pre-feasibility report for expansion of chemical

PRE-FEASIBILITY REPORT

FOR EXPANSION OF

CHEMICAL MANUFACTURING

UNIT

BY STAHL INDIA PVT LTD,

KANCHIPURAM

EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,

770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.

1

1.1 Introduction of the project

The existing industry mainly manufactures chemicals like Syntan, Fat liquor,

Superplastisicer, Biocides, Acrylic Resin, Urethane Resin, Solvent based blending’s &

Water based blending’s. Due to the increase in demand from the customers, the

industry has decided to increase the production capacity from 24180 MT/Annum to

70800 MT/Annum. The project has been granted EC by MoEF on 03.06.2009 by letter

no. F. No. J-11011/167/2009-IA-II (I) (attached as

Annexure IV) to M/s Clariant Chemicals (India) Limited. Now the name of the company

has been changed to M/s Stahl India Pvt. Ltd. As per G.O.I EIA Notification dated

14/09/2006, they fall under the category A of the 5(f). The chemical products

manufactured by Stahl India are used for leather Preparation, Leather Finishing &

Industrial Preservative all over India. After expansion the increased demand of

customers shall be fulfilled.

1.1.1 Profile of promoter

Stahl is a Multinational company established in 1914 by Harry Stahl in Peabody,

Massachusetts in USA. Now Stahl has its presence in 28 countries. It has 8

manufacturing locations in different countries including India. Stahl has following

chemical products:

Leather Finish

Shoe Finish

Permuthane

Industrial Colorants

Wet end Products

In 1998, Stahl has formed its Indian subsidiary Stahl India Pvt. Ltd. The products

manufactured in the Stahl India plant are mostly water based emulsions or

suspensions. The present production capacity is 24180 MT/Annum. With increase in

demand Stahl India wish to expand the production capacity of existing products.

1.1.2 About the Existing Facility Details

Current Manufacturing Unit in Kanchipuram has been extra ordinary in developing

human resources, efforts in conserving environment, commitment to CSR. Street



2

lights at this facility are powered by Solar Panels. Manufacturing unit is working

extensively to support local needy community as part of its CSR drive.

1.1.3 Need of the Project

The chemical products manufactured by Stahl India are used by tannery industries all

over India hence with increase in demand of leather demand of these chemicals are

also increasing. The industry mainly manufactures chemicals like Syntan, Fat liquor,

Superplastisicer, Biocides, Acrylic Resin, Urethane Resin, Solvent based blending’s &

Water based blending’s. Due to the increase in demand from the customers, the

industry has decided to increase the production capacity from 24180 MT/Annum to

70800 MT/Annum.

1.1.4 Social Impact

The project site is part of Sengundram Industrial Area, therefore it is designated for

industrial activity. There are farm lands surrounding the facility with few villages which

are far from the industrial estate. The total manning of the company with plant is

expected to be around 250 persons. Barring the senior and some middle

management, the majority of the remaining workforce shall be recruited from within

the state. However, as there are hardly any similar process plants in this region,

sourcing of local skilled manpower may be a challenge in future. Skill level requirement

for this plant operation is of very high standard, the manpower shall have to be trained

in synthetic organic chemical practices. This shall have a positive effect on the

surrounding environment. In addition, in line with Stahl’s general HR practices, our

work force in this company have been enjoying much better facilities and working

conditions than the standards followed in other companies. This facility further

promotes small scale ancillary units, packing materials, workshops etc. generating

more employment. The process to construct housing facility for our work force has

already been initiated. The prospect for employment generation is substantial and it

will have important social benefits.

1.2 PROJECT DESCRIPTION

1.2.1 Project Details

S.No Particulars Existing Proposed Total



3

1 Type of Industry Synthetic Organic Chemicals Manufacturing Unit

3 Category 5(f), ‘A’

4 Location SF No. 534, 535, 536, 757, 759, 768, 769, 770 of

Sinagadibakkam Village, Kanchipuram Taluk And

District, Tamil Nadu

5 Land use at the

project site

Industrial

6 Plant Capacity 24180 MT/Annum 46620

MT/Annum

70800

MT/Annum

7 Estimated Project

Cost

Rs. 80 Crore Rs. 15 Crore Rs. 95 Crore

8 Population 150 No. 100 No. 250 No.

9 Power Requirement

in HP

Licensed – 5000 HP

Connected – 2640

HP

- 360 HP


Connected –

3000 HP

10 D.G. Set back up 1000 KVA & 160

KVA

1000 KVA 1000 KVA – 2

Nos. & 160

KVA

12 Capacity of Boiler 5 TPH & 0.5 TPH 6 TPH 5 TPH & 6 TPH

13 Air Pollution

Control System

Multi cyclone and

wet bottom,

cyclone

separators with

bag filter

arrangement,

stack, common

wet scrubber, wet

scrubber with

Multi cyclone

and wet

bottom, stack

and common

wet scrubber.

Multi cyclone

and wet

bottom,

cyclone

separators with

bag filter

arrangement,

stack, common

wet scrubber,



4

stack, stack and

bag filter with

stack

wet scrubber

with stack,

stack and bag

filter with stack

14 Water Requirement 97 KLD 210 KLD 260 KLD

15 Waste water

Discharge

17.5 KLD 48.5 KLD 66 KLD

16 Waste Water

Treatment Method

MEE & STP of 25

KLD

60 KLD ETP

with RO

60 KLD ETP

with RO, MEE

& STP of 25

KLD

1.2.2 Land Area Details

Particulars Existing Area Proposed Area

Total area after

expansion

% Area

(after expansion)

Total Land Area 19.66 ha --- 19.66 ha 100

Built up area 2.35 ha 0.14 ha 2.49 ha -

Ground Coverage 2.18 ha 0.05 ha 2.23 ha 11.4

Green Belt Area 11.51 ha --- 11.51 ha 58.5

Open & Road Area

5.97 ha --- 5.92 ha 30.1



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11.08%

58.55%

30.37%

EXISTING LANDUSE

Ground Coverage Green Belt Area Open & Road Area

11.4%

58.5%

30.1%

LAND USE AFTER EXPANSION

Ground Coverage Green Belt Area Open & Road Area



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1.2.3 The Google Image of Project Site

1.2.4 10 Km Buffer Zone Map

Map is also attached as Annexure II



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1.2.5 Layout Plan

The layout map is additionally attached as Annexure III

1.2.6 Project Description with Process Details

Stahl India Pvt. Ltd. is expanding its existing Synthetic Organic Chemicals Manufacturing Unit

from present capacity of 24180 MTPA to 70800 MTPA to meet with the increased demand of

the chemicals used leather preparation & finishing.

