1 3

9 Cooling Tower- common 100 cu.m 1 125 cu.m 1 2

10 Boilers- common 850 kg/hr. 3 850 kg/hr. 1 4

3.4.3 Reactor vessel Specifications

Table 3.17 Reactor vessel specifications

S.

No.

Synthesis

Unit

Vessel

parameters Values Units

1. Synthetic

tanning

agents

Material of

construction

Mild steel glass lined Stainless steel

Exi-3 Nos

Pro-0 Nos

Exi-1Nos

Pro-0Nos

Exi-1 Nos

Pro-0 Nos

Exi-1 Nos

Pro-0 Nos

Exi-0 Nos

Pro-1 Nos -

Volume 10 5 3 2 5 - kl

Operating

pressure ATM ATM ATM ATM ATM - Kg/cm2

Type (shell +

jacket)

Limpet

Coil

+Jacket

Limpet

coil Jacket

Limpet

coil

Limpet

coil - -

Stirrer type +

rpm

Anchor

60 RPM

Anchor

60RPM

Impeller

100 RPM

Anchor

100 RPM

Anchor

100 RPM - rpm

Operating

temperature

(range)

70- 165 70 – 165 70 – 165 70 – 110 70 – 110 - o C

2. Synthetic

fat liquors Material of

construction

Mild steel glass lined Stainless steel

Exi - 4 Nos

Pro - 2 Nos

Exi - 3 Nos

Pro - 1 Nos

Exi - 0 Nos

Pro - 1 Nos

Exi - 1 Nos

Pro -0 Nos

Exi-0 Nos

Pro-1 Nos

Volume 3 4 10 4 5 kl

Operating

pressure ATM ATM ATM ATM ATM Kg/cm2

Type (shell +

jacket) shell + jacket

shell +

jacket

Limpet

coil

Limpet

coil Limpet coil -

Stirrer type Impeller Impeller

Gas

dispersion

–two stage

Turbine Anchor rpm

Operating

temperature 60 - 100 60 - 100 60 - 120 60- 120 60 -120 o C


30

3. Construction

chemicals

Material of construction

Construction

chemicals will be

manufactured in the

reactors used for

manufacturing

Syntans

Volume

Operating pressure

Type (shell + jacket)

Stirrer type

Operating temperature

4. Finishing

Chemicals

Material of construction SS

Volume 2 KL

Operating pressure ATM

Type (shell + jacket) Jacket

Stirrer type Propeller

Operating temperature 90 Deg

5. Beam house

Chemicals

Material of construction

Syntan Plant

Equipments will be

used for

manufacturing of

Beam House

Chemicals

Volume

Operating pressure

Type (shell + jacket)

Stirrer type

Operating temperature

6. Agro Chemicals Material of construction Glass lined reactor

Volume 10 KL

Operating pressure ATM

Type (shell + jacket) Jacket

Stirrer type Anchor

Operating temperature 90 Deg

3.4.4 Scrubbing System Specifications

Table 3.18 Scrubber specifications (Existing & Proposed)

S.

No. Synthesis Unit Vessel Parameters Values Units

EXISTING PROPOSED

1. Synthetic fat liquors

Capacity 10 10 cu.m/hr

Scrubbing media NaOH NaOH

Concentration of scrubbing

media 12 12 %

Type Packed

tower

Packed

tower

Stack height 12 12 m

2. Syntan Capacity 5 cu.m/hr


31

Scrubbing media NaOH


media 12 %

Type Packed tower

Stack height 18 m

3. Utility

(Emergency scrubber)

Capacity 12 cu.m/hr

Scrubbing media NaOH


media 12 %

Type Packed tower

Stack height 10 M

3.4.5 Boiler Specifications

Table 3.19 Boiler specifications (Existing & Proposed)

S.

No. Synthesis Unit Vessel Parameters Values Units

1. Utility

Capacity

850

Existing

3Nos.

850

Proposed

1 No.

kg/hr

Fuel used FO/LDO FO/LDO

Fuel consumption 35 35 kl/month

Height of stack 18 18 m

3.4.6 Manpower

The existing manpower available is 130 persons. Additionally appx 10% - 15% manpower is

required for the proposed expansion.

