PROJECT PRE-FEASIBILITY REPORT (PFR) For PROPOSED PROJECT FOR THE MANUFACTURE OF CHEMICAL FERTILIZER (SSP/TSP/Phosphoric Acid) [Schedule 5 (a) Category–“A” as per EIA Notification 2006] At PLOT NO C-190 GIDC SAYKHA,TALUKA VAGRA, DISTRICT BHARUCH, GUJARAT. Plot area: 17,380 m 2 Production Capacity: 1,90,000 TPA Applicant Consultant Kisan Shakti Fertilizers and Pesticides Pvt Ltd. Shri Ram Fertilizers Complex ,1st Floor, New Mondhan Nanded-431602, Maharashtra Eco Chem Sales & Services Office floor, Ashoka Pavilion ’A’, New Civil Road, Surat, 395001. (QCI/NABET Accredited No. NABET/EIA/1417/ SA 2 002) E-mail: [email protected]Tel No: +912612231630 October – 2017 Doc. No: 2017_ECSS_EIAI2_1700019
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PROJECT PRE-FEASIBILITY REPORT
(PFR)
For
PROPOSED PROJECT FOR THE MANUFACTURE OF CHEMICAL FERTILIZER (SSP/TSP/Phosphoric Acid)
[Schedule 5 (a) Category–“A” as per EIA Notification 2006]
At
PLOT NO C-190 GIDC SAYKHA,TALUKA VAGRA, DISTRICT BHARUCH, GUJARAT.
Plot area: 17,380 m2
Production Capacity: 1,90,000 TPA
Applicant Consultant
Kisan Shakti Fertilizers and
Pesticides Pvt Ltd.
Shri Ram Fertilizers Complex ,1st Floor, New Mondhan Nanded-431602,
Maharashtra
Eco Chem Sales & Services
Office floor, Ashoka Pavilion ’A’, New Civil Road, Surat, 395001.
(QCI/NABET Accredited No. NABET/EIA/1417/ SA 2 002)
9.0 ANALYSIS OF PROPOSAL: ..........................................................................................24
9.1 Financial & Social Benefits ..........................................................................................24
LIST OF TABLE
TABLE 1.1: PROJECT SUMMARY .................................................................................................... 3 TABLE 1.2: PROPOSED PRODUCTS ............................................................................................... 9 TABLE 1.3: RAW MATERIAL REQUIREMENT ...................................................................................17 TABLE 1.4: LAND BREAKUP .........................................................................................................18 TABLE 1.5: WATER CONSUMPTION AND WASTEWATER GENERATION .............................................19 TABLE 1.6: FLUE GAS EMISSION ..................................................................................................20 TABLE 1.7: PROCESS EMISSION ...................................................................................................21 TABLE 1.8: SOLID/HAZARDOUS WASTE GENERATION & MANAGEMENT ...........................................21 TABLE 1.9: ENVIRONMENTAL SETTINGS .......................................................................................22 TABLE 1.10: PROJECT COST .......................................................................................................24
LIST OF FIGURE
FIGURE 1.1: STUDY AREA MAP ..................................................................................................... 6 FIGURE 1.2: LOCATION MAP.......................................................................................................... 7 FIGURE 1.3 : GOOGLE IMAGE OF PROJECT SITE AND PLANT LAYOUT ............................................... 8 FIGURE 1.4 : MATERIAL BALANCE & PROCESS FLOW DIAGRAM OF SSP...........................................13 FIGURE 1.5 : MATERIAL BALANCE & PROCESS FLOW DIAGRAM OF TSP ...........................................13 FIGURE 1.6 : MATERIAL BALANCE & PROCESS FLOW DIAGRAM OF PHOSPHORIC ACID ......................15
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
3
1.0 EXECUTIVE SUMMARY
Suraj Group of Industries is one of the well-established groups run by a family member. The
group is founded by Mr. Ramesh Parsewar (M.D.) various industries like P.V.C. Pipes and Steel
Pipes unit run by Mr. Ramesh Parsewar. All fertilizers units likes Rajlaxmi Agrotech India
Pvt.Ltd., Kisan Shakti Krishi Udhyog Pvt.Ltd., are run by Mr. Sagar Chidrawar Director. The
Group industries are located at Nanded, Yavatmal and Jalna district of Maharashtra State.
