pre - feasibility report...

Proposed Expansion of Caustic soda manufacturing, Boiler, D. G. Sets and Production of Chlorinated Paraffin Wax (CPW),Sodium Hypochlorite, Aluminum Chloride, Mono Chloro Acetic acid and Sulphuryl chloride within existing plant premises at SP-460, Matsya Industrial Area (MIA), Alwar (Rajasthan)

Pre - feasibility Report

M/s. Lords Chloro Alkali Ltd. 19

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

INTRODUCTION

Lords Chloro Alkali Ltd. (LCAL) was incorporated in 1979, for producing and exporting a

wide range of chemicals, which commanded the market in North India.

LCAL has built sophisticated manufacturing facilities at Alwar (Rajasthan), having

locational advantage in chlor-alkali deficit region. A well integrated Caustic-Soda Plant

with a capacity of 275 TPD and with a production potential to tap by-products, both

functional and non-functional.

Our manufacturing unit is set up in the developed industrial area at SP-460, MIA, Alwar in

the colorful state of Rajasthan, India.

The plant is fully mechanized with the latest state-of-the-art technology machineries

from:

M/s. Asahi Kasei Chemicals Corporation, Japan UDHE Germany

Table - 1Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Product Details Name of Product Production Capacity TPAExisting

(a)Proposed

(b)Total(a+b)

Caustic soda 90729 74271 165000Chlorine 80190 66247 146437Hydrochloric acid 66000 53475 119475Hydrogen 2272 1857 4129Calcium Hypo 10000 0 10000Stable Bleaching Powder 14520 0 14520Trichloroethylene 5000 0 5000Chlorinated Paraffin wax (CPW) 0 99000 99000Hydrochloric acid 0 154440 154440Sodium hypochlorite 0 33000 33000Aluminum Chloride 0 33000 33000Mono Chloro Acetic acid 0 33000 33000Sulphuryl chloride 0 33000 33000

B. Boiler Details Boiler requirement

Particulars Existing Proposed After Expansion

Boiler Capacity 15 TPH (10+5) 10 TPH 25 TPH (10+10+5)

C. D.G. Details Diesel Generator Set (DG Set) requirement





Diesel GeneratorSet (DG Set)

2 DG Sets of1000 KVA (500KVA + 500 KVA

each)

2 DG Sets of 2000KVA

(1000 KVA forcaustic

1000 KVA forchloro-products

each)

4 DG Sets of 3000KVA

(2 x 1000 KVA2 x 500 KVA)

D. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time totime; this project falls under Category “B” as project site is located innotified industrial area. Project Activity ‘1(d)’, ‘4 (d)’ & ‘5(f)’.

E. Location Details

Plot No. SP-460, Matsya Industrial Area (MIA), Alwar (Rajasthan).

Tehsil Alwar

District Alwar

State Rajasthan

Latitude 27°30'37.30"N to 27°30'15.20"N

Longitude 76°40'51.86"E to 76°41'10.43"E

Toposheet No. 54A/10, 54A/11, 54A/14, 54A/15

F. Area Details

Total Plant Area

o Total plant area: 338958.75 sq. m.

o No additional land is required for the proposed expansion, as the samewill be done within the existing plant premises.

Greenbelt / PlantationArea (ha)

40% (135660 sq. m.) of the total plant area has already been developedunder greenbelt / plantation. Green belt is developed along with the roadand plant boundary to reduce noise levels, dust pollution and improvesurrounding environment. The same shall be maintained.

G. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Town /City Alwar ~6.5 km in NW direction from the Project Site

2. Nearest National Highway/ State Highway

o SH 14 - Alwar - Bharatpur (~3.0 km in NNE direction)

o SH 25 - Alwar - Rajgarh (~6.0 km in WNW direction)

3. Nearest Railway station Alwar Railway Station ~8.0 km in NW direction from project site

4. Nearest Airport Jaipur Airport, ~112 km SW direction from project site

5. National Parks, Wild LifeSanctuaries, BiosphereReserves, Tiger/ ElephantReserves, Wildlife

No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / ElephantReserve, Wildlife Corridors etc. falls within 15 km radius of the plant site.




Corridors etc. within 10km radius

6. Reserved Forests (RF) /Protected Forests (PF)etc. within 10 Km. radius

o Bhugar Protected Forest (~ 7.0 km in West direction)

o Bhakhera Protected Forest (~ 9.0 km in WNW direction)

7. River / Water Body(within 10 km radius)

o Bhurja Nadi (~ 5.0 km in SW direction)

o Ruparel Nadi (~ 6.5 km in SSE direction)

o Sukhri Nadi (~ 9.8 km in SSE direction)

o Jaisamand Lake (~ 10.0 km in WSW direction)

o Siliserh Lake (~14.5 km in West direction)

E. Cost Details

Total Cost of theExpansion Project

Cost of Existing Cost of Proposed Total Cost after Expansion

218 Cr. 357 Cr. 575 Cr.H. Basic Requirements for the

project Existing Additional for proposedexpansion

Total after proposedexpansion

Water Requirement (KLD) 1944 3170 5114

Source: Ground water supply from Bore Wells, application for approval fromCGWA Submitted and it is under process.

Power Requirement(MW)

Existing Additional for proposedexpansion


30 MW 45 MW 75 MW

Source: Jaipur Vidhut Vitaran Nigam Ltd. (JVVNL) & D.G Set (for emergency).

Man Power Requirement(Persons)

Existing Additional for proposedexpansion


250 250 500

Source: Preference will be given to local area

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

The company is strategically located in the heart of North India where the demand is

always more than the supply. We supply our products to most of the paper, soap, dyes,

chemicals and plastic industries based at the western part of UP, Haryana, Punjab &

Delhi. Besides this, there is also in-house consumption of Chlorine.

