20 PRE – FEASIBILITY REPORT For Proposed Expansion of Fertilizer Project By BEC Fertilizer (Unit of Bhilai Engineering Corporation Ltd) At Plot No. 96 Sector – A, Sirgitti, CSIDC Industrial Estate Bilaspur (Chhattisgarh)
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20
PRE – FEASIBILITY REPORT For
Proposed Expansion of Fertilizer Project
By
BEC Fertilizer (Unit of Bhilai Engineering Corporation Ltd)
At
Plot No. 96
Sector – A, Sirgitti, CSIDC Industrial Estate
Bilaspur (Chhattisgarh)
1
PRE-FEASIBILITY REPORTOFBEC FERTILIZERS
INDEX
Sr. No. Description Page no.
1.0 EXECUTIVE SUMMARY 3
2.0 INTRODUCTION OF THE PROPOSED PROJECT 4
2.1 Project Proponent 4
2.2 Need for Project 5
2.3 Employment Generation 5
3.0 Project description 6
3.1 Product and Raw Material 7
3.2 Manufacturing Process 8
3.2.1 Sulphufic Acid (SAP) 8
3.2.2 Single Super Phophate (SSP) 9
3.2.2(A) Boronated Single Super Phosphate (BSSP) 11
3.2.3 Triple Super Phosphate (TSP) 12
3.2.4 Granulated Single / Triple Super Phosphate 13
3.2.5 Sodium Silico Fluoride (By-product) 13
3.3 Resource – Utilize and Recycling 14
3.4 Waste Water Generation 15
3.5 Air Emission 16
3.6 Solid Waste Generation 16
3.7 Purpose of EIA study 17
4.0 Site Analysis 17
4.1 Connectivity 17
4.2 Land use / Topography 17
4.3 Infrastructure 18
5.0 Planning brief 18
6.0 Existing / Proposed infrastructure 18
7.0 Rehabilitation and Resettlement (R&R) Plan 19
8.0 Project Schedule and Cost estimates 19
9.0 Analysis of project 19
2
LIST OF FIGURES
Sr. No. Description of Figure
Fig. 1 Location map of BEC Fertilizers (CSIDC Sirgitti) Bilaspur
Fig. 2 Plant lay-out of proposed / existing fertilizer project
Fig. 3 Process flow diagram of Sulphuric Acid Plant.
Fig. 4 Process flow diagram of Single / Triple Super Phosphate
Fig. 5 Process flow diagram of Granulation (SSP/TSP)
Fig. 6 Process flow diagram of Sodium Silico Fluoride (By product)
Fig. 7 Schematic diagram of Pollution Control System (SSP/TSP)
Fig. 8 Schematic flow diagram of Effluent Treatment Plant (ETP)
Fig. 9 Topography map of Bilaspur district.
3
1.0 EXECUTIVE SUMMARY
M/s. Bhilai Engineering Corporation Limited (BEC), Bhilai is a diversified
Engineering manufacturing organization with multidisciplinary facilities. It is engaged in meeting the engineering challenges of business with a devoted sense of commitment and conviction. BEC‟s main product ranges from design, engineering,
manufacturing of steel plant and other core sector equipments for over 40 years, to manufacture and supply of Fertilizer since year 1985.
M/s. BEC Fertilizers (BECF) is a unit of M/s. Bhilai Engineering Corporation Limited
and entered in the business of Manufacturing fertilizers and other Agro-inputs since 1985. BEC has a unit at Bilaspur (1985) and Pulgaon (2001). Now BECF propose to
do the expansion of their Bilaspur unit to meet the growing demand of fertilizer by the farmers at Sirgitti CSIDC Industrial Estate..
Proposed Project Summary:
Sr. No.
Description Quantity
1 Project Location Plot no. 96, Sirgitti, CSIDC Industrial area, Bilaspur.
2 Category of Project as per EIA Notification 5(a) “A”
3 Project cost 75.00 Crores
4 Plot area 47.66 Acres (Existing premises)
5 Proposed Product & By-Product As mentioned in para 3.1 of report.
6 Raw Material As mentioned in para 3.1 of report.
7 Resources
(i) Electricity Requirement Existing 0.7 MW, Proposed 3.2 MW
Source of electricity Chhattisgarh State Electricity Board (CSEB)
D. G. Sets
T.G. Set
2 nos. of 1070 KVA are already available to meet emergency requirement.
