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DEEPAK PHENOLICS

LIMITED

Prefeasibility Report for Addition in the Existing Plant by M/s. Deepak Phenolics Limited on Plot No. 12/B/1, GIDC Dahej, Taluka Vagra, District Bharuch

JANUARY 2017

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

DEEPAK PHENOLICS LTD PFR FOR ADDITION IN THE EXISTING PLANT

AT DAHEJ GIDC EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | JANUARY 2017 2

DEEPAK PHENOLICS LIMITED

Prefeasibility Report for Addition in the Existing Plant by M/s. Deepak Phenolics Limited on Plot No. 12/B/1, GIDC Dahej, Taluka Vagra, District Bharuch © Kadam Environmental Consultants (‘Kadam’), January, 2017

This report is released for the use of the M/s. Deepak Phenolics Limited, Regulators and relevant

stakeholders solely as part of the subject project’s Environmental Clearance process. Information

provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used

for any other purpose without the written consent of Kadam.

PROJECT DETAILS

Name of

Publication

Prefeasibility Report for Addition in the Existing Plant by M/s. Deepak Phenolics Limited

on Plot No. 12/B/1, GIDC Dahej, Taluka Vagra, District Bharuch

Project Number 1523088110 Report No. 1 Version 1 Released January, 2017

Prepared &

Managed By

Dhara Patel &

Jitixa Upadhyay Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91 265 300106

Delhi / NCR

SPAZE IT PARK, Unit no. 1124, 11th Floor, Tower B 3, Sector 49, Near Omaxe City Centre mall,

Sohna Road, Gurgaon -122 002 (Haryana)

E: [email protected];T: 0124-4242430; M:+91-98998-04300

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.

Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it

is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims

any liability resulting from the use or application of the information contained in this report. The information is not

intended to serve as legal advice related to the individual situation.

mailto:[email protected]

mailto:[email protected]




CONTENTS

1 EXECUTIVE SUMMARY ................................................................................. 5

1.1 PLANT FEATURES AND PRODUCTION CAPACITY .......................................................... 5

1.2 ENVIRONMENT ............................................................................................ 6

1.2.1 Water .............................................................................................. 6

1.2.2 Effluent Generation, Treatment and Disposal ............................................... 6

1.2.3 Power .............................................................................................. 6

1.2.4 Air Emission ....................................................................................... 6

1.2.5 Hazardous Water Generation and Disposal .................................................. 6

1.3 SUBMISSION .............................................................................................. 6

2 INTRODUCTION .......................................................................................... 7

2.1 BRIEF DESCRIPTION OF THE PROJECT .................................................................... 7

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION .............................................. 7

2.3 GLOBAL MARKET, DOMESTIC MARKET AND DEMAND SUPPLY GAP ....................................... 7

2.4 IMPORT VS. INDIGENOUS PRODUCTION ................................................................ 13

2.5 EXPORT POSSIBILITY ................................................................................... 13

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ........................... 13

3 PROJECT DESCRIPTION ............................................................................. 14

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ......... 14

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY &

PROJECT LAY OUT) WITH COORDINATES ........................................................................ 14

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................ 16

3.4 SIZE OR MAGNITUDE OF OPERATION................................................................... 17

3.5 TECHNOLOGY AND PROCESS DESCRIPTION ............................................................ 18

3.6 RAW MATERIALS ....................................................................................... 19

3.7 PROCESS DESCRIPTION ................................................................................ 19

3.8 ADDITIVES AND CHEMICALS ............................................................................ 19

3.9 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ......................... 19

3.9.1 Transportation details of Raw Materials .................................................... 19

3.10 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN

20

3.10.1 Water consumption ............................................................................ 20

3.10.2 Power Requirement ............................................................................ 20

3.11 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT

/DISPOSAL ...................................................................................................... 21

4 SITE ANALYSIS ......................................................................................... 24

4.1 CONNECTIVITY ......................................................................................... 24

4.2 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................... 24




4.3 TOPOGRAPHY (ALONG WITH MAP) ...................................................................... 24

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING

AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE

FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC. SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE

HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION

SHOULD BE GIVEN. ............................................................................................. 24

4.5 EXISTING INFRASTRUCTURE ............................................................................ 25

4.6 SOIL CLASSIFICATION .................................................................................. 25

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................... 25

4.7.1 Temperature .................................................................................... 25

4.7.2 Wind ............................................................................................. 26

4.7.3 Rainfall ........................................................................................... 26

4.7.4 Cloud Cover ..................................................................................... 26

4.7.5 Humidity ......................................................................................... 26

4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................... 26

5 PLANNING BRIEF ...................................................................................... 27

6 PROPOSED INFRASTRUCTURE .................................................................... 28

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................ 28

6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ......................................................... 28

6.3 GREEN BELT ............................................................................................ 28

6.4 SOCIAL INFRASTRUCTURE .............................................................................. 28

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/WATER WAYS ETC) ............. 28

6.5.1 By Road .......................................................................................... 28

6.5.2 By Rail ........................................................................................... 28

6.5.3 By Air ............................................................................................ 28

6.5.4 By Water ........................................................................................ 29

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ...................................... 29

