PREFEASIBILITY REPORT

1.0 INTRODUCTION

1.1 IDENTIFICATION OF PROJECT

The project proponent M/s. New India Group, New Delhi, is engaged in the production of Linear
Alkyl Benzene Sulphonic Acid. New India Group (NIG) is proposing to set up a surfactant
manufacturing facility in Chennai under the name and style of “Detergeo Chem Private
Limited” to cater to the raw material demand of the home-care and personal-care industry in
South India.

NIG has selected the following surfactants for its key product portfolio: Linear Alkylbenzene
Sulphonic Acid 96% (LABSA 96%) and Linear Alkylbenzene Sulphonic Acid 90% (LABSA
90%). Additionally, NIG shall also produce Alpha Olefin Sulfonate (AOS), Sodium Lauryl
Sulphate (SLS) and Sodium Lauryl Ether Sulphate (SLES) to cater to the raw material demand
of the FMCG industry in the region. All the above products will be manufactured on the same
plant however organic feedstock shall change depending on the requirement of the final product.

IDENTIFICATION OF PROJECT PROPONENT

The New India Group is a fourth generation family-owned and professionally managed
diversified business group. The group was founded in 1947 and is primarily into manufacturing
and trading of dyes, chemicals and textiles. The group’s mission is to best serve the needs of its
valuable customers by conducting business in line with its core values of: integrity and
reliability.

BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project will fall under Schedule 5(f) of the EIA Notification - 2006 and
Amendments thereon. As the project site is located inside a notified industrial estate this project
falls under ‘B’ category and requires clearance from SEIAA-Tamil Nadu.

1.2 NEED FOR THE PROJECT AND IMPORTANCE TO THE NATION

With the increase in the population and usage of soaps and detergents by the people, its market is
has good prospective and bright future. So, we need a raw material from which the soaps and
detergents could be made instantly and easily. Acid slurry is one such material, from the soaps

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and liquid detergents could be made from. And demand of Linear Alkyl Benzene Sulphonic Acid
(LABSA) is always there in domestic market and as well as in global market for FMCG industry.
To meet the current market demand, New India Group has planned to set up a new
manufacturing unit Detergeo Chem Pvt. Ltd. intended for the production of LABSA and other
alternative surfactants (AOS, SLS and SLES) at Plot No.F-52, SIPCOT, Gummidipoondi,
Chennai (India).

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2.0 SITE ANALYSIS

2.1 LOCATION
New India Group has planned to set up a new manufacturing unit Detergeo Chem intended for
the production of LABSA and other alternate surfactants (AOS, SLS and SLES) at Plot No.F-52,
SIPCOT, Gummidipoondi, Chennai (India).The satellite Imagery of the site is shown Figure 2.1.
The location of the project site is represented in Figure 2.2.

Figure 2.1 Satellite image of project site

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Figure 2.2 Location map of project site

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2.2 CONNECTIVITY
The site is well connected by the Guntur and Chennai National Highway (NH 5) at a distance of
0.8 km. This unit is located in the South eastern direction of this road. The raw material &
product is conveniently transported by this road.

Figure 2.3 Connectivity map of project site

2.3 LANDUSE CLASSIFICATION & LANDUSE BREAKUP

Tamil Nadu Government has recognized the location of this unit as “SIPCOT Industrial Area”
and encouraging entrepreneurs to come forward for setting up industries. The area is dominated
by large scale industries and other medium scale industries.
The total plot area of the facility is 4048 sq.m. The land use breakup of the project site is given in
Table 2.1. The topo map of the project site and its surrounding area covering 10 km radius are
given in Figures 2.4. Map Showing the Water Body is given in Figure 2.5. Environmental
settings are presented in Table 2.2.

