appendix i 6) (i) : raigad, maharashtra latitude - 21 deg...

APPENDIX I

(See paragraph – 6)

FORM 1 (I) Basic Information Name of the Project : SKI Carbon Black India Pvt Ltd.

Unit –Hi Tech Carbon, Patalganga Location / site alternatives under consideration : Patalaganaga, Raigad-Maharashtra

Installation of Tail gas for Fuel project The existing plant site is located at Near Patalganga Industrial Area Village Talvali and Lohop, Tal : Khalapur, Dist : Raigad, Maharashtra Geographical location of site : Latitude - 21 deg. 30 ’ N Longitude - 72 deg. 55 ’ E Village - Talvali and Lohop Taluka - Khalapur District - Raigad State - Maharashtra Topography of the Site :

Status of Area - Approx. 5 km from developed Patalganga Industrial area. Terrain - Uneven with hard marrum. (No filling required)

Climatic condition - Arid to semi arid. The site is situated near notified industrial area i.e. The Patalganga industrial area. It is 10 km from Mumbai-Pune National Highway 4 and 7 km from the Mumbai-Pune expressway. It is just 12 km from Mumbai-Goa national highway 17.

The nearest railway station is Rasayani/ Apte which is on Konkan railway, hardly 7 km from the area.

The site is about 80 km from Santacruz domestic airport and Chatrapati Shivaji International Airport. Map of Khalapur Taluka area indicating exact plant location and colored site photographs are enclosed.

Size of the Project * :

Total area of the plot is 257580.00 m2 PRODUCT & ITS CAPACITY :

Products Production capacity

Carbon Black

0 ( No increase in Capacity) Electricity

0( No increase in Capacity Expected cost of the project : Rs. 146.5 Crores

Contact Information :

1. Name of the proponent

SKI Carbon Black (India) Pvt Ltd.

Unit- Hi-tech Carbon -Patalganga

2. Detailed address

A-96, II nd floor, “Ahura Center”

Opp MIDC Ltd, Office,

Mahakali Caves Road,

Andheri (East), Mumbai - 400 093.

3. Signing Authorit

Vinay Bhalerao

(Unit Head / Jt. President)

4. Contact Numbers

044-2798923 – 6

Extn : 2103 Screening Category

:

An Old Industrial Establishment(Fuel Conservation Project requiring modification at existing Catgory A Project)

Capacity corresponding to sectoral activity (such as production capacity for manufacturing, mining lease

area and production capacity for mineral production, area for mineral exploration, length for linear transport

infrastructure, generation capacity for power generation etc.,)

(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will cause physical

changes in the locality (topography, land use, changes in water bodies, etc.) Sr. No.

Information/Checklist confirmation Yes / No Details thereof (with approximate quantities /rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

No No Change in existing Land use pattern, new construction proposed in Developed Area

1.2 Clearance of existing land, vegetation and buildings? No

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g. bore houses, soil testing? No

1.5 Construction works? Yes Industrial equipments installation

1.6 Demolition works? No

1.7 Temporary sites used for construction works or housing of construction workers?

Yes There might be some temporary hutments of workers and site office which will be demolished after completion of work.

1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations

Yes Soil Excavation for the construction of foundation of different new equipments with in project scope

1.9 Underground works including mining or tunneling?

No --

1.10 Reclamation works? No. -- 1.11 Dredging? No --

1.12 Offshore structures? No --

1.13 Production and manufacturing processes? No No change in manufacturing process. Only the fuel used for combustion in Reactors will be changed with the implementation of Project proposal

1.14 Facilities for storage of goods or materials? No --

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

No Not Applicable. A Fuel Substitution project not generating Solid waste or liquid effluents

1.16 Facilities for long term housing of operational workers?

No --

1.17 New road, rail or sea traffic during construction or operation?

NO No new Road Traffic, Existing sytem is capable to cater for movement of Project items and personnel during

Sr. No.

Information/Checklist confirmation Yes / No Details thereof (with approximate quantities /rates, wherever possible) with source of information data construction Phase

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

No

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

No

1.20 New or diverted transmission lines or pipelines? No 1.21 Impoundment, damming, culverting, realignment or

other changes to the hydrology of watercourses or aquifers?

No --

1.22 Stream crossings? No -- 1.23 Abstraction or transfers of water form ground or

surface waters? No

1.24 Changes in water bodies or the land surface affecting drainage or run-off?

No No such work is involved in the scope of project/ activity

1.25 Transport of personnel or materials for construction, operation or decommissioning?

Yes Transport of construction materials equipments and people movement will be there during project construction phase.

1.26 Long-term dismantling or decommissioning or restoration works?


1.27 Ongoing activity during decommissioning which could have an impact on the environment?


1.28 Influx of people to an area in either temporarily or permanently?

Yes Construction people will be temporarily coming to site during project construction phase

1.29 Introduction of alien species? No -- 1.30 Loss of native species or genetic diversity? No -- 1.31 Any other actions? No --

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sr. No.