1.2.7 Raw Materials with daily requirement

The raw materials used in the manufacturing process with their monthly & annual

consumption is given below:

Sl. No.

Production Family

Capacity (MT)/Annu

m

Capacity (MT)/Month

Name of the Raw Material

Monthly Consumptio

n in MT

1 Syntans 26400 2200

Phenol 170

Naphthalene 220

Sulphuric Acid 381

Formaldehyde 240



8

Caustic Soda Lye 412

Urea 65

Others 220

Maida Flour 190

China Clay 130

Glauber Salt 190

Water 326

2 Superplasti

cisers 4800 400

Naphthalene 84

Sulphuric Acid 80

Formaldehyde 46

Caustic Soda Lye 76

Water 114

3 Fat Liquors 7200 600

Vegetable Oils 42

Mineral Oils 17

Emulsifiers 54

Esters 21

Organic Acids 29

Solvents 6

Organochlorine compounds

8

Sulfochlorinated and Chlorinated

Paraffins 75

Alkaline Compounds

29

Inorganic salts 19

Water 300

4 Biocides 8400 700

Fungicide / Algicide 80

Methyl Isothiozolinones

30

Formaldehyde compounds

50

Alkaline Compounds

20

Benzisothiozolinones

50

Surfactants 10

Glycols 40

Water 420

5 Acrylic Resin

4000 333

Monomers 116

Surfacttants 1

Inorganic Salts 6

Water 210

6 Water based

10000 833 Casein Powder 48

Solvents 4



9

blendings/Dispersion

s

Plasticizers 15

Pigments 50

Inorganic Salts 4

Waxes 40

Surfacttants 6

Water 666

7 Polyurethanes Resins

4000 334

Monomers 60

Polyols 33

Water 241

8

Solvent based

blendings/Dispersion

s

6000 500

Monomers 6

Resin Powder 16

Solvents 171

Plasticizers 29

Organic Dyes 5

Silicones 29

Surfacttants 1

Nitro Cellulose 16

Water 227

1.2.8 Manufacturing process

1. Syntan

Naphthalene/Phenol is sulphonated with sulphuric acid. Then the reaction mass is

condensed with formaldehyde and Urea through multiple condensation process.

The condensed reaction mass is neutralised with caustic lye solution. The mass is

spray dried in the spray dryer at the temperature using furnace Oil. The product is

supplied as liquid also without converting into powder. This product is used in

leather process industry.

2. Fat Liquor

The synthetic and semi synthetic oils are saponified and blended with mineral oil

and various emulsifiers and packed as customer requirements. They are used in

leather processing industry.

3. Super Plasticizer

Naphthalene is sulphonated with sulphuric acid. Then the reaction mass is

condensed with formaldehyde through multiple condensation process. The

condensed reaction mass is neutralised with caustic lye solution. The excess

sodium salt is separated through crystallisation and centrifuging process and the



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desalted mass is spray dried in the spray drier at the temperature using furnace Oil

. The product is supplied as liquid also without converting into powder. This product

is used as a water reducing agent in the preparation of RCC mixture for

construction.

4. Biocides

The actives are blended /milled in the reactor and packed as per the customer

requirements. The biocides are used as preservatives in leather process industry,

Metal working fluids industry Personal care products, Paint industry and emulsions.

5. Acrylic Resins:

The raw materials for acrylic resins are acrylate monomers, surfactants and water.

The acrylate monomers are first blended in a pre-mixer and then taken to a batch

reactor along with surfactants and water. A small quantity catalyst is then added to

catalyse the polymerisation. This reactor is also a jacketed vessel with a low speed

stirrer. The reactor is first heated to 40-45C to initiate polymerisation, and then

cooled as the reaction progresses. After the reaction is completed, the reactor

contents are filtered; quality tested and then packed off. Any batch that does not

pass the quality test will be sent to the recycle store for further processing or

blending.

6. Urethane Resins:

The raw materials for polyurethane resins are urethane monomers, polyols and

water. Small quantities of catalyst and other additives are also used. The urethane

monomers and polyols are typically reacted in a batch reactor at 60 to 95C to

produce a pre-polymer. The reactor is a jacketed vessel with a low speed stirrer.

Low-pressure steam (3 bar) is used for heating the reactor. After completion of the

reaction, the pre-polymer from the reactor vessel is transferred to an emulsion tank

in which the pre-polymer is emulsified with water using a high-speed stirrer. The

emulsion is then passed through a filter; quality tested and then packed. Any

batch that does not pass the quality test is sent to the recycle store for further

processing or blending.

7. Solvent Based Blending’s:



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The raw materials for solvent based blending’s are solvents, nitro-cellulose cotton,

plasticizers, emulsifiers, urethane monomers, polyols, wax emulsions, casein

solutions and resins produced in the plant. The manufacturing process does not

involve any chemical reaction. All the required raw materials are mixed in a batch-

mixing kettle using a high speed stirrer, at ambient temperature. After the

completion of mixing, the contents are filtered; quality tested and then packed off.

Any batch that does not pass the quality test will be sent to the recycle store for

further processing or blending.

8. Water Based Blending’s:

The raw materials for pigment dispersions are pigments, surfactants, casein

binders, synthetic waxes, synthetic waxes, surfactants and water. The

manufacturing process does not involve any chemical reaction. The raw materials

are mixed in a batch-mixing kettle using a high-speed stirrer then the slurry is

transferred to a bead mill for grinding based on requirement. The product is then

quality tested, filtered and packed off. Any batch that does not pass the quality test

will be sent to the recycle store for further processing or blending.

