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ARCHEAN CHEMICAL INDUSTRIES

PVT. LTD.

Pre-Feasibility Report - Environmental Clearance


Expansion of Chemical Fertilizer Manufacturing
Unit of Sulphate of Potash (SOP) from 1,00,000
MTA to 4,00,000 MTA, Bromine from 12,500 MTA to
80,000 MTA, Co-Generation Power Plant (CPP)
from 10 MW to 45 MW, production of Bromine
derivatives and recovery of Industrial chemicals
from waste streams at Greater Rann of Kachchh,
Near Hajipir village, Tehsil Bhuj, District Kachchh,
Gujarat.

FEBRUARY , 2015

Kadam
Environmental Consultants
www.kadamenviro.com

Environment for Development


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER QUALITY CONTROL
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH SHEET

M/S. ARCHEAN CHEMICAL INDUSTRIES LIMITED

Pre-Feasibility Report - Environmental Clearance


Expansion of Chemical Fertilizer Manufacturing Unit
of Sulphate of Potash (SOP) from 1,00,000 MTA to
4,00,000 MTA, Bromine from 12,500 MTA to 80,000
MTA, Co-Generation Power Plant (CPP) from 10 MW
to 45 MW, production of Bromine derivatives and
recovery of Industrial chemicals from waste
streams at Greater Rann of Kachchh, Near Hajipir
village, Tehsil Bhuj, District Kachchh, Gujarat.
© Kadam Environmental Consultants (‘Kadam’), February, 2015

This report is released for the use of the M/s. Archean Chemical Industries 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
Pre-Feasibility Report for Environmental Clearance Expansion of Chemical Fertilizer
Manufacturing Unit of Sulphate of Potash (SOP) from 1,00,000 MTA to 4,00,000 MTA,
Name of Bromine from 12,500 MTA to 80,000 MTA, Co-Generation Power Plant (CPP) from 10 MW to
Publication 45 MW, production of Bromine derivatives and recovery of Industrial chemicals from waste
streams at Greater Rann of Kachchh, Near Hajipir village, Tehsil Bhuj, District Kachchh,
Gujarat.
February,
Project Number 1520711606 Report No. 1 Version 1 Released
2015
Prepared &
Ishita Garg & Bhavin Jambucha Released By Jagdishchandra Rathi
Managed By
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: kadamenviro@kadamenviro.com; T:+91-265-3001000; F: +91-265-3001069
Delhi / NCR
Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,
Gurgaon, Haryana, INDIA - 122002.
E: delhi@kadamenviro.com; T: +91-124-4242430 to 436; F: +91-124-4242433
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.

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 II


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH TABLE OF CONTENT

CONTENTS
1 INTRODUCTION ....................................................................................... 8

1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................ 8


1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................... 8
1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION .....................8
1.4 DEMAND SUPPLY GAP ................................................................................... 8
1.5 IMPORTS VS. INDIGENOUS PRODUCTION ................................................................ 8
1.6 EXPORT POSSIBILITY & DOMESTIC/EXPORT MARKETS .................................................. 9
1.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT .............................9

2 PROJECT DESCRIPTION ............................................................................ 10

2.1 TYPE OF PROJECT ..................................................................................... 10


2.2 LOCATION OF THE PROJECT ........................................................................... 10
2.3 DETAILS OF ALTERNATE SITES CONSIDERED .......................................................... 10
2.4 SIZE OR MAGNITUDE OF OPERATION .................................................................. 10
2.4.1 Storage Details of Finished Products ....................................................... 11
2.5 PROCESS DESCRIPTION ............................................................................... 12
2.5.1 Sulphate of Potash ............................................................................ 12
2.5.2 Bromine ........................................................................................ 13
2.5.3 Magnesium Oxide (MgO) .................................................................... 14
2.5.4 TBBA – Tetra Bromo Bisphenol ............................................................. 15
2.5.5 Bromine Derivatives .......................................................................... 16
2.5.6 Hydrobromic Acid 48% (HBr) ............................................................... 16
2.5.7 Magnesium Chloride-46 % (MgCl2) ......................................................... 17
2.5.8 Magnesium Sulphate-98 % (MgSO4) ....................................................... 18
2.5.9 Co-Generation Power Plant .................................................................. 18
2.6 RAW MATERIALS ...................................................................................... 19
2.7 UTILITIES ............................................................................................. 20
2.7.1 Power Requirement ........................................................................... 20
2.7.2 Fuel Requirement ............................................................................. 20
2.7.3 Water Requirement ........................................................................... 21
2.8 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT ................................................ 23
2.8.1 Air Emissions & Control ...................................................................... 23
2.8.2 Waste Water Generation ..................................................................... 24
2.8.3 Hazardous Waste and Other Solid Waste ................................................. 25
3 SITE ANALYSIS ....................................................................................... 26

3.1 CONNECTIVITY ........................................................................................ 26


3.1.1 By Road ........................................................................................ 26
3.1.2 By Rail .......................................................................................... 26
3.1.3 By Air ........................................................................................... 26
3.1.4 By Water ....................................................................................... 26
3.2 LAND FORM, LAND USE AND LAND OWNERSHIP ....................................................... 26

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH TABLE OF CONTENT

3.3 TOPOGRAPHY (ALONG WITH MAP) ..................................................................... 26


3.4 EXISTING LAND USE PATTERN ........................................................................ 26
3.5 SENSITIVE AREAS ..................................................................................... 27
3.5.1 Water Bodies .................................................................................. 27
3.5.2 Defense Installation .......................................................................... 27
3.5.3 Religious Place ................................................................................ 27
3.5.4 Flora and Fauna ............................................................................... 27
3.6 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................. 28
3.7 SOIL CLASSIFICATION ................................................................................. 28
3.8 CLIMATIC DATA FROM SECONDARY SOURCES ......................................................... 28
3.9 EXISTING INFRASTRUCTURE ........................................................................... 28

4 PLANNING BRIEF..................................................................................... 30

4.1 PLANNING CONCEPT ................................................................................... 30


4.2 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................... 30
4.3 AMENITIES/FACILITIES ................................................................................ 30

