Prefeasibility Report Veritas Polychem Private Limited

Pre-Feasibility Report

Of
Proposed establishment of Integrated Project consisting of Poly vinyl
Chloride (PVC) Plant, Polymer modified bitumen (PMB) Plant, Gas
Storage Terminal, LPG Bottling Plant, Gas Based Captive Power Plant,
Sea Water Desalination Plant (RO process) for captive consumption
by Veritas Polychem Private Limited

Activity 5(e) – Category A

Prepared By

Veritas Polychem Private Limited

Corporate office: Veritas House, 70 Mint Road,
Fort, Mumbai 400 001
Maharashtra, India

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 Prefeasibility Report Veritas Polychem Private Limited

Table of Contents
1 EXECUTIVE SUMMARY ............................................................................................................ 5
2 INTRODUCTION OF THE PROJECT ...................................................................................... 9
IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ....................................................... 9
BRIEF DESCRIPTION OF NATURE OF THE PROJECT ........................................................................... 9
NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION ..................... 9
Poly Vinyl Chloride (PVC) .......................................................................................................... 9
Polymer Modifed Bitumen (PMB) .......................................................................................... 9
Gas storage tank farm and bottling unit ......................................................................... 10
DEMAND – SUPPLY GAP .................................................................................................................... 10
Poly Vinyl Chloride (PVC) ....................................................................................................... 11
PVC India Production Demand in MMT ........................................................................... 12
Vinyl Chloride Monomer (VCM)........................................................................................... 15
Why India for PVC plant? ....................................................................................................... 15
2.4.4.1 Water Conservation ........................................................................................................ 15
Polymer Modified Bitumen (PMB) ..................................................................................... 16
Liquefied Petroleum Gas (LPG)............................................................................................ 19
2.4.6.1 Description of the LPG Market: ................................................................................... 19
IMPORTS VS INDIGENOUS PRODUCTION ........................................................................................... 21
EXPORT POSSIBILITY ......................................................................................................................... 22
DOMESTIC / EXPORT MARKET ......................................................................................................... 22
EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ............................. 22
3 PROJECT DESCRIPTION ........................................................................................................ 23
TYPE OF PROJECT .............................................................................................................................. 23
LOCATION ........................................................................................................................................... 23
DETAILS OF ALTERNATIVE SITES ..................................................................................................... 24
SIZE OR MAGNITUDE OF OPERATION ................................................................................................ 26
PROJECT DESCRIPTION WITH PROJECT DETAILS ............................................................................. 26
PVC Plant ....................................................................................................................................... 26
3.5.1.1 Basic structure of PVC .................................................................................................... 27
3.5.1.2 PVC Process Technology Review ............................................................................... 27
3.5.1.3 Product applications of PVC ......................................................................................... 28
3.5.1.4 Product PVC ........................................................................................................................ 28
3.5.1.5 Installed production capacity ...................................................................................... 28
3.5.1.6 PVC Plant Process Description .................................................................................... 28
3.5.1.7 VCM unloading, storage and feeding system ......................................................... 28
3.5.1.8 VCM Pipeline transfer facilities................................................................................... 29
3.5.1.9 Receipt and storage facility at Gas Storage Terminal ......................................... 30
3.5.1.10 Preparation and charging of demineralized water ......................................... 31
3.5.1.11 Preparation and feeding of additive agents ....................................................... 31
3.5.1.12 Polymerization .............................................................................................................. 31
3.5.1.13 Shortstop (Terminator) system .............................................................................. 32
3.5.1.14 Vacuum system ............................................................................................................. 32
3.5.1.15 VCM Recovery system ................................................................................................ 32
3.5.1.16 PVC slurry stripping .................................................................................................... 32

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 Prefeasibility Report Veritas Polychem Private Limited

3.5.1.17 PVC centrifuge and drying ........................................................................................ 32

3.5.1.18 PVC Packaging and product warehouse .............................................................. 32
3.5.1.19 PVC dispatch................................................................................................................... 32
3.5.1.20 Process Flow Diagram ................................................................................................ 33
3.5.1.21 Technology Licensor – INEOS Technologies...................................................... 33
PMB Plant ..................................................................................................................................... 35
3.5.2.1 Design basis ........................................................................................................................ 35
3.5.2.2 Process Description ......................................................................................................... 36
3.5.2.3 Process Flow Diagram .................................................................................................... 39
Utilities ........................................................................................................................................... 39
Gas Storage terminal and bottling unit ........................................................................... 40
3.5.4.1 Design basis ........................................................................................................................ 40
3.5.4.2 Process Description ......................................................................................................... 40
Gas based Captive power plant............................................................................................ 43
3.5.5.1 Waste Heat recovery Boilers ....................................................................................... 43
3.5.5.2 Fuel supply source and quantity ................................................................................ 43
3.5.5.3 Regasification of LNG ...................................................................................................... 44
Utility Plants ................................................................................................................................ 44
3.5.6.1 Cooling Water System .................................................................................................... 44
3.5.6.2 Sea Water Desalination Plant ...................................................................................... 45
3.5.6.3 Demineralization (DM) Water Plant ......................................................................... 45
3.5.6.4 Compressed Air System ................................................................................................. 45
3.5.6.5 Nitrogen generation system......................................................................................... 46
RAW MATERIAL REQUIRED ............................................................................................................... 46
Manpower ..................................................................................................................................... 47
RESOURCE OPTIMIZATION................................................................................................................. 47
WATER, ENERGY / POWER AVAILABILITY AND SOURCE ............................................................... 48
Water .............................................................................................................................................. 48
Energy............................................................................................................................................. 48
Power .............................................................................................................................................. 48
WASTE GENERATION, MANAGEMENT AND DISPOSAL .................................................................... 49
Industrial Waste water ........................................................................................................... 49
Solid waste – const .................................................................................................................... 49
Non hazardous waste .............................................................................................................. 49
Hazardous waste ....................................................................................................................... 49
4 SITE ANALYSIS......................................................................................................................... 51
CONNECTIVITY ................................................................................................................................... 51
LAND FORM, LAND USE AND LAND OWNERSHIP ............................................................................. 51
TOPOGRAPHY (ALONG WITH MAP) .................................................................................................. 51
EXISTING LAND USE PATTERN .......................................................................................................... 51
EXISTING INFRASTRUCTURE ............................................................................................................. 52
SOIL CLASSIFICATION......................................................................................................................... 52
CLIMATE DATA FROM SECONDARY SOURCES ................................................................................... 55
SOCIAL INFRASTRUCTURE AVAILABLE ............................................................................................. 57
5 PLANNING BRIEF .................................................................................................................... 58
PLANNING CONCEPT.......................................................................................................................... 58
POPULATION PROJECTION ................................................................................................................ 58

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LAND USE PLANNING ......................................................................................................................... 58

ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ...................................... 59
AMENITIES / FACILITIES ................................................................................................................... 59
6 PROPOSED INFRASTRUCTURE .......................................................................................... 60
INDUSTRIAL AREA (PROCESSING AREA) ......................................................................................... 60
RESIDENTIAL AREA (NON-PROCESSING AREA) ............................................................................... 60
GREEN BELT ....................................................................................................................................... 60
SOCIAL INFRASTRUCTURE ................................................................................................................. 60
CONNECTIVITY ................................................................................................................................... 60
DRINKING WATER MANAGEMENT .................................................................................................... 60
SEWERAGE SYSTEM ........................................................................................................................... 60
Sewage Treatment Plant (STP) ........................................................................................... 60
INDUSTRIAL WASTE MANAGEMENT ................................................................................................. 61
SOLID WASTE MANAGEMENT ............................................................................................................ 61
POWER REQUIREMENT AND SUPPLY / SOURCE ............................................................................... 61
7 REHABILITATION & RESETTLEMENT PLAN ................................................................. 62
8 PROJECT SCHEDULE AND COST ESTIMATES ................................................................. 63
LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION ......................... 63
ESTIMATED PROJECT COST ................................................................................................................ 63
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION)................................... 64

List of Annexures
Annexure No Description
I Land ownership documents
II GPS location on google map.
III Proposed plot layout
IV Topography map of 10 km radius
V Waste water treatment scheme

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 Prefeasibility Report Veritas Polychem Private Limited

1 EXECUTIVE SUMMARY

GROUPE VERITAS (GV), a diversified multinational business group with business

interests in the following domains:
➢ International Trade, Distribution & Manufacturing
➢ Infrastructure & Logistics
➢ Alternate Fuel & Energy
➢ Agro Ventures & Biotechnology
➢ Information Technology

The various verticals under each Business Domain are depicted below:

The promoters of GV, a third-generation business family, have more than two decades of
experience in International Trade and Distribution. GV, with a customer base in excess of
30,000 is the preferred customer/supply chain partner for most of the top principals and
customers around the world due to:
✓ Global reach with offices across the world
✓ Extensive knowledgebase from research and experience
✓ A one-stop-shop for basket of products and services
✓ Adaptation of technology to improve transparency and efficiency
✓ Stakeholders being the #1 priority

GV, with Group-wide revenues in excess of US$ 4 Billion, is driven by its 900+
motivated associates and team members operating out of its 18 offices in India and 16
international offices and is ably supported by globally integrated systems and processes,
highly evolved corporate governance, and state-of-the-art logistics infrastructure across
India and the Globe. GV handles millions of tons of product across its different business
verticals, with distribution in India and the Middle East being the most prominent
markets.
VIL, a public listed entity and a key group company of GV, is primarily engaged in the
business of International Trade & Distribution and Infrastructure & Logistics with
specialization in International Trade & Distribution of Chemicals, Petrochemicals,

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 Prefeasibility Report Veritas Polychem Private Limited

Petroleum products, Polymers, Metals & Minerals, Paper & Paper Boards, Rubber,
Fertilizers, and Agro Commodities.
The Trade is supported by VIL’s Infrastructure & Logistics assets such as:
✓ Strategically located terminals with various tank size configurations and
specifications, for storing Class A/B/C products, which include specialized tanks
requiring heating, refrigeration, corrosion resistance, etc.
✓ Vessels that are owned and time chartered; as well as arrangements with several
shipping agents and shipping lines.
✓ Exclusive management of Tank Terminals, Logistics Parks and Dry warehouses in
UAE / INDIA with specific thrust on major port cities.
✓ A mini petroleum refinery associated with our own tank storage terminal which
is one of the largest in Hamriyah, UAE.
✓ Drumming facilities for liquid bulk.
✓ Surface transportation
✓ Hazel International FZE (HIF), a wholly owned subsidiary company of VIL, which
has constructed a tank terminal for storage of petrochemicals with a capacity of
~200,000 m3 at Hamriyah Free Zone, Sharjah, UAE with an asset value of ~$220
Million. The terminal is ~340 meters away from the jetty with direct pipeline
connectivity. It has 30 tanks spread across 30,000 square meters, which are used
to store Class A, B, and C petrochemicals, Base Oils, Bitumen, Ethanol, etc. In
addition to storage, the terminal offers value-added manufacturing facilities such
as Blending, Sparging, Fractionating and Distillation, Drumming and other
services as may be required by our customers.
Synergising two primary Business Domains, i.e International Trade & Distribution and
Infrastructure & Logistics, the group is able to deal in large volumes of various products
annually, for example GV’s Bitumen storage and trade business alone is over 1 million
tonnes per annum. Across business domains and geographies, GV trades in almost 6
million tonnes of various petrochemicals annually.
GV now proposes to set up an Integrated industrial complex at Dighi Port, Maharashtra,
which shall, inter-alia, comprise of:

1. PVC plant 2,00,000 MTPA

2. PMB plant 3,60,000 MTPA
3. 32 mounded bullets of capacity 2500 m3 each (8 for VCM, 12 for LPG & 12 for
Propylene)
4. LPG Bottling plant
5. Captive gas-based power plant (18MW)
6. Sea Water Desalination Plant (RO process)

The above facilities (collectively called as “Project”) would be natural backward

integration for the Group GV given its existing business facilities & operations and trade
relationship.
The Project will be implemented, financed and operated by Veritas Polychem Private
Limited, a 100% subsidiary of Veritas (India) Limited. An overview of the Company is
given under:

Table 1-1: Overview of the Company

Name Veritas Polychem Private limited

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 Prefeasibility Report Veritas Polychem Private Limited

Registered 701, Embassy Centre, Nariman Point, Mumbai

Office 400021, Maharashtra, India
Corporate Veritas House, 70 Mint Road,
office Fort, Mumbai, Maharashtra - 400 001
Promoter Veritas India Limited
Constitution Private Limited Company
Listing Unlisted
Sector Oil & Gas (Petrochemicals)

A brief about the Board of Directors of VPPL is mentioned below:

Table 1-2: Brief Profile of Board of Directors of VPPL

Name Description
Nitinkumar Mr. Nitinkumar Didwania, is an M.Com and Masters in Economics
Didwania from Mumbai University. Mr. Didwania is the promoter,
shareholder and the group Chairman. He has over 20 years of
experience in the petrochemical and other trading business. He is
supported by a team of well qualified and professional people.
Mr. Praveen Mr. Bhatnagar, is a Chemical Engineer from Delhi University and a
Bhatnagar post graduate from Indian Institute of Foreign Trade. Mr.
Bhatnagar has three decades of experience in the polymer and
petrochemical industry. Having worked with LG Chem Ltd, Hi
Tech Carbon, Oriental Carbon and Chemicals Ltd and Godrej
Industries etc., and he has expertise to set up the manufacturing
facilities
The Company would be broad basing its Board of Directors as per its business plan.