As far as the disposal and utilization of chlorine by-products is concerned we have earned

a very satisfactory position We are capable of supplying 49 ancillary units of CPW chlorine

within a radius of 1 KM. Rest of the chlorine is consumed by various paper mills and other

industries from western UP and Rajasthan, which is in a radius of 100 KM from our




manufacturing unit. Our wide array of chemicals finds acceptance all over the country,

which is sold directly and through our wide dealer network, outspread across the

country.

The proposed plant will be located at SP-460, MIA, Alwar in the name of M/S. Lords

Chloro Alkali Ltd. is engaged in the manufacturing of Caustic soda lye. Based on the

market scenario now, company proposes to set up a production capacity for

manufacturing of Chlorinated Paraffin and Sodium Hypochlorite for captive consumption

of chlorine, to minimize the hazards and risk of chlorine storage and transportation.

The proposed expansion activities will be carried out in our existing plant premise which

is located in SP-460, MIA industrial area where all resources are easily available and well

developed communication facilities, infrastructure already exists.

Background:

ProponentLCAL has its manufacturing plant at MIA -Alwar (Rajasthan), having locational advantage

in Chlor-Alkali deficit region. A well integrated Caustic-Soda with a production potential

to tap by products.

The plant is strategically located in the heart of North India where the demand is always

favorable. We supply our products to most of the paper, soap, dyes, chemicals and

plastic industries based at the western part of UP, Haryana, Punjab & Delhi. Besides this,

there is also in-house consumption of Chlorine.

(ii) Brief description of nature of the project

M/s. Lords Chloro Alkali Ltd. has Proposed Expansion of Caustic soda manufacturing,

Boiler, D. G. Sets and Production of Chlorinated Paraffin Wax (CPW), Sodium

Hypochlorite within existing plant premises at SP-460, Matsya Industrial Area (MIA),

Alwar (Rajathan).

As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this

project falls under Category “B” as project site is located in notified industrial area.

Project Activity ‘1(d)’, ‘4 (d)’ & ‘5(f)’.

(iii) Need for the project and its importance to the country and or region:-

During the manufacturing of Caustic soda, Chlorine and Hydrogen gases are co-

generated. Chlorine thus produced is partly utilized captive for HCl production and the

rest is compressed and filled in tonners for sale off to respective consumers.




Expansion of Caustic Soda plant is done for getting a competitive edge in the market and

to make the manufacturing more economically feasible and also to conserve the

resources through various reuse/recycle opportunities created within the plant.

The main objective to produce Chlorinated paraffin and Sodium Hypochlorite is to

increase captive use of chlorine, resulting in reduced risks and hazards that arise during

chlorine handling & transportation.

Apart from this, forward utilization of chlorine will provide an edge to survive and sustain

in this highly competitive manufacturing industrial environment.

(iv) Demand supply gap:-

The Chlor-Alkali Industry in the country produces mainly Caustic Soda, Chlorine. The

growth of Caustic Soda and Soda Ash Industry is very important for the Nation and if

competitiveness of this Industry is maintained, it can certainly grow at a much faster rate.

Latest technology of Membrane cell for manufacturing of caustic soda, installation of

latest generation electrolyzer, which being environment friendly are highly energy

efficient.

Caustic Soda has its applications in various segments and the demand is on an increasing

trend:

o Soaps and Detergent Industryo Pulp and Paper Industryo Textile Processing Industryo Aluminium Smeltingo Dyes and Dyestuff Industryo Plastic Polymerso Rayon Grade Pulpo Pharmaceuticalso Electroplatingo Adhesives/Additives.Major applications of Chlorinated paraffin are in the field of

o PVC industryo Lubricants / Metal working fluid industryo Other misc. industry including rubber, sealant, paint industry & textile industry

In all of these applications, there is a long history of safe use and some majorcustomers have been using chlorinated paraffin for over 50 years.

Major applications of Sodium Hypochlorite are in the field of -

o Bleachingo Cleaning & Destaining




o Disinfectiono Deodorizingo Water Treatmento Endodontics

(v) Imports vs. Indigenous production:-

The products which will be manufactured will be as per customer’s specifications. This

will have acceptability in the domestic markets. The product also has an export potential.

The export market can also be explored in future. The Company has been selling its

products to many institutes, Government organizations, thermal power stations and

state governments of Rajasthan, Uttar Pradesh and Punjab from India and final product is

being transported by road.

(vi) Export possibility:-

Expansion of Caustic Soda plant is done for getting a competitive edge in the market and

to make the manufacturing more economically feasible and also to conserve the

resources through various reuse/recycle opportunities created within the plant.

(vii) Domestic/export Markets:-

The products which will be manufactured will be as per customer’s specifications. This

will have acceptability in the domestic markets. The product also has an export potential.

The export market can also be explored in future.

(viii) Employment Generation (Direct and Indirect) due to the project:-

The company has employed more than 250 workers and staff directly and indirectly in

manufacturing units. Business approach is directed towards better interactions with the

labour and development of human resources.

Sr.No.

Manpower requirement (Persons)


1 Skilled 180 110 290

2 Unskilled 30 90 120

3 Semi skilled 40 50 90

Total manpower 250 250 500

Unskilled/ semi skilled manpower can be sourced from the local area and skilled

manpower shall have to be sourced from where it is available.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.




There are no interlinked projects related to this expansion project.

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates

Figure - 1: Location Map




(iii) Key Plan

Figure2: Key Plan




Figure - 3: Site Layout Plan




Figure - 4: Site Photographs




(iii) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since the proposed expansion will be done within the existing plant premises and no

additional land will be required; therefore, no alternative site has been considered.

(iv) Size or magnitude of operation

M/s. Lords Chloro Alkali Ltd. has Proposed Expansion of Caustic soda manufacturing,

Boiler, D. G. Sets and Production of Chlorinated Paraffin Wax (CPW), Sodium

Hypochlorite within existing plant premises at SP-460, Matsya Industrial Area (MIA),

Alwar (Rajasthan).

The process includes basic raw material requirement, sizing of equipment, utilities &

services, infrastructure facilities & sources of waste generation, their quantity, treatment

& safe disposal of the waste.

