PROJECT PRE FEASIBILITY REPORT

On

Proposed Project

For
Manufacturing of Carbon Black

At
Survey No. 3705 to 3710, 3712, 3713, 3715, 3717, 3718, 3720,
3722 to 3724, 3726, 3727, 3730, 3733 to 3740, 3742, 3743, 4049,
4084 to 4090, 4095, 4105, 4107, 4108, 4110, 4112, 4133 to 4135,
4301, 4317, 5134, 5220 to 5222, 5226, 5227, 5236, 5264, Village:
Karanj, Taluka: Umbergaon
Dist.: Valsad, Gujarat

Project proponent

Madura Carbon India Ltd.

CONTENTS
Chapters
S. No. Particulars Page No.
1 EXECUTIVE SUMMARY 1-2
2 INTRODUCTION OF THE PROJECT 3-4
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 3
2.1.1 IDENTIFICATION OF THE PROJECT 3
2.1.2 PROJECT PROPONENT 3
2.1.3 NATURE OF THE PROJECT 3
2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP 4
2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION 4
2.1.6 EXPORT POSSIBILITY 4
2.1.7 DOMESTIC / EXPORT MARKETS 4
2.1.8 EMPLOYMENT GENERATION DUE TO PROPOSED PROJECT 4
3 PROJECT DISCRIPTION 5-16
3.1 TYPE & LOCATION OF PROJECT 5
3.1.1 TYPE 5
3.1.2 LOCATION 5
3.2 DETAILS OF ALTERNATIVE SITE 6
3.3 SIZE & MAGNITUDE OF OPERATION 6
3.4 PROJECT DISCRIPTION WITH PROCESS DETAILS 6
3.4.1 CARBON BLACK 6
3.4.1.1 PROCESS DESCRIPTION 6
3.4.1.2 PROCESS FLOW DIAGRAM 8
3.4.1.3 MATERIAL BALANCE 9
3.4.2 THERMAL POWER PLANT 9
3.4.2.1 PROCESS FLOW DIAGRAM 9
3.4.2.2 PROCESS DESCRIPTION 9
3.5 RAW MATERIAL FOR FINISHED PRODUCTS 10
3.6 STORAGE & TRANSPORT OF RAW MATERIAL 10
3.7 RESOURCE OPTIMIZATION & AVAILABILITY 10
3.7.1 LAND & BUILDING REQUIREMENT 10
3.7.2 EQUIPMENT 10
3.7.3 POWER REQUIREMENT 11
3.7.4 FUEL REQUIREMENT 11
3.7.5 WATER REQUIREMENT 11
3.7.6 MAN-POWER REQUIREMENT 12
3.8 QUANTITY OF WASTE TO BE GENERATED 12
3.8.1 WASTE WATER GENERATION & MANAGEMENT 12
3.8.1.1 WASTE WATER TREATMENT AND DISPOSAL 14
3.9 AIR EMISSIONS & CONTROL 14
3.9.1 PROCESS EMISSION 14
3.9.2 UTILITY EMISSION 14
3.9.3 FUGITIVE EMISSION 15
3.10 HAZARDOUS/NON-HAZARDOUS WASTES MANAGEMENT 15
3.11 NOISE CONTROL 15
3.12 HEALTH AND SAFETY MEASURES 16
3.13 ENVIRONMENTAL HEALTH & SAFETY CELL 16
4 SITE ANALYSIS 17-19
4.1 CONNECTIVITY 17
4.2 LAND FORM, LAND USE & LAND OWNERSHIP 17

i
S. No. Particulars Page No.
4.3 TOPOGRAPHY 17
4.4 SALIENT FEATURES 17
4.5 EXISTING INFRASTRUCTURE 17
4.6 SOIL CLASSIFICATION 17
4.7 CLIMATE & METEROLOGY 17
4.7.1 TEMPERATURE 18
4.7.2 HUMIDITY 18
4.7.3 RAINFALL 18
4.7.4 WIND PATTERN 18
4.8 SOCIAL INFRASTRUCTURE 19
4.8.1 EDUCATIONAL FACILITIES 19
4.8.2 MEDICAL FACILITIES 19
5 PLANNING BRIEF 20-21
5.1 PLANNING CONCEPT 20
5.2 DEMOGRAPHIC DETAILS 20
5.3 AREA STATEMENT 20
5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 20
5.5 AMENITIES/FACILITIES 20
5.5.1 DRINKING WATER FACILITIES 20
5.5.2 POWER SUPPLY FACILITIES 20
5.5.3 COMMUNICATION & BANKING FACILITIES 21
5.5.4 TRANSPORT FACILITIES 21
6 PROPOSED INFRASTRUCTURE 22-22
6.1 INDUSTRIAL AREA 22
6.2 RESIDENTIAL AREA 22
6.3 GREENBELT AREA 22
6.4 SOCIAL INFRASTRUCTURE 22
6.5 CONNECTIVITY 22
6.6 DRINKING WATER MANAGEMENT 22
6.7 SEWERAGE SYSTEM 22
6.8 INDUSTRIAL WASTE MANAGEMENT 22
6.9 SOLID WASTE MANAGEMENT 22
6.10 POWER REQUIREMENT & SOURCE OF SUPPLY 22
7 REHABILITATION & RESETTLEMENT ( R& R) PLAN 23-23
7.1 POLICY TO BE ADOPTED 23
8 PROJECT SCHEDULE & COST ESTIMATES 24-24
8.1 TIME SCHEDULE OF THE PROJECT 24
8.2 ESTIMATED PROJECT COST 24
9 ANALYSIS OF PROPOSAL 25-25
9.1 FINANCIAL & SOCIAL BENEFITS 25

ii
List of Tables
Table No. Topic Page No.
1.1 PROJECT SUMMARY 1
2.1 LIST OF PRODUCTS 3
2.2 LIST OF DIRECTORES 3
3.1 MATERIAL BALANCE FOR CARBON BLACK 9
3.2 LIST OF RAW MATERIALS 10
3.3 DETAILS OF STORAGE OF MATERIALS 10
3.4 LIST OF PROPOSED EQUIPMENT 11
3.5 TOTAL WATER CONSUMPTION (KL/DAY) 12
3.6 MAN-POWER REQUIREMENT 12
3.7 CATEGORY-WISE WASTEWATER GENERATION 12
3.8 ETP UNIT 14
3.9 DETAILS OF PROCESS VENTS 14
3.10 DETAILS OF UTILITY EMISSIONS 15
3.12 HAZARDOUS AND SOLID WASTE GENERATION, MANAGEMENT AND 15
DISPOSAL
4.1 SALIENT FEATURES OF THE PROJECT SITE 17
4.2 SUMMARY METEOROLOGICAL DATA AT NEAREST IMD STATION- 18
DAHANU
5.1 DISTRIBUTION OF POPULATION 20
5.2 AREA STATTEMENT CHART 21
8.1 TOTAL CAPITAL COST PROJECTION 24
8.2 RECURRING COST PROVISION FOR EHS 24