These industries are producing PVC pipes, Drip System, Single Super Phosphate Fertilizers
and NPK mixed fertilizers. The Company has vast experience in the field of fertilizers with big
market Network throughout the Maharashtra. Considering the availability of Raw Material at
hand and make high grade fertilizers availability within the Country the management has
decided to establish the fertilizers unit Kisan Shakti Fertilizers and Pesticide Private Limited at
Gujrat.
The pre-feasibility report includes a brief introduction of the company, need and justification of
the project, manufacturing process description, required and available resources, proposed
Environment Management Systems, land-use and proposed infrastructure, project schedule and
cost.
Kisan Shakti Fertilizers & Pesticides Pvt Ltd. has engaged Eco Chem Sales & Services, Surat
(Accreditation certificate number NABET/EIA/1720/RA 051 is valid up to 3rd Feb. 2020.) as their
Environmental Consultant to conduct the EIA studies for obtaining Environmental Clearance
(EC) for the proposed venture at GIDC Saykha. Proposed project at a glance is mentioned in
table 1.1.
Table 1.1: Project Summary
S. No. Description Proposed Project Details
1. Name of project Environmental clearance for proposed manufacturing of Chemical
Fertilizer by Kisan Shakti Fertilizers & Pesticides Pvt Ltd.
as Per Reaction No 1st - P2O5 in rock 426/1008X100= 42.26%
as per reaction no 1st - Total P2O5 in SSP
426/1771X100=24.05%
Rock Consumption as per reaction 24.05/42.26=0.5690
Blending Ratio Of BRP: Chips i.e. 75:25 P2O5 in BRP 34% X 0.75= 25.50% P2O5 in Chips 23% X 0.25= 5.75% 31.25%
As Per Reaction Total P2O5 in SSP produced from
BRP / Chips =24.05X31.25/42.26=17.78
We can achieve 92% conversion efficiency with beneficiated
Rock Phosphate / Chips so water soluble P2O5 come in SSP 17.78 X 0.92=16.35%
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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Figure 1.4 : Material balance & process flow diagram of SSP
Figure 1.5 : Material balance & process flow diagram of TSP
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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3.6.2 Phosphoric Acid Plant
A) Process Description:
Rock Phosphate Storage and Handling Section: Ground rock is transported to a silo by a bucket
elevator. From the silo, slide gate valve and rotary valve transport the rock to belt conveyor. It is
then transported to bucket elevator from which it enters the transit bin. A belt conveyor feeds
rock to the reactor. Cyclone, bag filter and de-dusting fan are provided for entrapment of
phosphate particles from air.
Reaction Section: Ground rock phosphate is fed to the reactor. Rock feed rate is maintained
using a weigh band feeder. Rock reacts with ratio controlled quantity of H2SO4 to form
Phosphoric acid and byproduct Gypsum. Filter wash liquor with low levels of phosphoric acid
(RPA) is also recycled to the reactor. The Reaction mass flows through the reactor by underflow
or overflow channels. From reactor compartment 3 the slurry is pumped to a flash cooler before
entering reactor compartment 4. In the flash cooler heat is removed to maintain reaction
temperature to ensure di-hydrate gypsum is produced. The evaporated vapors are condensed
before gas scrubbing section. Overflow from the last section of the reactor enters the digestion
tank. Slurry pump is used to feed slurry from the digestion tank to belt filter for gypsum
separation from weak phosphoric acid product.
Gas Scrubbing Section: Waste gases from reactor, digester and filter are sent to gas scrubber
through their respective gas ducts. Waste water from transit water tank through pump is
discharged to the top most inlet nozzle of the gas scrubber. Process water is fed to the gas
scrubber circulation tank. Waste water enters the circulation through an outlet in the scrubber.
Part of the scrubbing liquid is sent to the gas ducts, and pre-condenser while remaining
scrubbing liquid is recirculated to the scrubber through spray nozzles. The gases after being
scrubbed are discharged to the atmosphere through blowing fan and gas stack.
Concentration Section: The concentration section concentrates WPA (28%) to CPA 52%. The
following main steps are involved in the continuous concentration of Weak Phosphoric Acid.
Weak Phosphoric Acid (28 – 30% P2O5) is mixed with concentrated acid (48 – 50% P2O5) to
ensure an easy settling of Total Dissolved Solids in the weak acid.
