pre-feasibility report for expansion of chemical
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PRE-FEASIBILITY REPORT
FOR EXPANSION OF
CHEMICAL MANUFACTURING
UNIT
BY STAHL INDIA PVT LTD,
KANCHIPURAM
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
1
1.1 Introduction of the project
The existing industry mainly manufactures chemicals like Syntan, Fat liquor,
Superplastisicer, Biocides, Acrylic Resin, Urethane Resin, Solvent based blending’s &
Water based blending’s. Due to the increase in demand from the customers, the
industry has decided to increase the production capacity from 24180 MT/Annum to
70800 MT/Annum. The project has been granted EC by MoEF on 03.06.2009 by letter
no. F. No. J-11011/167/2009-IA-II (I) (attached as
Annexure IV) to M/s Clariant Chemicals (India) Limited. Now the name of the company
has been changed to M/s Stahl India Pvt. Ltd. As per G.O.I EIA Notification dated
14/09/2006, they fall under the category A of the 5(f). The chemical products
manufactured by Stahl India are used for leather Preparation, Leather Finishing &
Industrial Preservative all over India. After expansion the increased demand of
customers shall be fulfilled.
1.1.1 Profile of promoter
Stahl is a Multinational company established in 1914 by Harry Stahl in Peabody,
Massachusetts in USA. Now Stahl has its presence in 28 countries. It has 8
manufacturing locations in different countries including India. Stahl has following
chemical products:
Leather Finish
Shoe Finish
Permuthane
Industrial Colorants
Wet end Products
In 1998, Stahl has formed its Indian subsidiary Stahl India Pvt. Ltd. The products
manufactured in the Stahl India plant are mostly water based emulsions or
suspensions. The present production capacity is 24180 MT/Annum. With increase in
demand Stahl India wish to expand the production capacity of existing products.
1.1.2 About the Existing Facility Details
Current Manufacturing Unit in Kanchipuram has been extra ordinary in developing
human resources, efforts in conserving environment, commitment to CSR. Street
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
2
lights at this facility are powered by Solar Panels. Manufacturing unit is working
extensively to support local needy community as part of its CSR drive.
1.1.3 Need of the Project
The chemical products manufactured by Stahl India are used by tannery industries all
over India hence with increase in demand of leather demand of these chemicals are
also increasing. The industry mainly manufactures chemicals like Syntan, Fat liquor,
Superplastisicer, Biocides, Acrylic Resin, Urethane Resin, Solvent based blending’s &
Water based blending’s. Due to the increase in demand from the customers, the
industry has decided to increase the production capacity from 24180 MT/Annum to
70800 MT/Annum.
1.1.4 Social Impact
The project site is part of Sengundram Industrial Area, therefore it is designated for
industrial activity. There are farm lands surrounding the facility with few villages which
are far from the industrial estate. The total manning of the company with plant is
expected to be around 250 persons. Barring the senior and some middle
management, the majority of the remaining workforce shall be recruited from within
the state. However, as there are hardly any similar process plants in this region,
sourcing of local skilled manpower may be a challenge in future. Skill level requirement
for this plant operation is of very high standard, the manpower shall have to be trained
in synthetic organic chemical practices. This shall have a positive effect on the
surrounding environment. In addition, in line with Stahl’s general HR practices, our
work force in this company have been enjoying much better facilities and working
conditions than the standards followed in other companies. This facility further
promotes small scale ancillary units, packing materials, workshops etc. generating
more employment. The process to construct housing facility for our work force has
already been initiated. The prospect for employment generation is substantial and it
will have important social benefits.
1.2 PROJECT DESCRIPTION
1.2.1 Project Details
S.No Particulars Existing Proposed Total
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
3
1 Type of Industry Synthetic Organic Chemicals Manufacturing Unit
3 Category 5(f), ‘A’
4 Location SF No. 534, 535, 536, 757, 759, 768, 769, 770 of
Sinagadibakkam Village, Kanchipuram Taluk And
District, Tamil Nadu
5 Land use at the
project site
Industrial
6 Plant Capacity 24180 MT/Annum 46620
MT/Annum
70800
MT/Annum
7 Estimated Project
Cost
Rs. 80 Crore Rs. 15 Crore Rs. 95 Crore
8 Population 150 No. 100 No. 250 No.
9 Power Requirement
in HP
Licensed – 5000 HP
Connected – 2640
HP
- 360 HP
Licensed – 5000 HP
Connected –
3000 HP
10 D.G. Set back up 1000 KVA & 160
KVA
1000 KVA 1000 KVA – 2
Nos. & 160
KVA
12 Capacity of Boiler 5 TPH & 0.5 TPH 6 TPH 5 TPH & 6 TPH
13 Air Pollution
Control System
Multi cyclone and
wet bottom,
cyclone
separators with
bag filter
arrangement,
stack, common
wet scrubber, wet
scrubber with
Multi cyclone
and wet
bottom, stack
and common
wet scrubber.
Multi cyclone
and wet
bottom,
cyclone
separators with
bag filter
arrangement,
stack, common
wet scrubber,
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
4
stack, stack and
bag filter with
stack
wet scrubber
with stack,
stack and bag
filter with stack
14 Water Requirement 97 KLD 210 KLD 260 KLD
15 Waste water
Discharge
17.5 KLD 48.5 KLD 66 KLD
16 Waste Water
Treatment Method
MEE & STP of 25
KLD
60 KLD ETP
with RO
60 KLD ETP
with RO, MEE
& STP of 25
KLD
1.2.2 Land Area Details
Particulars Existing Area Proposed Area
Total area after
expansion
% Area
(after expansion)
Total Land Area 19.66 ha --- 19.66 ha 100
Built up area 2.35 ha 0.14 ha 2.49 ha -
Ground Coverage 2.18 ha 0.05 ha 2.23 ha 11.4
Green Belt Area 11.51 ha --- 11.51 ha 58.5
Open & Road Area
5.97 ha --- 5.92 ha 30.1
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
5
11.08%
58.55%
30.37%
EXISTING LANDUSE
Ground Coverage Green Belt Area Open & Road Area
11.4%
58.5%
30.1%
LAND USE AFTER EXPANSION
Ground Coverage Green Belt Area Open & Road Area
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
6
1.2.3 The Google Image of Project Site
1.2.4 10 Km Buffer Zone Map
Map is also attached as Annexure II
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
7
1.2.5 Layout Plan
The layout map is additionally attached as Annexure III
1.2.6 Project Description with Process Details
Stahl India Pvt. Ltd. is expanding its existing Synthetic Organic Chemicals Manufacturing Unit
from present capacity of 24180 MTPA to 70800 MTPA to meet with the increased demand of
the chemicals used leather preparation & finishing.