01 No.of 2500 KVA capacity will be installed to utilize surplus steam of Acid plant using waste heat.
(ii) Water consumption Existing 350 KLD, Proposed 1550 KLD
Source of water CSIDC – SirgittiBilaspur.
Waste water generation Existing 40 KLD, Proposed 120 KLD
Mode of disposal It shall be utilized for irrigation after treatment in factory premises. ZERO effluent discharge from factory premises.
(ii) Fuel Coal - Existing 5 MT/Day, Proposed30 MT / Day
8 Solid waste generation As Mentioned in para 3.6 of report.
4
2.0 INTRODUCTION OF THE PROJECT
Since 1985 BECF is in the field of Manufacturing fertilizers and other Agro-inputs. We already have two units to manufacture Single Super Phosphate (SSP) at Bilaspur
(CG) and Pulgaon (Dist. – Wardha, Maharastra) of production capacity 140000 TPA and 66000 TPA respectively.
The existing capacity of Bilaspur unit is to produce following:
01. Sulphuric Acid - 40,000 TPA
02. Single Super Phosphate - 1,40,000 TPA
03. Granulated NPK Fertilizer - 45,000 TPA
BECF proposes to expand the capacity of Bilaspur unit by installing new plants in
the existing premises. Proposed capacity shall be:
01. Sulphuric Acid - 1,40,000 TPA 02. Single/ Triple/ Boronated Super Phosphate - 4,40,000 TPA
03. Granulated Fertilizer - 4,40,000 TPA (SSP/TSP / NPK /CustomizedFertilizer)
2.1 Project Proponent
M/s. BEC Fertilizers (BECF) – a unit of Bhilai Engineering Corporation Ltd. BEC Ltd. has five units located in Raipur and Bhilai cities of the Chhattisgarh State, India. There are 5 Regional offices in New Delhi, Mumbai, Kolkata, Chennai and Bangalore
to facilitate and support various projects and develop corporate relations. BEC is the most successful Engineering, Procurement and Construction (EPC) Company
including Heavy Equipment supplier in India. It undertakes complete project implementation including Mechanical, Structural, Electrical and Civil jobs. BEC Ltd. has group companies namely Vishva Vishal Engineering Limited, BEC Food and BEC
Fertilizers.
Fertilizers and Agro Chemicals Industry in India is keys to the Agriculture sector. BEC Fertilizers include a modern technology Fertilizers manufacturing complex at Bilaspur C.G., and the second fertilizer unit at Pulgaon, Maharashtra State to
manufacture "ANAND" Single Super Phosphate and NPK Fertilizers.
The proposed project will be started after receiving statutory clearances from
authority. Production Capacity, raw material and proposed product is discussed in para 3.0 of the report.
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2.2 Demand – Supply
The production and consumption of the SSP in the last decade is as follows:-
All India production & consumption of SSP
Year Production / MT
Consumption / MT
2001-02 2504.60 2590,90
2002-03 2407.78 2390.40
2003-04 2543.40 2449.00
2004-05 2469.10 2472.30
2005-06 2795.20 2705.00
2006-07 2972.00 2928.60
2007-08 2246.30 2244.00
2008-09 2533.60 2614.70
Source : Fertilizer statistics 08-09 of FAI, New Delhi.
SSP consumption ( 2008 - 09) in major marketing zone of BECF, Biaspur
1 Chhatisgarh 158850 MT
2 Maharashtra 587520 MT
3 Madhya Pradesh
513580 MT
Total 1259950 MT
2.3 Need for Project
Super Phosphate (SSP) Fertilizer industry is the pioneering fertilizer in the country and the first SSP plant is said to have been established by EID Parry in the year
1906. Manufacturing of SSP is based on perhaps the simplest chemical reaction amongst chemical fertilizer industry. The main raw materials required are rock
phosphate and sulphuric acid. SSP is a straight Phosphatic multi-nutrient fertilizer which contain 16% citrate soluble P2O5, 12% Sulphur, 21% calcium and some other essential micro nutrients in small proportions.
SSP is a poor farmer's fertilizer (price-wise), is an option to optimize the use of phosphatic fertilizer. It also helps to treat Sulphur deficiency in soil (40% Indian soil
Sulphur deficient) as well for further enhancement of yields at the least cost. In various crops, which require more of Sulphur and phosphate like oilseeds, pulses, sugarcanes, fruits and vegetables, tea etc. SSP is an essential fertilizer.