5 PROPOSED INFRASTRUCTURE ................................................................... 31

5.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................... 31


5.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ........................................................ 31
5.3 EQUIPMENT LIST ...................................................................................... 31
5.4 GREEN BELT........................................................................................... 33
5.5 SOCIAL INFRASTRUCTURE ............................................................................. 33
5.6 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC) ............. 33
5.7 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) .................................... 33
5.8 SEWAGE SYSTEM ...................................................................................... 33
5.9 SOLID & INDUSTRIAL WASTE MANAGEMENT .......................................................... 33

6 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 34

7 PROJECT SCHEDULE AND COST ESTIMATE ................................................... 35

7.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION ........................ 35
7.2 ESTIMATED PROJECT COST............................................................................ 35
7.2.1 Profitability ..................................................................................... 35

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 IV


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH TABLE OF CONTENT

ANNEXURES
Annexure 1: Land Lease and Possession Documents ...................................................................... 37

Annexure 2: General and Specific Location Map ............................................................................ 53

Annexure 3: Project Boundary Map .............................................................................................. 54

Annexure 4: Project Site Located on Toposheet............................................................................. 55

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH TABLE OF CONTENT

LIST OF TABLES
Table 2-1: Co-ordinates of Project Boundary ................................................................................. 10

Table 2-2: List of Proposed Products and Production Capacity ........................................................ 10

Table 2-3: Finished Products Storage Details ................................................................................. 11

Table 2-4: Mass Balance – Sulphate of Potash (SOP) ..................................................................... 13

Table 2-5: Mass Balance – Bromine .............................................................................................. 14

Table 2-6: Mass Balance – Magnesium Oxide (MgO) ...................................................................... 14

Table 2-7: Mass Balance – TBBA – Tetra Bromo Bisphenol ............................................................. 15

Table 2-8: Mass Balance – Hydrobromic Acid (48%) ...................................................................... 17

Table 2-9: Mass Balance – Magnesium Chloride-46 % (MgCl2) ........................................................ 17

Table 2-10: Details of Raw Material Quantity and Means of Storage ................................................ 19

Table 2-11: Fuel Details............................................................................................................... 20

Table 2-12: Details of Existing Stacks, Fuel Used and APCM ........................................................... 23

Table 2-13: Waste Water Details .................................................................................................. 24

Table 2-14: Hazardous Waste Details ........................................................................................... 25

Table 3-1: Distance of Villages from Project Site............................................................................ 27

Table 3-2: Distance of Ponds from Project Site .............................................................................. 27

Table 3-3: Distance of Reserve Forest from Project Site ................................................................. 28

Table 5-1: Equipment List ............................................................................................................ 32

Table 7-1: Project Cost ................................................................................................................ 35

LIST OF FIGURES
Figure 2-1: Process Flow Diagram – Sulphate of Potash (SOP) ....................................................... 12

Figure 2-2: Process Flow Diagram – Bromine ................................................................................ 14

Figure 2-3: Process Flow Diagram – TBBA – Tetra Bromo Bisphenol ............................................... 15

Figure 2-4: Process Flow Diagram – Hydrobromic Acid (48%) ........................................................ 17

Figure 2-5: Flow diagram of CPP .................................................................................................. 19

Figure 2-6: Water Diagram .......................................................................................................... 22

Figure 2-7: Block Diagram of ETP ................................................................................................. 24

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH TABLE OF CONTENT

LIST OF PHOTOGRAPHS
Photograph 3-1: Photographs of Existing & Proposed Site .............................................................. 29

Photograph 5-1: Green Belt Development at Existing Site .............................................................. 33

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 VII


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH INTRODUCTION

1 INTRODUCTION

1.1 Identification of Project and project Proponent


Archean Chemical Industries Limited (ACIL) have established marine based fertilizer chemical complex
at Greater Ran of Kutch in the leased land allotted to by Gujarat Government & having valid EC vide
No.- J-11011/149/2010-IA II (1) dated 02-09-2011. Commercial operations were started in the year
2014. Greater Ran of Kutch is the best location for extraction of marine Chemicals. To meet demand &
supply in the market globally for products like Bromine & Sulphate of Potash, it was essential to go for
expansion to capture domestic & Global Market.

1.2 Brief Description of Nature of the Project


ACIL is having existing unit located in Greater Rann of Kutch, Near Hajipir, Tal. Bhuj, Gujarat. The
company intends to go for expansion of the existing products (Sulphate of Potash, Liquid Bromine,
Green Bromine and Epsomite) & with other by products related to Bromine & Bromine derivatives in
the existing manufacturing facilities.

The area of Existing manufacturing facility will be about 75 hectares from a total area of 500 hectares.
The site is about 16 Kms north of Hajipir, which is the nearest village. In this regard, the unit intends
to obtain environmental clearance from the Ministry of Environment and Forest for expansion & to
include value added bromine related products. A total investment of approx. Rs. 1,400 crores will be
made for this new project.

1.3 Need for the Project and its Importance to the Country and or Region
By expanding our Bromine capacity & Sulphate of Potash, we can reduce the imports in to India, &
exports can be increased which will generate foreign exchange to the country. Further there is scope
for additional employment about 1,000 peoples & the remote area where our plant exist can generate
more ancillary engineering industries.

1.4 Demand Supply Gap


About 18,000 MT Per Annum Bromine is being consumed in India by Pharma/Pesticide/Dyes &
Intermediate Industries. Further the global market for Bromine is about 6,00,000 MTPA.

1.5 Imports vs. Indigenous Production


Due to high demand of Bromine in Indian Market, many industries are importing Bromine from
Isreal/USA. To substitute imports in to Indian market & to increase exports mainly to China & other
European Countries, ACIL intend to go for expansion of Bromine & SOP Plants.

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 8


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH INTRODUCTION

1.6 Export Possibility & Domestic/Export Markets


With the expansion project, ACIL can increase their domestic/exports markets for Bromine & Sulphate
of Potash to various countries.

1.7 Employment Generation (Direct and Indirect) due to the project


Presently about 3,000 employees are employed. By the expansion project, additional local employment
for about 1,000 peoples shall be generated.

Local skilled and semi-skilled workers will be engaged during construction phase. The positives impact
include enhanced direct employment for technical/administrative works and indirect employment
opportunities for transporters of raw materials and finished goods.