Information/checklist confirmation Yes/No Details thereof (with approximate quantities / rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha) No New equipments shall be installed in developed part of the Existing Project area

2.2 Water (expected source & competing users) unit: KLD

No No new provision required as the cooling water need of 240 KLD is offset by the condensed water recovery in proposal

2.3 Minerals (MT) No --

2.4 Construction material – stone, aggregates, sand / soil Yes No External Soil required, Approx. 200MT of Aggregate and sand is

(expected source – MT) expected and shall be sourced locally. A Detail of the required construction materials will be worked out during project engineering stage

2.5 Forests and timber (source – MT) No --

2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes No additional Fuel Requirement, Power requirement is met from Existing Captive Power Plant operating on waste gas from process. Details mentioned in enclosed prefeasibility report

2.7 Any other natural resources (use appropriate standard units)

No Fuel Oil conservation expected Approx 18000MT per annum

3. Use, storage, transport, handling or production of substances or materials, which could be harmful

to human health or the environment or raise concerns about actual or perceived risks to human health.

Sr. No.

Information/Checklist confirmation Yes/No Details thereof (with approximate quantities / rates, wherever possible) with source of information data

3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

Yes Hazardous material like- Thermal insulation will be utilized during the project construction. However theses will be handled as per pollution control guidelines --

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases) No --

3.3 Affect the welfare of people e.g. by changing living conditions? No --

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

No --

3.5 Any other causes No --

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr. No.

Information/Checklist confirmation Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of information data

4.1 Spoil, overburden or mine wastes No No such work is involved in the scope of project/ activity -

4.2 Municipal waste (domestic and or commercial wastes)

No No such impact from Project /Activity

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

Yes Hazardous waste generated will be handled as per pollution control board norms. Details of generated waste are given in Pre-feasibility report

4.4 Other industrial process wastes Yes General Purpose Lubricating Oil& Grease and Approx quantity provided in prefeasibility report

4.5 Surplus product No -- 4.6 Sewage sludge or other sludge from

effluent treatment No

4.7 Construction or demolition wastes Yes Only construction wastes. Solid wastes would be mainly due to excavation in the form of rubble and soil. This soil and rubble will be reused for leveling of project site.

4.8 Redundant machinery or equipment No --

4.9 Contaminated soils or other materials No --

4.10 Agricultural wastes No --

4.11 Other solid wastes No --

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr. No.

Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

5.1 Emissions from combustion of fossil fuels from stationary or mobile sources.

No There will be no increase. However there will be , CO2 emission reduction 58740 MT/yr due to reduced usage of liquid hydrocarbon fuel

5.2 Emissions from production processes No No impact, there will be reduction in CO2 emission (58740 Mt/yr)

5.3 Emissions from materials handling including storage or transport

No

5.4 Emissions from construction activities including plant and equipment

Yes / Marginal

Very minimal impact only due to Vehicular movement for transportation of material and erection of equipments --

5.5 Dust or odours from handling of materials including construction materials, sewage and waste

No

5.6 Emissions from incineration of waste No -- 5.7 Emissions from burning of waste in

open air (e.g. slash materials, construction debris)

No --

5.8 Emissions from any other sources

No --

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr. No.

Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines, ventilation plant, crushers

No Installation / operation of Rotary equipments will generate noise but this will be contained within the norms with appropriate engineering controls

6.2 From industrial or similar processes No

6.3 From construction or demolition Yes Noise generated from mobile construction equipments will be nominal and to control the same the following measures shall be adopted:

Sr. No.

Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data Properly maintained equipments with mufflers will be used. Use of equipment generating noise of not greater than 90 db (A) will be used. High noise generating construction activities would be carried out only during day time. Personnel working near high noise construction machinery shall wear ear muffs or ear plugs as protective gear and all such area shall have proper sign board. Semiskilled construction workers shall be provided with onsite safety training and proponent ensures supplies of protective gear

6.4 From blasting or piling No No such work is involved in the scope of project/ activity

6.5 From construction or operational traffic No Not Applicable. Work is limited in volume and will carried out inside the premises

6.6 From lighting or cooling systems No 6.7 From any other sources No --

7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers,

surface waters, groundwater, coastal waters or the sea:

Sr. No.


7.1 From handling, storage, use or spillage of hazardous materials

No --

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

No

7.3 By deposition of pollutants emitted to air into the land or into water

No

7.4 From any other sources No --

7.5 Is there a risk of long term build up of pollutants in the environment from these sources?

No --

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment

Sr. No.


8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

No --

8.2 From any other causes

No --

8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?

Yes There is no history of such a disaster in the area under reference. However, a Disaster Management plan is enclosed. (Annexure No)

9. Factors which should be considered (such as consequential development) which could lead to

environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. No.


