PRE-FEASIBILITY

REPORT

Proposed Expansion of
Ganjam Chlor Alkali Plant

M/s. Grasim Industries Ltd.,

Chemical Division,
Ganjam

June 2016
CONTENTS
Executive Summary 1

Introduction 3

Project Details 4

Raw Materials 17
Resource Requirements 19

Product & Bi Product 20

Construction Details 21

Rejects (Pollution Potential and Mitigation Measures) 22

Project Cost 25

Amenities/ Facilities 26

Selection of Site 27

Social Aspects 28

Details of Site 29

Annex 1: Plant Layout

R-1(17.02.16)

Executive Summary
Name of the unit : M/s. Grasim Industries Ltd., Chemical Division, Ganjam
Location of the factory : Post : Jayshree, Dist : Ganjam,
Odisha, Pin Code: 761025
Promoter of the unit : Aditya Birla Group-Grasim Industries Ltd. –Chemical Division
Telephone number : 06811 254329, 254336
Fax number : 06811254384
Contact information : Mr. D.P. Modani
Grasim Industries Ltd. (Chemical Division)
Post : Jayshree, Dist : Ganjam,
Odisha, Pin Code: 761025
Category of industry : Chlor Alkali
Location : Post : Jayshree, Dist : Gaanjam,
Odisha, Pin Code: 761025
Production details
Name of Product Production Capacity TPA
Existing Proposed Total
(a) (b) (a+b)
Caustic Soda 72,000 33,000 1,05,000
Liquid Chlorine 46,350 26,650 73,000
Hydrochloric Acid 60,000 30,000 90,000
Hydrogen Gas- Million NM3 21.17 9.83 31.0
Sodium Hypochlorite 32400 1300 33700
Poly Aluminum Chloride- 10 % liquid --- 73,000 73,000
Calcium Chloride --- 18,250 18,250
Carbon Di Oxide --- 7,300 7,300
Stable Bleaching Powder --- 18,250 18,250
Chlorinated Paraffin’s --- 18,250 18,250

Cost of the project : 500 crores

Land area : Total area available 130 acres
Source of water : Bore wells
Source of power : OPTCL

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The plant will be located at Ganjam in the name of M/S.Grasim Industries Ltd. is engaged in the
manufacturing of caustic soda lye. Based on their market scenario now, company proposes to
increase its production capacity by increasing production capacity of Caustic Soda Lye, and also
plans to produce chemicals like Poly Aluminium chloride, Calcium Chloride, Carbon dioxide,
Stable Bleaching powder and Chlorinated Paraffin.

Location of project:

Post :Jayshree,
Dist : Ganjam,
Odisha,
Pin Code: 761025

The proposed expansion activities will be carried out in our existing premise which is located in
Ganjam, area where the all resources are easily available and well developed communication
facilities, infrastructure i.e. road, sea-port, air- port etc.

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 Introduction

Background:
Proponent
Grasim Industries Limited is an Aditya Birla Group company, operating in India since last 6
decades and operating globally since last 40 years. Grasim Industries Ltd. Is India’s pioneer
industry group for production of Viscose Staple Fibre (VSF) along with captive co-generation of
chemicals and power and largest manufacturer of VSF.

Basic objective of the proposed project

M/s. Grasim Industries Ltd. Ganjam is engaged in the manufacturing of the Caustic Soda Lye,
Now, company proposes to increase production capacity by increasing existing Caustic Soda Lye
production and also plans to produce new products like Poly Aluminium chloride, Calcium
Chloride, Carbon Dioxide, Stable Bleaching powder and Chlorinated Paraffin. The management
is engaged in manufacturing activities and has a wide experience in the similar field.

Objective of the project

In view of the market demand in India and other overseas countries the company is proposed
to increase their production capacity by increasing its production capacity of Caustic Soda Lye
and related products. Taking in consideration of sustainable development/ environmental
friendly process and its products quality the generation of Chlorine gas and Hydrogen gas and
Hydrogen Chloride etc. as by products from Caustic Soda Lye plant would be used in production
of other proposed products.
Other factors include:
 Cost Competitiveness
 Easy Availability of skilled and non-skilled workers
 Availability of developed infrastructure facility
 Well Connectivity of road, railways etc.

