PREFEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/.../0_0_05032015V0QARPrefeasibilityReportTORAmendment.pdfPrefeasibility Report for Proposed expansion

PREFEASIBILITY REPORT

FOR

“Proposed Expansion and New Component

(Zinc Di-Thio Phosphate) Manufacturing Unit

at Existing Facility”

BY

Indian additives LTD

AT

VILLAGE: Manali

Taluk: Thiruvottiyur

DISTrict: Thirvallur

STATE: TAMIL NADU

i

Table of Contents 1. EXECUTIVE SUMMARY ............................................................................................................. 1

2. INTRODUCTION OF THE PROJECT ....................................................................................... 3

2.1 Introduction about the company ............................................................................................ 3

2.2 Brief Description of the Project ............................................................................................... 4

2.3 Project Benefits ........................................................................................................................ 5

3. PROJECT DESCRIPTION ........................................................................................................... 6

3.1 Type of the Project .................................................................................................................. 6

3.1.1 Proposed Expansion .......................................................................................................... 6

3.1.2 Proposed New Component (ZDTP) .................................................................................. 6

3.2 Project Location ....................................................................................................................... 6

3.3 Products Manufactured ........................................................................................................... 8

3.4 Manufacturing Process Description......................................................................................... 8

3.4.1 Proposed Expansion............................................................................................................. 8

i. Succinminde unit .................................................................................................................... 9

ii. PIBSA (Poly Iso Butylene Succinic Anhydride) unit .......................................................... 10

iii. Phenates/Sulfonate Unit ..................................................................................................... 11

iv. Blending Unit ........................................................................................................................ 12

3.4.2 Proposed New Component (ZDTP) Manufacturing ....................................................... 13

i. Zinc Di-Thio Phospate (ZDTP) Plant ................................................................................... 13

3.5 Raw Material Requirement.................................................................................................... 14

3.5.1 Proposed Expansion........................................................................................................... 14

3.5.2 For Proposed New Component (ZDTP) .......................................................................... 16

3.6 Utilities ................................................................................................................................... 16

3.7 Power and Fuels ..................................................................................................................... 17

3.8 Water Requirement ............................................................................................................... 17

3.9 Landuse .................................................................................................................................. 18

3.10 Manpower ............................................................................................................................. 19

3.11 Liquid Waste Management.................................................................................................... 19

3.11.1 Treatment of Lquid Waste ........................................................................................... 19

3.11.2 Effluent Treatment Plant (ETP)Description .............................................................. 20

3.12 Air Pollution Control Measures ............................................................................................. 24

3.12.1 For Proposed new component (ZDTP) - H2S off gas treatement facility ................ 24

ii

3.13 Hazardous and Solid waste Management ............................................................................. 27

3.14 Greenbelt Development ........................................................................................................ 28

3.15 Environment, Safety and Health Monitoring ......................................................................... 28

4. SITE ANALYSIS ......................................................................................................................... 30

4.1 Connectivity ........................................................................................................................... 30

4.2 Land form, land use, land ownership .................................................................................... 30

4.3 Existing land use pattern ....................................................................................................... 30

4.4 Climatic Conditions ................................................................................................................ 30

4.5 Social infrastructure available ............................................................................................... 31

5. Conclusion ................................................................................................................................ 33

List of Tables

Table 1.1 List of products manufactured ............................................................................................. 2

Table 3.1 List of products manufactured ............................................................................................. 8

Table 3.2 List of Raw materials for Proposed Expansion ................................................................. 15

Table 3.3 List of Raw materials for New Component (ZDTP) .......................................................... 16

Table 3.4 Capacity of DG, Boilers and Thermic fluid Heaters ........................................................... 16

Table 3.5 Power and Fuel requirement .............................................................................................. 17

Table 3.6 Water Requirement for the project .................................................................................... 18

Table 3.7Land Use within the Site ...................................................................................................... 18

Table 3.8 Wastewater Generation ...................................................................................................... 19

Table 3.9 Existing & proposed Stack/ Vent details ........................................................................... 26

Table 3.10 Hazardous wastes Generation .......................................................................................... 27

Table 3.11Non-Hazardous wastes ...................................................................................................... 28

Table 4.1Nearby areas from site Boundary ....................................................................................... 30

Table 4.2Meterological Observations ................................................................................................. 31

Table 4.3 Proposed project surrounding features............................................................................. 32

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List of Figures

Figure 3-1 Location of Proposed Project Site ...................................................................................... 7

Figure 3-2 Satellite Image of the Site & its 10Km Radius ................................................................... 7

Figure 3.3 Dispersants process flow diagram ...................................................................................... 9

Figure 3.4 PIBSA process flow diagram ............................................................................................. 10

Figure 3.5 Phenate process flow diagram .......................................................................................... 12

Figure 3.6 Blending process flow diagram ........................................................................................ 12

Figure 3-7 ZDTP Process Flow Diagram ............................................................................................ 14

Figure 3-8ETP and STP Process Flow Disgram ................................................................................. 23

Figure 3-9 H2S Treatment System ...................................................................................................... 25

Prefeasibility Report for Proposed expansion and New Component (ZDTP) Manufacturing Unit by IAL

1

1. EXECUTIVE SUMMARY

Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai

Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC. On

24th May 1989, Chevron Oronite Company LLC, USA (then Chevron Chemical

Company) and Chennai Petroleum Corporation Limited, Chennai (then Madras

Refineries Limited) signed an agreement to form a Company to engage in the

development, manufacture and marketing of certain additive intermediates,

(components) and packages for Lubricating Oils. The Company, christened as

‘Indian Additives Limited’, was thus born legally on 13th July 1989,theplant has

been operational since 1993. IAL was originally incorporated as a government

company to foster domestic manufacture of lubricating oil additives so as to

reduce reliance on import of such products. IAL’s operation has, therefore, has a

bearing on increasing national foreign exchange savings through import

substitution.

