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Indobaijin Chemicals Pvt Ltd Plot No: Z-7/1 & Z-8/Part, SEZ-1,
GIDC Dahej, Taluka – Vagra, Dist: Bharuch,
Gujarat
PRE- FEASIBILITY REPORT
FOR
Proposed Expansion in Existing Production Capacity within existing premises
Prepared By
Eco Chem Sales & Services Surat
(NABET Accredited consultant)
INDOBAIJIN CHEMICALS PVT LTD.
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Contents EXECUTIVE SUMMARY ................................................................................................................................................. 5
1.0 PROJECT BRIEF ....................................................................................................................................................... 6
2.0 INTRODUCTION OF THE PROJECT .......................................................................................................................... 9
2.1 DETAILS OF THE PROJECT PROPONENT ............................................................................................................. 9
2.2 DESCRIPTION OF NATURE OF THE PROJECT .................................................................................................... 10
2.2.1 NEED OF PROPOSED PROJECT .................................................................................................................. 10
2.2.2 DEMAND SUPPLY GAP .............................................................................................................................. 10
3.0 PROJECT DESCRIPTION ........................................................................................................................................ 12
3.1 PROPOSED PROJECT & APPLICABILITY OF EIA ................................................................................................. 12
3.2 PROJECT LOCATION ..................................................................................................................................... 12
3.2.3 SITE SELECTION CRITERIA: ........................................................................................................................ 17
3.3 RESOURCE REQUIREMENT .............................................................................................................................. 18
3.3.1 LAND REQUIREMENT ................................................................................................................................ 18
3.3.2 MAN POWER REQUIREMENT: .................................................................................................................. 18
3.3.3 ELECTRICITY REQUIREMENT: .................................................................................................................... 19
3.3.4 WATER REQUIREMENT: ............................................................................................................................ 20
4.0 RAW MATERIAL AND PRODUCT DETAILS ............................................................................................................ 21
4.1 RAW MATERIAL DETAILS ................................................................................................................................. 21
4.2 PRODUCT DETAILS ........................................................................................................................................... 21
5.0 MANUFACTURING PROCESS: ............................................................................................................................... 22
7.0 ENVIRONMENTAL MANAGEMENT PLAN ............................................................................................................. 25
7.1 AIR ENVIRONMENT:......................................................................................................................................... 25
7.2 WATER ENVIRONMENT: ............................................................................................................................ 26
7.3 SOLID/HAZARDOUS WASTE ....................................................................................................................... 33
7.4 NOISE ENVIRONMENT ............................................................................................................................... 34
7.5 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT ................................................................................. 35
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8.0 SITE ANALYSIS ...................................................................................................................................................... 36
8.1 CONNECTIVITY ................................................................................................................................................. 36
8.2 TOPOGRAPHY .................................................................................................................................................. 37
8.3 EXISTING INFRASTRUCTURE ............................................................................................................................ 37
8.4 SOIL CLASSIFICATION ....................................................................................................................................... 37
8.5 CLIMATE DATA FROM SECONDARY SOURCE ................................................................................................... 37
9.1 PROJECT SCHEDULE & COST ESTIMATES ............................................................................................................. 38
9.1 PROJECT SCHEDULE ......................................................................................................................................... 38
9.2 PROJECT COST ESTIMATION ............................................................................................................................ 38
FINANCIAL & SOCIAL BENEFITS ................................................................................................................................. 40
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LIST OF TABLES
Table 1: Land Breakup................................................................................................................................. 18
Table 2: Water Consumption ...................................................................................................................... 20
Table 3: Raw Material Consumption .......................................................................................................... 21
Table 4: Details of Product .......................................................................................................................... 21
Table 5: Details of Air Emission ................................................................................................................... 25
Table 6: Water Consumption ...................................................................................................................... 26
Table 7: Wastewater Generation ................................................................................................................ 27
Table 8: Sizing of Sewage Treatment Plant................................................................................................. 33
Table 9: Hazardous/Solid Waste Generation .............................................................................................. 33
Table 10: Salient Features of the project site ............................................................................................. 36
Table 11: Climate Data ................................................................................................................................ 37
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LIST OF FIGURES
Figure 1: world consumption of carbon disulfide ....................................................................................... 11
Figure 2: Short view of the project site ...................................................................................................... 14
Figure 3: Site Plant Layout with nearby industries ..................................................................................... 15
Figure 4: Plant Layout ................................................................................................................................. 16
Figure 5: Manufacturing Process flow sheet .............................................................................................. 24
Figure 6: Water balance diagram, in KLD ................................................................................................... 29
Figure 7: Flow Diagram of Combination Cooling Tower ............................................................................. 30
Figure 8: Sewage Treatment Plant (STP) Flow Diagram ............................................................................. 32
LIST OF ANNEXURES
Annexure 1: Existing Environmental Clearance ......................................................................................... 41
Annexure 2: Consent to Operate (CC&A) .................................................................................................. 47
Annexure 3: Water withdrawal Permission from GIDC .............................................................................. 53
Annexure 4: Land Document ...................................................................................................................... 54
Annexure 5: Membership of BEIL ............................................................................................................... 56
Annexure 6: EC letter for Dahej SEZ ........................................................................................................... 57
Annexure 7: Watercess returns of last three years .................................................................................... 63
Annexure 8: Electricity of last two months................................................................................................. 66
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EXECUTIVE SUMMARY
India is one of the leading manufacturers and suppliers of pesticides intermediates. India has a
good engineering & research scientist pool along with long proven expertise of producing quality
products. The proposed project is an expansion project proposed by Indobaijin Chemicals Pvt. Ltd.
with a total product capacity of Carbon Disulphide of 75000 MTPA. Carbon disulfide has been an
important industrial chemical since the late nineteenth century. It is used in a variety of applications
like production of regenerated cellulose (rayon and cellophane) and the manufacture of organic
sulfur compounds including agricultural, pharmaceutical, rubber chemicals and especially as
Pesticide intermediate. The proposed project will be undertaken within the existing premises of
Indobaijin Chemicals Pvt. Ltd. located at Plot No: Z-7/1 & Z-8/Part, SEZ-1, Village: Dahej, Tehsil:
Vagra, District: Bharuch, Gujarat.