9.1 Lead to development of supporting. lities, ancillary development or development stimulated by the project which could have impact on the environment e.g.:

Supporting infrastructure (roads, power

supply, waste or waste water treatment, etc.)

Housing development Extractive industries

Supply industries

Other

No

No

No

No

No

Factory is an Old Industrial Establishment. Proposed Project /activity is for Installation of Tail gas for Fuel project

9.2 Lead to after-use of the site, which could have an impact on the environment

No --

9.3 Set a precedent for later developments No

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects No

(III) Environmental Sensitivity

Sr. No.

Areas Name/ Identity

Aerial distance (within 15 km.) Proposed project location boundary

1 Areas protected under international conventions, national or

local legislation for their ecological, landscape, cultural or other related value

No --

2 Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

No --

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

No --

4 Inland, coastal, marine or underground waters No -- 5 State, National boundaries

No --

6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas

No --

7 Defense installations No --

8 Densely populated or built-up area No --

9 Areas occupied by sensitive man-made land uses (hospitals,

schools, places of worship, community facilities) No --

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry,

agriculture, fisheries, tourism, minerals)

No --

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards

are exceeded)

No --

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or

extreme or adverse climatic conditions)

No --

(IV). Proposed Terms of Reference for EIA studies

Sr. No. Description 1 Introduction to the project 2 Project details 3 Existing Environmental Setting 4 Impact Identification and Impact Assessment 5 Mitigation Methods 6 Environmental Impact Statement 7 Conclusion

BIRLA CARBON TECHNOLOGY, TALOJA Page 1

BIRLA CARBON

Tail Gas for Fuel Project (TGF)

Project Report

BC-Technology

4/20/2015

Brief Project Report on Tail Gas for Fuel Project- A novel technology development and proposal to construct a ‘Tail Gas for Fuel’ setup for fuel oil conservation at Birla Carbon’s Patalaganga plant


April 20, 2015

BIRLA CARBON TEECHNOLOGY, TALOJA Page 2

Topics:

1. Executive Summary Page 3

2. Project Description & Process Page 4-16

3. Project Schedule & Financial Pages 16-17

4. Conclusion Pages 17

List of Annexure

1. Annexure- 1 Plot Plan with Mark up

2. Annexure- 2 & 3 Equipment Area Mark up

3. Annexure- 4 Project Management Plan

4. Annexure- 5 Process Flow Diagram- Schematic

5. Annexure- 6 & 7 Form V & Environmental Monitoring

Reports

6. Annexure-8 Environmental Clearance Certificate

7. Annexure-9 Site & Soil Study Report


April 20, 2015


1. EXECUTIVE SUMMARY

‘Tail gas for Fuel Project’ is one of Birla Carbon’s long term R&D based initiatives to develop and

commercialise a novel process technology targeted to reduce its total oil consumption.

This proposal outlines the project plan to design, test and install the new tail gas recycling

process unit in existing process plant. This shall provide opportunity to reduce its total oil

consumption by up to 15% and substantial reduction of green house gas (GHG) emissions.

It proposes to execute the project in phase wise manner where Stage-1 to install a

demonstration unit on one Tread reactor and Stage-2 for installing similar setup on other three

reactors at its manufacturing facility located at Patalaganga, near Mumbai. Project Stage-1 on

successful commissioning and operation for a reasonable period aims to augment the system

design and roadmap for Stage-2, as commercialisation of new process.

Benefits & Project Future

The project on successful demonstration and completion shall be commercialised & deployed

across all other Plants/Units. It has potential of long term impact on Group’s Carbon Black

business and Sustainability.

Key benefits are the reduction of operating cost, reduction of GHG emissions and generate new

avenues to improve energy efficiency in recovery cycle of manufacturing process

Project Technology & Deployment Plan

Process design is owned by the Birla Carbon Technology group and detail engineering proposed

to be carried out by a reputed firm having experience in similar processes across various

petrochemical industries.

The Process design has been done for easy scalability and demonstration unit will have modular

design for installation of multiple units for similar size reactors.

Environmental Management Plan and Project Risk

Process change does not enhance productivity and no increase in emissions will occur from this

change. On the other hand the CO2 emissions stand to be reduced up to 15% on account of

reduced fuel oil consumption. No increase in waste water discharge from the unit as plant is

equipped with a Zero liquid discharge system.

The major project risks are process equipments installed shall be exposed to harsher

environment and a new process application hence investment risk is higher.

