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Pre-Feasibility Report

FOR

1500 TPD Ammonia(an-hydrous) Plant

At

Village Tondhare, Taloja MIDC, District

Raigad, Maharashtra

Project Proponent:

M/s Performance Chemiserve Pvt. Ltd. (PCPL, step down subsidiary of Deepak

Frtilisers and Petrochemicals Corporation Ltd)

Registered Office: Deepak Complex, Near Golf Course, Shastri Nagar,

Airport Road, Yerwada, Pune, Maharashtra

Proposed Environmental Consultant:

EQMS INDIA PVTLTD.

Corporate Office:304-305, III Floor, Rishabh Corporate Tower

Plot No. 16, Community Centre, Karkardooma Delhi-110092,

INDIA. +91-11-30003200

2018

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INDEX 1 EXECUTIVE SUMMARY ......................................................................................................................... 3

2 INTRODUCTION ..................................................................................................................................... 5

2.1 PROJECT & PROJECT PROPONENT .............................................................................................................. 5

2.2 BRIEF ABOUT PROCESS AND PLANT ............................................................................................................ 5

2.3 NEED FOR THE PROJECT .............................................................................................................................. 6

2.4 PLANT CAPACITY AND EMPLOYMENT GENERATION..................................................................................... 7

3 PROJECT DESCRIPTION ...................................................................................................................... 8

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ........................... 8

3.2 PROJECT LOCATION WITH CO-ORDINATES .................................................................................................. 8

3.3 MANUFACTURING PROCESS: ...................................................................................................................... 10

3.4 OFFSITE FACILITIES AND UTILITIES ............................................................................................................. 14

3.5 RAW MATERIAL REQUIREMENT WITH SOURCE OF SUPPLY AND MODE TRANSPORTATION ........................ 19

3.6 AVAILABILITY OF WATER ITS SOURCE ........................................................................................................ 19

3.7 ELECTRICITY & FUEL REQUIREMENTS ....................................................................................................... 21

3.8 LAND REQUIREMENT AND PLANT LAYOUT : ................................................................................................ 21

3.9 WASTE GENERATION, POLLUTION CONTROL AND ENVIRONMENTAL MANAGEMENT ................................ 23

3.9.1 Gaseous Emission and Pollution Control Measures ..................................................................... 23

3.9.2 Noise Environment .............................................................................................................................. 24

3.9.3 Waste water Generation & Management Plan ................................................................................ 24

3.9.4 Solid & Hazardous Waste Generation & Management Plan ......................................................... 24

4 SITE ANALYSIS .................................................................................................................................... 27

4.1 CONNECTIVITY ............................................................................................................................................ 27

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ....................................................................................... 27

4.3 TOPOGRAPHY WITH TOPOSHEET MAP ...................................................................................................... 27

4.4 HABITATION AROUND. .................................................................................................................................. 27

4.5 EXISTING LAND USE PATTERN ................................................................................................................... 27

4.6 EXISTING INFRASTRUCTURE ....................................................................................................................... 27

4.7 SOIL CLASSIFICATION AND SOIL INVESTIGATION WILL BE DONE DURING CONSTRUCTION ....................... 28

4.8 CLIMATIC DATA FROM SECONDARY SOURCES .......................................................................................... 28

5 PLANNING BRIEF AND INFRASTRUCTURE ..................................................................................... 29

5.1 PLANNING CONCEPT AND INFRASTRUCTURE PLANNING ............................................................................ 29

5.2 PROPOSED AMENITIES/FACILITIES ................................................................. ERROR! BOOKMARK NOT DEFINED.

6 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................................................ 32

7 PROJECT SCHEDULE AND COST ESTIMATE .................................................................................. 33

7.1 LIKELY DATE OF CONSTRUCTION STARTING AND COMPLETION ............................................................... 33

7.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT. .................................................................................................................................................................. 33

8 ANALYSIS OF PROPOSAL ................................................................................................................. 34

8.1 FINANCIAL &SOCIAL BENEFITS ................................................................................................................... 34

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1 EXECUTIVE SUMMARY

The proposed Ammonia (an-hydrous) Production plant of 1500 TPD capacity at village Ton

hare, Taloja MIDC, Tal-Panvel, Dist-Raigad, Maharashtra, is a greenfield project and is

being setup by M/s Performance Chemiserve Private Limited (PCPL) which is a step-down

Subsidiary of Deepak Fertilizers and Petrochemicals Ltd (DFPCL). PCPL was incorporated

in the year 2006 and is engaged in the business of drumming of chemicals like IPA and

Methanol. PCPL has been acquired by STL (Smartchem Technologies Limited a wholly

owned Subsidiary of DFPCL) and is being used as a Special Purpose Vehicle (SPV) for

setting up the facilities for manufacture of Ammonia. DFPCL and STL have entered into

arrangements for purchase of ammonia from PCPL.

Ammonia is the key input material to produce Nitric acid, Technical Ammonium Nitrate and

Phosphatic Fertilizers which are currently being produced at different plants of DFPCL/STL

in India.

Ammonia (anhydrous) is classified as straight nitrogenous fertilizer as per schedule to The

Fertilizer (Control) Order 1985, (Order No. No.11-3/83-STU, SCHEDULE I [See Clause

2(h) & (q)], PG: 29, point no 7) and will fall under Chemical Fertilizer -sector 5 (a) category

A, to the schedule of EIA notification 2006.

