SITE PLAN — PHASE 1 ACTIVE ZONE (5 ACRES)
| Road Frontage (South) · North Arrow ↑ | All dimensions in feet | Scale 1:60
Utilities Block
ETP + ZLD Plant
SCADA + Solar
Furnace + TOH (RCC)
Main PEB Process Shed
MVR + Spray Dryers
Raw Material Storage
Chemical Storage
FG Warehouse + Packing
QC Lab + Maintenance
Admin Block + Canteen
Future Expansion (7 Ac)
AREA SCHEDULE — PHASE 1 BUILDINGS & STRUCTURES
| # | Facility | Dimensions (ft) | Area (sqft) | Construction | Zone |
|---|---|---|---|---|---|
| 1 | Utilities Block (HT Sub + DG + MCC + Compressor) | 190 × 50 | 9,500 | RCC G+0 | A |
| 2 | ETP 25 KLD + ZLD 25 KLD Plant | 300 × 50 | 15,000 | Tanks + RCC Shed | A |
| 3 | SCADA Room + Solar Ground Mount | 168 × 50 | 8,400 | RCC + Galv Frame | A |
| 4 | Furnace + TOH Building (FIRE-RATED RCC) | 190 × 100 | 19,000 | Fire-rated RCC mandatory | B |
| 5 | Main PEB Process Shed | 300 × 100 | 30,000 | PEB 40 ft eave | B |
| 6 | MVR Evaporator + Spray Dryer Block | 168 × 100 | 16,800 | PEB 50 ft eave | B |
| 7 | Rice Husk Covered Storage | 110 × 67 | 7,370 | PEB open sides | C |
| 8 | RHA Silo Farm (5 silos, 100 MT) | 50 × 67 | 3,350 | Bolted Steel | C |
| 9 | Chemical Storage (NaOH Tanks + CaO + CTAB) | 170 × 67 | 11,390 | HDPE Tanks + RCC Shed | C |
| 10 | FG Warehouse (PS + PCC storage + bagging) | 130 × 67 | 8,710 | PEB insulated | C |
| 11 | QC Laboratory + Maintenance Workshop | 168 × 67 | 11,256 | RCC G+0 | C |
| 12 | Admin Office + Reception (G+1) | 95 × 47 | 4,465 (×2) | RCC G+1 | D |
| 13 | Canteen + Welfare Block + First Aid | 97 × 47 | 4,559 | RCC G+0 | D |
| 14 | Staff + Visitor Parking | 130 × 47 | 6,110 | Paved | D |
| 15 | FG Dispatch + Truck Staging + Loading Dock | 258 × 47 | 12,126 | Paved + Dock levellers | D |
| 16 | Internal Roads (E-W + N-S + Perimeter) | — | ~18,000 | Concrete 200mm thick | All |
| 17 | Green Belt + Setbacks (20 ft all sides) | — | ~12,000 | Landscaped | All |
| TOTAL BUILT-UP AREA (excl. roads/green) | ~170,000 | Within 5-Acre Active Zone | |||
EQUIPMENT SCHEDULE — PHASE 1A PROCESS EQUIPMENT
| Tag | Equipment | Capacity / Spec | Vendor (India) | ₹L |
|---|---|---|---|---|
| FUR-001 | Rice Husk Grate Furnace | 20 TPD · ≤700°C | Raj International / Chanderpur | 65 |
| TOH-001 | Thermal Oil Heater | 3.5 MMkcal/hr · Therminol 55 | Hytherm Engineers, Mumbai | 48 |
| CO2-001 | CO₂ Roots Blower + Scrubber | 25 MT/day CO₂ extraction | Everest Blowers, Delhi | 8 |
| R-001/2/3 | Leach Reactors × 3 | 10 KL each · SS304/PP-lined | Hydro Air Engineers, Hyd | 42 |
| FP-001/2 | Filter Press × 2 | 1200mm PP plates | Star Filter Press, Gujarat | 26 |
| SD-001/2 | Spray Dryers × 2 | 500 kg/hr each · SS304/316L | Raj Process Equipments, Pune | 121 |
| SLK-001 | CaO Slaker | 13.4 MT/day · Paddle type | Bharat Engineers, Hyd | 27 |
| CAU-001 | Draft-Tube Causticiser | Dorr-Oliver · CE 86–88% | Bharat Engineers, Hyd | |
| HCY-001/2 | PCC Hydrocyclone 2-stage | D4 + D6 classifiers | Krebs Engineers, Vadodara | 26 |
| MVR-001 | 2-Effect MVR Evaporator | Saves 65% evap energy | IPEC, Pune | 74 |
| ETP-001 | ETP Plant 25 KLD | Multi-stage biological | Thermax Enviro / Enviro Labs | 64 |
| ZLD-001 | ZLD Plant 25 KLD | MBR + RO + MEE | Thermax Enviro / Enviro Labs | |
| LAB-001 | QC Lab — BET + PSD + XRF | Full QC suite | Quantachrome India / Malvern | 32 |
| MISC | Tanks, Pumps, Conveyors, Bags | All ancillaries | Kirloskar / ELGI / Sintex | 105 |
| TOTAL PROCESS EQUIPMENT (India BOM) | 638 | |||
TPC ₹19.13 Cr (India BOM) · Debt ₹12.43 Cr @ 10.5% · Equity ₹6.70 Cr · Y4+ DSCR 14.79× · ±10–15% until vendor RFQs received
DESIGN NOTES & CONSTRAINTS
① CRITICAL — FIRE-RATED RCC ONLY for Furnace + TOH building. NO PEB (Pre-Engineered Building) in hazardous zone. RCC 230mm walls minimum.
② SETBACKS: 20 ft green belt all sides. 30 ft fire clearance around furnace. TSPCB setback norms apply. No structure within 15 ft of compound wall.
③ ZLD FROM DAY 1: ETP + ZLD placed in north zone for gravity-flow drainage from process. 80% water recovery; 84 KLD fresh makeup only.
④ CHIMNEY: 120 ft RCC chimney minimum for natural draft + CEMS compliance. CEMS auto-shutoff at 720°C protects RHA amorphous character.
⑤ SOLAR: 115 kWp ground-mounted (north zone) + ~135 kWp rooftop on PEB sheds = 250 kWp total. Reduces grid draw by ~315,000 kWh/yr.
⑥ FUTURE EXPANSION (7 ACRES): East zone reserved for Phase 2 second production line (74 GJ/day thermal anchor post Phase 1B). Zero bank debt — self-funded from Y2+ accruals.
⑦ CTAB STORAGE: Climate-controlled, fire-rated, import-grade drums. 4-week buffer mandatory (highest supply risk item at ₹1.8L/MT).
⑧ INTERNAL ROADS: 25 ft E-W service road + 20 ft N-S spine. 200mm thick M30 concrete. Fire tender access around all buildings within 30 ft.