prefeasibility report - welcome to environment€¦ · · 2014-12-08prefeasibility report for...

PREFEASIBILITY REPORT

FOR

“Proposed capacity expansion of existing

facility”

BY

Indian additives LTD

AT

VILLAGE: Manali

Taluk: Thiruvottiyur

DISTrict: Thirvallur

STATE: TAMIL NADU

i

Table of Contents 1. EXECUTIVE SUMMARY ........................................................................................................ 1

2. INTRODUCTION OF THE PROJECT ................................................................................... 3

2.1 Introduction about the company .................................................................................................. 3

2.2 Brief Description of the Project ..................................................................................................... 3

2.3 Project Benefits ...................................................................................................................................... 4

3. PROJECT DESCRIPTION ...................................................................................................... 5

3.1 Type of the Project ............................................................................................................................... 5

3.2 Project Location ..................................................................................................................................... 5

3.3 Products Manufactured ..................................................................................................................... 7

3.4 Manufacturing Process Description ............................................................................................ 7

3.4.1 Succinminde unit ......................................................................................................................... 7

3.4.2 PIBSA (Poly Iso Butylene Succinic Anhydride) unit ................................................... 8

3.4.3 Phenates/Sulfonate Unit .......................................................................................................... 9

3.4.4 Blending Unit .............................................................................................................................. 11

3.5 Raw Material Requirement ........................................................................................................... 12

3.6 Utilities .................................................................................................................................................... 13

3.7 Power and Fuels ................................................................................................................................. 14

3.8 Water Requirement .......................................................................................................................... 15

3.9 Landuse .................................................................................................................................................. 16

3.10 Manpower ............................................................................................................................................. 16

3.11 Liquid Waste Management ........................................................................................................... 16

3.11.1 Treatment of Lquid Waste ................................................................................................... 17

3.11.1.1 Effluent Treatment Plant (ETP) Description .......................................................... 17

3.12 Air Pollution Control Measures................................................................................................... 21

3.13 Hazardous and Solid waste Management .............................................................................. 23

3.14 Greenbelt Development .................................................................................................................. 24

3.15 Environment, Safety and Health Monitoring ........................................................................ 24

4. SITE ANALYSIS ................................................................................................................... 27

4.1 Connectivity.......................................................................................................................................... 27

4.2 Land form, land use, land ownership ....................................................................................... 27

4.3 Existing land use pattern ............................................................................................................... 27

ii

4.4 Climatic Conditions ........................................................................................................................... 27

4.5 Social infrastructure available..................................................................................................... 28

5. Conclusion ........................................................................................................................... 30

List of Tables

Table 1.1 List of products – Existing and Proposed ............................................................................... 2

Table 3.1 List of Products existing and Proposed ................................................................................. 7

Table 3.2 List of Raw materials ..................................................................................................................... 12

Table 3.3 Capacity of DG, Boilers and Thermic fluid Heaters ......................................................... 13

Table 3.4 Power and Fuel requirement ..................................................................................................... 14

Table 3.5 Water Requirement and Recycling ......................................................................................... 15

Table 3.6 Land Use within the Site .............................................................................................................. 16

Table 3.7 Wastewater Generation ............................................................................................................... 16

Table 3.8 Existing APC Measures for the production. ........................................................................ 22

Table 3.9 Hazardous wastes Generation ................................................................................................. 23

Table 3.10 Non-Hazardous wastes ............................................................................................................ 24

Table 4.1Nearby areas from site Boundary ............................................................................................ 27

Table 4.2 Meterological Observations ....................................................................................................... 28

Table 4.3 Proposed project surrounding features ............................................................................... 29

List of Figures

Figure 3.1 Location of Proposed Project Site............................................................................................. 6

Figure 3.2 Satellite Image of the Site & its 10Km Radius ..................................................................... 6

Figure 3.3 Dispersants process flow diagram ........................................................................................... 8

Figure 3.4 PIBSA process flow diagram ....................................................................................................... 9

Figure 3.5 Phenate process flow diagram ................................................................................................ 11

Figure 3.6 Blending process flow diagram ............................................................................................. 11

Figure 3.7 ETP and STP Process Flow Disgram ..................................................................................... 20

Prefeasibility Report for Proposed Capacity Expansion of Existing Facility by Indian Additives Ltd.