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Figure 2.4 Topo map (10km around project site)

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

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Table 2.1 Land Use Break up of Project Site

S. No Land Use Breakup Details Area (Sq.m.)
1. Production Shed 1400
2. UG WATER Tank/Cooling Towers 96
3. Sulphur Yard 80
4. Tank Farm 336
5. DG/Electrical (G + 1) 54
6. Repair Workshop 36
7. Store/Office/LAB/Canteen 105
8. ETP/Septic Tank 60
9. Car Parking 36
10. Greenbelt Area (33% of total area) 1336
11. Roads 508
Total Area 4047

Table 2.2 Environmental Settings of Project Site

S. NO. PARTICULARS
1 Site Latitude
2 Site Longitude
3 Site Elevation
4 Nearest highway
5 Nearest railway station
6 Nearest airport
7 Nearest town/ city
8 Topography
Archaeologically important
9 Nil within 10 km radius
places
National parks/ Wildlife
10
Sanctuaries
11 Reservoir/River/Lake
DETAILS
13°24'47.84"N
80° 6'46.20"E
67 m
Guntur and Chennai National Highway (NH5) –
0.8 km (ESE)
Gummidipundi Railway Station- 1.2 Km (ESE)
Chennai International Airport – 47.13 km (SSE)
Gummidipundi Town – 0.7 km (SSE)
Plain
Nil within 10 km radius
Poovalambedu Pond 7.7 km (WSW)
Arani River 6.49 km (SSW)
Panpakkam Lake 4.33 km (SSE)
Pattupalli Lake 6.56 km (ENE)
Pallavada Lake 11.55 km (NW)
Ponneri Lake 13.8 km (ESE)
Pulicate Lake 14.9 km (ENE)

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S. NO. PARTICULARS DETAILS

Puliyar Forest 6.31 km (WSW)
12 Reserved/ Protected Forests Siruvada Forest 9.57 km
Thervoy Reserve Forest 9.82 km
13 Seismicity Zone II
14 Defence Installations Nil within 10 km radius
15 Nearest Port Chennai Port – 41.5 km (SE)

2.4 SITE SUITABILITY / ALTERNATE SITES CONSIDERED

The proposed project site is leased from SIPCOT. This site has the following advantages:
 The Plant is located in the SIPCOT hence basic infrastructure of roads, power, water
etc. is readily available.
 The plant is located near high demand area.
 There is no likelihood of any residential development in the vicinity of the Plant.
 Possible mutual aid in emergency will be available in the Industrial Area.
 There is potential for future growth in demand.
 Adequate availability of land within the SIPCOT for future expansion etc.

Hence, no alternative sites were considered.

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3.0 PROJECT DESCRIPTION

3.1 MAGNITUDE OF OPERATION
Production capacities of the products, has been estimated as 43000 MT/A.

3.2 RAW MATERIALS REQUIRED FOR PRODUCTION

Table 3.1 List of Raw Materials

Sr. Quantity in TPD
Name Of Raw Materials Mode of Transport
No. (ANY ONE OR MIX)
1 Linear Alkyl Benzene 90 MS Tanker
2 Alpha Olefin 90 20/40 feet container
3 Lauryl Ether 90 Road
4 Lauryl Alcohol 90 20/40 feet containers
5 Sulfuric Acid 98% 10 MS Tanker
6 Caustic Soda Liquid 10 MS Tanker
7 Sulfur 13 Trailer

Sr. Physical Type of Capacity of

Description No.
No. Form Storage storage, MT
➢ Raw Materials
1 Linear Alkyl Benzene Liquid MS Tank 100 3
2 Alpha Olefin Liquid SS Tank 50 1
3 Lauryl Ether Liquid SS Tank 50 1
4 Lauryl Alcohol Liquid SS Tank 50 1
5 Sulfuric Acid Liquid MS Tank 10 1
6 Caustic Soda Liquid Liquid MS Tank 10 1
7 Sulfur Solid Closed Yard 50 1
➢
1 LABSA 96% Liquid MS Tank 100 2
2 AOS 38% Liquid SS Tank 50 1
3 SLES 28% Liquid SS Tank 50 1
4 SLS 28% Liquid SS Tank 50 1
5 LABSA 90% Liquid MS Tank 50 1