6.7 SEWAGE SYSTEM ....................................................................................... 29

6.8 INDUSTRIAL WASTE MANAGEMENT ..................................................................... 29

6.9 SOLID WASTE MANAGEMENT ............................................................................ 29

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE .......................................................... 29

7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................... 30

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING

HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) ......... 30

8 PROJECT SCHEDULE AND COST ESTIMATE .................................................... 31

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE

PROJECT TO BE GIVEN) ......................................................................................... 31

9 ANALYSIS OF PROPOSAL ........................................................................... 32

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA ......................................................... 32




1 EXECUTIVE SUMMARY

1.1 Plant Features and Production Capacity

Deepak Phenolics Limited (formerly known as Deepak Clean Tech Limited) is a wholly owned

subsidiary of Deepak Nitrite Limited.

Proposed production capacity is given as below;

S.

No. Name of Product

Production Capacity in MT/ Month

Remarks As per EC

received Addition

Amendment

Required

Products

1 Phenol 16667 4723 21390 The design

capacity and

plant machinery

will remain

same.

Amendment in

capacities are

considered

based on full

utilization of

design capacities

considering

design margin.

A

communication

from licensor

confirming the

proposed

capacity

utilization is

received.

2 Cumene 25000 2807 27807

3 Acetone 10000 2834 12834

4 Propane Return Stream 0 4367 4367

5 Alpha Methyl Styrene

(AMS) 500 313 813

6 Benzene Rich Cut 175 -48 127

7 Recovery Column Bottoms /

Heavies 730 1428 2158

8 Acetone Purge 0 17 17

9 Lights Hydrocarbon Purge 0 35 35

10 Poly- iso propyl Benzene

(PIPB) Drag 0 88 88

11

Hydrogenation Products :

Cyclohexanone,

cyclohexanol, Methyl Iso-

butyl Ketone (MIBK),

Isopropyl Alcohol (IPA)

2650 14836 17486

12 Cyclohexanol Rich Stream 0 257 257

13 Acetone Rich Stream 0 289 289

14 Acetophenone 0 353 353

15 Wet IPA 0 250 250

Total 55722 32549 88271

16 Power (MW) 42 0 42

17 Steam (TPH) 100 100 200




1.2 Environment

1.2.1 Water

Existing water requirement is 2048 KLD (Environment Clearance received) and additional water

requirement will be 7026 KLD. So after amendment total water consumption will be 9074 KLD. Out of

9074 KLD, fresh water requirement will be 7814 KLD. Source of water for proposed amendment will

be GIDC water supply.

1.2.2 Effluent Generation, Treatment and Disposal

Existing wastewater generation as per Environment Clearance received is 949 KLD which is discharged

to GIDC drain for final disposal. Additional wastewater generation will be 1260 KLD which will be

recycled. So after amendment total wastewater generation will be 2209 KLD out of which 1260 KLD

will be recycled and 949 KLD will be discharged to GIDC drain for final disposal.

1.2.3 Power

DPL has an applied for 19 MW (20 MVA) power connection to Dakshin Gujarat Vij Company Ltd.

(DGVCL). A captive power plant of 42 MW and 1 DG Set of Capacity of 1500 kVA as a backup option.

Only 1 DG Set of Capacity of 1500 kVA is proposed in amendment and after amendment DPL will have

2 DG sets of Capacity of 1500 kVA each along with proposed connection load of 19 MW to be supplied

by Dakshin Gujarat Vij Company Ltd. (DGVCL) and captive power plant of 42 MW.

1.2.4 Air Emission

ESP is attached to existing Cogen Plant Boiler and Boiler for phenol & Cumene. ESP will be attached to

proposed Boilers. Adequate stack height is provided to stacks of boiler, incinerators and D.G Set. Coal/

Lignite/NG/HSD/FO will be used as fuel.

1.2.5 Hazardous Water Generation and Disposal

Due to proposed amendment hazardous waste generation will increase. Hazardous waste generated

from the existing plant operation will be disposed in nearby Waste Management landfill facility. The

unit has membership of M/s. Saurastra Enviro Projects Pvt. Ltd. (SEPPL) for Integrated Common

Hazardous Waste Management Facility.

1.3 Submission

In the light of the above, we would like to state that the proposed amendment at Dahej would have in

place systems, procedures and hardware to ensure that all guidelines for protecting the environmental

emission norms are followed and its operation has no adverse impact on environment

DEEPAK PHENOLICS LTD PFR FOR ADDITION IN THE EXISTING

PLANT AT DAHEJ GIDC PROJECT DESCRIPTION


2 INTRODUCTION

2.1 Brief Description of the Project

Deepak Phenolics Limited (formerly known as Deepak Clean Tech Limited) is a wholly owned

subsidiary of Deepak Nitrite Limited.

