PREFEASIBILITY REPORT 1 ABC/NIG/PFR/VER2.0 1.0 INTRODUCTION 1.1 IDENTIFICATION OF PROJECT The project proponent M/s. New India Group, New Delhi, is engaged in the production of Linear Alkyl Benzene Sulphonic Acid. New India Group (NIG) is proposing to set up a surfactant manufacturing facility in Chennai under the name and style of “Detergeo Chem Private Limited” to cater to the raw material demand of the home-care and personal-care industry in South India. NIG has selected the following surfactants for its key product portfolio: Linear Alkylbenzene Sulphonic Acid 96% (LABSA 96%) and Linear Alkylbenzene Sulphonic Acid 90% (LABSA 90%). Additionally, NIG shall also produce Alpha Olefin Sulfonate (AOS), Sodium Lauryl Sulphate (SLS) and Sodium Lauryl Ether Sulphate (SLES) to cater to the raw material demand of the FMCG industry in the region. All the above products will be manufactured on the same plant however organic feedstock shall change depending on the requirement of the final product. IDENTIFICATION OF PROJECT PROPONENT The New India Group is a fourth generation family-owned and professionally managed diversified business group. The group was founded in 1947 and is primarily into manufacturing and trading of dyes, chemicals and textiles. The group’s mission is to best serve the needs of its valuable customers by conducting business in line with its core values of: integrity and reliability. BRIEF DESCRIPTION OF NATURE OF THE PROJECT The proposed project will fall under Schedule 5(f) of the EIA Notification - 2006 and Amendments thereon. As the project site is located inside a notified industrial estate this project falls under ‘B’ category and requires clearance from SEIAA-Tamil Nadu. 1.2 NEED FOR THE PROJECT AND IMPORTANCE TO THE NATION With the increase in the population and usage of soaps and detergents by the people, its market is has good prospective and bright future. So, we need a raw material from which the soaps and detergents could be made instantly and easily. Acid slurry is one such material, from the soaps
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PREFEASIBILITY REPORT
1 ABC/NIG/PFR/VER2.0
1.0 INTRODUCTION
1.1 IDENTIFICATION OF PROJECT
The project proponent M/s. New India Group, New Delhi, is engaged in the production of Linear
Alkyl Benzene Sulphonic Acid. New India Group (NIG) is proposing to set up a surfactant
manufacturing facility in Chennai under the name and style of “Detergeo Chem Private
Limited” to cater to the raw material demand of the home-care and personal-care industry in
South India.
NIG has selected the following surfactants for its key product portfolio: Linear Alkylbenzene
Sulphonic Acid 96% (LABSA 96%) and Linear Alkylbenzene Sulphonic Acid 90% (LABSA
90%). Additionally, NIG shall also produce Alpha Olefin Sulfonate (AOS), Sodium Lauryl
Sulphate (SLS) and Sodium Lauryl Ether Sulphate (SLES) to cater to the raw material demand
of the FMCG industry in the region. All the above products will be manufactured on the same
plant however organic feedstock shall change depending on the requirement of the final product.
IDENTIFICATION OF PROJECT PROPONENT
The New India Group is a fourth generation family-owned and professionally managed
diversified business group. The group was founded in 1947 and is primarily into manufacturing
and trading of dyes, chemicals and textiles. The group’s mission is to best serve the needs of its
valuable customers by conducting business in line with its core values of: integrity and
reliability.
BRIEF DESCRIPTION OF NATURE OF THE PROJECT
The proposed project will fall under Schedule 5(f) of the EIA Notification - 2006 and
Amendments thereon. As the project site is located inside a notified industrial estate this project
falls under ‘B’ category and requires clearance from SEIAA-Tamil Nadu.
1.2 NEED FOR THE PROJECT AND IMPORTANCE TO THE NATION
With the increase in the population and usage of soaps and detergents by the people, its market is
has good prospective and bright future. So, we need a raw material from which the soaps and
detergents could be made instantly and easily. Acid slurry is one such material, from the soaps
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and liquid detergents could be made from. And demand of Linear Alkyl Benzene Sulphonic Acid
(LABSA) is always there in domestic market and as well as in global market for FMCG industry.