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S.S.P. is cheapest among phosphoric fertilizer and essential for cultivation of Sugarcane, Pulses, Oil seeds, Fruits and vegetables etc. The DOF has indicated that
40% of Indian soil is deficient of Sulphur, which needs use of SSP.
Triple Super Phosphate (TSP) which is a concentrated form of Single Super
Phosphate can also be manufactured in the existing SSP plant.
S.S.P. industries are widespread throughout India, rather-than limited to any specific location. Presently there are 62 SSP units under the concession scheme as on
31.3.2009 on the basis of assessment made by PDIL.
Points for need for proposed expansion of Bilaspur unit,
1. SSP consumption has remained static during last decade.
2Chhattisgarh, Maharashtra and Madhya Pradesh accounts for 45% of SSP consumption in India, which is major marketing zone for unit based in
Bilaspur.
3. BECF markets its product from existing two units (Bilaspur&Pulgaon)
in Maharashtra, Madhya Pradesh, Chhattisgarh, West Bengal & Tripura States under "ANAND" brand which is very well accepted and preferred by farmers for its quality and reliability since 1985.
4. Bilaspur Unit will also give BECF a flexibility to meet our eastern zone requirement, which is presently supplied partly from Pulgaon unit.
2.4 Employment Generation
There were upliftments of socio-economic standard of local people surrounding the project site due to proposed project. During the construction phase work will be
generated for skilled, semiskilled and unskilled labors. Technical persons will be recruited during the operation phase. It is expected to direct or indirect employ about 100 – 150 people of various skills will be required during construction as well as
operation phase.
3.0 PROJECT DESCRIPTION
M/s. BEC Fertilizers (BECF) proposes to expand unit at Sirgitti CSIDC Industrial
Estate, Sirgitti, Bilaspur (CG) is notified industrial estate. Location map of Sirgitti CSIDC Industrial Estate is attached as Figure – 1. Plant layout of existing and
proposed fertilizer project is attached as Figure – 2.
Total plot area is 47.66 Acres. Existing plant is located in about 12 Acres area so
sufficient land is available for expansion of the unit. Environmental settings and infrastructures available surrounding the proposed project is as under,
Env. Settings & Infrastructure
Name & Arial Distance
Town/City Bilaspur – 10 Kms
Forest There is no forest with in 10 kms. radius
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of proposed project site, as it is with in Sirgitti CSIDC Industrial area.
River Arpa (12 Kms.)
Village Sirgitti
Railway station Bilaspur - 05 Kms.
National Highway NH – 200 (5Kms.)
3.1 Product and Raw Material
Capacity of the existing and proposed plants along with raw material requirements is as follows:
A) Products
SN PRODUCT / PLANT EXISTING CAP (MT PA)
PROPOSED CAP (MT PA MAX
REMARKS
01 Sulphuric Acid 40,000 1,40,000
2 A Single Super Phosphate / 1,40,000 4,40,000 Combined capacity of all the three products will not exceed 4,40,000 TPA B Triple Super Phosphate / - 1,00,000
C Boronated Single Super Phosphate - 40,000
03 Granulated Fertilizer
(SSP/TSP/NPK/ Customized Fert)
45,000 (NPK) 4,40,000
B) Raw Material Requirements
SN RAW MATERIALS EXISTING (MT/PA)
PROPOSED
(MT/PA)
01 Sulphur 13,500 47,000
02 Rock Phosphate 78,000 2,46.000
03 SulphuricAcid (Con. 98%) 50,000 1,58,000
04 Phosphoric Acid (P2O5 100% basis) - 36,000
Sourcing of raw materials
i. Sulphur -Sulphur is not available in sufficient quantity indigenously. In India it is procured from Oil Refineries but major quantity shall be imported from Iran, Iraq, and Saudi Arabia etc.
ii. Rock Phosphate–Rock Phosphate in India is not available to meet requirement fully. It will be partly procured from M/s RSMML Udaipur but major quantity shall be procured from Jordan, Egypt, Syria, Morocco, Israel
etc. iii. Sulphuric Acid – Sulphuric Acid required shall be met through own
production. BECF is having already plant of Sulphuric Acid (Cap. 40,000
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TPA). It is proposing to install another plant (Cap. 1,00,000 TPA) in the existing premises to meet the future requirements. If required, Sulphuric
Acid shall be procured indigenously also. iv. Phosphoric Acid – Phosphoric Acid shall be procured partly from Indian
manufacturers but major quantity shall be imported from various sources.
