Complete site layout, zoning, civil, structural, electrical, water, and solar design for the Fluxara Advanced Renewables & Applications plant — Kothakota, Wanaparthy, Telangana.
| Zone | Name / Use | Building ft | Zone ft | Zone sq ft | Construction | Height | Floor Load | Key Notes |
|---|---|---|---|---|---|---|---|---|
| A | Core Process Building | 160 × 120 | 200 × 80 | 16,000 | RCC, fire-rated | 28 ft clear | 10 MT/m² | Leach reactors, precipitators, causticiser, spray dryers, MVR evaporator, filter presses. PP-lined walls where acid/alkali contact. Roof: RCC with skylight panels. Crane rail for 2T EOT crane. |
| B | Furnace + THU Zone | 100 × 80 | 120 × 100 | 12,000 | RCC fire-rated ONLY — NOT PEB | 32 ft | 15 MT/m² | Combustion furnace (≤700°C, CEMS), THU hot oil circuit (Therminol 55, 180–220°C, atmospheric). Fire walls 4-hr rating. Explosion relief panels on roof. CO₂ flue to process building via insulated duct. Separate access road. |
| C | RHA + Rice Husk Storage | 160 × 90 | 200 × 100 | 20,000 | Open-sided PEB | 20 ft eaves | 5 MT/m² | 7-day rice husk buffer (140 MT = 560 m³). Purchased RHA bay (135 MT = 200 m³). Dedicated dust suppression system. Fire detection + sprinkler. Separate zones for RH and RHA with concrete berm divider. HDPE lined floor. |
| D | Chemical Storage | 120 × 80 | 150 × 100 | 15,000 | Bunded RCC, classified | 18 ft | 8 MT/m² | Sub-zones: NaOH 48% lye (3 × 20 KL PP-lined tanks + 7-day buffer), CaO dry store (bunded silo 50 MT), CTAB warehouse (AC, 4-week buffer mandatory), stearic acid. Chemical segregation walls. Acid/alkali neutralisation pit. HAZCHEM placards. |
| E | FG Warehouse + Dispatch | 200 × 120 | 200 × 80 | 16,000 | PEB insulated | 24 ft eaves | 5 MT/m² | 250 kWp rooftop solar (this + admin roofs). Racking for 1,200 MT PS (600 bags × 25 kg) + 1,500 MT PCC. Dock leveller × 2. Loading bay for 40 ft containers. Palletiser area. Lot control by QC. Rooftop solar panel loading: ≤20 kg/m² — check rafter design. |
| F | ETP + ZLD Plant | 80 × 60 | 120 × 70 | 8,400 | Open + partial roofing | 20 ft (tanks) | — | 25 KLD ZLD capacity. Clarifier → MEE → ATFD sequence. NaOH recovery pre-treatment. Process water storage: 2 × 200 KL tanks. Firefighting water: 250 KL dedicated tank. ETP at lowest grade point — gravity inlet. Salt recovery for road-grade use. |
| G | Admin + QC Lab + Canteen | 120 × 80 | 180 × 82 | 14,760 | RCC G+1 | 24 ft (2 floors) | 4 MT/m² | Ground: reception, accounts, manager cabin, QC lab (XRF, BET, particle sizer, FTIR), change room × 2, canteen 60 pax. Upper: 8-bed worker accommodation, safety training room, first-aid bay, CCTV monitoring station. 58 kWp rooftop solar. Solar hot water for canteen. |
| H | Electrical + SCADA + Utilities | 80 × 60 | 130 × 80 | 10,400 | RCC | 16 ft | 5 MT/m² | 750 kW HT panel room, 11/0.415 kV transformer yard (outdoor), MCC (5 × panels), DG set room (500 kVA), UPS room, Siemens S7-1200 PLC room, Ignition SCADA servers, compressed air station (2 × 75 kW screw compressors), instrument air dryer, nitrogen generator. |