Ammonia, an inorganic chemical, is produced using Natural gas as feed stock. Natural Gas

contains mainly methane. The hydrocarbons are reformed to carbon dioxide and hydrogen

by means of steam at high temperature in the primary reformer. Nitrogen required for

synthesis reaction is obtained from air. The carbon dioxide and hydrogen stream are mixed

with the air, apart from reforming in the secondary reformer. Natural gas contains sulphur

traces which harms the catalyst in the reforming reactor and even consumes hydrogen by

undesired side reactions. A packed bed reactor is utilised for the removal of sulphur in the

Desulphurization unit for sulphur removal, if any and subsequently proceeded to produce

synthesis gas for ammonia production. Carbon mono oxide which is formed in the process

is converted to Carbon dioxide by using steam which result shift reaction producing

hydrogen. All the carbon dioxide produced is removed by the absorption process and

vented to atmosphere. The traces of carbon dioxide and carbon monoxide are converted to

methane by means of hydrogen on the catalyst like nickel Oxide in the Methenator reactor.

After Methanation gas is cooled first with water and then with Ammonia. The chilled gas

goes to the syngas drying process. Dried raw synthesis goes for cryogenic purification

process. The ammonia synthesis takes place in the catalyst reaction where Iron acts as the

catalyst. Ammonia liquefaction takes place in the compression absorption refrigeration

system to produce final product Ammonia.

The site is well connected by road and rail. The nearest National highway (NH 4) runs at

distance of 4.0 km from the project site. The nearest Navade railway station and Mumbai

Chhatrapati Shiva Ji International airport are located at an aerial distance of ~ 3.52 km in

(SW), and 40 Km (W) from the project site.

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Total plot area is about 50 acres. The proposed project has an employment potential of

about 3000 workmen during construction phase and about 150-200 during operation

phase. The estimated costs of this project is Rs. 2772.84 Crores.

The normal and peak power requirement for the plant is 12 MW and 14MW respectively.

The power will be sourced from proposed captive power plant (proposed installed capacity

of 16 MW) which will use steam turbine generator (STG). Gas Turbine generator or Gas

Engines will also be installed as stand. This will be used during start-up of the plant or

during maintenance of STG. The power requirement for lighting purposes and non-plant

buildings will be sourced from power grid (state electricity authorities). Additionally, D.G.

sets of capacity 3.0 MW will be installed for this power-backup. The total requirements of

fresh water for the proposed project during construction and operation phases are 300 KLD

and 14184 KLD respectively. The water demand will be met MIDC pipeline located next to

the proposed site.

Plant wastewater will be treated in Effluent treatment plant while domestic sewage will be

treated in sewage treatment plant. The treated waste water from the ammonia plant will be

sent to CETP conforming to CETP input norms. Gaseous emission from fuel burning,

consist of common pollutants like SO2, NOx, and PM would be discharged into

atmosphere through Stack of suitable height. Emission will meet the discharge standards

of NH3 < 175 mg/NM3 and SO2 <40 mg/NM3. Adequate systems shall be provided to

capture the emissions from process plants &comply with discharge standard. Green belt

will be developed covering >33% of the total project area. The inorganic hazardous

residues will be sent to common secure land fill (TSDF).

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2 INTRODUCTION

2.1 Project & Project Proponent

The proposed Ammonia (an-hydrous) Production plant at village Tondhare, MIDC Taloja,

Tal-Panvel, Dist-Raigad, Maharashtra, is a greenfield project and is being setup by M/s

Performance Chemiserve Private Limited (PCPL) which is a Subsidiary of Deepak

Fertilizers and Petrochemicals Ltd (DFPCL). PCPL was incorporated in the year 2006 and

is engaged in the business of drumming of chemicals, IPA and Methanol. PCPL has been

acquired by STL (Smartchem Technologies Limited a wholly owned Subsidiary of DFPCL)

and is being used as a Special Purpose Vehicle (SPV) for setting up the facilities for

manufacture of Ammonia. DFPCL and STL have entered into arrangements for purchase

of ammonia from PCPL and have also supported PCPL for availing borrowings for the

funding of the project

Performance Chemiserve Private Limited was registered at Registrar of Companies, Pune

on 01 March, 2006 and is categorized as Company limited by Shares and an Indian Non-

Government Company with its registered office at Deepak Complex, opp. Golf Course,

Shastri Nagar, Yerawada, Pune Maharashtra 411006, India. It currently has 2 Active

Directors namely Mr Ashok Praful Chandra Shah and Mr Raghunath Madhav Kelkar.

Ammonia is the key input material to produce Nitric acid, Technical Ammonium Nitrate and

Phosphatic Fertilizers which are currently being produced at different plants of DFPCL in

India.

Ammonia (anhydrous) is classified as straight nitrogenous fertilizer as per schedule to The

Fertiliser (Control) Order 1985, (Order No. No.11-3/83-STU, SCHEDULE I [See Clause

2(h) & (q)], PG: 29, point no 7) and will fall under Chemical Fertilizer -sector 5 (a) category

A, to the schedule of EIA notification 2006.