1.2.7 Raw Materials with daily requirement
The raw materials used in the manufacturing process with their monthly & annual
consumption is given below:
Sl. No.
Production Family
Capacity (MT)/Annu
m
Capacity (MT)/Month
Name of the Raw Material
Monthly Consumptio
n in MT
1 Syntans 26400 2200
Phenol 170
Naphthalene 220
Sulphuric Acid 381
Formaldehyde 240
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
8
Caustic Soda Lye 412
Urea 65
Others 220
Maida Flour 190
China Clay 130
Glauber Salt 190
Water 326
2 Superplasti
cisers 4800 400
Naphthalene 84
Sulphuric Acid 80
Formaldehyde 46
Caustic Soda Lye 76
Water 114
3 Fat Liquors 7200 600
Vegetable Oils 42
Mineral Oils 17
Emulsifiers 54
Esters 21
Organic Acids 29
Solvents 6
Organochlorine compounds
8
Sulfochlorinated and Chlorinated
Paraffins 75
Alkaline Compounds
29
Inorganic salts 19
Water 300
4 Biocides 8400 700
Fungicide / Algicide 80
Methyl Isothiozolinones
30
Formaldehyde compounds
50
Alkaline Compounds
20
Benzisothiozolinones
50
Surfactants 10
Glycols 40
Water 420
5 Acrylic Resin
4000 333
Monomers 116
Surfacttants 1
Inorganic Salts 6
Water 210
6 Water based
10000 833 Casein Powder 48
Solvents 4
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
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blendings/Dispersion
s
Plasticizers 15
Pigments 50
Inorganic Salts 4
Waxes 40
Surfacttants 6
Water 666
7 Polyurethanes Resins
4000 334
Monomers 60
Polyols 33
Water 241
8
Solvent based
blendings/Dispersion
s
6000 500
Monomers 6
Resin Powder 16
Solvents 171
Plasticizers 29
Organic Dyes 5
Silicones 29
Surfacttants 1
Nitro Cellulose 16
Water 227
1.2.8 Manufacturing process
1. Syntan
Naphthalene/Phenol is sulphonated with sulphuric acid. Then the reaction mass is
condensed with formaldehyde and Urea through multiple condensation process.
The condensed reaction mass is neutralised with caustic lye solution. The mass is
spray dried in the spray dryer at the temperature using furnace Oil. The product is
supplied as liquid also without converting into powder. This product is used in
leather process industry.
2. Fat Liquor
The synthetic and semi synthetic oils are saponified and blended with mineral oil
and various emulsifiers and packed as customer requirements. They are used in
leather processing industry.
3. Super Plasticizer
Naphthalene is sulphonated with sulphuric acid. Then the reaction mass is
condensed with formaldehyde through multiple condensation process. The
condensed reaction mass is neutralised with caustic lye solution. The excess
sodium salt is separated through crystallisation and centrifuging process and the
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
10
desalted mass is spray dried in the spray drier at the temperature using furnace Oil
. The product is supplied as liquid also without converting into powder. This product
is used as a water reducing agent in the preparation of RCC mixture for
construction.
4. Biocides
The actives are blended /milled in the reactor and packed as per the customer
requirements. The biocides are used as preservatives in leather process industry,
Metal working fluids industry Personal care products, Paint industry and emulsions.
5. Acrylic Resins:
The raw materials for acrylic resins are acrylate monomers, surfactants and water.
The acrylate monomers are first blended in a pre-mixer and then taken to a batch
reactor along with surfactants and water. A small quantity catalyst is then added to
catalyse the polymerisation. This reactor is also a jacketed vessel with a low speed
stirrer. The reactor is first heated to 40-45C to initiate polymerisation, and then
cooled as the reaction progresses. After the reaction is completed, the reactor
contents are filtered; quality tested and then packed off. Any batch that does not
pass the quality test will be sent to the recycle store for further processing or
blending.
6. Urethane Resins:
The raw materials for polyurethane resins are urethane monomers, polyols and
water. Small quantities of catalyst and other additives are also used. The urethane
monomers and polyols are typically reacted in a batch reactor at 60 to 95C to
produce a pre-polymer. The reactor is a jacketed vessel with a low speed stirrer.
Low-pressure steam (3 bar) is used for heating the reactor. After completion of the
reaction, the pre-polymer from the reactor vessel is transferred to an emulsion tank
in which the pre-polymer is emulsified with water using a high-speed stirrer. The
emulsion is then passed through a filter; quality tested and then packed. Any
batch that does not pass the quality test is sent to the recycle store for further
processing or blending.
7. Solvent Based Blending’s:
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
11
The raw materials for solvent based blending’s are solvents, nitro-cellulose cotton,
plasticizers, emulsifiers, urethane monomers, polyols, wax emulsions, casein
solutions and resins produced in the plant. The manufacturing process does not
involve any chemical reaction. All the required raw materials are mixed in a batch-
mixing kettle using a high speed stirrer, at ambient temperature. After the
completion of mixing, the contents are filtered; quality tested and then packed off.
Any batch that does not pass the quality test will be sent to the recycle store for
further processing or blending.
8. Water Based Blending’s:
The raw materials for pigment dispersions are pigments, surfactants, casein
binders, synthetic waxes, synthetic waxes, surfactants and water. The
manufacturing process does not involve any chemical reaction. The raw materials
are mixed in a batch-mixing kettle using a high-speed stirrer then the slurry is
transferred to a bead mill for grinding based on requirement. The product is then
quality tested, filtered and packed off. Any batch that does not pass the quality test
will be sent to the recycle store for further processing or blending.