List of Figures
Sr. No. Description Page No.
3.1 SATELLITE IMAGE OF THE PROJECT SITE 5
3.2 WATER BALANCE DIAGRAM (KL/DAY) 13
3.3 ORGANOGRAM OF PROPOSED EHS CELL 16

iii
 Project Pre‐feasibility report

CHAPTER – 1
EXECUTIVE SUMMARY
The project is summarized in the below table:
Table 1.1: Project Summary
PARTICULARS DETAILS
Name of the unit M/s. Madura Carbon India Ltd.
Occupier Mr. Vipan Kalra (CMD)
Products S. No. Name of the Product Quantity
1. Carbon Black 230000 TPA
2. Thermal Power plant 45 MW
Location Survey no. 3705 to 3710, 3712, 3713, 3715, 3717, 3718, 3720, 3722 to 3724,
3726, 3727, 3730, 3733 to 3740, 3742, 3743, 4049, 4084 to 4090, 4095, 4105,
4107, 4108, 4110, 4112, 4133 to 4135, 4301, 4317, 5134, 5220 to 5222, 5226,
5227, 5236, 5264, Village: Karanj, Taluka: Umbergaon, Dist.: Valsad, Gujarat
Nature of Proposed project by manufacturing of Carbon Black (2,30,000 TPA) & Power
project Generation (45 MW)
RESOURCES
Resource type Requirement Source
Land 235239 m2 NA land
Water Total: 3220 kL/day (Fresh – 2890 Damanganga Canal Distry.
kL/day + Recycle – 330 kL/day)
 Domestic: 110 kL/day
 Gardening: 175 kL/day
 Industrial: 2935 kL/day
Power 13 MW TPP & DGVCL
Fuel CBFS (Carbon black feed stock)/ Imported
LDO/ Local market
POLLUTION POTENTIAL & MITIGATION MEASURES
Parameter Potential Mitigation
Wastewater Total: 347 kL/day  The total domestic wastewater
 Domestic: 100 kL/day generated will be 100 kL/day which
 Industrial: 247 kL/day will be treated in STP. Treated
water from STP will be used for
gardening.
 Wastewater generated from
industrial activities will be 247
kL/day, from which 30 kL/day will be
treated in ETP and the treated
wastewater will be recyled for plant
washing. Remaining water like
boiler blowdown, CT blowdown &
DM plant reject will be directed to
RO. Permeate from RO will be
recycled for plant uses.
 Reject from RO-1 & RO-2 @84
kL/day will be evaporated in MEE.
MEE condensate will be collected in
plant water tank, from where it will
be recycled for plant uses. Hence,
there will be no discharge of treated
effluent outside premises.
Air Emissions Emission from utility stack  The utility emissions are likely to
 Boiler – 92 TPH x 2 nos. occur from boiler, DG set & dryer due
to proposed project.

Project: Proposed project for manufacturing of Carbon Black 1|Page

 Project Pre‐feasibility report

PARTICULARS DETAILS
 Dryer – one no.  Mixed Gas/ Tail Gas from Carbon
 DG set – 1000 kVA x one no. Black Unit will be used as fuel in
boiler & dryer. LDO/ HSD will be used
as fuel in DG Set.
 Adequate chimney height will be
provided.
 Bag filter will be used as APCM
 Good housekeeping will be
maintained in the plant.
Hazardous & Sr. Type of Category Quantity  The Hazardous wastes will be
solid waste No Waste (T/Annum) handled, stored & transported as per
1 ETP 35.3 200 CPCB/ MoEF Guidelines
Sludge +
 ETP sludge will be disposed to TSDF
MEE Salt
2 Oily 28.1 2
site
Cotton  Oily cotton waste will be incinerated
Waste at CHWIF.
3 Spent 5.1 100  Spent used oil & Discarded bags will
used Oil be sold to registered re-processor..
4 Discarded 33.1 5
Bags
Noise Proposed operations  The major sources of noise
 Inside the plant: <85 dB(A) generation in plant area will be
equipment, boilers and pumps
 DG sets will be provided with
accoustic enclosure
 Regular maintenance will be carried
out.
 Ear plugs and Ear muffs will be
provided to the workers in Utility
Section
 Turbine will be equipped with sound
proof chamber.

Project: Proposed project for manufacturing of Carbon Black 2|Page

 Project Pre‐feasibility report

CHAPTER – 2
INTRODUCTION OF THE PROJECT
2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT

Madura Carbon India Limited, is to be located at survey no. 3705 to 3710, 3712, 3713, 3715, 3717,
3718, 3720, 3722 to 3724, 3726, 3727, 3730, 3733 to 3740, 3742, 3743, 4049, 4084 to 4090, 4095,
4105, 4107, 4108, 4110, 4112, 4133 to 4135, 4301, 4317, 5134, 5220 to 5222, 5226, 5227, 5236,
5264, Village: Karanj, Taluka: Umbergaon, Dist. Valsad.
The list of products is provided in table 2.1.
Table 2.1: List of Product
S. No. Name of the Product Quantity
1. Carbon Black 230000 TPA
2. Thermal Power Plant (TPP) 45 MW
2.1.2 PROJECT PROPONENT
The list of directors for Madura Industrial Textiles Ltd. is given below –
Table 2.2: List of Directors
S. No. Name of Directors Residential Address
1. Mr. Vipan Ramnath Kalra 21 A/ 21B, Royal Accord III, Lokhandwala Complex,
Andheri (W), Mumbai – 400 053
2. Mr. Anil Radheshyam Kalra 12 A/ 12B, Royal Accord III, Lokhandwala Complex,
Andheri (W), Mumbai – 400 053
3. Mr. Sanil Radheshyam Kalra 11 A/ 11B, Royal Accord III, Lokhandwala Complex,
Andheri (W), Mumbai – 400 053
4. Mrs. Promilla Raman Kalra 51, Royal Accord III, Lokhandwala Complex, Andheri (W),
Mumbai – 400 053
5. Mr. Gautam Kalra 21 A/ 21B, Royal Accord III, Lokhandwala Complex,
Andheri (W), Mumbai – 400 053
6. Mr. Rishi Kalra 51, Royal Accord III, Lokhandwala Complex, Andheri (W),
Mumbai – 400 053
7. Mr. Varun Kalra 12 A/ 12B, Royal Accord III, Lokhandwala Complex,
Andheri (W), Mumbai – 400 053
2.1.3 NATURE OF THE PROJECT
The proposed project falls under item no. 5(e) i.e. “Petroleum products and petrochemical based
processing such as production of carbon black and electrode grade graphite (processes other
than cracking and reformation and not covered under the complexes)”and under the category
A as it is not located in GIDC, as per the EIA notification, 14 September 2006 (& amendments).