3.2 Manufacturing Process
3.2.1 Sulphuric Acid
Sulphur is the basic raw material for the production of Sulphuric Acid. Sulphuric acid produced in the plant shall be utilized for manufacturing Single Super
Phosphate Fertilizer.
Raw material consumption
Sulphur - 335 Kg PMT of Sulphuric Acid.
The major steps involved in the process are as follows:
01. Sulphur melting and purification.
02. Sulphur combustion. 03. Waste heat recovery to generate steam. 04. Catalytic conversion of SO2 to SO3
05. Absorption of SO3 to produce Sulphuric Acid.
Sulphuric acid is manufactured by contact process using DCDA (Double conversion & double absorption) technology, which is latest and most efficient today. Following
chemical reactions take place in the process.
01. S+O2 = SO3
02. SO2 + ½ O2 = SO3 03. SO3 + H2O = H2SO4
Manufacturing Process
Sulphur used as raw material is in solid form, which is first converted into
liquid form using steam. It is purified in the settling pit before sending to furnace for combustion. In the Furnace,Sulphur burns with air to form Sulphur Dioxide. As the process is Exothermic so temperature of the gases
in the furnace rises to above 1000ºC.
Hot gases from the furnace are cooled in the waste heat boiler (01) to produce steam. Gases after cooling are filtered and sent to convertor. In the
convertor SO2 gets converted into SO3 in presence of catalyst (Vanadium Pentoxide).SO3 gasesafter third pass, are further sent to intermediate
absorption tower where SO3 gases are absorbed in directly with water to form Sulphuric Acid. Unconverted gases are again sent to fourth pass of the convertor to convert remaining gases to SO3. SO3 is again absorption
in the final absorption tower to form Sulphuric Acid. Finally gases from absorption tower are let-out to atmosphere through stack.
Sulphuric acid produced is further cooled in the cooler before being sent to
Acid storage tanks.
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Alkali Scrubber
SO2 in the stack gases are maintained as per the norms prescribed.
During plant start-up SO2 in the exit gases may rise above norms, so it is treated in the Alkali scrubber with caustic solution to form Sodium Sulphide. And clean gases are let-out to atmosphere through Chimney.
Reaction
2NaOH + SO2 = Na2SO3 + H2O
Process flow diagram for manufacturing of Sulphuric Acid is attached as
Fig.3
Specifications of SulphuricAcid - Technical Grade (IS 266:1993)
1 Total acidity (As H2SO4) 98%
2 Residue on ignition. 0.2%
3 Iron (As Fe) 0.05%
4 Chloride (As Cl) -
5 Lead (As Pb) 0.005%
6 Arsenic (As As) 0.004%
Power Generation
Steam is generated in the boiler with the waste heat of the system. Part of the steam
is utilized in the process but major part (About 85%) after super heating is utilized to generate power using condensing Turbo Generator set (Capacity-2500 KVA)
All the power requirement of the Acid Plant shall be fully met through captive power generation. Surplus power available shall be utilized to meet the part requirement of
Fertilizer Plant.
3.2.2 Single Super Phosphate
Single Super Phosphate (SSP) manufacturing is a simple process. By digesting the Rock Phosphate with Sulphuric Acid it is produced. During the reaction the insoluble Phosphates are converted into water soluble phosphates thus when SSP is applied in
field the Phosphates are readily available in the soil and absorbed by plants for its growth.
Raw material consumption (PMT of SSP)
A) Rock Phosphate - 560 Kg.
B) Sulphuric Acid (Conc. 98%) - 360 Kg.
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Manufacturing process
Rock Phosphate is ground to fine powder (90% of 100mesh) in a Milling section and it
is conveyed through Screw Conveyor and Bucket Elevator to the Mixer where reactions take place. ParallelySulphuric. Acid, water and recycledFlouro Silicic Acid liquer are also added in the mixer in a pre-determined ratio. The Rock Phosphate,
Acid and dilution liquor react together in the Mixer (Reactor) to produce single Super Phosphate.
01. Chemical reaction Reaction - I
CaF2.3[Ca3{Po4}3] + 7H2SO4 + 3H2O Rock Phosphate Sulphuric Acid
3CaH4(PO4)2-H2O + 2HF + 7CaSO4 + 2H2O Single Supher Phosphate Gypsum
Reaction - II
4HF + 3SiO2 + H2O SiO2.H2O + 2H2SiF6
Silica Sod.Silico-fluoride
As a result of reaction, fluorine containing gas is generated and by using a scrubber
blower continuously the gases are sucked in closed circuit and sent to gas Scrubbing Section. The flow diagram of gas scrubbing system is attached as Fig. 7
The produced Single Super Phosphate (SSP) in a semi solid mass is conveyed through a moving reactor called Den and solidify. SSP it is cut by a revolving cutter to a powdery mass and conveyed to the product yard for curing. Product is packed in 50
Kg. bags .
