Proposed Greenfield Chemical Complex Pre-Feasibility Report

Pre-Feasibility Report
Proposed Greenfield Chemical Complex

(Light Soda Ash Plant of Capacity 11, 00,000,TPA, Dense Soda Ash 5,00,000 TPA,
Sodium Bicarbonate 2,00,000 TPA, Captive Co-gen Power Plant 120 MW,
Seawater Intake and Effluent Disposal System)
Village: Bada, Taluka: Mandvi,

District: Kutch, State: Gujarat
Applicant:
M/s GHCL Ltd.

GHCL House
Opp. Punjabi Hall
Navrangpura
Ahmedabad 380009
Gujarat, India
Proposed Greenfield Chemical Complex – Soda Ash manufacturing, GHCL Ltd.
INDEX
Sr.No. Chapter Page No.
1. Executive Summary 3
2. Introduction of Project 5
(i) Identification of Project and Project Proponent 5
(ii) Brief Description nature of Project 7
(iii) Need of Project and it’s importance to Society/Nation 8
(iv) Demand Supply Gap 8
(v) Imports vs Indigenous Production 9
(vi) Export possibility 10
(vii) Domestic/Export Mrkets 11
(viii) Employment Generation 14
3. Project Description 15
(i) Type of Project 15
(ii) Project Location 15
(iii) Details of alternative site considered and basis of selecting the 18
proposed site
(iv) Size of Operations 24
(v) Project Description with Brief Process Details 26
(vi) Raw material Requirement along with estimated quantity, likely 45
source, marketing area of final product, mode of transport of raw
material and finished product
(vii) Resource optimization/recycling and reuse envisaged in the 49
project
(viii) Availability of water, its source 49
(ix) Quantity of waste to be generated along with its mode of disposal 50
(x) Schematic representation of feasibility drawing which give 56
information of EIA purpose
(xi) List of major plant equipment 59
4 Site Analysis 60
(i) Connectivity 60
(ii) Land Form, Land Use and Land Ownership 60
(iii) Topography 60
(iv) Existing Land use pattern 60
(v) Soil Classification 61
(vi) Climatic data 61
(vii) Temperature 62
(viii) Rainfall 62
(ix) Humidity 62
(x) Winds 62
(xi) Social Infrastructure 63
5. Planning Brief 64
(i) Planning Concept 64
(ii) Landuse Planning 64
6. Proposed Infrastructure 65
7. Rehabilitation & Resettlement Plan 67
8. Project Schedule and Cost Estimate 68
9. Analysis of Proposal / Final Recommendations 72
Encl. I: List of Survey Nos. 75
Page 2 of 79
Chapter 1: Executive Summary
1.1. NAME OF GHCL LTD.

COMPANY
1.2. Location of At various Survey No. (Encl. I)

Proposed plant / Village : Bada
Factory Taluka. - Mandvi
District - Kutch
State : Gujarat (INDIA)
1.3. Promoter of Unit GHCL Ltd
1.4. Registered Address GHCL Ltd

GHCL House
Opp. Punjabi Hall
Navrangpura,
Ahmedabad-380 009
Gujarat, India
1.5. Contact Information  Mr. NN Radia, COO

 Ph. No : +91 79 26434100
Fax- : +91 79 26423623
E-mail : nradia@ghcl.co.in
 Mr. VN Desai, Projects
 Ph. No : +91 79 26434101
E-mail : vndesai@ghcl.co.in
1.6. Category of Category A : 4(e) - Soda Ash Plant ,1(d) Captive

Industry Co-generation Power plant and associated facilities
1.7. Process  Energy efficient “dry liming process” for

Technology Manufacturing of Soda ash. (Light / Dense
Ash, and Sodium Bicarbonate)
 Solid fuel based CFBC Boiler for captive co-
generation power plant.
1.8. Plant & Production  Soda Ash plant : 11,00,000 TPA Light Soda
Capacity details ash (i.e. Phase 1 : 5,50,000 TPA & Phase 2 :
5,50,000 TPA)
 5,00,000 TPA Dense Soda ash (i.e. Phase 1 :
2,50,000 TPA and Phase 2 : 2,50,000 TPA)
 SBC (Sodium Bi-carbonate) plant – 2,00,000
TPA ( i.e. Phase 1 : 1,00,000 TPA and Phase 2
: 1,00,000 TPA)
 Captive co-generation Power Plant: 120 MW
(i.e. 60 MW in Phase 1 and additional 60 MW in
Phase 2 ), Emergency DG Set: 5 MVA.
Page 3 of 79
1.9. Cost of Project Approx. Rs 3550.00 Crores for Phase 1 Project.
1.10. Land Area Land area of approx. 1481.48 acres.
1.11. Source of Water  Sea water from Arabian Sea for cooling and
also for conversion of some seawater through
RO/DM process for process water,
miscellaneous sweet water requirement.
 Further if Govt. sanctions then Sweet water from
Narmada canal for domestic purpose
 During construction stage of plant a small R.O
Plant installation/operation should be permitted
to meet construction water requirement.
1.12. Source of Power  Captive Co-generation power plant – 120 MW.

Phase wise installation (Phase 1: 60 MW and
Phase 2: 60 MW).
 For initial start-up and for emergency purpose
around 5.00 MVA will be contracted with
Paschim Gujarat Electricity Board
Page 4 of 79
Chapter 2: Introduction of project

(i) Identification of Project and Project Proponent
GHCL Limited was incorporated in the year 1983. The company has
established itself as a well-diversified group with an ascertained footprint in
Chemicals, Textiles and Consumer Products segment.
GHCL BUSINESS SEGMENTS

 SODA ASH - 56%
 CONSUMER PRODUCT - 2%
 TEXTILES - 42%
In Chemicals sector, the company is mainly in the business of manufacturing

of Soda Ash (i.e. Anhydrous Sodium Carbonate) and Sodium Bicarbonate.
Soda Ash is a major raw material for Detergents, Glass, Ceramic and many
more industrial products. Sodium Bicarbonate (Baking soda) is mainly used
by food industry.
It’s Textile operations is an integrated vertical set up which commences right

from spinning of yarn, weaving, dyeing, printing till the finished products, like
sheets & duvets. Our product is primarily exported worldwide.
Consumer Products operation is another business for GHCL, where it is a

leader in manufacturing and selling premium Edible salt, Industrial grade salt
and Honey domestically.
The manufacturing facility of Soda Ash plant is located at Sutrapada of District

Gir-Somanath in the state of Gujarat, India. The region is famously known as
the Saurashtra coastal belt region and is one of ideal location for the
manufacturing of Soda Ash.
GHCL Limited, is one of the leading manufacturers of Soda Ash in India, with
annual production capacity of 11,00,000 metric tons. This contributes to
almost 25% of the annual domestic requirement.
Page 5 of 79
GHCL’s Soda Ash product lines consist of Light grade, Dense Grade and
Sodium Bicarbonate (Baking Soda). GHCL’s Soda Ash and Sodium bi
Carbonate is available across the Indian market under the brand name ‘LION’.
GHCL has been in existence for more than three decades and has over the
years, grown to be a leader in its areas of operations. GHCL has embarked
top line of Rs. 3272.44 Crores with EBITDA of Rs. 753.17 Crores in FY 19-20
and net worth of 2185 crore. Overall group employs directly /indirectly around
6,000 people.
GHCL is distinguished by its growth, financial performance and outstanding

people and processes. GHCL is a customer-friendly company committed to
leadership through quality. We strive for building relationships, encouraging
entrepreneurship and sharing prosperity.
GHCL has come off age as one of the most reputed organizations and
throughout its voyage of three long decades and continuing. It has achieved
historical landmarks which further add to its agility and continuous growth
model.
In view of present manufacturing capacity of GHCL and considering expected

growth, GHCL has Signed an M.O.U in Jan- 2017 during Vibrant Gujarat
Summit 2017 for Green Field Chemical complex in the district Kutch, Gujarat
state., In 1st phase of Project, we intent to mainly set up Soda Ash plant,
Sodium Bicarbonate plant along with integrated Captive Co-generation power
plant and associated utilities. Subsequently our aim is to expand capacity of
Soda Ash & Sodium Bicarbonate Plant and add Caustic Soda & other solar
salt based products.
Page 6 of 79
Soda Ash 1st Phase capacity 5,50,000 TPA with provision of doubling the
capacity in 2nd Phase up to 11,00,000 TPA. We have taken actions to
develop Salt work right in the initial stage as it is one of the major raw
materials. The solar salt works capacity accordingly works out to 11,00,000 /
12,00,000 TPA for 1st phase of Chemical complex and additional
11,00,000/12,00,000 TPA in 2nd phase of Chemical complex.
The Green field Project will be set up in Kutch District of Gujarat looking to the
favourable industrial climate, availability of land. There is sufficient scope of
potential of development in area and friendly industrial policy of Govt. of
Gujarat and further supports.
(ii) Brief description of nature of the Project
Soda Ash (Na2CO3) is classified as a heavy chemical. The nature of project is

Soda Ash Industry. The major raw materials are salt, chemical grade
limestone. Soda Ash process demands most stable un-interrupted supply of
utilities such as steam at various pressures, electric power, sea water for
process cooling, sweet water for process etc. To meet these demands an
integrated captive cogeneration power plant along with process plant is
conceptualised. Further considering the large quantity of cooling water
requirement, Sea water based Cooling is necessary and sea water
withdrawals and discharge is planned accordingly.
 The plant will be having Light soda ash production capacity of 5,50,000 TPA
in the 1st phase and doubling the capacity up to 11,00,000 TPA in the 2 nd
phase.
 The plant will also be having Dense Soda Ash production capacity of 2,50,000
TPA in 1st phase and in doubling the capacity in 2nd phase.
 The plant will have 1,00,000 TPA Bicarbonate in 1 st phase and further
1,00,000 TPA in 2nd phase.
 In Phase 1, Captive co generation power plant will be rated for 60 MW of
power generation. The actual load of steam & power generation will depend
on rated production of Soda Ash Light, Dense Soda ash, Bicarbonate and
other operating loads. During 2nd phase of process plants expansion and the
C.P.P capacity expansion up to 120 MW is expected.
 If salt in sufficient quantity will be available then addition of Caustic and salt
derivates shall be planned in future.
 Seawater Intake and Effluent disposal system of rated capacity are planned.
 The project falls under Category A project/activity 4 (e) Soda Ash Industry of
EIA Notification,2006 and its amendments.
Page 7 of 79
(iii) Need of Project it’s importance to Society/Nation
Soda Ash is having significant importance because of its applications in major

sectors i.e. Manufacturing of Glass, Usage in chemical industry, Paper and
Detergent manufacturing, whereas baking Soda is mainly used by food
industry.
However in India Detergent industry is largest consumer of Soda ash. At

present scenario the Light Soda ash demand across the globe is decreasing
due to increase in demand of Liquid Detergent .Whereas the Dense Soda Ash
demand is on increasing trend with demand of Glass worldwide. As such
demand of Soda Ash is shifting to Dense Soda Ash especially in Developed
economies.
Among the various Processes of Soda ash production techniques, the Dry
Liming is preferred for synthetic soda ash production. Solution mining
technique is used where natural deposits are available to produce soda ash.
As United States is having the largest natural deposits of Trona, its a leading
producer of Natural Soda Ash. Whereas in India all the Soda Ash production
is done through synthetic route i.e. by Chemical process.
India is one of fastest growing economies in the world. Considering the rising
population and growth of urbanisation has increased consumption of industrial
products, which has resulted the increase in demand of housing,
transportation, consumer product, processed foods, beverages, driving growth
in glass, soaps / detergents and various other chemicals directly or indirectly
for production of chemicals.
The Indian Subcontinent is one of the world’s fastest growing Soda Ash
markets, driven by India’s booming economy. The Soda Ash per capita
consumption in India is 2.8 Kg only. If India has to reach the per capita
consumption as of developed nations, which is approximately 17 Kg of Soda
Ash then addition of capacity is must. This would imply about 19 million MT of
additional annual demand. Indian soda ash market is getting ready to meet
this demand growth and GHCL is focusing on becoming Industry leader in
Soda ash.
In order to cater to increasing demand for Soda Ash user industry it is

required to set up additional capacities. The project will contribute significantly
to project region through direct and indirect employment generation and
create indirect oppurtunities for user industries. It will also contribute towards
revenue generation for Govt. of Gujarat and contribute to the country’s
economic development.
Page 8 of 79
(iv) Demand Supply Gap
The global production capacity of soda ash is concentrated in USA, China,

Europe and India. The manufacturing capacity of soda ash is highly
concentrated with China and the US controlling ~64% of the total global
capacity.
Turkey exported ~21% of the total global volumes and has taken on an
important position backed by a consistent increase in the soda ash capacity
during the past few years.
According to business intelligence report by IndustryARC, the global soda ash

market was worth $16,545 million as of 2018, and its value will continue to
growing with a CAGR of 3.4% during the forecast period of 2019 to 2025.
Asia-Pacific will witness significant growth in the soda ash market with the
market share rising to more than 50% during the forecast period. The Asia
Pacific soda ash market is flourishing due to increased production of glass,
detergents as well as other chemicals, and prosperity of emerging economies
such as China, India, Thailand, Malaysia, Vietnam, and others.
(V) Imports vs Indigenous production
The installed Indian capacity as on March 2020 is 4,239,500 MTPA.
The imports during 2019-20 were 946 KMT. The import demand of the
chemical is globally spread given its diversified end user industry base. The
top 5 importing countries by volume are India, Brazil, Mexico, Indonesia and
Germany which together account for ~44% of the global import demand
volume.
India facing cheap imports from Turkey, US and other regions.
Page 9 of 79
Top 5 Import Destinations of Selected chemicals during 2018-19