As per the provision of the SO 1533, the proposed project falls under the item no. 5(b) -“A” and the
project is to be appraised at the MoEFCC, New Delhi. Further, the proposed project is located in the
Notified industrial estate/park (as described in Item 3(b) of notification), Hence Public hearing shall
be exempted (A copy of Gazette notification is attached as Annexure-6)
This pre-feasibility report has been prepared as a part of the ToR application, which includes a brief
introduction of the company, need and justification of the project, manufacturing process
description, required and available resources, proposed Environment Management Systems,
existing land-use and proposed infrastructure, project schedule and cost estimate, and proposed
Terms of reference for conducting the EIA studies.
The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultant to
conduct the EIA studies for obtaining EC for the proposed project. ECSS is a NABET accredited (QCI
approved) Environmental Consultant.
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1.0 PROJECT BRIEF
PROJECT BRIEF
No. Description Proposed Project Details
1 Name of project &
Address
M/s. Indobaijin Chemicals Pvt Ltd
Plot No: Z-7/1 & Z-8/Part, SEZ-1,
GIDC Dahej, Taluka – Vagra,
Dist: Bharuch,
Gujarat
2 Project Category 5 (b)-A of EIA notification – 2006
3 Project capital cost Existing cost: Rs. 178 Crores
Expansion cost: Rs. 15 Crores
4 Products Enhancement of production capacity of Carbon Di
Sulphide (CS2) from 50,000 MTPA to 75,000 MTPA and
steam export capacity from 45,000 MTPA to 65,000
MTPA
No Product Existing
capacity
(MTPA)
Proposed
Capacity
(MTPA)
Total
Capacity
(MTPA)
1 Carbon Di-
Sulphide
50,000 25,000 75,000
2 Steam Export 45,000 20,000 65,000
5 By-products No By-Product will be generated
6 Resource Requirement
Land 50,000 m2
(No additional land will be required due to proposed
expansion)
Water Source : GIDC water supply
Existing Water Consumption:
Domestic Activities: 50 KLD
Industrial Activities: 700 KLD
Proposed Additional Water Consumption:
Construction phase: 5-10 KLD
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Operation phase:
Existing Proposed Total
Domestic
Activity
50 KLD Nil 50 KLD
Industrial
Activity
700 KLD Nil 700 KLD
No additional water will be required for domestic as well
as industrial purpose as current water consumption is
around 450 KLD only, hence no additional water will be
required for the proposed expansion.
Electricity Source: Torrent Energy Ltd
Total Connected load -5110 KW
Original Contract Demand -1920 KW
Existing Contract Demand, which is used - 1520 KW
Proposed additional Contract Demand – 30 KW
No change in existing contract demand due to proposed
expansion as only additional 30 KW of additional
connected load is required for proposed expansion,
which is already available with unit. Hence no additional
electricity will be required for proposed expansion.
Fuel Existing:
Natural gas: 29350000 Nm3
After Proposed Expansion:
Natural gas: 37500000 Nm3
Manpower Existing: 98 Nos.
Proposed additional Manpower:
Construction phase –75 Nos.
Operation phase – 12 nos.
7 Source of Pollution
Waste Water
Generation
No industrial wastewater is discharged from the
existing unit hence the unit is a zero liquid discharged
unit. After the proposed expansion same shall be
achieved.
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Existing sewage is treated in STP and treated water is
reused in gardening purpose. After the proposed
expansion same practice shall be continued.
Air Emission Flue stack Emission:
PM10 , PM2.5, SOx & NOx
Process stack Emission:
CS2, SO2, H2S
Solid/Hazardous Waste
Generation
Hazardous waste:
Furnace Slag from furnace pipe and reactor cleaning,
Used Spent Oil, Discarded Containers/liners/Barrels
contaminated with Hazardous waste/chemicals,
Evaporation salt, Sludge from Sulfur Filter
Solid Waste:
STP Sludge
8 Mode of Treatment
Wastewater 1) No Additional Industrial effluent will be generated due
to the proposed expansion.
2) Additional Domestic sewage will be treated in existing
Sewage Treatment Plant (STP) and treated water shall
be reused in toilet flashing and partially fed to
combination cooling tower.
Air No additional furnace, flare stack or D.G. Set will be
installed due to proposed expansion. Adequate Air
pollution control devices are already provided to achieve
GPCB norms.
Solid Waste Solid/hazardous waste for collection, storage and
disposal will be carried out as per Hazardous Waste
Management Rules.
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2.0 INTRODUCTION OF THE PROJECT
2.1 DETAILS OF THE PROJECT PROPONENT
Indo-Baijin Chemicals Private Limited is a Joint Venture Company of Indofil Industries Limited, India
& Shanghai Baijin Chemicals Group Co. Ltd., China. Proponent is proposing to expand its current
manufacturing plant for producing Carbon Di-sulphide using Natural Gas (NG) as raw material at its
existing plant located at Special Economy Zone (SEZ), Dahej, Gujarat, India.
Indofil Industries Limited is a company from K.K. Modi Group of India an Industrial Conglomerate
with diverse businesses in the Agro Chemicals, Fine Specialty Chemicals, Entertainments, Healthcare
etc.
Indofil Industries Limited is uniquely placed both in Agriculture chemical as well as Specialty and
Performance chemical business. In India, Indofil is successful in strategic marketing of insecticides
including IGRs, Fungicides, Bactericides, Herbicides, Acaricides, Surfactants and Plant growth
regulators. Indofil is working for betterment of farmers, operating in Indian Market for more than 4
decades. INDOFIL is an ISO-9001-2000 and ISO 14001 Company and famous for excellence in product
quality. Indofil have stringent safety regime and an ability to handle hazardous chemicals such as
carbon disulphuide.
Shanghai Baijin Chemicals Group Co. Ltd., China was established in 1990. With Carbon Di-sulphide
production as the major business, Baijin group, consistently extending the industrial chain of fine
chemicals, chemical fibers, coke chemicals as well as endeavoring in international trade, technical
export and R&D, is a group company with the largest production scale, the most complete technical
processes and latest technologies. Shanghai BaiJin Chemical Group Co., Ltd, has a total asset of 2.6
billion Chinese yuan and 8 subordinates. The company also owns 14 proprietary patents and is
applying 2 international patents at present. Successively, 7 carbon disulfide manufacturing plants in
Shanxi, Chongqing, Sichuan, Xinjiang, Anhui, Shandong, and Jiangsu respectively have been
established, with an annual output of 3,50,000 tons.