The project brief is summarized in the table below Project summary at a glance

Brief Project summary

Sr No Particulars Details
1 Name of Company Veritas Polychem Private Limited
2 Products PVC, PMB, LPG, Propylene
3 Location Gat No. 49, 50, 51, 52, 53, 54, 56, 57, 61, 63, 66,
75-A & adjacent reclaimed land, Dighi Port
Area. Village Nanavali, Taluka Shrivardhan, Dist.
Raigad, Maharashtra
4 Name of the project Establishment of Integrated Project consisting of
Poly vinyl Chloride (PVC) Plant, Polymer
modified bitumen (PMB) Plant, Gas Storage
Terminal, LPG Bottling Plant, Gas Based Captive
Power Plant, Sea Water Desalination Plant (RO
process) for captive consumption by Veritas
Polychem Private Limited
5 Total land area of the 59.277 Acres
plot
6 Total proposed built up 22.60 Acres
area

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7 Main raw material Vinyl chloride monomer (VCM), Bitumen,

Polymers, LPG, Propylene, LNG
8 Water Water requirement at site will be met by Sea
water desalination Plant.
9 Power Captive power plant of 18 MW will be installed
based on LNG.
10 Expected Manpower Total ~ 1000 Nos (Permanent 500 Nos, Contract
500 Nos).
11 Waste water generation, Trade effluent will be treated and discharged to
treatment and disposal sea.

Domestic sewage - Sewage will be treated in

independent STP and treated water will be used
onsite for green belt maintenance.
12 Air emissions Air emissions will be there from Captive power
plant stack, process stacks, scrubber stacks.

It will be treated and let to atmosphere as per

EP guidelines.
13 Waste generation and Waste generation in the form of solid and liquid
disposal will be stored and disposed as per rules.
14 Project cost ~ 2050.47 Crores

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2 INTRODUCTION OF THE PROJECT

Identification of the Project and Project Proponent

Proposed Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer
modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based
Captive Power Plant, Sea Water Desalination Plant (RO process) along with associated
utilities will be executed by Veritas Polychem Private Limited (wholly subsidiary of
Veritas (India) Limited).

Brief Description of nature of the Project

It is an integrated petrochemical complex consisting of Poly vinyl Chloride (PVC) Plant,

Polymer modified bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas
Based Captive Power Plant, Sea Water Desalination Plant (RO process) for captive
consumption and associated utilities and infrastructure.

Need of the Project and Its Importance to the country and/or Region

Poly Vinyl Chloride (PVC)

PVC is third most used plastic in the world. Globally the PVC supply outstrips the demand.
However, prospering Indian market for PVC historically in short supply and in 2016
demand supply gas has reached about 1.4 million MT. The gap is solely catered to by
imports. Hence in order to fulfill the demand VPPL decided India as location for the PVC
plant.

GV further foresees clear demand supply gas in the Indian market during the life of PVC
plant as
o No additional capacity is being added in India.
o Steady and assured growth of domestic demand.

PVC enjoy huge market in India (2.8 million Ton for 2016) and is expected to cross 4
Million MT by 2020.

India’s per capita consumption of PVC is 2.5 kg as compared to global average of 6 kg.
India’s PVC import demand is met by South Korea, Taiwan, USA, Japan and China.

Polymer Modified Bitumen (PMB)

India is witnessing tremendous boom in infrastructure development. In keeping with

plan to develop modern and efficient highways, National highway authority of India
(NHIA) has planned to increase length of road across the country. This is apart from plans
of many smaller authorities.

Bitumen, product of refineries is mainly used for road construction. VPPL plans to
manufacture polymer modified bitumen (PMB), a formulation of bitumen with suitable
polymer. In India, its application in road construction and maintenance is a recent

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 Prefeasibility Report Veritas Polychem Private Limited

phenomenon and the usage is stated to pick up for PMB as it is advantageous over
bitumen in following aspects

o Greater rigidity and water resistance

o Resistance to permanent deformation and crack formation
o Higher durability

PMB scores over standard bitumen especially under conditions of heavy load traffic and
in extreme climate conditions. GV this foresees an opportunity to serve the nation with a
superior product that lead to durable and robust road infrastructure.

Gas storage tank farm and bottling unit

India is net importer of Liquified petroleum gas (LPG). VPPL intend to utilize available
space for storage and bottling of LPG. The facility will cater for domestic and industrial
demand of the gas in the proximate market.

VPPL intends to use liquefied gas facility for storage and supply of propylene.

Propylene is raw material for the second most consumed polymer viz. polypropylene,
which India is net imported off. The gas will also cater to few other end applications
including propylene oxide, propylene glycols, acetone, phenol and polyols.

Demand – Supply gap

PVC Industry in India is more than 50 years old. The production plant of 60,000 TPA
capacity was commissioned in 1961 by M/s Calico Industries. In India, PVC production is
having strong support in the form of backward integration to chloro alkali plants, which
are essentially promoted by textile, paper and soda ash for want of sodium hydroxide in
their process. Earlier PVC was produced from calcium carbide through acetylene route,
which was energy intensive and involved heavy usage of mercury in the process. It
proved to be uneconomical. Hence manufacturing shifted to economical ethylene-based
PVC manufacture.

Till date, there are 5 PVC manufacturers in India having capacity of 1.4 million MT with a
capacity utilization of around 100 %. Reliance being leader having plant capacity of
735,000 TPA, Finolex with capacity of 270,000 TPA, Chemplast Sanmar with a capacity of
250,000 TPA, DCW with a capacity fo 90,000 TPA and Shriram Chemicals with a capacity
of 70,000 TPA. With a total annual consumption of PVC around more than 2.8 Million MT,
1.4 million MT PVC is being currently imported.

The committee of Perspective Planning of Petrochemical Industries estimates PVC

demand to be around 4 million MT by 2020 and over 5 million MT by 2025.

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Poly Vinyl Chloride (PVC)

Globally, plastics industry is one of the leading contributors to economic growth Globally,
plastics industry is one of the leading contributors to economic growth. In spite of
recession and long-term consolidation trend, the plastics industry has been one of the
largest and fastest-growing industry. In the second half of the 20th century, plastics
emerged as one of the most globally-utilized and multipurpose materials.

The plastics industry is the third largest manufacturing industry contributing

significantly to the world economy. Competition in the industry is constantly growing.
Plastic manufacturing is increasingly shifting towards Asia, especially to China and India.
Global plastic demand in 2015-16 was observed to be close to 170 million metric tonnes
(MMT). Asia's current 43% share is expected to grow to 47% by 2021, by which timeline
global plastic consumption is estimated to reach 250 MMT.

Globally, PVC is the third largest consumed polymer.

The world demand for PVC grew from 35 _MMT in 2010 to 41 MMT in 2016 as depicted
in the following diagram. For the said period, the supply has invariably been in excess to
the demand. The global consumption of PVC is slated to reach 46 MMT by 2020, which
will be met by excessive capacities.

Source: Platts
On the contrary, for the similar period, the Indian demand growth out-spaced the
supply. The demand supply gap remained negative throughout the period under
consideration. This is evident from the following graph:

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 Prefeasibility Report Veritas Polychem Private Limited

PVC India Production Demand in MMT

Source: Platts
The deficit is slated to increase further till 2020. It will reach 2.6 MMT by the year,
whereby in-land supply and demand figures will be 1.4 MMT and 4.0 MMTY,
respectively. The widened gap occurs as no capacity additions are planned, whether by
existing or new manufacturers, for the period 2016-2020. It is schematically shown
below:

Source: Platts

It is to seen from the above diagram that capacities built up in North America, Asia
(largely China and North East Asia), and to small extent, in the rest of the world. As far
as future capacity built-up is concerned, one can see these emerging only on North
America. It leads to conclusion that in India no new capacities are planned until 2020,
though market reports, as recent as April 2017, reveal a 0.6 MMT new capacities planned
by Chemplast Sanmar. It will overcome the 2020 projected deficit only by 23%, the
balance yet being managed by progressive imports till that year.

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In the global PVC trade that occurred from 2010 and its projection till 2020, as
represented by the following graph, North America and Rest of Asia (after exclusion of
India and China) continue to export its excess PVC capacity. Europe became net exporter
in 2015. China is likely to join this club by 2020. For the decade under consideration,

India remained NET IMPORTER and will continue to do so.

The diagram clearly depicts India's increasing import from 0.6 MMT in 2010 to
1.3 MMT in 2015 with projections of close to 3 MMT by 2020.

This is where GV sees its opportunity to overcome a fraction of the deficit by

manufacturing PVC. As the planned capacity amounts to 150,000 MTpa, it will be about
11% of the imports registered in 2015 and, at constant capacity, will be about 5% of the
projected imports in 2020.

PVC holds a significant share among polymers. PVC consumption in India is about 50
years old and is flourishing since last couple of decades. Indian PVC industry is currently
valued at >US$4b. The following pie-charts would explain the anticipated upsurge in
PVC demand growth.

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 Prefeasibility Report Veritas Polychem Private Limited

Source: Platts

It can be seen that there is a clear distinction in the global and India usage patterns. In
either cases, the application pipes & fittings takes the biggest pie, however, in India 73%
of the PVC is used in making pipes and fittings, courtesy to agricultural revolution. In
this segment, Indian PVC is widely used in making pipes and hoses that are extensively
used in irrigation. In Agriculture Segment, the double digit growth is persistent.

In depth market research indicates that, the pie belonging to profiles (current 3% usage)
will increase substantially post 2016 owing to various upcoming infrastructure projects
declared by Government of India coupled with booming real estate market. It is
noteworthy that PVC actually replaces wood as well as metals consumed by these
industries on large scale.

Thus, the PVC market in India in Infrastructure segment will be driven by:

1. Smart City Projects covering 100 cities

2. Atal Mission for Rejuvenation & Urban Transformation (AMRUT)
3. 50 million new dwellings for housing to all Indians by 2020

Further consumption drivers have been pipes & fittings towards water management and
water conservation. PVC industry is one of the major contributors to the economy of the
country. With huge investments in infrastructure development, India will be the growth
center of the global PVC industry. PVC products have huge potential to curb the
challenges faced by the country. Introduction of innovative technologies and products
based on PVC will certainly make difference in the sustainable management of country's
infrastructure and economy.

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Vinyl Chloride Monomer (VCM)

VCM is the key raw material for the manufacture of PVC. As a measure of profitability of
the plant, Delta (A) PVC is considered as a crucial figure. A represents the price
differential between the product PVC and the raw material VCM. The long-term average
A value (i.e. for the period 2011-2016) is approximately US$205. The history of the
individual prices (in US$/MT) and the A values is represented by the following diagram:

Source: Platts

One can observe from the above diagram that A is continuously increasing from and is
>205 during latter half of 2016, the above published data indicates the South East prices
of VCM, while prices of VCM imports in India indicate lower levels.

The Suspension grade PVC price in India considered in the financials in fact, includes the
customs duty @ 7.5% which is charged to importers after adding 1% landing charges on
the C & F price. With the clearing and forwarding charges, insurance, loading and
unloading of containers and the logistics cost comes to approximately Rs 4,000 PMT, to
bring parity with the import pricing of Suspension grade PVC by importers. However, in
the financials we have conservatively considered the above charges of Rs 2,000 per MT.

This prompts GV to safely assess that the envisaged PVC manufacturing plant will run
with healthy bottom-lines.

Why India for PVC plant?

2.4.4.1 Water Conservation

It is observed that about 40% water is wasted during transportation due to leaks and
breakages in ageing metal pipelines. Products like weld-able PVC pipes, expandable PVC

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 Prefeasibility Report Veritas Polychem Private Limited

pipe have the capacity to reduce the wastage by replacement of these aging pipelines.
Advantage of these products is that they can be used with trenchless installations
without disturbing the existing pipeline.

On the other hand, damaged leaking sewer pipelines are contaminating ground water
resources leading to the severe health hazards. PVC products like spiral wound pipe
renewal system, fold and form PVC pipes can be used for replacement of these old
damaged pipes to increase the life of the sewer system.

