19 Jul 2018 163234160YP69R5LIPFR Expansion PVC&Carbide PDF

Proposed Capacity Enhancement of PVC Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide
Plant
(Acetylene from 90 TPD to 110 TPD) through modernization within existing project premises at DCM Shriram Complex
Kota, Shriram Nagar, Tehsil: Ladpura, District: Kota (Rajasthan)
Pre - Feasibility Report
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY

M/s. Shriram Vinyl & Chemical Industries has an existing PVC Resin Plant having
capacity for PVC Resin 200 TPD and Calcium Carbide Plant having capacity Acetylene 90
TPD & Calcium Carbide 330 TPD at DCM Shriram Complex Kota, Shriram Nagar, Tehsil:
Ladpura, District: Kota (Rajasthan).
Proposed Capacity Enhancement of PVC Plant (PVC Resin from 200 TPD to 250 TPD)
and Calcium Carbide Plant (Acetylene from 90 TPD to 110 TPD) through modernization
within existing project premises at DCM Shriram Complex Kota, Shriram Nagar, Tehsil:
PVC plant & and Calcium Carbide Plant are located within DCM Shriram Complex, Kota
having Khasra No. 122 - 129 of Village Anandpura, 319, 322 - 324 of Village Raipura, 1 -
4, 9 - 20, 264, 268 - 269 of Village Umedganj & 289 - 295, 297 of Village Kansua, Tehsil
Ladpura, District Kota of Rajasthan. The project site is located within Notified Large
Scale Industrial Area. Land is already under possession of project proponent, Land
ownership document are enclosed herewith as Annexure - 1.
Land area details for PVC & Calcium Carbide Plant:
Particulars Land Area Details Land Area Details for Total land
for PVC Plant (A) Calcium Carbide Plant (B) (A+B)
Existing land area 3.83 Hact. 8.83 Hect. 12.66 Hect.
Additional land area
No addition No addition No addition
for expansion
Total land area after
3.83 Hect. 8.83Hect. 12.66 Hect.
expansion
Consent to establish for PVC plant was granted by RSPCB vide letter no. F.12(21-255)
RPCB/Gr.1/3692,dated 28.10.2004 and a valid Consent to Operate (CTO) has also been
obtained from RSPCB vide their letter no. F(Tech)/Kota(Ladpura)/3(1)/2008-
2009/2551-2553, dated 28.06.2017, copy of same is enclosed herewith as Annexure – 2.
Consent to establish for Calcium Carbide Plant was granted by RSPCB vide letter no.
F.12(21-50) RPCB/Gr.1/3188,dated 10.09.2004 and a valid Consent to Operate (CTO)
has also been obtained from RSPCB vide their letter no.
F(SCMG)/Kota(Ladpura)/2613(1)/2017-2018/2634-2636, dated 29.06.2017, copy of
same is enclosed herewith as Annexure – 3.
Now, M/s. Shriram Vinyl & Chemical Industries has planned to enhance capacity of PVC
Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant (Acetylene from
90 TPD to 110 TPD) through modernization within existing project premises at DCM
Shriram, Kota Complex, Shriram Nagar, Tehsil: Ladpura, District: Kota (Rajasthan).
M/s. Shriram Vinyl & Chemical Industries (A unit of DCM Shriram Ltd.) 22
Proposed Capacity Enhancement of PVC Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant
Existing and Proposed Capacity details are as follows:
Existing Additional Final Capacity

S. No. Unit
Capacity Capacity after expansion
1. PVC Resin (TPD) 200 50 250
2. Acetylene (TPD) 90 20 110
3. Calcium Carbide (TPD) 330 - 330
4. Hydrated Lime sludge (TPD) – By Product 350 60 410
5. Steam from waste heat recovery boiler (TPD) – 360 - 360
By Product
Table - 1
Nature, Size, Location of the Project and Environmental Setting Deatils
S.
PARTICULARS DETAILS
NO.
A. Nature of the Project Expansion {enhancement capacity of PVC Plant (PVC Resin from 200
TPD to 250 TPD) and Calcium Carbide Plant (Acetylene from 90 TPD
to 110 TPD)} through modernization within existing project
premises)
B. Size of the Project Proposed Capacity: Proposed Capacity Enhancement of PVC Plant
(PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant
(Acetylene from 90 TPD to 110 TPD).
Plant Area: Total Land area of the project consists of 791 Acre
(320.106 ha.) area of DCM Shriram Kota Complex out of which ~
9.48 Acre (3.83 Ha.) for PVC plant & ~ 21.84 Acre (8.83 Ha.) for
Calcium Carbide Plant. Land area details for PVC & Calcium Carbide
Plant.
C. Category of the As per EIA Notification dated 14th Sept., 2006 & as amended from
Project time to time; this project falls under Category “B”; Project Activity ‘5
(e)’ petrochemical based processing (processes other than cracking
& reformation and not covered under the complexes).
D. Location Details: DCM Shriram Complex-Kota, Shriram Nagar, Tehsil: Ladpura, District: Kota
(Rajasthan)
Khasra No’s 122 - 129 of Village Anandpura, 319, 322 - 324 of Village
Khasra No’s / Village Raipura, 1 - 4, 9 - 20, 264, 268 - 269 of Village Umedganj & 289 - 295,
297 of Village Kansua.
Tehsil Ladpura
District Kota
S.
PARTICULARS DETAILS
NO.
State Rajasthan
Latitude & Longitude Latitude: 25° 8'25.50"N and Longitude 75°53'8.82"E
Toposheet No. 45O12, 45O15, 45O16, 45O13 & 54C/4
E. Environmental Setting Details (with approximate aerial distance and direction from the plant
site)
1. Nearest Town DCM Shriram Complex located within municipal premises Kota City.
District Headquarter Kota is located @ distance of approx. 3.5 km.
2. Nearest National  NH 76 ( 2.0 km in SE direction)

Highway / State  NH 12 ( 3.5 km in SW direction)
Highway  SH 51 ( 1.0 km in North direction)
 SH 70 ( 4.5 km in North direction)
 SH 33 ( 7.0 km in NW direction)
3. Nearest Railway Dakaniya Talaav Railway Station (~3.0 km in NW direction)
station
4. Nearest Airport Kota Airport. (~ 4.0 km in NW direction)
5. National Parks,  National Chambal Sanctuary (~ 6.2 km in NW direction)

Wildlife Sanctuaries,  Jawahar Sagar Wildlife Sanctuary (~ 14.5 km in West direction)
Biosphere Reserves,
within 10 km radius
6. Reserved Forests
(RF) / Protected  RF (~ 2.0 km in South direction)
Forests (PF)etc.  PF (~ 14.0 km in SSE direction)
within 10 km radius
7. River / Water Body  Sur Sagar (~ 1.0 km in East direction)