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2.2 DESCRIPTION OF NATURE OF THE PROJECT
The company is located at Plot No: Z-7/1 & Z-8/part, SEZ-1, GIDC Dahej, Taluka-Vagra, District:
Bharuch, Gujarat. The unit is involved in manufacturing of Carbon Di-sulphide, having granted
capacity of 50,000 MT/Annum and steam export with capacity 45,000 MT/Annum.
The unit has also obtained Environmental Clearance for existing products vide letter No: J-
11011/301/2011-IA II (I), dated: 24/12/2012 (Attached as Annexure-1) & the unit holds
Consolidated Consent having Order no. AWH-64179 dated 02/04/2014, which is valid up to:
01/04/2019 (Attached as Annexure-2)
2.2.1 NEED OF PROPOSED PROJECT
As India is a developing country with increasing population, pesticides’ and pesticides intermediates’
demand is increasing day by day. Asia is accounted for about 72% of world production and nearly
75% of world consumption of carbon disulfide.
Carbon disulfide has been an important industrial chemical since the late nineteenth century. It is
used in a variety of applications like production of regenerated cellulose (rayon and cellophane) and
the manufacture of organic sulfur compounds including agricultural, pharmaceutical, rubber
chemicals and especially as Pesticide intermediate.
China is the dominant global player in this industry, with 49% of global consumption, followed by
India (13%). Both the countries have expanding industries, which account for the majority of carbon
disulfide consumption. The situation is similar in Western Europe, which accounted for 12% of world
consumption in 2010. In total, 98% of the world consumption of carbon disulfide was accounted for
Asia, Europe and America (74.5%, 15.8% and 7.7% of global demand, respectively). The rise of Asia
as the powerhouse where carbon disulfide is consumed (and produced) is closely related to the
changes in the global pattern of the textile, rubber, mining and agricultural chemicals industries,
which have increasingly relocated their manufacturing bases to this region. Hence, the demand of
carbon disulphide is increasingly gradually.
2.2.2 DEMAND SUPPLY GAP
As discussed above, the consumption of carbon disulfide is consumed (and produced) is closely
related to the changes in the global pattern of the textile, rubber, mining and agricultural chemicals
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industries, which have increasingly relocated their manufacturing bases to this region. The following
pie chart shows world consumption of carbon disulfide in the past few years:
Figure 1: world consumption of carbon disulfide
The production of regenerated cellulose (in the form of rayon fibers, cellophane, sponges and
casing) is the dominant industrial application of carbon disulfide, accounting for 70% of total
demand. In the absence of new applications, the health of the overall carbon disulfide market will
depend on sustainable growth in the fibers application, which on a global scale is expected to rise in
the near future. Other important areas where carbon disulfide is being used are in the production of
rubber chemicals (predominantly as vulcanization accelerators) and agricultural chemicals (as
fumigants). With the increasing prices of basic raw materials, the use of carbon disulfide in the
manufacture of mining chemicals (as flotation agents) is gaining in importance and has the highest
forecast growth rate among the different applications.
Future growth is expected to be most significant in Asia, whereas other regions with significant
demand are expected to stagnate or to grow at only about 1–2% annually over the forecast period.
On a global level, demand has increased 4% annually on average between 2010 and 2015. Indian
demand for CS2 is around 95,000 tons/annum.
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2.2.5 EMPLOYMENT GENERATION
The proposed expansion project shall generate employment during the construction for local skilled
and semi-skilled workers. Thus no need to provide housing facility to workers. Approx. 75 nos. of
people will get direct employment during construction phase.
During the operation phase, additional 12 nos. of individuals will get direct employment during
operation phase depending on their education background and technical skills.
3.0 PROJECT DESCRIPTION
3.1 PROPOSED PROJECT & APPLICABILITY OF EIA
The existing unit of Indobaijin Chemicals Pvt Ltd is located at at Plot No: Z-7/1 & Z-8/part, SEZ-1,
GIDC Dahej, Taluka-Vagra, District: Bharuch, Gujarat. The unit is now planning to increase its
production capacity from 50,000 MT/Annum to 75,000 MT/Annum.
The applicability of the SO 1533 for the proposed expansion project was explored by considering
different possibilities & provisions made in the said EIA notification, SO 1533 amended on 14th
September 2006. Considering the products, the proposed expansion project falls under Category 5
(b) - “A”.
3.2 PROJECT LOCATION
The company is located at Dahej SEZ in Vagra Taluka in western part of the Bharuch district,
Gujarat. It is well connected with National Highway (NH-8). Road and Railway both are having the
connectivity to New Delhi, the National Capital and Mumbai, the commercial Capital of India. SEZ is
a part of Dahej Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) and is within
Delhi-Mumbai Investment Corridor (DMIC).
Connectivity:
Road: SEZ is on 4 lane State Highway connecting at Bharuch (40 km) and National Highway No. 8
Rail: 40 km from Bharuch, Main Rail Head connecting Mumbai – Delhi.
Port: Gujarat Chemical Port Terminal Company Limited for chemical cargo and Adani-Petro LNG for
solid bulk cargo handling.
Airport: Baroda-150 km and Surat-120 km (Daily flights to Mumbai & Delhi).
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Four corners Latitudes and Longitudes of the proposed project are as under:
Project Co-ordinates
Corner Latitude Longitude
A 21°42'35.74"N 72°37’06.78"E
B 21°42'36.02"N 72°37'10.94"E
C 21°42'27.10"N 72°37'11.04"E
D 21°42'30.92"N 72°37'10.30"E
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Figure 2: Short view of the project site
Source: Google Earth Image
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Figure 3: Site Plant Layout with nearby industries
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Figure 4: Plant Layout
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3.2.2 ALTERNATIVE STUDIES:
As the proposed project is capacity enhancement project, alternative site has not been considered.