(v) Project Description with Process Details

Project Description

Name of Product Production Capacity TPAExisting

(a)Proposed

(b)Total(a+b)

Caustic soda 90729 74271 165000Chlorine 80190 66247 146437Hydrochloric acid 66000 53475 119475Hydrogen 2272 1857 4129Calcium Hypo 10000 0 10000Stable Bleaching Powder 14520 0 14520Trichloroethylene 5000 0 5000Chlorinated Paraffin wax (CPW) 0 99000 99000Hydrochloric acid 0 154440 154440Sodium hypochlorite 0 33000 33000Aluminum Chloride 0 33000 33000Mono Chloro Acetic acid 0 33000 33000Sulphuryl chloride 0 33000 33000

Process Description

(vi) Raw material required along with estimated quantity, likely sources, marketing area offinal product/s, Mode of transport of raw material and finished product.

The detail of the Raw materials is given in below table:

Raw material requirement (After expansion)

Sr.No.

Details of Raw Material Basis taken forcalculation (plant

average)Existing @275 TPD Proposed @ 225 TPD After Expansion @ 500

TPD




Name of Rawmaterial

QuantityTPD

Name ofRaw

material

QuantityTPD

Name ofRaw material

QuantityTPD

Kg/T of product

1 Salt 440 Salt 360 Salt 800 16002 Hydrated

lime2.475 Hydrated

lime2.02 Hydrated

lime4.49 9

3 Soda Ash 1.237 Soda Ash 1.01 Soda Ash 2.24 4.54 Caustic lye

(Captive)4.193 Caustic

lye3.43 Caustic lye 7.62 15.25

5 BariumChloride

3.245 BariumChloride

2.65 BariumChloride

5.89 11.8

6 HCl(Captive) 49.5 HCl 40.50 HCl 90.0 1807 Sulphuric

acid4.4 Sulphuric

acid3.60 Sulphuric

acid8.0 16

8 Alphacellulose

0.123 Alphacellulose

0.10 Alphacellulose

0.22 0.45

9 Sodiumsulphite

0.715 Sodiumsulphite

0.58 Sodiumsulphite

1.29 2.6

10 Paraffin 0 Paraffin 135 Paraffin 135 0.45 T/T CPW11 Chlorine

For CPW0 Chlorine

For CPW333 Chlorine

For CPW333 1.11 T/T CPW

12 Hydratedlime (SBP)



33 0.75 T/T SBP

13 ChlorineFor SBP

17.6 ChlorineFor SBP

0 ChlorineFor SBP

17.6 0.40 T/T SBP

14 Caustic forNa-Hypo

0 Causticfor Na-Hypo

15 Caustic forNa-Hypo

15 150 @100 TPDSodium Hypochlorite

MARKETING AREA AND MODE OF TRANSPORTATION OF FINAL PRODUCT

Caustic Soda has its applications in various segments and the demand is on an

increasing trend:

Soaps and Detergent Industry

Pulp and Paper Industry

Textile Processing Industry

Aluminium Smelting

Dyes and Dyestuff Industry

Plastic Polymers

Rayon Grade Pulp

Pharmaceuticals

Electroplating




Adhesives/Additives.

Major applications of Chlorinated paraffin are in the field of

PVC industry

Lubricants / Metal working fluid industry

Other misc. industry including rubber, sealant, paint industry & textile industry

In all of these applications, there is a long history of safe use and some major customers

have been using chlorinated paraffin for over 50 years.

Major applications of Sodium Hypochlorite are in the field of -

Bleaching

Cleaning & Destaining

Disinfection

Deodorizing

Water Treatment

Endodontics

(vii) Resource optimization/recycling and reuse envisaged in the project, if any, should bebriefly outlined

All plants have collection pits constructed in each of the sections. The wastewatergenerated is collected in the collection pits and after physico-chemical treatment(wherever required) is reused in the respective plant process itself. The effluent mainly isgenerated from the caustic soda plant utilities that consists of cooling water of accessoryequipments like blowers air compressors, blow down of cooling tower water, unusedcondensate, maintenance, regeneration water etc




TREATMENT METHODOLOGY AT ETP:

Collection ofincoming

effluent is pit

EQUALIZATION /NEUTRALIZATION

(By chemical addition)

Filtration thruSAND FILTER

Pumping to pondfor forced solarevaporation by

sprinklers

Clarification

Filtration thruACTIVATED

CARBON

No effluentis

discharged

Waste Water Treatment Facility (STP / ETP) in KLD:

Sr.No.

Water treatment capacity in KLD

Existing Proposed After Expansion

1 ETP Capacity 640 0 640

(viii) Availability of water its sources, Energy/Power requirement and source should be given

Water Requirement and Source

Existing water requirement is 1944 KLD and additional 3170 KLD is required for proposed

expansion project. Total water requirement after proposed expansion project will be 5114

KLD.

Details of water requirement in KLD are as follows:-

Sr.No.

Particulars / Uses Water requirement in KLD Source

Existing@275TPD

Proposed@ 150 TPD

After Expansion@ 425 TPD

1 Domestic Water 12 50 62 Borewell2 Industrial / Process water 910 1670 2580

3 Cooling water 1000 1450 2450

4. Other Req., if any 22 0 22

Total 1944 3170 5114

Source of Water: Ground water supply.

Power Requirement and Source

Existing power requirement is 30 MW and additional 45 MW is required for proposed

expansion project. Total power requirement after proposed expansion project will be 75




MW, which will be sourced from Jaipur Vidhut Vitaran Nigam Ltd. (JVVNL) & D.G Set (for

emergency).

Details of Capacity of Boiler and Diesel Generator Set (DG Set) with Stack Details are as

follows:-

Sr.No.

Boiler and Diesel Generator Set (DG Set) requirement


1 Boiler Capacity 10+5 (TPH) 10 (TPH) 10+10+5 (TPH)

2 Diesel GeneratorSet (DG Set)

500 + 500 KVA 1000 KVA forcaustic

1000 KVA forchloro products

Total four2x 500 KVA

2x 1000 KVA

One new boiler of 10 TPH will be required(iX) Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal.

