Subject: Expansion of Chlor-Alkali Plant and inclusion of Synthetic Organic Chemicals
manufacturing unit at Sy. No. 132-134 and 137, Saggonda Village, Gopalapuram
Mandal, West Godavari District, Andhra Pradesh by M/s. The Andhra Sugars
Limited, Chemicals and Fertilizers Division.
Project proposal:
M/s. The Andhra Sugars Limited located at Survey No. 132, 133, 134 & 137 Saggonda Village,
Gopalapuram Mandal, West Godavari District, Andhra Pradesh obtained Environmental
Clearance for Expansion of Caustic Soda Plant of capacity 400 TPD of Vide Letter no J-
1101/245/2005- IA II (I) dated 08.02.2006. The unit obtained consent and authorization (CFO) for
manufacturing of 400 TPD Caustic Soda of vide Letter No. APPCB/VSP/RJY/44/CFO/HO/2016
dated 09.02.2016. It has obtained
The Andhra Sugars Limited, Saggonda is proposed to expand manufacturing capacity of existing
facility and inclusion of synthetic organic chemicals in existing area of 320 acres with capital
investment for proposed expansion is Rs. 800 crores. Expansion includes enhancement of process
equipment and storage facility. The proposed expansion has employment potential of 452 no.s.
The site is located at the intersection of latitude 17010’49”N and longitude 81037’8”E. The site is
surrounded by open lands in north, South and east directions. Coal Based power plant in west of
site. The main approach road site road connecting Gopavaram village to Gutala village. River
Godavari is towards east of the site at a distance of 4 Km from the site flowing from north to
south . Kavvada Canal Flows from SW to NE direction of the site at a distance of 5 km in north
direction. Vinjaram Reserved forest is at a distance of 8.5 Km towards NE Direction of the site.
Polavarm Reserved forest is at distance of 7.4 Km towards NW direction of the site. There are no
ecologically sensitive areas like national parks, sanctuaries within 10 km radius of the site.
Manufacturing capacity is presented as follows;
Manufacturing Capacity
S.No. Product Name Capacity (TPD)
Existing Proposed Total after
expansion
1. Caustic Soda 400 400 800
2. Caustic Potash -- 100 100
3. Liquid Chlorine 240 4 244
4. Hydrochloric Acid (33%) 600 400 1000
5. Caustic Soda Flakes 140 140 280
6. Hydrogen Gas (bottling) 2.83 1.0 3.83
7. Liquid Hydrogen 1.0 1.0 2.0
8. Sodium Hypochlorite 20 20 40
9. Sulphuric Acid 300 -- 300
10. Poly Aluminum Chloride 90 -- 90
11. Sodium Chlorate -- 60 60
12. 1. Chlorinated Paraffin Wax (52%) -- 20 20
2. Hydrochloric Acid (33%) -- 30 30
13. 1. Mono Chloro Acitic Acid -- 20 20
2. Hydrochloric Acid (33%) -- 33 33
14. Chloro Methanes : --
1. Methyl Chloride 10 10
2. Methylene Chloride 61 61
3. Chloroform 56 56
4. Carbon tetrachloride 7.6 7.6
5. Hydrochloric Acid (33%) 65.8 65.8
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List of Utilities
S.No Utility Existing Proposed After Expansion
1 Husk Fired Boilers (TPH) 1 x 15 -- 1 x 15
1 x 10 1 x 10
2 Coal/Husk Fired Boiler (TPH) 1 x 25 1 x 25
3 Oil Fired Boiler (TPH) 1x6 -- 1x6
4 Waste Heat Recovery Boiler (TPH) 1 x 15 -- 1 x 15
5 Incinerator (Kg/hr) 1 x 383
DG Sets (KVA)* 1 x 4750 -- 1 x 4750
3 x 1000 3 x 1000
* DG sets will be used during load shut down by APTRANSCO
Process Description
Chlor-Alkali: The Caustic soda manufacturing technology being used i.e. membrane technology
is completely environment friendly. The by-products are hydrogen and chlorine. Hydrochloric
acid is manufactured using H2 and Cl2 (produced from cell house).
