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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)

E-mail: [email protected] Tel No: +912612231630

October – 2017 Doc. No: 2017_ECSS_EIAI2_1700019

mailto:[email protected]

Prefeasibility Report for Proposed Chemical Fertilizer Plant

by Kisan Shakti Fertilizers & Pesticides Pvt. Ltd.

1

CONTENTS

1.0 EXECUTIVE SUMMARY ................................................................................................. 3

2.0 INTRODUCTION OF PROPOSED PROJECT ..................................................................... 5

2.1 Project Proponent ........................................................................................................ 5

2.2 Nature of the Project .................................................................................................... 5

2.3 Need of the Project ...................................................................................................... 5

2.4 Demand – Supply Gap and Import vs Indigenous Production ...................................... 5

2.5 Employment Generation .............................................................................................. 5

3.0 PROJECT DESCRIPTION ................................................................................................... 6

3.1 Type of Project ............................................................................................................. 6

3.2 Location of Project ....................................................................................................... 6

3.3 Alternative Site ............................................................................................................. 9

3.4 Size of Operation ......................................................................................................... 9

3.5 Products ...................................................................................................................... 9

3.6 Manufacturing Process .................................................................................................... 9

3.7 RESOURCE REQUIREMENT ....................................................................................18

3.7.1 Land ....................................................................................................................18

3.7.2 Water........................................................................................................................18

3.7.3 Electricity .............................................................................................................19

3.7.4 Fuel ..........................................................................................................................19

3.7.5 Manpower ................................................................................................................19

3.8 WASTE TO BE GENERATED ....................................................................................20

3.8.1 Sewage ................................................................................................................20

3.8.2 Effluent ................................................................................................................20

3.8.3 Air Emission .........................................................................................................20

3.8.4 Solid/Hazardous Waste .......................................................................................21

3.8.5 Noise ...................................................................................................................21

3.9 Purpose of EIA Study ..................................................................................................21

4.0 SITE ANALYSIS .................................................................................................................22

4.1 Connectivity ................................................................................................................22

4.2 Land form & Land Use ................................................................................................22

4.3 Topography.................................................................................................................22

4.4 Existing Infrastructure (Social/Commercial) ................................................................23

4.5 Soil Classification ........................................................................................................23

4.6 Climatic data from secondary sources ........................................................................23

5.0 PLANNING BRIEF ..............................................................................................................23

5.1 Population Projection ..................................................................................................23



2

5.2 Land use Planning ......................................................................................................23

5.3 Amenities / Facilities ...................................................................................................24

6.0 PROPOSED INFRASTRUCTURE ......................................................................................24

7.0 REHABILITATION& RESETTLEMENT (R&R) PLAN: .........................................................24

8.0 PROJECT SCHEDULE & COST ESTIMATION ..............................................................24

8.1 Project Schedule .........................................................................................................24

8.2 Cost Estimation ...........................................................................................................24

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



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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.

2. Project Site Plot no: C-190,GIDC, Saykha – 392140, Tal-Vagra, Dist – Bharuch,

Gujarat

3. Project Category 5(a) Category “A” of EIA notification.

4. Project cost Rs. 38.01 Crores

Cost of EMP Rs. 1.50 Crores

5. Products 1. Single Super Phosphate(SSP) (Granules and/or Powder) -100000

TPA

2. Triple Super Phosphate(TSP) (Granules and/or Powder) - 60000 TPA

3. Phosphoric Acid(Intermediate) -30000 TPA

6. By-Product Gypsum – 51150 TPA and Silica – 155 TPA

7. Raw Materials S. No

Raw material Quantity (TPA)

1. Rock Phosphate (P2O5 30%) 1,97,000.00

2. Sulphuric acid (98%) 1,36,200.00

3. Phosphoric Acid (P2O5 – 54%) 34,800.00

4. Process Water 12,400.00



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S. No. Description Proposed Project Details

8. Resource Requirement

(i) Land Total plot area – 17,397.0 m2

(ii) Water Source: GIDC Water supply

Construction phase:

Domestic – 7.0 KLD

Construction activities and curing – 13.0 KLD

Operation phase:

Industrial – 1970.00 KLD

Domestic – 15.00 KLD

Total – 1985.00 KLD

(iii) Electricity 1500 KW Power requirement will be met through GSECL

Backup power Back up 1 No. of D.G. Set (500 KVA)

(iv) Fuel Furnace Oil – 2376.0 TPA

HSD – 140.0 Ltr./hr

(v) Man power Construction Phase: 125 – 150 nos.