1

1. EXECUTIVE SUMMARY

Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai

Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC. On

24th May 1989, Chevron Oronite Company LLC, USA (then Chevron Chemical

Company) and Chennai Petroleum Corporation Limited, Chennai (then Madras

Refineries Limited) signed an agreement to form a Company to engage in the

development, manufacture and marketing of certain additive intermediates,

(components) and packages for Lubricating Oils. The Company, christened as

‘Indian Additives Limited’, was thus born legally on 13th July 1989,the plant has

been operational since 1993. IAL was originally incorporated as a government

company to foster domestic manufacture of lubricating oil additives so as to

reduce reliance on import of such products. IAL’s operation has, therefore, has a

bearing on increasing national foreign exchange savings through import

substitution.

The manufacturing facilityis located at SF No. 265(P) Manali Village,

AmbatturTaluk, Tiruvallur District, and Tamil Nadu in a spread of 23.57 acres

land. The site is located about 4 km away from Thiruvottiyur Town and it is in the

express highway connecting Thiruvottiyur and Ponneri. The site is located south

of this road. The nearest railway station is Thiruvottiyur.

IAL proposes to expand the capacity of its existing manufacturing facilityto meet

the growing market demand in lubricating oil additives. The proposed expansion

activity is planned through debottlenecking with some minor investments, with

out change in process, raw materials and products. The expansion project scope

mainly involves addition of inline blenders, pumps and enhancement of vessels/

storage tanks.The cost estimate for the proposed capacity expansion will be

around Rs.12 crores and implementation period will be 10-12 months.


2

Table 1.1 List of products – Existing and Proposed

S.No Product Existing Proposed

MT/annum

1 Automotive, Marine,

Industrial, Rail Road

and Natural gas

engine Lubricating Oil

additive packages.

25000 60000

2 Succinimides 10000 25000

3 Phenate/sulfonate 10000 20000 4 PIBSA 8500 20000

5

By product (Mix of sodium sulphide, sodium hydrogen sulphide& caustic)

3500 7000

IAL has valid consent orders under Air & Water Acts for the manufacturing of

products against existing capacities.


3

2. INTRODUCTION OF THE PROJECT

2.1 Introduction about the company

Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai

Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC.

The plant has been operational since 1993. IAL, an ISO 14001 certified

company, is one of the leading manufacturers of lubricating oil additives for

Automotive, Marine, Industrial, Rail Road & Natural gas engines lubricating

oils. These lubricating oil additives play a crucial role in engine performance

parameters like high specific power outputs, improved fuel-efficiency norms,

improved driveability, extended drain Intervals, fuel economy and longer and

trouble - free engine life.IAL primarily caters to sectors of national and public

interest as a majority of IAL’s products are manufactured to meet the

requirements of the Indian Railways, and government companies such as

Indian Oil Corporation, Bharat Petroleum Corporation Limited and Hindustan

Petroleum Corporation Limited.IAL’s operation has, therefore, has a bearing

on increasing national foreign exchange savings through import substitution.

IAL has been operating with valid consent orders under Air & Water Acts

from TamilNadu Pollution Controal Board and complying with all

environmental legislations. IAL has initiated many Environmental

improvement actions towards improving its Environment standards like

installation of online pollution monitoring systems and hooking up to

Pollution Control Board for real time monitoring.

2.2 Brief Description of the Project

IAL’s existing manufacturing facility consists of intermediates (components)

and blending facilities for making different lubricating oil additive packages .

The intermediates (components) manufacturing involves batch processes to

produce Dispersants(Succinimides), Detergents(Phenates/Sulfonate), PIBSAs.

Blending is the key operation where the aboveintermediates (components)

made within IAL and other intermediates (components) imported from other


4

Chevron Oronite facilities are blended to make different lubricating oil

additive packages based on market requirements. IAL is planning to expand

the capacity of all the above manufacturing facilities through debottlenecking

to meet the growing market demand in lubricating oil additive segment. The

expansion project scope mainly involves addition of inline blenders, pumps

and enhancement of vessels/ storage tanks.. Utility & off-site requirements

will be met by existing units which have enough capacity margins to support

proposed expansion. The cost estimate for the debottlenecking items

involved in proposed capacity expansion will be around Rs.12 crores and

implementation period will be 10-12 months.

The proposed capacity expansion does not require any new process or new

raw materials. Hence there will not be any new pollutants on account of this

expansion except for increase in loads due to high volumes. The existing

effluent treatment plant and other treatment systems have adequate design

capabilities to handethe additional pollutant loads from expansion as there

are no changes in characteristics.

2.3 Project Benefits

The proposed capacity expansion will enhance the Indigenous availability of

lubricating oil additives to meet the growing rquirements in automobile,

marine and industrial segments. This expansion will also help to boost the

economy of the countrythrough additional revenues and import substitutions.

