PFD File

PUNJAB ALKALIES AND
CHEMICALS LTD. (PACL)
Pre-Feasibility Report: Environmental

Clearance for Proposed Capacity
Expansion of Existing Chlor Alkali Plant
and establishment of New Flaker Plant,
Hydrogen Peroxide Plant & Captive
Power Plant at Village Naya Nangal,
Dist. Rupnagar, Punjab
OCTOBER, 2018
Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development

PRE-FEASIBILITY REPORT: PROPOSED CAPACITY EXPANSION OF EXISTING CHLOR ALKALI
PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT, HYDROGEN PEROXIDE PLANT & CAPTIVE
PACL POWER PLANT AT NAYA NANGAL, PUNJAB QUALITY CONTROL SHEET
Punjab Alkalies & Chemicals Ltd. (PACL)
Pre-Feasibility Report: Environmental Clearance for

Proposed Capacity Expansion of Existing Chlor Alkali Plant
and establishment of New Flaker Plant, Hydrogen
Peroxide Plant & Captive Power Plant at Village Naya
Nangal, Dist. Rupnagar, Punjab
© Kadam Environmental Consultants (‘Kadam’), August, 2018
This report is released for the use of Punjab Alkalies and Chemicals Ltd. (PACL), Regulators and relevant
stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless
attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without
the written consent of Kadam.
QUALITY CONTROL
PROJECT DETAILS
Name of Pre-Feasibility Report: Proposed Capacity Expansion of Existing Chlor Alkali Plant and establishment of New
Publication Flaker Plant, Hydrogen Peroxide Plant & Captive Power Plant at Village Naya Nangal, Dist. Rupnagar, Punjab.
Project October,
1835371306 Report No. 1 Version 0 Released
Number 2018
AUTHORS
Data Collection and compilation: Mr. Kshaumesh Antani, Mr. Bhavin Jambucha
Kadam
Supervision, Checking and Release: Mr. Sangram Kadam
Client Punjab Alkalies and Chemicals Ltd. (PACL)
CONTACT DETAILS
Vadodara Office: Address: 871/B/3, GIDC Makarpura, Vadodara, India–390 010; T:+91-265-6131000; E:
[email protected];
Delhi / NCR Office: Address: Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna
Road, Gurgaon, Haryana, INDIA – 122002; T:0124-4242430 to 436; E: [email protected];
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan, believes that the
facts presented in the report are accurate as on the date it was written and takes full responsibility of what has been mentioned.
However, we are human: it is impossible to dismiss absolutely, the possibility of unintended errors or omissions. Kadam therefore
specifically disclaims any liability resulting from third party use or application of the information contained in this report for
reasons other than for which this report has been prepared and such third party users are encouraged to procure latest
information prior to applying it. Any reader dis-satisfied with report quality or facts presented in this report or having suggestions
is encouraged to directly contact us at +91-265-6131-000 or write to us at [email protected].
KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 2

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB LIST OF TABLES
CONTENTS
1 EXECUTIVE SUMMARY ................................................................................................ 9
1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 9

1.2 UTILITY & FUEL ......................................................................................................... 9
1.3 INFRASTRUCTURE ...................................................................................................... 10
1.4 ENVIRONMENT.......................................................................................................... 10
1.5 SENSITIVITY ............................................................................................................ 10
1.6 CONCLUSION ........................................................................................................... 10
2 INTRODUCTION ....................................................................................................... 11
2.1.1 Identification of Project Proponent & Project ............................................................. 11

2.1.2 Project Proponent .............................................................................................. 11
2.1.3 Proposed Project ............................................................................................... 11
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ..................................................................... 11
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION ......................................... 13
2.3.1 Chlor-Alkali Plant ............................................................................................... 13
2.3.2 Stable Bleaching Powder...................................................................................... 13
2.3.3 Hydrogen Peroxide ............................................................................................ 13
2.3.4 Captive Power Plant ........................................................................................... 13
2.4 DEMAND & SUPPLY GAP................................................................................................ 13
2.5 EXPORT POSSIBILITY ................................................................................................... 14
2.5.1 Domestic / Export Market .................................................................................... 14
2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT ............................................. 14
3 PROJECT DESCRIPTION ............................................................................................ 15
3.1 TYPE OF PROJECT ...................................................................................................... 15

3.2 LOCATION OF THE PROJECT ............................................................................................ 15
3.3 DETAILS OF ALTERNATE SITES CONSIDERED........................................................................... 18
3.4 SIZE OR MAGNITUDE OF OPERATION................................................................................... 18
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ...................................................................... 18
3.5.1 Chlor Alkali Plant (Existing + Expansion) – 800 TPD along with New Flaker Plant – 200 TPD .... 18
3.5.2 Stable Bleaching Powder (New Plant) – 100 TPD ........................................................ 23
3.5.3 Hydrogen Peroxide (New Plant) – 50 TPD ................................................................. 24
3.5.4 Coal & Biomass based Captive Power Plant (New Plant) – 75 MW .................................... 26
3.6 RAW MATERIAL DETAILS ................................................................................................ 29
3.7 UTILITIES .............................................................................................................. 29
3.7.1 Power Requirement ............................................................................................ 29
3.7.2 Fuel Requirement .............................................................................................. 30
3.7.3 Water Requirement ............................................................................................ 30
3.7.4 Storage Details ................................................................................................. 31
3.8 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 34
3.8.1 Air Emissions & Control ....................................................................................... 34
3.8.2 Noise Generation ............................................................................................... 35
3.8.3 Waste Water Generation ...................................................................................... 35
3.8.4 Hazardous Waste & Other Solid Wastes ................................................................... 36

3.8.5 Solvent Details.................................................................................................. 38

3.8.6 Catalyst Details ................................................................................................. 38
4 SITE ANALYSIS ........................................................................................................ 39
4.1 CONNECTIVITY ......................................................................................................... 39

4.1.1 By Road.......................................................................................................... 39
4.1.2 By Rail ........................................................................................................... 39
4.1.3 By Air ............................................................................................................ 39
4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 39
4.2.1 Nangal Wildlife Sanctuary .................................................................................... 40
4.3 TOPOGRAPHY ........................................................................................................... 40
4.4 EXISTING INFRASTRUCTURE ............................................................................................ 40
4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 40
4.5.1 Soil Classification ............................................................................................... 40
4.5.2 Geology .......................................................................................................... 40
4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 41
4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 41
5 PLANNING BRIEF ..................................................................................................... 42
5.1 PLANNING CONCEPT .................................................................................................... 42

5.2 POPULATION PROJECTION .............................................................................................. 42
5.3 LAND USE PLANNING ................................................................................................... 42
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 42
5.5 AMENITIES / FACILITIES ............................................................................................... 42
6 PROPOSED INFRASTRUCTURE ................................................................................... 43
6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 43

6.2 RESIDENTIAL AND NON- PROCESSING AREA ........................................................................... 43
6.3 GREENBELT ............................................................................................................. 43
6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 43
6.5 CONNECTIVITY ......................................................................................................... 43
6.6 DRINKING WATER MANAGEMENT ...................................................................................... 44
6.7 SEWERAGE SYSTEM .................................................................................................... 44
6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 44
6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 44
7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .................................................... 45
8 PROJECT SCHEDULE AND COST ESTIMATE................................................................... 46
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 46

8.2 ESTIMATED PROJECT COST ............................................................................................ 46
8.2.1 Economic Viability .............................................................................................. 46
9 ANALYSIS OF PROPOSAL .......................................................................................... 47
9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 47

ANNEXURES
Annexure 1: Copy of Letter from MoEF regarding non-requirement of EC for project ........................................... 49
Annexure 2: Copies of CTO (Air & Water), Renewal Letters & Authorization of Hazardous Waste .......................... 52
Annexure 3: Land Possession Documents ......................................................................................................... 74
Annexure 4: Site Layout Map showing Existing & Proposed Units along with Greenbelt ........................................ 97

LIST OF TABLES
Table 1-1: List of Utilities & Fuel ........................................................................................................................9
Table 2-1: Details of Directors ......................................................................................................................... 11
Table 2-2: Products Capacity (Existing & Proposed) .......................................................................................... 11
Table 2-3: Power Generation Capacity (Proposed)............................................................................................. 12
Table 3-1: Co-ordinates of Site Boundary ......................................................................................................... 18
Table 3-2: Mass Balance – Chlor Alkali Plant ..................................................................................................... 22
Table 3-3: Mass Balance – Stable Bleaching Powder .......................................................................................... 24
Table 3-4: Mass Balance for Hydrogen Peroxide ................................................................................................ 26
Table 3-5: Details of Raw material Quantity, Source and Mode of Transport ....................................................... 29
Table 3-6: List of Fuel Requirement ................................................................................................................. 30
Table 3-7: Water Consumption Details ............................................................................................................. 30
Table 3-8: Means of Storage of Raw Materials, Products & Fuel ......................................................................... 32
Table 3-9: Details of Flue Stack Emissions & Process Vents................................................................................ 34
Table 3-10: Wastewater Generation Details ...................................................................................................... 36
Table 3-11: Hazardous Waste Generation and Disposal ..................................................................................... 36
Table 3-12: Solid Waste Generation & Disposal ................................................................................................. 36
Table 3-13: Other wastes generated ................................................................................................................ 37
Table 3-14: Lists of Solvents Used ................................................................................................................... 38
Table 4-1: List of Villages in Nearby Area (within 5 Km) .................................................................................... 39
Table 4-2: Details of Protected Forest & Wild life Santuary ................................................................................ 40
Table 8-1: Estimated Cost – Chlor Alkali, Flaker, SBP & Hydrogen Peroxide Plant ................................................ 46
Table 8-2: Estimated Cost – Captive Power Plant .............................................................................................. 46
LIST OF FIGURES
Figure 3-1: General Location of Proposed Project Site ....................................................................................... 15
Figure 3-2: Project Site on Toposheet No. F43E3 & F4E7 showing 3, 5, 7 & 10 km Radii Circles ........................... 16
Figure 3-3: Specific Map showing Project Boundary ........................................................................................... 17
Figure 3-4: Process Flow Diagram – Caustic Soda & Flaker Plant ........................................................................ 22
Figure 3-5: Process Flow Diagram – SBP Plant .................................................................................................. 23
Figure 3-6: Process Flow Diagram of Hydrogen Peroxide ................................................................................... 25
Figure 3-7: Process Flow Diagram of Coal based Captive Power plant ................................................................. 28