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

2 PROJECT DESCRIPTION

2.1 Type of Project


As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project
falls under the Project / Activity: 5(a) – Chemical fertilizers which shall be treated as Category “A”.

2.2 Location of the Project


The project is located at Greater Rann of Kachchh, Near Hajipir village, Tehsil Bhuj, District Kachchh,
Gujarat. The area is already under use for the existing plant process.

Plot is taken on lease from Governor of Gujarat. Agreement documents of the same and Land
possession documents for plot are attached as Annexure 1.

Location map showing general & specific location of proposed project is given in Annexure 2. Project
boundary map is given in Annexure 3. The co-ordinates of the project site are given in Table 2-1.

Table 2-1: Co-ordinates of Project Boundary


Code Latitude Longitude
1 23°50'23.78"N 69°13'31.93"E
2 23°50'26.22"N 69°14'58.77"E
3 23°49'24.02"N 69°15'0.76"E
4 23°49'22.20"N 69°13'33.26"E

2.3 Details of Alternate Sites Considered

Alternative sites are not identified since the existing facility possesses sufficient land, infrastructure,
utilities and road connectivity for expansion activities.

2.4 Size or Magnitude of Operation


Plot area of the project consists of 500 Ha. Details of all the proposed products are listed in Table
2-2.
Table 2-2: List of Proposed Products and Production Capacity
Existing Capacity Expansion Total Capacity
S. No Name
(MT) (MT) (MT)

Products
1 Sulphate of Potash (SOP) 1,00,000 3,00,000 4,00,000
2 Bromine (Br2) 12,500 67,500 80,000
3 Green Bromine 2,500 0 2,500
4 Epsomite (MgSO4.7H2O) 81,000 1,62,000 2,43,000
5 Magnesium Oxide (MgO) 0 2,00,000 2,00,000
6 Tetra Bromo Bisphenol -A(TBBA) 0 10,000 10,000

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

Existing Capacity Expansion Total Capacity


S. No Name
(MT) (MT) (MT)
7 Bis-di-Bromo Propyle Ether (BDDP) 0 5,000 5,000
8 Deca Bromo Diphenyl Ether (DBDE) 0 4,000 4,000
9 Hexa Bromo Benzene (HBB) 0 1,000 1,000
10 Hydro Bromic Acid- 48%(HBR) 0 5,000 5,000
11 Magnesium Chloride-46 % (MgCl2) 0 6,00,000 6,00,000
12 Magnesium Sulphate-98 % (MgSO4) 0 6,00,000 6,00,000
Co-Generation Power Plant
CO-GEN 10 MW 35 MW 45 MW

2.4.1 Storage Details of Finished Products

Storage details of the finished products are tabulated in Table 2-3.

Table 2-3: Finished Products Storage Details


Existing Expansion
S.
Product State Consumption Consumption
No Storage Storage
(TPM) (TPM)
Tanks
1 Bromine Liquid 1,042 5,625 Tanks
(2 x 45 MT)
2 Epsomite Solid 6,750 HDPE Bags 13,500 HDPE Bags
Sulphate of Potash HDPE HDPE
3 Solid 8,333 25,000
(SOP) Bags/storage Bags/storage
Magnesium Oxide
4 Solid Nil Nil 16,666 HDPE Bags
(MgO)
Tetra bromo bis phenol-
5 Solid Nil Nil 833 HDPE Bags
A (TBBA)
Bis Di Bromo propyle
6 Solid Nil Nil 416 HDPE Bags
ether (BDDP)
Deca Bromo Diphenyl
7 Solid Nil Nil 333 HDPE Bags
Ether (DBDE)
8 Hexa bromo Benzene Solid Nil Nil 83 HDPE Bags
Hydro Bromic Acid
9 Liquid Nil Nil 416 Tanks
(HBR)
Magnesium Chloride-46
10 Solid Nil Nil 50,000 HDPE Bags
% (MgCl2)
Magnesium sulphate-
11 Solid Nil Nil 50,000 HDPE Bags
98% (MgSO4)

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

2.5 Process Description

2.5.1 Sulphate of Potash

Process Description

Harvested crude Magnesium salt will be leached in NaCl saturated circulating brine at an elevated
temperature making MgSO4 and minor amounts KCl (if any) get dissolved. After adjustment of the
solution in terms of MgSO4 concentration and post separation of non-dissolved NaCl, the clear liquor
will be cooled to 10 - 15 °C to produce a pure and NaCl free Epsomite. Some of this Epsomite will be
used in the process of SOP production, while the rest is saleable. The same circulation liquor will be
reused and a small part will be bleed-off and sent to the solar pond system. The non-dissolved NaCl
will be re-dissolved in Sea water and sent back to the solar ponds.

Secondly the Harvested Salt Mixture will be mixed with seawater in order to decompose Carnallite and
dissolve MgCl2. The remaining un-dissolved KCl, MgSO4 and NaCl mixture will be used for the SOP
process and the mother liquor called ‘Carnallite decomposed liquor’ will be recycled to Solar Pond.

The above two beneficiated raw salts

 Harvested epsomite salt;


 Harvested salt mixture;

will be mixed together, in a KCl:MgSO4 concentration that corresponds to the same ratio as existing in
Kainite. This mixture called ‘Synthetic Kainite’ will be mixed with seawater and cooled SOP mother
liquor for dissolution, so that Primary Schoenite will be generated. The ‘Schoenite mother liquor
‘separated from Primary Schoenite will be re-cycled to Solar Pond.

Primary Schoenite generated from the earlier stage and the recovered/secondary Schoenite will be
leached with seawater at 48°C, by which K2SO4 begins to crystallize out while MgSO4 will remain in
solution. When the MgSO4 concentration will reach approx 225 g/1000g H2O, the resulting slurry will
be centrifuged, washed with small amount of fresh water and dewatered to produce SOP and a Hot
SOP mother liquor. The Hot SOP mother liquor will be cooled to 10 -15 °C in order to generate
recovered /secondary Schoenite and cooled SOP mother liquor, depending on the NaCl concentration
in Schoenite, purification of Schoenite will be accomplished by using a wash with fresh water and / or
a flotation to remove NaCl.