1.2.9 Machinery
List of Plant and Machinery to be installed:
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
12
List of Machineries
1. Cooling water pump 51. Blower k400
101. P206 Oleum transfer pump
151. Blender motor (2) B802
2. Chiller Pumps 52. Cir.pump p408. 102. P123A Buffer tank transfer pump 152. Ball Mill M1/74
3. Chiller Pumps 53. Homogeneous pumpP409
103. P123B Buffer tank transfer pump
153. Blender dust collector motor
4. Raw water Pumps 54. Vacuum Pump XV 400
104. P124 1-3% Acid transfer pump
154. Borewell pump No.4
5. Cooling Tower Fans 55. 4KL Vessel R107 105. P125 3-5% Acid transfer pump
155. Borewell pump No.5
6. D.M. Water Pumps 56. Scrubber vent Blower K707
106. P126 35% acid transfer pump
156. Borewell pump No.1
7. Compressors chiller 57. FO Transfer pump P515 A
107. P129 Flare scrubber on pump
157. Borewell pump No.2
8. Air Compressors 58. HSDTransfer pumpP516 A 108. R103 Agitator
158. Borewell pump No.3
9. DG Engine oil pump 59. Unloading pump P514
109. P127A Tempered water pump
159. Bore well Pump No.6
10. DG Air compressor 60. FO Transfer pump P515 B
110. P127B Tempered water pump
160. Utility Effluent Pump P901A
11. Cooling water pump
61. HSD Transfer pump P 516 B 111. CF103 centrifuge
161. Utility Effluent Pump P901B
12. Cooling water pump
62. Naphthalene transfer pump P 209 112. CF104 centrifuge
162. Fatrap effluent pump P902A
13. Chiller Pumps 63. Naphthalene transfer pump P 210
113. F102screw feeder charging
163. Fatrap effluent pump P902B
14. Chiller Pumps 64. Phenol unloading pump P 205 A 114. Pulvariser 164. Vertical pump
15. Raw water Pumps 65. Phenol transfer pump P 205 B 115. CF107 Centrifuge
165. Nbond Stroke pump
16. Cooling Tower Fans
66. Agitator Dual Speed AV 102A 116. CF106 Centrifuge
166. Callendria Feed Pump P904
17. D.M. Water Pumps
67. Agitator Dual Speed AV 102C
117. K121 SO3 scrubber vent blower
167. Concentrate Pump P903
18. Air Compressors 68. Product transfer pump P 103A
118. P128A Scrubber circulation pump
168. Concentrate Pump P904
19. Compressors chiller
69. Agitator Dual Speed AV 102B
119. P128B Scrubber circulation pump
169. Concentrate Pump P905
20. Drinking WaterPump
70. Agitator Dual Speed AV102D
120. P406 35% tanker loading pump
170. Condensate Pump P906
21. Refined fish oil pump P401
71. Product transfer pump P103B
121. Formaldehyde scr.pump p211
171. Vaccum Pump XV901
22. Common fish oil pump P410
72. Sulphuric acid unloading P207 122. Steam Dryer X407
172. ETP Holding tank Pump P901
23. Oil Transfer pump P400B (Biocides)
73. Caustic soda pump P203
123. Steam Dryer X4047/1
173. ETP Holding tank Pump P902
24. Intermediate Transfer P301
74. Formaldehyde pump P201 124. Uracil Hoist . 3
174. Buffing machine
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
13
25. T301 Agitator AT 301
75. sulphuric acid pump p208 125. CF105centrifuge
175. Sharing machine
26. T302 Agitator AT 302
76. Caustic soda pump P204 126. CF108 Centrifuge
176. ML Transfer pump P109 A
27. B 301 Agitator AB 301
77. Formaldehyde pump P202
127. V109A Agitator AV109A
177. KC6 chiller compressor
28. B 302 Agitator AB 302
78. Oleum Transfer Pump P206 128. Main fan
178. Crystalliser Feed pump P107 A
29. B 303 Agitator AB 303
79. Oleum Scrubber Blower OSB - 1 129. Spray machine
179. Centrifuge Feed pump P108A
30. S 301 Agitator AS 301
80. Olum Scrubber Pump OSP – 1
130. Cooling water pump
180. Slurry tank agitator AV105
31. S 302 Agitator AS 302
81. Feed water pump No.1 131. Lubricator
181. Crystalliser X101
32. Exhaust K 301 82. Feed water pump No.2 132. Product air lock
182. Agitator AV102E
33. Elgi water compressor (P400A) 83. Boiler Fan CP4/3 133. Back filter air lock
183. Brine Compressor KC3
34. Mineral Oil Transfer pump P405A
84. Neut.Disc.Pump P106A 134. Backfilter screw
184. Brine Primary pump P110A
35. Mineral Oil Transfer pump P405B
85. R101 agitator AR101 135. Cooling fan
185. ML Transfer pump P109B
36. Horizontal Bead Mill
86. R 102 agitator AR102 136. FD Fan
186. Centrifuge I CF101
37. Screw Feed pump 87. V 103 Agitator AV103 137. Fuel Oil pump
187. Centrifuge II CF102
38. Oil pump 88. Agitator AV102 138. Feed pump 188. Centrifuge feed pump P108B
39. Lift M3/32 89. Hoist No.1 X101A 139. Bagging Screwmotor
40. Portable Agitator 90. Reactor R106 M1/75 140. FD Fan K704
41. Transfer pump P302
91. Condensate transfer Pump P111 141. Ring Main P705
42. Transfer pump P405
92. Neut.Dish.Pump P102 142. Heater H1
43. S3052KL Vessel Agitator
93. Condensate transfer Pump P112 143. Dust Collector DC3
44. S306 DFX AGITATOR
94. V101 Agitator AV101
144. Conveyor Drive Motor (CS701)
45. S304 6kl Agitator 95. Hoist No.2 X101B
145. Automatic Switching Machine (ST701)
46. Homogenous pump DFX
96. Napathaline Scrubber NSB – 2
146. Screw Fedder Motor (SF701)
47. Gear Pump DFX 97. Formaledhyde Scrubber Pump P213
147. sko transfer pump(P702b)
48. Screw motor 98. Formaledhyde Scrubber ID Fan K212
148. vibrosezwer (vs701)
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
14
49. SPARK FILTER MOTOR
99. R104 Agitator AR104
149. V109B Agitator AV109B
50. V) TOXIC CABIN 100. R105 Agitator AR105
150. Blender motor (1)B 801
1.2.10 Detail of Products & by-products
List of existing & proposed products is given in the table below:
TABLE – Detail of product:
Sl. No.
