1.0 introduction 1.1 identification of project...prefeasibility report 1 abc/nig/pfr/ver2.0 1.0...

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



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).



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



Figure 2.2 Location map of project site



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.



Figure 2.4 Topo map (10km around project site)



Figure 2.5 Water body map (10km around project site)



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)



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.



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



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

https://en.wikipedia.org/wiki/Contact_process

https://en.wikipedia.org/wiki/Sulfur_dioxide

https://en.wikipedia.org/wiki/Sulfur

https://en.wikipedia.org/wiki/Oxygen

https://en.wikipedia.org/wiki/Potassium_oxide

https://en.wikipedia.org/wiki/Diatomaceous_earth

https://en.wikipedia.org/wiki/Silicon_dioxide



provided to the neutralization vessel. The product is formed as paste which then diluted with

pure water to get desired concentration of detergent liquid.

Figure 3.1 Line Diagram of Sulphonation Plant



Figure 3.2 Line Diagram for Surfactant drying system to make powder of high purity

3.5 INFRASTRUCTURE REQUIREMENTS

A. PROCESS EQUIPMENTS:

i. Air Drying Plant

The process air is first compressed to a pressure of approximately 1 kg/cm2 and chilled to

a temperature of 16°C in the air chiller vessel. The chilled air is then dried in automatic

desiccant- type air dryers to a guaranteed dew point of 60°C. The dual air dryers are

equipped with 11 individual bubble tight control valves. This ensures absolutely no

interruption of process air when changing dryers and a smooth pressure transition when

changing to regeneration. On power failure, these valves are designed to automatically

close to prevent back up of corrosive gas into the dryers, and to keep moist atmospheric

air from reaching the dryers and gas plant. The cooling air blower supplies cool air to the

regenerated (off-line) air dryer to reduce the bed temperature to an acceptable level, prior

to bringing the regenerated air dryer back on-line.



ii. SO3 gas Plant

Sulfur burning in equipment specifically designed to produce SO3 gas for sulfonation

Converter gas from a sulfuric acid plant contains 10–12% SO3 and appears to be a

potential SO3 source for Sulphonation.

Molten sulphur is supplied to the sulphur burner by a submersible pump from the sulphur

melter. A steam and condensate system is utilized to supply the necessary tracing circuits

for all the sulphur piping and sulphur melter.

The molten sulphur is delivered to the refractory-lined atomizing sulphur burner where

combustion with the dry process air, generates sulphur dioxide (SO2). The sulphur

dioxide gas leaving the burner is cooled and delivered to a four-stage Vanadium oxide

catalytic converter, where the gas is filtered and converted to sulphur trioxide (SO3). An

injection air system is used to cool the gas between the converter stages. When the

conversion efficiency of the converter approaches 98%, the sulphur trioxide gas leaving

the converter is cooled to nearly ambient temperature in a cascade cooler prior to entering

the Brinktype inlet mist eliminator which removes traces of sulphuric acid or oleum. Heat

recovered from the SO2 and SO3 coolers is used to regenerate the air dryers, thus

eliminating the need for an external heat source. A Continuous source of dry air-SO3 gas

is required for film Sulphonation and sulfation.

iii. Sulphonation Plant

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.



iv. Exhaust Gas Treatment System

The excess/vent gas is seperated from the sulphonic acid stream and is directed to the

Exhaust Gas Treatment System. The Exhaust Gas Treatment System consists mainly of

the following: Wet Electrostatic Precipitator (ESP) and Alkali Scrubber.

The electrostatic precipitator (ESP) employs a proprietary electrode design in an air

jacketed bank of collection tubes. The High Intensity Toroidal Electron Corona (HITEC)

produced by the electrode charges the inlet particulars, which are collected at the passive

tube wall. Coalesced organic acids (bottoms) discharge at the bottom of the vessel.

The Alkali Scrubber is used to neutralize the SOx gases.

v. Hydrolyzer

The sulfonic acid stream is diverted to the hydrolyzer vessel for ageing after leaving the

reactor outlet. Hydration water is injected and mixed with the sulfonic acid, leaving the

digesters to remove anhydrides.

vi. Neutralization Chamber

A continuous neutralizer system is used to make the sulphonates and sulphates. The

neutralizer combines sulfonic acid or organo-sulfuric acid with a neutralizing agent,

additives, and diluent (water), in dominant bath neutralization.

vii. Auto Control Systems

A typical sulfonation plant control system consists of two components that are integrated

into a single system: A main instrument control panel (ICP) and a motor control center

