pre feasibility study for mibk plant_india

Pre Feasibility Report for the Proposed Methyl Iso Butyl Ketone Plant at Manali, Chennai by M/s Cetex Petrochemicals

PRE FEASIBILITY REPORT

1.0. EXECUTIVE SUMMARY

Tamil Nadu is the eleventh largest state in India by area and the seventh most populous

state in India. The state is ranked 6th among states in India according to the Human

Development Index as of 2011. It is the second largest state economy in India as of

2012. The state has the highest number (10.56 per cent) of business enterprises and stands

second in total employment (9.97 per cent) in India. Tamil Nadu was ranked as the third

most developed state in India based on a "Multidimensional Development Index". Tamil

Nadu covers an area of 130,058 km2 (50,216 sq mi), and is the eleventh largest state in

India. The bordering states are Kerala to the west, Karnataka to the North West

and Andhra Pradesh to the north. To the east is the Bay of Bengal and the union territory

of Puducherry. The southernmost tip of the Indian Peninsula is located in Tamil Nadu. At

this point is the town of Kanyakumari which is the meeting point of the Arabian Sea, the

Bay of Bengal, and the Indian Ocean. The south boundary of India is Kanyakumari, Tamil

Nadu.

Tamil Nadu is mostly dependent on monsoon rains, and thereby is prone to droughts when

the monsoons fail. The climate of the state ranges from dry sub-humid to semi-arid. The

state has three distinct periods of rainfall:

Advancing monsoon period, south west monsoon from June to September, with

strong southwest winds;

North east monsoon from October to December, with dominant north east winds;

Dry season from January to May.

The annual rainfall of the state is about 945 mm (37.2 in) of which 48 per cent is through

the north east monsoon, and 32 per cent through the south west monsoon. Since the state is

entirely dependent on rains for recharging its water resources, monsoon failures lead to

acute water scarcity and severe drought.

1.1. About Manali

Manali is an Industrial town and Municipality in Thiruvallur district in the Indian state

of Tamil Nadu. It is located in north of Chennai City. Manali is a Northern Suburb of


Chennai city. It borders Tiruvottiyur to the east, Mathur MMDA to the west, Kodungaiyur

to the south, 100 ft road to the North. The main through fares in the area is Kamarajar

Salai, Chinna mathur Road, Parthasarathy Street.

Figure 1: Location of the Project Site


1.2. Industries located in Manali

Madras Fertilizers Limited (MFL)

Manali Petro Chemical Ltd(MPL)

Futura Polymers Ltd

Cetex Petro Chemicals Ltd

Tamil Nadu Petro products Limited(TPL)

Sriram Fibres Ltd (SRF)

Madras Rubber Factory (MRF)

Kothari chemicals and pesticides

Balmer lawrie & co

Infra tanks and polymers

The Hunstman Polyurethenes

ICI limited

Chennai Petroleum Corporation Limited (CPCL)(formerly MRL)

2.0. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

Cetex Petrochemicals Limited was established in 1988-1989 by RPG group of companies

as a green field petrochemical plant at the petrochemical zone at Manali, Chennai. The

plant to manufacture Methyl Ethyl Ketone (MEK) and its intermediate, Secondary Butyl

Alcohol (SBA) was set up with Technology from Edeleanu, Gmbh, a German company

belonging to the then Deutsche Texaco group.

The current installed capacity of the plant is 10000 MT per year for MEK/SBA. After

initial difficulties, the plant stabilized operations from 1991 and has been a leading player

in the MEK market in India since then. M/s Cetex petrochemicals limited have applied for

Environmental Clearance (EC) for the expansion of MEK plant, with a total project cost of

38 Crores. The details of existing and proposed products are given below in Table 2-1.

2.1. Identification of the project and Project Proponent

Cetex is also proposing to add a new manufacturing facility to produce Methyl Iso Butyl

Ketone (MIBK) and Methyl Iso Butyl Carbinol (MIBC) to further increase its Indian

market presence and more in the International market in the Asian region. Presently there


is no manufacturer of MIBK or MIBC in India and all the country’s requirement is

currently being met by imports, mainly from Taiwan, USA and Korea. The current

demand of MIBK in India is estimated to be around 20000 MT per year.

Table 1: Details of Existing and After Expansion Capacities

S.No. Name of the product Existing Capacity

(TPA)

Capacity after expansion

(TPA)

1 Methyl Ethyl Ketone 5000 10000

2 SecondaryButyl Alcohol 6000 12000

Fine Chemicals

3 Cinnamic Alcohol 180 1080

4 Anisyl Alcohol 180 276

5 Styrallyl Alcohol 180 228

6 Styrallyl Acetate - 150

7 Oximone - 20

8 Phenyl Ethyl Alcohol - 96

9 Tertiary Butyl

Cyclohexyl Acetate - 200

Total 11540 24050

2.2. Brief Description of Nature of the Project

Cetex has already identified critical equipments and technology for the manufacture of

MIBK from Shell, USA at a cost of 20% of the original cost. The surplus utilities

available from the MEK/SBA plant would be utilized for the MIBK plant.