Process flow diagram (PFD) and Material Balance for Sulphate of Potash is given in Figure 2-1 &

Table 2-4 respectively.

Figure 2-1: Process Flow Diagram – Sulphate of Potash (SOP)

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

Table 2-4: Mass Balance – Sulphate of Potash (SOP)


S. N. Raw Materials Input (MT) / MT of Product
1 KTMS 10
2 Sea Water 20
3 Process Water 5
4 RO Water 1
Total 36

S. N. Product Output/Day of Product


1 SOP 1 MT
2 Effluent 22 m3

2.5.2 Bromine

Steaming out process (STO) for Liquid Bromine:

Feed bitterns from reservoir will be acidified to 3.5 pH by addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings. Steam and chlorine will be injected at the bottom
of thetower. Liberated bromine will be condensed and purified in a separate tower by heating with
indirectsteam, Bromine will again get condensed and refluxed backed to top of tower and liquid
bromine will bedrawn from the bottom of this purifying tower, cooled and bottled in glass bottles
and/or filled in ISO tanks for dispatch.

Air Blow out Process (ABO) for Liquid Bromine

Bittern from the reservoir will be acidified to pH 3.5 by the addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings; air and chlorine will be injected at the bottom of
the tower. Liberated Bromine laden by air will be made to react with soda ash or caustic soda solution
venting of un-reacted air by circulating in a series of packed towers.

The reaction in the absorber reactor is as follows:

3Na2CO3 + 3Br2 = 5NaBr + NaBrO3 + 3CO2

or, 6NaOH + 3Br2 = 5NaBr + NaBrO3 + 3H2O

Part of this enriched alkaline solution (AB solution) will be the mixture of bromide, bromate
compounds from which again Bromine will be regenerated by the addition of acid. Regeneration of
Bromine will be done by a method similar to steaming out process but with smaller equipment as the
feed liquor will be highly concentrated.

5NaBr + NaBrO3 + 6HCl = 6NaCl + 3Br2 + 3H2O

Regenerated Bromine led out by steam given at the bottom of the tower will be condensed, separated
and processed further in distillation unit for the removal of impurities and packed in glass bottles and
/or in ISO tanks for dispatch.

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

Process flow diagram (PFD) and Material Balance for Bromine is given in Figure 2-4 & Table 2-5
respectively.

Figure 2-2: Process Flow Diagram – Bromine


Table 2-5: Mass Balance – Bromine
Input/ MT of
S. N. Raw Materials Unit
Product
1 Bittern 201 m3
2 Sulphuric Acid 0.51 MT
3 Liquid Chlorine 0.55 MT
4 Caustic Lye (48%) 0.1 MT
5 Lime 0.77 MT
6 Caster Oil 0.010 MT
7 RO Water (make up water) 25 m3
8 Reject Water(Dilution & Washing water) 25 m3

S. No. Product Output/Day of Product

1 Bromine 1 MT
2 Effluent 434 m3
3 ETP Sludge 0.715 MT

2.5.3 Magnesium Oxide (MgO)

Process Description

STEP-1: De-sulphatation of Bittern & Removal of Gypsum

STEP-2: Hydrated lime Addition and Precipitation of Mg(OH)2 and Filtration and Washing of Mg(OH)2

STEP-3: Calcination of Magnesium Hydroxide at 1800°C to form Dead Burnt Magnesia

STEP-4: Evaporation of 15% Calcium Chloride Solution to produce 70% Calcium Chloride Flakes.

Material Balance for Magnesium Oxide (MgO) is given in Table 2-6.

Table 2-6: Mass Balance – Magnesium Oxide (MgO)

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

S. N. Raw Materials Input/ MT of Product


1 Bittern 7 % Mg 9 MT
2 Hydrated Lime 80% 2.4 MT
3 Water 10 m3
4 Steam 3 MT

S. No. Product Output/Day of Product (MT)


1 MgO 1
2 By Product-Gypsum 0.162
3 CaCl2 Flakes 0.66

2.5.4 TBBA – Tetra Bromo Bisphenol

TBBA-Tetra Bromo Bisphenol-A is prepared by bromination of Bisphenol-A in MCB as a solvent using


Bromine, Hydrogen Peroxide and Water. The reaction mass is maintained at a specific temperature for
a period of time sufficient for Bisphenol-A to undergo tetrabromination .Here liberated Hydrogen
Bromide is getting oxidized by Hydrogen Peroxide to Bromine.

The Product solution then washed with an alkali solution then cooled to crystallize the product .Filter
this mass and Then again heating the reaction mass for the removal of traces impurities that present
in the mass up to specific temperature. The final product is filtered, dried, pulverized and packed.

Process flow diagram (PFD) and Material Balance for TBBA – Tetra Bromo Bisphenol is given in
Figure 2-3 & Table 2-7 respectively.

Figure 2-3: Process Flow Diagram – TBBA – Tetra Bromo Bisphenol


Table 2-7: Mass Balance – TBBA – Tetra Bromo Bisphenol
S. No. Raw Materials Input (MT) / MT of Product
1 Bromine 0.65
2 Bis Phenol-A 0.456
3 Mono Chlorobenzene (MCB) 0.06
4 Sodium Meta bisulphide 0.028
5 Sodium Sulphide 0.02
6 Hydrogen Peroxide 0.3

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S. No. Product Output/Day of Product (MT)

1 TBBA 1

2.5.5 Bromine Derivatives

Bis-di-Bromo Propyle Ether (BDDP)

Process: Complete bromination of ether.

Deca Bromo Diphenyl Ether (DBDE)

Process:
Step 1: Solution preparation- Charge bromine to reactor, cool br2 to 10°C, charge AlCl3 to reactor.

Step 2: Reaction & Cooling- Charge DPE to melter, add DPE in liquid form, maintain temperature upto
17°C, after completion of addition of DPE raise temperature to reflux. Add water to the reaction mass
and cool the reaction mass to 30°C, distill the excess bromine to recover, cool the contents to room
temperature.

Step 3: Filtration- Transfer reactor mix to nutsche filter/centrifuge in lots, unload wet cake, wash wet
cake with dilute HCl & spin dry, transfer ML to storage tank.