A. PVC to control Deforestation and Ultimately Reduce it:

PVC windows and wood PVC composites are taking care of ecology and environment by
reducing the demand for wood and wood-based products. Use of PVC in construction is
practiced in developed countries for more than 2 decades and India is following suit.
Forest cover in the country has reduced to 19% of total geographical area from 30% at
the beginning of 20th century. Wood PVC composites are considered as an option for
wood and wood-based products like plywood or particle boards for furniture
applications as well as construction boards, tiles etc due to the superior water
resistance. This segment is growing very fast in the country at the rate of 30%. There
are many more applications yet to be emerged for wood PVC composites including
decorative profiles, decking, outdoor furniture, etc.

B. Benefits to Agriculture and Food Preservation:

India is an agriculture-based country and is continuously improving the food grain
production after Green Revolution. Food grain production increased to 253 MMT in
2013 from 241 MMT in 2011. Unfortunately, available storage facilities of food grain
cannot manage with this kind of production which is leading to food grain wastage to
the tune of 20 MMT. PVC based food grain storage structures are beneficial in terms of
handling and installation.

The structures are made up of gas tight through zip-lock type joint which gives perfect
conditions for hermetic storage of food grains. Adoption of these structures can save
precious resource — food grains with economical storage for long duration.

PVC industry is one of the major contributors to the economy of the country. With
massive investments in infrastructure development, India will be the growth centre of
the global PVC industry. PVC products have huge potential to curb the challenges faced
by the country. Introduction of innovative technologies and products based on PVC will
certainly make difference in the sustainable management of country's infrastructure
and economy.

Polymer Modified Bitumen (PMB)

PMB is one of the specially designed and engineered bitumen grades that is used
in making pavement, roads for heavy duty traffic and home roofing solutions to
withstand extreme weather conditions. PMB with added polymer, which gives it
extra strength, high cohesiveness and resistance to fatigue, stripping and
deformations, makes it a favorable material for infrastructure.

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When a polymer is added to regular bitumen, it becomes more elastomeric,

which provides it with additional elasticity. The polymer that is added is Styrene
Butadiene Styrene (SBS), which acts as a binder modification agent. The primary
objective of SBS polymer modified bitumen is to provide extra life to pavement,
roads and construction designs. Some of the qualities exhibited by PMB are:

• Higher rigidity
• Increased resistance to deformations
• Increased resistance to cracks and stripping
• Better water resistance properties
• High durability

PMB is used for:

• Construction of hilly terrain road and in heavy rainfall areas
• Roads for high and heavy traffic.
• High loading .
• High temperature amplitude.
• More durable pavement.
• Draining pavements.

To meet the demands of technological and demographic changes, the use of polymer
modified bitumen has become increasingly important. Increased stress on highways
due to heavier loads, higher tire pressures, and ever rising traffic counts are causing
premature failures. Severe climates, always a source of concern, and an increased
emphasis on safety have prompted research towards the amelioration of highway
paving materials. As the network of highways ages, the demand for quality
maintenance and recycling products is becoming more important than that for new
construction. To address these problems, the highway engineer has turned to polymer
modification for custom design of pavement materials. It is possible to construct roads
which require overlay not before 8 to 12 years as well as save on huge quantities of fuel.
PMB can enhance the service life of roads by 50% to 150%.

PMB can be used as binder in Bituminous Macadam, Bituminous concrete in

construction of road. Use of PMB increases the rut, creep and fatigue resistance of the
pavement, enhancing its performance and service life.

Use of PMB in 'wearing course' enhances its overlay period where as its use in the
binder course can enhance the design life of the road or reduce thickness of pavement
resulting saving in initial cost of road.

Wearing course of a road costs around 10 percent of the cost of the road. Bitumen
contributes around 50 percent to this cost. Use of PMB costs around 25 to 50 percent
more than convention bitumen, depending on the type of PMB. Thus, use of SBS PMB in
wearing course, increases the cost of wearing course by 12.5 percent to 25 percent and
that of the road by 1.25 to 2.5 percent. But the life of wearing course increases by 50 to
150 percent.

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Period of overlay of a road, ordinarily being overlaid at five years, will increase to eight
(or even 12) years if PMB is used as binder in place of conventional bitumen. Thus
saving costs in the long run.

There are guidelines and specifications on modified bitumen issued by BIS (IS
15462:2002), by IRC (SP 53 2002, 2010) and the Ministry of Surface Transport And
Highways (MORT&H) specs 2001 Clause 521.

The global modified bitumen market is projected to reach USD 19.29 billion by
2021, at a CAGR of 6.5% from 2016 to 2021. The growth of the market is attributed
to the growing construction industry in emerging nations, cost-effectiveness of
modified bitumen, and increasing demand for modified bitumen in regions such as
Asia-Pacific and the Middle East & Africa. Modified bitumen is largely used in road
construction. In addition, rising awareness about the benefits of modified bitumen
is also fueling the demand. In 2015 — 2016 it is estimated that the demand for PMB
in India was 430,000 MT. India is expected to lead the growth in the PMB market
owing to its increasing consumption over the years for existing as well as new
infrastructure projects. India has the second largest road network globally; in FY16
it was estimated to be over 5.23 Million Km and, over 64.5% of all goods in the
country are transported through roads, while, 85.9% of the total passenger traffic
use the road network to commute. In FY16 the length of national highways was
100,475 km and as part of infrastructure reforms, the government plans to double
the length of national highways to km. The Indian roads and bridge infrastructure
industry will be worth USD19.2 billion by the end FYI 7 (Source:
IBEF).

Modified Bitumen Market, by Region, 2021 (USD Million)

Market size in 2021

Source: Markets and Markets Analysis

As of May 2017 the price differential between Imported Bitumen and PMB is Rs

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11,358.45. The cost of Imported Bitumen being USD 262 PMT CIF + 5% duty is
Rs. 17,631.55 and the current price of PMB ex warehouse of one of the largest
manufactures like Hincol is Rs 28,990/MT. We understand from the market
sources, there are discounts being offered on PMB as well as on bitumen
privately, by PSU's to their trade partners. The discounts may vary from 8% to as
high as 10% as per market conditions. If discounts are considered as a regular
practice, the price differential may reduce to below Rs 8500 / MT.

Liquefied Petroleum Gas (LPG)

2.4.6.1 Description of the LPG Market:

Liquefied Petroleum Gas (LPG) is primarily a mixture of Propane and Butane.
The LPG Market is divided in two parts:
1. LPG for domestic (predominantly cooking gas)/ small consumers use
2. Commercial / Industry Use
LPG can be used in many applications in the industrial sector namely: any
process-heating, powering industrial ovens, production of food, kilns, furnaces,
metal finishing, textiles, production of packing material as well as in powering
forklift trucks in warehouses. The graph below illustrates the Indian LPG —
Sector wise demand:
Indian LPG demand

Source: Poten & Partners

LPG market is a lucrative, fast-growing, with current Indian market size being as
high as over 21.1 million tons in 2016— 17 with annualized growth of 9%.

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However, India is and will remain net imported of LPG and constituent gases, viz
propane and butane. Domestic LPG production is at the hands of the PSU's,
capacity of which is not able to reach the demand as elaborated by the following
figure.

Source: Petroleum Planning & Analysis Cell (Ministry of Petroleum & Natural Gas,
Government of India)

As can be seen from this data, there is sufficient scope for import of LPG and
constituent gases. It is estimated that, by 2020, when the demand would reach 24
MMT LPG, the deficit could be yet 12 MMT that will be overcome by imports.

Projections:

GV plans to have a total storage capacity of 30,600 MT of LPG / Propylene.

The proposed LPG storage capacities at gas terminal are as follows: -

Capacity in m3/ Number of

Product Capacity in MT (at 300C)
Bullet Bullets
30,600
LPG / Propylene 2,500 m3 24 (60,000 m3 * 0.51 MT/
m3)

Total Capacity of LPG/Propylene will be 60,000 cubic meters.

With the storage of 60,000 Cubic meter of LPG, Veritas will be the largest private
operator in India. Groupe Veritas plans to serve the local distribution companies
(LDCs), end-users and even the PSU — LPG producers. As per our assessment, the
current private LPG static capacities are as follows: -

Company Location LPG Static Capacity

IMC Kandla Port 5,600 CBM

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Aegis Logistics Limited Mumbai 20,000 MT

Pipavav 8,100 MT

* Source • IMC Storage Network Existing Capacities, Aegis Investor Presentation

May 2017

As observed, with Aegis's current combined Static capacity for LPG as of FYI 17
stands at 28,100 MT, the total LPG throughput volumes for two Aegis's terminals
(located at Mumbai and Pipavav) was 1,350,000 metric tons in FY 2016-17,
amounting to a growth of over 38% compared to the previous year’s numbers
With subsidies on the LPG coming down the growth in the private operators would
be phenomenal.

The major private LPG importers who are actively marketing and importing LPG
into India are as follows:

1. Adani Gas
2. Shiv Vani Universal
3. India LPG
4. Oil Gas India
5. Gujarat Oleo Chem Ltd
6. Geo Global Resources
7. Niko Resources Ltd
8. Pankaj Petrochem Private Ltd

Period : 2012-13 to 2021-22 ('OOOMT)

Demand: 12th Plan Demand: 13th Plan
Product 2012- 2013- 2014- 2015- 2016- 2017- 2018- 2019- 2020- 2021-
s 13 14 15 16 17 18 19 20 21 22

LPG 16986 18363 19675 20857 21831 22597 23271 23868 24342 24770

Source: Petroleum Planning & Analysis Cell Working Group Report on demand estimates of the
petroleum products-I2 th & 13th Five Year Plan.

Import of Crude oil and Petroleum Products ('000MT)

Import 2010- 2011- 12 2012- 13 2013- 14 2014- 15 2015- 16 2016-17 (P)

11
LPG 4484.3 5790.0 6300.8 6567.4 8313.4 8959.2 11042.4

Imports vs indigenous production

See above 2.4

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Export Possibility

See above 2.4

Domestic / Export market

See above 2.4

Employment Generation (Direct and indirect) due to the project

The facility will generate direct and indirect employment.

Direct employment at site will be ~ 1000 persons (Permanent 500 and Contract
workmen 500) from this proposed project during operation phase.

There will be at least an indirect employment generation of 4000 personnel in the

transport sector, and, associated businesses like packaging, drums manufacturing, etc.

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3 PROJECT DESCRIPTION

Type of Project

(including interlinked and interdependent projects, if any)

It is an Integrated Project consisting of Poly vinyl Chloride (PVC) Plant, Polymer modified
bitumen (PMB) Plant, Gas Storage Terminal, LPG Bottling Plant, Gas Based Captive Power
Plant, Sea Water Desalination Plant (RO process) for captive consumption.

There is no interlinking and interdependent project.

Location

(Map showing general location, specific location, and project boundary and project site
layout) with co ordinates

The proposed project is establishment of integrated complex at Dighi Port.

Brief location details are as follows:

Sr. No. Particulars Details

1 Taluka, District, State Taluka Shrivardhan, Dist. Raigad, Maharashtra
2 Location Dighi Port
3 Latitude & Longitude Latitude: 18016’50.00” N
Longitude 73027’20.00” E
Sr. No. Location Name Approx. distance (km)
1 Nearest National Highway NH 753F 3
2 National Highway NH 66 50
3 Nearest Air port Mumbai 100
4 Nearest Railway station Mangaon 50
5 Nearest Port Dighi 2.2

The Geographical Location of this site is at 18016’50.00” N Latitude and 73027’20.00” E

Longitude with an elevation of 3 meter above sea level MSL.
Site coordinates are as follows:
Points Latitude Longitude
A1 18 16 56.4927 N 72 57 6.1849 E
C 18 16 51.5849 N 72 57 18.6952 E
D 18 16 50.0844 N 72 57 23.5391 E
E 18 16 39.7746 N 72 57 18.2611 E
G7 18 16 40.258 N 72 57 16.0215 E
G6 18 16 43.6531 N 72 57 13.7271 E
G5 18 16 44.1146 N 72 57 11.6066 E
G4 18 16 44.4566 N 72 57 10.0437 E
G3 18 16 45.1123 N 72 57 7.316 E

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R1F 18 16 46.4633 N 72 57 5.3791 E

R1 18 16 49.7273 N 72 57 4.2456 E
R5 18 16 51.2486 N 72 57 4.606 E
R4 18 16 52.2664 N 72 57 4.5899 E
R3 18 16 53.5718 N 72 57 4.7428 E
R 18 16 53.9207 N 72 57 4.8939 E
R2 18 16 55.4399 N 72 57 5.6567 E
P 18 16 52.3747 N 72 57 1.4053 E
N 18 16 50.2165 N 72 57 0.7049 E
M 18 16 48.2722 N 72 56 59.3793 E
L 18 16 46.1441 N 72 56 58.9709 E
F1 18 16 48.2337 N 72 57 3.6208 E
K 18 16 45.3075 N 72 57 2.4977 E
J 18 16 43.019 N 72 57 1.199 E
H 18 16 42.7522 N 72 57 6.8351 E
G1 18 16 44.5888 N 72 57 6.2927 E

Please refer Annexure II for Google map.