Product Country Quantity (MT)
SODA ASH Turkey 210097.925
Romania 136852.5
USA 120511.382
Bulgaria 109357.312
Kenya 86823.99
Product Total 663643.109
Source: Chemical and Petrochemical Statistics 2019
Indian Soda ash Market constitutes of two varities Light Soda ash & Dense
Soda ash which share approximately` 60% & 40% respectively.
Total Indian market for the GHCL products and GHCL’s share of that are:
 Soda Ash: Market Size – 40 Lakh MT, GHCL Market Share 25% Approx.
 Sodium Bicarb - Market Size – 2.50 Lakh MT, GHCL Market Share 25%
Approx.S
Statistics:
1. Last 5-year’s Production data (Soda Ash)
UNIT 2016-17 2017-18 2018-19 2019-20 2020-21

TCL 8,16,000 8,18,000 8,18,000 7,92,000 7,05,000
GHCL 8,01,269 9,36,972 9,72,288 10,04,505 9,11,343
NIRMA+SCL 10,31,000 12,27,000 12,16,000 12,33,000 9,73,000
DCW 99,000 1,07,000 1,04,500 98,500 90,000
TAC 70,000 91,000 55,000 59,800 28,000
RSPL - - 45,000 2,35,000 3,80,000
*Based on internal estimates
(vi) Export Possibility
The large demand requirement has enabled limited surplus production for
export from most countries and has led to a high degree of concentration in
the export supply market. This includes China, which has the largest
production capacity of soda ash but is also the largest consumer of soda ash.
China exports ~9% of the total global supply volume of soda ash even though
it holds ~45% of the global production capacity. Furthermore, the top 5
countries are controlling almost 86% of the total global export volume. The US
is the largest exporter of soda ash providing ~43% of the total global volumes
followed by Turkey.
SA demand all over the world has grown significantly; we at GHCL were also
able to sell SA to Bangladesh, Thailand, UAE and other South East Asian and
Middle East countries.
Page 10 of 79
Top 5 Export Destinations of Selected chemicals during 2018-19

Product Country Quantity (MT)
SODA ASH Indonesia 18815.033
Sri Lanka 13102.938
Bangladesh 12192.04
Nepal 10982.671
Philippines 3604.347
Product Total 58697.029
Source: Chemical and Petrochemical Statistics 2019
(vii) Domestic/export markets
Indian Soda Ash Scenario
Soda Ash demand in India grew at CAGR of 5.54% during 2013-19 and is
anticipated to achieve a healthy CAGR during 2021-2030. Proposed plant
capacities would further contribute to growth of Soda Ash demand in the
country. The Indian government is putting lots of effort to improve the
condition of the market of Soda Ash buy showing concerns over
supplementing its end-users such as Dye Industries, Detergent Industries,
Fertilizer Industries, etc. According to a report provided by the Federation of
Indian Chambers of Commerce and Industry (FICCI), the chemical industry in
India is expected to grow at a robust rate for the next five years. (Source:
Chemanalyst)
2. Next 5 year’s anticipated growth (Year wise of Soda Ash / Sodium Bi

Carbonate of Indian Market and Abroad.
a. Soda Ash
As per IHS, World Soda Ash demand has grown by around 3.2% per year
since 2000 but trade has grown by an average annual rate of 3.9%.
Considering the growth at 2 % we will require additional 2 Million MT more SA
every year across globe. However, with various environmental sanctions in
China, few plants shutting down and all capacity expansion or new plants
being delayed by 2 years we anticipate that there will be a high
demand/supply disruption coming years.
India SA scenario follows similar trend to that of Indian GDP. India being a
huge market a robust growth of 5-6 % every year in SA demand is
anticipated. This further can be augmented due to continuing urbanisation
which further has a positive impact on glass, detergent and other chemicals.
The above growth can also be contemplated with RSPL’s entry to Indian SA
market and being able to sell SA, catering the extra demand which is there.
b. Sodium Bicarbonate:
The estimated demand growth for year 2020-21 was around 8% even with
effect of COVID. The demand growth can also be observed from GHCL
Page 11 of 79
bicarbonate sales figures, our sales for Sodium bicarbonate grew at a CAGR
of 18% over last 6 years. We expect the demand to continue growing at 8 to 9
% over the next 5 years.
The growth in end use applications such as food and beverages, animal feed,
fire extinguishers, personal care, flue gas desulphurisation and other industrial
applications.
Indian Soda Ash Demand can be segregated segment wise as per below
chart:
Indian Detergent Market Outlook
 Indian domestic soap and detergent market is growing at a steady pace due
to health and hygiene awareness in people all across India. We anticipate 5-
6% growth for next 3-5 years in Indian Soap and detergent market.
 This has been due to rise in demand of detergents in rural India and
penetration of washing machines.
Indian Glass Market Outlook

 The growth in flat glass segment in tremendous, with various housing
projects, more usage of glass in manufacturing for aesthetic look, usage and
government initiatives to promote solar energy the demand of solar glass
panels is on a positive trend.
 With various health/food safety and environmental issues. The related
measures initiated government; people have recognized the importance of
glass packing instead of plastic.
 We are seeing a trend shift of major SA consuming industry from Detergent to
Glass segment. This emphasizes on expansion of our dense SA
manufacturing capabilities.
Page 12 of 79
As per market and demand trend mentioned above, the growth in demand for
Soda Ash and Sodium Bicarbonate is clearly visible. We foresee 6% demand
growth every year similar to trend of Indian GDP figures.
Worldwide Soda Ash Scenario
In 2020, world soda ash demand was approximately around 58.5 Million MT.
The Soda Ash market globally can be segregated into its consuming sectors
such as Glass, Chemicals, Detergents, Metal and Mining’s, etc.
The Flat Glass being the top SA consuming sector (26% of Total Demand
Globally) and its demand consists mainly of Solar Glass, Auto manufacturing
& in construction sector. While container glass, Chemicals and silicates and
detergent industries each consumes more than 10% of total SA demand
globally.
A demand surge was observed during recent times in Container glass in

pharma industry for making vaccine vials for mass Vaccination drives across
the world to tackle Covid.
Detergent & Soap [CATEGORY NAME]

formulations [PERCENTAGE]
13%
Flat Glass
26%
Chemicals
14%
Container Glass
19%
Others
18%
FY 20-21 Segment wise
Other Glass
6% Demand in %
India & all over the World we are witnessing the effects of the corona Virus
pandemic, this in turn has created a great awareness in people that how
important health and hygiene is. Today people are not carefree and use of
Soaps, detergents, disinfectants, water treatment and cleanliness has
increased significantly.
With the growing demand in Glass, detergent, water treatment and other
chemicals the SA demand will also grow in the same fashion. All SA
Page 13 of 79
consuming industries are growing at steady pace and we can foresee the
same demand trend in Soda Ash also.
(viii) Employment Generation
On implementation of the proposed project around 1,200 nos. of suitably

qualified People direct employment to take place. Further, there will be also
indirect jobs and business opportunities to the local people such as daily wage
labourers, transporters and raw material suppliers. This may be of the order of
3,000 people. The project would increase and generate opportunities for
ancillary and auxiliary business at the local and regional levels too.
Page 14 of 79
Chapter 3: Project Description

(i) Type of Project
Setting up of Green field Chemical complex with Soda Ash and Sodium
Bicarbonate manufacturing Plant along with integrated Captive Co generation
Power plant with necessary facility e.g. Sea water intake, RO/DM Plant,
Effluent out fall facility etc. As per EIA Notification 2006, Schedule Soda ash
Process/ project activity is listed as Project Sr. 4(e) and Category ‘A’.
The Soda Ash process along with Captive Co-generation power plant in
totality requires huge quantity of cooling water. Thus to meet the overall water
requirement for proposed project & operation, Sea water from Arabian sea is
best option. The proposed site location is in proximity of Arabian Sea.
Erection of sea water intake withdrawal and effluent disposal facility in Arabian
Sea at designated points will take place. The point of intake and disposal will
be suggested by CSIR-NIO – (National Institute of Oceanography). Based on
the prefeasibility study by leading Marine consultants, Laying of Pipeline for
Sea water intake and effluent disposal will be executed through experienced
agencies. Since the activity attracts provision of CRZ Notification, 2011
required statutory approvals will be obtained from, GPCB, GCZMA and
MoEF&CC.
(ii) Project Location

The location of project will be at Village Bada, Taluka Mandvi, District Kutch of
Gujarat State. Refer Figure 1. The geographical information of Latitude and
Longitude of four extreme corners of the site under consideration is as follows:
(A) 22o53’53.19’’N& 69o09’26.63”E

(B) 22o53’41.63”N & 69o09’58.16”E
(C) 22°52'29.66"N & 69° 8'16.32"E
(D) 22o52’57.10”N & 69o07’33.09”E
Refer the Figure 2 for Google image showing the project Site..
Page 15 of 79
Figure 1: Project Location near Village Bada, District Kutch, Gujarat
Page 16 of 79
Figure 2: Google Image Showing the Project Location
Page 17 of 79
(iii) Details of Alternative Sites considered and basis of selecting the

proposed site
Various criteria considered for exploring alternative project site are

environmental consideration, availability of land, stable shore, reasonable
distance from town, abundant sea water availability i.e. round the clock- 365
days etc. The selection of the Site carried out based on various site surveys,
review of available data and other important considerations. We have listed
some of the parameters considered while selecting project site:
Criteria for site selection:
 Availability of Land – Availability of Land to the required extent in a single

stretch with a view to accommodate to the extent possible all the integrated
facility within.
 Proximity to Sea – Proximity to the Sea is one of the most important criteria
looking to huge quantity of cooling water required for Soda ash process for
Captive cogeneration power plant. We shall incur huge cost of establishing
sea water facility but in Nation’s interest to save sweet water it is our prime
consideration. We shall have to further invest for Conversion of Sea water to
sweet water through RO/DM route.
 Proximity to infrastructure facility of Rail / Road – This is a very important
and critical factor for Soda ash/ Chlor-alkali project. The large quantity of Raw
material i.e. Salt, Lime Stone, Coke/anthracite, Coal/ Lignite/PetCoke,
packaging materials etc. is required for production of Soda Ash, Sodium
bicarbonate, Caustic soda etc. Thus Vehicle movement for bringing (inbound)
Raw material and dispatch (out bond) of finished product being very high,
proper road connectivity and other infrastructure like rail, port are considered.
It is also our responsibility to keep in consideration existing traffic density.
 Proximity to major Raw material availability – like Chemical Grade
Limestone, Salt Coke etc. – Transport cost and least downtime for
transportation of Raw material is key factor and having direct influence on
profitability. Thus selection to nearest right Source of Raw material is also a
key selection criteria. In our case for establishing large salt works site have
been identified in around 100 kms radius. Whereas for lime stone studies/
exploration process is on.
Site Selection
For setting up proposed Soda Ash project, following locations in Gujarat were
considered/reviewed/visited:
 Site 1 – Village Pingleswar, Taluka, Abdasa, Dist. Kutch
 Site 2 – Village Suthri, Taluka, Abdasa, Dist. Kutch
 Site 3 – Village Bambhdai, Taluka, Mandvi, Dist. Kutch
 Site 4 – Village Bada, Taluka, Mandvi, Dist. Kutch
 Site 5 – Village Modhva, Taluka, Mandvi, Dist. Kutch
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The Location of the alternative Sites considered are shown in Figure 3 as per
Google image. The comparison of the review sites is also given in Table 1.
Figure 3: Location of alternative sites
Page 19 of 79
Sr. Environmental & Pingleshwar Suthri Bambhdai Bada Modhva

No. Social Dimensions
Location Taluka: Abdasa, Taluka: Abdasa, Taluka: Mandvi, Taluka: Mandvi, Taluka: Mandvi,
District: Kutch District: Kutch District: Kutch District: Kutch District: Kutch
Coordinates 1) 23°06’23.03”N 1) 22°59’41.12”N 1) 22° 56’3” N 1) 22°53'53.19"N 1) 22°47’06.02”N

68°44’21.83”E 68°58’31.97”E 69°04’55.1”E 69° 9'26.63"E 69°28’44.14”E
2) 23°07’22.66”N 2) 22° 55’57” N 2) 22°53'41.63"N 2) 22°49’24.26”N
68°45’31.14”E 69°05’48.8”E 69° 9'58.16"E 69°30’17.58”E
3) 23°06’48.34”N 3) 22° 55’27” N 3) 22°52'29.66"N 3) 22°48’25.27”N
68°46’20.38”E 69°05’47”E 69° 8'16.32"E 69°26’30.78”E
4) 23°06’16.27”N 4) 22° 55’17” N 4) 22°52'57.10"N 4) 22°48’08.36”N
68°46’17.92”E 69°05’46”E 69° 7'33.09"E 69°25’26.10”E
5) 23°04’36.30”N 5) 22° 55’17” N
68°46’53.33”E 69°05’42”E
6) 22° 55’02.0” N
69°05’42”E
7) 22° 54’32.4” N
69°05’45.1”E
8) 22° 54’20” N
69°05’10”E
9) 22° 54’43” N
69°05’02”E
1. Presence of ecologically sensitive areas/zone
Mangroves Scattered locally Nil Nil Nil Nil
Turtle /nesting ground Turtle hatchery near Sandy beach and Sandy beach and Sandy beach and Sandy beach and
or hatchery / Sand dune Pingleshwar Beach hence turtle / Sand hence turtle / Sand hence turtle / Sand hence turtle / Sand
dune studies may be dune studies may be dune studies may dune studies may
necessary necessary be necessary. be necessary
Presence of rocks
in intertidal and
subtidal region
creates unfavorable
approach towards
shore.
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Wild life sanctuaries Kutch Bustard No wild life sanctuary No wild life sanctuary No wild life Nesting ground of
and distance from plant Sanctuary is located within 10 km of plant within 10 km of plant sanctuary within 10 flamingos in winter
site about 6 km. site site km of plant site
Rivers/Riverlets/Stream Nairo Seasonal River Nil One River and Nil Nil
within plant. stream
Forest/ Any Reserve Yes, Rapar Ghadvali, Reserve Forest ~ 1 Reserve Forest near Near by but outside Reserve Forest ~ 1
forest 2-2.5 Km, km. about 0.5 km plant boundary. km
Ashirwandh, 10-15 Unclass forest
Km scrub forest
Distance from Sea ~ 1 km 1 km (Further there 1.5 km (Further ~ 0.8 km ~ 1.2 km

is in between creek there is in between
also) creek also)
2. Cultural Attributes
Religious structures, Pingleshwar Temple Small mosque is Shiva Temple ~ 0.5 Vipassana Centre ~ Nil
Ancient buildings located at 7 km located about 0.5 km km 0.6 km
identified by distance
Archaeological Society
of India
3 Public Utilites
Highways - GJ SH 6 at 110 km - GJ SH 6 at 110 km - GJ SH 6 50 km - GJ SH 6 at 6km - GJ SH 6 at 7 km

away away - NH41 at 11 km, - NH41 at 6 km
- NH41 at 15 km, - NH41 at 2-3Km.
Port Jakhau Port ~30 km Mundra Port ~ 97 km Mundra Port ~ 80 km Mundra Port ~ 55 Mundra Port ~ 50
km km
Railway station Adipur ~ 138 km Adipur ~ 116 km Adipur ~ 100 km Adipur ~ 116 km Adipur ~ 92 km
Bhuj ~ 108 km Bhuj ~ 100 km Bhuj ~ 97 km Bhuj ~ 66 km Bhuj ~ 62 km
Power station/Sub ~ 8 km ~ 10 km ~ 15 km ~ 10 km ~ 15 km
station
Page 21 of 79