ABBREVIATIONS AND ACRONYMS

RF : Reserve Forest
PACL : Punjab Alkalies & Chemicals Ltd.
SLF : Secured Landfill Facility
PSIDC : Punjab State Industrial Development Corporation Limited
RO : Reverse Osmosis
MEE : Multiple Effect Evaporator
ECZ : Eco Sensitive Zone
WLS : Wildlife Sanctuary
MTPA : Metric Tons per Annum
EC : Environmental Clearance
EIA : Environmental Impact Assessment
CtE : Consent to Establish
CC&A : Consolidated Consents and Authorisation
APCM : Air Pollution Control Measures
HFO : Heavy Fuel Oil
FO : Furnace Oil
HSD : High Speed Diesel
MW : Mega Watt
TPA : Tons per Annum
TCD : Tonnes Crushed Daily
TPM : Tonnes per Month
pH : Potential of Hydrogen
CPP : Captive Power Plant
DG : Diesel Generator
KLD : Kilo Litre Per Day
ETP : Effluent Treatment Plant
IMD : Indian Meteorological Department
PPCB : Punjab Pollution Control Board
ZLD : Zero Liquid Discharge
NFL : National Fertilisers Ltd.
IAS : Indian Administrative Services
AMAI : Alkali Manufacturers’ Association of India
CAGR : Compounded Annual Growth Rate
MT : Metric Tonnes
SBP : Stable bleaching powder
EAQ : Ethyl Anthra Quinone
TBU : Tetra Butyl Urea
TOP : Tetra Octyl Phosphate
CFBC : Circulating fluidised bed combustion
PNFC : Punjab National Fertiliser Corporation
cusecs : Cubic feet per second
PM : Particulate Matter
SH : State Highway
HCl : Hydrochloric Acid
Cl2 : Chlorine

CPCB : Central Pollution Control Board

H2O2 : Hydrogen Peroxide
NW : Northwest
SW : Southwest
NE : Northeast
R&R : Rehabilitation and Resettlement
INR : Indian Rupees
NCR : National Capital Region

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB EXECUTIVE SUMMARY
1 EXECUTIVE SUMMARY
Punjab Alkalies and Chemicals Ltd. (PACL) is promoted by the Punjab State Industrial Development Corporation
Limited (PSIDC), a wholly owned Punjab Government Company. Its turnover was INR 305 crores for FY. 2016-17.
The PACL facility is located at Nangal-Una Road, Naya Nangal, Rupnagar Dist., Punjab - 140126.
As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category
including Project / Activity: 4(d) – Chlor Alkali industry along with 1(d) – Thermal Power Plants and categorized
under “A”, due to the following reasons:
 Project is outside the notified industrial area/estate and overall Chlor-Alkali capacity is ≥300 TPD;
 Inter-state boundary between Punjab & Himachal Pradesh is ~1.0 km West of the site.
1.1 Plant Features and Production Capacity
Cost of existing project is INR 353.87 crores (Gross Block) as per annual report dated 31.03.2018. The expected
cost of the proposed expansion project will be around INR 1,240 Crore.
The project is an expansion project to increase the capacity of existing Chlor-Alkali plant from 300 TPD to 800 TPD
along with Flaker Unit (New Unit) – 200 TPD, Stable Bleaching Powder (New Plant) – 100 TPD, Hydrogen Peroxide
(New Plant) – 50 TPD and Coal & Biomass based Captive Power Plant (New Plant) – 75 MW within the existing
factory premises.
1.2 Utility & Fuel
The estimated list of utilities & fuel required for the project is as given in Table 1-1.
Table 1-1: List of Utilities & Fuel

S. Utilities /
Unit Existing Proposed Total Source
No. Fuel
Utilities
River Sutlej by the Irrigation Department,
1 Raw Water KLD 4,983 7,032 12,015
Government of Punjab
Existing power is being supplied from existing
grid supply from Government of Punjab. After
2 Power MW 40 35 75
Expansion, requirement will be met from 75 MW
CPP and existing grid.
Fuel
3 Coal TPD 0 1,040 1,040 Local Depot
4 Biomass TPD 0 1,800 1,800 Local Depot
5 Hydrogen Gas Nm /day
3
87,000 1,45,000 2,32,000 In-House
6 FO LPD 6,000 10,000 16,000 In-House
7 HSD LPD 500 833 1,333 Local depot
Note: The above mentioned quantities are tentative and shall be finalized in EIA report.
Manpower: The existing manpower deployed at PACL’s Naya Nangal site is 400 persons. During the constructional
phase approximately 500 persons and during operational phase approximately additional 200 personnel will be
hired. Local skilled and semi-skilled workers will be preferentially hired for the purpose.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB EXECUTIVE SUMMARY
1.3 Infrastructure
The proposed expansion would be implemented in PACL’s existing manufacturing facility.
Main components of the proposed project includes Chlor Alkali Plant along with flaker unit, SBP plant, Hydrogen
peroxide plant and their associated utilities / components like Captive Power Plant having Boiler House, Steam
Turbine, Generator, Utility Area consisting of cooling tower, ESP section Fly ash storage area. Water & wastewater
infrastructure like Effluent collection and conveyance system, Hazardous storage facility area and Secured Landfill
are being used.
1.4 Environment
Environmental issues associated with proposed units are:
 Air Emissions: Likely air pollutants from proposed project shall be HCl, Acid mist and Cl2 from process vents
and PM, SO2, NOx from proposed flue gas stacks, as point sources.
 Wastewater: This is a Zero Discharge plant based on Reverse Osmosis (RO) followed by Multiple Effect
Evaporator (MEE) processes. The RO & MEE permeate is sent back as raw water make up. The capacity of this
plant will be increased to meet the additional effluent load.
 Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per the
Hazardous and Other Wastes (Management and Trans boundary Movement) Rules, 2016.
 Other Wastes: These would be managed as per the Rules applicable to the type of wastes generated at the
site.
1.5 Sensitivity
The proposed expansion of PACL’s Chlor-Alkali project as well as new coal based Captive power plant would take
place in its existing manufacturing facility at Naya Nangal. National Fertilisers Ltd. (NFL) is an industry operating
adjacent to PACL. The Project site falls in Zone-IV of Seismicity. Civil works and Structures shall be designed
according to applicable codes.
Nangal wild life sanctuary is within the study area of 10 Km from the project boundary. Aerial distance of this
sanctuary from PACL is ~2.5 Km. Distance certificate shall be procured from the forest department. Map of eco-
sensitive zone of Nangal Wildlife Santuary with latitude and longitude is published vide Annuxure I of MoEF&CC
Notification S.O. 840(E) vide 16th March, 2017. The notification states “The Eco-Sensitive Zone is spread over an
area of 1.26 Sq. Kms with an extent upto 100 meters around the boundary of Nangal Wildlife Sanctuary”. Thus, the
proposed project does not require Wild Life Clearance.
1.6 Conclusion
The project has been conceived assuming that there will be a growth in demand for the proposed products, leading
to a reasonable rate of return in the medium term. The project is considered ‘bankable’.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB INTRODUCTION
2 INTRODUCTION
2.1.1 Identification of Project Proponent & Project
2.1.2 Project Proponent
Punjab Alkalies and Chemicals Limited (PACL) was incorporated as a Public Limited Company on December 1975
under the name “Punjab Alkalies Limited”. The name of the Company was subsequently changed to Punjab Alkalies
& Chemicals Limited and a “Fresh Certificate of Incorporation Consequent on Change of Name” dated 19th April
1983 was obtained from the Registrar of Companies, Punjab, HP & Chandigarh, Jalandhar. The Company is
promoted by the Punjab State Industrial Development Corporation Limited (PSIDC), a wholly owned Punjab
Government Company.
Total capacity at site is 99,000 MTPA of caustic soda. This entire capacity was established in stages, between the
years 1984 to 1998 and did not entail securing Environmental Clearance based on regulations in place during that
time. PACL had received a letter from MoEF regarding non-requirement of EC for expansion of Chlor-Alkali plant
from 73,730 MTPA to 99,000 MTPA due to no additional pollution load certificate given by Punjab State Pollution
Control Board. Copy of the same is attached as Annexure 1.
The company is managed by a Board of Directors comprising of senior Government officers, professionals and
experienced persons as per Table 2-1 below:
Table 2-1: Details of Directors

Sr. No. Name of the Director Designation
1. Smt. Vini Mahajan, IAS Chairperson
2. Sh. Amit Dhaka, IAS, (PSIDC Nominee) Managing Director
3. Smt. Neelima, IAS Director
4. Dr. A.K. Kundra, IAS (Retd.) Director
5. Sh. D.C. Mehandru Director
6. Sh. J.S. Mann Director
2.1.3 Proposed Project
The proposed project is for expansion in existing production capacity of the Chlor-alkali plant and new power plant
located at Nangal-Una Road, Naya Nangal, District: Rupnagar, Punjab, India.
Copy of existing CTO (Air & Water) along with valid renewal copies and Authorization for Hazardous Waste are
attached as Annexure 2.
As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category
including Project / Activity: 4(d) – Chlor Alkali industry along with 1(d) – Thermal Power Plants and categorized
under “A”, due to the following reasons:
 Project is outside the notified industrial area/estate and overall Chlor-Alkali capacity is ≥300 TPD;
 Inter-state boundary between Punjab & Himachal Pradesh is ~1.0 km West of the site.
2.2 Brief Description of nature of the Project
Details of existing and proposed products are listed in Table 2-2. Details of proposed power plant is given in Table
2-3.
Table 2-2: Products Capacity (Existing & Proposed)

Capacity (MTPA)
Sr.
Product CAS No. Additional Total after End Use of the Product
No. Existing
Proposed expansion
Products
Pulp, Paper, Pharmaceuticals, Textile,
1 Caustic Soda Lye 1310-73-2 99,000 1,65,000 2,64,000 ETP & other organic & inorganic
chemicals
In house usage: used as fuel in flaring
and process boilers, will be used in
277.20 462 739.2
2 Hydrogen Gas 1333-74-0 Hydrogen Peroxide plant. It will be also
Lac Nm3 Lac Nm3 Lac Nm3
sold to Petroleum refining and
Pharmaceuticals units
3 Liquid Chlorine 7782-50-5 87,714 1,46,190 2,33,904 Dyes intermediates & Pharmaceuticals
Pulp, Paper, Pharmaceuticals, Textile,
4 Caustic Flakes* 1310-73-2 0 66,000 66,000 ETP & other organic & inorganic
chemicals
Stable Bleaching
5 7778-54-3 0 33,000 33,000 Water treatment plants, paper industries
Powder*
Bleaching agent for Pulp, Paper,
Textiles, Sugar, Coir & Tobacco
Industries, Antiseptic agent, Sterilizing
6 Hydrogen Peroxide* 7722-84-1 0 16,500 16,500 agent, Effluent treatment, Propellant for
Rockets & Aircrafts, Chemical reagent
for extraction of different metals like
Cobalt, Uranium, Tungsten, etc.
By Products
ETP, other organic & inorganic
1 Hydrochloric Acid 7647-01-0 39,600 66,000 1,05,600
chemicals
2 Sodium Hypo Chloride 7681-52-9 2,000 4,000 6,000 Water purification, textile dyes
SSP, manufacturing of hydrochloric acid,
nitric acid, sulphate salts, synthetic
detergents, dyes and pigments,
explosives, and drugs; Petroleum
3 Dilute Sulphuric Acid 664-93-9 2,100 3,500 5,600
refining to wash impurities out of
gasoline and other refinery products;
Metal processing metals; Rayon
manufacturing).
* Indicates Products that does not require EC, but are part of the proposed project.
Table 2-3: Power Generation Capacity (Proposed)

