PET Plant
PET Plant
PET Plant
FOR
AT
MANGALORE SEZ LIMITED
VILLAGE: BAJPE
TALUK: MANGALORE
DIST: DAKSHINA KANNADA
KARNATAKA
[Project termed under schedule 5 (e), category B project, and petrochemical
based processing]
November 2015
BY
TABLE OF CONTENTS
1. EXECUTIVE SUMMARY ......................................................................................................... 1
1. INTRODUCTION ....................................................................................................................... 4
1.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT .................................... 4
1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ................................................. 5
1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR
REGION ............................................................................................................................................ 5
1.4 DEMAND-SUPPLY GAP ..................................................................................................... 6
1.5 IMPORTS VS. INDIGENOUS PRODUCTION ................................................................... 6
1.6 EXPORT POSSIBILITY ....................................................................................................... 7
1.7 DOMESTIC / EXPORT MARKETS .................................................................................... 7
1.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 7
2. PROJECT DESCRIPTION ....................................................................................................... 8
2.1 TYPE OF PROJECT.............................................................................................................. 8
2.2 LOCATION ........................................................................................................................... 9
2.3 SALIENT FEATURES OF THE PROJECT SITE .............................................................. 10
2.4 BASIS OF CALCULATION FOR STEAM AND FUEL ................................................... 13
2.5 SIZE OR MAGNITUDE OF OPERATION ........................................................................ 14
2.6 PROJECT DESCRIPTION WITH PROCESS DETAILS .................................................. 15
2.6.1 MANUFACTURING PROCESS OF PTA.................................................................. 15
2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET .............................. 20
2.6.3 RAW MATERIALS REQUIRED ................................................................................... 24
2.6.4 RAW-MATERIALS AND ITS CONSUMPTION FOR PTA PLANT....................... 24
2.6.5 RAW-MATERIALS AND ITS CONSUMPTION FOR POLYESTER CHIPS / PET 25
2.7 RESOURCE OPTIMIZATION ........................................................................................... 26
2.7.1 SPECIFICATION OF PROPOSED FUELS ............................................................... 26
2.7.2 COAL LINKAGE ........................................................................................................ 28
2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER REQUIREMENT .... 30
2.9 QUANTITY OF WASTE WATER GENERATED ............................................................ 31
2.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH
GIVE INFORMATION OF EIA PURPOSE .................................................................................. 33
2.11 PROPOSED EMISSIONS & STACK DETAILS ........................................................... 33
3. SITE ANALYSIS....................................................................................................................... 39
3.1 CONNECTIVITY ................................................................................................................ 39
3.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................... 39
3.3 TOPOGRAPHY (ALONG WITH MAP) ............................................................................ 40
3.4 EXISTING LAND USE PATTERN.................................................................................... 41
3.5 EXISTING INFRASTRUCTURE ....................................................................................... 43
3.6 SOIL CLASSIFICATION ................................................................................................... 43
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Prefeasibility Report for Change in Fuel configuration
3.7 CLIMATIC DATA FROM SECONDARY SOURCES ...................................................... 43
3.8 SOCIAL INFRASTRUCTURE ........................................................................................... 44
4. PROPOSED INFRASTRUCTURE ......................................................................................... 45
4.1 INDUSTRIAL AREA .......................................................................................................... 45
4.2 RESIDENTIAL AREA ........................................................................................................ 46
4.3 GREENBELT ...................................................................................................................... 46
4.4 SOCIAL INFRASTRUCTURE ........................................................................................... 46
4.5 CONNECTIVITY ................................................................................................................ 46
4.6 DRINKING WATER MANAGEMENT ............................................................................. 46
4.7 SEWERAGE SYSTEM ....................................................................................................... 46
4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT ........................................................ 47
4.8.1 ASH GENERATION ................................................................................................... 47
4.8.2 DUST SUPPRESSION AND TREATMENT SYSTEM FOR COAL ........................ 47
4.8.3 ELECTROSTATIC PRECIPITATOR (ESP) .............................................................. 47
4.8.4 ASH HANDLING SYSTEM ....................................................................................... 48
4.8.4.1 HAZARDOUS WASTE AND ITS MANAGEMENT ............................................ 50
4.8.5 NOISE AND ODOUR CONTROL ............................................................................. 52
4.8.6 HAZARDOUS CHEMICAL STORAGE & HANDLING .......................................... 52
4.9 POWER REQUIREMENT .................................................................................................. 54
5. PLANNING BRIEF .................................................................................................................. 55
5.1 PLANNING CONCEPT ...................................................................................................... 55