Project Financing & Approval

It is a company’s research based project and funded by company’s Research and Development

fund. The principal approval is received for initial investment however final decision is guided

by early pay back of investment. An investment estimate of 1179Mn INR and a simple payback

period of ~5 years

Project Duration

A project period of 28 months is planned for completion, wherein activities for Project stage -2 is

scheduled to start post completion of Project stage-1 on installation & commissioning activities

of demonstration setup. Project stage-1 shall start in Jan 2015 & planned to complete in initial

12 Months and a detail schedule is included in Annexure-4 for reference


April 20, 2015


2. PROJECT DESCRIPTION & PROCESS DETAILS

2.1. About Birla Carbon Patalaganga Unit:

Patalaganga unit is part of the Aditya Birla Group’s Carbon Black business, the largest

manufacturer and supplier of high quality Carbon Black additives globally and a flagship

business of the US$40 billion Aditya Birla Group. Carbon Black business’s Current footprint

extends across 12 countries with 17 manufacturing facilities with combined annual capacity of

2 million tonnes.

2.2. Project location

Birla carbon’s Patalaganga unit:

Address Details

SKI Carbon Black (India) Pvt. Ltd.

VIllage : Lohop/Talvali, Patalganga,

Taluka: Khalapur, Dist: Raigad - 410 207,

Maharashtra, India

GENERAL LOCATION MAP

* Located near Reliance Ind. Patalaganga at about 4.2 KM

* Nearest Highway – Near Mumbai Pune Express way NH4

Screen Shot of Route map

2.3. Size & Magnitude of operation

Birla Carbon Patalaganga


April 20, 2015


Existing Patalaganga unit has a sanctioned carbon black production capacity of 120,000 TPA

produced from its Tread Reactors. We have installed , total 4 No of Reactors (3 working and 1

cold standby) at site. Our total production capacity remains well within the rated capacity

limit under any product mix combination.

With installation of Tail gas recycling equipment set on these reactors the production capacity

will not increase as no capacity building equipment or yield enhancement process is added in

this project’s scope nor it creates any opportunity for production capacity increase, in near

future.

Since, this manufacturing unit is already operating, the project team studied in detail the

current Environmental Clearance guidelines issued to the Patalaganga Unit from the

honourable office of ‘The Ministry of Environment and Forests’ vide Letter dated 22nd March

2013 towards consent for operation and hold that there shall be no new requests towards new

provisions or modifications to the existing compliance points as outlined under ‘Special

Conditions and General Condition’ of Point 7.0 of EC letter in reference.

Project implementation shall not increase Productivity or any gaseous emissions and does not

requests any change in existing provisions for river water drawn for plant use or any additional

liquid effluent stream generated from new process requiring installation of any additional

special waste water treatment process.

2.4. Process Description

Product and Application-

The Birla Carbon Patalaganga plant produces ASTM grades of Carbon black also commercially

known as furnace grade carbon black.

This is majorly consumed as filler for different Rubber and Plastics applications, it is important

for imparting Mechanical Strength, Colour, UV resistance, Electrical Conductivity and other

properties.

Raw Material-

The main raw material for Carbon Black manufacturing is ‘Carbon Black Feed Stock Oil’, a

heavy-residue by product of Crude-Oil refining, obtained from FCC bottoms. Majority carbon

black producers import this Feedstock sourcing from US Gulf coast area due to economic

considerations and quality/quantity limitations of oil from domestic refineries.

Process Details-

Typically Carbon Black Manufacturing Operation can be broken down in 4 key areas of

Reaction -> Collection -> Densification & Drying -> Storage

The project activities shall be limited to modifications of Process unit in Reaction area.

In the Reaction area production of Carbon Black takes place in fine black powder form

suspended in gas phase, referred to as dense Smoke.

Carbon Black Production process is essentially a Thermal or Pyrolitic cracking of heavy

feedstock oil in Tubular- Refractory lined reactors. The Thermal Cracking reaction is a partial

combustion process & requires generating sufficient heat in a reducing atmosphere in order to

break-down the large oil molecules and liberate elemental carbon. This Process of partial

combustion & thermal cracking generates fine particulates of carbon black along with some

combustible gasses like CO & H2 also other non combustibles like CO2, N2 and H2O.


April 20, 2015


This process of conversion of Heavy Oil to Carbon Black and Lean Tail Gas happens at

extremely high temperature of around 2000° C, this reaction needs to be stopped by quenching

with water spray and further lowering of this gas temperature up-to 1000° C for safe handling

by downstream equipments.

Carbon black and gas mixture is then passed through high efficiency Bag collectors for

separation of Lean Tail Gas and collection of fine carbon black particles. The filtered gas is then

sent to the onsite captive power plant for combustion and generation of Steam & electrical

power through steam turbines. A small part of Tail gas is utilized to generate heat for Carbon

black drying process in the Tail gas fired Rotary drum dryers.

In new proposed Tail Gas for Fuel process it shall recycle a part of this waste tail gas and feed

to Carbon Black reactors as heat source for the Thermal cracking reaction and replace the

auxiliary fuel oil being utilized. Through this process modification a substantial reduction of

total plant oil requirement can be achieved and this reduction is estimated in range of 12 to

15% on continuous basis.

Prior to recycling the Lean Tail Gas it needs to be pre-conditioned in order to achieve the

desired heat input to the reactors. The conditioning process of Tail gas shall involve

dehumidification and heating operation prior to injecting into the reactor combustor.