Since, by nature, the project is an expansion project, the existing premises of operational unit is the
most convenient site for the proposed expansion project. Moreover all the utilities & infrastructure
facilities are available in the present set up. Hence the existing premise with available infrastructure
& ease of operation is the best option available for the proposed expansion.
3.2.3 SITE SELECTION CRITERIA:
The land for the proposed expansion project is already in the possession of Indobaijin as the
proposed project is an expansion project. All the infrastructure facilities are available with the
existing unit of Indobaijin.
The project site is in Special Economic Zone (SEZ), which has all the facility such as RCC road,
water supply, effluent disposal line, power supply from Torrent Energy Ltd, Gas supply, Fire and
Safety Services.
The existing project site is well connected by road to National Highway No. 8.
Easy availability of infrastructure facilities.
No prime agricultural land / forest land needed to be converted for industrial use.
There is enough extra land to raise required green belt / green cover.
Area where proposed site is to be located has no history of natural calamities like floods, cloud
burst etc.
Proximity to raw material suppliers
The human resource required for the proposed project will be easily available
In addition to the above, the following factors within the study area have also been considered:
There is no National Park or Wild Life Sanctuary.
There are no metropolitan cities.
There are no ecologically sensitive areas.
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3.3 RESOURCE REQUIREMENT
To carry out the proposed expansion, various resources like raw materials, power, fuel, water,
manpower, etc will be utilized.
3.3.1 LAND REQUIREMENT
As mentioned above, the proposed expansion shall be developed within existing premises by using
the existing infrastructure. No additional land will be purchased/procured for the proposed
expansion. Plant layout is attached as Figure No: 3. Land document is attached as Annexure-4.
Total Plot Area – 50,000 m2
Existing spare land of 220 m2 will be utilized for the proposed expansion.
Table 1: Land Breakup
No. Description Existing Area (m2)
Proposed Area (m2)
Total Area (m2)
Percentage %
1. Plant Area 15,999 220 16,219 32.44
2. Ground coverage Area 13,931 -- 13,931 27.86
3. Future expansion 3,569 - 220 3,349 6.70
4. Greenbelt area 16,501 -- 16,501 33.00
Total Area 50,000 0.0 50,000 100
3.3.2 MAN POWER REQUIREMENT:
The company has already employed maximum nos. of manpower from the nearby area. Same policy
of local employment will be followed for the proposed expansion project as well.
The existing unit has existing manpower of 98 nos. Additional manpower shall be employed during
the construction & operation phase directly and indirectly through contracts for Civil Construction,
Piping Works and Associated Amenities. Approximately 75 nos. of people will get direct employment
during the construction phase.
Based on the unit’s organizational pattern, after proposed expansion total 110 nos. of technical staff
will be required to operate the plant after the proposed expansion.
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3.3.3 ELECTRICITY REQUIREMENT:
Source: Torrent Energy Ltd
Total Connected load -5110 KW
Original Contract Demand -1920 KW
Existing Contract Demand, which is used - 1520 KW
Proposed additional Contract Demand – 30 KW
No change in existing contract demand due to proposed expansion as only additional 30 KW of
additional connected load is required for proposed expansion, which is already available with unit.
Hence no additional electricity will be required for proposed expansion.
With all these actions, unit is able to operate plant with lesser amount of electricity. Hence no
additional power will be required for the proposed expansion. To substantiate the electricity
consumption below the consented quantity bill of last two month is attached as Annexure-8.
The proponent is energy conscious and has taken various actions to reduce the power
consumption:
Replacing higher HP pumps with lower HP pumps
Replacing various lights with LED lights
Avoiding double pumping at various locations
Replacing cooling tower fans by FRP fans
Replacing electrical driven pump & blower with steam turbine driven etc.
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3.3.4 WATER REQUIREMENT:
Source of water: GIDC Water Supply
Unit has obtained permission for 750 KLD water for the existing unit and no additional water will be
required for the proposed expansion. (Copy of the water withdrawal permission is attached as
Annexure-3)
Table 2: Water Consumption
Existing (KLD)
Actual Water consumption (KLD)
Proposed (KLD)
Total (KLD)
i) Domestic 50 45 5 50
ii) Industrial
a) Processing 17 10 7 17
b) Waste heat
recovery Boiler
595 357 238 595
b) Combination
Cooling
80 33 47 80
d) Washing 8 5 3 80
Total Requirement 750 450 300 750
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4.0 RAW MATERIAL AND PRODUCT DETAILS
4.1 RAW MATERIAL DETAILS
An estimated requirement of various raw materials for the proposed expansion is given in following
table. The basic raw materials required are given below:
Table 3: Raw Material Consumption
No. Raw Material Existing Quantity
Per annum
Proposed Quantity
Per annum
Total Quantity
Per annum
1 Sulphur 43500 MT 21750 MT 65250 MT
2 Natural Gas 29350000 Nm3 815000 Nm3 37500000 Nm3
3. Water 250000 M3 Nil 250000 M3
4. Electric Power 1900 kVA Nil 1900 kVA
4.2 PRODUCT DETAILS
The unit is engaged in manufacturing CS2 with capacity of 50,000 MT/Annum and increase the
production capacity up to 75,000 MT/Annum.
Table 4: Details of Product
No. Product Existing
Quantity
Proposed
Quantity
Total
Quantity
1 Carbon Di-sulphide 50,000 MTPA 25,000 MTPA 75,000 MTPA
2 Steam Export 45,000 MTPA 20,000 MTPA 65,000 MTPA
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5.0 MANUFACTURING PROCESS:
This plant will produce liquid Carbon Di sulphide (CS2) by using natural gas and melting sulfur as raw
materials, the whole process consists various units like of Molten Sulfur Preparation Unit, Natural Gas
Purification Unit, CS2 Synthesis Unit, CS2 Refining Unit, Sulfur Recovery Unit, Tail Gas Treatment Unit, CS2
Tank Farm and Utilities to meet the requirements of process. The natural gas based proprietary
technology of CS2 production for this project has been provided by Shanghai Baijin Chemical Group
Company and same procedure will be adopted for the continued in the proposed expansion. The
synthesis process is as under:
a) Liquid Sulfur Unit
Solid sulphur powder, granular or flake sulfur is acceptable and large lump sulfur is not permissible. The
Sulphur is stored in solid sulfur storage yard. It is then fed to melting sulfur tank and then the molten
sulfur is pumped into sulfur filter for filtration. Finally this on-spec liquid sulfur is flown into the
underground molten sulfur storage pit for pumping into the reacting furnace as the raw material of CS2
synthesis. While the liquid sulfur recovered by the flash system of the CS2 production and Sulfur
Recovery Unit, shall enter directly the underground pit of the liquid sulfur, where it is also transmitted by
the liquid sulfur feed pump to the CS2 reacting furnace for reaction. Provisions for receiving molten liquid
sulfur from outsource and unloading from liquid sulfur tankers directly into molten sulfur storage tank
are provided.