GPS Location on Google Imagery of the proposed site is attached as Annexure I.

Land Form: Land is reclaimed land and contour plan showing slight variation in
elevation.

Land Ownership: Land ownership is with project proponents (Group Veritas).

Existing Land use Pattern: The Land is vacant and meant for industrial use.

Existing Infrastructure: Dighi port is adjacent to site. There are tankages of M/s IMC,
and other companies.

Lay-Out

Refer Annexure II for the plant site layout plan.

Details of Alternative sites

(Sites considered and the basis of selecting the proposed site, particularly the environmental
considerations gone into should be given)

Dighi port site is selected based on following considerations.

Major raw materials such as VCM, Bitumen, LPG, Propylene will be transported by sea
route.

Dighi port situated in Raigad District in the state of Maharashtra is a multipurpose, Multi
cargo, all weather port which has direct berthing port with a state-of-the-art cargo

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handling equipment's. It has ample land bank approximately 1,200 acres. It is a natural
harbor and an exclusive channel offering a depth of 9.5 m, making it one of the deepest
channels in Maharashtra.

The total waterfront of approximately 5 km is available for development of port related

activities. The port is capable of handling bulk, break bulk, liquid, RORO & container
cargo. The port is well connected to national highway 753F & NH 66. It is also part of the
Delhi Mumbai industrial corridor. The strategic location would facilitate fast
turnarounds of vessels due to high levels of efficiencies.

Being in Konkan i.e. western side of the country, its proximity to the Middle Eastern
region for sourcing of VCM. The central government has already sanctioned and started
the construction of the Railway line connecting the Central Railway station at Roha to
the Dighi port which is about 35 Km from the port. This will enhance the connectivity
with the central and northern parts of the country where in there is a huge potential for
revenue to be generated from the sale of the PVC so manufactured from the region. The
nearest airports are Mumbai and Pune. The nearest sea port is JNPT, which is about 70
km from the Dighi port.

Dighi, as a strategic location for this Complex, carries many advantages:

1. Part of Delhi Mumbai Industrial Corridor

2. One of the seven Mega National Investment & Manufacturing Zone
3. West Coast Sagarmala Economic Cluster
4. MOU signed with Maharashtra Maritime Board for constructing and upgrading
100 km of the proximate road net-work
5. MSRDC approval for 44 km road development upto Indapur on Mumbai Goa
National Highway
6. MOU signed with Rail Vikas Nigam to construct 35 km rail link to the nearest
station Roha on Konkan Railway.
7. Dighi has 2 operational berths, 2 more will be operational by the time this project
is commissioned.
8. Road tender by MSRDC has been awarded and concrete road about 80 % is
completed.
9. Proper two lane 7 meters wide concrete road with 1.5 m side shoulders from
Mangaon to Dighi port.
10. From the junction NH 753F & NH 66 located in Mangaon the four cities can easily
be connected i.e Mumbai, Pune, Ratnagiri & Goa.

MSRDC have already given the road construction contract to J.M. Mhatre & Co.
With the construction of 2 lane road between Dighi and Mangaon the current
capacity to receive and dispatch 500 trucks and trailers per day at Dighi, will go
up to 1200 trucks and trailers per day. Therefore, with a maximum number of
200 trucks to be dispatched every day from VPPL's site, we do _not anticipate any
evacuations problems. The break up for the same would be at the very most 130
trucks per day for PVC, PMB and 60 trucks for the Gas Storage outflows.

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Size or magnitude of operation

It is an integrated petrochemicals complex consisting of,

1. PVC plant 2,00,000 MTPA

2. PMB plant 3,60,000 MTPA
3. 32 mounded bullets of capacity 2500 m3 each (8 for VCM, 12 for LPG, 12 for
Propylene)
4. Captive gas-based power plant (18 MW)
5. LPG Bottling Plant

6. Sea Water Desalination Plant (RO process)

o All other associated utilities such as DM Plants, Effluent treatment plants,
Sewage treatment plant, Compressed air & Nitrogen generation plant and
infrastructure facility.

Project description with Project details

(A schematic diagram / flow chart showing the project layout, components of the
project etc should be given).

PVC Plant

VPPL will relocate the PVC plant of Petronas presently situated in Malaysia. The plant is
capable of producing suspension grade PVC (Grades K57-K72). It is backed by a
technology by world largest PVC technology provider namely Ineos Technologies, UK.

The plant will be polymerization plant which will convert imported VCM (vinyl chloride
monomer) to PVC. Ineos technologies will provide all the technology upgrades and
developments as well as tailored support on Environment.

The plant design meets and exceeds European Union standards and safety and
environment norms, which are among highest in the world.

The proposed plant capacity of PVC will be 200,000 TPA.

The basic raw materials required is VCM, which will be imported from Qatar, China, Japan,
Europe etc.

It will be stored under pressure in mounded bullets with ASME specifications and as per
PESO guidelines.

The other component will be water. Especially for India, Ineos’s condenser process allows
fast reactions without use of chilled water for reactor cooling. This is specially advantage
in India, where cooling water temperatures are high, hence it saves the high energy
consumption.

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3.5.1.1 Basic structure of PVC

PVC is most versatile thermoplastic forming on one extreme, highly rigid products such
as pipes and profiles and on the other, highly flexible products such as soft leather cloth
and flexible footwear. The basic structure of this polymer is (C2H3Cl)n

The degree of polymerization varies from 300 to 1500. The chlorine content in PVC is
about 57% by weight which makes it less dependent on hydrocarbon content.

Reaction:

VCM PVC

3.5.1.2 PVC Process Technology Review

There are many polymerization routes for manufacture of PVC. They are as follows,

Process Route % of world production

Suspension polymerization 80
Emulsion polymerization 10
Bulk or mass polymerization 8 – 10
Copolymer PVC Not known
It can be seen from above that suspension polymerization is the most prevalent
technology in the world today. The leading licensors for this technology are Ineos
Technologies (UK) and Oxy Vinyl corporation (USA). In this process, Vinyl chloride
monomer droplets are dispersed in water medium aided with suspending agents and
agitation in the reactors/Polymerizes. Polymerization for VCM to PVC takes place in this
medium initiated by peroxide catalyst. Multiple batch reactors discharge into a
continuous polymer separation and finishing line. The polymer slurry from reactors is
first separated from unconverted VCM by degassing and steam stripping. Water is
separated from the polymer by means of centrifuging followed by drying.

PVC produced by emulsion polymerization process is mainly used as latex or paste in

specialty applications. In Europe, manufacture of PVC started with the emulsion process.
The process is similar to suspension process except that large amount of emulsifying
agents are used which result in very fine PVC particles. Consequently, separation of these
fine PVC particles from water cannot be done by centrifuging action. Hence this
technology employs spray driers to separate water from the fine PVC particles.

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3.5.1.3 Product applications of PVC

PVC products are generally classified in the industry in terms of K-values. Higher the K
value, higher is the molecular weight. A, low molecular weight PVC with a K value of 57
finds main application in rigid films and sheets; blow molded bottles and other injection
molded articles. PVC, if used in food application, should have a residual VCM content less
than 1 ppm.

Higher molecular weight PVC with a K value of 66-67 finds major application in extrusion
of pipes and profiles. This constitutes one of the major PVC consumption. PVC with still
higher K value of 70-72 along with high porosity finds typical application in wires and
cables and other flexible applications such as shoe lasts, flexible films etc. Emulsion PVC
is used in form of plastisols or latex typically for PVC coating, multilayer films, battery
separators and such specialty applications.

3.5.1.4 Product PVC

The plant is capable of manufacturing suspension PVC grades K-57 to K-73. Low K value
and high K value grades can also be produced. The plant is capable to produce the full
range of PVC grades for fulfilling most market requirements.

3.5.1.5 Installed production capacity

The installed capacity of the PVC plant is 200,000 MTPA.

Institute of Chemical Engineers (UK) has been appointed for carefully

evaluating/examining the plant in the month of March 2017, before the process of
dismantling of the plant started at site.

3.5.1.6 PVC Plant Process Description

The plant section shall comprise of the following sections

o VCM unloading, storage and feeding system

o Preparation and charging of DM water
o Preparation and feeding of additives
o Polymerization reaction
o PVC slurry stripping
o VCM Recovery system
o PVC drying
o PVC packaging and product warehousing
o PVC dispatch

3.5.1.7 VCM unloading, storage and feeding system

VCM is colorless liquid with a characteristic’s sweet odor. It is highly reactive, though
not with water, and may polymerize in presence of oxygen, heat and light. Its vapor are
both toxic and flammable.

Vinyl chloride monomer 99.5 to 100 % CAS No 75-01-4

Molecular weight 62.5

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Molecular formula C2H3Cl i.e. CH2-CHCl

Boiling point (-)14 deg C
Vapor pressure 2660 mm Hg @ 25 Deg C
Vapor density (Air=1) 2.15
Specific gravity (water =1) 0.91 @ 25/25 deg C
Water solubility 2.7 g / Lit
pH Not applicable
VOC content (%) 100 %
Volatility 100 %
Evaporation rate (ether = 1) >15
Flash point (-) 78 Deg C

Each consignment in the range of 5500 – 11000 m3 of pressurized VCM shall be unloaded
from ship with the help of unloading pumps through one no of 8-inch marine unloading
arm and shall be transferred to proposed VCM storage bullets at VPPL’s gas storage
terminal + bottling unit.

No Parameter VCM
Unloading condition
1 Unloading at Dighi port
2 Unloaded by Marine unloading arm
3 Pressure at ship pump flange kg/cm2g 30 (minimum)
4 Unloading carrier Approx. 7500 MT

Marine unloading arm

3.5.1.8 VCM Pipeline transfer facilities

8 inch pipeline will be employed for transfer of VCM from ship. Two mas flow meters one
at Jetty end one at tank end will be provided for mass measurement and input to leak
detection system. The motorized operated valve shall be provided at jetty for emergency
shut down operation in case of leak.

Alternate facilities for unloading of VCM and other gases

Ship to shore transfer system will be used as an alternative for unloading of the cargo
from ship to shore.

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Dighi port is located on the Rajapuri creek. The port being at the interior of the creek, the
sea is calm all around the year, therefore, vessel offloading is possible through the floating
hose assembly without any hinderance.

Ship to shore transfer systems are in use for the transfer of VCM and other gases between
tankers and shore facilities. A ship to shore transfer system provides a safe solution to
tanker loading/unloading requirements in shallow water, offering a more reliable,
efficient and cost-effective alternative to jetty systems. Ship to shore transfer systems are
ideally suited for shallow water applications. The life of the system is approximately 25
years.

The ship to shore transfer system allows the tankers to safely maintain position for the
period required to load or offload the cargo. Typically, flexible pipes of predetermined
sizes are used for station keeping of the tanker. When berthed, the tanker remains on the
location using its own anchor. On the tanker side, the ship ropes are connected on either
side to the bow and the stern and on the to the quick release hooks. After the tanker is
positioned and anchored, picking up a submerged hose string and connecting this hose
to its mid ship manifold, loading / offloading operation shall start. The other end of the
hose string is connected to a pipeline end manifold (PLEM), which in turn is fixed to a
subsea pipeline, transferring the product to or from any installation located onshore. On
completion of loading operation, the hose string is laid down on the seabed, ready for
being picked up again when the next tanker arrives.

3.5.1.9 Receipt and storage facility at Gas Storage Terminal

The VCM from ship will be transferred and stored in 8 no of pressurized VCM bullets at
10 kg/cm2g. The mounded vessels will be fabricated and installed as per OISD – 150.

The mechanical design of storage vessel shall be based on following considerations.

I. Design code – ASME SEC VIII or PD – 5500 or equivalent duly approved by CCOE.
A single code shall be adopted for design, fabrication, inspection and testing.
Specific consideration shall be given to

a) Internal vapor and hydraulic pressure

b) External loading on the vessel
c) Internal vacuum

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II. Material – The Material of construction for bullets is SA 537 CL.II the selected
material conforms to the design code.
III. Design temperature (-)27 to 55 deg C
IV. Design pressure is 25 kg.cm2g
V. Other considerations

a) Internal corrosive allowance: 1.5 mm

b) Radiography – full
c) Stress relieving – 100 % irrespective of thickness
d) Earthquake resistance as per IS:1893:2000
e) Hydrotest pressure as per design code

The cathodic protection shall be provided to protect the external surface of the bullet
from corrosion. Fire Safe Remote Operated valves (ROV’s) shall be provided on first
flange on liquid lines at a minimum distance of 3 m from the vessel.

Each vessel has two safety relief valves. Each storage vessel shall have minimum two
different type of level indicators and one independent high-level switch. Each vessel is
provided with one pressure and temperature measuring instrument. The pressure gauge
shall be provided with isolation valves.