Process flow diagram for manufacturing of Single Super Phosphate is attached as
Figure– 4.
Specification of SSP:
As per FCO (Fertilizer Control Order) Ministry of Agriculture, Government of India
has amended
specifications of Single Super Phosphate (Powder) / G.S.S.P. effective from 10.05.2011.
1 Moisture, percent by weight, maximum 12.0
2 Free Phosphoric acid (As P2O5), percent by weight maximum 4.00
3 Water soluble phosphates (As P2O5) percent by weight minimum
14.50
4 Citrate soluble phosphates (As P2O5) % by wt minimum 16.00
5 Sulphur (As S), percent by weight, minimum 11.00
Advantages of SSP Fertilizer :
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1. Provides 15% of total phosphate requirement of the country.
2. Lowest price fertilizer preferred by small and marginal farmers. 3. Multi-nutrient fertilizer containing P2O5 as primary nutrient and Sulphur
and Calcium as secondary nutrients.
4. It is the cheapest source of Sulphur for the soil. 5. Only phosphatic fertilizer which can utilize Indian rock phosphate
deposits.
6. Least foreign exchange per unit of P205 7. Utilize acid, effluent from other chemical industry and thus reduce nation's
cost of effluent disposal.
3.2.2(A) Boronated Single Super Phosphate (BSSP)
Manufacturing process of BSSP is same as that of SSP. It shall also be manufactured in the existing SSP plant. Rock Phosphate and Sulphuric are the main raw material
for manufacturing SSP. For BSSP Sodium Borate Penta hydrate (Na2B4O7.5H2O) is added extra as per the requirement along with water in the Mixer. The remaining process is same.
Boron is a micronutrient, which is also necessary for the growth of plants to increase the yield. As per FCO (Fertilizer Control Order), the Boron contained in the BSSP
should be 0.15% to 0.20%. Above 10 Kg/MT of Sodium Borate is added to get desired Boron in the product. BECF shall manufacture Boronated SSP also in the existing
SSP plant.
Specifications of BSSP (Powder) as per FCO
I Moisture, per cent by weight, maximum 12.0
II Free Phosphoric acid (As P22O5) per cent by weight, maximum 4.0
III Water soluble phosphate (As P2O5), per cent by weight, minimum 16.0
IV Boron (As B), percent by weight maximum 0.15 to 0.20
3.2.3 Triple Super Phosphate (TSP)
Triple Super Phosphate is manufactured by digesting rock phosphate with
phosphoric acid. Manufacturing process of TSP is same as of Single Super Phosphate (SSP) except Phosphoric acid used for TSP in place of Sulphuric Acid used for SSP.
TSP is considered as the concentrated form of Single Super Phosphate. Consequently, TSP can also be manufactured in the existing SSP plant. BECF proposes to manufacture TSP also in the existing and proposed SSP plant. Process flow diagram
for manufacturing of Triple Super Phosphate is attached as Figure– 4
Raw Material consumption (PMT of TSP)
A) Rock Phosphate 460 Kgs B) Phosphoric Acid (P2O5 100%) 360 Kgs.