b) Natural Gas Purification Unit
Natural gas received is purified by the Natural Gas Purification Unit with Pressure Swing Adsorption (PSA)
unit to desired purity for the reaction. Off gases are used for reactor heating purposes.
c) Reaction Unit
Natural Gas – Sulfur Method is adopted with natural gas as feed for CS2 production.
CH4 + 2S2 CS2 + 2H2S
After the natural gas (feed natural gas), with its pressure stabilized via PSA purified gas buffer tank, is
metered accurately, it enters the preheating section of tubular heating furnace. After mixing with the
liquid sulfur (excess sulfur) from the liquid sulfur Unit via mixer, it enters the heating section of tubular
heating furnace, where the material is fluidized severely and the liquid sulfur vaporized. The gaseous
sulfur and natural gas (mainly methane) are heated with partial chemical reaction inside furnace. The
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mixed gas coming from the tubular heating furnace enters the adiabatic reactor, while the unreacted
gaseous sulfur and natural gas continue to react inside the adiabatic reactor. Upon completion of
reaction, the reaction process gas coming from the adiabatic reactor is sent to the refining unit.
d) Refining Unit
The hot gases received from reaction section are cooled to recover Sulphur/H2S & CS2 is refined.
Recovered Sulphur is send to Sulphur tanks while H2S is send to Claus unit for further conversion to
elemental Sulphur.
e) CS2 Tank Farm
For the convenience of production management, the on-spec CS2 produced by CS2 Refinery Unit enters
the finished product intermediate tanks separately. The finished product produced in each shift, after
qualified via laboratory test, is sent by the finished product forwarding pumps, to the large CS2 tank in
the tank farm or to the pitch-arm loading station for tank truck loading.
f) Sulfur Recovery Unit
The sulfur recovery unit (SRU) comprises of one thermal reaction section and two catalytic reaction
sections. Here Sulphur is recovered from H2S based on partial oxidation of H2S, and subsequent reaction
of H2S and SO2.
g) Tail Gas Treatment Unit
In the tail gas treatment unit, the residual H2S containing gas from the Claus unit is recovered via Amine
absorption and regeneration process. The recovered gas is fed back to the Claus furnace for recovery.
The treated gas from the Amine section is then taken to a thermal oxidizer furnace, where the traces of
H2S remaining are converted to SO2, before the gases leave from the stack. This ensures a recovery
Efficiency of 99.9% in SRU.
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h) Energy Saving & Heat Recovery Plan
The proposed plant will consist of various waste heat recovery boilers /turbines to recover energy in
most economical way. The plant will be self-sufficient in Steam production and also export steam to
neighbouring company. An optimized energy saving scheme will be part of Basic Energy Package.
Figure 5: Manufacturing Process flow sheet
Salient Features of the Process/Technology adopted /to be adopted
Existing CS2 manufacturing plant in India requires 350 kg charcoal per MT CS2 production which
comes from 1000 kgs of wood which results in to deforestation of 58 km2 per year.
SBC technology is well proven and replaces charcoal by Natural gas.
Proposed plant will be zero effluent discharge plant.
SRU is based on SCOT process technology, which shall achieve recovery efficiency of 99.9%.
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7.0 ENVIRONMENTAL MANAGEMENT PLAN
7.1 AIR ENVIRONMENT:
Adequate and efficient measures shall be provided to keep the process and dust emission at a
minimum level. The particulars of most specific individual sources and their pollution control
measures are as follows:
Table 5: Details of Air Emission
Stack No: 1
Stack : 1
Stack attached to : Tail Gas Treatment Unit & Flue Gas from Reaction heating Furnace
Stack height from GL : 80 m
Temperature : 270oC
Expected Pollutants : SOx, NOx, CO2
Air Pollution Control Devices : Sulfur recovery Unit
Stack No: 2
Stack : 1 (Emergency Flare Stack)
Stack attached to : Emergency system venting
Stack height from GL : 30 m
Expected Pollutants : SO2
Air Pollution Control Devices : --
Stack No: 3 & 4
Stack : 2 (Emergency back-up power Generator- DG )
Stack attached to : D G Set if capacity 1650 kVA
Stack height from GL : 11 m
Expected Pollutants : SOx, NOx, CO
Air Pollution Control Devices : --
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No additional furnace, emergency flare stack or D.G.Set will be required the proposed expansion as the
existing furnace has additional capacity to take care of additional load for the proposed expansion.
7.2 WATER ENVIRONMENT:
Water Consumption
Existing water requirement for domestic and industrial purposes is 750 KLD and is obtained from
the GIDC water supply.
Table 6: Water Consumption
Existing (KLD)
Actual Water consumption (KLD)
Proposed (KLD)
Total (KLD)
i) Domestic 50 45 5 50
ii) Industrial
a) Processing 17 10 7 17
b) Waste heat
recovery Boiler
595 357 238 595
b) Combination
Cooling
80 33 47 80
d) Washing 8 5 3 80
Total Requirement 750 450 300 750
In the proposed expansion, no additional water will be required as existing water quantity shall be
sufficient to meet additional water requirement for proposed expansion. Unit has implemented
various schemes for water conservation such as –
Using treated waste water for make up in dyke wall
Steam condensate recovery system
Replacing filter press in waste water treatment plant with pressure sand filter
Providing side stream filter for cooling tower etc.
With all these actions, unit is able to operate plant with around 450 KL/day water consumption.
Hence no additional water will be required for the proposed expansion. To substantiate the water
consumption below the consented quantity water cess return of last three years is attached as
Annexure-7.
