ARCHEAN GROUP
ARCHEAN CHEMICAL INDUSTRIES PRIVATE LIMITED
Marine Chemicals
From Brine at
Rann of Kutch in India
C G Sethuram
India - Gujarat
SITE
Gujarat
District Kutch
Satellite Image of Site
It all started…..
Month and Year Activity
Jan 2005 MOU with Government of Gujarat in the Vibrant Gujarat
Summit 2005 for production of Salt and Salt based
Chemicals
July 2006 Agreement for Licensing & Know How with CSMCRI,
Bhavnagar for SOP, MOP, MgO, Brominating Reagents-
Integrated patented process
Feb 2008 Allotment order from Government of Gujarat (GOG) for
Phase 1- 60000 acres of area
Mar-July 2008 Demonstration work at CSMCRI
July 2008 Lease agreement with GOG
Jan-Sept 2008 Brine field designs and construction planning
Few Initial Photos of Site
Approach Road Brine Channel
Salt Desert Top Salt Layer
It takes time…a long time !!!!
Month & Year Activity / Clearance
Feb 2010 Application to the Ministry for Environmental
Clearance of the Project
Mar-Dec 2010 Various studies and EIA as stipulated by the
Government in Terms of Reference
Jan-June 2011 Evaluation and site visits by Expert Committee,
MOEF,Delhi
Sept 2011 Environmental Clearance from MOEF, Delhi
Apr 2012 Consent to Establish the Plant from Government
of Gujarat
Some Help and Validations…
Month & Year Validation Activity
Nov 2008 Mr. David Butts and Mr. Guy Wilkins, Experts in
Marine Chemicals and Brine Field Development
–Visit site and provide guidance on Brine Fields
and Evaporation circuit
Feb 2009 After initial studies on GRK brine a team from
KUTec visits site and offers to associate for SOP
Feb 2009 DDPS-QVF offers to provide equipment and
technology for Bromine production
June 2009 Mr. Harry Ritchie , Expert in Salt production
visits site and provides guidance on Salt
July 2009 Courtesy KUTec visits to Potash plants in
Europe take place
Validations
Demonstration at CSMCRI (Mar 2008)
Discussion at CSMCRI Pilot plant
Validations
Testing Sub Soil Brine in Rann
Mr.Guy Wilkins (Solar Salt
Engineering) visit to site
Validations
Discussion at Weather Station
Mr David Butts (DSB International)
Lab experiment on Soil Quality
Analysis-Mr David Butts
Validations
Team KUTec at CSMCRI
Team K-Utec at site (Feb 2009)
Validations
Mr. Harry Ritchie at Brine Field
Construction area
Mr.Harry Ritchie at the Rann Brine
Channel (June 2009)
Money- The Tough Resource
Till 2010 all project funding internally done from
Archean Group
In 2010 Pre-Money valuation and Capital infusion
from Sojitz, Japan with minor equity participation
By end 2010 Consortium of 6 Banks agree to
lend by providing term loans after a long and
detailed appraisal
Project cost and Capacities get revised in 2012-
Revised Equity and Debt get secured
Basic Details of the Project Phase 1
Location Greater Rann of Kutch
Hajipir, Bhuj Taluk, Kutch District,
Gujarat, India
Total Area under 24271 Hectares (60000 Acres)
Lease
Brine Bed Area 16187 Hectares
Evaporation Circuit 7594 Hectares
Area
Plant Area 500 Hectares
Current Phase 1 Products & Capacities
Product Production Capacity (MTA)
Industrial Salt (NaCl) As per market demand
Sulphate of Potash 130000
Liquid Bromine 10500
Marine Chemicals Project Configuration
Brine Field and Evaporation Circuit
SOP Plant
Liquid Bromine Plant
CoGen Power Plant
ISBL Utilities including Desalination Plant
OSBL Facilities including Sea Water Intake
Infrastructure
Overall Site Plan
Evaporation Circuit Layout
Satellite View - Site
Satellite View - Site
Salt Manufacturing from Sea brine
Sea Brine 6-10o Be 10-14o Be 14-17o Be 38-40-49o Be
3-3.5o Be CaCO3 Crystallization
I IV Magnesium
Chloride
Recovery
Mixed Salt
Pans
Salt Storage
Heaps 36 to 38 o Be
12-13o Be Gypsum 17-24o Be
Crystallization starts Pre Crystallizer
Sels Mixt
II III Area
Pans
34 to 36 o Be
Bittern Reservoir
Crude Salt
Pans
Most Gypsum
separates 29 to 34 o Be
Reservoir Condensor Crystalliser
Area Area Area
24-25o Be 25.5 -29o Be
Feed Preparation
FIELD – POND SEQUENCE
25 deg.Be’ 29 deg.Be’ 32 deg.Be’ 36 deg.Be’
CRY CIRCUIT CIRCUIT CRY
Channels
in Salt bed
Crude Salts Crude Magnesium
Sulphate Salts Kainite
Salt - NaCl
End Bittern
for Bromine
MgCl2
Sea water GRK Brine
BISCHOFITE Constituents
(w/v%) (w/v%)
100
(KCl.MgCl2.6H2O) CARNALLITE Na 1.05 10.25
KIESERITE 90
K 0.03 0.38
80
MgSO4.6H2O
70 Mg 0.12 1.15
(KCl.MgSO4.3H2O) KAINITE
60 Cl 1.89 18.46
50
LEONITE
SO4 0.26 1.64
40
MgSO4.7H2O 6
5 3
(K2.SO4.MgSO4.3H2O) 3
SCHOENITE 0 1 Phase diagram of oceanic salt system at 25oC
(concentrations expressed in mol / 1000 moles H2O).7
2 20
SYLVITE Compositions of Dead sea brine (●), oceanic bittern
[before (▲) and after (Δ) desulfatation] and SEL
ASRTAKANITE 10
[before (■) and after (□) desulfatation] are also
GLASERITE
MgSO4 K2Cl2 shown. Compositions are provided in Table 1 for
4 30 20 10 0 10 2 Dead sea brine (1), SEL (2), desulfated SEL (3),
30
0 10 0 oceanic bittern of sp gr 1.263 (5) and desulfated
THENARDITE oceanic bittern of sp gr 1.221 (6).