2.2 Brief about Process and Plant

The ammonia plant is based on the KBR Purifier™ Process, a low energy natural gas

reforming process offered and licensed by KBR. The plant is designed to produce 1500

MTPD warm as well as cold ammonia. Warm ammonia shall be directly used in process

plant. Cold ammonia at 6 kg/cm²g and -33 ºC to be sent to the Ammonia storage Tank,

located in DFPCL/STL existing manufacturing complex through pipeline.

All the components of the ammonia plant are based on well proven technology features. All

process equipment is single train. All major compressors are centrifugal compressors. The

Process Air Compressor, Synthesis Gas Compressor and Ammonia Refrigerant

Compressor are driven by steam turbines. The HP boiler feed water pump is normally

driven by a steam turbine drive but with motor as backup. Feed gas compressor, ID fan,

FD fan and all other pumps have motor drives. The process is detailed in next section on

Project description.

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2.3 Need for the Project

PCPL’s promoting companies (STL/DFPCL) requires Ammonia as input material to

produce Nitric acid, Technical Ammonium Nitrate and Phosphatic Fertilizers at its different

plants. Currently DFPCL produces about 390MTPD of Ammonia at its Ammonia plant in

Taloja against the total requirement of Ammonia of about 1,583 MTPD. The rest of the

Ammonia is being procured from domestic as well as international markets through JNPT

Port using DFPCL’s Ammonia Tank in JNPT. The proposed plant will help in bridging this

internal supply and demand gap of Ammonia.

STL/DFPCL’s Ammonia requirements are estimated to reach ~2200+MTPD by 2020. Out

of which, ~1,600 MT would be required at Taloja. The break-up of STL/DFPCL’s Ammonia

requirements by year 2020 is provided in Table 1given as below.

Table 1: Break-Up of DFPCL’s Ammonia Requirement by 2020

S. No. Particulars Ammonia Consumption (MTPD) – Year 2020

Taloja Requirements: 1. Industrial Chemicals (Nitric Acid) 201 2. Technical Ammonium Nitrate (TAN) 585 3. Fertilisers - ANP/NPK Plants 797 4. Sub-Total 1,583

Expansion Projects: 5. NA Complex – Dahej 150 6. TAN Complex – Paradeep 500

7. Sub-Total 650 Grand Total 2,233

Considering internal production of 390 MTPD, Ammonia import requirement post above

expansions will be 1,843 MTPD. While getting Ammonia from the world markets is not a

constraint, the Ammonia prices has been always the concern; prices being varying from

USD 160-170 per MT to USD 700 per MT on FOB Middle East basis. With this kind of

volatility in Ammonia prices, it is extremely difficult to manage profitability of downstream

businesses; particularly for DFPCL whose Ammonia dependence is so immense.

STL/DFPCL would also need to evaluate the requirements of additional Ammonia Port-

based tankages at JNPT to handle such large imports apart from increasing incidences of

demurrages on imports (given congestion at JNPT). It is also extremely challenging to

manage about 1,200-1,500 MTPD of Ammonia transfer from JNPT to Taloja site by road

tankers. In addition to transfer hazards, MIDC as well as other authorities are insisting on

DFPCL to reduce Ammonia truck movement within Taloja MIDC.

The proposed project will secure DFPCL/STL main Raw Material Ammonia and give

advantage to have better control on Ammonia import costs and also de-risk of transporting

ammonia by road from JNPT to Taloja.

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2.4 Plant Capacity and Employment Generation

a) Capacity: 1500 TPD Ammonia (An-hydrous) Plant

b) Employment Generation

Construction Period: About 3000 persons. Operation Period: About 150-200 Persons

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3 PROJECT DESCRIPTION

3.1 Type of Project including Interlinked and Interdependent Projects, if any

The proposed greenfield project is Ammonia (an-hydrous) production plant with installed

capacity of 1500 TPD at village Tondhare, Taloja MIDC, Tal-Panvel, Dist-Raigad,

Maharashtra. Ammonia plant along with associated offsite & utilities will be designed based

on latest technology in the world with lowest energy consumption. Natural Gas is the main

feed stock

The key input material natural gas will be sourced through existing GAIL pipeline running

close to the proposed project site. Transportation of finished product Ammonia will be

made through pipeline to DFPCL/STL other plant located nearby. There will be no storage

of ammonia at this plant. The ammonia transportation pipeline also does not attract

provision of Environmental clearance. There are no separate interlinked or interdependent

projects to the proposed project.

3.2 Project Location with Co-ordinates

The project site is located at Village Tondhare, Taloja MIDC, Tal-Panvel, Dist-Raigad,

Maharashtra. The approximate coordinate of project site are19° 4'20.94"N & 73°

7'58.11"E. The Google image with view of 10 & 15 km area around is shown at Figure – 1.

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Figure 1: Project Location

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3.3 Manufacturing Process:

Ammonia, an inorganic chemical, is produced using Natural gas as feed stock. Natural Gas

contains mainly methane. The hydrocarbons are reformed to carbon dioxide and hydrogen

by means of steam at high temperature in the primary reformer. Nitrogen required for

synthesis reaction is obtained from air. The carbon dioxide and hydrogen stream are mixed

with the air, apart from reforming in the secondary reformer. Natural gas contains sulphur

traces which harms the catalyst in the reforming reactor and even consumes hydrogen by

undesired side reactions. A packed bed reactor is utilised for the removal of sulphur in the

Desulphurization unit for sulphur removal, if any and subsequently proceeded to produce

synthesis gas for ammonia production. Carbon mono oxide which is formed in the process

is converted to Carbon dioxide by using steam which result shift reaction producing

hydrogen. All the carbon dioxide produced is removed by the absorption process. CO2

recovered from CO2 removal system shall be vented in to the atmosphere. The traces of

carbon dioxide and carbon monoxide are converted to methane by means of hydrogen on

the catalyst like nickel Oxide in the Methanator reactor. After Methanation gas is cooled

first with water and then with Ammonia. The chilled gas goes to the syngas drying process.