The existing Plant has around 120employees and 200contract workmen

supporting all operational activities and there will be a marginal increase in

manpower after proposed capacity expansion, 140employees and 260

contract workmen. Apart from this, there will also be a considerable increase

in indirect employment on account of this proposed expansion.


5

3. PROJECT DESCRIPTION

3.1 Type of the Project IAL proposes to expand the capacity of all the existingmanufacturing facilities

through debottlenecking with some minor investments. The expansion

project scope mainly involves addition of inline blenders, pumps and

enhancement of vessels/ storage tanks.. Utility & off-site requirements will be

met by existing units which have enough capacity margins to support

proposed expansion.The proposed project falls under the schedule 5 (f) as per

the EIA notification dated September 14, 2006 and its amendments. There is

no interlinked project.

3.2 Project Location The proposed expansion project is planned with in the existing manufacturing

facility located at SF No. 265(P) Manali Village, Thiruvottiyur Taluk, Tiruvallur

District, and Tamil Nadu. The site is located about 4 km away from

Thiruvottiyur Town and it is in the express highway connecting Thiruvottiyur

and Ponneri. The site is located south of this road. The nearest railway station

is Thiruvottiyur. The location of the site is shown in Fig. 3.1. The plot plan of

the site with facilities is enclosed in Annexure-4.

The Project site with coordinates isgiven in Figure 3.1. The 10 Km radius

map from the project is given in (Fig 3.2).


6

Figure 3.1 Location of Proposed Project Site

Figure 3.2 Satellite Image of the Site & its 10Km Radius


7

3.3 Products Manufactured The list of products proposed is given in Table 3-1 below.

Table 3.1 List of Products existing and Proposed

S.No Product Existing Proposed

MT/annum

1 Automotive, Marine,

Industrial, Rail Road

and Natural gas

engine Lubricating Oil

additive packages.

25000 60000

2 Succinimides 10000 25000

3 Phenates/sulfonates 10000 20000 4 PIBSAs 8500 20000

5

By product (Mix of sodium sulphide, sodium hydrogen sulphide& caustic)

3500 7000

3.4 Manufacturing Process Description The process units built for Additives manufacturing are as under:

Dispersant ( Succinimides) plant

Detergent (Phenate / Sulfonate) plant.

PIBSA Plant (Raw material for Dispersant plant)

Blending plant (final blended products -Automotive, Marine, Industrial,

Rail Road,& Natural gas lubricating Oil engine additive packages. )

A brief process description is given below:

3.4.1 Succinminde unit

The Succinimides unit consists of a batch agitated reactors and overhead

collection systems. Succinimides are produced by reacting Poly Iso Butyl

Succinic anhydride (PIBSA) and Heavy polyamine (HPA) mixture in typical

proportions. PIBSA and HPA are reacted in the reactor at typical process


8

conditions. The reactor overhead systems collects water formed during the

reaction, along with the nitrogen used in the reactor to help sweep water

vapour. A vent stream consisting of nitrogen is produced from the overhead

system which is discharged through a high point vent system. The product

from the reactor is stored in storage tanks and used in blending plant for

making finished lubricating oil additive packages.Different types of

succinimides are manufactured in this unit by based on the requirement in

blending plant.

Figure 3.3 Dispersants process flow diagram

3.4.2 PIBSA (Poly Iso Butylene Succinic Anhydride) unit

PIBSA is an intermediate chemical that is used as key raw material for the

production of succinimides. PIBSA is formed by reacting poly iso-butene with

maleic anhydride. The operation is done in batches.

The PIBSA plant includes a hot oil coiled reactor, a reactor overhead system

with steam ejectors and a filtration section. Polybutene is charged with

excess maleic anhydride to the reactor. After the reaction, excess Maleic

anhydride is stripped and reused back in next batches. A condensate stream


9

containing trace quantities of Maleic acid and a vent stream consisting mostly

of air leaks into vacuum system are discharged to the overhead system which

is been scrubbed with water being discharged through vent. From the

reactor, crude PIBSA is transferred to intermediate tank and then filtered.

The filtrate is transferred to the intermediate storage tanks. The remnants

left in the filter are filter cake which was collected in barrels and disposed as

hazardous wastes as per authorization approval from PCB. Different grades

of PIBSA are manufactured in this plant.

Figure 3.4 PIBSA process flow diagram

3.4.3 Phenates/Sulfonate Unit

Phenates are classified functionally as detergents. This is produced by

reacting alkyl phenol with lime, sulfur and carbon dioxide in the presence of

promoters such as ethylene glycol, Do Decyl alcohol, and sulfonic acid /

Sulfonate. The Phenate plant consists of hot oil coiled reactors, reactor

overhead system with steam jet ejectors a recovery section to recycle the

promoters, and a filtration section.