Moreover, the project of power generation of 45 MW falls under item no. 1(d) i.e. Thermal Power
Plants and under the category B (<50 MW and  5 MW (all other fuels except biomass and municipal
solid non-hazardous waste) as per the EIA notification, 14 September 2006 (& amendments).

Project: Proposed project for manufacturing of Carbon Black 3|Page

 Project Pre‐feasibility report

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP

Carbon black is reinforcing material & filler in rubber products. There is severe crisis, due to lack of
availability of Carbon Black. Currently, the carbon black demand, including that of tyre manufacturers,
is at 12.85 lakh tonnes while the country’s manufacturing capacity is at 9.5 lakh tonnes.

Apparently the Carbon Black manufacturers were not aware that imposition of Anti-Dumping on
Chinese Tyres would create a huge spike in demand for Carbon Black. Further, global supply
constraints were causing increase in prices of Carbon Black.

Due to acute shortage and spiraling prices of Carbon Black in last months, all Rubber goods
manufacturers are struggling to maintain their production and supply.

The industry are in a dilemma, that there is a serious shortfall leading to non-availability of Carbon
Black, along with spiraling prices, and many of the small & medium industries are on the verge of
closing down. Hence, this project will bridge for demand & gap.

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION

At present the carbon black from international market is not available at competitive prices. Increase
in production can fill the gap.

2.1.6 EXPORT POSSIBILITY

The domestic production in the current scenario will have a competitive edge over the international
prices which will help in bridging the gap of demand and supply for export.

2.1.7 DOMESTIC / EXPORT MARKETS

The rubber industry is growing domestically fast. There has been no increase in capacity of carbon
black in last few years. The gap between demand and supply is increasing consistently.

2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT

The proposed project will provide direct employment opportunity to 385 persons. The man-power
required for the proposed project will be employed locally from the nearby areas.

Project: Proposed project for manufacturing of Carbon Black 4|Page

 Project Pre‐feasibility report

CHAPTER – 3
PROJECT DESCRIPTION
3.1 TYPE & LOCATION OF THE PROJECT

3.1.1 TYPE
The proposed project is the new project for manufacturing of Carbon Black @230000TPA along with
power generation @45 MW for utilization of the off-gas generated from the process.

3.1.2 LOCATION
The project is to be located at survey no. 3705 to 3710, 3712, 3713, 3715, 3717, 3718, 3720, 3722
to 3724, 3726, 3727, 3730, 3733 to 3740, 3742, 3743, 4049, 4084 to 4090, 4095, 4105, 4107, 4108,
4110, 4112, 4133 to 4135, 4301, 4317, 5134, 5220 to 5222, 5226, 5227, 5236, 5264, Village: Karanj,
Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest town to the project site is Sarigam.
Sarigam GIDC is a cluster of profuse large-scale, medium scale and small-scale industries, engaged
in manufacturing of various products, bulk drugs, organic pigments, Organic and Inorganic Chemicals,

The site is approximately 10-15 km from Vapi - a well-known industrial town. It is situated on the
banks of Damanganga River in southern Gujarat, India. The satellite image of the project site is
provided in figure 3.1 and the site layout plan of the project site in figure 3.2.

Figure 3.1: Satellite image of the project site

(Source: Google Earth)

Project: Proposed project for manufacturing of Carbon Black 5|Page

 Project Pre‐feasibility report

3.2 DETAILS OF THE ALTERNATIVE SITE

Many sites was opted for plant but due to non-availability of such large area in GIDC Sarigam and
due to vicinity of MCIL’s sister concern unit, the particular site is selected.
 Sister concern unit of Madura Carbon India Ltd. is close to the GIDC Sarigam.
 Due to Sarigam industrial area, required skilled man power will be available easily.
 Location of site is approximately 6 km from NH8, which is very suitable for transportation of
raw materials & finished products from proposed site.
Based on the above reasons, this location is most suitable for the proposed project.

3.3 SIZE & MAGNITUDE OF OPERATION

The proponent plans to establish a new project for manufacturing of carbon black 230000 T/annum
along with a Thermal Power Plant of 45 MW for utilization of the off-gas generated from the process.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

3.4.1 CARBON BLACK

3.4.1.1 PROCESS DESCRIPTION

In this project, oil furnace black process will be used for producing carbon black.
Heavy aromatic oils of petroleum oil refinery or coal tar distillation units are used as main feedstock.
The furnace is basically a specially designed refractory lined horizontal steel vessel having different
segments like combustion zone, venture zone, reaction zone, quench zone & evaporation cum
conveying sections.
Combustion zone or hot flue gas generating section: Secondary feed stock e.g., natural gas or
fuel oil or sometimes the main feed stock in proper ratio with preheated air is introduced in this section
to produce hot gas. Adiabatic flame Temperature is maintained nearly 1900oC-20000C.
Venture section: Preheated main feed stock (aromatic oil) is introduced in atomized form under
controlled conditions on the hot gas where liquid oil vaporizes. Velocity of gas stream maintained ~
2000 FPM.

Reaction section: Pyrolysis of oil takes place in the vapour phase to form microscopic carbon
particles. The basic reaction is dehydrogenation.

Hydrocarbon + Oxygen + Energy  Carbon Black + Carbon Monoxide + Hydrogen +Carbon

Dioxide + Water etc.