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 PROJECT DETAILS
Need/ justification of the project

 Demand supply gap

The company wishes to capture this opportunity by expanding the current capacities to be
able to service the growing market demand of the proposed product. Grasim Industries Ltd.
already has an experience of managing of these products’ business, this being an extension
is an indication that the demand is there for the product and this is just an effort to
accomplish the supply gap and reap the profits.

Asian demand for caustic soda continues to be strong regardless of a price rise driven by
tight supply situation worldwide. The forward integration products such as Stable Bleaching
powder, Poly Aluminum Chloride, Chlorinated Paraffin, calcium Chloride have significant
market potential within the nation, neighboring countries and extend even up to European
countries, Australia etc. Also huge potential is there for organic chlorine derivatives.

 Imports vs. Indigenous production

The products which will be manufactured in said premises will be of international standards.
This will have acceptability in the export as well as domestic markets.

 Export possibility
M/s. Grasim Industries Ltd. with its business spread across India, Thailand and China,
M/s. Grasim Industries Ltd.is a major business of the M/s. Aditya Birla Group, India’s
first multinational corporation. Grasim Industries Ltd. has expertise in manufacturing of
these products and other own brand products.

 Employment generation
Manpower of the Company

Chemical Unit

Total workers in all shifts

Status Male Female
Existing Proposed Existing Proposed
Shift-1 52 62 0 0
Shift -2 51 61 0 0
Shift -3 53 63 0 0
Shift -4 (G) 131 145 0 0
Total 287 331 0 0

Total employment generation after proposed expansion would be 331 Nos.

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Features of the project

Membrane cell technology—

The technology advancement in the field of caustic manufacturing is fast paced and today the latest
generation electrolysers are capable of higher production with lesser power consumption. To survive
the competition, up-gradation of technology and de- bottlenecking of existing systems to the optimum
level is required for sustaining the position ahead of the competitors.

The latest generation electrolysers give us benefit of higher caustic production along with considerable
savings in energy consumption. Just by replacing the existing membrane cell plant electrolysers with the
latest ones and de-bottlenecking of brine and chlorine sections, a higher production with considerable
energy saving with no adverse impact on environment can be achieved.

The plant layout showing existing and proposed facilities is enclosed as Annex 1.

Process description
Caustic soda -
The caustic soda lye is manufactured by electrolysis of brine (sodium chloride solution of
concentration 310 gpl). For satisfactory operation of the membrane electrolysis cell, high purity of
brine is required. Brine is recycled continuously and the cycle consists of the following steps:

1. Brine Saturation
2. Brine Purification
3. Brine Settling, Filtering, Polishing
4. Secondary brine purification(Ion Exchange)
5. Electrolysis
6. De-Chlorination

Chlorate Destruction

After treatment in above steps, the brine meets the requirements and is feed into the anode chamber of
electrolyser cells. The brine flow in each electrolyser is regulated by means of rotameters. Uniform
distribution of brine into the different elements of the electrolyser is ensured by means of long thin inlet
hoses.
The cathode chamber of the electrolytic cells similarly receives weak caustic from the catholyte head
tank. The anode and cathode chambers of the cell are isolated from each other by membrane which is
selective to the migration of sodium ions.
Water to some extent also diffuses through the membrane from the anode chamber. Chlorine is
liberated at the anode surface and the brine in the node chamber is depleted to about 200-220 gpl. The
two phase mixture of depleted brine and chlorine overflows from the anode chamber via an insert pipe
into the anode header.
As a result of electrochemical reactions taking place in the cathodic chamber, Hydrogen is generated at
the cathode surface and OH ions combine with the Na+ ions diffusing through the membrane. A two
phase mixture of 33% NaOH and Hydrogen overflows from the cathode chamber into the catholyte

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header. The water required for cathodic reaction is partly supplied by the water transported through the
membrane and the rest is made up by addition of purified water in the re-circulation catholyte loop.
The Electrochemical reactions in the cell are as follows:

Anode 2Cl = Cl2 + 2e

Cathode H2O + e = 1/2H2 + OH
Na + OH = NaOH
The two phase mixture of 33% NaOH and hydrogen primarily gets separated in the catholyte header
itself. The depleted brine is de-chlorinated for removal of dissolved chlorine before re-saturation.
Sodium Chlorate, which is formed in the process, is decomposed into chlorine and sodium chloride by
reaction with hydrochloric acid.
The saturated brine is treated with chemicals to remove impurities of salt and brine purification
operations consisting of settling, filtration, polishing, ion exchange etc. are carried out to obtain very
high purity brine.
The process safety is ensured through elaborate process control, instrumentation and atomization. The
unsafe conditions are thus avoided and various emergency plant stoppage methods have been
incorporated in the plant design, to have safe plant operation.