10

The Phenate manufacturing operation is a batch process. The promoters and

diluents oil are premixed with alkyl phenol before charging to the reactor.

The remaining ingredients are charged in subsequent steps to form the

active Phenate.

Hydrogen sulfide and water are formed during part of this reaction sequence.

They are stripped through the overhead system.

Waste Gas containing Hydrogen Sulfide (H2S) is scrubbed in Caustic

scrubber unit, where H2S is fully absorbed in Caustic Lye and a byproduct

Spent Caustic is produced. Glycol, water, alcohol and oil are recovered from

the reactor overhead system and are separated in a water-glycol-oil

separator. The alcohol- oil stream is sent to an alcohol-oil recycle tank. The

wet glycol is sent to a glycol tank for recovery. The recovered alcohol and

glycol are being reused in the process. From the reactor the crude Phenate

product is sent to the filtration section for filtration. The final product is

stored in intermediate storage tanks and being used in blending plant for

making lubricating oil additives. The remnants left in the filter are filter cake

which was collected in barrels and disposed as hazardous wastes as per

authorization approval from PCB. Different types of detergents are

manufactured in this plant using similar raw materials.

In the same unit, Sulfonate is manufactured by reacting Sulfonic acid with

Lime, 2 Ethyl Hexanol, Calcium Chloride, Acetic acid and Formic acid in a

similar process. From the reactor, the crude Sulfonate is sent to the filtration

section for filtration. The final product is stored in intermediate storage

tanks and being used in blending plant for making lubricating oil additives.

The remnants left in the filter are filter cake which was collected in barrels

and disposed as hazardous wastes as per authorization approval from PCB.


11

Figure 3.5 Phenate process flow diagram

3.4.4 Blending Unit

Various components both manufactured within IAL and imported from other

Chevron Oronite facilities are blended in batch and continuous inline

blenders to make different lubricating oil additive packages. The product is

pumped in to finished storage tanks, or directly loaded in road tankers or

packed in MS barrels for dispatch to customers.

Figure 3.6 Blending process flow diagram


12

3.5 Raw Material Requirement

The raw material requirementsaredetailed in the Table3.2.

Following list of raw materials are used in the manufacturing of lubricating oil

additives and related intermediates. Raw materials are sourced locally as well

from global locations based on the requirement.

Table 3.2 List of Raw materials

S.No Raw Material Existing After Expansion

MT/Annum

1. 2 Ethyl Hexanol 43.0 86.0

2. Acetic Acid 6.0 13.0

3. Alkyl Phenol 3157.0 6314.0

4. Boric Acid 52.0 130.0

5. Calcium Chloride 7.0 14.0

6. Carbon-di-Oxide 434.0 869.0

7. Caustic Lye (100%) 708.5 1415.4

8. D.M. Water 1.8 3.6

9. Ethylene Carbonate 729.0 1823.0

10. Filter Aid-Coarse 105.3 210.7

11. Filter Aid-Fine 75.4 173.8

12. Formic Acid 2.4 5.8

13. Heavy Polyamine-HPA/DETA Mix 55.0 138.0

14. Heavy Polyamine-Pure 338.0 845.0

15. HR PIB 1000MW 758.0 1782.0

16. HR PIB 2300MW 4838.0 11384.0

17. IsoDecyl Alcohol 130.0 261.0

18. Maleic Anhydride 452.0 1064.0

19. Molybdenum Tri Oxide 60.2 150.5

20. Mono Ethylene Glycol 484.1 988.2

21. Mono Methyl Amine-MMA 18.1 36.1


13

S.No Raw Material Existing After Expansion

MT/Annum

22. Paraformaldehyde 25.0 50.0

23. Slaked Lime 1548.6 3098.2

24. Sulfonic Acid 862.0 1726.0

25. Sulfur 491.3 982.9

26. Lube Oil 150N 8562.0 22543.0

27. Imported Additive Components 3000.0 7200.0

Note: All raw materials consumptions are subject to change based on change in

product mix depending on market demand.