| I | Solar Ground-mount | — | 180 × 75 | 13,500 | Galv. steel mounting | 8 ft (tilted) | — | 150 kWp ground-mount (balance of 400 kWp after 250 kWp rooftop). Fixed tilt 12°–15° S-facing. 2-row tables, 1.5 m row spacing. Fenced with chain-link. Grass/gravel bed. Dual-axis tracking not specified — fixed tilt sufficient at this latitude. |
| J | Roads + Hardstanding + Truck Bays | — | various | 104,696 | PQC / WBM | — | 30 MT axle | Perimeter fire lane 20 ft. Main spine road N–S 40 ft. E–W service road 28 ft. Internal cross roads 20 ft. Container apron (2 × 40 ft container, 180 × 82 ft). Truck turning circles 60 ft radius. Staff + visitor parking (30 cars + 10 bikes). Gate + guardhouse. |
| K | Greenbelt + Retention Pond | — | distributed | 39,204 | Landscaping | — | — | TSPCB mandate: 15% of Phase 1 area. Native species (neem, cassia, bamboo). 500 trees ± planted at 16 ft spacing. Stormwater retention pond (100 KL) at SE corner for monsoon runoff. Peripheral drainage channel 2×2 ft RCC lined. No impermeable cover on greenbelt. |
| PHASE 1 TOTAL — 6 ACRES | 261,360 | = 750 ft × 348 ft (south portion of 12-acre site) | ||||||
| Zone | Foundation Type | Bearing Capacity | Depth | Concrete Grade | Notes |
|---|---|---|---|---|---|
| A (Process) | Isolated + Combined footings | ≥10 T/m² | 4–5 ft BGL | M30 | Equipment plinths M35. MVR + spray dryer vibration isolation pads. |
| B (Furnace) | Deep isolated footings | ≥15 T/m² | 6 ft BGL | M35 | Heat-resistant cement for furnace plinth. THU pipe supports on RCC pedestals. |
| C (Storage shed) | Strip + pad footings | ≥8 T/m² | 3 ft BGL | M25 | PEB column base plates on RCC pads 600×600×300 mm. |
| D (Chemical) | Raft slab (bunded) | ≥8 T/m² | 2.5 ft BGL | M30 | RCC bund walls 300 mm thick, minimum 1.1× largest tank volume. Acid-resistant screed on floor. |
| E (FG Warehouse) | Strip + pad footings | ≥8 T/m² | 3 ft BGL | M25 | Industrial floor slab 200 mm M30 with hardener for forklift loads. |
| G (Admin G+1) | Isolated footings | ≥8 T/m² | 4 ft BGL | M25 | Standard residential-grade for G+1. Seismic zone II — IS:1893. |
| J (Roads) | PQC or WBM | — | 18 in subbase | M30 PQC | Container apron: 250 mm PQC on 150 mm GSB. Internal roads: 150 mm WBM + 40 mm BM + seal coat. Kerb stones throughout. |
| System | Type | Capacity | Destination |
|---|---|---|---|
| Clean stormwater | RCC open drain, 2×2 ft | 100-yr storm event | Retention pond → percolation |
| Contaminated process drain | PP pipe 200 mm, closed | 130 KLD design flow | ETP inlet → ZLD |
| Cooling water blowdown | PP pipe 100 mm | 5 KLD | ETP MEE |
| Bund drain (emergency) | PP pipe 150 mm | Peak emergency | ETP sump, diversion valve |
| Roof drainage (clean) | PVC 110 mm downpipes | Monsoon design | Retention pond |
| Building | Frame Type | Roof System | Wall System | Crane / Lift | Special |
|---|---|---|---|---|---|
| A — Process | RCC moment frame (IS:456) | RCC flat + PEB roof extension | AAC block + cement plaster | 2T EOT single-girder crane, 200 ft span | 28 ft clear height for spray dryer. Vibration pads under MVR. |
