Archean EIA
Archean EIA
Archean EIA
PVT. LTD.
FEBRUARY , 2015
Kadam
Environmental Consultants
www.kadamenviro.com
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.
CONTENTS
1 INTRODUCTION ....................................................................................... 8
4 PLANNING BRIEF..................................................................................... 30
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
ANNEXURES
Annexure 1: Land Lease and Possession Documents ...................................................................... 37
LIST OF TABLES
Table 2-1: Co-ordinates of Project Boundary ................................................................................. 10
Table 2-10: Details of Raw Material Quantity and Means of Storage ................................................ 19
Table 2-12: Details of Existing Stacks, Fuel Used and APCM ........................................................... 23
LIST OF FIGURES
Figure 2-1: Process Flow Diagram – Sulphate of Potash (SOP) ....................................................... 12
Figure 2-3: Process Flow Diagram – TBBA – Tetra Bromo Bisphenol ............................................... 15
LIST OF PHOTOGRAPHS
Photograph 3-1: Photographs of Existing & Proposed Site .............................................................. 29
1 INTRODUCTION
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.
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.
2 PROJECT DESCRIPTION
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.
Alternative sites are not identified since the existing facility possesses sufficient land, infrastructure,
utilities and road connectivity for expansion activities.
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
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.
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 &
2.5.2 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.
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.
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.
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.
Process flow diagram (PFD) and Material Balance for Bromine is given in Figure 2-4 & Table 2-5
respectively.
1 Bromine 1 MT
2 Effluent 434 m3
3 ETP Sludge 0.715 MT
Process Description
STEP-2: Hydrated lime Addition and Precipitation of Mg(OH)2 and Filtration and Washing of Mg(OH)2
STEP-4: Evaporation of 15% Calcium Chloride Solution to produce 70% Calcium Chloride Flakes.
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.
1 TBBA 1
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.
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%.
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.
Process flow diagram (PFD) and Material Balance for Hydrobromic Acid (48%) is given in Figure 2-4
& Table 2-8 respectively.
1 HBR 1 MT
2 Effluent 2.95 m3
Process Description
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)
1 46% MgCl2 1 MT
2 By Product-Gypsum as 75% CaSO4.2H2O 0.162 MT
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
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.
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.
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.
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
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.
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.
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
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.
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
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
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
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.
Air emissions;
Wastewater;
Hazardous Materials;
Wastes.
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
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.
Summary of Hazardous waste from the proposed unit is tabulated in Table 2-14.
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.
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
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.
Site is approached through Border Security Force post which is at a distance of ~6-8 km from project
site.
Hajipir, a religious place, visited by people during festivals is at a distance of ~16 km from project site.
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.
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.
4 PLANNING BRIEF
4.3 Amenities/Facilities
Basic Amenities like public transport, water supply, telecommunications, educational institutions,
hospitals etc. are available in Nakhatrana Town.
5 PROPOSED INFRASTRUCTURE
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.
1. Administration building
2. Truck parking area
3. Security cabin
4. Utility area
5. Laboratory
6. Canteen
3 layers of green belt Green belt development along the periphery of the site
Not Envisaged as the expansion project site is a waste land developed for industrial use.
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.
ANNXURES
(Map showing Project Site on Toposheet No. F42D1, F42D2, F42D5 & F42D6 (Kachchh, Gujarat) – 5 Km Radius Circle)
(Map showing Project Site on Toposheet No. F42D1, F42D2, F42D5 & F42D6 (Kachchh, Gujarat) – 10 Km Radius Circle)
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