Step 4: Drying- Charge wet cake DBDPE finished product to vacuum tray dryer. Dry product at 50-
50°C, check moisture content less than 0.5% w/w, unload dry DBDPE finished product from vacuum
tray dryer is Deca bromo diphenylethane.

Hexa Bromo Benzene (HBB)

Process:
Hexa bromo benzene is synthesized by using benzene and bromine as raw materials and AlCl3 as
catalyst. The reaction conditions are improved and optimized. Under the obtained optimum conditions,
the purity of product is over 99%, the yield of product is98%.

2.5.6 Hydrobromic Acid 48% (HBr)

Process:

HBr is produced as a gas from the combustion of hydrogen and bromine gases, then absorbed into
water and cooled. The combustion process is highly controlled to provide ultimate safety. During the
combustion process, bromine and hydrogen react in equal volumes to produce HBr gas:

H2 + Br2 2 HBrg

This exothermic reaction generates a flame temperature of around 1,200°C and a heat load of
approximately 110 kcal/kg HBr when producing a cooled HBr gas at 50°C.

The combustion process is operated with a slight excess of H2 over stoichiometric conditions (typically
20-30%). Operating the system with this excess of H2 ensures the complete combustion of Br2, thus
preventing it from escaping into the atmosphere and producing a highly pure bromhydric acid.

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Process flow diagram (PFD) and Material Balance for Hydrobromic Acid (48%) is given in Figure 2-4
& Table 2-8 respectively.

Figure 2-4: Process Flow Diagram – Hydrobromic Acid (48%)


Table 2-8: Mass Balance – Hydrobromic Acid (48%)
S. N. Raw Materials Input/ MT of Product
1 Bromine 0.5 MT
2 SO2 0.45 MT
3 Water 2 m3

S. No. Product Output/Day of Product (MT)

1 HBR 1 MT
2 Effluent 2.95 m3

2.5.7 Magnesium Chloride-46 % (MgCl2)

Process Description

STEP 1: Removal of sulphate by precipitation of Gypsum (Adding CaCl2-solution)

STEP 2: Evaporation of water from De-sulphated Bittern, upgrading the MgCl2-brine (37.5°
containing 7% Magnesium) to a Smelt that contains 46% Magnesium Chloride

STEP 3: Preparation of Magnesium Chloride Flakes by continuously cooling of the smelt on water-
cooled cooling drum.

STEP 4: Product packing unit (50 Kg HDPE Woven Bags with Inner LLDPE Liners)

Material Balance for Magnesium Chloride-46 % (MgCl2) is given in Table 2-9.

Table 2-9: Mass Balance – Magnesium Chloride-46 % (MgCl2)


S. N. Raw Materials Input/ MT of Product
1 37.5° Bittern 7% Mg 1.7 MT
2 CaCl2 70% 0.11 MT
3 Steam at 6 Bar 0.6 MT

S. No. Product Output/Day of Product (MT)

1 46% MgCl2 1 MT
2 By Product-Gypsum as 75% CaSO4.2H2O 0.162 MT

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2.5.8 Magnesium Sulphate-98 % (MgSO4)

Process Description

Step 1: Harvested Crude Epsom Salt + Saturated Brine Leaching (24° Brine)

Step 2: Crude MgSO4 Solution + Salt (Solid) + Filtration produces Crude MgSO4 Solution

Step 3: Crude MgSO4 Solution on Crystallization gives Epsom Salt

Step 4: Epsom Salt on Drying at 250°C produces MgSO4 (Product)

2.5.9 Co-Generation Power Plant

Coal/lignite based Captive Co-generation Power Plant (CPP) consists of condensing type steam turbine
with boilers at operating steam temperature 540+/- 5deg C.

Basic process involves steam generation by combustion of coal in boiler. Steam is used to run turbine
for power generation.

Electricity is generated and distributed to process plant.

Power plant is mainly divided in following sections:

1. Coal yard and coal handling plant


2. Boiler and auxiliaries
3. Steam turbine and alternator
4. Condensers
5. Utility
6. Ash disposal system

1. Coal yard and Coal handling plant

Coal unloading activity involves unloading of coal from dumpers and truck by JCB’s in coal yard. Coal
is fed to coal bunker with the help of conveyor belt, screen and crusher.

2. Boiler and auxiliaries

There is a pulverized fuel boiler for generation of steam. It consists of steam drum, water wall and
economizer. Heat generated due to coal combustion in the form of flue gas is used at various levels in
boiler to maximize thermal efficiency. Steam is passed through super heaters to achieve final
temperature.

3. Steam turbine and alternator

High temperature, high pressure steam enters in turbine where heat energy is converted into kinetic
energy. Turbine is directly coupled to alternator where electricity is generated by electro motive force
produced. Steam is extracted for process and for heating water before feeding in boiler from various
extraction points in turbine. Power is generated and feed to different areas of plant through double
bus bar system to cater high reliability of electrical system.

4. Condenser system

Exhaust steam is condensed and recycled in boiler with pumping devices at various stages with
minimum make up of DM water.

5. Utility

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Instrument air compressors are installed for requirement of air at various control valves.

Cooling tower with well-designed water distribution system for removing heat from condenser,
alternator, oil coolers and at various fan bearing locations.

6. Ash disposal system

The ash is trapped in ESP and stored in an ash silo. The ash shall be sold to brick making units.

The Flow diagram of Coal based co-generation power plant is given in Figure 2-5.

Figure 2-5: Flow diagram of CPP

2.6 Raw Materials


Raw material shall be sourced from registered supplier within India and Imported (if required) based
on the need and availability. Details of raw material along with the Quantity and Means of storage is
given in Table 2-10.