Nearby Village, distance ~ 2 km ~2 km ~ 1.2 km ~ 1 km ~ 2 km

from the plant site, km
Fishing No Yes No No Yes
Any dams/check dams ~ 1 km Check dam Sandhog Two check dam and Salinity ingress No
River ~ 3 km & culverts in northern protection – Check
side dam of Vengadi
(seasonal river)
within 0.5 km from
northern boundary.
Approx. proximity to 100 120 90 70 90

nearest City (Bhuj), km
4 Mineral deposits and River sand No No No No

mining activities
General Intertidal / sandy Expansive alluvial Dry and Alluvial Sandy Loamy Dry, Marshy
Soil/Appearance /expansive alluvial nature soil nature soil suitable for Salt
work expansive of
alluvial soil.
5 Plant site Classification Private Land of Private Land / Waste Private Land/ Sarkar Private unirrigated Private Land &
as per Land Records of GEDA and Govt. land / Gauchar/ shree land/ Govt agriculture land/ Govt. Land
Gujarat State Land Forest Land waste/ Santhali land Shri Sarkar
land/Govt Land
Page 22 of 79
Final Selection of Project Site:

Site at Village Bada, Taluka Mandvi (Ref. Site. 4 of above table) is considered
as ‘Best’ among above site on account of following considerations:
 Availability of adequate and continuous land parcel for setting up of soda ash,
Bicarbonate plant, captive Cogeneration power plant, establishing sea water/
effluent disposal facilities along with other essential associated facilities. The
land is comprised of Government land /Shri Sarkar/ and private unirrigated
agricultural land.
 No notified ecologically sensitive area within radius of 10 km.
 No mangroves vegetation near the project site coastline/estuary
 Sparsely populated surroundings, nearest village Bada has population of
2719 as per Census, 2011.
 No forest land within identified project site. However for seawater intake and
outfall, pipeline will pass through adjoining unclass forest land. Prior to
undertake any permanent nature construction activities necessary
permissions / approval shall be obtained.
 Close proximity to Arabian Sea.
 No perennial river within vicinity, only seasonal river ‘Vengadi’ near
North/West boundary of plant land.
 State Highway No GJ SH 6 is appx. 6 km from proposed project site and
easily accessible.
 Proximity to availability of raw material i.e. salt, coke, lignite, limestone etc.
In summary, the ecologically sensitive zones/areas such as wildlife

sanctuaries are not located in the plant site and the site is with scatter shrubs.
Regulated CRZ buffer will be maintained. Sea water intake and outfall
systems are permitted activity as per CRZ notification, 2011. There are no
habitants existence in the plant site. The available raw materials such as
limestone, salt, Lignite/, coal and coke can be easily transported and required
quantity of seawater can be drawn from the Arabian sea due to its proximity.
There is no issue of rehabilitation and resettlement as there is no habitation in
the plant site.
Based on above merits, ‘Bada’ site has emerged as the most suitable
project site out of alternative sites examined/explored and therefore
selected for setting up of proposed Chemical Complex.
Salient features of selected Site: Location at Village Bada

Following key criteria justify the selection of site for proposed Chemical
complex.
 Availability of adequate and continuous land parcel for setting up of soda
ash, Bicarbonate plant, captive Cogeneration power plant, establishing sea
Page 23 of 79
water/ effluent disposal facilities along with other essential associated

facilities. The land is comprised of Government land /Shri Sarkar/ and private
unirrigated agricultural land.
 No forest land within identified project site. However for seawater intake and
outfall, pipeline will pass through adjoining unclass forest land. Prior to
undertake any permanent nature construction activities necessary
permissions / approval shall be obtained.
 Availability of Sea water from Arabian sea located in Near Plant site.
 Major raw material Salt, Coke, Lignite etc. From the nearby vicinity.
 The nearness of Gujarat State Highway number 6 (GJ SH 6) within 6 km
which is well connected for efficient transport of Raw Material as well as
Finished Goods
 No notified ecologically sensitive area within radius of 10 km
(iv) Size of Operations
The production capacity of proposed plant is as mentioned below:

Sr. No. Product Name Proposed production Capacity (Phase 1
& Phase 2)
1 Soda ash
st
 Light Soda ash 3000 TPD 1 phase 1500 TPD
nd
2 phase1500 TPD)
 Dense Soda ash
st
1500 TPD 1 Phase 750 TPD
nd
2 Phase 750TPD
st
 Sodium Bi- 600 TPD 1 Phase 300 TPD
nd
Carbonate 2 Phase 300TPD
st
2 Power 120 MW 60 MW 1 Phase
nd
60 MW 2 Phase
Steam (CFBC Boiler)
150 TPH x 3 Nos in Phase 1 and Doubling in
Phase 2
3 Emergency DG Set 5 MVA
4 Seawater Intake and Effluent Suitable Rated capacity
3
Disposal and RODM and Seawater Intake 1600000 m /day
3
associated infrastructure Effluent 1580000 m /day
Page 24 of 79
(v) Project Description with Brief Process Details
Section / Process detail

Unit No.
101 BRINE PREPARATION:
a) Salt washing and dissolving
b) Brine preparation and purification
102 LIME KILNS ALONG WITH BRIQUETTE HANDLING AND
MANUFACTURING
a) Lime stone and coke/briquette/anthracite storage in day bins,
weighing, mixing and feeding to kilns.
b) Lime kiln
c) CO2 gas cooling and cleaning
103 BURNT LIME GRINDING, ABSORPTION, DISTILLATION
104 COMPRESSION OF CO2 GAS , CARBONATION
105 FILTRATION AND CALCINATION
a) Bicarbonate filtration.
b) Calcinations.
c) Calciner gas condensation.
d) Weak liquor Distillation.
106 DENSIFICATION
107 LIGHT AND DENSE SODA ASH STORAGE AND PACKING
108 SBC – Sodium Bicarbonate Unit
RMH RAW MATERIALS HANDLING:
1200 a) coal / lignite/petcock/anthracite handling and storage
b) coke handling and storage
c) salt handling and storage
d) lime stone handling and storage
e) Briquette Plant /storage handling.
UTILITY - ENERGY CENTER
1100 a) Steam generation i.e boiler house and steam distribution
b) Electricity generation/Distribution
1300 SWEET WATER

Raw water receiving treatment and storage.
1400 SEA WATER

a) Sea water intake,
b) Sea water distribution /pumping for cooling
c) R.O. and desalination, storage of DM water, process water.
1500 EFFLUENT DISPOSAL SYSTEM
Note : The Section number mentioned above is for reference and may subject to
change also. It will be finalised after having Basic Engineering Package
from Technology Supplier.
Page 25 of 79
Process Description (Dry Liming Process) for Soda ash Manufacturing
 Unit No. 101: Brine Preparation & Purification

 Unit No. 102: Lime Kilns, gas cleaning, briquette handling and Manufacturing
 Unit No. 103: Lime Grinding, Absorption and Distillation Unit
 Unit No. 104: Carbonation and Compression
 Unit No. 105: Filtration and Calcinations Unit
 Unit No. 106: Densification of Soda Ash
 Unit No. 107: Product storage and handling
 Unit No. 108: Sodium Bicarbonate- SBC
Figure 4 showing flow Diagram showing Soda Ash Manufacturing Process.
Page 26 of 79
Figure 4 Soda Ash Manufacturing Process

Unit No. 101: Brine Preparation & Purification
Solar salt is one of the basic raw materials used for production of Soda Ash.
Either salt in solid form can be transported to plant site or Raw Brine can be
prepared at salt works and it can be pumped to plant site if the solar salt
works is nearby. Presently for the proposed GHCL plant, both option of Salt
transportation in solid form & raw brine to plant site has been considered.
The raw salt is first washed in salt washery for removal of impurities such as
Sulphates, Clay and Ca++, Mg++ to certain possible extent. The washed salt is
then dissolved in salt dissolver to obtain raw brine. This raw brine is further
processed to the Brine purification area.
The remaining soluble and insoluble impurities are removed in the reactors.
The raw brine containing impurities is transported to reactors, where the brine
Page 27 of 79
is reacted with Milk of Lime and Soda Ash solution. The Mg and Ca impurities
are precipitated as per the following reactions:
MgCl2 + Ca(OH)2  Mg(OH)2 + CaCl2

CaCl2 + Na2CO3  CaCO3 + 2 NaСl
MgSO4 + Ca(OH)2  Mg(OH)2 + CaSO4
CaSO4 + Na2CO3  CaCO3 + Na2SO4
The precipitated impurities are then thickened in the Settler and purified brine
overflows from the settler to the purified brine storage tank.
The sludge containing precipitated Ca and Mg salts is extracted from the

bottom of the settler and transported to the sludge tank for dilution. The
diluted sludge is then transported to the effluent handling system. Sludge
washing settler shall also be used to recover salt from the sludge.
A part of the sludge from settler is recycled to the reaction tank to increase the
surface available for crystallization of CaCO3 and Mg(OH)2. A small quantity
of flocculent is also added to the settler to improve the settling characteristic.
Unit No. 102: Lime Kilns, Gas cleaning and briquette manufacturing
and handling
To produce Soda Ash, carbon dioxide (CO2) gas is required for the formation
of Sodium Bicarbonate; and Calcium Oxide (CaO) is required for release of
Ammonia from Ammonium Chloride – the Mother liquor. Both CO2 and CaO
required for Soda Ash production are obtained by decomposing limestone
(CaCO3) at high temperature in the lime kilns by using Coke / briquettes /
anthracite as fuel. Briquette will be manufactured from Breeze as indicated
separately below.
Limestone, coke or briquette or anthracite are stored in stockpiles. Both raw

materials are conveyed to lime kiln feed system, provided with adequate
screening provisions for a sized material feeding to limekilns. The screened
material gets mixed on the conveyor belt while getting conveyed to the kiln
feeding equipment. The Lime stone and Coke or Briquette mixture travels
down in the lime kiln. During this travel the lime stone decomposes due to
high temperature in to Carbon Dioxide and Calcium Oxide.
Following are the reactions by which CaO and CO2 are obtained.
CaCO3  CaO + CO2

C + O2  CO2
The lime kiln gas (CO2) is passed through the scrubbing system. The cooled
gas leaving the scrubbing system is further cleaned by passing through Wet
Page 28 of 79
Electrostatic precipitator (ESPs). The cleaned / cooled gas is then sent to the
compression section.
The burnt lime i.e. Calcium Oxide (CaO) discharged from the lime kilns are
conveyed to the lime grinding section.
Briquette: to be used in kiln as a fuel is manufactured as mentioned below:

 Screened coke breeze is fed to drier through belt where reduction in moisture
is achieved through heated air. Air is heated by medium pressure steam in
pre-heater.
 Dry breeze Through VFD is conveyed to mixer through belt.
 Binder (Starch) is fed through weigh feeder to breeze belt, where premixing of
dried breeze, binder and recycle breeze (From screening of briquettes) is
done.
 In mixer, mixing of dried breeze, binder & recycle breeze is done with
controlled quantity of water. Reaction mixture flows to hydraulic press,
briquettes are formed, called green briquettes.
 Green briquette are then send to online dryer for curing
 After curing, these briquettes are ready for use as a fuel in kilns.
 Storage and handling
Figure 5 shows Mechanized Briquette Plant.
Page 29 of 79
MECHANIZED BRIQUETTE PLANT FLOW DIAGARAM

Wet Breeze
O/size
Screen
Exhaust Air
Air Hot Air

Air preheater Drier
22# bar
steam
Condensate Dry breeze
Binder (Starch)
Dry breeze hopper
Water Mixer
Hydraulic press
Screen for Briquette Fines to Mixer (Recycle)
Green Briquettes Cured briquettes

for Curing to drayer
Figure 5 Mechanized Briquette Plant
Unit No. 103: Lime Grinding, Absorption and Distillation

a. Lime Grinding : Production of Dry Lime Powder
The burnt lime from lime kilns is conveyed to burnt Lime hopper. The
controlled quantity of burnt lime is fed to the Crusher and then fed to lime
Grinding mill. The size distribution of ground lime is very critical and is a key
factor for the operation of dry liming process. The ground lime is
pneumatically conveyed to the ground lime hopper.
b. Prelimer and distillation
The ground lime from hopper is fed to Prelimer by weigh feeder and screw
conveyor. The mother liquor from Bi-carb filters is preheated in pre-heater and
is fed after desorption of CO2 in free ammonia still to prelimer. Simultaneously
the ammonia generated in prelimer and free ammonia still is cooled and
mother liquor is heated in the preheater. The cooled ammonia gas goes to the
absorber and heated mother liquor fed to prelimer.
Page 30 of 79
In Prelimer ground lime is reacted with Ammonium chloride (Mother Liquor).