Quench zone: the reaction rate is controlled by using water sprays.

Evaporation cum conveying sections: Water vaporizes in this zone. After all, carbon particles along
with combustion gas convey to the next downstream equipment.

Furnace black process consists of several downstream sections after reactor e.g., Heat recovery
sections, filtration sections, conveying section, beading & drying sections and finished product
transportation & storage, ware housing, pulling & dispatch section. The process which is selected for
this project is illustrated bellow.

Heat recovery sections: Hot reactor combustion gas along with carbon black particles are cooled
down by air. Preheated air is used in combustion section of reactor. Relatively cooled combustion gas
along with carbon black again passes through oil preheater to preheat main feed stock. After passing

Project: Proposed project for manufacturing of Carbon Black 6|Page

 Project Pre‐feasibility report

through oil preheater, the combustion gas has sufficient sensible heat. In most of the energy efficient
carbon black plants have in line sensible heat recovery (waste heat recovery) boilers. Saturated
Steam is generated from waste heat recovery boilers which are used for steam tracing, & other
equipment heating purposes.

Main Filtration section: High filtration efficiency pulsejet bag filter modules (main filter) will be used
for filtering carbon black from carbon black laden gas (process gas). A specially designed
agglomerator unit will be installed before bag house to agglomerate carbon black particles. This
agglomerator unit will not only enhance filtration efficiency, it will also enhance life of the filter cloth.
Agglomerated carbon black particles will be deposited on the outer surface of the cloth and
compressed air pulse will release carbon black particles from bags. A sequential timer will be used in
pulsing system. Gas will pass through bags and finally it will be passed through a common header
which is connected to other downstream unit e.g., dryer combustor etc. Carbon black dislodge from
the bags will be collected in hopper. Accumulated carbon black powder will be transported to the
conveying system via rotary air locks.

Conveying system: It consists of drop box of rotary air locks, suction conveying ducts, conveying
fans, conveying fan discharge ducts, conveying bag filter, conveying bag filter vent scrubber & a
surge tank at the bottom of conveying bag house. All the rotary air locks placed at the bottom of main
bag filter modules will be discharging carbon black particles to a common duct which is connected
with a pneumatic conveying fan. In this process, air will be used for conveying carbon black. All
carbon black particles from the rotary air locks discharge will be picked up by air and conveyed to
another bag filter called conveying bag filter by conveying fans. Air from the bag filter can be vented to
atmosphere after passing through venture scrubber. Carbon black collected from bag filter will be
stored in surge tank to remove adsorbed air from carbon black.

Beading & drying system: The beading & drying system consists of pelletizer, polisher, rotary dryer
with insulated jacket and combustor as hot gas generator and purge gas filter. Fluffy carbon black,
water and molasses solution (used as binder) mixed in pelletizer to form beads. Polishers are also
used for making uniform diameter beads or pallets. This polisher also helps to reduce fines in carbon
black. After polishing the pallets, the wet pallets pass through indirect heating rotary dryer to remove
water from pallets. Hot gas required for drying is generated in refractory lined combustor. Process
combustion gas from main bag filter is used as fuel in combustor. Vapour generated inside dryer
along with fines is sucked by purge gas fan and filter through purge gas filter. Carbon black from
purge gas filter is connected in main conveying line and vapour is vented to atmosphere after passing
through venture scrubber.

Product transportation & storage: This section consists of elevator, screw conveyors magnetic
separator, rotary screen, storage silos, off spec silo & de dusting bag house. Dried carbon black is
transported to final storage silos by above mentioned material handling equipment.

Warehouse, pulling & dispatch section: Depending on customer requirement, the granular carbon
black is packed in 25 kg paper bag or in 1 m PP jumbo bulk bags.

Capacity & Conversion: The capacity of the reactor is mainly dependent on air rate and oil BMCI.
The reactor is designed for an air rate of 13500 nm3/hr. An output of 78 T/day/reactor for N-330 grade
will be produced based on 130 BMCI oil. The yield for N-330 grade will be 56% on total oil. The
production capacity & yield will be different for other grades.

Energy efficiency: The system will be designed to extract heat up to 80%. Approximately 7.5 T
steam/ton of carbon black will be generated. The major part of steam will be used for sale to other
process industry and some will be used for power generation at a later stage in co-generation system.
The power consumption for the process would be 350 KwH/T of carbon black.

Emission: The system would be designed to control particulate matter well within the GPCB & CPCB
norms, around 50-60 mg/Nm3. The stacks for gas emission would be designed for height and velocity

Project: Proposed project for manufacturing of Carbon Black 7|Page

 Project Pre‐feasibility report

to comply with the GPCB & CPCB laid norms to ensure minimum impact from NOx and SOx
emissions. The pollution control system will be designed to ensure zero discharge from the plant.

3.4.1.2 PROCESS FLOW DIAGRAM

Project: Proposed project for manufacturing of Carbon Black 8|Page

 Project Pre‐feasibility report

3.4.1.3 MATERIAL BALANCE

Table 3.1: Material balance for carbon black

S. No. Quantity(T/T) Remarks

Raw material Input/T of Output/T of Product
Product
1 Carbon Black Feed 1.71 Carbon black 1 --
Stock as raw material
2 CBFS / LDO as 0.15 Off gas 3.2647 Off gas will be
secondary fuel used for dryer
combustor and
boiler for power
plant
3 Molasses 0.0045 -- -- --
4 Potassium Nitrate 0.0002 -- -- --
5 Water 2.4 -- -- --
Total 4.2647 -- 4.2647 --

3.4.2 THERMAL POWER PLANT

3.4.2.1 PROCESS FLOW DIAGRAM

3.4.2.2 PROCESS DESCRIPTION

Low Btu off gases generated in the manufacturing process of CB in the reactor section and separated
from accompanying CB particles in PBC section are collected in the off gas header. In spite of their
low calorific value, these gases can be utilized to recover their calorific value in a specially designed
boiler system to generate high pressure steam and in a specially designed dryer combustor furnace to
supply the heat energy requirements in the pelletizing and drying section.
The quantum of high pressure steam which can be generated through burning of these off gases
meets the plant requirement of steam and power.
So the benefit of above scheme is being fully taken care of by installing the following system:
1. High pressure boiler system
2. Turbo Generators
3. Power Export
High pressure boiler which can be run on a combination of off gases generates high pressure
superheated steam at 88atm& 525OC. This high-pressure steam is used to generate sufficient power
required for plant consumption through turbo generator system.