The manufacturing facility is located at SF No. 265(P) Manali Village,

AmbatturTaluk, Tiruvallur District, and Tamil Nadu in a spread of 23.57 acres

land. The site is located about 4 km away from Thiruvottiyur Town and it is in the

express highway connecting Thiruvottiyur and Ponneri. The site is located south

of this road. The nearest railway station is Thiruvottiyur.

IAL proposes to expand the capacity of its existing manufacturing facility to meet

the growing market demand in lubricating oil additives. The proposed expansion

activity is planned through debottlenecking with some minor investments, with

out change in process, raw materials and products. The expansion project scope

mainly involves addition of inline blenders, pumps and enhancement of vessels/

storage tanks, with an investment of Rs.12 Crores. The implementation period will

be around 10 months.

In addition, IAL proposes to set up new component manufacturing unit in the

existing facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the

intermediate for lubricating oil additive manufacturing. This is a backward

integration project involving installation of batch reactors, overhead and filtration


2

systems with other associated supporting facilities, including treatement facility

for H2S off gas generated from the process. The production from this faciliity will

be consumed in-house as intermediate for manufacturing lubricating oil additives

and also for exports. The investment for this proposal will be Rs.120 Crores and

implementation period will be 20 months.

Table 1.1 List of products manufactured

S.No Product Existing Proposed

Expansion

Proposed

New

component

(ZDTP)

MT/annum

1 Automotive,

Marine, Industrial,

Rail Road and

Natural gas engine

Lubricating Oil

additive packages.

25000 60000

-

2 Succinimides 10000 25000 -

3 Phenate/sulfonate 10000 20000 - 4 PIBSA 8500 20000 -

5

By product (Mix of sodium sulphide, sodium hydrogen sulphide& caustic)

3500 7000

-

6 Zinc Di-Thio Phospate (ZDTP)

- - 20000

7 By product (Sodium Sulphide flakes)

- - 5000


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2. INTRODUCTION OF THE PROJECT

2.1 Introduction about the company

Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai

Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC. The

plant has been operational since 1993. IAL, an ISO 14001 certified company, is

one of the leading manufacturers of lubricating oil additives for Automotive,

Marine, Industrial, Rail Road & Natural gas engines lubricating oils. These

lubricating oil additives play a crucial role in engine performance parameters

like high specific power outputs, improved fuel-efficiency norms, improved

driveability, extended drain Intervals, fuel economy and longer and trouble - free

engine life.IAL primarily caters to sectors of national and public interest as a

majority of IAL’s products are manufactured to meet the requirements of the

Indian Railways, and government companies such as Indian Oil Corporation,

Bharat Petroleum Corporation Limited and Hindustan Petroleum Corporation

Limited.IAL’s operation has, therefore, has a bearing on increasing national

foreign exchange savings through import substitution.

IAL has been operating with valid consent orders under Air & Water Acts from

TamilNadu Pollution Controal Board and complying with all environmental

legislations. IAL has initiated many Environmental improvement actions towards

improving its Environment standards like installation of online pollution

monitoring systems and hooking up to Pollution Control Board for real time

monitoring.

IAL’s existing manufacturing facility consists of intermediates (components) and

blending facilities for making different lubricating oil additive packages. The

intermediates (components) manufacturing involves batch processes to produce

Dispersants(Succinimides), Detergents(Phenates/Sulfonate), PIBSAs. Blending is

the key operation where the aboveintermediates (components) made within IAL

and other intermediates (components) imported/ bought outare blended to make

different lubricating oil additive packages based on market requirements.


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2.2 Brief Description of the Project

IAL’s existing manufacturing facility consists of intermediates (components) and

blending facilities for making different lubricating oil additive packages . The

intermediates (components) manufacturing involves batch processes to produce

Dispersants(Succinimides), Detergents(Phenates/Sulfonate), PIBSAs. Blending is

the key operation where the aboveintermediates (components) made within IAL

and other intermediates (components) imported from other Chevron Oronite

facilities are blended to make different lubricating oil additive packages based on

market requirements. IAL is planning to expand the capacity of all the above

manufacturing facilities through debottlenecking to meet the growing market

demand in lubricating oil additive segment. The expansion project scope mainly

involves addition of inline blenders, pumps and enhancement of vessels/ storage

tanks.. Utility & off-site requirements will be met by existing units which have

enough capacity margins to support proposed expansion. The investment for

proposed expansion is Rs.12 Crores and the implementation period will be around

10 months.

IAL also proposes to set up new component manufacturing unit in the existing

facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the intermediate

for lubricating oil additive manufacturing. This is a backward integration project

involving installation of batch reactors, overhead and filtration systems with

other associated supporting facilities, including treatement facility for H2S off gas

generated from the process. The production from this faciliity will be consumed

in-house as intermediate for manufacturing lubricating oil additives and also for

exports. The investment for proposed ZDTP production will be Rs.120 Crores and

implementation period will be 20 months.

Existing utility and support facilities will be shared to meet the requirements of

proposed project with appropriate augmentations.The existing effluent treatment

plant has adequate design capabilities to handle the additional pollutant loads

from this project, how ever, RO (Reverse Osmosis) plant capacity will be

augmented to meet the increased recycle requirement of effluent.The off-gas, H2S

generated from the proposed project will be treated with Caustic in scrubber and


5

spent caustic wil be converted as Sodium Sulphide flakes through evaporation

and flaking, which will be sold as by-product in the market.