Ammonia is released from Prelimer due to reaction of mother liquor and Lime.
The contents of Prelimer are passed to Separator, wherein the solids are
separated and clear solution flows to distiller for further Ammonia recovery.
The slurry from the distiller is fed to the dilution Tank after the stripping of
ammonia with steam. This effluent is then directed to mixing canal along with
liquid stream after dilution/treatment to sea.
In the ammonia distillation system ammonia is recovered from ammonium

chloride and is recycled back to the process. The ammonia recovery from
Mother liquor containing ammonium chloride and Ammonium bicarbonate is
based on the following chemical reaction.
NaHCO3 + NH4Cl  NaCl +NH4HCO3
2NH4HCO3  (NH4)2CO3 + CO2 + H2O

(NH4)2CO3  CO2 + 2NH3 + H2O
Ammonium chloride is decomposed by reaction with lime:
NH4Cl + Ca(OH)2  CaCl2 + 2NH4OH
The first 2 reactions leading to decomposition of ammonium bicarbonate to

ammonia and carbon dioxide occurs simultaneously on supply of heat. The
reaction leading to decomposition of Ammonium chloride to ammonia needs
lime and supply of heat.
c. Absorption
An efficient Ammonia recovery system is necessary for economic reasons and

also to minimize pollution. The purified brine is ammoniated and the process
reaction is complex and takes place through various process steps.
NH3 + H2O  NH4OH
2NH3 + CO2 + H2O  (NH4)2CO3 (NH4)2CO3 +

CO2 + H2O  2NH4HCO3
In the first stage of ammonia absorption, the exhaust gases from bicarbonate
filters are absorbed in filter gas scrubber to recover ammonia present in the
filter exhaust gases. This ammoniated brine is then passed to tower gas
scrubber and absorber to absorb the ammonia released from ammonia
distillation system. The make-up ammonia in the process is added in the
absorber as and when required to make up the losses. This ammoniated brine
is then taken to carbonation tower.
Page 31 of 79
d. Release of Ammonia from distillation system:
Ammonia Hydroxide solution is cracked with by heating with live steam in the
fixed ammonia still. The ammonia released from fixed ammonia still along with
ammonia released from prelimer is passed to absorption towers. The mother
liquor from Bicarb filters is preheated in preheater with hot gases from free
ammonia still and is fed after desorption of CO2 to free ammonia still. The
ammonia in mother liquor is stripped in free ammonia still by contacting with
hot ammonia gas from Fixed Ammonia still.
Unit No. 104: Compression and Carbonation

a. Compression
The gases necessary in the carbonation are compressed by CO 2

compressors. These are screw compressors and are steam turbine driven
with speed control for constant exhaust pressure. In all the compressors the
compressed gases are cooled in circulation coolers through external heat
exchangers. All the compressors are oil lubricated and are operated with DM
water injection to avoid fouling of the compressor internals. The gas streams
to be compressed are:
 Gases emits from calciner after cooling and washing are called "rich gases"
having a high CO2 content, 90-95 vol. % on dry basis.
 Limekiln gases after removal of dust particles in scrubbing system and ESPs -
these are called "lean gases" having a low CO2 content approx. 36-40 vol %
on dry basis.
 Bottom Gas Compressor compresses a mixture of Calciner gas and limekiln
gas, resulting in a Bottom Gas with a CO2 content of approx. 80-vol %. All
Calciner gases are recycled and the bottom gas demand is balanced by
adding limekiln gas to the rich gas system.
 Middle and Cleaning Gas Compressors compress limekiln gases to middle
and cleaning gas pressure. One Compressor is a common spare compressor,
which can be used as bottom gas compressor or as middle / cleaning gas
compressor. All compressed CO2 gases will be cooled in coolers with water.
b. Carbonation
In the carbonation process the ammoniated brine reacts with CO 2. This
reaction is exothermic and form Sodium Bicarbonate which is crystallize from
the solution after cooling in the lower part of the column. The overall reaction
can be described as follows
NH3 + CO2 + H2O + NaCI → NaHCO3 + NH4CI

The precipitated sodium bicarbonate has a tendency to adhere to bottom
portion of the carbonation tower and fouling coil tubes. The cleaning of
carbonation towers is therefore essential from time to time. Hence,
Page 32 of 79
carbonation towers are operated in cycles — Production cycle and cleaning

cycle.
A group of carbonation towers consists of cleaning tower and production

towers are operated simultaneously.
The carbonation of the A-liquor starts with a cleaning step, as production

tower needs periodic cleaning. The precipitated bicarbonate in the cleaning
tower will be dissolved in the A-liquor, supplied at the top of the cleaning
tower. A minimum amount of gas is necessary to obtain sufficient agitation in
the cleaning tower.
Between the cleaning and production towers there is a small storage tank of
carbonated brine (C-liquor). From this storage the C-liquor is pumped to the
top of the production tower, operated in parallel at a constant liquid level.
There will supply of CO2 gas shall be at the bottom (bottom gas with high CO 2
content) and at the middle (middle gas from the lime kilns) of the production
towers. The CO2 gas flows counter-current to the liquid to the top of the tower.
The CO2 gas gets dissolved in the liquid, followed by the crystallization of
bicarbonates. The exothermal reaction makes it necessary to cool the liquor to
obtain a satisfactory NaHCO3 yield. Cooling takes place in cooling boxes with
cooling water and/or chilled water. In production tower operation, temperature
control is essential to obtain well-grown Sodium Bicarbonate crystals.
The bottom liquor temperature is controlled by the flow rate of cooling water
through the cooling boxes. The production rate of a production tower is
controlled by the gas flow to the tower.
Unit No. 105: Filtration and Calcination Unit
a. Filtration: In Filtration the draw liquor coming from the carbonation is

collected in the Slurry Distribution tank and from there it is distributed to the
vacuum filters/Belt filter. The function of these filters is three-fold:
 To separate the solid Bicarbonate from the mother liquor

 To wash the Cl - (Chlorides) containing mother liquor from the filter cake
 To dry/ Minimise the moisture the filter cake
 The filter consists of a Rotary vaccum drum/Belt filter, composed of a number
of shallow compartments connected to an automatic valve in the centre. The
drum rotates with its circumference dipping into a trough, filled with
Bicarbonate slurry. The shell of the drum is covered with a drainage grid and
a filter cloth. For belt filter the above operations takes place on the filter cloth
placed above the belt and being operated above the vacuum.
 The vacuum within the drum compartments causes a flow of filtrate and air
through the filter medium and central outlet into the gas-liquid separator.
Page 33 of 79
Instead of filter drum, filter belt is also option available but it requires more
space.
 The liquor flows via the filter liquor tank to the distillation unit. The filter gas
flows via a Filter gas scrubber and Vacuum pump in counter-current with
purified brine to the atmosphere. The cake on the filter cloth is washed with
almost ammonia free water, the cake is discharged from the drum surface and
after removal of the cake, blow back air is applied for cleaning of the filter
cloth. The crude Bicarbonate (filter cake) is transported to the Calciner.
 The cake is dried mainly by displacement of the liquid in the pores of the cake
by air. At regular intervals washing of the filter cloth is necessary.
b. Calcination:
In the Calcination section, the crude bicarbonate from filtration section is
decomposed into Light Soda Ash, carbon dioxide, ammonia and water vapor
by applying heat energy. Crude bicarbonate from the filtration section contains
ammonium bicarbonate as impurities. This ammonium bicarbonate also
decomposes to ammonia, CO2 and water vapor. The crude bicarbonate is fed
in a controlled manner to the Calciner.
Calciner is rotating equipment heated by MP-Medium pressure steam in

heating coils. Heating by medium pressure steam leads to decomposition of
bicarbonate cake by endothermic reaction.
2NaHCO3 → Na2CO3 + CO2 + H2O
The decomposition of crude bicarbonate depends on the temperature.

Generally the normal operating temperature is around 200° to 220°C. The
Calciner is operated at a slight vacuum to avoid dust problems.
The dry and light Soda Ash discharged from the Calciner is partially recycled
back to the Calciner through recycle conveyors. Recycling of Soda Ash is
required to avoid problems related to conveying and fouling inside the
Calciner.
The exhaust gases from the Calciner, rich in CO2 content, are passed through
cyclone separators for the removal of fine Soda Ash dust and then cooled and
washed in Calciner gas cooler / Calciner gas scrubber and sent to compressor
after Ammonia removal.
c. Wash water Distillation:

The Calciner gas from the calcinations is taken to Reboiler of weak liquor still
for heat recovery. There after gas is cooled down in the Calciner gas
condenser and is compressed as Bottom gas for process use. The condensed
liquor of the Calciner gas condenser contains dissolved ammonia. Ammonia is
distilled in the weak liquor still and absorbed in the weak liquor still absorber.
Thus recovered condensate is used as wash water for rotary vacuum filters.
Page 34 of 79
d. Soda Ash Cooling and Conveying

The product light Soda Ash is then cooled in Soda Ash cooler and is
transported to light ash silos for storage purpose and further bagging.
Unit No. 106: Densification of Soda Ash

Light soda ash is converted to Dense Soda by densification process. Required
quantity of the light Soda Ash is taken to light Soda Ash hopper. Light Soda
Ash is fed to hydrator by screw feeder. DM water and part of scrubber
circulation water is dosed into the Hydrator.
Hydrator is rotating equipment where light Soda Ash is mixed with controlled
quantity of DM water and part of scrubber circulation water. Sodium
Monohydrate is formed in the hydrator which has a very compact structure.
Monohydrate from the Hydrator is then transferred to fluid bed dryer cooler. In
fluid bed dryer cooler, the water is removed from wet dense Soda Ash and is
also cooled before discharging from fluid bed dryer. Dense Soda Ash is then
screened through lump sieve and dense soda of uniform particle size is
conveyed to a separate set of storage Silos.
The difference in dense Soda Ash and light Soda Ash is in the bulk density
and particle size.
Unit No.107: Product storage and handling
The product i.e. light soda Ash after cooling is transported to storage silos by
various conveyors and elevators. The stored material in the silo is further
bagged in different size of packages as per customer’s requirement with help
of bagging machines. The bagged material is either shipped to Customer or
stored in the warehouse based on the market conditions. The light and dense
ash is bagged in 25/50 kg. HDPE bags or 1000 kgs (jumbo) bags.
Unit No. 108: Sodium Bi Carbonate
Refined sodium bicarbonate is manufactured by dissolution of Dry soda ash in
previously de-carbonated circulating mother liquor. Subsequently carbonation
of this soda solution is done with compressed Carbon dioxide gas therefore
formation of Bicarbonate Slurry takes place. After the separation of formed
bicarbonate slurry, drying of separated sediment is done and Bicarbonate is
produced.
Sodium bicarbonate manufacturing process includes following basic stages:
1) Soda solution preparation

2) Carbonation of soda solution
3) Bicarbonate slurry separation
4) Bicarbonate drying and gas treatment
Page 35 of 79
Process Diagram for Manufacturing of Sodium Bicarbonate is shown In Figure 6.
Figure 6: Refined Sodium bi carbonate manufacturing Process
Page 36 of 79
Soda solution of certain concentration is prepared by dissolving light soda ash

in de-carbonated mother liquor. This prepared soda solution is pumped to the
top of carbonation column. Cleaned and cooled CO2 gas (38-40 Vol %) from
lime kiln is compressed with CO2 gas compressor and flow in Carbonation
column from bottom in counter current direction to the Soda solution.
At carbonation column sodium bicarbonate formation reaction takes place

according to following equation:
Na2CO3 + CO2 + H2O  2NaHCO3
The reaction runs with heat evolution, but due to water evaporation the
temperature of outlet bicarbonate slurry is substantially reduced.
Temperature profile in the column and particle size of obtained sodium

bicarbonate sediment are controlled according to the temperature of inlet soda
solution and carbon dioxide gas flow.
Adequate capacity/nos. well-designed stainless steel carbonation columns will

be considered, one out of them will be standby. (The exact Capacity/ Nos of
Columns required shall be selected according to Detail Engineering)
Carbonation column will be regularly required to be cleaned from sodium

bicarbonate crust every 10-15 days. Wash liquor is used to dilute circulating
mother liquor.
Bicarbonate slurry from carbonation column is settled and its thickened part
separated at centrifuge. Separated wet residue is washed with desalinated
water. Mother liquor (filtrate) together with settler drain are fed to de-
carbonator. Washed residue is fed to fluid-bed unit for drying.
Sodium bicarbonate is dried at fluid-bed drier with de-dusted ambient air

heated with steam at a heater. This drier enables to increase average
bicarbonate particle size. Dried product is fed in air stream to FB unit cooler
section.
Exhaust air purified from bicarbonate dust at cyclones and bag filter is vented
by fan. Dry sodium bicarbonate extracted at cyclones is recycled to final
product line, whereas dust collected at bag filter is fed to mother liquor tank.
Dried and cooled sodium bicarbonate is transfer to packaging and bagging.
A small amount of steam condensate will be formed. It is fed to condensate