During the operation phase, the solid waste will be generated from the effluent

treatment plant in the form of ETP sludge which will be given to TSDF.

Solid waste is being / will be generated which will be given to the authorized vendor

approved by CPCB.

Details of solid waste generation and management and disposal.

DETAILS OF SOLID WASTE GENERATION AND MANAGEMENT AND DISPOSAL

S. No. Particular Existingquantity

AdditionalQuantity

TotalQuantity

Management &Disposal

1 Residue sludge and filtercakes (Non hazardous)

5000MTA

2230 7230 MTA SLF

2 Discardedcontainers/barrels/linersused for hazardouswastes/chemicals

50 MTA 10 60 MTA SLF

3 Spent resin 0.50MTA

0.45 0.95 MTA SLF

4 Chemical sludge form ETP 50 MTA 10 60 MTA SLF

5 Used/Spent oil 15 KLA 15 30 KLA Sales toauthorizedrecycler

Hazardous Waste Generation

Hazardous waste is being / will be generated which will be given to the authorized

vendor approved by CPCB and dried sludge is being / will be generated from ETP will be

managed by self, for proper disposal of these hazardous waste.




(X) Schematic representation of the feasibility drawing which give information of EIApurpose.

CAUSTIC SODA MANUFACTURING PROCESS

MEMBRANE CELL

BRINE PURIFICATION

General

Brine for Ion Exchange membranes Chloro-alkali process is prepared by dissolving salt

through salt feeding facilities into the return brine from the electrolysis plant, and

purified in primary brine purification plant.

The membrane Chloro-alkali process, however, requires a secondary brine purification

process also.

After the conventional treatment, brine is purified with brine filter and ion exchange

resin column in order to obtain suitable quality for the ion exchange membrane Chloro-

alkali process.

Primary Brine Purification

Primary brine purification section is composed of salt conveyor system. Salt saturator,

reactor, Clarifier, clarified brine tank and associated facilities.

This process includes salt saturation, chemical dosage, reaction and sedimentation. The

purpose of this process is to re-saturate the return brine with raw salt and to remove

impurities from the saturated raw brine.

The return brine is fed to the top of salt saturator and is saturated with salt while the

brine flows upward through the salt bed in salt saturator. The salt is continuously

supplied at the top of salt saturator by salt conveyor system.

The saturated raw brine overflows from salt saturator and flows into reactor. Chemicals,

such as Barium chloride, Sodium carbonate, Caustic Soda and flocculent along with re-

circulated sludge from brine clarifier, are fed to reactor.

Calcium, Magnesium and other multivalent cat ions in the raw brine react with those

chemicals and are changed to suspended solids while the brine is fed into clarifier.

The suspended solid in the brine are removed by settling separation in clarifier. The

brine, thus clarified, flows into clarified brine tank over the weir of clarifier. Slurry on the

bottom of clarifier is pumped out and re-circulated to the brine line before reactor.




A part of slurry is purged to clarifier slurry pit and pumped out to sludge filtration section.

Secondary Brine Purification

Secondary brine purification section is composed of brine filter and Ion exchange resin

column.

The suspended solids in the brine is filtrated by brine filter and discharged with filter aid

to filter slurry put. The discharged brine with filter aid is pumped out to sludge filter

section. Ion exchange resin column packed with special ion exchange resin is operated

and controlled automatically from control room.

This specially developed ion exchange resin can remove multivalent cat ions harmful to

the ion exchange membrane to such an extent as cannot be achieved by conventional

chemical treatment. It ensures stable operation of Ion exchange Membrane cell.

ELECTROLYSIS

The electrolysis section is consists of electrolyzers, catholyte and anolyte circulation

tanks.

Electrolyzer

Electrolyser is composed of a number of bi-polar cell frames with metal anodes and

activated cathode, ion exchange membranes press unit for mounting cell frames, sub

headers for anolyte and catholyte sub headers for discharging electrolysis products.

Anolyte circulation

Anolyte is fed from anolyte circulation tank to each of anode compartment through sub

headers and hoses and re-circulated to anolyte circulation tank. Purified brine is fed to

the anolyte tank in order to keep anolyte concentration within designed level. The dilute

brine is sent to return brine tank for de- chlorination.

Catholyte circulation

Catholyte is fed from catholyte circulation tank to each of catholyte compartment

through sub headers and hoses and re-circulated to catholyte circulation tank. Caustic

soda concentration is continuously monitored to designed level by feeding DM water.

Caustic soda generated is sent to caustic soda tank.

Main reaction




In the ion exchange membrane process for producing caustic soda perm selective cat ion

exchange membrane are installed between anode and cathode. The electrolysis is

carried out in accordance with following reactions:

Anode Clˉ = ½ Cl2 + eˉ

Cathode H2O + eˉ = ½ H2 + OHˉ

Total NaCl + H2O = NaOH + ½ Cl2 + ½ H2

The return brine is dilute brine is sent to salt saturator where the salt is continuously fed

in order to keep desired concentration. The plant is operated on continuous basis.