5.2 POPULATION PROJECTION............................................................................................ 55
5.3 LAND USE PLANNING..................................................................................................... 56
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ....................................................... 57
5.4.1 PHYSICAL INFRASTRUCTURE .............................................................................. 57
5.4.2 SOCIAL INFRASTRUCTURE ................................................................................... 57
5.4.3 AMENITIES/FACILITIES .......................................................................................... 57
6. REHABILITATION AND RESETTLEMENT (R & R) PLAN ........................................... 58
6.1 BRIEF OUTLINE ON THE POLICY ADOPTED ............................................................. 58
7. PROJECT SCHEDULE & COST ESTIMATES ................................................................... 59
7.1 TIME SCHEDULE FOR THE PROJECT........................................................................... 59
7.2 ESTIMATED PROJECT COST .......................................................................................... 59
8. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)........................................ 60
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Prefeasibility Report for Change in Fuel configuration
LIST OF TABLES
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Prefeasibility Report for Change in Fuel configuration
LIST OF FIGURES
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Prefeasibility Report for Change in Fuel configuration
1. EXECUTIVE SUMMARY
This is asummary forProposed amendment for Fuel Configuration for using
100% Coal in TWOOF FOUR Boilers in PTA Unit and all FourThermic Fluid
Heaters in PET Unit for the Proposed Manufacturing of Pure Terephthalic Acid
(PTA) & Polyester Chips / PET Chips of Various Types & Grades and Power
Generation through Captive Power Plant at Mangalore SEZ in Dakshina Kannada
District of Karnataka. This project falls under item no. 5(e) i.e. Petrochemical based
processing industry under the category ―B‖ as per the EIA notification 2006 and
amendments thereof. JBF received Environmental Clearance for Manufacture of
Purified Terephthalic Acid (PTA), Polyester chips / PET Chips of various types and
grades and Power generation through Captive Power Plant from SEIAA vide letter
no. SEIAA/26/IND/2011 dated 30 March 2012 (Annexure-1) and CFE from
Karnataka State Pollution Control Board vide letter no. KSPCB/ HPI/ 269/ JBFL/
CFE/2011-12/443 dated 13 July 2012 (Annexure-2) Subsequently, JBF signed a
licensing agreement with world-renowned BP Technology wherein for the first time,
BP would be licensing its PTA manufacturing technology to a Non-Affiliate Third
Party, which considerably reduced our Water consumption, Power consumption,
Process Emissions, Effluent generation & discharge and led to a positive change in
the overall Environmental footprint of the Plant. Thus, due to change in Process
Licensor, JBF applied for and received a Corrigendum to Environmental Clearance
from SEIAA vide letter no. SEIAA/26/IND/2011 dated 18 April 2013 (enclosed as
Annexure 3), amendments for fuel change to Environmental Clearance from SEIAA
vide letter no SEIAA/17/IND/2014 dated 06 August 2015 (enclosed Annexure 4)
and amendment to CFE from KSPCB vide letter PCB/HPI/269/2013-14/3892 dated
07 October 2013 (enclosed Annexure 5). The construction activities have
commenced and are progressing in full swing, about 80% of Overall Project is
completed.
Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with
renewable Bio-fuel becoming visible, JBF has already obtained permission to use
85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.
However, it is prudent to have a fall-back arrangement in order to ensure reliability &
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Prefeasibility Report for Change in Fuel configuration
availability, by designing the system for firing 100% Coal. Hence, JBFwould like to
propose fuel conversion as follows.
The Present Consented fuel configuration and proposed change in fuel configuration
is as listed in the table below:
S.No. Particulars Present EC Proposed change
3) Steam Generator / Boiler 3 x 120 TPH Boiler: 2 X 120 TPH ONG Boilers
(4 Nos.)
Total Capacity: 460 TPH Natural Gas: Normal FuelConsumption:
(120+120+120+100) 3,00,000 SCM/ day
(or) Natural Gas: 300,000
Furnace oil 216 MTPD SCM/Day
1 x 100 TPH Boiler Fuel Oil– 36T/ day
PLUS
The total Coal consumption for Boilers and Thermic Fluid Heaters is 741TPD.
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Prefeasibility Report for Change in Fuel configuration
The reduction in SO2 emission during coal combustion will be attained by employing
desulfurization process which involves the use of Calcium – based sorbent such as limestone
powder that captures the SO2 emitted during combustion of Fuel. This measure taken is
expected to achieve a reduction of at least70 % ofSO2 emissions. The addition of sand will
ensure the removal of excess Calcium in the form of Calcium silicate.
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Prefeasibility Report for Change in Fuel configuration
1. INTRODUCTION
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Prefeasibility Report for Change in Fuel configuration
The existing production units of JBF group in India & UAE are already
manufacturing Polyester Chips & consuming PTA as key raw material and demand
on PTA based processing of Polyester chips and Polyester Yarn are increasing
internationally. At present the plant has obtained Environmental Clearance to use85%
Biomass + 15% Coal in one of four boilers and four Thermic fluid heaters vide letter
no. SEIAA 17/IND 2014 dated 06/08/2015. The same is enclosed in Annexure-3.
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Prefeasibility Report for Change in Fuel configuration
Owing to the delay in GAIL’s supply of Natural Gas to Mangalore and with
renewable Bio-fuel becoming visible, JBF has already obtained permission to use
85% Biomass & 15% Coal in our Solid fuel fired Boiler and Thermic Fluid Heaters.
Due to monsoons for nearly 6 months a year in DK District, the Biomass procured
will not be able to provide adequate Heating Value to support the minor variations in
process demands leading to frequent stops in a manufacturing process which has been
designed to operate on a continual basis all year round. Therefore, it is prudent to
have a fall-back arrangement in order to ensure reliability & availability, by designing
the system for firing 100% Coal. Hence we propose the use of 100% Coal in our
Thermic Fluid Heaters and two of the four Boilers.