The proposed ZDTP project will be constructed in the demarcated plot space with

in the existing manufacturing facility.

2.3 Project Benefits

The proposed project which is of backward integration model will help in

improving company’s revenue apart from mitigating other business risks as the

company is currently sourcing this intermediate from external supplier. This

project also provides opportunity to export the manufactured component to

other lubricating oil additive companies acrossthe world. Hence this will help to

boost the economy of the countrythrough additional revenues from exports.

The existing Plant has around 140 employees and 260 contract workmen

supporting all operational activities and there will be an

After the proposed expansion the man power requirement will be 140employees

and 260 contract workmen.

After the proposed ZDTP project, the manpower will be 156 employees and 300

contract workmen. Apart from this, there will also be a considerable increase in

indirect employment on account of increased material movements.


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3. PROJECT DESCRIPTION

3.1 Type of the Project The proposed project falls under the schedule 5 (f) as per the EIA notification

dated September 14, 2006 and its amendments. There is no interlinked project

3.1.1 Proposed Expansion

IAL proposes to expand the capacity of all the existingmanufacturing facilities

through debottlenecking with some minor investments. The expansion

project scope mainly involves addition of inline blenders, pumps and

enhancement of vessels/ storage tanks. Utility & off-site requirements will be

met by existing units which have enough capacity margins to support

proposed expansion

3.1.2 Proposed New Component (ZDTP)

IAL also proposes to set up new component manufacturing unit in the existing

facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the

intermediate for lubricating oil additive manufacturing. This is a backward

integration project involving installation of batch reactors, overhead and

filtration systems with other associated supporting facilities, including

treatement facility for H2S off gas generated from the process. The production

from this faciliity will be consumed in-house as intermediate for

manufacturing lubricating oil additives and also for exports.

3.2 Project Location The proposed project is planned with in the existing manufacturing facility

located at SF No. 265(P) Manali Village, Thiruvottiyur Taluk, Tiruvallur District,

and Tamil Nadu. The site is located about 4 km away from Thiruvottiyur Town

and it is in the express highway connecting Thiruvottiyur and Ponneri. The site is

located south of this road. The nearest railway station is Thiruvottiyur. The

location of the site is shown in Figure 3.1. The plot plan of the site with facilities

is enclosed in Annexure-4.

The 10Km radius Google map of the project site and surrounding features is given

in Figure 3.2


7

Figure 3-1 Location of Proposed Project Site

Figure 3-2 Satellite Image of the Site & its 10Km Radius


8

3.3 Products Manufactured The list of products proposed is given in Table 3-1 below.

Table 3.1 List of products manufactured

S.No Product Existing Proposed

Expansion

Proposed

New

component

(ZDTP)

MT/annum

1 Automotive,

Marine, Industrial,

Rail Road and

Natural gas engine

Lubricating Oil

additive packages.

25000 60000

-

2 Succinimides 10000 25000 -

3 Phenate/sulfonate 10000 20000 - 4 PIBSA 8500 20000 -

5

By product (Mix of sodium sulphide, sodium hydrogen sulphide& caustic)

3500 7000

-

6 Zinc Di-Thio Phospate (ZDTP)

- - 20000

7 By product (Sodium Sulphide flakes)

- - 5000

3.4 Manufacturing Process Description


The process units built for Additives manufacturing are as under:

Dispersant ( Succinimides) plant

Detergent (Phenate / Sulfonate) plant.

PIBSA Plant (Raw material for Dispersant plant)


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Blending plant (final blended products -Automotive, Marine, Industrial,

Rail Road,& Natural gas lubricating Oil engine additive packages. )

A brief process description is given below:

i. Succinminde unit

The Succinimides unit consists of a batch agitated reactors and overhead

collection systems. Succinimides are produced by reacting Poly Iso Butyl

Succinic anhydride (PIBSA) and Heavy polyamine (HPA) mixture in typical

proportions. PIBSA and HPA are reacted in the reactor at typical process

conditions. The reactor overhead systems collects water formed during the

reaction, along with the nitrogen used in the reactor to help sweep water

vapour. A vent stream consisting of nitrogen is produced from the overhead

system which is discharged through a high point vent system. The product

from the reactor is stored in storage tanks and used in blending plant for

making finished lubricating oil additive packages.Different types of

succinimides are manufactured in this unit by based on the requirement in

blending plant.

Figure 3.3 Dispersants process flow diagram


10

ii. PIBSA (Poly Iso Butylene Succinic Anhydride) unit

PIBSA is an intermediate chemical that is used as key raw material for the

production of succinimides. PIBSA is formed by reacting poly iso-butene with

maleic anhydride. The operation is done in batches.

The PIBSA plant includes a hot oil coiled reactor, a reactor overhead system with

steam ejectors and a filtration section. Polybutene is charged with excess maleic

anhydride to the reactor. After the reaction, excess Maleic anhydride is stripped

and reused back in next batches. A condensate stream containing trace

quantities of Maleic acid and a vent stream consisting mostly of air leaks into

vacuum system are discharged to the overhead system which is been scrubbed

with water being discharged through vent. From the reactor, crude PIBSA is

transferred to intermediate tank and then filtered. The filtrate is transferred to

the intermediate storage tanks. The remnants left in the filter are filter cake

which was collected in barrels and disposed as hazardous wastes as per

authorization approval from PCB. Different grades of PIBSA are manufactured in

this plant.