Brief Process Flow Sheet & Flow diagram is given below:-




Process Flow Chart for Caustic Soda, Liq. Cl2 & HCl Production

Sold to customers

BrineSaturation

BrinePurification

Electrolysis

Common Salt

Caustic Soda(32%)

Sold to customers

99% Concentration Flakes

Cl2 gas

H2 gas

Treatment

Treatment

Dried

Compressed

Liquid Cl2

FurnaceComm.HCl

48% Concentration

Chilled

Used as fuel/ Bottled

Filled in tonnersand supplied

Customer




Mass balance

Sr. No. PARTICULARS INPUTMT/MT MT/DAY MT/Month

1 Salt 1.6 800 240002 Water 0.45 225 67503 Barium Chloride 0.012 6.00 1804 Soda ash 0.0045 2.25 67.55 Caustic Soda 0.015 7.50 2256 Alpha Cellulose 0.00045 0.22 6.67 Hydrochloric acid 0.180 90.0 27008 Sodium Sulphite 0.0026 1.30 39.09 Hydrated Lime 0.009 4.50 135.0

Output – Basis 330 days/yearS.No Particulars MT/day MT/Annum Remarks

1 Caustic soda Lye 500 165000 product2 Chlorine 443.74 146437 By product3 Hydrogen 12.51 4129 By product

PROCESS DESCRIPTION OF HYDROCHLORIC ACID

Hydrogen & Chlorine coming from cell house taken In HCl synthesis unit chlorine combines

with hydrogen to produce 30% to 32% Hydrochloric acid.

REACTION H2 + CL2 = 2 HCL

Brief outline

Hydrogen gas from cell house enters to hydrogen gas holder is sent to HCl synthesis unit

through hydrogen blowers. Chlorine gas from chlorine blower discharge and hydrogen gas

from 2nd stage hydrogen blower discharge flow to HCl synthesis unit and are synthesize to

get 30 to 33% HCl product .HCl goes to HCL receiver tank through density vessel. From HCl

receiver tank acid is pumped to five numbers HCL storage tanks each having capacity 150 M³.

From HCl storage tanks HCl is filled in road tanker by HCl filling pumps for dispatch.

HCL Synthesis Unit

This plant consists of three Nos. HCL units with attached graphite absorbers. Wet Cl2 gas

supplied by Cl2 blower and MCP at a pressure of 2000-2500 mmwc and H2 gas supplied by

2nd stage H2 blowers and MCP at a pressure of 2000-2500 mmwc are burnt in HCl synthesis

unit and form HCl gas. HCl gas is cooled by cooling water in synthesis unit. Required quantity

of absorption water is fed to tail gas tower to absorb unabsorbed HCl gas from main

synthesis unit. Dilute HCl thus flows by gravity to the burner cooler absorber unit where 30-

33% HCl is produced. The product acid flows through density vessel where concentration and




temperature of acid is monitored. HCl from density vessel flows to HCl receiver tank from

where it is pumped to HCl storage tanks as well as brine over head HCl tank for Calcium

chloride preparation use and MCP plant.

The chlorine flow to the HCl synthesis as well as H2 flow is controlled by a proportional flow

controller. Provision is made for safety interlocking system which is actuated by a flame

protection device. For start up, the unit start up blowers are installed to create suction.

These blowers remain stopped during running of the unit. Flame arrestors are also

incorporated in H2 as well as in Cl2 line for protection of back fire. N2 automatic purging

system in unit is provided for safety purpose.

The product HCl is stored in storage tanks. It is first approved by QCD then it is filled in road

tankers by HCl filling pumps. The product manufactured is tested to Indian standard IS:265

The raw materials used are hydrogen, chlorine and DM water.

STABLE BLEACHING POWDER MANUFACTURING PROCESS

PROCEDURE

Received Hydrated Lime as taken in hopper to the required level. Attain a vacuum of 640

mm of Hg. Confirm liquid chlorine has been taken in storage tank. Now liquid chlorine outlet

valve of chlorine tank and inlet valve in the header to chlorination drum is opened,

subsequently chlorine charging nozzle valves (4 Nos.) are opened. The flow of chlorine

starts due to pressure differential between drum and chlorine storage tank. The vacuum

drops which is seen with the help of manometer. During chlorination vacuum is lowered by

about 20 mm mercury. The opening of nozzle valves are adjusted accordingly, the liquid

chlorine get vaporized as it enters the drum because of low pressure. The chlorine reacts

with Hydrated Lime according to following chemical reaction.

2 Ca(OH)2 + 2 Cl2 = Ca(OCl )2 + CaCl2 + 2 H2O + Heat




The reaction is exothermic. To control the rise in temperature cooling water from cooling

tower pumps is circulated in the jacket of the drum. Chlorine feeding rate, temperature and

vacuum is recorded after every 15 minutes during chlorination (while 30 minutes for drying

and cooling) by taking reading of weighing scale of chlorine storage tank, temperature gauge

and vacuum gauge. The water formed due to reaction is partly get evaporated continuously

due to low pressure of the system utilizing the heat of reaction.

At the end of chlorination a bleaching powder with about 2-3 percent water is obtained with

the increase of chlorine absorbed. Temperature is not allowed to exceed 60C at the end of

the chlorination. For a batch of 6.5 MT SBP and 35-37 % of available chlorine. 2400 – 2700 Kgs

of chlorine is utilized. The amount varies from batch to batch due to variation in the quantity

of lime and chlorine absorbed.

The water let out at the end of chlorination is removed by drying the product using steam in

the jacket under vacuum at 600-700 mm of Hg.

Mass BalanceInput

S. No. Particulars MT/MT MT/Day MT/Month1 Hydrated Lime 0.75 33 9902 Liquid chlorine 0.400 17.6 528




Total 1.15 50.60 1518

OutputS. No. Particulars MT/Day MT/Month Remarks1 Stable Bleaching powder 44 1320 Product2 Dilute MoL 6.6 198 By product

Total 50.6 1518

MANUFACTURING PROCESS DESCRIPTION TRICHLOROETHYLENE

Process Description

Purified acetylene obtained by adding water to calcium carbide and gaseous chlorine, are

reacted under control conditions to form tetra-chloroethane in the same medium. The

product is continuously drawn from the middle of the tower and collected in a product tank.

The tetra-chloro-ethane produced is further sent to lime boiling section and subjected to de-

hydro chlorination with lime and to form crude-trichloro-ethylene. Crude tri-chloro-ethylene

is further distilled to obtain pure TCE by way of distillation and after ensuring quality to

prescribed standards packed in 300 Kg HM/MS barrels. The overall reaction is as under: -

C2H2 + 2Cl2 C2H2 Cl4

C2H2 Cl4 + Ca(OH)2 2CH2 HCl3 + CaCl2 + 2H2O.