Operation Phase: 90 nos.

(vi) Utility Furnace Oil Steam Boiler –1 no.-1 TPH @10 bar

Cooling Tower – 1no. 275 TR @ Delta T -10 deg C

9. Source of Pollution

(i) Wastewater

Generation

Effluent – 34 KLD

(ii) Air Emission From Scrubber & Boiler and D.G. Set

PM : <150 mg/Nm3

SO2 : < 100 ppm

NOx : < 50 ppm

Fluorine based gases like HF and SiF4 :< 25 mg/Nm3

(iii) Solid/Hazardous

waste

Generation

ETP waste, Used Oil, discarded containers

10. Treatment Facility

(i) Wastewater Treated in Effluent Treatment Plant (50.0 KLD capacity)

(ii) Air Air pollution control device Ventury Scrubber (3 stage) shall be provided to

achieve GPCB norms.

(iii) Solid/haz.

Waste

Collection, storage and disposal of solid/hazardous waste to be carried out

as hazardous waste management rules, 2016

The solid, liquid and gaseous wastes from the proposed plant will be disposed-off in an

environmentally acceptable manner. Process effluents will be properly treated in adequate

effluent treatment plant and treated wastewater will be recycled back to process for reuse.

Proper precaution will be taken and adequate green belt will be developed to keep noise level

within prescribed limit. Adequate measure has been contemplated to ensure least pollution from

the proposed project.



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2.0 INTRODUCTION OF PROPOSED PROJECT

2.1 Project Proponent The Suraj group involved in various agriculture product like P.V.C. pipes & drip Irrigation system

as well as Chemical Fertilizers and NPK mixed fertilizers. Supreme Gold Irrigation is run by Mr.

Ramesh Parsewar have 500 Crore turn over with market network throughout Maharashtra

covertly all remote places. Mr. Sagar Chidrawar and Santosh Chidrawar brothers are managing

the fertilizers units Rajlaxmi Agrotech India Pvt.Ltd., and Kisan Shakti Krishi Udhyog Pvt.Ltd. Mr.

Sagar Chidrawar is director of Fertilizers unit. The proposal unit Kisan Shakti Fertilizers &

Pesticide is being run by Mr. Sagar Chidrawar (D.). The unit will have established for

manufacturing of Phosphoric Acid, Single Super Phosphate and Triple Super Phosphate.

2.2 Nature of the Project

Proposed Greenfield project to be developed at Plot No.C-190, GIDC Saykha notified industrial

area, Tal-Vagra, Dist – Bharuch of Gujarat state. Proposed project is fall under 5(a) category “A”

of EIA notification – 2006.

2.3 Need of the Project

Availability of nutrient phosphate is very low in India, we have to depend on import of phosphatic

fertilizers like Diammonium phosphate (DAP) thus to save foreign currency and meet the

requirement of phosphate nutrient this project is very much helpful for farmers using high and

low nutrient value fertilizers

2.4 Demand – Supply Gap and Import vs Indigenous Production

Single super phosphate is very cheap source of phosphatic fertilizers. It has high acceptance

among the low budget dry farming like oilseed, cereals and also for cash crop like sugar cane,

bannana etc. It also contains secondary nutrients like Sulphur and calcium. In case of triple

super phosphate, it provides high qty of “p” i.e. 46% this p is equivalent to available phosphate

in DAP fertilizer with low cost.so these fertilizer will help to reduce burden on importing fertilizers

from other countries. Since very high requirement in country may restrict the export. But

Srilanka, Bangladesh has consumption of 14.5% super phosphate but logistically it cost at

higher side, from production point

2.5 Employment Generation

There are possibilities to generate employment during the construction as well as operation

phase of the proposed project. Local skilled and semi-skilled workers will be hired during

construction phase, thus no need to provide housing facility to workers. 125 – 150 nos. of

people will get direct employment during construction phase.

Technical staff for plant operation, general staff for administrative work and other ancillary

services i.e. Security, O&M contractor and maintenance services will have required during

operation phase. 90 nos. technical person will get direct and other contractor worker will get

indirect employment during operation phase.



6

3.0 PROJECT DESCRIPTION

3.1 Type of Project

Proposed Green field project to be developed by Kisan Shakti Fertilizers & Pesticides Pvt Ltd. in

GIDC Saykha, Notified Industrial Area. All the industrial infrastructure facility is being available

at GIDC to support proposed development.