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Prefeasibility Report for Change in Fuel configuration
As PTA is the key raw material for manufacturing of Polyester chips in the chain of
textile commodity, Polyester chips / PET chips have a growing market in India as
well as outside India due to its wide application in the Film, Bottle /Jar,
Pharmaceutical, Beverages etc. Thus under the name of JBF Petrochemicals Ltd., JBF
group proposes the project of PTA & PET chips along with power generation through
captive power plants in SEZ at Mangalore SEZ. Once the PTA plant is under
continuous operation, there will be additional generation of Power of around 8 MW,
which will be exported to OSBL for running the Utilities.
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Prefeasibility Report for Change in Fuel configuration
2. PROJECT DESCRIPTION
2.1 TYPE OF PROJECT
The project involves the proposed change in fuel configuration in boilers and Thermic
Fluid Heaters in the proposed production of ―PTA & Polyester chips / PET chips of
various types & grades and Power Generationthrough Captive Power Plants‖ which
falls under item no. 5(e) i.e. Petrochemical based processing under the category ―B‖
as per the EIA notification 2006 and as amended in 2009.
The Capital Cost Projection and its break up for the Proposed Project are given in
Table 2.2.
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Prefeasibility Report for Change in Fuel configuration
2.2 LOCATION
The project is located at Mangalore SEZ, Village: Bajpe, Tehsil: Mangalore, Dist:
Dakshina Kannada, Karnataka State. The Satellite image of project site within 10 Km
radius is given in Figure 2-1.
Mangalore is an industrial city with well-established infrastructure like road and rail
connectivity, maritime seaport as well as airport facilities and assumes strategic
importance to business and economic development because of its geographic
advantages. A special purpose vehicle (SPV), named Mangalore SEZ Ltd (MSEZL)
has been incorporated with (i) ONGC-MRPL, (ii) Karnataka Industrial Areas
Development Board (KIADB) representative of Government of Karnataka, (iii)
Kanara Chamber of Commerce and industries (KCCI) and (iv) Infrastructure
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Prefeasibility Report for Change in Fuel configuration
Leasing and Financial Services Ltd (IL&FS) as joint venture partners. Mangalore
SEZ is notified as SEZ by Ministry of Commerce & Industries for setting up
Petroleum and Petrochemicals Units. The layout of Mangalore SEZ is enclosed in
Annexure-10.
The Mangalore SEZ has acquired around 1800 acres of land for Phase I project and
the project is approved by Ministry of Environment & Forests vide their approval No.
21-383/2007-IA, dated 3rd April 2008 and Consent for Establishment from Karnataka
State Pollution Control Board dated 30th April 2008 (Copies enclosed in Annexure-6
& 7). Mangalore SEZ is providing developed industrial plots for setting up Petroleum
and Petrochemicals Units in place of the previously approved Olefin Complex.
Mangalore SEZ is providing the entire infrastructure like road connectivity, graded
plots, water infrastructure, Waste water collection system, solid waste management
system, green belt, marine disposal facilities for treated waste water etc. JBF
Petrochemicals has signed MoU with Mangalore SEZ Ltd. for leasing 115.3 Acres of
land for setting up the project.
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Prefeasibility Report for Change in Fuel configuration
Features Description
No Sanctuaries/ National Parks or Reserved Forests. However,
Forest/Wildlife
Pilikula Nisarga Dhama (Zoo), located at about 15 km from the
Sanctuary
proposed site
Historical/
Nil
Archaeological Place
Total estimated land requirement for PTA & PET units is 115.3
Acres being leased from Mangalore SEZ Ltd. The land is in
Project site
possession of Mangalore SEZ which is notified by Ministry of
Commerce & Industries, Gol.
The geographical coordinates of the project is as attached as Annexure -11. The plant
layout plan has been attached as Annexure-12. The location drawing of the proposed
unit in Mangalore SEZ is shown below in Figure 2-3.
Construction activities at site are in progress and recent photographs of the site are
given in figure below.
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Prefeasibility Report for Change in Fuel configuration
Figure 2-4 Recent site photos
Construction of WWTP
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Prefeasibility Report for Change in Fuel configuration
Para Xylene Tanks
The PTA Plants will require High Pressure Steam @ 330 ˚C& 90 BarG and will be
catered to by FOUR Boilers; TWO of Steam Generation capacity 120 TPH using
Natural Gas / Furnace Oil as fuel. TWO Boilers, ONE of capacity 100 TPH (Phase –
1) & ONE of 120 TPH (Phase – 2), shall operate on Coal as Fuel.
The PET Plant has FOUR (3 Working – 1 Standby) Thermic Fluid Heaters (TFH),
each of capacity 9.5 Million Kcal/h. The fuel proposed to be used isCoal (low-ash
Coals like Indonesian/ Australian) from existing 85% Biomass +15% Coal.
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Prefeasibility Report for Change in Fuel configuration
Stack Height Calculation; H : 14 x (204) 0.3 Or 69m.
JBF has already designed a 90m Stack which, as per calculation, is capable of
effectively dispersing emissions.