3.6 Utilities

The utility requirements for the proposed capacity expansionwill be met from

existing facility which have capacity margins. Details of the utilities are listed in

Table 3.3

Table 3.3 Capacity of DG, Boilers and Thermic fluid Heaters

Details Capacity Fuel

Existing Proposed

Boilers 1x 5.0 TPH

1x 6.5 TPH

1x 5.0 TPH

1x 6.5 TPH

Furnace Oil

Thermic Fluid Heaters 2x 0.6MMKCal/hr

1x 2.0 MMKCal/hr

2x 0.6 MMKCal/hr

1x 2.0 MMKCal/hr

Furnace Oil

DG Sets 2x 550 kVA

1x 1010 kVA

1x 1500 kVA

2x 550 kVA

1x 1010 kVA

1x 1500 kVA

HSD


14

3.7 Power and Fuels

Power requirement is being met from TNEB and third party producer.However,

DG sets are available to back-up power requirement during power restrictions

by TNEB. The current power requirement is 5,50,000 KWH/month. After

proposed capacity expansion, the power requirement will be 7,50,000

KWH/month. However existing DG sets are adequate for future back up

requirements in case of power disturption.

The unit uses furnace oil as the main fuel for its package steam boilers and

thermic fluid heaters. Diesel fuel is used for DG generators based on the

utilization. Currently, the unit consumes around 250KL/month of FO and around

60*KL/month of Diesel. After proposed capacity expansion, FO consumption will

be around 400 KL/month and Diesel consumption will be around 80*KL/month.

Details of the power and fuel requirements are listed in Table 3.4

Table 3.4 Power and Fuel requirement

Details Capacity Source

Existing Proposed

Power Requirement 550000

KWH/Month

750000

KWH/Month

TNEB/ Third party

producer

Fuel oil for Diesel

generators (HSD)

60* KL/month

80* KL/month

PSU Oil companies

Fuel oil for Boilers &

Thermic Fluid heaters

(Furnace Oil)

240 KL/month

400 KL/month PSU Oil companies

* Consumption based on current power restrictions and may varybased on

changes in restrictions from TNEB.


15

3.8 Water Requirement

The total requirement of raw water for the existing unit is 175 KLD and after

proposed capacity expansion, the raw water requirement will be 245 KLD.

Entire water requirement will be met from Chennai Metro Water Corporation

(CMWSSB) and there is no bore well source inside the Plant premises. Water

requirement for the proposed project is given in Table 3.5 . The agreement for

water supply is enclosed in Annexure-5

Table 3.5 Water Requirement and Recycling

S.

No

Description Existing

KLD

Proposed KLD

A Quantity of raw water consumption

1 DM plant 47 66

2 Cooling tower 83 104

3 Caustic scrubber 15 30

4 Potable water 30 45

5 Floor washings &

Miscellaneous

0 0

6 Total raw water consumption 175 245

B Quantity of effluent generation

1 Effluent from Process 140 196

2 Cooling tower blow down

3 DM plant washings

4 Boiler blow down

5 Sewage 27 40

Total effluent generation 167 236

C Effluent Recycle

1 Water recycle to DM plant 63 89

2 Water recycle to CT plant 16 23

D Water for Gardening 88 124


16

3.9 Landuse

There is no change in land distribution after proposed capacity expansion as all

the new equipment will be installed in the spare slots within existing buildings &

layouts. The existing land distribution details are as given in below:

Table 3.6 Land Use within the Site

Land allocation details Area in acres

Building Area 2.10

Roads and drains Area 3.39

Tank farm and yards 4.94

Effluent treatment plant 2.78

Greenbelt development 8.56

Vacant land 1.80

Total Area 23.57

3.10 Manpower

The existing Plant has around 120employees and 200 contract workmen

supporting all activities and there will be a marginal increase in manpower after

proposed capacity expansion, 140 employees and 260 contract workmens.

3.11 Liquid Waste Management

Table 3.7 Wastewater Generation

S.No. Waste Water Details Quantity (in KLD)

Existing After Expansion

1 Effluent from Process

140 196 2 Cooling tower blow down

3 DM plant washings

4. Boiler blow down

5. Sewage (STP) 27 40

Total 167 236


17

3.11.1 Treatment of Lquid Waste

Trade effluent streams of total quantity 196 KLD generated from process

are treated in ETP of 300 KLD capacity. Sewage stream of quantity 40 KLD

is treated in STP of 60 KLD capacity. Treated water is partially used for

green belt development and the remaining water is sent to RO plant for

further treatment and recycled to CT and DM plant.

The existing effluent treatement plant and STP facilities are adequate

enough to handle increased effluents from the proposed capacity expansion.

3.11.1.1 Effluent Treatment Plant (ETP) Description

The unit has well established ETP Plant where the combined effluent

from process units and Utility systems are treated through Activated

Sludge aerobic process as detailed below. Sewage effluent is treated

separately in exclusive sewage treatment plant. The treated effluent

meeting PCB norms is then treated in multi stage Reverse Osmosis Plant

for recycle into process while the rejects are concentrated to salts in

multiple effect evaporators for disposal.