3.5.1.10 Preparation and charging of demineralized water

Part of Demin water from Demin water tank is used in polymerization charging, bearing
seal priming, sealing, agitator/pump seal flushing, reactor rinsing etc. Part of cold
demineralized water is stored in clod DM water tank and used for buffer preparation,
catalyst preparation and additive preparation.

3.5.1.11 Preparation and feeding of additive agents

All the chemical agents for polymerization, such as initiators, dispersants, buffering
agents, defoaming agents, shortstops (terminators) are prepared and stored in their own
vessels. When the polymerization reaction occurs, chemical agents are sent to
polymerizes by pumps as per specified quantity in the recipe and specified procedure.

3.5.1.12 Polymerization

DM water, Dispersants, buffers and initiators are automatically added into the
polymerization reactor in a closed state according to PVC production process recipe for
the type and amount of raw materials and the feeding program of DCS setting.
Polymerization starts when the initiators are automatically added. By automatically
adjusting the level of cooling water, the reaction temperature is maintained.

Polymerization reaction takes place in accordance with the required temperature curves,
the polymerization heat is measured by a microcomputer to calculate the monomer
conversion rate. When the conversion rate is met, the terminators are automatically
added into polymerization reactor to terminate the reaction, PVD slurries are
automatically discharged to the vessel. After PVC is blown down, the reactor wall shall be
rinsed with water of appropriate pressure.

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3.5.1.13 Shortstop (Terminator) system

This process adopts two short stop systems for two different purposes and adopts
different short stops. One is for normal production stop of each batch operation, the other
is for emergency, during mechanical or power failure.

3.5.1.14 Vacuum system

Vacuum system shall be adopted to draw out air from all equipment of the unit containing
VCM to ensure safety of the unit after maintenance.

3.5.1.15 VCM Recovery system

Unreacted VCM from polymerization reactor and stripping outlet trough shall pass
through the VCM recovery unit in order to be used for utilization in the polymerizer.

3.5.1.16 PVC slurry stripping

PVC slurry stripping process shall be provided to remove efficiently and recover residual
vinyl chloride monomer from PVC resin. The PVC from blow down vessel enters the
stripping tower. In the stripping tower PVC slurry shall make heat exchange with cooling
water in counter current flow. After stripping, PVC slurry shall be stored in bin and sent
to PVC drying section. The VCM after stripping passes through the top stripping tower
condenser then to gas liquid separator and finally sent to VCM recovery section.

3.5.1.17 PVC centrifuge and drying

The section comprises of dewatering, finished product drying, screening and gas
conveyance.

PVC slurry after stripping enters centrifuge. After dewatering in centrifuge, wet PVC resin
is fed in dryer. Warm air shall be used to dry the PVC resin. Then after PVC enters the
vortex type cyclone dryer for drying of critical moisture content. The dried PVC powder
shall be separated with the air flow by the cyclone separator set. Finished PVC product
after screening shall be delivered to PVC intermediate silo and it goes into packaging
process by mixing pump.

Part of mother liquor from the PVC centrifuge goes to stripping tower for flushing the
tower, and part of it goes to PVC mother liquor treatment and recycle system.

3.5.1.18 PVC Packaging and product warehouse

PVC material from finished product silo is measured and bagged into 25 kg /bag by
quantitative semi-automatic packaging machine. After packaging, the packed PVC will be
transported to PVC warehouse by forklift.

3.5.1.19 PVC dispatch

Currently the site is connected via state highway 97 to national highway 66. SH97
connects the national highway at Mangaon, approximately 40 km from plant site. It is
foreseen that in first couple of years of plant operation, PVC shall be dispatched using this
connectivity. The state highway is already in use for dispatch of products of other
companies.

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The 43 km road and construction and widening tender from Indapur to Dighi port on
NH66 has been allotted to M/s JM Mhatre Infrastructure limited by MSRDC.

MOU is also signed between Maharashtra Maritime Board and Rail Vikas Nigam to
construct 35 km rail link from Dighi port to the nearest station Roha on Konkan Railway,
the link to permit speed up to 100 kmph which will further boost movement of goods.

3.5.1.20 Process Flow Diagram

Brief PVC process flow diagram is indicated below,

3.5.1.21 Technology Licensor – INEOS Technologies

a) INEOS is leading technology licenser by virtue of following strengths

o High quality and low-cost production facilities

o Well invested plants across the globe
o Large plant that benefit from economies of scale
o Favorable locations
o Experienced technical management
➢ Leading market position
➢ Operating diversity – product, customers, geographic regions, applications
and end use markets

b) INEOS Technologies key values are

o Excellence in safety, health and environmental performance

o Focus on customer satisfaction, total quality and reliability
o Continuous improvement to reduce costs

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o Encouragement of innovation and reward of achievement

c) Ineos Technologies (VINYL)

Leveraging INEOS’s position as the largest PVC producer in Europe; INEOS Technologies
Vinyls delivers a wide range of technologies, product know-how, and expertise that helps
customers all over the world to maximize operational performance. INEOS Technologies
(Vinyl) services are tailored to meet VPPL’s requirements from assistance during
engineering design and construction through to plant commissioning and from research
and development support to reliable supply of PVC additives and catalysts.

d) Vinyls Licensing

INEOS Technologies (Vinyl)is the leading licensor of Poly Vinyl Chloride (PVC), Ethylene
Di Chloride (EDC) and Vinyl chloride monomer (VCM) technologies for the PVC and Vinyl
industries worldwide.

With long experience of over 60years through its founder companies, INEOS
Technologies Vinyl’s technical expertise is recognized as being the industry leader. Their
S-PVC licensing technology brings together feature from all of INEOS Chlor-Vinyl’s plants
and which has been continuously developed to keep INEOS Chlor-Vinyls plants
competitive in the challenging European and Asian markets in terms of cost, quality and
environmental performance.

e) Vinyls catalysts and additives

Based on over 70 years of Chlor-Vinyl’s experience, INEOS Technologies Vinyl’s range

PVC additives brings real value to PVC plants. Process economics are improved by using
INEOS Technologies Vinyl’s high quality and well proven additives to reduce wastage,
increased output reduce downtime and improve quality.

INEOS Technologies Vinyls supports the entire range of Vinyls additives with technical
support across the INEOS group, drawing on dedicated people with many years of
experience in chemistry, engineering, Vinyls technology and Vinyls production.

f) Safety, Health and Environmental Benefits

INEOS plant design meets and exceed European Union standards of safety and
environmental performance, which are among the highest in the world. INEOS process
complies fully with all the European Council of Vinyls Manufacturer (ECVM)
environmental standards.

The closed process design minimizes reactor opening loss, with associated operator
hygiene and environmental benefits. The expected opening frequency is once in 500
batches, although frequencies of once per 2000 batches have been achieved on several
licensee plants.

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The continuous stripping column reduces the residual VCM in finished product to less 1
ppm. The stripping also reduces the loss of VCM to atmosphere from the slurry Tank and
Drier.

The reactor protection systems major hazard releases are of very high integrity and
include a reaction short stop system of extremely high reliability and effectiveness. INEOS
has > 400 reactor years operating experience on large reactor plants without
experiencing a release of VCM to atmosphere.

The INEOS Technologies process for initiator synthesis external to reactor is intrinsically
safe in that it is very difficult to overcharge initiator. Overcharging one of the initiator
components does not increase the yield of product but rather reduces the yield.

Initiator is not stored for any significant length of time but is made up as required and
used immediately. The inventory of initiator on the plant is very low and is in dilute
solution. It therefore does not constitute a significant hazard.

INEOS initiator does not require sub zero refrigerated storage. Hence VPPL does not have
to create cold storage for initiators.

The VCM recovery system does not use a gas holder, this gives obvious environmental
benefits.

All VCM contaminated water is stripped before final discharge ot levels > 1 ppm VCM.

g) Process economics

INEOS Technologies low cost initiator reduces initiator cost to those of the precursors, all
of which are easily available chemicals. This gives a significant saving in additives cost
per MT of PVC.

INEOS Technologies condenser process allows fast reactions without the need to use
chilled water for cooling the reactors. This is especially advantage where cooling water
temperatures are high because it saves the capital expenses of a large refrigeration
system and high electricity costs.

PMB Plant

3.5.2.1 Design basis

Plant Capacity: - 360,000 MTPA (1200 Tons Day).

Bitumen Grade: - Grade 60 — 70 and Grade 80 - 100

Bitumen Property Table: -

Properties Class 80 - 100 Class 60 - 70

Penetration at 25°C, 0.1mm 80 100 60 70

Softening point, °C 45.0 52.0 45.0 52.0

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Flash point, °C 276 - 276 -

Viscosity at 60°C (Poise) 140 - 260 -
Viscosity at 170°C (Poise) 0.45 - 0.65 -

3.5.2.2 Process Description

• Unloading & Handling facilities at Dighi jetty

Bitumen shall be unloaded from ship with the help of ship unloading through one number of
12” marine unloading arm/electrically heat traced pipeline & shall be transferred to proposed
storage tanks at VPPL.

• Pipeline transfer facilities:

12“lines shall be employed for transfer operation of Bitumen from Ship. Two mass flow
meters, one at jetty end & one at tank end shall be provided for mass measurement & input to
leak detection system. The motorized operated valve shall be provided at jetty for emergency
shutdown operation in case of leak. Lines shall have Electric Heat Tracing (EHT).

Unloading through 1 No of 12" transfer line

• Receipt & Storage facility
The Bitumen from ship will be transferred & stored in 2 nos of storage tank with a storage
capacity of 5000 m3 each.

Bitumen is stored in Conical Roof & inverted cone at bottom storage tanks. Each inlet line is
provided with motorized valve which has provision to open / close by hand in case of power
break-off. These tanks shall have one nozzle for inlet & one for pump recycle inlet, also one
outlet nozzle for PMB blender pump suction header. Tanks are provided with LP steam supply
& condensate return line to keep required temperature inside storage tank.

Inlet nozzle of recycle line is provided with jet mixer to mix the content in the tank & maintain
uniform density. Tanks are equipped with temperature & pressure transmitter which are
connected to level indicator. Level indicator will indicate level of tank after considering
temperature & pressure in the tank. High level switch is also provided.

• Combining Agent

Combining agents are sometimes added to PMBs to improve their performance properties and
shelf life and will comply with the requirements of the AAPA Guide to the safe use of SBS.

• Polymer

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The common generic polymer types used for the manufacture of PMBs are Styrene Butadiene
Styrene (SBS), Polyethylene’s and Ethylene Vinyl Acetate (EVA).

• Mixing

All polymer maintained at elevated temperatures for long periods will be subject to three
competing reactions: increase in molecular weight leading to gelation, caused by cross linking
of the unsaturated bonds; a similar, oxygen induced, polymerization; and breakdown
reactions. Additionally, bitumen are subject to hardening on prolonged high temperature
exposure. All of these reactions can be minimized by maintaining close control of operating
temperatures and residence times in the mixing equipment. Additional measures that will
reduce any tendency to polymerize by nitrogen blanketing of the mixing vessel. Component
materials have to be thoroughly mixed to ensure production of a homogeneous PMB. Critical
elements that are common to all processes include procedures for proportioning of materials,
temperature control, mixing time and conditions, and maintenance and cleanliness of
equipment.

• Storage of The Finished Product

2 nos. of Tanks for the storage of finished product with a storage capacity of 5000 cu.m will be
designed to minimize deterioration in storage, with strict control of

The common generic polymer types used for the manufacture of PMBs are Styrene Butadiene
Styrene (SBS), Polyethylene’s and Ethylene Vinyl Acetate (EVA).

• Mixing

All polymer maintained at elevated temperatures for long periods will be subject to three
competing reactions: increase in molecular weight leading to gelation, caused by cross linking
of the unsaturated bonds; a similar, oxygen induced, polymerization; and breakdown
reactions. Additionally, bitumen are subject to hardening on prolonged high temperature
exposure. All of these reactions can be minimized by maintaining close control of operating
temperatures and residence times in the mixing equipment. Additional measures that will
reduce any tendency to polymerize by nitrogen blanketing of the mixing vessel. Component
materials have to be thoroughly mixed to ensure production of a homogeneous PMB. Critical
elements that are common to all processes include procedures for proportioning of materials,
temperature control, mixing time and conditions, and maintenance and cleanliness of
equipment.

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• Storage of The Finished Product

2 nos. of Tanks for the storage of finished product with a storage capacity of 5000 cu.m will be
designed to minimize deterioration in storage, with strict control of temperature, minimal
surface area to reduce oxidation, and provision for mixing or circulation to ensure that the
product remains homogenous in storage.

Polymer Modified Bitumen is stored in Conical Roof & inverted cone at bottom storage tanks.
Each inlet line is provided with motorized valve which has provision to open / close by hand
in case of power break-off. These tanks shall have one nozzle for inlet & one for pump recycle
inlet, also one outlet nozzle for drum filling pump suction header. Tanks are provided with LP
steam supply & condensate return line to keep required temperature inside storage tank.