| B — Furnace | RCC fire-rated frame ONLY | RCC with explosion relief panels | RCC 200 mm (4-hr fire wall) | 3T monorail hoist for furnace maintenance | Fire walls to adjacent zones. Heat-resistant refractory lining in furnace room. NOT PEB under any circumstances. |
| C — RHA Shed | PEB (TATA Bluescope or equivalent) | Galvalume ribbed sheet, ridge vent | Open sides + knee wall 1.2 m RCC | None | Open sides on 3 sides for natural ventilation. Dust suppression header along ridge. 3T bobcat loading access. |
| D — Chemical | RCC frame | RCC + FRP translucent panels for light | RCC 150 mm (chemical resistant) | 500 kg chain-block on monorail | Cross-ventilation mandatory. Explosion-proof lighting in CTAB section. HAZCHEM placards IS:6005. |
| E — FG Warehouse | PEB (pre-eng, insulated panels) | Galvalume with 50 mm PUF insulation | Insulated sandwich panel | 2T forklift access, no overhead crane | Rooftop solar: 192 kWp on FG warehouse. Verify rafter capacity ≥20 kg/m² extra dead load. Dock levellers × 2. |
| G — Admin G+1 | RCC frame (IS:456) | RCC flat roof + waterproofing | 230 mm brick + plaster | None (stairs + ramp for QC equipment) | QC lab on ground floor (heavy equipment access). 58 kWp rooftop solar. Seismic zone II compliance. |
| H — Electrical | RCC frame | RCC flat + waterproofing | RCC 150 mm | Cable tray system + raised floor in MCC room | Transformer yard (outdoor, concrete plinth + oil sump). Cable entry rooms segregated LT/HT. DG exhaust duct to roof. |
| Level | Equipment | Rating | Location | Notes |
|---|---|---|---|---|
| Grid Incomer | TSSPDCL 11 kV overhead line | 750 kW sanctioned | H-frame at site boundary | Monthly HT bill. Reactive penalty if PF <0.9. |
| HT Panel | 11 kV VCB switchgear | 1,250 A | Zone H — HT room | Metering cubicle + protection relay (IDMT/REF/DEF). |
| Transformer | 11/0.415 kV ONAN Dyn11 | 1,000 kVA | Zone H — outdoor yard | Oil-filled, OLTC not required. Oil sump with gravel bed. Firewall between transformer and building. |
| LT Incomer | ACB 2000 A, draw-out | 2,000 A at 415V | Zone H — MCC room | Bus coupler for DG changeover. 4-pole. |
| MCC Panels | 5 × MCC panels (Siemens/ABB) | Various feeders | Zone H — MCC room | MCC-1: Leach + pumps. MCC-2: MVR + evaporators. MCC-3: Spray dryers. MCC-4: FG handling + packaging. MCC-5: Utilities + lighting. |
| APFC Panel | Automatic PF correction | 300 kVAR steps | Zone H — MCC room | Target PF 0.97. Detuned capacitor banks (7% reactor) to avoid harmonic resonance with VFDs. |
| Solar Inverters | Grid-tied string inverters | 4 × 100 kW | Zone H + roof plant rooms | Rooftop: 2 × 100 kW (250 kWp). Ground: 2 × 75 kW (150 kWp). All Tier-1 (Huawei/SMA/Sungrow). |
| DG Set | 500 kVA diesel genset | 400 kW prime | Zone H — DG room (ventilated) | For critical process loads during grid failure (MVR minimum speed, instrument air, SCADA, lighting). 1,000 L day tank. AMC with OEM. |
| UPS | Online double-conversion | 30 kVA | Zone H — server room | SCADA, PLC, fire panel, CCTV, process instruments. 30-min battery autonomy. |