During the manufacture of MIBK co-products viz. Methyl Isobutyl Carbinol (MIBC), Di

Acetone Alcohol (DAA) and Hexylene Glycol (HG) are also produced. These co-

products have market abroad and as the existing MEK/SBA customers also consume

MIBK and MIBC, Cetex will be in a better position to market these products. Apart from

this by-products viz. Shell Froth-10 (SFR10) and Oxygenated Solvent Hydrocarbon Blend

Stock (OSHBS) are also generated, which will be sold in the market at fuel cost. The

proposed capacity of each product is given below in Table 2.


Table 2: Proposed Capacity of MIBK Plant

Methyl Isobutyl Ketone (MIBK) 30000 MT p.a.

By Products

Methyl Isobutyl Carbiol (MIBC) 10000 MT p.a.

Di Acetone Alcohol (DAA) 5000 MT p.a.

Hexylene Glycol (HG) 5000 MT p.a.

The current Indian demand for MIBK is around 20000 MT per annum and the entire

requirement of the country is being imported. The demand for MIBK in India is expected

to reach 35000 MT per annum in 2015. As there is no manufacturer in India / South East

Asia, Cetex will be in an advantageous position to market entire requirement of this

region.With FTA (Free Trade Agreement) between ASEAN countries, those countries will

prefer supplies from India to take advantage of duty benefits.

MIBK is primarily used in solvent applications in the following areas:

Paints & Coatings-Primarily in nitrocellulose lacquers and solvent-borne

Coatings

High-solid coatings-which require stronger solvents

Replacement for ester- based solvents-to reduce volatile organic Compound (VOC)

levels and achieve lower solvent levels

Pesticide solvent

Extraction operations-to refine mining distillates, dewax mineral oils, purify fatty

acids, and manufacture penicillin and other antibiotics

Other solvent application- as purge solvent in the cleanup of paint equipment in

automotive plants in the formulation of inks and adhesives

Rubber additive- for rubber anti-ozonants

Acetylenic surfactants

MIBC is primarily used in solvent applications in the Ore Beneficiation for rare metals

and also as a co-solvent along with SBA in the manufacture of the Lube Oil Additive, Zinc

Di Alkyl Di Thio Phosphate, which is internationally dominated by the Lube Additive

Manufacturing Majors Chevron Oronite, Lubrizol, Afton and Infineum International.


DAA finds application as a specialty solvent in Paints, particularly NC Lacquers. HG also

finds application as a specialty solvent in the Pharma & Personal Care Products sector.

2.3. Need for the Project and its Importance to the Country and or Region

Production of some MIBK derivatives is moving out of the developed regions. Some

applications (especially antiozonants) are moving to Asia, particularly China. MIBK

consumption for antiozonants is forecast to grow at an average annual rate of 8.5% in Asia

(excluding Japan) and approximately 1.0–1.5% in the United States and Western Europe.

MIBK consumption will grow at an average rate of 3.8% per year from 2011 to 2016,

driven by demand in Asia. The following pie chart shows country wise consumption of

MIBK and MIBC.

The current Indian demand for MIBK is around 20000 MT per annum and the entire

requirement of the country is being imported. The demand for MIBK in India is expected

to reach 35000 MT per annum in 2015. As there is no manufacturer in India / South East

Asia, Cetex will be in an advantageous position to market entire requirement of this

region. With FTA (Free Trade Agreement) between ASEAN countries, those countries

will prefer supplies from India to take advantage of duty benefits.

2.4. Demand Supply Gap Sector wise consumption of MIBK in the World in 2011 is given below:

Figure 2: World Consumption of MIBK


Figure 3: World Consumption of MIBK-2011

Figure 4: World Consumption of MIBC-2011

Solvent applications consume the majority of MIBK in most regions and consumption is

expected to stay relatively flat in the developed regions. There may be some reformulation

in certain MIBK applications because of environmental regulations, but cost pressures

may limit reformulation activity.


MIBC's major application is in the manufacture of lube oil additives, followed by its use

as the principal flotation frothier in treating copper and other ores. Surface coatings make

up a minor portion of MIBC consumption. World MIBC statistics are difficult to estimate,

but overall, MIBC will experience positive growth in lube oil applications and as a

flotation frothier (especially in actively mined regions). Consumption of MIBC

Worldwide is forecast to grow at an average annual rate of 2.5% during 2011–2016.

Indian demand is expected to grow at an average 7% to 8% per year and China’s MIBK

demand is rising by 12 % annually (source: IHS Chemical).