Inlet nozzle of recycle line is provided with jet mixer to mix the content in the tank & maintain
uniform density. Tanks are equipped with temperature & pressure transmitter which are
connected to level indicator. Level indicator will indicate level of tank after considering
temperature & pressure in the tank. High level switch is also provided.

The heating system will be designed such that the PMB is not exposed to high contact
temperatures around the heating elements or flues for prolonged periods. Prolonged exposure
of PMBs to heating elements may result in deterioration and carbonization of the binder. Tanks
will be provided with good circulation of the PMB around heating elements or flues, either
through the use of mechanical stirrers and/or by circulating the tank contents with a pump.

The tank heating system commonly used for PMB storage uses heat transfer oil and automated
temperature controls to limit overheating.

• Loading Gantry

All supply lines throughout the plant, including loading equipment to be designed and
procedures will be established as to avoid contamination during change of product or cleaning
of supply lines. The use of oils such as kerosene, diesel, or gas oil for flushing lines will be
avoided.

Where lines need to be flushed, it will be done with hot bitumen or finished product. Any oils
used for flushing or cleaning of supply lines will be collected and disposed of separately and
will not be added to products or components in storage or delivery vehicles.

• Bitumen Barrel Filling and Packing Facility

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The Polymer Modified Bitumen will have a mechanized and semi auto with a capacity of 6000
Drums per day.

Facilities for receipt and storage of Bulk Bitumen and all infrastructures required for Bitumen
handling including tank truck unloading arrangement.

3.5.2.3 Process Flow Diagram

Brief process flow diagram is indicated below.

Utilities

Following utilities are envisaged in this project. Further description of the utilities
systems is in subsequent chapter.

➢ Electricity

➢ Steam

➢ Potable Water (From SWRO System)

➢ Cooling Water

➢ Demineralized water

➢ Nitrogen gas

➢ Instrument & Plant Air

➢ Effluent treatment
➢ Sewage Treatment Plant
Utilities will be common to all manufacturing units within the Complex.

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Gas Storage terminal and bottling unit

3.5.4.1 Design basis

The detailed feasibility study is based on the following process parameters.

LPG-Composition

Designation LPG
Sp. Gr. @ 15 Deg C 0.51 – 0.58
Viscosity @ ST, CST 018 – 0.40
Water Content in LPG 200 ppm (As caustic Solution)
RSH – H (wppm) 10 (Max)
Re Entry – S + RSH -S, wppm (Max) 40
Caustic (NaOH) Traces
Total Sulphur Presence, ppm 150 (Max)
Liquid Propylene: - Composition wt%

Composition Propylene
Ethylene 0.02
Ethane 1.089
Propylene 95.196
Propane 3.69

Properties of Propylene
Water Content in Propylene 200ppm (As caustic Solution)
As H2 S, RSH, & COS, wppm(max) 5,10,10 Respectively
SP. GR. @ 15 Deg C 0.515 – 0.522
Viscosity @ ST, CST 0.15-0.38
Total Sulphur Presence, ppm 25 (max)
Caustic (NaOH) Traces

Sr. No Parameter LPG Propylene

A Unloading Condition
1 Unloading at Dighi Port Dighi Port
2 Unloading by Marine Unloading arm Marine Unloading arm
3 Pressure at ship pump
30.0 (min) 30.0 (min)
flange, kg /cm2g
4 Unloading Carrier 5,500 – 11,000m3 5,500 – 11,000m3

3.5.4.2 Process Description

Unloading & Handling facilities at Dighi jetty:

Pressurized liquid LPG and propylene shall be unloaded from ship with the help of ship
unloading pumps through two numbers of 8” marine unloading arm & shall be transferred
to proposed LPG and propylene bullets at VPPL gas storage Terminal.

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Pipeline transfer facilities

Both the 8“lines shall be employed for transfer operation of LPG and propylene from ship. Two
mass flow meters, one at jetty end& one at tank end, shall be provided for mass measurement
& input to leak detection system. The motorised operated valve shall be provided at jetty for
emergency shutdown operation in case of leak.

Receipt & Storage facility at Gas Storage Terminal

The LPG /Propylene from ship will be transferred & stored in 24 nos of pressurized mounded
bullets (Propylene Compliant) at 23.0 kg/cm2

The Mounded Vessels shall be fabricated & installed as per OISD-150.

The mechanical design of storage vessel shall be based on following considerations:

1. Design Code - ASME SEC. VIII or PD - 5500 or equivalent duly approved by CCOE.A
single code shall be adopted for design, fabrication, and inspection and testing. The
specific consideration shall be given to:
a. Internal vapor and hydraulic pressure
b. External loadings on the vessel
c. Internal vacuum
2. Material - The material of construction for bullets is SA 537 CL.II, the selected
material conforms to design code.
3. Design Temperature is (-) 27OC to + 55O C.
4. Design Pressure is 25 kg/cm2 g.
5. Other Considerations
a. Internal Corrosion Allowance: 1.5 mm (minimum)
b. Radiography: Full
c. Stress Relieving: 100% irrespective of thickness.
d. Earthquake pressure as per IS: 1893
e. Hydrotest pressure: As per Design Code

The Cathodic protection shall be provided to protect the external surface of the bullet from
corrosion.

Fire safe Remote Operated Valve(s) (ROVs) shall be provided on first flange on liquid line(s)
at a minimum distance of 3 m from the vessel.

Each vessel has two safety relief valves (SRV). Each storage vessel shall have minimum two
different types of level indicators and one independent high level switch. Each vessel is

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provided with one pressure and temperature measuring instrument. The pressure gauge shall
be provided with isolation valves.

• Dispatch Facilities at Gas storage Terminal

a. LPG & Propylene truck Loading:

LPG and propylene will be sent to truck loading facility.

• Process parameters

Unloading & handling facilities at Dighi jetty:

Ship unloading frequency Initially 2 Vessels in a week

Unloading by 2 Nos of 8” Marine Unloading Arm

• Pipeline transfer facilities

Unloading through 2 Nos of 8" transfer line

• Receipt & Storage facility at LPG Marketing Terminal

Storage Capacity of 24 Propylene complaint bullets with storage capacity of

Bullet cu.m 2500M3 in each bullet
No. of Mounded Bullet 24 Nos. each

• VCM/LPG/Propylene Transfer Pump

Liq. VCM from bottom outlet of all the VCM bullets is pumped to the PVC plant by 3 VCM
transfer pumps out of the 3 pumps, one is standby (VCM 2 mounds, 4 bullets each).

Liq. LPG from the bottom outlet is pumped to marketing area by 3 LPG transfer pumps. Out
of 6 pumps, 2 each being at 3 mounds, 1 pump at each mound will be standby. LPG 3
mounds 4 bullets each.

4 Propylene pumps (2+2) of similar draw suction of liquid Propylene from bottom of the
Propylene Bullets and send the product to marketing area. There will be 2 mounds of 6
bullets each.

VCM Transfer Pump

Type Vertical Canned Type with double mechanical
seal
Flow, MT/hr 70 (2W + 1S)
MOC LTCS
LPG Transfer Pump

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Type Vertical Canned Type with double mechanical

seal
Flow, MT/hr 100 (3W + 3S)
MOC LTCS
Propylene Transfer Pump
Type Vertical Canned Type with double mechanical
seal
Flow, MT/hr 100 (2W + 2S)
MOC LTCS
Dispatch Facilities at Gas Terminal
Loading to Un-insulated road tankers.
Loading temperature, °C 15
Loading by LPG / Propylene transfer pumps
No. of loading Station 4 bay Tanker Loading Facility
Pumping Rate, MT/hr 100

Bulk of Propylene/ LPG will also be transported by sea vessel.

Gas based Captive power plant

For operation of integrated petrochemical complex, captive power plant of 18 MW has

been envisaged.

Captive power plant producing 18 MW at 11 KV 50 Hz shall be installed. There will be gas

fired generators in multiple units (4 x 4.5 MW) which will be designed taking into
consideration, availability of 100 % operating power during maintenance downtime of
any one of the generating units.

Total expected connected load at site will be around 18 MW and operating load will be
12 MW at site.

3.5.5.1 Waste Heat recovery Boilers

Heat energy of the 18 MW gas turbines exhaust shall be utilized in the waste heat
recovery boilers for generating steam required at site.

Parameters of WHRB will be as follows

o Inlet gas temperature 450 ~ 500 deg C

o Inlet gas source: Gas engine exhaust
o Outlet gas temperature: 120 ~ 150 deg C
o Outlet “superheated” steam parameter – 10 barg @ 250 deg C
o Outlet “superheated” steam flow: 3 x 4 = 12 TPH

3.5.5.2 Fuel supply source and quantity

LNG will be used as fuel for gas turbines. Total requirement of fuel LNG for the 18 MW
power plant and PVC plant will be approximately 82,000 to 85,000 SCM per day which

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will be approximately 64 – 65 Ton a day if whole plant is running at its fill capacity. LNG
will be procured from IOC by way of a long-term agreement.

IOC currently has a system of “LNG at doorstep”. The natural gas is presently being
supplied in the country to its consumers through a network of pipelines or through road
transportation to customers.

Indian Oil has pioneered and commenced reliable supply of liquefied natural gas from to
its end user since 2007. The supply of LNG is done using cryogenic road transportation,
transfer to cryogenic storage tank at various customers premises and then using ambient
air vaporizers for onsite regasification of LNG for the cleanest natural gas supply to the
end use for power generation. This system is named by IOC as “LNG at Doorstep” and has
been offered to VPPL for a contract of 5 years.

The gas specification being offered top veritas by IOC are as follows.

Chemical name Methane

Chemical family Complex mixture of saturated hydrocarbons
Gross Calorific value 51500 Btu/kg or 12978 Kcal/kg
Molecular weight 16.042
Melting point @ 1 atm -182.2 deg C
Boiling point @ 1 atm -161.0 deg C
Auto ignition temperature 537.2 Deg C
Expansion ratio of liquid at 1 to 627
boiling point to gas at 15.6 deg C
Liquid density at boiling point 425.61 kg/m3 (26.56 lb/ft3)
Appearance, odor and state Colorless, odorless, cryogenic liquid

3.5.5.3 Regasification of LNG

LNG vaporizers (re gasifiers) are heat exchangers used for degasifying liquified natural
gas which is stored as a liquid under cryogenic temperature. Veritas has been
recommended to use ambient air heated vaporizers with capacity of 90,000 scmd. The
regasification cost for LNG using ambient air heated vaporizers is minimum. The ambient
air vaporizers are basically the heat exchangers using fans and blowers.

The storage capacity of LNG would be 3 x 110 KL cryogenic tanks. The quantity stored
will be sufficient for 4 to 5 days subject to plant operating at rated capacity.

Utility Plants

3.5.6.1 Cooling Water System

Open loop induced draft cooling tower of capacity 4000 m3/hr circulation (8 x 500
m3/hr) shall be installed for process and utility requirement with supply and return
temperature of 35 and 45 Deg C respectively.

Cooling towers shall be of FRP construction with hot dip galvanized structural members.

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Cold water basin shall be of RCC type. Cooling tower basin capacity shall be cooling water
pumped in five to six minutes by circulation pump.

No Description Capacity Quantity Power

Working Standby Total consumption,
kw
1 Cooling Tower 233.1 8 1 9 8 x 17
fan m3/sec
2 Cooling Tower 1950 8 1 9 8 x 110
circulation m3/hr
pumps
3 Blow down 1 0 1 11
pumps

3.5.6.2 Sea Water Desalination Plant

The scheme proposed is to treat Sea water (to remove dissolved solids) and to convert
it to produce potable water required at site for various purposes, 4.5 MLD capacity.

The proposed scheme is broadly as per following treatment steps

o Sea water intake pump house

o Electro chlorination system for sea water intake
o Pretreatment scheme for SWRO
o Chemical dosing for pretreatment system
o Reverse osmosis system
o Carbonation system
o Chlorination system for Potable water
o Remineralization system for potable water

3.5.6.3 Demineralization (DM) Water Plant

The scheme is proposed to generate Demin water of capacity 120 m3/hr required for
power plant. The proposed scheme is broadly as per following treatment steps

o Reverse osmosis system

o Degassing tower
o Mixed bed (MB) unit
o DM water storage tank
o Chemical handling system
o Effluent collection system

3.5.6.4 Compressed Air System

2 Nos of (1 working + 1 standby) of oil lubricated centrifugal compressors of capacity

1950 cubic meter/hr each shall be installed for process and utility requirement.

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Considering the requirement (dew point at a line pressure shall be 15 Deg C below
ambient air). 2 Nos of (1 working + 1 standby) of heatless desiccant dryer each of capacity
1950 m3/hr shall be installed.

VFD will be used for capacity control, It will contribute for power saving.

3.5.6.5 Nitrogen generation system

The Nitrogen generation system shall be for pipe line purging and blanketing.