Products Existing capacity
(MT/ Annum) (Phsae-1 & 2)
Proposed (MT/Annum)
(Phsae-3)
Total After Expansion
(MT/Annum)
End Use
1. Syntan 9600 16800 26,400 Leather Preparation
2. Bates 3600 0 0 -- 3. Fat liquor 3600 3600 7200 Leather
Preparation
4. Superplastisicer 2400 2400 4800 Leather Preparation
5. Biocides 4800 3600 8400 Industrial Preservative
6. Uracil 180 0 0 --
7. Acrylic Resin - 4000 4000 Leather Finishing
8. Urethane Resin - 4000 4000 Leather Finishing
9. Solvent based blending’s
- 6000 6000 Leather Finishing
10. Water based blending’s
-
10,000 10,000 Leather Finishing
Total 24180 46,620 70800
TABLE – Detail of By-Product:
Sl. No.
Products Existing capacity
(MT/Month) (Phsae-1 & 2)
Proposed (MT/Month) (Phsae-3)
Total After Expansion (MT/Month)
1. Sodium Sulphate 30 0 0
2. Weak Sulphuric 200 0 0
Total 2015 0 0
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
15
1.3 Environment Management
1.3.1 Manpower
During Construction phase: 50 nos. labour During Operation phase: No. of Employees
Existing (Nos) Proposed (Nos) Total ( Nos)
150 100 250
1.3.2 Water Management
1.3.2.1 Water consumption & source &Waste water generation
Source of Water: Tanker Water Supplier. Present water requirement is 97 KLD & the
total water requirement after expansion is 260 KLD. Water is used in the process,
Domestic use, boiler & cooling tower & Gardening. Total waste water generated in existing
unit is 17.5 KLD & after expansion it will increased to 70 KLD. The detailed break up of
waste water & its treatment is given below:
Present effluent generation from the process is 7.5 KLD which is being neutralized
and evaporated by the multiple effective evaporators followed by condenser. The 7
KLD condensate from MEE is reused in Boiler & Cooling make up & 0.5 KL
concentrate is sent to Solar Evaporation Pond. 10 KLD of domestic waste is being
treated in STP of 25 KLD and 9 KLD treated water generated shall be reused for green
belt development.
The effluent generation from the process after expansion shall be 50 KLD which shall
be treated in ETP of 60 KLD followed by RO. 44 KLD of Permeate generated from
R.O. shall be reused Vessels/Plant washings. 6 KLD reject from R.O. & 4 KLD waste
water generated from Biocide plant shall be neutralized and evaporated by the multiple
effective evaporators followed by condenser. The 9 KLD condensate from MEE is
reused in Boiler & Cooling make up & 1 KL concentrate is sent to Solar Evaporation
Pond. 16 KLD of domestic waste is being treated in STP of 25 KLD and 14 KLD treated
water generated shall be reused for green belt development.
In existing it is a Zero Liquid Discharge Unit and the same shall be maintained after
expansion also. The detailed water management is given below:
TABLE – Details of Water Consumption
S. No
Description Existing ( m3/d)
Proposed ( m3/d)
Total ( m3/d)
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
16
1 Process (Addition Into Products & Vessels/Plant washings)
37 132 (44 KL Permeate from
RO)
169 (44 KL Permeate from
RO)
2 Boiler and Cooling Tower make-up
18 (7 KL Condensate from
MEE)
18 (2 KL Condensate from
MEE)
36 (9 KL Condensate from
MEE)
3 Domestic 12 7 19
4 Gardening 9 (STP outlet) 21 (Fresh water)
5 (STP outlet) 1 (Fresh water)
14 (STP outlet) 22 (Fresh water)
Total 97 210 260
TABLE – Details of Waste Water Generation
S. No
Description Quantum of effluent ( m3/d)
Existing Proposed Total
1 Process (Addition Into Products & Vessels/Plant washings)
5 45 50
2 Boiler and Chiller Blow down 2.5 2.5 5
3 Domestic 10 6 16
4 Gardening 0 0 0
TOTAL TRADE EFFLUENT 7.5 42.5 50
Total Quantity of Sewage 10 6 16
Total Quantity of Waste Water 17.5 48.5 66
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
17
1.3.2.2 WATER BALANCE
EXISTING
Domestic12 KLD
Vessels/Plant washings
5 KLD
Addition Into Products32 KLD
Boiler & Cooling Tower Makeup
18 KLD
Gardening9 KLD
Waste Water10 KLD
Waste Water5 KLD
Waste WaterNil
Boiler/Cooling Tower Blow Down
2.5
Waste WaterNil
Waste Water7.5 KLD
MEE 7 KLD condensate reused
Fresh Water81 KLD
TREATED
WATER
FROM
MEE
Recycled Water16 KLD
Total Water Requirement 97 KLD
STP25 KLD
Treated Water9 KLD
TREATED
WATER
FROM
STP
9 KLD treated water Reused
Concentrate -0.5 KL to Solar Evaporation Pond
7 KLD from MEE11 KLD
Gardening21 KLD
Waste WaterNil
9 KLD from STP
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
18
EXISTING + PROPOSED
1.3.2.3 Process & Operation of MEE
Multiple effect evaporators
Selection basis
The liquid effluent of reactor washings, floor washings and scrubber water is generated
from the process of fat liquor plant, spray dryer plant, biocides plant and QC lab
washing. Taking into account of the nature of the effluent form all the sources and after
taking lot of pilot trails, it was decided to install physically evaporation system (multiple
effect evaporator) and the system is functioning effectively.
Pre-treatment
The effluents from different plants are collected in a common underground collection
sump (cap 8 KLD), where pH is adjusted and pumped to the intermediate storage
tanks (10m3 & 20m3) located at effluent treatment plant.