Sr. Existing Additional Total after
Type of Unit Unit End Use of the Product
No. Capacity Proposed Capacity expansion
Captive Power
1 MW 0 75 75 Captive Use
Plant

2.3 Need for the Project and its Importance to the Country & Region
2.3.1 Chlor-Alkali Plant
Based on the current market scenario of Caustic soda, the existing production is required to be increased from
99,000 MTPA (300 MTPD) to 2,64,000 MTPA (800 TPD) and also due to the availability of infrastructure at the
existing facility the need for the proposed expansion of the project is decided to be carried out.
The size of the Indian Chlor-Alkali sector at 4.1 million tonnes1 (~5% of world market). The Chlor-Alkali industry is
the oldest and largest segment of the inorganic chemical industry. It comprises of caustic soda, liquid chlorine and
soda ash.
Caustic soda is used in various applications such as finishing operations in textiles, manufacture of soaps and
detergents, alumina, paper and pulp, control of pH (softening) of water, general cleansing and bleaching. The
aluminium industry is the biggest demand driver for caustic soda.
Chlorine is used in multiple sectors such as manufacture of polymers like PVC, bleaching applications, paper and
pulp and textile industry. Alumina processing is expected to drive the caustic soda demand in the country. Textile
and chemical sectors are expected to further push the caustic soda demand in India.
Indian Chlor Alkali industry is driven by caustic soda demand which stood at ~7 million metric tonnes in FY 2017 2.
This project aims to satisfy pending Caustic Soda demand in the Country and will help in import substitution to a
great extent.
2.3.2 Stable Bleaching Powder
As a chlorine derivative, stable bleaching powder is proposed to cater the market requirement which includes water
treatment plants, paper industries of North India. It is used as a strong oxidising, bleaching and disinfecting agent.
2.3.3 Hydrogen Peroxide
There are only four major manufacturers in India namely, Gujarat Alkalies and Chemicals Ltd., National Peroxide,
Asian Peroxide, Hindustan organic Chemicals Ltd.
Based on data of FY 2014-15, the total production is 96,172 MTPA against the demand of 1,19,800 MTPA. There is
a huge gap of 23,268 MTPA between supply and demand.
Hence the proposed project will cater the need of Hydrogen Peroxide demand in the market.
2.3.4 Captive Power Plant
Power is one of the main input for the production of Caustic Soda and it constitute about 70% of cost of
production. At present the power requirement of PACL is about 40 MW and is being received from PSPCL Grid. After
expansion the total Power requirement will increase to 75 MW. To counter the ever increase of power cost, PACL
has decided to set up its own Captive Power Plant of 75 MW capacity in phased manner.
2.4 Demand & Supply Gap
The chlor-alkali industry mainly consists of the production of two key products – caustic soda and chlorine.
Together, the alkali chemicals comprised 70% of the total chemicals production in FY17. According to Alkali
Manufacturers’ Association of India (AMAI), the Indian Chlor-alkali market was estimated at around USD 1.9 billion
-------------------------------------------------------------------
1
Source: Alkali Manufacturers Association of India (AMAI) Bulletin, June 2018
2
Reference: Indian Chemical Industry 12th Five Year Plan 2012-2017

in FY 2010, vis-à-vis global market size of USD 48 billion. Caustic soda and chlorine are produced together in the
ratio of 1:0.89 (also known as Electrochemical Unit or ECU) through electrolysis of salt. On account of their co-
production, the market dynamics for caustic soda and chlorine are heavily influenced by each other. Internationally,
it is chlorine based, whereas, in India, it is influenced by caustic soda.
Caustic soda finds its application mainly in alumina, textiles, paper, organics, inorganics, soaps & detergents, etc.
The segment has grown at an estimated Compounded Annual Growth Rate (CAGR) of ~6%.
2.5 Export Possibility
2.5.1 Domestic / Export Market
The finished products are conforming to Indian Standard /as per the customer requirement. The customers are
located in the plant’s vicinity. Some customers are located outside Punjab also, but mainly in northern India only.
Sale is made to direct customers and through traders.
Export of the products is not envisaged.
2.6 Employment Generation (Direct & Indirect) due to the project
The existing manpower deployed at PACL’s Naya Nangal site is 400 persons direct and about 500 indirect. The
existing manpower will be sufficient to operate the plants after expansion in Caustic Soda Plant. However, 200
person will be required for operating Power Plant. Local skilled and semi-skilled workers will be preferentially hired
for the purpose.
The positive impact includes enhanced direct employment for technical / administrative works and indirect
employment opportunities for transporters of raw material like salt, coal etc. and finished goods.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PROJECT DESCRIPTION
3 PROJECT DESCRIPTION
3.1 Type of Project
The project is an expansion project to increase the capacity of existing Chlor-Alkali plant from 300 TPD to 800 TPD
along with Flaker Unit (New Unit) – 200 TPD, Stable Bleaching Powder (New Plant) – 100 TPD, Hydrogen Peroxide
(New Plant) – 50 TPD and Coal & Biomass based Captive Power Plant (New Plant) – 75 MW within the existing
factory premises. The project does not include any interlinked or interdependent projects.
3.2 Location of the Project
Punjab Alkalies and Chemicals Limited (PACL) is located at Nangal-Una Road, Naya Nangal, Dist. Rupnagar, Punjab-
140126.
Location map showing general location of proposed project is given in Figure 3-1. Map showing project site on
Toposheet No. F43E3 & F4E7 showing 3, 5, 7 & 10 km Radii Circles is given in Figure 3-2. Map showing specific
project boundary is given in Figure 3-3. The co-ordinates of the project site are given in Table 3-1.
Figure 3-1: General Location of Proposed Project Site

PRE-FEASIBILITY REPORT: PROPOSED CAPACITY EXPANSION OF EXISTING CHLOR ALKALI PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT, HYDROGEN PEROXIDE PLANT & CAPTIVE POWER PLANT AT VILLAGE
PACL NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PROJECT DESCRIPTION
Figure 3-2: Project Site on Toposheet No. F43E3 & F4E7 showing 3, 5, 7 & 10 km Radii Circles

PRE-FEASIBILITY REPORT: PROPOSED CAPACITY EXPANSION OF EXISTING CHLOR ALKALI PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT,
PACL HYDROGEN PEROXIDE PLANT & CAPTIVE POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PROJECT DESCRIPTION
Figure 3-3: Specific Map showing Project Boundary
Red highlighted boundary shows boundary of Plant. No extra land is required.

Table 3-1: Co-ordinates of Site Boundary

Code Latitude Longitude
A 31°22'17.57"N 76°20'39.64"E
B 31°22'17.16"N 76°20'58.91"E
C 31°21'55.62"N 76°20'57.89"E
D 31°21'55.21"N 76°20'48.11"E
E 31°21'53.70"N 76°20'41.81"E
F 31°21'55.74"N 76°20'38.47"E
3.3 Details of Alternate Sites Considered

The proposed expansion will be carried out within the existing factory premises considering the following points:
 Less investment per MT of installed plant capacity.

 Availability of required infrastructure.
 Reduction in per MT of manufacturing cost.
 Proximity to market.
 Waste water and solid / hazardous waste treatment / disposal infrastructure is readily available.
Hence need of alternative site identification is not considered.
3.4 Size or Magnitude of Operation
The total plot area is 85.6 Acres i.e. 34.64 Hectare (~3,46,408 m2) [Total plot area is 88.86 (82.43 + 6.43) Acres
out of which 3.26 Acre is given on lease to M/s. Flowtech Chemicals (P) Limited]. Lease agreements documents
have been signed by PACL with the Industries Department, Government of Punjab and are attached as Annexure
3.
The area allocated for existing Caustic Soda Plant will be sufficient for expansion also. The land requirement for
proposed new flaker plant, SBP plant, H2O2 plant & Captive Power Plant will be allocated from the spare land
available in the premises of PACL. No additional land is to be required to be acquired for setting up of these
expansion units. Tentative site layout map (Block diagram) is shown in Annexure 4.
3.5 Project Description with Process Details
3.5.1 Chlor Alkali Plant (Existing + Expansion) – 800 TPD along with New Flaker Plant – 200 TPD
The process is based on Membrane Cell technology. The main steps in the process to manufacture caustic soda
are:
 Purification of brine.
 Electrolysis.
 Concentration and flaking of caustic soda solution.
In the process Hydrogen and Chlorine gas are produced as the co-product.

Brine Purification
General
Brine for ion exchange membrane Chlor-Alkali process is prepared by dissolving salt in the return brine from the
electrolysis plant, and purified in two stages. Primary purification removes impurities like calcium, magnesium,
sulphate, iron, silica etc. to ppm level.
Secondary purification is required to make brine suitable for the ion exchange membrane Chlor-alkali process.
Primary Brine Purification

Primary Brine Purification section consists of Salt Handling system, Brine Saturator, Reactor Clarifier, Clarified Brine
Tank and associated facilities.
This process includes Brine saturation, chemicals dosage, reaction and sedimentation. The purpose of this process
is to re-saturate the return brine with raw salt and to remove impurities from the saturated raw brine.
The return brine is fed from the top of the Brine Saturator and saturated with salt. The salt is continuously supplied
to the top of the saturator by a Belt Conveyor System.
The saturated raw brine overflows from the Brine Saturator and flows into Reactor. Chemicals such as barium
carbonate, sodium carbonate, caustic soda are fed to Reactor.
Calcium, magnesium and other multivalent cations and sulphate anions in the raw brine react with these chemicals
reacts & flocks are settled & drained while the brine is held in the reactor.
pH of the brine is controlled by the addition of caustic-soda to the brine. Then the brine overflows from the reactor
into the Brine Clarifier. Flocculent is fed to the brine line entering the clarifier.
Suspended solids in the brine are removed by settling in the Clarifier provided with water seal & insulated from the
sides. The brine, thus clarified, flows into clarified Brine Tank over the weir of Clarifier & is pumped out and
recirculated to the brine system before Reactor for better clarification. Slurry is periodically measured for better
control.
A part of slurry is sent to Sludge Filter System. The clarified brine is sent to Secondary Brine purification section by
clarified brine pump.
Secondary Brine Purification

Secondary Brine Purification Section consists of Brine Filter and Ion Exchange Resin Column.
The clarified brine is filtered through the filter and flows into filtered Brine tank. Suspended solids caught on the
filter element surface are blown down to Filter Slurry Pit. Filter Slurry in the pit is sent to centrifuge where most of
the brine is recovered and fed back to Return Brine Tank.
Ion Exchange Resin Column packed with special Ion Exchange resin is operated and controlled automatically from
control room.
This specially developed Ion exchange resin can remove multivalent cations harmful to the Ion exchange
membrane. The brine thus purified is fed to Electrolyser and electrolysis is conducted.
Electrolysis
Electrolysis section consists of bipolar Electrolysers and their associated equipment.