T C E PROCESS DESCRIPTION

The principal raw materials for TCE production are Acetylene and Chlorine gas.

The Tetra chloro ethane is synthesized in Tetra synthesis tower using chlorine and acetylene

gas with Ferric chloride as catalyst with the help of auto ratio controller. The acetylene is

manufactured in acetylene generator from calcium carbide. Lime and acetylene are

produced.

The tetra chloro ethane is de-hydrochlorinated in lime boiling section to produce crude

trichloroethylene.

The Crude Trichloroethylene is distilled in fractionating column 1 & 2 to make pure

Trichloroethylene.

The by-products are Lime and Calcium chloride. The lime is used in lime boiling for de-hydro

chlorination of tetra chloro ethane and calcium chloride is produced is also sold out in the

market.




Liquid Chlorine Calcium Carbide

Evaporator Generator

Chlorine Gas Crude Acetylene

Purification

Purified acetylene

Synthesis Tower

Tetra chloro ethane

De-hydro chlorination

Crude Trichloroethylene

Distillation

Trichloroethylene

MANUFACTURING PROCESS CHLORINATED PARAFFIN WAX (CPW)

About chlorinated paraffins:Chlorinated paraffins are manufactured by the chlorination of n-paraffin or paraffin wax,

normally in a batch process. The reaction is exothermic and leads to the generation of the by-

product hydrochloric acid. After removing residual traces of acid, a stabilizer is added to

produce finished batches.

Increasing the chlorine content results in products with higher viscosity and density.

Liquid grades of chlorinated paraffin are produced in various ranges generally from 42 to 62%

chlorine.

Raw materials:

Heavy normal paraffin (HNP) , Wax, Chlorine, Stabilizers, Hydrated Lime.

Process:

Cm Hn+2 + xCl2 Cm H2n-x+ Cl x + xHCl + Heat




It is a batch process consisting of the reaction as shown above and is highly exothermic

therefore heat is continuously with the help of cooling water circulated in the outer jacket.

CPW is the chlorine derivative of straight chain hydrocarbons.

As chlorine increases in the system HCl vapors also produced simultaneously are absorbed in

water to make acid. When chlorine content in CPW is reached in the range 42 – 62 % (as

desired) , the chlorine supply is cut off to stop the reaction and air is generally passed to CPW

in degasser but as a modification now we propose to pass nitrogen to eliminate excess

chlorine to enhance better product quality and at the end of chlorination hot water is

circulated to avoid retention of high un-reacted high chlorine.

Now CPW is further stabilized with suitable stabilizers for stability and packed in HM-HDPE

barrels. We also get HCl as byproduct and HYPO produced by absorption of traces of un-

reacted chlorine in alkali are also saleable.

Mass BalanceInput

S. No. Particulars MT/MT MT/Day MT/Month1 Paraffin 0.45 135 40502 Liquid chlorine 1.11 333 99903 Water for HCl 1.0 300 9000

Total 2.56 768 23040Output

S. No. Particulars MT/Day MT/Month Remarks1 Chlorinated Paraffin 300 9000 Product2 Hydrochloric acid 468 14040 By




productTotal 135 23040

MANUFACTURING PROCESS SODIUM HYPOCHLORITE

During manufacturing of caustic soda, liquefaction and compression of chlorine, HCl

synthesis, if any unrecated or unabsorbed chlorine is remaining, it is sucked and scrubbed by

dilute caustic in a alkali scrubbing tower to form sodium hypochlorite. The process of alkali

scrubbing is effective and efficient and complete chlorine absorption takes place in the

scrubber ensuring that there is no chlorine emission through the vent into atmosphere.

Reacting chlorine and sodium hydroxide produce Sodium Hypochlorite:

Cl2 + 2 NaOH = NaOCl + NaCl + H2O

Chlorine Sodium Hydroxide Sodium Hypochlorite Sodium Chloride Water

MANUFACTURING PROCESS Sulphuryl ChlorideSulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride.Chemical Reaction:

S + 3Cl2 + 2SO3 - ----------- 3SO2Cl232 210 160 402 Sulphuryl Chloride




MANUFACTURING PROCESS Aluminum Chloride

Gaseous chlorine is reacted with molten Aluminum in specially designed reactor to formAluminum Chloride in gaseous phase. Heat liberated because of the exothermic reaction isremoved partially in melting solid Aluminum and balance by radiation from the moltenAluminum surface. Vapors of Aluminum Chloride lose their heat of sublimation from the wallof the condenser and get deposited there. This deposited solid is discharged into speciallydesigned containers by hammering the condenser wall from outside, periodically. Aftercooling, it is conveyed to a silo from where it is size graded and packed under dry airblanketing.

Unreacted Chlorine and uncondensed gases are efficiently scrubbed in well-designedscrubbers.

Mass BalanceMass balance per ton of product and per day basis is given in Table




MANUFACTURING PROCESS Mono Chloro Acetic Acid

Acetic Acid will be charged in the reactor and heated to 100˚C through hot water circulation.Chlorine shall be charged in the reactor for chlorination. Acetic acid will be converted intoMono Chloro Acetic Acid (MCA) in presence of suitable catalyst.During the process, HCl gas will be generated, which will be scrubbed through scrubber anddissolved in water to get 30% HCl liquor.After completion of reaction, the mass will be transferred in buckets for crystallization wherenatural followed by induced cooling takes place. After about 70 hrs, pure MCAA crystals shallbe recovered. After centrifuging, MCAA product will be ready for packing. The Mother Liquor(ML) generated from centrifuge shall be separated out and sold as ML of MCA.

Reaction and Process Flow Diagram

Reaction involved is shown below and the process flow diagram is shown in Figure 3-9.