There are three effluent streams generated in the plant depending upon

the place of origin.

a) Stream A

Basically consist of process waste water, wash/storm water from

curbed process area, process wash downs, and streams from lab,

pump leakage, storm water from truck loading and tank farm

areas. This stream contains oil and other Chemicals.

b) Stream B

Consist of cooling tower blow down, Boiler blow down and DM

plant regeneration wastes.

c) Stream C

Sanitary waste water – Treated in a Separate Sewage Treatment

Plant (STP)


18

The effluent treatment plant basically consists of three sections:

Oil/water separation and oil recovery.

Treatment of separator water and its disposal.

Sludge Digestion, thickening and dewatering

The free-floating oil in the process effluents from various unit

processes is removed by skimmers and corrugated float separator

units. The emulsified oil in the effluent stream is removed by

dissolved floatation techniques. These various steps of oil removal

enable a reduction in the Bio-chemical Oxygen demand

contributed by the oil.

In the oil –water mixture, the free oil due to its relative lower

specific gravity, floats on the surface which is removed by

mechanical skimming. The collected process effluent is pumped to

cross flow separator (CFS) where further free oil is removed. The

effluent from CFS bearing certain amount of emulsified oil and free

oil is sent to Dissolved Air floatation unit (DAF) through a Surge

Pond. The DAF unit acts as secondary treatment in the removal of

oil.

The out let of the DAF unit is sent to Equalization basin where the

utility stream is mixed. The combined effluent is subjected to

biological treatment based on activated sludge system.(Aerobic

Process) An activated sludge unit consisting of an aeration basin

and a clarifier removes dissolved organic contaminants. The waste

biological sludge is sent to a sludge digester where it is further

degraded the water from the digester is sent back for treatment

and the digested sludge is sent to dewatering facility. The

dewatered sludge is sent to solar ponds for drying. The treated

water is pumped to surge pond (west) The treated water is used

for firefighting, gardening. The treated water is partially sent to RO

plant for further processing &recycle to plant for usage in DM


19

plant and Cooling Tower and the remaining water is used for

gardening/green belt activities.

The Sanitary waste water (Stream C) is separately treated in a

Sewage Treatment Plant (S.T.P). The treated water is transferred

to Surge pond (West).

The Process flow Diiagram of ETP and STP are given in Figure 3.7

Online monitoring of parameters (pH & TDS) for treated effluent

from ETP done and it is also connected with CAC, TNPCB.


20

Figure 3.7 ETP and STP Process Flow Disgram

Oxidation Ditch

(T-819)

Chemical sump

(T-802)

Process plant (N-Pit, Hot well)

Utility sump (T-

811)

Sanitary sump (T-

812)

Boiler Blow down & DM Plant

Sanitary waste from plant &

Non plant area

Cross flow

separator

(T-803)

Surge pond

(East)

(T-804)

Dissolved

air

floatation

(T-805)

)

Alum Dosing Poly electrolyte Dosing

Equalization basin

(T-813) Aeration Tank(T-814

aeration tank)

Surge Pond (West)

(Treated water)

9Treated

VAZ Solution

dosing

Sludge for

drying

Final Clarifier (T-820)

Intermediate Sludge

Sump T-818

Sewage

Treatment Plant

Urea & DAP

Over flow sump RO Plant

Recycle

to plant

Gardening


21

3.12 Air Pollution Control Measures

The existing package boilers, thermic fluid heaters and DG sets are of high

efficient in terms of combustion control and are featured with in-built pollution

control design. Hence the pollutant load from theseunits will be minimal which

finally been vented through chimneys of appropriate height.

The process vents from intermediates (components) manufacturing facilities are

scrubbed in scrubersfor key pollutants before being discharged to atmosphere.

The unit has also installed online stack monitoring station (CEMS) for Hot oil

stack and boiler stack and connected with Care Air Center (TNPCB). PM, SOX &

NOX are being analyzed. 12 Nos of H2S sensor installed in different areas of plant

permises to monitor H2S. H2S sensor at the caustic scrubber vent is hooked upto

CAC, TNPCB.

The unit has installed Online Ambient Air Quality (AAQ) monitoring station and

it is connected with Care Air Center (CAC), TNPCB. PM10, SOX, NOX, CO, NO, NO2

& 03 are the parameters which are being analyzed. The unit has also installed

continuous VOC monitors in the plant.