The conditioning process of Tail gas includes dehumidifying and heating the tail to improve its

heat value before injection to reactor combustor. The process unit shall comprise of;

Individual tail gas condenser unit comprising one shell and tube Heat exchanger,

hot well and condensate pump for each Tread reactor

Individual Tail gas blower unit comprising of one blower and drive for each Tread

Reactor

Individual Tail das heating unit comprising of one shell & tube heat exchanger for

each Tread reactor

One common Oxygen supply system comprising of;

o One set of Liquid oxygen storage tanks & vaporizing system in Stage-I

having supply capacity of~800NM3/hr

o One VSA plant of ~2400Nm3/hr flow capacity as complete oxygen supply

source in Stage-II

One common cooling water source for the Tail gas conditioning operation and shall

be drawn from exiting facility’s cooling tower due to excess generation capacity

o In stage –I around 350 Cum/hr of Water circulation load is expected

o In stage-II around 800 Cum/hr of water circulation load is expected

A schematic representation of proposed setup is annexed for both project stages i.e. of

the commercial unit Stage-2, followed by Project stage-1 of demonstration setup. Refer

annexure-2 &3 for new major equipment installations in the proposed setup.

2.5. Project Overview

This project proposes to better utilise the waste Tail gas generated from the Carbon black

process. By developing a novel process to condition the tail gas and feed in existing Tread

reactors as fuel replacing the fuel oil requirements completely.

This project provides us an opportunity to reduce the plant CO2 emissions by up to 15%

supports the groups Sustainability initiative.


April 20, 2015


Project shall be completed in stage wise implementation process wherein-

Stage-0 is Project design and Cost Estimation

Stage-1 is Construction and operation of demonstration unit at our Patalaganga plant

Stage-2 is Commercialisation of process at the Patalaganga plant and develop expertise

for implementation at other plants of Birla Carbon

Currently project stage-0 is nearing completion and further activities can be taken up after

obtaining the environmental consent for project construction and operation at our Patalaganga

plant location.

Project implementation shall not increase Productivity or any gaseous emissions and does not

require any change in existing provisions for river water drawn for plant use or any additional

liquid effluent stream generated from new process requiring installation of any additional waste

water treatment process.

2.6. Project Fuel Oil Savings

Simple Illustration for projected oil savings at PTG Plant on 5 Year basis;

Reduced Oil Consumption on 5 year term PTG

Avg. Fuel Oil Consumption MT/Day 52

Plant Operability Days/yr 330

Yearly Fuel Oil Consumption MT/ yr 17107

Total For 5 yrs MT 85536

Total Oil saving @ 100% Max MT 85536

*Assumption basis- Fuel Consumption pattern is in same range.

2.7. Raw Material Requirement

Basic raw material required for carbon black manufacturing is Feedstock oil and accounts for

around 70% of the total manufacturing cost. Feedstock oil for the Patalaganga unit is currently

sourced from US Gulf coast. The maximum sulphur content in the oil is ensured less than 2.5%

by wt as specified under ‘special guidelines point- 5’ of letter issued by MoEF vide letter Dated

22nd March 2013 (F.No. J-11011/35/2007-IA II (I)

The current raw material quantity as well as quality requirement along with source shall not be

affected by proposed project installation and operation.

2.8. Natural Resource Optimisation

The re-cycling of tail gas to replace the fuel oil provides us opportunity to save approximately

18000MT per annum of heavy oil for the Patalaganga unit on successful completion of the

project.

The process of Tail gas recycling shall utilise the excess power available from onsite power

generation facility operating on waste Tail gas and any additional fuel is not consumed.

The process also helps in conserving water by recovering water through Tail gas condensing

operation, estimated from this process at around 8900 kg/hr. This condensed water shall be


April 20, 2015


utilised for reactor quenching operation and shall in turn help in reducing the fresh water

intake, for reaction quenching purpose, by same quantity

The Patalaganga unit has four (4 Nos.) Tread reactors where three (3Nos.) Reactors are run at a

time and one (1) reactor is a standby reactor, the system has been designed to minimise the

downtime due to frequent refractory replacement requirement.

Even after TGF Project Implementation same operating philosophy shall continue i.e. one

reactor shall always be a stand by unit and remaining three shall be run as per the production

requirement. The common facilities shall be designed to meet maximum demand on three

(3Nos.) Tread reactor output basis; i.e. the Oxygen supply unit, the cooling water supply, the

Power distribution transformers and compressed air system shall be sized to meet the three

(3Nos.) reactor operation demand.