Dried raw synthesis goes for cryogenic purification process. The ammonia synthesis takes

place in the catalyst reaction where Iron acts as the catalyst. Ammonia liquefaction takes

place in the compression absorption refrigeration system to produce final product

Ammonia. The details of each step are elaborated further below:

Natural Gas supply

Natural Gas is used as feed stock and fuel for ammonia plant. Fuel gas is used for burner

of feed-stock pre-heater, primary reformer, Steam super-heater burner and start-up heater

in Ammonia Plant and Boiler/GTG in offsites. Feed gas goes to Desulphurization unit for

sulphur removal, if any and subsequently proceeded to produce synthesis gas for

ammonia production.

Desulphurization

Natural gas contains sulphur traces which harms the catalyst in the reforming reactor and

even consumes hydrogen by undesired side reactions. A packed bed reactor is utilised for

the removal of sulphur. Zinc oxide-based bed absorbs the sulphur.

Primary Reformer

Natural Gas contains mainly methane. The hydrocarbons are reformed to carbon dioxide

and hydrogen by means of steam at high temperature.

CH4 +H2O +Heat �---------------� CO + 3H2

CO +H2O + Heat �---------------� CO 2+ H2

Secondary Reformer

Nitrogen required for synthesis reaction is obtained from air, so the carbon dioxide and

hydrogen stream is mixed with the air, apart from reforming in the secondary reformer.

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Shift Conversion

Carbon mono oxide which is formed in the previous process is converted to Carbon dioxide

by using steam which result shift reaction producing hydrogen. High and low shift reactions

are used for this conversion process.

Carbon dioxide removal

All the carbon dioxide produced is removed by the absorption process, Absorption and

stripping towers recover most of the gas which shall be vented to atmosphere.

Methanation

The traces of carbon dioxide and carbon monoxide are converted to methane by means of

hydrogen on the catalyst like nickel Oxide in Methanator reactor. Heat is produced due to

exothermic reaction.

Drying

After Methanation gas is cooled first with water and then with Ammonia. The chilled gas

goes to the syngas dries, containing solid desiccants. Exiting these driers, the total of

water, Carbon dioxide and ammonia content is reduced to less than 1.0 ppmv on type 13X

zeolite (Alumino-silicate) bed.

Cryogenic Purification

Dried raw synthesis gas is cooled to about -129 °C in the cryogenic purifier by heat

exchange with purified syngas with purifier vent gas in the exchanger. The operation of the

purifier is controlled by a hydrogen analyser on the syngas, to maintain the exact ratio of

2.998 to 1 (hydrogen to Nitrogen).

Ammonia Synthesis

Iron acts as the catalyst in the catalyst in the reaction which proceeds for the formation of

ammonia

3H2 + N2�--------------� 2 NH3 +Heat

Ammonia Refrigeration

A compression absorption refrigeration system is used for the liquefaction & production of

ammonia. At 1 atm the boiling point of ammonia is -33 °C.

Detailed schematic diagram for ammonia production using natural gas as feed is given at

Figure 2. The broad material balance is also shown at Figure 3.

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Figure 2: Ammonia manufacturing process

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Figure 3: Ammonia Plant material balance

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3.4 Offsite facilities and utilities

The following offsite and utility facilities are planned for this project:

- Raw Water & Drinking water facility

- DM, CPU water plant

- Cooling Tower & Side steam filter

- Steam Generation

- Energy Generation

- Plant Air and Instrument Air generation facility

- Natural Gas Unit

- Effluent treatment Plant

- Reverse osmosis (RO) unit

- Emergency Diesel Generator

- Firefighting System

- Flare

Raw water and Drinking water Facility

Raw water from MIDC will be taken to a raw water reservoir located in the PCPL area we may

need to build our own. Raw water reservoir consists of under-ground RCC pit and transfer

pumps. Raw water from reservoir will be pumped to raw water storage tanks, where raw & fire

water is stored and pumped to DM-CPU plant, cooling water make up, drinking water system,

and service water & fire water network.

DM, CPU Water Plant

The DM Package will treat raw water to demineralized water of suitable quality to feed the

Polished Water unit. Polished water system will treat demineralized water along with condensate

recovered in ammonia plant and Off-site to provide uninterrupted supply of polished water of

suitable quality and quantity to feed the BFW System (Deaerator make-up), based on Mixed Bed

Technology.

Cooling Tower & Side steam filter

Cooling tower is designed for approach 4 °C and range of 10 °C with wet bulb temperature of 29

°C. Cooling tower circulation pumps supplies cooling water to various consumers located in

ammonia plant and offsite and utility. Suspended solid from cooling water are removed in side

stream filter through cooling water discharge header. Cooling Tower blow down and side stream

filter backwash will be transferred to Effluent Treatment Plant (ETP).