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Process flow diagram for Caustic soda plant

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Mass balance

INPUT

Sl.No Particulars
MT/MT MT/DAY MT/Month

1 Salt 1.4613 420.373 12611.19

2 Water 0.4500 129.451 3883.552

total 1.9113 549.824 16494.742

3 Barium Carbonate 0.0150 4.315 131.176

4 Soda ash 0.0025 0.719 21.863

5 Caustic Soda 0.012 3.452 104.94

6 Alpha Cellulose 0.00025 0.863 26.25

7 Hydrochloric acid 0.090 25.88 787

8 Sodium Sulphite 0.0010 0.287 8.75

9 Coagulant 0.00010 0.0287 0.875

Total 0.120 35.544 1080.854

Output

S.No Particulars MT/day MT/Month Remarks

1 Caustic soda Lye 287.671 8750 product

2 Chlorine/HCl/Hypo 457 13916 By product

3 Hydrogen 7.25 220.4 Byproduct

Total 751.921 22886.40 -

Equivalent to NM3 80555 2449677 --

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Chlorinated Paraffin–

The manufacturing of CHLORINATED PARAFFIN (CP) involves reaction of gaseous chlorine with
liquid heavy normal paraffin (HNP) in a batch reactor at 90-110⁰C.

CmHyClxHCl + Heat CmHn +xCl2 (n= x+y)

The heat of reaction is removed with the help of cooling water circulating through a cooling coil (or
Jacket) in the glass lined rector.The HCl gas evolved in the process is stripped of HNP droplets in a
condenser. Then the HCl gas is absorbed in water to form HCl solution. The last trace of unabsorbed
HCl gas along with un-reacted chlorine is absorbed in alkali to remove last traces of gaseous
pollutants.

After reaction is over, the CP liquid is stripped of dissolved gases (chlorine) under vacuum or by
bubbling a stream of dry air through the liquid.

Then the CP is strained from any suspended impurities before packing as finished product. HCl
absorption system has proper heat removal arrangement and final traces of chlorine are sent to
Hypo section of caustic soda plant and there it is neutralized in caustic solution.

Mass Balance

Input

S.no Particulars MT/MT MT/Day MT/Month

1 Paraffin 0.45 22.492 684
2 Liquid chlorine 1.25 62.53 1901
3 Water for HCl 1.0 50 1520.85
Total 2.15 135 4105.85

Output

S.no Particulars MT/Day MT/Month Remarks

1 Chlorinated Paraffin 50 1521 Product
2 Hydrochloric acid 85 2585.445 By
product
Total 135 4106

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Page | 10
Poly Aluminium Chloride –
Poly Aluminium chloride (PAC) is manufactured by chemical reaction between alumina hydrate powder
and hydrochloric acid at specified pressure and temperature conditions.

A specific amount of Hydrochloric acid (HCl) having the concentration of (30-32) % by weight and
specific amount of Aluminium Hydroxide are mixed with each other by agitator. The mixer is fed to
glass-lined reactor where reaction is effected with agitation, temperature and pressure. After the
reaction has been completed, the product is fed to the dilution tank. Untreated aluminium hydroxide is
removed by filtering the product with the filter press. The filtered product is fed to the formulation tank,
where water and chemicals are added and dissolved by agitation. The solution is diluted by adding
process water, to precisely adjust the concentration of aluminium hydroxide. The product thus formed is
fed to the storage tank. Solid cakes, which contain aluminium content, from the filter press is recycled
back to the process.

The reaction in the reactor is as follows.

2Al(OH)3 + 3 HCl(Al2(OH)3Cl3)m + 3 H2O m = 1 to 1.5

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Mass Balance

Input

S.no Particulars MT/MT MT/Day MT/Month

1 Alumina Hydrate 0.32 35.61 1083
2 Hydrochloric acid 0.62 124.3 3781
3 Water 0.20 40.11 1220
Total 1.14 200.02 6084

Output

S.no Particulars MT/Day MT/Month Remarks

1 Poly Aluminium Chloride (10%) 200 6084 Product

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Stable Bleaching Powder–

Stable bleaching powderIs manufactured as a consequence of composite chemical reaction between

fully slaked lime of very high quality 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 over sized material. The over sized material is
further pulvarised and mixed with product.

