PRE-FEASIBILITY REPORT

PROPOSED EXPANSION PROJECT FOR

MANUFACTURING OF CARBON BLACK & CAPTIVE

POWER PLANT (GREEN POWER)

[Category: 5 (e) B]

OF

PLOT NO. 1, PALEJ INDUSTRIAL ESTATE OF GIDC

TALUKA & DIST.: BHARUCH, STATE: GUJARAT

PREPARED BY

3RD FLOOR, AKASHGANGA COMPLEX,

NR. PARIMAL UNDERPASS, B/S. SUVIDHA SHOPPING CENTRE, PALDI, AHMEDABAD – 380 007.

TELEFAX: (079) 2665 0473, 2665 0878 ENVISAFE@GMAIL.COM

APRIL, 2018

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Table of Contents

Page | i

TABLE OF CONTENTS

Contents …………………………………………………………………………………. i

List of Tables…………………………………………………………………………….. iii

List of Figures……………………………………………………………………………. iii

List of Drawings…………………………………………………………………………. iii

CONTENTS

SR. NO.

TITLE PAGE NO.

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY 1-4

1.1 General 1

1.2 Silent Features of the Plant Site 1

1.3 Resources Requirements 1

1.4 Pollution Potential and Mitigative Measures 3

2.0 INTRODUCTION 5-8

2.1 Background 5

2.2 Regulatory Framework 5

2.3 Nature of the Project 6

2.4 Project Proponent 6

2.5 Need for the Project & Project Benefits 7

3.0 PROJECT LOCATION & SITE ANALYSIS 9-12

3.1 Location 9

3.2 Site Analysis & Infrastructure Set-up 11

3.3 Details of Alternative Sites and Justification of Site Selection 11

4.0 PROJECT DESCRIPTION 13-17

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Table of Contents

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SR. NO.

TITLE PAGE NO.

4.1 Details of Products and Production Capacity 13

4.2 Land and Project Layout 13

4.3 Resources Requirements 15

4.4 Details of Manufacturing Process 17

4.5 Raw Material Requirements 17

4.6 Details of Machineries & Equipment 17

5.0 POLLUTION POTENTIAL AND CONTROL MEASURES 18-25

5.1 Water Pollution

(a) Details of Water Requirement & Wastewater Generation 18

(b) Wastewater Management System 20

5.2 Air Pollution

(a) Process Gas Generation 21

(b) Flue Gas Generation 22

(c) Fugitive Emission 23

5.3 Hazardous Waste Generation and Management 24

5.4 Noise & Vibration Control 24

6.0 PROJECT SCHEDULE & COST ESTIMATES 26

6.1 Schedule of Approval and Implementation 26

6.2 Capital Investment 26

7.0 FINAL RECOMMENDATIONS 27

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Table of Contents

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[

LIST OF TABLES

TABLE NO.

TITLE PAGE NO.

1 Promoters of the Company 6

2(a) List of Products 13

2(b) List of Existing By-Products 13

3 Break-up of Plot Area 15

4 Details of Fuel Requirement 16

5 Details of Manpower Requirement 16

6 Details of Raw Material Requirements 17

7 Details of Proposed Machineries and Equipments 17

8 Category-wise Water Requirement & Wastewater Generation 19

9 Summary of Water Balance 19

10 Details of Process Gas Stack & APCM 22

11 Details of Flue Gas Stack 23

12 Hazardous Waste Generation and Management 24

13 Capital Cost 26

[

LIST OF FIGURES

FIGURE NO.

TITLE PAGE NO.

1 Location of Project Site 9

2 Google Image of 500 m & 1 km Radial Distance from the Project Site

10 [

LIST OF DRAWINGS

DRAWING NO.

TITLE PAGE NO.

1 Plant Layout 14

2 Water Balance Diagram 20

3 Schematic flow diagram of Existing Effluent Treatment Plant 21

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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1. EXECUTIVE SUMMARY

1.1 General

M/s. Phillips Carbon Black Ltd. is an existing large-scale unit located at Plot no. 1,

Palej industrial estate of GIDC in Bharuch District of Gujarat state. It is involved in the

manufacturing of Carbon Black with the total production capacity of 10,083 TPM and

captive power generation of 18 MW (Operational 12 MW). Now, the unit proposes to

expand manufacturing capacity by addition of various other grades of Carbon Black

with additional production capacity of 10,103 TPM and captive power generation of 12

MW. Hence, total production capacity of carbon black will increase up to 20,186 TPM

and captive power generation up to 30 MW after proposed expansion.

The proposed project is covered under Category 5(e)-B as per new EIA Notification of

Ministry of Environment Forest & Climate change (MoEF&CC), dated 14/09/2006 and

subsequent amendments. Therefore, unit requires obtaining Environmental Clearance

from State Level Environment Impact Assessment Authority (SEIAA), Gujarat.

1.2 Salient Features of the plant site

• The project site is located in the notified industrial area developed by Gujarat

Industrial Development Corporation (GIDC) having all basic facilities like availability

of electricity, transportation and telecommunication systems etc.

• The proposed expansion will be carried out in existing industrial premises located in

the industrial estate of GIDC. Existing plot size is adequate for the proposed

expansion requirements and will facilitate existing infrastructure mainly covering

utility services. Thus, no additional land will be required.

• Plant site is about 24 km away from Bharuch city and about 34 km away from

Vadodara city which are well connected by road, rail to rest of India.

• Availability of trained and skilled manpower in nearby areas.

• There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-

1986 exists within 10 Km radius areas from the Plant Site.

1.3 Resources Requirements

• Land: The total plot area for the existing plant is 1,24,479 m2. Proposed expansion

will be carried out within existing premise. Hence, no additional land will be required

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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for the proposed expansion. Land allotment letter for the existing plant is enclosed

as Annexure 1.

• Water: Presently, water requirement of the unit is met by borewell water supply and

same source will be utilized after proposed expansion. The total fresh water

requirement for the existing plant is 1,390 KLD which will increase up to 2,560 KLD

after proposed expansion.

• Power: At present, the total power requirement is 5 MW which is fulfilled by own

captive power plant having power generation capacity of 18 MW out of which 12

MW is operational and excess power generated (7 MW) is sent to Grid.

After proposed expansion, self-power consumption will increase up to 10MW (5

MW existing + 5 MW proposed). Power generation capacity will increase up to 30

MW. Excess power generated will be sent to Grid after proposed expansion.

Also, for startup of the plant, unit requires power supply of 2,500 kVA which is

procured from Dakshin Gujarat Vij Company Ltd. Unit will install two nos. of DG

Sets (standby) of 750 kVA each in case of emergency power supply.