Domestic19 KLD
Vessels/Plant washings
49 KLD
Addition Into Products120 KLD
Boiler & Cooling Tower Makeup
36 KLD
Gardening14 KLD
Waste Water16 KLD
Waste Water49 KLD
Waste WaterNil
Boiler/Cooling Tower Blow Down
5 KLD
Waste WaterNil
Waste Water50 KLD
MEE
44 KLD Permeate for Reuse
Fresh Water193 KLD
TREATED
WATER
FROM
MEE
Recycled Water67 KLD
Total Water Requirement 260 KLD
STP25 KLD
Treated Water14 KLD
TREATED
WATER
FROM
STP
14 KLD Reused
Concentrate -1 KL to Solar Evaporation Pond
9 KLD from MEE27 KLD Fresh
Gardening22 KLD
Waste WaterNil
14 KLD from STP
4 KLD from
Biocide plant
45 KLD from other plants
ETP of 60 KLD with R.O.
Reject of 6 KLD
9 KLD condensate Reused
TREATED
WATER
FROM
RO
14 KLD treated water Reused
44 KLD from R.O.
44 KLD from R.O.
5 KLD Fresh
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
19
Treatment Process
The effluent is evaporated in a multiple effect evaporator system. The evaporated
water is condensed and it is used for cooling water makeup. The concentrate from the
evaporation system is sent to solar pond for drying.
1.3.2.4 Process & Operation of STP
Sewage treatment plant
The sewage from the canteen house and bathroom, toilets will be led by gravity
through drain channels to a underground collection pit. The drain will be provided with
a bar screen for screening and removing coarse suspended matter. The sewage will
be received in a collection sump and transferred to the aeration tank by pumping. In
collection sump coarse bubble aeration will be provided to keep the sewage in
homogenized, aerobic condition.
Biological Treatment
The collected/homogenized sewage will be pumped to the aeration tank to reduce
organic pollutants in the presence of re-circulated active bio-mass (mixed liquid
suspended solids).
Here oxygen the main source of growth for the microorganism is supplied through fine
bubble diffusers connected to twin lobe type blowers. This will be led to the reduction
of BOD, COD and other organic pollutants. In this aerobic process, the sewage as
discussed earlier will be subjected to extended aeration type activated sludge process
for bio-degradation of organic.
The wastewater sludge mixture will then enter in to a secondary tank where the sludge
will be settled. The settle sludge will be re circulated back to aeration tank to maintain
the active biomass to the desired level or to sludge drying beds for drying the disposal
if excess. The clear supernatant at the top of the settling tank would overflow into the
clarified water tank. Liquid chlorine will be added in the clarified water tank to further
oxidize the residual organic and to disinfect the water.
The clarified water will be pumped through a multi grade filter for removal of suspended
solids and passed through an activated carbon filter for removing the traces of organic,
color and odour left in water.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
20
Filter backwash water and sludge pit filtrate water are collected in a drain and shall be
put into the sewage collection sump for further treatment. The treated water is used
for gardening.
Sewage plant details
Sewage plant capacity-25m3/day
Sewage collection sump volume 60 m3
No of compartments One
Liquid depth 3m
Overall size of the tank 7m x 3m x 3m
Aeration Tank
Volume of tank provided 30m3
Liquid depth 2.7 m
Aeration tank size 2.3 m x 5.9m x 2.7m (2.2m + 0.5m FB)
Secondary Settling Tank
Volume of tank 8.5 m3
Size of the tank 2.85 m x 1.5m x 2.7m (2.0 + 0.7m FB)
Clarified water tank
Volume of tank 4.0 m3
Size of the tank 1.31 m x 1.5m x 2.7m (1.8 + 0.9m FB)
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
21
Filter water storage tank
Volume of tank 4.0 m3
Size of the tank 1.31 m x 1.5m x 2.7m (1.8 + 0.9m FB)
Air blower
Air Blower Capacity 50- M3/hr
1.3.2.5 Process & Operation of ETP
Raw Effluent Collection/Equalisation The raw effluent from the processing sections will be collected in two batch effluent Collection cum Equalisation tanks. The equalisation tanks will be provided with diffused air agitation system to attenuate the variations in effluent flow and characteristics. Electro Coagulation Treatment & Primary Clarification The equalized raw effluent from the collection tank will be pumped to the proposed Electro Coagulation plant capable of handling 3m3 /hour of effluent flow. The electro coagulation process encompasses the addition of an electrical current to sacrificial electrodes. This is done within a highly turbulent electrochemical cell with a positive anode and negative cathode. Many processes like oxidation, reduction, and neutralisation occur simultaneously in any electrochemical cell. The electro coagulated floc differs significantly from the floc formed during chemical coagulation process, containing less bound water, more resistant to shear and hence better dewatering characteristics. Parallel Plate Separation The effluent after electro Coagulation treatment will be mixed with poly electrolyte solution and taken to a Parallel Plate Separator for solid-liquid separation. The clarified water overflowing from the Parallel Plate Separator will contain COD & BOD content around 8500mg/l and 3700 mg/l respectively. This primary treated effluent will be provided with two stage aerobic biological treatment for removal of COD & BOD to a level of 250 mg/l and 30 mg/l, respectively. Two-Stage Aerobic Biological Treatment and Secondary Clarification
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
22
The effluent overflowing from the Parallel Plate Separator will be provided with two-stage aerobic biological treatment designed on the basis of activated sludge process working on extended aeration principle. The stage-I aeration tank will be provided with an air blower of 420m3/hr capacity with diffused aeration piping system for supplying necessary Dissolved Oxygen and Mixing in the aeration tank. The overflow from aeration tank-I will be taken to Aeration tank –II provided with an air blower of 120m3/hr capacity with diffused aeration piping system for supplying necessary Dissolved Oxygen and Mixing in the aeration tank. The overflow from the aeration tank-II will be taken to a secondary settling tank, where solid- liquid separation takes place and the clarified water is taken to interim collection tank. The bio-sludge from the secondary clarifier will be recycled back to the aeration tank I & II to maintain the desired bacterial concentration and the excess bio-sludge will be drained to a bio-sludge collection tank for further treatment.