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Prefeasibility Report for Change in Fuel configuration
This chapter includes the manufacturing process and flow diagrams for the
manufacturing processes.
b) OXIDATION REACTION
Rotary Filters separates TA crystals from mother liquor. The mother liquor,
which contains acetic acid, water, and catalyst, is recycled to reactor. TA
solids are sent to Purification. Process gases are sent to LP absorber for acid
recovery
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Prefeasibility Report for Change in Fuel configuration
portion of the Off-gas from the CATOX is used for pneumatic conveying of
PTA
The solvent recovery area involves several steps to recover acetic acid &
catalyst from the TA mother liquor purge stream. The purge stream is first
evaporated to vaporize the acetic acid. This vapor stream is then sent to LP
absorber, which is a two-stage scrubber using acetic acid followed by water.
Various other Oxidation process vapor streams are also scrubbed in the
LPA. The recovered acid from the LPA is recycled, while the overhead
gases VOC are treated in CATOX.
f) PURIFICATION REACTION
CTA cake is first mixed with water. The CTA / Water slurry is heated in a
series of heat exchangers to the temperature required to dissolve all of the
solids in water, upstream of Purification reactor. The heated CTA / water
solution is reacted with hydrogen, in presence of a Palladium-on-carbon
catalyst, to convert the major CTA impurity (4-Carboxy Benzaldehyde) into
water soluble Para - Toluic acid
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Prefeasibility Report for Change in Fuel configuration
h) PTA SEPARATION, DRYING AND BAGGING
In PTA solids separation section, PTA crystals are separated from mother
liquor. Majority of mother liquor is recycled. The cake discharges to the
PTA dryer. Evaporated moisture is cooled & scrubbed in Dryer scrubber to
remove solids. The treated vapors are sent to CATOX for VOC destruction.
Dry PTA from Dryer is pneumatically conveyed to the Product handling
area for bagging & dispatch.
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Prefeasibility Report for Change in Fuel configuration
Figure 2-5Process Flow Diagram of PTA Manufacturing
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Prefeasibility Report for Change in Fuel configuration
Figure 2-6PTA Block Diagram with Vent and Effluent streams
19
2.6.2 MANUFACTURING PROCESS OF POLYESTER CHIPS/PET
b) ESTERIFICATION REACTION
Under the continuous process from one side slurry of PTA received goes under
gradual heating up to 2500C to start esterification reaction. The reacted mass is
passed through esterification stage – II having temperature of 250 to 2600C and
form Monomer during the process. During this process, water is generated as
byproduct and is transferred to Effluent Treatment System for the treatment.
During the esterification reaction, Antimony Trioxide is added as a catalyst to
accelerate the rate of reaction.
c) PREPOLYMERIZATION
d) POLYCONDENSATION
20
e) DRYING OF THE CHIPS
Preferred size of chips are dried in Dryer and passed through Classifier and
transferred to Intermediate Storage Vessel.
21
Figure 2-7Flow Diagram for PET/Polyester chips manufacturing
22
Figure 2-8Site Layout Plan for Manufacturing of Polyester Chips / PET
23
2.6.3 RAW MATERIALS REQUIRED
The raw materials and products for the proposed project will be brought and sent to
the Mangalore Port through a dedicated road cum pipeline corridor, the layout of
which is attached as Annexure- 13.
The raw material requirement along with their specific consumption in PTA
manufacturing is as follows.
24
Apart from above inputs, following catalyst & chemicals will be used during manufacturing of
PTA:
a) Caustic Soda solution - for neutralization of effluent and as scrubbing media in vent scrubber
b) Aluminium oxide pellets - used as desiccant.
c) Ceramic-base CATOX catalyst for destruction of VOC.
d) Sodium Formate (40% solution) is used as Scrubbing media
The raw material requirement along with their specific consumption in PET/Polyester
chips manufacturing is as follows.
25
2.7 RESOURCE OPTIMIZATION
TwoBoilers each of capacity 120 TPH are proposed to be based onNatural gas / Furnace
Oil and TwoBoilersof capacity 100TPH & 120 TPH arebased on 100 % Coal will be
installed with a capacity considering peak load of 460 TPH at 90 BarGworking pressure
for high pressure steam generation for the PTA process.
Normally each PTA plant upon stabilization, will consume 125TPH of high pressure
steam. During process upsets, about 340 TPH of high pressure steam will be consumed.
Hence 4 nos. of Boilers withcombined steam generation capacity 460 TPH will be
installed for generation of high pressure steam to meet the peak load requirement during
start up / breakdown / upset conditions of the PTA plant.
The Coal requirements in the premises under normal operating situation will be576 TPD
for Boiler and 165 TPD for Thermic Fluid Heater. Total Coal consumption is 741 TPD
i. Natural Gas
26
ii. Furnace Oil
Table 2 – 8 Typical Properties of Furnace Oil
iii. Coal
Table 2–9 Typical Properties of Coal
SL. NO. DESCRIPTION UNIT VALUE
1 Calorific value KCAL / KG 5000 – 5200
2 Bulk density KG/M3 650 – 850
3 Ash fusion point DEGREE C 1250
4 Maximum quantity to be fired MT/DAY 200
5 Hard grove index HGI 45 – 50
6 Range of particle size MM 0 – 50
PROXIMATE ANALYSIS
1 Moisture content % 15 – 20
2 Ash content % 8 – 10%
3 Volatile matter % 38 – 42
4 Fixed carbon % 25 – 35
ULTIMATE ANALYSIS
1 Carbon % 70 – 75
2 Oxygen % 15 – 20
27
SL. NO. DESCRIPTION UNIT VALUE
3 Hydrogen % 5–6
4 Nitrogen % 1.2 - 1.5
5 Sulfur % 0.1 - 0.9
Coal will be transported through trucks from New Mangalore Port to JBF plant
through dedicated MSEZ Corridor. The coal linkage drawing is shown below in
Figure 2-9.