Table 2-10: Details of Raw Material Quantity and Means of Storage


S. Existing Expansion
Raw Material State
No. Consumption Storage Details Consumption Storage Details
KTMS-RM for Open area Open area
1 Solid 83,000 TPM 2,49,000 TPM
SOP (60,000 m2) (1,50,000 m2)
Sea Water-RM 2,00,000 Reservoir 6,00,000 Reservoir
2 Liquid
for SOP (m3/month) (40000 m3) (m3/month) (10,00,000 m3)

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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S. Existing Expansion
Raw Material State
No. Consumption Storage Details Consumption Storage Details
Bittern-RM for Open reservoir Within Existing
3 Liquid 2,10,000 TPM 5,24,000 TPM
Br2 (27,75,000 m3) area
Tonners under Tonners under
Liquid Chlorine-
4 Liquid 575 TPM chlorine shed 2,530 TPM chlorine shed
RM for Br2
(2,500 m2) (3,750 m2)
Sulphuric acid- Tanks
5 Liquid 533 TPM 2,346 TPM 300 MT
RM for Br2 (40 MT x4)
Castor Oil- Cans in storage Cans in storage
6 Liquid 2.6 TPM 11.4 TPM
additive for Br2 godowns godowns
SO2- RM for Tonners under
7 Gas Nil Nil 200 TPM
HBr shed
BIS phenol-A-
8 Solid Nil Nil 380 TPM HDPE Bags
RM for TBBA
Mono
Chlorobenzene
9 Liquid Nil Nil 50 TPM Tanks
(MCB)-RM for
TBBA
Sodium
HDPE Bags in
10 Metabisulphite- Solid Nil Nil 24 TPM
storage godowns
RM for TBBA
Sodium
HDPE Bags in
11 Sulphide-RM Solid Nil Nil 17 TPM
storage godowns
for TBBA
Hydrogen
12 Peroxide-RM Liquid Nil Nil 250 TPM Tanks
for TBBA

2.7 Utilities

2.7.1 Power Requirement

Co-generation power plant of 10 MW is existing and will undergo expansion of 35 MW for supply of
power to the plant. 2 Nos. of DG Sets (3000 kVA + 500 KVA) will be installed & used during
emergency conditions and power outrages only.

2.7.2 Fuel Requirement

Coal / Lignite will be used for boilers and HSD will be used for DG Sets. Details of the same is
tabulated in Table 2-11

Table 2-11: Fuel Details

S. Type of Quantity
Used in Source
No. Fuel
Existing Proposed
Coal / Imported/
1 Coal Fire Steam Boiler 6.75 TPH 23.6 TPH
Lignite Indigenous

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

S. Type of Quantity
Used in Source
No. Fuel
Existing Proposed
DG Sets Local Depot/
2 HSD 680 Ltr/Hr. -
(2 Nos. 3,000 kVA & 500 kVA) Suppliers

2.7.3 Water Requirement

Total Water requirement of 75,000 KLD will be extracted from Sea. Flow chart of Water and waste
water distribution is shown in Figure 2-6.

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LIMITED KACHCHH PROJECT DESCRIPTION

Figure 2-6: Water Diagram

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

2.8 Pollution Load on Environment due to Project


Environmental issues associated with pesticides manufacturing, formulation and packaging include:

 Air emissions;
 Wastewater;
 Hazardous Materials;
 Wastes.

2.8.1 Air Emissions & Control

During construction phase, vehicular emissions shall be from use of construction machinery and
vehicles. Apart from it, application of heavy machinery and earth movers will generate emissions.
Suitable dust suppression techniques such as water sprinkling will be taken at these times as relevant.

The principal air pollutants are volatile organic compounds (HBr) and particulate matter (PM). It will be
controlled by caustic scrubbers. Adequate stack height and proper pollution control equipment will be
provided for all flue gas stacks & process stacks. Fugitive emissions from storage & handling of
bromine is also envisaged due to the project.

The ambient air quality & stack emissions will be maintained as per GPCB/CPCB norms.

Details of existing & proposed stacks with fuel consumption and attached Air Pollution Control
Equipment details are tabulated in Table 2-12

Table 2-12: Details of Existing & Proposed Stacks, Fuel Used and APCM
Stack Height
No of
S. No of Stack Fuel Expected Existing &
Stack Attached to Stack APCM
No. (Expansion) Used Pollutants Proposed
(Existing)
(m)
Flue Gas Stacks
1 Boiler - 1 Coal / PM, SO2 & Common Stack
1 1 ESP
2 Boiler - 2 Lignite NOx of 76 m
D.G. Set - 1 Adequate PM, SO2 &
3 HSD 30
(3,000 kVA) Stack Ht. NOx
1 -
D.G. Set -2 Adequate PM, SO2 &
4 HSD 9
(500 kVA each) Stack Ht. NOx
Process Stacks / Vents
Bromine Plant Caustic
1 1 2 - HBr 29
Process Vent Scrubber
Dry
Chlorine Vaporizer Absorbent
2 1 1 - HBr 20
Unit Aluminum
Oxide
Bromine Bottling Caustic
3 1 1 - HBr 20
Section Scrubber

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INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PROJECT DESCRIPTION

2.8.2 Waste Water Generation

Waste Water Generation and Treatment Details

The waste water will be generated from the process, utilities and domestic area as shown in Table
2-13 and Figure 2-7
Currently, sewage is treated in STP (150 KLD). Waste water stream from SOP is sent to reservoir for
further recovery. Effluent from bromine plant & boiler is treated in ETP designed for a flow rate of
m3/hr. Treated effluent is send to Solar Evaporation ponds for evaporation. Settled sludge is used for
bund and road strengthening and hence achieving Zero Liquid discharge.

For the expansion units, sewage will be treated in existing STP (150 KLD). Waste water stream from
SOP will be sent to reservoir for further recovery. Effluent from proposed bromine plant & boilers shall
be treated in proposed ETP designed for flow rate of 1,000 m3/hr. Treated effluent shall be send to
Solar Evaporation ponds for evaporation. Effluent from Bromine plant shall be used for manufacturing
of fine chemicals. Settled sludge will be used bund & road strengthening and hence achieving Zero
Liquid discharge.

Table 2-13: Waste Water Details


S. No. Waste Water Stream Treatment/Disposal Recovery / Reuse

1 SOP Reservoir Recovery of other chemicals*.


1) Effluent - used for fine chemicals
2 Bromine ETP (during expansion phase).
2) Solar Pond - Gypsum used for
3 Boiler ETP strengthening of bund & roads.
4 Cooling Systems & Washing Slurry preparation Lime slurry
5 Domestic STP Gardening

* Epsomite, MgSO4, MgCl2 and MgO

Block diagram of Effluent Treatment System is shown below as Figure 2-7.