Steam Generation

The Steam Generation System includes all the equipment required to produce and deliver

required steam (48 kg/cm²g and 386°C) to Plant. The design capacity (100 TPH) ensures the

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continuous supply of steam in adequate quantity to achieve the starting-up, normal operation

and shut-down of the plant.

Energy Generation

The Power Generation System includes all the equipment needed to produce electrical energy

from the excess steam produced by the ammonia plant and auxiliary boiler. The steam Turbo-

generator has the capacity of 16 MW. Cooling water for the steam condenser is supplied by the

cooling water pumps, and in the event of a power failure, the Emergency Cooling Water Pump

will circulate cooling water to Auxiliary turbo generator systems (lubricant oil cooler, generator

cooler) and other.

The normal and peak power requirement for the plant is 12 MW and 14MW respectively. The

power will be sourced from proposed captive power plant (proposed installed capacity of 16 MW)

which will use steam turbine generator (STG) and natural gas as fuel. Gas Turbine generator or

Gas Engines will also be installed as stand by which also be used during start-up of the plant or

during maintenance of STG. The power requirement for lighting purposes and non-plant

buildings will be sourced from power grid (state electricity authorities). Additionally, D.G. sets of

capacity 3.0 MW will be installed for this power-backup

Plant & Instrument air Generation Unit

The compressor located in the ISBL is the main source of compressed air for the whole unit, with

a capacity of 850 Nm³ / h. The OSBL air compressor works as a backup of the ISBL air

compressor and guarantees the instrument air supply in case of failure of the same compressor.

Natural Gas Unit

The Natural Gas of the battery limit passes through the Natural Gas Measurement Unit and then through two paths: one going to the Ammonia Unit (U-3211) and another going to Steam/Power Generation Unit & Pilots of the flares burners.

Flare systems

Ammonia Flare is supplied for safe burning of vent streams containing ammonia vapors.

Discharge of synthesis gases, ammonia gases & PSV will be the source of Ammonia Flare.

Hydrocarbon Flare is provided for safe burning of the components without ammonia vapors.

Nitrogen is used as purge gas for the flare header to prevent air ingress. Fuel gas for burner

pilots must be Natural Gas in normal operation.

The distribution system for water, DM plant, steam generation and natural gas are shown at

Figure 4 to 6.

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Figure 4: Raw Water and Drinking Water distribution system

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Figure 5: DM Plant and Cooling Tower Distribution system

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Figure 6: Steam Generation and Natural Gas distribution System

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3.5 Raw Material requirement with source of supply and mode transportation

The estimated natural gas quantity of 1.30 MMSCMD. Gas quantity will vary depending on

heating value of Gas. This includes the gas requirement for power generation as well. The

normal and peak power requirement for the plant is 12 MW and 14MW respectively. The

power will be sourced from proposed captive power plant (proposed installed capacity of 16

MW) which will use steam turbine generator (STG) and natural gas as fuel. Gas Turbine

generator or Gas Engines will also be installed as stand by which also be used during start-up

of the plant or during maintenance of STG. The power requirement for lighting purposes and

non-plant buildings will be sourced from power grid (state electricity authorities). Additionally,

D.G. sets of capacity 3.0 MW will be installed for this power-backup. NG shall be sourced from

Domestic Gas or from aggregators/suppliers who in turn source LNG from overseas. The gas

will be transported to the plant to the existing GAIL gas pipeline next to nearby MIDC area

Finished Product Ammonia also shall be dispatched through pipeline to STL/DFPCL Ammonia

Storage Tank. No ammonia storage will be made at this plant. The storage at this plant will be

of few chemicals and other utilities as per details given below:

Details of Storage Tanks

Sr no

Tank Fluid Diameter(D) mm

Height (H) mm

Volume(V) m3

1. OASE solution storage tank OASE 11100 10900 1054.78

2. Raw Water Storage Tank Raw Water 26000 20000 10619

3. Potable Water Storage Tank Potable water 2500 5300 26

4. Demineralised-Water Tank DM Water 18000 14400 3664

5. Polished-Water Tank Water 18000 14400 3664

6. Process-Condensate Tank Condensate 12000 9600 1085

7. Off-Spec Condensed Tank Condensate 9000 9600 611

8. Diesel Storage Tank Diesel 3100 4000 30

9. Sodium Hydroxide Storage Tank Sodium Hydroxide

Total Volume: 15 m³ (Part of DM water / Polisher vendor Package)

10. Sulphuric Acid Storage tank Sulphuric Acid Total Volume: 15 m³ (Part of DM water / Polisher vendor Package)

3.6 Availability of Water its Source

The total water requirement of 300 KLD during construction stage and 14184 KLD during

operation phase will be sourced from MIDC Taloja. Approval for the same from MIDC is in

progress. Provision of water recovery, reuse is made through process optimizations and

reverse osmosis plant. The unit wise water consumption details with recovery and recycling

provision are shown at Figure 7.