28
Figure 2-9 Movement of Coal from Port
JBF Project
Site
MSEZL’s 60m
Wide Road-
cum-Pipeline
Corridor
29
2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/ POWER
REQUIREMENT
30
2.9 QUANTITY OF WASTE WATER GENERATED
The proposed project will have effluent treatment plant consisting of Physico-chemical
treatment, primary treatment & secondary treatment. After micro filtration and RO
(tertiary treatment), 70% of the treated effluent is recycled to the plant. The remaining
30% of the treated effluent meeting Environmental norms will be discharged to the final
outlet as approved to Mangalore SEZ.
31
Table 2–13 Waste Water Generation – Total
Avg. COD
SI. No. Details Proposed Qty KL/day Avg. COD mg/ltr.
mg/ltr.
1. Domestic 200 - -
2. Process 13,408 14,000 6000-7500
3. Cooling Tower & Utilities 8,192 100 -
Total 21,800
JBF will have designed capacity of effluent treatment plant to take care of normal, peak,
routine & non-routine operations. Condensate water generated due to high pressure steam
supply to the process plant will be recycled to boiler, and the Blow-down will be routed to
ETP. Domestic waste as overflow of soak pit will be connected to biological treatment
section of the Sewage treatment plant for final treatment.
The average COD level in the generated effluent will be about 14000 mg/l, BOD 6000 to
7500 mg/l. 70 % of the treated effluent will be recycled back to cooling tower. Effluent will
be treated up to a Statutory Board Standard prior to its final discharge. There will be a
Methane gas generation during the anaerobic treatment of effluent which will be utilized
for making HP Steam (90BarG) for Process. The ETP Process Flow Diagrams are
enclosed in Annexure-14.
Table 2–14 Components for operation and treatment of waste water
SI. DESCRIPTION USAGE
NO.
1 Various size of collection sump ETP
2 Oil & grease separator ETP
3 Neutralization sump ETP
4 Caustic solution / lime solution tank ETP
5 Polyelectrolyte solution tank ETP
6 Anaerobic digesters ETP
7 Aeration tank ETP
8 Clarifier ETP
32
SI. DESCRIPTION USAGE
NO.
9 Thickener and belt filter press ETP
10 Sludge drying bed ETP sludge removal
11 Aerator ETP
12 Diffuser ETP
13 Pressure sand and activated carbon filter ETP
14 Ultra filtration unit ETP
15 Reverse osmosis plant ETP
16 Treated water, permeate and rejected water tank ETP
17 Gas compression system with blower & tank Biogas utilization
18 Flare Burning of low pressure gas
19 TOC meter Online water monitoring
20 De-mineralize water polishing system ETP
21 Quality control laboratories with instruments to Water analysis
analyze major parameters of effluent
33
Table 2–15 Stack and Emission Details
SI. Description/Parameter Value Remarks
No.
1 SO2 245.25 kg/hr Total Emissions from JBF PTA
(Phase 1 & 2) and PET Plants.
34
Table 2–16 Details of Air pollution control Equipment as approved in EC & CFE
DESIGN DESIGN
S. DESCRIPTION OF
QTY. MOC CAPACITY / SPECIFICATION TEMP PRESS.
NO EQUIPMENT
(⁰ C) (BAR G)
01 Catalytic oxidation reactor ONE SS 316 L H-4.2 M,Φ-3.1 M 19.5 M3 Catalyst 430 10.6/-0.18
Shell 10.6/-
Shell- SS 316 A-2382 M2 Shell-430 0.18
02 Recuperative heater ONE
Tube – SS 316 Q-17.6 M KCAL/H Tube-430 Tube 10.6/-
0.18
Shell-103/ FV
Shell-CS A-91 M2 Shell-320
03 Catox start-up heater ONE Tube- 10.6/-
Tube – Titanium Q-3.8 M KCAL/H Tube-430
0.18
06 Process vent stack ONE SS 304 L H- 13.0 / 32.8 M Φ- 2.4 / 1.9 M 196 0.15 /-0.18
35
DESIGN DESIGN
S. DESCRIPTION OF
QTY. MOC CAPACITY / SPECIFICATION TEMP PRESS.
NO EQUIPMENT
(⁰ C) (BAR G)
0.18
36
DESIGN DESIGN
S. DESCRIPTION OF
QTY. MOC CAPACITY / SPECIFICATION TEMP PRESS.