3.4.7 Power

The existing power requirement is 100000 units sourced through TANGEDCO. For the

expansion DG set of 500 KVA is proposed.

Table 3.20 Details of DG sets

SL.NO. Equipment Capacity (kVA)

1 DG Set - 1 No. (Existing) 1000

2 DG Set - 1 No. (Existing) 500


32

3.4.8 WATER

The source of water for the project is from CMWSSB. The existing requirement is 77 KLD &

additionally 54 KLD is required for proposed operations. Water balance table for the operation

of the existing & proposed plant are as follows.

Table 3.21 Water balance table

SL.NO. Requirement

Existing

requirement

(KLD)

Proposed

additional

requirement

(KLD)

Final

requirement

(KLD)

1 Domestic 15 26 41

2

Process Softener 1 1 2

Floor washing 2 1 3

TSC & QC 2 1 3

Spray drier 1 1 2

Spray drier

washing 1 8 9

Boiler 17 -2 15

Cooling tower 4 11 15

HCl column 6 6 12

Product 20 20 40

Scrubber

column 6 4 10

Salt separator 2 3 5

Total 77 80 157

Less: Recycled for process 0 -26 -26

Net water requirement 77 54 131


33

Figure 3.8 Water balance chart (existing)


34

Figure 3.9 Water balance chart (expansion)


35

3.4.9 POLLUTION CONTROL MEASURES

3.4.9.1 AIR (EMISSIONS)

For existing plant the following measures are taken up for control of gaseous emissions:

The existing emission sources i.e., Spray Dryer, Boiler, DG set, Gas Scrubber (Tonner Shed)

Syntan Scrubber, Reactor (SFL & SYNTAN) are designed with adequate stack heights and air

pollution control measures to meet the standards set by the TNPCB / CPCB.

Table 3.22 Details of air pollution control measures

S.No. Sources of Emission

APC

Measures

Provided

Stack Details

Dimension

( Dia in

mm)

Height from

GL (in Meter)

1 Reactors

(Synthetic Fat liquor plant)

Scrubber

stack 50 12

2 Reactors (Syntan plant) Scrubber

stack 200 18

3 Emergency scrubber

(Tonner shed)

Scrubber

stack 75 10

4 Boiler

850kg/hr Common

stack 450 18

850 kg.hr

5 DG 1000 KVA Stack 150 13

6 DG 500 KVA Stack 150 13

The proposed air emissions generated from the above process will be treated in the existing Air

Pollution Control (APCS) System. The adequacy of the existing APC is sufficient for the proposed

activities.

3.4.9.2 LIQUID (EFFLUENT)

The main sources of effluent is process softener water, Floor washings, TSC & QC, Spray Dryer

Scrubber, Spray Dryer washing, Boiler and cooling tower.


36

Table 3.23 Trade Effluent Generation Details

Sl. No. Source Quantity (KLD)

existing

Quantity (KLD)

proposed

1 Low TDS 25.0 15.0

2 High TDS 8.0 15.0

Total 33.0 30.0

Table 3.24 Trade Effluent Disposal Details

Sl. No. Description of Outlet Quantity (KLD) Disposal

1

From scrubber blowdown,

reactor washing, boiler

blowdown

30 Zero Liquid Discharge

(Evaporator cum ATFD)

3.4.9.3 MULTI EFFECT EVAPORATOR PLANT

Feed is received in a level controlled balance tank and passed backward through preheaters using

vapour from preceding effect as heating medium. Pre-heated feed is then fed to the 1st effect

calandria. It is uniformly distributed in the calandria top so that liquid falls inside the tube area in

the form of thin film. Dry saturated steam/vapour is supplied as heating medium in the jacket

which causes evaporation of water from feed liquid in the calandria. Vapors generated are

separated in 1st vapour separator and passed in to the jacket of 2nd calandria as heating medium.

Concentrated product from 1st effect is fed to calandria of 2nd effect. It then it passes through all

the effect to meet its final required concentration. Product with desired solid content from last

effect is taken out. Vapours from last effect are condensed in surface condenser. All the

evaporation effects operate under vacuum maintained by vacuum pump/system. The concentrated

product at the desired concentration is continuously taken out from the plant

To lower the steam utility consumption, TVR (Thermal Vapour Recompression) system is used.