Calculation Basis:

1x Rx. Unit Total (3x Rx. Unit)

Parameter Unit Stage-I Stage-II

1 Plant Production Capacity MT/Day 240 240

2 Reactor Capacity (each-Rx A/B/C/D) MT/Day 80 80

3 Process Air Flow Nm3/hr 14500 43500

4 Quench Water Flow Kg/hr 5500 16500

5 Tail Gas Volume Nm3/hr 30100 90300

6 Moisture In Tail gas Kg/hr 7658 22973

7 F.oil Flow kg/hr 750 2250

8 F.oil LHV kcal/kg 9300 9300

9 Tail Gas LHV(De Humidified) kcal/kg 714 714

10 Tail gas Fuel Equivalent Nm3/hr 10447 31342

11 Condensate Recycled kg/hr 2973 8919

12 Fresh Water reqd. for Quench Kg/hr 2527 7581

13 Quench Water conserved Kg/hr 2973 8919

Fuel Oil Conservation & Emission Reduction

Individual tread reactors currently have fuel oil consumption of 750 kg/hr (each) on maximum

basis and total fuel consumption capacity of 2.25MT/hr OR 18000MT of heavy fuel oil on

(maximum consumption basis) for 8000 hrs of plant operation yearly.

Tail gas recycling process shall conserve this fuel oil by fuel substitution and usage of Waste

Tail Gas from current manufacturing process.TGF Project on completion shall help achieve

substantial reduction of GHG emission levels, up to 15% on current level, as detailed below;

Calculations for Fuel Conservation

Stage-I Stage-II

(Per Rx. Unit) (Total Plant)

1 Current fuel oil usage in reactor kg/hr 750 2250

2 Feedstock oil usage in reactor kg/hr 5400 16200

3 Fuel oil usage post implementation kg/hr Nil Nil

4 CO2 Emission reduction MT/yr 19580 58740

5 Fuel Oil Conserved MT/yr 6000 18000

Emission Reduction (Estimated Values):


April 20, 2015


With TGF project implementation the reactor fuel oil conserved shall be substituted by

the waste Tail Gas drawn from the existing Tail Gas header. Currently total TG

generated from process is feed to existing boiler and Rotary Drum dryer at an average

flow rate of ~ 78,000Nm3/hr.

The TG consumption in dryer shall be unchanged however there shall be reduction in

total TG available to boiler on account of additional TG drawn for consumption in TGF

process. An estimated average consumption of around 10.5% per reactor basis on

total TG from process is expected and this in turn shall impact the TG available to

boiler as TG quantity to boiler shall be reduced by same amount.

The reduction in Tail gas combustion in boiler shall thus help in reduced emission

from boiler stack and estimated around 31.5% based on all three reactor operation

utilising tail gas as fuel.

As per current operations we monitor gaseous emission level in five key areas,

viz. 1- Main Boiler Stack, 2- Product Dryer Stack, 3- PGF-1/2 Stack, 4-Packing Bag

Filter vent, 5- Plant Ambient air quality monitoring

Flue gas emissions measured at boiler stack is provided below with the projected

figures of Stack emission reduction for both Stage-I & Stage-II of TGF project;

(On Account of Tail Gas quantity reduction for Combustion in Boiler)

Current Level

Project Stage-I

Project Stage-II

1 Total Tail Gas from Process Nm3/hr 78000 78000 78000

2 Tail Gas Flow to Boiler Nm3/hr 63000 56385 43155

3 CO2 MT/day 538 482 369

4 SO2 kg/day 1775 1589 1216

5 NOx kg/day 60 54 41

6 CO kg/day 37.48 33.54 25.67

7 T-Pm kg/day 165.00 147.68 113.03

2.9. Power and Water Consumption Requirement & Availability

Power Source & Consumption

HTC-PTG unit has installed its own captive power generation unit operating on the waste tail

gas being generated from the process and has an installed capacity of 23 MW. Power plant

caters to the existing plant requirements of process equipment load along with the auxiliary and

utility load and exports excess power to the Local state electricity board grid.

The current excess generation shall be able to provided additional expected process & utility

load of around 2100KWH and no auxiliary fuel shall be required for such consumption.


Estimated Power Consumption for New Installed facility

Equipment Name Capacity Flow rate Installed Motor Power (KW) Operating Load

Phase-I Phase-II Phase-I Phase-II Phase-I Phase-II

(New Equipments)