CH3COOH + Cl2 ----------- Cl.CH2COOH + HCl

Acetic Acid Chlorine MCA Hydrochloric Acid




Block Diagram for Mono Chloro Acetic Acid Manufacturing

Mass Balance

Mass balance per ton of product and per day basis is given in Table

Mass Balance – Mono Chloro Acetic Acid

S. No. Raw MaterialsInput/MT of Product Input /Day of

(MT) Product (MT)

1 Acetic Acid 0.670 67

2 Chlorine (Liq.) 0.900 90

3 Catalyst 0.0375 3.75

3 Water 0.051 5.1

Total 1.659 165.9

S.

Output/MT of ProductOutput/Day

HW /RemarksMaterial / Product / Liquid Air of Product

No. Recovery SolidItem Byproduct Effluent Emission MT

Waste

1 MCA 1.00 - - - - 100 Product

2 Dil. HCl - - - 0.621 - 62.1 By Product

3 Rec. Catalyst - - - 0.038 - 3.80 Recycle

Total1.00 0 0 0.659 0

165.901.659

PLANT LAYOUT

The features of the layout are as follows:

Process plants will be consolidated into comprehensive production unit requiringshort conveying distances and lengths of gas ducts;

Sufficient space will be provided for ease of operation and maintenance;

The lengths of power cables will be minimized by suitably locating loaddistribution centres in respect of process departments;




Outward movements of materials from customers/suppliers will be segregatedfrom internal plant traffic; and

Safety requirements will be kept in mind while locating the workshops andvehicular movement inside the plant.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to SH 14 & SH 25. Nearest Town & city to the plant site is Alwar

(6.5 km). Nearest Airport Jaipur is approx. 112 km from the plant site. The site is well

connected with communication facilities like telephone, fax, wireless and as such, no

constraints are envisaged in this aspect as the Tehsil and District headquarters are near

to the site.

(ii) Land from Land use and Land ownership

Total plant area is 338958.75 sq. m. Since, the proposed expansion will be done within

the existing plant premises, thus, no additional land is required for the proposed

expansion project. Hence, land ownership will be considered as industrial type.

(iii) Topography

The local land use plan be followed; therefore drainage pattern will not be changed

during construction phase.

The topography of the area will have localized changes; however except the site, the

overall topography will be same as the present.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of

the Gazette notification should be given.

Environmental Settings of the Area

S. NO. PARTICULARS DETAILS

1. Nearest Town /City Alwar ~6.5 km in NW direction from the Project Site

2. Nearest National Highway / StateHighway

o SH 14 - Alwar - Bharatpur (~3.0 km in NNE direction)

o SH 25 - Alwar - Rajgarh (~6.0 km in NW direction)

3. Nearest Railway station Alwar Railway Station ~8.0 km in NW direction fromproject site

4. Nearest Airport Jaipur Airport, ~112 km SW direction from project site




5. National Parks, Wild LifeSanctuaries, Biosphere Reserves,Tiger/ Elephant Reserves, WildlifeCorridors etc. within 10 km radius

No National Park, Wild Life Sanctuary, BiosphereReserve, Tiger / Elephant Reserve, Wildlife Corridorsetc. falls within 10 km radius of the plant site.

6. Reserved Forests (RF) /Protected Forests (PF) etc.within 10 Km. radius

o Bhugar Protected Forest (~ 7.0 km in West direction)

o Bhakhera Protected Forest (~ 9.0 km in WNWdirection)

7. River / Water Body (within 10 kmradius)

o Bhurja Nadi (~ 5.0 km in SW direction)

o Ruparel Nadi (~ 6.5 km in SSE direction)

o Sukhri Nadi (~ 9.8 km in SSE direction)

o Jaisamand Lake (~ 10.0 km in WSW direction)

o Siliserh Lake (~14.5 km in West direction)

8. Seismic Zone Zone – IV [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Total plant area is about 338958.75 sq. m. Proposed expansion will be done within the

existing plant premises. M/s. Lords Chloro Alkali Ltd. is having an existing Unit of Caustic

soda manufacturing 275 TPD at SP-460, Matsya Industrial Area (MIA), Alwar (Rajathan).

(vi) Soil classification

Alwar Township is relatively flat, located in the alluvial plain beneath the Arvali

Mountainsin the west. The soil is mainly alluvial and non-calcareous, semi-consolidated to

consolidated, brown in colour, and loamy sand to sandy loam in texture. Exposed rocks

belong to the Delhi Super-group of lower proterozoic age, consisting of schist,

quartzites, slates and gneisses. Subsurface layers of unconsolidated quaternary

formations form the principal aquifer system. According to the Vulnerability Atlas of

India, part of Alwar District, including Alwar Town is in an area of high earthquake risk

(Zone IV). Although Rajasthan has not experienced a major earthquake in the recent

past, there have been 37 events with a magnitude of 5-7 since 1720, with the most recent

occurring in 2001. This measured 6.9 on the Richter Scale, but because the epicentre was

in neighbouring Gujarat, no major damage was reported in Alwar.

(vii) Climatic data from secondary sources

The climate is semi-arid and mostly dry, with a hot summer period in April to July,

followed by a short monsoon in July to September, and a cool dry winter period between

October and March. Average daily temperatures peak at around 41 °C in June (when the

minimum is 28 °C at night), and in January the temperature falls to an average of 23 °C




during the day and 8 °C at night. The long term average annual rainfall is 638 mm, of

whicharound85% falls during the monsoon. However rainfall is highly variable, and has

been generally low in most recent years.

Relative humidity is around 70% during the monsoon, but is much lower throughout the

rest of the year, falling to 20-25% in the summer. Winds are generally light and variable

during the cool winter period, and mainly from the north and north-west, and the

strongest winds are the south-western lies that bring the monsoon in June and July.

(viii) Social Infrastructure available

The nearest City is Alwar, which is approx. 6.5 km distance from the plant site. At Alwar

city schools, dispensaries, small hospitals, places of worship etc are available. Electrical

power supply in most of surrounding villages is available.