The reaction in the drum is as follows.

Ca(OH)2 + Cl2------ CaOCl2 + H2O

Stable Bleaching Powder contains +35% Chlorine and is a powerful oxidizing agent. It is stable for 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.

Mass Balance

Input

S.no Particulars MT/MT MT/Day MT/Month

1 Hydrated Lime 0.75 37.52 1141
2 Liquid chlorine 0.400 20 608
Total 1.15 57.5 1749

Output

S.no Particulars MT/Day MT/Month Remarks

1 Stable Bleaching powder 50 1521 Product
2 Sodium Hypo 7.5 228 By product
Total 57.5 1749

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Page | 14
Calcium Chloride –

35% Calcium Chloride Section will be designed to operate on a continuous basis. Limestone with 40-80
mm size will be fed at the top of the Reactor and 31% of Hydrochloric Acid will flow counter current
from the bottom. In the Reactor HCl will react with Limestone to produce Calcium Chloride Solution and
Carbon Dioxide Gas.
35% Solution of Calcium Chloride produced in the Reactor will overflow to a Neutralization Tank where
the pH of the Solution will be corrected by addition of lime solution. The reacted solution will be taken
to a settler where magnesium and iron components will be precipitated out.
Clarified Calcium Chloride Solution will be filtered and the clear solution will be taken to the evaporation
unit for drying

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Mass Balance

Input

S.no Particulars MT/MT MT/Day MT/Month

1 Limestone 0.9 45 1350
2 HCl 0.67 33.5 1005
Total 1.57 78.5 2355

Output

S.no Particulars MT/Day MT/Month Remarks

1 Calcium Chloride 50 1500 Product
2 Carbon Di Oxide 20 600 By product
3 Water 8.5 255 reused
Total 78.5 2355

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 Raw Materials
MT/Annum
1. For manufacture of caustic soda:
S,no Particulars Existing Proposed Total Storage type
1 Salt 115200 52800 168000 RCC godown
2 Barium Carbonate 1080 495 1575 Bags
3 Soda Ash 180 83 263 Bags
4 Alpha Cellulose 864 396 1260 Bags
5 Caustic soda 18 8 26 MS tanks
6 Hydrochloric acid 6480 2970 9450 MSRL tanks
7 Sodium Bi Sulphite 72 33 105 Bags
8 Coagulant 7.2 3.3 10.5 Bags
9 Sulphuric acid 828 379 1207 MS tanks

2. For manufacture of Stable Bleaching Powder:

S,no Particulars Existing Proposed Total Storage type
1 Hydrated lime -- 13692 13692 Bags
2 Liquid Chlorine -- 7296 7296 MS Tank
Thermally
Insulated

3. For manufacture of Polyaluminum chloride:

S,no Particulars Existing Proposed Total Storage type
1 Alumina Hydrate -- 12972 12972 Jumbo bags
2 Hydrochloric acid -- 25141 25141 MSRL tanks

4. For manufacture of Calcium Chloride:

S,no Particulars Existing Proposed Total Storage type
1 Limestone -- 16200 16200 RCC godown
2 Hydrochloric acid -- 12060 12060 MSRL tanks

5. For manufacture of Chlorinated Paraffin:

S,no Particulars Existing Proposed Total Storage type
1 Paraffin -- 8208 8208 MS epoxy
coated tanks
2 Liquid chlorine -- 22812 22812 Pipeline/ MS
tonners

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Raw Material sources:
The company will purchase raw materials from local and / or import depends on
availability and market value.

Market area of finished products:

The proposed production of the existing unit is increase in the view of market demand. The
same products would be consumed at domestic level as well as export to various
countries as per market demand.

Mode of transportation of raw material and products:

The required raw material for the manufacturing of proposed products would be transported by
either sea or road and in case of products it would be transported by either sea or road and also
the same will be depend upon the availability / comfort ability.

Recycle/Reuse options:
Quality of raw material, in-process inspection, stringent process controls, safety and
pollution control auto systems, power savers, on-line sensors etc. are some of the major
focus areas to optimize and conserve resources. Emission controls will be done by
installing efficient scrubbing systems. Water reuse/recycling arrangements will be done
in all sections for water conservation. By-products will be used for manufacturing of
different products.