3.2 Location of Project

Kisan Shakti Fertilizers & Pesticides Pvt. Ltd decided to set an industrial plant at Plot No. C-190,

GIDC Saykha notified industrial area, Tal-Vagra, Dist – Bharuch of Gujarat state For

development of proposed industrial plant, company has procured 17380.0 m2 area from GIDC

authority. Location of plant site and Key map and Google image of proposed project site is

depicted as figure 1.1 & 1.2 respectively. Proposed project coordinate is as under:

Latitude : 210 46’11.8’’ N

Longitude : 720 49’48.8” E

Figure 1.1: Study Area Map



7

Figure 1.2: Location map



8

Figure 1.3 : Google Image of Project site and Plant Layout



9

Layout plan showing complete manufacturing facility, utility area, greenbelt area, treatment

facility, admin building, parking, entry and exit gate etc. is also attached as Annexure – 1 with

ToR application. Proposed project is located in GIDC Saykha notified industrial area. National

park, Reserve forest, Biosphere reserves, Wild life sanctuary, Archaeological place, Eco

sensitive area etc. are not located within the 10 Km radius of the proposed project.

3.3 Alternative Site

A suitable site must be found for a new/green field project, and the site and equipment layout

planned accordingly. GIDC Saykha notified industrial area have all required infrastructure for

industrial development as well as it full fills all the above factors, thus project proponent has

decided to develop a Chemical Fertilizer plant within GIDC and no other alternative site study

has been conducted.

3.4 Size of Operation

Project proponent proposes to manufacture chemical Fertilizer with production capacity of

1,90,000 TPA. Product wise quantities are incorporated in section – 3.5 of prefeasibility report.

3.5 Products

Kisan Shakti Fertilizers & Pesticides Pvt Ltd has observed that there are good scopes in

chemical fertilizer sector and there will be demand for these sectors perennially. Kisan Shakti

Fertilizers & Pesticides Pvt Ltd aims to engage in R&D and entering new markets in order to

make new products and derive the maximum value from feedstock by adopting modern

machineries, equipment and process technologies, with emphasis on waste minimization

techniques. List of proposed products/by-products to be manufactured is mentioned in table –

1.2.

Table 1.2: Proposed Products

S. No. Name of Products Quantity in TPA

1. Single Super Phosphate(SSP) - (Granules and/or Powder) 100000

2. Triple Super Phosphate(TSP) - (Granules and/or Powder) 60000

3. Phosphoric Acid 30000

TOTAL 190000

By-product

1. Gypsum 51150

2. Silica 155

3.6 Manufacturing Process

3.6.1 SSP/TSP

A) PROCESS DESCRIPTION OF TSP/SSP:

The manufacturing process involves reaction of finely ground Rock Phosphate (85% passing

through 200 mesh & 95% through 100 mesh) with 75% Phosphoric acid (54% P2O5

Concentration) for TSP and with 98% Sulphuric acid for SSP. Brief process description is

summarized below for the various sections of the plant.



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B) TSP / SSP SECTION

a)Rock Phosphate Grinding Section: Ungrounded Rock Phosphate is fed to a ball mill by a

crane and conveyors/ bucket elevators to get ground rock of quality 85% passing through 200

mesh & 95% through 100 mesh. The ground rock is then transported to a silo for storage. The

ground rock from silo is then transferred to ground rock feed hopper which is equipped with a

rotary valve for material movement to a weigh band feeder. From the weigh band feeder the

rock is fed to a pre-mixer for SSP and directly fed to reactor for TSP production. The entire

section is provided with an integral dust extraction system.

b) Reaction and Fluorine Recovery Section: To produce powdered SSP, rock phosphate &

Scrubber Liquor (recycled from the scrubbing section) are fed to pre-mixer & further this wetted

rock is fed to reactor. Sulphuric acid (98% conc.) is first diluted with process water in

graphite/equivalent diluter and is then fed in the main mixer in a controlled manner with the aid

of ratio controllers, such that the dosage of Sulphuric acid is optimum.To produce powdered

TSP, 74.52% Phosphoric acid is fed directly to reactor with small quantity of Sulphuric acid.

Reactor: The mixer is a specially designed vertical turbine reactor. The mixer operates with an

agitator at a high speed of 250 rpm and with low residence time. Temperature during reaction

would be in the range of 130-135°C for SSP reaction & 85°C for TSP reaction. The MOC of the

mixer will be CS with special abrasion resistant resin coating and MOC for agitator will be

SS904L with ceramic coating. From the mixer, the solid mass is fed to a Belt Den.