tank which will be used in plant.
Page 37 of 79
Unit No.1100: Energy Centre

Circulating fluidized bed combustion (CFBC) technology will be adopted for
the proposed captive power plant. A 60MW captive co-generation power plant
consisting of Double extraction cum condensing turbo-alternator and required
capacity lignite/coal/petcoke based CFBC Boilers; along with captive power
plant machineries will be installed in order to meet internal steam and power
requirement of the phase I capacity of proposed plant.
The steam generator units proposed for the plant will be compact, semi-
outdoor, natural/assisted circulation, balanced draft, single drum, water tube
type provided with Circulating Fluidized Bed Combustion system. In a typical
Circulating Fluidized Bed furnace, the lignite/ coal/ Pet coke fed on a bed of
suitable inert material with addition of a sorbent material (such as lime stone)
is burnt in suspension through the action of primary air distributed below the
combustor. In addition, secondary air is introduced at suitable points in the
combustion zone to ensure controlled and complete combustion of the fuel.
Suitable lignite/ coal/ Pet coke feeding and grounded limestone feeding
arrangements are provided in the typical Circulating Fluidized Bed
Combustion systems and bed material is commonly used for initial start-up of
the boiler. The steam generators will be designed for satisfactory continuous
operation with the range of lignite/ coal/ Pet coke expected for this plant
without any need for auxiliary fuel i.e. Oil for fire stabilization etc. lignite/ coal/
Pet coke are used as fuel after mixing in appropriate ratios. Steam generating
unit would be provided with electrostatic precipitator in the flue gas path. The
overall efficiency of ESP will be around 99.9%. The ESP would have
adequate number of ash hoppers provided with electric heaters. The design of
ESP will be such that the dust burden at the outlet of chimney will meet the
existing air pollution control norms .Common chimney with separate flue duct
for boiler will be constructed. The NOx emission from the steam generator is
least in case of CFBC steam generator design in view of low combustion
temperature maintained in the furnace.
The steam generator and auxiliaries will perform continuously maintaining

noise limits as per relevant standard specification but not more than 85 dB (A)
at 1.0 meter from any equipment or sub equipment. The steam from the boiler
will be used to generate power in Double extraction cum back pressure turbo
generators/condenser. The extracted / back pressure steam at various
pressure will be used in process.
A DG set of required capacity – around 5 MVA with suitable noise hood and
exhaust chimney will be installed for emergency power requirement. From
state electricity board some power, around 5 MVA at 66 K.V will be
contracted. The purpose is for cold start-up of the plant as well as in running
plant utilisation to the extent required for over all steam power balancing. The
Page 38 of 79
contracted state power will be stepped down to 11.00 k.V, and can be
momentarily synchronised with captive generation which will be also at 11
K.V.
Unit No. 1200: Raw Material Handling
Following are the major raw materials
Salt: Solar salt from captive salt works and from various suppliers will be
transported by surface transport. The salt will be unloaded, washed in a
scientific manner and stored. The salt will be feed to plant in a controlled
manner as needed. However the requirement being round the clock proper
mechanised systems will be installed.
Lime stone: Chemical grade Sized limestone shall be sourced from local
market/ captive mines or from imported source. The lime stone from captive
mines and local source will be transported to plant site through surface/Road
transport. Whereas the imported lime stone will be received at the nearby
port, unloaded and stored for certain period. The efforts will be to shift the lime
stone from port to the plant site within the shortest possible time.
The Lime Kilns requires specific sizes of lime stone and for CFBC Boiler i.e.
for Desulphurisation process, 1 mm or so size limestone is required. The
proper unloading, screening, sizing, storage and feeding facilities for Boilers
and Lime Kilns day bunkers will be created. All the transfer towers of lime
stone handling system will have dust separation and collection equipment’s to
see that dust emission is controlled/ minimised to best possible required
extent.
Coke/Briquettes/Anthracite: The high calorific non coking coke of particular

size is used in the Lime Kilns. Based on the operating load of Kiln and GCV
the quantity of fuel requirements are decided. The material handling facilities
will be created for proper unloading, storage, screening, feeding etc. Based on
its availability in the market at reasonable price sourcing is planned.
Otherwise coke/lignite breeze is procured and Briquettes according to
requirement will be utilised.
Lignite/Coal/Pet coke: There shall be few high pressure boilers to meet the
steam requirement of entire plant. The quantity of fuel requirement depends
upon calorific value but is estimated to around 2,500 to 5,400 TPD. The lignite
will be sourced from G.M.D.C mines and transported by trucks. The imported
Coal and Pet-Coke will be received in big parcel at the port, unloaded, stored
and then transported to plant site. At plant site suitable and desired unloading,
screening, sizing, storage and conveying facilities shall be created. The Fuel
stock piles will be covered from environment angle.
Page 39 of 79
Unit No. 1300: Sweet Water Section

As Sweet water source is not available nearby plant, the entire requirement
will be met by sea water desalination process by using reverse osmosis
technology. For Pre-treatment and filtration plant of RO water will be of
conventional type or ultra filtration technology will be adopted depending of
TSS load. A large storage tank will be made to ensure consistent supply.
RO water will be used for DM water generation for process and power plant
usage. For D M water generation, we may opt following two option or
combination of the two depending of the RO product water quality.
 RO water will be input to D M plant ion exchange vessels. Mix bed unit out let
water (D M Water) will be stored in D M storage tank.
 RO water will be passed through secondary RO water plant and product of
the secondary RO will be passed through D M plant ion exchange vessels.
 D M water generated will be supplied to boiler make up water, Dense soda
ash plant hydrator, injection water for C02 compressor and other misc. usage
for process.
 Part of the RO water or secondary RO water shall be passed through softener
unit to ensure proper quality soft water for washing at filtration sec, purge
water in process and drinking water after proper treatment.
Nano filtration water will be used for salt dissolution in brine section. Though
this technology is still to be proven for consistency of economics, we may go
for RO water for brine preparation as the cost of RO water generation has
reduced drastically with the use of energy recovery instrument.
The condensate from Turbo-alternator & All the other sources will be collected
in condensate collection tank & after polishing it will be used as DM water.
The technology proposed to meet sweet water requirement is generally as

under.
Page 40 of 79
FT : FLOCCULATION TANK
LC : LAMELLA CLARIFIER
CWST : CLARIFIED WATER STORAGE TANK
SS : SLUDGE SUMP
MGF : MULTI GRADE FILTER
PSF : PRESSURE SAND FILTER
SWRO-CF : CARTRIDGE FILTER FOR SWRO
NF-CF : CARTRIDGE FILTER FOR NF
SWRO : SEA WATER REVERSE OSMOSIS
ROPWST : RO PERMEATE WATER STORAGE TANK
NF : NANOFILTRATION
NFPWST : NF PERMEATE WATER STORAGE TANK
UF : ULTRA FILTRATION
SRO : SECONDARY RO
FM : FLASH MIXER
Page 41 of 79
1) REVERSE OSMOSIS
MICRON FILTRATION
The feed water will be passed through a cartridge filter, which removes fine
suspended solids before entering the reverse osmosis system. This is
essential for RO feed water to make it free from fine particulate matter to
avoid any clogging of membrane element surface which severely affects the
performance of membrane elements. This also eliminates problem in high-
pressure pumps due to presence of particulate matter.
DE-SALINATION BY REVERSE OSMOSIS:
Filtered water is pumped to RO system by means of a horizontal multistage

centrifugal high-pressure pump. RO feed water parameters such as pH, free
residual chlorine, turbidity and silt density index are monitored at regular
intervals by means of appropriate instruments.
Control system of the plant ensures proper interlock to safeguard the system
viz. High pressure pumps, RO membrane elements and chemical dosing
pumps from operational problems.
During high TDS condition, reject water at high pressure passes through the
energy recovery device (Pressure Exchangers). This would result in sizing the
High-pressure pump with a reduced flow capacity thus resulting in
considerable saving in the power consumed. Chemical cleaning system is
provided to clean RO membrane elements periodically. This will ensure
satisfactory performance of the plant by removing scaling materials and
foulness from the membrane elements. Monitoring and control of parameters
at pre-treatment section of the plant is essential to minimize frequent cleaning
operations and have the desired life of membranes.
RO permeate will get collected in Desalinated water storage tank. The

permeate water from RO will be sent to D M Plant for further processing.
Reject from SWRO/secondary RO will be diluted with process effluent &

discharged in to sea.
Page 42 of 79
2) DEMINERALIZATION PLANT
SAC : STRONG ACID CATION EXCHANGER

WBA : WEAK BASE ANION EXCHANGER
DGT : DEGASSER TOWER
DGWST : DEGASSED WATER STORAGE TANK
SBA : STRONG BASE ANION EXCHANGER
MB : MIXED BED
DMST : DM WATER STORAGE TANK
Required streams of Demineralization Plant will be installed consist of strong

Acid Cation Exchanger, Weak base anion, Degasser Tower, DG Water
storage tank, strong base anion and Mixed bed unit.
STRONG ACID CATION EXCHANGER (SAC)
Strong Acidic Cation exchanger consists of strong acidic cation resin charged
with mobile replaceable hydrogen ions. Water is fed to strong acid cation
exchanger, which in turn passes through a column of cation exchange resin.
Thus cations in the raw water which are mainly Ca, Mg, and Na gets adsorbed
on the resin surface. The resin in turn releases hydrogen ions in the water.
Hence, the water coming out of cation exchanger will contain acidic due to
formation of Hydrochloric acid, Sulfuric acid, Carbonic acid etc. Hence, the pH
of Decationised water will be typically about 3 to 3.5
After constant usage the hydrogen charge on the cation resin gets
exhausted, a solution of hydrochloric acid is passed through the cation resin
bed for regeneration. During this regeneration process cation resin is restored
for hydrogen charge. To wash away traces of chemicals used for regeneration
entire system is flushed with purified water, which is rejected. After this
operation the cation exchanger will be ready for the next cycle of operation.
WEAK BASE ANION EXCHANGER (WBA)

The de-cationised water will then be passed through the weak base anion
(WBA) unit. Weak base anion exchanger consists of weak base anion resin
having quaternary ammonium group. Thus the free mineral acid present in
Page 43 of 79
water mainly Hydrochloric acid, Sulphuric acid and nitric acid will get absorbed
/react with weak base anion resins.
Thus the exhausted resins can be easily regenerated with a very less quantity
of caustic or soda ash and gives very low operating cost. WBA resin needs a
little more sodium hydroxide or soda ash than the stoichiometric requirement.
It can also be efficiently regenerated using waste sodium hydroxide reducing
operation cost considerably.
DEGASEER SYSTEM
The reaction takes places during the normal operations are as under:
The contents of water split the carbonic acid (H2CO3) into carbon dioxide CO2
and water H2O. The CO2 is driven out with air through the air vent provided at
the top of degasser.
The water is introduced into degasser top via spraying nozzle. This nozzle
distributes the water over the whole surface of tower packing. An air stream is
led under these packing into the degasser. The downward trickling water
comes into contact with the updraft flowing air.
The cation and anion resins in Mixed bed will be regenerated by hydrochloric
acid (30-33%) and sodium hydroxide (40-42%) simultaneously. The effluent
wastewater during regeneration from DM plant will be collected in the
Neutralization pit & will be diluted with process effluent and discharged in to
sea.
3) NANO FILTERATION
Nano filtration is a low to moderately high pressure process in which

monovalent ions will pass freely through the membrane but highly charged,
multivalent salts and low molecular weight organics will be rejected to a much
greater degree. Membranes used in this process falls in between RO and
Ultra filtration. Typical NF applications include water softening, desalination of
dyestuffs, acid and caustic recovery and color removal.
This is widely used for sea water softening before thermal desalination or
SWRO. In this case the efficiency and out put of the desalination plant
increase considerably. With Nano membranes technology we can remove
more than 80 % of Ca and Mg salts , more than 90 % of the sulfates and
retain more than 70 % of chlorides which will contribute in salt recovery in salt
dissolution section. Most of the water will be used for salt washing and
dissolving.
Page 44 of 79
Unit No. 1400: SEA WATER

Soda ash manufacturing process is being exothermic process in nature,
demands large quantity of water for process cooling purpose. Additionally to
meet DM water and RO/Nano filtration process water Sea water is used as
input feed/ water for conversion. Since ultimately the cooling water quantity
demand is very high, thus sea water from Arabian sea is ideal source of water
for the plant. The Return Cooling water (sea water) after performing the
cooling duty for process cooling, will be also used for dilution of process
effluent with a view to meet the statutory quality norms prior to ultimate
disposal to Sea.
The Overall Sea water system is bifurcated in following sub sections.
 Sea water intake,
 Sea water distribution /pumping for process cooling & Sea water conversion
to RO/Nano/DM water
 R.O. and desalination, Storage of DM water, Process water.
Unit No. 1500: EFFLUENT DISPOSAL SYSTEM

The liquid effluent containing solids/sludge is generated in Brine
preparation/purification section, Lime kiln Gas cleaning section and Distillation
section. This effluent is pumped for necessary effluent treatment/dilution and
ultimately will be discharged as per stipulated CPCB norms, into Arabian Sea
through pipeline at a designated and approved location by the competent
authorities.
(vi) Raw material requirement Raw material requirement along with

estimated quantity, Likely source, Marketing area of Final product, Mode
of Transport of Raw Material and & Finished Product
Raw Material Consumption: Soda Ash plant (300 TPD)
Sr.No. Raw Material Appx Quantity

(Mt per year) *
1 Salt 20,00,000
2 Lime Stone 20,00,000
3 Sodium Sulphide / Sodium 4050
hydrogen sulphide
4 Coke / Briquette / Coke :1,30,000/Briquette: 1,55,000/
Anthracite (for Kilns) Anthracite:1,10,000
5 Ammonia 2740
Page 45 of 79
Fuel: Captive Co-gen Power Plant (120 MW)
Sr. No. Raw Material Appx Quantity (Mt per year) *
1 Fuel for Boiler Coal : 13,14,000 MTPA/Lignite : 19,71,000

(Coal / Lignite/ MTPA/Petcoke : 9,12,500 MTPA
Petcoke)
2 HSD * Note: Consumption of HSD will be required

during start up only. ;
Fuel: Emergency DG Sets
Sr. No Raw Quantity (Mt per year) Remarks

Material
1 HSD Only required during start This is stand by
up and meeting emergency Provision
Likely Sources of Raw material: The details of likely raw material sources
are as below:
Sr. Raw Material Source

No
1 Salt From Captive Salt works & Market
2 Lime Stone Limestone Mines and from Domestic /
international Market
3 Sodium Sulphide / sodium Bi Open Market
sulphide
4 Coke / Anthracite Open Market for Coke / Coke breeze/
Lignite breeze from Indian source,
Import from Russia, Peru etc.
5 Ammonia Open Market
6 Coal / Lignite / Pet coke GMDC & Imported Coal i.e. Indonesian /
Australian / South Africa Coal.
8 HSD Open Market
Page 46 of 79
Raw Material and Product Storage