Table 3 : Global & Domestic MIBK Capacity

Company Location Capacity

(KMT PA) Remarks

Arkema La Chambre,France 15

Carboclor Campana,Argentina 8 Closed

Celanese LaCangrejera,Mexico 50

Dow Chemical Institute, West Virginia,

US 35

Eastman Chemical Kingsport,Tennessee,US 9

Jilin Chemical Jilin, China 30

Kumho P& B Yosu,South Korea 30

Kyowa Hakko Yokkaichi,Japan 15

Lee Chang Yung

Chemical Lin Yuan, Taiwan 40

Mitsubushi

Chemical Mizushima, Japan 20

Mitsui Chemical Ichihara,Japan 30

Iwakuni,Japan 30 MIBC swing plant

Ningo-Oceanking

Chemical Ningbo, China 15

Rhodia Brasil Paulinia,Brazil 25

Sasol solvents Sasolburg, South Africa 60

Shell Chemical Berre,France 25 Closed since 2009,


bought by Lyondell

from Shell and

subsequently closed.

Shell Chemical Pernis, the Netherlands 45

Showa Denka Tokuyama, Japan 20

Taizhou

Petrochemical Taizhou, China 20

MIBK and MEK

plants in one site

Zhenjiang LCY

General Chemical Zhenjiang, China 25

Total Capacity 514

The commissioning of the 30,000T/year second MIBK plant by Sasol in South Africa in

2009 is the latest market investment in MIBK. Technology for the new plant is

proprietary to Sasol and includes some improvements to the technology used in the

existing plant (feedstock is backward integrated into upstream production activities). The

Indian domestic market size is given in Table 4 below.

Table 4 : Indian MIBK Imports (Domestic Market size)

Sl..no Country 2007-08

(MT)

2008-09

(MT)

2009-10

(MT)

1 Canada - - 0.375

2 China 62 141 174

3 France - 18

4 Germany 1 3 4

5 Japan 93 307 1265

6 Korea-N - 35 -

7 Korea-S 283 3898 1750

8 Netherlands 575 498 1549

9 Philippines - - 3

10 Singapore 633 118 -

11 S Africa 4290 2605 3002

12 Spain 60 62 70


13 Taiwan 1014 4701 4878

14 Thailand - - 29

15 UAE 52 21 -

16 USA 7556 2506 3973

Total 14619 14913 16697

Considering the industrial growth, the MIBK demand in India is expected to reach 35000

MT in 2015.

Table 5 : MIBK Consumers in India

Sl.No. Customer Qty in

MTPA

1 Lanxess India 2500

2 Micro Inks Limited 1250

3 Maruti Petrochem 400

4 NOCIL Limited 7000

5 Kansai Nerolac Paints 1000

6 DIC India Ltd. 1250

7 Vividh Rasayan 400

8 Flint Group 1000

9 Asian Paints 1200

10 Ranbaxy Fine Chemicals 200

11 Snocem Paints 200

12 Positive Packaging 750

13 Paper Products Ltd. 250

14 Others - approx. 2600

TOTAL 20000

2.5. China MIBK Demand

Methyl Iso Butyl Ketone (MIBK) prices in Asia may continue to rise on the back of tight

supply and stable-to-firm upstream acetone values, Regional MIBK producers have been

hiking prices to keep up with a steady increase in their feedstock costs. Tight supply in the

domestic Chinese market and a further strengthening in the prices of feedstock acetone

have lent support to regional MIBK makers’ progressively higher price targets.


Domestic Chinese MIBK prices increased driven by limited spot availability and

progressively higher acetone values. “MIBK prices have risen really because acetone

prices have been strengthening, and [the extended shutdown of the Taizhou plant] has

curbed supply. Consumption of MIBK by the key rubber chemical and tyre sector, which

accounts for 40% of China’s MIBK demand, has returned to the higher levels.

3.0. PROJECT DESCRIPTION WITH PROCESS DETAILS

Cetex petrochemicals propose to produce MIBK commercially using acetone and

hydrogen as raw material in a three step route. The key raw material in the manufacture of

Methyl Isobutyl Ketone (MIBK) is Acetone and shall be imported as bulk via M/s Mitsui

& Co. at Ennore port and stored at port storage tanks. The same will be transported via

tankers to factory site.

The first step in process is Acetone converted to Diacetone alcohol (DAA) by Aldol

condensation, followed by dehydration of DAA to Mesityl oxide (MO) and mild

hydrogenation of Mesityl oxide to MIBK. MIBK on further hydrogenation yields MIBC.

3.1. Diacetone alcohol (DAA) section

Aldol condensation of acetone takes place in the presence of strong base as catalyst

resin

Formation of DAA is an equilibrium reaction which is favored at low temperature

below 15°C

Conversion of Acetone to DAA is mainly governed by the quality of acetone feed

(Since, low converter activity is due to aldehydes, oxides and acids in recycle or

fresh makeup stream), temperature of the feed to the converters and the activity of

the catalyst.