Den: The belt den has a special rubber belt driven by a variable speed drive. The residence

time in the den is 7-10 minutes, and this allows the SSP / TSP matrix ex-reactor to be only

350mm high. The low height avoids compaction of the mass, allowing free air movement

through the reaction mass aiding reaction and reducing subsequent curing time as well. The

den has a special rubber hood connecting the duct body to the scrubber assembly. Sizing is

done to ensure minimum powder carry over in the exhaust fumes. The product is removed by a

reversible conveyor ex-den and transported for curing. The acidulation reaction releases fluorine

based gases like HF and SiF4. These gases are scrubbed in a 3 stage venture scrubber.

Scrubber: The scrubber assembly comprises of 3 units of venturi contact units along with

separator towers. The scrubbing liquor is re-circulated by high capacity pumps and is partially

moving in a counter current backward flow. All contact parts are of PP/FRP resin construction. A

demister is installed on the last tower prior to vapour exit to ensure no mist carryover. The

fluosilicic acid is recycled in the mixer.

c) Storage and Curing: The TSP / SSP is stored in piles for curing which require about 1 week,

depending upon the raw material quality, proportion and manufacturing conditions. The piles are

turned around 3- 4 times to aid the curing process. During curing free acidity, un-reacted rock

and moisture decrease while water soluble P2O5 increases.

C) GRANULAR SECTION (TSP/SSP): The powdered TSP/ SSP ex-den is further fed to

Granulation & Drying section to produce granulated TSP / SSP.

a) Granulation Section: Powdered TSP/SSP is fed to Granulator via inlet chute. Recycle

material is also added to Granulator through Secondary Belt Conveyor. Process Water is

sprayed on the bed of rolling material in the Rotary Drum Granulator and acts as binder. Small

quantity of steam is introduced to control the moisture and promotes the desired degree of

granulation. Rotary Drum Granulator is rotated with low rpm and it initiates the rolling action of

moisture laden material to accelerate granulation.



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b) Drying: Granular Material moves to Dryer where moisture level is brought down to around 3-

4% for TSP/SSP with hot air generated in HAG. Hot air and material move co-currently in the

rotating Drum Dryer in which the material is lifted up by lifters and showered down from the top

of the periphery of Dryer. This enhances the maximum contact time between hot air and

granules. Fuel oil/Natural gas is burnt in presence of air in the Combustion Chamber and hot air

is generated at a temperature of around 250°C.

Product separation: Product Material from Dryer containing different size of granules moves to

Dryer Conveyor and is fed to Vibro sieve where oversize and undersize granules are separated

from product size. Over size & undersize material from product material is mixed with recycle

material. Recycle material ex dryer is sent to Vibro sieve wherein the oversize removed is

crushed down to smaller size in Hammer Mill and sent to Recycle Conveyor. Under size

material is also directly fed to Recycle Conveyor. Product material is sent to cooler by conveyor.

c) Product cooling: Product is cooled down to around 55° C temperature in Product Cooler.

Product cooling is carried out based on fluidized bed principle with counter current flow of

ambient air. Air is introduced to Product Cooler with Cooler Fan.

D) GAS AND DUST SEPARATION SECTION

This section is divided into following four sub-sections –

a. Dryer Gas and Dust Recovery: Water vapor, SiF4 gas, engrossed air and dust is sucked by

Scrubber ID Fan. Dust is arrested in Dryer cyclone and Bag filter. Water vapors and air then

moves to the Scrubber system wherein SiF4 gas gets scrubbed and water condenses in

scrubber system. H2SIF6 will form and will be reused back into process

b. Air and dust from Product Cooler: Air and dust from Product Cooler is sucked by Scrubber ID

Fan. At the first stage, dust is separated in Product Cooler Cyclone and Air and other gases

moves to Scrubber system.