01. Chemical reaction
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Reaction - I
CaF2.3[Ca3{Po4}3] + 14H3PO4 + 3H2O Rock Phosphate Phosphoric Acid Acid
10CaH4(PO4)2 + 2HF Triple Supher Phosphate
Reaction - II
4HF + 3SiO2 + H2O SiO2.H2O + 2H2SiF6
Silica Sod.Silico-fluoride Air emission
Rock Phosphate contains Silica and Fluorine as impurities, which contributes to the
gas emission in the process. Rock Phosphate consumption for manufacturing TSP is only 460 Kgs PMT compared to 560 Kgs PMT for SSP, which is lower by 18%. Consequently gas emission in this TSP manufacturing will get reduced by 18%
compared to SSP production. The flow diagram of scrubbing system is as per Fig. 7. Specification of Triple Super Phosphate (TSP)
1 Moisture, percent by weight, maximum 12.0
2 Free Phosphoric acid (As P2O5), percent by weight maximum 3.00
3 Water soluble phosphates (As P2O5) percent by weight
minimum
42.50
4 Total phosphates (As P2O5) % by wt minimum 46.00
3.2.4 Granulated Fertilizer (GSSP/TSP/NPK/Customized)
The granulation plant is a multi product unit where one or many of the individual
fertilizers viz, Urea, TSP DAP, SSP, MOP, Boron, Zinc, Copper, Molibadenum, Sulphur, Iron, etc are mixed together in a predetermined ratio and they are broken
down and blended to make homogeneous mass. This mass is fed into granulator where required quantity of water is added to moist the mass and rotated in a drum called „Granulator‟. As a result of this the powdered mass is converted into granules
of various sizes. The wet granules are passed through a rotating dryer drum where hot air generated from a furnace is passed through the mass. At the end of the dryer
drum dried granules are received and it is fed into a cooler drum where atmospheric air is passed from the opposite direction to cool the material. The cooled granules are screened in vibrating screens to segregate product size, oversize & undersize
particles. The oversize granules are crushed and along with undersize material it is fed back to granulator for onward granulation. In the whole process no chemical reaction takes place as it is a simple physical crushing and mixing and granulating
process using suitable machineries.
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To produce granulated SSP, only SSP Powder will be the raw material. For NPK Mixture manufacture Urea, DAP, SSP, MOP, etc are the raw materials. For
Customized Fertilizers, in addition to the above, micro nutrients viz, Boron, Zinc & the other cation minerals in very small quantities will be added in the granulation process.
Process flow diagram of SSP/TSP/NPK/Customized Fert.is attached as Figure– 5.
Specification of GSSP:
1 Moisture, percent by weight, maximum 5.0
2 Free Phosphoric acid (As P2O5), percent by weight maximum 4.00
3 Water soluble phosphates (As P2O5) percent by weight
minimum
14.50
4 Citrate soluble phosphates (As P2O5) % by wt minimum 16.00
5 Sulphur (As S), percent by weight, minimum 11.00
6 Particle size
Not less than 90 % of the material shall pass through 4 mm IS sieve and shall be retained on 1 mm IS sieve. Not more than 5 % shall pass
through 1 mm IS sieve.
3.2.5 Sodium Silico Fluoride (By-Product)
The gaseous effluent generated in the Single Super Phosphate plant is absorbed in the scrubber section using water to convert into Hydro FluoroSilicio Acid. This acid is pumped out from the settling tank of the venturi and received at Sodium Silico
Fluoride Plant.
The production facilities are installed in most of the SSP plants mainly to convert the
liquid effluent (H2SiF6) in to a salable by-product. Hence it is primarily a pollution control process to treat the liquid effluent.
Here the acidic fluoric acid is reacted with Soda Ash solution to neutralize it to
generate Sodium Silico Fluoride crystals and neutral water.
```
FluoroSilicio Acid is received in a rubber lined Mild Steel reactor. This reactor is calibrated one and fitted with an agitator. In a row two such reactors are installed.
While one is under reaction process the other is made ready for next batch. Separately in a Soda Ash solution preparation tank Soda Ash is dissolved in fresh water and the concentration is analyzed. Metered quantity of soda ash solution is
slowly added into the reactor while the liquor is under agitation. The acid is neutralized by the alkaline soda solution and sodium silico fluoride crystals separate from the solution. The pH of the reaction mass is checked and when pH reach 7 soda
addition is stopped. After thorough agitation the solution is allowed to settle. The
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clear top solution (water) is decanted and the settled mass is taken to a centrifuge to separate water from the SSF crystal.
The wet mass is dried in a tray dryer and finally packed in 50 kg bag after quality analysis and approval. The collected water from centrifuge and reactors is stored and used in SSP plant for dilution of H2SO4.
Process flow diagram of Sodium Silico Fluoride is attached as Figure– 6.
Specification of Sodium Silico Fluoride:
1 Technical Grade White Crystalline Powder
2 Purity (On dry basis) Min.
percent
98.00
3 Moisture (Min. percent) 1.00
4 Insoluble (Max. percent) 1.00
3.3 Resource – Utilize& Recycling
Water
Water requirement after proposed expansion of the project for domestic and industrial activity during operation phase will be 1550 KLD. The water requirement
will be met through CSIDC water supply pipeline.