(within 10 km  Kansuwa Nadi (~ 3.0 km in North direction)
radius)  Alnia Nadi (~ 1.5 km in SSE direction)
 Kishor Talav (~ 6.0 km in NW direction)
 Chambal River (~7.0 km in NW direction) 6.2
 Chandloi Nadi (~ 10.0 km in NE direction)
 Abhera Talav (~ 13.0 km in NW direction)
8. Seismic Zone Zone -II [as per IS 1893 (Part-I): 2002]
9. Soil Type Clayey loam to clay, generally non calcareous, colour varies from
brown to dark brown.
Table - 2
Salient Features of the Project
Sr. Particulars PVC Plant (A) Calcium Carbide Plant Total (A+B)
No. (B)
1 Product PVC Resin Calcium Carbide Products: PVC Resin, Acetylene, Calcium Carbide
2 Land Area Details
Existing land area 3.83 Hect. 8.83 Hect. 12.66 Hect.
Additional land area
for expansion
Total land area after
3.83 Hect. 8.83 Hect. 12.66 Hect.
expansion
3 Capacity Details
Existing Capacity 330 PVC Resin 200 TPD, Acetylene 90 TPD & calcium Carbide 330 TPD
200 TPD 90 TPD
TPD
Additional Capacity No PVC Resin 50 TPD & Acetylene 20 TPD
50TPD 20 TPD
addition
Total after 330 PVC Resin 250 TPD, Acetylene 110 TPD & calcium Carbide 330 TPD
250 TPD 110 TPD
expansion TPD
4. Water Requirement
Total Water 9140 KLD
2700 KLD 6440 KLD
Requirement
Fresh Water 2390 KLD 6000 KLD 8390 KLD
Recycled Treated 750 KLD
310 KLD 440 KLD
Water
Industrial Process 9100 KLD
2685 KLD 6415 KLD
Water Requirement
Domestic Water 40 KLD
15 KLD 25 KLD
Requirement
5. Waste Water Generation
Form Existing 4040
1240 2800
Project
Form Additional NIL

Nil NIL
Expansion
Form total capacity 4040
1240 2800
after expansion
6. Raw Material
For Existing Acetylene Gas 90 TPD & HCl (30%) 425 TPD Lime Stone*/ Lime: For PVC Pant Acetylene Gas 90 TPD & HCl (30%) 425 TPD and for Calcium
Capacity 700 TPD/425 TPD Carbide Plant (Acetylene production) Lime Stone*/ Lime: 700 TPD/425
Total Carbon TPD
Material: 320 TPD Total Carbon Material: 320 TPD (Charcoal/Coal /Petcoke/ Other Coke)
(Charcoal/Coal
/Petcoke/ Other
Coke)
For Additional Acetylene Gas 20 TPD & HCl (30%) 105 TPD No addition For PVC Plant Acetylene Gas 20 TPD & HCl (30%) 105 TPD
Capacity
For total capacity Acetylene Gas 110 TPD & Lime Stone*/ Lime: For PVC Pant Acetylene Gas 110 TPD &
after expansion HCl (30%) 530 TPD 700 TPD/425 TPD HCl (30%) 530 TPD and for Calcium Carbide Plant (Acetylene production)
Total Carbon Lime Stone*/ Lime: 700 TPD/425 TPD
Material: 320 TPD Total Carbon Material: 320 TPD (Charcoal/Coal /Petcoke/ Other Coke)
(Charcoal/Coal
/Petcoke/ Other
Coke)
7. Power Requirement
For Existing 57.63 MW
3.63 MW 54.0 MW
Capacity
For Additional 0.87 MW
0.75 MW 0.12 MW
Capacity
For total capacity 58.50 MW
4.38 MW 54.12 MW
after expansion
8. Manpower Requirement
Total Manpower 187 501 688
(A) Contract 375
75 300
Manpower
Skilled 45 130 175
Semi skilled 20 110 130

Unskilled 10 60 70
(B) Permanent 313
112 201
Manpower
9 Cost Details
Project Cost:
Existing Project Cost Rs. 106.33 Cr Rs. 115.66 Cr Rs. 221.99 Cr
Additional Project
Rs. 29.0 Cr Rs. 3.30 Cr Rs. 32.30 Cr
Cost for expansion
Total Project Cost Rs. 254.29 Cr
Rs. 135.33 Cr Rs. 118.96 Cr
after expansion
EMP Capital Cost
Existing EMP Cost Rs. 37.00 Lacs Rs. 1075.00 Lacs Rs. 1112.00 Lacs
Additional EMP Cost
Rs. 56.00 Lacs Nil Rs. 56.00 Lacs
for expansion
Total EMP Cost after
Rs. 93.00 Lacs Rs. 1075.00 Lacs Rs. 1168.00 Lacs
expansion
EMP Recurring Cost
Existing EMP
Rs. 15.00 Lacs Rs. 732.00 Lacs Rs. 747.00 Lacs
Recurring Cost
Additional EMP
Recurring Cost for Rs. 18.00 Lacs Rs. 5.00 Lacs Rs. 23.00 Lacs
expansion
Total EMP
Recurring Cost after Rs. 33.00 Lacs Rs. 737.00 Lacs Rs. 770.00 Lacs
expansion
10. Green Area 106 Ha. Area has been 106 Ha. Area has been developed as green belt area which is 33% of total land
Development of developed as green area in which approx. 5 lacs trees has been planted.
DCM Shriram Kota belt area which is
106 Ha. Area has been developed as green belt area which is 33% of total land
Complex 33% of total land area
area in which approx. 5 lakhs trees has been planted.
in which approx. 5
lacs trees has been
planted.
11. Solid waste Generation