The reduced TDS acid is injected into a high flow rate recirculation loop of a forced circulation
evaporation set up. The mixed material is flashed in a flash chamber.
The re-circulated material is fed to a shell and tube exchanger with graphite tubes. Control
parameters ensure that Δt across the heat exchanger is kept low to avoid solids precipitation.
The vapors from the flash chamber are led to a condenser to trap all condensable and any acid
carryover. Although a mist eliminator will be mounted on the system, the water is slightly acidic
during run. Hence the cooling tower is specifically capable of working on acidic water.
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
15
Figure 1.6 : Material balance & process flow diagram of Phosphoric Acid
MATERIAL BALANCE OF PHOSPHORIC ACID FOR DIHYDRATE PROCESS
S NO DESCRIPTION FORMULA UNIT VALUE
A CASE DETAILS
i. Capacity TPD P2O5 24
ii. Working hours hrs 24
iii. Capacity in TPH Qp TPH 1.00
iv. P2O5 in product acid Pa % 29
v. Product acid (28% P2O5) Qwpa = Qp/Pa TPH 3.45
vi. Product acid (54% P2O5) Qcpa = Qp/0.54 TPH 1.92
B ROCK PHOSPHATE SPECIFICATION
i. P2O5 % 27
ii. CaO % 46
iii. F % 3.5
iv. SiO2 % 13.0
v. SO3 % 2
vi. Moisture % 3
vii. CO2 % 6
SR. NO. RAW MATERIAL
1 ROCK PHOSPHATE (P2O5 30%) 3.90 Ton/Ton
2 98.5% SULPHURIC ACID 3.28 Ton/Ton
3 GYPSUM CAKE PRODUCTION 6.10 Ton/Ton
30% P2O5, 1.94MT WATER
REACTOR
FILTRATION
WEAK ACID
WASH FILTRATE
WASH (3.78MT)
(PR. WATER)
P GYPSUM
(6.11MT@ 40% MOISTURE)
2.44MT WATER
1MT, P2O5
CONC. ACID
(0.54MT WATER)
WATER EVAPORATE CONCENTRATION
(1.50MT)
PRODUCT
COOLING TOWER
52% P2O5 ACID
PROCESS FLOW AND MATERIAL BALANCE PHOSPHORIC ACID
CONSUMPTION RATE
SULPHURIC ACID (98%)
SPENT ACID (70%)
ROCK PHOSPHATE
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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viii. Al2O3 % 0.6
ix. Fe2O3 % 1.8
x. MgO % 0.6
xi. Na2O % 0.56 C RAW MATERIAL CONSUMPTION
1 ROCK PHOSPHATE CONSUMPTION
i. Yield R0 % 92
ii. Rock phosphate Consumption t/t P2O5 4.03
Qr = Qp*100/Pr.R0 TPH 4.03
Qr*24 TPD 96.62
2 SULPHURIC ACID CONSUMPTION
i. Acid strength % 98.5
ii.
Consumption
Qs = (1.745CaO -0.718Pr(1-R0)-
1.225*SO3/100+1.5Pr/Pa)/100 ton/ton rock
0.801
iii.
iv. Actual acid consumption t/t rock 0.813108342
t/t P2O5 3.273383021
Qs TPH 3.27
D GYPSUM PRODUCTION
i.
Mass flow rate of gypsum
Gh = (3.07(CaO-0.2Pr(R0/Pa))+SiO2-
0.53F)/100
ton/ton rock 1.52
TPH 6.11
ii. Vol flow rate of gypsum Vg = Gh/SG m3/hr 2.63
E VOLUME OF SLURRY i. Spe. gravity of cake SG 2.32
ii. Solid content G0 Wt% 33
iii. vol% 21.7
iv. Volume of slurry Vsl = (Gh/SG)*(100/G0)
m3/T rock 3.02
v. m³/hr 12.143
vi. Density of slurry ρsl T/m³ 1.53
vii. Mass flow rate of slurry Gsl = Vsl*ρsl TPH 18.58
F RECYCLE ACID
i. Density of recycle acid Da 1.333
ii. P2O5 recycled
P1= Vsl(100-G0/100)(PaDa/100)-
PrR0/100 ton/ton rock 0.66
iii. Recycle acid flow rate Vra = P1*100/Pa T/T rock 2.292
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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iv. TPH 9.226
3.6 Raw Materials
Raw materials to be required for proposed project has been estimated based on operation of
similar type of plant as well as proposed plant design data. Detail of raw material consumption
for proposed plant is summarized in table 1.3.