Figure 3.4 PIBSA process flow diagram


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iii. Phenates/Sulfonate Unit

Phenates are classified functionally as detergents. This is produced by reacting

alkyl phenol with lime, sulfur and carbon dioxide in the presence of promoters

such as ethylene glycol, Do Decyl alcohol, and sulfonic acid / Sulfonate. The

Phenate plant consists of hot oil coiled reactors, reactor overhead system with

steam jet ejectors a recovery section to recycle the promoters, and a filtration

section.

The Phenate manufacturing operation is a batch process. The promoters and

diluents oil are premixed with alkyl phenol before charging to the reactor. The

remaining ingredients are charged in subsequent steps to form the active

Phenate.

Hydrogen sulfide and water are formed during part of this reaction sequence.

They are stripped through the overhead system.

Waste Gas containing Hydrogen Sulfide (H2S) is scrubbed in Caustic scrubber

unit, where H2S is fully absorbed in Caustic Lye and a byproduct Spent Caustic is

produced. Glycol, water, alcohol and oil are recovered from the reactor

overhead system and are separated in a water-glycol-oil separator. The alcohol-

oil stream is sent to an alcohol-oil recycle tank. The wet glycol is sent to a glycol

tank for recovery. The recovered alcohol and glycol are being reused in the

process. From the reactor the crude Phenate product is sent to the filtration

section for filtration. The final product is stored in intermediate storage tanks

and being used in blending plant for making lubricating oil additives. The

remnants left in the filter are filter cake which was collected in barrels and

disposed as hazardous wastes as per authorization approval from PCB. Different

types of detergents are manufactured in this plant using similar raw materials.

In the same unit, Sulfonate is manufactured by reacting Sulfonic acid with Lime,

2 Ethyl Hexanol, Calcium Chloride, Acetic acid and Formic acid in a similar

process. From the reactor, the crude Sulfonate is sent to the filtration section for

filtration. The final product is stored in intermediate storage tanks and being

used in blending plant for making lubricating oil additives. The remnants left in


12

the filter are filter cake which was collected in barrels and disposed as

hazardous wastes as per authorization approval from PCB.

Figure 3.5 Phenate process flow diagram

iv. Blending Unit

Various components both manufactured within IAL and imported from other

Chevron Oronite facilities are blended in batch and continuous inline blenders to

make different lubricating oil additive packages. The product is pumped in to

finished storage tanks, or directly loaded in road tankers or packed in MS barrels

for dispatch to customers.

Figure 3.6 Blending process flow diagram


13

3.4.2 Proposed New Component (ZDTP) Manufacturing

i. Zinc Di-Thio Phospate (ZDTP) Plant

A brief process description for manufacturing this component (ZDTP)is given

below:

The ZDTP plant is designed to produce 20000tons/annum of ZDTP. This is

produced by reacting mixed alcohol (Secondary Butyl Alcohol and methyl ISo-

Butyl carbinol) with Phosporous Penta Sulfide (P2S5)and Zinc oxide (ZnO) in the

presence of promoter acetic acid.

The ZDTP plant consists of a steam coiled reactor, a reactor overhead system

with steam vacuum pump, a neutralizer reactor, wiped film evaporator and a

filtration section.

The ZDTP manufacturing operation is a batch process. The mixed alcohol and

P2S5 are mixed with lube oilin the reactor. This forms acid which will be

neutralized with zinc oxide to form crude component. Hydrogen sulfide and

water are formed aspart of this reaction. The overhead streamcontaining

Hydrogen Sulfide (H2S) is treated with Caustic in scrubber and spent caustic

containing Sodium Sulphide is then converted to Sodium Sulphide flakes (by-

product) throughevaporation and flakingprocesses.

From the neutralizer, the crude ZDTP product is sent to the wiped film

evaporation section to strip out the unreacted solventsin the crude. The spent

solventwill bedisposed to third party as per PCB authorization. From the

evaporator, the crude ZDTP product is sent to the filtration section for filtration.

The final product is stored in component storage tanks. The remnant left in the

filter is filter cake which will be collected in barrels and disposed to third party

as per PCB authorization

.


14

Figure 3-7 ZDTP Process Flow Diagram

3.5 Raw Material Requirement


Following list of raw materials are used in the manufacturing of lubricating oil

additives and related intermediates. Raw materials are sourced locally as well

from global locations based on the requirement.

ZDTP process flow diagram - IAL

DTPA reactor

Neutraliser

Wiped Film Evaporator

SBA

MIBC

H2S to Scrubber system

Acetic acid

Zinc oxide

Filter feed tank

Schenk filter

ZDTP Storage tanks

Filter Aid

Filter Aid

Precoat tankLube oil

Filter cake

Crude ZDTP tank

Lube oil

P2S5

Spent Solvent


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Table 3.2 List of Raw materials for Proposed Expansion

S.No Raw Material Existing After Expansion

MT/Annum

1. 2 Ethyl Hexanol 43.0 86.0

2. Acetic Acid 6.0 13.0

3. Alkyl Phenol 3157.0 6314.0

4. Boric Acid 52.0 130.0

5. Calcium Chloride 7.0 14.0

6. Carbon-di-Oxide 434.0 869.0

7. Caustic Lye (100%) 708.5 1415.4

8. D.M. Water 1.8 3.6

9. Ethylene Carbonate 729.0 1823.0

10. Filter Aid-Coarse 105.3 210.7

11. Filter Aid-Fine 75.4 173.8

12. Formic Acid 2.4 5.8

13. Heavy Polyamine-HPA/DETA Mix 55.0 138.0

14. Heavy Polyamine-Pure 338.0 845.0

15. HR PIB 1000MW 758.0 1782.0

16. HR PIB 2300MW 4838.0 11384.0

17. IsoDecyl Alcohol 130.0 261.0

18. Maleic Anhydride 452.0 1064.0

19. Molybdenum Tri Oxide 60.2 150.5

20. Mono Ethylene Glycol 484.1 988.2

21. Mono Methyl Amine-MMA 18.1 36.1

22. Paraformaldehyde 25.0 50.0

23. Slaked Lime 1548.6 3098.2

24. Sulfonic Acid 862.0 1726.0

25. Sulfur 491.3 982.9

26. Lube Oil 150N 8562.0 22543.0

27. Imported Additive Components 3000.0 7200.0


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3.5.2 For Proposed New Component (ZDTP)