Project: Proposed project for manufacturing of Carbon Black 9|Page

 Project Pre‐feasibility report

3.5 RAW MATERIAL FOR FINISHED PRODUCTS

The raw materials for the proposed range of products will be indigenously available and will be also
imported. The product-wise raw-material consumption is given in Table 3.1.
Table 3.2: List of Raw Materials
Name of product Raw material Requirement
(T/T of product)
Carbon Black Carbon Black Feed Stock as raw material 1.71
CBFS / secondary fuel 0.15
Molasses 0.0045
Potassium Nitrate 0.0002

3.6 STORAGE & TRANSPORT OF RAW MATERIAL

The details of storage and transportation of raw materials & products are given in Table 3.2 below:
Table 3.3: Details of storage of materials

Name Source Means of Means of Storage Max. Qty. to

transportation storage (No. Location be stored at
of containers any given
& size) time i.e.
storage
capacity
Product
Carbon Black -- Trucks Bulk Bag & Ware 3000 T
Paper Bag House
Raw Materials
Carbon Black Feed Import & Tankers 6 x 5000 kL Tank Farm 20000 kL
Stock as raw material Indian (Tanks)
Market 6 x 1250 kL
(Tanks)
Molasses Local Tankers 60 kL (1 Tank 60 kL
Tank)
Potassium Nitrate Local Truck 50 kg Bags In Store 3T

3.7 RESOURCE OPTIMIZATION & AVAILABILITY

The major resources for the proposed project will be plant & machinery, raw-materials, power, fuel,
water, man-power, etc.

3.7.1 Land & Building Requirement

Total plot area for proposed project will be 235239 m2. The letter of intent for proposed land is
obtained.

3.7.2 Equipment
Based on process necessity, list of the proposed equipment’s and machinery is given in table 3.3.

Project: Proposed project for manufacturing of Carbon Black 10 | P a g e

 Project Pre‐feasibility report

Table 3.4: List of Proposed Equipment

Sr. No. Equipment Capacity x Size
1 Oil Tank Storage and Unloading / Charging System (Day 6 Nos X 5000 kL + 6Nos
Tanks) X 1250 kL
2 Process Air Blowers 8 Nos.
3 Air Compressors (Normal & HP) 5 X 2 Nos.
4 KNO3 Dosing System 2 X 2 Nos.
5 Reactors 8 Nos.
6 Air Preheater 8 Nos.
7 Oil Preheater 8 Nos.
8 In-line Boiler 6 Nos. X 3 TPH
2 Nos. X 3.5 TPH
9 Quench Tower 4 Nos.
10 Agglomerator 4 Nos.
11 Process Bag Collectors 13 X 2 Modules
12 Pneumatic Conveying System 2 X 2 Nos.
13 Dense Tank Bag Collectors 4 X 2 Nos.
14 Dense (Surge) Tank 3 X 2 Nos.
15 Pelletizing System 4 Nos.
16 Dryer System along with Vapor Bag Collectors 2 Nos. X 240 TPD
17 Dryer System along with Vapor Bag Collectors 2 Nos. X 180 TPD
18 Fugitive Dedusting bag filter Systems Lot
19 Elevator 4 Nos.
20 Screw Conveyors & Product Distribution System Bulk
21 Product Silos 2 X 14 Nos. X 150 T
22 Packing Machines with Rerun System including Palletizer Lot
23 Water pumps & Storage Tanks Lot
24 Electrical Distribution System Lot
25 Instrumentation System Lot
26 Civil, Structure, Warehouse, Non-Plant Building & Roads Lot
27 Piping System Lot
28 Fire Fighting System Lot
29 Cooling tower 2400 m3/day
30 Power Plant with Tail Gas Boiler & Air Cooled Condensers 2 X 16 MW + 2 X 6.5 MW
Boiler (2 Nos. X 92 TPH)
31 Reject silos 2 X 2 Nos.
3.7.3 Power Requirement
For proposed project 13 MW power will be required. The total requirement will be fulfilled by in-house
TPP & Dakshin Gujarat Vij Co. Ltd. (DGVCL).

3.7.4 Fuel Requirement

LDO /FO/CBFS will be used as auxiliary fuel for startup in boilers & dryer. HSD will be used as fuel in
D.G. Set. CBFS will be Imported & sourced from Indian Market also. LDO, HSD & FO sources from
local market. Tail gas will be generated during carbon black manufacturing process.
3.7.5 Water Requirement
Necessary water requirement for the proposed project will be fulfilled from Damanganga Canal Distry.
Total water requirement for proposed project will be 3220 kL/day. From which 2890 kL/day will be
fresh water & remaining 330 kL/day will be recycled water
The category wise bifurcation of the water requirement is given in the Water Balance Data in Table
3.5.

Project: Proposed project for manufacturing of Carbon Black 11 | P a g e

 Project Pre‐feasibility report

Table 3.5: Total Water Consumption (kL/day)

S. No. Particulars Requirement (kL/day)

Fresh Recycle Total
1. Domestic 0 110 110
2. Gardening 0 175 175
3. Industrial
4. Process 1500 0 1500
5. Cooling Tower (Make-up) 84 16 100
6. Boiler (Make-up) 220 0 220
7. DM plant Regeneration 16 0 16
8. Plant Washing 1 29 30
9. Dryer 1040 0 1040
10. RO Reject 29 0 29
Sub-Total: Industrial 2890 45 2935
Grand Total 2890 330 3220

3.7.6 Man-Power Requirement

The man-power required for the project will be employed locally from the nearby areas. Skilled as well
as unskilled labor will be employed for the project. Due to proposed project, 385 persons will be
employed. The man-power requirement for the proposed expansion project is provided in table 3.6.
Table 3.6: Man-power requirement
S. No. Types of Employee Numbers of
Manpower
1 Managerial 15
2 Supervisory 60
3 Skilled 100
4 Unskilled 160
5 Others 50
Total 385
3.8 QUANTITY OF WASTE TO BE GENERATED

3.8.1 WASTE WATER GENERATION & MANAGEMENT

The category wise bifurcation of the wastewater generation is given in table 3.7.
Table 3.7: Category-wise Wastewater Generation
Particulars Wastewater Generation (in kl/day)
Domestic 100
Industrial
Process 0
Cooling tower blow down 60
Plant Washing 30
Boiler blow down 107
DM plant Regeneration 16
RO Reject 34
Sub – Total: Industrial 247
Grand Total 347