Stabilizing agent (here Citric acid is used) is added to the product stream at a point

downstream from the converters before it is heated for distillation to prevent the

reversion of DAA to Acetone


Two stage converters with inter-stage cooling system provided, since the reaction

is slightly exothermic

For maintaining low temperature of converter feed, butane chilling system will

been employed at both before and after first stage converter

Product effluent from second stage converter after dosing stabilizing agent, fed to

Acetone recycle column to separate unreacted acetone and DAA product

Crude DAA separates at bottom of recycle column and taken out to MO section

Top distillates of recycle column condensed and recycled back to converters along

with fresh makeup

3.2. Mesityl Oxide (M.O) section

Mesityl oxide is produced by dehydration of Crude DAA in the presence of acid

catalyst (2% Sulphuric acid) along with water as dehydration product in DAA

dehydration column

Reaction take place at 125 – 130 °C in liquid phase

M.O along with light components is distilled out as top product

Bottoms sent to M.O flash kettle for flash separation of M.O from unreacted DAA

Heavier component at the bottom of M.O flash kettle is sent to recovery column

for neutralization and recovery of DAA and acetone from aqueous phase

Top distillate from dehydration column is sent to M.O distillation column for

separation of M.O from acetone and water

Acetone along with water is getting separated out from M.O in M.O distillation

column as top distillate

M.O and some quantity of water stays at bottom in M.O distillation column is

pumped to M.O Phase separator for separation of Organic at top and Aqueous at

bottom in separator

Top organic phase is taken as reflux for DAA dehydration Column and a part is

stored in intermediate storage tank for MIBK / MIBC section

3.3. Methyl Isobutyl Ketone (MIBK) section

Mesityl Oxide along with hydrogen is superheated and fed to MIBK reactors

MIBK is formed by mild hydrogenation of Mesityl Oxide in the presence of

Palladium based catalyst


MIBK reaction is taking place in vapour phase @ 175 °C and 4 barg

Crude MIBK is then sent to distillation section for purification and to obtain

finished MIBK product

During MIBK reaction, MIBC also formed as by product, separated in distillation

section and sent to MIBC section

3.4. Methyl Isobutyl Carbinol (MIBC) section

Crude MIBK shall be feed to MIBC reactors along with hydrogen after

superheated to 170 °C

MIBC is formed on intense hydrogenation of MIBK in the presence of Nickel

based Catalyst

MIBC reaction is taking place in vapour phase @ 170 °C and 11 barg

Crude MIBC is then sent to distillation section for purification and to obtain

finished MIBK product

Heavy ends (High boiling components) formed during reaction are separated in

distillation section and taken as by-product

3.5. Hexylene Glycol (HG) section

A part of Fin. DAA is fed to HG reactor along with Hydrogen after DAA purified

via distillation

Raney nickel is used as catalyst since the reaction is liquid phase

Crude HG obtained from reactor is taken for purification section

High boiling and unreacted DAA are separated and fed back into system, finished

HG is taken as product

3.6. Recovery Section

Purpose of this section is to recover organics that come from the water cuts

collected from all other sections

Organic separated in phase separator is fed back in corresponding purification

section and aqueous phase is taken out and sent to effluent treatment plant


3.7. Utilities

For process heat supply, high pressure steam shall be supplied from boiler having

capacity of 25 tons per hour

For high temperature applications such as superheating required before

MIBK/MIBC reactor, thermic fluid/oil shall be supplied from thermic fluid heater

having capacity of 4 Million Kcal / day

Common stack for boiler and thermic fluid heater will be installed as per norms

Fuel for Boiler & Thermic fluid heater will be design as multi-fuel fired with

Wood, Biomass and COAL.

A coal based captive power plant is proposed for 2 MW.

Figure 5: Process Flow Diagram

3.8. Product Specifications

Product Name: Methyl Iso Butyl Ketone


Chemical name: MIBK, isobutyl methyl Ketone, isopropyl acetone,2 methyl -4-

Penatanone,4 methyl-2-Pentanone,4 methyl pentane-2-one;2 methyl pentane-4-one. CAS

Number: 108-10-1

Table 6 : Methyl Iso Butyl Ketone - Product Specifications

Property Unit Specification Test Method

Purity Wt% 99 Min GC

Water Wt% 0.10Max ASTM D 1364

Color Pt-Co 10 Max ASTM D 1209

Acidity as acetic

acid Wt% 0.010 Max ASTM D 1613

Appearance - Clear & FFSM ASTM D 4176

Density@ 20

degree Celsius g/ml 0.799-0.844 ASTM D 4052

Non Volatile

residue g/100ml 0.002 Max ASTM D 1353

Distillation, IBP Degree Celsius 114 Min ASTM D1078

Distillation, DP Degree Celsius 117 Max ASTM D1078

Storage and distribution: MIBK is stored in drums and/or in bulk tanks and transported by

tanker trucks. It has a specific gravity of 0.802 and a low flash point of 16 degree Celsius

which makes it highly flammable. It should be therefore stored in a cool, dry, well-

ventilated area that is free from risk of ignition. For transportation purposes, MIBK is

classified as a packing group 2, hazard class 3, and is an irritant.