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Wastewater Generation:
Indo Baijin is/will use using high cost Hydrogen Reduction Technology instead of cheaper and generally
used desulphurization technology to eliminate generation of high quantities of waste water.
The wastewater is mainly the blow down water from various waste heat recovery units (waste heat
boiler), DM plant wash water, the unrecovered steam condensate (majority of which is recovered),
moisture separated in the oxidation tower, the ground flush water, etc. They are/will be collected, mixed
and cooled inside the plant, and then sent to the wastewater treatment unit.
Table 7: Wastewater Generation
Existing wastewater
(KLD)
Actual Wastewater generation
(KLD)
Proposed Wastewater
(KLD)
Total (KLD)
i) Domestic 20 15 5 20
ii) Industrial
a) Processing 17 10 7 17
b) Waste heat
recovery Boiler
460 282 178 460
b) Combination
Cooling
0 0 0 0
d) Washing 8 5 3 8
Total Requirement 505 312 193 505
Existing wastewater Generation:
1. The evaporation losses of 585 KLD from combination cooling tower, these water is coming from 80
KLD of fresh water and 505 KLD of recycle water steams from process, waste heat recovery boiler,
washing and domestic activities.
2. The total fresh water intake of 750 KLD is the sum of evaporation losses of 585 KLD in cooling
tower + 135 KLD steam export + 30 KLD horticulture consumption.
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Actual wastewater Generation:
1. The evaporation losses of 345 KLD from combination cooling tower, these water is coming from
33 KLD of fresh water and 312 KLD of recycle water steams from process, waste heat recovery
boiler, washing and domestic activities.
2. The total fresh water intake of 450 KLD is the sum of evaporation losses of 345 KLD in cooling
tower + 75 KLD steam export + 30 KLD horticulture consumption.
Proposed additional wastewater Generation:
1. The evaporation losses of 240 KLD from combination cooling tower, these water is coming from
47 KLD of fresh water and 193 KLD of recycle water steams from process, waste heat recovery
boiler, washing and domestic activities.
2. The total additional fresh water intake of 300 KLD is the sum of evaporation losses of 240 KLD
in cooling tower + 60 KLD steam export.
Conclusion:
No additional water will be required for proposed expansion as actual water consumption will be very
much less than the granted water withdrawal permission from GIDC, hence no additional water
permission will be required due to proposed expansion.
No additional wastewater treatment facility will be required for proposed expansion as existing facility
is adequate to treat the existing as well as proposed quantity of effluent. The existing wastewater
treatment facility i. e Combination Cooling Tower has capacity to treat 585 KLD wastewater, but actual
wastewater generation of existing unit is around 345 KLD only. Hence existing treatment facility has
spare capacity to treat the additional load due to proposed expansion.
All the generated effluent is/will be evaporated in Combination Cooling Tower hence unit is/will be a
zero liquid discharge unit.
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Figure 6: Water balance diagram, in KLD
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Action Plan for Zero Discharge of Effluent
a) Wastewater Streams :
i) Water from the Boiler feed water pollutant rejects from the demineralising section, and blowdown
water from waste heat recovery boiler. The average composition of this stream is within 800 ppm
of dissolved salts. The maximum actual quantity is 282 KLD.
ii) From the tail gas treatment section of Sulphur recovery unit, the excess water condensed from the
flue gas is separated in the water removal tower. This water called Sour water and has traces of
H2S. This is treated in an oxidation tower to convert the H2S into safe salt Na2S2O3. The maximum
actual quantity is 10 KLD. The concentration of dissolved salts is within 200 ppm.
iii) The third stream is from general washing of plant and lab areas, this quantity is maximum actual 5
KLD. The concentration of dissolved salts is within 200 ppm.
Action Plan for Zero Waste Water Discharge:
As all the waste water streams are not having any COD and BOD, and only have shall quantity of dissolved
solids (salts), the design Philosophy of the plant has included the concept of ‘Zero Waste Water
Discharge”. In existing practice, Indo Baijin is using “Combination Type Cooling Towers” to achieve zero
liquid discharge and same shall be utilized after proposed expansion.
Figure 7: Flow Diagram of Combination Cooling Tower
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Inside this cooling tower, the circulating cooling water flows through the inside of the cooling tube
bundles. This tube bundle is cooled from the outside in set up similar to a conventional cooling tower.
The outside water is circulated and sprayed on top of the tube bundle, and also a draft is maintained by a
fan across the cooling tower. By evaporation of outside water, the water inside the tube bundle is cooled
and returned to the plant supply. As the outside water is not taken directly to the plant cooling duties it
can be used and circulated with high solid content.
Combination Cooling Tower Treatment Scheme
To understand the concept of this Combination type of cooling tower, we need to compare this with the
conventional cooling tower working.
Working of Conventional Cooling Tower:
In a conventional cooling tower, the cooling water return streams from the plant are cooled by direct
contact with air, and the cooling takes place by part evaporation from the circulating water. During this
process the salt concentration of the water increases, and some water is drained off as blowdown to limit
the concentration of salts in the cooling water circuit. This is required to ensure water quality fit for heat
transfer in the plant equipment. This demands that only clean good water is added for making up the
losses in the cooling water system which are based on conventional cooling towers.
The Working of Combination Cooling Tower:
In this cooling tower, the cooling operation in the cooling tower is separated & isolated from the
circulating cooling water used to remove heat from the plant equipment. This ensures a closed circuit for
cooling in the plant, and hence no contamination of this stream takes place. The hot return stream from
the plant is cooled by indirect contact in the cooling tower, by a local circulation of water which in turn is
cooled by evaporative cooling by contact with air.
The local circulation water stream in the cooling tower can be used continuously till it reaches a critical
concentration of dissolved solids, after which it is discharged to a final evaporator for separation of salts
for disposal. The design of the cooling tower ensures continuous wetting of heat transfer surface to
enable required evaporative cooling and maintaining clean surfaces without any scales formation. This
design feature is achieved by the patented co-current air-water flow technology by the supplier.
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Due to these design features it is not necessary to add clean water make up in this type of cooling tower.
Hence in our units set up we add recycle water streams as part of make up water to the cooling tower.