Existing S. Cat. Waste Stream Existing Additional Total After Used Oil=5 From PVC Plant:
No. Quantity Proposed Expansion MT/Annum S. Cat. Waste Stream Existing Additional Total After
Sch. Code Waste/Residue No. Quantity Proposed Expansion
Containing Oil=10-15 Sch. Code
1. I 5.1 Used or Spent Oil 20 MTA Nil 20 MT
(from different kg/Annum
operations) Empty discarded
(from different
container of
2. I 5.2 Wastes or 10-15 Nil 10-15 operations)
hazardous chemicals
Residues kg/Annum kg/Annum 7. I 5.2 Wastes or 10-15 Nil 10-15
= 80-100
Containing Oil Residues kg/Annum kg/Annum
Nos./Annum
3. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA Containing Oil
Plastic Production 8. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA
4. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA Plastic Production
Plastic Production 9. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA
5. I 33.1 Empty Barrels / 80-100 20-25 100-125 Plastic Production
Containers Nos./ Nos/Annum Nos./Annum 10. I 33.1 Empty Barrels / 80-100 20-25 100-125
Contaminated Annum Containers Nos./ Nos/Annum Nos./Annum
with Hazardous Contaminated Annum
Chemicals/Wastes with Hazardous
Chemicals/Wastes
From Calcium Carbide Plant:
TPD, Used Oil=5 TPA, Waste/Residue Containing Oil=10-15 kg/Annum and
Empty discarded container of hazardous chemicals = 80-100 Nos./Annum
Additional by Nil
Nil Nil
expansion
Total after S. Cat. Waste Stream Existing Additional Total After Lime Sludge-304 From PVC Plant:
expansion No. Quantity Proposed Expansion TPD, Used Oil=5 S. Cat. Waste Stream Existing Additional Total After
Sch. Code MT/Annum No. Quantity Proposed Expansion
Waste/Residue Sch. Code
Containing Oil=10-15
(from different 16. I 5.1 Used or Spent Oil 20 MTA Nil 20 MT
kg/Annum
operations) (from different
Empty discarded
12. I 5.2 Wastes or 10-15 Nil 10-15 operations)
container of
Residues kg/Annum kg/Annum 17. I 5.2 Wastes or 10-15 Nil 10-15
hazardous chemicals
Containing Oil
13. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA = 80-100 Residues kg/Annum kg/Annum
Plastic Production Nos./Annum Containing Oil
14. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA 18. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA
Plastic Production Plastic Production
15. I 33.1 Empty Barrels / 80-100 20-25 100-125 19. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA
Containers Nos./ Nos/Annum Nos./Annum Plastic Production
Contaminated Annum 20. I 33.1 Empty Barrels / 80-100 8-10 100-125
with Hazardous Containers Nos./ Nos/Annum Nos./Annum
Chemicals/Wastes Contaminated Annum
with Hazardous
Chemicals/Wastes
From Calcium Carbide Plant:
Used Oil=5 TPA, Waste/Residue Containing Oil=10-15 kg/Annum and
Empty discarded container of hazardous chemicals = 80-100 Nos./Annum
12 Effluent Treatment Apart from pollutant specific at source treatment, a centralised effluent treatment plant has been provided within DCM Shriram Kota Complex to further treat the effluent
Plant (ETP) generation in the plants before final discharge.
For Existing
1650 KL Capacity to treat 6000 KLD Effluent
Capacity
For Additional
No addition
Capacity
For total capacity
1650 KL Capacity to treat 6000 KLD Effluent
after expansion
13 Sewage Treatment
Common Sewage Treatment Plant has been provided within DCM Shriram Kota Complex for treatment of domestic sewerage generation from entire complex
Plant (STP)
For Existing
250 KLD
Capacity
For Additional
No addition
Capacity
For total capacity
250 KLD
after expansion
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent
DCM Shriram Limited is a integrated large industrial house engaged in manufacturing
and marketing of Urea fertilizer, PVC, Caustic Soda, Chlorine, Cement, Sugar and Textiles
with manufacturing facilities located in Rajasthan, Gujarat, Utter Pradesh, Hyderabad
and overseas countries, Vietnam and Philippines. DCM Shriram has more than 100 years
of operating experience in India and extensive experience of over 50 years of plant
operations mainly in Power, Fertilizer, Chemicals etc. The turnover of the company for
the year 2017-18 is ~INR 6,976 Crores. The manufacturing facilities are located in Kota
[Rajasthan], Integrated chemical complex to produce Fertilizers, PVC Resins, PVC
compounds, Chlor Alkali,
 Cement, Calcium Carbide, SBP, Fenesta, UPVC Windows, Extrusion Plant and Coal
Based CPP;
 Bharuch in Gujarat: Chlor-Alkali Plant with Captive Cogeneration Power Plant;
 Ajbapur, Rupapur, Hariawan and Loni in U.P.: Sugar Plant with Bagasse Based
Power Plant;
 Hyderabad, and overseas at Vietnam & Philippines: Bio seeds.
The products are well established in the Indian market and meet international quality
standards. DCM Shriram Ltd. has an excellent track record in the field of productivity,
Safety, Health and Environment protection. All plants are Certified to ISO
9001(QMS)/14001(EMS) & OHSAS 18001. The SHE performance of the Company is
recognized through National/International Awards. All locations have Safety, Health
and Environment (SHE) cells. A Whole Time Director (EHS) is coordinating SHE
activities across the company.
(ii) Brief description of nature of the project
M/s. Shriram Vinyl & Chemical Industries has an existing PVC Resin Plant having
capacity for PVC Resin 200 TPD and Calcium Carbide Plant having capacity Acetylene 90
TPD & Calcium Carbide 330 TPD at DCM Shriram Complex Kota, Shriram Nagar, Tehsil:
PVC plant and Calcium Carbide Plant are located within DCM Shriram Complex, Kota
having Khasra No. 122 - 129 of Village Anandpura, 319, 322 - 324 of Village Raipura, 1 -
4, 9 - 20, 264, 268 - 269 of Village Umedganj & 289 - 295, 297 of Village Kansua, Tehsil
Ladpura, District Kota of Rajasthan. The project site is located within notified industrial
estate.
Now, M/s. Shriram Vinyl & Chemical Industries has planned to enhance capacity of PVC
Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant (Acetylene from
90 TPD to 110 TPD) through modernization within existing project premises at DCM
Shriram Complexs Kota, Shriram Nagar, Tehsil: Ladpura, District: Kota (Rajasthan).
As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this
project falls under Category “B”; Project Activity ‘5 (e)’ petrochemical based processing
(processes other than cracking & reformation and not covered under the complexes).
(iii) Need for the project and its importance to the country and or region
PVC is a versatile polymer, finding varied applications, the most important one being the
manufacture of Pipes & Fittings for irrigation purposes. PVC Pipes have very many
advantages over conventional pipes, some of them being:
Less energy is required to manufacture PVC compared to other pipe materials. PVC’s
lighter weight makes it easier and less costly to handle, transport and install. In fact,
most PVC pipe sizes can be handled manually, reducing the need for expensive
installation equipment. Sludge, slime and other residue buildups are virtually
nonexistent because of PVC pipe’s extremely smooth inner surface. The smooth interior
walls of PVC pipe translate into increased flow rates at flatter grades, resulting in
reduced trenching costs and fewer lift stations. Tough but flexible PVC will resist earth
and live load deflection and will bend under shifting soil conditions. Non-corrosive PVC
will withstand “hot soil” conditions. In fact, PVC requires virtually no maintenance. But
if it does become damaged, it can be easily hand-cut and repaired, resulting in lower
repair costs and less interruption in water service to the consumer.
Installation Made Easy Because of its lightweight and durability, PVC pipe saves time
and reduces labor, transportation and maintenance costs. As could be seen under the
Section “Demand-Supply gap”, India is deficient in PVC resin production and there is a
dire need to add capacity in the country to meet the growing demand. This would also
obviate the need to import large volumes of PVC, thereby saving considerable foreign
exchange. Also, currently, the capacity to make PVC resin is highly skewed towards the
Western region of the country. In order to optimize on transportation cost and to give a
fillip to PVC Pipe producers in the South, it is important that such capacity augmentation
takes place in South India.
(iv) Demand- Supply Gap
The demand for PVC is also expected to continue in future. In pipes sector, which
accounts for 70% of resin consumption, government investments in water services will
continue, as a number of smaller towns do not have adequate drinking water facilities.
In other major sectors such as films, footwear, cables, etc. no structural changes have
taken place, which would significantly change the pattern of PVC consumption. Under
these circumstances to bridge the gap, M/s. Shriram Vinyl & Chemical Industries is
proposing an expansion in PVC Plant.
(v) Imports vs. Indigenous Production
The additional production from project will substitute the imports.
(vi) Export Possibility