Table 1.3: Raw Material Requirement
S.
No
.
Products Raw Material Quantity in Source of Supply Mode of
Transport Ton/Ton TPA
1.
Single Super
Phosphate
(SSP)
Rock
Phosphate
(P2O5 30%)
0.56 56000 1) Gulf Fert
International FZE
2) R.S.M.M. Ltd.
Udaipur
By road
Suphuric Acid
(98%)
0.36 36000 1) Navin Fluorine
International Ltd. Surat
2) R.R. Chemical
Ankleshwar
By road
Process Water 0.1 10000 GIDC Pipe line
2.
Triple Super
Phosphate
TSP
Rock
Phosphate
(P2O5 30%)
0.40 24000 1) Gulf Fert
International FZE
2) R.S.M.M.Ltd.
Udaipur
By road
Phosphoric
Acid (P2O5
54%)
0.58 34800 Own Plant -
Suphuric Acid
(98%)
0.03 1800 1) Navin Fluorine
International Ltd. Surat
2) R.R.Chemical
Ankleshwar
By road
Process Water 0.04 2400 GIDC Pipe line
3.
Phosphoric
Acid(Interme
diate)
Rock
Phosphate
(P2O5 30%)
3.9 117000 1) Gulf Fert
International FZE
2) R.S.M.M.Ltd.
Udaipur
By road
Suphuric Acid
(98%)
3.28 98400 1) Navin Fluorine
International Ltd. Surat
2) R.R.Chemical
Ankleshwar
By road
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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3.7 RESOURCE REQUIREMENT
Various resources like land, utility, power, fuel, water, manpower etc. will be utilized for carry out
production activities. Simply production is converting resources into finished product.
3.7.1 Land
Kisan Shakti Fertilizers & Pesticides Pvt Ltd. has procured 17380 m2 land from GIDC Saykha to
develop the industrial infrastructure for propose Chemical Fertilizer. Offer cum allotment letter is
attached as Annexure – 2 with ToR application. Proposed project will be set on Plot No: C-190.
Out of 17380.0 m2 area approx. 11592.0 m2 will be utilized for proposed project and remaining
5788.0 m2 area will be kept for greenbelt development. Construction of admin. building, plant
building, Raw material storage area, finished products storage area, utility area, treatment
facility, parking, fire hydrant and other ancillary amenities shall be undertaken within the plot
area. Proposed project will be developed in accordance with local development plan and used
for industrial purpose. Bifurcation of plot area is mentioned in table 1.4.
Table 1.4: Land Breakup
S.
No.
Description Area in
m2
Area in
%
1. Production plant 3604 20.74
2. Raw material storage 1510 8.69
3. Utility area 540 3.11
4. Treatment area – ETP, STP, waste storage area etc. 250 1.44
5. Greenbelt area 5788 33.30
6. Internal Road and open area 4290 24.68
7. Packing Area 848 4.88
8. Parking area 150 0.86
9. Weigh Bridge 137 0.79
10. Transformer – Metering Room 113 0.65
11. Office/Lab 150 0.86
TOTAL 17380 100
3.7.2 Water
Proposed project is located in GIDC Saykha, notified industrial estate, having all basic amenities
for water, power, transport etc. Water requirement for proposed project will be fulfilled by GIDC.
Project proponent has already made to application to GIDC to obtained permission for
withdrawal of proposed water. Bifurcation of daily water consumption during construction and
operation phase is described below in table 1.5.
Construction Phase:
Domestic – 7 KLD
Construction activities, curing and Dust suppression – 13 KLD
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
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Operation Phase:
Table 1.5: Water Consumption and Wastewater Generation
S.
No. Activities
Water
Consumption
in KLD
Wastewater
Generation
in KLD
Remarks
1. Domestic 15 12 Sewage will be treated in package
STP of capacity 25 KLD.
2. Industrial
Process 130 -- No wastewater generation as it will
be recycled back to process
Washing
10 10 Wastewater will be treated in ETP of
capacity 50 KLD.