This enables recycling of all waste water streams (after suitable pre-treatment) of the plant as make up to
this cooling tower. Therefore the plant facility does not discharge any waste water from the premises.
The addition of recycle streams also enable saving of fresh water consumption of over 200 KLD for our
unit. Elimination of blowdown from the cooling tower saves another 80 KLD considering a concentration
cycle of 7. Therefore this system saves about 300 KLD or 100,000 m3/annum for our unit.
In our existing project these is served as the Heat Sink and also Zero Discharge Unit, by combining the
functions of the cooling tower and also a water evaporator. Adequate overdesign has been built into this
system to ensure sufficient spare capacity.
Domestic Waste Water:
The domestic waste water streams shall be treated in a modern packaged sewage treatment unit with
capacity of 50 KLD, and the treated water shall be available for reuse in toilets, and feeding to the Zero
Discharge cooling tower unit.
Figure 8: Sewage Treatment Plant (STP) Flow Diagram
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Table 8: Sizing of Sewage Treatment Plant
7.3 SOLID/HAZARDOUS WASTE
The entire quantity of hazardous waste is handled and disposed as per Hazardous Waste (Management,
Handling and Trans-boundary Movement) Rules - 2016. Furnace slag from furnace pipe and reactor
cleaning, Used spent Oil, Discarded Container/Barrels/Liners, Evaporation salt and Sludge from sulfur
filter are generated from existing unit. Unit has obtained membership for BEIL (Attached as Annexure-5).
After expansion, no additional quantity of Hazardous waste will be generated except Sludge from sulfur
filter. As a solid waste STP sludge is generated, which is used as manure in the premises.
Table 9: Hazardous/Solid Waste Generation
No. Name of Waste Waste category
Existing Total after Proposed expansion
Solid waste Disposal / Management
1 Furnace slag from furnace pipe and reactor cleaning
1.1 55 MTPA 55 MTPA Collection, Storage, Transportation & Disposal at common incineration facility.
2 Used spent Oil 5.1 1.0002 MTPA
1.0002 MTPA
Collection, Storage, Transportation & Disposal by selling to register refiners
3 Discarded Container/Barrels/Liners
33.1 100 MTPA 100 MTPA Collection, Storage, Transportation & Disposal by GPCB approved scrap dealer
4 Evaporation salt 37.3 144 MTPA 144 MTPA Collection, Storage, Transportation & Disposal at TSDF, BEIL.
5 Sludge from sulfur filter -- 55 MTPA 78 MTPA
Collection, Storage, Transportation & Disposal at at common incineration facility.
S No Unit Size
1 Collection tank 3 m X 1 m X 3 m
2 Aeration tank 3 m X 3 m X 3 m
3 Treated water tank 2 m X 2 m X 3 m
4 Filtered water tank 2 m X 2 m X 3 m
5 Sand filter cum solid collection tank 2 m X 2 m X 3 m
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No. Name of Waste Waste category
Existing Total after Proposed expansion
Solid waste Disposal / Management
Solid waste
1 STP Sludge 30 kg/day -- Used as manure
7.4 NOISE ENVIRONMENT
The industry is in the SEZ area and located 8-km away from the nearest settlement. There are two
categories of noise generated due to the unit.
Noise due to plant operation
Noise due to transportation of vehicles.
Noise Control Measures:
All the vibrating parts are checked periodically and serviced to reduce the noise generation. The
equipment, which is prone to generate excessive noise, is already provided with enclosures. To
minimize the adverse effect on the health, ear muffs/ earplugs is provided to the workers working
under high noise area.
The industry has already developed 16500 m2 area for green belt around the periphery of the plant. This
will help in reducing the adverse effect of noise pollution in general. All the equipment in the complex is
designed/operated in such away that the noise level shall not exceed 85 dB (A).
All rotating equipment in the plant would be designed/operated to have a total noise level not
exceeding 85 to 90 dB (A) as per the requirement of OSHA (Occupational Safety and Health
Administration) standard and the Environment (Protection) Rules.
However, if during operation, the noise level exceeds the above norms then the protective measures
given in Environmental Management Plan will be followed. Hence, no impact due to proposed plant on
ambient noise is anticipated.
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7.5 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT
The company is very much concerned in terms of health, safety and environment protection. Indo Baijin
commitment towards safety can be reflected from its ‘Health, Safety & Environment Policy’ prepared
for the existing project.
No major accident has taken place in the factory so far in the existing project. From their previous
performance, same dedication is to be continued for the proposed expansion. To maintain high
standards in Health, Safety and Environment, various activities are undertaken at the site.
The following key safety measures are implemented in the existing plant and the same shall be a part of
proposed expansion project:
1. Safety Training is provided to the employees.
2. Safety Sirens with Alarm System in case of emergency are provided.
3. Emergency Control Room is established.
4. Assembly point is provided.
5. Sprinkler Systems will be provided as needed
6. Fire Hydrant System is installed.
7. Fire Extinguishers are provided.
8. Mock drills are periodically conducted and factors like response time are evaluated.
9. Fire squad team is formed for handling any emergency situation.
10. First Aid Facility and training are provided.
11. Personal protective gears and equipments are provided to employees.
12. Health check-ups are organized at regular intervals.
13. Safety / Health records are maintained.
14. MSDS for all the chemicals are easily available.
Fire Fighting Details:
3217 m3 dedicated water storage for firefighting.
46 hydrant point with hose boxes nearby.
2 Electrical operated water Monitor, can be operated from remote location.
10 Manual Water monitors.
160 Different size of ABC pressurised Extinguishers.
16 Different size of CO2 Extinguishers.
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8.0 SITE ANALYSIS
8.1 CONNECTIVITY
The project location is well connected with road, rail and air route to transport raw materials,
machineries, etc. and hence it exhibits good potential for industrial growth. The salient features
mentioned below, indicate favorable conditions for industrial development at the project location.