There is certainly possibility of exports. But as given above the domestic market itself is
more than the domestic production capacity, hence focus is on domestic sales.
(vii) Domestic / Export Markets
The demand for PVC is also expected to continue in future. In pipes sector, which
accounts for 70% of resin consumption, government investments in water services will
continue, as a number of smaller towns do not have adequate drinking water facilities.
In other major sectors such as films, footwear, cables, etc. no structural changes have
taken place, which would significantly change the pattern of PVC consumption
(viii) Employment Generation (Direct and Indirect) due to the project
M/s. Shriram Vinyl & Chemical Industries generally employ maximum possible staffing
from nearby area. The present total manpower requirement for PVC plant is 187
persons, out of which 75 persons are contract manpower & 112 persons have been
appointed as staff.
The present total manpower requirement for Calcium Carbide plant is 501 persons, out
of which 300 persons are contract manpower & 201 persons have been appointed as
staff. Details of Manpower requirement are as follows:
Table: 3
Man Power Requirement (Persons):
Particulars Manpower required Manpower required for Total Manpower
for PVC Plant (A) Calcium Carbide Plant (B) required (A+B)
(B) Contract Manpower 75 300 375
Skilled 45 130 175
Semi skilled 20 110 130
Unskilled 10 60 70
(B) Permanent Manpower 112 201 313
Total Manpower 187 501 688
Contract Manpowers (skilled, semi-skilled and unskilled manpower) are arranged by
contractor from the nearby villages / local area.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects if any
M/s. Shriram Vinyl & Chemical Industries has planned to enhance capacity of PVC Plant
(PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant (Acetylene from 90
TPD to 110 TPD) through modernization within existing project premises at DCM
Shriram Complex Kota, Shriram Nagar, Tehsil: Ladpura, District: Kota (Rajasthan).
Total Land area of the project consists of 791 Acre (320.106 ha.) area of DCM Shriram
Kota Complex out of which ~ 9.48 Acre (3.83 Ha.) for PVC plant & ~ 21.84 Acre (8.83
Ha.) for Calcium Carbide Plant. Land area details for PVC & Calcium Carbide Plant.
Approximately 106 Ha. Area has been developed as green belt area which is 33% of
total land area in which approx. 5 lakhs trees has been planted.
Interlinked and Independent Projects:

Interlinked Project: There will be no interlinked project.
Independent Project: Yes, it is an independent project in which capacity enhancement
of PVC Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide Plant
(Acetylene from 90 TPD to 110 TPD) through modernization within existing plant /
project premises.
(ii) Location (map showing general location, specific location, and project boundary &
project site layout) with coordinates
Figure - 1: Location Map
Figure - 2: PVC PLANT LAYOUT

Figure - 3: CALCIUM CARBIDE PLANT LAYOUT
(iii) KEY PLAN/ENVIRONMET SETTING MAP
Figure - 4: ENVIRONMET SETTING MAP (15 KM RADIUS)
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
Since, the expansion project is proposed within the existing plant premises and no
additional land is required for the same; therefore, no alternative site has been
considered. Total Land area of the project consists of 791 Acre (320.106 ha.) area of
DCM Shriram Kota Complex out of which ~ 9.48 Acre (3.83 Ha.) for PVC plant & ~
21.84 Acre (8.83 Ha.) for Calcium Carbide Plant. Land area details for PVC & Calcium
Carbide Plant.
Table: 4
Land area details for PVC & Calcium Carbide Plant:
Particulars Land Area Details Land Area Details for Total land
for PVC Plant (A) Calcium Carbide Plant (B) (A+B)
Existing land area 3.83 Hect. 8.83 Hect. 12.66 Hect.
Additional land
area for expansion
Total land area
3.83 Hect. 8.83 Hect. 12.66 Hect.
after expansion
(v) Size or magnitude of operation
Table: 5
Existing and proposed Production details
Existing Additional Final Capacity
S. No. Unit
Capacity Capacity after expansion
1. PVC Resin (TPD) 200 50 250
2. Acetylene (TPD) 90 20 110
3. Calcium Carbide (TPD) 330 - 330
4. Hydrated Lime sludge (TPD) – By 350 60 410
Product
5. Steam from waste heat recovery 360 - 360
boiler (TPD) – By Product
(vi) Project description with process details (a schematic diagram/ flow chart
showing the project layout, components of the project etc. should be given)
Project Description
PROCESS DESCRIPTION FOR PVC PLANT:

Acetylene gas from Calcium Carbide Plant and HCl gas (converted from liquid HCl,
which is supplied by Caustic Soda Plant) are mixed in a defined ratio and mixture is
passed through VC reactors where synthesis of Vinyl Chloride Monomer (VCM gas)
takes place. After purification and dehumidification of VCM gas, this VCM gas further
fed to Polymerizers. Polymerization is a batch process, where VCM gas is converted to
PVC resin by using certain catalysts and chemicals and by maintaining defined process
conditions. The PVC resin thus formed in Polymerizers is in slurry form (water+ PVC
resin). This Slurry is then feed to RVCM tower for recycling of residual VCM gas. After
RVCM tower, this slurry is passed through centrifuges to separate water from it. After
centrifuge PVC slurry gets converted to PVC cake, which is fed to PVC dryers to
archived desired moisture content and other specifications
Monomer:
C2H2 + HCl → C2H3Cl
Acetylene Hydrochloric Acid Vinyl Chloride Monomer
Polymer Section:
nC2H3Cl → (C2H3Cl) n
Vinyl Chloride Monomer Poly Vinyl Chloride
Process flow chart is shown in Figure - 5.
Figure - 5: Process Flow Chart of PVC Plant

PROCESS DESCRIPTION FOR ACETYLENE PLANT:

In house manufactured Calcium Carbide is used to generate Acetylene Gas. Calcium
Carbide (solid) of desired size is fed to the wet acetylene generators where it is reacted
with water. The products of reaction are acetylene gas & hydrated lime slurry.
The reaction of calcium carbide with water is as below.
CaC2 + 2 H2O → C2H2 + Ca(OH)2
Purified acetylene gas is sent to dedicated Gas Holder. From Gas Holder it is sent to PVC
plant through Root Blowers & closed pipelines.
Process flow chart is shown in Figure - 6.
Figure - 6: Process Flow Chart of Acetylene Plant