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3.3 PROCESS DESCRIPTION

Sulfur Trioxide Gas Generation

Sulfur trioxide gas is generated by burning sulfur at high temperature and sulfur dioxide then
formed in presence of air which later converted to sulfur trioxide in presence of a catalyst in a
well closed loop system. Industrially SO3 is made by the contact process. Sulfur dioxide,
which in turn is produced by the burning of sulfur. After being purified by filtration, the SO2
is then oxidized by atmospheric oxygen at between 400 and 600 °C over a catalyst. A typical
catalyst consists of vanadium pentoxide (V2O5) activated with potassium oxide K2O
on kieselguhr or silica support. The heat generated during this process is utilized for steam
generation. This steam is consumed in various uses like sulfur melting, Air drying and water
chilling etc.

Sulphonation System

The Sulfonic acid forms in the unit when an SO3-in-air mixture is injected into a multi-tube
reactor, simultaneously with the desired organic feed. The removable organic distribution
flanges are factory calibrated prior to installation in the reactor. Uniform distribution of the
air-SO3 gas is the result of symmetrical gas flow through the reactor. Reaction temperature is
also a very important parameter of control in sulfonation and sulfation process. Cooling
jackets in the reactor remove heat of reaction. Organic feed rate to the reactor vessels is
measured by means of a highly accurate mass flow meter and controlled by a control valve
and centrifugal pump. The organic feed rate is controlled based on the preset sulphur-to-
organic mole ratio. Exhaust gas is separated from the acid recycle stream in the liquid
separator and cyclone vessels. For the production of sulfonic acid, the acid product is fed
directly to the digestion system where reaction with absorbed SO3 goes to completion.

Neutralization

The Sulphonic acids produced after Sulphonation of LAB/AO/LE/LA is neutralized to make

their respective sodium salt.

This process takes place by mixing Sulphonic acid with liquid sodium hydroxide solution up
to getting neutral pH of the product. This reaction is exothermic hence proper cooling is

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provided to the neutralization vessel. The product is formed as paste which then diluted with
pure water to get desired concentration of detergent liquid.

Figure 3.1 Line Diagram of Sulphonation Plant

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

3.5 INFRASTRUCTURE REQUIREMENTS

A. PROCESS EQUIPMENTS:
i. Air Drying Plant

The process air is first compressed to a pressure of approximately 1 kg/cm2 and chilled to
a temperature of 16°C in the air chiller vessel. The chilled air is then dried in automatic
desiccant- type air dryers to a guaranteed dew point of 60°C. The dual air dryers are
equipped with 11 individual bubble tight control valves. This ensures absolutely no
interruption of process air when changing dryers and a smooth pressure transition when
changing to regeneration. On power failure, these valves are designed to automatically
close to prevent back up of corrosive gas into the dryers, and to keep moist atmospheric
air from reaching the dryers and gas plant. The cooling air blower supplies cool air to the
regenerated (off-line) air dryer to reduce the bed temperature to an acceptable level, prior
to bringing the regenerated air dryer back on-line.

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ii. SO3 gas Plant

Sulfur burning in equipment specifically designed to produce SO3 gas for sulfonation
Converter gas from a sulfuric acid plant contains 10–12% SO3 and appears to be a
potential SO3 source for Sulphonation.

Molten sulphur is supplied to the sulphur burner by a submersible pump from the sulphur
melter. A steam and condensate system is utilized to supply the necessary tracing circuits
for all the sulphur piping and sulphur melter.