Project: Proposed project for manufacturing of Carbon Black 12 | P a g e

 Project Pre‐feasibility report

Figure 3.2: Water Balance Diagram (kL/day)

Project: Proposed project for manufacturing of Carbon Black 13 | P a g e

 Project Pre‐feasibility report

3.8.1.1 WASTE WATER TREATMENT AND DISPOSAL

The total domestic wastewater generated will be 100 kL/day which will be treated in STP. Treated
water from STP will be used for gardening.
Industrial waste water is Categorized in two section as following:
1. Effluent from Plant wash: It is further sub categorized in two section which are:
i) Effluent containing free floating oil particles from tank farm & reactor section of plant passes
through Oil Skimmer to reduce the oil content and then passes through Pressure sand bed
filter before being recycled back either for plant wash.
ii) Effluent containing Suspended carbon black particle from Bag filter, Silo & Packing area
passes through Pressure sand bed filter before being recycled back for plant wash.

2. Effluent from DM Unit, boiler & CT blowdown: Boiler blowdown, CT blowdown & DM plant reject
will be directed to Neutralization cum collection pit before being sent to RO. Permeate from RO will
be recycled back for plant uses

3. Reject from RO-1 & RO-2: Reject from RO-1 & RO-2 will be directed to MEE for evaporation.
Recovered condensate will be recycled back for plant uses.
Table 3.8: ETP units
Sr. No. Unit Quantity Capacity
(Nos.)
1 Oil & Grease Trap 1 30 kL/day
2 Collection cum Neutralization Tank 1 100 kL/day
3 Multi Effect Evaporator 1 100 kL/day

3.9 AIR EMISSION AND CONTROL

3.9.1 PROCESS EMISSIONS

The details of process vents are provided in table 3.10.
Table 3.9: Details of process vents

Sr. No Stack attached No of Height Emissions Air Pollution

to Stack (m) Control Measures
Attached
1 Process Bag 4 35 Normally closed Stack (Normally
Collector closed)
2 Dense Bag 4 35 PM Bag Filter/Adequate
collector stack Height
3 Vapor Bag 4 35 PM, SO2, NOx (as Bag Filter /Adequate
collector NO2) stack Height
3.9.2 UTILITY EMISSIONS
The details of utility stacks are provided in table 3.11.

Project: Proposed project for manufacturing of Carbon Black 14 | P a g e

 Project Pre‐feasibility report

Table 3.10: Details of utility emissions

Sr. Locations Fuel Stack Emissions
No Height
1 Boiler – 2 nos. Mixed Gas/ Tail 100 m PM, SO2, NOx
Capacity: 92 TPH Gas from CB Unit/
Fuel Oil
2 DG Set - stand by – one LDO /HSD 35 m PM, SO2, NOx
no.
Capacity: 1000 kVA
3 Dryer – 4 nos. Mixed Gas/ Tail Common PM, SO2, NOx
Gas from CB Unit / stack -2 nos.
Fuel Oil 60 m (each)
3.9.3 FUGITIVE EMISSIONS
The fugitive emissions are likely to occur from following sources:
 Equipment leaks like pumps, pipelines, reactors etc.
 Process venting
 Evaporation losses
 Accident and equipment failures
Following measures will be adopted to control fugitive emissions:
 All vessels used in the manufacturing areas shall be closed and the transfer of material within
the plant shall be through pipelines.
 A Leak detection and repair (LDAR) will be prepared and implement.
 Pumps will have double mechanical seal to prevent any chance of emission.
 Detectors will be installed near all potential sources of leakage to detect and provide alarm in
case of any leakage.

3.10 HAZARDOUS AND NON-HAZARDOUS WASTE MANAGEMENT

The detail of the hazardous waste and its management is given below in table 3.12.
Table 3.12: Hazardous and Solid waste generation, management and disposal
Sr. No Type of Waste Category Quantity Disposal
(T/Annum)
1 ETP Sludge+ MEE Salt 35.3 200 Disposal at TDSF
2 Oily Cotton Waste 28.1 2 Incineration at CHWIF
3 Spent used Oil 5.1 100 Sale to reprocessor
4 Discarded Bags 33.1 5 Sale to reprocessor

3.11 NOISE CONTROL

Noise are likely to generate in the process area mainly from operation of heavy duty motors, blowers
and compressors in various sections of the manufacturing plant area. The compressors and blowers’
operation in utility area also result in high noise generation viz. above 85 dB (A). Due to power plant
operations, noise pollution is arising from turbine, compressor, generator room, etc. Also there will no
generation of noise from soot blowing. The control measures to be taken for reduction in noise levels
are as below:
 The plant and equipment will be specified and designed with a view to minimize noise
pollution.
 The major noise producing equipment such as turbine will be provided with acoustic
enclosure.
 Sturdy foundation & pads to all the noise generating equipment will be provided.
 Ear Plugs and Ear muffs will be provided to the workers in Utility Section.

Project: Proposed project for manufacturing of Carbon Black 15 | P a g e

 Project Pre‐feasibility report

 Regular maintenance of equipment’s will be carried out to minimize the noise generated by
the equipment’s.
 Regular monitoring of noise levels at all areas will be carried out.
 Greenbelt will be maintained.

3.12 HEALTH AND SAFETY MEASURES

In proposed operations, following safety measures to be implemented:
 Fire hydrant system will be provided.
 Automatic hydrant sprinkler system will be provided.
 Fire extinguishers of proper type & size will be placed in complete plant as per rules &
regulations.
 All other area of the plant will be fully ventilated for human comfort.
 First Aid facility will be provided at all the necessary locations.
 Personal protective gears and equipment’s will be provided to the employees.
 Health check-ups will be organized at regular intervals.
 Safety Training will be provided to the employees timely.
 Manual call bells in case of emergency will be provided.
 Emergency Control Room with emergency sirens will be established.
3.13 ENVIRONMENTAL HEALTH & SAFETY CELL
The environment cell will also be responsible to plan, implement and monitor the environmental
performance of the proposed project.
Figure 3.3: Organogram of proposed EHS Cell