 Air Pollution Control Equipment
Location of APCE Type of APCE Design Efficiency
PVC Packing Plant Cyclone system 98.5
(proposed) (for fugitive dust control)
(vii) Raw material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of raw material and finished product.
a) Raw Material Requirements
Details reg. raw material is given in Table - 6 and Table - 7:
Table - 6
Raw Material Requirement, Source & Transportation for PVC Plant
S. Name of Quantity (TPD) Source Distance & No. of trips
No. Raw Additional Total Mode of per day &
Material for Capacity Transportation Loading
Existing Capacity
Proposed After
Expansion Expansion
1. Internal
Continuous
Acetylene (Calcium 1000 M (Approx)
90 20 110 round the
Gas Carbide Closed Pipe lines
clock
Plant)
2. Internal
Continuous
(Caustic 200 M ( Approx)
HCl (30%) 425 105 530 round the
soda Closed Pipe lines
clock
Plant)
Table - 7
Raw Material Requirement, Source & Transportation for Calcium Carbide Plant
S. Name of Raw Quantity (TPD) Source Distance & No. of trips
No. Material Additional Total Mode of per day &
for Capacity Transportation Loading
Existing Capacity
Proposed After
Expansion Expansion
1. Lime Stone*/ 700 700
Merta
Lime City 14 trips/30
TPD/425 Nil TPD/425 300 KM / Truck
Borunda MT
TPD TPD Gotan
2.
Total
Ghandi
Carbon
Dham 750 KM / Truck & 12 Trip / 27
Material
Meethap Rail Transfort MT
320 TPD Nil 320 TPD
(Charcoal/ ur Jam Rail Transport
Nagar : 3 No. rake /
Coal/Petcoke
Vadodara month @
/ Anthracite
/Other Coke) 3500MT/rake
Fuel Requirement: No fuel required for the enhancement capacity of PVC Resin &
Acetylene, as sufficient continues power is available in DCM Shriram Complex to cater the
requirements.
b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for M/s. Shriram Vinyl & Chemical Industries are
Rajasthan, Delhi, Haryana & Uttar Pradesh. Mode of transportation for final product
will be road.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
 Dust collected from various air pollution control equipment is recycled into the
process.
 Sewage sludge generated from STPs is used as manure in greenbelt development/
plantation within the complex.
 Water used for cooling at various stages of PVC resin & Acetylene manufacturing is
partially subjected to evaporation and partially recycled to the maximum possible
extent & balance is discharged into the drain.
 Domestic wastewater generated from plant is treated in common STP and 100%
treated water is utilized within the premises for horticulture & greenbelt development.
(ix) Availability of water its source, energy /power requirement and source should
be given.
a) Water Requirement and Source
The total water requirement for PVC plant is 2700 KLD, out of which 2390 KLD is Fresh
water & 310 KLD is recycled water.
The total water requirement for Calcium Carbide plant is 6440 KLD, out of which 6000
KLD is Fresh water & 440 KLD is recycled water.
Water requirement of M/s DCM Shriram integrated complex, for various industrial &
domestic purposes, is fulfilled through water supplied by RMC Division of Command
Area Development (CAD) through the Right Main Canal (RMC) of Chambal River
throughout the year.
The company has common water supply agreement with State Government for the
entire complex which is valid till 25.06.2022. Metering system has been provided for
measurement of water intake.
As the PVC & Calcium Carbide Plant is located within the DCM Shriram integrated
complex. Water supply of this plant is fulfilled by common water supply system. Break-
up of water requirement and waste water generation in given below in Table – 8 & 9.
Table - 8
Water Requirement Details
Particulars Water Water Total Water Additional Total Water
required required requirement Water Requirement
for PVC for Calcium (A+B) requirement After
Plant (A) Carbide Existing Proposed Expansion
Plant (B) Expansion
Total Water Requirement 2700 KLD 6440 KLD 9140 KLD Nil 9140 KLD
Fresh Water 2390 KLD 6000 KLD 8390 KLD Nil 8390 KLD
Recycled Treated Water 310 KLD 440 KLD 750 KLD Nil 750 KLD
Industrial Process Water 9100 KLD Nil 9100 KLD
2685 KLD 6415 KLD
Requirement
Domestic Water 40 KLD Nil 40 KLD
15 KLD 25 KLD
Requirement
Table – 9
Waste Water Generation Details
Particulars Waste Water Waste Water Total Waste
from PVC Plant from Calcium Water
(A) Carbide Plant (B) generation
(A+B)
From Existing Plant 1240 2800 4040
From Additional Expansion Nil NIL NIL
From total capacity after expansion 1240 2800 4040
Water Agreement
Water Balance Chart for Calcium Carbide Plant
Steam Condensate
from PVC Plant (190)
All figures in KLD.
Steam Condensate
from Caustic Soda
Plant (140)
Steam to PVC
Boiler Feed 350 and Caustic
Soda Plants
Evaporation &
Drift Losses 10
(1435) Boiler
10
Blowdown
30
Blowdown and
Cooling Towers 110 Filter Back 110
1545 wash
Evopration and
Raw Water losses rom
(6000) 1710
sludge
4400
Effluent from
Process 2680 2680
process
25
10
With product
Septic Tank/
Domestic 25
Soak Pits
Effluent
Acidic Water
440 Neutralization
from PVC Plant
System
3240
b) Power Requirement and Source

The existing power requirement for PVC Plant is 3.63 MW. Additional 0.75 MW power
will be required for proposed expansion project. Thus, the total power requirement
after proposed expansion for PVC Plant will be 4.38 MW.
The existing power requirement for Calcium Carbide Plant is 54.0 MW. Additional 0.12
MW power will be required for proposed expansion project. Thus, the total power
requirement after proposed expansion for Calcium Carbide Plant will be 54.12 MW.
Table: 10
Power Requirement details of both plants are as follows:
Particulars Power required Power required for Total Power

For Existing Capacity 3.63 MW 54.0 MW 57.63 MW

For Additional Capacity 0.75 MW 0.12 MW 0.87 MW
For total capacity after

4.38 MW 54.12 MW 58.50 MW
expansion
Source: Owned Captive Power Plant located within DCM Shriram kota complex and/or RSEB.
(X) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
 Domestic wastewater generated from plant is treated in common STP and the
treated water is utilized for greenbelt development/ plantation.
process.
plantation.
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to NH 76 (2.0 km in SE direction), NH 12 (3.5 km in SW
direction), SH 51 (1.0 km in North direction), SH 70 (4.5 km in North direction) & SH
33 (7.0 km in NW direction) from the plant site. Nearest city to the plant site is Kota.
Nearest Railway Station is Dakaniya Talaav Railway Station (~3.0 km in NW direction
from the plant site) and nearest Airport is Kota Airport (~ 4.0 km in NW direction from
the plant site).
The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect as the Tehsil and
District headquarters are near to the site.
(ii) Land form Land use and land ownership

Proposed project is located at Khasra No. 122 - 129 of Village Anandpura, 319, 322 -
324 of Village Raipura, 1 - 4, 9 - 20, 264, 268 - 269 of Village Umedganj & 289 - 295,
297 of Village Kansua, Tehsil Ladpura, District Kota of Rajasthan.
total land area in which approx. 5 lakhs trees have been planted.
(iii) Topography
The terrain of the proposed area for expansion project is within the DCM Shriram
complex & largely flat with mild undulations.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ), shortest distances from the periphery of the project
to periphery of the forests, national park, wild life sanctuary, eco sensitive areas,
water bodies (distance from the HFL of the river), CRZ. In case of notified
industrial area, a copy of the gazette notification should be given
Table - 11
Environmental Settings of the Area
S. Details
Particulars
No. (with approx. aerial distance & direction from the plant site)
1. Nearest Town DCM Shriram Kota complex located within municipal premises
Kota City. District Headquarter Kota is located @ distance of
approx. 3.5 km.
2. Nearest National  NH 76 ( 2.0 km in SE direction)