NO EQUIPMENT
(⁰ C) (BAR G)
pumps
PTA crystallizer overflow ko
20 ONE SS 304 L H-2.7 M Φ- 2 M 131 1.1
drum
21 Blowdown drum ONE CS H-4.2 M Φ-2.1 M 131 1.1/-0.18
Liq. catalyst tank vent
22 ONE SS 316 L H-6 M Φ-0.4 M 50 0.50 / -0.18
scrubber
Acetic acid tank vent
23 ONE SS 316 L H-6 M Φ-0.4 M 100 0.50 / -0.18
scrubber
24 Oxid. unit psv sump ONE CS Epoxy coated L-7.4 M- Φ 5.0 M 210 1.0 / -0.18
Shell- SS 316 L
H-11 M Φ-0.8 M2 PACKED BEDS OF
25 Low pressure absorber ONE Packing’s moc poly 115 3.5 /-0.18
HT. 1.9 & 1.3 M
Propylene
26 Low pressure absorber drum ONE SS 316 L L-10 M- Φ 4 M 115 3.5 /-0.18
27 LP absorber circulation pump TWO SS 316 L V 163 M3/H, ∆P-15 BAR,P 160 KW 115 24
Shell-10.3/-
DH tower overhead final Shell-CS A-1587 M2 Shell – 65 0.18
28 ONE
condenser Tube – DSS 2205 Q-40 MKCAL/H Tube-146 Tube- 12.4/-
0.18
SHELL- SS 317 L CLAD
H-25 M- Φ 3.4 M PACKED BED OF 8.4
29 High pressure absorber ONE ON CS 154 12.4 /-0.18
M & 10 TRAYS
TRAYS –SS 316 L
SHELL-CS A-280 M2 SHELL – 65 Shell-10.3/-
30 HP absorber reflux cooler ONE
TUBE – DSS 2205 Q-3.6 MKCAL/H Tube-115 0.18
37
DESIGN DESIGN
S. DESCRIPTION OF
QTY. MOC CAPACITY / SPECIFICATION TEMP PRESS.
NO EQUIPMENT
(⁰ C) (BAR G)
Tube- 24 /-
0.18
Shell-7.8 / FV
SHELL-CS A-275 M2 Shell –200
31 HP absorber vent gas heater ONE Tube- 12.4 /-
TUBE – SS 316 L Q-6.5 MKCAL/H Tube-145
0.18
Flue gas handling volume- 156000M3/H
32 ESP ONE STEEL 190°C -
Dust removal efficiency-99.5 %
To Control Particulate Matter
SHELL-MS ELEMENT- Total No Of Filter-48
33 Bag Filters ONE < 120ᵒC 0.5-0.7 MPa
POLY PROPYLENE Filter Area-36 m2
Filtration Air Volume-1080 m3-8640 m3
38
3. SITE ANALYSIS
3.1 CONNECTIVITY
The project site is located within Mangalore SEZ and is well connected by Road. The
location of the site is given in Figure 4-1 below and the Port Road corridor is enclosed in
Annexure-13.
The proposed project site is within Mangalore SEZ area. The land use classification for
the study area is given in table below
39
Table 3-1 Land Use classification for the Project Site
40
3.4 EXISTING LAND USE PATTERN
41
Figure 3-3Land use map of Study Area
CASHEWNUT
21%
MANGO PADDY
4%
COCONUT
ARECANUT
BANANA PADDY BANANA
1% 53% MANGO
ARECANUT CASHEWNUT
6%
COCONUT
15%
42
3.5 EXISTING INFRASTRUCTURE
SANDY CLAY
1. JBF PROJECT SITE 38.2 19.6 19.4 22.8
LOAM
43
3.8 SOCIAL INFRASTRUCTURE
The project will provide employment to local youth, thus increasing their standard of
living and helping strengthen the social infrastructures of the region.
44
4. PROPOSED INFRASTRUCTURE
4.1 INDUSTRIAL AREA
Table 4-1 Summary of proposed change
Diesel
2160 KL/month
7. Steam generators Steam generator / Boiler Steam generator / Boiler
/ boilers 3x 120 TPH (4 Nos.)
Natural gas/Furnace Oil Total capacity: 460 TPH
(120+120+120+100 )
1x100 TPH boiler 2 x 120 TPH Boiler
85% biomass+ 15% coal (no fuel change)
(165 TPD Biomass + 25 TPD Natural gas/ Furnace Oil
Coal) 1 x100 TPH (Phase – 1) &
1x120 TPH(Phase –
2)Boilers
Coal 576T/DAY
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8. Total Coal 741 TPD
consumption
4.3 GREENBELT
The proposed project site is situated within the Mangalore SEZ and they have provided
33% area of open land as greenbelt as a developer of SEZ which is also covered in their
environment clearance.
A green belt of required width (3m) will be provided all around the plant boundary limits.
In addition, avenue trees will be planted along the roads.
4.5 CONNECTIVITY
Connectivity between Mangalore Port and JBF site has been shown in Annexure-13.
Sewage from the plant would be disposed to the sewage pits/network from where it is
pumped to the main STP for treatment and the treated water is used for horticulture.
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4.8 INDUSTRIAL & SOLID WASTE MANAGEMENT
4.8.1 ASH GENERATION
When coal is used as fuel, water sprinkling is proposed for dust suppression at the rate of
2.5 Kg/ Sq.cm of the area incase of track hopper and 4.5 Kg/ Sq.cm in case of wagon
tipper coal stock. Of the water used, 10 % will be absorbed by Coal and 20 % will be lost
in evaporation. The treatment system proposed will be Settling Pond. The water after
treatment can be recirculated for dust suppression.