The proposed Cumene/Phenol project is located at Dahej, Gujarat INDIA. Technology and engineering

services are being provided by Kellogg, Brown & Root International Inc. (KBR), USA for Phenol and by

UOP LLC, USA for Cumene. The EPCM contractor is ThyssenKrupp Industrial Solutions India Pvt. Ltd.

(formerly known as UHDE, India) for both Phenol and Cumene. This is being set up as per MOU

with the Government of Gujarat during Vibrant Gujarat Summit 2011.

The company has also decided to put up Cyclohexanone plant, Methyl-Isobutyl-Ketone (MIBK) plant,

Isopropyl Alcohol (IPA) plant and Acetophenone Plant at Dahej, Gujarat within the same plot. This is

being submitted for Vibrant Gujarat Summit 2017. The technology licensor selection is under

progress for these plants.

2.2 Need for the project and its importance to region

Table 2-1: Product and importance

S. No Product Application

1 Phenol Building Block for Phenolic, Resins, BPA, Epoxy resins, Agrochemicals, Alkyl Phenol,

Pharmaceuticals

2 Acetone Building Block for BPA, MIBK, MIBC, IPA, Pharmaceuticals

3 AMS

Used as a co-monomer in polymerization process, acrylonitrile-butadiene-styrene

(ABS) resins, perfumes, antioxidants, drying oils and lubricating oils, For production

of low molecular weight polymers

4 Cyclohexanone Consumed in production of precursors to Nylon 6,6 and Nylon 6. for production of

adipic acid, for production of Cyclohexanone Oxime

5 Methyl-isobutyl-ketone

Used as a chemical intermediate, a solvent for manufacturing paints, rubbers,

pharmaceuticals, other chemicals, and industrial cleaners, used in the

semiconductor industry, Food and Drug Administration (FDA)-approved indirect

food additive for adhesives, paper and paperboard, and polymers

6 Isopropyl Alcohol

Used as a solvent for coatings or for industrial processes, pharmaceutical

applications, used as a chemical intermediate, used as a gasoline additive, used as

a cleaning fluid, A major ingredient in "gas dryer" fuel additives, As a biological

specimen preservative

7 Acetophenone Used for fragrance in soaps and perfumes, as a flavoring agent in foods, solvent for

plastics and resins, Used as a flavoring, solvent, and polymerization catalyst

2.3 Global Market, Domestic Market and Demand Supply Gap

Phenol: Global market

In the next five years, global phenol capacity is expected to increase by a total of 12%, with Northeast

Asia accounting for about 72% of this capacity increase, to raise its share of total global capacity to




46% in 2020. Overall, phenol production has increased at an average annual rate of 1.8% since 2010.

Production growth is expected to increase at a higher average rate of 2.7% per year. The following

pie chart shows world consumption of phenol globally.

Source: HIS

Phenol: Domestic market

Phenol Market in India

Phenol Capacity: 85 KTA (HOC 45 KTA & SII 40 KTA)

Phenol Production: 75 KTA

Phenol Demand: 300 KTA

Phenol Imports: 225 KTA

A key point to be noted is that the proposed phenol plant would substitute an equivalent volume

which currently being imported into India. Therefore, marketing uncertainties are minimal.

India will be a very close second after China in terms of demand growth, with phenol consumption

increasing at an average rate of 7.7% per year over the next five years. Imports into India have also

grown significantly, at 16% per year over the past five years.

Phenol: Demand supply gap

In India there is a gap of 225 KTPA Phenol which is covered through import. Out of 300 KTPA Cumene

produced, about 270 KTPA will be captively used for phenol production and rest will be sold. There is

enough gape in country for this small quantity of Cumene sale.

Acetone: Global market

Globally, production growth of acetone is expected to increase at a higher average rate of 3.0 % per

year. For Asia region, Acetone growth rates will be 4% per year. The below figure shows the world

acetone demand based on the application.




Source: RAJEEV M. PANDIA, “THE PHENOL-ACETONE VALUE CHAIN: PROSPECTS AND

OPPORTUNITIES”, SEOUL, 2013

Acetone: Domestic market

The demand for acetone in the domestic market has almost doubled in the last decade. Due to static

production capabilities, the dependency of the country on imports has increased as domestic

production struggles to keep up with the demand. A huge disparity in domestic demand and supply

status is visible due to lack of any planned projects for acetone production. Since a majority of

domestic acetone is fulfilled through imports from other countries, acetone pricing is vulnerable to

international demand, supply situation and volatility in the international market. Acetone Market in

India

Acetone Capacity: 51 KTA (HOC 27 KTA & SII 24 KTA)

Acetone Production: 45 KTA

Acetone Demand: 200 KTA

Acetone Imports: 180 KTA

Phenol Plant Clear Case for India

Phenol Demand in India – 300000 MT/ Annum

Acetone Demand in India– 200000 Mt / Annum

Expected growth of Phenol is 8%

No manufacturing facility for BPA& Polycarbonate in India

Import Duty on Phenol in India – 7.5%

Import duty on Cumene in India – 5%




Phenol and Acetone are key precursors to a host of other chemicals which are highly correlated to the

GDP and Income growth taking place in India. Expected growth rate in India of Phenol / Acetone will

be around 8% CAGR for next few years.