Highway / State  NH 12 ( 3.5 km in SW direction)
Highway
SH 33 ( 7.0 km in NW direction)
3. Nearest Railway Dakaniya Talaav Railway Station (~3.0 km in NW direction)
station
4. Nearest Airport Kota Airport. (~ 4.0 km in NW direction)
5. National Parks,  Jawahar Sagar Wildlife Sanctuary (~ 14.5 km in West
Wildlife direction)
Sanctuaries,  National Chambal Sanctuary (~ 6.2 km in NW direction)
Biosphere
Reserves, within 10
km radius
S. Details
Particulars
No. (with approx. aerial distance & direction from the plant site)
6. Reserved Forests
(RF) / Protected  RF (~ 2.0 km in South direction)
Forests (PF) etc.  PF (~ 14.0 km in SSE direction)
within 10 km radius
7. River / Water Body  Sur Sagar (~ 1.0 km in East direction)
(within 10 km  Kansuwa Nadi (~ 3.0 km in North direction)
radius)
 Alnia Nadi (~ 1.5 km in SSE direction)
 Kishor Talav (~ 6.0 km in NW direction)
 Chambal River (~6.2 km in NW direction)
 Chandloi Nadi (~ 10.0 km in NE direction)
 Abhera Talav (~ 13.0 km in NW direction)
8. Seismic Zone Zone –II [as per IS 1893 (Part-I): 2002]
9. Soil Type Clayey loam to clay, generally non calcareous, colour varies
from brown to dark brown.
(v) Existing Infrastructure
No additional land is required for proposed expansion, as expansion will be done
within the existing plant premises.
Following infrastructure facilities are available, which will be expanded as per the
requirement:
 Workshop
A common mechanical and electrical workshop is located to take care of the regular
maintenance/repair jobs in the plant.
 Machinery Stores
A temporary store house required for storing tools, spare parts, consumables etc.
already exists. During construction, open area will be made available for storing
machinery and construction materials for the proposed expansion project.
 Cranes, Monorails and pulley blocks
Adequate sized maintenance cranes/hoists, monorails and pulley blocks are available
at all suitable locations in the plant for ease of maintenance and operation.
 Time and security office
Time office & a security office have already been established at the main gate entrance
of the plant.
 Health Centre
Health centre/ dispensary is provided.
 Weighbridge
Electrical weighbridges are available to take care of the incoming and outgoing
materials in the existing plant premises.
 Bag Godown
Space has been provided in the packing plant area for the storage of bags.
 Parking
Adequate parking space is available within site for the parking of the vehicles.
 Residential area
Well established residential colony is available along with all the required social
amenities for the Staff and Workers.
 Storage facilities
Adequate storage facilities are provided for the storage of raw materials & finished
product, which are detailed in below Table 12 & 13:
Table: 12
STORAGE FACILITIES FOR PVC PLANT
Type of Type of Storage Capacity No. of storage
Materials days
Additional Total after Additional Total after
for Expansion for Expansion
Existing Existing
Proposed Proposed
Expansion Expansion
PVC Resin Go down NIL Go down 600 MT NIL 600 MT 3 days
(packed) NIL
PVC resin Silo NIL Silo 300 MT NIL 300 MT 1 Day
Hydro Tank Nil Tank 3 X 50 Nil 3 X 50 =150 No separate
chloric Acid =150 M3 M3 storage ,All
(30%) (Process (Process tanks are used
Tanks) Tanks) as process tanks
Acetylene Gas Nil Gas Holder 2600 M3 Nil 2600 M3 Continuous
Holder ( Gas Holder) ( Gas Holder)
supply to PVC
Plant from
existing gas
holder
Table: 13
STORAGE FACILITIES FOR CALCIUM CARBIDE PLANT
S. No. Raw Material Existing Storage Additional Capacity after
Capacity Proposed Expansion
Capacity
1. Lime Stone*/ Lime 14,000 MT/400 MT Nil 14,000 MT/400 MT
2. Total Carbon Material 20000 MT Nil 20000 MT

(Charcoal/Coal/Anthracite/
/Petcoke/ Other Coke)
(vi) Soil Classification

Soils predominate in the area: Clayey loam to clay, generally non calcareous, colour
varies from brown to dark brown.
(vii) Climatic Data from Secondary Sources
Climate of the district can be classified as semi arid type. The summers are hot and dry
and winters are cold. The cold season prevails from December to February followed by
hot season from March to mid of June. After summers the rainy season starts with the
onset of monsoon rains lasting till the end of September. The period September to
November constitutes post monsoon period. January is the coldest month with mean
daily maximum temperature at 24.3°C and a mean daily minimum temperature at
10.6°C. Mean daily maximum temperature during summers is 46.2°C and mean daily
minimum temperature is 29.7°C.
(viii) Social Infrastructure available
Nearest city is Kota. Telephone and medical facilities are available in the nearby area.
Educational Institutions, Technical Institute for skill up-gradation, Dispensary etc.
Almost all the villages in the buffer zone are electrified. As part of company policy,
regular CSR initiatives is undertaken for community development.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) / Town and
country Planning/ Development authority classification.
The existing industry is PVC industry (Red Category) and proposed expansion is
proposed within the existing plant premises located in large scale industrial area.
Facilities required for the expansion project is proposed to provide as per requirement.
Transportation of raw material and final product is done trough rail and/or road.
(ii) Population Projection
Indirect employment is expected due to project. Temporary influx of people is expected
during the execution of the project..
(iii) Land use planning

(iv) Assessment of infrastructure demand (Physical & Social)
M/s. Shriram Vinyl & Chemical Industries (A unit of DCM Shriram Ltd.) has already
estimated the demand of infrastructure (Physical & Social) in the nearby area of the
plant site and appropriate developmental activities is undertaken under corporate
social responsibilities for various rural developmental programmes and initiatives for
the up-liftment of the nearby communities from time to time.
(v) Amenities/Facilities
M/s. Shriram Vinyl & Chemical Industries (A unit of DCM Shriram Ltd.) has provided
medical facilities, shopping facilities, canteen etc. for the permanent and contract
employees.
M/s. Shriram Vinyl & Chemical Industries (A unit of DCM Shriram Ltd.) is already
working on development of the amenities/facilities in nearby area of the plant site as
per requirement of local people of the nearby area under corporate social
responsibilities programme.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
No additional area is required for the proposed expansion project, as expansion is
proposed within the existing plant premises.
(ii) Residential Area (Non-processing area)
Well established residential facilities are already available in proximity of plants,
hence, no additional infrastructure is proposed for the expansion project..
(iii) Greenbelt
DCM Shriram Complex consists of 791 Acre (320.106 ha.) area. Out of which
approximately 106 Ha. Area has been developed as green belt area which is 33% of
Greenbelt/Plantation photographs are as under:
(iv) Social Infrastructure