Particulars of stacks and vents are detailed in Table 3.8:


22

Table 3.8 Existing APC Measures for the production.

Stack No 1 2 3 4 5 6 7 8

Material of

Construction

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon Steel Carbon

Steel

Carbon

Steel

Stack

attached to

Common

Stack to 2

Nos. of oil

fired

Boilers

Common

Stack to 3

Nos. of Oil

fired

Thermic

fluid

heater

Exhaust

pipe to

D.G set

550

KVA

Exhaust

pipe to

D.G set

550

KVA

High Point

discharge

via water

scrubber

for PIBSA

reactor

vent

High point

discharge to

Succinimides

Reactor

Vent from

Phenate

reactor

through

Caustic

scrubber

Common

Exhaust

Stack to

1DG set

of 1010

KVA

& 1DG set

of 1500

KVA

Stack Height

(Above the

ground

level)

47 m 30 m 16 m 16 m 22 m 17 m 27 m 30 m

Stack dia at

top (Circular

inside

dimensions)

0.80 m 0.3 m 0.2 m 0.2 m 0.15 m 0.1 m 0.1 m 0.4 m


23

There are no additions/changes in existing stacks or process vents on account of

this proposed capacity expansion. How ever, existing air pollution control

measures are adequately sized to handle the increased pollutant loads.

3.13 Hazardous and Solid waste Management

Hazardous wastes from the existing to proposed are increasing, the details of

Hazardous wastes generated are given in Table 3.9. The hazardous wastes

generated from this unit are collected, stored and disposed through authorized

disposal cum recycle facilities as per the authorization from PCB and the unit has

agreements with all waste disposal facilities for the same. There is no internl

disposal facility availability within the site.

The Authorization Letter from TNPCB is enclosed as Annexure-6.

Table 3.9 Hazardous wastes Generation

Category

No. Hazardous wastes

Quantity (MT/ year) Method of Disposal

Existing Proposed

20.3 Distillation residue 800 1250

Collection, Storage and

Disposal for incineration & co-

incineration at authorized

TSDF facilities

5.1 Used/ Spent oil 100 150


Disposal to Authorized

Recycling Agencies.

5.2 Wastes/ residues

containing oil

7 10.5


Disposal incineration & co-

incineration at authorized

TSDF facilities

34.3

Chemical sludge

from waste water

treatment

10 15


Disposal for land fill at

authorized TSDF facilities.


24

Category

No. Hazardous wastes

Quantity (MT/ year) Method of Disposal

Existing Proposed

34.2

Toxic metal

containing Residue

from used ion

exchange material

in water

purification

0.5 1


Disposal for land fill at

authorized TSDF facilities.

33.3 Discarded

Containers 2500 3500


Disposal to Authorized

Recycling Agencies.

Table 3.10 Non-Hazardous wastes

Details of waste Quantity (MT/ year)

Method of Disposal Existing Proposed

Used paper waste 0.32 0.48 Sold as scrap to authorized

buyers

Food waste 1.08 1.44

Taken back by outsourced

catering service provider for

appropriate disposal

3.14 Greenbelt Development

Greenbelt is already developed inside the factory premises covering a total area

of about 8.56 acres which is more than 33% of the total area. The species and

plantation norms are followed as per the CPCB/ PCB directions.

3.15 Environment, Safety and Health Monitoring

The environment, safety and health-monitoring programme in the factory are as

follows:

Daily monitoring of water and wastewater


25

Online monitoring of stack, ambient air, weather and effluent parameters

Fortnight monitoring of ambient air

Monthly monitoring of noise and work place air

Monitoring of occupational safety

Yearly monitoring of occupational health.

To prevent air pollution, IAL has designed and installed the stacks of Boilers, Hot

oil units and DGs asper the guidelines of the central pollution control board

(CPCB). IAL has a robust and a highly reliable caustic scrubber system to prevent

the release of H2S vapours from Detergent plant to the atmosphere.

Online H2S sensor provided in caustic scrubber vent is hooked up with CARE

AIR CENTRE, TNPCB for continuous monitoring. IAL has totally 12 Nos H2S

sensors located in different areas of the plant to monitor and prevent H2S

emissions.

IAL has installed Onlineambient air quality station (AAQ) and online stack

monitoring station (CEMS) and is connected with the Care Air Center, TNPCB. ,

PM10, SOX, NOX, CO, NO, NO2, VOC & 03 are the parameters which are

continuously monitored and displayed. IAL has installed LED display for Online

monitoring of stack, AAQ and effluent parameters in the main gate for public

viewing. IAL has implemented various process improvement measures to reduce

the generation of hazardous wastes in each category. IAL’s hazardous waste

generation has and continues to be well within the limits authorized by the

TNPCB.