Project: Proposed project for manufacturing of Carbon Black 16 | P a g e

 Project Pre‐feasibility report

CHAPTER – 4

SITE ANALYSIS
4.1 CONNECTIVITY
The proposed project is located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The
nearest town to the project site is Sarigam which is situated at about 2.59 kms from project site. The
site is approximately 6.1 km from National Highway. The land and infrastructure is already available
and the raw material is easily available through the easy transport via road connectivity. The nearest
Railway station is Bhilad railway station which is approximately 5.85 km from the project site.
4.2 LANDFORM, LAND USE & LAND OWNERSHIP
The land is currently vacant land purchased from private owners. The total land area is 235239 m2.
4.3 TOPOGRAPHY
The topography of land is flat.
4.4 SALIENT FEATURES
Table 4.1: Salient Features of the Project Site
S. No. Particulars Details
1 Village Karanj
2 Taluka/ Tehsil Umbergaon
3 District Valsad
4 Nearest Town Sarigam ≈ 2.59 km (SE)
5 Approx. Geographical positioning Lat.: 20°18'7.41"N, Long: 72°50'20.66"E
6 Nearest Water body River Damanganga ≈ 6.66 km. (NE)
River Darotha ≈ 5.00 km (E)
7 Nearest Highway N.H. 8 ≈ 6.1 km (E)
8 Nearest Railway line/ Railway station Bhilad≈ 5.85 km (SE)
9 Nearest Airport/ Airbase Airport - Daman ≈ 14.5 km (N)
10 Reserved Forests Patches of RF within 10 km radial periphery of
project site.
11 Protected Areas/ Sanctuaries No
12 State/ International boundary UT of Daman & Diu ≈ 7.65 km (NE)
13 Defense installations No
14 CRZ applicability No
15 Seismicity Seismic Zone-III (Moderate)
Note: All the above mentioned distances are the aerial distance from the project site

4.5 EXISTING INFRASTRUCTURE

Well-developed infrastructure is available around the site.
4.6 SOIL CLASSIFICATION
About 60% of the Umbergaon taluka is covered by Ustropepts, of which Calcarious Typic Ustropepts
soil is predominant. Typic Chromusterts with small amount of Vertic Ustropepts are the other soil
types found in Umbergaon taluka along.

4.7 CLIMATE& METEROLOGY

The year can be divided into four seasons. Climate is warm and dry from mid-March to June, during
season of summer, climate remains warm and dry, while during rainy season, from mid-June to end of

Project: Proposed project for manufacturing of Carbon Black 17 | P a g e

 Project Pre‐feasibility report

September, climate is humid and pleasant. From October to November mild warm climate prevails,
and from December to February climate is cold.
The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of IMD,
Dahanu published by IMD.
Table 4.2: Summary Meteorological Data at nearest IMD Station –Dahanu
Location: In the compound of Old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o
58’, Long: E 72o 43’)
Aerial Dist from Project Site: Approx.40.48 km (SSW)
Height of installation: 11m above MSL,
Month Temperature Relative Cloud Mean Pre- Rainfall (mm)
(oC) Humidity Cover Wind dominant
(%) (Oktas) Speed Wind
Max. Min. Mor. Eve. Max. Min. (m/s) Direction
January 27.7 16.5 67 69 1.3 1.1 11.3 N 0.2
February 28.3 17.4 66 69 1.1 0.8 11.7 N 0.2
March 30.3 20.7 68 67 1.4 1.1 12.9 N 0.1
April 32.2 24.0 74 69 2.1 1.4 13.7 W 0.1
May 33.1 26.8 77 73 3.8 2.3 15.5 W 5.2
June 32.2 26.3 85 80 6.1 5.6 17.7 SW 522.1
July 30.1 25.0 89 84 7.1 6.8 22.6 SW 771.7
August 29.5 24.7 88 83 6.9 6.7 22.6 W 502.3
September 30.0 24.0 87 79 5.4 4.9 14.6 W 319.1
October 32.1 23.1 77 72 2.8 2.4 10.0 E 44.4
November 32.1 20.5 67 71 1.9 1.9 9.4 N 17.1
December 29.8 18.0 67 71 1.6 1.5 10.0 N 0.3
(Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)

4.7.1 TEMPERATURE
The summer season from March to May is a one of continuous increase in temperatures which
decreases during monsoons, increases slightly during the post-monsoon season and again
decreases during the winter.May is generally the hottest month with the mean daily maximum
temperature recorded at 33.1 oC and mean daily minimum temperature recorded at 26.8oC. January is
the coldest month with the mean daily maximum temperature as 27.7 oC and mean daily minimum
temperature observed as 16.5 oC.

4.7.2 HUMIDITY
The climate of the region is characterized by a humid summer because of the closeness to coastline.
Humidity is usually high during the monsoon months, with average relative humidity generally
exceeding 80%. Humidity decreases gradually during the post-monsoon months and for rest of the
year i.e. the period of December to April, the average relative humidity ranges around 50-70%.

4.7.3 RAINFALL
About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to
September, July being the month with highest rainfall. The total annual rainfall observed from the
historical data of year 1951-1980 is 2182 mm.

4.7.4 WIND PATTERN

The annual resultant vector for wind direction shows winds blowing from WSW. During summers and
monsoon, the winds blow mostly from the sea i.e. the SW or WSW direction. The post-monsoon &
winter seasons experience a change in direction, with the winds blowing from NE, ENE or NNE. The

Project: Proposed project for manufacturing of Carbon Black 18 | P a g e

 Project Pre‐feasibility report

wind speed is high during monsoon and post monsoon seasons, slightly moderate during summer
and winter seasons.

4.8 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well-being of the region. There
are about 43 villages and 7 Towns in the Umbergaoun Taluka.

4.8.1 EDUCATIONAL FACILITIES

As per census of India, 113 Primary school, 0 Middle School, 13 Secondary School, 6 senior
secondary school and 0 Training institute were found in 43 villages. The female literacy rate is 59%.

4.8.2 MEDICAL FACILITIES

Out of the 43 villages, There is no hospital in villages, There is no Dispensary in villages, Primary
health centers in 6 villages and Primary health sub center in 39 villages.

Project: Proposed project for manufacturing of Carbon Black 19 | P a g e

 Project Pre‐feasibility report

CHAPTER – 5
PLANNING BRIEF
5.1 PLANNING CONCEPT

The project is to be located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest
town to the project site is Sarigam which is situated at about 2.59 kms from project site. The region is
well planned with all the basic infrastructural facilities like internal roads, water supply, arrangements
for power, streetlights, solid waste disposal sites etc.