Acetone: Demand supply gap

Acetone demand in India is 200 KTPA against production of 45 KTPA and there is sufficient gap for

production.

Cyclohexanone: Global market

Cyclohexanone is captively consumed on site for the production of adipic acid and caprolactam (over

95%), so only a small amount enters the world’s trade markets.

Less than 4% is consumed in markets other than nylon. This includes use as solvents for paints and

dyes, in pesticides, and as an intermediate for pharmaceuticals, films, soaps, and coatings.

The following pie chart shows world consumption of Cyclohexanone:




Much of this demand is sustained by its consumption in caprolactam (69% of total demand in 2014),

which is the main precursor to supply the expansive nylon production. Other chemical demand

includes cyclohexylamines; isobornylcyclohexanol, which is used in the perfumery industry; polyester

polyols; and other small chemical applications.

Cyclohexanone: Domestic Market

Cyclohexanone Capacity: 0 KTPA

Cyclohexanone Production: 0 KTPA

Cyclohexanone Demand: 35 KTPA

Cyclohexanone Imports: 35 KTPA

Methyl-Isobutyl-Ketone (MIBK): Global market

Total consumption of MIBK grew at an average annual rate of almost 7% during 2011–14. World

MIBC statistics are difficult to estimate, but overall, MIBC will experience positive growth in lube oil

applications and as a flotation frother (especially in actively mined regions). Consumption of MIBC

worldwide is forecast to grow at an average annual rate of 2.5-3.0% during 2014-19.

The following pie chart shows world consumption of MIBK:

Consumption of MIBK is expected to stay relatively flat in the developed regions. Its use in rubber

antiozonants has grown over the last three years (from approximately 25% of total MIBK consumption

in 2011 to 32% in 2014 in the major consuming countries/regions), driven by increased tire production

Asia.

Stronger demand and higher feedstock costs helped boost prices for MIBK and MIBC throughout 2010

and 2011 after the economic downturn.

Methyl-Isobutyl-Ketone (MIBK): Domestic Market

MIBK Capacity: 0 KTPA

MIBK Production: 0 KTPA

MIBK Demand: 30 KTPA

MIBK Imports: 30 KTPA




Isopropyl alcohol (IPA): Global market

Consumption of industrial-grade IPA (as a direct solvent and for chemical derivatives) accounted for

77% of total IPA demand in the major consuming regions in 2014, and direct solvent applications

accounted for approximately 63% of total industrial-grade demand.

The following pie chart shows world consumption of isopropyl alcohol:

The IPA market will continue to be oversupplied during 2014-19, especially with global demand

growing at an estimated average annual rate of 1.9% through 2019 and capacity growing at an

average annual rate of 2.9%.

Isopropyl alcohol (IPA): Domestic Market

IPA Capacity: 60 KTPA

IPA Production: 60 KTPA

IPA Demand: 130 KTPA

IPA Imports: 70 KTPA

Acetophenone: Global Market

One of the key drivers for the global acetophenone market can be attributed to the application of

precursor to resins. Also, increasing demand from end use industries such as use in pharmaceuticals,

food & beverages, consumer goods (detergent, soaps, lotions and creams) are fuelling the growth of

the acetophenone market.

The global acetophenone market is dominated by Asia Pacific (excluding Japan) region in terms of

global consumption of acetophenone. The emerging economies such as China and India witness an

increased demand for high end and luxury products as a result of increase in disposable income and

living standard.




Acetophenone: Domestic Market

Acetophenone Capacity: 0.48 KTPA

Acetophenone Production: 0.48 KTPA

Acetophenone Demand: 3.5 KTPA

Acetophenone Imports: 3.02 KTPA

2.4 Import vs. Indigenous Production

All the products, as mentioned above, are currently imported in India in quantity excess to our

production capabilities. Hence, all these products has potential for domestic sale. This is in spirit of our

prime minister’s “MAKE IN INDIA” drive, and shall save foreign exchange for our country.

2.5 Export Possibility

There is good market potential for exports of above mentioned products and depending on market

conditions, these products will be exported.

2.6 Employment Generation (Direct and Indirect) due to the project

The employment generation (direct and indirect) due to the Phenol and Cumene project will be more

than 200 people. Moreover, when the above mentioned proposed plants i.e. Cyclohexanone, Methyl-

Isobutyl-Ketone, Isopropyl Alcohol & Acetophenone will come, it will create additional employments.




3 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if

any

Not applicable

3.2 Location (map showing general location, specific location and project

boundary & project lay out) with coordinates

The site is located at Dahej Industrial Estate (GIDC), within Village Dahej, of Vagra Taluka in Bharuch

District.

Total area of the project is 1,63,645 m2. Out of that, 1,40,125.73 m2 is owned by Deepak Phenolics

Limited and balance 23,519.27 m2 area is taken on lease from Deepak Nitrite Limited.