Telephone, Medical facilities are available in the nearby towns. Almost all the villages in

the buffer zone are electrified. L.T. power is being supplied for drawing water from a

large number of tube wells sunk around the important village of the buffer zone, for

irrigation purpose. Most of the tanks and ponds as well as the river water are being

utilized for irrigation.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country

Planning/ Development authority classification.

The existing industry is Chloro Alkaly industry. Transportation of raw material and final

product is being / will be done via existing road and rail network and cement concrete

road has been developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will

generally be outsider.

(iii) Land use planning (breakup along with green belt etc)

Total plant area is about 338958.75 sq. m. Proposed Expansion Project will be set up in

the existing plant premises. No additional land will be required. About 40 % of the total

project area is being covered under green belt & plantation in order to reduce dust &

noise pollution levels & to increase aesthetic beauty of the area.

(iv) Assessment of infrastructure demand (Physical & Social)

M/s. Lords Chloro Alkali Ltd. has assessed the demand of infrastructure (Physical &

Social) in nearby area of the plant site and development activities are being undertaken




under corporate social responsibilities program for rural development initiatives for the

upliftment of the nearby communities from time to time.

(v) Amenities/Facilities

M/s. Lords Chloro Alkali Ltd. has constructed dispensary, canteen etc for the permanent

and contract employees.

M/s. Lords Chloro Alkali Ltd. will develop the Amenities/Facilities in nearby area of the

plant site as per requirement of local people of the nearby area under corporate social

responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional infrastructure will be required for the proposed expansion project as the

proposed project will be set up in the existing plant premises.

(ii) Residential area (Non Processing area)

No residential colony has been envisaged for plant employees. However, guest house &

resting shelter is being /will be provided at project site for plant official and labourers.

(iii) Green Belt

The company has already developed green belt in 40 % plot area. Care had been taken to

ensure that the plants in the second row are staggered between the plants of the first

row. Plantation of selected tree species, which are suitable to condition, has been done

for attenuation of air & noise pollution.




Figure - 5: Green Belt Plantation Photographs

Proposed Expansion of Caustic soda manufacturing, Boiler, D. G. Sets and Production of Chlorinated Paraffin Wax (CPW),Sodium Hypochlorite within existing plant premises at SP-460, Matsya Industrial Area (MIA), Alwar (Rajasthan)



The Following Species of trees. Shrubs, creepers and flowers are planted in LACL.

S.No. Local Name Botanical Name1. Amal tas Cassia fitula2. Gul mohar Delonix regia3. Neem Azadirachta indica4. Sheeshan Dalbergia Sissoo5. Subabool Leucacna leucocephala

6. Ber Zizyphus mauritiana7. Kesi Cemea -8. Siris Albizzia lebbeck9. Karanj Pogmia ponnata10. Peepal Ficus religiosa11. Botte brush Callitemon laceodatum12. Champa -13. Dina ka Raj -14. Eucalyptus Eucalyptus hybrid15. Lal kaner Nerium odorum16. Ashok Polyalthia lonifolia17. Gurhal Hibiscus rosa sinensis18. Gulab (Rose) Rose chinensis19. Chandni Tabernacmontana coronaria20. Relia -21. Chameli Jasminum officinale22. Serva -23. Beganvilas Bogounvillea spectabilis24. Neinthera -25. Mayur pankhi Thusa compacta26. Nagoot -27. Arenthema -28. Nag champa -29. Satavar Asparagus rakmosus30. Blosson -31. Sadabahar Vinca rosa32. Basak Adhato da vasica33. Jungle Jalebi Pitha colobium dulce34. Banana Musa sapientum35. Amrud Psidium guajava

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and

indirect employment opportunities in the region including ancillary development and

supporting infrastructure.




(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless

as such, no constraints are envisaged in this aspect as the Tehsil and District

headquarters are near to the site.

(vi) Drinking Water

22 m3/ day water will be required for drinking purpose and other domestic uses after

proposed expansion project which will be sourced from Ground Water.

(vii) Sewage Treatment System

The entire domestic effluent generated from office toilets, canteen and guest house shall

be treated in STP proposed in the expansion phase.

(viii) Industrial Waste / Hazardous Waste management

Hazardous waste is being / will be generated which will be given to the authorized

vendor approved by CPCB and dried sludge is being / will be generated from ETP will be

managed by self, for proper disposal of these hazardous waste.

Details of solid waste generation and management and disposal.

S. No. Particular Existingquantity

AdditionalQuantity

TotalQuantity

Management &Disposal

1 Residue sludge and filtercakes (Non hazardous)

5000MTA

2230 7230 MTA SLF

2 Discardedcontainers/barrels/linersused for hazardouswastes/chemicals

50 MTA 10 60 MTA SLF

3 Spent resin 0.50MTA

0.45 0.95 MTA SLF

4 Chemical sludge form ETP 50 MTA 10 60 MTA SLF

5 Used/Spent oil 15 KLA 15 30 KLA Sales toauthorizedrecycler

(ix) Solid Waste Management

Solid waste is being / will be generated which will be given to the authorized vendor

approved by CPCB.

(x) Power requirement and source

Existing power requirement is 30 MW and additional 45 MW is required for proposed

expansion project. Total power requirement after proposed expansion project will be 75




MW, which will be sourced from Jaipur Vidhut Vitaran Nigam Ltd. (JVVNL) & D.G Set (for

emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including

home oustees, land oustees and landless labourers (a brief outline to be given).

Proposed Expansion will be done within the existing plant premises. No additional land is

required for proposed expansion project. Therefore there will not be displacement of

people and hence Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the

project to be given).

The expansion of the project will start only after obtaining Environmental Clearance and

other statutory permissions. Project will be completed in 12 months period after getting

all the regulatory approvals.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

Total Cost after Expansion of the Project: Rs. 575 Crore

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area.

The project activity and the management will support local administration and provide

other form of assistance for the development of public amenities in the region.

Plantation will be developed in and around the project area. The project will help in

improving the overall status of the area.

pre - feasibility report...

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