The molten sulphur is delivered to the refractory-lined atomizing sulphur burner where
combustion with the dry process air, generates sulphur dioxide (SO2). The sulphur
dioxide gas leaving the burner is cooled and delivered to a four-stage Vanadium oxide
catalytic converter, where the gas is filtered and converted to sulphur trioxide (SO3). An
injection air system is used to cool the gas between the converter stages. When the
conversion efficiency of the converter approaches 98%, the sulphur trioxide gas leaving
the converter is cooled to nearly ambient temperature in a cascade cooler prior to entering
the Brinktype inlet mist eliminator which removes traces of sulphuric acid or oleum. Heat
recovered from the SO2 and SO3 coolers is used to regenerate the air dryers, thus
eliminating the need for an external heat source. A Continuous source of dry air-SO3 gas
is required for film Sulphonation and sulfation.

iii. Sulphonation Plant

The Sulfonic acid forms in the unit when an SO3-in-air mixture is injected into a multi-
tube reactor, simultaneously with the desired organic feed. The removable organic
distribution flanges are factory calibrated prior to installation in the reactor. Uniform
distribution of the air-SO3 gas is the result of symmetrical gas flow through the reactor.
Reaction temperature is also a very important parameter of control in sulfonation and
sulfation process. Cooling jackets in the reactor remove heat of reaction. Organic feed
rate to the reactor vessels is measured by means of a highly accurate mass flow meter and
controlled by a control valve and centrifugal pump. The organic feed rate is controlled
based on the preset sulphur-to-organic mole ratio.

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iv. Exhaust Gas Treatment System

The excess/vent gas is seperated from the sulphonic acid stream and is directed to the
Exhaust Gas Treatment System. The Exhaust Gas Treatment System consists mainly of
the following: Wet Electrostatic Precipitator (ESP) and Alkali Scrubber.
The electrostatic precipitator (ESP) employs a proprietary electrode design in an air
jacketed bank of collection tubes. The High Intensity Toroidal Electron Corona (HITEC)
produced by the electrode charges the inlet particulars, which are collected at the passive
tube wall. Coalesced organic acids (bottoms) discharge at the bottom of the vessel.
The Alkali Scrubber is used to neutralize the SOx gases.

v. Hydrolyzer

The sulfonic acid stream is diverted to the hydrolyzer vessel for ageing after leaving the
reactor outlet. Hydration water is injected and mixed with the sulfonic acid, leaving the
digesters to remove anhydrides.

vi. Neutralization Chamber

A continuous neutralizer system is used to make the sulphonates and sulphates. The
neutralizer combines sulfonic acid or organo-sulfuric acid with a neutralizing agent,
additives, and diluent (water), in dominant bath neutralization.

vii. Auto Control Systems

A typical sulfonation plant control system consists of two components that are integrated
into a single system: A main instrument control panel (ICP) and a motor control center
(MCC). When properly designed and installed, this system not only allows operation of
the sulfonation plant but also improves the operators' understanding of the plant's
operation through graphic interfaces. Better control results in improved product
consistency and quality. The ICP integrates the loop control, logic control, data
acquisition, and operator interface into a single system. The motor control center (MCC)
includes a main power disconnect, a lighting transformer, motor starters, variable
frequency speed controllers, and disconnects as required for the equipment.

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

These tanks are required for the storage and transport of LABSA, Caustic soda Lye and
Sulfuric acid, Lauryl Alcohal, Ethoxylated Lauryl Alcohol and Alpha Olefin, Alpha
Olefin Sulphonate (AOS), Sodium Lauryl Ether Sulphate (SLES), Sodium Laureth
Sulphate (SLS).