1.2.9 Machinery

List of Plant and Machinery to be installed:



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List of Machineries

1. Cooling water pump 51. Blower k400

101. P206 Oleum transfer pump

151. Blender motor (2) B802

2. Chiller Pumps 52. Cir.pump p408. 102. P123A Buffer tank transfer pump 152. Ball Mill M1/74

3. Chiller Pumps 53. Homogeneous pumpP409

103. P123B Buffer tank transfer pump

153. Blender dust collector motor

4. Raw water Pumps 54. Vacuum Pump XV 400

104. P124 1-3% Acid transfer pump

154. Borewell pump No.4

5. Cooling Tower Fans 55. 4KL Vessel R107 105. P125 3-5% Acid transfer pump


6. D.M. Water Pumps 56. Scrubber vent Blower K707

106. P126 35% acid transfer pump


7. Compressors chiller 57. FO Transfer pump P515 A

107. P129 Flare scrubber on pump


8. Air Compressors 58. HSDTransfer pumpP516 A 108. R103 Agitator


9. DG Engine oil pump 59. Unloading pump P514

109. P127A Tempered water pump

159. Bore well Pump No.6

10. DG Air compressor 60. FO Transfer pump P515 B

110. P127B Tempered water pump

160. Utility Effluent Pump P901A

11. Cooling water pump

61. HSD Transfer pump P 516 B 111. CF103 centrifuge

161. Utility Effluent Pump P901B


62. Naphthalene transfer pump P 209 112. CF104 centrifuge

162. Fatrap effluent pump P902A

13. Chiller Pumps 63. Naphthalene transfer pump P 210

113. F102screw feeder charging

163. Fatrap effluent pump P902B

14. Chiller Pumps 64. Phenol unloading pump P 205 A 114. Pulvariser 164. Vertical pump

15. Raw water Pumps 65. Phenol transfer pump P 205 B 115. CF107 Centrifuge

165. Nbond Stroke pump

16. Cooling Tower Fans

66. Agitator Dual Speed AV 102A 116. CF106 Centrifuge

166. Callendria Feed Pump P904

17. D.M. Water Pumps

67. Agitator Dual Speed AV 102C

117. K121 SO3 scrubber vent blower

167. Concentrate Pump P903

18. Air Compressors 68. Product transfer pump P 103A

118. P128A Scrubber circulation pump


19. Compressors chiller

69. Agitator Dual Speed AV 102B

119. P128B Scrubber circulation pump


20. Drinking WaterPump

70. Agitator Dual Speed AV102D

120. P406 35% tanker loading pump

170. Condensate Pump P906

21. Refined fish oil pump P401

71. Product transfer pump P103B

121. Formaldehyde scr.pump p211

171. Vaccum Pump XV901

22. Common fish oil pump P410

72. Sulphuric acid unloading P207 122. Steam Dryer X407

172. ETP Holding tank Pump P901

23. Oil Transfer pump P400B (Biocides)

73. Caustic soda pump P203

123. Steam Dryer X4047/1

173. ETP Holding tank Pump P902

24. Intermediate Transfer P301

74. Formaldehyde pump P201 124. Uracil Hoist . 3

174. Buffing machine



13

25. T301 Agitator AT 301

75. sulphuric acid pump p208 125. CF105centrifuge

175. Sharing machine

26. T302 Agitator AT 302

76. Caustic soda pump P204 126. CF108 Centrifuge

176. ML Transfer pump P109 A

27. B 301 Agitator AB 301

77. Formaldehyde pump P202

127. V109A Agitator AV109A

177. KC6 chiller compressor


78. Oleum Transfer Pump P206 128. Main fan

178. Crystalliser Feed pump P107 A


79. Oleum Scrubber Blower OSB - 1 129. Spray machine

179. Centrifuge Feed pump P108A

30. S 301 Agitator AS 301

80. Olum Scrubber Pump OSP – 1


180. Slurry tank agitator AV105

31. S 302 Agitator AS 302

81. Feed water pump No.1 131. Lubricator

181. Crystalliser X101

32. Exhaust K 301 82. Feed water pump No.2 132. Product air lock

182. Agitator AV102E

33. Elgi water compressor (P400A) 83. Boiler Fan CP4/3 133. Back filter air lock

183. Brine Compressor KC3

34. Mineral Oil Transfer pump P405A

84. Neut.Disc.Pump P106A 134. Backfilter screw

184. Brine Primary pump P110A

35. Mineral Oil Transfer pump P405B

85. R101 agitator AR101 135. Cooling fan

185. ML Transfer pump P109B

36. Horizontal Bead Mill

86. R 102 agitator AR102 136. FD Fan

186. Centrifuge I CF101

37. Screw Feed pump 87. V 103 Agitator AV103 137. Fuel Oil pump

187. Centrifuge II CF102

38. Oil pump 88. Agitator AV102 138. Feed pump 188. Centrifuge feed pump P108B

39. Lift M3/32 89. Hoist No.1 X101A 139. Bagging Screwmotor

40. Portable Agitator 90. Reactor R106 M1/75 140. FD Fan K704

41. Transfer pump P302

91. Condensate transfer Pump P111 141. Ring Main P705

42. Transfer pump P405

92. Neut.Dish.Pump P102 142. Heater H1

43. S3052KL Vessel Agitator

93. Condensate transfer Pump P112 143. Dust Collector DC3

44. S306 DFX AGITATOR

94. V101 Agitator AV101

144. Conveyor Drive Motor (CS701)

45. S304 6kl Agitator 95. Hoist No.2 X101B

145. Automatic Switching Machine (ST701)

46. Homogenous pump DFX

96. Napathaline Scrubber NSB – 2

146. Screw Fedder Motor (SF701)

47. Gear Pump DFX 97. Formaledhyde Scrubber Pump P213

147. sko transfer pump(P702b)

48. Screw motor 98. Formaledhyde Scrubber ID Fan K212

148. vibrosezwer (vs701)



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49. SPARK FILTER MOTOR

99. R104 Agitator AR104

149. V109B Agitator AV109B

50. V) TOXIC CABIN 100. R105 Agitator AR105

150. Blender motor (1)B 801

1.2.10 Detail of Products & by-products

List of existing & proposed products is given in the table below:

TABLE – Detail of product:

Sl. No.