Chloromethanes: Chloromethanes (CMS) process by M/s HUALU uses the methanol route and
comprises of the following main 3 steps. The first step is Hydro chlorination of methanol in
vapor phase in presence of catalyst to produce methyl chloride. The second step is thermal
chlorination of methyl chloride in vapor phase with chlorine as feedstock to produce the derived
Chloromethanes.
Poly Aluminium Chloride: The production process of liquid Poly Aluminium Chloride (PAC)
consists in the etching of Alumina with an aqueous solution of Hydrochloric acid.
Chlorinated Paraffin Wax: Controlled Chlorination of paraffin wax yields Chlorianted paraffin
wax.
Sodium Chlorate: Sodium chlorate is produced from commonly found raw material- salt (NaCl)
and water along with the use of large amounts of electrical energy. The manufacturing process
involves the electrolysis of an acidified sodium chloride solution in a specially designed
electrochemical cell.
Monochloro Acetic Acid (MCA): The manufacture of MCA involves the reaction of
Chlorine and acetic acid in Chlorinators using a suitable catalyst under high temperature.
Sources of Air Pollution
The sources of air pollution from the plant are from proposed 25 TPH Husk/Coal Fired Boiler.
Existing sources of air pollution includes 15 TPH and 10 TPH Husk Fired Boiler, 6 TPH Oil Fired
Boiler 15 TPH Waste Heat Recovery Boiler , 4750 KVA DG Set and 3 x 1000 KVA DG Set
Capacity. The DG sets required for emergency power during load shut down. Existing DG Sets
includes 1 x 4750 KVA and 3 x 1000 KVA Capacity DG Sets. Control Equipments includes ESP
and Bag filter Bag filters will be provided as air pollution control equipment for 25 TPH Coal
Fired Boiler.
In chloro-alkali plant the gaseous emissions are chlorine and hydrogen chloride vapours. Due to
advancement of control checks and due to membrane cell electrolysis, possibility of chlorine
emission to atmosphere is negligible. Scrubbing systems are provided to neutralize sniff gases
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effectively. Even the dilute chlorine is also being converted to sodium hypochlorite after
neutralisation with caustic soda at control temperature leading to value addition.
Water requirement and its management:
Water is required for process, scrubbers, washing, cooling tower makeup, steam generation and
domestic purposes. The required water shall be drawn from river infiltration wells if river in
addition to reuse of treated wastewater. The total water requirement after expansion is in the
order of 9252 KLD consisting of 8428 KLD fresh water and 824 KLD of recycled water. The
effluents are treated in “treated in ETP followed by RO plant & R.O. permeate will be utilized for
cooling towers makeup & R.O. rejects will be utilized in Brine Saturator to achieve Zero Liquid
discharge. Domestic wastewater sent to sewage treatment plant and treated wastewater reused
for green belt development within plant premises.
Solid and Hazardous waste:
Solid wastes are generated from the process like brine sludge, saturator mud, ETP sludge and
Alumina sludge will be disposed in existing lined land fill facility. Hazardous waste - spent
catalyst will be sent to TSDF, Waste oils burned in heating furnace in existing plant. Sulphur
sludge is being utilized in Single Superphosphate plant at Kovvur as filler. Gypsum will be sold
to Cement Industries / sent to lined land fill within the premises.
Applicability of EIA notification 2006: Chlor-alkali industry are listed at serial no. 4(d),
synthetic organic chemicals are listed at serial no. 5(f) of schedule of EIA Notification, 2006 and
categorized under “A” or “B” depending upon the location of the plant outside or inside the
notified industrial area. In the instant case the plant is located outside the notified industrial area.
Hence the project is considered as category “A” and is appraised at centre level.
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