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 Resource Requirements

Existing infrastructure

 Land: 130 acres

 Power: Power requirement for the proposed production will be taken from the OPTCL grid.

 Water: Source of water for running operations in plant are bore wells.

 Fuel: Steam required for the proposed expansion will be sourced from proposed dual fuel fired
boiler.

 Rail: The nearest broad gauge railhead is Berhampur.

 Road: The proposed plant is connected to National high way NH-.16 The distance from the plant
to National high way is about 1 Km.

 Air: The nearest domestic airport is available at Bhubhaneswar (130 km).

 Communication: All facilities are available i.e. Telephone, Fax, Internet etc., continuous up-
gradation will be done.

 Manpower:

Status Total workers in all shifts

Male Female
Existing Proposed Existing Proposed
Shift-1 52 62 0 0
Shift -2 51 61 0 0
Shift -3 53 63 0 0
Shift -4 (G) 131 145 0 0
Total 287 331 0 0

Total employment generation after proposed expansion would be 331 Nos

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 Product & Bi Product

Name of Product
Production Capacity TPA

Existing Proposed Total

(a) (b) (a+b)
Caustic Soda 72,000 33,000 105,000

Liquid Chlorine 46,350 26,650 73,000

Hydrochloric Acid 60,000 30,000 90,000
Hydrogen Gas- Million NM3 21.17 9.83 31.0
Sodium Hypochlorite 32400 1300 33700
Poly Aluminum --- 73,000 73,000
Chloride- 10 % liquid
Calcium Chloride --- 18,250 18,250
Carbon Di Oxide --- 7,300 7,300
Stable Bleaching Powder --- 18,250 18,250
Chlorinated Paraffin’s --- 18,250 18,250

Connectivity:

The proposed plant is to be set–up in Ganjam. Existing roads and rails will be used for
the proposed project. No new roads or rails are envisaged outside the boundary of the
plant.

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 Construction Details

Estimated project cost: total estimated cost of the project would be 500 Crores.

Project Schedule & Cost Estimation:

o Proposed date of start of construction and machine erection/ installation:

After getting Environment Clearance from SEAC and No Objection Certificate from the
OSPCB.

o Date of completion:
It would be approximately 15-18 months from the date of start construction and other
activities.

o Proposed date of start production:

After getting the statutory required Consent & Authorization from the OSPCB.

Rehabilitation and Resettle (R& R) Plan:

o Not applicable, since proposed project is to be established within existing plant

premises

Traffic:

The proposed plant is to be set–up in Ganjam. Existing roads and rails will be used for the
proposed project. No new roads or rails are envisaged outside the boundary of the plant.

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 Rejects (Pollution Potential and Mitigation Measures)

Hazardous Waste -

Used oil is the only hazardous waste generated from the plant process. The used oil is collected and
stored as per norms. Thereafter it is sold off to authorized recyclers.

Solid waste –

All the solid waste generated will be stored in, HDPE lined pits, which will avoid contamination of
soil.During handling of solid waste all adequate measures will be provided to avoid contamination of
land or water due to accidental spillage of materials during handling and storage.

Domestic waste –

All the wastes from domestic operations are sent to septic tank followed by soak pit. And the trade
effluents from existing, proposed project will be treated in ETP and treated effluent will be sent to guard
pond for natural evaporation.

Air Pollution control -

For chlorine gas - Alkali Scrubbers will be installed for absorption to produce bleach liquor, which is a
saleable product used for bleaching. No waste is generated from the scrubbing process.

Water Scrubbersare installed for absorption of HCl vapors in water. HCl thus produced is a product. No
waste is generated from the scrubbing process

Apart from above, on-line monitoring sensors for chlorine and HClwill be installed in the plant, covering
entire work zones. Continuous monitoring sensors at emission vents will be installed for vigilance round
the clock. The pollution control equipments will be so interlocked with process that, in case of failure of
pollution control equipment, the process will automatically trip down without fail. Also back up power
supply for running pollution control equipments is made available to prevent failure. The entire process
is DCS controlled for stringent control over process parameters.

Efficient air pollution control devices are installed in each plant to ensure minimum air pollutant
emissions to ambient air.