• Fuel: Presently, Off gas @ 68,000 Nm3/hr is utilized for boiler of captive power

plant and LDO @ 60,090 Lit/day is required as standby fuel in manufacturing

process for heating of reactors only during startup.

Off gas generation will increase upto 1,28,000 Nm3/hr after proposed expansion.

There will be no increase in LDO requirement for the proposed expansion. Diesel

requirement for standby DG Sets (2 Nos. x 750 kVA) will be 320 Lit/hr which will be

used only during emergency situations when both grid and CPP power is not

available.

• Manpower: Total 305 personnel are working in the existing plant and after

proposed expansion manpower requirement will increase upto about 421

personnel.

• Finance: The unit is a large scale unit and has made capital investment of Rs.

215.5 Crore in the existing plant. The estimated cost for the proposed expansion

will be about Rs. 190 Crore. Capital cost towards Environmental protection

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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measures is Rs. 3 Crore which will increase upto Rs. 27 Crore after proposed

expansion.

1.4 Pollution Potential and Mitigative Measures

• Water Pollution: Presently, there is no effluent generation from manufacturing

process. Effluent generated from other industrial activities including WTP reject is

188 KLD which is collected and treated in ETP having primary and tertiary

treatment. Treated effluent of 188 KLD from ETP is reused in the manufacturing

process. Hence, the unit maintains “Zero Effluent Discharge”.

After proposed expansion, there will not be any effluent generation from

manufacturing process. Effluent generation from other industrial activities including

WTP reject will be 400 KLD. This effluent will be collected and treated in upgraded

ETP. Treated effluent of 400 KLD from ETP will be entirely reused in manufacturing

process. There will not be any wastewater discharge from industrial activity. Hence,

the unit will maintain “Zero Effluent Discharge”.

Sewage generation after proposed expansion will be 100 KLD which will be treated

in STP and treated sewage will be re-used for greenbelt development.

• Air Pollution: The main source of flue gas generation from existing plant is steam

boiler of captive power plant. Since off gases from manufacturing process are

passing through process bag filters and utilized as fuel for steam boiler, there is no

requirement of APCM. However, unit has provided adequate stack height to the

captive power plant for proper dispersion of pollutants. There is process gas

generation in the form of PM, SO2, NOx and H2S from different sections of the plant.

Unit has provided separate bag filters along with stack of adequate height as an

APCM for all the respective sections of the plant.

After proposed expansion, main source of flue gas generation will be proposed

steam boiler and DG sets (standby). Since off gases from manufacturing process

will be passing through process bag filters and will be utilized as fuel for steam

boiler, there will be no requirement of APCM. However, unit will provide stack of

adequate height to the proposed captive power plant and DG sets for proper

dispersion of pollutants. There will be increase in above listed process gas

generation. Unit will provide additional separate bag filters along with stacks of

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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adequate height as an APCM for all the different sections of the plant. There will be

chances of fugitive emissions due to process, material handling and transportation.

Adequate measures will be provided for control of fugitive emissions.

• Hazardous Waste: The main source of hazardous waste from the existing plant is

ETP sludge and other wastes from plant viz. spent ion exchange resin, waste

insulation material. The ancillary source of hazardous waste is used oil from plant &

machinery and discarded containers/bags/liners/waste paper bags/waste plastic

bags from storage and handling of raw materials. The unit has provided an

adequate designated storage area for the storage of hazardous waste. After the

proposed expansion, there will be increase in existing hazardous waste generation.

There will not be any additional hazardous waste generation from the proposed

expansion.

• Greenbelt Development: The unit has developed green belt in 41,100 m2 (33.02%)

within the existing industrial premises. At present, unit has planted around 1,200

nos. of trees of various types. Unit proposes to plant additional 800 nos. of trees

during proposed expansion.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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2. INTRODUCTION

2.1 Background

M/s. Phillips Carbon Black Ltd. is an existing large-scale unit located at Palej

industrial estate of GIDC in Bharuch District of Gujarat State. It is involved in

manufacturing of Carbon Black with the total production capacity of 10,083 TPM and

captive power generation of 18 MW (Operational 12 MW). Now, the unit proposes to

expand manufacturing capacity by addition of various grades of Carbon Black with

additional production capacity of 10,103 TPM and captive power generation of 12 MW.

Hence, total production capacity of carbon black will increase up to 20,186 TPM and

captive power generation up to 30 MW after proposed expansion.

2.2 Regulatory Framework

Unit has been granted fresh Consent to Establish (CTE/NOC) in the name of Gujarat

Carbon & Industries Ltd. for manufacturing of carbon black in the year 1978 from

Gujarat Pollution Control Board (GPCB). Unit has been taken over by Phillips Carbon

Black Ltd. in November 1997 for manufacturing of carbon black. Unit had been granted

Consolidated Consent & Authorization (CC&A / CTO) on 25/11/1997 in the name of

Phillips Carbon Black Ltd. Presently, unit has been granted amendment in Consolidated

Consent & Authorization (CC&A / CTO) vide order no AWH-429310 dated 29/11/2017

which is valid upto 16/04/2018 for existing plant. Copy of CC&A is enclosed as

Annexure- 2. Unit has applied for the renewal of CC&A on 22/03/2018 for the existing

plant.

The unit has not obtained Environmental Clearance (EC) for their existing plant as it

was not covered under purview of the EIA Notification-1994 at the time of its

establishment in year 1978 and subsequent expansion carried out in September 2002

and August 2003 under. Since then, no expansion was carried out which may attract

applicability of EIA Notification 2006 and subsequent amendments.

The proposed expansion project is covered under Category 5(e)-B for manufacturing of

Carbon Black as per new EIA Notification of Ministry of Environment Forest & Climate

Change (MoEF&CC), dated 14/09/2006 and subsequent amendments. Unit will not

require to obtain Environmental Clearance for expansion in captive power plant since, it

will utilize off gases generated from manufacturing process in steam boiler and for

power generation and there will not be any auxiliary fuel required for the proposed

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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project. Therefore, unit requires obtaining Environmental Clearance for expansion in

manufacturing of Carbon Black from State Level Environment Impact Assessment

Authority (SEIAA), Gujarat. As a part of application for obtaining Environmental

Clearance, the unit requires to submit Form-1 and Pre-Feasibility Report of the

proposed expansion project.

The objectives of the report are,

a) To assess the feasibility of the proposed expansion project.

b) To identify various sources of pollution and anticipate the impacts of the

proposed expansion project on the environment.

c) To suggest preventive and mitigation measures to minimize the adverse impacts

and to prepare Environmental Management Plan (EMP).

d) Propose the Terms of Reference to carry out EIA Study for the proposed

expansion project.