Scrubber
50 -- No wastewater generation as it will
be recycled back to process
Cooling 1740 20 Wastewater will be treated in ETP of
capacity 50 KLD. Boiler 40 4
3. Other
Gardening 12 - Treated water from STP will be used.
Total 1985 34
3.7.3 Electricity
Construction Phase:
Diesel operated construction equipment and machineries will be used during construction
phase. One D. G. set of capacity 500 KVA will be kept as a stand-by arrangement used during
power interruption.
Operation Phase:
Electricity: 1500 KW
Backup Power: D. G. set (500 KVA) – 1 no.
3.7.4 Fuel
Furnace Oil – 2376.0 TPA for Boiler
HSD – 140.0 l/hr.
3.7.5 Manpower
Construction Phase: Local construction workers will be employed from surrounding area during
this phase. It is estimated that 125 – 150 Nos. of Local workers (skilled and semiskilled) will get
direct employment during construction phase.
Operation Phase: An industrial plant normally runs in three shifts and at full rated plant capacity.
Technical and non-technical personnel will be required for manufacturing unit, utility unit, O&M
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
20
of plant, security, admin etc. it is estimated that 90 nos. technical person will get direct and other
contractor worker will get indirect employment during operation phase.
3.7.6 Utility
The requirement of utilities for the proposed project has been estimated based on plant
operation capacity.
Furnace Oil Steam Boiler – 1TPH @ 10 Bar Pressure
Cooling Tower – 275 TR @ Delta T-10 deg C
Air Compressor – for Instrument Air at 7 to 8 bar pressure
3.8 WASTE TO BE GENERATED
It is envisage that due to proposed project activity various wastes to be generated which are
described as under:
3.8.1 Sewage
Construction Phase: Sewage will be expected to generate due to domestic activities of
workmen and staff personnel during construction phase. On site sanitation facilities will be
provided to construction workers. Separate arrangement of sanitation facility for female workers.
It is estimated that 6.0 KLD sewage generated, which will send to soak pit through septic tank.
Operation Phase: Sewage quantity of 12 KLD will be generated and it shall be treated in
package STP of capacity 25 KLD.
3.8.2 Effluent
Effluent generated from the manufacturing process and other ancillary operation will be treated
in adequate newly constructed effluent treatment plant of capacity 50 KLD. It is estimated that
34 KLD effluent will be treated in ETP and treated water will be reused back to process, hence
proposed project is Zero Liquid Discharge (ZLD) unit.
3.8.3 Air Emission
Stack discharge norms for Fluorine and the SPM will be maintained. Air emission (flue gases
stack and process emission), nature of emitted pollutants and system provided for air pollution
control in proposed plant is mentioned in table 1.6 and 1.7.
Table 1.6: Flue Gas Emission
S. No.
Description Proposed Flue Gas Emission
1. Stack Attached to 1. Boiler 2. Phosphoric Acid 3. SSP/TSP Granulator HAG
2. Stack Height (m) Common Stack: 30 m
3. Stack Dia (mm) 1250/1600/1900
4. Fuel & its consumption Furnace Oil: 2376 MTPA
5. Pollutant SPM, NOx and SO2
6. Emissions control system Adequate stack height and ventury scrubber.
Prefeasibility Report for Proposed Chemical Fertilizer Plant
by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.
21
Table 1.7: Process Emission
S. No. Description Proposed Process Emission
1. Vent attached to 1. Phosphoric Acid 2. SSP/TSP
2. Vent length (m) 10/20
3. Vent Dia (mm) 800/1000
4. Pollutant Fluorine based gases like HF and SiF4.
6. Permissible Limit Fluorine < 25 mg/Nm3
7. Emissions control system
Ventury Scrubber System to control the gaseous emission from SSP/TSP and PA plant. Generated Fluorine Gas from process emission will be scrubbed in water to produce Hydro Flousilisic Acid (H 2SiF 6 ). Hydro Flousilisic Acid will be recycled back in the process.
3.8.4 Solid/Hazardous Waste
All the solid/hazardous wastes to be generated at the end of manufacturing process or waste
treatment process will be stored on impervious floor having roof, boundary wall and leachate
collection as well as transfer facility. Management of wastes shall be done as per Hazardous
and other waste ( Management and Transboundary Movement), Rules 2016 of Environment
Protection Act, 1986. Solid/hazardous waste generated from plant is mentioned in table 1.8.