Mass balance of SSP

SINGLE SUPER PHOSPHATE Consumption Norms of Rock & Acid Based on Chemical Consumption of Rock Phosphate &

chemicals reaction 2Ca5( PO4) 3 F+ 7 H2SO4 + 6.5 H2O

3CA(H2PO4) 2H2O+7CASO4+3.5 H2 +HF

(1008) + (686) + ( 117)

(756) +(952) + (63)

MASS BALANCE (1008+686+117)- (756+952+63)

1811- 1771

2Ca5( PO4)3 F+ 10Ca= 40X10= 400 6P=31X6=186 24O= 16X24=384 2F=19X2=38 1008



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P2O5 percentage in 2Ca5 ( PO4)3F There is 3P2O5 in Tri Calcium Phosphate 6P=31X6=186

15O= 16X15=240 426

3Ca(H3PO4) 2H2O 3Ca=40X3 18H=1X18 6P=31X6 27O=16X27 756

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%



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Figure 1.4 : Material balance & process flow diagram of SSP

Figure 1.5 : Material balance & process flow diagram of TSP



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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.



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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



16

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



17

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%)



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%)



2) R.R.Chemical

Ankleshwar

By road



18

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



19

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



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.



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.

Table 1.8: Solid/hazardous Waste Generation & Management

S.

No.

Name Category Quantity Disposal/ Management

Hazardous Waste

1. ETP sludge 35.3 16.5 TPA Disposed to TSDF site

2. Used Oil 5.1 10.0 LPA Sell to authorized recycler

3. Discarded Containers 33.1 500 nos./Annum Sell to authorized recycler

3.8.5 Noise

Construction Phase: Noise will be generated during construction phase due to vehicular

movement, operation of construction equipment. Well maintain vehicles and construction

equipment shall be engaged to minimize the noise pollution.

Operation phase: Noise will be generated due to various industrial activities, use of utility, plant

machineries, vehicular movement etc. Proper mitigation measures will be implemented to

control the noise to keep it within the prescribed norms. The industry has proposed 5788.0

m2area for green belt around the periphery of the plant boundary and open space of plot.

Greenbelt will help in reducing the adverse effect of noise pollution in general.

3.9 Purpose of EIA Study

As per the provision made in EIA Notification Dated 14th September 2006 and its amendment

till date, it has been noticed that the proposed project to be developed for manufacturing of

Chemical fertilizer thus project activity falls under schedule I: 5(a)–Chemical fertilizers. Project is



22

located in GIDC Saykha notified industrial area; hence project category is “A”. It is necessary to

get Environmental Clearance (EC) prior to commissioning of the proposed project by applying to

EAC, MoEF & CC New Delhi, along with the Environment Impact Assessment Study Report.

Therefore, the EIA study is required to be conducted for obtaining the EC.

4.0 SITE ANALYSIS

Propose project site were selected for evaluation based upon their general suitability for

industrial development. Site analysis was done to ensure that development is undertaken in

such a way that reduces negative impacts to the onsite environment and surrounding

ecosystems. Propose project site is supported by various basic infrastructure facilities i.e. water

supply, transportation, electricity supply, fuel supply etc.

4.1 Connectivity

Proposed project site is connected with road, rail and air transport. Raw materials, finished

products & personnel during the construction and operation phase shall be done by means of

existing transportation facility.

Railway station : Bharuch (18.7 km)

Highway : SH – 6 (6.67 kms), SH-64 (10.61 kms)

Airport : Baroda (74.16 km)

4.2 Land form & Land Use

Proposed project site is located in GIDC Saykha, Notified Industrial Area. Existing land use

pattern of proposed project site is non-agricultural. Land use pattern is non-agricultural and

mainly used for the industrial activities. The environmental setting contains an idea on the

environmental conditions/locations within the vicinity of the proposed project.

Environmental settings available surrounding of the proposed project site is mentioned in table

1.9

Table 1.9: Environmental Settings

S. No.

Particulars Description

1. Forest & Marine Sanctuary

There is no forest & Marine Sanctuary within 10 kms. radius of proposed project site.

2. Stream / Rivers River Bhukhi – Approx. 1.2 km, South East direction. River Narmada – Approx. 9.64 km, South direction.

3. Sea Arabian Sea (approx. 33.9 km)

4. Water body/Pond/Lack None

5. Hill / Mountain There is no Hill /Mountain within 10 kms. radius of proposed project site.

6. Villages Saykha (2.86 km) village

7. Historical, religious and other important cultural places.

None

4.3 Topography

Proposed project site is located at 21°46’11.8” N and 72°49’48.8”E. It has an average elevation

of 9.7 meters above sea level. Proposed project site is located in GIDC Saykha, notified



23

industrial area, where land is already developed for industrial purpose.The overall project site is

located on plain barren land devoid of any permanent and economically useful vegetation. The

topography of the proposed site for project is plain terrain. Forest, national park, eco sensitive

area, wild life sanctuary, Historical, religious and other important cultural place etc. is not

located within 10 Km periphery of the proposed project site. There is no change in land

use/topography as the proposed project shall be established in well-developed industrial Area of

GIDC Saykha.