Raw Material Storage:
SN Particular Qty. at Storage

1 Lime Stone 6,00,000 MT
2 Salt 6,00,000 MT
3 Coke 20000 Ton
4 Briquette 20000 Ton
5 Anthracite 20000 Ton
6 Ammonia 45 Tons*3 (2W+1S)
Product Storage:
SN Particular Qty at Storage

1 Soda Ash Product Storage in
Silo – 30000 MT (phase wise
installation)
Go-down – 45000 MT
2 Sodium Bi-carbonate 6000 Tons
For 120 MW Captive Power Plant
Fuel Storage:
SN Particular Qty at Storage

1 Lignite 25000 Ton
2 Coal 60000 Ton
3 Pet Coke 12500 Ton
3 HSD 60 KL
Storage Hazardous Chemicals:

SN Name of Hazardous Chemical Storage Capacity of Hazardous
Chemical
1 Liquid Ammonia 45 MT x 3 (i.e. 2Working +1Stand by)
2 Liquid Chlorine 4500 kg
3 HCl 300 MT
4 HSD 60 KL (3 Tanks of 20 KL each)
5 Sodium sulphide / Sodium 200 MT
hydrogen sulphide
6 NaOH 100 MT
Page 47 of 79
Mode of transportation of raw material and products:
Sr.No Raw materials/Product Transport through

Raw Materials
1 Coal/Lignite/Pet coke By Road/ By Sea
2 Limestone By Road/ By Sea
3 Salt By Road/ By Sea
4 HSD By Road
5 Coke/ Anthracite By Road/By Sea
6 Ammonia By Road.
Products
Soda Ash (Light Soda ash,
1 Dense Soda ash, Sodium Bi- By Road/By Rail/By Sea
carbonate)
Market area of finished Product: Soda Ash

Sr.No Application Sector Nature of Application
1 Soap and Detergents Manufacture of detergents and saponification of fats
2 Glass Industry Raw material for the glass melt and for reacting with
sand
3 Chemical Industry Used in the production of many products including
the followings.
Perborates, Phosphates, Soluble Silicates, Metal
Carbonate, Sodium Nitrate Chromates and
Dichromate, Bleaching Agents, Borax, Fertilizers,
Dyes, Tanning Agents, Catalysts, Cryolite,
Adhesives, Ultramarine pigments.
4 Pulp and Paper Used for cooking wood, neutralization, cleaning,
industry bleaching and treatment of recycled paper.
5 Pharmaceutical Ultra pure soda ash is used as an excipient in the
production of medicines.
6 Petrochemicals Neutralization aid
7 Artificial Silk industry/ De-acidification of artificial silk
Textile industry Dyeing, bleaching and finishing of wool and cotton.
8 Coke ovens, Gas Gas purification (desulphurization) and
Works hydrogenation plants.
9 Iron and Steel Industry Removal of Sulphur and Phosphorous from pig iron,
Cast Iron and Steel.
Ore beneficiation used as floatation agent and fluxing
agent.
10 Heavy Metal Industry Digestion and beneficiation of ore e.g. antimony,
lead, chrome, cobalt, Nickel, bismuth and tin.
11 Aluminium Industry Reaction with Bauxite
12 Ceramic Industry Production of refractory materials and glass
13 Enamel Industry As a flux
14 Food Industry Hydrolysis of proteins, production of margarine and
Page 48 of 79
Sr.No Application Sector Nature of Application

starch and softening of sugar beet juice.
15 Environmental Purification of flue gases by injecting Soda Ash (Dry)
Protection Regeneration of acidic lakes by the introduction of
briquettes of Soda Ash, so that organic sediments
exhibit an alkaline reaction over a long period.
16 Miscellaneous Water treatment, metal degreasing, general cleanser
in photography.
As reagent in analytical chemistry, pharmaceutical
aid (alkaliser).
In veterinary treatment, soda ash has been used as
an emetic.
In solutions, it is used to cleanse skin and in eczema
to soften scabs of ringworm.
Captive Co-generation Power Plant (120 MW)

Steam and power will be used for Soda Ash plant and other utilities. However,
for surplus power, possibility of power wheeling will be explored.
(vii) Resource optimization/ recycling and reuse envisaged in the project
 Utilization of undersize limestone generated from Soda Ash manufacturing

process: Undersize limestone will be generated during the sizing process of
Lime stone required for consumption in Lime Kiln. This undersize, Lime stone
is proposed to be utilised in boiler after further sizing i.e. 1 mm or so fines for
Flue Gas De-sulphurisation system for SOX control.
Utilisation of this undersize limestone will help solid waste management and
fresh limestone resource conservation/ optimisation
 Utilization of undersize /breeze coke: This will be utilised for briquette
manufacturing.
(viii) Availability of Water, its source:

In order to meet overall water requirement for proposed project, Arabian Sea
is the best option for Seawater intake and effluent disposal due to its proximity
to Plant site, enormous size & large assimilation capacity.
During construction stage of plant a small R.O Plant installation/operation

should be permitted to meet construction water requirement.
Erection of Seawater Intake and Effluent Disposal facilities in Arabian Sea at a

designated points suggested by NIO based on pre-feasibility study conducted
by leading Marine Consultant and laying of pipeline for Seawater intake and
effluent disposal will fall under the CRZ area. The CRZ demarcation will be
carried out through the MoEF&CC approved agencies as per the CRZ
Notification and will be submitted to state level Committee - GCZMA for
getting CRZ recommendations.
Page 49 of 79
The National Institute of Oceanography (NIO), Mumbai being engaged for the
marine EIA studies for Seawater intake and effluent disposal facilities. The
CRZ clearances shall be obtained based on the NIO study reports concurrent
to the environmental clearance.
The total sea water requirement for the project is estimated as 16 lakh m 3/day
which will be met through sea water intake system. The total effluent of 15.8
lakh m3/day will be disposed to a location recommended in EIA studies
through suitably designed effluent disposal system.
(ix) Waste to be generated along with its mode of disposal

The type and mode of disposal of solid/Hazardous waste generated from the
proposed plant are given below:
Sr. No. Type of Waste Mode of Disposal
1 ETP Sludge from treatment The effluent from the power plant, RO/DM
of effluent generated from Plant will require only neutralization & will
captive power plant and have negligible BOD/COD. Sludge will be
RO/DM Plant disposed off at authorised TSDF site for land
filling.
2 Used Oil It will be sold to MoEF&CC/CPCB authorised
recyclers only ~ 12 KL
Discarded Drums It will be sold to approved traders only
3 Discarded Bags It will be sent back to the supplier for reuse.
4 Spent Ion Resin To be sold to authorized recyclers or will be
incinerated at MOEF&CC/CPCB approved
TSDF for which plant will obtain membership.
5 Lead Acid Batteries It will be sold to authorized agency through
auction
6 Ash (Fly ash & Bottom ash) The boiler ash of coal as fuel will be used for
cement manufacturing/brick manufacturing.
7 Limestone Rejects Can be used in boilers for desulphurization
and as a sweetener in cement industry, road
making, Pavement etc. 5% of Limestone
Consumption
8 Settled Sludge Since settled sludge, non-hazardous in
nature, is proposed to be disposed off in
nearby landfill site.
A. Details of Liquid effluent treatment and disposal :
The main raw water source for water for soda ash plant, other ancillary
facilities as well as captive power plant will be seawater and allotted sweet
water if available and hence the wastewater generation quantity is based on
water input.
The wastewater generation streams will be from soda Ash plant and Captive
Co-generation power plant. The main effluent parameter to be ensured with
respect to the GPCB/CPCB standards will be pH, temperature and suspended
solids.
Page 50 of 79
The Soda ash effluent stream will be mixed with brine treatment plant reject,
Boiler blow down from CPP and once through return cooling Seawater which
in turn will bring down the temperature, pH as well as to reduce concentration
of suspended solids. Online pH, NH3 and temperature monitoring system will
be provided to maintain the records.
The treated effluent conforming to the prescribed norms will travel through a
channel and ultimately will be disposed into Arabian sea at a designated
disposal point as per recommendation of CSIR-NIO (Mumbai) through a
submerged pipeline. A diffuser system for proper dispersion of effluent will be
laid in the Arabian sea by ensuring the requirement of minimum depth and the
exit velocity. The Effluent treatment scheme for Soda ash plant is shown in
below Figure – 7.
Page 51 of 79
Figure 7: Effluent Treatment Scheme
Page 52 of 79
B. Domestic Effluent:
Domestic waste water will be treated in Sewage Treatment Plant (STP) and
treated water will be used for plantation / Greenbelt development around the
Plant premises.
The Sewage will be first passed through a Bar Screen Chamber and An Oil &
Grease Trap where any extraneous / floating matter would get trapped.
The sewage would then be collected in a receiving sump where the variation
in flow and characteristics are dampened, which otherwise can lead to
operational problems and moreover it allows a constant flow rate downstream.
Here the sewage is kept in mixed condition by means of coarse air bubble.
The equalized sewage will then be pumped for necessary treatment of

BOD/COD reduction.
The Clear supernatant after disinfection shall be used for

landscaping/gardening.
The Biological sludge generated will be drained to the sludge holding tank
from where it can be removed periodically for suitable disposal.
A. Sewage Treatment Plant layout

BAR SCREEN CHAMBER
OIL & GREASE TRAP
RECEIVING SUMP
PRIMARY TREATMENT
CHLORINE CONTACT TANK
TREATED WATER TANK SLUDGE DRYING BEDS
FOR DUST SUPPRESSION & Sludge for use as manure

GRADENING
Note: STP capacity and it’s design will be carried out in such a way that the
effluent quality will be maintained as per GPCB standards.
Page 53 of 79
C. Air Pollution and Emission Control:

Air Pollutants: In the proposed soda ash plant and CPP project, SO 2, NOx,
PM10 and NH3 will be major air pollutants. Adequate stack height for process
stacks and CFBC boilers will be provided for effective dispersion of air
pollutants. Scrubbers, Dust collectors, bag filters etc. will be provided for
process stacks like Lime kiln, Ammonia recovery system, Filtration,
Densification & Lime Grinding. For CFBC boilers ESPs for dust control and
lime injection, Desulphurisation will be provided SO2 control.
Various Soda ash Process Stacks will be connected to Air pollution control
system as mentioned below as a Pollution control Measure.
Stack Stack attached to Air pollution Stack Height Expected

No. control System # Pollutants to
(m) monitor & control.
1 Lime Kilns Scrubber & 68 mtr PM, SO2, NOx

ESP in Series.
2 Ammonia Recovery Water Scrubber 42 Mtr Ammonia

system
3 Lime Grinding System Bag Filter 65 Mtr PM
4 Calciner unit Scrubber 37 Mtr PM
5 Densification Scrubber 43 mtr PM
6 Sodium Bi- Carbonate Bag filter 30 mtr PM

Unit
Note: # Selection of Final stack heights will be based on final EIA /EMP studies.
Captive Power Plant Stacks will be connected to Air pollution control system
as mentioned below as a Pollution control Measure.
Stack Stack attached to Air pollution Stack Height Expected

No. control System (m)# Pollutants
1 Common stack for Individual ESP for 130 mtr PM, SO2, NOx,
CFBC Boilers Each Boiler Mercury
Lime dosing & Or as required
Desulphurisation
2 Emergency DG - 30 Mtr PM, NOx, NMHC,
CO
Note: # Selection of Final stack heights will be based on final EIA /EMP studies.
Page 54 of 79
Emission levels for Captive power plant stack and process stacks:
SN Detail of Air pollutant Emissions From Stack Emissions From

attached to Boiler Process vent (soda ash
plant)
3 3
(ppm or mg/Nm ) (ppm or mg/Nm )
3
1 Particulate Matter 30 mg/Nm ----
3
2 SOx 100 mg/Nm ----
3
3 NOx 100 mg/Nm ----
3
4 Mercury 0.03 mg/Nm ----
5 Ammonia ---- 175 ppm – Tower gas
Scrubber
6 Particulate Matter --- Dense Soda ash
3
scrubber – 150 mg/Nm
7 Particulate Matter --- Lime Grinding Mill – 150
3
mg/Nm
3
8 Particulate Matter ---- SBC stack – 150 mg/Nm
9 Particulate Matter ---- Calciner unit Scrubber -
3
150 mg/Nm
Emission levels for DGs set stack:
SN Details of Air pollutants Emissions From Stack attached to Emergency DG

3
stack (ppm or mg/Nm )
1 NOx 710 ppmv
3
2 NMHC 100 mg/Nm
3
3 PM 75 mg/Nm
3
4 CO 150 mg/Nm
Page 55 of 79
(x) Schematic representation of feasibility drawing which give information

of EIA purpose
The schematic layout of proposed project is shown below:
Page 56 of 79
Figure 8: Schematic Layout
Page 57 of 79
 The proposed project is a Greenfield development.