Electrolyser
Electrolyser consists of number of bipolar type cell frames with the metal anode and the activated cathode, the
Ion exchange membrane, press unit for mounting cell frames, sub-headers for feeding anolyte and catholyte, sub-
headers, and oil pressure unit which supplies oil to oil cylinders.
Cell frames holding the Ion Exchange membrane in between are fixed by the oil cylinder installed at the end of the
press unit. This structure ensures no leakage of electrolytes because uniform pressure can be applied to gasket
surface and cell frame of metal structure ensures no electrolyte leakage caused by deformation even after a long
period of operation.
Anolyte Circulation
Anolyte circulation system is composed of Anolyte Circulation Tank and anolyte circulation pump. Anolyte is fed into
each of anode compartment of cell frames through sub-headers and hoses, and recirculated to Anolyte circulation
Tank. Purified brine is fed to maintain anolyte concentration within a designed level. A part of the anolyte, is taken
out from Anolyte Circulation Tank to Depleted Brine Tank by overflow.
Anolyte Circulation system is designed to ensure steady and uniform distribution of anolyte to each cell and to
cope-up with any change in electrolysis conditions such as production rate change.
The diluted brine collected in Depleted Brine Tank is sent to De-chlorination Tower for removal of Chlorine gas.
Chlorine gas generated in electrolyser is separated in Anolyte Circulation Tank and sent to Chlorine gas cooling,
drying and compression section.
Catholyte Circulation
Catholyte Circulation System is composed of Catholyte Circulation Tank, Catholyte Circulation Pump and Catholyte
Cooler.
Catholyte is circulated through cathode compartment of cell frames to Catholyte Circulation Tank by Catholyte
Circulation Pump, and a part of it is taken out from Catholyte Circulation Tank to Caustic Soda Tank and sent out to
caustic evaporation section. To keep the concentration of caustic soda at designed level, demineralised water is fed
to catholyte inlet sub-header. Hydrogen gas generated in Electrolyser is separated from the catholyte in catholyte
Circulation Tank and sent to Hydrogen Gas Cooling and Compression Section. Heat generated in electrolyser is
removed by cooling water in Catholyte Cooler.
De-Chlorination of Return Brine

De-chlorination section is composed of a Vacuum Tank, Vacuum Pumps, cooler and associated facilities. Return
brine (depleted brine) from Electrolysis Section free of chlorine is sent for saturation.
From the vacuum tank chlorine gas is sucked by the vacuum pump through a water cooled cooler and is then
introduced to chlorine gas product main line.
The depleted brine, de-chlorinated through vacuum tank still contains small amount of free chlorine which can
cause damage to the filter elements in Brine Filters and damage ion exchange resin in Ion Exchange Resin
Columns. Sodium Bisulphite is added to kill free chlorine. Return brine is then fed to Return Brine Tank & pumped
to salt saturator.
Caustic Concentration
The caustic soda concentration system consists of triple effect falling film evaporators operating on backward feed
flow scheme. 30% caustic solution at 80°C is fed to third effect evaporator. Vapours are separated from solution
and concentrated solution of third effect evaporator is pumped to second effect evaporator after passing through
two heat exchangers in series. In the second effect evaporator, flash evaporation of liquor takes place and liquor is
further heated by steam and vapours are separated in second effect evaporator to concentrate liquor.

The concentrate from the second effect evaporator is pumped through first effect evaporator after passing through
two heat exchangers in series. Steam at 11 kg/cm 2(a) pressure is used to attain required concentration of caustic.
Chlorine Liquefaction & Bottling
Chlorine Gas Cooling

Chlorine Gas coming out of Electrolysers contains water vapours saturated at about 90°C and has little amount of
Sodium Chloride as entrainment. Gas is first passed through Chlorine Recuperator to recover heat in order to pre
heat brine being sent to Ion Exchange Columns for feeding the Electrolysers.
It is then cooled in two stages to reduce water vapours load , first by cooling water at about 30°C and then by
chilled water at approx. 10°C.
Chlorine gas temperature is generally around 15-20°C as cooling below 9-10°C will result into formation of chlorine
hydrate.
Sodium Chloride entrainment is removed by passing the gas through Wet Chlorine Filter Candles made of Glass
Wool.
Cooled gas is then dried with direct spray of sulphuric acid in packed towers.
Chlorine Gas Drying

The cooled chlorine gas is led to chlorine Gas Drying Tower. The moisture of chlorine gas is absorbed into
sulphuric Acid of 98% concentration fed into the two stage chlorine gas drying tower, and gets diluted to 78%
by absorption of moisture from chlorine gas. Chlorine Gas Drying Tower has a cooler to cool circulating sulphuric
Acid. The Dry Chlorine gas is sent for compression.
Chlorine Gas Compression

Dry chlorine gas from chlorine Gas Drying Section is compressed to 4 kg/cm2 (a) by using Acid Ring type
Compressor.
Chlorine Gas Liquefaction and Filling

Chlorine gas from compressor is sent to chlorine Gas Liquefaction Unit to be condensed by the Freon 22 refrigerant.
The unliquefied gases along with inert gas from Liquefier are sent to HCI Synthesis unit for burning with Hydrogen
to produce HCl.
Liquefied chlorine enters Chlorine Storage Tank from where it is transferred by means of compressed dry air to
chlorine bottling section. Part of liquid Chlorine is vaporised and sent to nearby customers through pipeline.
Waste Chlorine Neutralization / Sodium Hypochlorite Section

Waste chlorine gas, only in case of plant emergency, is led to the Sodium Hypochlorite Unit. Chlorine Gas during
start up and plant tripping is fed to the absorption tower. This unit consists of packed tower in which caustic
solution is circulated to absorb waste chlorine. Temperature of the liquid is controlled by heat transfer through plate
type heat exchanger with chilled water.
After a desired strength of sodium hypochlorite is reached, the solution is sent to a Hypo Reactor. Here it is reacted
with fresh chlorine to produce marketable quality Sodium Hypochlorite.
HCL Synthesis
The HCl Synthesis unit consists of combustion furnace fitted with absorbers. The chlorine gas reacts with Hydrogen
to form HCl gas which is cooled and absorbed in DM water. The flow rate of DM water is adjusted to obtain 30-33%
HCl Solution. The flow rates of Chlorine and Hydrogen are controlled by flow controllers. Safety Interlocking

provisions are made which get actuated by flame protection device. The Hydrochloric Acid Solution is collected in a
product tank from where is pumped to HCl Storage Tanks.
Hydrogen Bottling and Storage

Hydrogen gas is compressed and filled in hydrogen cylinder banks of the customers and also stored in cylinder
banks.
Caustic Soda and Flaking Plant

Flaker plant is a double effect evaporator. 48% Caustic is fed to produce 98% Caustic Flakes. Salt mixture (KNO 3,
NaNO2 & NaNO3) which is heated by burning Hydrogen in a heating media to increase Caustic lye temperature in
final concentrator. 98 % Caustic flakes is then cooled and packed using a polythene liner to avoid moisture pick-up
as it is a hygroscopic product.
The process flow diagram is given in Figure 3-4.
Figure 3-4: Process Flow Diagram – Caustic Soda & Flaker Plant
Mass balance is provided in Table 3-2.
Table 3-2: Mass Balance – Chlor Alkali Plant

S. Input/MT of Product
No. Raw Materials Quantity (MT)
1 Industrial Washery Salt 1.59
2 Soda Ash 0.004
3 Barium Carbonate 0.008
4 Sodium Bisulphite 0.001
5 Flocal 0.00002
6 Alpha Cellulose 0.00005
7 Sulphuric Acid 0.02
8 Water (for process) 2.464
Total 4.087
S. Output/MT of Product Remarks

No. Waste Air Recovery/ Solid

Product Unit
water Emission Product Waste
1 Caustic Soda Lye MT -- -- 1 -- Product
2 Hydrogen Gas NM 3
-- -- 280 -- Product
3 Chlorine Gas MT -- -- 0.886 -- Product
4 Hydrochloric Acid MT -- -- 0.4 --
5 Sodium Hypo Chloride MT -- -- 0.02 --
By - Product
6 Liquid Chlorine MT -- -- 0.908 --
7 Dilute Sulphuric acid MT -- -- 0.02 --
8 Effluent (from process) M3 0.8 -- -- -- to RO
9 Air emissions/losses 0.004 Losses
10 Process sludge MT -- -- -- 0.0235 To own SLF
0.8 0.004 3.259 0.0235
Total --
4.087
3.5.2 Stable Bleaching Powder (New Plant) – 100 TPD
Stable bleaching powder (SBP) is manufactured as a consequence of composite chemical reaction between
hydrated lime and liquid chlorine.
The chlorination drum where the chemical reaction occurs, temperature is controlled by circulating water in jacket.
After complete chlorination, the product is dried under vacuum, cooled and discharged to packing hopper via
vibrating screen, which separates oversized material. The oversized material is further pulverized and mixed with
product. The reaction in the drum is as follows:
Ca (OH) 2 + Cl2 CaOCl2 + H2O
Stable Bleaching Powder contains 34% chlorine and is a powerful oxidizing agent. It is stable for a longer period of
time i.e. very low losses of available Chlorine over extended period of time, when properly stored even under
changing climatic conditions. This is because of low moisture content in the product and absence of heavy metal
impurities in the raw material. Above all the best quality Hydrated Lime and the Chlorine generated from its own
plant are used in the manufacture of SBP.
Process flow diagram of SBP plant is shown in Figure 3-5.
Figure 3-5: Process Flow Diagram – SBP Plant

Mass Balance
Mass balance per ton of product and per day basis is given in Table 3-3.
Table 3-3: Mass Balance – Stable Bleaching Powder

S.
Raw Materials Input/MT of Product (MT)
No.
1 Hydrated Lime 0.73
2 Caustic Soda 0.02
3 Liquid Chlorine 0.45
Total 1.2
Output/MT of Product
S. Output/Day of
No. Product / By Liquid Air HW / Solid Product MT
Material / Item Recovery
product Effluent Emission Waste
1 SBP 1 -- -- -- -- 100
Sodium Hypo
2 -- -- -- -- 0.2 20
(10%)
1 -- -- -- 0.2
Total 120
1.2
3.5.3 Hydrogen Peroxide (New Plant) – 50 TPD
Process Description
This process is based on circulating working solution, known as the auto oxidation process for Hydrogen Peroxide
production. The steps for the Hydrogen Peroxide manufacturing are Hydrogenation, Oxidation, Extraction and
Distillation. The working solution consists of two organic solvents AB and tributylurea and 2 EAQ (Ethyl Anthra
Quinone).
Hydrogenation
Working solution and Hydrogen are fed to hydrogenator and in the presence of palladium catalyst, 2 EAQ will be
converted to 2 Ethyl hydro anthrax quinine. The working solution, excess hydrogen and catalyst discharge from the
top of the hydrogenator. Gas and liquid streams are separated with the Hydrogen being returned to hydrogenator
via a recycle compressor. The working solution and catalyst flow to primary filters. Here a forward flow of liquid is
separated from catalyst and passes to an oxidizer feed tank while the reaming working solution and catalyst are
returned to hydrogenator.
Oxidation
The hydrogenated working solution is oxidized with air (oxygen) in an oxidizer. In this step of process Hydrogen
Peroxide is produced which is dissolved in working solution. The depleted air from the oxidizer will pass through the
solvent recovery system before discharge to the atmosphere.
Extraction
Working solution from the oxidizer degases into the bottom and demineralized water into the top of an extractor.
Due to different densities of the two phases, this working solution flows upwards and discharges from the top of
the extractors after being tripped of it hydrogen peroxide. The aqueous phase discharging from the bottom of the
extractor contains up to 35% Hydrogen Peroxide.