Following list of raw materials are used in the manufacturing of the component

ZDTP. Raw materials are sourced locally as well from global locations based on

the requirement.The raw material requirements are detailed in the Table3.3.

Table 3.3 List of Raw materials for New Component (ZDTP)

S. No Raw Materials Quantity (MT/Per Annum)

1 Phosporous Penta Sulphide (P2S5)

5336

2 Secondary Butyl Alcohol (SBA)

6013

3 Methyl Iso-Butly Carbinol (MIBC)

2702

4 Zinc Oxide 2003

5 Glacial acetic acid 20

6 Lube oil (150N) 6983

7 Caustic lye (100%) 1925

8 Filter aid 342

3.6 Utilities

The utility requirements for the proposed proposed projectwillbe met from existing

facility with appropriate augmentations. Details of the utilities are listed in Table

3.4

Table 3.4 Capacity of DG, Boilers and Thermic fluid Heaters

Details Capacity Fuel

Existing After proposed Expansion

After proposed new component (ZDTP)

Boilers 1x 5.0 TPH 1x 6.5 TPH

1x 5.0 TPH 1 x 10 TPH

1x 5.0 TPH 1x 10 TPH 1x 15 TPH (stand-by)

Furnace Oil

Thermic Fluid Heaters

2x 0.6MMKCal/hr (standby) 1 X 2.0 MMKCal/hr

2x 0.6 MMKCal/hr (will be decommissioned) 2x 2.0 MMKCal/hr (1 unit as stand-by)

2x 2.0 MMKCal/hr (1 unit as stand-by)

Furnace Oil

DG Sets 2x 550 kVA 1x 1010 kVA 1x 1500 kVA

1x 550 kVA 1x 1010 kVA 1x 1500 kVA -

1x 550 kVA 1x 1010 kVA 1x 1500 kVA

HSD


17

3.7 Power and Fuels

Power requirement is being met from TNEB (Tamilnadu Electricity Board) and third

party producer.However, adequate DG sets are available to back-up power

requirement during power restrictions by TNEB.

The unit uses furnace oil as the main fuel for its package steam boilers and thermic

fluid heaters. Diesel fuel is used for DG generators and consumption quantities will

vary based on the utilization. Details of the power and fuel requirements are listed

in Table 3.5

Table 3.5 Power and Fuel requirement

Details Capacity Source



Power Requirement

550000 KWH/Month

750000 KWH/Month

1050000 KWH/Month

TNEB/ Third party producer

Fuel oil for Diesel generators (HSD)

60* KL/month 80* KL/month 110* KL/month PSU Oil companies

Fuel oil for Boilers & Thermic Fluid heaters (Furnace Oil)

240 KL/month 400 KL/month 625 KL/month PSU Oil companies

* Consumption based on current power restrictions and may varybased on changes

in restrictions from TNEB.

3.8 Water Requirement

The total requirement of raw water for the existing unit after proposed expansion

will be 245 KLD and after proposed new component (ZDTP) will be308KLD. Entire

water requirement will be met from Chennai Metro Water Corporation (CMWSSB)

and there is no bore well source inside the Plant premises. Details of water


18

requirement for the proposed project is given in Table 3.6.The agreement for water

supply is enclosed in Annexure-5

Table 3.6 Water Requirement for the project

S. No

Description Existing (KLD)

After proposed Expansion (KLD)

After proposed new component

(ZDTP) (KLD)

1 DM plant 47 66 75

2 Cooling tower 83 104 141

3 Caustic scrubber 15 30 42

4 Potable water 30 45 50

Total raw water consumption

175 245 308

3.9 Landuse

The proposed project is planned in the demarked area within the existing

facility.There are no major changes in land distribution and the details are as given

below:

Table 3.7Land Use within the Site

Land allocation details Area in acres Existing After proposed

Expansion After proposed new component (ZDTP)

Total Area 23.57 23.57 23.57

Roads and drains Area 3.39 3.39 3.39

Tank farm and yards 4.94 4.94 5.94

Effluent treatment plant 2.78 2.78 2.78

Building Area 2.1 2.1 2.9

Greenbelt development 8.56 8.56 8.56

Vacant land 1.8 1.8 -


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3.10 Manpower

The existing Plant has around 140 employees and 260 contract workmen

supporting all operational activities and there will be an

After the proposed expansion the man power requirement will be 140employees

and 260 contract workmen.

After the proposed ZDTP project, the manpower will be 156 employees and 300

contract workmen.