(MCC). When properly designed and installed, this system not only allows operation of

the sulfonation plant but also improves the operators' understanding of the plant's

operation through graphic interfaces. Better control results in improved product

consistency and quality. The ICP integrates the loop control, logic control, data

acquisition, and operator interface into a single system. The motor control center (MCC)

includes a main power disconnect, a lighting transformer, motor starters, variable

frequency speed controllers, and disconnects as required for the equipment.



viii. Stainless Steel (SS) and Mild Steel(MS) Tanks

These tanks are required for the storage and transport of LABSA, Caustic soda Lye and

Sulfuric acid, Lauryl Alcohal, Ethoxylated Lauryl Alcohol and Alpha Olefin, Alpha

Olefin Sulphonate (AOS), Sodium Lauryl Ether Sulphate (SLES), Sodium Laureth

Sulphate (SLS).

B. UTILITIES AND OTHERS

1. Boiler / Cooling Tower

2. Effluent Treatment Plant

3. Auto control system

4. Fire extinguisher

5. Administration Building & Security Area

6. Parking Area

7. Greenbelt Area

Table 3.3 List of Equipments

S. No Description Quantity Capacity

1 Sulfur Trioxide gas

Generation Plant 1 1250 kg SO3/hr

2 Air Drying Unit 1 9000CMPH

3 Film Sulphonation/Salfation

Reactor 1 5000 kg/hr

4 Neutralization Unit 1 5000 kg/hr

5 Water Purification Plant 1 10 KL/hr

6 Cooling Tower 2 800 TR

7 Vent Gas Treatment System

with ESP 1 6000 CMPH

8 Chilled Water Unit 1 100 TR

9 Heat (Steam) Recovery

System 1 1000 kg/hr

10 Electricity Generator 1 630 KW

11 Weigh Bridge 1 60 MT cap

12 Cooling Tower /Pumps As per requirements

13 Water Hydrants System As per requirements

14 Spray Drying Plant 1 50TPD

15 Noodling Plant 1 50 TPD



Figure 3.3 Site layout



3.5.1 MANPOWER

The details of manpower is given in table. Total manpower will be 27 Nos.

Detail Number

Factory managers 01

Plant Operator 03

Yard Supervisor 01

Labour 06

Weighbridge Operator 02

Maintenance Manager 01

Welder 01

Fitter 01

Electrician and Instrument

Technician 01

Chemist 03

Accountant 02

Peon 01

Security Supervisor 01

Security 03

Total 27

3.5.2 POWER

The Power requirement will be 630 KW sourced through TNEB. DG set details are given

below.

Table 3.4 Details

SL.NO. Equipment Capacity

1 DG Set - 1 630 KW

3.5.3 WATER REQUIREMENT

The unit proposes to consume 155 KLD of Fresh water. The entire quantity of raw water will

be supplied by SIPCOT. Water balance table for the operation of the proposed plant is as

follows.

Initiatives for water reduction:

• The plant will implement a scheme for source reduction of water coming from

washings by articulating a recycle and reuse scheme.



• The plant will have cool atmospheric air in most of the heat exchanger instead of

water.

• The plant will have a zero discharge and will successfully recycle the entire water

back to plant use.

• Water harvesting system will be installed to collect natural water.

Table 3.5 Water Balance

S. No. Particulars Water Requirement (KLD)

1. Domestic 2.0

2. Gardening 1.0

3. Industrial

Process 2.0

Cooling makeup water 122.0

Boiler makeup water 23.0

4. Alkali Scrubber 5.0

Actual Requirement 155

ETP recycle water 5.0

Condensate Recovery 17.5

Evaporation Loss 124.5



Figure 3.4 Water balance chart

Raw Water Waste water Recyclable water

Loss 120 KL/day

Domestic 2.0 KL/day

Total Water Requirement 155 KLD

Gardening 1.0 KL/day

Industrial 152.0 KL/day

Septic Tank & Soak Pit 0.4 KL/day

Process 2.0 KL/day

Cooling water 500 KL/day

Makeup water 23.0 KL/day

Makeup water 122.0

KL/day

Condensate Recovery

17.5 KL/day

Boiler 35 KL/day

Evaporation 4.5 KL/day

ETP 5.1 KL/day

Process Effluent

0.5 KL/day

Bleed Off 2.0 KL/day

Blowdown 1.0 KL/day

Sewage 1.6 KL/day

Alkali Scrubber 5.0 KL/day

ETP Sludge will be disposed at TSDF



3.5.4 POLLUTION CONTROL MEASURES

3.5.4.1 AIR (EMISSIONS)

The following measures are proposed for control of gaseous emissions:

The emission sources will be D.G. Sets, sulphonation plant and are designed with

adequate stack heights and air pollution control measures to meet the standards set by the

TNPCB / CPCB.