Per Reactor Total Unit- 3xRx's Per

Reactor

Total Unit-

3xRx's

Unit Per

Reactor

Total Unit-

3xRx's

Unit

1 Tail Bas Blower 9500 Nm3/hr 4x *9500 Nm3/hr 355 4 x 355 KW 266.25 798.75 KWH

2 Condensate Water Pump 3 Cum/hr 4x 3 Cum/hr 5.5 4 x 5.5 KW 4.125 12.375 KWH

3 Cooling water Pump 350 Cum/hr 4x 350 Cum/hr 90 4 x 90 KW 67.5 202.5 KWH

Total Power 450.5 1802 KW 337.875 1013.625 KWH

4 Roots Blower VSA Plant Nil 3800 Nm3/hr Nil 1100 KW Nil 825 KWH

5 Vacuum Bower VSA Plant

Nil 3800 Nm3/hr Nil 450 KW Nil 337.5 KWH

6 Oxygen Booster Blower Nil 38000 Nm3/hr Nil 315 KW Nil 236.25 KWH

7 Eq. Power for

Compressed air - - 22 90 KW 16.5 67.5 KWH

8 Additional Cooling Tower

Load - - 0 0 KW 0 0 KWH

9 Additional Lighting &

Utilities - - 5 25 KW 4.25 21.25 KWH

Total power consumption based on 100% equipment load: 359 2501 KWH 258 1801 MW/

month

Phase wise daily power consumption for TGF setup Operation-

Stage-1: Around 8.7 MW Power shall be consumed from the excess power generation capability available at site utilising the waste tail gas

Stage-2: Around 60 MW Power shall be consumed from the excess power generation capability available at site utilising the waste tail gas


Water Source & Consumption

Currently Patalaganga plant gets water from ‘The Patalaganga-River’ which is drawn off site

Utilising submerged water pumps. The water is transferred via pipelines then treated on site

and stored to meet its daily water consumption requirements. Total Daily water requirement for

its current operations is in the range of 4000 KL per day. As per the EC letter issued by MOeF

Vide Letter NO- F. No. J-11011/35/2007-IA II (I) plant is permitted to not more than

4000m3/day of river water and this consumption requirement shall remain unchanged on

account of any or all process changes by executing proposed TGF project.

Current major usage areas for Process & different Utilities Installed on maximum basis are;

Quench water to Reactors & Bag collector, Pelletizing : 920 Cu M/day

DM water generation Plant : 600 Cu M/day

Cooling Tower Make Up : 1350 Cu M/day

Agriculture, Rinsing and back wash of Water Treatment system : 840 Cu M/day

Others like Fire water system make up/ Potable water supply : 345 Cu M/day

2.10. Waste Generation Quantities and Management Scheme from Proposed Project

The process of Waste Tail Gas recycling has no effluent or reject stream hence it will not

generate any new solid or liquid waste.

Process operation of 'the tail gas recycling equipments' shall require installing and operating of

few rotary equipments which shall be utilising small quantity of lubricating oils, the

consumption and estimated reject quantity is listed for reference.

An Estimate of waste generated from Construction activities during Project execution is also

provided along with the disposal process in a tabular form below. Data for Installation and

operation of both Project Stage-I and Full Scale implementation Project Stage-II in Tables below;


Stage-I : Demonstration setup Implementation

Hazardous waste Category:

Waste from Project Activity

S.NO Project Item/ Activity Frequency Unit Quantity Type Total Qty Processing Mode

(kg) (kg/yr)

1

Combustion Choke Refractory

Once

250

Gen Solid Waste - Earth from excavation & Debris from foundation

250

Recycled by the supplying manufacturer

2

Ceramic Insulation Waste

Once

250

From project activity of Heat exchanger & Pipeline Insulation

500

Reprocessing through Authorised agency

3

Ceramic Insulation Waste

Once in 5 Yrs

2500

From project activity of Heat exchanger & Pipeline Insulation replacement

500

Reprocessing through Authorised Agency

Waste from Operations

S.NO Equipment Name Capacity Flow-rate Installed Motor Power

Lubrication Waste Type Oil/ Grease Qty Rejected

Oil/ Grease Qty Rejected

(KW) (kg/day) (Kg/yr)

1 Tail Bas Blower 8550 Nm3/Hr 315 Grease Nil 3.6

2 Condensate Water Pump 3 Cum/hr 5 Oil Lubrication Nil 1.2

3 Cooling water Pump 350 Cum/hr 75 Oil Lubrication Nil 18

Total Power 395 Total Qty 22.8

Non Hazardous Waste Category:

Project Item/ Activity Frequency Unit Quantity Type Total Qty Processing Mode

MT MT/yr

4 Civil Construction waste Project construction Phase only

35 Gen Solid Waste - Earth from excavation & Debris from foundation

35 Used in premises for land fill and levelling purpose

5 Metal Fabrication Erection Project construction Phase only

6 Steel Scrap from Fabrication of Structures and Pipelines

6 Disposal to verified Metal recyclers

6 New Item Procurement Project construction Phase only

1 Wood, Paper and Plastic sheets from Packing Material

1 Waste Segregation and disposed through verified recycler


April 20, 2015


Stage-II : Commercial setup Implementation

Hazardous waste Category:

Waste from Project Activity

S.NO Project Item/ Activity Frequency Unit Quantity Type Total Qty Processing Mode

(kg) (kg/yr)