Figure 3-1: Site on Google Map

Table 3-1: Coordinates of the Site

Legend Latitude Longitude

A N 21° 41’ 57.3” E 72° 35’ 48.7”

B N 21° 41’ 41.6” E 72° 35’ 50.8”

C N 21° 41’ 42.3” E 72° 35’ 33.3”

D N 21° 41’ 55.8” E 72° 35’ 32.0”

DEEPAK PHENOLICS LTD PFR FOR ADDITION IN THE EXISTING PLANT AT DAHEJ GIDC PROJECT DESCRIPTION


Figure 3-2: Site Layout Map




Table 3-2: Area Breakup at Site

S.

No. Area

Area in m2

As per EC Received Amendment Required % of Plot Area

1 Production 15802 27395 16.74

2

Storage

Product Storage 2813 12145 7.42

Raw Material 12409

Mounded Bullets 0 8653 5.29

Drum Storage 774 774 0.47

3 Boiler (including C&A

handling and STG) 733.8 11325 6.92

4 Substation 272.2 1269 0.78

5 DG Room 77 77 0.05

6 Security Room 40.5 570 0.35

7 Office 807.6

8 Cooling Tower 1575 1350 0.82

9 Effluent Treatment

Plant 2450 2377 1.45

10 Road & open area 41975.2 32435 19.82

11 Green belt Area 49364.4 50935 31.13

12 Fire water tank 455.5 2260 1.38

13 Raw Water 1026 5367 3.28

14 Flare 175 180 0.11

15 Process water/ DM

water 332.7 461 0.28

16 Chilled water 190.6 168 0.28

17 CCR 1131.9 452 0.28

18 Engg Store /

Warehouse 1088.3 560 0.34

19 Coal storage 712 2877 1.76

20 N2 storage 400 300 0.18

22 Chemical Store - 420 0.26

23 Other 1165.1 1295 0.79

Total 140118 163645 100.00

3.3 Details of alternate sites considered and the basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted

Not Applicable




3.4 Size or Magnitude of Operation

Products and Production capacity are given in Table 3-1

Table 3-3: Product Details

S. No. Name of Product

Production Capacity in MT/ Month

Remarks As per EC

received Addition

Amendment

Required

1 Phenol 16667 4723 21390 The design

capacity and plant

machinery will

remain same.

Amendment in

capacities is

considered based

on full utilization

of design

capacities

considering

design margin.

A communication

from licensor

confirming the

proposed capacity

utilization is

attached as

Figure 3-3

2 Cumene 25000 2807 27807

3 Acetone 10000 2834 12834

4 Propane Return Stream 0 4367 4367

5 Alpha Methyl Styrene (AMS) 500 313 813

6 Benzene Rich Cut 175 -48 127

7 Recovery Column Bottoms /

Heavies 730 1428 2158

8 Acetone Purge 0 17 17

9 Lights Hydrocarbon Purge 0 35 35

10 Poly- iso propyl Benzene

(PIPB) Drag 0 88 88

11

Hydrogenation Products :

Cyclohexanone, cyclohexanol,

Methyl Iso-butyl Ketone

(MIBK), Isopropyl Alcohol

(IPA)

2650 14836 17486

12 Cyclohexanol Rich Stream 0 257 257

13 Acetone Rich Stream 0 289 289

14 Acetophenone 0 353 353

15 Wet IPA 0 250 250

Total 55722 32549 88271

16 Power (MW) 42 0 42

17 Steam (TPH) 100 100 200




Figure 3-3: Licensor’s Note on Proposed Capacity Utilization

3.5 Technology and Process Description

Technology and Process Description as per Annexure 6 of Form - 1




3.6 Raw Materials

Table 3-4: Details of Raw Material

S. No. Raw Materials / Product Consumption, MTPM

As per EC received

1 Propylene 7916

2 Benzene 14666

3 Caustic soda Lye 165

4 Sulphuric acid 98% 206

5 Hexamethylenamine (Dytek or HMDA) 16

6 Cumene 1316

Amendment Required for

1 Propylene 14188

2 Benzene 18274

3 Caustic soda Lye 347

4 Sulphuric acid 98% 175

5 HCl (30 wt%) 39

6 Hydrogen

3.7 Process Description

Process description is given in Annexure 6 of Form-1

3.8 Additives and Chemicals

Additives and chemicals as per raw material list provided in Table 3-5

3.9 Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw material and

finished product.

3.9.1 Transportation details of Raw Materials

Details of transportation of raw material are given in Table 3-5.