Product treatment
Hydrogen peroxide passes through coalesces, where traces of solvents are separated from Hydrogen Peroxide.
Purified Hydrogen Peroxide is pumped to the product day tank to the distillation.
Distillation
Crude Hydrogen Peroxide with a concentration of 35% is pumped to vaporizer system. The steam is supplied to
vaporizer for boil up to Hydrogen peroxide. The vapour from the vaporiser passes through the mist separator prior
to entering the bottom of an absorption columns. Hydrogen Peroxide, having a high boiling temperature than after
is the “Heavy” key component in the still, so it concentrate in the bottom at strength from 50% to 70%.
Demineralized water is use for the reflux in the column. The product is drawn from the bottom of the column and
pumped to the storage tanks.
Chemical Reaction
Reaction 1
Reaction 2
Process Flow Diagram
The Process flow diagram for the above reaction is shown Figure 3-6.
Figure 3-6: Process Flow Diagram of Hydrogen Peroxide

Mass Balance
The mass Balance for Hydrogen Peroxide is given in Table 3-4.
Table 3-4: Mass Balance for Hydrogen Peroxide

S. Input/MT of Product
No. Raw Materials Quantity (MT)
1 Hydrogen Gas 0.065
2 Oxygen (air) 1.435
3 Stabilizer 0.001
4 Phosphoric acid 0.001
5 Aromatic Solvent 0.001
6 Ethyl Anthra Quinon (EAQ) 0.0012
7 Tetra Butyl Urea (TBU) 0.001
8 Tetra Octyl Phosphate (TOP) 0.0002
9 Treated Alumina 0.0115
10 Water 5
Total 6.0169
Output/MT of Product
S.
Waste Air Recovery/ Solid Remarks
No. Product
waster Emission Product Waste
1 Hydrogen peroxide (100 %) -- -- 1 -- Product

2 Water with product -- -- 1 -- Product
3 Stabilizer with product -- -- 0.001 -- By-Product
4 Phosphoric acid with product -- -- 0.001 -- By-Product
5 TOC as process emission -- 0.0006 -- -- To vent
6 SS, EAQ, TBU, TOP losses with spent alumina -- -- -- 0.0034 To TSDF
7 Spent alumina -- -- -- 0.0115 To TSDF
8 Liquid effluent** 4.5 -- -- -- To ETP
4.5 0.0006 2.002 0.0149 --
Total
6.5169
Note: ** 50% liquid effluent generated will be recycled/reused with in plant by using a polishing column.
3.5.4 Coal & Biomass based Captive Power Plant (New Plant) – 75 MW
Coal based Captive Power Plant (CPP) consists of 3 Units of 21 MW each and 1 Unit of 12 MW comprising
Condensing type steam turbine.
Punjab is predominantly rich in agriculture and contributes the major share to the grain basket of India. It has
surplus production of major crops. It produces 25% of country's cotton, 22% of wheat and 55% of rice, even
though it has only 1.5% of total country cultivable area. Punjab has been meeting its electrical power requirements
primarily through conventional thermal and hydro power generation. Hydro power generation has a tendency to
fluctuate depending on the availability of water. Thermal power generation has to depend on coal which has to be
transported from eastern part of India involving large distances. Cost of generation from coal continuous to
escalate and moreover it is polluting.
Punjab has the potential to generate about 2,000 MW of power using biomass alone. Considering this fact in view,
PACL has decided to use Bio-mass (initially) and coal in its proposed Captive power plants.

Basic process involves steam generation by combustion of coal & biomass in boilers. Steam will be used to run
turbine for power generation. Electricity will be generated at 11 KV and distributed to process plant.
Power plant will be mainly divided in following sections:
Biomass handling, Coal yard and Coal handling plant
Initially the Bio-mass fuel will be used to generate the Power. It will be procured during the season and will be
stored in the near vicinity of PACL premises, which will be hired on lease basis. Biomass will be stored in limited
quantity at site.
PACL shall also have facility to use Coal. Imported coal will be procured from local market. The coal will be
transported by road through dumpers / trucks / rail. Coal unloading activity involves unloading of coal from
dumpers and truck by JCBs in coal yard. Coal will be fed to coal bunker with the help of conveyor belt, screen and
crusher.
Boiler and auxiliaries
Four (4) Nos of CFBC boilers of 80 TPH capacities are proposed for generation of steam. To control air emissions
within the stipulated norms, ESP will be provided to reduce PM emissions, limestone will be dosed along with coal
to reduce SO2 emissions. And since, CFBC boilers are proposed, NOx generation will be limited due to lower
temperature operations. These consists of steam drum, water wall & economizer. Heat generated due to coal &
biomass combustion in the form of flue gas will be used at various levels in boiler to maximize thermal efficiency.
Steam will be passed through super heaters to achieve final temperature.
Steam turbine and alternator
High temperature, high pressure steam will enter in turbine where heat energy will be converted into kinetic
energy. Turbine is directly coupled to alternator where electricity is generated by electro motive force produced.
Three (3) Nos of Turbines of 21 MW capacities & One (1) turbine of 12 MW capacity will be provided.
Steam will be extracted for process and for heating water before feeding in boiler from various extraction points in
turbine. Power will be generated at 11 KV through and fed to different areas of chlor alkali plant through double
bus bar system to cater high reliability of electrical system.
Condenser system
Exhaust steam will be condensed and recycled in boiler with pumping devices at various stages with minimum
make up of D.M. water.
Utility
Instrument air compressors will be installed for requirement of air at various control valves.
Cooling tower with well-designed water distribution system for removing heat from condenser, alternator, oil
coolers and at various fan bearing locations will be provided. Existing raw water reservoirs will be used for catering
raw water requirement.
Ash disposal system
The ash from bottom will be trapped in ESP & will be stored in an ash silo. The ash shall be given for cement and
brick manufacturing, road construction and road backfilling inside and outside the factory premises, wherever
required.
The process flow diagram of coal based captive power plant is given in Figure 3-7.

Figure 3-7: Process Flow Diagram of Coal based Captive Power plant

3.6 Raw material details
The major raw materials is industrial salt. Details of raw material along with the Quantity, Source and Mode of
Transport is given in Table 3-5.
Table 3-5: Details of Raw material Quantity, Source and Mode of Transport
S. Quantity (MTPA)
Raw Material Source Mode of Transport
No. Existing Proposed Total
Chlor – Alkali
1 Industrial Washery Salt 1,57,410 2,62,350 4,19,760 Sea salt from Gujarat. Rail & Road
2 Soda Ash 396 660 1,056 Gujarat Road
3 Barium Carbonate 792 1,320 2,112 Chennai / Andhra Pradesh Road
4 Sodium Bisulphite 148 247 395 Gujarat / Rajasthan Road
5 Flocal 1.5 2.5 4 Ludhiana Road
6 Alpha Cellulose 4.7 7.8 12.5 Germany Road
7 Sulphuric Acid 1,961 3,268 5,229 Punjab Road
Stable Bleaching
Powder
Andhra Pradesh / Tamil
8 Hydrated Lime 0 24,090 24,090 Road
Nadu / Rajasthan
9 Caustic Soda 0 660 660 In-house Pipeline
10 Liquid Chlorine 0 14,850 14,850 In-house Pipeline
Hydrogen Peroxide
131 131
11 Hydrogen Gas 0 In-house Pipeline
Lac Nm3 Lac Nm3
Ethyl Anthra Quinon
12 0 1.8 1.8
(EAQ)
13 Aeromatic Solvent 0 1.5 1.5
14 Tetra Butyl Urea (TBU) 0 1.5 1.5
Local Market Trucks
Tetra Octyl Phosphate
15 0 0.3 0.3
(TOP)
16 Catalyst 0 0.06 0.06
17 Stabilizer 0 1.5 1.5
18 Phosphoric Acid 0 1.5 1.5 Gujarat Road
19 Treated Alumina 0 17 17 Local market Trucks
Power Plant
20 Coal 0 3,64,000 3,64,000 Local Depot Truck / Rail
21 Biomass 0 6,30,000 6,30,000 Local Market Truck / Tractors
22 Limestone 0 36,750 36,750 Local Market Truck / Tractors
3.7 Utilities
The estimated list of utilities required for the new project is as given below:
3.7.1 Power Requirement
The power requirement of 40 MW for the existing project is being met from existing grid supply from Government
of Punjab. A new Bio-mass/ Coal based Captive power plant will be established at the site of 75 MW capacity to

cater the requirement of existing & proposed units. The balance power required will be met from grid supply. The
existing DG sets of 1.5 MW capacity are being used during power failures for emergency purpose only. The DG set
of 2.5 MW capacity shall also be required to be installed for meeting the additional emergency load of expansion of
Caustic Soda Plant.
Emergency Power:
In case of plant start-up, emergency, scheduled/un-scheduled stoppages, statutory inspection of the proposed Bio-
mass/ coal based captive power plant, the Grid supply will be used.
3.7.2 Fuel Requirement
Details of fuel to be used is given in Table 3-6.
Table 3-6: List of Fuel Requirement

S. No. Utilities / Fuel Unit Existing Proposed Total Source
1 Coal TPD 0 1,040 1,040 Local Depot
2 Biomass TPD 0 1,800 1,800 Local Depot
3 Hydrogen Gas Nm /day
3
87,000 1,45,000 2,32,000 In-House
4 FO LPD 6,000 10,000 16,000 In-House
5 HSD LPD 500 833 1,333 Local depot
3.7.3 Water Requirement
The water is supplied from river Sutlej by the Irrigation Department, Government of Punjab, through the existing
Bhakra-Nangal dam project located nearby.
The raw water is conveyed to a reservoir located in the adjacent Fertiliser manufacturing facility of Punjab National
Fertiliser Corporation (PNFC) which is now closed. The water is then piped to PACL’s raw water and fire storage
tank within the facility.
The existing agreement between PACL & Irrigation Department, Govt. of Punjab is for a drawl of 2 cusecs (~4,983
KLD). However, after the proposed expansion, additional water requirement will be ~7,032 KLD. Thus, total water
requirement will be ~12,015 KLD. Agreement for additional water quantity will be enhanced.
Details of existing & proposed water requirement for the project are given in Table 3-7 below:
Table 3-7: Water Consumption Details

Fresh Water Quantity, KLD
S. No. Area of Consumption
Existing Proposed Total
1 Process 991 1,906 2,897
2 Washing (Reactor and Floor) 70 80 150
3 Boiler 200 350 550
4 Cooling Tower 1,337 4,628 5,965
5 Gardening 122 53 175
6 Domestic 75 15 90
7 To adjacent plants 450 0 450
8 Misc. 647 0 647
9 Others (for Domestic in PACL Colony) 1,091 0 1,091
Total 4,983 7,032 12,015

3.7.4 Storage Details
The Unit will create additional storage facilities for the proposed project for products, raw materials as per the
MSIHC rules. Means of storage of raw materials, products, fuel, including hazardous chemicals is tabulated in Table
3-8.