3.8.1. Uses of MIBK

Solvent for high solids coatings

Solvent for traffic paints

Solvent for automotive coatings

Solvent for industrial maintenance coatings and marine coatings

Solvent for textile coatings

Solvent for leather finishing

Solvent for nitrocellulose lacquers

Solvent for acrylic and vinyl-acrylic resins for adhesives


Solvent for de-waxing mineral oil

Extraction solvent for antibiotics and other pharmaceuticals

Extraction solvent for metals separation

Extraction solvent for tall oil soap purification

Carrier solvent for pesticides

Chemical intermediate

3.8.2. Uses of MIBC

It is used as flotation- frothier for treatment of copper ores, coal, tar and sand

mining.

It is used as a latent solvent for coatings to reduce viscosity and improve flow and

leveling.

It is used as coupling solvent for waterborne coatings.

It is used in talc processing

Solvent for dyes and stains

Solvent for oils, esters, gums, natural resins, phenolic, waxes

Solvent for nitrocellulose lacquers and ethylcellulose lacquers

Production of plasticizers.

Hydraulic Fluid Diluent

Process solvent for soaps

It is primarily used to manufacture lube oil additives

Chemical intermediate for higher alcohols, surfactants

3.8.3. Uses of Di Acetone Alcohol

It has special utility in coatings industry to dissolve cellulose acetate to give

solutions high tolerance for water.

It is also used as feed material for production of hexylene glycol, an Acetylenic

surfactant.

3.8.4. Uses of Hexylene Glycol

It is used primarily in industrial coatings (45%) and as a chemical intermediate

(20%).


It is used as a selective solvent in petroleum refining

Component of hydraulic fluids

Solvent for inks and cosmetics

It is also used as a cement additive

3.9. Raw materials required

3.9.1. MIBK – Raw-material

Major raw material required for producing MIBK/MIBC is Acetone. Acetone is

manufactured in India by Hindustan Organic Chemicals (HOC), Cochin but due to various

constrains, the plant cannot supply Cetex’s demand of Acetone. However, Acetone is

freely available from Global Scale Producers across the world at competitive rates.

Acetone is a co-product during the manufacture of Phenol and the Phenol demand

worldwide is increasing over 10% every year. Acetone availability therefore will be easy

and competitive.

SABIC is one of the largest manufacturers of Acetone located in Saudi Arabia, who may

offer competitive long term formula based pricing. There are also other suppliers of

Acetone internationally and Cetex can have very good price over acetone on rate contract

basis or by other means. The import will be received at Ennore port, Chennai and as the

site is not very far away from the port, handling and transportation will be cheaper. Hence,

the company does not foresee a problem in competitive sourcing of Acetone or Logistics.

Table 7 : Proposed (MIBK plant)

S.No. Raw Material Requirement, MT

(Annual) Source

1 Acetone 60,000 MITSUI & Co. pte ltd. (Via Import), Hindustan Organic Chemicals (Cochin)

2 Hydrogen 1500 CPCL (Manali) & In-house generation

3.9.2. Mitsui & Co.

Cetex has already started the dialogue with Mitsui & Co (Asia Pacific) Pte. Ltd., Asia’s

largest manufacturer / trader of Acetone, located at Singapore, for the supply of Acetone


to Cetex and supply of MIBK to their various stock points. Cetex is negotiating with them

for the supply of Acetone with a formula linked to the MIBK price. Cetex has signed a

MoU for supply of Acetone to Cetex as well as MIBK to Mitsui.

3.10. Availability of Water, Sources, Energy/ Power requirement

Water requirement will be met through CMWSSB .Water requirement for the project for

existing and expansion is as follows,

Water Requirement

Existing and Expansion: MEK &Fine chemical manufacturing unit – 845 KLD

Expansion: MIBK Plant – 600 KLD

Energy Source:

From TNEB and proposed coals based 2 MW power plant

Power Requirement

Existing (MEK Expansion and Fine Chemical unit): 0.95 MW

Expansion (MIBK): 1.8 MW, 2 MW Captive Power plant either Coal/Biomass

DG Sets

Existing : 1500 KVA x 1 No

Expansion: 1500 KVA x 1 No


4.0. SITE ANALYSIS

4.1. Site Connectivity

The proposed CETEX site is well connected to State Highway 104 and the nearest railway

station is Thiruvottiyur 3 Km, and the nearest airport is Chennai International Airport 25

Km.

4.2. Topography Along With the Map

In general the site topography is to be convex in relation to the surrounding so that the

rain-water is drained away from the site naturally. So, a site with convex topography can

be regarded as excellent and that with concave topography is regarded as bad. The

proposed site is flat and the Topo map is given in Annexure 4.

4.3. Existing Land Use Pattern

The projects involving clearance under Coastal Regulation Zone Notification, 1991 shall

submit with the application a C.R.Z map duly demarcated by one of the authorized

agencies, showing the project activities, w.r.t. C.R.Z (at the stage of TOR) and the

recommendations of the State Coastal Zone Management Authority (at the state of EC).

Simultaneous action shall also be taken to obtain the requisite clearance under the

provisions of the C.R.Z Notification, 1991 for the activities to be located in the CRZ.

4.4. Soil classification

The soil nature is totally clay type, hence, for the construction of basement work pile

foundation is recommended. The approximate soil bearing capacity is 25MT/Sq. meters.