Interim Collection tank The overflow from the Secondary Settling tank will be collected in an interim collection tank from where it will be pumped to Pressure sand filter followed by Activated Carbon filter. Pressure Sand Filtration & Activated Carbon Adsorption The treated water from the interim collection tank will be pumped to a pressure sand filter to filter the fine suspended solids present in the treated effluent. The filtered water will be passed through a tank filled with coconut shell based granular activated carbon to polish the treated effluent and remove the trace organic content (COD) in the treated water to less than 50 mg/l. Sludge Dewatering & Disposal The chemical sludge from the parallel plate separator and excess bio-sludge from the Secondary Settling tank will be collected into separate HDPE collection tanks from where it will be pumped to a recessed type plate filter press. The filtrate from the filter press can be collected and taken to raw effluent collection tank for further treatment. The dried sludge will be packed in polythene bags and stored for disposal. Reverse Osmosis The Treated water from the Activated Carbon Filter will be taken to the 1st Stage of the Two -stage Reverse Osmosis plant for recovering 60% ( permeat) as product water with TDS content less than 200 mg/l. The Reject from the 1st Stage will be taken to the 2nd Stage RO for recovering further 50% (permeat) s Product water. The Reject water from the 2nd stage will be taken to the Multiple Effect Evaporator for concentration of dissolved salts and further water recovery. The solids slurry from the evaporator will be filtered in a basket filter and the mother liquor is taken back to the evaporator for further evaporation. The Condensate water from the Multiple effect evaporator is Product water and is used back in the Process.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
23
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
24
Schematic Diagram of ETP
Characteristics of ETP inlet & Outlet are given below:
Sl. No Parameter
Concentration
Raw Effluent from Collection
Tank ( mg / l)
Treated Water from RO for
Process ( mg / l )
TNPCB Standards (
mg / l )
1 pH 9.0 to 11 6.0 - 7.0 5.5 – 9.0
2 Colour Black/Grayish colourless colourless
3 TDS 8460-13900 < 200 < 2100
4 TSS 50 – 100 <10 < 100
5 COD 18000-25000 0 < 250
6 BOD 4000 – 5000 0 < 30
50 KLD
44 KLD
9 KLD
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
25
1.3.2.6 Rain water harvesting scheme
The main source of ground water recharging in the study area is rainwater, which
infiltrates into the ground through various lithological units present in the study area. 3
number of rainwater harvesting pits has been installed to recharge the ground water. The
runoff from the rooftop and storm water shall go to the recharge pits.
Scheme for Ground Water Recharging
The rainwater is diverted from the rooftop using rain water pipes to the surface /
underground drainage network. The entire campus is sub divided for recharging
structures.
The rainwater is diverted into the desilting tank to remove inorganic impurities and the
outflow of the desilting tank is taken into the recharge well.
Desilting Tank
The desilting tanks are used to remove silt and other floating impurities from rainwater.
Desilting tank is like an ordinary container having provision for the inflow, outflow and
overflow. Apart from removing silt it holds the excess amount of water till it is soaked up
by the recharge structure. The bottom of tank will have unpaved surface (layers of coarse
sand) to allow standing water to percolate into the soil. The rainwater collected in these
desilting chambers shall be utilized for horticulture.
Recharge well
The Recharge Well consist the pit size of with dia 2.6 m and effective depth of 3.0 m with
of 18.90 mm PVC perforated pipe will be lowered in the middle of the boreholes and the
pit will be filled with gravel and pebbles consisting of boulders, gravel and coarse sand.
The mouth of the PVC pipe shall be protected to avoid silt getting into it. The depth of the
bore will depend on the soil condition/water strata. The schematic diagram is enclosed. It
should be therefore concluded that there is no significant impact on surface water quality
& hydrology of the area. The proposed rainwater-harvesting scheme will stabilize the
groundwater table in the area.
The rain water collected shall also be collected into the proposed water body & utilized
for misc. purposes.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
26
DESIGN CRITERIA: SOIL QUALITY : Silt clay INFILTRATION RATE : 12.7 mm/hr PEAK HOURLY RAINFALL : 60 mm/hr NO. OF RAINWATER HARVESTING PITS : 3 No. SIZE OF PITS : 3m x 3m x 2m SIZE of PROPOSED WATER BODY : 248 cubic meter (11.3m X 11mX 2m)
Rain water calculation:
S.No. Description of Area
Area Considered
(Sq. M)
Harvesting Factor /
Collection Efficiency per area
Retention time for
capacity of recharge tank (in minutes)
(Peak hourly: 60
mm/hr)
Total Volume of
Water Available for Rain Water
Collection (Cubic
Mtrs) (Peak)
1 Water Available from Terraces of buildings and other roof-top surfaces
22300 0.85 15 284
GRAND TOTAL
22300 sqm 284 Cubic Mtrs
RAIN WATER HARVESTING DIAGRAM
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
27
1.3.3 Waste Generation and Management
1.3.3.1 Municipal Solid Waste
1.3.3.2 Process Waste (Non-Hazardous)
Process Waste
Existing
Proposed
Total Disposal method
STP Sludge 100 Kg/Annum
50 Kg/Annum
150 Kg/Annum
Sludge will be passed through filter press where it will be dewatered/ dried to form a cake and then will be used as manure in green areas. The unused sludge shall be given to farmers or nursery
Boiler Ash 7.2 MT / Annum
7.8 MT / Annum
15 MT / Annum
Shall be disposed off MSW site.
1.3.3.3 Hazardous Waste
Some of the raw materials solvents, fuels and products are classified as hazardous
substances. Based on the physical, thermal, chemical and biological properties
available from the material safety data sheets (MSDS) of the various substances
handled in the proposed project, the hazardous substances are identified. The
hazardous waste generated is given below:
Category Type of Waste Color of
Bins
Disposal Method
(Existing) Total
Waste (Kg/day)
(After Expansion) Total Waste
(Kg/day) Bio
Degradable Organic Waste
(Includes Food & Kitchen Waste,
Leaves etc.)
Green
Vermicomposting with in
project site
25 40
Non-Biodegradabl
e
Recyclable Waste (Includes Poly-bags, Plastic, metal, wood,
paper, glass, containers etc.)
Blue Authorized recycler
175 450
- Total - - 200 490
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
28
Used oil generated from machineries/D.G. Set will be carefully stored in HDPE
drums in isolated covered facility. The used oil will be sold to vendors authorized
by Central Pollution Control Board for the treatment of the same. The industry is a
member of the Tamil Nadu Waste Management Ltd and has been authorized to
dispose its Hazardous waste to the TSDF / Incineration facility at Gummidipoondi.