Water Consumption Activities Existing water Consumption
(M3/day)
Proposed water Consumption
(M3/day)
Domestic 10 20
Processing 320 1500
Washing + Floor Cleaning 20 30
Total 350 1550
Power / Energy `
Power requirement of proposed project will be made available through Chhattisgarh
State Electricity Board (CSEB). Total power requirement of proposed plant shall be 3200 KWH.
2 nos. of D. G. sets of capacity 1070 KVA are available to meet emergency power
requirement of the plant.
01 No. TG Set (Condensing Type) of 2500 KVA shall be installed to generate power
with available Surplus team from Sulphuric Acid plant.
01 No. 33KV Electrical Sub Station of capacity ( 4000 KVA) shall be installed.
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Fuel
Coal – Existing 5.0MT/Day Proposed 30 MT/Day for Granulation plant.
3.4 Waste Water Generation and utilization
Water Consumption
Activities
Existing
Waste Water
Generation
(M3/day)
Proposed Waste
Water
Generation
(M3/day)
End Use
Domestic 10 20 Soaked
Processing 20 70 Treated effluent shall be used for irrigation in the existing
plant premises
Washing+ Floor Cleaning 10 30 - Do -
Total 40 120
To treat the sewage generated due to domestic activities will be disposed through septic tank following by soak pit.
Floor washing, spillages and oil & grease etc from plants need to be treated. These floor washing and spillages are collected and taken through an exclusive pipe line to
the final effluent treatment section for treatment. Similarly floor washing liquid effluent from SSF plant is diverted to final effluent treatment plant for neutralization, etc. Total effluent generated in the project is 120 M3/D. It shall be utilized for
irrigation purpose inside the factory premises.
All the effluent water from cooling towers bleed, boiler blowdown and RO plant of
Sulphuric Acid plant shall be recycled and utilized fully in the SSP / TSP Plants for processing.
The granulation plant does not generate any effluent as it is a dry mixing process.
No water from factory premises shall be discharged outside factory premises hence it will be a ZERO effluent discharge unit.
Schematic flow diagram of ETP is attached as Figure – 8.
3.5 Air Emission
Sr.
No.
Stack Attached to
Height from ground (m)
Diameter
(m)
Air Pollution Control system
Expected pollutants
1 Flue Gas Stack
Granulation Plant 15 meter 600 mm Twin Cyclone SPM, SO2, NOx
2 Process Stack
(A) SSP Plant at Den Outlet
30 meter 1000 mm Cyclone separator Multi stage scrubber system with venturi and spraying towers
SPM, Fluorine
(B) Acid Plant at final absorption tower
30 meter 1000 mm Alkali scrubber, demister and mis-eliminators
SO2, Acid mist
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3.6 Solid Waste Generation and disposal
During manufacturing process of Sulphuric Acid, SSP, TSP fertilizer and granulation
of SSP/TSP fertilizers, following solid / hazardous will be generated, which will be disposed as detailed below on the basis of guidelines provided by Chhattisgarh Environment Conservation Board (CECB)
Sr. No.
Name of waste Quantity
Category of Waste (Schedule - I)
Mode of disposal
1 E.T.P. Sludge 1 MT/PM 34.3 Stored in haz. Waste storage area and shall be utilized in SSP plant.
2 Used oil 3000 Liters
/PA
5.1 Sold to MoEF approved recyclers.
3 Empty Containers
50Nos/PA 33.3 Sold to MoEF/CECB approved scrap dealer.
4 Sulphur sludge 40 MT/PM - Stored in hazardous waste area. It shall be used in the SSP product, as modifier.
5 Catalyst (V2O5) 3000 Ltrs/PA - Packed in 200 Ltrs drums and stored in specified area.Sold to MoEF/CECB approved agency
3.7 Purpose of EIA Study
The applicability of the SO 1533 for the proposed project was explored by considering different possibilities & provision made in the said notification. Schedule I of the SO
1533 was referred & categories covered under the schedule I are examined for applicability of the notification. Considering the products & project location of the proposed project it is noticed that the proposed project falls under Category 5 (a) “A”
of the Schedule-I of EIA Notification SO 1533.
As per the provision of the SO 1533, it is necessary to get Environmental Clearance by applying to DoEF along with the Rapid Environmental Impacts Assessment Study
Report for the proposed expansion project prior to commissioning of the project activities. Therefore the EIA is required to conduct to comply with provisions of SO
1533 made for Category 5(a) “A” of schedule –I of the notification.