2.3 Nature of the Project

The unit is an existing large-scale unit involved in the manufacturing of Carbon Black

and propose to expand manufacturing by addition of various grades of Carbon Black.

Thus, this is a brown field project where unit intends to add new products covered

under Category 5(e)-B as per new EIA notification.

The unit believes in sustainable development and is equally concerned about

environment preservation and pollution control. The unit will provide an adequate

Environmental Management System to meet desired norms of effluent discharge

(Water + Air + Solid) as per the statutory requirements for their proposed project and

also will continue its endeavor for the pollution prevention and betterment of

environment.

2.4 Project Proponent

M/s. Carbon Black Ltd. is group company of RP-Sanjiv Goenka Group and details of

its directors are given below.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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Table-1: Promoters of the Company

Sr. No.

Name Designation Qualification Experience

(years)

1 Mr. Sanjiv Goenka Non-Executive Director (Chairman)

B. Com. 33

2 Mr. Kaushik Roy

Managing Director Mechanical Engineer with a Post Graduate Degree from IIT Kharagpur and Business Administration from the University of Tokyo

27

3 Mr. Shashwat Goenka

Non-Executive Director

Graduated from the Wharton School, University of Pennsylvania with a Bachelor of Science in Economics, specializing in Finance, Marketing and Management

4

4 Mr. C R Paul

Non- Executive and Independent Director

M.SC, F.I.E.E 58

5 Mr. Om Parkash Malhotra

Non- Executive and Independent Director

B. Chem. Engg., M.I.E., F.I.I., C.H.E

53

6 Mr. Kanwar Satya Brata Sanyal

Non- Executive and Independent Director

M.A., C.B.I.M, F.I.P (London) 52

7 Mr. Paras Kumar Chowdhary

Non- Executive and Independent Director

B.SC Physics (Hons.) 40

8 Mr. Pradip Roy

Non- Executive and Independent Director

B.SC (Hons.) in Petroleum Engineering, CAIIB and Management Graduate from Faculty of Management Studies, Delhi University

42

9 Mrs. Kusum Dadoo Non- Executive and Independent Director

Science Graduate from Bethune College and a Law Graduate from Calcutta University

38

2.5 Need for the Project & Project Benefits

Phillips Carbon Black Ltd. is India's largest and globally seventh largest Carbon Black

producer with a total production capacity of 4,72,000 MT per annum in India. Carbon

black is majorly consumed (70%) as raw material in tyre manufacturing industries and

some are in high end specialized applications such as plastics products, inks, paints

etc.

Demand-Supply Gap

It is observed that the global carbon black market is expected to surpass $25 billion by

2020 growing at a CAGR of over 4% driven by rising demand from tyre industry, in

addition to construction and manufacturing sectors which use carbon black to provide

strength to industrial rubber compounds and other equipment.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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Imports vs. Indigenous production

Tyre production in Asia is going to increase by 3.6% per anum in coming years. Also,

Carbon black market in India is expected to grow at 4-5 % CAGR higher than the global

average of 3.3% during the next 5 years. This growth is driven by growth in Indian

economy of over 7% as well as capacity expansion plans of major tyre companies such

as Apollo tyres, MRF, CEAT, Bridgestone etc. to similar increase in Carbon Black

requirement. The waste gas from the Carbon Black manufacturing process is a raw

material for power generation & therefore creating a sustainable green environment.

Employment Generation (Direct and Indirect) due to project

Proposed unit will give direct employment to local people based on qualification and

requirement. In addition to direct employment, indirect employment shall generate

ancillary business to some extent for the local population.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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3. PROJECT LOCATION & SITE ANALYSIS

3.1 Location

The unit is located at Plot No. 1, Palej Industrial estate of GIDC in Bharuch District of

Gujarat State. Plot allotment letter from GIDC is enclosed as Annexure 1.

The location map of project site is shown in Figure-1 and the area covering 500 m & 1

km radial distance from the project site is given as Figure-2.

Figure-1: Location of Project Site

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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Figure –2: Google Image of 500 m & 1 km Radial Distance from Project Site

Project Site

500 m radial distance S1 Steelco Gujarat Ltd.

1 km radial distance S2 Palej Village

N

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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3.2 Site Analysis & Infrastructure setup

The salient features of the project site and study area are given below:

1. Location

:

Plot no. 1, GIDC – Palej,

Taluka & Dist. Bharuch, Gujarat

2. Geographical Locations

:

Latitude: 21°55'44.97"N

Longitude: 73° 4'43.82"E

Topo Sheet: F43/N1

3. Land use of Project site : 100% Industrial Land

4. Infrastructure Setup

(a) Village / Habitation : Palej: 500 m, South

(b) City : Bharuch: 24 km, SSW

(c) Highways : NH No.8: 500 m in East

(d) Railway Station : Palej: 1 km, SW

(e) Sea Coast : Gulf of Khambhat: 63 km, West

(f) Domestic Airport : Vadodara: 47 km, NNE

(g) International Airport : Ahmedabad: 135 km, NNW

(h) Defense installations : None

5. Place of Interest / Tourist places : None

6.

Protected areas within 10 Km radius from the Plant Site (if, any):

There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco - sensitive area notified under Section 3 of the Environment (Protection)

Act – 1986 within 10 Km radius areas from the Plant Site.

7. Displacement of population : None

8. Seismic Zone :

As per the earthquake sensitivity

index, the unit is situated in Zone- III

having moderate Damage Risk

(MSK- VII).

3.3 Details of Alternative Sites and Justification of Site Selection

The unit is located in plot no. 1, Palej industrial estate of GIDC in Bharuch District of

Gujarat State. It is an existing unit and proposed expansion for manufacturing of carbon

black will be carried out within the same premises. Therefore, there is no need to

examine an alternative site. Specific site selection criteria for the proposed expansion

project are given below;

• The existing unit is having all basic facilities like availability of electricity, transport

and telecommunication systems etc.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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• Plant site is 24 km away from Bharuch city which is having transportation facilities

like linkage with Bombay and Delhi by Broad Gauge railway and National Highway

No. 8.

• All required common environmental infrastructure are in existence in the area

namely hazardous waste disposal facility of Bharuch Enviro Infrastructure Ltd.

(BEIL).

• Availability of trained and skilled manpower nearby because of the proximity to

various industrial areas and city/town.

• The proposed products will be manufactured within the existing industrial

establishment, which would facilitate existing infrastructure mainly covering utility

services.