Name of Process Name of Process Waste
(Category No)
Quantity (T/Year)
Existing
Quantity (T/Year)
Proposed
Quantity (T/Year)
Total
5 Industrial operations using mineral/synthetic oil as lubricant in hydraulic systems(Schedule I)
5.1 Used/spent
oil
2.5 1.5 4
20 Production and/or industrial use of
solvents(Schedule I)
20.2. Spent solvents
1.5 13.5 15
5 Industrial operations using mineral/synthetic oil as lubricant in hydraulic systems(Schedule I)
5.2 Wastes/resid
ues containing oil
0.5 1.0 1.5
34 Purification and treatment of exhaust air, water and
waste water from the processes in this schedule
and CETPs(Schedule I)
34.3. Chemical
sludge from waste water treatment
21 49 70
33 Disposal of barrels / containers used for handling
of hazardous wastes / chemicals(Schedule I)
33.3. Discarded
containers / barrels /
liners contaminated
with hazardous
wastes/ chemicals
60 120 180
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
29
Sludge from solar pan shall be mixed with husk, packed in HDPE bags and then
set to authorized incineration facility.
1.3.4 Air Emissions and Control
Source of Air Pollution Existing Proposed Total
D.G. Set back up 1000 KVA & 160 KVA
1000 KVA 1000 KVA – 2 Nos. & 160 KVA
Capacity of Boiler 5 TPH & 0.5 TPH 6 TPH 5 TPH & 6 TPH
Fuel Consumption per day
Existing Proposed Total
Briquettes Kgs 8,000 8,000 16,000
Furnace Oil Liters 1,800 1,800 3,600
Diesel Liters 270 270 540
The major air pollutants sources are Boiler & D.G. sets. For mitigation of impacts of
air pollution, stack & Air Pollution control devices shall be provided as per the detail
give below:
Stack No
Source of emission
Pollution Control measures
Stack top dimension (in Metres)
Stack Height above ground level (meters)
Material of Construction
Maximum Discharge (in m3/hr)
EXISTING
1 Boiler 5 TPH
Multi cyclone and wet bottom
0.9 32 MS 14600
2 Spray dryer
section
Cyclone separators with bag
filter arrangemen
t
1.2 18 SS 23300
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
30
3 Hot Air Burner
Stack 0.7 31 MS 2500
4 Syntan plant
Reactors
Common wet
scrubber
1.1 30 MS with FRP Lining
500
6 Tox cabin - Cresol
pumping
Wet scrubber with stack
0.5 8 FRP 300
7 Fat Liquor plant
reactors
Common wet
scrubber
0.1 30 HDPE 500
8 DG set (1000 KVA )
Stack 0.15 14 MS 1554
9 DG set (160 KVA)
Stack 0.15 4 MS --
10 Powder Blending section
Bag Filters with stack
0.4 6 MS ---
11 Blending plant - liquid
Bag Filters with stack
0.4 5 MS --
12 Spray dryer
packing section
Bag Filters with stack
0.3 4 MS --
13 Blending plant - liquid
Wet scrubber with stack
0.1 13 FRP --
14 Tox cabin-
Biocide plant
Wet scrubber with stack
0.5 17 FRP --
15 Raw Mtl bulk
storage-Raw Mtl tankfarm
Wet scrubber with stack
0.36 9 FRP --
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
31
PROPOSED
16 Boiler 6 TPH
Multi cyclone and wet bottom
0.9 32 MS 14600
17 DG set (1000 KVA )
Stack 0.15 14 MS 1554
18 Syntan plant
Reactors
Common wet
scrubber
1.1 30 FRP 500
VOC Control: All vessel/ Charging area vents are connected with scrubber.
Leak Proof Pumps are used for transferring. Local Exhaust ventilation is being
used near drum/vessel openings which is connected to scrubber.
1.3.5 Power Requirement Source & Back-up
The power is being supplied by Tamil Nadu State Electricity Board
Particulars Existing Proposed Total
Power Requirement in HP
Licensed – 5000 HP
Connected – 2640 HP
- 360 HP
Licensed – 5000 HP Connected – 3000
HP
D.G. Set back up 1000 KVA & 160 KVA
1000 KVA 1000 KVA – 2 Nos. & 160 KVA
1.3.6 Noise Pollution Management
To reduce Ambient Noise level the following measures will be adopted --
Existing DG set has been bought acoustically enclosed & placed inside a
acoustically treated room as per CPCB guidelines & same shall be done for
proposed D.G. set.
Noise generating units like machinery area, canteen etc. are well insulated with
enclosed doors. Earmuffs are being used while running equipments of the Industry.
Maintenance of vehicles and machinery will be done in a sustainable manner to
ensure best performance and less loss.
Vehicle and people flow during shift changes shall be regulated by allowing exits in a
phased manner.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
32
The green belt will help in reducing noise levels in the complex as a result of
attenuation of noise generated due to plant operations and transportation. Total
green area in existing industry is 11.51 ha.
1.3.7 Safety
. Safety in design and operations are therefore of paramount importance.
1.3.7.1 Safety in Design
Following are the strategies to improve the safety of the people and plant:
Use of proven technologies and equipment
Use of latest safety process know-how
Modern risk assessment techniques to design effective safeguarding system
for all critical locations in the process
Design plant in accordance with applicable codes and standards and maintain
standard engineering practices during detailed engineering
Carryout extensive studies during the process design stage to ensure safety,
occupational health and environmental aspects are addressed in P& IDs, PFDs
and other engineering deliverables.
Minimize presence of large hydro-carbon inventories by designing liquid hold
up volumes in vessels based on control and operational requirements
Locate storage tanks in off site area
Pressure relief valves in all pressure vessels.
Occupational Health
Fixed detection system with alarms and data logging
Trained personnel made fully aware of the hazards of process and operations.