| SCADA/PLC | Siemens S7-1200 PLC + Ignition SCADA | — | Zone H — server room | All process VFDs on PROFINET. Modbus TCP to meters. 4G/fibre remote access for MAIS oversight. OPC-UA tags for Digital Twin future state. |
| Equipment | Qty | kW each | Total kW | VFD? |
|---|---|---|---|---|
| MVR compressor (evaporator) | 1 | 132 | 132 | Yes |
| Spray dryers (blower + fan) | 3 | 37 | 111 | Yes |
| Screw compressors (instrument air) | 2 | 75 | 150 | Yes |
| Leach reactor agitators | 6 | 15 | 90 | No |
| Causticiser / draft-tube | 1 | 22 | 22 | Yes |
| Filter press hydraulic units | 3 | 11 | 33 | No |
| NaOH lye transfer pumps | 4 | 7.5 | 30 | Yes |
| Process water pumps | 6 | 5.5 | 33 | Yes |
| CO₂ blower (flue to precipitator) | 2 | 15 | 30 | Yes |
| Bag filter / dust collector | 3 | 11 | 33 | No |
| ETP + ZLD plant | 1 | 45 | 45 | Partial |
| Lighting (process + yard) | — | — | 25 | No |
| HVAC (lab + server room) | — | — | 20 | No |
| Miscellaneous / future | — | — | 46 | — |
| TOTAL INSTALLED | ~900 kW | — | ||
| OPERATING (0.77 demand factor) | ~695 kW | — | ||
| Stream | KLD | Source / Destination | Notes |
|---|---|---|---|
| Fresh borewell intake | 130 | Borewells → softener (if TDS >500) → process water tank | 2 borewells × 80 KLD each → redundancy |
| ZLD recycle return | 520 | ZLD treated permeate → process water tank | 80% recovery of ~650 KLD total demand |
| NaOH leaching circuit | 280 | Process water → PP-lined reactors → filter press → ZLD | Sodium silicate solution; NaOH recovery loop |
| Causticisation + PCC precipitation | 180 | Process water → causticiser → hydrocyclone → ZLD | Ca(OH)₂ slaking water + wash water |
| Spray dryer make-up | 90 | Boiler feed quality demineralised water | Evaporated, exits as water vapour in exhaust |
| THU cooling circuit | 60 | Closed circuit, cooling tower blowdown → ZLD | 10 KLD blowdown; remainder recirculated |
| Evaporation + losses | 40 | Lost to atmosphere | Unavoidable process losses |
| ZLD concentrate (salt cake) | ~2 MT/day | ATFD solid cake → licensed disposal | NaCl + Na₂CO₃ salt mix; road-grade / disposed as per TSPCB approval |
| Stormwater (clean) | Seasonal | Retention pond → greenbelt percolation | Segregated from process drain |
| Stage | Technology | Capacity | Purpose |
|---|---|---|---|
| Primary treatment | Neutralisation + pH correction | Full 650 KLD | pH to 6–9, remove suspended solids. NaOH/H₂SO₄ dosing. |
| Clarifier | Lamella plate clarifier | 650 KLD | Remove CaCO₃ fines, silica carry-over, sludge to filter press → brick kiln feed or desilicated residue blend. |
| Ultrafiltration | UF membrane 0.1 µm | 650 KLD permeate | Polish turbidity <1 NTU before RO. |
| Softening (optional) | Antiscalant dosing or IX softener | — | Needed if borewell TDS >500 or Ca/Mg hardness >300. |
| Reverse Osmosis | 2-stage RO | 500 KLD permeate | 80% recovery. Permeate → process water tank. Reject → MEE. |
| MEE (Multiple Effect Evaporator) | 3-effect MEE, TVR | 25 KLD concentrate | Concentrate RO reject to 30% TDS. Heat source: THU hot oil loop. |