• There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-

1986 exists within 10 Km radius areas from the Plant Site.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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4. PROJECT DESCRIPTION

4.1 Details of Products and Production Capacity

Presently, unit is involved in the manufacturing of Carbon Black with the total

production capacity of 10,083 TPM and captive power generation of 18 MW

(Operational 12 MW).

Now, unit proposes to expand manufacturing by addition of various grades of Carbon

Black with additional production capacity of 10,103 TPM and expansion in additional

captive power generation of 12 MW. List of existing and proposed products is given in

Table-2(a) & 2(b) respectively.

Table–2(a): List of Existing Products:

Sr. No.

Name of Products Capacity

1. Carbon Black (Product Line I) 2,500 TPM

2. Carbon Black (Product Line II) 4,583 TPM

3. Carbon Black (Product Line III) 3,000 TPM

Total 10,083 TPM

4. Captive Power Plant (Green Power) 18 MW

Table–2(b): List of Products after proposed expansion:

Sr. No.

Name of Products Capacity

CAS No. End-use

1. Carbon Black of various

grades (Product Line I to VII) 20,186 TPM 1333-86-4

Automotive Industry,

Plastic, Paints & Inks

2. Captive Power Plant

(Green Power) 30 MW --

Captive consumption

and export to power grid

4.2 Land and Project Layout

Total land acquired for the existing plant is 1,24,479 m2. Proposed expansion will be

carried within the existing premise hence, no additional land will be required. Out of

total land available, unit has developed green belt area in 41,100 m2 (33.02%) within

the existing plant.

The detailed break-up of the land is given in Table 3 and Plant Layout is shown in

Drawing – 1 and enclosed in Annexure 3.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

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Drawing - 1: Plant Layout

LEGEND

Fuel Oil & Raw Material Storage Area

Fire Water Tank

Product Storage Area

Process / RO Water Tank

Hazardous Chemicals & Hazardous Waste Storage Area

Water Pump House

Greenbelt Area

Roads

DG Sets

Proposed Expansion

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

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Table - 3: Break-up of Plot Area

Sr.

No. Units

Area, m2 % of total

Area Existing Proposed

Expansion Total

1. Process Plant 25,168 5,675 30,843 24.78

2. Storage - Raw Material & Product

13,116 3,946 17,062 13.71

3. Storage - Hazardous Waste 92 100 192 0.15

4. Utilities 1,372 1,670 3,042 2.44

5. Effluent Treatment Plant 2,045 1,455 3,500 2.81

6. Green Belt 41,100 -- 41,100 33.02

7. Roads 3,292 1,708 5,000 4.02

8. Parking Area 2,934 2,066 5,000 4.02

9. Administrative Building 1,970 800 2,770 2.23

10. Undeveloped Land 33,390 (-17,420) 15,970 12.83

Total 1,24,479 Nil 1,24,479 100.00

4.3 Resource Requirements

[A] Water

The water requirement of the existing plant is met through borewell and the same

source will be used after the proposed expansion project. Presently, fresh water

requirement for various domestic, gardening & industrial activities is 1,390 KLD which

will increase up to 2,578 KLD.

[B] Power

At present, the total power requirement is 5 MW which is fulfilled by own captive power

plant having power generation capacity of 18 MW out of which 12 MW is operational

and excess power generated (7 MW) is sent to Grid.

After proposed expansion, self-power consumption will increase up to 10MW (5 MW

existing + 5 MW proposed). Power generation capacity will increase up to 30 MW.

Excess power generated will be sent to Grid after proposed expansion.

Also, for startup of the plant, unit requires power supply of 2,500 kVA which is procured

from Dakshin Gujarat Vij Company Ltd. Unit will install two nos. of DG Sets (standby) of

750 kVA each in case of emergency power supply.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

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[C] Fuel

Presently, Off gas @ 68,000 Nm3/hr is utilized for boiler of captive power plant and

LDO @ 60,090 Lit/day is required as standby fuel in manufacturing process for heating

of reactors only during startup.

Off gas generation will increase upto 1,28,000 Nm3/hr after proposed expansion. There

will be no increase in LDO requirement for the proposed expansion. Diesel requirement

for standby DG Sets (2 Nos. x 750 kVA) will be 320 Lit/hr which will be used only

during emergency situations when both grid and CPP power is not available. Details of

fuel requirement are given in Table 4.

Table 4: Details of Fuel Requirement

Sr. No.

Type of Fuel Utility Requirement

Existing Proposed Total

1.

Off Gas from Carbon

Black manufacturing

plant

Boilers of CPP 68,000

Nm3/hr

60,000

Nm3/hr

1,28,000

Nm3

2. LDO

Process Reactor

Heating during

Startup (Standby)

60,099

Lit/Day --

60,099

Lit/Day

3. Diesel DG Sets

(Standby) 160 Lit/hr 160 Lit/hr

320

Lit/hr

[D] Manpower

Total 305 personnel are working in the existing plant and after proposed expansion

manpower requirement will increase up to 421 personnel at the different level for the

operation phase. Details of personnel requirement at various cadres are given in Table

5.

Table - 5: Details of Manpower Requirement after proposed expansion

Description

*Management Staff

*Company Workers

*Contractor workers

*Total

E P T E P T E P T E P T

Administration 6 2 8 1 -- 1 2 2 4 9 4 13

Production & allied services

31 15 46 3 1 4 108 60 168 142 76 218

Stores & Dispatch 7 2 9 1 -- 1 6 1 7 14 3 17

Others 75 20 95 15 3 18 50 10 60 140 33 173

Total 119 39 158 20 4 24 166 73 239 305 116 421

*E-Existing, P-Proposed, T-Total after Proposed Expansion

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

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4.4 Details of Manufacturing Process

Manufacturing of carbon black mainly involve various unit operations like thermal

cracking, heating, cooling and drying. Off gases generated in the manufacturing

process of carbon black are utilized as fuel in the steam boiler to generate high

pressure steam and also utilized for power generation. Details of manufacturing

process for the all the proposed products with process description, process flow

diagram and material balance are described in Annexure 4.

4.5 Raw Material Requirements

Various raw materials will be required for manufacturing of existing and proposed

products. Details of raw material requirement after proposed expansion are given below

in Table 6.

Table 6: Details of Raw Material Requirements (After proposed expansion)

Sr. No.

Name of Raw Material Requirement

1 Primary Carbon Black Feed Stock (CBFS) 33,026 TPM

2 Secondary Feed Stock (SFS) 1,101 TPM

3 Additives (Potassium Nitrate, Potassium Carbonate, Potassium Acetate)

29 TPM

4 Molasses 100 TPM

4.6 Details of Machineries & Equipment

Additional plant machineries and equipment will be required for the proposed

expansion. The list of plant machineries for the proposed expansion project is given in

Table 7. However, the actual requirements of machineries & equipment are not limited

to the basic list below as some minor requirements can also be cited depending up on

necessity noticed during installation & operations.