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Figure 7: Unit wise water Consumption Details

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3.7 Electricity& Fuel Requirements

The normal and peak power requirement for the plant is 12 MW and 14MW respectively. The power will be sourced from proposed captive power plant (proposed installed capacity of 16 MW) which will use steam turbine generator (STG) and natural gas as fuel. Gas Turbine generator or Gas Engines will also be installed as stand by which also be used during start-up of the plant or during maintenance of STG. The power requirement for lighting purposes and non-plant buildings will be sourced from power grid (state electricity authorities). Additionally, D.G. sets of capacity 3.0 MW will be installed for this power-backup. The steam turbine generator will be installed for captive power generation. The Gas turbine generator will also be installed as stand by with heat recovery systems which is normally to be operated during start-up of the plant.

3.8 Land requirement and Plant Layout:

Total plot area is about 50 acres. The 33% area of the land is earmarked for green belt

development. The proposed site layout plan is shown in Figure8.

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Figure 8: Plant Lay Out

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3.9 Waste Generation, Pollution Control and Environmental Management

3.9.1 Gaseous Emission and Pollution Control Measures

Gaseous emission from fuel burning, consist of common pollutants like SO2, NO2, and PM would be discharged into atmosphere through Stack of suitable height. Process emission quality will be maintained as per the following standards:

NH3 < 175 mg/NM3 SO2 <40 mg/NM3

Adequate systems shall be provided to capture the emissions from process plants & maintain the emission quality as per recommended guidelines. On line analyzers for CO, O2, and NOx shall be provided for Auxiliary boiler flue gas/reformer Stack. The details of various emissions with source and discharge is given at below table:

Source Flow / Condition Components (Mol.

%) Discharge

Reformer Flue Gas

193810 kg/hr (Wet) MW=27.3 Temp: 121°C NOx (as NO2) < 90 mg/Nm³ (dry)

O2: 1.38 N2/Ar.: 72.13 CO2: 7.23 H2O: 19.26

Vented to Atmosphere through Stack

CO2 Vent 82,589 kg/hr Dry Basis CO2: 99.83 CH4: 0.01 N2: 0.02 H2: 0.14

Vented to Atmosphere

Deaerator Vent 500 kg/hr 129°C

Steam Vented to Atmosphere

Gas Turbine/Gas Engine

145,000 kg/hr 150°C

Component (% vol.) -N2: 74-78 - O2: 13-14 -CO2: 3-5 -H2O: 5-6 -Ar: 1

Vented to Atmosphere

Auxiliary Boiler 1,16,700 kg/hr Component (% vol.) -N2: 69.31 - O2: 1.68 -CO2: 8.76 -H2O: 19.35 -Ar.: 0.90 -SO2: 1 ppmv mg/Nm³ @ 3% O2 Dry NOx :108 Particulate: 10 SOx : 5

Vented to Atmosphere through Stack

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3.9.2 Handling of CO2 emissions: DFPCL is already operating CO2 liquification plant. With

the availability of CO2 from this plant the capacity of CO2 liquification plant shall be

further enhanced. In long term PCPL is in discussion with Oil Exploration Companies to

use CO2 for Enhanced Oil Recovery (EOR). CO2 EOR is being used by USA/Europe

and other developed countries to enhance oil recovery from oil wells. USA is recovering

over 300, 000 barrels of per day by CO2. Over 67 millions of CO2 is injected/stored every

year. Till date more than 1.5 billion barrel oil has been recovered via CO2 EOR in USA.

CO2 EOR helps in additional recovery of 25-30% from oil well which is not possible by

traditional way. CO2 EOR can be major turnaround for Indian Oil industries. If

implemented in India, it can substantially reduce India dependency for oil imports. PCPL

has already engaged a consultant who is assisting them to present case with Institute of

Reservoir Studies (IRS), Ahmedabad, ONGC/Director of Hydrocarbon to use CO2 for EOR

purpose in INDIA. In addition to reduction of Green House Gas (GHG) emission, CO2 EOR

will result in reduction of Indian oil export and consequently save foreign exchange.

3.9.3 Noise Environment

Installation of the plant machinery will be done after- due consideration to design noise levels and noise mitigation measures. Noise levels shall be within specified norms. As such, there will be no major sources of industrial noise. Provision of acoustic enclosures for DG set and personal protective equipment to workers will be made.

3.9.4 Waste water Generation & Management Plan

The main sources of effluent generation from the plant are process, washings, blow downs from cooling tower& boiler. The effluent will be treated in ETP with design capacity of 170 m3/hr. Treated water will be sent to CETP conforming to CETP inlet norms.

The domestic sewage which will be treated in STP with design capacity of 25m3/day. Treated water will be used for green belt development.

Typical flow diagram of ETP, Effluent Management and STP is given at Figure 9 to 11.

3.9.5 Solid & Hazardous Waste Generation & Management Plan

Solid and Hazardous waste generated from the process and utilities are waste oil from DG

sets, used batteries, catalyst, containers, empty drums. The containers will be used for

packing product, and or returned to the product seller or sold to authorized buyers after

detoxification. Catalyst will be sent back for reprocessing or recovery. Sludge generated

from ETP will classify under hazardous waste category and sent TSDF site.

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Figure9 : Typical flow diagram of ETP

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Figure10: Typical flow diagram of Effluent Management

Figure11: Typical flow diagram of STP

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4 SITE ANALYSIS

4.1 Connectivity

• The proposed site is part of MIDC Taloja, Raigad, Maharashtra

• The nearest city from the site is Panvel at a distance of 8.6km, SW

• The nearest railway station is Navade Road Railway Station 3.54km, SW

• The nearest airport is at Mumbai Chhatrapati ShivaJi International Airport: 40 km, (W).