Products Existing capacity

(MT/ Annum) (Phsae-1 & 2)

Proposed (MT/Annum)

(Phsae-3)

Total After Expansion

(MT/Annum)

End Use

1. Syntan 9600 16800 26,400 Leather Preparation

2. Bates 3600 0 0 -- 3. Fat liquor 3600 3600 7200 Leather

Preparation

4. Superplastisicer 2400 2400 4800 Leather Preparation

5. Biocides 4800 3600 8400 Industrial Preservative

6. Uracil 180 0 0 --

7. Acrylic Resin - 4000 4000 Leather Finishing

8. Urethane Resin - 4000 4000 Leather Finishing

9. Solvent based blending’s

- 6000 6000 Leather Finishing

10. Water based blending’s

-

10,000 10,000 Leather Finishing

Total 24180 46,620 70800

TABLE – Detail of By-Product:

Sl. No.

Products Existing capacity

(MT/Month) (Phsae-1 & 2)

Proposed (MT/Month) (Phsae-3)

Total After Expansion (MT/Month)

1. Sodium Sulphate 30 0 0

2. Weak Sulphuric 200 0 0

Total 2015 0 0



15

1.3 Environment Management

1.3.1 Manpower

During Construction phase: 50 nos. labour During Operation phase: No. of Employees

Existing (Nos) Proposed (Nos) Total ( Nos)

150 100 250

1.3.2 Water Management

1.3.2.1 Water consumption & source &Waste water generation

Source of Water: Tanker Water Supplier. Present water requirement is 97 KLD & the

total water requirement after expansion is 260 KLD. Water is used in the process,

Domestic use, boiler & cooling tower & Gardening. Total waste water generated in existing

unit is 17.5 KLD & after expansion it will increased to 70 KLD. The detailed break up of

waste water & its treatment is given below:

Present effluent generation from the process is 7.5 KLD which is being neutralized

and evaporated by the multiple effective evaporators followed by condenser. The 7

KLD condensate from MEE is reused in Boiler & Cooling make up & 0.5 KL

concentrate is sent to Solar Evaporation Pond. 10 KLD of domestic waste is being

treated in STP of 25 KLD and 9 KLD treated water generated shall be reused for green

belt development.

The effluent generation from the process after expansion shall be 50 KLD which shall

be treated in ETP of 60 KLD followed by RO. 44 KLD of Permeate generated from

R.O. shall be reused Vessels/Plant washings. 6 KLD reject from R.O. & 4 KLD waste

water generated from Biocide plant shall be neutralized and evaporated by the multiple

effective evaporators followed by condenser. The 9 KLD condensate from MEE is

reused in Boiler & Cooling make up & 1 KL concentrate is sent to Solar Evaporation

Pond. 16 KLD of domestic waste is being treated in STP of 25 KLD and 14 KLD treated

water generated shall be reused for green belt development.

In existing it is a Zero Liquid Discharge Unit and the same shall be maintained after

expansion also. The detailed water management is given below:

TABLE – Details of Water Consumption

S. No

Description Existing ( m3/d)

Proposed ( m3/d)

Total ( m3/d)



16

1 Process (Addition Into Products & Vessels/Plant washings)

37 132 (44 KL Permeate from

RO)

169 (44 KL Permeate from

RO)

2 Boiler and Cooling Tower make-up

18 (7 KL Condensate from

MEE)


MEE)


MEE)

3 Domestic 12 7 19

4 Gardening 9 (STP outlet) 21 (Fresh water)

5 (STP outlet) 1 (Fresh water)

14 (STP outlet) 22 (Fresh water)

Total 97 210 260

TABLE – Details of Waste Water Generation

S. No

Description Quantum of effluent ( m3/d)

Existing Proposed Total

1 Process (Addition Into Products & Vessels/Plant washings)

5 45 50

2 Boiler and Chiller Blow down 2.5 2.5 5

3 Domestic 10 6 16

4 Gardening 0 0 0

TOTAL TRADE EFFLUENT 7.5 42.5 50

Total Quantity of Sewage 10 6 16

Total Quantity of Waste Water 17.5 48.5 66



17

1.3.2.2 WATER BALANCE

EXISTING

Domestic12 KLD

Vessels/Plant washings

5 KLD

Addition Into Products32 KLD

Boiler & Cooling Tower Makeup

18 KLD

Gardening9 KLD

Waste Water10 KLD

Waste Water5 KLD

Waste WaterNil

Boiler/Cooling Tower Blow Down

2.5

Waste WaterNil

Waste Water7.5 KLD

MEE 7 KLD condensate reused

Fresh Water81 KLD

TREATED

WATER

FROM

MEE

Recycled Water16 KLD

Total Water Requirement 97 KLD

STP25 KLD

Treated Water9 KLD

TREATED

WATER

FROM

STP

9 KLD treated water Reused

Concentrate -0.5 KL to Solar Evaporation Pond

7 KLD from MEE11 KLD

Gardening21 KLD

Waste WaterNil

9 KLD from STP



18

EXISTING + PROPOSED

1.3.2.3 Process & Operation of MEE

Multiple effect evaporators

Selection basis

The liquid effluent of reactor washings, floor washings and scrubber water is generated

from the process of fat liquor plant, spray dryer plant, biocides plant and QC lab

washing. Taking into account of the nature of the effluent form all the sources and after

taking lot of pilot trails, it was decided to install physically evaporation system (multiple

effect evaporator) and the system is functioning effectively.

Pre-treatment

The effluents from different plants are collected in a common underground collection

sump (cap 8 KLD), where pH is adjusted and pumped to the intermediate storage

tanks (10m3 & 20m3) located at effluent treatment plant.