Table – 7: Details of Proposed Machineries and Equipment

Sr. No. Name MOC Qty. Capacity

1. Reactors (Associated Downstream Equipment)

MS-Refractory lined

4 36 TPD to 152 TPD

2. Dryers -- 4 36 TPD to 152 TPD

3. Air Cooled Condenser -- -- 45 Ton

4. Compressed Air System -- 4 5,000 Nm3/hr

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

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5. Pollution Potential and Control Measures

5.1 Water Pollution

(a) Details of Water Requirement & Wastewater Generation

Presently, the water requirement of the unit is met by borewell water supply and same

source will be utilized after proposed expansion. The total fresh water requirement for

the existing unit is 1,390 KLD which will increase up to 2,578 KLD after proposed

expansion.

Based on the material balance and operational experience of the existing plant, the

water consumption and wastewater generation for products as well as for various

categories have been calculated. The fresh water requirement for industrial activities

will be 2,458 KLD, which will be mainly utilized in the manufacturing process, boiler,

cooling and washing activity. The water requirement for domestic activity will be 120

KLD.

Presently, there is no effluent generation from manufacturing process in existing plant

and there will not be any effluent generation from manufacturing process as well after

proposed expansion. Industrial effluent generation from industrial activities is 188 KLD

which will increase upto 400 KLD after proposed expansion. There will be no cooling

blow down from cooling tower, since they are advanced air-cooled type of cooling

towers.

Category-wise water requirement and wastewater generation is given in Table 8.

Summary of the water balance is given in Table 9. The water balance diagram is given

in Drawing 2.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 19

Table – 8: Category-wise Water Requirement & Wastewater Generation

Sr. No.

Particulars Stream

# Water Requirement, KLD

# Wastewater Generation, KLD

E P T E P T

I Domestic Fresh 100 20 120 100 Nil *100

II Gardening Reuse Nil 100 *100 Nil Nil Nil

III Industrial

a Process Fresh 810 820 1,630

Nil Nil Nil Reuse 188 212 **400

b Boiler Fresh 192 158 350 Nil 62 62

c Cooling Fresh 100 40 140 Nil 18 18

d Washing Fresh 50 20 70 50 20 70

e Water Treatment Plant Fresh 138 112 250 138 112 250

Total Industrial (Requirement / Generation)

Fresh + Reuse

1,478 1,362 2,840 188 212 400

Reuse 188 212 400 188 212 **400

Total Industrial (Requirement / Discharge)

Fresh 1,290 1,150 2,440 Nil Nil Nil

Net Fresh Water Requirement / Discharge

(I + II + III) Fresh 1,390 1,170 2,560 Nil Nil Nil

Notes: #E- Existing, P-Proposed, T-Total after proposed expansion * Domestic sewage @100 KLD will be treated in STP and re-used for greenbelt development ** Industrial effluent generation @ 400 will be treated in ETP and entirely re-used in manufacturing process

Table – 9: Summary of water balance

Categories Water Requirement, KLD

Wastewater Generation / Discharge, KLD

Fresh Reuse Total Generation Reuse Discharge

Domestic 120 Nil 120 100 100 Nil

Gardening Nil 100 100 Nil Nil Nil

Industrial 2,440 400 2,840 400 400 Nil

Total 2,560 500 3,060 500 500 Nil

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 20

Drawing – 2: Water Balance Diagram

(b) Wastewater Management System

Presently, there is no effluent generation from manufacturing process in existing plant.

Industrial effluent generated from washing @50 KLD and WTP @138 KLD is given

primary and tertiary treatment in ETP. Treated effluent from ETP @188 KLD is re-used

in manufacturing process. Hence, unit maintains zero liquid discharge.

There will not be any effluent generation from manufacturing process from proposed

expansion project. Effluent will be generated from cooling @18 KLD, washing @70

KLD, boiler blowdown @62, effluent neutralizing pit @10 KLD and WTP rejects @240

KLD after proposed expansion. Hence, total industrial effluent generation after

proposed expansion will be 400 KLD. It will be treated in ETP comprising of primary

and tertiary treatment and reused entirely in manufacturing process. Hence, unit will

maintain zero liquid discharge after proposed expansion.

Effluent Neutralizing

Pit

(10)

Reject (240)

(1,630)

(100)

(360)

DM Plant

(120) Gross Water Requirement: 3,060 (Fresh: 2,560, Reuse: 500)

Domestic

Gardening (100)

ETP

RO Plant (600)

(240)

Process (2,030)

Cooling Makeup

(140)

Washing (70)

(10)

(70)

(2,440)

STP

Boiler Makeup

(350)

(400)

(400)

All the quantities are expressed in KLD

(62) (18)

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 21

Existing ETP will be upgraded for treatment additional effluent generation with design

consideration of 450 KLD after proposed expansion. Schematic flow diagram of existing

ETP is given in Drawing 3.

Drawing 3: Schematic flow diagram of existing ETP

5.2 Air Pollution

Main source of air pollution is process gas generation from various sections of existing

plant and flue gas generation from boiler of CPP. There will be same source of air

pollution after proposed expansion. There will be also chances of fugitive emission due

to manufacturing activities, raw material handling and transportation. Various sources of

air pollution are described hereunder:

(a) Process Gas Generation

At present, there is process gas generation in the form of PM, SO2, NOx & H2S gas

from various sections of plants like manufacturing process, vapor bag collection (VBC),

palletizing and dryer. Individual bag-filters are provided to each sections of plant. There

will be increase in above listed air pollutants from process gas generation after

proposed expansion.

Individual bag-filters along with stack of adequate height will be provided to each

sections of plant. The details of air pollution control system for the process gas

generation are given hereunder in Table 10. Schematic diagram of air pollution control

measure is given as Figure 3.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 22

Table – 10: Details of Process Gas Stack & APCM

Sr. No.