Pressure swing absorption (PSA) – Nitrogen generation plant is proposed to generated

nitrogen gas of capacity 300 Nm3/hr.

It will consist of

o Air compressor
o Molecular sieve units
o Nitrogen surge vessel
o Oxygen analyzer
o Nitrogen storage tank

Raw material required

(Raw materials along with estimated quantity, likely source, marketing area of final
product/s, mode of transport of raw material and finish products.)

Following Major Raw materials will be required at site for the manufacturing activities.

No Raw CAS No Unit State Consumption Likely Mode of

Material per year (for source transport to
rated plant site
capacity)
1 Vinyl 75-01-4 MT Liquid Imported Ship/pipeline
Chloride 200,800
Monomer
2 LNG 74-82-8 MT Liquid 19,700 Local Road tanker
3 64742- Imported Ship/pipeline
Bitumen MT Liquid 360,000
93-4
4 SBS 9003- Local Paper
MT Solid 15,000
(Polymer) 55-8 bags/Road
5 EVA 24937- Local Paper
MT Solid 15,000
(Polymer) 78-8 bags/Road
6 LPG for 68476- Imported Ship/pipeline
MT Liquid 300,000
bottling 85-7

Following finished products will be manufactured at site, its marketing area, mode of
transport is as below,

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No Products CAS Unit State Production Marketing Mode of

No per year area transport
(as per from site
rated plant
capacity)
1 S-PVC (Sus. MT Solid Local Truck
9002-
Poly Vinyl 200,000
86-2
Chloride)
2 Polymer Local Truck/Tanker
64742-
Modified MT Solid 360,000
93-4
Bitumen
3 LPG Local & Truck/
68476-
(Bottles) & MT Liquid 600,000 overseas Tanker/ Sea
85-7
Bulk vessel
4 Propylene 74-98- Local & Tanker/ Sea
MT Liquid 360,000
Bulk 6 overseas vessel

Following major bulk storages are proposed at site.

N Chemical State Uni Storage type Storage capacity
o t
1 Vinyl Chloride Liquid M3 Mounded Bullets 8 x 2500 = 20,000
Monomer
2 LPG/ Propylene* Liquid M3 Mounded Bullets 24 x 2500 = 60,000
3 LNG Liquid KL Cryogenic Tanks 3 x 110 = 330
4 Bitumen Liquid M3 Heated Tanks 2 x 5000 = 10,000
5 PMB Liquid M3 Heated Tanks 2 x 5000 = 10000
6 SBS (Polymer) Solid MT Paper Bags 200
7 EVA (Polymer) Solid MT Paper Bags 200
* LPG/Propylene will be stored.

Manpower
Expected manpower requirement for operation phase at site for the projects shall be as
follows,

Description Number
Permanent 500
Contract workmen 500
Total 1000

Resource optimization

(Recycling and reuse envisaged in the project, if any, should be briefly outlined)

Following are some of the recycle options proposed by the industry.

o Improvement of yield of the products so as to reduce the waste generation during

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manufacturing.
o Waste / Used oil will be sent to Authorized Waste / Used oil Reprocessing units.
o Container & container liners of chemicals, Polythene / HDPE Bags, broken plastic
drums shall be disposed of to outside agencies after decontamination.
o Used Lead acid batteries will be sent back to suppliers on buy back basis.

Water, Energy / Power availability and source

(Availability of water, its source, Energy/power and requirement and source should
be given)

Water

Sea water will be the source of water requirement for the integrated petrochemical
complex.

The fresh water requirement for entire integrated complex is as follows.

Unit Capacity UOM Make up Quantity per day

Domestic - M3/day 100
DM Plant (For Boilers, 120 M3/day 2880
reactor and seal, m3/hr
processing)
Cooling Towers 4000 M3/day 1095
m3/hr
circulation
flow
Gardening/green belt - M3/day 230
maintenance
Total - M3/day 4305

It is proposed to treat sea water to remove TDS and to produce 4,455 m3/day potable
water required for domestic, Process, Boilers & Cooling towers and for green belt
maintenance purpose.

Energy

Energy in the form of steam will be generated in waste heat recovery section of gas fired
power generator. There will be 4 x 4.5 mw gas fired power generators. Waste heat
recovery section capacity of each generator will be 12 TPH steam (at pressure 10
kg/cm2g and temperature 250 deg C).

Power

For the operation of the integrated petrochemical complex, captive power generation has
been envisaged.

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The captive power of 18 MW (4 x 4.5 MW natural gas fired generators) will be produced
at 11 KV, 50 Hz frequency. The system will be designed taking into consideration,
availability of 100 % operating power during maintenance downtime of any one of the
generating units.

Fuel natural gas shall be procured from IOC, which will be received at site via road
tankers.

Waste generation, Management and disposal

Quantity of waste to be generated (liquid and solid) and scheme of their

management/disposal

Industrial Waste water

Industrial waste water (Process water) shall be treated in the ETP and the treated effluent
shall be disposed off in deep sea using pipelines and diffuser.

Solid waste – construction

Solid waste will be handed over to the authorized waste management companies/
agencies.

Nonhazardous waste

Non-hazardous waste will be converted to organic manure compost and will be used as
fertilizer for greenery.
Non-Hazardous waste details
Sr. Quantity in
Particulars Method of Disposal
No. TPA
1 STP Sludge 100 Used as manure
2 Insulation waste 2 Insulation waste Landfill.
Biodegradable garbage will be composted,
3 Garbage 10 used as manure and the rest will be
incinerated
4 Canteen Waste 10 Composting and used as manure
Note : Above is estimate, will be detailed in EIA

Hazardous waste

Hazardous waste details

Sr. Type of Waste Category Quantity per Method of Disposal
No. year
1 spent and lube oils 5.1 10 Ton Sale to authorized recyclers

2 Sludge and Filter 3.3 5 Ton Incineration.

contaminated with oil

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3 Discarded Containers 33.1 5 Ton Sale to scrap dealers after

and Barrels decontamination /
detoxification
4 Chemical Sludge from 35.3 127 Ton Landfill CHWTSDF
Waste Water Treatment
Plant (WWTP)
5 Filter and filter material 35.1 2 Ton Incineration
which have organic
liquid in them, for
example mineral oils,
synthetic oil and organic
chlorine compounds
Note : Above is estimate, will be detailed in EIA

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4 SITE ANALYSIS

Connectivity

The project site is at Dighi port. Dighi port situated in Raigad District in the state of
Maharashtra is a multipurpose, Multi cargo, all weather port which has direct berthing port
with a state-of-the-art cargo handling equipment's. It has ample land bank approximately
1,200 acres. It is a natural harbor and an exclusive channel offering a depth of 9.5 m, making
if one of the deepest channels in Maharashtra.

The port is well connected to national highway NH 753F and NH66. It is also part of the Delhi
Mumbai industrial corridor.

The central government has already sanctioned and started the construction of the Railway
line connecting the Central Railway station at Roha to the Dighi port which is about 35 Km
from the port. This will enhance the connectivity with the central and northern parts of the
country where in there is a huge potential for revenue to be generated from the sale of the
PVC so manufactured from the region.

The nearest airports are Mumbai and Pune. The nearest sea port is JNPT, which is about 70
km from the Dighi port.

Proper two lane 7 meters wide concrete road with 1.5-meter side shoulders connectivity is
available from Mangaon to Dighi Port.

From the junction NH 753F and NH66 located in Mangaon the four cities can easily be
connected i.e Mumbai, Pune, Ratnagiri & Goa.

MSRDC have already given the road construction contract to J.M. Mhatre & Co. With the
construction of 4 lane road between Dighi and Mangaon the current capacity to receive and
dispatch 500 trucks and trailers per day at Dighi, will go up to 1200 trucks and trailers per
day. Therefore, with a maximum number of 200 trucks to be dispatched every day from
VPPL's site, we do not anticipate any evacuations problems. The break up for the same would
be at the very most 130 trucks per day for PVC, PMB and 60 trucks for the Gas Storage
outflows.

Land form, Land use and land ownership

Total land is 59.277 Acres. And is in is in possession of Project Proponent.

Topography (along with map)

The Topography map with a 10 km radius is enclosed as Annexure- III.

Existing land use pattern

The land use pattern of project area (core area) 59.277 Acres. Shortest distance of
environmental components in buffer area from the project periphery is given in table
below.

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No Particulars Details (Distance & Direction w.r.t. site)

1 Water bodies -Rajapuri creek adjacent to site towards north.
-Murud Janjira Lakes ~ 5 km
-Dam near Kudki ~ 9.37 Km
-Dam near Undergaon Tisale ~5.97 km
-Dam near Usadi ~8.00 km
2 Reserve Forests ~ 1.5 km towards south side of the project side
3 National Parks/ Wild Life -Phansad wildlife sanctuary located at ~7.5 km
Sanctuaries / Eco sensitive to North.
areas etc -Murud Jangira is towards NE across Rajapuri
creek at ~ 3.5 km.
-Kasa fort ~ 5Km toward NW side.
4 Habitation Nanavali village is ~ 1 km SW
Dighi village ~ 2 km SE
Rajapuri- ~ 3 km NE across Rajapuri creek

Existing infrastructure

Currently the land is vacant. There is Dighi port adjacent to site where bulk liquid and solid
consignments are handled.

Soil classification

The soils of the district are formed from the Deccan trap which is the predominating
rock formation of this district with small out-crops of laterite at a few places in the
Poladpur taluka and in the Matheran hills. Various types of these soils are marked out
as per topographical situation and location. They are generally grouped as
forest, varkas, rice, khar or salt, coastal alluvial and laterite soils.

Forest soils:

These soils are not used for agricultural purposes but yield valuable forest products such
as teak-wood, hirda (myrobalan), beheda, pepper, etc. However, these soils are heavily
eroded due to grazing and cutting of the forest trees.

Varkas soils:

These soils are located just below the forest soils all along the steeper slopes. They are
shallow in depth, which varies only between a foot and a foot and a half, heavily eroded
and sandy in texture and yellowish red to yellowish grey in colour with acidic reaction.
They are poor in organic matter and nitrogen and possess very little retentivity of

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moisture. They yieldkharif millets but the production thereof could be increased with
the addition of bulky manures, lime and nitrogenous and phosphatic fertilisers.

Rice soils.

The district is the second largest producer of rice in the Maharashtra State. The region
is peculiarly terraced and, though the small strips in between the two terraces are
levelled, it is difficult to get even a few gunthas of land in one piece in a levelled
condition. The depth varies between two and six feet. They are loamy in texture,
yellowish or reddish grey in colour, neutral in reaction and almost devoid of lime. They
are formed from the trap rock from the Sahyadri ranges under heavy rainfall and humid
climatic conditions. The linear response of rice to the application of nitrogenous,
phosphatic and potassic fertilisers is observed in these soils. Addition of bulky manures
in these soils is also found to be advantageous from the point of view of yield. There are
some patches of manat soils in Mangaon taluka which are rich in clay and silt and which
become stiff and hard when dry.

Khar soils.

These soils are situated on the flat, levelled land near the sea at the point of creeks
formed due to the rivers. They are flat clay to clay loam in texture and reddish or
yellowish grey in colour. These soils contain hardly more than one per cent of soluble
salts. These soils are formed due to the deposition of salts by the sea or from lands
reclaimed from the sea. Large tracts of land are going out of cultivation due to the ingress
of the sea and, in order to reclaim these lands, the Government have formed the Khar
Land Development Board which has undertaken ambitious projects of the reclamation
of khar lands.

Coastal alluvium soils.

These soils are found all along the coast and at places where there are no creeks. They
are deep soils developed on flat land and loamy in texture with reddish grey colour. They
are devoid of clay fraction or humus and are open in nature. The profile is difficult to
differentiate and is excessively drained. Calcium carbonate is found in abundance
throughout the profile, but calcium has not entered the clay complex. The sub-soil water
level is only from ten to fifteen feet deep. The salt contents of the well water are higher
in the proximity of the sea; but due to excellent drainage, its use has not produced any

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deleterious effects. The soils are almost neutral or slightly on the alkaline side of
neutrality. Good garden crops like coconut, areca-nut, plantain, etc., are grown in these
soils, depending upon the availability of water.

Laterite soils.