1. Caustic soda plant

Sn Name of the Control system End use Waste
Scrubber generated
1 Alkali Absorption of Bleach liquor, which is a No waste is
Scrubbers unreacted Chlorine to product, will be used for generated.
produce bleach liquor bleaching.
2 Water Absorption of HCl thus produced will No waste is
Scrubbers HClvapours in water. be sold generated.

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2.Stable Bleaching Powder plant:
Sn Name of the Control system End use Waste
Scrubber generated
1 Alkali Absorption of chlorine Bleach liquor thus No waste is
Scrubbers produced will be generated.
recycled in plant
process.
2. Bag filters For control of SPM Not applicable Not applicable

3. Poly Aluminium chloride plant

Sn Name of the Control system End use Waste
Scrubber generated
1 Water Absorption of HCl and Al2O3 enriched No waste is
Scrubbers unreacted HClvapours water thus producedwill generated.
in water. be used in PAC
formulations.

4. Chlorinated Paraffin plant

Sn Name of the Control system End use Waste
Scrubber generated
1 Water Absorption of HCl thus produced is No waste is
Scrubbers HClvapours in water. sold generated.

Noise pollution control –

 Manufacturers/Suppliers of major noise generating machines/ equipments like air compressors,

feeder pumps, generators, etc. shall be instructed to make required design modifications
wherever possible before supply and installation to mitigate the noise generation and to comply
with the national / international regulatory norms with respect to noise generation for
individual units
 It shall be ensured that low noise equipment are procured wherever feasible
 Acoustic laggings and silencers shall be used in equipment wherever necessary
 Acoustic design with sound proofing/ glass paneling shall be provided at critical operating
stations/ control rooms
 Use of personal protective devices such as ear-muffs, ear-plugs etc. shall be enforced wherever
necessary
 Either Acoustic barriers/ shelters shall be developed in noisy workplaces or acoustic enclosures
shall be provided for the high noise generating equipment
 Implementation of greenbelt development, landscaping, horticulture etc. is expected to reduce
noise impacts within the project premises.

Odour pollution control –

There is no such chemical that will cause odour problems. Although basic condition of
the plant will be maintained through excellent housekeeping and maintenance

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 practices. This will prevent leakages and fugitive emissions causing any such probability
of foul odours.

Hazard identification and Safety systems–

 All the preventive and mitigation measures would be taken to mitigate the environmental
hazards
 General Recommendations after assessing risks associated with the proposed project in detail
are as under:
 Surrounding population shall be made aware of the safety precautions to be taken in the event
of any mishap within the plant. This can effectively be done by conducting the training
awareness programs
 Critical switches and alarm should be always kept in line
 Fire detectors should be installed near those units which handle large amount of flammable
material and operate under high temperature and pressure
 A wind direction pointer should also be installed at storage site so that in an emergency the
wind direction can be directly seen and downwind population cautioned
 Shut off and isolation valves should be easily approachable in emergencies
 Material Safety Data Sheet and Toxicological Data should be displayed at the facility
 The Disaster Management Plan describes the emergencies arising out of natural and man-made
calamities. The duties of various persons are well defined and the emergency committees are
formulated for the various levels of emergencies. This DMP is prepared to take care of almost all
the hazardous situations arising out of accidental release of hazardous chemicals handled in the
various units.
 The maximum damage distances due to the accidental release of hazardous chemicals in the
proposed expansion are well within the plant boundary limits in most cases. It is, however,
recommended to implement all the associated safety for the proposed activity.

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 Project Cost

Estimated project cost: total estimated cost of the project would be 500 Crores, details are as
summarized under:

Sr. No. Description Rupees

(in Crores)
1 Civil Construction 120
2 Plant & Machinery 300
3 Pre- Operative Expenses 80
Total Project Cost 500

Economic Viability / Payback period calculation: expected payback period/ turnover is 5 years, details
are as summarized under:-

Year Expected
turnover
(Rupees in
Crore)

2015 – 2016- Construction begins --

2016 – 2017 50 % Capacity utilization 600

2017 – 2018 75 % capacity utilization 1089

2018 – 2019 90% capacity utilization 1139

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 Amenities/ Facilities

Transport:
o Rail: The nearest broad gauge railhead is Brahmapur.

o Road: The proposed plant is connected to National high way NH-.16 The distance
from the plant to National high way is about 1 Km.

o Air: The nearest domestic airport is available at Bhubaneswar (130 km).