Source of Emission Status Ht. &

Dia. (m)

Pollutant Concentration,

mg/Nm3

Air Pollution Control Mesures

1. Process Bag Filter - 1 for line 1 & 2 (Common Stack)

Existing 60 & 2

PM < 150

SO2 < 40

NOx < 25

H2S < 45

Bag Filter

2. Process Bag Filter - 2 for line 3

Existing 35 & 0.4 Bag Filter

3. VBC of line 1 Existing 45 & 0.4 Bag Filter

4. VBC of line 2 Existing 45 & 0.5 Bag Filter

5. VBC of line 3 Existing 35 & 0.4 Bag Filter

6. Dryer of line 1 Existing 45 & 1 Bag Filter

7. Dryer of line 2 Existing 45 & 1 Bag Filter

8. Dryer of line 3 Existing 35 & 1 Bag Filter

9. Process Bag Filter – 1S for line 1S, 2S, 3S & 4S (Common Stack)

Proposed 60 & 2 Bag Filter

10. VBC of line 1S Proposed 35 & 0.4 Bag Filter

11. VBC of line 2S Proposed 45 & 0.4 Bag Filter

12. VBC of line 3S Proposed 45 & 0.4 Bag Filter

13. VBC of line 4S Proposed 45 & 0.4 Bag Filter

14. Dryer of line 1S Proposed 35 & 0.6 Bag Filter

15. Dryer of line 2S Proposed 45 & 0.9 Bag Filter

16. Dryer of line 3S Proposed 45 & 0.9 Bag Filter

17. Dryer of line 4S Proposed 45 & 1.2 Bag Filter

(b) Flue Gas Generation

Since off gases from manufacturing process are passing through process bag filters and

utilized as fuel for steam boiler, there is no requirement of APCM. However, stack of

adequate height is provided for proper dispersion of pollutants. Diesel will be used as

fuel for proposed DG Sets (standby). Stack of adequate height will be provided as an

APCM. The details of flue gas emission are given hereunder in Table - 11.

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 23

Table 11: Details of Flue Gas Stack

Sr. No.

Source of Emission

with capacity

Status Stack Height & Dia.

Fuel Name &

Qty.

Conc. of Polluants

Air Pollution Control Mesures

1. Boiler for CPP

(60 TPH) Existing

80 &

1.86

Off

Gases

(68,000

Nm3/hr)

PM ≤ 150

mg/Nm3

SO2 ≤ 100

ppm

NOx ≤ 50

ppm

Stack of Adequate

Height as per CPCB

Guidelines

2. Boiler for CPP

(60 TPH) Proposed

80 &

1.86

Off

Gases

(60,000

Nm3/hr)

Stack of Adequate

Height as per CPCB

Guidelines

3.

DG Sets

(Standby)

(2 Nos. x 750

kVA)

Proposed 11 &

0.2

Diesel

(160

Lit/hr)

Common Stack of

Adequate Height as

per CPCB Guidelines

(c) Fugitive Emission

There are chances of fugitive emission during manufacturing process as well as due to

storage & handling of raw materials and products. The unit will take following precaution

for the control of fugitive emission and will implement the same for the proposed

expansion.

Probable Sources Control Measures

Manufacturing activities • All equipments are maintained regularly along with

checking of flange and welded joints.

• All raw materials and end products are properly metered

so that there is no possibility of overloading.

• Proper safety interlocks are incorporated.

• Bulk transportation within the process is done by closed

bucket elevator and screw conveyer

Emission from Carbon black storage tank and packing

• Dedusting system with proper bag filters provided. All

storage tanks are closed with proper venting system and

level is checked regularly without overfilling.

Pump and compressor Emissions

• Mechanical seals are provided in pumps and agitators

• Standby arrangement for critical equipment for periodic

maintenance

Valves, Flanges, plugs and instrument connections

• Welded pipes are used wherever feasible.

• Suitable gasket materials are used.

• Suitable glad packing is used in valves.

• Periodic inspection and maintenance of pipes and pipe

fittings is carried out.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 24

5.3 Hazardous Waste Generation and Management

Hazardous waste generation from existing plant is in the form of ETP sludge and other

wastes from manufacturing process viz. spent ion exchange resin and waste insulation

material. The ancillary sources of hazardous waste generation are discarded container /

barrels / Liners / waste paper bags / waste plastic bags and used oil generated from

plant machineries. Unit has obtained membership from Bharuch Enviro Infrastructure

Limited (BEIL) for proper disposal of hazardous waste.

There will be increase in Hazardous waste generation from above categories of wastes.

Unit will obtain membership for increased hazardous waste generation from GPCB

approved TSDF / CHWIF facilities. The details of hazardous waste generation and

handling / Management are given in Table-12.

Table –12: Hazardous Waste Generation and Management

Type of waste

Source of Generation Cat.

*Quantity MT/Annum Method of Disposal

E P T

ETP Sludge ETP Sch.-I

35.3 40 14 56

Collection, Storage,

Transportation and Disposal at

TSDF-BEIL

Spent ion

Exchange Resin WTP

Sch.-I

35.2 0.24 Nil 0.24 Collection, Storage,

Transportation and Disposal at

TSDF-BEIL Waste Insulation

Materials

Mfg.

Process

Sch.-I

33.1 2 14 16

Used / Spent Oil Plant &

Machinery

Sch.-I

5.1 0.2 0.2 0.4

Reuse or disposal by selling to

Registered Refiners

Discarded

Containers/

Barrels/ Liners/

Waste Paper

Bags/ Waste

Plastic Bags

Raw

Material

Storage &

Handling

Sch.-I

33.1 8 16 24

Collection, Storage,

Decontamination,

Transportation and Disposal to

registered users

*E: Existing, P: Proposed, T: Total after Proposed expansion

Unit has provided designated area of 90 m2 for storage of hazardous chemicals within

the premises having impervious floor, roof cover and leachate collection system. It will

be expanded upto 190 m2 during proposed expansion project.

5.4 Noise & Vibration Control

The source of noise generation may be from the plant machineries and transportation

of raw materials and finished product.However, the following adequate precautions are

taken for control of noise and will be implemented for the proposed expansion:

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 25

• Proper and timely oiling, lubrication and preventive maintenance is carried out for

the machineries and equipments to reduce noise generation.

• Adequate noise control measures such as anti-vibration pad for equipment with high

vibration are provided. Sound proof DG set and screw compressors will be installed.

All the air and steam vents will have proper silencer

• To minimize the adverse effect on the health, ear muffs / earplugs are provided to

the working under high noise area.

• To reduce the noise generation during the transportation activities; the vehicles are

kept periodically serviced and maintained as per the requirement of latest trend in

automobile industry. Only those vehicles with PUC’s are allowed for the

transportation.

• The transport contractors are informed to avoid unnecessary speeding of vehicles

inside the premises. Speed limit is fixed to 20km/hr and is strictly adhered to.

• Green belt area is developed to prevent the noise pollution inside and outside the

factory premises.