 Application made to District Collector for allotment Government land and
Industries Commissioner for allotment of Private and Govt. Land.
 The total area admeasures 1481.48 acres.
 The site is well connected to NH41 about 6 km NE.
 The nearby villages are Bada, Bhada, Bayat, Layja Mota which have basic
infrastructure like school, temple, meditation centre, drinking water, Bus
service, Hospital, Primary Health Sub Centre etc.
 The nearest densely populated area is Mandvi about 22 km East.
 There are few seasonal rivers in the study area Vengadi Nadi which runs
parallel to Western Boundary, Kharod Nadi about 7.5 km East and Sai Nadi
about 9.5 km west.
 However, all such drainages are seasonal in nature and flows only during
rainy days.
 The vegetation types are representative of Semi-arid, desert eco-system
typical of Kutch.
 The sand dunes run throughout along the coast. The CRZ buffer of 500 m
towards sea and 100m for Vengadi Nadi Discharge mouth are applicable.
 The notified protected area is Narayan Sarovar Wildlife Sanctuary, Kutch
about 80 km West.
Page 58 of 79
Figure 9: Area Overview
(xi) List of major plant equipment are as below:

Solar Salt Washery Unit Heat Exchangers shell & tube
Salt Dissolvers Heat Exchangers PHE
Lime Kilns Vessels and Tank
Electrostatic Precipitators Absorber & Distiller Column
Lime Grinding System Various CI&CS Non metallic Tower
CO2 Gas Scrubber Boiler, ESP and Desulphurisation
Carbonation Towers Turbine Generators
Settlers Chillers
CO2 Compressors Air Compressors
Calciner Various material Handling & Storage
system
Product Rotary Coolers Bagging Machines
Hydrator Coal Handling plant with crusher
Fluidized Bed Dryer Ash Handling plant with dust collector
Pumps Chimney
Water treatment RO/DM Unit Seawater Intake & Effluent disposal
system
Page 59 of 79
Chapter 4: Site Analysis

(i) Connectivity
 6 km from State highway - GJ SH 6
 116 km from Adipur Railway station
 66 km from Bhuj Railway station
 68 km from Bhuj Air port
 55 km from Mundra port
(ii) Land form, Land Use and Land Ownership

Approx. 251.14 acres of land belongs to Govt. (Shri Sarkar) and 1230.34
acres to Pvt. land owners.
(iii) Topography
The topography of the project site and the study area of 10 km radial zone are
almost plain. There are hillocks or undulating land in the study area mostly
nearby the Sea coast.
(iv) Existing land use pattern

Project Site: Approx. – Total 1481.48 acre.
The land use is mainly comprised of single crop land, barren land, built up,
water body, fallow land, sand, Unclass forest land, sand dunes along sea
coast, sea and river as water body in study area. The vegetation is mainly
comprised of prosopis juliflora.
 Government / Shri Sarkar– about 251.14 Acre

 Private unirrigated agricultural land about 1230.34 Acre
 No forest land within the proposed project boundary. However to lay Sea
water intake pipeline to plant and effluent outfall line’s corridor will pass
through Unclass Forest land. For this necessary permission will be obtained
from the concern authority.
 Arabian Sea: ~ 0.8 km
 Forest & Sand Dunes: Unclass forest & Sand Dunes outside plant boundary
River / Steam: Seasonal River (vengadi) within 0.5 kms from top
north corner of boundary, outside site boundary.
 There are no protected areas within the site.
(v) Existing Infrastructure

The proposed project is a Greenfield development project.
Page 60 of 79
Land: Approx. 251.14 acres Govt. (Shri Sarkar) land and 1230.34 acres
private unirrigated agriculture land. No forest land within the proposed plant
boundary.
Water: requirement will be met by use of sea water as main source. Arabian
Sea is located at a distance of about 0.8 km
Fuel: Domestic or imported coal, lignite. Necessary fuel linkages will be
established.
Transport: Nearest railway station, Bhuj ~ 66 km, GJ SH6 ~6 km, Nearest
Airport, Bhuj ~ 68 km, Nearest sea port, Mundra - 55 km.
(vi) Soil Classification

Other agriculture crops grown in this area are sesame, bajara, castor and groundnut.
Cotton was observed as a standing crop. There were no standing crops in many
agriculture fields. A major portion of the land is barren in the study area. Ground
water is over exploited in this region. Narmada canal exists but yet not operational.
Due to water scarcity, rainfed agriculture is mostly practiced in the study area. Soil in
this region has low productivity. Soil type is sandy loam.
(vii) Climatic data from secondary sources

The climate in the study area falls under extreme temperature and frequent
draught. The rainfall in this area is due to south-west monsoon and this
monsoon is erratic and generally experience weak rains. Due to high rate of
evapotranspiration the land area become arid and cause increase in seawater
salinity. The climate of the area is characterised by hot summers and cool
winters with extreme temperatures. Rainfall is generally less in these arid area
and confines to period from June to October.
The region is deficit in water resources. The nearest meteorological station is
located at Bhuj about 60 km from the project site. The air temperature
reported from 5°C - 41°C with relative humidity varies from 80 - 90% during
monsoon season. Visibility is good throughout the field studies. The average
visibility is more than 1 km; however, few days in winter reported lower than 1
km visibility. The meteorological data shows that the mid-November to
February is the winter season of the year; December is the coldest month with
the average temperature 9°C.
Air and Noise Quality: The study area is principally located within a rural
community comprised primarily of residential units and wind mill installations
therefore; existing air and noise quality is reasonably good. There are no
densely populated installation or large commercial areas near the project site.
Soil: contains high sand content. Cotton was observed as a standing crop
while the other crops grown in this area includes sesame, bajra, castor, and
groundnut.
Page 61 of 79
a. Temperature
The period from March to June is marked by continuous increase in the
temperatures. June is the hottest months of the year with a mean daily
maximum and minimum temperature (in June) of 32.9C and 27.7C
respectively. With the onset of southwest monsoon by about mid-June, the
temperatures go down considerably. From November onwards, both the day
and night temperatures decrease till December.
b. Rainfall
Average annual rainfall based on rainfall data recorded at Mandvi taluka
headquarter, for last 30 years has been observed as 434 mm (Source -
Director of Relief, Revenue Department, Gandhinagar). The annual rainfall as
recorded at Mandvi Taluka headquarter during the year 2018 is 118 mm
(Director of Relief, Revenue Department, Gandhinagar).
c. Humidity
During the monsoon season (July/August) relative humidity, higher than 83%
have been recorded. The driest part of the year is the December period with
the relative humidity going below 60%. Relative humidity varies between 58%
to 76% during period of December to March.
Meteorological data as recorded at IMD Mandvi
(Based on last 60 years data)
Mean
Relative Mean
Temperature Wind
Humidity Cloudiness
Month Speed
Mean Daily Mean Daily 08:30 17:30 08:30 17:30
Km/hr
Max C Min C % % Oktas 0ktas
Jan. 26.0 14.1 59 60 14.2 1.8 1.7
Feb. 26.7 14.8 70 66 15.5 1.5 1.2
Mar. 29.2 17.9 76 71 18.7 1.9 1.5
Apr. 31.5 21.8 81 74 22.1 2.5 1.9
May 32.7 26.0 81 78 31.1 3.6 2.6
Jun. 32.9 27.7 82 78 32.5 5.3 4.6
Jul. 31.7 26.9 84 80 32.7 6.5 6.2
Aug. 30.5 26.0 84 80 32.2 6.5 6.0
Sep. 31.0 25.3 82 77 24.6 4.7 4.2
Oct. 32.4 22.6 75 71 16.4 1.6 1.8
Nov. 30.6 18.4 60 63 13.8 1.6 1.6
Dec. 27.7 15.2 58 59 14.1 1.8 1.9
Annual
30.2 21.4 74 71 22.3 3.3 2.9
mean
d. Winds
Due to Arabian Sea in the vicinity, winds are generally high throughout the
year, except during the south west monsoon season, when these are high to
strong. Mean wind speed is highest in July (32.7km/hr) and lowest in
December (14.1 km/hr).
Page 62 of 79
(viii) Social Infrastructure

 Nearest village: Bada
 Total Population: 2719
 Education: Primary school - 1
 Secondary school - 1
 Senior sec school - 1
 Health: Primary Health Sub Centre
 Charitable non Govt hospital/nursing home -1
Source: Census: 2011
Social Infrastructure overview in the study area:

Education: As per 20011 village directory record, almost all villages having
education facility in the form of primary schools, and middle school.
Medical/Primary Health Care: Medical facilities in terms of community health
workers are available in some of the villages. Only primary health sub centers
are available in few villages.
Drinking Water: The water supply in the region is through dug wells, hand
pumps, taps and other allied sources. The quality of the drinking water is poor
due to high TDS.
Drainage and Sanitation Facilities: Drainage and sanitation facilities were
not adequate in the study area. Mostly Open drainage, and open kuccha
drainage observed in the village.
Communication: Communication facility is fairly good in this region. Near
about 50% villages having telephone connectivity and having post office.
Transportation: A well planned and efficient network of transport is an
essential component for a developing country. In the absence of efficient
network of transport, a State’s economy would suffer from major grid lock in
terms of overall growth potential of that area. In village public bus facility was
availed and other facilities were private bus.
Road Approach: Roads are the basic means of communication for the
development of any economy. All type of roads was present in the study area.
Bank Facilities: Banking and credit society facility was not found in village.
Self-help group activities were performed by the women groups.
Power Supply: Almost all villages are electrified in the region and electricity
is available for both domestic and agriculture.
Page 63 of 79
Chapter 5: Planning Brief

(i) Planning Concept:
M/s GHCL has signed an MOU with Govt. of Gujarat in 2017 for development
of Greenfield Chemical Complex in District Kutch Gujarat. To further increase
its Soda Ash production and with a vision to diversify its product profile in
future GHCL proposes to develop Greenfield Chemical Complex-Soda Ash
manufacturing, Sodium bicarbonate, captive Co-gen power plant and
seawater intake and outfall system. Soda Ash manufacturing process being
exothermic in nature requires large quantity of process and cooling water.
Proposed site is located in proximity to Arabian Sea coast off village Bada,
Taluka Mandvi, Kutch Gujarat.
The total identified land is about 1481.48 acres. The preliminary plant layout is
made keeping in mind environment siting parameters, wind direction,
availability of water, raw material, and transport infrastructure, lesser
conveyance for process plants, utilities near point of consumption, ease of
inbound and outbound traffic and space for ease of operation and provision
for future expansion etc.
(ii) Land use planning: approximate area allocation is shown below:
S.No. Category Approx. Area allocation (Ha.)

1. Process Plant 29.96
Units
2. Utilities 15.45
3. RM & Fuel 47.67
Handling & Storage
4. Storage Finish 3.75
Goods
5. ETP 8
6. Non Plant Building 56.29
7. Green Belt 197.85
8. Truck parking, 31.9214
equipment storage,
water reservoir
9. Open Vacant area 123.11
10. Open area 70
temporary reserve
for Construction
stage, fabrication,
storage etc.
11. Future 15.55
Development
Total 599.5 Ha.
(1481.4) acres
Page 64 of 79
Chapter 6: Proposed Infrastructure

(i) Industrial Area:
Light & Dense Soda ash plant: will comprise of Brine Preparation unit, Lime
Kilns, Absorption & Distillation, Compression and carbonation units, Filtration
& Calcination units.
Sodium Bicarbonate: Filtration, Carbonation, Decantation, Centrifuge, Mixing,
Decarbonation.
Captive Co-gen power plant: CFBC Boilers, Steam Turbine,
Alternator/Generator.
Seawater Intake & Effluent Disposal: Intake point, pipeline, Sump and Pump
House, RO-DM plant & Pipeline, Channel, Mixing pond, Pipelines and Diffuser
system.
(ii) Non Processing Area: includes weighbridges, administrative buildings,

Laboratory, Security cabins, Water reservoirs, storage areas, Parking etc.
The total land area required for establishment of proposed project is 1481.48
acres.
(iii) Greenbelt: Effective Greenbelt will be developed along the plant periphery for
attenuation of noise and air pollution. The native plant species based on EIA
recommendation will be developed. 33% area will be reserved for Green Belt
Development.
(iv) Social Infrastructure: Basic amenities within study area include primary
school, PHCs, water supply, electric supply, banks, post office, petrol pumps,
bus service etc. Through GHCL Foundation company will strengthen the
social infrastructure through its needs base CSR activities in field of
healthcare, Education, skill development, Animal Husbandry etc. The
proposed project has potential to generate direct employment for about 1200
& indirect employment for 3000 people.
(v) Connectivity: The proposed site is well connected with existing road
infrastructure. The SH 6 is about 6 km NE. The nearest railway station is at
Bhuj about 66 km & Bhuj airport about 68 km. The nearest sea port is at
Mundra about 55 km. The existing road infrastructure is adequate through NH
41. Approach roads and existing internal roads will be strengthened to
accommodate plant access.
(vi) Drinking Water Management: From Sea water through RO/DM route,
Process water, Domestic water & DM water will be produced. Ultimate water
source will be seawater Intake point from Arabian Sea. We shall survey if
some quantity from Narmada water is available through pipeline route and if
sanctioned will use at least to the extent of domestic use.
Page 65 of 79
(vii) Sewerage System: Domestic effluent will be treated through the Sewage
Treatment plant. Treated water will be used for dust suppression as well as for
Plantation/Green belt development around the plant premises. Sludge will be
used as manure in development of Greenbelt/Plantation.
(viii) Industrial Waste Management: Hazardous waste will be collected, stored,

sent to authorize vendors for disposal as per waste characteristics based on
Hazardous waste Rules, 2016.
Recyclable hazardous waste may be generated in the form of used oil from
DG sets, Equipments, plant maintenance etc. and Used Batteries. It will be
disposed off through MoEF&CC/CPCB authorized recycler. E-waste, Bio
medical waste management will be done as per prescribed rules. The Boiler
fly ash will be sold to cement manufacturers, RCC block makers or for road
construction purpose.
Effluent: The liquid effluent from proposed plant will be disposed off through
channel, pipeline and diffuser system at recommended location in CSIR–NIO
EIA report. Combine effluent from process plant, utilities and return once
through cooling and dilution water will be discharged at a location
recommended in EIA. Details for Waste generation & disposal are given in
Chapter 3 Section (ix) of this report.
(ix) Solid Waste: Municipal waste like canteen waste, cardboard, paper,
glassware, scrap, metal, plastic etc. will be disposed in line with Solid Waste
Management Rules 2016. Adequate waste collection bins will be provided
across the plant.
(x) Power Requirement: It is proposed to establish 120 MW Solid fuel based

Captive Co-generation power plant to supply reliable and uninterrupted power.
Initial start-up power will be by setting up of 11 / 66 KV substation with Gujarat
Electricity Board grid connection. This will also ensure meeting power load
gaps/emergencies.
Page 66 of 79
Chapter 7: Rehabilitation and Resettlement