5.2 DEMOGRAPHIC DETAILS

The average household size is around 4 to 5.

Table 5.1: Distribution of population

Sr. Particulars Observed values in

No. Umbergaoun Taluka
1 Total Population 522408
2 No. of Households 109628
3 Avg. household size (persons) 5
4 Male population 270118
5 Male population (in %) 51.7%
6 Female population 252290
7 Female population (in %) 48.3
8 Sex ratio 934
(Source: Primary Census Abstract – Census of India, 2011)

5.3 AREA STATEMENT

The proposed project will be established in an area of approx. 235239 m2. The establishment will
include required buildings for manufacturing facilities, utilities including additional ETP, admin building
and internal roads for proper movement. A thick greenbelt will be developed around the periphery of
the plant area.

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

In this proposed project the company will acquire plant and machinery so there will be some demand
of change in physical infrastructure and social infrastructure. As manpower requirement for the
proposed project shall be fulfilled locally, employment generation will lead to additional benefits to
social infrastructure.

5.5 AMENITIES/ FACILITIES

5.5.1 DRINKING WATER FACILITIES

Tap water is available in 34 villages as per the Census 2011. 8 had Wells, 16 villages had tanks and
all vilages had hand pumps. 31 Villages had River passing. Power supply was also available in all the
villages.

5.5.2 POWER SUPPLY FACILITIES

As per census 2011, all the villages have power supply facilities in the study region.

Project: Proposed project for manufacturing of Carbon Black 20 | P a g e

 Project Pre‐feasibility report

5.5.3 COMMUNICATION & BANKING FACILITIES

Communication facilities like Post and telegraph, telephones exist in almost all the villages as per the
2011 census.

5.5.4 TRANSPORT FACILITIES

Bus service is available in the study region. The villages are well connected with the State Highways.
National Highway-8 also passes from Bhilad. The Western railway line between Bombay to
Ahmedabad passes from the study region and Bhilad Town has a railway station on the same.

Project: Proposed project for manufacturing of Carbon Black 21 | P a g e

 Project Pre‐feasibility report

CHAPTER – 6

PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA

The total area of the land will be 235239 m2.

6.2 RESIDENTIAL AREA

In the said proposal, temporary residence will be provided to no proposed construction workers.

6.3 GREENBELT AREA

Maximum open land will be allotted for green belt development. If required, experts will also be
consulted for selection of species for the development of the greenbelt.
6.4 SOCIAL INFRASTRUCTURE

6.5 CONNECTIVITY
The proposed project is located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The
nearest town to the project site is Sarigam which is situated at about 2.59 kms from project site. The
site is approximately 6.1 km from National Highway. The land and infrastructure is already available
and the raw material is easily available through the easy transport via road connectivity. The nearest
Railway station is Bhilad railway station which is approximately 5.85 km from the project site.
6.6 DRINKING WATER MANAGEMENT
The fresh water to be sourced from Damanganga Canal Distributory. Adequate treatment will be
provided to source water before use.
6.7 SEWARAGE SYSTEM
From proposed operation, the domestic waste water generated @100 kl/day will be treated in STP.
6.8 INDUSTRIAL WASTE MANAGEMENT
Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained in
Chapter 03, Section 3.8.1.
6.9 SOLID WASTE MANAGEMENT
Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant, Used oil
from gear boxes of the machineries, Used Containers/ Bags/ Carboys from storage of raw materials.
Adequate storage area for proper storage of wastes will be provided. Details of solid waste generation
are given in table 3.11.
6.10 POWER REQUIREMENT & SOURCE OF SUPPLY
The power requirement for the proposed project will be 13 MW which will be sourced from Captive
Power Plant / Dakshin Gujarat Electricity Board.

Project: Proposed project for manufacturing of Carbon Black 22 | P a g e

 Project Pre‐feasibility report

CHAPTER – 7

REHABILITATION & RESETTLEMENT (R&R) PLAN

7.1 POLICY TO BE ADOPTED
The proposed project is to be established in NA land. Hence, no displacement of any population is
required for the proposed project. Therefore, detailed Social Impact Assessment studies or R&R
action study has not been proposed.

Project: Proposed project for manufacturing of Carbon Black 23 | P a g e

 Project Pre‐feasibility report

CHAPTER – 8
PROJECT SCHEDULE & COST ESTIMATES
8.1 TIME SCHEDULE OF THE PROJECT
The installation/ construction will be started after getting approval for Environmental Clearance and
NOC from authorities.
8.2 ESTIMATED PROJECT COST
The approx. capital cost for proposed project will be 415 Cr. (in INR). The bifurcation is as below

Table 8.1: Total Capital Cost Projection

Sr. No. Purpose Capital Cost in Crore
(INR)
1. Land 20
2. Building 35
3. Plant & Machinery 325
4 Electrification and Administrative set-up 25
5. Safety instruments 5
6. Chartered services/ Government fees 5
TOTAL 415

Table 8.2: Recurring cost provision for EHS

Sr. Purpose Recurring Cost
No. (Lakhs per annum)
1. ETP operations (chemicals/electricity/manpower) 50
2. Air pollution control device 4
3. Fees for Common disposal facilities 20
4. Env. Monitoring expenses 20
5. Safety instruments maintenance 20
6. Environment & safety training 10
7. Chartered services/ Government fees 10
8. Green belt maintenance 10
9. Corporate Environment Responsibility (@1.5% of capital cost) 622.5
10. Medical surveillance 10
TOTAL 776.5

Project: Proposed project for manufacturing of Carbon Black 24 | P a g e

 Project Pre‐feasibility report

CHAPTER – 9
ANALYSIS OF PROPOSAL
9.1 FINANCIAL & SOCIAL BENEFITS
The project benefits from proposed project are as below -
 Large demand of carbon black due to serious shortfall in domestic market & increased prices,
many small & medium scale rubber industries are closing down. The new project will bridge
the gap between demand & supply.
 There will be reduction in the total load on the electricity department due to power generation
from waste gas.
 Considerable employment & trade opportunities in India.
 Considerable benefit to public infrastructure of this region.
 The company will carry out the social development activities in surrounding area.

Project: Proposed project for manufacturing of Carbon Black 25 | P a g e