• Noise monitoring is carried out regularly at different parts of the plant.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 26

6. PROJECT SCHEDULE & COST ESTIMATES

6.1 Schedule of Approval and Implementation

The proposed expansion project has been planned for manufacturing of Carbon Black.

The entire development will take about 1 year for the completion of proposed

expansion. The construction activities and installation of plant & machineries will be

started after obtaining necessary approval from State Level Environment Impact

Assessment Authority (SEIAA) and State Pollution Control Board (SPCB).

6.2 Capital Investment

The proposed unit is a large-scale unit with the capital investment of Rs. 21,517 Lacs

in the existing plant and estimated cost of proposed expansion project will be about

19,000 Lacs. Break-up of the capital cost is given in Table - 13.

Table – 13: Capital Cost

Sr. No.

Description Capital Investment, Rs. in Lacs

Existing Proposed Total

1. Land & Site Development 2,600 -- 2,600

2. Building 3,169 600 3,769

3. Environmental Protection Measure 300 2,400 2,700

4. Plant & Machineries 15,448 16,000 31,448

Total 21,517 19,000 40,517

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd., Palej

Pre-Feasibility Report

Page | 27

7. FINAL RECOMMENDATIONS

The unit will provide adequate measures for the prevention and control of pollution.

With the execution and operation of such control measures along with proper

Environmental Management System, there will not be any major potential for negative

impact on the environment due to proposed expansion project.

On the contrary, there will be positive impact on the socio-economic environment since

proposed expansion project will generate some permanent and secondary employment.

The unit will also establish Cordial relation with the nearby villagers and will carry out

social welfare activities according to their needs.

The proposed expansion project will also boost up ancillary industrial and commercial

activity. Thus, it will improve the economic condition of the area.

ANNEXURES

LIST OF ANNEXURES ANNEXURE 1: Plot Allotment Letter ANNEXURE 2: Copies of CTE/NOC & CC&A/CTO ANNEXURE 3: Plant Layout ANNEXURE 4: Manufacturing Process Details

ANNEXURE 1

PLOT ALLOTTMENT LETTER

ANNEXURE 2:

COPIES OF CTE/NOC AND CC&A/CTO

Outward No:379129,27/12/2016

Outward No:379129,27/12/2016

GUJARAT POLLUTION CONTROL BOARDPARYAVARAN BHAVAN

Sector-10-A, Gandhinagar 382 010

Phone (079)23222425

(079)23232152

Fax (079)23232156

Website www.gpcb.gov.inBy R.P.A.D

~,~",.GPCB

No' GPCB/BRCH-B/CCA-69(8)1ID-15482

To,

Mis. PHILIPS CARBON BLACK LTD

N.H.NO~8, VILLAG[·PALEJ.

TAL & D1ST: BHARUCH

SUB: _ Amendment Consolidated consent and Authorization (CC & A) under various

Environmental Acts fRules.

REF: _ (I) Previously issued CC&A vide letter no: GPCBiBRCH-B-CCA-69(3)ilD-

15482/117494 dated 09/07/2012 under various Environmental Acts/Rules

(2) Your application for CC&A Amendment inward no: 12S559 dated: 15/09/2017.

Dear Sir.

This has reference to the CCA amendment issued vide letter no: GPCB'HRCH-B-CCA-

69(3)1ID-1548211 17494 dated 09/07/2012 under the provisions of the various Environmental

Act/Rules, which stands amended as under,

Condition no. 4.1 under hazardous waste management and handling of hazardous waste for

serial no. I of waste ETP Sludge category 35.3 of Schedule I quantity of ETP sludge (settling

pond sludge) shall be shall be read as 40 MTiYear and its facility shall be read as Collection.

Storage, Transportation, Disposal by sent 10 Recycling Solution P. Ltd (RSPL) Panoli site or

send it to Cement Industry for Co processing and if bOlh shall nOI able to receipt the waste then

unit shall dispose off it to TSDF site.

2. All other conditions of CCA order issued vide letter no. GPCBiBRCH-B-CCA-69(3)ilD-

15482/117494 dated 09/07/2012 and subsequent amendment under the provisions of the various

Environmental Act/Rules shall remain unchanged.

For and on behalf of

GUJARAT POLLUTION CONTROL ~~

(A.V.S~

SR.ENVIRONMENTAL ENGINEER

Page I of I

Clean Gujarat Green GujaratISO-9001-2008 & ISO-14001 - 2004 Certified Organisation

Outward No:429310,29/11/2017

ANNEXURE 3:

PLANT LAYOUT

DBC

SURGE BIN

Dryer

SCALE DRN BY CHD. BYAPPD BY

EQPT.NO./ N.T.S.S.SINGH S.K.GHOSHS.BHUTADA

SIGNATURE DATE

DRG. NO. REV.NO.

AREA

PHILLIPS CARBON BLACK CO. LTD.

PCBL/CIV/PLP/002

01.01.14

3

PALEJ , GUJARAT

REV. NO. DATE DRN BY& DATE CHD BY &DATE APPD BY &DATE REVISIONS

TITLE:- PLOT PLAN

03.07.18

3WAY VENT VALVE

QUENCH TOWER

HEAD-1 HEAD-2 VENTURI PART COOLER COOLER QUENCH-1 QUENCH-3

700 NB SMOKE HEADER ( EXISTING)

DBC

SU

RG

E B

IN

Dryer

DBC

SU

RG

E B

IN

Dryer

DBC

SU

RG

E B

IN

Dryer

DBC

SURGE BIN

Dryer

7) Process/RO water tank

6) Fire water tank

1) Fuel oil & raw material storage area

5) DG set

3) Hazardous chemical & hazardous waste Storage area

2) Product storage area

8) Water pump house

4) Green belt area

9) Road

10) New Proposed Additional Lines & Equipments

ANNEXURE 4:

MANUFACTURING PROCESS DETAILS

Proposed Expansion Project for Manufacturing of Carbon Black Phillips Carbon Black Ltd.., Palej

Page | 1

DETAILS OF MANUFACTURING PROCESS

Manufacturing Process Description

➢ The basic process consists of atomizing the feedstock into the combustion zone of the

reactor where the combustion of fuel instantly vapourizes the feedstock and

decomposes into carbon primary black and hydrogen. The remaining feedstock reacts

with excess oxygen in the primary combustion stream to maintain the reaction

temperature for carbon formation. In some reactors, a number of feedstock streams are

atomized radially into high velocity combustion gases.

➢ The reaction products must be quenched rapidly with water sprays to lower the

temperature to prevent loss of the carbon black product through reaction with carbon

dioxide & water, products of the combustion reactions. The hot, heavy carbon black

smoke from the reactors enters the air preheater where thermal energy is transferred to

preheat the primary combustion air.