Table 3.6 Details of air pollution control measures

S.

No.

Stack

No Source

Contro1

Measures

Top

dimension

Height

above

GL

Material of

Construction

Exit

Gas

Velocity

(m/s)

Exit

Gas

Temp

Max

Discharge

(Cubic

meter/min)

1. 1 Stack Attached

to D.G. Set-1

Not

Applicable 0.2 15 Mild Steel 21.4 40 453

2. 2

Stack Attached

to Sulphonation

Plant

Alkali

Scrubber,

ESP

0.5 30 Mild Steel 6.6 35 85

The proposed air emissions will be generated from the above process will be treated in the

Wet Electrostatic Precipitator (WESP) and Wet Alkali Scrubber System.

3.5.4.2 POSSIBLE FUGITIVE EMISSION SOURCES:

- Chemical storages

- Process reactor vent

- Laboratory testing

Fugitive emissions control Measures:

Chemical Storages tanks will be closed and only breathing vent will be there, as such there

will be no fugitive emission there.

Process reactor vent has well equipped vent treatment system with ESP (Electro Static

Precipitator) and Alkali scrubber to remove all fugitive emissions.

Laboratory testing will be equipped with fuming chamber for any fugitive emissions.



3.5.5 WASTE GENERATION

3.5.5.1 WASTE WATER GENERATION DETAILS & MANAGEMENT

S. No. Particulars

Water

Generated

(KLD)

1. Washing / Spillage Effluent 1.6

2. Domestic Sewage 0.4

3. Utilities Cooling 2.0

Boiler 1.0

4. Process 0.5

These are the four waste water streams generated. Washing/Spillage Effluent, utilities and

process waste water will be collected and fed into the Effluent treatment plant

appropriately. The domestic sewage will be treated through septic tank and soak pits. The

treated water from ETP will be reused for Alkali Scrubber.



3.5.5.2 SOLID WASTE (HAZARDOUS & NON-HAZARDOUS WASTES)

The solid waste generated from proposed will be as follows:

Hazardous Waste Generation

S.

N

Name of

Process

Waste(Catego

ry No)

Quantit

y

Waste

Type

Waste

Storage

Waste

Disposal

Source

of

generati

on

of waste

Physical

status

1 Used or spent

oil

25

l/year

Recyc

lable

MS/Plas

tic

Drums

Use within

premises as

a lubricant/

sell to

registered

recycler

Pump

Seal

Oil

DG Oil

Oily

2 Sulphur

Sludge

0.5

MT/Yea

r

Incine

rable

HDPE

bags

Disposable

at TSDF

Site

Expired

Raw

Materials

Solid

3 ETP Waste

1

MT/Yea

r

Non

recycl

able

HDPE

Bags

Disposal at

TSDF Site

ETP

filter Solid

Non Hazardous Waste Generation

Description of

Non-

Hazardous

Waste

Qty of

Waste

Discharged

from

Disposal

Method

Equipment/

facility

used

Discarded

Plastic Bags

100

Nos/year

Stores

& office

Will be reuse

within

premises

Sell to approved

scrap vendor

Discarded

Drums/Contai

ner

100

Nos/year Stores/Plant

Will be reuse

within

premises

Sell to approved

scrap vendor

3.5.6 RAINWATER HARVESTING & STORMWATER MANAGEMENT

Water harvesting system will be installed in the plant to collect rain water and storm water

and their management.



3.5.7 FUEL REQUIREMENT

S. No Name of fuel points of use Quantity

1 HSD D. G. Set-1 100 L/hr

2 Sulfur Sulphonation Plant 12.5 TPD

3.5.8 GREENBELT DEVELOPMENT

Greenbelt totaling 33% of plot area will be developed.

3.6 ENVIRONMENTAL MANAGEMENT PLAN

Table 5.1 EMP budget

S. No. Infrastructure Capital cost

( lakhs)

Recurring

cost (Lakhs)

including

power and

O&M

1. Air Pollution Control 100 5

2. Effluent Treatment Plant (ETP) &

Rain water harvesting measures 15 5

3. Environment Monitoring and

Management 20 2

4. Solid and Hazardous Waste

Management 15 5

5. Occupational Health & Safety 25 7.5

6. Green belt Development 20 5

Total 195 29.5

3.7 PROJECT COST & IMPLEMENTATION SCHEDULE

The cost for the proposed project is estimated at 15 Crores. After obtaining Environmental

Clearance (EC) and Consent to Establish for the proposed project, construction activity will

be commenced.

1.0 introduction 1.1 identification of project...prefeasibility report 1 abc/nig/pfr/ver2.0 1.0...

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