Domestic19 KLD

Vessels/Plant washings

49 KLD

Addition Into Products120 KLD

Boiler & Cooling Tower Makeup

36 KLD

Gardening14 KLD

Waste Water16 KLD

Waste Water49 KLD

Waste WaterNil

Boiler/Cooling Tower Blow Down

5 KLD

Waste WaterNil

Waste Water50 KLD

MEE

44 KLD Permeate for Reuse

Fresh Water193 KLD

TREATED

WATER

FROM

MEE

Recycled Water67 KLD

Total Water Requirement 260 KLD

STP25 KLD

Treated Water14 KLD

TREATED

WATER

FROM

STP

14 KLD Reused

Concentrate -1 KL to Solar Evaporation Pond

9 KLD from MEE27 KLD Fresh

Gardening22 KLD

Waste WaterNil

14 KLD from STP

4 KLD from

Biocide plant

45 KLD from other plants

ETP of 60 KLD with R.O.

Reject of 6 KLD

9 KLD condensate Reused

TREATED

WATER

FROM

RO

14 KLD treated water Reused

44 KLD from R.O.

44 KLD from R.O.

5 KLD Fresh



19

Treatment Process

The effluent is evaporated in a multiple effect evaporator system. The evaporated

water is condensed and it is used for cooling water makeup. The concentrate from the

evaporation system is sent to solar pond for drying.

1.3.2.4 Process & Operation of STP

Sewage treatment plant

The sewage from the canteen house and bathroom, toilets will be led by gravity

through drain channels to a underground collection pit. The drain will be provided with

a bar screen for screening and removing coarse suspended matter. The sewage will

be received in a collection sump and transferred to the aeration tank by pumping. In

collection sump coarse bubble aeration will be provided to keep the sewage in

homogenized, aerobic condition.

Biological Treatment

The collected/homogenized sewage will be pumped to the aeration tank to reduce

organic pollutants in the presence of re-circulated active bio-mass (mixed liquid

suspended solids).

Here oxygen the main source of growth for the microorganism is supplied through fine

bubble diffusers connected to twin lobe type blowers. This will be led to the reduction

of BOD, COD and other organic pollutants. In this aerobic process, the sewage as

discussed earlier will be subjected to extended aeration type activated sludge process

for bio-degradation of organic.

The wastewater sludge mixture will then enter in to a secondary tank where the sludge

will be settled. The settle sludge will be re circulated back to aeration tank to maintain

the active biomass to the desired level or to sludge drying beds for drying the disposal

if excess. The clear supernatant at the top of the settling tank would overflow into the

clarified water tank. Liquid chlorine will be added in the clarified water tank to further

oxidize the residual organic and to disinfect the water.

The clarified water will be pumped through a multi grade filter for removal of suspended

solids and passed through an activated carbon filter for removing the traces of organic,

color and odour left in water.



20

Filter backwash water and sludge pit filtrate water are collected in a drain and shall be

put into the sewage collection sump for further treatment. The treated water is used

for gardening.

Sewage plant details

Sewage plant capacity-25m3/day

Sewage collection sump volume 60 m3

No of compartments One

Liquid depth 3m

Overall size of the tank 7m x 3m x 3m

Aeration Tank

Volume of tank provided 30m3

Liquid depth 2.7 m

Aeration tank size 2.3 m x 5.9m x 2.7m (2.2m + 0.5m FB)

Secondary Settling Tank

Volume of tank 8.5 m3

Size of the tank 2.85 m x 1.5m x 2.7m (2.0 + 0.7m FB)

Clarified water tank





21

Filter water storage tank



Air blower

Air Blower Capacity 50- M3/hr

1.3.2.5 Process & Operation of ETP

Raw Effluent Collection/Equalisation The raw effluent from the processing sections will be collected in two batch effluent Collection cum Equalisation tanks. The equalisation tanks will be provided with diffused air agitation system to attenuate the variations in effluent flow and characteristics. Electro Coagulation Treatment & Primary Clarification The equalized raw effluent from the collection tank will be pumped to the proposed Electro Coagulation plant capable of handling 3m3 /hour of effluent flow. The electro coagulation process encompasses the addition of an electrical current to sacrificial electrodes. This is done within a highly turbulent electrochemical cell with a positive anode and negative cathode. Many processes like oxidation, reduction, and neutralisation occur simultaneously in any electrochemical cell. The electro coagulated floc differs significantly from the floc formed during chemical coagulation process, containing less bound water, more resistant to shear and hence better dewatering characteristics. Parallel Plate Separation The effluent after electro Coagulation treatment will be mixed with poly electrolyte solution and taken to a Parallel Plate Separator for solid-liquid separation. The clarified water overflowing from the Parallel Plate Separator will contain COD & BOD content around 8500mg/l and 3700 mg/l respectively. This primary treated effluent will be provided with two stage aerobic biological treatment for removal of COD & BOD to a level of 250 mg/l and 30 mg/l, respectively. Two-Stage Aerobic Biological Treatment and Secondary Clarification



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The effluent overflowing from the Parallel Plate Separator will be provided with two-stage aerobic biological treatment designed on the basis of activated sludge process working on extended aeration principle. The stage-I aeration tank will be provided with an air blower of 420m3/hr capacity with diffused aeration piping system for supplying necessary Dissolved Oxygen and Mixing in the aeration tank. The overflow from aeration tank-I will be taken to Aeration tank –II provided with an air blower of 120m3/hr capacity with diffused aeration piping system for supplying necessary Dissolved Oxygen and Mixing in the aeration tank. The overflow from the aeration tank-II will be taken to a secondary settling tank, where solid- liquid separation takes place and the clarified water is taken to interim collection tank. The bio-sludge from the secondary clarifier will be recycled back to the aeration tank I & II to maintain the desired bacterial concentration and the excess bio-sludge will be drained to a bio-sludge collection tank for further treatment.