Table 3-5: Details of Consumption and Transportation of Raw Material

Raw Material Consumption(MTPM) Source Mode of Transport

As per EC received

Propylene 7916 Indigenous Sea/Pipeline/Road

Benzene 14666 Indigenous Sea/Pipeline/Road

Caustic soda Lye 165 Indigenous Road

Sulphuric acid 98% 206 Indigenous Road

Hexamethylenamine (Dytek

or HMDA) 16 Indigenous Road

Cumene 1316 Captive/ Export/

Domestic Sea/Pipeline/Road




Raw Material Consumption(MTPM) Source Mode of Transport


Propylene 14188 Refineries Road tanker / Pipe line/

Sea

Benzene 18274 Refineries Road tanker / Pipe line/

Sea

Cumene 27807 Captive/ Export/

Domestic Sea/Pipeline/Road

Caustic soda Lye 347 Manufacturer Road tanker

Sulphuric acid 98% 175 Manufacturer Road tanker

HCl (30 wt%) 39 Manufacturer Road tanker

Hydrogen 578 Neighboring industry Pipeline/ Road

3.10 Availability of water its source, energy/power requirement and source

should be given

3.10.1 Water consumption

Existing water requirement is 2048 KLD (Environment Clearance received) and additional water

requirement will be 7026 KLD. So after amendment total water consumption will be 9074 KLD, out of

which 1260 KLD waster will be recycled through Reverse Osmosis. Hence the revised fresh water

requirement will be 7814 KLD. Source of water for proposed amendment will be GIDC water supply.

Table 3-6: Details of Water Consumption

S. No. Description Water Consumption in KLD

As per EC Received Addition Amendment Required

1 Raw water to DM Plant 677 1047 1724

a Process 177 103 280

b Boiler 500 719 1219

2 Cooling & Chilling 1299 5979 7278

3 Washing 35 0 35

4 Domestic 12 0 12

5 Gardening 25 0 25

Total Gross 2048 7026 9074

6 Recycle water from

RO 0 1260 1260

Total Fresh water

Consumption 2048 5766 7814

3.10.2 Power Requirement









Table 3-7: Fuel Consumptions

S. No. Stack Attached to Capacity Type of Fuel used Fuel consumption

(Kg/hr.)

As per EC received

1 Cogen Plant Boiler 100 TPH Indian/Imported Coal 17300/11500

2 Boiler for phenol & Cumene 100 TPH Indian/Imported Coal 21000/14000

3 Incinerator for 304 Nm3/hr.

Vent gas 304 Nm3/hr. Gas 25 m3/ hr.

4 DG Set (1 no.) 1500 KVA HSD 500 lit/hr.


1 Boiler-1 100 TPH Indian/Imported Coal/

Imported Coal+ Lignite

46000/42000/

16000+38000 2 Boiler-2 with Power Generator 100 TPH

3 Incinerator 36440 Nm3/hr. Gas 29

4 DG Set- 1 1500 KVA HSD 500 lit/hr.

5 DG Set- 2 1500 KVA HSD 500 lit/hr.

Table 3-8: Details of Process Vents

Stack Attached to Nos. of Stack

Stack Height in m

Pollutants Emitted

Air Pollution Control Measure

As per EC received

Process vent 1 30 VOC Incinerator

Amendment required for

Process Emergency Relief (Intermittent)

1 65 HC Flare

Coal Handling-1 (Crusher House)

1 17 PM Bag Filter

3.11 Quantity of waste to be generated (liquid and solid) and scheme for their

management /disposal

Quantity of wastewater generation is given in Table 3-9 and hazardous waste generation is given in

Table 3-10.

Table 3-9: Waste Water Generation Details

S.

No. Description

Waste water generation in KLD Remarks

As per EC

received Addition

Amendment

Required

1 Process 405 172 577

2 Boiler 144 -12 132

Not accounted as it

shall be used

internally for dust

suppression.

3 DM Regeneration 0 564 564

DM regeneration,

Condensate Polishing

& PSF back washes

4 Cooling & Chilling 354 654 1008




S.

No. Description

Waste water generation in KLD Remarks

As per EC

received Addition

Amendment

Required

5 Washing 35 13 48

6 Domestic 10 2 12

Total Water to ETP 949 1260 2209

8 Recycle water from

RO 0 1260 1260

Final discharge to

GIDC drain 949 0 949

Details of ETP is given in Annexure 9 of Form-1

Table 3-10: Hazardous waste generation

S. No.

Type of Waste

Hazardous Waste

Category

Waste Quantity in MTPA

Treatment / Disposal As per EC received

Addition Amendment

Required

1 ETP Sludge 34.3 3120 -2553 567

Collection, Storage, Transportation and Disposal at TSDF site. Salt Sale/ TSDF

Site

2 Used Oil 5.1 3000 0 3000 L

Collection, storage, Transportation & Disposal by

selling to Registered Re-processor

3 Boiler Ash 36.2 48396 100782 149178

Collection, storage, Transportation & Disposal by selling to brick manufacturer

or cement industry

4 Spent Carbon 35.3 66 -50 16 Collection, Storage,

Transportation and Disposal at TSDF site.

5 Discarded Container/

bags 33.3 240000 0 240000

Collection, decontamination, storage, transportation & sell

to registered vendor

6 Spent Resin 19.1 0 9 9 Collection, Storage,

Transportation and Disposal at TSDF site.

8 Spent

Catalyst 35.2 0 18 18

Collection, Storage, Transportation and Disposal

at TSDF site.

9 Spent

Adsorbent 35.1 0 145 145


at TSDF site.