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Relatively low operation costs
Operation capability at high temperatures up to 700oC,or (1,300oF) and high
pressure (up to 10 atmospheres or 150 pounds per square inch, psi) or under
vacuum
Capability to handle relatively large gas-flow rates (on the order of 50,000
m3/min)
a) Fly Ash
The ash removal system consists of three stages ESP, dust hoppers & pneumatic
ash conveying system. One cone pump (0.6 m3) will be installed under each
hopper and the dry ash shall be sent into ash silo of capacity 150 m3, which will
handle the ash discharging capacity of3.5days. The conveying distance is 50m.
Adequate dust collector or bag filters will be provided at the Ashsilo for dust
suppression & venting clean (Filtered) air from conveying system. The dry ash
can be loaded and transported for integrated utilization. Fluidization device will
be equipped to ensure smooth ash discharge into the ash silo. The fluidization air
can be provided by gasification fan, and the electric heater at the outlet of fan.
The layout showing the Ash handling system is enclosed in Annexure-15.
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Table 4-3 Specification of ash conveying system
S.No Item Unit Parameter
1 Designed output T/H 3
2 Average ash-gas ratio kg/kg 35
3 Average conveying pressure MPa 0.1
4 Speed at the front part of ash-pipe m/s 2 ~4
5 Speed at the end part of ash pipe m/s 8 ~9
6 Air consumption for conveying m3/min 7.0
7 Airconsumption for instrument m3/min 0.5
b) Bottom ash
When burning Coal, the slag shall be discharged, and this discharged slag after
cooling can be used as bed material within the Boiler to ensure better fluidized
combustion. Bed material shall be added into boiler by coal feeder at the feed-end
of the boiler when starting and operating the boiler.
PLC shall be used for the control of ash handling system. Automatic control
consists of PLC, local control station and sensors.
c) Desulfurization Arrangement
The reduction in SO2 emission during coal combustion will be attained by utilizing
low-sulfur coal (Indonesian coal) as well as by employing desulfurization process
which involves the use of Ca-based sorbent such as limestone powder that captures
the SO2 emitted.
JBF has made all the required provision for feeding Limestone along with coal into
the boiler in the mole ratio of Ca:S = 2 for the removal of SO2 emitted. This measure
taken is expected to achieve a reduction of MINIMUM70 % in SO2 emissions. The
addition of sand will ensure the removal of excess calcium in the form of Calcium
silicate. A brief description of the system is as follows:
Limestone is stored in a Steel Bin and discharged through a Screw Conveyorfirst and
then through two conveyors before entering the Boiler Furnace through Rotary
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Feeders, whose function is to regulate flow of Fuel, Sand and Limestone entering the
Furnace. The Limestone Bin has a storage inventory of 20m3. A rotary valve operated
by a variable frequency drive linked to the control systemis mounted at the hopper
discharge and serves as the material metering device.This valvedischarges material
through a small, vented chute directly into a blow-through rotary airlock runningat a
constant speed. The blow-through rotary airlock is the primary seal between the
metering system and the pneumatic conveying line; the metering rotary valve is the
secondary seal. Each feeder hopper is equipped with its own reverse jet pulse dust
filter system, which traps nuisance dust generated during feeder refill and returns it to
the process. The dust filter also facilitates air displacement in the hopper as material
is metered out or replenished, as well as air leakage from the blow-through rotary
airlock. Every precaution is taken to assure that the conveying lines do not become
plugged with material.
The SO2 emitted during the operation of PTA plant and PET Plant will be 204 kg/h
and 41.25 kg/h, respectively.
The detailed calculations regarding SO2 emissions will be furnished in the EIA report.
All the hazardous and non-hazardous waste will be stored in an integrated scrap yard
in a segregated manner. Some of the wastes, like contaminated packing material,
sweeping material and other non-hazardous waste will be disposed through registered
recycler and re-processor having KSPCB/CPCB approval.
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Table 4-4 Estimated Hazardous Waste Generation & Disposal
51
the premises.
Guidelines approved by MoEF / KSPCB for notified area as Mangalore SEZ Ltd. will
be executed in ref. to disposal of hazardous &non-hazardous waste.
Integrated scrap yard will have segregation of hazardous &non-hazardous area in a
close covered shed with a separate entry for hazardous &non-hazardous storage area.
INTEGRATED SCRAP
55 YARD
100
m 45 m
m
Residual ETP Waste Paper Empty bags/liners
sludge of FO 40x20 waste & 30x20
15x25 Insulation
Leach 15x25
ate Pit
Process waste Empty
(L.W.) & Scrap PTA PVC
Spent Catox containers
30x15 material &
15x12.50 / barrels /
Glass 55
carboys
15x12.50
20x15
m
Used & Waste Oil
Waste resin, 30x7.50
used carbon
Wooden Iron scrap
catalyst, Mol. Oil & Chemical soak
scrap 20x15
Sieve, exp. cotton waste 15x12.50
Chemical & 30x7.50
Lead acid
battery Gate Gate
15x12.50 01 02
All equipment in the power plant would be designed/operated to have a noise level
not exceeding 85 dB as per the requirement of Occupational Safety and Health
Administration Standard (OSHA). In addition, since most of the noise generating
equipment would be in closed structures, the noise transmitted outside would be still
lower.