• National Highway (NH-4) passes at 4.0km from the project site.

4.2 Land Form, Land Use and Land Ownership

About 50 Acre land parcels in and around MIDC Taloja is acquired through direct purchase

from land owners and MIDC. The use of land is being changed from Agriculture to Industrial

and the land parcels which are not part of Taloja MIDC shall be converted to MIDC as per

MIDC provisions.

4.3 Topography with Toposheet Map

The proposed industry is located at Latitude - 19° 4'20.94"N and Longitude - 73° 7'58.11"E.

Elevation above mean sea level is: 12 m. Toposheet (Annexure II) of the site is shown below.

The surrounding 10 km radius study area exhibits topographically flat terrain in the east and

relatively elevated terrain in the west side.

4.3.1 Habitation Around.

Nearest city Panvel has a population of 34,345 as per census 2011. It has more than 7,563

households of Maratha, Muslim, Buddhist, and also includes SC, ST, OBC and open

categories community. The village has basically an agrarian economy and industrial workers

and farming is the main occupation of the villagers. The local self-Government vests with a

Gram Panchayat having an elected body of headed by a Sarpanch.

4.4 Existing Land Use Pattern

The present land use of project area is partly industrial partly barren as though part land is

agricultural is not under cultivation and is surrounded by industries constructed on MIDC

allotted plots.

4.5 Existing Infrastructure

This is the green filed project, presently no infrastructure at the site and it will be developed as

per project planning. However, as the part of the land is MIDC land, it has access to MIDC

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infrastructure like roads, by-pass roads, over bridges, drainage, parking facility, airport and

electricity etc

4.6 Soil Classification and Soil Investigation will be done during Construction

Soil is texturally sandy loam to clay, yellowish in colour and under laid with Murom derived

from the basic rock basalt.

4.7 Climatic Data from Secondary Sources

The climate, if proposed area is characterized by hot summer and general dryness throughout

the year except the south west monsoon season. The year may be divided into three seasons.

The winter or cold season is from December to February, summer or hot season from March to

May. The south west monsoon season is from June to September, while October and

November constitute the post monsoon season. The annual average rainfall of the area is

3267 mm, month of May is the generally the hottest month of the year with average

temperature in between 32 to 37ºC. In cold season the area is sometimes affected by the mild

cold waves from north India and the minimum temperature may drop to 14 to 17ºC. The air is

generally dry except during the south west monsoon season, when the relative humidity is

high.

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5 PLANNING BRIEF AND INFRASTRUCTURE

5.1 Planning Concept and Infrastructure planning

5.1.1 Implementation Modalities

Implementation of project would involve several activities, of which some are pre-project

activities and others are related to physical execution of the project. The total project including

offsite facilities will be executed by PCPL on EPC basis with the help of reputed EPC

contractor who will provide services for detailed engineering, procurement, construction and

supervision of pre-commissioning & commissioning activities. License, know-how and basic

engineering already obtained from reputed process licensors KBR.

5.1.2 Pre-project Activities

The pre-project activities to be completed before the physical execution of the project are briefly enumerated below: a) Approval of the project by competent authority. b) Preparation of Environment Impact Assessment (EIA) study and clearance by Central

Pollution Control Boards (MoEF). c) Soil investigation work for ascertaining soil characteristics of the area identified within the

present boundary for location of the new facilities. d) Selection of EPC contractor. e) Appointment of Owner's Project Management team/Project Management Consultant. f) Mobilization of resources for construction facilities. g) Firming up of arrangement for supply of raw materials from concerned agency. h) Drawing up of a project implementation plan based on a network of activities All the pre-project activities mentioned above should be completed before the zero date of the project.

5.1.3 Physical Execution of the Project In order to perform the above activities, PCPL project management/PMC group consisting of highly competent, dedicated and qualified team of professionals with wide experience in the field to coordinate and follow-up so as to ensure completion of the project within projected time schedule Project Management PCPL/DFPCL has a formidable and highly dedicated project team of qualified engineers of various disciplines and a very skilled and experienced workforce. The team has recently executed projects of more than Rs. 1,000. In addition to PCPL team, Appointment of Project Management Consultant (PMC) shall also be appointed to act as the “Owner’s Engineer” for assisting the owner in overall supervision, progress monitoring / reporting, discharge of owner’s obligations and will be responsible for overall project management. Engineering and Construction

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EPC contractor will be responsible for carrying out Detailed Engineering of all facilities inside the complex and construction of the plant within budget, quality, Safety and given schedule. PCPL and PMC team will overview/monitor the performance of EPC contractor.