Figure 2-7: Block Diagram of ETP

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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2.8.3 Hazardous Waste and Other Solid Waste

Summary of Hazardous waste from the proposed unit is tabulated in Table 2-14.

Table 2-14: Hazardous Waste Details

S. Type of Hazardous Generation (TPA) Treatment /


Source
No. Waste Waste Category Disposal
Existing Proposed
Used for preparation
ETP sludge-
1 34.3 10,725 80,000 ETP and maintenance of
Gypsum
bunds and roads
Sold to authorized
2 Used Oil 5.1 1 - DG Sets
recyclers/vendors
Power Sold to brick
3 Fly Ash - 3,600 10,000
Plant manufacturers
Discarded
Bromine Sold to authorized
4 Bottles & 33.3 5 15
Section recyclers/vendors
Bags

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH SITE ANALYSIS

3 SITE ANALYSIS

3.1 Connectivity

3.1.1 By Road

ACIL has developed an approach road (Salt pan Road) from Hajipir which is ~ 16 Km in South
Direction. This road connects to the State Highway (SH – 42) at a distance of ~ 30 Km in South
Direction.

3.1.2 By Rail

Major railway station for public transportation is Bhuj Railway Station located at an aerial distance of
~80 Km in SE Direction from the project site.

3.1.3 By Air

Nearest airport from project site is Bhuj Airport located at an aerial distance of ~ 75 Km in SE
Direction.

3.1.4 By Water

Jakhau harbour at Kutch is located at an aerial distance of ~90 Km in SW direction. Also, Kandla port
at Gandhidham is located at an aerial distance of ~125 Km in SE direction.

3.2 Land Form, Land Use and Land ownership


The 500 ha un-surveyed land owned by the company is earmarked for industrial use. Only 15% of this
land is used for existing plant activities. Remaining area is available for expansion project.

3.3 Topography (along with map)


Project site shown on Toposheet No. F42D1, F42D2, F42D5 & F42D6 (Kachchh, Gujarat) is shown in
Annexure 4.

3.4 Existing Land Use Pattern


Waste land at Greater Rann of Kachchh has been developed for industrial use.

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INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH SITE ANALYSIS

3.5 Sensitive Areas


There are no villages within 10 Km from the project site. Distance of other villages from project site is
tabulated in Table 3-1.

Table 3-1: Distance of Villages from Project Site


S. N. Villages Distance from Site (in Km) Direction w.r.t Site

1 Luna 13.29 S
2 Bhitara Mota 11.87 SE
3 Hajipir 16.07 SSW
4 Udhamo 21.57 ESE
5 Gorewali 29.2 ESE
6 Mithadi 25 SE
7 Nara 23.27 SSW
8 Jumara 24.29 SW
9 Dhoro 26.4 SSW

3.5.1 Water Bodies

There are no major water bodies in vicinity of site. Rann of Kachchh gets flooded with sea water.
Distance and direction of other water bodies with respect to site are tabulated in Table 3-2.

Table 3-2: Distance of Ponds from Project Site


S. N. Villages Distance from Site (in Km) Direction w.r.t Site
1 Luna Pond 13.57 SSE
2 Hajipir Pond 16.25 SSW
3 Chhari Lake 26.22 SSE
4 Nara Dam 24.17 SSW

3.5.2 Defense Installation

Site is approached through Border Security Force post which is at a distance of ~6-8 km from project
site.

3.5.3 Religious Place

Hajipir, a religious place, visited by people during festivals is at a distance of ~16 km from project site.

3.5.4 Flora and Fauna

Banni Grasslands is an area spanning 3,500 sq km having a large shallow lake of 80 sq km. This area
is best accessible from Nakhatrana and is part of Chari-Dhand Wetland Conservation Reserve. This
makes the area heaven for birds for nesting and for bird watches to spot them. This area of great
Rann of kutch lies on one of India’s most important avian highways (both the birds flying from the
southward in winter and the few species migrating eastward from the middle-east and Africa stopover
in this area) are a top site for birding with waterfowl congregations at Charri Fulay lake, grassland and
scrubland birds, as also characteristic desert species seen in the vicinity.

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INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH SITE ANALYSIS

No forests, national park, wild life sanctuary, etc. are located in 15 Km from the nearest boundary of
the project site. Details of reserve forest from the project site are tabulated in Table 3-3.

Table 3-3: Distance of Reserve Forest from Project Site


S. N. Name of Reserve Forest Distance from Site (in Km) Direction w.r.t Site
1 Jumara 20.85 SW
2 Rajday 26 SSW
3 Lodiya 52 E

3.6 Social Infrastructure Available


Hajipir Village is the nearest habitation at an aerial distance of ~ 16 Km from project site having
private hospital, school, place of worship and community facility.

3.7 Soil Classification


Soil investigation has been done and accordingly existing plant has been established.

3.8 Climatic Data from Secondary Sources


Based on the available long-term climatological tables (1961 – 1990) published by India Meteorological
Department (IMD) of Bhuj (Rudramata (A)) District, average temperature, relative humidity and wind
speed for summer season were 37.9°C, 48% and 16.5 Km/Hr respectively. 1st Pre-dominant wind
direction is noted from West to East (42.12 %). 2nd pre-dominant wind direction is from SW to NE
(21.7%).

Above mentioned climatic conditions will be considered during designing stage.

3.9 Existing Infrastructure


Existing infrastructure includes roads, Medical facility, Laboratory, Power plant, SOP plant, ETP, STP,
Desalination Plant etc. at the project premises. Photographs of site are shown in Photograph 3-1.

Existing Project Site Bromine Bottling section

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH SITE ANALYSIS

Proposed Expansion Site Salt wash and conveyor area

EIA Team member at SOP Plant EIA Co-ordinator’ at Power Plant

Photograph 3-1: Photographs of Existing & Proposed Site

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH PLANNING BRIEF

4 PLANNING BRIEF

4.1 Planning Concept


Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc.
are already developed on the project site and will be expanded as per the requirement. Transportation
of raw material and finished goods will be carried out through approach road and finally through
existing state high SH-42.