| ATFD (Agitated Thin Film Dryer) | Scraped-surface evaporator | ~2 MT/day solid | Dry MEE concentrate to solid salt cake. ZLD final stage. |
| Treated permeate quality | — | — | TDS <200 ppm, TSS <5 ppm, pH 6.5–8.5, COD <30 mg/L. Suitable for process reuse. |
| Roof Area | Gross Roof sq ft | Usable (75%) | kWp @ 75 sq ft/kWp | Notes |
|---|---|---|---|---|
| Process Building (Zone A) | 160×120 = 19,200 | 14,400 | 192 | Skylights occupy ~25%. Structural check for 3 kN/m² panel + wind load. |
| FG Warehouse (Zone E) | 200×120 = 24,000 | 4,350 | 58 | Balance of rooftop allocation. PEB purlin reinforcement may be needed. |
| Total Rooftop | 250 kWp | 62.5% of 400 kWp target | ||
| Parameter | Value | Notes |
|---|---|---|
| Capacity | 150 kWp | Balance after rooftop |
| Zone dimensions | 180 × 75 ft = 13,500 sq ft | 75 sq ft/kWp × 150 = 11,250 sq ft + 20% aisle = 13,500 sq ft |
| Panel count | ~375 panels | @ 400 Wp monocrystalline each |
| Table configuration | 2-portrait per row, fixed tilt 13° | S-facing, fixed tilt optimised for Kothakota lat. 16°N |
| Row pitch | 10 ft (3.05 m) | No inter-row shading at winter solstice 10 am–2 pm |
| Mounting structure | Hot-dip galvanised C-channel | Driven pile foundation (600 mm depth), no civil needed |
| Inverter | 2 × 75 kW string inverters | Tier-1. Located in weatherproof enclosure at field edge. |
| Fencing | Chain-link 1.8 m, barbed wire top | Perimeter of Zone I only. Access gate for maintenance. |
| Cable routing | DC: 4 mm² / AC: 95 mm² armoured | Underground conduit to Zone H inverter room via cable trench. |
| Element | Dimensions | Sq ft | Specification | Load Design |
|---|---|---|---|---|
| Perimeter fire lane | 20 ft wide, all 4 sides · 2 × 750 + 2 × 348 = 2,196 LF | 43,920 | 150 mm WBM + 40 mm BM + seal coat | 30 MT axle (tanker) |
| Main N–S spine road | 40 ft wide × 348 ft long | 13,920 | 250 mm PQC M30 on 150 mm GSB | 40 MT (container trailer) |
| E–W service road | 28 ft wide × 750 ft long | 21,000 | 200 mm PQC M30 on 150 mm GSB | 30 MT axle |
| Internal cross roads | 20 ft wide × ~1,200 LF total | 24,000 | 150 mm WBM + 40 mm BM | 20 MT (dumper) |
| Container apron | 180 × 82 ft | 14,760 | 250 mm PQC M35 · jointed slab | 40 MT (laden 20 ft FCL container) |
| Truck bays (raw material) | 2 bays × 40 × 60 ft | 4,800 | 200 mm PQC + kerb | 30 MT axle |
| Staff + visitor parking | 140 × 82 ft | 11,480 | Interlocking paver blocks on compacted subgrade | 3 MT (cars) |
| Transformer + DG yard | 60 × 40 ft | 2,400 | Oil-resistant PCC M25 + oil sump | — |
| Gate + guardhouse | 90 × 20 ft (includes gate arm swing) | 1,800 | RCC guardroom 10×12 ft + boom barrier × 2 | — |
| Perimeter compound wall | 2,200 LF × 8 ft height | — | 230 mm brick + plaster · RCC pillars @ 10 ft c/c · broken-glass / barbed-wire topping | — |
| Roads & Hardstanding Total | 138,080 | Including apron, parking, yards, perimeter lane | ||
| Item | Qty | Unit | Notes |
|---|---|---|---|
| Site clearing & levelling | 261,360 | sq ft | Topsoil strip 200 mm, soil testing before founding |