Proposed expansion project will result in growth of the surrounding areas by
increasing indirect employment opportunities in the region including ancillary
development and supporting infrastructure.
(v) Connectivity
The site is well connected to NH 76 (2.0 km in SE direction), NH 12 (3.5 km in SW
direction), SH 51 (1.0 km in North direction), SH 70 (4.5 km in North direction) & SH
33 (7.0 km in NW direction) from the plant site. Nearest city to the plant site is Kota.
Nearest Railway Station is Dakaniya Talaav Railway Station (~3.0 km in NW direction
from the plant site) and nearest Airport is Kota Airport (~ 4.0 km in NW direction from
the plant site).
The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect as the Tehsil and
District headquarters are near to the site. All communication facilities such as
telephone, telefax & internet are available in the vicinity of the project site.
(vi) Drinking Water

No increase in domestic water requirement is proposed. Hence, domestic water
requirement is 40 KLD (existing water requirement). Which is supplied from in-house
water treatment plant.
(vii) Sewerage system
Centralized / Common waste water treatment plants for domestic sewerage and
effluent generation has been provided within DCM Shriram Complex, Kota to treat
domestic sewerage and effluent generation from respective plants of DCM Shriram of
Kota complex. Capacity of Common waste water treatment plant and STP are as
follows:
COMMON WASTE WATER EFFLUENT TREATMENT PLANT CAPACITY DETAILS:
PARTICULARS Capacity of ETP
For Existing Capacity 1650 KL Capacity to treat 6000 KLD Effluent
For Additional Capacity No addition
For total capacity after expansion 1650 KL Capacity to treat 6000 KLD Effluent
Hydrated lime slurry, which is obtained during the chemical reaction, is by product of
the process and contains 92-94 % water & 6-8 % hydrated lime. This hydrated lime
slurry is pumped to decanter system/lagoon which facilitates recovering hydrated lime
by decanting water. Hydrated lime is utilized in Cement manufacturing within the
complex and water is sent to centralized effluent treatment scheme for neutralization
with acidic effluent of PVC plant and settling of suspended solids and clear water
pumped back to carbide plant (near Acetylene gas generation plant). The treated
effluent is discharged into internal common drain, which ultimately flows outside the
complex along with effluents discharged by other units operative within the complex
after two settling pits (two polishing pits provided before discharge of total effluents in
addition to large settling system in centralized effluent treatment scheme).
Centralized effluent treatment scheme is having neutralization system of capacity
about 450 m3 with settling capacity is about 1200 m3 (Three pits in series after
neutralization pit). The part effluent from fertilizer is utilized in centralized effluent
treatment scheme to improve the settling. The centralized effluent treatment scheme is
having identical standby arrangement for changing over the system during
cleaning/maintenance. The neutralization system having auto pH correction system &
flow measuring device at the outlet.
The treated effluent, before finally discharging outside the complex, is passed through
settling tank (i.e. two nos. polishing pits). Industry has installed on-line effluent
monitoring system at the final outlet of the complex for measuring parameters-pH, TSS,
Ammonical Nitrogen, Temperature & Flow. The schematic diagram of Common Waste
Water Treatment Plant is as under:
COMMON SEWAGE TREATMENT PLANT (STP) CAPACITY DETAILS
PARTICULARS Capacity of STP
For Existing Capacity 250 KLD
For Additional Capacity No addition
For total capacity after expansion 250 KLD
The domestic effluent (sewage water) generated in DCM Shriram Kota complex is
treated in a common Sewage Treatment Plant of 250 KLD capacity (for entire DCM
Shriram, Kota complex) of MBBR Technology. The treated sewage water (domestic
water) is gainfully utilized in horticulture & plantation development within the
complex. The schematic diagram of STP is as under:
(viii) Industrial waste management

 Water used for cooling at various stages of PVC resin & Acetylene
manufacturing is partially subjected to evaporation and partially recycled to the
maximum possible extent & balance is discharged into the drain.
 Domestic wastewater generated from plant is treated in common STP and the treated
water is utilized for greenbelt development/ plantation.
(ix) Solid waste management
process.
plantation.
Table: 14
SOLID/HAZARDOUS WASTE GENERATION FROM PVC PLANT
S. Cat. Waste Stream Existing Additional Total After

No. Quantity Proposed Expansion
Sch. Code
(from different
operations)
22. I 5.2 Wastes or Residues 10-15 Nil 10-15
Containing Oil kg/Annum kg/Annum
23. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA

Plastic Production
24. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA

Plastic Production
25. I 33.1
Empty Barrels / 80-100 Nos./ 20-25 100-125
Containers Annum Nos/Annum Nos./Annum
Contaminated with
Hazardous
Chemicals/Wastes
CAPACITY & MODE OF SECURED STORAGE & ENVIRONMENTAL SAFE GUARDS
S. Category Waste Stream Storage Secured Storage & Environment

No Sch. Code Capacity friendly disposal
1. I 5.1 Used or Spent Oil 20 MT Different grades of oil are being used in
(from different plants. The used oil is being reclaimed in
operations) oil reclamation plant by centrifuging and
filtration. This oil is again used in
equipment. In this process some oil is
generated as used oil. This oil is
collected in drums and stored in a
facility having covered shed & spillage
recovery system.
The used oil collected in a drum is sold
to authorised/registered recyclers.
2. I 5.2 Wastes or - Mainly oil soaked cotton waste from
Residues maintenance activities. It is stored in
Containing Oil MS/PVC drums and incinerated in Kiln
3. I 22.1 Spent catalysts – 20 MT Spent carbon catalyst containing
Plastic mercury is generated during
Production manufacture of intermediate product
Vinyl Chloride for manufacturing of PVC
Resin. It is collected in PVC/HDPE
S. Category Waste Stream Storage Secured Storage & Environment

No Sch. Code Capacity friendly disposal
containers and stored in a facility having
covered shed. The collected spent
catalyst is sold to authorized/registered
recycler.
4. I 22.2 Process 20 MT Process residue (mainly toluene) is
Residues- Plastic generated during manufacture of
Production intermediate product Vinyl Chloride for
manufacturing of PVC Resin. It is
collected in closed process vessel (with
standby facility). The residue collected
in above vessel is transferred in MS
drums before sale to
authorized/registered recyclers. The
filled-in drums are stored in a covered
shed.
5. I 33.1 Empty Barrels / 1000 The empty containers of oil, catalyst
Containers Nos. and/or chemicals are generated and it is
Contaminated reused for packaging of hazardous waste
with Hazardous before sale.
Chemicals/Waste
s
Table: 15
SOLID/HAZARDOUS WASTE GENERATION FROM CALCIUM CARBIDE PLANT
Solid waste Generation