Part of vapours from intermediate effect is thermally recompressed by motive steam and mix flow

is given in the jacket to 1st effect of evaporator.

Technical Specification for Evaporator

Equipment: Triple effect forced circulation evaporator with Thermal Vapour


37

Recompression (TVR) system.

Capacity: 833 - 1200 kg/h water evaporation [design capacity] 1042 kg/h water evaporation

[max as per material balance].

Operating Parameters

Figure 3.10 Material Balance Block Diagram

3.4.9.4 AGITATED THIN FILM DRYER

Concentrated product received from the evaporation plant is fed to the Agitated thin film dryer at

the dryer shell. Feed is uniformed distributed over the inner heated surface to form thin film of

product by the continuous agitator type scrapper blades specially designed for the requirement.

Steam is provided in the outer shell. Vapours generated are taken out by vacuum pump/ID fan.

Dried product comes down from the heat exchanger inner surface of shell. The dried product is at

8-10% moisture.

Feed rate

Feed Temperature

Initial Solids

Solids in Concentrate

Concentrate Output

Water Evaporation

1875 (Kg/h)

30 (˚C)

20-25(1 to 1.1)45 (%)

(W/W) 833-1042 (%)

1200 (kg/h)

1042 (kg/h)

Condenser Steam Condensate = 670 kg/h

Dry Saturate Stream at 7 Bar-g

Pressure = 670 kg/h

In baggable form 403 – 504 kg/h at 6 – 8% Moisture

Vertical Thin Film Dryer

833 – 1042 kg/h Concentrate at 45% TS

Water Evaporation 833 -1042 kg/h

Triple Effect Forced Circulation Evaporation with

Thermal Vapour recompression (TVR) System Dry Saturate Stream at 8 Bar-g

Pressure = 265 kg/h

Water Evaporation 430 - 650 kg/h

Total Condensate

Condenser

Total Condensate


38

Technical Specification for Dryer

Equipment : Vertical Thin Film Dryer

Capacity : 430 - 650 kg/h water evaporation [design capacity] 403 - 504 kg/h

water evaporation [max as per material balance].

Operating Parameters

Feed rate

Initial TS

Final Moisture

Water Evaporation

Dried (baggable) Solids Output

833 – 1042 kg/h

45 (%)

6 – 8 (%)

430 – 538 kg/h

430 – 650 kg/h

Figure 3.11 Zero Liquid Discharge Flow Diagram

Balance Tank

100 KL Tank Common Trade Effluent

Collection Sump

Multi Stage Evaporator

Concentrate

Feed Tank

(Balance Tank)

Vapour

Condensate

Collection

Tank (25 KL

& 20 KL

Capacity)

IP Division PC Division

25 KL Tank

Agitated Thin Film Dryer

(ATFD)

Mixed Salt

Recycle to

Process


39

3.4.9.5 LIQUID (SEWAGE)

The sewage generated from the bath, toilet from the various divisions within the complex and

waste water from the central kitchen are all collection in a sump. From the collection sump the

sewage water is pumped to Aeration Tank where it is continuously aerated with a fixed surface

aerator. To this aeration tank dozing of 2% solution of Urea and 1% of Di Ammonium Phosphate

solution are done. The aerated sewage is allowed to over flow to a setting tank, where the sediments

are allowed settled and the clear supernatant over flows from the top of settling tank which is used

for gardening.

The following figure shows the Details of Sewage Treatment Plant located in site.


40

Figure 3.12 STP in Detail


41

3.4.9.5.1 SEWAGE TREATMENT PLANT DETAILS

Table 3.25 Treatment Units Detail

Sl.No. Name of the Treatment Units Number of

Units

Dimension in

Meters

1 Collection Tank 1 2m Dia X 1.2

2 Aeration Tank 1 4.6 X 4.6 X 3

3 Secondary Settling Tank 1 2.7m Dia X 2

4 Pressure Sand Filter 1 0.45m Dia X 1.5

5 Activated Carbon Filter 1 0.45m Dia X 1.5

6 Sludge Drying Beds 3 2.5 X 5 X 0.6

3.4.9.5.2 SEWAGE DISPOSAL DETAILS

Table 3.26 Sewage Disposal Details

Sl.No. Description of Outlet Quantity (KLD) Disposal

1 STP Outlet 15.0 On land for gardening

Figure 3.13 Flow Chart of STP

Collection

Sump

Aeration

Tank

Settling Tank

Treated Water Sump

Sludge Drying Bed

Gardening

PC

GDM

IP


42

3.4.9.6 SOLID (NON HAZARDOUS)

The main sources of solid wastes will be from kitchen, process and STP sludge.