To meet the current market demand, New India Group has planned to set up a new
manufacturing unit Detergeo Chem Pvt. Ltd. intended for the production of LABSA and other
alternative surfactants (AOS, SLS and SLES) at Plot No.F-52, SIPCOT, Gummidipoondi,
Chennai (India).
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2.0 SITE ANALYSIS
2.1 LOCATION
New India Group has planned to set up a new manufacturing unit Detergeo Chem intended for
the production of LABSA and other alternate surfactants (AOS, SLS and SLES) at Plot No.F-52,
SIPCOT, Gummidipoondi, Chennai (India).The satellite Imagery of the site is shown Figure 2.1.
The location of the project site is represented in Figure 2.2.
Figure 2.1 Satellite image of project site
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Figure 2.2 Location map of project site
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2.2 CONNECTIVITY
The site is well connected by the Guntur and Chennai National Highway (NH 5) at a distance of
0.8 km. This unit is located in the South eastern direction of this road. The raw material &
product is conveniently transported by this road.
Figure 2.3 Connectivity map of project site
2.3 LANDUSE CLASSIFICATION & LANDUSE BREAKUP
Tamil Nadu Government has recognized the location of this unit as “SIPCOT Industrial Area”
and encouraging entrepreneurs to come forward for setting up industries. The area is dominated
by large scale industries and other medium scale industries.
The total plot area of the facility is 4048 sq.m. The land use breakup of the project site is given in
Table 2.1. The topo map of the project site and its surrounding area covering 10 km radius are
given in Figures 2.4. Map Showing the Water Body is given in Figure 2.5. Environmental
settings are presented in Table 2.2.
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Figure 2.4 Topo map (10km around project site)
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Figure 2.5 Water body map (10km around project site)
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Table 2.1 Land Use Break up of Project Site
S. No Land Use Breakup Details Area (Sq.m.)
1. Production Shed 1400
2. UG WATER Tank/Cooling Towers 96
3. Sulphur Yard 80
4. Tank Farm 336
5. DG/Electrical (G + 1) 54
6. Repair Workshop 36
7. Store/Office/LAB/Canteen 105
8. ETP/Septic Tank 60
9. Car Parking 36
10. Greenbelt Area (33% of total area) 1336
11. Roads 508
Total Area 4047
Table 2.2 Environmental Settings of Project Site
S. NO. PARTICULARS DETAILS
1 Site Latitude 13°24'47.84"N
2 Site Longitude 80° 6'46.20"E
3 Site Elevation 67 m
4 Nearest highway Guntur and Chennai National Highway (NH5) –
0.8 km (ESE)
5 Nearest railway station Gummidipundi Railway Station- 1.2 Km (ESE)
6 Nearest airport Chennai International Airport – 47.13 km (SSE)
7 Nearest town/ city Gummidipundi Town – 0.7 km (SSE)
8 Topography Plain
9 Archaeologically important
places Nil within 10 km radius
10 National parks/ Wildlife
Sanctuaries Nil within 10 km radius
11 Reservoir/River/Lake
Poovalambedu Pond 7.7 km (WSW)
Arani River 6.49 km (SSW)
Panpakkam Lake 4.33 km (SSE)
Pattupalli Lake 6.56 km (ENE)
Pallavada Lake 11.55 km (NW)
Ponneri Lake 13.8 km (ESE)
Pulicate Lake 14.9 km (ENE)
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S. NO. PARTICULARS DETAILS
12 Reserved/ Protected Forests
Puliyar Forest 6.31 km (WSW)
Siruvada Forest 9.57 km
Thervoy Reserve Forest 9.82 km
13 Seismicity Zone II
14 Defence Installations Nil within 10 km radius
15 Nearest Port Chennai Port – 41.5 km (SE)
2.4 SITE SUITABILITY / ALTERNATE SITES CONSIDERED
The proposed project site is leased from SIPCOT. This site has the following advantages:
The Plant is located in the SIPCOT hence basic infrastructure of roads, power, water
etc. is readily available.