There will be no generation of bad odour as process will be carried out in closed
reactor with auto-operations in the plant.
The raw materials consumed falls under Hazardous chemicals as per the MSIHC
rules, 2000. The details pertaining to the hazardous chemicals in terms of health,
52
explosion and fire hazards and measures for storage, handling & transportation will
be considered complying with statutory regulations under the various acts & rules.
All measures shall be taken to minimize the environmental impact during the process.
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4.9 POWER REQUIREMENT
Power plant consisting of 2 nos. of 15 MW each rated capacity which can be able to
generate net 12MW per turbine during performance running at around 35°C. Initially
diesel will be used as main fuel for power generation and changeover to natural gas will
be made as and when gas will be available.
Figure 4-2Flow Chart for Captive power plant and Heat recovery system
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5. PLANNING BRIEF
5.1 PLANNING CONCEPT
The existing plants of JBF group in India & UAE already manufacture Polyester Chips &
consume PTA as key raw material and demand on PTA based processing of Polyester
chips and Polyester Yarn are increasing internationally. Paraxylene (Px) is a basic raw
material for PTA manufacturing which may be sourced from the aromatic complex being
developed by ONGC Mangalore Petrochemicals in Mangalore SEZ or can be imported,
as the PTA plant is being developed in SEZ. The Mangalore SEZ Ltd. is providing all the
required infrastructure like road connectivity, graded plots, water infrastructure, waste
water collection system, solid waste management system, marine disposal facility for
treated waste water and green belt development. Apart of PTA produced will be used for
PET manufacturing plant being situated adjacent to the PTA plant in Mangalore, the rest
being exported to JBF RAK, UAE.
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S.No Demographic Parameters Details
9. Literate (%) 102647(74.46%)
10. Main workers (%) 58883(42.71%)
11. Marginal workers (%) 7902(5.73%)
12. Non- workers (%) 71065(51.55%)
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5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
5.4.1 PHYSICAL INFRASTRUCTURE
The project with an investment of more than Rs. 3500 crores will bring improvement
in physical infrastructure like roads, electricity, water infrastructure along with
various other developmental activities as per its Corporate Social Benefit strategies.
The project wills provide employment to local youth, thus increasing their standard of
living and thus helping strengthen the social infrastructures of the region.
5.4.3 AMENITIES/FACILITIES
57
6. REHABILITATION AND RESETTLEMENT (R & R) PLAN
58
7. PROJECT SCHEDULE & COST ESTIMATES
The proposed change converts the idea of turning waste into energy, and also reduce
emission load on the environment
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8. ANALYSIS OF PROPOSAL (FINAL
RECOMMENDATIONS)
The project will bring in the following benefits for the proposed manufacturing plant
The proposed fuel viz., coal will provide support for uninterrupted Production
with lower down-time and is not likely to be affected by monsoons as compared
to Biomass.
The ash content is lower at about 10% as compared to Indian coal which contains
40% Ash.
The following environmental and societal benefits are expected from the given industry:
This process utilizes a Catalyst based Oxidation process for destruction of
organics and organic halides, CATOX, which eliminates the requirement for the
use of an incinerator.
Local production of PTA/PET/Polyester chips means reduction of import of the
same. Thus saving millions of gallons of fuel used up in shipping every year.
33% green belt being provided by the MSEZ, along with extra green belt
proposed by JBF will help keep the air clean..
Project using raw material from nearby OMPL, decreases the need of transport
and thus fuel usage.
500 people, mostly from the neighboring areas will benefit directly or indirectly
from the proposed Project.
About 115 persons from the rehabilitated families will be recruited by JBF, thus
improving their standards of life.
JBFs will be maximizing its utilization, recycling and reuse of wastes, even
producing energy form the off gas, which will be a highly pro environmental
benefit from the project.
Around 70% of the effluent water will be treated and reused, so it will use lesser
amount of raw water thus making it an additional environmental benefit.
Flexibility of the using Butane-rich Natural Gas as when available, in place of
Furnace Oil, as Fuel. GAIL is laying a pipeline from Kochi.
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Low NOx burners are used throughout the plant.
Comprehensive effluent treatment plant using both conventional & tertiary
treatment technology to achieve over 70% recycle and improved quality treated
wastewater discharge.
Water consumption is reduced right at the design phase by recycling over 15000
KLD of Condensate, Process and treated water back into the process, which helps
reduce the overall water requirement.
ETP is designed in a way, so as to use the natural gradient of site for flow to
reduce the total no. of pumps required.
Mangalore City’s sewage treated and reused for Industrial purpose.
Advanced British Petroleum technology from Process Licensor to optimize the
overall energy efficiency of the plant reducing total fuel consumption and water
consumption, thereby reducing products’ environmental footprint.
Online analyzers are being proposed for real time stack monitoring.
Variable speed drives are being used.
Methane Gas, generated from Anaerobic Digester, is used to generate about 14
tons per hour of High Pressure Steam (90BarG) to meet about 20% of Process
steam requirements.
Boiler chimney height is proposed for 90meters.
Vapor Absorption machines (VAM) are being used for refrigeration and air
conditioning purposes.
61