Existing Hazardous waste: Used Oil=5 TPA, Waste/Residue Containing
Oil=10-15 kg/Annum, Empty discarded container of hazardous
chemicals = 80-100 Nos./Annum
Additional by expansion Nil
Total after expansion Hazardous waste: Used Oil=5 TPA, Waste/Residue Containing
Oil=10-15 kg/Annum, Empty discarded container of hazardous
chemicals = 80-100 Nos./Annum
(x) Power requirement and source
The existing power requirement for PVC Plant is 3.63 MW. Additional 0.75 MW power
will be required for proposed expansion project. Thus, the total power requirement
after proposed expansion for PVC Plant will be 4.38 MW.
The existing power requirement for Calcium Carbide Plant is 54.0 MW. Additional 0.12
MW power will be required for proposed expansion project. Thus, the total power
requirement after proposed expansion for Calcium Carbide Plant will be 54.12 MW,
Power Requirement details of both plants are as follows:
Particulars Power required Power required for Total Power

For Existing Capacity 3.63 MW 54.0 MW 57.63 MW

For Additional Capacity 0.75 MW 0.12 MW 0.77 MW
For total capacity after

4.38 MW 54.12 MW 58.50 MW
expansion
Source: Owned Captive Power Plant located within DCM Shriram kota complex and/or RSEB.
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless labourers
R & R Plan is not applicable; as the expansion project is proposed within the existing
premises.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion
The project will start only after obtaining Environmental Clearance and/or other
applicable clearance. An implementation period of 13 months from the date of signing/
effectiveness of the main equipment supply contract is foreseen for this project.
(ii) Estimated project cost Details
Table: 16
Estimated Project and EMP Cost Details
S. Cost Details PVC Plant Calcium Carbide Total Cost
No. (A) Plant (B) (A+ B)
1. Project Cost
Existing Project Cost Rs. 106.33 Cr Rs. 115.66 Cr Rs. 221.99 Cr
Additional Project Cost for expansion Rs. 29.0 Cr Rs. 3.30 Cr Rs. 32.30 Cr
Total Project Cost after expansion Rs. 135.33 Cr Rs. 118.96 Cr Rs. 254.29 Cr
2. EMP Capital Cost
Existing EMP Cost Rs. 37.00 Lacs Rs. 1075.00 Lacs Rs. 1112.00 Lacs
Additional EMP Cost for expansion Rs. 56.00 Lacs Nil Rs. 56.00 Lacs
Total EMP Cost after expansion Rs. 93.00 Lacs Rs. 1075.00 Lacs Rs. 1168.00 Lacs
3. EMP Recurring Cost
Existing EMP Recurring Cost Rs. 15.00 Lacs Rs. 732.00 Lacs Rs. 747.00 Lacs
Additional EMP Recurring Cost for expansion Rs. 18.00 Lacs Rs. 5.00 Lacs Rs. 23.00 Lacs
Total EMP Recurring Cost after expansion Rs. 33.00 Lacs Rs. 737.00 Lacs Rs. 770.00 Lacs
9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local
people including tribal, population, if any in the area
M/s. Shriram Vinyl & Chemical Industries (A unit of DCMShriram Ltd.) has planned to
enhance capacity of PVC Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium
Carbide Plant (Acetylene from 90 TPD to 110 TPD) through modernization within
existing project premises at DCM Shriram Complex Kota, Shriram Nagar, Tehsil:
Ladpura, District: Kota (Rajasthan). Proposed expansion of project will result in growth
and development of the surrounding areas by increasing direct and indirect
employment opportunities in the region which will not only improve the socio-
economic condition but will also raise the living standard of the local population.
Special emphasis on financial and social benefits will be given to the local people
including marginalized population, if any, in the area. Development of social amenities
will be in the form of medical facilities, education to underprivileged and creation of
self-help groups.
Also, Rajasthan state will get revenues in terms of taxes and local people will get
opportunities in terms of indirect employment. Business opportunities for the local
people will be enhanced like transport of PVC Resin in the market, maintenance &
housekeeping contract work etc.
No increase in the natural resources consumption like fresh water consumption and
environmental discharges like wastewater & air emissions due to the proposed
expansion are envisaged, hence, adverse impact on the environment is envisaged,
however, proper mitigation measure will be taken up where ever required.

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Proposed Capacity Enhancement of PVC Plant (PVC Resin from 200 TPD to 250 TPD) and Calcium Carbide

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

Existing and Proposed Capacity details are as follows:

Existing Additional Final Capacity

2. Nearest National  NH 76 ( 2.0 km in SE direction)

4. Nearest Airport Kota Airport. (~ 4.0 km in NW direction)

5. National Parks,  National Chambal Sanctuary (~ 6.2 km in NW direction)

7. River / Water Body  Sur Sagar (~ 1.0 km in East direction)

Form Additional NIL

Semi skilled 20 110 130

11. Solid waste Generation

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(vi) Export Possibility

Interlinked and Independent Projects:

Figure - 1: Location Map

Figure - 2: PVC PLANT LAYOUT

Figure - 3: CALCIUM CARBIDE PLANT LAYOUT

(iii) KEY PLAN/ENVIRONMET SETTING MAP

Figure - 4: ENVIRONMET SETTING MAP (15 KM RADIUS)

PROCESS DESCRIPTION FOR PVC PLANT:

Figure - 5: Process Flow Chart of PVC Plant

PROCESS DESCRIPTION FOR ACETYLENE PLANT:

Figure - 6: Process Flow Chart of Acetylene Plant

b) Marketing Area and Mode of transportation of Final Product

From Additional Expansion Nil NIL NIL

From total capacity after expansion 1240 2800 4040

Water Balance Chart for Calcium Carbide Plant

b) Power Requirement and Source

Particulars Power required Power required for Total Power

For Existing Capacity 3.63 MW 54.0 MW 57.63 MW

For total capacity after

(ii) Land form Land use and land ownership

2. Nearest National  NH 76 ( 2.0 km in SE direction)

1. Lime Stone*/ Lime 14,000 MT/400 MT Nil 14,000 MT/400 MT

2. Total Carbon Material 20000 MT Nil 20000 MT

(vi) Soil Classification

(iii) Land use planning

(iv) Social Infrastructure

(vi) Drinking Water

PARTICULARS Capacity of ETP

For Existing Capacity 1650 KL Capacity to treat 6000 KLD Effluent

For Additional Capacity No addition

COMMON SEWAGE TREATMENT PLANT (STP) CAPACITY DETAILS

PARTICULARS Capacity of STP

For Existing Capacity 250 KLD

For Additional Capacity No addition

For total capacity after expansion 250 KLD

(viii) Industrial waste management

S. Cat. Waste Stream Existing Additional Total After

23. I 22.1 Spent catalysts – 120 MTA 30 MTA 150 MTA

24. I 22.2 Process Residues- 166 MTA 41 MTA 207 MTA

S. Category Waste Stream Storage Secured Storage & Environment

S. Category Waste Stream Storage Secured Storage & Environment

Solid waste Generation

Power Requirement details of both plants are as follows:

Particulars Power required Power required for Total Power

For Existing Capacity 3.63 MW 54.0 MW 57.63 MW

For total capacity after

Existing Project Cost Rs. 106.33 Cr Rs. 115.66 Cr Rs. 221.99 Cr

2. EMP Capital Cost

3. EMP Recurring Cost

9.0 ANALYSIS OF PROPOSAL