B. UTILITIES AND OTHERS

1. Boiler / Cooling Tower
2. Effluent Treatment Plant
3. Auto control system
4. Fire extinguisher
5. Administration Building & Security Area
6. Parking Area
7. Greenbelt Area
Table 3.3 List of Equipments

S. No Description Quantity Capacity

Sulfur Trioxide gas
1 1 1250 kg SO3/hr
Generation Plant
2 Air Drying Unit 1 9000CMPH
Film Sulphonation/Salfation
3 1 5000 kg/hr
Reactor
4 Neutralization Unit 1 5000 kg/hr
5 Water Purification Plant 1 10 KL/hr
6 Cooling Tower 2 800 TR
Vent Gas Treatment System
7 1 6000 CMPH
with ESP
8 Chilled Water Unit 1 100 TR
Heat (Steam) Recovery
9 1 1000 kg/hr
System
10 Electricity Generator 1 630 KW
11 Weigh Bridge 1 60 MT cap
12 Cooling Tower /Pumps As per requirements
13 Water Hydrants System As per requirements
14 Spray Drying Plant 1 50TPD
15 Noodling Plant 1 50 TPD

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Figure 3.3 Site layout

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3.5.1 MANPOWER
The details of manpower is given in table. Total manpower will be 27 Nos.
Detail Number
Factory managers 01
Plant Operator 03
Yard Supervisor 01
Labour 06
Weighbridge Operator 02
Maintenance Manager 01
Welder 01
Fitter 01
Electrician and Instrument
01
Technician
Chemist 03
Accountant 02
Peon 01
Security Supervisor 01
Security 03
Total 27

3.5.2 POWER
The Power requirement will be 630 KW sourced through TNEB. DG set details are given
below.
Table 3.4 Details
SL.NO. Equipment Capacity
1 DG Set - 1 630 KW

3.5.3 WATER REQUIREMENT

The unit proposes to consume 155 KLD of Fresh water. The entire quantity of raw water will
be supplied by SIPCOT. Water balance table for the operation of the proposed plant is as
follows.

Initiatives for water reduction:

• The plant will implement a scheme for source reduction of water coming from
washings by articulating a recycle and reuse scheme.

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• The plant will have cool atmospheric air in most of the heat exchanger instead of
water.
• The plant will have a zero discharge and will successfully recycle the entire water
back to plant use.
• Water harvesting system will be installed to collect natural water.

Table 3.5 Water Balance

S. No. Particulars Water Requirement (KLD)
1. Domestic 2.0
2. Gardening 1.0
Process 2.0

3. Industrial Cooling makeup water 122.0

Boiler makeup water 23.0

4. Alkali Scrubber 5.0

Actual Requirement 155

ETP recycle water 5.0
Condensate Recovery 17.5
Evaporation Loss 124.5

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Total Water
Requirement 155 KLD

Domestic Septic Tank Gardening Industrial

2.0 KL/day & Soak Pit 1.0 KL/day 152.0 KL/day
0.4 KL/day

Loss
120 KL/day

Process Makeup Makeup water Evaporation

4.5 KL/day
2.0 KL/day water 122.0 23.0 KL/day
KL/day

Process Cooling water Boiler

Effluent 500 KL/day 35 KL/day
0.5 KL/day

Bleed Off Blowdown

2.0 KL/day 1.0 KL/day
Condensate
Recovery
Sewage 17.5 KL/day
ETP 5.1 KL/day
1.6 KL/day

ETP Sludge will be Alkali Scrubber

Raw Water
disposed at TSDF 5.0 KL/day
Waste water
Recyclable water

Figure 3.4 Water balance chart

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3.5.4 POLLUTION CONTROL MEASURES

3.5.4.1 AIR (EMISSIONS)
The following measures are proposed for control of gaseous emissions:
 The emission sources will be D.G. Sets, sulphonation plant and are designed with
adequate stack heights and air pollution control measures to meet the standards set by the
TNPCB / CPCB.

Table 3.6 Details of air pollution control measures

Exit Max
Height Exit
S. Stack Contro1 Top Material of Gas Discharge
Source above Gas
No. No Measures dimension Construction Velocity (Cubic
GL Temp
(m/s) meter/min)
Stack Attached Not
1. 1 0.2 15 Mild Steel 21.4 40 453
to D.G. Set-1 Applicable
Stack Attached Alkali
2. 2 to Sulphonation Scrubber, 0.5 30 Mild Steel 6.6 35 85
Plant ESP

The proposed air emissions will be generated from the above process will be treated in the
Wet Electrostatic Precipitator (WESP) and Wet Alkali Scrubber System.