In line with IAL's commitment towards environmental protection, IAL has made

considerable amount of investment of around Rs.400 lakhs in the past 2 years

towards various environmental improvement initiatives. Being a company with

significant government investment, IAL is proactive and committed towards

ensuring environmental compliance with applicable laws and standards. IAL has

never failed in complying with the environmental legislations and has always

shown a proactive approach in making its plant one of the best plants in terms of


26

environmental management. Local TNPCB officials showcase IAL as a role model

to their counterparts from other States.


27

4. SITE ANALYSIS

4.1 Connectivity

The proposed site on the SH – 56 and it is in the express highway connecting

Thiruvottiyur and Ponneri. The site is located south of this road.

4.2 Land form, land use, land ownership

The Plant is located at SF No. 265(P) Manali Village, Thiruvottiyur Taluk,

Tiruvallur District, and Tamil Nadu. The present land use is industrial. The land

documents related to the site is enclosed in Annexure-2.

4.3 Existing land use pattern

The present land use is in industrial.zone. The details of sensitive areas from

the site boundary is given in Table 4.1. The site does not fall with in CRZ area.

Table 4.1Nearby areas from site Boundary S.No Name km

Water Bodies

1.

Surplus canal from

Korttalaiyar River

0.13 Km (North)

2. Buckingham canal 0.63 Km (East)

3. Retteri 7.56 Km(South-west)

4. Madhavaram Lake 3.57Km (South West)

5. KadapakkamPanchayat Lake 4.56 Km (North West)

6. Periyathoppu Lake 3.1Km (South West)

7. Bay of Bengal 3.13Km (East)

4.4 Climatic Conditions

The study region receives rainfall predominantly during monsoon season with

an average annual rainfall of about 1211 mm per year. The South west monsoon


28

season is from July – September and North east monsoon is from October to

December. The relative humidity recorded in the district is about 49-79%. The

wind directions during the study period are SW-W-WSW and SE. Accordingly,

the impact zone will be spread in NE-E-ENE and NW directions. The average

wind speed observed during the study period is 3 m/sec with the considerable

frequency of a wind range of calm to about 22 km/hour. Due to its proximity

with the Bay of Bengal, the ambient temperature at project site ranged between

25-40°C. The area has a tropical climate with the highest and lowest

temperatures recorded is Maximum of 40.3°C and Minimum of 25°C

respectively.

Table 4.2 Meterological Observations

S.No Parameter Observation

1 Wind Direction SW-SE-W-WSW

2 Wind Speed Range 2 to 8.8 m/sec

3 Annual Average Rainfall 1211 mm

4 Average Wind Speed 3 m/sec

5 Temperature Range Max. Temp: 40°C

Min. Temp: 25°C

6 Average Temperature 32°C

7 Humidity Range (24hr) 49 to 79 %

8 Cloud cover Partly cloudy

4.5 Social infrastructure available

The social infrastructure facilities available near the site are given in Table 4.3.


29

Table 4.3 Proposed project surrounding features

S.No. Name km

Schools & Colleges

1. CPLC Polytechnic College 1.70

2. ThirunthangalNadar Arts College 4.05

3. Tamil Nadu Horticulture Institute 4.5

4. Tamil Nadu Veterinary and Animal Sciences

University

4.34

5. Institute of Poultry Production and Management 5.00

Religious Places

1 ThyagarajaSwamy Temple 2.08

2 KalyanaVaradarajPerumalKoil 2.46

3 St. Marys Orthodox Syrian Church 2.58

Hospital

1 Aakash Hospital 2.35

2 Sugam Hospital 2.33

3 Mary Clinic 3.69

4 Vasan Eye Care Hospital 8.17


30

5. Conclusion

Since the proposed project is coming up in the existing plant Industrial area,

there will not be any change in land use.

The proposed project is only expansion of existing capacity so no new pollutants

are added to the environment. However, the increase in pollutant loads are

appropriately handled through dedicated pollution control measures.

The treated waste water will be partly reused for gardening with in the facility

and rest will be recycled for process reuse like Cooling Towers and boiler feed

water make-up after treatement through RO system.

There will be positive impact on Social conditions in and around the site due to

the proposed project.

The marginal impact of proposed capacity expansion with in the existing facility

will be fully mitigated by the Environment Management Plans (EMP).

prefeasibility report - welcome to environment€¦ · · 2014-12-08prefeasibility report for...

Documents