10 Heavies from MIBK plant

H 3 0 2424 2424 Send to Authorized Vendor /

CHWIF

11 Heavies from Acetophenone

plant H 3 0 50 50

Send to Authorized Vendor / CHWIF

12 Lights from

Acetophenone plant

H 3 0 10 10 Send to Authorized Vendor /

CHWIF

13 Spent resin

from DM/CPU 34.2 0 7 7


at TSDF site.

14 Spent carbon

from A-4160 0 25 25





S. No.

Type of Waste

Hazardous Waste

Category

Waste Quantity in MTPA

Treatment / Disposal As per EC received

Addition Amendment

Required

DM/CPU/ETP at TSDF site.


PLANT AT DAHEJ GIDC SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

Most of the industries in Dahej are located in GIDC Industrial Area 1 & 2. The study area is well

connected by roads to Bharuch. All the areas in the study area linked either by 4 lane roads.

Project Site is situated in GIDC Dahej, a well-known Industrial area at an aerial distance about 37.39

km from Bharuch towards WNW direction. Bharuch is district headquarter place and easily approachable.

4.2 4.2 Land Form, Land Use and Land ownership

Total area of the project is 1,63,645 m2. Out of that, 1,40,125.73 m2 is owned by Deepak Phenolics

Limited and balance 23,519.27 m2 area is taken on lease from Deepak Nitrite Limited. As the project is

located in notified industrial estate, the landuse of the project site is industrial.

4.3 Topography (along with map)

The project site generally flat with average level difference of 2.0m. There are isolated pockets of 1.0

– 2.0 m above or below the average ground well. Shallow depressions are observed on the site and a

large area in the middle of the plot towards eastern boundary is elevated.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the

project to periphery of the forests, national park, wild life sanctuary, etc.

sensitive areas, water bodies (distance from the HFL of the river), CRZ. In

case of notified industrial area, a copy of the Gazette notification should be

given.

Land use pattern: Industrial

Table 4-1: Distance of Project Site from Sensitive Areas

Area Distance in km Direction

Reserved Forest 5.90 W

Mangroves 7.00 W

Table 4-2: Distance of Project site from Water Bodies

Water Body Distance in km Direction

Bay of Cambay 7.00 W

Narmada Estuary 1.80 S

Ambheta Pond 1.43 SSW

Dahej Pond-I 1.90 NW

Dahej Pond-II 2.21 NW

Suva Pond 6.03 ESE




Water Body Distance in km Direction

Jolwa Pond 6.19 ENE

Vadadla Pond 5.26 NE

Lakhigam Pond 4.49 W

Kadodara Pond 9.00 NE

Vav Pond 8.00 NE

4.5 Existing Infrastructure

Proposed amendment of the project will be done on existing land. Land is used for Industrial purpose.

During amendment additional facility will be develop as pre the requirement for production of new

products.

4.6 Soil classification

Not required

4.7 Climatic data from secondary sources

The general agro-climatic zone of the study area is Semi-arid. Information presented in subsequent

paragraphs is from the most recently published Long Term Climatological Tables for the nearest

observatory, Bharuch by the Indian Meteorological Department (IMD).

4.7.1 Temperature

Mean daily maximum temperature is recorded in the month of April at 40 °C. From October to

December, both day and night temperatures begin to decrease rapidly. January is generally the

coldest month, with a minimum temperature of 11.9 °C. During the post-monsoon months of October

and November, day temperatures remain between 16.9-22.0 ºC. In winters, i.e. December, January

and February, average day temperatures remain between 11.9-14.4 ºC.




4.7.2 Wind

Table 4-3: Predominant Wind Direction

Month Predominant Wind

First Second Third

Morning Evening Morning Evening Morning Evening

January NE NE SE SW SW NW

February NE NE NW SW SW NW

March SW SW NE NW NW NE

April SW SW NW NW SE W

May SW SW NW NW S S

June SW SW S S W S

July SW SW S S W W

August SW SW W W NW NW

September SW SW NW NW S S

October SW SW NE NE SE SE

November NE NE SE SE SW SW

December NE NE SE NW NW NW

4.7.3 Rainfall

The total rainfall in year is observed to be 924.8 mm. Distribution of rainfall by season is 2.3 mm in

winter (December, January, February), 14.3 mm in summer (March, April, May), 869.3 mm in

monsoons (June, July, August, September) and 38.9 mm in post-monsoon (October - November).

4.7.4 Cloud Cover

The area remains cloudy between June - September, which is the active period of the monsoon

season. Cloud cover is 6-8 oktas during monsoon season, while it is 0-2 oktas in post monsoon, winter

and summer season.

4.7.5 Humidity

Most humid conditions are found in the monsoons, followed by post-monsoons, winter and summer in

that order. Mornings are more humid than evenings and humidity ranges from a high of 80-90% in

monsoon mornings to a low of 26-38% in summer evenings. During post-monsoon season, in morning

humidity remains between 68-75% and in the evening it remains between 37-44%.

4.8 Social infrastructure available

Not applicable




5 PLANNING BRIEF

Project implementation by DPL project team for Cumene & phenol plant based on Basic package of

licenser & detailed engineering. EPCM contractor is Thyssenkrupp Industrial solutions (India).