The elevation of the site is about 6.7 meters above the sea level. The humidity of the wind

varies from 35% to 87%.The site has to be totally fenced or walled, and the same has to be

done at a later stage.

4.5. Climate Data from Secondary Sources

The city gets most of its seasonal rainfall from the north–east monsoon winds, from mid–

October to mid–December. Cyclones in the Bay of Bengal sometimes hit the city. The

highest annual rainfall recorded is 257 cm in 2005. Prevailing winds in Chennai are

usually southwesterly between April and Octoberand northeasterly during the rest of the


year. Historically, Chennai has relied on annual monsoon rains to replenish water

reservoirs, as no major rivers flow through the area. Chennai has a water table at 2 meters

for 60 percent of the year. The normal climatologically table is given in Table 8.

Table 8 : Climate data for Manali, Chennai, India (1901–2011) Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year

Record high °C 33 37 39 43 46 45 41 40 39 39 34 33 45

Average high °C 28.8 30.5 32.6 34.7 37.4 37.3 35.3 34.5 33.9 31.8 29.4 28.4 32.88

Average low °C 20.4 21.1 23 25.8 27.6 27.4 26.1 25.5 25.2 24.2 22.6 21.2 24.17

Record low °C 14 15 17 20 21 21 22 21 21 17 15 14 14

Precipitation mm 22.5 2.2 4 7.7 43.9 55.9 100.3 140.4 137.3 278.8 407.4 191.1 1,391.50

Avg. precipitation

days 1.3 0.4 0.3 0.6 1.4 4 6.9 8.5 7.1 10.6 11.7 6.3 59.1

Mean

monthly sunshine

hours

269.7 268.8 294.5 291 279 204 186 192.2 198 195.3 183 204.6 2,766.10

5.0. PLANNING BRIEF

Population and the distance of the populated areas from the sites should be considered for

evaluating the sites. For this reason the populations of villages within 10 km radius and

their distances from the site have to be considered.

While Transportation, the collection personnel shall wear gloves, masks, rubber gum boots

while unloading the same PPE shall be used. While loading the wastes into incinerators,

the staff shall wear helmet, goggles, masks, asbestos temperature resistant gloves, and

boots. While segregation, they shall ensure protection from needle pricking and shall use

hard gloves. Any needle stick injury shall be attended to immediately; they shall

thoroughly wash the injured area using soap/ detergent and then apply disinfectant to the

area. Further to this they shall get checked up for infections. Health check-up and

vaccinations will be done as per standard prescribed by health department and records

maintained.


5.1. Land Use Planning (Break up along with green belt)

Land Break up for Existing MEK, MEK Expansion and MIBK Expansion is given in

Please refer Annexure 3.

5.2. Amenities/Facilities

The site is well connected with the facilities such as hospitals and schools nearby areas.

Apollo Hospital: 4.7 km SE

Government Ophthalmic Hospital: 11.6 km S

Madras Medical Mission: 13.9 km SW

Thiruvottiyur Church of Christ: 2.5 km SE

Thyaga Raja Swamy Temple: 2.3 km SE

Thiruvottiyur mosque: 2.7 km SE

6.0. PROPOSED INFRASTRUCTURE

6.1. Industrial Area (Processing Area)

The proposed project is the production of Methyl Iso Butyl Ketone (MIBK), and the

breakup of the chemical unit operations equipment is detailed in table 8.

Table 9 : Breakup of the chemical unit operations equipment

S.

No Tag No. Equipment

Item

nos.

Capacity

(each item) Remarks

1 E - 4109 Acetone Chiller 1 335,160 Kcal/hr Reduce the

acetone feed temp

below ambient

2 V-4101

to 4106

DAA First stage converters 6 2.78 m3 Anion resin

catalyst packed in

converters for

production of

DAA from

Acetone (DMK)


3 E – 4110 Interstage cooler 1 262,080 Kcal/hr Cools down first

stage product

temp. before

sending it to

second stage

4 V – 4107

to 4112

DAA Second stage converters 6 2.78 m3 Anion resin

catalyst packed in

converters for

production of

DAA from

Acetone (DMK)

5 C – 4101 DMK Recycle column 1 114” D x 27’ H

; 10 Trays

114 inch Dia. and

45 feet tall

6 V – 4113 DMK Recycle Column OVHD

Accumulator

1 11.65 m3

7 T – 4102 50% Citric acid tank 1 56.8 m3

8 T – 4101 10% Caustic storage surge tank 1 33.3 m3 Regeneration of

Anion resin

catalyst

9 E – 4108 Converter product pre-heater 1 335,160 Kcal/hr

10 E – 4107,

4106

DMK Cooler 2 370,433 Kcal/hr

11 E – 4112 DMK recycle column feed

preheater

1 3,981,600

Kcal/hr

12 E - 4111 DMK recycle column bottoms

cooler

1 206,640 Kcal/hr

13 E – 4101 C – 4101 reboiler 1 3,049,225

Kcal/hr

14 E – 4102

to 4105

C – 4101 Overhead condensers 4 6,375,600

Kcal/hr

Each condenser

have 6,375,600

Kcal/hr heat duty

15 C – 4201 #1 MO (Mesityl Oxide) Column 1 20 Trays Size:


4’ top/5’ Bot. Dia.