Table 10: Salient Features of the project site
Particulars Details
Approx. Geographical Co-ordinates
Latitude Longitude
A 21°42'35.74"N 72°37’06.78"E
B 21°42'36.02"N 72°37'10.94"E
C 21°42'27.10"N 72°37'11.04"E
D 21°42'30.92"N 72°37'10.30"E
Village Vadadla(@ 2.4 km in NE direction)
Nearest Town Bharuch (@ 40.0 km in E direction)
Nearest City Bharuch (@ 40.0 km in E direction)
River/Streams Narmada Estuary (@3.00 km in S direction)
Sea Arabian Sea (@ 11.0 km in W direction)
Nearest Highway
N. H. No – 228 (@ 36 km in E direction)
N. H. No –8 (@ 36 km in E direction)
S. H. No – 6 (@ 42 km in EEN direction)
Nearest Railway Station Dahej Railway Line (@ 2.50 km in WWN direction)
Bharuch (@ 40 km in E direction)
Nearest Airport Surat Airport (@ 66 km in SSE direction)
National parks/ sanctuaries None within 10 km radial area
Defense installations None within 10 km radial area
Note: All the above – mentioned distances are aerial distances from the project site.
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8.2 TOPOGRAPHY
Proposed expansion is between 20007” to 21005” North Latitude and 72043” to 73000” East
Longitude having elevation of 25 meters above sea level. The topography of the proposed site for
the project is plain terrain.
No forests, national park or wild life sanctuary is located within 10 km periphery of the project site.
No change in Land use/Topography is envisaged as the proposed project is expansion project and is
established in SEZ-1, Dahej.
8.3 EXISTING INFRASTRUCTURE
Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities
such as park, market, playground etc. education, health care, community development, income
distribution, employment and social welfare are available in the study area of project site.
8.4 SOIL CLASSIFICATION
Proposed expansion will be carried out in existing premises located in SEZ, where land is already
developed for industrial purpose. Quality of soil is not considerably fertile for agriculture activities
and no evidence of any influence of soil contaminant has been noticed.
8.5 CLIMATE DATA FROM SECONDARY SOURCE
Table 11: Climate Data
Climate Type and Details
Climate Temperate climate-Semi Arid
Seismic Zone Zone III
Maximum temperature, °C 44 °C
Minimum temperature, °C 12°C
Relative Humidity Max.:- 97 %; Min.:- 20%
Max Rainfall 1500 – 2200 mm
Climate Temperate climate
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9.1 PROJECT SCHEDULE & COST ESTIMATES
9.1 PROJECT SCHEDULE
Proposed expansion activities will be started after getting statutory clearance from related authorities.
9.2 PROJECT COST ESTIMATION
No. Project Estimate cost
1 Proposed expansion cost Rs. 15 Crores
9.3 CSR ACTIVITIES
Indobaijin which is a part of Indofil group company, has always engaged in social welfare activities &
programs. It directly organizes various programs for social welfare & upliftment or indirectly contributes in
such activities conducted by other organizations by providing financial & other aid. Indobaijin is committed
to contribute in social welfare & upliftment activities on a regular basis. Indobaijin will continue such
activities to fulfill the requirements of its social responsibility under CSR Programs. With development of
community services like medical services, blood donation camp, donation for schools etc will also be
developed as a part of corporate social responsibility. Medical camps and education programmes would be
conducted for the welfare of employees and their families.
Indobaijin Chemicals Pvt Ltd. in collaboration with a non-government organisation (NGO) Ballygunge
Society for Environment & Development undertakes CSR activities in the village Purba Gopinathpur. The
following activities are evident of the fact that Indobaijin is a promoter of CSR Programs:
Donation given to JCI - Bharuch for Election Awareness Campaign organized by them at Dahej.
Donation given to CM of Gujarat (Mrs. Anandiben Patel) under Clean India Campaign.
Food Packets distributed to poor villagers of Vagra Taluka who attended “Garib Kalyan Mela” at
Jambusar.
Houses for Poor Villagers of Dahej: Given approval to construct 3 (Three) houses for poors of
Dahej village. This will be sample houses. Based on the success of this; new project will be
assigned.
Development of Digital Classroom: Given approval to Primary Girls School of Dahej to develop 1
(One) class room of the school as Digital Room.
Organised various seed to seed demonstrations, soil testing and training on safe and judicious
use of pesticides
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Operated Agril Library having more than 200 books on agriculture thrice a week at the local club
premises
Provided computer training through two trainers to 80 students thrice a week
Trained 65 young people, mostly girls, for athletics and 40 youths for football, twice every week,
under eminent coaches.
Organised health camps once in every fortnight to provide treatment for ailment and health
counseling.
Constructed sanitary facilities, especially for girls and women, at the village club premises.
Planted around 250 saplings throughout the village.
Organised cultural programmes, rally and competitions to increase awareness about the
environment.
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FINANCIAL & SOCIAL BENEFITS
The proposed activities will be carried out in the existing unit itself. Hence, no additional land is
to be purchased.
This project utilizes natural gas as one of the raw materials for the synthesis of the product.
Currently all the existing CS2 manufacturing units in India use wood charcoal for this purpose.
Considering 350 kilograms of charcoal consumption per ton of CS2, one ton of wood is used per
ton of CS2. Thus at 50,000 tons of CS2 production per annum, this project will reduce
deforestation to the extent of 58 km2 per year in the country. Thus, the project entails financial
benefits in terms of energy saving.
The company has also allocated some budget for CSR activities, which can lead to improved
social infrastructure, if planned properly.
Temporary employment of 75 people during the construction phase of the proposed
expansion. Employment to approx. 12 people is a direct benefit.
Conclusion:
As summarized in the above sections, it has been noticed that the proposed project for expansion
in capacity will not have any major impacts, which can lead to serious issue of environmental
pollution or any other hazards.
Considering the probability of impacts, proponent has planned adequate mitigation measures and
EMP. Further, it is also planned by proponent to organize CSR programs, rainwater harvesting,
energy conservation, which will have considerable beneficial impacts. Looking to the employment
potentials and other allied developmental potentials, it is noticed that the proposed project will
significantly help in improving social status of the region.
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Annexure 1: Existing Environmental Clearance
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Annexure 2: Consent to Operate (CC&A)
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Annexure 3: Water withdrawal Permission from GIDC
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Annexure 4: Land Document
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Annexure 5: Membership of BEIL
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Annexure 6: EC letter for Dahej SEZ
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Annexure 7: Watercess returns of last three years
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Annexure 8: Electricity of last two months
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