4.2 Assessment of Infrastructure Demand (Physical & Social)


Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities
such as park, market, playground etc. education, health care and community development are
available in Nakhatrana Town.

4.3 Amenities/Facilities
Basic Amenities like public transport, water supply, telecommunications, educational institutions,
hospitals etc. are available in Nakhatrana Town.

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER PROPOSED
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH INFRASTRUCTURE

5 PROPOSED INFRASTRUCTURE

5.1 Industrial Area (Processing Area)


The industrial area shall comprise of following sections:

1. Process section
2. Raw material storage
3. Packing material storage
4. Finished product storage
5. ETP area

The Plant building will have ground floor + four floors for installing reaction vessels etc., and five
mezzanine floors in between for installing heat exchangers, dosing vessels, receivers etc. Cooling
tower and various scrubbers will to be located on the terrace roof.

SOP, Bromine and its derivatives will be manufactured in a dedicated set of equipment of the Plant.

Procurement of Raw materials will be undertaken as per the production plan maintaining their stock
level around one week’s requirement.

Finished products will be stocked for a maximum period of one week under normal circumstances.

5.2 Residential Area (Non-Processing Area)


Requirement of residential area will be developed as shown below:

1. Administration building
2. Truck parking area
3. Security cabin
4. Utility area
5. Laboratory
6. Canteen

5.3 Equipment List


For the proposed project equipment mentioned in Table 5-1 shall be in place:

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INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH INFRASTRUCTURE

Table 5-1: Equipment List


S. N. Name of Equipment
Plant Section
1. MS Glass Lined Reactor
2. Reactor
3. Distillation Column
4. Evaporator
5. Heat exchangers
6. Centrifuge
7. Dryer
8. Centrifugal pump
9. Steam jet ejector
10. Storage Tank
11. MS Storage tank
12. Cooling tower with pumps
13. Chilled Water Plant with pumps
14. Steam Boiler
15. Compressed Air
16. BFW softener
17. HBr scrubber
18. Vent gas scrubber
Utility Section
19. Emergency Power Generator
20. Power transformer with switch gear
21. Water storage tank
22. Fire Hydrant System
23. Chlorine cylinder. Hoist
24. ETP
25. R O Plant
26. Fork Lift
27. STP

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INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH INFRASTRUCTURE

5.4 Green Belt


Since, the project is located in Rann of Kachchh, having high alkalinity of the soil, it is not feasible to
develop green belt. However, attempts are made to develop local species of the Rann as shown in
Photograph 5-1.
Photograph 5-1: Green Belt Development at Existing Site

3 layers of green belt Green belt development along the periphery of the site

5.5 Social Infrastructure


Refer Chapter 3, Section 3.6.

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


Refer Chapter 3, Section 3.1.

5.7 Drinking Water Management (Source & Supply of Water)


Ground water is presently being purchased from nearby village and is used for domestic and process
purposes after desalination.

5.8 Sewage System


Domestic waste water shall be treated STP and reused in gardening. Process waste will be treated in
ETP and sludge will be used for strengthening of roads and bunds.

5.9 Solid & Industrial Waste Management


Solid and hazardous waste as mentioned in Chapter 2, Section 2.8.3 shall be collected, stored,
disposed to authorized vendors and sold to local suppliers as per it’s characterization and based on the
prescribed Hazardous Waste Rules, 2008 amended till date.

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH R & R PLAN

6 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

Not Envisaged as the expansion project site is a waste land developed for industrial use.

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER PROJECT SCHEDULE &
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH COST ESTIMATE

7 PROJECT SCHEDULE AND COST ESTIMATE

7.1 Likely date of start of construction and likely data of completion


The construction is likely to start after getting Environmental Clearance and NOC/CTE from the
authorized committee. The EIA studies are likely to get completed in 9-14 months. After receiving EC,
tenders shall be floated, offers/bids shall be received. Once, CTE is obtained finalization of contractors,
and civil work shall be started. Mechanical completion and commissioning is expected to be completed
in 30 months. CTO shall be obtained before operating the plant.

7.2 Estimated Project Cost


The project cost is estimated to be INR 1,400 Crore. Summary of project cost is shown in Table 7-1.

Table 7-1: Project Cost


S. No. Particulars Amount (INR in Crores)
1 Bromine Plant 600
2 SOP 250
3 MgO 300
4 Co-Generation Power Plant 120
5 Derivatives 60
6 Others (ETP, STP, Desalination Plant) 70
TOTAL 1,400

7.2.1 Profitability

ACIL will be the first manufacturer of SOP in India. Also, with this expansion project, they will be the
biggest producers of Bromine and Bromine derivatives in India. The project will be a substitute of
import of SOP and Bromine by providing a suitable source for import, export and coastal movement of
SOP & Bromine. It will encourage industrial growth in the region and result in additional revenue for
government.

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ANNXURES

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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Annexure 1: Land Lease and Possession Documents

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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 39


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 40


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 41


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 42


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 43


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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Copy of Lease Agreement – Translated in English

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KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 45


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
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KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 47


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 48


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 49


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 50


M/S. ARCHEAN CHEMICAL PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER
INDUSTRIES LIMITED MANUFACTURING UNIT AT GREATER RANN OF KACHCHH ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 51


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Annexure 2: General and Specific Location Map

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Annexure 3: Project Boundary Map

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Annexure 4: Project Site Located on Toposheet

(Map showing Project Site on Toposheet No. F42D1, F42D2, F42D5 & F42D6 (Kachchh, Gujarat) – 5 Km Radius Circle)

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 55


M/S. ARCHEAN CHEMICAL INDUSTRIES PRE-FEASIBILITY REPORT - EXPANSION OF CHEMICAL FERTILIZER MANUFACTURING UNIT AT GREATER RANN OF
LIMITED KACHCHH ANNEXURES

(Map showing Project Site on Toposheet No. F42D1, F42D2, F42D5 & F42D6 (Kachchh, Gujarat) – 10 Km Radius Circle)

KADAM ENVIRONMENTAL CONSULTANTS | FEBRUARY, 2015 56


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