3.11 Liquid Waste Management

Table 3.8 Wastewater Generation

S. No

Description Existing (KLD)

After proposed Expansion (KLD)

After proposed new component (ZDTP) (KLD)

A Effluent/ sewage generation details

1 Effluent from Process 140 196 265

2 Cooling tower blow down

3 DM plant washings

4 Process condensate

5 Boiler blow down

6 Sewage 27 40 45

Total effluent generation 167 236 310

B Treated effluent usage details

1 Recycle to DM plant 63 89 100

2 Recycle to CT plant 16 23 86

3 Gardening 88 124 124

3.11.1 Treatment of Lquid Waste

Based on the adequacy review, the existing ETP and STP facilities are

capable enough to handle increased effluents from the proposed ZDTP

project. RO plant capacity wil be augmented to handle the additional recycle

requiments.


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i. For Proposed Expansion

Trade effluent streams of total quantity 196 KLD generated from process

are treated in ETP of 300 KLD capacity. Sewage stream of quantity 40 KLD

is treated in STP of 60 KLD capacity. Treated water is partially used for

green belt development and the remaining water is sent to RO plant for

further treatment and recycled to CT and DM plant

ii. For Proposed new Component (ZDTP)

Trade effluent streams of total quantity 265 KLD generatedfrom process

will betreated in existing Effluent Treatement Plant (ETP), which is capable

of handling300 KLD of effluent.There are no major changes to the effluent

charecteristics. Sewage stream of quantity 45 KLD will betreated in existing

Sewarage Treatement Plant (STP), which is capable of handling 60 KLD

effluent.Treated water from both the treatement plants is partially used for

green belt development whilethe rest is being treated inReverse Osmosis

(RO) plant for recycle to Cooling Tower (CT) and Demineralization (DM)

plant.

3.11.2 Effluent Treatment Plant (ETP)Description

The unit has well established ETP Plant where the combined effluent from process

units and Utility systems are treated through Activated Sludge aerobic process as

detailed below. Sewage effluent is treated separately in exclusive sewage

treatment plant. The treated effluent meeting PCB norms is then treated in multi

stage Reverse Osmosis Plant for recycle into process while the rejects are

concentrated to salts in multiple effect evaporators for disposal.

There are three effluent streams generated in the plant depending upon the place

of origin.

a) Stream A

Basically consist of process waste water, wash/storm water from

curbed process area, process wash downs, and streams from lab,

pump leakage, storm water from truck loading and tank farm

areas. This stream contains oil and other Chemicals.


21

b) Stream B

Consist of cooling tower blow down, Boiler blow down and DM

plant regeneration wastes.

c) Stream C

Sanitary waste water – Treated in a Separate Sewage Treatment

Plant (STP)

The effluent treatment plant basically consists of three sections:

Oil/water separation and oil recovery.

Treatment of separator water and its disposal.

Sludge Digestion, thickening and dewatering

The free-floating oil in the process effluents from various unit

processes is removed by skimmers and corrugated float separator

units. The emulsified oil in the effluent stream is removed by

dissolved floatation techniques. These various steps of oil removal

enable a reduction in the Bio-chemical Oxygen demand

contributed by the oil.

In the oil –water mixture, the free oil due to its relative lower

specific gravity, floats on the surface which is removed by

mechanical skimming. The collected process effluent is pumped to

cross flow separator (CFS) where further free oil is removed. The

effluent from CFS bearing certain amount of emulsified oil and free

oil is sent to Dissolved Air floatation unit (DAF) through a Surge

Pond. The DAF unit acts as secondary treatment in the removal of

oil.

The out let of the DAF unit is sent to Equalization basin where the

utility stream is mixed. The combined effluent is subjected to

biological treatment based on activated sludge system.(Aerobic

Process) An activated sludge unit consisting of an aeration basin

and a clarifier removes dissolved organic contaminants. The waste

biological sludge is sent to a sludge digester where it is further


22

degraded the water from the digester is sent back for treatment

and the digested sludge is sent to dewatering facility. The

dewatered sludge is sent to solar ponds for drying. The treated

water is pumped to surge pond (west) The treated water is used

for firefighting, gardening. The treated water is partially sent to RO

plant for further processing &recycle to plant for usage in DM

plant and Cooling Tower and the remaining water is used for

gardening/green belt activities.

The Sanitary waste water (Stream C) is separately treated in a

Sewage Treatment Plant (S.T.P). The treated water is transferred

to Surge pond (West).

The Process flow Diiagram of ETP and STP are given in Figure 3.4

Online monitoring of parameters (pH & TDS) for treated effluent

from ETP done and it is also connected with CAC, TNPCB.


23

Figure 3-8ETP and STP Process Flow Disgram

Oxidation Ditch

(T-819)

Chemical sump

(T-802)

Process plant (N-Pit, Hot well)

Utility sump (T-

811)

Sanitary sump (T-

812)

Boiler Blow down & DM Plant

Sanitary waste from plant &

Non plant area

Cross flow

separator

(T-803)

Surge pond

(East)

(T-804)

Dissolved

air

floatation

(T-805)

)

Alum Dosing Poly electrolyte Dosing

Equalization basin

(T-813) Aeration Tank(T-814

aeration tank)

Surge Pond (West)

(Treated water)

9Treated

VAZ Solution

dosing

Sludge for

drying

Final Clarifier (T-820)

Intermediate Sludge

Sump T-818

Sewage

Treatment Plant

Urea & DAP

Over flow sump RO Plant

Recycle

to plant

Gardening


24

3.12 Air Pollution Control Measures

The existing/ proposed package boilers, thermic fluid heaters and DG sets are of

highly efficient in terms of combustion control and featured with in-built pollution

control design. Hence the pollutant load from theseunits will be minimal which

finally been vented through chimneys of appropriate height.