Table 3-8: Means of Storage of Raw Materials, Products & Fuel

S. Requirement (MTPA) Means of
Chemical State Source / Consumer Means of Storage
No. Existing Proposed Total Transportation
Raw Material
1 Industrial Washery Salt 1,57,410 2,62,350 4,19,760 Solid Gujarat Road/ Rail Covered Storage Yard
2 Soda Ash 396 660 1,056 Solid Gujarat Road Covered Storage Yard
3 Barium Carbonate 792 1,320 2,112 Solid Chennai / A.P Road Covered Storage Yard
4 Sodium Bi-Sulphite 148 247 395 Solid Gujarat / Rajasthan Road Covered Storage Yard
5 Flocal 1.5 2.5 4 Solid Ludhiana Road Covered Storage Yard
6 Alpha Cellulose 4.7 7.8 12.5 Solid Germany Road Covered Storage Yard
7 Sulphuric Acid 1,961 3,268 5,229 Liquid Punjab Road Tank
8 Hydrated Lime 0 24,090 24,090 Solid A.P / T.N / Rajasthan Road Covered Storage Yard
9 Caustic Soda 0 660 660 Liquid In-house Pipeline Tank
10 Liquid Chlorine 0 14,850 14,850 Gas In-house Pipeline Tank
11 Hydrogen Gas (Nm ) 3
0 131 Lac 131 Lac Gas In-house Pipeline Holder Tank
12 Ethyl Anthra Quinon (EAQ) 0 1.8 1.8 Solid Local market Trucks Covered Storage Yard
13 Aromatic Solvent 0 1.5 1.5 Liquid Local market Tankers Tank
14 Tetra Butyl Urea (TBU) 0 1.5 1.5 Liquid Local market Tankers Tank
15 Tetra Octyl Phosphate (TOP) 0 0.3 0.3 Liquid Local market Tankers Tank
16 Catalyst 0 0.06 0.06 Solid Local market Trucks Covered Storage Yard
17 Stabilizer (Dequest) 0 1.5 1.5 Liquid Local market Tankers Tank
18 Phosphoric Acid 0 1.5 1.5 Liquid Gujarat Road Tank
19 Treated Alumina 0 17 17 Solid Local market Trucks Covered Storage Yard
Products / By-Products
1 Caustic Soda 99,000 2,64,000 1,98,000 Liquid Tanker Tanks
277.20 462 739.2 Sold to nearby Temporary storage in
2 Hydrogen Gas Truck / Pipeline
Lac Nm3 Lac Nm3 Lac Nm3 consumers and in hydrogen holder
87,714 2,33,904 1,75,428 Gas North India Truck / Pipeline ---
3 Chlorine
89,900 2,39,733 1,79,800 Liquid - Bullet / Tonners

S. Requirement (MTPA) Means of

Chemical State Source / Consumer Means of Storage
No. Existing Proposed Total Transportation
4 Hydrochloric Acid 39,600 66,000 1,05,600 Liquid Tanker Tank

5 Sodium Hypo Chloride 2,000 4,000 6,000 Liquid Tanker Tank
6 Dilute Sulphuric Acid 2,100 3,500 5,600 Liquid Tanker Tank
7 Caustic Soda Flakes 0 66,000 66,000 Solid Trucks Covered Storage Yard
8 Stable Bleaching Power 0 33,000 33,000 Solid Trucks Covered Storage Yard
9 Hydrogen Peroxide 0 16,500 16,500 Liquid Tanker Tank
Fuel
1 Coal 0 3,64,000 3,64,000 Solid Local Depot Truck / Rail Coal Storage Yard
2 Biomass 0 6,30,000 6,30,000 Solid Local Market Truck / Tractors Storage yard
3 Limestone 0 36,750 36,750 Solid Local Market Truck / Tractors Storage yard
4 Furnace Oil (FO), LPD 6,000 10,000 16,000 Liquid Local Market Tanker Tanks
5 High Speed Diesel (HSD), LPD 500 833 1,333 Liquid Local Market Truck Drums

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB SITE ANALYSIS
3.8 Pollution Load on Environment due to project
Environmental issues include:
 Air emissions;
 Wastewater generation;
 Noise generation;
 Hazardous waste & Solid waste generation.
3.8.1 Air Emissions & Control
Volume Source
Particulate Matter (PM) emission from coal storage yard for proposed Coal based captive power plant is envisaged
as volume source emission as the same would be established within the existing premises.
Fugitive Emissions
Fugitive emissions of chlorine due to storage & handling of chlorine as well as that of PM due to storage of coal are
envisaged in the project.
Line Source Emissions
Approximately additional vehicular movement - 250 vehicles per day (200 trucks/tankers/tractor, 25 cars & 25 two
wheeler) is envisaged on SH-25 (Una-Naya Nangal to Chandigarh via Anandpur Sahib) which involves vehicular
emissions, majorly PM, CO & HC’s.
Point Source
Likely air pollutants from proposed project shall be HCl, Acid mist and Cl2 from process vents and PM, SO2, NOx
from proposed flue gas stacks, as point sources. These are in addition to the existing Flue Gas stacks & Process
Vents.
The ambient air quality & stack emissions will be maintained as per PPCB / CPCB norms.
Details of existing & proposed stacks with attached Air Pollution Control Equipment details are tabulated in Table
3-9.
Table 3-9: Details of Flue Stack Emissions & Process Vents
Stack Details
Sr. Air Pollution
Stack Attached to Height Diameter Temp Velocity Pollutants
No. Control measures
(m) (m) (°C) (m/s)
Flue Gas Stacks (Existing)
Boiler Section Unit-1 Adequate Stack
1 40 0.55 125 12.5 PM, SO2, NOx
(Thermax) Height
2 40 0.55 125 12.5 PM, SO2, NOx
(Thermax) Height
3 40 0.55 125 12.5 PM, SO2, NOx
(Srerling) Height
4 40 0.55 125 12.5 PM, SO2, NOx
(Srerling) Height
Adequate Stack
5 DG SET - 1 9 0.15 150 12.5 PM, SO2, NOx
Height
6 DG SET - 2 9 0.15 150 12.5 PM, SO2, NOx Adequate Stack

Stack Details
Sr. Air Pollution
Stack Attached to Height Diameter Temp Velocity Pollutants
No. Control measures
(m) (m) (°C) (m/s)
Height
Flue Gas Stacks (Proposed)
1 CPP Stack 1 55 2.5 150 15 PM, SO2, NOx ESP
Adequate Stack
5 Flaker Stack 30 0.2 150 15 PM, SO2, NOx
Height
Adequate Stack
6 DG SET – 3 9 0.15 150 12.5 PM, SO2, NOx
Height
Adequate Stack
7 DG SET – 4 9 0.15 150 12.5 PM, SO2, NOx
Height
Process Vents (Existing)
1 Sodium Hypo – Unit 1 15 0.15 45 7.5 Cl2 Alkali Scrubber
Water Sprinkling
3 HCl Furnace – Unit 1 25 0.15 55 5 HCl Acid Mist
System
Water Sprinkling
5 HCl Furnace – Unit 2 25 0.15 55 5 HCl Acid Mist
System
Process Vents (Proposed)
Water Sprinkling
2 HCL Plant – Unit 3 25 0.15 55 5 HCl Acid Mist
System
Chiller, Demister,
3 Solvent Recovery H2O2 32 0.4 45 2.5 HC Activated Carbon
Adsorbed
3.8.2 Noise Generation
From the proposed project, noise will be generated from the various activities. Source of noise generation are:
 The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during construction
phase;
 Operation of Boilers, Turbine, DG sets, Cooling Towers, Pumps, FD-ID Fans & Compressors;
 Vehicle movement for transportation of raw material & finished goods.
3.8.3 Waste Water Generation
The main source of the industrial wastewater generation will be from process, plant washings, cooling tower &
boiler blow down. The total quantity of effluent generation will be increased from ~380 KLD to ~1,745 KLD.
The untreated effluent, is sent to existing Zero Liquid Discharge (ZLD) facility which is a Zero Discharge plant based
on Reverse Osmosis (RO) followed by Multiple Effect Evaporator (MEE) processes. The RO permeate is sent back as
raw water make up.
The capacity of this plant will be increased to meet the additional effluent load.
Due to expansion activities, total effluent will be treated in the above facility and the RO permeate will be recycled
back as raw water makeup.

Thus, after the expansion, Zero Liquid Discharge (ZLD) concept will be achieved.
Details of Waste water generation is given in Table 3-10 below:
Table 3-10: Wastewater Generation Details
Sr. Wastewater Generation (m3/day)

Source Disposal method
After PH correction, sent to collection pit
1 Process & Boiler 240 600 840
and then to RO plant
4 Cooling Tower 45 160 205 -do-
6 Domestic 15 5 20 -
8 Misc. 0 600 600 From CPP, Hydrogen peroxide
Sewage line laid by Municipal Council Nangal
Others (for Domestic in PACL is already existing and company Sewage is
9 80 0 80
Colony) connected to the main line laid by Municipal
Council.
Total Waste Water
380 1,365 1,745
Generation
3.8.4 Hazardous Waste & Other Solid Wastes
The hazardous wastes generated would be Used Oil, Spent Catalyst, Empty Barrels / Containers / Liners & MEE
sludge. Details of the same is as tabulated in Table 3-11.
Table 3-11: Hazardous Waste Generation and Disposal

Sr. Quantities Generated (MTPA)
Waste Category3 Source Mode of Disposal
No Existing Proposed Total
Erstwhile Disposed off in Secured
Brine sludge mercury cell Landfill Facility (ON
1. 16.3 26,642 0 -
(mercury based) based Chlor- DRY BASIS) within
alkali process PACL premises
Sold to authorized
2. Used or spent oil 5.1 Entire Site 1.0 1.7 2.7
recyclers
Disposed off to
3. MEE sludge 35.3 MEE 450 750 1,200
authorized TSDF
Note: The above mentioned quantities are tentative and shall be finalized in EIA report. In 1998, PACL changed the
Chlor-Alkali process from Mercury cell based process to Membrane cell based process. However, the brine sludge
generated till 1998 was disposed off in Secured Landfill facility developed within PACL site. The details of solid
waste is given in Table 3-12.
Table 3-12: Solid Waste Generation & Disposal

Sr. Quantity (MTPA)
Solid Waste Mode of Disposal
Although Brine sludge is not hazardous waste4, the
1. Brine Sludge 2,300 3,833 6,133 same is disposed off to secured landfill facility
developed inside PACL premises
-------------------------------------------------------------------
3
As per the Hazardous and other wastes (Management and Trans boundary Movement) Rules, 2016.
4
As per OM No. 23-206/2014-HSMD by MoEF&CC (HSM Division) dated 02-05-2016.