4.0 SITE ANALYSIS
4.1 Connectivity
CSIDC Sirgitti Industrial area, Bilaspur is notified industrial estate and well connected with road, rail and air route. Details about the connectivity with proposed
project site is shown in below table.
Sr.
No.
Description of Connectivity Distance in Kms.
1 National Highway (NH – 200) 5
2 Railway station (Bilaspur) 5
3 Air port (Chakrabhata) 7
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4.2 Land Use / Topography
Sirgitti is located 10 Kms from west of Arpa river. Terrain of land is plain flat.
Proposed project site is in notified industrial area, thus land use pattern of project site is non- agricultural and used only for industrial activities. The economy of Sirgitti is dependent on agriculture.
No other forests, national park or wild life sanctuary located within 10 kms periphery of the proposed project site. No change in land use as the proposed expansion project shall be established in CSIDC Sirgitti industrial area. Topography
map of Bilaspur District is attached in Fig 9
4.3 Infrastructure
Key infrastructures available at or near by proposed project site is described below.
Sr. No.
Description Available within 10 km around the project
1 Marine Sanctuary No
2 Stream / Rivers Yes (Arpa River)
3 Airports Yes (Raipur – 130 Km)
4 Railway station Yes (Bilaspur – 5 Km)
5 Bus Station Yes
6 National Highways Yes (NH – 200)
7 Bank Yes
9 Social Infrastructure
Primary / High School Yes
Religious Place Yes
5.0 PLANNING BRIEF
Proposed plant expansion activities will be started after getting statutory clearance form related authorities. The project will be completed within two years.
Further proposed project activities will take care of all the rules and regulation of statutory authority and provide the control measure and devices to achieve the standard norms.
6.0 EXISTING/PROPOSED INFRASTRUCTURE
Sr.
No.
Infrastructure Description
1 Total plot area 47.66Acres (Existing)
2 Processing area (Plant area) As mentioned in Layout plan.
3 Non-processing area (Residential
area)
Not at project site. Residential area is at Bilaspur city
or Sirgittivillage.
4 Green belt As per statutory requirement.
5 Social Infrastructure As mention in para 4.3
6 Connectivity As mention in para 4.1
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Sr.
No.
Infrastructure Description
7 Drinking water management CSIDC water supply
8 Effluent Treatment plant ETP shall be designedto treat the effluent generated
from process.
9 Industrial waste management Proper EMP shall be in place in EIA report.
9 Solid waste management Proper EMP shall be in place in EIA report.
10 Power requirement & Supply source
Existing 0.7MW, Proposed 3.2MW
Source : CSEB
Existing infrastructure
BEC Fertilizer, Bilaspur is a running unit since 1985. It has created all necessary infrastructures for the operation of the unit. It is planning to carry out expansion of
the unit by installation of new plants in the existing premises.
The total plot area is 47.66 acres. Existing plant is installed in the area of about 12Acres. Additional area required for expansion is about 12 Acres. Remaining area
available shall be utilized for future expansion. Presently surplus land is being utilized by plantation of various types of trees. Treated effluent of plant is being used
for irrigation.
All the existing facilities e.g. administrative building, raw material / finished goods storage, raw water storage, roads / drains, weighbridge. Canteen, workshop, DG sets,
Laboratories etc. shall be utilized during installation and operation of the new plant.
During construction of plant, essential requirements of power, water, skilled & unskilled manpower and other services will also be available. Apart from that,
communication and transportation will also be made available.
It will help in smooth and timely execution of the project.
7.0 REHABILITATION & RESETTLEMENT (R&R) PLAN
Rehabilitation & Resettlement (R&R) plan is not applicable to proposed project as it is
proposed in well-developed notified industrial area at CSIDC Sirgitti, Bilaspur. .
8.0 PROJECT SCHEDULE & COST ESTIMATES
Proposed project activities will be started after getting statutory clearance form
related authorities. The project will be completed within two years.
8.1 Project Cost Estimates
Sr. No.
Particulate Estimate cost
(in Crores)
1 Plant (factory shed & Plant machineryetc) Existing 22.00
Proposed 97.00
2 Pollution control measurement
(ETP and Hazardous Waste)
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9.0 ANALYSIS OF PROPOSAL
We have analyzed our proposal and found following financial & social benefits to the
local people in the project area.
01. Employment to approx. 100 - 150 local people is direct benefit to local people. 02. Farmers will get benefit of procuring locally made, high quality fertilizer.
03. Govt. will get revenue.
3 Green belt development & maintenance
Layout Map showing the Proposed Expansion Unit
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