55’-8” Height

16 E – 4202 C – 4201 Column reboiler 1 1,360,800

Kcal/hr

17 E – 4201 C – 4201 Flash kettle 1 302,400 Kcal/hr

18 T – 4202 MO Catalyst (2% Sulphuric acid)

make up tank

1 15.17 m3

19 C – 4202 #2 MO Column 1 25 Trays Size: 5’ D x 47’-

8” H

20 V – 4202 C – 4202 overhead accumulator 1 4.77 m3

21 V – 4201 C – 4202 bottoms phase separator 1 4.47 m3

22 E – 4205 C – 4202 Column Tops condenser 1 1,461,600

Kcal/hr

23 E – 4204 C – 4202 Column reboiler 1 378,000 Kcal/hr

24 E – 4203 C – 4202 Column bottoms cooler 1 148,680 Kcal/hr

25 C – 4203 MO Recovery column 1 10 Trays Size: 30” D x 28’-

4.5/8” H

26 V – 4203 C – 4203 Column accumulator 1 2.08 m3

27 V – 4204 C – 4203 Column phase separator 1 Size: 3’ D x

12.75’ L

28 E – 4207 C – 4203 Column Tops condenser 1 126,000 Kcal/hr

29 E – 4308 MO vaporizer 1 352,800 Kcal/hr

30 V – 4304 MO Separator 1 Size: 42”D x

21’-9” H

31 E – 4309 MO Superheater 1 37,800 Kcal/hr

32 E – 4310,

4311

MIBK Reactor – jacketed hot oil

circulation

2 1,348,200

Kcal/hr

MO is fed after

superheated to

reaction temp.