Commissioning Commissioning, sustained load run and guarantee test will be under the total responsibility of the licensor for the main plants. The owners will have to make arrangement for the supply of raw materials in adequate quantities. The utility requirements like power, water etc. would be kept ready to be supplied whenever necessary. The owner will also supply the necessary operators, engineers and skilled and non-skilled worker, who will be involved in the commissioning activities. Commissioning spares also will have to be procured before the commissioning activities start

5.2 Infrastructure planning

The entire complex shall consist of the following units:

1. Ammonia Plant

Offsites & Utilities:

2. Power receiving switch yard and sub-station

3. Steam Turbine Generator/GTG/Gas Engine

4. DG set

5. Complete firefighting system

6. Fire and smoke / gas detectors

7. Intake pipeline for water

8. Water treatment plant

9. Water reservoir

10. DM Water plant

11. DM Water tank

12. Condensate tank

13. Process water tank

14. Cooling Tower including pumps, motors / turbine and dosing system

15. Boilers and stack

16. Instrument air compressors, receivers and dryer

17. Inert gas generation unit

18. Effluent treatment plant including RO unit

19. Storage tanks including pumps for

• Caustic soda

• Sulphuric acid

• Diesel

20. Weighbridge

21. Flare stack

22. Buildings to house

a) Control system & Electrical switchgear

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b) Plant offices

c) Administrative offices & canteen

d) Workshop

e) Engineering & chemical stores

f) Security

g) Medical Centre

h) Rest rooms

23. Pipe racks & cable racks

5.3 Green belt

Sufficient area will be developed as greenbelt.

5.4 Power requirement & supply/ source

Captive power plant of 16 MW will be installed. PCPL will also take power from Local Grid.

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6 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

There is no R& R issue involved. The total land is being acquired by PCPL through direct

purchase and from MIDC.

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7 PROJECT SCHEDULE AND COST ESTIMATE

7.1 Likely Date of Construction Starting and Completion

The construction is likely to start after getting Environmental Clearance and/or NOC/CTE from

MOEF&CC/SEIAA/SPCB. Construction for the proposed project shall start immediately upon

approval and will be completed in 18 months.

7.2 Estimated Project Cost along with Analysis in Terms of Economic Viability of the

Project.

The estimated cost of the project is Rs. 2772.84 Cr.

7.2.1 Fixed Capital: Rs 2496.04 Cr

7.2.2 IDC: Rs 260.67 Cr

7.2.3 Working Capital Margin: Rs 16.13 Cr

7.2.4 Revenues: 1566.53 Cr

7.2.5 Profitability:

Post Tax Project IRR - 15.2 %

Payback period - 5 years

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8 ANALYSIS OF PROPOSAL

8.1 Financial &Social Benefits

• India as a country is dependent on Ammonia imports to large extent, particularly when

it comes to non-urea consumption. Most of the Ammonia is imported on east coast and

west coast from middle east and south east Asia. STL/DFPCL’s increased Ammonia

requirements necessitated the evaluation of the options of domestically manufacture or

meeting the additional Ammonia demand avoiding logistic costs & hurdles and

ammonia price volatility issues. The current tankage for Ammonia at JNPT is stressed

to handle/ sustain such large imports apart from increasing incidences of demurrages

on imports given congestion at JNPT port, which leads to inefficiencies in operations,

challenges related to steady-state availability of ammonia to down-streams plants and

would increase the cost of imported ammonia for DFPCL/ STL.

• Additionally, it is also extremely challenging to manage about 1,200-1,500 MTPD of

Ammonia transfer from JNPT to Taloja site. Since Taloja site does not have any rail link

with JNPT port and hence all the ammonia is being moved through road tankers only.

• In order to transport 1200 MTPD Ammonia around 100 tankers are required to be

delivered from JNPT port to Taloja site. The tanker turnaround time is 6-8 hours

depending on the traffic congestion between JNPT and Taloja and the availability of

tankers at right time is also an issue. The above turn-around time includes both loading

and unloading operations. Further, the time taken for unloading will depend on the

temperature at which the ammonia is being received. Moreover, tankers have to pass

through densely populated areas which cause concern to safety of habitat and

habitants. Hence, the proposed project will have positive environment impact in

reducing the ammonia transportation hazards and risks as there will be reduction in the

movement of more than 100 tankers per day

• Further, Project site will not have any requirements of Ammonia Storage Tank as all

ammonia manufactured will be transported by pipeline and used continuously in

STL/DFPCL downstream plants. Any additional/surplus Ammonia due to any problems

in downstream plants shall be stored in DFPCL/STL existing Ammonia Storage tanks.

Thus, project is not creating any additional hazard, which is strong positive from

perspective of EC approval.

• The demand for ammonia for non-urea fertilizer use i.e. for production of NPKs,

industrial chemicals viz. nitric acid, ammonium nitrate, amines, soda ash etc. is

estimated at about 20 lakh MT per annum. Presently, the growth of ammonia based

downstream industry is adversely affected due to ammonia pricing volatility, high

logistics costs, limited import infrastructure and transport hazards. As of date, the

demand supply gap for ammonia in the country is at a level around 52 lakh MT

(industrial + fertilizers together). Securing own Ammonia therefore for manufacturing of

the industrial chemicals and non-urea fertilizers s important for the sustenance and

growth of the industry and also reduce country’s import dependence of this vital bulk

chemical.

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• Ammonia is a source of nitrogen for growing plants. Every fertilizer contains nitrogen

either in the form of ammonia or compounds derived from ammonia. The

widespread uses of ammonia in agriculture was brought about by the green revolution,

which also involved development of high yielding crops and advances in pesticides. A

field that produced 20 bushels of corn in 1940 produces over 100 bushels today. While

high yield crops and pesticides have contributed to greater production, fertilizer has

been the most influential factor in driving the green revolution.

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ANNEXURE I- Google Image of Project Site

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ANNEXURE I (a)-Google Image of Study Area

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ANNEXURE II- Topo Map of Project Site