The unit has also installed online stack monitoring station (CEMS) for Hot oil stack

and boiler stack and connected with Care Air Center (TNPCB). PM, SOX& NOX are

being analyzed. 12 Nos of H2S sensor installed in different areas of plant permises to

monitor H2S. H2S sensor at the caustic scrubbers ventswill behooked upto CAC,

TNPCB.

The unit has installed Online Ambient Air Quality (AAQ) monitoring station and it is

connected with Care Air Center (CAC), TNPCB. PM10, SOX, NOX, CO, NO, NO2& 03 are

the parameters which are being analyzed.The unit has also installed continuous

VOC monitors in the plant.

3.12.1 For Proposed new component (ZDTP) - H2S off gas treatement facility

H2S generated from the ZDTP plant is treated in dedicated Caustic scrubber

system and converted to ~ 13 to 15% Sodium sulphide (Na2S) solution. The

Na2S solution is further concentrated in Multiple Effect Evaporators (MEE)

system and then flaking is done in flakers to manufacture Na2S flakes. The

process condensate from the MEE system is recycled back to Caustic

scrubber system for caustic dilution and the balance is sent to ETP for

treatment. The Na2S flakes from flakers are baggedand sold as by product in

the market to textile, paper and leather industries.


25

Figure 3-9 H2S Treatment System

Particulars of stacks and vents are detailed in Table 3.9.

ZDTP - H2S TREATMENT SYSTEM - IAL

H2S from ZDTP Plant

Multiple Effect Evaporator System

Flakers

Process condensate to ETP

Bagging & Storage

Na2S Solution Storage

Na2S Flakes

Caustic Scrubber Sytem

Caustic Solution

Na2S Flakes Dispatch

Process condensate recycle for dilution


26

Table 3.9 Existing & proposed Stack/ Vent details

Stack No 1

(Existing)

2

(Existing)

3

(Existing)

4

(Existing)

5

(Existing)

6

(Existing)

7

(Existing)

8 (For

Proposed

ZDTP)

Material of

Construction

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon

Steel

Carbon Steel Carbon

Steel

Carbon Steel

Stack attached

to

Common

Stack to 3

Nos. of oil

fired

Boilers

Common

Stack to 2

Nos. of Oil

fired

Thermic

fluid heater

Exhaust

pipe to D.G

set

550

KVA

Common

Exhaust

Stack to

1DG set of

1010

KVA

& 1DG set

of 1500

KVA

High Point

discharge

via water

scrubber

for PIBSA

reactor vent

High point

discharge to

Succinimides

Reactor

Vent from

Phenate

reactor

through

Caustic

scrubber

Proposed

vent from

Caustic

scrubber

attached to

ZDTP reactor

Stack Height

(Above the

ground level)

47 m 30 m 16 m 30 m 22 m 17 m 27 m 30 m

Stack dia at

top (Circular

inside

dimensions)

0.80 m 0.3 m 0.2 m 0.4 m 0.15 m 0.1 m 0.1 m 0.2 m


27

Existing/ proposed air pollution control measures are adequately sized to handle

the increased pollutant loads.

3.13 Hazardous and Solid waste Management

Hazardous wastes from the existing to proposed are increasing, the details of

Hazardous wastes generated are given in Table 3.10. The hazardous wastes

generated from this unit are collected, stored and disposed through authorized

disposal cum recycle facilities as per the authorization from PCB and the unit has

agreements with all waste disposal facilities for the same.There is no internl

disposal facility availability within the site.

The Authorization Letter from TNPCB is enclosed as Annexure-6.

Table 3.10 Hazardous wastes Generation

Cat.

No.

Details of waste Quantity (MT/ year) Method of Disposal



20.3 Distillation residue

(from process)

800 1250 2300 Collection, Storage and

Disposal for incineration at

common TSDF facilities & co-

incineration at cement

industries.

5.1 Used/ Spent oil 100 150 150 Collection, Storage and

Disposal to Authorized

Recycling Agencies.

5.2 Wastes/ residues

containing oil

7 10.5 15 Collection, Storage and


Recycling Agencies.

34.3 Chemical sludge

from waste water

treatment

10 15 20 Collection, Storage and

Disposal for land fill at

authorized TSDF facilities.

34.2 Toxic metal

containing

Residue from

0.5 1 2


28

Cat.

No.

Details of waste Quantity (MT/ year) Method of Disposal



water

purification

20.2 Spent Solvents ** ** 1500 Collection, Storage and


Recycling Agencies. 33.3 Discarded

Containers

2500 Nos 3500 Nos 4000 Nos

** Not applicable

Table 3.11Non-Hazardous wastes

Details of

waste

Quantity (MT/ year) Method of Disposal

Existing After

proposed

Expansion

After

proposed new

component

(ZDTP)

Used paper

waste

0.32 0.48 0.55 Sold as scrap to

authorized buyers

Food waste 1.08 1.44 1.65 Taken back by outsourced

catering service provider

for appropriate disposal

3.14 Greenbelt Development

Greenbelt is already developed inside the factory premises covering a total area of

about 8.56 acres which is more than 33% of the total area. The species and

plantation norms are followed as per the CPCB/ PCB directions.

3.15 Environment, Safety and Health Monitoring

The environment, safety and health-monitoring programme in the factory are as

follows:


29

Daily monitoring of water and wastewater

Online monitoring of stack, ambient air, weather and effluent parameters

Fortnight monitoring of ambient air

Monthly monitoring of noise and work place air

Monitoring of occupational safety

Yearly monitoring of occupational health.

To prevent air pollution, IAL has designed and installed the stacks of Boilers, Hot oil

units and DGs asper the guidelines of the central pollution control board (CPCB). IAL

has a robust and a highly reliable caustic scrubber system to prevent the release of

H2S vapours from Detergent plant to the atmosphere.