Interim Collection tank The overflow from the Secondary Settling tank will be collected in an interim collection tank from where it will be pumped to Pressure sand filter followed by Activated Carbon filter. Pressure Sand Filtration & Activated Carbon Adsorption The treated water from the interim collection tank will be pumped to a pressure sand filter to filter the fine suspended solids present in the treated effluent. The filtered water will be passed through a tank filled with coconut shell based granular activated carbon to polish the treated effluent and remove the trace organic content (COD) in the treated water to less than 50 mg/l. Sludge Dewatering & Disposal The chemical sludge from the parallel plate separator and excess bio-sludge from the Secondary Settling tank will be collected into separate HDPE collection tanks from where it will be pumped to a recessed type plate filter press. The filtrate from the filter press can be collected and taken to raw effluent collection tank for further treatment. The dried sludge will be packed in polythene bags and stored for disposal. Reverse Osmosis The Treated water from the Activated Carbon Filter will be taken to the 1st Stage of the Two -stage Reverse Osmosis plant for recovering 60% ( permeat) as product water with TDS content less than 200 mg/l. The Reject from the 1st Stage will be taken to the 2nd Stage RO for recovering further 50% (permeat) s Product water. The Reject water from the 2nd stage will be taken to the Multiple Effect Evaporator for concentration of dissolved salts and further water recovery. The solids slurry from the evaporator will be filtered in a basket filter and the mother liquor is taken back to the evaporator for further evaporation. The Condensate water from the Multiple effect evaporator is Product water and is used back in the Process.



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24

Schematic Diagram of ETP

Characteristics of ETP inlet & Outlet are given below:

Sl. No Parameter

Concentration

Raw Effluent from Collection

Tank ( mg / l)

Treated Water from RO for

Process ( mg / l )

TNPCB Standards (

mg / l )

1 pH 9.0 to 11 6.0 - 7.0 5.5 – 9.0

2 Colour Black/Grayish colourless colourless

3 TDS 8460-13900 < 200 < 2100

4 TSS 50 – 100 <10 < 100

5 COD 18000-25000 0 < 250

6 BOD 4000 – 5000 0 < 30

50 KLD

44 KLD

9 KLD



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1.3.2.6 Rain water harvesting scheme

The main source of ground water recharging in the study area is rainwater, which

infiltrates into the ground through various lithological units present in the study area. 3

number of rainwater harvesting pits has been installed to recharge the ground water. The

runoff from the rooftop and storm water shall go to the recharge pits.

Scheme for Ground Water Recharging

The rainwater is diverted from the rooftop using rain water pipes to the surface /

underground drainage network. The entire campus is sub divided for recharging

structures.

The rainwater is diverted into the desilting tank to remove inorganic impurities and the

outflow of the desilting tank is taken into the recharge well.

Desilting Tank

The desilting tanks are used to remove silt and other floating impurities from rainwater.

Desilting tank is like an ordinary container having provision for the inflow, outflow and

overflow. Apart from removing silt it holds the excess amount of water till it is soaked up

by the recharge structure. The bottom of tank will have unpaved surface (layers of coarse

sand) to allow standing water to percolate into the soil. The rainwater collected in these

desilting chambers shall be utilized for horticulture.

Recharge well

The Recharge Well consist the pit size of with dia 2.6 m and effective depth of 3.0 m with

of 18.90 mm PVC perforated pipe will be lowered in the middle of the boreholes and the

pit will be filled with gravel and pebbles consisting of boulders, gravel and coarse sand.

The mouth of the PVC pipe shall be protected to avoid silt getting into it. The depth of the

bore will depend on the soil condition/water strata. The schematic diagram is enclosed. It

should be therefore concluded that there is no significant impact on surface water quality

& hydrology of the area. The proposed rainwater-harvesting scheme will stabilize the

groundwater table in the area.

The rain water collected shall also be collected into the proposed water body & utilized

for misc. purposes.



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DESIGN CRITERIA: SOIL QUALITY : Silt clay INFILTRATION RATE : 12.7 mm/hr PEAK HOURLY RAINFALL : 60 mm/hr NO. OF RAINWATER HARVESTING PITS : 3 No. SIZE OF PITS : 3m x 3m x 2m SIZE of PROPOSED WATER BODY : 248 cubic meter (11.3m X 11mX 2m)

Rain water calculation:

S.No. Description of Area

Area Considered

(Sq. M)

Harvesting Factor /

Collection Efficiency per area

Retention time for

capacity of recharge tank (in minutes)

(Peak hourly: 60

mm/hr)

Total Volume of

Water Available for Rain Water

Collection (Cubic

Mtrs) (Peak)

1 Water Available from Terraces of buildings and other roof-top surfaces

22300 0.85 15 284

GRAND TOTAL

22300 sqm 284 Cubic Mtrs

RAIN WATER HARVESTING DIAGRAM



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1.3.3 Waste Generation and Management

1.3.3.1 Municipal Solid Waste

1.3.3.2 Process Waste (Non-Hazardous)

Process Waste

Existing

Proposed

Total Disposal method

STP Sludge 100 Kg/Annum

50 Kg/Annum

150 Kg/Annum

Sludge will be passed through filter press where it will be dewatered/ dried to form a cake and then will be used as manure in green areas. The unused sludge shall be given to farmers or nursery

Boiler Ash 7.2 MT / Annum

7.8 MT / Annum

15 MT / Annum

Shall be disposed off MSW site.

1.3.3.3 Hazardous Waste

Some of the raw materials solvents, fuels and products are classified as hazardous

substances. Based on the physical, thermal, chemical and biological properties

available from the material safety data sheets (MSDS) of the various substances

handled in the proposed project, the hazardous substances are identified. The

hazardous waste generated is given below:

Category Type of Waste Color of

Bins

Disposal Method

(Existing) Total

Waste (Kg/day)

(After Expansion) Total Waste

(Kg/day) Bio

Degradable Organic Waste

(Includes Food & Kitchen Waste,

Leaves etc.)

Green

Vermicomposting with in

project site

25 40

Non-Biodegradabl

e

Recyclable Waste (Includes Poly-bags, Plastic, metal, wood,

paper, glass, containers etc.)

