1 PRE-FEASIBILITY REPORT for PROPOSED EXPANSION OF SILICA SAND PRODUCTION (GLASS GRADE) & LPG STORAGE CAPACITY FOR GLASS MANUFACTURING UNIT of M/s. GUJARAT GUARDIAN LIMITED VILLAGE: KONDH, VALIA ROAD, TAL: ANKLESHWAR - 393001, DIST: BHARUCH (GUJ.) NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company Aqua-Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat - 395002 Prepared By: NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company Aqua-Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat - 395002 NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company Aqua-Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat - 395002 Prepared By:
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1
PRE-FEASIBILITY REPORT
for
PROPOSED EXPANSION OF SILICA SAND
PRODUCTION (GLASS GRADE) & LPG STORAGE
CAPACITY FOR GLASS MANUFACTURING UNIT
of
M/s. GUJARAT GUARDIAN LIMITED
VILLAGE: KONDH, VALIA ROAD,
TAL: ANKLESHWAR - 393001, DIST: BHARUCH (GUJ.)
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
2
CONTENTS
Sr.
No.
Description Page No.
1. Executive Summary 3
2. Introduction of the Project/Background information 10
3. Project Description 12
4. Site Analysis 19
5. Planning Brief 20
6. Proposed Infrastructure 21
7. Rehabilitation and resettlement (R & R) Plan 22
8. Project Schedule & Cost Estimates 22
9. Analysis of Proposal (Final Recommendations) 23
3
1.0 EXECUTIVE SUMMARY
1.1 Company Profile
M/s. Gujarat Guardian Limited proposes expansion of Silica Sand production (Glass Grade)
& LPG Storage capacity in Existing Glass Manufacturing Unit at Village: Kondh, Valia Road,
Tal: Ankleshwar - 393001, Dist: Bharuch (Guj.). Total Cost of the Project is Rs. 624 Crores
(Existing = Rs. 584 Crores + Additional Proposed = Rs. 40 Crores). Total Plot Area is
6,55,990.4 m2
.
1.2 Project Details
1.2.1 Products along with Production Capacity
Float Plant Details:
Quantity in Square Meter/Annum S. No. Product
Permitted Additional Total
1 Float Glass
2 Mirror
3 Lacquered Glass
4 Coater Glass
2,50,00,000
- 2,50,00,000
Proposed Expansion Details:
SR.
NO.
PRODUCT NAME EXISTING CAPACITY
(MT/MONTH)
PROPOSED CAPACITY
(MT/MONTH)
1 Silica Sand (Glass Grade) 13,500 56,225
2 By-Products (Coarse, Fines and rejects) 19,620 30,275
3 Total 33,120 86,500
LPG Storage Tank Details
Existing Capacity:
LPG Tanks = 4 Nos. (Capacity = 56.25 MT each)
SR.
NO.
Storage Material No. of Tanks Capacity Total Capacity Tank Dimensions
1 LPG 4 56.25 MT (each) 225 MT Length = 16.2 m
Diameter = 3200 mm
4
Total Proposed Capacity:
LPG Tanks = 6 Nos. (Capacity = 120 MT each)
Proposed combine capacity: 720 MT
SR.
NO.
Storage
Material
No. of Tanks Capacity Total Capacity Tank Dimensions
1 LPG 6 120 MT
(each)
720 MT Design Pressure : 21 Kg/cm2
Overall Length = 24000 mm,
Tank ID = 4010 mm,
Tank Shell = 28 mm thick
Dished End = 18 mm Thick
Note: M/s. Gujarat Guardian Limited is exploring the option to merge the existing and
proposed LPG storage yard for future so that the new LPG yard would be (existing +
proposed) with 720 MT capacity. By proposing this we are also proposing that existing yard
be demolished and merged with new LPG storage yard in case above is the decision.
Existing LPG storage yard: 225 MT
Additional Proposed LPG storage: 495 MT
Total Storage of LPG onsite: 720 MT
1.2.2 Raw Material Requirement
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
Float Glass
1 Sand MT 14,000 0 14,000
2 Soda Ash MT 4,500 0 4,500
3 Dolomite MT 3,800 0 3,800
4 Limestone MT 1,400 0 1,400
5 Feldspar MT 850 0 850
6 Salt Cake MT 215 0 215
7 Carbon MT 21 0 21
8 Cullet MT 6000 0 6000
Wet Coater
1 Raw Glass Sq. Meter 5,83,000 0 5,83,000
2 Washing & Polishing Chemicals Kg 2,062 0 2,062
3 Tin Sensitizer Litre 119 0 119
4 Palladium Sensitizer Litre 45 0 45
5 Silver Solution
Silver Nitrate
Litre
Kg
2,600
1,088 0
2,600
1,088
6 Reducer/
Silver less solution
Litre
Litre
4,830
2,920 0
4,830
2,920
7 GMPA & GMPB Litre 1,190 0 1,190
5
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
8 Paint MT 68 0 68
9 Ortho-Xylene Litre 9,971 0 9,971
10 HCL-32% Litre 11,393 0 11,393
11 Caustic-32% Litre 13,508 0 13,508
12 Ferric Sulfate kg 256 0 256
Lacquered Glass
1 Raw Glass Sq. Meter 1,50,000 0 1,50,000
2 Washing and polishing chemical Kg 200 0 200
3 Adhesion Promoter Litre 50 0 50
4 Paint MT 10 0 10
A GLASSOLUX NG 9003 PURE WHITE Kg 2,500 0 2,500
B GLASSOLUX NG 2105 Sapphire Kg 2,500 0 2,500
C GLASSOLUX NG 3004 Burgundy Kg 2,500 0 2,500
D GLASSOLUX NG 6113 Fluo green Kg 2,500 0 2,500
E GLASSOLUX NG 9005 Black Kg 2,500 0 2,500
F Ivory Kg 2,500 0 2,500
G Red Kg 2,500 0 2,500
5 Ortho-Xylene Litre 1,000 0 1,000
Sand Beneficiation Plant
1 Raw Silica Sand MT 33,120 53,380 86,500
1.3 Water Requirement, Waste Water Generation and Treatment
Total water requirement is 1650 KL/Day at present which is met through Valia Water Supply
System (Canal Water). The wastewater generation is 921 KL/Day at present. There will be no
increase in Water Consumption as well as Wastewater Generation after proposed
expansion. Out of 921 KL/Day of wastewater, 205 KL/day of domestic wastewater is treated
in STP and then reused for land irrigation/gardening. 716 KL/day of Industrial waste water
(i.e. 150 + 566) is recycled back to Sand Plant for Sand Washing and also is used for
irrigation. Ultimately it is a Zero Liquid Discharge Unit and after proposed expansion it will
remain ZLD.