Sr. Quantity (MTPA)

Solid Waste Mode of Disposal
Given to nearest Cement plant & Brick
2. Fly Ash5 0 55,000 55,000 manufacturing units (Gujarat Ambuja Cement (~60
Km).
Apart from the wastes mentioned above, Construction & demolition waste will be generated due to demolition of
clarifier and other old / unused structures in the area. The list of other wastes generated at the site due to various
operations are tabulated inTable 3-13.
Table 3-13: Other wastes generated

Sr. Physical Applicable Quantity Storage Management
Waste Type Source
No. State Rule (MTPA) Method Method
Shall be handled
as per the Solid
Solid Waste Waste
Municipal Solid Canteen, As and when
1. Solid Management HDPE Drums Management
Waste Office blocks generated
Rules, 2016 Rules, 2016 as
amended from
time to time
Storage will
be done as
Shall be handled
per Bio-
Bio-Medical as per the Bio-
Medical
On-site Waste Medical Waste
As and when Waste
2. Biomedical Wastes Occupational Solid Management Management
generated Management
Health centre Rules, 2016 as Rules, 2016 as
Rules, 2016
amended amended from
as amended
time to time
from time to
time
Shall be handled
Company
as per the
owned The Batteries Common
Batteries
vehicles, other (Management Waste
Used Lead Acid As and when (Management &
3. devices (such Solid & Handling storage
Batteries generated Handling) Rules,
as UPS) being Rules), 2001 areas in the
2010 as
operated as amended site
amended from
within the site
time to time
Shall be handled
as per the E-
The E-Waste As and when Waste
Waste
(Management) generated due Storage
4. Electronic wastes Entire Site Solid (Management)
Rules, 2016 as to equipment areas within
Rules, 2016 as
amended obsolescence the site
amended from
time to time
The Plastic Shall be handled
Entire Site Generated Waste
Waste as per the
5. Plastic wastes (Office blocks, Solid during use of storage
Management Plastic Waste
Canteen etc.) plastic items areas at site
Rules, 2016 as Management
-------------------------------------------------------------------
5
Considering worst case, i.e. Ash Content as 15% in coal.

Sr. Physical Applicable Quantity Storage Management

Waste Type Source
No. State Rule (MTPA) Method Method
amended Rules, 2016
Generated
during
Non-Hazardous Scrap Sold to scrap
equipment
metallic scrap, storage dealers duly
6. Entire Site Solid None obsolescence
wooden & paper areas in the approved by the
and discarding
scrap site company
of such items
as wastes
Sold to scrap
Project and
As and when dealers duly
7. Waste Glass wool maintenance Solid None Storage area
generated approved by the
activities
company
Sold to scrap
Project and
As and when dealers duly
8. PVC/FRP waste maintenance Solid None Storage area
generated approved by the
activities
company
Secured Landfill Facility Disposal System for Brine Sludge (PACL to give details on the lines of
following information):
To dispose off brine sludge generated, PACL has developed a Secured landfill facility inside the factory premises for
solid waste disposal as recommended by Punjab Pollution Control Board (PPCB). The design/construction of SLF
constructed in the premises is approved by Punjab Pollution Control Board (PPCB).
3.8.5 Solvent Details
Detail of Solvent to be used is given in Table 3-14.
Table 3-14: Lists of Solvents Used

S. Consumption
Name of Solvent Products Used
No (KG/MT)
1 Ethyl Anthra Quinon and aromatic solvent Hydrogen peroxide 1.2
There is no requirement of adding a fresh solvent in the system as such because of the provision of closed circuit.
Only some make up addition is done due to losses in system.
3.8.6 Catalyst Details
During the process only catalyst used will be Palladium in Hydrogen Peroxide plant which will be stored in Drums.
Used catalyst will be given to authorized reprocessor.

4 SITE ANALYSIS
4.1 Connectivity
4.1.1 By Road
The site is well connected with the roads connecting SH-25 (Naya Nangal to Chandigarh via Anandpur Sahib) which
is located at an approximate road distance of ~1.4 km towards North (approximate aerial distance of ~1.1 km
towards North).
4.1.2 By Rail
Nearest railway station is Nangal Dam Railway station located at an approximate road distance of 5.6 km towards
East Northeast (approximate aerial distance of ~2.5 km towards East Northeast).
4.1.3 By Air
Ludhiana airport is located at an approximate road distance of ~90 km towards Southwest (approximate aerial
distance of ~68.5 km towards Southwest). Another major airport is located at Chandigarh at an approximate road
distance of ~118 km towards Southeast (approximate aerial distance of ~88 km towards Southeast). Amritsar
airport is located at an approximate road distance of ~151 km towards West Northwest (approximate aerial
distance of ~88 km towards West Northwest).
4.2 Land Form, Land use & Land Ownership
The activities of proposed expansion as well as new SBP plant, H2O2 plant and coal based captive power plant will
be carried out within the existing factory premises of PACL, Naya Nangal wherein Chlor alkali products are already
being manufactured. No changes in land use are envisaged. Land cover within the factory would change nominally
at places where the additional process units would be constructed for the proposed expansion as well as new coal
based captive power plant. Land Cover will be as per the Site Layout Map as shown in Annexure 4.
Within the study area populated or built up area are present. List of villages within 5 Km of the project site are
tabulated in Table 4-1. Details of other villages within 10 Km will be furnished in EIA report.
Table 4-1: List of Villages in Nearby Area (within 5 Km)

S. No. Village/ Town Distance (km) Direction
1 Poona ~ 0.7 SW
2 Ajauli ~ 0.8 NW
3 Manjara ~ 1.3 SSW
4 Majuwal ~ 2.2 SE
5 Santokgarh ~ 2.3 WSW
6 Chhotewal ~ 2.8 SSE
7 Nangal Township ~ 3.6 NE
8 Saijuwal ~ 3.6 SW
9 Megpur ~ 4.3 E
10 Mankpur ~ 4.6 E
11 Suksal ~ 4.7 S
12 Fatehpur ~ 4.7 NW
Details of nearby protected forest and wildlife sanctuary is provided in Table 4-2.

And other villages which will be detailed out in EIA report.
Table 4-2: Details of Protected Forest & Wild life Santuary

S. No. Sensitive Area Distance (km) Direction
Protected Forests
1 Boru ~9 NNE
2 Thapal ~10 NE
3 Palsed ~10 ENE
4 Bhakra ~10 ENE
Wildlife Sanctuary
1 Nangal Wildlife Sanctuary & Eco Sensitive Zone ~2.5 NE
4.2.1 Nangal Wildlife Sanctuary
Nangal wild life sanctuary is within the study area of 10 Km from the project boundary. Aerial distance of this
sanctuary from PACL is ~2.5 Km. Distance certificate shall be procured from the forest department. Map of eco-
sensitive zone of Nangal Wildlife Santuary with latitude and longitude is published vide Annuxure I of MoEF&CC
Notification S.O. 840(E) vide 16th March, 2017. The notification states “The Eco-Sensitive Zone is spread over an
area of 1.26 Sq. Kms with an extent upto 100 meters around the boundary of Nangal Wildlife Sanctuary”. Thus, the
proposed project does not require Wild Life Clearance.
4.3 Topography
The Project site is shown on OSM sheet in Figure 3-2.
4.4 Existing Infrastructure
Existing infrastructure like roads, power supply, water supply line, etc. are readily available at the site.
4.5 Soil Classification, Geology & Drainage
4.5.1 Soil Classification6
There are two types of soils are found in the district- (1) Reddish chestnut soils which is seen in the northeastern
part of the district, particularly in the Rupnagar and Anandpur Sahib blocks. These soils are loam to clay-loam in
nature and de-calcified. (2) Tropical arid brown soils (weakly solonized) are mainly found in rest of the area which
are mainly calcareous sandy loam. The soils of the District vary in texture generally from loam to silty clay loam
except along the Sutlej River and chos (seasonal canals) where some sandy patches may be found. Chamkaur
Sahib and Morinda blocks have sodic soils. The soils of Anandpur Sahib and Rupnagar blocks are undulating.
4.5.2 Geology
Geology of the District7
Geologically, the rocks are disposed into two broad belts; outer and inner, formed of the upper and lower Tertiary
period respectively. The rock formation met with in the upper Shiwaliks consist of soft earth clay and bouldary
-------------------------------------------------------------------
6
Source: http://cgwb.gov.in/District_Profile/Punjab/Ropar.pdf
7
Source: http://www.pbforests.gov.in/Pdfs/working_plan/Working%20plan%20of%20Ropar%20Forest%20Division.pdf

conglomerates. The middle shiwaliks are composed of massive sand rock and clay beds. The lower Shiwaliks have
grey micaceous sand stones and slabs and are unfossiliferous. The piedmont plain area is composed of the alluvium
derived from these shiwaliks intercepted by seasonal rivulets or ' choes'. The soils derived from these formations
are unstable and prone to erosion, indicating the desirability of permanent vegetation especially on the hill slopes.
Geology of the project site
This will be detailed in the EIA report.
Geomorphology8
The entire district can be grouped into 4 units such as Siwalik Hills, Intermontane valley, alluvial fan and alluvial
plain. The Siwalik Hills separates the main Himalayan ranges from the Indo-Gangetic alluvial plain. The area is
highly dissected and has an uneven topography. Adjacent to the hills is a long narrow intermontane valley, which
extends from Nangal to Rupnagar trending northwest to southeast. Anandpur Sahib tehsil of the district lies in the
intermontane valley and occupies a length of 40 km. The average width of the valley in the district is 5 km. Sutlej
River and its tributaries drain in this valley. Adjacent to this is the alluvial fan which forms the transitional area
between the alluvial plains and hilly area of Himalayan foot hills. The coarse sediments brought down by hill
torrents forms the alluvial fan deposits. These alluvial fans coalesced to form Kandi and Sirowal formation. The
southern part of the district is mainly alluvial plain, which forms a part of vast Indo-Gangetic alluvial plain.
Seismicity of the study area
The area comes under the high damage risk zone (Zone-IV) of the Seismic Zonation of Punjab State9.
4.6 Climatic data from secondary sources
Based on the long-term climatological tables (1996 – 2009) published by Indian Meteorological Department (IMD)
of Bhiwani (Chandigarh) for October-December, the mean daily maximum temperature was recorded as 33.2°C.
The maximum and minimum mean hourly relative humidity recorded are 81% and 49% respectively. Average wind
speed for post monsoon season is 1.56 km/hr (0.43 m/sec). Pre-dominant wind direction in post monsoon season is
from NW (20.3%) followed by SW (8.7%) & NE (7.5%).
Site specific meteorological data will be collected during the Baseline Environmental Monitoring for post monsoon
season for the year 2018.
4.7 Social Infrastructure Available
Key infrastructure such as schools, colleges, hospitals, schools, bank, places of worship and social / community
facilities such as park, market, playground etc. education, health care, community development, income
distribution, employment and social welfare are available in Naya Nangal as well as Nangal towns.
-------------------------------------------------------------------
8
Source: http://cgwb.gov.in/District_Profile/Punjab/Ropar.pdf
9
Sources: http://asc-india.org/seismi/seis-punjab.htm; http://www.bmtpc.org/disaster%20resistnace%20technolgies/ZONE%20IV.htm