| Compound wall | 2,200 | LF | 8 ft RCC pillar + brick wall, gate × 2 |
| PCC / RCC construction (buildings A, B, D, G, H) | ~6,500 | m³ concrete | M25–M35 as specified; reinforcement ~85 MT steel |
| PEB structures (C, E) | ~36,000 | sq ft | Supply & erect by TATA Bluescope / Kirby / equivalent |
| Flooring — industrial hardener | ~30,000 | sq ft | Zones A, D, E · 200 mm M30 slab + hardener |
| Acid-resistant screed / epoxy | ~8,000 | sq ft | Zone A process floor, Zone D bund floors |
| PQC road + apron | ~50,000 | sq ft | Spine road + container apron |
| WBM road + BM | ~90,000 | sq ft | Perimeter fire lane + internal roads |
| Drainage channels (RCC) | ~3,200 | LF | Peripheral storm + process drain channels |
| Process water tanks (underground PP-lined) | 2 × 200 KL | nos | RCC construction |
| Fire water tank (overhead/ground) | 1 × 250 KL | nos | RCC at 5 m elevation or ground-level + jockey pump |
| Borewell | 2 nos × 300 ft | nos | Submit for groundwater NOC — CGWB |
| Greenbelt plantation | 500 | trees | Native species: neem, cassia, bamboo. TSPCB requirement. |
| Solar ground-mount civil (driven piles) | ~375 | nos | 600 mm depth × 60 mm GI pipe — no concrete needed |
| Cable trenches (process) | ~4,500 | LF | 600×400 RCC trench with precast cover slabs |
| HT underground cable (11 kV, XLPE) | ~600 | m | From DISCOM pole → site HT panel. XLPE 3-core 185 mm². |
| Paint (anti-corrosion, chemical-resistant) | — | — | Jotun Jotamastic or equivalent; PP lining for tank interiors |
| Signage (HAZCHEM, safety, directional) | 1 | lot | IS:9457 / GHS-compatible; bilingual (Telugu + English) |
| Zone | Description | Dimensions (ft) | Sq ft | Notes |
|---|---|---|---|---|
| B2 | Second Furnace + THU (RCC) | 120 × 100 | 12,000 | Mirror of Phase 1 Zone B. New combustion capacity + additional CO₂ feed. |
| A2 | Second Process Building extension | 200 × 80 | 16,000 | Additional leach, precipitate, spray-dry line for 20 TPD more PS. |
| E2 | Additional FG Warehouse | 200 × 120 | 24,000 | For doubled PS (40 TPD) and PCC (60 TPD) throughput. |
| — | Roads + yard + fire lanes | various | ~100,000 | Perimeter lane + new spine road extension northward. |
| — | Additional solar (Phase 2) | various | ~20,000 | Additional 200 kWp ground-mount to offset doubled electrical load. |
| — | Buffer + greenbelt + flex | — | ~89,360 | TSPCB 15% greenbelt maintained at Phase 2 scale. Flex for future options. |
| Phase 2 Land Bank | 261,360 | = 6 Acres · 750 ft × 349 ft | ||
| Year | Milestone | Funding |
|---|---|---|
| Y1 | Phase 1 at 60% utilisation; Y1 net cash +₹4.77 Cr. Begin Phase 2 feasibility study. | Phase 1 revenues |
| Y2 | Phase 1 at 75%; Y2 EBITDA ₹11.8 Cr. Commission Phase 2 engineering. Order second furnace. | Accruals from Y1–Y2 |
| Y2–Y3 | Phase 2 civil, equipment procurement, installation. Parallel with Phase 1 operations. | ₹15–20 Cr from accruals |
| Y3 | Phase 2 commissioning; Phase 1 achieving 90% + FSSAI dental grade revenue. | Internal — zero bank debt |
| Y4+ | Full 40 TPD PS + 60 TPD PCC. Revenue potential ₹125–150 Cr/yr. | Fully self-funded |