3.5.4.2 POSSIBLE FUGITIVE EMISSION SOURCES:

- Chemical storages
- Process reactor vent
- Laboratory testing
Fugitive emissions control Measures:
Chemical Storages tanks will be closed and only breathing vent will be there, as such there
will be no fugitive emission there.
Process reactor vent has well equipped vent treatment system with ESP (Electro Static
Precipitator) and Alkali scrubber to remove all fugitive emissions.
Laboratory testing will be equipped with fuming chamber for any fugitive emissions.

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3.5.5 WASTE GENERATION

3.5.5.1 WASTE WATER GENERATION DETAILS & MANAGEMENT

Water
S. No. Particulars Generated
(KLD)
1. Washing / Spillage Effluent 1.6
2. Domestic Sewage 0.4
Cooling 2.0
3. Utilities
Boiler 1.0
4. Process 0.5

These are the four waste water streams generated. Washing/Spillage Effluent, utilities and
process waste water will be collected and fed into the Effluent treatment plant
appropriately. The domestic sewage will be treated through septic tank and soak pits. The
treated water from ETP will be reused for Alkali Scrubber.

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3.5.5.2 SOLID WASTE (HAZARDOUS & NON-HAZARDOUS WASTES)

The solid waste generated from proposed will be as follows:

Hazardous Waste Generation

Source
Name of
of
S. Process Quantit Waste Waste Waste Physical
generati
N Waste(Catego y Type Storage Disposal status
on
ry No)
of waste
Use within
premises as Pump
MS/Plas
Used or spent 25 Recyc a lubricant/ Seal
1 tic Oily
oil l/year lable sell to Oil
Drums
registered DG Oil
recycler
0.5 Disposable Expired
Sulphur Incine HDPE
2 MT/Yea at TSDF Raw Solid
Sludge rable bags
r Site Materials
1 Non
HDPE Disposal at ETP
3 ETP Waste MT/Yea recycl Solid
Bags TSDF Site filter
r able

Non Hazardous Waste Generation

Description of
Equipment/
Non- Qty of Discharged Disposal
facility
Hazardous Waste from Method
used
Waste
Will be reuse
Discarded 100 Stores Sell to approved
within
Plastic Bags Nos/year & office scrap vendor
premises
Discarded Will be reuse
100 Sell to approved
Drums/Contai Stores/Plant within
Nos/year scrap vendor
ner premises

3.5.6 RAINWATER HARVESTING & STORMWATER MANAGEMENT

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

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3.5.7 FUEL REQUIREMENT

S. No Name of fuel points of use Quantity

1 HSD D. G. Set-1 100 L/hr
2 Sulfur Sulphonation Plant 12.5 TPD

3.5.8 GREENBELT DEVELOPMENT

Greenbelt totaling 33% of plot area will be developed.

3.6 ENVIRONMENTAL MANAGEMENT PLAN

Table 5.1 EMP budget
Recurring
cost (Lakhs)
Capital cost
S. No. Infrastructure including
( lakhs)
power and
O&M
1. Air Pollution Control 100 5
Effluent Treatment Plant (ETP) &
2. 15 5
Rain water harvesting measures
Environment Monitoring and
3. 20 2
Management
Solid and Hazardous Waste
4. 15 5
Management
5. Occupational Health & Safety 25 7.5
6. Green belt Development 20 5
Total 195 29.5

3.7 PROJECT COST & IMPLEMENTATION SCHEDULE

The cost for the proposed project is estimated at 15 Crores. After obtaining Environmental
Clearance (EC) and Consent to Establish for the proposed project, construction activity will
be commenced.

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