Blue Authorized recycler

175 450

- Total - - 200 490



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Used oil generated from machineries/D.G. Set will be carefully stored in HDPE

drums in isolated covered facility. The used oil will be sold to vendors authorized

by Central Pollution Control Board for the treatment of the same. The industry is a

member of the Tamil Nadu Waste Management Ltd and has been authorized to

dispose its Hazardous waste to the TSDF / Incineration facility at Gummidipoondi.

Name of Process Name of Process Waste

(Category No)

Quantity (T/Year)

Existing

Quantity (T/Year)

Proposed

Quantity (T/Year)

Total

5 Industrial operations using mineral/synthetic oil as lubricant in hydraulic systems(Schedule I)

5.1 Used/spent

oil

2.5 1.5 4

20 Production and/or industrial use of

solvents(Schedule I)

20.2. Spent solvents

1.5 13.5 15

5 Industrial operations using mineral/synthetic oil as lubricant in hydraulic systems(Schedule I)

5.2 Wastes/resid

ues containing oil

0.5 1.0 1.5

34 Purification and treatment of exhaust air, water and

waste water from the processes in this schedule

and CETPs(Schedule I)

34.3. Chemical

sludge from waste water treatment

21 49 70

33 Disposal of barrels / containers used for handling

of hazardous wastes / chemicals(Schedule I)

33.3. Discarded

containers / barrels /

liners contaminated

with hazardous

wastes/ chemicals

60 120 180



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Sludge from solar pan shall be mixed with husk, packed in HDPE bags and then

set to authorized incineration facility.

1.3.4 Air Emissions and Control

Source of Air Pollution Existing Proposed Total

D.G. Set back up 1000 KVA & 160 KVA

1000 KVA 1000 KVA – 2 Nos. & 160 KVA

Capacity of Boiler 5 TPH & 0.5 TPH 6 TPH 5 TPH & 6 TPH

Fuel Consumption per day

Existing Proposed Total

Briquettes Kgs 8,000 8,000 16,000

Furnace Oil Liters 1,800 1,800 3,600

Diesel Liters 270 270 540

The major air pollutants sources are Boiler & D.G. sets. For mitigation of impacts of

air pollution, stack & Air Pollution control devices shall be provided as per the detail

give below:

Stack No

Source of emission

Pollution Control measures

Stack top dimension (in Metres)

Stack Height above ground level (meters)

Material of Construction

Maximum Discharge (in m3/hr)

EXISTING

1 Boiler 5 TPH

Multi cyclone and wet bottom

0.9 32 MS 14600

2 Spray dryer

section

Cyclone separators with bag

filter arrangemen

t

1.2 18 SS 23300



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3 Hot Air Burner

Stack 0.7 31 MS 2500

4 Syntan plant

Reactors

Common wet

scrubber

1.1 30 MS with FRP Lining

500

6 Tox cabin - Cresol

pumping

Wet scrubber with stack

0.5 8 FRP 300

7 Fat Liquor plant

reactors

Common wet

scrubber

0.1 30 HDPE 500

8 DG set (1000 KVA )

Stack 0.15 14 MS 1554

9 DG set (160 KVA)

Stack 0.15 4 MS --

10 Powder Blending section

Bag Filters with stack

0.4 6 MS ---

11 Blending plant - liquid


0.4 5 MS --

12 Spray dryer

packing section


0.3 4 MS --

13 Blending plant - liquid


0.1 13 FRP --

14 Tox cabin-

Biocide plant


0.5 17 FRP --

15 Raw Mtl bulk

storage-Raw Mtl tankfarm


0.36 9 FRP --



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PROPOSED

16 Boiler 6 TPH

Multi cyclone and wet bottom

0.9 32 MS 14600

17 DG set (1000 KVA )

Stack 0.15 14 MS 1554

18 Syntan plant

Reactors

Common wet

scrubber

1.1 30 FRP 500

VOC Control: All vessel/ Charging area vents are connected with scrubber.

Leak Proof Pumps are used for transferring. Local Exhaust ventilation is being

used near drum/vessel openings which is connected to scrubber.

1.3.5 Power Requirement Source & Back-up

The power is being supplied by Tamil Nadu State Electricity Board

Particulars Existing Proposed Total

Power Requirement in HP


Connected – 2640 HP

- 360 HP

Licensed – 5000 HP Connected – 3000

HP

D.G. Set back up 1000 KVA & 160 KVA

1000 KVA 1000 KVA – 2 Nos. & 160 KVA

1.3.6 Noise Pollution Management

To reduce Ambient Noise level the following measures will be adopted --

Existing DG set has been bought acoustically enclosed & placed inside a

acoustically treated room as per CPCB guidelines & same shall be done for

proposed D.G. set.

Noise generating units like machinery area, canteen etc. are well insulated with

enclosed doors. Earmuffs are being used while running equipments of the Industry.

Maintenance of vehicles and machinery will be done in a sustainable manner to

ensure best performance and less loss.

Vehicle and people flow during shift changes shall be regulated by allowing exits in a

phased manner.



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The green belt will help in reducing noise levels in the complex as a result of

attenuation of noise generated due to plant operations and transportation. Total

green area in existing industry is 11.51 ha.

1.3.7 Safety

. Safety in design and operations are therefore of paramount importance.

1.3.7.1 Safety in Design

Following are the strategies to improve the safety of the people and plant:

Use of proven technologies and equipment

Use of latest safety process know-how

Modern risk assessment techniques to design effective safeguarding system

for all critical locations in the process

Design plant in accordance with applicable codes and standards and maintain

standard engineering practices during detailed engineering

Carryout extensive studies during the process design stage to ensure safety,

occupational health and environmental aspects are addressed in P& IDs, PFDs

and other engineering deliverables.

Minimize presence of large hydro-carbon inventories by designing liquid hold

up volumes in vessels based on control and operational requirements

Locate storage tanks in off site area

Pressure relief valves in all pressure vessels.

Occupational Health

Fixed detection system with alarms and data logging

Trained personnel made fully aware of the hazards of process and operations.