Personnel must also be informed of the health hazards
Periodic refresher training
Minimize unnecessary exposure to airborne contaminants and direct exposure
to chemical hazards
Good housekeeping
Emergency showers and eye wash facilities at appropriate locations
Health surveillance programs
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
33
1.3.7.2 Safety in Operations
A suitable organization shall be implemented to manage the safety of people and
plant. The organization shall be responsible for building and maintaining “a culture of
safety” and shall thrive to elevate safety to near religious levels. Suitable systems shall
be designed and implemented for safety training and awareness.
A suitable fire protection system with dedicated firewater network for the whole
complex has been designed and installed. Besides, facilities such as dedicated fire
station equipped with fire fighting equipment such as fire tenders has been put up. A
dedicated fire alarm system and special arrangements to protect control rooms in case
of fire has also been commissioned as part of the project. Existing unit is operating at
highest safety standards with the principle that safety of a person overrides all
production targets.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
34
1.4 LAND DETAILS
1.4.1 Land Form & Land Use
The land has been allotted to Indorama industries Ltd. By HPSIDC which is an
industrial land and there is no change in land area or plot area as this is an expansion
project with respect to the annual production. The plant is operational as per the old
EC granted in 2010 by SEIAA, and hence there is no change in landuse. Land papers
are attached in annexure VIII.
1.4.2 Existing Infrastructure around the Site
1.4.2.1 Routes or facilities used by the public for access:
Nearest Railway Station : Old Kanchipuram Railway Station- 9.84 Km SW
Nearest Airport : Chennai International Airport, - 42.85 Km NE
Nearest Highway : NH-4 – 0.25 Km NW
1.4.2.2 Social Infrastructure:
Particular Distance
Hospital Meenakshi Medical College & RI Arignar Anna Mem Cancer Hospital And RI Aggrawal Eye Hospital Post Office Post Office, Kanchipuram Places of worship Kailasanather Temple Pallur Sri Varahi Temple School Bharathidasan Maticulation HS School St Josephs Residential School Sri Sankara Arts And Science College Jeppiaar Institute of Technology Bank ICICI Bank HDFC Bank Vijaya Bank
7.47 Km W 8.36 Km W 10.97 Km SW 11.53 Km SW 12.02 Km SW 15.51 Km NW 12.48 Km SW 15.91 Km NE 7.11 Km SW 9.02 Km E 10.49 Km SW 11.00 Km SW 11.13 Km SW
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
35
1.4.3 Proposed Infrastructure
1.4.3.1 Processing Area
1.4.3.2 Green Belt
Green belt planning has been done as per guidelines laid by CPCB. With ecological
perspectives for the expansion of the project availability of space and other aspects
has been considered. This will help in increasing the aesthetic effect of the
environment. Green belt/greenery will be developed along most of the periphery of the
project area as well as along roads. In existing the green area is 11.51 ha (2.0 ha
grass / small plant area where daily watering done and 9.51 ha has big trees around
6000 which takes water from ground by self).
For proposed green area, the trees planted will be of adequate height. Any tree that does
not survive will be replaced. Ornamental trees will also be planted to improve the aesthetic
looks of the project area. The following characteristics have been taken into consideration
while selecting plant species for green belt development and tree plantation.
They shall be fast growing and tall trees.
They shall be perennial and evergreen.
They shall have thick canopy cover.
They shall have large leaf area index.
Since tree trunks are devoid of foliage, scrub should form there to give coverage to
the trunks. The trees will maintain regional ecological balance and conform to soil and
hydrological conditions. Indigenous species would be preferred. Before planting of
trees, seedlings, saplings, grass species, shrubs, soil preparation, soil amendments
etc are to be undertaken well in advance. For proper survival and healthy growth of
plant species a nursery is also maintained at the site. It is ensured that proper density
of plants is maintained at site. Post plantation care is also necessary and maintained
in planned and scientific manner.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
36
1.4.3.3 Sewerage System
All the treated water generated shall be reused within the premises for landscaping and
boiler & cooling tower makeup. It is a zero liquid discharge unit. After expansion also it will
remain a zero liquid discharge unit.
1.4.3.4 Liquid Waste
In existing 25 KLD STP has already been provided to treat domestic waste. The
effluent in existing is being neutralized and evaporated by the multiple effective
evaporators and send to solar evaporation pan to achieve zero discharge. After
expansion ETP of capacity 60 KLD with RO shall also be provided for treatment of
effluent. After expansion also it will remain a zero liquid discharge unit.
1.4.3.5 Parking Facility
Adequate parking provision has been provided on surface. Also separate loading & unloading area
has been provided within the project premises.
1.4.3.6 Rehabilitation and resettlement Plan
As this is an expansion project, there is no need for R&R activities for the activity.
EC Application For Expansion of Synthetic Organic Chemicals Manufacturing Unit At SF No. 534, 535, 536, 757, 759, 768, 769,
770 of Singadivakkam Village, Kanchipuram Taluk And District, Tamil Nadu By M/s Stahl India Pvt. Ltd.
37
1.5 PROJECT SCHEDULE AND COST ESTIMATES
1.5.1 Likely Date of Start of Construction and Completion
The project is operational at 46620 TPA capacity and the expansion will take place
after 6 months after getting Environmental clearance.
1.5.2 Estimated Project Cost
Cost of existing unit is 80 crore & for proposed expansion is estimated as Rs. 15 Crore.
Hence total cost will be 95 crores.
1.6 PROJECT BENEFITS
1 After expansion it will be an environmentally sustainable project. It will attract
people to develop organized chemical manufacturing Industry.
2 Organized methods for manufacturing of the chemicals are being used and shall
be maintained for chemical to be manufactured after expansion also.
3 The chemical products manufactured by Stahl India are used for leather
Preparation, Leather Finishing & Industrial Preservative all over India. After
expansion the increased demand of customers shall be fulfilled.
4 After expansion additional employment opportunities will lead to a rise in the
income and improve standard of living. The expansion of existing industry would
also generate jobs for the labours during construction phase as well as during
operation phase. It will provide direct and indirect employment to local youth.
5 Chemical manufacturing Industry is a large and growing domestic market. There
will be economic benefit due to selling of products all over India.
6 26.5% of water requirement shall be met by recycled water.
7 The industry has a Zero Liquid Discharge system and shall adopt all the necessary
steps to protect the environment.
8 Addition of revenue to the state by taxes.
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