Plan
(i) The land to be utilized for the proposed project is presently vacant with no
permanent habitation. In view of this no rehabilitation and resettlement plan
for human habitat is foreseen. The nearest habitation is at Village Bada,
which is at a distance of around 1 Km from the proposed site and thus is not
expected to be affected either during construction phase or during normal
operation. However, there will be temporary influx of construction workers
requiring temporary habitation arrangements. In fact, this should be
considered having positive social and economic impact on local populous
with creation of job/employment during construction phase. Rehabilitation
and Resettlement plan will be prepared after detailed census survey during
EIA Study and will be submitted in EIA Report. As a part of Corporate Social
Responsibility, we would aim at the improvement in the living standards of
inhabitants nearby project area by not only by being a catalyst for
development but also will develop infrastructure in nearby area.
Page 67 of 79
Chapter 8: Project Schedule and Cost

Estimation
(i) Time Schedule for the Project
 Start date of Basic Engineering : (Sep-2021)
 Start Date of Detailed Engineering : (Mar-2022)
 Proposed date of start of construction (i.e. only after obtaining the
Environmental Clearance from MOEF&CC) : (July-2022)
 Date of project completion : (June-2025)
Approx. Project Schedule in the form of Bar Chart is as follows:
Page 68 of 79
Page 69 of 79
The overall project duration up to Mechanical Completion (Plant ready for

commencing pre commissioning activities) in 30 to 33 months from the zero
date is considered based on the following:
 The zero date is considered as readiness of the basic engineering package /
Initial clearance from Statutory authority
 Land acquisition, followed by soil investigation/contour survey within next 3
month from the zero date.
 Process Data sheets and specifications of the following long delivery critical
items should be made available by the process licenser within 2 months from
the zero date.
 Boilers
 T.G Sets
 Calciner
 Lime Kilns
 All Cast Iron/CS/Nonmetallic Columns
 Carbonation Towers
 CO2 Compressors
 Lime Kiln
 Lime Grinding
 Process data sheets for all balance equipment shall be made available
within five months from the zero date.
 Procurement cycle from the date of issue of enquiry to order finalization is
considered as 3 months. Order shall be placed within 2 weeks from receipt
of the technical recommendations from the engineering consultant.
(ii) Estimated Project Cost along with analysis in terms of economic

viability of the project.
The estimated capital cost, including foreign exchange component, for the
proposed Soda Ash Plant Phase 1: Capacity 5,50,000 TPA Light Soda Ash,
and 2,50,000 TPA Dense Soda Ash, 1,00,000 TPA Sodium Bi-carbonate is
Apx. Rs 3550 Crores.
The approximate breakup of the above indicated Capital Cost is estimated

as follows:
Page 70 of 79
Project Cost For Phase 1 :

a) Land : Approx. Rs. 100/- Crores
b) Buildings : Approx. Rs. 200/- Crores
c) Plant and Machineries : Approx. Rs. 1900/- Crores

d) Electrifications : Approx. Rs. 250/- Crores
e) Instrumentation : Approx. Rs. 200/- Crores
f) Piping, Insulation etc : Approx. Rs. 350/- Crores
g) Infrastructure facilities : Approx. Rs. 550/- Crores
(These include sea water intake and effluent
disposal facilities.
h) Total : Rs. 3550/- (Tentative for Phase 1)
The above indicated estimated capital cost does not include the costs for
following:
 Lease Hold Land and development costs
 Costs towards process technology and the services by technology provider
 Preoperative expenses
 Margin money for working capital
 Interest for the construction duration.
Page 71 of 79
Chapter 9: Analysis of Proposal / Final

Recommendations
(i) Financial and Social Benefits
 Proposed activity will provide benefits to local people in terms of economic
and social welfare
 Employment oppurtunities based on skill, direct and indirect employment
generation
 Local people will get some contract services to get indirect income
 Company will contribute in improving education, health facilities, skill
development in nearby areas through CSR works through GHCL Foundation.
 The project is aimed to honour commitment to Govt. of Gujarat during Vibrant
Gujarat Summit 2017 for development of Greenfield Chemical Complex Soda
Ash in Kutch District. It will bring industrial development and create
employment oppurtunities in the region.
A. Market Study:
Detail market study i.e. supply and demand situation for Soda Ash, indicates
that the current supply position will continue to be tight due to continuous
growth in Glass and Detergent industry.
 India is one of the fastest growing economies in the world, growing at a rate
of 8.6 % in the past 5 years.
 Rising population, urbanization and higher disposable incomes have fueled
this growth and led to increased consumption for industrial products.
 This has resulted in increased demand for housing, transportation, consumer
products, processed foods and beverages driving growth in glass, soaps and
detergents and other chemical products.
 Soda Ash is a key raw material for glass, soaps and detergents and multiple
chemicals.
 Economic growth is fueling the growth of Soda Ash industry in India resulting
demand growing at more than double the rate of global demand.
 Domestic production has grown up by 2% over the last 5 years whereas the
surplus demand is catered to by imports.
 Industry estimates projected growth driven by growth in the glass industry
too.
 Hence current market conditions are considered to be favorable for setting
up a new Soda Ash manufacturing unit. Further keeping in view the in house
consumption of Soda Ash for Detergent, a sizeable Soda Ash manufacturing
facility is very much favorable.
Page 72 of 79
B. Financial Analysis:
The cost of production and profitability, besides various analyses suggest that
the proposed Soda Ash manufacturing facility shall be financially viable.
The IRR of the project Ph-1 is 12% based on 10 year projected financial
statements. The sensitivity is more attributed to the selling price and project
cost. The market information indicates increasing trend in the Soda Ash price
only due to rising demand.
Financial and social benefits with special emphasis on the benefit to the local
people including tribal population, if any, in the area.
The surrounding inhabitants are mainly agricultural oriented. The frequent
drought prone condition leads to migration of the people to other areas.
Unemployment and underemployment are the main problems of the
inhabitants. Opportunities for jobs in activities will serve as a source of
permanent livelihood. Around 1,200 persons will get direct employment &
3,000 persons indirectly employed as our project comes up. Additionally even
during peak construction around 4,000/5,000 contract people may be
employed indirectly. The plant activities will also provide indirect employment
to nearby villagers.
GHCL Ltd will undertake in the nearby villages the following activities as a part
of CORPORATE SOCIAL RESPONSIBILITY programme.
a) Health and Family Welfare:

 Arrangement of free of cost medical checkup camps for the employees, which
will be also extended for the villagers.
 In emergency, plant Ambulance facilities will be extended to nearby villagers.
 Health camps in participation with the Govt. as well as NGOs will be
organized.
b) Education:
 A school support program will put in place in which the Government schools in
the nearby villages will be supported by us in terms of infrastructure and
quality of education. Thus ultimately upgrade level of schools.
 School will be set up for the children of the employees. It will be also extended
for the nearby villagers. Provided they meet the minimum standards.
c) Socio Development Activities:

 Employment opportunities for local people meeting the basic requirements.
 Development of facilities within villages like roads etc.
 Supply of drinking water in the period of scarcity to the nearby villages.
 Deepening of nearby village ponds for storage of rainwater.
 Animal Husbandry promotion through providing support for breed
improvement, animal healthcare, fodder improvement etc.
Page 73 of 79
 Partnering with the Govt. and other NGOs to bring resources and expertise for
the benefit of the community.
 Relief work will be provided during natural calamities by extending immediate
necessary help to the affected nearby villages and people.
 The company will provide funds for the various development activities of the
neighboring villages as and when we find that community development
activity is the motto.
 Promotion of festivals related and other Cultural activities in nearby
villages/schools.
d) Environmental Activities:
 Roof Rain water harvesting structure will be constructed within the plant
premises which will recharge ground water.
 The necessary Air Pollution Control measures like ESPs, Bag house/Bag
filters etc. will be installed to control dust emission if any.
 The treated domestic wastewater i.e. treated effluent will be used for
gardening, developing green belt and sanitation purpose.
 Greenbelt will be developed in 33% of the total area to minimize the air impact
and noise impact on the surrounding area. The number of trees to be planted
as a part of the plantation program will take as 1,000 trees per hectare for
green belt as well as along roads.
Page 74 of 79
Enclosure I: List of Survey Nos.

1 Government-Shri Sarkar New Map 251 Old Map 280/Paiki 2
2 Government-Shri Sarkar New Map 459 Old Map 381
3 Government-Shri Sarkar New Map 453 Old Map 370/2
9 Government-Shri Sarkar New Map 406 Old Map 526 (paiki) Traverse
12 Government-Shri Sarkar New Map 470 ----- 526
15 Government-Shri Sarkar New Map 267 ----- NIL
17 Government-Shri Sarkar New Map 1087 ----- NIL
24 Pvt Land New Map 477 Old Map 526/P7
25 Pvt Land New Map 476 Old Map 389
26 Pvt Land New Map 452 Old Map 370/1
34 Pvt Land New Map 467 Old Map 385/2/Paiki2
36 Pvt Land New Map 438 Old Map 349/Paiki1
Page 75 of 79

54 Pvt Land New Map 307 Old Map 257/Paiki 1
57 Pvt Land New Map 447 Old Map 369/2 /P2
60 Pvt Land New Map 249 Old Map 280/1 /Paiki2
84 Pvt Land New Map 439 Old Map 366/Paiki1/paiki1
90 Pvt Land New Map 457 Old Map 526/4/Paiki2
95 Pvt Land New Map 428 Old Map 300/1/P1
Page 76 of 79

110 Pvt Land New Map 285/1 Old Map 268 (285)
111 Pvt Land New Map 285/2 Old Map 268 (285)
126 Pvt Land New Map 479 Old Map 385/1/P1/P1
526/Paiki4/1/Paiki1/
131 Pvt Land New Map 430 -----
Paiki2
132 Pvt Land New Map 429 ----- 526/Paiki2/Paiki2
133 Pvt Land ----- 1099 Old Map 526/P2/P1
134 Pvt Land ----- 1096 Old Map 526/P12
135 Pvt Land ----- 1097 Old Map 526/P13
136 Pvt Land ----- 1098 Old Map 526/P14
137 Pvt Land ----- 1094 Old Map 526/10
138 Pvt Land ----- 1095 ----- 526/11
139 Pvt Land ----- 1111 ----- 526/8
Page 77 of 79
148 Pvt Land New Map 266/Paiki1 Old Map 219(paiki)

162 Pvt Land New Map 278 Old Map 273/paiki1
163 Pvt Land New Map 284 Old Map 273/paiki2
167 Pvt Land New Map 305/Paiki 1 Old Map 227 (paiki)
168 Pvt Land New Map 487 ----- 526/8/1

Page 78 of 79

Page 79 of 79

Proposed Greenfield Chemical Complex Pre-Feasibility Report

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Pre-Feasibility Report

Proposed Greenfield Chemical Complex

Village: Bada, Taluka: Mandvi,

M/s GHCL Ltd.

Chapter 1: Executive Summary

1.1. NAME OF GHCL LTD.

1.2. Location of At various Survey No. (Encl. I)

1.3. Promoter of Unit GHCL Ltd

1.4. Registered Address GHCL Ltd

1.5. Contact Information  Mr. NN Radia, COO

1.6. Category of Category A : 4(e) - Soda Ash Plant ,1(d) Captive

1.7. Process  Energy efficient “dry liming process” for

1.9. Cost of Project Approx. Rs 3550.00 Crores for Phase 1 Project.

1.10. Land Area Land area of approx. 1481.48 acres.

1.12. Source of Power  Captive Co-generation power plant – 120 MW.

Chapter 2: Introduction of project

GHCL BUSINESS SEGMENTS

In Chemicals sector, the company is mainly in the business of manufacturing

It’s Textile operations is an integrated vertical set up which commences right

Consumer Products operation is another business for GHCL, where it is a

The manufacturing facility of Soda Ash plant is located at Sutrapada of District

GHCL is distinguished by its growth, financial performance and outstanding

In view of present manufacturing capacity of GHCL and considering expected

(ii) Brief description of nature of the Project

Soda Ash (Na2CO3) is classified as a heavy chemical. The nature of project is

(iii) Need of Project it’s importance to Society/Nation

Soda Ash is having significant importance because of its applications in major

However in India Detergent industry is largest consumer of Soda ash. At

In order to cater to increasing demand for Soda Ash user industry it is

(iv) Demand Supply Gap

The global production capacity of soda ash is concentrated in USA, China,

According to business intelligence report by IndustryARC, the global soda ash

(V) Imports vs Indigenous production

The installed Indian capacity as on March 2020 is 4,239,500 MTPA.

India facing cheap imports from Turkey, US and other regions.

Top 5 Import Destinations of Selected chemicals during 2018-19

UNIT 2016-17 2017-18 2018-19 2019-20 2020-21

(vi) Export Possibility

Top 5 Export Destinations of Selected chemicals during 2018-19

(vii) Domestic/export markets

Indian Soda Ash Scenario

2. Next 5 year’s anticipated growth (Year wise of Soda Ash / Sodium Bi

Indian Detergent Market Outlook

Indian Glass Market Outlook

Worldwide Soda Ash Scenario

A demand surge was observed during recent times in Container glass in

Detergent & Soap [CATEGORY NAME]

(viii) Employment Generation

On implementation of the proposed project around 1,200 nos. of suitably

Chapter 3: Project Description

(ii) Project Location

(A) 22o53’53.19’’N& 69o09’26.63”E

Figure 1: Project Location near Village Bada, District Kutch, Gujarat

Figure 2: Google Image Showing the Project Location

(iii) Details of Alternative Sites considered and basis of selecting the

Various criteria considered for exploring alternative project site are

Criteria for site selection:

 Availability of Land – Availability of Land to the required extent in a single

Figure 3: Location of alternative sites

Sr. Environmental & Pingleshwar Suthri Bambhdai Bada Modhva

Coordinates 1) 23°06’23.03”N 1) 22°59’41.12”N 1) 22° 56’3” N 1) 22°53'53.19"N 1) 22°47’06.02”N

1. Presence of ecologically sensitive areas/zone

Mangroves Scattered locally Nil Nil Nil Nil