Personnel must also be informed of the health hazards

Periodic refresher training

Minimize unnecessary exposure to airborne contaminants and direct exposure

to chemical hazards

Good housekeeping

Emergency showers and eye wash facilities at appropriate locations

Health surveillance programs



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1.3.7.2 Safety in Operations

A suitable organization shall be implemented to manage the safety of people and

plant. The organization shall be responsible for building and maintaining “a culture of

safety” and shall thrive to elevate safety to near religious levels. Suitable systems shall

be designed and implemented for safety training and awareness.

A suitable fire protection system with dedicated firewater network for the whole

complex has been designed and installed. Besides, facilities such as dedicated fire

station equipped with fire fighting equipment such as fire tenders has been put up. A

dedicated fire alarm system and special arrangements to protect control rooms in case

of fire has also been commissioned as part of the project. Existing unit is operating at

highest safety standards with the principle that safety of a person overrides all

production targets.



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1.4 LAND DETAILS

1.4.1 Land Form & Land Use

The land has been allotted to Indorama industries Ltd. By HPSIDC which is an

industrial land and there is no change in land area or plot area as this is an expansion

project with respect to the annual production. The plant is operational as per the old

EC granted in 2010 by SEIAA, and hence there is no change in landuse. Land papers

are attached in annexure VIII.

1.4.2 Existing Infrastructure around the Site

1.4.2.1 Routes or facilities used by the public for access:

Nearest Railway Station : Old Kanchipuram Railway Station- 9.84 Km SW

Nearest Airport : Chennai International Airport, - 42.85 Km NE

Nearest Highway : NH-4 – 0.25 Km NW

1.4.2.2 Social Infrastructure:

Particular Distance

Hospital Meenakshi Medical College & RI Arignar Anna Mem Cancer Hospital And RI Aggrawal Eye Hospital Post Office Post Office, Kanchipuram Places of worship Kailasanather Temple Pallur Sri Varahi Temple School Bharathidasan Maticulation HS School St Josephs Residential School Sri Sankara Arts And Science College Jeppiaar Institute of Technology Bank ICICI Bank HDFC Bank Vijaya Bank

7.47 Km W 8.36 Km W 10.97 Km SW 11.53 Km SW 12.02 Km SW 15.51 Km NW 12.48 Km SW 15.91 Km NE 7.11 Km SW 9.02 Km E 10.49 Km SW 11.00 Km SW 11.13 Km SW



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1.4.3 Proposed Infrastructure

1.4.3.1 Processing Area

1.4.3.2 Green Belt

Green belt planning has been done as per guidelines laid by CPCB. With ecological

perspectives for the expansion of the project availability of space and other aspects

has been considered. This will help in increasing the aesthetic effect of the

environment. Green belt/greenery will be developed along most of the periphery of the

project area as well as along roads. In existing the green area is 11.51 ha (2.0 ha

grass / small plant area where daily watering done and 9.51 ha has big trees around

6000 which takes water from ground by self).

For proposed green area, the trees planted will be of adequate height. Any tree that does

not survive will be replaced. Ornamental trees will also be planted to improve the aesthetic

looks of the project area. The following characteristics have been taken into consideration

while selecting plant species for green belt development and tree plantation.

They shall be fast growing and tall trees.

They shall be perennial and evergreen.

They shall have thick canopy cover.

They shall have large leaf area index.

Since tree trunks are devoid of foliage, scrub should form there to give coverage to

the trunks. The trees will maintain regional ecological balance and conform to soil and

hydrological conditions. Indigenous species would be preferred. Before planting of

trees, seedlings, saplings, grass species, shrubs, soil preparation, soil amendments

etc are to be undertaken well in advance. For proper survival and healthy growth of

plant species a nursery is also maintained at the site. It is ensured that proper density

of plants is maintained at site. Post plantation care is also necessary and maintained

in planned and scientific manner.



36

1.4.3.3 Sewerage System

All the treated water generated shall be reused within the premises for landscaping and

boiler & cooling tower makeup. It is a zero liquid discharge unit. After expansion also it will

remain a zero liquid discharge unit.

1.4.3.4 Liquid Waste

In existing 25 KLD STP has already been provided to treat domestic waste. The

effluent in existing is being neutralized and evaporated by the multiple effective

evaporators and send to solar evaporation pan to achieve zero discharge. After

expansion ETP of capacity 60 KLD with RO shall also be provided for treatment of

effluent. After expansion also it will remain a zero liquid discharge unit.

1.4.3.5 Parking Facility

Adequate parking provision has been provided on surface. Also separate loading & unloading area

has been provided within the project premises.

1.4.3.6 Rehabilitation and resettlement Plan

As this is an expansion project, there is no need for R&R activities for the activity.



37

1.5 PROJECT SCHEDULE AND COST ESTIMATES

1.5.1 Likely Date of Start of Construction and Completion

The project is operational at 46620 TPA capacity and the expansion will take place

after 6 months after getting Environmental clearance.

1.5.2 Estimated Project Cost

Cost of existing unit is 80 crore & for proposed expansion is estimated as Rs. 15 Crore.

Hence total cost will be 95 crores.

1.6 PROJECT BENEFITS

1 After expansion it will be an environmentally sustainable project. It will attract

people to develop organized chemical manufacturing Industry.

2 Organized methods for manufacturing of the chemicals are being used and shall

be maintained for chemical to be manufactured after expansion also.

3 The chemical products manufactured by Stahl India are used for leather

Preparation, Leather Finishing & Industrial Preservative all over India. After

expansion the increased demand of customers shall be fulfilled.

4 After expansion additional employment opportunities will lead to a rise in the

income and improve standard of living. The expansion of existing industry would

also generate jobs for the labours during construction phase as well as during

operation phase. It will provide direct and indirect employment to local youth.

5 Chemical manufacturing Industry is a large and growing domestic market. There

will be economic benefit due to selling of products all over India.

6 26.5% of water requirement shall be met by recycled water.

7 The industry has a Zero Liquid Discharge system and shall adopt all the necessary

steps to protect the environment.

8 Addition of revenue to the state by taxes.

pre-feasibility report for expansion of chemical

Documents