The following chart shows the status of the project.

Long lead equipment procurement has been completed. Delivery of equipments has been started at

site.

Implementation of Cumene / phenol project including associated Utilities is in progress and

plants are scheduled to be commissioned in 2017 Q – 4.

Preliminary project fesibility study has been completed for Cyclohaxanone Plant, MIBK Plant,

IPA plant and Acetophenone Plant.

Licensor selection for Cyclohexanone plant, MIBK plant, IPA plant and Acetophenone plant is

in progress.


PLANT AT DAHEJ GIDC PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The total plot area of the unit is 1,63,645 m2.

6.2 Residential Area (non-processing area)

No Residential area

6.3 Green belt

31.13% of total plot area will be developed as greenbelt.

6.4 Social Infrastructure

Not applicable

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc)

Proposed Project Site is located at GIDC- Dahej, Taluka Vagra, and District Bharuch in south Gujarat.

Dahej, know a days is well known industrial region and developing very fast, it has also a PCPIR

region. Bharuch, is a district Headquarter as well as major Town and proposed site is located at an

aerial distance of 38 km towards E direction.

6.5.1 By Road

SH 6 is the main approach road from Bharuch to Project site. It is six lane state highway from Bharuch

up to Dahej. Dahej Village is main center of this industrial region, at an aerial distance of about 1.87

km towards NW direction from site. Dahej is well connected to Bharuch by State Transport Buses and

Private vehicles.

6.5.2 By Rail

Site is also approachable by railway which connected Bharuch and Dahej via Samni & Vagra. Dahej is

nearest railway station at an aerial distance of about 1.43 km in NW direction from project site. District

Head Quarter Bharuch is a Major railway station lies on Mumbai-Vadodara mainline, at an aerial

distance of about of 42 km in E direction from projects site. Bharuch is well connected with various

parts of the country.

6.5.3 By Air

Nearest domestic airport from proposed project site is located at Vadodara, at an aerial distance of

about 95 km towards NE direction. Vadodara is well connected with Mumbai and Delhi with daily

multiple flights.


PLANT AT DAHEJ GIDC PROPOSED INFRASTRUCTURE


Ahmedabad Airport (Domestic as well as international) is located at about 151 km towards N direction

from project site. Regular flights to all aver India and abroad are available from here.

6.5.4 By Water

Dahej is a port Village lies on the Bay of Cambay, having a small jetty under maritime board. There

are several other private jetties developed by industries.

6.6 Drinking water management (source & supply of water)

GIDC water facilities will be used.

6.7 Sewage system

Domestic Sewage waters will be disposed in GIDC common effluent pipeline after treatment in ETP

6.8 Industrial waste management

The wastewater generated from the industrial unit will be disposed in GIDC common effluent pipeline

to sea after treatment in ETP. The hazardous waste will be disposed to M/s. Saurastra Enviro Projects

Pvt. Ltd. (SEPPL).

6.9 Solid waste management

The solid wastes generated from the plant operations will be disposed in nearby Waste Management

landfill facility. The unit has membership of M/s. Saurashtra Enviro Projects for Integrated Common

Hazardous Waste Management Facility.

6.10 Power requirement & supply/ source







AT DAHEJ GIDC REHABILITATION & RESETTLEMENTS

(R & R) PLAN


7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected

persons including home oustees, land oustees and landless labourers

(a brief outline to be given)

Not applicable as rehabilitation and resettlement will not be required, since the project lies in

Industrial Area, with land acquisition procedures completed by the GIDC.


AT DAHEJ GIDC PROJECT SCHEDULE AND COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time

schedule for the project to be given)

Phenol and Cumene plant:

Mechanical completion

Start date: 30th June, 2017

End date: 29th September, 2017

Pre-commissioning and commissioning:

Start date: 3rd October, 2017

End date: 30th December, 2017

Additional capital cost of the proposed project will be INR 400 Crore.

Cyclohexanone, MIBK, IPA, and Acetophenone: The likely implementation period for these units is 18

– 20 months.

Estimated project cost along with analysis in terms of economic viability of the project.

Product Project cost, Crore

Cyclohexanone INR 118

MIBK INR 182

IPA INR 80

Acetophenone INR 20

Total INR 400


AT DAHEJ GIDC PROJECT SCHEDULE AND COST

ESTIMATE


9 ANALYSIS OF PROPOSAL

9.1 Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area

The employment generation (direct and indirect) due to the Phenol and Cumene project will be more

than 200 people. Moreover, when the above mentioned proposed plants i.e. Cyclohexanone, Methyl-

Isobutyl-Ketone, Isopropyl Alcohol & Acetophenone will come, it will create additional employments.

Employment will get generated in market by sales and service for providing products to the industry.

Also the increased capacity will increase the raw material consumption as well as the supporting

services and will give further business to the vendor industry. Many people will get indirect benefits

due to coming up Industries in local market. Transporters will be engaged to bring raw materials and

supply finished goods.

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

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