The plant is located near high demand area.
There is no likelihood of any residential development in the vicinity of the Plant.
Possible mutual aid in emergency will be available in the Industrial Area.
There is potential for future growth in demand.
Adequate availability of land within the SIPCOT for future expansion etc.
Hence, no alternative sites were considered.
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3.0 PROJECT DESCRIPTION
3.1 MAGNITUDE OF OPERATION
Production capacities of the products, has been estimated as 43000 MT/A.
3.2 RAW MATERIALS REQUIRED FOR PRODUCTION
Table 3.1 List of Raw Materials
Sr.
No. Name Of Raw Materials
Quantity in TPD
(ANY ONE OR MIX) Mode of Transport
1 Linear Alkyl Benzene 90 MS Tanker
2 Alpha Olefin 90 20/40 feet container
3 Lauryl Ether 90 Road
4 Lauryl Alcohol 90 20/40 feet containers
5 Sulfuric Acid 98% 10 MS Tanker
6 Caustic Soda Liquid 10 MS Tanker
7 Sulfur 13 Trailer
Sr.
No. Description
Physical
Form
Type of
Storage
Capacity of
storage, MT No.
➢ Raw Materials
1 Linear Alkyl Benzene Liquid MS Tank 100 3
2 Alpha Olefin Liquid SS Tank 50 1
3 Lauryl Ether Liquid SS Tank 50 1
4 Lauryl Alcohol Liquid SS Tank 50 1
5 Sulfuric Acid Liquid MS Tank 10 1
6 Caustic Soda Liquid Liquid MS Tank 10 1
7 Sulfur Solid Closed Yard 50 1
➢
1 LABSA 96% Liquid MS Tank 100 2
2 AOS 38% Liquid SS Tank 50 1
3 SLES 28% Liquid SS Tank 50 1
4 SLS 28% Liquid SS Tank 50 1
5 LABSA 90% Liquid MS Tank 50 1
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3.3 PROCESS DESCRIPTION
Sulfur Trioxide Gas Generation
Sulfur trioxide gas is generated by burning sulfur at high temperature and sulfur dioxide then
formed in presence of air which later converted to sulfur trioxide in presence of a catalyst in a
well closed loop system. Industrially SO3 is made by the contact process. Sulfur dioxide,
which in turn is produced by the burning of sulfur. After being purified by filtration, the SO2
is then oxidized by atmospheric oxygen at between 400 and 600 °C over a catalyst. A typical
catalyst consists of vanadium pentoxide (V2O5) activated with potassium oxide K2O
on kieselguhr or silica support. The heat generated during this process is utilized for steam
generation. This steam is consumed in various uses like sulfur melting, Air drying and water
chilling etc.
Sulphonation System
The Sulfonic acid forms in the unit when an SO3-in-air mixture is injected into a multi-tube
reactor, simultaneously with the desired organic feed. The removable organic distribution
flanges are factory calibrated prior to installation in the reactor. Uniform distribution of the
air-SO3 gas is the result of symmetrical gas flow through the reactor. Reaction temperature is
also a very important parameter of control in sulfonation and sulfation process. Cooling
jackets in the reactor remove heat of reaction. Organic feed rate to the reactor vessels is
measured by means of a highly accurate mass flow meter and controlled by a control valve
and centrifugal pump. The organic feed rate is controlled based on the preset sulphur-to-
organic mole ratio. Exhaust gas is separated from the acid recycle stream in the liquid
separator and cyclone vessels. For the production of sulfonic acid, the acid product is fed
directly to the digestion system where reaction with absorbed SO3 goes to completion.
Neutralization
The Sulphonic acids produced after Sulphonation of LAB/AO/LE/LA is neutralized to make
their respective sodium salt.
This process takes place by mixing Sulphonic acid with liquid sodium hydroxide solution up
to getting neutral pH of the product. This reaction is exothermic hence proper cooling is