➢ From the air preheater the lowering of temperature in a tower from which they enter the

bag filter that separates the fluffy carbon black product from the tail gases. Since the tail

gases are composed mainly of water, nitrogen, carbon monoxide, carbon dioxide, &

hydrogen, they have heating value as a fuel to preheat feedstock and for heating the

pellet dryers.

➢ Unused tail gas is frequently flared prior to venting to the atmosphere after removal of

particulate matter. The fluffy density carbon black is then conveyed to the wet pelletizers

where water is added to transform the product into wet granules. Dry pelletization in

rotating drums is practiced for some special applications. The wet pellets are then dried

in a rotary dryer where finished product goes to storage tanks for shipping in bulk or in

bags.

Proposed Expansion Project for Manufacturing of Carbon Black

Phillips Carbon Black Ltd.., Palej

Page | 2

Process Flow Diagram

Description Unit Line-1 Line-2 Line-3 Line-4 Line-5 Line-6 Line-7 TotalLine Capacity TPD 83.33 152.77 100 36 50 80 152.77 654.87CBFS(Primary feedstock) Ton/Ton 1.7 1.64 1.71 1.92 1.64 1.7 1.64 1.73SFS(Secondary feedstock)/Natural gas Ton/Ton 0.2 0 0.2 0.4 0 0.2 0Total Feedstock consumption Ton/Ton 1.9 1.64 1.91 2.32 1.64 1.9 1.64Total Feedstock consumption TPD 158 251 191 84 82 152 251 1168Total Feedstock consumption TPM 4750 7516 5730 2506 2460 4560 7516 35038Reactor Stage

CBFS (Primary Feed Stock) TPD 141.66 250.54 171.00 69.12 82.00 136.00 250.54 1100.87

SFS(Secondary feedstock)/Natural gas TPD 16.67 0.00 20.00 14.40 0.00 16.00 0.00 67.07

Nm3/h 12,000 16000 14500 6000 7000 14000 17000 74500

Nm3/d 288000 384000 348000 144000 168000 336000 408000 2076000

TPD 372.96 497.28 450.66 186.48 217.56 435.12 528.36 2688.42Nm3/h 200 550 225 100 0 150 550 1775

Nm3/d 4800 13200 5400 2400 0 3600 13200 42600

TPD 6.216 17.094 6.993 3.108 0 4.662 17.094 55.167

Quench water TPD 116.66 128.43 140 72 72 132 128.43 789.52

Pot Acetate/Pot Carbonate/Pot Nitrate TPD 0.12 0.23 0.14 0.03 0.08 0.14 0.23 0.97

Pot Acetate/Pot Carbonate/Pot Nitrate TPM 3.6 6.9 4.2 0.9 2.4 4.2 6.9 29.1

654.28 893.58 788.79 345.14 371.64 723.92 924.66 4702.01OutputCarbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87

Off gas TPD 570.95 740.81 688.79 309.14 321.64 643.92 771.89 4047.14

654.28 893.58 788.79 345.14 371.64 723.92 924.66 4702.01In Line Boiler StageInputCarbon Black TPD 83.33 654.87

Off gas TPD 570.95 4047.14

Water TPD 73.44 73.44

727.72 2842.45OutputSteam out TPD 71.97 71.97

Carbon black TPD 83.33 336.1

Off gas TPD 570.95 2432.91

Blow down water TPD 1.47 1.47

727.72 2842.45

Carbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87

off gas TPD 570.95 740.81 688.79 309.14 321.64 643.92 771.89 4047.14

Quench Water TPD 60 120 80 24 64.8 120 120 588.80

714.28 1013.58 868.79 369.14 436.44 843.92 1044.66 5290.81OutputCarbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87Off gas TPD 630.95 860.81 768.79 333.14 386.44 763.92 891.89 4635.94

714.28 1013.58 868.79 369.14 436.44 843.92 1044.66 5290.81

Carbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87off gas TPD 630.95 860.81 768.79 333.14 386.44 763.92 891.89 4635.94

714.28 1013.58 868.79 369.14 436.44 843.92 1044.66 5290.81OutputCarbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87

Off gas to dryer combustor TPD 170.33 258.25 207.54 56.63 73.42 122.23 187.30 1075.70

Off gas to Boiler TPD 460.62 602.56 561.25 276.50 313.02 641.69 704.59 3560.24

714.28 1013.58 868.79 369.14 436.44 843.92 1044.66 5290.81

Offgas TPD 170.33 258.25 207.54 56.63 73.42 122.23 187.30 1075.70

Air (100% of off gas by volume) TPD 218.36 331.08 266.07 72.60 94.13 156.70 240.11 1379.05388.69 589.33 473.61 129.24 167.55 278.92 427.41 2454.75

OutputFlue Gas TPD 388.69 589.33 473.61 129.24 167.55 278.92 427.41 2454.75

Carbon Black TPD 83.33 152.77 100 36 50 80 152.77 654.87Water TPD 82.9 152.0 99.5 35.8 49.8 79.6 152.0 651.73Molasses TPD 0.42 0.76 0.5 0.19 0.24 0.4 0.76 3.27

166.68 305.57 200.02 72.02 100.00 160.02 305.57 1309.87OutputWet Carbon Black TPD 166.68 305.57 200.02 72.02 100.00 160.02 305.57 1309.87

InputWet Carbon Black TPD 166.68 305.57 200.02 72.02 100.00 160.02 305.57 1309.87

Flue gas TPD 388.69 589.33 473.61 129.24 167.55 278.92 427.41 2454.75

555.37 894.89 673.63 201.25 267.55 438.94 732.98 3764.62OutputDry Carbon Black Pellets TPD 83.33 152.77 100 36 50 80 152.77 654.87

Flow to VBC TPD 161.09 270.66 194.74 61.86 83.51 135.80 238.28 1145.95

To dryer stack TPD 311.0 471.5 378.9 103.4 134.0 223.1 341.9 1963.80

555.37 894.89 673.63 201.25 267.55 438.94 732.98 3764.62Product Silo StageInputDry Carbon Black Pellets TPD 83.33 152.77 100 36 50 80 152.77 654.87

Dry Carbon Black Pellets TPD 83.33 152.77 100 36 50 80 152.77 654.87

Rotary Dryer

Output

InputVenturi Cooler / Quench Tower Stage

InputPBC Stage

Not 

applicable

Not 

applicable

Inputs

Atomizing Air

Air

InputDryer Comb. Stage

InputPelleting Stage

Not 

applicable

Not 

applicable

Not 

applicable

Not 

applicable