1 Combustion Choke Refractory

Once 1250 Gen Solid Waste - Earth from excavation & Debris from foundation

250 Recycled by the supplying manufacturer

2 Ceramic Insulation Waste

Once 1000 From project activity of Heat exchanger & Pipeline Insulation

500 Reprocessing through Authorised agency

3 Ceramic Insulation Waste

Once in 5 Yrs 7500 From project activity of Heat exchanger & Pipeline Insulation

replacement

500 Reprocessing through Authorised agency

Waste from Operations

S.NO Equipment Name Capacity Flow rate Installed Motor

Power

Lubrication Oil/ Grease Qty

Rejected

Oil/ Grease Qty Rejected

(KW) (kg/day) (Kg/yr)

1

Tail Bas Blower- 4Nos

8550 Nm3/Hr

1260

Grease

Nil

14.4

2

Condensate Water Pump- 4Nos

3 Cum/hr

20

Oil Lubrication

Nil

4.8

3

Cooling water Pump-

4Nos

350 Cum/hr

300

Oil Lubrication

Nil

72

4

Roots Blower VSA Plant

2400 Nm3/hr

1100

Grease

Nil

7.2

5

Vacuum Bower VSA Plant

2400 Nm3/hr

225

Grease

Nil

3.6

6

Oxygen Booster Blower

2400 Nm3/hr

165

Grease

Nil

4.8 7

Instrument Air Compressor

65 Nm3/hr

90

Oil Lubrication

Nil

24

Total Power (KWH)

3160

Total Qty (kg/yr)

130.8


April 20, 2015


Non Hazardous Waste Category:

Project Item/ Activity

Frequency

Unit Quantity

Type

Total Quantity

Processing Mode

(MT)

(MT/yr)

4

Civil Construction waste

Project construction Phase only

250

Gen Solid Waste - Earth from excavation & Debris from foundation

35

Used in premises for land fill and levelling purpose

5

Metal Fabrication Erection


36

Steel Scrap from Fabrication of Structures and Pipelines

6

Disposal to verified Metal recyclers

6

New Item Procurement


4

Wood, Paper and Plastic sheets from Packing Material

1

Waste Segregation and disposed through verified recycler


2.11. Drawing representation for new facilities considered for feasibility

Drawing representing new equipments footprints in updated equipment layout has been

provided as Annexure-2, 3. Proposed installations next to Reactor Area & Cooling-tower

have been marked and provide for Project Stage-1.

A mark up Plot plan for proposed Stage-1 installation has been included as Annexure-1.

3. Project Schedule & Financials

3.1. Project Schedule

Preliminary plan for Stage –I & Stage-II of the Project has been prepared and outlined below,

execution of Project Stage-I is estimated to start by January 2016 and complete by Jun 2017

Followed by Project Stage-2 to complete by May 2019. A detail activity schedule is attached in

‘.mpp’ file format including activities of Stage-2 as Annexure-4 of attachments;

Project Milestones Stage-I

Nov-2014 Approval of AR for Initial investment

Dec- 2014 Start Phase1 Application for EC & CTE

Jan- 2015 Start of FEED and Cost Estimation

Dec-2015 End of phase1 obtain Environmental approval

Jan-2016 Start of Detail Engineering

Apr-2016 Ordering and Construction

Mar-2017 Project Commissioning

Project Milestones Stage-II

June-2017 Design finalisation for Commercial unit

Sep- 2017 Start AR Approval for Commercial Investment

Oct- 2017 Start of Start of Detail engineering for commercial unit

Jan-2018 Ordering and Construction

May-2019 Project Commissioning for Commercial unit

3.2. Project Financials

The total project expenditure for the ‘Stage-I of demonstration set up’ is estimated at 265.5mn

INR ($ 4.425mn) outlined below along with the total Estimate on Stage-II for Commercial Unit’

at 1200.01mn INR($ 20.01mn);


April 20, 2015


Total Project Expenditure estimated:

Stage-I

Stage-II

Financials (USD) Project Cost Project Cost

1 FEED Study + 30% DE PTG 1,50,000 NIL

2 Modify existing eq. 3,50,000

7,20,000

3 Eng. and Prof. Fees 5,00,000

9,00,000

4 Cap ex for New Equipment 10,70,333

1,27,49,333

5 Cap ex for E&I Installation 3,50,000

7,00,000

6 Piping & Erection 4,00,000

9,20,000

7 Civil + Structure 7,00,000

1,400,000

8 Contingency

5,00,000

1,500,000

VAT @12%

4,04,440

1,982,320

Total( in USD)

44,24,773

20,001,653

4. Conclusion

Proposed TGF project does not increase the existing operating unit’s production capacity, It

targets to reduce overall gaseous emission from plant and shall not alter water and land use

Status of the Patalaganga Unit.

The Project does not have a negative impact on any pollutants from the proposed change in

process operations requiring re-evaluation of environmental impact associated with of the

Patalaganga unit.

Project proposes development and commercialisation of a breakthrough environmental

technology for Carbon Black process and essential for long term sustainability.

*End of Report.

appendix i 6) (i) : raigad, maharashtra latitude - 21 deg...

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