Out-crops of laterite rock are observed amongst the Sahyadri ranges amidst the trap rock
mainly at Matheran and in the Poladpur taluka. These soils mostly occur on the mountain
peaks. They are coarser in texture, wherever there are no forests. They are yellowish-red
in colour and shallow in depth and yield coarse millets and niger. The heavy rains in the
mountainous regions thoroughly leach the soils turning them acidic in reaction and devoid
of calcium carbonate. They are rich in sesquioxides, the ratio of silica to sesquioxides being
less than two. But they are generally poor in exchangeable bases or in fertility constituents.
However, the soils from the forest region are well-supplied with nitrogen and organic
matter.
Typical soil analysis is as follows
Description of Soils
Chemical
Coastal Salt land or
Analysis Loamy Varkas Laterite
Alluvial Khar land
(1) (2) (3) (4) (5) (6)
Yellowish Yellowish red Reddish or
Reddish
Colour to reddish to yellowish Yellowish red yellowish
grey
grey. grey. grey.
Depth 1'—3' 1' - 2' 3' — 5' 5' — 10' 5' — 10'
Per cent on
drv matter
oven
Organic matter 0.7 — 1.8 0.5 — 1.0 2.0 — 3.0 0.7 — 1.5 0.5 — 1.5
Calcium
Nil — 0.01 Trace Trace 5.0 — 10.0 0.05 — 2.00
Carbonate
Sand (Coarse
5.0 — 10.0 60.0 — 70.0 8.0 — 10.0 20.0 — 35.0 20.0 — 30.0
and fine)
Silt 30.0 — 35.0 10.0 — 15.0 40.0 — 60.0 30.0 — 40.0 25.0 — 30.0
Clay 30.0 — 40.0 10.0 — 20.0 30.0 — 40.0 15.0 — 30.0 10.0 — 20.0
Clay to Clay
Textural class Loam Sandy Sandy loam Clay loam
loam
Total soluble
0.04 — 0.05 Trace 0.02 — 0.04 Trace 1.0 — 3.0
salts
Organic carbon 0.4 — 0.9 0.27 — 0.67 1.5 — 3.0 0.4 — 1.6 0.5 — 1.05
Total Nitrogen 0.04 — 0.06 0.02 — 0.05 0.15 — 0.20 0.06 — 0.10 0.05 — 0.07
C/N 10—16 10—16 10—15 10—16 10—15
PH value 6.7 — 7.2 6.0 — 7.5 4.5 — 6.0 7.0 — 8.0 7.0 — 8.0
Mgm. per cent
drv matter
on oven
Available P205 8—10 5.10 Trace—5 10—15 10—15
Available K20 12—20 10—20 5—10 20—25 10—15

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Description of Soils
Chemical
Coastal Salt land or
Analysis Loamy Varkas Laterite
Alluvial Khar land
(1) (2) (3) (4) (5) (6)
millie
equivalent
dry matter
per cent on
oven.
Exchangeable
20—25 18—25 5—10 30—35 20—30
Ca
Exchangeable
7—8 7—10 1—2 5—7 10—11
Mg
Exchangeable
0.08 — 2.0 2—3 0.01 — 0.02 2.3 7.5 — 12.0
Na
Exchangeable
0.82 — 1.0 0.44 — 0.8 1—2 0.4 — 0.6 1.2
K
Exchangeable
-- -- 4—6 -- --
H
Total
Exchangeable 30—35 40—43 15—18 35—40 20 — 35
bases
Base Exchange
20—35 40—45 19—24 35—40 30—35
Capacity

Climate data from secondary sources

Climate:
Dighi comes in Shrivardhan Tahsil of Raigad district of Maharashtra. The climate of this
district is typical of that on the west coast of India, with plentiful and regular seasonable
rainfall, oppressive weather in the hot months and high humidity throughout the year. The
summer season from March to May is followed by the south-west monsoon season from
June to September. October and November form the post-monsoon or the retreating
monsoon season. The period from December to February is the cold season.
Rainfall:
The district has a network of eleven rain gauge stations with records extending to 82
years for most of the stations. The south-west monsoon commences by about the first
week of June and the rains continue till about the beginning of October. The average
annual rainfall for the district as a whole is 3,028.9 mm. (119.25"). The rainfall increases
rapidly from the coast Howards the Western Ghats on the eastern border of the district.
In the coastal strip the annual rainfall decreases from south to north. Uran and Alibag at
the northern end of the coast get annually 2,072.3 mm. (81.58") and 2,080.8 mm.

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(81.92") of rain, respectively, Matheran gets as much as 5,167.5 mm. (203.45") of rain
annually. Nearly 95 per cent, of the annual rainfall is received during the south-west
monsoon months, and the rainfall in October forms the major portion of the rest. July is
the month with the heaviest rainfall, the same being 38 per cent of the annual rainfall.
Temperature:
Being a coastal district the diurnal (daily) and seasonal variations of temperature are
not large. The period from March to May is one of increasing temperatures. May is the
hottest month with a mean daily maximum temperature at 31.7°C (89.1°F) and the mean
daily minimum temperature at 26.4°C (79.5°F). Fresh breezes from the sea relieve the
oppressive heat particularly in the coastal regions in the afternoons. The onset of the
south-west monsoon early in June brings down the temperatures slightly. After the
withdrawal of the south-west monsoon by the end of September the day temperatures
increase slightly and the weather in October and November is almost like the summer
months. In the period from December to February the weather is cooler than in the post-
monsoon months.
Humidity:
The air is humid throughout the year. Relative humidity is on an average over 80 per
cent during the south-west monsoon season. In the rest of the year the relative humidity
is between 65 per cent and 75 per cent.
Cloudiness:
During the south-west monsoon season skies are heavily clouded to overcast. In May
and October the clouding is moderate. Clear or very lightly clouded skies are common in
the rest of the year.
Winds:
Winds are very strong and blow from west or south-west during monsoon season.
During the period from October to December winds are generally moderate but
sometimes strong in October and blow from directions between north-east and south-
east. In the three months from January to March the winds continue to be moderate and
are predominantly from directions between north and east. In April while there is a
slight strengthening of wind, the direction is variable. In May there is a further
strengthening of winds and the directions are between south-west and north-west.
Special weather phenomena:

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In association with cyclonic storms in the Arabian sea in the post-monsoon months and
to a lesser extent in May, the district experiences very strong winds, sometimes reaching
gale force, particularly very near the coast and also heavy widespread rain. Occasionally
these storms may cross the coast in the northern part of the district and cause heavy
damage. Thunderstorms occur in April and May and just before the onset of the
monsoon and in the late September to the middle of November.

Social infrastructure available

There is no major social infrastructure around project site.

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5 PLANNING BRIEF

Planning Concept

Type of Industry: Integrated Petrochemical complex.

Facilities: Facilities required for Petrochemical complex will be provided as per
requirement.
Transportation: Transportation of raw material and final products is done via roads and
sea.
Town and Country Planning Classification: Industry land is private land converted to
industrial use and is in possession of project proponent.

Population Projection

In 2011, Raigad district had population of 2,634,200 of which male and female were
1,344,345 and 1,289,855 respectively. In 2001 census, Raigad had a population of
2,207,929 of which males were 1,117,628 and remaining 1,090,301 were females. Raigad
District population constituted 2.34 percent of total Maharashtra population.

In 2001 census, this figure for Raigad District was at 2.28 percent of Maharashtra
population.

There was change of 19.31 percent in the population compared to population as per 2001.
In the previous census of India 2001, Raigad District recorded increase of 20.99 percent
to its population compared to 1991.

The initial provisional data released by census India 2011, shows that density of Raigad
district for 2011 is 368 people per sq. km. In 2001, Raigad district density was at 309
people per sq. km. Raigad district administers 7,152 square kilometers of areas.

There is a scope for increase in the population from the proposed project. Skilled workers
prefer to stay in the nearby locations to avoid travelling from long distances. Local non-
technical villagers will be preferred for the unskilled jobs such as gardening, material
movement etc. Local educated youth will be employed as semi-skilled workers and
training will be provided. Hence, there is a possibility of increase in population of the
skilled and semi-skilled. However, on the whole there is a possibility of little increase in
population of the area.

Land use planning

The unit has been proposed in the existing land. Land use pattern of the project area is
given in table below,
No Description/Purpose Area in Acres % of Total area
1 Total project land area 59.277 100
2 Total Built-up Area 22.60 38.12
3 Green Area 20.025 33.78
4 Parking Area 5.67 9.56
5 Area for road & Open space 10.982 18.52

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Assessment of Infrastructure Demand (Physical and social)

Infrastructure such as residence, transport, health center, hospitals, amenities etc around
the project will be required.

Amenities / Facilities

Industry will provide the following amenities / facilities in the proposed project.
o Canteen
o Potable drinking water
o Training block
o Concrete/tarred internal roads
o Emergency and firefighting facilities
o Occupational health center & Emergency services.
o Rest Room for employees/Drivers
o Pre-employment and routine medical examinations and the necessary
follow up actions
o Transport facilities for commuting employees
o Communication systems like Phone, Internet etc.
o Security systems.

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6 PROPOSED INFRASTRUCTURE

Industrial Area (Processing area)

Production Plants, administration facilities, warehousing/storages, loading/unloading,

utility area, Utility plants is proposed at the site.

Residential area (non-processing area)

There is no any residential area proposed at site.

Green Belt

Green belt of adequate area within and around the project site shall be carried out as per
industries norms and requirement.

Social Infrastructure

As a part of Entrepreneur Social Commitment (ESC), Industry will contribute for

development of social infrastructure around site.

Connectivity

The site is connected by road and sea.

Drinking water management

Sea water will be used for converting to potable water at desalination plant. Domestic
water requirement is ~ 100 cmd at site.

Sewerage System

Sewage Treatment Plant (STP)

Sewage is proposed to be treated in independent STP of installed capacity of 80 cubic
meter per day and treated sewage water will be used for gardening/green belt
maintenance at the site.

Sewage for entire site will be collected by gravity sewers leading to sewage collection pit
at STP.

Proposed scheme has following broad steps.

o Screening
o Oil and grease trap
o Equalization tank
o Bioreactor
o Secondary settling unit
o Disinfection system
o Multigrade filter
o Activated carbon filter
o Sludge handling system

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Industrial waste management

Manufacturing facility generally contributes to all types of waste such as liquid, solid and
gaseous. The management of these wastes is to be handled carefully and by adopting
proper segregation techniques.

Refer 3.9 above for details.

Solid waste management

Refer 3.9 above for details.

Power requirement and supply / source

Refer 3.8.3 above for details.

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7 REHABILITATION & RESETTLEMENT PLAN

(Policy to be adopted (center/state) in respect of project affected persons including home

oustees, land oustees and landless labors (a brief outline to be given)

The proposed new facility shall be at plot owned by the company which is located at Dighi
port. It does not require acquisition of Land and the Infrastructure so there is no any kind
of activity of Rehabilitation and Resettlement required to be carried out.

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8 PROJECT SCHEDULE AND COST ESTIMATES

Likely date of start of construction and likely date of completion

Project is expected to be completed in 30 months.

Estimated project cost

The project cost is Rs. 2050.42 Cr as stated in the Ultra Mega project
approval from the Government of Maharashtra.

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9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATION)

Benefits of the Project

➢ Socio-Economic Project: Substantial state interest and welfare of the people.
➢ Employment: Project will generate direct and indirect employment
➢ Low Cost Housing: Promotion and Development of low income and cost housing approximately
500 crores of saving annually in terms of the capital outlay with PVC Profiles.
➢ Pradhan Mantri Ujjwala Yojana: LPG bottling plant will support the PMUY. The LPG bottling
plant will upsurge the usage of LPG in the deep villages of the state.
➢ Delhi Mumbai Industrial Corridor (DMIC): Visibility and Momentum enhancement of DMIC.
➢ Skill development and economic upliftment: Location of the whole project being remote village-
Dighi, will bring in employment and skill up-gradation of the work-force and in turn prosperity to
the villages nearby.
➢ Development of Port: The project will bring in over 2 – 3 MMT of captive cargo to the port
presently under stress and enhance prominence of the port.
➢ Domestic Production: Boosting domestic (State) manufacturing capacities will directly bring in
prosperity to the State, more so in this underdeveloped area.
➢ Import Substitution: (Over 1.8 MMTA of PVC is being imported into India)- will save foreign
exchange exchequer. Aprox Rs 1,250 Cr annually.
➢ Decrease Life Cycle cost of Road: PMB is especially beneficial for coastal roads and increases the
durability & safety of roads upto 8 times compared to normal bitumen roads. If the durability of
roads goes up by 8 times the cost of new development, operations and maintenance of the roads
will decrease substantially, on a most conservative basis we estimate it will go down by half in effect
translating to a savings of atleast Rs 1500 crores annually.
➢ Green Power: Power generation though NG instead of Coal based which is highly polluting but
cheaper. The Power Plant is for Captive use however, extra power will be supplied to the existing
port, as it does not have the grid connectivity which will benefit the port.

Monetary Benefits
* Assumptions

2021 -
Unit Category
2021 2031 2021 - 2051
GST
189.00 2,775.11 14,863.53
PVC Low Cost
Housing
Savings* 500.00 5,000.00 15,000.00
GST 228.10 3,349.16 17,938.16
PMB
Annual Savings*
1,500.00 15,000.00 45,000.00
Gas
Storage +
GST
LPG
bottling 658.49 9,572.65 75,815.08
Total (In Crores)
3,075.58 35,696.92 1,68,616.76

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Annexure I

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Annexure II

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Annexure III

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Annexure IV

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Annexure V

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