into reactor to

form MIBK

33 E – 4312 MIBK reactor feed / product

interchanger

1 272,200 Kcal/hr

34 E – 4313 MIBK reactor condenser 1 302,400 Kcal/hr


35 V – 4305 MIBK reactor accumulator 1 4.47 m3

36 E – 4316 MIBK reactor hot oil cooler 1 403,200 Kcal/hr

37 C – 4301 MIBK lights end removal column 1 50 Trays Size: 6’D x 90’-5”

H

38 C – 4302 MIBK Finishing column 1 50 Trays Size: 5’D x 84’-6”

H

39 V – 4301 C – 4301 column accumulator 1 8.70 m3

40 V – 4303 C – 4301 column side cuts phase

separator

1 8.70 m3

41 E – 4306 C – 4301 Side cuts cooler 1 378,000 Kcal/hr

42 E – 4302 C – 4301 Column condenser 1 1,663,200

Kcal/hr

43 E – 4301 C – 4301 Column reboiler 1 2,142,000

Kcal/hr

44 E – 4304 C – 4302 Column condenser 1 831,600 Kcal/hr


46 E – 4307 C – 4302 Column bottoms cooler 1 5040 Kcal/hr

47 E – 4305 C – 4302 Column tops cooler 1 88,200 Kcal/hr

48 E – 4408 MIBK Vaporizer 1 352,800 Kcal/hr

49 V – 4404 MIBK Separator 1 2.31 m3

50 E – 4409 MIBK Superheater 1 100,800 Kcal/hr

51 E – 4410,

4411

MIBC Reactor – Hot oil jacketed 2 478,800 Kcal/hr

52 E – 4416 MIBC reactor hot oil cooler 1 514,080 Kcal/hr

53 E – 4412 MIBC reactor feed / product

interchanger

1 277,200 Kcal/hr

54 E – 4413 MIBC reactor condenser 1 428,400 Kcal/hr

55 V – 4405 MIBC reactor accumulator 1 4.47 m3

56 C – 4401 Crude MIBC column 1 65 Trays Size: 6’ D x 84’ H

57 E – 4401 C – 4401 reboiler 1 645,120 Kcal/hr

58 E – 4402 C – 4401 column tops condenser 1 504,000 Kcal/hr

59 V – 4401 C – 4401 Column overhead

accumulator

1 3.75 m3


60 C – 4402 MIBC finishing column 1 50 Trays Size: 4’-6” D x

10’-7”H


62 E – 4404 C – 4402 Column tops condenser 1 504,000 Kcal/hr

63 V – 4402 C – 4402 Column accumulator 1 2.08 m3

64 E – 4405 C – 4402 Column vent condenser 1 8820 Kcal/hr

65 E – 4407 C – 4402 Column bottoms cooler 1 26,712 Kcal/hr

66 V – 4403 MIBC Vacuum pump K.O pot 1 0.15 m3

67 E – 4406 Vacuum pump seal liquid cooler 1 4427 Kcal/hr

68 V – 4505 Feed (DAA) surge vessel 1 0.42 m3

69 V – 4506 HG Reactor 1 3.14 m3 Agitated vertical

jacketed vessel,

with internal

filter. Cooling

load: 88200

Kcal/hr

70 V – 4503 HG reactor accumulator 1 2.27 m3

71 V – 4504 HG reactor vent KO Pot 1 0.23 m3

72 E – 4509 Crude HG Cooler 1 31,248 Kcal/hr

73 E – 4508 Vent cooler 1 18,144 Kcal/hr

74 E – 4501 C – 4501 Column feed preheater 1 156,240 Kcal/hr

75 C – 4501 Lights Ends Column 1 20 Trays


77 E – 4502 C – 4501 Partial condenser 1 91,980 Kcal/hr

78 E – 4503 C – 4501 Column Condenser 1 112,896 Kcal/hr

79 V – 4501 C – 4501 Column Reflux

accumulator

1 1.2 m3

80 C – 4502 Heavy Ends Column 1 Structured

Packing

Size: 4’ D x 44’-

3” H

81 E – 4505 C – 4502 Column Reboiler 1 274,680 Kcal/hr

82 E – 4506 C – 4502 Column Condenser 1 347,760 Kcal/hr

83 V – 4502 C – 4502 Reflux Accumulator 1 1.2 m3

84 E – 4507 C – 4503 Feed cooler 1 73,584 Kcal/hr


85 C – 4503 DAA Treater (Stabilising) Column 1 Hollow column Size: 3’ D x 19’-

9” H

6.2. Greenbelt

Development of green belt was conceived at the beginning; Green belt already exists all

along the plant boundary. For the proposed facility area also 33 % of the total area will be

covered under greenbelt. A significant area will be covered under lawn and eco

beautification nursery will be developed within the premises The species selected will be

as per the management requirement and CPCB guidelines. The distance between two

plants will be been kept minimum for thick belt Regular maintenance of green belt The

proposed facility will also be covered with a green belt to minimize the pollution.

6.3. Industrial Waste Management

The Hazardous wastes will be treated as per Hazardous Wastes (Management and

Handling) Rules, 1989 and its subsequent amendments. Electronic waste will be processed

as per E-waste Management and Handling Rules 2011, The Batteries (Management and

Handling) Rules, 2001. Bio Medical Waste will be processed as per Bio-Medical Waste

(Management and Handling) (Amendment) Rules, 2003 and its subsequent amendments.

6.4. Solid Waste Management

General office E waste is expected with a maximum quantity of 100 kg/year and will be

sent to the TNPCB Authorised E-waste recyclers. Treated sewage sludge will be used as

manure for green belt development inside the plant premises and sludge arising during

effluent treatment will be sent to the nearest TSDF, Gummidipoondi. MoU made for the

existing plant with nearby TSDF for waste disposal.


7.0. REHABILITATION AND RESETTLEMENT (R&R PLAN)

No R&R is required because industry is in notified industrial area, Manali.

The company has formed Cetex Foundation to take care of the CSR activities. The main

objective is to help the underprivileged for Health & Education. The Foundation has

donated to Voluntary Agencies engaged in the Health Care Segment with the motto to

help poor. The Foundation has also conducted Health Camps for all associates including

contract workers.

More than 1000 Trees were planted last year in Cetex factory and outside. The company

has also donated for the higher education of children belonging to the employees &

contract workers.

8.0. PROJECT SCHEDULE AND COST ESTIMATES

Financial projections for the existing operations as well as the expansion project intended

by the Company have been worked out and given in Table 10.

Table 10 : Cost Estimates of the project

S. No Particulars Cost in Indian

Rupees

1 Total cost of the project 135 Cr. Rs.

2 Capital cost for environmental

pollution control equipment, etc 5 Cr. Rs.

9.0. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

During the construction phase of the project, direct and indirect employment opportunities

associated with developments will be provided to the residents of the surrounding areas,

this would improve socio-economic environment of the project area. There will be

cumulative positive impact on the environment in terms of better solid waste management.

More Employment opportunities will be created and aesthetics of the area will be


improved. Demand for housing will increase. Ancillary industries, shops, small hotels etc

will come up.

The company has formed Cetex Foundation to take care of the CSR activities. The main

objective is to help the underprivileged for Health & Education. The Foundation has

donated to Voluntary Agencies engaged in the Health Care Segment with the motto to

help poor. The Foundation has also conducted Health Camps for all associates including

contract workers.

More than 1000 Trees were planted last year in Cetex factory and outside. The company

has also donated for the higher education of children belonging to the employees &

contract workers.


Figure 6 : Site Photographs

Proposed site for MIBKproject

Proposed site for MIBK project




Entrance of Cetex Petrochemicals, Manali


Figure 7 : Google Image


Figure 8 : Google Image 500m radius


Figure 9 : Google Image 1 km radius


Figure 10 : Google Image 5km radius


Figure 11 : Google Image 10 km radius

pre feasibility study for mibk plant_india

Documents

manali manali

indian state of tamil

state ranges

populous state

developed state

north east monsoon

north west

south west monsoon