ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS SOUTHERN PETROCHEMICAL INDUSTRIES CORPORATION LIMITED Pre-Feasibility Report Energy Reduction and Capacity Expansion by Modernization of Ammonia – urea plants at SPIC Nagar, Tuticorin District-628005, Tamil Nadu MARCH 2018 Southern Petrochemical Industries Corporation Limited 1 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS Contents 1 EXECUTIVE SUMMARY ............................................................................................................... 4 2 INTRODUCTION .......................................................................................................................... 5 2.1 BRIEF DESCRIPTION OF THE PROJECT ................................................................................................ 5 2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION .................................................................. 5 2.3 DEMAND SUPPLY GAP ........................................................................................................................ 6 2.4 EXPORT POSSIBILITY ......................................................................................................................... 6 2.5 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ......................................... 7 3 PROJECT DESCRIPTION ............................................................................................................ 8 3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY .......................... 8 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT) WITH COORDINATES ......................................................................................................... 8 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ........................ 11 3.4 TECHNOLOGY AND PROCESS DESCRIPTION ....................................................................................... 11 3.4.1 Salient Features of Technology ......................................................................................... 17 3.5 RAW MATERIALS ............................................................................................................................. 19 3.6 ADDITIVES AND CHEMICALS ............................................................................................................. 19 3.7 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. .................................... 19 3.7.1 Transportation details of Raw Materials ........................................................................... 19 3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 20 3.9 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL .................................................................................................................................................. 20 4 SITE ANALYSIS .......................................................................................................................... 22 4.1 CONNECTIVITY ................................................................................................................................ 22 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ................................................................................ 22 4.3 TOPOGRAPHY (ALONG WITH MAP) .................................................................................................... 23 4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ETC SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ...................................................................................................................................... 25 4.5 EXISTING INFRASTRUCTURE ............................................................................................................. 25 4.6 SOIL CLASSIFICATION ...................................................................................................................... 26 4.7 CLIMATIC DATA FROM SECONDARY SOURCES ..................................................................................... 27 4.7.1 Temperature ......................................................................................................................... 27 4.7.2 Wind ...................................................................................................................................... 27 4.7.3 Rainfall .................................................................................................................................. 28 4.7.4 Cloud Cover .......................................................................................................................... 28 2 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS 4.7.5 Humidity ................................................................................................................................ 28 4.8 SOCIAL INFRASTRUCTURE AVAILABLE ................................................................................................ 28 4.8.1 Assessment of Infrastructure Demand (Physical) ........................................................... 28 4.8.2 Assessment of Infrastructure Demand (Social) .............................................................. 28 5 PLANNING BRIEF ...................................................................................................................... 30 5.1 TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION ................................... 30 5.1.1 Population Projection .......................................................................................................... 30 5.2 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT, ETC) ..................................................... 31 5.2.1 Land Use and Availability ................................................................................................... 31 6 PROPOSED INFRASTRUCTURE .............................................................................................. 32 6.1 INDUSTRIAL AREA (PROCESSING AREA) ............................................................................................ 32 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) ................................................................................... 32 6.3 GREEN BELT .................................................................................................................................... 32 6.4 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ....................................................... 32 6.5 SEWAGE SYSTEM .............................................................................................................................. 32 6.6 INDUSTRIAL WASTE MANAGEMENT .................................................................................................... 32 6.7 POWER REQUIREMENT & SUPPLY/ SOURCE ........................................................................................ 33 7 REHABILITATION AND RESETTLEMENTS (R& R) PLAN ................................................. 34 7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) ......................... 34 8 PROJECT SCHEDULE AND COST ESTIMATE ....................................................................... 35 8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN) ................................................................................................................................ 35 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. 35 9 ANALYSIS OF PROPOSAL ........................................................................................................ 36 3 ENERGY REDUCTION AND CAPACITY EXPANSION BY MODERNIZATION OF AMMONIA – UREA PFR PLANTS 1 EXECUTIVE SUMMARY S. Item Details No. Energy Reduction and capacity expansion by 1 Name of the Project/s Modernization of Ammonia –Urea plants 2 S. No. in the Schedule 5(a), Chemical Fertilizers Ammonia Proposed capacity / area / length / tonnage to be 547500 MTPA 3 handled/ command area / lease area / no. of wells Urea (Neem Coated) 759200 MTPA to be drilled Carbon Di Oxide 684375 MTPA 4 New / Expansion / Modernization Expansion Ammonia 420000 MTPA 5 Existing Capacity / Area etc. Urea 620400 MTPA Carbon Di Oxide 642000 MTPA 6 Category of Project (A or B) “A” Does it attract the general conditions? If yes, please 7 No specify. Does it attract specific condition? If yes, please 8 No specify SPIC Nagar, Mullakadu Village, Thoothukudi Taluka, Location Tuticorin District, Tamilnadu Survey No: 426/2,428,429/3A,431/2, 432/2, Plot Survey / Khasra No. 433,434/2, 435/2A, 436/1, 439 etc 9 Village Mullakadu Tehsil / Taluka / Mandal Thoothukudi District