Online H2S sensor provided in caustic scrubber vent is hooked up with CARE AIR

CENTRE, TNPCB for continuous monitoring. IAL has totally 12 Nos H2S sensors

located in different areas of the plant to monitor and prevent H2S emissions.

IAL has installed Onlineambient air quality station (AAQ) and online stack

monitoring station (CEMS) and is connected with the Care Air Center, TNPCB. ,

PM10, SOX, NOX, CO, NO, NO2, VOC & 03are the parameters which are continuously

monitored and displayed. IAL has installed LED display for Online monitoring of

stack, AAQ and effluent parameters in the main gate for public viewing. IAL has

implemented various process improvement measures to reduce the generation of

hazardous wastes in each category. IAL’s hazardous waste generation has and

continues to be well within the limits authorized by the TNPCB.

In line with IAL's commitment towards environmental protection, IAL has made

considerable amount of investment of around Rs.400 lakhs in the past 2 years

towards various environmental improvement initiatives. Being a company with

significant government investment, IAL is proactive and committed towards

ensuring environmental compliance with applicable laws and standards. IAL has

never failed in complying with the environmental legislations and has always shown

a proactive approach in making its plant one of the best plants in terms of

environmental management. Local TNPCB officials showcase IAL as a role model to

their counterparts from other States.


30

4. SITE ANALYSIS

4.1 Connectivity

The proposed site on the SH – 56and it is in the express highway connecting

Thiruvottiyur and Ponneri. The site is located south of this road.

4.2 Land form, land use, land ownership

The Plant is located at SF No. 265(P) Manali Village, Thiruvottiyur Taluk, Tiruvallur

District, and Tamil Nadu. The present land use is industrial. The land documents

related to the site is enclosed in Annexure-2.

4.3 Existing land use pattern

The present land use is in industrial.zone. The details of sensitive areas from the

site boundary is given in Table 4.1. The site does not fall with in CRZ area.

Table 4.1Nearby areas from site Boundary S.No Name km

Water Bodies

1.

Surplus canal from

Korttalaiyar River

0.13 Km (North)

2. Buckingham canal 0.63 Km (East)

3. Retteri 7.56 Km(South-west)

4. Madhavaram Lake 3.57Km (South West)

5. KadapakkamPanchayat Lake 4.56 Km (North West)

6. Periyathoppu Lake 3.1Km (South West)

7. Bay of Bengal 3.13Km (East)

4.4 Climatic Conditions

The study region receives rainfall predominantly during monsoon season with an

average annual rainfall of about 1211 mm per year. The South west monsoon season


31

is from July – September and North east monsoon is from October to December. The

relative humidity recorded in the district is about 49-79%. The wind directions

during the study period are SW-W-WSW and SE. Accordingly, the impact zone will

be spread in NE-E-ENE and NW directions. The average wind speed observed during

the study period is 3 m/sec with the considerable frequency of a wind range of calm

to about 22 km/hour. Due to its proximity with the Bay of Bengal, the ambient

temperature at project site ranged between 25-40°C. The area has a tropical climate

with the highest and lowest temperatures recorded is Maximum of 40.3°C and

Minimum of 25°C respectively.

Table 4.2Meterological Observations

S.No Parameter Observation

1 Wind Direction SW-SE-W-WSW

2 Wind Speed Range 2 to 8.8 m/sec

3 Annual Average Rainfall 1211 mm

4 Average Wind Speed 3 m/sec

5 Temperature Range Max. Temp: 40°C

Min. Temp: 25°C

6 Average Temperature 32°C

7 Humidity Range (24hr) 49 to 79 %

8 Cloud cover Partly cloudy

4.5 Social infrastructure available

The social infrastructure facilities available near the site are given in Table 4.3.


32

Table 4.3 Proposed project surrounding features

S.No. Name km

Schools & Colleges

1. CPLC Polytechnic College 1.70

2. ThirunthangalNadar Arts College 4.05

3. Tamil Nadu Horticulture Institute 4.5

4. Tamil Nadu Veterinary and Animal Sciences

University

4.34

5. Institute of Poultry Production and Management 5.00

Religious Places

1 ThyagarajaSwamy Temple 2.08

2 KalyanaVaradarajPerumalKoil 2.46

3 St. Marys Orthodox Syrian Church 2.58

Hospital

1 Aakash Hospital 2.35

2 Sugam Hospital 2.33

3 Mary Clinic 3.69

4 Vasan Eye Care Hospital 8.17


33

5. Conclusion

Since the proposed project is coming up in the existing plant Industrial area,

there will not be any change in total land use.

The proposed expansion and new component manufacrturing (ZDTP) is within

the existing facility, hence most of the supporting facilities like utilities, effluent

and sewage treatement systems will be shared with the existing set up.

The increase in pollutant loads due to the proposed project is appropriately

handled through pollution control measures.

The treated waste water will be partly reused for gardening with in the facility

and rest will be recycled for process reuse like Cooling Towers and boiler feed

water make-up after treatement through RO system. RO plant will be upgraded

as part of this project to meet the additional recyle requirements.

The facility has a well developed green belt covering more than 33% of the total

plot area. There are no changes to the green belt area on account of this

proposed project.

There will be positive impact on Social conditions in and around the site due to

the proposed project.

The impact of proposed project with in the existing facility will be fully mitigated

by the Environment Management Plans (EMP).

Documents

PREFEASIBILITY REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/.../0_0_05032015V0QARPrefeasibilityReportTORAmendment.pdfPrefeasibility Report for Proposed expansion