4.4 Existing Infrastructure (Social/Commercial)

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community

facilities such as park, market, playground etc. education, health care, community development,

income distribution, employment and social welfare are available in nearby area of proposed

project site.

4.5 Soil Classification

Proposed project site is located in GIDC Saykha, notified industrial area, where land is already

developed for industrial purpose. Quality of soil is not considerably fertile for agriculture

activities and no evidence of any influence of soil contaminant has been noticed.

4.6 Climatic data from secondary sources

Proposed project site is fall under seismic zone – III which is not highly earthquake prone area.

Semi-Arid type of climate is observed with temperature ranges 16.2°C (mini.) to 45.8°C (max).

Wind is observed from west at 14 kmph speed. There is a chance of humidity in the weather

due to Arabian Sea. Humidity is ranges from 14 – 94%. Normally during June to September

month, rain is expected.

5.0 PLANNING BRIEF

Kisan Shakti Fertilizers and Pesticides Pvt Ltd proposed to set up manufacturing plant for

chemical fertilizers at C-190, GIDC Saykha, Notified Industrial Area, Tal-Vagra, Dist – Bharuch,

Gujarat. The proposed project will be started after getting Environmental Clearance from EAC,

Consent to Operate from GPCB and other statutory clearances required for. 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.

5.1 Population Projection

125 – 150 Nos. of skilled and semi-skilled construction workers will get direct employment

during construction phase while 90 nos. of technical personal and other contract workmen will

get direct or indirect employment after commissioning of proposed project.

5.2 Land use Planning

Kisan Shakti Fertilizers and Pesticides Pvt Ltd. has already occupied total 17380.00 m2 land for

development of proposed project. All the industrial infrastructures like STP, ETP, storm water

drainage systems, sewerage network, internal RCC road, rain water harvesting system, area

lighting and electrification, water supply system, waste management system etc. will be

developed in said plot area. It is proposed to develop 5788.00 m2. Greenbelt area as per CPCB

guideline and it is 33.3% of area utilized for proposed project development.



24

5.3 Amenities / Facilities

All amenities/facilities will be required to develop green filed project is available in proposed site

as well as nearby town i.e. at Bharuch.

6.0 PROPOSED INFRASTRUCTURE

Proposed industrial plant to be supported by various basic infrastructure facilities i.e. water

supply, transportation, electricity supply, fuel supply, storage, Canteen, restrooms, drinking

water facilities, sanitation facilities etc.

In addition to above treatment facilities like ETP, APC, waste handing system etc. will also be

provided at proposed project.

7.0 REHABILITATION& RESETTLEMENT (R&R) PLAN:

Proposed project activities will be carried out in GIDC Saykha, Notified Industrial Area, which is

developed for industrial purpose and there is no population or local inhabitant at the proposed

project site. Thus Rehabilitation & Resettlement (R&R) Plan is not applicable to propose project.

8.0 PROJECT SCHEDULE & COST ESTIMATION

8.1 Project Schedule

The proposed project will be started after getting Environmental Clearance from EAC, consent

to Operate from GPCB and other statutory clearances required for.

8.2 Cost Estimation

Capital towards proposed industrial plant development including land purchase, building

construction, plant machinery – purchase and commissioning, environmental management,

greenbelt development etc. The overall project cost has been estimated Rs. 38.01 Crores, and

is summarized in table 1.10.

Table 1.10: Project Cost

S. No.

Particulars Cost in (Crores)

1. Land 3.01

2. Building and civil work 13.00

3. Plant and Machinery purchase 17.00

4. Utility /off sites 3.50

5. Environmental Management System 1.50

Total Project Cost 38.01

9.0 ANALYSIS OF PROPOSAL:

9.1 Financial & Social Benefits

Approximately125 – 150 Nos. will be employed directly during construction phase.

All local people shall be employed as per their skills, qualifications and company’s

requirement during operation phase.



25

Proposed project will contribute to state and national economic growth to a measurable

extent.

Adopt water conservation techniques and pollution abatement measures to protect existing

environment and ecology.



26

ANNEXURE 1– LAYOUT PLAN



27

ANNEXURE 2– LAND ALLOTMENT LETTER

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