Table 3.27 Non Hazardous waste generation

Sl. No. Nature of Solid Waste Quantity Unit Mode of

Disposal

1 STP sludge 10 Kg/day Used as

Manure

2 Bio degradable Waste (Food and Garbage) 40 Kg/day Municipal

Disposal

3 Non Bio degradable Waste (Stationary, Scrap and

Packaging Waste) 10 Kg/day

Authorized

Venders

3.4.9.7 SOLID (HAZARDOUS)

Table 3.28 Hazardous waste generation

Sl.No. Name of the

Process

Name of the

process waste

(Category No.)

Quantity

T/Y

Waste

Storage Waste Disposal

1

Industrial operation

using

mineral/synthetic oil

as lubricant in

hydraulic system

(Schedule I)

5.1 Used/Spent

Oil 1

HDPE

Carboys

Recover and

Reuse CPCB

Authorized

Recycle

2

Purification and

treatment of exhaust

air, water and waste

water from the

processes in this

schedule and CETPs

(Schedule I)

34.3 Chemical

sludge from

waste water

treatment

30 Plastic

Bags

Common

Landfill TSDF


43

3.5 RAINWATER HARVESTING & STORMWATER MANAGEMENT

Recently we have constructed 7 Nos of rain water connecting system and existing storm water

management will be continued effectively.

Storm water drains will be provided along the factory to ensure that this is totally separated

from process effluent. This will minimize runoff of the contaminated water to the land

surrounding the site.

Runoff from roof top area will be collected by means of down take pipes and recharged into

the ground after filtration.

Surface runoff will be diverted to the channel provided along the site boundary and

discharged in the external storm water drain.

4 GREENBELT DEVELOPMENT

The following floral species have already been planted at the site. For the expansion the following

proposed species will be planted.

Table 4.1 List of greenbelt species

S. No. Floral species Status

1 Anona squamosa Existing

2 Azadirachta indica Existing

3 Bauhinia purpurea Existing

4 Caesalpinia pulcherrima Existing

5 Eucalyptus citriodora Existing

6 Hibiscus rosa-sinensis Existing

7 Psidium guayava Existing

8 Albizia odoratissima Proposed

9 Bahinia varigata Proposed

10 Derris indica Proposed

11 Polyalthia longifolia Proposed

12 Psidium longifolia Proposed

13 Saraca asoka Proposed

14 Mangifera indica Proposed


44

5 ENVIRONMENTAL MANAGEMENT PLAN

So far amount of 591 Lakhs for Capital and 7.85 Lakhs amount was incurred for Environmental

Management activities. The details are as follows

Table 5.1 EMP budget

S. No. Infrastructure Capital cost Recurring cost

1. Air Pollution Control 6 Lakhs 0.5 Lakhs/Month

2. Effluent Treatment Plant (ETP) &

Rain water harvesting measures 500 Lakhs 1.7 Lakhs/Month

3. Environment Monitoring and

Management 17 Lakhs 2 Lakhs/Month

4.

Solid and Hazardous Waste

Management (Membership &

Facility development)

10 Lakhs 0.85 Lakhs/Month

5. Energy Management 23 Lakhs -

6. Occupational Health & Safety 30 Lakhs 2.5 Lakhs/Month

7. Green belt Development 5 Lakhs 0.3 Lakhs/Month

8. Environment Management Cell - -

Total 591 Lakhs 7.85 Lakhs

And in addition to the above the expenditure made for Stack Monitoring System (Online) Rs. 27.0

Lakhs and ZLD Scheme Rs. 400 Lakhs.

6 PROJECT COST & IMPLEMENTATION SCHEDULE

Cost for the proposed expansion is estimated at 7.5 Crores approximately.

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