6
1.4 Air Pollution Source and Control Management
There is no addition or changes in the Flue Gas Stacks & Process Vents
Flue Gas Stacks
Sr.
No.
Stack Attached
To
No. of
Stacks
Height From
Ground (m)
Fuel Used Air Pollution
Control System
Expected
Pollutants
1. Melting Furnace 1 91 Natural Gas,
LPG
Low NOx Burner,
Stack height
PM,TF
2. DG Set
(2.5 MW)
1 30 Diesel NA PM, NOx,
NMHC, CO
3. DG Set
(2.5 MW)
1 30 Diesel NA PM, NOx,
NMHC, CO
4. DG Set
(500 KVA)
1 14 Diesel NA PM, NOx,
NMHC, CO
5. LPG Hot water
generator
exhaust
1 12 LPG NA PM, SO2, NOx
6. Diesel Engine 1
(155 KVA)
1 12 Diesel NA PM, NOx, CO
7. Diesel engine 2
(155 KVA)
1 12 Diesel NA PM, NOx, CO
8. Diesel engine 3
(155 KVA)
1 11 Diesel NA PM, NOx, CO
9. Diesel engine 4
(155 KVA)
1 11 Diesel NA PM, NOx, CO
10. Glass Edge
Burner
1 16 Natural Gas,
LPG
NA PM, SO2, NOx
Process Vents
S.
No.
Stack attached to No. of
Stacks
Stack
height (m)
Pollutant
Emitted
Air Pollution Control
Measures Attached
1. Main Melting Furnace 1 91 PM, TF Stack
2. Ammonia Cracking Plant 1 21 PM,
Ammonia
Stack, Nitrogen
Purging
3. Mirror Line Plant 7 12 VOC,
Ammonia
Stack
4. SO2 Vent 2 17 SO2 Stack
5. Batch House Raw 9 36.5 PM Dust Collector
7
Materials DCF Vents
6. Batch House Raw
Materials DCF Vents at
Basement
2 5.5 PM Dust Collector
7. Batch House Unloading
DCF Vent
1 6 PM Dust Collector
8. Cullet Return System DCF
Vent
1 3 PM Dust Collector
9. Hot Air Exhaust 5 16 PM Not Required
1.5 Hazardous Waste Management
S. No. Items Category Existing Additional Total Treatment and Disposal
Method
1 Used Oil 5.1 25
KL/Year
- 25
KL/Year
Collection, Storage,
Transportation & Sending to
Registered Refiners for recycle
/ reuse
2 Chemical Sludge
from Wastewater
Treatment
35.3 5
MT/Year
- 5
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
3 Waste residue
containing oil
5.2 20
MT/Year
- 20
MT/Year
Collection, Storage,
Transportation & Sent to GPCB
registered TSDF for land Filling
or Incineration
4 Process wastes,
residues & debris
from production
and/or industrial use
of paints, pigments,
lacquers, varnishes,
plastics and inks
21.1 20
MT/Year
- 20
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company
Recycle as a fuel or
Incineration
5 Spent solvents from
the production
and/or industrial use
of solvents
20.2 5
MT/Year
- 5
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company
Recycle as a fuel or
Incineration
7 Discarded Containers
& barrels
contaminated with
hazardous
wastes/chemicals
33.3
240
MT/Year
- 240
MT/Year
Collection, Storage,
Transportation & Disposal by
selling to Registered Vendors
8
8 Furnace/reactor
residue and debris
from pyrolytic
operations
D1 60
MT/Year
- 60
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
9 Inorganic Tin
compounds
B 7 1
MT/Year
- 1
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company for
Recycling
10 Spent catalyst and
molecular sieves
1.7 4
MT/Year
- 4
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company for
Recycling
11 Spent ion exchange
resin containing toxic
metal
34.2 15
MT/Year
- 15
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
Solid (Non-Hazardous) Wastes:
S.No Waste Type Permitted Additional Total Disposal Method