Communication:
o All facilities are available i.e. Telephone, Fax, Internet etc.

Education:
o Ganjam has a literacy rate of 70.0%

o There are 12 primary, 7 upper primary, 11 secondary, 5 colleges and 2 ITIs offer several
industrial training programs in Cutting and Sewing, Fitting, Diesel engine mechanic,
Information Technology and electronic system management.

o There are 32 primary health centers (PHC), 8 community health centers (CHC) and 1 civil
hospital present in Bharuch. The district has a presence of private specialized hospitals
to provide a comprehensive range of tertiary and secondary care services backed by
state-of- the- art technology and trained medicos.

Health:
o The company is having separate OHC and providing first aid facility and appointed a
qualified part time Doctor of medical inspection. Also company is conducting the yearly
medical checkup of all employees and the records are marinating. The company has also
providing the Antidote Kits. In case of Emergency or major accident the company is
having its own transport facility to shift the injured employees to outside Hospital for
further treatment.

o The Ganjam district has a presence of private specialized hospitals to provide a

comprehensive range of tertiary and secondary care services backed by state-of- the-
art technology and trained medicos.

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 Selection of Site

Land availability
No procurement of land is to be done. The expansion will take place in the available land,
within the existing industrial premises

Water availability
Water is procured from borewell located at Kalyanpur, at about a distance of 10 km from the
site.

Infrastructural availability
All the necessary infrastructural facilities are available for the proposed expansion.

Raw material availability and its transportation

The company will purchase raw materials from local and / or import depends on availability and
market value

The required raw material for the manufacturing of proposed products would be transported
by either sea or road and in case of products it would be transported by either sea or
road/air-ways and also the same will be depend upon the availability / comfort ability.

Product demand around the site

The proposed production of the existing unit is increase in the view of market demand. The
same products would be consumed at domestic level as well as export to various countries as
per market demand.

Product transportation
No new road, rail, air/waterborne or other transport infrastructure including new or altered
routes and stations are envisaged for the proposed plant. Existing transportation facilities are
capable to take care of the increasing traffic.

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 Social Aspects
M/s. Grasim Industries Ltd. - Chemical Division, Ganjam will undertake development activities including
community welfare programme for the overall improvement of the socio-economic environment in the
project area through its effective Corporate Social Responsibility (CSR) programme. The details of these
activities are given below:

 Preventive healthcare by organizing health camps for immunization through vaccination.

 Curative healthcare by conducting specific health camps such as eye care for Cataract, Glaucoma
etc.

 Support the health care units/hospitals in the region by providing infrastructural facilities.

 Conducting awareness camps for reproductive and child health.

 Initiatives on supporting the Ayurveda, Yoga and Homeopathy

 Improve the level of literacy at primary, secondary and advanced levels of education by
providing scholarships to the meritorious students, enhancing school infrastructural facilities,
industrial training etc.

 Residential Bridge course for drop out students through free coaching classes for students
belonging to economically weak background.

 Sustainable livelihood and farming systems by providing awareness on various agricultural

practices for better yield, pesticide and fertilizer management, etc.

 Training and awareness to the self help groups for income generation

 Infrastructure development through providing drinking water facilities in the village of the
region.

 Solar powered study centers to benefit the student for whom electric power is not available

 Social welfare and woman Empowerment.

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 Details of Site

 Land requirement and availability:

There is no land requirement for the expansion project. The expansion will take place within the
existing industrial premises

 Land ownership details:

Land is owned by M/S Grasim Chemical Division

 Total area of the project site

Total land area after proposed expansion will be 45837.06 m².

 Geographical details
o Latitude: 19° 22' 46.20" N, Longitude: 85° 03' 13.13" E
o District – Ganjam (Municipal Corporation)
o State - Orissa
 Approach
o Rail - The nearest broad gauge railhead is Brahmapur, about 30 km away
o Road - The proposed plant is connected to National high way NH-16. The distance
from the plant to National high way is about 1 Km
o Airport – 130 km at Bhubneshwar
 Distance from nearest residential area – About 0.5 km
 Distance from nearest industrial area – No industrial area nearby
 Distance from nearest water bodies
o River – Rushikulya, about 0.5 km away
o Canal – Not applicable
o Dam – Not applicable
 Distance from ecological sensitive area – Not applicable
 Seismic zone – Not applicable

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ANNEX 1: PLANT LAYOUT