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PLANNING BRIEF
5 PLANNING BRIEF
5.1 Planning Concept
Basic facilities of infrastructure like storage area, processing area, internal roads etc are available on existing site.
Transportation of raw material and finished goods will be carried out through existing road.
5.2 Population Projection
Refer Chapter 2, Section 2.6.
5.3 Land use Planning
There will be no change in landuse as the necessary expansion will be within the existing premises of PACL, Naya
Nangal site.
5.4 Assessment of Infrastructure Demand (Physical & Social)
Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park,
market, playground etc. education, health care, community development, income distribution, employment and
social welfare are available in Naya Nangal as well as Nangal towns.
5.5 Amenities / Facilities
Basic Amenities like public transport, water supply, telecommunications, educational institutions, hospitals etc. are
available in Naya Nangal & Nangal towns.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PROPOSED INFRASTRUCTURE
6 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (Processing Area)
The proposed expansion will mainly comprise of following additional sections:
 Chlor Alkali Sections:

 Brine purification sections;
 Electrolyser cells;
 Cooling towers;
 Chlorine processing / refrigeration / filling / storage;
 Hypo plant;
 Flaker Plant;
 SLF (Secured Landfill Facility) cells;
 DG Sets;
 SBP Plant.
 Hydrogen Peroxide Plant.
The proposed power plant will mainly comprise of following sections:
 Boiler House consisting of CFBC Boilers, Steam Turbines & Alternator;

 Coal & biomass storage area;
 Utility Area consisting of cooling tower, compressors, ESP section;
 Fly Ash & Hazardous waste storage area.
Adequate storage space for fuel storage, hazardous and other solid waste is already available. Additional storage
space will be provided as per the requirement.
6.2 Residential and Non- Processing Area
No residential units / areas are planned in the facility for the proposed project. During Construction phase,
temporary storage areas would be created within the site for storage of construction materials like Bricks, cement,
steel etc.. Further, during construction phase, no residential space for construction workers would be created within
the site.
6.3 Greenbelt
The green belt area of ~13 Acre is already developed by PACL. Since, PACL was established in year 1984, no norms
for green belt were in place at that time. Yet ~ 15 % of green belt is already developed in the premises. This will
remain unchanged after the expansion also. Map showing greenbelt area within the project premises is shown in
Annexure 4.
6.4 Social Infrastructure
Civic / infrastructural facilities like public transport, water supply, telecommunications, educational institutions,
hospitals etc. are available in Nangal and Naya Nangal.
6.5 Connectivity
Please Refer Chapter 3.8.5, Section 4.1.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB PROPOSED INFRASTRUCTURE
6.6 Drinking Water Management
The water is supplied from river Sutlej by the Irrigation Department, Government of Punjab, through the existing
Bhakra-Nangal dam project located nearby.
6.7 Sewerage System
The sewage is discharged into the Naya Nangal Municipal Council sewage drains. The sewage generated from PACL
site is in the process of being connected to this sewage drain.
6.8 Industrial Waste & Solid Waste Management
Solid and hazardous waste are mentioned in Chapter 3, Section 0.
6.9 Power Requirement & Supply / Source
Refer Chapter 3, Section 3.7.1.

PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT, HYDROGEN PEROXIDE PLANT & CAPTIVE REHABILITATION AND
PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB RESETTLEMENTS
7 REHABILITATION AND RESETTLEMENT (R& R) PLAN
Since the proposed expansion as well as captive power plant establishment are taking place in the existing facility,
no additional land is acquired for the proposed expansion project. Thus, all the proposed units will be inside the
existing plant premises. Consequently, R & R issues are not envisaged.

PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT, HYDROGEN PEROXIDE PLANT & CAPTIVE PROJECT SCHEDULE & COST
PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB ESTIMATE
8 PROJECT SCHEDULE AND COST ESTIMATE
8.1 Likely date of start of construction and likely date of completion
The construction is likely to start after getting Environmental Clearance from MoEF&CC, Govt. of India, New Delhi
and NOC / CTE from PPCB. This is likely to occur in the month of September 2019.
8.2 Estimated Project Cost
The total investment for proposed expansion is envisaged to be INR 1,240 crores. Plant-wise project cost is
tabulated in Table 8-1 and Table 8-2.
Table 8-1: Estimated Cost – Chlor Alkali, Flaker, SBP & Hydrogen Peroxide Plant
Cost (INR -
S. No. Particulars
Crore)
1 Land Development & Civil and Structures 75
2 Plants Machinery, Equipment, Erection/Insulation/Painting & Installation, Technical Consultancy etc. 660
3 Pre-operative Expenses & Others 25
4 Contingency & Others expense 25
5 Flaker 40
Total Project Cost 825
Table 8-2: Estimated Cost – Captive Power Plant

Cost (INR -
S. No. Items
Crore)
1 Land Development & Civil and Structures 60
2 Plants Machinery, Equipment, Erection/Insulation/Painting & Installation, Technical Consultancy etc. 315
3 IDC+FC, Pre-operative Expenses & Contingency 40
Total Project Cost 415
8.2.1 Economic Viability
The project has been conceived assuming that there will be a growth in demand for the proposed products, leading
to a reasonable rate of return in the medium term. The project is considered ‘bankable’.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB ANALYSIS OF PROPOSAL
9 ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits
There shall be employment generation for the local people during the construction and operational phase of the
proposed facility.
The existing manpower deployed at PACL’s Naya Nangal site is 400 persons direct and about 500 indirect. The
existing manpower will be sufficient to operate the plants after expansion in Caustic Soda Plant. However, 200
person will be required for operating Power Plant. Local skilled and semi-skilled workers will be preferentially hired
for the purpose.
The positive impacts include enhanced direct employment for technical / administrative works and indirect
employment opportunities for transporters of raw material like salt, etc. and finished goods.
There will be indirect development of small businesses for various aspects around the site.

PACL POWER PLANT AT VILLAGE NAYA NANGAL, DIST. RUPNAGAR, PUNJAB ANNEXURES
ANNEXURES

Annexure 1: Copy of Letter from MoEF regarding non-requirement of EC for project



Annexure 2: Copies of CTO (Air & Water), Renewal Letters & Authorization of Hazardous Waste
Copy of CTO (Air)




Copy of Latest CTO (Air– Renewal Letter valid till 31/12/2018)


Previous CTO (Air)




Copy of CTO (Water)




Copy of Latest CTO (Water – Renewal Letter valid till 31/12/2018)


Previous CTO (Water)




Copy of Authorization (Hazardous Waste valid till 31/03/2019)


Annexure 3: Land Possession Documents
Deed of 82.43 Acres
















Deed of 6.43 Acres







PRE-FEASIBILITY REPORT: PROPOSED CAPACITY EXPANSION OF EXISTING CHLOR ALKALI PLANT AND ESTABLISHMENT OF NEW FLAKER PLANT, HYDROGEN PEROXIDE PLANT & CAPTIVE POWER PLANT AT VILLAGE
PACL NAYA NANGAL, DIST. RUPNAGAR, PUNJAB ANNEXURES
Annexure 4: Site Layout Map showing Existing & Proposed Units along with Greenbelt

Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development
CONTACT DETAILS
Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-613 1000
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11th Floor, Tower B-3, Sector 49, Near
Omaxe City Center Mall, Sohna Road, Gurgaon, India – 122 002
E: [email protected]; T: 0124-424 2430-436

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PUNJAB ALKALIES AND

CHEMICALS LTD. (PACL)

Pre-Feasibility Report: Environmental

Environment for Development

Punjab Alkalies & Chemicals Ltd. (PACL)

Pre-Feasibility Report: Environmental Clearance for

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 2

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 9

2.1.1 Identification of Project Proponent & Project ............................................................. 11

3 PROJECT DESCRIPTION ............................................................................................ 15

3.1 TYPE OF PROJECT ...................................................................................................... 15

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 3

3.8.5 Solvent Details.................................................................................................. 38

4.1 CONNECTIVITY ......................................................................................................... 39

5 PLANNING BRIEF ..................................................................................................... 42

5.1 PLANNING CONCEPT .................................................................................................... 42

6 PROPOSED INFRASTRUCTURE ................................................................................... 43

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 43

7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .................................................... 45

8 PROJECT SCHEDULE AND COST ESTIMATE................................................................... 46

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 46

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 47

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 4

Annexure 3: Land Possession Documents ......................................................................................................... 74

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 5

Table 2-1: Details of Directors ......................................................................................................................... 11

Table 2-2: Products Capacity (Existing & Proposed) .......................................................................................... 11

Table 2-3: Power Generation Capacity (Proposed)............................................................................................. 12

Table 3-1: Co-ordinates of Site Boundary ......................................................................................................... 18

Table 3-2: Mass Balance – Chlor Alkali Plant ..................................................................................................... 22

Table 3-3: Mass Balance – Stable Bleaching Powder .......................................................................................... 24

Table 3-4: Mass Balance for Hydrogen Peroxide ................................................................................................ 26

Table 3-6: List of Fuel Requirement ................................................................................................................. 30

Table 3-7: Water Consumption Details ............................................................................................................. 30

Table 3-9: Details of Flue Stack Emissions & Process Vents................................................................................ 34

Table 3-10: Wastewater Generation Details ...................................................................................................... 36

Table 3-11: Hazardous Waste Generation and Disposal ..................................................................................... 36

Table 3-12: Solid Waste Generation & Disposal ................................................................................................. 36

Table 3-13: Other wastes generated ................................................................................................................ 37

Table 3-14: Lists of Solvents Used ................................................................................................................... 38

Table 4-1: List of Villages in Nearby Area (within 5 Km) .................................................................................... 39

Table 8-2: Estimated Cost – Captive Power Plant .............................................................................................. 46

Figure 3-3: Specific Map showing Project Boundary ........................................................................................... 17

Figure 3-5: Process Flow Diagram – SBP Plant .................................................................................................. 23

Figure 3-6: Process Flow Diagram of Hydrogen Peroxide ................................................................................... 25

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 6

ABBREVIATIONS AND ACRONYMS

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 7

CPCB : Central Pollution Control Board

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 8

1.1 Plant Features and Production Capacity

1.2 Utility & Fuel

Table 1-1: List of Utilities & Fuel

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 9

The proposed expansion would be implemented in PACL’s existing manufacturing facility.

KADAM ENVIRONMENTAL CONSULTANTS | OCTOBER, 2018 10

2.1.1 Identification of Project Proponent & Project

2.1.2 Project Proponent

Table 2-1: Details of Directors