Na2.SO4
Janecke Diagram – CSMCRI’s data
K2SO4
Crystallizer- C1
Crystallizer- KTMS
Pumping Station 1
Pumping Station 1
Pumping Station 1
Pumping Station 2
Pumping Station 3
Pumping Station 4
Pumping Station 5
Pumping Station 5
Rain- The spoiler !!!
Year Rainfall in mm per year
Prior to 2008 Average < 150
2009 > 300
2010 > 600
2011 > 900
Till Date 2012 > 300
Gates in Crystallizer
Gates in Crystallizer
Construction of Cause Way
Salt in C1 Crystallizer-Already formed
KTMS Crystallizer
Weather Station
Temporary on site Laboratory
Engineering and Technology
Product Party Place Details
Project CSMCRI India SOP, MgO, Green
Concept Bromine and Derivatives
Brine Field Archean India Phase 1 – 60000 acres
SOP KUTec Germany 20 TPH
Liquid DDPS-QVF Germany 10500 MTA
Bromine
Detail HDO India Plant
Engineering Technologies
Typical Salt Washery Scheme
SALT STOCK PILE
HOPPER-1
CLARIFIER-1 CONVEYOR-3
RAW SALT FEED
METAL SCREW
CONVEYOR
CONVEYOR-1 CONVEYOR-2
CONVEYOR-4
CLARIFIER-2
HOPPER-2
SALT STOCK PILE
SINGLE TRAIN CAPACITY - 200 TPH
NUMBER OF TRAINS - 3 TRAINS
TOTAL CAPACITY PER DAY - 600 TPH = 12000 TPD
TOTAL CAPACIITY PER YEAR . 12000 X 250 = 3 MILLION MTA
Plant Layout
Plant Layout
Chemistry of Production of SOP
KTMS + MgSO4 2KCl.MgSO4.2.75 H2O
Synthetic Kainite
2KCl.MgSO4.3H2O + Cold ML + SW K2SO4.MgSO4.6H2O + EL
Synthetic Kainite Primary Schoenite
K2SO4.MgSO4.6H2O + K2SO4.MgSO4.6H2O + SW 2K2SO4 + Hot ML
Primary Schoenite Secondary Schoenite SOP
Hot ML K2SO4.MgSO4.6H2O + Cold ML
Secondary Schoenite
KTMS: Kainite type Mixed Salt, ML:Mother liquor, SW: Sea Water, EL: End Liquor Containing MgCl2
SOP Plant-Rough 3 D Layout
SOP
Kainite
Hoppers
SOP
Crushers Plant
Epsomite
Utilities Thickeners
/ Reactors
Tank
farm
Chemistry of Production of Bromine
Cl2
MgBr2 MgCl2 + Br2
Bromine Plant-Rough 3 D Layout
Key Vendors-Too much of Germany !! ??
Equipment Vendor
Centrifuges Siebtechnik
Cooling Crystallizers Ebner
Dryer Siebtechnik
Glass Columns DDPS-QVF
Process Control System Siemens
Some Other Key Vendors
Equipment or Service Vendor
Harvesters for Salt and Kainite RovDurant Engineering,
South Africa
CoGen Plant – Consultancy for EPC Snyder Energo, India
CoGen Plant-Boilers Cethar Vessels, India
CoGen Plant- Steam Turbine Qingdao, China
through APT, India
CoGen Plant-Balance of Plant and APT, India
Erection and Commissioning
Piling and Ground Improvement Keller Engineering , India
(Parent Company from
Germany !!)
Harvester
Some more Tests….. With Kainite and SOP
More Trials at KUTec in 2012
Compaction & Granulation Trials
at Koppern, Germany in 2012
Infrastructure
Existing Own Office at Gandhidham about 4 hours
from the site used for Project activities
Office cum Residential Facility being built at
Nakhatrana about 75 minutes from the site
Shift Facilities will be built at site
Company Transport to site -To and Fro
Doctor and Medical Facilities at site
Nakhatrana Site Office being built……
Nakhatrana Accommodation getting ready…
Key Utilities
CoGen Power Plant - Coal Based - 10 MWH
Operating Capacity
Desalination Plant- Sea Water RO-10 MLD
Capacity
Process Air Compressors
VAM Chilling Plant
Full Fledged Workshop for Maintenance
Sea Water Feed Scheme
Lakhpat Fort near Sea Water Intake Point
North of Lakhpat Fort will be the Pipeline
Current Approach Road to Site
Temporary Camp Area
Temporary Container Camp Offices
Construction Progress-Boiler Area
Construction Progress-Bromine Plant Area
Construction Progress-ESP Area
Construction Progress- Storage Area
Archean – KUTec
It all started then….and…Continues….
Thank you
Corporate office: 5th Floor, Tower 2 - TVH Beliciaa Towers, 94 MRC Nagar, Chennai 600 028, Tamil Nadu, India
Tel: 91.44.4303 3444, Fax: 91.44.4303 3555 / 777
www.archeangroup.com, sethuram@archeangroup.com
